Rendezvous - 2005-2007 PDF

2005-2007 Buick Rendezvous
All Models
MODEL IDENTIFICATION
NOTE: Metro, Prizm and Tracker, and Saturn are not covered in this article. For A/C
compressor clutch diagnosis on Metro, Prizm, Tracker, and Saturn, see
appropriate MANUAL A/C-HEATER SYSTEMS article.
MODEL IDENTIFICATION (CARS)

Body Code (1) Model
C Park Avenue
E Eldorado
F Camaro & Firebird
G Aurora
H Bonneville & LeSabre
J Cavalier & Sunfire
K DeVille & Seville
N Alero, Grand Am & Malibu
V Catera
W Century, Grand Prix, Impala, Intrigue, Lumina, Monte Carlo
& Regal
Y Corvette
(1) Vehicle body code is fourth character of VIN.
MODEL IDENTIFICATION (LIGHT TRUCKS & VANS)

Series (1) Model(s)
A FWD Aztek
B AWD Aztek
C 2WD - Pickup, Sierra, Suburban, Tahoe, Silverado & Yukon
G Express & Savana
K 4WD - Pickup, Escalade, Sierra, Suburban, Tahoe, Silverado & Yukon
L AWD Astro & Safari
M 2WD Astro & Safari
S 2WD - Blazer, Jimmy, Pickup & Sonoma
T 4WD - Blazer, Bravada, Jimmy, Pickup & Sonoma
U Montana, Silhouette & Venture
(1) Vehicle series code is fifth character of VIN.
DESCRIPTION & OPERATION
A/C COMPRESSOR CLUTCH CONTROLS (CARS)
To provide improved idle quality, improved Wide Open Throttle (WOT) performance and A/C system
protection, the compressor clutch is controlled by PCM/ECM.
For proper control of cooling fans, compressor clutch, and Idle Air Control (IAC) valve, a refrigerant pressure
sensor is used. The PCM/ECM uses signals provided by sensor to monitor high and low side refrigerant
pressures. If PCM/ECM detects a fault in refrigerant pressure circuit, compressor clutch will be disabled.
The A/C clutch relay is controlled by PCM/ECM. This allows PCM/ECM to raise idle speed before engaging
compressor clutch, or disable compressor clutch during WOT, high engine RPM, high power steering loads, and
hot engine restarts. The PCM/ECM also disables compressor clutch if coolant temperature becomes excessive.
NOTE: This article ONLY contains those testing procedures required to test A/C
compressor clutch control circuit. Other diagnostic information may be
referenced while performing A/C compressor clutch control diagnosis. For
additional information, see appropriate SELF-DIAGNOSTICS article in ENGINE
PERFORMANCE.
A/C CLUTCH RELAY LOCATION (CARS)

Application Location
C Body Right Front Of Engine Compartment, In Fuse/Relay Block
K Body In Underhood Fuse/Relay Block, On Right Side Of Engine
Compartment
E Body In Underhood Fuse/Relay Block, On Left Side Of Engine
Compartment
F Body In Underhood Electrical Center, In Left Front Of Engine
Compartment
G Body In Underhood Relay Center, On Right Side Of Engine Compartment
H Body In Underhood Fuse Block, At Right Front Of Engine Compartment
J Body In Underhood Fuse/Relay Block, At Left Front Of Engine
Compartment
N Body In Underhood Fuse/Relay Block, At Left Side Of Engine
Compartment
V Body Left Front of Engine Compartment, In ECM Housing
W Body In Underhood Electrical Center, On Right Side Of Engine
Compartment
Y Body In Underhood Electrical Center, In Front Of Battery
A/C COMPRESSOR CLUTCH CONTROLS (LIGHT TRUCKS & VANS)
FWD Vans
To provide improved idle quality, maintain Wide Open Throttle (WOT) performance and provide A/C system
protection, compressor clutch is controlled by PCM.
The A/C clutch relay is controlled by PCM according to information received from A/C pressure sensor and
various other sensors. This allows the PCM to raise idle speed before engaging compressor clutch. PCM will
disable compressor clutch during WOT, when refrigerant pressure is incorrect or if coolant temperature exceeds
a predetermined value. The PCM inhibits compressor clutch operation when engine speed is greater than 4500
RPM for 5 seconds, or when throttle angle exceeds 90 percent.
RWD Trucks & Vans
The A/C clutch relay is controlled by PCM/VCM. The PCM/VCM improves idle quality by delaying
compressor clutch engagement until idle speed is increased, or disengages compressor clutch when idle speed is
too low. Compressor clutch is cycled by PCM/VCM. The PCM/VCM smooths cycling of compressor clutch by
adding fuel the instant compressor clutch is applied.
A/C CLUTCH RELAY LOCATION (LIGHT TRUCKS & VANS)

A & B Series In Underhood Fuse/Relay Block, On Right Side Above Battery
C & K Series In Underhood Fuse/Relay Center, On Left Side Of Engine
Compartment
S & T Series In Underhood Fuse Block, On Left Side Of Engine Compartment
G Series In Underhood Fuse/Relay Center, Left Front Of Engine
Compartment
L & M Series In Underhood Fuse/Relay Center, Left Side Of Engine Compartment
U Body In Underhood Accessory Wiring Junction Block
A/C CLUTCH CIRCUIT DIAGNOSIS (CARS)

To help save diagnostic time, ALWAYS check for blown fuses or fusible links before proceeding with
diagnosis. If fuses are blown, locate and repair short circuit before replacing fuses.
Ensure all related relay and wire harness connections are clean and tight. Repair as necessary. See WIRING
DIAGRAMS .
NOTE: Vehicles may be equipped with a PCM using an Electronically Erasable

Programmable Read Only Memory (EEPROM). When replacing PCM, the new
PCM must be programmed.
2.2L & 2.4L: CAVALIER & SUNFIRE (2000)
NOTE: For circuit, wire color and terminal identification, see WIRING DIAGRAMS . Also
see WIRING DIAGRAMS in appropriate MANUAL or AUTOMATIC A/C HEATER
SYSTEMS article.
Description
Powertrain Control Module (PCM) receives an A/C request signal from Instrument Panel Cluster (IPC) over
UART serial data line. When A/C is requested, the PCM provides a ground path to A/C clutch relay control
circuit. When relay circuit is grounded, A/C clutch relay is energized. PCM delays grounding relay circuit for .3
second. This allows PCM to adjust engine idle RPM for additional load.
PCM will temporarily de-energize A/C clutch relay when one or more of the following conditions occur:
A hot engine restart.

Wide open throttle (TPS position over 90 percent).
If engine RPM is greater than 6000 RPM.
During Idle Air Control (IAC) valve reset
A/C clutch relay will remain de-energized when one or both of the following conditions occur:
DTC P0530 or U1016 are set.

When there is no A/C request signal to PCM.
For additional trouble shooting information, go to MANUAL A/C-HEATER SYSTEMS - CAVALIER &
SUNFIRE article.
Diagnostic System Check
1. Install scan tool. If scan tool powers up, go to next step. If scan tool does not power up, see SCAN TOOL
DOES NOT POWER UP in appropriate BODY CONTROL MODULES article.
2. Turn ignition on, engine off. Try to establish scan tool communication with Body Control Module (BCM)
and Powertrain Control Module (PCM). If communication with both modules is established, go to next
step. If communication with both modules is not established, see SCAN TOOL DOES NOT
COMMUNICATE WITH CLASS 2 DEVICE in appropriate BODY CONTROL MODULES article.
3. Select display DTC function for each module. Record all displayed DTCs, status of displayed DTCs and
which module set DTC. If DTCs are displayed, go to next step. If no DTCs are displayed, see
DIAGNOSIS .
4. If scan tool displays any DTCs beginning with "B", see appropriate SELF-DIAGNOSTICS article in
BODY CONTROL MODULES. If scan tool displays DTCs beginning with "P", see appropriate SELF-
DIAGNOSTICS article in ENGINE PERFORMANCE. If scan tool displays DTCs beginning with "U",
see SCAN TOOL DOES NOT COMMUNICATE WITH CLASS 2 DEVICE in appropriate BODY
CONTROL MODULES article.
Diagnosis
1. If diagnostic system check has not been performed, see DIAGNOSTIC SYSTEM CHECK . If
diagnostic system check has been performed, go to next step.
2. Install scan tool. Check for any DTCs that may be set. If DTC P0530 or U1016 are set, see appropriate
SELF-DIAGNOSTICS article in ENGINE PERFORMANCE. If no DTCs are set, go to next step.
3. If A/C compressor clutch is engaged, go to next step. If A/C compressor clutch is not engaged, go to step
5.
4. Remove A/C clutch relay. If A/C compressor clutch disengages, go to step 6 . If A/C compressor clutch
does not disengage, go to step 7 .
5. Start engine and allow it to reach normal operating temperature. Cycle A/C on and off at control panel. If
A/C compressor clutch cycles on and off, go to step 8 . If A/C compressor clutch does not cycle on and
off, go to step 9 .
6. Using a test light connected to battery voltage, probe A/C clutch relay control circuit terminal (Dark
Green/White wire) at A/C clutch relay connector. See WIRING DIAGRAMS . If test light comes on, go
to step 20 . If test light does not come on, go to step 30 .
7. Disconnect A/C compressor clutch harness connector. If A/C compressor clutch disengages, go to step
21 . If A/C compressor clutch does not disengage, go to step 32 .
8. Turn ignition switch to OFF position. Install A/C manifold gauge set. Compare high-side pressure
reading on gauge with scan tool reading. If readings are within 20 psi (1.4 kg/cm2 ) of each other, go to
step 36 . If readings are not as specified, go to step 10 .
9. While observing scan tool, turn A/C on, then off. If scan tool indicates A/C was requested, then not
requested, go to step 11 . If operation is not as specified, go to step 12 .
10. Disconnect A/C refrigerant pressure sensor electrical connector. Connect DVOM between battery voltage
and A/C refrigerant pressure sensor ground circuit (Black wire). If DVOM reads battery voltage, go to
step 31 . If DVOM does not read battery voltage, go to step 22 .
11. Turn engine off, leaving ignition switch in ON position. If A/C high side value is 40-430 psi (2.8-30.2
kg/cm2 ), go to step 13 . If A/C high side value is not 40-430 psi (2.8-30.2 kg/cm2 ) go to step 14 .
12. Connect test light between ground and A/C selector switch input circuit (Light Green/Black wire) to
instrument cluster. Cycle A/C selector switch on and off. If test light turns on and off when A/C selector
switch is cycled, go to step 34 . If test light does not turn on and off when A/C selector switch is cycled,
go to step 23 .
13. Remove A/C relay. Using a test light connected to ground, probe ignition feed circuit (Pink wire) and
battery feed circuit (Orange wire). If test light is on for both circuits, go to step 15 . If test light is off for
both circuits, go to step 24 .
14. Install an A/C manifold gauge set. Observe A/C high side pressure on scan tool and manifold gauge set.
If A/C high side pressure is within 20 psi (1.4 kg/cm2 ) of each other, see DIAGNOSTIC SYSTEM
CHECK . If A/C high side pressure is not within 20 psi (1.4 kg/cm2 ) of each other, go to step 31 .
15. Connect a fused jumper between A/C relay ignition feed terminal No. 85 (Pink wire) and compressor
clutch feed terminal No. 87 (Dark Green wire). If A/C compressor clutch engages, go to next step. If A/C
compressor clutch does not engage, go to step 17 .
16. Remove fused jumper wire. Start engine. Ensure A/C is selected on, then command A/C compressor
clutch relay on using scan tool. Using a test light connected to battery voltage, probe A/C compressor
clutch relay control terminal No. 86 (Dark Green/White wire). If test light is on, go to step 30 . If test
light is off, go to step 18 .
17. Disconnect A/C compressor clutch electrical connector. Leave fused jumper connected. Using a test light
connected to ground, probe A/C compressor clutch ignition feed circuit (Dark Green wire). If test light is
on, go to step 19 . If test light is off, go to step 26 .
18. Turn ignition switch to ON position, with engine OFF. Using a test light connected to ground, probe
compressor clutch relay control terminal No. 86 (Dark Green/White wire). If test light is on, go to step
27 . If test light is off, go to step 28 .
19. Using a test light connected to battery voltage, probe A/C compressor clutch ground circuit (Black wire)
at A/C compressor clutch connector. If test light is on, go to step 33 . If test light is off, go to step 29 .
20. Check A/C compressor clutch relay control circuit (Dark Green/White wire) for short to ground. If
problem was found, repair as necessary. After repairs, go to step 36 . If problem was not found, go to step
35 .
21. Repair short to battery voltage in A/C compressor clutch ignition feed circuit (Dark Green wire). After
repairs, go to step 36 .
22. Check A/C refrigerant pressure sensor ground (Black wire) for open or poor connections. If problem was
found, repair as necessary. After repairs, go to step 36 . If problem was not found, go to step 35 .
23. Repair signal from A/C selector switch. After repairs, go to step 36 .
24. If test light was not on at A/C relay battery feed terminal No. 30 or ignition feed terminal No. 85, check
short to ground in A/C compressor clutch ignition feed circuit (Dark Green wire), A/C compressor clutch
diode, battery feed circuit (Orange wire) and ignition feed circuit (Pink wire). If problem was found,
repair as necessary. After repairs, go to step 36 . If problem was not found, go to next step.
25. Turn ignition switch to OFF position. Check for open in A/C compressor clutch relay battery feed circuit
(Orange wire) and ignition feed circuit (Pink wire). If problem was found, repair as necessary. After
repairs, go to step 36 . If problem was not found, go to step 30 .
26. Turn ignition switch to OFF position. Repair open in A/C compressor clutch ignition feed circuit (Dark
Green wire). After repairs, go to step 36 .
27. Check A/C compressor clutch relay control circuit (Dark Green/White wire) for short to voltage. If
35 .
28. Check A/C compressor clutch relay control circuit (Dark Green/White wire) for open or poor
connections. If problem was found, repair as necessary. After repairs, go to step 36 . If problem was not
found, go to step 35 .
29. Repair open or poor connections in A/C compressor clutch ground circuit (Black wire). After repairs, go
to step 36 .
30. Turn ignition switch to OFF position. Check for poor connections at A/C relay. If connections are okay,
replace A/C compressor clutch relay. After repairs, go to step 36 .
31. Check for poor connections at A/C refrigerant pressure sensor. If connections are okay, replace A/C
refrigerant pressure sensor. After repairs, go to step 36 .
32. Replace malfunctioning A/C compressor clutch assembly. See appropriate COMPRESSOR SERVICING
article in GENERAL SERVICING. After repairs, go to step 36 .
33. Turn ignition switch to OFF position. Check for poor connections at A/C compressor clutch coil. If
connections are okay, replace A/C compressor clutch coil. See appropriate COMPRESSOR SERVICING
34. See SELF-DIAGNOSTIC SYSTEM in appropriate ANALOG INSTRUMENT PANELS article. After
35. Turn ignition switch to OFF position. Replace PCM. See appropriate REMOVAL, OVERHAUL &
INSTALLATION article in ENGINE PERFORMANCE. After repairs, go to next step.
36. Start engine. Idle engine. Cycle A/C selector switch on and off. If A/C compressor clutch cycles on and
off, system is okay.
Diagnostic Aids
If DTCs P0530 or U1060 are set, diagnose them before proceeding. See appropriate SELF-DIAGNOSTICS
article in ENGINE PERFORMANCE. If problem is insufficient cooling, check cooling fans for proper
operation. See ELECTRIC COOLING FANS - ALL MODELS article. If cooling fans operate correctly,
diagnose manual A/C-heater system. See MANUAL A/C-HEATER SYSTEMS - CAVALIER & SUNFIRE
article.
An A/C refrigerant pressure less than 43 psi (3.0 kg/cm2 ), or greater than 428 psi (30.1 kg/cm2 ), will cause
PCM to disable compressor clutch. With engine running and A/C on, use scan tool to monitor A/C high-side
pressure for 2 minutes. If pressure goes out of range, diagnose manual A/C-heater system.
2.2L & 2.4L: CAVALIER & SUNFIRE (2001)
SYSTEMS article.
Description
Powertrain Control Module (PCM) receives an A/C request signal from Body Control Module (BCM) over
UART serial data line. When A/C is requested, the PCM provides a ground path to A/C clutch relay control
circuit. When relay circuit is grounded, A/C clutch relay is energized. PCM delays grounding relay circuit for .3
PCM will temporarily de-energize A/C clutch relay when one or more of the following conditions occur:

During Idle Air Control (IAC) valve reset

For additional trouble shooting information, go to MANUAL A/C-HEATER SYSTEMS - CAVALIER &
SUNFIRE article.

2. Turn ignition on, engine off. Try to establish scan tool communication with Powertrain Control Module
(PCM). If communication with PCM is established, go to next step. If communication with PCM is not
established, see SCAN TOOL DOES NOT COMMUNICATE WITH CLASS 2 DEVICE in appropriate
BODY CONTROL MODULES article.
3. Select display DTC function for PCM. Record all displayed DTCs and status of displayed DTCs. If DTCs
are displayed, go to next step. If no DTCs are displayed, see COMPRESSOR CLUTCH DOES NOT
ENGAGE or COMPRESSOR CLUTCH DOES NOT DISENGAGE .
4. If scan tool does not display DTCs beginning with "U", see appropriate SELF-DIAGNOSTICS article in
ENGINE PERFORMANCE. If scan tool displays DTCs beginning with "U", see SCAN TOOL DOES
NOT COMMUNICATE WITH CLASS 2 DEVICE in appropriate BODY CONTROL MODULES
article.
Compressor Clutch Does Not Engage
2. Ensure outside air temperature is greater than 38F (3C). Start engine. Turn blower motor switch to
maximum speed position. Turn A/C request switch to ON position. Turn air temperature switch to coldest
position. Cycle mode switch through each position except off. If A/C compressor operates in each mode
position, problem is intermittent. If A/C compressor does not operate in each mode position, go to next
step.
3. Park vehicle inside or in shade. Open windows in order to ventilate interior of vehicle. Turn ignition
switch to OFF position. Install Refrigerant Station (J 43600 ACR 2000). Record outside air temperature
at vehicle. Record readings of low and high side STATIC pressures. Compare pressure values with
specifications for ambient air temperature. See PRESSURE-TEMPERATURE RELATIONSHIP article
in GENERAL SERVICING. If pressure values are within specification for ambient air temperature and
within 15 psi (1.1 kg/cm2 ) of each other, go to next step. If pressure values are not within specification
for ambient air temperature or within 15 psi (1.1 kg/cm2 ) of each other, see LEAK TESTING article in
GENERAL SERVICING.
4. Turn ignition switch to ON position, with engine off. Using scan tool, observe A/C high side pressure
sensor parameter in powertrain data list. Compare A/C high side pressure on scan tool to high side
pressure value on refrigerant station. If high side pressure values are within 15 psi (1.1 kg/cm2 ), go to
next step. If high side pressure values are not within 15 psi (1.1 kg/cm2 ), go to step 18 .
5. If HVAC control assembly is inoperative, go to step 9 . If HVAC control assembly is not inoperative, go
to next step.
6. Start engine. Using scan tool, observe A/C request parameter in powertrain data list 2. Turn blower motor
switch to maximum position. Turn mode switch to recirculation position. If scan tool indicates A/C
request parameter is YES, go to next step. If scan tool indicates A/C request parameter is not YES, go to
step 11 .
7. Using scan tool, observe A/C relay commanded parameter in powertrain data list 2. If scan tool indicates
A/C relay commanded parameter is ON, go to next step. If scan tool does not indicates A/C relay
commanded parameter is ON, go to step 28 .
8. Using scan tool, command A/C compressor clutch relay on and off. If A/C compressor clutch relay turns
on and off with each command, go to step 12 . If A/C compressor clutch relay does not turn on and off
with each command, go to step 14 .
9. Test ignition voltage circuit (Brown wire) to HVAC control assembly for short to ground, high resistance,
or open. If problem was found, repair as necessary. After repairs, go to step 35 . If problem was not
found, go to next step.
10. Check ground circuit (Black wire) to HVAC control assembly for open. If problem was found, repair as
necessary. After repairs, go to step 35 . If problem was not found, go to step 26 .
11. Start engine. Turn mode switch to MAX A/C position. Using test light connected to ground, probe A/C
request signal circuit (Light Green/Black wire) at Body Control Module (BCM). If test light is on, go to
step 27 . If test light is off, go to step 16 .
12. Turn ignition switch to OFF position. Disconnect A/C compressor clutch relay. Using a test light
connected to ground, probe switch side voltage supply circuit (Orange wire) of A/C compressor clutch
relay connector. If test light is on, go to next step. If test light is off, go to step 21 .
13. Connect fused jumper (10 amp) between switch side voltage circuit (Orange wire) of A/C compressor
clutch relay connector and A/C compressor clutch supply voltage circuit (Dark Green wire) of A/C
compressor clutch relay connector. Turn ignition switch to ON position, with engine off. If A/C
compressor clutch engages, go to step 24 . If A/C compressor clutch does not engage, go to step 17 .
14. Turn ignition switch to OFF position. Disconnect A/C compressor clutch relay. Turn ignition switch to
ON position, with engine off. Using a test light connected to ground, probe coil side voltage supply
circuit (Pink wire) of A/C compressor clutch relay connector. If test light is on, go to next step. If test
light is off, go to step 20 .
15. Connect test light between control circuit (Dark Green/White wire) of A/C compressor clutch relay
connector and coil side voltage supply circuit (Pink wire) of A/C compressor clutch relay connector.
Using scan tool, command A/C compressor clutch relay on and off. If test light turns on and off with each
command, go to step 24 . If test light does not turn on and off with each command, go to step 22 .
16. Check A/C request signal circuit (Light Green/Black wire) for short to ground, high resistance or open. If
26 .
17. Check A/C compressor clutch supply voltage circuit (Dark Green wire) at A/C compressor clutch for
short to ground, high resistance or open. If problem was found, repair as necessary. After repairs, go to
step 35 . If problem was not found, go to step 19 .
18. Check ground circuit (Black wire) of A/C pressure sensor for open. If problem was found, repair as
19. Check ground circuit (Black wire) of A/C compressor clutch for high resistance or open. If problem was
20. Repair coil side voltage supply circuit (Pink wire) of A/C compressor clutch relay. After repairs, go to
step 35 .
21. Repair switch side voltage supply circuit (Orange wire) of A/C compressor clutch relay. After repairs, go
to step 35 .
22. Check control circuit (Dark Green/White wire) of A/C compressor clutch relay for open, or short to
ground. If problem was found, repair as necessary. After repairs, go to step 35 . If problem was not found,
go to step 28 .
23. Check A/C high pressure sensor connector for poor connections. If problem was found, repair as
24. Check A/C compressor clutch relay connector for poor connections. If problem was found, repair as
25. Check A/C compressor clutch coil connector for poor connections. If problem was found, repair as
26. Check HVAC control assembly connector for poor connections. If problem was found, repair as
27. Check BCM connectors for poor connections. If problem was found, repair as necessary. After repairs, go
to step 35 . If problem was not found, go to step 33 .
28. Check PCM connectors for poor connections. If problem was found, repair as necessary. After repairs, go
29. Replace A/C high pressure switch. After repairs, go to step 35 .
30. Replace A/C compressor clutch relay. After repairs, go to step 35 .
31. Replace A/C compressor clutch coil. See appropriate COMPRESSOR SERVICING article in GENERAL
SERVICING. After repairs, go to step 35 .
32. Replace HVAC control assembly. See REMOVAL & INSTALLATION in appropriate MANUAL A/C-
HEATER SYSTEMS article. After repairs, go to step 35 .
33. Replace BCM. See appropriate BODY CONTROL MODULES article in ACCESSORIES &
EQUIPMENT. After repairs, go to step 35 .
34. Replace PCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article in ENGINE
PERFORMANCE. After repairs, go to next step.
35. Operate system to verify repair.
Compressor Clutch Does Not Disengage
2. Start engine. Turn mode switch to OFF position. Place A/C request switch in OFF position. If A/C
compressor operates, go to next step. If A/C compressor does not operate, problem is intermittent.
3. Using scan tool, observe A/C REQUEST parameter in POWERTRAIN DATA LIST 2. If scan tool
indicates A/C REQUEST parameter is NO, go to next step. If scan tool does not indicate A/C REQUEST
parameter is NO, go to step 6 .
4. Using scan tool, observe A/C RELAY COMMANDED parameter in POWERTRAIN DATA LIST 2. If
scan tool indicates A/C RELAY COMMANDED parameter is OFF, go to next step. If scan tool does not
indicate A/C RELAY COMMAND parameter is OFF, go to step 14 .
5. Check control circuit (Dark Green/White wire) of A/C compressor clutch relay for short to ground. If
problem was found, repair as necessary. after repairs, go to step 20 . If problem was not found, go to step
7.
6. Turn ignition switch to ON position. Turn mode switch to OFF position. Using test light connected to
ground, probe A/C request signal circuit (Light Green/Black wire) at BCM. If test light is on, go to step
9 . If test light is off, go to step 13 .
7. Remove A/C compressor clutch relay. If A/C compressor clutch turns off, go to step 10 . If A/C
compressor clutch does not turn off, go to next step.
8. Check A/C compressor clutch voltage supply circuit (Dark Green wire) for short to voltage. If problem
was found, repair as necessary. After repairs, go to step 20 . If problem was not found, go to step 11 .
9. Check A/C request signal circuit (Light Green/Black wire) for short to voltage. If problem was found,
repair as necessary. After repairs, go to step 20 . If problem was not found, go to step 12 .
11. Check A/C compressor clutch connector for poor connections. If problem was found, repair as necessary.
After repairs, go to step 20 . If problem was not found, go to step 16 .
16. Replace A/C compressor clutch. See appropriate COMPRESSOR SERVICING article in GENERAL
2.4L, 3.1L & 3.4L: ALERO, GRAND AM & MALIBU
SYSTEMS article.
Description
Powertrain Control Module (PCM) receives an A/C request signal from Body Control Module (BCM) over
Class 2 serial data line. When A/C is requested, PCM provides a ground path to A/C clutch relay control circuit.
When relay circuit is grounded, A/C clutch relay is energized. The PCM delays grounding relay circuit for .3
The PCM will temporarily de-energize A/C clutch relay when one or more of the following conditions occur:

During Idle Air Control (IAC) valve reset.

For additional trouble shooting information, go to appropriate MANUAL A/C-HEATER SYSTEMS article.
article.
maximum speed position. Turn A/C request switch to ON position. Turn air temperature switch to coldest
position. If A/C compressor operates, problem is intermittent. If A/C compressor does not operate, go to
next step.
3. Park vehicle inside or in shade. Open windows in order to ventilate interior of vehicle. If A/C system was
operating, then allow A/C system to equalize for about 2 minutes. Turn ignition switch to OFF position.
Install Refrigerant Station (J 43600 ACR 2000). Record outside air temperature at vehicle. Record
readings of low and high side static pressures. Compare pressure values with specifications for ambient
air temperature. See PRESSURE-TEMPERATURE RELATIONSHIP article in GENERAL
SERVICING. If pressure values are within specification for ambient air temperature and within 15 psi
(1.1 kg/cm2 ) of each other, go to next step. If pressure values are not within specification for ambient air
temperature or within 15 psi (1.1 kg/cm2 ) of each other, see LEAK TESTING article in GENERAL
SERVICING.
4. Turn ignition switch to ON position, with engine off. Using scan tool, observe A/C high side pressure
sensor parameter in powertrain data list. Compare A/C high side pressure on scan tool to high side
pressure value on refrigerant station. If high side pressure values are within 15 psi (1.1 kg/cm2 ), go to
next step. If high side pressure values are not within 15 psi (1.1 kg/cm2 ), go to step 18 .
to next step.
6. Start engine. Using scan tool, observe A/C request parameter in BCM data list 2. Turn blower motor
switch to maximum position. Turn mode switch to VENT position. Place A/C request switch in ON
position. If scan tool indicates A/C request parameter is YES, go to next step. If scan tool indicates A/C
request parameter is not YES, go to step 11 .
7. Using scan tool, observe A/C relay commanded parameter in powertrain data list 2. If scan tool indicates
A/C relay commanded parameter is ON, go to next step. If scan tool does not indicates A/C relay
commanded parameter is ON, go to step 28 .
9. Test ignition voltage circuit (Brown wire) to HVAC control assembly for short to ground, high resistance,
11. Start engine. Place A/C request switch in ON position. Measure voltage between A/C request circuit
(Light Green wire) at BCM and ground. If battery voltage is present, go to step 27 . If battery voltage is
not present, go to step 16 .
12. Turn ignition switch to OFF position. Disconnect A/C compressor clutch relay. Using a test light
connected to ground, probe switch side voltage supply circuit of A/C compressor clutch relay connector.
If test light is on, go to next step. If test light is off, go to step 21 .
13. Connect fused jumper (10 amp) between switch side voltage circuit of A/C compressor clutch relay
connector and A/C compressor clutch supply voltage circuit (Dark Green wire) of A/C compressor clutch
relay connector. Turn ignition switch to ON position, with engine off. If A/C compressor clutch engages,
go to step 24 . If A/C compressor clutch does not engage, go to step 17 .
ON position, with engine off. Using a test light connected to ground, probe coil side voltage supply
circuit of A/C compressor clutch relay connector. If test light is on, go to next step. If test light is off, go
to step 20 .
15. Connect test light between control circuit (Dark Green/White wire) of A/C compressor clutch relay
connector and coil side voltage supply circuit of A/C compressor clutch relay connector. Using scan tool,
command A/C compressor clutch relay on and off. If test light turns on and off with each command, go to
step 24 . If test light does not turn on and off with each command, go to step 22 .
16. Check A/C request signal circuit (Light Green wire) for short to ground, high resistance or open. If
26 .
19. Check ground circuit (Gray wire and Black wire) of A/C compressor clutch for high resistance or open. If
25 .
20. Repair coil side voltage supply circuit of A/C compressor clutch relay. After repairs, go to step 35 .
21. Repair switch side voltage supply circuit of A/C compressor clutch relay. After repairs, go to step 35 .
go to step 28 .
2. Start engine. Turn mode switch to OFF position. Place A/C request switch in OFF position. If A/C
indicates A/C REQUEST parameter is OFF, go to next step. If scan tool does not indicate A/C
REQUEST parameter is OFF, go to step 6 .
4. Using scan tool, observe A/C RELAY COMMANDED parameter in BODY CONTROL MODULE
DATA LIST 2. If scan tool indicates A/C RELAY COMMANDED parameter is OFF, go to next step. If
scan tool does not indicate A/C RELAY COMMAND parameter is OFF, go to step 14
problem was found, repair as necessary. after repairs, go to step 20 . If problem was not found, go to step
7.
6. Start engine. Place A/C switch in OFF position. Measure voltage between A/C request circuit (Light
Green wire) at BCM and ground. If battery voltage is present, go to step 9 . If battery voltage is not
present, go to step 13 .
9. Check A/C request signal circuit (Light Green wire) for short to voltage. If problem was found, repair as
Diagnostic Aids
If DTCs P0530, U1016 or U1064 are set, diagnose them before proceeding. See appropriate SELF-
DIAGNOSTICS article in ENGINE PERFORMANCE. If problem is insufficient cooling, check cooling fans
for proper operation. See ELECTRIC COOLING FANS - ALL MODELS article. If cooling fans operate
correctly, diagnose manual A/C-heater system. See appropriate MANUAL A/C-HEATER SYSTEMS article.
An A/C refrigerant pressure less than 43 psi (3.0 kg/cm2 ), or greater than 428 psi (30.1 kg/cm2 ), will cause
PCM to disable A/C compressor clutch. With engine running and A/C on, use scan tool to monitor A/C high-
side system pressure for 2 minutes. If pressure goes out of range, diagnose manual A/C-heater system. See
appropriate MANUAL A/C-HEATER SYSTEMS article.
3.0L: CATERA
SYSTEMS article.
NOTE: Catera is equipped with an anti-theft system. ECM must be programmed when
replaced. See appropriate ANTI-THEFT SYSTEMS article in ACCESSORIES &
EQUIPMENT or COMPUTER RELEARN PROCEDURES article in GENERAL
INFORMATION in ENGINE PERFORMANCE.
Description (A/C Request Circuit)
For proper A/C system operation, the A/C request circuit monitors selected A/C mode, A/C system pressure and
throttle position. When A/C mode is selected with A/C system pressure and throttle angle at a predetermined
value, Engine Control Module (ECM) energizes A/C clutch relay through A/C clutch relay control circuit. The
ECM de-energizes A/C clutch relay during wide open throttle, when engine coolant temperature or A/C system
pressure exceeds a predetermined threshold, or when a non-A/C mode is selected. If system does not operate as
specified, see DIAGNOSTIC SYSTEM CHECK .
Description (A/C Load Signal Circuit)
The ECM receives a signal from the A/C load signal circuit. A normally open pressure switch connected to
battery voltage monitors A/C system operating pressures. If pressures reach approximately 175 psi (12.2
kg/cm2 ) the switch will close, sending a signal to the ECM. The ECM will raise idle speed around 50 RPM to
compensate for the additional load. If system does not operate as specified, see DIAGNOSTIC SYSTEM
CHECK .
Description (A/C Compressor Control Circuit)
The ECM controls the ground side of the A/C clutch relay to energize the A/C compressor clutch. When
component is commanded on by the ECM, voltage on the control circuit should be at or near zero volts. When
component is commanded off by the ECM, voltage on the control circuit should be at or near battery voltage. If
system does not operate as specified, see DIAGNOSTIC SYSTEM CHECK .
2. Turn ignition on, engine off. Try to establish scan tool communication with Instrument Panel Cluster
(IPC), Body Control Module (BCM) and Powertrain Control Module (PCM). If communication with all
modules is established, go to next step. If communication with all modules is not established, see SCAN
TOOL DOES NOT COMMUNICATE WITH CLASS 2 DEVICE in appropriate BODY CONTROL
MODULES article.
COMPRESSOR CLUTCH DOES NOT ENGAGE or COMPRESSOR CLUTCH DOES NOT
DISENGAGE .
maximum speed position. Place A/C switch in ON position. Place air temperature control switch in
coldest position. If A/C compressor operates, problem is intermittent. If A/C compressor does not
operate, go to next step.
SERVICING.
on and off with each command, go to next step. If A/C compressor clutch relay does not turn on and off
5. Turn ignition switch to OFF position. Disconnect A/C compressor clutch relay. Using test light connected
to ground, probe switch side voltage supply circuit (Red wire) of A/C compressor clutch relay. If test
light is on, go to step 7 . If test light is off, go to step 17 .
6. Turn ignition switch to OFF position. Disconnect A/C compressor clutch relay. Turn ignition to ON
position, with engine off. Using test light connected to ground, probe coil side voltage supply circuit
(Brown wire) of A/C compressor clutch relay. If test light is on, go to step 9 . If test light is off, go to step
16 .
7. Connect fused jumper (10 amp) between switch side voltage circuit (Red wire) of A/C compressor clutch
relay and A/C compressor clutch supply voltage circuit (Green wire) of A/C compressor clutch. Turn
ignition to ON position, with engine off. If A/C compressor clutch engages, go to step 18 . If A/C
compressor clutch does not engage, go to next step.
8. Check A/C compressor clutch supply voltage circuit (Green wire) at A/C compressor clutch for short to
ground, high resistance, or open. If problem was found, repair as necessary. After repairs, go to step 26 .
If problem was not found, go to step 13 .
9. Connect test light between control circuit (Brown/Purple wire) of A/C compressor clutch relay and coil
side voltage supply circuit (Brown wire) of A/C compressor clutch relay. Using scan tool, command A/C
compressor clutch relay on and off. If test light turns on and off with each command, go to step 18 . If test
light does not turn on and off with each command, go to next step.
10. If test light remains on with each command, go to next step. If test light does not remain on with each
command, go to step 12 .
11. Check control circuit (Brown/Purple wire) and A/C cut out input circuit (Yellow/Blue wire) of A/C
compressor clutch relay for short to ground. If problem was found, repair as necessary. After repairs, go
12. Check control circuit (Brown/Purple wire) of A/C compressor clutch relay for open. If problem was
13. Check ground circuit (Brown/Black wire) between A/C compressor clutch and secondary cooling fan
temperature switch for high resistance or open. If problem was found, repair as necessary. After repairs,
go to step 26 . If problem was not found, go to next step.
14. Check ground circuit (Black wire) of secondary cooling fan temperature switch for high resistance or
open. If problem was found, repair as necessary. After repairs, go to step 26 . If problem was not found,
go to next step.
15. Ensure engine coolant temperature is less than 248F (120C). Measure resistance between switch side,
secondary cooling fan temperature switch terminals. If resistance is near zero, go to step 20 . If resistance
is not near zero, go to step 21 .
16. Repair coil side voltage supply circuit (Brown wire) of A/C compressor clutch relay. After repairs, go to
step 26 .
17. Repair switch side voltage supply circuit (Red wire) of A/C compressor clutch relay. After repairs, go to
step 26 .
19. Check ECM connectors for poor connections. If problem was found, repair as necessary. After repairs, go
21. Check secondary cooling fan temperature switch connector for poor connections. If problem was found,
23. Replace secondary cooling fan temperature switch. After repairs, go to step 26 .
25. Replace ECM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article in ENGINE
2. Start engine. Place A/C request switch in OFF position. If A/C compressor operates, go to next step. If
A/C compressor does not operate, problem is intermittent.
3. Remove A/C compressor clutch relay. If A/C compressor clutch turns off, go to next step. If A/C
compressor clutch does not turn off, go to step 5 .
4. Measure resistance between switch side A/C compressor clutch relay terminals. If resistance is infinite,
go to step 6 . If resistance is not infinite, go to step 7 .
5. Check A/C compressor clutch supply voltage circuit (Green wire) for short to voltage. If problem was
6. Check A/C clutch relay control circuit (Brown/Purple wire) to ECM and A/C cut out input circuit
(Yellow/Blue wire) to A/C-heater control for short to ground. If problem was found, repair as necessary.
8. Check ECM connectors for poor connections. If problem was found, repair as necessary. After repairs, go
10. Replace the A/C compressor clutch. See appropriate COMPRESSOR SERVICING article in GENERAL
11. Replace ECM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article in ENGINE
Diagnostic Aids
An intermittent condition may be caused by corrosion, misrouted wiring harness, rubbed through wire
insulation, or a wire broken inside insulation. Perform visual inspection and check for continuity along suspect
circuits. Repair as necessary.
3.1L, 3.5L & 3.8L: CENTURY, INTRIGUE & REGAL
SYSTEMS article.
Description
When A/C is selected through A/C control panel, a 12-volt signal is supplied to A/C request input terminal of
PCM. A/C clutch relay is controlled through PCM which also monitors A/C refrigerant pressure. If A/C
refrigerant pressure, and engine operating conditions are within a specific calibrated acceptable range, the PCM
will enable A/C clutch relay. This is accomplished by providing a ground path for A/C clutch relay coil with
PCM. When A/C clutch relay is enabled, battery voltage is supplied to compressor clutch coil.
The PCM will enable A/C compressor clutch whenever engine is running and A/C has been requested, unless:
Throttle angle is greater than 90 percent.

A/C head pressure is greater than 414 psi (29.1 kg/cm2 ) with A/C refrigerant pressure sensor reading
greater than 4.27 volts.
A/C head pressure is less than 35 psi (2.5 kg/cm2 ) with A/C refrigerant pressure sensor reading greater
than .40 volts.
Ignition voltage is less than 10.5 volts.
Engine speed is greater than 4500 RPM for 5 seconds or at 5400 RPM for any amount of time.
Engine coolant temperature is greater than 257F (125C).
Intake air temperature is less than 41F (5C).
2. Turn ignition on, engine off. Try to establish scan tool communication with HVAC control module, Body
Control Module (BCM) and Powertrain Control Module (PCM). If communication with all modules is
established, go to next step. If communication with all modules is not established, see SCAN TOOL
DOES NOT COMMUNICATE WITH CLASS 2 DEVICE in appropriate BODY CONTROL
MODULES article.
COMPRESSOR CLUTCH DOES NOT ENGAGE (AUTOMATIC A/C) , COMPRESSOR
CLUTCH DOES NOT ENGAGE (MANUAL A/C) , COMPRESSOR CLUTCH DOES NOT
DISENGAGE (AUTOMATIC A/C) or COMPRESSOR CLUTCH DOES NOT DISENGAGE
(MANUAL A/C) .
Compressor Clutch Does Not Engage (Automatic A/C)
SERVICING.
4. Turn ignition switch to ON position, with engine off. Using scan tool, observe A/C HIGH SIDE
PRESSURE SENSOR parameter in POWERTRAIN data list. Compare A/C high side pressure on scan
tool to high side pressure value on refrigerant station. If high side pressure values are within 15 psi (1.1
kg/cm2 ) of each other, go to next step. If high side pressure values are not within 15 psi (1.1 kg/cm2 ) of
each other, go to step 15 .
5. HVAC control module is inoperative when module does not respond to any operator control requests. If
HVAC control module is inoperative, go to step 14 . If HVAC control module is not inoperative, go to
next step.
6. Start engine. Using scan tool, observe A/C REQUEST parameter in POWERTRAIN data list. Turn air
temperature switch to coldest position. Place A/C REQUEST switch in ON position. If scan tool indicates
A/C REQUEST parameter is YES, go to next step. If scan tool does not indicate A/C request is YES, go
to step 26 .
7. Using scan tool, observe A/C RELAY COMMAND status in POWERTRAIN Data List. If scan tool
indicates A/C RELAY COMMAND status is ON, go to next step. If scan tool does not indicate A/C
RELAY COMMAND status is ON, go to step 27 .
with each command, go to next step.
9. Turn ignition switch to OFF position. Disconnect A/C compressor clutch relay. Turn ignition to ON
position, with engine off. Using test light connected to ground, probe coil side voltage supply circuit of
A/C compressor clutch relay. If test light is on, go to next step. If test light is off, go to step 22 .
10. Connect test light between control circuit (Dark Green/White wire) of A/C compressor clutch relay and
the coil side voltage supply circuit of A/C compressor clutch relay. Using scan tool, command A/C
11. If test light remains on with each command, go to step 18 . If test light does not remain on with each
12. Turn ignition switch to off position. Disconnect A/C compressor clutch relay. Using test light connected
to ground, probe switch side voltage supply circuit of A/C compressor clutch relay. If test light is on, go
to next step. If test light is not on, go to step 21 .
13. Connect fused jumper (10 amp) between switch side voltage circuit of A/C compressor clutch relay and
A/C compressor clutch supply voltage circuit (Dark Green wire) of A/C compressor clutch. Turn ignition
switch to ON position, with engine off. If A/C compressor clutch engages, go to step 24 . If A/C
14. Check ignition voltage circuit (Brown wire) of HVAC control assembly for short to ground, high
resistance, or open. If problem was found, repair as necessary. After repairs, go to step 33 . If problem
was not found, go to step 16 .
16. Check ground circuit (Black wire) of HVAC control module for open. If problem was found, repair as
17. Check control circuit (Dark Green/White wire) of A/C compressor clutch relay for open. If problem was
27 .
short to ground, high resistance, or open. If problem was found, repair as necessary. After repairs, go to
step 33 . If problem was not found, go to next step.
26. Check HVAC control module connector for poor connections. If problem was found, repair as necessary.
30. Replace the A/C compressor clutch coil. See appropriate COMPRESSOR SERVICING article in
GENERAL SERVICING. After repairs, go to step 33 .
31. Replace HVAC control assembly. See REMOVAL & INSTALLATION in appropriate AUTOMATIC
A/C-HEATER SYSTEMS article. After repairs, go to step 33 .
Compressor Clutch Does Not Engage (Manual A/C)
SERVICING.
5. If HVAC control module is inoperative, go to step 16 . If HVAC control module is not inoperative, go to
next step.
temperature switch to coldest position. Turn blower motor to ON position. Place A/C request switch in
ON position. If scan tool indicates A/C REQUEST parameter is ON, go to step 10 . If scan tool does not
indicate A/C REQUEST parameter is ON, go to next step.
7. If A/C request indicator illuminates, go to step 9 . If A/C request indicator does not illuminate, go to next
step.
8. Ensure blower motor switch is ON position. Turn ignition switch to ON position. Check blower motor off
circuit (Dark Green wire) at HVAC control assembly for short to voltage. If problem was found, repair as
9. Turn ignition to off position. Check A/C request signal circuit (Dark Green/White wire) for short to
ON position, with engine off. Using test light connected to ground, probe coil side voltage supply circuit
of A/C compressor clutch relay. If test light is on, go to next step. If test light is off, go to step 23 .
coil side voltage supply circuit of A/C compressor clutch relay. Using scan tool, command A/C
14. Turn ignition switch to off position. Disconnect A/C compressor clutch relay. Using test light connected
to next step. If test light is off, go to step 24 .
16. Check ignition voltage circuit (Brown wire) of HVAC control module for short to ground, high
29 .
33. Replace HVAC control module. See REMOVAL & INSTALLATION in appropriate MANUAL A/C-
Compressor Clutch Does Not Disengage (Automatic A/C)
2. Start engine. Turn blower motor switch to OFF position. Place A/C request switch in OFF position. If
A/C compressor operates, go to next step. If A/C compressor does not operate, problem is intermittent.
3. Using scan tool, observe A/C RELAY COMMAND STATUS in POWERTRAIN data list. If scan tool
indicates A/C RELAY COMMAND STATUS is ON, go to next step. If scan tool does not indicate A/C
RELAY COMMAND STATUS is ON, go to step 5 .
4. Using scan tool, observe A/C REQUEST parameter in the POWERTRAIN data list. If scan tool indicates
A/C REQUEST parameter is YES, go to step 10 . If scan tool does not indicate A/C REQUEST
parameter is YES, go to step 11 .
go to next step. If resistance is not infinite, go to step 9 .
7. Check A/C clutch relay control circuit (Dark Green/White wire) for short to ground. If problem was
8. Check A/C compressor clutch supply voltage circuit (Dark Green wire) for short to voltage. If problem
14. Replace HVAC control module. See REMOVAL & INSTALLATION in appropriate AUTOMATIC
Compressor Clutch Does Not Disengage (Manual A/C)
3. Using scan tool, observe A/C REQUEST parameter in POWERTRAIN data list. If scan tool indicates
A/C REQUEST parameter is ON, go to next step. If scan tool does not indicate A/C REQUEST
parameter is ON, go to step 6 .
4. Check A/C request signal circuit (Dark Green/White wire) for short to ground. If problem was found,
5. Turn ignition switch to OFF position. Back out terminal for A/C request circuit (Dark Green/White wire)
at HVAC control head. Start engine. Using scan tool, observe A/C REQUEST parameter. If scan tool
indicates A/C REQUEST parameter is ON, go to step 12 . If scan tool does not indicate A/C REQUEST
Diagnostic Aids
insulation or a wire broken inside insulation. Perform visual inspection and check for continuity along suspect
3.1L & 3.8L: GRAND PRIX

SYSTEMS article.
Description
Compressor for air conditioning system is belt-driven by engine through A/C compressor clutch. Clutch allows
compressor to engage for A/C and defroster operation, disengage when air conditioning is not requested and
disengage when engine load must be reduced. Battery voltage is supplied to powertrain control module (PCM)
when heater and A/C control mode selector knob is in MAX A/C, NORM A/C, BI-LEVEL, DEFOG or
DEFROST modes. Voltage signal tells PCM that A/C compressor operation is requested. Under normal
operating conditions, PCM supplies a ground to relay coil of A/C compressor control. Relay energizes. Voltage
is supplied to A/C compressor clutch through relay center fuse. A/C compressor clutch engages. Compressor
runs. If PCM determines engine load should be reduced, such as during full throttle conditions, PCM de-
energizes A/C compressor control relay in order to disengage compressor clutch. De-energization occurs even
though voltage signal from heater and A/C control is still present. Diode of A/C compressor clutch connects
across terminals of A/C compressor clutch. Diode provides a path for current which results from voltage spikes.
Voltage spikes generate from collapsing magnetic field of A/C compressor clutch coil. Voltage spikes occur
every time coil de-energizes.
article.
Compressor Does Not Engage
SERVICING.
next step.
6. Start engine. Using scan tool, observe A/C REQUEST parameter in ENGINE DATA 2 data list. Turn air
ON position. If scan tool indicates A/C REQUEST parameter is ON, go to step 11 . If scan tool does not
indicate A/C REQUEST parameter is ON, go to next step.
7. If A/C request indicator illuminates, go to step 9 . If A/C request indicator does not illuminate, go to next
step.
8. Ensure blower motor switch is in ON position. Turn ignition switch to ON position. Check blower motor
off circuit (Dark Green wire) at HVAC control assembly for short to voltage. If problem was found,
9. Turn ignition switch to OFF position. Disconnect PCM. Turn ignition switch to ON position, with engine
off. Turn air temperature switch to coldest position. Turn blower motor switch to maximum speed
position. Place A/C request switch in ON position. Measure voltage between A/C request signal circuit
(Dark Green/White wire) of PCM and ground. If voltage is 10-12.5 volts, go to step 30 . If voltage is not
10-12.5 volts, go to next step.
10. Turn ignition switch to OFF position. Check A/C request signal circuit (Dark Green/White wire) for short
to ground, high resistance, or open. If problem was found, repair as necessary. After repairs, go to step
36 . If problem was not found, go to step 29 .
17. Test ignition voltage circuit (Brown wire) of HVAC control module for short to ground, high resistance,
18. Check ground circuit (Black wire) of A/C refrigerant pressure sensor for open. If problem was found,
30 .
23. Check ground circuit (Black wire) of A/C compressor clutch for a high resistance or open. If problem was
26. Check A/C refrigerant pressure sensor connector for poor connections. If problem was found, repair as
31. Replace A/C refrigerant pressure sensor. After repairs, go to step 36 .
Compressor Does Not Disengage
2. Start engine. Turn blower motor switch to OFF position. If A/C compressor operates, go to next step. If
A/C compressor does not operate, problem is intermittent.
3. Using scan tool, observe A/C REQUEST parameter in ENGINE DATA 2 data list. If scan tool indicates
4. Check A/C request signal circuit (Dark Green/White wire) for short to voltage. If problem was found,
5. Turn ignition switch to OFF position. Disconnect HVAC control module. Back out terminal for A/C
request circuit (Dark Green/White wire) at HVAC control head. Start engine. Using scan tool, observe
A/C REQUEST parameter. If scan tool indicates A/C REQUEST parameter is ON, go to step 12 . If scan
tool does not indicate A/C REQUEST parameter is ON, go to step 11 .
3.1L: LUMINA
SYSTEMS article.
Description
When A/C is selected through A/C controller, a 12.0 volt signal is supplied to A/C request input of PCM. A/C
compressor clutch relay is controlled through PCM. PCM monitors A/C refrigerant pressure. If A/C refrigerant
pressure and engine operating conditions are within a specific calibrated acceptable ranges, PCM will enable
A/C compressor relay. This is accomplished by providing a ground path for A/C relay coil within PCM. When
A/C compressor relay is enabled battery voltage is supplied to compressor clutch coil.
The PCM will disengage A/C compressor clutch if one or more of the following conditions occur:
Throttle angle is greater than 96 percent.

A/C head pressure is greater than 440 psi (31 kg/cm2 ) with A/C refrigerant pressure sensor reading
greater than 4.27 volts.
A/C head pressure is less than 36 psi (2.5 kg/cm2 ) with A/C refrigerant pressure sensor reading less
than .35 volts.
Ignition voltage is less than 10.0 volts.
Engine speed is greater than 4700 RPM for 5 seconds or at 5400 RPM for any amount of time.
Engine coolant temperature is greater than 255F (124C).
Intake air temperature is less than 41F (5C).
and Powertrain Control Module (PCM). If communication with BCM and PCM is established, go to next
step. If communication with BCM or PCM is not established, see SCAN TOOL DOES NOT
3. Select display DTC function for BCM and PCM. Record all displayed DTCs and status of displayed
DTCs. If DTCs are displayed, go to next step. If no DTCs are displayed, see DIAGNOSIS .
4. If scan tool displays DTCs beginning with "B", see appropriate SELF-DIAGNOSTICS article in BODY
CONTROL MODULES. If scan tool displays DTCs beginning with "P", see appropriate SELF-
Diagnosis
NOTE: Before performing this step, ambient air temperature must be greater than
41F (5C), A/C pressure must be greater than 36 psi (2.5 kg/cm2 ) and
coolant temperature must be less than 250F (121C).
2. Turn A/C selector switch to OFF position. Turn ignition switch to ON position, with engine off. Listen
for engagement of A/C clutch. If A/C clutch engages, go to step 17 . If A/C clutch does not engage, go to
next step.
3. Start engine. Select DEFROST or MAX mode on HVAC control. Observe A/C compressor. If A/C
compressor clutch engages, see DIAGNOSTIC AIDS . If A/C clutch does not engage, go to next step.
4. With DEFROST or MAX mode selected, monitor A/C REQUEST display on scan tool in ENGINE data
list. If A/C REQUEST displays YES, go to step 8 . If A/C REQUEST does not display YES, go to next
step.
5. Turn ignition switch to OFF position. Disconnect PCM. Turn ignition switch to ON position. With
DEFROST or MAX mode selected, measure voltage between A/C request circuit (Light Green wire) at
PCM harness connector and ground. If battery voltage is present, go to step 7 . If battery voltage is not
present, go to next step.
6. Check A/C request circuit (Light Green wire) for open, shorted to ground or poor connections. If problem
was found, repair as necessary. After repair, go to step 28 . If problem was found, see DIAGNOSTIC
SYSTEM CHECK .
7. Check A/C request circuit (Light Green wire) for poor connection at PCM. If problem was found, repair
as necessary. After repairs, go to step 28 . If problem was not found, go to step 26 .
8. Observe A/C REFRIGERANT PRESSURE display on scan tool. If A/C pressure is 36 - 440 psi (2.5-31
kg/cm2 ), go to step 11 . If A/C pressure is not 36-440 psi (2.5-31 kg/cm2 ), go to next step.
9. Connect Manifold Gauge Set (J 39183-C R-134a). Observe high side refrigerant pressure on gauge. If
high side refrigerant pressure is 36-440 psi (2.5-31 kg/cm2 ), go to next step. If high side refrigerant
pressure is not 36-440 psi (2.5-31 kg/cm2 ), see DIAGNOSTIC SYSTEM CHECK .
10. Turn ignition switch to OFF position. Disconnect A/C Pressure sensor. Turn ignition switch to ON
position. View A/C HIGHSIDE display on scan tool in ENGINE data list. If scan tool displays A/C
HIGHSIDE pressure at zero psi, go to step 27 . If scan tool does not display A/C HIGHSIDE pressure at
zero psi, go to step 26 .
11. Disconnect A/C relay connector. Using test light connected to ground, probe ignition feed circuits (Pink
wires) at A/C relay connector. If test light is on, go to next step. If test light is off, go to step 22 .
12. Connect fused jumper between ignition feed circuit (Pink wire) and A/C compressor clutch control circuit
(Dark Green wire) at A/C relay connector. If A/C compressor clutch engages, go to next step. If A/C
13. Check A/C relay connector for poor connections. If problem was found, repair as necessary. After repairs,
go to step 28 . If problem was not found, go to step 23 .
14. Disconnect A/C compressor clutch connector (leave ignition control circuit and A/C compressor clutch
control circuit jumpered at A/C relay connector). Connect test light between A/C compressor clutch feed
circuit (Dark Green wire) and compressor ground circuit (Black wire). If test light is on, go to next step. If
test light is off, go to step 16 .
16. Check A/C compressor clutch control circuit (Dark Green/White wire) for open or short to ground. If
25 .
17. Turn ignition switch to ON position. Turn A/C off. Observe A/C REQUEST display on scan tool. If A/C
REQUEST displays YES, go to next step. If A/C REQUEST does not display YES, go to step 20 .
18. Turn ignition switch to OFF position. Disconnect PCM. Turn ignition to ON position. Turn A/C off.
Using DVOM, measure voltage between A/C request circuit (Light Green wire) at PCM connector and
ground. If battery voltage is present, go to next step. If battery voltage is not present, go to step 26 .
19. Turn ignition switch to OFF position. Disconnect A/C control head. Turn ignition switch to ON position.
Check A/C request circuit (Light Green wire) for short to battery voltage. If problem was found, repair as
necessary. After repairs, go to step 28 . If problem was not found, see DIAGNOSTIC SYSTEM
CHECK .
20. Disconnect A/C relay. Start vehicle and observe A/C compressor. If A/C compressor clutch engages, go
to next step. If A/C compressor clutch does not engage, go to step 23 .
21. Repair short to voltage in A/C compressor clutch control circuit (Dark Green/White wire). After repairs,
go to step 28 .
22. Repair open or short to ground in ignition feed circuit (Pink wire) to A/C compressor relay. After repairs,
go to step 28 .
23. Replace A/C compressor relay. After repairs, go to step 28 .
25. Repair open in A/C compressor clutch ground circuit (Black wire). After repairs, go to step 28 .
PERFORMANCE. After repairs, go to step 28 .
27. Replace A/C refrigerant pressure sensor. After repairs, go to next step.
NOTE: Before performing this step, ensure ambient air temperature is greater
than 41F (5C), A/C pressure is greater than 36 psi (2.5 kg/cm2 ) and
coolant temperature is less than 250F (121C).
28. Start engine. Turn A/C selector switch to ON position. Listen for engagement of A/C clutch. If A/C
clutch engages, system is okay.
Diagnostic Aids
circuits. Repair as necessary. If circuits are okay, check conditions listed under DESCRIPTION .
3.4L & 3.8L: IMPALA & MONTE CARLO
SYSTEMS article.
Description
When A/C is selected through HVAC controller, a 12 volt signal is supplied to Body Control Module (BCM).
BCM in turn signals PCM through Class 2 serial data circuit that A/C has been requested. PCM then determines
if conditions suitable for A/C operation are present. If PCM determines that engine operating conditions are
within acceptable ranges, PCM will enable A/C relay. PCM provides a ground path for A/C relay coil. This
action closes A/C compressor relay contacts and battery voltage is supplied to compressor clutch coil.
Compressor clutch coil has its own ground path.
PCM will enable A/C unless any of the following conditions are met:
Throttle position is more than 96 percent.

A/C pressure is more than 472 psi (4.9 volts) or less than 9 psi (0.1 volt) as determined by A/C pressure
sensor.
Ignition voltage is less than 10 volts.
Engine speed is more than 4700 RPM.
Engine Coolant Temperature (ECT) is more than 255F (124C).
Intake Air Temperature (IAT) is less than 41F (5C).
Class II communication error occurs between HVAC controller and PCM.
article.
SERVICING.
to next step.
6. Start engine. Using scan tool, observe A/C REQUEST SIGNAL parameter in POWERTRAIN DATA
LIST 2. Turn blower motor switch to maximum speed position. Turn mode switch to MAX air position.
Place A/C switch in ON position. If scan tool indicates A/C REQUEST parameter is YES, go to next
step. If scan tool does not indicate A/C REQUEST parameter is YES, go to step 11 .
7. Using scan tool, observe COMMANDED A/C parameter in POWERTRAIN DATA LIST 2. If scan tool
indicates COMMANDED A/C parameter is ON, go to next step. If scan tool does not indicate
COMMANDED A/C parameter is ON, go to step 28 .
9. Check ignition voltage circuit (Brown wire) to HVAC control assembly for short to ground, high
was not found, go to next step.
11. Using scan tool, observe A/C SWITCH parameter in BCM INPUTS. If scan tool indicates A/C SWITCH
parameter is ON, go to step 27 . If scan tool does not indicate A/C SWITCH parameter is ON, go to step
16 .
to ground, probe switch side voltage supply circuit (Orange wire) of A/C compressor clutch relay. If test
light is on, go to next step. If test light is off, go to step 21 .
clutch relay and A/C compressor clutch supply voltage circuit (Dark Green wire) of A/C compressor
clutch. If A/C compressor clutch engages, go to step 24 . If A/C compressor clutch does not engage, go to
step 17 .
(Pink wire) of A/C compressor clutch relay. If test light is on, go to next step. If test light is off, go to step
20 .
coil side voltage supply circuit (Pink wire) of A/C compressor clutch relay. Using scan tool, command
A/C compressor clutch relay on and off. If test light turns on and off with each command, go to step 24 .
If test light does not turn on and off with each command, go to step 22 .
16. Check A/C request signal circuit (Dark Green/White) for short to ground, high resistance, or open. If
26 .
step 35 .
to step 35 .
go to step 28 .
33. Replace BCM. See REMOVAL & INSTALLATION in appropriate BODY CONTROL MODULES
article. After repairs, go to step 35 .
indicates A/C REQUEST parameter is OFF, go to next step. If A/C REQUEST parameter is not OFF, go
to step 6 .
4. Using scan tool, observe COMMANDED A/C parameter in POWERTRAIN DATA LIST 2. If scan tool
indicates COMMANDED A/C parameter is OFF, go to next step. If scan tool does not indicate A/C
COMMAND parameter is OFF, go to step 14 .
5. Check control circuit (Dark Green wire) of A/C compressor clutch relay for short to ground. If problem
6. Using scan tool, observe A/C SWITCH parameter in BCM INPUTS. If scan tool indicates A/C SWITCH
parameter is ON, go to step 9 . If scan tool does not indicate A/C SWITCH parameter is ON, go to step
13 .
8. Check A/C compressor clutch voltage supply circuit (Dark Green wire) at A/C compressor clutch for
short to voltage. If problem was found, repair as necessary. After repairs, go to step 20 . If problem was
not found, go to step 11 .
9. Check A/C request signal circuit (Dark Green/White wire) for short to ground, high resistance, or open. If
12 .
3.5L & 4.0L: AURORA
SYSTEMS article.
Description
The purpose of the air conditioning (A/C) system is to provide cool air and remove humidity from interior of
vehicle. A/C system is engaged when HVAC control module is in any mode except OFF and VENT. A/C
system can operate regardless of temperature setting, as long as ambient temperature is greater than 38F (3C).
If A/C compressor is turned off due to low ambient temperatures, compressor will not be activated until
temperatures reach 42F (6C). Vehicle passenger can adjust temperature offset by adjusting right air
temperature switch assembly. Passenger temperatures can be set 8F (4C) cooler or warmer than drivers
setting.
HVAC control module is interface between vehicle operator and Instrument Panel Module (IPM). HVAC
control module receives power from rear fuse block on ignition 3 voltage circuit. IPM is also powered from rear
fuse block through ignition 3 voltage circuit along with battery positive voltage circuit. IPM and HVAC control
module communicate back and forth over HVAC control module signal and HVAC control module clock signal
circuits.
In order for Powertrain Control Module (PCM) to internally ground A/C compressor clutch relay control
circuit, Dash Integration Module (DIM) and PCM must communicate with each other over class 2 serial data
circuits. PCM monitors A/C refrigerant line pressure and engine coolant temperature. This information is placed
on class 2 serial data circuit and is monitored by DIM. DIM looks at A/C line pressure, engine coolant
temperature, battery voltage along with A/C request input from IPM. DIM will request A/C operation from
PCM if these parameters are within normal operating limits and IPM is requesting A/C operation.
PCM turns on A/C compressor by providing a path to ground through A/C compressor clutch relay control
circuit for A/C compressor clutch relay. Power is provided to A/C compressor clutch relay internally within
underhood fuse block. Once relay closes its internal switch, power from battery is provided to A/C compressor
clutch through A/C compressor clutch supply voltage circuit. Whenever compressor is turned off, A/C
compressor clutch diode provides a path for voltage spike resulting from collapsing magnetic field of the
compressor clutch coil. Ground circuit provides a path to ground for compressor. A/C clutch relay control
circuit is grounded internally within PCM.
2. Turn ignition on, engine off. Try to establish scan tool communication with Body Control Module
(BCM), Dash Integration Module (DIM), Instrument Panel Module (IPM) and Powertrain Control
Module (PCM). If communication with all modules is established, go to next step. If communication with
all modules is not established, see SCAN TOOL DOES NOT COMMUNICATE WITH CLASS 2
DEVICE in appropriate BODY CONTROL MODULES article.
which module set DTCs. If DTCs are displayed, go to next step. If no DTCs are displayed, see
DISENGAGE .
maximum speed position. Place mode switch in DEFROST position. Place air temperature control switch
in coldest position. If A/C compressor operates, problem is intermittent. If A/C compressor does not
SERVICING.
next step.
6. Start engine. Using scan tool, observe COMMANDED A/C parameter in POWERTRAIN data list. Turn
air temperature switch to coldest position. If scan tool indicates COMMANDED A/C parameter is ON,
go to step 13 . If scan tool does not indicate COMMANDED A/C parameter is ON, go to next step.
7. Using scan tool, observe A/C CLUTCH (DESIRED) parameter in DIM A/C INFORMATION list. If scan
tool indicates A/C CLUTCH (DESIRED) parameter is ON, go to next step. If scan tool does not indicate
A/C CLUTCH (DESIRED) parameter is ON, go to step 9 .
8. Using scan tool, observe A/C CLUTCH (ACTUAL) parameter in DIM A/C INFORMATION list. If scan
tool indicates A/C CLUTCH (ACTUAL) parameter is ON, go to step 13 . If scan tool does not indicate
A/C CLUTCH (ACTUAL) parameter is ON, go to step 34 .
9. Using scan tool, observe CONTROL HEAD (DESIRED) parameter in DIM A/C INFORMATION list. If
scan tool indicates CONTROL HEAD (DESIRED) parameter is ON, go to next step. If scan tool does not
indicate CONTROL HEAD (DESIRED) parameter is ON, go to step 12 .
10. Using scan tool, observe PRESSURE STATUS parameter in DIM A/C INFORMATION list. If scan tool
indicates PRESSURE STATUS parameter is NORMAL, go to next step. If scan tool does not indicate
PRESSURE STATUS parameter is NORMAL, problem is intermittent.
11. Using scan tool, observe TEMPERATURE STATUS parameter in DIM A/C INFORMATION list. If
scan tool indicates TEMPERATURE STATUS parameter is OK, go to step 31 . If scan tool does not
indicate TEMPERATURE STATUE parameter is OK, check engine for overheating.
12. Using scan tool, observe A/C CONTROL HEAD (DESIRED) parameter in DIM A/C INFORMATION
list. Turn mode switch to and from DEFROST position. If scan tool indicates A/C CONTROL HEAD
(DESIRED) parameter turns on and off with each command, go to step 30 . If scan tool does not indicate
A/C CONTROL HEAD (DESIRED) parameter turns on and off with each command, go to step 33 .
19. Check ignition voltage circuit (Brown wire and Orange wire) of HVAC control module for short to
34 .
30. Check IPM connector for poor connections. If problem was found, repair as necessary. After repairs, go
31. Check DIM connector for poor connections. If problem was found, repair as necessary. After repairs, go
35. Replace IPM. See appropriate INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
After repairs, go to step 42 .
36. Replace DIM. See REMOVAL & INSTALLATION in appropriate BODY CONTROL MODULES
39. Replace A/C compressor. See appropriate COMPRESSOR SERVICING article in GENERAL
2. Install scan tool. Turn ignition switch to ON position, with engine off. Using scan tool, command A/C
relay on and off. If A/C compressor clutch engages and disengages with each command, go to next step.
If A/C compressor clutch does not engage and disengage with each command, go to step 7 .
3. Start engine. Place A/C request switch in OFF position. Using scan tool, observe COMMANDED A/C
parameter in PCM ENGINE data list. If scan tool displays OFF, go to step 12 . If scan tool does not
display OFF, go to next step.
scan tool displays A/C OFF, go to next step. If scan tool does not display A/C OFF, go to step 6 .
tool displays OFF, go to step 12 . If scan tool does not display OFF, go to step 11 .
6. Using scan tool, observe A/C REQUESTED parameter in IPM HVAC SYSTEM data list. If scan tool
displays NO, go to step 11 . If scan tool does not display NO, go to step 10 .
ON position, with engine off. If A/C compressor clutch disengages, go to step 13 . If A/C compressor
clutch does not disengage, go to next step.
8. Disconnect A/C compressor. If A/C compressor clutch disengages, go to next step. If A/C compressor
clutch does not disengage, go to step 14 .
9. Repair short to voltage in A/C compressor clutch supply voltage circuit (Dark Green wire) of A/C relay.
Diagnostic Aids
3.8L: BONNEVILLE & LESABRE
SYSTEMS article.
Description
Compressor for air conditioning system is belt-driven by engine through A/C compressor clutch. Clutch
controls compressor in the following ways:
Disengages when air conditioning is not requested.

Disengages when engine load must be reduced.
Heater and A/C control automatically requests A/C compressor clutch engagement with system operating in
defrost mode.
Under normal operating conditions, the following events occur:
On Bonneville and LeSabre with manual A/C, A/C-heater control sends an A/C operation desired
message to Dash Integration Module (DIM), DIM sends a request A/C compressor clutch engagement to
Powertrain Control Module (PCM)
On Bonneville and LeSabre with automatic A/C, Instrument Panel Module (IPM) sends an A/C operation
desired message to Dash Integration Module (DIM), DIM sends a request for A/C compressor clutch
engagement to Powertrain Control Module (PCM)
On all models, PCM supplies a ground to A/C compressor control relay coil.
A/C CLU relay energizes.
Voltage is supplied to A/C compressor clutch through A/C CLU fuse.
A/C compressor clutch engages and compressor runs.
PCM monitors A/C refrigerant line pressure and engine coolant temperature. This information is placed on
Class 2 communication link and is monitored by DIM. DIM looks at A/C line pressure, engine coolant
temperature and battery voltage. DIM will request A/C operation from PCM if these parameters are within
normal operation limits and A/C-heater control is requesting A/C operation.
If PCM determines that engine load should be reduced, such as during full throttle conditions, PCM will de-
energize A/C compressor control relay. This will disengage compressor, even though request for A/C
compressor clutch engagement from A/C-heater control is still present.
A/C compressor clutch diode is connected across A/C compressor clutch terminals. This diode provides a path
for current resulting from voltage spikes. Collapsing magnetic field of A/C compressor clutch coil generate
these voltage spikes. Voltage spikes occur every time coil is de-energized.
Diagnostic System Check (Automatic A/C)
2. Turn ignition on, engine off. Try to establish scan tool communication with Dash Integration Module
(DIM), Instrument Panel Module (IPM) and Powertrain Control Module (PCM). If communication with
all modules is established, go to next step. If communication with all modules is not established, see
SCAN TOOL DOES NOT COMMUNICATE WITH CLASS 2 DEVICE in appropriate BODY
COMPRESSOR CLUTCH DOES NOT DISENGAGE (AUTOMATIC A/C) or COMPRESSOR
CLUTCH DOES NOT DISENGAGE (AUTOMATIC A/C) .
Diagnostic System Check (Manual A/C)
2. Turn ignition on, engine off. Try to establish scan tool communication with A/C-heater control module,
Dash Integration Module (DIM) and Powertrain Control Module (PCM). If communication with all
MODULES article.
COMPRESSOR CLUTCH DOES NOT ENGAGE (MANUAL A/C) or COMPRESSOR CLUTCH
DOES NOT DISENGAGE (MANUAL A/C) .
1. If diagnostic system check has not been performed, see DIAGNOSTIC SYSTEM CHECK
(AUTOMATIC A/C) . If diagnostic system check has been performed, go to next step.
SERVICING.
next step.
scan tool indicates TEMPERATURE STATUS parameter is okay, go to step 31 . If scan tool does not
indicate TEMPERATURE STATUS parameter is okay, check engine for overheating.
19. Check ignition voltage circuit (Brown wire and Orange wire) of HVAC control module for short to
34 .
1. If diagnostic system check has not been performed, see DIAGNOSTIC SYSTEM CHECK (MANUAL
A/C) . If diagnostic system check has been performed, go to next step.
maximum speed position. Place bi-level in ON position. Place air temperature control switch in coldest
position. If A/C compressor operates, problem is intermittent. If A/C compressor does not operate, go to
next step.
SERVICING.
next step.
air temperature switch to coldest position. Place bi-level switch in ON position. If scan tool indicates
COMMANDED A/C parameter is ON, go to step 13 . If scan tool does not indicate COMMANDED A/C
parameter is ON, go to next step.
scan tool indicates TEMPERATURE STATUS parameter is OK, go to step 30 . If scan tool does not
indicate TEMPERATURE STATUE parameter is OK, check engine for overheating.
15. Connect test light between control circuit (Dark Green/White wire) and coil side voltage supply circuit of
A/C compressor clutch relay. Using scan tool, command A/C compressor clutch relay on and off. If test
light turns on and off with each command, go to step 29 . If test light does not turn on and off with each
command, go to next step.
18. Connect fused jumper (10 amp) between switch side voltage circuit and supply voltage circuit (Dark
Green wire) of A/C compressor clutch relay. Turn ignition switch to ON position, with engine off. If A/C
20. Check ground circuit (Black wire) of HVAC control assembly for open. If problem was found, repair as
33 .
23. Check supply voltage circuit (Dark Green wire) at A/C compressor clutch for short to ground, high
2. Start engine. Turn blower motor switch to OFF position. Place A/C switch in OFF position. If A/C
compressor operates, go to next step. If A/C compressor clutch does not operate, problem is intermittent.
3. Using scan tool, observe A/C RELAY COMMANDED parameter in PCM data list. If scan tool indicates
A/C RELAY COMMANDED parameter is ON, go to next step. If scan tool does not indicate A/C
RELAY COMMANDED parameter is ON, go to step 7 .
list. If scan tool displays OFF, go to next step. If scan tool does not display OFF, go to step 12 .
displays YES, go to next step. If scan tool does not display YES, go to step 13 .
ON position. If A/C compressor clutch disengages, go to next step. If A/C compressor clutch does not
disengage, go to step 9 .
11 .
was found, repair as necessary. After repairs, go to step 22 . If problem was not found, go to next step.
17. Replace A/C compressor clutch hub and plate. See appropriate COMPRESSOR SERVICING article in
2. Start engine. Turn blower motor switch to OFF position. Place bi-level switch in OFF position. If A/C
3. Using scan tool, observe COMMANDED A/C parameter in POWERTRAIN data list. If scan tool
indicates COMMANDED A/C parameter is ON, go to next step. If scan tool does not indicate
COMMANDED A/C parameter is ON, go to step 6 .
5. Using scan tool, observe A/C CLUTCH (DESIRED) parameter in DIM A/C INFORMATION List. If
scan tool displays OFF, go to step 13 . If scan tool does not display OFF, go to step 12 .
10 .
3.8L: PARK AVENUE
SYSTEMS article.
Description
Compressor for air conditioning system is belt-driven by engine through A/C compressor clutch. Clutch
controls compressor in the following ways:
Disengages when air conditioning is not requested.

Disengages when engine load must be reduced.
Heater and A/C control automatically requests A/C compressor clutch engagement with system operating in
defrost mode.
Under normal operating conditions, the following events occur:
A/C-heater control sends an A/C operation desired message to Body Control Module (BCM). BCM sends
a request for A/C compressor clutch engagement to Powertrain Control Module (PCM).
PCM supplies a ground to A/C compressor control relay coil.
A/C CLU relay energizes.
Voltage is supplied to A/C compressor clutch through A/C CLU fuse.
A/C compressor clutch engages and compressor runs.
PCM monitors A/C refrigerant line pressure and engine coolant temperature. This information is placed on
Class 2 communication link and is monitored by DIM. DIM looks at A/C line pressure, engine coolant
temperature and battery voltage. DIM will request A/C operation from PCM if these parameters are within
normal operation limits and A/C-heater control is requesting A/C operation.
If PCM determines that engine load should be reduced, such as during full throttle conditions, PCM will de-
energize A/C compressor control relay. This will disengage compressor, even though request for A/C
compressor clutch engagement from A/C-heater control is still present.
A/C compressor clutch diode is connected across A/C compressor clutch terminals. This diode provides a path
for current resulting from voltage spikes. Collapsing magnetic field of A/C compressor clutch coil generate
these voltage spikes. Voltage spikes occur every time coil is de-energized.
2. Turn ignition on, engine off. Try to establish scan tool communication with A/C-heater control module,
Body Control Module (BCM) and Powertrain Control Module (PCM). If communication with all
MODULES article.
DISENGAGE .
SERVICING.
PRESSURE SENSOR parameter in POWERTRAIN data list. Compare A/C HIGH SIDE PRESSURE on
scan tool to high side pressure value on refrigerant station. If high side pressure values are within 15 psi
(1.1 kg/cm2 ) of each other, go to next step. If high side pressure values are not within 15 psi (1.1
kg/cm2 ) of each other, go to step 23 .
next step.
7. Using scan tool, observe A/C CLUTCH (DESIRED) parameter in BCM A/C INFORMATION list. If
scan tool indicates A/C CLUTCH (DESIRED) parameter is ON, go to next step. If scan tool does not
indicate A/C CLUTCH (DESIRED) parameter is ON, go to step 9 .
8. Using scan tool, observe A/C CLUTCH (ACTUAL) parameter in BCM A/C INFORMATION list. If
scan tool indicates A/C CLUTCH (ACTUAL) parameter is ON, go to step 13 . If scan tool does not
indicate A/C CLUTCH (ACTUAL) parameter is ON, go to step 34 .
9. Using scan tool, observe CONTROL HEAD (DESIRED) parameter in BCM A/C INFORMATION list.
If scan tool indicates CONTROL HEAD (DESIRED) parameter is ON, go to next step. If scan tool does
not indicate CONTROL HEAD (DESIRED) parameter is ON, go to step 12 .
10. Using scan tool, observe PRESSURE STATUS parameter in BCM A/C INFORMATION list. If scan tool
11. Using scan tool, observe TEMPERATURE STATUS parameter in BCM A/C INFORMATION list. If
indicate TEMPERATURE STATUS parameter is okay, check engine for overheating.
12. Using scan tool, observe A/C REQUESTED parameter in HVAC SYSTEM data list. Turn mode switch
to and from DEFROST position. If scan tool indicates A/C REQUESTED parameter turns on and off
with each command, go to step 30 . If scan tool does not indicate A/C REQUESTED parameter turns on
and off with each command, go to step 33 .
20. Check ground circuit (Black/White wire) of HVAC control module for open. If problem was found,
34 .

3. Using scan tool, observe COMMANDED A/C parameter in PCM data list. If scan tool indicates
COMMANDED A/C parameter is ON, go to next step. If scan tool does not indicate COMMANDED
A/C parameter is ON, go to step 7 .
4. Using scan tool, observe A/C CONTROL HEAD (DESIRED) parameter in BCM A/C INFORMATION
displays NO, go to next step. If scan tool does not display NO, go to step 13 .
6. Using scan tool, observe A/C CLUTCH (DESIRED) parameter in BCM A/C INFORMATION list. If
scan tool displays OFF, go to step 15 . If scan tool does not display OFF, go to step 14 .
ON position, with engine off. If A/C compressor clutch disengages, go to next step. If A/C compressor
11 .
12. Check HVAC connector for poor connections. If problem was found, repair as necessary. After repairs,
go to step 22 . If problem was not found, go to step 18 .
14. Check BCM connector for poor connections. If problem was found, repair as necessary. After repairs, go
3.8L & 5.7L: CAMARO & FIREBIRD
SYSTEMS article.
Description
A/C system can operate regardless of temperature setting, as long as ambient air temperature is greater than 38
F (3C). If A/C compressor clutch is turned off due to cold ambient air temperatures, compressor will not come
back on until ambient air temperatures reach 41F (5C).
Regardless of selected A/C mode setting, a request is made to Powertrain Control Module (PCM) to turn on
A/C compressor clutch. Request is made through A/C request signal circuit from HVAC control assembly.
Power and ground are provided to HVAC control assembly by ignition voltage and ground circuits.
When vehicle operator makes an A/C request, a 12 volt request signal is sent out over A/C request signal circuit
and grounded through PCM. When this request signal is grounded, PCM can activate A/C compressor clutch.
PCM turns on A/C compressor clutch by providing a path to ground through A/C compressor clutch relay
control circuit for A/C compressor clutch relay. Power is provided to A/C compressor clutch relay from of
underhood fuse block on ignition voltage circuit. Once relay closes its internal switch, power from battery is
provided to A/C compressor clutch through A/C compressor clutch supply voltage circuit. Whenever
compressor is turned off, A/C compressor clutch diode prevents a voltage spike from entering vehicles electrical
system. Ground circuit provides a path to ground for compressor. A/C compressor clutch relay control circuit is
grounded internally within PCM. On vehicles with V8 option, an A/C compressor clutch status signal is sent to
PCM on A/C compressor clutch supply voltage circuit.
article.
maximum speed position. Place A/C request switch in ON position. Place air temperature control switch
SERVICING.
next step.
ON position. If scan tool indicates A/C request parameter is YES, go to step 9 . If scan tool does not
indicate A/C parameter is YES, go to next step.
7. If A/C request indicator is on, go to next step. If A/C request indicator is off, go to step 27 .
22 .
If test light does not turn on and off with each command, go to next step.
to ground, probe switch side voltage supply circuit (Pink wire) of A/C compressor clutch relay. If test
14. Connect fused jumper (10 amp) between switch side voltage circuit (Pink wire) of A/C compressor clutch
relay and A/C compressor clutch supply voltage circuit (Dark Green wire) of A/C compressor clutch.
Turn ignition switch to ON position, with engine off. If A/C compressor clutch engages, go to step 25 . If
A/C compressor clutch does not engage, go to step 20 .
15. Check voltage supply circuit (Brown wire) to HVAC control assembly for short to ground, high
16. Check ground circuit (Gray wire for 3.8L and Purple wire for 5.7L) of A/C pressure sensor for open. If
24 .
17. Check ground circuit of HVAC control assembly for open. If problem was found, repair as necessary.
28 .
22. Repair switch side voltage supply circuit (Pink wire) of A/C compressor clutch relay. After repairs, go to
step 34 .
step 34 .
A/C REQUEST parameter is YES, go to next step. If scan tool does not indicate A/C REQUEST
parameter is YES, go to step 6 .
5. Turn ignition switch to OFF position. Disconnect HVAC control connector. Back out terminal for A/C
request circuit (Dark Green/White wire) from HVAC control assembly connector. Reconnect HVAC
control assembly connector. Start engine. Using scan tool, observe A/C REQUEST parameter. If scan
tool indicates A/C REQUEST parameter is YES, go to step 12 . If scan tool does not indicate A/C
REQUEST parameter is YES, go to step 11 .
6. Turn ignition switch to OFF position. Remove A/C compressor clutch relay. Turn ignition switch to ON
position. If A/C compressor clutch turns off, go to next step. If A/C compressor clutch does not turn off,
go to step 9 .
14. Replace A/C compressor clutch hub and plate assembly. See appropriate COMPRESSOR SERVICING
Diagnostic Aids
Check for poor harness connections at PCM and A/C control head. Inspect for corrosion, backed-out terminal
pins, and broken wires inside insulation. Check for damaged wire harness. If harness and connections are okay,
disconnect PCM harness connectors. Connect a DVOM between ground and A/C clutch relay control circuit at
PCM harness connector. Turn ignition switch to ON position. Observe DVOM while wiggling harness and
connectors. A change in voltage indicates location of fault.
An A/C refrigerant pressure less than 35 psi (2.5 kg/cm2 ), or greater than 414 psi (29.1 kg/cm2 ) will cause
PCM to disable A/C compressor clutch. With engine running and A/C on, use scan tool to monitor A/C high-
side system pressure for 2 minutes. If pressure goes out of range, diagnose A/C-heater system. See MANUAL
A/C-HEATER SYSTEMS - CAMARO & FIREBIRD article.
4.6L: DEVILLE & SEVILLE
SYSTEMS article.
NOTE: Since many DTCs cause PCM to disable A/C compressor clutch operation, any
DTCs stored in memory must be repaired and cleared before proceeding. See
appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
Description
When A/C request is selected, a signal is sent from Instrument Panel Module (IPM) to Powertrain Control
Module (PCM). In order for PCM to internally ground A/C clutch relay control circuit, Dash Integration
Module (DIM) and PCM must communicate with each other over class 2 serial data circuits. PCM monitors
A/C refrigerant line pressure and engine coolant temperature. This information is placed on class 2 serial data
circuit and is monitored by DIM. DIM looks at A/C line pressure, A/C refrigerant low temperature sensor,
engine coolant temperature, battery voltage along with A/C request input from HVAC control module. DIM
will request A/C operation from PCM if these parameters are within normal operating limits and IPM is
requesting A/C operation. If there is a malfunction in A/C system, instrument panel will read SERVICE A/C
SYSTEM to alert vehicle operator that there is a malfunction with A/C system.
PCM turns on A/C compressor by providing a path to ground through A/C clutch relay control circuit for A/C
compressor clutch relay. Power is provided to A/C compressor clutch relay internally of underhood fuse block.
Once relay closes its internal switch, power from battery is provided to A/C compressor clutch through A/C
compressor clutch supply voltage circuit. Whenever compressor is turned off, A/C compressor clutch diode
provides a path for voltage spike resulting from collapsing magnetic field of compressor clutch coil. Ground
circuit provides a pathway to ground for compressor. A/C clutch relay control circuit is grounded internally
within PCM.
2. Turn ignition on, engine off. Try to establish scan tool communication with Dash Integration module
(DIM), Instrument Panel Module (IPM), Powertrain Control Module (PCM) and rear climate control. If
communication with all modules is established, go to next step. If communication with all modules is not
DISENGAGE .
maximum speed position. Press A/C switch to ON position. Place air temperature control switch in
SERVICING.
5. If HVAC control module (IPM) is inoperative, go to step 19 . If HVAC control module (IPM) is not
inoperative, go to next step.
6. Start engine. Using scan tool, observe A/C RELAY COMMAND parameter in POWERTRAIN data list.
Place air temperature switch in coldest position. Press A/C switch to ON position. If scan tool indicates
A/C RELAY COMMAND parameter is ON, go to step 13 . If scan tool does not indicate A/C RELAY
COMMAND parameter is ON, go to next step.
indicate TEMPERATURE STATUS is okay, check engine for overheating.
12. Using scan tool, observe CONTROL HEAD (DESIRED) parameter in DIM A/C INFORMATION list.
Place mode switch in and out of DEFROST position. If scan tool indicates CONTROL HEAD
CONTROL HEAD (DESIRED) parameter turns on and off with each command, go to step 32 .
16. If test light remain on with each command, go to step 23 . If test light does not remain on with each
19. Check ignition voltage circuit (Brown wire) to IPM for a short to ground, high resistance, or open. If
21 .
20. Check ground circuit (Black wire or Black/White wire) of A/C pressure sensor for open. If problem was
21. Check ground circuit (Black wire) to IPM for open. If problem was found, repair as necessary. After
33 .
3. Using scan tool, observe A/C RELAY COMMAND parameter in POWERTRAIN data list. If scan tool
indicates A/C RELAY COMMAND parameter is ON, go to next step. If scan tool does not indicate A/C
RELAY COMMAND parameter is ON, go to step 6 .
scan tool displays OFF, go to next step. If scan tool does not display OFF, go to step 11 .
10 .
4.6L: ELDORADO
SYSTEMS article.
NOTE: Since many DTCs cause PCM to disable compressor clutch operation, any
DTCs stored in memory must be repaired and cleared before proceeding. See
Description
HVAC control module is interface between vehicle operator and HVAC control processor. When an A/C
request is selected, a signal is sent from HVAC control processor to Powertrain Control Module (PCM). PCM
monitors A/C refrigerant line pressure, A/C refrigerant temperatures and engine coolant temperature. If all PCM
signals are normal, A/C clutch relay control circuit will be grounded, allowing A/C compressor to engage. If
there is a malfunction in A/C system, driver information center will read either SERVICE A/C SYSTEM or
LOW RERFIG A/C OFF to alert vehicle operator that there is a malfunction with A/C system.
compressor clutch relay. Power is provided to A/C compressor clutch relay from underhood fuse/relay block on
A/C low pressure switch signal circuit and both A/C pressure switches. Once relay closes its internal switch,
power from battery is provided to A/C compressor clutch through A/C compressor clutch supply voltage circuit.
Ground circuit provides a path to ground for compressor. A/C clutch relay control circuit is grounded internally
within PCM.
PCM will open A/C clutch relay control circuit when coolant temperatures get too hot or their is a loss of
refrigerant. When engine coolant temperatures reach 259F (126C), PCM will open A/C clutch relay control
circuit. When PCM reads wide open throttle, PCM will shut off compressor for 20 seconds.
MODULES article.
DISENGAGE .
SERVICING.
next step.
5. Turn ignition switch to ON position, with engine off. Using scan tool, observe A/C OFF SWITCH
parameter in CLIMATE CONTROL PANEL (CCP) inputs. Cycle A/C switch on and off. If scan tool
parameter turns on and off each time switch is pressed, go to step 8 . If scan tool parameter does not turn
on and off each time switch is pressed, go to step 31 .
6. Check battery voltage circuit (Orange wire) to HVAC control module for short to ground, high resistance,
7. Test ground circuit (Black/White wire and Black wire) of HVAC control module for open or high
resistance. If problem was found, repair as necessary. After repairs, go to step 42 . If problem was not
8. Turn ignition switch to ON position, with engine off. If A/C system was operating, allow A/C system to
equalize for approximately 2 minutes. Using scan tool, observe A/C HIGH and LOW REFRIGERANT
PRESSURE SWITCHES in HEATING AND AIR CONDITIONING inputs. If scan tool indicates both
HIGH and LOW REFRIGERANT PRESSURE SWITCHES are CLOSED, go to step 12 . If scan tool
does not indicate both HIGH and LOW REFRIGERANT PRESSURE SWITCHES are CLOSED, go to
next step.
9. If scan tool indicates high refrigerant pressure switch is open, go to next step. If scan tool does not
indicate high refrigerant pressure switch is open, go to step 11 .
10. Turn ignition switch to OFF position. Disconnect A/C high pressure switch. Connect fused jumper (3
amp) across A/C high pressure switch connector. Start engine. Using scan tool, observe HIGH
REFRIGERANT PRESSURE SWITCH parameter. If scan tool indicates HIGH REFRIGERANT
PRESSURE SWITCH parameter is CLOSED, go to step 33 . If scan tool does not indicate HIGH
REFRIGERANT PRESSURE SWITCH parameter is CLOSED, go to step 14 .
11. Turn ignition switch to OFF position. Disconnect A/C low pressure switch. Connect fused jumper (3
amp) across A/C low pressure switch connector. Start engine. Using scan tool, observe LOW
REFRIGERANT PRESSURE SWITCH parameter. If scan tool indicates LOW REFRIGERANT
PRESSURE SWITCH parameter is CLOSED, go to step 29 . If scan tool does not indicate LOW
REFRIGERANT PRESSURE SWITCH parameter is CLOSED, go to step 15 .
12. Start engine. Using scan tool, observe A/C POSSIBLE parameter in HEATING AND AIR
CONDITIONING inputs. Place A/C in ON position. If scan tool indicates A/C POSSIBLE parameter is
ON, go to next step. If scan tool does not indicate A/C POSSIBLE parameter is ON, go to step 32 .
13. Start engine. Using scan tool, observe COMMANDED A/C parameter in POWERTRAIN data list. Place
air temperature switch in coldest position. Place A/C in ON position. If scan tool indicates
COMMANDED A/C parameter is ON, go to step 16 . If scan tool does not indicate COMMAND A/C
14. Turn ignition switch to OFF position. Reconnect A/C high pressure switch. Check A/C high pressure
switch input circuit (Dark Blue wire) for short to ground, high resistance, or open. If problem is found,
repair as necessary. After repairs, go to step 42 . If problem is not found, go to step 34 .
15. Turn ignition switch to OFF position. Connect A/C low pressure switch. Check A/C low pressure switch
input circuit (Dark Green wire) for short to ground, high resistance, or open. If problem is found, repair as
necessary. After repairs, go to step 42 . If problem is not found, go to step 34 .
clutch. Turn ignition switch to ON position, with engine off. If A/C compressor clutch engages, go to step
28 . If A/C compressor clutch does not engage, go to step 22 .
(Dark Blue wire) of A/C compressor clutch relay. If test light is on, go to next step. If test light is off, go
to step 26 .
coil side voltage supply circuit (Dark Green wire) of A/C compressor clutch relay. Using scan tool,
command A/C compressor clutch relay on and off. If test light turns on and off with each command, go to
step 28 .
21. If test light remains on with each command, go to step 24 . If test light does not remain on, go to step 25 .
34 .
26. Repair coil side voltage supply circuit (Dark Blue wire) of A/C compressor clutch relay. After repairs, go
to step 42 .
to step 42 .
29. Check A/C low pressure switch connector for poor connections. If problem was found, repair as
32. Check heater and A/C programmer connector for poor connections. If problem was found, repair as
33. Check A/C high pressure switch connector for poor connections. If problem was found, repair as
36. Replace A/C low pressure switch. After repairs, go to step 42 .
38. Replace HVAC control processor. See REMOVAL & INSTALLATION in appropriate AUTOMATIC
2. Start engine. Place A/C switch in OFF position. If A/C compressor operates, go to next step. If A/C
compressor does not operate, problem is intermittent.
3. Using scan tool, observe A/C OFF SWITCH parameter in CLIMATE CONTROL PANEL (CCP). If scan
tool indicates A/C OFF SWITCH parameter is OFF, go to next step. If scan tool does not indicate A/C
OFF SWITCH parameter is OFF, go to step 12 .
4. Using scan tool, observe A/C COMMAND parameter in HEATING AND AIR CONDITIONING inputs.
If scan tool displays NO, go to next step. If scan tool does not display NO, go to step 13 .
5. Using scan tool, observe A/C RELAY COMMAND parameter in POWERTRAIN data List 2. If scan tool
displays OFF, go to next step. If scan tool does not display OFF, go to step 14 .
14 .
13. Check HVAC control processor connector for poor connections. If problem was found, repair as
18. Replace HVAC control processor. See REMOVAL & INSTALLATION in appropriate AUTOMATIC
5.7L: CORVETTE
SYSTEMS article.
Description
The A/C clutch relay is PCM controlled to delay A/C compressor clutch engagement after A/C is turned on.
This allows PCM to adjust engine RPM before the A/C compressor clutch engages. The PCM will engage
compressor clutch any time A/C has been requested, unless one or more of the following conditions occur:
Coolant temperature is high.

A/C system pressure is low.
A/C system pressure is high.
During wide open throttle.
High engine RPM.
Certain DTCs are set.
When A/C-heater control panel is placed in A/C mode, a 12-volt signal is sent to PCM. When PCM receives
this signal, PCM will ground A/C clutch relay control circuit to energize A/C clutch relay. This is shown on
scan tool as A/C REQUEST YES.
When an A/C request has been detected by PCM, the PCM will ground A/C clutch relay control circuit. As a
result, relay contacts close, allowing current to flow through relay to compressor clutch. When A/C REQUEST
has been detected by PCM, cooling fans will turn on when A/C system pressure is greater than a predetermined
value.
Diagnostic System Check (Automatic A/C)
MODULES article.
COMPRESSOR CLUTCH DOES NOT ENGAGE (AUTOMATIC A/C) or COMPRESSOR
CLUTCH DOES NOT DISENGAGE (AUTOMATIC A/C) .
Diagnostic System Check (Manual A/C)
ENGAGE (MANUAL A/C) or COMPRESSOR CLUTCH DOES NOT DISENGAGE (MANUAL
A/C) .
article.
SERVICING.
PRESSURE parameter in POWERTRAIN data list. Compare A/C HIGH SIDE PRESSURE parameter on
next step.
6. Start engine. Using scan tool, observe A/C REQUEST SIGNAL parameter in POWERTRAIN data list.
Place air temperature switch in coldest position. Place A/C request switch in ON position. If scan tool
indicates A/C REQUEST SIGNAL parameter is YES, go to next step. If scan tool does not indicate A/C
REQUEST SIGNAL parameter is YES, go to step 26 .
7. Using scan tool, observe A/C RELAY COMMAND STATUS in POWERTRAIN data list. If scan tool
indicates A/C RELAY COMMAND STATUS is ON, go to next step. If scan tool does not indicate A/C
RELAY COMMAND STATUS is ON, go to step 27 .
light does not turn on an off with each command, go to next step.
15. Check low reference circuit (Black wire) of A/C refrigerant pressure sensor for open. If problem was
27 .
1. If diagnostic system check has not been performed, see Diagnostic System Check (Manual A/C) . If
SERVICING.
next step.
6. Start engine. Using scan tool, observe A/C REQUEST parameter in POWERTRAIN data list. Place air
temperature switch in coldest position. Turn blower motor to ON position. Place A/C REQUEST switch
in ON position. If scan tool indicates A/C REQUEST parameter is ON, go to step 10 . If scan tool does
not indicate A/C REQUEST parameter is ON, go to next step.
7. If A/C request indicator is on, go to step 9 . If A/C request indicator is not on, go to next step.
8. Ensure blower motor switch is in ON position. Turn ignition switch to ON position. Check blower motor
off circuit (Light Green wire) at HVAC control module for short to voltage. If problem was found, repair
as necessary. After repairs, go to step 35 . If problem was not found, go to step 28 .
17. Check ground circuit (Black wire) of A/C refrigerant pressure sensor for open. If problem was found,
29 .
23. Repair switch side voltage supply circuit of the A/C compressor clutch relay. After repairs, go to step 35 .
24. Repair coil side voltage supply circuit of the A/C compressor clutch relay. After repairs, go to step 35 .
2. Start engine. Place blower motor switch in OFF position. Place A/C request switch in OFF position. If
3. Using scan tool, observe A/C RELAY COMMAND parameter in POWERTRAIN data list. If scan tool
indicates A/C RELAY COMMAND parameter is ON, go to next step. If scan tool does not indicate A/C
RELAY COMMAND parameter is ON, go to step 5 .
4. Using scan tool, observe A/C REQUEST SIGNAL parameter in POWERTRAIN data list. If scan tool
indicates A/C REQUEST SIGNAL parameter is YES, go to step 10 . If scan tool does not indicate A/C
5. Remove A/C compressor clutch relay. If A/C compressor clutch turns OFF, go to next step. If A/C
5. Turn ignition switch to OFF position. Disconnect HVAC control module connector. Back out terminal for
A/C request circuit (Dark Green/White wire) from HVAC control module connector. Reconnect HVAC
control module connector. Start engine. Using scan tool, observe A/C REQUEST parameter. If scan tool
indicates A/C REQUEST parameter is ON, go to step 12 . If scan tool does not indicate A/C REQUEST
parameter in ON, go to step 11 .
6. Remove A/C compressor clutch relay. If A/C compressor clutch turns off. go to next step. If A/C
A/C CLUTCH CIRCUIT DIAGNOSIS (LIGHT TRUCKS & VANS)

To save diagnostic time, ALWAYS check for blown fuses or fusible links before proceeding with diagnosis. If
fuses are blown, locate and repair short circuit before replacing fuses. Ensure all related relay and wire harness
connections are clean and tight. Repair as necessary. See WIRING DIAGRAMS .
NOTE: Vehicles may be equipped with a PCM using an Electronically Erasable

Programmable Read Only Memory (EEPROM). When replacing PCM, the new
PCM must be programmed.
2.2L: "S" & "T" SERIES
SYSTEMS article.
Description
Regardless of selected A/C mode setting, a request is made to Powertrain Control Module (PCM)/Vehicle
Control Module (VCM) to turn on A/C compressor. Request is made through A/C request signal circuit from
HVAC control assembly. Power and ground are provided to HVAC control assembly by ignition voltage,
ground circuits and splice pack.
In order for PCM/VCM to internally ground A/C clutch relay control circuit, request signal needs to be
grounded. A 12-volt request signal is sent out over A/C request signal circuit and grounded through PCM/VCM
when vehicle operator makes an A/C request. When this request signal is grounded, PCM/VCM can activate
A/C compressor clutch.
PCM/VCM turns on A/C compressor by providing a path to ground through A/C clutch relay control circuit for
A/C compressor clutch relay. Power is provided to A/C compressor clutch relay internally of underhood fuse
block. Once relay closes its internal switch, power from battery is provided to A/C compressor clutch through
A/C compressor clutch supply voltage circuit. Whenever compressor is turned off, A/C compressor clutch diode
prevents a voltage spike from burning up compressor clutch coil. Ground circuit and underhood fuse block
provides a path to ground for compressor. A/C clutch relay control circuit is grounded internally within the
PCM/VCM.
A/C system is protected by A/C refrigerant pressure sensor. Sensors output to PCM/VCM is variable and is
dependent upon pressure inside line. A higher pressure results in a higher voltage output. A/C pressure is
constantly monitored in order to allow A/C compressor clutch to disengage as needed. If line pressures climbs
greater than 410 psi (28.8 kg/cm2 ) or fall less than 30 psi (2.1 kg/cm2 ), PCM will turn off A/C compressor
clutch. When high side pressures drop back down between 150-250 psi (10.5-17.6 kg/cm2 ), PCM/VCM will
allow the A/C compressor to operate.
A/C clutch relay will remain de-energized when DTC P0530 is set, or if there is no A/C request signal due to an
open A/C select switch circuit. For additional diagnosis, see appropriate MANUAL A/C-HEATER SYSTEMS
article.
(PCM) on 2001 vehicles or HVAC control module on 2000 models. On all models, if communication
with module is established, go to next step. If communication with module is not established, see SCAN
MODULES article.
article.
maximum speed position. Place mode switch in bi-level position. Place air temperature control switch in
SERVICING.
to next step.
6. Start engine. Using scan tool, observe A/C REQUEST SIGNAL parameter in POWERTRAIN ENGINE
2 data list. Turn air temperature switch to coldest position. Place mode switch in BI-LEVEL position. If
scan tool indicates A/C REQUEST SIGNAL parameter is YES, go to next step. If scan tool does not
indicate A/C REQUEST SIGNAL parameter is YES, go to step 29 .
7. Using scan tool, observe A/C REFRIGERANT PRESSURE SENSOR parameter in POWERTRAIN data
list. If scan tool indicates A/C HIGH SIDE PRESSURE parameter is 45-425 psi (3.2-29.9 kg/cm2 ), go to
step 11 . If scan tool does not indicate A/C HIGH SIDE PRESSURE parameter is 45-425 psi (3.2-29.9
kg/cm2 ), go to next step.
8. Turn ignition switch to OFF position. Disconnect A/C refrigerant pressure sensor. Start engine. Using
scan tool, observe A/C HIGH SIDE PRESSURE parameter. If scan tool indicates A/C HIGH SIDE
PRESSURE parameter is greater than 425 psi (29.9 kg/cm2 ), go to next step. If scan tool does not
indicate A/C HIGH SIDE PRESSURE parameter is greater than 425 psi (29.9 kg/cm2 ), go to step 22 .
9. Turn ignition switch to OFF position. Connect fused jumper (3 amp) between signal circuit (Red/Black
wire) and low reference circuit (Black wire) of A/C refrigerant pressure sensor. Start engine. Using scan
tool, observe A/C HIGH SIDE PRESSURE parameter. If scan tool indicates A/C REFRIGERANT
PRESSURE SENSOR parameter is less than 45 psi (3.2 kg/cm2 ), go to next step. If scan tool does not
indicate A/C REFRIGERANT PRESSURE SENSOR parameter is less than 45 psi (3.2 kg/cm2 ), go to
step 23 .
10. Turn ignition switch to OFF position. Disconnect fused jumper wire. Connect fused jumper (3 amp)
between 5-volt reference circuit (Gray wire) and signal circuit (Red/Black wire) of A/C refrigerant
pressure sensor. Start engine. Using scan tool, observe A/C HIGH SIDE PRESSURE parameter. If scan
tool indicates A/C REFRIGERANT PRESSURE SENSOR parameter is greater than 425 psi (29.9
kg/cm2 ), go to step 21 . If scan tool does not indicate A/C REFRIGERANT PRESSURE SENSOR
parameter is greater than 425 psi (29.9 kg/cm2 ), go to step 20 .
of A/C relay. If test light is on, go to next step. If test light is off, go to step 31 .
A/C compressor clutch supply voltage circuit (Dark Green wire) of A/C compressor clutch. If A/C
resistance or open. If problem was found, repair as necessary. After repairs, go to step 44 . If problem was
19. Check ground circuit of HVAC control assembly for open. If problem was found, repair as necessary.
20. Check 5-volt reference circuit (Gray wire) of A/C refrigerant pressure sensor for short to ground. If
37 .
21. Check 5-volt reference circuit (Gray wire) of A/C refrigerant pressure sensor for short to voltage, high
22. Check signal circuit (Red/Black wire) of A/C refrigerant pressure sensor for short to ground. If problem
23. Check signal circuit of A/C refrigerant pressure sensor for short to voltage, high resistance, or open. If
problem was found, repair as necessary. After repairs, go to step 44 . If problem was not found, go to next
step.
24. Check low reference circuit (Black wire) of A/C refrigerant pressure sensor for high resistance or open. If
37 .
37 .
27. Check A/C compressor clutch supply voltage circuit (Dark Green wire) of A/C compressor clutch for
29. Turn ignition switch to OFF position. Check A/C request signal circuit (Light Blue wire) for short to
37. Check PCM/VCM connectors for poor connections. If problem was found, repair as necessary. After
43. Replace PCM/VCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article in ENGINE
2. Start engine. Turn blower motor switch to OFF position. Place mode switch in OFF position. If A/C
compressor clutch engages, go to next step. If A/C compressor clutch does not engage, problem is
intermittent.
3. Using scan tool, observe A/C REQUEST SIGNAL parameter in powertrain data list. If scan tool indicates
A/C REQUEST SIGNAL parameter is YES, go to next step. If scan tool does not indicate A/C
4. Check A/C Request Signal circuit (Light Blue wire) for short to ground. If problem was found, repair as
necessary. After repairs, go to step 17 . If problem was not found, go to next step.
5. Turn ignition switch to OFF position. Disconnect PCM harness connector. Start engine. Using scan tool,
observe A/C REQUEST SIGNAL parameter. If scan tool indicates A/C REQUEST parameter is YES, go
to step 12 . If scan tool does not indicate A/C REQUEST parameter is YES, go to step 11 .
7. Measure resistance between switch side of A/C compressor clutch relay terminals. If resistance is infinite,
12 .
3.4L: "A" & "B" SERIES
SYSTEMS article.
Description
Powertrain Control Module (PCM) will operate A/C system without any driver input. PCM will command A/C
compressor clutch on to help reduce moisture inside vehicle. A/C compressor is on, even in cool weather
conditions, to help eliminate moisture from fogging windshield. A/C LED will not illuminate unless driver
presses A/C request switch on HVAC control module. Otherwise, A/C system may be running without A/C
LED indicator illuminated.
Regardless of selected A/C mode setting, a request is made to PCM to turn on A/C compressor on class 2 serial
data circuit. Request is made by HVAC control module to Body Control Module (BCM) through A/C request
signal circuit when A/C switch grounds 12-volt signal from BCM. BCM then sends a class 2 message to PCM
on BCM class 2 serial data circuit. PCM grounds clutch relay control circuit and engages A/C compressor
clutch. Power is provided to HVAC control module by console junction block through ignition voltage, which
is routed through splice pack and battery positive voltage circuits.
compressor clutch relay. Power is provided to A/C compressor clutch relay internally through underhood
junction block. Once relay closes its internal switch, power from battery is provided to A/C compressor clutch
through A/C compressor clutch supply voltage circuit. Whenever compressor is turned off, A/C compressor
clutch diode, located in underhood junction block, prevents a voltage spike from entering vehicles electrical
system. ground circuit provides a path to ground for compressor and relay. A/C clutch relay control circuit is
grounded internally within PCM.
BCM or PCM will shut off A/C compressor under extreme vehicle loads. If system voltage falls below 10 volts,
an A/C command will not be given until voltage is raised to 10.5 volts. If coolant temperature rises greater than
259F (126C) or throttle is opened 95 percent or more, compressor clutch will be turned off.
A/C compressor clutch is protected from an overheating condition by an A/C compressor temperature switch
mounted at rear of compressor. Switch is wired internally to compressor and is not serviceable. Switch shuts off
compressor when temperatures reach 311F (155C) and allows clutch to engage again when temperatures fall
to 257F (125C).
A/C system is protected by A/C refrigerant pressure sensor. Sensors' output to PCM is variable and is dependent
upon pressure inside line. A higher pressure results in a higher voltage output. A/C pressure is constantly
monitored in order to allow A/C compressor clutch to disengage as needed. If line pressures climb greater than
432 psi (30.4 kg/cm2 ), PCM will turn off A/C compressor clutch until pressure lowers to 219 psi (15.4
kg/cm2 ). If line pressures fall below 27 psi (1.9 kg/cm2 ), PCM will turn off A/C compressor clutch until
pressure raises to 30 psi (2.1 kg/cm2 ).
A/C system is protected by evaporator temperature sensor. This sensor is mounted on evaporator core and
provides HVAC control module with surface temperature of evaporator core. If evaporator temperature sensor
reads a temperature of 32F (0C), HVAC control module will turn off A/C compressor clutch until evaporator
temperatures reach 36F (2C).
article.
SERVICING.
next step.
6. Start engine. Using scan tool, observe A/C REQUEST SIGNAL parameter in POWERTRAIN data list.
Place air temperature switch in coldest position. Place A/C request switch in ON position. If scan tool
REQUEST SIGNAL parameter is YES, go to next step.
7. If A/C request indicator is on, go to next step. If A/C request indicator is not on, go to step 32 .
40 . If problem was not found, go to next step.
9. Disconnect evaporator temperature sensor. Measure resistance of evaporator temperature sensor. See
EVAPORATOR TEMPERATURE SENSOR RESISTANCE table. If resistance is near values
specified in sensor resistance table, go to next step. If resistance is not near values specified in sensor
resistance table, go to step 30 .
10. Check evaporator temperature signal circuit (Gray wire) for short to ground, high resistance, or open. If
step.
11. Check low reference circuit (Black wire) for short to ground, high resistance, or open. If problem was
on and off with each command, go to step 16 . If A/C compressor clutch relay does not turn on and off,
go to next step.
33 .
27. Check off blower motor control circuit (Dark Green wire) for short to voltage. If problem was found,
30. Check evaporator temperature sensor for poor connections. If problem was found, repair as necessary.
35. Replace evaporator temperature sensor. See REMOVAL & INSTALLATION in appropriate MANUAL
38. Replace the HVAC control module. See REMOVAL & INSTALLATION in appropriate MANUAL
EVAPORATOR TEMPERATURE SENSOR RESISTANCE

Temp. - F (C) Resistance (K/Ohms)
-22 (-30) 52.8
-2 (-20) 30.4
14 (-10) 18.0
32 (0) 11.4
50 (10) 7.3
68 (20) 4.9
86 (30) 3.3
104 (40) 2.3
122 (50) 1.9
5. Turn ignition switch to OFF position. Disconnect A/C high pressure switch. Start engine. Using scan tool,
observe A/C REQUEST SIGNAL parameter. If scan tool indicates A/C REQUEST SIGNAL parameter is
YES, go to step 13 . If scan tool does not indicate A/C REQUEST SIGNAL parameter is YES, go to step
12 .
7. Remove A/C compressor clutch relay. If A/C compressor is on, go to step 10 . If A/C compressor is not
on, go to next step.
8. Measure resistance between switch side A/C compressor clutch relay terminals. If resistance infinite, go
to next step. If resistance is not infinite, go to step 11 .
3.4L: "U" SERIES (2000)
SYSTEMS article.
Description
Compressor for air conditioning system is belt-driven by engine through A/C compressor clutch. Clutch allows
compressor to perform the following functions:
Engage for A/C and defroster operation.

Disengage when air conditioning is not requested.
Disengage when engine load must be reduced.
Battery voltage is supplied to Powertrain Control Module (PCM) when A/C control is activated or when A/C-
heater control mode selector is placed in any of the following modes: MAX A/C, NORM A/C, BI-LEVEL,
DEFOG or DEFROST. Voltage signal tells PCM that A/C compressor operation is requested. Under normal
operating conditions, PCM supplies a ground to relay coil of A/C CLU relay, relay energizes, voltage is
supplied to A/C compressor clutch coil through relay center fuse, A/C compressor clutch coil engages and
compressor runs.
If PCM determines engine load should be reduced, such as during full throttle conditions, PCM de-energizes
A/C CLU relay in order to disengage compressor clutch coil. De-energization occurs even though voltage signal
from A/C-heater control is still present at PCM.
A/C CLU diode provides a path for high current that results from voltage spikes generated from collapsing
magnetic field of A/C compressor clutch coil. Voltage spikes occur every time coil de-energizes.
and Powertrain Control Module (PCM). If communication with all modules is established, go to next
step. If communication with all modules is not established, see SCAN TOOL DOES NOT
DISENGAGE .
2. Turn ignition switch to OFF position. Install both high and low A/C freon pressure gages. Read freon
pressure with engine off. Freon pressure in high and low sides should equal each other after A/C system
has come to rest. Freon pressure will fluctuate depending on ambient temperature. Proper clutch operation
depends on correct refrigerant charge, low freon charge will shut off A/C compressor operation. If high
and low side freon pressures are below 50 psi (3.5 kg/cm2 ), see LEAK TESTING article in GENERAL
SERVICING. If high and low side freon pressures are not below 50 psi (3.5 kg/cm2 ), go to next step.
3. If high and low side freon pressures is greater than 100 psi (7.0 kg/cm2 ), go to next step. If high and low
side freon pressures are not greater than 100 psi (7.0 kg/cm2 ), go to step 5 .
4. Evacuate and recharge A/C system according to proper freon fill specifications. See appropriate
GENERAL SERVICING PROCEDURES articles. After repairs, go to step 23 .
5. Check A/C compressor clutch supply voltage circuit (Dark Green wire) for a short to ground. If problem
was found, repair as necessary. After repairs, go to step 23 . If problem was not found go to next step.
6. Remove A/C CLU relay from underhood accessory wiring junction block. Disconnect A/C compressor
clutch coil connector. Connect fused jumper (10 amp) between ignition feed terminal for switch side of
A/C CLU relay and A/C compressor clutch supply voltage circuit (Dark Green wire) at A/C CLU relay.
Connect DVOM between A/C compressor clutch coil connector terminal "B" (Dark Green wire) and
ground. Turn ignition switch to ON position. Measure available voltage at A/C compressor clutch coil
connector terminal "B". If battery voltage is present, go to step 8 . If battery voltage is not present, go to
next step.
7. Repair poor connection or open in A/C compressor voltage supply circuit (Dark Green wire). After
8. Using DVOM, measure resistance between terminal "A" (Black wire) of A/C compressor clutch coil
connector and ground. If resistance is 0-2 ohms, go to step 10 . If resistance is not 0-2 ohms, go to next
step.
9. Repair poor connection or open in A/C compressor clutch ground circuit (Black wire). After repairs, go to
step 23 .
10. Disconnect PCM connector C2. Reinstall A/C CLU relay. Connect fused jumper (10 amp) between A/C
CLU relay control circuit (Dark Green/White wire) at PCM connector C2 and ground. Turn ignition
switch to ON position. Using DVOM, measure voltage between A/C compressor clutch voltage supply
circuit (Dark Green wire) and ground. If battery voltage is present, go to next step. If battery voltage is
not present, go to step 12 .
11. Remove fused jumper between PCM connector C2 and ground. Reconnect A/C compressor clutch coil
connector. Reinstall fused jumper between A/C CLU relay control circuit (Dark Green/White wire) at
PCM connector C2 and ground. Turn ignition on. If A/C compressor clutch engages, see TESTING under
appropriate MANUAL A/C-HEATER SYSTEMS article. If A/C compressor clutch does not engage, go
to step 22 .
12. Turn ignition switch to OFF position. Remove A/C CLU relay. Using DVOM, measure resistance of
Dark Green/White wire between PCM connector C2 and underhood accessory wiring junction block
connector C1. If resistance is 0-2 ohms, go to step 14 . If resistance is not 0-2 ohms, go to next step.
13. Repair poor connection or open in Dark Green/White wire between PCM connector C2 and underhood
accessory wiring junction block connector C1. After repairs, go to step 23 .
14. Replace A/C CLU relay and retest A/C system. If problem has been corrected, go to step 23 . If problem
has not been corrected, go to next step.
15. Disconnect A/C-heater control connector C2. Using DVOM, measure resistance in Dark Green/White
wire between PCM connector C2 and A/C-heater control connector C2. If resistance is 0-2 ohms, go to
step 17 . If resistance is not 0-2 ohms, go to next step.
16. Repair poor connection or open in Dark Green/White wire between PCM connector C2 and A/C-heater
control connector C2. After repairs, go to step 23 .
17. Using DVOM, check continuity between Dark Green/White wire at PCM connector C2 and ground. If
continuity exists, go to next step. If continuity does not exist, go to step 19 .
18. Repair short to ground in Dark Green/White wire between Dark Green/White wire at PCM connector C2
and ground. After repairs, go to step 23 .
19. Disconnect DVOM. Reconnect all connectors back to their respective modules. Install scan tool to
diagnostic link connector. Start engine and allow to idle in park. Select area of scan tool which will read
HVAC button output status. Depress A/C button on and off several times. If scan tool reads A/C
REQUEST being sent by HVAC control head, go to next step. If scan tool does not read A/C REQUEST
being sent by HVAC control head, go to step 21 .
20. Check PCM and underhood accessory wiring junction block connectors for poor connections. If problem
was found, repair as necessary. If problem was not found, replace PCM. See appropriate REMOVAL,
OVERHAUL & INSTALLATION article in ENGINE PERFORMANCE. After repairs, go to step 23 .
21. Replace A/C-heater control. See REMOVAL & INSTALLATION in appropriate MANUAL A/C-
SERVICING. After repairs, go to next step.
2. Disconnect PCM connector C2. Turn ignition switch to ON position. If A/C compressor clutch
disengages, go to next step. If A/C compressor clutch does not disengage, go to step 4 .
PERFORMANCE. After repairs, go to step 11 .
4. Disconnect A/C CLU relay from underhood accessory wiring junction block. Turn ignition switch to ON
position. If A/C compressor clutch disengages, go to next step. If A/C compressor clutch does not
5. Turn ignition switch to OFF position. Using DVOM, check continuity between PCM connector C2
terminal No. 39 (Dark Green/White wire) and ground. If continuity exists, go to next step. If continuity
does not exist, go to step 7 .
6. Repair short to ground in Dark Green/White wire between underhood accessory wiring junction block
and PCM connector. After repairs, go to step 11 .
7. Replace A/C CLU relay. After repairs, go to step 11 .
8. Disconnect A/C compressor clutch coil connector. Using DVOM, measure voltage between A/C
compressor clutch coil connector terminal "B" (Dark Green wire) and ground. Turn ignition switch to ON
position. If battery voltage is present, go to next step. If battery voltage is not present, go to step 10 .
9. Repair short to battery voltage in Dark Green wire between underhood accessory wiring junction block
and A/C compressor clutch coil. After repairs, go to step 11 .
SERVICING. After repairs, go to next step.
11. Turn ignition switch to OFF position. Reconnect all connectors/components disconnected. Operate
system to verify repair.
Diagnostic Aids
Check for poor harness connections at PCM and A/C-heater control panel. Inspect for corrosion, backed-out
terminal pins, and broken wires inside insulation. Check for damaged wire harness. If harness and connections
are okay, disconnect PCM harness connectors. Connect a DVOM between ground and A/C clutch relay control
circuit at PCM harness connector. Turn ignition switch to ON position. Observe DVOM while wiggling harness
and connectors. A change in voltage indicates location of fault.
3.4L: "U" SERIES (2001)
SYSTEMS article.
Description
Powertrain Control Module (PCM) will operate A/C system without any driver input. PCM will command A/C
compressor clutch on to help reduce moisture inside vehicle. A/C compressor is on, even in cool weather
conditions, to help eliminate moisture from fogging windshield. A/C LED will not illuminate unless driver
presses A/C request switch on HVAC control module. Otherwise, A/C system may be running without A/C
LED indicator illuminated.
Regardless of selected A/C mode setting, a request is made to PCM to turn on A/C compressor. Request is
made by HVAC control module to PCM through A/C request signal circuit when A/C switch grounds 12 volt
signal from PCM. PCM turns on A/C compressor by providing a path to ground through A/C clutch relay
control circuit for A/C compressor clutch relay. Power is provided to A/C compressor clutch relay internally of
underhood junction block. Once relay closes its internal switch, power from battery is provided to A/C
compressor clutch through A/C compressor clutch supply voltage circuit. Whenever compressor is turned off,
A/C compressor clutch diode, located in underhood junction block, provides a path for voltage spike resulting
from collapsing magnetic field of compressor clutch coil. Ground circuit provides a path to ground for
compressor and relay. A/C clutch relay control circuit is grounded internally within PCM.
PCM will shut off A/C compressor under extreme vehicle loads, such as wide open throttle. PCM will shut off
A/C compressor under extreme vehicle loads. If system voltage falls below 10 volts, an A/C command will not
be given until voltage is raised to 10.8 volts. If coolant temperature rises greater than 259F (126C) or throttle
is opened 95% or more, compressor clutch will be turned off. Compressor operation will be allowed when
throttle is backed off to 90%.
A/C compressor clutch is protected from an overheating condition by an A/C compressor temperature switch
mounted at rear of compressor. Switch is wired internally to compressor and is not serviceable. Switch shuts off
compressor when temperatures reach 311F (155C) and allows clutch to engage again when temperatures fall
to 257F (125C).
A/C system is protected by A/C refrigerant pressure sensor. Sensors output to PCM is variable and is dependent
upon pressure inside line. A higher pressure results in a higher voltage output. A/C pressure is constantly
monitored in order to allow A/C compressor clutch to disengage as needed. If line pressures climb greater than
432 psi (30.4 kg/cm2 ), PCM will turn off A/C compressor clutch until pressure lowers to 235 psi (16.5
kg/cm2 ). If line pressures fall below 26 psi (1.8 kg/cm2 ), PCM will turn off A/C compressor clutch until
pressure raises to 30 psi (2.1 kg/cm2 ). A 5 volt reference signal is sent out over 5 volt reference circuit, from
PCM, to A/C refrigerant pressure sensor. PCM monitors A/C pressure by monitoring voltage drop in sensor on
A/C pressure sensor signal circuit. This circuit is how PCM monitors HVAC pressures. Ground for A/C
refrigerant pressure sensor is provided by low reference circuit.
A/C system is protected by evaporator temperature sensor. This sensor is mounted on evaporator core and
provides HVAC control module with surface temperature of evaporator core. If evaporator temperature sensor
reads a temperature of 32F (0C), HVAC control module will turn off A/C compressor clutch until evaporator
temperatures reach 36F (2C). HVAC control module sends out a 5 volt reference signal to evaporator
temperature sensor over 5 volt reference circuit. A thermistor varies reference voltage back to HVAC control
module through low reference circuit.
article.
SERVICING.
to next step.
6. Start engine. Using scan tool, observe A/C REQUEST SIGNAL parameter in POWERTRAIN engine
data list. Place air temperature switch in coldest position. Turn blower motor to on position. Place A/C
request switch in ON position. If scan tool indicates A/C REQUEST parameter is YES, go to step 13 . If
scan tool does not indicate A/C REQUEST parameter is YES, go to next step.
7. If A/C request indicator is on, go to step 9 . If A/C request indicator is not on, go to next step.
8. Ensure blower motor is in ON position. Turn ignition switch to ON position. Check OFF blower motor
control circuit (Dark Green wire) at HVAC control module for short to voltage. If problem was found,
to ground, high resistance or open. If problem was found, repair as necessary. After repairs, go to step
40 . If problem was not found, go to next step.
10. Disconnect evaporator temperature sensor. Measure resistance of evaporator temperature sensor. See
EVAPORATOR TEMPERATURE SENSOR RESISTANCE table under 3.4L: "A" & "B" SERIES. If
resistance measures near value specified in sensor resistance table, go to next step. If resistance does not
measure near value specified in sensor resistance table, go to step 30 .
11. Check evaporator temperature sensor signal circuit (White wire) for short to ground, high resistance or
open. If problem was found, repair as necessary. After repairs, go to step 40 . If problem was not found,
go to next step.
12. Check evaporator temperature sensor low reference circuit (Black wire) for short to ground, high
19. Check voltage supply circuits (Brown wires and Orange wire) to HVAC control assembly for short to
ground, high resistance or open. If problem was found, repair as necessary. After repairs, go to step 40 . If
problem is not found, go to step 21 .
found, repair as necessary. After repairs, go to step 40 . If problem is not found, go to step 33 .
problem was found, repair as necessary. After repairs, go to step 40 . If problem is not found, go to step
33 .
step 40 . If problem is not found, go to next step.
found, repair as necessary. After repairs, go to step 40 . If problem is not found, go to step 31 .
30. Check evaporator temperature sensor connector for poor connections. If problem was found, repair as
After repairs, go to step 40 . If problem is not found, go to step 37 .
After repairs, go to step 40 . If problem is not found, go to step 38 .
to step 40 . If problem is not found, go to step 39 .
35. Replace evaporator temperature sensor. See REMOVAL & INSTALLATION in appropriate MANUAL
37. Replace A/C compressor. See REMOVAL & INSTALLATION in appropriate MANUAL A/C-HEATER
SYSTEMS article. After repairs, go to step 40 .
3. Using scan tool, observe A/C REQUEST SIGNAL parameter in POWERTRAIN ENGINE data list. If
scan tool indicates A/C REQUEST SIGNAL parameter is YES, go to next step. If scan tool does not
indicate A/C REQUEST SIGNAL parameter is YES, go to step 6 .
5. Turn ignition switch to OFF position. Disconnect HVAC control module connector. Back out terminal for
A/C request signal circuit (Dark Green/White wire) from HVAC control head. Reconnect HVAC control
module connector. Start engine. Using scan tool, observe A/C REQUEST SIGNAL parameter. If scan
tool indicates A/C REQUEST SIGNAL parameter is YES, go to step 12 . If scan tool does not indicate
A/C REQUEST SIGNAL parameter is YES, go to step 11 .
7. Measure resistance between switch side of A/C compressor clutch relay terminals. If resistance is infinite,
12 .
14. Replace A/C compressor. See REMOVAL & INSTALLATION in appropriate MANUAL A/C-HEATER
SYSTEMS article. After repairs, go to step 17 .
4.3L: "M" & "L" SERIES
SYSTEMS article.
NOTE: HVAC control assembly may be referred to as HVAC control module. 2000
vehicles use a Vehicle Control Module (VCM) and 2001 vehicles use a
Powertrain Control Module (PCM).
Description
Control Module (VCM) to turn on A/C compressor clutch. Request is sent to PCM/VCM through A/C request
signal circuit from HVAC control assembly. Power and ground is provided to HVAC control assembly by
ignition voltage and ground circuits.
A/C compressor clutch relay. Ignition voltage circuit provides power to A/C compressor clutch relay control.
Once relay contact closes its internal switch, power from battery voltage circuit is provided to A/C compressor
clutch through A/C compressor clutch supply voltage circuit. Whenever compressor is turned off, A/C
compressor clutch diode prevents a voltage spike from entering vehicles electrical system. Ground circuit
provides a pathway to ground for compressor. Both A/C request signal and A/C clutch relay control circuits are
grounded internally within PCM/VCM.
A/C system is protected by 2 pressure switches. A/C high pressure switch interrupts A/C request signal when
A/C line pressure exceeds a predetermined value. A/C low pressure switch interrupts A/C low pressure switch
signal when A/C line pressure drops below a predetermined value. When PCM/VCM stops receiving required
signals, A/C compressor clutch relay control circuit is no longer grounded, thus shutting off compressor.
SERVICING.
to next step.
4. Start engine. Using scan tool, observe A/C REQUEST parameter. Place air temperature switch in coldest
position. Place mode switch in bi-level position. If scan tool indicates A/C REQUEST parameter is ON,
go to step 6 . If scan tool does not indicate A/C REQUEST parameter is ON, go to next step.
amp) between A/C request circuits (Light Orange wire and Dark Green/White wire) at A/C high pressure
switch connector. Start engine. Using scan tool, observe A/C REQUEST parameter. Place air temperature
switch in coldest position. Place mode switch in bi-level position. If scan tool indicated A/C request
parameter is ON, go to step 29 . If scan tool does not indicate A/C REQUEST parameter is ON, go to step
23 .
6. If scan tool indicates A/C LOW PRESSURE SWITCH parameter is CLOSED, go to step 8 . If scan tool
does not indicate A/C LOW PRESSURE SWITCH parameter is CLOSED, go to next step.
amp) between A/C low pressure switch signal circuit (Dark Green wire) and ground circuit (Black wire)
at A/C low pressure switch connector. Start engine. Using scan tool, observe A/C LOW PRESSURE
SWITCH parameter. If scan tool indicates A/C LOW PRESSURE SWITCH parameter is CLOSED, go to
step 26 . If scan tool does not indicate A/C LOW PRESSURE SWITCH is CLOSED, go to step 19 .
8. Using scan tool, command A/C compressor clutch relay on and off. If A/C compressor clutch relay turn
24 .
30 .
19. Check A/C low pressure switch signal circuit (Dark Green wire) for high resistance or open. If problem
20. Check ground circuit (Black wire) of A/C low pressure switch for high resistance or open. If problem was
23. Turn ignition switch to OFF position. Reconnect A/C high pressure switch. Check A/C request signal
circuit (Light Green wire and Dark Green/White wire) for short to ground, high resistance, or open. If
30 .
step 37 .
After repairs, go to step 37 . If problem was not found, go to step 34 . at the harness connector of the A/C
compressor clutch.
1. Start engine. Place blower motor switch in OFF position. Place mode switch in OFF position. If A/C
parameter in ON, go to step 5 .
3. Check A/C request signal circuit (Light Green wire and Dark Green/White wire) for short to ground. If
step.
observe A/C REQUEST parameter. If scan tool indicates A/C REQUEST parameter is ON, go to step 11 .
If scan tool does not indicate A/C REQUEST parameter is ON, go to step 10 .
4.3L: "S" & "T" SERIES (AUTOMATIC A/C)
SYSTEMS article.
Description
A/C system is engaged when HVAC switch is pressed. A/C system can operate regardless of temperature
setting, as long as outside ambient temperature is greater than 40F (4C). If A/C is selected and A/C is not
available, A/C LED will flash, indicating that A/C is not allowed. A/C compressor is activated when FROST
DEFROST is selected. A/C will not be allowed if engine exceeds 5985 RPM.
HVAC control module receives power from instrument panel fuse block on ignition voltage circuit along with
battery voltage circuit. HVAC control module communicates directly to Powertrain Control Module
(PCM)/Vehicle Control Module (VCM) on class 2 serial data and PCM/VCM class 2 serial data circuits
through splice pack.
Regardless of selected A/C mode setting, a request is made to PCM to turn on A/C compressor. Request is
made through A/C request signal circuit, through A/C high pressure switch, from HVAC control module.
block. Once A/C compressor clutch relay closes its internal switch, power from battery is provided to A/C
compressor clutch through A/C compressor clutch supply voltage circuit. Whenever compressor is turned off,
A/C compressor clutch diode prevents a voltage spike. Ground circuit and underhood fuse block provides a path
to ground for compressor. A/C clutch relay control circuit is grounded internally within PCM/VCM.
A/C system is protected by 2 pressure switches. A/C high pressure switch interrupts A/C request signal circuit
when A/C line pressures climb greater than 410 psi (28.8 kg/cm2 ). A/C low pressure switch interrupts A/C low
pressure switch signal circuit when A/C line pressures fall below 30 psi (2.1 kg/cm2 ). When PCM/VCM sees
an open in either signal, A/C clutch relay control circuit is no longer grounded, thus shutting off compressor.
When high side pressures drop back down to 150-250 psi (10.5-17.6 kg/cm2 ), PCM/VCM will allow A/C
compressor to operate.
Control Module (BCM) and Powertrain Control Module (PCM)/Vehicle Control Module (VCM). If
DISENGAGE .
CONTROL MODULES If scan tool displays DTCs beginning with "P" see appropriate SELF-
SERVICING.
next step.
2 data list. Place air temperature switch in coldest position. Place mode switch in bi-level position. If scan
A/C REQUEST SIGNAL parameter is YES, go to next step.
amp) between A/C Request Signal circuits (Light Blue wire and Dark Green/White wire) at A/C high
pressure switch connector. Start engine. Using scan tool, observe A/C REQUEST SIGNAL parameter.
Place air temperature switch in coldest position. Place mode switch in bi-level position. If scan tool
7. Turn engine off. Ensure ignition is in ON position. If scan tool indicates A/C COMPRESSOR CYCLING
SWITCH parameter reads LOW PRESSURE, go to step 9 . If scan tool does not indicate A/C
COMPRESSOR CYCLING SWITCH parameter reads LOW PRESSURE, go to next step.
amp) between A/C low pressure switch signal circuit (Dark Green wire) and ground circuit (Black/White
wire) at A/C low pressure switch connector. Start engine. Using scan tool, observe A/C COMPRESSOR
CYCLING SWITCH parameter. If scan tool indicates A/C COMPRESSOR CYCLING SWITCH
parameter reads LOW PRESSURE, go to step 28 . If scan tool does not indicate A/C COMPRESSOR
CYCLING SWITCH parameter reads LOW PRESSURE, go to step 19 .
9. Using scan tool, command A/C relay on and off. If A/C compressor clutch relay turns on and off with
each command, go to step 13 . If A/C compressor clutch relay does not turn on and off with each
coil side voltage supply circuit of A/C Relay. Using scan tool, command A/C compressor clutch relay on
and off. If test light turns on and off with each command, go to step 27 . If test light does not turn on and
off with each command, go to next step.
15. Check control circuit (Dark Green/White wire) of A/C compressor clutch relay for open or short to
voltage. If problem was found, repair as necessary. After repairs, go to step 39 . If problem was not
32 .
20. Check ground circuit (Black/White wire) of A/C low pressure switch for high resistance or open. If
32 .
step.
24. Turn ignition switch to OFF position. Disconnect A/C high pressure switch. Turn ignition switch to ON
position. Place mode switch in bi-level position. Using test light connected to ground, probe A/C request
signal circuit (Light Blue wire) of A/C high pressure switch. If test light is on, go to step 32 . If test light
is off, go to step 30 .
A/C compressor clutch engages, go to next step. If A/C compressor clutch does not engage, problem is
intermittent.
4. Check A/C request signal circuit (Light Blue wire and Dark Green/White wire) for short to ground. If
step.
4.3L: "S" & "T" SERIES (MANUAL A/C)
SYSTEMS article.
Description
Vehicle operator can activate A/C system by activating the following modes: MAX A/C, A/C BI-LEVEL,
MIX-BLEND or FRONT DEFROST. A/C system can operate regardless of temperature setting, as long as
ambient air temperature is greater than 38F (3C) degrees. If A/C compressor clutch is turned off due to cold
ambient air temperatures, compressor will not come back on until ambient air temperatures reach 41F (5C).
Control Module (VCM) to turn on A/C compressor. Request is made through A/C request signal circuit from
HVAC control assembly. Power is provided to HVAC control assembly by ignition voltage.
In order for PCM/VCM to internally ground A/C clutch relay control circuit, 2 separate request signals need to
be grounded. A 12-volt request signal is sent out over A/C request signal circuit, through A/C high pressure
switch, and grounded through PCM/VCM when vehicle operator makes an A/C request. A separate 12-volt
request signal is sent out over A/C low pressure switch signal circuit, through A/C low pressure switch and
ground circuit. When both these request signals are grounded, PCM/VCM can activate A/C compressor clutch.
block. Once relay closes its internal switch, power from battery is provided to A/C compressor clutch through
A/C compressor clutch supply voltage circuit. Whenever compressor is turned off, A/C compressor clutch diode
prevents a voltage spike from burning up compressor clutch coil. Ground circuit and underhood fuse block
provides a path to ground for compressor. A/C clutch relay control circuit is grounded internally within
PCM/VCM.
A/C line pressures climb greater than 410 psi (28.8 kg/cm2 ). A/C low pressure switch interrupts A/C low
pressure switch signal when A/C line pressure fall below 30 psi (2.1 kg/cm2 ). When the PCM/VCM sees an
open in either signal, A/C clutch relay control circuit is no longer grounded, thus shutting off compressor. When
high side pressures drop back down between 150-250 psi (10.5-17.6 kg/cm2 ), PCM/VCM will allow the A/C
compressor to operate.
(PCM)/Vehicle Control Module (VCM). If communication with PCM is established, go to next step. If
communication with PCM is not established, see SCAN TOOL DOES NOT COMMUNICATE WITH
CLASS 2 DEVICE in appropriate BODY CONTROL MODULES article.
article.
SERVICING.
next step.
2 data list. Place air temperature switch in coldest position. Place mode switch in bi-level position. If scan
A/C REQUEST SIGNAL parameter is YES, go to next step.
amp) between A/C Request Signal circuits (Light Blue wire and Dark Green/White wire) at A/C high
pressure switch connector. Start engine. Using scan tool, observe A/C REQUEST SIGNAL parameter.
Place air temperature switch in coldest position. Place mode switch in bi-level position. If scan tool
7. Turn engine off. Ensure ignition is in ON position. If scan tool indicates A/C COMPRESSOR CYCLING
SWITCH parameter reads LOW PRESSURE, go to step 9 . If scan tool does not indicate A/C
COMPRESSOR CYCLING SWITCH parameter reads LOW PRESSURE, go to next step.
amp) between A/C low pressure switch signal circuit (Dark Green wire) and ground circuit (Black/White
wire) at A/C low pressure switch connector. Start engine. Using scan tool, observe A/C COMPRESSOR
CYCLING SWITCH parameter. If scan tool indicates A/C COMPRESSOR CYCLING SWITCH
parameter reads LOW PRESSURE, go to step 28 . If scan tool does not indicate A/C COMPRESSOR
CYCLING SWITCH parameter reads LOW PRESSURE, go to step 19 .
9. Using scan tool, command A/C relay on and off. If A/C compressor clutch relay turns on and off with
each command, go to step 13 . If A/C compressor clutch relay does not turn on and off with each
coil side voltage supply circuit of A/C Relay. Using scan tool, command A/C compressor clutch relay on
and off. If test light turns on and off with each command, go to step 27 . If test light does not turn on and
off with each command, go to next step.
15. Check control circuit (Dark Green/White wire) of A/C compressor clutch relay for open or short to
voltage. If problem was found, repair as necessary. After repairs, go to step 39 . If problem was not
32 .
20. Check ground circuit (Black/White wire) of A/C low pressure switch for high resistance or open. If
32 .
step.
24. Turn ignition switch to OFF position. Disconnect A/C high pressure switch. Turn ignition switch to ON
position. Place mode switch in bi-level position. Using test light connected to ground, probe A/C request
signal circuit (Light Blue wire) of A/C high pressure switch. If test light is on, go to step 32 . If test light
is off, go to step 30 .
2. Start engine. Place blower motor switch in OFF position. Place mode switch in OFF position. If A/C
compressor clutch engages, go to next step. If A/C compressor clutch does not engage, problem is
intermittent.
indicates A/C REQUEST SIGNAL parameter is ON, go to next step. If scan tool does not indicate A/C
REQUEST SIGNAL parameter is ON, go to step 6 .
step.
ON, go to step 12 . If scan tool does not indicate A/C REQUEST SIGNAL parameter is ON, go to step
11 .
4.3L & 7.4L: "C" & "K" SERIES (2000) OR 4.3L, 5.0L & 5.7L: "G" SERIES (2000)
SYSTEMS article.
Description
A/C clutch relay is controlled by Vehicle Control Module (VCM) to delay A/C compressor clutch engagement
after A/C is turned on. This allows VCM to adjust engine RPM before A/C compressor clutch engages. VCM
will engage A/C compressor clutch any time A/C has been requested unless coolant temperature is high, A/C
system pressure is low, A/C system pressure is high, wide open throttle, or engine RPM is high.
When A/C-heater control panel is placed in A/C mode, a 12-volt signal is sent to VCM. When VCM receives
this signal, VCM will ground A/C clutch relay control circuit to energize A/C clutch relay. This is shown on
scan tool as A/C REQUEST YES.
When an A/C request has been detected by VCM, VCM will ground A/C clutch relay control circuit. As a
result, relay contacts close, allowing current to flow through relay to A/C compressor clutch. When A/C
REQUEST has been detected by VCM, cooling fans will turn on when A/C pressure is greater than a
predetermined value.
Diagnosis
1. If On-Board Diagnostic (OBD) System Check has not been performed, see appropriate SELF-
DIAGNOSTICS article in ENGINE PERFORMANCE. If OBD System Check has been performed, go to
next step.
2. This diagnostic test assumes the following:
A/C system is adequately charged.
This table only diagnoses control of A/C compressor clutch.
A/C compressor has no mechanical failures.
Engine coolant temperature is more than 140F (60C), but less than 250F (121C).
HVAC control module is functioning.
Start and idle engine. Turn off HVAC controls. If A/C compressor clutch engaged, go to step 4 . If A/C
compressor clutch did not engage, go to next step.
3. Start engine. Idle engine until normal operating temperature is reached. Leave engine at normal idle. Turn
A/C on. If A/C clutch engage within 60 seconds, see DIAGNOSTIC AIDS . If A/C clutch does not
engage within 60 seconds, go to step 7 .
4. Disconnect A/C clutch relay from underhood electrical center. If A/C compressor clutch stays engaged,
go to next step. If A/C compressor clutch does not stay engaged, go to step 6 .
5. Check for short to voltage in Dark Green wire between A/C clutch relay and A/C compressor clutch. If
problem was found, go to step 33 . If problem was not found, go to step 17 .
6. Using test light connected to battery voltage, probe A/C clutch relay control circuit (Dark Green/White
wire) at underhood electrical center. If test light is on, go to step 24 . If test light is off, go to step 29 .
7. Install scan tool. Start engine. Turn A/C on. Monitor A/C REQUEST in scan tool data list. A/C request
should display YES. If scan tool displays YES, go to next step. If scan tool does not display YES, go to
step 18 .
8. Monitor A/C EVAPORATOR SWITCH with scan tool. Turn A/C on. If scan tool indicates switch is
CLOSED, go to step 12 . If scan tool does not indicate switch is CLOSED, go to next step.
9. Disconnect A/C evaporator cycling cutoff switch connector. Turn ignition switch to ON position, with
engine off. Using fused jumper, connect Dark Green wire at A/C evaporator cycling cutoff switch
connector to ground. If scan tool indicates switch is CLOSED, go to next step. If scan tool does not
indicate switch is CLOSED, go to step 31 .
10. Using test light connected to battery voltage, probe ground circuit (Black wire) of A/C evaporator cycling
cutoff switch connector. If test light is on, go to next step. If test light is off, go to step 33 .
11. Replace A/C high pressure cutoff switch. After repairs, go to step 35 .
CAUTION: Avoid contact with moving parts and hot surfaces while working
around a running engine in order to prevent physical injury.
12. Turn engine off. Disconnect A/C compressor clutch harness connector. Start engine. Turn A/C on. Using
test light connected to ground, probe A/C clutch voltage supply circuit (Dark Green wire) at A/C
compressor clutch harness connector. If test light is on, go to next step. If test light is off, go to step 20 .
13. Using test light connected to ground, probe A/C clutch ground circuit (Black wire) at A/C clutch
connector. If test light is on, go to step 15 . If test light is off, go to next step.
14. Repair A/C clutch ground circuit (Black wire). After repairs, go to step 35 .
15. Check A/C compressor clutch connector for poor connections. If problem was found, go to next step. If
problem was not found, go to step 17 .
16. Repair A/C compressor clutch connector. After repairs, go to step 35 .
18. Turn ignition switch to OFF position. Disconnect VCM connector C3. Turn ignition switch to ON
position, with engine off. Turn A/C on. Using test light connected to ground, probe the VCM connector
C3 terminal No. 25 (Dark Green/White wire). If test light is on, go to step 32 . If test light is off, go to
next step.
19. Check for open in A/C request signal circuit (Light Blue wire and Dark Green/White wire) between
HVAC control module and VCM. If problem was found, go to step 33 . If problem was not found, see
TESTING in appropriate MANUAL A/C-HEATER SYSTEMS article.
20. Reconnect A/C clutch connector. Install scan tool. Turn ignition switch to ON position, with engine off.
Using scan tool, command A/C relay on. If A/C relay clicks, go to step 26 . If A/C relay does not click,
go to next step.
21. Disconnect A/C relay. Turn ignition switch to ON position, with engine off. Using test light connected to
ground, probe ignition voltage circuit (Pink wire on 7.4L) at A/C relay connector. If test light is on, go to
step 23 . If test light is off, go to next step.
22. Repair open in A/C relay ignition voltage circuit (Pink wire on 7.4L). If fuse is blown, repair short to
ground in A/C relay ignition voltage circuit. After repairs, go to step 35 .
23. Using test light connected to battery voltage, probe A/C relay control circuit (Dark Green/White wire) at
A/C relay connector. Using scan tool, command A/C relay on. If test light is on, go to step 29 . If test
light is off, go to next step.
24. Check for open, short to voltage or short to ground in A/C relay control circuit (Dark Green/White wire)
between the underhood fuse block and VCM connector C3. If problem was found, go to next step. If
25. Repair Dark Green/White wire between underhood fuse block and VCM connector C3. After repairs, go
to step 35 .
26. Remove A/C compressor clutch relay. Using test light connected to ground, probe battery voltage circuit
(Orange wire on 7.4L) at A/C compressor clutch relay connector. If test light is on, go to step 28 . If test
light is off, go to next step.
27. Repair open in A/C relay battery voltage feed circuit (Pink wire on 7.4L). If fuse is blown, repair short to
ground in A/C relay battery voltage circuit. After repairs, go to step 35 .
28. Turn ignition switch to ON position, with engine off. Using fused jumper, connect A/C relay battery
voltage feed circuit to A/C clutch voltage supply circuit (Dark Green wire) at A/C compressor clutch
relay connector. If A/C clutch engages, go to next step. If A/C clutch does not engage, go to step 30 .
30. Repair open or short to ground in A/C compressor clutch control circuit (Dark Green/White wire). After
31. Check for open in A/C cycling signal circuit (Dark Green wire). If problem was found, go to step 33 . If
problem was not found, go to next step.
32. Check VCM connectors for poor connections. If problem was found, go to next step. If problem was not
33. Repair circuit as necessary. After repairs, go to step 35 .
34. Replace VCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article in ENGINE
A/C on. A/C clutch should engage within 60 seconds. Using scan tool, check for DTCs. If DTCs are not
present, system is okay.
Diagnostic Aids
Intermittent conditions can be caused by poor connections, rubbed wire through insulation or a broken wire
within the insulation. Check circuits thoroughly. For additional information, see appropriate MANUAL A/C-
HEATER SYSTEMS article.
4.8L, 5.3L & 6.0L: "C" & "K" SERIES (2000)
SYSTEMS article.
Description
PCM controls operation of A/C clutch relay. When any A/C mode is selected on Heating, Ventilation and Air
Conditioning (HVAC) control module, a 12-volt signal is sent through A/C high pressure switch and to PCM. If
conditions are met, PCM will send another 12-volt signal to A/C compressor cycling switch, which is ground
signal. When these 2 signals are received by PCM, PCM supplies a ground for A/C compressor clutch relay.
PCM controlled HVAC system consists of the following components:
A/C high pressure switch.

A/C compressor cycling switch.
A/C compressor relay.
PCM
PCM will engage A/C compressor clutch unless one or more of the following conditions occur:
Throttle angle at 100 percent.

A/C compressor cycling switch pressure is less than 18 psi (1.2 km/cm2 ) or greater than 49 psi (3.4
km/cm2 ).
A/C high pressure cut-out switch pressure is greater than 420 psi (29.5 km/cm2 ).
Engine speed is greater than 5500 RPM.
Engine coolant temperature greater than 250F (121C).
Any condition described above will prevent operation of A/C compressor clutch.
Diagnosis
1. If On-Board Diagnostic (OBD) System Check has not been performed, see appropriate SELF-
DIAGNOSTICS article in ENGINE PERFORMANCE. If OBD System Check has been performed, go to
next step.
2. This diagnostic procedure only diagnoses the A/C compressor clutch circuit. This procedure assumes the
following conditions are true:
A/C system is fully charged.
A/C compressor has no mechanical failures.
Engine coolant temperature is greater than 140F (60C), but less than 250F (121C).
HVAC control module is functioning normally.
Start engine and turn HVAC controls to off position. If A/C compressor clutch is engaged, go to step 12 .
If A/C compressor clutch is not engaged, go to next step.
3. Select any A/C position on HVAC control panel. Set blower switch to high. If A/C compressor clutch
engages, system is operating properly at this time. If A/C compressor clutch is not engaged, go to next
step.
4. Check condition of both A/C and IGN E fuses (10 amp). If both fuses are okay, go to next step. If one or
more fuses are blown, go to step 28 .
5. Connect scan tool and monitor A/C request signal. If scan tool displays A/C request as YES, go to next
step. If scan tool does not display A/C request as YES, go to step 20 .
6. Monitor A/C compressor cycling switch signal with scan tool. If scan tool displays A/C cycling switch as
closed, go to next step. If scan tool does not display A/C cycling switch as closed, go to step 24 .
7. Turn ignition switch to OFF position. Disconnect A/C clutch relay. Turn ignition switch on, engine off.
Using test light connected to battery voltage, probe A/C clutch relay control circuit (Dark Green/White
wire). See WIRING DIAGRAMS . Using scan tool, command A/C clutch relay on and off. If test light
turns on and off, go to next step. If test light does not turn on and off, go to step 31 .
8. Using test light connected to ground, probe both A/C relay battery voltage supply circuits. If test light
comes on at both terminals, go to next step. If test light does not come on at both terminals, go to step 32 .
9. Connect a fused jumper between battery voltage circuit and A/C compressor clutch circuit (Dark Green
wire). If A/C compressor clutch engages, go to step 34 . If A/C compressor clutch does not engage, go to
next step.
10. Using fused jumper connected, raise and support vehicle. Disconnect A/C compressor clutch connector.
Using test light connected to ground, probe A/C compressor clutch connector feed from relay terminal
(Dark Green wire). If test light comes on, go to next step. If test light does not come on, go to step 33 .
11. Connect a test light between terminals of A/C compressor clutch connector. If test light comes on, go to
step 35 . If test light does not come on, go to step 36 .
12. Monitor A/C request signal on scan tool. If scan tool indicates A/C request as YES, go to next step. If
scan tool indicates A/C request as NO, go to step 16 .
13. Disconnect A/C high pressure cut-out switch located on rear of compressor. If scan tool indicates A/C
request as YES, go to next step. If scan tool indicates A/C request as NO, diagnose A/C-heater system.
See appropriate MANUAL or AUTOMATIC A/C-HEATER SYSTEMS article.
14. Turn ignition switch to OFF position. Disconnect PCM connector C2. Turn ignition switch to ON
position. Use a DVOM to measure voltage between PCM connector C2 A/C request terminal (Dark
Green/White wire) and ground. If any voltage reading is indicated, go to step 37 . If no voltage reading is
indicated, go to next step.
15. Turn ignition switch to OFF position. Use a DVOM to measure resistance between A/C request terminal
(Dark Green/White wire) and all other terminals at connector C2. If reading is 0-2 ohms at any terminal,
go to step 38 . If reading is not 0-2 ohms at any terminal, go to step 55 .
16. Disconnect A/C clutch relay. If A/C compressor clutch disengages, go to next step. If A/C compressor
17. Using test light connected to battery voltage, probe A/C clutch relay control circuit (Dark Green/White
wire) at relay connector. If test light comes on, go to next step. If test light does not come on, go to step
40 .
18. Turn ignition switch to OFF position. Disconnect PCM connector C2. Using test light connected to
battery voltage, probe A/C clutch relay control circuit terminal (Dark Green/White wire) at PCM
connector C2. If test light comes on, go to step 41 . If test light does not come on, go to next step.
19. Using DVOM, measure resistance between A/C clutch relay control circuit terminal (Dark Green/White
wire) and all other terminals at connector C2. If reading is 0-2 ohms at any terminal, go to step 42 . If
reading is not 0-2 ohms at any terminal, go to step 55 .
20. Turn engine off. Disconnect A/C high pressure cut-out switch located on rear of compressor. Turn
ignition switch to ON position. Using DVOM, measure voltage between ground and A/C request circuit
(Dark Green/White wire) on HVAC module side. If battery voltage is indicated, go to next step. If battery
voltage is not indicated, diagnose A/C-heater system. See appropriate MANUAL or AUTOMATIC A/C-
21. Connect a fused jumper wire between A/C high pressure cut-out switch connector terminals. Start engine
and monitor A/C REQUEST on scan tool. If scan tool indicates A/C REQUEST as YES, go to step 43 . If
scan tool does not indicate A/C REQUEST as YES, go to next step.
22. Turn ignition switch to OFF position. Disconnect PCM connector C2. Using DVOM, check for continuity
of A/C request signal circuit between PCM and A/C high pressure cut-out switch (Dark Green/White
wire). If continuity is indicated, go to next step. If continuity is not indicated, go to step 45 .
23. Using DVOM, check continuity of A/C request signal circuit to ground. If continuity is indicated, go to
step 46 . If continuity is not indicated, go to step 54 .
24. Turn engine off. Disconnect A/C compressor cycling switch connector to the accumulator. Turn ignition
switch to ON position. Using DVOM, measure voltage between battery ground and A/C compressor
cycling switch signal circuit (Dark Green wire). If battery voltage is indicated, go to next step. If battery
voltage is not indicated, go to step 26 .
25. Connect a fused jumper wire between A/C compressor cycling switch connector terminals. If scan tool
indicates A/C COMPRESSOR CYCLING SWITCH as CLOSED, go to step 47 . If scan tool does not
indicate A/C COMPRESSOR CYCLING SWITCH as CLOSED, go to step 49 .
26. Turn ignition switch to OFF position. Disconnect PCM connector C2. Using DVOM, check continuity of
A/C compressor cycling switch circuit between PCM and cycling switch (Dark Green wire). If continuity
is indicated, go to next step. If continuity is not indicated, go to step 50 .
27. Using DVOM, check continuity between A/C compressor cycling switch circuit and ground. If continuity
is indicated, go to step 51 . If continuity is not indicated, go to step 54 .
28. If A/C fuse (10 amp) is blown, go to step 52 . If A/C fuse is okay, go to next step.
29. Remove A/C clutch relay from underhood electrical center. Using test light connected to battery voltage,
probe A/C clutch relay ignition supply circuit on fuse side. If test light come on, go to step 52 . If test
light does not come on, go to next step.
30. Disconnect A/C compressor clutch connector. Using test light connected to battery voltage, probe A/C
compressor clutch supply circuit terminal (Dark Green wire). If test light comes on, go to step 53 . If test
light does not come on, replace A/C compressor clutch.
31. Turn ignition switch to OFF position. Disconnect PCM connector C2. Using DVOM, check continuity of
A/C relay control circuit between PCM and underhood electrical center (Dark Green/White wire). If
continuity is indicated, go to step 54 . If continuity is not indicated, go to step 56 .
32. Repair open in circuit that did not turn test light on. Recheck system operation.
33. Repair open in A/C clutch circuit between relay and clutch. Recheck system operation.
34. Replace A/C clutch relay. Recheck system operation.
35. Check for proper terminal contact at A/C compressor clutch. If poor connection is found, repair as
necessary and recheck system operation. If connections are okay, replace A/C compressor clutch. See
appropriate COMPRESSOR SERVICING article in GENERAL SERVICING.
36. Repair open in A/C clutch ground circuit (Black wire). Recheck system operation.
37. Repair short to voltage in A/C request circuit (Dark Green/White wire) between A/C high pressure cut-
out switch and PCM. Recheck system operation.
38. Repair short to voltage in circuit that had continuity. Recheck system operation.
39. Repair short to voltage in Dark Green wire between A/C clutch relay and A/C compressor clutch.
Recheck system operation.
40. Replace A/C clutch relay. Recheck system operation.
41. Repair short to ground in Dark Green/White wire between A/C clutch relay and PCM. Recheck system
operation.
42. Repair short to ground in circuit that had continuity. Recheck system operation.
43. Check for proper terminal contact at A/C high pressure cut-out switch. Repair as necessary and recheck
system operation. If connections are okay, go to next step.
44. Replace A/C high pressure cut-out switch. Recheck system operation.
45. Repair open in Dark Green/White wire between A/C high pressure cut-out switch and PCM. Recheck
system operation.
46. Repair short to ground in Dark Green/White wire between A/C high pressure cut-out switch and PCM.
Recheck system operation.
47. Check for proper terminal contact at A/C compressor cycling switch. Repair as necessary and recheck
system operation. If connections are okay, go to next step.
48. Replace A/C compressor cycling switch. Recheck system operation.
49. Repair open in A/C compressor cycling switch ground circuit (Black wire). Recheck system operation.
50. Repair open in A/C compressor cycling switch signal circuit (Dark Green wire). Recheck system
operation.
51. Repair short to ground in A/C compressor cycling switch signal circuit (Dark Green wire). Recheck
system operation.
52. Replace underhood electrical center. Recheck system operation.
53. Check for, and repair, short to ground in Dark Green wire. If wire is okay, replace shorted A/C
compressor clutch diode. Recheck system operation.
54. Check for proper terminal contact at PCM. Repair as necessary and recheck system operation. If
connections are okay, go to next step.
55. Replace PCM and program. See appropriate REMOVAL, OVERHAUL & INSTALLATION article in
ENGINE PERFORMANCE. Recheck system operation.
56. Repair open in A/C clutch relay control circuit (Dark Green/White wire) between underhood fuse block
and PCM. Recheck system operation.
Diagnostic Aids
within the insulation. Check circuits thoroughly. For additional information, see appropriate MANUAL or
AUTOMATIC A/C-HEATER SYSTEMS article.
5.0L & 5.7L: "C" & "K" SERIES (2000) OR 7.4L: "G" SERIES (2000)
SYSTEMS article.
Description
Vehicle Control Module (VCM) control of A/C clutch improves idle quality and performance by performing the
following conditions:
Delaying clutch engagement until idle speed is increased.

Releasing clutch when idle speed is too low.
Providing additional fuel at the instant clutch is applied. Additional fuel smooths cycling of compressor.
Turning air conditioning on supplies battery voltage through pressure switches to VCM. When VCM receives
voltage on A/C request signal, A/C enable relay circuit is grounded. A/C compressor clutch then engages.
Diagnosis
1. Before using this table confirm A/C system has an adequate state of charge. If A/C system has an
adequate state of charge, go to next step. If A/C system does not have an adequate state of charge, see
CHARGING A/C SYSTEM in GENERAL SERVICING PROCEDURES article.
A/C on. If A/C clutch engages within 60 seconds, see DIAGNOSTIC AIDS . If A/C clutch does not
engage within 60 seconds, go to next step.
3. Turn ignition switch to OFF position. Install scan tool. Start engine. Turn A/C on. Monitor A/C
REQUEST in scan tool data list. If A/C REQUEST is YES, go to next step. If A/C REQUEST is not
YES, go to step 14 .
4. Using scan tool, monitor A/C EVAPORATOR SWITCH. If scan tool indicates switch is CLOSED, go to
step 8 . If scan tool does not indicate switch is CLOSED, go to next step.
5. Turn ignition switch to OFF position. Disconnect A/C cycling switch connector. Turn ignition switch to
ON position, with engine off. Connect fused jumper between Dark Green wire at A/C cycling switch
connector and ground. If scan tool indicates switch is CLOSED, go to next step. If scan tool does not
indicate switch is CLOSED, go to step 27 .
6. Using test light connected to battery voltage, probe Black/White wire of A/C cycling switch connector. If
test light is on, go to next step. If test light is off, go to step 30 .
7. Replace A/C cycling switch. After repairs, go to step 32 .
CAUTION: Avoid contact with moving parts and hot surfaces while working
around a running engine in order to prevent physical injury.
8. Turn ignition switch to OFF position. Disconnect A/C compressor clutch connector. Start engine. Turn
A/C on. Using test light connected to ground, probe A/C clutch voltage supply circuit (Dark Green wire)
at A/C compressor clutch connector. If test light is on, go to next step. If test light is off, go to step 16 .
9. Using test light connected to battery voltage, probe A/C clutch ground circuit (Black wire) at A/C clutch
connector. If test light is on, go to step 11 . If test light is off, go to next step.
10. Repair A/C clutch ground circuit (Black wire). After repairs, go to step 32 .
11. Check A/C compressor clutch connector for poor connections. If problem was found, go to next step. If
12. Repair A/C compressor clutch connector. After repairs, go to step 32 .
14. Turn ignition switch to OFF position. Disconnect VCM connector C3. Turn ignition switch to ON
position, with engine off. Turn A/C on. Using test light connected to ground, probe VCM connector C3
terminal No. 25 (Dark Green/White wire). If test light is on, go to step 29 . If test light is off, go to next
step.
15. Check A/C request signal circuit (Dark Green/White wire and Light Green wire) for open between
HVAC control module and VCM. If problem was found, go to step 30 . If problem was not found, go to
step 28 .
16. Reconnect A/C clutch connector. Install scan tool. Turn ignition switch to ON position, with engine off.
Using scan tool, command A/C relay on. If A/C relay clicks, go to step 22 . If A/C relay does not click,
go to next step.
17. Disconnect A/C compressor clutch relay. Turn ignition switch to ON position, with engine off. Using test
light connected to ground, probe ignition voltage circuit (Pink wire) at A/C relay connector. If test light is
on, go to step 19 . If test light is off, go to next step.
18. Repair open in A/C relay ignition voltage circuit (Pink wire). If fuse is blown, repair short to ground in
Pink wire. After repairs, go to step 32 .
19. Using test light connected to battery voltage, probe A/C relay control circuit (Dark Green/White wire) at
A/C compressor clutch relay connector. Using scan tool, command A/C compressor clutch relay on. If
test light is on, go to step 25 . If test light is off, go to next step.
20. Check for open or short to voltage in Dark Green/White wire between underhood fuse block and VCM
connector C3. If problem was found, go to next step. If problem was not found, go to step 29 .
21. Repair Dark Green/White wire between underhood fuse block and VCM connector C3. After repairs, go
to step 32 .
22. Remove A/C compressor clutch relay. Using test light connected to ground, probe battery feed circuit
(Orange wire) at A/C compressor clutch relay connector. If test light is on, go to step 24 . If test light is
off, go to next step.
23. Repair open in A/C compressor clutch relay battery feed circuit. If fuse is blown, repair short to ground in
Orange wire. After repairs, go to step 32 .
24. Turn ignition switch to ON position, with engine off. Using fused jumper wire, connect battery feed
circuit and A/C compressor clutch voltage supply circuit (Dark Green wire) at A/C compressor clutch
relay connector. If A/C clutch engages, go to next step. If A/C clutch does not engage, go to step 26 .
26. Repair open or short to ground in A/C compressor clutch voltage supply circuit (Dark Green wire). After
27. Check for open in A/C cycling switch signal circuit (Dark Green wire). If problem was found, go to step
29. Check VCM connectors for poor connections. If problem was found, go to next step. If problem was not
30. Repair circuit as necessary. After repairs, go to step 32 .
31. Replace VCM. See appropriate REMOVAL, OVERHAUL & INSTALLATION article in ENGINE
A/C on. A/C clutch should engage within 60 seconds. Using scan tool, check for DTCs. If DTCs are not
present, system is okay.
Diagnostic Aids
within the insulation. Check circuits thoroughly. For additional information, see appropriate MANUAL A/C-
6.5L: "C" & "K" SERIES (2000)
SYSTEMS article.
HVAC Compressor Controls System Check
1. Start vehicle. Turn blower switch to HIGH position. Turn A/C on. A/C compressor clutch engages. If
cold air comes from air vents, system is okay. If air from vents does not get cold, see COMPRESSOR
CLUTCH DOES NOT ENGAGE .
2. Turn A/C off, leave blower on high. A/C compressor clutch should disengage. If cool air from vents turns
warm after a few minutes, system is okay. If air remains cool coming from vents, see COMPRESSOR
CLUTCH DOES NOT DISENGAGE .
1. Ensure A/C system has sufficient refrigerant charge. If refrigerant charge is sufficient, go to next step. If
refrigerant charge is not sufficient, see CHARGING A/C SYSTEM in GENERAL SERVICING
PROCEDURES article.
2. Disconnect PCM connector C3. Connect fused jumper wire between VCM connector C3 terminal D5
(Dark Green/White wire) and ground. Turn ignition switch to ON position. If audible click from A/C
compressor clutch is heard, go to step 14 . If audible click from A/C compressor clutch is not heard, go to
next step.
3. Remove A/C compressor clutch relay. Connect fused jumper wire between A/C compressor clutch relay
connector terminals B4 (Orange wire) and A6 (Dark Green wire). If clutch engages, go to next step. If
clutch does not engage, go to step 7 .
4. Disconnect PCM connector C3. Connect fused jumper wire between A/C compressor clutch relay
terminals A4 (Pink wire) and B6 (Dark Green/White wire). Using DVOM, measure voltage between
PCM connector C3 terminal D5 (Dark Green/White wire) and ground. Turn ignition switch to ON
position. If battery voltage is present, go to next step. If battery voltage is not present, go to step 6 .
5. Replace A/C compressor clutch relay. After repairs, recheck system operation.
6. Repair open in Dark Green wire between underhood fuse block and PCM. After repairs, recheck system
operation.
7. Disconnect A/C compressor clutch connector. Using DVOM, check continuity between A/C compressor
clutch connector terminal "A" (Black wire) and ground. If continuity exists, go to step 9 . If continuity
does not exist, go to next step.
8. Repair open in Black wire between compressor clutch and ground. After repairs, recheck system
operation.
9. Connect fused jumper wire between A/C compressor clutch relay connector terminals B4 (Orange wire)
and A6 (Dark Green wire). Using DVOM, measure voltage between terminals of compressor clutch
connector. If battery voltage is present, go to step 11 . If battery voltage is not present, go to next step.
10. Repair open in Dark Green wire between underhood fuse block and compressor clutch connector. After
repairs, recheck system operation.
11. Remove fused jumper wire between at A/C compressor clutch relay connector. Using DVOM, check
continuity between compressor clutch connector terminals. Reverse meter leads at connector and check
continuity again. If continuity is present in one direction only, go to step 13 . If continuity is not present
in one direction only, go to next step.
12. Replace diode located within A/C compressor clutch harness. After repairs, recheck system operation.
SERVICING. After repairs, recheck system operation.
14. Disconnect A/C compressor cycling switch. Connect jumper between A/C compressor cycling switch
connector terminals. Using DVOM, measure voltage between PCM connector C1 terminal C2 (Dark
Green wire) and ground. Turn ignition switch to ON position. Turn front blower switch to any position
except OFF. Push in A/C Button. If battery voltage is present, go to next step. If battery voltage is not
present, go to step 16 .
15. Replace A/C compressor cycling switch. After repairs, recheck system operation.
16. Disconnect A/C high pressure switch connector. Connect fused jumper wire between A/C high pressure
switch connectors. Using DVOM, measure voltage between PCM connector C1 terminal C2 (Dark Green
wire) and ground. Turn ignition switch to ON position. Turn front blower switch to any position except
OFF. Push in A/C Button. If battery voltage is present, go to next step. If battery voltage is not present, go
to step 18 .
17. Replace A/C high pressure switch. After repairs, recheck system operation.
18. Disconnect HVAC control module connector C3. Connect fused jumper between HVAC control module
connector C3 terminals No. 5 (Brown wire) and No. 10 (Light Green wire). Using DVOM, measure
voltage between PCM connector C1 terminal C2 (Dark Green/White) and ground. Turn ignition switch to
ON position. Turn front blower switch to any position except OFF. Push in A/C Button. If battery voltage
is present, go to next step. If battery voltage is not present, go to step 20 .
HEATER SYSTEMS article. After repairs, recheck system operation.
20. Repair open in Brown wire, Light Green wire, Dark Green wire or Dark Green/White wire between
instrument panel fuse block and PCM. After repairs, recheck system operation.
1. If HVAC compressor controls system check has been performed, go to next step. If HVAC compressor
controls system check has not been performed, see HVAC COMPRESSOR CONTROLS SYSTEM
CHECK .
2. Turn ignition switch to ON position. Remove A/C Compressor Clutch Relay. If A/C compressor clutch
disengages, go to step 6 . If A/C compressor clutch does not disengage, go to next step.
3. Using DVOM, measure voltage between A/C compressor clutch relay connector terminal A6 (Dark
Green wire) and ground. If voltage is greater than 0.5 volt, go to next step. If voltage is not greater than
0.5 volts, go to step 5 .
4. Repair short to battery voltage in Dark Green wire between A/C compressor clutch relay and A/C
compressor clutch. After repairs, perform HVAC COMPRESSOR CONTROLS SYSTEM CHECK .
SERVICING. After repairs, perform HVAC COMPRESSOR CONTROLS SYSTEM CHECK .
6. Connect fused jumper between A/C compressor clutch relay connector terminal A4 (Pink wire) and
battery voltage. Connect second jumper between A/C compressor clutch relay connector terminal B6
(Dark Green/White wire) and ground. If relay clicks, go to step 8 .
7. Replace A/C Compressor Clutch Relay. After repairs, perform HVAC COMPRESSOR CONTROLS
SYSTEM CHECK .
8. Turn ignition switch to OFF position. Using DVOM, measure continuity between A/C compressor clutch
relay connector terminal B6 (Dark Green/White wire) and ground. If continuity is present, go to next step.
If continuity does not exist, go to step 10 .
9. Repair short to ground in Dark Green/White wire between A/C compressor clutch relay and PCM. After
repairs, perform HVAC COMPRESSOR CONTROLS SYSTEM CHECK .
10. Turn ignition switch to ON position. Disconnect HVAC Control Module connector C3. Using DVOM,
measure voltage between PCM connector C1 terminal C2 (Dark Green/White wire) and ground. If battery
voltage is present, go to step 12 . If battery voltage is not present, go to next step.
HEATER SYSTEMS article. After repairs, perform HVAC COMPRESSOR CONTROLS SYSTEM
CHECK .
12. Repair short to battery voltage in Light Green wire, Dark Green wire or Dark Green/White wire between
HVAC control module and PCM. After repairs, perform HVAC COMPRESSOR CONTROLS
SYSTEM CHECK .
4.3L, 4.8L, 5.3L, 6.0L, 6.6L & 8.1L: "C" & "K" SERIES (AUTOMATIC A/C 2001)
SYSTEMS article.
Description
A/C system can operate regardless of temperature setting, as long as outside ambient temperature is greater than
40F (4C). If A/C is requested and temperatures are too low, LED will flash 3 times to remind vehicle operator
that A/C is not available.
Regardless of selected A/C mode setting, a request is made to Powertrain Control Module (PCM) to turn on
A/C compressor. request is sent to PCM through A/C request signal circuit from HVAC control module. Power
and ground are provided to HVAC control module by fuse block through ignition voltage and ground circuits.
In order for PCM to internally ground A/C clutch relay control circuit, 2 separate request signals need to be
grounded. A 12-volt reference signal is sent out over A/C request signal circuits, through A/C high pressure
switch and grounded through HVAC control module when vehicle operator makes an A/C request. A separate
12-volt reference signal is sent out over A/C refrigerant low pressure cut-out switch signal circuit, through A/C
low pressure switch and ground circuit. When both these reference signals are grounded, PCM can activate A/C
compressor clutch.
compressor clutch relay. Power is provided to A/C compressor clutch relay internally of engine wiring harness
clutch diode provides a path for voltage spike resulting from collapsing magnetic field of compressor clutch
coil. Ground circuit provides a pathway to ground for compressor. A/C clutch relay control circuit is grounded
internally within PCM.
A/C line pressure exceeds a predetermined value. A/C low pressure switch interrupts A/C refrigerant low
pressure cut-out switch signal when A/C line pressure falls less than 21-25 psi (1.5-1.8 kg/cm2 ). When PCM
sees an open in either signal, A/C clutch relay control circuit is no longer grounded, thus shutting off
compressor. Low pressure switch will close when pressure reaches 38-42 psi (2.7-3.0 kg/cm2 ).
Control Module (BCM) and Powertrain Control Module (PCM)/Vehicle Control Module (VCM). If
DISENGAGE .
SERVICING.
next step.
5. Start engine. Using scan tool, observe A/C REQUEST SIGNAL parameter. Place A/C request switch in
ON position. If scan tool indicates A/C REQUEST SIGNAL parameter is YES, go to step 8 . If scan tool
does not indicate A/C REQUEST SIGNAL parameter is YES, go to next step.
amp) between A/C high pressure switch connector terminals. Start engine. Using scan tool, observe A/C
REQUEST SIGNAL parameter. Place A/C request switch in ON position. If scan tool indicates A/C
REQUEST SIGNAL parameter is YES, go to step 31 . If scan tool does not indicate A/C REQUEST
SIGNAL parameter is YES, go to step 25 .
8. If scan tool indicates A/C COMPRESSOR CYCLING SWITCH parameter is NORMAL, go to step 10 .
If scan tool does not indicate A/C COMPRESSOR CYCLING SWITCH parameter is NORMAL, go to
next step.
amp) between A/C low pressure switch connector terminals. Start engine. Using scan tool, observe A/C
COMPRESSOR CYCLING SWITCH parameter. If scan tool indicates A/C COMPRESSOR CYCLING
SWITCH parameter is NORMAL, go to step 28 . If scan tool does not indicate A/C COMPRESSOR
CYCLING SWITCH parameter is NORMAL, go to step 21 .
32 .
circuit (Light Blue wire and Dark Green/White wire) for short to ground, high resistance or open. If
32 .
step.
5. Turn ignition switch to off position. Disconnect A/C high pressure switch. Start engine. Using scan tool,
11 .
12 .
11. Check HVAC control module for poor connections. If problem was found, repair as necessary. After
4.3L, 4.8L, 5.3L, 6.0L, 6.6L & 8.1L: "C" & "K" SERIES (MANUAL A/C 2001)
SYSTEMS article.
Description
A/C system can operate regardless of temperature setting, however, recirculation is only available when HVAC
control module is either in A/C or BI-LEVEL mode. Regardless of selected A/C mode setting, a request is made
to Powertrain Control Module (PCM) to turn on A/C compressor. Request is sent to PCM through A/C request
signal circuit from HVAC control module. Power and ground are provided to HVAC control module by left
instrument panel fuse block through ignition voltage and ground circuits.
In order for PCM to internally ground A/C clutch relay control circuit, 2 separate request signals need to be
grounded. A 12 volt reference signal is sent out over A/C request signal circuits, through A/C high pressure
switch and grounded through HVAC control module when vehicle operator makes an A/C request. A separate
12 volt reference signal is sent out over A/C refrigerant low pressure cut-out switch signal circuit, through A/C
low pressure switch and ground circuit. When both these reference signals are grounded, PCM can activate A/C
compressor clutch.
compressor clutch relay. Power is provided to A/C compressor clutch relay internally of engine wiring harness
clutch diode prevents a voltage spike from entering vehicles electrical system. Ground circuit provides a
pathway to ground for compressor. A/C clutch relay control circuit is grounded internally within PCM.
A/C line pressure exceeds a predetermined value. A/C low pressure switch interrupts A/C refrigerant low
pressure cut-out switch signal when A/C line pressure falls less than 21-25 psi (1.5-1.8 kg/cm2 ). When PCM
sees an open in either signal, A/C clutch relay control circuit is no longer grounded, thus shutting off
compressor. Low pressure switch will close when pressure reaches 38-42 psi (2.7-3.0 kg/cm2 ).
SERVICING.
next step.
4. Start engine. Using scan tool, observe A/C REQUEST SIGNAL parameter. Place A/C request switch in
ON position. If scan tool indicates A/C REQUEST SIGNAL parameter is YES, go to step 7 . If scan tool
does not indicate A/C REQUEST parameter is YES, go to next step.
6. Ensure blower motor switch is not in OFF position. Turn ignition switch to OFF position. Disconnect
A/C high pressure switch. Connect fused jumper (3 amp) between A/C high pressure switch connector
terminals. Start engine. Using scan tool, observe A/C REQUEST SIGNAL parameter. Place A/C request
switch in ON position. If scan tool indicates A/C REQUEST SIGNAL parameter is YES, go to step 31 .
If scan tool does not indicate A/C REQUEST SIGNAL parameter is YES, go to step 25 .
7. If scan tool indicates A/C COMPRESSOR CYCLING SWITCH parameter is CLOSED, go to step 9 . If
scan tool does not indicate A/C COMPRESSOR CYCLING SWITCH parameter is CLOSED, go to next
step.
amp) between A/C low pressure switch signal circuit (Dark Green wire) and ground. Start engine. Using
scan tool, observe A/C COMPRESSOR CYCLING SWITCH parameter. If scan tool indicates A/C
COMPRESSOR CYCLING SWITCH parameter is NORMAL, go to step 28 . If scan tool does not
indicate A/C COMPRESSOR CYCLING SWITCH parameter is NORMAL, go to step 21 .
32 .
20. Ensure that blower motor switch is not in OFF position. Check off blower motor control circuit (Dark
Green wire) for short to voltage. If problem was found, repair as necessary. After repairs, go to step 39 .
circuit (Light Blue wire and Dark Green/White wire) for short to ground, high resistance or open. If
32 .
A/C compressor operates, go to next step. If A/C compressor clutch does not operate, problem is
intermittent.
step.
10 .
4.3L, 5.0L, 5.7L, 6.5L & 8.1L: "G" SERIES (2001)
SYSTEMS article.
Description
A/C system can operate regardless of air temperature setting. Regardless of selected A/C mode setting, a request
is made to Powertrain Control Module (PCM) to turn on A/C compressor clutch. Request is sent to PCM
through A/C request signal circuit and A/C high pressure switch from HVAC control assembly. On vehicles
equipped with diesel engine, A/C request is sent to PCM through the A/C request signal circuit and A/C high
and low pressure switches from HVAC control assembly. Power and ground are provided to HVAC control
assembly by ignition voltage and ground circuits.
PCM turns on A/C compressor by providing a path to ground through A/C compressor clutch relay control
circuit for A/C compressor clutch relay. Ignition voltage circuit provides power to A/C compressor clutch relay
control. Once relay contact closes its internal switch, power from battery positive voltage circuit is provided to
A/C compressor clutch through A/C compressor clutch supply voltage circuit. Whenever compressor is turned
off, A/C clutch diode prevents a voltage spike from damaging compressor clutch coil. Ground circuit provides a
pathway to ground for compressor and diode. Both A/C request signal and A/C clutch relay control circuits are
grounded by ground circuits.
A/C line pressure exceeds a predetermined value. A/C low pressure switch interrupts A/C low pressure switch
signal when A/C line pressure drops below a predetermined value. When PCM stops receiving the required
signals, A/C compressor clutch relay control circuit is no longer grounded, thus shutting off compressor.
Compressor Clutch Does Not Engage (Without 6.5L)
1. Ensure outside air temperature is greater than 3C (38F). Start engine. Turn blower motor switch to
SERVICING.
to next step.
4. Start engine. Using scan tool, observe A/C REQUEST SIGNAL parameter in ENGINE DATA 2 data list.
Place A/C request switch in ON position. If scan tool indicates A/C REQUEST SIGNAL parameter is
8.
6. Check ground circuit (Black wire) to HVAC control assembly for high resistance or open. If problem was
7. If scan tool indicates A/C COMPRESSOR CYCLING SWITCH parameter is CLOSED, go to step 14 . If
scan tool does not indicate A/C COMPRESSOR CYCLING SWITCH parameter is CLOSED, go to step
9.
REQUEST parameter. Place A/C request switch in ON position. If scan tool indicates A/C REQUEST
parameter is YES, go to step 30 . If scan tool does not indicate A/C REQUEST parameter is YES, go to
step 10 .
9. Turn ignition switch to OFF position. Disconnect A/C low pressure cutout switch. Connect fused jumper
(3 amp) between A/C low pressure cutout switch signal connector terminals. Start engine. Using scan
tool, observe A/C COMPRESSOR CYCLING SWITCH parameter. If scan tool indicates A/C
COMPRESSOR CYCLING SWITCH parameter is CLOSED, go to step 27 . If scan tool does not
indicate A/C COMPRESSOR CYCLING SWITCH parameter is CLOSED, go to step 12 .
circuit (Light Green wire and Dark Green/White wire) for short to ground, high resistance or open. If
step.
11. Measure voltage between A/C request signal circuit (Dark Green/White wire) at PCM an ground. If
battery voltage is present, go to step 31 . If battery voltage is not present, go to step 29 .
(Pink wire) of A/C compressor clutch relay. If test light is on , go to next step. If test light is off, go to
step 24 .
31 .
step 38 .
to step 38 .
Compressor Clutch Does Not Engage (With 6.5L)
1. Ensure ambient air temperature is greater than 3C (38F). Start engine. Turn blower motor switch to
SERVICING.
to next step.
4. Start engine. Using scan tool, observe A/C REQUEST parameter in ENGINE DATA 1 data list. Place
A/C request switch in ON position. If scan tool indicates A/C REQUEST parameter is ON, go to step 11 .
not found, go to next step.
6. Check ground circuit (Black wire) to HVAC control assembly for high resistance or open. If problem was
parameter is ON, go to step 27 . If scan tool does not indicate A/C REQUEST parameter is ON, go to
next step.
amp) between A/C low pressure switch connector terminals. Start engine. Using scan tool, observe A/C
parameter is ON, go to step 24 . If scan tool does not indicate A/C REQUEST parameter is ON, go to
next step.
9. Turn ignition switch to OFF position. Reconnect A/C high pressure switch. Reconnect A/C low pressure
switch. Check A/C request signal circuit (Light Green wire, Dark Green wire and Dark Green/White
wire) for short to ground, high resistance or open. If problem was found, repair as necessary. After
repairs, go to step 35 . If problem was not found, go to next step.
10. Measure voltage between A/C request signal circuit (Dark Green/White wire) at PCM and ground. If
battery voltage is present, go to step 28 . If battery voltage is not present, go to step 26 .
14. Turn ignition to OFF position. Disconnect A/C compressor clutch relay. Turn ignition switch to ON
position, with engine off. Using test light connected to ground, probe coil side voltage supply circuit of
A/C compressor clutch relay. If test light is on, go to next step. If test light is off, go to step 21 .
step 35 . If problem was not found, go to next.
19. Check control circuit (Dark Green/White wire) of the A/C compressor clutch relay for a short to ground.
If problem was found, repair as necessary. After repairs, go to step 35 . If problem was not found, go to
step 28 .
step 35 .
to step 35 .

2. Using scan tool, observe A/C REQUEST parameter in ENGINE DATA 2 data list. If scan tool indicates
WIRING DIAGRAMS
ALERO & GRAND AM
Fig. 1: A/C Compressor Clutch Control Circuit Wiring Diagram (2000 Alero & Grand Am)
Fig. 2: A/C Compressor Clutch Control Circuit Wiring Diagram (2001 Alero & Grand Am 2.4L VIN T
Engine)
Fig. 3: A/C Compressor Clutch Control Circuit Wiring Diagram (2001 Alero & Grand Am 3.4L VIN E
Engine)
ASTRO & SAFARI

Fig. 4: A/C Compressor Clutch Control Circuit Wiring Diagram (2000-01 Astro & Safari)
AURORA
Fig. 5: A/C Compressor Clutch Control Circuit Wiring Diagram (2001 Aurora)
AZTEK
Fig. 6: A/C Compressor Clutch Control Circuit Wiring Diagram (2001 Aztek)
BLAZER, BRAVADA, ENVOY & JIMMY

Fig. 7: A/C Compressor Clutch Control Circuit Wiring Diagram (2000-01 Blazer, Jimmy, Sonoma & S10
Pickup - With Manual A/C-Heater System & 4.3L VINs W & X Engine)
Fig. 8: A/C Compressor Clutch Control Circuit Wiring Diagram (2000-01 Blazer, Bravada, Envoy &
Jimmy - With Automatic A/C-Heater System)
BONNEVILLE & LESABRE

Fig. 9: A/C Compressor Clutch Control Circuit Wiring Diagram (2000-01 Bonneville & LeSabre)
"C" & "K" PICKUP

Fig. 10: A/C Compressor Clutch Control Circuit Wiring Diagram (2000 "C" & "K" Pickup, Escalade,
Tahoe & Yukon - 5.7L VIN R & 7.4 VIN J)
Fig. 11: A/C Compressor Clutch Control Circuit Wiring Diagram (2000 "C" & "K" Pickup - Diesel
Engine)
CAMARO & FIREBIRD

Fig. 12: A/C Compressor Clutch Control Circuit Wiring Diagram (2000-01 Camaro & Firebird - With
3.8L VIN K Engine)
Fig. 13: A/C Compressor Clutch Control Circuit Wiring Diagram (2000-01 Camaro & Firebird - With
5.7L VIN G Engine)
CATERA
Fig. 14: A/C Compressor Clutch Control Circuit Wiring Diagram (2000-01 Catera)
CAVALIER & SUNFIRE

Fig. 15: A/C Compressor Clutch Control Circuit Wiring Diagram (2000 Cavalier & Sunfire)
Fig. 16: A/C Compressor Clutch Control Circuit Wiring Diagram (2001 Cavalier & Sunfire)
CENTURY & REGAL

Fig. 17: A/C Compressor Clutch Control Circuit Wiring Diagram (2000-01 Century & Regal)
CORVETTE
Fig. 18: A/C Compressor Clutch Control Circuit Wiring Diagram (2000-01 Corvette)
DEVILLE
Fig. 19: A/C Compressor Clutch Control Circuit Wiring Diagram (2000 DeVille)
Fig. 20: A/C Compressor Clutch Control Circuit Wiring Diagram (2001 DeVille)
ELDORADO
Fig. 21: A/C Compressor Clutch Control Circuit Wiring Diagram (2000 Eldorado)
Fig. 22: A/C Compressor Clutch Control Circuit Wiring Diagram (2001 Eldorado)
EXPRESS & SAVANA

Fig. 23: A/C Compressor Clutch Control Circuit Wiring Diagram (2000 Express & Savana - Except
Diesel Engine)
Fig. 24: A/C Compressor Clutch Control Circuit Wiring Diagram (2000 Express & Savana - Diesel
Engine)
Fig. 25: A/C Compressor Clutch Control Circuit Wiring Diagram (2001 Express & Savana - Except
Diesel Engine)
Fig. 26: A/C Compressor Clutch Control Circuit Wiring Diagram (2001 Express & Savana - Diesel
Engine)
GRAND PRIX
Fig. 27: A/C Compressor Clutch Control Circuit Wiring Diagram (2000 Grand Prix)
Fig. 28: A/C Compressor Clutch Control Circuit Wiring Diagram (2001 Grand Prix)
IMPALA & MONTE CARLO

Fig. 29: A/C Compressor Clutch Control Circuit Wiring Diagram (2000 Impala & Monte Carlo)
Fig. 30: A/C Compressor Clutch Control Circuit Wiring Diagram (2001 Impala & Monte Carlo)
INTRIGUE
Fig. 31: A/C Compressor Clutch Control Circuit Wiring Diagram (2000-01 Intrigue)
LUMINA
Fig. 32: A/C Compressor Clutch Control Circuit Wiring Diagram (2000-01 Lumina)
MALIBU
Fig. 33: A/C Compressor Clutch Control Circuit Wiring Diagram (2000-01 Malibu)
MONTANA, SILHOUETTE & VENTURE

Fig. 34: A/C Compressor Clutch Control Circuit Wiring Diagram (2000 Montana, Silhouette & Venture)
Fig. 35: A/C Compressor Clutch Control Circuit Wiring Diagram (2001 Montana, Silhouette & Venture)
PARK AVENUE
Fig. 36: A/C Compressor Clutch Control Circuit Wiring Diagram (2000-01 Park Avenue)
SEVILLE
Fig. 37: A/C Compressor Clutch Control Circuit Wiring Diagram (2000-01 Seville)
SIERRA, SILVERADO, SUBURBAN, TAHOE, YUKON

Fig. 38: A/C Compressor Clutch Control Circuit Wiring Diagram (2000-01 Sierra, Silverado, Suburban,
Tahoe, Yukon & Yukon XL)
SONOMA & S10 PICKUP

Fig. 39: A/C Compressor Clutch Control Circuit Wiring Diagram (2000-01 Sonoma & S10 Pickup - 2.2L
VIN 4 & VIN 5 Engine)
General Motors Corp. - Air Bag Restraint Systems
WARNING: Accidental air bag deployment is possible. Personal injury may result.
Read and follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS
before working on air bag system or related components.
Supplemental Inflatable Restraint (SIR) system is designed to supplement protection provided by driver-side
and passenger-side seat belts. A frontal impact of sufficient force, up to 30 degrees off center line of vehicle
will deploy driver-side and passenger-side air bag modules. A side impact of sufficient force will deploy side
impact air bag module on side of impact. Steering wheel, steering column and knee bolsters also absorb impact
energy. SDM maintains a 36 Volt Loop Reserve (36 VLR) energy supply to provide deployment energy for up
to one minute after loss of ignition voltage.
SIR system consists of Sensing and Diagnostic Module (SDM), driver-side and passenger-side air bag modules,
driver and passenger side impact air bag modules, Side Impact Sensors (SIS), SIR coil assembly, driver-side
and passenger-side knee bolsters and AIR BAG warning light.
COMPONENT LOCATIONS
COMPONENT LOCATIONS
Component Location
AIR BAG warning light Instrument Panel Cluster (IPC)
Driver-side air bag module On steering wheel
Knee bolsters Driver-side & passenger-side lower instrument
panel
Passenger-side air bag module Passenger-side instrument panel
Sensing & Diagnostic Module (SDM) Under passenger front seat
Side impact air bag modules Driver-side & passenger-side front seat outer seat
backs
Side Impact Sensors (SIS) Driver-side & passenger-side lower B-pillars
SIR coil assembly Under steering wheel
SYSTEM OPERATION CHECK

If system is functioning normally, AIR BAG warning light flashes 7 times and then turns off when ignition is
turned on. System malfunction is indicated when light does not illuminate at all, light comes on while vehicle is
driven, light flashes 7 times and remains on or light does not flash but remains on when ignition is turned on.
AIR BAG SAFETY PRECAUTIONS

Observe the following precautions when working with SIR system:
SDM maintains sufficient voltage to cause air bag deployment for up to one minute after ignition is
turned off, battery is disconnected or fuse powering SDM is removed. Disable air bag system before
working on vehicle. See DISABLING & ACTIVATING AIR BAG SYSTEM .
If vehicle interior is exposed to moisture and becomes soaked up to level of SDM, SDM and harness
connector must be replaced. SDM could be activated when powered, causing air bag deployment.
After repairs, ensure AIR BAG warning light is working properly and no system faults are indicated. See
SYSTEM OPERATION CHECK .
Always wear safety glasses when servicing or handling an air bag module.
Air bag modules must be stored in original special containers until used for service. Store in a clean, dry
place, away from sources of extreme heat, sparks, or high electrical energy.
SIR components should not be subjected to temperatures greater than 150F (65C).
SIR components should not be used if they have been dropped from a height of 3 feet (0.9 m) or greater.
When placing a live air bag module on a bench or other surface, always make certain that trim cover faces
up. This will reduce motion of module if accidentally deployed.
After deployment, air bag surface may contain deposits of sodium hydroxide, which can irritate skin.
Always wear safety glasses, rubber gloves and long-sleeved shirt during clean-up and wash hands using
mild soap and water. Follow correct disposal procedures. See DISPOSAL PROCEDURES .
At no time should any electrical source be allowed near inflator on back of air bag module.
Do not apply power to SIR system unless all components are connected or a diagnostic test requests it, as
this will set a Diagnostic Trouble Code (DTC).
When carrying a live air bag module, trim cover should be pointed away from body to minimize injury in
case of accidental deployment.
Do not attempt to service SIR components. If defective, these parts must be replaced.
Do not probe a wire through insulator. Wire will be damaged and eventually fail due to corrosion.
When performing electrical tests, prevent accidental shorting of terminals. Such mistakes can damage
fuses or components and may cause a second fault code to set, making diagnosis of original problem
more difficult.
When using diagnostic tests to diagnose SIR system, under no circumstances should a volt/ohmmeter, test
light or any type of electrical equipment not specified by manufacturer be used.
If SIR system is not fully functional for any reason, vehicle should not be driven until system is repaired.
Do not remove bulbs, modules, sensors or other components or in any way disable system from operating
normally.
ADJUSTMENTS
CENTERING SIR COIL ASSEMBLY
With Centering Window & Service Lock
Hold SIR coil face up. See Fig. 1 . While depressing service lock, rotate coil hub clockwise until it stops. Rotate
coil hub counterclockwise slowly until centering window appears Yellow and line-up marks are aligned.
Release service lock.
With Centering Window & No Service Lock
Hold SIR coil face up. See Fig. 1 . Rotate coil hub clockwise until it stops. Rotate coil hub counterclockwise
slowly until centering window appears Yellow and both line-up marks are aligned. Prevent coil hub from
moving until installed on steering column.
With Service Lock & No Centering Window
Hold SIR coil assembly with rear side facing up. See Fig. 1 . While depressing service lock, rotate coil hub in
direction indicated by directional arrow until it stops. Rotate coil hub in opposite direction 2 1/2 turns. Release
service lock.
Without Centering Window Or Service Lock
Hold SIR coil assembly face up. See Fig. 1 . Rotate coil hub in direction of arrow until it stops. Rotate coil hub
in opposite direction 2 1/2 turns. Prevent coil hub from moving until installed on steering column.
Fig. 1: Identifying SIR Coil Assembly Types
Courtesy of GENERAL MOTORS CORP.
DISABLING & ACTIVATING AIR BAG SYSTEM
NOTE: SIR components are placed in various zones. Work being performed will
determine applicable disabling and activating procedure. See REMOVAL &
INSTALLATION . To identify disabling and activating component zones, refer to
illustration. See Fig. 2 .
Fig. 2: Identifying SRS Component Disabling & Activating Zones (Typical)
DISABLING SYSTEM
Read and follow service precautions. See AIR BAG SAFETY
PRECAUTIONS .
NOTE: When SIR fuse is removed from junction block and ignition is on, AIR BAG
warning light will be on. This does not indicate a system malfunction.
Zone 2
1. Turn steering wheel to place vehicle wheels in straight-ahead position. Turn ignition off and remove key.
Remove SIR fuse (10-amp) from fuse block, located in junction block in center console. See Fig. 3 .
2. Remove driver-side lower B-pillar trim panel. Remove Side Impact Sensor (SIS) from lower B-pillar. See
SIDE IMPACT SENSOR (SIS) under REMOVAL & INSTALLATION. Remove Connector Position
Assurance (CPA) clip from Side Impact Sensor (SIS) connector. Disconnect SIS connector.
Fig. 3: Identifying SIR Fuse Location
Zone 3
2. Remove driver-side insulator panel. Remove Connector Position Assurance (CPA) clip from driver-side
air bag module connector. Disconnect driver-side air bag module connector.
Fig. 4: Identifying Driver-side Air Bag Module Connector
Zone 5
2. Remove passenger-side insulator panel. Remove Connector Position Assurance (CPA) clip from
passenger-side air bag module connector. See Fig. 5 . Disconnect passenger-side air bag module
connector.
Fig. 5: Identifying Passenger-side Air Bag Module Connector
Zone 6
2. Remove passenger-side lower B-pillar trim panel. Remove Side Impact Sensor (SIS) from lower B-pillar.
See SIDE IMPACT SENSOR (SIS) under REMOVAL & INSTALLATION. Remove Connector
Position Assurance (CPA) clip from Side Impact Sensor (SIS) connector. Disconnect SIS connector.
Zone 7
2. Remove Connector Position Assurance (CPA) clip from driver side impact air bag module connector. See
Fig. 6 . Disconnect driver side impact air bag module connector.
Fig. 6: Identifying Side Impact Air Bag Module Connector (Driver-side Shown; Passenger-side Is
Similar)
Zone 9
2. If disabling passenger side impact air bag module only, go to step 6 . If disabling other air bag system
components, complete all remaining steps.
3. Remove driver-side insulator panel. Remove Connector Position Assurance (CPA) clip from driver-side
air bag module connector. See Fig. 4 . Disconnect driver-side air bag module connector.
4. Remove passenger-side insulator panel. Remove CPA clip from passenger-side air bag module connector.
See Fig. 5 . Disconnect passenger-side air bag module connector.
5. Remove CPA clip from driver side impact air bag module connector, located under driver seat. See Fig.
6 . Disconnect driver side impact air bag module connector.
6. Remove Connector Position Assurance (CPA) clip from passenger side impact air bag module connector.
See Fig. 6 . Disconnect passenger side impact air bag module connector.
ACTIVATING SYSTEM
Zone 2
1. Ensure ignition is off and key is removed. Connect Side Impact Sensor (SIS) connector. Install Connector
Position Assurance (CPA) clip. Install SIS in lower B-pillar. See SIDE IMPACT SENSOR (SIS) under
REMOVAL & INSTALLATION. Install lower B-pillar trim panel.
2. Install SIR fuse in fuse block. See Fig. 3 . Staying well away from air bag modules, turn ignition on.
Check air bag system for proper operation. See SYSTEM OPERATION CHECK .
Zone 3
1. Ensure ignition is off and key is removed. Connect driver-side air bag module connector. Install
Connector Position Assurance (CPA) clip. Install driver-side insulator panel.
Zone 5
1. Ensure ignition is off and key is removed. Connect passenger-side air bag module connector. See Fig. 5 .
Install Connector Position Assurance (CPA) clip. Install passenger-side insulator panel.
Zone 6
1. Ensure ignition is off and key is removed. Connect Side Impact Sensor (SIS) connector. Install Connector
Position Assurance (CPA) clip. Install SIS in lower B-pillar. See SIDE IMPACT SENSOR (SIS) under
REMOVAL & INSTALLATION. Install lower B-pillar trim panel.
Zone 7
1. Ensure ignition is off and key is removed. Connect driver side impact air bag module connector, located
under driver seat. See Fig. 6 . Install Connector Position Assurance (CPA) clip.
Zone 9
1. Ensure ignition is off and key is removed. If activating passenger side impact air bag module only, go to
step 5 . If activating other air bag system components, complete all remaining steps.
2. Connect passenger-side air bag module connector. See Fig. 5 . Install Connector Position Assurance
(CPA) clip. Install passenger-side insulator panel.
3. Connect driver-side air bag module connector. See Fig. 4 . Install CPA clip. Install driver-side insulator
panel.
4. Install driver side impact air bag module connector, located under driver seat. See Fig. 6 . Install CPA
clip.
5. Connect passenger side impact air bag module connector, located under passenger front seat. See Fig. 6 .
Install Connector Position Assurance (CPA) clip. Go to next step.
DISPOSAL PROCEDURES
PRECAUTIONS .
NOTE: If vehicle is to be scrapped, perform on-vehicle air bag deployment procedure.

See ON-VEHICLE DEPLOYMENT . If vehicle will remain in service, perform off
vehicle deployment procedure. See OFF-VEHICLE DEPLOYMENT .
ON-VEHICLE DEPLOYMENT
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Turn ignition off and remove key. Put
on safety glasses. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .
2. Disconnect driver-side and passenger-side air bag module connectors. See Fig. 4 & Fig. 5 . Disconnect
driver and passenger side impact air bag module connectors. See Fig. 6 . Cut air bag module harness
connectors from vehicle leaving at least 6" (152 mm) of wire at each connector.
3. Strip 0.50" (13 mm) of insulation from each driver-side air bag module connector wire lead. Cut two 20-
foot (6.1 m) deployment wires from 18-gauge multi-strand wire. Strip 0.50" (13 mm) of insulation from
both ends of wires. Twist wires together at one end to short.
4. Twist together one connector wire lead to other end of each deployment wire. See Fig. 7 . Bend twisted
connection flat and wrap tightly with electrical tape to insulate. Repeat for remaining connector wire lead.
5. Remove all loose objects from front seats. Ensure no one is in vehicle. Connect deployment harness to
driver-side air bag module connector. Stretch wires away from vehicle as far as possible.
6. Repeat steps 3 through 5 for passenger-side air bag module and side impact air bag modules. Cover
windshield and front door openings with a drop cloth.
7. Separate wire ends. Connect each pair of wires to a 12-volt battery. Selected air bag module should
deploy. If air bag module did not deploy, go to next step. If air bag modules did deploy, disconnect wires
from battery. DO NOT touch air bag module area for at least 10 minutes due to heat generated during
deployment. Wear gloves and safety glasses before handling deployed air bag module. Wash hands with
mild soap and water afterward.
8. If air bag modules do not deploy, carefully remove from vehicle. See AIR BAG MODULES under
REMOVAL & INSTALLATION. Temporarily store air bag modules with trim facing up. Contact
manufacturer for additional instructions.
Fig. 7: Preparing Deployment Harness For On-vehicle Deployment
OFF-VEHICLE DEPLOYMENT
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Turn ignition off and remove key. Put
on safety glasses. Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .
2. Short 2 SIR Deployment Harness (J-38826) leads together by fully seating one banana plug into the other.
Connect appropriate pigtail adapter to SIR deployment harness. See Fig. 8 .
3. Remove driver-side air bag module. See AIR BAG MODULES under REMOVAL & INSTALLATION.
Remove horn lead, redundant steering wheel control leads, horn buttons and steering wheel control
buttons from air bag module, if applicable.
4. Place air bag module with vinyl trim cover facing up, on a flat surface (preferably paved surface
outdoors) in center of an area at least 6 feet (1.8 m) in diameter, away from any loose or flammable
objects. Extend SIR deployment harness and pigtail adapter to full length from air bag module. Place a
12-volt battery near shorted end of SIR deployment harness.
5. Connect driver-side air bag module to SIR deployment harness. Ensure area around driver-side air bag
module is clear of people and loose objects. Verify that air bag module is resting with trim cover facing
up.
6. Separate 2 banana plugs on SIR deployment harness. Connect SIR deployment harness wires to battery.
Air bag module should deploy immediately. If air bag module does not deploy, go to step 8 . If air bag
module did deploy, disconnect SIR deployment harness from battery. Short 2 SIR deployment harness
leads together. DO NOT touch metal surfaces of air bag module for at least 10 minutes due to heat
generated during deployment. Wear gloves and safety glasses when handling deployed air bag module.
Wash hands with mild soap and water after handling. Dispose of deployed air bag module as you would
any other part. Inspect pigtail adapter and SIR deployment harness for damage after each use.
7. Using Deployment Fixture (J-39401-B) to hold passenger-side air bag module, driver and passenger side
impact air bag modules, repeat deployment procedure. Use Deployment Adapter (J-38826-25) for side
impact air bag modules. If any air bag module fails to deploy, go to next step.
8. Ensure that SIR deployment harness is disconnected from battery and that 2 banana plugs have been
shorted together. Disconnect pigtail adapter from air bag module. Temporarily store air bag module(s)
with trim cover facing up. Contact manufacturer for additional instructions.
Fig. 8: Preparing Deployment Harness For Off-vehicle Deployment
POST-COLLISION INSPECTION
When a vehicle has been involved in a collision, certain components of the passive restraint system must be
inspected or replaced. See AIR BAG/SRS COMPONENT INSPECTION & REPLACEMENT TABLES
article in the GENERAL INFORMATION section.
REMOVAL & INSTALLATION
PRECAUTIONS .
AIR BAG MODULES
Removal & Installation (Driver-side)
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See ZONE 3
under DISABLING & ACTIVATING AIR BAG SYSTEM.
2. Turn ignition on. Turn steering wheel so that 2 holes on back of steering wheel are accessible. Install Air
Bag Module Remover (J-44248) into holes. See Fig. 9 . Release driver-side air bag module spring clips.
Turn steering wheel 180 degrees and repeat procedure for remaining 2 spring clips. Pull driver-side air
bag module away from steering wheel.
3. Remove Connector Position Assurance (CPA) clip from driver-side air bag connector. See Fig. 10 .
Disconnect driver-side air bag module connector. Remove horn lead from steering wheel. Turn horn
contact lead 1/4 turn counterclockwise to release from steering wheel. Remove horn contact lead from
steering column. Remove driver-side air bag module.
4. To install, reverse removal procedure. Activate air bag system. See ZONE 3 under DISABLING &
ACTIVATING AIR BAG SYSTEM.
Fig. 9: Identifying Air Bag Module Remover

Fig. 10: Identifying Driver-side Air Bag Module
Removal & Installation (Passenger-side)
2. Remove glove box mounting screws. Remove glove box. Remove Connector Position Assurance (CPA)
clip from passenger-side air bag module connector and disconnect connector. See Fig. 5 .
3. Remove air bag module mounting nuts. See Fig. 11 . Remove passenger-side air bag module from
instrument panel.
4. To install, reverse removal procedure. Tighten air bag module mounting nuts and glove box mounting
screws to specification. See TORQUE SPECIFICATIONS . Activate air bag system. See ZONE 5
Fig. 11: Identifying Passenger-side Air Bag Module
Removal & Installation (Side Impact)
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. For driver side
impact air bag module, see ZONE 7 under DISABLING & ACTIVATING AIR BAG SYSTEM.. For
passenger side impact air bag module, see ZONE 9 under DISABLING & ACTIVATING AIR BAG
SYSTEM..
2. Disconnect applicable front seat electrical connectors. Remove front seat bolts. Remove front seat.
Loosen J-clip from lower edge of seat back. Remove seat back cover. Remove side impact air bag module
mounting nuts. See Fig. 12 . Make note of side impact air bag pigtail wire harness routing for use during
installation.
3. Remove side impact air bag module pigtail wire harness retaining clips. Carefully pull pigtail harness up
into seat back while guiding harness through seat frame. Remove side impact air bag module from seat.
4. To install, reverse removal procedure. Ensure side impact air bag module harness is routed correctly.
Tighten side impact air bag module nuts and seat mounting bolts to specification. See TORQUE
SPECIFICATIONS . Activate air bag system. For passenger side impact air bag module, see ZONE 9
under DISABLING & ACTIVATING AIR BAG SYSTEM.. For driver side impact air bag module, see
ZONE 7 under DISABLING & ACTIVATING AIR BAG SYSTEM..
Fig. 12: Identifying Side Impact Air Bag Module (Driver-side Shown; Passenger-side Is Similar)
INSTRUMENT PANEL CLUSTER (IPC) (SIDE IMPACT)
Removal & Installation
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Ensure ignition is off and key is
removed.
2. Remove IPC trim bezel. See Fig. 13 . Remove IPC mounting screws. Disconnect IPC electrical
connectors. Remove IPC from instrument panel.
3. To install, reverse removal procedure. TIghten IPC screws to specification. See TORQUE
SPECIFICATIONS .
Fig. 13: Identifying Instrument Panel Cluster (IPC)

SENSING & DIAGNOSTIC MODULE (SDM)

2. Remove passenger front seat. Remove carpet retainer. Remove right side cowl trim panel and insulator
panel. Roll back carpet and insulation to access SDM. Remove Connector Position Assurance (CPA) clip
from SDM harness connector. See Fig. 14 . Disconnect SDM harness connector. Remove SDM bolts.
Remove SDM.
3. To install, reverse removal procedure. Tighten SDM bolts and seat mounting bolts to specification. See
TORQUE SPECIFICATIONS . Activate air bag system. See ZONE 9 under DISABLING &
ACTIVATING AIR BAG SYSTEM.
Fig. 14: Identifying Sensing & Diagnostic Module (SDM)
SIDE IMPACT SENSOR (SIS)
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. For driver SIS,
see ZONE 2 under DISABLING & ACTIVATING AIR BAG SYSTEM.. For passenger side impact
sensor, see ZONE 6 under DISABLING & ACTIVATING AIR BAG SYSTEM..
2. Remove applicable lower B-pillar trim panel. Remove SIS mounting bolts from SIS. See Fig. 15 .
Remove SIS from B-pillar. Remove Connector Position Assurance (CPA) clip from SIS connector.
Disconnect SIS connector.
3. To install, reverse removal procedure. Tighten SIS mounting bolts to specification. See TORQUE
SPECIFICATIONS . Activate air bag system. For passenger side impact sensor, see ZONE 6 under
DISABLING & ACTIVATING AIR BAG SYSTEM.. For driver SIS, see ZONE 2 under DISABLING
& ACTIVATING AIR BAG SYSTEM..
Fig. 15: Identifying Side Impact Sensor (SIS)

SIR COIL ASSEMBLY
NOTE: New coil assemblies are pre-centered and include a centering tab that is
removed once coil is installed.
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Ensure front wheels face straight ahead.
Disable air bag system. See ZONE 3 under DISABLING & ACTIVATING AIR BAG SYSTEM.
2. Remove driver-side air bag module. See AIR BAG MODULES . Remove steering wheel. See
STEERING WHEEL . Remove upper and lower steering column covers.
3. Disconnect SIR wire harness connectors. Remove wire harness straps from steering column wire harness.
Remove SIR coil assembly from steering shaft. See Fig. 16 .
4. To install, reverse removal procedure. If necessary, center SIR coil assembly. See CENTERING SIR
COIL ASSEMBLY under ADJUSTMENTS. Tighten steering wheel nut to specification. See TORQUE
SPECIFICATIONS . Activate air bag system. See ZONE 3 under DISABLING & ACTIVATING AIR
BAG SYSTEM.
Fig. 16: Identifying SIR Coil Assembly

STEERING WHEEL
2. Remove driver-side air bag module. See AIR BAG MODULES . Scribe mark on steering shaft and
steering wheel for use during installation. Remove steering wheel nut. Using Steering Wheel Puller (J-
1859-A) with Puller Legs (J-42578), remove steering wheel.
3. To install, reverse removal procedure. Tighten steering wheel nut to specification. See TORQUE
SPECIFICATIONS . Activate air bag system. See ZONE 3 under DISABLING & ACTIVATING AIR
BAG SYSTEM.
DIAGNOSTICS
PRECAUTIONS .
DIAGNOSTIC TROUBLE CODES (DTC'S)
Sensing & Diagnostic Module (SDM) provides a record of each DTC, stored according to type. SDM performs
diagnostic monitoring of SIR system electrical components and sets a DTC when a malfunction is detected.
Current DTC's are stored in SDM and are erased when fault is corrected. Current DTC's can be read using a
scan tool such as Tech 2.
SCAN TOOL DIAGNOSTICS
Scan Tool (Tech 2) reads and clears current and history codes. Ensure scan tool contains correct software
cartridge for SIR diagnostics. To use scan tool, connect it to Data Link Connector (DLC), located near base of
steering column. Plug in power source and turn ignition on. Follow scan tool manufacturer instructions for
communication with SIR system.
DIAGNOSTIC PROCEDURES
Diagnostic procedures are designed to find and repair SIR malfunctions. It is important to use diagnostic tests
and follow sequence listed below.
Perform SIR Diagnostic System Check
SIR diagnostic system check should always be starting point for any SIR diagnostics. It checks for proper AIR
BAG warning light operation and SIR trouble codes using both flash code and scan tool methods. See SIR
DIAGNOSTIC SYSTEM CHECK under DIAGNOSTICS.
Refer To Proper Diagnostic Test
SIR diagnostic system check indicates correct test to diagnose SIR problems. Bypassing procedures may result
in extended diagnostic time, incorrect diagnosis and incorrect parts replacement.
Repeat SIR Diagnostic System Check

Performing SIR diagnostic system check after all repair or diagnostic procedures ensures that repair has been
made correctly and that no other conditions exist.
SIR DIAGNOSTIC SYSTEM CHECK
Diagnostic Procedure
1. Observe AIR BAG warning light when turning ignition on. If AIR BAG warning light flashes 7 times and
goes off, go to next step. If AIR BAG warning light does not flash 7 times and go off, inspect vehicle for
damage to wiring system, visible body damage, faulty or intermittent electrical connections or addition of
aftermarket devices which could affect SIR operation. Diagnose AIR BAG warning light malfunction.
See AIR BAG WARNING LIGHT CIRCUIT MALFUNCTION .
2. Install scan tool to Data Link Connector (DLC), located under left side of instrument panel. If scan tool
powers up, go to next step. If scan tool does not power up, inspect and repair data link communication
circuits.
3. If scan tool communicates with SDM, go to next step. If scan tool does not communicate with SDM,
inspect and repair data link communications circuits.
4. Using scan tool, request SIR DTC display. If scan tool displays history or current SIR DTC's, go to next
step. If scan tool does not display any SIR DTC's, system is okay.
5. If scan tool displays any DTC's that begin with "U", inspect and repair applicable data link
communication circuits and components. If no DTC's are displayed that begin with "U", go to next step.
6. If scan tool displays DTC B1000, go to DTC B1000 . If scan tool displays other DTC's, diagnose and
repair applicable SIR DTC's. See DIAGNOSTIC TROUBLE CODE (DTC) IDENTIFICATION
table.
DIAGNOSTIC TROUBLE CODE (DTC) IDENTIFICATION

Trouble Code Possible Cause
B0016 Passenger deployment loop resistance low
B0017 Passenger deployment loop resistance high
B0018 Passenger deployment loop voltage short to ground or voltage
B0022 Driver deployment loop resistance low
B0024 Driver deployment loop short to ground or voltage
B0026 Driver deployment loop resistance high
B0028 Passenger side impact deployment loop resistance low
B0029 Passenger side impact deployment loop resistance high
B0030 Passenger side impact deployment loop short to ground or voltage
B0040 Driver side impact deployment loop resistance low
B0041 Driver side impact deployment resistance high
B0045 Driver side impact deployment loop short to ground or voltage
B0051 Deployment commanded
B0053 Deployment commanded with loop malfunction
B0077 Driver SIS valid identification message not received
B0078 Passenger SIS valid identification message not received
B0079 Driver SIS identification not correct
B0080 Driver SIS NOK message
B0081 Passenger SIS identification not correct
B0082 Passenger SIS NOK message
B1000 SDM malfunction
B1001 Option configuration error
CONNECTOR IDENTIFICATION
NOTE: Refer to illustrations to identify connector terminals. See Fig. 17 , Fig. 18 , Fig.
19 , Fig. 20 , Fig. 21 & Fig. 22 .
Fig. 17: Identifying Sensing & Diagnostic Module (SDM) Connector Terminals
Fig. 18: Identifying Driver-side Air Bag Module Connector Terminals
Fig. 19: Identifying Lower SIR Coil Connector Terminals
Fig. 20: Identifying Passenger-side Air Bag Module Connector Terminals
Fig. 21: Identifying Side Impact Air Bag Module Connector Terminals
Fig. 22: Identifying Side Impact Sensor (SIS) Connector Terminals
DIAGNOSTIC TESTS
AIR BAG WARNING LIGHT CIRCUIT MALFUNCTION
Circuit Description
When ignition is turned on, Sensing and Diagnostic Module (SDM) will command Instrument Panel Cluster
(IPC) to flash AIR BAG warning light 7 times while SDM checks SIR system for malfunctions. If SIR system
is okay, AIR BAG warning light will then turn off.
Diagnostic Aids
If ignition voltage is outside normal operating range, (9-16 volts), AIR BAG warning light will turn on with no
DTC's set.
NOTE: For circuit number and wire color identification, see WIRING DIAGRAMS .
1. If SIR diagnostic system check has been performed, go to next step. If SIR diagnostic system check has
not been performed, go to SIR DIAGNOSTIC SYSTEM CHECK .
2. Turn ignition off. Observe AIR BAG warning light while turning ignition on. If AIR BAG warning light
does not flash 7 times, go to next step. If AIR BAG warning light does flash 7 times, go to step 4 .
3. Replace Instrument Panel Cluster (IPC). See INSTRUMENT PANEL CLUSTER (IPC) under
REMOVAL & INSTALLATION. Go to step 13 .
4. If AIR BAG warning light turns off after flashing 7 times, check for intermittent connections in AIR
BAG warning light circuit. If AIR BAG warning light does not turn off after flashing 7 times, go to next
step.
5. Connect scan tool to Data Link Connector (DLC), located under left side of instrument panel. If scan tool
communicates with IPC, go to next step. If scan tool does not communicate with IPC, check data link
communication circuits.
6. Using scan tool, request SIR data list display. If ignition voltage is greater than 9 volts, go to next step. If
ignition voltage is 9 volts or less, go to step 8 .
7. If ignition voltage is more than 16 volts, check battery and charging system. Go to step 13 . If ignition
voltage is 16 volts or less, go to step 12 .
8. Turn ignition off. Disconnect SDM connector. See Fig. 14 . If SDM connector is damaged, replace SDM
connector. See WIRE REPAIR . Go to step 13 . If SDM connector is okay, go to next step.
NOTE: Use Digital Multimeter (J-39200) and Connector Test Adapter Kit (J-35616-
A) or Flat WIre Probe Adapter Kit (J-42675) when performing electrical
tests.
9. Remove SIR fuse from fuse block, located in center console. See Fig. 3 . Check Yellow wire between
SDM connector terminal A1 and SIR fuse for open or high resistance. If open or high resistance is found
and corrected, go to step 13 . If open or high resistance is not found, go to next step.
10. Check voltage feed circuit to SIR fuse for open or high resistance. If open or high resistance is found and
corrected, go to step 13 . If open or high resistance is not found, go to next step.
11. Check Black/White wire between SDM connector terminal A18 and ground for an open or high
resistance. If an open or high resistance condition is found and corrected, go to step 13 . If an open or
high resistance is not found, go to next step.
12. Replace SDM. See SENSING & DIAGNOSTIC MODULE (SDM) under REMOVAL &
INSTALLATION. Reconnect all SIR components. Clear all SIR DTC's. Go to SIR DIAGNOSTIC
SYSTEM CHECK .
13. Reconnect all SIR components. Road test vehicle. If AIR BAG warning light operates normally, system
is okay. If AIR BAG warning light is malfunctioning, go to step 2 .
DTC B0016 ,B0017 ,B0018 : PASSENGER-SIDE AIR BAG DEPLOYMENT LOOP RESISTANCE
LOW/RESISTANCE HIGH/SHORT TO GROUND OR VOLTAGE
Circuit Description
When ignition is turned on, Sensing and Diagnostic Module (SDM) performs tests on deployment loops to
check for circuit continuity and shorts to ground or voltage.
Conditions For Setting DTC
DTC B0016 will set when deployment loop resistance is less than 1.3 ohms for 500 milliseconds. DTC B0017
will set when deployment loop high-side voltage is less than 2.4 volts and deployment loop resistance is 6 ohms
or more for 500 milliseconds or when deployment loop resistance is more than 4.8 ohms for 500 milliseconds.
DTC B0018 will set when high-side voltage is more than 6 volts for 500 milliseconds or when high-side circuit
voltage is less than 2.4 volts and deployment loop resistance is less than 6 ohms for 500 milliseconds.
Action Taken
SDM turns on AIR BAG warning light and sets DTC.
Conditions For Clearing DTC
Current DTC clears when condition responsible for setting DTC no longer exists and scan tool CLEAR DTC
command has been used to clear DTC's. History DTC clears when 255 malfunction-free ignition cycles have
occurred.
Diagnostic Aids
Malfunction is likely to be caused by a short between circuits 1403 and 1404 or by an open or high resistance
condition or by a short to ground or voltage in either circuit. A malfunctioning electrical connector or SDM
could also cause condition.
2. Turn ignition off. Disconnect passenger-side air bag module connector. See Fig. 5 . If harness-side of
connector is damaged, go to next step. If passenger-side air bag module side of connector is damaged, go
to step 7 . If both sides of connector are okay, go to step 4 .
3. Replace connector. See WIRE REPAIR . Go to step 9 .
4. Install SIR Driver/Passenger Load Tool (J-38715-A) using Load Tool Adapter (J-38715-100) to harness-
side of connector. Turn ignition on. Using scan tool, check for SIR DTC's. If DTC B0016, B0017 or
B0018 is retrieved as a current DTC, go to next step. If DTC B0016, B0017 or B0018 is not retrieved as a
current DTC, go to step 7 .
5. Turn ignition off. Remove SIR driver/passenger load tool and load tool adapter from harness connector.
Disconnect SDM harness connector. See Fig. 14 . If SDM connector is okay, go to next step. If SDM
harness connector shows signs of corrosion or damage, replace SDM connector. See WIRE REPAIR .
Go to step 9 .
tests.
6. When diagnosing air bag system:

If DTC B0016 is retrieved by scan tool, check for a short between circuits 1403 and 1404. If
condition is found and corrected, go to step 9 . If condition is not found, go to step 8 .
If DTC B0017 is retrieved, check for an open or high resistance in circuits 1403 or 1404. If
If DTC B0018 is retrieved, check for a short to ground or voltage in circuits 1403 or 1404. If
7. Replace passenger-side air bag module. See AIR BAG MODULES under REMOVAL &
INSTALLATION. Go to step 9 .
INSTALLATION. Go to next step.
9. Reconnect all SIR components. Using scan tool, clear all SIR DTC's. Road test vehicle, then check for
DTC's. If DTC resets, go to step 2 . If DTC does not reset, system is normal.
DTC B0022 , B0024 , B0026 : DRIVER DEPLOYMENT LOOP RESISTANCE LOW/SHORT TO

GROUND OR VOLTAGE/RESISTANCE HIGH
Circuit Description
will set when high-side voltage is more than 6 volts for 500 milliseconds or when high-side voltage is less than
2.4 volts and deployment loop resistance is less than 6 ohms for 500 milliseconds. DTC B0026 will set when
deployment loop high-side voltage is less than 2.4 volts and deployment loop resistance is 6 ohms or more for
500 milliseconds or when deployment loop resistance is more than 4.8 ohms for 500 milliseconds.
Action Taken
occurred.
Diagnostic Aids
Malfunction is likely to be caused by a short between circuits 347 and 348 or by an open or high resistance
2. Turn ignition off. Disconnect driver-side air bag module connector, located at base of steering column.
See Fig. 4 . If harness-side of connector is damaged, go to next step. If SIR coil side of connector is
damaged, go to step 9 . If both sides of connector are okay, go to step 4 .
3. Replace harness-side of connector. See WIRE REPAIR . Go to step 11 .
4. Install SIR Driver/Passenger Load Tool (J-38715-A) using Load Tool Adapter (J38715-100) to harness-
side of connector. Turn ignition on. Using scan tool, check for SIR DTC's. If DTC B0022, B0024 or
B0026 is retrieved as a current DTC, go to step 6 . If DTC B0022, B0024 or B0026 is not retrieved as a
current DTC, go to next step.
5. Remove SIR driver/passenger load tool and load tool adapter from harness-side of connector. Reconnect
driver-side air bag module connector. Remove driver-side air bag module. See AIR BAG MODULES
under REMOVAL & INSTALLATION. Install SIR driver/passenger load tool using Load Tool Adapter
(J-38715-30A) to upper SIR coil connector. Turn ignition on. Using scan tool, check for SIR DTC's. If
DTC B0022, B0024 or B0026 is retrieved as a current DTC, go to step 9 . If DTC B0022, B0024 or
B0026 is not retrieved as a current DTC, go to step 8 .
6. Turn ignition off. Remove SIR driver/passenger load tool from harness connector. Disconnect SDM
harness connector. See Fig. 14 . If SDM connector is okay, go to next step. If SDM harness connector
shows signs of corrosion or damage, replace SDM connector. See WIRE REPAIR . Go to step 11 .
tests.

If DTC B0022 is retrieved by scan tool, check for a short between circuits 347 and 348. If condition
is found and corrected, go to step 11 . If condition is not found, go to step 10 .
If DTC B0024 is retrieved, check for a short to ground or voltage in circuits 347 and 348. If
If DTC B0026 is retrieved, check for an open or high resistance in circuits 347 and 348. If
8. Replace driver-side air bag module. See AIR BAG MODULES under REMOVAL & INSTALLATION.
Go to step 11 .
9. Replace SIR coil. See SIR COIL ASSEMBLY under REMOVAL & INSTALLATION. Go to step 11 .
11. Reconnect all SIR components. Ensure all components are properly mounted. Using scan tool, clear all
SIR DTC's. Road test vehicle. If DTC resets, go to step 2 . If DTC does not reset, system is normal.
DTC B0028 , B0029 , B0030 : PASSENGER SIDE IMPACT AIR BAG DEPLOYMENT LOOP
RESISTANCE LOW/RESISTANCE HIGH/SHORT TO GROUND OR VOLTAGE
Circuit Description
will set when deployment loop high-side voltage is less than 2.4 volts and deployment loop resistance is more
than 6 ohms for 500 milliseconds or when deployment loop resistance is more than 4.8 ohms for 500
milliseconds. DTC B0030 will set when deployment loop high-side or low-side circuits are shorted to ground or
voltage for 500 milliseconds or when high-side circuit voltage is less than 2.4 volts and deployment loop
resistance is less than 6 ohms for 500 milliseconds.
Action Taken
occurred.
Diagnostic Aids
Malfunction is likely to be caused by a short between circuits 2135 or 2136 or by an open or high resistance
2. Turn ignition off. Disconnect passenger side impact air bag module connector, located under passenger-
side front seat. See Fig. 6 . If connector is damaged, go to next step. If connector is okay, go to step 4 .
3. If harness side of connector is damaged, replace connector. See WIRE REPAIR . Go to step 9 . If side
impact air bag module side of connector is damaged, replace passenger side impact air bag module. See
AIR BAG MODULES under REMOVAL & INSTALLATION. Go to step 9 .
4. Install SIR Driver/Passenger Load Tool (J-38715-A) to harness-side of passenger side impact air bag
module wire harness. Turn ignition on. Using scan tool, check for SIR DTC's. If DTC B0028, B0029 or
5. Remove SIR driver/passenger load tool from connector. Replace passenger side impact air bag module.
See AIR BAG MODULES under REMOVAL & INSTALLATION. Go to step 9 .
6. Turn ignition off. Remove load tool and load tool adapter from connector. Disconnect SDM connector.
See Fig. 14 . If SDM connector shows signs of corrosion or damage, replace SDM connector. See WIRE
REPAIR . Go to step 9 . If SDM connector is okay, go to next step.
tests.

SIR DTC's. Road test vehicle, then check for DTC's. If current DTC is retrieved by scan tool, go to step
2 . If current DTC is not retrieved by scan tool, system is normal.
DTC B0040 , B0041 , B0045 : DRIVER SIDE IMPACT AIR BAG DEPLOYMENT LOOP
RESISTANCE LOW/RESISTANCE HIGH/SHORT TO GROUND OR VOLTAGE
Circuit Description
will set when deployment loop high-side voltage is less than 2.4 volts and deployment loop resistance is more
than 6 ohms for 500 milliseconds or when deployment loop resistance is more than 4.8 ohms for 500
milliseconds. DTC B0045 will set when deployment loop high-side or low-side circuits are shorted to ground or
voltage for 500 milliseconds or when high-side circuit voltage is less than 2.4 volts and deployment loop
resistance is less than 6 ohms for 500 milliseconds.
Action Taken
occurred.
Diagnostic Aids
Malfunction is likely to be caused by a short between circuits 2137 or 2138 or by an open or high resistance
2. Turn ignition off. Disconnect driver side impact air bag module connector, located under driver-side front
seat. See Fig. 6 . If connector is damaged, go to next step. If connector is okay, go to step 4 .
impact air bag module side of connector is damaged, replace driver side impact air bag module. See AIR
BAG MODULES under REMOVAL & INSTALLATION. Go to step 9 .
4. Install SIR Driver/Passenger Load Tool (J-38715-A) to harness-side of passenger side impact air bag
module wire harness. Turn ignition on. Using scan tool, check for SIR DTC's. If DTC B0040, B0041 or
5. Remove SIR driver/passenger load tool from connector. Replace passenger side impact air bag module.
See AIR BAG MODULES under REMOVAL & INSTALLATION. Go to step 9 .
6. Turn ignition off. Remove load tool and load tool adapter from connector. Disconnect SDM connector.
See Fig. 14 . If SDM connector shows signs of corrosion or damage, replace SDM connector. See WIRE
REPAIR . Go to step 9 . If SDM connector is okay, go to next step.
tests.

SIR DTC's. Road test vehicle, then check for DTC's. If current DTC is retrieved by scan tool, go to step
2 . If current DTC is not retrieved by scan tool, system is normal.
DTC B0051 : DEPLOYMENT COMMANDED
Circuit Description
Sensing and Diagnostic Module (SDM) contains a sensing device which converts vehicle velocity changes to an
electrical signal. SDM processes electrical signals and compares them to values stored in memory. When
signals exceed stored value, additional signal processing is performed and signals are compared to values stored
in memory. When 2 signals exceed stored values, SDM causes current to flow through air bag modules,
deploying air bags and causing DTC B1051 to set.
DTC sets when SDM (SDM) detects a frontal impact of sufficient force to deploy air bags.
Action Taken
SDM sets DTC, turns on AIR BAG warning light and records crash data.

DTC B1051 is a latched code and cannot be cleared. Replace SDM after completing diagnostic procedure.
1. If SIR Diagnostic System Check has been performed, go to next step. If SIR Diagnostic System Check
has not been performed, go to SIR DIAGNOSTIC SYSTEM CHECK .
2. Turn ignition off. If air bags have deployed, go to step 5 . If air bags have not deployed, go to next step.
3. Inspect vehicle and undercarriage for signs of impact. If impact has occurred, go to step 5 . If no impact
has occurred, go to next step.
5. Using scan tool, request SIR DTC display. If history DTC's exist, go to Diagnostic aids for specific
displayed DTC. Replace components and perform inspections as required following an accident. See
POST-COLLISION INSPECTION . Go to next step.
6. Reconnect all SIR components. Using scan tool, clear all DTC's. Road test vehicle, then check for SIR
DTC's. If DTC B0051 is retrieved, go to step 2 . If DTC B0051 is not retrieved, system is normal.
DTC B0053 : DEPLOYMENT COMMANDED WITH LOOP MALFUNCTION
Circuit Description
Sensing and Diagnostic Module (SDM) contains a sensing device which converts vehicle velocity changes to an
electrical signal. Electrical signal is processed by SDM and compared to a value stored in memory. When signal
exceeds stored value, additional signal processing is performed and signals are compared to values stored in
memory. When 2 signals exceed stored values, SDM will cause current to flow through air bag modules,
deploying air bags. DTC B0053 will set along with DTC B0051 when a deployment occurs while an inflator
circuit fault exists that could result in a non-deployment situation in one or both air bag modules.
DTC will set when SDM detects an impact of sufficient force to deploy air bags and a deployment loop
malfunction exists.
Action Taken
SDM sets DTC, turns on AIR BAG warning light and records crash data.
DTC B0053 is a latched code and cannot be cleared. Replace SDM after completing diagnostic procedure.
Diagnostic Aids
DTC B0053 will be accompanied by at least one other DTC. Repair malfunction causing other DTC's before
installing new SDM.
2. Turn ignition off. If air bags have not deployed, go to next step. If air bags have deployed, go to step 5 .
3. Inspect vehicle and undercarriage for signs of impact. If no impact has occurred, go to next step. If impact
has occurred, go to step 5 .
5. Using scan tool, request SIR DTC display. If history DTC's exist, go to Diagnostic aids for specific
displayed DTC. Replace components and perform inspections as required following an accident. See
POST-COLLISION INSPECTION . Go to next step.
6. Reconnect all SIR components. Using scan tool, clear all DTC's. Road test vehicle, then check for SIR
DTC's. If DTC B0053 is retrieved, go to step 2 . If DTC B0053 is not retrieved, system is normal.
DTC B0077 ,B0078 ,B0079 , B0080 ,B0081 ,B0082 : DRIVER SIS VALID IDENTIFICATION
MESSAGE NOT RECEIVED/PASSENGER SIS VALID IDENTIFICATION MESSAGE NOT
RECEIVED/DRIVER SIS IDENTIFICATION ERROR/DRIVER SIS NOK MESSAGE/PASSENGER
SIS IDENTIFICATION ERROR/PASSENGER SIS NOK MESSAGE
Circuit Description
Side Impact Sensor (SIS) uses a unidirectional 2-wire circuit. SIS modulates current on the interface to send
identification, State Of Health (SOH) and deployment commands to Sensing and Diagnostic Module (SDM).
SDM provides power and ground to Side Impact Sensor (SIS). When ignition is turned on and power from
SDM is detected by SIS, SIS performs internal diagnostics, then sends an identification message to SDM. SDM
receives identification message within 5 seconds of power being turned on and determines if message is valid.
SIS continually communicates a status message to SDM. When a fault is detected, SDM resets SIS twice by
removing and reapplying power to SIS. If fault is still present, SDM will set DTC.
DTC B0077 will set when SDM does not receive a valid identification message within 5 seconds of driver-side
SIS being powered up, status message is not retrieved or SDM has reset SIS twice without detecting valid
identification message. DTC B0078 will set when SDM does not receive a valid identification message within 5
seconds of passenger-side SIS being powered up, status message is not retrieved or SDM has reset SIS twice
without detecting valid identification message.
DTC B0079 will set when SDM receives an identification message from driver-side SIS that does not match
identification stored in memory or after SDM has tried twice to reset SIS without detecting correct identification
message. DTC B0081 will set when SDM receives an identification message from passenger-side SIS that does
not match identification stored in memory or after SDM has tried twice to reset SIS without detecting correct
identification message.
DTC B0080 will set when SDM has received a Not Okay (NOK) message from driver-side SIS. DTC B0082
will set when SDM has received a Not Okay (NOK) message from passenger-side SIS.
Action Taken
DTC will clear when condition responsible for setting DTC no longer exists and CLEAR DTC command is
issued via scan tool. History DTC will clear once 255 malfunction free ignition cycles have occurred.
Diagnostic Aids
Condition could be caused by a short to ground or voltage or high or low resistance in circuits 2131, 2132, 2133
or 2134.
2. Using scan tool, request SIR DTC display. If DTC B0079, B0080, B0081 or B0082 is retrieved as a
current DTC, go to step 10 . If DTC B0079, B0080, B0081 or B0082 is not retrieved as a current DTC,
go to next step.
3. Turn ignition off. If DTC B0077 is current, disconnect driver-side SIS connector. See SIDE IMPACT
SENSOR (SIS) under REMOVAL & INSTALLATION. If DTC B0078 is current, disconnect passenger-
side SIS connector. If connector is damaged or corroded, go to next step. If connector is okay, go to step
5.
4. If SIS side of connector is damaged, replace SIS. Go to step 11 . If harness side of connector is damaged,
replace connector. See WIRING DIAGRAMS . Go to step 11 .
5. Disconnect SDM connector. See Fig. 14 . If SDM connector or SDM terminals show signs of corrosion,
poor connections or other damage, go to next step. If SDM connector and terminals are okay, go to step
7.
6. If SDM connector is damaged, replace connector. See WIRE REPAIR . Go to step 11 . If SDM
terminals are damaged, go to step 12 .
tests.
7. If DTC B0077 is current, disconnect driver-side SIS connector. If DTC B0078 is current, disconnect
passenger-side SIS connector. Test high-side and low-side circuits of applicable SIS for an open or high
resistance. If open or high resistance is found and corrected, go to step 11 . If open or high resistance is
not found, go to next step.
8. Inspect applicable SIS circuits for a short between high-side and low-side circuits. If a short is found and
corrected, go to step 11 . If a short is not found, go to next step.
9. Turn ignition on. Check applicable SIS circuits for a short to voltage. If short to voltage is found and
corrected, go to step 11 . If short to voltage is not found and corrected, go to next step.
10. If DTC B0077, B0079 or B0080 is displayed by scan tool, replace driver-side SIS. See SIDE IMPACT
SENSOR (SIS) under REMOVAL & INSTALLATION. Go to next step. If DTC B0078, B0081 or
B0082 is displayed by scan tool, replace passenger-side SIS. Go to next step.
11. Using scan tool, clear all SIR DTC's. Road test vehicle, then check for DTC's. If DTC's are retrieved, go
to next step. If DTC's are not retrieved, system is normal.
13. Using scan tool, clear all SIR DTC's. Road test vehicle, then check for DTC's. If DTC is retrieved, go to
step 2 . If DTC is not retrieved, system is normal.
DTC B1000 : SDM MALFUNCTION
Circuit Description
DTC B1000 indicates an internal SDM malfunction. No external circuits are involved.
DTC sets when SDM detects an internal malfunction.
Action Taken
SDM refuses all additional inputs.
Current DTC clears when malfunction is no longer present. History DTC clears when SDM ignition cycle
counter reaches the reset threshold, without a repeat of malfunction.
Diagnostic Aids
DTC may be stored as history DTC without affecting operation of SDM. If DTC is retrieved only as a history
DTC and not as a current DTC, DO NOT replace SDM. If DTC is retrieved as a history and current DTC,
replace SDM.
2. Using scan tool, request SIR DTC display. If DTC B1000 is retrieved as a current DTC, go to next step.
If DTC B1000 is retrieved as a history DTC, go to DIAGNOSTIC AIDS .
INSTALLATION. Reconnect all SIR components. Go to next step.
4. Using scan tool, erase DTC's. Road test vehicle, then check for DTC's. IF DTC B1000 is retrieved by
scan tool, go to step 2 . If DTC B1000 is not retrieved, system is normal.
DTC B1001 : OPTION CONFIGURATION ERROR
Circuit Description
When ignition is turned on, Sensing and Diagnostic Module (SDM) compares restraints identification stored in
SDM to restraints identification stored in Body Control Module (BCM). SDM will then compare Vehicle
Identification Number (VIN) stored in BCM to VIN stored in SDM.
DTC sets when restraints identification stored in SDM does not match restraints identification stored in BCM or
when VIN stored in SDM does not match VIN stored in BCM.
Action Taken
SDM sets DTC, turns on AIR BAG warning light and disables deployment loops.
DTC clears when restraints identification stored in SDM matches restraints identification stored in BCM and
VIN information stored in SDM matches VIN stored in BCM.
Diagnostic Aids
DTC is an indication that restraints identification stored in IPC and SDM DO NOT match or that VIN stored in
IPC and SDM DO NOT match. If IPC and/or Powertrain Control Module (PCM) were replaced,
reprogramming is necessary.
2. Using scan tool, verify that PCM is programmed with correct VIN. If VIN is not correct, go to next step.
If VIN is correct, go to step 4 .
3. Using scan tool, program correct VIN into PCM. Go to step 8 .
4. If BCM was not replaced, go to next step. If BCM was replaced, go to step 6 .
5. Using scan tool, verify BCM is programed with correct VIN. If VIN is correct, go to step 7 . If VIN is not
correct, go to next step.
6. Using scan tool, follow instructions under BCM SPECIAL FUNCTIONS to program BCM. Go to step 8 .
8. Reconnect all SIR components. Using scan tool, clear DTC's. Road test vehicle, then check for DTC's. If
DTC's are retrieved, go to step 2 . If no DTC's are retrieved, system is normal.
WIRE REPAIR
SIR system requires special wiring repair procedures due to sensitive nature of circuitry. Wire Repair Kit (J-
38125-B) contains special sealed splices for use in repairing SIR wiring. Splices use a heat shrink sleeve with
sealing adhesive to produce a sealed splice and a cross-hatched core crimp to produce a positive contact for low
energy circuits.
Repair damaged SIR wire harness connectors and terminals (except pigtails) using connector repair assembly
packs and splice crimping tool provided. Terminals in SIR system are manufactured from a special metal to
provide necessary contact integrity for sensitive, low-energy circuits. These terminals are only available in
connector repair assembly packs. No other terminal should be substituted.
If individual terminals on SDM harness connector are damaged, SDM harness connector must be replaced using
SDM harness connector pigtail assembly or SDM harness connector replacement kit. If individual terminals on
any other SIR connector are damaged, entire connector must be replaced. Use appropriate connector repair
assembly pack. Replace entire SIR wire harness, if necessary, to maintain SIR circuit integrity.
DO NOT make wiring, connector or terminal repairs on components with wiring pigtails. If a wiring pigtail is
damaged, entire component (including pigtail) should be replaced.
Any wiring other than a pigtail can be repaired by splicing in a new section of wire of same gauge. Sealed
splices and crimping tool must be used for these splices. Open wire harness by removing tape as necessary,
using a sewing seam ripper. Refer to instructions in kit for wiring repair procedure.
TORQUE SPECIFICATIONS
Application Ft. Lbs. (N.m)
Seat mounting bolts 37 (50)
Steering wheel nut 30 (41)
INCH Lbs. (N.m)
Glove box mounting screws 18 (2)
Instrument Panel Cluster (IPC) mounting screws 18 (2)
Passenger-side air bag module mounting nuts 89 (10)
Sensing & Diagnostic Module (SDM) bolts 89 (10)
Side impact air bag module nuts 89 (10)
Side Impact Sensor (SIS) mounting bolts 89 (10)
Steering column
Lower cover screws 31 (3.5)
Upper cover screws 13 (1.5)
WIRING DIAGRAMS
Fig. 23: Air Bag System Wiring Diagram (Aztek)
General Motors Corp. - Air Bag Restraint Systems
Read and follow all WARNINGS and AIR BAG SAFETY PRECAUTIONS
before working on air bag system or related components.
SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM
SIR system is designed to supplement protection provided by driver and passenger-side seat belts. A frontal
impact of sufficient force up to 30 degrees off center line of vehicle will deploy driver and passenger-side air
bags. A side impact of sufficient force will trigger side impact air bag on side of impact. Steering wheel,
steering column and knee bolsters also absorb crash energy.
SIR system consists of Sensing and Diagnostic Module (SDM), driver and passenger-side air bag modules,
driver and passenger side impact air bag modules, Side Impact Sensors (SIS), SIR coil assembly, AIR BAG
warning light and driver and passenger-side knee bolsters.
AIR BAG MODULES
Air bag modules consist of an inflatable bag and an inflator. When vehicle is in an accident of sufficient force,
SDM causes current flow through deployment loops. Current passing through inflators ignites inflator charges,
producing gas which rapidly inflates air bags.
AIR BAG WARNING LIGHT
Ignition switch applies battery voltage to AIR BAG warning light. SDM controls AIR BAG warning light
operation. When ignition switch is first turned on, AIR BAG warning light verifies system operation by flashing
7 times and turning off. During vehicle operation, AIR BAG warning light warns driver of malfunctions which
could potentially affect SIR system operation.
KNEE BOLSTERS
Knee bolsters are used to absorb energy and control forward movement of driver and front seat passenger. This
is accomplished by limiting leg movement during a frontal crash.
SDM monitors vehicle velocity changes to detect frontal crashes which are severe enough to warrant air bag
module deployment. When a frontal crash of sufficient force is detected, SDM causes enough current flow
through air bag modules to deploy air bags. SDM also maintains a 36 Volt Loop Reserve (36 VLR) energy
supply to provide deployment energy for up to one minute after loss of voltage.
Additionally, SDM provides diagnostic monitoring of SIR system electrical components. When a malfunction is
detected, SDM sets a Diagnostic Trouble Code (DTC) which can be retrieved using a scan tool. SDM warns
driver of system malfunctions by controlling AIR BAG warning light.
SIR COIL ASSEMBLY
SIR coil assembly consists of 2 or more current-carrying coils. Coils are attached to steering column and allow
rotation of steering wheel, while maintaining continuous continuity of driver-side air bag module deployment
loop.
SIS contains an accelerometer which monitors vehicle acceleration and velocity changes to detect side impacts
severe enough to warrant deployment of side impact air bag modules. SIS is not part of deployment loop, but
instead provides input to SDM.
COMPONENT LOCATIONS
COMPONENT LOCATIONS
Component Location
AIR BAG warning light In instrument cluster
Driver air bag Steering wheel
Knee bolsters Lower side of driver & passenger-side dash
Passenger air bag Passenger-side of dash
Sensing & Diagnostic Module Under passenger-side front seat
(SDM)
Side impact air bag modules Driver & passenger-side front seat outer seat backs
Side Impact Sensors (SIS) Driver & passenger-side lower B-pillars
SIR coil Under steering wheel
SYSTEM OPERATION CHECK

If system is functioning normally, AIR BAG warning light flashes 7 times and then turns off when ignition
switch is turned on. System malfunction is indicated when light does not illuminate at all, light comes on while
vehicle is driven, light flashes 7 times and remains on, or light does not flash but remains on when ignition
switch is turned on.
AIR BAG SAFETY PRECAUTIONS

Observe the following precautions when working with SIR system:
SDM maintains sufficient voltage to cause air bag deployment for up to one minute after ignition switch
is turned off, battery is disconnected, or fuse powering SDM is removed. In order to begin servicing
immediately, inflator modules must be removed from deployment loop. See DISABLING &
ACTIVATING AIR BAG SYSTEM .
After repairs, ensure AIR BAG warning light is working properly and no system faults are indicated. See
SYSTEM OPERATION CHECK .
Always wear safety glasses when servicing or handling an air bag module.
Air bag modules must be stored in original special containers until used for service. Store in a clean, dry
place, away from sources of extreme heat, sparks, or high electrical energy.
Air bag modules or SDMs should not be subjected to temperatures greater than 150F (65C).
Air bag modules, SDM, SIS and SIR coil assembly should not be used if they have been dropped from a
height of 3 feet (0.9 m) or greater.
When placing a live air bag module on a bench or other surface, always make certain that trim cover faces
up. This will reduce motion of module if accidentally deployed.
After deployment, air bag surface may contain deposits of sodium hydroxide, which can irritate skin.
Always wear safety glasses, rubber gloves and long-sleeved shirt during clean-up and wash hands using
mild soap and water. Follow correct disposal procedures. See DISPOSAL PROCEDURES .
At no time should any electrical source be allowed near inflator on back of air bag module.
Do not apply power to SIR system unless all components are connected or a diagnostic test requests it, as
this will set a diagnostic trouble code.
When carrying a live air bag module, trim cover should be pointed away from body to minimize injury in
case of accidental deployment.
Do not attempt to service SDM, SIR coil assembly or air bag modules. If defective, these parts must be
replaced.
Do not probe a wire through insulator; this damages wire and eventually causes failure due to corrosion.
When performing electrical tests, prevent accidental shorting of terminals. Such mistakes can damage
fuses or components and may cause a second fault code to set, making diagnosis of original problem
more difficult.
When using diagnostic tests to diagnose SIR system, under no circumstances should a volt-ohmmeter,
test light or any type of electrical equipment not specified by manufacturer be used.
If SIR system is not fully functional for any reason, vehicle should not be driven until system is repaired.
Do not remove bulbs, modules, sensors or other components or in any way disable system from operating
normally.
ADJUSTMENTS
CENTERING COIL ASSEMBLY
NOTE: New coil assemblies are pre-centered and include a centering tab that is
removed once coil is installed.
Hold coil assembly with clear bottom upward to see coil bottom. See Fig. 1 . While holding coil assembly
housing, depress spring lock and rotate hub in direction of arrow until it stops. Coil ribbon should now be
wound up snugly against center hub. Rotate coil hub in opposite direction approximately 2 1-2 turns. Release
spring lock between locking tabs.
Fig. 1: Centering SIR Coil Assembly
DISABLING & ACTIVATING AIR BAG SYSTEM
CAUTION: Vehicle computer and memory systems may loose memory data when
battery is disconnected. Driveability problems may exist until computer
systems have completed a relearn cycle. See Computer Relearn
Procedures in the Reference Information section. Record preset radio
stations and obtain code for theft deterrent-equipped radios before
disconnecting battery.
DISABLING SYSTEM
WARNING: Accidental air bag deployment is possible. Personal injury could result.
SDM maintains sufficient voltage to cause air bag deployment for up to
one minute after ignition switch is turned off, battery is disconnected, or
fuse powering SDM is removed. In order to begin servicing immediately,
inflator modules must be removed from deployment loop.
NOTE: When SIR fuse is removed and ignition switch is in RUN position, AIR BAG
warning light will be on. This does not indicate a system malfunction.
1. Turn steering wheel to place vehicle wheels in straight-ahead position. Turn ignition switch to LOCK
position.
2. Remove center console accessory wiring junction block cover. Remove SIR fuse (10-amp) from fuse
block. Wait at least ten seconds before continuing. Remove driver-side insulator panel. See Fig. 2 .
Remove Connector Position Assurance (CPA) clip and disconnect driver-side air bag module Yellow 2-
pin connector, located at base of steering column.
3. Remove passenger-side CPA and disconnect passenger-side air bag module Yellow 2-pin connector,
located below glove box. See Fig. 3 . Remove CPA clip from driver side impact air bag connector,
located under driver-side front seat. See Fig. 4 . Disconnect driver side impact air bag connector.
4. Remove CPA clip from passenger side impact air bag connector, located under passenger-side front seat.
Disconnect passenger side impact air bag module connector. System is now disabled.
Fig. 2: Locating Driver-side Air Bag Yellow 2-pin Connector

Fig. 3: Locating Passenger-side Air Bag Yellow 2-pin Connector

Fig. 4: Locating Side Impact Air Bag Yellow 2-pin Connector (Driver-side Shown; Passenger-side Is
Similar)
ACTIVATING SYSTEM
1. Ensure ignition is off and SIR fuse is removed from console fuse block. Connect passenger side impact
air bag module 2-pin connector, located under passenger-side front seat. See Fig. 4 . Install Connector
Position Assurance (CPA) clip.
2. Connect passenger-side air bag module connector, located under glove box. See Fig. 3 . Install CPA clip.
Connect driver side impact air bag module connector, located under driver-side front seat. See Fig. 2 .
Install CPA connector.
3. Connect driver-side air bag module connector, located near base of steering column. Install CPA clip.
Install driver-side insulator panel. Install SIR fuse. Install center console accessory wiring junction block
cover. Check system for proper operation. See SYSTEM OPERATION CHECK .
DISPOSAL PROCEDURES
DO NOT dispose of undeployed air bag modules at normal refuse
locations. Undeployed air bag modules contain substances that can
cause severe illness or personal injury if sealed container is damaged
during disposal.
NOTE: If vehicle is to be scrapped, perform on-vehicle air bag deployment procedure.
ON-VEHICLE DEPLOYMENT
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Turn ignition switch off, remove
ignition key and put on safety glasses. Disconnect driver and passenger-side air bag module connectors.
See Fig. 2 & Fig. 3 . Disconnect driver and passenger side impact air bag modules. See Fig. 4 . Cut air
bag module harness connectors from vehicle leaving at least 6" (152 mm) of wire at each connector.
2. Strip 0.50" (13 mm) of insulation from each connector wire lead. Cut 2 20-foot (6.1 m) deployment wires
from 18-gauge multi-strand wire. Strip 0.50" (13 mm) of insulation from both ends of wires. Twist wires
together at one end to short.
3. Twist together one connector wire lead to other end of each deployment wire. See Fig. 5 . Bend twisted
connection flat and wrap tightly with electrical tape to insulate. Repeat this step for other connector wire
lead.
4. Remove all loose objects from front seats. Ensure no one is in vehicle. Connect deployment harness to
driver-side air bag module connector. Stretch wires away from vehicle as far as possible.
5. Repeat steps 1) through 4) for passenger-side air bag module and driver and passenger side impact air bag
modules. Cover windshield and front door openings with a drop cloth.
6. Separate wire ends. Connect each pair of wires to a 12-volt battery. Air bag module should deploy.
Disconnect wires from battery. DO NOT touch air bag module area for at least 10 minutes due to heat
generated during deployment. Wear gloves and safety glasses before handling deployed air bag module.
Wash hands with mild soap and water afterward. Deployed air bag modules can be disposed of like any
other part.
7. If air bag modules do not deploy, carefully remove from vehicle. See AIR BAG MODULES under
REMOVAL & INSTALLATION. Temporarily store module with trim facing up. Contact manufacturer
for proper disposal instructions.
Fig. 5: Preparing Deployment Harness For On-vehicle Deployment
OFF-VEHICLE DEPLOYMENT
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Turn ignition switch OFF, remove key
and put on safety glasses. Short 2 SIR Deployment Harness (J-38826) leads together by fully seating one
banana plug into the other. Connect appropriate pigtail adapter to SIR deployment harness. See Fig. 6 .
2. Remove driver-side air bag module. See AIR BAG MODULES under REMOVAL & INSTALLATION.
Remove horn lead, redundant steering wheel control leads, horn buttons and steering wheel control
buttons from air bag module, if applicable.
3. Place air bag module with vinyl trim cover facing up, on a work bench or other surface (preferably paved
surface outdoors) away from any loose or flammable objects. Clear space at least 6 feet (1.8 m) in
diameter around air bag. Extend SIR deployment harness and pigtail adapter to full length from air bag
module. Place a 12-volt battery near shorted end of SIR deployment harness.
4. Connect air bag module to pigtail adapter on SIR deployment harness. Ensure area around air bag module
is clear of people and loose objects. Verify that air bag module is resting with trim cover facing up.
5. Separate 2 banana plugs on SIR deployment harness. Connect SIR deployment harness wires to battery.
Air bag module should deploy immediately. If air bag module does not deploy, go to step 7 . Disconnect
SIR deployment harness from battery. Short 2 SIR deployment harness leads together. DO NOT touch
metal surfaces of air bag module for at least 10 minutes due to heat generated during deployment. Wear
gloves and safety glasses when handling deployed air bag module. Wash hands with mild soap and water
after handling. Dispose of deployed air bag module as you would any other part. Inspect pigtail adapter
and SIR deployment harness for damage after each use.
6. Repeat deployment procedure for passenger-side air bag module and driver and passenger side impact air
bag modules. Mount each air bag module in Deployment Fixture (J-39401-B) prior to deployment. If air
bag module(s) fail to deploy, go to next step.
7. Ensure that SIR deployment harness is disconnected from battery and that 2 banana plugs have been
shorted together. Disconnect pigtail adapter from air bag module. Temporarily store air bag module(s)
with trim cover facing up. Contact manufacturer for proper disposal instructions.
Fig. 6: Preparing Deployment Harness For Off-vehicle Deployment
POST-COLLISION INSPECTION
When a vehicle has been involved in a collision, certain components of the passive restraint system must be
inspected or replaced. See AIR BAG/SRS COMPONENT INSPECTION & REPLACEMENT TABLES
article in the GENERAL INFORMATION section.
See AIR BAG SAFETY PRECAUTIONS . After component replacement,
check system operation. See SYSTEM OPERATION CHECK .
Removal
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Disable air bag system. See
DISABLING & ACTIVATING AIR BAG SYSTEM .
2. Remove right-front seat. Remove carpet retainer. Roll back carpet and insulation to access SDM. Remove
Connector Position Assurance (CPA) clip and disconnect SDM connector. See Fig. 7 . Remove SDM
bolts and SDM.
Installation
1. Mount SDM on vehicle, ensuring directional arrow is pointing forward. Install SDM bolts and tighten to
specification. See TORQUE SPECIFICATIONS . Reconnect SDM connector and CPA clip.
2. Position insulation and carpet over SDM. Install carpet retainer. Install right-front seat. Tighten seat bolts
to specification. See TORQUE SPECIFICATIONS . Activate air bag system. See DISABLING &
ACTIVATING AIR BAG SYSTEM . Check system for proper operation. See SYSTEM
OPERATION CHECK .
Fig. 7: Identifying Sensing & Diagnostic Module (SDM)
STEERING WHEEL
Removal
2. Remove driver-side air bag module. See AIR BAG MODULES . Scribe mark on steering shaft and
steering wheel to ensure proper alignment during installation. Disconnect steering wheel control electrical
connector. Remove steering wheel nut. Using Steering Wheel Puller (J-1859-A) with Puller Legs (J-
42578), remove steering wheel.
Installation
1. Align mark on steering wheel with mark on shaft. Install steering wheel on steering shaft. Install steering
wheel nut and tighten to specification. See TORQUE SPECIFICATIONS . Connect steering wheel
control electrical connector. Install driver-side air bag module. See AIR BAG MODULES .
2. Activate air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Check system for
proper operation. See SYSTEM OPERATION CHECK .
SIR COIL ASSEMBLY
Removal
1. Before proceeding, see AIR BAG SAFETY PRECAUTIONS . Ensure front wheels face straight ahead.
Disable air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM .
2. Remove driver-side air bag module. See AIR BAG MODULES . Remove upper and lower steering
column covers. Remove steering wheel. See STEERING WHEEL .
3. Disconnect SIR coil-to-wire harness connector, located at base of steering column. Remove wire harness
straps from steering wheel column wire harness. See Fig. 8 . Remove SIR coil retaining ring. Remove
SIR coil assembly.
NOTE: SIR coil assembly will become uncentered if steering column is separated
from steering gear and allowed to rotate, or if centering spring is
depressed, allowing hub to rotate while coil assembly is removed from
column.
Installation
1. Center SIR coil assembly if necessary. See CENTERING COIL ASSEMBLY under ADJUSTMENTS.
Install SIR coil onto steering shaft.
2. Install SIR coil retaining ring securely in groove on steering shaft. Route SIR coil wire harness along
steering column. Connect SIR coil-to-harness connector. Install wire harness straps.
3. Install steering wheel. Tighten steering wheel nut to specification. See TORQUE SPECIFICATIONS .
Install upper and lower steering column covers. Activate air bag system. See DISABLING &
OPERATION CHECK .
Fig. 8: Identifying SIR Coil Assembly
AIR BAG MODULES
Removal & Installation (Driver-side)
2. Turn ignition on. Turn steering wheel so that 2 holes on back of steering wheel are accessible. Install Air
Bag Module Remover (J-44248) into holes. See Fig. 9 . Release driver-side air bag module spring clips.
Turn steering wheel 180 degrees and repeat procedure for remaining 2 spring clips.
3. Remove Connector Position Assurance (CPA) clip from driver-side air bag connector and disconnect
connector. See Fig. 10 . Remove horn ground lead from steering wheel. Turn horn contact lead 1-4 turn
counterclockwise to release from steering wheel. Remove horn contact lead from steering column.
Remove air bag module.
4. To install, reverse removal procedure. Activate air bag system. See DISABLING & ACTIVATING
AIR BAG SYSTEM . Check system for proper operation. See SYSTEM OPERATION CHECK .
Removal & Installation (Passenger-side)
2. Remove glove box light electrical connector. Remove glove box. Remove Connector Position Assurance
(CPA) clip from passenger-side air bag module connector and disconnect air bag module connector.
3. Remove air bag module mounting nuts. See Fig. 11 . Remove air bag module from instrument panel.
4. To install, reverse removal procedure. Tighten air bag module nuts and glove box mounting screws to
specification. See TORQUE SPECIFICATIONS . Activate air bag system. See DISABLING &
OPERATION CHECK .
Removal & Installation (Side Impact)
2. Disconnect applicable side impact air bag module connector. See Fig. 4 . Remove applicable front seat.
Loosen J-clip, located along edge of lower seat back. Remove seat back cover. Remove side impact air
bag module nuts. See Fig. 12 . Make note of side impact air bag pigtail wire harness routing for use
during installation.
3. Remove side impact air bag pigtail wire harness retaining clips. Carefully pull pigtail harness up into seat
back while guiding harness through seat frame. Remove side impact air bag module from seat.
4. To install, reverse removal procedure. Ensure side impact air bag harness is routed correctly. Tighten side
impact air bag module nuts and seat bolts to specification. See TORQUE SPECIFICATIONS . Activate
air bag system. See DISABLING & ACTIVATING AIR BAG SYSTEM . Check system for proper
operation. See SYSTEM OPERATION CHECK .
Fig. 9: Identifying Air Bag Module Remover
Fig. 10: Identifying Driver-side Air Bag Module
Fig. 11: Identifying Passenger-side Air Bag Module
Fig. 12: Identifying Side Impact Air Bag Module (Driver-side Shown; Passenger-side Is Similar)
2. Remove B-pillar lower trim panel. Remove Connector Position Assurance (CPA) clip from SIS
connector. Disconnect SIS connector. Remove SIS bolts and remove SIS from B-pillar.
3. To install, reverse removal procedure. Tighten SIS bolts to specification. See TORQUE
SPECIFICATIONS . Activate air bag system. See DISABLING & ACTIVATING AIR BAG
SYSTEM . Check system for proper operation. See SYSTEM OPERATION CHECK .
Fig. 13: Identifying Side Impact Sensor (SIS)

DIAGNOSTICS
Failure to follow service precautions may result in air bag deployment
and personal injury. See AIR BAG SAFETY PRECAUTIONS . After
component replacement, check system operation. See SYSTEM
OPERATION CHECK .
DIAGNOSTIC TROUBLE CODES (DTCS)
Sensing & Diagnostic Module (SDM) provides a record of Diagnostic Trouble Codes (DTC), stored according
to type. SDM performs diagnostic monitoring of SIR system electrical components and sets a DTC when a
malfunction is detected. Current DTCs are stored in SDM and are read and erased using a scan tool such as
Tech 2. History DTCs will clear following a specific number of malfunction free ignition cycles. See Clearing
DTC under specific DTC heading.

Scan Tool (Tech 2) reads and clears current and history codes. Ensure scan tool contains correct software
cartridge for SIR diagnostics. To use scan tool, connect it to Data Link Connector (DLC) connector, located
under left side of instrument panel, to right of steering column. Follow scan tool manufacturer instructions for
communication with SIR system.
DIAGNOSTIC PROCEDURES
Diagnostic procedures are designed to find and repair SIR malfunctions. It is important to use diagnostic tests
and follow sequence listed below:
Perform SIR System Diagnostic Check
SIR diagnostic system check should always be starting point for any SIR diagnostics. It checks for proper AIR
BAG warning light operation and SIR trouble codes. See SIR DIAGNOSTIC SYSTEM CHECK under
DIAGNOSTIC TESTS.
Refer To Proper Diagnostic Test
SIR diagnostic system check indicates correct test to use to diagnose SIR problems. Bypassing procedures may
result in extended diagnostic time, incorrect diagnosis and incorrect parts replacement.
Repeat SIR Diagnostic System Check
Performing SIR diagnostic system check after all repair or diagnostic procedures are completed ensures that
repairs have been made correctly and that no other conditions exist.
DIAGNOSTIC TESTS
DIAGNOSTIC TROUBLE CODE (DTC) IDENTIFICATION
Trouble Code Possible Cause
DTC B0016 Passenger deployment loop resistance low
DTC B0017 Passenger deployment loop resistance high
DTC B0018 Passenger deployment loop short to ground-voltage
DTC B0022 Driver deployment loop resistance low
DTC B0024 Driver deployment loop short to ground-voltage
DTC B0026 Driver deployment loop resistance high
DTC B0028 Passenger side impact deployment loop resistance low
DTC B0029 Passenger side impact deployment loop resistance high
DTC B0030 Passenger side impact deployment loop short to ground-voltage
DTC B0040 Driver side impact deployment loop resistance low
DTC B0041 Driver side impact deployment loop resistance high
DTC B0045 Driver side impact deployment loop short to ground-voltage
DTC B0051 Deployment commanded
DTC B0053 Deployment commanded with loop malfunction
DTC B0077 Driver SIS malfunction
DTC B0078 Passenger SIS malfunction
DTC B0079 Incorrect driver SIS installed
DTC B0080 Driver SIS Not Okay (NOK)
DTC B0081 Incorrect passenger SIS installed
DTC B0082 Passenger SIS Not Okay (NOK)
DTC B1000 Internal SDM malfunction
CONNECTOR IDENTIFICATION
NOTE: Refer to illustrations to identify SIR connector terminals. See Fig. 14 - Fig. 17 .
Fig. 14: Identifying Sensing & Diagnostic Module (SDM) Connector Terminals
Fig. 15: Identifying Driver-side Air Bag Module Connector Terminals
Fig. 16: Identifying Passenger-side Air Bag Module Connector Terminals
Fig. 17: Identifying Side Impact Air Bag Module Connector Terminals
SIR DIAGNOSTIC SYSTEM CHECK
To avoid air bag deployment and injury when trouble shooting system,
only use test equipment specified in diagnostic tests. Carefully follow all
instructions.
Circuit Description
When ignition switch is turned on, AIR BAG warning light should flash 7 times and go off. If malfunctions
exist in air bag system, AIR BAG warning light should stay on.
1. Turn ignition on and note AIR BAG warning light. If light flashes 7 times, go to next step. If light does
not flash, inspect vehicle and easily accessible air bag system components for obvious damage, addition
of aftermarket accessories or conditions which could cause malfunction. Diagnose air bag warning light
problems. See AIR BAG WARNING LIGHT CIRCUIT MALFUNCTION .
2. Install scan tool to Data Link Connector (DLC), located below steering column. If scan tool powers up,
go to next step. If scan tool does not power up, inspect data link communication circuits.
3. If scan tool communicates with Sensing and Diagnostic Module (SDM), go to next step. If scan tool does
not communicate with SDM, inspect Class 2 data link communication circuits.
4. Using scan tool, request SIR DTCs. If current or history DTCs exist, go to next step. If no DTCs exist,
system is okay at this time.
5. If scan tool displays any "U" type DTCs, diagnose applicable Class 2 data serial circuits. If scan tool
displays other DTC's, perform appropriate diagnostic test. See DIAGNOSTIC TROUBLE CODE
(DTC) IDENTIFICATION table.
AIR BAG WARNING LIGHT CIRCUIT MALFUNCTION
Circuit Description
When ignition switch is turned on, Sensing and Diagnostic Module (SDM) performs diagnostic tests on SIR
system while AIR BAG warning light flashes 7 times. If no system malfunctions exist, AIR BAG warning light
will then turn off.
Diagnostic Aids
A loss of serial data communication between SDM and Instrument Panel Cluster (IPC) or Ignition 1 (IGN1)
voltage outside normal operating range (9-16 volts) will cause AIR BAG warning light to be on with no DTCs
set.
2. Turn ignition off. Observe AIR BAG warning light when turning ignition on. If AIR BAG warning light
flashes 7 times, go to next step. If AIR BAG warning light does not flash 7 times, go to step 12 .
3. If AIR BAG warning light stays on after flashing 7 times, go to next step. If AIR BAG warning light goes
off after flashing 7 times, check for intermittent or poor connections in SIR system. Go to step 15 .
4. Install scan tool to Data Link Connector (DLC) connector, located under steering column. If scan tool
communicates with Instrument Panel Cluster (IPC), go to next step. If scan tool does not communicate
with IPC, inspect data link communications circuits. Go to step 15 .
5. Using scan tool, request SIR data list display. If Ignition 1 voltage is more than 9 volts, go to next step. If
voltage is 9 volts or less, go to step 7 .
6. If scan tool indicates voltage is greater than 16 volts, inspect battery and charging system. Go to step 15 .
If voltage is 9-16 volts, go to step 14 .
7. Turn ignition off. Disconnect SDM connector. If connector shows signs of corrosion, poor connections or
damage, go to step 13 . If connector is okay, go to next step.
8. Remove SIR fuse from console fuse block. Test circuit 1139 for open or high resistance between SDM
connector terminal A1 and console fuse block terminal B6. Press MIN MAX button on DMM. Connect
leads of DMM to appropriate terminals. If low or no resistance is not indicated, go to next step. If low or
no resistance is indicated, go to step 10 .
9. Repair open or high resistance in circuit 1139. See WIRE REPAIR . Go to step 15 .
10. Turn ignition off. Test circuit 1751 for open or high resistance between SDM connector terminal A18 and
SDM ground point G305, located under right side seat belt anchor bolt. Press MIN MAX button on
DMM. Connect leads of DMM to appropriate terminals. If low or no resistance is not indicated, go to
next step. If low or no resistance is indicated, go to step 14 .
12. Replace IPC. Go to step 15 .
13. Replace SDM connector. See WIRE REPAIR . Go to step 15 .
15. Reconnect all SIR system components. Ensure that all components are properly mounted. Go to SIR
DIAGNOSTIC SYSTEM CHECK .
DTC B0016 : PASSENGER DEPLOYMENT LOOP RESISTANCE LOW
Circuit Description
When ignition switch is turned on, Sensing and Diagnostic Module (SDM) performs continuous diagnostic tests
on deployment loop to check for proper circuit continuity and for shorts to ground or voltage.
DTC sets when passenger-side air bag module deployment loop resistance is less than 1.3 ohms for 500
milliseconds.
Action Taken
Current DTC clears when condition responsible for DTC no longer exists and CLEAR CODES command is
issued via scan tool. History DTC clears when 255 malfunction free ignition cycles have occurred.
Diagnostic Aids
Condition could be caused by a short between circuits 1403 and 1404. A malfunctioning passenger-side air bag
module, SDM or circuit connectors could also cause condition.
2. Turn ignition off. Disconnect passenger-side air bag module connector. See Fig. 3 . If connector shows
signs of corrosion, poor connections or damage, go to next step. If connector is okay, go to step 4 .
3. If harness side of connector is damaged, replace connector. See WIRE REPAIR . Go to step 12 . If
passenger-side air bag module side of connector is damaged, replace passenger-side air bag module. See
4. Reconnect passenger-side air bag module connector. Ensure Connector Position Assurance (CPA) clip is
installed correctly. Install scan tool to Data Link Connector (DLC), located below steering column. Turn
ignition on. Using scan tool, check for SIR DTCs. If DTC B0016 is retrieved, go to next step. If DTC
B0016 is not retrieved, go to DIAGNOSTIC AIDS .
5. Turn ignition off. Disconnect passenger-side air bag connector. Install SIR Driver-Passenger Load Tool
(J-38715-A) using Load Tool Adapter (J-38715-5) to harness side of connector. Turn ignition on. Using
scan tool, check for SIR DTCs. If DTC B0016 is not retrieved, go to next step. If DTC B0016 is
retrieved, go to step 7 .
6. Turn ignition off. Replace passenger-side air bag module. See AIR BAG MODULES under REMOVAL
& INSTALLATION. Go to step 12 .
7. Turn ignition off. Remove SIR Driver-Passenger Load Tool (J-38715-A) and Load Tool Adapter (J-
38715-5) from harness side of connector. Disconnect SDM connector. If connector shows signs of
corrosion, poor connections or damage, go to step 10 . If connector is okay, go to next step.
8. Using Digital Multimeter (J-39200) with Test Adapter Kit (J-35616-A), measure resistance between
SDM terminals A3 and A8. If resistance is not infinite, go to next step. If resistance is infinite, go to step
11 .
9. Repair short between circuits 1403 and 1404. See WIRE REPAIR . Go to step 12 .
12. Reconnect all SIR components. Ensure that all components are properly mounted. Using scan tool, clear
all SIR DTCs. Go to SIR DIAGNOSTIC SYSTEM CHECK .
DTC B0017 : PASSENGER DEPLOYMENT LOOP RESISTANCE HIGH
Circuit Description
DTC sets when passenger-side air bag module deployment loop high-side voltage is less than 2.4 volts and
deployment loop resistance is more than 6 ohms for 500 milliseconds during deployment loop voltage out of
range test or when deployment loop resistance is more than 4.8 ohms for 500 milliseconds during deployment
loop resistance test.
Action Taken
Diagnostic Aids
Condition could be caused by an open or high resistance condition in circuits 1403 or 1404.
4. Reconnect passenger-side air bag connector. Ensure Connector Position Assurance (CPA) clip is installed
correctly. Install scan tool to Data Link Connector (DLC), located below steering column. Turn ignition
on. Using scan tool, check for SIR DTCs. If DTC B0017 is retrieved, go to next step. If DTC B0017 is
not retrieved, go to DIAGNOSTIC AIDS .
SDM terminal A8 and passenger-side air bag module harness connector terminal "A". Press MIN MAX
button on DMM. Connect leads of DMM to appropriate terminals. If low or no resistance is not indicated,
go to next step. If low or no resistance is indicated, go to step 10 .
10. Measure resistance between SDM terminal A3 and passenger-side air bag module harness connector
terminal "B". Press MIN MAX button on DMM. Connect leads of DMM to appropriate terminals. If low
or no resistance is not indicated, go to next step. If low or no resistance is indicated, go to step 13 .
DTC B0018 : PASSENGER DEPLOYMENT LOOP SHORT TO GROUND-VOLTAGE
Circuit Description
DTC sets when passenger-side air bag module deployment loop high-side voltage is more than 6 volts for 500
milliseconds during deployment loop voltage out of range test or when deployment loop resistance is less than 6
ohms for 500 milliseconds during deployment loop resistance test.
Action Taken
Diagnostic Aids
Condition could be caused by a short to ground or voltage in circuits 1403 or 1404. A malfunctioning SDM,
passenger-side air bag module or circuit connectors could also cause condition.
4. Reconnect passenger-side air bag connector. Ensure Connector Position Assurance (CPA) clip is installed
correctly. Install scan tool to Data Link Connector (DLC), located below steering column. Turn ignition
on. Using scan tool, check for SIR DTCs. If DTC B0018 is retrieved, go to next step. If DTC B0018 is
not retrieved, go to DIAGNOSTIC AIDS .
SDM terminal A8 and ground. If resistance is not infinite, go to next step. If resistance is infinite, go to
step 10 .
9. Repair short to ground circuit 1404. See WIRE REPAIR . Go to step 18 .
10. Measure resistance between SDM terminal A3 and ground. If resistance is not infinite, go to next step. If
resistance is infinite, go to step 12 .
11. Repair short to ground in circuit 1403. See WIRE REPAIR . Go to step 18 .
12. Turn ignition on. Measure voltage between SDM terminal A8 and ground. If voltage is one volt or more,
go to next step. If voltage is less than one volt, go to step 14 .
13. Repair short to voltage in circuit 1404. See WIRE REPAIR . Go to step 18 .
14. Measure voltage between SDM terminal A3 and ground. If voltage is one volt or more, go to next step. If
voltage is less than one volt, go to step 17 .
DTC B0022 : DRIVER DEPLOYMENT LOOP RESISTANCE LOW
Circuit Description
DTC sets when driver-side air bag module deployment loop resistance is less than 1.3 ohms for 500
milliseconds.
Action Taken
Diagnostic Aids
Condition could be caused by a short between circuits 347 and 348. A malfunctioning SDM or shorting bar on
circuit connectors could also cause condition.
2. Disconnect driver-side air bag harness connector. See Fig. 2 . If connector shows signs of corrosion, poor
connections or damage, go to next step. If connector is okay, go to step 4 .
3. If harness side of connector is damaged, replace connector. See WIRE REPAIR . Go to step 14 . If SIR
coil side of connector is damaged, replace SIR coil. See SIR COIL ASSEMBLY under REMOVAL &
4. Connect driver-side air bag connector. Ensure Connector Position Assurance (CPA) clip is installed
correctly. Turn ignition on. Using scan tool, check for SIR DTCs. If DTC B0022 is retrieved, go to next
step. If DTC B0022 is not retrieved, go to DIAGNOSTIC AIDS .
5. Turn ignition off. Disconnect driver-side air bag module connector. Install SIR Driver-Passenger Load
Tool (J-38715-A) to harness side of connector. Turn ignition on. Using scan tool, check for SIR DTCs. If
DTC B0022 is retrieved, go to step 9 . If DTC B0022 is not retrieved, go to next step.
6. Turn ignition off. Remove SIR Driver-Passenger Load Tool (J-38715-A) from harness side of connector.
Reconnect harness connector. Remove driver-side air bag module. See AIR BAG MODULES under
REMOVAL & INSTALLATION. Connect SIR Driver-Passenger Load Tool (J-38715-A) using Load
Tool Adapter (J-38715-30A) to SIR coil connector. Turn ignition on. If DTC B0022 is retrieved, go to
next step. If DTC B0022 is not retrieved, go to step 8 .
7. Replace SIR coil assembly. See SIR COIL ASSEMBLY under REMOVAL & INSTALLATION. Go to
step 14 .
Go to step 14 .
Disconnect SDM connector. If connector shows signs of corrosion, poor connections or damage, go to
step 12 . If connector is okay, go to next step.
SDM connector terminals A6 and A7. If resistance is not infinite, go to next step. If resistance is infinite,
go to step 13 .
DTC B0024 : DRIVER DEPLOYMENT LOOP SHORT TO GROUND-VOLTAGE
Circuit Description
DTC sets when driver-side air bag module deployment loop high-side voltage is more than 6 volts for 500
milliseconds during voltage out of range test or when high-side circuit voltage is less than 2.4 volts and
deployment loop resistance is less than 6 ohms for 500 milliseconds during deployment loop resistance test.
Action Taken
Diagnostic Aids
Condition could be caused by a short to ground or voltage in circuits 347 or 348. A malfunctioning SDM or
step 20 .
Go to step 20 .
SDM connector terminal A6 and ground. If resistance is not infinite, go to next step. If resistance is
infinite, go to step 12 .
12. Measure resistance between SDM connector terminal A7 and ground. If resistance is not infinite, go to
next step. If resistance is infinite, go to step 14 .
14. Turn ignition on. Measure voltage between SDM connector terminal A6 and ground. If voltage one volt
or more, go to next step. If voltage is less than one volt, go to step 16 .
16. Measure voltage between SDM connector terminal A7 and ground. If voltage is one volt or more, go to
next step. If voltage is less than one volt, go to step 19 .
DTC B0026 : DRIVER DEPLOYMENT LOOP RESISTANCE HIGH
Circuit Description
DTC sets when driver-side air bag module deployment loop high-side voltage is less than 2.4 volts and
deployment loop resistance is more than 6 ohms for 500 milliseconds during deployment loop voltage out of
range test or when deployment loop resistance is more than 4.8 ohms for 500 milliseconds during resistance
measurement test.
Action Taken
Diagnostic Aids
Condition could be caused by an open or high resistance in circuits 347 or 348. A malfunctioning SDM or
step 16 .
Go to step 16 .
10. Using Digital Multimeter (J-39200) with Test Adapter Kit (J-35616-A), measure continuity between
SDM connector terminal A6 and wire harness-to-SIR coil connector terminal "A". Press MIN MAX
12. Measure continuity between SDM connector terminal A7 and wire harness-to-SIR coil connector terminal
"B". Press MIN MAX button on DMM. Connect leads of DMM to appropriate terminals. If low or no
resistance is not indicated, go to next step. If low or no resistance is indicated, go to step 15 .
DTC B0028 : PASSENGER SIDE IMPACT DEPLOYMENT LOOP RESISTANCE LOW
Circuit Description
DTC sets when passenger side impact deployment loop resistance is less than 1.3 ohms for 500 milliseconds.
Action Taken
Diagnostic Aids
Condition could be caused by a short between circuits 2135 and 2136. A malfunctioning side impact air bag
2. Disconnect passenger side impact air bag harness connector, located under passenger-side front seat. If
connector shows signs of corrosion, poor connections or damage, go to next step. If connector is okay, go
to step 4 .
impact connector is damaged, replace side impact air bag module. See AIR BAG MODULES under
4. Connect side impact air bag connector. Ensure Connector Position Assurance (CPA) clip is installed
5. Turn ignition off. Disconnect side impact air bag module connector. Install SIR Driver-Passenger Load
6. Replace side impact air bag module. See AIR BAG MODULES under REMOVAL &
Disconnect SDM connector. If SDM connector shows signs of corrosion, poor connections or damage, go
to step 10 . If connector is okay, go to next step.
SDM connector terminals B3 and B4. If resistance is not infinite, go to next step. If resistance is infinite,
go to step 12 .
DTC B0029 : PASSENGER SIDE IMPACT DEPLOYMENT LOOP RESISTANCE HIGH
Circuit Description
DTC sets when passenger side impact deployment loop high-side voltage is less than 2.4 volts and deployment
loop resistance is more than 6 ohms for 500 milliseconds during voltage out of range test or when deployment
loop resistance is more that 4.8 ohms for 500 milliseconds during deployment loop resistance test.
Action Taken
Diagnostic Aids
Condition could be caused by an open or high resistance in circuits 2135 or 2136. A malfunctioning side impact
air bag module, SDM or circuit connectors could also cause condition.
to step 4 .
6. Replace passenger side impact air bag module. See AIR BAG MODULES under REMOVAL &
SDM connector terminal B4 and side impact air bag harness connector terminal "A". Press MIN MAX
10. Measure continuity between SDM connector terminal B3 and side impact air bag harness connector
DTC B0030 : PASSENGER SIDE IMPACT DEPLOYMENT LOOP SHORTED TO GROUND-

VOLTAGE
Circuit Description
DTC sets when passenger side impact deployment loop high-side voltage is more than 6 volts during
deployment loop voltage out of range test or when high-side voltage is less than 2.4 volts and deployment loop
resistance is less than 6 ohms for 500 milliseconds during deployment loop resistance test.
Action Taken
Diagnostic Aids
Condition could be caused by a short to ground or voltage in circuits 2135 or 2136. A malfunctioning side
impact air bag module, SDM or circuit connectors could also cause condition.
to step 4 .
6. Replace passenger side impact air bag module. See AIR BAG MODULES under REMOVAL &
SDM connector terminal B4 and ground. If resistance is not infinite, go to next step. If resistance is
10. Measure resistance between SDM connector terminal B3 and ground. If resistance is not infinite, go to
12. Turn ignition on. Measure voltage between SDM connector terminal B4 and ground. If voltage one volt
14. Measure voltage between SDM connector terminal B3 and ground. If voltage is one volt or more, go to
DTC B0040 : DRIVER SIDE IMPACT DEPLOYMENT LOOP RESISTANCE LOW
Circuit Description
When ignition switch is turned on Sensing and Diagnostic Module (SDM) performs continuous diagnostic tests
DTC sets when driver side impact deployment loop resistance is less than 1.3 ohms for 500 milliseconds.
Action Taken
Diagnostic Aids
Condition could be caused a short between circuits 2137 and 2138. A malfunctioning side impact air bag
2. Disconnect driver side impact air bag harness connector, located under driver-side front seat. If connector
shows signs of corrosion, poor connections or damage, go to next step. If connector is okay, go to step 4 .
go to step 12 .
DTC B0041 : DRIVER SIDE IMPACT DEPLOYMENT LOOP RESISTANCE HIGH
Circuit Description
DTC sets when driver side impact deployment loop high-side voltage is less than 2.4 volts and deployment loop
resistance is more than 6 ohms for 500 milliseconds during voltage out of range test or when deployment loop
resistance is more that 4.8 ohms for 500 milliseconds during deployment loop resistance test.
Action Taken
Diagnostic Aids
Condition could be caused by an open or high resistance in circuits 2137 or 2138. A malfunctioning side impact
air bag module, SDM or circuit connectors could also cause condition.
SDM connector terminal B1 and side impact air bag harness connector terminal "A". Press MIN MAX
10. Measure continuity between SDM connector terminal B2 and side impact air bag harness connector
DTC B0045 : DRIVER SIDE IMPACT DEPLOYMENT LOOP SHORTED TO GROUND-VOLTAGE
Circuit Description
DTC sets when driver side impact deployment loop high-side voltage is more than 6 volts during deployment
loop voltage out of range test or when high-side voltage is less than 2.4 volts and deployment loop resistance is
less than 6 ohms for 500 milliseconds during deployment loop resistance test.
Action Taken

Diagnostic Aids
Condition could be caused by a short to ground or voltage in circuits 2137 or 2138. A malfunctioning side
impact air bag module, SDM or circuit connectors could also cause condition.
SDM connector terminal B1 and ground. If resistance is not infinite, go to next step. If resistance is
12. Turn ignition on. Measure voltage between SDM connector terminal B1 and ground. If voltage one volt
DTC B0051 : DEPLOYMENT COMMANDED
Circuit Description
SDM contains sensing devices which convert vehicle velocity changes to electrical signals. Electrical signal is
processed by SDM and compared to a value stored in memory. When signals exceed stored values, additional
signal processing is performed and signals are compared to values stored in memory. When 2 signals exceed
stored values, SDM causes current to flow through air bag modules, deploying air bags and causing DTC
B0051 to set.
DTC sets when SDM detects a frontal or side impact of sufficient force to warrant deployment of air bags.
Action Taken
SDM turns on AIR BAG warning light and records crash data.
DTC B0051 is a latched code and cannot be cleared. Replace SDM after following diagnostic procedure.
3. Inspect front of vehicle and undercarriage for signs of impact. If impact has occurred, go to step 5 . If no
impact has occurred, go to next step.
5. Replace components and perform inspections as required following an accident. See POST-
COLLISION INSPECTION . Go to next step.
all DTCs. Go to SIR DIAGNOSTIC SYSTEM CHECK .
DTC B0053 : DEPLOYMENT COMMANDED WITH LOOP MALFUNCTION

Circuit Description
SDM contains a sensing device which converts vehicle velocity changes to an electrical signal. Electrical signal
is processed by SDM and compared to a value stored in memory. When signal exceeds stored value, additional
signal processing is performed and signals are compared to values stored in memory. When 2 signals exceed
stored values, SDM will cause current to flow through air bag modules, deploying air bags. DTC B0053 and
B0051 will set when a deployment occurs while an inflator circuit fault exists that could result in a non-
deployment situation in one or both air bag modules.
DTC sets when SDM detects a frontal or side impact of sufficient force to warrant deployment of air bags.
Action Taken
SDM turns on AIR BAG warning light and records crash data.
DTC B0053 is a latched code and cannot be cleared. Replace SDM after following instructions in diagnostic
procedure.
Diagnostic Aids
DTC B0053 will be accompanied by another DTC (other than DTC B0051 and B1000). Repair malfunction(s)
causing other DTCs before installing new SDM.
3. Inspect front of vehicle and undercarriage for signs of impact. If impact has occurred, go to step 5 . If no
impact has occurred, go to next step.
5. Using scan tool, request SIR DTC display. If history DTC exists, go to diagnostic aids for specific DTC.
Replace components and perform inspections as required following an accident. See POST-
COLLISION INSPECTION . Go to next step.
6. Reconnect all SIR components. Ensure that all components are properly mounted. Go to SIR
DIAGNOSTIC SYSTEM CHECK .
DTC B0077 : DRIVER SIS MALFUNCTION

Circuit Description
When ignition switch is turned on, Sensing and Diagnostic Module (SDM) performs tests to diagnose critical
internal malfunctions. SDM then provides input power to Side Impact Sensor (SIS). SIS performs internal
diagnostics, then sends an identification message to SDM. SDM will consider this a valid identification
message if received within 5 seconds of SIS powering up. SIS continually communicates a status message to
SDM. SDM can reset SIS by removing and reapplying power to SIS.
DTC sets when a valid identification message is not received by SDM within 5 seconds of SIS being powered
up, a valid identification message is not received or SDM has failed twice to reset SIS.
Action Taken
Diagnostic Aids
Condition could be caused by a short between circuits 2131 and 2132, or by a short to ground or voltage in
circuits 2131 or 2132. A malfunctioning SDM, SIS or circuit connector could also cause condition.
2. Turn ignition off. Disconnect SIS connector. See SIDE IMPACT SENSOR (SIS) under REMOVAL &
INSTALLATION. If harness side of connector is damaged or corroded, go to next step. If harness side of
connector is okay, go to step 4 .
3. Replace SIS harness connector. See WIRE REPAIR . Go to step 24 .
4. Inspect SIS terminals for corrosion or damaged terminals. If terminals are okay, go to next step. If
terminals are not okay, go to step 20 .
5. Disconnect SDM connector. Inspect connector for signs of corrosion, damaged terminals or poor
connections. If connector is okay, go to next step. If connector is not okay, go to step 21 .
go to step 8 .
8. Measure continuity of circuit 2131 between SDM connector B5 and SIS harness connector terminal "B".
Press MIN MAX button on DMM. Connect leads of DMM to appropriate terminals. If low or no
10. Measure continuity of circuit 2132 between SDM connector B6 and SIS harness connector terminal "A".
next step. If resistance infinite, go to step 14 .
15. Repair short to ground in circuit 2132. Go to step 24 .
16. Turn ignition on. Measure voltage between SDM connector terminal B5 and ground. If voltage is one volt
20. Replace SIS. See SIDE IMPACT SENSOR (SIS) under REMOVAL & INSTALLATION. Go to step
22 .
21. Replace SDM connector. Go to next step.
22. Reconnect all SIR components. Using scan tool, clear all SIR DTCs. Go to SIR DIAGNOSTIC
SYSTEM CHECK . If DTC B0077 resets, go to next step. If DTC B0077 does not reset, system is okay.
DTC B0078 : PASSENGER SIS MALFUNCTION
Circuit Description
DTC sets when a valid identification message is not received by SDM within 5 seconds of SIS being powered
up, a valid identification message is not received or SDM has failed twice to reset SIS.
Action Taken
Diagnostic Aids
Condition could be caused by a short between circuits 2133 and 2134, or by a short to ground or voltage in
circuits 2133 or 2134. A malfunctioning SDM, SIS or circuit connector could also cause condition.
2. Turn ignition off. Disconnect SIS connector. See SIDE IMPACT SENSOR (SIS) under REMOVAL &
INSTALLATION. If harness side of connector is damaged or corroded, go to next step. If harness side of
connector is okay, go to step 4 .
3. Replace SIS harness connector. See WIRE REPAIR . Go to step 24 .
4. Inspect SIS terminals for corrosion or damaged terminals. If terminals are okay, go to next step. If
terminals are not okay, go to step 20 .
5. Disconnect SDM connector. Inspect connector for signs of corrosion, damaged terminals or poor
connections. If connector is okay, go to next step. If connector is not okay, go to step 21 .
go to step 8 .
8. Measure continuity of circuit 2133 between SDM connector B8 and SIS harness connector terminal "B".
10. Measure continuity of circuit 2134 between SDM connector B7 and SIS harness connector terminal "A".
next step. If resistance infinite, go to step 14 .
15. Repair short to ground in circuit 2134. Go to step 24 .
16. Turn ignition on. Measure voltage between SDM connector terminal B8 and ground. If voltage is one volt
20. Replace SIS. See SIDE IMPACT SENSOR (SIS) under REMOVAL & INSTALLATION. Go to step
22 .
21. Replace SDM connector. Go to next step.
SYSTEM CHECK . If DTC B0078 resets, go to next step. If DTC B0078 does not reset, system is okay.
DTC B0079 : INCORRECT DRIVER SIS INSTALLED
Circuit Description
DTC sets when SDM has received an identification message from SIS that does not match identification
message stored in SDM.
Action Taken
SDM turns on AIR BAG warning light and attempts to reset SIS.
Diagnostic Aids
DTC B0079 is an indication that incorrect driver-side SIS is installed.
2. Turn ignition off. Install scan tool. Turn ignition on. Using scan tool, check for SIR DTCs. If DTC B0079
is retrieved, go to next step. If DTC B0079 is not retrieved, go to DIAGNOSTIC AIDS .
3. Turn ignition off. Replace driver-side SIS. See SIDE IMPACT SENSOR (SIS) under REMOVAL &
SYSTEM CHECK .
DTC B0080 : DRIVER SIS NOT OKAY (NOK)
Circuit Description
DTC sets when SDM has received a Not Okay (NOK) message from SIS.
Action Taken
Diagnostic Aids
DTC B0080 is an indication that an internal malfunction exists in driver-side SIS.
2. Install scan tool. Turn ignition on. Using scan tool, check for SIR DTCs. If DTC B0080 is retrieved, go to
next step. If DTC B0080 is not retrieved, go to DIAGNOSTIC AIDS .
3. Replace SIS. See SIDE IMPACT SENSOR (SIS) under REMOVAL & INSTALLATION. Go to next
step.
DTC B0081 : INCORRECT PASSENGER SIS INSTALLED
Circuit Description
DTC sets when SDM has received an identification message from SIS that does not match identification
message stored in SDM.
Action Taken
Diagnostic Aids
DTC B0081 is an indication that incorrect passenger-side SIS is installed in vehicle.
2. Turn ignition off. Install scan tool. Turn ignition on. Using scan tool, check for SIR DTCs. If DTC B0081
is retrieved, go to next step. If DTC B0081 is not retrieved, go to DIAGNOSTIC AIDS .
3. Turn ignition off. Replace driver-side SIS. See SIDE IMPACT SENSOR (SIS) under REMOVAL &
SYSTEM CHECK .
DTC B0082 : PASSENGER SIS NOT OKAY (NOK)
Circuit Description
DTC sets when SDM has received a Not Okay (NOK) message from SIS.
Action Taken
Diagnostic Aids
DTC B0082 is an indication that an internal malfunction exists in passenger-side SIS.
2. Install scan tool. Turn ignition on. Using scan tool, check for SIR DTCs. If DTC B0082 is retrieved, go to
next step. If DTC B0082 is not retrieved, go to DIAGNOSTIC AIDS .
3. Replace passenger-side SIS. See SIDE IMPACT SENSOR (SIS) under REMOVAL &
DTC B1000 : INTERNAL SDM MALFUNCTION
Circuit Description
DTC B1000 indicates internal SDM malfunction. Malfunction is detected within SDM. No external circuits are
involved.
DTC sets when SDM detects either a write error malfunction or a checksum memory malfunction.
Action Taken
SDM turns on AIR BAG warning light.
DTC B1000 is a latched code and cannot be cleared. Replace SDM after following instructions in diagnostic
procedure.
Diagnostic Aids
DTC B1000 is an indication of an internal SDM malfunction.
INSTALLATION. Reconnect all SIR components. Ensure that all components are properly mounted.
Using scan tool, clear all SIR DTCs. Go to SIR DIAGNOSTIC SYSTEM CHECK .
DTC B1001 : OPTION CONFIGURATION ERROR
Circuit Description
When ignition is turned on, Sensing and Diagnostic Module (SDM) compares restraints identification stored in
SDM to restraints identification stored in Body Control Module (BCM). SDM then compares Vehicle
Identification Number (VIN) stored in SDM to VIN stored in BCM.
DTC sets when restraints identification stored in SDM does not match restraints identification stored in BCM or
VIN stored in SDM does not match VIN stored in BCM.
Action Taken
SDM turns on AIR BAG warning light and disables all air bag deployment loops.
DTC clears when restraints identification and VIN stored in SDM matches restraints identification and VIN
stored in BCM.
Diagnostic Aids
DTC B1001 is indication that restraints identification and VIN stored in BCM and SDM do not match. If either
BCM or Powertrain Control Module (PCM) were replaced, modules need to be reprogrammed for proper
operation.
2. Using scan tool, verify Powertrain Control Module (PCM) is programmed with correct Vehicle
Identification Number (VIN) by comparing VIN stored in PCM to VIN plate on vehicle. If VIN is not
correct, go to next step. If VIN is correct, go to step 4 .
3. Using scan tool, program correct VIN into PCM. Go to next step.
4. If Body Control Module (BCM) was replaced, go to next step. If BCM was not replaced, verify BCM is
programmed with same VIN that is in PCM. If VIN is correct, go to step 6 . If VIN is not correct, go to
next step.
5. Using scan tool, follow instructions under BCM SPECIAL FUNCTIONS to reprogram BCM. Go to step
7.
6. Turn ignition off. Replace SDM. See SENSING & DIAGNOSTIC MODULE (SDM) under
REMOVAL & INSTALLATION. Go to next step.
7. Using scan tool, clear DTCs. Turn ignition switch off then on. Road test vehicle. Using scan tool, retrieve
SIR DTCs.
WIRE REPAIR
SIR system requires special wiring repair procedures due to sensitive nature of circuitry. Wire Repair Kit (J-
38125-B) contains special sealed splices for use in repairing SIR wiring. Splices use a heat shrink sleeve with
sealing adhesive to produce a sealed splice and a cross-hatched core crimp to produce a positive contact for low
energy circuits.
Repair damaged SIR wire harness connectors and terminals (except pigtails) using connector repair assembly
packs and splice crimping tool provided. Terminals in SIR system are manufactured from a special metal to
provide necessary contact integrity for sensitive, low-energy circuits. These terminals are only available in
connector repair assembly packs. No other terminal should be substituted.
If individual terminals on SDM harness connector are damaged, SDM harness connector must be replaced using
SDM harness connector pigtail assembly or SDM harness connector replacement kit. If individual terminals on
any other SIR connector are damaged, entire connector must be replaced. Use appropriate connector repair
assembly pack. Replace entire SIR wire harness, if necessary to maintain SIR circuit integrity.
DO NOT make wiring, connector or terminal repairs on components with wiring pigtails. If a wiring pigtail is
damaged, entire component (including pigtail) should be replaced.
Any wiring other than a pigtail can be repaired by splicing in a new section of wire of same gauge. Sealed
splices and crimping tool must be used for these splices. Open wire harness by removing tape as necessary,
using a sewing seam ripper. Refer to instructions in kit for wiring repair procedure.
Application Ft. Lbs (N.m)
Seat bolts 37 (50)
Steering wheel nut 30 (41)
INCH Lbs. (N.m)
Glove box screws 18 (2)
Passenger-side air bag module nuts 106 (12)
Sensing & Diagnostic Module (SDM) bolts 89 (10)
Side Impact Sensor (SIS) bolts 89 (10)
WIRING DIAGRAMS
Fig. 18: SIR System Wiring Diagrams (Aztek)
Antilock Brake System - Aztek & Rendezvous
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications

Specification
Application Metric English
Brake Pipe Fittings at Brake Pressure Modulator Valve
24 N.m 18 lb ft
(BPMV) and Master Cylinder
Brake Pressure Modulator Valve (BPMV) and Electronic
Brake Control Module (EBCM) Assembly to Mounting 10 N.m 89 lb in
Bracket
Electronic Brake Control Module (EBCM) to Brake
5 N.m 44 lb in
Pressure Modulator Valve (BPMV)
Master Cylinder to Brake Booster Studs 25 N.m 18 lb in
Mounting Bracket Nut/Bolt Assembly to Shock Tower 10 N.m 89 lb in
Switch Bank Nuts/Bolts 2.5 N.m 22 lb in
SCHEMATIC AND ROUTING DIAGRAMS

ABS SCHEMATICS
Fig. 1: Brake Pressure Modulation, Ground, Power, and Stop Lamp Switch
Fig. 2: DLC, Indicators, and Traction Control Switch - 3.4L
Fig. 3: DLC, Indicators and Traction Control - 3.6L
Fig. 4: Wheel Speed Sensors
COMPONENT LOCATOR
ABS COMPONENT VIEWS
Fig. 5: Right Front Wheel Component View
Callouts For Fig. 5

Callout Component Name
1 Wheel Speed Sensor (WSS)-RF
2 Pigtail Connector
Fig. 6: LR Engine Compartment Location View
Callouts For Fig. 6

1 Brake Fluid Level Switch
2 Cruise Control Module
3 Electronic Brake Control Module (EBCM)
Fig. 7: Rear Wheel Speed Sensors Component View
Callouts For Fig. 7

1 Wheel Speed Sensor-LR (RR similar)
2 Rear Strut
ABS CONNECTOR END VIEWS
Electronic Brake Control Module (EBCM)

15326390
Connector Part Information
30-Way F GT 150 280 Series Sealed 4.0 5.8 (BK)
Pin Wire Color Circuit No. Function

1 - - Not Used
2 BN 882 Right Rear Wheel Speed Sensor Signal
Right Rear Wheel Speed Sensor Low
3 WH 883
Reference
4 D-GN 872 Right Front Wheel Speed Sensor Signal
Right Front Wheel Speed Sensor Low
5 TN 833
Reference
6 WH 17 Stop Lamp Switch Signal
7 - - Not Used
8 PK 1039 Ignition 1 Voltage
9 TN/BK 464 Delivered Torque Signal (NW9 or M76)
10 - - Not Used
11 WH 121 Engine Speed Signal (NW9 or M76)
12 BK/WH 251 Ground
13 RD 1442 Battery Positive Voltage
14 OG 1740 Battery Positive Voltage
15 BK/WH 251 Ground
16-19 - - Not Used
20 L-BU 830 Left Front Wheel Speed Sensor Signal
Left Front Wheel Speed Sensor Low
21 YE 873
Reference
22 BK 884 Left Rear Wheel Speed Sensor Signal
Left Rear Wheel Speed Sensor Low
23 RD 885
Reference
24 - - Not Used
25 L-BU 1122 ABS/TCS Class 2 Serial Data
26 - - Not Used
27 OG/BK 463 Requested Torque Signal
28-30 - - Not Used
I/P Switch Assembly - C1 (Pontiac)
12162455
8-Way F 280 Series (NA)

A GY 8 Instrument Panel Lamp Supply Voltage
B BK 150 Ground
C WH/BK 1221 Lift Gate Release Switch Signal
D BN/WH 1571 Traction Control Switch Signal
E-H - - Not Used
I/P Switch Assembly C4 - JM4 (Buick)

12162455
8-Way F 280 Series (NAT)

B BK 150 Ground
C-D - - Not Used
E BN/WH 1571 Traction Control Switch Signal (NW9)
F - - Not Used
Rear Parking Assist Disable Switch Input
G L-GN 9380
(UD7)
H BN 241 Ignition 3 Voltage
Wheel Speed Sensor - LF
12052644
Connector Part Information 2-Way F Metri-Pack 150 Series Sealed (WH)
Left Front Wheel Speed Sensor Low
A YE 873
Reference
B L-BU 830 Left Front Wheel Speed Sensor Signal
Wheel Speed Sensor - LR
12052644
2-Way F Metri-Pack 150 Series Sealed (WH)

A WH 883
Reference
B BK 882 Right Rear Wheel Speed Sensor Signal
Wheel Speed Sensor - RF

12052644

A D-GN 872 Right Front Wheel Speed Sensor Signal
Right Front Wheel Speed Sensor Low
B TN 833
Reference
Wheel Speed Sensor - RR
12052644

A WH 883
Reference
B BK 882 Right Rear Wheel Speed Sensor Signal
DIAGNOSTIC INFORMATION AND PROCEDURES
DIAGNOSTIC STARTING POINT - ANTILOCK BRAKE SYSTEM
Begin the system diagnosis with Diagnostic System Check - Vehicle in Vehicle DTC Information. The
Diagnostic System Check will provide the following information:
The identification of the control modules which command the system

The ability of the control modules to communicate through the serial data circuit
The identification of any stored diagnostic trouble codes (DTCs) and their status
The use of the Diagnostic System Check will identify the correct procedure for diagnosing the system and
where the procedure is located.
SCAN TOOL OUTPUT CONTROLS
Scan Tool Output Controls

Scan Tool Output Additional Menu
Control Selection(s) Description
Automated Bleed Used in order to bleed the ABS hydraulics. Refer to ABS
-
Procedure Automated Bleed Procedure.
ABS Warning Lamp Solenoid Test Commands the ABS indicator ON and OFF.
LF Inlet Solenoid Solenoid Test Commands the solenoid ON and OFF.
LF Outlet Solenoid Solenoid Test Commands the solenoid ON and OFF.
LR Inlet Solenoid Solenoid Test Commands the solenoid ON and OFF.
LR Outlet Solenoid Solenoid Test Commands the solenoid ON and OFF.
LF Master Cylinder Commands the solenoid ON and OFF.
Solenoid Test
Isolation Solenoid
LF Prime Solenoid Solenoid Test Commands the solenoid ON and OFF.
Pump Motor - Commands the pump motor ON and OFF.
RF Inlet Solenoid Solenoid Test Commands the solenoid ON and OFF.
RF Outlet Solenoid Solenoid Test Commands the solenoid ON and OFF.
RF Master Cylinder
Solenoid Test Commands the solenoid ON and OFF.
Isolation Solenoid
RF Prime Solenoid Solenoid Test Commands the solenoid ON and OFF.
RR Inlet Solenoid Solenoid Test Commands the solenoid ON and OFF.
RR Outlet Solenoid Solenoid Test Commands the solenoid ON and OFF.
Commands the traction control system ON and OFF.
TCS On/Off test -
Performs the same function as the traction control switch.
SCAN TOOL DATA LIST
The EBCM Scan Tool Data Lists contain all the antilock brake system related parameters that are available on
the scan tool. The parameters in the list are arranged in alphabetical order. The column, 'Data List,' indicates the
location of the parameter within the scan tool menu selections.
Use the EBCM Scan Tool Data Lists as directed by a diagnostic table or in order to supplement the diagnostic
procedures. Begin all the diagnostic procedures with the ABS Diagnostic Starting Point. Use the EBCM Scan
Tool Data Lists only after the following is determined:
There is no published DTC procedure nor published symptom procedure for the customer concern.
OR
The DTC or symptom diagnostic procedure indicated by the diagnostic system check does not resolve the
customer concern.
The Typical Data Values are obtained from a properly operating vehicle under the conditions specified in the
first row of the Scan Tool Data List table. Comparison of the parameter values from the suspect vehicle with the
Typical Data Values may reveal the source of the customer concern.
The ID Information menu is located on the EBCM main screen.
EBCM Scan Tool Data List

Ignition is ON, engine OFF, and vehicle is stationary
Scan Tool Parameter Data List Units Displayed Typical Data Value
ABS Warning Lamp ABS On/Off Off
ABS Active ABS Yes/No No
Brake Switch ABS Applied/Released Released
DRP Active ABS/TCS Yes/No No
DRP Disabled ABS/TCS Yes/No No
EBCM to PCM
TCS N.m Varies
Requested Torque
Engine Speed TCS RPM 0
Ignition Voltage ABS/TCS Volts B+
LF TCS Isolation
TCS Active/Inactive Inactive
Solenoid
Left Front Wheel Speed ABS/TCS km/h or mph 0
Left Rear Wheel Speed ABS/TCS km/h or mph 0
LF Inlet Valve Solenoid ABS Active/Inactive Inactive
LF Outlet Valve Solenoid ABS Active/Inactive Inactive
LF TCS Prime Solenoid TCS Active/Inactive Inactive
Low Traction Lamp TCS On/Off Off
Motor Relay State ABS/TCS On/Off Off
PCM To EBCM
TCS N.m Varies
Delivered Torque
RF Inlet Valve Solenoid ABS Active/Inactive Inactive
RF Outlet Valve Solenoid ABS Active/Inactive Inactive
RF TCS Isolation
TCS Active/Inactive Inactive
Solenoid
RF TCS Prime Solenoid TCS Active/Inactive Inactive
Right Front Wheel Speed ABS/TCS km/h or mph 0
Right Rear Wheel Speed ABS/TCS km/h or mph 0
Rough Road Parameter TCS g 0
TCS Active TCS Yes/No No
TCS Switch State ABS/TCS Pressed/Release Pressed
TCS Warning Lamp TCS On/Off Off
Valve Relay State ABS/TCS On/Off On
SCAN TOOL DATA DEFINITIONS
Data Display/Definitions
The Scan Tool Data Display/Definitions contains a brief description of all the ABS/TCS/VSES data parameters.
The menus available depend on the number and type of system on the vehicle and are listed below in
alphanumeric order.
ABS DATA
TCS DATA
ABS Active
The scan tool displays Yes or No. The scan tool will display Yes when the ABS is active and No during
normal vehicle operation.
ABS Warning Lamp
The scan tool will display On or Off depending on the state of the ABS indicator.
Brake Switch
The scan tool will display Applied or Released depending on the state of the brake switch.
DRP Active
The scan tool will display Yes/No depending on the state of the DRP.
DRP Disabled
The scan tool will display Yes/No depending on the state of the DRP.
EBTCM to PCM Requested Torque

The scan tool displays 0-100 percent. The scan tool displays the duty cycle of the Delivered Torque
PWM signal. The duty cycle of the signal is used to transmit how much torque the EBCM is requesting
the PCM to deliver. Normal values are between 10 and 90 percent duty cycle. The signal should be at 90
percent duty cycle when traction control is not active and at a lower value, approximately 10 percent,
when the traction control is active.
Engine Speed
The scan tool will display between 0 to 10200 RPM which is a digital tachometer display.
Ignition Voltage
The scan tool displays 0-17 Volts. The scan tool displays the level of ignition voltage at the EBCM.
LF Inlet Valve Solenoid
The scan tool will display Active or Inactive. The scan tool displays the commanded state of the LF inlet
solenoid valve.
LF Outlet Valve Solenoid
The scan tool will display Active or Inactive. The scan tool displays the commanded state of the LF outlet
solenoid valve.
LF TCS Isolation Solenoid
The scan tool will display Active/Inactive. This displays the commanded state of the solenoid valve.
LF TCS Prime Solenoid
The scan tool will display Active/Inactive. This displays the commanded of the solenoid valve.
Left Front Wheel Speed
The scan tool displays 0-255 km/h or (0-158 mph). The scan tool displays the actual speed of the left
front wheel.
Left Rear Wheel Speed
The scan tool displays 0-255 km/h or (0-158 mph). The scan tool displays the actual speed of the left rear
wheel.
Low Traction Lamp
The scan tool will display On/Off. This will indicate the state of the LOW TRAC Indicator.
LR Inlet Valve Solenoid
The scan tool displays Active or Inactive. The scan tool displays the commanded state of the LR inlet
solenoid valve.
LR Outlet Valve Solenoid
The scan tool displays Active or Inactive. The scan tool displays the commanded state of the LR outlet
solenoid valve.
Monitor Relay State
The scan tool display On/Off. This is the commanded state of the relay.
PCM to EBTCM Delivered Torque
The scan tool displays 0-100 percent. The scan tool displays the duty cycle of the Requested Torque
PWM signal. The duty cycle of the signal is used to transmit how much engine torque the PCM is
delivering. Normal values are between 10 and 90 percent duty cycle. The signal is at low values,
approximately 10 percent, at idle and at higher values under driving conditions.
RF Inlet Valve Solenoid
The scan tool displays Active or Inactive. The scan tool displays the commanded state of the RF inlet
solenoid valve.
RF Outlet Valve Solenoid
The scan tool displays Active or Inactive. The scan tool displays the commanded state of the RF outlet
solenoid valve.
Right Front Wheel Speed
The scan tool displays 0-255 km/h or (0-158 mph). The scan tool displays the actual speed of the right
front wheel.
RF TCS Isolation Solenoid
The scan tool will display Active/Inactive. This will be the commanded state of the solenoid valve.
RF TCS Prime Solenoid
The scan tool will display Active/Inactive. This will be the commanded state of the solenoid valve.
RR Inlet Valve Solenoid

The scan tool displays Active or Inactive - The scan tool displays the commanded state of the RR inlet
solenoid valve.
RR Outlet Valve Solenoid
The scan tool displays Active or Inactive - The scan tool displays the commanded state of the RR outlet
solenoid valve.
Right Rear Wheel Speed
The scan tool displays 0-255 km/h or (0-158 mph). The scan tool displays the actual speed of the right
rear wheel.
Rough Road Parameters
The scan tool will display 0 to 1 g. The scan tool will display the EBCM calculation of the road surface
roughness. This information is then sent to the PCM over the class 2 serial data line. This information is
used by the PCM for misfire detection.
TCS Active
The scan tool displays Off or On. The scan tool displays On if the TCS indicator is currently being
commanded ON.
TCS Switch State
The scan tool displays Pressed or Released. The scan tool will display the state of the Traction Control
Switch.
TCS Warning Lamp
The scan tool will display On or Off depending on the state of the TCS indicator.
Valve Relay State
The scan tool will display On/Off depending on the state of the relay.
DIAGNOSTIC TEST DRIVE
When servicing vehicles, the vehicle antilock brake and traction control system, test drives will be necessary to
allow all tests to be run, and all system functions to be enabled and exercised. A test drive may also be required
to duplicate specific DTCs covered in this section. The diagnostic system check (including test drive) should be
run when vehicle repairs are complete in order to verify the repair.
The diagnostic test drive will vary for ABS/TCS problems.

1. Read the Diagnostic Aids and the Conditions for Setting the DTC.
2. Reconnect any previously disconnected components.
3. Start the engine.
4. Drive the vehicle under the following conditions for at least 10 minutes. At no times should any unlawful
or unsafe maneuvers be performed.
Highway driving.
Rough roads.
Verify customers concern and duplicate driving conditions.
With the engine still running use the scan tool and check for any DTCs. If any DTCs are set,
perform the appropriate DTC table.
ENHANCED DIAGNOSTICS
History Data
Enhanced diagnostic information is found in the History Data function of the scan tool. Enhanced diagnostic
information provides the service technician with specific malfunction occurrence information.
The scan tool will display the last 3 DTCs to occur, one at a time. The DTC with the most recent occurrence
will be displayed first. Each DTC will include the following:
The number of drive cycles since the DTC last occurred.

The number of occurrences for the DTC since the scan tool DTC information was last cleared.
The most recent DTC will also display various data parameters with values from the time of the DTC
occurrence.
Diagnostic Strategy
In difficult diagnostic situations use the above information to identify malfunction occurrence trends. Ask
question such as the following:
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
diagnostic techniques may be required to identify the source of the malfunction?
A malfunction that occurs more frequently increases the odds of finding the cause of the malfunction.
Use the information in order to determine if a DTC is intermittent. Use the information in order to determine if
the DTC has not set for long periods of time due to weather changes or a repair prior to this visit.
DTC B2747
Circuit Description
The traction control switch is a momentary switch. The signal circuit of the traction control switch is grounded,
when the driver presses the traction control switch. The traction control system will change state from traction
on to traction off, or from traction off to traction on, each time the traction control switch is pressed.
DTC Descriptor
This diagnostic procedure supports the following DTC:
DTC B2747 Traction Control Switch Circuit Low
Conditions for Running the DTC
The battery voltage is between 9-16 volts.

The park brake is not applied.
Conditions for Setting the DTC
The signal circuit voltage of the traction control switch is no more than 2 volts.
All of the above conditions are present for greater than 60 seconds.
Action Taken When the DTC Sets
If equipped, the following actions occur:
The body control module (BCM) stores DTC B2747 in memory.

The traction control switch input is ignored until the fault is no longer current.
Conditions for Clearing the DTC
A current DTC B2747 will clear if the BCM no longer detects a short to ground for longer than 60
seconds.
A history DTC B2747 will clear after 100 consecutive ignition cycles if the condition for the malfunction
is no longer present.
A scan tool may be used to clear the DTC.
Diagnostic Aids
Check for a traction control switch that may be sticking in the pressed position. For an intermittent condition
refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.
Test Description
The numbers below refer to the step numbers on the diagnostic table.
2: This step verifies that the fault is present.
3: This step tests for a shorted switch.
DTC B2747
Step Action Yes No
Schematic Reference: ABS Schematics
Connector End View Reference: ABS Connector End Views or Computer/Integrating Systems
Connector End Views in Computer/Intergrating Systems
Did you perform the Diagnostic System Check - Go to Diagnostic
Vehicle? System Check -
1
Vehicle in Vehicle
Go to Step 2 DTC Information
1. Install a scan tool.
2. Turn ON the ignition, with the engine OFF.
3. With a scan tool, observe the TCS Switch State
2 input parameter in the Body Control Module
(BCM) input data list.
Go to Diagnostic
Does the scan tool display Active? Go to Step 3 Aids
1. Turn OFF the ignition.
2. Disconnect the traction control switch.
3
4. With a scan tool, observe the TCS Switch State
input parameter.
Does the scan tool display Inactive? Go to Step 6 Go to Step 4

Test the traction control switch input/signal circuit for a
short to ground. Refer to Circuit Testing and Wiring
4
Repairs in Wiring Systems.
Did you find and correct the condition? Go to Step 9 Go to Step 5
Inspect for poor connections at the harness connector of
the BCM. Refer to Testing for Intermittent
5 Conditions and Poor Connections and Connector
the traction control switch. Refer to Testing for
6 Intermittent Conditions and Poor Connections and
Connector Repairs in Wiring Systems.
Replace the BCM. Refer to Control Module
7 References in Computer/Integrating Systems for
replacement, setup, and programming.
Did you complete the replacement? Go to Step 9 -
Replace the traction control switch. Refer to Traction
Control Switch Replacement in Instrument Panel,
8
Gages, and Console.
1. Use the scan tool in order to clear the DTCs.
2. Operate the vehicle within the Conditions for
9 Running the DTC, as specified in the supporting
text.
Does the DTC reset? Go to Step 2 System OK
DTC C0035-C0051
Circuit Description
As the wheel spins, the wheel speed sensor produces an AC signal. The electronic brake control module
(EBCM) uses the frequency of the AC signal to calculate the wheel speed.
DTC Descriptors
This diagnostic procedure supports the following DTCs:
DTC C0035 Left Front Wheel Speed Sensor Circuit

DTC C0036 Left Front Wheel Speed Sensor Circuit Range Performance
DTC C0040 Right Front Wheel Speed Sensor Circuit
DTC C0041 Right Front Wheel Speed Sensor Circuit Range Performance
DTC C0045 Left Rear Wheel Speed Sensor Circuit
DTC C0046 Left Rear Wheel Speed Sensor Circuit Range Performance
DTC C0050 Right Rear Wheel Speed Sensor Circuit
DTC C0051 Right Rear Wheel Speed Sensor Circuit Range Performance
C0035 C0040 C0045 C0050
The ignition is ON.
C0036 C0041 C0046 C0051
Vehicle speed is over 40 km/h (25 mph).

The brake pedal is not pressed.
The ABS is not active.
C0035 C0040 C0045 C0050
One of the following conditions exists for 0.02 seconds:
A short to voltage in the wheel speed sensor signal circuit

An open in the wheel speed sensor signal circuit
C0036 C0041 C0046 C0051
All of the following conditions exists for 0.01 seconds:
The suspect wheel speed equals zero.

The other wheel speeds are greater than 40 km/h (25 mph) for 0.01 seconds.
The suspect wheel equals zero during drive off, and the other wheels are greater than 18 km/h (11 mph).
A short to ground-the wheel speed sensor signal circuit is shorted to ground.
A deviation of 2 wheel speeds at either side of the vehicle greater than 6 km/h (4 mph), or at the front
axle greater than 10 km/h (6 mph) for a time period of 10-20 seconds.
The EBCM disables the ABS/traction control system (TCS) for the duration of the ignition cycle.
A DTC malfunction will set.
The ANTI-LOCK indicator turns ON.
The TRAC Off indicator turns ON.
The red BRAKE Warning indicator could turn ON.
The AWD disable indicator could turn ON, if equipped.
The condition for the DTC is no longer present and the DTC is cleared with a scan tool.
The EBCM automatically clears the history DTC when a current DTC is not detected in 100 consecutive
drive cycles.
Diagnostic Aids
C0035 C0040 C0045 C0050
If the customer comments that the ABS indicator is ON only during moist environmental conditions, such as
rain, snow, vehicle wash, etc., inspect the wheel speed sensor wiring for signs of water intrusion. If the DTC is
not current, clear all DTCs and simulate the effects of water intrusion by using the following procedure:
1. Spray the suspected area with a 5 percent saltwater solution. To create a 5 percent saltwater solution, add
2 teaspoons of salt to 354 ml (12 oz.) of water.
2. Test drive the vehicle over various road surfaces, such as bumps, turns, etc., above 40 km/h (25 mph) for
at least 30 seconds.
3. If the DTC returns, replace the suspected wheel speed sensor or repair the wheel speed sensor wiring.
4. Rinse the area thoroughly when completed.
C0036 C0041 C0046 C0051
Under the following conditions, 2 Wheel Speed Sensor Input is 0 DTCs are set:
The 2 suspect wheel speeds equal zero for 10-20 seconds.

The other wheel speeds are greater than 16 km/h (10 mph).
The other wheel speeds are within 11 km/h (7 mph) of each other.
Diagnose each wheel speed sensor individually.
C0036 C0041 C0046 C0051
A possible cause of this DTC is electrical noise on the wheel speed sensor harness wiring. Electrical noise could
result from the wheel speed sensor wires being routed too close to high energy ignition system components,
such as spark plug wires.
Test Description
3: This step tests the wheel speed sensor for the proper resistance value.
4: This step ensures that the wheel speed sensor generates the proper voltage.
DTC C0035-C0051
Step
Action Value(s) Yes No
Connector End View Reference: ABS Connector End Views
Did you perform the Diagnostic System Check - Go to
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
Go to Step 2 Information
2. Turn ON the ignition.
3. Set up the scan tool snap shot feature to
trigger for this DTC.
4. Drive the vehicle at a speed greater than
the specified value. 40 km/h (25
2
mph)
Does the scan tool indicate that this wheel speed Go to
DTC set? Go to Step 3 Diagnostic Aids
1. Raise and support the vehicle. Refer to
Lifting and Jacking the Vehicle in
General Information.
2. Disconnect the wheel speed sensor
connector. 800-1,600
3
3. Measure the resistance across the wheel ohms
speed sensor.
Does the resistance measure within the specified

range? Go to Step 4 Go to Step 8
1. Spin the wheel.
2. Measure the AC voltage across the wheel
4 speed sensor. 100 mV
Does the AC voltage measure greater than the

specified value? Go to Step 5 Go to Step 8
Inspect for poor connections at the harness
connector of the wheel speed sensor. Refer to
Testing for Intermittent Conditions and Poor
5 -
Connections and Connector Repairs in Wiring
Systems.
1. Disconnect the electronic brake control
module (EBCM) harness connector.
2. Install the J 39700 using. See Special
Tools. J 39700-530 to the EBCM harness
connector only.
3. Test the wheel speed sensor circuits for the
following:
6 An open -
A short to ground
A short to voltage
Shorted together
Refer to Testing for Intermittent Conditions

and Poor Connections and Wiring Repairs in
Wiring Systems.Did you find and correct the
condition? Go to Step 10 Go to Step 7
connector for the EBCM. Refer Testing for
7 Intermittent Conditions and Poor Connections -
and Connector Repairs in Wiring Systems.
Replace the wheel speed sensor. Refer to Wheel
Bearing/Hub Replacement - Front or Wheel
Bearing/Hub Replacement - Rear (Front
8 Wheel Drive/Drum) or Wheel Bearing/Hub -
Replacement - Rear (Disc and AWD) in Rear
Suspension.
Replace the EBCM. Refer to Control Module
References in Computer/Integrating Systems for
9 -
replacement, setup, and, programming.
Did you complete the repair? Go to Step 10 -
1. Use the scan tool in order to clear the
DTCs.
2. Operate the vehicle within the Conditions
10 for Running the DTC, as specified in the -
supporting text.
DTC C0060-C0095
Circuit Description
The inlet and outlet valve solenoid circuits are supplied with battery power, when the ignition is in the ON
position. The electronic brake control module (EBCM) controls the valve functions, by grounding the circuit
when necessary.
DTC Descriptors
DTC C0060 Left Front ABS Solenoid 1 Circuit Malfunction

DTC C0065 Left Front ABS Solenoid 2 Circuit Malfunction
DTC C0070 Right Front ABS Solenoid 1 Circuit Malfunction
DTC C0075 Right Front ABS Solenoid 2 Circuit Malfunction
DTC C0080 Left Rear ABS Solenoid 1 Circuit Malfunction
DTC C0085 Left Rear ABS Solenoid 2 Circuit Malfunction
DTC C0090 Right Rear ABS Solenoid 1 Circuit Malfunction
DTC C0095 Right Rear ABS Solenoid 2 Circuit Malfunction
The DTC can set anytime the ignition switch is in the ON position.
The DTC can set when the vehicle speed is greater then 6 km/h (4 mph) and the brake pedal is not
applied.
The DTC can set when the vehicle speed is greater then 15 km/h (9 mph) and the brake pedal is applied.
The DTC will set when the EBCM detects one of the following internal to the EBCM only:
An open in the solenoid coil or circuit

A short to ground in the solenoid coil or circuit
A short to voltage in the solenoid coil or circuit
The EBCM disables the ABS/traction control system (TCS)/dynamic rear proportion (DRP) for the
duration of the ignition cycle.
A malfunction DTC will set.
drive cycles.
Diagnostic Aids
The solenoid valve circuit and the solenoid coil are internal to the EBCM. No part of the solenoid circuit is
diagnosable external to the EBCM. The DTC sets when there is a malfunction in the solenoid circuit internal to
the EBCM only.
Test Description
The numbers below refer to the step numbers on the Diagnostic Table.
2: This step determines if the DTC is current

DTC C0060-C0095
Step Action Yes No
1
Vehicle in Vehicle
1. Using a scan tool clear the DTC.
2. Remove the scan tool from the DLC.
3. Carefully drive the vehicle above 15 km/h (9
mph) for several minutes.
4. Turn the ignition switch to the OFF position.
2
6. Turn the ignition switch to the ON position,
engine off.
7. Using the scan tool in Diagnostic Trouble Codes, Go to Testing for
check for DTCs. Intermittent
Conditions and
Did any one of the DTCs C0060-C0095 reset as a Poor Connections
current DTC? Go to Step 3 in Wiring Systems
Replace the electronic brake control module (EBCM).
Refer to Control Module References in
3 Computer/Integrating Systems for replacement, setup,
and programming.
Is the repair complete? Go to Step 4 -
4 Running the DTC, as specification in the
supporting text.
DTC C0110
Circuit Description
The pump motor is an integral part of the brake pressure modulator valve (BPMV), while the pump motor relay
is integral to the electronic brake control module (EBCM). The pump motor relay is not engaged during normal
system operation. When the ABS or traction control system (TCS) operation is required, the EBCM activates
the pump motor relay and battery power is provided to the pump motor.
DTC Descriptor
DTC C0110 Pump Motor Circuit Malfunction
The ignition switch is in the ON position.

The initialization is complete.
Pump motor voltage is not present 60 milliseconds after activation of the pump motor relay.
Pump motor voltage is present for more than 2.5 seconds with no activation of the pump motor relay.
Pump motor voltage is not present for 40 milliseconds after the pump motor relay is commanded off.
The EBCM disables the ABS/TCS for the duration of the ignition cycle.
drive cycles.
Diagnostic Aids
It is very important that a thorough inspection of the wiring and connectors be performed. Failure to
carefully and fully inspect wiring and connectors may result in misdiagnosis, causing part replacement
with reappearance of the malfunction.
Thoroughly inspect any circuitry that may be causing the complaint for the following conditions:
Backed out terminals
Improper mating
Broken locks
Improperly formed or damaged terminals
Poor terminal-to-wiring connections
Physical damage to the wiring harness

The following conditions may cause an intermittent malfunction:
A poor connection
Rubbed-through wire insulation
A broken wire inside the insulation
If an intermittent malfunction exists, refer to Testing for Intermittent Conditions and Poor
Connections in Wiring Systems.
Test Description
The number below refers to the step number on the diagnostic table.
3: Tests the pump motor circuits of the BPMV for a short to the housing of the BPMV. The wiring from
the BPMV to the EBCM should not be repaired.
DTC C0110
Step Action Value(s) Yes No
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
module (EBCM) harness connector.
2. Connect the J 39700 universal pinout box
using the . See Special Tools. J 39700-530
Cable Adapter to the EBCM harness
connector only.
3. Test both ground circuits of the EBCM,
including the EBCM ground, for a high
2 resistance, or an open. Refer to Circuit -
Testing and Wiring Repairs in Wiring
Systems.
4. Test the Battery Positive Voltage circuits
for an open, high resistance, or a short to
ground. Refer to Circuit Testing and
Wiring Repairs in Wiring Systems.

1. Disconnect the pump motor harness pigtail
connector of the brake pressure modulator
valve (BPMV).
2. Measure the resistance between each pump
motor control circuit and the housing of the
BPMV at the pump motor harness pigtail
3 connector of the BPMV. 5 ohms
Does the resistance measure less than the

Inspect for poor connections at the pump motor
harness pigtail connector of the BPMV. Refer to
4 -
Systems.
connector of the EBCM. Refer to Testing for
Intermittent Conditions and Poor
5 -
Connections , Connector Repairs and Wiring
Systems.
Replace the BPMV. Refer to Control Module
6 -
7 -
DTCs.
2. Operate the vehicle within the conditions
supporting text.
DTC C0121
Circuit Description
The solenoid valve relay supplies power to the solenoid valve coils in the electronic brake control module
(EBCM). The solenoid valve relay, located in the EBCM, is activated whenever the ignition switch is in the
RUN position, and no faults are present. The solenoid valve relay remains engaged, until the ignition is turned
OFF, or a failure is detected.
DTC Descriptor
DTC C0121 Valve Relay Circuit Malfunction
DTC C0121 will set anytime the solenoid valve relay is commanded on and the EBCM does not see
battery voltage at the solenoid valves.
DTC C0121 will set anytime the EBCM commands the solenoid valve relay off and battery voltage is still
present at the solenoid valves.
The EBCM disables the ABS/traction control system (TCS)/dynamic rear proportion (DRP) for the
duration of the ignition cycle.
A malfunction DTC is set.
drive cycles.
Diagnostic Aids
Thoroughly inspect any circuitry that may be causing the complaint, for the following conditions:
Improper mating
Broken locks

A poor connection
The solenoid valve relay is an integral part of the EBCM and is not serviced separately.
Test Description
2: This step determines if the DTC is current.
DTC C0121
Step Action Yes No
1
Vehicle in Vehicle
2 3. Use the scan tool in order to clear the DTCs.
Go to Diagnostic
Does the DTC reset? Go to Step 3 Aids
1. Connect the J 39700 Universal Pinout Box using
the . See Special Tools. J 39700-530 Cable
Adapter to the EBCM harness connector only.
2. Test the battery positive voltage circuit for an
3 open, high resistance, or a short to ground. Refer
to Circuit Testing andWiring Repairs in
Wiring Systems.

and programming.
Running the DTC, as specified in the supporting
5 text.
DTC C0141-C0156
Circuit Description
The isolation and prime valve solenoid circuits are supplied with battery power, when the ignition is in the ON
position. The electronic brake control module (EBCM) controls the valve functions, by grounding the circuit
when necessary.
DTC Descriptors
DTC C0141 Left Front TCS Solenoid 1 Circuit Malfunction

DTC C0146 Left Front TCS Solenoid 2 Circuit Malfunction
DTC C0151 Right Front TCS Solenoid 1 Circuit Malfunction
DTC C0156 Right Front TCS Solenoid 2 Circuit Malfunction

The DTC can be set after system initialization.
An open in the solenoid coil or circuit

A short to ground in the solenoid coil or circuit
A short to voltage in the solenoid coil or circuit
The EBCM disables the ABS/traction control system (TCS)/DRP for the duration of the ignition cycle.
Condition for DTC is no longer present and scan tool clear DTC function is used.
100 ignition cycles pass with no DTCs detected.
Diagnostic Aids
diagnosable, external to the EBCM. The DTC sets when there is a malfunction in the solenoid circuit, internal
to the EBCM only.
Test Description
2: This step determines if the DTC is current.
DTC C0141-C0156
Step Action Yes No
1
Vehicle in Vehicle
2
6. Turn the ignition switch to the ON position,
engine off.
7. Using the scan tool in Diagnostic Trouble Codes,
check for DTCs.
Did any one of the DTCs C0141-C0151 reset as a Go to Diagnostic

current DTC? Go to Step 3 Aids
and programming.
text.
DTC C0161
Circuit Description
The stop lamp switch is a normally open switch. When the brake pedal is depressed, the electronic brake control
module (EBCM) will sense battery voltage. This allows the EBCM to determine the state of the brake lamps.
The EBCM sources 5 volts on the stop lamp switch signal circuit, when the stop lamp switch is inactive. The
voltage is supplied a ground path through the stop lamp bulbs.
DTC Descriptor
DTC C0161 ABS/TCS Brake Switch Circuit Malfunction
The ignition switch is ON.
EBCM detects open in the brake signal circuit.

Both brake lamps are faulty.
The stop lamp switch input voltage is between 6.6-9 volts for 0.5 second.

The EBCM stores the information-only DTC, for as long as the condition is present.
The ABS remains functional.
The ABS indicator remains OFF.
The electronic brake control module (EBCM) automatically clears the history DTC when a current DTC
is not detected in 100 consecutive drive cycles.
Diagnostic Aids
Improper mating
Broken locks
Possible causes of this DTC are the following conditions:

A signal circuit of the stop lamp switch is open.
The stop lamp switch is misadjusted.
Verify proper stop lamp switch operation using the data list of the scan tool. As the brake is
applied, the data list displays the stop lamp switch ON, within 2.54 cm (1 in) of travel.
All brake lamps are open.
All brake lamp grounds are open.
Circuit has a wiring problem, terminal corrosion, or poor connections
Loose or corroded EBCM ground
Test Description
3: This DTC detects an open stop lamp switch signal circuit from the stop lamp side of the splice pack to
the EBCM.
4: The EBCM sources 5 volts on the stop lamp switch signal circuit. This small voltage has a ground path
through the stop lamp bulbs. This DTC sets if the path to ground is open.
DTC C0161
Step Action Yes No
Connector End View Reference: ABS Connector End Views or Lighting Systems Connector End
Views in Lighting Systems
1 Vehicle in Vehicle
1. Press the brake pedal.
2. With the scan tool, observe the Brake Switch
2 Status parameter in the ABS data list.
Does the Brake Switch Status parameter display

Applied? Go to Step 4 Go to Step 3
Test the signal circuit of the stop lamp switch for an
open. Refer to Circuit Testing and Wiring Repairs in
3
Wiring Systems.
Press the brake pedal. Go to Diagnostic
4
Are all of the stop lamps OFF? Go to Step 5 Aids
Test the feed circuit of the stop lamps for an open or
high resistance. Refer to Circuit Testing and Wiring
5
Test the ground circuit of the stop lamps for an open or
high resistance. Refer to Circuit Testing and Wiring
6
Repairs in Wiring Systems. Go to Diagnostic
Did you find and correct the condition? Go to Step 9 Aids
the electronic brake control module (EBCM). Refer to
7
Systems.
8
text.
DTC C0236
Circuit Description
The RPM signal circuit provides the electronic brake control module (EBCM) with an indication of engine
RPM to help determine traction control system (TCS) control methods and rates when a TCS event takes place.
DTC Descriptor
DTC C0236 TCS RPM Signal Circuit Malfunction
The ignition switch is ON and the engine running.

After 2 seconds starting, and if there is a undervoltage condition
The EBCM does not received an RPM input signal after one second, after the engine has been started.
A malfunction DTC is stored.

The TRAC OFF indicator is turned on.
The TCS is disabled. The ABS remains functional.
The condition for DTC is no longer present and the scan tool Clear DTCs function is used.
100 ignition cycles have passed with no DTCs detected.
Diagnostic Aids
Perform a thorough inspection of the wiring. Perform a thorough inspection of the connectors. Failure to
carefully and fully inspect the wiring and the connectors may result in misdiagnosis. Misdiagnosis causes part
replacement with reappearance of the malfunction.
Test Description
2: If the instrument panel tachometer is working properly, the cause of the malfunction is most likely
between the powertrain control module (PCM) and the EBCM, or the EBCM itself.
9: At this point, the PCM is likely causing the malfunction. Refer to the OBD system check.
DTC C0236
Connector End View Reference: ABS Connector End Views or Engine Controls Connector End
Views in Engine Controls - 3.6L
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
2. Vary the engine RPM with the throttle
while observing the instrument panel (I/P)
2 tachometer. -
Does the I/P tachometer work properly as the

engine RPM changes? Go to Step 3 Go to Step 9
1. Turn the ignition switch to the OFF
position.
2. Disconnect the powertrain control module
(PCM) connector C2 from the PCM.
module (EBCM) connector from the
EBCM.
3 4. Install the J 39700 Universal Pinout Box 0-5 ohms
with the . See Special Tools. J 39700-530
Cable Adapter to the EBCM harness only.
5. Use a J 39200 DMM to measure the
resistance between the PCM harness
connector tach signal circuit, and the
universal breakout box terminal 11.
Is the resistance within the specified range? Go to Step 4 Go to Step 10

Use a J 39200 DMM to measure the resistance
between the universal breakout box terminal 11
4 0L
and a good ground.
1. Turn the ignition switch to the ON position
2. Use a DMM to measure the voltage
5 between the universal breakout box 0-2 V
terminal 11 and a good ground.
Is the voltage within the specified range? Go to Step 6 Go to Step 12

1. Inspect the PCM connector C2 for the
following:
Damage
Poor terminal contact
Corrosion
2. Inspect the EBCM connector for the

following:
Damage
Corrosion
6 -
3. Ensure both the PCM connector C2 and the
EBCM connector are properly retained
when connected.
Are the following signs present on either

connector:
Is poor terminal contact present?

Is corrosion present?
Are damaged terminals present? Go to Step 13 Go to Step 7
1. Reconnect all the connectors.
2. Using the scan tool clear the DTC. Go to
Diagnostic
7 3. Disconnect the scan tool from the DLC. - System Check
4. Start the engine. - Vehicle in
Vehicle DTC
Did DTC C0236 reset? Go to Step 8 Information
8 -
Check the PCM. Refer to Diagnostic System
9 Check - Vehicle in Vehicle DTC Information. -
Repair an open between PCM and EBCM tach
signal circuit. Refer to Wiring Repairs in Wiring
10 -
Systems.
Repair a short to ground in tach signal circuit.
11 Refer to Wiring Repairs Wiring Systems. -
Repair a short to voltage in TACH signal circuit.
12 Refer to Wiring Repairs in Wiring Systems. -
Replace all terminals or replace connectors that
exhibit signs of the following:

Corrosion
13 -
Damaged terminals
Refer to Wiring Repairs in Wiring Systems.

DTCs.
supporting text.
Dose the DTC reset? Go to Step 2 System OK
DTC C0240
Circuit Description
The powertrain control module (PCM) monitors various parameters and will not allow traction control
operation if any parameter falls below a specified value.
DTC Descriptor
DTC C0240 Powertrain Control Module (PCM) Traction Control Not Allowed
The ignition is ON.
The PCM detects a malfunction and then causes traction control system (TCS) shut down, until the malfunction
has been corrected.
A DTC C0240 is stored.

The TCS is disabled.
If the TCS is again allowed to function, the indicator will be turned off, but the DTC will be stored.
The electronic brake control module (EBCM) automatically clears the history DTC, when a current DTC
is not detected in 100 consecutive drive cycles.
Test Description
4: This step checks if DTC C0240 resets.
DTC C0240
Step Action Yes No
1
Vehicle in Vehicle
1. Turn the ignition switch to the RUN position Go to Diagnostic
with the engine off. Trouble Code
2 2. Using a Scan Tool, read the ABS/TCS DTCs. (DTC) List -
Vehicle in Vehicle
Are any other DTCs set? DTC Information Go to Step 3
3 Is DTC C0240 set as a current code? Go to Step 5 Go to Step 4
1. Using the scan tool clear the DTC.
4 3. Carefully drive the vehicle above 12 km/h (8 Go to Diagnostic
mph) for several minutes. System Check -
Vehicle in Vehicle
Did DTC C0240 set as a current DTC? Go to Step 5 DTC Information
Perform the Powertrain OBD System Check. Refer to Go to Diagnostic
Diagnostic System Check - Vehicle in Vehicle DTC Trouble Code
5 Information. (DTC) List -
Did the vehicle pass the OBD System Check? Vehicle in Vehicle
Running the DTC as specified in the supporting
6 text.
Did the DTC reset? Go to Step 2 System OK
DTC C0241 OR P0856
Circuit Description
The electronic brake control module (EBCM) and the powertrain control module (PCM) simultaneously control
the traction control. The EBCM sends a Requested Torque message via a pulse width modulated (PWM) signal
to the PCM. The duty cycle of the signal is used to determine how much engine torque the EBCM is requesting
the PCM to deliver. Normal values are between 10-90 percent duty cycle. The signal should be at 90 percent
when traction control is not active and at lower values during traction control activations. The PCM supplies the
pull up voltage that the EBCM switches to ground, to create the signal.
DTC Descriptors
DTC C0241 PCM Indicated Requested Torque Malfunction

DTC P0856 Traction Control Torque Request Circuit
The ignition is ON.
The PCM diagnoses the requested torque PWM signal circuit and sends a class 2 serial data message to the
EBCM indicating a fault is present. A fault exists in the circuit if the PCM detects one of the following
conditions:
The requested torque PWM signal is less than 5 percent duty cycle or greater than 95 percent duty cycle.
The requested torque PWM signal is not present for 10 seconds.
The EBCM disables the traction control module (TCS) for the duration of the ignition cycle.

The condition for the DTC is no longer present, the DTC is not current, and you used the scan tool Clear
DTC function.
drive cycles.
Test Description
3: Use the scan tool in order to determine if the requested torque signal has a valid duty cycle.
4: Measure the requested torque signal in order to determine if the signal has a valid duty cycle.
5: Measure the requested torque signal in order to determine if the signal has a valid frequency.
11: This vehicle is equipped with a PCM which uses an electrically erasable programmable read only
memory (EEPROM). When replacing the PCM, the replacement PCM must be programmed.
DTC C0241 or P0856

Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
Inspect the electronic brake control module
(EBCM) ground and powertrain control module
(PCM) ground, making sure each ground is clean
2 and torqued to the proper specification. Refer to -
2. Start the engine. Go to Testing
3. With the scan tool, observe the Torque for
3 Request Signal parameter in the 100% Intermittent
Powertrain Control Module data list. Conditions and
Poor
Does the scan tool display less than the specified Connections in
value? Wiring Systems Go to Step 4
2. Disconnect the EBCM harness connector.
3. Install the J 39700 Universal Breakout
Box using the . See Special Tools. J
39700-530 Cable Adapter to the EBCM
harness connector and the EBCM
connector.
4 5-95%
5. Measure the DC duty cycle between the
requested torque signal circuit and a good
ground.
Is the duty cycle within the specified range? Go to Step 5 Go to Step 6

Measure the DC Hz between the requested
torque signal circuit and a good ground.
5 121-134 Hz
Does the frequency measure within the specified
2. Disconnect the cable adapter from the
EBCM connector.
IMPORTANT:
Disconnecting the EBCM connector and
turning ON the ignition could cause
other modules to set loss of
communication DTCs (Uxxxx). Once the
6 EBCM is reconnected, the EBCM may 4-6 V
set DTC C0241.
3. Turn ON the ignition, with the engine

OFF.
4. Measure the voltage from the requested
torque signal circuit to a good ground.
Does the voltage measure within the specified

2. Disconnect the PCM harness connector.
3. Test the requested torque signal circuit for
the following conditions:
7 A short to voltage -
A short to ground
Refer to Circuit Testing and Wiring Repairs in

3. Test the requested torque signal circuit for
8 An open -
A high resistance

connector of the PCM. Refer to Testing for
9 -
Systems.
10 -
Systems.
IMPORTANT:
The replacement PCM must be programmed.
11 Replace the PCM. Refer to Control Module -

replacement, setup, and programming.Did you
complete the repair? Go to Step 13 -
12 -
DTCs.
13 for Running the DTC as specified in the -
supporting text.
DTC C0244 OR P1689
Circuit Description
Traction Control is simultaneously controlled by the electronic brake control module (EBCM) and the
powertrain control module (PCM). The PCM sends a DELIVERED TORQUE message via a pulse width
modulated (PWM) signal to the EBCM confirming the delivered torque level for proper Traction Control
system operation. The EBCM supplies the pull up voltage.
DTC Descriptors
DTC C0244 Pulse Width Modulated (PWM) Delivered Torque

DTC P1689 Traction Control Delivered Torque Output Circuit

DTC C0244 can be set anytime when ignition voltage is present. A malfunction exists, if the PWM signal is out
of range, or no signal is received for a period of 2 seconds.

The traction control system (TCS) is disabled.
The TRAC OFF indicator is turned on. The ABS remains functional.
drive cycles.
Diagnostic Aids
If an intermittent malfunction exists, refer to Checking Aftermarket Accessories in Wiring Systems.
Possible causes for DTC C0244 to set:
An open in the torque delivered control circuit
Torque Delivered Control circuit shorted to ground or voltage

A communication frequency problem
A communication duty cycle problem
Torque delivered control circuit has a wiring problem, terminal corrosion, or poor connections
EBCM not receiving information from the PCM
Test Description
3: Use the scan tool in order to determine if the delivered torque signal has a valid duty cycle.
9: This vehicle is equipped with a PCM which uses an electrically erasable programmable read only
memory (EEPROM). When replacing the PCM, the replacement PCM must be programmed.
DTC C0244 or P1689

Vehicle? Diagnostic
System Check -
1 -
Vehicle in
Vehicle DTC
Inspect the electronic brake control module
(EBCM) ground and powertrain control module
(PCM) ground, making sure each ground is clean
2 and torqued to the proper specification. Refer to -
Go to Testing
2. Start the engine. for
3. With a scan tool, observe the PCM to Intermittent
3 EBTCM Delivered parameter in the 90%
Conditions and
Powertrain Control Module data list. Poor
Connections in
Does the scan tool display the specified value? Go to Step 4 Wiring Systems
3. Install the J 39700 Universal Breakout Box
using the . See Special Tools. J 39700-530
Cable Adapter to the EBCM harness
connector and the EBCM connector.
OFF.
4 6. Measure the voltage from the delivered B+
torque signal circuit to a good ground.
Does the voltage measure near the specified

value? Go to Step 5 Go to Step 6
2. Disconnect the cable adapter from the
EBCM connector.
5 OFF. -
4. Test the delivered torque signal circuit for
a short to voltage. Refer to Circuit Testing
and Wiring Repairs in Wiring Systems.

2. Disconnect the J 39700-530 from the
EBCM connector.
3. Test the delivered torque signal circuit for
An open
6 -
A short to ground
A high resistance
Refer to Circuit Testing and


Inspect for poor connections the harness
Inspect for poor connections the harness
andConnector Repairs in Wiring Systems.
IMPORTANT:
The replacement PCM must be programmed.
9 Replace the PCM. Refer to Control Module -

replacement, setup, and programming.Did you
complete the repair? Go to Step 11 -
10 -
DTCs.
supporting text.
DTC C0245
Circuit Description
The speed sensors used on the front of this vehicle are multiple pole and the rear uses a single pole magnetic
pickup. This sensor produces an AC signal that the electronic brake control module (EBCM) uses the frequency
from to calculate the wheel speed.
DTC Descriptor
DTC C0245 Wheel Speed Sensor Frequency Error

The EBCM detects a deviation between the left and right rear wheel speeds of greater than 6 km/h (3.75
mph) at a vehicle speed of less than 100 km/h (62 mph) on vehicles equipped with TCS.
The EBCM detects a deviation between the left and right front wheel speeds of greater than 10 km/h
(6.25 mph) at a vehicle speed of less than 100 km/h (62 mph).
The EBCM detects a deviation between the left and right rear wheel speeds of greater than 6 percent of
the vehicle speed at greater than 100 km/h (62 mph) on vehicles equipped with TCS.
The EBCM detects a deviation between the left and right front wheel speeds of greater than 4 km/h plus 6
percent of the vehicle speed at greater than 100 km/h (62 mph).
This DTC will set when the EBCM cannot specifically identify which wheel speed sensor is causing the
malfunction. If the EBCM can identify the specific wheel speed sensor causing the malfunction, DTC C0245
will become a history DTC, and the DTC associated with the sensor (DTC C0036, DTC C0041, DTC C0046,
DTC C0051, or DTC C0056) will be set concurrent with DTC C0245.
A malfunction DTC stores.

The ABS/traction control system (TCS) disables.
The amber ABS/TCS indicators turn ON.
The red BRAKE Warning indicator turn ON.
drive cycles.
Diagnostic Aids
Improper mating
Broken locks

A poor connection
If the customer's comments reflect that the amber ABS/TCS indicator is on only during moist
environmental conditions, such as rain, snow, or vehicle wash, inspect all the wheel speed sensor circuitry
for signs of water intrusion. If the DTC is not current, clear all DTCs and simulate the effects of water
intrusion by using the following procedure:
1. Spray the suspected area with a 5 percent saltwater solution.
Add 2 teaspoons of salt to 12 ounces of water to make a 5 percent saltwater solution.
2. Test drive the vehicle over various road surfaces, such as bumps, turns, etc., above 40 km/h (25
mph) for at least 30 seconds.
3. If the DTC returns, replace the suspected harness.
Test Description
2: If DTC C0245 is a history code, this step checks if a specific Wheel Speed Circuit Malfunction DTC is
set concurrently with DTC C0245.
7: This step checks if the wheel speed sensor harness is routed in close proximity to the spark plug wires.
9: In this step, if the scan tool can record any erroneous wheel speed sensor signals, diagnose those
sensors first.
DTC C0245
Step Action Yes No
1
Vehicle in Vehicle
Is the following DTCs set concurrently with a history
DTC C0245?
DTC C0036
2 DTC C0041 Go to Diagnostic
DTC C0046
Trouble Code
(DTC) List -
DTC C0051
Vehicle in Vehicle
DTC C0056 DTC Information Go to Step 3
Inspect the wheel speed sensor for physical damage.
3
Is physical damage of the wheel speed sensor evident? Go to Step 4 Go to Step 5
Replace the wheel speed sensor. Refer to Wheel Speed
Sensor Replacement - Front or Wheel Speed Sensor
4
Replacement - Rear.
Is the replacement complete? Go to Step 14 -
Inspect the jumper harness for physical damage.
5
Is physical damage of the jumper harness evident? Go to Step 6 Go to Step 7
Replace the jumper harness. Refer to Wheel Speed
Sensor Jumper Harness Replacement - Front or
6 Wheel Speed Sensor Jumper Harness Replacement
- Rear.
Check for proper routing of the wheel speed sensor
harness. Check that the wheel speed sensor harness is
7
routed away from the spark plug wires.
Is the wheel speed sensor harness properly routed? Go to Step 9 Go to Step 8
Reroute the wheel speed sensor harness away from the
8 spark plug wires.
Is the reroute complete? Go to Step 14 -
2. Turn the ignition switch to the RUN position.
3. Set the scan tool to Snap Shot Auto Trigger
mode and monitor the wheel speed sensors.
9
4. Carefully drive the vehicle above 40 Km/h (25
Did the scan tool trigger on any of the wheel speed

sensors? Go to Step 10 Go to Step 11
Note which wheel speed sensor triggered the scan tool.
Follow the appropriate wheel speed sensor malfunction
10 DTC table, for the wheel speed sensor that triggered.
Refer to DTC table.
1. Reconnect all previously disconnected
components.
11 3. Remove the scan tool from the DLC.
Does the DTC reset as a current DTC? Go to Step 13 Go to Step 12

The malfunction is intermittent. Inspect all connectors
and harnesses for damage that may result in an open or
high resistance when connected. Refer to Testing for
12
Intermittent Conditions and Poor Connections in
Wiring Systems.
Computer/Integrating Systems for replacement, setup,
13 and programming.
2. Operate the vehicle within the conditions for
14 running the DTC, as specified in the supporting
text.
DTC C0565
Circuit Description
The electronic brake control module (EBCM) learns the model it is installed in, by using the vehicle ID
information via the class 2 serial data line. Each time the vehicle is in the RUN position or the powertrain
control module (PCM) communicates this information via class 2, the EBCM internally compares the VIN
information with the information stored in digits 2 through 5 of the VIN. If digit 5 of the VIN is incorrect, the
EBCM will indicate a VIN information error is present.
DTC Descriptor
DTC C0565 Vehicle Identification Number (VIN) Information Error
The EBCM detects digit 5 of the VIN is incorrect.

The condition must occur when the ignition switch is first turned on.
The EBCM stores DTC C0565 in memory.
The EBCM recognizes digit 5 of the VIN as valid information.

A history DTC will clear after 100 consecutive ignition cycles, if the condition for the malfunction is no
longer present.
Diagnostic Aids
DTC C0565 is related to an internal VIN error in the EBCM. The VIN information is not removable from the
EBCM.
DTC C0565
Step Action Yes No
1
Vehicle in Vehicle
Are any other DTCs present besides C0565? Go to Diagnostic
Trouble Code
2 (DTC) List -
Vehicle in Vehicle
DTC Information Go to Step 3
Replace the electronic brake control module (EBCM)
with the correct module, and part number. Refer to
3 Control Module References in Computer/Integrating
Systems for replacement, setup, and programming.
text.
DTC C0896
Circuit Description
The electronic brake control module (EBCM) is required to operate within a specified range of voltage to
function properly. During ABS and traction control system (TCS) operation, there are current requirements that
will cause the voltage to drop. Because of this, voltage is monitored out of ABS/TCS control to indicate a good
charging system condition, and also during ABS/TCS control when voltage may drop significantly. The EBCM
also monitors for high voltage conditions which could damage the EBCM.
DTC Descriptor
DTC C0896 Device Voltage Range/Performance

The EBCM operating voltage falls below 9.4 volts out of ABS/TCS control, or 8.8 volts during ABS/TCS
control.
The EBCM operating voltage rises above 17.4 volts.
The low voltage or the high voltage is detected for more than 500 milliseconds with the vehicle speed
above 6 km/h (3.6 mph).

The ABS and the traction control indicators are turned ON.
The ABS/TCS is disabled.
The brake warning indicator turns ON.
drive cycles.
Diagnostic Aids
Improper mating
Broken locks

A poor connection
Connections in Wiring Systems for further diagnosis.
Test Description
2: This step checks if the voltage is above the maximum of the range.
4: This step checks if the voltage is below the minimum of the range.
6: This step checks for the integrity of the ground circuit.
DTC C0896
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
1. Turn all the accessories OFF.
4. Use the scan tool to monitor the battery
2 0-17.4 V
voltage while running the engine at
approximately 2,000 RPM.
Is the monitored battery voltage within the

specified range? Go to Step 4 Go to Step 3
Use a J 39200 DMM to measure the voltage Go to
between the battery positive terminal and ground. Symptoms -
Is the voltage within the specified range? Engine
3 0-17.4 V
Electrical in
Engine
Go to Step 5 Electrical
Continue to monitor the battery voltage with the
scan tool while running the engine at
4 approximately 2,000 RPM. 0-9.4 V
Is the monitored battery voltage within the
position.
Go to
2. Disconnect the scan tool if still connected. Diagnostic
5 3. Test drive the vehicle above 6 km/h (3.5 -
System Check
mph). - Vehicle in
Vehicle DTC
Did DTC C0896 reset? Go to Step 10 Information
position.
module (EBCM) connector.
3. Install the J 39700 with the . See Special
6 Tools. J 39700-530 to the EBCM harness 0-5 ohms
connector only.
4. Use a J 39200 DMM to measure the
resistance between the J 39700 terminal 15
and a good ground. See Special Tools.

Repair open or high resistance in the ground
circuit. Refer to Circuit Testing and Wiring
7 -
Repairs Wiring Repairs.
1. Turn the ignition switch to the RUN
position. Go to
2. Use a J 39200 DMM to measure the Symptoms -
8 voltage between the J 39700 terminal 8 Above 9.4 V Engine
and 15. See Special Tools. Electrical in
Engine
Is the voltage within the specified range? Go to Step 9 Electrical
position.
2. Reconnect the EBCM connector.
3. Disconnect the scan tool if the scan tool is
9 still connected. -
4. Test drive the vehicle above 6 km/h (3.5
mph).
Did DTC C0896 reset? Go to Step 10 Go to Step 11

10 -
DTCs.
supporting text.

SYMPTOMS - ANTILOCK BRAKE SYSTEM
IMPORTANT: The following steps must be completed before using the symptom tables.
1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC

Information before using the Symptom Tables in order to verify that all of
the following are true:
There are no DTCs set.
The control module(s) can communicate via the serial data link.
2. Review the system operation in order to familiarize yourself with the

system functions. Refer to ABS Description and Operation.
Visual/Physical Inspection
Inspect for aftermarket devices which could affect the operation of the antilock brake system. Refer to
Checking Aftermarket Accessories in Wiring Systems.
Inspect the easily accessible or visible system components for obvious damage or conditions which could
cause the symptom.
Inspect the master cylinder reservoir for the proper fluid level.
Intermittent
Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to Testing for
Intermittent Conditions and Poor Connections in Wiring Systems.
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom:
ABS Indicator Always On

ABS Indicator Inoperative
Low Traction Indicator Always On
Low Traction Indicator Inoperative
Traction Off Indicator Always On
Traction Off Indicator Inoperative
ABS INDICATOR ALWAYS ON
Circuit Description
The instrument panel cluster (IPC) turns the ABS Indicator on during the IPC bulb check for approximately 3
seconds when the ignition switch is turned to the ON position. If the electronic brake control module (EBCM)
sets a diagnostic trouble code (DTC), the EBCM sends a class 2 message to the IPC to command the ABS
Indicator ON.
Diagnostic Aids
Improper mating
Broken locks

A poor connection
If an intermittent malfunction exists, refer to Inducing Intermittent Fault Conditions in Wiring

Systems.
Test Description
2: Checks if the scan tool can turn on and off all the indicator lamps in the instrument cluster.
4: Checks if the circuits going to the instrument cluster or the cluster are at fault.
ABS Indicator Always On

Step Action Yes No
Connector End View Reference: ABS Connector End Views or Instrument Panel, Gages, and
Console Connector End Views
1
Vehicle in Vehicle
1. Using a scan tool, select the Instrument Panel
Cluster Special Functions mode.
2. Go to Lamp Test.
2
3. In the Lamp Test mode you can turn on or off
the instrument panel indicators.
All indicators will turn ON when commanded
on.
Does the ABS indicator turn on then off? Go to Step 3 Go to Step 4

Refer to Control Module References in Go to Diagnostic
3 Computer/Integrating Systems for replacement, setup, System Check -
and programming. Vehicle in Vehicle
Is the replacement complete? DTC Information -
1. Disconnect the instrument cluster and connect a
test light across the appropriate power and
ground terminals.
2. Test light OFF, repair open in power or ground
circuit to cluster.
3. Test light ON, check connector for poor
4 connection to cluster.
4. If OK, replace the instrument cluster. Refer to
Instrument Panel Cluster (IPC) Replacement
Go to Diagnostic
in Instrument Panel, Gages and Console. System Check -
Vehicle in Vehicle
Is the instrument cluster replacement complete? DTC Information -
ABS INDICATOR INOPERATIVE
Circuit Description
The instrument panel cluster (IPC) turns the ABS indicator on during the IPC bulb check, for approximately 3
seconds, when the ignition switch is turned to the ON position. If the electronic brake control module (EBCM)
sets a diagnostic trouble code (DTC), the EBCM sends a class 2 message to the IPC to command the ABS
Indicator ON.
Diagnostic Aids
Improper mating
Broken locks

A poor connection

Systems.
Test Description
4: Checks if the circuits going to the instrument Cluster or the cluster are at fault.
ABS Indicator Inoperative

Step Action Yes No
Console Connector End Views in Instrument Panel, Gages and Console
1
Vehicle in Vehicle
2. Go to Lamp Test.
2 the instrument panel indicators.

ON.
Does the ABS Indicator turn ON then OFF? Go to Step 3 Go to Step 4

ground terminals.
circuit to cluster.
3. Test light ON, check connector for poor
connection to the cluster.
4 4. If OK, replace the instrument cluster. Refer to
Instrument Panel Cluster (IPC) Replacement Go to Diagnostic
in Instrument Panel, Gages, and Console. System Check -
Vehicle in Vehicle
LOW TRACTION INDICATOR ALWAYS ON
Circuit Description
The instrument panel cluster (IPC) turns the LOW TRAC indicator on, during the IPC bulb check, for
approximately 3 seconds when the ignition switch is turned to the ON position. If the electronic brake control
module (EBCM) sets a diagnostic trouble code (DTC), the EBCM sends the IPC the command to turn the LOW
TRAC indicator ON.
Diagnostic Aids
Improper mating
Broken locks

A poor connection
If an intermittent malfunction exists refer to Inducing Intermittent Fault Conditions in Electrical

Diagnosis for further diagnosis.
Test Description
Low Traction Indicator Always On

Step Action Yes No
Console Connector End Views in Instrument Panel, Gages, and Console
1
Vehicle in Vehicle
2. Go to Lamp Test.
2 the instrument panel indicators.

on.
Does the LOW TRAC Indicator turn on, then off? Go to Step 3 Go to Step 4
ground terminals.
circuit to cluster
4 3. Test light ON, check connector for poor
connection to cluster.
Vehicle in Vehicle
LOW TRACTION INDICATOR INOPERATIVE
Circuit Description
The instrument panel cluster (IPC) turns the LOW TRAC indicator on during the IPC bulb check, for
approximately 3 seconds, when the ignition switch is turned to the ON position. If the electronic brake control
module (EBCM) sets a diagnostic trouble code (DTC), the EBCM sends the IPC the command to turn the LOW
TRAC indicator ON.
Diagnostic Aids
Improper mating
Broken locks

A poor connection
If an intermittent malfunction exists, refer to Inducing Intermittent Fault Conditions in Wiring System
for further diagnosis.
Test Description
2: Checks if the scan tool can turn ON and OFF all the indicator lamps in the instrument cluster.
Low Traction Indicator Inoperative

Step Action Yes No
Console Connector End Views in Instrument Panel, Gages, and Console
1
Vehicle in Vehicle
2. Go to Lamp Test in Output Control.
the instrument panel indicators.
2 All indicators will turn ON when commanded

on.
Does the LOW TRAC Indicator turn on, then off? Go to Step 3 Go to Step 4
ground terminals.
circuit to cluster.
4 3. Test light ON, check connector for poor
connection to the cluster.
Vehicle in Vehicle
TRACTION OFF INDICATOR ALWAYS ON
Circuit Description
The TRAC OFF indicator is controlled by the instrument cluster via class 2 serial data messages from the
electronic brake control module (EBCM). When the body control module (BCM) sees the traction control
switch input grounded through the momentary traction control switch, it sends a class 2 message to the
electronic brake control module (EBCM) that tells the EBCM that the traction control switch has been pressed.
The EBCM then disables traction control and sends a message to the instrument cluster to turn the TRAC OFF
indicator ON. Each time the ignition is cycled from OFF to ON, the traction control system is enabled.
The following conditions will cause the TRAC OFF indicator to illuminate:
The EBCM has disabled the traction control system (TCS) due to a DTC.
The driver manually disabling the TCS via the traction control switch.
The instrument cluster bulb check-When the ignition switch is turned to ON, the TRAC OFF indicator
will turn ON for approximately 3 seconds and then turn OFF.
Diagnostic Aids
Improper mating
Broken locks

A poor connection

Systems for further diagnosis.
Traction Off Indicator Always On

Step Action Yes No
Connector End Views in Computer/Integrating Systems
1
Vehicle in Vehicle
3. With a scan tool, observe the Traction Switch
2 parameter in the Body Control Module data
display, Inputs.

1. Activate the traction control switch. Go to Testing for
2. With the scan tool, observe the Traction Switch Intermittent
3 parameter. Conditions and
Poor Connections
Does the Traction Switch parameter change state? in Wiring Systems Go to Step 4
2. Disconnect the traction control switch connector.
4 parameter.
Does the scan tool display Inactive ? Go to Step 7 Go to Step 5

Test the signal circuit of the traction control switch for
a short to ground. Refer to and Testing for Short to
5
Ground in Wiring Systems.
Inspect for poor connections at the harness connector
of the body control module (BCM). Refer to Testing
6 for Intermittent Conditions and Poor Connections
of the traction control switch. Refer to Testing for
8 -
Did you complete the replacement? Go to Step 10
9 Control Switch Replacement. -
Operate the system in order to verify the repair.
10
Did you correct the condition? System OK Go to Step 2
TRACTION OFF INDICATOR INOPERATIVE
Circuit Description
electronic brake control module (EBCM). When the body control module (BCM) sees the traction control
switch input grounded through the momentary traction control switch, it sends a class 2 message to the EBCM
that tells the EBCM that the traction control switch has been pressed. The EBCM then disables the traction
control and sends a message to the instrument cluster to turn the TRAC OFF indicator ON. Each time the
ignition is cycled from OFF to ON, the traction control system is enabled.
The EBCM has disabled the traction control system (TCS) due to a DTC.
The instrument cluster bulb check-When the ignition switch is turned to ON, the TRAC OFF indicator
will turn ON for approximately 3 seconds and then turn OFF.
Diagnostic Aids
Improper mating
Broken locks

A poor connection
If an intermittent malfunction exists, refer Inducing Intermittent Fault Conditions in Wiring System
for further diagnosis.
Traction Off Indicator Inoperative

Step Action Yes No
Connector End Views in Computer/Integrating Systems
1
Vehicle in Vehicle
2 parameter in the Body Control Module data Go to Testing for
display, inputs. Intermittent
4. Activate the traction control switch. Conditions and
Poor Connections
Does the Traction Switch parameter change state? in Wiring Systems Go to Step 3
2. Disconnect the traction control switch connector.
3. Connect a fused jumper from the signal circuit
of the traction control switch harness connector
to a good ground.
3 5. With a scan tool, observe the Traction Switch
parameter.
Does the scan tool display Active? Go to Step 5 Go to Step 4

Test the signal circuit of the traction control switch for
an open or high resistance. Refer to Testing for
Test the ground circuit of the traction control switch
for an open or high resistance. Refer to Testing for
5
Continuity in Wiring Systems.
of the traction control switch. Refer to Testing for
8 -
9 Control Switch Replacement. -
10
REPAIR INSTRUCTIONS
ABS AUTOMATED BLEED PROCEDURE
CAUTION: Refer to Brake Fluid Irritant Caution in Cautions and Notices.
NOTE: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in
Cautions and Notices.
IMPORTANT: In most circumstances a base brake bleed is all that is required for most
component replacements (such as wheel cylinders, calipers, brake tubes, and
master cylinder) except for brake pressure modulator valve (BPMV)
replacement.
The following automated ABS bleed procedure is required when one of the following occur:
Manual bleeding at the wheel cylinders does not achieve the desired pedal height or feel.
BPMV replacement
Extreme loss of brake fluid has occurred.
Air ingestion is suspected.
If none of the above conditions apply, use standard bleed procedures. Refer to Hydraulic Brake System
Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes.
The auto bleed procedure is used on BOSH 5.3 equipped vehicles. This procedure uses a scan tool to cycle the
system solenoid valves and run the pump in order to purge the air from the secondary circuits. These secondary
circuits are normally closed off, and are only opened during system initialization at vehicle start up and during
ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped inside
the BPMV to flow out toward the wheel cylinders or calipers where it can be purged out of the system.
Automated Bleed Procedure
Preliminary Inspection
1. Inspect the battery for full charge, repair the battery and charging system, as necessary. Refer to
Diagnostic System Check - Vehicle in Vehicle DTC Information.
2. Connect a scan tool to the data link connector (DLC) and select current and history DTCs. Repair any
DTCs prior to performing the ABS bleed procedure.
3. Inspect for visual damage and leaks and repair, as needed.
Preliminary Setup
1. Raise and vehicle on a suitable support. Refer to Lifting and Jacking the Vehicle in General
Information.
3. Remove all 4 tires, if necessary. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
4. Connect the pressure bleeding tool according to the manufacturer's instructions.
5. Turn the ignition switch to RUN position, engine off.
6. Connect a scan tool and establish communications with the ABS system.
7. Pressurize the bleeding tool to 206-241 kPa (30-35 psi).
Performing the Automated Bleed Procedure
NOTE: The Auto Bleed Procedure may be terminated at any time during the
process by pressing the EXIT button. No further Scan Tool prompts
pertaining to the Auto Bleed procedure will be given. After exiting the
bleed procedure, relieve bleed pressure and disconnect bleed equipment
per manufacturers instructions. Failure to properly relieve pressure may
result in spilled brake fluid causing damage to components and painted
surfaces.
1. With the pressure bleeding tool at 206-241 kPa (30-35 psi), and all bleeder screws in closed position,
select Automated Bleed Procedure on the scan tool and follow the instructions.
2. The first part of the automated bleed procedure will cycle the pump and front release valves for one
minute. After the cycling has stopped the scan tool will enter a cool down mode and display a 3 minute
timer. The auto bleed will not continue until this timer expired, and cannot be overridden.
3. During the next step, the scan tool will request the technician to open one of the bleeder screws. The scan
tool will then cycle the respective release valve and pump motor for one minute.
4. The scan tool will repeat step 3 for the remaining bleeder screws.
5. With the bleeder tool still attached to the vehicle and maintaining 241 kPa (35 psi), the scan tool will
instruct the technician to independently open each bleeder screw for approximately 20 seconds. This
should allow any remaining air to be purged from the brake lines.
6. When the automated bleed procedure is completed the scan tool will display the appropriate message.
7. Install all 4 tires, if necessary refer to Tire and Wheel Removal and Installation in Tires and Wheels.
8. Remove pressure from the pressure bleeding tool and then disconnect the tool from the vehicle.
9. Depress the brake pedal to gage pedal height and feel. Repeat steps 1-8 until the pedal is acceptable.
10. Remove the scan tool from the DLC connector.
11. Install.
12. Lower the vehicle.
13. Inspect the brake fluid level in master cylinder.
14. Road test the vehicle while making sure the brake pedal remains high and firm.
If the vehicle is equipped with a traction control system (TCS), the scan tool will cycle both the ABS and the
TCS solenoid valves. This bleed procedure is the same as above.
ELECTRONIC BRAKE CONTROL MODULE REPLACEMENT
Removal Procedure

NOTE: Always connect or disconnect the wiring harness connector from the
EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe
this precaution could result in damage to the EBCM/EBTCM.

2. Remove the air cleaner housing from the engine compartment. Refer to Air Cleaner Assembly
Replacement in Engine Controls.
Fig. 8: Identifying EBCM Harness Connector
3. Disconnect the electronic brake control module (EBCM) harness connector.

4. Brush off any dirt/debris that has accumulated on the assembly.
5. Disconnect the pump motor connector (3) at the bottom of the EBCM.
IMPORTANT: Do not damage the seal by prying the EBCM from the brake pressure
modulator valve (BPMV).
Do not damage the solenoid valves while removing the EBCM from
the BPMV.
Fig. 9: View Of EBCM To BPMV Screws

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

Fig. 10: Separating/Installing EBCM From BPMV
7. Separate the EBCM from the BPMV by gently pulling apart until separated (1).
Installation Procedure
IMPORTANT: Use only new wave springs and screws supplied with the new EBCM.
Fig. 11: Separating/Installing EBCM From BPMV
1. Clean the BPMV surface with alcohol using a clean towel.

2. Install the EBCM (1) to the BPMV.
NOTE: Refer to Fastener Notice in Cautions and Notices.
3. Install the 6 screws that attach the EBCM to the BPMV.
Tighten:
Tighten the top 4 mounting screws to 5 N.m (44 lb in). Tighten screws in an X pattern.
Tighten the bottom 2 mounting screws to 5 N.m (44 lb in).
Connect the pump motor connector to the bottom of the EBCM.

4. Connect the EBCM harness connector and depress the locking tab (1) to secure.
5. Install the air cleaner housing. Refer to Air Cleaner Assembly Replacement in Engine Controls.
6. Turn the ignition switch to the RUN position, do not start engine.
7. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information.
BRAKE PRESSURE MODULATOR VALVE (BPMV) REPLACEMENT

Removal Procedure
CAUTION: For safety reasons, the Brake Pressure Modulator Valve (BPMV) must not
be repaired; the complete unit must be replaced. With the exception of the
EBCM/EBTCM, no screws may be loosened. If screws are loosened, it will
not be possible to get the brake circuits leak-tight and personal injury may
result.

2. Remove the attaching bolts for the cruise control module, if equipped.
3. Swing the cruise control module off to the side, if equipped.
4. Remove the air cleaner housing from the engine compartment. Refer to Air Cleaner Assembly
Replacement in Engine Controls.
5. Disconnect the electronic brake control module (EBCM) harness connector (1).
6. Disconnect the EBCM to brake pressure modulator valve (BPMV) connector.
Fig. 14: Identifying Wheel Brake Pipes To BPMV

IMPORTANT: Note the locations of the brake pipes in order to aid in installation.
7. Disconnect the 4 wheel brake pipes from the BPMV.

8. Swing the 4 wheel brake pipes out of the way only after covering the open pipes to avoid dripping or
being contaminated.
Fig. 15: Master Cylinder Brake Pipes To BPMV
9. Disconnect the master cylinder brake pipes from the BPMV.

10. Loosen the brake pipes but do not remove the brake pipes from the master cylinder.
11. Swing the 2 master cylinder brake pipes out of the way only after covering the open pipes to avoid
dripping or being contaminated.
Fig. 16: Locating BPMV Mounting Bracket Nuts
12. Remove the 2 lower BPMV mounting bracket nuts (2) from the inner wheel housing mount surface of the
strut tower.
13. Loosen the top BPMV mounting nut.
14. Remove the BPMV mounting bracket and the EBCM assembly from the vehicle by sliding up and toward
the engine to separate from the wheelhouse slot.
Fig. 17: Identifying BPMV Mounting Bracket Hardware
NOTE: When removing the brake pressure modulator valve, protect the vehicle
exterior from possible brake fluid spillage. Brake fluid can cause damage
to painted surfaces.
15. Remove the 2 bolts (1) that connect the BPMV to the mounting bracket (2).
16. Remove the EBCM if replacing the BPMV only. Refer to Electronic Brake Control Module
Replacement.
Fig. 18: Identifying BPMV Mounting Bracket Hardware
1. Install EBCM onto the BPMV (1) if replacing the BPMV only. Refer to Electronic Brake Control
Module Replacement.
2. Install BPMV and EBCM as an assembly to the mounting bracket.
3. Install the 2 bolts (1) that connects the BPMV assembly to the mounting bracket (2).
Tighten: Tighten the bolts to 10 N.m (84 lb in).
Fig. 19: Locating BPMV Mounting Bracket Nuts

4. Install the BPMV bracket to the strut tower.
5. Install the 3 nuts (2) that attach the BPMV mounting bracket to the strut tower.
Tighten:
Tighten the nuts to 10 N.m (89 lb in).
Reposition any lines or hoses that were moved out of place.

Fig. 20: Master Cylinder Brake Pipes To BPMV
CAUTION: Make sure brake pipes are correctly connected to brake pressure
modulator valve. If brake pipes are switched by mistake, wheel
lockup will occur and personal injury may result. The only two ways
this condition can be detected are by using a Scan Tool or by doing
an Antilock stop.
IMPORTANT: If a new BPMV is being installed, remove the shipping plugs from the
valve openings during the next few steps when ready.
6. Install the master cylinder brake pipes into the BPMV.
Tighten: Tighten the fittings to 24 N.m (18 lb ft).

Fig. 21: Identifying Wheel Brake Pipes To BPMV
7. Install the 4 wheel brake pipes on the BPMV.
8. Connect the EBCM to BPMV connector.

9. Connect the EBCM harness connector.

10. Reinstall the air cleaner housing. Refer to Air Cleaner Assembly Replacement in Engine Controls.
11. Reinstall the cruise control module, if equipped.
12. When all procedures have been completed, the automated ABS bleed procedure is required. Refer to ABS
Automated Bleed Procedure.
WHEEL SPEED SENSOR REPLACEMENT - FRONT
Removal Procedure
Fig. 23: Front Wheel Speed Sensor Jumper Harness Electrical Connector
IMPORTANT: The front wheel speed sensors and rings are integral with the hub and
bearing assemblies.
If a speed sensor or a ring needs replacement, replace the entire hub and
bearing assembly. Do not service the harness pigtail individually because
the harness pigtail is part of the sensor. Refer to Wheel Bearing/Hub
Replacement - Front in Front Suspension.
1. Raise and support the vehicle on a suitable hoist. Refer to Lifting and Jacking the Vehicle in General
Information.
2. Remove the front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
3. Remove the front wheel speed sensor jumper harness electrical connector (1) from the front wheel speed
sensor connector (3).
Fig. 24: Hub & Bearing Assembly - Front

4. Remove the hub and bearing assembly (2). Refer to Wheel Bearing/Hub Replacement - Front in Front
Suspension.
Fig. 25: Hub & Bearing Assembly - Front
1. Install the hub and bearing assembly (2) to the vehicle. Refer to Wheel Bearing/Hub Replacement -
Front in Front Suspension.
Fig. 26: Front Wheel Speed Sensor Jumper Harness Electrical Connector
2. Install the front wheel speed sensor jumper harness electrical connector (1) to front wheel speed sensor
connector (3).
3. Install the wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
5. Turn the ignition switch to the RUN position with the engine off.
WHEEL SPEED SENSOR REPLACEMENT - REAR
Removal Procedure
Fig. 27: View Of Wheel Speed Sensor Components
IMPORTANT: The rear wheel speed sensors and rings are integral with the hub and
bearing assemblies.
If a speed sensor or a ring needs replacement, replace the entire hub and
bearing assembly. Refer to Wheel Bearing/Hub Replacement - Rear (Front
Wheel Drive/Drum) or Wheel Bearing/Hub Replacement - Rear (Disc and
AWD) in Rear Suspension.
Information.
2. Remove the rear tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
3. Remove the rear wheel speed sensor electrical connector located next to the rear strut.
Fig. 28: Installing Hub & Bearing Assembly - Rear

4. Remove the hub and bearing assembly (1). Refer to Wheel Bearing/Hub Replacement - Rear (Front
Wheel Drive/Drum) or Wheel Bearing/Hub Replacement - Rear (Disc and AWD) in Rear
Suspension.
Fig. 29: Installing Hub & Bearing Assembly - Rear
1. Install the hub and bearing assembly (1) to the vehicle. Refer to Wheel Bearing/Hub Replacement -
Rear (Front Wheel Drive/Drum) or Wheel Bearing/Hub Replacement - Rear (Disc and AWD) in
Rear Suspension.
Fig. 30: View Of Wheel Speed Sensor Components
2. Install the rear wheel speed sensor electrical connector.

3. Install the wheel and tire assembly. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
WHEEL SPEED SENSOR JUMPER HARNESS REPLACEMENT - FRONT

Removal Procedure
Fig. 31: Identifying Front Wheel Speed Sensor Jumper Harness To ABS Harness Connector
1. Disconnect the front wheel speed sensor jumper harness to ABS harness connector (8).
Information.
3. Remove the harness (4) from the splash shield retaining clip (5).
4. Remove the harness (4) from the control arm retaining clips (3).
Fig. 32: View Of Wheel Speed Sensor, Connector And Harness
5. Disconnect the front wheel speed jumper harness connector (2) from the front wheel sensor.
6. Remove the front wheel speed sensor jumper harness (1).
Fig. 33: View Of Wheel Speed Sensor, Connector And Harness
1. Connect the front wheel speed sensor jumper harness connector (2) to the wheel speed sensor.
Fig. 34: Identifying Front Wheel Speed Sensor Jumper Harness To ABS Harness Connector
2. Install the harness (4) to control arm retaining clips (3).

3. Install the harness (4) to splash shield retaining clip (5).
5. Connect the front wheel speed sensor jumper harness to ABS harness connector (8).
6. Turn the ignition switch to the RUN position, with the engine off.
7. Perform the diagnostic system check. Refer to Diagnostic System Check - Vehicle in Vehicle DTC
Information.
WHEEL SPEED SENSOR JUMPER HARNESS REPLACEMENT - REAR

Removal Procedure
Fig. 35: Locating Rear Wheel Speed Sensor Jumper Harness Retaining Clips
Information.
2. Disconnect the rear wheel speed jumper harness connector at the pass thru connector.
3. Remove the rear wheel speed sensor jumper harness (1) from the retaining clips (2).
4. Disconnect the rear wheel speed sensor jumper harness connector (1) from the wheel speed sensor,
located next to the rear strut (2).
5. Remove the rear wheel speed sensor jumper harness.
1. Connect the rear wheel speed sensor jumper harness connector (1) to the wheel speed sensor, located next
to the rear strut (2).
Fig. 38: Locating Rear Wheel Speed Sensor Jumper Harness Retaining Clips
2. Install the rear wheel speed jumper harness (1) into the retaining clips (2).
3. Connect the rear wheel speed sensor jumper harness connector to the pass thru connector.
6. Perform the diagnostic system check. Refer to Diagnostic System Check - Vehicle in Vehicle DTC
Information.
TRACTION CONTROL SWITCH REPLACEMENT
Removal Procedure
Fig. 39: View Of Instrument Panel Accessory Trim Plate
1. Remove the instrument panel accessory trim plate. Refer to Trim Plate Replacement - Instrument
Panel (I/P) Accessory in Instrument Panel, Gages and Console.
Fig. 40: Removing/Installing Traction Control Switch Bolts/Screws
2. Remove the bolts/screws from the switch bank to instrument panel.

3. Pull straight out from the instrument panel in order to remove the switch bank from the instrument panel.
Fig. 41: Identifying Traction Control Switch Electrical Connectors
4. Disconnect the electrical connectors.
Fig. 42: Identifying Traction Control Switch Electrical Connectors
1. Connect the electrical connectors.

2. Push in on the switch bank in order to install the switch bank.
Fig. 43: Removing/Installing Traction Control Switch Bolts/Screws
3. Install the bolts/screws to the switch bank to instrument panel.
Tighten: Tighten the bolts/screws to 2.5 N.m (22 lb in).

Fig. 44: View Of Instrument Panel Accessory Trim Plate
4. Install the instrument panel accessory trim plate. Refer to Trim Plate Replacement - Instrument Panel
(I/P) Accessory in Instrument Panel, Gages and Console.
DESCRIPTION AND OPERATION

ABS DESCRIPTION AND OPERATION
Fig. 45: BPMV and EBCM
Fig. 46: BPMV Hydraulic Flow
Callouts For Fig. 46

1 Master Cylinder
2 Master Cylinder Reservoir
3 Pump
4 Left Front Master Cylinder Isolation Valve
5 Left Front Prime Valve
6 Brake Pressure Modulator Valve (BPMV)
7 Damper
8 Right Rear Inlet Valve
9 Accumulator
10 Right Rear Brake
11 Right Rear Outlet Valve
12 Left Front Outlet Valve
13 Left Front Brake
14 Left Front Inlet Valve
15 Left Rear Inlet Valve
16 Left Rear Brake
17 Left Rear Outlet Valve
18 Right Front Brake
19 Right Front Outlet Valve
20 Accumulator
21 Right Front Inlet Valve
22 Damper
23 Right Front Master Cylinder Isolation Valve
24 Right Front Prime Valve
This vehicle is equipped with the Bosch 5.3 antilock braking system.
The vehicle is equipped with the following braking systems:
Antilock Brake System (ABS)

Dynamic Rear Proportioning (DRP)
Traction Control System (TCS) (w/NW9)
The following components are involved in the operation of the above systems:
Electronic Brake Control Module (EBCM) - The EBCM controls the system functions and detects
failures.
The EBCM contains the following components:
System Relay - The system relay is energized when the ignition is ON and no ABS DTCs are
present. It supplies battery positive voltage to the solenoid valves and pump motor.
Vent Tube - The vent tube, located in the EBCM connector, is an opening to the internal cavity of
the EBCM. It allows ventilation of the EBCM internals.
Brake Pressure Modulator Valve (BPMV) - The BPMV contains the hydraulic valves and pump motor
that are controlled electrically by the EBCM. The BPMV uses a 4 circuit configuration with a diagonal
split. The BPMV directs fluid from the reservoir of the master cylinder to the left front and right rear
wheels and fluid from the other reservoir to the right front and left rear wheels. The diagonal circuits are
hydraulically isolated so that a leak or malfunction in one circuit will allow continued braking ability on
the other.
IMPORTANT: There is a rubber isolator located under the BPMV and on the mounting
studs. The rubber isolators protect the BPMV and the EBCM from vehicle
vibrations.
The BPMV contains the following components:
Pump Motor
Inlet Valves (one per wheel)
Outlet Valves (one per wheel)
Master Cylinder Isolation Valves (w/NW9) (one per drive wheel)
Prime Valves (w/NW9) (one per drive wheel)
Wheel Speed Sensors (WSS) - As the wheel spins, the wheel speed sensor produces an AC signal. The
EBCM uses this AC signal to calculate wheel speed. The wheel speed sensors are replaceable only as part
of the wheel hub and bearing assemblies.
Traction Control Switch (w/NW9) - The TCS is manually disabled or enabled using the traction control
switch.
Stoplamp Switch - The EBCM uses the stoplamp switch as an indication that the brake pedal is applied.
Initialization Sequence
The EBCM performs one initialization test each ignition cycle. The initialization of the EBCM occurs when one
set of the following conditions occur:
Both of the following conditions occur:
The EBCM receives that there is a minimum of 500 rpm from the PCM via class 2 serial data message.
The stoplamp switch is not applied.
OR
Both of the following conditions occur:
The vehicle speed is greater than 16 km/h (10 mph).

The stoplamp switch is applied.
The initialization sequence may also be commanded with a scan tool.
The initialization sequence cycles each solenoid valve and the pump motor (as well as the necessary relays) for
approximately 1.5 seconds to check component operation. The EBCM sets a DTC if any error is detected. The
initialization sequence may be heard and felt while it is taking place, and is considered part of normal system
operation.
The EBCM defines a drive cycle as the completion of the initialization sequence.
Antilock Brake System
When wheel slip is detected during a brake application, the ABS enters antilock mode. During antilock braking,
hydraulic pressure in the individual wheel circuits is controlled to prevent any wheel from slipping. A separate
hydraulic line and specific solenoid valves are provided for each wheel. The ABS can decrease, hold, or
increase hydraulic pressure to each wheel brake. The ABS cannot, however, increase hydraulic pressure above
the amount which is transmitted by the master cylinder during braking.
During antilock braking, a series of rapid pulsations is felt in the brake pedal. These pulsations are caused by
the rapid changes in position of the individual solenoid valves as the EBCM responds to wheel speed sensor
inputs and attempts to prevent wheel slip. These pedal pulsations are present only during antilock braking and
stop when normal braking is resumed or when the vehicle comes to a stop. A ticking or popping noise may also
be heard as the solenoid valves cycle rapidly. During antilock braking on dry pavement, intermittent chirping
noises may be heard as the tires approach slipping. These noises and pedal pulsations are considered normal
during antilock operation.
Vehicles equipped with ABS may be stopped by applying normal force to the brake pedal. Brake pedal
operation during normal braking is no different than that of previous non-ABS systems. Maintaining a constant
force on the brake pedal provides the shortest stopping distance while maintaining vehicle stability.
Pressure Hold
The EBCM closes the inlet valve and keeps the outlet valve closed in order to isolate the system when wheel
slip occurs. This holds the pressure steady on the brake so that the hydraulic pressure does not increase or
decrease.
Pressure Decrease
The EBCM decreases the pressure to individual wheels during a deceleration when wheel slip occurs. The inlet
valve is closed and the outlet valve is opened. The excess fluid is stored in the accumulator until the return
pump can return the fluid to the master cylinder.
Pressure Increase
The EBCM increases the pressure to individual wheels during a deceleration in order to reduce the speed of the
wheel. The inlet valve is opened and the outlet valve is closed. The increased pressure is delivered from the
master cylinder.
The dynamic rear proportioning (DRP) is a control system that replaces the hydraulic proportioning function of
the mechanical proportioning valve in the base brake system. The DRP control system is part of the operation
software in the EBCM. The DRP uses active control with existing ABS in order to regulate the vehicle's rear
brake pressure.
The red brake warning indicator is illuminated when the dynamic rear proportioning function is disabled.
Traction Control System (TCS) (NW9)
When drive wheel slip is noted while the brake is not applied, the EBCM will enter traction control mode.
First, the EBCM requests the PCM to reduce the amount of torque to the drive wheels via the requested torque
signal circuit. The PCM reduces torque to the drive wheels by retarding spark timing and turning off fuel
injectors. The PCM reports the amount torque delivered to the drive wheels via the delivered torque signal
circuit.
If the engine torque reduction does not eliminate drive wheel slip, the EBCM will actively apply the drive
wheel brakes. During traction control braking, hydraulic pressure in each drive wheel circuit is controlled to
prevent the drive wheels from slipping. The master cylinder isolation valve closes in order to isolate the master
cylinder from the rest of the hydraulic system. The prime valve then opens in order to allow the pump to
accumulate brake fluid in order to build hydraulic pressure for braking. The drive wheel inlet and outlet
solenoid valves then open and close in order to perform the following functions:
Pressure hold
Pressure increase
Pressure decrease
ABS Indicator
The IPC illuminates the ABS indicator when the following occurs:
The electronic brake control module (EBCM) detects a malfunction with the antilock brake system. The
IPC receives a class 2 message from the EBCM requesting illumination.
The IPC performs the displays test at the start of each ignition cycle. The indicator illuminates for
approximately 3 seconds.
The IPC sends a class 2 message to the radio for audible warning when this indicator is on.
Brake System Indicator(s)
Brake Warning Indicator
The IPC illuminates the brake indicator when the following occurs:
The body control module (BCM) detects that the park brake is engaged. The IPC receives a class 2
message from the BCM requesting illumination. If the vehicle is shifted out of park with the park brake
engaged and a class 2 message is received indicating that the vehicle speed is greater than 3 MPH, the
BCM sends a class 2 message to the radio in order to activate the audible warning.
Low Brake Fluid Indicator
The IPC illuminates the low brake fluid indicator in the message center when the IPC receives a low signal
from the low brake fluid switch. The IPC sends a class 2 message to the radio in order to activate an audible
warning.
Traction Control System Indicator(s)
Service Traction System
The IPC illuminates the Service Traction System indicator in the message center when the electronic brake
control module (EBCM) detects a malfunction in the traction control system. The IPC receives a class 2
message from the EBCM requesting illumination.
The IPC sends a class 2 message to the radio in order to activate an audible warning.
Traction Active
The IPC illuminates the Traction Active indicator in the message center when the electronic brake control
module (EBCM) detects a traction control event. The IPC receives a class 2 message from the EBCM
requesting illumination.
Trac Off
The IPC illuminates the TRAC OFF indicator when:
The electronic brake control module (EBCM) inhibits the traction control system. The IPC receives a
class 2 message from the EBCM requesting illumination.
SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS
Special Tools
Illustration Tool Number/ Description
J 39200
Digital Multimeter
J 39700
Universal Pinout Box
J 39700-530
Cable Adapter
Tech 2 Scan Tool

Automatic Transaxle - Troubleshooting - 4T65-E - Aztek & Rendezvous
TROUBLESHOOTING
SYMPTOMS - AUTOMATIC TRANSMISSION
Symptoms - Automatic Transmission

Diagnostic Category Diagnostic Information
DEFINITION: This table consists of eight diagnostic categories that are located in the left-hand column.
Using this column, choose the appropriate category based on the operating conditions of the vehicle or
transmission. After selecting a category, use the right-hand column to locate the specific symptom
diagnostic information.
Fluid Diagnosis: Refer to Transmission Fluid Checking
This category contains the following topics: Procedure.
Refer to Incorrect Line Pressure.
Fluid condition - appearance, contaminants,
smell, overheating Refer to Automatic Transmission Fluid
Leaks.
Line pressure - high or low
Refer to Fluid Leak Diagnosis.
Fluid leaks
Noise and Vibration Diagnosis: Refer to Whine Noise Varying with RPM
This category contains the following topics: or Fluid Pressure.
Refer to Popping Noise.
Noise - drive gear, final drive, whine, growl,
hum, rattle, buzz, popping Refer to Buzz Noise or High Frequency
Rattle Sound.
Torque converter diagnosis
Refer to Whine/Growl Noise That Changes
Noise and vibration analysis
with Vehicle Speed.
Refer to Final Drive Noise or Hum Noise.
Refer to Noise in First, Second, Third, or

Fourth.
Refer to Noise in Random Ranges.
Refer to Abnormal Noise in Park or

Neutral Range.
Refer to Torque Converter Diagnosis
Procedure.
Refer to Noise and Vibration Analysis.
Range Performance Diagnosis: Refer to No Park Range.

This category contains the following topics:
Refer to Slips in Reverse or No Reverse.
No Park Refer to Slips in Drive or No Drive.
No Reverse or slips Refer to Locked Up in Drive/Reverse.

No Drive or slips Refer to No Engine Braking in Manual
No engine braking Second or Low Range.
Range selector displays incorrect range Refer to Range Selector Displays Incorrect
Range (3.4L) or Range Selector Displays
Incorrect Range (3.6L).
Shift Quality (Feel) Diagnosis: Refer to Harsh or Soft 1-2 Shift Feel.
Refer to Harsh or Soft 2-3/3-2 Shift Feel.
Harsh shifts Refer to Harsh or Soft 3-4/4-3 Shift Feel.
Soft shifts Refer to Harsh Park to Reverse/Drive
Engagement.
Harsh engagement, garage shifts
Refer to Delayed Park to Reverse/Drive
Delayed engagement, garage shifts
Engagement.
Slipping or Missing Gears: Refer to Slipping or No First Gear.
Refer to Slipping or No Second Gear.
No upshift Refer to Slipping or No Third Gear.
Slipping or missing gears Refer to Slipping or No Fourth Gear.
One forward gear only Refer to First Gear Only.
Two forward gears only Refer to Second Gear Only.
Non-First gear start Refer to Third Gear Only.
Refer to Fourth Gear Only.
Refer to First and Second Gear Only (2-3

Solenoid Stuck On).
Refer to First and Fourth Gear Only (1-2
Solenoid Stuck On).
Refer to Second and Third Gear Only (1-2
Solenoid Stuck Off).
Refer to Third and Fourth Gear Only (2-3
Solenoid Stuck Off).
Shift Speed Diagnosis: Refer to High or Low Upshift or Downshift
This category contains the following topic: Speed.
Incorrect shift points
Torque Converter Diagnosis: Refer to Torque Converter Diagnosis
This category contains the following topics: Procedure.
Refer to No Torque Converter Clutch
Torque converter diagnosis
(TCC) Apply.
TCC does not apply
Refer to Converter Clutch Stuck On in All
TCC does not release Gears.
TCC shudder Refer to Converter Clutch Stuck On in
Second, Third and Fourth Gear.
Refer to Harsh Torque Converter Clutch
(TCC) Apply or Release.
Refer to Converter Clutch Apply Rough,
Slips, or Shudders.
Symptom Can Not Be Duplicated or Symptom Refer to Transmission Fluid Checking
Not Found: Procedure.
Refer to Road Test Procedure.
Transmission fluid diagnosis Refer to Line Pressure Check Procedure.
Road testing
Line pressure diagnosis
RANGE SELECTOR DISPLAYS INCORRECT RANGE (3.4L)
Fig. 1: Transmission Internal Mode Switch (IMS) Schematic (3.4L)

Circuit Description
The transmission internal mode switch (IMS) is a sliding contact switch attached to the selector detent inside
the transmission side cover. The 4 inputs to the PCM indicate the position of the transmission range selector.
The input voltage level at the PCM is high, B+, when the IMS is open and low when the switch is closed to
ground. The 4 input parameters represented are Signals A, B, C and P, Parity. Refer to Transmission Internal
Mode Switch Logic .
Test Description
2: HI values for all signals in all ranges indicates the ground circuit is OPEN.
3: With the 20-way connector disconnected, all signals should indicate HI.
5: If a circuit affects the other, this indicates a short between the 2 circuits.
11: This step tests the internal transmission harness. If no fault is found in the harness, the fault will be in
the switch.
Range Selector Displays Incorrect Range (3.4L)

OFF.
3. Select IMS on the scan tool.
1 4. Place the range selector in each -
transmission range: P, R, N, D4, D3, D2 Go to
and D1. Intermittent
Conditions in
Does each range selected match the scan tool Engine Controls
IMS display? - 3.4L Go to Step 2
1. Select IMS A/B/C/P on the scan tool.
2. Place the range selector in each
transmission range: P, R, N, D4, D3, D2
2 and D1. HI/HI/HI/HI
Does the IMS A/B/C/P display the specified

values for each range? Go to Step 12 Go to Step 3
2. Disconnect the AT Inline 20-way
connector. Additional DTCs may set.
3 -
OFF.
Do the scan tool IMS A/B/C/P signals all
indicate HI?
Go to Step 4 Go to Step 8
2. Install the J 44152 jumper harness on the
engine side of the AT Inline 20-way
connector.Special Tools .
OFF.
4. Using the J 39200 digital multimeter
(DMM) and the J 35616 GM terminal test
kit, measure the voltage at the TR signal A
circuit of the J 44152 .Special Tools .
Refer to Automatic Transmission Inline

4 20-Way Connector End View (3.4L) or -
Automatic Transmission Inline 20-Way
Connector End View (3.6L) .
5. Measure the voltage at the TR signal B

6. Measure the voltage at the TR signal C
7. Measure the voltage at the TR signal P
Does the voltage measure ignition voltage at all

four terminals? Go to Step 5 Go to Step 9
Connect a fused jumper wire from the TR signal
A circuit of the J 44152 to ground while
monitoring the scan tool IMS A/B/C/P
parameter.Special Tools .
Refer to Automatic Transmission Inline 20-
5 -
Way Connector End View (3.4L) or
When the TR signal A circuit is grounded, do
any other signal circuits indicate LOW? Go to Step 10 Go to Step 6
B circuit of the J 44152 to ground while
6 -
When the TR signal B circuit is grounded, do
C circuit of the J 44152 to ground while
7 -
When the TR signal C circuit is grounded, do
Test the the TR signal circuits of the IMS that
did not indicate HI for a short to ground between
the PCM and the AT Inline 20-way connector.
8 -
Refer to Testing for Short to Ground and
did not indicate ignition voltage for an open
between the PCM and the AT Inline 20-way
9 connector. -
Refer to Testing for Continuity and Wiring
Test the affected the TR signal circuits of the
IMS for a shorted together condition between the
PCM and the AT Inline 20-way connector.
10 -
Wiring Systems.
Test the the TR signal circuits of the IMS for an
open or shorted condition between the AT Inline
11 20-way connector and the IMS. -
Refer to Circuit Testing in Wiring Systems.
Did you find the condition? Go to Step 14 Go to Step 15
Test the ground circuit of the IMS for an open
between the AT Inline 20-way connector and the
ground connection to the chassis.
12 -
13 between the AT Inline 20-way connector and the -
IMS.
Refer to Testing for Continuity in Wiring
Systems.
Replace the automatic transmission wiring
harness assembly.
14 - -
Refer to Wiring Harness Replacement .
Replace the lever assembly-manual shaft detent
with internal mode switch.
Refer to Manual Shift Shaft Position (Internal
15 - -
Mode) Switch and Parking System Components
Removal in Transmission Unit Repair Manual.
Replace the PCM.
16 Computer/Integrating Systems for replacement, - -
set-up and programming.
OFF.
2. With the scan tool, observe the IMS
17 display while selecting each transmission -
range: P, R, N, D4, D3, D2, and D1.
Does each selected transmission range match the

scan tool IMS display? System OK Go to Step 1
RANGE SELECTOR DISPLAYS INCORRECT RANGE (3.6L)

Fig. 2: Transmission Internal Mode Switch (IMS) Schematic (3.6L)
Circuit Description
The transmission internal mode switch (IMS) is a sliding contact switch attached to the selector detent inside
the transmission side cover. The 4 inputs to the TCM indicate the position of the transmission range selector.
The input voltage level at the TCM is high, B+, when the IMS is open and low when the switch is closed to
ground. The 4 input parameters represented are Signals A, B, C and P, Parity. Refer to Transmission Internal
Mode Switch Logic .
Test Description
2: HI values for all signals in all ranges indicates the ground circuit is OPEN.
3: With the 20-way connector disconnected, all signals should indicate HI.
5: If a circuit affects the other, this indicates a short between the 2 circuits.
11: This step tests the internal transmission harness. If no fault is found in the harness, the fault will be in
the switch.
Range Selector Displays Incorrect Range (3.6L)

OFF.
3. Select IMS on the scan tool.
1 4. Place the range selector in each -
transmission range: P, R, N, D4, D3, D2 Go to
and D1. Intermittent
Conditions in
Does each range selected match the scan tool Engine Controls
IMS display? - 3.6L Go to Step 2
2. Place the range selector in each
transmission range: P, R, N, D4, D3, D2
2 and D1. HI/HI/HI/HI
Does the IMS A/B/C/P display the specified

values for each range? Go to Step 12 Go to Step 3
2. Disconnect the AT Inline 20-way
connector. Additional DTCs may set.
3 OFF. -
Do the scan tool IMS A/B/C/P signals all

indicate HI? Go to Step 4 Go to Step 8
2. Install the J 44152 jumper harness on the
engine side of the AT Inline 20-way
connector.Special Tools .
OFF.
4. Using the J 39200 digital multimeter
(DMM) and the J 35616 GM terminal test
kit, measure the voltage at the TR signal A
circuit of theJ 44152 .Special Tools .
Refer to Automatic Transmission Inline
20-Way Connector End View (3.4L) or
5. Measure the voltage at the TR signal B

4 -
6. Measure the voltage at the TR signal C
7. Measure the voltage at the TR signal P
Does the voltage measure ignition voltage at all

four terminals? Go to Step 5 Go to Step 9
A circuit of the J 44152 to ground while
5 -
When the TR signal A circuit is grounded, do
B circuit of the J 44152 to ground while
6 -
When the TR signal B circuit is grounded, do
C circuit of the J 44152 to ground while
7 -
When the TR signal C circuit is grounded, do
did not indicate HI for a short to ground between
the TCM and the AT Inline 20-way connector.
Refer to Testing for Short to Ground
8 -
andWiring Repairs in Wiring Systems.
did not indicate ignition voltage for an open
between the TCM and the AT Inline 20-way
9 connector. -
Refer to Testing for Continuity andWiring
Test the affected the TR signal circuits of the
IMS for a shorted together condition between the
TCM and the AT Inline 20-way connector.
10 -
Wiring Systems.
Test the the TR signal circuits of the IMS for an
open or shorted condition between the AT Inline
11 20-way connector and the IMS. -
ground connection to the chassis.
12 -
Refer to Testing for Continuity andWiring
IMS.
13 -
Refer to Testing for Continuity in Wiring
Systems.
Replace the automatic transmission wiring
harness assembly.
14 - -
Refer to Wiring Harness Replacement .
Replace the lever assembly-manual shaft detent
with internal mode switch.
Refer to Manual Shift Shaft Position (Internal
15 - -
Mode) Switch and Parking System Components
Removal in Transmission Unit Repair Manual.
Replace the TCM.
Computer/Integrating Systems for replacement,
16 set-up and programming. - -
OFF.
2. With the scan tool, observe the IMS
17 display while selecting each transmission -
range: P, R, N, D4, D3, D2, and D1.
Does each selected transmission range match the

scan tool IMS display? System OK Go to Step 1
TRANSMISSION FLUID CHECKING PROCEDURE
Transmission Fluid Checking Procedure

1. Start the engine and allow the engine to
idle until the transmission has reached the
value specified.
2. Depress the brake pedal and move the shift 82-93C
1
lever through the gear ranges, pausing a (180-200F)
few seconds in each gear.
Is the fluid red or light brown? Go to Step 4 Go to Step 2

Does the fluid have a burnt odor or a dark brown
2 -
color? Go to Step 11 Go to Step 3
Does the fluid have a cloudy or milky
3 -
appearance? Go to Step 10 Go to Step 4
Check the fluid level. The vehicle must be level,
with the engine running and the shift lever in the
PARK range. Check both sides of the fluid level
4 -
indicator, and read the lower level. The proper
fluid level should be in the middle of the X-hatch.
Is the fluid level too high? Go to Step 9 Go to Step 5
5 Is the fluid level low? - Go to Step 6 System OK
Add DEXRON III automatic transmission fluid
in increments of 0.5 L (0.5 qt) until the fluid is in
the middle of the X-hatch. Check both sides of
6 -
the fluid level indicator, and read the lower level.
Did you add more than 1.5 L (1.6 qt) to the
transmission? Go to Step 7 Go to Step 9
Check for external leaks. Refer to Fluid Leak
7 Diagnosis. -
Did you find any leaks? Go to Step 8 Go to Step 15
Correct the leak condition.
8 - -
Did you correct the leak condition? Go to Step 15
Remove any excess fluid to the proper level, the
9 middle of the X-hatch. - -
Is the fluid level satisfactory? System OK
The transmission is contaminated with engine
coolant.
10 - -
Replace the cooler.
Is the replacement complete? Go to Step 12
IMPORTANT:
Transmission fluid may turn dark with
normal use. This does not always
indicate oxidation or contamination.
1. Drain the fluid to determine if the fluid is

contaminated. Refer to Oil Pan
11 Replacement . -
2. A very small amount of material in the
bottom pan is a normal condition, but large
pieces of metal or other material in the
bottom pan require a transmission
overhaul.
Was the fluid contaminated? Go to Step 12 Go to Step 13

Perform root cause and repair as necessary.
12 - -
Is the repair complete? Go to Step 13
Flush the cooler. Refer to Automatic
Transmission Oil Cooler Flushing and Flow
13 Test (J35944-A) or Automatic Transmission - -
Oil Cooler Flushing and Flow Test (J45096).
Has the cooler been flushed? Go to Step 14
Change the fluid and the filter. Refer to Oil Filter
14 and Seal Replacement . - -
Is the procedure complete? Go to Step 15
Add new fluid to the proper level, in the middle
15 of the X-hatch. - -
Is the procedure complete? System OK
LINE PRESSURE CHECK PROCEDURE
Tools Required
J 21867 Pressure Gage
IMPORTANT: Before performing a line pressure check, verify that the pressure
control (PC) solenoid valve is receiving the correct electrical signal
from the PCM.
Some conditions may be intermittent, therefore this test should be
performed at least 3 times.
CAUTION: Keep the brakes applied at all times in order to prevent unexpected
vehicle motion. Personal injury may result if the vehicle moves
unexpectedly.
2. Start the engine and set the parking brake.

3. Check for a stored Diagnostic Trouble Code (DTC).
4. Repair the vehicle, if necessary.
5. Check the fluid level. Refer to the Transmission Fluid Checking Procedure.
6. Check the manual linkage for proper adjustment.
Fig. 3: Checking Line Pressure
7. Turn the engine Off. Remove the oil pressure test hole plug and install the J 21867 .
8. Put the gear selector in PARK range and set the parking brake.
9. Start the engine and allow the engine to warm up at idle.
NOTE: The total test running time should not be longer than 2 minutes. Running
the test longer than 2 minutes may damage the transaxle.
10. Access the PC solenoid valve control test on the scan tool.
11. Increase the PC solenoid actual current from 0 to 1 amps in 0.1 amp increments. Allow the pressure to
stabilize for five seconds after each pressure change. Read the corresponding line pressure on the J
21867 .
12. Refer to the Line Pressure specification table. Compare the data to the table.
13. If pressure readings differ greatly from the table, refer to Incorrect Line Pressure.
14. Shut the engine OFF. Remove the J 21867 .
15. Apply sealant GM P/N 12345382 (Canadian P/N 1095348) to the oil pressure test hole plug.
16. Install the oil pressure test hole plug.
Tighten: Tighten the plug to 12 N.m (106 lb in).
ROAD TEST PROCEDURE
The following test provides a method of evaluating the condition of the automatic transmission. The test is
structured so that most driving conditions would be achieved. The test is divided into the following parts:
Electrical Function Check

Upshift Control and Torque Converter Clutch (TCC) Apply
Part Throttle Detent Downshifts
Full Throttle Detent Downshifts
Manual Downshifts
Coasting Downshifts
Manual Gear Range Selection
REVERSE
Manual FIRST
Manual SECOND
Manual THIRD
IMPORTANT: Complete the test in the sequence given. Incomplete testing cannot guarantee
an accurate evaluation.
Before the road test, ensure the following:
The engine is performing properly.

Transmission fluid level is correct. Refer to the Transmission Fluid Checking Procedure.
Tire pressure is correct.
During the road test:
Perform the test only when traffic conditions permit.

Operate the vehicle in a controlled, safe manner.
Observe all traffic regulations.
View the scan tool data while conducting this test.
Take along qualified help in order to operate the vehicle safely.
Observe any unusual sounds or smells.
After the road test, check the following:
Transmission fluid level. Refer to the Transmission Fluid Checking Procedure.

Diagnostic Trouble Codes (DTCs) that may have set during the testing. Refer to the applicable DTC.
Scan tool data for any abnormal readings or data.
Electrical Function Check
Perform this check first, in order to ensure the electronic transmission components are connected and
functioning properly. If these components are not checked, a simple electrical condition could be mis-
diagnosed.
1. Connect the scan tool.

2. Ensure the gear selector is in PARK and set the parking brake.
4. Verify that the following scan tool data can be obtained and is functioning properly.
Refer to Scan Tool Data List (3.4L) or Scan Tool Data List (3.6L) for typical data values. Data that is
questionable may indicate a concern.
Engine Speed
Transmission input speed (turbine)
Transmission output speed
Vehicle speed
TFP manual valve position switch
Transmission range
Commanded gear (current gear)
PC solenoid reference current
PC solenoid actual current
PC solenoid duty cycle
Brake switch
Engine coolant temperature
Transmission fluid temperature
Throttle angle
Ignition voltage
1-2 shift solenoid
2-3 shift solenoid
TCC solenoid duty cycle
TCC slip speed
5. Monitor the brake switch signal while depressing and releasing the brake pedal. The scan tool should
display:
Closed when the brake pedal is released.
Open when the brake pedal is depressed.
6. Check the garage shifts.

1. Apply the brake pedal and ensure the parking brake is set.
2. Move the gear selector through the following ranges:
1. PARK to REVERSE
2. REVERSE to NEUTRAL
3. NEUTRAL to DRIVE
3. Pause 2 to 3 seconds in each gear position.
4. Verify the gear engagements are immediate and not harsh.
IMPORTANT: Harsh engagement may be caused by any of the following

conditions:
High idle speed. Compare engine idle speed to desired idle
speed.
Commanded low PC solenoid current. Compare PC solenoid
reference current to PC solenoid actual current.
A default condition caused by certain DTCs that result in
maximum line pressure to prevent slippage.
Soft or delayed engagement may be caused by any of the following
conditions:
Low idle speed. Compare engine idle speed to desired idle
speed.
Low fluid level.
Commanded high PC solenoid current. Compare PC solenoid

reference current to PC solenoid actual current.
Cold transmission fluid. Check for low transmission fluid
temperature.
7. Monitor transmission range on the scan tool.

2. Move the gear selector through all ranges.
3. Pause 2 to 3 seconds in each range.
4. Return gear selector to PARK.
5. Verify that all selector positions match the scan tool display.
8. Check throttle angle input.
2. Ensure the gear selector is in PARK.
3. Monitor throttle angle while increasing and decreasing engine speed with the throttle pedal. The
scan tool throttle angle should increase and decrease with engine speed.
If any of the above checks do not perform properly, record the result for reference after completion of the road
test.
Upshift Control and Torque Converter Clutch (TCC) Apply
The PCM calculates the upshift points based primarily on two inputs: throttle angle and vehicle speed. When
the PCM determines that conditions are met for a shift to occur, the PCM commands the shift by closing or
opening the ground circuit for the appropriate solenoid.
Perform the following steps:
1. Refer to the Shift Speed table and choose a throttle position of 12 percent, 25 percent or 50 percent. All
throttle angles shown should be tested to cover the normal driving range.
2. Monitor the following scan tool parameters:
Throttle angle
Vehicle speed
Engine speed
Commanded gear
Slip speed
Solenoid states
3. Place the gear selector in the OVERDRIVE position.

4. Accelerate the vehicle using the chosen throttle angle. Hold the throttle steady.
5. As the transmission upshifts, note the vehicle speed when the shift occurs for each gear change. There
should be a noticeable shift feel or engine speed change within 1 to 2 seconds of the commanded gear
change.
6. Compare the shift speeds to the Shift Speed table. Refer to Shift Speed . Shift speeds may vary slightly
due to transmission fluid temperature or hydraulic delays in responding to electronic controls.
Note any harsh, soft or delayed shifts or slipping.
Note any noise or vibration.
7. Repeat steps 1 through 6 to complete all throttle angles.
IMPORTANT: This transmission is equipped with an electronically controlled capacity

clutch (ECCC). The pressure plate does not fully lock to the torque
converter cover. Apply pressure on the clutch plate is controlled to
maintain a small amount of slippage (about 20 RPM) in SECOND, THIRD
and FOURTH gears, depending on the vehicle application. ECCC was
developed to reduce the possibility of noise, vibration or chuggle caused
by TCC apply. Typical apply speeds are 49-52 km/h (30-32 mph) in THIRD
gear and 65-73 km/h (40-45 mph) in FOURTH gear. Full lockup is available
at highway speeds on some applications.
IMPORTANT: The TCC will not engage until the engine is in closed loop operation and
the vehicle speed is as shown in the Shift Speed table. Refer to Shift
Speed . The vehicle must be in a near-cruise condition, not accelerating or
coasting, and on a level road surface.
8. Check for TCC apply in THIRD and FOURTH gear.

Note the TCC apply point. When the TCC applies there should be a noticeable drop in engine speed
and a drop in slip speed to below 100 RPM. If the TCC apply can not be detected:
Check for DTCs
Refer to Torque Converter Diagnosis Procedure
Refer to the Shift Speed table for the correct TCC apply speeds.
Lightly tap and release the brake pedal. The TCC will release on most applications.
Part Throttle Detent Downshift

2. Accelerate the vehicle to 64-88 km/h (40-55 mph) in FOURTH gear.
3. Quickly increase throttle angle to greater than 50 percent.
4. Verify the following:
The TCC releases
The transmission downshifts immediately to THIRD gear
Full Throttle Detent Downshift

2. Accelerate the vehicle to speeds of 64-88 km/h (40-55 mph) in FOURTH gear.
3. Quickly increase throttle angle to 100 percent (WOT).
The TCC releases
The transmission downshifts immediately to SECOND gear
Manual Downshifts
The shift solenoid valves do not control the 4-3 manual downshift. The 4-3 manual downshift is hydraulic. The
3-2 and 2-1 manual downshifts are electronic. The solenoid states will change during, or shortly after a 4-3
downshift is selected.
Manual 4-3 Downshift

2. Accelerate the vehicle to 64-88 km/h (40-55 mph) in FOURTH gear.
3. Release the throttle while moving the gear selector to THIRD.
The TCC releases
The transmission downshifts immediately to THIRD gear
The engine slows the vehicle

2. Accelerate the vehicle to 64-72 km/h (40-45 mph).
3. Release the throttle while moving the gear selector to SECOND.
The TCC releases
The transmission downshifts immediately to SECOND gear
The engine slows the vehicle

2. Accelerate the vehicle to 64 km/h (40 mph).
3. Release the throttle while moving the gear selector to FIRST.
The TCC releases
The transmission downshifts immediately to SECOND Gear.
The engine slows the vehicle.
The transmission downshifts to FIRST gear at the calibrated speed, typically 48-64 km/h (30-40
mph).
Coasting Downshifts

2. Accelerate the vehicle to FOURTH gear with the TCC applied.
3. Release the throttle and lightly apply the brakes.
The TCC releases
Downshifts occur at speeds shown in the Shift Speed table. Refer to Shift Speed .
Manual Gear Range Selection
The shift solenoids control the upshifts in the manual gear ranges.
Perform the following tests using 10-15 percent throttle angle.
Reverse
1. With the vehicle stopped, move the gear selector to REVERSE.

2. Slowly accelerate the vehicle.
3. Verify that there is no noticeable slip, noise or vibration.
Manual First
1. With the vehicle stopped, move the gear selector to FIRST.

No upshifts occur
The TCC does not apply
There is no noticeable slip, noise, or vibration
Manual Second
1. With the vehicle stopped, move the gear selector to SECOND.

The 1-2 shift occurs
The 2-3 shift does not occur
Manual Third
1. With the vehicle stopped, move the gear selector to THIRD.

TORQUE CONVERTER DIAGNOSIS PROCEDURE
IMPORTANT: Before replacing the torque converter, refer to Torque Converter Replacement
Guide.
The torque converter clutch (TCC) is applied by fluid pressure, which is controlled by a PWM solenoid valve.
This solenoid valve is located inside of the automatic transmission assembly. The solenoid valve is controlled
through a combination of computer controlled switches and sensors.
Torque Converter Stator
The torque converter stator roller clutch can have two different malfunctions.
The stator assembly freewheels in both directions.

The stator assembly remains locked up at all times.
Poor Acceleration at Low Speed
If the stator is freewheeling at all times, the car tends to have poor acceleration from a standstill. At speeds
above 50-55 km/h (30-35 mph), the car may act normally. For poor acceleration, you should first determine that
the exhaust system is not blocked, and the transmission is in First gear when starting out.
If the engine freely accelerates to high RPM in NEUTRAL, you can assume that the engine and the exhaust
system are normal. Check for poor performance in DRIVE and REVERSE to help determine if the stator is
freewheeling at all times.
Poor Acceleration at High Speed
If the stator is locked up at all times, performance is normal when accelerating from a standstill. Engine RPM
and car speed are limited or restricted at high speeds. Visual examination of the converter may reveal a blue
color from overheating.
If the converter has been removed, you can check the stator roller clutch by inserting a finger into the splined
inner race of the roller clutch and trying to turn the race in both directions. You should be able to freely turn the
inner race clockwise, but you should have difficulty in moving the inner race counterclockwise or you may be
unable to move the race at all.
Noise
IMPORTANT: Do not confuse this noise with pump whine noise, which is usually noticeable
in PARK, NEUTRAL and all other gear ranges. Pump whine will vary with line
pressure.
You may notice a torque converter whine when the vehicle is stopped and the transmission is in DRIVE or
REVERSE. This noise will increase as you increase the engine RPM. The noise will stop when the vehicle is
moving or when you apply the torque converter clutch, 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 your foot on the brake.
2. Put the gear selector in DRIVE.
NOTE: You may damage the transmission if you depress the accelerator for more
than 6 seconds.
3. Depress the accelerator to approximately 1,200 RPM for no more than 6 seconds.
A torque converter noise will increase under this load.
Torque Converter Clutch Shudder
The key to diagnosing torque converter clutch (TCC) shudder is to note when it happens and under what
conditions.
TCC shudder which is caused by the transmission should only occur during the apply or the release of the
converter clutch. Shudder should never occur after the TCC plate is fully applied.
If the shudder occurs while the TCC is applying, the problem can be within the transmission or the torque
converter. Something is causing one of the following conditions to occur:
Something is not allowing the clutch to become fully engaged.

Something is not allowing the clutch to release.
The clutch is releasing and applying at the same time.
One of the following conditions may be causing the problem to occur:
Leaking turbine shaft seals

A restricted release orifice
A distorted clutch or housing surface due to long converter bolts
Defective friction material on the TCC plate
If Shudder Occurs After TCC has Applied
If shudder occurs after the TCC has applied, most of the time there is nothing wrong with the transmission.
As mentioned above, the TCC is not likely to slip after the TCC has been applied. Engine problems may go
unnoticed under light throttle and load, but they become noticeable after the TCC apply when going up a hill or
accelerating. This is due to the mechanical coupling between the engine and the transmission.
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 in order to avoid misdiagnosis of TCC shudder. An inspection will also avoid
the unnecessary disassembly of a transmission or the unnecessary replacement of a torque converter
Spark plugs - Inspect for cracks, high resistance or a broken insulator.
Plug wires - Look in each end. If there is red dust (ozone) or a black substance (carbon) present, then the
wires are bad. Also look for a white discoloration of the wire. This indicates arcing during hard
acceleration.
Coil - Look for a black discoloration on the bottom of the coil. This indicates arcing while the engine is
misfiring.
Fuel injector - The filter may be plugged.
Vacuum leak - The engine will not get a correct amount of fuel. The mixture may run rich or lean
depending on where the leak occurs.
EGR valve - The valve may let in too much or too little unburnable exhaust gas and could cause the
engine to run rich or lean.
MAP/MAF sensor - Like a vacuum leak, the engine will not get the correct amount of fuel for proper
engine operation.
Carbon on the intake valves - Carbon restricts the proper flow of air/fuel mixture into the cylinders.
Flat cam - Valves do not open enough to let the proper fuel/air mixture into the cylinders.
Oxygen sensor - This sensor may command the engine too rich or too lean for too long.
Fuel pressure - This may be too low.
Engine mounts - Vibration of the mounts can be multiplied by TCC engagement.
Axle joints - Check for vibration.
TP Sensor - The TCC apply and release depends on the TP Sensor in many engines. If the TP Sensor is
out of specification, TCC may remain applied during initial engine loading.
Cylinder balance - Bad piston rings or poorly sealing valves can cause low power in a cylinder.
Fuel contamination - This causes poor engine performance.
Torque Converter Evaluation and Diagnosis
Replace the torque converter if any of the following conditions exist:
External leaks appear in the hub weld area.

The converter hub is scored or damaged.
The converter pilot is broken, damaged, or fits poorly into the crankshaft.
You discover steel particles after flushing the cooler and the cooler lines.
The pump is damaged, or you discover steel particles in the converter.
The vehicle has TCC shudder and/or no TCC apply. Replace the torque converter only after all hydraulic
and electrical diagnoses have been made. The converter clutch material may be glazed.
The converter has an imbalance which cannot be corrected. Refer to Flexplate/Torque Converter
Vibration Test.
The converter is contaminated with engine coolant which contains antifreeze.
An internal failure occurs in the stator roller clutch.
You notice excessive end play.
Overheating produces heavy debris in the clutch.
You discover steel particles or clutch lining material in the fluid filter or on the magnet, when no internal
parts in the unit are worn or damaged. This condition indicates that lining material came from the
converter.
Do not replace the torque converter if you discover any of the following symptoms:
The oil has an odor or the oil is discolored, if there are no metal or clutch facing particles present.
The threads in one or more of the converter bolt holes are damaged. Correct the condition with a new
thread insert.
Transmission failure did not display evidence of damaged or worn internal parts, steel particles or clutch
plate lining material in the unit and inside the fluid filter.
The vehicle has been exposed to high mileage only. An exception may exist where the lining of the
torque converter clutch dampener plate has seen excess wear by vehicles operated in heavy and/or
constant traffic, such as taxi, delivery, or police use.
TORQUE CONVERTER REPLACEMENT GUIDE
Torque Converter Replacement Guide

Condition Action
Fluid
Transmission Fluid Oxidized/Discolored Do not replace the torque converter.
Refer to Transmission Fluid Checking
No metal debris Procedure.
Clutch fiber material
Transmission Fluid Contaminated with Replace the torque converter.
Engine Coolant/Oil Refer to Torque Converter Cover Replacement
(LA1) .
Transmission Fluid Contaminated with Replace the torque converter if the following
Sludge/Metal Particles conditions are found:
Pump damage
Drive sprocket support damage
Turbine/stator shaft damage
No damage found in transmission
Do not replace the torque converter for other

transmission component damage.
Fluid Leaks from Torque Converter Perform the powder/dye leak check
Refer to Fluid Leak Diagnosis.
Replace the torque converter if the following

conditions are found:
Leak present at weld areas-hub, lug, or
closure weld
Hub surface is damaged-scored,
raised/transferred metal
Bushing is damaged
Function/Appearance
Torque Converter Discolored/Overheated Replace the torque converter.
Refer to Torque Converter Cover Replacement
(LA1) .
Broken/Cracked Flexplate Replace the torque converter.
(LA1) .
Stripped Converter Bolt Holes Replace the torque converter.
(LA1) .
Torque Converter Pilot Damaged Replace the torque converter.
(LA1) .
Torque Converter Ballooning Replace the torque converter if end play exceeds
0.7mm (0.3 in) using J 35138 .
Driveability - Non TCC
Harsh Gear Shifts-Non TCC Do not replace the torque converter.
Refer to Symptoms - Automatic Transmission.
No Drive/Slips in Drive-Non TCC Do not replace the torque converter until
completing all engine and transmission diagnostics.
Refer to Slips in Drive or No Drive.
Idle Surge/Rough Idle Do not replace the torque converter.
Refer to Rough, Unstable, or Incorrect Idle and
Stalling in Engine Controls-3.4L.
Poor Acceleration above 48 km/h (30 mph)- Do not replace the torque converter until
Launch completing all engine and transmission diagnostics.
Refer to Lack of Power, Sluggishness, or

Sponginess in Engine Controls-3.4L.
Refer to Hesitation, Sag, Stumble in Engine
Controls-3.4L.
Refer to Symptoms - Automatic
Transmission.
DTC P0741-TCC Stuck OFF/High Slip- Do not replace the torque converter.
Intermittent Only Refer to DTC P0741 (3.4L) or DTC P0741 (3.6L) .
DTC P0741-TCC Stuck OFF/High Slip Refer to DTC P0741 (3.4L) or DTC P0741 (3.6L) .
DTC P0742-TCC Stuck ON Do not replace the torque converter.
Refer to DTC P0742 (3.4L) or DTC P0742 (3.6L) .
DTC P1887-TCC Release Switch Do not replace the torque converter.
Refer to DTC P1887 (3.4L) .
TCC Apply/Release Shudder Refer to Converter Clutch Apply Rough, Slips, or
Shudders.
TCC Chuggle Refer to Symptoms - Engine Mechanical in
Engine Mechanical-3.4L.
Refer to Surges/Chuggles in Engine
Mechanical-3.4L.
Refer to Symptoms - Automatic
Transmission.
Noise and Vibration
Noise-Whine Refer to Symptoms - Automatic
Transmission.
Do not replace the torque converter if noise is
present in Neutral/Park. Refer to Symptoms -
Engine Mechanical in Engine Mechanical-
3.4L.
Vibration-Out of Balance Refer to Flexplate/Torque Converter
Vibration Test.
Refer to Vibration Analysis-Engine in
Vibration Diagnosis and Correction.
FLEXPLATE/TORQUE CONVERTER VIBRATION TEST
Isolating Vibration
NOTE: Some engine/transaxle combinations cannot be balanced in this manner due to

restricted access or limited clearances between the torque converter bolts and
the engine. Ensure that the bolts do not bottom out in the lug nuts or the torque
converter cover could be dented and cause internal damage.
To isolate and correct a flywheel or torque converter vibration, separate the torque converter from the flywheel
to determine if vibration is in the engine or transmission.
1. With the engine at idle speed and the transmission in PARK or NEUTRAL, observe the vibration.
2. Turn the engine OFF.
3. Raise and suitably support the vehicle.
Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the transmission converter cover bolts and the cover.
Refer to Torque Converter Cover Replacement (LA1) .

5. Verify the bolt torques attaching the converter to the flywheel are to specification.
6. Remove the bolts attaching the converter to the flywheel.
Refer to Flywheel to Torque Converter Bolt Replacement (LA1) .
7. Slide the torque converter away from the flywheel.

8. Rotate the flywheel (1) to inspect for defects or damage.
Refer to Engine Flywheel Cleaning and Inspection in Engine Mechanical.
9. Rotate the torque converter to inspect lugs and pilot (2) for damage. Verify the presence of balance
weight on the outside diameter of the torque converter.
Refer to Vibration Analysis - Engine, in Vibration Diagnosis and Correction.
Installing Torque Converter
Refer to Lifting and Jacking the Vehicle in General Information.

Fig. 4: View Of Torque Converter Hub In Engine Crankshaft
2. Align the torque converter pilot (2) in the engine crankshaft (3) and slide the torque converter up against
the flywheel.
Refer to Noise and Vibration Analysis.
Repeat this procedure until you obtain the best possible balance.
5. Install the transmission converter cover bolts and the cover.
Refer to Torque Converter Cover Replacement (LA1) .
NOISE AND VIBRATION ANALYSIS
A noise or vibration that is noticeable when the vehicle is in motion MAY NOT be the result of the
transmission.
If noise or vibration is noticeable in PARK and NEUTRAL with the engine at idle, but is less noticeable as
RPM increases, the cause may be from poor engine performance.
Vibration may also be caused by a small amount of water inside the converter.
Inspect the tires for the following conditions:
Uneven wear
Imbalance
Mixed sizes
Mixed radial and bias ply
Inspect the suspension components for the following conditions:

Alignment and wear
Loose fasteners
Driveline damage or wear
Inspect the engine and transmission mounts for damage and loose bolts.
Inspect the transmission case mounting holes for the following conditions:
Missing bolts, nuts, and studs
Stripped threads
Cracks
Inspect the flywheel for the following conditions:

Missing or loose bolts
Cracks
Imbalance
Inspect the torque converter for the following conditions:

Missing or loose bolts or lugs
Missing or loose balance weights
Imbalance caused by heat distortion or fluid contamination
CLUTCH PLATE DIAGNOSIS

Composition Plates
Dry the plates and inspect the plates for the following conditions:
Pitting
Flaking
Delamination - splitting or separation of bonded clutch material
Wear
Glazing
Cracking
Charring
Chips or metal particles embedded in the lining
Replace a composition plate which shows any of these conditions.
Steel Plates
Wipe the plates dry and check the plates for heat discoloration. If the surfaces are smooth, even if color smear is
indicated, you can reuse the plate. If the plate is discolored with heat spots or if the surface is scuffed, replace
the plate.
Causes of Burned Clutch Plates
The following conditions can result in a burned clutch plate:
Incorrect usage of clutch or apply plates

Engine coolant or water in the transmission fluid
A cracked clutch piston
Damaged or missing seals
Low line pressure
Valve body conditions
The valve body face is not flat.
Porosity is between channels.
The valve bushing clips are improperly installed.
The checkballs are misplaced.
The Teflon seal rings are worn or damaged.
ENGINE COOLANT/WATER IN TRANSMISSION
NOTE: The antifreeze or water will deteriorate the seals, gaskets and the glue that
bonds the clutch material to the pressure plate. Both conditions may cause
damage to the transmission.
If antifreeze or water has entered the transmission, perform the following:
1. Disassemble the transmission.

2. Replace all of the rubber type seals. The coolant will attack the seal material which will cause leakage.
3. Replace the composition-faced clutch plate assemblies. The facing material may separate from the steel
center portion.
4. Replace all of the nylon parts - washers.
5. Replace the torque converter.
6. Thoroughly clean and rebuild the transmission, using new gaskets and oil filter.
7. Flush the cooler lines after the transmission cooler has been properly repaired or replaced.
FLUID LEAK DIAGNOSIS
General Method
1. Verify that the leak is transmission fluid.

2. Thoroughly clean the suspected leak area.
3. Operate the vehicle for 24 km (15 mi), or until normal operating temperatures are reached.
4. Park the vehicle over clean paper or cardboard.
5. Shut OFF the engine.
6. Look for fluid spots on the paper.
7. Make the necessary repairs.
Powder Method
1. Thoroughly clean the suspected leak area with solvent.

2. Apply an aerosol type powder, such as foot powder, to the suspected leak area.
3. Operate the vehicle for 24 km (15 mi), or until normal operating temperatures are reached.
4. Shut OFF the engine.
5. Inspect the suspected leak area.
6. Trace the leak path through the powder in order to find the source of the leak.
Dye and Black Light Method
A fluid dye and black light kit is available from various tool manufacturers.
1. Follow the manufacturer's instructions in order to determine the amount of dye to use.
2. Detect the leak with the black light.
Find the Cause of the Leak

Pinpoint the leak and trace the leak back to the source. You must determine the cause of the leak in order to
repair the leak properly. For example, if you replace a gasket, but the sealing flange is bent, the new gasket will
not repair the leak. You must also repair the bent flange. Before you attempt to repair a leak, check for the
following conditions, and make repairs as necessary:
Gaskets
Fluid level/pressure is too high

Plugged vent or drain-back holes
Improperly tightened fasteners
Dirty or 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
Incorrect gasket
Seals
Fluid level/pressure is too high

Plugged vent or drain-back holes
Damaged seal bore
Damaged or worn seal
Improper installation
Cracks in component
Manual or output shaft surface is scratched, nicked, or damaged
Loose or worn bearing causing excess seal wear
Possible Points of Fluid Leaks
Transmission Oil Pan
Incorrectly tightened oil pan bolts

Improperly installed or damaged oil pan gasket
Damaged oil pan or mounting face
Incorrect oil pan gasket
Case Leak
Damaged or missing fill tube seal

Mislocated fill 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 line pressure pipe plug
Porous casting warped torque converter housing
Leak at the Torque Converter End
Converter leak in the weld area

Converter seal lip cut. Check the converter hub for damage
Converter seal bushing moved forward and damaged
Converter seal garter spring missing from the seal
Porous casting of the transmission case or the oil pump
Leak at the Vent Pipe or the Fluid Fill Tube
Overfilled system
Water or coolant in the fluid - the fluid will appear milky.
Transmission case porous
Incorrect fluid level indicator
Plugged vent
Drain-back holes plugged
Mispositioned oil pump to case gasket, if equipped
Fig. 5: Possible Leak Points

1 Manual Shift Shaft Seal Assembly
2 Oil Pressure Test Hole Plug
3 Vent Assembly
4 Reverse Band Servo Cover Seal
5 Oil Fill Tube Seal
6 Vehicle Speed Sensor Seal
7 Drive Shaft Oil Seal Assembly (Right)
8 Forward Band Servo Cover Seal
9 Park Pawl Actuator Guide Seal
10 Torque Converter Oil Seal Assembly
11 Torque Converter Assembly (Welds/Cracks)
12 Oil Cooler Pipe Fittings
13 Case Assembly (Porosity/Cracks)
14 Case Side Cover Gasket
15 Electrical Connector Seal
16 Drive Shaft Oil Seal Assembly (Left)
17 Case Side Cover Inner Gasket
18 Oil Pan Gasket
CASE POROSITY REPAIR
Some external leaks are caused by case porosity in non-pressurized areas. You can usually repair these leaks
with the transmission in the vehicle.
1. Thoroughly clean the area to be repaired with a cleaning solvent. Air dry the area.
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. Using instructions from the manufacturer, mix a sufficient amount of an epoxy to make the repair.
3. While the transmission case is still hot, apply the epoxy. You can use a clean, dry soldering acid brush to
clean the area and also to apply the epoxy cement. Make certain that the area to be repaired is fully
covered.
4. Allow the epoxy cement to cure for 3 hours before starting the engine.
5. Repeat the fluid leak diagnosis procedures.
SHIFT SOLENOID LEAK TEST
Tools Required
J 44246 Solenoid Testing Kit.Special Tools .
Leak Test Procedure
IMPORTANT: This procedure tests On/Off type solenoid valves.

Visually inspect the physical condition of the solenoid before
testing. Inspect the O-rings before and after the test to be sure that
they are not cut or damaged.
1. Remove the solenoid from the control valve body. Refer to 1-2 Shift Solenoid Valve Replacement or 2-
3 Shift Solenoid Valve Replacement .
Fig. 6: Installing Valve Into Bore No. 2 Of J 44246

2. Install the 1-2, 3-4 or the 2-3 shift solenoid valve into bore number 2 of the J 44246 and install the
factory retainer clip to retain the solenoid.Special Tools .
Fig. 7: Connecting Solenoid Testing Harness To Solenoid
3. Connect the solenoid testing harness supplied with the J 44246 to the solenoid.Special Tools .
IMPORTANT: Do not use air pressure in excess of 827 kPa (120 psi). Excessive
pressure will not allow the solenoid ball check valve to seat properly.
Recommended air pressure is 345 kPa (50 psi).
4. Apply compressed air to the J 44246 .Special Tools .

5. Air should flow through the solenoid. If air does not flow through the solenoid, replace the solenoid.
6. Connect the solenoid testing harness to the (12 volt) positive and negative (-) battery terminals.
7. Observe if the solenoid is operating electrically. An audible clicking noise can be heard when connecting
or disconnecting power.
IMPORTANT: All solenoids need to be energized to seal.

A small amount of air leakage is normal, 21 kPa (3 psi).
8. Observe the air flow through the solenoid. The flow will completely or nearly completely stop. Replace
the solenoid if there continues to be an obvious air leak when the solenoid is energized.
IMPORTANT: Inspect the O-rings after the test to be sure that they are not cut or
damaged.
9. Install the solenoid into the control valve body. Refer to 1-2 Shift Solenoid Valve Replacement or 2-3
Shift Solenoid Valve Replacement .
AUTOMATIC TRANSMISSION OIL COOLER FLUSHING AND FLOW TEST (J35944-A)
GM studies indicate that plugged or restricted transmission oil coolers and pipes cause insufficient transmission
lubrication and elevated operating temperatures which can lead to premature transmission wear-out. Many
repeat repair cases could have been prevented by following published procedures for transmission oil cooler
flushing and flow checking. This procedure includes flow checking and flushing the auxiliary transmission oil
cooler, if equipped.
IMPORTANT: Use the J 35944-A or equivalent to flush the transmission oil cooler and the oil
cooler pipes whenever the transaxle is removed for the following repairs
(Special Tools ):
Torque converter
Oil pump
Oil pump drive shaft
Drive sprocket support
Transaxle overhaul complete
Transaxle assembly replacement
IMPORTANT: Use the J 35944-A or equivalent to flush the transmission oil cooler and the oil
cooler pipes whenever the transmission is removed for the following repairs
(Special Tools ):
Torque converter
Oil pump
Turbine shaft
Transmission overhaul complete
Transmission assembly replacement
Only GM Goodwrench DEXRONIII automatic transmission fluid should be used when doing a repair on a
GM transmission.
Time allowance for performing the cooler flow checking and flushing procedure has been included in the
appropriate labor time guide operations since the 1987 model year. The service procedure steps for oil cooler
flushing are as follows:
Cooler Flow Check and Flushing Steps
1. Tools Required
2. Preparation
3. Back Flush
4. Forward Flush
5. Flow Check
6. Clean-up
Tools Required
J 35944-A Transmission Oil Cooler and Line Flusher.Special Tools .

J 35944-22 Transmission Oil Cooler Flushing Fluid.Special Tools .
Measuring cup
Funnel
Water supply - hot water recommended
Water hose, at least 16 mm (5/8 in) ID
Shop air supply with water/oil filters, regulator and pressure gage
Air chuck with clip, if available
Oil drain container
Pail with lid - 19 L (5 gallon)
Eye protection
Rubber gloves
Preparation
1. During the installation of the repaired or replacement transmission, do not connect the oil cooler pipes.
Fig. 8: Identifying Flusher Tank & Components
NOTE: Do not use solutions that contain alcohol or glycol. Use of solutions that
contain alcohol or glycol may damage the oil cooler line flusher, oil cooler
components and/or transmission components.
IMPORTANT: The J 35944-22 is environmentally safe, yet powerful enough to cut

through transmission fluid to dislodge any contaminants from the
cooler.Special Tools . The safety precautions on the label, regarding
potential skin and eye irritations associated with prolonged exposure, are
typical precautions that apply to many similar cleaning solutions. It
should be noted that according to GM, use of other non-approved fluids
for cooler flushing can have an adverse reaction to the seals inside the
transmission.
2. Remove the fill cap (9) on the J 35944-A and fill the flusher tank (4) with 0.Special Tools .6 L (20-21
oz.) of J 35944-22 , using the measuring cup (6).Special Tools . Do not overfill.
3. Install the fill cap (9) on the J 35944-A and pressurize the flusher tank (4) to 550-700 kPa (80-100 psi),
using the shop air supply at the tank air valve (2).Special Tools .
4. With the water supply valve (1) on the J 35944-A in the OFF position, connect the water supply hose
from the .Special Tools .J 35944-A to the water supply at the faucet.Special Tools .
5. Turn ON the water supply at the faucet.
Back Flush
1. Inspect the transmission oil cooler pipes for kinks or damage. Repair as necessary.
Fig. 9: Connecting J 35944 To Oil Cooler

2 Connect the J 35944-A to the oil cooler feed top connector Special Tools
3. Clip the discharge hose (2) onto the oil drain container.
4. Attach the J 35944-A to the undercarriage of the vehicle with the hook provided and connect the flushing
system feed supply hose (1) from the .Special Tools .J 35944-A to the bottom connector oil cooler return
pipe.Special Tools .
5. Turn the J 35944-A water supply valve (3) to the ON position and allow water to flow through the oil
cooler and pipes for 10 seconds to remove any remaining transmission fluid.Special Tools . If water does
not flow through the oil cooler and pipes, the cause of the blockage must be diagnosed and the plugged
component must be repaired or replaced. Continue with the cooler flushing and flow check procedure
once the blockage is corrected.
6. Turn the J 35944-A water supply valve (3) to the OFF position and clip the discharge hose onto a 19 liter
(5 gallon) pail with a lid, to avoid splashback.Special Tools .
Fig. 10: J 35944-A Water Supply Valve ON/OFF Positions
IMPORTANT: Flushing for approximately 2 minutes in each cooler line direction will
result in a total of about 8-10 gallons of waste fluid. This mixture of water
and flushing fluid is to be captured in a bucket or similar container.
7. Turn the J 35944-A water supply valve (3) to the ON position and depress the trigger (1) to mix cooler
flushing solution into the water flow.Special Tools . Use the clip provided on the handle to hold the
trigger (1) down. The discharge will foam vigorously when the solution is introduced into the water
stream.
8. Flush the oil cooler and pipes with water and solution for 2 minutes. During this flush, attach the shop air
supply 825 kPa (120 psi) to the flushing system feed air valve (2) located on the J 35944-A , for 3-5
seconds at the end of every 15-20 second interval to create a surging action.Special Tools .
9. Release the trigger (1) and turn the J 35944-A water supply valve (3) to the OFF position.Special Tools .
Forward Flush
Fig. 11: Connecting J 35944 To Oil Cooler
1. Disconnect both hoses (1 and 2) from the oil cooler pipes and connect them to the opposite oil cooler
pipe. This will allow the oil cooler and pipes to be flushed in the normal flow direction.
2. Repeat Step 6 and 7 of the Back Flush.
Fig. 12: J 35944-A Water Supply Valve ON/OFF Positions
3. Release the trigger (1) of the J 35944-A and allow water only to rinse the oil cooler and pipes for 1
minute.Special Tools .
4. Turn the J 35944-A water supply valve (3) to the OFF position and turn OFF the water supply at the
faucet.Special Tools .
5. Attach the shop air supply to the flushing system feed air valve (2) on the and J 35944-A blow out the
water from the oil cooler and pipes.Special Tools . Continue, until no water comes out of the discharge
hose.
Flow Test
Fig. 13: Clipping The Discharge Hose To An Empty Oil Container
IMPORTANT: The Flow Test must be performed after the flush to ensure that all flushing
solution and water is removed from the oil cooling system.
1. Disconnect the hose from the oil cooler pipe. Connect the oil cooler feed pipe, top connector, to the
transmission for normal flow.
2. Clip the discharge hose (1) to an empty oil container.
3. Confirm the transmission is filled with automatic transmission fluid. Refer to Fluid Capacity
Specifications for the correct automatic transmission fluid capacity.
4. Start the engine with the transmission in PARK range and run for 30 seconds after fluid begins to flow
from the discharge hose (1). A minimum of 1.9 L (2 quarts) must be discharged during this 30 second run
time.
5. If the fluid flow meets or exceeds 1.9 L (2 quarts) in 30 seconds, connect the oil cooler feed pipe to the
front connector on the transmission.
6. If fluid flow is less than 1.9 L (2 qt) in 30 seconds, perform the following diagnosis:
1. Disconnect the J 35944-A discharge hose (1) from the oil cooler return pipe.Special Tools .
2.
Disconnect the oil cooler feed pipe at the radiator.
Connect the J 35944-A discharge hose (1) to the oil cooler feed pipe, radiator end.Special Tools .
3.
4.
Clip the discharge hose (1) onto the oil drain container.
5.
Start the engine with the transmission in PARK range and run for 30 seconds after fluid begins to
flow from the discharge hose (1). A minimum of 1.9 L (2 qt) must be discharged during this 30
second run time.
7. If the amount of transmission fluid flow remains less than 1.9 L (2 qt) in 30 seconds, inspect the oil
cooler feed pipe, top connector, for restrictions or damage. If no condition is found with the feed pipe,
inspect the transmission.
Clean-up
1. Disconnect the water supply hose from the J 35944-A and bleed any remaining air pressure from the
flusher tank.Special Tools .
2. Remove the fill cap from the J 35944-A and return any unused flushing solution to its container.Special
Tools . Rinse the J 35944-A with water.Special Tools . Do not store the J 35944-A with flushing
solution in it.Special Tools .
3. After every third use, clean the J 35944-A as described in the instructions included with the tool.Special
Tools .
4. Dispose of any waste water/solution and transmission fluid in accordance with local regulations.
AUTOMATIC TRANSMISSION OIL COOLER FLUSHING AND FLOW TEST (J45096)
GM studies indicate that plugged or restricted transmission oil coolers and pipes cause insufficient transmission
lubrication and elevated operating temperatures which can lead to premature transmission failure. Many repeat
repair cases could have been prevented by following published procedures for transmission oil cooler flushing
and flow checking. This procedure includes flow checking and flushing the auxiliary transmission oil cooler, if
equipped.
IMPORTANT: Use the J 45096 or equivalent to flush and flow test the transmission oil cooler
and the oil cooler pipes after the transaxle is removed for repairs.Special
Tools .
Only GM Goodwrench DEXRONIII automatic transmission fluid should be used when doing a repair on a
GM transmission.
Time allowance for performing the cooler flow checking and flushing procedure has been included in the
appropriate labor time guide operations since the 1987 model year. The service procedure steps for oil cooler
flushing and flow testing are as follows:
Cooler Flow Check and Flushing Steps
1. Machine Set-up
2. Determine Minimum Flow Rate
3. Back Flush
4. Forward Flush
5. Flow Test
6. Code Recording Procedure
7. Clean-up
Tools Required
J 45096 Transmission Oil Cooling System Flush and Flow Test Tool.Special Tools .
Shop air supply with water/oil filters, regulator and pressure gage - minimum 90 psi
Eye protection
Rubber gloves
Machine Set-up
Fig. 14: View Of Main Power Switch & Main Function Switch
1. Verify that the main power switch (1) is in the OFF position.
2. Place the main function switch (2) in the IDLE position.
Fig. 15: Connecting To 12V DC Power Source
3. Connect J 45096 to the vehicle 12V DC power source by connecting the red battery clip to the positive,
+, battery post on the vehicle and connect the negative lead to a known good chassis ground.Special
Tools .
4. Turn the main power switch to the ON position.
Fig. 16: Filling Supply Tank With Transmission Fluid
NOTE: Do not overfill the supply vessel. Damage to the unit may result. To verify
the fluid level, view the LCD screen display while filling the unit, to ensure
the fluid level does not exceed 30 L (32 qt).
5. Fill the supply tank with DexronIII/Mercon, or equivalent, through the fill port.
6. Reinstall and tighten the fill cap.
Fig. 17: Applying Shop Air Supply Hose To Quick-Disconnect

7. Connect a shop air supply hose to the quick-disconnect on the rear panel marked SUPPLY AIR.
Determine Minimum Flow Rate

Fig. 18: Identifying Machine Display Of Automatic Transmission Fluid Temperature
1. From the machine display, identify the temperature of the automatic transmission fluid that is stored in
the supply vessel of J 45096 .Special Tools .
Fig. 19: Identifying Transmission Oil Cooler Metal Composition
2. Determine whether the transmission oil cooler is steel or aluminum by using a magnet (1) at the cooler
flange (2) at the radiator.
3. Refer to the table below. Using the temperature from step 1, locate on either the Steel MINIMUM Flow
Rate table or the Aluminum MINIMUM Flow Rate table the minimum flow rate in gallons per minutes
(GPM). Record the minimum flow rate in GPMs and the supply fluid temperature for further reference.
Example:
Fluid temperature: 75F
Cooler type: Steel
The MINIMUM flow rate for this example would be 0.8 GPM.
4. Inspect transmission oil cooler lines for damage or kinks that could cause restricted oil flow. Repair as
needed and refer to the appropriate GM service manual procedures.
Minimum Flow Rate in Gallons Per Minute (GPM)

Temperature Range Steel Aluminum
65 - 66F 0.6 gpm 0.5 gpm
67 - 70F 0.7 gpm 0.6 gpm
71 - 75F 0.8 gpm 0.7 gpm
76 - 80F 0.9 gpm 0.8 gpm
81 - 84F 1.0 gpm 0.9 gpm
85 - 89F 1.1 gpm 1.0 gpm
90 - 94F 1.2 gpm 1.1 gpm
95 - 98F 1.3 gpm 1.2 gpm
99 - 103F 1.4 gpm 1.3 gpm
104 - 108F 1.5 gpm 1.4 gpm
109 - 112F 1.6 gpm 1.5 gpm
113 - 117F 1.7 gpm 1.6 gpm
118 - 120F 1.8 gpm 1.7 gpm
Back Flush Procedure

Fig. 20: Connecting J 45096 Adapters To Oil Cooler Supply And Return Lines
1. Connect the J 45096 adapters (1) to the vehicle's transmission oil cooler supply and return lines at the
transmission.Special Tools .
Fig. 21: Identifying Black Supply Hose And Clear Waste Hose
2. Connect the black supply hose (1) to the return line, top connector of the transmission, and the clear
waste hose (2) to the feed line, bottom connector of the transmission, to the vehicle cooler lines. This is
the reverse flow - backflush direction.
Fig. 22: Setting Main Function Switch To FLUSH Position
3. Turn the main function switch to the FLUSH position. Allow the machine to operate for 30 seconds.
Fig. 23: Setting Main Function Switch To IDLE Position
4. Turn the main function switch to the IDLE position and allow the supply vessel pressure to dissipate.
Forward Flush
Fig. 24: Identifying Black Supply Hose And Clear Waste Hose
1. Disconnect the supply and waste hoses from the vehicle cooler lines. Reverse the supply and waste hoses
to provide a normal flow direction.
Fig. 25: Setting Main Function Switch To FLUSH Position
2. Turn the main function switch to the FLUSH position and allow machine to operate for 30 seconds.
Flow Test
Fig. 26: Setting Main Function Switch To FLOW Position
IMPORTANT: If the flow rate is less than 0.5 gpm, the LCD displays an error message.
Refer to the Troubleshooting section of the operation manual.
1. Turn the main function switch to the FLOW position and allow the oil to flow for 15 seconds. Observe
and note the flow rate; this is the TESTED flow rate.
2. Compare the TESTED flow rate to the MINIMUM flow rate information previously recorded.
If the TESTED flow rate is equal to or greater than the MINIMUM flow rate recorded, the oil
cooling system is functioning properly. Perform Code Recording Procedure.
If the TESTED flow rate is less than the MINIMUM flow rate previously recorded, repeat the back
flush and forward flush procedures.
3. If the TESTED flow rate is less than the MINIMUM flow rate after the second test, perform Code
Recording Procedure.
1. Replace the transmission oil cooler.
2. Reconnect supply and waste hoses to the cooler lines in the normal flow direction. Perform Flow
Test.
3. Perform Code Recording Procedure.
Code Recording Procedure
Fig. 27: Setting Main Function Switch To CODE Position

1. Turn the main function switch to the CODE position.
IMPORTANT: If power is interrupted prior to the recording of the seven-character

code, the code will be lost and the flow rate test will need to be
repeated.
The flow test must run for a minimum of 8-10 seconds and be above
0.5 gpm for a code to be generated.
2. Record TESTED flow rate, temperature, cycle and seven-character flow code information on repair order.
Clean-up
Fig. 28: View Of Main Power Switch & Main Function Switch
1. Turn the main function switch (2) to the IDLE position and allow the supply vessel pressure to dissipate.
2. Turn the main power switch (1) to the OFF position.
3. Disconnect the supply and waste hoses and the 12-volt power source from the vehicle.
Note: A small amount of water may drain from the bottom of the unit when the air supply is
disconnected. This is a normal operation of the built-in water separator.
Fig. 29: Applying Shop Air Supply Hose To Quick-Disconnect

4. Disconnect the air supply hose from J 45096 .Special Tools .

5. Dispose of the waste ATF in accordance with all applicable federal, state, and local requirements.
AUTOMATIC TRANSMISSION FLUID LEAKS
Automatic Transmission Fluid Leaks

Checks Cause
DEFINITION: Automatic transmission fluid leaks that occur on the transmission.
Automatic Transmission Fluid High fluid level - causing an oil leak at the vent assembly (37).
Level
Contaminated with engine coolant, engine oil, brake fluid, etc.
Automatic Transmission Fluid
Condition Oxidized and degraded - causing oil foaming and an oil leak at
the vent assembly
The vent assembly (37) is plugged or damaged - causing high
internal pressure inside the transmission and causing oil leakage
Vent Assembly
at another component.
Channel plate gasket (430) improperly torqued.
The oil pan bolts and screws are loose, cross-threaded, or
missing.
Oil Pan Assembly
The oil pan (24) is damaged.
The oil pan gasket (25) is out of position or damaged.
The oil filter assembly (100) is damaged.
Oil Filter and Seal Assembly The oil filter seal assembly (101) is missing or damaged -
causing oil foaming and an oil leak at the vent assembly.
The thermo element plate pins (120, 123) are misadjusted.
Thermo Element Assembly The thermo element (121) or thermo element plate (122) is out of
position, missing, or damaged - causing a high fluid level in the
oil pan, oil foaming, and an oil leak at the vent assembly (37).
The control valve body cover bolts and screws (56, 57, 58) are
loose, cross-threaded, or missing.
The control valve body cover (53) is porous or damaged.
Control Valve Body Cover
Assembly The control valve body cover gaskets (54, 59) are out of position
or damaged.
The wiring harness assembly (224) is damaged or is leaking at
the electrical connector terminals.
Front Wheel Drive Shaft Oil The front wheel drive shaft oil seal assemblies (4, 409) are loose or
Seal Assemblies damaged.
The forward band servo cover bolts and screws (12) are loose,
cross-threaded, or missing.
Forward Band Servo Assembly The forward band servo cover (13) is porous or damaged.
The forward band servo cover seal (14) is out of position or is
damaged.
The reverse band servo cover retaining ring (39) is out of
position or is damaged.
Reverse Band Servo Assembly The reverse band servo cover (40) is porous or is damaged.
The forward band servo cover seal (14) is out of position or is

damaged.
Oil Cooler Pipe Fitting The oil cooler pipe fitting assemblies (28, 29) are loose, cross-threaded,
Assemblies damaged, or are missing a sealer.
The case extension bolts and screws (5) are loose, cross-threaded,
or are missing.
The case extension assembly (6) is porous or damaged.
The case extension seal (8) is out of position or is damaged.
Case Extension Assembly The front differential carrier bushing (7A) or the output shaft
bearing assembly (7B) is worn or damaged.
The case extension assembly (6) oil drain back holes are plugged
or missing - causing repeat leaks at the right side front wheel
drive shaft oil seal assembly (4).
The vehicle speed sensor bolt or screw (9) is loose, cross-
threaded, or missing.
Vehicle Speed Sensor Assembly
The vehicle speed sensor O-ring seal (11) is out of position or is
damaged.
The oil pressure test hole plug (38) is loose, cross-threaded, damaged,
Oil Pressure Test Hole Plug
or is missing a sealer.
The manual shift shaft seal assembly (806) is out of position or is
Manual Shift Shaft Assembly damaged.
The manual shift shaft (807) sealing surface is damaged.
The park pawl actuator pin (808) is loose or missing.
Park Pawl Actuator Guide The park pawl actuator guide (809) is damaged.
Assembly The park pawl actuator guide O-ring seal (810) is out of position,
missing, or damaged.
Torque Converter Oil Seal The torque converter oil seal assembly (525) is loose or damaged.
Assembly
The drive sprocket support (522) oil drain back holes are plugged or
Drive Sprocket Support
missing - causing repeat leaks at the torque converter oil seal assembly
Assembly
(525).
Case Assembly The case assembly (3) is porous or damaged.
INCORRECT LINE PRESSURE
Incorrect Line Pressure

Checks Cause
DEFINITION: Transmission main line pressure that is determined to be high or low. Refer to Line
Pressure Check Procedure.
Automatic Transmission Fluid Low fluid level
Level - low pressure only
Thermo Element Assembly - low The thermo element plate pins (120, 123) are misadjusted.
pressure only
The thermo element (121) or the thermo element plate (122) is
out of position, missing, or damaged - causing low fluid level in
the oil pan.
Oil Filter and Seal Assembly The oil filter assembly (100) is missing or damaged.
The oil filter seal assembly (101) is missing or damaged, low
pressure only.
Wiring Harness Assembly The wiring harness assembly (224) is disconnected or damaged.
Oil Pump Assembly The following components are worn or damaged - low pressure
only:
The oil pump cover (201)
The oil pump body (202)
The oil pump vane ring (209)
The oil pump rotor (210)
The oil pump vanes (211)
The oil pump slide oil seal ring (212)
The oil pump slide O-ring seal (213)
The oil pump slide (214)
The oil pump slide (214) is binding, high pressure only.

The oil pump prime springs (222, 223) or the oil pump slide
pivot pin (215) is missing or damaged, low pressure only.
The oil pump slide seal (220) or the oil pump slide seal support
(221) is missing or damaged, high pressure only.
Pressure Control Solenoid Valve The pressure control solenoid valve assembly (322) is damaged.
Assembly
The solenoid valve O-ring seals (305, 316) are missing or
damaged.
The valve retainer (314) is missing or damaged.
Torque Signal Regulator Valve The torque signal regulator valve (321) is binding or damaged.
Assembly
The valve retainer (314) is missing or damaged.
Pressure Regulator Valve The pressure regulator valve (313) is binding or is damaged.
Assembly
The pressure regulator valve springs (311, 312) is missing or
damaged.
The reverse boost valve (310) is binding or is damaged, high
pressure only.
The line boost valve (304) is binding or is damaged, high
pressure only.
The valve retainer (302) is missing or is damaged.
Actuator Feed Limit Valve The actuator feed limit valve (414) is binding or is damaged.
Assembly - low pressure only
The actuator feed limit valve spring (415) is missing or is
damaged.
The actuator feed limit valve spring retainer (416) is missing or
damaged.
Low Blow Off Valve Assembly
- low pressure only The low blow off valve spring (323) is missing or is damaged.
The low blow off ball valve (324) is missing, binding, or is
damaged.
The low blow off valve spring retainer (325) is missing or is
damaged.
DELAYED PARK TO REVERSE/DRIVE ENGAGEMENT
Delayed Park to Reverse/Drive Engagement

Checks Cause
DEFINITION: Gear engagement that takes longer than 3 seconds when the engine is idling in Park or
Neutral, and the gear selector is moved to Drive or Reverse range.
Level
Transmission Main Line Low transmission main line pressure
Pressure
Reverse Band Servo Assembly - The reverse band servo piston oil seal ring (43) is damaged or rolled.
Reverse engagement only
Forward Band Servo Assembly - The forward band servo piston oil seal ring (18) is damaged or rolled.
Drive engagement only
Control Valve Body Assembly - The reverse servo boost valve (367A) is binding or is damaged.
Control Valve Body Assembly - The forward servo boost valve (367B) is binding or is damaged.
Control Valve Body Spacer Plate The thermal element is damaged or is not functioning properly.
Assembly - Drive engagement
only
TCC Blowoff Ball Valve The TCC blowoff ball valve (420) is not seating - causing torque
Assembly converter drain back.
Input Clutch Assembly The input clutch housing oil seal rings (628) are damaged or
rolled.
The input clutch housing assembly (632) sealing surfaces are
damaged.
The input clutch housing ball check valve assembly (633) is
plugged or damaged.
The input clutch inner piston seal (634) is damaged or rolled.
The input clutch outer piston seal (635) is damaged or rolled.
The input clutch piston assembly (636) sealing surfaces are

damaged.
HARSH PARK TO REVERSE/DRIVE ENGAGEMENT

Harsh Park to Reverse/Drive Engagement
Checks Cause
DEFINITION: Gear engagement that is harsh when the engine is idling in Park or Neutral, and the gear
selector is moved to Drive or Reverse range.
Transmission Main Line
High transmission main line pressure
Pressure
Reverse Band Servo Assembly - The reverse band servo piston cushion spring (45) is broken or is
Reverse engagement only missing.
Forward Band Servo Assembly - The forward band servo piston cushion spring (19) is broken or is
Drive engagement only missing.
Transmission Case Cover Ball
Check Valve - Reverse The #5 Ball check valve (372) is mislocated or is missing.
engagement only
Transmission Case Cover Ball
Check Valve - Drive engagement The #6 Ball check valve (372) is mislocated or is missing.
only
Control Valve Body Assembly -
The reverse servo boost valve (367A) is binding or is damaged.
Control Valve Body Assembly -
The forward servo boost valve (367B) is binding or is damaged.
Control Valve Body Spacer Plate
Assembly - Drive engagement The thermal element is damaged or is not functioning properly.
only
SLIPS IN DRIVE OR NO DRIVE
Slips in Drive or No Drive

Checks Cause
DEFINITION: A large engine RPM increase is noted with little or no vehicle forward speed increase
during the following conditions:
The engine is running.

The transmission is in Drive range.
The vehicle is stopped or moving slowly.
The vehicle brakes are not applied.
The throttle is opened 25 percent or greater.

Level
Pressure
Manual Linkage Misadjusted
Oil Filter Assembly The oil filter assembly (100) is missing, plugged, or damaged.
The oil filter seal assembly (101) is missing or damaged.

Accumulator and Manual 2-1 A loose or damaged forward band servo oil pipe (124).
Band Servo Assembly
Loose manual 2-1 band servo cover or accumulator cover bolts
(103, 131).
Missing or damaged manual 2-1 servo cover gasket (105).
A damaged accumulator cover spacer plate assembly (134).
Forward Band Servo Assembly A servo piston oil seal ring (18) is missing or is damaged.
A servo piston (16) is damaged or is stuck in the servo cover
(13).
The servo piston cushion spring (19) or the retainer (20) is
missing or damaged.
The servo piston pin (21) is not engaged to the forward band
assembly (688).
The forward band assembly (688) is worn or burned.
The forward band assembly (688) is disengaged from the anchor

pin (117A).
The anchor pin (117A) is loose or missing.
Control Valve Body Assembly The #3 Ball check valve (372) is missing.
Torque Converter Assembly The torque converter assembly (1) stator clutch is not holding
The torque converter assembly (1) blades are broken or damaged
Drive Link Assembly The drive link assembly (507) is broken.
The drive/driven sprockets (516/506) are damaged.
Input Clutch Assembly The input clutch sprag assembly (722) is damaged or
misassembled.
The input clutch housing oil seal rings (628) are missing or are
damaged.
missing or is damaged.
The input clutch piston inner/outer seals (634/635) are missing or
are damaged.
The input clutch piston (636) is damaged.
The input clutch plates (654-658) are worn.
1-2 Clutch Roller Assembly The 1-2 clutch roller assembly (683) is damaged.
Input and Reaction Carrier The input carrier assembly (672) or the reaction carrier assembly (675)
Assemblies components are damaged.
Differential Carrier Assembly The park pawl assembly (694) is broken or damaged.
The sun gear shaft (689), the internal gear assembly (693), or the
carrier assembly (700) components are damaged.
Forward Band Servo Forward band servo piston apply pin (21) nicked or scratched
SLIPS IN REVERSE OR NO REVERSE
Slips in Reverse or No Reverse

Checks Cause
DEFINITION: A large engine RPM increase is noted with little or no vehicle rearward speed increase
during the following conditions:

The transmission is in Reverse range.
The vehicle is stopped or moving slowly.
The throttle is opened 25 percent or greater.

Level
Pressure

Reverse Band Servo Assembly A servo piston oil seal ring (43) is missing or is damaged.
A servo piston (44) is damaged or is stuck in the case bore.
The servo piston cushion springs (45, 47) or the retainer (46) is
missing or damaged.
The servo piston pin (48) is not engaged to the reverse band
assembly (615).
The reverse band assembly (615) is worn or burned.
The reverse band assembly (615) is disengaged from the anchor

pin (117B) band.
The anchor pin (117B) is loose or missing.
Torque Converter Assembly The torque converter assembly (1) stator clutch is not holding.
Drive Link Assembly The drive link assembly (507) is broken.
The drive/driven sprockets (516/506) are damaged.
misassembled.
The input clutch housing oil seal rings (628) are missing or are
damaged.
missing or is damaged.
are damaged.
Reverse Reaction Drum The reverse reaction drum (669) splines are damaged.
LOCKED UP IN DRIVE/REVERSE
Locked up in Drive/Reverse
Checks Cause
DEFINITION: The vehicle cannot be moved forward or backward during the following conditions:

The transmission is in Drive or Reverse range.
The throttle is closed (idling).

NO PARK RANGE
No Park Range
Checks Cause
DEFINITION: One of the two following conditions occur:
The transmission range selector cannot be moved into Park.

The vehicle can move forward or backward more than 1 meter (3 ft) after the transmission range
selector is moved into Park.
Park Pawl Actuator Assembly The actuator assembly (800) is damaged.
The actuator guide (809) is damaged or debris is present.
HARSH OR SOFT 1-2 SHIFT FEEL

Harsh or Soft 1-2 Shift Feel
Checks Cause
DEFINITION: One of the two following conditions occurs during a first to second gear steady throttle
upshift, or a second to first gear coast, or a light to moderate throttle detent downshift:
Harsh shift feel - an unacceptable quick gear change occurs.

Soft shift feel - an unacceptable long gear change occurs.

Level - soft shift only
Transmission Main Line Low or high transmission main line pressure
pressure
Oil Filter Assembly - soft shift The oil filter assembly (100) is missing, plugged, or damaged.
only
1-2 Accumulator Assembly Misassembled or upside down 1-2 accumulator assembly
Damaged or missing 1-2 accumulator piston oil seal ring (137A)

A damaged or missing 1-2 accumulator piston cushion spring
(139) or outer spring (142)
A stuck or binding 1-2 accumulator piston (136A)
Debris in the passages of the accumulator cover spacer plate
(134)
Control Valve Body Assembly Debris in the passages of the control valve body (301) or spacer
plate assembly (370)
Missing or mislocated #2 ball check valve (372)
Misassembled 1-2 accumulator valve (340-345) line-up
Stuck or binding 1-2 accumulator valve (341)
Damaged or missing 1-2 accumulator valve spring (340)
Missing, damaged, or misassembled 2-3 accumulator valve
bushing (345), bore plug (343), or retainers (342, 385)
Driven Sprocket Support A damaged second clutch housing oil seal rings (613) or the four
Assembly - soft shift only lobe oil seal ring seals (612)
Worn or damaged second clutch housing bushings (616, 619)
Second Clutch Assembly Missing or not seated second clutch basking plate retaining ring
(627)
Missing or misassembled second clutch backing plate (626)
Worn, damaged or misassembled clutch plates (623-625)
Missing or not seated second clutch spring retaining ring (622)
A damaged spring assembly (621) or piston (620)
A missing or damaged second clutch housing ball check valve
assembly (618)
A damaged second clutch housing assembly (617)
HARSH OR SOFT 2-3/3-2 SHIFT FEEL
Harsh or Soft 2-3/3-2 Shift Feel

Checks Cause
DEFINITION: One of the two following conditions occurs during a second to third gear steady throttle
upshift, or a third to second gear coast, or a light to moderate throttle detent downshift:


Level, soft shift only
Pressure
Oil Filter Assembly, soft shift The oil filter assembly (100) is missing, plugged, or damaged.
only
2-3 Accumulator Assembly Misassembled upside down 2-3 accumulator assembly
Damaged or missing 2-3 accumulator piston oil seal ring (137B)

A damaged or missing 2-3 accumulator piston cushion spring
(143) or outer spring (138)
A stuck or binding 2-3 accumulator piston (136B)
Debris in the passages of the accumulator cover spacer plate
(134)
Control Valve Body Assembly Debris in the passages of the control valve body (301) or control
valve body spacer plate assembly and gasket assembly (396)
Missing or mislocated #4 or #9 ball check valves (372)
Misassembled 2-3 accumulator valve (340-345) line-up

bushing (345), bore plug (343), or retainers (342, 385)
Driven Sprocket Support A plugged third clutch oil passage in the driven sprocket support
Assembly, soft shift only assembly (609)
Third Clutch Assembly The input clutch housing oil seal rings (628) are missing or are
damaged.
The third clutch ball check valve assembly (724) is missing or is
damaged.
The third clutch piston (642) is damaged.
The third clutch piston inner seal (641) is missing or damage.
The third clutch plates (645-648) are worn or misassembled.
HARSH OR SOFT 3-4/4-3 SHIFT FEEL
Harsh or Soft 3-4/4-3 Shift Feel

Checks Cause
DEFINITION: One of the two following conditions occurs during a third to fourth gear steady throttle
upshift, or a fourth to third gear coast, or a light to moderate throttle detent downshift:


Level, soft shift only
Pressure
Oil Filter Assembly, soft shift The oil filter assembly (100) is missing, plugged, or damaged.
only
3-4 Accumulator Assembly Misassembled upside down 3-4 accumulator assembly
Damaged or missing 3-4 accumulator piston oil seal ring (427)

A damaged or missing 3-4 accumulator piston outer spring (423)
A stuck or binding 3-4 accumulator piston (428)
A damaged 3-4 accumulator piston cylinder (421) or O-ring seal
(422)
Control Valve Body Assembly Debris in the passages of the control valve body (301) or spacer
plate and gasket assembly (396).
Misassembled 3-4 accumulator valve (339, 350, 351) line-up
spring (351) or retainer (314A)
Driven Sprocket Support A missing or damaged fourth clutch orifice (607)
Assembly, soft shift only
A damaged driven sprocket support assembly (609)
Fourth Clutch Assembly Worn, damaged, or misassembled clutch plates (500-502)
A missing or not seated fourth clutch spring retaining ring (601)
Worn or damaged fourth clutch piston seals (604, 605)
HIGH OR LOW UPSHIFT OR DOWNSHIFT SPEED
High or Low Upshift or Downshift Speed

Checks Cause
DEFINITION: An upshift or a downshift, or TCC apply, that occurs at a speed outside of the calibrated
range. Refer to Shift Speed .
ECM/PCM Calibration Incorrect calibration in the ECM/PCM.
Information
Throttle Position (TP) Sensor Misadjusted or faulty TP sensor.
FIRST AND SECOND GEAR ONLY (2-3 SOLENOID STUCK ON)
First and Second Gear Only (2-3 Solenoid Stuck On)

Checks Cause
DEFINITION: The transmission only provides first and second gear in Drive range. The shift pattern as
the vehicle accelerates from a stop is 1-2-2-1. First gear ratio is 2.921:1 and second gear ratio is 1.568:1.
Control Valve Body Assembly A faulty 2-3 shift solenoid valve assembly (315B) is stuck On.
Debris is found in the control valve body (301) or the control

valve body spacer plate and gasket assembly (396)
FIRST AND FOURTH GEAR ONLY (1-2 SOLENOID STUCK ON)
First and Fourth Gear Only (1-2 Solenoid Stuck On)

Checks Cause
DEFINITION: The transmission only provides first and fourth gear in Drive range. The shift pattern as
the vehicle accelerates from a stop is 1-1-4-4. First gear ratio is 2.921:1 and fourth gear ratio is 0.705:1.
Control Valve Body Assembly A faulty 1-2, 3-4 shift solenoid valve assembly (315A) is stuck
On.
SECOND AND THIRD GEAR ONLY (1-2 SOLENOID STUCK OFF)
Second and Third Gear Only (1-2 Solenoid Stuck Off)

Checks Cause
DEFINITION: The transmission only provides second and third gear in Drive range. The shift pattern as
the vehicle accelerates from a stop is 2-2-3-3. Second gear ratio is 1.568:1 and third gear ratio is 1.000:1.
Control Valve Body Assembly A faulty 1-2, 3-4 shift solenoid valve assembly (315A) is stuck
Off.
A missing or damaged shift solenoid valve O-ring seal (316)
Plugged or damaged solenoid valve screen/seal assembly (382)

Case Cover Assembly A stuck, binding, or missing actuator feed limit valve line-up (414-416)
THIRD AND FOURTH GEAR ONLY (2-3 SOLENOID STUCK OFF)
Third and Fourth Gear Only (2-3 Solenoid Stuck Off)

Checks Cause
DEFINITION: The transmission only provides third and fourth gear in Drive range. The shift pattern as
the vehicle accelerates from a stop is 4-3-3-4. Third gear ratio is 1.000:1 and fourth gear ratio is 0.705:1.
Control Valve Body Assembly A faulty 2-3 shift solenoid valve assembly (315B) is stuck Off.
A missing or mislocated 2-3 shift solenoid valve (315B) and

retainer (314C)
A missing or damaged shift solenoid valve O-ring seal (316)
Plugged or damaged solenoid valve screen/seal assembly (382)
FIRST GEAR ONLY
First Gear Only

Checks Cause
DEFINITION: The transmission only provides first gear in Drive range. The vehicle accelerates from a
stop in first gear and does not upshift. First gear ratio is 2.921:1.
Control Valve Body Assembly The 1-2 shift valve (318) is stuck or binding.

The spacer plate and gaskets (369-371) are misassembled.
Second Clutch Assembly A missing or not seated second clutch backing plate retaining
ring (627)
A missing or misassembled second clutch backing plate (626)
Worn, damaged, or misassembled clutch plates (623-625)
A missing or not seated second clutch spring retaining ring (622)
A missing or damaged second clutch housing ball check valve

assembly (618)
A damaged second clutch housing assembly (617)
Reverse Reaction Drum Damaged splines of the reverse reaction drum (669)
SECOND GEAR ONLY
Second Gear Only

Checks Cause
DEFINITION: The transmission only provides second gear in Drive range. The vehicle accelerates from
a stop in second gear and does not upshift. Second gear ratio is 1.568:1.

Input Carrier Assembly A damaged input sun gear (668)
Damaged input carrier (672) planetary pinions
THIRD GEAR ONLY
Third Gear Only

Checks Cause
DEFINITION: The transmission only provides third gear in Drive range. The vehicle accelerates from a
stop in third gear and does not upshift. Third gear ratio is 1.000:1.
Control Valve Body Assembly Debris is found in the control valve body (301) or the control valve
body spacer plate and gasket assembly (396).
FOURTH GEAR ONLY
Fourth Gear Only

Checks Cause
DEFINITION: The transmission only provides fourth gear in Drive range. The vehicle accelerates from a
stop in fourth gear and does not upshift. Fourth gear ratio is 0.705:1.
Control Valve Body Assembly Debris is found in the control valve body (301) or the control valve
body spacer plate and gasket assembly (396)
SLIPPING OR NO FIRST GEAR
Slipping or No First Gear

Checks Cause
DEFINITION: A large engine RPM increase is noted in first gear, Drive range, with little or no vehicle
forward speed increase. Second, third, and fourth gear operation are normal. Shifts into first gear are soft
or do not occur. First gear ratio is 2.921:1.
Level
Pressure
The oil filter seal assembly (101) is missing or is damaged.

Accumulator and Manual 2-1 A loose or damaged forward band servo oil pipe (124)
Band Servo Assembly
Loose manual 2-1 band servo cover of accumulator cover bolts
(103, 131)
A missing or a damaged manual 2-1 servo cover gasket (105)
A damaged accumulator cover spacer plate assembly (134)
Forward Band Servo Assembly The servo piston oil seal ring (18) is missing or damaged.
The servo piston (16) is damaged or stuck in the servo cover
(13).
The servo piston cushion spring (19) or the retainer (20) is
missing or damaged.
The servo piston pin (21) is not engaged to the forward band
assembly (688).
The forward band assembly (688) is worn or burned.
The forward band assembly (688) is disengaged from the anchor
pin (117A).
The band anchor pin (117A) is loose or missing.
The #3 ball check valve (372) is missing.
misassembled.
The input clutch housing oil seal rings (628) are missing or
damaged.
missing or damaged.
damaged.
1-2 Clutch Roller Assembly The 1-2 clutch roller assembly (683) is damaged.
SLIPPING OR NO SECOND GEAR
Slipping or No Second Gear

Checks Cause
DEFINITION: A large engine RPM increase is noted in second gear, Drive range, with little or no
vehicle forward speed increase. First, third, and fourth gear operation are normal. Shifts into second gear
are soft or do not occur. Second gear ratio is 1.568:1.
Level
Pressure

Debris is found in the passages of the control valve body (301) or
of the control valve body spacer plate and gasket assembly (396)
Driven Sprocket Support Damaged second clutch housing oil seal rings (613)
Assembly
Damaged four lobe oil seal ring seals (612)
Worn or damaged second clutch housing bushings (616, 619)
Second Clutch Assembly Missing or not seated second clutch backing plate retaining ring
(627)
Missing or misassembled second clutch backing plate (626)
Worn, damaged, or misassembled clutch plates (623-625)
Missing or not seated second clutch spring retaining ring (622)
Damaged spring assembly (621) or piston (620)
Missing or damaged second clutch housing ball check valve
assembly (618)
Damaged second clutch housing assembly (617)
SLIPPING OR NO THIRD GEAR
Slipping or No Third Gear

Checks Cause
DEFINITION: A large engine RPM increase is noted in third gear, Drive range, with little or no vehicle
forward speed increase. First, second, and fourth gear operation are normal. Shifts into third gear are soft
or do not occur. Third gear ratio is 1.000:1.
Level
Pressure

Control Valve Body Assembly The 2-3 shift valve (357) or the 3-2 manual downshift valve
(356) is stuck or binding.
The #4 or the #9 ball check valve is missing or mislocated.
Assembly assembly (609)
Third Clutch Assembly Input clutch housing oil seal rings (628) are missing or damaged.
The third clutch ball check valve assembly (724) is missing or
damaged.
The third clutch piston (642) is damaged.
The third clutch piston inner seal (641) is missing or damaged.
The third clutch plates (645-648) are worn or misassembled.
Third Clutch Sprag Assembly
The sprag (720) was misassembled or backwards on the inner
race (661).
A damaged third clutch sprag assembly (653, 661, 719-721)
SLIPPING OR NO FOURTH GEAR
Slipping or No Fourth Gear

Checks Cause
DEFINITION: A large engine RPM increase is noted in fourth gear, Drive range, with little or no vehicle
forward speed increase. First, second, and third gear operation are normal. Shifts into fourth gear are soft
or do not occur. Fourth gear ratio is 0.705:1.
Level
Pressure

Control Valve Body Assembly The 3-4 shift valve (362) or the 4-3 manual downshift valve
Case Cover Assembly Distortion or damage occurs at the manual valve (404) or at the case
cover (401), causing PRN oil leak.
Assembly assembly (609)
Fourth Clutch Assembly The clutch plates (500-502) are worn, damaged, or
misassembled.
A missing or not seated fourth clutch spring retaining ring (601)
Worn or damaged fourth clutch piston seals (604, 605)
Third Clutch Sprag Assembly The sprag (720) was misassembled or backwards on the inner
race (661).
A damaged third clutch sprag assembly (653, 661, 719-721)
NO ENGINE BRAKING IN MANUAL SECOND OR LOW RANGE
No Engine Braking in Manual Second or Low Range

Checks Cause
DEFINITION: A large engine RPM increase and forward vehicle speed decrease do not immediately
occur when the transmission is shifted from third or fourth gear in Drive or Manual Third range to either
first or second gear, Manual Second, or Low range.
Accumulator and Manual 2-1 A loose or damaged manual 2-1 band servo oil pipe (125)
Band Servo Assembly
Loose manual 2-1 band servo cover or accumulator cover bolts
(103, 131)
A damaged accumulator cover spacer plate assembly (134)
A damaged or missing servo piston seal (107) or a servo piston
cylinder O-ring seal (113)
A missing servo exhaust screen assembly (115), allowing debris
into the cylinder
A misassembled manual 2-1 servo assembly (103-115)
Manual 2-1 Band Assembly A band assembly (680) that is worn or burned
A band assembly (680) that is disengaged from the anchor pin
(102)
A band anchor pin (102) that is loose or missing
WHINE NOISE VARYING WITH RPM OR FLUID PRESSURE
Whine Noise Varying with RPM or Fluid Pressure

Checks Action
DEFINITION: In all ranges, a whine which may be sensitive to RPM load, or which ceases when the
TCC engages, or which is sensitive to the oil pressure
Torque Converter (1) Verify that the noise is internal to the torque converter by placing
your left foot on the brake with the gear or selector in Drive.
Momentarily stall the engine. Torque Converter noise increases
under load.
Oil Pump System Verify that the noise is internal to the oil pump during a preliminary
oil pressure check. An increase in line pressure will vary an oil
pump noise.
POPPING NOISE
Popping Noise
Checks Action
DEFINITION: A popping noise, similar to popcorn popping
Oil Pump System Check fluid level.
Inspect for pump cavitation, indicated by bubbles in fluid.

Inspect the transmission fluid filter for a leaky seam.
Inspect the transmission fluid filter seal for improper
positioning or for a cut seal.
BUZZ NOISE OR HIGH FREQUENCY RATTLE SOUND
Buzz Noise or High Frequency Rattle Sound

Checks Action
DEFINITION: A buzz or high frequency rattle
Trace Cooler Pipes
Verify a pressure buzz by watching for a needle vibration of the
pressure gage. A road test may be necessary. Refer to Road Test
Check for binding or contact at
Procedure.
the Radiator, other than at the
Cooler Pipe connectors
WHINE/GROWL NOISE THAT CHANGES WITH VEHICLE SPEED
Whine/Growl Noise That Changes with Vehicle Speed

Checks Action
DEFINITION: A whine or growl that increases and fades with vehicle speed and is most noticeable
under light acceleration
Drive Link Assembly System Verify that the noise comes from the sprockets or the from the drive
link assembly chain by placing your left foot on the brake and by
moving the gear selector from Park or Reverse. If the noise stops,
check the following items.
Drive Sprocket Support (522) and The bearing outer race support is rough or nicked.
Driven Sprocket Support (609)
Drive Sprocket (516) and Driven Broken or sheared teeth
Sprocket (506)
Nicked or scored bearing surfaces
The bearing race or roller bearing surfaces on the gear

support inner bearing are rough or pitted
A damaged bearing
Drive Chain (507) Stretched
FINAL DRIVE NOISE OR HUM NOISE
Final Drive Noise or Hum Noise

Checks Cause
DEFINITION: A final drive noise or hum is most noticeable under light throttle acceleration or turns
Final Drive Gear Set (700) Worn planet pinions
Final Drive Internal Gear (693) Worn washers
Worn or damaged teeth
Differential Carrier (700) Worn or pitted gears
Differential Side Gears (705) A damaged thrust washer
NOISE IN FIRST, SECOND, THIRD, OR FOURTH
Noise in First, Second, Third or Fourth

Checks Cause
Final Drive Sun Gear (697) Worn or damaged gears
Final Drive Pinions (711)
NOISE IN RANDOM RANGES
Noise in Random Ranges

Checks Action
DEFINITION: Noise only in certain gear ranges
Refer to Range Reference . Determine the power flow and the applicable components that may be
causing this noise.
ABNORMAL NOISE IN PARK OR NEUTRAL RANGE
Abnormal Noise in Park or Neutral Range

Checks Cause
DEFINITION: Noise only in Park or Neutral
Drive Sprocket Support (522) and Nicked or scored bearing surfaces
Driven Sprocket Support (609)
The bearing race or roller bearing on the gear support inner
bearing are rough or pitted.
The bearing outer race support is rough or nicked.
A damaged bearing
Forth Clutch Assembly Clutch plates (501) damaged or worn
CONVERTER CLUTCH STUCK ON IN ALL GEARS
TCC Stuck On in All Gears

Checks Cause
DEFINITION: No difference in RPM is noted between the engine speed and the transmission input,
turbine, speed in any transmission range. This condition may also cause the engine to stall when the
vehicle is slowed to a stop or when the transmission is shifted from Park or Neutral range into Reverse or
Drive range.
Control Valve Body Assembly The TCC control valve (335) or the TCC regulator apply valve
The spacer plate and gaskets (369-371) are misassembled or
contain incorrect parts.
CONVERTER CLUTCH STUCK ON IN SECOND, THIRD AND FOURTH GEAR
Converter Clutch Stuck On in 2nd, 3rd and 4th Gear

Checks Cause
DEFINITION: No difference in RPM is noted between the engine speed and the transaxle input (turbine)
shaft speed in second, third and fourth gear, DRIVE range. TCC is not ON in first gear and the engine
does not stall when the vehicle slows to a stop or is shifted from PARK or NEUTRAL range to
REVERSE or DRIVE range.
Control Valve Body Assembly The TCC PWM solenoid valve assembly (334) is faulty (stuck
ON).
The control valve body spacer plate gaskets assembly (396) are
misassembled or contain incorrect parts.
The PWM internal O-ring is missing or damaged.
HARSH TORQUE CONVERTER CLUTCH (TCC) APPLY OR RELEASE
Harsh TCC Apply or Release

Checks Cause
DEFINITION: An unacceptably quick TCC apply or release occurs in third or fourth gear, Drive or
Manual third range, with the throttle held steady.
Control Valve Body Assembly The TCC regulator apply valve (327) is stuck or binding.
The TCC regulator apply valve spring (326) is missing or

damaged.
The TCC control valve spring (336) is missing or damaged.
TCC PWM Solenoid faulty.
CONVERTER CLUTCH APPLY ROUGH, SLIPS, OR SHUDDERS
Soft TCC Apply (Shudder)

Checks Cause
DEFINITION: An unacceptably long TCC apply occurs in third or fourth gear, Drive or Manual Third
range, with the throttle held steady. This can cause a momentary rapid jerking sensation in the vehicle
during the TCC apply.
Control Valve Body Assembly The TCC regulator apply valve (327) is stuck or binding.
The TCC regulator apply valve spring (326) is missing or

damaged.
TCC control valve stuck or binding.
TCC control valve spring is missing or damaged.
TCC PWM solenoid faulty.
Case Cover Assembly The TCC blowoff ball valve (420B) or the spring (418) is damaged or is
not seating.
Turbine Shaft Assembly The turbine shaft O-ring seal (520) is damaged or is missing.
The turbine shaft oil seal rings (513, 519) are damaged or
missing.
The turbine shaft (518) is damaged.
Drive Sprocket Support The turbine shaft bushing (523) is worn or damaged.
Assembly
Torque Converter Assembly The torque converter bushing is worn or damaged
The torque converter cover surface is damaged under lug thread
(s) due to the flexplate bolt bottoms out.
The torque converter is damaged internally
The TCC friction material is missing or damaged
The TCC plate is distorted or damaged
The torque converter internal O-ring seal is missing or

damaged
NO TORQUE CONVERTER CLUTCH (TCC) APPLY
No TCC Apply
Checks Cause
DEFINITION: A large difference in RPM is noted between the engine speed and the transmission input,
turbine, speed in third or fourth gear, Drive or Manual Third range when the TCC is commanded On by
the PCM.
Control Valve Body Assembly The TCC PWM solenoid valve assembly (334) is stuck Off.
The TCC control valve (335) or the TCC regulator apply valve
The #10 ball check valve (372) is missing or is mislocated.
Case Cover Assembly The TCC blowoff ball valve (420B) or the spring (418) is damaged or is
not seating.
Turbine Shaft Assembly The turbine shaft O-ring seal (520) is damaged or is missing.
The turbine shaft oil seal rings (513, 519) are damaged or
missing.
The turbine shaft (518) is damaged.
Drive Sprocket Support The turbine shaft bushing (523) is worn or damaged.
Assembly
Bearing damage
Torque Converter Assembly The torque converter bushing is worn or damaged
The torque converter cover surface is damaged under lug thread
(s) due to the flexplate bolt bottoms out
The torque converter is damaged internally
The TCC friction material is missing or damaged
The TCC plate is distorted or damaged

The torque converter internal O-ring seal is missing or
damaged
Automatic Level Control - Aztek & Rendezvous
SPECIFICATIONS

Specification
Air Compressor Bracket to Body Bolts 10 N.m 89 lb in
Air Compressor Bracket to Body Nuts 10 N.m 89 lb in
Air Compressor to Bracket Bolts 6 N.m 53 lb in
Air Dryer Bracket Screw 6 N.m 53 lb in
Air Line Tube Repair Nut 8 N.m 70 lb in
Automatic Level Control Relay Bolt 6 N.m 53 lb in
Automatic Level Control Shield Bolt 6 N.m 53 lb in
Height Sensor Ball Stud 4 N.m 35 lb in
Height Sensor Bracket to Body Bolts 85 N.m 63 lb ft
Inflator Fill Valve Nut 6 N.m 53 lb in
Inflator Solenoid Screws 6 N.m 53 lb in

AUTOMATIC LEVEL CONTROL SUSPENSION SCHEMATICS
Fig. 1: Automatic Level Control Suspension
COMPONENT LOCATOR
AUTOMATIC LEVEL CONTROL SUSPENSION COMPONENT VIEWS
Fig. 2: Relay, Switch, Solenoid and Compressor Assembly Component View
Callouts For Fig. 2

1 Inflator Air Switch
2 Inflator Soleniod
3 Automatic Level Control (ALC) Compressor
4 Exhaust Solenoid
5 Automatic Level Control (ALC) Compressor Relay
Fig. 3: Automatic Level Control (ALC) Sensor Component View
Callouts For Fig. 3

1 Auto Level Control (ALC) Sensor
AUTOMATIC LEVEL CONTROL SUSPENSION CONNECTOR END VIEWS
Auto Level Control (ALC) Air Compressor

1205-9472
7-Way F Metri-Pack Mixed Series Sealed (BK)

A OG 840 Battery Positive Voltage
B OG 840 Battery Positive Voltage
Auto Level Control Exhaust Solenoid
C WH 320
Control
Automatic Level Control Relay Coil Supply
D YE 321
Voltage
E OG 1240 Battery Positive Voltage
F OG 840 Battery Positive Voltage
G BK 450 Ground
Automatic Level Control Inflator Relay Coil
H WH 837
Control
Automatic Level Control (ALC) Compressor Relay

12110787
4-Way F Metri Pack 150 Series (GY)

85 BK 450 Ground
86 YE 321
Voltage
Automatic Level Control (ALC) Inflator Air Switch
12089248
4-Way F Metri Pack 150 Series (NAT)

A OG 840 Battery Positive Voltage
B - - Not Used
C L- BU 1770 Ride Control Serial Data
Automatic Level Control Inflation Timer
D WH 1245
Relay Coil Control
Automatic Level Control (ALC) Inflator Solenoid
12052643
2-Way F Metri Pack 150 Series, Sealed (RED)

A - 840 Battery Positive Voltage
Automatic Level Control (ALC) Inflator
B - 837
Relay Coil Control
Auto Level Control (ALC) Sensor

15326836
8-Way F GT 150 Series Sealed (BK)

Automatic Level Control Exhaust Solenoid
A WH 320
Control
B YE 321
Voltage
C BK/WH 151 Ground
D YE 843 Accessory Voltage
E L- BU 1770 Ride Control Serial Data
Automatic Level Control Inflator Relay Coil
F WH 837
Control
Automatic Level Control Inflation Timer
G WH 1245
Relay Coil Control
H OG 840 Battery Positive Voltage

DIAGNOSTIC STARTING POINT - AUTOMATIC LEVEL CONTROL
Begin the system diagnosis with the Diagnostic System Check - Vehicle in Vehicle DTC Information. The
Diagnostic System Check - Vehicle will provide the following information:

The identification of any stored DTCs and their status
The use of the Diagnostic System Check - Vehicle will identify the correct procedure for diagnosing the system
and where the procedure is located.
DIAGNOSTIC TROUBLE CODE (DTC) DISPLAYING
All the Automatic Level Control diagnostic trouble codes are displayed with a blink code on the accessory
inflator switch LED. The diagnostic codes will flash after the completion of the self test. The self test is
achieved by pressing the accessory inflator switch for 3 seconds. The self test will take 200 seconds to
complete.
The number of flashing pulses on the inflator switch LED shall represent the number of the diagnostic code.
The flashing pulses shall have a repetition rate of 0.5 seconds and each code digit shall be separated by a 1.0
second delay. Each code cycle shall be separated by a 3.0 second delay. All current failure codes shall be
flashed in numerical order. All current failure codes shall be flashed until they are acknowledged by depressing
the accessory inflator switch, or until the module enters asleep mode. The module will flash these codes with
every successive self test request until the failure is removed. The blink code shall take priority over other
processes that have access to the accessory inflator switch LED.
DIAGNOSTIC TROUBLE CODE (DTC) CLEARING
The Automatic Level Control diagnostic trouble codes will clear when the ignition switch has been transitioned
from off to on and the conditions that caused the code to set have been removed.
DTC 011
Circuit Description
The automatic level control sensor monitors the accessory inflator valve circuit for a short to ground, or an open
circuit.
DTC Descriptor
DTC 011 Accessory Inflator Valve Circuit
The ignition is ON.
Open in control circuit of the accessory inflator valve

Short to ground in the control circuit of the accessory inflator valve
A malfunctioning accessory inflator valve
The automatic level control sensor disables inflator functions.

Leveling functions shall continue.
The automatic level control sensor will recheck the accessory inflator valve circuitry periodically.
The conditions that caused the DTC to set have been removed.
Diagnostic Aids
When this DTC occurs, DTCs 032 and 033 will be set.
Test Description
2: This step tests for voltage at the coil side of the accessory inflator valve. The ELC relay fuse supplies
power to the coil side of the accessory inflator valve.
3: This step verifies that the height sensor is providing ground to the accessory inflator valve.
4: This step tests if ground is constantly being applied to the accessory inflator valve.
9: This step verifies that the automatic level control sensor is self tested after replacement.
DTC 011
Step Action Yes No
Schematic Reference: Automatic Level Control Suspension Schematics
1
Vehicle in Vehicle
2. Disconnect the accessory inflator valve.
3. Probe the battery positive voltage circuit of the
2 accessory inflator valve with a test lamp that is
connected to a good ground.
Does the test lamp illuminate? Go to Step 3 Go to Step 7

1. Connect a test lamp between the control circuit
of the accessory inflator valve and the battery
positive voltage circuit of the accessory inflator
valve.
3 2. With the accessory inflator switch, command the
accessory inflator valve ON and OFF.
Does the test lamp turn ON and OFF with each

command? Go to Step 5 Go to Step 4
Test the control circuit of the accessory inflator valve
for the following conditions:
A ground
4 An open

Wiring Systems.
Inspect for poor connections at the accessory inflator
valve. Refer to Testing for Intermittent Conditions
5 and Poor Connections andWiring Repairs in Wiring
Systems.
the height sensor. Refer to Testing for Intermittent
6 Conditions and Poor Connections and Wiring
Repair the battery positive voltage circuit of the
accessory inflator valve. Refer to Wiring Repairs in
7 -
Wiring Systems.
Did you complete the repair? Go to Step 10
Replace the accessory inflator valve. Refer to Inflator
8 Solenoid Replacement . -
IMPORTANT:
System untested code will continue to flash until
Self test has been completed after automatic level
control sensor replacement.
9 -
Replace the automatic level control sensor. Refer to
Automatic Level Control Sensor Replacement .Did
you complete the replacement? Go to Step 10
Operate the vehicle within the Conditions for Running
10 the DTC as specified in the supporting text.
DTC 012
Circuit Description
The System OK code is used to identify that the self test has found no faults with the automatic level control
system.
DTC Descriptor
DTC 012 System OK
The ignition is ON.
No DTCs are set after self test has been completed.

Automatic level control system functions normally.
DTC 012
Step Action Yes No
1
Vehicle in Vehicle
The automatic level control system is functioning
2 normally. -
Is this code present after self test? System OK
DTC 013
Circuit Description
The automatic level control sensor, monitors the body to suspension height and detects when it is out of range.
DTC Descriptor
DTC 013 Level Control Sensor Circuit
The ignition is ON.
When the automatic level control sensor detects body to suspension height is out of voltage range (0.5-4.5 volts)
for at least 1.0 seconds.
Leveling functions are disabled.

The accessory inflator function continues to operate.

Diagnostic Aids
This DTC is set when ride height is physically being held out of range.
This DTC can set when the sensor link is damaged or detached.
Test Description
2: This step tests for mechanical damage to automatic level control sensor link.
3: Automatic level control sensor replacement.
DTC 013
Step Action Yes No
1
Vehicle in Vehicle
Inspect the automatic level control sensor link for
2 damage or being disconnected.
3 Automatic Level Control Sensor Replacement . -
DTC 021
Circuit Description
The automatic level control sensor monitors the compressor relay coil control circuity for a short to ground.
DTC Descriptor
DTC 021 Compressor Relay Circuit Short to Ground
The ignition is ON.

This DTC is set when the automatic level control sensor detects the compressor relay coil control circuit is
shorted to ground.
The automatic level control sensor disables the compressor.

Lowering functions shall continue.
The ignition has transitioned from OFF to ON.
Diagnostic Aids
Compressor motor will run continuously.

When this occurs, DTC 023 will be set.
Test Description
2: This step tests for short to ground in compressor relay control circuit.
DTC 021
Step Action Yes No
1
Vehicle in Vehicle
Test the control circuit of the compressor relay for a
2
IMPORTANT:
System untested codes will continue to flash until
the self test has been completed after automatic
3 level control sensor replacement.

you complete the replacement? Go to Step 4 -
DTC 022
Circuit Description
The automatic level control sensor monitors the level control compressor relay coil control circuity for a open
circuit or short to battery.
DTC Descriptor
DTC 022 Level Control Compressor Relay Circuit Short to Battery or Open
The ignition is ON.
This DTC is set when the automatic level control sensor detects the level control compressor relay coil control
circuit is open or shorted to battery.
The automatic level control sensor disables the compressor.

Lowering functions shall continue.
Diagnostic Aids
A short to battery or an open circuit in the level control compressor relay coil control circuit will set this DTC.
Test Description
2: This step tests for battery positive voltage at the relay coil. The ELC fuse supplies power to the relay
coil of the level control compressor relay.
3: This step verifies that the automatic level control sensor is providing ground to the level control
compressor relay.
4: This step tests if battery positive voltage is constantly being applied to the level control compressor
relay control circuit or the circuit is open.
DTC 022
Step Action Yes No
1
Vehicle in Vehicle
2. Disconnect the level control compressor relay.
2 level control compressor relay with a test lamp
that is connected to a good ground.

1. Connect a test lamp between the coil control
circuit of the level control compressor relay and
the battery positive voltage circuit of the level
control compressor relay.
3 2. With the accessory inflator switch, command the
accessory inflator valve ON and OFF.

Test the control circuit of the level control compressor
relay for a short to voltage, ground, or an open. Refer to
4 Circuit Testing and Wiring Repairs in Wiring
Systems.
Inspect for poor connections at the level control
compressor relay. Refer to Testing for Intermittent
5 Conditions and Poor Connections and Wiring
the automatic level control sensor. Refer to Testing for
Intermittent Conditions and Poor Connections and
6 Wiring Repairs in Wiring Systems.
Repair the battery positive voltage circuit of the level
control compressor relay coil. Refer to Wiring Repairs
7 -
in Wiring Systems.
Replace the level control compressor relay. Refer to
8 Automatic Level Control Relay Replacement . -
IMPORTANT:
self test has been completed after automatic level
9 -
DTC 023
Circuit Description
The automatic level control sensor monitors for excessive compressor activity and the compressor is limited to
255 seconds for a leveling function.
DTC Descriptor
DTC 023 Excessive Compressor Activity
The ignition is ON.
This DTC is set when the automatic level control sensor detects the compressor has been running for 255
seconds during a leveling function.

The automatic level control sensor disables the leveling functions.
Diagnostic Aids
An AIR LEAK in the system will cause this DTC to set.

If the rod is disconnected, DTC 033 will be set.
Test Description
3: This step tests for battery positive voltage at the level control compressor relay. The ELC fuse supplies
power to the level control compressor relay.
4: This step verifies that the level control compressor relay contacts are working.
5: This step tests the ground circuit for the compressor motor.
10: This step verifies that the level control compressor relay is replaced.
DTC 023
Step Action Yes No
1
Vehicle in Vehicle
1. Check all air lines and exhaust valves for air
leakage.
2 2. Check both rear shock absorbers for air leakage.

2. Disconnect the level control compressor relay.
3 level control compressor relay with a test lamp

1. Connect a test lamp between the battery positive
output circuit of the level control compressor
relay and the compressor motor ground circuit.
2. With the accessory inflator switch, command the
4 accessory inflator valve ON and OFF.

Test the ground circuit of the compressor motor for a
open. Refer to Circuit Testing and Wiring Repairs in
5
Wiring Systems.
Inspect for poor connections at the compressor motor.
Refer to Testing for Intermittent Conditions and
6 Poor Connections and Wiring Repairs in Wiring
Systems.
of the level control compressor relay. Refer to Testing
Repair the battery positive voltage circuit of the level
control compressor relay coil. Refer to Wiring Repairs
8 -
in Wiring Systems.
Replace the compressor motor. Refer to Air
9 Compressor Replacement . -
Replace the level control compressor relay. Refer to
10 Automatic Level Control Relay Replacement . -
DTC 031
Circuit Description
The automatic level control sensor monitors the exhaust valve control circuity for a short to ground.
DTC Descriptor
DTC 031 Exhaust Valve Circuit Short to Ground

The ignition is ON.
This DTC is set when the automatic level control sensor detects the exhaust valve control circuit is shorted to
ground.
The automatic level control sensor disables leveling functions.
Diagnostic Aids
A short to ground in the exhaust valve control circuit will set this DTC.
Test Description
2: This step tests for voltage at the coil side of the exhaust valve. The ELC fuse supplies power to the coil
side of the exhaust valve.
3: This step verifies that the automatic level control sensor is providing ground to the exhaust valve.
4: This step tests if ground is constantly being applied to the exhaust valve.
DTC 031
Step Action Yes No
1
Vehicle in Vehicle
2. Disconnect the exhaust valve.
2 exhaust valve with a test lamp that is connected
to a good ground.

Connect a test lamp between the control circuit of the
exhaust valve and the battery positive voltage circuit of
3
the exhaust valve.
Test the control circuit of the exhaust valve for a short
to ground. Refer to Circuit Testing and Wiring
4
Inspect for poor connections at the exhaust valve. Refer
to Testing for Intermittent Conditions and Poor
5
Connections and Wiring Repairs in Wiring Systems.
Repair the battery positive voltage circuit of the
exhaust valve. Refer to Wiring Repairs in Wiring
7 -
Systems.
Replace the exhaust valve. Refer to Air Compressor
8 Replacement . -
IMPORTANT:
9 -
DTC 032
Circuit Description
The automatic level control sensor monitors the exhaust valve control circuity for a short to battery positive
voltage or an open circuit.
DTC Descriptor

DTC 032 Exhaust Valve Circuit Short to Battery or Open
The ignition is ON.
This DTC is set when the automatic level control sensor detects the exhaust valve control circuit is shorted to
battery positive voltage or an open circuit.
The automatic level control sensor disables leveling functions.
The ignition switch has cycled from OFF to ON.
Diagnostic Aids
A short to battery positive voltage or an open circuit in the exhaust valve control circuit will set this DTC.
Test Description
2: This step tests for voltage at the coil side of the exhaust valve. The ELC fuse supplies power to the coil
side of the exhaust valve.
3: This step verifies that the automatic level control sensor is providing ground to the exhaust valve.
4: This step tests if ground is constantly being applied to the exhaust valve.
DTC 032
Step Action Yes No
1
Vehicle in Vehicle
2 2. Disconnect the exhaust valve.
exhaust valve with a test lamp that is connected
to a good ground.

Connect a test lamp between the control circuit of the
3 exhaust valve and a good ground.
Test the control circuit of the exhaust valve for a short
to battery positive voltage. Refer to Circuit Testing
4
Test the control circuit of the exhaust valve for an open
circuit. Refer to Testing for Continuity and Wiring
5
Inspect for poor connections at the exhaust valve. Refer
6
Connections and Wiring Repairs in Wiring Systems.
Repair the battery positive voltage circuit to the exhaust
8 valve. Refer to Wiring Repairs in Wiring Systems. -
Replace the exhaust valve. Refer to Air Compressor
9 Replacement . -
IMPORTANT:
10 -
DTC 033
Circuit Description
The automatic level control sensor monitors the exhaust valve on time when the vehicle is lowering and is
limited to 255 seconds.
DTC Descriptor
DTC 033 Exhaust Valve Excessive On Time
The ignition is ON.
This DTC is set when the automatic level control sensor detects the exhaust valve has been on for 255 seconds
and the automatic level control sensor did not detect the calibrated downward movement.
The automatic level control sensor disables the leveling functions.
The ignition switch has been cycled from OFF to ON.
Diagnostic Aids
An air line or exhaust valve blockage in the system will cause this DTC to set.
Test Description
2: This step tests for something mechanical that is not allowing the vehicle to lower.
3: This step verifies the automatic level control sensor connector to have a good connection.
DTC 033
Step Action Yes No
1
Vehicle in Vehicle
1. Check all air lines and exhaust valves for airflow
blockage.
2 2. Check both rear shock absorbers for binding.

IMPORTANT:
System untested codes will continue to flash until a
4 -
SYMPTOMS - AUTOMATIC LEVEL CONTROL
Review the system operation in order to familiarize yourself with the system functions. Refer to Automatic
Level Control Description and Operation .
Inspect for aftermarket devices which could affect the operation of the ALC system. Refer to Checking
Aftermarket Accessories in Wiring Systems.
cause the symptom.
Intermittent
Symptom List
Automatic Level Control Inflator Fill Valve Inoperative
AUTOMATIC LEVEL CONTROL INFLATOR FILL VALVE INOPERATIVE

Automatic Level Control Inflator Fill Valve Inoperative
Step Action Yes No
Did you review the Automatic Level Control System Go to Symptoms -
1 Description and Operation and perform the necessary Automatic Level
inspections? Go to Step 2 Control
1. Turn ON the ignition, with the engine OFF. Go to Testing for
Intermittent
2 2. Turn ON the air inflator switch. Conditions and
Poor Connections
Does the ALC inflator fill valve operate normally? in Wiring Systems Go to Step 3
1. Disconnect the air inflator switch connector.
2. Connect a 10 A fused jumper from the ALC
inflation timer relay coil control circuit to the
ground circuit of the air inflator switch.
3 3. Probe the ALC inflator solenoid valve supply
voltage circuit of the ALC air inflator relay
connector with a test lamp that is connected to a
good ground.

1. Disconnect the ALC air inflator solenoid valve
connector.
2. Connect a test lamp between the ALC inflator
4 solenoid valve supply voltage circuit of the ALC
air inflator solenoid valve connector and a good
ground.

Connect a test lamp between the ALC inflator solenoid
valve supply voltage circuit and the ground circuit of
5
the ALC air inflator solenoid valve connector.
Repair the open in the ALC inflator solenoid valve
supply voltage circuit. Refer to Wiring Repairs in
6
Wiring Systems.
Repair the open in the ground circuit of the ALC air
7 inflator solenoid valve connector.
Replace ALC air inflator relay. Refer to Automatic
8 Level Control Relay Replacement .
Replace the ALC air inflator solenoid valve. Refer to
9 Inflator Solenoid Replacement .
10
REPAIR INSTRUCTIONS
AUTOMATIC LEVEL CONTROL RELAY REPLACEMENT
Removal Procedure
1. Raise and support vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Fig. 4: Automatic Level Control Relay Electrical Connector

2. Remove the electrical connector (1) from the relay (2).

Fig. 5: Locating Relay Bolt
3. Remove the relay bolt (1) from the bracket.

Fig. 6: Automatic Level Control Relay
4. Remove the relay (1) from the compressor assembly.
Fig. 7: Automatic Level Control Relay
1. Install the relay (1) to the compressor assembly.

Fig. 8: Locating Relay Bolt
2. Install the relay nut (1) to the bracket.
Tighten: Tighten nut to 6 N.m (53 lb in)

Fig. 9: Automatic Level Control Relay Electrical Connector
3. Install the electrical connector (1) to the relay (2).

ACCESSORY FILL VALVE REPLACEMENT
Removal Procedure
Fig. 10: Accessory Fill Valve Access Cover
1. Remove the accessory fill valve access cover.

2. Remove the lower rear quarter trim panel. Refer to Trim Panel Replacement - Rear Quarter Lower
(Aztek) or Trim Panel Replacement - Rear Quarter Lower (Rendezvous) in Interior Trim.
3. Disconnect the air hose (1) from the accessory fill valve (5).
4. Remove the cap (2), nut (3), and washer (4) from the accessory fill valve (5)
5. Remove the accessory fill valve from the trim panel.
Fig. 11: Accessory Fill Valve Access Cover
1. Install the accessory fill valve into the trim panel.
2. Install the washer (4) and the nut (3) to the accessory fill valve.
Tighten: Tighten the accessory fill valve nut to 6 N.m (53 lb in).
3. Install the cap to the accessory fill valve.

4. Install the hose (1) onto the accessory fill valve (5).
5. Install the lower rear quarter trim panel. Refer to Trim Panel Replacement - Rear Quarter Lower
6. Install the accessory fill valve access cover.
AUTOMATIC LEVEL CONTROL INFLATOR AIR SWITCH REPLACEMENT
Removal Procedure
1. Remove the inflator fill valve access cover.

2. Remove the lower rear quarter trim panel. Refer to Trim Panel Replacement - Rear Quarter Lower
3. Remove the switch from the inflator control panel.
Fig. 12: Accessory Inflator Switch Electrical Connector

4. Disconnect the electrical connector (1) from the accessory inflator switch (2).
Fig. 13: Accessory Inflator Switch Electrical Connector
1. Connect the electrical connector (1) to the accessory inflator switch (2).
2. Install the inflator switch in the inflator control panel.
3. Install the lower rear quarter trim panel. Refer to Trim Panel Replacement - Rear Quarter Lower
4. Install the inflator fill valve access cover.
AUTOMATIC LEVEL CONTROL AIR DRYER REPLACEMENT
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
Fig. 14: Air Dryer Hose
2. Remove the hose (1) from the air dryer (2).

Fig. 15: Automatic Level Control Air Dryer Mounting Screw
3. Remove the mounting screw (1).

Fig. 16: Aligning Air Dryer For Removal/Installation
4. Rotate the air dryer (1) to remove from compressor.
Fig. 17: Aligning Air Dryer For Removal/Installation
1. Install the air dryer (1) to the compressor.

Fig. 18: Automatic Level Control Air Dryer Mounting Screw
2. Install the air dryer mounting screw (1).
Tighten: Tighten the screw to 6 N.m (53 lb in).

Fig. 19: Air Dryer Hose
3. Install the hose (1) onto the air dryer (2).

AUTOMATIC LEVEL CONTROL AIR COMPRESSOR AIR FILTER REPLACEMENT
Removal Procedure
Fig. 20: Automatic Level Control Air Compressor Air Filter
2. Squeeze the clips on side of the filter.
3. Pull the filter out of the hole in the rail.
Fig. 21: View Of Automatic Level Control Air Compressor Filter With Hose
4. Remove the automatic level control air compressor filter from the hose.
Fig. 22: View Of Automatic Level Control Air Compressor Filter With Hose
1. Install the automatic level control air compressor filter to the hose.
Fig. 23: Automatic Level Control Air Compressor Air Filter
IMPORTANT: To prevent water from entering the automatic level control air
compressor, snap the filter completely into the underbody rail during
installation.
2. Install the automatic level control air compressor filter to the underbody rail.
3. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
AUTOMATIC LEVEL CONTROL SENSOR LINK REPLACEMENT
Removal Procedure
NOTE: When you are servicing the automatic level control sensor link, ensure that the
sensor link and the sensor arm are not damaged. Ensure the sensor arm and
the sensor link are properly oriented. Improper orientation of the sensor arm
and the sensor link may cause damage to the automatic level control system or
the vehicle.
Fig. 24: Automatic Level Control Sensor Link
2. Remove the ALC sensor link from the lower control arm ball stud.
3. Remove the ALC sensor link from the sensor arm ball stud.
Fig. 25: Automatic Level Control Sensor Link
1. Install the ALC sensor link to the lower control arm ball stud.
2. Install the ALC sensor link to the sensor arm ball stud.
AUTOMATIC LEVEL CONTROL SENSOR REPLACEMENT
Removal Procedure
IMPORTANT: When replacing the height sensor a diagnostic system check must be
performed.
Fig. 26: View Of Automatic Level Control Sensor Electrical Connector

2. Remove the automatic level control sensor electrical connector (1).

3. Remove the automatic level control sensor link from the lower control arm ball stud.
Fig. 27: Identifying Automatic Level Control Height Sensor Bracket Bolts
4. Remove the automatic level control height sensor bracket bolts (1).
5. Remove the automatic level control height sensor with the bracket from the vehicle.
6. Remove the automatic level control height sensor link from the height sensor arm.
1. Install the automatic level control height sensor link onto the height sensor arm.
2. Install the automatic level control height sensor with the bracket onto the vehicle.

Fig. 28: Identifying Automatic Level Control Height Sensor Bracket Bolts
3. Install the automatic level control height sensor bracket bolts (1).
Tighten: Tighten the height sensor bracket bolts to 85 N.m (63 lb ft).
4. Install the automatic level control sensor link to the lower control arm ball stud.
Fig. 29: View Of Automatic Level Control Sensor Electrical Connector
5. Install the automatic level control sensor electrical connector (1).

7. Perform a diagnostic system check. Refer to Diagnostic System Check - Vehicle in Vehicle DTC
Information.
AUTOMATIC LEVEL CONTROL SENSOR LINK BALL STUD REPLACEMENT
Removal Procedure
Fig. 30: Locating Automatic Level Control Sensor Link Ball Stud
IMPORTANT: When removing the link, do NOT bend or break the sensor arm.
2. Remove the automatic level control sensor link from the lower control arm ball stud.
3. Remove the ball stud from the rear lower control arm.
Fig. 31: Locating Automatic Level Control Sensor Link Ball Stud
1. Install the ball stud to the rear lower control arm.
Tighten: Tighten the height sensor ball stud to 4 N.m (35 lb in).
2. Install the automatic level control sensor link to the lower control arm ball stud.
AIR TUBE REPLACEMENT

Fig. 32: View Of Air Tube
At the rear shock absorbers, the air tube connectors are held on with spring clips which snap into the grooves of
the shock absorber air fittings. Air tube connectors are sealed using two O-rings.
IMPORTANT: Before disconnecting any air tube, clean the connector and the surrounding
area to prevent dirt and other foreign material from entering the ELC system.
To disconnect an air tube from a shock absorber, rotate the spring clip 90 degrees out of the slots, and pull the
connector from the shock absorber.
IMPORTANT: Ensure that the air tube is routed correctly and all fasteners are used.
To connect an air tube to a shock absorber, lubricate the two O-rings using silicone lubricant, rotate the spring
clip 90 degrees into the slots, and push the air tube connector on the shock absorber fitting until spring clip
snaps into fitting groove.
Removal Procedure
Fig. 33: Identifying Air Tubes Connected To Shock Absorbers
1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
2. Disconnect the air tube from the left rear shock absorber.
3. Disconnect the left rear air tube from the tee connector and remove from the vehicle.
4. Disconnect the air tube from the right rear shock absorber.
5. Disconnect the right rear air tube from the tee connector.
6. Remove the air tube from the routing clips and from the vehicle.
Fig. 34: Identifying Air Tubes Connected To Shock Absorbers
1. Install the right rear air tube on the vehicle in the routing clips.
2. Connect the right rear air tube to the tee connector.
3. Connect the right rear air tube to the right rear shock absorber.
4. Connect the left rear air tube to the tee connector.
5. Connect the left rear air tube to the right rear shock absorber.
IMPORTANT: Before driving the vehicle, turn the ignition on and wait approximately 45
seconds. This will ensure that the air adjustable shock absorbers are
filled with residual pressure.
AIR LINE TUBING REPAIR
1. Locate the leaking area with soap and water or a stethoscope.
Fig. 35: Cross Section Of Air Line Tubing

2. Cut and remove the leaking line (2) section.

3. Remove the plastic retainer pin from one of the nuts.
4. Slide the air line tube onto the nut until the line bottoms in the rubber seal (5).

5. Hold the air line tube in position.
Tighten: Tighten the air line tube repair nut to 8 N.m (70 lb in).
6. Install the air line tube to the other end of the coupling.
7. Repeat Steps 3 through 5.
IMPORTANT: Ensure that the repaired air line tube is secured in a location where the
line is not pinched, or kinked, and will not contact the exhaust system.
8. Install the air line tube to the vehicle.

9. Inflate the automatic level control system and inspect for leaks.
SHOCK ABSORBER CROSSOVER AIR TUBE REPLACEMENT
Removal Procedure
1. Remove the ELC/TRAILER fuse.

Fig. 36: View Of Air Line
IMPORTANT: The ALC system air lines use spring clip connectors with molded sealing
shoulders in the fittings and on the end of the air lines. In order to help
seal the air line, 2 O-rings are used at each connector. In order to prevent
dirt and other foreign material from entering the ALC system, clean the
connector and the surrounding area, before disconnecting any air line.
In order to disconnect the air line from a fitting, rotate the spring clip 90
degrees out of the slots and pull the connector from the fitting. In order to
connect an air line to a fitting, lubricate the O-rings with silicone lubricant.
Do not use petroleum based lubricants. Rotate the spring clip into the
connector slots, and push the connector onto the fitting until the spring
clip snaps into place on the fitting.
3. Remove the air line (1) from the left rear shock absorber.
4. Remove the air line (1) from the right rear shock absorber.
5. Remove the air line from the retaining clips.
6. Remove the clips from the vehicle, if necessary.
Fig. 37: View Of Air Line
IMPORTANT: Replace any clips which you have removed from the vehicle with new
clips.
1. Install the clips to the vehicle.

2. Install the air line (1) to the right shock absorber.
3. Install the air line (1) to the left shock absorber.
5. Remove the ELC/TRAILER fuse.
AIR COMPRESSOR SHIELD REPLACEMENT
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Lower the automatic level control (ALC) air compressor assembly. Refer to Air Compressor
Replacement .
Fig. 38: Locating ALC Shield Bolt
3. Remove the ALC shield bolt (1) and retainers.

4. Remove the ALC shield (2) from the vehicle.
Fig. 39: Locating ALC Shield Bolt
1. Install the ALC shield (2) onto the vehicle.

2. Install the ALC shield bolt (1) and retainers to the vehicle.
Tighten: Tighten the bolts to 6 N.m (53 in lb).
3. Install the ALC compressor assembly onto the vehicle. Refer to Air Compressor Replacement .
AIR COMPRESSOR REPLACEMENT
Removal Procedure
2. Remove the air compressor filter from the underbody rail. Refer to Automatic Level Control Air
Compressor Air Filter Replacement .
Fig. 40: View Of Inflator Solenoid

3. Remove the air tubes (1) from the inflator solenoid. Refer to Inflator Solenoid Replacement .
Fig. 41: Identifying Compressor Bracket Bolts
4. Remove the compressor bracket bolts.

5. Remove the compressor bracket nuts.
6. Disconnect the air compressor electrical connector.
7. Remove the air compressor assembly from the vehicle.
Fig. 42: Locating Compressor Wires In The Connector
8. Remove the compressor wires from the connector.

9. Remove the air dryer. Refer to Automatic Level Control Air Dryer Replacement .
Fig. 43: View Of Air Compressor Bolts
10. Remove the air compressor bolts (1).

11. Remove the air compressor from the air compressor assembly bracket.
Fig. 44: Identifying Compressor Motor Bolts
12. Remove the bolts (1) and bracket from the compressor motor.
Fig. 45: Identifying Compressor Motor Bolts
1. Install the bolts (1) and bracket to the compressor.
Tighten: Tighten the air compressor bolts to 6 N.m (53 lb in).
2. Install the air compressor to the air compressor bracket.

Fig. 46: View Of Air Compressor Bolts
3. Install the air compressor bolts (1).
Tighten: Tighten the air compressor bolts to 6 N.m (53 lb in).
4. Install the air dryer. Refer to Automatic Level Control Air Dryer Replacement .
5. Install the air tubes (1) onto the inflator solenoid. Refer to Inflator Solenoid Replacement .
Fig. 48: Locating Compressor Wires In The Connector
6. Install the compressor wires into the electrical connector.

Fig. 49: Identifying Compressor Bracket Bolts
7. Install the air compressor filter to the underbody rail.

8. Install the air compressor bracket nuts.
Tighten: Tighten the air compressor bracket nuts to 10 N.m (89 lb in).
9. Install the air compressor bracket bolts.
Tighten: Tighten the air compressor bracket bolts to 10 N.m (89 lb in).
10. Connect the air compressor electrical connector.

11. Install the air compressor and bracket to the underbody rail.
INFLATOR SOLENOID REPLACEMENT
Removal Procedure

2. Remove the hoses (1) from the inflator solenoid.
3. Remove the electrical connector (2) from the inflator solenoid.
4. Remove the screws (3) from the inflator solenoid to the air compressor assembly bracket.
5. Remove the inflator solenoid from the air compressor bracket.

1. Install the inflator solenoid to the air compressor assembly bracket.
2. Install the screws (3) into the inflator solenoid and the air compressor bracket.
Tighten: Tighten the screws to 6 N.m (53 lb in).

3. Install the electrical connector (2) onto the inflator solenoid.
4. Install the hoses (1) onto the inflator solenoid.

AUTOMATIC LEVEL CONTROL DESCRIPTION AND OPERATION
Automatic Level Control (ALC) System
The ALC system controls the ride height of the rear of the vehicle. The system consists of the following
components:
Two air assisted shock absorbers.

A level sensor with an integrated control module.
A compressor with an integral exhaust solenoid valve.
A compressor relay.
A inflator solenoid valve.
A accessory inflator switch with an LED for diagnostics.
The level sensor senses the height of the rear of the vehicle. The exhaust valve energizes if the vehicle is higher
than desired. The compressor relay energizes in order to activate the compressor assembly if the vehicle is
lower than desired.
Voltage is applied at all times to the rear suspension leveling air compressor and the ALC sensor. This allows
the ALC system to vent after the load is removed from the vehicle, even if the ignition is in the OFF position.
Approximately 30 seconds after the ignition is turned to the ON position, the compressor will run for 4 seconds
to ensure that the shock absorbers will be filled with adequate residual pressure.
The ALC sensor must detect an out of trim state for 20 seconds before activating the intake or exhaust output.
This action prevents operation during normal riding motions. In addition, the sensor limits the compressor run
time or the exhaust solenoid valve energized time to a maximum of 255 seconds. This time limit is necessary to
prevent continuous compressor operation in case of a severe system leak or continuous vent. Cycling the
ignition resets the 255 second run timer.
Rear Suspension Leveling Air Compressor
The compressor is a positive displacement rocking piston air pump powered by a 12-volt direct current
permanent magnet motor. The compressor head casting contains the piston intake valves and contains the piston
exhaust valves. The compressor is mounted to the underbody by a bracket.
ALC Sensor
The ALC sensor is an electronic device. The following is controlled by the ALC sensor:
The Automatic Level Control Compressor
The Exhaust Solenoid Valve
The Inflator Solenoid Valve
The sensor circuitry provides a 20 second delay before either circuit can be completed to prevent falsely
actuating the compressor or to prevent falsely actuating the solenoid valve circuits during normal ride motions.
The sensor also limits the compressor run time or the solenoid valve energized time to a maximum of 255
seconds. This time limit function is necessary to prevent continuous compressor operation in the case of a
severe system leak or in the case of a continuous exhaust valve operation. Turning the ignition off and on resets
the electronic timer to renew the 255 second maximum run time. The sensor is located in the rear of the vehicle
mounted to the underbody. The actuator arm of the sensor attaches to the rear suspension by a link.
The ALC system is capable of performing diagnostics on all components of the system. This self diagnostic
feature will aid in the repair of the system. The diagnostic codes will be used to provide more detailed
information regarding the system fault found during self test. The self test will be entered by pressing the
accessory inflator switch continuously for 3 seconds. The self test will begin by raising the rear of the vehicle.
Then hold the rear of the vehicle up for a calibrated amount of time to check for leaks, then lower the rear of the
vehicle to trim height. The self test will take roughly 200 seconds to complete. The flashing pulses on the
accessory inflator switch LED shall represent the number of the diagnostic code.
When the sensor has been replaced a" System Untested" code will be represented by a continuous flashing pulse
with a repetition rate of 0.25 seconds. The self test will have to be performed and a code 12 system OK will
have to be displayed on the accessory inflator switch LED before the system can function normally.
Rear Leveling Shock Absorbers
The shock absorber is essentially a conventional shock absorber enclosed in an air chamber. The shock
absorbers are constructed with a rubber-like sleeve attached to the dust tube and attached to the shock reservoir.
This makes a flexible chamber which extends the shock when the air pressure in the chamber is increased. The
weight of the vehicle collapses the shock absorber when the air pressure is reduced. To maintain proper
operation and to maintain reliability of the shock absorber a minimum residual air pressure of 55 kPa (8 psi) is
maintained at all times by the air dryer.
Tubing and Fittings
The snap-on connectors attach the tubing to the rear shock absorbers. The connector housings contain retainer
clips. When a tubing is attached to a shock fitting, the retainer clip snaps into a groove in the shock fitting,
locking the tubing in position. All tubing fittings are sealed with 2 O-rings.
Air Compressor Filter
The air enters the ALC system through the filter mounted to the air compressor bracket. The filter housing
contains a foam filter which prevents contaminants from entering the ALC system.
Raising Vehicle
The vehicle body is forced downward when a load is added to the vehicle. This load causes the sensor actuating
arm to rotate upward. The upward movement of the sensor actuating arm activates the internal timing circuit.
The sensor completes the compressor circuit to ground after an initial delay of 20 seconds. With the compressor
circuit complete, the compressor runs, taking in air through the air compressor filter and sending the air though
the tubing to the shock absorbers. As the shock absorbers inflate, the rear of the vehicle moves upward, rotating
the sensor actuating arm back toward its original position prior to the load addition. The sensor opens the
compressor circuit and shuts off the compressor once the body reaches its original height +/- 4 mm (+/- 0.16 in).
Lowering Vehicle
The body is forced upward when an excess load is removed from the rear of the vehicle. This causes the sensor
actuating arm to rotate downward. The downward rotation of the actuating arm activates the internal timing
circuit. The sensor completes the solenoid valve circuit to ground after an initial delay of 20 seconds. With the
solenoid valve energized, the air begins to exhaust out of the shock absorbers back through the air dryer, the
solenoid valve, the air compressor filter and into the atmosphere. The sensor actuating arm rotates upward
toward its original position as the rear of the vehicle lowers. When the vehicle body reaches its original height
+/- 4 mm (+/- 0.16 in), the sensor opens the solenoid circuit, de-energizing the solenoid valve, which prevents
any further air from escaping.
Air Replenishment Cycle
The air replenishment cycle serves to ensure that the shock absorbers are filled with at least minimum residual
pressure. The sensor commands an air replenishment cycle each time the ignition switch is turned on. Sensor
position is checked when the ignition switch is turned on. If the sensor indicates that it is not necessary to raise
or lower the vehicle, an internal timer circuit is activated. After a 30 second delay, the compressor is turned on
for approximately 4 seconds. This ensures that the shock absorbers are filled with adequate residual pressure.
If the weight is added to, or removed from, the vehicle during the initial 30 second delay, the air replenishment
cycle will be overridden and the vehicle will raise or lower after the normal delay.
Compressor Head Relief
A 1.5 second actuation of the exhaust solenoid valve occurs each time the compressor is to start to ensure the
low compressor motor starting current. The 1.5 second actuation of the exhaust solenoid valve reduces the air
pressure in the compressor head cavity.
Inflator Solenoid
The inflator solenoid has battery voltage to it at all times and is controlled buy the height sensor with providing
a ground to the solenoid. The solenoid valve is mounted to the compressor bracket under the vehicle.
Inflator Switch
The inflator switch is in the rear cargo area on the drivers side on the vehicle. When the switch is depressed, the
compressor is activated along with the inflator solenoid and air pressure is directed to the Schrader valve that is
located next to the Inflator switch. The LED on the switch is also on during the inflator function. Depress the
switch again and the compressor and the LED are deactivated. The switch and LED are also used for
diagnostics Depress and hold the switch for 3 seconds and the system enters self test After roughly 200
seconds the LED will blink out the diagnostic codes.
Servicing
APPLICATION
TRANSAXLE APPLICATION
Application Transaxle Model (RPO Code)
AWD 4T65-E (M76)
FWD 4T65-E (M15)
IDENTIFICATION
Transaxle has a metal identification plate or Service Replacement Transmission Assembly (SRTA) plate
attached to rear face of transaxle. See Fig. 1 .
Fig. 1: Locating Transaxle ID Plate & SRTA Plate Information
OIL PAN GASKET
Fig. 2: Identifying Oil Pan Gasket (Hydra-Matic 4T65-E)
LUBRICATION
SERVICE INTERVALS
Change the ATF and filter every 50,000 miles if the vehicle is mainly driven under one or more of these
conditions:
In heavy traffic where the outside temperature regularly reaches 90F (32C) or higher.
In hilly or mountainous terrain.
When doing frequent towing.
Uses such as found in taxi, police or delivery service.
If the vehicle is not used under any of these conditions, change the fluid and filter every 100,000 miles.
CHECKING FLUID LEVEL & CONDITION
1. Start the engine and allow the engine to idle until the transaxle has reached 180-200F (82-93C).
Depress the brake pedal and move the shift control lever through the gear ranges, pausing a few seconds
in each gear. Is the fluid Red or Light Brown? If so, go to step 4 . If not, go to next step.
2. Does the fluid have a burnt odor or a Dark Brown color? If so, go to step 11 . If not, go to next step.
3. Does the fluid have a cloudy or milky appearance? If so, go to step 10 . If not, go to next step.
4. Check the fluid level. The vehicle must be level, with the engine running and the shift control lever in the
Park range. Check both sides of the fluid level indicator, and read the lower level. The proper fluid level
should be in the middle of the cross-hatch. Is the fluid level too high? If so, go to step 9 . If not, go to next
step.
5. Is the fluid level low? If not, system is okay. If so, go to next step.
6. Add DEXRON-III(R) ATF in increments of 17 oz. (0.5L) until the fluid is in the middle of the cross-
hatch. Check both sides of the fluid level indicator, and read the lower level. Did you add more than 51
oz. (1.5L) to the transaxle? If not, go to step 9 . If so, go to next step.
7. Check for external leaks. Did you find any leaks? If not, go to step 15 . If so, go to next step.
8. Correct the leak condition. Did you correct the leak condition? If so, go to step 15 .
9. Remove any excess fluid to the proper level, the middle of the cross-hatch. Is the fluid level satisfactory?
If so, system is okay.
10. The transmission is contaminated with engine coolant. Replace the cooler. Is the replacement complete?
If so, go to step 12 .
NOTE: Transmission fluid may turn dark with normal use. This does not always
indicate oxidation or contamination.
11. Drain the fluid to determine if the fluid is contaminated. A very small amount of material in the bottom
pan is a normal condition, but large pieces of metal or other material in the bottom pan require a
transmission overhaul. Was the fluid contaminated? If so, go to step 13 . If not, go to next step.
NOTE: Transmission fluid circulates between the transmission assembly and the
transfer case. In situations where transmission related conditions
circulate debris into the transfer case, the transfer case must be
disassembled, cleaned, and inspected for damage.
12. Overhaul the transmission. See appropriate OVERHAUL article in AUTOMATIC TRANSMISSIONS. Is
the overhaul complete? If so, go to next step.
13. Flush the cooler. See OIL COOLER FLUSHING . Has the cooler been flushed? If so, go to next step.
14. Change the fluid and the filter. See DRAINING & REFILLING . Is the procedure complete? If so, go to
next step.
15. Add new fluid to the proper level, in the middle of the cross-hatch. Is the procedure complete? If so,
system is okay.
RECOMMENDED FLUIDS
Manufacturer recommends DEXRON-III(R) ATF. Fill transaxle with appropriate quantity. See FLUID
CAPACITIES .
FLUID CAPACITIES
TRANSAXLE FLUID CAPACITIES (1)

Application Specification Qts. (L)
Bottom Pan Removal
AWD 7.8 (7.4)
FWD 7.4 (7.0)
Complete Overhaul
AWD 10.4 (9.8)
FWD 10.0 (9.4)
Dry Fill
AWD 13.8 (13)
FWD 13.4 (12.7)
(1) Fluid capacities listed are approximate. Always fill to specified area on dipstick. See CHECKING
FLUID LEVEL & CONDITION .
DRAINING & REFILLING
CAUTION: Do not use any type of grease to retain parts during the assembly of this
unit. Using greases other than the recommended assembly lube changes
the transaxle fluid characteristics. Using greases other than the
recommended assembly lube causes undesirable shift conditions and/or
filter clogging. Use Transjel(tm) Lubricant (J-36850) or equivalent during
the assembly of this unit.
1. Raise and support the vehicle. Place a drain pan under the transaxle bottom oil pan. Remove the oil pan
bolts (23) from the front. See Fig. 3 . Remove the oil pan bolts (23) from the sides. Loosen the rear oil
pan bolts (23) approximately 4 turns.
NOTE: Ensure care is taken NOT to damage the mating surfaces of the oil pan
and of the case or oil leaks may occur.
2. Use a rubber mallet to lightly tap the oil pan or use a screwdriver to pry the oil pan loose. Allow the fluid
to drain. Remove the remaining oil pan bolts (23).
3. Remove the oil pan (24). Remove the oil pan gasket (25). Remove the filter (100). Remove the lip ring
seal (101) pressed into the case only if replacement is necessary. Inspect the oil pan and the filter screen
for the following foreign material:
Inspect for metal particles.
Inspect for clutch facing material.
Inspect for rubber particles.
Inspect for engine coolant.
4. Determine the source of the contamination if foreign material is evident. Correct the source of the
contamination. Use solvent to clean the screen and blow-dry if reusing. Install a new seal (101). See Fig.
4 . Install the filter (100). See Fig. 3 .
5. Inspect the oil pan flange (1) for distortion. See Fig. 5 . Replace the oil pan (1) if bent or distorted. Do not
attempt to straighten. Inspect the washers on the bolts when service requires the removal of the bottom oil
pan. Install a new bolt and washer assembly if the washer is inverted. See Fig. 6 .
NOTE: Ensure the oil pan and the case flanges are dry and are free of any oil film
or leakage may result.
6. Use solvent to clean the case. Air dry the case. Use solvent to clean the oil pan gasket surfaces. Air dry
the oil pan gasket surfaces. Ensure all traces of the old gasket material are removed.
7. Install the oil pan gasket (25). See Fig. 3 . Install the oil pan (24). Install the oil pan bolts (23). See Fig.
6 . Tighten the oil pan bolts (23) to specification. See TORQUE SPECIFICATIONS .
8. Lower the vehicle. Fill the transaxle with the proper quantity of DEXRON-III(R) ATF. Place the gear
selector in the Park position. Start the engine.
CAUTION: Do not overfill the transaxle. Overfilling of the transaxle causes

foaming, loss of fluid, shift complaints, and possible damage to the
transaxle.
9. Run the engine at a slow idle. DO NOT race the engine. Adjust the fluid level. See CHECKING FLUID
LEVEL & CONDITION . Inspect for proper completion of the repairs. Inspect for fluid leaks.
Fig. 3: Removing & Installing Oil Pan & Filter
Fig. 4: Installing Oil Filter Seal
Fig. 5: Inspecting Oil Pan Flange
Fig. 6: Identifying Conical Washers
OIL COOLER FLUSHING
CAUTION: Flushing Fluid (J-35944-22) is environmentally safe, yet powerful enough

to cut through transmission fluid to dislodge any contaminants from the
cooler. The safety precautions on the label regarding potential skin and
eye irritations associated with prolonged exposure are typical precautions
that apply to many similar cleaning solutions. It should be noted that
according to General Motors, use of other non-approved fluids for cooler
flushing can have an adverse reaction to the seals inside the
transmission.
CAUTION: Do not use solutions that contain alcohol or glycol. Use of solutions that
contain alcohol or glycol may damage flushing equipment, oil cooler
components and/or transmission components.
NOTE: GM studies indicate that plugged or restricted transmission oil coolers and
pipes cause insufficient transmission lubrication and elevated operating
temperatures which can lead to premature transmission wear-out. Many cases
could have been prevented by following published procedures for transmission
oil cooler flushing and flow checking. This procedure includes flushing and
flow checking the auxiliary transmission oil cooler, if equipped. GM requires
that transmission oil cooler flushing and flow checking be performed whenever
a transmission is removed from the vehicle for service within warranty,
including: Goodwin, SWAT, major overhaul, torque converter replacement and
oil pump replacement.
Preparation
1. After the repair or replacement transmission is installed in the vehicle, do not reconnect the oil cooler
pipes.
2. Remove the fill cap (9) on the Transmission Oil Cooler and Line Flusher (J-35944-A) and fill the flusher
tank (4) with 20 oz. (0.6L) of flushing fluid using the measuring cup (6). DO NOT overfill. Install the fill
cap (9) on the transmission oil cooler and line flusher and pressurize the flusher tank (4) to 80-100 psi,
using the shop air supply at the tank air valve (9). See Fig. 7 .
3. Connect the transmission oil cooler and line flusher discharge hose (5) to the oil cooler return pipe (top
connector). Clip the discharge hose (5) onto the oil drain container. Attach the transmission oil cooler and
line flusher to the undercarriage of the vehicle with the hook provided, and connect the flushing system
feed supply hose (3) from the transmission oil cooler and line flusher to the oil cooler feed pipe (bottom
connector).
4. With the water supply valve (1) on the transmission oil cooler and line flusher in the OFF position,
connect the water supply hose (7) from the transmission oil cooler and line flusher to the water supply at
the faucet. See Fig. 7 and Fig. 8 . Turn ON the water supply at the faucet.
Fig. 7: Identifying Flushing Equipment
Fig. 8: Connecting Flushing Equipment
Initial Flush
1. Turn the transmission oil cooler and line flusher water supply valve (1) to the ON position and allow
water to flow through the oil cooler and pipes for 10 seconds to remove any remaining transmission fluid.
See Fig. 9 . If water does not flow through the oil cooler and pipes, the cause of the blockage must be
diagnosed and the plugged component must be repaired or replaced. Continue with the cooler flushing
and flow check procedure once the blockage is corrected.
2. Turn the transmission oil cooler and line flusher water supply valve (1) to the OFF position and clip the
discharge hose (5) onto an appropriate container with a lid, to avoid splashback. See Fig. 10 . Turn the
transmission oil cooler and line flusher water supply valve (1) to the ON position and depress the trigger
(8) to mix cooler flushing solution into the water flow. See Fig. 7 . Use the clip provided on the handle to
hold the trigger (8) down. The discharge will foam vigorously when the solution is introduced into the
water stream.
NOTE: Flushing for approximately 2 minutes in each cooler line direction will
result in a total of about 8-10 gallons of waste fluid. This mixture of water
and flushing fluid is to be captured in an appropriate container for proper
disposal.
3. Flush the oil cooler and pipes with water and solution for 2 minutes. During this flush, attach the shop air
supply of 120 psi to the flushing system feed air valve (2) located on the transmission oil cooler and line
flusher for 3-5 seconds at the end of every 15-20 second interval to create a surging action.
4. Release the trigger (8) and turn the transmission oil cooler and line flusher water supply valve (1) to the
OFF position.
Fig. 9: Flushing Oil Cooling System
Fig. 10: Capturing Fluid Discharge
Back Flush
1. Disconnect both hoses from the oil cooler pipes and then connect them to the opposite oil cooler pipe.
This will allow the oil cooler and pipes to be back flushed. Repeat steps 2 and 3 of the INITIAL FLUSH
procedure. Release the trigger (8) of the transmission oil cooler and line flusher and allow water only to
rinse the oil cooler and pipes for one minute.
2. Turn the transmission oil cooler and line flusher water supply valve (1) to the OFF position and turn OFF
the water supply at the faucet. See Fig. 8 . Attach the shop air supply to the flushing system feed air valve
(2) on the transmission oil cooler and line flusher, and blow out the water from the oil cooler and pipes.
Continue until no water comes out of the discharge hose (5).
OIL COOLER FLOW TEST
Flow Check
1. Disconnect both hoses from the oil cooler pipes. Connect the oil cooler feed pipe (vertical/top connector)
to the transmission and the return pipe (horizontal/bottom connector) to the discharge hose (5). Clip the
discharge hose (5) onto the empty oil drain container. See Fig. 10 .
2. Confirm the transmission is filled with DEXRON-III(R) ATF. See CHECKING FLUID LEVEL &
CONDITION . Start the engine with the transmission in Park range and run for 30 seconds. A minimum
of 2 qts. (1.9L) must be discharged during this 30-second run time. If fluid flow is greater than 2 qts.
(1.9L) in 30 seconds, go to next step. If fluid flow is less than 2 qts. (1.9L) in 30 seconds, perform the
following diagnosis: Disconnect the oil cooler feed line at the radiator. Connect the discharge hose (5) to
the cooler feed line. Clip the discharge hose (5) to the empty oil drain container. See Fig. 10 . Start the
engine with the transmission in Park range and run for 30 seconds. A minimum of 2 qts. (1.9L) must be
discharged during this 30-second run time. Perform the following according to the flow rate:
Insufficient feed flow: inspect the transmission.
Sufficient feed flow: inspect the oil cooler return pipe and the oil cooler (and auxiliary cooler, if
equipped).
3. Remove the discharge hose (5), reconnect the cooler feed and return pipes to the transmission and refill
the unit to the proper fluid level. Inspect the transmission oil cooler pipe connections at the radiator, the
auxiliary cooler (if equipped) and the transmission for leaks.
Clean-up
Disconnect the water supply hose (7) from the transmission oil cooler and line flusher and bleed any remaining
air pressure from the flusher tank (4). See Fig. 7 . Remove the fill cap (9) from the transmission oil cooler and
line flusher and return any unused flushing solution to its container. Rinse the transmission oil cooler and line
flusher with water. Do not store the transmission oil cooler and line flusher with flushing solution in it. After
every 3rd use, clean the transmission oil cooler and line flusher as described in the instructions included with
the tool. Dispose of any waste water/solution and transmission fluid in accordance with local regulations.
ON-VEHICLE REPAIRS
Various components may be serviced without transaxle removal. For servicing of these components, see
appropriate component under ADJUSTMENTS and/or REMOVAL & INSTALLATION . For additional
information on servicing electrical components, see appropriate DIAGNOSIS article in AUTOMATIC
TRANSMISSIONS.
ADJUSTMENTS
WARNING: Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system.

When servicing vehicle, use care to avoid accidental air bag deployment.
SIR system-related components are located in various locations
throughout interior and exterior of vehicle, depending on application. Do
not use electrical test equipment on or near these circuits. If necessary,
deactivate SIR system before servicing components. See AIR BAG
DEACTIVATION PROCEDURES article in GENERAL INFORMATION.
PARK/NEUTRAL POSITION SWITCH
1. If a new Park/Neutral Position (PNP) switch has been rotated and the pin is broken or if using an old PNP
switch, adjust the PNP switch. Place the shift shaft in the Neutral position.
2. Use the Park/Neutral Position Switch Alignment Tool (J-41545) to align the slots of the PNP switch to
the Neutral position. Align the flats of the shift shaft to the flats in the PNP switch.
NOTE: If the PNP switch bolt holes do not align with the mounting boss on the
transaxle, verify that the shaft is in the Neutral position.
3. Install the PNP switch to the mounting boss. See Fig. 11 .

4. Assemble the PNP switch mounting bolts loosely. Install the PNP switch alignment tool on locations (1)
and (2) in order to align the PNP switch. See Fig. 12 . Install the PNP switch mounting bolts. Tighten the
PNP switch mounting bolts to specification. See TORQUE SPECIFICATIONS .
Fig. 11: Removing & Installing Park/Neutral Position Switch

Fig. 12: Identifying Park/Neutral Position Switch Alignment Tool
SHIFT CABLE
NOTE: Adjust the shift cable while the transaxle and while the gear selector are in the
Neutral position only. Failure to do so may cause misadjustment of shift cable.
1. Set the parking brake. Block the wheels.
CAUTION: Do not pry and do not pull up on any other part of the shift cable or
damage may occur.
2. Use an appropriate tool to pry on the shift cable terminal at the manual control lever pin to remove the
shift cable terminal from the manual control lever pin. See Fig. 13 .
3. Fully lift the adjuster lock button. Ensure the adjuster is free to move. Rotate the manual control lever
fully counterclockwise to the Park gear, then rotate the lever clockwise 2 clicks into the Neutral gear to
place the manual control lever in the Neutral gear.
4. Perform the following steps to place the inside car gear shifter in the Neutral position:
A. Rotate the shift control lever to the Low one position, fully down.
B. Push forward on the lever while slowly pushing up. The shift control lever moves up while clicking
over the gear over travel stops.
C. Release the shift control lever once the shift control lever stops solidly. The shift control lever is in
the Neutral gear.
5. Grasp the shift cable terminal in the underhood. Pull the shift cable terminal toward the pin on the manual
control lever. The shift cable adjuster spring should compress as the terminal is moved toward the pin.
6. Carefully push down the pin until the pin snaps to attach the pin to the manual control lever. DO NOT
move the manual control lever out of position. DO NOT pull the terminal beyond the pin then push back
or the shifter may move out of the Neutral gear.
7. Press the adjuster lock button down flush with the adjuster body. See Fig. 14 . Shift to Park. Release the
parking brake while applying the service brake. Start the engine. Ensure all the indicated gear positions
match the vehicle response.
Fig. 13: Adjusting Shift Cable (1 Of 2)

Fig. 14: Adjusting Shift Cable (2 Of 2)
WARNING: Vehicle is equipped with Supplemental Inflatable Restraint (SIR) system.

When servicing vehicle, use care to avoid accidental air bag deployment.
SIR system-related components are located in various locations
throughout interior and exterior of vehicle, depending on application. Do
not use electrical test equipment on or near these circuits. If necessary,
deactivate SIR system before servicing components. See AIR BAG
DEACTIVATION PROCEDURES article in GENERAL INFORMATION.
CAUTION: When battery is disconnected, vehicle computer and memory systems

may lose memory data. Driveability problems may exist until computer
systems have completed a relearn cycle. See COMPUTER RELEARN
PROCEDURES article in GENERAL INFORMATION before disconnecting
battery.
NOTE: Use the correct fastener in the correct location. Replacement fasteners must be
the correct part number for that application. Fasteners requiring replacement or
fasteners requiring the use of thread locking compound or sealant are identified
in the service procedure. Do not use paints, lubricants, or corrosion inhibitors
on fasteners or fastener joint surfaces unless specified. These coatings affect
fastener torque and joint clamping force and may damage the fastener. Use the
correct tightening sequence and specifications when installing fasteners in
order to avoid damage to parts and systems.
NOTE: Some removal and installation procedures may require the removal of engine
and/or transaxle mounts. For procedures related to these components, see
appropriate REMOVAL & INSTALLATION article.
ACCUMULATOR & 2-1 MANUAL SERVO
Removal
1. Raise and support the vehicle. Remove the oil pan. Remove the filter. See DRAINING & REFILLING
under LUBRICATION.
2. Remove the accumulator bolts. Remove the manual 2-1 band servo cover bolts. See Fig. 15 .
3. Use a large flat-blade tool in order to gently pry the lube oil pipe retainer from the case. See Fig. 16 .
Remove the lube oil pipe from the front differential carrier internal gear lube hole. See Fig. 17 .
4. Remove the accumulator. Remove the manual 2-1 band servo cover. Remove the manual 2-1 band servo.
Remove the manual 2-1 band servo cover gasket. See Fig. 18 .
5. To disassemble, inspect and service the accumulator and 2-1 manual servo, see appropriate OVERHAUL
article in AUTOMATIC TRANSMISSIONS.
Fig. 15: Identifying Accumulator & 2-1 Manual Servo Cover Bolts
Fig. 16: Removing & Installing Lube Oil Pipe

Fig. 17: Removing & Installing Accumulator & 2-1 Manual Band Servo
Fig. 18: Removing & Installing 2-1 Manual Band Servo & Seal
Installation
1. Install the manual 2-1 band servo cover gasket into the case. Lubricate the manual 2-1 band servo cover
gasket with automatic transmission fluid. Install the manual 2-1 band servo. See Fig. 18 . Install the
manual 2-1 band servo cover. See Fig. 17 .
2. Install the manual 2-1 band servo cover bolts. See Fig. 15 . Tighten the bolts to specification. See
TORQUE SPECIFICATIONS . Install the accumulator. Install the lube oil pipe into the case at the lube
hole for the front differential carrier internal gear.
3. Use a flat-blade tool in order to lock the lube oil pipe retainer into the case. Tighten the accumulator
attaching bolts to specification. See TORQUE SPECIFICATIONS .
4. If removed, install the new filter seal. Install the filter. Install the oil pan. See DRAINING &
REFILLING under LUBRICATION. Lower the vehicle.
CASE EXTENSION HOUSING
Removal
1. Raise and support the vehicle. Disconnect the right drive axle from the transaxle. See appropriate article
in DRIVE AXLES. Remove the transaxle brace. See TRANSAXLE BRACE .
2. Remove the vehicle speed sensor. See VEHICLE SPEED SENSOR . Remove the case extension
housing bolts. See Fig. 19 .
3. Remove the case extension housing with axle seal and the O-ring. Inspect the case extension for the
Damaged or porous sealing surface for the case extension seal.
Damaged or porous sealing surface for the vehicle speed sensor.
Damaged or porous sealing surface for the right drive axle oil seal.
Damaged or porous sealing surface for the case extension housing.
Damaged or worn differential carrier bushing or output shaft bearing.
Damaged bolt holes.
Inspect the drive axle seal and replace if necessary.

Fig. 19: Removing & Installing Case Extension
Installation
1. Perform a differential carrier end play inspection. See appropriate OVERHAUL article in AUTOMATIC
TRANSMISSIONS. If removed, install the drive axle seal. Install the case extension housing with the
axle seal and the O-ring. See Fig. 19 .
2. Install the case extension housing bolts. Tighten the case extension housing bolts to specification. See
TORQUE SPECIFICATIONS . Install the vehicle speed sensor. See VEHICLE SPEED SENSOR .
3. Install the transaxle brace. See TRANSAXLE BRACE . Connect the right drive axle to the transaxle.
See appropriate article in DRIVE AXLES. Lower the vehicle.
WARNING: Do not overfill the transaxle. Overfilling of the transaxle causes

foaming, loss of fluid, shift complaints, and possible damage to the
transaxle.
4. Fill transaxle with appropriate fluid to proper level. See LUBRICATION . Inspect for completion of the
repairs. Inspect for fluid leaks.
CASE SIDE COVER
Removal
1. Disconnect the negative battery cable. Remove the throttle body air inlet duct. Install the engine support
fixture and remove the engine mount struts. See appropriate REMOVAL & INSTALLATION article.
Raise and support the vehicle.
2. Remove the left front tire and wheel. Remove the left engine splash shield. Remove the stabilizer shaft
links from the lower control arms. See appropriate FRONT article in SUSPENSION. Remove the left tie
rod end from the steering knuckle.
3. Remove the wheel speed sensor harness connector. Remove the left lower ball joint from the left steering
knuckle. See appropriate FRONT article in SUSPENSION. Disconnect the left drive axle from the
transaxle. See appropriate article in DRIVE AXLES. Reposition and secure the drive axle.
CAUTION: Failure to disconnect the intermediate shaft from the rack and pinion
stub shaft can result in damage to the steering gear and/or damage
to the intermediate shaft. This damage may cause loss of steering
control which could result in personal injury.
4. Remove the intermediate shaft from the steering gear. See appropriate POWER RACK & PINION article
in STEERING. Disconnect the catalytic converter pipe from the right (rear) exhaust manifold. Support
the right side of the frame with a utility stand.
5. Support the left side of the frame with a utility stand. Remove the transaxle mount and bracket. See
TRANSAXLE MOUNT & BRACKET .
6. Loosen the engine mount lower nuts. See appropriate REMOVAL & INSTALLATION article. Loosen
the right side frame bolts. Remove the left side frame bolts. Use the utility stand in order to lower left side
of the frame.
7. Position the drain pan under the transaxle. Remove the wiring harness connectors. Remove the case side
cover bolts. See Fig. 20 . Remove the case side cover pan (53). See Fig. 21 . Remove the case side cover
gasket (54). Remove the case side cover inner gasket (59).
8. Inspect the case side cover (53) for the following conditions:
Damaged or porous gasket sealing surfaces.
Damaged or porous casting surfaces.
Damaged or stripped bolt holes.
9. Inspect the case side cover gasket (54) and case side cover inner gasket (59) for damage. The gaskets are
reusable if they are NOT damaged. Clean the case side cover. Clean the case side cover gasket surfaces.
Fig. 20: Identifying Case Side Cover Bolt Locations
Fig. 21: Removing & Installing Case Side Cover Pan
Installation
1. Install the Transjel(tm) Lubricant (J-36850) to the case side cover O-ring (59). See Fig. 21 . Install the O-
ring (59) to the case side cover. Install the case side cover gasket (54).
2. Install the case side cover (53). Install the case side cover bolts. See Fig. 20 . Tighten bolts to
specification See TORQUE SPECIFICATIONS Remove the drain pan from under the transaxle
3. Install the wiring harness connectors. Use the utility stand in order to raise the left side of the frame.
Install the NEW left side frame bolts. Install the NEW right side frame bolts. Install the engine mount
lower nuts
4. Install the transaxle mount and bracket. See TRANSAXLE MOUNT & BRACKET . Tighten the bolts
to specification. See TORQUE SPECIFICATIONS . Lower the vehicle.
5. Remove the utility stand support from the right side of the frame. Remove the utility stand support from
the left side of the frame. Connect the catalytic converter pipe to the right (rear) exhaust manifold.
CAUTION: When installing the intermediate shaft make sure that the shaft is
seated prior to pinch bolt installation. If the pinch bolt is inserted into
the coupling before shaft installation, the two mating shafts may
disengage. Disengagement of the two mating shafts will cause loss
of steering control which could result in personal injury.
6. Install the intermediate shaft to the steering gear. See appropriate POWER RACK & PINION article in
STEERING.
7. Install the left drive axle to the transaxle. See appropriate article in DRIVE AXLES. Install the left lower
ball joint to the left steering knuckle. See appropriate FRONT article in SUSPENSION.
8. Install the wheel speed sensor harness connector. Install the left tie rod end to the steering knuckle. Install
the stabilizer shaft links to the lower control arms. See appropriate FRONT article in SUSPENSION.
9. Install the left engine splash shield. Install the left front tire and wheel. Lower the vehicle. Install the
engine mount struts. See appropriate REMOVAL & INSTALLATION article.
10. Remove the engine support fixture. See appropriate REMOVAL & INSTALLATION article. Remove the
throttle body air inlet duct. Connect the negative battery cable.
CAUTION: Do not overfill the transmission. Overfilling will result in foaming,

loss of fluid, and possible damage to the transmission.
11. Fill transaxle with appropriate fluid to proper level. See LUBRICATION . Inspect for fluid leaks.
Inspect for proper completion of the repairs. Inspect for fluid leaks.
CONTROL VALVE BODY
Removal
1. Remove the case side cover. See CASE SIDE COVER . Remove the oil pump. See OIL PUMP .
Remove the valve body bolts (374-381 and 384). See Fig. 22 .
CAUTION: Carefully remove the valve body or the ball check valves will fall out.
2. Remove the valve body (300) while keeping the spacer plate (370) with the transaxle. See Fig. 23 .
Remove the ball check valves (372 and 373) from the valve body. See Fig. 24 .
3. Remove the spacer plate (370) and gasket. See Fig. 25 . Remove the ball check valves (372) from the
case cover. See Fig. 26 . Inspect each check valve seat in the spacer plate (370) for excessive peening.
See Fig. 27 .
4. Place a ball check valve (372) on each seat and use a flashlight in order to look for visible light between
the valve and the seat. Inspect all components removed from the transaxle. See appropriate OVERHAUL
article in AUTOMATIC TRANSMISSIONS.
Fig. 22: Identifying Valve Body Bolts
Fig. 23: Removing & Installing Control Valve Body Assembly
Fig. 24: Locating Check Balls In Valve Body
Fig. 25: Identifying Spacer Plate
Fig. 26: Locating Check Balls In Case Cover
Fig. 27: Inspecting Check Valve Seats In Spacer Plate
Installation
CAUTION: Do not use any type of grease to retain parts during the assembly of this
unit. Using greases other than the recommended assembly lube changes
the transaxle fluid characteristics. Using greases other than the
recommended assembly lube causes undesirable shift conditions and/or
filter clogging. Use Transjel(tm) Lubricant (J-36850) or equivalent during
the assembly of this unit.
1. Install the ball check valves (372) into the case cover. See Fig. 26 . Use the Transjel(tm) lubricant to
retain the ball check valves in their proper locations. Install the gasket and the spacer plate (370). See Fig.
25 .
2. Install the ball check valves (372 and 373) into the valve body. See Fig. 24 . Use the Transjel(tm)
lubricant to retain the ball check valves in their proper locations.
NOTE: Do not use impact type tools on the valve body or on the oil pump.
3. Install the gasket (371) and the valve body (300). See Fig. 23 . Install the valve body bolts (374-381 and
384). See Fig. 22 .
4. Tighten the valve body bolts as follows:
M6 X 1.0 X 20 - 70 INCH lbs. (8 N.m).
M6 X 1.0 X 30 - 106 INCH lbs. (12 N.m).
M6 X 1.0 X 45 - 106 INCH lbs. (12 N.m).
M6 X 1.0 X 55 - 97 INCH lbs. (11 N.m).
M6 X 1.0 X 60 - 106 INCH lbs. (12 N.m).
M6 X 1.0 X 65 - 106 INCH lbs. (12 N.m).
M6 X 1.0 X 85 - 97 INCH lbs. (11 N.m).
M6 X 1.0 X 95 - 97 INCH lbs. (11 N.m).
M8 X 1.25 X 90 - 18 ft. lbs. (24 N.m).
5. DO NOT use impact type tools on the valve body or on the oil pump. Install the oil pump. See OIL
PUMP . Install the case side cover. See CASE SIDE COVER .
FLUID FILLER TUBE
Removal
Remove the oil indicator from the filler tube. Remove the air cleaner assembly. Remove the retaining nut from
the EGR at the top of the filler tube. See Fig. 28 . Remove the lower retaining bolt at the base of the filler tube.
Remove the fluid filler tube.
Fig. 28: Removing & Installing Fluid Filler Tube
Installation
CAUTION: Do not place the fluid filler tube seal on the fluid filler tube when installing
the tube or damage to the seal will result.
Install the fluid filler tube seal in the transaxle. See Fig. 29 . Position the fluid filler tube into the transaxle.
Install the fluid filler tube bracket bolt through the fluid filler tube bracket. See Fig. 28 . Tighten the fluid filler
tube bracket bolt to specification. See TORQUE SPECIFICATIONS . At the top of the filler tube, install the
retaining nut to the filler tube the EGR at the top of the filler tube. Install the air cleaner assembly. Fill transaxle
with appropriate fluid to proper level. See LUBRICATION . Inspect for fluid leaks.
Fig. 29: Installing Fluid Filler Tube Seal

FORWARD SERVO (FWD)
NOTE: This procedure is for front-wheel-drive vehicles ONLY. The forward servo for
all-wheel-drive vehicles is serviced with the transfer case removed, which
MUST be serviced with the transmission removed from the vehicle. For transfer
case replacement, see appropriate REMOVAL & INSTALLATION article in
AUTOMATIC TRANSMISSIONS.
Removal
1. Install the engine support fixture. See appropriate REMOVAL & INSTALLATION article. Raise and
support the vehicle. Remove the stabilizer shaft. Remove the power steering gear heat shield. Remove the
power steering gear from the frame. See appropriate POWER RACK & PINION article in STEERING.
2. Use a strap in order to secure the power steering gear to the exhaust manifold. See appropriate POWER
RACK & PINION article in STEERING. Remove the power steering cooler line clamps from the frame.
Use wire in order to secure the power steering cooler line to an engine component.
3. Remove the engine mount nuts. See appropriate REMOVAL & INSTALLATION article. Remove the
transaxle mount nuts. Use a utility stand in order to support the frame front. Use a utility stand in order to
support the frame rear.
4. Remove the frame bolts. Use the utility stand in order to lower the frame rear for access to the forward
servo cover. Position a drain pan under the forward servo cover.
5. Remove the forward band servo cover bolts. Remove the forward servo cover. Remove the forward servo
cover O-ring. Remove the servo piston assembly. Remove the servo spring. See Fig. 30 .
Fig. 30: Removing & Installing Forward Servo
Installation
1. Install the servo spring. Install the servo piston assembly. Install the forward servo cover O-ring. Install
the forward servo cover. See Fig. 30 .
2. Install the 3 forward servo cover attaching bolts. Tighten the forward servo cover attaching bolts to
specification. See TORQUE SPECIFICATIONS .
3. Remove the drain pan from under the forward servo cover. Use the utility stand in order to raise the frame
rear. Install the NEW frame bolts. Install the powertrain mounts to the frame. Install the transaxle mount
nuts. Install the engine mount nuts. See appropriate REMOVAL & INSTALLATION article.
4. Install the power steering gear to the frame. See appropriate POWER RACK & PINION article in
STEERING. Install the power steering gear heat shield. Install the stabilizer shaft.
5. Lower the vehicle. Remove the engine support fixture. Fill transaxle with appropriate fluid to proper
level. See LUBRICATION .
INPUT SPEED SENSOR
Removal
1. Remove the case side cover. See CASE SIDE COVER .
2. Disconnect the transaxle wiring harness. Remove the input speed sensor clip (441) from the case cover.
See Fig. 31 .
3. Remove the input speed sensor (440) from the case cover. Inspect the input speed sensor (440) for the
Damaged or missing magnet.
Damaged housing.
Bent or missing electrical terminals.
Damaged speed sensor clip (441).
Fig. 31: Removing & Installing Input Shaft Speed Sensor

Installation
1. Install the input speed sensor (440) into the case cover. See Fig. 31 .
2. Install the input speed sensor clip (441) into the case cover.
3. Connect the transaxle wiring harness.
4. Install the case side cover. See CASE SIDE COVER .
OIL COOLER HOSES
CAUTION: Allow sufficient clearance around the transaxle oil cooler pipes and
around the hoses to prevent damage or wear which may cause fluid loss.
Removal
Remove the Transaxle Oil Cooler (TOC) hose retainer bolt. See Fig. 32 . Position a drain pan below the oil
cooler hoses. Reposition the TOC connector cap. Use a flat-blade tool in order to remove the TOC connector
retainer. See Fig. 33 . Repeat this procedure for the other connections as needed. Remove the TOC inlet hose
from the transaxle. See Fig. 34 . Remove the TOC outlet hose from the transaxle. Remove the TOC hoses from
the radiator. See Fig. 35 . Remove the TOC hoses.
Fig. 32: Removing & Installing Oil Cooler Hoses At Transaxle
Fig. 33: Removing Retaining Ring
Fig. 34: Removing & Installing Oil Cooler Hoses At Transaxle
Fig. 35: Removing & Installing Oil Cooler Pipes At Radiator
Installation
NOTE: Allow sufficient clearance around the transaxle oil cooler pipes and around the
hoses to prevent damage or wear which may cause fluid loss.
Install the TOC hose connector retainers. See Fig. 36 . Install the TOC hoses to the radiator. See Fig. 35 . Install
the TOC inlet hose to the transaxle. See Fig. 34 . Install the TOC outlet hose to the transaxle. Tighten the
transaxle oil cooler hose clip bolt to specification. See TORQUE SPECIFICATIONS . Lower the vehicle.
Adjust the fluid level. Inspect for proper completion of the repairs. Fill transaxle with appropriate fluid to
proper level. See LUBRICATION .
Fig. 36: Starting Retaining Ring Onto Quick Connect Fitting
OIL PRESSURE TEST PLUG
Removal
Remove the throttle body air inlet duct. Remove the pressure test hole plug (38). See Fig. 37 .
Fig. 37: Removing & Installing Oil Pressure Test Plug
Installation
Install the pressure test hole plug (38). See Fig. 37 . Tighten the line pressure pipe plug to specification. See
TORQUE SPECIFICATIONS . Install the throttle body air inlet duct.
OIL PUMP
Removal
NOTE: Do not remove the 3 bolts which hold the pump together.
Remove the case side cover. See CASE SIDE COVER . Remove the oil pump bolts (205, 206, 207). See Fig.
38 . Remove the oil pump from the valve body. See Fig. 39 . Clean and inspect the oil pump. See appropriate
OVERHAUL article in AUTOMATIC TRANSMISSIONS.
Fig. 38: Identifying Oil Pump Bolts
Fig. 39: Removing & Installing Oil Pump Assembly

Installation
Install the oil pump to the valve body. See Fig. 39 . Install the oil pump bolts (205, 206, 207). See Fig. 38 .
Tighten the oil pump bolts as follows:
M6 X 1.0 X 20 (205) - 70 INCH lbs. (8 N.m).

M6 X 1.0 X 85 (207) - 106 INCH lbs. (12 N.m).
M6 X 1.0 X 95 (206) - 12 ft. lbs. (16 N.m).
Install the case side cover. See CASE SIDE COVER .

OUTPUT SHAFT
NOTE: This procedure is for front-wheel-drive vehicles ONLY. The output shaft for all-
wheel-drive vehicles is serviced with the transfer case which MUST be serviced
with the transmission removed from the vehicle. For transfer case replacement,
see appropriate REMOVAL & INSTALLATION article in AUTOMATIC
TRANSMISSIONS.
Removal
1. Disconnect the left and right drive axles from the transaxle. See appropriate DRIVE AXLES article in
DRIVE AXLES. Remove the case extension housing. See CASE EXTENSION HOUSING . Rotate the
differential carrier until the end of the output shaft can be seen and the differential pinion shaft is in a
horizontal position. See Fig. 40 .
2. Place the Axle Removal Wedge (J-42562) between the end of the output shaft and the differential pinion
shaft. Using a hammer, hit the end of the axle removal wedge in order to compress the output shaft
compression ring and push the output shaft through the differential side gear.
3. Remove the differential carrier. Using snap ring pliers remove the compression ring from the output shaft.
See Fig. 41 . Be careful not to damage the bearing on the output shaft. See Fig. 43 .
4. Remove the output shaft through the left wheel opening. See Fig. 42 . Inspect the output shaft and the
bearing for the following:
A cracked or deformed bearing cage.
Damaged bushing journals.
Stripped splines.
A damaged retainer ring groove.

Fig. 40: Removing Output Shaft
Fig. 41: Removing Differential Carrier Assembly
Fig. 42: Removing & Installing Output Shaft
Fig. 43: Identifying Fourth Clutch Bearing
Installation
1. Install the drive axle retaining ring and the output shaft differential inboard snap ring onto the output
shaft. See Fig. 43 . Install the fourth clutch bearing onto the output shaft. See Fig. 43 .
2. Hold the front differential carrier in place and carefully install the output shaft into the transmission
through the left wheel opening. See Fig. 42 .
3. Extend the output shaft through the differential side gear. Install the case extension housing. See CASE
EXTENSION HOUSING .
PARK/NEUTRAL POSITION SWITCH
WARNING: Before servicing any electrical component, the ignition key must be in the
OFF or LOCK position and all electrical loads must be OFF, unless
instructed otherwise in these procedures. If a tool or equipment could
easily come in contact with a live exposed electrical terminal, also
disconnect the negative battery cable. Failure to follow these precautions
may cause personal injury and/or damage to the vehicle or its
components.
Removal
1. Apply the parking brake. Block the wheels. Shift the transmission into Neutral. Remove the throttle body
air inlet duct. Use a flat-blade tool in order to remove the shift cable from the manual control lever. See
Fig. 44 .
2. Remove the shift cable from the shift cable bracket. See Fig. 45 . Remove the electrical connectors.
Remove the manual control lever. Remove the PNP switch bolts. See Fig. 11 . Remove the PNP switch.
Fig. 44: Removing & Installing Shift Cable At PNP Switch

Fig. 45: Removing & Installing Shift Cable At Transaxle Bracket

Installation
CAUTION: Do not rotate a new PNP switch. A new PNP switch is produced in the
Neutral position. If the bolt holes do not align with the holes in the
transaxle, verify that the transmission is in Neutral. Adjust the PNP switch
if the new switch has been rotated and the pin is broken or if using an old
PNP switch.
1. Align the flats of the shift shaft to the flats in the PNP switch. Install the PNP switch to the transaxle.
Install the PNP switch bolts. See Fig. 11 . Tighten the PNP switch bolts to specification. See TORQUE
SPECIFICATIONS .
2. Install the manual control lever. Tighten the manual control lever nut to specification. See TORQUE
SPECIFICATIONS . Install the electrical connectors.
3. Install the shift cable. See Fig. 44 . Verify that the engine starts ONLY with the transmission in Park or
Neutral.
4. Adjust as necessary. Install the throttle body air inlet duct. Remove the blocks from the wheels. Release
the parking brake.
PRESSURE CONTROL SOLENOID
Removal
Remove the case side cover. See CASE SIDE COVER . Disconnect the transaxle wiring harness. Remove the
pressure control solenoid (322). See Fig. 46 .
Fig. 46: Removing & Installing Pressure Control Solenoid

Installation
Install the pressure control solenoid (322). See Fig. 46 . Connect the transaxle wiring harness. Install the case
side cover. See CASE SIDE COVER .
REVERSE SERVO
Removal
1. Remove the throttle body air inlet duct. Use a large flat-blade tool in order to depress the reverse servo
cover. See Fig. 47 .
2. Use a small flat-blade tool in order to remove the retaining ring. See Fig. 48 . Use a small flat-blade tool
in order to pull the O-ring seal out through the slot in the case. Use side cutting pliers in order to cut the
servo cover O-ring seal.
3. Depress the reverse servo cover, grasp one end of the cut seal and pull the seal out of the servo cover.
4. Use a large flat-blade tool in order to depress the reverse servo cover, grasp one end of the cut seal and
pull the seal out of the servo cover.
5. Remove the reverse servo cover. See Fig. 48 . Remove the servo assembly. Remove the servo spring.
Fig. 47: Removing & Installing Reverse Servo Assembly Cover
Fig. 48: Removing & Installing Reverse Servo Assembly
Installation
NOTE: Failure to perform the following step may result in no reverse gear due to
the servo pin not aligning with the reverse band.
1. Raise the driver (left) side of the vehicle until it is higher than the passenger (right) differential side. This
ensures that the reverse band is in the proper location.
2. Install the servo spring. See Fig. 48 . Install the servo assembly.
3. Install the reverse servo cover with new O-ring seal. See Fig. 47 . Install the snap ring. Install the throttle
body air inlet duct.
SHIFT CABLE
Removal
1. Remove the throttle body air inlet duct. Use a flat-blade tool in order to remove the retaining clip from the
shift cable at the shift cable bracket. See Fig. 45 .
2. Use a large flat-blade tool in order to remove the shift cable from the manual control lever. See Fig. 44 .
Use pliers in order to depress the cable retainers.
3. Remove the shift cable from the shift cable bracket. Remove the knee bolster.
4. If the vehicle is equipped with a console shift, perform the following steps:
A. Remove the console trim plate. See appropriate SHIFT INTERLOCK article in AUTOMATIC
TRANSMISSIONS.
B. Remove the transaxle shift cable from the floor shift control. See Fig. 49 .
5. If the vehicle is equipped with a column shift, perform the following steps:
A. Remove the retaining clip from the shift cable at steering column. See Fig. 50 .
B. Use a flat-blade tool in order to remove the automatic transaxle range selector cable from the
column control lever.
C. Remove the shift cable from the column control lever.
6. Remove the shift cable through the hole in the cowl. See Fig. 51 .
Fig. 49: Removing & Installing Shift Cable At Control
Fig. 50: Removing & Installing Retaining Clip
Fig. 51: Locating Shift Cable Pass-Through
Installation
1. Properly route the shift cable through the engine compartment. See Fig. 52 . Install the shift cable through
the cowl. See Fig. 51 .
2. If the vehicle is equipped with a column shift, perform the following steps:
A. Install the shift cable to the steering column bracket.
B. Install the retaining clip to the shift cable. See Fig. 50 .
C. Install the shift cable to the column control lever.
3. If the vehicle is equipped with a console shift, perform the following steps:
A. Install the transaxle shift cable to the floor shift control. See Fig. 49 .
B. Install the console trim plate. See appropriate SHIFT INTERLOCK article in AUTOMATIC
TRANSMISSIONS.
4. Install the knee bolster. Install the shift cable to the shift cable bracket. Install the shift cable to the PNP
lever. Install the retaining clip to the shift cable. See Fig. 44 .
5. Adjust the shift cable. See SHIFT CABLE under ADJUSTMENTS. Adjust the shift cable. Install the
throttle body air inlet duct.
Fig. 52: Identifying Shift Cable Routing
TCC PULSE WIDTH MODULATION SOLENOID
Removal
1. Remove the case side cover. See CASE SIDE COVER . Disconnect the transaxle wiring harness.
2. Remove the torque converter clutch PWM solenoid (334). See Fig. 53 .
Fig. 53: Exploded View Of TCC Pulse Width Modulation Solenoid
Installation
1. Install the TCC PWM solenoid (334). See Fig. 53 . Connect the transaxle wiring harness.
2. Install the case side cover. See CASE SIDE COVER .
TFP MANUAL VALVE POSITION SWITCH
Removal
1. Remove the case side cover. See CASE SIDE COVER . Disconnect the transaxle wiring harness.
2. Remove the control valve body bolts (375, 379, 381) that mount the fluid pressure manual valve position
switch to the control valve body (300). See Fig. 54 .
NOTE: When removing the TFP switch handle the switch carefully, the fluid
pressure manual valve position switch is very delicate.
3. Carefully remove the fluid pressure manual valve position switch. Handle the switch carefully, the fluid
pressure manual valve position switch is very delicate. Inspect the fluid pressure manual valve position
switch (395) for the following conditions:
Damaged electrical connector terminals.
Damaged seals.
Damaged switch membranes.
Debris on the switch membranes.

Fig. 54: Removing & Installing Transmission Fluid Pressure Manual Valve Position Switch
Installation
1. Carefully install the fluid pressure manual valve position switch. Handle the switch carefully, the fluid
pressure manual valve position switch is very delicate. See Fig. 54 .
2. Install the control valve body bolts (375, 379, 381) that mount the fluid pressure manual valve position
switch to the control valve body (300). Tighten the control valve body bolt (375) to 106 INCH lbs. (12
N.m). Tighten the control valve body bolt (379) to 106 INCH lbs. (12 N.m).
3. Tighten the control valve body bolt (381) to 70 INCH lbs. (8 N.m). Connect the transaxle wiring harness.
Install the case side cover. See CASE SIDE COVER .
THERMO ELEMENT
Removal
1. Remove the transaxle oil pan. See DRAINING & REFILLING under LUBRICATION.
2. Remove the thermo element pins and washers (120 and 123). See Fig. 55 .
3. Remove the thermo element (121) and the thermo element plate (122).
Fig. 55: Removing & Installing Thermo Element

Installation
1. Use the Thermo Element Height Gage (J-34094-A) to set the middle thermo pin (123). See Fig. 56 .
Install the new thermo element plate (122). Install the pin and washer (120).
2. Use the thermo element height gage to set the height of the pin and washer (120) furthest from the
accumulator. Use the thermo element height gage to set the height of the second pin and washer (120).
3. Carefully install the thermo element (121) between the 2 pin and washers (120). The "V" in the thermo
element (121) must contact the thermo element plate (122). Install the oil pan. See DRAINING &
REFILLING under LUBRICATION. Refill fluid as necessary. Fill transaxle with appropriate fluid to
proper level. See LUBRICATION .
Fig. 56: Identifying Thermo Element Height Gage

TRANSAXLE BRACE
Removal
Disconnect the negative battery cable. Raise and support the vehicle. Remove the right front tire and wheel.
Remove the right engine splash shield. Remove the transaxle brace bolts. See Fig. 57 . Remove the transaxle
brace.
Fig. 57: Removing & Installing Transaxle Brace
Installation
Position the transaxle brace to transaxle and engine. Hand start the bolts to the engine. Hand start the bolts to
the transaxle. Install the transaxle brace bolts to the engine. Install the transaxle brace bolts to the transaxle. See
Fig. 57 . Tighten the transaxle brace bolts to the transaxle to specification. See TORQUE
SPECIFICATIONS . Tighten the transaxle brace bolts to the engine to specification. Install the right engine
splash shield. Install the right front tire and wheel. Lower the vehicle. Connect the negative battery cable.
TRANSAXLE MOUNT & BRACKET
Removal
1. Raise and support the vehicle. Remove the left front tire and wheel. Remove the left inner splash shield.
2. Use a utility stand with a block of wood in order to support the transaxle. Remove the transaxle mount
upper nuts. See Fig. 58 .
3. Remove the transaxle bracket to transaxle mount upper nuts. See Fig. 58 . Remove the transaxle mount
bracket bolts. Remove the transaxle mount bracket. See Fig. 59 .
4. Remove the transaxle mount lower nuts to the transaxle mount frame bracket. Remove the transaxle
mount from the transaxle mount frame bracket.
Fig. 58: Removing & Installing Transaxle Upper Mount Nuts

Fig. 59: Removing & Installing Transaxle Bracket Bolts
Installation
1. Install the transaxle mount to the transaxle mount frame bracket. Install the transaxle mount lower nuts to
the transaxle mount frame bracket. Tighten transaxle mount lower nuts to specification. See TORQUE
SPECIFICATIONS .
2. Position the transaxle mount to the frame. Install the transaxle mount bracket bolts. See Fig. 59 . Start
with the forward lower bolt and work clockwise to tighten the transaxle bracket bolts to specification. See
TORQUE SPECIFICATIONS .
3. Remove the utility stand. Install the transaxle mount upper nuts. See Fig. 58 . Tighten the transaxle mount
upper nuts to specification. See TORQUE SPECIFICATIONS .
4. Install the left engine splash shield. Install the left front tire and wheel. Lower the vehicle.
TRANSAXLE VENT
Removal
Remove the throttle body air inlet duct. Use a hammer and a chisel in order to raise the transaxle vent seat off of
the transaxle. See Fig. 60 . Use a flat-blade tool in order to pry the transaxle vent (37) out of the transaxle.
Fig. 60: Removing & Installing Transmission Vent Tube
Installation
Use a small hammer and a flat-blade tool and tap down on the transaxle vent seat in order to install the transaxle
vent (37). See Fig. 60 . Install the air cleaner intake duct.
VEHICLE SPEED SENSOR
Removal
NOTE: Handle the vehicle speed sensor (10) carefully.
Raise and support the vehicle. Remove the right front tire and wheel assembly. Remove the right engine splash
shield. Remove the vehicle speed sensor wiring harness connector. Remove the vehicle speed sensor bolt (9).
See Fig. 61 . Remove the vehicle speed sensor (10) from the extension case. Remove the O-ring (11) from the
vehicle speed sensor (10). See Fig. 62 . Inspect the vehicle speed sensor and O-ring seal for the following:
Damaged connector.
Cracked housing.
Signs of rotor damage.
Cuts or nicks on the O-ring seal (11).
Fig. 61: Removing & Installing Vehicle Speed Sensor

Fig. 62: Removing & Installing Vehicle Speed Sensor O-ring
Installation
Install the O-ring (11) to the vehicle speed sensor (10). See Fig. 62 . Install the vehicle speed sensor (10) to the
extension case. Install the vehicle speed sensor bolt (9). See Fig. 61 . Tighten the vehicle speed sensor bolt (9)
to specification. See TORQUE SPECIFICATIONS . Install the vehicle speed sensor wiring harness
connector. Install the right front tire and wheel assembly. Lower the vehicle.
WIRING HARNESS
Removal
Remove the case side cover. See CASE SIDE COVER . Use a small flat-blade tool in order to remove the
wiring harness from the solenoid valve(s), TFP manual valve position switch and/or the temperature sensor. See
Fig. 63 . Remove the wiring harness. Remove the clips retaining the solenoid(s).
Fig. 63: Removing & Installing Wiring Harness
Installation
Connect the wiring harness. See Fig. 63 . Install the wiring harness to the solenoid valve(s), TFP manual valve
position switch and/or the temperature sensor. Install the case side cover. See CASE SIDE COVER .
1-2 SHIFT SOLENOID VALVE
Removal
Remove the case side cover. See CASE SIDE COVER . Disconnect the transaxle wiring harness. Remove the
1-2 shift solenoid (315A). See Fig. 64 .
Fig. 64: Exploded View Of 1-2 Shift Solenoid Valve Components
Installation
Install the 1-2 shift solenoid (315A). See Fig. 64 . Connect the transaxle wiring harness. Install the case side
cover. See CASE SIDE COVER .
2-3 SHIFT SOLENOID VALVE
Removal
Remove the case side cover. See CASE SIDE COVER . Disconnect the transaxle wiring harness. Using a
small screwdriver or pick, remove the 2-3 shift solenoid valve retainer (314C) from the control valve body
(301). See Fig. 65 . Remove the 2-3 shift solenoid (315B). Remove the O-ring seal (316) from the 2-3 shift
solenoid valve (315B) ONLY if it is damaged.
Fig. 65: Exploded View Of 2-3 Shift Solenoid Valve Components

Installation
Install a new O-ring seal (316) onto the 2-3 shift solenoid valve (315B) if the O-ring was removed. Install the 2-
3 shift solenoid (315B). See Fig. 65 . Install the 2-3 shift solenoid valve retainer (314C) into the control valve
body (301). Connect the transaxle wiring harness. Install the case side cover. See CASE SIDE COVER .
Brace-To-Engine Bolt 46 (62)
Brace-To-Transaxle Bolt 32 (43)
Case Extension Housing Bolt 27 (37)
Engine Mount Strut 35 (48)
Manual 2-1 Band Servo Cover Bolt 17 (23)
Oil Cooler Hose Clip Bolt 18 (24)
Oil Cooler Hose Fitting 17 (23)
Oil Cooler Pipe Fitting 33 (45)
PNP Switch Mounting Bolt 23 (31)
Selector Lever Nut 15 (20)
Transaxle Bracket Bolt 70 (95)
Transaxle Mount Upper Nut 35 (48)
INCH Lbs. (N.m)
Accumulator Bolt 97 (11)
Forward Servo Cover Attaching Bolt 97 (11)
Fluid Filler Tube Bracket Bolt 115 (13)
Line Pressure Pipe Plug 97 (11)
Oil Cooler Pipe Clip Bolt 27 (3)
Oil Pan Bolt 124 (14)
Vehicle Speed Sensor Bolt 97 (11)
Body Front End - Aztek & Rendezvous
SPECIFICATIONS

Specification
Fender To Door Hinge Pillar Bolt 6 N.m 53 lb in
Fender To Rocker Panel Bolt 6 N.m 53 lb in
Front Bumper Fascia and Fender Screw 2 N.m 18 lb in
Front End Sheet Metal Diagonal Brace To The Inner Fender
10 N.m 89 lb in
Bolt
Front End Sheet Metal Diagonal Brace To The Radiator
10 N.m 89 lb in
Support Bolt
Front Fender Compartment Side Rail Bolt 10 N.m 89 lb in
Front Fender Liner Front Nut 10 N.m 89 lb in
Front Fender Liner Rear Nut 10 N.m 89 lb in
Hood Hinge To Fender Bolt 6 N.m 53 lb in
Hood Latch Nut 6 N.m 53 lb in
Hood Latch Support Bracket Bolt 25 N.m 18 lb ft
Hood Release Handle Base Bolts 2 N.m 18 lb in
Upper Hood Hinge Bolt 25 N.m 18 lb ft
REPAIR INSTRUCTIONS
HOOD ADJUSTMENT
Fig. 1: View Of Hood Bumpers (Front)
The hood hinges are bolted to the fender and to the hood.
Make fore and aft adjustments by elongating the hood-side hinge holes.
Make vertical adjustment at the front by adjusting the hood bumpers up or down.
Gap tolerances are 2-6 mm (0.10-0.22 in).
Flush tolerances are 0-2 mm (0-0.06 mm).
Fig. 2: Identifying Hood Bumpers (Side)
1. Open the hood.

2. Loosen the hinge to hood bolts.
3. Adjust the hood to the fender position.
4. Close the hood.
5. Check the hood alignment.
6. Open the hood.
7. Adjust the hood as needed.
8. Install the hinge to the hood bolts.
Tighten: Tighten the hood hinge bolts to 25 N.m (18 lb ft).
9. Adjust the hood bumpers.

10. Close the hood.
HOOD REPLACEMENT
Removal Procedure
Fig. 3: Identifying Upper Hood Hinge Bolts
1. Open and support the hood.

2. Remove the hood assist rods. Refer to Assist Rod Replacement - Hood.
3. Mark the upper hood hinge location to the hood with an grease pencil.
4. Remove the bolts from the upper hood hinge, with an assistant.
Fig. 4: View Of Hood

5. Remove the hood from the vehicle, with an assistant.
Fig. 5: View Of Hood

1. Install the hood to the vehicle, with an assistant.

Fig. 6: Aligning Hood To Hinges
2. Align the hood hinges to the alignment marks on the hood.

Fig. 7: Identifying Upper Hood Hinge Bolts
3. Install the bolts to the upper hood hinge, with an assistant.
Tighten: Tighten the upper hood hinge bolts to 25 N.m (18 lb ft).
4. Install the hood assist rods. Refer to Assist Rod Replacement - Hood.
5. Adjust the hood as required. Refer to Hood Adjustment.
HOOD HINGE REPLACEMENT
Removal Procedure
CAUTION: When a hood hold open device is being removed or installed, provide
alternate support to avoid the possibility of damage to the vehicle or
personal injury.
Fig. 8: View Of Hood Hinge To Fender Bolts

1. Remove the hood. Refer to Hood Replacement.

2. Remove the hood rear side seal. Refer to Seal Replacement - Hood Rear Side.
3. Remove the hood assist rod. Refer to Assist Rod Replacement - Hood.
4. Remove the hood hinge to fender bolts.
5. Remove the hood hinge from the fender.
Fig. 9: View Of Hood Hinge To Fender Bolts

1. Position the hood hinge to the fender.
2. Install the hood hinge to fender bolts.
Tighten: Tighten the hood hinge to fender bolts to 6 N.m (53 lb in).
3. Install the hood. Refer to Hood Replacement.

4. Install the hood assist rod. Refer to Assist Rod Replacement - Hood.
5. Install the hood rear side seal. Refer to Seal Replacement - Hood Rear Side.
6. Adjust the hood, as required. Refer to Hood Adjustment.
HOOD LATCH REPLACEMENT
Removal Procedure
Fig. 10: View Of Hood Latch
1. Open the hood.

2. Mark the hood latch to the hood latch support bracket with a grease pencil.
Fig. 11: Identifying Hood Latch Retaining Nuts
3. Remove the nuts from the hood latch.
IMPORTANT: Do not crimp the hood latch release cable.

Fig. 12: Locating Hood Latch Release Cable
4. Disconnect the hood latch release cable from the hood latch by squeezing the hood release cable retainer.
5. Remove the hood latch from the hood latch support bracket.
Fig. 13: Locating Hood Latch Release Cable
IMPORTANT: The hood latch release cable must be connected to the hood latch
support bracket.
1. Install the hood latch release cable to the hood latch.

2. Align the hood latch to the marks on the hood latch support bracket.
Fig. 14: Identifying Hood Latch Retaining Nuts

3. Install the nuts to the hood latch.
Tighten: Tighten the hood latch nuts to 6 N.m (53 lb in).
4. Adjust the hood, if required. Refer to Hood Adjustment.

5. Close the hood.
HOOD LATCH SUPPORT REPLACEMENT

Removal Procedure
Fig. 15: View Of Hood Latch Support Bracket & Electrical Harness
1. Open the hood.

2. Remove the electrical harness from the hood latch support bracket.
3. Remove the hood latch from the hood latch support bracket. Refer to Hood Latch Replacement.
Fig. 16: Identifying Hood Latch Support Bracket Mounting Bolts
4. Remove the four bolts from the hood latch support bracket.
Fig. 17: Locating Hood Latch Support Bracket
5. Reposition the hood latch release cable from the hood latch support bracket.
6. Remove the hood latch support bracket from the upper radiator tie bar.
Fig. 18: Locating Hood Latch Support Bracket
1. Install the hood latch support bracket to the upper radiator tie bar.
Fig. 19: Identifying Hood Latch Support Bracket Mounting Bolts
2. Install the four bolts to the hood latch support bracket.
Tighten: Tighten the hood latch support bracket bolts to 25 N.m (18 lb ft).
Fig. 20: Aligning Hood Latch Release Cable
3. Reposition the hood latch release cable to the hood latch support bracket.
4. Install the hood latch to the hood latch support bracket. Refer to Hood Latch Replacement.
5. Adjust the hood, if required. Refer to Hood Adjustment.
6. Connect the electrical harness to the hood latch support bracket.
7. Close the hood.
HOOD LATCH RELEASE CABLE REPLACEMENT
Removal Procedure
Fig. 21: View Of Engine Compartment
1. Open the hood.

2. Remove the left diagonal brace. Refer to Brace Replacement - Front Fender Upper Diagonal - Left.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
4. Disconnect the hood release cable from the hood latch. Refer to Hood Latch Replacement.
5. Remove the hood release cable from the hood latch bracket.
6. Remove the hood release cable retainers from the upper tie bar.
7. Remove the hood release cable retainers from the engine compartment side rail.
8. Remove the hood release cable from the hood release handle. Refer to Hood Latch Release Handle
Replacement.
9. Pull the carpet back to access the hood release cable.
IMPORTANT: Ensure the end of the wire or string remains in the passenger
compartment.
10. Tie the wire or string to the end of the hood release cable in order to aid in the installation of the new
hood release cable.
Fig. 22: View Of Hood Latch Cable & Grommet
11. Remove the grommet from the dash using a small flat bladed tool.
12. Remove the hood release cable from the dash.
13. Remove the wire or string from the hood release cable.
14. Remove the hood release cable from the vehicle.
1. Tie the wire or string to the hood release cable.

2. Install the hood release cable to the vehicle.
3. Pull the hood release cable through the dash until the grommet is seated in the hole.
Fig. 23: View Of Hood Latch Cable & Grommet

4. Install the grommet into the dash using a small flat bladed tool.
Fig. 24: View Of Engine Compartment
5. Install the hood release cable retainers to the engine compartment side rail.
6. Install the hood release cable retainers to the upper tie bar.
7. Connect the hood release cable to the hood latch. Refer to Hood Latch Replacement.
8. Install the hood release cable to the hood release handle. Refer to Hood Latch Release Handle
Replacement.
9. Pull the carpet back.
10. Remove the block from the hood latch.
11. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
12. Install the diagonal brace. Refer to Brace Replacement - Front Fender Upper Diagonal - Left.
13. Test the hood release cable for proper operation before closing the hood.
14. Close the hood.
HOOD LATCH RELEASE HANDLE REPLACEMENT
Removal Procedure
1. Remove the left IP Insulator Panel. Refer to Closeout/Insulator Panel Replacement - Left in Instrument
Panel, Gauges, and Console.
2. Remove the knee bolster panel. Refer to Knee Bolster Replacement in Instrument Panel, Gauges, and
Console.
Fig. 25: Hood Release Handle Base
3. Remove the bolts from the hood release handle base.

Fig. 26: Locating Hood Release Handle
4. Remove the hood release cable from the hood release handle.
5. Remove the hood release handle from the instrument panel.
Fig. 27: Locating Hood Release Handle
1. Install the hood release cable to the hood release handle.

Fig. 28: Hood Release Handle Base
2. Install the hood release handle to the instrument panel.
3. Install the bolts to hood release handle base.
Tighten: Tighten the hood release handle base bolts to 2 N.m (18 lb in).
4. Install the knee bolster panel. Refer to Knee Bolster Replacement in Instrument Panel, Gauges, and
Console.
5. Install the left IP Insulator Panel. Refer to Closeout/Insulator Panel Replacement - Left in Instrument
Panel, Gauges, and Console.
HOOD INSULATOR REPLACEMENT
Tools Required
J 38778 Door Trim Pad and Garnish Clip Remover
Removal Procedure
Fig. 29: Locating Hood Insulator Push-In Retainers

1. Open the hood.

2. Remove the hood insulator push-in retainers using J 38778 .
Fig. 30: View Of Hood Insulator
3. Remove the hood insulator from the hood.
Fig. 31: View Of Hood Insulator
1. Install the hood insulator to the hood support brackets.

2. Align the hood insulator retainers holes to the holes in the hood.
Fig. 32: Locating Hood Insulator Push-In Retainers
3. Install the push-in retainers to the hood.

4. Close the hood.
ASSIST ROD REPLACEMENT - HOOD
Removal Procedure
Fig. 33: Using Flat Bladed Tool To Lift Assist Rod Retainer Clips
CAUTION: When a hood hold open device is being removed or installed, provide
alternate support to avoid the possibility of damage to the vehicle or
personal injury.
1. Open and support the hood.

2. Lift up the retainer clips on the assist rod using a small flat-bladed tool.
Fig. 34: View Of Assist Rod
NOTE: Refer to Liftgate/Hood Assist Rod Notice in Cautions and Notices.
3. Pull the upper end of the assist rod from the ball joint on the hood.
4. Pull the lower end of the assist rod from the ball joint on the lower hood hinge.
Fig. 35: Pressing Upper End Of Assist Rod Onto Ball Joint
1. Press the upper end of the assist rods on to the ball joint on the hood.
Fig. 36: Installing Lower End Of Assist Rod
2. Press the lower end of the assist rods on to the ball joint on the lower hood hinge
3. Remove the support from the hood.
4. Close the hood.
FENDER REPLACEMENT - FRONT
Removal Procedure
NOTE: When removing body panels, apply tape to corners of panel and adjacent
surfaces to help prevent paint damage.
1. Apply protective tape to the front edge of the front door and the rear edge of the front bumper fascia.
2. Remove the front park/turn signal lamp. Refer to Park/Turn Signal Lamp Replacement (Aztek) or
Park/Turn Signal Lamp Replacement (Rendezvous) in Lighting Systems.
3. Remove the front fender wheel opening molding. Refer to Molding Replacement - Front Wheel
Opening (Aztek) or Molding Replacement - Front Wheel Opening (Rendezvous) in Exterior Trim.
4. Remove the front fender liner. Refer to Front Fender Liner Replacement.
5. Remove the front fender sound insulator. Refer to Fender Sound Insulator Replacement - Front.
6. Remove the rocker panel molding. Refer to Molding Replacement - Rocker Panel in Exterior Trim.
Fig. 37: Identifying Front Bumper Fascia Mounting Bolts

7. Remove the bolts from the front bumper fascia at the front fender.
8. Remove the bolts from the fender at the door hinge pillar.
Fig. 38: Locating Fender To Rocker Panel Bolts

9. Remove the bolts from the fender at the rocker panel.

Fig. 39: View Of Fender To Front Compartment Side Rail Bolts
10. Remove the bolts from the fender at the front compartment side rail.
11. Remove the fender from the vehicle.
1. Install the front fender to the vehicle.

Fig. 40: View Of Fender To Front Compartment Side Rail Bolts
2. Install the bolts to the fender at the front compartment side rail.
Tighten: Tighten the front fender compartment side rail bolts to 10 N.m (89 lb in).
Fig. 41: Locating Fender To Rocker Panel Bolts
3. Install the bolts to the fender at the rocker panel.
Tighten: Tighten the fender to rocker panel bolts to 6 N.m (53 lb in).
Fig. 42: Identifying Front Bumper Fascia Mounting Bolts
4. Install the bolts to the fender at the door hinge pillar.
Tighten: Tighten the fender to door hinge pillar bolts to 6 N.m (53 lb in).
5. Install the front fender wheel opening molding. Refer to Molding Replacement - Front Wheel Opening
(Aztek) or Molding Replacement - Front Wheel Opening (Rendezvous) in Exterior Trim.
6. Install the front fender sound insulator. Refer to Fender Sound Insulator Replacement - Front.
7. Install the front fender liner. Refer to Front Fender Liner Replacement.
8. Install the rocker panel molding. Refer to Molding Replacement - Rocker Panel in Exterior Trim.
9. Remove the protective tape to the front edge of the front door and the rear edge of the front bumper
fascia.
BRACE REPLACEMENT - FRONT FENDER UPPER DIAGONAL - LEFT
Removal Procedure
Fig. 43: View Of Engine Coolant Heater Harness

1. Open the hood.

2. Remove the engine coolant heater harness from the front fender diagonal brace, if equipped.
Fig. 44: Identifying Engine Coolant Reservoir
3. Reposition the engine coolant reservoir from the front fender diagonal brace. Refer to Coolant Recovery
Reservoir Replacement in Engine Cooling.
Fig. 45: View Of Cruise Control Module
4. If equipped, reposition the cruise control module from the front fender diagonal brace. Refer to Cruise
Control Module Replacement in Cruise Control.
Fig. 46: Locating Front End Sheet Metal Diagonal Brace To Inner Fender Bolt
5. Remove the front end sheet metal diagonal brace to the inner fender bolt.
6. Remove the front end sheet metal diagonal brace to radiator support bolts.
Fig. 47: View Of Front End Sheet Metal Diagonal Brace
7. Remove the front end sheet metal diagonal brace.
Fig. 48: View Of Front End Sheet Metal Diagonal Brace
1. Position the front end sheet metal diagonal brace to the radiator support and to the inner fender.
Fig. 49: Locating Front End Sheet Metal Diagonal Brace To Inner Fender Bolt
2. Install the bolts to the front end sheet metal diagonal brace at the radiator support.
Tighten: Tighten the front end sheet metal diagonal brace at radiator support bolts to 10 N.m (89 lb in).
3. Install the bolts to the front end sheet metal diagonal brace at the inner fender.
Tighten: Tighten the front end sheet metal diagonal brace to the inner fender bolts to 10 N.m (89 lb in).

4. If removed, reposition the cruise control module to the front fender diagonal brace. Refer to Cruise
Control Module Replacement in Cruise Control.
Fig. 51: Identifying Engine Coolant Reservoir
5. Reposition the engine coolant reservoir to the front fender diagonal brace. Refer to Coolant Recovery
Reservoir Replacement in Engine Cooling.
Fig. 52: View Of Engine Coolant Heater Harness
6. Install the engine coolant heater harness to the front fender diagonal brace, if equipped.
7. Close the hood.
BRACE REPLACEMENT - FRONT FENDER UPPER DIAGONAL - RIGHT
Removal Procedure
1. Open the hood.

Fig. 53: Identifying Underhood Wiring Junction Block
2. Reposition the underhood wiring junction block from the front fender diagonal brace. Refer to
Underhood Electrical Center or Junction Block Replacement in Wiring Systems.
Fig. 54: Locating Front End Sheet Metal Diagonal Brace Bolts
3. Remove the bolt from the front end sheet metal diagonal brace at the inner fender.
4. Remove the bolts from the front end sheet metal diagonal brace at the radiator support.
Fig. 55: Front End Sheet Metal Diagonal Brace
5. Remove the front end sheet metal diagonal brace.
Fig. 56: Front End Sheet Metal Diagonal Brace
1. Position the front end sheet metal diagonal brace to the radiator support and to the inner fender.

Fig. 57: Locating Front End Sheet Metal Diagonal Brace Bolts
2. Install the bolts to the front end sheet metal diagonal brace at the radiator support.
Tighten: Tighten the front end sheet metal diagonal brace at radiator support bolts to 10 N.m (89 lb in).
3. Install the bolts to the front end sheet metal diagonal brace at the inner fender.
Tighten: Tighten the front end sheet metal diagonal brace to the inner fender bolts to 10 N.m (89 lb in).
Fig. 58: Identifying Underhood Wiring Junction Block
4. Reposition the underhood wiring junction block to the front fender diagonal brace. Refer to Underhood
Electrical Center or Junction Block Replacement in Wiring Systems.
5. Close the hood.
AIR INLET GRILLE PANEL REPLACEMENT
Tools Required
J 38778 Door Trim Pad and Garnish Clip Remover. See Special Tools.
Removal Procedure
Fig. 59: View Of Windshield Wiper Washer Hose
1. Open the hood.

2. Remove the windshield wiper arms. Refer to Wiper Arm Replacement in Wiper Washer Systems.
3. Reposition the windshield wiper washer hose from the air inlet grille.
Fig. 60: Identifying Air Inlet Grille Push-In Retainers
4. Remove the push-in retainers from the air inlet grille, using the J 38778 . See Special Tools.
Fig. 61: Locating Air Inlet Grille Extensions
5. Remove the air inlet grille extensions from the air inlet grille at the windshield.
Pull up and out in order to release the retainers on the air inlet grille extensions.
Fig. 62: View Of Air Inlet Grille
6. Remove the air inlet grille from the vehicle.
Fig. 63: View Of Air Inlet Grille
IMPORTANT: Inspect the position of the air inlet seal to the windshield. If not seated
properly, reposition the air inlet grille as required.
1. Position the air inlet grille to the vehicle.

Fig. 64: Locating Air Inlet Grille Extensions
2. Install the air inlet grille extensions to the air inlet grille and the windshield, pressing into place until fully
seated.
Fig. 65: Identifying Air Inlet Grille Push-In Retainers
3. Install the push-in retainers to the air inlet grille.

Fig. 66: View Of Windshield Wiper Washer Hose
4. Reposition the windshield wiper washer hose to the air inlet grille.
5. Install the windshield wiper arms. Refer to Wiper Arm Replacement in Wiper Washer Systems.
6. Close the hood.
SEAL REPLACEMENT - PLENUM TO HOOD
Removal Procedure
Fig. 67: View Of Hood Rear Weatherstrip
1. Open the hood.

2. Remove the push-in retainers from the hood rear weatherstrip.
3. Remove the hood rear weatherstrip from under the air inlet grille.
4. Remove the hood rear weatherstrip from the vehicle.
Fig. 68: View Of Hood Rear Weatherstrip

1. Align the hood rear weatherstrip to the holes in the cowl under the air inlet grille.
2. Install the push-in retainers to the hood rear weatherstrip.
3. Close the hood.
SEAL REPLACEMENT - HOOD REAR SIDE
Removal Procedure
Fig. 69: Identifying Rear Side Hood Seal

1. Open the hood.

2. Pull the rear side hood seal from the pinch-weld flange and motor compartment flange.
3. Remove the rear side hood seal from the vehicle.
4. Clean any adhesive from the pinch-weld flange and motor compartment flange surface.
Fig. 70: Identifying Rear Side Hood Seal

1. Remove the protective backing paper from the adhesive on the rear side hood seal.
2. Install the rear side hood seal to the pinch-weld flange and motor compartment flange.
3. Press the side rear hood seal onto the pinch-weld flange and motor compartment flange until the adhesive
is fully adhered.
4. Close the hood.
FRONT FENDER LINER REPLACEMENT
Removal Procedure
Fig. 71: View Of Front Fender Liner Retaining Screws
1. Remove the screws from the front fender liner at the front bumper fascia and fender.
Fig. 72: Identifying Rear Fender Liner Rear Stud Nut
2. Remove the nut from the stud at the rear of the front fender liner.
Fig. 73: Locating Front Fender Liner Rear Stud Nut
3. Remove the nut from the stud at the front of the front fender liner.
4. Remove the front fender liner.
Fig. 74: Identifying Rear Fender Liner Rear Stud Nut
1. Position the fender liner to the fender, over the studs and behind the rocker molding.
2. Install the nut to the stud at the rear of the front fender liner.
Tighten: Tighten the front fender liner rear nut to 10 N.m (89 lb in).
Fig. 75: Locating Front Fender Liner Rear Stud Nut
3. Install the nut to the stud at the front of the front fender liner.
Tighten: Tighten the front fender liner front nut to 10 N.m (89 lb in).
4. Install the screws to the front fender liner at the front bumper fascia and fender.
Tighten: Tighten the front bumper fascia and fender screws to 2 N.m (18 lb in).
FENDER SOUND INSULATOR REPLACEMENT - FRONT
Removal Procedure
Fig. 77: Identifying Front Fender Insulator
1. Remove the front fender liner. Refer to Front Fender Liner Replacement.
2. Remove the front fender insulator from the stud, by pulling off.
3. Remove the front fender insulator from the inner fender.
IMPORTANT: The front fender insulator must be kept near the flange of the front fender
wheel opening to avoid interference with the front door edge.
Fig. 78: Identifying Front Fender Insulator

1. Install the front fender insulator to the stud in the inner fender, pressing into place until fully seated.
2. Install the front fender liner. Refer to Front Fender Liner Replacement.
SPLASH SHIELD REPLACEMENT - ENGINE
Tools Required
J 38778 Door Trim Pad and Garnish Clip Remover. See Special Tools.
Removal Procedure
Fig. 79: View Of Engine Splash Shield Push-In Retainers

1. Remove the push-in retainers holding the engine splash to the lower flange of the engine compartment
side rail using J 38778 . See Special Tools.
2. Remove the engine splash shield from the lower flange of the engine compartment side rail.
Fig. 80: View Of Engine Splash Shield Push-In Retainers

1. Install the engine splash shield front tab to the front fender liner.
2. Align the holes in the engine splash shield to the holes in the outboard side engine compartment side rail.
3. Insert the push-in retainers to the engine splash shield.
SPECIAL TOOLS
Special Tools
Illustration Tool Number/Description
J 38778
Door Trim Pad and Garnish Clip Remover
Anti-Lock Brakes - Aztek & Rendezvous
SPECIFICATIONS
Fig. 1: Torque Specifications


Fig. 2: ABS Schematics Diagram (Brake Pressure Modulation, Ground, Power & Stoplamp Switch)
Fig. 3: ABS Schematics Diagram (DLC, Indicators & Traction Control Switch)
Fig. 4: ABS Schematics Diagram (Wheel Speed Sensors)
COMPONENT LOCATOR
ABS COMPONENT VIEWS
Fig. 5: Locating ABS Components - Right Front Wheel
Fig. 6: Locating ABS Components - LR Engine Compartment
Fig. 7: Locating ABS Components - LR Wheel Speed Sensor
ABS CONNECTOR END VIEWS
Fig. 8: Identifying Electronic Brake Control Module (EBCM) Terminals (1 Of 2)

Fig. 9: Identifying Electronic Brake Control Module (EBCM) Terminals (2 Of 2)
Fig. 10: Identifying I/P Switch Assembly - C1 Terminals (Pontiac)
Fig. 11: Identifying Wheel Speed Sensor - LF Terminals
Fig. 12: Identifying Wheel Speed Sensor - LR Terminals
Fig. 13: Identifying Wheel Speed Sensor - RF Terminals
Fig. 14: Identifying Wheel Speed Sensor - RR Terminals

DIAGNOSTIC STARTING POINT - ANTI-LOCK BRAKE SYSTEM
Begin the system diagnosis with DIAGNOSTIC SYSTEM CHECK - ABS . The Diagnostic System Check
will provide the following information:

ABS - DIAGNOSTIC PROCEDURE
Circuit Description
The ABS Diagnostic System Check is an organized approach to identify problems associated with the EBCM.
This check must be the starting point for any EBCM complaint, and will direct you to the next logical step in
diagnosing the complaint. The EBCM is a very reliable component and is not likely the cause of the
malfunction. Most system complaints are linked to faulty wiring, connectors, and occasionally to components.
Understanding the ABS system and using the tables correctly will reduce diagnostic time and prevent
unnecessary parts replacement.
Fig. 15: Diagnostic System Check - ABS
SCAN TOOL OUTPUT CONTROLS DATA LIST
Fig. 16: Scan Tool Output Controls Data List (1 Of 2)

Fig. 17: Scan Tool Output Controls Data List (2 Of 2)

SCAN TOOL DATA LIST
The EBCM Scan Tool Data Lists contain all the anti-lock brake system related parameters that are available on
the scan tool. The parameters in the list are arranged in alphabetical order. The column, 'Data List,' indicates the
location of the parameter within the scan tool menu selections.
Use the EBCM Scan Tool Data Lists as directed by a diagnostic table or in order to supplement the diagnostic
procedures. Begin all the diagnostic procedures with the ABS Diagnostic Starting Point. Use the EBCM Scan
Tool Data Lists only after the following is determined:
OR
customer concern.
first row of the Scan Tool Data List table.
Comparison of the parameter values from the suspect vehicle with the Typical Data Values may reveal the
source of the customer concern.
The ID Information menu is located on the EBCM main screen.
Fig. 18: EBCM Scan Tool Data List (1 Of 2)

Fig. 19: EBCM Scan Tool Data List (2 Of 2)
Data Display/Definitions
The Scan Tool Data Display/Definitions contains a brief description of all the ABS/TCS/VSES data parameters.
The menus available depend on the number and type of system on the vehicle and are listed below in
alphanumeric order.
ABS DATA
TCS DATA
ABS Active: The scan tool displays Yes or No. The scan tool will display Yes when the ABS is active and No
during normal vehicle operation.
ABS Warning Lamp: The scan tool will display On or Off depending on the state of the ABS indicator.
Brake Switch: The scan tool will display Applied or Released depending on the state of the brake switch.
DRP Active: The scan tool will display Yes/No depending on the state of the DRP.
DRP Disabled: The scan tool will display Yes/No depending on the state of the DRP.
EBTCM to PCM Requested Torque: The scan tool displays 0-100 percent. The scan tool displays the duty
cycle of the Delivered Torque PWM signal. The duty cycle of the signal is used to transmit how much torque
the EBCM is requesting the PCM to deliver. Normal values are between 10 and 90 percent duty cycle. The
signal should be at 90 percent duty cycle when traction control is not active and at a lower value, approximately
10 percent, when the traction control is active.
Engine Speed: The scan tool will display between 0 to 10200 RPM which is a digital tachometer display.
Ignition Voltage: The scan tool displays 0-17 Volts. The scan tool displays the level of ignition voltage at the
EBCM.
LF Inlet Valve Solenoid: The scan tool will display Active or Inactive. The scan tool displays the commanded
state of the LF inlet solenoid valve.
LF Outlet Valve Solenoid: The scan tool will display Active or Inactive. The scan tool displays the
commanded state of the LF outlet solenoid valve.
LF TCS Isolation Solenoid: The scan tool will display Active/Inactive. This displays the commanded state of
the solenoid valve.
LF TCS Prime Solenoid: The scan tool will display Active/Inactive. This displays the commanded of the
solenoid valve.
Left Front Wheel Speed: The scan tool displays 0-255 km/h or (0-158 mph). The scan tool displays the actual
speed of the left front wheel.
Left Rear Wheel Speed: The scan tool displays 0-255 km/h or (0-158 mph). The scan tool displays the actual
speed of the left rear wheel.
Low Traction Lamp: The scan tool will display On/Off. This will indicate the state of the LOW TRAC
Indicator.
LR Inlet Valve Solenoid: The scan tool displays Active or Inactive. The scan tool displays the commanded
state of the LR inlet solenoid valve.
LR Outlet Valve Solenoid: The scan tool displays Active or Inactive. The scan tool displays the commanded
state of the LR outlet solenoid valve.
Monitor Relay State: The scan tool display On/Off. This is the commanded state of the relay.
PCM to EBTCM Delivered Torque: The scan tool displays 0-100 percent. The scan tool displays the duty
cycle of the Requested Torque PWM signal. The duty cycle of the signal is used to transmit how much engine
torque the PCM is delivering. Normal values are between 10 and 90 percent duty cycle. The signal is at low
values, approximately 10 percent, at idle and at higher values under driving conditions.
RF Inlet Valve Solenoid: The scan tool displays Active or Inactive. The scan tool displays the commanded
state of the RF inlet solenoid valve.
RF Outlet Valve Solenoid: The scan tool displays Active or Inactive. The scan tool displays the commanded
state of the RF outlet solenoid valve.
Right Front Wheel Speed: The scan tool displays 0-255 km/h or (0-158 mph). The scan tool displays the
actual speed of the right front wheel.
RF TCS Isolation Solenoid: The scan tool will display Active/Inactive. This will be the commanded state of
the solenoid valve.
RF TCS Prime Solenoid: The scan tool will display Active/Inactive. This will be the commanded state of the
solenoid valve.
RR Inlet Valve Solenoid: The scan tool displays Active or Inactive - The scan tool displays the commanded
state of the RR inlet solenoid valve.
RR Outlet Valve Solenoid: The scan tool displays Active or Inactive - The scan tool displays the commanded
state of the RR outlet solenoid valve.
Right Rear Wheel Speed: The scan tool displays 0-255 km/h or (0-158 mph). The scan tool displays the actual
speed of the right rear wheel.
Rough Road Parameters: The scan tool will display 0 to 1 g. The scan tool will display the EBCM calculation
of the road surface roughness. This information is then sent to the PCM over the class 2 serial data line. This
information is used by the PCM for misfire detection.
TCS Active: The scan tool displays Off or On. The scan tool displays On if the TCS indicator is currently being
commanded ON.
TCS Switch State: The scan tool displays Pressed or Released. The scan tool will display the state of the
Traction Control Switch.
TCS Warning Lamp: The scan tool will display On or Off depending on the state of the TCS indicator.
Valve Relay State: The scan tool will display On/Off depending on the state of the relay.
DIAGNOSTIC TROUBLE CODE (DTC) LIST
Diagnostic Trouble Code (DTC) List

DTC Description
DTC B2747 Traction Control Circuit Malfunction
DTC C0035, C0036, C0040, C0041, C0045, Wheel Speed Circuit
C0046, C0050, C0051
DTC C0060, C0065, C0070, C0075, C0080, ABS Solenoid Circuit Malfunction
C0085, C0090, C0095
DTC C0110 Pump Motor Circuit Malfunction
DTC C0121 Valve Relay Circuit Malfunction
DTC C0141, C0146, C0151, C0156 TCS Solenoid Circuit Malfunction
DTC C0161 ABS/TCS Brake Switch Circuit Malfunction
DTC C0236 Rear Wheel Speed Signal Circuit Missing
DTC C0240 PCM Traction Control Not Allowed
DTC C0241, P1571 EBCM Control Valve Circuit
DTC C0244, P1689 EBCM Malfunction
DTC C0245 EBCM Malfunction
DTC C0565 VIN Information Error EBCM
DTC C0896 ESC Voltage Is Outside The Normal Range Of 9 To
15.5 Volts
DIAGNOSTIC TEST DRIVE
When servicing vehicles, the vehicle anti-lock brake and traction control system, test drives will be necessary to
allow all tests to be run, and all system functions to be enabled and exercised. A test drive may also be required
to duplicate specific DTCs covered in this section. The diagnostic system check (including test drive) should be
run when vehicle repairs are complete in order to verify the repair.
The diagnostic test drive will vary for ABS/TCS problems.
1. Read the Diagnostic Aids and the Conditions for Setting the DTC.
2. Reconnect any previously disconnected components.
4. Drive the vehicle under the following conditions for at least 10 minutes. At no times should any unlawful
or unsafe maneuvers be performed.
Highway driving.
Rough roads.
Verify customers concern and duplicate driving conditions.
With the engine still running use the scan tool and check for any DTCs. If any DTCs are set,
perform the appropriate DTC table.
ENHANCED DIAGNOSTICS
History Data
Enhanced diagnostic information is found in the History Data function of the scan tool. Enhanced diagnostic
information provides the service technician with specific malfunction occurrence information.
The scan tool will display the last 3 DTCs to occur, one at a time. The DTC with the most recent occurrence
will be displayed first. Each DTC will include the following:
The number of drive cycles since the DTC last occurred.

The number of occurrences for the DTC since the scan tool DTC information was last cleared.
The most recent DTC will also display various data parameters with values from the time of the DTC
occurrence.
Diagnostic Strategy
In difficult diagnostic situations use the above information to identify malfunction occurrence trends. Ask
question such as the following:
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
diagnostic techniques may be required to identify the source of the malfunction?
A malfunction that occurs more frequently increases the odds of finding the cause of the malfunction.
Use the information in order to determine if a DTC is intermittent. Use the information in order to determine if
the DTC has not set for long periods of time due to weather changes or a repair prior to this visit.
DTC B2747: TRACTION CONTROL CIRCUIT MALFUNCTION
Circuit Description
The traction control switch is a momentary switch. The signal circuit of the traction control switch is grounded
when the driver presses the traction control switch. The traction control system will change state from traction
on to traction off or from traction off to traction on each time the traction control switch is pressed.
The battery voltage is between 9.0 volts and 16.0 volts.

The park brake is not applied.
The signal circuit voltage of the traction control switch is no more than 2.0 volts.
All of the above conditions are present for greater than 60 seconds.
If equipped the following actions occur:
The BCM stores DTC B2747 in memory.

The traction control switch input is ignored until the fault is no longer current.
A current DTC B2747 will clear if the BCM no longer detects a short to ground for longer than 60
seconds.
A history DTC B2747 will clear after 100 consecutive ignition cycles if the condition for the malfunction
is no longer present.
A scan tool may be used to clear the DTC.
Diagnostic Aids
Check for a traction control switch that may be sticking in the pressed position. For an intermittent condition
refer to TESTING FOR INTERMITTENT AND POOR CONNECTIONS in Wiring Systems.
Test Description
2. This step verifies that the fault is present.

3. This step tests for a shorted switch.
Fig. 20: DTC B2747 Diagnostic Procedure

DTC C0035 TO C0051: WHEEL SPEED CIRCUIT
Circuit Description
As the wheel spins, the wheel speed sensor produces an AC signal. The EBCM uses the frequency of the AC
signal to calculate the wheel speed.
C0035, C0040, C0045 Or C0050
The ignition is ON.
C0036, C0041, C0046 Or C0051
Vehicle speed is over 40 km/h (25 mph).

The brake pedal is not pressed.
The ABS is not active.
C0035, C0040, C0045 Or C0050
One of the following conditions exists for 0.02 seconds:
A short to voltage - in the wheel speed sensor signal circuit.

An open - in the wheel speed sensor signal circuit.
C0036, C0041, C0046 Or C0051
All of the following conditions exists for 0.01 seconds:
The suspect wheel speed equals zero.

The other wheel speeds are greater than 40 km/h (25 mph) for 0.01 seconds.
The suspect wheel equals zero during drive off, and the other wheels are greater than 18 km/h (11 mph).
A short to ground - the wheel speed sensor signal circuit is shorted to ground.
A deviation of two wheel speeds at either side of the vehicle greater than 6 km/h (4 mph), or at the front
axle greater than 10 km/h (6 mph) for a time period of 10 to 20 seconds.
A DTC malfunction will set.
The Red BRAKE Warning indicator could turn on.
The AWD disable indicator could turn on if equipped.
drive cycles.
Diagnostic Aids
C0035, C0040, C0045 Or C0050
If the customer comments that the ABS indicator is ON only during moist environmental conditions (rain,
snow, vehicle wash, etc.), inspect the wheel speed sensor wiring for signs of water intrusion. If the DTC is not
current, clear all DTCs and simulate the effects of water intrusion by using the following procedure:
1. Spray the suspected area with a 5 percent saltwater solution. To create a 5 percent saltwater solution, add
2 teaspoons of salt to 354 ml (12 oz) of water.
2. Test drive the vehicle over various road surfaces (bumps, turns, etc.) above 40 km/h (25 mph) for at least
30 seconds.
3. If the DTC returns, replace the suspected wheel speed sensor or repair the wheel speed sensor wiring.
4. Rinse the area thoroughly when completed.
C0036, C0041, C0046 Or C0051
Under the following conditions, 2 Wheel Speed Sensor Input is 0 DTCs are set:
The 2 suspect wheel speeds equal zero for 10-20 seconds.

The other wheel speeds are greater than 16 km/h (10 mph).
The other wheel speeds are within 11 km/h (7 mph) of each other.
Diagnose each wheel speed sensor individually.
C0036, C0041, C0046 Or C0051
A possible cause of this DTC is electrical noise on the wheel speed sensor harness wiring. Electrical noise could
result from the wheel speed sensor wires being routed too close to high energy ignition system components,
such as spark plug wires.
Test Description
3. This step tests the wheel speed sensor for the proper resistance value.
4. This step ensures that the wheel speed sensor generates the proper voltage.
Fig. 21: DTC C0035-C0051 Diagnostic Procedure (Steps 1-7)

Fig. 22: DTC C0035-C0051 Diagnostic Procedure (Steps 8-10)
DTC C0060 TO C0095: ABS SOLENOID CIRCUIT MALFUNCTION
Circuit Description
The inlet and outlet valve solenoid circuits are supplied with battery power when the ignition is in the ON
position. The EBCM controls the valve functions by grounding the circuit when necessary.
The DTC can set anytime the ignition switch is in the ON position.
The DTC can set when the vehicle speed is greater then 6 km/h (4 mph) and the brake pedal is not
applied.
The DTC can set when the vehicle speed is greater then 15 km/h (9 mph) and the brake pedal is applied.
An open in the solenoid coil or circuit.

A short to ground in the solenoid coil or circuit.
A short to voltage in the solenoid coil or circuit.
The EBCM disables the ABS/TCS/DRP for the duration of the ignition cycle.
drive cycles.
Diagnostic Aids
the EBCM only.
Test Description
The numbers below refer to step numbers on the Diagnostic Table.
2. This step determines if the DTC is current.
Fig. 23: DTC C0060-C0095 Diagnostic Procedure

DTC C0110: PUMP MOTOR CIRCUIT MALFUNCTION
Circuit Description
The pump motor is an integral part of the BPMV, while the pump motor relay is integral to the EBCM. The
pump motor relay is not engaged during normal system operation. When ABS or TCS operation is required the
EBCM activates the pump motor relay and battery power is provided to the pump motor.

Initialization is complete.
Pump motor voltage is not present 60 milliseconds after activation of the pump motor relay.
Pump motor voltage is present for more than 2.5 seconds with no activation of the pump motor relay.
Pump motor voltage is not present for 40 milliseconds after the pump motor relay is commanded off.
drive cycles.
Diagnostic Aids
Improper mating
Broken locks
Poor terminal-to-wiring connections.

A poor connection
If an intermittent malfunction exists refer to TESTING FOR INTERMITTENT AND POOR

CONNECTIONS in Wiring Systems.
Test Description
3. Tests the pump motor circuits of the BPMV for a short to the housing of the BPMV. The wiring from
the BPMV to the EBCM should not be repaired.
Fig. 24: DTC C0110 Diagnostic Procedure
DTC C0121: VALVE RELAY CIRCUIT MALFUNCTION
Circuit Description
The solenoid valve relay supplies power to the solenoid valve coils in the EBCM. The solenoid valve relay,
located in the EBCM, is activated whenever the ignition switch is in the RUN position and no faults are present.
The solenoid valve relay remains engaged until the ignition is turned OFF or a failure is detected.

DTC C0121 will set anytime the solenoid valve relay is commanded on and the EBCM does not see
battery voltage at the solenoid valves.
DTC C0121 will set anytime the EBCM commands the solenoid valve relay off and battery voltage is still
present at the solenoid valves.
drive cycles.
Diagnostic Aids
Improper mating
Broken locks

A poor connection
If an intermittent malfunction exists, refer to TESTING FOR INTERMITTENT AND POOR

The solenoid valve relay is an integral part of the EBCM and is not serviced separately.
Test Description
The number below refers to step number on the Diagnostic Table.

DTC C0141 TO C0156: TCS SOLENOID CIRCUIT MALFUNCTION
Circuit Description
The isolation and prime valve solenoid circuits are supplied with battery power when the ignition is in the ON
position. The EBCM controls the valve functions by grounding the circuit when necessary.


An open in the solenoid coil or circuit.

A short to ground in the solenoid coil or circuit.
A short to voltage in the solenoid coil or circuit.
Condition for DTC is no longer present and scan tool clear DTC function is used.
100 ignition cycles pass with no DTC(s) detected.
Diagnostic Aids
the EBCM only.
Test Description
The numbers below refer to step numbers on the Diagnostic Table.

Fig. 26: DTC C0141-C0156 Diagnostic Procedure
DTC C0161: ABS/TCS BRAKE SWITCH CIRCUIT MALFUNCTION
Circuit Description
The Stoplamp Switch is a normally open switch, when the brake pedal is depressed the EBCM will sense
battery voltage. This allows the EBCM to determine the state of the brake lamps. The EBCM sources 5 volts on
the stop lamp switch signal circuit when the stop lamp switch is inactive. The voltage is supplied a ground path
through the stop lamp bulbs.
EBCM detects open in the brake signal circuit.

Both brake lamps are faulty.
The stoplamp switch input voltage is between 6.6 and 9 volts for 0.5 second.

The EBCM stores this information-only DTC for as long as the condition is present.
The ABS indicator remains OFF.
drive cycles.
Diagnostic Aids

Improper mating
Broken locks
Possible causes of this DTC are the following conditions:
A signal circuit of the stop lamp switch is open

The stop lamp switch is misadjusted
Verify proper stop lamp switch operation using the data list of the scan tool. As the brake is applied, the
data list displays the stop lamp switch ON within 2.54 cm (1 in) of travel
All brake lamps are open
All brake lamp grounds are open
Circuit has a wiring problem, terminal corrosion, or poor connections
Loose or corroded EBCM ground

Test Description
2. This DTC detects an open stop lamp switch signal circuit from the stop lamp side of the splice pack to
the EBCM.
3. The EBCM sources 5 volts on the stop lamp switch signal circuit. This small voltage has a ground path
through the stop lamp bulbs. This DTC sets if the path to ground is open.

DTC C0236: REAR WHEEL SPEED SIGNAL CIRCUIT MISSING
Circuit Description
The RPM signal circuit provides the EBCM with an indication of engine RPM to help determine TCS control
methods and rates when a TCS event takes place.
The ignition switch is ON and the engine running

After 2 seconds starting, and if there is a undervoltage condition.

The EBCM does not received an RPM input signal after 1 second, after the engine has been started.

The TCS is disabled. ABS remains functional.
The condition for DTC is no longer present and the scan tool Clear DTCs function is used.
100 ignition cycles have passed with no DTC(s) detected.
Diagnostic Aids
Perform a thorough inspection of the wiring. Perform a thorough inspection of the connectors. Failure to
carefully and fully inspect the wiring and the connectors may result in misdiagnosis. Misdiagnosis causes part
replacement with reappearance of the malfunction.
Test Description
The number(s) below refer to the step number(s) on the diagnostic table.
2. If the instrument panel tachometer is working properly, the cause of the malfunction is most likely
between the PCM and the EBCM, or the EBCM itself.
9. At this point, the PCM is likely causing the malfunction. Refer to the OBD system check.
Fig. 28: DTC C0236 Diagnostic Procedure (Steps 1-4)
DTC C0240: PCM TRACTION CONTROL NOT ALLOWED
Circuit Description
The PCM monitors various parameters and will not allow traction control operation if any parameter falls below
a specified value.
The ignition is ON.
The PCM detects a malfunction and then causes TCS shut down until the malfunction has been corrected.
A DTC C0240 is stored.

If the TCS is again allowed to function, the indicator will be turned off but the DTC will be stored.
drive cycles.
Test Description
4. This step checks if DTC C0240 resets.

DTC C0241 OR P1571: EBCM CONTROL VALVE CIRCUIT
Circuit Description
The EBCM and the PCM simultaneously control the traction control. The EBCM sends a Requested Torque
message via a pulse width modulated (PWM) signal to the PCM. The duty cycle of the signal is used to
determine how much engine torque the EBCM is requesting the PCM to deliver. Normal values are between 10
and 90 percent duty cycle. The signal should be at 90 percent when traction control is not active and at lower
values during traction control activations. The PCM supplies the pull up voltage that the EBCM switches to
ground to create the signal.
The ignition is ON.
The PCM diagnoses the requested torque PWM signal circuit and sends a class 2 serial data message to the
EBCM indicating a fault is present. A fault exists in the circuit if the PCM detects one of the following
conditions:
The requested torque PWM signal is less than 5 percent duty cycle or greater than 95 percent duty cycle.
The requested torque PWM signal is not present for 10 seconds.

The EBCM disables the TCS for the duration of the ignition cycle.
The TRAC OFF indicator turns ON.
The condition for the DTC is no longer present (the DTC is not current) and you used the scan tool Clear
DTC function.
drive cycles.
Test Description
3. Use the scan tool in order to determine if the requested torque signal has a valid duty cycle.
4. Measure the requested torque signal in order to determine if the signal has a valid duty cycle.
5. Measure the requested torque signal in order to determine if the signal has a valid frequency.
11. This vehicle is equipped with a PCM which uses an Electrically Erasable Programmable Read Only
Memory (EEPROM). When replacing the PCM, the replacement PCM must be programmed.
Fig. 31: DTC C0241 Or P1571 Diagnostic Procedure (Steps 1-7)
DTC C0244 OR P1689: EBCM MALFUNCTION
Circuit Description
Traction Control is simultaneously controlled by the EBCM and the PCM. The PCM sends a DELIVERED
TORQUE message via a Pulse Width
Modulated (PWM) signal to the EBCM confirming the delivered torque level for proper Traction Control
system operation. The EBCM supplies the pull up voltage.

DTC C0244 can be set anytime when ignition voltage is present. A malfunction exists if the PWM signal is out
of range or no signal is received for a period of 2 seconds.

The TRAC OFF indicator is turned on. The ABS remains functional.
drive cycles.
Diagnostic Aids
If an intermittent malfunction exists refer to CHECKING AFTERMARKET ACCESSORIES in
Wiring Systems.
Possible causes for DTC C0244 to set:
Open in the Torque Delivered Control circuit.
Torque Delivered Control circuit shorted to ground or voltage.
Communication frequency problem.
Communication duty cycle problem.
Torque Delivered Control circuit has a wiring problem, terminal corrosion, or poor connections.
EBCM not receiving information from the PCM.
Test Description
3. Use the scan tool in order to determine if the delivered torque signal has a valid duty cycle.
9. This vehicle is equipped with a PCM which uses an Electrically Erasable Programmable Read Only
Memory (EEPROM). When replacing the PCM, the replacement PCM must be programmed.
DTC C0245: EBCM MALFUNCTION
Circuit Description
The speed sensors used on the front of this vehicle are multiple pole and the rear uses a single pole magnetic
pickup. This sensor produces an AC signal that the EBCM uses the frequency from to calculate the wheel
speed.

The EBCM detects a deviation between the left and right rear wheel speeds of greater than 6 km/h (3.75
mph) at a vehicle speed of less than 100 km/h (62 mph) on vehicles equipped with TCS.
The EBCM detects a deviation between the left and right front wheel speeds of greater than 10 km/h
(6.25 mph) at a vehicle speed of less than 100 km/h (62 mph).
The EBCM detects a deviation between the left and right rear wheel speeds of greater than 6 percent of
the vehicle speed at greater than 100 km/h (62 mph) on vehicles equipped with TCS.
The EBCM detects a deviation between the left and right front wheel speeds of greater than 4 km/h plus 6
percent of the vehicle speed at greater than 100 km/h (62 mph).
This DTC will set when the EBCM cannot specifically identify which wheel speed sensor is causing the
malfunction. If the EBCM can identify the specific wheel speed sensor causing the malfunction, DTC C0245
will become a history DTC, and the DTC associated with the sensor (DTC C0036, DTC C0041, DTC C0046,
DTC C0051, or DTC C0056) will be set concurrent with DTC C0245.
A malfunction DTC stores.

The ABS/TCS disables.
The amber ABS/TCS indicator(s) turn on.
The Red BRAKE Warning indicator turn on.
drive cycles.
Diagnostic Aids
Improper mating
Broken locks

A poor connection
If the customer's comments reflect that the amber ABS/TCS indicator is on only during moist
environmental conditions (rain, snow, vehicle wash), inspect all the wheel speed sensor circuitry for signs
of water intrusion. If the DTC is not current, clear all DTCs and simulate the effects of water intrusion by
using the following procedure:
1. Spray the suspected area with a five percent saltwater solution.
Add two teaspoons of salt to twelve ounces of water to make a five percent saltwater solution.
2. Test drive the vehicle over various road surfaces (bumps, turns, etc.) above 40 km/h (25 mph) for at least
30 seconds.
3. If the DTC returns, replace the suspected harness.

Test Description
The numbers below refer to step numbers on the diagnostic table.
2. If DTC C0245 is a history code, this step checks if a specific Wheel Speed Circuit Malfunction DTC is
set concurrently with DTC C0245.
7. This step checks if the wheel speed sensor harness is routed in close proximity to the spark plug wires.
9. In this step, if the scan tool can record any erroneous wheel speed sensor signals, diagnose that sensor
(s) first.
DTC C0565: VIN INFORMATION ERROR EBCM
Circuit Description
The EBCM learns the model that it is installed in by using the Vehicle ID information (VIN) via the class 2
serial data line. Each time the vehicle is in the RUN position or the PCM communicates this information via
Class 2, the EBCM internally compares the VIN information with that information stored in digits 2 through 5
of the VIN. If digit 5 of the VIN is incorrect, the EBCM will indicate a VIN information error is present.
The EBCM detects digit 5 of the VIN is incorrect.

The condition must occur when the ignition switch is first turned on.
The EBCM stores DTC C0565 in memory.
The EBCM recognizes digit 5 of the VIN as valid information.

A history DTC will clear after 100 consecutive ignition cycles if the condition for the malfunction is no
longer present.
Diagnostic Aids
DTC C0565 is related to an internal VIN error in the EBCM. The VIN information is not removable from the
EBCM.
DTC C0896: ESC VOLTAGE IS OUTSIDE THE NORMAL RANGE OF 9 TO 15.5 VOLTS
Circuit Description
The EBCM is required to operate within a specified range of voltage to function properly. During ABS and
TCS operation, there are current requirements that will cause the voltage to drop. Because of this, voltage is
monitored out of ABS/TCS control to indicate a good charging system condition, and also during ABS/TCS
control when voltage may drop significantly.
The EBCM also monitors for high voltage conditions which could damage the EBCM.

The EBCM operating voltage falls below 9.4 volts out of ABS/TCS control, or 8.8 volts during ABS/TCS
control.
The EBCM operating voltage rises above 17.4 volts.
The low voltage or the high voltage is detected for more than 500 milliseconds with the vehicle speed
above 6 km/h (3.6 mph).

The ABS and the Traction Control indicators are turned on.
The ABS/TCS is disabled.
The Brake warning indicator turns on.
drive cycles.
Diagnostic Aids
Improper mating
Broken locks

A poor connection
If an intermittent malfunction exists, refer to TESTING FOR INTERMITTENT AND POOR

CONNECTIONS in Wiring Systems for further diagnosis.
Test Description
2. This step checks if the voltage is above the maximum of the range.
4. Step 4 checks if the voltage is below the minimum of the range.
6. This step checks for the integrity of the ground circuit.
SYMPTOMS - ANTI-LOCK BRAKE SYSTEM
Important: The following steps must be completed before using the symptom tables.
1. Perform the DIAGNOSTIC SYSTEM CHECK - ABS before using the Symptom Tables in order to
verify that all of the following are true:
2. Review the system operation in order to familiarize yourself with the system functions. Refer to ABS
DESCRIPTION AND OPERATION .
Inspect for aftermarket devices which could affect the operation of the anti-lock brake system. Refer to
CHECKING AFTERMARKET ACCESSORIES in Wiring Systems.
cause the symptom.
Inspect the master cylinder reservoir for the proper fluid level.
Intermittent
Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to TESTING FOR
INTERMITTENT AND POOR CONNECTIONS in Wiring Systems.
Symptom List

TRACTION OFF INDICATOR INOPERATIVE .
Circuit Description
The Instrument Panel Cluster (IPC) turns the ABS Indicator on during the IPC bulb check for approximately 3
seconds when the ignition switch is turned to the ON position. If the EBCM sets a Diagnostic Trouble Code
(DTC) the EBCM sends a class 2 message to the IPC to command the ABS Indicator on.
Diagnostic Aids
Improper mating
Broken locks

A poor connection
If an intermittent malfunction exists refer to INDUCING INTERMITTENT FAULT CONDITIONS in

Wiring Systems.
Test Description
2. Checks if the scan tool can turn on and off all the indicator lamps in the instrument cluster.
4. Checks if the circuits going to the instrument cluster or the cluster is at fault.
Fig. 39: ABS Indicator Always On Diagnostic Procedure


Circuit Description
The Instrument Panel Cluster (IPC) turns the ABS Indicator on during the IPC bulb check for approximately 3
seconds when the ignition switch is turned to the ON position. If the EBCM sets a Diagnostic Trouble Code
(DTC) the EBCM sends a class 2 message to the IPC to command the ABS Indicator on.
Diagnostic Aids
Improper mating
Broken locks

A poor connection

Wiring Systems.
Test Description
4. Checks if the circuits going to the instrument Cluster or the cluster is at fault.
Fig. 40: ABS Indicator Inoperative Diagnostic Procedure
Circuit Description
The Instrument Panel Cluster (IPC) turns the LOW TRAC Indicator on during the IPC bulb check for
approximately 3 seconds when the ignition switch is turned to the ON position. If the EBCM sets a Diagnostic
Trouble Code (DTC) the EBCM sends the IPC the command to turn the LOW TRAC Indicator on.
Diagnostic Aids
Improper mating
Broken locks

A poor connection

Electrical Diagnosis for further diagnosis.
Test Description
2. Checks if the circuits going to the instrument cluster or the cluster is at fault.
Fig. 41: Low Traction Indicator Always On Diagnostic Procedure

Circuit Description
The Instrument Panel Cluster (IPC) turns the LOW TRAC Indicator on during the IPC bulb check for
approximately 3 seconds when the ignition switch is turned to the ON position. If the EBCM sets a Diagnostic
Trouble Code (DTC) the EBCM sends the IPC the command to turn the LOW TRAC Indicator on.
Diagnostic Aids
Improper mating
Broken locks

A poor connection

Wiring System for further diagnosis.
Test Description
4. Checks if the circuits going to the instrument Cluster or the cluster is at fault.
Fig. 42: Low Traction Indicator Inoperative Diagnostic Procedure

Circuit Description
EBCM. When the body control module (BCM) sees the traction control switch input grounded through the
momentary traction control switch, it sends a class 2 message to the EBCM that tells the EBCM that the traction
control switch has been pressed.
The EBCM then disables traction control and sends a message to the instrument cluster to turn the TRAC OFF
indicator ON. Each time the ignition is cycled from OFF to ON, the traction control system is enabled.
The EBCM has disabled the TCS due to a DTC.

The instrument cluster bulb check. When the ignition switch is turned to ON, the TRAC OFF indicator
will turn on for approximately 3 seconds and then turn OFF.
Diagnostic Aids
Improper mating
Broken locks

A poor connection

Wiring Systems for further diagnosis.
Fig. 43: Traction Off Indicator Always On Diagnostic Procedure
TRACTION OFF INDICATOR INOPERATIVE
Circuit Description
EBCM. When the body control module (BCM) sees the traction control switch input grounded through the
momentary traction control switch, it sends a class 2 message to the EBCM that tells the EBCM that the traction
control switch has been pressed. The EBCM then disables traction control and sends a message to the
instrument cluster to turn the TRAC OFF indicator ON. Each time the ignition is cycled from OFF to ON, the
traction control system is enabled.
The EBCM has disabled the TCS due to a DTC.
The instrument cluster bulb check. When the ignition switch is turned to ON, the TRAC OFF indicator
will turn on for approximately 3 seconds and then turn OFF.
Diagnostic Aids
Improper mating
Broken locks

A poor connection
INDUCING INTERMITTENT FAULT CONDITIONS in Wiring System for further diagnosis.

Fig. 44: Traction Off Indicator Inoperative Diagnostic Procedure
REPAIR INSTRUCTIONS
ABS AUTOMATED BLEED PROCEDURE
Important: In most circumstances a base brake bleed is all that is required for most component replacements
(such as wheel cylinders, calipers, brake tubes, and master cylinder) except for BPMV replacement.
The following automated ABS bleed procedure is required when one of the following occur:
Manual bleeding at the wheel cylinders does not achieve the desired pedal height or feel.
Brake Pressure Modulator Valve replacement (BPMV).
Extreme loss of brake fluid has occurred.
Air ingestion is suspected.
If none of the above conditions apply use standard bleed procedures. Refer to HYDRAULIC BRAKE
SYSTEM BLEEDING (MANUAL) or HYDRAULIC BRAKE SYSTEM BLEEDING (PRESSURE) in
Hydraulic Brakes.
The auto bleed procedure is used on BOSH 5.3 equipped vehicles. This procedure uses a scan tool to cycle the
system solenoid valves and run the pump in order to purge the air from the secondary circuits. These secondary
circuits are normally closed off, and are only opened during system initialization at vehicle start up and during
ABS operation. The automated bleed procedure opens these secondary circuits and allows any air trapped inside
the BPMV to flow out toward the wheel cylinders or calipers where it can be purged out of the system.
Automated Bleed Procedure
1. Inspect the battery for full charge, repair the battery and charging system as necessary.
2. Connect a scan tool to the Data Link Connector (DLC) and select current and history DTCs. Repair any
DTCs prior to performing the ABS bleed procedure.
3. Inspect for visual damage and leaks and repair as needed.
Preliminary Setup
1. Raise and vehicle on a suitable support.

2. Turn the ignition switch to OFF position.
3. Remove all four tires.
4. Connect the pressure bleeding tool according to the manufacturer's instructions.
5. Turn the ignition switch to RUN position, engine off.
6. Connect a scan tool and establish communications with the ABS system.
7. Pressurize the bleeding tool to 206 to 241 kPa (30 to 35 psi).
Performing the Automated Bleed Procedure
NOTE: The Auto Bleed Procedure may be terminated at any time during the process by
pressing the EXIT button. No further Scan Tool prompts pertaining to the Auto
Bleed procedure will be given. After exiting the bleed procedure, relieve bleed
pressure and disconnect bleed equipment per manufacturers instructions.
Failure to properly relieve pressure may result in spilled brake fluid causing
damage to components and painted surfaces.
1. With the pressure bleeding tool at 206 to 241 kPa (30 to 35 psi), and all bleeder screws in closed position,
select Automated Bleed Procedure on the scan tool and follow the instructions.
2. The first part of the automated bleed procedure will cycle the pump and front release valves for one
minute. After the cycling has stopped the scan tool will enter a "cool down" mode and display a 3 minute
timer. The auto bleed will not continue until this timer expired, and cannot be overridden.
3. During the next step, the scan tool will request the technician to open one of the bleeder screws. The scan
tool will then cycle the respective release valve and pump motor for 1 minute.
4. The scan tool will repeat step 3 for the remaining bleeder screws.
5. With the bleeder tool still attached to the vehicle and maintaining 241 kPa (35 psi), the scan tool will
instruct the technician to independently open each bleeder screw for approximately 20 seconds. This
should allow any remaining air to be purged from the brake lines.
6. When the automated bleed procedure is completed the scan tool will display the appropriate message.
7. Install all four tires, if necessary.
8. Remove pressure from the pressure bleeding tool and then disconnect the tool from the vehicle.
9. Depress the brake pedal to gage pedal height and feel. Repeat steps 1 through 8 until the pedal is
acceptable.
10. Remove the scan tool from the DLC connector.
11. Install.
13. Inspect the brake fluid level in master cylinder.
14. Road test the vehicle while making sure the brake pedal remains high and firm.
If vehicle is equipped with TCS the scan tool will cycle both the ABS and TCS solenoids valves. This bleed
procedure is the same as above.
ELECTRONIC BRAKE CONTROL MODULE (EBCM) REPLACEMENT
Removal Procedure
NOTE: Always connect or disconnect the wiring harness connector from the
EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe
this precaution could result in damage to the EBCM/EBTCM.

2. Remove the air cleaner housing from the engine compartment.
Fig. 45: Disconnecting EBCM Harness Connector

4. Brush off any dirt/debris that has accumulated on the assembly.
5. Disconnect the pump motor connector (3) at the bottom of the EBCM.
Important:
Do not damage the seal by prying the EBCM from the BPMV.

Do not damage the solenoid valves while removing the EBCM from the BPMV.
6. Remove the six EBCM to BPMV screws (2).
Fig. 46: Disconnecting Pump Motor Connector At Bottom Of EBCM

7. Separate the EBCM from the BPMV by gently pulling apart until separated (1).
Fig. 47: Separating EBCM From BPMV
Important: Use only new wave springs and screws supplied with the new EBCM.
1. Clean the BPMV surface with alcohol using a clean rag.

2. Install the EBCM (1) to the BPMV.
3. Install the 6 screws that attaches the EBCM to BPMV.
Tighten
Tighten the top 4 mounting screws to 5 N.m (44 lb in). Tighten screws in an X pattern.
Tighten the bottom 2 mounting screws to 5 N.m (44 lb in).
Connect the pump motor connector to the bottom of the EBCM.
Fig. 48: Installing EBCM-To-BPMV
4. Connect the EBCM harness connector and depress the locking tab (1) to secure.
5. Install the air cleaner housing.
6. Turn the ignition switch to the RUN position, do not start engine.
7. Perform the DIAGNOSTIC SYSTEM CHECK - ABS .
Fig. 49: Connecting EBCM Harness Connector
BRAKE PRESSURE MODULATOR VALVE (BPMV) REPLACEMENT
Removal Procedure
CAUTION: For safety reasons, the Brake Pressure Modulator Valve (BPMV) must not
be repaired, the complete unit must be replaced. With the exception of the
EBCM/EBTCM, no screws may be loosened. If screws are loosened, it will
not be possible to get the brake circuits leak-tight and personal injury may
result.
Fig. 50: Disconnecting EBCM Harness Connector

2. Remove the attaching bolts for the cruise control module.

3. Swing the cruise control module off to the side.
4. Remove the air cleaner housing from the engine compartment.
5. Disengage the red locking tab from the connector (1).
6. Push down lock tab (1) and then move sliding connector cover (2) to the open position.
Important: Note the locations of the brake pipes in order to aid in installation.
8. Disconnect the 4 wheel brake pipes from the BPMV.
9. Swing the four wheel brake pipes out of the way only after covering the open pipes to avoid dripping or
being contaminated.
Fig. 51: Disconnecting Wheel Brake Pipes From BPMV

10. Disconnect the master cylinder brake pipes from the BPMV.
11. Loosen the brake pipes but do not remove the brake pipes from the master cylinder.
12. Swing the 2 master cylinder brake pipes out of the way only after covering the open pipes to avoid
dripping or being contaminated.
Fig. 52: Disconnecting Master Cylinder Brake Pipes From BPMV
13. Remove the 3 BPMV mounting bracket nuts (2) from the inner wheel housing mount surface of the strut
tower.
14. Reinstall the top nut upside down on the top stud.
15. Lightly tap on the bottom of the nut until the stud has loosened up.
16. Disconnect the ground strap between the EBCM assembly and the chassis.
17. Remove the BPMV mounting bracket and EBCM assembly from the vehicle.
Fig. 53: Removing BPMV Mounting Bracket And EBCM Assembly From Vehicle
NOTE: When removing the brake pressure modulator valve, protect the vehicle
exterior from possible brake fluid spillage. Brake fluid can cause damage
to painted surfaces.
18. Remove the two bolts (1) that connect the BPMV to the mounting bracket (2).
19. Remove EBCM if replacing the BPMV only. Refer to ELECTRONIC BRAKE CONTROL MODULE
(EBCM) REPLACEMENT .
Fig. 54: Removing BPMV

1. Install EBCM onto the BPMV (1) if replacing the BPMV only. Refer to ELECTRONIC BRAKE
CONTROL MODULE (EBCM) REPLACEMENT .
2. Install BPMV and EBCM as an assembly to the mounting bracket.
3. Install the 2 bolts (1) that connects the BPMV assembly to the mounting bracket (2).
Tighten
Tighten the 2 bolts 10 N.m (84 lb in).

Fig. 55: Installing BPMV And EBCM To Mounting Bracket
4. Install the BPMV bracket to the strut tower.

5. Install the 3 nuts (2) that attach the BPMV mounting bracket to the strut tower.
Tighten
Tighten the nuts to 10 N.m (89 lb in).

Reposition any lines or hoses that were moved out of place.
Fig. 56: Installing BPMV Bracket To Strut Tower

CAUTION: Make sure brake pipes are correctly connected to brake pressure
modulator valve. If brake pipes are switched by mistake, wheel
lockup will occur and personal injury may result. The only two ways
this condition can be detected are by using a Scan Tool or by doing
an Anti-lock stop.
Important: If a new BPMV is being installed, remove the shipping plugs from the valve openings during
the next few steps when ready.
6. Install the master cylinder brake pipes into the BPMV.
Tighten
Tighten the fittings to 24 N.m (18 lb ft).

Fig. 57: Installing Master Cylinder Brake Pipes Into BPMV
7. Install the four wheel brake pipes on the BPMV.
Tighten
Tighten the fittings to 25 N.m (18 lb ft).
8. Reconnect the ground strap between the EBCM assembly and the chassis.
Fig. 58: Installing Wheel Brake Pipes On BPMV

9. Connect the EBCM harness connector.

10. Push down lock tab (1) and then move sliding connector cover (2) back in home position to lock.
11. Insert red locking tab back in place.
12. Reinstall the air cleaner housing.
13. Reinstall the cruise control module.
14. When all procedures have been completed, the automated ABS bleed procedure is required. Refer to ABS
AUTOMATED BLEED PROCEDURE .
Fig. 59: Connecting EBCM Harness Connector

WHEEL SPEED SENSOR REPLACEMENT - FRONT
Removal Procedure
Important: The front wheel speed sensors and rings are integral with the hub and bearing assemblies.
If a speed sensor or a ring needs replacement, replace the entire hub and bearing assembly. Do not service the
harness pigtail individually because the harness pigtail is part of the sensor. Refer to WHEEL
BEARING/HUB REPLACEMENT - FRONT in Front Suspension.
1. Raise and support the vehicle on a suitable hoist.
2. Remove the front tire and wheel assembly.
3. Remove the front wheel speed sensor jumper harness electrical connector (1) from the front wheel speed
sensor connector (3).
Fig. 60: Removing Front Wheel Speed Sensor Jumper Harness Electrical Connector
4. Remove the hub and bearing assembly (2). Refer to WHEEL BEARING/HUB REPLACEMENT -
FRONT in Front Suspension.
Fig. 61: Removing Hub & Bearing Assembly
1. Install the hub and bearing assembly (2) to the vehicle. Refer to WHEEL BEARING/HUB
REPLACEMENT - FRONT in Front Suspension.
Fig. 62: Installing Hub & Bearing Assembly
2. Install the front wheel speed sensor jumper harness electrical connector (1) to front wheel speed sensor
connector (3).
3. Install the wheel and tire assembly.
Fig. 63: Installing Front Wheel Speed Sensor Jumper Harness Electrical Connector
WHEEL SPEED SENSOR REPLACEMENT - REAR (EXCEPT AWD)
Removal Procedure
Important: The rear wheel speed sensors and rings are integral with the hub and bearing assemblies.
If a speed sensor or a ring needs replacement, replace the entire hub and bearing assembly. Refer to REAR
WHEEL BEARING/HUB REPLACEMENT (FWD -- DRUM) in Rear Suspension.

2. Remove the rear tire and wheel assembly.
Fig. 64: Removing Rear Wheel Speed Sensor Electrical Connector
3. Remove the rear wheel speed sensor electrical connector located next to the rear strut.
4. Remove the hub and bearing assembly (1). Refer to REAR WHEEL BEARING/HUB
REPLACEMENT (FWD -- DRUM) in Rear Suspension.
Fig. 65: Removing Hub & Bearing Assembly
1. Install the hub and bearing assembly (1) to the vehicle. Refer to REAR WHEEL BEARING/HUB
REPLACEMENT (FWD -- DRUM) in Rear Suspension.
Fig. 66: Installing Hub & Bearing Assembly
2. Install the rear wheel speed sensor electrical connector.

3. Install the wheel and tire assembly.
Fig. 67: Installing Rear Wheel Speed Sensor Electrical Connector
WHEEL SPEED SENSOR REPLACEMENT - REAR (AWD)
Removal Procedure
1. Raise and support the vehicle.

2. Remove the tire and wheel.
3. Remove the brake caliper and support the brake caliper. Do NOT disconnect the brake hose. Refer to
BRAKE ROTOR in Disc Brakes.
4. Remove the brake caliper bracket. Refer to BRAKE CALIPER in Disc Brakes.
5. Remove the brake rotor.
Fig. 68: Removing Rear Wheel Speed Sensor

6. Disconnect the wheel speed sensor electrical connector.

7. Disconnect the wheel speed sensor electrical connector from the connector bracket.
8. Disconnect the drive axle from the wheel bearing/hub. Refer to PROPELLER SHAFT
REPLACEMENT in Wheel Drive Shafts.
9. Remove and DISCARD the wheel bearing/hub bolts.
10. Remove the wheel bearing/hub.
1. Install the wheel bearing/hub.

CAUTION: These fasteners MUST be replaced with new fasteners anytime they
become loose or are removed. Failure to replace these fasteners after
they become loose or are removed may cause loss of vehicle control
and personal injury.
2. Install the NEW wheel bearing/hub bolts.
Tighten
Tighten the NEW wheel bearing/hub bolts to 85 N.m (63 lb ft).
3. Connect the drive axle to the wheel bearing/hub.

4. Install the wheel speed sensor electrical connector to the connector bracket.
Fig. 69: Installing Rear Wheel Speed Sensor

5. Connect the wheel speed sensor electrical connector.

6. Install the brake rotor.
7. Install the brake caliper bracket.
8. Install the brake caliper.
9. Install the tire and wheel.
WHEEL SPEED SENSOR JUMPER HARNESS REPLACEMENT
Removal Procedure
1. Remove the wheel speed sensor connectors (2,3).

2. Remove the jumper harness grommet from the retainer.
3. Remove the upper jumper harness connector from the rear body pass-thru connector.
Fig. 70: Removing Jumper Harness
1. Install the upper jumper harness connector from the rear body pass-thru connector.
2. Install the jumper harness grommet to the retainer.
3. Install the wheel speed sensor connectors (2,3).
Fig. 71: Installing Jumper Harness
WHEEL SPEED SENSOR JUMPER HARNESS REPLACEMENT - FRONT
Removal Procedure
1. Disconnect the front wheel speed sensor jumper harness to ABS harness connector (8).
3. Remove the harness (4) from the splash shield retaining clip (5).
4. Remove the harness (4) from the control arm retaining clips (3).
Fig. 72: Removing Front Wheel Speed Sensor Jumper Harness
5. Disconnect the front wheel speed jumper harness connector (2) from the front wheel sensor.
6. Remove the front wheel speed sensor jumper harness (1).
Fig. 73: Removing Front Wheel Speed Sensor Jumper Harness From Sensor
1. Connect the front wheel speed sensor jumper harness connector (2) to the wheel speed sensor.
Fig. 74: Installing Front Wheel Speed Sensor Jumper Harness To Sensor
2. Install the harness (4) to control arm retaining clips (3).

3. Install the harness (4) to splash shield retaining clip (5).
5. Connect the front wheel speed sensor jumper harness to ABS harness connector (8).
7. Perform the diagnostic system check. Refer to DIAGNOSTIC SYSTEM CHECK - ABS .
Fig. 75: Installing Front Wheel Speed Sensor Jumper Harness
WHEEL SPEED SENSOR JUMPER HARNESS REPLACEMENT - REAR
Removal Procedure

2. Disconnect the rear wheel speed jumper harness connector at the pass-through connector.
3. Remove the rear wheel speed sensor jumper harness (1) from the retaining clips (2).
Fig. 76: Removing Rear Wheel Speed Sensor Jumper Harness
4. Disconnect the rear wheel speed sensor jumper harness connector (1) from the wheel speed sensor,
located next to the rear strut (2).
5. Remove the rear wheel speed sensor jumper harness.
Fig. 77: Disconnecting Rear Wheel Speed Sensor Jumper Harness Connector
1. Connect the rear wheel speed sensor jumper harness connector (1) to the wheel speed sensor, located next
to the rear strut (2).
Fig. 78: Connecting Rear Wheel Speed Sensor Jumper Harness Connector
2. Install the rear wheel speed jumper harness (1) into the retaining clips (2).
3. Connect the rear wheel speed sensor jumper harness connector to the pass-through connector.
6. Perform the diagnostic system check. Refer to DIAGNOSTIC SYSTEM CHECK - ABS .
Fig. 79: Installing Rear Wheel Speed Jumper Harness
TRACTION CONTROL SWITCH REPLACEMENT
Removal Procedure
1. Remove the instrument panel accessory trim plate. Refer to TRIM PLATE REPLACEMENT --
INSTRUMENT PANEL (I/P) ACCESSORY (AZTEK) in Instrument Panel, Gages and Console.
Fig. 80: Locating Traction Control Switch
2. Remove the bolts/screws from the switch bank to instrument panel.

3. Pull straight out from the instrument panel in order to remove the switch bank from the instrument panel.
Fig. 81: Removing Switch Bank

Fig. 82: Disconnecting Electrical Connectors

2. Push in on the switch bank in order to install the switch bank.
Fig. 83: Connecting Electrical Connectors
3. Install the bolts/screws to the switch bank to instrument panel.
Tighten
Tighten the bolts/screws to 2.5 N.m (22 lb in).

Fig. 84: Installing Switch Bank
4. Install the instrument panel accessory trim plate.

Fig. 85: Locating Traction Control Switch

ABS DESCRIPTION AND OPERATION
Fig. 86: Identifying BPMV & EBCM Unit
Fig. 87: BPMV Hydraulic Flow Diagram
This vehicle is equipped with the Bosch 5.3 anti-lock braking system.
The vehicle is equipped with the following braking systems:
Anti-Lock Brake System (ABS)

Traction Control System (TCS) (w/NW9)
The following components are involved in the operation of the above systems:
Electronic Brake Control Module (EBCM) - The EBCM controls the system functions and detects
failures.
The EBCM contains the following components:
System Relay - The system relay is energized when the ignition is ON and no ABS DTCs are
present. It supplies battery positive voltage to the solenoid valves and pump motor.
Vent Tube - The vent tube, located in the EBCM connector, is an opening to the internal cavity of
the EBCM. It allows ventilation of the EBCM internals.
Brake Pressure Modulator Valve (BPMV) - The BPMV contains the hydraulic valves and pump motor
that are controlled electrically by the EBCM. The BPMV uses a 4 circuit configuration with a diagonal
split. The BPMV directs fluid from the reservoir of the master cylinder to the left front and right rear
wheels and fluid from the other reservoir to the right front and left rear wheels. The diagonal circuits are
hydraulically isolated so that a leak or malfunction in one circuit will allow continued braking ability on
the other.
Important: There is a rubber isolator located under the BPMV and on the mounting studs. The rubber isolators
protect the BPMV and the EBCM from vehicle vibrations.
The BPMV contains the following components:

Pump Motor
Inlet Valves (one per wheel)
Outlet Valves (one per wheel)
Master Cylinder Isolation Valves (w/NW9) (one per drive wheel)
Prime Valves (w/NW9) (one per drive wheel)
Wheel Speed Sensors (WSS) - As the wheel spins, the wheel speed sensor produces an AC signal. The
EBCM uses this AC signal to calculate wheel speed. The wheel speed sensors are replaceable only as part
of the wheel hub and bearing assemblies.
Traction Control Switch (w/NW9) - The TCS is manually disabled or enabled using the traction control
switch.
Stoplamp Switch - The EBCM uses the stoplamp switch as an indication that the brake pedal is applied.
Initialization Sequence
The EBCM performs one initialization test each ignition cycle. The initialization of the EBCM occurs when one
set of the following conditions occur: Both of the following conditions occur:
The EBCM receives that there is a minimum of 500 RPM from the PCM via class 2 serial data message.
The stoplamp switch is not applied.
OR Both of the following conditions occur:

The stoplamp switch is applied.
The initialization sequence may also be commanded with a scan tool.
The initialization sequence cycles each solenoid valve and the pump motor (as well as the necessary relays) for
approximately 1.5 seconds to check component operation. The EBCM sets a DTC if any error is detected. The
initialization sequence may be heard and felt while it is taking place, and is considered part of normal system
operation.
The EBCM defines a drive cycle as the completion of the initialization sequence.
Anti-Lock Brake System
When wheel slip is detected during a brake application, the ABS enters anti-lock mode. During anti-lock
braking, hydraulic pressure in the individual wheel circuits is controlled to prevent any wheel from slipping. A
separate hydraulic line and specific solenoid valves are provided for each wheel. The ABS can decrease, hold,
or increase hydraulic pressure to each wheel brake. The ABS cannot, however, increase hydraulic pressure
above the amount which is transmitted by the master cylinder during braking.
During anti-lock braking, a series of rapid pulsations is felt in the brake pedal. These pulsations are caused by
the rapid changes in position of the individual solenoid valves as the EBCM responds to wheel speed sensor
inputs and attempts to prevent wheel slip. These pedal pulsations are present only during anti-lock braking and
stop when normal braking is resumed or when the vehicle comes to a stop. A ticking or popping noise may also
be heard as the solenoid valves cycle rapidly. During anti-lock braking on dry pavement, intermittent chirping
noises may be heard as the tires approach slipping. These noises and pedal pulsations are considered normal
during anti-lock operation.
Vehicles equipped with ABS may be stopped by applying normal force to the brake pedal. Brake pedal
operation during normal braking is no different than that of previous non-ABS systems. Maintaining a constant
force on the brake pedal provides the shortest stopping distance while maintaining vehicle stability.
Pressure Hold
The EBCM closes the inlet valve and keeps the outlet valve closed in order to isolate the system when wheel
slip occurs. This holds the pressure steady on the brake so that the hydraulic pressure does not increase or
decrease.
Pressure Decrease
The EBCM decreases the pressure to individual wheels during a deceleration when wheel slip occurs. The inlet
valve is closed and the outlet valve is opened. The excess fluid is stored in the accumulator until the return
pump can return the fluid to the master cylinder.
Pressure Increase
The EBCM increases the pressure to individual wheels during a deceleration in order to reduce the speed of the
wheel. The inlet valve is opened and the outlet valve is closed. The increased pressure is delivered from the
master cylinder.
brake pressure.
The red brake warning indicator is illuminated when the dynamic rear proportioning function is disabled.
Traction Control System (TCS) (NW9)
When drive wheel slip is noted while the brake is not applied, the EBCM will enter traction control mode.
First, the EBCM requests the PCM to reduce the amount of torque to the drive wheels via the requested torque
signal circuit. The PCM reduces torque to the drive wheels by retarding spark timing and turning off fuel
injectors. The PCM reports the amount torque delivered to the drive wheels via the delivered torque signal
circuit.
If the engine torque reduction does not eliminate drive wheel slip, the EBCM will actively apply the drive
wheel brakes. During traction control braking, hydraulic pressure in each drive wheel circuit is controlled to
prevent the drive wheels from slipping. The master cylinder isolation valve closes in order to isolate the master
cylinder from the rest of the hydraulic system. The prime valve then opens in order to allow the pump to
accumulate brake fluid in order to build hydraulic pressure for braking. The drive wheel inlet and outlet
solenoid valves then open and close in order to perform the following functions:
Pressure hold
Pressure increase
Pressure decrease
ABS Indicator
The IPC illuminates the ABS indicator when the following occurs:
The electronic brake control module (EBCM) detects a malfunction with the anti-lock brake system. The
IPC receives a class 2 message from the EBCM requesting illumination.
Brake System Indicator(s)
Brake Warning Indicator
The body control module (BCM) detects that the park brake is engaged. The IPC receives a class 2
message from the BCM requesting illumination. If the vehicle is shifted out of park with the park brake
engaged and a class 2 message is received indicating that the vehicle speed is greater than 3 MPH, the
BCM sends a class 2 message to the radio in order to activate the audible warning.
Low Brake Fluid Indicator
The IPC illuminates the low brake fluid indicator in the message center when the IPC receives a low signal
from the low brake fluid switch. The IPC sends a class 2 message to the radio in order to activate an audible
warning.
Traction Control System Indicator(s)
Service Traction System
The IPC illuminates the Service Traction System indicator in the message center when the electronic brake
control module (EBCM) detects a malfunction in the traction control system. The IPC receives a class 2
message from the EBCM requesting illumination.
Traction Active
The IPC illuminates the Traction Active indicator in the message center when the electronic brake control
module (EBCM) detects a traction control event. The IPC receives a class 2 message from the EBCM
TRAC Off
The IPC illuminates the TRAC OFF indicator when:
The electronic brake control module (EBCM) inhibits the traction control system. The IPC receives a
class 2 message from the EBCM requesting illumination.
SPECIAL TOOLS & EQUIPMENT
Fig. 88: Special Tools & Equipment

Anti-Lock/TCS - Aztek
Model Body Code (1)
Aztec
AWD "B"
FWD "A"
(1) Vehicle body code is fifth character of VIN.
DESCRIPTION
CAUTION: See ANTI-LOCK BRAKE SAFETY PRECAUTIONS article in GENERAL

INFORMATION before servicing anti-lock brake system.
The Bosch 5.3 Anti-Lock Brake System/Traction Control System (ABS/TCS) increases vehicle steerability,
directional stability and optimum deceleration in severe braking conditions on most road surfaces. The ABS
monitors wheel speed and controls brakeline pressure to eliminate uncontrolled skidding.
The system also monitors rear wheel speed and compares it to front wheel speed. If excessive front wheel speed
is detected at either front wheel, TCS will be activated. TCS uses engine fuel/timing management to provide
improved traction and vehicle stability. The TCS uses front brake intervention to assist the wheel slip condition.
Major system components include Electronic Brake Control Module (EBCM), wheel speed sensors, instrument
cluster warning indicators, brakelight switch, TRAC on/off switch, solenoid valve relay and pump motor relay,
Dynamic Rear Proportioning (DRP), and Brake Pressure Modulator Valve (BPMV) assembly. BPMV assembly
houses electric pump motor and solenoid valves. EBCM and BPMV assembly is located on left rear of engine
compartment.
brake pressure. The red brake warning indicator is illuminated when the dynamic rear proportioning function is
disabled.
NOTE: For more information on brake system, see appropriate DISC & DRUM article.
OPERATION
During normal driving and braking operations, ABS acts like a conventional braking system. Wheel speed
sensors transmit an AC voltage signal about wheel acceleration, deceleration and slip value to EBCM. The
EBCM controls braking by activating and deactivating BPMV.
The modulator valve consists of rapidly switching solenoid valves, accumulator chamber and a return pump.
The valves decrease brake fluid pressure to each wheel to prevent wheel lock-up.
The modulator valve can supply only as much fluid pressure as applied through the master cylinder. The
modulator valve alone cannot apply the brakes. A slight pulsation should be felt through brake pedal when ABS
is active.
The BRAKE warning indicator and ABS indicator will illuminate when ignition switch is turned to RUN
position and should go out after a 3 second self-test. If any indicator remains illuminated after vehicle is started,
a system malfunction is indicated. See DIAGNOSIS & TESTING .
The BRAKE warning indicator will activate if parking brake is applied or brake fluid is low. The ABS indicator
is controlled by EBCM and comes on if problem is detected with ABS. When indicator is illuminated, ABS is
disabled and braking is accomplished by conventional brake system. If both warning indicators are illuminated,
check conventional brake system for hydraulic system failure.
The TRAC OFF indicator illuminates when EBCM inhibits the traction control system due to a malfunction in
the TCS. LOW TRAC indicator is illuminated when BCM detects that the traction control switch has been
pressed, disabling the traction control or when EBCM detects a traction control event. The Instrument Panel
Cluster (IPC) receives a class 2 signal from the EBCM requesting illumination. The IPC also sends a class 2
message to the BCM to activate an audible warning signal.
BLEEDING BRAKE SYSTEM

MANUAL BLEEDING PROCEDURE
1. Deplete vacuum reserve from power brake booster by depressing brake pedal several times with engine
off. Fill master cylinder reservoir and keep full during bleeding procedure. If master cylinder is not
suspected of having air in bore, go to step 4 . If master cylinder is known or suspected of having air in
bore, go to next step.
2. Disconnect forward brakeline fitting at master cylinder. Allow fluid to flow from fitting. Tighten fitting to
specification. See TORQUE SPECIFICATIONS . Have an assistant depress brake pedal slowly and
hold. Again, loosen forward fitting. Tighten fitting while pedal is still at floor. Release brake pedal
slowly. Wait 15 seconds.
NOTE: Rapid pumping of brake pedal causes master cylinder secondary piston to
move into a position that makes bleeding system difficult.
3. Repeat step 2 , including 15 second wait, until fluid is clear and free of air bubbles. Repeat procedure at
other (rear most) brakeline fitting on master cylinder. Master cylinder is now bled. If wheel
cylinders/calipers are not suspected to have air in them, bleeding is not necessary.
NOTE: When performing manual bleeding procedure, use the following bleeding
sequence: RR, LF, LR, RF.
4. If wheel cylinders/calipers are known or suspected to have air in them, raise and support vehicle. Place
proper size box end wrench over bleeder valve. Attach one end of clear tube over valve and submerge
other end in container partially filled with clean brake fluid.
5. Have an assistant depress brake pedal slowly and hold. Loosen bleeder valve to purge air from cylinder.
Tighten bleeder valve to specification and slowly release brake pedal. See TORQUE
SPECIFICATIONS . Wait 15 seconds. Repeat procedure, including 15 second wait, until all air is
removed.
6. Remove tube and wrench. Install bleeder valve cap. Fill master cylinder reservoir with fluid. Ensure there
is no sponginess in brake pedal and that BRAKE warning indicator is off.
PRESSURE BLEEDING PROCEDURE
1. Fill master cylinder reservoir with DOT 3 brake fluid to full mark. Install Bleeder Adapter (J-35589-A) to
brake master cylinder. Pressurize bleeder to 25-30 psi (1.76-2.11 kg/cm2 ). Connect bleeder hose to
adapter and bleed air from adapter.
2. Place proper size box end wrench over rear bleeder valve of brake modulator. Attach one end of clear
tube over valve and submerge other end in container partially filled with clean brake fluid.
3. Loosen bleeder valve at least 3/4 turn to purge air from modulator. Tighten bleeder valve when air is no
longer present in tube. See TORQUE SPECIFICATIONS . Repeat procedure on forward bleeder valve
of modulator until all air is removed.
NOTE: When performing pressure bleeding procedure, use the following wheel
bleeding sequence: RR, LF, LR, RF.
4. Raise and support vehicle. Remove bleeder valve caps from wheels and place proper size box end wrench
over right rear bleeder valve. Attach one end of clear tube over valve and submerge other end in container
partially filled with clean brake fluid.
5. Loosen bleeder valve at least 3/4 turn to purge air from cylinder. Tighten bleeder valve when air is no
longer present in tube. See TORQUE SPECIFICATIONS . Repeat procedure at all wheels until all air
is removed.
6. Remove tube and wrench. Install bleeder valve caps. Remove bleeder adapter and fill master cylinder.
Ensure there is no sponginess in brake pedal and that BRAKE warning indicator is off.
AUTO BLEED PROCEDURE
NOTE: Auto bleed procedure is used to provide a complete bleed procedure on

ABS/TCS equipped vehicles. This procedure cycles system valves and runs
pump to purge air from circuits normally closed during non-ABS/TCS (normal)
brake system operation and bleeding. This procedure should be used when air
is suspected in secondary circuits or when Brake Pressure Modulator Valve
(BPMV) assembly has been replaced.
CAUTION: Perform MANUAL BLEEDING PROCEDURE or PRESSURE BLEEDING
PROCEDURE before performing auto bleed procedure.
1. Raise and support vehicle. Remove wheels. Inspect brake system for leaks or damage. Repair as
necessary before continuing.
2. Ensure battery is fully charged and connect pressure bleeding tool at 30-35 psi (2.12-2.47 kg/cm2 ).
Connect scan tool to Data Link Connector (DLC) located under left side of instrument panel. Turn
ignition on, with engine off. Using scan tool, select ABS/TCS system features. Select SPECIAL TESTS
and then select AUTOMATED BLEED PROCEDURE.
3. Follow scan tool menu-driven instructions until proper brake pedal height is achieved. If malfunctions are
detected, bleeding procedure will be aborted. The scan tool will enter a cycle and cool down period for
solenoid valves. The cool down period cannot be overridden.
4. If Diagnostic Trouble Codes (DTCs) are set, scan tool will display DTCS PRESENT, or list DTCs
depending on when DTCs were set. Select TROUBLE CODES to display or clear codes. If DTCs are set,
proceed to DIAGNOSTIC TESTS . If bleed procedure was aborted but no DTCs are set, see
INTERMITTENTS & POOR CONNECTIONS or SYMPTOM DIAGNOSIS under DIAGNOSIS &
TESTING. Repair ABS/TCS as necessary before continuing.
5. When auto bleed procedure is complete, depress brake pedal. Brake pedal should be high and firm. If
brake pedal is not high and firm, reinspect brake system for leaks or damage. If brake system is okay and
pedal travel is still excessive, repeat auto bleed procedure.
6. Remove scan tool. Remove pressure bleeding equipment if used. Reinstall wheels and lower vehicle. Fill
master cylinder reservoir with fluid as necessary. Road test vehicle. If brake pedal is spongy, perform
conventional brake bleeding procedure. See MANUAL BLEEDING PROCEDURE or PRESSURE
BLEEDING PROCEDURE .
DIAGNOSIS & TESTING
NOTE: Testing of system requires the use of Universal Breakout Box (J-39700) and
Adapter Cable (J-39700-99).
The EBCM has self-diagnostic capability which can detect system failures. Diagnostic trouble codes stored by
EBCM can be displayed using scan tool. Begin ABS/TCS diagnosis with PRE-DIAGNOSTIC INSPECTION
procedure.
PRE-DIAGNOSTIC INSPECTION
When checking potential ABS/TCS faults, check following before performing diagnostic trouble code testing:
1. Check all fuses related to ABS/TCS operation.

2. Check all ABS/TCS wiring harness connectors for proper engagement, loose wires or terminals and/or
corrosion. Check harness routing; pay particular attention to wheel speed sensor wiring harness routing.
3. Ensure parking brake switch is functioning properly.
4. Ensure brake switch is properly adjusted.
5. Check brake system for leaks and proper fluid level.
6. Check ABS/TCS ground circuit for clean tight connections. See appropriate diagram in GROUND
DISTRIBUTION article in WIRING DIAGRAMS.
7. Always perform diagnostic system check before diagnosing DTCs. See DIAGNOSTIC SYSTEM
CHECK .
DIAGNOSTIC SYSTEM CHECK
NOTE: When using scan tool for diagnostics, ABS/TCS system is disabled by EBCM.
ANTI-LOCK indicator will illuminate indicating only normal power assist braking
is available. After diagnostics have been completed, disconnect scan tool from
Data Link Connector (DLC) and turn ignition off for a least 10 seconds before
road testing. This procedure is done to reset EBCM.
1. Install scan tool. If scan tool powers up, go to next step. If scan tool does not power up, diagnose data link
communications. See DATA LINK CONNECTORS article in WIRING DIAGRAMS.
2. Turn ignition on, with engine off. Using scan tool, attempt to establish communication with BCM,
EBCM, IPC and PCM. If scan tool communicates with all control modules, go to next step. If scan tool
does not communicate with all control modules, see appropriate MODULE COMMUNICATIONS
NETWORK article in ACCESSORIES & EQUIPMENT.
3. Select DTCs function on scan tool for BCM, EBCM, IPC or PCM. If scan tool displays any DTCs, go to
next step. If scan tool does not display any DTCs, go to SYMPTOM DIAGNOSIS .
4. If scan tool displays any DTCs which begins with a "U", see appropriate MODULE
COMMUNICATIONS NETWORK article in ACCESSORIES & EQUIPMENT. If scan tool does not
display any DTCs which begins with a "U", go to next step.
5. If scan tool displays DTC B1000, B1007 or B1440, diagnose affected DTCs. See appropriate BODY
CONTROL MODULES article in ACCESSORIES & EQUIPMENT. If DTC B1000, B1007 or B1440 is
not displayed, go to next step.
6. If scan tool displays DTC B1327, B1328, B1507 or B1508, diagnose affected DTCs. See appropriate
SELF-DIAGNOSTICS article in ENGINE PERFORMANCE. If DTC B1327, B1328, B1507 or B1508 is
not displayed, diagnose affected DTC(s) displayed.
If multiple DTCs are displayed, begin diagnosis with DTC that is displayed first. See DIAGNOSTIC
TROUBLE CODE DEFINITIONS table. Diagnose all codes in the order displayed by scan tool.
DIAGNOSTIC TROUBLE CODE DEFINITIONS

DTC (1)
Definition
B2747 Traction Control Switch Circuit Shorted To Ground
C0035 Wheel Speed Sensor Circuit Failure
C0060 - C0095 Inlet & Outlet Solenoid Valve Circuit Failure
C0110 Pump Motor Circuit Failure
C0121 Solenoid Valve Relay Circuit Failure
C0141 - C0156 Isolation & Prime Solenoid Valve Circuit Failure
C0161 Stoplamp Switch Circuit Failure
C0235 Engine Speed Signal Circuit Failure
C0237 Engine Speed Signal Circuit Failure
C0240 TCS Malfunction
C0241 PWM Requested Torque Signal Malfunction
C0244 PWM Delivered Torque Signal Malfunction
C0245 Wheel Speed Deviation
C0550 EBCM Malfunction
C0565 Incorrect VIN Information
C0896 EBCM Voltage Out Of Range
P1504 Engine Speed Signal Circuit Failure
P1571 PWM Requested Torque Signal Malfunction
P1689 PWM Delivered Torque Signal Malfunction
U1000 & U1255 (2)
U1300 (2)
U1301 (2)
(1) Always perform diagnostic system check before diagnosing DTCs. See DIAGNOSTIC SYSTEM
CHECK under DIAGNOSIS & TESTING.
(2) See appropriate MODULE COMMUNICATIONS NETWORK article in ACCESSORIES &
EQUIPMENT.
CLEARING DIAGNOSTIC TROUBLE CODES
NOTE: DTCs cannot be cleared by disconnecting EBCM, disconnecting negative

battery cable, or by turning ignition off. DTCs can only be cleared by using a
scan tool. DTCs will be erased when ignition is cycled 100 times without fault
reappearing. The ignition cycle counter in EBCM will be reset to zero.
1. Connect scan tool. Before clearing DTCs, check and note current DTC data. Select ABS/TCS function.
Select DTC(S) function and then CLEAR CODES function.
2. Verify DTCs are cleared. If other DTCs are displayed, either DTCs were not cleared or ABS/TCS fault
still exists. Diagnose fault and repeat procedure.
SYMPTOM DIAGNOSIS
If no DTCs are stored, perform appropriate symptom diagnostic test as necessary. See SYMPTOM
DIAGNOSTIC INDEX table.
SYMPTOM DIAGNOSTIC INDEX

Symptom (1) Test
ABS Indicator Always On A
ABS Indicator Inoperative B
Low Traction Indicator Always On C
Low Traction Indicator Inoperative D
TRACTION OFF Indicator Always On E
TRACTION OFF Indicator Inoperative F
(1) See appropriate test under SYMPTOM TESTS .
INTERMITTENTS & POOR CONNECTIONS
Failures in ABS/TCS may be difficult to diagnose accurately. If an ABS/TCS failure or fault occurs, ABS
and/or TRAC OFF indicator will illuminate. If fault is an intermittent problem which has corrected itself (ABS
and/or TRAC OFF indicator off), DTC will be stored.
ABS/TCS self-diagnostic system can be used to help identify suspect circuit. Perform following procedure:
Display and record DTC history data. Record any descriptive driving circumstances during failure
occurrence. Clear any ABS/TCS DTCs set in EBCM.
Test drive vehicle. Attempt to repeat failure under condition in which failure occurred. Use scan tool in
snapshot mode while test driving vehicle.
After duplicating condition, stop vehicle and display any ABS/TCS DTCs which may have been stored.
If no trouble codes were stored, see SYMPTOM TESTS .
Most intermittent problems are caused by faulty electrical connectors or wiring. When an intermittent failure is
encountered, check suspect circuits for:
Poor mating of connector halves, or terminals not fully seated in connector body (backed out).
Improperly formed or damaged terminals. All connector terminals in a problem circuit should be
carefully reformed to increase contact tension.
Check for dirt or corrosion on terminals, which could impede proper terminal contact.
Poor terminal-to-wire connection. This requires removing terminal from connector body to inspect.
Wheel speed sensor cables not attached in retainers or routed too close to spark plug wires.
Low system voltage. If low system voltage is detected at EBCM, ABS indicator is turned on until normal
system voltage is achieved.
SYMPTOM TESTS
NOTE: For terminal and circuit identification, see WIRING DIAGRAMS .
TEST A: ABS INDICATOR ALWAYS ON
1. Perform diagnostic system check. See DIAGNOSTIC SYSTEM CHECK under DIAGNOSIS &
TESTING. After performing diagnostic system check, go to next step.
2. Using scan tool, select Instrument Panel Cluster Special Functions mode. Go to Displays Test in Output
Control. In Displays Test mode instrument panel indicators can turn ON or OFF. All indicators will turn
ON when commanded on. If ABS indicator turns on, then turns off, go to next step. If ABS indicator does
not turn on, then turn off, go to step 4 .
3. Replace EBCM. See ELECTRONIC BRAKE CONTROL MODULE & BRAKE PRESSURE
MODULATOR VALVE ASSEMBLY under REMOVAL & INSTALLATION. Operate system to
verify repairs. Go to DIAGNOSTIC SYSTEM CHECK under DIAGNOSIS & TESTING.
4. Disconnect instrument cluster. Connect a test light across appropriate power and ground terminals. If test
light does not illuminate, repair open in power or ground circuit to cluster. If test light illuminates, check
connector for poor connection to cluster. If connection is okay, replace instrument cluster. Operate system
to verify repairs. Go to DIAGNOSTIC SYSTEM CHECK under DIAGNOSIS & TESTING.
TEST B: ABS INDICATOR INOPERATIVE
ON when commanded on. If ABS indicator turns on, then turns off, go to next step. If ABS indicator does
not turn on, then turn off, go to step 4 .
TEST C: LOW TRACTION INDICATOR ALWAYS ON
ON when commanded on. If LOW TRAC indicator turns on, then turns off, go to next step. If LOW
TRAC indicator does not turn on, then turn off, go to step 4 .
TEST D: LOW TRACTION INDICATOR ALWAYS ON
ON when commanded on. If LOW TRAC indicator turns on, then turns off, go to next step. If LOW
TRAC indicator does not turn on, then turn off, go to step 4 .
TEST E: TRACTION OFF INDICATOR ALWAYS ON
2. Install scan tool. Turn ignition on, with engine off. Using scan tool, observe Traction Switch parameter in
Body Control Module data list. If scan tool displays OFF, go to next step. If scan tool does not display
OFF, go to step 4 .
3. Activate traction control switch. Using scan tool, observe Traction Switch parameter. If Traction Switch
parameter changes state, see INTERMITTENT & POOR CONNECTIONS under DIAGNOSIS &
TESTING. If Traction Switch parameter does not change state, go to next step.
4. Turn ignition off. Disconnect traction control switch connector. Turn ignition on, with engine off. Using
scan tool, observe Traction Switch parameter. If scan tool displays OFF, go to step 7 . If scan tool does
not display OFF, go to next step.
5. Test traction control switch signal circuit for a short to ground. Repair circuit as necessary, then go to step
10 . If condition was not found, go to next step.
6. Inspect for poor connections at BCM harness connector. Repair as necessary, then go to step 10 . If
condition was not found, go to step 8 .
7. Inspect for poor connections at traction control switch harness connector. Repair as necessary, then go to
step 10 . If condition was not found, go to step 9 .
8. Replace BCM. See appropriate BODY CONTROL MODULE article in ACCESSORIES &
EQUIPMENT. Go to step 10 .
9. Replace traction control switch. See TRACTION CONTROL SWITCH under REMOVAL &
10. Operate system in order to verify repair. If condition is not corrected, go to step 2 .
TEST F: TRACTION OFF INDICATOR INOPERATIVE
2. Install scan tool. Turn ignition on, with engine off. Using scan tool, observe Traction Switch parameter in
Body Control Module data list. If Traction Switch parameter changes state, see INTERMITTENT &
POOR CONNECTIONS under DIAGNOSIS & TESTING. If Traction Switch parameter does not
change state, go to next step.
3. Turn ignition off. Disconnect traction control switch connector. Connect a fused jumper wire from
traction control switch harness connector to a good ground. Turn ignition on, with engine off. Using scan
tool, observe Traction Switch parameter. If scan tool displays ON, go to step 5 . If scan tool does not
display ON, go to next step.
4. Test traction control switch signal circuit for an open or high resistance. See INTERMITTENT &
POOR CONNECTIONS under DIAGNOSIS & TESTING. Repair circuit as necessary, then go to step
10 . If condition was not found, go to step 6 .
5. Test traction control switch ground circuit for an open or high resistance. Repair circuit as necessary, then
go to step 10 . If condition was not found, go to step 7 .
10. Operate system in order to verify repair. If condition is corrected, system is okay. If condition is not
corrected, go to step 2 .
DIAGNOSTIC TESTS
NOTE: For terminal and circuit identification, see WIRING DIAGRAMS . Testing of
system requires use of Universal Breakout Box (J-39700) and Cable Adapter (J-
39700-99). After repairs, recheck system operation to verify problem has been
repaired. See DIAGNOSTIC SYSTEM CHECK under DIAGNOSIS & TESTING. For
connector terminal locations, see Fig. 1 - Fig. 7 .
Fig. 1: Identifying BCM Connector C0 Terminals
Fig. 5: Identifying PCM Connector Terminals
Fig. 6: Identifying EBCM Connector Terminals

Fig. 7: Identifying Traction Control Switch Connector Terminals
DTC B2747: TRACTION CONTROL SWITCH CIRCUIT SHORTED TO GROUND
2. Install scan tool. Turn ignition on, with engine off. Using scan tool, observe TCS Switch State input
parameter in BCM input data list. If scan tool displays Active, go to next step. If scan tool does not
display Active, check for a traction control switch that may be sticking in pressed position. If problem is
intermittent, see INTERMITTENTS & POOR CONNECTIONS under DIAGNOSIS & TESTING.
3. Turn ignition off. Disconnect traction control switch. Turn ignition on, with engine off. Using scan tool,
observe TCS Switch State input parameter. If scan tool displays Inactive, go to step 6 . If scan tool does
not display Inactive, go to next step.
4. Check traction control switch connector terminal "D" (Brown/White wire) for a short to ground. See Fig.
7 . Repair circuit as necessary, then go to step 9 . If condition was not found, go to next step.
condition was not found, go to step 7
9. Using scan tool, clear DTCs. Operate vehicle to verify repair. If DTC resets, go to step 2 If DTC does not
reset, system is okay.
DTC C0035, DTC C0036, DTC C0040, DTC C0041, DTC C0045, DTC C0046, DTC C0050 & DTC
C0051: WHEEL SPEED SENSOR CIRCUIT FAILURE
2. Install scan tool. Turn ignition on. Set up scan tool snap shot to trigger for this DTC. Drive vehicle at
greater than 5 MPH. If scan tool indicates that suspect wheel speed DTC is set, go to next step. If scan
tool does not indicate that suspect wheel speed DTC is set, inspect WSS for signs of water intrusion. If
DTC is not current, clear DTCs using scan tool. Operate vehicle under condition simulating effects of
water intrusion. Diagnose each WSS individually. Inspect WSS wires. Ensure wires are not routed close
to high energy ignition system components.
3. Raise and support vehicle. Disconnect suspect wheel speed sensor connector. Measure resistance across
wheel speed sensor. Resistance should be 800-1600 ohms. If resistance is as specified, go to next step. If
resistance is not as specified, go to step 8 .
4. Spin wheel. Measure AC voltage across wheel speed sensor. If AC voltage is greater than 100 mV, go to
next step. If AC voltage is less than 100 mV, go to step 8 .
5. Inspect for poor connections at suspect wheel speed sensor harness connector. Repair as necessary, then
go to step 10 . If condition was not found, go to next step.
6. Disconnect EBCM harness connector. Using a cable adapter, install universal breakout box to EBCM
harness connector only. Test wheel speed sensor circuits for an open, short to ground, short to voltage or
circuits shorted together. See WIRING DIAGRAMS . Repair circuit(s) as necessary, then go to step 10 .
If condition was not found, go to next step.
7. Inspect for poor connections at EBCM harness connector. Repair as necessary, then go to step 10 . If
8. Replace wheel speed sensor. See appropriate article in SUSPENSION. Go to step 10 .
MODULATOR VALVE ASSEMBLY under REMOVAL & INSTALLATION. Go to next step.
10. Using scan tool, clear DTCs. Operate vehicle to verify repair. If DTC resets, go to step 2 . If DTC does
not reset, system is okay.
DTC C0060 - DTC C0095: INLET & OUTLET SOLENOID VALVE CIRCUIT FAILURE
2. Using scan tool, clear DTC. Remove scan tool from DLC. Carefully drive vehicle greater than 8 MPH for
several minutes. Turn ignition off. Install scan tool. Turn ignition on, with engine off. Using scan tool,
check for DTCs. If DTCs C0060-C0095 reset as a current DTC, go to next step. If DTCs C0060-C0095
did not reset as a current DTC, see INTERMITTENT & POOR CONNECTIONS under DIAGNOSIS
& TESTING.
DTC C0110: PUMP MOTOR CIRCUIT FAILURE
NOTE: Wiring from BPMV to EBCM should not be repaired.
2. Disconnect EBCM harness connector. Using cable adapter, connect universal breakout box to EBCM
harness connector only. Test universal breakout box connector terminals No. 12 and 15 (ground circuits)
for high resistance or for an open. Test universal breakout box connector terminals No. 13 and 14 (battery
positive voltage circuits) for an open, high resistance, or a short to ground. Repair circuit(s) as necessary,
then go to step 8 . If condition was not found, go to next step.
3. Disconnect BPMV pump motor harness pigtail connector. Measure resistance between each pump motor
control circuit and BPMV housing at pump motor harness pigtail connector. If resistance is less than 5
ohms, go to next step. If resistance is more than 5 ohms, go to step 5 .
4. Inspect for poor connections at BPMV pump motor harness pigtail connector. Repair as necessary, then
6. Replace BPMV. See ELECTRONIC BRAKE CONTROL MODULE & BRAKE PRESSURE
MODULATOR VALVE ASSEMBLY under REMOVAL & INSTALLATION. Go to step 8 .
DTC C0121: SOLENOID VALVE RELAY CIRCUIT FAILURE
2. Install scan tool. Turn ignition on, with engine off. Using scan tool, clear DTCs. If DTC resets, go to next
step. If DTC does not reset, see INTERMITTENT & POOR CONNECTIONS under DIAGNOSIS &
TESTING.
3. Using cable adapter, connect universal breakout box to EBCM harness connector only. Test universal
breakout box connector terminals No. 13 and 14 for an open, high resistance or a short to ground. Repair
circuit(s) as necessary, then go to step 5 . If condition was not found, go to next step.
DTC C0141 - DTC C0156: ISOLATION & PRIME SOLENOID VALVE CIRCUIT FAILURE
NOTE: Solenoid valve circuit and solenoid coil are internal to EBCM. No part of
solenoid circuit is diagnosable external to EBCM.
2. Using scan tool, clear DTC. Remove scan tool from DLC. Carefully drive vehicle greater than 8 MPH for
several minutes. Turn ignition off. Install scan tool. Turn ignition on, with engine off. Using scan tool,
check for DTCs. If DTCs C0141-C0156 reset as a current DTC, go to next step. If DTCs C0141-C0156
did not reset as a current DTC, system is okay.
DTC C0161: STOPLAMP SWITCH CIRCUIT FAILURE
2. Press brake pedal. Using scan tool, observe Brake Switch Status parameter in ABS data list. If Brake
Switch Status parameter displays Active, go to step 4 . If Brake Switch Status parameter does not display
Active, go to next step.
3. Test stoplamp switch connector terminal "B" (White wire) for an open. Repair circuit as necessary, then
4. Press brake pedal. If all stoplamps are off, go to next step. If all stoplamps are on, go to step 7 .
5. Test stoplamp switch connector terminal "A" (Orange wire) for an open or high resistance. Repair circuit
(s) as necessary, then go to step 15 . If condition was not found, go to next step.
6. Test stoplamp ground circuits for an open or high resistance. See WIRING DIAGRAMS . Repair circuit
(s) as necessary, then go to step 15 . If condition was not found, see INTERMITTENT & POOR
CONNECTIONS under DIAGNOSIS & TESTING.
7. Press brake pedal. Using scan tool, observe Brake Switch Status parameters. If Brake Switch Status
parameter changes state, see INTERMITTENT & POOR CONNECTIONS under DIAGNOSIS &
TESTING. If Brake Switch Status parameter does not change state, go to next step.
8. Turn ignition off. Inspect stoplamp switch. Adjust and/or calibrate switch as necessary, then go to step
15 . If condition was not found, go to next step.
9. Turn ignition switch off. Disconnect stoplamp switch connector. Turn ignition on, with engine off. Using
scan tool, observe Brake Switch Status parameter. If scan tool displays Released, go to step 11 . If scan
tool does not display Released, go to next step.
10. Check stoplamp switch connector terminal "B" (White wire) for a short to voltage. Repair circuit as
necessary, then go to step 15 . If condition was not found, go to step 12 .
11. Inspect for poor connections at stoplamp switch harness connector. Repair as necessary, then go to step
13. Replace stoplamp switch. Go to step 15 .
DTC C0235 - DTC C0237 OR DTC P1504: ENGINE SPEED SIGNAL CIRCUIT FAILURE
2. Start engine. Vary engine RPM with throttle while observing instrument panel tachometer. If instrument
panel tachometer operates properly as engine RPM changes, go to next step. If instrument panel
tachometer does not operate properly as engine RPM changes, go to step 9 .
3. Turn ignition switch off. Disconnect PCM connector C2. Disconnect EBCM connector. Using cable
adapter, connect universal breakout box to EBCM harness connector only. Using DVOM, measure
resistance between PCM harness connector terminal No. 8 (White wire) and universal breakout box
terminal No. 11. See Fig. 5 . If resistance is 0-5 ohms, go to next step. If resistance is not 0-5 ohms, go to
step 10 .
4. Measure resistance between universal breakout box terminal No. 11 and good ground. If resistance is
infinite, go to next step. If resistance is not infinite, go to step 11 .
5. Turn ignition on. Measure voltage between universal breakout box terminal No. 11 and a good ground. If
voltage is 0-2 volts, go to next step. If voltage is not 0-2 volts, go to step 12 .
6. Inspect PCM connector C2 and EBCM connector for damage, poor terminal contact and corrosion.
Ensure both connectors are properly retained when connected. If damage, poor terminal contact or
corrosion are present, go to step 13 . If connectors are okay, go to next step.
7. Reconnect all connectors. Using scan tool, clear DTCs. Disconnect scan tool from DLC. Start engine. If
DTCs reset, go to next step. If DTCs did not reset, see DIAGNOSTIC SYSTEM CHECK under
DIAGNOSIS & TESTING.
MODULATOR VALVE ASSEMBLY under REMOVAL & INSTALLATION. Go to step 14 .
9. Check PCM. See appropriate article in ENGINE PERFORMANCE. Go to step 14 .
10. Repair open in White wire between PCM and EBCM. Go to step 14 .
11. Repair short to ground in White wire between PCM and EBCM. Go to step 14 .
12. Repair short to voltage in White wire between PCM and EBCM. Go to step 14 .
13. Replace all terminals or replace connectors showing signs of poor terminal contact, corrosion, or
damaged terminals. Go to next step.
DTC C0240: TCS MALFUNCTION
2. Turn ignition switch to RUN, with engine off. Using scan tool, read ABS/TCS DTCs. If any other DTCs
are set, see appropriate DTC test. If no other DTCs are set, go to next step.
3. If DTC C0240 is set as a current code, go to step 5 . If DTC C0240 is not set as a current code, go to next
step.
4. Using scan tool, clear DTCs. Remove scan tool from DLC. Carefully drive vehicle greater than 8 MPH
for several minutes. Check for DTC. If DTC C0240 sets as a current code, go to next step. If DTC C0240
does not set as a current code, see DIAGNOSTIC SYSTEM CHECK under DIAGNOSIS & TESTING.
5. Perform Powertrain OBD system check. See appropriate article in ENGINE PERFORMANCE. If vehicle
passes OBD system check, go to next step. If vehicle does not pass OBD system check, see
DIAGNOSTIC TROUBLE CODE DEFINITIONS table under DIAGNOSIS & TESTING.
DTC C0241 OR DTC P1571: PWM REQUESTED TORQUE SIGNAL MALFUNCTION
2. Inspect EBCM and PCM grounds. Ensure each ground is clean and properly tightened. Repair as
necessary, then go to step 13 . If grounds are okay, go to next step.
3. Install scan tool. Start engine. Using scan tool, observe Torque Request Signal parameter in Powertrain
Control Module data list. Value should be 100 percent. If scan tool displays less than specified value, see
INTERMITTENT & POOR CONNECTIONS under DIAGNOSIS & TESTING. If scan tool displays
specified value, go to next step.
4. Turn ignition off. Disconnect EBCM harness connector. Using cable adapter, connect universal breakout
box to EBCM harness connector and EBCM connector. Start engine. Measure DC duty cycle between
universal breakout box terminal No. 27 and a good ground. Duty cycle range should be 5-95 percent. If
duty cycle is within specified range, go to next step. If duty cycle is not within specified range, go to step
6.
5. Measure DC Hz between universal breakout box terminal No. 27 and a good ground. Frequency should
measure 121-134 Hz. If frequency is within specified range, go to step 8 . If frequency is not within
specified range, go to next step.
CAUTION: Disconnecting EBCM connector and turning ignition on could cause

other modules to set loss of communication DTCs. Once EBCM is
reconnected, EBCM may set DTC C0241.
6. Turn ignition off. Disconnect cable adapter from EBCM connector. Turn ignition on, with engine off.
Measure voltage between breakout box terminal No. 27 and a good ground. Voltage should be 4-6 volts.
If voltage is within specified range, go to step 10 . If voltage is not within specified range, go to next step.
7. Turn ignition off. Disconnect PCM harness connector. Test PCM harness connector terminal No. 71
(Orange/Black wire) for a short to ground and short to voltage. Repair circuit as necessary, then go to step
8. Turn ignition off. Disconnect PCM harness connector. Test PCM harness connector terminal No. 71
(Orange/Black wire) for an open or high resistance. Repair circuit as necessary, then go to step 13 . If
condition was not found, go to next step.
9. Inspect for poor connections at PCM harness connector. Repair as necessary, then go to step 13 . If
11. Replace PCM. See appropriate article in ENGINE PERFORMANCE. Go to step 13 .
NOTE: PCM must be programmed. See COMPUTER RELEARN PROCEDURES
article in GENERAL INFORMATION.
DTC C0244 OR DTC P1689: PWM DELIVERED TORQUE SIGNAL MALFUNCTION
2. Inspect EBCM and PCM grounds. Ensure each ground is clean and properly tightened. Repair as
necessary, then go to step 11 . If grounds are okay, go to next step.
3. Install scan tool. Start engine. Using scan tool, observe PCM to EBCM Delivered parameter in
Powertrain Control Module data list. Value should be 90 percent. If scan tool displays specified value, go
to next step. If scan tool does not display specified value, see INTERMITTENT & POOR
CONNECTIONS under DIAGNOSIS & TESTING.
4. Turn ignition off. Disconnect EBCM harness connector. Using cable adapter, install universal breakout
box to EBCM harness connector and EBCM connector. Disconnect PCM harness connector. Turn
ignition on, with engine off. Measure voltage between breakout box terminal No. 9 and a good ground. If
battery is prresent, go to next step. If battery voltage is not present, go to step 6 .
5. Turn ignition off. Disconnect cable adapter from EBCM connector. Turn ignition on, with engine off.
Check breakout box terminal No. 9 (delivered torque signal circuit) for a short to voltage. Repair circuit
as necessary, then go to step 11 . If condition was not found, go to step 7 .
6. Turn ignition off. Disconnect cable adapter from EBCM connector. Check breakout box terminal No. 9
(delivered torque signal circuit) for an open, short to ground or high resistance. Repair circuit as
necessary, then go to step 11 . If condition was not found, go to step 8 .
7. Inspect for poor connections at PCM harness connector. Repair as necessary, then go to step 11 . If
NOTE: PCM must be programmed.
9. Replace PCM. See appropriate article in ENGINE PERFORMANCE. Go to step 13 .

DTC C0245: WHEEL SPEED DEVIATION
2. If DTC(s) C0036, C0041, C0046, C0051 or C0056 set concurrently with a history DTC C0245, repair
cause to concurrent DTC(s) before repairing cause of DTC C0245. If no DTC(s) are set concurrently with
a history DTC C0245, go to next step.
3. Inspect suspect wheel speed sensor for physical damage. If physical damage is evident, go to next step. If
damage is not evident, go to step 5 .
4. Replace damaged wheel speed sensor. See WHEEL SPEED SENSOR under REMOVAL &
5. Inspect jumper harness for physical damage. If physical damage is evident, go to next step. If damage is
not evident, go to step 7 .
6. Replace wheel speed sensor jumper harness. See WHEEL SPEED SENSOR under REMOVAL &
7. Check for proper routing of wheel speed sensor harness. Ensure wheel speed sensor harness is routed
away from spark plug wires. If harness is not properly routed, go to step 8 . If harness is okay, go to step
9.
8. Reroute wheel speed sensor harness away from spark plug wires, then go to step 14 .
9. Install scan tool. Turn ignition switch to RUN position. Set scan tool to Snap Shot Auto Trigger mode.
Monitor wheel speed sensors. Carefully drive vehicle greater than 8 MPH for several minutes. If scan tool
triggered any wheel speed sensor, go to next step. If scan tool did not trigger any wheel speed sensor, go
to step 11 .
10. Note which wheel speed sensor triggered scan tool. See appropriate test for DTC set. Go to step 14 .
11. Reconnect all previously disconnected components. Using scan tool, clear DTCs. Remove scan tool from
DLC. Carefully drive vehicle greater than 8 MPH for several minutes. Check for DTC. If DTC resets as a
current DTC, go to step 13 . If DTC does not reset as a current DTC, go to next step.
12. Malfunction is intermittent. Inspect all connectors and harnesses for damage that may result in an open or
high resistance when connected. See INTERMITTENT & POOR CONNECTIONS under
DIAGNOSIS & TESTING. Go to step 14 .
DTC C0550: EBCM MALFUNCTION
2. If any DTCs besides C0550 are present, repair those DTC(s) before repairing cause of DTC C0550. If no
other DTCs are present, go to next step.
DTC C0565: INCORRECT VIN INFORMATION
2. If any DTCs besides C0565 are present, repair those DTC(s) before repairing cause of DTC C0565. If no
other DTCs are present, go to next step.
DTC C0896: EBCM VOLTAGE OUT OF RANGE
2. Turn all accessories off. Install scan tool. Start engine. Using scan tool, monitor battery voltage while
running engine at approximately 2000 RPM. Voltage should be 0-17.4 volts. If voltage is within specified
range, go to step 4 . If voltage is not within specified range, go to next step.
3. Using DVOM, measure voltage between positive battery terminal and ground. Voltage should be 0-17.4
volts. If voltage is within specified range, go to step 5 . If voltage is not within specified range, check
charging system and repair as needed.
4. Using scan tool, continue to monitor battery voltage while running engine at approximately 2000 RPM.
Voltage should be 0-9.4 volts. If monitored battery voltage is within specified range, go to step 6 . If
monitored battery voltage is not within specified range, go to next step.
5. Turn ignition switch off. Disconnect scan tool, if still connected. Test drive vehicle greater than 3.5 MPH.
If DTC C0896 resets, go to step 10 . If DTC C0896 does not reset, see DIAGNOSTIC SYSTEM
CHECK under DIAGNOSIS & TESTING.
6. Turn ignition switch off. Disconnect EBCM connector. Using cable adapter, install universal breakout
box to EBCM harness connector only. Measure resistance between universal breakout box terminal No.
15 and ground. If resistance is 0-5 ohms, go to step 8 . If resistance is not 0-5 ohms, go to next step.
7. Repair open or high resistance in ground circuit, then go to step 11 .
8. Turn ignition switch to RUN position. Measure voltage between universal breakout box terminals No. 8
and 15. Voltage should be greater than 9.4 volts. If voltage is more than 9.4 volts, go to next step. If
voltage is less than 9.4 volts, check charging system and repair as needed.
9. Turn ignition switch off. Reconnect EBCM connector. Disconnect scan tool, if still connected. Test drive
vehicle greater than 3.5 MPH. If DTC C0896 resets, go to next step. If DTC C0896 does not reset, go to
step 11 .

battery.
ELECTRONIC BRAKE CONTROL MODULE & BRAKE PRESSURE MODULATOR VALVE

ASSEMBLY
CAUTION: BPMV can only be serviced as a complete assembly. Only exception is

replacement of EBCM. With the exception of EBCM no screws may be
loosened. If screws are loosened, it will not be possible to get brake line
leak-tight and personal injury may result.
CAUTION: Always connect or disconnect wiring harness connector from EBCM with
ignition switch in OFF position. Failure to do so may result in damage to
EBCM.
Removal
1. BPMV and EBCM assembly is located near brake booster. EBCM and BPMV are individual units that
are connected together. Turn ignition switch to OFF position. Disconnect negative battery cable.
2. Remove air cleaner assembly. Disconnect EBCM harness connector ensuring connector tab is released by
pushing down lock tab and slide connector cover. Disconnect BPMV pump motor ground cable located at
bottom of EBCM. Label brakelines for installation reference and remove brakelines from BPMV.
3. Remove EBCM and BPMV assembly from vehicle. To remove EBCM from BPMV, remove BPMV-to-
EBCM mounting screws. Separate EBCM from BPMV by gently pulling apart. DO NOT pry apart using
a tool. Replace seal, if damaged.
Installation
CAUTION: Ensure brake pipes are correctly connected to BPMV. If brake pipes are
switched, wheel lock-up will occur and personal injury may result. The
only two ways this condition can be detected are by using a scan tool or
by performing an anti-lock stop.
NOTE: Ensure correct fasteners are used in correct locations. Do not use paints,
lubricants, or corrosion inhibitors unless specified.
1. To install, reverse removal procedure. Ensure brakelines are installed in original locations. Ensure EBCM
harness connector tab is locked down. Tighten bolts, nuts and brakelines to specification. See TORQUE
SPECIFICATIONS .
2. If NEW BPMV assembly is being installed, ensure shipping plugs are removed from valve openings.
Refill brake master cylinder reservoir, bleed brakes and check for leaks. See BLEEDING BRAKE
SYSTEM .
3. Using scan tool, perform DIAGNOSTIC SYSTEM CHECK under DIAGNOSIS & TESTING and
check if any DTCs have been set. Diagnose and repair as necessary.
PUMP MOTOR RELAY & SOLENOID VALVE RELAY
Pump motor relay and solenoid valve relay are mounted on EBCM and are not serviceable. Relays must be
replaced as an assembly with EBCM. See ELECTRONIC BRAKE CONTROL MODULE & BRAKE
PRESSURE MODULATOR VALVE (BPMV) ASSEMBLY .
WHEEL SPEED SENSOR
NOTE: The front and rear wheel speed sensors and toothed sensor rings (tone rings)
are part of wheel bearing hub assembly and must be replaced as a complete
assembly if defective.
Removal & Installation (Front & Rear)
The wheel speed sensors are part of wheel bearing hub assembly and must be serviced by replacing hub. See
appropriate FRONT or REAR article in SUSPENSION.
TOOTHED SENSOR RING
NOTE: The front and rear wheel speed sensors and toothed sensor rings (tone rings)
are part of wheel bearing hub assembly and must be replaced as a complete
assembly if defective.
Removal & Installation (Front & Rear)
The toothed sensor ring are part of hub assembly and must be serviced by replacing hub assembly. See
appropriate FRONT or REAR article in SUSPENSION.
TRACTION CONTROL SWITCH
1. Remove instrument panel accessory trim plate. Remove switch bank retaining bolts and screws. Pull
switch bank straight out from instrument panel. Disconnect electrical connectors.
2. To install, reverse removal procedure. Ensure correct fasteners are used. Tighten bolts and screws to
Brakeline Fittings (At BPMV) 11 (15)
Wheel Lug Nuts 100 (134)
INCH Lbs. (N.m)
ABS & TCS Modulator Bleeder Valve 80 (9)
BPMV Bracket Bolt & Nut 89 (10)
BPMV Bracket Nut-To-BPMV 106 (12)
EBCM-To-BPMV Bolt & Screw 27 (3)
Wheel Speed Sensor Mounting Bolt 89 (10)
WIRING DIAGRAMS
Fig. 8: Anti-Lock Brakes Wiring Diagram (Aztek)
Disc & Drum - Aztek & Rendezvous
NOTE: This article covers base brake systems only. For information on Anti-Lock
Brake System (ABS) see appropriate ANTI-LOCK article.
HYDRAULIC BRAKE SYSTEM
Description
The hydraulic brake system consists of the following:
Hydraulic Brake Master Cylinder Fluid Reservoir
Contains supply of brake fluid for the hydraulic brake system.
Hydraulic Brake Master Cylinder
Converts mechanical input force into hydraulic output pressure. Hydraulic output pressure is distributed
from the master cylinder through 2 hydraulic circuits, supplying diagonally-opposed wheel apply circuits.
Hydraulic Brake Pressure Balance Control System
Regulates brake fluid pressure delivered to hydraulic brake wheel circuits, in order to control the
distribution of braking force. Pressure balance control is achieved through Dynamic Rear Proportioning
(DRP), which is a function of the ABS modulator. See appropriate ANTI-LOCK article for specific
information on the operation of DRP.
Hydraulic Brake Pipes and Flexible Brake Hoses
Carries brake fluid to and from hydraulic brake system components.
Hydraulic Brake Wheel Apply Components
Converts hydraulic input pressure into mechanical output force.
Operation
Mechanical force is converted into hydraulic pressure by the master cylinder, regulated to meet braking system
demands by the pressure balance control system, and delivered to the hydraulic brake wheel circuits by the
pipes and flexible hoses. The wheel apply components then convert the hydraulic pressure back into mechanical
force which presses linings against rotating brake system components.
BRAKE ASSIST SYSTEM
Description
The brake assist system consists of the following:
Brake Pedal
Receives, multiplies and transfers brake system input force from driver.
Brake Pedal Pushrod
Transfers multiplied input force received from brake pedal to brake booster.
Vacuum Brake Booster
Uses source vacuum to decrease effort required by driver when applying brake system input force. When
brake system input force is applied, air at atmospheric pressure is admitted to the rear of both vacuum
diaphragms, providing a decrease in brake pedal effort required. When input force is removed, vacuum
replaces atmospheric pressure within the booster.
Vacuum Source
Supplies force used by vacuum brake booster to decrease brake pedal effort.
Vacuum Source Delivery System
Enables delivery and retention of source vacuum for vacuum brake booster.
Operation
Brake system input force is multiplied by the brake pedal and transferred by the pedal pushrod to the hydraulic
brake master cylinder. Effort required to apply the brake system is reduced by the vacuum brake booster.
BRAKE WARNING SYSTEM
Brake System Indicator
The IPC detects a low brake fluid condition. The IPC receives a discrete input from the brake fluid level
switch requesting illumination.
The IPC detects the park brake is engaged. The IPC receives a discrete input from the park brake switch
DISC BRAKE SYSTEM
Description
The disc brake system consists of the following components:
Disc Brake Pads
Applies mechanical output force from the hydraulic brake calipers to friction surfaces of brake rotors.
Disc Brake Rotors
Uses mechanical output force applied to friction surfaces from the disc brake pads to slow speed of tire
and wheel assembly rotation.
Disc Brake Pad Hardware
Secures disc brake pads firmly in proper relationship to the hydraulic brake calipers; enables a sliding
motion of brake pads when mechanical output force is applied.
Disc Brake Caliper Hardware
Provides mounting for hydraulic brake caliper and secures the caliper firmly in proper relationship to
caliper bracket. Enables a sliding motion of the brake caliper to the brake pads when mechanical output
force is applied.
Operation
Mechanical output force is applied from the hydraulic brake caliper pistons to the inner brake pads. As the
pistons press the inner brake pads outward, the caliper housings draw the outer brake pads inward. This allows
the output force to be equally distributed. The brake pads apply the output force to the friction surfaces on both
sides of the brake rotors, which slows the rotation of the tire and wheel assemblies. The correct function of both
the brake pad and brake caliper hardware is essential for even distribution of braking force.
DRUM BRAKE SYSTEM
Description
The drum brake system consists of the following:
Drum Brake Shoes
Applies mechanical output force (from hydraulic brake wheel cylinders) to friction surface of brake
drums.
Brake Drums
Uses mechanical output force applied to friction surface from drum brake shoes to slow speed of tire and
wheel assembly rotation.
Drum Brake Hardware
Secures drum brake shoes firmly in proper relationship to hydraulic brake wheel cylinders. Enables
sliding motion of brake shoes needed to expand toward friction surface of drums when mechanical output
force is applied; provides return of brake shoes when mechanical output force is relieved.
Drum Brake Adjusting Hardware
Provides automatic adjustment of brake shoes to brake drum friction surface whenever brake apply occurs
during rearward motion of the vehicle.
Operation
Mechanical output force is applied from the hydraulic brake wheel cylinder pistons to the top of the drum brake
shoes. The output force is then distributed between the primary and secondary brake shoes as the shoes expand
toward the friction surface of the brake drums. The brake shoes apply the output force to the friction surface of
the brake drums, which slows the rotation of the tire and wheel assemblies. The proper function of both the
drum brake hardware and adjusting hardware is essential to the proper distribution of braking force.
PARK BRAKE SYSTEM
Description
The park brake system consists of the following:
Park Brake Pedal Assembly
Receives and transfers park brake system apply input force from driver to park brake cable system.
Releases applied park brake system when depressed again.
Park Brake Cables
Transfers input force received from park brake pedal, through park brake cable equalizer, to park brake
apply lever.
Park Brake Cable Equalizer
Evenly distributes input force to both the left and right park brake units. Threaded park brake cable
equalizers are also used to remove slack in park brake cables.
Park Brake Apply Lever
Multiplies and transfers input force to park brake actuator/adjuster.

Park Brake Actuator/Adjuster
Uses multiplied input force from apply lever to expand park brake shoe (rear disc, drum-in-hat system),
or drum brake shoes toward the friction surface of the drum-in-hat of the rear brake rotor, or the brake
drum. Threaded park brake actuators/adjusters are also used to control clearance between the park brake
shoe (rear disc, drum-in-hat system), or the drum brake shoes and the friction surface of the drum-in-hat
(of the rear brake rotor), or the brake drum.
Park Brake Shoe (Rear Disc, Drum-In-Hat System)
Applies mechanical output force from park brake actuator/adjuster to friction surface of the drum-in-hat
(of the rear brake rotor).
Operation
Park brake apply input force is received by the park brake pedal assembly being depressed, transferred and
evenly distributed, through the park brake cables and the park brake cable equalizer, to the left and right park
brake apply levers. The park brake apply levers multiply and transfer the apply input force to the park brake
actuators/adjusters which expand the park brake shoe (rear disc, drum-in-hat system), or the drum brake shoes
toward the friction surface of the drum-in-hat (of the rear brake rotor), or the brake drum in order to prevent the
rotation of the rear tire and wheel assemblies. The park brake pedal assembly releases an applied park brake
system when it is depressed again.
BLEEDING, FILLING & FLUSHING BRAKE SYSTEM

BRAKE BLEEDING SEQUENCE
BRAKE BLEEDING SEQUENCE

Application Sequence
Aztek & Rendezvous RR, LF, LR, RF
HYDRAULIC BRAKE SYSTEM BLEEDING
CAUTION: When adding fluid to the brake master cylinder reservoir, use only Delco
Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent
DOT-3 brake fluid from a clean, sealed brake fluid container. The use of
any type of fluid other than the recommended type of brake fluid, may
cause contamination which could result in damage to the internal rubber
seals and/or rubber linings of hydraulic brake system components.
CAUTION: Avoid spilling brake fluid onto painted surfaces, electrical connections,
wiring, or cables. Brake fluid will damage painted surfaces and cause
corrosion to electrical components. If any brake fluid comes in contact
with painted surfaces, immediately flush the area with water. If any brake
fluid comes in contact with electrical connections, wiring, or cables, use a
clean shop cloth to wipe away the fluid.
Manual
1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills.
2. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort
increases significantly, in order to deplete the brake booster power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the
brake pipes from the master cylinder, you must perform the following steps:
A. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add
Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake
fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is
necessary, clean the outside of the reservoir on and around the cap prior to removal.
B. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front
brake pipe from the front port of the brake master cylinder.
C. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder.
D. Reconnect the brake pipe to the master cylinder port and tighten securely.
E. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal.
F. Loosen the same brake pipe to purge air from the open port of the master cylinder.
G. Tighten the brake pipe, then have the assistant slowly release the brake pedal.
H. Wait 15 seconds, then repeat steps B -F until all air is purged from the same port of the master
cylinder.
I. With the front brake pipe installed securely to the master cylinder, after all air has been purged
from the front port of the master cylinder, loosen and separate the rear brake pipe from the master
cylinder, then repeat steps B -G .
J. After completing the final master cylinder port bleeding procedure, ensure that both of the brake
pipe-to-master cylinder fittings are properly tightened.
4. Fill the brake master cylinder reservoir with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N
992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the
brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as
needed to maintain the proper level. Clean the outside of the reservoir on and around the reservoir cap
prior to removing the cap and diaphragm.
5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
6. Install a transparent hose over the end of the bleeder valve.
7. Submerge the open end of the transparent hose into a transparent container partially filled with Delco
Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a
clean, sealed brake fluid container.
8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal.
9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit.
10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal.
11. Wait 15 seconds, then repeat steps 8 -10 until all air is purged from the same wheel hydraulic circuit.
12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel
hydraulic circuit bleeder valve.
13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7 -11 .
14. With the left front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the left front hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel
16. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged
from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel
18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel
hydraulic circuit bleeder valves are properly tightened.
19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM P/N
12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid
container.
20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal.
21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy
after repeating the bleeding procedure, perform the following steps:
A. Inspect the brake system for external leaks. See BRAKE SYSTEM EXTERNAL LEAK
INSPECTION under HYDRAULIC BRAKE SYSTEM in ADJUSTMENTS & INSPECTION.
B. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the
system.
22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains
illuminated.
NOTE: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
23. If the brake system warning lamp remains illuminated, see BRAKE WARNING INDICATOR
ALWAYS ON under TROUBLE SHOOTING.
Pressure
A. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add
Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake
fluid from a clean, sealed brake fluid container. If removal of the reservoir cap and diaphragm is
necessary, clean the outside of the reservoir on and around the cap prior to removal.
B. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front
C. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder.
D. Reconnect the brake pipe to the master cylinder port and tighten securely.
E. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal.
F. Loosen the same brake pipe to purge air from the open port of the master cylinder.
G. Tighten the brake pipe, then have the assistant slowly release the brake pedal.
H. Wait 15 seconds, then repeat steps B -F until all air is purged from the same port of the master
cylinder.
I. With the front brake pipe installed securely to the master cylinder, after all air has been purged
cylinder, then repeat steps B -G .
J. After completing the final master cylinder port bleeding procedure, ensure that both of the brake
container. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap
and diaphragm.
5. Install the Master Cylinder Bleeder Adapter (J-35589-A) to the brake master cylinder reservoir.
6. Check the brake fluid level in the Diaphragm Type Brake Pressure Bleeder, or equivalent (J-29532), or
equivalent. Add Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3
brake fluid from a clean, sealed brake fluid container as necessary to bring the level to approximately the
half-full point.
7. Connect the Diaphragm type brake pressure bleeder or equivalent, to the master cylinder bleeder adapter.
8. Charge the pressure bleeder, or equivalent, air tank to 25-30 psi (175-205 kPa).
9. Open the pressure bleeder, or equivalent, fluid tank valve to allow pressurized brake fluid to enter the
brake system.
10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that
there are no existing external brake fluid leaks. Any brake fluid leaks identified require repair prior to
completing this procedure.
Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a
clean, sealed brake fluid container.
14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air
bubbles stop flowing from the bleeder, then tighten the bleeder valve.
16. Install a transparent hose over the end of the bleeder valve, then repeat steps 13 and 14 .
22. Close the pressure bleeder, or equivalent, fluid tank valve, then disconnect the pressure bleeder, or
equivalent, from the bleeder adapter.
23. Remove the bleeder adapter from the brake master cylinder reservoir.
container.
26. If the brake pedal feels spongy perform the following steps:
INSPECTION under HYDRAULIC BRAKE SYSTEM in ADJUSTMENTS & INSPECTION.
B. Using a scan tool, perform the anti-lock brake system automated bleeding procedure to remove any
air that may have been trapped in the BPMV. See appropriate ANTI-LOCK article.
illuminated.
NOTE: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
28. If the brake system warning lamp remains illuminated, See HYDRAULIC BRAKE SYSTEM
DIAGNOSIS under TROUBLE SHOOTING.
MASTER CYLINDER RESERVOIR
Filling
When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967
(Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of
any type of fluid other than the recommended type of brake fluid, may cause contamination which could result
in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.
Avoid spilling brake fluid onto painted surfaces, electrical connections, wiring, or cables. Brake fluid will
damage painted surfaces and cause corrosion to electrical components. If any brake fluid comes in contact with
painted surfaces, immediately flush the area with water. If any brake fluid comes in contact with electrical
connections, wiring, or cables, use a clean shop cloth to wipe away the fluid.
1. Visually inspect the brake fluid level through the brake master cylinder reservoir.
2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system
should be inspected for wear and possible brake fluid leaks.
3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of
the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the
maximum-fill level.
4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill
level.
5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal
conditions.
6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and
around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme 11(R), GM
P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid
container.
MASTER CYLINDER BENCH BLEEDING
When adding fluid to the brake master cylinder reservoir, use only Delco Supreme 11(R), GM P/N 12377967
(Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. The use of
any type of fluid other than the recommended type of brake fluid, may cause contamination which could result
in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.
1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of the primary
piston is accessible.
2. Remove the master cylinder reservoir cap and diaphragm.
3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also
provide for hose attachment.
4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the
master cylinder reservoir.
5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11(R), GM P/N
container.
6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully
submerged in the brake fluid.
7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth
of about 1" (25 mm), several times. Observe the flow of fluid coming from the ports. As air is bled from
the primary and secondary pistons, the effort required to depress the primary piston will increase and the
amount of travel will decrease.
8. Continue to depress and release the primary piston until fluid flows freely from the ports with no
evidence of air bubbles.
9. Remove the transparent hoses from the master cylinder reservoir.
10. Install the master cylinder reservoir cap and diaphragm.
11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder
with a clean shop cloth to prevent brake fluid spills.
12. Remove the master cylinder from the vise.
HYDRAULIC BRAKE SYSTEM FLUSHING
1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination:
A. Fluid separation, indicating 2 types of fluid are present; a substance other than the recommended
brake fluid has been introduced into the brake hydraulic system:
Swirled appearance - oil-based substance.
Layered appearance - silicone-based substance.
B. Fluid discoloration, indicating the presence of moisture or particles that have been introduced into
the brake hydraulic system:
Cloudy appearance - moisture.
Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust.
2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for
swelling, indicating brake fluid contamination.
3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid
separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master
cylinder grommets, perform the following:
A. Remove ALL of the following components listed from the vehicle. Each component contains
internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the
brake hydraulic system. Refer to the procedures indicated:
MASTER CYLINDER under REMOVAL & INSTALLATION
BRAKE HOSE under REMOVAL & INSTALLATION
BRAKE CALIPER under REMOVAL & INSTALLATION
WHEEL CYLINDER if equipped, under REMOVAL & INSTALLATION
Brake Pressure Modulator Valve (BPMV). For replacement, see appropriate ANTI-LOCK
article.
B. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent.
C. Dry the brake pipes using non-lubricated, filtered air.
D. Repair or replace ALL of the following components listed and install them to the vehicle. Each
component contains internal rubber seals/linings which have been contaminated by the
contaminated brake fluid in the brake hydraulic system. Refer to the procedures indicated:
MASTER CYLINDER under OVERHAUL or MASTER CYLINDER under REMOVAL
& INSTALLATION; also perform the following: Clean the brake master cylinder reservoir
using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered
air. Inspect the reservoir for cracks and/or damage and replace if necessary. See MASTER
CYLINDER under REMOVAL & INSTALLATION. Replace the brake master cylinder
reservoir cap diaphragm.
BRAKE CALIPER - FRONT under OVERHAUL or BRAKE CALIPER under

BRAKE CALIPER - REAR , if equipped, under OVERHAUL or BRAKE CALIPER if
equipped, under REMOVAL & INSTALLATION
WHEEL CYLINDER , if equipped, under REMOVAL & INSTALLATION.
article.
4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS
contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder
reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the
hydraulic system.
5. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11(R), GM U.S.
P/N 12377967, GM Canada P/N 992667, or equivalent DOT-3 brake fluid from a clean, sealed brake
fluid container.
6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled
to the maximum-fill level with the correct brake fluid as indicated. See HYDRAULIC BRAKE
SYSTEM BLEEDING .
ADJUSTMENTS & INSPECTIONS
BRAKE PEDAL
Brake Pedal Pushrod Inspection
1. Disconnect the brake pedal pushrod from the brake pedal.

2. Inspect the brake pedal pushrod eyelet bushing for cracks and/or excessive wear.
3. Reposition the pedal pushrod boot toward the front of the vehicle to expose as much of the pedal pushrod
as possible.
4. Inspect the brake pedal pushrod for straightness.
5. If the brake pedal pushrod eyelet bushing exhibited cracks and/or excessive wear, then the bushing
requires replacement.
6. If the brake pedal pushrod is not straight, then the pushrod requires replacement.
7. Return the pedal pushrod boot to its original position on the pedal pushrod.
8. Connect the brake pedal pushrod to the brake pedal.
Brake Pedal Travel Measurement & Inspection
2. Install the Brake Pedal Effort Gage (J-28662) to the brake pedal.
3. Measure and record the distance from the brake pedal to the rim of the steering wheel; note the points of
measurement.
4. Apply and maintain the brakes with 100 lbs (445 N) of force to the brake pedal, as indicated on the effort
gage.
5. While maintaining 100 lbs (445 N) of force to the brake pedal, measure and record the distance from the
same point on the brake pedal to the same point on the rim of the steering wheel.
6. Release the brakes and repeat steps 4 and 5 to obtain a second measurement. After obtaining a second
measurement, proceed to the next step.
7. Average the first and second measurements recorded during the 2 applies of the brakes.
8. Subtract the initial measurement, unapplied, from the averaged, applied measurement to obtain the brake
pedal travel distance. Maximum brake pedal travel-measured with the ignition OFF, brake booster power
assist depleted, and the brakes cool is 2.91" (74 mm).
Fig. 1: Measuring Brake Pedal Travel
STOPLIGHT SWITCH
NOTE: Proper stoplight switch adjustment is essential. Improper stoplight switch

adjustment may cause brake drag, heat buildup and excessive brake lining
wear.
Adjustment
Adjust the stoplight switch and cruise control release at the same time. The adjustment procedures for the
stoplight switch and the cruise control release switch are identical.
1. Insert the stoplight switch and the cruise control switch if equipped into the brake pedal bracket.
2. Install the stoplight switch and the cruise control switch if equipped into the slotted grooves until the
switches are fully depressed against the brake pedal, then turn the switches clockwise approximately 1/4
turn, the switches should now be installed and adjusted.
3. Inspect the stoplights and the cruise control for proper operation.
FRONT & REAR DISC BRAKE
Brake Caliper Inspection
1. Inspect the brake caliper housing for cracks, excess wear, and/or damage. If any of these conditions are
present, the brake caliper requires replacement.
2. Inspect the caliper piston dust boot seal for cracks, tears, cuts, deterioration and/or improper seating in the
caliper body. If any of these conditions are present, the brake caliper requires overhaul or replacement.
3. Inspect for brake fluid leakage around the caliper piston dust boot seal and on the disc brake pads. If there
is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement.
4. Inspect for smooth and complete travel of the caliper piston, or pistons, into the caliper bore, or bores:
The movement of a caliper piston into a caliper bore should be smooth and even. If a caliper piston is
frozen or difficult to bottom, the caliper requires overhaul or replacement.
For single piston caliper applications, insert a discarded inner brake pad or block of wood in front
of the piston. Using a large C-clamp installed over the body of the caliper and against the brake pad
or block of wood, slowly bottom the piston in the bore.
For dual piston caliper applications, insert a discarded inner brake pad or block of wood in front of
the pistons. Using 2 large C-clamps installed over the body of the caliper and against the brake pad
or block of wood, slowly bottom the pistons evenly into the bores.
Brake Pad Inspection
1. Inspect the disc brake pads at regular intervals, or whenever the tire and wheel assemblies are removed
from the vehicle.
2. If replacement is necessary, always replace disc brake pads in axle sets.
3. Inspect both edges of the disc brake pad friction surfaces. The highest rate of wear normally occurs at the
trailing edge of the disc brake pads.
4. Inspect the thickness of the disc brake pads in order to ensure that they have not worn prematurely. The
disc brake pad wear should be approximately even per axle set.
5. Both front and rear disc brake pads have integral, audible wear sensors. When the disc brake pad wear
reaches the minimum allowable thickness, the wear sensor contacts the disc brake rotor. The wear
indicator will then produce an audible, high-pitched warning noise during wheel rotation.
6. Replace the disc brake pads when the friction surface is worn to within 0.030" (0.76 mm) of the mounting
plates.
7. Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake pads to
ensure that they are level. Place the disc brake pad friction surfaces together and measure the gap between
the surfaces. If more than .005" (.13 mm) gap exists midway between the length of the disc brake pads,
replace the disc brake pads.
8. Verify that any disc brake pad shims that may be required are in place and not damaged or excessively
corroded. Replace any missing or damaged shims in order to preserve proper disc brake performance.
9. Replace the disc brake pads if any have separated from the mounting plates.
10. Inspect the disc brake pads friction surfaces for cracks, fractures, or damage which may cause noise or
otherwise impair disc brake performance.
Brake Rotor Surface & Wear Inspection
1. With the tire and wheel assemblies removed and the brake rotors retained by wheel lug nuts, clean the
braking (friction) surfaces of the brake rotor with denatured alcohol or an equivalent approved brake
cleaner.
2. Inspect the braking surfaces of the brake rotor for the following braking surface conditions:
Heavy rust and/or pitting Light surface rust can be removed with an abrasive disc; heavy surface
rust and/or pitting must be removed by refinishing the rotor.
Cracks and/or heat spots
Excessive blueing discoloration
3. If the braking surfaces of the brake rotor exhibits one or more of the Braking Surface Conditions, the
rotor requires refinishing or replacement.
4. Using a micrometer calibrated in ten-thousands of an inch, measure and record the thickness variation of
the brake rotor at four or more points, around the rotor. Ensure that the measurements are only taken
within the brake pad lining contact area and that the micrometer is positioned the same distance from the
outside edge of the rotor for each measurement.
5. Compare the thickness variation recorded to the following specification: Brake rotor maximum allowable
thickness variation, see DISC BRAKE SPECIFICATIONS .
6. If the brake rotor thickness variation exceeds the specification, the rotor requires refinishing or
replacement.
7. Using the micrometer, measure and record any grooves present on the rotor braking surface.
8. Compare the groove (scoring) depth recorded to the following specification: Brake rotor maximum
allowable scoring, see DISC BRAKE SPECIFICATIONS .
9. If the brake rotor scoring depth exceeds the specification, or if an excessive amount of scoring is present,
the rotor requires refinishing or replacement.
10. Mount a dial indicator, (J-8001) or equivalent, and position the indicator button so it contacts the brake
rotor at a 90 degree angle, approximately 0.5" (13 mm) from the rotor's outer edge.
11. Measure and record the lateral runout of the brake rotor.
A. Rotate the rotor until the lowest reading is displayed on the indicator dial, then zero the dial.
B. Rotate the rotor until the highest reading is displayed on the dial.
C. Measure and record the amount of sealed wheel bearing play, then subtract the bearing play from
the lateral runout recorded to obtain the true amount of lateral runout.
12. Compare the lateral runout of the brake rotor to the following specification:
Front Brake rotor maximum allowable lateral runout, see DISC BRAKE SPECIFICATIONS .
Rear Brake rotor maximum allowable lateral runout, see DISC BRAKE SPECIFICATIONS .
13. If the brake rotor lateral runout exceeds the specification, the rotor requires refinishing or replacement.
Brake Rotor Thickness Measurement
1. Clean the brake pad lining contact surface of the brake rotor with denatured alcohol or an equivalent
brake cleaner.
2. Using a micrometer calibrated in ten-thousands of an inch, measure and record the lowest thickness of the
brake rotor at four or more points, equally spaced around the rotor. Ensure that the measurements are only
taken within the brake pad lining contact area and that the micrometer is positioned the same distance
from the outside edge of the rotor for each measurement.
3. Compare the lowest thickness measurement recorded to the following specifications:
Front brake rotor minimum allowable thickness after refinishing, see DISC BRAKE
SPECIFICATIONS .
Rear brake rotor minimum allowable thickness after refinishing, see DISC BRAKE
SPECIFICATIONS .
4. If the lowest thickness measurement of the brake rotor is above the minimum allowable thickness after
refinishing specification; the rotor may be able to be refinished, depending upon surface and wear
conditions which may be present.
5. If the lowest thickness measurement of the brake rotor is at or below the minimum allowable thickness
after refinishing specification; the rotor may not be refinished.
Front brake rotor discard thickness, see DISC BRAKE SPECIFICATIONS .
Rear brake rotor discard thickness, see DISC BRAKE SPECIFICATIONS .
7. If the lowest thickness measurement of the brake rotor is at or below the discard thickness specification;
the rotor requires replacement.
Front Disc Brake Mounting & Hardware Inspection
1. Inspect the disc brake pad mounting hardware for the following:
Missing mounting hardware.
Excessive corrosion.
Bent mounting tabs.
Looseness at the caliper mounting bracket.
Looseness at the disc brake pads.
2. If any of the conditions listed are found, the disc brake pad mounting hardware requires replacement.
3. Ensure the disc brake pads are held firmly in place on the caliper mounting bracket, yet slide easily on the
mounting hardware without binding.
4. Inspect the caliper slide pins by gently pulling outward, without disengaging the slides from the boots,
then pushing inward, and observe for the following: See Fig. 2 .
Binding
Seizing
Looseness
Bent Or Damaged Slide Pins
Cracked Or Torn Slide Pin Boots
Missing Slide Pin Boots
Bent Or Damaged Caliper Mounting Bracket
5. If any of the conditions listed are found, the caliper mounting hardware requires replacement.
Fig. 2: Inspecting Caliper Slide Pins

Rear Disc Brake Mounting & Hardware Inspection
Bent mounting tabs.
4. Inspect the caliper bolts for the following:
Binding
Seizing
Looseness In The Caliper Mounting Bracket
Bent Or Damaged Caliper Bolts
Cracked Or Torn Boots
Missing Boots
Bent Or Damaged Caliper Mounting Bracket
BRAKE ROTOR THICKNESS VARIATION MEASUREMENT
NOTE: Any disc brake rotor that exhibits thickness variation exceeding the maximum
acceptable level must be refinished or replaced. Thickness variation exceeding
the maximum acceptable level can cause brake pulsation.
1. If the inboard friction surface of the brake rotor is not accessible, reposition and support the caliper with
the brake pads.
2. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved brake
cleaner.
3. Using a micrometer calibrated in thousanths-of-a-millimeter, or ten-thousanths-of-an-inch, measure and
record the thickness of the brake rotor at 4 or more points, evenly spaced around the rotor. Ensure that the
measurements are only taken within the friction surfaces and that the micrometer is positioned the same
distance from the outer edge of the rotor, about 0.5 in. (13 mm), for each measurement.
4. Calculate the difference between the highest and lowest thickness measurements recorded to obtain the
amount of thickness variation.
5. Compare the thickness variation measurement to the following specification. See DISC BRAKE
SPECIFICATIONS .
6. If the brake rotor thickness variation measurement exceeds the specification, the rotor requires refinishing
or replacement.
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) CORRECTION
NOTE: Brake rotor thickness variation MUST be checked BEFORE checking for
assembled lateral runout (LRO). Thickness variation exceeding the maximum
acceptable level can cause brake pulsation. See BRAKE ROTOR THICKNESS
VARIATION MEASUREMENT .
NOTE: Brake rotor assembled lateral runout (LRO) exceeding the maximum allowable
specification can cause thickness variation to develop in the brake rotor over
time, usually between 3000-7000 mi (4828-11265 km). See BRAKE ROTOR
ASSEMBLED LATERAL RUNOUT (LRO) MEASUREMENT .
Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications.
Determine which method to use for the specific vehicle being repaired.
A. The indexing method of correcting assembled LRO is most effective when the LRO specification is only
exceeded by a relatively small amount: 0.001-0.005 in (0.025-0.127 mm). Indexing is used to achieve the
best possible match of high spots to low spots between related components. See BRAKE ROTOR
ASSEMBLED LATERAL RUNOUT (LRO) CORRECTION - INDEXING .
B. The correction plate method of correcting assembled LRO involves the addition of a tapered plate
between the brake rotor and the hub/axle flange. The correction plate method can be used to correct LRO
that exceeds the specification by up to 0.009 in (0.23 mm). See BRAKE ROTOR ASSEMBLED
LATERAL RUNOUT (LRO) CORRECTION - CORRECTION PLATES .
C. The on-vehicle brake lathe method is used to bring the LRO to within specifications through
compensating for LRO while refinishing the brake rotor. See BRAKE ROTOR ASSEMBLED
LATERAL RUNOUT (LRO) CORRECTION - ON-VEHICLE LATHE .
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) MEASUREMENT
time, usually between 3000-7000 mi (4828-11265 km).
1. Matchmark the position of the brake rotor to the wheel studs if this has not been done already.
NOTE: Whenever the brake rotor has been separated from the hub/axle flange,
and rust or contaminants should be cleaned from the hub/axle flange and
the brake rotor mating surfaces. Failure to do this may result in excessive
assembled lateral runout (LRO) of the brake rotor, which could lead to
brake pulsation.
2. Inspect the mating surface of the hub/axle flange and the brake rotor to ensure that there are no foreign
particles, corrosion, rust or debris remaining. If the wheel hub/axle flange and/or if the brake rotor mating
surfaces exhibit these conditions, perform the following steps:
A. Remove the brake rotor from the vehicle. See BRAKE ROTOR under REMOVAL &
INSTALLATION.
B. Using the Wheel Hub Resurfacing Kit (J-42450-A), thoroughly clean any rust or corrosion from the
mating surface of the hub/axle flange.
C. Using the Rotor Resurfacing Kit (J-41013), thoroughly clean any rust or corrosion from the mating
surface of the brake rotor.
D. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved
brake cleaner.
3. Install the rotor to the hub/axle flange using the matchmark made prior to removal.
4. Hold the rotor firmly in place against the hub/axle flange and install one of the Conical Brake Rotor
Washers (J-45101-100), and one lug nut onto the upper most wheel stud.
5. Continue to hold the rotor secure and tighten the lug nut firmly by hand.
6. Install the remaining Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts
firmly by hand in a star-pattern.
7. Using the Torque-Limiting Socket Set (J-39544-KIT), or equivalent, tighten the lug nuts in a star-pattern
to specifications, in order to properly secure the rotor. See TORQUE SPECIFICATIONS .
8. If the brake rotor has been refinished or replaced with a NEW rotor, proceed to step 14 .
9. If the brake rotor meets the following criteria, proceed to next step.
The rotor is within specifications and is being reused.
The rotor has NOT been refinished.
The rotor does NOT exhibit thickness variation exceeding the maximum allowable level.
10. Mount a dial indicator, Hub And Wheel Runout Gage (J-45101), or equivalent, to the steering knuckle
and position the indicator button so it contacts the brake rotor friction surface at a 90 degree angel,
approximately 0.5 in. (13 mm) from the outer edge of the rotor.
11. Measure and record the assembled LRO of the brake rotor.
A. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero.
B. Rotate the rotor until the highest reading is displayed on the dial.
C. Mark the locations of the high spot relative to the nearest wheel stud, or studs.
D. Measure and record the amount of LRO.
12. Compare the brake rotor assembled LRO to the following specifications. See LATERAL RUNOUT
SPECIFICATIONS table.
LATERAL RUNOUT SPECIFICATIONS

Application In. (mm)
Front Brake Rotor Maximum Allowable 0.002 (0.06)
Assembled Lateral Runout
Rear Brake Rotor Maximum Allowable 0.002 (0.06)
Assembled Lateral Runout
13. If the brake rotor assembled LRO is within specifications, proceed to step 18 . If the brake rotor
assembled LRO exceeds the specification, refinish the rotor to ensure true parallelism. See BRAKE
ROTOR REFINISHING under SERVICING. After refinishing the rotor, proceed to next step.
14. Mount a dial indicator, Hub And Wheel Runout Gage, or equivalent, to the steering knuckle and position
the indicator button so it contacts the brake rotor friction surface at a 90 degree angle, approximately 0.5
in. (13 mm) from the outer edge of the rotor.
Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero.
Rotate the rotor until the highest reading is displayed on the dial.
Mark the location of the high spot relative to the nearest wheel stud, or studs.
Measure and record the amount of LRO.
16. Compare the brake rotor assembled LRO to the following specifications. See LATERAL RUNOUT
17. If the brake rotor assembled LRO measurement exceeds the specifications, bring the LRO to within
specifications. See BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) CORRECTION .
18. If the brake rotor assembled LRO measurement is within specification, install the brake caliper and
depress the brake pedal several times to secure the rotor in place before removing the Conical Brake
Rotor Washer and the lug nuts.
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) CORRECTION - INDEXING
time, usually between 3000-7000 mi. (4800-11300 km). See BRAKE ROTOR
ASSEMBLED LATERAL RUNOUT (LRO) MEASUREMENT .
1. Remove the Conical Brake Rotor Washers (J-45101-100) and the lug nuts that were installed during the
assembled LRO measurement procedure.
particles or debris remaining.
3. Index the brake rotor in a different orientation to the hub/axle flange.
Washers and one lug nut onto the upper-most wheel stud.
6. Install the remaining Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten nuts
7. Using the Torque-Limiting Socket Set (J-39544-KIT), or equivalent, tighten the lug nuts in a star-pattern
to specification, in order to properly secure the rotor.
8. Measure the assembled LRO of the brake rotor. See BRAKE ROTOR ASSEMBLED LATERAL
RUNOUT (LRO) MEASUREMENT .
9. Compare the amount of change between this measurement and the original measurement.
10. If this measurement is within specifications, proceed to step 14 .
11. If this measurement still exceeds specifications, repeat steps 1 -9 until the best assembled LRO
measurement is obtained.
12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was
originally.
13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, see
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) CORRECTION .
14. If the brake rotor assembled LRO is within specification, install the brake caliper and depress the brake
pedal several times to secure the rotor in place before removing the Conical Brake Rotor Washers and lug
nuts.
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) CORRECTION - CORRECTION

PLATES
NOTE: Brake rotor thickness variation must be checked before checking for
NOTE: Brake rotor assembled lateral runout (LRO) exceeding the maximum
allowable specification can cause thickness variation to develop in the
brake rotor over time, usually between 3000-7000 mi. (4800-11000 km). See
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) MEASUREMENT .
1. Rotate the brake rotor to position the high spot, identified and marked during the brake rotor assembled
LRO measurement procedure, to face upward.
assembled LRO measurement procedure and/or the indexing correction procedure.
3. Inspect the mounting surface of the hub/axle flange and the brake rotor to ensure that there are no foreign
4. Select the correction plate, following the manufacturer's instructions, which has a specification closest to
the assembled LRO measurement. For example: If the assembled LRO measurement was 0.003 in. (0.076
mm), the 0.003 in. (0.076 mm) correction plate would be used. If the measurement was 0.005 in. (0.127
mm), the 0.006 in. (0.152 mm) correction plate would be used.
5. Determine the positioning for the correction plate using the high spot mark made during the brake rotor
assembled LRO measurement procedure.
NOTE: DO NOT install used correction plates in an attempt to correct brake rotor
assembled lateral runout (LRO).
NOTE: DO NOT stack up, or install more than one correction plate onto one
hub/axle flange location, in an attempt to correct brake rotor assembled
LRO.
6. Install the correction plate onto the hub/axle flange, with the V-shaped notch orientated to align with the
high spot mark, that was positioned to face upward.
7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper
orientation to the flange.
Washers and one lug nut onto the upper-most wheel stud.
10. Install the remaining Conical Brake Rotor Washers and lug nuts onto the wheel studs and tighten the nuts
11. Using the Torque-Limiting Socket Set, or equivalent, tighten the lug nuts in a star-pattern to specification,
in order to properly secure the rotor.
depress the brake pedal several times to secure the rotor in place before removing the Conical Brake
Rotor Washers and lug nuts.
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) CORRECTION - ON-VEHICLE LATHE
NOTE: Brake rotor thickness variation must be checked before checking for
NOTE: Brake rotor assembled lateral runout (LRO) exceeding the maximum
brake rotor over time, usually between 3000-7000 mi. (4800-11300 km). See
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) MEASUREMENT .
1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any
rotating components, such as the brake rotor.
assembled LRO measurement procedure and/or the indexing correction procedure.
4. Set up the lathe, following the manufacturer's instructions.
5. Refinish the brake rotor, following the brake lathe manufacturer's instructions.
6. After each successive cut, inspect the brake rotor thickness.
7. If at any time the brake rotor exceeds the minimum allowable thickness after refinish specification, the
brake rotor must be replaced. After replacing the rotor, proceed to step 10 .
8. After refinishing the brake rotor, use the following procedure in order to obtain the desired non-
directional finish:
A. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional
finish
B. Using moderate pressure, apply the non-directional finish:
If the lathe is equipped with a non-directional finishing tool, apply the finish with 120 grit
aluminum oxide sandpaper.
If the lathe is not equipped with a non-directional finishing tool, apply the finish with a
sanding block and 150 grit aluminum oxide sandpaper.
C. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured
alcohol, or an equivalent approved brake cleaner.
9. Remove the lathe from the vehicle.
pedal several times to secure the rotor in place before removing the Conical Brake Rotor Washers and the
lug nuts.
REAR DRUM BRAKE
Brake Drum Diameter Measurement
1. Clean the brake shoe lining contact surface of the brake drum with denatured alcohol or an equivalent
brake cleaner.
2. Using a brake drum micrometer calibrated in thousands of an inch, measure and record the largest
diameter of the brake drum at four or more points, equally spaced around the drum. Ensure that the
measurements are only taken within the brake shoe lining contact area and that the micrometer is
positioned the same distance from the outside edge of the drum for each measurement.
3. Compare the largest diameter measurement recorded to the following specifications:
Brake drum maximum allowable diameter after refinishing, see DRUM BRAKE
SPECIFICATIONS .
Brake drum discard diameter, see DRUM BRAKE SPECIFICATIONS .
4. If the largest diameter measurement of the brake drum is less than the maximum allowable diameter after
refinishing specification; the drum may be able to be refinished, depending upon surface and wear
5. If the largest diameter measurement of the brake drum is equal to or greater than the maximum allowable
diameter after resurfacing specification; the drum may not be refinished.
6. If the largest diameter measurement of the brake drum is equal to or greater than the discard diameter
specification; the drum requires replacement.
Brake Drum Surface & Wear Inspection
1. With the brake drum removed, clean the braking (friction) surface of the brake drum with denatured
alcohol or an equivalent approved brake cleaner.
2. Inspect the braking surface of the brake drum for the following Braking Surface Conditions:
Heavy rust and/or pitting Light surface rust can be removed with an abrasive disc; heavy surface
rust and/or pitting must be removed by refinishing the drum.
Missing balance weights
3. If the braking surface of the brake drum exhibits one or more of the Braking Surface Conditions, the
drum requires refinishing or replacement.
4. Using a brake drum micrometer calibrated in thousands of an inch, measure and record any grooves
present on the drum braking surface. Ensure that the measurements are only taken within the brake shoe
lining contact area.
5. Compare the groove (scoring) depth recorded to the following specification: Brake drum maximum
allowable scoring, see DRUM BRAKE SPECIFICATIONS .
6. If the brake drum scoring depth exceeds the specification, or if an excessive amount of scoring is present,
the drum requires refinishing or replacement.
7. Mount the brake drum on a brake lathe.
8. Mount a dial indicator, (J-8001) or equivalent, and position the indicator button so it contacts the braking
surface of the brake drum at a 90 degree angle, approximately 0.75 in (19 mm) from the drum's outer
edge.
9. Measure and record the radial runout of the brake drum.
A. Rotate the drum until the lowest reading is displayed on the indicator dial, then zero the dial.
B. Rotate the drum until the highest reading is displayed on the dial.
10. Compare the radial runout of the brake drum to the following specification: Brake drum maximum
allowable radial runout, see DRUM BRAKE SPECIFICATIONS .
11. If the brake drum radial runout exceeds the specification, the drum requires refinishing or replacement.
Drum Brake Adjustment

2. Remove the rear wheels and tires.
3. Relieve cable tension from the park brake system at the equalizer. There should be no tension on the park
brake cables, so that the brake shoes are positioned only by the adjuster strut.
4. Remove the rear drums. See BRAKE DRUM under REMOVAL & INSTALLATION.
5. Set the Drum-to-Brake Shoe Clearance Gage (J-21177-A) so that it contacts the inside diameter of the
drum at the widest point.
6. Position the drum-to-brake shoe clearance gage over the shoes at the widest point.
7. Turn the adjuster nut until the shoes just contact the clearance gage.
8. Repeat steps 2 -5 for the other rear brake assembly.
9. Install the rear drums. See BRAKE DRUM under REMOVAL & INSTALLATION.
10. Install the rear wheels and tires.
11. Adjust the park brake cable. See appropriate procedure under PARK BRAKE .
Drum Brake Adjusting Hardware Inspection
1. Visually inspect the adjuster actuator spring for the following:

Excessive Corrosion
Excessive Stretching
Broken Hook Ends
Twisting Or Binding
Missing
2. If any of the conditions listed were found, the drum brake system adjuster hardware requires replacement.
3. Visually inspect the adjuster actuator lever for the following conditions:
Bent
Broken
Missing
Broken Spring Attachment Tab
4. If any of the conditions listed were found, the adjuster actuator lever and/or attaching hardware requires
replacement.
Drum Brake Hardware Inspection
1. Visually inspect the drum brake system universal spring for the following:
Bent Or Damaged
Broken Or Excessive Corrosion
Twisting Or Binding
2. If any of the conditions listed were found, the drum brake system hardware requires replacement.
3. Visually inspect the park brake lever for the following:
Bent
Broken Pivot
Broken At Park Brake Cable Attachment
4. If any of the conditions listed were found, the park brake lever and/or attaching hardware requires
replacement.
HYDRAULIC BRAKE SYSTEM
Brake Pipe & Hose Inspection
1. Visually inspect all of the brake pipes for the following conditions:
Kinks improper routing missing or damaged retainers
Leaking fittings, excessive corrosion.
2. If any of the brake pipes exhibited any of the conditions listed, then the identified pipe, or pipes, require
replacement.
3. Ensure that the vehicle axles are properly supported at ride height in order to maintain the proper
relationship of the flexible brake hoses to the chassis.
4. Visually inspect all of the flexible brake hoses for the following conditions:
Kinks, improper routing, twists, chafing, missing or damaged retainers.
Leaking connections, cracking, dry-rot, blisters, bulges.
5. If any of the flexible brake hoses exhibited any of the conditions listed, then the identified flexible brake
hose, or hoses require replacement.
6. Squeeze the flexible brake hoses with firm finger pressure to check for soft spots, indicating an internal
restriction. Check the entire length of each flexible brake hose.
7. If any of the flexible brake hoses were found to have soft spots, then the identified flexible brake hose, or
hoses require replacement.
Brake System External Leak Inspection
1. In order to inspect for external brake fluid leaks, first check the fluid level in the master cylinder. While a
slight brake fluid level drop can be considered a normal condition due to brake lining wear, a very low
level may indicate a brake fluid leak in the hydraulic system.
2. If the fluid level is abnormally low, adjust the brake fluid level. See MASTER CYLINDER
RESERVOIR under BLEEDING, FILLING & FLUSHING BRAKE SYSTEM.
3. Start the engine and allow it to idle.
4. Apply constant, moderate foot pressure to the brake pedal. If the brake pedal gradually falls away while
under foot pressure, there may be a brake fluid leak.
6. Visually inspect the following brake system components for brake fluid leaks, excessive corrosion, and
damage. Give particular attention to all brake pipe and flexible hose connections to ensure that there are
not any slight brake fluid leaks, even though the brake pedal may feel firm and hold steady:
Master Cylinder Brake Pipe Fittings
All Brake Pipe Connections
Brake Pipes
Brake Hoses And Connections
Brake Calipers And/Or Wheel Cylinders, If Equipped
7. While slight dampness around the master cylinder reservoir can be considered acceptable, brake fluid
leaking from any of the brake system components requires immediate attention. If any of these
components exhibit signs of brake fluid leakage, repair or replace those components. After the repair or
replacement, reinspect the hydraulic brake system to assure proper function.
Brake System Internal Leak Inspection

2. Apply light, steady pressure to the brake pedal. Observe both the brake pedal feel and travel.
3. Release the brakes and turn OFF the ignition.
4. If the brake pedal apply felt spongy, but the brake pedal travel was not excessive, perform the following
steps:
INSPECTION .
B. Pressure bleed the brake system in order to purge any air that may be trapped in the system. See
HYDRAULIC BRAKE SYSTEM BLEEDING under BLEEDING, FILLING & FLUSHING
BRAKE SYSTEM.
5. If the brake pedal apply did not feel spongy, but the brake pedal travel was excessive, perform the
following steps:
A. Loosen the master cylinder-to-brake power booster mounting nuts.
B. Carefully pull the master cylinder away from the brake power booster just enough to inspect the
mounting surface of the master cylinder.
C. Inspect the master cylinder mounting surface at the primary piston for brake fluid leaks.
6. If the master cylinder exhibits any leakage around the primary piston, then the primary piston primary
seal and/or secondary seal is leaking and the master cylinder requires overhaul or replacement.
7. If the master cylinder primary piston does not exhibit any leakage, pressure bleed the brake system. See
HYDRAULIC BRAKE SYSTEM BLEEDING under BLEEDING, FILLING & FLUSHING BRAKE
SYSTEM.
8. If the brake pedal apply did not feel spongy, and the brake pedal travel was initially steady and not
excessive, but then gradually fell, then the master cylinder requires overhaul or replacement due to an
internal leak past the secondary piston from the secondary piston primary seal or secondary seal.
excessive, then fell slightly, then became steady again, then the Brake Pressure Modulator Valve (BPMV)
may be leaking internally, and may require replacement.
Hydraulic Brake Component Operation Visual Inspection - Disc
1. With the tire and wheel assemblies removed and the brake rotors retained by wheel lug nuts, visually
inspect the caliper piston dust boot sealing area to ensure that there are no brake fluid leaks.
2. If any evidence of a brake fluid leak is present, the brake caliper requires overhaul or replacement.
3. While the brake system is at rest, observe the position of the caliper piston in relation to the caliper
housing.
4. Have an assistant apply and release the brake pedal several times while you observe the operation of the
hydraulic brake caliper.
A. Observe the caliper piston for unrestricted and even movement during each apply of the brake
system.
B. Observe the caliper piston for an unrestricted and even return motion during each release of the
brake system.
See Fig. 3 .
5. If the caliper piston did not exhibit unrestricted and even movement during brake system apply and/or
release, the piston square seal may be worn or damaged and the caliper may require overhaul or
replacement.
Fig. 3: Inspecting Hydraulic Brake Component Operation
Hydraulic Brake Component Operation Visual Inspection - Drum
1. With the rear tire and wheel assemblies and the brake drums removed, visually inspect the wheel cylinder
pistons boot sealing areas to ensure that there are no brake fluid leaks.
2. If any evidence of a brake fluid leak is present, the brake wheel cylinder requires replacement.
3. Using firm hand pressure, simultaneously and evenly apply force on both brake shoes in order to
compress the wheel cylinder pistons into their bore.
4. Evenly release the force from both brake shoes to allow the wheel cylinder pistons to return.
5. If one or both of the wheel cylinder pistons did not exhibit unrestricted and even movement during apply
and/or release of force, the wheel cylinder may require replacement.
PARK BRAKE
NOTE: Perform the Park Brake System Check prior to performing this procedure in
order to ensure that all of the park brake system components are operating
properly.
Disc Adjustment
1. Apply the park brake until three clicks are heard.

3. Use your hands in order to rotate both of the rear wheels.
If both of the rear the wheels exhibit drag or do not rotate, the park brake cable is adjusted properly,
go to step 8 .
If either of the rear wheels rotate freely, go to next step.
NOTE: The brake linings must be adjusted prior to adjusting the park brake cable.
4. Adjust the applicable brake lining as necessary.

5. For vehicles with drum brakes. See DRUM BRAKE ADJUSTMENT .
6. Tighten the park brake equalizer nut until both rear wheels exhibit drag or do not rotate.
7. Release the park brake.
8. Verify that both rear wheels rotate freely.
9. For vehicles with rear disc, verify that the park brake actuator levers have returned to their stops (full
release position). If the park brake levers do not return to their stops (full release position), adjust the park
brake shoe and lining.
Drum Adjustment
1. Apply and fully release the park brake six times. Verify that the park brake pedal releases completely.
2. Turn ON the ignition. Verify that the BRAKE indicator lamp is off. If the BRAKE lamp is on, then check
the following:
Ensure that the park brake is in release mode and fully returned to the stop.
Check the front park brake cable slack. Remove the slack in the front park brake cable by pulling
downward on the cable.
4. Remove the rear wheels and tires.
5. Adjust the drum brakes. See DRUM BRAKE ADJUSTMENT .
6. Install the rear wheels and tires.
7. Adjust the park brake system by turning the nut at the equalizer while spinning both rear wheels. When
either rear wheel starts to drag, back off the nut one full turn.
8. Lower the vehicle to curb height.
9. Apply the park brake five clicks and check the forward rotation of the rear wheels. With five clicks
applied it should be very difficult to turn by hand (should require 30-40 N.m of torque, measured with a
torque wrench on a wheel stud). With less then five clicks applied, wheels should turn easily by hand.
Readjust the equalizer nut as needed to obtain this condition.
10. Release the park brake. Verify that the wheels rotate freely.
Park Brake Inspection - Disc

3. Remove the rear brake caliper bracket with the rear brake caliper. See BRAKE CALIPER BRACKET
under REMOVAL & INSTALLATION.
4. Remove the rear brake rotor. See BRAKE ROTOR under REMOVAL & INSTALLATION.
5. Inspect the park brake shoe and lining. If it exhibits any of the following conditions, then it requires
replacement :
Excessive wear indicated by the park brake lining being worn down to the shoe.
Brake lining cracking.
Oil or fluid contamination of the brake lining.
6. Install the rear brake rotor. See BRAKE ROTOR under REMOVAL & INSTALLATION.
7. Install the rear brake caliper with the rear brake caliper bracket. See BRAKE CALIPER BRACKET
Park Brake Inspection - Drum
1. With the brake drums removed, visually inspect the upper return/adjuster actuator spring and the lower
return spring for the following:
Excessive Corrosion
Broken Hook Ends
Twisting Or Binding
2. If any of the conditions listed were found, which could lead to improper park brake apply and/or release,
the adjuster hardware and/or return springs require replacement.
3. Visually inspect the adjuster and the adjuster actuator lever for the following:
Misalignment with the park brake lever.
Misalignment with the drum brake shoes.
Broken or bent adjuster actuator lever.
Bent adjuster actuator lever pivot pin.
the adjuster hardware requires repair or replacement.
5. Inspect the park brake lever for the following:
Bent
Broken Pivot Pin
Seized At The Pivot Pin
Broken At Park Brake Cable Attachment
Improper Contact With The Adjuster
the park brake lever requires repair or replacement.
7. Visually inspect the park brake cable for the following:
Improper mounting to the backing plate.
Improper mounting at the park brake lever.
Broken or missing cable end lug.
the park brake cable requires repair or replacement.
9. Apply the park brake lever/pedal three clicks.
Unequal travel between the left and the right park brake systems.
No travel on one or both of the park brake systems.
the park brake cable requires replacement and/or adjustment.
12. Release the park brake lever/pedal.
Unequal release between the left and the right park brake systems.
No release at one or both of the park brake systems.

the park brake cable requires replacement and/or adjustment.
TROUBLE SHOOTING
GENERAL DIAGNOSIS
The following steps must be completed before performing symptom tests.
1. Perform the Vehicle Road Test in order to duplicate the customer's concern before performing any
symptom test. See VEHICLE ROAD TEST under SYSTEM TESTS.
2. Review DESCRIPTION & OPERATION in order to familiarize yourself with the system functions.
Inspect for aftermarket devices which could affect the operation of the hydraulic brake system.
cause the symptom.
Intermittent
Faulty electrical connections or wiring may be the cause of intermittent conditions.
Symptom List
To diagnose brake system by symptom, refer to the appropriate symptom test under SYMPTOM TESTS from
the following list in order:
BRAKE WARNING INDICATOR ALWAYS ON

BRAKE WARNING INDICATOR INOPERATIVE
BRAKE PULSATION
BRAKE SYSTEM NOISE
BRAKING ACTION UNEVEN
BRAKE PEDAL EXCESSIVE TRAVEL
BRAKE PEDAL EXCESSIVE EFFORT
BRAKES DRAG
BRAKE SYSTEM SLOW RELEASE
BRAKE FLUID LOSS
PARK BRAKE WILL NOT HOLD OR RELEASE
SELF DIAGNOSTIC SYSTEM
NOTE: For more information on scan tool usage and data lists, see appropriate BODY
CONTROL MODULES article in ACCESSORIES & EQUIPMENT.
SCAN TOOL DATA LIST
SCAN TOOL DATA LIST (INSTRUMENT PANEL CLUSTER)

(1) Scan Tool Data List Units Displayed Typical Data Value
Parameter
Low Brake Fluid Level Volts 2.5
Park Brake Switch Inputs for Analog Dash Off/On Off
(1) Ignition ON, engine OFF, brake fluid level normal, and park brake released.
Brake Fluid Level
Scan tool displays: okay or Low. The status of the brake fluid level sensor signal.
Park Brake Switch
Scan tool displays: Applied/Released - Display indicates the state of the brake switch.
Red Brake Warning Indicator
Scan tool displays: Off/On - Display indicates if the red BRAKE warning indicator is currently ON.
SYSTEM TESTS
VEHICLE ROAD TEST
1. Visually inspect easily accessible brake system components for obvious damage and/or leaks which may
indicate that the vehicle should not be driven until further inspections have been completed.
2. Inspect the brake master cylinder reservoir fluid level and adjust only if necessary for brake system road
testing. See MASTER CYLINDER RESERVOIR under BLEEDING, FILLING & FLUSHING
BRAKE SYSTEM.
3. Inspect the tire inflation pressures and adjust as necessary.
4. Inspect the tire tread patterns to ensure that they are the same or very similar, especially per axle.
5. Ensure that the vehicle is not loaded unevenly prior to brake system road testing.
Road Test Procedure
WARNING: Road test a vehicle under safe conditions and while obeying all traffic
laws. Do not attempt any maneuvers that could jeopardize vehicle control.
Failure to adhere to these precautions could lead to serious personal
injury and vehicle damage.

2. Check to see if the brake system warning lamp remains illuminated.
3. If the brake system warning lamp remains illuminated, DO NOT proceed to test drive the vehicle until it
is diagnosed and repaired. See HYDRAULIC BRAKE SYSTEM DIAGNOSIS under TROUBLE
SHOOTING.
4. Select a smooth, dry, clean and level road or large lot that is as free of traffic and obstacles as possible for
brake system low speed road testing.
5. With the transmission in PARK, lightly apply the brake pedal. Observe both the pedal feel and the pedal
travel.
6. If the brake pedal apply felt spongy, or the pedal travel was excessive, DO NOT drive the vehicle until it
is repaired.
7. If the brake pedal apply did not feel spongy and the pedal travel was not excessive, proceed to next step.
8. Release and apply the brakes.
9. While continuing to apply the brakes, shift the transmission into DRIVE, release the brakes and allow the
engine to idle the vehicle away from the stopped position. Observe for a slow release of the brake system.
10. With the aid of an assistant to observe the vehicle's performance from outside of the vehicle, drive the
vehicle at a low speed and lightly apply the brakes while driving past the assistant. Have the assistant
observe for brake system noise from the side of the vehicle closest to them, while you observe both the
pedal effort and the pedal travel.
11. If the brake pedal apply effort was excessive, or the pedal travel was excessive, DO NOT continue to test
drive the vehicle until it is repaired.
12. If the brake pedal apply effort was not excessive and the pedal travel was not excessive, proceed to next
step.
13. Drive the vehicle in the opposite direction, at the same low speed and lightly apply the brakes while
driving past the assistant. Have the assistant observe for brake system noise from the side of the vehicle
closest to them.
14. Drive the vehicle at a low speed and shift the transmission into NEUTRAL without applying the brakes.
Observe for a rapid deceleration in vehicle speed, indicating possible brake drag.
15. Select a smooth, dry, clean and level road that is as free of heavy traffic as possible for brake system
moderate speed road testing.
16. Drive the vehicle at a moderate speed. Observe for a pull and/or incorrect tracking of the vehicle without
the brakes applied.
17. While continuing to drive the vehicle at a moderate speed, perform several light applies of the brakes.
Observe the pedal effort and the pedal travel, observe for brake system noise, pulsation and/or brake drag.
19. If the brake pedal apply effort was not excessive and the pedal travel was not excessive, proceed to next
step.
20. While continuing to drive the vehicle at a moderate speed, perform several moderate applies of the
brakes. Observe the pedal effort and the pedal travel, observe for brake system pulsation and/or uneven
braking action, either side to side, or front to rear. A small amount of vehicle front end dip is expected
during a moderate apply of the brakes.
BRAKE ASSIST DIAGNOSIS
1. Were you sent here from a Symptom Test? If so, go to next step. If not, go to GENERAL DIAGNOSIS
under TROUBLE SHOOTING.
2. Inspect for proper brake pedal travel. See BRAKE PEDAL TRAVEL MEASUREMENT &
INSPECTION under BRAKE PEDAL in ADJUSTMENTS & INSPECTION. Is the brake pedal travel
distance within the acceptable limits? If so, go to step 5 . If not, go to next step.
3. Inspect for worn, missing, misaligned, bent or damaged brake pedal system components.
For the brake pedal pushrod component inspection, see BRAKE PEDAL PUSHROD
INSPECTION under BRAKE PEDAL in ADJUSTMENTS & INSPECTION.
Inspect the brake pedal bushings for excessive wear and/or damage and inspect the brake pedal for
a misaligned, bent and/or damaged condition.
Replace the brake pedal system components that are worn, missing, misaligned, bent or damaged, refer to
the following procedures as necessary.
BRAKE PEDAL ASSEMBLY under REMOVAL & INSTALLATION
VACUUM BRAKE BOOSTER under REMOVAL & INSTALLATION (for a bent or damaged
pedal pushrod replacement)
Did you find and replace any worn, missing, misaligned, bent or damaged brake pedal system
components? If so, go to next step. If not, go to step 5 .
4. Reinspect for proper brake pedal travel. See BRAKE PEDAL TRAVEL MEASUREMENT &
5. Check the engine vacuum source that supplies vacuum to the vacuum brake booster. See BRAKE
VACUUM SOURCE TEST under SYSTEM TESTS. Is the vacuum reading within the acceptable
limits? If so, go to next step. If not, diagnose and repair low engine vacuum.
6. During the vacuum source inspection, did the vacuum booster check valve operate properly? If so, go to
step 8 . If not, go to next step.
7. Replace the vacuum booster check valve. See VACUUM BRAKE BOOSTER CHECK VALVE
AND/OR HOSE under REMOVAL & INSTALLATION. After completing the replacement, go to next
step.
8. Pump the brake pedal several times until the brake pedal becomes hard. Maintain moderate foot pressure
on the brake pedal and start the engine. Observe pedal operation. Did the brake pedal drop slightly, then
remain firm after the engine was started? If so, go to next step. If not, the go to step 12 .
9. Release the brake pedal. Turn the ignition OFF, then wait 15 seconds. Pump the brake pedal 2 times to
check for vacuum booster available vacuum reserve. Observe pedal effort. (If operating properly, the
vacuum brake booster should maintain assist for at least 2 pedal applications.) Did the brake pedal effort
increase significantly? If so, go to step 12 . If not, go to next step.
10. Inspect the brake pedal pushrod and the brake pedal for misalignment, a bent condition and/or damage. Is
the brake pedal pushrod and/or the brake pedal misaligned, bent or damaged? If so, go to next step. If not,
go to step 13 .
11. Replace the brake pedal pushrod and/or the brake pedal, as necessary. Refer to the following procedure
(s).
BRAKE PEDAL ASSEMBLY under REMOVAL & INSTALLATION.
VACUUM BRAKE BOOSTER under REMOVAL & INSTALLATION (for a bent or damaged
pedal pushrod replacement).
After completing the replacement, go to step 13 .
12. Replace the vacuum brake booster. VACUUM BRAKE BOOSTER under REMOVAL &
INSTALLATION. After completing the replacement, go to next step.
13. Install or connect any components that were removed or disconnected during diagnosis. After completing
the operation, the system should be okay.
DISC BRAKE DIAGNOSIS
2. Visually inspect the disc brake pads for the following:
Lining thickness.
Uneven and/or abnormal wear (edge-to-edge and/or side-to-side).
Evidence of contamination from an external substance.
Looseness or damage (including pad hardware).
Did you find any conditions to indicate a concern with any of the (front and/or rear) disc brake pads? If
so, go to next step. If not, go to step 12 .
3. Are any of the (front and/or rear) disc brake pads contaminated? If so, go to step 8 . If not, go to next step.
4. Are any of the (front and/or rear) disc brake pads worn unevenly? If so, go to step 7 . If not, go to next
step.
5. Are any of the (front and/or rear) disc brake pads and/or pad hardware loose or damaged? If so, go to step
7 . If not, go to next step.
6. Remove and inspect the worn disc brake pads for glazing, looseness, heat spots or damage. Replace the
worn disc brake pads as a complete axle set. See BRAKE PADS under REMOVAL &
INSTALLATION. After completing the inspection and replacement, go to step 12 .
7. Support the brake caliper with heavy mechanic's wire, or equivalent, whenever it is separated from it's
mount and the hydraulic flexible brake hose is still connected. Failure to support the caliper in this
manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to
the brake hose and in turn may cause a brake fluid leak.
A. Remove the (front and/or rear) disc brake calipers (as appropriate) from the mounting brackets and
support the calipers. DO NOT disconnect the hydraulic brake flex hoses from the calipers. See
BRAKE CALIPER under REMOVAL & INSTALLATION.
B. Inspect the disc brake caliper mounting bracket and the mounting/sliding hardware for the
following conditions: See FRONT DISC BRAKE MOUNTING & HARDWARE
INSPECTION and REAR DISC BRAKE MOUNTING & HARDWARE INSPECTION , if
equipped, under FRONT & REAR DISC BRAKE in ADJUSTMENTS & INSPECTION.
Loose, bent, cracked, or damaged caliper mounting bracket.
Binding or seized hardware.
Worn, damaged or missing hardware components.
C. Replace components as required. Refer to the following procedures, as required:

BRAKE CALIPER BRACKET and/or BRAKE HARDWARE under REMOVAL &
INSTALLATION.
D. Replace the unevenly-worn, loose or damaged disc brake pads as a complete axle set. See BRAKE
PADS under REMOVAL & INSTALLATION.
After completing the inspection and replacement, go to step 12 .
8. Inspect the disc brake calipers, brake hoses and brake pipes for evidence of an external brake fluid leak.
Replace any components found to be leaking brake fluid. Refer to the following procedures as required:
BRAKE CALIPER - FRONT under OVERHAUL or BRAKE CALIPER under REMOVAL &
INSTALLATION.
BRAKE CALIPER - REAR under OVERHAUL or BRAKE CALIPER under REMOVAL &
INSTALLATION, if equipped.
BRAKE PIPE under REMOVAL & INSTALLATION
Did you find and correct the source of the leak causing contamination of the pads? If so, go to step 11 . If
no, go to next step.
9. Inspect the wheel drive shaft outer seals (boots) for damage and evidence of a grease leak. Replace any
wheel drive shaft seal (boot) that is found to be leaking grease which may be the source of the
contamination to the pads. See appropriate AXLE SHAFTS article in DRIVELINES/AXLES. Did you
find and correct the source of the leak causing contamination of the pads? If so, go to step 11 . If not, go
to next step.
10. Inspect the following systems for damage and evidence of an external fluid leak and replace any
components found to be leaking fluid which may be the source of the contamination to the pads. Refer to
the following procedures:
For power steering leaks, see TROUBLE SHOOTING article in GENERAL INFORMATION.
For transmission leaks, See ON-VEHICLE REPAIRS in SERVICING - AZTEK &

RENDEZVOUS article in TRANSMISSIONS.
Did you find and correct the source of the leak causing contamination of the pads? If so, go to next step.
11.
A. Clean the remaining disc brake system components to remove any traces of the contaminant.
NOTE: Support the brake caliper with heavy mechanic's wire, or equivalent,
whenever it is separated from it's mount and the hydraulic flexible
brake hose is still connected. Failure to support the caliper in this
manner will cause the flexible brake hose to bear the weight of the
caliper, which may cause damage to the brake hose and in turn may
cause a brake fluid leak.
B. Remove the (front and/or rear) disc brake calipers (as appropriate) from the mounting brackets and
support the calipers. DO NOT disconnect the hydraulic brake flex hoses from the calipers. See
BRAKE CALIPER under REMOVAL & INSTALLATION.
C. Inspect the disc brake caliper mounting/sliding hardware for the following conditions: See FRONT
DISC BRAKE MOUNTING & HARDWARE INSPECTION and REAR DISC BRAKE
MOUNTING & HARDWARE INSPECTION , if equipped, under FRONT & REAR DISC
BRAKE in ADJUSTMENTS & INSPECTION.
Binding or seized hardware.
Distorted, worn, damaged or missing hardware components.
D. Replace the caliper mounting/sliding hardware components as required. See BRAKE

HARDWARE under REMOVAL & INSTALLATION.
E. Replace the contaminated disc brake pads as a complete axle set. See BRAKE PADS under
REMOVAL & INSTALLATION.
After completing the cleaning, inspection and replacement, go to next step.
12. Check the thickness of each of the disc brake rotors. Make a determination for each brake rotor if the
rotor can be REFINISHED and REMAIN ABOVE the minimum requirements. See BRAKE ROTOR
THICKNESS MEASUREMENT under FRONT & REAR DISC BRAKE in ADJUSTMENTS &
INSPECTION. Does the disc brake rotor meet the minimum requirements for REFINISHING? If so, go
to next step. If not, go to step 15 .
13.
Inspect each of the disc brake rotors for the following surface and wear conditions: See BRAKE
ROTOR SURFACE & WEAR INSPECTION under FRONT & REAR DISC BRAKE in
ADJUSTMENTS & INSPECTION.
Braking Surface Conditions:
Heavy rust and/or pitting.

Cracks and/or heat spots.
Excessive blueing discoloration.
Braking Surface Wear Conditions:
Deep or excessive scoring beyond maximum acceptable level.

Lateral runout beyond maximum acceptable level.
Thickness variation beyond maximum acceptable level.
Make a determination for each brake rotor if the rotor requires refinishing based upon the results of
the inspection. If the brake rotor exhibits any of the following conditions, it requires refinishing.
Rotor exhibits one or more of the Braking Surface Conditions listed previously.
Rotor is beyond the acceptable level in one or more of the Braking Surface Wear Conditions
listed previously.
Does the brake rotor require REFINISHING? If so, go to next step. If not, go to step 18 .
14.
A. Refinish the brake rotor. See BRAKE ROTOR REFINISHING under SERVICING.
B. Inspect the brake rotor thickness. See BRAKE ROTOR THICKNESS MEASUREMENT under
FRONT & REAR DISC BRAKE in ADJUSTMENTS & INSPECTION.
Were you able to REFINISH the brake rotor within the minimum requirements? If so, go to step 18 . If
not, go to step 17 .
15. Is the brake rotor at or below the DISCARD requirements? If so, go to step 17 . If not, go to next step.
16.
A. Inspect each of the disc brake rotors for the following surface and wear conditions: See BRAKE
Braking Surface Conditions
Heavy rust and/or pitting

Braking Surface Wear Conditions
Deep or excessive scoring beyond maximum acceptable level

Lateral runout beyond maximum acceptable level
Thickness variation beyond maximum acceptable level
B. Make a determination for each brake rotor if the rotor requires replacement based upon the results
of the inspection. If a brake rotor exhibits any of the following conditions, it requires replacement.
Rotor exhibits one or more of the Braking Surface Conditions listed previously
Rotor is beyond the acceptable level in one or more of the Braking Surface Wear Conditions
listed previously
Does the brake rotor require REPLACEMENT? If so, go to next step. If not, go to step 18 .
17. Replace the brake rotor. See BRAKE ROTOR under REMOVAL & INSTALLATION. After
completing the replacement, go to next step.
18. Install or connect components that were removed or disconnected during diagnosis. After completing the
operation, the system should be okay.
DRUM BRAKE DIAGNOSIS
2. Remove the brake drums. See BRAKE DRUM under REMOVAL & INSTALLATION. Inspect the
drum brake shoes for the following conditions:
Lining thickness below specifications.
Uneven and/or abnormal wear - edge-to-edge and/or side-to-side.
Contamination from an external substance.
Looseness, damage, glazing, or incorrect lining material.
Did you find any conditions to indicate a concern with any of the drum brake shoes? If so, go to next step.
If not, go to step 7 .
3. Are any of the brake shoes contaminated? If so, go to next step. If not, go to step 5 .
4. Inspect the wheel cylinders for evidence of an external brake fluid leak. Replace any wheel cylinder that
is found to be leaking brake fluid. See WHEEL CYLINDER under REMOVAL & INSTALLATION.
After completing the inspection and replacement, go to step 6 .
5. Inspect the drum brake hardware for any components which are worn, damaged, discolored due to stress,
broken or missing. See DRUM BRAKE HARDWARE INSPECTION under ADJUSTMENTS &
INSPECTION. Replace components as required. See BRAKE HARDWARE under REMOVAL &
INSTALLATION. Replace the drum brake shoes. See BRAKE SHOE under REMOVAL &
INSTALLATION. After completing the inspection and replacement, go to step 8 .
6. Clean the remaining drum brake system components to remove any traces of the contaminant. Inspect the
drum brake hardware for any components which are worn, damaged, discolored due to stress, broken or
missing. See DRUM BRAKE HARDWARE INSPECTION under ADJUSTMENTS & INSPECTION.
Replace the drum brake hardware components as required. See BRAKE HARDWARE under
REMOVAL & INSTALLATION. Replace the contaminated brake shoes. See BRAKE SHOE under
REMOVAL & INSTALLATION. After completing the cleaning, inspection and replacement, go to step
8.
7. Inspect the drum brake hardware for any components which are worn, damaged, discolored due to stress,
broken or missing. See DRUM BRAKE HARDWARE INSPECTION under ADJUSTMENTS &
INSPECTION. Replace components as required. See BRAKE HARDWARE under REMOVAL &
INSTALLATION. After completing the inspection and, if necessary, the replacement, go to next step.
8. Check the diameter of each of the brake drums. Make a determination for each brake drum if the drum
can be REFINISHED and REMAIN ABOVE the minimum requirements. See BRAKE DRUM
DIAMETER MEASUREMENT under REAR DRUM BRAKE in ADJUSTMENTS & INSPECTION.
Does the brake drum meet the minimum requirements for REFINISHING? If so, go to next step. If not,
go to step 11 .
9.
A. Inspect each of the brake drums for the following surface and wear conditions: See BRAKE
DRUM SURFACE & WEAR INSPECTION under REAR DRUM BRAKE in ADJUSTMENTS
& INSPECTION.
Heavy rust and/or pitting.

Missing balance weights.
Deep or excessive scoring beyond maximum acceptable level.

Radial runout beyond maximum acceptable level.
B. Make a determination for each brake drum if the drum requires refinishing based upon the results
of the inspection. If the brake drum exhibits any of the following conditions, it requires refinishing.
Drum exhibits one or more of the Braking Surface Conditions listed previously.
Drum is beyond the acceptable level in one or more of the Braking Surface Wear Conditions
listed previously
Does the brake drum require REFINISHING? If so, go to next step. If not, go to step 14 .
10. Refinish the brake drum. See BRAKE DRUM REFINISHING under SERVICING. Inspect the brake
drum diameter. See BRAKE DRUM DIAMETER MEASUREMENT under REAR DRUM BRAKE in
ADJUSTMENTS & INSPECTION. Were you able to REFINISH the brake drum within the minimum
requirements? If so, go to step 14 . If not, go to step 13 .
11. Is the brake drum at or below the DISCARD requirements? If so, go to step 13 . If not, go to next step.
12.
A. Inspect each of the brake drums for the following surface and wear conditions: See BRAKE
DRUM SURFACE & WEAR INSPECTION under REAR DRUM BRAKE in ADJUSTMENTS
& INSPECTION.

Deep or excessive scoring beyond maximum acceptable level

Radial runout beyond maximum acceptable level
B. Make a determination for each brake drum if the drum requires replacement based upon the results
of the inspection. If a brake drum exhibits any of the following conditions, it requires replacement.
Drum exhibits one or more of the Braking Surface Conditions listed previously
Drum is beyond the acceptable level in one or more of the Braking Surface Wear Conditions
listed previously
Does the brake drum require REPLACEMENT? If so, go to next step. If not, go to step 14 .
13. Replace the brake drum. See BRAKE DRUM under REMOVAL & INSTALLATION. After completing
the replacement, go to next step.
14. Inspect the brake shoes for proper adjustment. See DRUM BRAKE ADJUSTMENT under REAR
DRUM BRAKE in ADJUSTMENTS & INSPECTION. Are the brake shoes adjusted properly? If so, go
to step 18 . If not, go to next step.
15. Inspect the components of the brake drum adjustment hardware system for free movement and correct
operation. See DRUM BRAKE ADJUSTING HARDWARE INSPECTION under REAR DRUM
BRAKE in ADJUSTMENTS & INSPECTION. Do the drum brake adjusting hardware components
operate freely and correctly? If so, go to step 17 . If not, go to next step.
16. Replace the drum brake adjusting hardware components as necessary. See DRUM BRAKE
ADJUSTING HARDWARE INSPECTION under REAR DRUM BRAKE in ADJUSTMENTS &
INSPECTION. After completing the replacement, go to next step.
17. Adjust the drum brake shoes. See DRUM BRAKE ADJUSTMENT under REAR DRUM BRAKE in
ADJUSTMENTS & INSPECTION. Were you able to complete the adjustment? If so, go to step 20 . If
not, then return to the symptom table. See SYMPTOM LIST under GENERAL DIAGNOSIS in
TROUBLE SHOOTING.
18. Inspect the drum brake backing plate for the following:
Excessive wear or rust.
Damage and/or evidence of contact with the brake drum.
Does the drum brake backing plate exhibit any of these conditions? If so, go to next step. If not, the go to
step 20 .
19. Repair or replace the drum brake backing plate as necessary. See BRAKE BAKING PLATE under
REMOVAL & INSTALLATION. After completing the repair or replacement, go to next step.
HYDRAULIC BRAKE DIAGNOSIS
2. Inspect and adjust the brake fluid level in the brake master cylinder. See MASTER CYLINDER
RESERVOIR under BLEEDING, FILLING & FLUSHING BRAKE SYSTEM. Was the brake fluid
level low? If so, go to next step. If not, go to step 4 .
Fluid separation, indicating 2 types of fluid are present

Fluid discoloration

Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for
swelling, indicating fluid contamination. Do any of the above conditions exist? If so, go to step 5 . If not,
go to step 6 .
Fluid separation, indicating 2 types of fluid are present

Fluid discoloration

Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for
swelling, indicating fluid contamination. Do any of the above conditions exist? If so, go to next step. If
not, go to step 12 .
5. Flush the hydraulic brake system. See HYDRAULIC BRAKE SYSTEM FLUSHING under
BLEEDING, FILLING & FLUSHING BRAKE SYSTEM. If the brake fluid WAS contaminated with an
oil-based or a silicone-based fluid, indicated by fluid separation and/or a swollen master cylinder
reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following
steps. Refer to the procedures indicated:
Remove ALL of the following components listed. Each component contains internal rubber
seals/linings which have been contaminated.
Clean out the hydraulic brake pipes using denatured alcohol, or equivalent.
Dry the brake pipes using non-lubricated, filtered air.
Repair or replace ALL of the following components listed. Each component contains internal
rubber seals/linings which have been contaminated.
A. MASTER CYLINDER under OVERHAUL or MASTER CYLINDER under REMOVAL
& INSTALLATION.
B. Brake master cylinder reservoir: Clean the brake master cylinder reservoir using denatured
alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air, or if
necessary, replace the brake master cylinder reservoir.
C. Replace the brake master cylinder reservoir cap diaphragm.
D. BRAKE HOSE under REMOVAL & INSTALLATION.
E. BRAKE CALIPER - FRONT under OVERHAUL or BRAKE CALIPER under
F. BRAKE CALIPER - REAR under OVERHAUL or BRAKE CALIPER under
REMOVAL & INSTALLATION if equipped
G. WHEEL CYLINDER under REMOVAL & INSTALLATION, if equipped.
H. Brake Pressure Modulator Valve (BPMV). For replacement, see appropriate ANTI-LOCK
article.
If the brake fluid was NOT contaminated with an oil-based fluid, but WAS contaminated with
water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap
diaphragm. Refill and bleed the hydraulic brake system. See HYDRAULIC BRAKE SYSTEM
BLEEDING under BLEEDING, FILLING & FLUSHING BRAKE SYSTEM. After completing
the operation and any required repairs and/or replacements, go to step 9 .
6.
A. Inspect the following hydraulic brake system components for external fluid leaks. Repair or replace
any of the components found to be leaking brake fluid. Refer to the appropriate procedures:
MASTER CYLINDER under OVERHAUL or MASTER CYLINDER under REMOVAL
& INSTALLATION Brake master cylinder reservoir cap diaphragm.
BRAKE HOSE under REMOVAL & INSTALLATION.
BRAKE PIPE under REMOVAL & INSTALLATION.
BRAKE CALIPER - FRONT under OVERHAUL or BRAKE CALIPER - FRONT under

BRAKE CALIPER - REAR under OVERHAUL or BRAKE CALIPER under
REMOVAL & INSTALLATION, if equipped.
WHEEL CYLINDER under REMOVAL & INSTALLATION, if equipped.
article.
B. If you repaired or replaced any of the brake system components listed, bleed the hydraulic brake
system. See HYDRAULIC BRAKE SYSTEM BLEEDING under BLEEDING, FILLING &
FLUSHING BRAKE SYSTEM. While bleeding the hydraulic brake system, observe for the
The presence of air in the system at a bleeder valve location other than at the repair location,
except if the brake master cylinder was replaced.
An unrestricted and even flow of brake fluid per axle during the bleeding procedure.
Did you find and correct a condition? If so, go to next step. If not, go to step 12 .
7. Was there air in the system at a bleeder valve location other than at the repair location, except if the brake
master cylinder was replaced? If so, go to step 19 . If not, go to next step.
8. Was the flow of brake fluid unrestricted and even per axle during the bleeding procedure? If so, go to
next step. If not, go to step 10 .
9. Inspect the hydraulic function of the brake calipers/wheel cylinders for proper operation. See
HYDRAULIC BRAKE COMPONENT OPERATION VISUAL INSPECTION - DISC or
HYDRAULIC BRAKE COMPONENT OPERATION VISUAL INSPECTION - DRUM under
HYDRAULIC BRAKE SYSTEM in ADJUSTMENTS & INSPECTION. Was the hydraulic function of
the brake calipers/wheel cylinders operating properly? If so, go to step 21 . If not, go to step 14 .
10. Was the flow of brake fluid restricted or uneven through front axle hydraulic components during the
bleeding procedure? If so, go to step 13 . If not, go to next step.
11. Was the flow of brake fluid restricted or uneven through rear axle hydraulic components during the
bleeding procedure? If so, go to step 17 .
12. Inspect the hydraulic function of the brake calipers/wheel cylinders for proper operation. See
HYDRAULIC BRAKE COMPONENT OPERATION VISUAL INSPECTION - DISC or
HYDRAULIC BRAKE COMPONENT OPERATION VISUAL INSPECTION - DRUM under
HYDRAULIC BRAKE SYSTEM in ADJUSTMENTS & INSPECTION. Was the hydraulic function of
the brake calipers/wheel cylinders operating properly? If so, go to step 15 . If not, go to next step.
13. Determine if the brake caliper is restricting the flow of brake fluid and/or not operating properly:
A. Raise and support the vehicle.
B. Remove the tire and wheel assemblies.
C. Open the suspected caliper bleeder valve.
D. Using a large C-clamp, compress the caliper piston and observe for an unrestricted flow of brake
fluid and for free movement of the caliper piston.
E. Close the caliper bleeder valve.
Was the flow of brake fluid unrestricted and did the caliper piston move freely? If so, go to step 17 . If
not, go to next step.
14. Repair or replace any brake caliper/wheel cylinder that was not operating properly. Refer to the
appropriate procedure.
BRAKE CALIPER - FRONT under OVERHAUL or BRAKE CALIPER - FRONT under
BRAKE CALIPER - REAR under OVERHAUL or BRAKE CALIPER under REMOVAL &
INSTALLATION, if equipped.
WHEEL CYLINDER under REMOVAL & INSTALLATION, if equipped.
After completing the repair and/or replacement, go to step 21 .

15. Bleed the hydraulic brake system to observe for the presence of air in the system and to observe for an
unrestricted and even flow of brake fluid per axle during the bleeding procedure. See HYDRAULIC
BRAKE SYSTEM BLEEDING under BLEEDING, FILLING & FLUSHING BRAKE SYSTEM. Was
there air in the system? If so, go to step 19 . If not, the go to next step.
16. Was the flow of brake fluid unrestricted and even per axle during the bleeding procedure? If so, go to step
21 . If not, go to next step.
17. Inspect the hydraulic brake pipes and flexible brake hoses for signs of a fluid restriction; such as being
bent, kinked, pinched or damaged. See BRAKE PIPE & HOSE INSPECTION under HYDRAULIC
BRAKE SYSTEM in ADJUSTMENTS & INSPECTION. Replace any of the hydraulic brake pipes
and/or flexible brake hoses found to be bent, kinked, pinched, or damaged. Refer to the following
procedures as necessary:
BRAKE PIPE under REMOVAL & INSTALLATION
If none of the hydraulic brake pipes or flexible brake hoses were visibly bent, kinked, pinched, or
damaged, replace the hydraulic brake flex hose at the restricted location. Did you find and correct a
condition? If so, go to step 21 . If not, go to next step.
18. Replace the Brake Pressure Modulator Valve (BPMV), in order to correct the hydraulic brake dynamic
rear proportioning mechanical operation. See REMOVAL & INSTALLATION in appropriate ANTI-
LOCK article. After completing the replacement, go to step 21 .
19. Inspect the hydraulic brake system components for brake fluid seepage at a seal and/or fitting location,
which may have drawn air into the system. Inspect the hydraulic brake system components for evidence
of a recent repair, which may have introduced air into the system. Repair or replace any of the
components found to be installed incorrectly or seeping brake fluid. Did you find and correct a condition?
If so, go to step 21 . If not, go to next step.
20. Inspect the brake master cylinder for internal fluid leaks. See BRAKE SYSTEM INTERNAL LEAK
INSPECTION under HYDRAULIC BRAKE SYSTEM in ADJUSTMENTS & INSPECTION. Repair or
replace the brake master cylinder if it is found to be leaking brake fluid internally. See MASTER
CYLINDER under OVERHAUL or MASTER CYLINDER under REMOVAL & INSTALLATION.
Did you find and correct a condition? If so, go to next step. If not, go to SYMPTOM LIST under
GENERAL DIAGNOSIS in TROUBLE SHOOTING.
PARK BRAKE DIAGNOSIS
1. Were you sent here from a Brake System Symptom Test? If so, go to step 4 . If not, go to next step.
2. Were you sent here from a Park Brake Symptom Test? If so, go to step 4 . If not, go to next step.
3. Is the symptom related to the ability of the park brake system to hold and/or release? If so, go to next
step. If not, go to GENERAL DIAGNOSIS under TROUBLE SHOOTING.
4. Raise and support the vehicle with the rear axle supported by jack stands. Shift the transmission into
NEUTRAL. With the park brake RELEASED, attempt to rotate the rear wheels to check the rear brakes
for a significant amount of drag.
Do the rear brakes have a significant amount of drag? If so, go to step 11 . If not, the go to next step.
5. Shift the transmission into NEUTRAL. Apply the park brake. Attempt to rotate the rear wheels to check
the rear brakes for a significant amount of drag.
Do the rear brakes have a significant amount of drag? If so, go to next step. If not, the go to step 7 .
6. Release the park brake. Rotate the rear wheels to check the rear brakes for a significant reduction in the
amount of drag. Did the rear brakes exhibit a significant reduction in the amount of drag? If so, go to step
21 . If not, go to step 11 .
7. Visually check the park brake cable connections and the cables that are accessible on the UNDERSIDE of
the vehicle for disconnections and/or damage. Were any or the park brake cables disconnected and/or
damaged? If so, go to next step. If not, go to step 9 .
8. Reconnect or replace the park brake cables as necessary. See PARK BRAKE CABLE under
REMOVAL & INSTALLATION. After completing the repair and/or replacement, go to next step.
9. Check the adjustment of the park brake. See appropriate procedure under PARK BRAKE in
ADJUSTMENTS & INSPECTION. Was the park brake adjusted properly? If so, go to step 11 . If not, go
to next step.
10. Adjust the park brake. See appropriate procedure under PARK BRAKE in ADJUSTMENTS &
INSPECTION. Were you able to attain adjustment of the park brake? If so, go to step 16 . If not, go to
next step.
11. DO NOT depress the brake pedal with the brake rotors and/or the brake drums removed, or with the brake
calipers repositioned away from the brake rotors, or damage to the brake system may result.
Remove the rear brake rotors or brake drums. See BRAKE ROTOR or BRAKE DRUM under
If equipped with rear disc brakes, inspect the park brake shoe hardware for looseness, damaged,
broken or missing components. See PARK BRAKE INSPECTION - DISC under PARK BRAKE
in ADJUSTMENTS & INSPECTION.
If equipped with drum brakes, inspect the park brake hardware for looseness, damaged, broken or
missing components. See PARK BRAKE INSPECTION - DRUM under PARK BRAKE in
Check the park brake actuators or adjusters for a seized condition.
Does the park brake hardware and/or the park brake actuators or adjusters require replacement? If so, go
to next step. If not, go to step 13 .
12. Replace park brake hardware components as necessary:
If equipped with rear disc brakes, see PARK BRAKE SHOE - REAR DISC under REMOVAL &
INSTALLATION
If equipped with drum brakes, see PARK BRAKE HARDWARE under REMOVAL &
INSTALLATION.
Replace the park brake actuators or adjusters as necessary:
If equipped with rear disc brakes, see PARK BRAKE ACTUATOR under REMOVAL &
INSTALLATION.
If equipped with drum brakes, see ADJUSTING SCREW under REMOVAL &
INSTALLATION.
After completing the replacement, go to next step.
13. Have an assistant apply and release the park brake, while you observe the park brake cables for free
movement. Did the park brake cables move freely? If so, go to next step. If not, go to step 17 .
14. Check the adjustment of the park brake. See appropriate procedure under PARK BRAKE in
ADJUSTMENTS & INSPECTION. Was the park brake adjusted properly? If so, go to step 16 . If not, go
to next step.
INSPECTION. Were you able to attain adjustment of the park brake? If so, go to next step. If not, go to
step 26 .
16. With the transmission still in NEUTRAL, apply the park brake. Attempt to rotate the rear wheels to check
the rear brakes for a significant amount of drag. Release the park brake. Rotate the rear wheels to check
the rear brakes for a significant reduction of drag. Did the park brake apply and release properly? If so, go
to step 28 . If not, go to SYMPTOM LIST under GENERAL DIAGNOSIS in TROUBLE SHOOTING.
17. Disconnect the park brake cable connections that are accessible on the UNDERSIDE of the vehicle one at
a time and check each cable for free movement. Do any of the park brake cables accessible on the
underside of the vehicle require replacement? If so, go to next step. If not, go to step 19 .
18. Replace any of the park brake cables that do not have free movement (not releasing properly). See PARK
BRAKE CABLE under REMOVAL & INSTALLATION. After completing the replacement, go to next
step.
19. Disconnect the front park brake cable connection accessible INSIDE the vehicle at the park brake pedal
assembly and check for free movement. Replace the front park brake cable if it does not have free
movement. See PARK BRAKE CABLE under REMOVAL & INSTALLATION. Did you find and
correct a condition? If so, go to step 24 . If not, go to next step.
20. Replace the park brake pedal assembly (not releasing properly). See PARK BRAKE PEDAL
ASSEMBLY under REMOVAL & INSTALLATION. After completing the replacement, go to step 25 .
21. Check the adjustment of the park brake. See PARK BRAKE under ADJUSTMENTS. Is the park brake
adjusted properly? If so, go to step 27 . If not, go to next step.
INSPECTION. Were you able to attain adjustment of the park brake system? If so, go to step 27 . If not,
go to next step.
23. Remove the rear brake rotors or brake drums, if they have not yet been removed. See BRAKE ROTOR
or BRAKE DRUM under REMOVAL & INSTALLATION. Check the park brake actuators or adjusters
for a seized condition. Replace the park brake actuators or adjusters as necessary.
If equipped with rear disc brakes, see PARK BRAKE ACTUATOR under REMOVAL &
INSTALLATION.
If equipped with drum brakes, see ADJUSTING SCREW under REMOVAL &
INSTALLATION.
Did you find and correct a condition? If so, go to next step. If not, go to step 26 .
go to step 26 .
go to SYMPTOM LIST under GENERAL DIAGNOSIS in TROUBLE SHOOTING.
26. Replace the component that is used to adjust the park brake system. See Equalizer under PARK BRAKE
CABLE in REMOVAL & INSTALLATION. Adjust the park brake. See appropriate procedure under
PARK BRAKE in ADJUSTMENTS & INSPECTION. Did you complete the replacement and
adjustment? If so, go to next step. If not, go to SYMPTOM LIST under GENERAL DIAGNOSIS in
TROUBLE SHOOTING.
27. With the transmission still in NEUTRAL, apply the park brake. Attempt to rotate the rear wheels to check
the rear brakes for a significant amount of drag. Release the park brake. Rotate the rear wheels to check
the rear brakes for a significant reduction of drag. Did the park brake apply and release properly? If so, go
to next step. If not, see SYMPTOM LIST under GENERAL DIAGNOSIS in TROUBLE SHOOTING.
28. Install or connect any components that were removed or disconnected during diagnosis. After completing
the operation, the system should be okay.
BRAKE VACUUM SOURCE TEST
1. Disconnect the engine vacuum hose from the vacuum brake booster check valve.
2. Install a vacuum gage to the engine vacuum hose.
3. Start the engine and allow the engine to idle until normal operating temperatures are reached.
4. Check to see if the engine vacuum reading is within the specified normal engine vacuum range.
Specification 14-20 in. Hg (47-68 kPa)
5. Turn the ignition OFF.
6. If the engine vacuum reading is within the specified normal range, proceed to step 10 .
7. If the engine vacuum reading is NOT within the specified normal range, inspect the engine vacuum hose
for the following conditions.
Tight connection to the engine.
Collapse, deformation or contamination.
Cracks, cuts, dry-rot.
8. If any of these conditions were found with the engine vacuum hose, replace the hose, then repeat steps 2 -
4.
9. If none of these conditions were found with the engine vacuum hose, then there is an engine vacuum
source problem, check the engine vacuum system.
10. Remove the vacuum brake booster check valve from the booster.
11. Install the check valve to the engine vacuum hose.
12. Install the vacuum gage to the check valve.
15. Check to see if the engine vacuum reading is maintained within the specified normal engine vacuum
range of 47-68 kPa (14-20 in. Hg)
16. If the engine vacuum reading is maintained within the specified normal range, proceed to step 18 .
17. If the engine vacuum reading is NOT maintained within the specified normal range, replace the brake
booster check valve, then repeat steps 11 -15 .
18. Inspect the brake booster check valve grommet for the following conditions:
Firm connection to the vacuum brake booster.
Deformation or contamination.
Cracks, cuts, dry-rot.
Go to next step.
19. If any of these conditions were found with the check valve grommet, replace the grommet.
SYMPTOM TESTS
BRAKING ACTION UNEVEN
Pulls To One Side
2. Inspect the suspension system for proper operation. See appropriate article in SUSPENSION. Did you
find and correct a condition? If so, go to step 7 . If not, go to next step.
3. Inspect the steering system for proper operation. See POWER RACK & PINION - AZTEK &
RENDEZVOUS article in STEERING. Did you find and correct a condition? If so, go to step 7 . If not,
go to next step.
4. Inspect the hydraulic brake system for proper operation. SeeHYDRAULIC BRAKE SYSTEM
DIAGNOSIS . Did you find and correct a condition? If so, go to step 7 . If not, go to next step.
5. Inspect the disc brake system for proper operation. See DISC BRAKE SYSTEM DIAGNOSIS . Did
you find and correct a condition? If so, go to step 7 . If not, go to next step.
6. Inspect the drum brake system, if equipped, for proper operation. See DRUM BRAKE SYSTEM
DIAGNOSIS . Did you find and correct a condition? If so, go to next step. If not, go to GENERAL
7. Road test the vehicle in order to confirm proper operation. See VEHICLE ROAD TEST under
SYSTEM TESTS. Is the condition still present? If so, go to step 2 . If not, the system should be okay.
Front To Rear
6. Inspect the brake assist system for proper operation. See BRAKE ASSIST SYSTEM DIAGNOSIS .
Did you find and correct a condition? If so, go to next step. If not, go to GENERAL DIAGNOSIS under
TROUBLE SHOOTING.
SYSTEM TESTS. Is the condition still present? If so, go to step 2 . If not, the system should be okay.
BRAKE FLUID LOSS
5. Road test the vehicle to confirm proper operation. See VEHICLE ROAD TEST under SYSTEM
TESTS. Is the condition still present? If so, go to step 2 . If not, the system should be okay.
Did you find and correct a condition? If so, go to step 6 . If not, go to next step.
3. Inspect the hydraulic brake system for proper operation. See HYDRAULIC BRAKE SYSTEM
2. Inspect for proper brake pedal travel. See BRAKE PEDAL TRAVEL MEASUREMENT &
3.
A. Inspect for worn, missing, misaligned, bent or damaged brake pedal system components.
For the brake pedal pushrod component inspection, see BRAKE PEDAL PUSHROD
INSPECTION under BRAKE PEDAL in ADJUSTMENTS & INSPECTION.
Inspect the brake pedal bushings for excessive wear and/or damage and inspect the brake
pedal for a bent and/or damaged condition.
B. Replace the brake pedal system components that are worn, missing, misaligned, bent or damaged,
refer to the following procedure(s) as necessary.
BRAKE PEDAL ASSEMBLY under REMOVAL & INSTALLATION
VACUUM BRAKE BOOSTER under REMOVAL & INSTALLATION (for pedal pushrod
replacement)
Did you find and replace any worn, missing, misaligned, bent or damaged brake pedal system
components? If so, go to next step. If not, go to step 5 .
4. Reinspect for proper brake pedal travel. See BRAKE PEDAL TRAVEL MEASUREMENT &
Did you find and correct a condition? If so, go to next step. If not, go to GENERAL DIAGNOSIS under
TROUBLE SHOOTING.
BRAKES DRAG
3. Inspect the park brake system for proper operation. See PARK BRAKE SYSTEM DIAGNOSIS . Did
DIAGNOSIS . Did you find and correct a condition? If so, go to next step. If not go to GENERAL
SYSTEM TESTS. Is the condition still present? If so, go to step 2 . If not, then the system should be
okay.
you find and correct a condition? If so, go to next step. If not, go to GENERAL DIAGNOSIS under
TROUBLE SHOOTING.
BRAKE PULSATION
3. Inspect the anti-lock brake system for proper operation. See appropriate ANTI-LOCK article. Did you
okay.
BRAKE SYSTEM NOISE
you find and correct a condition? If so, go to next step. If not, the go to GENERAL DIAGNOSIS under
TROUBLE SHOOTING.
okay.
1. Did you review the hydraulic brakes operation and perform the necessary inspection? If so, go to next
2. Inspect the brake fluid level. Is the brake fluid level okay? If so, go to next step. If not, go to BRAKE
FLUID LOSS .
3. Turn ON the ignition, with the engine OFF. Disengage the park brake. With a scan tool, observe the Park
Brake Switch parameter in the BCM Inputs data list. Does the scan tool indicate that the Park Brake
Switch parameter is Inactive? If so, go to next step. If not, go to step 5 .
4. With a scan tool, observe the Brake Warning Lamp parameter in the IPC Inputs data list. Does the scan
tool indicate that the Brake Warning Lamp parameter is ON? If so, go to step 12 . If not, go to step 6 .
5. Disconnect the park brake warning lamp switch. With a scan tool, observe the Park Brake Switch
parameter. Does the scan tool indicate that the Park Brake Switch parameter is Inactive? If so, go to step
6. Disconnect the brake fluid level switch. With a scan tool, observe the Brake Warning Lamp parameter.
Does the scan tool indicate that the Brake Warning Lamp parameter is ON? If so, go to step 10 . If not, go
to step 8 .
7. Turn OFF the ignition. Test the signal circuit of the park brake warning lamp switch for a short to ground.
See INTERMITTENT under GENERAL DIAGNOSIS in TROUBLE SHOOTING. See
INSTRUMENT CLUSTER in SYSTEM WIRING DIAGRAMS article in ELECTRICAL. Did you find
and correct the condition? If so, go to step 17 . If not, the go to step 11 .
8. Turn OFF the ignition. Test the signal circuit of the brake fluid level switch for a short to ground. See
INTERMITTENT under GENERAL DIAGNOSIS in TROUBLE SHOOTING. See ANTI-LOCK
BRAKES in SYSTEM WIRING DIAGRAMS article in ELECTRICAL. Did you find and correct the
condition? If so, go to step 17 . If not, go to step 11 .
9. Inspect for poor connections at the harness connector of the park brake warning lamp switch. See
INTERMITTENT under GENERAL DIAGNOSIS in TROUBLE SHOOTING. See INSTRUMENT
CLUSTER in SYSTEM WIRING DIAGRAMS article in ELECTRICAL. Did you find and correct the
10. Inspect for poor connections at the harness connector of the brake fluid level switch. See
INTERMITTENT under GENERAL DIAGNOSIS in TROUBLE SHOOTING. See ANTI-LOCK
BRAKES in SYSTEM WIRING DIAGRAMS article in ELECTRICAL. Did you find and correct the
11. Inspect for poor connections at the harness connector of the Body Control Module. See
INTERMITTENT under GENERAL DIAGNOSIS in TROUBLE SHOOTING. Did you find and
correct the condition? If so, go to step 17 . If not, go to step 15 .
12. Inspect for poor connections at the harness connector of the instrument Panel cluster. See
INTERMITTENT under GENERAL DIAGNOSIS in TROUBLE SHOOTING. Did you find and
correct the condition? If so, go to step 17 . If not, go to step 16 .
13. Replace the park brake warning lamp switch. See PARK BRAKE WARNING LAMP SWITCH under
REMOVAL & INSTALLATION. After repairs are complete, go to step 17 .
14. Replace the brake fluid level switch. See MASTER CYLINDER FLUID LEVEL SENSOR under
REMOVAL & INSTALLATION. After repairs are complete, go to step 17 .
15. Replace the Body Control Module. See appropriate BODY CONTROL MODULES article in
ACCESSORIES & EQUIPMENT. After repairs are complete, go to step 17 .
16. Replace the Instrument Panel Cluster (IPC). See REMOVAL & INSTALLATION in appropriate
INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT. After repairs are complete, go to
next step.
17. Operate the system in order to verify the repair. Did you correct the condition? If so, the system should be
okay. If not, go to step 2 .
1. Did you review the hydraulic brakes operation and perform the necessary inspection? If so, go to next
2. Turn ON the ignition, with the engine OFF. Observe the brake warning indicator. Does the brake warning
indicator illuminate briefly during the bulb check? If so, go to next step. If not, go to step 11 .
3. Turn ON the ignition, with the engine OFF. Apply the park brake. Does the brake warning indicator
illuminate? If so, go to next step. If not, go to step 7 .
4. Turn OFF the ignition. Release park brake. Disconnect the brake fluid level indicator switch. Connect a
3-amp fused jumper wire between the signal circuit of the brake fluid level indicator switch and a good
ground. Does the brake warning indicator illuminate? If so, go to next step. If not, go to step 9 .
5. Inspect for poor connections or a poor ground at the brake fluid level indicator switch. Did you find and
correct the condition? If so, go to step 17 . If not, go to next step.
6. Inspect brake fluid level indicator switch for proper operation. Does brake fluid level indicator switch
work properly? If so, go to INTERMITTENT under GENERAL DIAGNOSIS in TROUBLE
SHOOTING. If not, go to step 15 .
7. Disconnect the park brake warning lamp switch. Connect a 3-amp fused jumper wire between the signal
circuit of the park brake warning lamp switch and ground. Does the brake warning indicator illuminate?
If so, go to step 10 . If not, go to next step.
8. Turn OFF the ignition. Disconnect the body control module. Test the signal circuit of the park brake
warning lamp switch for a high resistance or an open. See INSTRUMENT CLUSTER in SYSTEM
WIRING DIAGRAMS article in ELECTRICAL. Did you find and correct the condition? If so, go to step
9. Turn OFF the ignition. Disconnect the instrument panel cluster. Test the signal circuit of the brake fluid
level indicator switch for a high resistance or an open. See INSTRUMENT CLUSTER in SYSTEM
WIRING DIAGRAMS article in ELECTRICAL. Did you find and correct the condition? If so, go to step
10. Inspect for poor connections or a poor case ground at the park brake warning lamp switch. See
INTERMITTENT under GENERAL DIAGNOSIS in TROUBLE SHOOTING. See INSTRUMENT
CLUSTER in SYSTEM WIRING DIAGRAMS article in ELECTRICAL. Did you find and correct the
11. Inspect for poor connections at the harness connector of the instrument cluster. See INTERMITTENT
under GENERAL DIAGNOSIS in TROUBLE SHOOTING. Did you find and correct the condition? If
so, go to step 17 . If not, go to step 14 .
12. Inspect for poor connections at the harness connector of the Body Control Module. INTERMITTENT
under GENERAL DIAGNOSIS in TROUBLE SHOOTING. Did you find and correct the condition? If
so, go to step 17 . If not, go to step 16 .
13. Replace the park brake warning lamp switch. See PARK BRAKE WARNING LAMP SWITCH under
REMOVAL & INSTALLATION. After repairs are complete, go to step 17
14. Replace the instrument cluster. After repairs are complete, go to step 17 .
15. Replace the brake fluid level indicator switch. See MASTER CYLINDER FLUID LEVEL SENSOR
under REMOVAL & INSTALLATION. After repairs are complete, go to step 17 .
16. Replace the Body Control Module. See appropriate BODY CONTROL MODULES article in
ACCESSORIES & EQUIPMENT. After repairs are complete, go to next step.
17. Operate the system in order to verify the repair. Did you correct the condition? If so, the system should be
okay. If not, go to step 2 .
PARK BRAKE WILL NOT HOLD OR RELEASE
you find and correct a condition? If so, go to step 6 . If not, go to the next step.
DIAGNOSIS . Did you find and correct a condition? If so, go to step 6 . If not, go to the next step.
you find and correct a condition? If so, go to step 6 . If not, go to the next step.
okay.
SERVICING
BRAKE DRUM REFINISHING
CAUTION: Improperly tightened wheel nuts can lead to brake pulsation and rotor
damage. In order to avoid expensive brake repairs, evenly tighten the
wheel nuts to the proper torque specification.
NOTE: DO NOT refinish the brake drums in order to correct any of the following
complaints:
Brake noise (growl/squeal).

Premature brake lining wear.
Cosmetic or superficial corrosion of the drum braking surface.
Drum discoloration.
Refinish the brake drums ONLY when one or more of the following conditions
exist:
Severe scoring of the drum braking surface (groove depth in excess of

specification)
Brake pulsation caused by the following:
A. Brake drum out of round (runout in excess of specification)
B. Corrosion or pitting that is deeper than the drum braking surface
1. Use a micrometer in order to measure the largest diameter of the brake drum. If the largest diameter of the
brake drum exceeds the brake drum maximum refinish diameter, DO NOT refinish the brake drum.
Replace the brake drum.
2. Use the Rotor/Drum Flange Resurfacing Kit (J-41013) in order to THOROUGHLY clean the rust from
the brake drum flange.
3. Refinish the brake drum.
4. After machining the brake drum, use 120 grit aluminum oxide sandpaper in order to create a non-
directional braking surface.
5. Clean the braking surfaces with GM P/N 12377981 or equivalent brake parts cleaner.
BRAKE ROTOR REFINISHING
1. The disc brake rotors do not require refinishing as part of routine brake system service. DO NOT refinish
disc brake rotors in an attempt to correct the following conditions:
Brake system noise - squeal, growl, groan.
Uneven and/or premature disc brake pad wear.
Superficial or cosmetic corrosion/rust of the disc brake rotor surface.
Scoring of the disc brake rotor surface less than the maximum allowable specification.
2. Disc brake rotors should only be refinished if the following conditions exist:
Excessive corrosion/rust and/or pitting.
Scoring of the disc brake rotor surface in excess of the maximum allowable specification.
Lateral runout in excess of the maximum allowable specification.
Thickness variation in excess of the maximum allowable specification.
3. Inspect each of the disc brake rotors and determine if the rotors can be refinished and remain above the
minimum allowable thickness after refinish specification:
Inspect the thickness of each of the disc brake rotors. See BRAKE ROTOR THICKNESS
MEASUREMENT under FRONT & REAR DISC BRAKE in ADJUSTMENTS & INSPECTION.
Inspect each of the disc brake rotors for excessive surface wear and/or lateral runout. See BRAKE
4. If the rotors can be refinished, proceed with the rotor refinishing procedure.
CAUTION: Failure to clean the corrosion from the wheel bearing flange, brake
rotor mating surface, and brake rotor mounting face may result in
increased lateral runout of the brake rotor and brake system
pulsation.
5. Use the Rotor Resurfacing Kit (J-41013) in order to thoroughly clean any corrosion from the wheel
bearing flange.
6. Use the Wheel Hub Resurfacing Kit (J-42450-A) in order to thoroughly clean any corrosion/rust from the
brake rotor mating surface and mounting face.
7. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that
all mounting attachments and adapters are clean and free of debris.
8. Ensure that any vibration dampening attachments are securely in place.
9. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor
friction surfaces.
10. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or
more of the way around the brake rotor surface on each side, the brake rotor is properly mounted to the
lathe.
11. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount
the rotor to the lathe.
12. Following the brake lathe manufacturer's instructions, refinish the brake rotor.
13. After each successive cut, inspect the brake rotor thickness. See BRAKE ROTOR THICKNESS
MEASUREMENT under FRONT & REAR DISC BRAKE in ADJUSTMENTS & INSPECTION.
brake rotor must be replaced.
directional finish:
A. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional
finish.
B. Using moderate pressure, apply the non-directional finish:
C. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured
alcohol or an equivalent brake cleaner.
16. Remove the brake rotor from the brake lathe.
BURNISHING PADS & ROTORS
WARNING: Road test a vehicle under safe conditions and while obeying all traffic
Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly
prepared after service has been performed on the disc brake system.
This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or
whenever the disc brake pads have been replaced.
1. Select a smooth road with little or no traffic.

2. Accelerate the vehicle to 30 MPH.
NOTE: Use care to avoid overheating the brakes while performing this step.
3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. DO NOT allow the
brakes to lock.
4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods
between stops in order to properly burnish the brake pads and rotors.

ADJUSTING SCREW
Removal
1. Remove the brake drum. See BRAKE DRUM .

2. Remove the adjuster spring. Disengage the adjuster spring hook end from the tab on the adjuster actuator.
3. Use the Brake Shoe Spanner and Spring Remover (J-38400) in order to spread the brake shoes apart.
4. Remove the adjuster.
Installation
1. Use the brake shoe spanner and spring remover in order to spread the brake shoes apart.
2. Install the adjuster. Ensure that the adjuster engages the brake shoes, the park brake actuator, and the
adjuster actuator properly.
3. Install the adjuster spring.
Install the straight end of the adjuster spring into the brake shoe.
Install the hook end of the adjuster spring to the adjuster actuator.
4. Install the brake drum. See BRAKE DRUM .
BRAKE BACKING PLATE
CAUTION: Do not pry against the splash shield or backing plate in attempt to free the
drum. This will bend the splash shield or backing plate. A bent backing
plate may cause brake chatter and/or pulsation.
Removal

4. Remove the brake shoes. See BRAKE SHOE .
5. Remove the park brake cable from the park brake actuator lever.
6. Using the Park Brake Cable Release Tool (J-37043), remove the park brake cable ONLY from the
backing plate.
7. Remove the wheel cylinder. See WHEEL CYLINDER .
8. Remove the wheel bearing/hub. See appropriate REAR article in SUSPENSION.
9. Remove the backing plate.
Installation
1. Install the backing plate.

2. Install the wheel bearing/hub. See appropriate REAR article in SUSPENSION.
3. Install the wheel cylinder. See WHEEL CYLINDER .
4. Install the park brake cable to the backing plate.
5. Install the park brake cable to the park brake actuator.
6. Install the brake shoes. See BRAKE SHOE .
BRAKE CALIPER
Removal (Front)
1. Inspect the fluid level in the brake master cylinder reservoir.

2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level,
then no brake fluid needs to be removed from the reservoir before proceeding. If the brake fluid level is
higher than midway between the maximum-full point and the minimum allowable level, then remove
brake fluid to the midway point before proceeding.
5. Install 2 nuts to retain the rotor to the hub.
6. Install a large C-clamp over the top of the brake caliper and against the back of the outboard brake pad.
7. Tighten the C-clamp until the caliper piston is pushed into the caliper bore enough to slide the caliper off
the rotor.
8. Remove the brake hose bolt.
9. Remove the brake hose from the brake caliper.
10. Remove and discard the 2 copper brake hose gaskets. These gaskets may be stuck to the brake caliper
and/or the brake hose end.
11. Plug the openings in the brake caliper and the brake hose in order to prevent brake fluid loss and
contamination.
12. Clean off any dirt or corrosion on the brake caliper near the brake hose fitting.
13. Remove the brake caliper bolts.
CAUTION: Do not allow calipers to hang from the flexible hoses. Doing so can
damage the hoses.
14. Remove the brake caliper from the brake caliper bracket.
15. Inspect the piston boot for the following conditions:
Cuts
Tears
Deterioration
Replace the piston boot if damage exists. See BRAKE CALIPER - FRONT under OVERHAUL.
NOTE: Do not attempt to polish away the corrosion.
16. Inspect the caliper bolts for corrosion or damage. If corrosion is found on the brake caliper bolt shaft,
replace the following:
Brake Caliper Bolt
Brake Caliper Bolt Bushing
Brake Caliper Bolt Boot
Installation (Front)
1. Ensure that the caliper bolt boots are properly installed.

2. Install the caliper to the caliper bracket.
NOTE: DO NOT lubricate the bolt threads.
3. Lubricate the brake caliper bolt shaft.

4. Lubricate the brake caliper bolt boots in the caliper bracket.
5. Install the brake caliper bolts. Tighten the bolts to specification. See TORQUE SPECIFICATIONS .
6. Use a flat-bladed tool in order to install the caliper bracket boot over the shoulder of the caliper bolt.
7. Remove the plugs in the brake hose end.
8. Assemble the brake hose bolt and the NEW copper brake hose gaskets to the brake hose.
9. Install the brake hose bolt to the brake caliper. Tighten the bolt to specification. See TORQUE
SPECIFICATIONS .
10. Remove the nuts securing the rotor to the hub.
13. Fill the master cylinder to the proper level. See MASTER CYLINDER RESERVOIR under
BLEEDING, FILLING & FLUSHING BRAKE SYSTEM.
14. Bleed the brake system. See HYDRAULIC BRAKE SYSTEM BLEEDING under BLEEDING,
FILLING & FLUSHING BRAKE SYSTEM.
15. Apply approximately 175 ft lbs (778 N.m) of force to the brake pedal for ten seconds.
16. Inspect the brake caliper and hydraulic brake system for brake fluid leaks.
Removal (Rear)

5. Install 2 nuts to retain the rotor to the hub.
6. Install a large C-clamp over the top of the brake caliper and against the back of the outboard brake pad.
the rotor.
8. Remove the brake hose bolt.
contamination.
13. Remove the brake caliper bolts.
15. Inspect the brake caliper piston boot for the following conditions:
Cuts
Tears
Deterioration
Replace the brake caliper piston boot if damage exists. See BRAKE CALIPER - REAR under
OVERHAUL.
replace the brake caliper bolt, replace the brake caliper bolt bushing, and replace the brake caliper bolt
boot. DO NOT attempt to polish away the corrosion.
Installation (Rear)
1. Ensure that the caliper bolt bushings and the caliper bolt boots are properly installed.
2. Install the brake caliper to the brake caliper bracket.
3. Lubricate the brake caliper bolt shaft. DO NOT lubricate the threads.
4. Lubricate the brake caliper bolt boots in the brake caliper bracket.
5. Install the brake caliper bolts. Tighten the brake caliper bolts to specification. See TORQUE
SPECIFICATIONS .
6. Use a flat-bladed tool in order to install the brake caliper bracket boot over the shoulder of the brake
caliper bolt.
9. Install the brake hose bolt to the brake caliper. See BRAKE HOSE .
15. Apply approximately 175 ft lbs (778 N.m) of force to the brake pedal for ten seconds.
BRAKE CALIPER BRACKET
Removal (Front)

5. Remove the brake caliper. See BRAKE CALIPER .
6. Remove the brake pads from the brake caliper bracket.
7. Remove the brake pad retainers from the brake caliper bracket.
8. Remove the brake caliper bracket bolts.
9. Use a wire brush in order to remove any thread locker and debris from the bolt threads.
10. Remove the brake caliper bracket.
11. Inspect the brake mounting and hardware. See FRONT DISC BRAKE MOUNTING & HARDWARE
INSPECTION under ADJUSTMENTS & INSPECTION.
12. Replace any damaged or missing hardware. See BRAKE HARDWARE .
13. Inspect and replace the brake caliper bracket if cracks or damage exists.
14. Use a wire brush in order to remove any rust and debris from the brake caliper bracket where the brake
pad retainers contact the brake caliper bracket.
15. Use a wire brush in order to clean away any rust and debris from the brake pads where the brake pads
contact the brake pad retainers.
16. Remove any rust and debris from the brake pad retainers.
1. Clean any corrosion from the brake rotor flange.

2. Use the Hub Cleaning Kit (J-42450-A) in order to clean the hub flange.
4. To ensure that the proper clamp load will be present when installed. It is imperative that the threads on
the caliper bracket bolts, as well as the mounting holes in the knuckle, be cleaned of all debris and
inspected before proceeding with installation. Clean and visually inspect the threads of the caliper bracket
bolts and mounting holes in the knuckle.
NOTE: Apply Threadlocker GM P/N 12345493 (10953488) or equivalent to the

threads of the brake caliper bracket bolts.
5. Install the brake caliper bracket bolts. Tighten the brake caliper bracket bolts to specification. See
6. Lubricate and Install the brake pad retainers to the brake caliper bracket.
7. Lubricate and Install the brake caliper pin boots to the brake caliper pins.
8. Lubricate the caliper pins with the grease supplied in the service kit.
9. Push the caliper pins in until the pin boots are fully seated.
10. Push the caliper pins in and out in order to ensure caliper pins move easily.
11. Install the brake pads to the brake caliper bracket.
12. Install the brake caliper. See BRAKE CALIPER .
Removal (Rear)

5. Remove the brake caliper. See BRAKE CALIPER .
8. Remove the brake caliper bracket bolts.
9. Remove the brake caliper bracket.
10. Remove the brake caliper bolt boots from the brake caliper bracket.
11. Remove the brake caliper bolt bushings from the brake caliper bracket.
12. Inspect and replace the brake caliper bracket if cracks or deformation damage exists.
13. Use a wire brush in order to clean away any rust and debris from the brake caliper bracket where the
brake pads contact the brake caliper bracket.
Installation (Rear)

2. Install the caliper bracket bolts. Tighten the brake caliper bracket bolts to specification. See TORQUE
SPECIFICATIONS .
3. Install the brake pad retainers to the brake caliper bracket.
4. Apply a thin coat of (GM P/N 18010909) or equivalent to the brake pad retainers where the brake pads
contact the brake pad retainers.
5. Lubricate the brake caliper bolt bushings with (GM P/N 18010909) or equivalent.
6. Install the brake caliper bolt bushings to the brake caliper bracket.
7. Lubricate the brake caliper bolt boots with (GM P/N 18010909) or equivalent.
8. Install the brake caliper bolt boots to the brake caliper bracket.
9. Install the brake caliper. See BRAKE CALIPER .
BRAKE DRUM
Removal

4. Mark the relationship of the drum to the hub.
5 Remove and discard the retaining clip (if applicable)
6. Remove the brake drum.
7. If the brake drum does not come off easily, perform the following steps:
A. Loosen the park brake cable.
B. Remove the access hole plug from the backing plate.
C. Insert a flat-bladed tool through the backing plate access hole in order to disengage the self
adjuster.
D. Insert another flat-bladed tool through the same backing plate access hole in order to loosen the
adjuster screw.
E. Install the access hole plug in order to prevent dirt or contamination from entering the drum brake.
F. Apply a small amount of penetrating oil around the brake drum center hole.
G. Remove the brake drum.
Installation
1. Align the marks on the brake drum and the hub made during the removal procedure.
2. Install the brake drum.
3. Inspect the brake to shoe adjustment. See DRUM BRAKE ADJUSTMENT under REAR DRUM
BRAKE in ADJUSTMENTS & INSPECTION.
BRAKE HOSE
Removal (Front)

3. Clean all dirt and foreign material from the brake hose and the brake pipe fittings.
4. Remove the brake pipe fitting from the brake hose. Install a rubber cap or plug to the exposed brake pipe
fitting end in order to prevent brake fluid loss and contamination.
5. Use a flat-bladed tool in order to remove the brake hose retainer from the brake hose.
6. Remove the brake hose from the brake hose bracket.
7. Remove the brake hose bolt from the brake caliper.
10. Install a rubber plug into the brake hose bolt hole of the brake caliper in order to prevent brake fluid loss
and contamination.
1. Remove the rubber plug from the brake hose bolt hole of the brake caliper.
3. Install the brake hose bolt to the brake caliper. Tighten the brake hose bolt to specification. See
4. Install the brake hose to the brake hose bracket. Make sure the brake hose is not twisted or kinked after
installation. Damage to the hose could result. Use the stripe on the brake hose in order to align the brake
hose with the notch in the brake hose bracket.
5. Install the brake hose retainer to the brake hose.
6. Remove the rubber cap or plug from the exposed brake pipe fitting end.
7. Install the brake pipe fitting to the brake hose. Tighten the brake pipe fitting to specification. See
8. Bleed the hydraulic brake system. See HYDRAULIC BRAKE SYSTEM BLEEDING under
Removal - Rear Disc

2. Remove the wheel and tire.
4. Remove the brake pipe fitting from the brake hose. Install a rubber cap or plug to the exposed brake pipe
fitting end in order to prevent brake fluid loss and contamination.
5. Use a flat-bladed tool in order to remove the brake hose retainer from the brake hose.
6. Remove the brake hose from the brake hose bracket.
7. Remove the brake hose bolt from the brake caliper.
9. Remove and discard the 2 copper brake hose gasket. These gaskets may be stuck to the brake caliper
and contamination.
Installation - Rear Disc
1. Remove the rubber plug from the brake caliper.

3. Install the brake hose bolt to the brake caliper. Tighten the brake hose bolt to specification. See
4. Install the brake hose to the brake hose bracket. Make sure the brake hose is not twisted or kinked after
installation. Damage to the hose could result. Use the stripe on the brake hose in order to align the brake
5. Install the brake hose retainer to the brake hose.
7. Install the brake pipe fitting to the brake hose. Tighten the brake pipe fitting to specification. See
9. Install the wheel and tire.
Removal - Rear Drum

2. Clean all dirt and foreign material from the brake hoses and the fittings.
3. Remove the brake pipes from the brake hose.
4. Remove the retainers from the brake hose at the brackets.
5. Remove the hose from the brackets.
6. Remove the hose.
Installation - Rear Drum
1. Align the hose fitting with the notch in the brackets. Ensure that there are no kinks in the brake hose.
2. Install the brake hose to the brackets.
3. Install the brake hose retainers to the hose fittings.
4. Install the brake pipes to the brake hose. Tighten the fittings to specification. See TORQUE
SPECIFICATIONS .
BRAKE PADS
NOTE: Use GM replacement brake lining material or equivalent for all GM vehicles in
order to maintain the balance between front and rear brake performance. GM
replacement brake parts have been carefully selected in order to provide the
proper brake balance for stopping and control over a full range of operation
conditions. Installation of front or rear brake lining material not recommended
for this vehicle may change the intended brake balance.
Removal (Front)

5. Install 2 wheel nuts in order to secure the rotor.
6. Install a C-clamp over the top of the brake caliper and against the back of the outboard brake pad.
7. Tighten the C-clamp until the brake caliper piston pushes into the brake caliper bore enough to slide the
brake caliper off of the rotor.
8. Remove the C-clamp from the brake caliper.
9. Remove the lower brake caliper bolt.
10. Rotate the brake caliper upward in order to access the brake pads.
13. Install a C-clamp over the brake caliper and against the block of wood or the old brake pad.
14. Tighten the C-clamp until the brake caliper piston pushes completely into the brake caliper bore.
16. Inspect the brake caliper bolt boots for the following conditions:
Cuts
Tears
Deterioration
Replace the brake caliper bolt boots if damage exists. See BRAKE CALIPER BRACKET .
Cuts
Tears
Deterioration
Replace the brake caliper piston boot if damage exists. See BRAKE CALIPER - FRONT under
OVERHAUL.
18. Inspect the brake caliper bolts for corrosion or damage. If corrosion is found, use new parts, including
bushings, when installing the brake caliper. DO NOT attempt to polish away corrosion.
NOTE: Use denatured alcohol to clean the outside surface of caliper boot before
installing new brake pads.
1. If you are installing new brake pads, use a C-clamp in order to compress the piston to the bottom of the
caliper bore. Use the old brake pad, a metal plate or a wooden block across the face of the piston in order
to protect the piston and the caliper boot.
2. Install the four brake pad retainers to the caliper bracket.
3. Install the brake pads over the brake pad retainers and onto the caliper bracket. Ensure that the wear
sensor is positioned at the leading edge (upward) of the inner pad during forward wheel rotation.
4. Thoroughly clean and apply LOCTITE(R) DRI-LOC 201(R) (GM P/N 12345493) or equivalent to the
threads of the brake caliper pin bolts.
5. Pivot the caliper down onto the pads. Use care to avoid damaging pin boot when rotating caliper.
6. Install the lower caliper bolt. Tighten the caliper bolt to specification. See TORQUE
SPECIFICATIONS .
7. Remove the 2 wheel nuts securing the rotor to the hub and bearing.
11. Pump the brake pedal (3/4 of a full stroke) as many times as necessary to obtain a firm brake pedal.
12. Burnish the pads and the rotors. See BURNISHING PADS & ROTORS under SERVICING.
Removal (Rear)

5. Install 2 wheel nuts to secure the rotor.
6. Install a C-clamp over the brake caliper and against the back of the outboard brake pad.
9. Remove the upper caliper bolt.
10. Pivot the brake caliper down in order to access the brake pads. DO NOT remove the brake caliper from
the brake caliper bracket.
11. Remove the brake pads from the caliper bracket.
12. Remove the brake pad retainers from the caliper bracket.
13. Install a C-clamp over the brake caliper and against the block of wood or the old brake pad.
16. Inspect the brake caliper bolt boots for the following conditions:
Cuts
Tears
Deterioration
Replace the brake caliper bolt boots if damage exists. See BRAKE CALIPER BRACKET .
Cuts
Tears
Deterioration
Replace the brake caliper piston boot if damage exists. See BRAKE CALIPER - REAR under
OVERHAUL.
18. Inspect the brake caliper bolts for corrosion or damage. If corrosion exists, use new components
(including bushings) when installing the brake caliper. DO NOT attempt to polish away the corrosion.
Installation (Rear)
NOTE: Use denatured alcohol to clean the outside surface of caliper boot before
2. Install the 2 brake pad retainers to the caliper bracket.
3. Install the brake pads over the brake pad retainers and onto the caliper bracket. Ensure that the wear
sensor is positioned at the leading edge (downward) of the outer pad during forward wheel rotation.
4. Pivot the caliper upward in position around the pads. Use care to avoid damaging pin boot when rotating
caliper.
5. Lubricate the bolt and the bolt boot using silicone grease.
6. Install the upper caliper bolt. Tighten the caliper bolt to specification. See TORQUE
SPECIFICATIONS .
7. Remove the wheel nuts securing the rotor to the hub and bearing.
12. Burnish the pads and the rotors. See BURNISHING PADS & ROTORS under SERVICING.
BRAKE PEDAL ASSEMBLY
Removal
1. Disable the SIR system. See appropriate AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS.
2. Remove the left side insulator panel.
3. Remove the booster push rod from the brake pedal.
4. Disconnect the electrical connectors from the cruise control release if equipped and stoplight switch.
5. Remove the knee bolster.
6. Remove the brake booster mounting nuts.
7. Remove the brake pedal bracket mounting nuts. See Fig. 4 .
8. Remove the upper mounting nuts from the brake pedal brace.
9. Remove the brake pedal with the bracket.
10. Remove the brake pedal brace from the bracket.
11. Remove the cruise control release switch, if equipped, and the stoplight switch from the brake pedal with
the bracket.
Fig. 4: Exploded View Of Brake Pedal and Mounting Hardware
Installation
1. Install the cruise control release switch, if equipped, and the stoplight switch to the brake pedal with the
bracket.
2. Install the brake pedal brace with the mounting nuts to the bracket. See Fig. 4 . Tighten the nuts to
3. Install the brake pedal with the bracket.
4. Install the upper mounting bolt for the brake pedal brace. Tighten the bolt to specification. See TORQUE
SPECIFICATIONS .
5. Install the brake pedal bracket mounting nuts. Tighten the nuts to specification. See TORQUE
SPECIFICATIONS .
6. Install the brake booster mounting nuts. Tighten the nuts to specification. See TORQUE
SPECIFICATIONS .
7. Install the knee bolster.
8. Connect the electrical connectors to the cruise control release if equipped and stoplight switch.
9. Install the booster push rod to the brake pedal.
10. Adjust the stoplight switch and the cruise control release switch if equipped. See STOPLIGHT
SWITCH under ADJUSTMENTS & INSPECTION.
11. Install the left side insulator panel.
12. Enable the SIR system. See appropriate AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS.
BRAKE PIPE
WARNING: Always use double walled steel brake pipe when replacing brake pipes.
The use of any other pipe is not recommended and may cause brake
system failure. Carefully route and retain replacement brake pipes.
Always use the correct fasteners and the original location for replacement
brake pipes. Failure to properly route and retain brake pipes may cause
damage to the brake pipes and cause brake system failure.
CAUTION: Do not use single lap flaring tools. Double lap flaring tools must be used
to produce a flare strong enough to hold the system pressure. Using
single lap flaring tools could cause system damage.
1. Obtain the recommended tubing and steel fitting nuts of the correct size. Outside diameter tubing is used
in order to specify the size.
2. Cut the tubing to length. In order to determine the correct length, measure the old pipe using a string and
adding 1/8 in (3 mm) for each ISO flare.
3. Before starting the flare, install the fittings on the tubing.
4. Chamfer the inside and outside diameter of the pipe with the de-burring tool.
5. Remove all traces of lubricant from the brake pipe and the flaring tool.
6. Clamp the ISO Flaring Kit (J-29803-A). Tool body in a vise. See Fig. 5 .
7. Select the correct size collet and forming mandrel for the pipe size used.
8. Insert the proper forming mandrel into the tool body.
9. While holding the mandrel in place with a finger, thread the forcing screw until the screw makes contact
with the forming mandrel and begins to move the forming mandrel.
10. When contact is made with the forming mandrel, turn the forcing screw back one complete turn.
11. Slide the clamping nut over the brake pipe into the correct collet. Leave approximately 3/4 in (19 mm) of
tubing extending out the collet.
12. Insert the collet into the tool body. The brake pipe end must contact the face of the forming mandrel.
13. Tighten the clamping nut into the tool body very tight or the pipe may push out.
14. Wrench tighten the forcing screw until the screw bottoms. DO NOT over tighten the forcing screw or the
flare may become over-sized.
15. Back the clamping nut out of the tool body.
16. Disassemble the clamping nut and collet. The flare is now ready for use.
17. Bend the pipe to match the old pipe. Maintain a clearance of 3/4 in (19 mm) for all moving or vibrating
components.
Fig. 5: Using ISO Flaring Kit

BRAKE ROTOR
Removal (Front)
5. Install a C-clamp over the top of the brake caliper and against the back of the outboard brake pad.
8. Remove the brake caliper bracket with the brake caliper. DO NOT disconnect the hydraulic brake flex
hose from the caliper. See BRAKE CALIPER BRACKET .
9. Use a strap or heavy gage wire in order to support the brake caliper and the brake caliper bracket.

4. Install the brake caliper bracket with the brake caliper. See BRAKE CALIPER BRACKET .
8. If the brake rotor was refinished, or if a new brake rotor was installed, burnish the brake pads and brake
rotors. See BURNISHING PADS & ROTORS under SERVICING.
Removal (Rear)

3. Remove the brake caliper bracket with the brake caliper. DO NOT disconnect the hydraulic brake flex
hose from the caliper. See BRAKE CALIPER BRACKET .
Installation (Rear)

4. Install the brake caliper bracket with the brake caliper. See BRAKE CALIPER BRACKET .
7. If the brake rotor was refinished, or if a new brake rotor was installed, burnish the brake pads and brake
rotors. See BURNISHING PADS & ROTORS under SERVICING.
BRAKE SHOE
WARNING: Keep fingers away from rear brake shoe springs to prevent fingers from
being pinched between spring and shoe web or spring and backing plate.
Removal

CAUTION: Do not over stretch the adjuster spring. Damage can occur if the
spring is over stretched.
3. Disengage the adjuster spring hook end from the tab on the adjuster actuator. See Fig. 6 .
4. Remove the straight end of the adjuster spring from the brake shoe.
5. Remove the adjuster actuator from the brake shoe.
6. Remove the return spring from the brake shoes.
8. Remove the brake shoe hold-down springs and retainers from the brake shoes.
9. Remove the adjuster from the brake shoes and the park brake actuator lever.
10. Remove the horseshoe clip retaining the park brake actuator lever to the brake shoe.
11. Remove the park brake actuator lever and wave washer from the brake shoe.
12. Clean all of the drum brake system components with denatured alcohol.
13. Inspect all of the drum brake system components. See DRUM BRAKE HARDWARE INSPECTION
and DRUM BRAKE ADJUSTING HARDWARE INSPECTION under REAR DRUM BRAKE in
14. Replace drum brake system components as necessary. See BRAKE HARDWARE .
15. Inspect the wheel cylinder for the following conditions:
Brake fluid leakage
Worn or damaged dust boots
16. Replace damaged or leaking wheel cylinders as necessary. See WHEEL CYLINDER .
Installation
1. Apply GM P/N 1052196 brake lubricant (or equivalent) to the following areas:
The brake shoe contact points on the backing plate.
The adjuster screw threads.
The inside diameter of the adjuster socket.
2. Install the park brake actuator lever and wave washer to the brake shoe.
3. Install the horseshoe clip to the park brake actuator lever pivot pin.
4. Install the brake shoes to the brake backing plate.
5. Install the brake shoe hold-down pins, springs and retainers to the brake shoes.
6. Install the park brake cable to the park brake actuator lever.
7. Install the adjuster screw to the brake shoe and the park brake actuator. Ensure that the adjuster engages
the brake shoe and the park brake actuator properly.
8. Apply GM P/N 1052196 brake lubricant (or equivalent) to the adjuster actuator/brake shoe interface.
9. Install the adjuster actuator to the brake shoe.
10. Install the straight end of the adjuster spring to the brake shoe.
11. Install the adjuster spring hook end to the tab on the adjuster actuator.
12. Install the return spring to the brake shoes.
13. Move the park brake actuator lever in order to spread the brake shoes apart. The adjuster actuator lever
should move downward, then upward as the park brake actuator lever is released, forcing the adjuster
wheel to rotate. If the adjuster does not operate properly, remove then reinstall the adjuster. Ensure that
the adjuster operates properly.
14. Adjust the brake shoes. See DRUM BRAKE ADJUSTMENT under REAR DRUM BRAKE in
15. Adjust the park brake cable. See appropriate procedure under PARK BRAKE in ADJUSTMENTS &
INSPECTION.
Fig. 6: Exploded View Of Rear Brake Shoe Assembly
BRAKE HARDWARE
Removal - Front Disc

5. Using a C-clamp installed to the center of the outer disc brake pad and the back of the caliper, slowly
compress the caliper piston into its bore just enough to remove the caliper from the mounting bracket.
6. Remove the disc brake caliper bolts.
7. Remove the disc brake caliper from the mounting bracket.
8. Remove the disc brake pads from the disc brake caliper bracket.
9. Remove the disc brake pad retainers from the disc brake caliper bracket.
10. Remove the caliper pins from the disc brake caliper mounting bracket.
11. Remove the caliper pin boots from the disc brake caliper mounting bracket.
12. Lightly wire brush all brake pad contact areas in order to remove any corrosion.
Installation - Front Disc
1. Lubricate and Install the caliper pin boots to the disc brake caliper mounting bracket.
2. Lubricate and Install the caliper pins to the disc brake caliper mounting bracket.
3. Lubricate and Install the disc brake pad retainers to the disc brake caliper bracket.
4. Install the disc brake pads to the disc brake caliper bracket.
5. Install the disc brake caliper to the mounting bracket.
6. Install the disc brake caliper bolts. Tighten the disc brake caliper bolts to specification. See TORQUE
SPECIFICATIONS .
7. Apply and release the brake pedal (3/4 stroke) as many times as necessary in order to obtain a firm brake
pedal.
Removal (Rear) Disc

7. Use a strap or heavy gage wire in order to support the brake caliper and the brake caliper bracket.
Installation - Rear Disc

4. Lubricate and Install the caliper bolt boots to the disc brake caliper mounting bracket.
5. Lubricate and Install the disc brake pad retainers to the disc brake caliper bracket.
8. Install the disc brake caliper bolts. Tighten the disc brake caliper bolts to specification. See TORQUE
SPECIFICATIONS .
pedal.
Removal - Drum

3. Disengage the adjuster spring hook end from the tab on the adjuster actuator.
Installation - Drum
Removal - Drum Adjusting

2. Remove the adjuster spring from the adjuster actuator lever.
3. Remove the straight end of the adjuster actuator spring from the brake shoe.
4. Remove the adjuster actuator lever.
Installation - Drum Adjusting
1. Install the adjuster actuator lever.

3. Install the hook end of the adjuster spring to the adjuster actuator lever.
4. Inspect the adjuster for proper engagement with the drum brake system components. Ensure that the
adjuster engages the brake shoes and, the park brake actuator, and the adjuster actuator properly.
MASTER CYLINDER
Removal
1. Disconnect brake pipes from the master cylinder.

2. Disconnect fluid level sensor electrical connector.
3. Remove master cylinder mounting nuts.
4. Remove the master cylinder. See Fig. 7
5. Drain the master cylinder reservoir of all brake fluid.
6. Remove the master cylinder reservoir. See MASTER CYLINDER RESERVOIR .
Installation
1. Install the master cylinder reservoir. See MASTER CYLINDER RESERVOIR .

2. Bench bleed the master cylinder prior to installation. See MASTER CYLINDER BENCH BLEEDING
under BLEEDING, FILLING & FLUSHING BRAKE SYSTEM.
3. Install the master cylinder. See MASTER CYLINDER RESERVOIR .
4. Install the master cylinder mounting nuts. Tighten the master cylinder mounting nuts to specification. See
5. Connect the fluid level sensor electrical connector.
6. Connect the brake pipes to the master cylinder. Tighten the master cylinder tube nuts to specification. See
7. Fill the master cylinder reservoir with brake fluid. See MASTER CYLINDER RESERVOIR under
Fig. 7: Removing & Installing Master Cylinder From Power Brake Booster
MASTER CYLINDER FLUID LEVEL SENSOR
Removal
1. Disconnect the electrical connector from the fluid level sensor.

2. Remove the fluid level sensor. See Fig. 8 . Use needle nose pliers in order to compress the switch locking
tabs at the outboard side of the master cylinder. See Fig. 9 .
Fig. 8: Locating Fluid Level Sensor Electrical Connector
Fig. 9: Depressing Locking Tabs On Fluid Level Sensor
Installation
1. Install the fluid level sensor until the locking tabs snap into place.
2. Connect the electrical connector to the fluid level sensor.
MASTER CYLINDER RESERVOIR
Removal
1. Remove the master cylinder. See MASTER CYLINDER .
CAUTION: Do not overtighten vise, or damage to the master cylinder will result.
2. Clamp the flange on the master cylinder body in a vise. DO NOT clamp the master cylinder body.
3. Drive out the spring pins. Use a suitable punch. DO NOT damage the reservoir or the cylinder body when
pushing out the pins. See Fig. 10 .
4. Remove the reservoir body by pulling the body straight up and away from the cylinder body. See Fig.
11 .
5. Remove the O-rings from the grooves in the reservoir.
6. Inspect the reservoir for cracks or deformation. Replace the reservoir if necessary.
7. Clean the reservoir. Use clean denatured alcohol.
8. Dry the reservoir. Use non-lubricated compressed air.
Installation
1. Lubricate the NEW O-rings and the reservoir-to-housing fittings. Use clean brake fluid.
2. Insert the O-rings into the grooves in the reservoir. Ensure that the O-rings are properly seated. See Fig.
11 .
3. Install the reservoir to the master cylinder body. Use your hand in order to push the reservoir straight
down into the body.
4. Install the spring pins in order to retain the reservoir. DO NOT damage the reservoir or the cylinder body.
5. Install the master cylinder. See MASTER CYLINDER .
Fig. 10: Removing Master Cylinder Reservoir
Fig. 11: Exploded View Of Master Cylinder and Reservoir
PARK BRAKE ACTUATOR
Removal

2. Remove the rear tire and wheel assemblies.
3. Relieve the park brake system tension at the equalizer assembly.
4. Remove the rear caliper bracket. See BRAKE CALIPER BRACKET .
5. Remove the rear rotor. See BRAKE ROTOR .
6. Disconnect and remove the rear park brake cable from the bracket at the rear wheel. See PARK BRAKE
CABLE . See Fig. 12 .
7. Disconnect the park brake cable return spring from the park brake actuator and bracket at the rear wheel.
8. Remove the rear hub. See appropriate REAR article in SUSPENSION. The rear hub, backing plate, park
brake cable bracket, and park brake actuator will be removed as an assembly.
9. Remove the 2 retainers and the park brake cable bracket from the park brake actuator. Position the rear
hub aside.
10. Remove the park brake shoe and actuator from the backing plate.
11. Separate the actuator from the park brake shoe.
Installation
1. Assemble the actuator to the park brake shoe.

2. Install the park brake shoe and actuator onto the backing plate.
3. Position the park brake shoe, actuator, and backing plate over the rear hub.
4. Install the park brake cable bracket and the 2 retainers.
5. Install the rear hub. See appropriate REAR article in SUSPENSION. The rear hub, backing plate, park
brake cable bracket, and park brake actuator will be installed as an assembly.
6. Install and connect the rear park brake cable to the bracket at the rear wheel. See PARK BRAKE
CABLE . See Fig. 12 .
7. Connect the park brake cable return spring to the park brake actuator and bracket at the rear wheel.
8. Install the rear rotor. See BRAKE ROTOR .
9. Install the rear caliper bracket. See BRAKE CALIPER BRACKET .
10. Install the rear tire and wheel assemblies.
INSPECTION.
Fig. 12: Removing Rear Park Brake Cable From Bracket
PARK BRAKE CABLE

Removal (Front)
1. Remove the left-side instrument panel insulator.

2. Remove the left-side door sill plate.
3. Fold back the carpet for access.
5. Loosen the park brake cable equalizer nut in order to remove the park brake left side cable from the park
brake equalizer.
6. Remove the park brake cable end from the park brake cable connector.
7. Remove the park brake cable from the park brake cable equalizer.
8. Remove the park brake cable from the park brake cable guides.
9. Remove the park brake cable nuts from the underbody studs.
10. Remove the park brake cable clips from the park brake cable.
12. Remove the park brake cable end from the park brake lever clevis.
13. Use the Park Brake Cable Release Tool (J-37043) in order to remove the cable from the lever.
14. Remove the front park brake cable from the vehicle.
1. Install the front park brake cable to the vehicle.

2. Install the park brake cable to the park brake lever.
3. Install the park brake cable end to the park brake lever clevis.
5. Install the park brake cable clips to the park brake cable shielded areas.
6. Install the park brake cable nuts to the underbody studs. Tighten the park brake cable nuts to
7. Install the park brake cable to the park brake cable guides.
8. Install the park brake cable to the park brake equalizer.
9. Install the park brake cable end to the park brake cable connector.
10. Install the park brake left side cable to the park brake equalizer.
INSPECTION.
13. Fold the carpet back in place.
14. Install the left-side door sill plate.
15. Install the left-side instrument panel insulator.
Removal - Left Rear

brake equalizer.
4. Remove the tire and wheel. Remove the brake drum. See BRAKE DRUM .
5. Remove the park brake cable from the park brake actuator.
6. Use the Park Brake Cable Release Tool (J-37043) in order to remove the park brake cable. Remove the
park brake cable from the backing plate.
Installation - Left Rear
1. Install the park brake cable. Install the park brake cable to the backing plate.
3. Install the tire and wheel. Install the brake drum. See BRAKE DRUM .
INSPECTION.
Removal - Right Rear

brake equalizer.
4. Remove the park brake cable from the park brake actuator.
5. Drill out the 2 rivets retaining the park brake cable to the rear crossmember.
Installation - Right Rear
1. Install the park brake cable.

2. Install the park brake cable to the park brake cable bracket.
5. Secure the park brake cable to the rear crossmember with 2 rivets.
INSPECTION.
Removal - Equalizer

2. Disconnect the left rear park brake cable and adjustment stud assembly from the equalizer assembly by
removing the equalizer nut from the adjustment stud.
3. Disconnect the front park brake cable from the right rear cable at the connector clip. See Fig. 13 .
4. Remove the equalizer assembly from the front park brake cable. Use a flat bladed tool to release the
assembly from the cable. See Fig. 14 .
Installation - Equalizer
1. Install the equalizer assembly to the front park brake cable. See Fig. 15 .
2. Connect the front park brake cable to the right rear cable at the connector clip. See Fig. 13 .
3. Connect the left rear park brake cable and adjustment stud assembly to the equalizer assembly by
installing the adjustment stud to the equalizer nut.
INSPECTION.
Fig. 13: Disconnecting Front Park Brake Cable From Right Rear Cable
Fig. 14: Removing Equalizer Assembly From Front Park Brake Cable
Fig. 15: Equalizer Assembly

PARK BRAKE HARDWARE
WARNING: Keep fingers away from rear brake shoe springs to prevent fingers from
Removal

3. Disengage the adjuster spring hook end from the tab on the adjuster actuator. See Fig. 16 .
9. Remove the adjuster from the brake shoes and the park brake actuator lever.
14. Replace drum brake system components as necessary. See BRAKE HARDWARE .
15. Inspect the wheel cylinder for brake fluid leakage and worn or damaged dust boots.
16. Replace damaged or leaking wheel cylinders as necessary. See WHEEL CYLINDER .
Installation
1. Apply GM P/N 1052196 brake lubricant (or equivalent) to the following areas:
The brake shoe contact points on the backing plate.
The adjuster screw threads.
The inside diameter of the adjuster socket.
See Fig. 16 .
6. Install the park brake cable to the park brake actuator lever.
7. Install the adjuster screw to the brake shoe and the park brake actuator. Ensure that the adjuster engages
the brake shoe and the park brake actuator properly.
8. Apply GM P/N 1052196 brake lubricant (or equivalent) to the adjuster actuator/brake shoe interface.
9. Install the adjuster actuator to the brake shoe.
10. Install the straight end of the adjuster spring to the brake shoe. DO NOT over stretch the adjuster spring.
Damage can occur if the spring is over stretched.
13. Move the park brake actuator lever in order to spread the brake shoes apart. The adjuster actuator lever
should move downward, then upward as the park brake actuator lever is released, forcing the adjuster
wheel to rotate. If the adjuster does not operate properly, remove then reinstall the adjuster.
14. Adjust the brake shoes. See DRUM BRAKE ADJUSTMENT under REAR DRUM BRAKE in
INSPECTION.
Fig. 16: Identifying Park Brake Hardware Components
PARK BRAKE PEDAL ASSEMBLY
Removal
1. Remove the left side instrument panel insulator.

2. Pull back the carpet for access.
4. Loosen the park brake cable and the equalizer.
5. Disconnect the front cable from the rear cable at the connector clip.
6. Remove the front cable from the connector clip.
7. Use the Park Brake Cable Release Tool (J-37043) in order to remove the front cable clip from the
underbody bracket.
9. Disconnect the electrical connector at the park brake switch.
10. Remove the three lever nuts from the body mounting studs.
11. Remove the park brake lever with the park brake cable.
12. Remove the cable button end from the lever clevis.
13. Use the park brake cable release tool in order to remove the cable from the lever.
14. Remove the switch, if being replaced.
Installation
1. Install the switch, if removed.

2. Install the cable to the new park brake lever.
3. Install the cable end to the lever clevis.
4. Install the new park brake lever.
5. Install the three lever to body mounting nuts. Tighten park brake lever mounting nuts to specification. See
6. Connect the electrical connector at the park brake switch.
8. Feed the cable through the underbody and clip the cable into place.
9. Tighten the park brake cable at the equalizer.
11. Position the carpet in place.
12. Install the left side insulator panel.
INSPECTION.
PARK BRAKE SHOE - REAR DISC
Removal

2. Remove the rear tire and wheel assemblies.
3. Relieve the park brake system tension at the equalizer assembly.
4. Remove the rear caliper bracket. See BRAKE CALIPER BRACKET .
5. Remove the rear rotor. See BRAKE ROTOR .
6. Disconnect and remove the rear park brake cable from the bracket at the rear wheel. See PARK BRAKE
CABLE .
7. Disconnect the park brake cable return spring from the park brake actuator and bracket at the rear wheel.
8. Remove the rear hub. See appropriate REAR article in SUSPENSION. The rear hub, backing plate, park
brake cable bracket, and park brake actuator will be removed as an assembly.
9. Remove the 2 retainers and the park brake cable bracket from the park brake actuator. Position the rear
hub aside.
10. Remove the park brake shoe and actuator from the backing plate.
11. Separate the park brake shoe from the actuator.
Installation
1. Assemble the park brake shoe to the actuator.

2. Install the park brake shoe and actuator onto the backing plate.
3. Position the park brake shoe, actuator, and backing plate over the rear hub.
4. Install the park brake cable bracket and the 2 retainers.
5. Install the rear hub. See appropriate REAR article in SUSPENSION. The rear hub, backing plate, park
brake cable bracket, and park brake actuator will be installed as an assembly.
6. Connect the rear park brake cable to the bracket at the rear wheel. See PARK BRAKE CABLE .
7. Connect the park brake cable return spring to the park brake actuator and bracket at the rear wheel.
8. Install the rear rotor. See BRAKE ROTOR .
9. Install the rear caliper bracket. See BRAKE CALIPER BRACKET .
10. Install the rear tire and wheel assemblies.
INSPECTION.
PARK BRAKE WARNING LAMP SWITCH
Removal
1. Remove the left-side instrument panel insulator.

2. Remove the left-side door sill plate.
3. Remove the park brake indicator switch electrical connector.
4. Remove the park brake indicator switch screw.
5. Remove the park brake indicator switch.
Installation
1. Install the park brake indicator switch.

2. Install the park brake indicator switch screw. Tighten the park brake indicator switch screw to
3. Install the park brake indicator switch electrical connector.
4. Install the left-side door sill plate.
5. Install the left-side instrument panel insulator.
PROPORTIONING VALVE
NOTE: Note the locations of the brake pipes in order to aid in installation.
1. Disconnect the brake pipes from the proportion valve.

2. Remove Master Cylinder brake pipes from proportion valve.
3. Remove the nuts that retain the proportion valve to the mounting bracket.
4. Remove the proportion valve from the bracket.
5. To install, place the proportion valve on bracket and install retaining nuts.
6. Install master cylinder brake pipes to proportion valve.
7. Install the brake pipes to the proportion valve.
8. Bleed brake system. See BLEEDING, FILLING & FLUSHING BRAKE SYSTEM .
STOPLIGHT SWITCH
Removal

3. Remove the stoplight switch from the brake pedal bracket by turning the switch counterclockwise
approximately 1/4 turn, and pulling back. See Fig. 17 .
Installation
1. Install the stoplight switch into the slotted grooves until switch is fully depressed against the brake pedal,
then turn the switch clockwise approximately 1/4 turn, the switch should now be installed and adjusted.
See Fig. 17 .
3. Install the left side instrument panel insulator.
4. If necessary, adjust the stoplight switch. See STOPLIGHT SWITCH under ADJUSTMENTS &
INSPECTION.
Fig. 17: Removing & Installing Stoplight Switch
VACUUM BRAKE BOOSTER
Removal
1. Remove the air cleaner and the duct.

2. Remove the vacuum hose from the vacuum check valve. Reposition the vacuum hose.
3. Remove the throttle cables from the throttle body and the bracket.
4. Drain the cooling system. Remove the heater inlet pipe. See REMOVAL & INSTALLATION in
appropriate A/C HEATER SYSTEMS article in HVAC.
5. Remove the fuel lines from the pipes and the vapor line. See appropriate REMOVAL, OVERHAUL &
INSTALLATION article in ENGINES.
6. Remove the ABS hydraulic modulator/master cylinder. See MASTER CYLINDER .
7. Remove the bolt retaining the pipe assembly from the EGR valve and carefully pull the pipe assembly
back. Unscrew the EGR pipe assembly nut from the exhaust manifold. Remove the EGR pipe.
8. Remove exhaust crossover. See appropriate REMOVAL, OVERHAUL & INSTALLATION article in
ENGINES.
9. Remove the oil level indicator from the filler tube. Remove the fluid filler tube nut from the EGR valve.
Remove the fluid filler tube bolt from the transaxle. Remove the fluid filler tube.
11. Remove the knee bolster.
12. Disable the SIR system. See appropriate AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS.
NOTE: When disconnecting the pushrod from the brake pedal, the brake pedal
must be held stationary or damage to the brake switch may result.
13. Remove the booster push rod retaining clip and washer from the brake pedal assembly.
14. Remove the brake booster push rod from the brake pedal.
15. Remove the master cylinder/ABS modulator. See MASTER CYLINDER .
17. Remove the brake booster.
Installation
WARNING: When replacing the power booster brake, make sure that the cruise
control cable is not routed between the booster and the cowl. If the cable
is damaged or pinched, it must be replaced. Failure to do this could result
in personal injury.
1. Position the brake booster to the cowl and the mounting plate.
2. Install the brake booster mounting nuts. Tighten the brake booster mounting nuts to specification. See
3. Install the master cylinder/ABS modulator. See appropriate AIR BAG RESTRAINT SYSTEMS article in
RESTRAINTS.
4. Install the brake booster push rod to the brake pedal.
5. Install the brake booster rod retaining washer and clip to the brake pedal assembly.
6. Adjust the stoplight switch. See STOPLIGHT SWITCH under ADJUSTMENTS & INSPECTION.
7. Enable the SIR system. See AIR BAG RESTRAINT SYSTEMS article in RESTRAINTS.
8. Install the knee bolster.
9. Install the left side instrument panel insulator.
10. Install the fluid filler tube seal in the transaxle. Install the fluid filler tube. Install the fluid filler tube bolt.
Tighten the bolt to specification. Install the fluid filler tube nut. Tighten the nut to specification. See
TORQUE SPECIFICATIONS . Inspect and adjust the fluid level as needed. See SERVICING -
AZTEK & RENDEZVOUS article in TRANSMISSION.
11. Install exhaust crossover. See appropriate REMOVAL, OVERHAUL & INSTALLATION article in
ENGINES.
12. Install the EGR valve pipe to the exhaust manifold. Tighten the EGR pipe nut to specification. See
TORQUE SPECIFICATIONS . Install the EGR pipe bolt to the EGR valve. Tighten the EGR pipe bolt
to specification.
13. Install the fuel lines to the pipes and the vapor line. See appropriate REMOVAL, OVERHAUL &
INSTALLATION article in ENGINES.
14. Install the heater inlet pipe. See REMOVAL & INSTALLATION in appropriate A/C HEATER
SYSTEMS article in HVAC.
15. Install the throttle cables to the throttle body and the bracket.
16. Install the vacuum hose to the check valve.
17. Install the air cleaner and duct assembly.
VACUUM BRAKE BOOSTER CHECK VALVE AND/OR HOSE
Removal
1. Remove the vacuum hose from the intake manifold.

3. Remove the vacuum hose from the vacuum brake booster check valve.
Installation
1. Install the vacuum hose to the intake manifold.

2. Install the check valve to the vacuum brake booster.
3. Install the vacuum hose to the vacuum brake booster check valve.
WHEEL CYLINDER
Removal

3. Clean all dirt and foreign material from the wheel cylinder brake pipe fitting and the bleeder valve.
5. Remove the brake pipe nut.
6. Install a cap over the end of the brake pipe in order to prevent brake fluid loss and/or brake fluid
contamination.
7. Remove the wheel cylinder bolts.
8. Use the Brake Shoe Spanner and Spring Remover (J-38400) in order to spread the brake shoes apart.
9. Remove the wheel cylinder.
10. Clean the old sealant from the backing plate where the wheel cylinder was installed. Clean the sealant
from the wheel cylinder if you are reusing the wheel cylinder.
Installation
1. Apply LOCTITE(R) GM P/N 12345382 (or equivalent) to the wheel cylinder shoulder face which
contacts the backing plate.
2. Use the brake shoe spanner and spring remover in order to spread the brake shoes apart.
3. Install the wheel cylinder.
4. Install the wheel cylinder bolts. Tighten the bolts to specification. See TORQUE SPECIFICATIONS .
5. Remove the cap from the brake pipe and install the brake pipe to the wheel cylinder. Tighten the nut to
7. Bleed the hydraulic brake system at the wheel cylinder. See HYDRAULIC BRAKE SYSTEM
BLEEDING under BLEEDING, FILLING & FLUSHING BRAKE SYSTEM.
OVERHAUL
WARNING: Do not hone master cylinder bore. Honing destroys hardened surface,
causing premature piston seal failure. If bore surface is rough or pitted,
replace master cylinder.
BRAKE CALIPER - FRONT
See Fig. 18 for assistance with overhaul.
Replace all the components included in the repair kit.

Lubricate all of the rubber parts with clean brake fluid in order to ease assembly.
Perform this overhaul procedure on a clean bench.
Disassembly

3. Remove the brake caliper. See BRAKE CALIPER under REMOVAL & INSTALLATION.
WARNING: Do not place fingers in front of the caliper piston(s) in an attempt to

catch or protect it when applying compressed air. The piston(s) can
fly out with force and could result in serious bodily injury.
CAUTION: Use clean cloths to pad interior of caliper housing during piston
removal. Use just enough air to ease the pistons out of the bores. If
the pistons are blown out, even with the padding provided, it may be
damaged.
4. Blow compressed air into the brake caliper hose hole in order to remove the brake caliper piston. The
piston will come out through the piston boot.
5. Inspect and replace the brake caliper piston if any of the following conditions are found:
Scoring
Nicks
Corrosion
Worn Or Damaged Chrome Plating
6. Remove the piston seal from the groove in the caliper bore. Use a small wooden or plastic tool. DO NOT
use a metal tool for seal removal. Damage to the caliper bore or the seal grooves can result.
7. Inspect the caliper bore and the seal grooves for the following conditions:
Scoring
Nicks
Corrosion
Wear
8. Use a piece of crocus cloth in order to polish out light corrosion.

9. Replace the caliper housing if corrosion in and around the seal groove cannot be cleaned with a piece of
crocus cloth.
10. Inspect and replace any brake caliper bolt boots that exhibit any of the following conditions:
Cuts
Tears
Deterioration
replace the brake caliper bolt and the brake caliper bolt boot. DO NOT attempt to polish away the
corrosion.
12. Inspect the seal groove in the caliper bore for nicks or burrs. Replace the caliper if the seal groove is
damaged.
13. Remove the bleeder valve cap and the bleeder valve from the brake caliper housing.
14. Clean all the parts with clean, denatured alcohol.
15. Dry all the parts with filtered, non-lubricated compressed air.
16. Use filtered, non-lubricated compressed air in order to blow out all of the passages in the caliper housing
and the bleeder valve.
Assembly
1. Install the bleeder valve and the bleeder valve cap to the caliper housing.
2. Install a NEW lubricated piston seal to the caliper bore grooves. Ensure that the piston seal is not twisted.
3. Install the lubricated boot onto the brake caliper piston.
4. Lubricate the brake caliper piston with clean brake fluid.
5. Install the brake caliper piston and the brake caliper piston boot into the bore of the caliper. Push the
brake caliper piston to the bottom of the bore.
6. Seat the caliper boot in the caliper housing counterbore using the Dust Boot Seal Installer (J-36349).
7. Install the caliper. See BRAKE CALIPER under REMOVAL & INSTALLATION.
Fig. 18: Exploded View Of Single Piston Caliper Assembly
BRAKE CALIPER - REAR
Removal
1. Remove the rear brake caliper from the vehicle. See BRAKE CALIPER under REMOVAL &
INSTALLATION.
2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the
caliper bore through the fluid inlet hole.
3. Using a small wooden or plastic tool, remove the piston dust boot seal from the seal counterbore in the
caliper and discard the boot seal.
4. Using a small wooden or plastic tool, remove the piston seal from the caliper bore and discard the piston
seal.
5. Remove the bleeder valve and cap from the caliper.
6. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or
equivalent. DO NOT use abrasives to clean the brake caliper piston.
7. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered air.
8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion.
9. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a
fine emery paper. If the imperfection cannot be removed, replace the caliper assembly.
10. If cracks, scoring, pitting, excessive rust, and/or excessive corrosion are present in the caliper bore,
replace the caliper assembly.
11. Inspect the caliper piston for cracks, scoring, and/or damage to the chrome plating. Replace the caliper
piston if any of these conditions exist.
Installation
1. Lubricate the NEW piston seal with Delco Supreme 11(R) (GM P/N 12377967) or equivalent DOT-3
brake fluid from a clean, sealed brake fluid container.
2. Install the lubricated, NEW piston seal into the caliper bore.
3. Install the caliper piston into the caliper bore.
4. Install the NEW piston dust boot seal over the caliper piston.
5. Fully seat the dust boot seal into caliper counterbore.
6. Install the retaining ring that secures the dust boot to the caliper housing.
7. Install the bleeder valve and cap to the caliper and tighten the valve securely.
8. Install the rear brake caliper to the vehicle. See BRAKE CALIPER under REMOVAL &
INSTALLATION.
MASTER CYLINDER
Disassembly
1. Remove the brake master cylinder from the vehicle. See MASTER CYLINDER under REMOVAL &
INSTALLATION.
3. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the
cap and diaphragm.
4. Remove the reservoir cap and diaphragm from the reservoir.
5. Inspect the reservoir cap and diaphragm for the following conditions. If any of these conditions are
present, replace the affected components.
Cuts Or Cracks
Nicks Or Deformation
6. Remove the master cylinder reservoir from the master cylinder. See MASTER CYLINDER
RESERVOIR under REMOVAL & INSTALLATION.
7. Using a smooth, round-ended tool, depress the primary piston and remove the piston retainer.
8. Remove the primary piston assembly from the cylinder bore.
9. Plug the cylinder inlet ports and the rear outlet port. Apply low pressure, non-lubricated, filtered air into
the front outlet port, in order the remove the secondary piston with the primary and secondary seals, and
the return spring.
10. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer from the
secondary piston.
Assembly
NOTE: DO NOT use abrasives to clean the brake master cylinder bore.
1. Clean the interior and exterior of the master cylinder, the secondary piston, and the return spring in
denatured alcohol, or equivalent.
2. Inspect the master cylinder bore, inlet and outlet ports, the secondary piston, and the return spring for
cracks, scoring, pitting, and/or corrosion. Replace the master cylinder if any of these conditions exist.
3. Dry the master cylinder and the individual components with non-lubricated, filtered air.
4. Lubricate the master cylinder bore, the secondary piston, the return spring, and all of the individual
overhaul components with Delco Supreme 11(R), GM P/N 12377967 (Canadian P/N 992667), or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
5. Assemble the lubricated, new primary seal and retainer, and new secondary seal onto the secondary
piston.
6. Install the lubricated return spring and secondary piston assembly into the cylinder bore.
7. Install the lubricated, NEW primary piston assembly into the cylinder bore.
8. Using a smooth, round-ended tool, depress the primary piston and install the NEW piston retainer.
9. Install the master cylinder reservoir to the master cylinder. See MASTER CYLINDER RESERVOIR
10. Install the reservoir cap and diaphragm to the reservoir.
11. Install the master cylinder to the vehicle. See MASTER CYLINDER under REMOVAL &
INSTALLATION.
REAR WHEEL CYLINDER - DRUM
NOTE: Manufacturer recommends replacing wheel cylinder, not rebuilding.

DISC BRAKE SPECIFICATIONS
NOTE: For Disc Brake Specifications, see DISC BRAKES in SPECIFICATION article.
DRUM BRAKE SPECIFICATIONS
NOTE: For Drum Brake Specifications, see DRUM BRAKE in SPECIFICATION article.
PARK BRAKE SPECIFICATIONS
NOTE: For Park Brake Specifications, see PARK BRAKE in SPECIFICATION article.
NOTE: For Torque Specifications, see TORQUE SPECIFICATIONS in SPECIFICATION

article.
Disc & Drum - Trucks - Except Tracker
Vehicle model can be identified by fifth character of Vehicle Identification Number (VIN), stamped on metal
pad on top of left end of instrument panel, near windshield. See MODEL IDENTIFICATION table.
Series (1) Model
"A" 2WD Aztek
"B" 4WD Aztek
"C" Silverado, Sierra, Suburban, Tahoe & Yukon
"G" Express & Savana
"K" Escalade, Silverado, Sierra, Suburban, Tahoe & Yukon
"L" AWD Astro & Safari
"M" 2WD Astro & Safari
"S" 2WD Blazer, Envoy, Jimmy, S10 & Sonoma
"T" 4WD Blazer, Bravada, Envoy, Jimmy, S10 & Sonoma
"U" Silhouette, Montana & Venture
(1) Vehicle series is fifth character of VIN.
NOTE: This article covers base brake systems only. For information on Anti-Lock
Brake System (ABS) see appropriate ANTI-LOCK article.
BRAKE SHOE ASSEMBLY
Some "U" series vehicles are equipped with leading/trailing brakes, identified by adjuster screw hole in backing
plate, located above horizontal centerline of rear axle. All other models are equipped with dual-servo brakes,
identified by adjuster screw hole at bottom of backing plate.
Brake assembly consists of backing plate, brake shoes, return springs, automatic adjusting assembly and a
wheel cylinder.
Automatic adjusting assembly consists of an actuator lever, return spring, actuator link, adjusting screw and
spring. Automatic adjustment is accomplished through movement of actuating lever and secondary shoe.
BRAKE WARNING LIGHT
Aztek
Brake warning light is energized when ignition is on and parking brake is applied. If brake fluid level is low, a
low brake fluid level indicator is displayed on message center.
Montana, Silhouette & Venture
Brake warning light is energized when ignition is on and parking brake is applied, or when master cylinder fluid
level is low. Brake warning light is not energized if hydraulic pressure is lost; system is not equipped with
pressure differential switch.
Except Aztek, Montana, Silhouette & Venture
Pressure differential warning switch in combination valve energizes brake warning light on instrument panel
when front or rear brakes lose hydraulic pressure. After repairing failed side of hydraulic system, depress brake
pedal with moderate to heavy pressure to hydraulically center the piston. This will turn off brake warning light.
On vehicles with Hydro-Boost, insufficient flow of power steering fluid to the hydraulic booster system will
turn on brake warning light.
CALIPERS
Front brakes are single piston caliper or dual piston caliper design. See Fig. 11 and Fig. 12 . Rear brakes are
sliding caliper design. Caliper is attached to caliper mount. Caliper is mounted to steering knuckle or caliper
adapter, depending on application. Caliper assembly slides back and forth in machined cutouts.
HYDRAULIC CONTROL VALVES
Dynamic Rear Proportioning (Aztek)
Dynamic Rear Proportioning (DRP) is a control system that replaces hydraulic proportioning function of
mechanical proportioning valve in base brake system. DRP control system is part of operation software in
EBCM. DRP uses active control with existing ABS in order to regulate vehicle's rear brake pressure.
Combination Valve (Except Aztek, Montana, Silhouette & Venture)
System uses a combination valve to regulate brake system hydraulic pressure. Combination valve, located in
brake lines between master cylinder and wheels, has 3 pressure control functions:
Metering (or hold-off) section of valve limits pressure to front brakes until pressure of rear brake shoe
retractor springs is overcome, then allows pressure to front brakes.
Warning switch section of valve constantly compares front and rear brake pressures from master cylinder.
See BRAKE WARNING LIGHT under DESCRIPTION & OPERATION.
Proportioning section of valve allows input pressure to rise to predetermined level before allowing output
pressure to rear brakes. This prevents rear wheel lock-up on vehicles with light rear wheel loads.
Combination valve also contains a by-pass feature. This ensures full system pressure is applied to rear brakes if
front brakes lose hydraulic pressure (or if rear brakes lose hydraulic pressure, full pressure is applied to front
brakes).
Proportioning Valves (Montana, Silhouette & Venture)
System uses 2 proportioning valves, threaded into master cylinder, to regulate brake system hydraulic pressure.
Valves allow input pressure to rise to predetermined level before allowing output pressure to rear brakes. This
prevents rear wheel lock-up on vehicles with light rear wheel loads. Valves also incorporate a by-pass feature
which ensures full system pressure is applied to rear brakes if front brakes lose hydraulic pressure (or if rear
brakes lose hydraulic pressure, full pressure is applied to front brakes).
BLEEDING BRAKE SYSTEM
NOTE: The following bleeding procedures apply to all vehicles except model year 2000
Montana, Silhouette and Venture FWD vans. Manufacturer recommends using
Tech 1 bleeding procedure. See ANTI-LOCK - FWD VAN article. On vehicles with
Hydro-Boost, check for air bubbles in power steering fluid reservoir. If air
bubbles are present, bleed Hydro-Boost system before bleeding brake system.
See POWER BRAKE BOOSTER - BENDIX HYDRO-BOOST article.
MASTER CYLINDER BLEEDING
NOTE: To prevent air from entering brake system, bench bleed master cylinder before
installing.
1. Place master cylinder in soft-jaw vise with front end tilted slightly down. DO NOT overtighten vise. Plug
both outlet ports of master cylinder. Fill master cylinder reservoir.
2. Press and release piston about 1" (25 mm) several times. As air is bled from master cylinder, the primary
piston will not travel the full 1" (25 mm) stroke.
3. Repeat previous step with front end of master cylinder tilted slightly up. Reposition master cylinder in
vise to level position. Loosen front outlet plug and push piston into bore to expel air from cylinder.
Tighten plug and allow piston to return to original position. Repeat procedure at rear outlet plug.
4. Fill reservoir and install master cylinder. DO NOT fully tighten brake lines at this time. Slowly press
brake pedal to floor and hold. Tighten brake lines. Release brake pedal. Bleed brake system. See
MANUAL BLEEDING or PRESSURE BLEEDING .
MANUAL BLEEDING
NOTE: Air tends to cling to caliper walls. When bleeding vehicles with disc brakes,
lightly tap caliper to help remove air.
1. Deplete vacuum reserve from power brake booster by depressing brake pedal several times with engine
off. Fill master cylinder and keep at least three quarters full during bleeding procedure. If master cylinder
is not known or suspected to have air in bore, go to step 4. If master cylinder is known or suspected to
have air in bore, go to next step.
2. Disconnect forward brakeline fitting at master cylinder. Allow fluid to flow from fitting. Tighten fitting to
specification. See TORQUE SPECIFICATIONS. Have an assistant depress brake pedal slowly and
hold. Loosen forward fitting. Tighten fitting while pedal is still at floor. Release brake pedal slowly. Wait
15 seconds.
NOTE: Rapid pumping of brake pedal causes master cylinder secondary piston to
move into a position that makes bleeding system difficult.
3. Repeat step 2, including 15 second wait, until fluid is clear and free of air bubbles. Repeat procedure at
other (rearmost) brakeline fitting on master cylinder. Master cylinder is now bled. If wheel
cylinders/calipers are not suspected to have air in them, it is not necessary to bleed them.
NOTE: On vehicles with 4WAL, if brake pressure modulator valve was replaced,
or is suspected to have air trapped inside, it must be bled next. See
appropriate ANTI-LOCK article.
4. If wheel cylinders/calipers are known or suspected to have air in them, raise and support vehicle. Remove
bleeder valve cap from right rear wheel. Place proper size box end wrench over bleeder valve. Attach one
end of clear tube over valve and submerge other end in container partially filled with clean brake fluid.
5. Have an assistant depress brake pedal slowly and hold. Loosen bleeder valve to purge air from cylinder.
Tighten bleeder valve and slowly release brake pedal. Wait 15 seconds. Repeat sequence, including 15
second wait, until all air is removed.
6. Remove tube and wrench. Repeat step 5 at left rear, right front, and left front wheels in this order. Fill
master cylinder reservoir, and install cover. Ensure there is no sponginess in brake pedal and that BRAKE
warning light is off.
PRESSURE BLEEDING
NOTE: Air tends to cling to caliper walls. When bleeding vehicles with disc brakes,
lightly tap caliper to help remove air.
WARNING: Do not use rigid clamp to position hold-off valve stem. This may damage
valve assembly, causing brake failure.
1. Clean master cylinder cap and surrounding area. Remove cap. Install Brake Pressure Bleeder Adapter (J-
35589-A) onto master cylinder reservoir. With pressure tank at least 2/3 full, connect pressure bleeder to
master cylinder with adapters. Attach bleeder hose to right rear bleeder valve.
NOTE: On vehicles with 4WAL, if brake pressure modulator valve was replaced,
or is suspected to have air trapped inside, it must be bled next. See
appropriate ANTI-LOCK article.
2. Place other end of hose in glass jar partially filled with brake fluid so end of hose is submerged in fluid.
Open release valve on pressure bleeder. Set pressure bleeder to 25-30 psi (1.75-2.11 kg/cm2 ) or pressure
specified by equipment manufacturer.
3. Open bleeder screw 3/4 - 1 turn and note fluid flow. Close bleeder screw when no air bubbles are present
in fluid flow. Repeat procedure on left rear, right front, and left front wheels in this order.
4. Check brake pedal operation. Remove pressure bleeder. Remove valve retainer from hold-off valve.
Refill master cylinder reservoir, if necessary.
ADJUSTMENTS
BRAKE PEDAL TRAVEL
1. Apply brake pedal 3-5 times to deplete brake booster vacuum reserve. Using Brake Pedal Effort Gauge
(J-28662) measure and record distance "A". See Fig. 1. Apply brake pedal with 100 lbs. (45.4 kg) of
force and record distance "B". See Fig. 1. Release brake pedal and remeasure distance "B". Average "B"
measurements and subtract distance "A" from average to obtain brake pedal travel distance. See BRAKE
PEDAL TRAVEL SPECIFICATIONS.
BRAKE PEDAL TRAVEL SPECIFICATIONS

Model In. (mm)
"A", "B" & "U" Series 2.91 (74)
"C", "G" & "K" Series
Vacuum Assist 2.56 (65)
Hydraulic Assist 3.54 (90)
"L" & "M" Series 2.83 (72)
"S" & "T" Series 2.5 (64)
PARKING BRAKE
NOTE: Ensure rear brake shoes are adjusted before adjusting parking brake. See
REAR BRAKE SHOES under ADJUSTMENTS.
Aztek - (Disc)
1. Apply parking brake three clicks. Raise and support vehicle. Attempt to rotate rear wheels by hand. If rear
wheels exhibit drag or do not rotate, parking brake is properly adjusted. If either wheel rotates freely
proceed to next step.
2. Adjust applicable brake lining as necessary. Adjust rear brake shoes. See REAR BRAKE SHOES.
Tighten park brake adjuster nut until both rear wheels exhibit drag. Release parking brake. Rear wheels
should rotate freely. For vehicles with rear disc, verify that park brake actuator levers have returned to
their stops (full release position). If park brake levers do not return to their stops (full release position),
adjust park brake shoe and lining. Lower vehicle.
Aztek (Drum)
1. Apply and fully release parking brake six times. Verify that park brake pedal releases completely. Turn
ON ignition. Verify that brake indicator lamp is off. If brake indicator lamp is on, then ensure that
parking brake is in release mode and fully returned to stop. Check front park cable slack. Remove slack in
front park brake cable by pulling downward on cable.
2. Raise and support vehicle. Adjust rear brake shoes. See REAR BRAKE SHOES. Loosen parking brake
cable adjusting nut. Fully release parking brake pedal. Tighten adjusting nut until wheels will not rotate
forward without excessive force. Back off adjusting nut until little or no drag exists when wheels are
rotated forward. Lower vehicle.
Astro & Safari
Raise and support vehicle. Rotate rear wheels and note amount of drag present. Tighten cable adjuster nut until
rear brake shoe drag begins to increase. Lower vehicle. Apply and release parking brake lever three times. Raise
vehicle. Retighten cable adjuster nut until rear brake shoe drag is present. Loosen cable adjuster nut two
revolutions. Lower vehicle.
1. Apply parking brake three clicks. Raise and support vehicle. Attempt to rotate rear wheels by hand. If rear
wheels exhibit drag or do not rotate, parking brake is properly adjusted. If either wheel rotates freely
proceed to next step.
2. Adjust rear brake shoes. See REAR BRAKE SHOES. Tighten park brake adjuster nut until both rear
wheels exhibit drag. Release parking brake. Rear wheels should rotate freely. Lower vehicle.
"C" & "K" Series (Rear Disc)
NOTE: If parking brake pedal assembly is being replaced, ensure factory installed self
adjuster lock-out pin has been removed before installing assembly.
Remove rear brake caliper and rotor. See REAR BRAKE ROTOR. Using outside/inside brake shoe clearance
gauge, verify parking brake shoes have a clearance of .026" (.66 mm). See Fig. 6 and Fig. 7 . Reinstall brake
rotor. Repeat procedure for opposite side. From inside vehicle, fully apply and release parking brake 3 times to
activate self-adjusting mechanism.
Express & Savana
Block front wheels. Raise and support rear axle. Release parking brake. Measure exposed threads on cable
adjuster. Tighten cable adjuster nut until threads measure .511" (13 mm). Verify parking brake will hold with
pedal depressed. If additional adjustment is necessary, tighten cable adjuster nut in .196" (5 mm) increments
until rear wheels exhibit moderate drag. Loosen cable adjuster nut until drag is not present. Verify parking
brake will hold with pedal depressed. Lower vehicle.
"S" & "T" Series
Raise and support vehicle. Loosen parking brake cable adjusting nut. Fully release parking brake pedal. Tighten
adjusting nut until wheels will not rotate forward without excessive force. Back off adjusting nut until little or
no drag exists when wheels are rotated forward. Lower vehicle.
REAR BRAKE SHOES
Aztek
1. Ensure parking brake is released. Raise and support vehicle. Remove tire and wheel. Remove brake
drums. Ensure that stops on both of park brake lever is against brake shoe edges. If parking brake cable is
holding stops off edge of brake shoe, adjust park brake cable.
2. Install Drum Brake Shoe Clearance Gauge (J-21177-A) so that it contacts inside diameter of drum. Rotate
adjuster wheel and use drum brake shoe clearance gauge in order to adjust brake shoe diameter to 0.05
in" (1.27 mm) less than drum inside diameter measurement.
3. Install brake drum. Apply brake pedal 30-35 times with a one second pause between each brake
application. Install tire and wheel. Lower vehicle. Check parking brake adjustment. See PARKING
BRAKE.
1. Ensure parking brake is released. Raise and support vehicle. Mark relationship of wheel and drum bearing
flange. Remove rear wheels. Remove brake drums.
2. Install Drum Brake Shoe Clearance Gauge (J-21177-A) so that it contacts inside diameter of drum.
Position clearance gauge over brake shoes. Rotate adjuster nut until shoes contact gauge.
"G", "L", "M", "S" & "T" Series
1. Raise and support vehicle. Mark relationship of wheel and drum bearing flange. Remove rear wheels.
Remove brake drums.
2. Install Drum Brake Shoe Clearance Gauge (J-21177-A) so that it contacts inside diameter of drum.
Position clearance gauge over brake shoes. Rotate adjusting screw until clearance between gauge and
shoes is .02" (.5 mm). Using punch and hammer, remove knockout plug in backing plate.
3. Install brake drum. Tighten adjusting screw until light drag is present. Drag should be equal for both
wheels. Apply brake pedal two times to center brake shoes on locating pins. Install adjusting hole cover
into backing plate. Lower vehicle. Check parking brake adjustment. See PARKING BRAKE.
STOPLIGHT SWITCH
NOTE: On all models, except Aztek, Montana, Silhouette and Venture, stoplight switch
is installed along with brake push rod and is not adjustable.
Aztek
Insert stoplight and cruise control switch (if equipped) into brake pedal bracket. Install stoplight switch and
cruise control switch (if equipped) into slotted grooves until switches are fully depresed against brake pedal,
then turn switches clock-wise approximately 1/4 turn, switches should now be installed and adjusted.
Depress and hold brake pedal. Push switch forward until firmly seated in retaining clip. Pull brake pedal
rearward against pedal stop (clicks can be heard as switch ratchets through retaining clip). Release brake pedal.
Switch is adjusted if brake lights do not come on with pedal released.
TESTING
BRAKE WARNING LIGHT
Electrical Circuit
Disconnect wire from switch terminal on combination valve. Connect wire to ground. Turn ignition on. If brake
warning light does not come on, repair brake warning light bulb or wiring circuit. If light operates, brake
warning light electrical circuit is okay.
NOTE: On Astro and Safari, system is not equipped with pressure differential switch.
Warning Light Switch
1. Fill master cylinder reservoir. Attach bleeder hose to bleeder screw at either rear wheel. Immerse other
end of hose in container of brake fluid. Turn ignition on.
2. While depressing brake pedal, open bleeder screw (close bleeder screw before releasing pedal). On all
models except Astro and Safari, if light comes on, go to next step. If light does not come on, switch is
defective; replace combination valve.
3. Close bleeder screw. Depress brake pedal with moderate to heavy pressure. If light goes out, switch is
okay. If light stays on, switch is defective, replace combination valve. Repeat test on front brake system.
System should function in same manner as rear.

FRONT BRAKE CALIPER
NOTE: Replace all pads on an axle if wear indicator on any pad contacts rotor or if pad
is worn to within .03" (.8 mm) of pad backing.
Removal (Dual Piston)
1. Remove 2/3 of brake fluid from master cylinder. Raise and support vehicle. Remove wheel. Position "C"
clamp onto caliper and tighten until piston bottoms in its bore.
2. Disconnect brake hose from caliper. Remove caliper guide pins. See Fig. 12. Remove caliper. Remove
pads from caliper. Note retainer spring on inner pad (some models) and remove if replacing pads.
Installation
1. Remove caliper sleeves from caliper. See Fig. 12. Apply silicone grease to outer diameter of caliper
sleeves and inner diameter of bushings. Insert caliper sleeves into bushings.
2. Install retainer spring on inner pad (if removed). Install pads in caliper. Install caliper. Install guide pins
and tighten to specification. See TORQUE SPECIFICATIONS.
3. Connect brake hose to caliper and tighten to specification. See TORQUE SPECIFICATIONS. Bleed
brake system. See MANUAL BLEEDING or PRESSURE BLEEDING .
4. If outer pads are equipped with locking ears, bend ears toward caliper until ears touch caliper. This
prevents movement of outer pad in caliper. See Fig. 2.
Fig. 2: Bending Outer Pad Ears Toward Caliper
Removal (Single Piston)
1. Remove two-thirds of brake fluid from master cylinder. Raise and support vehicle. Remove wheel. Using
"C" clamp or large pliers, compress caliper piston until it bottoms in its bore.
2. Disconnect brake hose from caliper. Remove and discard gaskets. See Fig. 11. Remove caliper mounting
bolts. Remove caliper.
Installation
1. Lubricate sleeves and bushings with silicone lubricant. Install NEW "O" rings to caliper. Install caliper
mounting bolt sleeves. See Fig. 11. Install brake linings. Install caliper mounting bolts. On "S" & "T"
models, bend outer pad ears toward caliper. See Fig. 2.
2. To complete installation, reverse removal procedure. Tighten all fasteners to specification. See TORQUE
SPECIFICATIONS. Bleed brake system. See MANUAL BLEEDING or PRESSURE BLEEDING .
FRONT BRAKE ROTOR
Removal ("C" & "K" Series)
Raise and support vehicle. Remove wheels and tires. Remove front wheel hub extension, dual rear wheels only.
Remove brake caliper (DO NOT disconnect brake hose) and wire aside. See FRONT BRAKE CALIPER.
Remove rotor retainer push nuts, if equipped. Remove rotor and hub assembly.
Inspection
Inspect rotor lateral runout and parallelism. See DISC BRAKE SPECIFICATIONS. If lateral runout cannot
be corrected check hub bearing for excessive lateral runout or looseness. Hub bearing assembly lateral runout
cannot exceed .0016" (.040 mm).
Installation
Align rotor to original position. To complete installation, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS. Bleed brake system. See MANUAL BLEEDING or
PRESSURE BLEEDING .
Removal ("A", "B", "G", "L", "M", "S", "T" & "U" Series)
Remove brake caliper (DO NOT disconnect brake hose) and wire aside. See FRONT BRAKE CALIPER.
Remove rotor.
Installation
Install hub and rotor assembly. To complete installation, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS. Bleed brake system. See MANUAL BLEEDING or
PRESSURE BLEEDING .
REAR BRAKE CALIPER
NOTE: For rear disc pad removal and installation, DO NOT disconnect brake hose from
caliper (wire aside). Replace all pads on an axle if wear indicator on any pad
contacts rotor or if pad is worn to within .03" (.8 mm) of pad backing.
Removal ("A", "B", "C", "K" & "U" Series)
1. Remove 2/3 of brake fluid from master cylinder reservoir. Raise and support vehicle. Remove wheel.
Using "C" clamp, compress caliper piston until it bottoms out in its bore.
2. Remove brake hose from caliper. Remove and discard brake hose gaskets. Plug openings in brake caliper
and brake hose in order to prevent brake fluid loss and contamination. Remove caliper guide pin bolts.
Remove brake caliper.
Removal ("S" & "T" Series)
1. Remove 2/3 of brake fluid from master cylinder reservoir. Raise and support vehicle. Remove wheel.
Using "C" clamp, compress caliper piston until it bottoms out in its bore.
2. Remove brake hose from caliper. Remove caliper guide pin bolts. Remove caliper from caliper anchor
bracket.
Installation
To install, reverse removal procedure. Lubricate caliper guide pin bolts with silicon lubricant. Tighten all nuts
and bolts to specification. See TORQUE SPECIFICATIONS. Bleed brake system. See MANUAL
BLEEDING or PRESSURE BLEEDING .
REAR BRAKE ROTOR
Removal
Raise and support vehicle. Remove 2/3 of brake fluid from master cylinder reservoir. Remove brake caliper,
and wire aside. See REAR BRAKE CALIPER. Remove rotor.
Installation
To install, reverse removal procedure. Tighten all nuts and bolts to specification. See TORQUE
SPECIFICATIONS. Bleed brake system. See MANUAL BLEEDING or PRESSURE BLEEDING .
REAR BRAKE DRUM
Removal & Installation (Aztek)
1. Ensure parking brake is released. Raise and support vehicle. Remove tire and wheel. Mark relationship of
drum to hub. Remove and discard retaining clip, if applicable. Remove brake drum. If brake drum does
not come off easily, go to next step.
2. Loosen parking brake cable. Remove access hole plug from backing plate. Insert a flat- bladed tool
through backing plate access hole in order to disengage self adjuster. Insert another flat-bladed tool
through same backing plate access hole to loosen adjuster screw. Install access hole plug in order to
prevent dirt or contamination from entering drum brake. Apply a small amount of penetrating oil around
brake drum center hole. Remove brake drum. To install, reverse removal procedure. Adjust rear brake
shoes. See REAR BRAKE SHOES under ADJUSTMENTS.
Removal & Installation (Except Aztek, & Express & Savana With Full-Floating Axle)
Ensure parking brake is released. On Savana and Express, remove left kick panel. Place parking brake lever in
full upright position. With an assistant in vehicle, raise and support vehicle. Pull rearward on front of cable
strand until parking brake lever reaches its full reset position. Insert a pin into parking brake lever to hold
tension. See Fig. 3. On all models, remove wheel. Reference mark rear brake drum-to-axle. Remove brake drum
(if necessary, back off adjuster wheel before removing brake drum). To install, reverse removal procedure.
Adjust rear brake shoes. See REAR BRAKE SHOES under ADJUSTMENTS.
Fig. 3: Locking Parking Brake Lever (Savana & Express)
Removal (Express & Savana With Full-Floating Axle)
1. Ensure parking brake is released. Raise and support rear of vehicle. Remove wheel. Remove bolts from
end of axle shaft. See Fig. 4.
2. Lightly tap axle shaft flange with soft hammer to loosen shaft. Grip rib on axle shaft flange with locking
pliers. Twist axle shaft to start shaft removal. Pull axle shaft from axle housing.
3. Bend lock washer tab away from lock nut. Using Wheel Bearing Nut Wrench (J-2222-C), remove lock
nut. Remove lock washer. Remove adjusting nut and washer. Remove hub and brake drum assembly (if
necessary, back off adjuster wheel before removing brake drum).
Fig. 4: Exploded View Of Rear Axle Shaft, Hub & Brake Drum Assembly (Full-Floating Axle)
Installation
1. Apply light coat of bearing lubricant to axle tube. Install hub and brake drum assembly. Install washer
and adjusting nut. Using Wheel Bearing Nut Wrench (J-2222-C), tighten adjusting nut to specification,
while turning hub and rotor assembly. See TORQUE SPECIFICATIONS.
2. To complete installation, reverse removal procedure. Tighten fasteners to specification. See TORQUE
SPECIFICATIONS.
REAR BRAKE SHOES
NOTE: Do not interchange left and right adjusting screw assemblies as one side is
right-hand thread and other is left-hand thread.
Removal ("G", "L", "M", "S" & "T" Series)
1. Raise and support vehicle. Remove tire and wheel. On Express and Savana, install pin into parking brake
lever. See Fig. 3. Remove rear brake drum. See REAR BRAKE DRUM.
2. Remove return springs, hold down springs and pins, and brake shoe guide. See Fig. 13Remove rear brake
shoe actuator and link. Remove parking brake lever and strut. Remove rear brake shoe adjuster and
spring. Remove brake shoes.
Removal (Aztek, Montana, Silhouette & Venture)
1. Raise and support vehicle. Remove wheel and tire. Remove brake drum. See REAR BRAKE DRUM.
Using Brake Shoe Spring Remover (J-38400), remove adjuster and return springs. See Fig. 14.
2. Remove primary brake shoe. Remove adjuster actuator from primary brake shoe. Remove adjuster from
secondary brake shoe and park brake actuator. Remove park brake actuator from secondary brake shoe.
3. Using Brake Shoe Spring Remover (J-38400), remove secondary return spring. Remove secondary brake
shoe.
Installation
To install, reverse removal procedure. Lubricate backing plate and adjusting screws with silicone lubricant.
Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS. Bleed brake system. See
MANUAL BLEEDING or PRESSURE BLEEDING .
PARKING BRAKE SHOES (REAR DISC BRAKES)
Removal (1500)

2. Remove the tire and the wheel.
3. Remove the caliper and mounting bracket as an assembly.
4. Relieve the tension on the park brake cables by loosening the nut at the equalizer.
5. Remove the parking brake cable from the lever.
6. Remove the rotor.
7. Remove the rear axle shaft.
8. Turn the star adjuster screw (5) to the fully home position in the notched adjustment nut. See Fig. 5.
9. Remove the park brake shoe assembly by sliding the shoe (2) toward the retaining spring clip (3) until the
shoe disengages from the spring clip and pin.
Fig. 5: Identifying Rear Park Brake Components (Rear Disc Brakes)

Installation
1. Clean the debris and the dust from the park brake components using a clean towel.
2. Align the slots in both the star adjuster screw and tappet to be parallel with the backing plate face.
3. Position the park brake shoe on the inboard side of the actuator.
4. Slide the parking brake shoe into position and seat into the retaining spring.
5. Inspect the shoe assembly position.
6. The shoe must be central on the backing plate with both tips located in the slots.
7. Adjust the park brake shoe. Using outside/inside brake shoe clearance gauge, verify parking brake shoes
have a clearance of .026" (.66 mm). See Fig. 6 and Fig. 7 .
8. Install the axle shaft.
9. Install the rotor. Install the park brake cable to the park brake lever.
NOTE: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or
sealant are identified in the service procedure. Do not use paints,
lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces
unless specified. These coatings affect fastener torque and joint clamping
force and may damage the fastener. Use the correct tightening sequence
and specifications when installing fasteners in order to avoid damage to
parts and systems.
10. Tighten the nut to the intermediate cable at the equalizer to 31 INCH lbs. (3.5 N.m).
11. Install the caliper and mounting bracket as an assembly.
13. Remove the safety stands.
15. Adjust parking brake cable.
Fig. 6: Measuring Rotor Inner Park Brake Diameter
Fig. 7: Measuring Park Brake Shoe Outer Diameter (Widest Point)
Removal (2500)

2. Remove the tire and the wheel.
3. Remove the caliper and mounting bracket as an assembly.
4. Relieve the tension on the park brake cables by loosening the nut at the equalizer.
5. Remove the parking brake cable from the lever.
6. Remove the rotor.
7. Remove the axle shaft. See AXLE SHAFT article in DRIVE AXLES.
8. Remove the park brake shoe return springs (4 and 6). See Fig. 5
9. Remove the park brake shoe anchor spring clips and pins (3).
10. Remove the park brake shoes (2).
Installation
1. Clean the debris and the dust from the park brake components using a clean towel.
2. Install the park brake shoes (2).
3. Install the park brake shoe anchor spring clips and pins (3).
4. Install the park brake shoe return springs (4 and 6).
5. Adjust the park brake shoe. Using outside/inside brake shoe clearance gauge, verify parking brake shoes
have a clearance of .026" (.66 mm). See Fig. 6 and Fig. 7 .
6. Install the axle shaft.
7. Install the rotor.
8. Install the park brake cable to the park brake lever.
NOTE: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or
sealant are identified in the service procedure. Do not use paints,
lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces
unless specified. These coatings affect fastener torque and joint clamping
force and may damage the fastener. Use the correct tightening sequence
and specifications when installing fasteners in order to avoid damage to
parts and systems.
9. Tighten the nut to the intermediate cable at the equalizer. Tighten the nut to 31 INCH lbs. (3.5 N.m).
10. Install the caliper and mounting bracket as an assembly.
12. Remove the safety stands.
14. Adjust parking brake cable.
WHEEL CYLINDER
Removal & Installation (Aztek, Montana, Silhouette and Venture)
Remove rear brake drum. See REAR BRAKE DRUM. Remove brake pipe. On Aztek models, install a cap
over end of brake pipe in order to prevent brake fluid loss and/or brake fluid contamination. On all models,
remove wheel cylinder bolts. Using Brake Shoe Spring Remover (J-38400), spread brake shoes apart. Remove
wheel cylinder. To install, reverse removal procedure. Bleed brake system. See MANUAL BLEEDING or
PRESSURE BLEEDING under BLEEDING BRAKE SYSTEM.
Removal & Installation ("G", "L", "M", "S" & "T" Series)
Remove rear brake shoes. See REAR BRAKE SHOES. Disconnect brake line from wheel cylinder. Remove
brake cylinder retaining bolts and brake cylinder. To install, reverse removal procedure. Bleed brake system.
See MANUAL BLEEDING or PRESSURE BLEEDING under BLEEDING BRAKE SYSTEM.
MASTER CYLINDER
Removal
1. With engine off, press brake pedal several times to release vacuum in power brake unit. Clean dirt and
grease from master cylinder brake line fittings. Disconnect brake lines from master cylinder and plug line
ends. On Aztek, disconnect fluid level sensor electrical connector.
2. On vehicles with combination valve and bracket attached to master cylinder mounting studs, remove
combination valve and bracket. On vehicles without power brake unit, disconnect brake pedal push rod at
brake pedal. On all vehicles, remove master cylinder retaining nuts and master cylinder.
Installation
1. Bench bleed master cylinder before installing. See MASTER CYLINDER BLEEDING under
BLEEDING BRAKE SYSTEM. Position master cylinder on mounting studs. Position combination valve
and bracket on mounting studs (if applicable). Loosely install master cylinder retaining nuts. Connect
brake lines to master cylinder but DO NOT tighten.
2. Tighten master cylinder retaining nuts. On Aztek, connect fluid level sensor electrical connector. Tighten
brake lines. See TORQUE SPECIFICATIONS. Connect brake pedal push rod (if disconnected). Fill
fluid reservoir. Bleed brake system. See MANUAL BLEEDING or PRESSURE BLEEDING .
POWER BRAKE BOOSTER
Removal (Aztek)
1. Remove air cleaner and duct. Remove vacuum hose from check valve. Reposition vacuum hose. Remove
throttle cables from throttle body and bracket. Remove heater inlet pipe. Remove fuel lines from pipes
and vapor line.
2. Remove ABS hydraulic modulator/master cylinder. Remove EGR tube. Remove exhaust crossover.
Remove transmission fluid filler tube. Remove left side instrument panel insulator.
NOTE: When disconnecting pushrod from brake pedal, brake pedal must be held
staionary or damage to brake switch may result.
3. Remove knee bolster. Disable SIR system. Remove booster push rod retaining clip and washer from
brake pedal asembly. Remove brake booster push rod from brake pedal. Remove master cylinder/ABS
modulator. Remove mounting nuts and brake booster.
Installation
CAUTION: When replacing power booster brake, ensure that cruise control cable is
not routed between booster and cowl. If cable is damaged or pinched, it
must be replaced. Failure to do this could result in personal injury.
To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS. Bleed brake system if lines were disconnected from master cylinder. See MANUAL
BLEEDING or PRESSURE BLEEDING under BLEEDING BRAKE SYSTEM.
Removal & Installation (Except Aztek)
NOTE: For Hydro-Boost removal and installation. See POWER BRAKE BOOSTER -
BENDIX HYDRO-BOOST article.
1. Remove master cylinder. See MASTER CYLINDER. Ensure no brake fluid contacts ABS control unit
or related electrical connectors and wiring.
2. Disconnect vacuum hose from booster. Disconnect booster push rod from brake pedal. Remove booster
mounting nuts from inside vehicle. Remove booster and gasket.
3. To install, reverse removal procedure. On Savana and Express, tighten booster retaining nuts to
specification in a cross pattern using following procedure. Tighten right lower, left upper, left lower and
then right upper retaining nut. Bleed brake system if lines were disconnected from master cylinder. See
MANUAL BLEEDING or PRESSURE BLEEDING under BLEEDING BRAKE SYSTEM.
COMBINATION VALVE
Removal (Astro & Safari)
Raise and support vehicle. Disconnect brake warning light electrical connector from combination valve switch.
Disconnect brake lines from valve. Cap brake line ends. Remove valve mounting bolts. Remove valve.
Installation
To install, reverse removal procedure. Bleed brake system. See MANUAL BLEEDING or PRESSURE
BLEEDING under BLEEDING BRAKE SYSTEM. Center the brake warning light switch piston by applying
moderate to heavy force on brake pedal.
Removal (Express & Savana)
Raise and support vehicle. Remove combination valve shield. Disconnect electrical connector from combination
valve. Disconnect front and rear brake pipes. Remove combination valve from master cylinder.
Installation
NOTE: Install NEW transfer tubes with new combination valve. See Fig. 8.
To install, reverse removal procedure. Bleed brake system. See MANUAL BLEEDING or PRESSURE
BLEEDING under BLEEDING BRAKE SYSTEM. Center the brake warning light switch piston by applying
moderate to heavy force on brake pedal.
Fig. 8: Exploded View Of Combination Valve (Express & Savana)

REAR AXLE BEARING & OIL SEAL (SEMI-FLOATING AXLE)
Removal ("L", "M", S" & "T" Series)
1. Raise and support vehicle. Remove wheels and brake drums, if equipped. Loosen differential cover plate
and drain lubricant from axle. Remove cover plate.
2. Remove pinion shaft lock bolt. See Fig. 9 and Fig. 10 . Remove pinion shaft. Push axle shaft toward
center of vehicle and remove "C" lock from end of axle shaft. Remove axle shaft.
3. Pry seal from axle housing. Using slide hammer and axle bearing puller, remove bearing from axle
housing.
Fig. 9: Locating "C" Lock & Pinion Shaft Lock Bolt (Astro, Safari, & "S" & "T" Series Shown; Others
Similar)
Installation
1. Lubricate bearing with gear lubricant. Using handle and bearing installer, install bearing in axle housing
until bearing installer bottoms against shoulder of axle housing.
2. Using seal installer, install seal until even with surface of axle housing. Lubricate seal lips with gear
lubricant. Install axle shaft and "C" lock. See Fig. 9 and Fig. 10 . Pull axle shaft outward to ensure "C"
lock seats in side gear.
3. Install pinion shaft. Install NEW pinion shaft lock bolt. Tighten lock bolt to 25 ft. lbs. (34 N.m). Install
differential cover and new gasket. Fill drive axle with gear lubricant.
Fig. 10: Removing & Installing "C" Lock & Pinion Shaft On Locking Differential (Typical)
Removal (Except "L", "M", S" & "T" Series)
1. Raise and support vehicle. Remove wheel and brake drum. Loosen differential cover plate and drain
lubricant from axle. Remove cover plate. Remove pinion shaft lock bolt. See Fig. 9 and Fig. 10 .
2. On locking differential models, remove pinion shaft part way. Rotate differential case until pinion shaft
contacts axle housing. Using screwdriver, rotate "C" lock until it aligns with thrust block. On all models,
push axle shaft toward center of vehicle and remove "C" lock from end of axle shaft.
3. Remove axle shaft from axle housing. Using seal remover, remove seal from axle housing. Remove
bearing using slide hammer and bearing puller.
Installation
1. Lubricate bearing and seal lips with wheel bearing grease. Fill axle cavity between seal and axle with
wheel bearing grease.
2. Using Bearing Installer (J-23690) on 8 1/2" and 8 5/8" ring gear or (J-29709) on 9 1/2" ring gear, install
bearing until installer contacts axle housing. Using Seal Installer (J-21128) on 8 1/2" and 8 5/8" ring gear
or (J-29713) on 9 1/2" ring gear, install seal until even with axle housing.
3. Install axle shaft. DO NOT damage seal. Ensure splines on axle shaft engage with splines on side gear.
To install remaining components, reverse removal procedure. Ensure "C" lock is fully seated or
positioned in thrust block. See Fig. 9 and Fig. 10 .
4. Install pinion shaft. Apply Loctite No. 242 to pinion shaft lock bolt threads and tighten to specifications.
See TORQUE SPECIFICATIONS. Install differential cover and new gasket. Fill axle with gear
lubricant.
REAR AXLE HUB BEARINGS & OIL SEAL (FULL-FLOATING AXLE)
NOTE: Outer bearing race is seated against a retaining ring inside hub, on inboard side
of race. Remove retaining ring from inside of hub before driving out race.
Removal
1. Remove rear hub and rotor assembly. See REAR BRAKE ROTOR. Using a long drift and hammer,
drive out inner bearing race, inner bearing and oil seal from outboard to inboard side of hub.
2. Remove retaining ring from inside of hub, inboard of outer bearing. Using handle and outer bearing race
remover/installer, drive out outer bearing race from outboard to inboard side of hub.
Installation
1. Clean and pack bearings with wheel bearing lubricant. Using handle and bearing race installer, drive
outer wheel bearing race into hub from inboard side of hub (ensure chamfered edge of bearing race
installer is facing upward so that it does not contact bearing race).
2. Install retaining ring on inboard side of outer bearing race. Turn hub and rotor assembly inboard side
down. Using outer bearing race remover/installer, seat outer bearing race against retaining ring.
3. Using inner bearing race remover/installer, drive inner bearing race into hub from inboard side of hub.
Install inner bearing. Install new oil seal using axle shaft seal installer.
4. To complete installation, reverse removal procedure. To adjust wheel bearings, see REAR BRAKE
ROTOR.
OVERHAUL
NOTE: Use exploded view illustrations for overhaul of brake assemblies. See Fig. 11-
Fig. 20 .
WARNING: Do not hone master cylinder bore. Honing destroys hardened surface,
causing premature piston seal failure. If bore surface is rough or pitted,
replace master cylinder.
Fig. 11: Exploded View Of Single Piston Caliper Assembly (Typical)
Fig. 12: Exploded View Of Dual Piston Caliper Assembly (Typical)
Fig. 13: Exploded View Of Rear Brake Shoe Assembly (Except, Montana, Silhouette & Venture)
Fig. 14: Exploded View Of Rear Brake Shoe Assembly (Montana, Silhouette & Venture)
Fig. 15: Exploded View Of Power Brake Booster (Dual Diaphragm)
Fig. 16: Exploded View Of Power Brake Booster (Single Diaphragm)
Fig. 17: Exploded View Of Cast Iron Master Cylinder

Fig. 18: Exploded View Of Composite Master Cylinder (Except Montana, Silhouette & Venture)
Fig. 19: Exploded View Of Composite Master Cylinder (Montana, Silhouette & Venture)
Fig. 20: Exploded View Of Rear Wheel Cylinder (Typical)

Astro, Safari, & "S" & "T" Series
Drum
Original Diameter 9.50 (241.3)
Discard Diameter 9.59 (243.6)
Maximum Allowable Diameter After Refinish Diameter 9.56 (242.8)
Width 2.00 (50.8)
Aztek
Drum
Allowable Radial Runout (Maximum) .006 (.015)
Allowable Scoring (Maximum) .06 (1.5)
Express & Savana
Drum
Original Diameter
1500 & 2500 Series 11.15 (283.2)
2500 (Diesel) & 3500 13.00 (330.2)
Discard Diameter
11.15" Drum 11.24 (285.5)
13.00" Drum 13.09 (332.5)
Maximum Allowable Diameter After Refinish
11.15" Drum 11.21 (284.7)
13.00" Drum 13.06 (331.7)
Width
11.15" Drum 2.75 (69.9)
13.00" Drum 2.50 (63.5) Or 3.50
(88.9)
Drum
Original Diameter 8.86 (225.0)
Wheel Cylinder Diameter .937 (23.80)

Lateral Runout (All Models) .003 (.08)
Parallelism (All Models) .0005 (.013)
Original Thickness
Astro & Safari
2WD 1.04 (26.4)
AWD 1.25 (31.75)
Aztek
Front 1.18 (30.0)
Rear .43 (11.0)
"C" & "K" Series
Front
1500 Series 1.14 (29)
2500 & 3500 Series 1.50 (38)
Rear
8 5/8" Ring Gear .787 (20)
9 1/2" Ring Gear & 10 1/2" Ring Gear 1.14 (29)
11 1/2" Ring Gear 1.18 (30)
Express & Savana
1500 & 2500 (Light Duty) 1.25 (31.75)
2500 (Gasoline Engine) 1.26 (32.0)
2500 (Diesel) & 3500 1.5 (38.1)
Montana, Silhouette,& Venture 1.27 (32.2)
"S" & "T" Series 1.03 (26.2)
Front
Single Piston 1.03 (26.2)
Dual Piston 1.14 (29)
Rear .787 (20)
Minimum Refinish Thickness (1)
Astro, Safari
2WD .980 (24.89)
AWD 1.23 (31.2)
Aztek
Front 1.125 (28.58)
Rear .41 (10.6)
"C" & "K" Series
Front
1500 & 2500 Series 1.1 (28)
3500 Series 1.46 (37)
Rear
8 5/8" Ring Gear .748 (19)
9 1/2" & 10 1/2" Ring Gear 1.1 (28)
11 1/2" Ring Gear 1.142 (29)
Express & Savana
1500 & 2500 Light Duty 1.23 (31.24)
2500 (Diesel) & 3500 Series 1.48 (37.59)
Montana, Silhouette & Venture 1.25 (31.8)
"S" & "T" Series
Front
Single Piston
.98 (24.89)
Dual Piston 1.13 (28.7)
Rear .735 (18.67)
Discard Thickness
Astro, Safari
2WD .965 (24.51)
AWD 1.215 (30.86)
Aztek
Front 1.063 (27.0)
Rear .35 (9.0)
"C" & "K" Series
Front
1500 1.082 (27.50)
2500 & 3500 1.437 (36.50)
Rear
8 5/8" Ring Gear .728 (18.5)
9 1/2" & 10 1/2" Ring Gear 1.082 (27.5)
11 1/2" Ring Gear 1.122 (28.5)
Express & Savana
1500 & 2500 1.215 (30.86)
2500 (Diesel) & 3500 1.465 (37.21)
Montana, Silhouette & Venture 1.21 (30.7)
"S" & "T" Series .965 (24.51)
Front
Single Piston .965 (24.51)
Dual Piston 1.08 (27.4)
Rear .728 (18.5)
(1) Use specification stamped on rotor (if available).
Axle Shaft-To-Hub Bolt 52 (71)
Backing Plate Bolts 103 (140)
"C" & "K" Series 100 (136)
"L", "M", & "S" & "T" Series 35 (47)
Brake Cylinder Bolts 13 (18)
Brake Line Fittings
"A", "B" & "U" Series 15 (20)
"C", "G" & "K" Series 18 (24)
"L", "M", & "S" & "T" Series 13 (18)
Brake Line Fittings-To-EBCM 15 (20)
Brake Hose-To-Front Brake Caliper
"A", "B" & "U" Series 40 (54)
"C", "G" & "K" Series 38 (52)
"L", "M", & "S" & "T" Series 32 (43)
Brake Hose-To-Rear Brake Caliper "A" & "B" Series 32 (43)
Brake Hose-To-Rear Brake Caliper "C" & "K" Series
1500 35 (47)
2500 & 3500 38 (52)
Caliper Guide Pin
"C" & "K" Series
Front 80 (108)
Rear
1500 31 (42)
2500 & 3500 80 (108)
"S" & "T" Series
Front
Single Piston 38 (52)
Dual Piston 85 (115)
Rear 23 (31)
Caliper Bolt
Aztek
Front 26 (35)
Rear 33 (45)
Except Aztek 38 (52)
Caliper Mounting Bracket-To-Backing Plate
15 Series 148 (200)
25 Series 122 (165)
Caliper Mounting Bracket-To-Knuckle
15 Series 129 (175)
25 Series 221 (300)
Combination Valve Allen Bolts 12 (16)
Differential Cover Bolt
Astro & Safari 22 (30)
"C" & "K" Series 24 (33)
Express & Savana 30 (41)
"S" & "T" Series
7 5/8" Ring Gear 25 (34)
8 5/8" Ring Gear 29 (39)
Astro & Safari 19 (26)
"C", "G", "K", & "S" & "T" Series
7 5/8" Ring Gear 20 (27)
8 1/2" & 8 5/8" Ring Gear 27 (37)
9 1/2" Ring Gear 37 (50)
Power Booster Nuts
"C", "G", "K", "L" & "M" Series 27 (37)
"S" & "T" Series 30 (41)
Montana, Silhouette & Venture 18 (24)
Wheel Lug Nut
"A", "B", "L", "M" & "U" Series 100 (136)
"C", "G" & "K" Series
Single Wheel 140 (190)
Dual Wheel 175 (237)
"S" & "T" Series 92 (125)
Wheel Cylinder Bolt (Aztek) 8.9 (12)
(1) Use NEW pinion shaft lock bolt. DO NOT reuse bolt.
(2) On "C" and "K" series, apply Loctite No. 242 to bolt threads.
Bumpers - Aztek & Rendezvous
SPECIFICATIONS

Specification
Front Bumper Fascia Bolt 10 N.m 89 lb in
Front Bumper Fascia Lower Support Bolt 10 N.m 89 lb in
Front Bumper Fascia Upper Support Bolt 5 N.m 44 lb in
Front Bumper Impact Bar Bolt 50 N.m 37 lb ft
Front Inboard Upper Front Bumper Impact Bar Bolt 50 N.m 37 lb ft
Grille Screws 2 N.m 18 lb in
Lower Outboard Front Bumper Impact Bar Bolt 25 N.m 18 lb ft
Rear Bumper Impact Bar Bolt 50 N.m 37 lb ft

INSPECTION AFTER COLLISION
The following components may require replacement, if the collision was so severe that the bumper did not
return to the original position:
The bumper fascia

The bumper energy absorber
The bumper impact bar
REPAIR INSTRUCTIONS
FASCIA REPLACEMENT - FRONT BUMPER - UPPER (AZTEK)
Tools Required
Removal Procedure
Fig. 1: View Of Front Bumper Fascia Bolts (Aztek)
1. Remove the front fender liners. Refer to Front Fender Liner Replacement in Body Front End.
2. Remove the headlamps. Refer to Headlamp Assembly or Headlamp Bulb Replacement (Aztek) or
Headlamp Assembly or Headlamp Bulb Replacement (Rendezvous) in Lighting Systems.
3. Remove the fog lamps. Refer to Fog Lamp Replacement - Front (Aztek) or Fog Lamp Replacement -
Front (Rendezvous) in Lighting Systems.
4. Remove the bolts from the front bumper fascia at the fender.
Fig. 2: Identifying Upper Bumper Fascia Support Push-In Retainers (Aztek)
5. Remove the push-in retainers from the upper bumper fascia support using J 38778 .
Fig. 3: Locating Front Bumper Energy Absorber Push-In Retainers (Aztek)
6. Remove the push-in retainers to the fascia at the front bumper energy absorber using J 38778 .
7. Remove the fascia from the vehicle.
8. Remove the grilles from the fascia. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille
Replacement (Rendezvous) .
9. Remove the fascia outer support from the fascia.
Fig. 4: View of Upper & Lower Fascia (Aztek)
10. Remove the upper fascia from the lower fascia.
1. Install the upper fascia to the lower fascia.

2. Install the fascia outer support to the fascia.

3. Install the grilles. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille Replacement
(Rendezvous) .
4. Position the fascia to the vehicle.
5. Align the alignment pins of the fascia to the front fenders and moldings.
6. Install the push-in the retainers starting at the center, to the front upper bumper fascia support.

7. Install the bolts to the front fascia at the front fenders.
Tighten: Tighten the front fascia bolts to 10 N.m (89 lb in).
IMPORTANT: Push the retainer tabs up and against the front bumper energy absorber.
8. Install the push-in retainers to the fascia at the energy absorber.

9. Install the fog lamps. Refer to Fog Lamp Replacement - Front (Aztek) or Fog Lamp Replacement -
10. Install the headlamps. Refer to Headlamp Assembly or Headlamp Bulb Replacement (Aztek) or
11. Install the front fender liners. Refer to Front Fender Liner Replacement in Body Front End.
FASCIA REPLACEMENT - FRONT BUMPER - UPPER (RENDEZVOUS)

Tools Required
Removal Procedure
Fig. 9: View Of Front Bumper Fascia (Rendezvous)

6. Remove the push-in retainers from the fascia at the front bumper energy absorber using J 38778 .
Fig. 10: Locating Front Fender Ball Socket Retainer (Rendezvous)
7. Disengage the ball socket retainer from the ball on the front fender.
9. Remove the grille from the fascia. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille
10. Remove the fascia outer support.
Fig. 11: View Of Upper & Lower Fascia (Rendezvous)

2. Install the fascia outer support.

3. Install the grille to the fascia. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille
6. Engage the ball socket to the ball on the front fender

FASCIA REPLACEMENT - FRONT BUMPER - LOWER (AZTEK)
Tools Required
Removal Procedure

6. Remove the push-in retainers to the fascia at the front bumper energy absorber using J 38778 .
8. Remove the grilles from the fascia. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille
9. Remove the fascia outer support from the fascia.

2. Install the fascia outer support to the fascia.

3. Install the grilles. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille Replacement
(Rendezvous) .


FASCIA REPLACEMENT - FRONT BUMPER - LOWER (RENDEZVOUS)

Tools Required
Removal Procedure

6. Remove the push-in retainers from the fascia at the front bumper energy absorber using J 38778 .
7. Disengage the ball socket retainer from the ball on the front fender.
9. Remove the grille from the fascia. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille
10. Remove the fascia outer support.

2. Install the fascia outer support.

3. Install the grille to the fascia. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille
6. Engage the ball socket to the ball on the front fender

FASCIA GRILLE REPLACEMENT (AZTEK)
Removal Procedure
Fig. 29: View Of Fascia Grille Retaining Tabs (Aztek)

1. Remove the headlamp assembly. Refer to Headlamp Assembly or Headlamp Bulb Replacement
(Aztek) or Headlamp Assembly or Headlamp Bulb Replacement (Rendezvous) in Lighting Systems.
2. Using a small flat-bladed tool, reach into the opening behind the front fascia and depress the retaining
tabs (1, 2, 3, 4, 5) that lock the front fascia grille to the front fascia.
3. Remove the grille from the front fascia.
Fig. 30: View Of Fascia Grille Retaining Tabs (Aztek)
1. Position the grille retaining tabs to the slots in the front fascia.
2. Install the grille by pressing into place until the retaining tabs (1, 2, 3, 4, 5) are fully seated.
3. Install the headlamp assembly. Refer to Headlamp Assembly or Headlamp Bulb Replacement (Aztek)
or Headlamp Assembly or Headlamp Bulb Replacement (Rendezvous) in Lighting Systems.
FASCIA GRILLE REPLACEMENT (RENDEZVOUS)
Removal Procedure
Fig. 31: Locating Fascia Grille Retaining Screws (Rendezvous)
1. Remove the headlamp assembly refer to Headlamp Assembly or Headlamp Bulb Replacement
2. Remove the grille screws.
Fig. 32: View Of Upper Grille Retainers (Rendezvous)
3. Remove the retainers from the top of the grille.

4. Using a flat bladed tool, reach into the opening behind front fascia and depress the tabs that lock the front
fascia grille to the front fascia.
5. Remove the grille from the front fascia.
Fig. 33: View Of Upper Grille Retainers (Rendezvous)
1. Align the grille pin and locking tabs to the front fascia.
2. Press inward on the grille until all tabs are locked in place.
3. Install the retainers to the top of the grille.
Fig. 34: Locating Fascia Grille Retaining Screws (Rendezvous)
4. Install the grille screws.
Tighten: Tighten the grille screws to 2 N.m (18 lb in).

5. Install the headlamp assembly refer to Headlamp Assembly or Headlamp Bulb Replacement (Aztek)
or Headlamp Assembly or Headlamp Bulb Replacement (Rendezvous) in Lighting Systems.
FASCIA SUPPORT REPLACEMENT - FRONT BUMPER UPPER
Removal Procedure
Fig. 35: View Of Headlamp Wiring Harness

1. Remove the fascia. Refer to Fascia Replacement - Front Bumper - Upper (Aztek) or Fascia
Replacement - Front Bumper - Upper (Rendezvous) .
2. Remove the hood latch and cable. Refer to Hood Latch Release Cable Replacement .
3. Disconnect the headlamp wiring harness from the fascia upper support.
4. Remove the bolts from the fascia upper support.
Fig. 36: Identifying Fascia Upper Support

5. Remove the fascia upper support from the upper radiator support.
Fig. 37: Identifying Fascia Upper Support
1. Position the fascia upper support to the upper radiator support.

Fig. 38: View Of Headlamp Wiring Harness
2. Install the bolts to the fascia upper support.
3. Install the bolts to the fascia lower support.
4. Connect the headlamp wiring harness to the fascia upper support.

5. Install the hood latch and cable. Refer to Hood Latch Release Cable Replacement .
6. Install the front bumper fascia. Refer to Fascia Replacement - Front Bumper - Upper (Aztek) or
Fascia Replacement - Front Bumper - Upper (Rendezvous) .
IMPACT BAR REPLACEMENT - FRONT BUMPER
Removal Procedure
Fig. 39: Cross Sectional View Of Upper Inboard Impact Bolt

1. Remove the front bumper fascia. Refer to Fascia Replacement - Front Bumper - Upper (Aztek) or
Fascia Replacement - Front Bumper - Upper (Rendezvous)
2. Remove the energy absorber. Refer to Energy Absorber Replacement - Front (Aztek) or Energy
Absorber Replacement - Front (Rendezvous) .
3. Remove the bolt from the upper inboard impact bar through the access hole in the radiator support.
Fig. 40: Locating Horns Mounting Bolts

4. Disconnect the electrical connector from the horn.

5. Remove the horns from the impact bar.
Fig. 41: View Of Impact Bar Bolts
6. Remove the remainder of the impact bar bolts.

7. Remove the impact bar.
IMPORTANT: Position the left side first, then the right side.
1. Position the impact bar to the body using the alignment pin for location.
2. Install the bolts to secure the impact bar to the front bumper.
Tighten: Tighten the bolts to 25 N.m (18 lb ft).

Fig. 43: Cross Sectional View Of Upper Inboard Impact Bolt
3. Through the access hole in the radiator support, install the bolt to secure the impact bar to the front
bumper.
Tighten: Tighten the bolt to 50 N.m (37 lb ft).

Fig. 44: Locating Horns Mounting Bolts
4. Install the horn to the impact bar.

5. Install the impact bar bolt to the horn.
6. Connect the electrical connector to the horn.

7. Install the energy absorber. Refer to Energy Absorber Replacement - Front (Aztek) or Energy
Absorber Replacement - Front (Rendezvous) .
ENERGY ABSORBER REPLACEMENT - FRONT (AZTEK)
Tools Required
Removal Procedure
Fig. 45: View Of Front Bumper Energy Absorber Push-In Retainers (Aztek)
2. Use J 38778 to remove the push-in retainers from the front bumper energy absorber.
Fig. 46: Identifying Front Bumper Energy Absorber (Aztek)
3. Remove the energy absorber from the front bumper impact bar.
Fig. 47: Identifying Front Bumper Energy Absorber (Aztek)
1. Position the energy absorber to the front bumper impact bar.

2. Starting with the center hole, install the push-in retainers to the front bumper energy absorber.
ENERGY ABSORBER REPLACEMENT - FRONT (RENDEZVOUS)
Tools Required
Removal Procedure
2. Use J 38778 to remove the push-in retainers from the front bumper energy absorber.
3. Remove the energy absorber from the front bumper impact bar.
1. Position the energy absorber to the front bumper impact bar.

2. Starting with the center hole, install the push-in retainers to the front bumper energy absorber.
FASCIA REPLACEMENT - REAR BUMPER (AZTEK)
Tools Required
Removal Procedure
Fig. 51: View Of Rear Bumper Fascia Inboard Side Push-In Retainers (Aztek)
1. Open the endgate.

2. Using J 38778 , remove the rear bumper fascia push-in retainers at the inboard side of the rear quarter
panel.
Fig. 52: Locating Rear Bumper Fascia Push-In Retainers To Rear Impact Bar (Aztek)
3. Using J 38778 , remove the push-in retainers from the rear bumper fascia at the rear impact bar.
Fig. 53: Identifying Rear Bumper Fascia Upper Tab Push-In Retainers (Aztek)
4. Using J 38778 , remove the push-in retainers from the rear bumper fascia upper tabs.
5. Remove the rear bumper fascia from the vehicle.
Fig. 54: View Of Rear Bumper Fascia (Aztek)
6. Remove the grommets from the rear pillar using a small flat-bladed tool, if required.
Fig. 55: View Of Rear Bumper Fascia (Aztek)
1. Install the grommets to the rear pillar, if removed.

2. Position the rear bumper fascia to the vehicle.
3. Install the rear bumper fascia tabs to the rear quarter moldings.
4. Starting at the center hole, install the push-in retainers to the lower rear bumper fascia.
Fig. 57: Identifying Rear Bumper Fascia Upper Tab Push-In Retainers (Aztek)
5. Install the push-in retainers to the rear bumper fascia upper tabs.
Fig. 58: View Of Rear Bumper Fascia Inboard Side Push-In Retainers (Aztek)
6. Install the rear bumper fascia push-in retainers to the inboard side of the rear quarter panel.
7. Close the endgate.
FASCIA REPLACEMENT - REAR BUMPER (RENDEZVOUS)
Tools Required
Removal Procedure
Fig. 59: View Of RH/LH Rear Bumper Fascia Screws (Rendezvous)

2. Remove the screws from the right and left side of the rear bumper fascia at the inboard side of the rear
quarter panel, using the J 38778 .
Fig. 60: Identifying Rear Bumper Fascia Push-In Retainers To The Rear Impact Bar (Rendezvous)
3. Using J 38778 , remove the push-in retainers from the rear bumper fascia at the rear impact bar.
4. Using J 38778 , remove the push-in retainers from the rear bumper right and left fascia upper tabs.
Fig. 61: Locating Ball Stud On Rear Bumper Fascia (Rendezvous)
5. Disengage the ball stud on each side of the rear bumper fascia.
6. Partially remove the rear bumper fascia from the vehicle.
Fig. 62: Identifying Rear Parking Assist Electrical Connector (Rendezvous)
7. Disconnect the rear parking assist electrical connector.

8. Remove the rear fascia from the vehicle.
9. Remove the rear parking assist object sensor from the rear bumper fascia. Refer to Rear Object Sensor
Replacement in Rear Parking Assist.
10. Remove the energy absorber from the rear fascia.
Fig. 63: Identifying Rear Parking Assist Electrical Connector (Rendezvous)
1. Install the energy absorber to the rear fascia.

2. Install the rear parking assist object sensor to the rear bumper fascia. Refer to Rear Object Sensor
Replacement in Rear Parking Assist.
3. Partially install the rear bumper fascia.
4. Connect the rear parking assist electrical connector.
Fig. 64: Locating Ball Stud On Rear Bumper Fascia (Rendezvous)
5. Position the rear bumper fascia to the vehicle.

6. Engage the ball stud on each side of the rear bumper fascia.
7. Starting at the center hole, install the push-in retainers to the lower rear bumper fascia.
8. Install the push-in retainers to the rear bumper fascia upper tabs.
Fig. 66: View Of RH/LH Rear Bumper Fascia Screws (Rendezvous)
9. Install the screws to the rear bumper fascia at the inboard side of the rear quarter panel.
ENERGY ABSORBER REPLACEMENT - REAR (AZTEK)
Tools Required
Removal Procedure
Fig. 67: View Of Rear Bumper Energy Absorber Push-In Retainers (Aztek)
1. Remove the rear bumper fascia. Refer to Fascia Replacement - Rear Bumper (Aztek) or Fascia
Replacement - Rear Bumper (Rendezvous) .
2. Using J 38778 , remove the push-in retainers from the rear bumper energy absorber.
Fig. 68: Identifying Rear Bumper Energy Absorber (Aztek)
3. Remove the rear bumper energy absorber from the rear bumper impact bar.
1. Install the rear bumper energy absorber to the rear bumper impact bar.
Fig. 70: View Of Rear Bumper Energy Absorber Push-In Retainers (Aztek)
2. Install the push-in retainers to the rear bumper energy absorber.

3. Install the rear bumper fascia. Refer to Fascia Replacement - Rear Bumper (Aztek) or Fascia
ENERGY ABSORBER REPLACEMENT - REAR (RENDEZVOUS)
Tools Required
Removal Procedure
2. Remove the rear bumper energy absorber from the rear fascia.
1. Install the rear bumper energy absorber to the rear fascia.

IMPACT BAR REPLACEMENT - REAR BUMPER
Removal Procedure
2. Remove the energy absorber. Refer to Energy Absorber Replacement - Rear (Aztek) or Energy
Absorber Replacement - Rear (Rendezvous) .
3. Remove the impact bar bolts.
Fig. 74: Identifying Impact Bar
4. Remove the impact bar.
IMPORTANT: Position the left side first, then the right side.
1. Position the impact bar to the body using the alignment pin for location.

2. Install the impact bar bolts.
Tighten: Tighten the impact bar bolts to 50 N.m (37 lb ft).
3. Install the energy absorber. Refer to Energy Absorber Replacement - Rear (Aztek) or Energy
Absorber Replacement - Rear (Rendezvous) .

SPECIAL TOOLS
Special Tools
Illustration Part Number/Description
J 38778
Venture
CABIN AIR FILTERS
Passenger Compartment Air Filter - Aztek, Montana, Rendezvoius, Silhouette, Trans Sport &
Venture
NOTE: Manufacturer's terminology for this filter is passenger compartment air filter or
ventilation filter.
CABIN AIR FILTER
Removal (1997-2000)
1. Open the instrument panel compartment door. Remove the rear compartment door.
2. Open the heater A/C module access door.
3. Pull out and remove the first passenger compartment air filter.
4. Pull out and remove the second passenger compartment air filter. See Fig. 1.
Fig. 1: Removing & Installation Of Passenger Compartment Air Filter

Venture
Installation (1997-2000)
1. Insert the first passenger compartment air filter into the opening. Slide over and install the first passenger
compartment air filter.
2. Slide the second passenger compartment air filter directly into the opening. Install the second passenger
compartment air filter. See Fig. 1.
3. Close the heater A/C module access door.
4. Install the rear compartment door.
5. Close the instrument panel door.
Removal (2001-2006)
NOTE: Numbers in parenthesis refer to numbers in figures.
1. Open the instrument panel compartment door.

2. Remove the rear inside instrument panel compartment door. Open the HVAC module assembly access
door (1). See Fig. 2.
Venture
Fig. 2: Identifying HVAC Module Assembly Access Door (2001-2006)

3. Pull out and remove the right hand compartment air filter. See Fig. 1.
4. Slide the left hand passenger compartment air filter to the opening. Pull out and remove the remaining
passenger compartment air filter.
Installation (2001-2006)
1. Install the left hand passenger compartment air filter into the opening. Slide the left hand passenger
compartment air filter over. See Fig. 1.
2. Install the right hand passenger compartment air filter directly into the opening.
3. Close the HVAC module assembly access door (1). See Fig. 2.
4. Install the rear inside instrument panel compartment door. Close the instrument panel compartment door.
Generators & Regulators
WARNING: Vehicles are equipped with air bag supplemental restraint system. Before
attempting any repairs involving steering column, instrument panel or
related components, see SERVICE PRECAUTIONS and DISABLING &
ACTIVATING AIR BAG SYSTEM in appropriate AIR BAG RESTRAINT
SYSTEMS article in ACCESSORIES & EQUIPMENT.

battery.
The Valeo SG10 and SG12 generators have high amperage output. Generators include a delta stator, rectifier
bridge, rotor with slip rings and brushes, conventional pulley and dual internal fans. A built-in regulator
incorporates fault detection circuitry. A conventional pulley and dual internal fans are used to cool slip ring end
frame, rectifier bridge and regulator.
The generator operates with 3 wire connections and a ground path through the mounting bracket. The first wire
connection is the BAT (output) terminal. This terminal must be connected to the battery during operation. The
second wire connection is between generator terminal "L" (connector terminal "B") internal regulator light
driver to Powertrain Control Module (PCM). This circuit monitors and controls generator operation. The PCM
controls indicator light function. The third wire connection is between generator terminal "F" (connector
terminal "C") and PCM. The PCM also monitors this circuit.
Regulated voltage varies with temperature. System limits voltage by controlling rotor field current while field
current is on. Regulator switches rotor field current on and off at a fixed frequency of 400 cycles per second to
help control radio noise. By varying overall on/off time, correct average field current for proper system voltage
control is obtained. At high speeds, with lower electrical loads, on-time may be 10 percent. At low speeds, with
higher electrical loads, on-time may be as much as 90 percent. See GENERATOR SPECIFICATIONS .
ADJUSTMENTS
BELT TENSION
NOTE: Drive belt tension is controlled by a belt tensioner. No adjustment is required.
TROUBLE SHOOTING
NOTE: For additional information, see TROUBLE SHOOTING article in GENERAL

INFORMATION.
PRELIMINARY INSPECTION
Verify customer complaint by operating suspected system. Visually inspect for obvious signs of mechanical and
electrical damage. Inspect for blown fuses. Inspect for loose or corroded connections, damaged wiring
harnesses and/or switches. Check for a broken or partially broken wire inside insulation, which could cause
system malfunction but prove good in a continuity/voltage check with system disconnected. Ensure any
aftermarket electronic equipment is properly installed. If fault is found, repair as necessary. If no fault is found,
perform self-diagnostics. See SELF-DIAGNOSTIC SYSTEM .
ON-VEHICLE TESTING

battery.
NOTE: Before making electrical checks, visually inspect all terminals for clean, tight
connections. Ensure all charging system related fuses are okay. Check
generator mounting bolts and drive belt tension. Ensure battery is in good
condition prior to testing charging system. Ensure starting system is okay. See
STARTERS - AZTEK article.
NOTE: Connector Test Adapter Kit (J-35616-A) must be used whenever a test
procedure requires checking or probing terminal. Manufacturer recommends
using CS Electronic Generator Tester (J-41450-B) to test charging system.
Follow instructions provided with tester. No additional testing available.
BATTERY TESTING & INSPECTION
NOTE: Manufacturer recommends using Battery Tester (J-42000) for testing battery.
Follow instructions provided with tester.
1. Inspect battery for a cracked, broken or damaged case. If battery case is okay, go to next step. If battery
case is not okay, go to step 19 .
2. Compare battery cold cranking amperage and reserve capacity rating to specifications. See BATTERY
SPECIFICATIONS table. If battery meets or exceeds specifications, go to next step. If battery does not
meet or exceed specifications, go to step 19 .
BATTERY SPECIFICATIONS
Application Specification
3.4L (LA1) Engine (GM P/N 19001810)
Replacement 78A-72
Battery
Number
Cold 660 Amps
Cranking
Amps
Reserve 115 Minutes
Capacity
Rating
3. Inspect battery hydrometer display. If hydrometer display shows a Yellow dot, go to next step. If
hydrometer display does not show a Yellow dot, go to step 5 .
4. Using a small screwdriver, tap top of hydrometer display to dislodge any air bubbles inside. If
hydrometer display does not show a Yellow dot, go to next step. If hydrometer display still shows a
Yellow dot, go to step 19 .
5. Attempt to rotate negative battery cable connector clockwise with moderate finger pressure. If negative
connector rotates, go to next step. If negative connector does not rotate, go to step 7 .
6. Using an INCH lbs. torque wrench, record torque value while loosening negative battery cable bolt. If
torque is less than 89 INCH lbs. (10 N.m), go to next step. If torque is equal to or greater than 89 INCH
lbs. (10 N.m), go to step 8 .
7. Disconnect negative battery cable, and go to step 9 .
8. Disconnect negative battery cable. Inspect battery and cable terminals for corrosion and defects. After
repair are made, go to next step.
9. Attempt to rotate positive battery cable connector clockwise with moderate finger pressure. If battery
cable rotates, go to next step. If battery cable does not rotate, go to step 11 .
10. Using an INCH lbs. torque wrench, record torque value while loosening positive battery cable bolt. If
torque is less than 89 INCH lbs. (10 N.m), go to next step. If torque is equal to or greater than 89 INCH
lbs. (10 N.m), go to step 12 .
11. Disconnect positive battery cable, and go to step 13 .
12. Disconnect positive battery cable. Inspect battery and cable terminals for corrosion and defects. After
repairs are made, go to next step.
13. Using a wire brush, clean lead face of both battery terminals and metal contact surfaces on both cable
connectors. Remove bolts from both battery cable connectors and inspect for corrosion and defects. If
battery and cable terminals are clean and in good condition, go to next step. If corrosion or defects were
found, clean, repair or replace as necessary, and retest system.
14. Connect positive battery cable to battery and tighten bolt to 11 ft. lbs. (15 N.m), and go to next step.
15. Connect negative battery cable to battery and tighten bolt to 11 ft. lbs. (15 N.m), and go to next step.
16. Ensure all electrical loads are off. Follow manufacturers instructions and install Battery Tester (J-42000)
to vehicle battery. Follow any instructions displayed on battery tester. If battery tester passed battery, go
to next step. If battery tester did not pass battery, go to step 18 .
17. Press CODE button on battery tester. Record displayed code on vehicle repair order for warranty
purposes. If battery is okay, go to next step.
18. Press CODE button on battery tester. Record displayed code on vehicle repair order for warranty
purposes. If battery does not pass test, replace battery and go to next step.
19. After repairs are made, testing is complete.
SELF-DIAGNOSTIC SYSTEM
NOTE: Diagnostic trouble code tests are written specifically for use with GM Tech I or
Tech II scan tools. Generic scan tool can be used but may have limited
functions. This article only covers the portion of those systems which relates to
charging system diagnosis. For further information, see appropriate SELF-
DIAGNOSTICS article in ENGINE PERFORMANCE or BODY CONTROL
MODULES - AZTEK article in ACCESSORIES & EQUIPMENT.
Begin system diagnosis with diagnostic system check. Diagnostic system check will provide following
information:
Identification of control module(s) which command system.

Ability of control module(s) to communicate through serial data circuit.
Identification of any stored DTCs and their current status.
Using diagnostic system check will identify correct procedure for diagnosing system and where procedure is
located.
ENGINE ELECTRICAL DIAGNOSTIC SYSTEM CHECK
1. Perform battery inspection test. See BATTERY TESTING & INSPECTION under ON-VEHICLE
TESTING. After performing inspection, go to next step.
2. Connect scan tool to Data Link Connector (DLC). Turn ignition switch to RUN position. If scan tool
powers up, go to next step. If scan tool does not power up, see BODY CONTROL MODULES - AZTEK
article in ACCESSORIES & EQUIPMENT.
3. Turn ignition switch to RUN position. Using scan tool, attempt to communicate with Body Control
Module (BCM), Instrument Panel Cluster Module (IPC) and Powertrain Control Module (PCM) on class
2 serial data circuit. If scan tool communicates with each module, go to next step. If scan tool does not
communicate with each module, see BODY CONTROL MODULES - AZTEK article in ACCESSORIES
& EQUIPMENT.
4. Using scan tool, select DISPLAY DTC function and retrieve any BCM, IPC or PCM DTCs. Record all
displayed DTCs, status of displayed DTCs and module that set the DTC. If any DTCs are displayed, go to
next step. If no DTCs are displayed, repair charging system by symptom. See SYMPTOM INDEX table
under SYSTEM TESTS.
5. If scan tool does not display DTCs which begin with "U", go to next step. If scan tool displays DTCs
which begin with "U", perform appropriate test. See BODY CONTROL MODULES - AZTEK article in
ACCESSORIES & EQUIPMENT.
6. If scan tool displays DTCs B1000, perform appropriate. See DIAGNOSTIC TROUBLE CODE
DEFINITIONS in BODY CONTROL MODULES - AZTEK article. If scan tool displays any other DTCs
which begin with "B", see DIAGNOSTIC TROUBLE CODE DEFINITIONS .

DTC (1) Description
B1327 Device Power Circuit Low
B1328 Device Power Circuit High
B1482 Courtesy Light Supply Circuit Low
B1507 High Power Control Circuit Low
B1508 High Power Control Circuit High
P0560 System Voltage
P0620 Generator Turn On Signal Circuit Low
(1) Codes listed in this table are only for testing covered in this article. For complete DTC listing, see
BODY CONTROL MODULES - AZTEK article in ACCESSORIES & EQUIPMENT.
DIAGNOSTIC TESTS
NOTE: For correct circuit identification for DTCs which begin with "B", see GROUND
DISTRIBUTION or POWER DISTRIBUTION article in WIRING DIAGRAMS.
DTC B1327: DEVICE POWER CIRCUIT LOW
1. If engine electrical diagnostic system check was performed, go to next step. If engine electrical diagnostic
system check was not performed, go to ENGINE ELECTRICAL DIAGNOSTIC SYSTEM CHECK
under SELF-DIAGNOSTIC SYSTEM.
2. Connect scan tool to Data Link Connector (DLC). Turn ignition switch to RUN position. Using scan tool,
observe ELECTRONIC BATTERY FD from BCM data list. If scan tool indicates battery voltage is 9
volts or more, go to next step. If scan tool indicates battery voltage is less than 9 volts, go to TEST A:
CHARGING SYSTEM TEST under SYSTEM TESTS.
3. Replace theft deterrent module. See REMOVAL & INSTALLATION in appropriate STEERING
COLUMN SWITCHES article in ACCESSORIES & EQUIPMENT. After repairs are made, go to next
step.
4. Using scan tool, clear DTCs. Turn ignition switch to RUN position. If DTC B1327 does not reset, system
is okay. If DTC B1327 resets, go to step 2 .
DTC B1328: DEVICE POWER CIRCUIT HIGH
2. Connect scan tool to Data Link Connector (DLC). Start engine. Using scan tool, observe ELECTRONICS
BATTERY FD parameter from BCM data list. If scan tool indicates battery voltage is 18.0 volts or more,
go to next step. If scan tool indicates battery voltage is less than 18.0 volts, go to step 4 .
3. Using DVOM measure voltage across battery terminals. If battery voltage is less than 18.0 volts, go to
next step. If battery voltage is 18.0 volts or more, go to TEST A: CHARGING SYSTEM TEST under
SYSTEM TESTS.
4. Replace Body Control Module (BCM). After replacement, reprogram BCM. See BODY CONTROL
MODULES - AZTEK article in ACCESSORIES & EQUIPMENT. After repair are made, go to next step.
5. Using scan tool, clear DTCs. Start engine. If DTC B1328 does not reset, system is okay. If DTC B1328
resets, go to step 2 .
DTC B1482: COURTESY LIGHT SUPPLY CIRCUIT LOW
2. Connect scan tool to Data Link Connector (DLC). Start engine. Using scan tool, observe ELECTRONICS
BATTERY FD parameter from BCM data list. If scan tool indicates DTC B1482 is not current, go to next
step. If scan tool indicates DTC B1482 is current, problem may be intermittent. Check wiring and
connection, and see PRELIMINARY INSPECTION under TROUBLE SHOOTING.
3. Test courtesy light supply voltage circuit for a short to ground. See appropriate
ILLUMINATION/INTERIOR LIGHTS article. If no problem exists, go to next step. If problem exists,
repair circuit as necessary and go to step 6 .
4. Inspect Body Control Module (BCM) harness connector for poor connections. If no problem exists, go to
next step. If problem exists, repair circuit as necessary and go to step 6 .
5. Replace BCM. After replacement, reprogram BCM. See BODY CONTROL MODULES - AZTEK
article in ACCESSORIES & EQUIPMENT. After repairs are made, go to next step.
6. Using scan tool, clear DTCs. Start engine. If DTC B1482 does not reset, system is okay. If DTC B1482
resets, go to step 2 .
DTC B1507: HIGH POWER CONTROL CIRCUIT LOW
observe DTC information for DTC B1507 from BCM data list. If scan tool indicates DTC B1482 is not
current, go to next step. If scan tool indicates DTC B1482 is current, problem may be intermittent. Check
wiring and connections, and see PRELIMINARY INSPECTION under TROUBLE SHOOTING.
3. Test BCM load control circuit for a short to ground. See POWER DISTRIBUTION and GROUND
DISTRIBUTION articles in WIRING DIAGRAMS. If no problem exists, go to next step. If problem
exists, repair circuit as necessary and then go to step 6 .
4. Inspect BCM harness connector for poor connections. If no problem exists, go to next step. If problem
exists, repair as necessary and then go to step 6 .
6. Using scan tool, clear DTCs. Turn ignition switch to ON position. If DTC B1507 does not reset, system is
okay. If DTC B1507 resets, go to step 2 .
DTC B1508: HIGH POWER CONTROL CIRCUIT HIGH
observe DTC information for DTC B1508 from BCM data list. If scan tool indicates DTC B1482 is not
current, go to next step. If scan tool indicates DTC B1482 is current, problem may be intermittent. Check
wiring and connections, and see PRELIMINARY INSPECTION under TROUBLE SHOOTING.
3. Test BCM load control circuit for a short to voltage. See POWER DISTRIBUTION and GROUND
DISTRIBUTION articles in WIRING DIAGRAMS. If no problem exists, go to next step. If problem
4. Inspect BCM harness connector for poor connections. If no problem exists, go to next step. If problem
6. Using scan tool, clear DTCs. Turn ignition switch to ON position. If DTC B1508 does not reset, system is
okay. If DTC B1508 resets, go to step 2 .
DTC P0560: SYSTEM VOLTAGE
observe ignition 1 signal parameter from PCM data list. If scan tool ignition 1 signal parameter is less
than 9-16 volts, go to next step. If scan tool ignition 1 signal parameter is 9-16 volts or more, go to step
6.
3. Using scan tool, compare ignition 0 parameter with ignition 1 signal parameter from PCM data list. If
readings differ by greater than 0.5 volt, go to next step. If readings differ by less than 0.5 volt, go to
TEST A: CHARGING SYSTEM TEST under SYSTEM TESTS.
4. Test PCM battery positive voltage circuit for high resistance. See POWER DISTRIBUTION and
GROUND DISTRIBUTION articles in WIRING DIAGRAMS. If no problem exists, go to next step. If
problem exists, repair circuit as necessary and then go to step 7 .
5. Inspect PCM harness connector for poor connections. If no problem exists, go to next step. If problem
6. Replace PCM. After replacement, reprogram PCM. See BODY CONTROL MODULES - AZTEK article
in ACCESSORIES & EQUIPMENT. After repairs are made, go to next step.
7. Review and record scan tool fail records data. Using scan tool, clear DTCs. Operate vehicle at less than
25 MPH with engine speed greater than 1000 RPM. Using scan tool, observe specific DTC information
for DTC P0560 until test runs. If scan tool indicates DTC P0560 passed this ignition, system is okay. If
scan tool indicates DTC P0560 failed this ignition, go to step 2 .
DTC P0620: GENERATOR TURN ON SIGNAL CIRCUIT LOW

observe specific DTC information for DTC P0620 from engine controls. If scan tool indicates DTC
P0620 failed this ignition, go to next step. If scan tool indicates DTC P0620 passed this ignition, problem
may be intermittent. Check wiring and connections, and see PRELIMINARY INSPECTION under
TROUBLE SHOOTING.
3. Test generator turn-on signal circuit for a short to ground. See WIRING DIAGRAMS . If no problem
exists, go to next step. If problem exists, repair circuit as necessary and then go to step 6 .
4. Inspect PCM harness connector for poor connections. If no problem exists, go to next step. If problem
exists, repair as necessary and then go to step 6 .
5. Replace PCM. After replacement, reprogram PCM. See BODY CONTROL MODULES - AZTEK article
in ACCESSORIES & EQUIPMENT. After repairs are made, go to next step.
6. Review and record scan tool fail records data. Using scan tool, clear DTCs. Start engine. Using scan tool,
observe specific DTC information for DTC P0620 until test runs. If scan tool indicates DTC P0620
passed this ignition, system is okay. If scan tool indicates DTC P0620 failed this ignition, go to step 2 .
SYSTEM TESTS
NOTE: Before performing any system test, perform PRELIMINARY INSPECTION under
TROUBLE SHOOTING. Ensure starting system is okay. See appropriate
STARTERS article.
SYMPTOM INDEX
Symptom Perform Test
Charging System Test A
Charge Indicator Light Always On B
Charge Indicator Light Inoperative C
Generator Noisy D
TEST A: CHARGING SYSTEM TEST
2. Turn off all electrical loads. Connect scan tool to Data Link Connector (DLC). Start engine. Using scan
tool, observe ignition 1 parameter from PCM data list. If ignition 1 parameter indicates voltage is 11-15.5
volts, go to next step. If ignition 1 parameter indicates voltage is not 11-15.5 volts, problem may be
intermittent. Check wiring and connections, and see PRELIMINARY INSPECTION under TROUBLE
SHOOTING.
NOTE: Green POWER light of tester should remain illuminated while tester is
being used.
3. Turn ignition switch to OFF position. Using charging system Electronic Generator Tester (J41450-B),
connect Red lead to generator output terminal and Black lead to metal generator housing. If Green
POWER light does not illuminate, go to next step. If Green POWER light illuminates, go to step 6 .
4. Using a DVOM, measure voltage between output terminal of generator and generator metal housing. If
battery voltage does not exist, go to next step. If battery voltage exists, go to step 14 .
5. Using a DVOM, measure voltage between output terminal of generator and battery negative terminal. If
battery voltage exists, go to step 12 . If battery voltage does not exist, go to step 11 .
CAUTION: Make sure load is completely turned off before connecting or

disconnecting carbon pile load tester to battery.
6. Connect carbon pile tester to battery. Connect inductive ammeter to output circuit of generator.
Disconnect generator harness connector. Locate matching harness connector on charging system
electronic generator tester and connect it to generator. If Red DIAGNOSTIC light illuminates, go to next
step. If Red DIAGNOSTIC light does not illuminate, go to step 13 .
7. Start engine and allow to idle for 30 seconds. Increase engine speed to 2500 RPM. If Red DIAGNOSTIC
light does not illuminate, go to next step. If Red DIAGNOSTIC light illuminates, go to step 15 .
8. Maintain engine speed at 2500 RPM. Turn On load of carbon pile tester and increase load until load is
equal to test value of generator. See GENERATOR SPECIFICATIONS . If Red DIAGNOSTIC light
does not illuminate, go to next step. If Red DIAGNOSTIC light illuminates, go to step 15 .
9. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. See
GENERATOR SPECIFICATIONS . Using a DVOM, measure voltage drop between generator output
terminal and positive battery terminal. If voltage drop is less than 0.5 volt, go to next step. If voltage drop
is 0.5 volt or more, go to step 11 .
10. Maintain engine speed at 2500 RPM and continue to operate generator at load test value. See
GENERATOR SPECIFICATIONS . Using a DVOM, measure voltage drop between generator metal
housing and negative battery terminal. If voltage drop is less than 0.5 volt, go to step 16 . If voltage drop
is 0.5 volt or more, go to step 12 .
11. Repair high resistance or open in generator battery positive voltage circuit. See WIRING DIAGRAMS .
After repairs are made, go to step 16 .
12. Repair high resistance or open in ground circuit of generator. See WIRING DIAGRAMS . After repairs
are made, go to step 16 .
13. Disconnect charging system electronic generator tester harness connector from generator, but leave
alligator clips connected so Green POWER light remains illuminated. Connect a jumper wire with an in-
line 100-ohm resistor between the charging system electronic generator tester harness connector terminal
"B" and a good ground. If Red DIAGNOSTIC light does not illuminate, go to next step. If Red
DIAGNOSTIC light illuminates, go to step 15 .
14. There is a problem with the charging system electronic generator tester. Refer to manufacturers
instructions, how to test the charging system electronic generator tester for proper operation. If the tester
has been repaired or replaced, go to step 3 .
15. Replace generator. See GENERATOR under REMOVAL & INSTALLATION. After repairs are made,
go to next step.
16. Retest system to verify repair. If problems were found and corrected, system is okay. If problem was not
TEST B: CHARGE INDICATOR LIGHT ALWAYS ON
2. Start engine. If battery charge indicator light remains illuminated after 5 second bulb check, go to next
step. If battery charge indicator light does not remain illuminated after 5 second bulb check, problem may
be intermittent. Check wiring and connections, and see PRELIMINARY INSPECTION under
TROUBLE SHOOTING.
3. Connect scan tool to Data Link Connector (DLC). Using scan tool, observe ignition 0 parameter from
PCM data list. If voltage measures 10-15 volts, go to next step. If voltage does not measure 10-15 volts,
go to TEST A: CHARGING SYSTEM TEST .
4. Replace instrument panel cluster. See ANALOG INSTRUMENT PANELS - AZTEK article in
ACCESSORIES & EQUIPMENT. After repairs are made, go to next step.
5. Operate system to verify repair. If problem was found and corrected, system is okay. If problem was not
found and corrected, go to step 2 .
TEST C: CHARGE INDICATOR LIGHT INOPERATIVE
2. Observe battery charge indicator while turning ignition switch to RUN position. If battery charge
indicator light does not illuminate during 5 second bulb check, go to next step. If battery charge indicator
light illuminates during 5 second bulb check, problem may be intermittent. Check wiring and
connections, and see PRELIMINARY INSPECTION under TROUBLE SHOOTING.
3. Replace instrument panel cluster. See ANALOG INSTRUMENT PANELS - AZTEK article in
ACCESSORIES & EQUIPMENT. After repairs are made, go to next step.
4. Operate system to verify repair. If problem was found and corrected, system is okay. If problem was not
found and corrected, go to step 2 .
TEST D: GENERATOR NOISY
1. Test generator for proper operation. See TEST A: CHARGING SYSTEM TEST . If generator
functions normally, go to next step. If generator does not function normally, go to step 12 .
2. Start engine. Verify that generator noise can be heard. Turn ignition switch to OFF position. Disconnect
4-pin harness connector from generator. Start engine. Listen for generator noise. If noise is still present,
go to next step. If noise has stopped, go to step 12 .
3. Turn ignition switch to OFF position. Remove drive belt. Spin generator pulley by hand. If pulley rotates
smoothly and no noise is present, go to next step. If pulley rotates roughly and/or noise is present, go to
step 12 .
4. Inspect pulley for looseness, or loose pulley nut. If pulley and nut are okay, go to next step. If pulley
and/or nut is loose, go to step 12 .
5. Loosen all generator mounting bolts. Tighten generator mounting bolts to specification. See TORQUE
SPECIFICATIONS . Install drive belt. Start engine and listen for noise. If noise is still present, go to
next step. If noise has decreased or stopped, system is okay.
6. Check for stretched or strained generator harness connections, or hoses or other equipment rubbing on
generator. If problem exists, repair as necessary and then go to next step. If no problem exists, go to step
8.
7. Reroute electrical connections, hoses, etc., away from generator. Start engine and listen for noises. If
noise is still present, go to next step. If noise has decreased or stopped, system is okay.
8. Check drive belt for proper tension. If drive belt is loose, go to next step. If drive belt is okay, go to step
10 .
9. Replace drive belt tensioner. See appropriate article in ENGINES. Start engine and listen for noise. If
noise has decreased or stopped, system is okay. If noise is still present, go to step 12 .
10. Check comparable vehicle for similar noise. If noise is not present in similar vehicle, go to next step. If
noise is present in similar vehicle, system is okay.
11. If no definite generator problems were found, ensure all other possible sources of noise are eliminated. If
all possibilities have been eliminated, replace generator. See GENERATOR under REMOVAL &
INSTALLATION. After repairs are made, go to next step.
12. Start engine and verify that noise is reduced or eliminated. If noise is still objectionable, go to step 2 .
BENCH TESTING
NOTE: Manufacturer recommends replacing generator assembly. Bench testing

procedures are not provided.
WARNING: When battery is disconnected, vehicle computer and memory systems

battery.
GENERATOR
1. Disconnect negative battery cable. Rotate and secure engine forward to access rear generator bolts.
Remove generator BAT terminal nut and lead. Remove drive belt. Remove generator front bolt and rear
bolts. Remove generator from bracket and position generator above drive axle. Remove drive belt
tensioner and generator bracket.
CAUTION: Do not disconnect power steering pipes from power steering pump.
2. Remove power steering pipes from power steering pipe retainer. Remove fuel pressure test port (Schrader
valve) cap from fuel injector rail. Remove power steering pump and reposition power steering pump in
front of timing chain cover in order to provide access for generator. Remove electrical harness from
retainer on right fender well and position aside. Remove generator.
3. To install, reverse removal procedure. Tighten bolts and nuts to specification. See TORQUE
SPECIFICATIONS .
OVERHAUL
NOTE: All generators are serviced by replacement only.
GENERATOR SPECIFICATIONS
GENERATOR OUTPUT RATING
Option Code Generator Rated AMP Output Load Test AMP Output
K68 SG10 105 73
KG7 SG12 125 87
Bracket Bolt 37 (50)
Generator Bolts 37 (50)
WIRING DIAGRAMS
Fig. 1: Charging System Wiring Diagram (Aztek)
GENERAL MOTORS (TRUCKS & VANS)
NOTE: Before performing Electronically Erasable Programmable Read Only Memory

(EEPROM) programming procedure, check for any applicable Technical Service
Bulletins (TSBs) that may apply to vehicle application. BCM/PCM/VCM must be
programmed with proper Regular Production Option (RPO) configurations.
Follow instructions on Techline(R) terminal and scan tool to program
BCM/PCM/VCM.
ASTRO & SAFARI
NOTE: Read all procedures listed to determine why and when each procedure is to be
performed before proceeding.
Crankshaft Position (CKP) Sensor Variation Learn Procedure
1. Procedure must be performed if any of following have been done:

EEPROM was reprogrammed.
If CKP sensor was removed or replaced.
VCM was replaced.
2. Install scan tool. Apply parking brake. Block rear wheels. Ensure hood is closed.
3. Place transmission in Park (A/T models) or Neutral (M/T models). Start and warm engine until engine
coolant temperature is at least 150F (65C). Ensure all accessories are off.
4. Apply service brakes. With engine idling, use scan tool to select and enable CKP sensor variation learn
procedure.
5. Gradually accelerate engine to 4000 RPM. Quickly release throttle to idle position once CKP sensor
variation learn procedure fuel cut-off is obtained and engine starts to decelerate. Once CKP sensor
variation values are learned, VCM will return engine control to operator and engine will respond to
throttle position.
CAUTION: Ensure throttle is quickly released to idle position once CKP sensor
variation learn procedure fuel cut-off is obtained and engine starts to
decelerate.
6. If CKP sensor variation learn procedure was completed, turn ignition off for at least 15 seconds and
remove scan tool. If CKP sensor variation learn procedure was not completed, DTC P1336 will set.
Perform diagnostic test procedures for DTC P1336 and repair as necessary. See appropriate SELF-
DIAGNOSTICS article in ENGINE PERFORMANCE.
Electronically Erasable Programmable Read Only Memory (EEPROM) Programming
1. If VCM was replaced, the EEPROM in the VCM must be programmed. If EEPROM is not programmed,
a DTC will be set.
2. Ensure battery is fully charged. Ensure cable is properly connected on Data Link Connector (DLC). Turn
ignition switch to ON position. Perform EEPROM programming using Techline(R) equipment. Follow
manufacturer's instructions and latest software applicable for vehicle model.
3. Once EEPROM is reprogrammed, CKP sensor variation learn procedure and password learn procedure
for anti-theft system must be performed. See CRANKSHAFT POSITION (CKP) SENSOR
VARIATION LEARN PROCEDURE. See PASSWORD LEARN PROCEDURE FOR ANTI-
THEFT SYSTEM.
NOTE: If EEPROM programming fails, ensure all harness connections on VCM are
okay. Check Techline(R) for latest software. If EEPROM programming still
fails, replace VCM.
4. Once CKP sensor variation learn procedure and password learn procedure for anti-theft system are
performed, perform Powertrain On-Board Diagnostic (OBD) system check. See POWERTRAIN ON-
BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article in
ENGINE PERFORMANCE.
Password Learn Procedure For Passlock(R) Anti-Theft System
NOTE: If BCM or VCM are replaced, modules must be programmed with vehicle
configuration before performing Passlock(R) reprogramming.
1. Password learn procedure must be performed if VCM, Passlock(R) module or sensor is replaced. A
password is communicated between VCM and Passlock(R) module to provide engine operation. If VCM
is replaced, VCM must learn password from Passlock(R) module.
2. Momentarily turn ignition switch to CRANK position, but do not start engine. Release switch to RUN
position, but do not turn off. Wait 10 minutes and observe SECURITY indicator light.
NOTE: Ensure battery is fully charged before proceeding. Ensure steps are
followed in correct order or procedure may need to be repeated.
3. If Passlock(R) sensor was replaced, SECURITY indicator will flash for 10 minutes. If Passlock(R)
module was replaced, SECURITY indicator will flash for a few seconds, then remain on for 10 minutes.
If VCM was replaced with a new programmed VCM and connected to vehicle for the first time, vehicle
will start and this procedure is not necessary. If replacement VCM was connected to any other vehicle at
any other time, SECURITY indicator will flash for a few seconds, then remain on for 10 minutes.
4. After 10 minutes, SECURITY indicator light will turn off. Turn ignition switch to OFF position and wait
10 seconds.
5. Repeat programming procedure 2 more times. New security code is ready to be communicated. New
password is learned on next ignition switch lock cylinder from OFF to CRANK to ON.
Vehicle Driveability Computer Relearn Procedure
Manufacturer does not provide a specific computer relearn procedure for obtaining proper driveability. If
vehicle battery was disconnected or Vehicle Control Module (VCM) was replaced, driving vehicle will enable
VCM to perform a computer relearn procedure for obtaining proper driveability. Inform customer that
driveability may differ from what they are accustomed to until VCM completes computer relearn procedure.
BLAZER, BRAVADA, ENVOY, JIMMY, PICKUP & SONOMA
BCM Programming
This procedure requires Techline(R) terminal and equipment. Ensure battery is fully charged. Ensure battery
and lighter connectors are secure. Ensure DLC is accessible. Turn ignition switch to ON position. Refer to
Techline(R) terminal and equipment user's instructions.
If BCM fails to program, check all BCM connections, check Techline(R) terminal and equipment for latest
software version. Retry programming. If BCM fails to program again, replace BCM. See appropriate BODY
CONTROL MODULES article in ACCESSORIES & EQUIPMENT. Clear DTCs after programming.
Crankshaft Position (CKP) Sensor Variation Learn Procedure (2.2L & 4.3L)

VCM was replaced.
2. Install scan tool. Apply parking brake. Block rear wheels. Ensure hood is closed.
procedure.
throttle position.
decelerate.
6. If CKP sensor variation learn procedure was completed, turn ignition off for at least 15 seconds. Remove
scan tool. If CKP sensor variation learn procedure was not completed, DTC P1336 will set. Perform
diagnostic test procedures for DTC P1336 and repair as necessary. See appropriate SELF-
Electronically Erasable Programmable Read Only Memory (EEPROM) Programming (2.2L)
1. If PCM was replaced, the EPROM in PCM must be programmed. If EEPROM is not programmed, a
DTC will set. Perform EEPROM programming using Techline(R) equipment manufacturer's instructions
and latest software applicable for vehicle model.
2. Once EEPROM is reprogrammed, CKP sensor variation learn procedure must be performed. See
CRANKSHAFT POSITION (CKP) SENSOR VARIATION LEARN PROCEDURE (2.2L & 4.3L).
1. If VCM was replaced, the EEPROM in VCM must be programmed. If EEPROM is not programmed, a
DTC will set.
ignition switch to ON position. Perform EEPROM programming using the Techline(R) equipment
3. Once EEPROM has been reprogrammed, CKP sensor variation learn procedure and password learn
procedure must be performed. See CRANKSHAFT POSITION (CKP) SENSOR VARIATION
LEARN PROCEDURE (2.2L & 4.3L). See PASSLOCK(R) ANTI-THEFT LEARN PROCEDURE.
Once CKP sensor variation learn procedure and password learn procedure are performed, perform
Powertrain On-Board Diagnostic (OBD) system check. See POWERTRAIN ON-BOARD DIAGNOSTIC
(OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
If EEPROM programming fails, ensure all harness connections on VCM are okay. Check Techline(R) for
latest software. If EEPROM programming still fails, replace VCM.
Passlock(R) Anti-Theft Learn Procedure
NOTE: This procedure allows relearning of BCM module or VCM/PCM learned data
code after replacement of BCM module, Passlock(R) sensor or VCM/PCM. DTC
B3031 will set when entering programming mode.
1. Turn ignition switch to OFF position. Replace failed component.

2. Place transmission in Park (A/T) or Neutral (M/T). Turn ignition switch momentarily to START position
(engine will not start), then leave in RUN position. SECURITY indicator will stay on for 10 minutes.
After 10 minutes, when indicator light turns off, turn ignition switch to OFF position for 5 seconds.
3. Repeat step 2 two more times. Auto learn procedure will be completed during next start attempt. If
VCM/PCM was replaced, reprogram VCM/PCM. See appropriate SELF-DIAGNOSTICS article in
ENGINE PERFORMANCE.
4. Check for DTCs. If Passlock(R) codes exist, go to appropriate ANTI-THEFT SYSTEMS article in
ACCESSORIES & EQUIPMENT. If PCM codes exist, diagnose affected DTC(s). See appropriate SELF-
Vehicle Driveability Computer Relearn Procedure (2.2L)
vehicle battery was disconnected or PCM was replaced, driving vehicle will enable PCM to perform a computer
relearn procedure for obtaining proper driveability. Inform customer that driveability may differ from what they
are accustomed to until PCM completes computer relearn procedure.
Vehicle Driveability Computer Relearn Procedure (4 3L)

vehicle battery was disconnected or VCM was replaced, driving vehicle will enable VCM to perform a
computer relearn procedure for obtaining proper driveability. Inform customer that driveability may differ from
what they are accustomed to until VCM completes computer relearn procedure.
CUTAWAY, EXPRESS, RV CUTAWAY & SAVANA
NOTE: References to California models apply to California emission vehicles, which

may be verified by underhood Emission Control label. California emissions may
be available in other states.
Electronically Erasable Programmable Read Only Memory (EEPROM) Programming (4.3L, 4.8L, 5.0L, 5.3L, 5.7L &
6.0L)
1. If VCM was replaced, EEPROM in VCM must be programmed. If EEPROM is not programmed, a DTC
will be set.
ignition switch to ON position. Perform EEPROM programming using Techline(R) equipment
for anti-theft system must be performed using proper procedure. See appropriate ANTI-THEFT
SYSTEMS article in ACCESSORIES & EQUIPMENT.
NOTE: If EEPROM programming fails, ensure all electrical connections on VCM

are okay. Check Techline(R) for latest software. If EEPROM programming
still fails, replace VCM.
performed, perform powertrain On-Board Diagnostic (OBD) system check. See POWERTRAIN ON-
ENGINE PERFORMANCE.
will be set.
3. Once EEPROM is reprogrammed, use scan tool to reset Idle Air Control (IAC) valve. On Calif. models,
go to next step. On except Calif. models, go to step 5.
4. Once EEPROM is reprogrammed, password learn procedure for anti-theft system must be performed. See
PASSWORD LEARN PROCEDURE FOR ANTI-THEFT SYSTEM (7.4L). Once password learn
procedure for anti-theft system has been performed, perform powertrain On-Board Diagnostic (OBD)
system check. See POWERTRAIN ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in
NOTE: CKP sensor variation learn procedure should ONLY be performed on

except Calif. models. DO NOT perform CKP sensor variation learn
procedure on Calif. models. Verify vehicle application by using underhood
emission control label. If EEPROM programming fails, ensure all electrical
connections on VCM are okay. Check Techline(R) for latest software. If
EEPROM programming still fails, replace VCM.
for anti-theft system must be performed using proper procedure. Once CKP sensor variation learn
procedure and password learn procedure for anti-theft system are performed, perform powertrain On-
Board Diagnostic (OBD) system check. See POWERTRAIN ON-BOARD DIAGNOSTIC (OBD)
SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
Powertrain Control Module (PCM) Programming (6.5L Diesel)
1. If PCM was replaced, PCM must be programmed. If PCM is not programmed, a DTC will be set.
2. Ensure battery is fully charged. Ensure cable at Data Link Connector (DLC) and power supply for scan
tool are properly connected. Turn ignition switch to ON position. Perform EEPROM programming using
Techline(R) equipment manufacturer's instructions and latest software applicable for the vehicle model.
3. Perform password learn procedure for anti-theft system. See PASSWORD LEARN PROCEDURE
FOR ANTI-THEFT SYSTEM (6.5L DIESEL). Once PCM is programmed, if only the PCM was
replaced, go to next step. If crankshaft position sensor, engine or PCM with fuel injection pump were
replaced, perform TDC offset learn procedure. See TDC OFFSET LEARN PROCEDURE (6.5L
DIESEL).
NOTE: If PCM programming fails, ensure all electrical connections on PCM are
fails, replace PCM.
4. Start and warm engine until engine coolant temperature is at least 170F (77C). This will allow TDC
offset to be programmed into the PCM if necessary. PCM has the ability to determine amount of offset
required to bring engine to TDC. PCM uses TDC to determine proper fuel injection pump timing. If TDC
offset is not programmed, DTC P1214 will be set.
TDC Offset Learn Procedure (6.5L Diesel)
1. Procedure must be performed if any of following have been done or exists:

If sent here from DTC P1214.
Engine has been replaced.
CKP sensor or engine front cover has been replaced.

PCM and fuel injection pump have been replaced.
NOTE: DO NOT perform procedure unless sent here from DTC P1214 or one
of the components listed above have been replaced.
2. PCM has the ability to determine amount of offset required to bring the engine to TDC when TDC offset
is not present or has been cleared. This procedure must be performed to allow PCM to be updated with
correct TDC offset for vehicle application.
3. Install scan tool. Start and warm engine until engine coolant temperature is at least 170F (77C). Using
scan tool, clear DTCs from PCM. Turn ignition switch to ON position, engine off. Fully depress and hold
throttle at full throttle for at least 45 seconds.
4. Turn ignition switch to OFF position for 30 seconds. Start engine. Verify scan tool indicates TDC offset
has been cleared to zero. If TDC offset has been cleared to zero, go to next step. If TDC offset has not
been cleared to zero, repeat step 3 until TDC offset has been cleared to zero.
5. With engine running, use scan tool to verify engine coolant temperature is greater than 170F (77C). It
may be necessary to drive vehicle to obtain correct engine coolant temperature if engine coolant
temperature is less than specified.
6. As soon at engine coolant temperature is greater than 170F (77C) and engine speed is less than 1500
RPM, the PCM automatically learns a new TDC offset. The new TDC offset will overwrite the previous
TDC offset. Using scan tool, note new TDC offset. TDC offset should be -.25 to -.75.
7. Turn engine off. If TDC offset is not within specification, go to next step. If TDC offset is within
specification, TDC offset learn procedure is complete.
8. Using Flange Nut Wrench (J41089), loosen fuel injection pump retaining nuts. Fuel injection pump must
be rotated to change TDC offset. Rotating fuel injection pump .039" (1.00 mm) will change TDC offset
about 2 degrees. Rotating fuel injection pump toward driver's side of vehicle will produce a positive (+)
number and rotating fuel injection pump toward passenger's side of vehicle will produce a negative (-)
number.
9. Using Fuel Injection Pump Wrench (J 29872-A), slightly rotate fuel injection pump. Tighten fuel
injection pump retaining nuts.
10. Repeat step 3 through 9 until TDC offset is within specification. If proper TDC offset cannot be obtained,
check the following:
Ensure engine coolant temperature is greater than 170F (77C).
Harness connectors at PCM are properly installed.
Harness connectors at injection timing stepper motor on side of fuel injection pump is correctly
installed.
Ensure latest Techline(R) software was used.
Check for proper base installation of fuel injection pump. The electric engine shutoff solenoid on
top of fuel injection pump should be about up and down.
Fuel injection pump may be defective, although manufacturer states this is highly unlikely.
Crankshaft Position (CKP) Sensor Variation Learn Procedure (4.3L, 5.0L, 5.7L & 7.4L Except Calif.)

VCM was replaced.
2. Install scan tool on Data Link Connector (DLC). Apply parking brake. Block rear wheels. Ensure hood is
closed.
procedure.
throttle position.
decelerate.
6. If CKP sensor variation learn procedure was completed, turn ignition off for at least 15 seconds. Remove
scan tool. If CKP sensor variation learn procedure was not completed, DTC P1336 will set. Perform test
procedures for DTC P1336 and repair as necessary. See appropriate SELF-DIAGNOSTICS article in
ENGINE PERFORMANCE.
Password Learn Procedure For Anti-Theft System (4.3L, 5.0L & 5.7L)
2. Start engine. After engine stalls, leave ignition switch turned to ON position for 10 minutes. The
SECURITY indicator light will stay on for 10 minutes and then turn off. The SECURITY indicator light
is located on right corner of instrument panel.
NOTE: Ensure battery is fully charged before proceeding. Ensure steps are
followed in correct order or procedure may need to be repeated.
3. After SECURITY indicator light turns off, turn ignition off for 30 seconds. Attempt to start engine. After
engine stalls, leave ignition switch turned to ON position for 10 minutes. SECURITY indicator light will
stay on for 10 minutes and then turn off. After SECURITY indicator light turns off, turn ignition off for
30 seconds.
4. Attempt to start engine. After engine stalls, leave ignition switch turned to ON position for 10 minutes.
SECURITY indicator light will stay on for 10 minutes and then turn off.
5. Turn ignition switch to OFF position for 30 seconds. Turn ignition switch to ON position and wait 30
seconds. Attempt to start engine. If engine starts, password learn procedure is complete. If engine does
not start, ensure procedure was properly followed. If procedure was properly followed, check for any
DTCs. If any DTCs exist, perform test procedures for specified DTC and repair as necessary. See
Password Learn Procedure For Anti-Theft System (6.5L Diesel)
1. Password learn procedure must be performed if PCM, Passlock(R) module or sensor is replaced. A
password is communicated between PCM and Passlock(R) module to provide engine operation. If PCM
is replaced, PCM must learn password from Passlock(R) module.
2. Attempt to start engine. Engine will start and then stall. After engine stalls, leave ignition switch turned to
ON position for 10 minutes. After engine stalls, the SECURITY indicator light will stay on for 10
minutes and then turn off. SECURITY indicator light is located on right corner of instrument panel.
NOTE: Ensure battery is fully charged before proceeding. Performing this

procedure will cause DTC P1630 to be set. It will be necessary to use scan
tool to check for DTC P1630 when performing this procedure. Ensure
steps are followed in correct order or procedure may need to be repeated.
3. After SECURITY indicator light goes off, turn ignition off for 30 seconds. Attempt to start engine. After
engine stalls, leave ignition switch turned to ON position for 10 minutes. SECURITY indicator light will
stay on for 10 minutes and then turn off. After SECURITY indicator light turns off, turn ignition off for
30 seconds.
4. Attempt to start. After engine stalls, leave ignition switch turned to ON position for 10 minutes.
SECURITY indicator light will stay on for 10 minutes and then turn off or until DTC P1630 is set.
seconds. Attempt to start engine. If engine starts, password learn procedure is complete. Ensure DTC
P1630 is cleared from PCM by turning ignition off for 30 seconds and then turning ignition switch turned
to ON position again. If DTC P1630 is not cleared from PCM, perform test procedures for DTC P1630
and repair as necessary. See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
NOTE: DTC P1630 will be set in PCM as result of this procedure. DTC P1630 may
be cleared from PCM by turning ignition off for 30 seconds and then
turning ignition switch to ON position again.
6. If engine does not start, ensure procedure was properly followed. If procedure was properly followed,
check for any DTCs. If any DTCs exist, perform test procedures for specified DTC and repair as
necessary. See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
Password Learn Procedure For Anti-Theft System (7.4L)
minutes and then turn off. SECURITY indicator light is located on right corner of instrument panel.
procedure will cause DTC P1630 to set. It will be necessary to use scan
tool to check for DTC P1630 when performing this procedure. Ensure
steps are followed in correct order or procedure may need to be repeated.
3. After SECURITY indicator light turns off, turn ignition off for 30 seconds. Attempt to start engine and
then leave ignition switch turned to ON position. After engine stalls, leave ignition switch turned to ON
position for 10 minutes. SECURITY indicator light will stay on for 10 minutes and then go off. After
SECURITY indicator light turns off, turn ignition off for 30 seconds.
SECURITY indicator light will stay on for 10 minutes and then turn off or until DTC 1630 is set.
1630 is cleared by turning ignition off for 30 seconds and then turning ignition switch to ON position
again. If DTC 1630 is not cleared, perform test procedures for DTC 1630 and repair as necessary. See
NOTE: DTC 1630 will be set as result of this procedure. DTC P1630 may be
cleared from VCM by turning ignition off for 30 seconds and then turning
ignition switch to ON position again.
Vehicle Driveability Computer Relearn Procedure (4.3L, 5.0L, 5.7L & 7.4L)
vehicle battery was disconnected or VCM was replaced, driving vehicle will enable VCM to perform a
what they are accustomed to until VCM completes computer relearn procedure.
Vehicle Driveability Computer Relearn Procedure (6.5L Diesel)
vehicle battery was disconnected or PCM was replaced, driving vehicle will enable PCM to perform a computer
relearn procedure for obtaining proper driveability. Inform customer that driveability may differ from what they
are accustomed to until PCM completes computer relearn procedure.
ESCALADE, PICKUP, SIERRA, SILVERADO, TAHOE, YUKON & YUKON XL
NOTE: References to California models apply to California emission vehicles, which

may be verified by underhood emission control label. California emissions may
be available in other states.
Crankshaft Position (CKP) Sensor Variation Learn Procedure (4.3L, 4.8L, 5.0L, 5.3L, 5.7L, 6.0L & 7.4L)

VCM was replaced.
2. Install scan tool on Data Link Connector (DLC). Apply parking brake. Block rear wheels. Ensure hood is
closed.
procedure.
throttle position.
decelerate.
6. If CKP sensor variation learn procedure was completed, turn ignition off for at least 15 seconds and
remove scan tool. If CKP sensor variation learn procedure was not completed, DTC P1336 will set.
Perform test procedures for DTC P1336 and repair as necessary. See appropriate SELF-DIAGNOSTICS
article in ENGINE PERFORMANCE.
Electronically Erasable Programmable Read Only Memory (EEPROM) Programming (4.3L, 5.0L & 5.7L)
will set.
ignition switch to ON position. Perform EEPROM programming using the Techline(R) equipment
manufacturer's instructions and latest software applicable for the vehicle model.
for anti-theft system must be performed using proper procedure.
NOTE: If EEPROM programming fails, ensure all harness connections on VCM are
fails, replace VCM.
performed, perform powertrain On-Board Diagnostic (OBD) system check. See POWERTRAIN ON-
ENGINE PERFORMANCE.
will set.
3. CKP sensor variation learn procedure should ONLY be performed on except Calif. models. DO NOT
perform CKP sensor variation learn procedure on Calif. models. Verify vehicle application by using
underhood emission control label. On Calif. models, go to next step. On except Calif. models, if
EEPROM programming fails, ensure all harness connections on VCM are okay. Check Techline(R) for
latest software. If EEPROM programming still fails, replace VCM. Once EEPROM is reprogrammed, use
scan tool to reset Idle Air Control (IAC) valve and then go to step 5.
4. Once EEPROM is reprogrammed, password learn procedure for anti-theft system must be performed
using proper procedure. Once password learn procedure for anti-theft system has been performed,
perform powertrain On-Board Diagnostic (OBD) system check. See POWERTRAIN ON-BOARD
DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article in ENGINE
PERFORMANCE.
for anti-theft system must be performed using proper procedure. Once CKP sensor variation learn
procedure and password learn procedure for anti-theft system are performed, perform powertrain On-
Board Diagnostic (OBD) system check. See POWERTRAIN ON-BOARD DIAGNOSTIC (OBD)
SYSTEM CHECK in appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
Powertrain Control Module (PCM) Programming (4.8L, 5.3L & 6.0L)
1. Ensure battery is fully charged. Turn ignition switch to ON position. Program PCM using Techline(R)
equipment manufacturer's instructions and latest software applicable for vehicle model.
2. Once PCM is reprogrammed, CKP sensor variation learn procedure, password learn procedure for anti-
theft system, and PCM idle learn procedure must be performed.
NOTE: If programming fails, ensure all harness connections on PCM are okay.
Check Techline(R) for latest software. If programming still fails, replace
PCM.
Powertrain Control Module (PCM) Programming (6.5L Diesel)
1. If PCM was replaced, the PCM must be programmed. If PCM is not programmed, a DTC will be set.
2. Ensure battery is fully charged. Ensure cable at Data Link Connector (DLC) and power supply for scan
tool are properly connected. Turn ignition switch to ON position. Perform EEPROM programming using
Techline(R) equipment manufacturer's instructions and latest software applicable for vehicle model.
3. Perform password learn procedure for anti-theft system using proper procedure. Once PCM is
programmed, if only the PCM was replaced, go to next step. If CKP sensor, engine or PCM with fuel
injection pump were replaced, perform TDC offset learn procedure. See TDC OFFSET LEARN
PROCEDURE (6.5L DIESEL).
NOTE: If PCM programming fails, ensure all harness connections on PCM are
fails, replace PCM.
4. Start and warm engine until engine coolant temperature is at least 170F (77C). This will allow TDC
offset to be programmed into PCM if necessary. PCM has the ability to determine amount of offset
required to bring engine to TDC. PCM uses TDC offset to determine proper fuel injection pump timing.
If TDC offset is not programmed, DTC P1214 will be set.
Password Learn Procedure For Anti-Theft System (4.3L, 4.8L, 5.3L & 6.0L)
1. Password relearn procedure must be performed if Passlock(R) sensor, BCM, PCM or VCM are replaced.
Ensure battery is fully charged.
2. Using scan tool, clear DTCs. Turn ignition switch from OFF to CRANK position, allowing vehicle to try
and start. Vehicle will start and then stall. Leave ignition switch turned to ON position while observing
SECURITY indicator on instrument panel. When security indicator turns off (after about 10 minutes),
turn ignition off. Wait 10 seconds. Repeat this step 3 more times. New password will be learned on next
start attempt.
Password Learn Procedure For Anti-Theft System (5.0L, 5.7L & 7.4L)
minutes and then turn off. The SECURITY indicator light is located on upper right corner of instrument
panel.

procedure will cause DTC P1630 to set. Use scan tool to check for DTC
P1630 when performing this procedure. Ensure steps are followed in
correct order or procedure may need to be repeated.
3. After SECURITY indicator light turns off, turn ignition off for 30 seconds. Start engine. After engine
stalls, leave ignition switch turned to ON position for 10 minutes. SECURITY indicator light will stay on
for 10 minutes and then go off. After SECURITY indicator light turns off, turn ignition off for 30
seconds.
4. Start engine. After engine stalls, leave ignition switch turned to ON position for 10 minutes. SECURITY
indicator light will stay on for 10 minutes and then turn off or until DTC P1630 is set.
P1630 is cleared from VCM by turning ignition off for 30 seconds and then turning ignition switch to ON
position again. If DTC P1630 is not cleared from VCM, perform test procedures for DTC P1630 and
repair as necessary. See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
NOTE: DTC 1630 will be set in VCM as result of this procedure. DTC P1630 may
be cleared from VCM by turning ignition off for 30 seconds and then
turning ignition switch turned to ON position again.
Password Learn Procedure For Anti-Theft System (6.5L Diesel)
1. Password learn procedure must be performed if PCM, Passlock(R) module or sensor is replaced. A
password is communicated between PCM and Passlock(R) module to provide engine operation. If PCM
is replaced, PCM must learn password from Passlock(R) module.
2. Start engine. After engine stalls, leave ignition switch turned to ON position for 10 minutes, the
SECURITY indicator light will stay on for 10 minutes and then turn off. SECURITY indicator light is
located on upper right corner of instrument panel. After SECURITY indicator light turns off, turn ignition
off for 30 seconds.

procedure will cause DTC P1630 to set. Use scan tool to check for DTC
P1630 when performing this procedure. Ensure steps are followed in
correct order or procedure may need to be repeated.
3. Start engine. After engine stalls, leave ignition switch turned to ON position for 10 minutes. SECURITY
indicator light will stay on for 10 minutes and then turn off. After SECURITY indicator light turns off,
turn ignition off for 30 seconds.
SECURITY indicator light will stay on for 10 minutes and then turn off or until DTC P1630 is set.
P1630 is cleared by turning ignition off for 30 seconds and then turning ignition switch to ON position
again. If DTC P1630 is not cleared, perform test procedures for DTC P1630 and repair as necessary. See
NOTE: DTC P1630 will be set as a result of this procedure. DTC P1630 may be
cleared from PCM by turning ignition off for 30 seconds and then turning
ignition switch to ON position again.
TDC Offset Learn Procedure (6.5L Diesel)
1. Procedure must be performed if any of following have been done or exists:

If sent here from DTC P1214.
Engine has been replaced.
CKP sensor or engine front cover has been replaced.
PCM and fuel injection pump have been replaced.
NOTE: DO NOT perform procedure unless sent here from DTC P1214 or one
of the components listed above has been replaced.
2. The PCM has the ability to determine amount of offset required to bring engine to TDC when TDC offset
is not present or has been cleared. This procedure must be performed to allow PCM to be updated with
the correct TDC offset for vehicle application.
3. Install scan tool. Start and warm engine until engine coolant temperature is at least 170F (77C). Using
scan tool, clear DTCs from PCM. Turn ignition switch to ON position, engine off. Fully depress and hold
throttle at full throttle for at least 45 seconds.
4. Turn ignition switch to OFF position for 30 seconds. Start engine. Verify scan tool indicates TDC offset
has been cleared to zero. If TDC offset has been cleared to zero, go to next step. If TDC offset has not
been cleared to zero, repeat step 3 until TDC offset has been cleared to zero.
5. With engine running, use scan tool to verify engine coolant temperature is greater than 170F (77C). It
may be necessary to drive vehicle to obtain correct engine coolant temperature.
6. As soon at engine coolant temperature is greater than 170F (77C) and engine speed is less than 1500
RPM, the PCM automatically learns a new TDC offset. The new TDC offset will overwrite previous
TDC offset. Using scan tool, note new TDC offset. TDC offset should be -.25 to -.75.
7. Turn engine off. If TDC offset is not within specification, go to next step. If TDC offset is within
specification, TDC offset learn procedure is complete.
8. Using Flange Nut Wrench (J 41089), loosen fuel injection pump retaining nuts. Fuel injection pump must
be rotated to change TDC offset. Rotating fuel injection pump .039" (1.00 mm) will change TDC offset
about 2 degrees. Rotating fuel injection pump toward driver's side of vehicle will produce a positive (+)
number and rotating fuel injection pump toward passenger's side of vehicle will produce a negative (-)
number.
9. Using Fuel Injection Pump Wrench (J 29872), slightly rotate fuel injection pump. Tighten fuel injection
pump retaining nuts.
10. Repeat steps 3 through 9 until TDC offset is within specification. If proper TDC offset cannot be
obtained, check the following:
Ensure engine coolant temperature is greater than 170F (77C).
PCM harness connectors for proper installation.
Harness connectors at injection timing stepper motor on side of fuel injection pump for proper
installation.
Ensure latest Techline(R) software was used.
Check for proper base installation of fuel injection pump. The electric engine shutoff solenoid on
top of fuel injection pump should be approximately straight up and down.
Fuel injection pump may be defective, although manufacturer states this is highly unlikely.
Vehicle Driveability Computer Relearn Procedure (4.8L, 5.3L & 6.0L)
1. On manual transmission vehicles, go to next step. On automatic transmission vehicles, turn ignition off.
Reconnect PCM battery connection. Turn A/C off. Set parking brake and block drive wheels. Start and
operate engine until coolant reaches 176F (80C). Place transmission in Drive. Operate engine at idle for
5 minutes. Place transmission in Park. Idle engine another 5 minutes. Turn engine off for 30 seconds.
PCM relearn procedure is complete.
2. On manual transmission vehicles, turn ignition off. Reconnect PCM battery connection. Turn A/C off. Set
parking brake and block drive wheels. Place transmission in Neutral. Start and operate engine until
coolant reaches 176F (80C). Operate engine at idle for 5 minutes. Turn engine off for 30 seconds. PCM
relearn procedure is complete.
Vehicle Driveability Computer Relearn Procedure (4.3L, 5.0L, 5.7L & 7.4L)
vehicle battery was disconnected or VCM was replaced, driving the vehicle will enable VCM to perform a
what they are accustomed to until VCM completes the computer relearn procedure.
Vehicle Driveability Computer Relearn Procedure (6.5L Diesel)
vehicle battery was disconnected or PCM was replaced, driving the vehicle will enable PCM to perform a
what they are accustomed to until PCM completes the computer relearn procedure.
MONTANA, SILHOUETTE & VENTURE
Crankshaft Position (CKP) Sensor Variation Learn Procedure
1. Procedure must be performed if any of following have been done or exist:

If DTC P1336 exists.
If crankshaft, CKP sensor, engine, PCM or vibration damper have been replaced.
2. CKP sensor variation compensating values are stored in PCM after a learn procedure has been performed.
If actual CKP sensor values are not within specification, DTC P0300 will be stored.
3. Using scan tool, check for stored DTCs. See appropriate SELF-DIAGNOSTICS article in ENGINE
PERFORMANCE. If no DTCs exist, or if DTC P1336 exists, go to next step. If any DTCs exist except
for P1336, perform test procedures for specified DTC and repair as necessary. See appropriate SELF-
DIAGNOSTICS article in ENGINE PERFORMANCE. Ensure all DTCs are learned from PCM, then go
to next step.
4. Ensure ignition is off. Apply parking brakes. Block front wheels. Ensure hood is closed. Start and warm
engine until engine coolant temperature is at least 158F (70C). Turn ignition switch to OFF position.
NOTE: Ensure engine coolant temperature is at least 158F (70C) before

performing CKP sensor variation learn procedure.
5. Using scan tool, select and enable CKP sensor variation learn procedure. Start engine. Apply service
brakes. Ensure transaxle is in Park.
6. Accelerate engine until CKP sensor variation learn procedure fuel cut-off is obtained at 5150 RPM.
Quickly release throttle to idle position once CKP sensor variation learn procedure fuel cut-off is obtained
and engine starts to decelerate. Once CKP sensor variation values are learned, PCM will return engine
control to operator and engine will respond to throttle position.
variation learn procedure fuel cut-off is obtained.
7. If CKP sensor variation learn procedure was not terminated, go to next step. If CKP sensor variation learn
procedure was terminated, this may be caused by PCM detecting a problem in CAM signal setting DTC
P0341 or a problem in 3X crank signal setting DTC P1374, or a problem in the 3X or 24X crank signal
setting DTC P0336. Using scan tool, check for stored DTCs. Perform test procedures for specified DTCs
and repair as necessary. See appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE.
8. Check status of DTC P1336 on scan tool. If scan tool indicates DTC P1336 ran and passed, CKP sensor
variation learn procedure fuel cut-off is complete. If scan tool indicates that DTC P1336 failed or was not
run, check for any other DTCs. See appropriate SELF-DIAGNOSTICS article in ENGINE
PERFORMANCE. If any other DTCs exist, perform test procedures for specified DTC and repair as
necessary. If no other DTCs exist, repeat CKP sensor variation learn procedure.
Electronically Erasable Programmable Read Only Memory (EEPROM) Programming
1. If PCM was replaced, the EEPROM in PCM must be programmed. If EEPROM is not programmed, a
DTC will set.
2. Ensure battery is fully charged. If battery is being charged, ensure battery charger is disconnected before
performing EEPROM programming procedure.
3. Ensure cable is properly connected on Data Link Connector (DLC). Turn ignition switch to ON position.
Perform EEPROM programming using Techline(R) equipment manufacturer's instructions and latest
software applicable for vehicle model. New PCM must learn PASS-Key(R) password. See PASS-KEY
(R) III MODULE PROGRAMMING.
4. Once EEPROM has been reprogrammed, perform powertrain On-Board Diagnostic (OBD) system check.
See POWERTRAIN ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK in appropriate SELF-
DIAGNOSTICS article in ENGINE PERFORMANCE. Ensure engine is idling for one minute before
checking for DTCs when performing powertrain OBD system check. Also, after EEPROM has been
reprogrammed, the CKP sensor variation learn procedure must be performed. See CRANKSHAFT
POSITION (CKP) SENSOR VARIATION LEARN PROCEDURE.
NOTE: If EEPROM programming fails, ensure all harness connections on PCM are
fails, replace PCM.
PASS-Key(R) III Module Programming
NOTE: New modules are unprogrammed. New module automatically learns first key
used to start engine. New module can only be programmed once.
PASS-Key(R) III System Auto Learn Procedure
NOTE: PASS-Key(R) III system auto learn procedure must be performed if all keys are
lost, or powertrain Control Module (PCM), PASS-Key(R) III module, ignition lock
cylinder, steering column assembly or ignition key are replaced. A password is
communicated between PASS-Key(R) III module and PCM to provide engine
operation. If PCM is replaced, the PCM must learn the password from the PASS-
Key(R) III module.
1. Insert a valid mechanical coded unlearned ignition key in ignition switch. Place ignition switch in RUN
position. The SECURITY indicator light will flash once per second for 10 minutes for the length of the
auto learn timer.
2. When auto learn timer expires and SECURITY indicator light goes off, place ignition switch in OFF
position. Remove ignition key. Wait 10 seconds.
3. Repeat steps 1 and 2 two more times. Insert the newly learned ignition key in ignition switch.
4. Place ignition switch in RUN position. The SECURITY indicator light should remain off to indicate that
ignition key was learned. This will be the only learned key. To program more keys, see PASS-KEY(R)
III SYSTEM QUICK LEARN PROCEDURE. If security indicator does not remain off, repeat
procedure.
PASS-Key(R) III System Quick Learn Procedure
NOTE: PASS-Key(R) III system quick learn procedure is used to learn additional
ignition keys. A learned key must be used to initiate procedure. Up to 10
ignition keys can be learned.
1. Insert a valid ignition key in ignition switch. Turn ignition switch to ON position. After 2 second bulb
test, turn ignition off and remove key.
2. Within 10 seconds, insert new valid mechanical code unlearned key and turn ignition switch to RUN
position. Security light will illuminate until key is learned. This may happen so quickly light illumination
is not observed. Turn ignition switch to OFF position. Remove ignition key 10 seconds after light goes
out.
3 To learn additional keys repeat step 2 To exit procedure turn ignition off for more than 10 seconds
what they are accustomed to until the PCM completes the computer relearn procedure.
TRACKER
NOTE: PCM does not have a reprogrammable EEPROM. No special procedures are
required for programming the PCM.
what they are accustomed to until PCM completes the computer relearn procedure.
Electric Cooling Fans - Trucks & Vans
MODEL IDENTIFICATION (LIGHT TRUCKS & VANS)
Series (1) Model
A FWD Aztek
B AWD Aztek
C 2WD Pickup, Tahoe & Yukon
K 4WD Escalade, Pickup, Tahoe & Yukon
U Silhouette, Trans Sport & Venture
(1) Vehicle series code is fifth character of VIN.

ELECTRIC COOLING FAN CONTROL (LIGHT TRUCKS & VANS)
All FWD and some RWD vehicles use an electric cooling fan. The electric cooling fan is used for radiator and
A/C condenser cooling. Cooling fan operates when A/C is on and when engine coolant temperature exceeds a
specific value. One or more cooling fan relays may be used. See COOLING FAN RELAY LOCATION table.
Some RWD trucks, vans and motorhomes are equipped with an auxiliary electric cooling fan. See WIRING
DIAGRAMS .
COOLING FAN RELAY LOCATION

"A" & "B" Series In Underhood Fuse Block, Above Battery
"C" & "K" Series On Engine Compartment Fuse/Relay Block Near Anti-Lock Brake Control
Module
"U" Series Inside Electrical Center At Right Front Of Engine Compartment
TROUBLE SHOOTING
PRELIMINARY INFORMATION
This article contains only information required to test electric cooling fans. Other diagnostic information may be
referenced while performing electric cooling fan diagnosis. See appropriate SELF-DIAGNOSTICS article in
ENGINE PERFORMANCE for complete information on engine control systems.
Some truck models are equipped with an auxiliary electric cooling fan. The auxiliary electric cooling fan is not
controlled by Powertrain Control Module (PCM).
Trouble shoot cooling fan using appropriate diagnostic information provided. For cooling fan relay location, see
COOLING FAN RELAY LOCATION table.
To help save diagnostic time, always check for blown fuses or fusible links before proceeding with any testing.
If fuses are blown, locate and repair short circuit before replacing fuses. Ensure all related relay and wire
harness connections are clean and tight. Repair as necessary. See WIRING DIAGRAMS for component,
terminal and wire color identification.
NOTE: Vehicles may be equipped with a PCM/VCM using an Electronically Erasable

Programmable Read Only Memory (EEPROM). When replacing PCM/VCM, the
new PCM/VCM must be programmed.
SCAN TOOL
A variety of information is transmitted through Data Link Connector (DLC). This data is transmitted at a high
frequency which requires the use of Tech 2 scan tool. Other types of scan tools are available and may function
and provide adequate information for diagnostic work. Always refer to scan tool manufacturer's instructions.
ELECTRIC COOLING FAN CIRCUIT DIAGNOSIS

To help save diagnostic time, check cooling system fluid level, water pump belt condition and tension. Always
check for blown fuses or fusible links before proceeding with any testing. If fuses are blown, locate and repair
short circuit before replacing fuses. Ensure all related relay and wire harness connections are clean and tight.
Repair as necessary. See WIRING DIAGRAMS .
3.4L "A" & "B" SERIES TRUCKS (AZTEK)
Description
Engine cooling fan system consists of two electrical cooling fans and three fan relays. Relays are arranged in a
series/parallel configuration that allows Powertrain Control Module (PCM) to operate both fans together at low
or high speeds. Cooling fans and fan relays receive battery voltage from underhood accessory wiring junction
block.
During low speed operation, PCM supplies ground path for low speed fan relay through low speed cooling fan
relay control circuit. This energizes cooling fan 1 relay coil, closes relay contacts, and supplies battery voltage
from cool fan 1 fuse through cooling fan motor supply voltage circuit to left cooling fan. Ground path for left
cooling fan is through cooling fan 2 relay and right cooling fan. Result is a series circuit with both fans running
at low speed.
During high speed operation, PCM supplies ground path for cooling fan 1 relay through low speed cooling fan
relay control circuit. After a 3-second delay, PCM supplies a ground path for cooling fan 3 relay and cooling
fan 2 relay through high speed cooling fan relay control circuit. This energizes cooling fan 2 relay coil, closes
relay contacts, and provides a ground path the left cooling fan. At the same time, cooling fan 2 relay coil is
energized closing relay contacts and provides battery voltage from cool fan 2 fuse on cooling fan motor supply
voltage circuit to right cooling fan. During high speed fan operation, both engine cooling fans have there own
ground path. Result is a parallel circuit with both fans running at high speed.
PCM commands low speed fans on under the following conditions:
Engine coolant temperature exceeds about 223F (106C).

A/C refrigerant pressure exceeds 190 psi (13 Kg/cm2 ).
After vehicle is shut off, if engine coolant temperature at key-off is greater than 284F (140C) and
system voltage is more than 12 volts. Fans will stay on for approximately 3 minutes.
PCM commands high speed fans on under the following conditions:
Engine coolant temperature reaches 230F (110C).

A/C refrigerant pressure exceeds 240 psi (17 Kg/cm2 ).
When certain DTCs set.
2. Turn ignition on, engine off. Try to establish scan tool communication with Instrument Cluster (IC) and
Powertrain Control Module (PCM). If communication with IC and PCM is established, go to next step. If
communication with IC and PCM is not established, see SCAN TOOL DOES NOT COMMUNICATE
WITH CLASS 2 DEVICE in appropriate BODY CONTROL MODULES article.
are displayed, go to next step. If no DTCs are displayed, see COOLING FAN INOPERATIVE or
COOLING FAN ALWAYS ON .
article.
Cooling Fan Inoperative
2. Install scan tool. Turn ignition on, engine off. Using scan tool, command fans low speed on and off. If
low speed cooling fans turn on and off with each command, go to next step. If low speed cooling fans do
not turn on and off with each command, go to step 4 .
NOTE: Before PCM changes speed of cooling fans, a 3-second delay will occur.
3. Using scan tool, command fans high speed on and off. If high speed cooling fans turn on and off with
each command, problem is intermittent. If high speed cooling fans do not turn on and off with each
NOTE: Do not remove fused jumper (20 amp) connected during this step. Use a
second fused jumper (20 amp) while performing the following steps.
4. Disconnect the cooling fan 1 relay. Connect first fused jumper (20 amp) between battery voltage circuit
of cooling fan 1 relay and cooling fan motor supply voltage circuit (Gray wire) of cooling fan 1 relay. If
both cooling fans operate in low speed, go to step 13 . If both cooling fans do not operate in low speed, go
to next step.
5. Disconnect cooling fan 2 relay. Connect second fused jumper (20 amp) between left cooling fan motor
low reference circuit (White wire) of cooling fan 2 relay and right cooling fan motor supply voltage
circuit (Light Blue wire) of cooling fan 2 relay. If both cooling fans operate in low speed, go to step 14 .
If both cooling fans do not operate in low speed, go to next step.
6. Connect second fused jumper (20 amp) between battery voltage circuit of cooling fan 2 relay and cooling
fan motor supply voltage circuit (Light Blue wire) of cooling fan 2 relay. If right cooling fan operates in
high speed, go to step 9 . If right cooling fan does not operate in high speed, go to next step.
7. Install cooling fan 2 relay. Disconnect right cooling fan electrical connector. Connect second fused
jumper (20 amp) between terminals of right cooling fan electrical connector. If left cooling fan operates
in high speed, go to step 16 . If left cooling fan does not operate in high speed, go to next step.
8. Connect second fused jumper (20 amp) between cooling fan motor supply voltage circuit (Light Blue
wire) of right cooling fan electrical connector and ground. If left cooling fan operates in high speed, go to
step 20 . If left cooling fan does not operate in high speed, go to step 21 .
9. Install cooling fan 2 relay. Disconnect left cooling fan electrical connector. Connect second fused jumper
(20 amp) between terminals of left cooling fan electrical connector. If right cooling fan operates in high
speed, go to step 17 . If right cooling fan does not operate in high speed, go to next step.
10. Connect second fused jumper (20 amp) between battery voltage and left cooling fan low reference circuit
(White wire) of left cooling fan electrical connector. If right cooling fan operates in high speed, go to step
18 . If right cooling fan does not operate in high speed, go to step 22 .
11. If right cooling fan operates in high speed, go to next step. If right cooling fan does not operate in high
speed, go to step 15 .
12. Disconnect cooling fan 2 relay. Connect fused jumper (20 amp) between left cooling fan low reference
circuit (White wire) of cooling fan 2 relay and ground circuit of cooling fan 2 relay. If left cooling fan
operates properly in high speed, go to step 14 . If left cooling fan does not operate properly in high speed,
go to step 19 .
13. Check cooling fan 1 relay connector for poor connections. If problem was found, repair as necessary.
16. Check right cooling fan connector for poor connections. If problem was found, repair as necessary. After
17. Check left cooling fan connector for poor connections. If problem was found, repair as necessary. After
18. Repair left cooling fan motor supply voltage circuit (Gray wire). After repairs, go to step 28 .
19. Repair left cooling fan motor ground circuit. After repairs, go to step 28 .
20. Repair right cooling fan motor ground circuit (Black wire). After repairs, go to step 28 .
21. Repair right cooling fan motor supply voltage circuit (Light Blue wire). After repairs, go to step 28 .
22. Repair left cooling fan low reference circuit (White wire). After repairs, go to step 28 .
23. Replace cooling fan 1 relay. After repairs, go to step 28 .
26. Replace right cooling fan. After repairs, go to step 28 .
27. Replace left cooling fan. After repairs, go to next step.
Cooling Fan Always On
2. Turn ignition on, engine off. If one or both cooling fans are on, go to next step. If one or both fans are not
on, problem is intermittent.
3. If both cooling fans are running continuously, go to step 5 . If both cooling fans are not running
continuously, go to next step.
4. Remove cooling fan 2 relay. If right cooling fan turned off, go to step 6 . If right cooling fan did not turn
off, go to step 7 .
5. Repair short to voltage in left cooling fan motor supply voltage circuit (Gray wire). After repairs, go to
step 8 .
6. Repair short to voltage in left cooling fan low reference circuit (White wire). After repairs, go to step 8 .
7. Repair short to voltage in right cooling fan motor supply voltage circuit (Light Blue wire). After repairs,
go to next step.
3.4L "U" SERIES TRUCKS (MONTANA, SILHOUETTE, TRANS SPORT & VENTURE)
Description
Engine cooling fan system consists of 2 electrical cooling fans and 3 fan relays. Relays are arranged in a
series/parallel configuration that allows Powertrain Control Module (PCM) to operate both fans together at low
or high speeds. Cooling fans and fan relays receive battery voltage from underhood junction block.
During low speed operation, PCM supplies ground path for low speed fan relay through low speed cooling fan
relay control circuit. This energizes cooling fan 1 relay coil, closes relay contacts, and supplies battery voltage
from cool fan 1 maxifuse(R) through cooling fan motor supply voltage circuit to left cooling fan. Ground path
for left cooling fan is through cooling fan relay and right cooling fan. Result is a series circuit with both fans
running at low speed.
During high speed operation, PCM supplies ground path for cooling fan 1 relay through low speed cooling fan
relay control circuit. After a 3-second delay, PCM supplies a ground path for cooling fan 2 relay and cooling
fan relay through high speed cooling fan relay control circuit. This energizes cooling fan relay coil, closes relay
contacts, and provides a ground path for left cooling fan. At the same time, cooling fan 2 relay coil is energized
closing relay contacts and provides battery voltage from cool fan 2 maxifuse(R) on cooling fan motor supply
voltage circuit to right cooling fan. During high speed fan operation, both engine cooling fans have there own
ground path. Result is a parallel circuit with both fans running at high speed.
2. Turn ignition on, engine off. Try to establish scan tool communication with Instrument Cluster (IC) and
Powertrain Control Module (PCM). If communication with IC and PCM is established, go to next step. If
communication with IC and PCM is not established, see SCAN TOOL DOES NOT COMMUNICATE
WITH CLASS 2 DEVICE in appropriate BODY CONTROL MODULES article.
are displayed, go to next step. If no DTCs are displayed, see COOLING FAN INOPERATIVE or
COOLING FAN ALWAYS ON .
article.
2. Install scan tool. Turn ignition on, engine off. Using scan tool, command fans low speed on and off. If
low speed cooling fans turn on and off with each command, go to next step. If low speed cooling fans do
not turn on and off with each command, go to step 4 .
NOTE: Before PCM changes speed of cooling fans, a 3-second delay will occur.
3. Using scan tool, command fans high speed on and off. If high speed cooling fans turn on and off with
each command, problem is intermittent. If high speed cooling fans do not turn on and off with each
NOTE: Do not remove fused jumper (20 amp) connected during this step. Use a
second fused jumper (20 amp) while performing the following steps.
4. Disconnect the cooling fan 1 relay. Connect first fused jumper (20 amp) between battery voltage circuit
of cooling fan 1 relay and cooling fan motor supply voltage circuit (Gray wire) of cooling fan 1 relay. If
both cooling fans operate in low speed, go to step 13 . If both cooling fans do not operate in low speed, go
to next step.
5. Disconnect cooling fan relay. Connect second fused jumper (20 amp) between right cooling fan low
reference circuit (White wire) of cooling fan relay and left cooling fan motor supply voltage circuit (Light
Blue wire) of cooling fan relay. If both cooling fans operate in low speed, go to step 14 . If both cooling
fans do not operate in high speed, go to next step.
6. Connect a fused jumper (20 amp) between battery voltage circuit of the cooling fan relay and cooling fan
motor supply voltage circuit (Light Blue wire) of cooling fan relay. If left cooling fan operates in high
speed, go to step 9 . If left cooling fan does not operate in high speed, go to next step.
7. Install cooling fan relay. Disconnect left cooling fan electrical connector. Connect second fused jumper
(20 amp) between terminals of left cooling fan electrical connector. If right cooling fan operates in high
speed, go to step 16 . If right cooling fan does not operate in high speed, go to next step.
8. Connect a fused jumper (20 amp) between cooling fan motor supply voltage circuit (Light Blue wire) of
left cooling fan electrical connector and ground. If right cooling fan operates in high speed, go to step 20 .
If right cooling fan does not operate in high speed, go to step 21 .
9. Install cooling fan relay. Disconnect right cooling fan electrical connector. Connect second fused jumper
(20 amp) between terminals of right cooling fan electrical connector. If left cooling fan operates in high
speed, go to step 17 . If left cooling fan does not operate in high speed, go to next step.
10. Connect a fused jumper (20 amp) between battery voltage and cooling fan low reference circuit (White
wire) of right cooling electrical connector. If left cooling fan operates in high speed, go to step 18 . If left
cooling fan does not operate in high speed, go to step 22 .
11. If left cooling fan is operating properly in high speed, go to next step. If left cooling fan is not operating
properly, go to step 15 .
12. Disconnect cooling fan relay. Connect second fused jumper (20 amp) between cooling fan low reference
circuit (White wire) of cooling fan relay and ground circuit (Black wire) of cooling fan relay. If right
cooling fan operates properly in high speed, go to step 14 . If right cooling fan relay does not operate in
high speed, go to step 19 .
14. Check cooling fan relay connector for poor connections. at the cooling fan relay. If problem was found,
15. Check cooling fan 2 relay connector for connections. If problem was found, repair as necessary. After
16. Check left cooling fan connector for poor connections. If problem was found, repair as necessary. After
17. Check right cooling fan connector for poor connections. If problem was found, repair as necessary. After
18. Repair right cooling fan motor supply voltage circuit. After repairs, go to step 28 .
19. Repair left cooling fan ground circuit. After repairs, go to step 28 .
20. Repair right cooling fan ground circuit. After repairs, go to step 28 .
21. Repair left cooling fan motor supply voltage circuit. After repairs, go to step 28 .
22. Repair cooling fan low reference circuit. After repairs, go to step 28 .
24. Replace cooling fan relay. After repairs, go to step 28 .
26. Replace left cooling fan. After repairs, go to step 28 .
27. Replace right cooling fan. After repairs, go to next step.
2. Turn ignition on, engine off. If one or both cooling fans are on, go to next step. If one or both cooling
fans are not on, problem is intermittent.
3. If both cooling fans are running continuously, go to step 5 . If both cooling fans are not running
continuously, go to next step.
4. Remove cooling fan relay. If left cooling fan turned off, go to step 6 . If left cooling fan did not turn off,
go to step 7 .
5. Repair short to voltage in supply voltage circuit (Gray wire) of right cooling fan motor. After repairs, go
to step 8 .
6. Repair short to voltage in low reference circuit (White wire) of right cooling fan motor. After repairs, go
to step 8 .
7. Repair short to voltage in supply voltage circuit (Light Blue wire) of left cooling fan motor. After repairs,
go to next step.
Diagnostic Aids
Check for poor connections at PCM, cooling fan relays, and cooling fan motors. Inspect harness connectors for
damaged, corroded or backed-out terminal pins. Inspect related wiring harnesses for damage or improper
routing.
5.0L, 5.7L & 7.4L "C" & "K" SERIES TRUCKS (ESCALADE, PICKUP, TAHOE & YUKON)
Description
Auxiliary cooling fan is controlled by VCM based on inputs from the A/C system, engine coolant temperature
sensor and vehicle speed sensor. Battery voltage is supplied to the auxiliary cooling fan relay. If ignition voltage
is supplied to auxiliary fan relay (coil side). VCM controls cooling fan by relay by providing a ground path.
VCM will turn on auxiliary cooling fan when certain Diagnostic Trouble Codes (DTCs) are present, engine
coolant temperature is more than 225F (107C) or A/C head pressure is more than 300 psi (21 Kg/cm2 ).
Auxiliary cooling fan will remain on for at least 30 seconds. VCM will turn auxiliary cooling fan off when
engine coolant temperature has dropped 7F (4C) or A/C head pressure has dropped to 250 psi (18 Kg/cm2 ).
NOTE: Check VCM DTCs that may affect system. If any DTCs are present, perform
testing for applicable DTC. Some DTCs may cause auxiliary cooling fan to stay
on at all times. Repair all DTCs that are set before proceeding with testing. See
Auxiliary Cooling Fan Inoperative
1. Disconnect auxiliary cooling fan relay. Connect test light between auxiliary cooling fan relay connector
terminal No. 30 (Orange wire) and ground. If test light is on, go to next step. If test light is off, go to step
8.
2. Turn ignition on. Connect test light between auxiliary fan relay connector terminal No. 85 (Orange wire)
and ground. If test light is on, go to next step. If test light is off, go to step 9 .
3. Connect fused jumper between auxiliary cooling fan relay connector terminals No. 30 (Orange wire) and
No. 87 (Red wire). If auxiliary cooling fan motor runs, go to step 5 . If auxiliary cooling fan motor does
not run, go to next step.
4. Connect test light between auxiliary cooling fan motor connector terminal "A" and battery voltage. If test
light is on, go to step 10 . If test light is off, go to step 11 .
5. Turn ignition off. Disconnect all VCM connectors. Connect DVOM between VCM connector C4
terminal No. 9 (Dark Blue wire) and auxiliary cooling fan relay connector terminal No. 86. If continuity
exists, go to next step. If continuity does not exist, go to step 12 .
6. Re-Connect auxiliary cooling fan relay. Turn ignition on. Connect fused jumper between VCM connector
C4 terminal No. 9 (Dark Blue wire) and ground. If auxiliary cooling fan motor runs, go to next step. If
auxiliary cooling fan motor does not run, go to step 13 .
7. Leave ignition switch on. Place recirculation button on HVAC control panel in ON position. Connect test
light between VCM connector C4 terminal No. 7 (Dark Green wire) and battery voltage. If test light is on,
system is okay. If test light is off, go to step 14 .
8. Repair open in Orange wire (switch feed) between underhood fuse block and auxiliary cooling fan relay.
After repairs, check system operation.
9. Repair open in Orange wire (coil feed) between underhood fuse block and auxiliary power center. After
repairs, check system operation.
10. Check Red wire between auxiliary cooling fan relay and auxiliary cooling fan motor for open. If problem
was found, repair as necessary. If problem was not found, replace auxiliary cooling fan motor. After
repairs, check system operation.
11. Repair open in Black wire between auxiliary cooling fan motor and ground. After repairs, check system
operation.
12. Repair open in Dark Blue wire between VCM and auxiliary cooling fan relay. After repairs, check system
operation.
13. Replace auxiliary cooling fan relay. After repairs, check system operation.
14. Check Dark Green wire between VCM and A/C-heater control module for open. If problem was found,
repair as necessary. If problem was not found, replace A/C-heater control module. After repairs, check
system operation.
Diagnostic Aids
If complaint is an overheating problem, verify if an actual boilover has occurred, or if the indicator light or
temperature gauge indicates an overheating problem. Verify temperature gauge reading with coolant sensor
reading on scan tool. If readings are okay and engine is overheating with the auxiliary cooling fan on, check
cooling system for proper operation and repair as necessary.
If condition is intermittent, check for poor connections at VCM, cooling fan relays, and cooling fan motors.
Inspect harness connectors for damaged, corroded or backed-out terminal pins. Inspect related wiring harnesses
for damage or improper routing.
WIRING DIAGRAMS
Fig. 1: Cooling Fan System Wiring Diagram (2000-01 Montana, Silhouette & Venture)
Fig. 2: Cooling Fan System Wiring Diagram (2001 Aztek)
Cruise Control - Aztek & Rendezvous

CRUISE CONTROL SCHEMATICS
Fig. 1: Cruise Control (LA1)

Fig. 2: Cruise Control (LY7)
COMPONENT LOCATOR
CRUISE CONTROL COMPONENT VIEWS
Callouts For Fig. 3

Fig. 4: Behind Brake Pedal Bracket Location View
Callouts For Fig. 4

1 Cruise Control Release Switch Connector (LA1)
2 Stop Lamp Switch
3 Stop Lamp Switch Connector C2
4 Stop Lamp Switch Connector C1
5 Cruise Control Release Switch (LA1)
Fig. 5: Instrument Panel and Center Console Location View - Pontiac
Callouts For Fig. 5

1 Instrument Cluster
2 Driver's Information/HUD Switches
3 A/C Sunload Sensor (CJ2)/Ambient Light Sensor (CJ3/C60)
4 Security Indicator Lamp
5 Inflatable Restraint I/P Module
6 HVAC Control Module
7 Fuse Block-Center Console
8 Cigar Lighter
9 Auxiliary Power Outlet-Center Console Lower (2002 and earlier)
10 Auxiliary Power Outlet-Center Console Upper
11 Radio
12 Ignition Switch
13 Turn Signal, Wiper, Washer, Cruise and High Beam Switch
CRUISE CONTROL CONNECTOR END VIEWS
Cruise Control Module (LA1)
12065425
10-Way F 150 Series (BK)

A GY 397 Cruise Control On Switch Signal
B D-BU 84 Cruise Control Set/Coast Switch Signal
C GY/BK 87 Cruise Control Resume/Accel Switch Signal
D BN 86 Cruise Control Release Signal
E BK/WH 451 Ground
F PK 39 Ignition 1 Voltage
G WH 17 Stop Lamp Switch Signal
H D-GN 83 Cruise Control Inhibit Signal
J WH 85 Cruise Control Engaged Signal
K D-GN 389 Vehicle Speed Signal
Cruise Control Release Switch (LA1)

12041433
2-Way F Metri-Pack 280 Series (BK)

A BN 86 Cruise Control Release Signal
B PK 39 Ignition 1 Voltage
Turn Signal/Multifunction Switch C4 (K34)
12047786
4-Way M 150 Series (BK)

A PK 39 Ignition 1 Voltage
B GY 397 Cruise Control On Switch Signal
C GY/BK 87 Cruise Control Resume/Accel Switch Signal
D D-BU 84 Cruise Control Set/Coast Switch Signal

DIAGNOSTIC STARTING POINT - CRUISE CONTROL
The identification of the control modules which command the system.

The ability of the control modules to communicate through the serial data circuit.
The identification of any stored diagnostic trouble codes (DTCs) and their status.

Engine Output
Cruise Inhibit
Controls The PCM inhibits cruise when you select On.
SCAN TOOL DATA LIST
Powertrain - 3.4L
Ignition ON/Engine Idling at Normal Operating Temperature/Vehicle is in Park or Neutral/Cruise
On/Off Switch is Turned Off
Cruise Control Active Engine Data 1 Yes / No No
Cruise Inhibit Reason Engine Data 1 1-6 1
Cruise Inhibit Signal Circuit Status Output Driver Data Ok/Fault Ok
Cruise Inhibit Signal Command Engine Data 1 On / Off On
Engine Speed Engine Data 1 RPM 0
Vehicle Speed Engine Data 1 km/h (mph) 0 km/h (0 mph)
Powertrain - 3.6L
Typical Data
Scan Tool Parameter Data List Units Displayed Value
Ignition ON/Engine Idling at Normal Operating Temperature/Vehicle is in Park or Neutral/Cruise
On/Off Switch is Turned Off
Cruise Control Active Cruise/Traction Yes/No No
Data
Last reason for
Cruise/Traction
Cruise Disengage (1 - 8) History cruise control Varies
Data
disengagement
Cruise/Traction
Cruise Inhibit Reason Varies OFF
Data
Cruise/Traction
Cruise On/Off Switch On/Off Off
Data
Cruise/Traction
Cruise Resume/Accel. Switch On/Off Off
Data
Cruise/Traction
Cruise Set/Coast Switch On/Off Off
Data
Cruise/Traction
Engine Speed RPM Varies
Data
Cruise/Traction
Stoplamp Pedal Switch Applied/Released Released
Data
Cruise/Traction
TCC Brake Pedal Switch Applied/Released Released
Data
Cruise/Traction
Traction Control Status Active/Inactive Inactive
Data
Cruise/Traction
Vehicle Speed Sensor km/h (mph) 0
Data
SCAN TOOL DATA DEFINITIONS (DISENGAGE HISTORY)
The Cruise Control Scan Tool Definitions - Disengage History is a common list for all of the available cruise
control disengagement definitions available on the scan tool. The cruise control system equipped on the vehicle
determines which cruise control disengagement parameters are available on the scan tool.
One of the following conditions must be present in order for a disengagement parameter to appear:
The cruise control system is active and disengagement is requested.

The engagement of the cruise control system is requested while a fault is present.
Accel Rate
The powertrain control module (PCM)/engine control module (ECM) detects that the vehicle acceleration
is greater than the calibrated cruise control threshold.
Bad Sequence
The PCM/ECM detects that a cruise control software execution error is present.
Brake
The PCM/ECM detects that the stop lamps have been activated or the PCM/ECM detects that a stop lamp
pedal activation had not occurred before the cruise control system was requested.
Cancel
The PCM/ECM detects that the cruise control cancel switch has been activated.
CC Sw. Position
The PCM/ECM detects that the acceleration mode is active without the activation of the Accel. switch.
Clutch
The PCM/ECM detects that the clutch pedal switch has been activated.
Clutch Switch
The PCM/ECM detects that the clutch pedal switch has been activated.
Cruise Off
The PCM/ECM detects that the cruise On/Off switch was turned to OFF when the cruise control system
was enabled.
Coast Low Speed
The PCM/ECM detects that the Set/Coast switch is activated until the vehicle speed is below 37 km/h (23
mph).
Coast Disengage
When the PCM/ECM detects that the cruise set/coast signal is active and the throttle blade fully closes the
cruise control system will disengage until the PCM/ECM detects that the set/coast signal is inactive. The
cruise control system will then engage and set with the new vehicle speed.
Decel Rate
The PCM/ECM detects that the vehicle deceleration is greater than the calibrated cruise control threshold.
DTC Set
The PCM/ECM detects that a DTC has been set which affects the cruise control operation.
Engine Run Time
The PCM/ECM detects that the cruise control system has been requested and the engine run time counter
is not active.
Engine Speed
The PCM/ECM detects that the engine speed is less than or greater than a calibrated RPM.
ETC
The PCM/ECM detects a fault within the throttle actuator control (TAC) system.
First Gear
While the cruise control system is active, the PCM/ECM detects that the transmission is in Drive 1.
High Accel.
The PCM/ECM detects that the vehicle acceleration is greater than the calibrated cruise control threshold.
High Decel.
The PCM/ECM detects that the vehicle deceleration is greater than the calibrated cruise control threshold.
High Speed
The PCM/ECM detects that the vehicle speed is greater than the calibrated amount.
Illegal Mode
The PCM/ECM detects that the acceleration mode is active without the activation of the Accel. switch.
Injector Disable
The PCM/ECM detects that the engine is overspeed and that the fuel shutoff has been activated.
Low Speed
The PCM/ECM detects that the vehicle speed is less than 37 km/h (23 mph) while the cruise control
system was enabled.
Low Voltage
The PCM/ECM detects that the ignition voltage is below 9 volts.
Manual/Neutral
The PCM/ECM detects that transmission is in Neutral, Reverse or Park.

Memory Corrupt
An internal PCM/ECM memory fault is detected.
MPH Limit
The PCM/ECM detects a that the vehicle is overspeed and that the fuel shutoff has been activated.
No History
This parameter is displayed when a new PCM/ECM has been installed.
None
This parameter is displayed when a new PCM/ECM has been installed.
Off
The PCM/ECM detects that the cruise On/Off switch was turned to OFF when the cruise control system
was enabled.
Over Set Speed
This parameter is displayed when the current vehicle speed is greater than the set vehicle speed by more
than a calibrated amount.
Over Speed
This parameter is displayed when the current vehicle speed is greater than the set vehicle speed by more
than a calibrated amount.
Over Speed Tap
This parameter is displayed when the Set/Coast switch is briefly applied while the current vehicle speed is
greater than the set vehicle speed by more than a calibrated amount.
Pedal Initialize
The PCM/ECM detects that a stop lamp pedal activation had not occurred before the cruise control
system was requested.
PCM Error
The PCM/ECM detects that a cruise control software execution error is present.
PCM Inhibit
The PCM/ECM detects a RAM corruption associated to the cruise control system.
Pedal > Cruise
The PCM/ECM detects that the accelerator pedal overrides the set vehicle speed for approximately 60
seconds.
Serial Data
A fault in the serial data circuit from the cruise control switch to the platform module is detected.
S/C On, CC Off
When the PCM/ECM detects that the cruise set/coast signal is active and the throttle blade fully closes the
cruise control system will disengage until the PCM/ECM detects that the set/coast signal is inactive. The
cruise control system will then engage and set with the new vehicle speed.
S/C On - Speed High
This parameter is displayed when the Set/Coast switch is briefly applied while the current vehicle speed is
greater than the set vehicle speed by more than a calibrated amount.
Stop Lamp Switch
The PCM/ECM detects that the stop lamps have been activated.
TAC Inhibit
The PCM/ECM detects a fault within the TAC system.
Traction
The PCM/ECM detects that the traction control system had been activated. It is also possible that a tire
with low air pressure can also set this disengagement reason.
Traction Loss
The PCM/ECM detects that the traction control system had been activated. It is also possible that a tire
with low air pressure can also set this disengagement reason.
Two Commands
The PCM/ECM detects that the Set/Coast switch and the Resume/Accel switch are active at the same
time.
Two CC Commands
The PCM/ECM detects that the Set/Coast switch and the Resume/Accel switch are active at the same
time.
Under Speed
The PCM/ECM detects that the vehicle speed is less than the cruise memory speed by more than a
calibrated amount.
Under Set Speed
The PCM/ECM detects that the vehicle speed is less than the cruise memory speed by more than a
calibrated amount.
SCAN TOOL DATA DEFINITIONS (CRUISE CONTROL)
The Scan Tool Data Definitions contains a brief description of all cruise control related parameters available on
the scan tool. On vehicles equipped with a 3.4L engine, a powertrain control module (PCM) is used. On
vehicles equipped with a 3.6L engine, an engine control module (ECM) is used.
Cruise Control Active
The scan tool displays Yes or No. The ECM determines the current status of cruise control operation. An
active cruise control system is displayed as Yes.
The scan tool displays Yes or No. The PCM monitors the cruise engaged signal circuit. The cruise control
module provides a ground on the cruise engaged signal circuit when the cruise control system is active.
An active cruise control system is displayed as Yes.
Cruise Disengage (1 - 8) History
The scan tool displays the last 8 reasons why the cruise control system was disengaged. Refer to the Scan
Tool Data Definitions (Disengaged History) for descriptions.
Cruise Inhibit Reason
The scan tool displays the reason that the cruise control is inhibited as detected by the ECM/PCM.
Cruise Inhibit Signal Circuit Status
The scan tool displays Ok or Fault. The PCM monitors the cruise inhibit circuit for a fault. A DTC is set
when a fault is detected.
Cruise Inhibit Signal Command

The scan tool displays On or Off. On is displayed when the PCM commands the cruise control module to
inhibit the cruise control system.
Cruise On/Off Switch
The scan tool displays On or Off. The ECM the monitors the cruise control on switch signal circuit. A
closed switch is displayed as On.
Cruise Resume/Accel. Switch
The scan tool displays On or Off. The ECM the monitors the cruise control s resume/accel switch signal
circuit. A closed switch is displayed as On.
Cruise Set/Coast Switch
The scan tool displays On or Off. The ECM the monitors the cruise control set/coast switch signal circuit.
A closed switch is displayed as On. The cruise control On/Off switch must be switched On in order to
correctly view the Cruise Set/Coast Switch parameter.
Engine Speed
The scan tool displays 0 to 9,999 RPM. The ECM/PCM monitors the crankshaft position (CKP) signal
circuit in order to determine the engine RPM.
Stoplamp Pedal Switch
The scan tool displays Applied or Released. The ECM monitors the stop lamp switch signal circuit. A
closed switch is displayed as Applied.
TCC Brake Pedal Switch
The scan tool displays Applied or Released. The ECM monitors the TCC brake switch/cruise control
release signal circuit. An open switch is displayed as Applied
Traction Control Status
The scan tool displays Active or Inactive. When the ECM receives a class 2 signal from the Electronic
Brake Control Module (EBCM) requesting a traction control related function, the scan tool displays
Active.
Vehicle Speed Sensor
The scan tool displays 0 to 150 km/h (93.2 mph). The ECM/PCM monitors the vehicle speed sensor
signal circuit in order to calculate the vehicle speed for display.
DTC P0567
Circuit Description
The cruise control resume/accel switch is an input to the engine control module (ECM). The ECM uses the
cruise control resume/accel switch signal circuit in order to detect when the driver has requested to accelerate
the set vehicle speed or to resume the cruise control system. The ECM detects a voltage signal on the cruise
control resume/accel switch signal circuit when the switch is applied.
DTC Descriptor
DTC P0567 Cruise Control Resume Switch Circuit
The ignition is ON.
The cruise control On/Off switch is ON.
The ECM detects a voltage signal on the cruise control resume/accel switch signal circuit for longer than
60 seconds.
This ECM runs this diagnostic every 0.05 seconds.
The ECM stores the DTC information into memory when the diagnostic runs and fails.
The malfunction indicator lamp (MIL) will not illuminate.
The ECM records the operating conditions at the time the diagnostic fails. The ECM stores this
information in the Failure Records.
The cruise control system is disabled.
Conditions for Clearing the MIL/DTC
A last test failed, or the current DTC, clears when the diagnostic runs and does not fail.
A history DTC clears after 40 consecutive warm-up cycles, if failures are not reported by this or any other
emission related diagnostic.
Use a scan tool in order to clear the MIL/DTC.
Diagnostic Aids
Ensure that the resume/accel switch is not stuck or sticking in the engaged position.
For an intermittent condition, refer to Testing for Intermittent Conditions and Poor Connections in
Wiring Systems.
Test Description
2: This step determines if condition is present.

3: This step determines if the switch is at fault.
DTC P0567
Step Action Yes No
Schematic Reference: Cruise Control Schematics
Connector End View Reference: Cruise Control Connector End Views or Engine Control Module
(ECM) Connector End Views in Engine Controls - 3.6L (LY7)
1
Vehicle in Vehicle
3. Turn the cruise control On/Off switch ON.
4. With the scan tool, observe the Cruise
2
Resume/Accel. Switch parameter in the
Powertrain 3.6L Cruise/Traction data list.
Does the Cruise Resume/Accel. Switch parameter Go to Diagnostic

display On? Go to Step 3 Aids
2. Disconnect C4 of the multifunction switch.
3 4. With the scan tool, observe the Cruise
Resume/Accel. Switch parameter.
Does the Cruise Resume/Accel. Switch parameter

display On? Go to Step 4 Go to Step 5
Test the cruise control resume/accel switch signal
circuit for a short to voltage. Refer to Circuit Testing
4
the multifunction switch. Refer to Testing for
the engine control module (ECM). Refer to Testing for
6
Replace the multifunction switch. Refer to
Multifunction, Turn Signal Switch Replacement in
7
Steering Wheel and Column.
Replace the ECM. Refer to Control Module
8
9 Running the DTC.
DTC P0568
Circuit Description
The cruise control set/coast switch is an input to the engine control module (ECM). The ECM uses the cruise
control set/coast switch signal circuit in order to detect when the driver has requested to set the vehicle speed or
to decelerate the vehicle speed. The ECM detects a voltage signal on the cruise control set/coast switch signal
circuit when the switch is applied.
DTC Descriptor
DTC P0568 Cruise Control Set Switch Circuit
The ignition is ON.

The cruise control On/Off switch is ON.
This DTC sets if the ECM Detects a voltage signal on the cruise control set/coast switch signal circuit for
greater than 60 seconds.
This ECM runs this diagnostic every 0.05 seconds.

The ECM stores the DTC information into memory when the diagnostic runs and fails.
The ECM records the operating conditions at the time the diagnostic fails. The ECM stores this
The cruise control system is disabled.
A last test failed, or the current DTC, clears when the diagnostic runs and does not fail.
A history DTC clears after 40 consecutive warm-up cycles, if failures are not reported by this or any other
emission related diagnostic.
Use a scan tool in order to clear the MIL/DTC.
Diagnostic Aids
Ensure that the set/coast switch is not stuck or sticking in the engaged position.
For an intermittent condition, refer to Testing for Intermittent Conditions and Poor Connections in Wiring
Systems.
Test Description
2: This step determines if condition is present.
DTC P0568
Step Action Yes No
Connector End View Reference: Cruise Control Connector End Views or Engine Control Module
(ECM) Connector End Views in Engine Controls - 3.6L (LY7)
1
Vehicle in Vehicle
3. Turn the cruise control On/Off switch ON.
4. Observe the Cruise Set/Coast Switch parameter
2
in the Powertrain 3.6 L Cruise/Traction Data,
data list.
Does the Cruise Set/Coast Switch parameter display Go to Diagnostic

On? Go to Step 3 Aids
3
4. Observe the Cruise Set/Coast Switch parameter.
Does the Cruise Set/Coast Switch parameter display

On? Go to Step 4 Go to Step 5
Test the cruise control set/coast switch signal circuit for
a short to voltage. Refer to Circuit Testing and Wiring
4
the multifunction switch. Refer to Testing for
the engine control module (ECM). Refer to Testing for
Replace the multifunction switch. Refer to
7
8
9 Running the DTC.
DTC P1554
Circuit Description
The powertrain control module (PCM) inhibits cruise control operation when certain conditions are not
appropriate for cruise control operation. The PCM removes the ground from the cruise control inhibit signal
circuit in order to disengage cruise control operation.

The powertrain control module (PCM) is commanding the cruise control module to inhibit cruise control
operation.
DTC Descriptor
DTC P1554 Cruise Control Feedback Circuit
The PCM detects a cruise control engaged signal from the cruise control module, while inhibiting cruise
control operation.
The above conditions are present for more than 1 second.
The PCM stores conditions which were present when the DTC set as Failure Records only. This information
will not be stored as Freeze Frame Records.
The DTC becomes history when the conditions for setting the DTC are no longer present.
The history DTC clears after 40 malfunction free warm-up cycles.
The PCM receives a clear code command from the scan tool.
Diagnostic Aids
Check for the following conditions:
A faulty connection at the PCM. Inspect the harness connectors for backed out terminals, improper
mating, broken locks, improperly formed or damaged terminals, and faulty terminal to wire connections.
Use a corresponding mating terminal to test for proper terminal tension.
Inspect the wiring harness for damage. If the harness appears to be OK, observe the Cruise Status display
on the scan tool while moving the connectors and wiring harnesses related to the cruise control module. A
change in the display will indicate the location of the malfunction.
If DTC P1554 cannot be duplicated, the information included in the Failure Records data can be useful in
determining how many ignition cycles have passed since the DTC was last set.
Test Description
8: This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read-only
memory (EEPROM). When the PCM is replaced, the new PCM must be programmed.
DTC P1554
Step Action Yes No
1
Vehicle in Vehicle
3. With a scan tool, monitor the DTC information
2 for DTC P1585 in the powertrain control module
(PCM).
Is DTC P1585 also set? Go to DTC P1585 Go to Step 3

With a scan tool, observe the Cruise Active display.
3
Does the Cruise Active display indicate YES? Go to Step 5 Go to Step 4
1. Review and record the Failure Records
Information.
2. Operate the vehicle within the Failure Records
condition.
4 3. Using a scan tool, monitor the Specific DTC
Information for DTC P1554 until the test runs.
Does the scan tool indicate that DTC P1554 failed this Go to Diagnostic
ignition? Go to Step 5 Aids
2. Disconnect the cruise control module harness
connector.
5 3. Turn ON the ignition, with the engine OFF.
4. Using the scan tool, observe the Cruise Active
display.
Does the Cruise Active display indicate YES? Go to Step 6 Go to Step 7

2. Disconnect the appropriate PCM connector.
3. Test the Cruise Engaged signal circuit for a short
6 to ground. Refer to Circuit Testing and Wiring

Replace the cruise control module. Refer to Control
7 Module References in Computer/Integrating Systems
for replacement, setup, and programming.
Replace the PCM. Refer to Control Module
8
1. Use a scan tool in order to clear the DTC.
9 Running the DTC as specified in the supporting
text.
DTC P1585
Circuit Description
The powertrain control module (PCM) has the ability to inhibit cruise control operation, if conditions exist that
would make cruise control operation undesirable. The PCM will interrupt the ground on the cruise inhibit
circuit to request that the cruise control be disengaged. The PCM also monitors the voltage on this circuit in
order to determine if a fault exists.
DTC Descriptor
DTC P1585 Cruise Control Inhibit Output Circuit
The ignition is ON.

The system voltage is between 9-16 volts.
The PCM detects that an improper voltage exists on the cruise control inhibit signal circuit.
The above condition is present for at least 30 seconds.
The PCM does not illuminate the malfunction indicator lamp (MIL).
The PCM stores the conditions which were present when the DTC set as Failure Records data only. This
information is not stored as Freeze Frame data.

A history DTC clears after 40 malfunction free warm-up cycles.
The PCM receives a clear code command from the scan tool.
Diagnostic Aids
Reviewing the Failure Records vehicle mileage since the diagnostic test last failed may help determine how
often the condition that caused the DTC to be set occurs. This may assist in diagnosing the condition.
DTC P1585 - Cruise Control Inhibit Control Circuit

Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
2. Disconnect the C103.
4. Measure the voltage on the cruise control
2 B+
inhibit signal circuit on the male terminal
side of C103.

Test the cruise control inhibit signal circuit for an
open, for a high resistance or for a short to
ground between C103 and the cruise control
3 -
module. Refer to Circuit Testing and to Wiring
Test the cruise control inhibit signal circuit for an
open, for a high resistance, or for a short to
ground between C103 and the powertrain control
4 -
module (PCM). Refer to Circuit Testing and to
and to Connector Repairs in Wiring Systems.
connector of the cruise control module. Refer to
6 Connections and to Connector Repairs in -
Wiring Systems.
7 -
Replace the cruise control module. Refer to
Control Module References in
8 Computer/Integrating Systems for replacement, -
setup, and programming.
1. Use the scan tool in order to clear the DTC.
9 for Running the DTC. -
SYMPTOMS - CRUISE CONTROL
1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information before using the Symptom
Tables in order to verify that all of the following are true:
There are not any DTCs set.
The control modules can communicate via the serial data link.
2. Review the system operation in order to understand the system functions. Refer to Cruise Control
Description and Operation (3.6L) or Cruise Control Description and Operation (3.4L) .
Inspect for aftermarket devices which could affect the operation of the Cruise Control System. Refer to
cause the symptom.
Intermittent
Symptom List
Refer to Cruise Control Inoperative/Malfunctioning (3.6L) or Cruise Control
Inoperative/Malfunctioning (3.4L)
Refer to Cruise Control Indicator Always On (3.6L) or Cruise Control Indicator Always On (3.4L)
Refer to Cruise Control Indicator Inoperative (3.6L) or Cruise Control Indicator Inoperative (3.4L)
CRUISE CONTROL INDICATOR ALWAYS ON (3.6L)
Cruise Control Indicator Always On (3.6L)

Step Action Yes No
Connector End View Reference: Cruise Control Connector End Views
1
Vehicle in Vehicle
Turn the ignition ON, with the engine OFF. Go to Testing for
Does the cruise indicator illuminate after the Intermittent
2 instrument panel cluster (IPC) displays test? Conditions and
Poor Connections
Go to Step 3 in Wiring Systems
3. Turn the ignition ON, with the engine OFF.
3
4. With the scan tool, observe the Cruise Control
parameter in the IPC data list.
Does the Cruise Lamp parameter display On? Go to Step 4 Go to Step 5

Replace the powertrain control module (PCM). Refer
to Control Module References in
and programming.
Replace the IPC. Refer to Control Module References
in Computer/Integrating Systems for replacement,
5
6
Does the system operate properly? System OK Go to Step 2
CRUISE CONTROL INDICATOR ALWAYS ON (3.4L)
Cruise Control Indicator Always On (3.4L)

Step Action Yes No
1
Vehicle in Vehicle
3. With a scan tool, observe the cruise lamp
2 parameter in the instrument panel cluster (IPC)
inputs.
Does the scan tool indicate that the cruise lamp is

commanded On? Go to Step 3 Go to Step 5
With a scan tool, observe the cruise parameter in the
powertrain control module (PCM) data list.
3
Does the scan tool indicate that the cruise control is
engaged? Go to Step 4 Go to Step 5
of the PCM. Refer to Testing for Intermittent
of the IPC. Refer to Testing for Intermittent
6
7
8
CRUISE CONTROL INDICATOR INOPERATIVE (3.6L)
Cruise Control Indicator Inoperative (3.6L)

Step Action Yes No
Connector End View Reference: Cruise Control Connector End Views
1
Vehicle in Vehicle
2 4. With the scan tool, command the Cruise Control
Lamp Test parameter On, in the instrument panel
cluster (IPC) Special Functions.
Does the Cruise indicator illuminate in the IPC? Go to Step 4 Go to Step 3

Replace the IPC. Refer to Instrument Panel Cluster
(IPC) Replacement in Instrument Panel, Gages, and
3
Console.
Replace the powertrain control module (PCM). Refer
and programming.
5
Does the system operate properly? System OK Go to Step 2
CRUISE CONTROL INDICATOR INOPERATIVE (3.4L)
Cruise Control Indicator Inoperative (3.4L)

Step Action Yes No
1
Vehicle in Vehicle
2. With a scan tool, command the cruise control
2 indicator ON.
Does the cruise control indicator illuminate? Go to Step 3 Go to Step 4

of the powertrain control module (PCM). Refer to
3
Systems.
of the instrument panel cluster (IPC). Refer to Testing
5
Did you find and correct the condition? Go to Step 7 -
6
7
CRUISE CONTROL INOPERATIVE/MALFUNCTIONING (3.6L)
Diagnostic Aids
Perform the following in order to avoid misdiagnosis:
Inspect for proper operation of the stop lamps. Refer to Exterior Lighting Systems Description and
Operation in Lighting Systems.
Electromagnetic interference (EMI) on the speed sensor signal circuit may cause erratic cruise control
operation.
For an intermittent condition, refer to Testing for Intermittent Conditions and Poor Connections in Wiring
Systems.
Conditions for Enabling Cruise Control

The vehicle is not in PARK, REVERSE, NEUTRAL, or 1st gear.
The system voltage is between 12 volts and 16 volts.
Cruise Control Inoperative/Malfunctioning (3.6L)

Step Action Yes No
Connector End View Reference: Cruise Control Connector End Views or to Engine Control
Module (ECM) Connector End Views in Engine Controls - 3.6L (LY7)
1
Vehicle in Vehicle
3. Turn the cruise On/Off switch OFF.
2 4. With the scan tool, observe the Cruise On/Off
Switch parameter in the Powertrain-3.6L
Cruise/Traction Data, data list.
Does the Cruise On/Off Switch parameter display Off? Go to Step 3 Go to Step 6
1. Turn the cruise On/Off switch ON.
2. With the scan tool, observe the Cruise On/Off
3 Switch parameter.
Does the Cruise On/Off Switch parameter display On? Go to Step 4 Go to Step 7
1. With the scan tool, observe the Cruise Set/Coast
2. Turn the cruise On/Off switch ON.
4 3. Press and hold the cruise control Set/Coast
button.
Does the Cruise Set/Coast Switch parameter Display

On? Go to Step 5 Go to Step 17
1. With the scan tool, observe the Cruise
Resume/Accel. Switch parameter in the
Powertrain-3.6L Cruise/Traction Data, data list.
5 2. Press and hold the Resume/Accel switch.
Does the Cruise Resume/Accel. Switch parameter

Display On? Go to Step 8 Go to Step 18
6
4. With the scan tool, observe the Cruise On/Off
Switch parameter.
4. Connect a test lamp between the ignition 3
voltage circuit and a good ground.
Does the test lamp illuminate?
Go to Stop Lamps
Inoperative or to
8 Do the stop lamps operate properly? Stop Lamps
Always On in
Go to Step 9 Lighting Systems
1. With the scan tool, observe the Stoplamp Pedal
9 2. Depress and hold the brake pedal.
Does the Stoplamp Pedal Switch parameter Display Go to Diagnostic

Applied? Aids Go to Step 11
1. Connect a 3-ampere fused jumper between the
ignition 3 voltage circuit and the cruise control
on switch signal circuit.
10 2. With the scan tool, observe the Cruise On/Off
Switch parameter.
Test the stop lamp signal circuit for an open or for a
high resistance between the stop lamp switch and the
11 engine control module (ECM). Refer to Circuit
Testing and Wiring Repairs in Wiring Systems.
Test the cruise control on switch signal circuit for a
short to voltage. Refer to Circuit Testing and Wiring
12
Test the cruise control on switch signal circuit for a
13
Test the cruise control set/coast switch signal circuit
for a short to ground. Refer to Circuit Testing and
14
Test the cruise control resume/accelerate switch signal
circuit for a short to ground. Refer to Circuit Testing
15
Test the cruise control on switch signal circuit for an
16 open, for a short to ground, or for a high resistance.
Wiring Systems.
Test the cruise control set/coast signal circuit for an
open, for a short to ground, or for a high resistance.
17 Refer to Circuit Testing and Wiring Repairs in
Wiring Systems.
Test the cruise control resume/accelerate signal circuit
for an open, for a short to ground, or for a high
18 resistance. Refer to Circuit Testing and Wiring
Repair the open, the high resistance, or the short to
ground in the ignition 3 voltage circuit. Refer to
19 Circuit Testing andWiring Repairs in Wiring
Systems.
of the multifunction turn signal lever. Refer to Testing
of the ECM. Refer to Testing for Intermittent
Replace the multifunction turn signal lever. Refer to
22
23
Operate the vehicle within the conditions for cruise
24 control operation.
Does the cruise control system operate properly? System OK Go to Step 2
CRUISE CONTROL INOPERATIVE/MALFUNCTIONING (3.4L)
Diagnostic Aids
IMPORTANT: Perform the following in order to avoid misdiagnosis.

Inspect for proper operation of the brake lamps.
Inspect for proper operation of the transmission range switch.
Inspect throttle linkage for mechanical binding which could cause the system to malfunction.
Cruise Control Inoperative/Malfunctioning (3.4L)

Vehicle? Diagnostic
System Check -
1 -
Vehicle in
Vehicle DTC
2. Disconnect the cruise control module.
2 OFF. -
4. Connect a test lamp between the ignition
positive voltage circuit and a good ground.

Connect the test lamp between the ignition
positive voltage circuit and the ground circuit of
3 -
the cruise control module.
1. Make sure that the cruise control switch is
OFF.
2. Connect a test lamp between the cruise
control ON switch circuit, the Set/Coast
4 switch signal circuit, and the -
Resume/Accelerate switch signal circuit
and a good ground one at a time.
Does the test lamp illuminate on any of the signal

circuits? Go to Step 13 Go to Step 5
1. Turn cruise control On/Off switch On.
2. Connect the test lamp between the cruise
5 control on signal circuit and a good -
ground.

control set/coast signal circuit and a good
ground.
6 2. Press and hold the SET/COAST button. -

control resume/accel switch signal circuit
and a good ground.
7 2. Press and hold the RESUME/ACCEL -
switch.

Connect the test lamp between the cruise control
8 release signal circuit and a good ground. -
Connect the test lamp between the stop lamp
9 signal circuit and a good ground. -
Press the brake pedal while monitoring the test
10 lamp. -
Measure the voltage at the cruise control engaged
signal circuit.
11 B+
Check the speedometer for proper operation. Go to
Does the speedometer operate properly? Speedometer
and/or
Odometer
12 - Inaccurate or
Inoperative in
Instrument
Panel, Gages
Go to Step 23 and Console
Test the suspected switch signal circuit for a
short to voltage. Refer to Circuit Testing and
13 -
Test the cruise control On/Off switch signal
circuit for an open or for a high resistance. Refer
14 to Circuit Testing and Wiring Repairs in -
Wiring Systems.
Test the ignition positive voltage circuit of the
cruise control on/off switch for an open or for a
high resistance. Refer to Circuit Testing and
15 Wiring Repairs in Wiring Systems. -
Test the cruise control set/coast switch signal
Wiring Systems.
Test the cruise control resume/accelerate switch
signal circuit for an open or for a high resistance.
17 Refer to Circuit Testing and Wiring Repairs in -
Wiring Systems.
Test the cruise control release switch signal
Wiring Systems.
Test the cruise control release switch signal
circuit for a short to voltage. Refer to Circuit
19 -
Test the stop lamp switch signal circuit for a Go to Stop
short to voltage. Refer to Circuit Testing and Lamps Always
20 -
Wiring Repairs in Wiring Systems. On in Lighting
Did you find and correct the condition? Go to Step 35 Systems
Test the stop lamp switch signal circuit for an
open or for a high resistance between the center Go to Stop
console fuse block and the cruise control module. Lamps
21 -
Refer to Circuit Testing and Wiring Repairs in Inoperative in
Wiring Systems. Lighting
Test the cruise engaged signal circuit for an open,
for a high resistance, or for a short to ground.
Wiring Systems.
Test the vehicle speed signal circuit for an open
or for a high resistance between the powertrain
control module (PCM) and the cruise control
23 -
module. Refer to Circuit Testing and Wiring
Inspect the cruise control release switch for
24 proper adjustment. Refer to Cruise Release -
Switch Adjustment in Cruise Control.
connector of the cruise control release switch.
25 -
and Poor Connections and Connector Repairs
in Wiring Systems.
connector of the cruise control switch. Refer to
27 -
Systems.
connector of the cruise control module. Refer to
28 -
Systems.
Repair the ignition positive voltage circuit of the
cruise control module. Refer to Wiring Repairs
29 -
in Wiring Systems.
Repair the ground circuit of the cruise control
module. Refer to Wiring Repairs in Wiring
30 -
Systems.
Replace the cruise control release switch. Refer
31 to Cruise Release Switch Replacement . -
32 -
Replace the cruise control switch. Refer to
Multifunction, Turn Signal Switch
33 -
Replacement in Steering Wheel and Column.
Replace the cruise control module. Refer to
34 Control Module References in -
1. Use a scan tool in order to clear the DTC.
35 for cruise control operation. -
Does the cruise control system operate correctly? System OK Go to Step 2
REPAIR INSTRUCTIONS
CRUISE CONTROL CABLE REPLACEMENT
Removal Procedure
Fig. 6: View Of Throttle Lever & Scan Tool Data List
1. Remove the cable from the throttle lever and accelerator control cable bracket.
Fig. 7: Rotating Cruise Control Cable To Engage/Release From Module
2. Rotate the cable counter clockwise at the module in order to remove the cable from the module.
3. Remove the cable from the module band.
Fig. 8: Rotating Cruise Control Cable To Engage/Release From Module
IMPORTANT: Ensure that the module strap is not twisted during the installation of the
cable.
1. Install the cable to the module band.

2. Install the cable to the module.
Fig. 9: View Of Throttle Lever & Scan Tool Data List
3. Install the cable to the throttle lever and accelerator control cable bracket.
CRUISE CONTROL MODULE REPLACEMENT
Removal Procedure
1. Remove the cruise control cable from the module. Refer to Cruise Control Cable Replacement .
2. Disconnect the electrical connector from the cruise control module.

3. Remove the cruise control module from the bracket.


1. Install the cruise control module to the bracket.

2. Connect the electrical connector to the cruise control module.
3. Install the cruise control cable to the module. Refer to Cruise Control Cable Replacement .
CRUISE RELEASE SWITCH ADJUSTMENT
NOTE: Proper stoplamp switch adjustment is essential. Improper stoplamp switch

wear.
1. Remove the left side instrument panel insulator. Refer to Closeout/Insulator Panel Replacement - Left
in Instrument Panel, Gages and Console.
Fig. 12: Aligning Cruise Release Switch Until Travel Stop Is Reached
2. Rotate the switch counter-clockwise until the travel stop is reached (approximately 60 degrees).
IMPORTANT: Do NOT move or push the brake pedal.
3. Insert the switch into the retainer until the switch plunger is fully depressed into the switch barrel.
4. Rotate the switch until the travel stop is reached (approximately 60 degrees). The electrical connector
index notch should be at the 12 o'clock position.
5. Ensure that the cruise control system operates properly.
6. Install the left side instrument panel insulator. Refer to Closeout/Insulator Panel Replacement - Left in
Instrument Panel, Gages and Console.
CRUISE RELEASE SWITCH REPLACEMENT
Removal Procedure
1. Remove the left side instrument panel insulator. Refer to Closeout/Insulator Panel Replacement - Left
2. Rotate the cruise control release switch counterclockwise until the travel stop has been reached
(approximately 60 degrees).
Fig. 14: Identifying Cruise Control Release Switch
3. Remove the cruise control release switch from the retainer.
4. Disconnect the cruise control release switch electrical connector.
1. Install the cruise control release switch electrical connector.

Fig. 15: Identifying Cruise Control Release Switch
2. With the electrical connector index notch at the 10 o'clock position, install the cruise control release
switch to the retainer.
IMPORTANT: Do NOT move or push the brake pedal.
3. Slide the switch into the retainer until the plunger is fully depressed into the barrel.
4. Rotate the cruise control release switch clockwise until the travel stop has been reached (approximately
60 degrees). The electrical connector index notch should now be at the 12 o'clock position.
5. Ensure that the cruise control system operates properly.
6. Install the left side instrument panel insulator. Refer to Closeout/Insulator Panel Replacement - Left in
CRUISE CONTROL DESCRIPTION AND OPERATION (3.6L)
Cruise control is a speed control system that maintains a desired vehicle speed under normal driving conditions
at vehicle speeds above 40 km/h (25 mph). Steep grades may cause variations in the selected vehicle speeds.
The following are the main components of the cruise control system:
The accelerator pedal

The engine control module (ECM)
The On/Off switch
The Resume/Accel switch
The Set/Coast switch
The torque converter clutch (TCC) brake/cruise release switch
The stop lamp switch
The throttle actuator control (TAC) motor
The vehicle speed sensor
Cruise Control Engaged
The cruise control system will engage and adjust the vehicle speed based on the activation of the following
cruise control switches:
On/off
Resume/accel.
Set/coast
The cruise control switches are located on the multifunction/turn signal lever.
The engine control module (ECM) monitors the signal circuits of the cruise control switches in order to
determine when to capture and maintain the selected vehicle speed. The ECM uses the throttle actuator control
(TAC) motor in order to control the vehicle speed. For further information on the TAC system, refer to Throttle
Actuator Control (TAC) System Description in Engine Controls - 3.6L (LY7).
Ignition positive voltage is supplied from the 10-ampere CRUISE fuse to the cruise control switch via the
ignition 1 voltage circuit. When the normally open cruise control on/off switch is turned ON, the switch closes
and the ECM detects a high signal voltage on the cruise control on switch signal circuit. When the normally
open set/coast switch is pressed, the switch closes and the ECM detects a high signal voltage on the cruise
control set/coast switch signal circuit. To engage the cruise control system, turn the On/Off switch On and
momentarily press the set/coast switch. The ECM will confirm that the cruise control enable criteria has been
achieved. The ECM will engage the cruise control system and record the selected vehicle speed. The ECM
sends a class 2 message to the instrument panel cluster in order to illuminate the cruise control indicator.
Pressing the accelerator pedal, while the cruise control system is engaged, will allow the driver to override the
cruise control system in order to accelerate the vehicle beyond the current set vehicle speed. When the
accelerator pedal is released, the vehicle will decelerate and resume the current set vehicle speed. The driver can
also override the current set vehicle speed via the set/coast switch and the resume/accel switch. When the cruise
control system is engaged, pressing and holding the set/coast switch will allow the vehicle to decelerate from
the current set vehicle speed without deactivating the cruise control system. When the set/coast switch is
released, the ECM will record the vehicle speed and maintain the vehicle speed as the new set vehicle speed.
When the cruise control system is engaged, momentarily pressing the set/coast switch will allow the vehicle to
decelerate at 1.6 km/h (1 mph) increments for each time that the set/coast is momentarily pressed, with a
minimum vehicle speed of 37 km/h (23 mph). When the normally open resume/accel switch is activated, the
switch closes and the ECM detects a high signal voltage on the cruise control resume/accel switch signal circuit.
Activating and holding the resume/accel switch, when the cruise control system is engaged, will allow the
vehicle to accelerate to a greater vehicle speed than the current set vehicle speed. When the resume/accel switch
is released, the ECM will record the vehicle speed and maintain the vehicle speed as the new set vehicle speed.
When the cruise control system is engaged, momentarily activating the resume/accel switch will allow the
vehicle to accelerate at 1.6 km/h (1 mph) increments for each time that the resume/accel switch is momentarily
activated, with the maximum acceleration total of 16 km/h (10 mph) over the current set vehicle speed.
Momentarily activating the resume/accel switch, after the cruise control system has been disengaged by
pressing the brake pedal, will recall the previous set vehicle speed that is recorded in the ECM.
Cruise Control Disengaged
The engine control module (ECM) disengages the cruise control operation based on the signals from the
following switches:
The On/Off switch

The torque converter clutch (TCC) brake switch
The stop lamp switch
The TCC brake switch and the stop lamp switch are incorporated into an assembly and are mounted to the brake
pedal bracket. Pressing the brake pedal while the cruise control is engaged will disengaged the cruise control
system. The ECM monitors the TCC brake switch/cruise control release signal circuit and the stoplamp switch
signal circuit. When the brake pedal is pressed, the normally closed TCC brake switch opens and the normally
open stoplamp switch closes. The ECM detects a low signal voltage on the TCC brake switch/cruise control
release signal circuit and detects a high signal voltage on the stop lamp switch signal circuit. The cruise control
system will also disengage when the cruise control On/Off switch is turned Off. The vehicle speed stored in the
memory of the ECM will be erased when the cruise control On/Off switch is turned to Off, or the ignition
switch is turned off.
The cruise control system will disengage when the ECM detects that the driver has the accelerator pedal
override active for approximately 60 seconds.
When the cruise control system is disengaged, the ECM sends a class 2 message to the instrument panel cluster
(IPC) in order to deactivate the cruise control indicator.
Cruise Control Inhibited
The engine control module (ECM) inhibits the cruise control operation when any of the following conditions
exist:
A cruise control system related DTC has been set.

The vehicle speed is less than 40 km/h (25 mph).
The vehicle is in PARK, REVERSE, NEUTRAL, or 1st gear.
The engine RPM is too low.
The engine RPM is too high.
The vehicle speed is too high.
The system voltage is not between 6 volts and 16 volts.
The antilock brake system/traction control system is active for more than 2 seconds.
CRUISE CONTROL DESCRIPTION AND OPERATION (3.4L)
Cruise control is a speed control system that maintains a desired vehicle speed under normal driving conditions
at speeds above 40km/h (25 mph). However, steep grades may cause variations in the selected speeds. The main
components of the cruise control system are:
The cruise control module assembly

The cruise control switches
The cruise control release switch
The powertrain control module (PCM)
The stoplamp switch assembly
The vehicle speed sensor
The cruise control system has the capability to adjust speeds and disengage the system based on the activation
of the following cruise control switches:
On/Off
Set/Coast
Resume/Accel (R/A)
The cruise control module controls the operation of the cruise control system. The cruise control module
monitors the signal circuits of the cruise control switches. When the normally open cruise On/Off switch closes
with a switch activation, the cruise control modules detects a high voltage on the signal circuit. The cruise
control module activates the cruise control system. The set/coast switch and the resume/accel switch will not
operate the system when the cruise control module has not activated the system based on the cruise control
on/off switch signal circuit.
The cruise control module monitors the cruise control set/coast switch in order to determine when to capture
and maintain the vehicle speed. The cruise control module monitors the vehicle speed signal circuit in order to
determine the desired speed. The PCM pulses the vehicle speed signal circuit at 4000 pulses per minute. After
an initial set speed has been established, the cruise control module also uses the cruise control set/coast switch
signal circuit in order to tap down the set speed when the cruise control module detects a switch activation.
The cruise control module monitors the cruise control resume/accel switch signal circuit in order to determine
when to resume the previous set speed. This feature only works within the same ignition cycle and as long as
the cruise wasn't turned off using the cruise control On/Off switch since the last cruise engagement. After the
set speed has been resumed, the cruise control module also uses the cruise control resume/accel switch signal
circuit in order to tap up the set speed when the cruise control module detects a switch activation.
The cruise control module assembly has a controller and an electric stepper motor to vary the throttle in each
different cruise control mode. Two components in the module assembly help to do this. The electronic
controller and the electric stepper motor. The controller monitors vehicle speed and operates the stepper motor.
The stepper motor operates in response to the controller, to maintain the desired cruise speed. The electric
stepper motor moves a strap that is attached to the cruise control cable which moves the throttle linkage.
Cruise Control Engaged
The cruise control module grounds the cruise engaged signal circuit when cruise control is engaged. The PCM
monitors the cruise engaged signal circuit in order to determine when the cruise control is engaged. The PCM
sends a class 2 message indicating that the cruise control is engaged to the instrument panel cluster (IPC )
(Buick Only). The IPC illuminates the cruise indicator. The cruise control module, cruise cancel signal circuit,
is a circuit used by the PCM to inhibit cruise control when conditions inconsistent with cruise operation are
present.
Cruise Control Disengaged
The cruise control release switch and stoplamp switch are used to disengage the cruise control. A release switch
assembly and a stoplamp switch assembly are mounted on the brake pedal bracket. To disengage the system the
driver presses the brake pedal. The speed of the vehicle at brake actuation will be stored in the memory of the
cruise module. The cruise control module uses that stored speed when the cruise control system operation is
resumed.
Cruise Control Inhibited
The PCM determines when the vehicle operating conditions are not appropriate for cruise control operation.
The PCM inhibits the cruise control operation when any of the following conditions occur:
The vehicle speed is less than 40 km/h (25 mph).

The vehicle is in PARK, REVERSE, NEUTRAL, or 1st gear.
The engine RPM is low.
The engine RPM is high with fuel cut-off.
The vehicle speed is too high.
The battery is either overcharged or undercharged.
The antilock brake system/traction control system is active for more than 2 seconds
When any of the conditions listed above are present, the PCM removes the ground from the cruise control
inhibit signal circuit. The cruise control module monitors the cruise control inhibit circuit in order to disable the
system. The PCM compares the status of the cruise control inhibit signal circuit to the status of the cruise
control engaged signal circuit. If the cruise control engaged signal circuit indicates that the cruise control
module has cruise control engaged while the PCM is inhibiting cruise control operation, the PCM sets a DTC.
The PCM also sends a class 2 message indicating that the cruise control is engaged to the IPC indicator, (if
equipped).
Another feature, internal to the cruise control module is the lash learn feature. The cruise control module has the
ability to learn and electronically compensate for up to 4mm of lash in the non-adjustable cruise control cable.
The cruise control module maintains this adjustment and updates this information every 30 seconds.
Disc Brakes - Aztek & Rendezvous
SPECIFICATIONS

Specification
Front Brakes
Brake Caliper Bolt 35 N.m 26 lb ft
Brake Caliper Bracket Bolt 185 N.m 137 lb ft
Brake Hose Fitting Bolt 54 N.m 32 lb ft
Rear Brakes
Brake Caliper Bolt 45 N.m 33 lb ft
Brake Caliper Bracket Bolt 130 N.m 96 lb ft
Brake Hose Fitting Bolt 43 N.m 32 lb ft
DISC BRAKE COMPONENT SPECIFICATIONS
Disc Brake Component Specifications

Specification
Front Brakes
Caliper Bore Diameter 64 mm 2.520 in
Rotor Diameter (All Wheel Drive) 300 mm 11.811 in
Rotor Diameter (Front Wheel Drive) 275 mm 10.945 in
Rotor Discard Thickness* 27.0 mm 1.063 in
Rotor Maximum Allowable Assembled Lateral 0.06 mm 0.002 in
Runout
Rotor Maximum Allowable Scoring 1.50 mm 0.059 in
Rotor Maximum Allowable Thickness Variation 0.025 mm 0.001 in
Rotor Minimum Allowable Thickness After Refinish 28.4 mm 1.118 in
Rotor Minimum Wear Stock 1.0 mm 0.039 in
Rotor Thickness (new) 30.0 mm 1.181 in
Rear Brakes
Caliper Bore Diameter 38.1 mm 1.500 in
Rotor Diameter 291.0 mm 11.457 in
Rotor Discard Thickness* 9.0 mm 0.35 in
Rotor Maximum Allowable Assembled Lateral 0.06 mm 0.002 in
Runout
Rotor Maximum Allowable Scoring 1.50 mm 0.059 in
Rotor Maximum Allowable Thickness Variation 0.025 mm 0.001 in
Rotor Minimum Allowable Thickness After Refinish 10.6 mm 0.42 in
Rotor Minimum Wear Stock 1.6 mm 0.06 in
Rotor Thickness (new) 11.0 mm 0.43 in
* All brake rotors have a discard dimension cast into them. Replace any rotor that does not meet this
specification. After refinishing the rotor, replace any rotor that does not meet the minimum thickness
specifications.

DIAGNOSTIC STARTING POINT - DISC BRAKES
Begin the disc brake system diagnosis with Diagnostic Starting Point - Hydraulic Brakes in Hydraulic
Brakes. The use of the Diagnostic Starting Point will lead to the identification of the correct procedure for
diagnosing the system and where the procedure is located.
BRAKE ROTOR THICKNESS MEASUREMENT
CAUTION: Refer to Brake Dust Caution in Cautions and Notices.
the brake pads. Refer to Brake Pads Replacement - Front and/or Brake Pads Replacement - Rear, if
equipped.
cleaner.
Fig. 1: Measuring Brake Rotor Thickness

record the thickness of the brake rotor at four or more points, evenly spaced around the rotor.
Ensure that the measurements are only taken within the friction surfaces and that the micrometer is
positioned the same distance from the outer edge of the rotor, about 13 mm (1/2 in), for each
measurement.
Specification:
Front brake rotor minimum allowable thickness after refinishing: 28.4 mm (1.118 in)
Rear brake rotor minimum allowable thickness after refinishing: 10.6 mm (0.42 in)
Front brake rotor discard thickness: 27.0 mm (1.063 in)
Rear brake rotor discard thickness: 9.0 mm (0.35 in)
5. If the lowest thickness measurement of the brake rotor is above the minimum allowable thickness after
refinishing specification, the rotor may be able to be refinished, depending upon surface and wear
6. If the lowest thickness measurement of the brake rotor is at or below the minimum allowable thickness
after refinishing specification, the rotor may not be refinished.
7. If the lowest thickness measurement of the brake rotor is at or below the discard thickness specification,
the rotor requires replacement.
BRAKE ROTOR THICKNESS VARIATION MEASUREMENT
IMPORTANT: Any disc brake rotor that exhibits thickness variation exceeding the maximum
acceptable level must be refinished or replaced. Thickness variation exceeding
the maximum acceptable level can cause brake pulsation.
equipped.
cleaner.

record the thickness of the brake rotor at four or more points, evenly spaced around the rotor.
Ensure that the measurements are only taken within the friction surfaces and that the micrometer is
positioned the same distance from the outer edge of the rotor, about 13 mm (0.5 in), for each
measurement.
4. Calculate the difference between the highest and lowest thickness measurements recorded to obtain the
amount of thickness variation.
5. Compare the thickness variation measurement to the following specification:
Specification: Brake rotor maximum allowable thickness variation: 0.025 mm (0.001 in)
IMPORTANT: Whenever a brake rotor is refinished or replaced, the assembled lateral

runout (LRO) of the rotor must be measured to ensure optimum
performance of the disc brakes.
6. If the brake rotor thickness variation measurement exceeds the specification, the rotor requires refinishing
or replacement.
BRAKE ROTOR SURFACE AND WEAR INSPECTION
equipped.
cleaner.
3. Inspect the friction surfaces of the brake rotor for the following Braking Surface Conditions:
Light surface rust can be removed with an abrasive disc. Heavy surface rust and/or pitting must be
removed by refinishing the rotor.

4. If the friction surfaces of the brake rotor exhibit one or more of the Braking Surface Conditions, the rotor
requires refinishing or replacement.

record the scoring depth of any grooves present on the rotor friction surfaces.
6. Compare the groove scoring depth recorded to the following specification:
Specification: Brake rotor maximum allowable scoring: 1.50 mm (0.059 in)
7. If the brake rotor scoring depth exceeds the specification, or if an excessive amount of scoring is present,
the rotor requires refinishing or replacement.
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) MEASUREMENT
Tools Required
J 39544-KIT Torque-Limiting Socket Set, or equivalent. See Special Tools.

J 41013 Rotor Resurfacing Kit. See Special Tools.
J 42450-A Wheel Hub Resurfacing Kit. See Special Tools.
J 45101 Hub and Wheel Runout Gage. See Special Tools.
J 45101-100 Conical Brake Rotor Washers. See Special Tools.
IMPORTANT: Brake rotor assembled lateral runout (LRO) exceeding the maximum
brake rotor over time, usually between 4 800-11 300 km (3,000-7,000 mi).
Brake rotor thickness variation MUST be checked BEFORE checking for
assembled LRO. Thickness variation exceeding the maximum acceptable
level can cause brake pulsation. Refer to Brake Rotor Thickness Variation
Measurement.
1. Matchmark the position of the brake rotor to the wheel studs if this has not been done already.
IMPORTANT: Whenever the brake rotor has been separated from the hub/axle flange,
any rust or contaminants should be cleaned from the hub/axle flange and
the brake rotor mating surfaces. Failure to do this may result in excessive
assembled LRO of the brake rotor, which could lead to brake pulsation.
particles, corrosion, rust, or debris remaining. If the wheel hub/axle flange and/or if the brake rotor
mating surfaces exhibit these conditions, perform the following steps:
1. Remove the brake rotor from the vehicle. Refer to Brake Rotor Replacement - Front and/or
Brake Rotor Replacement - Rear , if equipped.
2. Using the J 42450-A , thoroughly clean any rust or corrosion from the mating surface of the
hub/axle flange. See Special Tools.
3. Using the J 41013 , thoroughly clean any rust or corrosion from the mating surface of the brake
rotor. See Special Tools.
4. Clean the friction surfaces of the brake rotor with denatured alcohol, or an equivalent approved
brake cleaner.
3. Install the rotor to the hub/axle flange using the matchmark made prior to removal.
Fig. 4: Identifying J 45101-100 & Lug Nut

4. Hold the rotor firmly in place against the hub/axle flange and install one of the J 45101-100 (1), and one
lug nut (2) onto the upper-most wheel stud. See Special Tools.
Fig. 5: Installing All J 45101-100s & Lug Nuts
6. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly by hand
in a star-pattern. See Special Tools.
7. Using the J 39544-KIT , or equivalent, tighten the lug nuts in a star-pattern to specification, in order to
properly secure the rotor. See Special Tools. Refer to Tire and Wheel Removal and Installation in
Tires and Wheels.
8. If the brake rotor has been REFINISHED or REPLACED with a new rotor, proceed to step 14.
9. If the brake rotor meets the following criteria, proceed to step 10.
The rotor is within specifications and is being REUSED.
The rotor has NOT been refinished.
The rotor does NOT exhibit thickness variation exceeding the maximum allowable level.
Fig. 6: Mounting Dial Indicator To Measure Lateral Runout

10. Mount a dial indicator, J 45101 , or equivalent, to the steering knuckle and position the indicator button
so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the
outer edge of the rotor.
1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero.
2. Rotate the rotor until the highest reading is displayed on the dial.
3. Mark the location of the high spot relative to the nearest wheel stud, or studs.
4. Measure and record the amount of LRO.
12. Compare the brake rotor assembled LRO to the following specification:
Specification:
Front brake rotor maximum allowable assembled lateral runout: 0.06 mm (0.002 in)
Rear brake rotor maximum allowable assembled lateral runout: 0.06 mm (0.002 in)
13. If the brake rotor assembled LRO is within specifications, proceed to step 18.
If the brake rotor assembled LRO exceeds the specification, refinish the rotor to ensure true parallelism,
refer to Brake Rotor Refinishing. After refinishing the rotor, proceed to step 14.
14. Mount a dial indicator, J 45101 , or equivalent, to the steering knuckle and position the indicator button
so it contacts the brake rotor friction surface at a 90 degree angle, approximately 13 mm (0.5 in) from the
outer edge of the rotor.
1. Rotate the rotor until the lowest reading is displayed on the indicator dial, then set the dial to zero.
2. Rotate the rotor until the highest reading is displayed on the dial.
3. Mark the location of the high spot relative to the nearest wheel stud, or studs.
4. Measure and record the amount of LRO.
16. Compare the brake rotor assembled LRO to the following specification:
Specification:
Front brake rotor maximum allowable assembled lateral runout: 0.06 mm (0.002 in)
Rear brake rotor maximum allowable assembled lateral runout: 0.06 mm (0.002 in)
17. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within
specifications. Refer to Brake Rotor Assembled Lateral Runout (LRO) Correction.
depress the brake pedal several times to secure the rotor in place before removing the J 45101-100 and
the lug nuts. See Special Tools.
BRAKE PAD INSPECTION

Fig. 7: View Of Brake Pads & Audible Wear Sensors
Inspect the disc brake pads at regular intervals, or whenever the tire and wheel assemblies are removed
from the vehicle.
If replacement is necessary, always replace disc brake pads in axle sets.
Inspect both edges of the disc brake pad friction surfaces (3). The highest rate of wear normally occurs at
the trailing edge of the disc brake pads.
Inspect the thickness of the disc brake pads (3) in order to ensure that they have not worn prematurely.
The disc brake pad wear should be approximately even per axle set.
Both front and rear disc brake pads have integral, audible wear sensors (1). When the disc brake pad wear
reaches the minimum allowable thickness, the wear sensor contacts the disc brake rotor (2). The wear
indicator will then produce an audible, high-pitched warning noise during wheel rotation.
Replace the disc brake pads when the friction surface (3) is worn to within 0.76 mm (0.030 in) of the
mounting plates.
Remove the brake calipers and inspect the friction surfaces of the inner and outer disc brake pads to
ensure that they are level. Place the disc brake pad friction surfaces together and measure the gap between
the surfaces. If more than 0.13 mm (0.005 in) gap exists midway between the length of the disc brake
pads, replace the disc brake pads.
Verify that any disc brake pad shims that may be required are in place and not damaged or excessively
corroded. Replace any missing or damaged shims in order to preserve proper disc brake performance.
Replace the disc brake pads if any have separated from the mounting plates.
Inspect the disc brake pads friction surfaces for cracks, fractures, or damage which may cause noise or
otherwise impair disc brake performance.
BRAKE CALIPER INSPECTION

Fig. 8: Exploded View Of Brake Caliper
1. Inspect the brake caliper housing (1) for cracks, excess wear, and/or damage. If any of these conditions
are present, the brake caliper requires replacement.
2. Inspect the caliper piston dust boot seal (2) for cracks, tears, cuts, deterioration and/or improper seating in
the caliper body. If any of these conditions are present, the brake caliper requires overhaul or
replacement.
3. Inspect for brake fluid leakage around the caliper piston dust boot seal (2) and on the disc brake pads. If
there is any evidence of brake fluid leakage, the brake caliper requires overhaul or replacement.
Fig. 9: Compressing Caliper Piston

4. Inspect for smooth and complete travel of the caliper piston, or pistons, into the caliper bore, or bores:
The movement of a caliper piston into a caliper bore should be smooth and even. If a caliper piston is
frozen or difficult to bottom, the caliper requires overhaul or replacement.
For single piston caliper applications, insert a discarded inner brake pad (2) or block of wood in
front of the piston. Using a large C-clamp (1) installed over the body of the caliper (3) and against
the brake pad or block of wood, slowly bottom the piston in the bore.
For dual piston caliper applications, insert a discarded inner brake pad (2) or block of wood in front
of the pistons. Using 2 large C-clamps (1) installed over the body of the caliper (3) and against the
brake pad or block of wood, slowly bottom the pistons evenly into the bores.
DISC BRAKE MOUNTING AND HARDWARE INSPECTION - FRONT

Fig. 10: Disc Brake Pad Mounting Hardware
Bent mounting tabs.
Fig. 11: Inspecting Caliper Slide Pins

4. Inspect the caliper slide pins (3) by gently pulling outward, without disengaging the slides from the boots,
then pushing inward, and observe for the following:
Binding
Seizing
Looseness
Bent or damaged slide pins
Cracked or torn slide pin boots (2)
Missing slide pin boots
Bent or damaged caliper mounting bracket
DISC BRAKE MOUNTING AND HARDWARE INSPECTION - REAR

Fig. 12: Disc Brake Pad Mounting Hardware
Missing mounting hardware
Excessive corrosion
Bent mounting tabs
Looseness at the caliper mounting bracket
Looseness at the disc brake pads
Fig. 13: View Of Caliper, Pin, Boots & Caliper Mounting Bracket
4. Inspect the caliper bolts (1) for the following:

Binding
Seizing
Looseness in the caliper mounting bracket (3)
Bent or damaged caliper bolts
Cracked or torn boots (4)
Missing boots
Bent or damaged caliper mounting bracket (3)
REPAIR INSTRUCTIONS
BRAKE PADS REPLACEMENT - FRONT
Removal Procedure

4. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation .
5. Install two wheel nuts in order to secure the rotor.
Fig. 14: Compressing Piston Into Caliper Bore
6. Install a C-clamp (2) over the top of the brake caliper and against the back of the outboard brake pad.
7. Tighten the C-clamp (2) until the brake caliper piston pushes into the brake caliper bore enough to slide
the brake caliper (1) off of the rotor.
Fig. 15: Identifying Lower Brake Caliper Bolt
9. Remove the lower brake caliper bolt.

Fig. 16: View Of Brake Pads & Caliper Bracket - Rear
10. Rotate the brake caliper upward in order to access the brake pads.
Fig. 17: Compressing Caliper Piston
IMPORTANT: Insert a block of wood or the old brake pad brake between the C-clamp (1)
and the brake caliper piston in order to prevent damage to the brake
caliper piston and the brake caliper piston boot.
13. Install a C-clamp over the brake caliper and against the block of wood or the old brake pad (2).
Fig. 18: Caliper Mounting Bolt, Bracket, Boot & Slid Pins
16. Inspect the brake caliper bolt boots (4) for the following conditions:
Cuts
Tears
Deterioration
Replace the brake caliper bolt boots if damage exists. Refer to Brake Caliper Bracket
Replacement - Front.
Fig. 19: Inspecting Brake Caliper Piston Dust Boot
17. Inspect the brake caliper piston dust boot (1) for the following conditions:
Cuts
Tears
Leaking
Deterioration
Replace the brake caliper piston dust boot if damage exists. Refer to Brake Caliper Overhaul -
Front.
18. Inspect the brake caliper bolts for corrosion or damage. If corrosion is found, use new parts, including
bushings, when installing the brake caliper. Do not attempt to polish away corrosion.
IMPORTANT: Use denatured alcohol to clean the outside surface of caliper boot before

2. Install the four brake pad retainers to the caliper bracket.

IMPORTANT: Ensure that the wear sensor is positioned at the leading edge (upward) of
the inner pad during forward wheel rotation.
3. Install the brake pads over the brake pad retainers and onto the caliper bracket.
4. Thoroughly clean and apply Threadlocker GM P/N 12345493 (Canadian P/N 10953488) or equivalent to
the threads of the brake caliper pin bolts.
NOTE: Use care to avoid damaging pin boot when rotating caliper.
5. Pivot the caliper down onto the pads.

Fig. 21: Identifying Lower Brake Caliper Bolt
6. Install the lower caliper bolt.
Tighten: Tighten the caliper bolt to 35 N.m (26 lb ft).
7. Remove the two wheel nuts securing the rotor to the hub and bearing.
8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation .
11. Fill the master cylinder to the proper level. Refer to Master Cylinder Reservoir Filling In Hydraulic
Brakes.
12. Burnish the pads and the rotors. Refer to Burnishing Pads and Rotors.
BRAKE PADS REPLACEMENT - REAR
Removal Procedure

3. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
4. Remove the tire and the wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
5. Hand tighten two wheel lug nuts in order to retain the rotor to the hub.
Fig. 22: Pushing In Brake Caliper Piston
6. Compress the rear caliper piston.

1. Install a large C-clamp (3) over the top of the caliper housing (2) and against the back of the
outboard pad.
2. Slowly tighten the C-clamp (3) until the piston pushes into the caliper bore enough to slide the
caliper (2) off the rotor.
3. Remove the C-clamp from the caliper.
Fig. 23: View Of Upper Caliper Bolt - Rear
7. Remove the upper caliper bolt (2).

Fig. 24: Exploded View Of Rear Brake Caliper Components
8. In order to access the pads, rotate the caliper downward.

9. Remove the pads (9,10) from the caliper bracket (12).
10. Remove the two retainer slides (11) from the caliper bracket (12).
11. Inspect the following parts for cuts, tears, or deterioration. Replace any damaged parts:
The disc brake mounting and hardware - Refer to Disc Brake Mounting and Hardware
Inspection - Rear.
The caliper dust boot - Refer to Brake Caliper Inspection.
12. Inspect the caliper bolts (1) for corrosion or damage. If corrosion is found, use new caliper bolts when
installing the caliper.
1. Using a C-clamp, bottom the piston into the caliper bore. Use an old brake pad or wooden block across
the face of the piston. Do not damage the piston or the caliper boot.

2. Install the two retainer slides (11) to the caliper bracket.
IMPORTANT: The wear sensor is on the outside pad. The sensor is positioned at the
trailing or downward edge of the pad during forward wheel rotation.
3. Install the pads (9,10) to the caliper bracket (12).
4. Remove the support and reposition the caliper (15) back down over the front pads.
5. Lubricate the bolt and the bolt boot.
6. Install the upper caliper bolt.
Tighten: Tighten the caliper bolt to 45 N.m (33 lb ft).
7. Remove the two wheel lug nuts retaining the rotor to the hub.
8. Install the tire and the wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
10. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
11. Slowly release the brake pedal.
12. Wait 15 seconds, then repeat steps 10 and 11 until a firm brake pedal is obtained. This will properly seat
the brake caliper pistons and brake pads.
13. Fill the brake master cylinder reservoir to the proper level. Refer to Master Cylinder Reservoir Filling
in Hydraulic Brakes.
14. Burnish the pads and rotors. Refer to Burnishing Pads and Rotors.
BURNISHING PADS AND ROTORS
CAUTION: Road test a vehicle under safe conditions and while obeying all traffic
Burnishing the brake pads and brake rotors is necessary in order to ensure that the braking surfaces are properly
prepared after service has been performed on the disc brake system.
This procedure should be performed whenever the disc brake rotors have been refinished or replaced, and/or
whenever the disc brake pads have been replaced.
1. Select a smooth road with little or no traffic.

IMPORTANT: Use care to avoid overheating the brakes while performing this step.
3. Using moderate to firm pressure, apply the brakes to bring the vehicle to a stop. Do not allow the brakes
to lock.
4. Repeat steps 2 and 3 until approximately 20 stops have been completed. Allow sufficient cooling periods
between stops in order to properly burnish the brake pads and rotors.
BRAKE CALIPER REPLACEMENT - FRONT
Removal Procedure

4. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
5. Install two wheel lug nuts to retain the rotor to the hub.
Fig. 26: Compressing Piston Into Caliper Bore
6. Install a large C-clamp (2) over the top of the brake caliper and against the back of the outboard brake
pad.
the rotor.
Fig. 27: Identifying Brake Hose & Components
8. Remove the brake hose bolt (1).

9. Remove the brake hose (2) from the brake caliper.
10. Remove and discard the two copper brake hose gaskets (3). These gaskets may be stuck to the brake
caliper and/or the brake hose end.
contamination.
Fig. 28: Locating Brake Caliper Bolts
13. Remove the brake caliper bolts (3).

15. Inspect the brake caliper pin boots (4) for the following components:
Cuts
Tears
Deterioration
Replace the bolt boots if damage exists. Refer to Brake Caliper Bracket Replacement - Front.
16. If the caliper pin boots are damaged, inspect the caliper pins for corrosion or damage. If corrosion is
found on the brake caliper pin shaft, replace the brake caliper pin and the brake caliper pin boot. Do not
attempt to polish away the corrosion.
Fig. 30: Ensuring Caliper Bolt Boots Proper Installation
1. Ensure that the caliper bolt boots (3) are properly installed.
Fig. 31: Locating Brake Caliper Bolts
2. Install the caliper (1) to the caliper bracket (2).
3. Install the brake caliper bolts.

IMPORTANT: Install NEW copper brake hose gaskets (3).
5. Assemble the brake hose bolt (1) and the NEW copper brake hose gaskets (3) to the brake hose (2).
6. Install the brake hose bolt to the brake caliper.

8. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
10. Fill the master cylinder to the proper level. Refer to Master Cylinder Reservoir Filling in Hydraulic
Brakes.
11. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake
System Bleeding (Pressure) in Hydraulic Brakes.
12. Apply approximately 778 N.m (175 lb ft) of force to the brake pedal for ten seconds.
BRAKE CALIPER REPLACEMENT - REAR
Removal Procedure

5. Install two nuts to retain the rotor to the hub.
Fig. 33: Pushing In Brake Caliper Piston
6. Install a large C-clamp (3) over the top of the brake caliper and against the back of the outboard brake
pad.
the rotor.
8. Remove the brake hose bolt (1).

9. Remove the brake hose (2) from the brake caliper.
contamination.
13. Remove the brake caliper bolts (1,3).

14. Remove the brake caliper (15) from the brake caliper bracket (12).
15. Inspect the caliper bracket bolt boot on the caliper bracket for the following conditions:
Cuts
Tears
Deterioration
Replace any damaged caliper bracket bolt boots. Refer to Disc Brake Hardware Replacement -
Rear.
Fig. 36: Identifying Caliper Bolt Components
1. Ensure that the caliper bolt bushings (4) and the caliper bolt boots (3) are properly installed.
Fig. 37: View Of Brake Caliper Bracket
2. Install the brake caliper (1) to the brake caliper bracket (2).
Fig. 38: View Of Caliper, Pin, Boots & Caliper Mounting Bracket
3. lubricate the brake caliper bolt shaft. Do not lubricate the threads.
4. lubricate the brake caliper bolt boots (4) in the brake caliper bracket (3).
5. Install the brake caliper bolts.
Tighten: Tighten the brake caliper bolts to 45 N.m (33 lb ft).
6. Use a flat-bladed tool in order to install the brake caliper bracket boot over the shoulder of the brake
caliper bolt.

9. Install the brake hose bolt to the brake caliper. Refer to Brake Hose Replacement - Rear (Disc Brake)
or Brake Hose Replacement - Rear (Drum Brake) in Hydraulic Brakes.
Brakes.
System Bleeding (Pressure) in Hydraulic Brakes.
15. Apply approximately 778 N.m (175 lb ft) of force to the brake pedal for ten seconds.
BRAKE CALIPER OVERHAUL - FRONT
Tools Required
J 36349 Dust Boot Seal Installer
IMPORTANT: Replace all the components included in the repair kit.

Lubricate all of the rubber parts with clean brake fluid in order to ease
assembly.
Perform this overhaul procedure on a clean bench.
Disassembly Procedure

3. Remove the brake caliper. Refer to Brake Caliper Replacement - Front.
Fig. 40: Blowing Air Into Brake Caliper Hose Hole
CAUTION: Do not place fingers in front of the caliper piston(s) in an attempt to

NOTE: Use clean cloths to pad interior of caliper housing during piston removal.
Use just enough air to ease the pistons out of the bores. If the pistons are
blown out, even with the padding provided, it may be damaged.
4. Blow compressed air into the brake caliper (1) hose hole in order to remove the brake caliper piston. The
piston will come out through the piston boot.
IMPORTANT: Do not use abrasives to clean the brake caliper piston.
5. Inspect and replace the brake caliper piston if any of the following conditions are found:
Scoring
Nicks
Corrosion
Worn or damaged chrome plating
Fig. 41: Inspecting Brake Caliper Bore

NOTE: Do not use a metal tool for seal removal. Damage to the caliper bore or the
seal grooves can result.
6. Remove the piston seal (4) from the groove in the caliper bore (3). Use a small wooden or plastic tool.
7. Inspect the caliper bore (3) and the seal grooves for the following conditions:
Scoring
Nicks
Corrosion
Wear
8. Use a piece of crocus cloth in order to polish out light corrosion.

9. Replace the caliper (3) if corrosion in and around the seal groove cannot be cleaned with a piece of crocus
cloth.
10. Inspect and replace any brake caliper bolt boots (4) that exhibit any of the following conditions:
Cuts
Tears
Deterioration
replace the brake caliper bolt (1) and the brake caliper bolt boot (4). Do not attempt to polish away the
corrosion.
12. Inspect the seal groove in the caliper bore for nicks or burrs. Replace the caliper if the seal groove is
damaged.

13. Remove the bleeder valve cap (1) and the bleeder valve (2) from the brake caliper housing (3).
14. Clean all the parts with clean, denatured alcohol.
15. Dry all the parts with filtered, non-lubricated compressed air.
16. Use filtered, non-lubricated compressed air in order to blow out all of the passages in the caliper housing
and the bleeder valve.
Assembly Procedure
1. Install the bleeder valve and the bleeder valve cap to the caliper housing.
2. Install a new lubricated piston seal (4) to the caliper bore grooves. Ensure that the piston seal is not
twisted.
Fig. 45: Inspecting Brake Caliper Piston Dust Boot
3. Install the lubricated boot (1) onto the brake caliper piston (2).
4. Lubricate the brake caliper piston (2) with clean brake fluid.
5. Install the brake caliper piston and the brake caliper piston boot into the bore of the caliper. Push the
brake caliper piston to the bottom of the bore.
Fig. 46: Identifying J 36349
6. Seat the caliper boot in the caliper housing counterbore using the J 36349 .
7. Install the caliper. Refer to Brake Caliper Replacement - Front.
BRAKE CALIPER OVERHAUL - REAR

Removal Procedure
1. Remove the rear brake caliper from the vehicle. Refer to Brake Caliper Replacement - Rear.
CAUTION: Do not place fingers in front of the caliper piston(s) in an attempt to

NOTE: Use clean cloths to pad interior of caliper housing during piston removal.
Use just enough air to ease the pistons out of the bores. If the pistons are
blown out, even with the padding provided, it may be damaged.
2. Remove the brake caliper piston from the caliper bore by directing low pressure compressed air into the
caliper bore through the fluid inlet hole.
Fig. 47: View Of Dust Boot Retaining Ring
3. Remove the retaining ring that secures the dust boot to the caliper housing.
4. Remove the piston dust boot seal (2) from the seal counterbore in the caliper. Discard the boot seal.
5. Using a small wooden or plastic tool, remove the piston seal (4) from the caliper bore. Discard the piston
seal.
IMPORTANT: Do not use abrasives to clean the brake caliper piston.
6. Clean the brake caliper piston bore and seal counterbore, and the caliper piston with denatured alcohol, or
equivalent.
7. Dry the caliper piston bore and counterbore, and the piston with non-lubricated, filtered air.
8. Inspect the caliper bore for cracks, scoring, pitting, excessive rust, and/or excessive corrosion.
9. If light rust or light corrosion are present in the caliper bore, attempt to remove the imperfection with a
fine emery paper. If the imperfection cannot be removed, replace the caliper assembly.
10 If cracks scoring pitting excessive rust and/or excessive corrosion are present in the caliper bore
replace the caliper assembly.
11. Inspect the caliper piston for cracks, scoring, and/or damage to the chrome plating. Replace the caliper
piston if any of these conditions exist.

1. Lubricate the new piston seal (4) with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667),
or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
2. Install the lubricated, new piston seal (4) into the caliper bore.
3. Apply a thin coat of Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent
DOT-3 brake fluid from a clean, sealed brake fluid container onto the outer surface area of the caliper
piston (3).
Fig. 50: Identifying Caliper Piston & Piston Dust Boot Seal
4. Install the bottom half of the caliper piston (2) into the caliper bore.
5. Install the new piston dust boot seal (1) over the caliper piston (2).
6. Compress the caliper piston (2) to the bottom of the caliper bore.
7. Fully seat the piston dust boot seal (1) into caliper counterbore.
Fig. 51: View Of Dust Boot Retaining Ring
8. Install the retaining ring that secures the dust boot to the caliper housing.
9. Install the bleeder valve and cap to the caliper and tighten the valve securely.
10. Install the rear brake caliper to the vehicle. Refer to Brake Caliper Replacement - Rear.
DISC BRAKE HARDWARE REPLACEMENT - FRONT
Removal Procedure

4. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation .

whenever it is separated from its mount and the hydraulic flexible brake
hose is still connected. Failure to support the caliper in this manner will
cause the flexible brake hose to bear the weight of the caliper, which may
cause damage to the brake hose and in turn may cause a brake fluid leak.
6. Remove the disc brake caliper bolts.
10. Remove the caliper pins (5) from the disc brake caliper mounting bracket (3).
11. Remove the caliper pin boots (4) from the disc brake caliper mounting bracket.
12. Lightly wire brush all brake pad contact areas in order to remove any corrosion.
1. Lubricate the inner diameter of the caliper pin boot (4) and install to the caliper mounting bracket (3).
2. Lubricate the outer diameter of the caliper pins (5) and install to the caliper mounting bracket (3).
3. Install the disc brake pad retainers to the disc brake caliper bracket.
6. Install the disc brake caliper bolts.
Tighten: Tighten the disc brake caliper bolts to 35 N.m (26 lb ft).
pedal.
Brakes.
DISC BRAKE HARDWARE REPLACEMENT - REAR
Removal Procedure
Fig. 56: View Of Brake Caliper And Caliper Bracket


1. Remove the brake caliper from the mounting bracket and support the brake caliper (2) with heavy
mechanic's wire (1), or equivalent. It is not necessary to disconnect the hydraulic brake flexible hose from
the caliper. Refer to Brake Caliper Replacement - Rear.
Fig. 57: View Of Brake Pads, Brake Pad Retainers, & Caliper Bracket
2. Remove the brake pads (2) from the brake caliper bracket (1).
3. Remove the brake pad retainers (1) from the brake caliper bracket (3).
4. Remove the brake caliper bracket (3). Refer to Brake Caliper Bracket Replacement - Rear.
5. Mount the brake caliper bracket (3) in a vise.
1. Clean all parts in clean, denatured alcohol.

2. Dry with low pressure, non-lubricated, filtered air.
3. Inspect the brake caliper bracket for cracks. If cracked, replace bracket.
4. Lubricate the brake caliper pin bolt sleeves with high temperature silicone lubricant.
5. Install the brake caliper bracket. Refer to Brake Caliper Bracket Replacement - Rear.
Fig. 58: View Of Brake Pads, Brake Pad Retainers, & Caliper Bracket
6. Install the brake pad retainers (1) to the bracket caliper bracket (3).
7. Install the brake pads (2) to the bracket caliper bracket (3).
8. Install the brake caliper to the brake caliper bracket. Refer to Brake Caliper Replacement - Rear.
BRAKE CALIPER BRACKET REPLACEMENT - FRONT
Removal Procedure

1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire, or
equivalent. It is not necessary to disconnect the hydraulic brake flexible hose from the caliper. Refer to
Brake Caliper Replacement - Front.
2. Remove the front brake pads.
Fig. 59: Removing/Installing Brake Caliper Bracket & Bolts
3. Remove the caliper bracket bolts (2).

4. Remove the caliper bracket (1).
Fig. 60: Removing/Installing Brake Caliper Bracket & Bolts
IMPORTANT: To ensure that the proper clamp load will be present when installed. It is
imperative that the threads on the caliper bracket bolts, as well as the
mounting holes in the knuckle, be cleaned of all debris and inspected
before proceeding with installation.
1. Clean and visually inspect the threads of the caliper bracket bolts (2) and mounting holes in the knuckle.
2. Apply threadlocker, GM P/N 12345493 (Canadian P/N 10953488), or equivalent, to the threads of the
brake caliper bracket bolts (2).
3. Install the caliper bracket (1) with the bracket bolts (2).
Tighten: Tighten the caliper bracket bolts to 185 N.m (137 lb ft).
4. Install the front brake pads.

5. Install the caliper. Refer to Brake Caliper Replacement - Front.
BRAKE CALIPER BRACKET REPLACEMENT - REAR
Removal Procedure
1. Remove the caliper from the mounting bracket and support the caliper with heavy mechanic's wire, or
equivalent. It is not necessary to disconnect the hydraulic brake flexible hose from the caliper. Refer to
Brake Caliper Replacement - Rear.
2. Remove the rear brake pads.
Fig. 61: View Of Caliper Bracket Bolts
3. Remove the caliper bracket bolts (2).

4. Remove the caliper bracket (1).
Fig. 62: View Of Caliper Bracket Bolts
IMPORTANT: To ensure that the proper clamp load will be present when installed. It is
imperative that the threads on the caliper bracket bolts, as well as the
mounting holes in the knuckle, be cleaned of all debris and inspected
before proceeding with installation.
1. Clean and visually inspect the threads of the caliper bracket bolts (2) and mounting holes in the knuckle.
2. Apply threadlocker, GM P/N 12345493 (Canadian P/N 10953488), or equivalent, to the threads of the
brake caliper bracket bolts (2).
3. Install the caliper bracket (1) with the bracket bolts (2).
Tighten: Tighten the caliper bracket bolts to 130 N.m (96 lb ft).
4. Install the rear brake pads.

5. Install the caliper. Refer to Brake Caliper Replacement - Rear.
BRAKE ROTOR REPLACEMENT - FRONT
Tools Required
J 41013 Rotor/Drum Flange Resurfacing Kit. See Special Tools.

J 42450-A Wheel Hub/Flange Resurfacing Kit. See Special Tools.
Removal Procedure
NOTE: Any new rotor must have the protective coating removed from the friction
surfaces before being placed in service. Remove the protective coating
using denatured alcohol or an equivalent, and wipe the surface clean with
clean cloths. Do not use gasoline, kerosene, or other oil base solvents
which may leave an oily residue. This residue is damaging to the brake
lining and is flammable.
Fig. 63: View Of Brake Rotor - Front
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
3. Remove and support the caliper and bracket as an assembly with heavy mechanics wire. DO NOT
disconnect the hydraulic flexible brake hose. Refer to Brake Caliper Bracket Replacement - Front.
IMPORTANT: When a brake rotor has been separated from a hub/axle flange, the mating
surface of the brake rotor must be cleaned of any rust or contaminants.
Failure to do this may result in lateral runout of the brake rotor, and brake
pulsation.
5. If the brake rotor is to be reinstalled to the vehicle, use theJ 41013 in order to clean any rust or corrosion
from the hub/axle flange mating surface of the brake rotor. See Special Tools.
6. Use the J 42450-A in order to clean the wheel hub flange. See Special Tools.
Fig. 64: View Of Brake Rotor - Front

2. Install the caliper bracket. Refer to Brake Caliper Bracket Replacement - Front.
3. Install the tire and the wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
BRAKE ROTOR REPLACEMENT - REAR
Tools Required
J 41013 Rotor/Drum Flange Resurfacing Kit. See Special Tools.

J 42450-A Wheel Hub/Flange Resurfacing Kit. See Special Tools.
Removal Procedure
NOTE: Any new rotor must have the protective coating removed from the friction
surfaces before being placed in service. Remove the protective coating
using denatured alcohol or an equivalent, and wipe the surface clean with
clean cloths. Do not use gasoline, kerosene, or other oil base solvents
which may leave an oily residue. This residue is damaging to the brake
lining and is flammable.
Fig. 65: View Of Brake Rotor - Rear
Wheels.
3. Remove and support the caliper and bracket as an assembly with heavy mechanics wire. DO NOT
disconnect the hydraulic flexible brake hose. Refer to Brake Caliper Replacement - Rear.
IMPORTANT: When a brake rotor has been separated from a hub/axle flange, the mating
surface of the brake rotor must be cleaned of any rust or contaminants.
Failure to do this may result in lateral runout of the brake rotor, and brake
pulsation.
5. If the brake rotor is to be reinstalled to the vehicle, use theJ 41013 in order to clean any rust or corrosion
from the hub/axle flange mating surface of the brake rotor. See Special Tools.
6. Use the J 42450-A in order to clean the wheel hub flange. See Special Tools.
Fig. 66: View Of Brake Rotor - Rear

2. Install the caliper bracket. Refer to Brake Caliper Replacement - Rear.
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) CORRECTION
IMPORTANT: Brake rotor thickness variation MUST be checked BEFORE checking for
assembled lateral runout (LRO). Thickness variation exceeding the
maximum acceptable level can cause brake pulsation. Refer to Brake
Rotor Thickness Variation Measurement.
Brake rotor assembled lateral runout (LRO) exceeding the maximum
Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement.
Review the following acceptable methods for bringing the brake rotor assembled LRO to within specifications.
Determine which method to use for the specific vehicle being repaired.
The indexing method of correcting assembled LRO is most effective when the LRO specification is only
exceeded by a relatively small amount: 0.025-0.127 mm (0.001-0.005 in). Indexing is used to achieve the
best possible match of high spots to low spots between related components. Refer to Brake Rotor
Assembled Lateral Runout (LRO) Correction - Indexing.
The correction plate method of correcting assembled LRO involves the addition of a tapered plate
between the brake rotor and the hub/axle flange. The correction plate method can be used to correct LRO
that exceeds the specification by up to 0.23 mm (0.009 in). Refer to Brake Rotor Assembled Lateral
Runout (LRO) Correction - Correction Plates.
The on-vehicle brake lathe method is used to bring the LRO to within specifications through
compensating for LRO while refinishing the brake rotor. Refer to Brake Rotor Assembled Lateral
Runout (LRO) Correction - On-Vehicle Lathe.
If the assembled LRO cannot be corrected using these methods, then other components must be suspected as
causing and/or contributing to the LRO concern.
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) CORRECTION - INDEXING
Tools Required


1. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO measurement
procedure. See Special Tools.
3. Index the brake rotor in a different orientation to the hub/axle flange.
4. Hold the rotor firmly in place against the hub/axle flange and install one of theJ 45101-100 (1) and one
6. Install the remainingJ 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly by hand in
a star-pattern. See Special Tools.
Tires and Wheels.
8. Measure the assembled LRO of the brake rotor. Refer to Brake Rotor Assembled Lateral Runout
(LRO) Measurement.
9. Compare the amount of change between this measurement and the original measurement.
10. If this measurement is within specifications, proceed to step 14.
11. If this measurement still exceeds specifications, repeat steps 1-9 until the best assembled LRO
measurement is obtained.
12. Matchmark the final location of the rotor to the wheel studs if the orientation is different than it was
originally.
13. If the brake rotor assembled LRO measurement still exceeds the maximum allowable specification, refer
to Brake Rotor Assembled Lateral Runout (LRO) Correction.
pedal several times to secure the rotor in place before removing the J 45101-100 and the lug nuts. See
Special Tools.
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) CORRECTION - CORRECTION

PLATES
Tools Required

Fig. 69: Identifying Correction Plate, High Spot Mark & V-Shaped Notch
1. Rotate the brake rotor to position the high spot, identified and marked during the brake rotor assembled
LRO measurement procedure, to face upward.
2. Remove theJ 45101-100 and the lug nuts that were installed during the assembled LRO measurement
procedure and/or the indexing correction procedure. See Special Tools.
4. Select the correction plate, following the manufacturer's instructions, which has a specification closest to
the assembled LRO measurement.
For example: If the assembled LRO measurement was 0.076 mm (0.003 in), the 0.076 mm (0.003 in)
correction plate would be used. If the measurement was 0.127 mm (0.005 in), the 0.152 mm (0.006 in)
correction plate would be used.
5. Determine the positioning for the correction plate (1) using the high spot mark (3) made during the brake
rotor assembled LRO measurement procedure.
IMPORTANT: Do NOT install used correction plates in an attempt to correct brake

rotor assembled lateral runout (LRO).
Do NOT stack up, or install more than one correction plate onto one
hub/axle flange location, in an attempt to correct brake rotor
assembled LRO.
6. Install the correction plate (1) onto the hub/axle flange, with the V-shaped notch (2) orientated to align
with the high spot mark (3), that was positioned to face upward.
7. Install the brake rotor to the hub/axle flange. Use the matchmark made prior to removal for proper
orientation to the flange.
8. Hold the rotor firmly in place against the hub/axle flange and install one of theJ 45101-100 (1) and one
10. Install the remaining J 45101-100 and lug nuts onto the wheel studs and tighten the nuts firmly by hand
in a star-pattern. See Special Tools.
Tires and Wheels.
(LRO) Measurement.
depress the brake pedal several times to secure the rotor in place before removing the J 45101-100 and
the lug nuts. See Special Tools.
BRAKE ROTOR ASSEMBLED LATERAL RUNOUT (LRO) CORRECTION - ON-VEHICLE LATHE
Tools Required
1. Ensure that the caliper and caliper bracket that are already being supported, are clear from contacting any
rotating components, such as the brake rotor.
2. Remove the J 45101-100 and the lug nuts that were installed during the assembled LRO measurement
procedure and/or the indexing correction procedure. See Special Tools.
4. Set up the lathe, following the manufacturer's instructions.
5. Refinish the brake rotor, following the brake lathe manufacturer's instructions.
6. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness
Measurement.
brake rotor must be replaced. After replacing the rotor, proceed to step 10.
directional finish:
1. Follow the brake lathe manufacturer's recommended speed setting for applying a non-directional
finish
2. Using moderate pressure, apply the non-directional finish:
aluminum oxide sandpaper
sanding block and 150 grit aluminum oxide sandpaper
3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured
alcohol, or an equivalent approved brake cleaner
9. Remove the lathe from the vehicle.
(LRO) Measurement.
pedal several times to secure the rotor in place before removing the J 45101-100 and the lug nuts. See
Special Tools.
BRAKE ROTOR REFINISHING
Tools Required
J 41013 Rotor Resurfacing Kit. See Special Tools.

J 42450-A Wheel Hub Resurfacing Kit. See Special Tools.
IMPORTANT: The disc brake rotors do not require refinishing as part of routine brake
system service. New disc brake rotors do not require refinishing.
Do not refinish disc brake rotors in an attempt to correct the following

conditions:
Brake system noise - squeal, growl, groan

Uneven and/or premature disc brake pad wear
Superficial or cosmetic corrosion/rust of the disc brake rotor friction

surface
Scoring of the disc brake rotor friction surface less than the
maximum allowable specification
Before refinishing a brake rotor, the rotor MUST first be checked for
adequate thickness to allow the rotor to be refinished and remain above
the minimum allowable thickness after refinish specification. Refer to
Brake Rotor Thickness Measurement.
Disc brake rotors should only be refinished if they have adequate

thickness to be refinished and if one or more of the following conditions
exist:
Thickness variation in excess of the maximum allowable

specification
Excessive corrosion/rust and/or pitting
Scoring of the disc brake rotor surface in excess of the maximum

allowable specification
Disc brake rotors may need to be refinished as part of the process for
correcting brake rotor assembled lateral runout (LRO) that exceeds the
maximum allowable specification.
IMPORTANT: Whenever the brake rotor has been separated from the hub/axle flange,
clean any rust or contaminants from the hub/axle flange and the brake
rotor mating surfaces. Failure to do this may result in increased
assembled lateral runout (LRO) of the brake rotor, which could lead to
brake pulsation.
1. Using the J 42450-A , thoroughly clean any rust or corrosion from the mating surface of the hub/axle
flange. See Special Tools.
2. Using the J 41013 , thoroughly clean any rust or corrosion from the mating surface and mounting surface
of the brake rotor. See Special Tools.
3. Inspect the mating surfaces of the hub/axle flange and the rotor to ensure that there are no foreign
4. Mount the brake rotor to the brake lathe according to the lathe manufacturer's instructions, ensuring that
all mounting attachments and adapters are clean and free of debris.
6. With the brake lathe running, slowly bring in the cutting tools until they just contact the brake rotor
friction surfaces.
7. Observe the witness mark on the brake rotor. If the witness mark extends approximately three-quarters or
more of the way around the brake rotor friction surface on each side, the brake rotor is properly mounted
to the lathe.
8. If the witness mark does not extend three-quarters or more of the way around the brake rotor, re-mount
the rotor to the lathe.
9. Following the brake lathe manufacturer's instructions, refinish the brake rotor.
10. After each successive cut, inspect the brake rotor thickness. Refer to Brake Rotor Thickness
Measurement.
brake rotor must be replaced.
directional finish:
finish
aluminum oxide sandpaper
sanding block and 150 grit aluminum oxide sandpaper
3. After applying a non-directional finish, clean each friction surface of the brake rotor with denatured
alcohol, or an equivalent approved brake cleaner
13. Remove the brake rotor from the brake lathe.
14. Measure the assembled lateral runout (LRO) of the brake rotor to ensure optimum performance of the
disc brakes. Refer to Brake Rotor Assembled Lateral Runout (LRO) Measurement.
15. If the brake rotor assembled LRO measurement exceeds the specification, bring the LRO to within
specifications. Refer to Brake Rotor Assembled Lateral Runout (LRO) Correction.

DISC BRAKE SYSTEM DESCRIPTION AND OPERATION
System Component Description
The disc brake system consists of the following components:
Disc Brake Pads
Applies mechanical output force from the hydraulic brake calipers to friction surfaces of brake rotors.
Disc Brake Rotors
Uses mechanical output force applied to friction surfaces from the disc brake pads to slow speed of tire
and wheel assembly rotation.
Disc Brake Pad Hardware
Secures disc brake pads firmly in proper relationship to the hydraulic brake calipers. Enables a sliding
motion of brake pads when mechanical output force is applied.
Disc Brake Caliper Hardware
Provides mounting for hydraulic brake caliper and secures the caliper firmly in proper relationship to
caliper bracket. Enables a sliding motion of the brake caliper to the brake pads when mechanical output
force is applied.
System Operation
Mechanical output force is applied from the hydraulic brake caliper pistons to the inner brake pads. As the
pistons press the inner brake pads outward, the caliper housings draw the outer brake pads inward. This allows
the output force to be equally distributed. The brake pads apply the output force to the friction surfaces on both
sides of the brake rotors, which slows the rotation of the tire and wheel assemblies. The correct function of both
the brake pad and brake caliper hardware is essential for even distribution of braking force.

SPECIAL TOOLS
Special Tools
J 36349
Dust Boot Seal Installer
J 39544-KIT
Torque Limiting Socket Set
J 41013
Rotor Resurfacing Kit
J 42450-A
Wheel Hub Resurfacing Kit
J 45101
Hub and Wheel Runout Gage
J 45101-100
Conical Brake Rotor Washers
Doors - Aztek & Rendezvous
SPECIFICATIONS

Specification
Bodyside Front Door Hinge 25 N.m 18 lb ft
Bodyside Rear Door Hinge Bolt 35 N.m 25 lb ft
Doorside Front Door Hinge 25 N.m 18 lb ft
Doorside Rear Door Hinge Bolt 35 N.m 25 lb ft
Front Door Hinge Bolt 30 N.m 22 lb ft
Front Door Latch Screw 10 N.m 89 lb in
Front Door Lock Striker Screw 24 N.m 18 lb ft
Front Door Window Channel Screw 10 N.m 89 lb in
Front Door Window Front and Rear Clevice Clamp Bolt 11 N.m 97 lb in
Front Window Regulator Motor and Rail Bolt 11 N.m 97 lb in
Lower Door Hinge Side Bolt 35 N.m 25 lb ft
Outer Belt Sealing Strip Screw 2 N.m 18 lb in
Outside Rearview Mirror Nut 10 N.m 89 lb in
Rear Door Hinge Bolt 30 N.m 22 lb ft
Rear Door Latch Screw 10 N.m 89 lb in
Rear Door Lock Striker Screw 24 N.m 18 lb ft
Rear Door Outer Belt Sealing Strip Screw 2 N.m 18 lb in
Rear Door Window Rear and Rear Clevice Clamp Bolt 11 N.m 97 lb in
Rear Window Channel Screw 10 N.m 89 lb in
Rear Window Regulator Motor and Rail Bolt 10 N.m 89 lb in
Striker Screw 24 N.m 18 lb ft
Upper Door Hinge Keeper Strap Bolt 10 N.m 89 lb in

POWER WINDOWS SCHEMATICS
Fig. 1: Power Windows
DOOR LOCK/INDICATOR SCHEMATICS

Fig. 2: Door Lock Switches
Fig. 3: Door Lock Actuators
Fig. 4: Door Ajar Indicator
OUTSIDE MIRROR SCHEMATICS

Fig. 5: Base Mirrors
Fig. 6: Heated Mirrors
Fig. 7: Memory Mirrors - Power, Ground and Switches
Fig. 8: Memory Mirrors - Mirror Controls
COMPONENT LOCATOR
POWER DOOR SYSTEMS COMPONENT VIEWS
Fig. 9: Door Component View - Driver
Callouts For Fig. 9

1 Door Latch - Driver
2 Door Latch - C1 (Ajar Switch) - Driver
3 Door Lock Switch - Driver and Window Master Switch
4 Outside Rear View Mirror - Driver (Passenger Similar)
5 Window Motor - Driver
6 C301
7 Outside Rearview Mirror Switch
Fig. 10: Door Component View - Front Passenger

1 Door Lock and Window Switch - Front Passenger
2 Door Latch - Front Passenger
3 C302
4 Window Motor - Front Passenger
Fig. 11: Door Component View - LR

1 Door Latch - LR
2 Window Motor - LR
3 C351
4 Window Switch - LR
Fig. 12: Door Component View - RR

1 Window Motor - RR
2 Door Latch - RR
3 Window Switch - RR
4 C352
Fig. 13: Endgate Component View - Pontiac

1 C403
2 Endgate Harness
3 Endgate Latch - Right C1
4 Endgate Latch- Right C2
5 Lift Window Release Actuator - Right C1
6 Lift Window Release Actuator - Right C2
7 Lock Cylinder Switch - Endgate
8 Lift Window Release Actuator - Left C2
9 Lift Window Release Actuator - Left C1
10 Endgate Latch - Left C2
11 Endgate Latch - Left C1
POWER DOOR SYSTEMS CONNECTOR END VIEWS

Door Latch - C1 - Driver
12162190
4-Way F Metri-Pack 150.2 Series Sealed P2S (BK)

A - - Not Used
B D-BU/WH 727 Door Ajar Switch Signal
C D-BU 49 Driver Door Open Switch Signal
D BK 550 Ground
Door Latch - C1 - Front Passenger
12162190

A BK 750 Ground
B OG 54 Front Passenger Door Open Switch Signal
C D-BU/WH 727 Door Ajar Switch Signal
D - - Not Used
Door Latch - C1 - LR
12162190

A - - Not Used
B D-BU/WH 727 Door Ajar Switch Signal
C PK 775 Rear Passenger Door Open Switch Signal
D BK 550 Ground
Door Latch - C1 - RR
12162190

A BK 750 Ground
B PK 775 Rear Passenger Door Open Switch Signal
C D-BU/WH 727 Door Ajar Switch Signal
D - - Not Used
15300027
2-Way F Metri-Pack 280 Series Sealed (BK)

A TN 694 Driver Door Lock Motor Unlock
B GY 295 Door Lock Motor Lock
Door Latch - C2 - LR
15300027

A TN 294 Door Lock Motor Unlock
Door Latch - C2 - Front Passenger
15300027

Door Latch - C2 - RR
15300027

12052642
2-Way F Metri-Pack 150 Series Sealed (L-GN)

A BK 550 Ground
B PU 1124 Door Lock Key Switch Unlock Signal
Door Lock Switch - Driver
12064998

BK 550 Ground (Pontiac)
A Driver Door Lock Switch Lock Signal
RD/BK 780
(Buick)
B
- - Not Used (Buick)
Instrument Panel Lamp Supply Voltage
GY 8
C (Pontiac)
D - - Not Used
- - Not Used (Pontiac)
E
BK 550 Ground (Buick)
F
Driver Door Lock Switch Lock Signal
RD/BK 780
(Pontiac)
G
GY 8
(Buick)
H - - Not Used
Door Lock Switch - Front Passenger

12064998

A Driver Door Lock Switch Lock Signal
RD/BK 780
(Buick)
B
- - Not Used
GY 8
C (Pontiac)
D - - Not Used
E
F
Driver Door Lock Switch Lock Signal
RD/BK 780
(Pontiac)
G
GY 8
(Buick)
H - - Not Used
Outside Rearview Mirror - Driver (A43)

12064872
10-Way M Metri-Pack 150 Series (BU)

A L-GN 89 Driver Mirror Motor Down Control
B L-BU 82 Driver Mirror Motor Left Control
C WH 81 Driver Mirror Motor Right Control
Heated Mirror Element Supply Voltage
D OG 267
(DE5)
E BK 550 Ground (DE5)
Driver Mirror Horizontal Position Sensor
F GY 786
Signal
G BN 673 Low Reference
H D-GN 784 Driver Mirror Vertical Position Sensor Signal
J D-BU 672 5-Volt Reference
K - - Not Used
Outside Rearview Mirror - Driver (w/o A43)

12045688
8-Way M Metri-Pack 150 Series (BK)

A YE 88 Driver Mirror Motor Up Control
B L-GN 1499 Driver Mirror Motor Left/Down Control
C WH 81 Driver Mirror Motor Right Control
D OG 267
(UH9)
E BK 550 Ground (UH9)
F-H - - Not Used
Outside Rearview Mirror - Passenger (A43)

12064872
10-Way M Metri-Pack 150 Series (BU)
A PU/WH 889 Passenger Mirror Motor Down Control
B GY 90 Passenger Mirror Motor Left Control
C RD/WH 881 Passenger Mirror Motor Right Control
D OG 267 Heated Mirror Element Supply Voltage
E BK 750 Ground
Passenger Mirror Horizontal Position Sensor
F L-BU/WH 785
Signal
G L-GN 675 Low Reference
Passenger Mirror Vertical Position Sensor
H BN 787
Signal
J YE 674 5-Volt Reference
K - - Not Used
Outside Rearview Mirror - Passenger (w/o A43)
12045688
8-Way M Metri-Pack 150 Series (BK)

A BN/WH 1498 Driver Mirror Motor Up Control
B L-BU/WH 1497 Driver Mirror Motor Left/Down Control
C RD/WH 881 Driver Mirror Motor Right Control
D OG 267
(DE5)
E BK 750 Ground (DE5)
F-H - - Not Used
Outside Rearview Mirror Switch (A43)
12064769

10-Way F Metri-Pack 150 Series (NAT)

B BK 550 Ground
C L-GN 1514 Driver Mirror Switch Down Signal
D YE 1496 Mirror Motor Left/Up Control
E - - Not Used
F WH 1512 Driver Mirror Switch Right Signal
G GY 915 Mirror Switch Supply Voltage
H - - Not Used
J RD/WH 1513 Passenger Mirror Switch Right Signal
K PU/WH 1515 Passenger Mirror Switch Down Signal
Outside Rearview Mirror Switch (w/o A43)

12047886

A BN/WH 1498 Right Mirror Motor Up
B RD/WH 881 Right Mirror Motor Right
Mirror Selector Switch Right Signal/Right
C L-BU/WH 1497
Mirror Down/Right
D BK 550 Ground
E OG 840 Battery Positive Voltage
F WH 81 Left Mirror Motor Right
G YE 88 Left Mirror Motor Up
H L-GN 1499 Mirror Selector Switch Left Signal
Window Master Switch - C1

12084699
6-Way F Metri-Pack 280 Series (BU)

GY 8 Instrument Panel Lamp Supply Voltage - 1
A Instrument Panel Lamp Supply Voltage - 1
GY 8
(Pontiac)
B YE 143 Accessory Voltage
C - - Not Used
D D-BU 1307 Window Master Switch Lockout Signal
E BK 550 Ground
F - - Not Used
Window Master Switch - C2
12191825
Connector Part Information 8-Way F Metri-Pack 280 Series (BN)
Window Master Switch Front Passenger
A TN 167
Down Signal
Window Master Switch Front Passenger Up
B L-BU 166
Signal
C D-BU 164 Window Motor Driver Up
D BN 165 Window Motor Driver Down
Power Window Master Switch Left Rear Up
E D-GN 168
Signal
Window Master Switch Left Rear Down
F PU 169
Signal
Window Master Switch Right Rear Up
G L-GN 170
Signal
Window Master Switch Right Rear Down
H PU 171
Signal
Window Motor - Driver
12129487
2-Way F Metri-Pack 280 Series Flexlock Sealed (GY)

A BN 165 Window Motor Driver Down
B D-BU 164 Window Motor Driver Up
Window Motor - Front Passenger

12129487

A BN 667 Window Motor Front Passenger Down
B D-BU 666 Window Motor Front Passenger Up
Window Motor - LR
12129487

A BN 669 Window Motor Left Rear Down
B D-BU 668 Window Motor Left Rear Up
Window Motor - RR
12129487

A BN 671 Window Motor Right Rear Down
B D-BU 670 Window Motor Right Rear Up
Window Switch - Front Passenger
12191825
8-Way F Metri-Pack 280 Series (BN)

A YE 143 Accessory Voltage
GY 8 Instrument Panel Lamp Supply Voltage
B
GY 8 Instrument Panel Lamp Supply Voltage
C BK 750 Ground
Window Master Switch Front Passenger Up
D L-BU 166
Signal
E - - Not Used
F D-BU 666 Window Motor Front Passenger Up
G BN 667 Window Motor Right Front Down
Window Master Switch Front Passenger
H TN 167
Down Signal
Window Switch - LR
12191825

A D-BU 1307 Window Master Switch Lockout Signal
B-C - - Not Used
D D-GN 168 Window Master Switch Left Rear Up Signal
E - - Not Used
F D-BU 668 Window Motor Left Rear Up
G BN 669 Window Motor Left Rear Down
Window Master Switch Left Rear Down
H PU 169
Signal
Window Switch - RR
12191825

A D-BU 1307 Window Master Switch Lockout Signal
B-C - - Not Used
Window Master Switch Right Rear Up
D L-GN 170
Signal
E - - Not Used
F D-BU 670 Window Motor Right Rear Up
G BN 671 Window Motor Right Rear Down
Window Master Switch Right Rear Down
H PU 171
Signal

DIAGNOSTIC STARTING POINT - DOORS
For power mirror systems without the A43 memory feature, begin the diagnosis by reviewing the system
Description and Operation. Reviewing the Description and Operation information will help you determine the
correct symptom diagnostic procedure when a malfunction exists. Reviewing the Description and Operation
information will also help you determine if the condition described by the customer is normal operation. Refer
to Symptoms - Doors in order to identify the correct procedure for diagnosing the system and where the
procedure is located.
For power mirror systems with the A43 memory feature and all other door systems, begin the system diagnosis
with the Diagnostic System Check - Vehicle in Vehicle DTC Information. The Diagnostic System Check will
provide the following information:

The identification of any stored DTCs and their status.
Body Control Module

The BCM actuates the driver door lock actuator for
Driver Door Unlock Door Lock Test approximately 5 seconds when you select ON. The driver
door should unlock.
The BCM actuates the front passenger, LR and RR door
Passenger Door
Door Lock Test lock actuators for approximately 5 seconds when you select
Unlock
ON. All of the doors, except the driver door, should unlock.
The BCM actuates all of the door lock actuators for
Door Lock Door Lock Test approximately 5 seconds when you select ON. All of the
doors should lock.
Memory Seat Module

The driver mirror is commanded to rotate left or right for
Mirror Left/Right Left MirrorTest approximately 5 seconds when you select Left or Right. The
driver mirror should move left or right as selected.
The passenger mirror is commanded to rotate left or right
Mirror Left/Right Right Mirror Test for approximately 5 seconds when you select Left or Right.
The passenger mirror should move left or right as selected.
The driver mirror is commanded to rotate up or down for
Mirror Up/Down Left MirrorTest approximately 5 seconds when you select Up or Down. The
driver mirror should move up or down as selected.
The passenger mirror is commanded to rotate up or down
Mirror Up/Down Right Mirror Test for approximately 5 seconds when you select Up or Down.
The passenger mirror should move up or down as selected.
SCAN TOOL DATA LIST
Body Control Module

Operating Conditions: Key ON, Engine OFF.
8 Digit GM Part Number Module Information Numeric XXXXXXXX
Door Ajar Switches Input Active/Inactive Inactive
Door Lock Motor Output On/Off Off
Door Unlock Motor Output On/Off Off
Door Unlock Switch Input Active/Inactive Inactive
Driver Door Open Sw. Input Active/Inactive Inactive
Driver Door Unlock Motor Output On/Off Off
Key Cylinder Lock Switch Input Active/Inactive Inactive
Key Cylinder Unlock Input Active/Inactive Inactive
Lock/Unlock Switch Data Volts 0.0 - 25.5 Volts
Passenger Door Open Sw. Input Active/Inactive Inactive
Rear Door Open Switch Input Active/Inactive Inactive
Memory Seat Module

Typical Data
Operating Conditions: Key ON, Engine OFF.
Module
8 Digit GM Part Number Alpha-Numeric XXXXXXXX
Information
Mirror
Battery Voltage Voltage 12.8 Volts
Input/Output
Mirror
Driver Identification Driver 1/Driver 2 Driver 1
Input/Output
Mirror
Left Horizontal Motor Right/Left/Off Off
Input/Output
Mirror
Left Vertical Motor Up/Down/Off Off
Input/Output
Lt. Horiz. Mirror Pos Mirror Sensor Data Voltage 0.75- 4.50 Volts
Lt. Vertical Mirror Pos Mirror Sensor Data Voltage 0.75- 4.50 Volts
Mirror Driver 1/Driver 2/ Easy
Memory Switch Inactive
Input/Output Exit/Inactive
Memory 1 Left Horizontal Mirror Memory
Voltage 0.75- 4.50 Volts
Value Data
Mirror Memory
Memory 1 Left Vertical Value Voltage 0.75- 4.50 Volts
Data
Memory 1 Right Horizontal Mirror Memory
Value Data
Memory 1 Right Vertical Mirror Memory
Value Data
Memory 2 Left Horizontal Mirror Memory
Value Data
Mirror Memory
Memory 2 Left Vertical Value Voltage 0.75- 4.50 Volts
Data
Memory 2 Right Horizontal Mirror Memory
Value Data
Memory 2 Right Vertical Mirror Memory
Value Data
Left Right/Left Left/Left
Mirror Up/Left Down/Right
Mirror Switch State Idle
Input/Output Right/Right Left/Right Up/Right
Down/Idle
Mirror
PRNDL State Park/Reverse/Neutral/Drive/First Park
Input/Output
Mirror
Right Horizontal Motor Right/Left/Off Off
Input/Output
Mirror
Right Vertical Motor Up/Down/Off Off
Input/Output
Rt. Horiz. Mirror Pos. Mirror Sensor Data Voltage 0.75- 4.50 Volts
Rt. Vertical Mirror Pos. Mirror Sensor Data Voltage 0.75- 4.50 Volts
Mirror Off
System Power Mode Off Awake
Input/Output Awake/Accessory/Run/Crank
8 Digit GM Part Number
The scan tool displays the eight digit part number of the control module selected.
Battery Voltage
The scan tool displays 9.0-15.0 volts. The state of the battery voltage supplied to the MSM.
Door Ajar Switches
The scan tool displays Active/Inactive. The vehicle door ajar switches inputs to the BCM, where a closed
door ajar switch is displayed as Active.
Door Lock Motor
The scan tool displays On/Off. The door lock actuators output from the BCM, where the actuators
transition to the Lock position is displayed as On.
Door Unlock Motor
The scan tool displays On/Off. The door lock actuators output from the BCM, where the actuators
transition to the Unlock position is displayed as On.
Door Unlock Switch
The scan tool displays Active/Inactive. The vehicle door lock switches inputs to the BCM, where a switch
transition to the Lock position is displayed as Active.
Driver Identification
The scan tool displays Driver 1/Driver 2. The memory select switch input to the MSM to identify the
driver selected.
Drivers Door Open Sw.
The scan tool displays Active/Inactive. The driver door ajar switch input to the BCM, where an open door
is displayed as Active.
Drivers Door Unlock Motor
The scan tool displays On/Off. The driver door lock actuator output from the BCM, where the actuators
Key Cylinder Lock Switch
The scan tool displays Active/Inactive. The door lock cylinder switches inputs to the BCM, where a
switch transitioning to the Lock position is displayed as Active.
Key Cylinder Unlock
The scan tool displays Active/Inactive. The door lock cylinder switches inputs to the BCM, where a
switch transitioning to the Unlock position is displayed as Active.
Left Horizontal Motor
The scan tool displays Right/Left/Off. The driver mirror horizontal motor output from the MSM, where
the horizontal motor transitions are displayed as Right and Left.
Left Vertical Motor
The scan tool displays Up/Down/Off. The driver mirror vertical motor output from the MSM, where the
vertical motor transitions are displayed as Up and Down.
Lt. Horiz. Mirror Pos
The scan tool displays 0.75-4.50 volts. The driver mirror horizontal position sensor feedback voltage to
the MSM.
Lt. Vertical Mirror Pos
The scan tool displays 0.75-4.50 volts. The driver mirror vertical position sensor feedback voltage to the
MSM.
Liftgate Lock Motor
The scan tool displays On/Off. The liftgate lock actuators output from the BCM, where the actuators
transition to the Lock position is displayed as On.
Liftgate Unlock Motor
The scan tool displays On/Off. The liftgate lock actuators output from the BCM, where the actuators
Lock/Unlock Switch
The scan tool displays 0.0 -25.5 volts. The door lock switches feedback voltage to the BCM.
Memory Switch
The scan tool displays Driver 1/Driver 2/Easy Exit/Inactive. The memory switch input to the MSM,
indicating which memory function has been selected.
Memory 1 Left Horizontal Value
the MSM for memory position 1.
Memory 1 Left Vertical Value
MSM for memory position 1.
Memory 1 Right Horizontal Value
The scan tool displays 0.75-4.50 volts. The passenger mirror horizontal position sensor feedback voltage
to the MSM for memory position 1.
Memory 1 Right Vertical Value
The scan tool displays 0.75-4.50 volts. The passenger mirror vertical position sensor feedback voltage to
Memory 2 Left Horizontal Value
Memory 2 Left Vertical Value

MSM for memory position 2.
Memory 2 Right Horizontal Value
to the MSM for memory position 2.
Memory 2 Right Vertical Value
Mirror Switch State
The scan tool displays Left Right/Left Left/Left Up/Left Down/Right Right/Right Left/Right Up/Right
Down/Idle. The mirror switch input to the MSM, indicating which mirror function has been selected.
Passenger Door Open Sw.
The scan tool displays Active/Inactive. The passenger door ajar switch input to the BCM, where an open
door is displayed as Active.
PRNDL State
The scan tool displays Park/Reverse/Neutral/Drive/First. The PRNDL input to the MSM displaying gear
selection.
Right Horizontal Motor
The scan tool displays Right/Left/Off. The passenger mirror horizontal motor output from the MSM,
where the horizontal motor transitions are displayed as Right and Left.
Right Vertical Motor
The scan tool displays Up/Down/Off. The passenger mirror vertical motor output from the MSM, where
the vertical motor transitions are displayed as Up and Down.
Rt. Horiz. Mirror Pos.
to the MSM.
Rt. Vertical Mirror Pos.
the MSM.
Rear Door Open Sw.
The scan tool displays Active/Inactive. The LR and RR door ajar switches inputs to the BCM, where an
open door is displayed as Active.
System Power Mode
The scan tool displays Off Awake/Accessory/Run/Crank. The ignition switch input states to the MSM
used for power moding.
DTC B1349
Circuit Description
The body control module (BCM) door locks ground circuit 550 provides ground for the door lock and unlock
relays in the BCM that control the door lock actuators. If the BCM detects an open in this circuit, DTC B1349 is
set.
DTC Descriptor
DTC B1349 Device Ground Circuit Open
The BCM electronics ground circuit 1550 must be connected to ground and the BCM must be in its normal
operating state.
The BCM detects the door locks ground circuit 550 ground circuit open for greater than 0.375 seconds.
The BCM no longer detects the open circuit.

100 consecutive ignition cycles have been recorded without the DTC being detected.
Diagnostic Aids
If the BCM door locks ground circuit 550 is open from the center console fuse block connector C2, DTC
B1349 will not set. The BCM takes a redundant path to ground through another ground circuit in the
center console fuse block.
The BCM is mounted directly on top of the center console fuse block and is connected to the fuse block
through BCM connector C3. If during the replacement of the BCM the connector C3 is not fully seated in
the center console fuse block, DTC B1349 may set. If the fault occurred after BCM replacement, DTC
B1349 may be set with DTC B1354.
Check the BCM mounting to the center console fuse block. The BCM connector C3 may have come
loose from the fuse block.
If DTC B1349 is a history DTC, the fault may be intermittent. Refer to Testing for Intermittent
Conditions and Poor Connections in Wiring Systems.
The following conditions may cause an intermittent malfunction to occur:
An internal intermittent open in the BCM
An intermittent open in the connection of the BCM to the center console fuse block
DTC B1349
Step Action Yes No
Schematic Reference: Door Lock/Indicator Schematics
Connector End View Reference: Computer/Integrating Systems Connector End Views in
Computer/Integrating Systems or Electrical Center Identification Views in Wiring Systems
1
Vehicle in Vehicle
Inspect for poor connections between the body control
module (BCM) harness connector C3 and the center
console fuse block. Refer to Testing for Intermittent
2
Conditions and Poor Connections and Connector
3 -
text.
DTC B1560, B1565, B1570, OR B1575
Circuit Description
The outside rearview mirror switch supplies power and ground inputs to the memory seat module (MSM) for
use in driving the driver and passenger outside rearview mirror horizontal and vertical motors. When the MSM
recognizes the input combination, it moves the appropriate mirror motor in the requested direction. If the MSM
sees the input combination for greater than 30 seconds, a DTC B1560, B1565, B1570 or B1575 is set and the
mirror outputs are disabled.
DTC Descriptors
DTC B1560 Mirror Right Control Switch Circuit

DTC B1565 Mirror Left Control Switch Circuit
DTC B1570 Mirror Up Control Switch Circuit
DTC B1575 Mirror Down Control Switch Circuit
Conditions for Running the DTCs
Battery input voltage between 9-16 volts.
Conditions for Setting the DTCs
Mirror switch inputs to the MSM are active for greater than 30 seconds.
Mirror outputs are disabled.

Memory recall commands are ignored.
The MSM no longer detects the switch failure for greater than 30 seconds.
DTC will clear after 50 consecutive ignition cycles.
Diagnostic Aids

An outside rearview mirror switch that is sticking.
An outside rearview mirror switch that was pressed for longer than 30 seconds.
If the DTC does not reset after it has been cleared, then the malfunction may be intermittent. Refer to
Testing for Intermittent Conditions and Poor Connections in Wiring Systems.
Test Description
2: This step determines whether the DTC is current or intermittent.
3: This step tests for a stuck or shorted outside rearview mirror switch.
DTC B1560, B1565, B1570, or B1575

Step Action Yes No
Schematic Reference: Outside Mirror Schematics
Connector End View Reference: Power Door Systems Connector End Views or Power Seat Systems
Connector End Views
1
Vehicle in Vehicle
3. With a scan tool, monitor the DTC Information
2 for DTC B1560, B1565, B1570 or B1575 in the
memory seat module (MSM).
Does the scan tool indicate that DTC B1560, B1565, Go to Diagnostic
B1570 or B1575 is current? Go to Step 3 Aids
2. Disconnect the outside rearview mirror switch.
5. Operate the vehicle within normal operating
conditions.
Does the DTC reset? Go to Step 4 Go to Step 5

the MSM. Refer to Testing for Intermittent
the outside rearview mirror switch. Refer to Testing
Replace the MSM. Refer to Control Module
6
Replace the outside rearview mirror switch. Refer to
Power Mirror Switch Replacement (Aztek) or Power
7 Mirror Switch Replacement (Rendezvous).
text.
DTC B1580, B1590, B1610, OR B1620
Circuit Description
The memory seat module (MSM) receives inputs from the mirror position sensors during memory 1 and
memory 2 recall. The potentiometers in the position sensors vary in resistance as the motors move the mirror.
The MSM receives a variable voltage input depending on the resistance of the potentiometer. During memory
set, the MSM records the voltages across the mirrors. During memory recall, the MSM moves the mirror motors
until the voltage across each potentiometer matches the recorded voltage. During normal operation, the mirror
position sensors are checked against out-of-range limits. If the MSM sees the vertical or horizontal position
sensor input voltage out of normal range, a DTC B1580, B1590, B1610 or B1620 is set and the mirror outputs
are disabled during memory recall.
DTC Descriptors
DTC B1580 Mirror Horizontal Position Sensor Circuit

DTC B1590 Mirror Vertical Position Sensor Circuit
DTC B1610 Right Front Mirror Horizontal Position Sensor Circuit
DTC B1620 Right Front Mirror Vertical Position Sensor Circuit
Battery input voltage between 9-16 volts.
The outside rearview mirrors vertical or horizontal position sensor input voltage is less than 0.75 volts.
The outside rearview mirrors vertical or horizontal position sensor input voltage is greater than 4.50 volts.
The MSM will disable the affected motor during memory recall.
The MSM no longer detects the position sensor failure.

Diagnostic Aids
An intermittent malfunction may be caused by an outside rearview mirror that is being operated after
reaching the hard stop.
If the DTC does not reset after it has been cleared, then the malfunction may be intermittent. Refer to
Test Description
4: This step tests for an inoperative mirror motor. If the fuse in the jumper opens when you perform this
test, the 5-volt reference or mirror position sensor signal circuit is short to ground.
5: This step tests for an inoperative mirror assembly. If the fuse in the jumper opens when you perform
this test, the 5-volt reference or mirror position sensor signal circuit is short to ground.
6: This step tests for a short to ground or an open in the 5-volt reference or mirror position sensor signal
circuits.
7: This step tests for an inoperative mirror motor.
8: This step tests for an inoperative mirror assembly.
9: This step tests for a short to voltage in the 5-volt reference or mirror position sensor circuits.
DTC B1580, B1590, B1610, or B1620

Step Action Values Yes No
Connector End Views
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
OFF.
2 3. With a scan tool, observe the appropriate 0.75-4.50 V
Mirror Position Sensor parameters in the
memory seat module (MSM) data list.
Does the scan tool indicate that the Mirror
Position Sensor parameters are within the Go to
specified range? Diagnostic Aids Go to Step 3
3 Position Sensor parameter is less than the 0.75 V
2. Disconnect the appropriate mirror motor.
3. Connect a 3-amp fused jumper wire
between the 5-volt reference circuit and
the appropriate signal circuit of the
4 appropriate mirror motor. 4.50 V
OFF.

Position Sensor parameter is greater than the
2. Disconnect the fused jumper wire.
3. Connect the appropriate mirror motor.
4. Disconnect the appropriate mirror
assembly.
5 4.50 V
the appropriate signal circuit of the
appropriate mirror assembly.
OFF.

Position Sensor parameter is greater than the
2. Measure the voltage between the 5-volt
reference circuit of the appropriate mirror
6 motor and the low reference circuit of the 5V
appropriate mirror assembly.
Is the voltage less than the specified value? Go to Step 10 Go to Step 11

Disconnect the appropriate mirror motor.
7 Does the scan tool indicate that the Mirror 0.75 V
Position Sensor parameter is less than the
Disconnect the appropriate mirror assembly.
8 0.75 V
Position Sensor parameter is less than the
2. Disconnect the negative battery cable.
3. Measure the resistance from the low
9 reference circuit of the appropriate mirror 5 ohms
assembly to a good ground.
Is the resistance less than the specified value? Go to Step 12 Go to Step 13

Test the 5-volt reference circuit of the
appropriate mirror position sensor for a short to
10 ground or an open. Refer to Circuit Testing and -
Test the appropriate mirror position sensor signal
circuit for a short to ground or an open. Refer to
11 Circuit Testing andWiring Repairs in Wiring -
Systems.
Test the 5-volt reference circuit of the
appropriate mirror position sensor for a short to
12 voltage. Refer to Circuit Testing andWiring -
Test the low reference circuit of the appropriate
mirror position sensor for an open. Refer to
13 Circuit Testing and Wiring Repairs in Wiring -
Systems.
Test the appropriate mirror position sensor signal
14 -
connector of the appropriate outside rearview
mirror motor. Refer to Testing for Intermittent
15 -
Conditions and Poor Connections and
connector of the appropriate outside rearview
mirror assembly. Refer to Testing for
16 -
Systems.
connector of the MSM. Refer to Testing for
17 -
Systems.
Replace the appropriate outside rearview mirror
motor. Refer to Motor Replacement - Power
18 -
Mirror.
Replace the appropriate outside rearview mirror.
19 Refer to Mirror Replacement - Power. -
20 -
DTCs.
supporting text.
DTC B1600, B1605, B1630, OR B1635
Circuit Description
The memory seat module (MSM) monitors the outputs to the mirror motors during mirror operation. During
normal operation, the mirror motors are checked against out-of-range limits. If the MSM sees the mirror motor
output range high, a DTC B1600, B1605, B1630, or B1635 is set and the mirror motor output and the memory
recall is disabled for the motor affected.
DTC Descriptors
DTC B1600 Driver Mirror Motor Vertical Circuit

DTC B1605 Driver Mirror Motor Horizontal Circuit
DTC B1630 Right Front Mirror Motor Vertical Circuit
DTC B1635 Right Front Mirror Motor Horizontal Circuit
Battery input voltage between 9-16 volts
The outside rearview mirror motor circuit short to voltage

The outside rearview mirror motor circuit short to ground
The MSM will disable the affected motor output.
The MSM no longer detects the mirror motor circuit short to voltage.
The MSM no longer detects the mirror motor circuit short to ground.
Diagnostic Aids
If the DTC does not reset after it has been cleared, then the malfunction may be intermittent. Refer to Testing
for Intermittent Conditions and Poor Connections in Wiring Systems.
Test Description
2: Listen for the motor operation. Command both the Up and Down or Right and Left states. Repeat the
commands, as necessary.
3: This step verifies that the MSM is providing output to the mirror motor.
4: This step verifies that the MSM is providing output to the mirror assembly.
5: This step tests the mirror motor control circuits for a short to voltage or ground.
DTC B1600, B1605, B1630, or B1635

Step Action Yes No
Connector End Views
1
Vehicle in Vehicle
3. With a scan tool, command the appropriate
2 mirror motor Up and Down or Right and Left.
Does the mirror motor turn Up and Down or Right and Go to Diagnostic
Left with each command? Aids Go to Step 3
2. Disconnect the appropriate mirror motor.
3. Connect a test lamp between the appropriate
mirror motor control circuits.
mirror motor Up and Down or Right and Left.

2. Connect the appropriate mirror motor.
3. Disconnect the appropriate mirror motor
assembly.
4 mirror motor assembly control circuits.
mirror motor Up and Down or Right and Left.

Test the appropriate mirror motor control circuit of the
appropriate mirror motor for a short to voltage or a
5 short to ground. Refer to Circuit Testing and Wiring
of the outside rearview mirror motor. Refer to Testing

of the outside rearview mirror assembly. Refer to
7 Testing for Intermittent Conditions and Poor
Systems.
of the memory seat module (MSM). Refer to Testing
Replace the outside rearview mirror motor. Refer to
9 Motor Replacement - Power Mirror. -
Replace the outside rearview mirror assembly. Refer to
10 Mirror Replacement - Power. -
11 -
text.
DTC B3064 OR B3069
Circuit Description
The LF and RF door lock cylinder switches provide a ground input to the body control module (BCM) when
either of the switches are turned to the unlock position. This input is needed for the optional content Theft
Deterrent System when the keyless entry feature does not unlock the doors.
DTC Descriptors
DTC B3064 Right Front/Left Front Door Key Lock Switch Circuit Low
DTC B3069 Right Front/Left Front Door Key Unlock Switch Circuit Low
The BCM detects the door lock key switch signal circuit as continuously active for greater than 60 seconds.

The BCM will disable the input and all operations of the input until the fault no longer exists.
The BCM no longer detects the short to ground for greater than 60 seconds.
Diagnostic Aids
If the DTC B3069 is a history DTC, the fault may be intermittent. Refer to Testing for Intermittent
An intermittent short to ground in the key unlock input circuit
The key cylinder switch is intermittently shorted to ground internally.
The BCM is intermittently shorted to ground internally.
Test Description
2: This step determines whether the short to ground in the key cylinder unlock circuit is current or
intermittent.
3: This step determines whether the short to ground is in the door lock cylinder switches or the door lock
key switch unlock signal circuit.
4: This step determines whether the LF or RF door lock cylinder switch is shorted to ground.
DTC B3064 or B3069

Step Action Yes No
Connector End View Reference: Power Door Systems Connector End Views,
Computer/Integrating Systems Connector End Views in Computer/Integrating Systems, or Electrical
Center Identification Views in Wiring Systems
1
Vehicle in Vehicle
2 3. With a scan tool, observe the Key Cylinder
Unlock parameter in the body control module
(BCM) data list.
Go to Diagnostic
Does the scan tool display Inactive? Aids Go to Step 3
2. Disconnect the LF and RF door lock cylinder
switches.
4. With a scan tool, observe the Key Cylinder
Unlock parameter in the BCM data list.

2. Connect the LF door lock cylinder switch.
4
4. With a scan tool, observe the Key Cylinder
Unlock parameter in the BCM data list.

Test the door lock key switch unlock signal circuit for
a short to ground. Refer to Circuit Testing and Wiring
5
of the BCM. Refer to Testing for Intermittent
Replace the RF door lock cylinder switch. Refer to
7 Lock Replacement - Front Door. -
Replace the LF door lock cylinder switch. Refer to
8 Lock Replacement - Front Door. -
9 -
text.
DTC B3270
Circuit Description
The driver and front passenger door lock switches provide a path to ground for the driver door lock switch
signal circuit to the body control module (BCM) through a 470 ohm resistor when the door lock switch is
activated to the lock position. This input is used by the BCM to control the door locks.
DTC Descriptor
DTC B3270 Door Lock Switch Circuit
The BCM detects a short to ground through 470 ohms of resistance in the driver door lock switch signal circuit
for greater than 60 seconds.

The BCM no longer detects the short to ground through 470 ohms of resistance in the driver door lock
switch signal circuit for greater than 60 seconds.
Diagnostic Aids
If DTC B3270 is a history DTC, the fault may be intermittent. Refer to Testing for Intermittent
A door lock switch intermittently shorted to ground through the 470 ohm resistor may cause the
intermittent malfunction to occur.
Test Description
2: Determines whether the DTC is current or intermittent.
3: Determines whether the driver or front passenger door lock switch is shorted to ground.
DTC B3270
Step Action Yes No
Connector End View Reference: Power Door Systems Connector End Views
1
Vehicle in Vehicle
3. With a scan tool, monitor the DTC Information
2 for DTC B3270 in the body control module
(BCM).
Go to Diagnostic
Does the scan tool indicate that DTC B3270 is current? Go to Step 3 Aids
2. Disconnect the driver door lock switch.
5. Operate the vehicle within normal operating
conditions.
Does the DTC reset? Go to Step 4 Go to Step 5

Replace the front passenger door lock switch. Refer to
Power Door Lock Switch Replacement (Aztek) or
4 Power Door Lock Switch Replacement
(Rendezvous).
Replace the driver door lock switch. Refer to Power
Door Lock Switch Replacement (Aztek) or Power
5
Door Lock Switch Replacement (Rendezvous).
6 running the DTC as specified in the supporting
text.
DTC B3272
Circuit Description
The door lock switch provides a direct ground input to the body control module (BCM) when the door lock
switch is activated to the unlock position. This input is used by the BCM to control the door locks.
DTC Descriptor
DTC B3272 Door Unlock Switch Circuit
The BCM detects a short to ground in the driver door lock switch signal circuit for greater than 60 seconds.

The BCM no longer detects the short to ground in the driver door lock switch signal circuit for greater
than 60 seconds.
Diagnostic Aids
If the DTC B3272 is a history DTC, the fault may be intermittent. Refer to Testing for Intermittent
An intermittent short to ground in the driver door lock switch lock signal circuit
The door lock switch is intermittently shorted to ground internally
The BCM is intermittently shorted to ground internally
Test Description
2: Determines whether the DTC is current or intermittent.

3: Determines whether the driver door lock switch lock signal circuit or a door lock switch is shorted to
ground.
DTC B3272
Step Action Yes No
Connector End View Reference: Power Door Systems Connector End Views,Computer/Integrating
Systems Connector End Views in Computer/Integrating Systems, or Electrical Center Identification
Views
3. With a scan tool, observe the Door Unlock
2 Switch parameter in the body control module
(BCM) data list.
Go to Diagnostic
2. Disconnect the driver and front passenger door
lock switches.
Switch parameter in the BCM data list.

2. Connect the driver door lock switch.
4
Switch parameter in the BCM data list.

Test the driver door lock switch lock signal circuit for a
5
Replace the driver door lock switch. Refer to Power
Door Lock Switch Replacement (Aztek) or Power
7
Door Lock Switch Replacement (Rendezvous).
Replace the front passenger door lock switch. Refer to
Power Door Lock Switch Replacement (Aztek) or
8 Power Door Lock Switch Replacement
(Rendezvous).
9
text.
SYMPTOMS - DOORS
Power Windows, Power Door Locks and Rendezvous Power Mirrors w/A43
1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information, before using the
Symptom Tables in order to verify that all of the following are true:
2. Review the system operation in order to familiarize yourself with the system functions:
Refer to Power Windows Description and Operation.
Refer to Power Door Locks Description and Operation.
Refer to Outside Mirror Description and Operation.
Aztek Power Mirrors and Rendezvous Power Mirrors w/o A43
IMPORTANT: The following must be completed before using the symptom tables.
Review the outside mirror system operation in order to familiarize yourself with the system functions. Refer to
Outside Mirror Description and Operation.
Inspect for aftermarket devices which could affect the operation of the door systems. Refer to Checking
cause the symptom.
Intermittent
Symptom List
Power Windows Inoperative - All

Power Windows Inoperative - Express Down Function
Power Windows Inoperative - Lockout Function
Power Window Inoperative - Driver Door
Power Window Inoperative - Passenger Door
Door Ajar Indicator Malfunction
Power Door Locks Inoperative (Aztek) or Power Door Locks Inoperative (Rendezvous)
Power Door Locks Inoperative - Endgate/Liftgate
Automatic Door Locks Inoperative
Power Mirrors Inoperative (Aztek) or Power Mirrors Inoperative (Rendezvous w/o A43) or Power
Mirrors Inoperative (Rendezvous w/A43)
Power Mirrors - Mirror Tilt Inoperative in Reverse
Heated Mirrors Inoperative
POWER WINDOWS INOPERATIVE - ALL
Power Windows Inoperative - All

Step Action Yes No
Schematic Reference: Power Window Schematics
1
Vehicle in Vehicle
Verify that the all power windows inoperative fault Go to Testing for
is present. Intermittent
2 Do the power windows operate normally? Conditions and
Poor Connections
in Wiring Systems Go to Step 3
1. Disconnect the driver window switch.
3. Probe the accessory voltage circuit of the
3 driver window switch with a test lamp that is
4 Connect a test lamp between the accessory voltage

circuit of the driver window switch and the ground
circuit of the driver window switch.
Test the power window master switch lockout signal
circuit for a short to ground. Refer to Circuit
5
Test the accessory voltage circuit of the driver Go to Symptoms -
window switch for a short to ground or an open. Computer/Integrating
6 Refer to Circuit Testing and Wiring Repairs in Systems in
Wiring Systems. Computer/Integrating
Inspect for a poor connections at the harness
connector of the driver window switch. Refer to
7
Systems.
Repair the open in the ground circuit. Refer to
Replace the driver window switch. Refer to Power
Window Switch Replacement - Left Front
9 (Aztek) or Power Window Switch Replacement -
Left Front (Rendezvous).
10
POWER WINDOWS INOPERATIVE - EXPRESS DOWN FUNCTION
Power Windows Inoperative - Express Down Function

Step Action Yes No
Go to Diagnostic
Did you perform the Diagnostic System Check - System Check -
1
Vehicle? Vehicle in Vehicle
Verify that the power windows express down function Go to Testing for
fault is present. Intermittent
2 Does the power windows express down function Conditions and
operate normally? Poor Connections
Inspect for a poor connections at the harness connector

of the driver window switch. Refer to Testing for
3 Connector Repairs in Wiring Systems.
Window Switch Replacement - Left Front (Aztek)
4 or Power Window Switch Replacement - Left Front
(Rendezvous).
5
POWER WINDOWS INOPERATIVE - LOCKOUT FUNCTION
Power Windows Inoperative - Lockout Function

Step Action Yes No
Go to Diagnostic
1
Verify that the inoperative power windows lockout Go to Testing for
function fault is present. Intermittent
2 Does the power windows lockout function operate Conditions and
normally? Poor Connections
1. Disconnect the driver window switch.
2. Turn on the ignition, with the engine off.
3. Probe the power window master switch lockout
3 signal circuit of the driver window switch with a
test lamp that is connected to a good ground.

Repair the short to voltage in the power window
master switch lockout signal circuit. Refer to Wiring
4
Inspect for a poor connections at the harness connector
or Power Window Switch Replacement - Left Front
6 (Rendezvous).
7
POWER WINDOW INOPERATIVE - DRIVER DOOR
Power Window Inoperative - Driver Door

Step Action Yes No
Go to Diagnostic
1
Verify that the inoperative driver door power window Go to Testing for
2 Does the driver door power window operate normally? Conditions and
Poor Connections
1. Disconnect the driver window motor.
3. Probe the power window motor left front up
circuit of the driver window motor with a test
3 lamp that is connected to a good ground.
4. Activate the driver window switch to the UP
position.

1. Connect a test lamp between the power window
motor left front up circuit of the driver window
motor and the power window motor left front
down circuit of the driver window motor.
4
2. Activate the driver window switch to the
DOWN position.

Test the power window motor left front up circuit for
an open. Refer to Circuit Testing and Wiring
5
Test the power window motor left front down circuit
for an open. Refer to Circuit Testing and Wiring
6
of the driver window motor. Refer to Testing for
Replace the driver window motor. Refer to Window
9 Regulator Replacement - Front Door.
(Rendezvous).
11
POWER WINDOW INOPERATIVE - PASSENGER DOOR
Power Window Inoperative - Passenger Door

Step Action Yes No
Go to Diagnostic
1
Go to Testing for
Verify that the inoperative passenger door power
Intermittent
window fault is present.
2 Conditions and
Do the passenger door power windows operate
Poor Connections
normally?
Is the inoperative window the front passenger
3
window? Go to Step 5 Go to Step 4
4 Are the driver, LR and RR windows all inoperative? Go to Step 9 Go to Step 6
1. Disconnect the front passenger window switch.

5
3. Probe the accessory voltage circuit of the front
passenger window switch with a test lamp that is

1. Disconnect the appropriate window switch.
3. Probe the power window master switch lockout
6 signal circuit of the appropriate window switch
with a test lamp that is connected to a good
ground.

1. Disconnect the appropriate window switch.
master switch up circuit of the appropriate
window switch and the power window master
7 switch down signal circuit of the appropriate
window switch.
3. Activate the appropriate driver window switch
to the UP and DOWN positions.
Does the test lamp illuminate in both positions? Go to Step 8 Go to Step 11

1. Connect the appropriate window switch.
2. Disconnect the appropriate window motor.
motor up circuit of the appropriate window
8 motor and the power window motor down
circuit of the appropriate window motor.
4. Activate the appropriate window switch to the
UP and DOWN positions.
Does the test lamp illuminate in both positions? Go to Step 14 Go to Step 12

Test the accessory voltage circuit for an open. Refer to
Circuit Testing and Wiring Repairs in Wiring
9
Systems.
Test the power window master switch lockout signal
circuit of the appropriate window switch for an open.
Wiring Systems.
Test the appropriate power window master switch

signal circuits of the appropriate window switch for a
short to voltage or an open. Refer to Circuit Testing
11 and Wiring Repairs in Wiring Systems.
Test the appropriate power window motor up and
down circuits of the appropriate window motor for a
12 short to voltage or an open. Refer to Circuit Testing
of the appropriate window motor. Refer to Testing for
of the appropriate window switch. Refer to Testing for
Repair the open in the accessory voltage circuit. Refer
16 to Wiring Repairs in Wiring Systems.
(Rendezvous).
Replace the appropriate window motor. Refer to
Window Regulator Replacement - Front Door
18
orWindow Regulator Replacement - Rear Door.
Replace the appropriate window switch. Refer to
Power Window Switch Replacement - Right Front
(Aztek) or Power Window Switch Replacement -
Right Front (Rendezvous) or Power Window
19
Switch Replacement - Rear Door (Aztek) or Power
Window Switch Replacement - Rear Door
(Rendezvous).
20
DOOR AJAR INDICATOR MALFUNCTION
Door Ajar Indicator Malfunction

Step Action Yes No
Schematic Reference: Interior Lights Schematics
Computer/Integrating Systems Connector End Views in Computer/Integrating Systems, or
Instrument Panel, Gages, and Console Connector End Views in Instrument Panel, Gages, and
Console
1
Vehicle in Vehicle
Verify that the door ajar indicator malfunction fault is Go to Testing for
present. Intermittent
2 Does the door ajar indicator operate normally? Conditions and
Poor Connections
3 Is the door ajar indicator on all the time? Go to Step 4 Go to Step 6
2. Close all the doors.
4 4. With a scan tool, observe the Door Ajar
Switches parameter in the body control module
(BCM) data list.

1. Close all the doors.
2. With a scan tool, observe the driver door open
sw., the Passenger Door Open Sw., and the Rear
5 Door Open Switch parameters in the BCM data
list.
Does the scan tool display Inactive for all parameters? Go to Step 15 Go to Step 11
2. Close all of the doors.
3. With a scan tool, observe the Door Ajar
6 Switches parameter in the BCM Input data list.
4. Open, then close each door, one door at a time.
Did the scan tool display Active when any of the doors
were open? Go to Step 7 Go to Step 8
2. With a scan tool, observe the driver door open
sw., the Passenger Door Open Sw., and the Rear
Door Open Switch parameters in the BCM Input
data list.
7
3. Open, then close each door, one door at a time.
Did the scan tool display Active when any of the doors
1. Disconnect the BCM harness connector C2.
2. Probe the door ajar switch signal circuit with a
test lamp connected to battery positive voltage.
8 3. Open, then close each door, one door at a time.
Did the test lamp illuminate when any of the doors

1. Disconnect the BCM harness connector C2.
2. Probe each of the appropriate door open switch
signal circuits with a test lamp connected to
battery positive voltage.
9 3. Open, then close each of the appropriate doors,
one door at a time.
Did the test lamp illuminate when any of the doors

Test the door ajar switch signal circuit for a short to
ground. Refer to Circuit Testing and Wiring Repairs
10
in Wiring Systems.
Test the appropriate door open switch signal circuit for
a short to ground. Refer to Circuit Testing and
11
Test the door ajar switch signal circuit for an open.
12
Wiring Systems.
Test the appropriate door open switch signal circuit for
an open. Refer to Circuit Testing and Wiring Repairs
13
in Wiring Systems.
Test the ground circuit of the appropriate door ajar
switch for an open. Refer to Circuit Testing and
14
16 Conditions and Poor Connections andConnector
of the appropriate door lock. Refer to Testing for
Replace the IPC. Refer to Control Module
18 -
19 -
Replace the appropriate door lock. Refer to Lock
Replacement - Front Door or Lock Replacement -
20 -
Rear Door.
21
POWER DOOR LOCKS INOPERATIVE (AZTEK)
Test Description
3: This step verifies that all of the power door locks, including the endgate locks, are inoperative.
Power Door Locks Inoperative (Aztek)

Step Action Yes No
Did you perform the Diagnostic System Check -
Go to Diagnostic
Verify the power door locks inoperative fault is Go to Testing for
2 Do the power door locks operate normally? Conditions and
Poor Connections
in Wiring System Go to Step 3
Are all of the power door locks inoperative, including
3
the endgate locks? Go to Step 4 Go to Step 5
Switch parameter in the body control module
4 (BCM) data list.
4. Activate a door lock switch to UNLOCK.
Does the scan tool display change from Inactive to

Active? Go to Step 8 Go to Step 7
Test the appropriate door lock actuator unlock control
Systems.
Test the appropriate door lock actuator lock control
Systems.
Test the driver door lock switch lock signal circuit for
7
in Wiring Systems.
Inspect for poor connections at the center console fuse
block harness connector C2. Refer to Testing for
Inspect for poor connections at the BCM. Refer to
9 Connections and Connector Repairs in Wiring
Systems.
Inspect for poor connections at the appropriate door
lock actuator. Refer to Testing for Intermittent
10 Repairs in Wiring Systems.
11 -
Replace the appropriate door lock actuator. Refer to
Lock Actuator Replacement - Front Door or Lock
12 -
Actuator Replacement - Rear Door.
13
Did you find and correct the condition? System OK Go to Step 3
POWER DOOR LOCKS INOPERATIVE (RENDEZVOUS)
Power Door Locks Inoperative (Rendezvous)

Step Action Yes No
1
Vehicle in Vehicle
Verify the power door locks inoperative fault is Go to Testing for
2 Do the power door locks operate normally? Conditions and
Poor Connections
in Wiring System Go to Step 3
Are all of the power door locks inoperative from both
3
door lock switches? Go to Step 6 Go to Step 4
Are the power door locks inoperative from a single
4
door lock switch? Go to Step 7 Go to Step 5
Is the driver door lock actuator the inoperative
5
actuator? Go to Step 8 Go to Step 9
6 3. With a scan tool, command the door lock On and
Off.
Do the door lock actuators activate? Go to Step 10 Go to Step 11

Test the appropriate door lock switch ground circuit
Test the driver door lock actuator unlock control
circuit for an open. Refer to Circuit Testing and
8
Test the appropriate door lock actuator unlock control
9
10
in Wiring Systems.
11 Is the power door locks fuse open? Go to Step 14 Go to Step 15
12
in Wiring Systems.
Test the appropriate door lock actuator lock control
13
1. Replace the power door locks fuse.
2. Disconnect all of the door lock actuators.
14 3. Activate a door lock switch to the LOCK and
UNLOCK positions.
Does the power door locks fuse open? Go to Step 16 Go to Step 17

Test the body control module (BCM) ground circuit at
the center console fuse block harness connector C2 for
15 an open. Refer to Circuit Testing and Wiring Repairs
in Wiring Systems.
Test the door lock actuator unlock control, the driver
door lock actuator unlock control, and the door lock
actuator lock control circuits for a short to ground.
16
Wiring Systems.
1. Connect the door lock actuators, one at a time.

2. Activate a door lock switch to the LOCK and
UNLOCK positions after each door lock
actuator is connected.
17
Does the power door locks fuse open after any of the
door lock actuators is connected? Go to Step 21 Go to Step 18
Inspect for poor connections at the center console fuse
block harness connector C2. Refer to Testing for
Inspect for poor connections at the BCM. Refer to
Systems.
lock switch. Refer to Testing for Intermittent
lock actuator. Refer to Testing for Intermittent
22 -
Replace the appropriate door lock switch. Refer to
23 -
Replace the appropriate door lock actuator. Refer to
24 -
25
POWER DOOR LOCKS INOPERATIVE - ENDGATE/LIFTGATE
Power Door Locks Inoperative - Endgate/Liftgate

Step Action Yes No

1
Vehicle in Vehicle
Verify that the endgate power door locks inoperative Go to Testing for
2 Do the endgate power door locks operate normally? Conditions and
Poor Connections
1. Disconnect the appropriate endgate lock
actuator.
2. Probe the endgate lock actuator unlock control
3 circuit with a test lamp that is connected to a
good ground.
3. Activate a door lock switch to UNLOCK.

1. Probe the endgate lock actuator lock control
circuit with a test lamp that is connected to a
good ground.
4
2. Activate a door lock switch to LOCK.

1. Connect a test lamp between the endgate lock
actuator unlock control circuit and the endgate
lock actuator lock control circuit of the
appropriate endgate lock actuator harness
5 connector.
2. Activate a door lock switch to LOCK and
UNLOCK.

Test the endgate lock actuator unlock control circuit
for a short to ground or an open. Refer to Circuit
6
Test the endgate lock actuator lock control circuit for a
short to ground or an open. Refer to Circuit Testing
7
Inspect for poor connections at the endgate lock
actuators. Refer to Testing for Intermittent
Inspect for poor connections at the body control
module (BCM). Refer to Testing for Intermittent
Replace the appropriate endgate lock actuator. Refer to
10 Latch Replacement - Endgate in Body Rear End. -
11 -
12
AUTOMATIC DOOR LOCKS INOPERATIVE
Automatic Door Locks Inoperative

Step Action Yes No
Connector End View Reference: Power Door Systems Connector End Views or
Computer/Integrating Systems Connector End Views in Computer/Integrating Systems
1
Vehicle in Vehicle
Verify that the automatic door locks inoperative fault Go to Testing for
is present. Intermittent
2 Do the automatic door locks operate normally? Conditions and
Poor Connections
3 3. With a scan tool, observe the current automatic
door lock mode in Personalization. Go to Vehicle
Personalization in
Is the correct automatic door lock mode selected? Go to Step 4 Personalization
Do the power door locks operate normally? Go to Symptoms -
4
Go to Step 5 Doors
2. With a scan tool, observe the driver door open,
the Passenger Door Open and Rear Door Open
Switch parameters in the body control module
(BCM) data list.
5
Does the scan tool display Closed for the driver or
passenger door open switches, or Inactive for the rear
door open switch? Go to Step 7 Go to Step 6
Test the secondary door latch switch signal circuit of
the appropriate door lock harness connector for a short
6 to ground. Refer to Circuit Testing and Wiring
of the appropriate door lock. Refer to Testing for
9
Replace the appropriate door lock. Refer to Lock
Replacement - Front Door orLock Replacement -
10
Rear Door.
11
POWER MIRRORS INOPERATIVE (AZTEK)
Diagnostic Aids
If the power mirror system fuse is open and a short to ground in the battery positive voltage circuit is not
detected, the fault could be a short to ground in one of the power mirror control circuits. This would open
the power mirror system fuse when the mirror switch is pressed.
If both power mirrors are inoperative on one or more axis, the most probable cause is a power mirror
switch failure. However the fault could be an open circuit on two or more of the power mirror control
circuits.
The power mirror assembly is equipped with a pigtail harness and is not serviceable. If an internal open
or short is detected in the power mirror assembly, replace the power mirror assembly.
Test Description
6: This step tests the integrity of both the mirror control circuits and the power mirror switch. If both
power mirrors are inoperative on one or more axis, begin testing by disconnecting one of the power
mirrors, if an open circuit is detected and repaired for that power mirror, repeat step 6 for the other power
mirror.
7: This step tests the integrity of the battery positive voltage circuit not the fuse.
Power Mirrors Inoperative (Aztek)

Step Action Yes No
Did you review the Outside Mirror Description and Go to Symptoms -
1
Operation? Go to Step 2 Doors
1. Place the mirror selector switch in the LEFT
mirror position.
2. Activate the mirror position switch in the UP,
DOWN, LEFT and RIGHT directions and note
the operation.
2 3. Place the mirror selector switch in the RIGHT
mirror position.
4. Activate the mirror position switch in the UP, Go to Testing for
DOWN, LEFT and RIGHT directions and note Intermittent
the operation. Conditions and
Poor Connections
Do both power mirrors operate properly? in Wiring Systems Go to Step 3
Are both the left and right power mirrors completely
3
inoperative? Go to Step 4 Go to Step 6
1. Disconnect the power mirror switch.
4 power mirror switch harness connector with a

Connect a test lamp between the battery positive
voltage circuit of the power mirror switch harness
5 connector and the ground circuit of the power mirror
switch harness connector.
1. Disconnect the appropriate power mirror.
mirror motor control circuits of the power mirror
harness connector.
3. Place the mirror selector switch to the mirror to
be tested.
6
4. Activate the power mirror switch in both
directions for the functions being tested.
Does the test lamp illuminate in both directions? Go to Step 12 Go to Step 8

Test the battery positive voltage circuit of the power
mirror switch for a short to ground or an open. Refer to
Systems.
Test the mirror motor control circuits for an open.
8
Wiring Systems.
1. If the power mirror(s) were previously
disconnected, connect the power mirror(s).
2. If the power mirror switch was not previously
disconnected, disconnect the power mirror
switch.
9 3. Probe each of the power mirror motor control
circuits of the power mirror switch harness
connector with a test lamp that is connected to
Did the test lamp illuminate at any of the power mirror

motor control circuits? Go to Step 13 Go to Step 10
Probe each of the power mirror motor control circuits
of the power mirror switch harness connector with a
10 test lamp that is connected to a good ground.
of the power mirror switch. Refer to Testing for
of the power mirror(s). Refer to Testing for
Repair the short to ground in the power mirror motor
control circuit(s). Refer to Wiring Repairs in Wiring
13 Systems.
Repair the short to voltage in the power mirror motor
14
Systems.
Repair the open in the power mirror switch ground
15 circuit. Refer Wiring Repairs to in Wiring Systems.
Replace the power mirror switch. Refer to Power
Mirror Switch Replacement (Aztek) or Power
16
Mirror Switch Replacement (Rendezvous).
Replace the power mirror. Refer to Mirror
17 Replacement - Power.
18
POWER MIRRORS INOPERATIVE (RENDEZVOUS W/O A43)
Diagnostic Aids
If the power mirror system fuse is open and a short to ground in the battery positive voltage circuit is not
detected, the fault could be a short to ground in one of the power mirror control circuits. This would open
the power mirror system fuse when the mirror switch is pressed.
If both power mirrors are inoperative on one or more axis, the most probable cause is a power mirror
switch failure. However the fault could be an open circuit on two or more of the power mirror control
circuits.
The power mirror assembly is equipped with a pigtail harness that is not serviceable. If an open or short
circuit is detected in the power mirror assembly pigtail harness, replace the power mirror assembly.
Test Description
5: This step tests the integrity of both the mirror control circuits to the power mirror motor and the power
mirror switch. If both power mirror motors are inoperative on one or more axis, begin testing by
disconnecting one of the power mirror motors, if an open circuit is detected and repaired for that power
mirror motor, repeat step 5 for the other power mirror motor.
7: This step tests the integrity of both the mirror control circuits to the power mirror assembly and the
power mirror switch. If both power mirror assemblies are inoperative on one or more axis, begin testing
by disconnecting one of the power mirror assemblies, if an open circuit is detected and repaired for that
power mirror assembly, repeat step 7 for the other power mirror assembly.
8: This step tests the integrity of the battery positive voltage circuit not the fuse.
Power Mirrors Inoperative (Rendezvous w/o A43)

Step Action Yes No
1
1. Place the mirror selector switch in the LEFT
mirror position.
2. Activate the mirror position switch in the UP,
DOWN, LEFT and RIGHT directions and note
the operation.
2 3. Place the mirror selector switch in the RIGHT
mirror position.
4. Activate the mirror position switch in the UP, Go to Testing for
DOWN, LEFT and RIGHT directions and note Intermittent
the operation. Conditions and
Poor Connections
Do both power mirrors operate properly? in Wiring Systems Go to Step 3
Are both the left and right power mirrors completely
3
1. Disconnect the power mirror switch.
4 power mirror switch harness connector with a

1. Disconnect the appropriate power mirror motor.
motor harness connector.
5 3. Place the mirror selector switch to the mirror to
be tested.

voltage circuit of the power mirror switch harness
6 connector and the ground circuit of the power mirror
switch harness connector.
1. Connect the appropriate power mirror motor.
2. Disconnect the appropriate power mirror
assembly.
7 assembly harness connector.
4. Place the mirror selector switch to the mirror to
be tested.

Test the battery positive voltage circuit of the power
mirror switch for a short to ground or an open. Refer to
Systems.
Test the mirror motor control circuits for an open.
9
Wiring Systems.
1. If the power mirror was previously disconnected,
connect the power mirror.
2. If the power mirror switch was not previously
disconnected, disconnect the power mirror
switch.
10 3. Probe each of the power mirror motor control
circuits of the power mirror switch harness
connector with a test lamp that is connected to

Probe each of the power mirror motor control circuits
of the power mirror switch harness connector with a
11 test lamp that is connected to a good ground.
of the power mirror motor. Refer to Testing for
of the power mirror assembly. Refer to Testing for
13
of the power mirror switch. Refer to Testing for
Repair the short to ground in the power mirror motor
15
Systems.
Repair the short to voltage in the power mirror motor
16
Systems.
Repair the open in the power mirror switch ground
17 circuit. Refer Wiring Repairs to in Wiring Systems.
Replace the power mirror motor. Refer to Motor
18 Replacement - Power Mirror.
Replace the power mirror assembly. Refer to Mirror
19 Replacement - Power.
Replace the power mirror switch. Refer to Power
Mirror Switch Replacement (Aztek) or Power
20
Mirror Switch Replacement (Rendezvous)
21
POWER MIRRORS INOPERATIVE (RENDEZVOUS W/A43)
Diagnostic Aids
An intermittent power mirrors inoperative fault may be caused by an open outside rearview mirror switch
ground circuit. When the outside rearview mirror switch ground circuit is open, the switch may seek a
ground path through the illumination ground circuit.
An intermittent driver outside rearview mirror malfunction may be caused by an open driver mirror motor
left control circuit. When the driver mirror motor left control circuit is open, the driver mirror motor may
seek an alternate circuit path through the passenger mirror motor.
An intermittent passenger outside rearview mirror malfunction may be caused by an open passenger
mirror motor left control circuit. When the passenger mirror motor left control circuit is open, the
passenger mirror motor may seek an alternate circuit path through the driver mirror motor.
Test Description
3: This step tests for an open in the outside rearview mirror switch ground circuit. If the mirror switch
ground circuit is open, turning on the headlamps will remove the alternate ground path through the
illumination ground circuit.
4: This step tests to see if the malfunction is on the switch side of the memory seat module (MSM), or the
mirror motor side.
7: This step tests for a short to ground in the mirror switch or motor control circuits.
8: This step tests for an open or short to ground in the mirror switch supply voltage circuit.
10: This step tests for an open or short to ground in the mirror motor.
11: This step tests for an open or short to ground in the mirror motor assembly.
Power Mirrors Inoperative (Rendezvous w/A43)

Step Action Yes No
Connector End Views
1
Vehicle in Vehicle
Verify the power mirrors inoperative fault is present.
2
Does the power mirrors system operate normally? Go to Step 3 Go to Step 4
1. Turn ON the headlamp switch. Go to Testing for
2. Verify the power mirrors inoperative fault is Intermittent
3 present. Conditions and
Poor Connections
Does the power mirrors system operate normally? in Wiring Systems Go to Step 13
3. With a scan tool, command the left and right
4 mirrors Up, Down, Right and Left.
Do the mirrors move Up, Down, Right and Left as

commanded? Go to Step 5 Go to Step 9
5 Are both power mirrors inoperative? Go to Step 7 Go to Step 6
Is the horizontal function the inoperative mirror
6
function? Go to Step 14 Go to Step 15
1. With a scan tool, observe the mirror switch state

in the memory seat module (MSM) data list.
2. Activate the left and right mirrors to the Up,
7 Down, Left and Right positions
Does the scan tool display Idle? Go to Step 8 Go to Step 16

2. Disconnect the outside rearview mirror switch.
3. Probe the mirror switch supply voltage circuit of
8 the outside rearview mirror switch with a test
lamp that is connected to a good ground.

9 Is the mirror operation intermittent? Go to Step 19 Go to Step 10
2. Disconnect the appropriate outside rearview
mirror motor.
10 mirror motor control circuits of the outside
rearview mirror motor harness connector.
4. Activate the outside rearview mirror switch in
both directions for the functions being tested.

1. Connect the appropriate outside rearview mirror
motor.
2. Disconnect the appropriate outside rearview
mirror assembly.
11 mirror motor control circuits of the outside
rearview mirror motor assembly harness
connector.
4. Activate the outside rearview mirror switch in
both directions for the functions being tested.

12 Is the mirror inoperative in a single direction? Go to Step 20 Go to Step 21
Test the ground circuit of the outside rearview mirror
switch for an open. Refer to Circuit Testing and
13
Test the appropriate mirror switch right signal circuit

14
of the outside rearview mirror switch for an open.
Refer to Circuit Testing andWiring Repairs in
Wiring Systems.
Test the appropriate mirror switch down signal circuit
of the outside rearview mirror switch for an open.
15 Refer to Circuit Testing andWiring Repairs in
Wiring Systems.
Test the appropriate mirror switch signal circuit or
mirror motor right/up control circuit of the outside
rearview mirror switch for a short to ground. Refer to
16
Systems.
Test the mirror motor right/up control circuit of the
outside rearview mirror switch for an open. Refer to
Systems.
Test the mirror switch supply voltage circuit of the
outside rearview mirror switch for an open or short to
18 ground. Refer to Circuit Testing and Wiring Repairs
in Wiring Systems.
Test the appropriate mirror motor left control circuit of
the appropriate mirror motor for an open. Refer to
Systems.
appropriate mirror motor for a short to ground. Refer
20 to Circuit Testing and Wiring Repairs in Wiring
Systems.
appropriate mirror motor for an open. Refer to Circuit
21
Testing andWiring Repairs in Wiring Systems.
of the appropriate outside rearview mirror motor. Refer
22
Systems.
of the appropriate outside rearview mirror. Refer to
23 Systems.
of the outside rearview mirror switch. Refer to Testing
of the MSM. Refer to Testing for Intermittent
Replace the outside rearview mirror motor. Refer to
26 Motor Replacement - Power Mirror.
Replace the outside rearview mirror assembly. Refer to
27 Mirror Replacement - Power.
Replace the outside rearview mirror switch. Refer to
Power Mirror Switch Replacement (Aztek) or
28
Power Mirror Switch Replacement (Rendezvous).
29
30
POWER MIRRORS - MIRROR TILT INOPERATIVE IN REVERSE
Power Mirrors - Mirror Tilt Inoperative in Reverse

Step Action Yes No
Connector End Views
1
Vehicle in Vehicle
Verify that the power mirrors mirror tilt in reverse
fault is present. Go to Testing for
2 Does the mirror tilt in reverse operate normally? Intermittent
Conditions and
Poor Connections
Verify that the tilt mirror option is ON. Refer to Go to Driver
3 Driver Personalization in Personalization. Personalization in
Is the tilt mirror option ON? Go to Step 4 Personalization
Go to Power
Mirrors
Inoperative (Aztek)
or Power Mirrors
Inoperative
4 Do the power mirrors operate properly? (Rendezvous w/o
A43) or Power
Mirrors
Inoperative
(Rendezvous
Go to Step 5 w/A43)
of the memory seat module (MSM). Refer to Testing
6
7
HEATED MIRRORS INOPERATIVE
Heated Mirrors Inoperative

Step Action Yes No
1
Verify that the heated mirrors inoperative fault is present. Go to Testing for
Do the heated mirrors operate properly? Intermittent
2 Conditions and
Poor Connections
Does the rear window defogger operate properly? Go to Symptoms -
Stationary
3 Windows in
Stationary
Go to Step 4 Windows
Test the heated mirror/rear defog relay coil supply
voltage circuit of the appropriate outside rearview mirror
harness connector for a short to ground or an open. Refer
4
to Circuit Testing and Wiring Repairs in Wiring
Systems.
Test the ground circuit of the appropriate outside
rearview mirror harness connector for an open. Refer to
5
Circuit Testing and Wiring Repairs in Wiring Systems.
the appropriate outside rearview mirror. Refer to Testing
6 for Intermittent Conditions and Poor Connections and
Replace the appropriate outside rearview mirror face.
7 Refer to Mirror Face Replacement.
8
REPAIR INSTRUCTIONS
POWER WINDOW SWITCH REPLACEMENT - LEFT FRONT (AZTEK)
Removal Procedure
Fig. 14: View Of Front Door Lock Switch Plate (Aztek)
1. Remove the front door lock switch plate from the front door trim panel using a small flat-bladed tool at
the front of the power window control switch.
2. Disconnect the electrical connector from the front door window control switch.
3. Remove the front door window control switch from the front door trim panel.
4. Remove the front door window control switch (2) from the front door window switch plate using a small
flat-bladed tool.
1. Install the front door window control switch (2) into the front door window switch plate.
2. Connect the electrical connectors to the front door window control switch.
3. Install the front door window control switch plate to the front door panel pressing into place until fully
seated.
POWER WINDOW SWITCH REPLACEMENT - LEFT FRONT (RENDEZVOUS)
Removal Procedure
Fig. 16: Identifying Front Door Trim Panel Switch Plate (Rendezvous)
1. Use a small flat-bladed tool at the front of the power window switch in order to remove the switch plate
from the front door trim panel
Fig. 17: View Of LF Switch Plate Electrical Connectors (Rendezvous)
2. Disconnect the electrical connector from the power window switch.

3. Remove the power window switch from the front door trim panel.
Fig. 18: Identifying Front Door Switch Plate (Rendezvous)
4. Use a small flat-bladed tool in order to remove the power window switch from the switch plate
1. Install the power window switch into the power window switch plate.
2. Connect the electrical connectors to the power window switch.

3. Install the power window switch plate to the front door trim panel. Press the plate into place until fully
seated.
POWER WINDOW SWITCH REPLACEMENT - RIGHT FRONT (AZTEK)
Removal Procedure
Fig. 22: Locating RF Power Window Switch (Aztek)
1. Remove the front door window switch plate from the front door trim panel using a small flat-bladed tool
at the front of the power window control plate.
2. Disconnect the electrical connector from the front door window control switch.
3. Remove the front door window control switch plate from the front door trim panel.
4. Remove the front door window control switch (1) from the front door window switch plate using a small
flat-bladed tool.
Fig. 23: Locating RF Power Window Switch (Aztek)
1. Install the front door window control switch (1) into the front door window switch plate pressing into
place until fully seated.
2. Connect the electrical connectors to the front door window control switch.
3. Install the front door window control switch plate to the front door panel pressing into place until fully
seated.
POWER WINDOW SWITCH REPLACEMENT - RIGHT FRONT (RENDEZVOUS)
Removal Procedure
Fig. 24: View Of RF Power Window Switch (Rendezvous)
1. Use a small flat-bladed tool at the front of the power window control plate in order to remove the switch
plate from the front door trim panel
2. Disconnect the electrical connector from the power window switch.
3. Remove the power window switch plate from the front door trim panel.
4. Use a small flat-bladed tool in order to remove the power window switch from the switch plate
Fig. 25: View Of RF Power Window Switch (Rendezvous)

1. Install the power window switch into the power window switch plate. Press the switch into place until
fully seated.
2. Connect the electrical connectors to the power window switch.
3. Install the power window switch plate to the front door panel. Press the plate into place until fully seated.
POWER WINDOW SWITCH REPLACEMENT - REAR DOOR (AZTEK)
Removal Procedure
Fig. 26: View Of Rear Door Power Window Switch (Aztek)

IMPORTANT: Protect the trim panel at the point of insertion of the flat bladed tool to
avoid damaging the door panel.
1. Remove the power window switch mounting plate using a small flat-bladed tool.
Insert the tool at the rear of the switch mounting plate releasing the switch plate retainer.
2. Lift the rear of the switch plate.
3. Disconnect the electrical connector.
4. Remove the power window switch (1) from the mounting plate.
Fig. 27: View Of Rear Door Power Window Switch (Aztek)

1. Install the power window switch (1) to the mounting plate.

2. Connect the electrical connector.
3. Insert the front of the mounting plate into the trim panel.
4. Press down on the rear of the mounting plate until the plate is fully seated.
POWER WINDOW SWITCH REPLACEMENT - REAR DOOR (RENDEZVOUS)
Removal Procedure
Fig. 28: Identifying Rear Door Power Window Switch (Rendezvous)

IMPORTANT: Protect the trim panel at the point of insertion of the flat bladed tool to
avoid damaging the door panel.
1. Use a small flat-bladed tool to remove the mounting plate for the power window switch. Insert the tool at
the rear of the mounting plate and release the retainer.
Fig. 29: Locating Rear Of Switch Plate (Rendezvous)
2. Lift the rear of the switch plate.

Fig. 30: View Of Rear Door Power Window Switch Electrical Connector (Rendezvous)

4. Remove the power window switch from the mounting plate.
Fig. 31: View Of Rear Door Power Window Switch Electrical Connector (Rendezvous)
1. Install the power window switch to the mounting plate.

Fig. 32: Locating Rear Of Switch Plate (Rendezvous)
3. Insert the front of the mounting plate into the trim panel.
Fig. 33: Identifying Rear Door Power Window Switch (Rendezvous)
4. Press down on the rear of the mounting plate until the plate is fully seated.
POWER DOOR LOCK SWITCH REPLACEMENT (AZTEK)
Removal Procedure
1. Remove the front door lock switch plate from the front door trim panel using a small flat-bladed tool at
the front of the power window control switch.
2. Disconnect the electrical connector from the front door lock control switch.
3. Remove the front door lock control switch (1) from the front door trim panel.
4. Remove the front door lock control switch from the front door lock switch plate using a small flat-bladed
tool.
1. Install the front door lock control switch (1) into the front door lock switch plate.
2. Connect the electrical connectors to the front door lock control switch.
3. Install the front door lock control switch plate into the front door panel pressing into place until fully
seated.
POWER DOOR LOCK SWITCH REPLACEMENT (RENDEZVOUS)
Removal Procedure
Fig. 36: View Of Power Door Lock Switch (Rendezvous)
1. Remove the door trim panel. Refer to Trim Panel Replacement - Side Front Door (Aztek) or Trim
Panel Replacement - Side Front Door (Rendezvous).
2. Use a small flat-bladed tool to release the clips at the top and the bottom of the door lock switch.
3. Disconnect the electrical connector from the switch.
4. Remove the switch.
Fig. 37: View Of Power Door Lock Switch (Rendezvous)
1. Install the door lock switch to the trim panel. Press the switch into place until fully seated.
2. Connect the electrical connector to the door lock switch.
3. Install the door trim panel. Refer to Trim Panel Replacement - Side Front Door (Aztek) or Trim Panel
Replacement - Side Front Door (Rendezvous).
4. Test the lock switch for proper operation.
POWER MIRROR SWITCH REPLACEMENT (AZTEK)

Removal Procedure
Fig. 38: Identifying Power Mirror Switch Electrical Connector (Aztek)

1. Remove the front door trim panel. Refer to Trim Panel Replacement - Side Front Door (Aztek) or
Trim Panel Replacement - Side Front Door (Rendezvous).
2. Disconnect the electrical connector from the power mirror switch.
Fig. 39: Locating Power Mirror Switch
3. Remove the power mirror switch from the front door inner trim panel.
Fig. 40: Locating Power Mirror Switch
1. Install the power mirror switch to the front door inner trim panel, pressing into place until fully seated.
Fig. 41: Identifying Power Mirror Switch Electrical Connector (Aztek)
2. Connect the electrical connectors to the power mirror switch.

3. Install the front door trim panel. Refer to Trim Panel Replacement - Side Front Door (Aztek) or Trim
POWER MIRROR SWITCH REPLACEMENT (RENDEZVOUS)

Removal Procedure
1. Use a small flat-bladed tool in order to remove the switch plate from the front door trim panel
2. Disconnect the electrical connectors from the switch plate.

3. Use a small flat-bladed tool in order to remove the power mirror switch from the switch plate
1. Install the power mirror switch into the switch plate.

2. Connect the electrical connectors to the switch plate.

3. Install the switch plate to the front door trim panel. Press the plate into place until fully seated.
TRIM PANEL REPLACEMENT - SIDE FRONT DOOR (AZTEK)
Tools Required
Removal Procedure
Fig. 48: View Of Front Door Trim Panel Screws (Aztek)
1. Open the door.

2. Remove the power window switch assembly. Refer to Power Window Switch Replacement - Left
Front (Aztek) or Power Window Switch Replacement - Left Front (Rendezvous) or Power Window
Switch Replacement - Right Front (Aztek) or Power Window Switch Replacement - Right Front
(Rendezvous).
3. Remove the screws from the front door trim panel
Fig. 49: View Of Inner Door (Aztek)
4. Remove the front door trim panel using the J 38778 .

5. Remove the power mirror switch. Refer to Power Mirror Switch Replacement (Aztek) or Power
Mirror Switch Replacement (Rendezvous) if equipped.
6. Reposition the electrical harness connectors.
7. Remove the front door trim panel from the vehicle.
Fig. 50: View Of Inner Door (Aztek)
IMPORTANT: Before installing the front door trim panel to the front door inner panel,
the old trim panel retainers MUST be discarded and replaced with NEW
trim panel retainers.
1. Install the new trim panel retainers to the front door trim panel.
2. Route the electrical connectors to the front door trim panel.
3. Install the power mirror switch. Refer to Power Mirror Switch Replacement (Aztek) or Power Mirror
Switch Replacement (Rendezvous) if equipped.
4. Align the front door trim panel to the front door inner panel, guiding the front door handle through the
trim panel.
5. Install the upper edge of the front door trim panel to the top edge of the inner door panel, pressing down
firmly until the front door trim panel is fully seated.
6. Install the front door trim panel by firmly pressing the retainer clips until the clips are fully seated around
the perimeter of the front door trim panel.
Fig. 51: View Of Front Door Trim Panel Screws (Aztek)

7. Install the screws to the front door trim panel.
Tighten: Tighten the front door trim panel screws to 2 N.m (18 lb in).
8. Install the power window switch. Refer to Power Window Switch Replacement - Left Front (Aztek) or
Power Window Switch Replacement - Left Front (Rendezvous) or Power Window Switch
Replacement - Right Front (Aztek) or Power Window Switch Replacement - Right Front
(Rendezvous).
TRIM PANEL REPLACEMENT - SIDE FRONT DOOR (RENDEZVOUS)
Tools Required
Removal Procedure
Fig. 52: Identifying Door Trim Screws (Rendezvous)
1. Open the door.

2. Disconnect the power window switch assembly. Refer to Power Window Switch Replacement - Left
Front (Aztek) or Power Window Switch Replacement - Left Front (Rendezvous) or to Power
Window Switch Replacement - Right Front (Aztek) or Power Window Switch Replacement - Right
Front (Rendezvous).
3. Remove the screws from the front door trim panel
4. Use the J 38778 to remove the trim panel.
1. Reposition the electrical harness connectors.
2. Remove the trim panel from the vehicle.
IMPORTANT: Before installing the front door trim panel, discard the old trim panel
retainers and replace with NEW trim panel retainers.
1. Install the new retainers to the front door trim panel.

2. Route the electrical connectors through the trim panel.
3. Align the trim panel to the door inner panel, guiding the door handle through the trim panel.
4. Install the upper edge of the trim panel to the top edge of the inner door panel, pressing down firmly until
the trim panel is fully seated.
5. Install the trim panel by firmly pressing the retainer clips until the clips are fully seated around the
perimeter of the trim panel.

6. Install the screws to the front door trim panel.
7. Connect the power window switch. Refer to Power Window Switch Replacement - Left Front (Aztek)
or Power Window Switch Replacement - Left Front (Rendezvous) or to Power Window Switch
Replacement - Right Front (Aztek) or Power Window Switch Replacement - Right Front
(Rendezvous).
TRIM PANEL REPLACEMENT - SIDE REAR DOOR (AZTEK)
Tools Required
Removal Procedure
Fig. 54: Locating Rear Door Trim Panel Screws (Aztek)
1. Remove the power window switch. Refer to Power Window Switch Replacement - Rear Door (Aztek)
or Power Window Switch Replacement - Rear Door (Rendezvous).
2. Remove the power door lock switch (if equipped). Refer to Power Door Lock Switch Replacement
(Aztek) or Power Door Lock Switch Replacement (Rendezvous)
3. Remove the screws from the rear door trim panel.
Fig. 55: View Of Inner Rear Door (Aztek)

4. Remove the rear door trim panel using J 38778 .

5. Disconnect and reroute any electrical harness or connectors.
6. Remove the rear door trim panel from the vehicle.
IMPORTANT: Before installing the rear door trim panel to the rear door inner panel, the
old trim panel retainers MUST be discarded and replaced with NEW trim
panel retainers.
Fig. 56: View Of Inner Rear Door (Aztek)

1. Install the new trim panel retainers to the rear door trim panel.
2. Connect and route the electrical connectors through the openings in the rear door trim panel.
3. Align the rear door trim panel to the rear door inner panel, guiding the rear door handle through the trim
panel.
4. Install the upper edge of the rear door trim panel to the top edge of the inner door panel, pressing down
firmly until the rear door trim panel is fully seated.
5. Install the rear door trim panel pressing firmly until the retainer clips are fully seated around the perimeter
of the trim panel.

Fig. 57: Locating Rear Door Trim Panel Screws (Aztek)
6. Install the screws to the rear door trim panel.
Tighten: Tighten the rear door trim panel screws to 6 N.m (53 lb in).
7. Install the power door lock switch (if equipped). Refer to Power Door Lock Switch Replacement
(Aztek) or Power Door Lock Switch Replacement (Rendezvous).
8. Install the power window switch. Refer to Power Window Switch Replacement - Rear Door (Aztek) or
Power Window Switch Replacement - Rear Door (Rendezvous).
TRIM PANEL REPLACEMENT - SIDE REAR DOOR (RENDEZVOUS)
Tools Required
Removal Procedure

1. Remove the power window switch. Refer to Power Window Switch Replacement - Rear Door (Aztek)
or Power Window Switch Replacement - Rear Door (Rendezvous).
2. Remove the screws from the rear door trim panel.
3. Use J 38778 in order to remove the rear door trim panel.
4. Disconnect and reroute any electrical harness or connectors.
5. Remove the rear door trim panel.
IMPORTANT: Before installing the rear door trim panel, discard the old trim panel
retainers and replace with NEW trim panel retainers.

1. Install the new trim panel retainers to the rear door trim panel.
2. Connect and route the electrical connectors through the openings in the trim panel.
3. Align the trim panel to the inner panel, guiding the door handle through the trim panel.
4. Install the upper edge of the trim panel to the top edge of the inner door panel. Press down firmly until the
trim panel is fully seated.
5. Install the trim panel pressing firmly until the retainer clips are fully seated around the perimeter of the
trim panel.
6. Install the screws to the rear door trim panel.
7. Install the power window switch. Refer to Power Window Switch Replacement - Rear Door (Aztek) or
Power Window Switch Replacement - Rear Door (Rendezvous).
REFLECTOR REPLACEMENT - FRONT DOOR WARNING (AZTEK)
Removal Procedure
Fig. 60: View Of Reflector (Aztek)
1. Open the front door.

2. Apply protective coating/tape at the point of insertion of the flat bladed tool.
3. Remove the warning reflector from the front door trim panel using a small flat bladed tool, pressing on
the tabs from the top of the warning reflector.
Fig. 61: Identifying Warning Reflector
4. Remove the warning reflector from the front door trim panel.
1. Position the warning reflector to the front door trim panel.

Fig. 63: Installing Warning Reflector
2. Install the warning reflector into the front door trim panel pressing in until fully seated.
3. Remove the protective coating/tape from the point of insertion.
4. Close the front door.
REFLECTOR REPLACEMENT - FRONT DOOR WARNING (RENDEZVOUS)
Removal Procedure
Fig. 64: View Of Warning Reflector (Rendezvous)

3. Remove the warning reflector from the front door trim panel using a small flat bladed tool, pressing on
the tabs from the top of the warning reflector.
4. Remove the warning reflector from the front door trim panel.

1. Position the warning reflector to the front door trim panel.

2. Install the warning reflector into the front door trim panel pressing in until fully seated.
REFLECTOR REPLACEMENT - REAR DOOR WARNING (AZTEK)
Removal Procedure
Fig. 66: View Of Reflector (Aztek)

1. Open the rear door.

3. Remove the warning reflector from the rear door trim panel using a small flat bladed tool, pressing on the
tabs from the top of the warning reflector.
4. Remove the warning reflector from the rear door trim panel.
1. Position the warning reflector to the rear door trim panel.

Fig. 69: Installing Warning Reflector
2. Install the warning reflector into the rear door trim panel pressing in until fully seated.
4. Close the rear door.
REFLECTOR REPLACEMENT - REAR DOOR WARNING (RENDEZVOUS)
Removal Procedure

2. Apply protective tape at the point of insertion of the flat-bladed tool.
3. Use a small flat-bladed tool to remove the warning reflector from the rear door trim panel. Press on the
tabs from the top of the warning reflector.

1. Position the warning reflector to the rear door trim panel. Press on the reflector until fully seated.
2. Remove the protective tape from the point of insertion.
WATER DEFLECTOR REPLACEMENT - FRONT DOOR
Removal Procedure
Fig. 72: View Of Water Deflector

2. Remove the front door water deflector from the front door inner panel.
3. Remove the gasket from the inside door handle if equipped.
4. Pull the electrical connectors through the slit in the door handle cut out.
Fig. 73: View Of Water Deflector
1. Align the front door water deflector to the front door inner panel.
Secure the water deflector at the corners.
2. Pull the front door electrical connectors through the slit in the door handle cut out.
3. Install the front door water deflector, start pressing the adhesive pattern at the bottom center and working
outward and upward in order to prevent puckering.
4. Install the gasket to the inside door handle if equipped.
WATER DEFLECTOR REPLACEMENT - REAR DOOR
Removal Procedure
Fig. 74: Identifying Water Deflector
2. Remove the gasket from the inside door handle if equipped.
3. Remove the front door water deflector from the front door inner panel.
4. Pull the electrical connectors through the slit in the door handle cut out.
Fig. 75: Identifying Water Deflector

1. Align the front door water deflector to the front door inner panel.
Secure the water deflector at the corners.
2 Pull the front door electrical connectors through the slit in the door handle cut out
3. Install the front door water deflector, start pressing the adhesive pattern at the bottom center and working
outward and upward in order to prevent puckering.
4. Install the gasket to the inside door handle if equipped.
DOOR ADJUSTMENT
Fig. 76: Locating Door Hinge Bolts
1. Open the front door in order to access the rear door hinge bolts.
IMPORTANT: Do not remove the rear door hinge bolts.
2. Loosen the rear door side hinge bolts.

3. Pry off the washer from the lower bolt on the lower hinge.
4. Adjust the rear door up or down and in and out as required.
5. Tighten the door side hinge bolts.
Tighten: Tighten the rear door hinge to door bolts to 30 N.m (22 lb ft).
DOOR REPLACEMENT - FRONT
Removal Procedure
2. Remove the water deflector. Refer to Water Deflector Replacement - Front Door.
3. Remove the outside rearview mirror. Refer to Mirror Replacement - Power.
4. Remove the outer belt sealing strip. Refer to Sealing Strip Replacement - Front Door Window Belt
Outer.
5. Remove the inner belt sealing strip. Refer to Sealing Strip Replacement - Front Door Window Belt
Inner.
6. Remove the window. Refer to Window Replacement - Front Door.
7. Remove the frame applique. Refer to Door Frame Applique Replacement - Front.
8. Remove the window regulator. Refer to Window Regulator Replacement - Front Door.
9. Remove the outside door handle. Refer to Door Handle Replacement - Front Outside.
10. Remove the inside handle. Refer to Door Handle Replacement - Front Inside.
11. Remove the lock. Refer to Lock Replacement - Front Door.
12. Remove the window weatherstrip. Refer to Weatherstrip Replacement - Front Door Window.
13. Remove the rubber conduit. Refer to Rubber Conduit Replacement - Front Door.
14. Remove the wiring harness. Refer to Wiring Harness Replacement - Front Door.
15. Remove the body side moldings. Refer to Molding Replacement - Front Door Body Side (Aztek) or
Molding Replacement - Front Door Body Side (Rendezvous) in Exterior Trim.
16. Support the front door.

17. Remove the bolt from the upper hinge keeper strap.
IMPORTANT: Do not dislodge the washer on the lower hinge.
18. Remove the bolts from the front lower door hinge side.
19. With an assistant, lift off the front door from the upper hinge.
20. Remove the side hinge. Refer to Hinge Replacement - Front Door.
1. Install the front door side hinge. Refer to Hinge Replacement - Front Door.
2. With an assistant, lower the front door onto the body side strap of the upper door hinge.

3. With an assistant, install the front lower door hinge side bolts.
Tighten: Tighten the front lower door hinge side bolts to 30 N.m (22 lb ft).
4. With an assistant, install the keeper strap bolt of the upper door hinge.
Tighten: Tighten the keeper strap bolt to 10 N.m (89 lb in).
5. Install the wiring harness. Refer to Wiring Harness Replacement - Front Door.
6. Install the rubber conduit. Refer to Rubber Conduit Replacement - Front Door.
7. Install the body side moldings. Refer to Molding Replacement - Front Door Body Side (Aztek) or
Molding Replacement - Front Door Body Side (Rendezvous) in Exterior Trim.
8. Install the window weatherstrip. Refer to Weatherstrip Replacement - Front Door Window.
9. Install the lock. Refer to Lock Replacement - Front Door.
10. Install the inside door handle. Refer to Door Handle Replacement - Front Inside.
11. Install the outside door handle. Refer to Door Handle Replacement - Front Outside.
12. Install the window regulator. Refer to Window Regulator Replacement - Front Door.
13. Install the frame applique. Refer to Door Frame Applique Replacement - Front.
14. Install the window. Refer to Window Replacement - Front Door.
15. Install the outer belt sealing strip. Refer to Sealing Strip Replacement - Front Door Window Belt
Outer.
16. Install the inner belt sealing strip. Refer to Sealing Strip Replacement - Front Door Window Belt
Inner.
17. Install the outside rear view mirror. Refer to Mirror Replacement - Power.
18. Install the water deflector. Refer to Water Deflector Replacement - Front Door.
19. Install the trim panel. Refer to Trim Panel Replacement - Side Front Door (Aztek) or Trim Panel
20. Inspect the front door for proper operation and alignment. Refer to Door Adjustment.
DOOR REPLACEMENT - REAR
Removal Procedure
1. Remove the rear door trim panel. Refer to Trim Panel Replacement - Side Rear Door (Aztek) or Trim
Panel Replacement - Side Rear Door (Rendezvous).
2. Remove the water deflector. Refer to Water Deflector Replacement - Rear Door.
3. Remove the outer belt sealing strip. Refer to Sealing Strip Replacement - Rear Door Window Belt
Outer.
4. Remove the inner belt sealing strip. Refer to Sealing Strip Replacement - Rear Door Window Belt
Inner.
5. Remove the window. Refer to Window Replacement - Rear Door.
6. Remove the frame applique. Refer to Door Frame Applique Replacement - Rear.
7. Remove the window regulator. Refer to Window Regulator Replacement - Rear Door.
8. Remove the outside door handle. Refer to Door Handle Replacement - Rear Outside.
9. Remove the inside door handle. Refer to Door Handle Replacement - Rear Inside.
10. Remove the lock. Refer to Lock Replacement - Rear Door.
11. Remove the window weatherstrip. Refer to Weatherstrip Replacement - Rear Door Window.
12. Remove the rubber conduit. Refer to Rubber Conduit Replacement - Rear Door.
13. Remove the wiring harness. Refer to Wiring Harness Replacement - Rear Door.
14. Remove the body side moldings. Refer to Molding Replacement - Rear Door Body Side (Aztek) or
Molding Replacement - Rear Door Body Side (Rendezvous) in Exterior Trim.
Fig. 79: Identifying Rear Door Hinge Bolts
15. Support the rear door.

16. Remove the bolt from the upper hinge keeper strap.
IMPORTANT: Do not dislodge the washer on the lower hinge.
17. Remove the bolts from the lower door hinge side.
18. With the help of an assistant, remove the rear door from the upper hinge.
19. Remove the upper hinge from the rear door. Refer to Hinge Replacement - Rear Door.
1. Install the upper rear door hinge to the door. Refer to Hinge Replacement - Rear Door.
Fig. 80: Identifying Rear Door Hinge Bolts

2. With the aid of an assistant, lower the rear door onto the body side strap of the upper door hinge.
3. With the aid of an assistant, install the lower rear door hinge side bolts.
Tighten: Tighten the lower rear door hinge side bolts to 30 N.m (22 lb ft).
4. With the aid of an assistant, install the keeper strap bolt to the rear upper door hinge.
Tighten: Tighten the keeper strap bolt to 10 N.m (89 lb in).
5. Install the wiring harness. Refer to Wiring Harness Replacement - Rear Door.
6. Install the rubber conduit. Refer to Rubber Conduit Replacement - Rear Door.
7. Install the body side moldings. Refer to Molding Replacement - Rear Door Body Side (Aztek) or
Molding Replacement - Rear Door Body Side (Rendezvous) in Exterior Trim.
8. Install the window weatherstrip. Refer to Weatherstrip Replacement - Rear Door Window.
9. Install the door lock. Refer to Lock Replacement - Rear Door.
10. Install the inside door handle. Refer to Door Handle Replacement - Rear Inside.
11. Install the outside door handle. Refer to Door Handle Replacement - Rear Outside.
12. Install the window regulator. Refer to Window Regulator Replacement - Rear Door.
13. Install the door frame applique. Refer to Door Frame Applique Replacement - Rear.
14. Install the window. Refer to Window Replacement - Rear Door.
15. Inner the outer belt sealing strip. Refer to Sealing Strip Replacement - Rear Door Window Belt Outer.
16. Inner the inner belt sealing strip. Refer to Sealing Strip Replacement - Rear Door Window Belt Inner.
17. Install the water deflector. Refer to Water Deflector Replacement - Rear Door.
18. Install the trim panel. Refer to Trim Panel Replacement - Side Rear Door (Aztek) or Trim Panel
Replacement - Side Rear Door (Rendezvous).
19. Inspect the rear door for proper operation and alignment. Refer to Door Adjustment.
HINGE REPLACEMENT - FRONT DOOR
Removal Procedure
Fig. 81: View Of Body Side Door Hinge Bolts
IMPORTANT: In order to minimize door realignment, do not remove both door hinges at
the same time. Replace the broken door hinge first.
1 Open the front door

2. Clean the mounting surfaces of the hinges with a clean rag and mark the front door hinge locations on
each surface with a grease pencil or other suitable marker.
3. Support the front door.
4. Remove the bolts from the body side door hinge.
Fig. 82: Identifying Door Side Door Hinge Bolts

5. Remove the bolts from the door side door hinge.
6. Remove the door hinge from the vehicle.
Fig. 83: View Of Body Side Door Hinge Bolts

1. Position the front door hinge to the alignment marks.
2. Install the bolts to the body side door hinge.
Tighten: Tighten the bolts to the body side door hinge to 25 N.m (18 lb ft).
Fig. 84: Identifying Door Side Door Hinge Bolts
3. Install the bolts to the door side door hinge.
Tighten: Tighten the bolts to the door side door hinge to 25 N.m (18 lb ft).
4. Remove the support from the front door.

5. Inspect the door for proper operation and alignment. Refer to Door Adjustment.
HINGE REPLACEMENT - REAR DOOR
Removal Procedure
Fig. 85: Locating Door Side Rear Door Hinge Bolts

IMPORTANT: Complete this procedure with the rear door closed at all times. Replace
the broken door hinge first.

2. Clean the mounting surfaces with a clean rag and mark the rear door hinge locations on each surface with
a grease pencil or other suitable marker.
3. Remove the bolts from the door side rear door hinge.
Fig. 86: Body Side Rear Door Hinge Bolts View
4. Remove the bolts from the body side rear door hinge.
5. Remove the rear door hinge from the vehicle.
Fig. 87: Body Side Rear Door Hinge Bolts View
1. Position the rear door hinge to the alignment marks.

2. Install the bolts to the body side rear door hinge.
Tighten: Tighten the body side rear door hinge bolts to 35 N.m (25 lb ft).
Fig. 88: Locating Door Side Rear Door Hinge Bolts

3. Install the bolts to the door side rear door hinge.

Tighten: Tighten the door side rear door hinge bolts to 35 N.m (25 lb ft).

5. Inspect the rear door for proper operation and alignment. Refer to Door Adjustment.
DOOR HANDLE REPLACEMENT - FRONT OUTSIDE
Removal Procedure
NOTE: Refer to Tape Corners of Panel Notice in Cautions and Notices.
1. Place tape around the handle to protect the paint.
IMPORTANT: The outside door handles have adjustable handle-to-lock rods. This
allows for adjustment of the amount of travel needed to operate the
outside door handle.
It is important to remove all free play between the outside handle and the
lock. Do NOT operate the outside handle before you have made these
adjustments.
Fig. 89: View Of Outside Door Handle Rod-To-Lock
4. Disconnect the outside door handle rod-to-lock.

Fig. 90: Removing Center Of Rivet With Punch
5. Remove the center of the rivets using a center punch.

Fig. 91: Removing Rivet With Drill
6. Drill out the rivet from the front outside door handle using a 6.35-mm (1/4-in) drill bit.
Fig. 92: View Of Door Handle
7. Remove the outside door handle from the front door.

8. Remove the outside door handle from the door handle rod.
1. Install the outside door handle to the door handle rod.

2. Position the handle to the front door.
Fig. 94: Identifying Rivets
3. Install the new rivets to the outside door handle.

Fig. 95: Outside Door Handle Rod-To-Lock Installed
4. Connect the outside door handle rod-to-lock.

6. Install the door trim panel. Refer to Trim Panel Replacement - Side Front Door (Aztek) or Trim Panel
7. Remove the tape from around the handle.
DOOR HANDLE REPLACEMENT - REAR OUTSIDE

Removal Procedure
NOTE: Refer to Tape Corners of Panel Notice in Cautions and Notices.
1. Place tape around the handle to protect the paint.
IMPORTANT: The outside door handles have adjustable handle-to-lock rods. This
allows for adjustment of the amount of travel needed to operate the
outside door handle.
It is important to remove all free play between the outside handle and the
lock. Do NOT operate the outside handle before you have made these
adjustments.
2. Remove the trim panel. Refer to Trim Panel Replacement - Side Rear Door (Aztek) or Trim Panel
4. Disconnect the outside door handle rod-to-lock.

Fig. 97: Removing Center Of Rivet With Punch

Fig. 98: Removing Rivet With Drill
6. Drill out the rivet from the outside door handle using a 6.35-mm (1/4-in) drill bit.
7. Remove the outside door handle from the rear door.

8. Remove the outside door handle from the door handle rod.
1. Install the outside door handle to the door handle rod.

2. Position the door handle to the rear door.
Fig. 101: Identifying Rivets
3. Install the new rivets to the outside door handle.

4. Connect the outside door handle rod-to-lock.

7. Remove the tape from around the handle.
DOOR HANDLE REPLACEMENT - FRONT INSIDE

Removal Procedure
2. Remove the front door water deflector. Refer to Water Deflector Replacement - Front Door.
Fig. 103: Punching Out Rivets


Fig. 104: Drilling Out Rivets
4. Drill out the rivet from the front inside door handle using a 6.35 mm (1/4 in) drill bit.
Fig. 105: View Of Lock Rod & Door Handle Rod
5. Remove the front inside door handle from the front door inner panel.
6. Remove the lock rod and door handle rod from the front inside door handle.
Fig. 106: View Of Lock Rod & Door Handle Rod
1. Install the front inside door handle by inserting the tabs into the rear door inner panel slots.
2. Install the lock rod and the door handle rod to the front inside door handle.
Fig. 107: Locating Rivet
3. Install the rivet to the front inside door handle.

4. Install the water deflector to the front inside door handle. Refer to Water Deflector Replacement -
Front Door.
DOOR HANDLE REPLACEMENT - REAR INSIDE
Removal Procedure
2. Remove the rear door water deflector. Refer to Water Deflector Replacement - Rear Door.
Fig. 108: Removing Rivets With A Center Punch


Fig. 109: Drilling Out Door Handle Rivet
4. Drill out the rivet from the rear inside door handle using a 6.35 mm (1/4 in) drill bit.
Fig. 110: Expanded View Of Door Handle
5. Remove the rear inside door handle from the rear door inner panel.
6. Remove the lock rod and door handle rod from the rear inside door handle.
Fig. 111: Expanded View Of Door Handle
1. Install the lock rod and the door handle rod to the rear inside door handle.
2. Install the rear inside door handle by inserting the tabs into the rear door inner panel slots.
Fig. 112: View Of Door Rivet
3. Install the rivet to the rear inside door handle.

4. Install the rear door water deflector. Refer to Water Deflector Replacement - Rear Door.
5. Install the rear door trim panel. Refer to Trim Panel Replacement - Side Rear Door (Aztek) or Trim
LOCK REPLACEMENT - FRONT DOOR
Removal Procedure
1. Remove the trim panel. Refer to Trim Panel Replacement - Side Front Door (Aztek) or Trim Panel
3. Remove the inside handle rods from the front door inside handle. Refer to Door Handle Replacement -
Front Inside.
4. Disconnect the clip securing the outside handle rod to the front door lock.
Fig. 114: Identifying Front Door Lock Screws
5. Remove the screws from the front door lock.

Fig. 115: Front Door Lock Electrical Connectors
6. Disconnect the electrical connectors from the lock.

Fig. 116: View Of Lock With The Inside Handle Rods
7. Remove the lock with the inside handle rods attached to the lock through the access hole in the front door
inner panel.
Fig. 117: Identifying Door Lock
8. Remove the inside handle rods from the lock.
Fig. 118: Identifying Door Lock
1. Install the inside handle rods to the lock.

Fig. 119: View Of Lock With The Inside Handle Rods
2. Install the lock in the position through the access hole in the front door inner panel.
3. Connect the electrical connectors to the front door lock.

4. Install the lock screws to the front door lock.
Tighten: Tighten the lock screws to 10 N.m (89 lb in).

5. Connect the clip securing the outside handle rod to the front door lock.
6. Install the door handle rods to the inside door handle. Refer to Door Handle Replacement - Front
Inside.
9. Inspect the door lock system for the proper operation.
LOCK REPLACEMENT - REAR DOOR
Removal Procedure
3. Remove the inside handle rods from the rear door inside handle. Refer to Door Handle Replacement -
Rear Inside.

4. Disconnect the clip securing the outside handle rod to the rear door lock.
5. Remove the screws from the rear door lock.

6. Disconnect the electrical connectors from the lock.

Fig. 126: View Of Door Lock With Inside Handle Rods
7. Remove the lock from the rear door with the inside handle rods attached to the lock through the access
hole in the inner panel.
Fig. 127: Identifying Inside Handle Rods
8. Remove the inside handle rods from the lock.
Fig. 128: Identifying Inside Handle Rods
1. Install the inside handle rods to the lock.

Fig. 129: View Of Door Lock With Inside Handle Rods
2. Install the lock in position through the access hole in the rear door inner panel.
3. Connect the electrical connectors to the rear door lock.

4. Install the lock screws to the rear door lock.
Tighten: Tighten the lock screws to 10 N.m (89 lb in).

5. Connect the clip securing the outside handle rod to the rear door lock.
6. Install the handle rods to the inside door handle. Refer to Door Handle Replacement - Rear Inside.
9. Inspect the door lock system for the proper operation.
LOCK ACTUATOR REPLACEMENT - FRONT DOOR
Removal Procedure
1. Remove the front door lock. Refer to Lock Replacement - Front Door.
Fig. 133: Door Lock, Actuator & Screws

2. Remove the front door lock to front door lock actuator screws.
3. Remove the front door actuator from the front door lock.

1. Align the front door actuator to the front door lock.

2. Install the front door lock to front door actuator screws.
Tighten: Tighten the front door actuator screws to 2 N.m (18 lb in).
3. Install the front door lock. Refer to Lock Replacement - Front Door.
LOCK ACTUATOR REPLACEMENT - REAR DOOR
Removal Procedure
1. Remove the rear door lock. Refer to Lock Replacement - Rear Door.
2. Remove the rear door lock to rear door lock actuator screws.
3. Remove the rear door actuator from the rear door lock.
1. Align the rear door actuator to the rear door lock.

2. Install the rear door lock to rear door actuator screws.
Tighten: Tighten the rear door actuator screws to 2 N.m (18 lb in).
3. Install the rear door lock. Refer to Lock Replacement - Rear Door.
LOCK CYLINDER REPLACEMENT - DOOR
Removal Procedure
Fig. 137: Front Door Lock Cylinder

1. Remove the front door panel. Refer to Trim Panel Replacement - Side Front Door (Aztek) or Trim
2. Remove the front door water deflector. Refer to Water Deflector Replacement - Front Door.
3. Disconnect the front door lock cylinder rod from the front door lock.
4. Remove the front door lock cylinder retainer from the front door lock cylinder.
5. Remove the front door lock cylinder from the front door lock cylinder hole with the lock cylinder rod.
6. Remove the lock cylinder rod from the front door lock cylinder.
Fig. 138: Front Door Lock Cylinder

1. Install the lock cylinder rod to the front door lock cylinder.
2. Install the front door lock cylinder into the front door lock cylinder hole with the lock cylinder rod.
3. Install the front door lock cylinder retainer to the front door lock cylinder.
4. Connect the front door lock cylinder rod to the front door lock.
5. Install the front door water deflector. Refer to Water Deflector Replacement - Front Door.
6. Install the front door panel. Refer to Trim Panel Replacement - Side Front Door (Aztek) or Trim
FROZEN LOCK CYLINDER REPAIR
Tools Required
J 25070 Heat Gun. See Special Tools.
IMPORTANT: Do not damage the painted surfaces while using the heat gun.
1. Apply heat to the cylinder area using J 25070 . See Special Tools.
2. Hold the shutter door open with a paper clip or similar item and force air into the cylinder using
compressed air and a blow gun attachment.
3. While holding the shutter door open inject a small amount of multi-purpose lubricant GM P/N 12346241
or equivalent.
4. Work the key into the cylinder several times and wipe any excess lubricant residue from the key.
DOOR STRIKER REPLACEMENT - FRONT DOOR
Removal Procedure
Fig. 139: View Of Door Striker Components
1. Remove the center pillar lower trim in order to gain access to the anchor plate. Refer to Trim Panel
Replacement - Lower Center Pillar .
2. Mark the position of the front door lock striker with a grease pencil.
3. Remove the screws from the front door lock striker.
4. Remove the front door lock striker and the shims.
5. Remove the anchor plate.
Fig. 140: View Of Door Striker Components
1. Install the anchor plate.

2. Install the front door lock shims and striker.
3. Install the lock striker screws.
4. Align the lock striker to the alignment marks.
Tighten: Tighten the lock striker screws to 24 N.m (18 lb ft).
5. Adjust the lock striker if required. Refer to Lock Striker Adjustment - Door.
6. Install the center pillar lower trim. Refer to Trim Panel Replacement - Lower Center Pillar .
DOOR STRIKER REPLACEMENT - REAR DOOR
Removal Procedure
Fig. 141: Locating Rear Door Striker
1. Remove the rear quarter lower trim in order to gain access to the anchor plate. Refer to Trim Panel
Replacement - Rear Quarter Lower (Aztek) or Trim Panel Replacement - Rear Quarter Lower
(Rendezvous) .
2. Mark the position of the rear door lock striker with a grease pencil.
3. Remove the screws from the lock striker.
4. Remove the lock striker and the shims.
5. Remove the anchor plate.
Fig. 142: Locating Rear Door Striker

1. Install the anchor plate.
2. Install the lock shims and striker.
3. Install the lock striker screws.
4. Align the lock striker to the alignment marks.
Tighten: Tighten the lock striker screws to 24 N.m (18 lb ft).
5. Adjust the lock striker if required. Refer to Lock Striker Adjustment - Door.
6. Install the rear quarter lower trim. Refer to Trim Panel Replacement - Rear Quarter Lower (Aztek) or
Trim Panel Replacement - Rear Quarter Lower (Rendezvous) .
LOCK STRIKER ADJUSTMENT - DOOR
Tools Required
J 39346 Mini-Wedge Door Striker Aligner
Mini-Wedge Door Striker Aligner Adjustment Procedure
IMPORTANT: Properly align the door before adjusting the striker.
1. Open the door.

Fig. 143: View Of Lock Striker Components
2. Loosen the striker screws just enough to allow the movement of the door striker.
3. Install J 39346 .
IMPORTANT: Do not slam the door.

4. Close the door while holding the outside the handle in the open position.
5. Open the door.
6. Install the striker screws.
Tighten: Tighten the striker screws to 24 N.m (18 lb ft).
7. Remove J 39346 .
8. Close the door.
Non Mini-Wedge Door Striker Adjustment Procedure
IMPORTANT: Properly align the door before adjusting the striker.
1. Open the door.

Fig. 144: View Of Lock Striker Components
2. Loosen the striker screws just enough to allow the movement of the door striker.
3. Adjust the door striker up or down and inboard or outboard as required.
4. Apply modeling clay or body caulking compound to the door lock opening.
IMPORTANT: Do not close the door all the way.

5. Close the door far enough for the striker to make an impression into the modeling clay or body caulking
compound.
6. Open the door and check the door striker impression in the modeling clay or body caulking compound.
7. Readjust striker and add spacers as required.
Tighten: Tighten the striker screws to 24 N.m (18 lb ft).
8. Close the door.
DOOR HARDWARE LUBRICATION

Fig. 145: View Of Door Hardware
The mechanical components of the door are lubricated during assembly. If additional lubrication is required to
any door hardware mechanism, lubricate with Lubriplate Spray-Lube GM P/N 1052349 or Canadian P/N
992723, Lubriplate Auto-Lube GM P/N 1052196 or Canadian P/N 5264008, or equivalent. Lubrication of the
door hinge roller is not recommended, lubricating the door hinge roller may allow the door hinge roller to slide
against the door check link contacting surfaces causing uneven wear to the door hinge roller.
WIRING HARNESS REPLACEMENT - FRONT DOOR
Removal Procedure
Fig. 146: View Of Front Door Wiring Harness
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure
(LA1) in Engine Electrical.
3. Remove the front door water deflector. Refer to Water Deflector Replacement - Front Door
4. Remove the front door rubber conduit from the front door. Refer to Rubber Conduit Replacement -
Front Door.
5. Disconnect the front door wiring harness connectors from all the accessories.
6. Disconnect the front door wiring harness rosebud retainers from the inner front door panel.
7. Remove the front door wiring harness from the front door.
Fig. 147: View Of Front Door Wiring Harness
1. Install the front door wiring harness to the front door.

2. Connect the front door wiring harness rosebud retainers to the inner front door panel.
3. Connect the front door wiring harness connectors to all the accessories.
4. Install the front door rubber conduit from the front door. Refer to Rubber Conduit Replacement - Front
Door.
5. Install the front door water deflector. Refer to Water Deflector Replacement - Front Door.
7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure
WIRING HARNESS REPLACEMENT - REAR DOOR
Removal Procedure
Fig. 148: Locating Rear Door Wiring Harness
1. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure
3. Remove the rear door water deflector. Refer to Water Deflector Replacement - Rear Door.
4. Remove the rear door rubber conduit from the rear door. Refer to Rubber Conduit Replacement - Rear
Door.
5. Disconnect the rear door wiring harness connectors from all the accessories.
6. Disconnect the rear door wiring harness rosebud retainers from the inner rear door panel.
7. Remove the rear door wiring harness from the rear door.
Fig. 149: Locating Rear Door Wiring Harness
1. Install the rear door wiring harness to the rear door.

2. Connect the rear door wiring harness rosebud retainers to the inner rear door panel.
3. Connect the rear door wiring harness connectors to all the accessories.
4. Install the rear door rubber conduit from the rear door. Refer to Rubber Conduit Replacement - Rear
Door.
5. Install the rear door water deflector. Refer to Water Deflector Replacement - Rear Door.
7. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure
WINDOW REGULATOR REPLACEMENT - FRONT DOOR
Removal Procedure
3. Disconnect the window from the window regulator carrier plate. Refer to Window Replacement - Front
Door.
Fig. 150: Identifying Window Regulator - Front Door
4. Position the window in the full up position and tape it to the window frame.
5. Disconnect the electrical connector from the window regulator motor.
6. Loosen the bolts on the window regulator motor.
7. Loosen the bolts on the window regulator rail.
8. Remove the front window regulator, lifting up and out from the key slots on the door inner panel and
through the rear access hole.
Fig. 151: Identifying Window Regulator - Front Door

1. Install the front window regulator bolts half way into the rear window regulator motor and the rail.
2. Position the front window regulator rail through the rear access hole first.
3. Position the front window regulator motor through the rear access hole.
4. Install the front window regulator into the key slots. Attach the regulator to the motor and the rail. Secure
the regulator with bolts.
Tighten: Tighten the bolts to 11N.m (97 lb in).
5. Remove the tape and position the front window to the regulator carrier plate.
6. Connect the window to the regulator carrier plate. Refer to Window Replacement - Front Door.
7. Connect the electrical connector to the front window regulator motor.
WINDOW REGULATOR REPLACEMENT - REAR DOOR
Removal Procedure
Fig. 152: Identifying Window Regulator Replacement - Rear Door
3. Remove the speaker. Refer to Speaker Replacement - Rear Door .
4. Disconnect the window from the regulator carrier plate. Refer to Window Replacement - Rear Door.
5. Position the window in the full up position and tape it to the window frame.
6. Disconnect the electrical connector from the window regulator motor.
7. Loosen the bolts on the window regulator motor.
8. Loosen the bolts on the window regulator rail.
9. Remove the window regulator, lifting up and out from the key slots on the rear door inner panel and
through the rear access hole.
Fig. 153: Identifying Window Regulator Replacement - Rear Door
1. Install the rear window regulator bolts half way into the rear window regulator motor and the rail.
2. Position the window regulator rail through the rear access hole first.
3. Position the window regulator motor through the rear access hole.
4. Install the window regulator into the key slots. Attach the regulator to the motor and the rail. Secure the
regulator with bolts.
Tighten: Tighten the bolts to 11N.m (97 lb in).
5. Remove the tape and position the rear window to the regulator carrier plate.
6. Connect the window to the regulator carrier plate. Refer to Window Replacement - Rear Door.
7. Connect the electrical connector to the rear window regulator motor.
8. Install the rear speaker. Refer to Speaker Replacement - Rear Door .
WINDOW REPLACEMENT - FRONT DOOR
Removal Procedure
Fig. 154: Identifying Clevice Clamp Bolts
1. Position the front door window in the full down position.

Outer.
5. Remove the window weatherstrip. Refer to Weatherstrip Replacement - Front Door Window.
6. Loosen the bolts (1) to the front and rear clevice clamps.
Fig. 155: View Of Window Glass
7. Remove the window from the outside of the front door.
Fig. 156: View Of Window Glass
1. Position the window between the inner and the outer door panels.
2. Point the lower front corner of the window down and pass through the belt opening.
3. Align the edges with the window weatherstrip channel.
Fig. 157: Identifying Clevice Clamp Bolts
4. Turn the window to a horizontal position and align the window with the front and rear clevice clamps.
Tighten: Tighten the front and rear clevice clamps bolts (1) to 11 N.m (97 lb in).
5. Install the window weatherstrip. Refer to Weatherstrip Replacement - Front Door Window.
IMPORTANT: Do not allow the sealing lips on the outer belt sealing strip to roll over and
point downwards. If this condition is present the window will not raise
properly.
Outer.
8. Install the inner trim panel. Refer to Trim Panel Replacement - Side Front Door (Aztek) or Trim
WINDOW REPLACEMENT - REAR DOOR
Removal Procedure
Fig. 158: Loosening Clevice Clamp Bolts

1. Position the rear door window in the full down position.

Outer.
5. Remove the window weatherstrip. Refer to Weatherstrip Replacement - Rear Door Window.
6. Loosen the bolts (1) to the clevice clamps.
Fig. 159: Identifying Window Glass
7. Remove the window from the outside of the rear door.
Fig. 160: Identifying Window Glass
1. Position the rear door window between the inner and the outer door panels.
2. Point the lower rear corner of the window down and pass through the belt opening.
3. Align the edges with the weatherstrip channel.
Fig. 161: Loosening Clevice Clamp Bolts
4. Turn the window to a horizontal position and align the window with the clevice clamps.
Tighten: Tighten the clevice clamps bolts (1) to 11 N.m (97 lb in).
5. Install the window weatherstrip. Refer to Weatherstrip Replacement - Rear Door Window.
IMPORTANT: Do NOT allow the sealing lips on the outer belt sealing strip to roll over
and point downwards. If this condition is present the window will not raise
properly.
6. Install the outer belt sealing strip. Refer to Sealing Strip Replacement - Rear Door Window Belt
Outer.
DOOR FRAME APPLIQUE REPLACEMENT - FRONT
Removal Procedure
IMPORTANT: Protect the applique with heavy material tape in order to avoid damaging the
underlying paint finish or applique. Do not use a pointed or a sharp instrument
for the removal of the applique.
1. Remove the window outer belt sealing strip. Refer to Sealing Strip Replacement - Front Door Window
Belt Outer.
Fig. 162: Punching Out Rivets

Fig. 163: Drilling Out Rivets
3. Drill out the rivets from the front door frame applique.
Fig. 164: View Of Frame Applique
4. Remove the frame applique from the front door.
1. Install the frame applique to the front door.

Fig. 166: Installing Rivets
2. Install the new rivets to the front door applique.

Outer.
DOOR FRAME APPLIQUE REPLACEMENT - REAR
Removal Procedure
IMPORTANT: Protect the applique with heavy material tape in order to avoid damaging the
underlying paint finish or applique. Do not use a pointed or a sharp instrument
for the removal of the applique.
1. Remove the rear door window outer belt sealing strip. Refer to Sealing Strip Replacement - Rear Door
Window Belt Outer.
Fig. 167: Removing Center Of Rivets


Fig. 168: Drilling Out Frame Applique Rivets
3. Drill out the rivets from the frame applique.

4. Remove the frame applique from the rear door.
1. Install the frame applique to the rear door.

Fig. 171: Installing Rivets To Rear Door Applique
2. Install the new rivets to the rear door applique.

Outer.
DOOR FRAME APPLIQUE REPLACEMENT - REAR LOWER
Removal Procedure
Fig. 172: View Of Rear Lower Door Frame Applique
1. Apply tape to the area around the rear lower door frame applique.
2. Using a flat-bladed tool, remove the rear lower door frame applique.
3. Remove the rear lower door frame applique from the rear door.
Fig. 173: View Of Rear Lower Door Frame Applique

1. Position the rear lower door frame applique to the rear door.
2. Press in on the rear lower door frame applique until it is fully seated into the rear door.
3. Remove any tape applied to the rear door area.
RUBBER CONDUIT REPLACEMENT - FRONT DOOR
Removal Procedure
Fig. 174: Front Door Rubber Conduit

1. Remove the left or right instrument panel insulator as required. Refer to Closeout/Insulator Panel
Replacement - Left or Closeout/Insulator Panel Replacement - Right .
2. Disconnect the electrical from the front door wiring harness.
3 Remove the door rubber conduit from where it attaches at the windshield pillar
4. Remove the conduit from the front door.
5. Remove the front door wiring harness out from the rubber conduit.
Fig. 175: Front Door Rubber Conduit

1. Install the wiring harness from the front door through the rubber conduit.
2. Install the rubber conduit to the front door.
3. Install the rubber conduit to the windshield pillar.
4. Connect the front door wiring harness electrical connector.
5. Install the left or right instrument panel insulator as required. Refer to Closeout/Insulator Panel
Replacement - Left or Closeout/Insulator Panel Replacement - Right .
RUBBER CONDUIT REPLACEMENT - REAR DOOR
Removal Procedure
Fig. 176: View Of Rear Door Wiring Harness

IMPORTANT: Mark the location and the color of the wires to the electrical socket before
removing the wires.
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure
2. Remove the conduit from the center pillar.
3. Disconnect the rear door wiring harness electrical connector.
4. Disconnect the wire harness retainer from the wiring harness socket.
5. Remove the wiring harness wiring one at a time from the socket.
6. Remove the rubber conduit from the rear door.
7. Remove the wiring harness wiring from the rubber conduit.
Fig. 177: View Of Rear Door Wiring Harness
1. Install the rear door electrical harness through the rubber conduit.
2. Install the rear door wiring harness wires to the electrical socket.
3. Connect the rear door wiring harness electrical connector.
Fig. 178: Identifying Rear Door Rubber Conduit

4. Install the rubber conduit to the rear door.

5. Install the rubber conduit to the center pillar.
6. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure
SEALING STRIP REPLACEMENT - FRONT DOOR WINDOW BELT OUTER
Removal Procedure
Fig. 179: Locating Front Door Outer Belt Sealing Strip Rear Screw
1. Remove the outside rearview mirror. Refer to Mirror Replacement - Power.

2. Remove the rear screw from the front door outer belt sealing strip.
3. Remove the outer belt sealing strip by pulling the sealing strip from the front door pinchweld flange.
Fig. 180: Locating Front Door Outer Belt Sealing Strip Rear Screw
1. Position the outer belt sealing strip to the front door pinchweld flange.
2. Install the sealing strip to the pinchweld flange pressing into place until fully seated.

3. Install the screw to the rear of the front door outer belt sealing strip.
4. Install the outside rearview mirror. Refer to Mirror Replacement - Power.
SEALING STRIP REPLACEMENT - REAR DOOR WINDOW BELT OUTER
Removal Procedure
Fig. 181: View Of Outer Belt Sealing Strip Screw

1. Position the rear window all the way down.

2. Remove the outer belt sealing strip screw.
3. Pull the outer belt sealing strip from the rear door pinchweld flange.
Fig. 182: View Of Outer Belt Sealing Strip Screw

1. Position the outer belt sealing strip to the rear door pinchweld flange.
2. Install the sealing strip to the pinchweld flange, pressing into place until full seated.
3. Install the outer belt sealing strip screw.
SEALING STRIP REPLACEMENT - FRONT DOOR WINDOW BELT INNER
Removal Procedure
Fig. 183: Identifying Inner Window Sealing Strip
1. Lower the front door window.

3. Remove the inner window sealing strip by lifting the strip off the pinch-weld flange.
Fig. 184: Identifying Inner Window Sealing Strip
1. Position both ends of the inner window sealing strip to the pinch-weld flange with the center of the
sealing strip slightly bent upward.
IMPORTANT: Do not overstuff the sealing strip ends in an attempt to avoid puckers in
the top lip.
2. Engage each end of the sealing strip by pressing firmly onto the front and the rear ends of the weld flange
working toward the center.
4. Raise the front door window.
SEALING STRIP REPLACEMENT - REAR DOOR WINDOW BELT INNER
Removal Procedure
Fig. 185: Inner Window Sealing Strip

1. Lower the rear door window.

3. Remove the inner window sealing strip by lifting the strip off the pinch-weld flange.
Fig. 186: Inner Window Sealing Strip

1. Position both ends of the inner window sealing strip to the pinch-weld flange with the center of the inner
window sealing strip slightly bent upward.
IMPORTANT: Do not overstuff the sealing strip ends in an attempt to avoid puckers in
the top lip.
2. Engage each end of the sealing strip by pressing firmly onto the rear ends of the weld flange working
toward the center.
4. Raise the rear door window.
WEATHERSTRIP REPLACEMENT - FRONT DOOR WINDOW
Removal Procedure
1. Lower the window to the down position.

Fig. 187: Locating Window Channel Screw
Outer.
5. Remove the screw from the window channel.
6. Remove the window channel from the front door frame.

1. Position the window channel into the front door.
2. Install the front door window channel screws.
3. Install the window channel to the front door, starting in the top corner working out in both directions.
Firmly seat the window channel to the front door.
4. Inspect the window for proper operation.

Outer.
WEATHERSTRIP REPLACEMENT - REAR DOOR WINDOW
Removal Procedure
1. Place the rear window in the full down position.

Outer.
5. Remove the screw from the rear window channel.
6. Remove the channel from the rear door.
1. Position the channel to the rear door starting in the corner.
Work outward in both directions.
2. Firmly seat the channel to the rear door.
3. Install the screw to the rear window channel.
4. Inspect the rear door window for proper operation.

Outer.
WEATHERSTRIP REPLACEMENT - AUXILIARY
Tools Required
Removal Procedure
Fig. 191: View Of Rear Pillar Auxiliary Weatherstrip

2. Remove the rear pillar auxiliary weatherstrip using J 38778 .
Fig. 192: Locating Roof Rail Auxiliary Weatherstrip Push-In Retainers
3. Open the front and rear doors.

4. Remove the center pillar auxiliary weatherstrip using J 38778 .
Fig. 193: View Of Roof Rail Auxiliary Weatherstrip In Roof Rail Flange
5. Remove the roofrail auxiliary weatherstrip push-in retainers from the rear pillar using J 38778 .
6. Remove the roofrail auxiliary weatherstrip from the roof rail flange pulling from the rear to front.
Bending back the roofrail auxiliary weatherstrip onto itself to open the carrier while pulling forward will
ease the removal effort.
Fig. 194: View Of Roof Rail Auxiliary Weatherstrip In Roof Rail Flange
1. Position the roofrail auxiliary weatherstrip push-in retainer to the first hole in the upper rear corner.
2. Press in the push-in retainer until fully seated.
3. Install roofrail auxiliary weatherstrip onto the flange.
Bending back the roofrail auxiliary weatherstrip onto itself to open the carrier while pushing forward will
ease the installation effort.
4. Install the remaining push-in retainers to the rear pillar.

5. Install the center pillar auxiliary weatherstrip pressing in the push-in retainers until fully seated.
Fig. 196: View Of Rear Pillar Auxiliary Weatherstrip
6. Align the C-pillar auxiliary weatherstrip top push-in retainers to the top hole in the rear pillar.
7. Install the C-pillar auxiliary weatherstrip working downward pressing in the remainder of the push-in
retainers until fully seated.
WEATHERSTRIP REPLACEMENT - CENTER PILLAR AUXILIARY
Removal Procedure
1. Open the front and rear doors.

2. Remove the center pillar auxiliary weatherstrip.
1. Align the center pillar auxiliary weatherstrip top push-in retainers to the top hole in the center pillar.
2. Install the center pillar auxiliary weatherstrip working downward pressing in the remainder of the push-in
retainers until fully seated.
WEATHERSTRIP REPLACEMENT - FRONT DOOR OPENING
Removal Procedure
Fig. 199: Identifying Front Door Opening Weatherstrip

2. Remove the front door sill plates. Refer to Door Sill Plate Replacement - Front in Interior Trim.
3. Remove the windshield garnish molding. Refer to Garnish Molding Replacement - Windshield Pillar
in Interior Trim.
4. Remove the upper center pillar trim panel. Refer to Trim Panel Replacement - Upper Center Pillar in
Interior Trim.
5. Remove the center lower trim panel. Refer to Trim Panel Replacement - Lower Center Pillar in
Interior Trim.
6. Remove the front door opening weatherstrip by pulling it off the pinchweld flange.
Fig. 200: Identifying Front Door Opening Weatherstrip

1. Position the front door opening weatherstrip to the pinchweld flange.
Starting at the center of the rocker panel area and moving in a clockwise direction press the front door
opening weatherstrip to the pinchweld flange until fully seated.
IMPORTANT: The joint butt ends must have no gap and be located in the center of the
rocker panel area.
2. Install joint butt ends together.

3. Install the door sill plates. Refer to Door Sill Plate Replacement - Front in Interior Trim.
4. Install the windshield garnish molding. Refer to Garnish Molding Replacement - Windshield Pillar in
Interior Trim.
5. Install the upper center pillar trim panel. Refer to Trim Panel Replacement - Upper Center Pillar in
Interior Trim.
6. Install the center lower trim panel. Refer to Trim Panel Replacement - Lower Center Pillar in Interior
Trim.
WEATHERSTRIP REPLACEMENT - REAR DOOR OPENING
Removal Procedure
Fig. 201: View Of Rear Door Opening Weatherstrip

2. Remove the rear door sill plates. Refer to Door Sill Plate Replacement - Front in Interior Trim.
3. Remove the rear quarter upper trim panel. Refer to Trim Panel Replacement - Rear Quarter Upper
(Aztek) or Trim Panel Replacement - Rear Quarter Upper (Rendezvous) in Interior Trim.
4. Remove the rear quarter lower trim panel. Refer to Trim Panel Replacement - Rear Quarter Lower
5. Remove the upper center pillar trim panel. Refer to Trim Panel Replacement - Upper Center Pillar in
Interior Trim.
6. Remove the center lower trim panel. Refer to Trim Panel Replacement - Lower Center Pillar in
Interior Trim.
7. Remove the rear door opening weatherstrip by pulling it off the pinchweld flange.
Fig. 202: View Of Rear Door Opening Weatherstrip
1. Position the rear door opening weatherstrip to the pinchweld flange.
Starting at the center of the rocker panel area and moving in a clockwise direction press the rear door
opening weatherstrip to the pinchweld flange until fully seated.
IMPORTANT: The joint butt ends must have no gap and be located in the center of the
rocker panel area.
2. Install joint butt ends together.

3. Install the rear quarter upper trim panel. Refer to Trim Panel Replacement - Rear Quarter Upper
(Aztek) or Trim Panel Replacement - Rear Quarter Upper (Rendezvous) in Interior Trim.
4. Install the rear quarter lower trim panel. Refer to Trim Panel Replacement - Rear Quarter Lower
5. Install the upper center pillar trim panel. Refer to Trim Panel Replacement - Upper Center Pillar in
Interior Trim.
6. Install the center lower trim panel. Refer to Trim Panel Replacement - Lower Center Pillar in Interior
Trim.
7. Install the rear door sill plates. Refer to Door Sill Plate Replacement - Front in Interior Trim.
MIRROR REPLACEMENT - POWER
Removal Procedure
Fig. 203: Identifying Power Mirror
2. Remove the nuts from the outside rearview mirror.
3. Disconnect the electrical connector from the outside rearview mirror.
4. Remove the outside rearview mirror from the front door.
Fig. 204: Identifying Power Mirror
1. Install the outside rearview mirror to the front door.
2. Install the outside rearview mirror nuts.
Tighten: Tighten the outside rearview mirror nuts to 10 N.m (89 lb in).
3. Connect the electrical connector to the outside rearview mirror.

MOTOR REPLACEMENT - POWER MIRROR

Removal Procedure
2. Remove the mirror face. Refer to Mirror Face Replacement.
Fig. 205: Locating Mirror Motor Screws

3. Remove the mirror motor screws.

Fig. 206: Expanded View Of Mirror Motor
4. Pull the mirror motor out from the mirror housing to gain access to the mirror motor electrical connectors.
Fig. 207: View Of Mirror Motor Electrical Connectors
5. Disconnect the mirror motor electrical connectors.

6. Remove the mirror motor from the mirror housing.
Fig. 208: Expanded View Of Mirror Motor
1. Position the mirror motor to the mirror housing.

Fig. 209: View Of Mirror Motor Electrical Connectors
2. Connect the mirror motor electrical connectors.

Fig. 210: Locating Mirror Motor Screws
3. Position the mirror motor into the mirror housing.
4. Install the mirror motor screws.
5. Install the mirror face. Refer to Mirror Face Replacement.

7. Inspect the mirror for proper operation.
MIRROR FACE REPLACEMENT
Removal Procedure
CAUTION: When working with any type of glass or sheet metal with exposed or rough
edges, wear approved safety glasses and gloves in order to reduce the
chance of personal injury.
Fig. 211: Removing Mirror Face

1. Place your fingers as far as possible behind the mirror face toward the center of the back.
2. Remove the mirror face from the mirror housing with sufficient force to disengage the snap-locks on the
mirror motor.
3. Remove the mirror face from the mirror housing.
Fig. 212: View Of Heated Mirror Electrical Connectors
4. Disconnect the heated mirror electrical connectors if equipped.
Fig. 213: View Of Heated Mirror Electrical Connectors
1. Connect the heated mirror electrical connectors if equipped.

Fig. 214: Aligning Mirror Face Retention Clips With Adjuster Mechanism (DL3, DR4, DL8, 5M1)
2. Position the mirror face to the mirror motor.

Fig. 215: Mirror Glass & Motor
3. Install the mirror face to the mirror motor with the palm of the hand on the center of the glass, pressing in
until fully seated.
4. Inspect the mirror for proper operation.

POWER WINDOWS DESCRIPTION AND OPERATION
Power Windows System Components
The power window system consists of the following components:
Window master switch

Front passenger window switch
LR window switch
RR window switch
Window motors in each of the doors
System circuit breaker (POWER WDWS Circuit Breaker 30A)
Power Windows System Controls
The power windows system can be controlled by a power window up or down switch activation.
Driver Window Operation
When the ignition switch is in the RUN or ACCY position, or retained accessory power (RAP) is enabled and
the window master switch is activated to the DOWN position, battery positive voltage is applied to the window
motor causing the window to open. When the window master switch is activated to the UP position, battery
positive voltage is applied to the window motor in the opposite direction and the window closes.
The window master switch also controls the front passenger, LR, and RR windows.
Express Down Feature
The driver window will travel to the fully down position when the window master switch is pressed past the
first detent. Activating the window master switch to the UP position will cancel the express down feature.
Lockout Switch Feature
The window master switch has a lockout switch which disconnects the battery positive voltage to the LR and
RR window switches, disabling them.
Individual Window Operation
When the ignition switch is in the RUN or ACCY position, or RAP is enabled and an individual window switch
is activated to the DOWN position, battery positive voltage is applied to the window motor causing that
window to open. When the individual window switch is activated to the UP position, battery positive voltage is
applied to the window motor in the opposite direction causing that window to close.
POWER DOOR LOCKS DESCRIPTION AND OPERATION
Aztek Door Lock System Components
The power door lock system consists of the following components:
Body control module (BCM)

Driver door lock switch
Front passenger door lock switch
Door lock actuators in each of the doors and two actuators in the endgate
Door lock system fuses into the BCM (BCM D 25A fuse and GATE REL 20A fuse)
Rendezvous Door Lock System Components
The power door lock system consists of the following components:
Body control module (BCM)

Driver door lock switch
Front passenger door lock switch
Door lock actuators in each of the doors
Door lock system fuse into the BCM (BCM D 25A fuse)
Door Lock System Controls
The power door lock system can be controlled by any of the following:
A door lock switch LOCK or UNLOCK activation

A keyless entry transmitter activation
An automatic door lock activation (Personalization function)
An automatic door unlock activation (Personalization function)
A key cylinder unlock activation (Personalization function)
A delayed locking activation (Personalization function)
Door Lock Operation
When the BCM detects a transition of either of the door lock switches to the LOCK position, it switches the
door lock actuator lock control circuit to voltage. Since the lock actuator unlock control circuits are at ground
potential within the BCM, the door lock actuator motors transition to the Lock position.
Driver Door Unlock Operation
When the BCM detects a transition of either of the door lock switches to the UNLOCK position, it switches the
driver door lock actuator unlock control circuit to voltage. Since the door lock actuator lock control circuit is at
ground potential within the BCM, the LF door lock actuator motor transitions to the Unlock position.
The driver door lock actuator unlock control circuit is a dedicated control circuit used only for the driver door
lock actuator motor. This is done so that the driver door may be unlocked by itself using a keyless entry
transmitter or an automatic door unlock function (if programmed).
Passenger Door Unlock Operation
When the BCM detects a transition of either of the door lock switches to the UNLOCK position, it switches the
door lock actuator unlock control circuits to voltage. Since the door lock actuator lock control circuit is at
ground potential within the BCM, the passenger door lock actuator motors transition to the Unlock position.
The door lock actuator unlock control circuits are dedicated control circuits used only for the passenger door
lock actuator motors. This is done so that the driver door may be unlocked separate from the passenger doors
using a keyless entry transmitter or an automatic door unlock function (if programmed).
Automatic Door Lock/Unlock
The automatic door lock/unlock function is a Vehicle Personalization feature with the following six
programmable modes of operation:
1. The automatic door lock feature is disabled.

2. The automatic door lock on shift out of Park feature is disabled.
3. All of the doors lock when the vehicle is shifted out of Park with the ignition ON, and only the driver
door Unlocks when the vehicle is shifted into Park.
4. All of the doors lock when the vehicle is shifted out of Park with the ignition ON, and all of the doors
Unlock when the vehicle is shifted into Park.
5. All of the doors lock when the vehicle is shifted out of Park with the ignition ON, and only the driver
door Unlocks when the key is removed from the ignition.
6. All of the doors lock when the vehicle is shifted out of Park with the ignition ON, and all of the doors
Unlock when the key is removed from the ignition.
The automatic door lock function can only be enabled by the BCM if the driver, front passenger and rear door
switches are in an Inactive state (closed). For information on programming the automatic door locks, refer to in
Personalization.
Delayed Locking
The delayed locking function is a Vehicle Personalization feature that is intended to allow the doors to be
locked while passengers are exiting the vehicle. When delayed locking is in Active Mode, the BCM will delay
locking of the vehicle doors for 5 seconds after all of the doors have been closed. The delayed locking function
will be overridden if the BCM receives a door Unlock input or a key in ignition input.
Key Cylinder Unlock
This feature will unlock all of the doors when the BCM receives a KEYUNLK input signal for greater than 1
second. This feature is disabled from the factory and can be enabled using a scan tool.
Lockout Prevention
This function is intended to prevent the vehicle operator from locking the doors if the key is left in the ignition
and any vehicle door is open. The lockout prevention function can be overridden by the BCM if the BCM
receives a Remote Lock input or if the door is manually locked.
Unlock After Air Bag Deployment
This feature will unlock all of the vehicle doors, including the endgate, 15 seconds after air deployment.
DOOR AJAR INDICATOR DESCRIPTION AND OPERATION

Door Ajar Indicator
The IPC illuminates the door ajar indicator in the message center when the body control module (BCM) detects
any of the four vehicle doors is open. The IPC receives a class 2 message from the BCM requesting
illumination. The IPC sends a class 2 message to the radio in order to activate an audible warning.
OUTSIDE MIRROR DESCRIPTION AND OPERATION
Power Mirror System Components
The power mirror system consists of the following components:
Outside rearview mirror switch

Mirror selector switch
Driver outside rearview mirror
Passenger outside rearview mirror
PWR MIRROR Fuse 10A
Memory seat module, w/A43
Each of the outside power mirrors contains two motors. The vertical motor operates the up and down directions
and the horizontal motor operates the left and right directions. Each of the power mirror motors are circuit
breaker protected.
Power Mirror System Controls
The outside rearview mirror switch is a four position directional switch (Up, Down, Left and Right).
The mirror select switch is a three position switch (L, Off and R).
The memory seat module controls mirror operation on vehicles with the A43 memory seat and mirrors option.
Power Mirror System Operation w/o A43
The outside rearview mirror switch receives power through the battery positive voltage circuit from the PWR
MIRROR 10A Fuse. The power mirror switch also receives a constant ground.
The four positions of the direction switch have dual switch contacts. Each of the contacts are connected to
opposing sides of the appropriate power mirror motors through the selector switch. The selector switch
completes these circuits depending on the position of the selector switch (L or R).
If the selector switch is placed in the L position and the up switch is depressed, battery positive voltage will be
supplied to the left outside rearview mirror vertical motor through the left mirror motor up control circuit and
ground through the left mirror motor left control circuit. If the down switch is depressed, battery positive
voltage will be supplied to the left outside rearview mirror vertical motor through the left mirror motor left
control circuit and ground through the left mirror motor up control circuit.
The remainder of the mirror functions operate in the same manner as described above. Placing the power mirror
switch in opposing positions (left/right or up/down) will reverse the polarity to the mirror motor.
Power Mirror System Operation w/A43
The outside rear view mirror switch supplies power and ground inputs to the memory seat module (MSM) for
use in driving the driver and passenger outside rearview mirror horizontal and vertical motors. When the MSM
recognizes the input combination, it moves the appropriate mirror motor in the requested direction.
The MSM receives inputs from the mirror position sensors during Memory 1 and Memory 2 recall. The
potentiometers in the position sensors vary in resistance as the motors move the mirror. The MSM receives a
variable voltage input depending on the resistance of the potentiometer. During memory set, the MSM records
the voltages across the mirrors. During memory recall, the MSM moves the mirror motors until the voltage
across each potentiometer matches the recorded voltage.
Parallel Park Assist Mirror Operation
When the vehicle is shifted into reverse, the passenger outside rearview mirror will tilt down five degrees or to
the end of travel. The passenger outside rearview mirror will return to its original position 5 seconds after the
vehicle is shifted out of reverse.

SPECIAL TOOLS
Special Tools
J 25070
Heat Gun
J 38778
J 39346
Mini-Wedge Door Striker Aligner
Drive Axle - Locking/Limited Slip - Aztek & Rendezvous
SPECIFICATIONS

Specification
Clutch Pump Check Valve Bolts 10 N.m 106 lb in

DIFFERENTIAL LOCK SCHEMATICS
Fig. 1: Differential Lock

COMPONENT LOCATOR
REAR AXLE COMPONENT VIEWS
Fig. 2: Differential Clutch Pump Actuator Check Valve

Callouts For Fig. 2

1 O-ring
2 O-ring
3 Differential Clutch Pump Actuator Check Valve
4 Mounting Bolt
5 Mounting Bolt
REAR AXLE CONNECTOR END VIEWS
Differential Clutch Pump Actuator Check Valve

15326808
3-Way F GT 150 Series Sealed 4.5 (BK)

A L-BU 1296 Axle Actuator - Control
B BK 550 Ground
C PK 1439 Ignition 1 Voltage

DIAGNOSTIC STARTING POINT - LOCKING/LIMITED SLIP REAR AXLE
Diagnostic System Check - Vehicle in Vehicle DTC Information will provide the following information:
The Identification of the control module or modules which command the system.
The ability of the control module or modules to communicate through the serial data circuit.
The identification of any stored diagnostic trouble codes (DTCs) and the status of the codes.
The use of the Diagnostic System Check - Vehicle in Vehicle DTC Information will identify the correct
procedure for diagnosing the system and where the procedure is located.
SCAN TOOL DATA LIST
Use the scan tool data list under the following conditions:
The Diagnostic System Check is complete.

The on-board diagnostics are functioning properly.
The values below represent a typical display recorded from a properly functioning system.
IMPORTANT: Do not use a scan tool that displays faulty data. Report the condition to the
scan tool manufacturer. The use of a faulty scan tool can result in
misdiagnosis and the unnecessary replacement of parts.
Only the parameters listed below are used in this manual for diagnosing. If a scan tool displays other
parameters, the values are not recommended by General Motors for use in diagnosis.
Scan tool values below were recorded under the following conditions:
Engine at Idle
Upper radiator hose hot
Closed throttle
Transmission in PARK
Closed Loop operation
Accessories OFF
Brake pedal not applied
Scan Tool Data List

Scan Tool Parameter Data List* Units Displayed Typical Data Value
ABS System Disable F7 Yes/No No
AWD Circuit Status F7 OK/Short/Open OK
AWD Clutch Temp. Disable F7 Yes/No No
AWD Disable F7 Yes/No No
AWD Duty Cycle F7 Percent Varies
AWD Fluid Temp. Disable F7 Yes/No No
AWD Minispare Disable F7 Yes/No No
AWD Overtemp. Delay F7 Yes/No No
AWD Torque Management F7 Active/Inactive Inactive
AWD Voltage Disable F7 Yes/No No
AWD Wheel Speed Disable F7 Yes/No No
F0, F1, F2, F3, F4,
Calc. Throttle Position Percent Varies
F5, F7
F0, F1, F2, F3, F4,
Commanded Gear 1,2,3,4 1
F5, F7
ECT F0, F1, F7 C (F) Varies
F0, F1, F2, F3, F4,
Engine Speed RPM 650-750 RPM
F5, F7
Engine Torque F0, F1, F7 N.m (lb ft) Varies
F0, F1, F2, F3, F4,
Gear Ratio Ratio 3.98
F7
Ignition Voltage F0, F7 Volts 12.5-13.5 Volts
Park, Park/Reverse,
Reverse,
Reverse/Neutral,
Neutral,
Neutral/Drive 4,
Drive 4, Drive
IMS F0, F7 Park
4/Drive 3, Drive 3,
Drive 3/Drive 2,
Drive 2, Drive
2/Drive 1, Drive 1,
Invalid, Open
IMS A/B/C/P F0, F7 HI/LOW LOW/HI/HI/LOW
Last Disable Odometer F7 km (miles) Varies
Fluid Temp, Clutch
Temp, Wheel Speed,
Last Disable Reason F7 Voltage, Mini Spare, Varies
ABS System, Output
Controls
F0, F1, F2, F3, F4,
TP Angle Percent 0%
F5, F7
Trans. Fluid Temp. F0, F1, F5, F7 C (F) Varies
F0, F1, F2, F3, F4,
Transmission ISS RPM 600-700 RPM
F7
F0, F1, F2, F3, F4,
Transmission OSS RPM 0 RPM
F7
F0, F1, F2, F3, F4,
Vehicle Speed km/h (mph) 0 km/h
F7
*Data List Legend
F0: Transmission Data

F1: TCC Data
F2: 1-2 Shift Data
F3: 2-3 Shift Data
F4: 3-4 Shift Data
F5: PC Solenoid Data
F6: Transmission Adapts
F7: All-Wheel Drive Data
ABS System Disable
This parameter displays Yes if the Powertrain Control Module (PCM) or the Transmission Control
Module (TCM) is not receiving input from the Antilock Brake System (ABS), and the All-Wheel Drive
(AWD) system is disabled.
AWD Circuit Status
This parameter displays the status of the axle actuator control circuit to the AWD solenoid and displays
OK, Short, or Open. The AWD Disable lamp will be illuminated for short and open conditions.
AWD Clutch Temp. Disable
This parameter displays the status of powertrain software that has the ability to disable AWD based on a
rear drive module clutch slip/time calculation and displays Yes or No. If the software determines that a
clutch overtemperature condition exists, the AWD system will be deactivated by disabling the PWM
signal line to the AWD solenoid. The AWD system will be enabled again when the software calculates
that the clutch temperatures have dropped sufficiently. The AWD Disable lamp will be illuminated for a
Yes condition.
AWD Disabled
This parameter displays if the AWD system has been disabled and displays Yes or No. The AWD
Disabled lamp will be illuminated for a Yes condition.
AWD Duty Cycle
This parameter displays the commanded state of the AWD solenoid, expressed as a percent of ON time.
At vehicle start-up, duty cycle will be at 75-90 percent for 3 seconds. This is referred to as the pull-in
duty cycle. After 3 seconds, the duty cycle will drop to 20-30 percent for 30 seconds. This is referred to
as the hold-in duty cycle. After each 30 second hold-in period, the duty cycle will be increased to 75-90
percent for 0.5 second, before returning to the hold-in duty cycle. This is to assure solenoid pull-in.
AWD Fluid Temp. Disable
This parameter displays a fluid overtemperature condition in the rear drive module and displays Yes or
No. When the sump temperature exceeds approximately 110C (230F), a pull-up resistor grounds the
PWM signal line at the AWD solenoid. The pull-up resistor is an integral part of the AWD solenoid. The
AWD Disable lamp will be illuminated for a Yes condition.
AWD Minispare Disable
This parameter displays whether the ABS module detects a minispare on the vehicle and displays Yes or
No. The wheel rotational speed difference is detected by the wheel speed sensors of the ABS system. If
the ABS module detects a minispare on the vehicle, the AWD system will be deactivated by disabling the
PWM signal line to the AWD solenoid. The AWD Disable lamp will be illuminated for a Yes condition.
AWD Overtemp. Delay
This parameter displays whether the AWD system is in a reset mode following an AWD fluid
temperature disable. The rear drive module (RDM) resistor is an integral part of the AWD solenoid. The
RDM resistor senses for an overtemperature condition of 110C (230F) or greater. If this condition is
met, the scan tool will display Yes, the RDM resistor will ground the AWD solenoid PWM signal, and
the AWD Disable lamp will be illuminated. Following an overtemperature condition, if the RDM resistor
senses 95C (203F) or less, the RDM resistor removes the ground path from the AWD solenoid PWM
signal and the AWD system begins a 10 minute delay period. After the 10 minute delay period, and once
vehicle speed is 0 km/h (0 mph), the AWD Disable lamp will no longer be illuminated.
AWD Torque Management
This parameter displays when some form of torque management is being performed to protect the AWD
system, and displays Active. When there is no form of torque management being performed, the display
reads Inactive.
AWD Voltage Disable
This parameter displays whether the ignition voltage to the AWD solenoid is in the proper range, and
displays Yes or No. The ignition voltage range to the AWD solenoid is 9-16 volts. The AWD system will
be deactivated by disabling the PWM signal line to the AWD solenoid if the ignition voltage is out of
range. The AWD Disable lamp will be illuminated for a Yes condition.
AWD Wheel Speed Disable
This parameter displays whether the wheel speed data received from the ABS controller is valid, and
displays Yes or No. If the ABS module transmits is not satisfactory for the AWD system to be active, the
AWD system will be deactivated, by disabling the PWM signal line to the AWD solenoid. The AWD
Disable lamp will be illuminated for a Yes condition.
Calc. Throttle Position
This parameter displays a calculated value, which is determined by the accelerator pedal position and the
actual throttle position, used to optimize transmission controls. It represents the driver's intended request
for torque or acceleration. The range is 0-100%, where 0% represents an idle or coast request and 100%
represents a request for wide open throttle (WOT).
Commanded Gear
This parameter displays the current commanded state of the shift solenoid valves. The scan tool displays
1, 2, 3, 4 or 5.
ECT
This parameter displays the input signal from the engine coolant temperature (ECT) sensor. ECT is high
at 151C (304F) when the signal voltage is low, 0 volt. ECT is low at -40C (-40F) when the signal
voltage is high, 5 volt.
Engine Speed
This parameter displays the rotational speed of the engine expressed as revolutions per minute.
Engine Torque
This parameter displays a calculated value based on engine load, throttle position, mass air flow, and
other engine inputs. This parameter is accurate to within 20 N.m (15 ft lb) of actual measured engine
torque.
Gear Ratio
This parameter displays the actual transmission gear ratio. The scan tool displays the gear ratio calculated
from the automatic transmission input shaft speed sensor (AT ISS) and the automatic transmission output
shaft speed sensor (AT OSS) inputs.
Ignition Voltage
This parameter displays the system voltage measured at the ignition feed.
IMS
This parameter displays PARK, PARK/REVERSE, REVERSE, REVERSE/NEUTRAL, NEUTRAL,

NEUTRAL/DRIVE 4, DRIVE 4, DRIVE 4/DRIVE 3, DRIVE 3, DRIVE 3/DRIVE 2, DRIVE 2, DRIVE
2/DRIVE 1, DRIVE 1 or INVALID. The IMS Range display represents a decoded status of the four
inputs from the IMS. The combination of IMS inputs are used to determine which position the manual
valve is in at any time.
IMS A/B/C/P
This parameter displays the status of the four A/B/C/P inputs from the automatic transmission internal
mode switch. I indicates an ignition voltage signal. LOW indicates a 0 voltage signal. The scan tool will
display HI/LOW, HI/LOW, HI/LOW, HI/LOW.
Last Disable Odometer
This parameter displays the vehicle mileage at which the AWD Last Disable condition occurred.
Last Disable Reason
This parameter displays the last AWD disable reason. The possible reasons are Output Controls, Fluid
Temp, Clutch Temp, Wheel Speed, Voltage, Mini Spare, ABS System. The Output Controls reason
indicates that AWD was last disabled with a service scan tool. Fluid Temp, Clutch Temp, Wheel Speed,
Voltage, Mini Spare and ABS System each have a unique parameter that is described elsewhere in this
table.
TP Angle
This parameter displays a percentage that is calculated based on TP sensor voltage. The TP angle should
display 0 percent at idle and 100 percent at wide open throttle (WOT).
Trans. Fluid Temp.
This parameter displays the input signal of the transmission fluid temperature sensor. Transmission fluid
temperature is high, 151C (304F), when signal voltage is low, 0 volt. Transmission fluid temperature is
low, -40C (-40F), when signal voltage is high, 5 volt.
Transmission ISS
This parameter displays the rotational speed of the transmission input shaft. The scan tool displays input
shaft speed as revolutions per minute (RPM).
Transmission OSS
This parameter displays the rotational speed of the transmission output shaft. The scan tool displays
output shaft speed as revolutions per minute (RPM).
Vehicle Speed
This parameter displays the speed at which the vehicle is traveling. The scan tool displays vehicle speed
as kilometers per hour (km/h), miles per hour (MPH). The vehicle speed is calculated based on the input
signal from the vehicle speed sensor.
SYMPTOMS - LOCKING/LIMITED SLIP REAR AXLE
IMPORTANT: Review the Description and Operation in order to familiarize yourself with the
system functions. Refer to Locking Differential Description and Operation .
Inspect for aftermarket devices which could affect the operation of the Rear Axle Control System. Refer
to Checking Aftermarket Accessories in Wiring Systems.
cause the symptom.
Inspect the rear axle for the proper fluid level.
Intermittent
Symptom List
Differential Lock Inoperative

Differential Lock Indicator Inoperative
All-Wheel Drive (AWD) Disabled Indicator Always On
All-Wheel Drive (AWD) System Functional Inspection in Rear Drive Axle
ALL-WHEEL DRIVE (AWD) DISABLED INDICATOR ALWAYS ON
Circuit Description
The differential clutch pump actuator check valve assembly is a pulse width modulated actuator mounted to the
rear drive assembly. Ignition voltage is supplied to the clutch pump actuator check valve through a fused circuit.
The powertrain control module (PCM) or the transmission control module (TCM) controls the actuator with a
negative duty cycle. The actuator controls the supply fluid to the pump inlet in the rear drive assembly. When
the actuator is commanded OFF, the PCM/TCM will detect a high voltage. When the actuator is commanded
ON, the PCM/TCM will detect a low voltage. At engine start-up, the actuator is turned ON at 49-90 percent
duty cycle for 3 seconds, then drops to 16-28 percent for holding. Every 30 seconds, the duty cycle is ramped to
49-90 percent for 0.5 second, then back to 16-28 percent. If the PCM/TCM detects a voltage on the axle
actuator circuit that is outside of the calibrated limits then the all-wheel drive (AWD) disable lamp illuminates.
Conditions for Running the All-Wheel Drive (AWD) Disable Fault
The system voltage is 9-18 volts.

The engine speed is greater than 500 RPM for 5 seconds, and the engine is not in fuel shut-off.
The rear drive module must not be in an overtemperature condition.
Conditions for Turning On the All-Wheel Drive (AWD) Disable Lamp
The AWD disable lamp illuminates when one of the following conditions exists for 5 seconds:
The PCM/TCM commands the solenoid ON and the voltage feedback remains high, B+.
The PCM/TCM commands the solenoid OFF and the voltage feedback remains low, 0 volts. This
condition is present for 3 key cycles.
Action Taken When the All-Wheel Drive (AWD) Lamp Illuminates
The PCM/TCM does not illuminate the malfunction indicator lamp (MIL).
The PCM/TCM inhibits AWD.
The PCM/TCM records the operating conditions when the Conditions for Setting the DTC are met. The
PCM/TCM stores this information as Failure Records.
The PCM/TCM stores the AWD disable fault in PCM/TCM history.
Conditions for Clearing the All-Wheel Drive (AWD) Disable Fault
A scan tool can clear the fault.

The PCM/TCM clears the fault from PCM/TCM history if the vehicle completes 40 warm-up cycles
without a non-emission related diagnostic fault occurring.
The PCM/TCM cancels the fault default actions when the fault no longer exists.
IMPORTANT: When an AWD mini spare disable condition is present, after correcting the
condition, the vehicle must be driven 0.5 km (0.3 mi) in a straight line and then
brought to a complete stop before the PCM/TCM will command the AWD
disable lamp OFF.
Diagnostic Aids
An ABS DTC may cause the AWD Disabled light to illuminate. Check for ABS DTCs if no AWD fault is
present.
Test Description
3: This step tests the ignition 1 voltage circuit for proper voltage.
4: This step tests the ground circuit for an open.
5: This step tests the axle actuator control circuit duty cycle.
6: This step tests the axle actuator control circuit for an open or short.
All-Wheel Drive (AWD) Disabled Indicator Always On

Schematic Reference: Differential Lock Schematics
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
Verify the fault is present. Go to Testing
Does the system operate normally? for
Intermittent
2 - Conditions and
Poor
Connections in
Wiring Systems Go to Step 3
1. Disconnect the differential clutch pump
actuator check valve.
OFF.
3 3. Using a DMM, test the ignition 1 voltage 9-14 V
circuit for proper voltage.

voltage circuit and the ground circuit at
the differential clutch pump actuator check
valve.
4 -
OFF.

2. With the connector connected, connect a
DMM in parallel to the control circuit. Set
the DMM to read duty cycle.
IMPORTANT:
The differential clutch pump actuator
check valve duty cycle will initiate at 49- HI Range: 49-
90 percent duty cycle for 3 seconds, 90%
5 then drop to 16-28 percent duty cycle. LO Range:
Every 30 seconds, the duty cycle will
cycle up to 49-90 percent for 0.5
16-28%
seconds, then back to 16-28 percent.

4. Observe AWD Duty Cycle on the DMM
from the time of engine start.
Is the duty cycle functioning as described? Go to Step 9 Go to Step 6

Test the axle actuator control circuit for the
An open
A short to voltage
6 A short to ground -

Wiring Systems.
Locate and repair an open or short to ground in
the ignition 1 voltage circuit. Refer to Circuit
7 Testing and Wiring Repairs in Wiring - -
Systems.
Locate and repair an open in the ground circuit.
8 - -
Replace the differential clutch pump actuator
check valve. Refer to Differential Clutch Pump
9 - -
Check Valve Replacement .
Replace the PCM for 3.4L or the TCM for 3.6L.
faults. Go to All-
2. Operate the vehicle within the Conditions Wheel Drive
11 for Running the All-Wheel Drive (AWD) - (AWD) System
Disable Fault, as specified in the Functional
supporting text. Inspection in
Rear Drive
Does the fault set? Go to Step 3 Axle
DIFFERENTIAL LOCK INDICATOR INOPERATIVE
Circuit Description
The all-wheel drive (AWD) disable indicator lamp is located in the instrument panel cluster (IPC). Ignition 1
voltage is supplied to the IPC when the ignition switch is in the START or RUN position. When the powertrain
control module (PCM) or the transmission control module (TCM) receives a signal from the differential clutch
pump actuator check valve, indicating an overtemperature condition, or a signal from the antilock brake system
(ABS) controller indicating a speed differential between wheels, the AWD system is disabled. The PCM/TCM
then sends a class 2 signal to the IPC, illuminating the AWD disable indicator.
Test Description
2: This step tests for an intermittent condition.

3: This step determines if the failure is the result of a faulty instrument cluster.

Step Action Yes No
1
Vehicle in Vehicle
Verify the fault is present. Go to Testing for
Does the system operate normally? Intermittent
2 Conditions and
Poor Connections
3 3. Use the scan tool to command the AWD system
disabled.
Does the AWD Disable indicator turn ON? Go to Step 4 Go to Step 5

Replace the PCM for 3.4L or the TCM for 3.6L. Refer
4 Computer/Integrating Systems for replacement, setup, -
and programming.
Replace the instrument panel cluster. Refer to
Instrument Panel Cluster (IPC) Replacement in
5 -
Instrument Panel, Gages, and Console.
6
DIFFERENTIAL LOCK INOPERATIVE
Circuit Description
The powertrain control module (PCM) or the transmission control module (TCM) controls the actuator with a
negative duty cycle. The actuator controls the fluid supply to the pump inlet in the rear drive assembly. When
the actuator is commanded OFF, the PCM/TCM detects high voltage. When the actuator is commanded ON, the
PCM/TCM detects low voltage. At engine start-up, the actuator is turned ON at 49-90 percent duty cycle for 3
seconds, then drops to 16-28 percent for holding. Every 30 seconds, the duty cycle is ramped to 49-90 percent
for 0.5 second, then back to 16-28 percent.
Test Description
3: This step tests the ignition 1 voltage circuit for proper voltage.
4: This step tests the ground circuit for an open.
5: This step tests the axle actuator control circuit duty cycle.
6: This step tests the axle actuator control circuit for an open or short.
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
Verify the fault is present. Go to Testing
Does the system operate normally? for
Intermittent
2 - Conditions and
Poor
Connections in
1. Disconnect the differential clutch pump
actuator check valve.
OFF.
3 3. Using a DMM, test the ignition 1 voltage 9-14 V
circuit for proper voltage.

voltage circuit and the ground circuit at
the differential clutch pump actuator
check valve.
4 -
OFF.

2. With the connector connected, connect a
DMM in parallel to the axle actuator
control circuit and the ground circuit. Set
the DMM to measure duty cycle.
5
IMPORTANT:
The differential clutch pump actuator
check valve duty cycle will initiate at 49-
90 percent duty cycle for 3 seconds, HI Range: 49-
then drop to 16-28 percent duty cycle. 90%
LO Range:
Every 30 seconds, the duty cycle will 16-28%
cycle up to 49-90 percent for 0.5
seconds, then back to 16-28 percent.

4. Observe AWD Duty Cycle on the DMM
from the time of engine start.
Is the duty cycle functioning as described? Go to Step 10 Go to Step 6

Test the axle actuator control circuit for the
An open
A short to voltage
6 A short to ground -

Wiring Systems.
Verify that the differential clutch pump actuator
check valve connector is securely fastened.
Using a scan tool, check the status of the
7 AWD Mini Spare Disable -
AWD Fluid Temp Disable
Did you find and correct the conditions? Go to Step 12 Go to Step 11

Locate and repair an open, or a short to ground
in the ignition 1 voltage circuit. Refer to Circuit
8 Testing and Wiring Repairs in Wiring - -
Systems.
Locate and repair an open in the ground circuit.
9 - -
Replace the differential clutch pump actuator
check valve. Refer to Differential Clutch Pump
10 - -
Replace the PCM for 3.4L or the TCM for 3.6L.
11 setup, and programming. - -
Turn the ignition ON, with the engine OFF.
With the differential clutch pump actuator check
valve removed, command the valve ON, then
12 OFF. Refer to Differential Clutch Pump 2 mm
Does the differential clutch pump actuator check
valve move the specified value or more? Go to Step 13 Go to Step 3
Does the AWD system operate normally? Go to All-
Wheel Drive
(AWD) System
13 - Functional
Inspection in
Rear Drive
System OK Axle
REPAIR INSTRUCTIONS
DIFFERENTIAL CLUTCH PUMP CHECK VALVE REPLACEMENT
Removal Procedure
Fig. 3: Identifying Clutch Pump Check Valve Bolts
1. Drain the differential lubricant. Refer to Lubricant Change in Rear Drive Axle.
2. Disconnect the clutch pump check valve electrical connector.
3. Remove the clutch pump check valve mounting bolts (4, 5).
4. Remove the clutch pump check valve (3) by carefully pulling straight out of the differential carrier.
5. Remove the O-ring seals (1, 2) from the valve. The O-ring seals may be reused if not cut or damaged.
Fig. 4: Identifying Clutch Pump Check Valve Bolts
IMPORTANT: Inspect the clutch pump check valve O-ring seals in order to ensure they
are not cut or damaged. Replace cut or damaged O-ring seals with new
seals.
1. Lubricate the O-ring seals (1, 2) with synthetic gear oil GM P/N 12378514 (Canadian P/N 88901045) or
equivalent.
2. Install the O-ring seals to the valve.
3. Install the clutch pump check valve to the differential carrier by carefully pushing the valve straight in
until fully seated.
4. Install the clutch pump check valve mounting bolts (4, 5).
5. Connect the clutch pump check valve electrical connector.

6. Fill the rear differential lubricant. Refer to Lubricant Change in Rear Drive Axle.

LOCKING DIFFERENTIAL DESCRIPTION AND OPERATION
The all-wheel drive (AWD) system provides on-demand all-wheel drive, distributing variable torque/power to
the rear wheels via individual axle shaft assemblies. On-demand drive is provided to each of the rear wheels
only when slippage is detected at the front wheels. As long as there is no slippage at the front wheels, there is
no front-to-rear speed differential and no need for rear wheel drive torque. In the event there is front-to-rear
wheel speed differential/slippage, a rotational speed difference between the gerotor pump components occurs.
In those instances, the rotor draws fluid from the sump and through the internal passages of the differential
carrier, sending pressurized fluid to a piston, actuating the specific rear wheel clutch pack. In the event of a
spare wheel, of smaller diameter, in use on any of the 4 positions, the wheel rotational speed difference is
detected by the wheel speed sensors of the antilock brake system (ABS). The powertrain control module (PCM)
or the transmission control module (TCM) directs the differential inlet valve to close and block oil flow to the
gerotor pumps. The inlet valve also monitors the sump oil for an overtemperature condition. If differential oil
temperature exceeds 110C (230F), the valve will close and block oil flow to the gerotor pumps. In both spare
wheel usage and overtemperature conditions, an activated inlet valve will illuminate the control panel AWD
disable indicator.
View the list of major components that make up the AWD system below.
All-Wheel Drive (AWD) Disable Indicator
The AWD disable indicator is located in the instrument panel cluster (IPC). This lamp is used to inform the
driver that the AWD system has been disabled and no torque will be applied to the rear wheels during a slip
condition. The AWD disable indicator is controlled by the PCM/TCM via a class 2 message.
The differential clutch pump actuator check valve controls the oil flow to the gerotor pumps. Without fluid
pressure the pistons cannot apply the clutchpacks for rear wheel engagement. The actuator check valve will
open upon engine startup and remain open unless commanded closed by the PCM/TCM. The actuator check
valve also monitors the sump oil for an overtemperature condition. If differential oil temperature exceeds 110C
(230F), the valve will close and block oil flow to the gerotor pumps.

The PCM monitors the data from the ABS controller and rear drive module (RDM) for proper operating
conditions. If inappropriate conditions are present, the PCM commands the differential clutch pump actuator
check valve closed, disabling the AWD system. The PCM also commands the AWD disable indicator on.
Transmission Control Module (TCM)
The TCM monitors the data from the ABS controller and RDM for proper operating conditions. If inappropriate
conditions are present, the TCM commands the differential clutch pump actuator check valve closed, disabling
the AWD system. The TCM also commands the AWD disable indicator on.
AWD Axle Shafts - Aztek & Rendezvous

AXLE SHAFTS
The rear wheel drive axles are flexible assemblies. The rear wheel drive axles consist of the following
components:
2 wheel drive inner and outer shaft tri-pot joints.

A wheel drive shaft bar.
The wheel drive shaft bar connects the wheel drive shaft tri-pot joints. The wheel drive shaft tri-pot joints are
completely flexible. Both wheel drive shaft tri-pot joints can move in and out.
SEALS & CLAMPS
The rear wheel drive shaft tri-pot joint seals on the wheel drive axle are made of a thermoplastic material. The
clamps on the rear wheel drive axle seals are made of stainless steel. The seals provide protection of the internal
parts of the wheel drive shaft tri-pot joints. The seals also protect the grease from the following sources of
damage:
Harmful atmospheric conditions, such as extreme temperatures or ozone gas.

Foreign material, such as dirt or water.
Allows the angular and the axial movement of the rear wheel drive shaft tri-pot joints.
Protect the seals from sharp tools and from the sharp edges of the surrounding components. Any damage to the
seals or the clamps will result in leakage. Leakage will allow water to leak into the rear wheel drive shaft tri-pot
joints. Damage will also allow grease to leak out of the wheel drive shaft tri-pot joints. Leakage and the loss to
grease may cause noisy wheel drive shaft tri-pot operation and eventual failure of the internal components.
The clamps provide a leak proof connection for the wheel drive shaft tri-pot joints at the tri-pot housing and the
wheel drive shaft bar. The thermoplastic material performs well under normal conditions and normal operation.
However, the material is not strong enough to withstand abusive handling or damage from sharp objects, such
as tools or sharp edges of the surrounding vehicle components.
REAR WHEEL DRIVE SHAFT TRI-POT JOINTS
The rear wheel drive shaft tri-pot joints are made without an over-extension limitation retainer. Care must be
exercised when removing and installing the rear wheel drive shafts in order not to over-extend the tri-pot joints.
Damage and tri-pot failure may result. The joint is constructed as follows: The wheel drive axle has a female
spline. The female spline installs over an axle shaft that protrudes from the rear differential. The wheel drive
axle utilizes a barrel-type retaining ring in order to positively secure the inner tri-pot joint to the rear differential
axle shaft.
TROUBLE SHOOTING
NOTE: See FWD AXLE SHAFTS & CV JOINTS TROUBLE SHOOTING under
POWERTRAIN in BASIC TROUBLE SHOOTING article in GENERAL
INFORMATION.
AXLE SHAFTS
Tools Required; Slide Hammer (J 2619-O1) Axle Shaft Remover Extension (J 29794) Axle Shaft Puller (J
33008-A) Wheel Hub Remover (J 42129).
Removal
1. Apply the parking brake.

3. Remove the tire and wheel assembly.
NOTE: The wheel drive shaft nut must not be reused. Replace the wheel drive
shaft nut with NEW nut whenever it is removed.
4. Remove and discard the wheel drive shaft nut.

5. Release the parking brake.
6. Remove and support the brake caliper bracket.
7. Remove the nut securing the park brake cable routing bracket, if necessary.
8. Remove the bolt retaining the rear tie rod end from the rear suspension knuckle. Do NOT loosen the tie
rod end jam nut.
9. Loosen, but do not remove, the bolts securing the park brake cable bracket to the suspension knuckle.
11. Install the Wheel Hub Remover onto the wheel hub and secure with wheel nuts. See Fig. 1 .
12. Begin to disengage the wheel drive shaft from the wheel hub and bearing.
13. Remove the bolt and nut securing the upper control arm to the suspension knuckle.
14. Disengage the wheel drive shaft completely from the wheel hub and bearing.
15. Reposition the suspension knuckle toward the rear of the vehicle. Remove the Wheel Hub Remover from
the wheel hub.
NOTE: Support the wheel drive shaft until it is removed.
16. Assemble the Slide Hammer Axle Shaft Remover Extension and Axle Shaft Puller. See Fig. 2 and Fig.
3 . Install the tool assembly evenly onto the rear beveled surface of the wheel drive shaft inner joint
housing.
17. Disengage the wheel drive shaft from the rear axle differential using the tool assembly, then remove the
tool assembly.
18. Remove the wheel drive shaft from the vehicle.
NOTE: The differential output shaft oil seal must be replaced when removing the
rear wheel drive shaft.
19. Replace the rear wheel drive shaft oil seal.

Fig. 1: Identifying Wheel Hub Remover Tool
Fig. 2: Identifying Slide Hammer With Adapter
Fig. 3: Identifying Extension Tool
Installation
NOTE: Support the wheel drive shaft until it is completely installed. Do not damage the
differential output shaft oil seal.
1. Position the wheel drive shaft to the differential output shaft. Carefully align and guide the wheel drive
shaft onto the differential output shaft.
2. Install the wheel drive shaft fully onto the differential output shaft using light force.
3. Verify that the wheel drive shaft is fully seated on the differential output shaft retaining ring by grasping
the inner tripot housing and pulling outward. Do not pull on the wheel drive shaft bar. The wheel drive
shaft will remain firmly in place when properly engaged.
4. Begin to position the suspension knuckle to the wheel drive shaft. Align and carefully guide the wheel
drive shaft into the hub and bearing but do not seat fully.
5. Position the suspension knuckle to the upper control arm.
6. Install the bolt and nut to the upper control arm/suspension knuckle assembly. Tighten nuts and bolts to
7. Secure the park brake cable bracket.
8. Install the rear tie rod to the rear suspension knuckle.
9. Install the tie rod-to-knuckle bolt. Tighten bolt to specification. See TORQUE SPECIFICATIONS .
12. Install the park brake cable routing bracket and nut, if removed.
13. Set the park brake.
14. Install a NEW wheel drive shaft spindle nut. Slowly tighten the nut in order to draw the wheel drive shaft
spindle into the wheel hub and bearing. Tighten nut to specification. See TORQUE
SPECIFICATIONS .
15. Install the tire and wheel assembly.
OVERHAUL
INNER DRIVE SHAFT JOINT AND SEAL
Tools Required: Drive Axle Seal Clamp Pliers (J 35566) Drive Shaft Seal Clamp Pliers (J 42572).
Disassembly
1. Remove the small seal clamp from the wheel drive shaft bar using side cutters and discard the clamp.
NOTE: Do not cut into the wheel drive shaft trilobal tripot bushing.
2. Remove the large seal clamp from the tripot joint with side cutters and discard the clamp. See Fig. 4 .
3. Separate the wheel drive shaft inboard seal from the trilobal tripot bushing.
4. Slide the seal away from the joint along the wheel drive shaft bar.
5. Remove the housing from the tripot joint spider and the wheel drive shaft bar.
6. Remove the guide from the spring.
7. Remove the spring from the tripot housing.
NOTE: The correct 60 degree offset relationship between the inner and outer
tripot spiders must be maintained. Accurately reference mark the tripot
spider position on the wheel drive shaft bar before disassembly.
8. Reference mark the position of the tripot spider on the wheel drive shaft bar.
9. Using a brass drift and hammer, carefully tap around the tripot spider face in order to compress the barrel
retaining ring on the wheel drive shaft bar. Remove the tripot spider from the wheel drive shaft bar.
10. Remove and discard the barrel retaining ring from the wheel drive shaft bar.
11. Remove the joint seal from the wheel drive shaft bar.
12. Inspect the following parts for damage or wear:
The wheel drive shaft inboard seal
The tripot joint spider assembly
The housing
The trilobal tripot bushing

Fig. 4: Identifying Joint & Seal Components
Assembly
1. Place the NEW small seal clamp onto the small end of the joint seal.
2. Slide the joint seal and the small seal clamp onto the wheel drive shaft bar.
3. Position the small end of the joint seal into the joint seal groove on the wheel drive shaft bar. See Fig. 5 .
4. Using the Drive Shaft Seal Clamp Pliers, crimp the small seal retaining clamp. See Fig. 6 . Tighten the
clamp to specification. See TORQUE SPECIFICATIONS .
5. Install a NEW barrel retaining ring to the wheel drive shaft bar.
NOTE: The proper 60 degree offset relationship between the inner and outer tripot
spiders must be maintained. Align the reference mark on the tripot spider
and the wheel drive shaft bar. Ensure that the beveled edge of the tripot
spider faces the wheel drive shaft bar during reassembly.
6. Install the tripot spider to the wheel drive shaft bar, while compressing the barrel retaining ring with a
flat-bladed tool.
7. Verify positive engagement of the tripot spider to the wheel drive shaft bar by grasping the tripot spider
and attempting to pull free from the wheel drive shaft bar.
NOTE: Ensure the trilobal tripot bushing is flush with the face of the housing.
8. Place approximately half of the grease from the service kit in the wheel drive shaft inboard seal. Use the
remainder of the grease to repack the housing.
9. Install the spring to the tripot housing. Use grease from the housing in order to retain the spring.
10. Install the guide to the spring. Use grease from the housing in order to retain the guide.
11. Install the trilobal tripot bushing to the housing.
12. Position the larger NEW seal retaining clamp on the wheel drive shaft inboard seal.
13. Slide the housing over the tripot joint spider assembly on the wheel drive shaft bar.
14. Slide the large diameter of the wheel drive shaft inboard seal, with the larger clamp in place, over the
outside of the trilobal tripot bushing and locate the lip of the seal in the groove.
NOTE: The seal must not be dimpled, stretched or otherwise deformed. Inspect
the seal for proper shape. If the seal is not shaped correctly, equalize the
pressure in the seal by lifting the seal edge slightly and shape the seal
properly by hand.
15. Position the joint assembly at the proper vehicle dimension.

16. Align the following items while latching:
The wheel drive shaft inboard seal
The tripot housing
The large seal retaining clamp
17. Using the Drive Axle Seal Clamp Pliers, latch the large seal retaining clamp. See Fig. 7 . Ensure that the
latching tangs are fully engaged in the large seal clamp band.
18. Rotate the inner tripot housing 4 or 5 times in order to distribute the grease throughout the tripot spider
bearings.
Fig. 5: Installing New Seal
Fig. 6: Identifying Drive Shaft Seal Clamp Pliers
Fig. 7: Identifying Drive Axle Seal Clamp Pliers (J-35566)
OUTER DRIVE SHAFT JOINT AND SEAL
Tools Required: Drive Axle Seal Clamp Pliers (J 35566) Drive Shaft Seal Clamp Pliers (J 42572).
Disassembly
1. Remove the small seal clamp from the wheel drive shaft bar using side cutters and discard the clamp.
NOTE: Do not cut into the wheel drive shaft trilobal tripot bushing.
2. Remove the large seal clamp from the tripot joint with side cutters and discard the clamp. See Fig. 4 .
3. Separate the wheel drive shaft outboard seal from the trilobal tripot bushing.
4. Slide the seal away from the joint along the wheel drive shaft bar.
5. Remove the housing from the tripot joint spider and the wheel drive shaft bar.
NOTE: The correct 60 degree offset relationship between the inner and outer
tripot spiders must be maintained. Accurately reference mark the tripot
spider position on the wheel drive shaft bar before disassembly.
6. Reference mark the position of the tripot spider on the wheel drive shaft bar.
7. Using a brass drift and hammer, carefully tap around the tripot spider face in order to compress the barrel
retaining ring on the wheel drive shaft bar.
8. Remove the tripot spider from the wheel drive shaft bar.
9. Remove and discard the barrel retaining ring from the wheel drive shaft bar.
10. Remove the joint seal from the wheel drive shaft bar.
The wheel drive shaft outboard seal
The tripot joint spider assembly
The housing
The trilobal tripot bushing
Assembly
1. Place the new small seal clamp onto the small end of the joint seal.
2. Slide the joint seal and the small seal clamp onto the wheel drive shaft bar.
3. Position the small end of the joint seal into the joint seal groove on the wheel drive shaft bar. See Fig. 5 .
4. Using the Drive Shaft Seal Clamp Pliers, crimp the small seal retaining clamp. See Fig. 6 .
5. Install a new barrel retaining ring to the wheel drive shaft bar.
NOTE: The proper 60 degree offset relationship between the inner and outer tripot
spiders must be maintained.
6. Align the reference mark on the tripot spider and the wheel drive shaft bar.
NOTE: Ensure that the beveled edge of the tripot spider faces the wheel drive
shaft bar during reassembly.
7. Install the tripot spider to the wheel drive shaft bar, while compressing the barrel retaining ring with a
flat-bladed tool.
8. Verify positive engagement of the tripot spider to the wheel drive shaft bar by grasping the tripot spider
and attempting to pull free from the wheel drive shaft bar.
9. Place approximately half of the grease from the service kit in the wheel drive shaft outboard seal.
10. Use the remainder of the grease to repack the housing.
11. Install the trilobal tripot bushing to the housing. Install the spring to the tripot housing.
12. Use grease from the housing in order to retain the spring. Install the guide to the spring.
13. Use grease from the housing in order to retain the guide. Position the larger new seal retaining clamp on
the wheel drive shaft outboard seal.
14. Slide the housing over the tripot joint spider assembly on the wheel drive shaft bar. Slide the large
diameter of the wheel drive shaft outboard seal, with the larger clamp in place, over the outside of the
trilobal tripot bushing and locate the lip of the seal in the groove.
NOTE: The seal must not be dimpled, stretched or otherwise deformed.
15. Inspect the seal for proper shape. If the seal is not shaped correctly, equalize the pressure in the seal by
lifting the seal edge slightly and shape the seal properly by hand.
16. Position the joint assembly at the proper vehicle dimension. While latching, align the wheel drive shaft
outboard seal,the tripot housing and the large seal retaining clamp.
17. Using the Drive Axle Seal Clamp Pliers, latch the large seal retaining clamp. See Fig. 7 . Ensure that the
latching tangs are fully engaged in the large seal clamp band.
18. Rotate the outer tripot housing four or five times in order to distribute the grease throughout the tripot
spider bearings.
Axle Shaft Nut 192 (260)
Hub & Bearing Bolts 63 (85)
Seal Clamp 100 (136)
Tie Rod Bolt 63 (85)
Upper Control Arm-to-Knuckle Bolt 63 (85)
Wheel Lug Nut 100 (136)
INCH Lbs. (N.m)
Park Brake Cable Bracket Nut 89 (10)
Differential - Aztek & Rendezvous

DIFFERENTIAL
The rear differential assembly consists of a torque tube assembly, three-piece differential housing, ring and
pinion, and a differential carrier assembly. See Fig. 2 . The aluminum torque tube housing contains an internal
drive shaft that is supported by roller bearings at each end. The internal drive shaft is retained to the front
propeller shaft assembly by bolts and splined to the differential pinion shaft. External to the tube are a vehicle
mounting bracket and a noise and vibration dampener.
The pinion shaft is positioned in an aluminum pinion housing and is supported by tapered roller bearings. See
Fig. 2 . A shim between the pinion and differential housings provides the proper backlash for the ring and
pinion. The ring gear is retained externally to the differential carrier assembly by bolts. Both the transfer case
hypoid gears and the rear differential assembly use unique type synthetic gear oil. The differential carrier
assembly consists of left and right side clutch pack drum, separate left and right axle sub shafts, left and right
gerotor pump components, left and right clutch packs, left and right pistons, and internal valves. See Fig. 2 .
The Versatrak(R) on-demand system operates as follows: The drive shaft assembly, mated to the output flange
of the transfer case, is constantly rotating and spins at a rate equal to an average of the two front wheels. Under
normal straight-ahead non-slip driving conditions, the external and internal gears of the differential gerotor
pumps are rotating at an equal rate of speed. Under those conditions, there is no speed differential between the
pump gears, no pump pressure created, no clutch pack activation, and no torque transfer. During a front-wheel
slip condition, the external gears of the gerotor pumps rotate at a faster rate of speed than the rear-wheel driven
internal gears. See Fig. 2 . The gerotor pumps pull oil from the sump through the clutch pump check valve
sending pressurized oil to each individual piston to activate the separate clutch packs. On-demand torque/drive
is provided to each of the rear wheels as required. A valve internal to each piston housing controls maximum
clutch pack pressure. A second valve within each housing is temperature compensating and controls fluid flow
based on ambient temperature. The system operates in both forward and rearward vehicle directions.
In the event a spare wheel of a smaller diameter is used on any of the four positions, the wheel rotational speed
difference is detected by the wheel speed sensors of the Anti-Lock Brake System (ABS) system. The
Powertrain Control Module (PCM) directs the clutch pump check valve to close and block oil flow to the
gerotor pumps. The clutch pump check valve also monitors the sump oil for an over-temperature condition. If
differential oil temperature exceeds 230F (110C), the valve will close and block oil flow to the gerotor pumps.
In both spare wheel usage and over-temperature conditions, a "closed" valve will alert the PCM to illuminate
the control panel AWD DISABLE light.
DIFFERENTIAL LOCK SYSTEM
The All Wheel Drive (AWD) system provides On-Demand all wheel drive, distributing variable torque/power
to the rear wheels via individual axle shaft assemblies. On-Demand drive is provided to each of the rear wheels
wheel speed differential/slippage, a rotational speed difference between the gerotor pump components (rotor
and housing) occurs. In those instances, the rotor draws fluid from the sump and through the internal passages
of the differential carrier, sending pressurized fluid to a piston (actuating the specific rear wheel clutch pack). In
the event of a spare wheel (of smaller diameter) is used on any of the 4 positions, the wheel rotational speed
difference is detected by the wheel speed sensors of the ABS system. The powertrain module directs the
differential inlet valve to close and block oil flow to the gerotor pumps. The inlet valve also monitors the sump
oil for an "overtemperature" condition. If differential oil temperature exceeds 230F (110C), the valve will
close and block oil flow to the gerotor pumps. In both spare wheel usage and overtemperature conditions, an
activated inlet valve will illuminate the control panel AWD DISABLE indicator.
AWD DISABLE indicator
The AWD DISABLE indicator is located in the instrument panel cluster. This lamp is used to inform the driver
that the AWD system has been disabled and no torque will be applied to the rear wheels during a slip condition.
The AWD DISABLE indicator is controlled by the Powertrain Control Module (PCM) via a class 2 message.
pressure, the pistons cannot apply the clutchpacks for rear wheel engagement. The actuator check valve will
open upon engine start-up and remain open unless commanded closed by the Powertrain Control Module
(PCM). The actuator check valve also monitors the sump oil for an overtemperature condition. If differential oil
temperature exceeds 230F (110C), the valve will close and block oil flow to the gerotor pumps
Powertrain Control Module
The Powertrain Control Module (PCM) monitors the data from the ABS controller and Rear Drive Module
(RDM) for proper operating conditions. If inappropriate conditions are present the PCM commands the
differential clutch pump actuator check valve closed, disabling the AWD system. The PCM also commands the
AWD DISABLE indicator on.
COMPONENT LOCATIONS
See Fig. 1 and Fig. 2 for views of differential assembly.
Fig. 1: Exploded View Of Rear Axle Shaft & Differential
Courtesy of GENERAL MOTORS
Fig. 2: Identifying Differential Components
LUBRICATION
FLUID TYPE & CAPACITY
Use synthetic Gear Oil (12378514 for US; 88901045 for Canada). Fluid capacity is 2.1 qts. (1.9L).
LUBRICANT CHANGE
Raise and support the vehicle. Clean any dirt from around the differential drain plug. Position a drain pan under
drain plug. Remove the drain plug and gasket from the differential, and drain the oil. Install the drain plug and
gasket to the differential. Tighten the differential drain plug to specification. See TORQUE
SPECIFICATIONS . Clean any dirt from around the differential fill plug. Remove the fill plug from the
differential. Fill the differential with synthetic gear oil. See FLUID TYPE & CAPACITY . Inspect the gear oil
level to ensure it is even with the bottom of the fill plug hole to no lower than 0.25" (6 mm) below the opening.
Install the fill plug and gasket to the differential. Tighten the fill plug to specification. See TORQUE
SPECIFICATIONS . Lower the vehicle. Drive the vehicle in tight left and right circles after filling the
differential in order to distribute the gear lubricant throughout the differential and engage the all-wheel-drive
system. Raise and support the vehicle. Remove the fill plug from the differential. Inspect the gear oil level to
ensure it is even with the bottom of the fill plug hole to no lower than 0.25" (6 mm) below the opening.
Reinstall the fill plug and gasket to the differential and tighten the fill plug to specification. See TORQUE
SPECIFICATIONS . Lower the vehicle.
TROUBLE SHOOTING
DIAGNOSTIC STARTING POINT - REAR DIFFERENTIAL CARRIER
Begin the system diagnosis by reviewing the Fig. 1 , Fig. 2 , DIFFERENTIAL and DIFFERENTIAL LOCK
SYSTEM under DESCRIPTION & OPERATION. Reviewing the description and operation information will
help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the
description and operation information will also help you determine if the condition described by the customer is
normal operation. See SYMPTOMS - REAR DIFFERENTIAL CARRIER in order to identify the correct
DIAGNOSTIC STARTING POINT - REAR AXLE CONTROLS
Begin the system diagnosis with DIAGNOSTIC SYSTEM CHECK - REAR AXLE CONTROLS . The
The Identification of the control module(s) which command the system.

The ability of the control module(s) to communicate through the serial data circuit.
DIAGNOSTIC SYSTEM CHECK - REAR AXLE CONTROLS
Circuit Description
The Diagnostic System Check is an organized approach to identify a condition created by the rear axle controls.
The Diagnostic System Check is the starting point for a rear axle controls complaint. The Diagnostic System
Check directs you to the next logical step for diagnosing a rear axle control concern. Perform this check only if
there is a driveability complaint or if you have been directed here from another service information section.
Follow the table to help reduce diagnostic time and help prevent unnecessary replacement of parts.
Diagnostic Aids
Do not clear the DTC unless directed by a diagnostic procedure. Clearing the DTCs will erase all Freeze
Frame and Failure Records stored in PCM memory.
Use a scan tool that is known to function correctly. If necessary, test the scan tool on another vehicle.
Ensure the scan tool contains the most current file available.
The scan tool will display a loss of communication error message under the following conditions:
A. The PCM power is interrupted.
B. The ignition switch is turned OFF.
C. The battery voltage level is very low.
D. A poor connection at the diagnostic link connector (DLC).
Testing
NOTE: Check for applicable service bulletins before proceeding with this test. Perform
this test only if there is a driveability complaint or if you have been directed to
this table from another section in the service information. Do not turn the
ignition OFF when performing this diagnostic procedure. Do not clear the DTCs
unless instructed by this diagnostic procedure.
NOTE: This step determines if the scan tool is receiving power through the DLC
connector.
1. Install a scan tool. Turn ON the ignition, with the engine OFF. Does the scan tool turn ON? If so go to
next step. If not, go to SCAN TOOL DOES NOT POWER UP in appropriate BODY CONTROL
MODULES article.
NOTE: This step determines if the PCM is transmitting class 2 serial data to the
DLC and that the Class 2 data circuit is not open or shorted.
2. Attempt to establish communication with the PCM. Does the scan tool communicate with the PCM? If so
go to next step. If not, go to SCAN TOOL DOES NOT COMMUNICATE WITH CLASS 2 DEVICE in
appropriate BODY CONTROL MODULES article.
NOTE: The presence of DTCs indicates that the powertrain control module has
detected a fault. Go to symptoms for other concerns.
3. Select the powertrain control module display DTCs function on the scan tool. Does the scan tool display
any DTCs? If so go to next step. If not go to SYMPTOMS - REAR AXLE CONTROLS .
NOTE: This step determines if a DTC is current or stored in history.
4. Does the scan tool display any DTCs which begin with a "U"? If so go to SCAN TOOL DOES NOT
COMMUNICATE WITH CLASS 2 DEVICE in appropriate BODY CONTROL MODULES article. If
not, go to appropriate SELF DIAGNOSTICS in FAULT ISOLATION under ENGINE
PERFORMANCE.
SYMPTOMS - REAR DIFFERENTIAL CARRIER
NOTE: For noise concerns, see TROUBLE SHOOTING in VIBRATION - DRIVETRAIN

under GENERAL INFORMATION article.
Inspect for aftermarket devices, which could affect the operation of the vehicle.
Inspect the easily accessible or visible system components for obvious damage or conditions, which could
cause the symptom.
Check for the correct lubricant level and the proper viscosity.
Verify the exact operating conditions under which the concern exists. Note factors such as vehicle speed,
road conditions, ambient temperature, and other specifics.
Compare the driving characteristics or sounds, if applicable, to a known good vehicle and make sure you
are not trying to correct a normal condition.
Inspect for all-wheel drive activation and operation. See
Factors that may contribute to an inoperative rear differential include:
A. Low gear oil levels.
B. Differential inoperative due to Anti-Lock Brake System (ABS) function.
C. Inoperative Powertrain Control Module (PCM) and/or wiring system.
D. A mini spare or different size tire installed.
E. A fluid over-temperature condition.
F. An inoperative or "stuck" clutch pump check valve.
G. A defective rear differential assembly.
H. An inoperative transfer case assembly.
SYMPTOMS - REAR AXLE CONTROLS
Inspect for aftermarket devices which could affect the operation of the Rear Axle Control System.
cause the symptom.
Symptom List
For ALL-WHEEL DRIVE (AWD) INDICATOR ALWAYS ON testing, go to appropriate GAUGES &
INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
For DIFFERENTIAL LOCK INDICATOR INOPERATIVE testing, go to appropriate GAUGES &
INSTRUMENT PANELS article in ACCESSORIES & EQUIPMENT.
NOTE: DO NOT use a scan tool that displays faulty data. The use of a faulty scan tool
can result in misdiagnosis and the unnecessary replacement of parts. Only the
parameters listed under SCAN TOOL DEFINITIONS are used in diagnosing. If a
scan tool displays other parameters, the values are not recommended by
General Motors for use in diagnosis.
Only use scan tool diagnostics under the following conditions:

No DTCs are present.
The values listed in AWD SCAN TOOL DATA LIST table represent a typical display recorded from a
properly functioning system, recorded under the following conditions:
Engine at idle.
Upper radiator hose hot.
Closed throttle.
Transmission in PARK.
Closed Loop operation.
Accessories OFF.
Brake pedal not applied.
AWD SCAN TOOL DATA LIST

AWD Circuit Status (1) OK/Short/Open OK
AWD Clutch temperature (1) Yes/No No
Disable
AWD Duty Cycle (1) Percent Varies
AWD Fluid temperature (1) Yes/No No
Disable
AWD Voltage Disable (1) Yes/No No
AWD Mini Spare Disable (1) Yes/No No
AWD Overtemperature (1) Yes/No No
Display
AWD Torque Management (1) Active/Inactive Inactive
AWD Wheel Speed (1) Yes/No No
Disable
Last Disable Reason (1) Fluid Temp, Clutch Varies
Temp, Wheel Speed,
Voltage, Mini Spare,
ABS System
Current Gear (1) (2) (3) (4) (5) (6) (7) 1, 2, 3, 4 1
ECT (1) (2) (3) C (F) Varies
Engine Speed (1) (2) (3) (4) (5) (6) (7) RPM 650-750 RPM
Engine Torque (1) (2) (3) N.m (Ft. Lbs.) Varies
Gear Ratio (1) (2) (3) (4) (5) (6) Ratio 3.98
Ignition Voltage (1) (2) Volts 12.5-15.5
TP Angle (1) (2) (3) (4) (5) (6) (7) Percent 0%
Trans. Fluid Temp. (1) (2) (3) (7) C (F) Varies
Transmission ISS (1) (2) (3) (4) (5) (6) RPM 600-700 RPM
Transmission OSS (1) (2) (3) (4) (5) (6) RPM 0
Vehicle Speed (1) (2) (3) (4) (5) (6) MPH (KM/H) 0
(1) AWD data.
(2) Transmission data.
(3) TCC data.
(4) 1-2 Shift data.
(5) 2-3 Shift data.
(6) 3-4 Shift data.
(7) PC Solenoid data.
Scan Tool Data Definitions
AWD Circuit Status
Displays OK, Short or Open. This parameter indicates the status of the PWM signal line to the AWD
solenoid. The PCM can detect a short to ground, a short to power, or an open in the PWM signal line. The
AWD DISABLE light will be illuminated for Short and Open conditions.
AWD Clutch Temperature Disable
Displays Yes or No. This parameter displays the status of powertrain software that has the ability to
disable AWD based on a rear drive module clutch slip/time calculation. If the software determines that a
clutch over-temperature condition could exist, the PCM will deactivate the AWD system by disabling the
PWM signal line to the AWD solenoid. The AWD System will be re-enabled when the software
calculates that the clutch temperatures have dropped sufficiently. The AWD DISABLE light will be
illuminated for a YES condition.
AWD Duty Cycle
The All Wheel Drive (AWD) Duty Cycle parameter displays the commanded state of the AWD solenoid
expressed as a percent of ON time. At vehicle start-up, duty cycle will be at 75-90% for 3 seconds. This is
referred to as the pull-in duty cycle. After 3 seconds the duty cycle will drop to 20-30% for 30 seconds.
This is referred to as the hold-in duty cycle. After each 30 second hold-in period, the duty cycle will be
increased to 75-90%, pull-in duty cycle, for 0.5 second before returning to the hold-in duty cycle. This is
to assure solenoid pull-in.
AWD Fluid Temperature Disable
Displays YES or NO. This parameter indicates a fluid over-temperature condition in the rear drive
module. When the sump temperature exceeds approximately 230F (110C), a pull-up resistor grounds
the PWM signal line from the PCM at the AWD solenoid. The pull-up resistor is an integral part of the
AWD solenoid. The pull-up resistor will close the valve and command the PCM to illuminate the AWD
DISABLE light for a YES condition. The scan tool will indicate a 100% duty cycle because the pull-up
resistor in the valve is bypassing the PCM.
AWD Voltage Disable
Displays YES or NO. This parameter indicates whether the ignition voltage to the AWD solenoid is in the
proper range. The ignition voltage range to the AWD solenoid is 9.0 to 16.0 volts. The PCM will
deactivate the AWD system by disabling the PWM signal line to the AWD solenoid if the ignition
voltage is out of range. The AWD DISABLE light will be illuminated for a YES condition.
AWD Mini Spare Disable
The All Wheel Drive (AWD) Mini spare Disable parameter indicates whether the ABS module detects a
mini spare on the vehicle and displays Yes or No. The wheel rotational speed difference is detected by the
wheel speed sensors of the ABS system. If the ABS module detects a mini spare on the vehicle, the PCM
will deactivate the AWD system by disabling the PWM signal line to the AWD solenoid. The AWD
Disabled lamp will be illuminated for a Yes condition.
AWD Overtemperature Delay
The All Wheel Drive (AWD) Overtemperature Delay parameter indicates whether the AWD system is in
a reset mode following an AWD fluid temperature disable and displays Yes or No. There is a 10 minute
delay from the time the rear drive module resistor closes the PWM signal line until the PCM again checks
the signal line for an overtemperature condition. The rear drive module resistor is an integral part of the
AWD solenoid. The AWD Disabled lamp will be illuminated for a Yes condition.
AWD Torque Management
Displays ACTIVE or INACTIVE. This is an indication that some form of torque management is being
performed to protect the AWD System. If either or both of these powertrain software features are
functioning, a service scan tool will display ACTIVE.
AWD Wheel Speed Disable
Displays Yes or No. This parameter indicates whether the wheel speed data received from the ABS
controller is valid. If the ABS module detects an unacceptable wheel speed differential, the PCM will
deactivate the AWD system by disabling the PWM signal line to the AWD solenoid. The AWD
DISABLE, BRAKE, and ANTI-LOCK Indicators, will be illuminated for a Yes condition. The chime
will also sound.
AWD DISABLE Mileage
Displays mileage. This parameter indicates the vehicle mileage at which the AWD Last Disable condition
occurred.
Current Gear
Displays 1, 2, 3 or 4. This parameter indicates the current commanded state of the shift solenoid valves.
ECT (Engine Coolant Temperature)
The Engine Coolant Temperature (ECT) sensor is mounted in the coolant stream and sends engine
temperature information to the PCM. The PCM applies 5 volts to the ECT sensor circuit. The sensor is a
thermistor that changes internal resistance as temperature changes. When the sensor is cold, the internal
resistance is high, the PCM monitors a high signal voltage. The PCM interprets this voltage as a cold
engine. As the sensor warms, the internal resistance decreases, the voltage signal will decrease. The PCM
interprets the lower voltage as a warm engine.
Engine Speed
This parameter indicates the rotational speed of the engine expressed as revolutions per minute. The
engine speed is computed by the PCM from the fuel control reference input, the crankshaft position
sensor.
Engine Torque
This parameter indicates the amount of torque being delivered by the engine and is displayed in both
English and metric units.
Gear Ratio
This display is the actual transmission gear ratio as the transmission operates through all DRIVE,
REVERSE and PARK/NEUTRAL ranges.
Ignition Voltage
This parameter is the system voltage measured by the PCM at the PCM ignition input when the ignition
switch is in the RUN position.
Last Disable Reason
Displays only the last AWD DISABLE reason. The possible reasons are output controls, fluid temp,
clutch temp, wheel speed, voltage, mini spare or ABS System. The output controls reason indicates that
AWD was last disabled with a service scan tool. Fluid temp, clutch temp, wheel speed, voltage and mini
spare each have a unique parameter that is described elsewhere in this table. ABS system reason indicates
that messages normally sent to the PCM by the ABS controller are missing.
TP (Throttle Position) Angle
Displays 0-100%. The TP angle is computed by the PCM from the TP sensor voltage. The TP angle
should display 0% at idle and 100% at Wide Open Throttle (WOT).
Trans. Fluid Temp. (Transmission Fluid Temperature)

The Transmission Fluid Temperature parameter displays the temperature conversion of the voltage input
signal to the PCM from the transmission fluid temperature (TFT) sensor. When the TFT is high 304F
(151C), the signal voltage is low, 0 volts. When the TFT is low -40F (-40C), the signal voltage is high,
5 volts.
Transmission ISS (Input Shaft Speed)
Displays 600-700 RPM. This parameter is the rotational speed of the transmission input shaft as
expressed in Revolutions Per Minute (RPM).
Transmission OSS (Output Shaft Speed)
Displays 0 RPM. This display indicates the rotational speed of the transmission output shaft as expressed
in Revolutions Per Minute (RPM).
Vehicle Speed
This parameter is the Vehicle Speed Sensor (VSS) input signal converted by the PCM to be displayed as
vehicle speed in both Metric and English units.
in the service procedure. DO NOT use paints, lubricants, or corrosion inhibitors
DIFFERENTIAL ASSEMBLY
Removal
1. Set the parking brake. Raise and support the vehicle. Remove the right rear tire/wheel assembly. Place a
drain pan beneath the differential. Remove the differential drain plug. See Fig. 1 . Drain the rear
differential gear oil. Disconnect the electrical connector from the clutch pump check valve. See Fig. 1 .
Remove the right rear axle shaft. See appropriate AXLE SHAFTS - REAR article in
DRIVELINE/AXLE. Remove the front drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL
JOINTS article in DRIVELINE/AXLE.
2. Place an adjustable support beneath the torque tube. Loosen, but DO NOT remove the torque tube-to-
bracket through-bolt and nut. Remove torque tube bracket-to-body bolts. Remove the differential carrier-
to-cradle mounting bolts, nuts, washers and mounts from the differential. During the removal of the axle
shaft, the differential output shaft may become disengaged from the differential. If this occurs, firmly
grasp and separate the output shaft from the axle shaft. Align the splines on the output shaft to the
differential and reposition the output shaft to the differential.
3. While simultaneously moving the differential assembly to the right side of the vehicle, disengage the left
axle shaft from the differential. Remove the rear differential and torque tube as an assembly. Remove the
torque tube from the differential. See TORQUE TUBE ASSEMBLY .
Installation
1. Install the torque tube to the differential. See TORQUE TUBE ASSEMBLY . Install the rear differential
and torque tube assembly to the suspension cradle. Simultaneously guide the left axle shaft onto the
differential output shaft while positioning the differential assembly to the suspension cradle. Place an
adjustable support under the torque tube. Ensure that the left axle shaft is fully engaged to the differential
output shaft. Install the differential carrier mounts, washers, bolts and nuts to the differential.
2. Tighten the differential carrier-to-cradle mounting bolts to specification. See TORQUE
SPECIFICATIONS . Install the torque tube bracket-to-body bolts. Tighten the torque tube bracket-to-
body bolts to specification. See TORQUE SPECIFICATIONS . Tighten the torque tube-to-bracket
through-bolt and nut to specification. See TORQUE SPECIFICATIONS .
3. Install the front drive shaft. See appropriate DRIVE SHAFTS & UNIVERSAL JOINTS article under
DRIVELINE/AXLE. Install the right axle shaft. See appropriate AXLE SHAFTS - REAR article in
DRIVELINE/AXLE. Install the right rear tire and wheel assembly. Tighten bolts to specifications. See
TORQUE SPECIFICATIONS . Install the differential drain plug and gasket to the differential. Tighten
the drain plug to specification. See TORQUE SPECIFICATIONS .
4. Remove the differential fill plug. See Fig. 1 . Fill the axle with synthetic gear oil. Inspect the differential
oil level to ensure it is even with, to no lower than, 0.25" (6 mm) below the opening of the fill hole. See
LUBRICATION . Fill differential as necessary. Install the differential fill plug and gasket. Tighten the
fill plug to specifications. See TORQUE SPECIFICATIONS .
5. Connect the electrical connector to the clutch pump check valve. Remove the adjustable support from the
torque tube. Lower the vehicle. Operate the vehicle making tight left, then right turns in order to engage
the all-wheel-drive system and distribute the gear oil throughout the differential. Raise and support the
vehicle. Remove the differential fill plug. Fill the axle with synthetic gear oil. Inspect the differential oil
level to ensure it is even with, to no lower than, 0.25" (6 mm) below the opening of the fill hole. Install
the differential fill plug and gasket. Tighten the fill plug to specification. See TORQUE
SPECIFICATIONS . Lower the vehicle.
DIFFERENTIAL CARRIER ASSEMBLY MOUNT
Removal
1. Raise and support the vehicle. Support the front of the differential with a suitable stand. Loosen, but do
not remove, the torque tube-to-bracket through bolt and nut. See Fig. 1 .
2. Remove the cradle-to-differential mounting bolts, nuts, washers, and bushings from the differential. See
Fig. 3 . Raise the stand slightly in order to gain access to the differential-to-cradle bushings. Remove the
differential-to-cradle bushings. See Fig. 3 .
Fig. 3: Identifying Differential Mounting Bolts And Bushings
Installation
1. Install the differential-to-cradle bushings. See Fig. 3 . Lower and remove the jack stand.
2. Install the cradle-to-differential mounting bolts, bushings, washers, and nuts to the differential. Tighten
the bolts and nuts to specifications. See TORQUE SPECIFICATIONS .
3. Secure the torque tube-to-bracket through bolt and nut. Tighten the bolt and nut to specifications. See
TORQUE SPECIFICATIONS . Lower the vehicle.
DIFFERENTIAL CLUTCH PUMP CHECK VALVE
Removal
Drain the differential lubricant. See LUBRICATION . Disconnect the clutch pump check valve electrical
connector. Remove the clutch pump check valve mounting bolts. See Fig. 1 . Remove the clutch pump check
valve by carefully pulling straight out of the differential carrier. Remove the "O" ring seals from the valve. The
"O" ring seals may be reused if not cut or damaged. If reinstalling original valve, inspect for damaged, loose, or
missing pick up screen, damaged or missing "O" rings, damaged electrical connector, or oil passages restricted
by dirt or debris.
Installation
NOTE: Inspect the clutch pump check valve "O" ring seals to ensure they are not cut
or damaged. Replace cut or damaged "O" ring seals with NEW seals.
1. Lubricate the "O" ring seals with Synthetic Gear Oil (12378514 for United States or 88901045 for
Canada) or equivalent. Install the "O" ring seals to the valve. Install the clutch pump check valve to the
differential carrier by carefully pushing the valve straight in until fully seated.
2. Install the clutch pump check valve mounting bolts. See Fig. 1 . Tighten the bolts to specification. See
TORQUE SPECIFICATIONS . Connect the clutch pump check valve electrical connector. Inspect
differential fluid level. See LUBRICATION . Fill differential as necessary.
DRIVE PINION FLANGE/YOKE &/OR OIL SEAL
Removal
NOTE: The internal components of the torque tube assembly cannot be serviced
separately. If corrosion exists that cannot be polished off, or there is excessive
scoring or wear, the torque tube must be replaced as a complete assembly.
Drain differential. Remove the torque tube assembly. See TORQUE TUBE ASSEMBLY . Remove the drive
pinion housing oil seal, and discard. See Fig. 1 . Inspect the sealing surface of the drive shaft contained inside
the torque tube. Polish corrosion off with a crocus cloth.
Installation
NOTE: Required Tools: Seal Installer (J-44915).
Lubricate the NEW pinion housing assembly "O" ring and oil seal with Synthetic Gear Oil (12378514 for
United States; 88901045 for Canada) or equivalent. Use the Seal Installer in order to install the NEW oil seal to
the drive pinion housing. Install the torque tube assembly. See TORQUE TUBE ASSEMBLY . Tighten bolts
to specification. See TORQUE SPECIFICATIONS . Inspect the differential carrier lubricant level. See
LUBRICATION .
DRIVE PINION HOUSING AND/OR SEAL
Removal
1. Drain the differential lubricant. See LUBRICATION . Remove the torque tube assembly. See TORQUE
TUBE ASSEMBLY . Remove the drive pinion oil seal from the drive pinion housing and discard. See
Fig. 1 .
2. Remove the pinion housing-to-differential bolts. Remove the drive pinion and housing assembly.
Carefully remove the drive pinion housing shim from the differential. See Fig. 1 .
3. Remove the O-ring seal from the drive pinion housing and discard.
Installation
1. Lubricate the O-ring seal with synthetic gear oil GM P/N United States 12378514 Canada P/N 88901045
or equivalent. Using the Seal Installer, install the oil seal to the drive pinion housing. Install the O-ring
seal to the drive pinion housing.
2. Carefully install the drive pinion housing assembly and shim to the differential carrier. See Fig. 1 . Install
the pinion housing-to-differential mounting bolts. Tighten the bolts specifications. See TORQUE
SPECIFICATIONS .
3. Lubricate the sealing surfaces of the drive pinion oil seal with synthetic gear oil GM P/N United States
12378514 Canada P/N 88901045 or equivalent. Install the torque tube assembly. See TORQUE TUBE
ASSEMBLY . Fill the differential with synthetic gear oil. See LUBRICATION .
REAR AXLE SHAFT SEALS
NOTE: Required Tools: Output Shaft Seal Installer (J-44809).
NOTE: Inspect the sealing surface of the axle shaft inner tri-pot housing to ensure it is
free of corrosion. Use a crocus cloth in order to remove any light corrosion and
clean the sealing surface with denatured alcohol, or equivalent.
Raise and support the vehicle. Remove the left rear or right rear tire and wheel assembly. Remove the left axle
shaft or right axle shaft. See appropriate AXLE SHAFT - REAR article under DRIVELINE/AXLES. Remove
the differential output shaft oil seal. See Fig. 1 . Do not damage the differential sealing surfaces. Using the
Output Shaft Seal Installer, install the left or right axle shaft oil seal. Lubricate the axle shaft sealing surfaces of
the oil seal with synthetic gear oil GM P/N 12378514 Canadian P/N 88901045 or equivalent. Install the right or
left axle shaft. See appropriate AXLE SHAFT - REAR article under DRIVELINE/AXLES. Install the right or
left rear tire and wheel assembly. Tighten bolts to specifications. See TORQUE SPECIFICATIONS . Inspect
the differential lubricant level. See LUBRICATION . Lower the vehicle.
TORQUE TUBE ASSEMBLY
Removal
NOTE: The drive pinion oil seal must be replaced whenever the torque tube is
removed.
1. Raise and support the vehicle. Position a jack stand under the front of the rear differential and firmly
secure the differential to the jack. Remove the front drive shaft. See appropriate DRIVE SHAFT &
UNIVERSAL JOINTS article under DRIVELINE/AXLE.
2. Remove the bolts from the torque tube bracket. See Fig. 1 . Loosen, but DO NOT remove, the torque
tube-to-bracket through-bolt and nut. Remove the torque tube-to-differential bolts. Pull the torque tube
toward the front of the vehicle in order to disengage the torque tube from the differential pinion shaft.
Remove the torque tube from the differential. Remove the oil seal from the drive pinion housing and
discard.
Installation
1. Using Seal Installer, install a NEW oil seal to the drive pinion housing. See Fig. 1 . Align the splines on
the torque tube shaft to the differential pinion shaft. Install the torque tube to the differential.
2. Install the bolts to the torque tube bracket. Tighten the torque tube bracket bolts to specification. See
TORQUE SPECIFICATIONS . Tighten the torque tube-to-bracket through-bolt and nut to
specification. Install the torque tube-to-differential carrier bolts. Tighten the bolts to specification. See
3. Install the front drive shaft. See appropriate DRIVE SHAFT & UNIVERSAL JOINTS article under
DRIVELINE/AXLES. Tighten the mounting bolts to specification. See TORQUE SPECIFICATIONS .
Remove the jack stand from under the front of the rear differential. Lower the vehicle.
TORQUE TUBE MOUNTING BRACKET
Removal
Raise and support the vehicle. Place a jack stand under the torque tube. Remove the torque tube-to-bracket
through-bolt, nut, washers and spacers. Remove the torque tube bracket-to-body bolts. See Fig. 1 . Lower the
jack stand slightly in order to gain access to the torque tube bracket. Remove the torque tube-to-bracket through
bolt, nut, washers, and spacers. Remove the torque tube bracket.
Installation
NOTE: DO NOT fully tighten the torque tube-to-bracket through-bolt. Hand tighten only
until the bracket is secured to the vehicle body.
1. Install the torque tube bracket. Install the torque tube-to-bracket through-bolt, nut, washers and spacers.
Raise the jack stand in order to install the torque tube mounting bracket to the vehicle body.
2. Install the torque tube bracket-to-body bolts. Tighten the torque tube mounting bracket-to-body bolts to
specification. Tighten the torque tube-to-bracket through-bolt to specification. See TORQUE
SPECIFICATIONS . Remove the jack stand. Lower the vehicle.
VENT HOSE
Raise and support the vehicle. Remove the vent hose clamp from the vent hose. Release the grommet securing
the vent hose to the vehicle underbody. Remove the vent hose from the differential assembly vent tube by
carefully twisting the hose. See Fig. 1 . Install the vent hose to the differential assembly. Install the vent hose
clamp to the vent hose. Secure the grommet on the vent hose to the vehicle underbody. Lower the vehicle.
OVERHAUL
DIFFERENTIAL ASSEMBLY
Disassembly
NOTE: Do not disassemble the side cover or differential assembly. Oil seal damage or
the entry of foreign material into the hydraulic system may effect system
operation.
1. Remove the lubricant drain plug and gasket from the differential. See Fig. 1 . Allow the lubricant to drain.
Remove vent hose assembly and clamp. See VENT HOSE . Remove clutch pump check valve. Remove
"O" rings from check valve. The O-ring seals may be reused if not cut or damaged.
NOTE: Do not remove the dampeners from the torque tube. Removal and
reinstallation may effect component noise and/or vibration levels.
2. Remove torque tube bracket nut, bolt and spacers. Remove torque tube bracket. See Fig. 1 . Remove
torque tube-to-differential bolts. Separate torque tube from differential. Remove bolts from differential.
3. Remove pinion housing and shim. Remove oil seal and "O" ring from pinion housing. Remove left and
right axle shaft oil seals. See REAR AXLE SHAFT SEALS .
Differential Inspection
Inspect the differential for the following:
A damaged or restricted vent tube.

Damaged oil seal bores.
Damaged clutch pump check valve bore or bolt threads.
Worn or scored pinion housing bore.
Damage to the exterior of the differential.
Damaged axle shaft splines and/or missing axle shaft snap rings.
Rotate the pinion shaft by hand. The shaft should rotate with minimal resistance and no coarse or rough feeling.
If shaft rotation is not as described, inspect the pinion and housing assembly for the following:
Worn or damaged splines.

Abnormal pinion gear tooth wear.
Damaged pinion housing "O" ring seal groove.
Damaged oil seal and Worn bearings.
Reassembly
NOTE: Required Tools: Seal Installer (J-44809) and Output Shaft Seal Installer (J-
44809).
1. Using the Seal Installer, install left and right axle shaft oil seals. See REAR AXLE SHAFT SEALS .
Lubricate "O" ring seal with Lubricate the O-ring seal and oil seal sealing surface with gear oil GM P/N
12378514 (Canadian P/N 88901045). Install NEW "O" ring into groove of pinion housing. Using Seal
Installer, install oil seal into pinion housing.
2. Install pinion housing assembly and shim into differential. Install and tighten differential bolts to
specification. See TORQUE SPECIFICATIONS . Install torque tube onto differential. See TORQUE
TUBE ASSEMBLY . Install torque tube bracket nut and bolt. Install spacers to tube flange. Install the
bracket, bolt, washers and nut to the tube.
3. Install the O-ring seals onto the clutch pump check valve. Install the valve and bolts to the differential.
Tighten the valve bolts to specification. See TORQUE SPECIFICATIONS . Install the vent hose
assembly and clamp to the differential. Install the oil drain plug and gasket to the differential. Tighten the
drain plug to specification. See TORQUE SPECIFICATIONS .
SERVICING
DIFFERENTIAL CLUTCH PUMP CHECK VALVE CLEANING AND INSPECTION
Inspect the inlet valve for the following:
Damaged, loose, or missing pick up screen.

Damaged or missing O-rings.
Damaged electrical connector.
Oil passages restricted by dirt or debris.
TORQUE TUBE ASSEMBLY CLEANING AND INSPECTION
NOTE: The internal components of the torque tube assembly are not serviced
separately. Replace the tube and internal components as an assembly.
1. Inspect the torque tube for broken or cracked welds, dents or damage to the exterior of the tube, a
damaged propeller shaft flange, or loose or missing dampeners.
2. Inspect the propeller shaft seal surface for wear or excessive scoring. Inspect the propeller shaft splines
for any unusual or excessive wear.
Axle Shaft Nut 192 (260)
Brake Caliper Bolts 33 (45)
Brake Caliper Bracket Bolts 96 (130)
Dampener Bolt 47 (64)
Differential Carrier-To-Cradle Mount Bolts 37 (50)
Differential Drain & Fill Plugs 23 (32)
Drive Shaft-To-Transfer Case & Torque Tube Flange Bolt (8 mm) 24 (33)
Drive Shaft To Torque Tube Bolts 24 (33)
Rear Suspension Knuckle Bolt & Nut 63 (85)
Rear Tie Rod Bolt 63 (85)
Seal Clamps - Large & Small 100 (136)
Suspension Knuckle-To-Control Arm Bolt 63 (85)
Tie Rod Bolt 63 (85)
Torque Tube Bracket-To-Body Bolts 41 (56)
Torque Tube Bracket Through-Bolt & Nut 47 (64)
Torque Tube-To-Differential Bolts 18 (25)
Upper Control Arm Knuckle Bolts 63 (85)
INCH lbs. (N.m)
Clutch Pump Check Valve Bolts 106 (12)
Parking Brake Cable Bracket 89 (10)
Pinion Housing-To-Differential Bolts 106 (12)
Valve Bolts 106 (12)
Wheel Nut Caps 27 (3)
WIRING DIAGRAMS
NOTE: Go to SYSTEM WIRING DIAGRAMS under ELECTRICAL.
FWD Axle Shafts - Aztek & Rendezvous

GENERAL DESCRIPTION
Front wheel drive axles are flexible assemblies. Front wheel drive axles consist of the following components:
A front axle shaft inner tripot joint.

A front axle shaft outer constant velocity joint.
A front axle shaft bar. The front axle shaft bar connects the front axle shaft tripot joint and the front axle
shaft constant velocity joint.
See Fig. 1 . The front axle shaft tripot joint is completely flexible axially and laterally. The front axle shaft
constant velocity joint is flexible axially.
Fig. 1: Exploded View Of Inner & Outer CV Joints

SEALS & CLAMPS
NOTE: Protect the seals from sharp tools and from the sharp edges of the surrounding
components. Any damage to the seals or the clamps will result in leakage.
Leakage will allow water to leak into the front axle shaft tripot joint and the front
axle shaft constant velocity joint. Damage will also allow grease to leak out of
the front axle shaft tripot joints and the front axle shaft constant velocity joints.
Leakage may cause noisy front wheel drive axle operation and eventual failure
of the internal components.
The front axle shaft constant velocity joint and the front axle shaft tripot joint seals in the front wheel drive axle
are made of a thermoplastic material. The clamps on front wheel drive axle seals are made of stainless steel.
The seals provide the following functions:
Protection of the internal parts of the front axle shaft constant velocity joint and the front axle shaft tripot
joint. The seals protect the grease from harmful atmospheric conditions, such as extreme temperatures or
ozone gas. Protection is also provided against foreign material, such as dirt or water.
Allows the angular and the axial movement of the front axle shaft tripot joint.
Allows angular movement of the front axle shaft constant velocity joint.
The clamps provide a leak proof connection for the front axle shaft tripot joint and the front axle shaft constant
velocity joint at the following locations:
The housing.
The front axle shaft bar.
The thermoplastic material performs well under normal conditions and normal operation. However, the material
is not strong enough to withstand the following conditions:
Abusive handling.
Damage from sharp objects, such as tools or sharp edges of the surrounding vehicle components.
TRIPOT JOINT
The front axle shaft tripot joint is made without an over-extension limitation retainer. The joint is constructed as
follows:
The left front wheel drive axle has a female spline. The female spline installs over a stub shaft that
protrudes from the transaxle.
The right front wheel drive axle has a male spline. The right front wheel drive axle uses a barrel-type
retaining ring in order to interlock with the transaxle gears.
AXLE SHAFT CONSTANT VELOCITY JOINT
The front axle shaft constant velocity joint is of the Rzeppa joint design. The shaft end, which mates with the
knuckle/hub, has a helical spline. The helical spline ensures a tight, press-type fit. This design prevents end play
between the hub bearing and the front wheel drive axle.
TROUBLE SHOOTING
Begin the axle shaft system diagnosis with VIBRATION DIAGNOSIS & CORRECTION under
DIAGNOSTIC STARTING POINT in VIBRATION - DRIVETRAIN article in GENERAL INFORMATION.
The use of the Diagnostic Starting Point will determine if the concern is axle shaft related. When instructed to
exit the Vibration Diagnosis and Correction diagnostic and return to the Axle Shafts Diagnostic Starting Point,
proceed to DESCRIPTION & OPERATION in order to become familiar with the design of the axle shaft.
AXLE SHAFT
CAUTION: Prevent the seals (boots) from contacting the other components in order
to prevent damage to the seals (boots).
NOTE: Required Tools: Slide Hammer With Adapter (J-2619-O1), Axle Shaft Remover
Extension (J-29794), Axle Shaft Puller (J-33008-A) and Wheel Hub Remover (J-
42129).
Removal
1. Raise and support the vehicle. Remove tire and wheel assembly. Remove engine splash shield. Remove
stabilizer shaft link. See appropriate FRONT article in SUSPENSION. Disconnect the electrical
connector from the wheel speed sensor.
NOTE: Note the relationship between the halves of the 2-piece ramped washer.
The ramped sides must face each other when installing the washer.
2. Remove the front axle shaft nut and the ramped, 2-piece washer. Insert a drift or a flat-bladed tool
through the caliper and into the brake rotor to prevent the rotor from turning. See Fig. 2 . Discard the axle
shaft nut.
3. Disconnect the outer tie rod end from the steering knuckle; DO NOT loosen the tie rod end jam nut. See
appropriate POWER RACK & PINION article in STEERING. Disconnect the lower ball joint from the
steering knuckle. See appropriate FRONT article in SUSPENSION.
WARNING: DO NOT attempt to move vehicle with drive axle(s) removed from
wheel bearing. Wheel(s) could fall off, dropping vehicle to the
ground and causing personal injury or damage to the vehicle.
4. Install the wheel hub remover onto the wheel hub and bearing and secure with wheel nuts. Using the
wheel hub remover, disengage the axle shaft from the wheel hub and bearing and support the axle shaft.
5. Assemble the slide hammer, the axle shaft remover extension and the axle shaft puller. Using the
completed assembly, disengage the axle shaft from the transaxle. See Fig. 3 .
6. Remove the axle shaft from the vehicle. Remove and discard the axle shaft retaining ring.
On the right axle shaft, the retaining ring is on the splined shaft of the inner tripot housing.
On the left axle shaft, the retaining ring is on the splined transmission output shaft.
Fig. 2: Removing/Installing Drive Shaft Nut

Fig. 3: Removing Axle Shaft
Installation
CAUTION: Prevent the boots (seals) from contacting the other components in order
to prevent damage to the boots.
1. Install a NEW axle shaft retaining ring:

On the right axle shaft, the retaining ring is on the splined shaft of the inner tripot housing.
On the left axle shaft, the retaining ring is on the splined transmission output shaft.
2. Install the axle shaft to the transaxle. See Fig. 4 . Push the axle shaft into transaxle until the retaining ring
is fully seated.
3. Verify that the axle shaft retaining ring is properly seated.
A. Grasp the inner (tripot) housing.
B. Pull the inner (tripot) housing outboard. DO NOT pull on the axle shaft bar. The axle shaft will
remain in place when the retaining ring is properly seated.
4. Install the axle shaft to the wheel hub and bearing. Connect the ball joint to the steering knuckle. See
appropriate FRONT article in SUSPENSION. Connect the outer tie rod end assembly to the steering
knuckle. See appropriate POWER RACK & PINION article in STEERING.
NOTE: Ensure that the 2-piece, ramped washer is installed prior to installing the
axle shaft nut. The ramped sides of the washer must face each other.
5. Install the 2-piece, ramped washer to the axle shaft spindle. See Fig. 5 . Install a NEW axle shaft nut.
6. Insert a drift or a flat-bladed tool through the caliper and into the brake rotor to prevent the rotor from
turning. See Fig. 2 . Tighten the axle shaft nut to specification. See TORQUE SPECIFICATIONS .
7. Install the stabilizer shaft link. See appropriate AZTEK & RENDEZVOUS article in SUSPENSION.
Connect the wheel speed sensor electrical connector.
8. Install the engine splash shield. Install the tire and wheel assembly. Lower the vehicle. Inspect the
transaxle fluid level.
Fig. 4: Installing Drive Axle-To-Transaxle
Fig. 5: Installing 2 Piece Ramped Washer-To-Axle Shaft Spindle
OVERHAUL
INNER TRIPOT JOINT & SEAL
CAUTION: DO NOT cut into the axle shaft trilobal tripot bushing.
NOTE: Required Tools: Drive Shaft Seal Clamp Pliers (J-42572).
Disassembly
1. Remove the small seal clamp from the axle shaft bar using side cutters and discard the clamp. Remove
the large seal clamp from the tripot joint with side cutters and discard the clamp. Separate the axle shaft
inboard seal from the trilobal tripot bushing. Slide the seal away from the joint along the axle shaft bar.
See .
2. Remove the housing from the tripot joint spider and the axle shaft bar. Using a brass drift and hammer,
carefully tap around the tripot spider face in order to compress the barrel retaining ring on the axle shaft
bar. See Fig. 7 . Remove the tripot spider from the axle shaft bar.
3. Remove and discard the barrel retaining ring from the axle shaft bar. Remove the joint seal from the axle
shaft bar.
The axle shaft inboard seal.
The tripot joint spider assembly.
The housing.
The trilobal tripot bushing.

Fig. 6: Exploded View Of Front Drive Shaft
Fig. 7: Compressing Barrel Retaining Ring
Reassembly
1. Place the NEW small seal clamp onto the small end of the joint seal. See Fig. 8 . Slide the joint seal and
the small seal clamp onto the axle shaft bar. Position the small end of the joint seal into the joint seal
groove on the axle shaft bar.
2. Using the Drive Shaft Seal Clamp Pliers (J-42572), crimp the small seal retaining clamp. See Fig. 9 .
Tighten the clamp to specification. See TORQUE SPECIFICATIONS .
NOTE: Ensure that the beveled edge of the tripot spider faces the axle shaft bar
during reassembly.
3. Install a NEW barrel retaining ring to the axle shaft bar. Install the tripot spider to the axle shaft bar,
while compressing the barrel retaining ring with a flat-bladed tool. Verify positive engagement of the
tripot spider to the halfshaft bar by grasping the tripot spider and attempting to pull free from the axle
shaft bar.
4. Place approximately half of the grease from the service kit in the axle shaft inboard seal. Use the
remainder of the grease to repack the housing. Install the trilobal tripot bushing to the housing. Position
the larger NEW seal retaining clamp on the axle shaft inboard seal. Slide the housing over the tripot joint
spider assembly on the axle shaft bar.
5. Slide the large diameter of the axle shaft inboard seal, with the large clamp in place, over the outside of
the trilobal tripot bushing and locate the lip of the seal in the groove.
NOTE: The axle shaft inboard seal must not be dimpled, stretched out or out of
shape in any way. If the seal is not shaped correctly, carefully insert a thin,
flat, blunt tool (no sharp edges) between the large seal opening and the
trilobal tripot bushing in order to equalize the pressure. Shape the seal
properly by hand. Remove the tool.
6. Position the joint assembly at the proper vehicle dimension. Align the following items while crimping the
retaining clamp:
The axle shaft inboard seal.
The tripot housing.
The large seal retaining clamp.
Using the clamp pliers, crimp the large seal retaining clamp. See Fig. 9 . Tighten the clamp to
7. Rotate the inner tripot housing 4 or 5 times in order to distribute the grease throughout the tripot spider
bearings.
Fig. 8: Placing Seal Clamp Onto Joint Seal
Fig. 9: Tightening Drive Axle Inner Tripot Joint Seal (Boot) Clamp
OUTER CV JOINT & SEAL
Disassembly
1. Wrap a shop towel around the axle shaft. Place the axle shaft horizontally in a bench vise. Remove the
large seal retaining clamp from the CV joint seal. Use a side cutter or other suitable tool and discard the
clamp. Remove the small seal retaining clamp from the joint seal. Use a side cutter or other suitable tool
and discard the clamp.
2. Separate the seal from the joint outer race at the large diameter end. Position the seal behind the joint
face. Wipe the grease from the face of the joint inner race, cage, balls, etc.
3. Remove the outer joint from the axle shaft.
A. Hold the joint housing.
B. Position a wood block between the seal and the joint, along the joint face. See Fig. 10 .
C. Strike the wood block with a hammer to compress the axle shaft retaining clip.
D. Continue to strike the wood block in order to remove the outer joint from the axle shaft.
4. Remove the axle shaft retaining ring from the axle shaft. Remove the seal from the axle shaft. Remove
the axle shaft from the vise.
5. Wrap a shop towel around the joint outer race splined shaft. Place the outer race vertically in a bench
vise.
6. Make a ball accessible for removal. Tap gently on the joint cage, using a brass drift and a hammer, in
order to drive a ball toward the bottom of its track. See Fig. 11 . The opposing ball will be made
accessible for removal.
7. Remove the exposed ball. Use a small screwdriver to aid in removal if necessary. Position the cage and
inner race so they are level.
8. Repeat steps 6 and 7 until all 6 balls are removed in sequence. See Fig. 12 .
9. Position the cage and the inner race 90 degrees to the centerline of the outer race. Align the cage windows
with the lands of the outer race. Lift to remove the cage and the inner race from the outer race.
10. Position the cage and inner race so that the larger radius corners of the cage windows are up. Rotate the
inner race 90 degrees to the centerline of the cage. Align the lands of the inner race with the windows of
the cage. Insert an inner race land into a cage window. Pivot the inner race down and remove it from the
cage.
11. Clean the following thoroughly with clean solvent:
The inner race.
The outer race.
The cage.
The balls.
The axle shaft exposed end.
Thoroughly air dry all the parts.

Fig. 10: Removing Outer Joint Arm
Fig. 11: Removing Joint Outer Race Balls
Fig. 12: Disassembling Outer Joint Sequence

Reassembly
CAUTION: axle shaft boots, seals and clamps should be protected from sharp objects
any time service is performed on or near the axle shaft(s). Damage to the
boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the
joint and lead to increased noise and possible failure of the axle shaft.
1. Position the cage so the larger radius corners of the cage windows are up. Position the inner race 90
degrees to the centerline of the cage. Begin to insert the inner race up through the bottom of the cage.
2. Align a land of the inner race to a window of the cage. Insert the inner race land into the cage window.
Rotate the remainder of the inner race into the cage. Rotate the inner race within the cage so that the
grooved surface of the inner race is facing up. Align the inner race ball tracks with the cage windows.
3. Wrap a shop towel around the joint outer race splined shaft. Place the outer race vertically in a bench
vise. Position the cage and inner race 90 degrees to the centerline of the outer race. Align 2 cage windows
at 0 and 180 degrees. Rotate the inner race and cage assembly in the vertical plane. Align the 2 windows
at 0 and 180 degrees with 2 of the outer race lands. Insert the cage and inner race into the outer race.
NOTE: The larger radius corners of the cage windows should be positioned up
and the grooved surface of the inner race should be visible.
4. Position the cage and inner race so they are level. Align the cage windows and inner race ball tracks with
the outer race ball tracks. Rotate the appropriate component(s).
5. Position a cage window and inner race ball track for ball installation.
A. Press down on the cage following one of the outer race ball tracks. The opposing cage window and
inner race ball track will be accessible for ball installation.
B. After installing the first ball, use a brass drift and a hammer to tap gently on the cage, in order to
drive the cage and inner race down completely. No gap should exist between the ball and the inner
race ball track.
6. Insert a ball through the cage window onto the inner race ball track. Tap the ball lightly with a plastic
tipped hammer. Position the cage and inner race so they are level.
7. Repeat steps 5 and 6 until all 6 balls are installed in sequence. See Fig. 12 .
8. Insert approximately 60 percent of the grease from the service kit into the outer joint.
A. Spread the grease onto the ball tracks, the balls, the cage and the inner race.
B. Spread the remainder of the grease into the bottom of the outer race.
9. Remove the outer joint from the bench vise. Wrap a shop towel around the axle shaft. Place the axle shaft
horizontally in a bench vise. Install a NEW small seal retaining clamp onto the axle shaft. Install the seal
onto the axle shaft.
10. Install a NEW retaining ring to the axle shaft. Position the outer joint horizontally. Engage the inner race
splines onto the axle shaft splines.
11. Compress the axle shaft retaining ring.
A. Press the end of the retaining ring, using a flat bladed tool, into the axle shaft groove while firmly
pressing the outer joint onto the axle shaft.
B. Continue to work around the retaining ring until it is compressed.
NOTE: The axle shaft and inner race must be fully seated to each other.
12. Install the outer joint to the axle shaft.

A. Position a wood block squarely over the end of the outer joint threaded shaft.
B. Use a hammer to drive the outer joint onto the shaft.
C. Continue to drive the outer joint until the outer joint seats fully onto the axle shaft.
Insert the remaining grease from the service kit into the seal.
13. Position the small seal retaining clamp onto the neck of the seal. Position the seal and small retaining
clamp to the axle shaft as shown. See Fig. 13 . Measure distance "a" between the edge of the seal and the
edge of the last axle shaft groove closing edge; adjust fit accordingly. Distance "a" should be 0.1" (2.5
mm).
NOTE: The seal retaining clamp must not be over-tightened or under-tightened.
14. Using the Drive Shaft Seal Clamp Pliers (J-42572), crimp the small seal retaining clamp. Tighten the
small seal retaining clamp to specification. See Fig. 14 . See TORQUE SPECIFICATIONS . Measure
the air gap width. If air gap is greater than 0.079-0.118" (2-3 mm), crimp clamp until correct dimension is
attained.
15. Position the large seal retaining clamp onto the seal. See Fig. 15 . Position the seal and large retaining
clamp to the joint outer race. Measure the distance between the edge of the seal and the edge of the joint
outer race last groove closing edge; adjust fit accordingly. Distance should be 0.03" (0.8 mm).
16. Inspect the seal for proper shape. The seal must not be dimpled, stretched or otherwise deformed. If the
seal is NOT shaped correctly, equalize the pressure in the seal by lifting the seal edge slightly and shape
the seal properly by hand. Inspect the seal for damage. If the seal has been cut or punctured during
assembly, you must discard and replace the seal.
NOTE: The seal retaining clamp must not be over-tightened or under-tightened.
17. Using the clamp pliers, crimp the large seal retaining clamp. Tighten the large seal retaining clamp to
specification. See TORQUE SPECIFICATIONS . See Fig. 14 . Measure the air gap width in order to
ensure it is between 0.079-0.118" (2-3 mm). Crimp clamp until correct dimension is attained.
18. Inspect the outer CV joint and axle shaft for smooth operation. This will also distribute the grease within
the joint. Hold the axle shaft vertically, with the outer joint at the bottom. Rotate the axle shaft 4 or 5
times in a circular motion.
Fig. 13: Positioning Small Seal Retaining Clamp
Fig. 14: Tightening Drive Axle Outer CV Joint Seal (Boot) Clamp
Fig. 15: Positioning Large Seal Retaining Clamp
Axle Shaft (Hub) Nut 192 (260)
Large Seal Clamp (Inner & Outer) 100 (136)
Small Seal Clamp 100 (136)
Cooling System Specifications & Drive Belt Routing - All Models
MODEL IDENTIFICATION - CARS
Body Code (1) Model
"C" Park Avenue
"E" Eldorado
"F" Camaro & Firebird
"G" Aurora & Riviera
"H" Bonneville, & LeSabre
"J" Cavalier & Sunfire
"K" DeVille & Seville
"M" Metro
"N" Alero, Grand Am & Malibu
"S" Prizm
"V" Catera
"W" Century, Grand Prix, Impala, Intrigue, Lumina, Monte Carlo & Regal
"Y" Corvette
"Z" Saturn
(1) Vehicle body code is fourth character of VIN.
MODEL IDENTIFICATION - TRUCKS

Series (1) Model
"A" 2WD Aztek
"B" 4WD Aztek
"C" 2WD Pickup, Sierra, Silverado, Suburban, Tahoe & Yukon
"E" 2WD Tracker
"G" Cutaway, Express, G-Van & Savana
"J" 4WD Tracker
"K" 4WD Pickup, Sierra, Silverado, Suburban, Tahoe, Yukon & AWD Escalade
"L" AWD Astro & Safari
"M" 2WD Astro & Safari
"S" 2WD Blazer, Envoy, Jimmy, Pickup & Sonoma
"T" 4WD Blazer, Bravada, Envoy, Jimmy, Pickup & Sonoma
"U" Montana, Silhouette, Trans Sport & Venture
SPECIFICATIONS

battery.
BELT ADJUSTMENT
BELT ADJUSTMENT - CARS

Serpentine Belt (1)30-50 Lbs. (13.6-22.7 kg.)
Deflection @ 22 Lbs. (10.0 kg.)
Except Serpentine Belt
Metro
A/C Compressor & Power Steering Pump .28-.35" (7.0-9.0 mm)
Generator .24-.31" (6-8 mm)
(1) Serpentine belt is automatically adjusted by tensioner. Tension is checked with belt tension gauge. If
tension is not as specified, check belt length and tensioner operating range. Replace belt or tensioner
as necessary.
BELT ADJUSTMENT - TRUCKS

Application (1) Lbs. (kg)
All Models (1)
(1) Serpentine belt tension is maintained automatically by a spring-tensioned idler pulley. No adjustment
is necessary.
COOLING SYSTEM SPECIFICATIONS
COOLING SYSTEM SPECIFICATIONS - CARS

Coolant Replacement Interval
Except Metro & Prizm 60 Months Or 150,000 Miles
Metro 30 Months Or 30,000 Miles
Prizm 24 Months Or 30,000 Miles
Coolant Capacity (1)
1.0L 3.9 Qts. (4.1L)
1.3L
M/T 4.9 Qts. (4.4L)
A/T 5.0 Qts. (4.7L)
1.8L
Prizm
A/T 6.0 Qts. (5.7L)
M/T 6.1 Qts. (5.8L)
1.9L 7.0 Qts. (6.6L)
2.2L
"J" Body 9.6 Qts. (9.1L)
"Z" Body 7.4 Qts. (7.0L)
2.4L
"J" Body 9.9 Qts. (9.4L)
"N" Body 11.3 Qts. (10.7L)
3.0L
Except "Z" Body 10.0 Qts. (9.5L)
"Z" Body 7.8 Qts. (7.3L)
3.1L
"N" Body 13.1 Qts. (12.4L)
"W" Body 11.0 Qts. (10.4L)
3.4L 13.6 Qts. (12.9L)
3.5L 10.0 Qts. (9.5L)
3.8L Except "F", "H" & "W" Bodies 13.0 Qts. (12.3L)
"F" Body
A/T 12.3 Qts. (11.6L)
M/T 12.5 Qts. (11.8L)
"H" Body 10 Qts. (9.5L)
"W" Body 5.3 Qts. (5.0L)
4.0L 13.0 Qts. (12.3L)
4.6L Except "E" & "K" Body 10.7 Qts. (10.0L)
"E" & "K" Bodies 12.5 Qts. (11.8L)
5.7L
"F" Body
A/T 15.1 Qts. (14.3L)
M/T 15.3 Qts. (14.5L)
"Y" Body
A/T 12.3 Qts. (11.6L)
M/T 12.6 Qts. (11.9L)
Pressure Cap
"F" Body 18 psi
Metro 13 psi
Prizm 13 psi
Saturn 15 psi
All Others
(2) 15 psi
Thermostat
Metro
Starts To Open 190-197F (88-92C)
Fully Opens 212-221F (100-105C)
Prizm
Fully Opens 203F (95C)
Saturn
Fully Open 212-222F (100-106C)
All Others
Starts To Open 189F (87C)
Fully Opens 207F (97C)
(1) Specification is approximate and includes heater capacity.
(2) Or specification stamped on cap.
COOLING SYSTEM SPECIFICATIONS - TRUCKS

Coolant Replacement Interval
Except Tracker 60 Months Or 150,000 Miles
Tracker 30 Months Or 30,000 Miles
Pressure Cap
Except Tracker 15 psi
Tracker 13 psi
Thermostat Opens
Except Tracker
Starts 188F (87C)
Fully Open 206F (97C)
Tracker
Starts 179F (82C)
Fully Open 203F (95C)
Coolant Capacity (1)
1.6L 6.9 Qts. (6.5L)
2.0L 5.8 Qts. (5.5L)
2.2L
A/T 9.7 Qts. (9.2L)
M/T 9.9 Qts. (9.4L)
2.5L 8.5 Qts. (8.0L)
3.4L
Standard
With Rear Heater 11.9 Qts. (11.3L)
Without Rear Heater 9.6 Qts. (9.0L)
Heavy Duty
4.3L
"C" & "K" Series
A/T 12.7 Qts. (12.0L)
M/T 13.0 Qts. (12.3L)
"G" Series
"L" & "M" Series
Without Rear Heater 14.3
Qts. (12.8L)
"S" & "T" Series
A/T 11.7 Qts. (11.1L)
M/T 11.9 Qts. (11.3L)
4.8L
A/T 13.4 Qts. (12.7L)
M/T 13.7 Qts. (13.0L)
5.0L
With A/C 20.0 Qts. (18.9L)
Without A/C 17.0 Qts. (16.0L)
5.3L
With A/C 14.9 Qts. (14.1L)
With Rear A/C 15.8 Qts. (15.0L)
5.7L
Standard
With A/C 20.0 Qts. (19.0L)
Heavy Duty
With A/C 27.0 Qts. (25.5L)
6.0L
A/T
With Oil Cooler 14.4 Qts. (13.6L)
Without Oil Cooler 14.8 Qts. (14.0L)
M/T
With Oil Cooler 14.8 Qts. (14.0L)
Without Oil Cooler 15.2 Qts. (14.4L)
6.5L 27.5 Qts. (26.0L)
6.6L
A/T 20.3 Qts (19.2L)
M/T 20.7 Qts. (19.6L)
7.4L
Standard
With A/C 27.5 Qts. (26.0L)
Heavy Duty
With A/C 28.5 Qts. (27.0L)
8.1L
A/T 20.7 Qts. (19.6L)
M/T 21.1 Qts. (20.0L)
(1) Specification is approximate and includes heater capacity.
SERPENTINE BELT ROUTING & ALIGNMENT
NOTE: For serpentine belt routing, see underhood label or refer to appropriate
illustrations. See Fig. 1 -Fig. 24 .
Fig. 1: Serpentine Belt Routing (1.8L Prizm)
Fig. 2: Serpentine Belt Routing (1.9L Saturn DOHC)
Fig. 3: Serpentine Belt Routing (1.9L Saturn SOHC)

Fig. 4: Serpentine Belt Routing (2.0L Tracker)
Fig. 5: Serpentine Belt Routing (2.2L "J" Body - With A/C)
Fig. 6: Serpentine Belt Routing (2.2L "J" Body - Without A/C)
Fig. 7: Serpentine Belt Routing (2.2L "S" Series)
Fig. 8: Serpentine Belt Routing (2.4L "J" & "N" Bodies)
Fig. 9: Serpentine Belt Routing (2.5L Tracker)
Fig. 10: Serpentine Belt Routing (3.0L "V" Body)
Fig. 11: Serpentine Belt Routing (3.1 "N" & "W" Bodies)
Fig. 12: Serpentine Belt Routing (3.4L "N", "W" & "Z" Bodies, & "A", "B" & "U" Series)
Fig. 13: Serpentine Belt Routing (3.5L "N" & "W" Bodies)
Fig. 14: Serpentine Belt Routing (3.8L "C", "G", "H" & "W" Bodies)
Fig. 15: Serpentine Belt Routing (3.8L "F" Body)
Fig. 16: Serpentine Belt Routing (4.0L "G" Body & 4.6L "E" & "K" Bodies)
Fig. 17: Serpentine Belt Routing (4.3L, 5.0L, 5.7L & 7.4L, "S" & "T" Series)
Fig. 18: Serpentine Belt Routing (4.8L, 5.3L & 6.0L "C" & "K" Series)
Fig. 19: Serpentine Belt Routing (5.7L "F" Body)
Fig. 20: Serpentine Belt Routing (5.7L "Y" Body)
Fig. 21: Serpentine Belt Routing (6.5L Turbo-Diesel "C", "G" & "K" Series With Dual Generators)
Fig. 22: Serpentine Belt Routing (6.5L Turbo-Diesel "C", "G" & "K" Series Without Dual Generators)
Fig. 23: Serpentine Belt Routing (6.6L Turbo-Diesel "C" & "K" Series)
Fig. 24: Serpentine Belt Routing (8.1L "C", "G" &"K" Series )
Propeller Shaft - Aztek & Rendezvous
SPECIFICATIONS
Fig. 1: Torque Specifications

DIAGNOSTIC INFORMATION & PROCEDURES

DIAGNOSTIC STARTING POINT - PROPELLER SHAFT
Begin the propeller shaft system diagnosis with DIAGNOSTIC STARTING POINT -- VIBRATION
DIAGNOSIS AND CORRECTION . The use of the Diagnostic Starting Point will determine if the concern is
related to the propeller shaft. When instructed to exit the Vibration Diagnosis and Correction diagnostic and
return to the Diagnostic Starting Point - Propeller Shaft, proceed to Propeller Shaft Diagnosis in order to isolate
and identify propeller shaft related concerns. See Fig. 2 .
Fig. 2: Identifying Propeller Shaft Assembly
Review the propeller shaft system function. Refer to PROPELLER SHAFT DESCRIPTION AND
OPERATION .
Inspect for loose or missing propeller shaft-to-flange bolts (2) and (4). Tighten or replace as necessary. Refer to
PROPELLER SHAFT REPLACEMENT .
The propeller shaft (3) and the constant velocity (CV) joints are not serviceable. The CV joints and seals should
be inspected periodically, whenever the vehicle is serviced.
The CV joint seals should be inspected for the following:
Tears
Cracks
Contamination of the lubricating grease Carefully pinch the seal and feel for the presence of grit
Loose or missing seal clamps
Leakage of lubricating grease from the seals The CV joints should be inspected for the following
conditions:
Binding or impeded motion during axial movement of the front and rear CV joints
Binding or impeded motion during lateral movement of the rear CV joint
Loose or missing crimped-on end caps
Leakage of lubricating grease from the end caps
The propeller shaft must be replaced if any of the above conditions exist. This will ensure that the propeller
shaft continues to operate as intended, and does not damage the other driveline components.
REPAIR INSTRUCTIONS
PROPELLER SHAFT REPLACEMENT
Removal Procedure

2. Reference mark the propeller shaft at the transfer case flange.
Fig. 3: Making Reference Marks On Propeller Shaft
3. Remove the propeller shaft-to-transfer case flange bolts.

Fig. 4: Removing Propeller Shaft-To-Transfer Case Flange Bolts
4. Reference mark the propeller shaft at the torque tube flange.

Fig. 5: Locating Reference Mark Propeller Shaft
5. Remove the propeller shaft-to-torque tube flange bolts.

6. Push the propeller shaft toward the rear of the vehicle.
7. Remove the propeller shaft.
Fig. 6: Removing Propeller Shaft-To-Torque Tube Flange Bolts
1. Install the rear of the propeller shaft to the torque tube flange.
2. Align the reference marks on the propeller shaft and the torque tube flange.
Important: Thoroughly clean and apply threadlock GM P/N United States 12345493 P/N Canada
10953488 or equivalent to the bolt threads prior to assembly.
3. Hand install the propeller shaft-to-torque tube bolts in order to maintain the proper propeller shaft to
torque tube relationship. Ensure that the crescent washer is in place on each pair of bolts.
Fig. 7: Aligning Reference Marks On Propeller Shaft & Torque Tube Flange
4. Push the propeller shaft toward the rear of the vehicle and install the propeller shaft to the transfer case
flange.
5. Align the reference marks on the propeller shaft and the transfer case flange.
Fig. 8: Aligning Reference Marks On Propeller Shaft And Transfer Case Flange
6. Install the propeller shaft-to-transfer case bolts. Ensure that the crescent washer is in place on each pair of
bolts.
7. Tighten the bolts in a cross sequence.
Tighten
Tighten the bolts to 33 N.m (24 lb ft).

Fig. 9: Installing Propeller Shaft-To-Transfer Case Bolts
8. Tighten the propeller shaft to torque tube bolts in a cross sequence.
Tighten
Tighten the bolts to 33 N.m (24 lb ft).

Fig. 10: Tightening Propeller Shaft-To-Torque Tube Bolts

PROPELLER SHAFT DESCRIPTION AND OPERATION
Fig. 11: Identifying Propeller Shaft Assembly
The propeller shaft (3) is of a tubular design with constant velocity joints at both the transfer case and the torque
tube flanges. The forward and rearward ends of the propeller shaft mate to the transfer case and the torque tube
flanges with 6 bolts each (2, 4) utilizing special crescent-shaped washers to pair the bolts together in order to
evenly distribute the clamping force.
The front constant velocity (CV) joint receives the rotational forces from the transfer case output flange.
The front CV joint is of a ball-and-groove design using 6 ball bearings set in a race. The CV joint allows axial,
but not lateral movement of the joint in order to compensate for the driveline inclination changes imposed by
the powertrain during acceleration and deceleration. The CV joint is lubricated with a special grease that is
protected from foreign material contamination by a seal similar in design to the seal on a front wheel drive
shaft. The mating surface of the CV joint is protected by a metal cap which is crimped on to the CV joint, and
captured between the CV joint and the transfer case output flange.
The rear CV joint receives the rotational forces transmitted through the propeller shaft from the front CV joint.
These forces are then transferred to the torque tube input flange. The rear CV joint is similar in design to the
front CV joint, although the rear CV joint allows lateral as well as axial movement.
The lateral and axial movement of the CV joint compensates for driveline inclination changes as well as the
lateral movement of the driveline during acceleration and deceleration. The CV joint is lubricated with a special
grease that is protected from foreign material contamination by a bellows-type seal. The mating surface of the
CV joint is protected by a metal cap which is crimped on to the CV joint, and captured between the CV joint
and the torque tube input flange.
The propeller shaft and the constant velocity joints are not serviceable. The CV joints and seals should be
inspected periodically, whenever the vehicle is raised for service.
Rear Axle Controls - Aztek & Rendezvous

DIFFERENTIAL LOCK SCHEMATICS
Fig. 1: Differential Lock Schematics
COMPONENT LOCATOR
REAR AXLE COMPONENT VIEWS
Differential Clutch Pump Check Valve
Fig. 2: Locating Differential Clutch Pump Check Valve

Rear Axle Connector End Views

Fig. 3: Identifying Differential Clutch Pump Actuator Check Valve Connector Terminals

DIAGNOSTIC STARTING POINT - REAR AXLE CONTROLS
Begin the system diagnosis with DIAGNOSTIC SYSTEM CHECK - REAR AXLE CONTROLS . The
The Identification of the control module(s) which command the system
The ability of the control module(s) to communicate through the serial data circuit
DIAGNOSTIC SYSTEM CHECK - REAR AXLE CONTROLS
Circuit Description
The Diagnostic System Check is an organized approach to identify a condition created by the rear axle controls.
The Diagnostic System Check is the starting point for a rear axle controls complaint.
The Diagnostic System Check directs you to the next logical step for diagnosing a rear axle control concern.
Perform this check only if there is a driveability complaint or if you have been directed here from another
service information section.
Follow the table to help reduce diagnostic time and help prevent unnecessary replacement of parts.
DIAGNOSTIC AIDS
Important:
Do not clear the DTC unless directed by a diagnostic procedure. Clearing the DTCs will erase all Freeze
Frame and Failure Records stored in PCM memory.
Poor engine performance can sometimes be diagnosed as a rear axle driveability condition. In order to
avoid mis-diagnosis of the rear axle, always perform DIAGNOSTIC STARTING POINT -- ENGINE
CONTROLS .
Use a scan tool that is known to function correctly. If necessary, test the scan tool on another vehicle.
Ensure the scan tool contains the most current file available.
The scan tool will display a loss of communication error message under the following conditions:
The PCM power is interrupted.

The ignition switch is turned OFF.
The battery voltage level is very low.
A poor connection at the diagnostic link connector (DLC).
Test Description
1. This step determines if the scan tool is receiving power through the DLC connector.
2. This step determines if the PCM is transmitting class 2 serial data to the DLC and that the Class 2 data
circuit is not open or shorted.
3. The presence of DTCs indicates that the powertrain control module has detected a fault. Go to symptoms
for other concerns.
4. This step determines if a DTC is current or stored in history.
Diagnostic System Check - Rear Axle Controls
Fig. 4: Rear Axle Controls - Diagnostic Procedure

SCAN TOOL DATA LIST
Use the scan tool data list under the following conditions:

No DTCs are present.
The values below represent a typical display recorded from a properly functioning system.
Important: Do not use a scan tool that displays faulty data. Report the condition to the scan tool manufacturer.
The use of a faulty scan tool can result in misdiagnosis and the unnecessary replacement of parts.
Only the parameters listed below are used in this manual for diagnosing If a scan tool displays other
parameters, the values are not recommended by General Motors for use in diagnosis.
Scan tool values below were recorded under the following conditions:
Engine at Idle
Upper radiator hose hot
Closed throttle
Transmission in PARK
Closed Loop operation
Accessories OFF
Brake pedal not applied
Scan Tool Data List
Fig. 5: Scan Tool Data List (1 Of 2)

Fig. 6: Scan Tool Data List (2 Of 2)
ABS System Disable: This parameter displays Yes if the PCM is not receiving input from the Anti-Lock Brake
System (ABS), and the AWD system is disabled.
AWD Circuit Status: The All Wheel Drive (AWD) Circuit Status parameter indicates the status of the Axle
Actuator Control Circuit to the AWD solenoid and displays OK, Short or Open. The PCM can detect a short to
ground, a short to power, or an open in the Axle Actuator Control Circuit. The AWD Disabled lamp will be
illuminated for a short and open conditions.
AWD Clutch Temp. Disable: The All Wheel Drive (AWD) Clutch Temperature Disable parameter displays
the status of powertrain software that has the ability to disable AWD based on a rear drive module clutch
slip/time calculation and displays Yes or No. If the software determines that a clutch overtemperature condition
exists, the PCM will deactivate the AWD system by disabling the PWM signal line to the AWD solenoid. The
AWD system will be enabled again when the software calculates that the clutch temperatures have dropped
sufficiently. The AWD Disabled lamp will be illuminated for a Yes condition.
AWD Disabled: The All Wheel Drive (AWD) Disabled parameter indicates if the AWD system has been
disabled by the PCM and displays Yes or No. The AWD Disabled lamp will be illuminated for a Yes condition.
AWD Duty Cycle: The All Wheel Drive (AWD) Duty Cycle parameter displays the commanded state of the
AWD solenoid expressed as a percent of ON time. At vehicle start-up, duty cycle will be at 75-90% for 3
seconds. This is referred to as the pull-in duty cycle. After 3 seconds the duty cycle will drop to 20-30% for 30
seconds. This is referred to as the hold-in duty cycle. After each 30 second hold-in period, the duty cycle will be
increased to 75-90%, pull-in duty cycle, for 0.5 second before returning to the hold-in duty cycle. This is to
assure solenoid pull-in.
AWD Fluid Temp. Disable: The All Wheel Drive (AWD) Fluid Temperature Disable parameter indicates a
fluid overtemperature condition in the rear drive module and displays Yes or No. When the sump temperature
exceeds approximately 110C (230F), a pull-up resistor grounds the PWM signal line from the PCM at the
AWD solenoid. The pull-up resistor is an integral part of the AWD solenoid. The AWD Disabled lamp will be
illuminated for a Yes condition.
AWD Mini Spare Disable: The All Wheel Drive (AWD) Mini Spare Disable parameter indicates whether the
ABS module detects a mini spare on the vehicle and displays Yes or No. The wheel rotational speed difference
is detected by the wheel speed sensors of the ABS system. If the ABS module detects a mini spare on the
vehicle, the PCM will deactivate the AWD system by disabling the PWM signal line to the AWD solenoid. The
AWD Disabled lamp will be illuminated for a Yes condition.
AWD Overtemp. Delay: The All Wheel Drive (AWD) Overtemperature Delay parameter indicates whether the
AWD system is in a reset mode following an AWD fluid temperature disable and displays Yes or No. There is a
10 minute delay from the time the rear drive module resistor closes the PWM signal line until the PCM again
checks the signal line for an overtemperature condition. The rear drive module resistor is an integral part of the
AWD solenoid. The AWD Disabled lamp will be illuminated for a Yes condition.
AWD Torque Management: The All Wheel Drive (AWD) Torque Management parameter indicates when
some form of torque management is being performed to protect the AWD system and displays Active. When
there is no form of torque management being performed the display reads inactive.
AWD Voltage Disable: The All Wheel Drive (AWD) Voltage Disable parameter indicates whether the ignition
voltage to the AWD solenoid is in the proper range and displays Yes or No. The ignition voltage range to the
AWD solenoid is 9-16 volts. The PCM will deactivate the AWD system by disabling the PWM signal line to
the AWD solenoid if the ignition voltage is out of range. The AWD Disabled lamp will be illuminated for a Yes
condition.
AWD Wheel Speed Disable: The All Wheel Drive (AWD) Wheel Speed Disable parameter indicates whether
the wheel speed data received from the ABS controller is valid and displays Yes or No.
If the ABS module transmits it is not OK for the AWD system to be active, the PCM will deactivate the AWD
system by disabling the PWM signal line to the AWD solenoid. The AWD Disabled lamp will be illuminated
for a Yes condition.
Commanded Gear: This parameter indicates the current commanded state of the shift solenoid valves.
ECT: The Engine Coolant Temperature (ECT) sensor is mounted in the coolant stream and sends engine
temperature information to the PCM. The PCM applies 5 volts to the ECT sensor circuit. The sensor is a
thermistor that changes internal resistance as temperature changes. When the sensor is cold, the internal
resistance is high, the PCM monitors a high signal voltage. The PCM interprets this voltage as a cold engine. As
the sensor warms, the internal resistance decreases, the voltage signal will decrease. The PCM interprets the
lower voltage as a warm engine.
Engine Speed: This parameter indicates the rotational speed of the engine expressed as revolutions per minute.
The engine speed is computed by the PCM from the fuel control reference input, the crankshaft position sensor.
Engine Torque: This parameter indicates the amount of torque being delivered by the engine and is displayed
in both English and metric units.
Gear Ratio: This parameter displays the actual transmission gear ratio as the transmission operates through all
DRIVE, REVERSE and PARK/NEUTRAL ranges.
Ignition Voltage: This parameter is the system voltage measured by the PCM at the PCM ignition input when
the ignition switch is in the RUN position.
IMS: The Internal Mode Switch (IMS) parameter displays Park, Park/Reverse, Reverse, Reverse/Neutral,
Neutral, Neutral/Drive 4, Drive 4, Drive4/Drive 3, Drive 3, Drive 3/Drive 2, Drive 2, Drive 2/Drive 1, Drive 1,
Invalid or Open. The IMS Range display represents a decoded status of the four inputs from the IMS. This
range includes all possible in-between gear states as well as the detent gear states. The combination of IMS
inputs to the PCM are used by the PCM in order to determine the position of the manual valve at any given
time.
IMS A/B/C/P: The Internal Mode Switch (IMS) A/B/C/P parameter displays LOW or HI for the state of each
of the four inputs from the IMS. LOW displayed indicates a low voltage signal, 0 volts, being monitored at the
PCM. HI displayed indicates a high voltage signal, B+, being monitored at the PCM.
Last Disable Odometer: This parameter indicates the vehicle mileage at which the AWD Last Disable
condition occurred.
Last Disable Reason: This parameter indicates the last AWD disable reason. The possible reasons are Output
Controls, Fluid Temp, Clutch Temp, Wheel Speed, Voltage, Mini Spare, ABS System. The Output Controls
reason indicates that AWD was last disabled with a service scan tool. Fluid Temp, Clutch Temp, Wheel Speed,
Voltage, Mini Spare and ABS System each have a unique parameter that is described elsewhere in this table.
TP Angle: The Throttle Position (TP) Angle parameter displays a percentage that is computed by the PCM
from the TP sensor voltage. The TP angle should display 0% at idle and 100% at wide open throttle (WOT).
Trans. Fluid Temp.: The Transmission Fluid Temperature parameter displays the temperature conversion of
the voltage input signal to the PCM from the transmission fluid temperature (TFT) sensor. When the TFT is
high 151C (304F), the signal voltage is low, 0 volts. When the TFT is low -40C (-40F), the signal voltage is
high, 5 volts.
Transmission ISS: The Transmission Input Shaft Speed parameter displays the rotational speed of the
transmission Input shaft as expressed in revolutions per minute.
Transmission OSS: The Transmission Output Shaft Speed parameter displays the rotational speed of the
transmission output shaft as expressed in revolutions per minute.
Vehicle Speed: This parameter is the vehicle speed sensor (VSS) input signal converted by the PCM to be
displayed as vehicle speed in both metric and English units.
SYMPTOMS - REAR AXLE CONTROLS
Important: Review the system operation in order to familiarize yourself with the system functions. Refer to
System Operation.
Inspect for aftermarket devices which could affect the operation of the Rear Axle Control System.
Refer to CHECKING AFTERMARKET ACCESSORIES in Wiring Systems.
cause the symptom.
Intermittent
INTERMITTENT AND POOR CONNECTIONS in Wiring Systems.
Symptom List

ALL-WHEEL DRIVE (AWD) INDICATOR ALWAYS ON
ALL-WHEEL DRIVE (AWD) INDICATOR ALWAYS ON
Circuit Description
The PCM controls the actuator with a negative duty cycle. The actuator controls the supply fluid to the pump
inlet in the rear drive assembly. When the actuator is commanded OFF, the PCM will detect a high voltage.
When the actuator is commanded ON, the PCM will detect a low voltage. At engine start-up, the actuator is
turned ON at 49-90 percent duty cycle for 3 seconds, then drops to 16-28 percent for holding.
Every 30 seconds, the duty cycle is ramped to 49-90 percent for 0.5 second, then back to 16-28 percent.
If the PCM detects a voltage on the axle actuator circuit that is outside of the calibrated limits then the all-wheel
drive (AWD) disable lamp illuminates.
Conditions for Running the All-Wheel Drive (AWD) Disable Fault
The system voltage is 9-18 volts.

The engine speed is greater than 500 RPM for 5 seconds, and the engine is not in fuel shut-off.
The rear drive module must not be in an overtemperature condition.
Conditions for Turning On the All-Wheel Drive (AWD) Disable Lamp

The AWD disable lamp illuminates when one of the following conditions exists for 5 seconds:
The PCM commands the solenoid ON and the voltage feedback remains high, B+.
The PCM commands the solenoid OFF and the voltage feedback remains low, 0 volts. This condition is
present for 3 key cycles.
Action Taken When the All-Wheel Drive (AWD) Lamp Illuminates
The PCM does not illuminate the malfunction indicator lamp (MIL).
The PCM inhibits AWD.
The PCM records the operating conditions when the Conditions for Setting the DTC are met. The PCM
stores this information as Failure Records.
The PCM stores the AWD disable fault in PCM history.
Conditions for Clearing the All-Wheel Drive (AWD) Disable Fault
A scan tool can clear the fault.

The PCM clears the fault from PCM history if the vehicle completes 40 warm-up cycles without a non-
emission related diagnostic fault occurring.
The PCM cancels the fault default actions when the fault no longer exists.
Important: When an AWD mini spare disable condition is present, after correcting the condition, the vehicle
must be driven 0.5 km (0.3 mi) in a straight line and then brought to a complete stop before the PCM will
command the AWD disable lamp OFF.
Test Description
3. This step tests the ignition 1 voltage circuit for proper voltage.
4. This step tests the ground circuit for an open.
5. This step tests the axle actuator control circuit duty cycle.
6. This step tests the axle actuator control circuit for an open or short.
All-Wheel Drive (AWD) Indicator Always On

Fig. 7: AWD Indicator Always On Diagnostic Procedure (Steps 1-3)
Fig. 8: AWD Indicator Always On Diagnostic Procedure (Steps 4-11)
Circuit Description
The all-wheel drive (AWD) disable indicator lamp is located in the instrument panel cluster (IPC). Ignition 1
voltage is supplied to the IPC when the ignition switch is in the START or RUN position. When the PCM
receives a signal from the differential clutch pump actuator check valve, indicating an overtemp condition, or a
signal from the ABS controller indicating a speed differential between wheels, the AWD system is disabled.
The PCM then sends a class 2 signal to the IPC, illuminating the AWD disable indicator.
Test Description
2. This step tests for an intermittent condition.

3. This step determines if the failure is the result of a faulty instrument cluster.
Fig. 9: Differential Lock Indicator Inoperative Diagnostic Procedure

Circuit Description
The PCM controls the actuator with a negative duty cycle. The actuator controls the fluid supply to the pump
inlet in the rear drive assembly. When the actuator is commanded OFF, the PCM detects high voltage. When
the actuator is commanded ON, the PCM detects low voltage. At engine start-up, the actuator is turned ON at
49-90 percent duty cycle for 3 seconds, then drops to 16-28 percent for holding. Every 30 seconds, the duty
cycle is ramped to 49-90 percent for 0.5 second, then back to 16-28 percent.
Test Description
3. This step tests the ignition 1 voltage circuit for proper voltage.
4. This step tests the ground circuit for an open.
5. This step tests the axle actuator control circuit duty cycle.
6. This step tests the axle actuator control circuit for an open or short.
Fig. 10: Differential Lock Inoperative Diagnostic Procedure (Steps 1-6)

Fig. 11: Differential Lock Inoperative Diagnostic Procedure (Steps 7-13)

DIFFERENTIAL LOCK SYSTEM DESCRIPTION AND OPERATION
The All Wheel Drive (AWD) system provides On-Demand all wheel drive, distributing variable torque/power
to the rear wheels via individual axle shaft assemblies. On-Demand drive is provided to each of the rear wheels
wheel speed differential/slippage, a rotational speed difference between the gerotor pump components (rotor
and housing) occurs. In those instances, the rotor draws fluid from the sump and through the internal passages
of the differential carrier, sending pressurized fluid to a piston (actuating the specific rear wheel clutch pack). In
the event of a spare wheel (of smaller diameter) is used on any of the four positions, the wheel rotational speed
difference is detected by the wheel speed sensors of the ABS system. The powertrain module directs the
differential inlet valve to close and block oil flow to the gerotor pumps. The inlet valve also monitors the sump
oil for an "overtemperature" condition. If differential oil temperature exceeds 110C (230F), the valve will
close and block oil flow to the gerotor pumps. In both spare wheel usage and overtemperature conditions, an
activated inlet valve will illuminate the control panel AWD Disable indicator.
View the list of major components that make up the AWD system below.
AWD Disable indicator
The AWD Disable indicator is located in the instrument panel cluster. This lamp is used to inform the driver
that the AWD system has been disabled and no torque will be applied to the rear wheels during a slip condition.
The AWD Disable indicator is controlled by the powertrain control module via a class 2 message.
pressure the pistons cannot apply the clutch packs for rear wheel engagement. The actuator check valve will
open upon engine start-up and remain open unless commanded closed by the powertrain control module. The
actuator check valve also monitors the sump oil for an overtemperature condition. If differential oil temperature
exceeds 110C (230F), the valve will close and block oil flow to the gerotor pumps.
Powertrain Control Module
The powertrain control module monitors the data from the ABS controller and Rear Drive Module (RDM) for
proper operating conditions. If inappropriate conditions are present the PCM commands the differential clutch
pump actuator check valve closed, disabling the AWD system. The PCM also commands the AWD Disable
indicator on.
Propeller Shaft - Aztek & Rendezvous
SPECIFICATIONS

Specification
Propeller Shaft M8 Bolts 33 N.m 24 lb ft

DIAGNOSTIC STARTING POINT - PROPELLER SHAFT
Begin the propeller shaft system diagnosis with Diagnostic Starting Point - Vibration Diagnosis and
Correction in Vibration Diagnosis and Correction. The use of the Diagnostic Starting Point will determine if
the concern is related to the propeller shaft. When instructed to exit the Vibration Diagnosis and Correction
diagnostic and return to the Diagnostic Starting Point - Propeller Shaft, proceed to Propeller Shaft Diagnosis
in order to isolate and identify propeller shaft related concerns.
PROPELLER SHAFT DIAGNOSIS

Fig. 1: View Of Propeller Shaft
Review the propeller shaft system function. Refer to Propeller Shaft Description and Operation .
Inspect for loose or missing propeller shaft-to-flange bolts (2) and (4). Tighten or replace as necessary. Refer to
Propeller Shaft Replacement .
The propeller shaft (3) and the constant velocity (CV) joints are not serviceable. The CV joints and seals should
be inspected periodically, whenever the vehicle is serviced.
The CV joint seals should be inspected for the following:
Tears
Cracks
Contamination of the lubricating grease
Carefully pinch the seal and feel for the presence of grit
Loose or missing seal clamps
Leakage of lubricating grease from the seals
The CV joints should be inspected for the following conditions:
Binding or impeded motion during axial movement of the front and rear CV joints
Binding or impeded motion during lateral movement of the rear CV joint
Loose or missing crimped-on end caps
Leakage of lubricating grease from the end caps
The propeller shaft must be replaced if any of the above conditions exist. This will ensure that the propeller
shaft continues to operate as intended, and does not damage the other driveline components.
REPAIR INSTRUCTIONS
PROPELLER SHAFT REPLACEMENT
Removal Procedure
Fig. 2: Location For Reference Mark At Transfer Case Flange
2. Reference mark the propeller shaft at the transfer case flange.

Fig. 3: Removing/Installing Propeller Shaft-To-Transfer Case Flange Bolts
3. Remove the propeller shaft-to-transfer case flange bolts.

Fig. 4: Location For Reference Mark At Torque Tube Flange
4. Reference mark the propeller shaft at the torque tube flange.

Fig. 5: View Of Propeller Shaft-To-Torque Tube Flange Bolts
5. Remove the propeller shaft-to-torque tube flange bolts.

6. Push the propeller shaft toward the rear of the vehicle.
7. Remove the propeller shaft.
Fig. 6: Location For Reference Mark At Torque Tube Flange
1. Install the rear of the propeller shaft to the torque tube flange.
2. Align the reference marks on the propeller shaft and the torque tube flange.
IMPORTANT: Thoroughly clean and apply threadlocker GM P/N United States 12345493
P/N Canada 10953488 or equivalent to the bolt threads prior to assembly.
3. Hand install the propeller shaft-to-torque tube bolts in order to maintain the proper propeller shaft to
torque tube relationship. Ensure that the crescent washer is in place on each pair of bolts.
Fig. 7: Location For Reference Mark At Transfer Case Flange
4. Push the propeller shaft toward the rear of the vehicle and install the propeller shaft to the transfer case
flange.
5. Align the reference marks on the propeller shaft and the transfer case flange.

Fig. 8: Removing/Installing Propeller Shaft-To-Transfer Case Flange Bolts
6. Install the propeller shaft-to-transfer case bolts. Ensure that the crescent washer is in place on each pair of
bolts.
7. Tighten the bolts in a cross sequence.

Fig. 9: View Of Propeller Shaft-To-Torque Tube Flange Bolts
8. Tighten the propeller shaft to torque tube bolts in a cross sequence.

PROPELLER SHAFT DESCRIPTION AND OPERATION
Fig. 10: View Of Propeller Shaft Components
The propeller shaft (3) is of a tubular design with constant velocity joints at both the transfer case and the torque
tube flanges. The forward and rearward ends of the propeller shaft mate to the transfer case and the torque tube
flanges with 6 bolts each (2, 4) utilizing special crescent-shaped washers to pair the bolts together in order to
evenly distribute the clamping force.
The front constant velocity (CV) joint receives the rotational forces from the transfer case output flange. The
front CV joint is of a ball-and-groove design using 6 ball bearings set in a race. The CV joint allows axial, but
not lateral movement of the joint in order to compensate for the driveline inclination changes imposed by the
powertrain during acceleration and deceleration. The CV joint is lubricated with a special grease that is
protected from foreign material contamination by a seal similar in design to the seal on a front wheel drive
shaft. The mating surface of the CV joint is protected by a metal cap which is crimped on to the CV joint, and
captured between the CV joint and the transfer case output flange.
The rear CV joint receives the rotational forces transmitted through the propeller shaft from the front CV joint.
These forces are then transferred to the torque tube input flange. The rear CV joint is similar in design to the
front CV joint, although the rear CV joint allows lateral as well as axial movement. The lateral and axial
movement of the CV joint compensates for driveline inclination changes as well as the lateral movement of the
driveline during acceleration and deceleration. The CV joint is lubricated with a special grease that is protected
from foreign material contamination by a bellows-type seal. The mating surface of the CV joint is protected by
a metal cap which is crimped on to the CV joint, and captured between the CV joint and the torque tube input
flange.
The propeller shaft and the constant velocity joints are not serviceable The CV joints and seals should be
inspected periodically, whenever the vehicle is raised for service.
Drum Brakes - Aztek & Rendezvous
SPECIFICATIONS

Specification
Bleeder Valve 7 N.m 62 lb in
Brake Pipe to Wheel Cylinder 17 N.m 12 lb ft
Wheel Cylinder Bolts 12 N.m 110 lb in
DRUM BRAKE COMPONENT SPECIFICATIONS
Drum Brake Component Specifications

Specification
Brake Drum Discard Diameter 251.5 mm 9.902 in
Brake Drum Maximum Allowable Diameter After Refinish 251.0 mm 9.882 in
Brake Drum Maximum Allowable Radial Runout 0.15 mm 0.006 in
Brake Drum Maximum Allowable Scoring 1.5 mm 0.06 in

DIAGNOSTIC STARTING POINT - DRUM BRAKES
Begin the drum brake system diagnosis with Diagnostic Starting Point - Hydraulic Brakes in Hydraulic
Brakes. The use of the Diagnostic Starting Point leads to the identification of the correct procedure for
diagnosing the system and where the procedure is located.
BRAKE DRUM DIAMETER MEASUREMENT

Fig. 1: Measuring Brake Drum
1. Clean the brake shoe lining contact surface of the brake drum with denatured alcohol or an equivalent
brake cleaner.
2. Using a brake drum micrometer calibrated in thousands of an inch, measure and record the largest
diameter of the brake drum at four or more points, equally spaced around the drum.
Ensure that the measurements are only taken within the brake shoe lining contact area and that the
micrometer is positioned the same distance from the outside edge of the drum for each measurement.
3. Compare the largest diameter measurement recorded to the following specifications:
Specification:
Brake drum maximum allowable diameter after refinishing 251.0 mm (9.882 in).
Brake drum discard diameter 251.5 mm (9.902 in).
4. If the largest diameter measurement of the brake drum is less than the maximum allowable diameter after
refinishing specification; the drum may be able to be refinished, depending upon surface and wear
5. If the largest diameter measurement of the brake drum is equal to or greater than the maximum allowable
diameter after resurfacing specification; the drum may not be refinished.
6. If the largest diameter measurement of the brake drum is equal to or greater than the discard diameter
specification; the drum requires replacement.
BRAKE DRUM SURFACE AND WEAR INSPECTION
Tools Required
J 8001 Dial Indicator, or equivalent. See Special Tools.
1. With the brake drum removed, clean the braking (friction) surface of the brake drum with denatured
alcohol or an equivalent approved brake cleaner.
2. Inspect the braking surface of the brake drum for the following Braking Surface Conditions:
Light surface rust can be removed with an abrasive disc; heavy surface rust and/or pitting must be
removed by refinishing the drum.

3. If the braking surface of the brake drum exhibits one or more of the Braking Surface Conditions, the
drum requires refinishing or replacement.
Fig. 2: Measuring Brake Drum
4. Using a brake drum micrometer calibrated in thousands of an inch, measure and record any grooves
present on the drum braking surface.
Ensure that the measurements are only taken within the brake shoe lining contact area.
5. Compare the groove (scoring) depth recorded to the following specification:
Specification: Brake drum maximum allowable scoring 1.5 mm (0.06 in).
6. If the brake drum scoring depth exceeds the specification, or if an excessive amount of scoring is present,
the drum requires refinishing or replacement.
7. Mount the brake drum on a brake lathe.
8. Mount a dial indicator, J 8001 or equivalent, and position the indicator button so it contacts the braking
surface of the brake drum at a 90 degree angle, approximately 19 mm (0.75 in) from the drum's outer
edge.
9. Measure and record the radial runout of the brake drum.
1. Rotate the drum until the lowest reading is displayed on the indicator dial, then zero the dial.
2. Rotate the drum until the highest reading is displayed on the dial.
10. Compare the radial runout of the brake drum to the following specification:
Specification: Brake drum maximum allowable radial runout 0.15 mm (0.006 in).
11. If the brake drum radial runout exceeds the specification, the drum requires refinishing or replacement.
DRUM BRAKE HARDWARE INSPECTION
Fig. 3: View Of Brake Components


1. Visually inspect the drum brake system hold-down springs (4) for the following:
Excessive corrosion
Damaged or bent locating pins
Broken spring coils
Damaged retaining cups
2. Visually inspect the lower return spring (7) and the upper return/adjuster actuator spring (3) for the
following:
Excessive corrosion
Excessive stretching
Broken hook ends
Twisting or binding
3. If any of the conditions listed were found, the drum brake system hardware requires replacement.
4. Visually inspect the park brake lever (5) for the following:
Bent
Broken pivot
Broken at park brake cable attachment
5. If any of the conditions listed were found, the park brake lever and/or attaching hardware requires
replacement.
DRUM BRAKE ADJUSTING HARDWARE INSPECTION

Fig. 4: Identifying Park Brake Adjuster Actuator Components
1. Visually inspect the adjuster actuator spring (2) for the following:
Excessive corrosion
Excessive stretching
Broken hook ends
Twisting or binding
Missing
2. If any of the conditions listed were found, the drum brake system adjuster hardware requires replacement.
3. Visually inspect the adjuster actuator lever (1) for the following conditions:
Bent
Broken
Missing
Broken spring attachment tab
4. If any of the conditions listed were found, the adjuster actuator lever and/or attaching hardware requires
replacement.
REPAIR INSTRUCTIONS
BRAKE DRUM REPLACEMENT
Removal Procedure
1. Release the parking brake.

4. Mark the relationship of the drum to the hub.
5. Remove and discard the retaining clip (if applicable).
Fig. 5: View Of Brake Drum

7. If the brake drum does not come off easily, perform the following steps:
1. Loosen the parking brake cable.
2. Remove the access hole plug from the backing plate.
Fig. 6: Disengaging Self Adjuster
3. Insert a flat-bladed tool (2) through the backing plate access hole in order to disengage the self
adjuster.
4. Insert another flat-bladed tool through the same backing plate access hole in order to loosen the
adjuster screw.
5. Install the access hole plug in order to prevent dirt or contamination from entering the drum brake.
6. Apply a small amount of penetrating oil around the brake drum center hole.
1. Align the marks on the brake drum and the hub made during the removal procedure.

2. Install the brake drum.

3. Inspect the brake to shoe adjustment. Refer to Drum Brake Adjustment.
BRAKE DRUM REFINISHING
Tools Required
J 41013 Rotor/Drum Flange Resurfacing Kit

J 42450-A Hub Cleaning Kit

1. The brake drums do not require refinishing as part of routine brake system service. Do not refinish brake
drums in an attempt to correct the following conditions:
Brake system noise (squeal, growl, groan)
Uneven and/or premature brake lining wear
Superficial or cosmetic corrosion/rust of the brake drum surface
Scoring of the brake drum surface (less than the maximum allowable specification)
2. Brake drums should only be refinished if the following conditions exist:

Excessive corrosion/rust and/or pitting
Scoring of the brake drum surface (in excess of the maximum allowable specification)
Radial runout in excess of the maximum allowable specification
3. Inspect each of the brake drums and determine if the brake drums can be refinished and remain within the
maximum allowable diameter after refinish specification:
1. With the tire and wheel assemblies removed, measure the diameter of each of the brake drums.
Refer to Brake Drum Diameter Measurement .
2. Inspect each of the brake drums for excessive surface wear and/or radial runout. Refer to Brake
Drum Surface and Wear Inspection .
4. If the brake drums can be refinished, proceed with the rotor refinishing procedure.
5. If necessary, use the J 41013 in order to thoroughly clean any corrosion/rust from the brake drum flange.
6. Mount the brake drum to the brake lathe according to the lathe manufacturer's instructions.
8. With the brake lathe running, slowly bring in the cutting tool until it just contacts the brake drum friction
surface.
9. Observe the witness mark on the brake drum. If the witness mark extends approximately three-quarters or
more of the way around the brake drum surface, the brake drum is properly mounted to the lathe.
10. If the witness mark does not extend three-quarters or more of the way around the brake drum, re-mount
the brake drum to the lathe.
11. Following the brake lathe manufacturer's instructions, refinish the brake drum.
12. After each successive cut, inspect the brake drum diameter. Refer to Brake Drum Diameter
Measurement.
13. If at any time the brake drum exceeds the maximum allowable diameter after refinish specification, the
brake drum must be replaced.
14. After refinishing the brake drum, use the following procedure in order to obtain the desired non-
directional finish:
finish

3. After applying a non-directional finish, clean each friction surface of the brake drum with
denatured alcohol or an equivalent brake cleaner
15. Remove the brake drum from the brake lathe.
IMPORTANT: Failure to clean the corrosion from the wheel bearing flange may result in
increased lateral runout of the brake drum and brake system pulsation.
16. If necessary, use the J 42450-A in order to thoroughly clean any corrosion from the wheel bearing flange.
BRAKE SHOE REPLACEMENT
Removal Procedure
CAUTION: Keep fingers away from rear brake shoe springs to prevent fingers from
2. Remove the brake drum. Refer to Brake Drum Replacement.
NOTE: Do not over stretch the adjuster spring. Damage can occur if the spring is
over stretched.
3. Disengage the adjuster spring hook end from the tab on the adjuster actuator (1).
6. Remove the return spring (7) from the brake shoes.
7. Remove the park brake cable (6) from the park brake actuator lever (5).
8. Remove the brake shoe hold-down springs and retainers (4) from the brake shoes.
9. Remove the adjuster from the brake shoes and the park brake actuator lever (2).
13. Inspect all of the drum brake system components. Refer to Drum Brake Hardware Inspection and
Drum Brake Adjusting Hardware Inspection.
14. Replace drum brake system components as necessary.
15. Inspect the wheel cylinder for the following conditions:
Brake fluid leakage
Worn or damaged dust boots
16. Replace damaged or leaking wheel cylinders as necessary. Refer to Wheel Cylinder Replacement.
Fig. 9: Identifying Brake Shoe Assembly Lubrication Areas
1. Apply GM P/N 1052196 (Canadian P/N 5264008) brake lubricant or equivalent to the following areas:
The brake shoe contact points on the backing plate
The adjuster screw threads
The inside diameter of the adjuster socket

5. Install the brake shoe hold-down pins, springs and retainers (4) to the brake shoes.
6. Install the park brake cable (6) to the park brake actuator lever.
IMPORTANT: Ensure that the adjuster (2) engages the brake shoe (4) and the park brake
actuator (3) properly.
7. Install the adjuster screw to the brake shoe and the park brake actuator.
8. Apply GM P/N 1052196 (Canadian P/N 5264008) brake lubricant or equivalent to the adjuster
actuator/brake shoe interface.
9. Install the adjuster actuator (1) to the brake shoe.
NOTE: Do not over stretch the adjuster spring. Damage can occur if the spring is
over stretched.
10. Install the straight end of the adjuster spring (3) to the brake shoe.
11. Install the adjuster spring hook end to the tab on the adjuster actuator (1).
12. Install the return spring (7) to the brake shoes.
IMPORTANT: Ensure that the adjuster operates properly.

13. Move the park brake actuator lever (5) in order to spread the brake shoes apart. The adjuster actuator
lever should move downward, then upward as the park brake actuator lever is released, forcing the
adjuster wheel to rotate.
If the adjuster does not operate properly, remove then reinstall the adjuster.
14. Adjust the brake shoes. Refer to Drum Brake Adjustment.

15. Adjust the park brake cable. Refer to Park Brake Adjustment (Disc) or Park Brake Adjustment
(Drum) in Park Brake.
16. Install the brake drum. Refer to Brake Drum Replacement.
DRUM BRAKE BACKING PLATE REPLACEMENT
Tools Required
J 37043 Parking Brake Cable Release Tool. See Special Tools.
Removal Procedure
NOTE: Do not pry against the splash shield or backing plate in attempt to free the
drum. This will bend the splash shield or backing plate. A bent backing plate
may cause brake chatter and/or pulsation.
Fig. 13: Removing Cable From Lever
4. Remove the brake shoes. Refer to Brake Shoe Replacement.
6. Using the J 37043 , remove the park brake cable ONLY from the backing plate. See Special Tools.
Fig. 14: Removing/Installing Wheel Cylinder
7. Remove the wheel cylinder (3). Refer to Wheel Cylinder Replacement.

Fig. 15: Identifying Wheel Bearing/Hub
8. Remove the wheel bearing/hub. Refer to Wheel Bearing/Hub Replacement - Rear (Front Wheel
Drive/Drum) or Wheel Bearing/Hub Replacement - Rear (Disc and AWD) in Rear Suspension.
9. Remove the backing plate.
1. Install the backing plate.

Fig. 16: Identifying Wheel Bearing/Hub
2. Install the wheel bearing/hub. Refer to Wheel Bearing/Hub Replacement - Rear (Front Wheel
Drive/Drum) or Wheel Bearing/Hub Replacement - Rear (Disc and AWD) in Rear Suspension.
3. Install the wheel cylinder. Refer to Wheel Cylinder Replacement.

4. Install the park brake cable to the backing plate.
5. Install the park brake cable (6) to the park brake actuator (5).
6. Install the brake shoes. Refer to Brake Shoe Replacement.
7. Adjust the brake shoes. Refer to Drum Brake Adjustment.
8. Adjust the park brake cable. Refer to Park Brake Adjustment (Disc) or Park Brake Adjustment
(Drum) .
DRUM BRAKE HARDWARE REPLACEMENT
Removal Procedure


3. Disengage the adjuster spring hook end from the tab on the adjuster actuator (1).
5. Remove the return spring (7) from the brake shoes.

6. Remove the brake shoe hold-down springs and retainers (4) from the brake shoes.
9. Inspect all of the drum brake system components. Refer to Drum Brake Hardware Inspection and
Drum Brake Adjusting Hardware Inspection.
1. Install the brake shoe hold-down pins, springs and retainers (4) to the brake shoes.
3. Install the adjuster spring hook end to the tab on the adjuster actuator (1).
4. Install the return spring (7) to the brake shoes.

DRUM BRAKE ADJUSTING HARDWARE REPLACEMENT
Removal Procedure

2. Remove the adjuster spring (3) from the adjuster actuator lever.
3. Remove the straight end of the adjuster actuator spring from the brake shoe.
4. Remove the adjuster actuator lever (1).
1. Install the adjuster actuator lever (1).

3. Install the hook end of the adjuster spring to the adjuster actuator lever.
IMPORTANT: Ensure that the adjuster engages the brake shoes (4) and (5), the park
brake actuator (3), and the adjuster actuator (1) properly.
4. Inspect the adjuster (2) for proper engagement with the drum brake system components.
WHEEL CYLINDER REPLACEMENT
Tools Required
J 38400 Brake Shoe Spanner and Spring Remover. See Special Tools.
Removal Procedure
3. Clean all dirt and foreign material from the wheel cylinder brake pipe fitting and the bleeder valve.


5. Remove the brake pipe nut.
6 Install a cap over the end of the brake pipe in order to prevent brake fluid loss and/or brake fluid
contamination.

7. Remove the wheel cylinder bolts (2).

Fig. 28: Using J 38400 To Spread The Brake Shoes Apart
8. Use the J 38400 in order to spread the brake shoes apart (1). See Special Tools.
9. Remove the wheel cylinder.
10. Clean the old sealant from the backing plate where the wheel cylinder was installed. Clean the sealant
from the wheel cylinder if you are reusing the wheel cylinder.
1. Apply LOCTITE GM P/N 12345382 (or equivalent) to the wheel cylinder shoulder face which contacts
the backing plate.
Fig. 29: Using J 38400 To Spread The Brake Shoes Apart
2. Use the J 38400 in order to spread the brake shoes apart (1). See Special Tools.
3. Install the wheel cylinder.
4. Install the wheel cylinder bolts (2).
5. Remove the cap from the brake pipe and install the brake pipe to the wheel cylinder.
Tighten: Tighten the nut to 17 N.m (12 lb ft).

7. Bleed the hydraulic brake system at the wheel cylinder. Refer to Hydraulic Brake System Bleeding
(Manual) or Hydraulic Brake System Bleeding (Pressure) in Hydraulic Brakes.
DRUM BRAKE ADJUSTMENT
Tools Required
J 21177-A Drum-to-Brake Shoe Clearance Gage. See Special Tools.
2. Remove the rear wheels and tires. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
3. Relieve cable tension from the park brake system at the equalizer. there should be no tension on the park
brake cables, so that the brake shoes are positioned only by the adjuster strut.
Fig. 31: Setting J 21177-A To Widest Inside Diameter Of Drum
4. Remove the rear drums. Refer to Brake Drum Replacement.

5. Set the J 21177-A so that the J 21177-A contacts the inside diameter of the drum at the widest point. See
Special Tools.
Fig. 32: Setting J 21177-A To Widest Point Of Parking Shoes
6. Position the J 21177-A over the shoes at the widest point. See Special Tools.
7. Turn the adjuster nut until the shoes just contact the J 21177-A . See Special Tools.
8. Repeat steps 2-7 for the other rear brake assembly.
9. Install the rear drums. Refer to Brake Drum Replacement.
10. Install the rear wheels and tires. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
11. Adjust the park brake cable system. Refer to Park Brake Adjustment (Disc) or Park Brake
Adjustment (Drum) in Park Brake.

DRUM BRAKE SYSTEM DESCRIPTION AND OPERATION
The drum brake system consists of the following:
Drum Brake Shoes
Applies mechanical output force (from hydraulic brake wheel cylinders) to friction surface of brake
drums.
Brake Drums
Uses mechanical output force applied to friction surface from drum brake shoes to slow speed of tire and
wheel assembly rotation.
Drum Brake Hardware
Secures drum brake shoes firmly in proper relationship to hydraulic brake wheel cylinders. Enables
sliding motion of brake shoes needed to expand toward friction surface of drums when mechanical output
force is applied; provides return of brake shoes when mechanical output force is relieved.
Drum Brake Adjusting Hardware
Provides automatic adjustment of brake shoes to brake drum friction surface whenever brake apply occurs
during rearward motion of the vehicle.
System Operation
Mechanical output force is applied from the hydraulic brake wheel cylinder pistons to the top of the drum brake
shoes. The output force is then distributed between the primary and secondary brake shoes as the shoes expand
toward the friction surface of the brake drums. The brake shoes apply the output force to the friction surface of
the brake drums, which slows the rotation of the tire and wheel assemblies. The proper function of both the
drum brake hardware and adjusting hardware is essential to the proper distribution of braking force.

SPECIAL TOOLS
Special Tools
J 8001
Dial Indicator Set
J 21177-A
Drum to Brake Shoe Clearance Gage
J 37043
Parking Brake Cable Release Tool
J 38400
Brake Shoe Spanner and Spring Remover
J 41013
Rotor/Drum Flange Resurfacing Kit
BUZZERS, RELAYS & TIMERS
BUZZERS, RELAYS & TIMERS LOCATION
Component Location
A/C CLU Relay 52 In underhood accessory wiring junction block.
ACCY Relay In console accessory wiring junction block.
Air Pump Relay 63 In underhood accessory wiring junction block.
Automatic Level Control (ALC) Inflator Time Inside vehicle, behind left rear wheelhouse.
Relay
Automatic Level Control (ALC) Relay Inside vehicle, behind left rear wheelhouse.
Cool Fan 1 Relay 62 In underhood accessory wiring junction block.
Crank Relay 58 In underhood accessory wiring junction block.
DRL Relay 53 In underhood accessory wiring junction block.
Flasher In underhood accessory wiring junction block.
FOG LPS Relay In underhood accessory wiring junction block.
Fuel Pump Relay 51 In underhood accessory wiring junction block.
HDLP Lo-Beam Relay 54 In underhood accessory wiring junction block.
HDLP Hi-Beam Relay 56 In underhood accessory wiring junction block.
Horn Relay 50 In underhood accessory wiring junction block.
Ignition Relay 60 In underhood accessory wiring junction block.
PARK LPS Relay 55 In underhood accessory wiring junction block.
RAP Relay In console accessory wiring junction block.
CIRCUIT PROTECTION DEVICES

CIRCUIT PROTECTION DEVICES LOCATION
Component Location
ACCY Diode In console accessory wiring junction block.
Console Accessory Wiring Junction Block In console.
Underhood Accessory Wiring Junction Block Right side of engine compartment, above battery.
CONTROL UNITS
CONTROL UNITS LOCATION
Component Location
Body Control Module (BCM) In console, attached to console accessory wiring
junction block.
Cruise Control Module At left side of engine compartment, near strut tower.
See Fig. 12 .
Electronic Brake Control Module (EBCM) Left side of engine compartment. See Fig. 13 .
Engine Coolant Level Indicator Module On right rear side of radiator.
Ignition Control Module (ICM) On top of right valve cover.
Inflatable Restraint Sensing & Diagnostic Module Under right front seat.
(SDM)
Passkey Module On top of steering column, at ignition switch. See
Fig. 15 .
Powertrain Control Module (PCM) At left side of engine compartment, in air cleaner
assembly. See Fig. 10 .
Sunroof Control Module In roof.
MOTORS
MOTORS LOCATION
Component Location
Automatic Level Control (ALC) Compressor Under left side of vehicle, below driver's door.
Blower Motor Behind glove box, on heater-A/C assembly.
Idle Air Control (IAC) Valve On throttle body.
Left Temp Motor On left end of HVAC assembly. See Fig. 14 .
Mode Motor On left end of HVAC assembly. See Fig. 14 .
Recir/OSA Motor On right end of HVAC assembly. See Fig. 14 .
Right Temp Motor On right side of HVAC assembly, left of blower
motor.
Secondary Air Injection (AIR) Pump At left front of vehicle, below horn. See Fig. 11 .
Windshield Washer Pump On front washer solvent container.
Windshield Wiper Motor At right rear of engine compartment.
SENDING UNITS & SENSORS

SENDING UNITS & SENSORS LOCATION
Component Location
A/C Compressor Refrigerant Pressure Sensor Below air cleaner assembly, on evaporator inlet
tube.
Ambient Air Temperature Sensor At right front corner of vehicle, behind headlight.
See Fig. 16 .
Auto Level Control (ALC) Sensor Above rear axle, on rear crossmember.
Camshaft Position (CMP) Sensor On top front of engine. See Fig. 1 .
Crankshaft Position (CKP) Sensor A On front of engine, behind harmonic balancer. See
Fig. 3 .
Crankshaft Position (CKP) Sensor B On lower right side of engine. See Fig. 4 .
Daytime Running Lamp (DRL) Ambient Light Center of dash, near defrost vent.
Sensor
Engine Coolant Temperature (ECT) Sensor On top rear of engine, near thermostat housing. See
Fig. 6 .
Front Wheel Speed Sensor (Left/Right) On respective front hub assembly.
Frost Sensor In HVAC assembly, on evaporator coil.
Fuel Tank Pressure Sensor Inside fuel tank.
Heated Oxygen Sensor (HO2S) No. 1 At right side of engine, on exhaust manifold.
Heated Oxygen Sensor (HO2S) No. 2 On exhaust system, behind catalytic converter.
Inflatable Restraint Side Impact Sensor (Left) At base of left "B" pillar, above seat belt retractor.
Inflatable Restraint Side Impact Sensor (Right) At base of right "B" pillar, above seat belt retractor.
Intake Air Temperature (IAT) Sensor Near throttle body, in air intake duct. See Fig. 8 .
Knock Sensor (KS) On lower left side of engine, above starter. See Fig.
5.
Manifold Absolute Pressure (MAP) Sensor On top front of engine. See Fig. 9 .
Mass Airflow (MAF) Sensor At left side of engine compartment, on air cleaner
housing. See Fig. 8 .
Rear Wheel Speed Sensor (Left/Right) On respective rear hub assembly.
Throttle Position (TP) Sensor On throttle body.
Vehicle Speed Sensor (VSS) On transaxle.
SOLENOIDS & SOLENOID VALVES

SOLENOIDS & SOLENOID VALVES LOCATION
Component Location
Air Vacuum Control Solenoid Valve On right rear side of engine.
Automatic Level Control (ALC) Solenoid Valve Inside vehicle, behind left rear wheelhouse.
Automatic Transmission Shift Lock Control Inside console, under shifter.
Solenoid
Brake Pressure Modulator Valve (BPMV) Left side of engine compartment. See Fig. 13 .
Differential All Wheel Drive Actuator On lower front of rear differential.
Evaporative Emission (EVAP) Canister Purge On top right rear of engine, near throttle body. See
Solenoid Fig. 7 .
Evaporative Emission (EVAP) Canister Vent Below center of vehicle, near fuel tank.
Solenoid
Exhaust Gas Recirculation (EGR) Valve Top rear of engine, on intake manifold.
SWITCHES
SWITCHES LOCATION
Component Location
Automatic Level Control Inflator Air Switch Inside vehicle, behind left rear wheelhouse.
Brake Fluid Level Indicator Switch On side of brake fluid reservoir.
Cruise Control Release Switch On brake pedal support.
Engine Oil Level Indicator Switch On bottom of engine oil pan.
Engine Oil Pressure Indicator Switch On lower left side of engine, above starter. See Fig.
2.
Park Brake Indicator Switch On park brake assembly.
Seat Belt Switch In right half of driver's seat belt.
Stoplight Switch On brake pedal support.
Transaxle Range Switch On top of transaxle.
Windshield Washer Solvent Level Switch On front washer solvent container.
MISCELLANEOUS
MISCELLANEOUS LOCATION
Component Location
Audio Power Amplifier Under dash, between park brake lever & steering
column.
Blower Motor Resistor On HVAC assembly, in front of blower motor.
Data Link Connector (DLC) Below steering column.
CONNECTORS
CONNECTORS LOCATION
Component Location
C101 (Black, 16 Pin) In lower left side of engine compartment, near
EBCM.
C102 (Black, 16 Pin) On top of engine, near generator.
C103 (Black, 16 Pin) In lower left side of engine compartment, near
EBCM.
C105 (Gray, 4 Pin) Front of engine compartment, on cooling fan
support.
C111 (20 Pin) In lower left side of engine compartment, on top of
automatic transaxle.
C120 (Black, 2 Pin) Between battery & windshield fluid reservoir.
C151 (Black, 4 Pin) Left side of vehicle, behind left headlamp.
C152 (Black, 4 Pin) Right side of vehicle, behind right headlamp.
C153 (Black, 3 Pin) Behind left park/turn lamp.
C154 (Black, 3 Pin) Behind right park/turn lamp.
C200 (Black, 30 Pin) Behind right side of dash compartment, behind right
dash access panel.
C201 (Black, 40 Pin) On left side of steering column near base.
C203 (Light Gray, 40 Pin) Left side of steering column, above left kick panel,
under sound barrier.
C204 (Black 2 Pin) Inside console below shifter.
C210 (Black, 12 Pin) Front of dash, between vehicle interface unit &
vehicle communication unit.
C301 (Black, 40 Pin) Behind left kick panel, left of parking brake.
C302 (Black, 40 Pin) Above right kick panel, under sound barrier.
C303 (Black, 2 Pin) Body wiring harness to left side door wiring
harness.
C305 (Light Gray 16 Pin) Mounted as a pass-through, beneath vehicle, behind
driver's seat.
C306 (Gray, 2 Pin) Under right side of vehicle, between fuel tank &
right rear wheelhouse.
C308 (Black, 30 Pin) Left side of roof, rearward of left rear door.
C309 (Gray, 2 Pin) Under left side of vehicle, between fuel tank & right
rear wheelhouse.
C313 (Black, 8 Pin) Under driver's seat.
C314 (Black, 8 Pin) Under passenger's seat.
C321 (Black, 1 Pin) Body harness to lift window.
C351 (Black, 10 Pin) At left "B" pillar.
C352 (Black, 10 Pin) At right "B" pillar.
C397 (Black, 6 Pin) Dome lamp harness to sunroof harness.
C403 (Natural, 5 Pin) Under left side vehicle, behind left rear wheelhouse.
C405 (Gray, 4 Pin) Above left rear drive axle boot.
C407 (Natural, 5 Pin) Behind left rear taillamp.
C420 (W/ Trailer Provisions) (Natural, 5 Pin) Left rear of vehicle, behind left rear wheelhouse.
GROUNDS
GROUNDS LOCATION
Component Location
G100 Right side of engine compartment, on top of front
end upper crossmember.
G101 Left side of engine compartment, right of left
headlamp, on front upper crossmember.
G111 Engine compartment, mounted on bellhousing left
of starter.
G117 Engine compartment, mounted on bell housing, left
of starter.
G200 Right side of dash, on underside of cross-car beam.
G201 Left side of dash, on underside of cross-car beam.
G202 Left side of dash, on underside of cross-car beam,
between park brake assembly & steering column.
G301 On left "B" pillar, under seat belt anchor.
G302 On right "B" pillar, under seat belt anchor.
G303 In roof, near C308 connector.
G401 Left side of vehicle under rear side window,
between wheelwell & endgate.
G403 Left rear of vehicle under roof.
SPLICES
SPLICES LOCATION
Component Location
S105 Engine harness, top right side radiator, 6 cm from
starter breakout.
S106 Engine harness, front left side of engine
compartment, 47 cm from PCM breakout.
S109 Fuel injector harness, 39 cm from C102.
S123 Forward lamp harness, 5 cm from right foglamp
breakout.
S124 Forward lamp harness, 10 cm from ground G101
breakout.
S203 I/P harness, left side of dash, 13 cm from stoplamp
switch breakout.
S204 I/P harness, right side of dash, 24 cm from stoplamp
switch breakout.
S209 I/P harness, left side of dash, 7.5 cm from P101.
S211 I/P harness, left side of dash, 13 cm from pass-
through breakout.
S213 I/P harness, center of dash, 4 cm from blower motor
resistor, & auxiliary drop power connector breakout
S242 I/P harness, left side of dash, 24 cm from stoplamp
switch breakout.
S301 Body harness, left rear of vehicle, 25 cm from pass-
through.
S303 Body harness, front of right "B" pillar 80 cm from
inflatable restraint sensing & diagnostic module
breakout.
S304 Body harness, right front door 28 cm from inflatable
restraint sensing & diagnostic module breakout.
S305 Body harness, under left rear of vehicle, 7 cm from
C302 breakout.
S320 Body harness, front center of vehicle, 6.5 cm from
center console fuse block breakout.
S333 Body harness, left front of vehicle, right of drivers
seat 66 cm from center console fuse block breakout.
S390 Roof harness, overhead console, 15 cm left roof rail
reading lamp breakout.
S393 Roof harness, right side of overhead console, 64 cm
from left roof rail reading lamp.
S397 Roof harness, left side of overhead console, 40 cm
from G303 breakout.
S504 Left door harness, 10 cm from left window switch
breakout.
S604 Right door harness, 10 cm from right window
switch breakout.
S901 Endgate wiring harness, 9 cm from C403 breakout.
COMPONENT LOCATION GRAPHICS
NOTE: Figures may show multiple component locations. Refer to appropriate table for
proper figure references.
Fig. 1: Front Of Engine
Fig. 2: Left Side Of Engine
Fig. 4: Right Side Of Engine
Fig. 6: Rear Of Engine
Fig. 7: Right Rear Of Engine
Fig. 8: Left Side Of Engine Compartment
Fig. 9: Top Of Engine
Fig. 11: Left Front Of Vehicle
Fig. 13: Brake Pressure Modulator Valve (BPMV) Assembly
Fig. 14: HVAC Assembly
Fig. 15: Steering Column
Fig. 16: Right Front Of Vehicle
Aztek & Rendezvous

Component Location
A/C CLU Relay 52 In underhood fuse block.
ACCY Relay 27 In center console fuse block.
Air Pump Relay 63 In underhood fuse block.
Automatic Level Control Compressor Relay Inside vehicle, behind left rear wheelhouse.
Automatic Level Control Inflator Time Relay Inside vehicle, behind left rear wheelhouse.
Cool FANSP Relay 59 In underhood fuse block.
Cool FAN1 Relay 62 In underhood fuse block.
Cool FAN3 Relay 61 (Pontiac) In underhood fuse block.
Crank Relay 58 In underhood fuse block.
DRL Relay 53 In underhood fuse block.
FOG LPS Relay 57 In underhood fuse block.
Fuel Pump Relay 51 In underhood fuse block.
Hazard & Turn Signal Flasher In center console fuse block.
HDLP Lo-Beam Relay 54 In underhood fuse block.
HDLP Hi-Beam Relay 56 In underhood fuse block.
Horn Relay 50 In underhood fuse block.
IGN 3 Relay 23 In center console fuse block.
Ignition Relay 60 In underhood fuse block.
PARK LPS Relay 55 In underhood fuse block.
RAP Relay 33 In center console fuse block.
RR Defog Relay 20 In center console fuse block.

Component Location
Center Console Fuse Block In floor console.
Fusible Link In-line to generator, near positive battery cable.
Underhood Fuse Block Front of right wheelhouse, above battery.
Vehicle Communication Unit Under dash, left of blower motor.
Vehicle Interface Unit Under dash, left of blower motor.
CONTROL UNITS
Component Location
Part of HVAC module, behind glove box, in front of
Blower Motor Control Processor
blower motor.
Body Control Module In console, above fuse block, in center console.
Cruise Control Module (CCM) At left side of engine compartment, near strut tower.
See Fig. 12 .
Electronic Brake Control Module (EBCM) Left side of engine compartment. See Fig. 13 .
HVAC Control Module Center of dash, below radio.
Ignition Control Module On top of right valve cover.
Inflatable Restraint I/P Module Right side of dash, above glove box.
Inflatable Restraint Sensing & Diagnostic Module Under right front seat.
Inflatable Restraint Side Impact Module (Left) Left side of driver seat back cover.
Inflatable Restraint Side Impact Module (Right) Right side of passenger seat back cover.
Memory Seat & Mirror Module Under driver seat.
OnStar(R) Transceiver Under dash, left of blower motor.
Powertrain Control Module (PCM) At left side of engine compartment, in air cleaner
Rear Parking Assist Sensors Behind left rear wheelhouse.
Behind center of dash, near windshield defrost vent,
Remote Control Door Lock Receiver
in sun roof assembly.
Sun Roof Module In sun roof assembly.
Theft Deterrent Control Module In steering column, at ignition switch.
Turn Signal/Multifunction Flasher Module In center console fuse block.
MOTORS
MOTORS LOCATION
Component Location
Air Temperature Actuator (Left) On left end of HVAC assembly. See Fig. 14 .
Air Temperature Actuator (Right) On right end of HVAC assembly.
Automatic Level Control Compressor Under left side of vehicle, below driver's door.
Blower Motor Part of HVAC module, behind glove box.
Cooling Fan (Left) Mounted to rear left side of radiator.
Cooling Fan (Right) Mounted to rear right side of radiator.
Fuel Pump & Sender Assembly In fuel tank.
Idle Air Control Valve On throttle body.
Mode Actuator On left end of HVAC assembly. See Fig. 14 .
Recirculation Actuator On right end of HVAC assembly. See Fig. 14 .
Secondary Air Injection (AIR) Pump At left front of vehicle, below horn. See Fig. 11 .
Windshield Washer Fluid Pump On front washer solvent container.
Windshield Wiper Motor At right rear of engine compartment.

Component Location
A/C Refrigerant Pressure Sensor Left side of engine compartment, below air cleaner
assembly.
Ambient Air Temperature Sensor In front of radiator, behind right headlight. See Fig.
15 .
Auto Level Control Sensor (AWD) Mounted to rear crossmember, above rear axle,
behind left rear wheelhouse.
Auto Level Control Sensor (FWD) Above rear axle, on rear crossmember.
Crankshaft Position (CKP) Sensor A On lower right side of engine. See Fig. 4 .
Crankshaft Position (CKP) Sensor B On front of engine, behind harmonic balancer. See
Fig. 3 .
Daytime Running Lamp Ambient Light Sensor Center of dash, near defrost vent.
Engine Coolant Temperature (ECT) Sensor On top rear of engine, near thermostat housing. See
Fig. 6 .
Evaporative Temperature Sensor In HVAC module, mounted to evaporator coil.
Front Wheel Speed Sensor (Left/Right) On respective front hub assembly.
Heated Oxygen Sensor (HO2S 1) At right side of engine, on exhaust manifold.
Heated Oxygen Sensor (HO2S 2) On exhaust system, behind catalytic converter.
Inflatable Restraint Side Impact Sensor (Left) At base of left "B" pillar, above seat belt retractor.
Inflatable Restraint Side Impact Sensor (Right) At base of right "B" pillar, above seat belt retractor.
Knock Sensor (KS) On lower left side of engine, above starter. See Fig.
5.
Mass Airflow (MAF) Sensor At left side of engine compartment, on air cleaner
Rear Parking Assist Sensors Mounted to rear fascia.
Rear Wheel Speed Sensor (Left/Right) On respective rear hub assembly.
Center of dash, mounted to trim plate, near
Sunload Sensor
windshield defrost vent.
Throttle Position Sensor Top of engine, on rear side of throttle assembly.
Transaxle Fluid Temperature Sensor Inside automatic transaxle.
Vehicle Speed Sensor On transaxle.
Component Location
1-2 Shift Solenoid (1-2 SS) Valve Inside automatic transaxle.
Air Temperature Actuator (Left) Left side of HVAC module.
Air Temperature Actuator (Right) Right side of HVAC module.
A/T Shift Lock Control Solenoid (Buick) Part of steering column.
A/T Shift Lock Control Solenoid (Pontiac) Inside console, under transaxle shifter.
Automatic Level Control Solenoid Valve Inside vehicle, behind left rear wheelhouse.
Solenoid Fig. 7 .
Evaporative Emission Canister Vent Solenoid Below center of vehicle, near fuel tank.
Exhaust Gas Recirculation Valve Top rear of engine, on intake manifold.
Ignition Key Solenoid Part of steering column.
Liftgate Release Actuator (Left) Mounted on top left side of endgate.
Liftgate Release Actuator (Right) Mounted on top right side of endgate.
Recirculation Actuator In dash, behind glove box, on cowling.
Secondary Air Injection Solenoid Lower right side of engine.
Secondary Air Injection Vacuum Control Solenoid
On right rear side of engine.
Valve
Lower left of engine, integral to starter motor
Starter Solenoid
assembly.
Torque Converter Clutch Solenoid Valve Inside automatic transaxle.
SWITCHES
SWITCHES LOCATION
Component Location
Brake Fluid Level Switch On right side of brake fluid reservoir.
Cruise Control Release Switch On brake pedal support.
Engine Oil Level Switch On bottom of engine oil pan.
Engine Oil Pressure (EOP) Switch On lower left side of engine, above starter. See Fig.
2.
Park Brake Switch On park brake assembly.
Seat Belt Switch In right half of driver seat belt.
Windshield Washer Fluid Level Switch On front washer solvent container.
MISCELLANEOUS
Component Location
Audio Amplifier Under dash, between park brake lever & steering
column.
Blower Motor Resistor Assembly On HVAC assembly, in front of blower motor.
Data Link Connector Below steering column.
CONNECTORS
CONNECTORS LOCATION
Component Location
C101 (Black, 16 Pin) In lower left side of engine compartment, near EBCM.
C103 (Black, 16 Pin) In lower left side of engine compartment, near EBCM.
C105 (Gray, 4 Pin) Front of engine compartment, mounted to cooling fan support.
C111 (20 Pin) In lower left side of engine compartment, on top of automatic transaxle.
C155 (Black, 6 Pin) Forward lamp harness, to left front lamps.
C156 (Black, 6 Pin) Forward lamp harness, to right front lamps.
C200 (Black, 30 Pin) Behind right side of dash compartment, behind right dash access panel.
C201 (Black, 40 Pin) On left side of steering column, near base.
C203 (Light Gray, 40 Pin) Left side of steering column, above left kick panel, under sound barrier.
C204 (Black, 2 Pin) Inside console, below shifter.
Front of dash, between vehicle interface unit & vehicle communication
C210 (Black, 12 Pin)
unit.
C301 (Black, 40 Pin) Behind left kick panel, left of parking brake.
C302 (Black, 40 Pin) Above right kick panel, under sound barrier.
C303 (Black, 2 Pin) Body wiring harness to left side door wiring harness.
C305 (Natural/Light Gray, 16
Mounted as pass-through, under vehicle, behind driver seat.
Pin)
C306 (Black, 2 Pin) Under right side of vehicle, between fuel tank & right rear wheelhouse.
C308 (Black, 30 Pin) Left side of roof, rear of left rear door.
C309 (Black, 2 Pin) Under left side of vehicle, between fuel tank & right rear wheelhouse.
C310 (Light Gray, 22 Pin) Left side of roof, rear of left rear door.
C313 (Black, 8 Pin) Under driver seat.
C314 (Black, 8 Pin) Under passenger seat.
C317 (Light Gray, 22 Pin) Under driver seat.
C319 (Green, 2 Pin) Below driver seat.
C320 (Green, 2 Pin) Under passenger seat.
C351 (Black, 10 Pin) At left "B" pillar.
C352 (Black, 10 Pin) At right "B" pillar.
C397 (Black, 6 Pin) Dome lamp harness to sun roof harness.
C403 (Black, 10 Pin) Under left side vehicle, behind left rear wheelhouse.
C405 (Black, 6 Pin) Above left rear drive axle boot.
C411 (Black, 6 Pin) Body wiring harness to rear fascia.
C413 (Black, 16 Pin) Above right rear side of roof headliner.
C420 (Natural, 5 Pin) In left rear of vehicle, behind left rear wheelhouse.
GROUNDS
GROUNDS LOCATION
Component Location
G100 Right side of engine compartment, on top of front end upper crossmember.
G101 Left side of engine compartment, right of left headlamp, on front upper crossmember.
G111 Engine compartment, on bellhousing, left of starter.
G117 Engine compartment, on bell housing, above starter.
Left side of dash, on underside of cross-car beam, between park brake assembly & steering
G202
column.
G401 Left side of vehicle, under rear side window, between wheelwell & endgate.
G402 Right rear of vehicle, under roof.
G403 Left rear of vehicle, under roof.
SPLICES
SPLICES LOCATION
Component Location
S101 Forward lamp harness, left front of vehicle, 5 cm from right foglamp breakout.
S102 Forward lamp harness, right front of vehicle, 5 cm from right foglamp breakout.
S105 Engine harness, top right side of radiator, 6 cm from starter breakout.
S106 Engine harness, front left side of engine compartment, 47 cm from PCM breakout.
S123 Forward lamp harness, right front of vehicle, 5 cm from right foglamp breakout.
S124 Forward lamp harness, left front of vehicle, 10 cm from G101 breakout.
S203 I/P harness, left side of dash, 13 cm from stoplamp switch breakout.
S204 I/P harness, right side of dash, 24 cm from stoplamp switch breakout.
S205 I/P harness, right side of dash, 4 cm from HVAC/radio harness breakout.
S211 I/P harness, left side of dash, 13 cm from pass-through breakout.
I/P harness, center of dash, 4 cm from blower motor resistor & auxiliary drop power
S213
connector main branch breakout.
S242 I/P harness, left side of dash, 24 cm from stoplamp switch breakout.
S301 Body harness, left rear of vehicle, 25 cm from pass-through.
Body harness, on right "B" pillar, 80 cm from inflatable restraint sensing & diagnostic
S303
module breakout.
Body harness, right front door, 28 cm from inflatable restraint sensing & diagnostic module
S304
breakout.
S305 Body harness, under left rear of vehicle, 7 cm from C302 breakout.
S320 Body harness, front center of vehicle, 6.5 cm from center console fuse block breakout.
S333 Body harness, right of driver's seat, 66 cm from center console fuse block breakout.
S350 Driver seat harness, under driver seat, 13 cm from C313 breakout.
S351 Passenger seat harness, under passenger seat, 13 cm from C314 breakout.
S390 Roof harness, left side of overhead console, 15 cm from left roof rail reading lamp breakout.
S393 Roof harness, right side of overhead console, 64 cm from left roof rail reading lamp.
S397 Roof harness, left side of overhead console, 40 cm from G303 breakout.
S502 Left door harness, 15 cm from left door speaker breakout.
S504 Left door harness, 10 cm from left window switch breakout.
S604 Right door harness, 10 cm from right window switch breakout.
S907 Endgate wiring harness, 94 cm from liftgate applique grommet.

Fig. 7: Right Rear Of Engine
Fig. 11: Left Front Of Vehicle
Fig. 13: Brake Pressure Modulator Valve (BPMV) Assembly
Fig. 14: HVAC Assembly
Fig. 15: Right Front Of Vehicle
Aztek & Rendezvous

Component Location
A/C CLU Relay 52 (Buick) In underhood fuse block. See Fig. 6 .
A/C CLU Relay 52 (Pontiac) In underhood fuse block. See Fig. 7 .
ACCY Relay 27 In center console fuse block.
Air Pump Relay 63 (Buick) In underhood fuse block. See Fig. 6 .
Air Pump Relay 63 (Pontiac) In underhood fuse block. See Fig. 7 .
Automatic Level Control Compressor Relay Inside vehicle, behind left rear wheelhouse.
Automatic Level Control Inflator Time Relay Inside vehicle, behind left rear wheelhouse.
Cool FANSP Relay 59 (Buick) In underhood fuse block. See Fig. 6 .
Cool FAN1 Relay 62 (Buick) In underhood fuse block. See Fig. 6 .
Cool FAN1 Relay 62 (Pontiac) In underhood fuse block. See Fig. 7 .
Cool FAN2 Relay 61 (Buick) In underhood fuse block. See Fig. 6 .
Crank Relay 58 (Buick) In underhood fuse block. See Fig. 6 .
Crank Relay 58 (Pontiac) In underhood fuse block. See Fig. 7 .
DRL Relay 53 (Buick) In underhood fuse block. See Fig. 6 .
DRL Relay 53 (Pontiac) In underhood fuse block. See Fig. 7 .
Flasher In center console fuse block. See Fig. 8 .
FOG LPS Relay 57 (Buick) In underhood fuse block. See Fig. 6 .
FOG LPS Relay 57 (Pontiac) In underhood fuse block. See Fig. 7 .
Fuel Pump Relay 51 (Buick) In underhood fuse block. See Fig. 6 .
Fuel Pump Relay 51 (Pontiac) In underhood fuse block. See Fig. 7 .
HDLP Hi-Beam Relay 56 In underhood fuse block. See Fig. 6 .
HDLP Hi-Beam Relay 56 (Pontiac) In underhood fuse block. See Fig. 7 .
HDLP Lo-Beam Relay 54 (Buick) In underhood fuse block. See Fig. 6 .
HDLP Lo-Beam Relay 54 (Pontiac) In underhood fuse block. See Fig. 7 .
Horn Relay 50 (Buick) In underhood fuse block. See Fig. 6 .
Horn Relay 50 (Pontiac) In underhood fuse block. See Fig. 7 .
Ignition Relay 60 (Buick) In underhood fuse block. See Fig. 6 .
Ignition Relay 60 (Pontiac) In underhood fuse block. See Fig. 7 .
IGN 3 Relay 23 In center console fuse block.
PARK LPS Relay 55 (Buick) In underhood fuse block. See Fig. 6 .
PARK LPS Relay 55 (Pontiac) In underhood fuse block. See Fig. 7 .
RAP Relay 33 In center console fuse block.
RR Defog Relay 20 In center console fuse block.

Component Location
A/C Compressor Clutch Diode On A/C compressor clutch. See Fig. 19 .
Automatic Level Control (ALC) Compressor Relay Under center of vehicle chassis. See Fig. 13 .
Blower Motor Resistor/Blower Motor Processor Under right side of dash. See Fig. 10 .
Center Console Fuse Block (Buick) In floor console. See Fig. 5 .
Center Console Fuse Block (Pontiac) In floor console. See Fig. 4 .
Fusible Link In-line to generator, near positive battery cable.
Fusible Links (Starter) At starter. See Fig. 19 .
Front of right wheelhouse, above battery. See Fig.
Underhood Fuse Block
2.
CONTROL UNITS
Component Location
Part of HVAC module, behind glove box, in front of
blower motor.
In console, above fuse block, in center console. See
Body Control Module (Buick)
Fig. 5 .
In console, above fuse block, in center console. See
Body Control Module (Pontiac)
Fig. 4 .
At left side of engine compartment, near strut tower.
Cruise Control Module
See Fig. 16 .
Electronic Brake Control Module (EBCM) Left side of engine compartment.
HVAC Control Module Center of dash, below radio. See Fig. 12 .
Ignition Control Module On top of right valve cover. See Fig. 20 .
Inflatable Restraint I/P Module Right side of dash, above glove box. See Fig. 12 .
Inflatable Restraint Passenger Presence Module Under passenger seat on seat track.
Inflatable Restraint Sensing & Diagnostic Module Under right front seat. See Fig. 31 .
Inflatable Restraint Steering Wheel Module In steering wheel. See Fig. 31 .
Memory Seat & Mirror Module Under driver seat.
At left side of engine compartment, in air cleaner
Rear Parking Assist (RPA) Module Behind front center dash console. See Fig. 37 .
Behind center of dash, near windshield defrost vent,
Remote Control Door Lock Receiver
in sun roof assembly.
Under front passenger seat, below carpet. See Fig.
Sensing & Diagnostic Module (SDM)
34 .
Sun Roof Module In sun roof assembly. See Fig. 50 .
Theft Deterrent Control Module In steering column, at ignition switch. See Fig. 32 .
Transmission Control Module (TCM) Inside air cleaner assembly.
Turn Signal/Multifunction Flasher Module In center console fuse block.
Vehicle Communication Unit Under dash, left of blower motor.
Vehicle Interface Unit Under dash, left of blower motor.
MOTORS
MOTORS LOCATION
Component Location
A/C Compressor & A/C Compressor Clutch (3.4L) Right front lower engine. See Fig. 54 .
A/C Compressor Clutch (3.6L) Left front engine. See Fig. 55 .
A/C Temperature Actuator-Left Behind left side of dash. See Fig. 11 .
A/C Temperature Actuator-Right Behind right side of dash. See Fig. 11 .
Under left side of vehicle, below driver's door. See
Automatic Level Control (ALC) Compressor
Fig. 13 .
Automatic Transmission Shift Lock Control
In steering column. See Fig. 32 .
Actuator
Part of HVAC module, behind glove box. See Fig.
Blower Motor
10 .
Cooling Fan (Left) Mounted to rear left side of radiator. See Fig. 18 .
Cooling Fan (Right) Mounted to rear right side of radiator. See Fig. 18 .
Door Latch-Driver In driver's door. See Fig. 45 .
Door Latch-Front Passenger In front passenger's door. See Fig. 46 .
Door Latch-LR In left rear door. See Fig. 47 .
Door Latch-RR In right rear door. See Fig. 48 .
Endgate Latch-Left Left side of tailgate. See Fig. 41 .
Endgate Latch-Right Right side of tailgate. See Fig. 41 .
Fuel Pump & Sender Assembly In fuel tank. See Fig. 24 .
Idle Air Control Valve On throttle body. See Fig. 25 .
Lift Window Release Actuator-Left Left side of tailgate. See Fig. 41 .
Lift Window Release Actuator-Right Right side of tailgate. See Fig. 41 .
Mode Actuator On left end of HVAC assembly.
Rear Window Washer Pump Right front of engine compartment. See Fig. 52 .
Rear Window Wiper Motor In tailgate. See Fig. 53 .
Recirculation Actuator On right end of HVAC assembly. See Fig. 11 .
Secondary Air Injection (AIR) Pump At left front of vehicle, below horn.
Starter Motor On left rear of engine. See Fig. 19 .
Sunroof Motor Front of sunroof assembly. See Fig. 50 .
Window Motor-Driver In driver's door. See Fig. 45 .
Window Motor-Front Passenger In front passenger's door. See Fig. 46 .
Window Motor-LR In left rear door. See Fig. 47 .
Window Motor-RR In right rear door. See Fig. 48 .
Windshield Washer Fluid Pump On front washer solvent container. See Fig. 3 .
Windshield Wiper Motor At right rear of engine compartment. See Fig. 51 .

Component Location
Accelerator Pedal Position (APP) Sensor (3.6L) Above accelerator pedal. See Fig. 56 .
Left side of engine compartment, below air cleaner
A/C Refrigerant Pressure Sensor
assembly.
A/C Sunload Sensor/Ambient Light Sensor Center of dash. See Fig. 12 .
In front of radiator, behind right headlight. See Fig.
Ambient Air Temperature Sensor
9.
Mounted to rear crossmember, above rear axle,
Auto Level Control Sensor (AWD)
behind left rear wheelhouse. See Fig. 14 .
Auto Level Control Sensor (FWD) Above rear axle, on rear crossmember.
Crankshaft Position (CKP) Sensor A On lower right side of engine. See Fig. 19 .
On front of engine, behind harmonic balancer. See
Crankshaft Position (CKP) Sensor B
Fig. 22 .
Crankshaft Position (CKP) Sensor (3.6L) Left lower rear of engine. See Fig. 57 .
Daytime Running Lamp Ambient Light Sensor Center of dash, near defrost vent. See Fig. 39 .
On top rear of engine, near thermostat housing. See
Engine Coolant Temperature (ECT) Sensor
Fig. 30 .
Evaporative Temperature Sensor In HVAC module, mounted to evaporator coil.
Front End Sensor (EFS) Front of engine compartment. See Fig. 34 .
Fuel Level Sender In fuel tank. See Fig. 24 .
At right side of engine, on exhaust manifold. See
Heated Oxygen Sensor (HO2S 1)
Fig. 20 .
On exhaust system, behind catalytic converter. See
Heated Oxygen Sensor (HO2S 2)
Fig. 21 .
Inflatable Restraint Foreword Discriminating
Left front of engine compartment. See Fig. 33 .
Sensor-Left
Inflatable Restraint Foreword Discriminating
Right front of engine compartment. See Fig. 33 .
Sensor-Right
Inflatable Restraint Passenger Presence System Under passenger seat cushion.
(PPS) Sensor
Inflatable Restraint Passenger Seat Belt Tension
Behind passenger B-pillar trim.
Retractor Sensor
At base of left "B" pillar, above seat belt retractor.
Inflatable Restraint Side Impact Sensor (Left)
See Fig. 31 .
At base of right "B" pillar, above seat belt retractor.
Inflatable Restraint Side Impact Sensor (Right)
See Fig. 31 .
On lower left side of engine, above starter. See Fig.
Knock Sensor (KS)
19 .
Knock Sensor (KS) - Bank 1 Left lower side of engine. See Fig. 57 .
Left Rear Wheel Speed Sensor On left rear hub assembly. See Fig. 17 .
At left side of engine compartment, on air cleaner
Mass Airflow (MAF) Sensor
Object Sensor-LR Corner Behind left corner of rear bumper. See Fig. 37 .
Object Sensor-LR Middle Behind middle of rear bumper. See Fig. 37 .
Object Sensor-RR Corner Behind right corner of rear bumper. See Fig. 37 .
Object Sensor-RR Middle Behind middle of rear bumper. See Fig. 37 .
Right Front Wheel Speed Sensor (WSS) On right front hub assembly. See Fig. 15 .
Seat Position Sensor Front Vertical-Driver Driver's seat.
Side Impact Sensor At base of respective "B" pillar. See Fig. 34 .
Center of dash, mounted to trim plate, near
Sunload Sensor
windshield defrost vent. See Fig. 39 .
Top of engine, on rear side of throttle assembly. See
Throttle Position Sensor
Fig. 25 .
Transaxle Fluid Temperature Sensor Inside automatic transaxle.
Vehicle Speed Sensor On transaxle. See Fig. 22 .
Washer Fluid Level Sensor Right rear of engine compartment. See Fig. 52 .

Component Location
Air Temperature Actuator (Left) Left side of HVAC module.
Air Temperature Actuator (Right) Right side of HVAC module.
A/T Shift Lock Control Solenoid (Buick) Part of steering column.
A/T Shift Lock Control Solenoid (Pontiac) Inside console, under transaxle shifter.
Automatic Level Control (ALC) Inflator Solenoid Outside vehicle, under driver seat on compressor.
Canister Vent Solenoid In fuel tank assembly. See Fig. 24 .
Evaporative Emission Canister Vent Solenoid Below center of vehicle, near fuel tank.
Solenoid Fig. 27 .
Exhaust Gas Recirculation Valve Top rear of engine, on intake manifold. See Fig. 27 .
Exhaust Solenoid Under front of vehicle chassis. See Fig. 13 .
Fuel Injector 1 On intake manifold. See Fig. 26 .
Ignition Key Solenoid Part of steering column.
Inflator Solenoid Under front of vehicle chassis. See Fig. 13 .
Liftgate Lock Actuator In tailgate. See Fig. 43 .
Liftgate Release Actuator (Left) Mounted on top left side of endgate.
Liftgate Release Actuator (Right) Mounted on top right side of endgate.
Recirculation Actuator In dash, behind glove box, on cowling.
Secondary Air Injection Solenoid Lower right side of engine.
Secondary Air Injection Vacuum Control Solenoid
On right rear side of engine.
Valve
Lower left of engine, integral to starter motor
Starter Solenoid
Torque Converter Clutch Solenoid Valve Inside automatic transaxle.
SWITCHES
SWITCHES LOCATION
Component Location
Brake Fluid Level Switch On right side of brake fluid reservoir. See Fig. 16 .
Cruise Control Release Switch On brake pedal support. See Fig. 35 .
Endgate Lock Actuator & Ajar Switch-Left Left side of tailgate. See Fig. 42 .
Endgate Lock & Ajar Switch-Right Right side of tailgate. See Fig. 42 .
Engine Oil Level Switch On bottom of engine oil pan. See Fig. 54 .
On lower left side of engine, above starter. See Fig.
Engine Oil Pressure (EOP) Switch
54 .
Inflator Air Switch Center rear of vehicle. See Fig. 13 .
Key Warning Switch On steering column. See Fig. 38 .
Lift Window Release Actuator & Ajar Switch-Left Left side of tailgate. See Fig. 42 .
Lift Window Release Actuator & Ajar Switch-Right Right side of tailgate. See Fig. 42 .
Lock Cylinder Switch-Endgate (Pontiac) In tailgate. See Fig. 40 .
Park Brake Switch On park brake assembly.
Rear Wiper/Washer, Liftgate Release & Rear
Left rear "C" pillar, near speaker. See Fig. 37 .
Parking Assist (RPA) Switch Assembly
Seat Belt Switch In right half of driver seat belt.
Windshield Washer Fluid Level Switch On front washer solvent container.
MISCELLANEOUS
Component Location
Under dash, between park brake lever & steering
Audio Amplifier
column.
Blower Motor Resistor Assembly On HVAC assembly, in front of blower motor.
Data Link Connector Below steering column. See Fig. 44 .
Digital Radio Receiver Behind dash.
Generator Right side of engine. See Fig. 20 .
Horn-Right At right front of engine compartment. See Fig. 49 .
Ignition Coils Right side of dash. See Fig. 20 .
I/P Air Bag Top right side of dash.
Left Front Side Impact Air Bag Back of driver's seat. See Fig. 34 .
Remote Control Door Lock Receiver Under dash trim panel. See Fig. 36 .
Right Front Side Impact Air Bag On seat back of passenger's seat. See Fig. 34 .
Steering Wheel Air Bag In steering wheel. See Fig. 34 .
Vehicle Battery Right side of engine compartment. See Fig. 34 .
CONNECTORS
CONNECTORS LOCATION
Component Location
In lower left side of engine compartment, near
EBCM.
In lower left side of engine compartment, near
EBCM.
Front of engine compartment, mounted to cooling
C105 (Gray, 4 Pin)
fan support.
In lower left side of engine compartment, on top of
C111 (20 Pin)
automatic transaxle.
C155 (Black, 6 Pin) Forward lamp harness, to left front lamps.
C156 (Black, 6 Pin) Forward lamp harness, to right front lamps.
Behind right side of dash compartment, behind right
dash access panel.
C201 (Black, 40 Pin) On left side of steering column, near base.
Left side of steering column, above left kick panel,
C203 (Light Gray, 40 Pin)
under sound barrier.
Front of dash, between vehicle interface unit &
vehicle communication unit.
Behind left kick panel, left of parking brake. See
Fig. 45 .
Above right kick panel, under sound barrier. See
Fig. 46 .
Body wiring harness to left side door wiring
C303 (Black, 2 Pin)
harness.
Mounted as pass-through, under vehicle, behind
C305 (Natural/Light Gray, 16 Pin)
driver seat.
Under right side of vehicle, between fuel tank &
C306 (Black, 2 Pin)
right rear wheelhouse.
C308 (Black, 30 Pin) Left side of roof, rear of left rear door.
Under left side of vehicle, between fuel tank & right
C309 (Black, 2 Pin)
rear wheelhouse.
C310 (Light Gray, 22 Pin) Left side of roof, rear of left rear door.
C317 (Light Gray, 22 Pin) Under driver seat.
C319 (Green, 2 Pin) Below driver seat.
C320 (Green, 2 Pin) Under passenger seat.
C351 (Black, 10 Pin) At left "B" pillar. See Fig. 47 .
C352 (Black, 10 Pin) At right "B" pillar. See Fig. 48 .
C397 (Black, 6 Pin) Dome lamp harness to sun roof harness.
C403 (Black, 10 Pin) Under left side vehicle, behind left rear wheelhouse.
C405 (Black, 6 Pin) Above left rear drive axle boot.
C411 (Black, 6 Pin) Body wiring harness to rear fascia.
C413 (Black, 16 Pin) Above right rear side of roof headliner.
C420 (Natural, 5 Pin) In left rear of vehicle, behind left rear wheelhouse.
GROUNDS
GROUNDS LOCATION
Component Location
Right side of engine compartment, on top of front
G100
end upper cross member. See Fig. 1 .
Left side of engine compartment, right of left
G101
headlamp, on front upper crossmember.
G111 Engine compartment, on bellhousing, left of starter.
G117 Engine compartment, on bell housing, above starter.
Left side of dash, on underside of cross-car beam,
G202
between park brake assembly & steering column.
Left side of vehicle, under rear side window,
G401
between wheelwell & endgate.
G402 Right rear of vehicle, under roof.
G403 Left rear of vehicle, under roof.
SPLICES
SPLICES LOCATION
Component Location
SP205 Splice Pack Left side of dash behind access panel.
SP206 Splice Pack Left side of dash next to SP205.
SP250 Splice Pack Center dash next to light sensor.
SP315 Splice Pack In floor console, under rear air duct.
SP409 Splice Pack Behind left rear wheelhouse, under trim panel.
Forward lamp harness, left front of vehicle, 5 cm
S101
from right foglamp breakout.
Forward lamp harness, right front of vehicle, 5 cm
S102
Engine harness, top right side of radiator, 6 cm from
S105
starter breakout.
Engine harness, front left side of engine
S106
compartment, 47 cm from PCM breakout.
Forward lamp harness, right front of vehicle, 5 cm
S123
Forward lamp harness, left front of vehicle, 10 cm
S124
from G101 breakout.
I/P harness, left side of dash, 13 cm from stoplamp
S203
switch breakout.
I/P harness, right side of dash, 24 cm from stoplamp
S204
switch breakout.
I/P harness, right side of dash, 4 cm from
S205
HVAC/radio harness breakout.
I/P harness, left side of dash, 13 cm from pass-
S211
through breakout.
I/P harness, center of dash, 4 cm from blower motor
S213 resistor & auxiliary drop power connector main
branch breakout.
I/P harness, left side of dash, 24 cm from stoplamp
S242
switch breakout.
Body harness, left rear of vehicle, 25 cm from pass-
S301
through.
Body harness, on right "B" pillar, 80 cm from
S303 inflatable restraint sensing & diagnostic module
breakout.
Body harness, right front door, 28 cm from
S304 inflatable restraint sensing & diagnostic module
breakout.
Body harness, under left rear of vehicle, 7 cm from
S305
C302 breakout.
Body harness, front center of vehicle, 6.5 cm from
S320
Body harness, right of driver's seat, 66 cm from
S333
Driver seat harness, under driver seat, 13 cm from
S350
C313 breakout.
Passenger seat harness, under passenger seat, 13 cm
S351
from C314 breakout.
Roof harness, left side of overhead console, 15 cm
S390
from left roof rail reading lamp breakout.
Roof harness, right side of overhead console, 64 cm
S393
from left roof rail reading lamp.
Roof harness, left side of overhead console, 40 cm
S397
from G303 breakout.
Left door harness, 15 cm from left door speaker
S502
breakout.
Left door harness, 10 cm from left window switch
S504
breakout.
Right door harness, 10 cm from right window
S604
switch breakout.
Endgate wiring harness, 94 cm from liftgate
S907
applique grommet.
Fig. 1: Right Front Of Engine Compartment
Fig. 2: Right Rear Of Engine Compartment
Fig. 4: Center Console (Pontiac)
Fig. 5: Center Console (Buick)
Fig. 6: Underhood Fuse Block (Buick)
Fig. 7: Underhood Fuse Block (Pontiac)
Fig. 8: Center Console Fuse Box
Fig. 9: Front Of Engine Compartment
Fig. 10: Right Side Of Dash
Fig. 11: HVAC Air Plenum
Fig. 12: Dash
Fig. 13: Rear Of Vehicle
Fig. 14: Lower Left Rear Of Vehicle (AWD)
Fig. 15: Right Front Wheel
Fig. 16: Left Rear Of Engine Compartment
Fig. 17: Left Rear Wheel Speed Sensor
Fig. 18: Cooling Fans
Fig. 19: Lower Front Of Engine
Fig. 21: Exhaust
Fig. 22: Engine Assembly (3.4L)
Fig. 24: Fuel Tank
Fig. 25: Throttle Body Assembly
Fig. 27: Right Rear Of Engine (3.4L)

Fig. 28: Top Left Of Engine (3.4L)
Fig. 30: Top Rear Of Engine
Fig. 31: Vehicle Overview
Fig. 32: Steering Column Disassembled View (Pontiac)
Fig. 33: Front Of Engine Compartment
Fig. 34: Top View Of Vehicle
Fig. 35: Left Side Of Dash
Fig. 36: Upper Dash Trim Panel
Fig. 37: Vehicle Overview
Fig. 38: Theft Deterrent Control Module
Fig. 39: Dash Trim Panel
Fig. 40: Tailgate (Pontiac)
Fig. 43: Liftgate (Buick)
Fig. 44: Left Side Of Dash
Fig. 45: Driver's Door
Fig. 46: Front Passenger's Door
Fig. 47: Left Rear Door
Fig. 48: Right Rear Door
Fig. 49: Right Front Of Engine Compartment
Fig. 50: Sunroof
Fig. 51: Right Rear Of Engine Compartment
Fig. 52: Right Side Of Engine Compartment
Fig. 53: Liftgate
Fig. 54: Front Of Engine (3.4L)
Fig. 55: Lower Left Front Of Engine (3.6L)
Fig. 56: Above Accelerator Pedal (3.6L)
Fig. 57: Left Side Of Engine (3.6L)
Fuses & Circuit Breakers
IDENTIFICATION
WARNING: Vehicles are equipped with air bag supplemental restraint system. Before
attempting any repairs involving steering column, instrument panel or
related components, see AIR BAG SAFETY PRECAUTIONS and
DISABLING & ACTIVATING AIR BAG SYSTEM in AIR BAG RESTRAINT
SYSTEMS article in RESTRAINTS.

battery.
FUSIBLE LINKS
Fusible links are usually located between battery and starter or electrical center. For description and repair
procedures, see Fig. 1 .
Fig. 1: Repairing Fusible Links
INSTRUMENT PANEL FUSE BLOCK
Instrument panel fuse block is located under center of instrument panel, on right side. See Fig. 2 .
Fig. 2: Locating Instrument Panel Fuse Block
Fig. 3: Identifying Instrument Panel Fuse Block Components
Fig. 4: Instrument Panel Fuse Block Legend (1 Of 2)
Fig. 5: Instrument Panel Fuse Block Legend (2 Of 2)
UNDERHOOD FUSE BLOCK

Underhood fuse block is located in front of right wheelhouse, above battery. See Fig. 6 .
Fig. 6: Locating Underhood Fuse Block

Fig. 7: Identifying Underhood Fuse Block Components
Fig. 8: Underhood Fuse Block Legend (1 Of 3)
Removal & Installation - Aztec & Rendezvous
AIR INDUCTION SYSTEMS

AIR CLEANER ELEMENT
Remove the air cleaner intake duct. See AIR CLEANER INTAKE DUCT . Remove the filter element from
the air cleaner housing. To install, reverse removal procedure. Tighten air cleaner intake duct to specification.
See TORQUE SPECIFICATIONS .
AIR CLEANER ASSEMBLY
NOTE: Prior to disconnecting negative battery cable, record all of the customer's radio
station presets, turn off all the lamps and accessories and turn the ignition OFF.
After job has been completed, install the battery ground (negative) cable and
bolt to the battery. Tighten the battery terminal bolt to specification. Program all
of the customer's radio station presets and set the radio clock to the current
time.
1. Disconnect the negative battery cable. Reposition the reservoir hose clamp at the radiator overflow fitting
using Hose Clamp Pliers (J 38185). Remove the reservoir hose at the radiator overflow fitting. Remove
the reservoir mounting clip. Remove the coolant reservoir.
2. Rotate the cruise control cable counter clockwise at the module in order to remove the cable from the
module. See Fig. 1 . Remove the cable from the module band. Disconnect the electrical connector from
the cruise control module. Remove the cruise control module from the bracket.
3. Remove the engine coolant heater harness from the left front fender diagonal brace, if equipped. Remove
the front end sheet metal diagonal brace to the inner fender bolt. See Fig. 2 . Remove the front end sheet
metal diagonal brace to radiator support bolts. Remove the front end sheet metal diagonal brace.
4. Remove the air cleaner intake duct. See AIR CLEANER INTAKE DUCT . Unsnap the latch on the
upper cover and remove the cover. See Fig. 3 . Carefully remove the Powertrain Control Module (PCM)
leaving the 2 harnesses connected and set aside. Remove the 2 bolts from the air cleaner assembly and
remove the housing. See Fig. 4 .
5. To install, reverse removal procedure. Tighten the air cleaner housing bolts to specification. See
TORQUE SPECIFICATIONS . Tighten the air cleaner intake duct clamps to specification.
Fig. 1: Removing Cruise Control Cable From Module

Fig. 2: Locating Left Front Fender Diagonal Brace
Fig. 3: Locating Powertrain Control Module
Fig. 4: Removing/Installing Air Cleaner Assembly
AIR CLEANER INTAKE DUCT
1. Loosen the 2 intake air duct clamps from the Mass Airflow (MAF) sensor and the throttle body. See Fig.
5 . Disconnect the vent tube from the air cleaner intake duct. Disconnect the MAF sensor electrical
connector.
2. Unlatch the air cleaner cover clips and remove the air cleaner intake duct and air cleaner cover. Separate
the air cleaner intake duct from the MAF sensor and throttle body Remove air cleaner intake duct. To
install, reverse removal procedure. Tighten the air cleaner intake duct clamps to specification. See
Fig. 5: Locating IAT & MAF Sensors

THROTTLE BODY
CAUTION: Do not use solvent of any type when cleaning the gasket surfaces on the
intake manifold and the throttle body assembly, as damage to the gasket
surfaces and throttle body assembly may result. Use care in cleaning the
gasket surfaces on the intake manifold and the throttle body assembly, as
sharp tools may damage the gasket surfaces.
Removal
1. Partially drain the cooling system. Disconnect the Intake Air Temperature (IAT) sensor electrical
connector. See Fig. 5 . Disconnect the breather tube from the air cleaner intake duct.
2. Remove the air cleaner intake duct. Disconnect the Idle Air Control (IAC) valve electrical connector. See
Fig. 6 . Disconnect the Throttle Position (TP) sensor electrical connector. Disconnect the accelerator
cable cross slug from the throttle body lever. Disconnect the cruise control cable from the throttle lever.
Remove the accelerator control cable bracket with accelerator and cruise control cables attached and set
aside. Disconnect the throttle body coolant by-pass hoses.
3. Disconnect the heater pipe nut at the throttle body. Remove the nuts and bolts holding the throttle body to
the intake manifold. Remove the throttle body assembly.
Cleaning
CAUTION: Do not subject a throttle body assembly which contains the following
components to an immersion cleaner or a strong solvent: Throttle position
(TP) sensor Idle air control (IAC) valve Sealed throttle shaft bearings The
cleaners will damage the electric components or sensors. The cleaners
will damage some of these components that contain seals or "O" rings.
Solvents can wash away or break down the grease used on non-
serviceable throttle shaft bearings. Never use a wire brush or scraper to
clean the throttle body. A wire brush or sharp tools may damage the
throttle body components. Do not use a cleaner that contains methyl ethyl
ketone. This extremely strong solvent may damage components and is not
necessary for this type of cleaning.
Clean the throttle body bore and the throttle valve plate using a clean shop towel with GM Top Engine Cleaner,
(1052626) or an equivalent product. If the deposits are excessive, disassemble the throttle body for cleaning.
After disassembly, clean the throttle body using a parts cleaning brush. DO NOT immerse the throttle body in
any cleaning solvent. Assemble the throttle body.
Installation
1. Clean the gasket surface on the intake manifold and the throttle body assembly. Install a new gasket, if
necessary. Install the throttle body assembly. Install the throttle body retaining nuts and bolts. Tighten the
throttle body retaining nuts and bolts to specification. See TORQUE SPECIFICATIONS .
2. Connect the throttle body coolant by-pass hoses. Connect the heater pipe nut at the throttle body. Connect
the IAC valve electrical connector. Connect the TP sensor electrical connector.
3. Install the accelerator controls cable bracket. Connect the accelerator cable cross slug to the throttle body
lever. Connect the cruise control cable to the throttle body lever. Install the air intake tube and tighten the
clamps. Connect the IAT sensor electrical connector.
4. Connect the breather tube to the air intake tube. Refill the cooling system. See COOLING SYSTEM
BLEEDING under COOLING SYSTEM.
5. The throttle should operate freely without binding between full closed and wide open throttle. Inspect for
complete throttle opening and closing positions by operating the accelerator pedal. Also inspect for poor
carpet fit under the accelerator pedal.
Fig. 6: Locating IAC Valve & TP Sensor

COMPUTERIZED ENGINE CONTROLS
POWERTRAIN CONTROL MODULE
NOTE: In order to prevent internal damage to the Powertrain Control Module (PCM), the
ignition must be OFF when disconnecting or reconnecting the PCM connector.
Service should normally consist of either replacement of the PCM or Electrically
Erasable Programmable Read-Only Memory (EEPROM) re-programming. If the
diagnostic procedures call for the PCM to be replaced, the PCM should be
inspected first in order to verify the PCM is the correct part. DTC P0602
indicates the EEPROM programming has malfunctioned. When DTC P0602 is
set, re-program the EEPROM.
NOTE: There are no user serviceable parts in this PCM. The PCM should never be
opened for any reason. When replacing the production PCM with a service PCM
(controller), it is important to transfer the broadcast code and production PCM
number to the service PCM label. Do not record this information on the PCM
cover. Transfer allows positive identification of PCM parts throughout the
service life of the vehicle.
Removal
1. PCM is located inside air filter assembly. See Fig. 3 . Turn ignition off. Disconnect negative battery
cable. Remove the engine coolant heater harness from the front fender diagonal brace, if equipped.
2. Reposition the engine coolant reservoir from the front fender diagonal brace. See Fig. 2 . Reposition the
cruise control module from the front fender diagonal brace. Remove the front fender diagonal brace to the
inner fender bolt.
3. Remove the front fender diagonal brace to radiator support bolts. Remove the front fender diagonal brace.
Remove the air cleaner assembly cover and lift the PCM from the assembly. Disconnect the harness
connectors from the PCM. Remove the PCM from the engine compartment.
Installation
1. Install the connectors to the PCM. Tighten the PCM connector screws to specification. See TORQUE
SPECIFICATIONS . Install the PCM into the air cleaner assembly.
2. Install the air cleaner assembly cover. Tighten the air cleaner assembly cover retainers. Position the front
fender diagonal brace to the radiator support and to the inner fender. Install the bolts to the front fender
diagonal brace at the radiator support. Tighten the front fender diagonal brace-to-radiator support bolts to
specification.
3. Install the bolts to the front fender diagonal brace at the inner fender. Tighten the front fender diagonal
brace-to-the inner fender bolts to specification. Reposition the underhood wiring junction block to the
front fender diagonal brace. Connect the negative battery cable.
4. If a new PCM is being installed, program the EEPROM. See POWERTRAIN CONTROL MODULE
under PROGRAMMING.
PROGRAMMING
CRANKSHAFT POSITION SENSOR
NOTE: For additional diagnostic information, see DTC P0336: CRANKSHAFT POSITION
SENSOR CIRCUIT under DIAGNOSTIC TESTS in SELF-DIAGNOSTICS - 3.4L
AZTEK & RENDEZVOUS article.

2. With a scan tool, monitor the powertrain control module for DTCs. If other DTCs are set, except DTC
P1336, see DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 3.4L
3. With a scan tool, select the crankshaft position variation learn procedure.
4. Observe the fuel cut-off for the engine that you are performing the learn procedure on.
5. The scan tool instructs you to perform the following:
Block drive wheels.
Apply vehicles parking brake.
Cycle ignition from OFF to ON.
Apply and hold brake pedal.
Start and idle engine.
Turn OFF the A/C.
Place transmission in Park (A/T) or Neutral (M/T).
The scan tool monitors certain component signals to determine if all the conditions are met to
continue with the procedure. The scan tool only displays the condition that inhibits the procedure.
The scan tool monitors the following components:
A. Crankshaft Position (CKP) sensor activity. If there is a CKP sensor condition, refer to the
applicable DTC that set. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-
DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article.
B. Camshaft Position (CMP) sensor activity. If there is a CMP sensor condition, refer to the
applicable DTC that set. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-
C. Engine Coolant Temperature (ECT). If the engine coolant temperature is not warm enough,
idle the engine until the engine coolant temperature reaches the correct temperature.
6. With the scan tool, enable the crankshaft position system variation learn procedure.
NOTE: While the learn procedure is in progress, release the throttle immediately
when the engine starts to decelerate. The engine control is returned to the
operator and the engine responds to throttle position after the learn
procedure is complete.
7. Slowly increase the engine speed to the RPM that you observed.
8 Immediately release throttle when fuel cut-off is reached
9. The scan tool displays Learn Status: Learned this ignition. If the scan tool does NOT display this message
and no additional DTCs set, seeDIAGNOSTIC SYSTEM CHECK -- ENGINE CONTROLS under
SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article. If a
DTC set, see DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 3.4L
10. Turn ignition off for 30 seconds after the learn procedure has been completed successfully.
ENGINE OIL LIFE RESET
No Driver Information Center
1. With ignition on and engine off, fully push and release the accelerator pedal slowly 3 times within 5
seconds.
2. Turn ignition OFF.
3. If the CHANGE ENGINE OIL message comes back on, the engine oil life monitor has not reset. Repeat
the procedure.
Optional Driver Information Center
1. Turn ignition on, with engine off.

2. Press the MODE button until the DIC reads OIL LIFE LEFT/HOLD SET TO RESET.
3. Press and hold the SET button until 100 percent is displayed. You will hear 3 chimes and the CHANGE
ENGINE OIL message will go off. If the CHANGE ENGINE OIL message comes back on, the monitor
has not reset. Repeat the procedure.
NOTE: Programming Powertrain Control Module (PCM) requires a compatible scan tool
and a Techline(R) terminal. Procedure uses a Tech 2 scanner.
Remote Programming
NOTE: DO NOT program a control module unless you are directed by a service
procedure or you are directed by a technical service bulletin. Programming a
control module at any other time will not permanently correct a customer's
concern.
Before Programming a Control Module
1. Vehicle system voltage:

There is no charging system concern. All charging system concerns must be repaired before
programming a control module.
Battery voltage is greater than 12 volts but less than 16 volts. The battery must be charged before
programming the control module if the battery voltage is low.
A battery charger is NOT connected to the vehicle's battery. Incorrect system voltage or voltage
fluctuations from a battery charger, may cause programming failure or control module damage.
Turn OFF or disable any system that may put a load on the vehicle's battery.
A. Twilight sentinel and Interior lights.

B. Daytime Running Lights (DRL). Applying the parking brake, on most vehicles, disables the
DRL system. See owner's manual.
C. Heating, Ventilation, and Air Conditioning (HVAC) systems.
D. Engine cooling fans, etc.
2. The ignition switch is in the proper position. The scan tool prompts you to Turn ignition on, with engine
off. DO NOT change the position of the ignition switch during the programming procedure, unless
instructed to do so.
3. All tool connections are secure.
RS-232.
The connection at the Data Link Connector (DLC) is secure.
Voltage supply circuits.
4. DO NOT disturb the tool harnesses while programming. If an interruption occurs during the
programming procedure, programming failure or control module damage may occur.
Remote Programming
1. Turn ignition off

2. Install the Tech 2(tm) to the data link connector (DLC).
4. Turn OFF all vehicle accessories.
5. With the Tech 2(tm), select Service Programming.
6. Identify vehicle information as requested by the Tech 2(tm).
7. Select the type of module you are programming.
8. Select the type of programming to be performed.
9. Verify the displayed VIN with the vehicle VIN. If the displayed VIN does not match the actual VIN,
write down the actual VIN and correct the VIN at the Techline(tm) terminal.
10. When complete, Exit Service Programming.
11. Turn OFF the Tech 2(tm) and disconnect the Tech 2(tm) from the vehicle.
12. Turn ignition off
13. Connect the Tech 2(tm) to the Techline(tm) terminal.
14. Select Service Programming.
15. Select Tech 2(tm) as the tool you are using.
16. Select the type of programming to be performed.
17. Verify the displayed VIN with the vehicle VIN. Correct the VIN as necessary.
18. Select the type of module you are programming.
19. Identify what type of programming that you are performing.
Normal. This type of programming is for updating an existing calibration or programming a new
controller.
Vehicle Configuration Index (VCI). This selection is used if the vehicle VIN is unavailable or not
recognized by the Techline(tm) terminal. You will need to contact the Techline(tm) customer
support center to use this option.
Reconfigure. This is to reconfigure a vehicle, such as tire size and axle ratio changes.
20. Select the appropriate calibration file.

21. Ensure all connections are secure.
22. Select Reprog to initiate the download of the new calibration to the Tech 2(tm).
23. After the download is complete, turn OFF the Tech 2(tm).
24. Disconnect the Tech 2(tm) from the Techline(tm) terminal.
25. Install the Tech 2(tm) to the data link connector (DLC).
26. Turn ON the Tech 2(tm).
28. Select Service Programming.
NOTE: DO NOT Turn ignition off if the programming procedure is interrupted or

unsuccessful. Ensure that all the PCM and DLC connections are secure
and the Techline(tm) operating software is up to date. Attempt to
reprogram the control module. If the control module cannot be
programmed, replace the control module. See appropriate REMOVAL &
INSTALLATION article.
29. Select Program.

30. After the download is complete, EXIT Service Programming.
31. Turn ignition off for 30 seconds.
32. Turn OFF the Tech 2(tm).
33. If a control module is replaced the following service procedures must be performed: CRANKSHAFT
POSITION SENSOR ENGINE OIL LIFE RESET , and THEFT DETERRENT PASSWORD
LEARN PROCEDURE . After the 3 procedures are performed, you must perform
INSPECTION/MAINTENANCE COMPLETE SYSTEM SET PROCEDURE under DRIVE
CYCLES in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article.
Programming Verification
1. With a scan tool, clear the DTCs.

2. Attempt to start the engine.
3. Repeat the Service Programming procedure if the engine does not start or operates poorly. Perform the
following procedures before programming the PCM:
Ensure the control module and DLC connections are okay.
Ensure the Techline(tm) operating software is up to date.
Ensure the calibration part number is correct for the vehicle.
4. Attempt to program the control module. If the control module still cannot be programmed properly,
replace the control module. See POWERTRAIN CONTROL MODULE under COMPUTERIZED
ENGINE CONTROLS. You must program the replacement control module.
Off-Board Programming
NOTE: DO NOT program a control module unless you are directed by a service
procedure or you are directed by a technical service bulletin. Programming a
control module at any other time will not permanently correct a customer's
concern.
The Off-Board Programming is used in situations where a control module must

be programmed without having the vehicle present. The Off-Board
Programming Adapter must be used to perform the Off-Board Programming
procedure. The adapter allows the control module to power up and allows the
Tech 2(tm) to communicate with the control module.
DO NOT disturb the tool harnesses while programming. If an interruption

occurs during the programming procedure, programming failure or control
module damage may occur.
Before Programming a Control Module
Ensure that all connections are secure at the following locations:

A. Off-Board Programming Adapter.
B. Tech 2(tm).
C. Control module.
D. Techline(tm) terminal.
Off-Board Programming
1. Obtain the VIN of the vehicle for which the control module is being programmed.
2. With the Techline(tm) terminal, select Service Programming.
3. Select Tech 2(tm), Reprogram ECU, and Off-Board Programming Adapter as the ECU location.
4. Connect the control module, Off-Board Programming Adapter, and the Tech 2(tm) as described on the
Techline(tm) terminal. Ensure you use the correct harness connector from the Off-Board Programming
Adapter kit.
5. With the Tech 2(tm), select Service Programming Request Information function. The Tech 2(tm)
communicates with the control module and receives the access code.
6. With the Tech 2(tm), exit the Service Programming Request Information.
7. Disconnect the Tech 2(tm) from the Off-Board Programming Adapter.
8. Connect the Tech 2(tm) to the Techline(tm) terminal.
9. Turn ON the Tech 2(tm).
10. With the Techline(tm) terminal, enter the VIN of the vehicle that will be receiving the control module.
11. The Techline(tm) terminal will display the message, attaching to database.
12. Identify what type of programming that you are performing.
13. Select the appropriate calibration file.
14. Ensure all connections are secure.
15. The Techline(tm) terminal displays a summary screen that summarizes your selections. After confirming
you choices, the Techline(tm) terminal automatically loads the calibration files to the Tech 2(tm).
16. After download is complete, turn OFF the Tech 2(tm).
17. Disconnect the Tech 2(tm) from the Techline(tm) terminal.
18. Connect the Tech 2(tm) to the Off-Board Programming Adapter.
19. With the Tech 2(tm), select Service Programming.
NOTE: DO NOT turn OFF the Off-Board Programming Adapter if the programming
procedure is interrupted or unsuccessful. Ensure the control module and
the Off-Board Programming Adapter connections are secure and the
Techline(tm) operating software is up to date. Attempt to reprogram the
control module. If the control module cannot be programmed, replace the
control module. See appropriate REMOVAL, OVERHAUL & INSTALLATION
article.
20. With the Tech 2(tm), select Program.

21. After the download is complete, exit Service Programming.
22. Turn OFF the Off-Board Programming Adapter.
THEFT DETERRENT PASSWORD LEARN PROCEDURE
Set Up a New Theft Deterrent Control Module
NOTE: When replacing a theft deterrent control module with an GM Service Parts
Operation (SPO) Replacement Part, set up the control module prior to the 10-
minute relearn procedure or the 30-minute relearn procedure.
Use this procedure only if replacing the theft deterrent control module with an GM SPO Replacement Part.
1. Connect a scan tool to the vehicle.

3. With a scan tool, select Setup New VTD Module in the Vehicle Theft Deterrent, Special Functions data
list.
4. Follow the scan tool on-screen instructions.
NOTE: When replacing a theft deterrent control module with an GM SPO Replacement
Part, the module will learn the keys immediately. The existing Powertrain
Control Module (PCM) must learn the new fuel continue password when you
replace the theft deterrent control module.
When replacing a PCM with a GM SPO Replacement Part, the new PCM will
learn the incoming fuel continue password immediately after programming and
upon receipt of a password message. Once a password message is received
and a password is learned, perform the learn procedure to change this
password again. A PCM which had been installed in another vehicle will have
learned the fuel continue password of the other vehicle's theft deterrent control
module. Perform either the 10-minute relearn procedure or the 30-minute
relearn procedure after programming to learn the fuel continue password of the
current vehicle's theft deterrent control modules.
When performing either relearn procedure, all previously learned keys will be
erased from the theft deterrent control module's memory.
Additional keys may be learned immediately after the first relearn procedure by
inserting the additional key and turning the ignition to RUN within 10 seconds
of removing the previously learned key.
Use only a master key when performing the first relearn procedure. If you use a
valet key first, the theft deterrent control module will not allow additional keys
to be learned.
10-Minute Learn Procedure
Use this procedure after replacing the following components:
PassKey(R) III (PK3) keys.

Theft deterrent control module.
PCM.
NOTE: If replacing a theft deterrent control module with a GM SPO Replacement Part,
perform the procedure to setup a new theft deterrent control module prior to the
10-minute relearn procedure.
1. Connect a scan tool to the vehicle.

3. Ensure that all power consuming devices are turned OFF on the vehicle.
4. With scan tool, select Request Info. under Service Programming System and follow the scan tool on-
screen instructions.
5. Disconnect the scan tool from the vehicle and connect the scan tool to a Techline(tm) terminal with the
current Service Programming System (SPS) software.
6. On the Techline(tm) terminal, select Service Programming System and follow the Techline(tm) Terminal
on-screen instructions.
7. Disconnect the scan tool from the Techline(tm) terminal and re-connect the scan tool to the vehicle.
8. With a master PassKey(R) III key, turn ignition on, with engine off.
9. With a scan tool, select Program ECU under Service Programming System.
10. At this point the scan tool must remain connected for the duration of the 10-minute relearn procedure.
NOTE: On some vehicles the SECURITY telltale maybe illuminated on steady for
the duration of the 10-minute relearn procedure.
11. Observe the scan tool, after approximately 10 minutes the scan tool will display "Programming
Successful, Turn OFF Ignition". The vehicle is now ready to relearn the key information and/or the
passwords on the next ignition switch transition from OFF to ON.
12. Turn ignition off and wait 5 seconds.
13. With a master PassKey(R) III key, start the vehicle. The theft deterrent control module has now learned
the key transponder information and the PCM has now learned the fuel continue password.
NOTE: Perform this step ONLY on vehicles with EXPORT configured theft
deterrent control modules.
14. Turn ignition off and wait 15 seconds minimum.
NOTE: Perform this step ONLY on vehicles with EXPORT configured theft
deterrent control modules.
15. With a second master PassKey(R) III key, start the vehicle. The theft deterrent control module has now
learned the second master PassKey(R) III key transponder information.
16. With a scan tool, clear any DTCs.
30-Minute Learn Procedure
Use this procedure after replacing the following components:
PassKey(R) III (PK3) keys.

Theft deterrent control module.
PCM.
NOTE: This procedure is not available on vehicles equipped with option code (Z49 or
BAE).
If replacing a theft deterrent control module with an GM SPO Replacement Part,

perform the procedure to setup a new theft deterrent control module prior to the
30-minute relearn procedure.
1. With a master PassKey(R) III key (Black), Turn ignition on, with engine off.
2. Observe the Security telltale, after about 10 minutes, the telltale will turn off.
3. Turn ignition off and wait 5 seconds.
4. Repeat steps 1 -3 for 2 more times, for a total of 3 cycles or 30 minutes.
NOTE: The vehicle learns the key transponder information and/or passwords on
the ignition switch transition from OFF to CRANK. You must turn the
ignition OFF before attempting to start the engine.
5. With a master PassKey(R) III key, start engine. The vehicle has now learned the key transponder
information and the PCM has now learned the fuel continue password.
6. With a scan tool, clear any DTCs.
SENSORS
CAMSHAFT POSITION SENSOR
Removal
Turn ignition off. Remove the power steering pump. See appropriate POWER RACK & PINION article in
STEERING. Disconnect the Camshaft Position (CMP) sensor electrical connector. See Fig. 7 . Remove the
attaching bolt. Remove the CMP sensor. Inspect the sensor "O" ring for wear, cracks, or leakage if the sensor is
not being replaced.
Installation
Replace the "O" ring if the "O" ring is damaged. Lubricate the "O" ring with clean engine oil. Install the CMP
sensor. Tighten the CMP sensor retaining bolt to specification. See TORQUE SPECIFICATIONS . Connect
the CMP sensor electrical connector. Install the power steering pump. Tighten power steering pump mounting
bolts to specification.
Fig. 7: Removing/Installing Camshaft Position Sensor
CRANKSHAFT POSITION SENSOR "A" (24X)
1. The Crankshaft Position (CKP) sensor is located behind the crankshaft balancer. See Fig. 8 . Turn the
ignition off. Remove the drive belt. Raise and support the vehicle.
2. Remove the right front tire and wheel. Remove the right engine splash shield. Install a utility stand
beneath the frame right side rail in order to support the frame/powertrain. Remove the two frame right
side bolts. Use the utility stand to lower the frame enough to provide access to the crankshaft balancer.
3. Remove and discard the crankshaft balancer bolt. Using Crankshaft Balancer Puller (J-24420-C), remove
the crankshaft balancer. Note the routing of the CKP sensor harness before removal. Remove the harness
retaining clip and bolt. Disconnect the CKP sensor electrical connector. Remove the sensor bolts.
Remove the CKP sensor.
Installation
CAUTION: The inertial weight section of the crankshaft balancer is assembled to the
hub with a rubber type material. The correct installation procedures (with
the proper tool) must be followed or movement of the inertial weight
section of the hub will destroy the tuning of the crankshaft balancer.
1. Install the 24X CKP sensor with bolts and the route harness as noted during removal. Install the harness
retaining clip and bolt. Tighten the bolts to specification. See TORQUE SPECIFICATIONS .
2. Connect the CKP sensor electrical connector. Apply Sealer (12345739) or the equivalent to the keyway of
the crankshaft balancer. Install the crankshaft balancer into position over the key in the crankshaft. Using
Crankshaft Balancer Installer (J-29113), install the crankshaft balancer to the crankshaft.
3. Remove the crankshaft balancer installer from the crankshaft balancer. Install the crankshaft balancer
washer and the NEW crankshaft balancer bolt. Tighten the bolt to specification. Use the utility stand in
order to raise the frame/powertrain. Install the frame right side bolts. Tighten frame bolts to specification.
4. Install the engine splash shield. Install the right front tire and wheel. Tighten wheel lug nuts to
specification. Lower the vehicle. Install the drive belt. Perform the CKP System Variation Learn
Procedure. See CRANKSHAFT POSITION SENSOR under PROGRAMMING.
Fig. 8: Locating Crankshaft Position Sensor "A" (24X)
CRANKSHAFT POSITION SENSOR "B" (7X)
1. The Crankshaft Position (CKP) sensor is mounted in cylinder block. See Fig. 9 . Turn the ignition off.
Raise and support the vehicle.
2. On front-wheel drive vehicles, remove the right front tire and wheel. On all-wheel-drive vehicles,
disconnect the catalytic converter from the exhaust manifold and reposition.
3. On all models, disconnect the CKP sensor electrical connector. Remove the CKP sensor attaching bolt.
Remove the CKP sensor from the engine. Inspect for wear, cracks, or leakage if the sensor is not being
replaced.
Installation
1. Replace the "O" ring, if it is damaged. Lubricate the "O" ring with clean engine oil. Install the sensor to
the block. Install the CKP sensor attaching bolt. Tighten the bolt to specification. See TORQUE
SPECIFICATIONS .
2. Install the CKP sensor electrical connector. On front-wheel-drive vehicles, install the right tire and wheel.
Tighten wheel lug nuts to specification. On all-wheel-drive vehicles, install the catalytic converter to the
exhaust manifold. Tighten catalytic converter to the exhaust manifold nuts to specification. On all
models, lower the vehicle.
3. Perform the CKP System Variation Learn Procedure. See CRANKSHAFT POSITION SENSOR under
PROGRAMMING.
Fig. 9: Locating Crankshaft Position Sensor "B" (7X)

ENGINE COOLANT TEMPERATURE SENSOR
NOTE: Recover and store used coolant in a used coolant holding tank and submit the
used coolant for recycling on a regular basis. Do not pour used coolant down
the drain. Ethylene glycol antifreeze is very toxic. Disposing of ethylene glycol
into the sewer system or ground water is both illegal and ecologically unsound.
Removal
Turn ignition off. Drain the cooling system to below the Engine Coolant Temperature (ECT) sensor. See Fig.
10 . Disconnect the ECT sensor electrical connector. Carefully remove the ECT sensor.
Fig. 10: Locating Engine Coolant Temperature Sensor

Installation
NOTE: Replacement components must be the correct part number for the application.
Components requiring the use of the thread locking compound, lubricants,
corrosion inhibitors, or sealants are identified in the service procedure. Some
replacement components may come with these coatings already applied. Do not
use these coatings on components unless specified. These coatings can affect
the final torque, which may affect the operation of the component. Use the
correct torque specification when installing components in order to avoid
damage. Use care when handling the coolant sensor. Damage to the coolant
sensor will affect the operation of the fuel control system.
Coat the ECT sensor threads with Thread Sealer (9985253) or the equivalent. Install the ECT sensor. Tighten
the ECT sensor to specification. See TORQUE SPECIFICATIONS . Connect the ECT sensor electrical
connector. Refill the engine coolant system. See COOLING SYSTEM BLEEDING under COOLING
SYSTEM.
FUEL LEVEL SENSOR
Removal
1. Remove fuel sender assembly. See FUEL SENDER ASSEMBLY . Disconnect the fuel pump electrical
connector. See Fig. 11 .
2. Remove the fuel level sensor electrical connector retaining clip. Disconnect the fuel level sensor electrical
connector from under the fuel sender cover. Remove the fuel level sensor retaining clip. Squeeze the
locking tangs and remove the fuel level sensor from the fuel sender assembly.
Installation
Install the fuel level sensor to the fuel sender assembly. Install the fuel level sensor retaining clip. Connect the
fuel level sensor electrical connector. Install the fuel level sensor electrical connector retaining clip. Connect the
fuel pump electrical connector. Install the fuel sender assembly. Perform the following procedure in order to
inspect for leaks. Turn the ignition on for 2 seconds. Turn the ignition off for 10 seconds. Turn the ignition on.
Inspect for fuel leaks.
Fig. 11: Identifying Fuel Sender Assembly Components
FUEL TANK PRESSURE SENSOR
Remove the fuel tank. See FUEL TANK . Disconnect the electrical connector from the fuel tank pressure
sensor. Remove the fuel tank pressure sensor from the fuel sender assembly. See Fig. 11 . To install, reverse
removal procedure.
HEATED OXYGEN SENSOR

CAUTION: The Heated Oxygen Sensor (HO2S) uses a permanently attached pigtail
and connector. Do not remove this pigtail from the HO2S. Damage or the
removal of the pigtail or the connector could affect the proper operation of
the sensor. Take care when handling the HO2S. Keep the in-line electrical
connector and the louvered end free of grease, dirt, or other contaminants.
Also avoid using cleaning solvents of any type. Do not drop the HO2S.
NOTE: The oxygen sensor may be difficult to remove when the engine temperature is
less than 120F (48C). Downstream HO2S may also be referred to as HO2S 2.
Upstream HO2S may also be referred to as HO2S 1.
Removal
Locate HO2S to be removed. See Fig. 12 or Fig. 13 . Turn ignition off. On HO2S 1, disconnect the electrical
connector. On all applications, raise and support vehicle. On HO2S 2 disconnect the electrical connector. Using
Oxygen Sensor Wrench (J-39194-B), remove appropriate HO2S.
Installation
1. A special anti-seize compound is used on the oxygen sensor threads. The compound consists of a liquid
graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor
easier to remove. New sensors will have the compound applied to the threads.
2. If a sensor is removed and is to be reinstalled, the threads must have an anti-seize compound applied
before installation. Coat the threads of the HO2S with Anti-Seize Compound (5613695), if necessary.
3. Using Oxygen Sensor Wrench (J-39194-B), install the appropriate HO2S and tighten to specification. See
TORQUE SPECIFICATIONS . On HO2S 2, connect harness connector. On all applications, lower
vehicle. On HO2S 1, connect harness connector.
Fig. 12: Locating HO2S 1
Fig. 13: Locating HO2S 2
INTAKE AIR TEMPERATURE SENSOR
The Intake Air Temperature (IAT) sensor is located in the air cleaner intake duct. See Fig. 5 . Disconnect the
IAT sensor electrical connector. Carefully grasp the sensor and with a twisting and pulling motion, and remove
the IAT sensor from air intake duct. Install the IAT sensor by snapping into place. Connect the IAT sensor
electrical connector.
KNOCK SENSOR
Removal
Turn the ignition off. Raise and support the vehicle. Disconnect the wiring harness connector from the knock
sensor. See Fig. 14 . Remove the knock sensor from the engine block.
Installation
NOTE: Do not apply thread sealant to the sensor threads. The sensor threads are
coated at the factory and applying additional sealant affects the sensor's ability
to detect detonation.
Install the knock sensor into the engine block. Tighten the knock sensor to specification. See TORQUE
SPECIFICATIONS . Connect the knock sensor wiring harness connector to the knock sensor. Lower the
vehicle.
Fig. 14: Locating Knock Sensor
MANIFOLD ABSOLUTE PRESSURE SENSOR
Removal
Turn ignition off. Remove the screws that attach the Manifold Absolute Pressure (MAP) sensor to the bracket.
See Fig. 15 . Disconnect the MAP sensor electrical connector. Disconnect the MAP inlet vacuum hose. Remove
the MAP sensor from the bracket.
Installation
Position the MAP sensor to the bracket. Connect the MAP inlet vacuum hose. Connect the MAP sensor
electrical connector. Install the MAP sensor screws and tighten to specification. See TORQUE
SPECIFICATIONS .
Fig. 15: Locating Manifold Absolute Pressure Sensor

MASS AIRFLOW SENSOR
Removal
The Mass Airflow (MAF) sensor is mounted to the air filter housing. See Fig. 5 . Turn ignition off. Disconnect
the Intake Air Temperature (IAT) sensor electrical connector. Disconnect the of the MAF sensor electrical
connector. Loosen the air inlet duct clamp from the MAF sensor. Loosen the MAF sensor clamp from the air
filter housing. Remove the air inlet duct from the MAF sensor and the throttle body. Remove the MAF sensor
from the air filter housing.
Installation
Install the MAF sensor to the air filter housing. Install the air inlet duct to the MAF sensor and the throttle body.
Tighten clamps. Connect the IAT sensor electrical connector. Connect the MAF sensor electrical connector.
Start and idle the engine. Inspect the air intake duct for leaks.
THROTTLE POSITION SENSOR
Removal
1. Turn the ignition off. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE under
FUEL SYSTEMS. Remove the air cleaner intake duct. See AIR CLEANER INTAKE DUCT under
AIR INDUCTION SYSTEMS. Disconnect the EVAP purge line. See Fig. 16 . Disconnect the fuel lines.
See FUEL LINE DISCONNECT FITTINGS under FUEL SYSTEMS.
2. Disconnect the Throttle Position (TP) sensor electrical connector. See Fig. 6 . Remove the 2 TP sensor
bolts. Remove the TP sensor and "O" ring.
Installation
1. Install the TP sensor "O" ring on the TP sensor. Install the TP sensor on the throttle body assembly.
Install the 2 TP sensor bolts, using Loctite(R) 262 Thread-Locking Compound (1052624), or equivalent
on the bolts.
2. Tighten the TP sensor attaching bolts to specification. See TORQUE SPECIFICATIONS . Connect the
TP sensor electrical connector. Connect the EVAP purge line. Connect the fuel lines. Install the air
cleaner intake duct.
3. Perform the following procedure in order to inspect for leaks. Turn the ignition on for 2 seconds. Turn the
ignition off for 10 seconds. Turn the ignition on. Inspect for fuel leaks.
Fig. 16: Locating EVAP Canister Purge Solenoid
COOLING SYSTEM
COOLING SYSTEM BLEEDING
WARNING: To avoid being burned, do not remove the radiator cap or surge tank cap
while the engine is hot. The cooling system will release scalding fluid and
steam under pressure if radiator cap or surge tank cap is removed while
the engine and radiator are still hot.
CAUTION: When adding coolant, it is important that you use GM Goodwrench Dex-
Cool(R) or Havoline(R) Dex-Cool(R) coolant. If coolant other than Dex-Cool
(R) or Havoline(R) Dex-Cool(R) is added to the system, the engine coolant
will require change sooner; at 30,000 miles or 24 months. The air bleed
valves are brass. Do NOT over-tighten the air bleed valves.
NOTE: Recover and store used coolant in a used coolant holding tank and submit the
used coolant for recycling on a regular basis. Do not pour used coolant down
the drain. Ethylene glycol antifreeze is very toxic. Disposing of ethylene glycol
into the sewer system or ground water is both illegal and ecologically unsound.
CAUTION: Avoid spilling coolant mixture on engine parts. Coolant may cause undue
corrosion. If coolant is spilled during procedure, rinse area with clean
water.
1. Ensure the radiator drain cock is closed. Remove the radiator cap. Open the air bleed valve on the
thermostat housing 2 full turns. Open the air bleed valve above the water pump 2 full turns. Slowly add a
50/50 mixture of GM Goodwrench Dex-Cool(R) or Havoline(R) Dex-Cool(R) and clean, drinkable water
to the radiator until the coolant level is at the base of the radiator fill neck.
2. Wait for 2 minutes and reinspect the level of the coolant in the radiator. If necessary, add coolant to the
radiator until the coolant level is at the base of the radiator fill neck. Install the radiator cap. Ensure that
the radiator cap arrow points toward the radiator overflow tube.
3. Close the air bleed valves above the coolant pump and the thermostat housing. The air bleed valves are
brass. Do not over-tighten the air bleed valves. Fill the coolant reservoir with a 50/50 mixture of GM
Goodwrench Dex-Cool(R) Or Havoline(R) Dex-Cool(R) and clean, drinkable water.
NOTE: If the coolant temperature indicator turns ON, turn the engine OFF
immediately and allow the engine to cool. Do not remove the radiator cap.
4. Start the engine and allow the engine cooling fan to cycle on and off 3 times. Turn off the ignition. Allow
the engine to cool. Ensure that the engine coolant concentration is sufficient. Top off coolant reservoir, if
necessary.
MOTORS & SOLENOIDS

EVAP CANISTER PURGE SOLENOID
NOTE: EVAP canister purge solenoid may also be referred to as EVAP canister purge
valve or EVAP canister purge solenoid valve.
Removal
Turn ignition off. Disconnect the EVAP canister purge solenoid electrical connector. See Fig. 16 . Disconnect
the EVAP canister purge pipe from the EVAP canister purge solenoid. Disconnect the vacuum supply hose
from the EVAP canister purge solenoid. Remove the EVAP canister purge solenoid retaining bolt. Remove the
EVAP canister purge solenoid from the intake manifold.
Installation
Position the EVAP canister purge solenoid on the intake manifold and install the retainer bolt. Tighten the
EVAP canister purge solenoid retaining bolt to specification. See TORQUE SPECIFICATIONS . Connect the
EVAP canister purge pipe and the vacuum supply hose. Connect the EVAP canister purge valve electrical
connector.
EVAP CANISTER VENT SOLENOID
NOTE: The EVAP canister vent solenoid may also be referred to as a EVAP canister
vent valve or EVAP canister vent solenoid valve.
Removal
The EVAP canister vent valve is mounted to the fuel tank. See Fig. 17 . Remove the fuel tank. See FUEL
TANK under FUEL SYSTEMS. Disconnect the EVAP canister vent solenoid harness connector. Remove the
EVAP vent hose from EVAP canister vent solenoid. Bend the EVAP canister vent bracket tab to release the
EVAP canister vent solenoid. Remove the EVAP canister vent solenoid from the fuel tank.
Installation
Slide the EVAP canister vent solenoid on the EVAP canister vent bracket until the solenoid snaps into place.
Connect the EVAP vent hose to the EVAP canister vent solenoid. Connect the EVAP canister vent solenoid
harness connector. Install the fuel tank.
Fig. 17: Locating EVAP Canister, EVAP Vent Solenoid & Fuel Tank Pressure Sensor
IDLE AIR CONTROL VALVE
Removal
Remove the accelerator control cable bracket from the throttle body. See ACCELERATOR CONTROLS
CABLE BRACKET under MISCELLANEOUS. Remove the canister purge valve. Disconnect the Idle Air
Control (IAC) valve electrical connector. See Fig. 6 . Remove the IAC valve attaching screws. Remove the IAC
valve. Remove the IAC valve "O" ring.
Installation
CAUTION: The IAC valve may be damaged if installed with the cone (pintle) extended
more than 1.10" (28 mm). Measure the distance that the valve is extended
before installing a new valve. The distance from the idle air control valve
motor housing to the end of the idle air control valve pintle should be less
than 1.10" (28 mm). Manually compress the pintle until the extension is
less than 1.10" (28 mm).
1. Measure the distance between the tip of the IAC valve pintle and the mounting surface. See Fig. 18 . If
the distance is more than 1.10" (28 mm), use finger pressure in order to slowly retract the pintle. The
force required to retract the pintle of a new valve will not cause damage to the valve.
2. Lubricate the new IAC valve "O" ring with clean engine oil. Install the IAC valve "O" ring on the IAC
valve. Install the IAC valve. Install the IAC valve attaching screws and tighten to specification. See
TORQUE SPECIFICATIONS . Connect the IAC valve electrical connector.
3. Install the EVAP canister purge valve. Install the throttle control cable bracket. The PCM will reset the
IAC valve whenever the ignition is turned on, then off. Turn the ignition on, then off. Start the engine and
allow the engine to reach operating temperature.
Fig. 18: Measuring IAC Valve Pintle Distance

FUEL SYSTEMS
WARNING: Always release fuel system pressure before disconnecting any fuel
injection-related component. Do not allow fuel to contact engine or
electrical components.
FUEL SYSTEM PRESSURE RELEASE
Turn ignition off. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental
attempt is made to start the engine. Install Fuel Pressure Gauge Adaptor (J-34730-262) to the fuel pressure
connection on the fuel rail. Connect Fuel Pressure Gauge (J-34730-1A) to the fuel pressure connection. Wrap a
shop towel around the fuel pressure connection while connecting the fuel pressure gauge in order to avoid
spillage. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The
fuel connections are now safe for servicing. Drain any fuel remaining in the fuel pressure gauge into an
approved container. Remove the fuel pressure gauge and adaptor.
FUEL LINE DISCONNECT FITTINGS
Removal (Quick-Connect Fitting - With Metal Collar)
WARNING: Wear safety glasses when using compressed air, as flying dirt particles
may cause eye injury. Blow dirt out of the fitting using compressed air.
1. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove the retainer from
the quick-connect fitting. Blow any dirt out of the fitting, using compressed air.
2. Choose the correct Quick-Connect Separator tool from Tool Set (J-37088-A) for the size of the fitting.
Insert the quick-connect separator into the female connector, then push inward to release the locking tabs.
See Fig. 19 .
3. Pull the connection apart. Using a clean shop towel, wipe off the male pipe end. Inspect both ends of the
fitting for dirt and burrs. If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a
radial motion with the fuel pipe end in order to prevent damage to the "O" ring sealing surface. Clean or
replace the components and assemblies as required.
Installation
WARNING: In order to reduce the risk of fire and personal injury, before connecting
fuel pipe fittings, always apply a few drops of clean engine oil to the male
pipe end. This will ensure proper reconnection and prevent a possible
fuel leak. During normal operation, the "O" rings located in the female
connector will swell and may prevent proper reconnection if not
lubricated.
Apply a few drops of clean engine oil to the male pipe end. Push both sides of the fitting together to cause the
retaining tabs to snap into place. Once installed, pull on both sides of the fitting to make sure the connection is
secure. Install the retainer over the quick-connect fitting.
Fig. 19: Disconnecting Fuel Line Quick-Connect Fitting (With Metal Collar)
Removal (Quick-Connect Fitting - With Plastic Collar)
WARNING: Wear safety glasses when using compressed air, as flying dirt particles
may cause eye injury. Blow dirt out of the fitting using compressed air.
1. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Using compressed air,
blow any dirt out of the quick-connect fitting.
2. Squeeze the plastic tabs of the male end connector. See Fig. 20 . Pull the connection apart. Using a clean
shop towel, wipe off the male pipe end. Inspect both ends of the fitting for dirt and burrs.
3. If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use a radial motion with the
fuel pipe end in order to prevent damage to the "O" ring sealing surface. Clean or replace the components
and assemblies as required.
Installation
WARNING: In order to reduce the risk of fire and personal injury, before connecting
fuel pipe fittings, always apply a few drops of clean engine oil to the male
pipe end. This will ensure proper reconnection and prevent a possible
fuel leak. During normal operation, the "O" rings located in the female
connector will swell and may prevent proper reconnection if not
lubricated.
Apply a few drops of clean engine oil to the male pipe end. Push both sides of the fitting together to cause the
retaining tabs to snap into place. Once installed, pull on both sides of the fitting to make sure the connection is
secure.
Fig. 20: Disconnecting Fuel Line Quick-Connect Fitting (With Plastic Collar)
FUEL FILLER TUBE

Removal
NOTE: Cap the fittings and plug the holes when servicing the fuel system in order to
prevent dirt and other contaminants from entering the open pipes and
passages. Always maintain cleanliness when servicing fuel system
components.
1. Remove the fuel filler cap. Drain the fuel tank. See FUEL TANK DRAINING . Raise and support
vehicle. Remove the fuel filler pipe attaching nut to wheelhouse stud. SeeFig. 21 .
2. Remove the fuel filler pipe attaching screw to the wheelhouse panel. Loosen the fuel filler pipe clamp.
Remove the fuel filler pipe from the fuel tank. Remove the fuel filler pipe from the grommet on the fuel
filler pocket.
Installation
1. Install the fuel filler pipe through grommet on the fuel fill pocket. Install the fuel filler pipe to the fuel
tank. Fully seat the fill pipe to stop on the tank. Tighten the fuel filler pipe clamp to specification. See
2. Install the fuel filler pipe attaching screw to the wheelhouse panel. Tighten the fuel filler pipe attaching
screw to specification. Install the fuel filler pipe attaching nut to the wheelhouse panel. Tighten the fuel
filler pipe attaching nut to specification. Lower the vehicle.
3. Refill the fuel tank. Tighten the fuel filler cap. Reconnect the negative battery cable. Perform the
following procedure in order to inspect for leaks. Turn the ignition on for 2 seconds. Turn the ignition off
for 10 seconds. Turn the ignition on. Inspect for fuel leaks.
Fig. 21: Locating Fuel Filler Tube
FUEL FILTER
NOTE: There is not any service interval for in-pipe fuel filter replacement. Only replace
the in-line fuel filter if the filter is restricted. Cap the fittings and plug the holes
when servicing the fuel system in order to prevent dirt and other contaminants
from entering the open pipes and passages. Always maintain cleanliness when
servicing fuel system components. Always re-attach the fuel lines and fuel filter
with all original type fasteners and hardware. Do not repair sections of fuel
pipes.
1. Fuel filter is located underneath rear of vehicle. See Fig. 22 . Release fuel system pressure. See FUEL
SYSTEM PRESSURE RELEASE .
2. Raise and support vehicle. Remove the quick-connect fitting at the inlet of the in-pipe fuel filter. See
FUEL LINE DISCONNECT FITTINGS . Drain any remaining fuel into an approved gasoline
container.
3. Remove the in-pipe fuel filter mounting bracket nut from stud. Remove the quick-connect fitting at the
outlet of the in-pipe fuel filter. Remove the fuel filter from the fuel filter mounting bracket. To install,
reverse removal procedure.
Fig. 22: Locating Fuel Filter

FUEL LEVEL SENSOR

See FUEL LEVEL SENSOR under SENSORS.
FUEL PRESSURE REGULATOR
Removal
1. The fuel pressure regulator is located on end of fuel rail. See Fig. 23 . Release fuel system pressure. See
FUEL SYSTEM PRESSURE RELEASE .
2. Disconnect the fuel pressure regulator vacuum line. Remove the fuel pressure regulator retaining screw.
Using a shop towel to catch any spilled fuel, lift and twist the fuel pressure regulator in order to remove
the fuel pressure regulator from the fuel rail.
3. Remove the retainer and spacer bracket from the rail and discard. Remove the fuel pressure regulator
from the engine fuel return pipe. Remove the fuel pressure regulator inlet "O" ring and discard.
Installation
CAUTION: Do not use compressed air in order to test or clean a fuel pressure
regulator as damage to the fuel pressure regulator may result. Clean the
fuel pressure regulator filter screen with gasoline if necessary. Do not
immerse the fuel pressure regulator in a solvent bath in order to prevent
damage to the fuel pressure regulator. Connect the fuel return line before
tightening the regulator attaching screw in order to prevent the regulator
from rotating. Rotation of the regulator could damage the retainer and
spacer bracket and lead to a fuel leak at the regulator inlet.
1. Check the filter screen for contamination. If contaminated, replace the fuel pressure regulator. Lubricate
the new pressure regulator inlet "O" ring with clean engine oil and install on the regulator inlet. Install the
fuel return pipe to the regulator.
2. Install the new retainer and spacer bracket into the slot on the fuel rail. Install the pressure regulator to the
fuel rail. Tighten the engine fuel return pipe nut to specification. See TORQUE SPECIFICATIONS .
3. Connect the fuel pressure regulator vacuum line. Install the pressure regulator attaching screw. Tighten
the pressure regulator attaching screw to specification. Inspect and verify that the retainer and spacer
bracket is engaged in the slots in the fuel rail.
4. Grasp and pull on the regulator to ensure that the regulator is properly seated. Perform the following
procedure in order to inspect for leaks. Turn the ignition on for 2 seconds. Turn the ignition off for 10
seconds. Turn the ignition on. Inspect for fuel leaks.
Fig. 23: Removing/Installing Fuel Pressure Regulator
FUEL PUMP
The fuel pump is attached to the fuel sender assembly inside the fuel tank. See FUEL SENDER ASSEMBLY
for removal and installation.
FUEL RAIL & INJECTORS
CAUTION: Use care when servicing the fuel system components, especially the fuel
injector electrical connectors, the fuel injector tips, and the injector O-
rings. Plug the inlet and the outlet ports of the fuel rail in order to prevent
contamination. Do not use compressed air to clean the fuel rail assembly
as this may damage the fuel rail components. Do not immerse the fuel rail
assembly in a solvent bath in order to prevent damage to the fuel rail
assembly.
NOTE: An 8-digit identification number is located on the fuel rail assembly. Refer to
this model identification number if servicing or part replacement is required.
Fuel injector "O" rings should always be replaced whenever the fuel injectors
are serviced.
Removal
1. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove the upper intake
manifold. See appropriate article in ENGINES. Disconnect the engine fuel feed pipe at the fuel rail. See
FUEL LINE DISCONNECT FITTINGS .
2. Disconnect the engine fuel return pipe at the fuel pressure regulator. Remove the fuel feed pipe and fuel
return pipe "O" rings and discard. Disconnect the main injector harness electrical connector. To
disconnect fuel injector connector, pull up the lock release of the fuel injector connector. Depress the lock
tab and lift the connector from the injector. Disconnect all remaining fuel injector connectors.
3. Remove the injector electrical harness from the fuel rail. Disconnect the engine coolant temperature
sensor electrical connector. Remove the fuel rail retaining bolts. See Fig. 24 . Remove the fuel rail
assembly. Remove the injector "O" ring seal from the spray tip end of each injector. Discard the lower
"O" ring seals. See Fig. 25 .
4. To remove injector(s) from the fuel rail, remove the fuel injector retainer clip. Discard retaining clip.
Remove the fuel injector from the fuel rail. Remove and discard the fuel injector upper "O" ring.
Installation
WARNING: In order to reduce the risk of fire and personal injury that may result from
a fuel leak, always install the fuel injector "O" rings in the proper position.
If the upper and lower "O" rings are different colors (Black and Brown), be
sure to install the Black "O" ring in the upper position and the Brown "O"
ring in the lower position on the fuel injector. The "O" rings are the same
size but are made of different materials.
1. Lubricate the new injector upper "O" ring seal with clean engine oil. Install the new injector "O" ring seal
on the injector. Install a new retainer clip on the injector. Push the fuel injector into the fuel rail injector
socket with the electrical connector facing outward. The retainer clip locks on to a flange on the fuel rail
injector socket.
2. Install the fuel rail assembly into the intake manifold. Tilt the rail assembly to install the injectors. Install
the fuel rail attaching bolts. Tighten the fuel rail attaching bolt to specification. See TORQUE
SPECIFICATIONS .
3. Connect the engine coolant temperature sensor electrical connector. Install the injector electrical harness
to the fuel rail. Connect the fuel injector connectors. Push the slide locks into position. Connect the main
injector harness electrical connector. Install the new "O" rings on the fuel feed pipe and fuel return pipe.
4. Connect the fuel feed pipe at the fuel rail. Tighten the fuel feed pipe nut to specification. Connect the fuel
return pipe at the fuel pressure regulator. Tighten the fuel return pipe nut to specification. Install the upper
intake manifold. See appropriate article in ENGINES. Connect the negative battery cable.
Fig. 24: Removing/Installing Fuel Rail Assembly

Fig. 25: Identifying Fuel Injector Components
FUEL SENDER ASSEMBLY

Removal
CAUTION: Do not handle the fuel sender assembly by the fuel pipes. The amount of
leverage generated by handling the fuel pipes could damage the joints.
1. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Remove the fuel tank. See
FUEL TANK . Remove the fuel sender shield nuts. Remove the fuel sender shield. Disconnect the fuel
sender electrical connectors.
2. Disconnect the fuel pipes from the fuel sender. See FUEL LINE DISCONNECT FITTINGS . Using
Fuel Sender Lock Ring Tool (J-39765-A 1), remove the fuel sender lock ring. The fuel sender assembly
will spring up when the fuel sender assembly lock ring is removed.
3. The fuel sender must be tipped in order to remove the sender from the fuel tank. Remove the fuel sender
from the fuel tank. Remove and discard the fuel sender seal.
Installation
1. Clean the fuel sender sealing flange. Install the NEW fuel sender seal to the fuel tank. Do not fold over or
twist the fuel pump strainer when installing the fuel sender assembly, as this will restrict fuel flow. Also,
ensure that the fuel pump strainer does not block full travel of float arm.
2. Install the fuel sender and the fuel sender lock ring. Use the Fuel Sender Lock Ring Tool (J-39765-A1) in
order to install the fuel sender lock ring. Install the fuel pipes to the fuel sender. Install the fuel sender
sensor electrical connectors. Install the fuel sender shield.
3. Install the fuel sender shield nuts. Tighten the nuts to specification. See TORQUE SPECIFICATIONS .
Install the fuel tank.
4. Lower the vehicle. Add fuel and reinstall the fuel tank filler pipe cap. Connect the negative battery cable.
Perform the following procedure in order to inspect for leaks: Turn the ignition on for 2 seconds. Turn the
FUEL SYSTEM CLEANING
NOTE: When flushing the fuel tanks, handle the fuel and water mixture as a hazardous
material. Handle the fuel and water mixture in accordance with all applicable
local, state, and federal laws and regulations. Whenever the fuel tank is cleaned,
the fuel pump fuel strainer must be inspected. If the fuel pump fuel strainer is
contaminated, the fuel pump fuel strainer must be replaced and the fuel pump
must be inspected.
1. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Drain the fuel tank. See
FUEL TANK DRAINING .
2. Remove the fuel tank. See FUEL TANK . Remove the fuel sender assembly. See FUEL SENDER
ASSEMBLY .
3. Inspect the fuel pump inlet for dirt and debris. If dirt and debris are found, the fuel pump needs to be
replaced. Flush the fuel tank with hot water. Pour the water out of the fuel sender assembly opening in the
fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank is
complete.
4. Allow the tank to dry completely before reassembly. Install the fuel sender assembly. See FUEL
SENDER ASSEMBLY . Install the fuel tank. See FUEL TANK .
5. Refill the fuel system. Install the fuel filler cap. Connect the negative battery cable. Perform the following
procedure in order to inspect for leaks: Turn the ignition on for 2 seconds. Turn the ignition off for 10
seconds. Turn the ignition on. Inspect for fuel leaks.
FUEL TANK
Removal
1. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Drain the fuel tank. See
FUEL TANK DRAINING . Raise and support vehicle.
2. Disconnect the fuel tank wiring harness connector at the body pass through. See Fig. 26 . Disconnect the
quick-connect fittings at the fuel filter. SeeFig. 22 . See FUEL LINE DISCONNECT FITTINGS .
3. Disconnect the fuel tank EVAP pipe quick-connect fitting near the fuel filter. Remove the fuel feed, the
fuel return, and the EVAP lines from the fuel pipe retainer. Remove the retaining nut for the EVAP
canister bracket. Loosen the fuel tank filler pipe hose clamp at the fuel tank.
4. Disconnect the fuel tank filler pipe from the fuel tank. Do not bend the fuel tank straps. Bending the fuel
tank straps may damage the straps. With the aid of an assistant, support the fuel tank and remove the fuel
tank strap attaching bolts. Remove the fuel tank from the vehicle.
Fig. 26: Locating Fuel Sender Assembly Harness Connector
Installation
NOTE: When replacing the fuel system hose clamps, always replace the clamps with
the original equipment or parts that meet the GM specifications for those parts.
1. With the aid of an assistant, position and support the fuel tank. Do not bend the fuel tank straps. Bending
the fuel tank straps may damage the straps. Install the fuel tank retaining strap attaching bolts. Tighten the
fuel tank retaining strap bolts to specification. See TORQUE SPECIFICATIONS .
2. Install the EVAP canister retaining nut. Tighten the EVAP canister retaining nut to specification. Connect
the fuel tank filler pipe to the fuel tank. Tighten the fuel tank filler pipe hose clamp to specification.
Connect the fuel pipe quick-connect fittings at the fuel filter. Connect the fuel tank EVAP pipe quick-
connect fitting near the fuel filter.
3. Connect the fuel tank wiring harness connector at the body pass-through. Lower the vehicle. Add fuel and
reinstall the fuel tank filler pipe cap. Connect the negative battery cable. Perform the following procedure
in order to inspect for leaks: Turn the ignition on for 2 seconds. Turn the ignition off for 10 seconds. Turn
the ignition on. Inspect for fuel leaks.
FUEL TANK DRAINING
WARNING: Gasoline or gasoline vapors are highly flammable. A fire could occur if an
ignition source is present. Never drain or store gasoline in an open
container, due to the possibility of fire or explosion. Have a dry chemical
(Class B) fire extinguisher nearby.
NOTE: Lubricate the fuel drain hose with Transjel Transmission Assembly Lubricant (J
36850) or equivalent to aid in hose insertion. Do not use an unapproved
lubricant.
Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Install Fuel Flapper Door
Handle (J-42960-2) into the fuel fill pipe in order to hold the door open. Insert Fuel Tank Drain Hose (J-45004)
into the fuel tank until the hose reaches the bottom of the fuel tank. Use an air operated pump device in order to
drain as much fuel through the fuel fill pipe as possible.
See FUEL TANK PRESSURE SENSOR under SENSORS.
See IDLE AIR CONTROL VALVE under MOTORS & SOLENOIDS.
THROTTLE BODY
See THROTTLE BODY under AIR INDUCTION SYSTEMS.
IGNITION SYSTEMS
See CAMSHAFT POSITION SENSOR under SENSORS.
CRANKSHAFT POSITION SENSORS
See CRANKSHAFT POSITION SENSOR "A" (24X) or CRANKSHAFT POSITION SENSOR "B" (7X)
under SENSORS.
IGNITION COILS

1. Turn ignition off. Disconnect the spark plug wires from the ignition coils. Note the position from which
the wires are removed. Remove the 2 screws that secure the ignition coil to the ignition control module.
Remove the ignition coil.
2. To install, reverse removal procedure. Tighten the coil screws to specification. See TORQUE
SPECIFICATIONS . Connect the spark plug wires to the ignition coils. See Fig. 27 .
Fig. 27: Identifying Proper Spark Plug Routing At Ignition Coils

IGNITION CONTROL MODULE
1. Disconnect all the electrical connectors at the Ignition Control Module (ICM). Note the position of the
spark plug wires for installation and disconnect the spark plug wires from the ignition coils. Remove the
screws securing the coil assemblies to the ignition control module.
2. Disconnect the coils from the ignition control module. Remove the fasteners securing the ignition control
module assembly to the engine. Remove the ignition control module from the bracket.
3. To install, reverse removal procedure. Tighten the ignition control module screws to specification. See
TORQUE SPECIFICATIONS . Connect the spark plug wires to the ignition coils. See Fig. 27 .
KNOCK SENSOR
See KNOCK SENSOR under SENSORS.
SPARK PLUGS
Removal
1. Turn ignition off. To remove spark plugs from left cylinder bank (front cylinder head), remove the spark
plug wires from spark plugs. Remove spark plugs from engine. To remove spark plugs from the right
cylinder bank (rear cylinder head), remove the throttle air cleaner intake duct. See AIR CLEANER
INTAKE DUCT under AIR INDUCTION SYSTEMS.
2. Set the park brake. Shift the transaxle into Neutral. Remove the engine mount strut bolts. See Fig. 28 .
Swing the engine mount struts aside. Install the Engine Tilter Strap (J-41131) to the engine. See Fig. 29 .
3. Pull on the engine in order to rotate the engine forward. Tighten the engine tilter strap. Remove the spark
plug wires from the spark plugs. Remove the spark plugs from the engine.
Fig. 28: Removing Left Engine Mount Strut Bolt (Right Is Similar)
Fig. 29: Installing Engine Tilter Strap
Inspection
1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions.
Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following
conditions:
Spark plug fouling - Colder plug.
Pre-ignition, causing spark plug and/or engine damage - Hotter plug.
2. Inspect the terminal post for a bent or broken terminal post. See Fig. 30 . Test for a loose terminal post by
twisting and pulling the post. The terminal post should not move.
3. Inspect the insulator for flashover or carbon tracking, soot. This is caused by the electrical charge
traveling across the insulator between the terminal post and ground. Inspect spark plug boot for damage.
Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark
plug boot that is saturated causes arcing to ground.
4. Inspect the insulator for cracks. All or part of the electrical charge may arc through the crack instead of
the electrodes. Inspect for evidence of improper arcing. Measure the gap between the center electrode and
the side electrode terminals.
5. Inspect for the correct spark plug torque. Insufficient torque can prevent correct spark plug operation. An
over-torqued spark plug causes the insulator to crack.
6. Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode. Inspect for
a broken or worn side electrode. Inspect for a broken, worn, or loose center electrode by shaking the
spark plug. A rattling sound indicates internal damage. A loose center electrode reduces the spark
intensity.
7. Inspect for bridged electrodes. Deposits on the electrodes reduce or eliminates the gap. Inspect for worn
or missing platinum pads on the electrodes, if equipped. Inspect for excess fouling. Inspect the spark plug
recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat
correctly during installation.
8. Brown to Grayish-Tan with small amounts of White powdery deposits are normal combustion by-
products from fuels with additives. Carbon fouled - Dry, fluffy, black carbon, or soot is caused by rich
fuel mixtures such as leaking fuel injectors, excessive fuel pressure, restricted air filter element and
incorrect combustion. Reduced ignition system voltage output which includes weak coils, worn ignition
wires and incorrect spark plug gap can also cause carbon fouling.
9. Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal
combustion deposits may not burn off. Deposit fouling - oil, coolant, or additives that include substances
such as silicone, very White coating, reduces the spark intensity. Most powdery deposits will not effect
spark intensity unless they form into a glazing over the electrode.
Fig. 30: Identifying Spark Plug Components
Installation
CAUTION: Be sure plug threads smoothly into cylinder head and is fully seated. Use
a thread chaser if necessary to clean threads in cylinder head. Cross-
threading or failing to fully seat spark plug can cause overheating of plug,
exhaust blow-by, or thread damage. Follow the recommended torque
specifications carefully. Over or under-tightening can also cause severe
damage to engine or spark plug.
1. Gap the spark plugs to specification. See SPARK PLUGS under IGNITION SYSTEMS in SERVICE &
ADJUSTMENT SPECIFICATIONS - 3.4L AZTEK & RENDEZVOUS article. Install the spark plugs.
Tighten the spark plugs to specification. See TORQUE SPECIFICATIONS .
2. Install the spark plug wires to the spark plugs. Return the engine to the proper position. Remove the
engine tilter strap from the engine. Swing the engine mount struts in position. Install the engine mount
strut bolts and tighten bolts to specification.
SPARK PLUG WIRES
Removal
CAUTION: Twist the spark plug boot one-half turn in order to release the boot. Pull on
the spark plug boot only. Do not pull on the spark plug wire or the wire
could be damaged.
1. Remove the spark plug wires (2, 4, and 6) from the front bank (bank 1) spark plugs. Remove the spark
plug wires from the retaining clips. Set the park brake. Shift the transaxle into Neutral. Remove the
engine mount strut bolts. See Fig. 28 .
2. Swing the engine mount struts aside. Install the Engine Tilter Strap (J-41131) to the engine. See Fig. 29 .
Pull on the engine in order to rotate the engine forward. Tighten the engine tilter strap.
3. Remove the spark plug wires (1, 3, and 5) from the rear bank (bank 2) spark plugs. Remove the spark
plug wires from the retaining clips. Remove the spark plug wires from the ignition coils. Remove the
spark plug wires from the engine. See Fig. 31 and Fig. 32 . If you are replacing the spark plug wires,
transfer the boot heat shields, spark plug wire conduit and spark plug wire retaining clips.
Inspection
Spark plug wire integrity is vital for proper engine operation. A thorough inspection will be necessary to
accurately identify conditions that may affect engine operation. Inspect for correct routing of the spark plug
wires. Improper routing may cause cross-firing. Inspect each wire for any signs of cracks or splits in the wire.
Inspect each boot for the following conditions:
Tearing.
Piercing.
Arcing.
Carbon tracking.
Corroded terminal.
If corrosion, carbon tracking, or arcing are indicated on a spark plug wire boot or terminal, both the wire and the
component connected to the wire should be replaced.
Installation
1. Install the spark plug wires to the engine. Install the spark plug wires to the ignition coils. See Fig. 27 .
Install the spark plug wires (1, 3, and 5) to bank 2 spark plugs. Install the spark plug wires to the retaining
clips.
2. Return the engine to the proper position. Remove the engine tilter strap from the engine. Swing the
engine mount struts in position. Install the engine mount strut bolts and tighten bolts to specification. See
3. Install the spark plug wires (2, 4, and 6) to bank 1 spark plugs. Install the spark plug wires to the retaining
clips.
Fig. 31: Spark Plug Wire Routing (Bank 1)

Fig. 32: Spark Plug Wire Routing (Bank 2)
EMISSION SYSTEMS & SUB-SYSTEMS

EGR SYSTEM CLEANING
WARNING: Avoid breathing fumes and swallowing EGR exhaust deposits when
removing components for cleaning as bodily injury may result.
1. Turn the ignition off. Remove Exhaust Gas Recirculation (EGR) valve pipe. See EGR VALVE PIPE .
Clean and inspect the EGR pipe from the exhaust manifold to the EGR valve. Remove the EGR valve.
See EGR VALVE .
2. While holding the EGR valve base in your hand, try to rotate the connector housing. Replace the valve
that exhibits looseness. Inspect the EGR valve pintle and seat for deposits. Use a cloth or other suitable
soft device to remove deposits. Remove all loose particles.
3. If deposits are such that pintle and/or base interface cannot be cleaned adequately to allow the pintle to
seal against the seat, replace the valve. Damage to the EGR valve base will occur if cleaned with solvents,
sharp tools, wire brush, wheel or sand blasting. Cleaning by these methods is not recommended. Install
the EGR valve on the engine using a new gasket. Install the EGR valve pipe.
EGR VALVE
NOTE: Whenever the Exhaust Gas Recirculation (EGR) valve is removed, the EGR
system should be inspected and cleaned if needed. This will ensure that the
EGR system will function properly under all operating conditions. See EGR
SYSTEM CLEANING .
Removal
1. Disconnect the EGR valve electrical connector. See Fig. 33 . Remove the air cleaner assembly. See AIR
CLEANER ASSEMBLY under AIR INDUCTION SYSTEMS. Remove the transaxle fluid filler tube.
Remove the bolt retaining the pipe assembly from the EGR valve and carefully pull the pipe assembly
back.
2. Remove the EGR valve retaining bolts. Remove the EGR valve assembly. Remove the gasket. Clean the
EGR valve mating surface.
Fig. 33: Locating EGR Valve
Installation
Install the EGR valve with a new gasket to the intake manifold. Install the bolts through the EGR valve. Tighten
the bolts to specification. See TORQUE SPECIFICATIONS . Connect the pipe assembly to the EGR valve.
Install the transaxle fluid filler tube. Tighten transaxle fluid filler tube bolt/nut to specifications. Install air
cleaner assembly. Connect the EGR valve electrical connector.
EGR VALVE PIPE

Removal
1. Turn the ignition off. Apply the parking brake. Raise the front of the vehicle approximately 4" (100 mm)
with a floor jack. Remove the two front frame bolts. Do not lower the frame and powertrain more than
4" (100 mm) Slowly lower the frame and powertrain approximately 4" (100 mm) from the underbody
rails in order to gain access to the EGR pipe.
2. Place two jack stands beneath the frame to prevent any movement of the frame and powertrain assembly.
Remove the EGR pipe bolt and the EGR pipe from the EGR valve. See Fig. 34 . Loosen the EGR pipe
nut in order to remove the EGR pipe from the exhaust manifold. Remove the EGR pipe.
Fig. 34: Removing/Installing EGR Pipe
Installation
1. Install the EGR pipe to the exhaust manifold. Tighten the EGR pipe nut to specification. See TORQUE
SPECIFICATIONS . Install the EGR pipe and the EGR pipe bolt to the EGR valve. Tighten the EGR
pipe bolt to specification.
2. Use the floor jack in order to raise the frame and powertrain until the frame contacts the underbody rails.
Install the frame bolts and tighten bolts to specification. Remove the jack stands. Lower and remove the
floor jack. Release the parking brake.
EVAP CANISTER
NOTE: The EVAP canister may have released carbon particles which caused this part
to fail and may cause damage to other components. Check the EVAP canister
for loose carbon before returning the vehicle to service.
EVAP canister is mounted to the fuel tank. See Fig. 17 . Remove the fuel tank. See FUEL TANK under FUEL
SYSTEMS. Remove the 2 retaining nuts connecting the EVAP canister bracket to the fuel tank. Reposition the
EVAP canister and disconnect the EVAP system hoses/pipes from the EVAP canister. Remove the EVAP
canister from the EVAP canister bracket. To install, reverse removal procedure.
EVAP CANISTER PURGE SOLENOID
See EVAP CANISTER PURGE SOLENOID under MOTORS & SOLENOIDS.
EVAP CANISTER VENT SOLENOID
See EVAP CANISTER VENT SOLENOID under MOTORS & SOLENOIDS.
MISCELLANEOUS
ACCELERATOR CONTROLS CABLE
Removal
1. Remove the accelerator cable shield, if equipped. Disconnect the accelerator cable from the throttle body
lever. Disconnect the accelerator cable from the accelerator cable bracket.
2. Remove the push-in retainers from the Insulator Panel (IP) insulator to instrument panel. Remove the
press-on retainers from the IP insulator to dash mat. Unsnap the IP courtesy lamp from the IP insulator.
Remove the IP insulator from the instrument panel.
3. Disconnect the accelerator cable from the accelerator pedal. Squeeze the accelerator cable cover tangs
and push the accelerator cable through the bulkhead. Remove the accelerator cable from the vehicle. Note
the cable routing for aid in installation. See Fig. 35 .
Installation
WARNING: Do not route flexible components (hoses, wires, conduits, etc.) within
2" (50 mm) of moving parts unless flexible components can be securely
fastened. This is necessary in order to prevent possible interference and
damage to the component.
1. Install the accelerator cable into the vehicle using the routing noted during removal. Install the snap
retainer through the bulkhead. Connect the accelerator cable through the slot in the accelerator pedal
lever. Seat the snap retainer in the accelerator pedal lever.
2. Connect the accelerator cable to the throttle body lever. Connect the accelerator cable to the accelerator
cable bracket. Reinstall the accelerator cable shield, if equipped.
3. Inspect and check for complete throttle opening and closing positions by operating the accelerator pedal.
Also check for poor carpet fit under the accelerator pedal. Reinstall the left IP insulator.
Fig. 35: Routing Accelerator Controls Cable

ACCELERATOR CONTROLS CABLE BRACKET
Removal
1. Disconnect the accelerator controls cable cross slug from the throttle body lever. See Fig. 36 . Disconnect
the accelerator controls cable from the accelerator cable bracket. Disconnect the cruise control cable from
the throttle lever and accelerator bracket, if applicable. See Fig. 37 .
2. Disconnect the air cleaner intake duct from the throttle body. See AIR CLEANER INTAKE DUCT
under AIR INDUCTION SYSTEMS. Disconnect the wire harness from the retainer. Remove the nut and
bolts holding the accelerator cable bracket to the throttle body. Remove the accelerator cable bracket.
Installation
Position the accelerator cable bracket on the throttle body. Install the accelerator cable bracket nut and bolts.
Tighten the bolts/nut in sequence to specification. See Fig. 38 . See TORQUE SPECIFICATIONS . Install
the wire harness into the retainer. Install the air cleaner intake duct. Connect the accelerator controls cable to the
accelerator cable bracket. Connect the accelerator controls cable cross slug to the throttle body lever. Connect
the cruise control cable to the throttle lever and accelerator bracket, if applicable.
Fig. 36: Identifying Accelerator Controls Cable
Fig. 37: Identifying Cruise Control Cable
Fig. 38: Accelerator Cable Bracket Bolt/Nut Tightening Sequence
ACCELERATOR CONTROLS PEDAL
1. Remove the push-in retainers from the Insulator Panel (IP) insulator to instrument panel. Remove the
press-on retainers from the IP insulator to dash mat. Unsnap the IP courtesy lamp from the IP insulator.
Remove the IP insulator from the instrument panel.
2. Disconnect the accelerator cable from the accelerator pedal. Remove the fasteners holding the accelerator
pedal to the bulk head. See Fig. 39 . Remove the accelerator pedal. To install, reverse removal
procedures. Tighten accelerator bolts and studs to specification. See TORQUE SPECIFICATIONS .
3. Check for complete throttle opening and closing positions by operating the accelerator pedal. Also inspect
the carpet fit under the accelerator pedal. Reinstall the left instrument panel sound insulator.
Fig. 39: Removing/Installing Accelerator Controls Pedal
Catalytic Converter Nuts 25 (34)
Crankshaft Balancer Bolt (1) 52 (70)
EGR Valve Bolt 22 (30)
EGR Valve Pipe Bolt/Nut 18 (25)
Engine Coolant Temperature Sensor 15 (20)
Engine Mount Strut Bolt/Nut 35 (48)
Frame Bolts
Front Bolts 114 (155)
Rear Bolts 177 (240)
Fuel Feed Pipe Nut At Fuel Rail 13 (17)
Fuel Filler Pipe Attaching Nut/Screw 18 (25)
Fuel Return Pipe Nut At Pressure Regulator 13 (17)
Fuel Tank Strap Bolts 35 (47)
Heated Oxygen Sensor 30 (41)
Knock Sensor 14 (19)
Power Steering Mounting Bolts 25 (34)
Spark Plug (2)
Throttle Body Bolts/Nuts 21 (28)

INCH Lbs. (N.m)
Accelerator Control Cable Bracket (3)
Bolt 115 (13.0)
Nut 89 (10.0)
Accelerator Controls Pedal Bolts/Nuts 27 (3.0)
Air Cleaner Housing Assembly Bolts 89 (10.0)
Air Cleaner Intake Duct Clamps 18 (2.0)
Camshaft Position Sensor 71 (8.0)
Crankshaft Position Sensor "A" (24X) 89 (10.0)
Crankshaft Position Sensor "B" (7X) 97 (11)
EVAP Canister Purge Solenoid Bolt 89 (10.0)
EVAP Canister Retaining Nut 89 (10.0)
Front Fender Diagonal Brace-To-Inner Fender Bolts 89 (10.0)
Front Fender Diagonal Brace-To-Radiator Support Bolts 89 (10.0)
Fuel Filler Pipe Hose Clamp 22 (2.5)
Fuel Pressure Regulator Screw 76 (8.5)
Fuel Rail Bolt 89 (10.0)
Fuel Sender Shield Nuts 53 (6.0)
Idle Air Control Valve 27 (3.0)
Ignition Control Module Mounting Screw 40 (4.5)
Ignition Coil Mounting Screw 40 (4.5)
Manifold Absolute Pressure Sensor Screws 27 (3.0)
PCM Connector Screw 71 (8.0)
Throttle Position Sensor Bolts 18 (2.0)
Transaxle Fluid Filler Tube Bolt/Nut 115 (13.0)
3.4L V6 - VIN (E) - Aztek & Rendezvous
Application Ft. Lbs (N.m)
Air Injection Check Valve (With NC1 California Emissions) 15 (20)
Air Injection Check Valve Front Bracket Bolt/Nut (With NC1 18 (25)
California Emissions)
Air Injection Check Valve Pipe Adapter (With NC1 22 (30)
Air Injection Check Valve Rear Bracket Bolt/Nut (With NC1 18 (25)
Camshaft Sprocket Bolt 103 (140)
Connecting Rod Bearing Cap Nut
First Tightening Pass 15 (20)
Final Tightening Pass 75 Degrees
Coolant Drain Plug 14 (19)
Coolant Temperature Sensor 17 (23)
Crankshaft Balancer Bolt
Crankshaft Main Bearing Cap Bolt/Stud
Crankshaft Oil Deflector Nut 18 (25)
Crankshaft Position Sensor Wiring Bracket Bolt 20 (27)
Cylinder Head Bolts (1)
Drive Belt Tensioner Bolt 37 (50)
EGR Valve Pipe-To-Exhaust Manifold Nut 18 (25)
EGR Valve Pipe-To-EGR Valve Bolt 18 (25)
EGR Valve-To-Upper Intake Manifold Bolt 22 (30)
Engine Front Cover Small (M8) Bolt 20 (27)
Engine Front Cover Medium (M10) & Large (M12) Bolt 41 (55)
Engine Mount Bracket-To-Engine Block (AWD Only) Bolt 63 (85)
Engine Mount Bracket-To-Oil Pan Bolt 43 (58)
Engine Mount Lower Nut 35 (47)
Engine Mount Strut & A/C Compressor Bracket Bolt 37 (50)
Engine Mount Strut Bolt 35 (48)
Engine Mount Strut Bracket Left Bolt 52 (70)
Engine Mount Strut Bracket Right Bolt 37 (50)
Engine Mount Strut Bracket-To-Radiator Support Upper Bolt 19 (26)
Engine Mount Strut & Generator Bracket Bolt 37 (50)
Engine Mount Strut & Lift Bracket Bolt (Engine Lift Rear) 52 (70)
Engine Mount Strut Nut 35 (48)
Engine Mount Strut & Support Bracket
Large Bolt 41 (55)
Medium Bolt 41 (55)
Small Bolt 20 (27)
Engine Mount Upper Nut 39 (53)
Engine Oil Drain Plug 18 (25)
Engine Oil Pressure Indicator Switch 12 (16)
Exhaust Manifold Nut 12 (16)
Exhaust Manifold Stud 13 (18)
Flywheel Bolt 52 (71)
Fuel Feed & Return Pipe Bracket Stud 37 (50)
Fuel Feed & Return Pipe Retaining Clip Nut 18 (25)
Fuel Feed Pipe-To-Fuel Injector Rail Nut 13 (17)
Heated Oxygen Sensor 31 (42)
Heater Inlet Pipe Nut 18 (25)
Heater Inlet Pipe Stud 37 (50)
Ignition Coil Bracket Bolt/Nut/Stud 18 (25)
Intake Manifold Upper Studs/Bolts 18 (25)
Knock Sensor 14 (19)
Lower Intake Manifold Bolts (2)
MAP Sensor Bracket Bolt 18 (25)

Oil Filter 22 (30)
Oil Filter (With Out Oil Cooler) 29 (39)
Oil Cooler Connector 37 (50)
Oil Cooler Hose Fitting 14 (19)
Oil Filter Bypass Hole Plug 14 (19)
Oil Gallery Plug
1/4 Inch 14 (19)
3/8 Inch 24 (33)
Oil Level Indicator Tube Bolt 18 (25)
Oil Pan Vertical Bolts 18 (25)
Oil Pan Side/Horizontal Bolts 37 (50)
Oil Pump Bolt 30 (41)
Oil Pump Drive Gear Clamp Bolt 27 (36)
Spark Plug
Initial Installation 15 (20)
After Initial Installation 13 (15)
Thermostat Bypass Pipe-To-Throttle Body Nut 18 (25)
Throttle Body Bolt/Stud 18 (25)
Timing Chain Dampener Bolt 15 (21)
Valve Rocker Arm Bolt
Water Outlet Bolt 18 (25)
Water Pump Pulley Bolt 18 (25)
INCH Lbs. (N.m)
Accelerator Control Cable Bracket Bolt/Nut 89 (10)
Air Injection Check Valve Bolt/Nut (With NC1 California 89 (10)
Emissions)
Air Injection Check Valve Pipe Assembly Bolt 89 (10)
Air Injection Vacuum Solenoid Bolt (With NC1 California 89 (10)
Emissions)
Camshaft Position Sensor Bolt 89 (10)
Camshaft Thrust Plate Screw 89 (10)
Crankshaft Position Sensor Bolt (Front Cover) 89 (10)
Crankshaft Position Sensor Stud (Side Of Engine Block) 98 (11)
Crankshaft Position Sensor Shield Nut 98 (11)
Engine Oil Level Sensor Bolt 89 (10)
Engine Wiring Harness Bracket Bolt 110 (13)
Exhaust Manifold Heat Shield Bolt 89 (10)
Fuel Feed & Return Pipe Retaining Clip Bolt 71 (8)
Fuel Injector Rail Bolt 89 (10)
Fuel Pipe Clip Bolt 71 (8)
Intake Manifold Coolant Pipe Bolt 89 (10)
Intake Manifold Lower Bolts (2)
First Tightening Pass (4 Vertical & Then 4 Angle) 62 (7)
Final Pass (All) 115 (13)
MAP Sensor Bolt 44 (5)
Oil Cooler Pipe Bracket Bolt 89 (10)
Oil Pump Cover Bolt 89 (10)
Thermostat Bypass Pipe-To-Engine Front Cover Bolt 106 (12)
Valve Lifter Guide Bolt 89 (10)
Valve Rocker Arm Cover Bolt 89 (10)
Water Pump Bolt 98 (11)
(1) Tighten bolts following sequence shown. See Fig. 1.
(2) See TSB For Revised Lower Intake Torque . Tighten bolts following sequence shown. See Fig. 2.
Fig. 1: Identifying Cylinder Head Bolt Tightening Sequence

Fig. 2: Identifying Lower Intake Manifold Bolt Tightening Sequence
SPECIFICATIONS
Fig. 3: Fastener Tightening Specifications (1 Of 3)
ENGINE MECHANICAL SPECIFICATIONS

Fig. 6: Engine Mechanical Specifications (1 Of 4)
SEALERS, ADHESIVES & LUBRICANTS
Fig. 10: Sealers, Adhesives & Lubricants Application Reference

COMPONENT LOCATOR
DISASSEMBLED VIEWS
Upper Intake Manifold and Components

Fig. 11: Exploded View Of Upper Intake Manifold
Lower Intake Manifold, Cylinder Head & Components

Fig. 12: Exploded View Of Lower Intake Manifold And Cylinder Head
Engine Block and Components

Fig. 13: Exploded View Of Engine Block
Crankshaft and Components

Fig. 14: Exploded View Of Crankshaft
ENGINE IDENTIFICATION
Fig. 15: Identifying Engine Identification Number

The Vehicle Identification Number - VIN derivative (1) for 3100 LG8 and 3400 LA1 is stamped or laser etched
on the left side rear of the engine block. The Vehicle Identification Number - VIN derivative is nine digits long
and can be used to determine if a vehicle contains the original engine.
The first digit identifies the division.
The second digit identifies the model year.
The third digit identifies the assembly plant.
The fourth through ninth digits are the last six digits of the Vehicle Identification Number (VIN).
DIAGNOSTIC INFORMATION & PROCEDURES

DIAGNOSTIC STARTING POINT - ENGINE MECHANICAL
Begin the system diagnosis by reviewing the DISASSEMBLED VIEWS , ENGINE COMPONENT
DESCRIPTION , DRIVE BELT SYSTEM DESCRIPTION , LUBRICATION DESCRIPTION , and
NEW PRODUCT INFORMATION in Engine Mechanical. Reviewing the description and operation
information will help you determine the correct symptom diagnostic procedure when a malfunction exists.
Reviewing the description and operation information will also help you determine if the condition described by
the customer is normal operation. Refer to SYMPTOMS - ENGINE MECHANICAL in order to identify the
correct procedure for diagnosing the system and where the procedure is located.
SYMPTOMS - ENGINE MECHANICAL
Strategy Based Diagnostics
1. Perform DIAGNOSTIC STARTING POINT -- ENGINE CONTROLS before using the symptom
tables if applicable.
2. Review the system operations in order to familiarize yourself with the system functions. Refer to
DISASSEMBLED VIEWS , ENGINE COMPONENT DESCRIPTION , DRIVE BELT SYSTEM
DESCRIPTION , LUBRICATION DESCRIPTION , and NEW PRODUCT INFORMATION .
All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for
repairing all systems. The diagnostic flow may always be used in order to resolve a system problem. The
diagnostic flow is the place to start when repairs are necessary.
Inspect for aftermarket devices which could affect the operation of the Engine. Refer to CHECKING
AFTERMARKET ACCESSORIES .
cause the symptom.
Check for the correct oil level, proper oil viscosity, and correct filter application.
Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM,
ambient temperature, engine temperature, amount of engine warm-up time, and other specifics.
Compare the engine sounds if applicable to a known good engine and make sure you are not trying to
correct a normal condition.
Intermittent
Test the vehicle under the same conditions that the customer reported in order to verify the system is operating
properly.
Symptom List
BASE ENGINE MISFIRE WITHOUT INTERNAL ENGINE NOISES

BASE ENGINE MISFIRE WITH ABNORMAL INTERNAL LOWER ENGINE NOISES
BASE ENGINE MISFIRE WITH ABNORMAL VALVE TRAIN NOISE
BASE ENGINE MISFIRE WITH COOLANT CONSUMPTION
BASE ENGINE MISFIRE WITH EXCESSIVE OIL CONSUMPTION
ENGINE COMPRESSION TEST
ENGINE NOISE ON START-UP, BUT ONLY LASTING A FEW SECONDS
UPPER ENGINE NOISE, REGARDLESS OF ENGINE SPEED
LOWER ENGINE NOISE, REGARDLESS OF ENGINE SPEED
ENGINE NOISE UNDER LOAD
ENGINE WILL NOT CRANK - CRANKSHAFT WILL NOT ROTATE
OIL CONSUMPTION DIAGNOSIS
OIL PRESSURE DIAGNOSIS AND TESTING
OIL LEAK DIAGNOSIS
DRIVE BELT CHIRPING DIAGNOSIS
DRIVE BELT SQUEAL DIAGNOSIS
DRIVE BELT WHINE DIAGNOSIS
DRIVE BELT RUMBLING DIAGNOSIS
DRIVE BELT VIBRATION DIAGNOSIS
DRIVE BELT FALLS OFF DIAGNOSIS
DRIVE BELT EXCESSIVE WEAR DIAGNOSIS
DRIVE BELT TENSIONER DIAGNOSIS

Fig. 16: Base Engine Misfire Without Internal Engine Noises - Symptom Diagnostic Table (1 Of 2)
Fig. 17: Base Engine Misfire Without Internal Engine Noises - Symptom Diagnostic Table (2 Of 2)

Fig. 18: Base Engine Misfire With Abnormal Internal Lower Engine Noises - Symptom Diagnostic Table
Fig. 19: Base Engine Misfire With Abnormal Valve Train Noise - Symptom Diagnostic Table

Fig. 20: Base Engine Misfire With Coolant Consumption - Symptom Diagnostic Table
Fig. 21: Base Engine Misfire With Excessive Oil Consumption - Symptom Diagnostic Table
Fig. 22: Engine Noise On Start-Up, But Only Lasting Few Seconds - Symptom Diagnostic Table

Fig. 23: Upper Engine Noise, Regardless Of Engine Speed - Symptom Diagnostic Table (1 Of 2)
Fig. 24: Upper Engine Noise, Regardless Of Engine Speed - Symptom Diagnostic Table (2 Of 2)

Fig. 25: Lower Engine Noise, Regardless Of Engine Speed - Symptom Diagnostic Table (1 Of 2)
Fig. 26: Lower Engine Noise, Regardless Of Engine Speed - Symptom Diagnostic Table (2 Of 2)

Fig. 27: Engine Noise Under Load - Symptom Diagnostic Table
Fig. 28: Engine Will Not Crank - Crankshaft Will Not Rotate - Symptom Diagnostic Table (1 Of 2)
Fig. 29: Engine Will Not Crank - Crankshaft Will Not Rotate - Symptom Diagnostic Table (2 Of 2)
COOLANT IN COMBUSTION CHAMBER
Fig. 30: Coolant In Combustion Chamber - Symptom Diagnostic Table

COOLANT IN ENGINE OIL

Fig. 31: Coolant In Engine Oil - Symptom Diagnostic Table
A compression pressure test of the engine cylinders determines the condition of the rings, the valves, and the
head gasket.
Important: Remove the Powertrain Control Module (PCM) and the ignition fuses from the I/P fuse block.
Refer to ELECTRICAL CENTER IDENTIFICATION VIEWS .
1. Disable the ignition.

2. Disable the fuel systems.
3. Remove the spark plugs from all the cylinders.
4. Remove the air duct from the throttle body.
5. Block the throttle plate in the open position.
6. Measure the engine compression, using the following procedure:
6.1. Firmly install the compression gauge to the spark plug hole.
6.2. Have an assistant crank the engine through at least 4 compression strokes in the testing
cylinder.
6.3. Record the readings on the gauge at each stroke.
6.4. Disconnect the gauge.
6.5. Repeat the compression test for each cylinder.
7. Record the compression readings from all of the cylinders.
The lowest reading should not be less than 70 percent of the highest reading.
No cylinder reading should be less than 689kPa (100 psi).
8. The following list contains examples of the possible measurements:
When the compression measurement is normal, the compression builds up quickly and evenly to
the specified compression on each cylinder.
When the compression is low on the first stroke and tends to build up on the following strokes, but
does not reach the normal compression, the piston rings may be the cause.
If the compression improves considerably with the addition of three squirts of oil, the piston rings
may be the cause.
When the compression is low on the first stroke and does not build up in the following strokes, the
valves may be the cause.
The addition of oil does not affect the compression, the valves may be the cause.
When the compression is low on two adjacent cylinders, or coolant is present in the crankcase, the
head gasket may be the cause.
9. Remove the block from the throttle plate.
10. Install the air duct to the throttle body.
11. Install the spark plugs.
12. Install the Powertrain Control Module (PCM) fuse.
13. Install the ignition fuse to the I/P fuse block.
CYLINDER LEAKAGE TEST
Testing Procedure
Tools Required
J 35667-A Cylinder Head Leakdown Tester With the use of air pressure, a cylinder leakage test will aid in the
diagnosis. Use the cylinder leakage test in conjunction with the engine compression test in order to isolate the
cause of leaking cylinders.

2. Remove the spark plugs. Refer to SPARK PLUGS .
3. Install the J 35667-A.
4. Measure each cylinder on the compression stroke, with both valves closed.
Important: Hold the crankshaft balancer bolt in order to prevent piston movement.
5. Apply air pressure, using the J 35667-A. Refer to the manufacturer's instructions.
6. Record the cylinder leakage readings for each cylinder.
Important:
Normal cylinder leakage is from 12 to 18 percent.

Make a note of any cylinder with more leakage than the other cylinders.
Any cylinder with 30 percent leakage or more requires service.
7. Inspect the 4 primary areas in order to properly diagnose a leaking cylinder.

8. If air is heard from the intake or exhaust system, perform the following procedure:
Remove the valve rocker arm cover of the suspect cylinder head.
Ensure that both valves are closed.
Inspect the cylinder head for a broken valve spring.
Remove and inspect the suspect cylinder head. Refer to CYLINDER HEAD CLEANING AND
INSPECTION .
9. If air is heard from the crankcase system at the crankcase oil filler tube, perform the following procedure:
9.1. Remove the piston from the suspect cylinder.
9.2. Inspect the piston and connecting rod assembly. Refer to PISTON, CONNECTING ROD,
AND BEARINGS CLEANING AND INSPECTION .
9.3. Inspect the engine block. Refer to ENGINE BLOCK CLEANING AND INSPECTION .
10. If bubbles are found in the radiator, perform the following procedure:
Remove and inspect both cylinder heads. Refer to CYLINDER HEAD CLEANING AND
INSPECTION .
Inspect the engine block. Refer to ENGINE BLOCK CLEANING AND INSPECTION .
11. Remove the J 35667-A.

12. Install the spark plugs. Refer to SPARK PLUGS .
13. Connect the negative battery cable.
An engine that has excessive oil consumption uses 0.9 L (1 qt) of oil, or more, within 3,200 km (2,000 mi). The
following list indicates the conditions and corrections of excessive oil consumption:
An improperly read oil level indicator dipstick
Inspect the oil level while the vehicle is parked on a level surface.
Allow adequate drain-down time.
Improper oil viscosity
Use the recommended SAE viscosity for prevailing temperatures.
Continuous high-speed driving

Severe hauling, such as a trailer. This causes decreased oil mileage.
A malfunctioning crankcase ventilation system
External oil leaks
Tighten the bolts, as needed.
Replace the gaskets and seals, as needed.
Worn or omitted valve guides and/or valve stem seals
Ream the guides.

Install oversized service valves and/or new valve stem seals.
Broken or worn piston rings

Improperly installed or unseated piston rings
Improperly installed or improperly fitted piston
Plugged cylinder head gasket oil drain holes
Damaged intake gaskets
Low or No Oil Pressure
The following conditions may cause low or no oil pressure:
Low oil level Fill to the full mark on the oil level indicator.
Incorrect or malfunctioning oil pressure switch Replace the oil pressure switch.
Incorrect or malfunctioning oil pressure gage Replace the oil pressure gage.
Improper oil viscosity or diluted oil
Install oil of proper viscosity for expected temperature.

Install new oil if the oil is diluted.
A worn or dirty oil pump Clean or replace the oil pump.

A plugged oil filter Replace the oil filter.
A loose or plugged oil pickup screen Replace the oil pickup screen.
A hole in the oil pickup tube Replace the oil pickup tube.
Excessive bearing clearance Replace the bearings.
Cracked, porous, or plugged oil gallery Repair or replace the engine block.
Missing or improperly installed gallery plugs Install or repair the plugs as needed.
A stuck pressure regulator valve
Inspect the pressure regulator valve for sticking in the bore.

Inspect the bore for scoring and burrs.
A worn or poorly machined camshaft Replace the camshaft.

Worn valve guides Repair the valve guides as needed.
Oil Pressure Testing
Tools Required
J 25087-C Oil Pressure Tester
If the vehicle has low oil pressure complete the following steps:
1. Inspect the oil level.

2. Raise and support the vehicle. Refer to OIL PRESSURE DIAGNOSIS AND TESTING in General
Information.
3. Remove the oil filter.
4. Assemble the plunger valve in the large hole of the J 25087-C base. Insert the hose in the small hole of
the J 25087-C base. Connect the gage to the end of the hose.
5. Insert the flat side of the rubber plug in the bypass valve without depressing the bypass valve.
6. Install the J 25087-C on the filter mounting pad.
8. Inspect the overall oil pressure, the oil pressure switch, and for noisy lifters. Ensure that the engine is at
operating temperature before inspecting the oil pressure. The oil pressure should be approximately 414
kPa (60 psi) at 1,850 RPM using 5W-30 engine oil.
9. If adequate oil pressure is indicated, test the oil pressure switch.
10. If a low reading is indicated, press the valve on the tester base in order to isolate the oil pump and/or its
components from the lubricating system. An adequate reading at this time indicates a good pump and the
previous low pressure was due to worn bearings, etc. A low reading while pressing the valve indicates a
faulty pump.
OIL LEAK DIAGNOSIS
Tools Required
J 28428-E High Intensity Black Light Kit
You may repair most fluid leaks by first visually locating the leak, repairing or replacing the component, or by
resealing the gasket surface. Once the leak is identified, determine the cause of the leak. Repair the leak and the
cause of leak.
Locating and Identifying the Leak
Use the visual inspection method in order to determine if the leaking fluid is one of the following items:
Engine oil
Transmission fluid
Power steering fluid
Brake fluid
Some other fluid
Visual Inspection Method
Complete the following steps in order to perform the visual inspection method:
1. Bring the vehicle to normal operating temperature.

2. Park the vehicle over a large sheet of paper, or other clean surface.
3. Wait several minutes, then inspect for dripping fluids.
4. Identify the type of fluid, and the approximate location of the leak.
5. Visually inspect the suspected area. Use a small mirror if necessary.
6. Inspect for leaks at sealing surfaces, fittings, or from cracked or damaged components.
7. If you cannot locate the leak, perform the following steps:
7.1. Completely clean the entire engine and surrounding components.
7.2. Operate the vehicle for several miles at normal operation temperature and at varying speeds.
7.3. Park the vehicle over a large sheet of paper, or other clean surface.
7.4. Wait several minutes, then inspect for dripping fluids.
7.5. Identify the type of fluid, and the approximate location of the leak.
7.6. Visually inspect the suspected area. Use a small mirror if necessary.
8. If you still cannot locate the leak, use the powder method or the black light and dye method.
Powder Method
1. Completely clean the entire engine and surrounding components.

2. Apply an aerosol-type powder, baby powder, foot powder, etc., to the suspected area.
3. Operate the vehicle for several miles at normal operation temperature and at varying speeds.
4. Identify the type of fluid, and the approximate location of the leak, from the discolorations in the powder
surface.
5. Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see areas.
Black Light and Dye Method
A dye and light kit is available for finding leaks.
1. Use the J 28428-E or the equivalent. Refer to the manufacturer's instructions when using the tool.
2. Visually inspect the suspected area. Use a small mirror if necessary
Possible Causes for Leaks
Inspect the vehicle for the following conditions:

Higher than recommended fluid levels
Higher than recommended fluid pressures
Plugged or malfunctioning fluid filters or pressure bypass valves
Plugged or malfunctioning engine ventilation system
Improperly tightened or damaged fasteners
Cracked or porous components
Improper sealants or gaskets where required
Improper sealant or gasket installation
Damaged or worn gaskets or seals
Damaged or worn sealing surfaces
CRANKCASE VENTILATION SYSTEM INSPECTION/DIAGNOSIS
1. Disconnect the PCV hose.

3. Check for vacuum at the hose. If there is no vacuum, check for a plugged hose or manifold port. Check
for a hose that collapses when blocked (vacuum applied). Replace the plugged or the deteriorated hoses.
4. Allow the engine to idle at normal operating temperature.
5. Remove the engine oil dipstick and install a vacuum gage on the dipstick tube.
6. Block off the PCV system fresh air intake passage.
7. Run the engine at 1500 RPM for 30 seconds, then read vacuum gage while engine is running at 1500
RPM.
8. If vacuum is present, this indicates that the crankcase ventilation system is functioning properly.
9. If no vacuum is indicated, the engine may not be sealed and is drawing in outside air.
Check the valve covers, the oil pan gasket or other sealing areas for leaks.
If the vacuum gage registers a pressure, or if a vacuum gage is pushed out of dipstick tube, check for a
plugged PCV port, a plugged hose or an excessive engine blow-by.
Diagnostic Aids
The symptom may be intermittent due to moisture on the drive belt (s) or the pulleys. It may be necessary to
spray a small amount of water on the drive belt (s) in order to duplicate the customers concern. If spraying
water on the drive belt (s) duplicates the symptom, cleaning the belt pulleys may be the probable solution.
A loose or improper installation of a body component, a suspension component, or other items of the vehicle
may cause the chirping noise.
Test Description
The number (s) below refer to the step number (s) on the diagnostic table.
2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the
engine is not making the noise do not proceed further with this table.
3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief
period will verify the noise is related to the drive belt. When removing the drive belt (s) the water pump
may not be operating and the engine may overheat. Also DTCs may set when the engine is operating with
the drive belt removed.
4. Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it may be strings in the
drive belt grooves from the accumulation of rubber dust.
6. Misalignment of the pulleys may be caused from improper mounting of the accessory drive
component, incorrect installation of the accessory drive component pulley, or the pulley bent inward or
outward from a previous repair. Test for a misaligned pulley using a straight edge in the pulley grooves
across two or three pulleys. If a misaligned pulley is found refer to that accessory drive component for the
proper installation procedure for that pulley.
10. Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or washer was
installed.
12. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the
pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the
smooth surface of a pulley when the back side of the belt is used to drive the pulley.
14. Replacing the drive belt when it is not damaged or there is not excessive pilling will only be a
temporary repair.

Fig. 32: Drive Belt Chirping Diagnosis
Diagnostic Aids
A loose or improper installation of a body component, a suspension component, or other items of the vehicle
may cause the squeal noise.
If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are
operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose
or wrong fluid, or a generator failing are suggested items to inspect.
Test Description
2. The noise may not be engine related. This step is to verify that the engine is making the noise. If the
engine is not making the noise do not proceed further with this table
3. The noise may be an internal engine noise. Removing the drive belt and operating the engine for a brief
period will verify the squeal noise is the drive belt (s) or an accessory drive component. When removing
the drive belt the water pump may not be operating and the engine may overheat. Also DTCs may set
when the engine is operating with the drive belt removed.
4. This test is to verify that an accessory drive component does not have a seized bearing. With the belt
remove test the bearings in the accessory drive components for turning smoothly. Also test the accessory
drive components with the engine operating by varying the load on the components to verify that the
components operate properly.
5. This test is to verify that the drive belt tensioner operates properly. If the drive belt tensioner is not
operating properly, proper belt tension may not be achieved to keep the drive belt from slipping which
could cause a squeal noise.
6. This test is to verify that the drive belt (s) is not too long, which would prevent the drive belt tensioner
from working properly. Also if an incorrect length drive belt was installed, it may not be routed properly
and may be turning an accessory drive component in the wrong direction.
proper installation procedure for that pulley.
8. This test is to verify that the pulleys are the correct diameter or width. Using a known good vehicle
compare the pulley sizes.
Fig. 33: Drive Belt Squeal Diagnosis
Diagnostic Aids
The drive belt (s) will not cause the whine noise. If the whine noise is intermittent, verify the accessory drive
components by varying their loads making sure they are operated to their maximum capacity. Such items but
not limited to may be an A/C system overcharged, the power steering system restricted or the wrong fluid, or
the generator failing.
Test Description
3. This test is to verify that the noise is being caused by the drive belt (s) or the accessory drive
components. When removing the drive belt the water pump may not be operating and the engine may
overheat. Also DTCs may set when the engine is operating with the drive belt removed.
4. The inspection should include checking the drive belt tensioner and the drive belt idler pulley bearings.
The drive belt (s) may have to be installed and the accessory drive components operated separately by
varying their loads. Refer to the suspected accessory drive component for the proper inspection and
replacement procedure.
Fig. 34: Drive Belt Whine Diagnosis

Diagnostic Aids
Vibration from the engine operating may cause a body component or another part of the vehicle to make
rumbling noise.
The drive belt (s) may have a condition that can not be seen or felt. Sometimes replacing the drive belt may be
the only repair for the symptom.
If replacing the drive belt (s), completing the diagnostic table, and the noise is only heard when the drive belt (s)
is installed, there might be an accessory drive component with a failure. Varying the load on the different
accessory drive components may aid in identifying which component is causing the rumbling noise.
Test Description
The number (s) below refer to the step number (s) on the diagnostic table
2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may
cause a similar symptom.
3. This test is to verify that the drive belt (s) is causing the rumbling noise. Rumbling noise may be
confused with an internal engine noise due to the similarity in the description. Remove only one drive
belt at a time if the vehicle has multiple drive belts. When removing the drive belt the water pump may
not be operating and the engine may overheat. Also DTCs may set when the engine is operating with the
drive belt removed.
4. Inspecting the drive belt (s) is to ensure that it is not causing a the noise. Small cracks across the ribs of
the drive belt will not cause the noise. Belt separation is identified by the plys of the belt separating and
may be seen at the edge of the belt our felt as a lump in the belt.
5. Small amounts of pilling is normal condition and acceptable. When the pilling is severe the drive belt
does not have a smooth surface for proper operation.
Fig. 35: Drive Belt Rumbling Diagnosis
Diagnostic Aids
The accessory drive components can have an affect on engine vibration. Such as but not limited to the A/C
system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the
generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive
components.
Test Description
2. This test is to verify that the symptom is present during diagnosing. Other vehicle components may
cause a similar symptom such as the exhaust system, or the drivetrain.
3. This test is to verify that the drive belt (s) or accessory drive components may be causing the vibration.
When removing the drive belt the water pump may not be operating and the engine may overheat. Also
DTCs may set when the engine is operating with the drive belt removed.
4. The drive belt (s) may cause a vibration. While the drive belt (s) is removed this is the best time to
inspect the condition of the belt.
installed.
8. This step should only be performed if the water pump is driven by the drive belt. Inspect the water
pump shaft for being bent. Also inspect the water pump bearings for smoothness and excessive play.
Compare the water pump with a known good water pump.
9. Accessory drive component brackets that are bent, cracked, or loose may put extra strain on that
accessory component causing it to vibrate.
Fig. 36: Drive Belt Vibration Diagnosis

Diagnostic Aids
If the drive belt (s) repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.
An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to
fall off the pulleys. Verify the accessory drive components operate properly.
If the drive belt (s) is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive
belt.
Test Description
2. This inspection is to verify the condition of the drive belt. Damage may of occurred to the drive belt
when the drive belt fell off. The drive belt may of been damaged, which caused the drive belt to fall off.
Inspect the belt for cuts, tears, sections of ribs missing, or damaged belt plys.
proper installation procedure of that pulley.
5. Inspecting the pulleys for being bent should include inspecting for a dent or other damage to the
pulleys that would prevent the drive belt from not seating properly in all of the pulley grooves or on the
smooth surface of a pulley when the back side of the belt is used to drive the pulley.
6. Accessory drive component brackets that are bent or cracked may will let the drive belt fall off.
installed. Missing, loose, or the wrong fasteners may cause pulley misalignment from the bracket moving
under load. Over tightening of the fasteners may cause misalignment of the accessory component bracket.
Fig. 37: Drive Belt Falls Off Diagnosis
Diagnostic Aids
Excessive wear on a drive belt (s) is usually caused by an incorrect installation or the wrong drive belt for the
application.
Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive
belt (s) to make a noise or to fall off.
Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt (s)
fall off.
Test Description
2. The inspection is to verify the drive belt (s) is correctly installed on all of the drive belt pulleys. Wear
on the drive belt (s) may be caused by mis-positioning the drive belt (s) by one groove on a pulley.
3. The installation of a drive belt that is two wide or two narrow will cause wear on the drive belt.
The drive belt ribs should match all of the grooves on all of the pulleys.
4. This inspection is to verify the drive belt (s) is not contacting any parts of the engine or body while the
engine is operating. There should be sufficient clearance when the drive belt accessory drive components
load varies. The drive belt (s) should not come in contact with an engine or a body component when
snapping the throttle.
Fig. 38: Drive Belt Excessive Wear Diagnosis


Fig. 39: Drive Belt Tensioner Diagnosis
REPAIR INSTRUCTIONS
DRIVE BELT REPLACEMENT
Removal Procedure
1. Rotate the drive belt tensioner in order to release the pressure on the drive belt.
2. Remove the drive belt.
Fig. 40: Removing Drive Belt
1. Install the drive belt to all of the pulleys except the generator pulley.
2. Rotate the drive belt tensioner in order to install the drive belt over the generator pulley.
Fig. 41: Installing Drive Belt
Important: Ensure that the drive belt is aligned into the proper grooves of the accessory drive belt
pulleys.
3. Ensure that the drive belt is properly routed.

Fig. 42: Identifying Drive Belt Proper Aligning Position
DRIVE BELT TENSIONER REPLACEMENT
Removal Procedure
1. Remove the drive belt. Refer to DRIVE BELT REPLACEMENT .

2. Remove the drive belt tensioner bolt.
3. Remove the drive belt tensioner.
Fig. 43: Removing Drive Belt Tensioner
1. Install the drive belt tensioner.

2. Install the drive belt tensioner bolt.
Tighten
Tighten the bolt to 50 N.m (37 lb ft).
3. Install the drive belt. Refer to DRIVE BELT REPLACEMENT .
Fig. 44: Installing Drive Belt Tensioner

DRIVE BELT IDLER PULLEY REPLACEMENT - UPPER
Removal Procedure
2. Remove the drive belt idler pulley bolt.
3. Remove the drive belt idler pulley.
Fig. 45: Removing Drive Belt Upper Idler Pulley

1. Install the drive belt idler pulley.
2. Install the drive belt idler pulley bolt.
Tighten
Tighten the drive belt idler pulley bolt to 50 N.m (37 lb ft).

Fig. 46: Installing Drive Belt Upper Idler Pulley
ENGINE MOUNT INSPECTION
NOTE: In order to avoid oil pan damage and possible engine failure, insert a block of
wood that spans the width of the oil pan bottom between the oil pan and the
jack support.
Important: Before replacing any engine mount due to suspected fluid loss, verify that the source of the fluid is
the engine mount, not the engine or accessories.
1. Raise the engine in order to remove the weight from the engine mount and create slight tension in the
rubber.
2. Observe the engine mount while raising the engine. Replace the engine mount if the engine mount
exhibits any of the following conditions:
The hard rubber surface is covered with heat check cracks.
The rubber is separated from the metal plate of the engine mount.
The rubber is split through the center of the engine mount.
3. If there is movement between the metal plate of the engine mount and its attaching points, lower the
engine on the engine mount. Tighten the bolts or nuts attaching the engine mount to the frame or engine
mount bracket. Refer to ENGINE MOUNT BRACKET REPLACEMENT (FWD) or ENGINE
MOUNT BRACKET REPLACEMENT (AWD) .
ENGINE SUPPORT FIXTURE
Tools Required
J 28467-34 Lift Hook Wing Nut & Washer (2)

J 28467-6A Bracket Assembly (2)
J 28467-7A Bolt Hook (2)
J 28467-500 Engine Support Fixture
J 45057 Engine Support Bar Assembly
J 45057-2 Lower Support Bar
J 28467-B Side Rail Support Bracket
1. Remove the right engine mount strut. Refer to ENGINE MOUNT STRUT REPLACEMENT -
RIGHT .
2. Install the J 45057 to the right engine mount strut bracket (1).
Fig. 47: Installing Engine Support Bar Assembly (J 45057) To Right Engine Mount Strut Bracket
3. Install the J 45057 to the left side engine lift bracket.

Fig. 48: Installing Engine Support Bar Assembly (J 45057) To Left Side Engine Lift Bracket
4. Install the J 45057 to the right rear engine lift bracket.

5. For Buick vehicles, remove the headlamps. Refer to HEADLAMP ASSEMBLY OR HEADLAMP
BULB REPLACEMENT (AZTEK) or HEADLAMP ASSEMBLY OR HEADLAMP BULB
REPLACEMENT (RENDEZVOUS) .
6. Disconnect the hood strut assist rods from the fenders.
7. Carefully open and secure the hood in 90 degree position.
Fig. 49: Installing Engine Support Bar Assembly (J 45057) To Right Rear Engine Lift Bracket
8. Install the J 28467-B.

Fig. 50: Installing Side Rail Support Bracket (J 28467-B)
9. Install the J 28467-7A (1) and the J 28467-34 to the J 28467-500 and the rear hole on the right side of
the J 45057 (2).
Fig. 51: Installing Bolt Hook (J 28467-7A) To Engine Support Fixture (J 28467-500) And Rear Hole
On Right Side Of Engine Support Bar Assembly
10. Install the J 28467-7A (1) and the J 28467-34 to the J 28467-500 and the left side of the J 45057 (2).
11. Gently tighten the J 28467-34 lift hook wing nuts.
12. Raise the vehicle.
13. Remove the lower air baffle. Refer to RADIATOR AIR BAFFLE ASSEMBLIES AND
DEFLECTORS .
14. Remove the engine mount left bolt.
Fig. 52: Installing Bolt Hook (J 28467-7A) To Engine Support Fixture (J 28467-500) And Left Side
Of Engine Support Bar Assembly
15. Install the J 45057-2 to the radiator core support.

16. Use the engine mount bolt to install the J 45057-2 to the engine.
Fig. 53: Installing Lower Support Bar (J 45057-2) To Radiator Core Support
17. Ensure that the J 45057-2 is assembled properly and hand tighten the fasteners.
Fig. 54: Identifying Lower Support Bar (J 45057-2) Correct Assembling Position
ENGINE MOUNT REPLACEMENT
Removal Procedure
1. Disconnect the battery ground (negative) cable.

2. Remove the throttle body air inlet duct.
3. Remove the engine mount struts. Refer to ENGINE MOUNT STRUT REPLACEMENT - LEFT or
ENGINE MOUNT STRUT REPLACEMENT - RIGHT .
5. Remove the three-way catalytic converter pipe from the engine right side exhaust manifold.
Fig. 55: Removing Engine Mount Lower Nuts
6. Remove the right front wheel and tire.

7. Remove the right engine splash shield. Refer to SPLASH SHIELD REPLACEMENT -- ENGINE .
8. Remove the engine mount lower nuts.
NOTE: In order to avoid oil pan damage and possible engine failure, insert a block
of wood that spans the width of the oil pan bottom between the oil pan and
the jack support.
9. Use a utility stand and a block of wood in order to raise the engine.
10. Remove the engine mount bracket-to-oil pan bolts.
11. Remove the engine mount and the engine mount bracket.
Fig. 56: Removing Engine Mount And Engine Mount Bracket
12. Remove the engine mount upper nuts.

13. Remove the engine mount from the engine mount bracket.
Fig. 57: Removing Engine Mount From Engine Mount Bracket

1. Install the engine mount to the engine mount bracket.

2. Install the engine mount upper nuts.
Tighten
Tighten the engine mount upper nuts to 53 N.m (39 lb ft).

Fig. 58: Installing Engine Mount To Engine Mount Bracket
3. Install the engine mount bracket with the engine mount to the oil pan.
4. Install the engine mount bracket-to-oil pan bolts.
Tighten
Tighten the engine mount bracket bolts to 58 N.m (43 lb ft).
5. Use the utility stand in order to lower the engine.

Fig. 59: Installing Engine Mount Bracket With Engine Mount
6. Install the engine mount lower nuts.

Tighten
Tighten the engine mount lower nuts to 47 N.m (35 lb ft).
7. Install the right engine splash shield. Refer to SPLASH SHIELD REPLACEMENT -- ENGINE .
8. Install the right front wheel and tire.
9. Connect the three-way catalytic converter pipe to the engine right side exhaust manifold.
11. Install the engine mount struts. Refer to ENGINE MOUNT STRUT REPLACEMENT - LEFT and
12. Install the throttle body air inlet duct.
13. Connect the battery ground (negative) cable.
Fig. 60: Installing Engine Mount Lower Nuts

ENGINE MOUNT BRACKET REPLACEMENT (FWD)
Removal Procedure

2. Remove the engine mount struts. Refer to ENGINE MOUNT STRUT REPLACEMENT - LEFT and
4. Remove the catalytic converter pipe from the engine right side exhaust manifold.
7. Remove the engine mount bracket-to-oil pan bolts.
the jack support.
8. Insert a block of wood between the utility stand and the oil pan.
9. Use the utility stand in order to raise the oil pan.
Fig. 61: Removing Engine Mount Bracket - FWD

11. Remove the engine mount bracket from the engine mount.
Fig. 62: Removing Engine Mount Bracket From Engine Mount - FWD
1. Install the engine mount bracket to the engine mount.

Tighten
3. Use a utility stand in order to lower the engine.

Fig. 63: Installing Engine Mount Bracket To Engine Mount - FWD
4. Install the engine mount bracket to the oil pan.

Tighten
Tighten the engine mount bracket bolts to 58 N.m (43 lb ft).
8. Connect the catalytic converter pipe to the engine right side exhaust manifold.
Fig. 64: Installing Engine Mount Bracket - FWD
ENGINE MOUNT BRACKET REPLACEMENT (AWD)
Removal Procedure

4. Remove the catalytic converter pipe from the engine right side exhaust manifold.
7. Remove the engine mount bracket-to-oil pan bolts (1).
the jack support.
8. Insert a block of wood between the utility stand and the oil pan.
9. Use the utility stand in order to raise the oil pan.
Fig. 65: Removing Engine Mount Bracket-To-Oil Pan Bolts - AWD

Fig. 66: Removing Engine Mount Bracket From Engine Mount - AWD
Tighten
3. Use a utility stand in order to lower the engine.

Fig. 67: Installing Engine Mount Bracket To Engine Mount - AWD
4. Install the engine mount bracket to the oil pan.

Tighten
Tighten the engine mount bracket to oil pan bolts (1) to 58 N.m (43 lb ft).
Tighten the upper bracket to engine block bolt (2) to 85 N.m (63 lb ft).
8. Connect the catalytic converter pipe to the engine right side exhaust manifold.
Fig. 68: Installing Engine Mount Bracket-To-Oil Pan Bolts - AWD
ENGINE MOUNT STRUT REPLACEMENT - LEFT
Removal Procedure
1. Remove the bolt and the nut from the engine mount strut at the left engine mount strut bracket on the
engine.
Fig. 69: Removing Bolt And Nut From Engine Mount Strut At Left Engine Mount Strut Bracket
On Engine
2. Remove the bolt and the nut from the engine mount strut at the engine mount strut bracket on the upper
radiator support.
3. Remove the engine mount strut.
4. Inspect the rubber in the engine mount strut for the following conditions:
Hardness
Splitting
Cracking
Fig. 70: Removing Engine Mount Strut - Left
1. Install the engine mount strut.
2. Install the bolt and the nut to the engine mount strut at the engine mount strut bracket on the upper
radiator support.
Tighten
Tighten the engine mount strut bolt to 48 N.m (35 lb ft).

Fig. 71: Installing Engine Mount Strut - Left
3. Install the bolt and the nut to the engine mount strut at the left engine mount strut bracket on the engine.
Tighten
Tighten the engine mount strut nut to 48 N.m (35 lb ft).
Fig. 72: Installing Bolt And Nut To Engine Mount Strut At Left Engine Mount Strut Bracket On
Engine
ENGINE MOUNT STRUT REPLACEMENT - RIGHT

Removal Procedure
1. Remove the bolt and the nut from the engine mount strut at the right engine mount strut bracket on the
engine.
Fig. 73: Removing Bolt And Nut From Engine Mount Strut At Right Engine Mount Strut Bracket
On Engine
2. Remove the bolt and the nut from the engine mount strut at the engine mount strut bracket on the upper
radiator support.
Hardness
Splitting
Cracking
Fig. 74: Removing Engine Mount Strut - Right
2. Install the bolt and the nut to the engine mount strut at the engine mount strut bracket on the upper
radiator support.
Tighten
Tighten the engine mount strut bolt to 48 N.m (35 lb ft).

Fig. 75: Installing Engine Mount Strut - Right
3. Install the bolt and the nut to the engine mount strut at the right engine mount strut bracket on the engine.
Tighten
Tighten the engine mount strut nut to 48 N.m (35 lb ft).
Fig. 76: Installing Bolt And Nut To Engine Mount Strut At Right Engine Mount Strut Bracket On
Engine
ENGINE MOUNT STRUT BRACKET REPLACEMENT - LEFT
Removal Procedure
1. Remove the left engine mount strut from the left engine mount strut bracket. Refer to ENGINE MOUNT
STRUT REPLACEMENT - LEFT .
2. Remove the thermostat housing.
Fig. 77: Removing Left Engine Mount Strut From Left Engine Mount Strut Bracket
3. Remove the engine mount strut bracket bolts from the left engine mount strut bracket to the cylinder
head.
4. Remove the left engine mount strut bracket.
Fig. 78: Removing Left Engine Mount Strut Bracket
1. Install the left engine mount strut bracket.

2. Install the engine mount strut bracket bolts through the engine mount strut bracket to the cylinder head.
Tighten
Tighten the engine mount strut bracket bolts to 70 N.m (52 lb ft).
3. Install the thermostat housing.

Fig. 79: Installing Left Engine Mount Strut Bracket
4. Install the left engine mount strut to the left engine mount strut bracket. Refer to ENGINE MOUNT
STRUT REPLACEMENT - LEFT .
Fig. 80: Installing Left Engine Mount Strut To Left Engine Mount Strut Bracket
ENGINE MOUNT STRUT BRACKET REPLACEMENT - RIGHT
Removal Procedure
1. Remove the right engine mount strut from the right engine mount strut bracket. Refer to ENGINE
MOUNT STRUT REPLACEMENT - RIGHT .
Fig. 81: Removing Right Engine Mount Strut From Right Engine Mount Strut Bracket
2. Remove the engine oil cooler line bracket bolt, if equipped. Refer to OIL COOLER INLET LINE
REPLACEMENT .
4. Remove the lower radiator baffle. Refer to RADIATOR AIR BAFFLE ASSEMBLIES AND
DEFLECTORS .
5. Remove the lower engine mount strut bracket bolt from the right engine mount strut bracket.
Fig. 82: Removing Lower Engine Mount Strut Bracket Bolt
6. Remove the air conditioning compressor mounting bolts. Refer to COMPRESSOR REPLACEMENT .
7. Remove and set the air conditioning compressor aside.
Fig. 83: Removing A/C Compressor

9. Remove the vertical engine mount strut bracket bolt from the right engine mount strut bracket.
10. Remove the right engine mount strut bracket.
Fig. 84: Removing Right Engine Mount Strut Bracket
1. Position the right engine mount strut bracket over the pin locator.
2. Install the vertical engine mount strut bracket bolt through the right engine mount strut bracket to the
cylinder head.
Tighten
Tighten the engine mount strut bracket bolt to 50 N.m (37 lb ft).
Fig. 85: Installing Right Engine Mount Strut Bracket

4. Install the engine mount strut bracket lower bolt through the right engine mount strut bracket into the
cylinder block.
Tighten
Tighten the engine mount strut bracket bolt to 50 N.m (37 lb ft).
5. Install the air conditioning compressor. Refer to COMPRESSOR REPLACEMENT .

6. Install the lower radiator baffle. Refer to RADIATOR AIR BAFFLE ASSEMBLIES AND
DEFLECTORS .
8. Install the engine oil cooler line bracket bolt, if equipped. Refer to OIL COOLER INLET LINE
REPLACEMENT .
Fig. 86: Installing Engine Mount Strut Bracket Lower Bolt

9. Install the right engine mount strut to the right engine mount strut bracket. Refer to ENGINE MOUNT
STRUT REPLACEMENT - RIGHT .
Fig. 87: Installing Right Engine Mount Strut To Right Engine Mount Strut Bracket
ENGINE MOUNT STRUT BRACKET REPLACEMENT- UPPER RADIATOR SUPPORT
Removal Procedure
1. Remove the engine mount strut from the engine mount strut bracket at the upper radiator support.
Refer to ENGINE MOUNT STRUT REPLACEMENT - LEFT and/or ENGINE MOUNT STRUT
REPLACEMENT - RIGHT .
Fig. 88: Removing Engine Mount Strut From Engine Mount Strut Bracket At Upper Radiator
Support
2. Remove the engine mount strut bracket bolts from the engine mount strut bracket.
3. Remove the engine mount strut bracket from the upper radiator support.
Fig. 89: Removing Engine Mount Strut Bracket From Upper Radiator Support
1. Position the engine mount strut bracket over the upper radiator support. Ensure that the engine mount
strut bracket and the engine mount strut are aligned to the proper holes of the upper radiator support.
2. Install the engine mount strut bracket bolts to the engine mount strut bracket.
Tighten
Tighten the engine mount strut bracket bolts to 26 N.m (19 lb ft).
Fig. 90: Installing Engine Mount Strut Bracket From Upper Radiator Support
3. Install the engine mount strut to the engine mount strut bracket at the upper radiator support. Refer to
ENGINE MOUNT STRUT REPLACEMENT - LEFT and/or ENGINE MOUNT STRUT
Fig. 91: Installing Engine Mount Strut To Engine Mount Strut Bracket At Upper Radiator Support
OIL COOLER REPLACEMENT

Removal Procedure
1. Drain the engine coolant from the engine cooling system. Refer to DRAINING AND FILLING
COOLING SYSTEM .
3. Disconnect the knock sensor electrical connector.
4. Remove the oil filter. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT .
Fig. 92: Removing Oil Filter

5. Remove the oil cooler outlet hose from the oil cooler. Position the outlet hose aside.
Fig. 93: Removing Oil Cooler Outlet Hose From Oil Cooler
6. Remove the oil cooler connector.

Fig. 94: Removing Oil Cooler Connector
7. Remove the oil cooler inlet hose clamp and the oil cooler.
8. Clean and inspect the engine block mating surface.
Fig. 95: Removing Oil Cooler
1. Install the oil cooler and the oil cooler inlet hose clamp. Ensure that the oil cooler seal is in place.
Coat the seal with engine oil.

Fig. 96: Installing Oil Cooler
2. Install the oil cooler connector
Tighten
Tighten the oil cooler connector to 50 N.m (37 lb ft).

Fig. 97: Installing Oil Cooler Connector
3. Connect the oil cooler outlet hose to the oil cooler.

Fig. 98: Connecting Oil Cooler Outlet Hose To Oil Cooler
4. Install the oil filter. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT .
5. Connect the knock sensor electrical connector.
7. Fill the engine cooling system with engine coolant.
Refer to DRAINING AND FILLING COOLING SYSTEM .
8. Add engine oil as necessary. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT .
9. Inspect the oil cooler for leaks.
Fig. 99: Installing Oil Filter
OIL COOLER INLET LINE REPLACEMENT
Removal Procedure
1. Drain the engine coolant from the cooling system.

3. Disconnect the knock sensor electrical connector.
4. Remove the oil filter. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT .

5. Disconnect the oil cooler outlet hose from the oil cooler.
Fig. 101: Disconnecting Oil Cooler Outlet Hose From Oil Cooler

7. Remove the oil cooler inlet hose clamp and the oil cooler.
Fig. 103: Removing Oil Cooler
8. Remove the oil cooler inlet hose clamp and oil cooler inlet hose from the oil cooler hose fitting.
Fig. 104: Removing Oil Cooler Inlet Hose
9. If necessary, remove the oil cooler hose fitting.

Fig. 105: Removing Oil Cooler Hose Fitting
1. If removed, install the oil cooler hose fitting.
Tighten
Tighten the oil cooler hose fitting to 19 N.m (14 lb ft).

Fig. 106: Installing Oil Cooler Hose Fitting
2. Install the oil cooler inlet hose clamp and oil cooler inlet hose to the oil cooler hose fitting.
Fig. 107: Installing Oil Cooler Inlet Hose
3. Connect the oil cooler inlet hose clamp and the oil cooler. Ensure that the oil cooler seal is in place.
Coat the seal with engine oil.

4. Install the oil cooler connector.
Tighten

5. Connect the oil cooler outlet hose to the oil cooler.

Fig. 110: Connecting Oil Cooler Outlet Hose To Oil Cooler
7. Connect the knock sensor electrical connector.
9. Fill the cooling system with engine coolant. Refer to DRAINING AND FILLING COOLING
SYSTEM .
OIL COOLER OUTLET LINE REPLACEMENT
Removal Procedure
1. Drain the engine coolant from the cooling system.
2. Remove the oil cooler pipe bracket bolt from the oil cooler pipe bracket at the right engine mount strut
bracket.
Fig. 112: Removing Oil Cooler Pipe Bracket Bolt
3. Disconnect the upper oil cooler outlet hose from the thermostat bypass pipe.
5. Disconnect the lower oil cooler outlet hose from the oil cooler.
6. Remove the oil cooler outlet hoses and pipe.
7. Remove the upper and/or lower oil cooler outlet hose (s) from the oil cooler pipe.
Fig. 113: Disconnecting Lower Oil Cooler Outlet Hose From Oil Cooler
1. Install the upper and/or lower oil cooler outlet hose (s) to the oil cooler pipe.
2. Install the oil cooler outlet hoses and pipe.
3. Connect the lower oil cooler outlet hose to the oil cooler.
5. Connect the upper oil cooler outlet hose to the thermostat bypass pipe.
Fig. 114: Connecting Lower Oil Cooler Outlet Hose To Oil Cooler
6. Install the oil cooler pipe bracket bolt through the oil cooler pipe bracket into the right engine mount strut
bracket.
Tighten
Tighten the oil cooler pipe bracket bolt to 10 N.m (89 lb in).
SYSTEM .
Fig. 115: Installing Oil Cooler Pipe Bracket Bolt

OIL FILTER ADAPTER & BYPASS VALVE ASSEMBLY REPLACEMENT
Removal Procedure
1. Drain the engine coolant from the cooling system. Refer to DRAINING AND FILLING COOLING
SYSTEM .
3. Remove the oil filter. Refer to OIL COOLER REPLACEMENT .
4. Remove the oil cooler. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT .
5. Remove oil filter bypass hole plug.
Fig. 116: Removing Oil Filter Bypass Hole Plug
6. Insert a flat-bladed tool into the oil filter bypass hole and force the bypass valve (1 ) out.
Fig. 117: Identifying Bypass Valve And Valve Removal Depth
7. Remove the oil filter bypass valve.

Fig. 118: Removing Oil Filter Bypass Valve
8. If necessary, remove the oil filter adapter.

Fig. 119: Removing Oil Filter Adapter
1. If removed, install the oil filter adapter.
Tighten
Tighten the oil filter adapter to 39 N.m (29 lb ft).

Fig. 120: Installing Oil Filter Adapter
2. Install the oil filter bypass valve.

Fig. 121: Installing Oil Filter Bypass Valve
3. Install the oil filter bypass valve (1) to the proper depth.
Fig. 122: Identifying Oil Filter Bypass Valve Installation Depth
4. Install oil filter bypass hole plug.
Tighten
Tighten the oil filter bypass hole plug to 19 N.m (14 lb ft).
5. Install the oil cooler. Refer to OIL COOLER REPLACEMENT .
8. Add engine oil as necessary. Refer to OIL COOLER REPLACEMENT .
SYSTEM .
Fig. 123: Installing Oil Filter Bypass Hole Plug

OIL LEVEL INDICATOR AND TUBE REPLACEMENT
Removal Procedure
1. Remove the oil level indicator.

2. Remove the oil level indicator tube bolt and tube.
If you are unable to remove the oil level indicator tube, perform the following steps:
2.1. Apply penetrating oil to the bottom of the oil level indicator tube.
2.2. Move the oil level indicator tube back and forth in order to loosen the oil level indicator tube.
Fig. 124: Removing Oil Level Indicator And Tube

1. Clean the oil level indicator tube.
2. Apply GM sealant P/N 12345739 or equivalent around the oil level indicator tube 12.7 mm (0.50 in)
below the bead.
3. Install the oil level indicator tube and bolt.
Tighten
Tighten bolt to 25 N.m (18 lb ft.)
4. Install the oil level indicator.

Fig. 125: Installing Oil Level Indicator And Tube
INTAKE MANIFOLD REPLACEMENT - UPPER
Removal Procedure
Important: The fuel injector wiring harness connectors must be connected to their respective fuel injectors.
Failure to connect the fuel injector connectors to their respective fuel injectors may result in excessive exhaust
emissions and poor engine performance.
1. Drain the engine coolant from the cooling system. Refer to DRAINING AND FILLING COOLING
SYSTEM .
3. Remove the accelerator control and cruise control cables with bracket from the throttle body.
Fig. 126: Identifying Upper Intake Manifold
4. Disconnect the wiring harness connectors from the following throttle body components:
Throttle Position (TP) sensor
Idle Air Control (IAC) valve
5. Disconnect the engine left side spark plug wires. Refer to SPARK PLUG WIRES .
6. Disconnect the engine left side spark plug wire harness attachment clip.
7. Disconnect the throttle body heater hoses. Refer to THROTTLE BODY HEATER HOSE
REPLACEMENT - INLET or THROTTLE BODY HEATER HOSE REPLACEMENT -
OUTLET .
8. Disconnect the vacuum hoses from the evaporative emission (EVAP) canister purge solenoid valve.
9. Remove the EVAP canister purge solenoid valve. Refer to EVAP CANISTER PURGE SOLENOID .
10. Remove the ignition coil bracket.
Fig. 127: Removing Ignition Coil Bracket
11. Disconnect the wiring harness from the manifold air pressure (MAP) sensor.
Fig. 128: Disconnecting Wiring Harness From Manifold Air Pressure Sensor
12. Disconnect the vacuum harness from the MAP sensor and the upper intake manifold.
Fig. 129: Disconnecting Vacuum Harness From MAP Sensor And Upper Intake Manifold
13. Disconnect and remove the emission control vacuum harness.

14. Disconnect the vacuum brake booster hose from the upper intake manifold.
15. Disconnect the vacuum hose connections from the upper intake manifold:
Heating, Ventilation and Air Conditioning (HVAC) vacuum source hose
Fuel pressure regulator
16. Remove the exhaust gas recirculation (EGR) valve. Refer to EGR VALVE .
17. Remove the MAP sensor and the bracket. Refer to MANIFOLD ABSOLUTE PRESSURE SENSOR .
18. Remove generator through bolt bracket.
Fig. 130: Removing Emission Control Vacuum Harness And Vacuum Brake Booster Hose
19. Remove the upper intake manifold studs and bolts.

Fig. 131: Removing Upper Intake Manifold Studs And Bolts
20. Remove the upper intake manifold.

Fig. 132: Removing Upper Intake Manifold
21. If replacing the intake manifold, remove the throttle body. Refer to THROTTLE BODY .
Fig. 133: Removing Throttle Body
22. Remove the upper intake manifold gasket.

23. Clean and inspect the upper intake manifold. Refer to INTAKE MANIFOLD CLEANING AND
INSPECTION - UPPER in the Engine Unit Repair Manual.
Fig. 134: Removing Upper Intake Manifold Gasket
1. If removed, install the throttle body. Refer to THROTTLE BODY

Fig. 135: Installing Throttle Body
2. Install the upper intake manifold gasket.

Fig. 136: Installing Upper Intake Manifold Gasket
3. Install the upper intake manifold.

Fig. 137: Installing Upper Intake Manifold
4. Install the MAP sensor and the bracket. Refer to MANIFOLD ABSOLUTE PRESSURE SENSOR .
5. Install the upper intake manifold studs and bolts.
Tighten
Tighten bolts to 25 N.m (18 lb ft.)
6. Install generator through bolt bracket.

7. Install the EGR valve. Refer to EGR VALVE .
8. Connect the vacuum hose connections to the upper intake manifold:
Heater and air conditioning vacuum source hose
9. Connect the vacuum brake booster hose to the upper intake manifold.
Fig. 138: Installing Upper Intake Manifold Studs And Bolts

10. Install and connect the emission control vacuum harness.

Fig. 139: Installing Emission Control Vacuum Harness
11. Connect the vacuum hose to the MAP sensor and the upper intake manifold.
Fig. 140: Connecting Vacuum Hose To MAP Sensor And Upper Intake Manifold
12. Connect the wiring harness to the MAP sensor.

Fig. 141: Connecting Wiring Harness To MAP Sensor
13. Install the ignition coil bracket with the coils.

14. Install the EVAP canister purge solenoid valve. Refer to EVAP CANISTER PURGE SOLENOID .
Fig. 142: Installing Ignition Coil Bracket With Coils
15. Connect the vacuum hoses to the EVAP canister purge solenoid valve.
16. Connect the throttle body heater hoses. Refer to THROTTLE BODY HEATER HOSE
REPLACEMENT - INLET or THROTTLE BODY HEATER HOSE REPLACEMENT -
OUTLET .
17. Connect the engine left side spark plug wire harness attachment clip. Refer to SPARK PLUG WIRES .
18. Connect the engine left side spark plug wires. Refer to SPARK PLUG WIRES .
19. Connect the wiring harness connectors to the throttle body. Refer to THROTTLE BODY .
20. Install the accelerator control and cruise control cables with bracket to the throttle body. Refer to
ACCELERATOR CONTROLS CABLE .
SYSTEM .
Fig. 143: Connecting Vacuum Hoses To EVAP Canister Purge Solenoid Valve
INTAKE MANIFOLD REPLACEMENT - LOWER

Removal Procedure
1. Remove the upper intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - UPPER .
2. Remove the engine left side valve rocker arm cover. Refer to VALVE ROCKER ARM COVER
REPLACEMENT - LEFT .
3. Remove the engine right side valve rocker arm cover. Refer to VALVE ROCKER ARM COVER
4. Disconnect the wiring harness from the engine coolant temperature (ECT) sensor.
Fig. 144: Disconnecting Wiring Harness From Engine Coolant Temperature Sensor
Important: Use masking tape or another appropriate method in order to identify each fuel injector wiring
harness connector cylinder number.
5. Disconnect and remove the fuel injector, manifold air pressure (MAP) and ECT wiring harness.
6. Remove the fuel feed and return pipe from the fuel injector rail. Refer to FUEL LINE DISCONNECT
FITTINGS .
Fig. 145: Disconnecting Fuel Injector, Manifold Air Pressure And ECT Wiring Harness
7. Remove the fuel feed and return pipe retaining clip bolt.
8. Remove the fuel feed and return pipe retaining clip.
Fig. 146: Removing Fuel Feed And Return Pipe Retaining Clip
9. Remove the fuel injector rail bolts.

10. Remove the fuel injector rail with the fuel injectors.
Important: Do NOT disconnect the power steering pipes or hoses from the power steering pump.
11. Remove the power steering pump from the front engine cover and reposition. Refer to POWER
STEERING PUMP REPLACEMENT .
12. Disconnect the heater inlet pipe with heater hose from the lower intake manifold and reposition. Refer to
HEATER PIPE REPLACEMENT - INLET .
13. Disconnect the inlet radiator hose from the engine.
Fig. 147: Removing Fuel Injector Rail With Fuel Injectors
14. Disconnect the thermostat bypass hose from the lower intake manifold pipe.
Fig. 148: Disconnecting Thermostat Bypass Hose From Lower Intake Manifold Pipe
15. Remove the lower intake manifold bolts.

Fig. 149: Removing Lower Intake Manifold Bolts
16. Remove the lower intake manifold.

17. Loosen the valve rocker arms and remove the push rods. Refer to VALVE ROCKER ARM AND PUSH
ROD REMOVAL .
18. Remove the lower intake manifold gaskets and seals.
19. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the engine block.
20. Clean and inspect the lower intake manifold. Refer to INTAKE MANIFOLD CLEANING AND
INSPECTION - LOWER .
21. If you are replacing the lower intake manifold, perform the following steps:
Remove the ECT sensor. Refer to ENGINE COOLANT TEMPERATURE SENSOR .
Remove the thermostat.

Fig. 150: Removing Lower Intake Manifold
1. If you are replacing the lower intake manifold, perform the following steps.
Install the ECT sensor.
Install the thermostat.
Important: All gasket-mating surfaces need to be free of oil, and foreign material. Use GM P/N
12346139 (Canadian P/N 10953463) or equivalent to clean surfaces.
2. Install the lower intake manifold gaskets.
NOTE: When replacing lower intake manifold gasket, a revised intake manifold
gasket has been introduced by manufacturer. This new design gasket
helps resolve issues related to intake manifold oil/coolant leaks. The
gasket requires a revised torque specification and procedure in addition to
the use of NEW revised intake manifold bolts. Please review TSB ENGINE
OIL OR COOLANT LEAK (INSTALL NEW INTAKE MANIFOLD GASKET) for
complete information.
3. Install the push rods and tighten the valve rocker arms. Refer to VALVE ROCKER ARM AND PUSH
ROD INSTALLATION .
4. With the gaskets in place apply a small drop 8-10 mm (0.31-0.39 in) of RTV sealer GM P/N 12346286
(Canadian P/N 10953472) or equivalent to the 4 corners of the intake manifold to block joint (1).
Fig. 151: Installing Lower Intake Manifold Gaskets
5. Connect the 2 small drops with a bead of RTV sealer that is between 8-10 mm (0.31-0.39 in) wide and
3.0-5.0 mm (0.12-0.20 in) thick (2).
6. Install the lower intake manifold.
7. Apply sealer GM P/N 12345382, (Canadian P/N 10953489) or the equivalent to the lower intake
manifold bolt threads.
8. Install the lower intake manifold bolts.
Tighten . See TSB For Revised Lower Intake Torque
Fig. 152: Installing Lower Intake Manifold Bolts

9. Connect the thermostat bypass hose to the lower intake manifold pipe.
10. Connect the inlet radiator hose to the engine.
11. Connect the heater inlet pipe to the lower intake manifold.
12. Install the power steering pump to the front engine cover.
Fig. 153: Connecting Thermostat Bypass Hose To Lower Intake Manifold Pipe
13. Install the fuel injector rail.

14. Connect the fuel feed and return pipe to the fuel injector rail.
Fig. 154: Installing Fuel Injector Rail With Injectors
15. Install the fuel feed and return pipe retaining clip.
16. Install the fuel feed and return pipe retaining clip bolt.
Tighten
Tighten the fuel feed and return pipe retaining clip bolt to 8 N.m (71 lb in).
Fig. 155: Installing Fuel Feed And Return Pipe Retaining Clip
Important: The fuel injector wiring harness connectors must be connected to their respective fuel
injectors. Failure to connect the fuel injector connectors to their respective fuel injectors may result in
excessive exhaust emissions and poor engine performance.
17. Install and connect the fuel injector, MAP and ECT wiring harness.
Fig. 156: Installing Fuel Injector, MAP And ECT Wiring Harness
18. Install the wiring harness to the ECT sensor.

19. Install the engine right side valve rocker arm cover. Refer to VALVE ROCKER ARM COVER
20. Install the engine left side valve rocker arm cover. Refer to VALVE ROCKER ARM COVER
21. Install the upper intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - UPPER .
Fig. 157: Installing Wiring Harness To ECT Sensor
POSITIVE CRANKCASE VENTILATION (PCV) VALVE REPLACEMENT
Removal Procedure
1. Disconnect the vacuum hose from positive crankcase ventilation valve (2).
2. Remove the positive crankcase ventilation valve.
Fig. 158: Removing Positive Crankcase Ventilation Valve
1. Install the positive crankcase ventilation valve (2).

2. Connect the vacuum hose to positive crankcase ventilation valve.
Fig. 159: Installing Positive Crankcase Ventilation Valve
VALVE ROCKER ARM COVER REPLACEMENT - LEFT
Removal Procedure
1. Remove the right engine strut mount. Refer to ENGINE MOUNT STRUT REPLACEMENT -
RIGHT .
2. Remove the thermostat bypass pipe. Refer to THERMOSTAT BYPASS PIPES REPLACEMENT .
3. Remove the PCV valve from valve rocker arm cover.
4. Remove the valve rocker arm cover bolts.
5. Remove the valve rocker arm cover and gasket.
6. Clean the valve rocker arm cover. Refer to VALVE ROCKER ARM COVER CLEANING AND
INSPECTION in the Engine Unit Repair Manual.
7. Clean the valve rocker arm cover sealing surfaces.
Fig. 160: Removing Valve Rocker Arm Cover - Left

1. Install the valve rocker arm cover gasket into valve rocker arm cover
2. Apply sealer GM P/N 12346286 or equivalent to the notches where the cylinder head and intake manifold
meet.
3. Install the valve rocker arm cover.
Tighten
Tighten bolts to 10 N.m (89 lb in).
4. Install the PCV valve to valve rocker arm cover.

5. Install the thermostat bypass pipe.
6. Install the right engine mount strut. Refer to ENGINE MOUNT STRUT REPLACEMENT - RIGHT .
Fig. 161: Installing Valve Rocker Arm Cover - Left

VALVE ROCKER ARM COVER REPLACEMENT - RIGHT
Removal Procedure

2. Remove the generator. Refer to GENERATOR .
3. Remove the generator bracket.
4. Disconnect the engine right side spark plug wires. Refer to SPARK PLUG WIRES .
5. Disconnect the vacuum hoses from the evaporative emissions (EVAP) canister purge solenoid valve.
6. Remove the EVAP canister purge solenoid valve. Refer to EVAP CANISTER PURGE SOLENOID .
Fig. 162: Disconnecting Vacuum Hoses From Evaporative Emissions Canister Purge Solenoid
Valve
7. Remove the ignition module bracket with the coils.

8. Remove the vacuum hose from the grommet in the engine right side valve rocker arm cover.
Fig. 163: Removing Ignition Module Bracket With Coils - Valve Rocker Arm Right Cover
Replacement

11. Clean the valve rocker arm cover. Refer to VALVE ROCKER ARM COVER CLEANING AND
INSPECTION.
12. Clean the valve rocker arm cover gasket sealing surfaces on the cylinder head and the lower intake
manifold.
Fig. 164: Removing Valve Rocker Arm Cover - Right

1. Install the valve rocker arm cover gasket into the valve rocker arm cover.
2. Apply sealer GM P/N 12346286 or the equivalent to the notches where the cylinder head and intake
manifold meet.
3. Install valve rocker arm cover.
4. Install the valve rocker arm cover bolts.
Tighten
Tighten the bolts to 10 N.m (89 lb in).
5. Install the vacuum hose to the grommet in the engine right side valve rocker arm cover.
Fig. 165: Installing Valve Rocker Arm Right Cover

6. Install the ignition coil bracket with coils.

7. Install the EVAP canister purge solenoid valve.
Fig. 166: Installing Ignition Coil Bracket With Coils - Valve Rocker Arm Right Cover Replacement
8. Connect the vacuum hoses from the EVAP canister purge solenoid valve.
9. Connect the engine right side spark plug wires.
10. Install the generator bracket.
11. Install the generator.
Fig. 167: Connecting Vacuum Hoses From EVAP Canister Purge Solenoid Valve
VALVE ROCKER ARM AND PUSH ROD REPLACEMENT

Removal Procedure
1. Remove the valve rocker arm cover (s). Refer to VALVE ROCKER ARM COVER REPLACEMENT
- LEFT or VALVE ROCKER ARM COVER REPLACEMENT - RIGHT .
2. Remove the valve rocker arm bolt (s).
3. Remove the valve rocker arm (s).
Important: Place the valve train parts in a rack in order to ensure that they are installed in the same
location from which they were removed. Intake pushrods are yellow and measure 144.18 mm (5.68 in)
long. Exhaust pushrods are green and measure 152.51 mm (6.0 in) long.
Fig. 168: Removing Valve Rocker Arm

Important: Use care when removing the pushrods. Ensure that they do not fall down into the lifter
valley.
4. Remove the pushrod (s).

5. Clean and inspect the valve train components. Refer to VALVE ROCKER ARM AND PUSH RODS
CLEANING AND INSPECTION in the Engine Unit Repair Manual.
1. Install the pushrod (s) and the valve rocker arm (s). Refer to VALVE ROCKER ARM AND PUSH
ROD INSTALLATION.
2. Install the valve rocker arm cover (s). Refer to VALVE ROCKER ARM COVER REPLACEMENT -
LEFT .
Fig. 169: Installing Valve Rocker Arm

VALVE STEM OIL SEAL AND VALVE SPRING REPLACEMENT
Tools Required
J 22794 Spark Plug Port Adapter

J 38606 Valve Spring Compressor
Removal Procedure
Important:
Before you remove the valve keys, rotate the engine so that the piston in the cylinder you are working on
is at (TDC) top dead center. This will eliminate the possibility of the valve accidentally falling inside the
cylinder.
Do not loosen or remove the spark plug when the engine is hot.
Loosen the spark plug, and clean any dirt and debris from the spark plug recess area before removing.
1. Remove the spark plug. Refer to SPARK PLUGS .

2. Install the J 22794 into the spark plug port. Apply compressed air in order to hold the valves in place.
3. Remove the rocker arm. Refer to VALVE ROCKER ARM AND PUSH ROD REPLACEMENT .
4. Compress the valve spring with the J 38606.
Fig. 170: Compressing Valve Spring With Valve Spring Compressor (J 38606)
5. Remove the valve keys.
6. Remove the valve cap.
7. Remove the valve spring.
8. Inspect the valve spring for damage. Replace the spring if it is damaged. Refer to CYLINDER HEAD
9. Remove the spring seat/valve stem oil seal.
Fig. 171: Removing Valve Keys, Valve Cap And Valve Spring
1. Install the valve stem oil seal/spring seat.

Use a suitable driver.
Press over the valve guide boss.
2. Install the valve spring.

3. Install the valve cap.
Fig. 172: Installing Valve Keys, Valve Cap And Valve Spring
4. Use the J 38606 in order to compress the valve spring.

5. Install the valve keys. If necessary, hold the valve keys in place with grease.
6. Remove the J 38606 in order to release the valve spring.
7. Ensure that the valve keys are seated.
8. Install the valve rocker arm. Refer to VALVE ROCKER ARM AND PUSH ROD REPLACEMENT .
9. Release the air pressure and remove the J 22794.
10. Install the spark plug.
Fig. 173: Compressing Valve Spring With Valve Spring Compressor (J 38606)
VALVE LIFTER REPLACEMENT
Removal Procedure
1. Remove the engine left side valve rocker arm cover. Refer to VALVE ROCKER ARM COVER
2. Remove the engine right side valve rocker arm cover. Refer to VALVE ROCKER ARM COVER
3. Remove the upper intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - LOWER .
4. Remove the lower intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - UPPER .
5. Remove the valve rocker arms and pushrods. Refer to VALVE ROCKER ARM AND PUSH ROD
REPLACEMENT .
6. Remove the lifter guide bolts.
7. Remove the lifter guide.
Fig. 174: Removing Valve Lifter

Important: Place the valve train parts in a rack in order to ensure that they are installed in the same
location from which they were removed.
8. Remove the lifter (s).

9. Clean and inspect the valve lifter (s). Refer to VALVE LIFTERS CLEANING AND INSPECTION.
Important: Install the lifters to the same location from which they were removed.
1. Install the lifters and the lifter guide. Refer to VALVE LIFTER INSTALLATION in the Engine Unit
Repair Manual.
2. Install the valve rocker arms and pushrods. Refer to VALVE ROCKER ARM AND PUSH ROD
REPLACEMENT .
3. Install the lower intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - LOWER
5. Install the engine right side valve rocker arm cover. Refer to VALVE ROCKER ARM COVER
6. Install the engine left side valve rocker arm cover. Refer to VALVE ROCKER ARM COVER
Fig. 175: Installing Valve Lifter

CRANKSHAFT BALANCER REPLACEMENT
Tools Required
J 24420-C Crankshaft Balancer Puller

J 29113 Crankshaft Balancer Installer
Removal Procedure

3. Remove the right front tire and wheel.
Fig. 176: Removing Crankshaft Balancer Bolt

5. Install a utility stand beneath the frame right side rail in order to support the frame/powertrain.
6. Remove the two frame right side bolts.
7. Use the utility stand to lower the frame enough to provide access to the crankshaft balancer.
NOTE: The inertial weight section of the crankshaft balancer is assembled to the
hub with a rubber type material. The correct installation procedures (with
the proper tool) must be followed or movement of the inertial weight
section of the hub will destroy the tuning of the crankshaft balancer.
8. Remove and DISCARD the crankshaft balancer bolt.

9. Remove the crankshaft balancer using the J 24420-C.
10. Clean and inspect the crankshaft balancer. Refer to CRANKSHAFT BALANCER CLEANING AND
INSPECTION .
Fig. 177: Removing Crankshaft Balancer Using Crankshaft Balancer Puller (J 24420-C)
1. Apply sealer GM P/N 12345739 or the equivalent to the keyway of the crankshaft balancer.
2. Install the crankshaft balancer into position over the key in the crankshaft.
3. Use the J 29113 in order to install the crankshaft balancer to the crankshaft.
4. Remove the J 29113 from the crankshaft balancer.
Fig. 178: Installing Crankshaft Balancer Using crankshaft Balancer Installer (J 29113)
5. Install the crankshaft balancer washer and the NEW crankshaft balancer bolt.
Tighten
5.1. Tighten the bolt to 70 N.m (52 lb ft).

5.2. Use a torque angle meter in order to rotate the bolt 72 degrees.
6. Use the utility stand in order to raise the frame/powertrain.
7. Install the frame right side bolts.
8. Install the engine splash shield. Refer to SPLASH SHIELD REPLACEMENT -- ENGINE .
9. Install the right front tire and wheel.
Fig. 179: Installing Crankshaft Balancer Washer And Crankshaft Balancer Bolt
OIL PAN REPLACEMENT
Tools Required
J 39505 Torque Wrench Adapter
Removal Procedure
1. Disconnect the battery negative cable.

2. Remove the right engine mount strut from the engine. Refer to ENGINE MOUNT STRUT
3. Install the engine support fixture. Refer to ENGINE SUPPORT FIXTURE .
5. Remove the A/C compressor bolts and reposition the compressor in order to gain access to the oil pan.
Refer to COMPRESSOR REPLACEMENT .
6. Disconnect the catalytic converter from the exhaust manifold.
7. Remove the frame.
8. Drain the engine oil. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT .
9. Disconnect the oil level sensor electrical connector.
10. Remove the starter motor.
11. If the vehicle is equipped with All-Wheel-Drive (AWD), remove the transfer case brace. Refer to
SUPPORT BRACE REPLACEMENT .
12. Remove the transaxle brace.
Fig. 180: Disconnecting Oil Level Sensor Electrical Connector - Oil Pan Replacement
13. Install one end of a suitable utility strap to the transmission.

If the vehicle is equipped with All-Wheel-Drive (AWD), carefully wrap the utility strap around the
transfer case.
If the vehicle is equipped with Front-Wheel-Drive (FWD), carefully wrap the utility strap around
the transmission case extension housing.
14. Install the opposite end of the utility strap to a suitable underbody structure.
15. Tighten the utility strap in order to prevent movement of the powertrain.
Fig. 181: Installing Opposite End Of Utility Strap To Suitable Underbody Structure
16. Remove the J 45057-2 lower support bar.

17. Remove the engine mount with the engine mount bracket from the oil pan. Refer to ENGINE MOUNT
BRACKET REPLACEMENT (FWD) or ENGINE MOUNT BRACKET REPLACEMENT
(AWD) .
Important: Use the J 39505 in order to remove the engine right side oil pan side bolts.
18. Remove the oil pan and the oil pan gasket. Refer to OIL PAN REMOVAL .
19. Clean the oil pan and the engine block gasket surface. Refer to OIL PAN CLEANING AND
INSPECTION .
Fig. 182: Removing J 45057-2 lower support bar
Important:
Ensure that the transaxle brace is in position prior to installing the oil pan.
Use the J 39505 in order to install the engine right side oil pan side bolts.
1. Install the oil pan gasket and the oil pan. Refer to OIL PAN INSTALLATION .
2. Install the transaxle brace.
3. Install the engine mount with the engine mount bracket to the oil pan. Refer to ENGINE MOUNT
BRACKET REPLACEMENT (FWD) or ENGINE MOUNT BRACKET REPLACEMENT
(AWD) .
Fig. 183: Installing Engine Right Side Oil Pan Side Bolts Using Torque Wrench Adapter
4. Install the J 45057-2 lower support bar.

5. Remove the utility strap.
6. If the vehicle is equipped with All-Wheel-Drive (AWD), install the transfer case brace.
7. Install the starter motor.
Fig. 184: Installing J 45057-2 Lower Support Bar

8. Connect the oil level sensor electrical connector.

9. Install the frame.
10. Connect the catalytic converter to the exhaust manifold.
11. Install the A/C compressor. Refer to COMPRESSOR REPLACEMENT .
13. Remove the engine support fixture. Refer to ENGINE SUPPORT FIXTURE .
14. Install the right engine mount strut to the engine. Refer to ENGINE MOUNT STRUT
15. Fill the engine with oil. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT .
16. Connect the battery negative cable.
Fig. 185: Connecting Oil Level Sensor Electrical Connector - Oil Pan Replacement
ENGINE OIL PRESSURE SENSOR AND/OR SWITCH REPLACEMENT

Removal Procedure
1. Remove the battery negative cable from the battery.

3. Remove the electrical connector from the engine oil pressure sensor.
4. Remove the engine oil pressure switch.
Fig. 186: Removing Engine Oil Pressure Switch

1. Install the engine oil pressure switch.
Tighten
Tighten the switch to 16 N.m (12 lb ft).
2. Install the electrical connector to the engine oil pressure switch.

4. Install the battery negative cable to the battery.
Fig. 187: Installing Engine Oil Pressure Switch

ENGINE OIL LEVEL SENSOR AND/OR SWITCH REPLACEMENT
Removal Procedure

2. Drain the oil from the oil pan.
3. Disconnect the electrical connector from the oil level sensor.
Fig. 188: Disconnecting Electrical Connector From Oil Level Sensor

4. Remove the oil level sensor bolt.

5. Remove the oil level sensor from the oil pan.
Fig. 189: Removing Oil Level Sensor From Oil Pan
1. Install the oil level sensor to the oil pan.

2. Install the oil level sensor bolt.
Tighten

Fig. 190: Installing Oil Level Sensor To Oil Pan
3. Connect the electrical connector to the oil level sensor.

5. Ensure that the engine oil is filled to the proper level.
Fig. 191: Connecting Electrical Connector To Oil Level Sensor
CRANKSHAFT OIL DEFLECTOR REPLACEMENT
Removal Procedure
1. Remove the oil pan. Refer to OIL PAN REPLACEMENT .

2. Remove the crankshaft oil deflector nuts.
3. Remove the crankshaft oil deflector.
Fig. 192: Removing Crankshaft Oil Deflector
1. Install the crankshaft oil deflector.

2. Install the crankshaft oil deflector nuts.
Tighten
Tighten the crankshaft oil deflector nuts to 25 N.m (18 lb ft).
3. Install the oil pan. Refer to OIL PAN REPLACEMENT .
Fig. 193: Installing Crankshaft Oil Deflector

OIL PUMP REPLACEMENT
Removal Procedure
1. Remove the oil pan. Refer to OIL PAN REPLACEMENT .

2. Remove the oil pump bolt.
3. Remove the oil pump and oil pump drive shaft.
Fig. 194: Removing Oil Pump And Oil Pump Drive Shaft
6. Inspect the oil pump driveshaft at both ends for rounding of the corners.
7. Inspect the oil pump. Refer to OIL PUMP DISASSEMBLE , OIL PUMP CLEANING AND
INSPECTION , and OIL PUMP ASSEMBLE in Engine Unit Repair Manual.
Fig. 195: Removing Crankshaft Oil Deflector - Oil Pump Replacement

Important: Rotate the oil pump driveshaft as necessary in order to obtain the engagement with the oil pump
drive.

Tighten
Tighten the nuts to 25 N.m (18 lb ft).
Fig. 196: Installing Crankshaft Oil Deflector - Oil Pump Replacement

3. Install the oil pump and oil pump drive shaft.

4. Install the oil pump bolt.
Tighten
Tighten the oil pump bolt to 41 N.m (30 lb ft).
5. Install the oil pan. Refer to OIL PAN REPLACEMENT .

Fig. 197: Installing Oil Pump And Oil Pump Drive Shaft
OIL PUMP DRIVE REPLACEMENT
Removal Procedure
1. Remove the upper intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - UPPER .
2. Disconnect the fuel feed and return pipe from the fuel injector rail.
3. Remove the oil pump drive clamp bolt.
4. Remove the oil pump drive clamp.
5. Remove the oil pump drive.
Fig. 198: Removing Oil Pump Drive
1. Apply prelube GM P/N 1052365 or the equivalent to the oil pump drive gear.
2. Apply engine oil to the oil pump drive gear assembly for ease of assembly.
3. Install the oil pump drive gear assembly.
4. Install the oil pump drive gear clamp.
5. Install the oil pump drive gear clamp bolt.
Tighten
Tighten the oil pump drive gear clamp bolt to 36 N.m (27 lb ft).
6. Connect the fuel feed and return pipe to the fuel injector rail.
Fig. 199: Installing Oil Pump Drive
CRANKSHAFT FRONT OIL SEAL REPLACEMENT
Tools Required
J 35468 Crankshaft Front Oil Seal Installer
Removal Procedure
1. Remove the crankshaft balancer. Refer to CRANKSHAFT BALANCER REPLACEMENT .

2. Pry out the crankshaft front oil seal using a suitable tool. Use care not to damage the engine front cover or
the crankshaft.
3. Inspect the crankshaft, the crankshaft balancer and the engine front cover for wear and/or damage.
Replace the components as necessary. Refer to the following procedures:
CRANKSHAFT BALANCER CLEANING AND INSPECTION

ENGINE FRONT COVER CLEANING AND INSPECTION
Fig. 200: Prying Out Crankshaft Front Oil Seal
1. Align the J 35468 and the crankshaft front oil seal with the engine front cover and crankshaft.
2. Install the crankshaft front oil seal using the J 35468 and a suitable tool.
3. Install the crankshaft balancer. Refer to CRANKSHAFT BALANCER REPLACEMENT .
Fig. 201: Installing Crankshaft Front Oil Seal Using Crankshaft Front Oil Seal Installer (J 35468)
ENGINE FRONT COVER REPLACEMENT
Removal Procedure
1. Drain the engine cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
3. Remove the crankshaft balancer. Refer to CRANKSHAFT BALANCER REPLACEMENT .
4. Remove the drive belt tensioner. Refer to DRIVE BELT TENSIONER REPLACEMENT .
5. Remove the power steering pump with lines. Move the power steering pump aside. Refer to POWER
STEERING PUMP REPLACEMENT .
Fig. 202: Removing Crankshaft Position Sensor Wiring Harness Bracket

6. Disconnect the thermostat bypass pipe from the engine front cover. Refer to THERMOSTAT BYPASS
PIPES REPLACEMENT .
7. Disconnect the radiator outlet hose from the front cover.
8. Remove the coolant pump pulley. Refer to WATER PUMP REPLACEMENT .
9. Remove the crankshaft position sensor wiring harness bracket from the engine front cover.
10. Remove oil pan. Refer to OIL PAN REPLACEMENT .
11. Remove the engine front cover bolts (1,2,3).
12. Remove the engine front cover.
13. Remove the engine front cover gasket.
14. Clean the engine front cover and engine block gasket sealing surfaces. Refer to ENGINE FRONT
COVER CLEANING AND INSPECTION.
15. Inspect the engine front cover for damage to the engine front cover, crankshaft front oil seal or the gasket
sealing surface. Refer to ENGINE FRONT COVER CLEANING AND INSPECTION.
Fig. 203: Removing Engine Front Cover

16. If you are replacing the engine front cover, remove the drive belt shield.
17. If you are replacing the engine front cover, remove the crankshaft position sensor from the engine front
cover.
18. If you are replacing the engine front cover, remove the coolant pump from the engine front cover.
Refer to WATER PUMP REPLACEMENT .

Fig. 204: Removing Drive Belt Shield
1. If removed, install the coolant pump to the engine front cover. Refer to WATER PUMP
REPLACEMENT .
2. If removed, install the crankshaft position sensor to the engine front cover.
3. If removed, install the drive belt shield.
4. Install the drive belt shield bolt.
Tighten
Tighten the drive belt shield bolt to 10 N.m (89 lb in).
Fig. 205: Installing Drive Belt Shield Bolt

5. Install the engine front cover gasket.

6. Apply sealer GM P/N 12346004, (Canadian P/N 10953480) or equivalent to both sides of the lower tabs
of the engine front cover gasket, and the engine front cover bolts.
Fig. 206: Identifying Sealer Applying Width On Engine Front Cover Gasket Lower Tabs
7. Install the engine front cover.

8. Install the engine front cover bolts (2).
Tighten
Tighten the engine front cover bolts (2) to 55 N.m (41 lb ft).
Tighten
Tighten
Fig. 207: Installing Engine Front Cover

11. Install the crankshaft position sensor wiring bracket.

12. Install the crankshaft position sensor wiring bracket bolt.
Tighten
Tighten the crankshaft position sensor wiring bracket bolt to 27 N.m (20 lb ft).
13. Install the coolant pump pulley. Refer to WATER PUMP REPLACEMENT .
14. Connect the radiator outlet hose to the coolant pump.
15. Connect the thermostat bypass pipe to the engine front cover. Refer to THERMOSTAT BYPASS
PIPES REPLACEMENT .
16. Install the power steering pump with lines. Refer to POWER STEERING PUMP REPLACEMENT .
17. Install the drive belt tensioner. Refer to DRIVE BELT TENSIONER REPLACEMENT .
18. Install the crankshaft balancer. Refer to CRANKSHAFT BALANCER REPLACEMENT .
19. Fill the engine with new engine oil. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT .
SYSTEM .
Fig. 208: Installing Crankshaft Position Sensor Wiring Bracket
TIMING CHAIN AND SPROCKETS REPLACEMENT
Removal Procedure
1. Remove the engine front cover. Refer to ENGINE FRONT COVER REPLACEMENT .
2. Align the crankshaft timing mark (2) to the timing mark on the bottom of the timing chain dampener (1).
3. Align the timing mark on the camshaft gear (4) with the timing mark on top of the timing chain dampener
(3).
Fig. 209: Aligning Crankshaft And Camshaft Timing Mark With Timing Chain Dampener Marks
For Removal
4. Remove the camshaft sprocket bolt.

5. Remove the camshaft sprocket and timing chain.
Fig. 210: Removing Camshaft Sprocket And Timing Chain

6. Remove the crankshaft sprocket.

Fig. 211: Removing Crankshaft Sprocket
7. Remove the timing chain dampener bolts.

8. Remove the timing chain dampener.
9. Clean and inspect the timing chain and gears. Refer to TIMING CHAIN AND SPROCKETS
Fig. 212: Removing Timing Chain Dampener
1. Install the crankshaft sprocket.

2. Apply prelube GM P/N 1052365 or the equivalent to the crankshaft sprocket thrust surface.
Fig. 213: Installing Crankshaft Sprocket
3. Install the timing chain dampener.

4. Install the timing chain dampener bolts.
Tighten
Tighten the timing chain dampener bolt to 21 N.m (15 lb ft).

Fig. 214: Installing Timing Chain Dampener
6. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the
crankshaft gear.
(3).
Fig. 215: Aligning Crankshaft And Camshaft Timing Mark With Timing Chain Dampener Marks
For Installation
8. Align the dowel in the camshaft with the dowel hole in the camshaft sprocket.
9. Draw the camshaft sprocket onto the camshaft using the mounting bolt.
Tighten
10. Coat the crankshaft and camshaft sprocket with engine oil.
11. Install the engine front cover. Refer to ENGINE FRONT COVER REPLACEMENT .
Fig. 216: Installing Camshaft Sprocket Onto Camshaft

CYLINDER HEAD REPLACEMENT - LEFT

Removal Procedure
1. Disconnect the battery negative cable.

3. Drain the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
6. Remove the lower intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - LOWER .
7. Remove the exhaust crossover pipe. Refer to EXHAUST CROSSOVER PIPE REPLACEMENT .
8. Remove the pushrods and valve rocker arms. Refer to VALVE ROCKER ARM AND PUSH ROD
REPLACEMENT .
9. Remove the engine mount strut bracket. Refer to ENGINE MOUNT STRUT BRACKET
10. Remove the oil level indicator tube. Refer to OIL LEVEL INDICATOR AND TUBE
REPLACEMENT .
11. Remove and discard the cylinder head bolts.
12. Remove the cylinder head.
Fig. 217: Removing Cylinder Head - Left
13. Remove and discard the cylinder head gasket.

14. Clean the following areas:
The gasket sealing surfaces on the cylinder head, cylinder block, and intake manifolds.
The cylinder block bolt threads.
The cylinder head bolts.
15. Clean and inspect the cylinder head.

16. If the cylinder head is being replaced, perform the following steps:
Remove the exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT - RIGHT .
Remove the spark plugs from the cylinder head.

Fig. 218: Removing Cylinder Head Gasket - Left

Install the exhaust manifold to the cylinder head. Refer to EXHAUST MANIFOLD
Install the spark plugs to the cylinder head.
2. Install the new cylinder head gasket.

3. Install the engine left side exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT -
LEFT .
Fig. 219: Installing New Cylinder Head Gasket - Left
5. Install the cylinder head.

Fig. 220: Installing Cylinder Head - Left
6. Install the new cylinder head bolts.
Tighten
6.1. Tighten the bolts in the sequence shown to 60 N.m (44 lb ft),
6.2. Use a torque angle meter in order to rotate the cylinder head bolts 95 degrees.
7. Install the oil level indicator tube. Refer to OIL LEVEL INDICATOR AND TUBE
REPLACEMENT .
8. Install the engine mount strut bracket. Refer to ENGINE MOUNT STRUT BRACKET
9. Install the exhaust crossover pipe. Refer to EXHAUST CROSSOVER PIPE REPLACEMENT .
Fig. 221: Identifying Cylinder Head Bolts Tightening Sequence - Left

10. Install the lower intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - LOWER .
13. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
CYLINDER HEAD REPLACEMENT - RIGHT
Removal Procedure
1. Disconnect the battery negative cable from the battery.

6. Remove the lower intake manifold. Refer to INTAKE MANIFOLD REPLACEMENT - LOWER .
Fig. 222: Removing Cylinder Head - Right
7. Remove the exhaust crossover pipe. Refer to EXHAUST CROSSOVER PIPE REPLACEMENT .
8. Remove the pushrods and valve rocker arms. Refer to VALVE ROCKER ARM AND PUSH ROD
REPLACEMENT .

Remove the exhaust manifold. Refer to EXHAUST MANIFOLD REPLACEMENT - RIGHT .
Remove the spark plugs from the cylinder head. Refer to SPARK PLUGS .
Fig. 223: Removing Cylinder Head Gasket - Right

Install the exhaust manifold to the cylinder head. Refer to EXHAUST MANIFOLD
Install the spark plugs to the cylinder head. Refer to SPARK PLUGS .
2. Install the cylinder head gasket.

Fig. 224: Installing Cylinder Head Gasket - Right

Fig. 225: Installing Cylinder Head - Right

Tighten
4.1. Tighten the bolts in the sequence shown to 60 N.m (44 lb ft),
4.2. Use a torque angle meter in order to rotate the cylinder head bolts 95 degrees.
5. Install the exhaust crossover pipe. Refer to EXHAUST CROSSOVER PIPE REPLACEMENT .
6. Install the pushrods and valve rocker arms. Refer to VALVE ROCKER ARM AND PUSH ROD
REPLACEMENT .
7. Install the upper and lower intake manifolds. Refer to INTAKE MANIFOLD REPLACEMENT -
LOWER and INTAKE MANIFOLD REPLACEMENT - UPPER .
Fig. 226: Identifying Cylinder Head Bolts Tightening Sequence - Right

10. Fill the cooling system. Refer to DRAINING AND FILLING COOLING SYSTEM .
ENGINE FLYWHEEL REPLACEMENT
Removal Procedure
1. Remove the automatic transaxle. Refer to TRANSMISSION REPLACEMENT .

2. Remove the engine flywheel bolts and flywheel.
3. Clean the engine flywheel bolt threads and bolt holes.
4. Clean and inspect the engine flywheel. Refer to ENGINE FLYWHEEL CLEANING AND
INSPECTION .
Fig. 227: Removing Engine Flywheel Bolts And Flywheel

1. Install the engine flywheel and bolts
Tighten
Tighten bolts to 71 N.m (52 lb ft).
2. Install the automatic transaxle. Refer to TRANSMISSION REPLACEMENT .

Fig. 228: Installing Engine Flywheel And Bolts
CRANKSHAFT REAR OIL SEAL REPLACEMENT
Tools Required
J 34686 Rear Main Seal Installer
Removal Procedure
1. Remove the engine flywheel. Refer to ENGINE FLYWHEEL REPLACEMENT .
Important: Do not damage the crankshaft or seal bore.
2. Remove the crankshaft rear oil seal. Pry the crankshaft rear oil seal out using a suitable tool.
Fig. 229: Removing Crankshaft Rear Oil Seal
1. Apply engine oil to the inside diameter and the outside diameter of the new crankshaft rear oil seal.
2. Slide the crankshaft rear oil seal over the mandrel until the back of the crankshaft rear oil seal bottoms
squarely against the collar of the J 34686.
3. Perform the following steps in order to install the crankshaft rear oil seal:
3.1. Align the dowel pin of the J 34686 with the dowel pin in the crankshaft.
Fig. 230: Installing Crankshaft Rear Oil Seal Using Rear Main Seal Installer (J 34686)
3.2. Attach the J 34686 to the crankshaft by hand, or tighten attaching screws to 5 N.m (45 lb in).
3.3. Turn the T-handle of the J 34686 in order to allow the collar to push the seal into the bore.
Turn the handle until the collar is tight against the case. Ensure that the seal is seated properly.
3.4. Loosen the T-handle until the handle comes to a stop.

3.5. Remove the attaching screws.
4. Install the engine flywheel. Refer to ENGINE FLYWHEEL REPLACEMENT .
CAMSHAFT REAR BEARING HOLE PLUG REPLACEMENT

Removal Procedure
1. Remove the engine flywheel. Refer to ENGINE FLYWHEEL REPLACEMENT .

2. Remove the camshaft rear bearing hole plug.
Fig. 231: Removing Camshaft Rear Bearing Hole Plug
1. Coat the camshaft rear bearing hole plug with sealer. Use sealer GM P/N 12345493 or equivalent.
2. Use an impact wrench socket and a hammer in order to install the camshaft rear bearing hole plug.
Fig. 232: Installing Camshaft Rear Bearing Hole Plug
3. Ensure that the camshaft rear bearing plug is installed to specifications.

4. Install the engine flywheel. Refer to ENGINE FLYWHEEL REPLACEMENT .
Fig. 233: Identifying Camshaft Rear Bearing Plug Installation Specification

ENGINE REPLACEMENT
Removal Procedure

3. Remove the cruise control cable from the engine and reposition the cable away from the engine.
Refer to CRUISE CONTROL CABLE REPLACEMENT .
CAUTION: In order to avoid possible injury or vehicle damage, always replace

the accelerator control cable with a NEW cable whenever you remove
the engine from the vehicle.
In order to avoid cruise control cable damage, position the cable out of the way while you remove
or install the engine. Do not pry or lean against the cruise control cable and do not kink the cable.
You must replace a damaged cable.
4. Remove and discard the accelerator control cable from the engine and reposition the cable away from the
engine.
6. Disconnect the radiator hoses from the engine.
7. Disconnect the heater hoses from the engine.
Important: Relieve the fuel pressure. Refer to FUEL SYSTEM PRESSURE RELEASE .
9. Disconnect the fuel lines at quick connects.

10. Remove the upper engine wiring harness from engine and transmission.
11. Remove the vacuum hoses from the engine. Refer to VACUUM HOSE ROUTING .
12. Remove the vacuum brake booster hose.
13. Remove the automatic transaxle range selector cable. Refer to AUTOMATIC TRANSMISSION
RANGE SELECTOR CABLE REPLACEMENT .
16. Remove the lower engine wiring harness from engine and transmission.
17. Remove the three-way catalytic converter.
18. Remove rear prop shaft. Refer to PROPELLER SHAFT REPLACEMENT .
19. Remove the front tires and wheels.
20. Remove lower radiator baffle assembly.
21. Remove the engine splash shields. Refer to SPLASH SHIELD REPLACEMENT -- ENGINE .
22. Remove the stabilizer shaft links from the lower control arms. Refer to STABILIZER SHAFT LINK
REPLACEMENT .
23. Remove the tie rod ends from the steering knuckles. Refer to STEERING KNUCKLE
REPLACEMENT .
24. Remove the lower ball joints from the knuckles. Refer to LOWER BALL JOINT REPLACEMENT .
25. Remove the transaxle cooler lines and bracket from the transaxle.
26. Remove A/C compressor bolts and position compressor aside.
27. Disconnect the drive axles from the transaxle. Refer to AXLE SHAFT .
28. Secure the drive axles to the steering knuckle/struts.
CAUTION: Failure to disconnect the intermediate shaft from the rack and pinion
steering gear stub shaft can result in damage to the steering gear
and/or intermediate shaft. This damage may cause loss of steering
control which could result in an accident and possible personal
injury
29. Remove the intermediate shaft pinch bolt from the steering gear. Refer to INTERMEDIATE
STEERING SHAFT REPLACEMENT .
30. Lower the vehicle until the frame contacts the transaxle table.
31. Remove the frame bolts.
32. Raise the vehicle in order to separate the powertrain/frame assembly from the vehicle.
33. Remove starter.
34. Remove the engine flywheel to torque converter bolts.
Fig. 234: Installing Engine Hoist To Engine
35. Install engine hoist to engine.

36. Remove engine mount to frame nuts.
37. Remove the engine-to-transaxle bolts (3, 4, 5, 6) and studs (1,2).
38. Separate and remove the engine from the transaxle/frame and install to the engine stand.
Fig. 235: Separating Engine From Transaxle/Frame
1. Remove engine from engine stand.

2. Install and align the engine to the transaxle/frame.
3. Install the engine-to-transaxle bolts (3, 4, 5, 6) and studs (1,2).
Tighten
Tighten the bolts (3, 4, 5, 6) and studs (1, 2) to 75 N.m (55 lb ft).
4. Install engine mount to frame nuts.
Tighten
Tighten nuts to 43 N.m (32 lb ft).

5. Remove engine hoist from engine.
6. Install the engine flywheel to torque converter bolts.
Tighten
Tighten bolts to 62 N.m (46 lb ft).
Fig. 236: Installing Engine To Transaxle/Frame

7. Install starter.
8. Position the transaxle table with the powertrain/frame under the vehicle.
10. Install the new frame bolts.
12. Remove the transaxle table.
CAUTION: When installing the intermediate shaft make sure that the shaft is
seated prior to pinch bolt Installation. If the pinch bolt is Inserted into
the coupling before shaft Installation, the two mating shafts may
disengage. Disengagement of the two mating shafts will cause loss
of steering control which could result In personal injury.
13. Install the intermediate shaft pinch bolt to steering gear. Refer to INTERMEDIATE STEERING
SHAFT REPLACEMENT .
Fig. 237: Removing Engine Hoist From Engine

14. Install the drive axles to the transaxle. Refer to AXLE SHAFT .
15. Install the transaxle cooler lines and bracket to the transaxle.
16. Install A/C compressor and bolts.
17. Install the lower ball joints to the knuckles. Refer to LOWER BALL JOINT REPLACEMENT .
18. Install the tie rod ends to the steering knuckles. Refer to STEERING KNUCKLE REPLACEMENT .
19. Install the stabilizer shaft links to the lower control arms. Refer to STABILIZER SHAFT LINK
REPLACEMENT .
20. Install the engine splash shields. Refer to SPLASH SHIELD REPLACEMENT -- ENGINE .
21. Install lower radiator baffle.
22. Install the front tires and wheels.
23. Install the three-way catalytic converter.
24. Install the lower engine wiring harness to engine and transmission.
25. Install rear prop shaft. Refer to PROPELLER SHAFT REPLACEMENT .
27. Install the automatic transaxle range selector cable. Refer to AUTOMATIC TRANSMISSION RANGE
SELECTOR CABLE REPLACEMENT .
28. Install the vacuum brake booster hose.
29. Install the vacuum hoses to the engine. Refer to VACUUM HOSE ROUTING .
30. Install the upper engine wiring harness to engine and transmission.
31. Install the fuel lines at quick connects.
33. Connect the heater hoses to the engine.
34. Connect the radiator hoses to the engine.
CAUTION: In order to avoid possible injury or vehicle damage, always replace

the accelerator control cable with a NEW cable whenever you remove
the engine from the vehicle.
In order to avoid cruise control cable damage, position the cable out of the way while you remove
or Install the engine. Do not pry or lean against the cruise control cable and do not kink the cable.
You must replace a damaged cable.
35. Install the NEW accelerator control cable to the engine.

36. Install the cruise control cable to the engine. Refer to CRUISE CONTROL CABLE
REPLACEMENT .
SYSTEM .
39. Adjust the transaxle fluid level.
40. Fill the engine with oil. Refer to ENGINE OIL AND OIL FILTER REPLACEMENT .
41. Connect the negative battery cable.
42. Perform the CKP system variation learn procedure. Refer to CRANKSHAFT POSITION SENSOR .
43. Inspect for proper fluid levels and possible fluid leaks.
ENGINE OIL AND OIL FILTER REPLACEMENT
Removal Procedure

2. Position the oil drain pan under the engine oil drain plug.
3. Remove the engine oil drain plug.
4. Clean and inspect the engine oil drain plug, repair or replace if necessary.
5. Clean and inspect the engine oil drain plug sealing surface on the oil pan, repair or replace oil pan if
necessary.
Fig. 238: Removing Engine Oil Drain Plug

7. Clean and inspect the oil filter sealing area on the oil cooler adapter, repair or replace if necessary. Refer
to OIL COOLER REPLACEMENT .
1. Lightly oil the replacement oil filter gasket with clean oil and install the new oil filter.
2. Install the new oil filter.
Tighten
Tighten the new oil filter to 3/4 to 1 full turn, after the oil filter gasket contacts the oil filter mounting
surface.
Fig. 240: Installing New Oil Filter
3. Install the engine oil drain plug.
Tighten
Tighten the engine oil drain plug to 25 N.m (18 lb ft).
4. Remove the oil drain pan.

6. Fill the engine with new engine oil.
Fig. 241: Installing Engine Oil Drain Plug
DRAINING FLUIDS AND OIL FILTER REMOVAL
1. Remove the oil pan drain plug.

2. Drain the engine oil.
Fig. 242: Removing Oil Pan Drain Plug

4. Remove the coolant drain plug from the left side, if applicable.
Fig. 244: Removing Coolant Drain Plug From Left Side
5. Remove the coolant drain plug from the right side.

6. Drain the coolant.
Fig. 245: Removing Coolant Drain Plug From Right Side
CRANKSHAFT BALANCER REMOVAL
Tools Required
J 24420-C Harmonic Balancer Puller
1. Remove the crankshaft balancer retaining bolt and washer.

Fig. 246: Removing Crankshaft Balancer Retaining Bolt And Washer
2. Remove the crankshaft balancer using the J 24420-C.

Fig. 247: Removing Crankshaft Balancer Using Harmonic Balancer Puller (J 24420-C)
ENGINE FLYWHEEL REMOVAL
1. Remove the flywheel bolts.

2. Remove the flywheel retainer.
3. Remove the flywheel.
Fig. 248: Removing Engine Flywheel
DRIVE BELT TENSIONER REMOVAL

Fig. 249: Removing Drive Belt Tensioner
ENGINE MOUNT STRUT AND AIR CONDITIONING COMPRESSOR BRACKET REMOVAL
1. Remove the engine mount strut and A/C compressor bracket bolts.
2. Remove the engine mount strut and A/C compressor bracket.
Fig. 250: Removing Engine Mount Strut And A/C Compressor Bracket
ENGINE MOUNT STRUT AND ENGINE LIFT BRACKET REMOVAL
1. Remove the engine mount strut and lift bracket bolts.

2. Remove the engine mount strut and lift bracket.
Fig. 251: Removing Engine Mount Strut And Lift Bracket
ENGINE LIFT BRACKET AND GENERATOR BRACKET REMOVAL
1. Remove the generator bracket bolts (1-3).

3. Remove the front engine lift bracket.
Fig. 252: Removing Front Engine Lift Bracket And Generator Bracket
OIL LEVEL INDICATOR AND TUBE REMOVAL
1. Remove the thermostat bypass pipe to throttle body nut (2).

2. Remove the thermostat bypass pipe to throttle body hose clamps (1).
3. Remove the thermostat bypass pipe to engine front cover bolt (4).
4. Remove the thermostat bypass pipe hose clamp (5) and hose from pipe.
5. Remove the thermostat bypass pipe (3).
Fig. 253: Removing Thermostat Bypass Pipe
6. Remove the oil level indicator tube bolt.

7. Remove the oil level indicator and oil level indicator tube.
Fig. 254: Removing Oil Level Indicator And Oil Level Indicator Tube
OIL COOLER REMOVAL
1. Disconnect the upper oil cooler outlet hose from the thermostat bypass pipe.
2. Disconnect the lower oil cooler outlet hose from the oil cooler.
3. Remove the oil cooler outlet hoses and pipe.
Fig. 255: Removing Oil Cooler Outlet Hoses And Pipe

5. Remove the oil cooler inlet hose clamp and oil cooler.
Fig. 257: Removing Oil Cooler Inlet Hose Clamp And Oil Cooler
6. Remove the oil cooler inlet hose and oil cooler inlet hose clamp from the oil cooler hose fitting.
Fig. 258: Removing Oil Cooler Inlet Hose
7. Remove the oil cooler hose fitting.

Fig. 259: Removing Oil Cooler Hose Fitting
OIL FILTER ADAPTER REMOVAL
1. Remove the oil filter bypass hole plug.
Important: Do not remove the oil filter fitting unless replacement or repair is needed.
2. Remove the oil filter fitting, if necessary.

3. Remove the oil filter bypass valve, by prying out with a suitable tool.
Fig. 260: Removing Oil Filter Bypass Valve
AIR INJECTION CHECK VALVE REMOVAL
1. Remove air injection vacuum hose.

Fig. 261: Removing Air Injection Vacuum Hose
2. Remove air injection check valve pipe, clamps, and bolt.

Fig. 262: Removing Air Injection Check Valve Pipe
3. Remove air injection solenoid switch and bolt.

Fig. 263: Removing Air Injection Solenoid Switch
4. Remove air injection check valve front nuts.

Fig. 264: Removing Air Injection Check Valve Front Nuts
5. Remove air injection check valve rear nuts.

Fig. 265: Removing Air Injection Check Valve Rear Nuts
6. Remove air injection check valve front bracket and bolt.

Fig. 266: Removing Air Injection Check Valve Front Bracket
7. Remove air injection check valve rear bracket and nuts.

Fig. 267: Removing Air Injection Check Valve Rear Bracket And Nuts
8. Remove air injection check valve pipe adapters, front.

Fig. 268: Removing Air Injection Check Valve Pipe Adapters, Front
9. Remove air injection check valve pipe adapters, rear.
Fig. 269: Removing Air Injection Check Valve Pipe Adapters, Rear
EXHAUST MANIFOLD REMOVAL - LEFT

1. Remove the spark plug wires.
2. Remove the spark plugs.
3. Remove the exhaust manifold heat shield bolts.
4. Remove the exhaust manifold heat shield.
Fig. 270: Removing Left Exhaust Manifold Heat Shield

5. Remove the exhaust manifold nuts.

6. Remove the exhaust manifold.
7. Remove the exhaust manifold gasket.
8. Remove the exhaust studs, if required.
Fig. 271: Removing Left Exhaust Manifold And Manifold Gasket
EXHAUST MANIFOLD REMOVAL - RIGHT

3. Remove the EGR pipe from the exhaust manifold.
4. Remove the heated oxygen sensor.
Fig. 272: Removing Heated Oxygen Sensor - Right Exhaust Manifold Removal

6. Remove the exhaust manifold heat shields.
Fig. 273: Removing Right Exhaust Manifold Heat Shields

Fig. 274: Removing Right Exhaust Manifold And Manifold Gasket
WATER OUTLET AND THERMOSTAT REMOVAL
1. Remove the water outlet bolts.

2. Remove the water outlet.
Fig. 275: Removing Water Outlet
3. Remove the thermostat.

Fig. 276: Removing Thermostat
VALVE ROCKER ARM COVER REMOVAL - LEFT
Important: When removing the valve rocker arm cover make sure the gasket stays in place attached to
the cylinder head.

3. Cut the RTV in the channel where the intake, cylinder head and valve rocker arm cover meet with a
suitable tool.
4. Remove the valve rocker arm cover.
5. Cut the RTV in the channel where the intake, cylinder head and valve rocker arm cover meet, with
suitable tool.
6. Remove the valve rocker arm cover gasket.
Fig. 277: Removing Valve Rocker Arm Cover - Left

VALVE ROCKER ARM COVER REMOVAL - RIGHT
1. Remove the electronic ignition control module nuts and bolts.

2. Remove the electronic ignition control module.
3. Remove the electronic ignition control module studs.
Fig. 278: Removing Electronic Ignition Control Module

Important: When removing the valve rocker arm cover make sure the gasket stays in place attached to
the cylinder head.

6. Cut the RTV in the channel where the intake, cylinder head and valve rocker arm cover meet with a
suitable tool.
Fig. 279: Removing Valve Rocker Arm Cover - Right

INTAKE MANIFOLD REMOVAL - UPPER
1. Remove the MAP sensor electrical connector.

2. Remove the MAP sensor bolts.
3. Remove the MAP sensor from bracket.
4. Remove the MAP sensor bracket and bracket bolt.
Fig. 280: Removing MAP Sensor From Bracket
5. Remove the EGR valve pipe and bolt from the EGR valve.
6. Remove the EGR valve bolts.
7. Remove the EGR valve and gasket.
Fig. 281: Removing EGR Valve And Gasket
8. Remove the vacuum harness assembly.

Fig. 282: Removing Vacuum Harness Assembly
9. Remove the accelerator cable bracket and bracket bolts.

Fig. 283: Removing Accelerator Cable Bracket
10. Remove the purge valve bracket bolt, hose and valve assembly.
11. Remove the throttle body bolts.
12. Remove the throttle body and gasket.
13. Remove the upper intake manifold bolts.
14. Remove the upper intake manifold and gaskets.
Fig. 284: Removing Upper Intake Manifold And Gaskets
INTAKE MANIFOLD REMOVAL - LOWER

Fig. 285: Removing Fuel Feed And Return Pipe Retaining Clip

4. Remove the fuel injector rail assembly.
Fig. 286: Removing Fuel Injector Rail Assembly
5. Remove the heater inlet pipe nut.

6. Remove the heater inlet pipe.
Fig. 287: Removing Heater Inlet Pipe

Fig. 288: Removing Lower Intake Manifold
VALVE ROCKER ARM AND PUSH ROD REMOVAL
1. Remove the valve rocker arm bolts.
Important: Place the valve train components in a rack in order to ensure that the components are
installed in the same location from which they were removed.
2. Remove the valve rocker arms.
Fig. 289: Removing Valve Rocker Arms

3. Remove the push rods.

The intake push rods measure 146 mm (5.75 in).
The exhaust push rods measure 152.51 mm (6.0 in).

Fig. 290: Removing Push Rods
4. Remove the intake manifold gaskets.

Fig. 291: Removing Intake Manifold Gaskets
VALVE LIFTER REMOVAL
1. Remove the valve lifter guide bolts.

2. Remove the valve lifter guides.
Important: Once removed, place the valve lifters in an organized order so the valve lifters can be
installed into the original locations.
3. Remove the valve lifters.
Fig. 292: Removing Valve Lifter

WATER PUMP REMOVAL
1. Remove the water pump pulley bolts.

2. Remove the water pump pulley.
Fig. 293: Removing Water Pump Pulley
3. Remove the water pump bolts.

4. Remove the water pump.
5. Remove the water pump gasket.
Fig. 294: Removing Water Pump
CYLINDER HEAD REMOVAL - LEFT
1. Remove the cylinder head bolts.

Fig. 295: Removing Left Cylinder Head
3. Remove the cylinder head gasket.

4. Remove the dowel pins - cylinder head locator, if required.
Fig. 296: Removing Left Cylinder Head Gasket
CYLINDER HEAD REMOVAL - RIGHT
1. Remove the cylinder head bolts.

Fig. 297: Removing Right Cylinder Head
4. Remove the dowel pins - cylinder head locator, if required.
Fig. 298: Installing Left Cylinder Head Gasket

OIL PAN REMOVAL
1. Remove the oil level pressure sensor and sensor bolt.

2. Remove the oil pan side bolts.
3. Remove the oil pan bolts.
4. Remove the oil pan.
5. Remove the oil pan gasket.
Fig. 299: Removing Oil Pan

OIL PUMP REMOVAL

Fig. 300: Removing Oil Pump And Oil Pump Drive Shaft
Fig. 301: Removing Crankshaft Oil Deflector

OIL PUMP DRIVE REMOVAL

Fig. 302: Removing Oil Pump Drive
CRANKSHAFT FRONT OIL SEAL REMOVAL
Pry out the crankshaft front oil seal using a suitable tool. Use care not to damage the engine front cover or the
crankshaft.
Fig. 303: Removing Crankshaft Front Oil Seal

ENGINE FRONT COVER REMOVAL
1. Remove the crankshaft position sensor wiring bracket bolt.

2. Remove the crankshaft position sensor wiring bracket.
Fig. 304: Removing Crankshaft Position Sensor Wiring Bracket

3. Remove the engine front cover bolts (1), (2), and (3).
Fig. 305: Removing Engine Front Cover

TIMING CHAIN AND SPROCKETS REMOVAL

Fig. 306: Removing Camshaft Sprocket And Timing Chain

Fig. 307: Removing Crankshaft Sprocket

Fig. 308: Removing Timing Chain Dampener
CAMSHAFT REMOVAL
1. Remove the camshaft position sensor and sensor bolt.

Fig. 309: Removing Camshaft Position Sensor And Sensor Bolt
2. Remove the camshaft thrust plate screws.

3. Remove the camshaft thrust plate.
Fig. 310: Removing Camshaft Thrust Plate
NOTE: All camshaft journals are the same diameter, so care must be used in
removing or installing the camshaft to avoid damage to the camshaft
bearings
4. Complete the following steps in order to remove the camshaft:

4.1. Install a large screwdriver in the camshaft bolt hole. Do not damage the threads.
4.2. Carefully rotate and pull the camshaft out of the camshaft bearings.
Fig. 311: Removing Camshaft
PISTON, CONNECTING ROD & BEARING REMOVAL
Tools Required
J 24270 Ridge Reamer

J 5239 Connecting Rod Bolt Guide
1. Mark the piston with the number of the cylinder from which the piston is being removed.
2. Mark the connecting rod and the connecting rod cap in order to ensure correct assembly.
NOTE: If there is a pronounced ridge at the top of the piston travel, the ridge must
be removed with a ridge reamer before the piston and connecting rod
assembly are removed. Applying force may break the piston rings or
damage the piston.
3. Use the J 24270 in order to remove the cylinder bore ring ridge.
Complete the following steps:

3.1. Turn the crankshaft until the piston is at the bottom of the stroke.
3.2. Cover the piston with a cloth.
3.3. Remove the cylinder ring ridge.
3.4. Turn the crankshaft until the piston is at the top of the stroke.
3.5. Remove the cloth.
3.6. Remove the metal shavings from the cylinder and piston.
Fig. 312: Removing Cylinder Bore Ring Ridge Using Ridge Reamer (J 24270)
4. Remove the connecting rod nuts and cap.

5. Remove the connecting rod cap and bearing half.
NOTE: Install thread protector in order to avoid damage to the crankshaft journal.
6. Install J 5239 onto the connecting rod bolts.
7. Remove the connecting rod and piston assembly.
8. Push out the assembly using a suitable tool.
Fig. 313: Removing Connecting Rod And Piston Assembly
CRANKSHAFT REAR OIL SEAL REMOVAL
1. Remove the crankshaft rear oil seal.
Important: Do not damage the crankshaft or seal bore.
2. Pry out the crankshaft rear oil seal out using a suitable tool.

CRANKSHAFT AND BEARINGS REMOVAL
1. Remove the crankshaft position sensor stud.

2. Remove the crankshaft position sensor from the side of the block.
Fig. 315: Removing Crankshaft Position Sensor
3. Remove the crankshaft main bearing cap bolt and studs.

4. Remove the crankshaft main bearing caps and lower crankshaft main bearing halves.
Important: Use Care when handling the crankshaft.
Avoid damage to the crankshaft position sensor reluctor wheel teeth. Nicks, burrs or other damage to the
teeth may effect On-board Diagnostics - OBD II system performance.
5. Remove the crankshaft.

6. Remove the upper crankshaft main bearing halves.
Fig. 316: Removing Crankshaft And Upper Crankshaft Main Bearing Halves
CAMSHAFT BEARING REMOVAL

Tools Required
J 33049 Camshaft Bearing Remover/Installer
1. Select the expander assembly and driving washer.

2. Assemble the J 33049.
Fig. 317: Identifying Camshaft Bearing Remover/Installer (J 33049)
3. Drive out the camshaft bearings. Use the J 33049.

Fig. 318: Driving Out Camshaft Bearings
ENGINE BLOCK DISASSEMBLE

Fig. 319: Removing Camshaft Rear Bearing Hole Plug
2. Remove the rear oil gallery plugs (1, 2, 3).

Fig. 320: Removing Rear Oil Gallery Plugs
3. Remove the front oil gallery plugs (1, 2).

4. Remove all of the remaining engine block plugs.
Fig. 321: Removing Front Oil Gallery Plugs
5. Remove the knock sensor.

Fig. 322: Removing Knock Sensor
Fig. 323: Removing Engine Oil Pressure Switch

ENGINE BLOCK CLEANING AND INSPECTION
Tools Required
J8001 Dial Indicator Set

J 8087 Cylinder Bore Gage
1. Clean the sealing material from the gasket mating surfaces.
2. Boil the engine block in caustic solution.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.
5. Clean the blind holes.
6. Spray the cylinder bores and the machined surfaces with engine oil.
7. Inspect the threaded holes.
8. Clean the holes with a tap. Drill out the holes and install thread inserts, as needed.
Fig. 324: Identifying Engine Block For Cleaning
9. Use a straight edge and a feeler gauge in order to test the deck surface for flatness. Carefully machine
minor irregularities. Replace the block if more than 0.25 mm (0.010 in) must be removed.
10. Inspect the oil pan rail for nicks.
Inspect the front cover attaching area for nicks.
Use a flat mill file in order to remove any nicks.

Fig. 325: Testing Deck Surface For Flatness Using Straight Edge
11. Inspect the mating surfaces of the transmission case.

NOTE: A broken flywheel may result if the transmission case mating surface is
not flat.
12. Use the following procedure in order to measure the engine block flange runout at the 6 mounting bolt
hole bosses:
12.1. Temporarily install the crankshaft. Measure the crankshaft flange runout.
12.2. Hold the J 8001 gage plate flat against the crankshaft flange.
12.3. Place the dial indicator stem on the transmission mounting bolt hole boss.
Set the indicator to 0
12.4. Record the readings obtained from all of the bolt hole bosses. The measurements should not
vary more than 0.25 mm (0.010 in).
12.5. Retest the crankshaft flange runout if the readings vary more than 0.25 mm (0.010 in). If the
crankshaft flange runout is not within the specification, replace the engine block.
Fig. 326: Inspecting Mating Surfaces Of Transmission Case

Important: Perform the following inspections, and reconditioning if necessary, with the crankshaft main
bearing caps installed and tightened to specification.
13. Inspect the crankshaft main bearing bores.
Use the J 8087 in order to measure the bearing bore concentricity and alignment at the following
locations:
The camshaft
The crankshaft
14. Replace the engine block if the bores are out of specification.
Fig. 327: Inspecting Crankshaft Main Bearing Bores

15. Use the J 8087 in order to inspect the cylinder bores. Inspect the bores for the following conditions:
Wear
Taper
Runout
Ridging
Important: If the bore is worn beyond the limits, refit the bore with 0.5 mm (0.02 in) oversized pistons.
16. Leave sufficient material in order to allow honing when fitting the piston.
Fig. 328: Inspecting Cylinder Bores

CYLINDER BORING AND HONING
Boring Procedure
1. Before honing or boring, measure all of the new pistons. Select the smallest piston for the piston fitting.
Slightly varied pistons in a set may provide correction, if the first piston is too loosely fitted.
2. Before using any type of boring bar, file the top of the engine block to remove any dirt or burrs. If the
cylinder block is not straight, the boring bar may be tilted, causing the bored cylinder wall to have
incorrect right angles to the crankshaft.
3. Carefully follow the instructions furnished by the manufacturer regarding use of equipment.
4. Install all crankshaft main bearing caps to specification when boring cylinders. Cover or tape the
crankshaft bearings and other internal parts to protect these parts during the boring or honing operation.
Fig. 329: Identifying Cylinder Bore For Boring

5. Leave 0.03 mm (0.001 in) on the diameter for finish honing when performing the final cut with a boring
bar. Carefully perform the honing and boring operation to maintain the specified clearances between
pistons, rings, and cylinder bores.
Honing Procedure
1. 1. Follow the manufacturer's recommendations for use, cleaning, and lubrication when honing the
cylinders. Use only clean, sharp stones of the proper grade for the amount of material to be removed.
Dull, dirty stones cut unevenly and generate excessive heat. When using coarse or medium-grade stones,
leave sufficient metal so all stone marks may be removed with the fine stones used for finishing to
provide the proper clearance.
2. During the honing operation, thoroughly clean the cylinder bore. Check for the correct piston fit.
3. Make full strokes in the cylinder to eliminate taper.
Repeatedly check the measurement at the top, the middle, and the bottom of the cylinder bore.
NOTE: Handle the pistons with care. Do not force the pistons through the cylinder
until you hone the cylinder to the correct size. The piston can be distorted
through careless handling.
4. When finish honing a cylinder bore to fit a piston, move the hone up and down at a sufficient speed to
obtain a fine and uniform surface finish in a cross hatch pattern.
5. The finish marks should be clean but not sharp.
The finish marks should be free from imbedded particles and torn or folded metal.
6. Determine the finish hone cylinder measurement by measuring the piston to be installed, and by adding
the average of the clearance specification.
Measure the block and the piston at normal room temperature.
7. True up the refinished cylinder bores. Final hone each cylinder bore to remove all stone or cutter marks.
8. After final honing and before the piston is checked for fit, clean the bores with hot water and detergent.
Scrub the bores with a stiff bristle brush and rinse the bores thoroughly with hot water. Do not allow any
abrasive material to remain in the cylinder bores. This abrasive material will wear the new rings, the
cylinder bores, and the bearings lubricated by the contaminated oil. After washing dry the bore.
9. Permanently mark the piston for the cylinder to which the piston has been fitted.
10. Apply clean engine oil to each bore to prevent rusting.
ENGINE BLOCK ASSEMBLE
1. Apply sealer GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the oil pressure switch
threads.
Tighten
Tighten the engine oil pressure switch to 16 N.m (12 lb ft).

Fig. 330: Installing Engine Oil Pressure Switch
3. Apply sealer GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the knock sensor threads.
4. Install the knock sensor.
Tighten
Tighten the knock sensor to 19 N.m (14 lb ft).

Fig. 331: Installing Knock Sensor
5. Apply sealer GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the front oil gallery plug
threads (1 and 2).
6. Install the front oil gallery plug (1).
Tighten
Tighten the oil gallery plug (1) to 19 N.m (14 lb ft).
Tighten
Tighten the oil gallery plug (2) to 33 N.m (24 lb ft).

Fig. 332: Installing Front Oil Gallery Plug
8. Apply sealer GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the rear oil gallery plug
threads (1 and 4).
9. Install the rear oil gallery plugs (1 and 4).
Tighten
Tighten the oil gallery plugs (1 and 4) to 19 N.m (14 lb ft).
Tighten
Tighten the oil gallery plugs (2 and 3) to 33 N.m (24 lb ft).
11. Apply sealer GM P/N United States 12346004, GM P/N Canada 10953480 or the equivalent to the engine
block plugs.
12. Install the remaining engine block plugs.
Fig. 333: Installing Rear Oil Gallery Plugs

13. Apply sealant GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the coolant drain plug
threads.
14. Install the left coolant drain plug.
Tighten
Tighten the coolant drain plug to 19 N.m (14 lb ft).
Fig. 334: Installing Left Coolant Drain Plug

15. Apply sealant GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the coolant drain plug
threads.
16. Install the right coolant drain plug.
Tighten
Tighten the coolant drain plug to 19 N.m (14 lb ft).

Fig. 335: Installing Right Coolant Drain Plug
CRANKSHAFT AND BEARINGS CLEANING AND
Inspection
Tools Required

J 36660-A Torque Angle Meter
Important: Use Care when handling the crankshaft.
Avoid damage to the crankshaft position sensor reluctor wheel teeth. Nicks, burrs or other damage to the teeth
may effect On-board Diagnostics - OBD II system performance.
1. Clean the crankshaft of the following elements:

Oil
Sludge
Carbon
2. Inspect the crankshaft oil passages for obstructions.

Fig. 336: Identifying Crankshaft For Inspection
3. Inspect the crankshaft keyway for the following conditions:

A worn crankshaft key (1)
A worn crankshaft keyway (2)
4. Inspect the crankshaft threads (3) for damage.
Fig. 337: Inspecting Crankshaft Key, Keyway And Thread

Important: If cracks, severe gouges or burned spots are found, replace the crankshaft. Remove slight
roughness using a fine polishing cloth soaked in clean engine oil. Remove any burrs using a fine oil
stone.
5. Inspect the crankshaft bearing journals and the crankshaft thrust surfaces for the following conditions:
Wear without any grooves or scratches (1)
Grooves or scoring (2)
Scratches or excessive wear (3)
Pitting or embedded bearing material (4)
Inspect the corresponding crankshaft bearing inserts for embedded material and determine the
source of the material.
Overheating - discoloration
Fig. 338: Inspecting Crankshaft Bearing Journals And Crankshaft Thrust Surfaces
6. The crankshaft bearings are the precision insert type.

7. Inspect the outer surfaces of the crankshaft bearings for the following conditions:
Wear - surface wear indicates either movement of the insert, or high spots in the surrounding
material - spot wear.
Overheating or discoloration
Looseness or rotation indicated by flattened tangs and wear grooves

Fig. 339: Identifying Outer Surfaces Of Crankshaft Bearings For Inspection
Important: Note the location of the crankshaft main bearing high spots. If the spots are not in line, the
crankshaft is bent. Replace the crankshaft.
8. Inspect the crankshaft main bearings for craters or pockets. Flattened sections on the crankshaft bearing
halves also indicate fatigue.
9. Inspect the thrust surfaces of the main thrust bearing for the following conditions:
Wear
Grooving - Grooves are caused by irregularities of the crankshaft thrust surface.
Fig. 340: Identifying Crankshaft Main Bearings Fatigue

10. Inspect the crankshaft bearings for excessive scoring or discoloration.

11. Inspect the crankshaft main bearings for dirt or imbedded debris.
Fig. 341: Identifying Crankshaft Bearings Excessive Scoring Or Discoloration
12. Inspect the crankshaft main bearings for improper seating indicated by bright, polished sections.
13. Inspect the crankshaft bearings for uneven side-to-side wear. This may indicate a bent crankshaft or a
tapered bearing journal.
Fig. 342: Identifying Crankshaft Main Bearings Improper Seating
Important: If crankshaft bearing failure is due to conditions other than normal wear, investigate the
cause of the condition. Inspect the crankshaft or connecting rod bearing bores.
14. Inspect the connecting rod bearing bores or crankshaft main bearing bores using the following procedure:
14.1. Tighten the bearing cap to specification.
14.2. Use the J 8087 in order to measure the bearing bore for taper and out-of-round. Record the
readings for bearing selection.
14.3. No taper or out-of-round should exist.
Fig. 343: Inspecting Connecting Rod Bearing Bores
Bearing Selection
Measure the bearing clearance to determine the correct replacement bearing insert size. There are two methods
to measure bearing clearance. Method A gives more reliable results and is preferred.
Method A yields measurement from which the bearing clearance can be computed.
Method B yields the bearing clearance directly. Method B does not give any indication of bearing run-
out.
Fig. 344: Measuring Bearing Clearance Using Micrometer
Method A
Important: Do not mix inserts of different nominal size in the same bearing bore.
1. Measure the crankshaft bearing journal diameter with a micrometer in several places, 90 degrees apart.
Average the measurements.
2. Measure the crankshaft bearing journal taper and runout.
3. Install the crankshaft bearing inserts. Tighten the bearing cap bolts to specification using J36660-A.
4. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside
micrometer.
5. Measure the crankshaft main bearing inside diameter with an inside micrometer.
6. Select a set of bearing inserts that will produce the desired clearance.
7. If the specified clearances cannot be met, the crankshaft journals must be reconditioned and undersized
bearing inserts installed.
Fig. 345: Measuring Bearing Clearance Using Gaging Plastic
Method B
Important: Do not mix inserts of different nominal size in the same bearing bore.
1. Clean the used bearing inserts.

2. Install the used bearing inserts.
3. Place a piece of gaging plastic across the entire bearing width.
4. Install the bearing caps.
NOTE: In order to prevent the possibility of cylinder block or crankshaft bearing
cap damage, the crankshaft bearing caps are tapped into the cylinder
block cavity using a brass, lead, or a leather mallet before the attaching
bolts are installed. Do not use attaching bolts to pull the crankshaft
bearing caps into the seats. Failure to use this process may damage a
cylinder block or a bearing cap
5. Install the bearing cap bolts to specification using J 36660-A.
Important: Do not rotate the crankshaft.
6. Remove the bearing cap, leaving the gaging plastic in place. It does not matter whether the gaging plastic
adheres to the journal or to the bearing cap.
7. Measure the gaging plastic at its widest point with the scale printed on the gaging plastic package.
8. Remove the gaging plastic.
Inspect the crankshaft balancer sealing area for grooves (1).

Inspect the crankshaft balancer belt ribs for dents or damage.
Replace the crankshaft balancer if necessary.
Fig. 346: Identifying Crankshaft Balancer Sealing Area For Grooves Inspection
ENGINE FLYWHEEL CLEANING AND INSPECTION
Inspect the engine flywheel for cracks.

Inspect the engine flywheel teeth for damage.
Replace the engine flywheel if necessary.
Fig. 347: Identifying Crack Engine Flywheel
PISTON AND CONNECTING ROD DISASSEMBLE
Tools Required
J 24086-C Piston Pin Remover/Installer Set
1. Using piston ring pliers, remove the piston rings from the piston.
Fig. 348: Removing Piston Rings From Piston

2. Install fork insert J 24086-310 into fixture J 24086-10 Piston Pin Remover/Installer Base.
Fig. 349: Installing Fork Insert (J 24086-310) Into Fixture (J 24086-10) Piston Pin
Remover/Installer Base
3. Install the piston and connecting rod assembly onto J 24086-10.

4. Install the J 24086-107 onto the piston pin and J 24086-88A through the fixture and onto J 24086-107.
Fig. 350: Installing J 24086-107 Onto Piston Pin And J 24086-88A Through Fixture And Onto J
24086-107
NOTE: After the installer hub bottoms on the support assembly, do not exceed 35
000 kPa (5,000 psi) pressure, this could cause damage to the tool.
5. Press the piston pin from the piston and connecting rod assembly.
6. The piston and pin are a matched set and are not to be serviced separately. Mark, sort or organize the
piston and the matching piston pin.
Fig. 351: Pressing Piston Pin From Piston And Connecting Rod Assembly
PISTON, CONNECTING ROD & BEARINGS CLEANING & INSPECTION

Tools Required
CAUTION: Bodily injury may occur if the cleaning solvent is inhaled or exposed to
the skin.
Important: Measurement of all components should be taken with the components at room temperature.
Do not use a wire brush in order to clean any part of the piston.
1. Clean the piston and connecting rod in solvent.

Fig. 352: Identifying Piston, Piston Ring & Connecting Rod For Inspection
2. Clean the piston ring grooves with a suitable ring groove cleaning tool.
3. Clean the piston oil lubrication holes and slots.
Fig. 353: Separating Piston From Connecting Rod Using Special Tool
4. Inspect the piston for the following:

Eroded areas (1) on the top of the piston
Scuffed or damaged skirt (2)
Damage to the pin bore (3)
Cracks in the piston ring lands, the piston skirt, or the pin bosses
Piston ring grooves for nicks, burrs, or other warpage which may cause the piston ring to bind
5. Inspect the piston pin for scoring, wear or other damage.
Fig. 354: Inspecting Piston For Eroded Areas, Damaged Skirt And Damage Pin Bore
6. Measure the piston ring-to-piston ring groove side clearance.
6.1. Insert the edge of the piston ring into the piston ring groove
6.2. Roll the piston ring completely around the piston ring groove.
If binding is caused by distorted piston ring groove, replace the piston.
If binding is caused by a distorted piston ring, replace the piston ring.
Fig. 355: Measuring Piston Ring-To-Piston Ring Groove Side Clearance

7. Measure the piston ring side clearance with a feeler gage.

8. If the side clearance is too small try another ring set.
9. If the proper piston ring-to-piston ring groove clearance cannot be achieved, replace the piston and pin
assembly.
Proper ring-to-piston ring groove clearance for the top ring is 0.04-0.086 mm (0.00158-0.00338 in).
Proper ring-to-piston ring groove clearance for the second ring is 0.04-0.087 mm (0.00158-0.00342
in).
Fig. 356: Measuring Piston Ring Side Clearance With Feeler Gage
10. Measure the piston pin diameter using an outside micrometer.

Fig. 357: Measuring Piston Pin Diameter Using Outside Micrometer
Important: When fitting pistons, consider both the pistons and the cylinder bore conditions together.
Production and service pistons have the same nominal weight and may be intermixed without affecting
engine balance. If necessary, used pistons may be fitted selectively to any cylinder of the engine,
providing the pistons are in good condition and the same weight. Do not cut oversize pistons down or the
engine balance may be affected. Finish hone when selecting the piston.
11. Measure the piston pin bore using an inside micrometer.

12. Subtract the piston pin diameter from the piston pin bore diameter in order to determine the piston pin-to-
piston pin bore clearance.
13. Piston-to-piston pin bore clearance must measure 0.0096-0.0215 mm (0.0004- 0.0008 in). Replace the
piston and the piston pin if the piston and the piston pin are not within specifications.
Fig. 358: Identifying Piston Pin Bore Diameter For Measurement
14. Measure the piston diameter with a micrometer at a right angle to the piston bore with the piston pin
removed, and record the measurement. Measure the piston at 49.8 mm (1.9606 in) from dome of piston.
Piston diameter must measure 88.966- 88.984 mm (3.5026-3.5033 in). Replace the piston and the pin as
an assembly if the piston is not within specifications.
Fig. 359: Measuring Piston Diameter With Micrometer
15. Measure the cylinder bore, using J 8087.

Fig. 360: Measuring Cylinder Bore Using Cylinder Bore Gauge (J 8087)
16. Measure the J 8087. Record this reading.

17. Subtract the diameter of the piston from the diameter of the cylinder bore to determine the piston-to-bore
clearance. The cylinder bore clearance for pistons 1-4 must be 0.07-0.053 mm (0.0013-0.0027 in), pistons
5-6 must be - 0.008-0.048 mm (-0.0003-0.0018 in).
18. If a used piston is not acceptable, inspect the service piston sizes and determine if a new piston may be
selected. Service pistons are available in standard, and 0.5 mm (0.012 in) oversize.
19. When a piston has been selected, mark the piston in order to identify the cylinder for which the piston
was fitted.
Fig. 361: Measuring Cylinder Bore Gage Using Micrometer

20. Inspect the connecting rod for an out-of-round bearing bore. If the out-of-round measurement exceeds
0.005 mm (0.0002 in) the connecting rod must be replaced.
Fig. 362: Inspecting Connecting Rod For Out-Of-Round Bearing Bore
21. Inspect the connecting rod for twisting.

21.1. Install the connecting rod cap
21.2. Place the connecting rod assembly on a checking fixture. Inspect the assembly for bending or
twisting.
21.3. Do not attempt to straighten the connecting rod.
Ensure that the connecting rod meets the following conditions:
The connecting rods are not bent more than 0.18 mm (0.007 in).
The connecting rods are not twisted more than 0.038 mm (0.0015 in).
21.4. Replace any bent or twisted connecting rods

21.5. Inspect the new connecting rods before using the new rods.
22. Inspect the connecting rod for damage to the bearing cap and bolt threads.
Fig. 363: Inspecting Connecting Rod For Twisting
23. Measure the piston compression ring end gap.

Important: Fit each compression ring to the cylinder in which it will be used
23.1. Place the compression ring into the cylinder bore.

23.2. Push the compression ring into the bottom of the cylinder bore to approximately 6.5 mm
(0.25 in) above ring travel.
The ring must be square to the cylinder wall
23.3. Use a feeler gage in order to measure the end gap. The first compression ring end gap must
measure 0.15-0.36 mm (0.006-0.014 in), the second compression ring, 0.48-0.74 mm (0.0188-
0.0291 in).
23.4. Select another size ring set if the end gap exceeds specification. If ring gap clearance is below
specification, increase the gap by carefully filling off excess material.
Fig. 364: Measuring Piston Compression Ring End Gap Using Feeler Gage
24. Inspect the connecting rod bearings for craters or pockets. Flattened sections on the connecting rod
bearing halves may indicate fatigue.
Fig. 365: Inspecting Connecting Rod Bearings For Craters Or Pockets
25. Inspect the connecting rod bearings for excess scoring or discoloration.
26. Inspect the connecting rod bearings for dirt or debris imbedded into the connecting rod bearing halves.
Fig. 366: Inspecting Connecting Rod Bearings For Dirt Or Debris
27. Inspect the connecting rod bearings for improper seating indicated by bright, polished sections of the
bearings.
28. Inspect the inside of the connecting rod bearing and the outside diameter to the connecting rod bearing
journal for wear. This indicates high spots.
Fig. 367: Inspecting Connecting Rod Bearings For Improper Seating
PISTON AND CONNECTING ROD ASSEMBLE
Tools Required
J 24086-C Piston Pin Remover and Installer Set
Important: Assemble the piston for the specific cylinder with the connecting rod for the corresponding
crankshaft journal.
1. Install the fork insert J 24086-310 into fixture J 24086-10.

Fig. 368: Installing Fork Insert J 24086-310 Into Fixture J 24086-10
2. Lubricate the piston pin with clean engine oil.
Important: Ensure that the marks on the piston and connecting rod are aligned the same as when
removed. If installing a new piston, ensure that the arrow on top faces towards the front of the engine. If
no identification marks were made during disassembly, ensure that the flat area on the bottom of the
piston pin skirt is aligned with the small dimple above the connecting rod crankshaft bearing bore.
3. Assemble the piston, connecting rod and adapter J 24086-6A and install onto fixture J 24086-10.
Fig. 369: Assembling Piston, Connecting Rod And Adapter J 24086-6A

4. Adjust installation pin J 24086-9 to G-4.

Fig. 370: Identifying Installation Pin J 24086-9
NOTE: After the installer hub bottoms on the support assembly, do not exceed 35
000 kPa (5,000 psi) pressure, this could cause damage to the tool.
5. Insert pin J 24086-9 through fixture J 24086-10 and to the piston pin.
6. Press pin J 24086-9 until the install bottoms on fixture J 24086- 10.
Fig. 371: Inserting Pin J 24086-9 Through Fixture J 24086-10 And To Piston Pin
NOTE: Use a piston ring expander to install the piston rings. The rings may be
damaged if expanded more than necessary.
Important: To provide an effective compression seal, the ring gaps must be staggered a minimum of 90
degrees.
7. Using piston ring pliers, install the piston rings onto the piston.
7.1. Install the oil control ring spacer into the bottom groove of the piston
7.2. Install the lower oil control ring.
The oil control rings do not have a dimple or orientation mark and may be installed in either
direction.
Fig. 372: Installing Piston Rings Onto Piston
7.3. Install the upper oil control ring

7.4. Install the middle compression ring with the dot facing up.
7.5. Install the top compression ring in either direction. The ring has no orientation markings.
CAMSHAFT AND BEARINGS CLEANING AND INSPECTION
Tools Required
J 7872 Magnetic Base Dial Indicator Set
1. Clean the camshaft with cleaning solvent.

2. Inspect the camshaft for the following conditions:
Scored camshaft bearing journals (1)
Damaged camshaft lobes (2)
Damaged camshaft sprocket locator pins (3)
Damaged threads (4)
Damage to the camshaft reluctor tooth (5)
Fig. 373: Inspecting Camshaft For Scoring, Damaged Lobes, Sprocket Locator Pins And Threads
3. Measure the camshaft journals using a micrometer.

If the camshaft journals are not within specifications, replace the camshaft.
Fig. 374: Measuring Camshaft Journals Using Micrometer

4. Measure the camshaft runout using the J 7872.

4.1. Mount the camshaft in V-blocks between the centers
4.2. Use the J 7872 in order to measure the intermediate camshaft journal.
5. Measure the camshaft lobe lift using the J 7872.
5.1. Lubricate the camshaft using GM P/N 12345501 (Canadian P/N 992704) or the equivalent
5.2. Set the camshaft on V-blocks.
5.3. Use the J 7872 in order to measure the lobe lift.
6. If the runout or lobe lift is not within specifications, replace the camshaft.
Fig. 375: Measuring Camshaft Runout And Lobe Lift Using J 7872
TIMING CHAIN AND SPROCKETS CLEANING AND INSPECTION
Inspect the timing chain sprockets for teeth that are worn (1), broken (2), or chipped (3).
Inspect the timing chain for binding or stretching.
Inspect the timing chain dampener for excessive wear or cracks.
Replace the timing chain and sprockets as needed.
Fig. 376: Inspecting Timing Chain Sprockets For Worn, Broken Or Chipped Teeth
VALVE LIFTERS CLEANING AND INSPECTION
1. Clean the valve lifters in cleaning solvent.

2. Dry the valve lifters with compressed air.
3. Inspect the valve lifters for the following:
Bent or broken clip (1)
Worn push rod socket (2)
Scuffed or worn sides (3)
If the valve lifter shows wear, inspect the engine block lifter bores for wear or damage.
Flat spots on the roller (4)
Loose or damaged pin (5)
Plugged oil hole (6)
Worn or damaged roller bearing
The roller should rotate freely with no binding or roughness.
Fig. 377: Inspecting Valve Lifters For Bent Clip And Worn Push Rod Socket
4. Inspect the valve lifter guides for the following:
For cracks or damage
Excessive wear in the lifter mounting bores
Fig. 378: Inspecting Valve Lifter Guides For Cracks And Excessive Wear
VALVE ROCKER ARM AND PUSH RODS CLEANING AND INSPECTION
1. Clean the valve rocker arms and push rods in cleaning solvent.
2. Dry the valve rocker arms and push rods with compressed air.
3. Inspect the valve rocker arms for the following conditions:
Excessive wear at the valve contact or push rod socket area (1)
A loose or damaged pin (2)
A worn or damaged roller bearing (2)
The bolt threads for damage
Fig. 379: Inspecting Valve Rocker Arms For Excessive Wear Push Rod Socket Area And
Damaged Pin
Important: Keep the push rods in order. The intake and exhaust are different lengths.
4. Inspect the push rods for the following conditions:

Straightness using a straight edge (1)
Excessive wear on the push rod ends (3)
Clogging of the oil passage (2)
Fig. 380: Inspecting Push Rods For Straightness Using Straight Edge
CYLINDER HEAD DISASSEMBLE
Tools Required
Important: Ensure that the valve train components are marked, organized or sorted when disassembling the
cylinder head. Install the valve train components in the original location from which the components were
removed.
1. Remove the fuel line bracket bolt and stud.

2. Remove the fuel line bracket.
Fig. 381: Removing Fuel Line Bracket - Cylinder Head Disassemble
NOTE: Do not damage the valve guide. Remove any burrs that have formed at the
key groove by chamfering the valve stem with an oil stone or a file.
3. Compress the valve springs using the J 38606.

Fig. 382: Compressing Valve Springs Using J 38606 - Cylinder Head Disassemble
4. Remove the valve spring cap keys.

5. Remove the valve spring caps.
6. Remove the valve springs.
7. Remove the valves.
8. Remove the valve stem oil seals and spring seats as an assembly.
Fig. 383: Removing Valve Spring Caps, Spring And Valves - Cylinder Head Disassemble
CYLINDER HEAD CLEANING AND INSPECTION
Tools Required
J 8089 Carbon Removing Brush

J 9666 Valve Spring Tester
1. Inspect the cylinder head gasket and the mating surfaces. Inspect for leaks, corrosion, and blowby.
2. If the gasket failed, determine the cause.
The following conditions may cause gasket failure:
A loose or warped cylinder head
Missing, off location, or not fully seated dowel pins
Low torque on the cylinder head bolts
Cylinder head bolts with the incorrect length
A warped engine block surface
Scratched surfaces
Excessive intake manifold torque
Cracked engine block threaded holes
Fig. 384: Identifying Cylinder Head Gasket & Mating Surfaces For Inspection
Important: Do not scuff the chamber.
3. Use the J 8089 in order to remove the carbon from the combustion chambers.
4. Clean the following components:
The gasket surfaces
Do not use a motorized brush on any gasket sealing surface.
Valve stems and heads on a buffing wheel

The bolt hole threads
Remove all dirt, debris, or threadlocking material from the bolt holes.
Fig. 385: Removing Carbon From Combustion Chambers Using J 8089
5. Inspect the cylinder head mating surfaces for flatness. Recondition the cylinder head mating surface, if
necessary, by milling. Replace the cylinder head if you must remove more than 0.25 mm (0.010 in).
6. Inspect the cylinder head for cracks.
7. Inspect the cylinder head deck for corrosion. Do not attempt to weld the cylinder head. If the cylinder
head is damaged, replace the cylinder head.
Fig. 386: Inspecting Cylinder Head Mating Surfaces For Flatness
8. Inspect the valve springs for squareness.

Fig. 387: Inspecting Valve Springs For Squareness
9. Use the J 9666 in order to measure the valve spring tension.
Replace the spring if the spring tension is not within specification.

Fig. 388: Measuring Valve Spring Tension Using Valve Spring Tester (J 9666)
VALVE GUIDE REAMING/VALVE AND SEAT GRINDING
Tools Required
J 8520 Camshaft Lobe Lift Indicator Set
1. Inspect the valves for the following conditions:

Burnt or eroded areas (1)
A worn margin (2)
A bent stem (3)
A worn or scored stem (4)
A worn key groove (5)
A worn stem tip (6)
Fig. 389: Inspecting Valves For Eroded Areas, Bent And Worn Stem And Worn Stem Tip
2. Inspect the valve face for the following conditions:
Worn margin (4)
No margin (1)
Pitted surfaces (2)
3. Inspect the valve seats for a loose fit in the cylinder head.
Fig. 390: Inspecting Valve Face For Pitted Surfaces And Eroded Areas
NOTE: Proper valve stem-to-valve guide clearance is necessary for proper engine
operation and component life. Excessive clearance may cause a noisy
valve train, premature valve stem oil seal failure, excessive oil
consumption and related component damage.
Insufficient clearance may cause a noisy valve train, rough engine operation or sticking valves that may
lead to related component damage. Failure to inspect valve stem-to-valve guide clearance and repair or
replace necessary components may lead to extensive engine damage.
Important: Excessive valve stem-to guide clearance may cause the following conditions:
A noisy valve train

Premature valve stem oil seal wear
Component damage
Excessive engine oil consumption
4. Inspect for excessive valve stem (1) to guide (2) clearance.

Fig. 391: Inspecting For Excessive Valve Stem To Guide Clearance
5. Use a dial indicator in order to measure the valve stem-to-guide clearance. Complete the following steps:
5.1. Install the valve into the guide.
5.2. Install the J 8520 onto the cylinder head.
5.3. Locate the dial indicator so that the movement of the valve stem from side to side, crosswise to
the cylinder head, will cause a direct movement on the indicator stem.
5.4. Ensure that the indicator stem contacts the side of the valve stem just above the valve guide.
5.5. Drop the valve head about 2 mm (1/8 in) off the valve seat.
5.6. Use light pressure and move the valve stem side to side in order to obtain a clearance reading.
5.7. If the valve stem to guide clearance is not within specification, replace the valve and/or repair
the guide in order to obtain the proper clearances.
Fig. 392: Measuring Valve Stem-To-Guide Clearance Using Dial Indicator
Important: Replace a valve stem that has excessive scoring or wear. A valve guide that is worn and has
excessive stem-to-guide clearance may need to be sleeved.
6. Ream the valve guides for oversize valves if the clearance exceeds the specifications.
Fig. 393: Reaming Valve Guides For Oversize Valves
Important: Follow the manufacturers instructions when using valve guide reamers, sleeves, and
installers.
7. Ream the valve guide in order to obtain the proper specification.

Fig. 394: Reaming Valve Guide
Important: Valves that are pitted must be refaced to the proper angle. Replace valve stems that show
excessive wear, or replace valves that are warped. Several different types of equipment are available for
refacing valves and valve seats. Follow the manufacturers recommendations when performing these
procedures.
8. Inspect the valves for excessive scoring.

Fig. 395: Identifying Valve Spring Caps, Spring And Valves - Valve Guide Reaming/Valve And
Seat Grinding
9. Inspect the valve face.
Replace the valve if the valve margin is not within specifications after grinding.
10. Reface pitted valves on a valve refacing machine in order to ensure the correct relationship between the
head and the stem.
Important: Reconditioning the valve seats is very important. Ensure perfect seating of the valves in the
engine in order to deliver optimum power and performance. Clean the valve guides of all debris and dirt
before grinding the valve seat.
11. Recondition the valve seats after reaming the valve guide bores or installing the new valve guides.
12. The valve seats should be concentric to within 0.05 mm (0.031 in) total indicator reading.
Fig. 396: Inspecting Valve Face Margin
CYLINDER HEAD ASSEMBLE
Tools Required
Important: Use oversize valve stem seals if you install oversize valves.
1. Lubricate the valve stem with clean engine oil.

2. Install the valves.
3. Lightly lap the reconditioned valves into the valve seat.
4. Install the valve stem oil seals.
5. Install the valve springs.
6. Install the valve spring caps.
Fig. 397: Installing Valve Spring Caps, Spring And Valves

7. Compress the valve springs using the J 38606.

8. Install the valve spring cap keys.
Hold the valves in place with grease, if necessary.
9. Release the valve springs.

10. Ensure that the valve locks are seated.
11. Measure valve spring installed height.
12. If the valve spring installed height is not within specifications install 0.25 mm (0.010 in) rocker arm
shims as needed. If more than 2 shims are needed replace the cylinder head or valve.
Fig. 398: Compressing Valve Springs Using Valve Spring Compressor (J 38606)
NOTE: In order to avoid damage, install the spark plugs after the cylinder head
has been installed on the engine.
13. Install the fuel line bracket.

14. Install the fuel line bracket bolt or stud.
Tighten
Tighten the fuel line bracket bolt or stud to 50 N.m (37 lb ft).
Fig. 399: Installing Fuel Line Bracket

OIL PUMP DISASSEMBLE
1. Remove the oil pump driveshaft and oil pump driveshaft retainer.
Fig. 400: Removing Oil Pump Driveshaft And Oil Pump Driveshaft Retainer
Important: DO NOT remove the oil pump screen from the pipe. The pipe and oil pump screen are
serviced as a complete assembly.
2. Remove the oil pump screen, if necessary.
The oil pump screen has a press fit into the oil pump cover.
Fig. 401: Removing Oil Pump Screen
3. Remove the oil pump cover bolts.

Fig. 402: Removing Oil Pump Cover Bolts
4. Remove the oil pump cover.

Fig. 403: Removing Oil Pump Cover
5. Remove the oil pump drive gear and the oil pump driven gear.
6. Matchmark the gear teeth for assembly.
Fig. 404: Removing Oil Pump Drive Gear And Oil Pump Driven Gear
CAUTION: In some models, the pressure regulator valve spring is under
pressure. Remove the retaining pin carefully in order to avoid bodily
injury.
7. Remove the following items:

7.1. The oil pump pressure relief valve spring straight pin.
7.2. The oil pump pressure relief spring.
7.3. The oil pump pressure relief valve. If the valve is stuck, soak the pump housing in cleaning
solvent.
Fig. 405: Removing Oil Pump Pressure Relief Spring And Valve
OIL PUMP CLEANING AND INSPECTION

1. Clean all parts of sludge, oil, and varnish by soaking in cleaning solvent.
2. Inspect for foreign material and determine the source of the foreign material.
3. Inspect the pump housing and cover for the following conditions:
Cracks or casting imperfections
Scoring (3)
Damaged threads
4. Do not attempt to repair the pump housing.
Replace the pump housing.
5. Inspect the oil pump gears for the following conditions:

Scoring (1)
Excessive wear (2)

Fig. 406: Inspecting Pump Housing, Cover And Oil Pump Gears For Scoring And Excessive Wear
6. Inspect the idler shaft for looseness or scoring (4).
If loose or damaged, replace the oil pump.
7. Inspect the drive gear shaft for looseness or scoring (5).

8. Inspect the pressure regulator valve for the following conditions:
Scoring
Sticking
Burrs may be removed using a fine oil stone.
9. Inspect the pressure regulator valve spring for the following conditions:
Loss of tension
Bending
10. Inspect the suction pipe and screen assembly for the following conditions:
Looseness
If the suction pipe is loose, bent or has been removed, replace the pump body cover and suction
pipe.
Broken wire mesh or screen

Fig. 407: Inspecting Pressure Regulator Valve For Scoring And Spring For Loss Tension
11. Measure the oil pump gear lash. Install the gears, and measure in several places.
Fig. 408: Measuring Oil Pump Gear Lash
12. Measure the oil pump housing gear pocket (1, 2).
Fig. 409: Measuring Oil Pump Housing Gear Pocket
13. Measure the oil pump gears (1, 2).

Fig. 410: Measuring Oil Pump Gears
Important: When deciding pump serviceability based on end clearance, consider depth of the wear
pattern in the pump cover.
14. Measure the oil pump gear side clearance.

Fig. 411: Measuring Oil Pump Gear Side Clearance
OIL PUMP ASSEMBLE
Tools Required
J 21882 Oil Suction Pipe Installer

J 22144 Oil Suction Pipe Installer
1. Lubricate all the internal oil pump parts using engine oil during assembly.
2. Install the oil pump gears.
Fig. 412: Installing Oil Pump Gears
3. Install the oil pump cover.

4. Install the oil pump cover bolts.
Tighten
Tighten the oil pump cover bolts to 10 N.m (89 lb in).

Fig. 413: Installing Oil Pump Cover
5. Install the pressure regulator valve.

6. Install the pressure regulator spring.
7. Install the cotter pin.
Important: Make sure the cotter pin is properly secured.
8. Apply sealer GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the new suction pipe.
9. Tap the new suction pipe into place using a plastic hammer. Use the J 21882 for 5/8 inch pipe or J 22144
for 3/4 inch pipe.
Fig. 414: Installing Pressure Regulator Valve And Spring

1. Remove the crankshaft position sensor bolts from the engine front cover.
2. Remove the crankshaft position sensor.
Fig. 415: Removing Crankshaft Position Sensor
3. Clean the engine front cover with cleaning solvent.

4. Inspect the engine front cover sealing surfaces for damage.
5. Inspect the engine front cover threaded holes.
6. Repair or replace the engine front cover as necessary.
Fig. 416: Identifying Engine Front Cover For Inspection
7. Install the crankshaft position sensor to the engine front cover.

8. Install the crankshaft position sensor bolts. Apply threadlock GM P/N 12345382 (Canadian P/N
10953489) or the equivalent to the threads.
Tighten
Tighten the crankshaft position sensor bolts to 10 N.m (89 lb in).
Fig. 417: Installing Crankshaft Position Sensor

VALVE ROCKER ARM COVER CLEANING AND INSPECTION
1. Remove the rubber grommets.

2. Clean the valve rocker arm cover.
3. Inspect the valve rocker arm cover for damage.
Replace the valve rocker arm cover if necessary.
Fig. 418: Inspecting Valve Rocker Arm Cover For Damage

OIL PAN CLEANING AND INSPECTION

1. Remove the oil level sensor bolt, if equipped.
2. Remove the oil level sensor, if equipped.
3. Clean the oil pan in solvent. Remove all sludge and debris from the bottom of the oil pan.
4. Inspect the oil pan sealing surfaces for damage.
Replace the oil pan if necessary.
5. Install the oil level sensor, if equipped.

6. Install the oil level sensor bolt, if equipped.
Fig. 419: Removing Oil Level Sensor Bolt From Oil Pan
Tighten
Tighten the oil level sensor bolt to 10N.m (89lb in).
INTAKE MANIFOLD CLEANING AND INSPECTION - LOWER
Tools Required J 21882 Oil Suction Pipe Installer

1. Remove the engine coolant temperature sensor.
Fig. 420: Removing Engine Coolant Temperature Sensor

2. Remove the intake manifold coolant pipe bolt, if required.

3. Remove the intake manifold coolant pipe, if required.
Fig. 421: Removing Intake Manifold Coolant Pipe
Important: Use GM P/N 12346139 (Canadian P/N 10953463) or equivalent to clean the intake manifold
mating surfaces.
4. Clean the intake manifold gasket mating surfaces.

5. Clean the fuel injector bores.
6. Inspect the threaded holes for damage.
7. Inspect the intake manifold mating surfaces for damage.
Repair or replace the intake manifold as necessary.

Fig. 422: Identifying Lower Intake Manifold For Inspection
8. Apply sealant GM P/N 12345493 (Canadian P/N 10953488) to the end of a new intake manifold coolant
pipe.
9. Install the intake manifold coolant pipe using the J 21882.
10. Install the intake manifold coolant pipe bolt.
Tighten Tighten the intake manifold coolant pipe bolt to 10N.m (89lb in).
Fig. 423: Installing Intake Manifold Coolant Pipe
11. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of the engine
coolant temperature sensor.
12. Install the engine coolant temperature sensor.
Tighten
Tighten the engine coolant temperature sensor to 23N.m (17lbft).

Fig. 424: Installing Engine Coolant Temperature Sensor
INTAKE MANIFOLD CLEANING AND INSPECTION - UPPER
1. Remove the accelerator control cable bracket bolts (1,2) and the nut (3).
2. Remove the accelerator control cable bracket.
Fig. 425: Removing Accelerator Control Cable Bracket
3. Remove the throttle body bolt and stud.

4. Remove the throttle body.
5. Remove the throttle body gasket.
Fig. 426: Removing Throttle Body And Gasket

6. Clean the intake manifold gasket surfaces.

7. Clean the intake manifold bolts and studs.
8. Inspect the intake manifold mating surfaces for nicks or cracks.
Replace the intake manifold if damaged.

Fig. 427: Identifying Upper Intake Manifold For Inspection
9. Install the throttle body gasket.

10. Install the throttle body.
11. Install the throttle body bolt and stud.
Tighten Tighten the throttle body bolt and stud to 25N.m (18lbft).
Fig. 428: Installing Throttle Body And Gasket
12. Install the accelerator control cable bracket.

13. Install the accelerator control cable bracket bolts and nut.
Tighten Tighten the accelerator control cable bracket bolts in sequence (1, 2, 3) to 10 N.m (89 lb in).
Fig. 429: Installing Accelerator Control Cable Bracket
EXHAUST MANIFOLD CLEANING AND INSPECTION
1. Inspect the exhaust manifold mating surface for flatness.

2. Inspect the exhaust manifold for cracks or damage.
Replace the exhaust manifold if necessary.
Fig. 430: Inspecting Exhaust Manifold Mating Surface For Flatness

WATER PUMP CLEANING AND INSPECTION
1. Remove all gasket material from the sealing surface.

2. Inspect the water pump impeller for damage.
3. Inspect the water pump shaft for looseness.
4. Replace the water pump if necessary.
Fig. 431: Replacing Water Pump For Inspection

THREAD REPAIR
General purpose thread repair kits are available commercially.
Important: Refer to the thread repair kit manufacturer's instructions regarding the size of the drill and which
tap to use.
Always avoid any buildup of chips. Back out the tap every few turns and remove the chips.
1. Determine the size, the pitch, and the depth of the damaged thread.
2. Adjust the stop collars on the cutting tool as needed. Tap the stop collars to the required depth.
3. Drill out the damaged thread.
4. Remove the chips.
5. Apply clean engine oil to the top thread.
6. Use the tap in order to cut new thread.
7. Clean the thread.
Fig. 432: Identifying General Purpose Thread Repair Kits

8. Screw the thread insert onto the mandrel of the thread insert installer. Engage the tang of the thread insert
onto the end of the mandrel.
Important: The thread insert should be flush to 1 turn below the surface.
9. Lubricate the thread insert with clean engine oil - except when installing in aluminum - and install the
thread insert.
10. If the tang of the thread insert does not break off when backing out the thread insert installer, break off
the tang using a drift punch.
Fig. 433: Engaging Tang Of Thread Insert Onto End Of Mandrel

SERVICE PRIOR TO ASSEMBLY
Dirt will cause premature wear of the rebuilt engine.

Clean all of the components. Use the proper tools in order to measure components when inspecting for
excessive wear. Repair or replace the components that are not within the manufacturers specification.
When components are reinstalled into an engine, return the components to their original location, position, and
direction. During assembly, lubricate all of the moving parts with clean engine oil or engine assembly lubricant
unless otherwise specified. This will provide initial lubrication when the engine is first started.
ENGINE PRELUBING
Tools Required
J 45299 Engine Preluber
Important: A constant/continuous flow of clean engine oil is required in order to properly prime the engine.
Be sure to use an approved engine oil as specified in the owners manual.
1. Remove the engine oil filter, fill with clean engine oil.
2. Install the oil filter.
Tighten
Tighten the oil filter to 30 N.m (22 lb ft).
3. Locate the oil pressure sensor on left side of engine and remove.
4. Install the 1/4 inch adapter P/N 509373.
Fig. 434: Removing Oil Pressure Sensor From Left Side Of Engine
5. Install the flexible hose to the adapter and open the valve.
6. Pump the handle on J 45299 to flow a minimum of 1-2 quarts of engine oil. Observe the flow of engine
oil through the flexible hose and into the engine assembly.
7. Close the valve and remove the flexible hose and adapter from the engine.
8. Install the oil pressure sensor.
Tighten Tighten the oil pressure sensor to 16N.m (12lbft).
9. Top off the engine oil to the proper level.

Fig. 435: Identifying Engine Preluber
CAMSHAFT BEARING INSTALLATION

Tools Required
1. Assemble the J 33049 according to the manufacturer's instructions.

Fig. 436: Identifying Camshaft Bearing Remover/Installer (J 33049)
NOTE: Severe engine damage may result if the oil holes are not correctly aligned.
2. Install the camshaft bearings in the following order:
2.1. Index the camshaft bearing oil holes with the engine block oil passages.
2.2. Place the bearing on the J 33049.
2.3. Install the third camshaft bearing.
2.4. Install the second camshaft bearing.
2.5. Install the outer camshaft bearings.
Fig. 437: Installing Camshaft Bearings Using J 33049

3. Apply sealer GM P/N United States 12377901, GM P/N Canada 10953504 or the equivalent to the
camshaft rear bearing hole plug.
4. Install the camshaft rear bearing hole plug.
Fig. 438: Identifying Camshaft Rear Bearing Hole Plug Installation Depth
CRANKSHAFT AND BEARINGS INSTALLATION
Tools Required Torque Angle Meter
Important: Ensure that the crankshaft bearing cap bolt holes and the crankshaft bearing cap mating surfaces are
clean and dry.
1. Dip the crankshaft bearing cap bolts in clean engine oil.

NOTE: Upper and lower inserts may be different. Do not obstruct any oil
passages
2. Place the crankshaft bearing inserts into the crankshaft bearing cap and into the engine block.
Important: The crankshaft bearing inserts will project slightly when put into place. Ensure that the
bearing inserts project an equal distance on both sides. Ensure that the insert tangs are engaged.
3. Lubricate the crankshaft main bearing surface with clean engine oil.
4. Install the crankshaft.
NOTE: In order to prevent the possibility of cylinder block or crankshaft bearing

cap damage, the crankshaft bearing caps are tapped into the cylinder
block cavity using a brass, lead, or a leather mallet before the attaching
bolts are installed. Do not use attaching bolts to pull the crankshaft
bearing caps into the seats. Failure to use this process may damage a
cylinder block or a bearing cap
5. Install the crankshaft main bearing caps. Apply a small amount of sealer GM P/N 1052942 (Canadian
P/N 10953466) to the rear of the #4 crankshaft main bearing cap sealing surface.
6. Install the crankshaft main bearing cap bolts.
Tighten
Use the J 36660-A in order to tighten the crankshaft main bearing cap bolts to 50 N.m (37 lb ft) plus 77
degrees.
Fig. 439: Installing Crankshaft And Bearings
7. Measure the crankshaft end play.

7.1. Thrust the crankshaft forward or rearward
7.2. Insert a feeler gage between the number 3 crankshaft bearing and the bearing surface of the
crankshaft and measure the bearing clearance. The proper crankshaft end play clearance is 0.06-
0.21 mm (0.002-0.008 in).
7.3. If the bearing clearance is not within specifications, inspect the thrust surfaces for nicks,
gouges or raised metal. Minor imperfections may be removed with a fine stone.
Fig. 440: Measuring Crankshaft End Play

8. Install the crankshaft position sensor into the side of the engine block.
9. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or the equivalent to the crankshaft
position sensor stud threads.
10. Install the crankshaft position sensor stud.
Tighten Tighten the crankshaft position sensor stud to 11 N.m (98lb in).
Fig. 441: Installing Crankshaft Position Sensor
CRANKSHAFT REAR OIL SEAL INSTALLATION
Tools Required Rear Main Seal Installer
1. Apply engine oil to the inside diameter and the outside diameter of the new crankshaft rear oil seal.
2. Slide the crankshaft rear oil seal over the mandrel until the back of the crankshaft rear oil seal bottoms
squarely against the collar of the tool.
3.1. Align the dowel pin of the J 34686 with the dowel pin in the crankshaft.
3.2. Attach the J 34686 to the crankshaft by hand, or tighten attaching screws to 5 N.m (45 lb in).
Fig. 442: Installing Crankshaft Rear Oil Seal Using Rear Main Seal Installer (J 34686)
3.3. Turn the T-handle of the J 34686 in order to engage allow the collar to push the seal into the
bore.
Turn the handle until the collar is tight against the case. Ensure that the seal is seated properly
3.4. Loosen the T-handle until the T-handle comes to a stop.

3.5. Remove the attaching screws.
PISTON, CONNECTING ROD & BEARING INSTALLATION
Tools Required
J 5239 Connecting Rod Bolt Guide
J 8037 Piston Ring Compressor
Important: The piston and cylinder bore have been measured and the bore has been sized for the proper
clearance. Install the piston and connecting rod assembly into the proper cylinder bore. The piston alignment
mark MUST face the front of the engine block.
Fig. 443: Identifying Piston Rings, Piston And Connecting Rod
1. Lightly lubricate the following components with clean engine oil:
The piston
The piston rings
The cylinder bore
The bearing surfaces
2. Stagger the oil control ring end gaps a minimum of 90 degrees.

3. Stagger the compression ring end gaps a minimum of 25 mm (1.0 in).
4. Install the J 8037 onto the piston and compress the piston rings.
Important: The piston alignment mark MUST be facing the front of the engine block.
5. Install the J 5239 on the connecting rod bolts.

Fig. 444: Installing Connecting Rod Bolts Guide (J 5239) On Connecting Rod Bolts
6. Install the piston and connecting rod assembly into the proper cylinder bore.
7. Hold the piston ring compressor firmly against the engine block. Using a wooden hammer handle, lightly
tap the top of the piston until all of the piston rings enter the cylinder bore.
Fig. 445: Installing Piston And Connecting Rod Assembly
8. Guide the connecting rod end onto the crankshaft journal.

9. Install the bearing, cap, and nuts.
Tighten
9.1. Tighten the connecting rod bearing cap nuts a first pass to 20 N.m (15 lb ft).
9.2. Tighten the connecting rod bearing cap nuts a second pass to 75 degrees using the J 36660-A.
Fig. 446: Installing Connecting Rod Bearing, Cap And Nuts
10. With the pistons and connecting rods installed, use a soft faced mallet and lightly tap each connecting rod
assembly parallel to the crankpin to make sure that the rods have side clearance.
11. Measure the connecting rod side clearance using a feeler gage or dial indicator. Connecting rod side
clearance should be within 0.18-0.44 mm (0.007- 0.017 in).
Fig. 447: Measuring Connecting Rod Side Clearance

CAMSHAFT INSTALLATION
1. Coat the camshaft journals with clean engine oil.

2. Coat the camshaft lobes with prelube GM P/N United States 12345501, GM P/N Canada 992704 or the
equivalent.
3. Install the camshaft using the following procedure:
3.1. Install a large screwdriver into the camshaft bolt hole for support. Do not damage the threads.
3.2. Rotate the camshaft while installing the camshaft into the camshaft bearings.
Fig. 448: Installing Camshaft

4. Install the camshaft thrust plate.

5. Install the camshaft thrust plate screws.
Tighten Tighten the camshaft thrust plate screws to 10N.m (89lb in).
Fig. 449: Installing Camshaft Thrust Plate
6. Install the camshaft position sensor.

7. Install the camshaft position sensor bolt.
Tighten Tighten the camshaft position sensor bolt to 10N.m (89 lb in).
Fig. 450: Installing Camshaft Position Sensor
TIMING CHAIN AND SPROCKETS INSTALLATION

2. Apply prelube GM P/N United States 12345501, GM P/N Canada 992704 or the equivalent to the
crankshaft sprocket thrust surface.
Fig. 451: Installing Crankshaft Sprocket

Tighten Tighten the timing chain dampener bolt to 21 N.m (15 lb ft).
Fig. 452: Installing Timing Chain Dampener
6. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain to the
crankshaft gear.
(3).
Fig. 453: Identifying Aligning Marks On Camshaft Gear And On Timing Chain Dampener
Tighten Tighten the bolt to 140 N.m (103 lb ft).
Fig. 454: Installing Camshaft Sprocket Onto Camshaft

ENGINE FRONT COVER INSTALLATION

2. Apply sealer GM P/N 12346004, (Canadian P/N 10953480) or equivalent to both sides of the lower tabs
of the engine front cover gasket, and the engine front cover bolts.
Fig. 455: Identifying Engine Front Cover Gasket Lower Tabs For Applying Sealer

Tighten Tighten the engine front cover bolts (2) to 55 N.m (41 lb ft).
Fig. 456: Installing Engine Front Cover

Tighten Tighten the crankshaft position sensor wiring bracket bolt to 27 N.m (20 lb ft).
Fig. 457: Installing Crankshaft Position Sensor Wiring Bracket
CRANKSHAFT FRONT OIL SEAL INSTALLATION
Tools Required
J 35468 Cover Aligner and Seal Installer
1. Align the J 35468 and the crankshaft front oil seal with the engine front cover and crankshaft.
2. Install the crankshaft front oil seal using the J 35468 and a suitable tool.
Fig. 458: Installing Crankshaft Front Oil Seal Using Seal Installer (J 35468)
OIL PUMP DRIVE INSTALLATION
1. Apply prelube GM P/N United States 12345501, GM P/N Canada 992704 or the equivalent to the oil
pump drive gear.
Tighten Tighten the oil pump drive gear clamp bolt to 36 N.m (27 lb ft).
Fig. 459: Installing Oil Pump Drive Gear Assembly
OIL PUMP INSTALLATION

Tighten Tighten the crankshaft oil deflector nuts to 25N.m (18 lb ft).
Fig. 460: Installing Crankshaft Oil Deflector

Important: Do not reuse the oil pump driveshaft retainer. During assembly, install a NEW oil pump
driveshaft retainer.
3. Install the oil pump.

4. Position the oil pump onto the pins.
5. Install the oil pump bolt attaching the oil pump to the rear crankshaft bearing cap.
Tighten Tighten the oil pump bolt to 41 N.m (30 lb ft).

Fig. 461: Installing Oil Pump
OIL PAN INSTALLATION
1. Apply sealer GM P/N 12346141, Canadian P/N 10953433 or the equivalent to both sides of the
crankshaft rear main bearing cap (1). Press sealer into gap using a putty knife.
Fig. 462: Identifying Sealer Applying Width On Crankshaft Rear Main Bearing Cap
2. Install the oil pan gasket.

3. Install the oil pan.
4. Install the oil pan bolts.
Tighten Tighten the oil pan bolts to 25 N.m (18 lb ft).
5. Install the oil pan side bolts.
Tighten Tighten the oil pan side bolts to 50 N.m (37 lb ft).
Fig. 463: Installing Oil Pan
CYLINDER HEAD INSTALLATION - LEFT
1. Install the cylinder head locator dowel pins, if necessary.

2. Inspect the cylinder head locator dowel pins for proper installation.
Fig. 464: Installing Left Cylinder Head Gasket


Fig. 465: Installing Left Cylinder Head
5. Install the cylinder head bolts.

Tighten Tighten the cylinder head bolts in sequence to 60 N.m (44 lb ft). Turn the bolts an additional 95
degrees using the J 36660-A.
Fig. 466: Identifying Left Cylinder Head Bolts Tightening Sequence

CYLINDER HEAD INSTALLATION - RIGHT

Fig. 467: Installing Right Cylinder Head Gasket

Fig. 468: Installing Right Cylinder Head
5. Install the cylinder head bolts.

Tighten Tighten the cylinder head bolts in sequence to 60 N.m (44 lb ft). Turn the bolts an additional 95
degrees using the J 36660-A.
Fig. 469: Identifying Right Cylinder Head Bolts Tightening Sequence

WATER PUMP INSTALLATION
1. Install the water pump gasket.

2. Install the water pump.
3. Install the water pump bolts.
Tighten Tighten the water pump bolts to 11 N.m (98 lb in).

Fig. 470: Installing Water Pump Gasket And Water Pump
4. Install the water pump pulley.

5. Install the water pump pulley bolts.
Tighten Tighten the water pump pulley bolts to 25 N.m (18 lb ft).
Fig. 471: Installing Water Pump Pulley
VALVE LIFTER INSTALLATION
1. Coat the valve lifters using prelube GM P/N United States 1052367, GM P/N Canada 992869 or the
equivalent.
2. Install the valve lifters in their original locations.
3. Apply threadlock GM P/N United States 12345382, GM P/N Canada 10953489 or the equivalent to the
threads.
4. Install the valve lifter guides and guide bolts.
Tighten Tighten the valve lifter guide bolts to 10 N.m (89 lb in).
Fig. 472: Installing Valve Lifters
VALVE ROCKER ARM AND PUSH ROD INSTALLATION
Important: All gasket mating surfaces must be free of oil and foreign material. Use GM P/N 12346139
(Canadian P/N 10953463) or equivalent to clean surfaces.
Important: Do Not apply RTV sealer to the engine block before/prior to the installation of the manifold
gaskets. RTV sealer is not to be placed under the lower intake manifold gaskets.
Fig. 473: Installing Lower Intake Manifold Gaskets

2. Coat the ends of the push rods using prelube GM P/N 1052367, (Canadian P/N 992869) or the equivalent.
Important: The intake valve push rods measure 146.0 mm (5.75 in) in length.
3. Install the push rods in their original location.
The exhaust valve push rods measure 152.5 mm (6.0 in) in length.
Fig. 474: Installing Intake Valve Push Rods

4. Coat the rocker arm friction surfaces using prelube GM P/N 1052367, (Canadian P/N 992869) or the
equivalent.
Important: Shims may be required under the valve rocker arm pedestals if reconditioning has been
performed on the cylinder head or its components.
5. Install the valve rocker arms in their original positions.
6. Install the valve rocker arm bolts.
Tighten Use the J 36660-A to tighten the valve rocker arm bolts to 19 N.m (14 lb ft) plus 30 degrees.
Fig. 475: Installing Valve Rocker Arms

INTAKE MANIFOLD INSTALLATION - LOWER
Important: All gasket-mating surfaces need to be free of oil, and foreign material. Use GM P/N 12346139
(Canadian P/N 10953463) or equivalent to clean surfaces.
2. With gaskets in place apply a small drop 8-10 mm (0.31-0.39 in) of RTV sealer GM P/N 12346141
(Canadian P/N 10953433) or equivalent to the 4 corners of the intake manifold to block joint (1).
3. Connect the 2 small drops with a bead of RTV sealer that is between 8-10 mm (0.31-0.39 in) wide and
3.0-5.0 mm (0.12-0.20 in) thick (2).
Fig. 476: Installing Lower Intake Manifold

NOTE: Maximum gasket performance is achieved when using new fasteners,
which contain a thread-locking patch. If the fasteners are not replaced, a
thread locking chemical must be applied to the fastener threads. Failure to
replace the fasteners or apply a thread-locking chemical MAY reduce
gasket sealing capability.
Important: All lower intake manifold bolts need to be cleaned, free of any foreign material, and reused
only if new bolts are unavailable. Use GM P/N 12345382 (Canadian P/N 10953489) or equivalent and
apply to the old intake manifold bolt threads.
Important: Manufacturer recommends the center bolts be fully torqued before the diagonal bolts to
assure proper seal ability.
Fig. 477: Identifying Lower Intake Manifold Bolts Tightening Sequence

Important: Lower intake manifold bolts in location 6 and 7 should be torqued to specification using a
crows foot type tool.

Tighten
5.1. Tighten the lower intake manifold center bolts in sequence to 7 N.m (62 lb in) on the first pass.
5.2. Tighten the lower intake manifold center bolts in sequence to 13 N.m (115 lb in) on the final
pass.
5.3. Tighten the lower intake manifold diagonal bolts in sequence to 13 N.m (115 lb in) on the first
pass.
5.4. Tighten the lower intake manifold diagonal bolt in sequence to 25 N.m (18 lb ft) on the final
pass.
6. Install the heater inlet pipe.
7. Install the heater inlet pipe nut.
Tighten Tighten the heater inlet pipe nut to 25 N.m (18 lb ft).
Fig. 478: Installing Heater Inlet Pipe
Important: Do not press on the fuel pressure regulator valve when installing the fuel injector rail
assembly.
8. Install the fuel injector rail assembly.

8.1. Install the fuel injector O-rings using GM P/N 12345616, (Canadian P/N 993182) or equivalent
8.2. Install the injector nozzles into the lower intake manifold injector bores.
8.3. Press on the injector rail using the palms of both hands until the injectors are fully seated.
9. Install the fuel injector rail bolts.
Tighten Tighten the fuel injector rail bolts to 10 N.m (89 lb in).
Fig. 479: Installing Fuel Injector Rail Assembly
Tighten
Tighten the fuel feed and return pipe retaining clip bolt to 8 N.m (71 lb in).
Fig. 480: Installing Fuel Feed And Return Pipe Retaining Clip
Intake Manifold Installation - Upper
1. Install the upper intake manifold gaskets.

3. Install the upper intake manifold bolts and studs. Apply threadlock GM P/N 12345382 (Canadian P/N
10953489) to the threads.
Tighten
Tighten the upper intake manifold bolts and studs to 25 N.m (18 lb ft).
Fig. 481: Installing Upper Intake Manifold And Gaskets
4. Install the EGR valve pipe and bolt to the EGR.

Tighten
Tighten the EGR valve pipe bolt to 25 N.m (18 lb ft).
5. Install the EGR valve.

6. Install the EGR valve bolts.
Tighten
Tighten the EGR valve bolts to 25 N.m (18 lb ft).
Fig. 482: Installing Exhaust Gas Recirculation Valve

7. Install the map sensor bracket and bolts.

Tighten
Tighten the MAP sensor bracket bolts to 25 N.m (18 lb ft).
8. Install the MAP sensor.

9. Install the MAP sensor bolts.
Tighten
Tighten the MAP sensor bolts to 5 N.m (44 lb in).
10. Install the MAP sensor electrical connector.

Fig. 483: Installing Manifold Absolute Pressure Sensor
11. Install the vacuum lines to the upper intake manifold.

12. Install the throttle cable bracket.
13. Install the throttle cable bracket bolts.
Tighten
Tighten the throttle cable bracket bolts to 13 N.m (115 lb in).
Fig. 484: Installing Vacuum Lines To Upper Intake Manifold - Upper Intake Manifold Installation
Valve Rocker Arm Cover Installation - Right
2. Apply sealer GM P/N 12346141, (Canadian P/N 10953433) or the equivalent to the notches where the
cylinder head and intake manifold meet.
Tighten
Tighten the valve rocker arm cover bolts to 10 N.m (89 lb in).
Fig. 485: Installing Right Valve Rocker Arm Cover

5. Install the vacuum lines from the upper intake manifold.

Fig. 486: Installing Vacuum Lines To Upper Intake Manifold - Right Valve Rocker Arm Cover
Installation
6. Install the ignition coil studs.
Tighten
Tighten the ignition coil studs to 25 N.m (18 lb ft).
7. Install the electronic ignition control module.

8. Install the electronic ignition control module nuts and bolts.
Tighten
Tighten the electronic ignition control module nuts and bolts to 25 N.m (18 lb ft).
Fig. 487: Installing Electronic Ignition Control Module - Right Valve Rocker Arm Cover
Installation
VALVE ROCKER ARM COVER INSTALLATION - LEFT

2. Apply sealer GM P/N 12346141, (Canadian P/N 10953433) or the equivalent to the notches where the
cylinder head and intake manifold meet.
Tighten
Tighten the valve rocker arm cover bolts to 10 N.m (89 lb in).
Fig. 488: Installing Left Valve Rocker Arm Cover

WATER OUTLET AND THERMOSTAT INSTALLATION
1. Install the thermostat.

Fig. 489: Installing Thermostat
2. Install the water outlet.

3. Install the water outlet bolts.
Tighten
Tighten the water outlet bolts to 25 N.m (18 lb ft).
Fig. 490: Installing Water Outlet

EXHAUST MANIFOLD INSTALLATION - LEFT
1. Install the exhaust manifold studs.
Tighten
Tighten the exhaust manifold studs to 18 N.m (13 lb ft).

2. Install the exhaust manifold gasket.
3. Install the exhaust manifold.
4. Install the exhaust manifold nuts in sequence.
Tighten
Tighten the exhaust manifold nuts in sequence to 16 N.m (12 lb ft).
Fig. 491: Installing Left Exhaust Manifold And Gasket

5. Install the left side spark plugs.

Tighten
Tighten the spark plugs to 20 N.m (15 lb ft) when installing spark plugs into a new cylinder head.
Tighten the spark plugs to 15 N.m (13 lb ft) when re-installing after initial installation.
6. Install the exhaust manifold heat shield.

7. Install the exhaust manifold heat shield bolts.
Tighten
Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
Fig. 492: Installing Left Exhaust Manifold Heat Shield

EXHAUST MANIFOLD INSTALLATION - RIGHT
Tighten
Tighten the exhaust manifold studs to 18 N.m (13 lb ft).

4. Install the exhaust manifold nuts in sequence.
Tighten
Tighten the exhaust manifold nuts in sequence to 16 N.m (12 lb ft).
5. Install the right side spark plugs.
Tighten
Tighten the spark plugs to 20 N.m (15 lb ft) when installing spark plugs into a new cylinder head.
Fig. 493: Installing Right Exhaust Manifold And Gasket
6. Install the lower exhaust manifold heat shield.

7. Install the upper exhaust manifold heat shield.
Tighten
Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
Fig. 494: Installing Right Upper And Lower Exhaust Manifold Heat Shield
9. Coat the threads of the heated oxygen sensor with anti seize compound.
10. Install the heated oxygen sensor.
Tighten
Tighten the heated oxygen sensor to 42 N.m (31 lb ft).
11. Install the spark plug wires.

Fig. 495: Installing Heated Oxygen Sensor
AIR INJECTION CHECK VALVE INSTALLATION
1. Install air injection check valve pipe adapters, rear.
Tighten
Tighten the air injection check valve pipe adapters to 30 N.m (22 lb ft).
Fig. 496: Installing Rear Air Injection Check Valve Pipe Adapters
2. Install air injection check valve pipe adapters, front.
Tighten
Tighten the air injection check valve pipe adapters to 30 N.m (22 lb ft).
Fig. 497: Installing Front Air Injection Check Valve Pipe Adapters
3. Install air injection check valve rear bracket and nuts.
Tighten
Tighten the air injection check valve rear bracket nuts to 25 N.m (18 lb ft).
Fig. 498: Installing Air Injection Check Valve Rear Bracket

4. Install air injection check valve front bracket, bolt and nut.
Tighten
Tighten the air injection check valve front bracket bolt and nut to 25 N.m (18 lb ft).
Fig. 499: Installing Air Injection Check Valve Front Bracket

5. Install air injection check valve rear.
Tighten
Tighten the air injection check valve to 20 N.m (15 lb ft).
6. Install air injection check valve nut, rear.

Tighten
Tighten the air injection check valve nut rear to 10 N.m (89 lb in).
Fig. 500: Installing Rear Air Injection Check Valve

7. Install air injection check valve front.
Tighten
Tighten the air injection check valve front to 20 N.m (15 lb ft).
8. Install air injection check valve nut front.
Tighten
Tighten the air injection check valve nut to 10 N.m (89 lb in).
Fig. 501: Installing Front Air Injection Check Valve

9. Install air injection solenoid switch and bolt.
Tighten
Tighten the air injection solenoid switch bolt to 10 N.m (89 lb in).
Fig. 502: Installing Air Injection Solenoid Switch
10. Install air injection check valve pipe, clamps, and bolt.
Tighten
Tighten the air injection check valve pipe bolt to 10 N.m (89 lb in).
Fig. 503: Installing Air Injection Check Valve Pipe
11. Install air injection vacuum hose.

Fig. 504: Installing Air Injection Vacuum Hose
OIL FILTER ADAPTER INSTALLATION

2. Install the oil filter fitting, if necessary.
Tighten
Tighten the oil filter fitting to 39 N.m (29 lb ft).
3. Install the oil filter bypass valve plug. Apply sealer GM P/N 12345739 (Canadian P/N 10953541) or the
equivalent to the threads.
Tighten
Tighten the oil filter bypass valve plug to 19 N.m (14 lb ft).
Fig. 505: Installing Oil Filter Bypass Valve, Fitting And Bypass Valve Plug
Tighten
Tighten the oil filter to 30 N.m (22 lb ft).

OIL COOLER INSTALLATION
1. Install the oil cooler hose fitting.
Tighten
Tighten the oil cooler hose fitting to 19 N.m (14 lb ft).

Fig. 507: Installing Oil Cooler Hose Fitting
2. Install the oil cooler inlet hose clamp and the oil cooler inlet hose onto the oil cooler hose fitting.
Fig. 508: Installing Oil Cooler Inlet Hose
3. Install the oil cooler inlet hose clamp and oil cooler.
4. Install the oil cooler connector.
Tighten

5. Install the oil cooler outlet hoses and pipe.

6. Connect the lower oil cooler outlet hose to the oil cooler.
7. Connect the upper oil cooler hose to the thermostat bypass pipe.
Fig. 511: Installing Oil Cooler Outlet Hoses And Pipe
OIL LEVEL INDICATOR AND TUBE INSTALLATION
1. Install the oil level indicator and oil level indicator tube.
2. Install the oil level indicator tube bolt.
Tighten
Tighten the oil level indicator tube bolt to 25 N.m (18 lb ft).
3. Install the thermostat bypass pipe (3).

Fig. 512: Installing Oil Level Indicator And Oil Level Indicator Tube
4. Install the thermostat bypass pipe (3) and hose clamp (5).
5. Install the thermostat bypass pipe to engine front cover bolt (4).
Tighten
Tighten the thermostat bypass pipe to engine front cover bolt to 11 N.m (98 lb in).
6. Install the thermostat bypass pipe (3) to throttle body hose clamps (1).
7. Install the thermostat bypass pipe to throttle body nut (2).
Tighten
Tighten the thermostat bypass pipe to throttle body nut to 25 N.m (18 lb ft).
Fig. 513: Installing Thermostat Bypass Pipe

ENGINE LIFT BRACKET AND GENERATOR BRACKET INSTALLATION
1. Install the front engine lift hook.

3. Install the generator bracket bolts.
Tighten
Tighten the generator bracket bolts in sequence (1,2, 3) to 50 N.m (37 lb ft).
Fig. 514: Installing Front Engine Lift Hook And Generator Bracket
ENGINE MOUNT STRUT AND ENGINE LIFT BRACKET INSTALLATION
1. Install the engine mount strut and lift bracket.

2. Install the engine mount strut and lift bracket bolts.
Tighten
Tighten the engine mount strut and lift bracket bolts to 70 N.m (52 lb ft).
Fig. 515: Installing Engine Mount Strut And Lift Bracket
ENGINE MOUNT STRUT AND AIR CONDITIONING COMPRESSOR BRACKET INSTALLATION
1. Install the engine mount strut and A/C Compressor bracket.

2. Install the engine mount strut and A/C Compressor bracket bolts.
Tighten
Tighten the engine mount strut and lift bracket bolts to 50 N.m (37 lb ft).
Fig. 516: Installing Engine Mount Strut And A/C Compressor Bracket
DRIVE BELT TENSIONER INSTALLATION

Tighten
Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft).

Fig. 517: Installing Drive Belt Tensioner
ENGINE FLYWHEEL INSTALLATION
1. Install the flywheel.

2. Install the flywheel retainer.
3. Install the flywheel bolts.
Tighten
Tighten the flywheel bolts to 71 N m (52 lb ft)

Fig. 518: Installing Flywheel And Flywheel Retainer
CRANKSHAFT BALANCER INSTALLATION
Tools Required
J 29113 Crankshaft Balancer Installer

1. Apply sealer GM P/N 12346141, (Canadian P/N 10953433)) or the equivalent to the keyway of the
crankshaft balancer.
2. Place the crankshaft balancer into position over the key in the crankshaft.
3. Install the J 29113 onto the crankshaft.
4. Pull the crankshaft balancer into position.
5. Remove the J 29113 from the crankshaft balancer.
Fig. 519: Installing Crankshaft Balancer Installer (J 29113) Onto Crankshaft

NOTE: Do NOT use a power-assisted tool with the special tool in order to remove
or install this component. You cannot properly control the alignment of
this component using a power-assisted tool, and this can damage the
component.
6. Install the crankshaft balancer washer and bolt.
Tighten
Tighten the crankshaft balancer bolt a first pass to 70 N.m (52 lb ft).
Tighten the crankshaft balancer bolt a second pass to 85 degrees using the J36660-A.
Fig. 520: Installing Crankshaft Balancer Washer And Bolt

ROTATING THE ENGINE FOR SERVICE ACCESS
Tools Required
J 41131 Engine Tilter Strap

3. Shift the transaxle into Neutral.
4. Remove the engine mount strut bolts. Swing the engine mount struts aside.
5. Install the J 41131.
6. Pull on the engine in order to rotate the engine forward.
7. Tighten the J 41131.
Fig. 521: Installing Engine Tilter Strap (J 41131)


CRANKCASE VENTILATION SYSTEM DESCRIPTION
General Description
Fig. 522: Identifying Crankcase Ventilation System

A crankcase ventilation system is used to consume crankcase vapors in the combustion process instead of
venting them to atmosphere. Fresh air from the throttle body is supplied to the crankcase, mixed with blow by
gases and then passed through a PCV valve into the intake manifold.
Operation
Fig. 523: Crankcase Ventilation System Operation
The primary control is through the positive crankcase ventilation (PCV) valve which meters the flow at a rate
depending on inlet vacuum. To maintain idle quality, the PCV valve restricts the flow when inlet vacuum is
high. If abnormal operating conditions arise, the system is designed to allow excessive amounts of blow by
gases to back flow through the crankcase vent into the throttle body to be consumed by normal combustion.
Results of Incorrect Operation
A plugged valve may cause the following conditions:
Rough idle
Stalling or slow idle speed
Oil leaks
Sludge in engine
A leaking valve would cause:
Rough idle
Stalling
High idle speed
Functional Check of PCV valve
If an engine is idling rough, check for a clogged PCV valve. Replace if required. Use the following procedure:
1. Remove PCV valve from intake manifold.

2. Shake valve and listen for the rattle of needle inside the valve.
3. If valve does not rattle, replace valve.
With this system, any blow-by in excess of the system capacity (from a badly worn engine, sustained heavy
load, etc.) is exhausted into the intake manifold and is drawn into the engine.
Proper operation of the crankcase ventilation system is dependent upon a sealed engine. If oil sludging or
dilution is noted, and the crankcase ventilation system is functioning properly, check engine for possible cause
and correct to ensure that system will function as intended.
DRIVE BELT SYSTEM DESCRIPTION
The drive belt system consists of the following components:
The drive belt

The drive belt tensioner
The drive belt idler pulley
The crankshaft balancer pulley
The accessory drive component mounting brackets
The accessory drive components
The power steering pump, if belt driven

The generator
The A/C compressor, if equipped
The engine cooling fan, if belt driven
The water pump, if belt driven
The vacuum pump, if equipped
The air compressor, if equipped
The drive belt system may use one belt or two belts.
The drive belt is thin so that it can bend backwards and has several ribs to match the grooves in the pulleys.
There also may be a V-belt style belt used to drive certain accessory drive components. The drive belts are
made of different types of rubbers (chloroprene or EPDM) and have different layers or plys containing either
fiber cloth or cords for reinforcement.
Both sides of the drive belt may be used to drive the different accessory drive components. When the back side
of the drive belt is used to drive a pulley, the pulley is smooth.
The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component pulleys.
The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent the drive belt from
slipping. The drive belt tensioner arm will move when loads are applied to the drive belt by the accessory drive
components and the crankshaft.
The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys. Some
systems use an idler pulley in place of an accessory drive component when the vehicle is not equipped with the
accessory.
ENGINE COMPONENT DESCRIPTION
The cylinder block is made of cast alloy iron. The cylinder block has 6 cylinders that are arranged in a V shape.
There are 3 cylinders in each bank. The cylinder banks are set at a 60 degree angle from each other.
Starting from the front of the engine, the left bank cylinders are 1, 3, 5. The right bank cylinders are 2, 4, 6.
Four main bearings support the crankshaft. The crankshaft is retained by the bearing caps. The bearing caps are
machined with the block for proper alignment and clearances. The main bearing caps are drilled and tapped for
the structural oil pan side bolts.
The aluminum cylinder heads have individual intake and exhaust ports for each cylinder. The valve guides are
pressed in. The roller rocker arms are located on a pedestal in a slot in the cylinder head. The roller rocker arms
are retained on individual threaded bolts.
The crankshaft is cast nodular iron with deep rolled fillets on all 6 crankpins and all 4 main journals.
Four steel-backed aluminum bearings are used. The #3 bearing is the end-thrust bearing.
The camshaft is made from a new metal composite design. The camshaft profile is a hydraulic roller design.
The camshaft is supported by 4 journals. The camshaft includes an oil pump drive gear.
The pistons are cast aluminum using 2 compression rings and 1 oil control ring. The piston pin is offset 0.8 mm
(0.031 in) towards the major thrust side. This placement allows for a gradual change in thrust pressure against
the cylinder wall as the piston travels its path. The pins are chromium steel. The pins have a floating fit in the
pistons. The pins are retained in the connecting rods by a press fit.
The 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.
A roller rocker type valve train is used. Motion is transmitted from the camshaft through the hydraulic roller
lifter and from the pushrod to the roller rocker arm. The rocker arm pivots on the needle roller bearings. The
rocker arm transmits the camshaft motion to the valve. The rocker arm pedestal is located in a slot in the
cylinder head. The rocker arm is retained in the cylinder head by a bolt. The pushrod is located by the rocker
arm.
The intake manifold is a 2-piece cast aluminum unit.
The intake manifold centrally supports a fuel rail with 6 fuel injectors.
The exhaust manifolds are cast nodular iron.
NEW PRODUCT INFORMATION
The purpose of New Product Information is to highlight or indicate important product changes from the
previous model year.
Changes may include one or more of the following items:
A component comparison from the previous year

Fastener changes
Torque values and/or fastener tightening strategies
Changed engine specifications
New sealants and/or adhesives
Disassembly and assembly procedure revisions
Engine mechanical diagnostic procedure revisions
New special tools required
Component Comparison
No new components for 2003.
Fastener Changes
No fastener changes for 2003.
Torque Values and/or Fastener Tightening Strategies
Crankshaft Position Sensor Wiring Bracket Bolt was 40 N.m (30 lb ft) is now 27 N.m (20 lb ft).
Spark Plug - New Cylinder Head was 27 N.m (20 lb ft) is now 20 N.m (15 lb ft).
Lower Intake Manifold Bolt Strategy is now First Pass 7 N.m (62 lb in); Final Pass 13 N.m (115 lb in).
Changed Engine Specifications
A new Engine Mechanical Specifications chart has been implemented into the 2003 service manual.
New Sealants and/or Adhesives
No new sealants and/or adhesives for 2003.
Crankshaft Position Sensor Wiring Bracket Bolt was 40 N.m (30 lb ft) is now 27 N.m (20 lb ft).
Spark Plug - New Cylinder Head was 27 N.m (20 lb ft) is now 20 N.m (15 lb ft).
Lower Intake Manifold Bolt Strategy is now first pass 7 N.m (62 lb in), second pass 13 N.m (115 lb in).
A new Engine Mechanical Specifications chart has been implemented into the 2003 service manual.
No new sealants and/or adhesives for 2003.
Disassembly and Assembly Procedure Revisions
Oil Level Indicator and Tube Removal and Installation procedure has been revised.
Exhaust Manifold - Left/Right Removal and Installation procedure has been revised.
Water Outlet Removal and Installation is now Water Outlet and Thermostat Removal and Installation.
Valve Rocker Arm Cover Removal and Installation - Left/Right procedure has been revised.
Camshaft and Bearings Cleaning and Inspection procedure has been revised.
Intake Manifold Cleaning and Inspection - Lower procedure has been revised.
Valve Rocker Arm and Push Rod Installation procedure has been revised.
Engine Prelubing procedure has been added.
Engine Mechanical Diagnostic Procedure Revisions
Coolant in Combustion Chamber Diagnostic Procedure has been added.

Coolant in Engine Oil Diagnostic Procedure has been added.
New Special Tools Required
J 45299 Engine Preluber has been added.
LUBRICATION DESCRIPTION
Front View
Fig. 524: Front Cut-Away View Of Lubrication System
Full pressure lubrication, through a full flow oil filter, is furnished by a gear type oil pump. The oil is drawn up
through the pickup screen and the tube. The oil passes through the pump to the oil filter.
The oil filter is a full flow paper element unit. An oil filter bypass is used in order to ensure oil supply during
On a cold start
If the filter is plugged
If the filter develops excessive pressure drop
The bypass is designed to open at 69-83 kPa (10-12 psi).
A priority oil delivery system supplies oil first to the crankshaft journals. The oil from the crankshaft main
bearings is supplied to the connecting rod bearings by intersecting the passages drilled in the crankshaft.
The passages supply the oil to the crankshaft main bearings and the camshaft bearings through the intersecting
vertical drilled holes. The oil passages from the camshaft journals supply oil to the hydraulic lifters.
The hydraulic lifters pump oil up through the pushrods to the rocker arms. The cast dams in the crankcase
casting direct the oil that drains back from the rocker arms in order to supply the camshaft lobes.
The camshaft chain drive is lubricated by indirect oil splash.
Rear View
Fig. 525: Rear Cut-Away View Of Lubrication System
Right View
Fig. 526: Right Cut-Away View Of Lubrication System
CLEANLINESS AND CARE
An automobile engine is a combination of many of the following surfaces:

Machined
Honed
Polished
Lapped
The tolerances of these surfaces are measured in the ten-thousandths of an inch. When you service any internal
engine part, cleanliness and care are important. Apply a liberal coating of engine oil to the friction areas during
assembly in order to protect and lubricate the surfaces on initial operation.
Throughout this section, practice proper cleaning and protection procedures to the machined surfaces and to the
friction areas.
NOTE: Engine damage may result if an abrasive paper, pad, or motorized wire brush is
used to clean any engine gasket surfaces.
Whenever you remove the valve train components, keep the components in order. Follow this procedure in
order to install the components in the same locations and with the same mating surfaces as when removed.
Disconnect the negative battery cables before you perform any major work on the engine. For more information
on the disconnection of the battery, refer to Engine Electrical.
SEPARATING PARTS
In addition to the RTV sealant's sealing capabilities, the RTV sealants may form an adhesive bond between the
components. This may make the components difficult to remove or to separate. The RTV sealant is weakest in
shear strength and parts. If possible, bump the components sideways rather than using prying tools in order to
remove the components. This technique prevents damage when the bonding strength of the RTV sealant is
stronger than the component itself. Perform bumping at the bends or at the reinforced areas in order to prevent
part distortion.
REPLACING ENGINE GASKETS
1. Do not reuse any gasket unless otherwise specified. Reusable gaskets will be identified in the service
procedure. Do not apply sealant to any gasket or sealing surface unless called out in the service
procedure.
2. Use a rubber mallet in order to separate components. Bump the part sideways in order to loosen the
components. Perform the bumping at the bends or at the reinforced areas in order to prevent the distortion
of components.
Important: Do not use any other method or technique in order to remove the gasket material from a
components.
Do not use the following items in order to clean the gasket surfaces:
Abrasive pads
Sand paper
Power tools
These methods of cleaning may damage the component.
Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive
and may cause internal engine damage.
3. Remove all of the gasket and the sealing material from the component using a plastic or a wood scraper.
Do not gouge or scrape the sealing surfaces.
Important: Do not allow the sealant to enter any blind threaded holes. The sealant may cause the
Prevent you from properly seating the bolt

Cause damage when you tighten the bolt
4. When assembling components, use only the sealant specified in the service procedure. Ensure that the
sealing surfaces are clean and free of debris or oil. When applying sealant to a component, apply a bead
size as specified in the service procedure.
5. Tighten the bolts to the specifications.
USE OF RTV AND ANAEROBIC SEALER
The following 2 types of sealer are commonly used in engines:
The RTV sealer

The anaerobic gasket eliminator sealer
Follow the service procedure instructions. Use the correct sealer in the proper place in order to prevent oil leaks.
Do not interchange the 2 types of sealers.
Use the sealer recommended in the service procedure.
Applying RTV Sealer
Do not use the room temperature vulcanizing (RTV) sealant in areas where extreme temperatures are
expected. These areas include the following locations:
The exhaust manifold

The head gasket
The other surfaces where gasket eliminator is specified
Use a rubber mallet in order to separate the components sealed with RTV sealant. Bump the part
sideways in order to shear the RTV sealer.
Perform the bumping at the bends or the reinforced areas in order to prevent distortion of the components. The
RTV sealant is weaker in shear (lateral) strength than in tensile (vertical) strength.
component.
Abrasive pads
Sand Paper
Power tools
These methods of cleaning may damage the part.
Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and
may cause internal engine damage.
Remove all of the gasket material from the component using a plastic or a wood scraper. Use Loctite
brand gasket remover P/N 4MA or the equivalent. Follow all of the safety recommendations and the
directions that are on the container.
Important: Do not allow the sealer to enter the blind threaded holes. The sealer may cause the following
conditions:

Apply the RTV sealant to a clean surface. Use a bead size as specified in the procedure. Apply the bead to
the inside of any bolt holes.
Assemble the components while the RTV sealant is still wet (within 3 minutes). Do not wait for the RTV
sealant to skin over.
Important: Do not overtighten the bolts.
Tighten the bolts to specifications.
Applying Anaerobic Sealer
The anaerobic gasket eliminator hardens in the absence of air. This type of sealer is used where 2 rigid parts
(such as castings) are assembled together. When 2 rigid parts are disassembled and no sealer or gasket is readily
noticeable, the parts were probably assembled using a gasket eliminator.
component.
Abrasive pads
Sand paper
Power tools
Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is abrasive and
may cause internal engine damage.
Remove all of the gasket material from the component using a plastic or a wood scraper. Use Loctite
brand gasket remover P/N 4MA or the equivalent. Follow all of the safety recommendations and the
directions that are on the container.
Apply a continuous bead of the gasket eliminator to 1 flange. Clean and dry any surfaces that you will
reseal.
Important: Anaerobic sealed joints that are partially torqued and allowed to cure more than 5 minutes may
result in incorrect shimming and sealing of the joint.
Do not allow the sealer to enter the blind threaded holes. The sealer may cause the following conditions:

Spread the sealer evenly in order to get a uniform coating on the sealing surface.
Tighten the bolts to the specifications.
Remove the excess sealer from the outside of the joint.
TOOLS AND EQUIPMENT
Work in a clean and well-lit area. Have the following components available before you begin to work:
A suitable parts cleaning tank

A compressed air supply
Trays, in order to keep the parts and the fasteners organized
An adequate set of hand tools
An approved engine repair stand will prevent personal injury or damage to the engine components. The special
tools are designed in order to quickly and safely accomplish the operations for which the tools are intended.
Using the tools will minimize possible damage to the engine components. Precision measuring tools are
required for the inspection of certain critical components. Torque wrenches are needed for the correct assembly
of various parts.

Fig. 527: Identifying Special Tools & Equipment (1 Of 7)
3.4L V6
Engine is identified by eighth character of Vehicle Identification Number (VIN). VIN is visible through
windshield on left side of instrument panel. VIN is also located on Safety Compliance Certification Label
attached to left door lock pillar.
Engine may also be identified by engine identification (ID) number stamped on left side of cylinder block, on
engine-to-transaxle mating flange. Engine ID number, LA1, identifies 3.4L SFI engine.
VIN ENGINE CODE

Engine Code
3.4L SFI E
ADJUSTMENTS
VALVE CLEARANCE ADJUSTMENT
Engine has hydraulic valve lifters. Valve adjustment is not required.
TROUBLE SHOOTING
NOTE: To trouble shoot engine mechanical components, see appropriate table in

TROUBLE SHOOTING article in GENERAL INFORMATION.

battery.
NOTE: For reassembly reference, label all electrical connectors, vacuum hoses and
fuel lines before removal. Also, place mating marks on engine hood and other
major assemblies before removal.
FUEL PRESSURE RELEASE
Disconnect negative battery cable. Loosen fuel filler cap. Install Fuel Pressure Gauge (J-34730-1A) to fuel
pressure test head. Wrap shop towel around pressure connection when installing fuel pressure gauge to absorb
fuel leakage. Place gauge bleed hose in container. Open bleed valve to relieve fuel pressure.
COOLING SYSTEM BLEEDING
1. Open air bleed screw located on thermostat housing (there may be a second bleed screw on water pump).
Slowly fill cooling system through radiator neck to base of radiator neck. Wait 2 minutes. Recheck fluid
level. Add coolant to restore level to base of radiator neck.
2. Install radiator cap. Close air bleed screws. Start engine and allow fan to cycle on and off 3 times. Check
fluid level.
ENGINE
Removal
CAUTION: Always replace accelerator control cable with NEW cable whenever
engine is removed. This damage can result in loss of control of
vehicle.
CAUTION: Position cruise control cable aside to avoid damage. If cable is

damaged, it must be replaced. Damage can result in loss of control of
vehicle.
1. Disconnect battery cables. Remove throttle body and air inlet duct. Disconnect cruise control cable, and
position aside. Remove accelerator control cable. Drain cooling system. Disconnect radiator hoses and
heater hoses from engine. Remove engine mount struts.
2. Release fuel pressure. See FUEL PRESSURE RELEASE. Disconnect fuel lines at quick disconnects.
Disconnect necessary electrical connectors and vacuum lines from engine. Disconnect brake booster hose.
3. Disconnect transmission shift control cable and A/C lines. Raise and support vehicle. Drain engine oil.
Disconnect wiring harness grounds. Disconnect exhaust/converter pipe from right exhaust manifold. On
AWD Aztek, remove rear drive shaft. Remove front wheels.
4. Remove lower radiator baffle. Remove inner fender splash shields. Remove stabilizer shaft links from
lower control arms. Remove tie rod ends from steering knuckles. Remove lower ball joints from
knuckles. Drain transaxle fluid.
5. Remove transaxle cooler lines and bracket from transaxle. Remove drive axles from transaxle. See
appropriate FWD AXLE SHAFTS article in DRIVE AXLES. Wire drive axles to steering knuckles.
CAUTION: Failure to disconnect intermediate shaft from rack and pinion

steering gear stub shaft can result in damage to steering gear and/or
intermediate shaft. This damage can result in loss of control of
vehicle.
6. Remove pinch bolt/screw at intermediate shaft. Remove intermediate shaft from steering gear. Support
engine/transaxle/frame with transaxle table. Remove frame-to-body bolts. Raise vehicle, to separate
engine/transaxle/frame from vehicle. Remove starter. Remove flywheel-to-torque converter bolts. Install
engine hoist. Remove engine-to-transaxle bolts. Remove engine.
Installation
To install, reverse removal procedure. Tighten nuts and bolts to specification. See TORQUE
SPECIFICATIONS.
CAUTION: When installing intermediate shaft, ensure shaft is seated prior to pinch
bolt installation.
UPPER INTAKE MANIFOLD
Removal
1. Disconnect negative battery cable. Drain cooling system. Remove air cleaner ducts.
2. Remove accelerator and cruise control cables with bracket from throttle body. Remove front spark plug
wires. Disconnect harness connectors, vacuum hoses and coolant hoses from throttle body. Remove
ignition coil bracket with coils and canister purge solenoid.
3. Remove Manifold Absolute Pressure (MAP) sensor. Disconnect and remove emission control vacuum
harness. See Fig. 1. Remove EGR valve and generator front and side brackets. Remove upper intake
manifold retaining bolts. Remove upper intake manifold. See Fig. 2.
Installation
SPECIFICATIONS. Fill cooling system.
Fig. 1: Emission Control Vacuum Harness
Fig. 2: Upper Intake Manifold Assembly
LOWER INTAKE MANIFOLD
Removal
1. Disconnect negative battery cable. Remove upper intake manifold. See UPPER INTAKE MANIFOLD.
Remove valve covers. See VALVE COVERS. Disconnect harness connectors from intake manifold
components. Release fuel pressure. See FUEL PRESSURE RELEASE. Disconnect fuel lines from rail.
Remove fuel rail.
2. Unbolt power steering pump from front cover, and position aside. Disconnect upper radiator hose, heater
hoses and thermostat by-pass hose from lower intake manifold. Remove lower intake manifold retaining
bolts. Remove lower intake manifold. Loosen rocker arms and remove push rods to remove lower intake
manifold gaskets.
Installation
NOTE: When replacing lower intake manifold gasket, a revised intake manifold gasket
has been introduced by manufacturer. This new design gasket helps resolve
issues related to intake manifold oil/coolant leaks. The gasket requires a
revised torque specification and procedure in addition to the use of NEW
revised intake manifold bolts. Please review TSB ENGINE OIL OR COOLANT
LEAK (INSTALL NEW INTAKE MANIFOLD GASKET) for complete information.
NOTE: All gasket-mating surfaces need to be free of oil, and foreign material.
1. Clean all gasket mating surfaces. Install lower intake manifold gaskets. With the gaskets in place, apply a
0.31-0.39" (8-10 mm) drop of GM RTV sealer (12346286 US; 10953472 Canada) or equivalent to the 4
corners of the intake manifold-to-block joint. Connect the drops at both ends on the ridge where the front
and rear of lower intake manifold contacts the block with a bead of RTV sealer that is 0.31-0.39" (8-10
mm) wide and 0.12-0.20" (3.0-5.0 mm) thick.
2. Install push rods into original position and tighten rocker arms to specification. See TORQUE
SPECIFICATIONS. Install lower intake manifold. Apply Sealant (12345282) to bolt threads.
3. Hand tighten vertical bolts. Hand tighten diagonal bolts. Tighten bolts to specification. See TORQUE
SPECIFICATIONS. See Fig. 3. To complete installation, reverse removal procedure.
NOTE: An oil leak may result if vertical bolts are not tightened before diagonal bolts.
Fig. 3: Lower Intake Manifold Bolt Tightening Sequence
EXHAUST MANIFOLDS
Removal (Left)
1. Disconnect negative battery cable. Remove air cleaner duct. Drain cooling system. Remove left (front)
engine mount strut bracket. Disconnect upper radiator hose from engine. Remove A/T vacuum modulator
pipe (if equipped).
2. Remove thermostat by-pass pipe. Remove crossover pipe heat shield. Remove crossover pipe bolts at left
exhaust manifold. Remove left (front) exhaust manifold heat shield. Remove exhaust manifold retaining
nuts. Remove exhaust manifold and gasket.
Removal (Right)
1. Disconnect negative battery cable. Remove engine. See ENGINE.

2. Remove heat shields. Remove RH side spark plugs. Remove exhaust manifold and gaskets.
Installation
SPECIFICATIONS.
VALVE COVERS
Removal (Left)
Disconnect negative battery cable. Remove front spark plug wires. Remove A/T vacuum modulator pipe (if
equipped). Remove right engine strut at engine. Remove PCV valve. Remove valve cover retaining bolts.
Remove valve cover and gasket.
Removal (Right)
Disconnect negative battery cable. Remove accessory drive belt. Remove generator braces. Remove generator
and bracket. Remove rear spark plug wires. Remove ignition coil bracket, with coils and canister purge solenoid
attached. Remove vacuum hose from air duct at right valve cover. Remove valve cover retaining bolts. Remove
valve cover and gasket.
Installation
Apply RTV Sealer (12345739) where cylinder head and intake manifold meet. See Fig. 4. Install valve cover
and gasket. Tighten bolts to specification. See TORQUE SPECIFICATIONS. To complete installation,
reverse removal procedure.
Fig. 4: RTV Application To Seal Valve Covers
CYLINDER HEAD
NOTE: Place valve train parts in a rack to ensure installation in same location from
which they were removed. Intake push rod are 5.68" (144.18 mm) long, and
exhaust push rods are 6.0" (152.51 mm) long. If only removing rocker arms and
push rods, DO NOT remove lower intake manifold.
Removal
1. Disconnect negative battery cable. Raise and support vehicle. Drain cooling system. Drain engine oil.
Lower vehicle. Remove upper intake manifold. See UPPER INTAKE MANIFOLD. Remove lower
intake manifold. See LOWER INTAKE MANIFOLD.
2. Mark position of rocker arms and push rods. Remove rocker arm bolts. Remove rocker arms and push
rods. Remove exhaust crossover pipe. Remove right engine mount strut bracket. Remove oil level
indicator tube. Remove spark plug wires.
3. Remove spark plugs. Remove exhaust manifold. See EXHAUST MANIFOLDS. Remove cylinder head
retaining bolts in reverse order. See Fig. 5. Remove cylinder head and gasket.
Fig. 5: Cylinder Head Bolt Tightening Sequence
Inspection
If warpage of cylinder head gasket surface exceeds .005" (.127 mm), machine surface. See CYLINDER HEAD
table under ENGINE SPECIFICATIONS. DO NOT remove more than .010" (.25 mm) of material from original
surface.
Installation
1. Clean cylinder head bolt threads and cylinder block holes. Install new head gasket, make sure THIS SIDE
UP marking faces up.
2. Install cylinder head. Install head bolts and tighten in sequence to specification. See Fig. 5. See
TORQUE SPECIFICATIONS. To install remaining components, reverse removal procedure.
CRANKSHAFT FRONT SEAL
Removal
Disconnect negative battery cable. Remove accessory drive belt. Raise and support vehicle. Remove right front
wheel. Remove right inner fender splash shield. Remove crankshaft damper bolt and washer. Using Crankshaft
Damper Puller (J-24420-B), remove damper. Using a seal puller, carefully pry out seal.
Installation
Coat seal with oil to make installation easier. Using Front Cover Aligner & Oil Seal Installer (J-35468), install
crankshaft front seal. Clean damper key and keyway. Apply RTV Sealant (12345739) onto key and keyway.
Install damper using Crankshaft Damper Installer (J-29113). Install damper bolt and tighten to specification.
See TORQUE SPECIFICATIONS. To complete installation, reverse removal procedure.
FRONT COVER
Removal
1. Disconnect negative battery cable. Drain cooling system. Drain engine oil. Remove front crankshaft
damper. Remove accessory drive belt tensioner. Unbolt power steering pump, and position aside with
hoses attached.
2. Remove thermostat by-pass pipe. Disconnect lower radiator hose from water pump. Remove water pump
pulley. Remove upper and lower crankshaft position sensor wiring harness brackets from front cover.
Remove front cover retaining bolts. Remove front cover and gasket. See Fig. 6.
Installation
To install, reverse removal procedures. Apply Sealer (12346004) to both sides of lower edges of front cover
gasket where it contacts oil pan gasket.
Fig. 6: Front Cover Assembly
TIMING CHAIN
Removal
1. Disconnect negative battery cable. Drain cooling system. Drain engine oil. Remove front cover. See
FRONT COVER. Rotate crankshaft until timing marks on crankshaft sprocket and camshaft sprocket are
aligned on timing chain damper. See Fig. 7.
2. Remove camshaft sprocket bolt. Remove camshaft sprocket and timing chain. Using Crankshaft Sprocket
Puller (J5825-A), remove crankshaft sprocket. Remove timing chain damper bolts and remove damper.
Installation
1. Using Crankshaft Sprocket Installer (J-38612), install crankshaft sprocket. Install timing chain damper.
Tighten damper bolts to specification. See TORQUE SPECIFICATIONS.
2. Align crankshaft timing mark to timing mark on bottom of chain damper. Hold camshaft sprocket with
chain hanging down, and install chain to crankshaft gear. Align timing mark on camshaft gear with
timing mark on top of chain damper. See Fig. 7.
3. Install camshaft sprocket bolt. Lubricate chain with engine oil. Install timing chain front cover with NEW
gasket. Tighten cover bolts to specification. See TORQUE SPECIFICATIONS. To install remaining
components, reverse removal procedure.
Fig. 7: Aligning Timing Marks

ROCKER ARM & VALVE LASH ADJUSTER
NOTE: Place valve train parts in a rack to ensure installation in same location from
which they were removed. Intake push rods are 5.68" (144.18 mm) long, and
exhaust push rods are 6.0" (152.51 mm) long. If only removing rocker arms and
push rods, DO NOT remove lower intake manifold.
Removal
Remove upper intake manifold. See UPPER INTAKE MANIFOLD. Remove lower intake manifold. See
LOWER INTAKE MANIFOLD. Mark position of rocker arms and push rods. Remove rocker arms and push
rods. Remove guide bolts and guide. Remove valve lifters.
Installation
If installing new lifter, coat bottom of lifter with Lifter Prelube (1052365). Install lifter in original bore. To
complete installation, reverse removal procedure. Ensure push rods are installed correctly.
CAMSHAFT
NOTE: To remove camshaft, engine must be removed from vehicle.
Removal
Remove engine. See ENGINE. Remove upper intake manifold. See UPPER INTAKE MANIFOLD. Remove
lower intake manifold. See LOWER INTAKE MANIFOLD. Remove push rods and valve lifters, noting
location for installation reference. See ROCKER ARM & VALVE LASH ADJUSTER. Remove front cover.
See FRONT COVER. Remove timing chain and camshaft sprocket. See TIMING CHAIN. Remove oil pump
drive clamp. Remove oil pump drive assembly. See Fig. 8. Remove camshaft thrust plate screws and thrust
plate. Carefully rotate and pull camshaft out of bearing bore.
Inspection
If journal runout, lobe lift or oil clearance is not within specification, replace camshaft. See CAMSHAFT table
under ENGINE SPECIFICATIONS. If necessary, remove camshaft bearings using Remover/Installer (J-
33049).
CAUTION: If camshaft bearings were removed, ensure oil holes are aligned during
installation. Front and rear camshaft bearings have a different outside
diameter than inner bearings. See CYLINDER BLOCK table under ENGINE
SPECIFICATIONS. If replacing camshaft, coat lobes with Prelube (1052365)
prior to installation.
Installation
1. Lubricate camshaft bearings, camshaft lobes and thrust plate with Lubricant (1052365). Lubricate
camshaft journals with engine oil. Carefully rotate and install camshaft into bearing bore.
2. Install camshaft thrust plate. To install remaining components, reverse removal procedure. Ensure timing
marks are aligned. See Fig. 7. Install valve lifters and push rods in original locations. If camshaft was
replaced, add Engine Oil Supplement (1052367) to engine oil. Tighten nuts and bolts to specification. See
TORQUE SPECIFICATIONS.
Fig. 8: Front Cover & Camshaft Assembly

CRANKSHAFT REAR OIL SEAL

Removal
Remove transaxle and flywheel/flexplate. See appropriate TRANSMISSION REMOVAL & INSTALLATION
article in TRANSMISSION SERVICING for A/T, or appropriate article in CLUTCHES for M/T. Using
appropriate seal removing procedure, remove rear crankshaft oil seal.
Installation
1. Coat inner and outer seal surfaces with engine oil. Install seal on mandrel of Seal Installer (J-34686) until
dust lip bottoms against tool collar. Align seal installer dowel pin with crankshaft. Install seal installer on
crankshaft. See Fig. 9.
2. Turn seal installer handle until seal is installed. Remove seal installer. To complete installation, reverse
removal procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS.
Fig. 9: Installing Rear Crankshaft Seal

THERMOSTAT
in the procedure. DO NOT use paints, lubricants or corrosion inhibitors on
fasteners or fastener joint surfaces unless specified. These coatings affect
1. Remove the air cleaner and duct assembly. See Fig. 10. Drain the coolant until the coolant level is below
the thermostat. See COOLING SYSTEM BLEEDING.
2. Remove the crossover exhaust pipe. See Fig. 11. Remove the radiator hose from the thermostat housing.
3. Remove the thermostat housing bolts and clean any sealer from the bolt threads. See Fig. 12. Remove the
thermostat housing and gasket.
4. Remove the thermostat. Inspect and clean the mating surfaces.
5. Install the thermostat housing and gasket. Install RTV sealer (GM P/N 1052366) to the thermostat
housing bolt threads. Install the thermostat housing bolts. See TORQUE SPECIFICATIONS.
6. To complete installation, reverse removal procedure. Fill the cooling system. Inspect the cooling system
for leaks. Repair as necessary.
Fig. 10: Removing/Installing Air Cleaner Assembly
Fig. 11: Removing/Installing Exhaust Crossover Pipe
Fig. 12: Removing/Installing Thermostat Housing
WATER PUMP
Removal
Disconnect negative battery cable. Drain cooling system. Loosen water pump pulley bolts. Remove accessory
drive belt. Remove water pump pulley. Note locator tab near 12 o'clock position at top of water pump housing
for installation reference. Remove water pump retaining bolts. Remove water pump and gasket.
Installation
Install water pump with NEW gasket, ensuring locator tab at top of water pump housing is positioned vertically.
To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE
SPECIFICATIONS.
OIL PAN
Removal
1. Disconnect negative battery cable. Remove motor mount struts. Install Engine Support Fixture &
Adapters (J-28467-6A, J-28467-7A, J-28467-8A, J-28467-34 and J-28467-500).
2. Raise and support vehicle. Remove A/C compressor retaining bolts, and position aside with hoses
attached. Remove 3-way catalytic converter pipe from right (rear) exhaust manifold. Drain engine oil.
Disconnect oil level sensor harness connector. Remove starter. Remove transaxle brace from oil pan.
Remove lower engine and transaxle motor mount nuts.
3. Using support fixture, raise engine to gain access for oil pan removal. Remove engine mount and bracket
from oil pan. Remove left (front) and right (rear) oil pan side bolts. Remove oil pan-to-block retaining
bolts. Remove oil pan and gasket. See Fig. 13.
Installation
Apply a small amount of Sealant (1234579) on either side of rear main bearing cap, where seal surface on cap
meets cylinder block. See Fig. 14. Install gasket and oil pan. To complete installation, reverse removal
procedure. Tighten nuts and bolts to specification. See TORQUE SPECIFICATIONS. Fill crankcase with oil.
Fig. 13: Oil Pan Mounting
Fig. 14: Oil Pan Sealing
OVERHAUL
NOTE: For repair procedures not covered in this article, see ENGINE OVERHAUL
PROCEDURES article in GENERAL INFORMATION.
CYLINDER HEAD
Cylinder Head
1. Clean head gasket mating surface. Clean carbon from combustion chambers. DO NOT damage surfaces.
Check cylinder head for cracks, burrs, nicks and warpage.
2. Check cylinder head warpage. Resurface cylinder head if warpage exceeds specification. See
CYLINDER HEAD table under ENGINE SPECIFICATIONS. DO NOT machine more than .010" (.25
mm) from original cylinder head surface.
Valve Springs
1. Measure valve spring installed height from surface of cylinder head spring pad to underside of spring
retainer. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS. If installed
height is not within specification, a spacer can be installed between cylinder head and valve spring to
obtain correct height.
2. Inspect valve spring free length and pressure. Replace valve spring if free length and pressure are not
within specification.
CAUTION: Do not install valve spring spacers unless necessary. Using more spacers
than required can result in spring breakage or worn camshaft lobes.
Valve Stem Oil Seals
When installing new valve stem seals, ensure oil seal bottoms on valve guide. Oversized valve stem seals must
be installed when oversize valves are used.
Valve Guides
1. Valve guides must be reamed for an oversize valve if valve stem-to-guide oil clearance exceeds
specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Valves are available
with oversize stems.
2. If oversize valves or oversize valve stem oil seals are not available, valve guide may be reamed to use a
service bushing. Always use reamers in proper sequence (smallest first).
NOTE: Always grind valve seat after valve guide has been reamed or service bushing
has been installed.
Valve Seat
Ensure valve seat angle, seat width and seat runout are within specification. See CYLINDER HEAD table
under ENGINE SPECIFICATIONS. Valve seats must be ground when valve guide is reamed or replaced. Seat
replacement information is not available from manufacturer.
Valves
1. Ensure head diameter, valve face runout, stem diameter and valve margin are within specification. See
VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.
2. Oversize valves are available. When servicing valve stem tip, DO NOT remove more than .010" (.25)
from end of valve stem.
Valve Seat Correction Angles
Grind valve seat to a true 46-degree angle. If seat width is too wide after grinding, use a 20-degree stone to
lower seat, or a 70-degree stone to raise seat. See CYLINDER HEAD table under ENGINE
SPECIFICATIONS.
CYLINDER BLOCK ASSEMBLY
Piston & Rod Assembly
Mark piston in relation to cylinder bore and rod for reassembly. Ensure arrow on top of piston faces front of
engine upon reassembly. Replace rod if bend or twist exceeds specification. See CONNECTING RODS table
under ENGINE SPECIFICATIONS.
Fitting Pistons
Measure piston diameter with pin removed. Measure diameter at 90-degree angle to pin on pin center line. If
piston clearance is not within specification, machine cylinder bore and install oversize piston(s) as necessary.
See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS.
Piston Rings
Ensure ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS table under
ENGINE SPECIFICATIONS.
Installing Piston Rings
Install piston rings with identification mark toward top of piston and ring gaps properly spaced. See Fig. 15.
Fig. 15: Positioning Piston Ring Gaps
Rod Bearings
Ensure rod side clearance is .0007-.0024" (.018-.061 mm). If connecting rod bearing oil clearance is not within
correct specification, machine crankshaft and replace bearings. See CRANKSHAFT, MAIN &
CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.
Crankshaft & Main Bearings
Measure crankshaft main bearing for proper oil clearance, out-of-round and taper. If any measurements are not
within specification, machine crankshaft and replace bearings. See CRANKSHAFT, MAIN &
CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.
Crankshaft Flange Runout
1. With engine removed and crankshaft installed, or with crankshaft mounted on "V" blocks, measure
crankshaft flange runout. Mount dial indicator, and place dial indicator stem on crankshaft flange. Adjust
dial indicator to zero.
2. Mark reference point on crankshaft flange. Ensure crankshaft is thrust forward so end float will not affect
readings. Turn crankshaft 360 degrees.
3. Observe and record readings. Reading should not vary more than .0016" (.041 mm). If readings exceed
specification, replace crankshaft.
Thrust Bearing
1. With main bearing cap bolts installed and loosely tightened, pry crankshaft rearward to align bearing
caps, then push forward to align rear face of thrust main bearing. Tighten main bearing cap bolts to
specification. See TORQUE SPECIFICATIONS.
2. Measure crankshaft end play. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table
under ENGINE SPECIFICATIONS.
Cylinder Block
Measure block for flatness with a straightedge and feeler gauge across cylinder bores. If deck surface warpage
exceeds specification, machine surface. DO NOT remove more than .010" (.25 mm) of material from original
deck surface. If more is removed, block must be replaced.
ENGINE OILING
ENGINE LUBRICATION SYSTEM
Oil delivery system supplies oil to crankshaft journals first. See Fig. 16. Oil from main bearings is then supplied
to connecting rod bearings through intersecting passages in crankshaft. Passages in crankshaft main bearings
supply oil to camshaft bearings through vertical drilled holes. Oil passages from camshaft journals supply oil to
hydraulic lifters. Lifters pump oil through push rods to rocker arms. Oil drains back and is directed by cast dams
in crankcase casting to supply camshaft lobes. Cam chain drive is lubricated by indirect oil splash.
Fig. 16: Engine Oiling System
Crankcase Capacity
Engine oil capacity is 4.0 qts. (3.8L). More oil will be needed when changing oil filter.
Oil Pressure
Normal oil pressure is 50-65 psi (3.5-4.5 kg/cm2 ) at 1200 RPM (at normal operating temperature).
OIL PUMP
Removal & Disassembly
1. Remove oil pan. See OIL PAN under REMOVAL & INSTALLATION. Remove oil pump mounting
bolts. Remove oil pump and drive shaft extension.
2. To disassemble, remove pump cover. DO NOT remove pick-up tube from cover unless loose or broken.
If pick-up tube is loose, bent or has been removed, replace pick-up tube and pump cover.
WARNING: Pressure regulator valve spring is under pressure. Remove retaining

pin carefully in order to avoid possible injury.
3. Remove gears from pump body. Remove cotter pin securing spring and pressure regulator valve. Remove
valve and spring.
Inspection
1. Inspect components for damage. Using straightedge and feeler gauge, measure gear end clearance.
Measure housing pocket depth and diameter. Measure gear diameter and length (thickness). Measure side
clearance between gear tooth and housing.
2. Measure gear lash clearance between gear teeth. Check clearance between pressure regulator valve and
bore. Replace components or entire assembly if not within specification. See OIL PUMP
OIL PUMP SPECIFICATIONS

Diameter 1.503-1.505 (38.18-38.23)
End Clearance .002-.005 (.040-.125)
Gear Diameter 1.498-1.500 (38.05-38.10)
Housing Pocket Depth 1.202-1.204 (30.52-30.58)
Lash Clearance .0037-.0077 (.094-.195)
Length (Thickness) 1.199-1.200 (30.45-30.48)
Pressure Relief Valve-To-Bore Clearance .0015-.0035 (.038-.089)
Side Clearance .001-.003 (.038-.088)
NOTE: Use only original equipment gaskets for oil pump service, as gasket thickness
is critical.
Reassembly & Installation
1. Coat all components with engine oil. To reassemble, reverse disassembly procedure using NEW pump
cover gasket. If installing new pick-up tube, apply Sealant (1050026) to pick-up tube. Install pick-up tube
into pump cover using Suction Pipe Installer (J-21882) and plastic hammer.
2. To install, reverse removal procedure. Ensure pump extension shaft is fully engaged. Tighten oil pump
bolt to specification. See TORQUE SPECIFICATIONS.
Camshaft Sprocket Bolt 103 (140)
Connecting Rod Cap Nut
Step 1 15 (20)
Step 2 Additional 75 Degrees
Crankshaft Balancer Bolt 76 (103)
Cylinder Head Bolt (1) (2)
Step 1 (2)
Step 2 (2)
Engine Mount Bracket-To-Oil Pan 43 (58)

Engine Mount Nut 32 (43)
Engine Mount Strut Bracket
Right 37 (50)
Left 52 (71)
Radiator 21 (28)
Exhaust Crossover Pipe Nut 18 (24)
Exhaust Manifold Bolt 12 (16)
Flexplate/Flywheel Bolt (3) 52 (71)
Front Timing Case Cover Bolt
Large Diameter
Long 41 (56)
Short 35 (47)
Small Diameter 21 (28)
Ignition Coil Bracket 18 (24)
Intake Manifold Bolts
Lower
Step 1 (5)
Step 2 (5)
Step 3 (5)
Upper 18 (24)
Main Bearing Cap Bolt
Step 1 37 (50)
Oil Cooler Fitting 37 (50)
Oil Pan-To-Block
Bottom Bolt 18 (24)
Side Bolt 37 (50)
Oil Pump Mounting Bolt 30 (41)
Rocker Arm Bolt
Step 1 14 (19)
Serpentine Drive Belt Tensioner Bolt 37 (50)
Spark Plugs 15 (20)
Thermostat Housing Bolts 18 (25)
Throttle Body Bolt 18 (24)
Timing Chain Damper Bolt 15 (20)
Water Pump Pulley Bolt 18 (24)
INCH Lbs. (N.m)
Camshaft Thrust Plate Bolt 89 (10)
Thermostat By-Pass Pipe-To-Front Cover Bolt 106 (12)
Valve Cover Bolt (6) 89 (10)
Valve Lifter Guide Bolt 89 (10)
Water Pump-To-Front Cover Bolt 89 (10)
(1) Apply Sealant (1052080) to cylinder head bolts.
(2) Refer to TSB REVISED CYLINDER HEAD BOLT TORQUE SPECIFICATION AND
TIGHTENING SEQUENCE . Tighten cylinder head bolts in sequence. See Fig. 5.
(3) Apply Thread Locker (12345382) to flexplate/flywheel bolts.
(4) This information has been revised due to GM Administrative Message #VSS20030024, dated
3/4/2003.
(5) See TSB For Revised Lower Intake TorqueFig. 3.
(6) Finger tighten first.
ENGINE SPECIFICATIONS
GENERAL SPECIFICATIONS
Displacement 209 Cu. In. (3.4L)
Bore 3.62" (92.0 mm)
Stroke 3.31" (84.1 mm)
Compression Ratio 9.5:1
Fuel System SFI
CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS
Crankshaft End Play .0024-.0083 (.061-.211)
Main Bearings
Journal Diameter 2.6473-2.6483 (67.241-67.267)
Journal Out-Of-Round .0002 (.005)
Journal Runout .0016 (.041)
Journal Taper .0002 (.005)
Oil Clearance
Except Thrust Bearing .0008-.0025 (.020-.064)
Thrust Bearing .0012-.0030 (.030-.076)
Connecting Rod Bearings
Journal Out-Of-Round .0002 (.005)
Journal Taper .0002 (.005)
Oil Clearance .0007-.0024 (.018-.061)
CONNECTING RODS
Bore Diameter
Pin Bore (1)
Crankpin Bore 2.124-2.125 (53.95-

53.98)
Maximum Bend (2) .007 (.18)
Maximum Twist (3) .0015 (.038)
Side Play .0015 (.038)
(1) Information not available from manufacturer.
(2) Per 3" (76.2 mm) of rod length.

(3) Per 1" (25.4 mm) of rod length.
PISTONS, PINS & RINGS

Pistons
Clearance .0013-.0030 (.033-.076)
Diameter 3.6209-3.6216 (91.971-91.989)
Pin Bore .9057-.9060 (23.005-23.012)
Pins
Diameter .9052-.9054 (22.992-22.997)
Piston Fit .0004-.0008 (.010-.020)
Rod Fit Press Fit
Rings
No. 1
End Gap .006-.014 (.15-.36)
Side Clearance .0016-.0030 (.041-.076)
No. 2
End Gap .019-.029 (.48-.74)
Side Clearance .0016-.0035 (.041-.089)
No. 3 (Oil)
End Gap .010-.030 (.25-.76)
Side Clearance (Max.) .008 (.20)
CYLINDER BLOCK
Camshaft Bearing Bore
Front & Rear 2.0090-2.0110 (51.029-
51.079)
No. 2 & 3 1.9990-2.0010 (50.775-
50.825)
Crankshaft Main Bearing Bore 2.8407-2.8412 (72.155-72.168)
Cylinder Bore
Diameter 3.6228-3.6235 (92.019-
92.037)
Maximum Taper .0004 (.010)
Maximum Out-Of-Round .0003 (.008)
Maximum Deck Warpage (1) N/A
(1) Information is not available from manufacturer. DO NOT machine more than .010" (.25 mm) from
original surface.
VALVES & VALVE SPRINGS

Valves
Face Angle 45
Margin
Exhaust .0106" (.269 mm)
Intake .0083" (.211 mm)
Valve Springs
Free Length 1.91" (48.5 mm)
Installed Height 1.701" (43.21 mm)
Lbs. @ In. (kg @ mm)
Pressure
Valve Closed 72 @ 1.70 (32.7 @ 43.2)
Valve Open 230 @ 1.26 (104.3 @ 32.0)
CYLINDER HEAD
Valve Seats
Intake Valve
Seat Angle 46
Seat Width .061-.071" (1.55-1.80 mm)
Maximum Seat Runout .0014" (.036 mm)
Exhaust Valve
Seat Angle 46
Seat Width .067-.079" (1.70-2.01 mm)
Maximum Seat Runout .0014" (.036 mm)
Valve Guides
Valve Guide Oil Clearance .001-.003" (.03-.08 mm)
CAMSHAFT
Camshaft Bearing Inside Diameter 1.8710-1.8720 (47.523-47.549)
Journal Runout .001 (.03)
Lobe Lift
Intake .273 (6.93)
Exhaust .273 (6.93)
Oil Clearance .001-.004 (.025-.101)
Engine Controls - Troubleshooting - 3.4L - Aztek & Rendezvous
TROUBLESHOOTING
SYMPTOMS - ENGINE CONTROLS
Important Preliminary Checks Before Starting
Before using the Symptom tables, use the following:
Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information and verify all of the
following items:
Clear the DTCs.
Ensure that the scan tool data is within normal operating range. Refer to Scan Tool Data List .
Verify the customer complaint.

Perform the Visual/Physical Check.
Locate the correct symptom in the list at the end of this section. Follow the procedures in the appropriate
diagnostic table. If the condition can not be duplicated, or is determined to be intermittent, refer to Intermittent
Conditions.
Visual/Physical Check
NOTE: Use the connector test adapter kit J 35616-A for any test that requires probing
the following items:
The PCM harness connectors

The electrical center fuse/relay cavities
The component terminals
The component harness connector
Using this kit will prevent damage caused by the improper probing of connector
terminals.
Several of the symptom procedures call for a careful inspection. This can lead to correcting a condition without
further tests and can save valuable time. This inspection should include the following areas:
Inspect the powertrain control module (PCM) grounds for being clean, tight, and in their proper location.
Refer to Master Electrical Component List and Power and Grounding Connector End Views in Wiring
Systems.
Inspect the vacuum hoses for splits, kinks, and proper connections, as shown on Vehicle Emission
Control Information label. Inspect thoroughly for any type of leak or restriction. Refer to Emission Hose
Routing Diagram .
Inspect the air intake ducts for being collapsed, damaged areas, looseness, improper installation, or
leaking, especially between the mass air flow (MAF) sensor and the throttle body.
Inspect for air leaks at throttle body mounting area, MAF sensor and intake manifold sealing surfaces.
Inspect the wiring harness for poor connections, pinches, cuts, or other damage.
Inspect for loose, damaged, or missing sensors/components.
Use the following tables when diagnosing a symptom complaint:
Hard Start
Surges/Chuggles
Lack of Power, Sluggishness, or Sponginess
Detonation/Spark Knock
Hesitation, Sag, Stumble
Cuts Out, Misses
Poor Fuel Economy
Poor Fuel Fill Quality
Rough, Unstable, or Incorrect Idle and Stalling
Dieseling, Run-On
Backfire
Malfunction Indicator Lamp (MIL) Inoperative
Malfunction Indicator Lamp (MIL) Always On
Engine Cranks but Does Not Run
INTERMITTENT CONDITIONS
Intermittent Conditions
Inspection/Test Action
DEFINITION: The condition is not currently present but is indicated in DTC History.
OR
There is a customer complaint, but the symptom can not currently be duplicated, if the condition is not
DTC related.
Preliminary Perform the Diagnostic System Check - Vehicle in Vehicle DTC
Information before starting.
Harness/Connector Many intermittent open or shorted circuits come and go with
harness/connector movement caused by vibration, engine torque,
bumps/rough pavement, etc. Test for this type of condition by
performing the applicable procedure from the following list:
Move related connectors and wiring while monitoring the

appropriate scan tool data.
Move related connectors and wiring with the component
commanded ON, and OFF, with the scan tool. Observe the
component operation.
With the engine running, move related connectors and wiring
while monitoring engine operation.
If harness or connector movement affects the data displayed,

component/system operation, or engine operation, inspect and repair
the harness/connections as necessary. Refer to Electrical Connections
or Wiring.
Electrical Connections or Wiring Poor electrical connections/terminal tension or wiring conditions
cause most intermittents. Perform a careful inspection of the
suspected circuit for the following:
Inspect for poor mating of the connector halves, or
terminals not fully seated in the connector body (backed-
out).
Inspect for improperly formed or damaged terminals. Test
for poor terminal tension.
Inspect for poor terminal to wire connections including
terminals crimped over insulation. This requires removing
the terminal from the connector body.
Inspect for corrosion/water intrusion. Pierced or damaged
insulation can allow moisture to enter the wiring. The
conductor can corrode inside the insulation, with little
visible evidence. Look for swollen and stiff sections of
wire in the suspect circuits.
Inspect for wires that are broken inside the insulation.
Inspect the harness for pinched, cut, or rubbed through

wiring.
Ensure that the wiring does not come in contact with hot
exhaust components.
Refer to Testing for Intermittent Conditions and Poor
Control Module Power and Poor power or ground connections can cause widely varying
Grounds symptoms.
Component Power and Grounds
Test all control module power circuits. Many vehicles have
multiple circuits supplying power to the control module. Other
components in the system may have separate power circuits that
may also need to be tested. Inspect connections at the
module/component connectors, fuses, and any intermediate
connections between the power source and the
module/component. A test lamp or a DMM may indicate that
voltage is present, but neither tests a circuit ability to carry
sufficient current. Ensure that the circuit can carry the current
necessary to operate the component. Refer to Power
Distribution Schematics in Wiring Systems.
Test all control module ground and system ground circuits. The
control module may have multiple ground circuits. Other
components in the system may have separate grounds that may
also need to be tested. Inspect grounds for clean and tight
connections at the grounding point. Inspect the connections at the
component and in splice packs, where applicable. Ensure that the
circuit can carry the current necessary to operate the component.
Refer to Ground Distribution Schematics in Wiring Systems.
Temperature Sensitivity An intermittent condition may occur when a
component/connection reaches normal operating temperature.
The condition may occur only when the component/connection is
cold, or only when the component/connection is hot.
Freeze Frame, Failure Records, Snapshot, or Vehicle Data
Recorder data may help with this type of intermittent condition,
where applicable.
If the intermittent is related to heat, review the data for a
relationship with the following:
High ambient temperatures
Underhood/engine generated heat
Circuit generated heat due to a poor connection, or high

electrical load
Higher than normal load conditions (towing, etc.)
If the intermittent is related to cold, review the data for the

following:
Low ambient temperatures-In extremely low temperatures,
ice may form in a connection or component. Test for water
intrusion.
The condition only occurs on a cold start.
The condition goes away when the vehicle warms up.
Information from the customer may help to determine if the

trouble follows a pattern that is temperature related.
Electromagnetic Interference Some electrical components/circuits are sensitive to electromagnetic
(EMI) and Electrical Noise. interference (EMI) or other types of electrical noise. Inspect for the
A misrouted harness that is too close to high voltage/high current

devices such as secondary ignition components, motors,
generator etc. These components may induce electrical noise on a
circuit that could interfere with normal circuit operation.
Electrical system interference caused by a malfunctioning relay,
powertrain control module (PCM) driven solenoid or switch.
These conditions can cause a sharp electrical surge. Normally,
the condition occurs when the malfunctioning component is
operating.
Improper installation of non-factory or aftermarket add-on
accessories such as lights, 2-way radios, amplifiers, electric
motors, remote starters, alarm systems, cell phones, etc. these
accessories may lead to an emission related on-board diagnosis
(OBD) II failure while in use, but do not fail when the
accessories are not in use. Refer to Checking Aftermarket
Accessories in Wiring Systems. If a DTC is determined to be
intermittent, and the tests in this section do not reveal a
condition, refer to Vehicle Data Recorder.
Test for an open diode across the A/C compressor clutch and for
other open diodes. Some relays may contain a clamping diode.
Test the generator for a bad rectifier bridge that may be allowing
AC noise into the electrical system.
Incorrect PCM Programming There are only a few situations where reprogramming a PCM is
appropriate:
A new service PCM is installed.
A PCM from another vehicle is installed.
Revised software/calibration files have been released for

this vehicle.
IMPORTANT:
DO NOT re-program the PCM with the SAME
software/calibration files that are already present in the PCM.
This is not an effective repair for any type of driveability
condition.
Verify that the PCM contains the correct software/calibration. If

incorrect programming is found, reprogram the PCM with the
most current software/calibration. Refer to Service
Programming System (SPS) in Programming and Setup.
Duplicating Failure Conditions If none of the previous tests are successful, attempt to duplicate
and/or capture the failure conditions.
Freeze Frame/Failure Records, where applicable, contains the
conditions that were present when the DTC set.
1. Review and record Freeze Frame/Failure Records data.
2. Clear the DTCs using the scan tool.
3. Turn the key to OFF and wait 15 seconds.
4. Operate the vehicle under the same conditions that were
noted in Freeze Frame/Failure Records data, as closely as
possible. The vehicle must also be operating within the
Conditions for Running the DTC. Refer to Conditions for
Running the DTC in the supporting text of the DTC being
diagnosed.
5. Monitor DTC Status for the DTC being tested. The scan
tool indicates Ran, when the enabling conditions have been
satisfied long enough for the DTC to run. The scan tool
also indicates whether the DTC passed or failed.
An alternate method is to drive the vehicle with the DMM
connected to a suspected circuit. An abnormal reading on the
DMM when the condition occurs, may help you locate the
condition.
Scan Tool Snapshot The scan tool can be setup to take a Snapshot of the parameters
available via serial data. The Snapshot function records live data over a
period of time. The recorded data can be played back and analyzed.
The scan tool can also graph parameters singly or in combinations of
parameters for comparison. The Snapshot can be triggered manually at
the time the symptom is noticed, or setup in advance to trigger when a
DTC sets.
An abnormal value captured in the recorded data may point to a system
or component that needs to be investigated further.
Refer to the scan tool user instructions for more information on the
Snapshot function.
Vehicle Data Recorder The J 42598 Vehicle Data Recorder is connected to the data link
connector (DLC) and sent with the customer.Special Tools . The J
42598 captures data for later retrieval and analysis by the
technician.Special Tools . Refer to the Vehicle Data Recorder user
instructions for more information.
HARD START
Hard Start
DEFINITION: Engine cranks OK, but does not start for a long time. Does eventually run, or may start
but immediately stalls.
Preliminary Perform the Diagnostic System Check - Vehicle in Vehicle DTC
Information.
Sensor/System Test engine coolant temperature (ECT) sensor for being shifted in
value. Connect a scan tool and compare ECT with intake air
temperature (IAT) on a cold engine. The ECT and IAT should be
within +/- 3C (5F) of each other. Test the resistance of the ECT
sensor if the temperature is out of range with the IAT sensor.
Refer to Temperature vs Resistance . If the ECT sensor
resistance is not within the specification, refer to DTC P0117 or
DTC P0113 .
Monitor the 24X crank sensor and camshaft position (CMP)
sensor signal present parameters on a scan tool. If both are not
responding, test the sensor feed circuit. Both sensors use a
separate feed circuit but are internally connected to power. Test
all crankshaft position (CKP) sensor A and CMP sensor circuits
for intermittents. Refer to Testing for Intermittent Conditions
and Poor Connections in Wiring Systems.
Monitor the 3X crank sensor parameter on the scan tool. If the
3X crank sensor parameter is not responding, inspect the CKP
sensor B and circuits for intermittents. Inspect the ignition control
(IC) circuit, IC timing control circuit, low resolution engine
speed signal circuit and the low reference circuit for intermittents.
If these circuits become open, or shorted, they may not set a DTC
immediately, but are capable of causing driveability complaints.
Inspect the mass air flow (MAF) sensor for proper installation
and conditions. A MAF sensor with a damaged honeycomb may
cause a hard start.
Inspect the air intake ducts for being collapsed, damaged areas,
looseness, improper installation, or leaking, especially between
the MAF sensor and the throttle body.
Using a scan tool, test the idle air control (IAC) operation.
Command the engine RPM to 1,500 RPM and back to the
starting RPM.
If the engine RPM does not change when commanded refer to

DTC P0506 and DTC P0507 to diagnose the IAC system.
Inspect the exhaust gas recirculation (EGR) system for proper

operation, if applicable.
Fuel System Test the fuel system circuits for proper operation. Refer to Fuel
Pump Electrical Circuit Diagnosis.
Test for low fuel pressure. Refer to Fuel System Diagnosis.
Test for faulty fuel injectors. Refer to Fuel Injector Balance
Test with Special Tool, Fuel Injector Balance Test with Tech
2, Fuel Injector Coil Test test procedures.
Inspect for fuel contamination. Refer to Alcohol/Contaminants-
in-Fuel Diagnosis (Without Special Tool) or
Alcohol/Contaminants-in-Fuel Diagnosis (With Special Tool).
Ignition System Inspect for proper ignition voltage output using the following
steps:
1. Attach the J 26792 Spark Tester to engine ground.Special
Tools .
2. Connect the spark plug end of the spark plug wire to the J
26792 .Special Tools . Connect the other end of the spark
plug wire to the coil being tested.
3. Connect the spark plug end of the companion spark plug
wire to ground. The companion spark plug wire is the wire
attached to the corresponding coil tower.
4. Crank the engine while observing the J 26792 .Special
Tools . A spark should be observed.
5. Repeat the above steps for each coil.
If spark is not present at the coils, inspect for the following
conditions:
Coils-Cracks, carbon tracking/arcing, or a resistance value
outside the specified range.
Coil Resistance: 5,000-8,000 ohms
Spark Plug wires-signs of arcing, cross firing, cracks,

carbon tracking, plug boot damage, pinched, improper
routing, or a resistance value outside the specified range.
Spark Plug Wire Resistance: 9,842 ohms per meter

(3,000 ohms per foot)
IMPORTANT:
Spraying the secondary ignition wires with a light mist
of water may help locate an intermittent condition.
Ignition voltage arcs to ground when a secondary
component is faulty.
Defective ignition module

Ignition system wiring-Loose ignition module feed or
ground connection, or damaged system wiring.
Remove spark plugs and inspect for the following conditions:
Fouled plugs
Cracks
Wear
Improper gap
Burned or damaged electrodes
Improper heat range or reach

If spark plugs are gas or oil fouled, the cause of the fouling must
be determined before replacing the spark plugs. Refer to Spark
Plug Inspection .
Engine Mechanical Excessive oil in combustion chamber-Leaking valve seals. Refer
to Oil Consumption Diagnosis in Engine Mechanical.
Low cylinder compression. Refer to Engine Compression Test
in Engine Mechanical.
Inspect for incorrect engine parts, such as the following basic
components:
The cylinder heads
The camshaft and valve train components
The pistons, etc.
Refer to Symptoms - Engine Mechanical in Engine

Mechanical.
SURGES/CHUGGLES
Surges/Chuggles
DEFINITION: Engine power variation under steady throttle or cruise. Feels like the vehicle speeds up
and slows down with no change in the accelerator pedal.
Preliminary Perform the Diagnostic System Check - Vehicle in Vehicle
DTC Information.
Refer to Intermittent Conditions.
Search for bulletins.
Be sure driver understands transmission torque converter clutch

(TCC), and A/C compressor operation as explained in the owners
manual. Inform customer how TCC and the A/C clutch operates.
Sensor/System NOTE:
Refer to Silicon Contamination of Heated Oxygen Sensors
Notice in Cautions and Notices.
Monitor the heated oxygen sensors (HO2S). The heated oxygen

sensors should respond quickly to different throttle positions. If
not, inspect the HO2S for silicon or other contaminants from fuel
or use of improper RTV sealant. The sensors may have a white
powdery coating. Silicon contamination causes a high but false
HO2S signal voltage which is a rich exhaust indication. The
powertrain control module (PCM) will reduce the amount of fuel
delivered to the engine, causing a severe driveability problem.
Inspect the mass air flow (MAF) sensor and related wiring.
looseness, improper installation, or leaking especially between
Monitor the 24X crank sensor and the camshaft position (CMP)
sensor signal present parameters on the scan tool. If both sensors
are not responding, test each sensor feed circuit. Each sensor uses
a separate supply circuit but are internally connected to power.
Test all crankshaft position (CKP) sensor A and CMP sensor
circuits for intermittents. Refer to Testing for Intermittent
sensor B and related circuits for intermittents. Inspect the ignition
control (IC) circuit, IC timing control circuit, low resolution
engine speed signal circuit and the low reference circuit for
intermittents. If these circuits become open, or shorted may not
set a DTC immediately, but are capable of causing driveability
complaints. Refer to Testing for Intermittent Conditions and
Poor Connections in Wiring Systems.
Test the CKP sensor B for an internal short. Refer to Electronic
Ignition (EI) System Diagnosis.
Test the exhaust gas recirculation (EGR) system for proper
Fuel System Test the fuel pressure. Refer to Fuel System Diagnosis.
Inspect for contaminated fuel. Refer to Alcohol/Contaminants-
Ensure each fuel injector harness is connected to the correct fuel
injector/cylinder.
Inspect any items which may cause an engine to run rich, long
term fuel trim is significantly in the negative range. Refer to
Diagnostic Aids for DTC P0172 .
Inspect any items that may cause an engine to run lean, long term
fuel trim is significantly in the positive range. Refer to Diagnostic
Aids for DTC P0171 .
steps:
Tools .
26792 .Special Tools . Leave the other end of the spark
plug wire connected to the coil being tested.
conditions:
outside the specified range
Coil Resistance: 5000-8000 ohms (5K-8K ohms)
Spark plug wires-Signs of arcing, cross firing, cracks,

routing, or a resistance value outside the specified range
Spark Plug Wire Resistance: 9 686 ohms per meter

IMPORTANT:
of water may help locate an intermittent problem.
Ignition voltage will arc to ground when a secondary

Ignition system wiring-Loose ignition module voltage
supply or ground connection, or damaged system wiring
Fouled plugs
Cracks
Wear
Improper gap
Plug Inspection .
Additional Test the TCC operation.
Inspect the exhaust system for possible restriction:
Inspect exhaust system for damaged or collapsed pipes.
Inspect muffler for heat distress or possible internal failure.

Test for possible plugged catalytic converter by testing the
exhaust system back pressure.
LACK OF POWER, SLUGGISHNESS, OR SPONGINESS
Lack of Power, Sluggishness, or Sponginess

Inspection/Tests Action
DEFINITION: Engine delivers less than expected power. Little or no increase in speed when the
accelerator pedal is pushed down part way.
DTC Information.
Refer to Intermittent Conditions before beginning.
Fuel System Test Test the fuel system circuits for proper operation. Refer to Fuel

Inspect any items which may cause an engine to run lean, long
term fuel trim is significantly in the positive range. Refer to
Sensor/System Test the crankshaft position (CKP) sensor B for an internal short.
Refer to Electronic Ignition (EI) System Diagnosis.
Using a scan tool, monitor knock sensor (KS) system for
excessive spark retard activity. Refer to Knock Sensor (KS)
System Description .
If knock retard is above 10-12 degrees, disconnect the KS, and
ground the sensor harness connector. Monitor knock retard on the
scan tool. There should be no knock retard present. If knock
retard is still present, replace the powertrain control module
(PCM). Refer to Powertrain Control Module (PCM)
Replacement .
Inspect the exhaust gas recirculation (EGR) system for proper
the mass air flow (MAF) sensor and the throttle body.
steps:
Tools .
conditions:


IMPORTANT:

ground connection, or damaged system wiring
Fouled plugs
Cracks
Wear
Improper gap
Plug Inspection .
Low cylinder compression-Refer to Engine Compression Test
For incorrect basic engine parts-Inspect the following conditions:
Cylinder heads
Camshaft and valve train components
Pistons, etc.
Additional Inspect the exhaust system for any possible restrictions:

Inspect mufflers for heat distress or possible internal failure.
For possible plugged catalytic converter
Test for proper torque converter clutch (TCC) operation.
DETONATION/SPARK KNOCK
Detonation/Spark Knock
DEFINITION: A mild to severe ping, usually worse under acceleration. The engine makes sharp metallic
knocks that change with throttle opening.
DTC Information.
Refer to Intermittent Conditions before starting.

Ignition System Inspect the spark plugs for proper heat range and reach. Refer to
Ignition System Specifications .
Inspect for proper ignition voltage output using the following

steps:
Tools .
conditions:


IMPORTANT:

Fouled plugs
Cracks
Wear
Improper gap
Plug Inspection .
Engine Cooling System Inspect for obvious overheating problems:
Low engine coolant

Restricted air flow to radiator, or restricted water flow through
the radiator
Inoperative electric cooling fan circuits
Correct coolant solution should be a 50/50 mix. Refer to Cooling
System Description and Operation in Engine Cooling.
Low cylinder compression-Refer to Engine Compression Test
For incorrect basic engine parts-Inspect the following conditions:
Cylinder heads
Camshaft and valve train components
Pistons, etc.
Additional Test the crankshaft position (CKP) sensor B for an internal short.
Refer to Electronic Ignition (EI) System Diagnosis.
Test for proper exhaust gas recirculation (EGR) system
Inspect the Transaxle Range Switch input with the vehicle in
drive and the gear selector in drive or overdrive.
Test the torque converter clutch (TCC) operation. TCC applying
too soon can cause the engine to spark knock.
If the scan tool readings are normal and there are no engine
mechanical faults, fill the fuel tank with a known quality gasoline
that has a minimum octane reading of 87 and re-evaluate vehicle
performance.
HESITATION, SAG, STUMBLE

Hesitation, Sag, Stumble
DEFINITION: Momentary lack of response as the accelerator is pushed down. Can occur at any vehicle
speed. Usually more pronounced when first trying to make the vehicle move, as from a stop sign. May
cause the engine to stall if severe enough.
DTC Information.
Sensor/System NOTE:
Refer to Silicon Contamination of Heated Oxygen Sensors
Monitor the heated oxygen sensors (HO2S). The heated oxygen

sensors should respond quickly to different throttle positions. If
not, inspect the HO2S for silicon or other contaminants from fuel
or use of improper RTV sealant. The sensors may have a white
powdery coating. Silicon contamination causes a high but false
HO2S signal voltage, rich exhaust indication. The powertrain
control module (PCM) will reduce the amount of fuel delivered
to the engine, causing a severe driveability problem.
sensor signal present parameters on the scan tool. If both are not
all crankshaft position (CKP) A and CMP sensor circuits for
intermittents. Refer to Testing for Intermittent Conditions and
Poor Connections in Wiring Systems.
speed signal circuit and the 3X low reference circuit for
intermittents. If these circuits become open or shorted they may
not set a diagnostic trouble code (DTC) immediately, but are
capable of causing driveability complaints. Refer to Testing for
Intermittent Conditions and Poor Connections in Wiring
Systems.
Inspect the throttle position (TP) sensor and related wiring.
Inspect the mass air flow (MAF) sensor and related wiring.
Test the TP sensor and related wiring.
Test the MAF sensor and related wiring.
steps:
Tools .
conditions:


IMPORTANT:

Fouled plugs
Cracks
Wear
Improper gap
be determined before replacing the spark plugs.
CUTS OUT, MISSES
Cuts Out, Misses

DEFINITION: Steady pulsation or jerking that follows engine speed, usually more pronounced as engine
load increases.
DTC Information.

Sensor/System Inspect for conditions which may cause an incorrect idle speed:
Throttle body tampering, excessive deposits, or damage-
Refer to Fuel System Description .
Restricted air intake system
Large vacuum leak
Inspect the air intake ducts for being collapsed, damaged

areas, looseness, improper installation, or leaking
especially between the mass air flow (MAF) sensor and the
throttle body.
Inspect the throttle position (TP) sensor and related circuit
wiring. Refer to DTC P0123 .
sensor signal parameters on the scan tool. If both are not
speed signal circuit and the low reference circuit for intermittents.
If these circuits become open, or shorted, they may not set a
diagnostic trouble code (DTC) immediately, but are capable of
causing driveability complaints. Refer to Testing for
Systems.
Test the positive crankcase ventilation (PCV) valve for proper
operation.
Inspect the Transaxle Range Switch input with the vehicle in
drive and the gear selector in drive or overdrive.
Inspect the following for damage:
Bent balancer interrupter rings
Damaged crankshaft position sensor
steps:
Tools .
conditions:


IMPORTANT:

Fouled plugs
Cracks
Wear
Improper gap
Plug Inspection .
Engine Mechanical Inspect engine mechanical for the following conditions:
Test the compression-Refer to Engine Compression Test
Sticking or leaking valves
Worn camshaft lobes
Valve timing
Bent push rods
Worn rocker arms
Broken valve springs
Excessive oil in combustion chamber-Leaking valve seals
Low cylinder compression
For incorrect basic engine parts-Inspect the following

components:
Camshaft
Cylinder heads
Pistons, etc.

Mechanical.
Additional Inspect the exhaust system for possible restrictions:
Inspect mufflers for heat distress or possible internal

failure.
An engine miss condition can be caused by electromagnetic

interference (EMI) on the reference circuit. EMI can usually be
detected by monitoring engine RPM with a scan tool. A sudden
increase in RPM with little change in actual engine RPM change,
indicates EMI is present. If a problem exists, inspect routing of
secondary ignition wires, high voltage components, near the
ignition control circuits.
POOR FUEL ECONOMY

Poor Fuel Economy
DEFINITION: Fuel economy, as measured by an actual road test is noticeably lower than expected. Also,
the economy is noticeably lower than the economy was on this vehicle at one time, as previously shown
by an actual road test.
DTC Information.
Observe the owner's driving habits.
Is the A/C ON full time, defroster mode ON?
Are tires at correct pressure?
Are tires and wheels the correct size?
Are excessively heavy loads being carried?
Is acceleration too much, too often?

Ensure that each injector harness is connected to the correct
injector/cylinder.
Inspect for fuel in the pressure regulator vacuum hose.
Sensor/System Observe the 24X crank sensor and the camshaft position (CMP)
sensor signal present parameters on the scan tool. If both are not
responding, inspect the sensor feed circuit. Both sensors use a
common feed circuit.
Inspect the air intake system and crankcase for air leaks.
looseness, improper installation, or leaking, especially between
Inspect for proper operation of the speedometer. Refer to

Symptoms - Instrument Panel, Gages and Console in
steps:
Tools .
conditions:
Spark plug wires-signs of arcing, cross firing, cracks,

Spark Plug Wire Resistance: 3,000 ohms per foot (9,842

ohms per meter).
IMPORTANT:

Fouled plugs
Cracks
Wear
Improper gap

Plug Inspection .
Engine Cooling System Inspect the engine coolant level for correct level.
Inspect for incorrect or faulty engine thermostat. Refer to
Thermostat Diagnosis in Engine Cooling.
Engine Mechanical Inspect the engine for the following conditions:
Worn camshaft lobes
Valve timing
Bent push rods
Worn rocker arms

components:
The camshaft
The cylinder heads
The pistons, etc.

Mechanical.
Additional Test torque converter clutch (TCC) operation.
Inspect exhaust system for possible restriction:
Refer to Restricted Exhaust in Engine Exhaust.

failure.
POOR FUEL FILL QUALITY
Poor Fuel Fill Quality

Condition Causes
Difficult to fill Fill limiter vent valve stuck closed
Evaporative emission (EVAP) canister restricted
EVAP vent valve stuck closed
Restricted vapor lines
High reid vapor pressure or high fuel temperature
Fuel filler hose is pinched or kinked
Ignition switch ON (vent valve closed)
Over fill Pressure relief valve is stuck open or leaking
Fill limiter vent valve stuck open or leaking
Pre-mature shut-off of the fuel Fill limiter vent valve stuck closed
dispensing nozzle
EVAP canister restricted
EVAP vent valve stuck closed
Restricted vapor lines
Ignition switch ON (EVAP vent valve closed)
Fuel Spitback Restricted EVAP canister
Ignition switch ON (EVAP vent valve closed)
Liquid to EVAP canister. Fill limiter vent valve stuck open or leaking
Over filled fuel tank (cramming during fueling)
Liquid leak to ground Pressure relief valve is stuck open, or leaking
Fuel filler pipe loose or ruptured
Leaking fuel tank
Fuel Odor Pressure relief valve stuck open, or leaking
Saturated EVAP canister
Seepage from fuel lank
ROUGH, UNSTABLE, OR INCORRECT IDLE AND STALLING
Rough, Unstable, or Incorrect Idle and Stalling

DEFINITION: Engine runs unevenly at idle. If severe, the engine or vehicle may shake. Engine idle
speed may vary in RPM. Either condition may be severe enough to stall the engine.
DTC Information.
injector/cylinder.
Inspect for any items which may cause an engine to run rich, long
Inspect for any items which may cause an engine to run lean,
long term fuel trim is significantly in the positive range. Refer to
Sensor/System Test for conditions which cause an incorrect idle speed.
Throttle body tampering, excessive deposits, or damage-
Refer to Fuel System Description .
Restricted air intake system
Large vacuum leak
Inspect crankcase ventilation valve for proper operation.
Inspect the throttle position (TP) sensor and related wiring. Refer
to DTC P0123 .
sensor present parameters on the scan tool. If both are not
Monitor the 3X parameter on the scan tool. If the 3X is not
responding, inspect the CKP sensor B and circuits for
intermittents. Inspect the ignition control (IC) circuit, IC timing
control circuit, low resolution engine speed signal circuit and the
low reference circuit for intermittents. If these circuits become
open, or shorted may not set a DTC immediately, but are capable
of causing driveability complaints. Refer to Testing for
Systems.
Inspect the transaxle range switch input with the vehicle in drive
and the gear selector in drive or overdrive.
steps:
Tools .

conditions:
Spark plug wires-signs of arcing, cross firing, cracks,

Spark Plug Wire Resistance: 9,842 ohms per meter

IMPORTANT:
of water may help locate an intermittent condition.

Fouled plugs
Cracks
Wear
Improper gap
Plug Inspection .
Engine Mechanical Inspect Engine Mechanical for the following conditions:
Worn camshaft lobes
Valve timing
Bent push rods
Worn rocker arms

components:
The camshaft
The cylinder heads
The pistons, etc.

Mechanical.
Additional Inspect the exhaust system for possible restrictions:
Refer to Restricted Exhaust in Engine Exhaust.

Inspect the exhaust system for damaged or collapsed pipes.
Inspect the mufflers for heat distress or possible internal failure.
Test for possible catalytic converter restrictions by testing the
exhaust system back pressure.
An engine miss condition can be caused by electromagnetic
interference (EMI) on the reference circuit. EMI can usually be
detected by monitoring engine RPM with a scan tool. A sudden
increase in RPM with little change in actual engine RPM change,
indicates EMI is present. If a condition exists, inspect the routing
of secondary ignition wires, high voltage components, e.g. near
ignition control circuits.
Inspect for intake and exhaust manifold passages for casting
flash.
DIESELING, RUN-ON
Dieseling, Run-On
DEFINITION: Engine continues to run after key is turned OFF, but runs very rough. If engine runs
smooth, inspect the ignition switch and adjustment.
DTC Information


injector/cylinder.
Additional Test for short between battery positive voltage and any of the ignition
feed circuits. Refer to Wiring Repairs in Wiring Systems.
BACKFIRE
Backfire
Inspection/Test Actions
DEFINITION: Fuel ignites in the intake manifold, or in the exhaust system, making loud popping noise.
DTC Information.
Sensor/System Inspect for the following intermittent ignition system conditions:
Monitor the 24X crank sensor and the camshaft position

(CMP) sensor signal present parameters on the scan tool. If
both are not responding, test the sensor feed circuit. Both
sensors use a separate feed circuit but are internally
connected to power. Test all crankshaft position (CKP)
sensor A and CMP sensor circuits for intermittents. Refer
Monitor the 3X parameter on the scan tool. If the 3X is not
responding, inspect the CKP sensor B and circuits for
intermittents. Inspect the ignition control (IC) circuit, IC
timing control circuit, low resolution engine speed signal
circuit and the low reference circuit for intermittents. If
these circuits become open, or shorted, they may not set a
diagnostic trouble code (DTC) immediately, but are
capable of causing driveability complaints. Refer to
Test the CKP sensor B for an internal short. Refer to
Electronic Ignition (EI) System Diagnosis.
Inspect the mass air flow (MAF) sensor conditions. Ensure that
the MAF sensor honeycomb is not damaged.
Fuel System Test for low fuel pressure. Refer to Fuel System Diagnosis.
Test for contaminated fuel. Refer to Alcohol/Contaminants-in-
Fuel Diagnosis (Without Special Tool) or
Ensure each injector harness is connected to the correct
injector/cylinder.
steps:
Tools .
conditions:


IMPORTANT:

Fouled plugs
Cracks
Wear
Improper gap
Plug Inspection .
Engine Mechanical Inspect engine mechanical for the following conditions:
Test compression
Worn camshaft lobes
Valve timing
Bent push rods
Worn rocker arms
Low cylinder compression
For incorrect basic engine parts-Inspect the following

components:
Camshaft
Cylinder heads
Pistons, etc.
Refer to Base Engine Misfire without Internal Engine Noises

Additional Inspect intake and exhaust manifolds for casting flash.
Test the torque converter clutch (TCC) operation.
Inspect the exhaust system for possible restriction:

failure.
MALFUNCTION INDICATOR LAMP (MIL) INOPERATIVE
Circuit Description
Ignition voltage is supplied to the malfunction indicator lamp (MIL). The powertrain control module (PCM)
turns the MIL ON by grounding the MIL control circuit. There should be a steady MIL with the ignition ON
and the engine OFF.
MIL Operation
The MIL is located on the instrument panel cluster (IPC).
MIL Function
The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service
as soon as possible.
The MIL illuminates during a bulb test and a system test.
A DTC will be stored if a MIL is requested by the PCM.
MIL Illumination
The MIL will illuminate with ignition switch ON and the engine not running.
The MIL will turn OFF when the engine is started.
The MIL will remain ON if the self-diagnostic system has detected a malfunction.
The MIL may turn OFF if the malfunction is not present.
If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the
ignition switch is ON.
If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is
cycled OFF, then ON.
Test Description
4: This step tests for a short to voltage on the MIL control circuit. With the fuse removed there should be
no voltage on the MIL control circuit.
Malfunction Indicator Lamp (MIL) Inoperative

Schematic Reference: Engine Controls Schematics
Connector End View Reference: Engine Controls Connector End Views or Powertrain Control
Module (PCM) Connector End Views
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
1. Verify whether the instrument panel
cluster (IPC) is operational. If the
instrument panel (I/P) is completely
inoperative, refer to Diagnostic System
Check - Vehicle in Vehicle DTC
2 Information. -
2. Command the malfunction indicator lamp
(MIL) ON and OFF with a scan tool.
Go to
Does the MIL turn ON and OFF when Intermittent
commanded with a scan tool? Conditions Go to Step 3
Inspect the fuse that supplies ignition voltage to
3 the cluster. -
Is the fuse open? Go to Step 10 Go to Step 4
2. Remove the fuse that supplies voltage to
the cluster.
(PCM).
4 4. Turn ON the ignition, with the engine 0.3 V
OFF.
5. Measure the voltage from the MIL control
circuit in the PCM harness connector to a
good ground.

2. Install the fuse that supplies voltage to the
cluster.
OFF.
5 -
between the MIL control circuit in the
PCM harness connector and a good
ground.
Is the MIL illuminated? Go to Step 9 Go to Step 6

2. Remove the IPC. Refer to Instrument
Panel Cluster (IPC) Replacement in
6 3. Probe the ignition voltage circuit of the -
IPC harness connector with a test lamp

Test the MIL control circuit for an open or high
resistance. Refer to Circuit Testing and Wiring
7 -
Did you find and correct a condition? Go to Step 15 Go to Step 8
Test for an intermittent and for a poor
connection at the IPC. Refer to Testing for
8 -
Systems.
connection at the PCM. Refer to Testing for
9 -
Systems.
Repair the short to ground in the ignition voltage
circuit. Refer to Wiring Repairs in Wiring
10 - -
Systems.
Repair the short to voltage in the MIL control
circuit. Refer to Wiring Repairs in Wiring
11 - -
Systems.
Repair the open in the ignition voltage circuit.
12 Refer to Wiring Repairs in Wiring Systems. - -
13 - -
14 - -
Turn OFF the ignition for 30 seconds. Go to
Does the vehicle operate correctly, without any Diagnostic
MIL illumination and without any stored DTCs? Trouble Code
15 - (DTC) List -
Vehicle in
Vehicle DTC
System OK Information
MALFUNCTION INDICATOR LAMP (MIL) ALWAYS ON
Circuit Description
Ignition voltage is supplied to the malfunction indicator lamp (MIL). The powertrain control module (PCM)
turns the MIL ON by grounding the MIL control circuit.
MIL Operation
The MIL is located on the instrument panel (IPC).
MIL Function
The MIL informs the driver that a malfunction has occurred and the vehicle should be taken in for service
as soon as possible.
The MIL illuminates during a bulb test and a system test.
A DTC will be stored if a MIL is requested by the diagnostic.
MIL Illumination
The MIL will illuminate with ignition switch ON and the engine not running.
The MIL will turn OFF when the engine is started.
The MIL will remain ON if the self-diagnostic system has detected a malfunction.
The MIL may turn OFF if the malfunction is not present.
If the MIL is illuminated and then the engine stalls, the MIL will remain illuminated so long as the
ignition switch is ON.
If the MIL is not illuminated and the engine stalls, the MIL will not illuminate until the ignition switch is
cycled OFF, then ON.
Diagnostic Aids
If the problem is intermittent, refer to Intermittent Conditions.
Test Description
2: This step determines if the condition is with the MIL control circuit or the PCM.
Malfunction Indicator Lamp (MIL) Always On

Step Action Yes No
1
Vehicle in Vehicle
(PCM).
4. Observe the malfunction indicator lamp (MIL).
Is the MIL illuminated? Go to Step 3 Go to Step 5

1. Remove the instrument panel cluster (IPC). Refer
to Instrument Panel Cluster (IPC)
Replacement in Instrument Panel, Gages, and
Console.
3 2. Test the MIL control circuit for a short to
ground. Refer to Circuit Testing and Wiring

4
5 References in Computer/Integrating Systems for -
1. Turn the ignition OFF for 30 seconds. Go to Diagnostic
2. Start the engine. Trouble Code
6 (DTC) List -
Does the vehicle operate correctly without any MIL Vehicle in Vehicle
illumination, and without any stored DTCs? System OK DTC Information
ENGINE CRANKS BUT DOES NOT RUN
Description
The Engine Cranks but Does Not Run diagnostic table is an organized approach to identifying a condition that
causes an engine not to start. The Engine Cranks but Does Not Run diagnostic table directs the service
technician to the appropriate system diagnosis.
The Engine Cranks but Does Not Run diagnostic table assumes the following:
The battery is completely charged. Refer to Battery Inspection/Test in Engine Electrical.

The engine cranking speed is acceptable. Refer to Engine Cranks Slowly in Engine Electrical.
There is adequate fuel in the fuel tank.
Test Description
3: This step determines if the ignition relay is providing the listed fuses with voltage.
5: This step determines if the fuel pump is operating electrically.
6: If all the Cylinder Injector Circuit Status parameters display Fault, this indicates a condition with the
injector supply voltage circuit.
Engine Cranks but Does Not Run

Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
OFF. Go to
Diagnostic
2 2. Observe the DTC information with a scan - Trouble Code
tool. (DTC) List -
Vehicle in
Does the scan tool display DTC P0101, P0230, Vehicle DTC
P0336, P0601, P0602, P1626, P1630, or P1631? Information Go to Step 3
OFF.
2. Probe both sides of the following fuses:
3 ELEC ENG -
Fuel INJ
Go to Ignition
Does the test lamp illuminate on at least one side Relay
of the fuses listed? Go to Step 4 Diagnosis
2. Disconnect a spark plug wire.
3. Install the J 26792 Spark Tester to the Go to
4 spark plug wire.Special Tools . -
Electronic
4. Attempt to start the engine. Ignition (EI)
System
Does the J 26792 spark?.Special Tools . Go to Step 5 Diagnosis
Command the fuel pump ON with a scan tool. Go to Fuel
Does the fuel pump turn ON? Pump
5 - Electrical
Circuit
Go to Step 6 Diagnosis
While monitoring the Cylinder 1-6 Injector
Circuit Status parameters with a scan tool, crank
the engine. Go to Fuel
6 -
Do all of the Cylinder Injector Circuit Status Injector
parameters display OK while cranking the Circuit
engine? Go to Step 7 Diagnosis
2. Install all disconnected components.
3. Install the J 34730-1A Fuel Pressure
Gage.Special Tools . Refer to Fuel
System Diagnosis.
4. Turn ON the ignition, with the engine 358-405 kPa
7
OFF. (52-59 psi)
5. Command the fuel pump ON with a scan
tool.
Go to Fuel
Is the fuel pressure within the specified range System
when the fuel pump is operating? Go to Step 8 Diagnosis
Inspect for the following conditions:
Collapsed air intake duct
Restricted air filter element-Refer to Air
Cleaner Element Replacement .
Spark plugs for being gas or coolant
fouled-Refer to Spark Plug Inspection . If
the spark plugs are fouled, determine what
caused the condition.
Engine mechanical condition, for example,
worn timing chain and gears, low
compression-Refer to Symptoms - Engine
Mechanical and Engine Compression
Test in Engine Mechanical.
Restricted exhaust system-Refer to
8 Restricted Exhaust in Engine Exhaust. -
The engine coolant temperature (ECT)
sensor is NOT close to the actual engine
temperature. Refer to DTC P0128 .
Compare the manifold absolute
pressure/barometric pressure
(MAP/BARO) parameters to another
vehicle. The parameters should be close in
value. Refer to Manifold Absolute
Pressure (MAP) Sensor Diagnosis.
Throttle position (TP) sensor for being
stuck in range-Refer to DTC P0121 .
Go to
Did you find and correct the condition? Go to Step 9 Diagnostic Aids
1. Clear the DTCs with a scan tool.
9 2. Attempt to start the engine. -
Does the engine start and continue to operate? Go to Step 10 Go to Step 2

1. Allow the engine to reach operating Go to
temperature. Diagnostic
2. Observe the DTC information with a scan Trouble Code
10 tool. - (DTC) List -
Vehicle in
Are there any DTCs that have not been Vehicle DTC
diagnosed? Information System OK
IGNITION RELAY DIAGNOSIS
Circuit Description
The ignition relay is normally an open relay. The relay armature is held in the open position by spring tension.
When the ignition switch is turned to the Run or Start position, current will flow through the relay coil. A wire
connected to the other end of the relay coil completes the path to ground. The electromagnetic field created by
the relay coil overcomes the spring tension and moves the armature, allowing the relay contacts to close. The
closed relay contacts allow current to flow from the battery to the following fuses:
The Eng Controls fuse

The Fuel INJ fuse
The Elec Eng fuse
The O2 Sensors fuse
The Trans Sol fuse
The ABS fuse
The AWD fuse
When the ignition switch is turned to the OFF position, the electromagnetic field collapses. This action allows
the spring tension to move the armature away from the relay contacts, which interrupts current flow to the fuses.
If the ignition relay fails to close, the engine will crank but will not run. The class 2 communications will be
available with the use of a scan tool.
The ignition relay table assumes that the vehicle battery is fully charged. Refer to Battery Inspection/Test in
Engine Electrical.
Ignition Relay Diagnosis

Step Action Yes No
Schematic Reference: Ground Distribution Schematics and Power Distribution Schematics in
Wiring Systems, and Engine Controls Schematics
1
Vehicle in Vehicle
2. Remove the underhood junction block cover.
3. Probe the following fuses with a test lamp that is
2
The Fuel INJ fuse
The Elec Eng fuse
The O2 Sensors fuse
The Trans Sol fuse

The ABS fuse
The AWD fuse
Refer to Probing Electrical Connectors

and Troubleshooting with a Test Lamp
in Wiring Systems.
Does the test lamp illuminate on at least one test point

of each fuse? Go to Step 3 Go to Step 11
2. Probe both test points of the Fuel INJ fuse with a
Refer to Probing Electrical Connectors and
3 Troubleshooting with a Test Lamp in Wiring
Systems.
Does the test lamp illuminate on either test point of the

fuse? Go to Step 4 Go to Step 43
2. Remove the ignition relay from the underhood
junction block with the J 43244 Relay Puller
Pliers and Relay Replacement (Within an
Electrical Center) or Relay Replacement
(Attached to Wire Harness) in Wiring Systems.
3. Probe both test points of the 10-amp IGN 1 fuse
4 in the underhood junction block with a test lamp
that is connected to a good ground. Refer to
Probing Electrical Connectors and
Troubleshooting with a Test Lamp in Wiring
Systems.
Does the test lamp illuminate on any of the fuse test

points? Go to Step 7 Go to Step 5
Test the ignition relay load circuit bus bar of the
underhood junction block between the ignition relay
and the fuses to the circuit components for a short to
5
battery positive voltage. Refer to Circuit Testing in
Wiring Systems.
2. Remove the following fuses from the underhood
junction block:
The Fuel INJ fuse
The Elec Eng fuse
The O2 Sensors fuse
The Trans Sol fuse
The ABS fuse
The AWD fuse

6 3. Probe all these fuse terminals in the underhood
junction block with a test lamp that is connected
to a good ground. Refer to Probing Electrical
Connectors and Troubleshooting with a Test
Lamp in Wiring Systems. Go to Diagnostic
System Check -
Does the test lamp illuminate at any of the fuse Vehicle in Vehicle
terminals? DTC Information Go to Step 39
2. Disconnect the ignition switch electrical
connector.
3. Connect a 20-amp fused jumper wire from the
battery positive voltage wire terminal at the
ignition switch harness connector to the battery
positive voltage terminal at the ignition switch.
7 Refer to Using Fused Jumper Wires in Wiring
Systems.
4. Probe the ignition 1 voltage terminal of the
ignition switch with a test lamp that is connected
Lamp in Wiring Systems.

2. Disconnect the negative battery cable at the
battery. Refer to Battery Negative Cable
Disconnect/Connect Procedure (LA1) in
Engine Electrical.
3. Disconnect the console junction block electrical
8 connector that contains the ignition 1 voltage
circuit from the ignition switch.
4. Connect the negative battery cable to the battery.
5. Probe the ignition 1 voltage circuit between the
ignition switch and the console junction block at
the console junction block electrical connector
ground. Refer to Probing Electrical Connectors
and Troubleshooting with a Test Lamp in
Wiring Systems

Engine Electrical.
3. Disconnect the underhood junction block
electrical connector that contains the ignition 1
voltage circuit for the ignition relay.
9 4. Connect the negative battery cable to the battery.
5. Probe the ignition 1 voltage circuit of the ignition
relay at the underhood junction block electrical
connector with a test lamp that is connected to a
good ground. Refer to Probing Electrical
Lamp in Wiring Systems

Test the ignition 1 voltage bus bar circuit for the
ignition relay in the console junction block for a short
10 to battery positive voltage. Refer to Circuit Testing in
Wiring Systems.
Did you find a condition? Go to Step 41 Go to Step 42
in the underhood junction block with a test lamp
11 Probing Electrical Connectors and
Systems.
Does the test lamp illuminate on both test points of the

Does the test lamp illuminate on one test point of the
12
20-amp IGN 3 fuse? Go to Step 13 Go to Step 28
Test the battery positive voltage circuit between the

13 underhood junction block and the ignition switch for a
Test the ignition 1 voltage circuit between the ignition
switch and the console junction block for a short to
14 ground. Refer to Circuit Testing and Wiring Repairs
in Wiring Systems.
Test the ignition 1 voltage circuit between the console
junction block and the underhood junction block for a
Test the ignition 1 voltage bus bar circuit of the console
junction block between the ignition switch and the
16 underhood junction block for a short to ground. Refer
to Circuit Testing in Wiring Systems.
Test the ignition 1 voltage bus bar circuit of the
underhood junction block up to the 10-amp IGN 1 fuse
17 for a short to ground. Refer to Circuit Testing in
Wiring Systems.
Test the battery positive voltage bus bar circuit of the
underhood junction block from the 20-amp IGN 3 fuse
18 for a short to ground. Refer to Circuit Testing in
Wiring Systems.
in the underhood junction block with a test lamp
Systems.
Does the test lamp illuminate on both test points of the

Does the test lamp illuminate on one test point of the
20
10-amp IGN 1 fuse? Go to Step 27 Go to Step 21
2. Probe the ignition 1 voltage circuit at the ignition
switch electrical connector with a test lamp that
21 is connected to a good ground. Refer to Probing
Electrical Connectors and Troubleshooting
with a Test Lamp in Wiring Systems.

underhood junction block and the ignition switch for a
22 high resistance or an open. Refer to Circuit Testing
2. Probe the mounting stud for the battery positive
cable at the underhood junction block with a test
lamp that is connected to a good ground. Refer to
Troubleshooting with a Test Lamp in Wiring Go to Diagnostic
Systems. System Check -
Vehicle in Vehicle
Does the test lamp illuminate? Go to Step 40 DTC Information
2. Probe the ignition 1 voltage circuit for the
ignition relay at the console junction block
electrical connector that leads from the ignition
24 switch with a test lamp that is connected to a
good ground. Refer to Probing Electrical

2. Probe the ignition 1 voltage circuit for the
ignition relay at the console junction block
electrical connector that leads to the underhood
25 junction block with a test lamp that is connected

26 Disconnect/Connect Procedure (LA1) in
Engine Electrical.
electrical connector that contains the ignition 1
voltage circuit for the ignition relay.
4. Connect the negative battery cable at the battery.
6. Probe the ignition 1 voltage circuit at the
underhood junction block electrical connector
Wiring Systems.

Test the ignition 1 voltage bus bar circuit of the
underhood junction block between the 10-amp IGN 1
27 fuse and the ignition relay for a short to ground. Refer
to Circuit Testing in Wiring Systems.
2. Probe the mounting stud for the battery positive
cable at the underhood junction block with a test
Troubleshooting with a Test Lamp in Wiring Go to Diagnostic
Systems. System Check -
Vehicle in Vehicle
Does the test lamp illuminate? Go to Step 42 DTC Information
2. Remove the ignition relay with the J 43244 from
the underhood junction block.
ignition relay at the underhood junction block
29 with a test lamp that is connected to a good
Wiring Systems.

2. Probe the ignition 1 voltage circuit of the ignition
relay at the underhood junction block with a test
Systems.

2. Probe the coil ground circuit of the ignition relay
at the underhood junction block with a test lamp
that is connected to battery voltage. Refer to
Systems.

Engine Electrical.
32 electrical connectors.
4. Test the coil ground circuit wire of the ignition
relay at the underhood junction block electrical
connector for a high resistance or an open. Refer
to Circuit Testing and Wiring Repairs in
Wiring Systems.

2. Jumper the ignition relay battery positive voltage
circuit and the ignition relay load circuit together
at the underhood junction block with a 20-amp
fused jumper wire. Refer to Using Fused
Jumper Wires in Wiring Systems.
3. Probe the following fuses with a test lamp that is
connected to a good ground:
33 The Eng Controls fuse
The Fuel INJ fuse
The O2 Sensors fuse
The Trans Sol fuse
The ABS fuse
The AWD fuse
Refer to Probing Electrical Connectors

and Troubleshooting with a Test Lamp
in Wiring Systems.
Does the test lamp illuminate on at least one test point
of each fuse? Go to Step 34 Go to Step 42
Test for an intermittent and for a poor connection at the
underhood junction block, ignition relay connector
34 location. Refer to Testing for Intermittent Conditions
Repair the short to battery positive voltage in the
ignition 1 voltage circuit between the ignition switch
35 and the console junction block. Refer to Wiring
Repair the high resistance or an open in the ignition 1
voltage circuit between the console junction block and
36 the ignition switch. Refer to Wiring Repairs in Wiring
Systems.
Repair the high resistance or an open in the ignition 1
voltage circuit between the console junction block and
37 the underhood junction block. Refer to Wiring Repairs
in Wiring Systems.
Repair the short to battery positive voltage in the
ignition 1 voltage circuit between the console junction
block and the underhood junction block electrical
38
connector. Refer to Wiring Repairs in Wiring
Systems.
Replace the ignition relay. Refer to Circuit Protection
39 - Fusible Links in Wiring Systems.
Replace the ignition switch. Refer to Ignition Switch
40 Replacement in Steering Wheel and Column.
Replace the console junction block. Refer to Console
Electrical Center or Junction Block Replacement in
41
Wiring Systems.
Replace the underhood junction center. Refer to
42
1. Replace any open fuses.
43 2. Turn OFF the ignition for 30 seconds.
3. Attempt to start the engine. Go to Engine
Does the engine start and run? Cranks but Does
Go to Step 44 Not Run
Go to Diagnostic
Trouble Code
44 2. Operate the vehicle for 5 minutes. (DTC) List -
Vehicle in Vehicle
Does a DTC set during this ignition cycle? DTC Information System OK
FUEL PUMP ELECTRICAL CIRCUIT DIAGNOSIS
Circuit Description
When you turn ON the ignition switch, the control module enables the fuel pump relay which powers the fuel
pump ON. The fuel pump remains ON as long as the engine is cranking or running and the control module
receives ignition reference pulses. If there are no ignition reference pulses, the control module shuts the fuel
pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops.
Diagnostic Aids
Listen for an audible hiss from the fuel pump when the fuel pump relay is commanded ON. A vibration in
the fuel feed line when the fuel pump relay is commanded ON indicates that the fuel pump is operating.
If the condition is intermittent, refer to Intermittent Conditions.
Test Description
2: Command both the ON and OFF states. Repeat the commands as necessary.
3: This step determines if the condition is located on the coil side or the switch side of the circuit.
4: This step verifies that the powertrain control module (PCM) is providing voltage to the fuel pump
relay.
5: This step tests for an open in the fuel pump relay ground circuit.
6: This step determines if a voltage is constantly being applied to the fuel pump relay.
12: This tests for a grounded fuel pump supply voltage circuit. The fuel pump fuse supplies power to fuel
pump. Disconnecting the fuel pump in-line harness connector isolates the fuel pump supply voltage
circuit.
15: This step jumps the fuel pump relay in order to activate the fuel pump.
16: This step tests for an open in the fuel pump feed circuit between the in-line connector and the fuel
pump relay.
17: This step tests for an open or high resistance in the fuel pump ground circuit.
20: This step determines if the condition with the circuit is intermittent. If the fuse does not open, inspect
the supply voltage circuit between the fuse and the fuel pump for an intermittent condition.
Fuel Pump Electrical Circuit Diagnosis

Step Action Yes No
1
Vehicle in Vehicle
2 3. Command the fuel pump relay ON and OFF
with a scan tool.
Go to Intermittent
Does the fuel pump turn ON and OFF? Conditions Go to Step 3
Command the fuel pump relay ON and OFF with a
scan tool.
3
Do you hear a click when you command the fuel pump
relay ON and OFF? Go to Step 9 Go to Step 4
2. Disconnect the fuel pump relay.
4. Probe the control circuit of the fuel pump relay
4 with a test lamp that is connected to a good
ground.
5. Command the fuel pump ON and OFF with a
scan tool.
Does the test lamp turn ON and OFF? Go to Step 5 Go to Step 6

1. Connect the test lamp between the control circuit
of the fuel pump relay and the ground circuit of
the fuel pump relay.
5 2. Command the fuel pump ON and OFF with a
scan tool.
Does the test lamp turn ON and OFF? Go to Step 21 Go to Step 24

Does the test lamp remain illuminated with each
6
Test the control circuit of the fuel pump relay for a
short to voltage. Refer to Circuit Testing and Wiring
7
Test the control circuit of the fuel pump relay for a
short to ground or an open. Refer to Circuit Testing
8
Turn ON the ignition, with the engine OFF.
9
Does the fuel pump operate continuously? Go to Step 10 Go to Step 11
Does the fuel pump operate continuously? Go to Step 23 Go to Step 27

11 Is the fuel pump fuse open? Go to Step 12 Go to Step 14
1. Disconnect the fuel pump harness in-line
connector located near the fuel tank.
2. Test the fuel pump supply voltage circuit for a
12 short to ground. Refer to Circuit Testing and
3. Replace the fuel pump fuse if necessary.

1. Lower the fuel tank if necessary. Refer to Fuel
Tank Replacement .
2. Test or inspect the fuel tank electrical harness
for the following:
Damage to the harness
13 A grounded circuit-Refer to Circuit
Systems.
3. Replace the fuel pump fuse if necessary.

14 4. Probe the battery positive voltage circuit of the
fuel pump relay with a test lamp connected to a
good ground.

Connect a 10-amp fused jumper wire between the
battery positive voltage circuit and the fuel pump
15
supply voltage circuit in the fuel pump cavity.
Does the fuel pump operate? Go to Step 21 Go to Step 16
1. Disconnect the fuel pump harness in-line
connector located near the fuel tank.
2. Test the fuel pump supply voltage circuit for an
open or high resistance between the fuel pump
16 relay and the in-line connector. Refer to Circuit
Systems.

IMPORTANT:
Inspect the ground circuit for being tight, corrosion
on the terminals, or damage to the wiring harness.
17 Test the ground circuit of the fuel pump for an open or

high resistance between the body pass through
connector and the ground. Refer to Circuit Testing
and Wiring Repairs in Wiring Systems.Did you find
and correct the condition? Go to Step 29 Go to Step 18
Inspect for poor connections at the fuel pump in-line
connector to the body pass through connector. Refer to
18
Connections and Repairing Connector Terminals in
Wiring Systems.
1. Lower the fuel tank. Refer to Fuel Tank
Replacement .
2. Test or inspect the fuel tank electrical harness
for the following:
19 Damage to the harness
An open circuit-Refer to Circuit Testing


1. Connect all disconnected components.
2. Install a new fuel pump fuse.
20 3. With a scan tool, command the fuel pump ON.
Go to Intermittent
Is the fuel pump fuse open? Go to Step 26 Conditions
Inspect for poor connections at the fuel pump relay.
21 Poor Connections and Connector Repairs in Wiring
Systems.
Inspect for poor connections at the harness of the
powertrain control module (PCM). Refer to Testing
Repair the fuel pump supply voltage circuit for a short
to voltage. Refer to Wiring Repairs in Wiring
23
Systems.
Repair the fuel pump relay ground circuit for an open
24 ground. Refer to Wiring Repairs in Wiring Systems.
Repair the battery positive voltage circuit of the fuel
pump relay for an open. Refer to Wiring Repairs in
25
Wiring Systems.
IMPORTANT:
Inspect for poor connections at the fuel pump,
within the fuel tank, before replacing the fuel pump.
26 1. Replace the fuel pump. Refer to Fuel Sender

Assembly Replacement .
2. Replace the fuel pump fuse, if necessary.

IMPORTANT:
Before replacing the fuel pump relay, inspect the
fuel pump prime circuit for a short to voltage.
27
Replace the fuel pump relay.Did you complete the
replacement? Go to Step 29 -
28
Observe the Capture Info with a scan tool. Go to Diagnostic
Are there any DTCs that have not been diagnosed? Trouble Code
29 (DTC) List -
Vehicle in Vehicle
DTC Information System OK
FUEL SYSTEM DIAGNOSIS
System Description
When the ignition is turned ON, the powertrain control module (PCM) will turn ON the in-tank fuel pump. The
in-tank fuel pump will remain ON as long as the engine is cranking or running and the PCM is receiving
ignition reference pulses. If there are no ignition reference pulses, the PCM will turn the in-tank fuel pump OFF
2 seconds after the ignition is turned ON, or 2 seconds after the engine stops running.
The in-tank fuel pump is an electric pump attached to the fuel sender assembly. The fuel pump is designed to
provide fuel at a pressure above the pressure needed by the fuel injectors. A fuel pressure regulator, attached to
the fuel rail, keeps the fuel available to the fuel injectors at a regulated pressure. Unused fuel is returned to the
fuel tank by a separate fuel return pipe.
Test Description
2: This step verifies that the fuel pump is operating.

4: This step tests for an internal fuel leak. If the fuel pressure drops during this test, then an internal loss
of pressure is indicated.
6: This step tests the fuel pressure regulator. The fuel pressure regulator is controlled by engine vacuum.
With engine vacuum applied, the pressure should drop the specified value.
9: This step inspects the fuel pressure regulator for a fuel leak from the vacuum port. If fuel leaks from
the fuel pressure regulator while the fuel pump is commanded ON, replace the fuel pressure regulator.
10: This step tests for a loss of fuel pressure between the fuel feed pipe shut off adapter and the fuel
pump.
11: This step tests for a leaking fuel injector, or fuel pressure regulator. If the fuel pressure remains
constant during this test, the fuel injectors are not leaking fuel.
14: This step tests for a restricted fuel return pipe. If the fuel pressure is within the specified values, a
restriction in the fuel return pipe is indicated.
16: This step determines if the fuel pressure regulator, or the fuel pump, is the cause of the low fuel
pressure. If the pressure rises above the specified value, the fuel pump is OK.
18: This step verifies that a circuit condition is not the cause of a fuel pressure concern. Inspect all fuel
pump electrical circuits thoroughly.
Fuel System Diagnosis

Schematic Reference: Fuel System Description
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
IMPORTANT:
Inspect the fuel system for damage or external
2 leaks before proceeding with this diagnostic. -

Go to Fuel
2. Command the fuel pump ON with a scan Pump
tool. Electrical
Circuit
Does the fuel pump operate? Go to Step 3 Diagnosis
IMPORTANT:
Verify there is adequate fuel in the fuel tank
before proceeding with this diagnostic.

2. Turn OFF all accessories.
3. Install a J 34730-1A Fuel Pressure Gage
and the fuel pressure gage fitting.Special
Tools . Refer to Fuel Pressure Gage
Installation and Removal .
tool. 358-405 kPa
3
(52-59 psi)
IMPORTANT:
The fuel pump runs for
Command the fuel pump ON with a
scan tool in order to obtain the
highest possible fuel pressure.
DO NOT start the engine.
6. Observe the fuel pressure gage, with the

fuel pump commanded ON.
Is the fuel pressure within the specified value? Go to Step 4 Go to Step 12

IMPORTANT:
The fuel pressure may vary slightly when the
fuel pump stops running. After the fuel pump
stops running, the fuel pressure should
4 stabilize and remain constant. 34 kPa (5 psi)
Monitor the fuel pressure gage for one

minuteDoes the fuel pressure drop more than the
1. Relieve the fuel pressure to the first
specified value. 69 kPa (10
5 2. Monitor the fuel pressure gage for 5 psi)
minutes. 14 kPa (2 psi)
Does the fuel pressure drop more than the second
1. Turn OFF the ignition for 15 seconds.
3. Monitor the fuel pressure gage. 21-69 kPa (3-
6
4. Start the engine. 10 psi)
Does the fuel pressure drop the specified value

when the engine is started? Go to Step 7 Go to Step 8
1. Operate the vehicle within the conditions of
the customers concern.
2. Monitor the fuel related parameters with a
7 scan tool. - Go to
Symptoms -
Do any of the scan tool parameters indicate a lean Engine
condition? Go to Step 17 Controls
1. Disconnect the vacuum hose from the fuel
pressure regulator.
2. Monitor the fuel pressure gage.
3. Idle the engine.
21-69 kPa (3-
8 4. Apply 34-47 kPa (12-14 in) of vacuum to
10 psi)
the fuel pressure regulator with a hand held
vacuum pump.
Does the fuel pressure drop the specified value

when the vacuum is applied? Go to Step 21 Go to Step 23
2. Remove the vacuum hose from the fuel
pressure regulator.
9 4. Command the fuel pump ON with a scan -
tool.
5. Inspect for a fuel leak from the fuel
pressure regulator vacuum port.
Is the fuel pressure regulator leaking fuel? Go to Step 23 Go to Step 10

2. Relieve the fuel pressure. Refer to Fuel
Pressure Relief Procedure .
3. Disconnect the fuel feed hose and the fuel
return hose from the fuel rail pipes. Refer
to Quick Connect Fitting(s) Service
(Metal Collar) .
4. Install the J 37287 Fuel Line Shut-Off
Adapters between the fuel hoses and the
fuel rail pipes.Special Tools .
5. Open the valves on the fuel pipe shut off
adapters.
tool.
10 8. Bleed the air from the fuel pressure gage. -
IMPORTANT:
Command the fuel pump ON with a scan
tool in order to obtain the highest
possible fuel pressure.
9. Close the fuel feed pipe shut off valve.

10. Monitor the fuel pressure gage for one
minute.
Does the fuel pressure remain constant? Go to Step 19 Go to Step 11

2. Open the fuel feed pipe shut off valve.
4. Command the fuel pump ON and then OFF
11 with a scan tool. -
5. Close the fuel return pipe shut off valve.
6. Monitor the fuel pressure gage for one
minute.
Does the fuel pressure remain constant? Go to Step 23 Go to Step 20

Is the fuel pressure above the specified value? 427 kPa (59
12
psi) Go to Step 14 Go to Step 13
13 Is the fuel pressure above the specified value? 0 kPa (0 psi) Go to Step 16 Go to Step 17
3. Disconnect the fuel return hose from the
fuel rail return pipe. Refer to Quick
Connect Fitting(s) Service (Metal
Collar) .
4. Attach a length of flexible fuel hose to the
fuel rail outlet passage.
5. Place the open end of the flexible fuel hose
into an approved gasoline container.
358-405 kPa
14 6. Turn ON the ignition, with the engine OFF. (52-59 psi)
7. Monitor the fuel pressure gage while the
fuel pump is operating.
Is the fuel pressure within the specified value? Go to Step 22 Go to Step 15

Inspect the fuel rail return pipe and fuel rail outlet
15 passage for a restriction. -
3. Disconnect the fuel return hose from the
fuel rail return pipe. Refer to Quick
Connect Fitting(s) Service (Metal
Collar) .
4. Install the J 37287 between the fuel return
pipe and the fuel rail.Special Tools .
5. Open the valve in the fuel pipe shut off
adapter.
6. Turn ON the ignition with the engine OFF.
7. Bleed the air from the fuel system. 358 kPa (52
16
8. Monitor the fuel pressure gage. psi)
NOTE:
DO NOT allow the fuel pressure to
exceed 517 kPa (75 psi). Excessive
pressure may damage the fuel system.
9. Slowly close the valve in the fuel return

pipe shut off adapter.
tool.
Does the fuel pressure rise above the specified

Inspect the following components for a
restriction:
The fuel filter

The fuel feed pipe
17 -
Inspect the harness connectors and ground
circuits of the fuel pump for poor connections.
18 -
in Wiring Systems.
1. Remove the fuel sender assembly. Refer to
Fuel Sender Assembly Replacement .
2. Inspect the following components:
The fuel pump flex hose for damage
19 The in tank fuel pump harness -

connectors for poor connections
The fuel strainer for a restriction
Contaminates in the fuel tank

2. Raise the fuel rail with the fuel lines
connected. Refer to Fuel Rail Assembly
Replacement .
20 4. Command the fuel pump ON with a scan - -
tool.
5. Locate and replace the leaking fuel
injector. Refer to Fuel Injector
Replacement .

Repair the vacuum source to the fuel pressure
21 regulator. - -
Locate and repair the restricted fuel return line.
22 - -
IMPORTANT:
Inspect for a missing or damaged fuel
pressure regulator O-ring before replacing the
23 fuel pressure regulator. - -
Replace the fuel pressure regulator. Refer to Fuel

Pressure Regulator Replacement .Did you
complete the replacement? Go to Step 25
Replace the fuel pump. Refer to Fuel Sender
24 Assembly Replacement . - -
25 -
FUEL INJECTOR COIL TEST
Circuit Description
The control module enables the appropriate fuel injector on the intake stroke for each cylinder. Ignition voltage
is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control
circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or low will
affect engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The
fuel injector coil windings are affected by temperature. The resistance of the fuel injector coil windings will
increase as the temperature of the fuel injector increases.
Diagnostic Aids
Monitoring the misfire current counters, or misfire graph, may help isolate the fuel injector that is causing
the condition.
Operating the vehicle over a wide temperature range may help isolate the fuel injector that is causing the
condition.
Perform the fuel injector coil test within the conditions of the customers concern. A fuel injector
condition may only be apparent at a certain temperature, or under certain conditions.
If the fuel injector coil test does not isolate the condition perform the fuel injector balance test. Refer to
Fuel Injector Balance Test with Special Tool or Fuel Injector Balance Test with Tech 2.
Test Description
3: This step tests each fuel injector resistance within a specific temperature range. If any of the fuel
injectors display a resistance outside of the specified value, replace the fuel injector.
4: This step determines if all of the fuel injectors are within 3 ohms of each other. If the highest resistance
value is within 3 ohms of the lowest resistance value, then all of the fuel injector coil windings are OK.
6: This step determines if the ignition 1 voltage circuit under the intake plenum is causing the concern.
8: This step determines which fuel injector is faulty. After subtracting the highest and lowest resistance
values from the average value, replace the fuel injector that has the greatest resistance difference from the
average.
Fuel Injector Coil Test

Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
Observe the engine coolant temperature (ECT)
10-32C (50-
2 with a scan tool.
90F)
Is the ECT value within the specified range? Go to Step 3 Go to Step 4
1. Disconnect the fuel injector multi-way
harness connector.
2. Measure the resistance of each fuel
injector between the ignition feed circuit
and the fuel injector control circuit, at the
3 multi-way connector with a DMM. Refer 11-14 ohms
to Testing for Continuity in Wiring
Systems.
Do any of the fuel injectors display a resistance Go to

outside the specified range? Go to Step 5 Diagnostic Aids
1. Disconnect the fuel injector multi-way
connector.
2. Measure the resistance of each fuel
injector between the ignition feed circuit
and the fuel injector control circuit, at the
multi-way connector with a DMM. Refer
to Testing for Continuity in Wiring
4 3 ohms Go to Fuel
Systems.
Injector
3. Record each fuel injector value. Balance Test
4. Subtract the lowest resistance value from with Special
the highest resistance value. Tool or Fuel
Injector
Is the difference equal to, or less than, the Balance Test
specified value? with Tech 2 Go to Step 8
Remove the upper intake manifold. Refer to
Intake Manifold Replacement - Upper in
5 -
Engine Mechanical.
Did you complete the action? Go to Step 6 -
Measure the resistance of the ignition 1 voltage

6 5 ohms
circuit between the multi-way connector and the
affected fuel injector connector, with a DMM.
Is the resistance more than the specified value? Go to Step 7 Go to Step 9
Repair the open or high resistance in the ignition
7 1 voltage circuit. -
1. Add all of the fuel injector resistance
values, to obtain a total resistance value.
2. Divide the total resistance value by the
number of fuel injectors, to obtain an
average resistance value.
3. Subtract the lowest and the highest
8 individual fuel injector resistance values -
from the average resistance value.
4. Replace the fuel injector that displays the
greatest resistance difference, above or
below the average. Refer to Fuel Injector
Replacement .

Test for an intermittent and for a poor connection
at the affected fuel injector. Refer to Testing for
9 Intermittent Conditions and Poor -
Replace any fuel injectors that are out of the
specified range. Refer to Fuel Injector
10 11-14 ohms
Replacement .
11 -
FUEL INJECTOR BALANCE TEST WITH SPECIAL TOOL

Fig. 1: Performing Fuel Injector Balance Test With Special Tool

1 First Fuel Pressure Gage Reading
2 Second Fuel Pressure Gage Reading
System Description
The scan tool is first used to energize the fuel pump relay. The fuel injector tester is then used to pulse each
injector for a precise amount of time allowing a measured amount of fuel into the manifold. This causes a drop
in system fuel pressure that can be recorded and used to compare each injector.
Fuel Injector Balance Test Example (Typical)

Cylinder 1 2 3 4
1st Reading 296 kPa (43 psi) 296 kPa (43 psi) 296 kPa (43 psi) 296 kPa (43 psi)
2nd Reading 131 kPa (19 psi) 117 kPa (17 psi) 124 kPa (18 psi) 145 kPa (21 psi)
Amount of Drop 165 kPa (24 psi) 179 kPa (26 psi) 172 kPa (25 psi) 151 kPa (22 psi)
Average Range: Replace fuel Replace fuel
156-176 kPa (22.5- Injector OK injector- too much Injector OK injector- too little
25.5 psi) fuel pressure drop fuel pressure drop
Test Description
3: The engine coolant temperature (ECT) must be below the operating temperature in order to avoid
irregular fuel pressure readings due to hot soak fuel boiling.
6: If the pressure drop value for each fuel injector is within 10 kPa (1.5 psi) of the average pressure drop
value, the fuel injectors are flowing properly.
Fuel Injector Balance Test with Special Tool

Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
Did you perform the Fuel Injector Coil Test? Go to Fuel
2 - Injector Coil
Go to Step 3 Test
IMPORTANT:
DO NOT perform this test if the engine coolant
temperature (ECT) is above 94C (201F).
3 94C (201F) -
Observe the ECT parameter with a scan
tool.Does the scan tool indicate that the ECT
parameter is less than the specified value? Go to Step 4
IMPORTANT:

2. Install the J 34730-1A Fuel Pressure Gage
OFF. 358-405 kPa
4 4. Command the fuel pump ON with a scan (52-59 psi)
tool.
IMPORTANT:
You may need to command the
fuel pump ON a few times, in
order to obtain the highest
5. Observe the J 34730-1A , with the fuel

pump commanded ON.Special Tools . Go to Fuel
System
Is the fuel pressure within the specified range? Go to Step 5 Diagnosis
IMPORTANT:
fuel pump stops operating. After the fuel
pump stops operating, the fuel pressure
5 should stabilize and remain constant. 34 kPa (5 psi)
Monitor the J 34730-1A for 1 minute.Special Go to Fuel

Tools .Does the fuel pressure drop more than the System
specified value? Diagnosis Go to Step 6
1. Connect the J 39021 Fuel Injector
Coil/Balance Tester, .Special Tools .J
39021-210 Injector Test Adapter Box,
and .Special Tools .J 39021-410 Fuel
Injector Test Harness to the fuel injector
multi-way connector.Special Tools .
2. Set the amperage supply selector switch on
the fuel injector tester to the Balance Test
0.5-2.5 amp position.
3. Command the fuel pump ON and then
OFF with a scan tool.
4. Record the fuel pressure indicated by the J
34730-1A after the fuel pressure
stabilizes.Special Tools . This is the first
pressure reading.
10 kPa (1.5
6 IMPORTANT:
psi)
Record the fuel pressure value
immediately after the fuel injector stops
pulsing. The fuel pressure may rise after
the fuel injector stops pulsing. DO NOT
record the higher fuel pressure value.
5. Energize the fuel injector by depressing

the Push to Start Test button on the fuel
injector tester.
34730-1A .Special Tools . This is the
second fuel pressure reading.
7. Repeat steps 1-6 for each fuel injector.
8. Subtract the second pressure reading from
the first pressure reading for one fuel
injector. The result is the pressure drop
value.
9. Obtain a pressure drop value for each fuel
injector.
10. Add all of the individual pressure drop
values. This is the total pressure drop.
11. Divide the total pressure drop by the
number of fuel injectors. This is the
average pressure drop.
Does any fuel injector have a pressure drop value Go to

that is more than the average pressure drop or Symptoms -
less than the average pressure drop by the Engine
specified value? Go to Step 7 Controls
Clean the fuel injectors. Refer to Fuel Injector
7 Cleaning Procedure . - -
Did you complete the action? Go to Step 8
Observe the Capture Info with a scan tool. Go to
Are there any DTCs that have not been Diagnostic
diagnosed? Trouble Code
8 - (DTC) List -
Vehicle in
Vehicle DTC
Information System OK
FUEL INJECTOR BALANCE TEST WITH TECH 2
Circuit Description
The scan tool first energizes the fuel pump and then the injectors for a precise amount of time allowing a
measured amount of fuel into the manifold. This causes a drop in system fuel pressure that can be recorded and
used to compare each injector.
Test Description
3: The engine coolant temperature must be below the operating temperature in order to avoid irregular
fuel pressure readings due to hot soak fuel boiling.
6: If the pressure drop value for each fuel injector is within 10 kPa (1.5 psi) of the average pressure drop
value, the fuel injectors are flowing properly.
Fuel Injector Balance Test with Tech 2

Go to
Vehicle?
Diagnostic
System Check
- Vehicle in
1 -
Vehicle DTC
Did you perform the Fuel Injector Coil Test? Go to Fuel
2 - Injector Coil
Go to Step 3 Test
IMPORTANT:
DO NOT perform this test if the engine coolant
temperature (ECT) is above 94C (201F).
3 94C (201F) -
Observe the ECT parameter with a scan
tool.Does the scan tool indicate that the ECT
parameter is less than the specified value? Go to Step 4
IMPORTANT:

2. Turn OFF all the accessories.
3. Install the J 34730-1A Fuel Pressure Gage
OFF.
4 5. Command the fuel pump ON with a scan 358-405 kPa
tool. (52-59 psi)
IMPORTANT:
It may be necessary to command
the fuel pump ON a few times in
order to obtain the highest
6. Observe the J 34730-1A , with the fuel

pump commanded ON.Special Tools . Go to Fuel
System
Is the fuel pressure within the specified value? Go to Step 5 Diagnosis
IMPORTANT:
fuel pump stops operating. After the fuel
pump stops operating, the fuel pressure
should stabilize and remain constant.
5 Monitor the J 34730-1A for one minute.Special 34 kPa (5 psi) Go to Fuel

Tools .Does the fuel pressure drop more than the System
specified value? Diagnosis Go to Step 6
1. Select the Fuel Injector Balance Test
function, within the Special Functions
menu, with a scan tool.
2. Select an injector to be tested.
3. Press Enter. This will prime the fuel
system.
34730-1A after the fuel pressure
stabilizes.Special Tools . This is the 1st
pressure reading.
IMPORTANT:
Record the fuel pressure value
immediately after the fuel injector stops
pulsing. The fuel pressure may rise after
the fuel injector stops pulsing. DO NOT
record the higher fuel pressure value.
5. Energize the fuel injector by depressing

the Pulse Injector button on the scan tool. 10 kPa (1.5
6 This will energize the injector and psi)
decrease the fuel pressure.
34730-1A after the fuel injector has
stopped pulsing.Special Tools . This is the
2nd pressure reading.
7. Press Enter again to bring you back to the
Select Injector screen.
8. Repeat for each fuel injector.
9. Subtract the 2nd pressure reading from the
1st pressure reading for one fuel injector.
The result is the pressure drop value.
10. Obtain a pressure drop value for each fuel
injector.
11. Add all of the individual pressure drop
values. This is the total pressure drop.
12. Divide the total pressure drop by the
number of fuel injectors. This is the
average pressure drop.
Does any fuel injector have a pressure drop value
that is either higher than the average pressure Go to
drop or lower than the average pressure drop by Symptoms -
the specified value? Engine
Go to Step 7 Controls
Clean the fuel injectors. Refer to Fuel Injector
7 Cleaning Procedure . - -
Did you complete the action? Go to Step 8
Operate the vehicle in order to verify the repair. Go to
Does a driveability condition still exist? Symptoms -
8 -
Engine
Controls System OK
FUEL INJECTOR CIRCUIT DIAGNOSIS
Circuit Description
The powertrain control module (PCM) enables the appropriate fuel injector on the intake stroke for each
cylinder. A voltage is supplied directly to the fuel injectors. The PCM controls each fuel injector by grounding
the control circuit via a solid state device called a driver.
Diagnostic Aids
Monitoring the fuel injector circuit status with a scan tool, while moving the fuel injector harness, may
help isolate an intermittent condition.
Performing the Fuel Injector Coil Test may help isolate an intermittent condition. Refer to Fuel Injector
Coil Test.
For an intermittent condition, refer to Intermittent Conditions.
Test Description
4: This step tests for a short to ground on the ignition 1 voltage supply circuit of the fuel injector.
5: This step tests for a short to a PCM ground on the ignition 1 voltage supply circuit of the fuel injector.
6: This step tests for an open between the multi-way connector and the fuel injectors.
7: This step tests for an open or high resistance between the multi-way connector and the fuel injectors.
Fuel Injector Circuit Diagnosis

Go to
Vehicle?
Diagnostic
System Check -
Vehicle in
1 -
Vehicle DTC
Are any fuel injector DTCs set? Go to DTC
2 -
P0201-P0206 Go to Step 3
Inspect the fuel injector fuse.
3 -
Is the fuel injector fuse open? Go to Step 4 Go to Step 6
2. Disconnect the multi-way harness
connector of the fuel injectors.
4 3. Probe the ignition 1 voltage circuit of the -
fuel injector, fuse side, with a test lamp
connected to B+.

Turn ON the ignition, with the engine OFF.
5 -
2. Disconnect the multi-way harness
connector of the fuel injectors.
6 OFF. -
4. Probe the ignition 1 voltage circuit of the
fuel injector, fuse side, with a test lamp

Test for continuity between the ignition voltage
terminal and a fuel injector terminal, at the
multi-way harness connector, fuel injector side.
7 Refer to Testing for Continuity in Wiring 5 ohms
Systems.
Does the DMM display a resistance above the
Test the ignition 1 voltage circuit of the fuel
injector, between the multi-way harness
connector and the fuel injectors for a short to
8 -
ground. Refer to Circuit Testing and Wiring Go to
Repairs in Wiring Systems. Intermittent
Did you find and correct the condition? Go to Step 14 Conditions
Repair the short to ground in the ignition voltage
9 circuit of the fuel injector. Refer to Circuit -
Testing in Wiring Systems.
Repair the open in the ignition 1 voltage between
UBEC and the multi-way connector. Refer to
10 -
Circuit Testing in Wiring Systems.
Repair the ignition 1 voltage circuit of the fuel
injectors for an open and/or high resistance,
11 between the multi-way connector and the splice. -
Repair the poor connection at the multi-way
connector. Refer to Connector Repairs in
12 -
Wiring Systems.
Repair the short to a powertrain control module
(PCM) ground in the ignition voltage circuit of
13 the fuel injector. Refer to Wiring Repairs in -
Wiring Systems.
14 -
FUEL TANK LEAK TEST
Description
The fuel tank leak test is used to locate any fuel or fuel vapor escaping the fuel tank area. Fuel vapors escaping
above the fuel level will be detected when the evaporative emission (EVAP) diagnostics completes one test
cycle. The malfunction indicator lamp (MIL) will illuminate after the EVAP diagnostics completes two test
cycles.
Diagnostic Aids
Operate the vehicle under the condition of the customers concern. Under high temperature conditions,
fuel vapors may increase to the point of EVAP canister vapor saturation. Fuel vapors would then be
released into the atmosphere. Once the engine is running and EVAP purge is enabled, all fuel vapor
release would be eliminated.
Test for fuel leaking in the following locations:
The fuel tank
The fuel feed and return pipes
Test for fuel vapor leaks in the following locations:

The fuel tank, fill limiter vent valve, and rollover valves
The fuel fill pipe, hose, and fuel fill cap
The fuel sender housing and seal

The fuel tank pressure (FTP) sensor seal
The EVAP vapor pipe
Movement of the EVAP pipes or fuel pipes may help find an intermittent condition.
Test Description
1: Perform this procedure to determine that no EVAP DTC is present.

3: This test is to locate fuel leakage in the fuel lines.
4: This tests for fuel leaks below the fuel tank fuel level.
5: This test is to locate fuel vapors escaping above the fuel level in the fuel tank.
Fuel Tank Leak Test

Step Action Yes No
1
Vehicle in Vehicle
CAUTION:
Gasoline or gasoline vapors are highly flammable. A
fire could occur if an ignition source is present.
Never drain or store gasoline or diesel fuel in an
open container, due to the possibility of fire or
explosion. Have a dry chemical (Class B) fire
extinguisher nearby.
2
1. Raise the vehicle. Refer to Lifting and Jacking
the Vehicle in General Information.
2. Inspect the fuel tank and fuel pipes for damage or
external leaks.
Did you find fuel leaking from the fuel tank? Go to Step 6 Go to Step 3
2. Command the fuel pump ON with a scan tool.
3 3. Inspect for fuel leaking from the fuel pipes.
Did fuel leak from the fuel pipes? Go to Step 7 Go to Step 4

2. Install the J 41413-200 Evaporative Emissions
System Tester (EEST) and the .Special Tools .J
41415-40 Fuel Tank Cap Adapter.Special Tools .
3. Test for a leak referring to the J 41413 Operator
Manual.
IMPORTANT:
If the floating indicator registers any flow after
stabilizing, a leak is evident.
4
4. Raise the vehicle. Refer to Lifting and Jacking
the Vehicle in General Information.
5. Inspect for a fuel leak while the system is under
pressure.
Did fuel leak from the fuel tank? Go to Step 6 Go to Step 5

1. Using the J 41413-200 and the J 41413-210
Operator Manual, introduce smoke into the
evaporative emission (EVAP) system.Special
Tools .
IMPORTANT:
It may be necessary to partially lower the fuel
tank. Refer to Fuel Tank Replacement .
2. Inspect for leaks in any of the following

locations:
The fuel tank, fill limiter vent valve,
5 pressure relief valve, and rollover valves-

Refer to Fuel Tank Replacement .
The fuel sender housing and fuel sender
seal-Refer to Fuel Sender Assembly
Replacement .
The fuel tank pressure (FTP) sensor seal-
Refer to Fuel Tank Pressure Sensor
Replacement .
The EVAP vapor pipes
The fuel fill pipe and hose-Refer to Filler

Tube Replacement .
Go to Diagnostic
Did you find and correct the condition? Go to Step 8 Aids
Replace the fuel tank. Refer to Fuel Tank
6 Replacement .
Did you complete the repair? System OK -
Replace the leaking fuel pipe. Refer to Fuel Hose/Pipes
Replacement - Filter to Engine and Fuel Hoses/Pipes
7
Replacement - Filter to Tank .
Did you complete the replacement? System OK -
Operate the system under the condition of the customer
8 concern in order to verify the repair.
ALCOHOL/CONTAMINANTS-IN-FUEL DIAGNOSIS (WITHOUT SPECIAL TOOL)
Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start,
or misfires in one or more cylinders. Water may collect near a single fuel injector, at the lowest point in the fuel
rail, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the fuel system
components for rust or deterioration.
Alcohol concentrations of 10 percent or greater in fuel can be detrimental to fuel system components. Alcohol
contamination may cause fuel system corrosion, deterioration of rubber components, and subsequent fuel filter
restriction. Fuel contaminated with alcohol may cause driveability conditions such as hesitation, lack of power,
stalling, or no start. Some types of alcohol are more detrimental to fuel system components than others.
Alcohol in 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 alcohol contamination is suspected, use the following
procedure to test the fuel quality:
1. Fill the cylinder with fuel to the 90 ml mark using a 100 ml specified cylinder with 1 ml graduation
marks.
2. Add 10 ml of water to bring the total fluid volume to 100 ml and install a stopper.
3. Shake the cylinder vigorously for 10-15 seconds.
4. Carefully loosen the stopper to release the pressure.
5. Install the stopper and shake the cylinder vigorously again for 10-15 seconds.
6. Put the 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 more than 10 ml. For example, if the volume of the lower layer is increased to 15 ml, this
indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat more because
this procedure does not extract all of the alcohol from the fuel.
Particulate Contaminants in 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, use the following procedure to diagnose the fuel:
1. Draw approximately 0.5 liter of fuel using an approved fuel container.

2. Place the cylinder on a level surface for approximately 5 minutes to allow settling of the particulate
contamination.
Particulate contamination will show up in various shapes and colors. Sand will typically be identified by white
or light brown crystals. Rubber will appear as black and irregular particles. If particles are found, clean the
entire fuel system thoroughly. Refer to Fuel System Cleaning .
ALCOHOL/CONTAMINANTS-IN-FUEL DIAGNOSIS (WITH SPECIAL TOOL)
Description
Water contamination in the fuel system may cause driveability conditions such as hesitation, stalling, no start,
or misfires in one or more cylinders. Water may collect near a single fuel injector at the lowest point in the fuel
injection system, and cause a misfire in that cylinder. If the fuel system is contaminated with water, inspect the
fuel system components for rust or deterioration.
Ethanol concentrations of greater than 10 percent can cause driveability conditions and fuel system
deterioration. Fuel with more than 10 percent ethanol could result in driveability conditions such as hesitation,
lack of power, stalling, or no start. Excessive concentrations of ethanol used in vehicles not designed for it may
cause fuel system corrosion, deterioration of rubber components, and fuel filter restriction.
Test Procedure
1. Test the fuel composition using J 44175 Fuel Composition Tester and J44175-3 Instruction Manual. See
Special Tools .
2. If water appears in the fuel sample, perform the following steps:
1. Clean the fuel system. Refer to Fuel System Cleaning .
2. Replace the fuel filter. Refer to Fuel Filter Replacement .
3. Subtract 50 from the reading on the DMM in order to obtain the percentage of alcohol in the fuel sample.
Refer to the examples in the Fuel Composition Test Examples table.
4. If the fuel sample contains more than 15 percent ethanol, add fresh, regular gasoline to the vehicle's fuel
tank.
5. Test the fuel composition.
6. If testing shows the ethanol percentage is still more than 15 percent, replace the fuel in the vehicle. Refer
to Fuel System Cleaning .
Fuel Composition Test Examples

- Frequency (Hz) Subtract 50 Ethanol Percent
Example A 50 Hz -50 0
Example B 65 Hz -50 15
Example C 129 Hz -50 79
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR DIAGNOSIS
Circuit Description
The manifold absolute pressure (MAP) sensor responds to changes in intake manifold pressure which gives an
indication of the engine load The MAP sensor has a 5-volt reference circuit a low reference circuit and a
signal circuit. The powertrain control module (PCM) supplies 5 volts to the MAP sensor on the 5-volt reference
circuit and provides a ground on the low reference circuit. The MAP sensor provides a signal to the PCM on the
MAP sensor signal circuit, which is relative to the pressure changes in the manifold. With low MAP, such as
during idle or deceleration, the PCM should detect a low MAP sensor signal voltage. With high MAP, such as
ignition ON, engine OFF, or wide open throttle (WOT), the PCM should detect a high MAP sensor signal
voltage. The MAP sensor is also used in order to calculate the barometric pressure (BARO) when the ignition
switch is turned ON, with the engine OFF. The BARO reading may also be updated whenever the engine is
operated at WOT. The PCM monitors the MAP sensor signal for voltage outside of the normal range. If the
PCM detects a MAP sensor signal voltage that is excessively low, DTC P0107 sets. If the PCM detects a MAP
sensor signal voltage that is excessively high, DTC P0108 sets.
Diagnostic Aids
Poor idle characteristics may be caused by uncontrolled fueling due to an open or high resistance in the HO2S 1
low signal circuit. Before replacing any component, ensure that this condition does not exist.
Test Description
4: This step tests the MAP sensor's ability to correctly indicate BARO.
12: The measurement noted in this step will be used in subsequent steps if the measurement does not
exceed the specified value.
15: This step calculates the resistance in the 5-volt reference circuit.
16: This step calculates the resistance in the low reference circuit.
Manifold Absolute Pressure (MAP) Sensor Diagnosis

Vehicle? Diagnostic
1 -
System Check
Go to Step 2 - Vehicle
Disconnected, damaged, or incorrectly

routed vacuum hoses
Manifold absolute pressure (MAP) sensor
2 disconnected from the vacuum source -
Restrictions in the MAP sensor vacuum
source
Intake manifold vacuum leaks
IMPORTANT:
The vehicle used for the comparison is not
limited to the same type of vehicle as is being
serviced. A vehicle known to provide an
3 accurate reading is acceptable. -
Do you have access to another vehicle in which

the MAP sensor pressure can be observed with a
scan tool? Go to Step 4 Go to Step 5
OFF.
2. Observe the MAP sensor pressure with a
scan tool.
4 3. Observe the MAP sensor pressure in the 3 kPa
known good vehicle with a scan tool.
4. Compare the values.
Is the difference between the values less than the

IMPORTANT:
The Altitude vs. Barometric Pressure table
indicates a pressure range for a given altitude
under normal weather conditions. Weather
conditions consisting of very low or very high
pressure and/or very low or very high
temperature may cause a reading to be slightly
out of range.

5 -
OFF.
scan tool. Refer to Altitude vs Barometric
Pressure .
3. The MAP sensor pressure should be within
the range specified for your altitude.
Does the MAP sensor indicate the correct

barometric pressure? Go to Step 6 Go to Step 10
scan tool.
6 2. Start the engine. -
Does the MAP sensor pressure change? Go to Step 7 Go to Step 10
2. Remove the MAP sensor from the engine
vacuum source. Leave the MAP sensor
connected to the engine harness.
3. Connect a J 23738-A Mityvac to the MAP
sensor.Special Tools .
OFF.
7 5. Observe the MAP sensor pressure with the -
scan tool.
6. Apply vacuum to the MAP sensor with the
J 23738-A in 1 inch Hg increments until
15 inches Hg is reached.Special Tools .
Each 1 inch Hg should decrease MAP
sensor pressure by 3-4 kPa.
Is the decrease in MAP sensor pressure

consistent? Go to Step 8 Go to Step 10
Apply vacuum with the J 23738-A until 20
inches Hg is reached.Special Tools .
8 34 kPa
Is the MAP sensor pressure less than the
Disconnect the J 23738-A from the MAP
sensor.Special Tools .
9 -
Does the MAP sensor pressure return to the value
observed in step 4 or 5? System OK Go to Step 26
at the MAP sensor. Refer to Testing for
and Connector Repairs .
1. Disconnect the MAP sensor electrical
connector.
11 2. Observe the MAP sensor parameter with 0.1 V
the scan tool.

Measure the voltage from the 5-volt reference
circuit of the MAP sensor to a good ground with
12 a DMM. Refer to Circuit Testing . Note the 5.2 V
measurement as Supply Voltage.
Is the voltage more than the specified value? Go to Step 19 Go to Step 13
13 Is the voltage more than the specified value? 4.8 V Go to Step 14 Go to Step 20
1. Disconnect the harness connector from the
engine coolant temperature (ECT) sensor.
2. Connect a test lamp and a DMM in series
between the 5-volt reference circuit and the
14 low reference circuit of the MAP sensor, at 0 mA
the harness connector.
3. Measure the amperage, with the DMM.
Note the measurement as Amperage.
Is the amperage equal to the specified value? Go to Step 23 Go to Step 15

1. Remove the DMM from the circuit.
2. Connect the test lamp between the 5-volt
reference circuit and the low reference
circuit of the MAP sensor, at the harness
connector.
3. Measure the voltage from the 5-volt
reference circuit at the test lamp to a good
ground, with the DMM. Note the
measurement as Load Voltage Drop.
IMPORTANT:
15 Before any calculations are performed,
5 ohms
ensure that all measurements are
converted to like units. For example,
volts/amps or millivolts/milliamps.
4. Subtract the Load Voltage Drop from the

Supply Voltage. Note the result as Supply
Voltage Drop.
5. Divide the Supply Voltage Drop by the
Amperage.
Is the result more than the specified value? Go to Step 21 Go to Step 16
1. Measure the voltage from the low

reference circuit of the MAP sensor at the
test lamp to a good ground, with the DMM.
Note the result as Low Reference Voltage
16 Drop. 5 ohms
IMPORTANT:
Before any calculations are performed,
ensure that all measurements are
converted to like units. For example,
volts/amps or millivolts/milliamps.
2. Divide the Low Reference Voltage Drop
by the Amperage.
Is the result more than the specified value? Go to Step 24 Go to Step 17

1. Remove the test lamp.
between the 5-volt reference circuit and the
signal circuit of the MAP sensor, at the
17 harness connector. 4.9 V
3. Observe the MAP sensor parameter with
the scan tool.
Is the voltage more than the specified value? Go to Step 26 Go to Step 22

Test the MAP sensor signal circuit between the
powertrain control module (PCM) and the MAP
18 sensor for a short to voltage. Refer to Circuit -
Testing and Wiring Repairs .
Test the 5-volt reference circuit between the
PCM and the MAP sensor for a short to voltage.
19 -
Refer to Circuit Testing andWiring Repairs .
PCM and the MAP sensor for an open or for a
20 short to ground. Refer to Circuit Testing and -
Wiring Repairs .
PCM and the MAP sensor for high resistance.
21 -
Refer to Circuit Testing andWiring Repairs .
Test the MAP sensor signal circuit between the
PCM and the MAP sensor for an open or for a
Wiring Repairs .
Test the low reference circuit between the PCM
and the MAP sensor for an open. Refer to
23 -
Circuit Testing and Wiring Repairs .
Test the low reference circuit between the PCM
and the MAP sensor for high resistance. Refer to
24 -
Circuit Testing and Wiring Repairs .
Test for shorted terminals and for poor
connections at the PCM. Refer to Testing for
Intermittent Conditions and Poor Connections
25 -
andConnector Repairs .
Test the HO2S 1 low signal circuit for an open or
26 -
Wiring Repairs .
Test the HO2S 1 low signal circuit for an open or
27 -
Wiring Repairs .
Replace the MAP sensor. Refer to Manifold
Absolute Pressure (MAP) Sensor
28 -
Replacement .
References for replacement, setup, and
29 -
programming.
1. Reassemble the vehicle as necessary.
2. Clear the DTCs with the scan tool.
30 -
4. Operate the system in order to verify the
repair.
Did you correct the condition? Go to Step 31 Go to Step 2

Go to
Observe the Capture Info with a scan tool. Diagnostic
31 Are there any DTCs that have not been - Trouble Code
diagnosed? (DTC) List -
Vehicle System OK
IDLE AIR CONTROL (IAC) SYSTEM DIAGNOSIS
Circuit Description
The engine idle speed is controlled by the idle air control (IAC) valve. The IAC valve is on the throttle body.
The IAC valve pintle moves in and out of an idle air passage bore to control air flow around the throttle plate.
The IAC valve consists of a movable pintle, driven by a gear attached to an electric motor called a stepper
motor. The stepper motor is capable of highly accurate rotation, or of movement, called steps. The stepper
motor has 2 separate windings that are called coils. Each coil is supplied current by 2 circuits from the
powertrain control module (PCM). When the PCM changes polarity of a coil, the stepper motor moves one step.
The PCM uses a predetermined number of counts to determine the IAC pintle position. Observe IAC counts
with a scan tool. The IAC counts will increment up or down as the PCM attempts to change the IAC valve
pintle position. An IAC Reset will occur when the ignition key is turned OFF. First, the PCM will seat the IAC
pintle in the idle air passage bore. Second, the PCM will retract the pintle a predetermined number of counts to
allow for efficient engine start-up. If the engine idle speed is out of range for a calibrated period of time, an idle
speed diagnostic trouble code (DTC) sets.
Diagnostic Aids
High resistance in an IAC valve control circuit

The correct positive crankcase ventilation (PCV) valve, properly installed and proper operation of the
PCV valve
Proper operation and installation of all air intake components
Proper installation and operation of the mass air flow (MAF) sensor
A tampered with or damaged throttle stop screw
A tampered with or damaged throttle plate, throttle shaft, throttle linkage, or cruise control linkage
A skewed high throttle position (TP) sensor
Excessive deposits in the IAC passage or on the IAC pintle
Excessive deposits in the throttle bore or on the throttle plate
Vacuum leaks
A high or unstable idle condition could be caused by a non-IAC system problem that can not be
overcome by the IAC valve.
If the problem is determined to be intermittent, refer to Testing for Intermittent Conditions and Poor
Test Description
5: This test will determine the ability of the PCM and IAC valve control circuits to control the IAC valve.
7: This test will determine the ability of the PCM to provide the IAC control valve circuits with a ground.
On a normally operating system, the test lamp should not flash while the IAC Counts are incrementing.
Idle Air Control (IAC) System Diagnosis

Step Action Yes No
1
Vehicle in Vehicle
IMPORTANT:
Ensure that the Engine Speed parameter stabilizes
with each Commanded RPM change to determine if
the engine speed stays within 100 RPM less than the
Commanded RPM or within 150 RPM more than the
Commanded RPM.
1. Set the parking brake and block the drive wheels.

2 3. Turn OFF all accessories.
4. Slowly increment the engine speed to 1,700
RPM, then to 600 RPM, then to 1,700 RPM with
the scan tool RPM Control function.
5. Exit the RPM Control function.
Did the Engine Speed parameter stabilize within 100

RPM less than the commanded engine speed or within Go to Diagnostic
150 RPM above the Commanded RPM? Aids Go to Step 3
2. Disconnect the idle air control (IAC) valve.
3. Connect an J 37027-1A IAC Motor Driver to the
IAC valve.Special Tools .
5. Command the IAC valve in until 600 RPM is
reached with the J 37027-1A .Special Tools .
3
6. Command the IAC valve out until 1,700 RPM is
reached with the J 37027-1A .Special Tools .
7. Return the engine speed to the Desired Idle
Speed parameter.
Did the Engine Speed parameter steadily decrease to

600 RPM and steadily increase to 1,700 RPM when the
IAC valve was commanded in and out? Go to Step 5 Go to Step 4
Did you observe an excessively high idle condition that
4
could not be controlled with the IAC motor driver? Go to Step 11 Go to Step 12
1. Connect a test lamp between one of the IAC
valve control circuits and a good ground.
3. Observe the IAC Counts parameter with a scan
tool.
4. Command high RPM with the J 37027-1A until
the IAC Counts parameter starts to
increment.Special Tools .
5. Command low RPM with the J 37027-1A until
6. Return the Engine Speed to the Desired Idle
Speed parameter.
5 7. Repeat the above procedure for the other three
IAC valve control circuits.
Did the test lamp remain ON, never flashing, while the
IAC Counts were incrementing for any of the IAC
valve control circuits? Go to Step 10 Go to Step 6
Did the test lamp remain OFF, never flashing, while the
6 IAC Counts were incrementing for any of the IAC
valve control circuits? Go to Step 9 Go to Step 7
1. Connect a test lamp between the IAC coil A low
control circuit and the IAC coil A high control
circuit.
2. Observe the IAC Counts parameter with a scan
tool and the test lamp.
3. Command high RPM with the J 37027-1A until
4. Command low RPM with the J 37027-1A until
7 the IAC Counts parameter starts to
5. Return the Engine Speed parameter to the
Desired Idle Speed parameter.
6. Repeat the above procedure with the test lamp
connected between the IAC coil B low control
circuit and the IAC coil B high control circuit.
Did the test lamp stay illuminated, never flashing,

while the IAC Counts were incrementing? Go to Step 8 Go to Step 17
IAC valve. Refer to Testing for Intermittent
(PCM).
3. Test the circuit where the test lamp remained
OFF for the following conditions:
An open circuit
A short to ground
A short to another IAC valve control
9 circuit-Refer to Circuit Testing and

2. Test the IAC valve control circuit where the test
lamp remained illuminated for the following
conditions:
10 A short to voltage
A short to another IAC valve control

circuit- Refer to Circuit Testing and

1. Inspect for the following:
Throttle body damage and tampering
Skewed throttle position (TP) sensor signal
Throttle lever screw tampering, if equipped
Vacuum leaks
Faulty, incorrectly installed positive

crankcase ventilation (PCV) valve and
hose, if equipped
Throttle shaft binding
11 Throttle linkage or cruise control linkage

binding, if equipped
2. Remove the IAC valve. Refer to Idle Air
Control (IAC) Valve Replacement .
3. Inspect for the following conditions:
Debris in the IAC passage
Excessive deposits on the throttle plate
Excessive deposits in the throttle bore
Excessive deposits on IAC valve pintle

1. Inspect for the following conditions:
Throttle body damage and tampering
Throttle lever screw tampering, if equipped

Excessive deposits on the throttle plate
Restricted air intake system-Inspect the
A possible collapsed or clogged air
intake duct, before and after the air
filter element
A restricted air filter element
12 Restriction at the throttle body
intake screen, if equipped
2. Remove the IAC valve. Refer to Idle Air
Control (IAC) Valve Replacement .
3. Inspect for excessive deposits on the IAC valve
pintle and in the IAC valve passage.

PCM. Refer to Testing for Intermittent Conditions
13 and Poor Connections and to Connector Repairs in
Wiring Systems.
1. Disconnect the PCM.
2. Test all IAC valve control circuits for high

IAC valve. Refer to Testing for Intermittent
Replace the IAC valve. Refer to Idle Air Control
16 (IAC) Valve Replacement .
17
2. Clear any DTCs with a scan tool.
18 3. Start the engine.
4. Operate the system to verify the repair.
Did you correct the condition? Go to Step 19 Go to Step 2
Observe the Capture Info with a scan tool. Go to Diagnostic
Are there any DTCs that have not been diagnosed? Trouble Code
19 (DTC) List -
Vehicle in Vehicle
ELECTRONIC IGNITION (EI) SYSTEM DIAGNOSIS
Circuit Description
The ignition control module (ICM) has independent power and ground circuits. The circuits between the ICM
and the powertrain control module (PCM) consist of the following circuits:
The ignition control (IC) timing signal

The IC timing control
The low-resolution engine speed signal
A low reference
For a complete system description, refer to Electronic Ignition (EI) System Description .
Electronic Ignition (EI) System Diagnosis

Connector End View Reference: Powertrain Control Module (PCM) Connector End
Views or Engine Controls Connector End Views
Did you perform the Diagnostic System Go to
Check - Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
Inspect the fuse that supplies power on the
ignition 1 voltage circuit to the ignition
2 -
control module (ICM). Go to Step
Is the fuse open? 17 Go to Step 3
connection at the power and ground 2-way
connector of the ICM. Refer to Testing for
Connections and Connector Repairs in
Wiring Systems. Go to Step
Did you find and correct the condition? 24 Go to Step 4
1. Disconnect the power and ground 2-
way connector from the ICM.
2. Probe the ignition 1 voltage circuit
with a test lamp that is connected to
the ground circuit, at the 2-way
connector.
4 -
Refer to Probing Electrical
Connectors in Wiring Systems.

Probe the ignition 1 voltage circuit at the 2-
way connector, with a test lamp that is
5 -
connected to a good ground. Go to Step
Does the test lamp illuminate? 19 Go to Step 18
1. Disconnect the crankshaft position
(CKP) sensor A.
2. Observe the 3X crank sensor Go to
6 parameter with a scan tool. - Crankshaft
3. Crank the engine. Position
Sensor (CKP)
Does the scan tool indicate a 3X crank System
sensor signal present? Go to Step 7 Diagnosis
1. Remove the fuel pump relay with the
J 43244 Relay Puller Pliers.
2. Connect the CKP sensor A.
7 3. Test for spark at each cylinder with a -
J 26792 Spark Tester.Special Tools .
Did you have spark on any of the

cylinders? Go to Step 8 Go to Step 16
Go
to
8 Did you have spark on all of the cylinders?
Step
Go to Step 9 11
Does the spark tester indicate a bright blue Go to Step
9 -
spark on all cylinders? 10 Go to Step 11
2. Examine the spark plugs for any
10 abnormal conditions or damage. -
Refer to Spark Plug Inspection .
Are the spark plugs in good condition? System OK Go to Step 20

2. Connect the J 26792 to the spark
plug wire of the inoperative
cylinder.Special Tools .
3. Switch the inoperative spark plug
wire connection with a known good
11 cylinder at the ignition coils. -
4. Crank the engine.
Do you have spark on the inoperative Go to Step

cylinder? 12 Go to Step 14
1. Disconnect the spark plug wires from
the inoperative ignition coil.
12 2. Measure the secondary resistance of 5,000-8,000
the ignition coil. ohms
Go to Step
Is the resistance within the specified range? 13 Go to Step 22
1. Remove the inoperative ignition coil.
2. Connect a test lamp between the
control circuits of the ignition coil on
13 the ICM. -
Does the test lamp flash while the engine is Go to Step

being cranked? 15 Go to Step 23
Test the spark plug wires for the following
conditions:
Proper routing and correct firing

order-Refer to Ignition System
Specifications .
Arching to ground
14 IMPORTANT: -
If carbon tracking or corrosion is
detected, replace both
components that are affected.
Carbon tracking or corrosion
Go to Step
15 connection at the ignition coil. Refer to -
Testing for Intermittent Conditions and
Poor Connections and Connector
Repairs in Wiring Systems. Go to Step
connection at the ICM. Refer to Testing
for Intermittent Conditions and Poor
16 -
Connections andConnector Repairs in
Wiring Systems. Go to Step
Test the ignition 1 voltage circuit of the
ICM for a short to ground. Refer to Circuit
17 Testing and Wiring Repairs in Wiring -
Systems. Go to Step
Repair the open in the ignition 1 voltage
circuit of the ICM. Refer to Wiring
18 -
Repairs in Wiring Systems. Go to Step
Did you complete the repair? 24 -
Repair the open in the ground circuit of the
ICM. Refer to Wiring Repairs in Wiring
19 -
Systems. Go to Step
Did you complete the repair? 24 -
Replace the spark plugs. Refer to Spark
20 Plug Replacement . - Go to Step
Did you complete the replacement? 24 -
Replace the spark plug wires. Refer to
21 Spark Plug Wire Replacement . - Go to Step
Replace the ignition coil. Refer to Ignition
22 Coil(s) Replacement . - Go to Step
Replace the ICM. Refer to Ignition
23 Control Module Replacement . - Go to Step
2. Turn the ignition OFF for 30
seconds.
3. Start the engine and operate the
24 vehicle. -
4. Observe the vehicle performance and
driveability.
Does the vehicle operate normally? System OK Go to Step 1
CRANKSHAFT POSITION SENSOR (CKP) SYSTEM DIAGNOSIS

Circuit Description
The crankshaft position (CKP) sensor B is a 7X variable reluctance sensor. This produces 7 digital ON/OFF
pulses per engine revolution. These pulses occur when a reluctor wheel, mounted to the crankshaft and
containing 6 slots evenly spaced 60 degrees apart and one slot spaced at 10 degrees, passes by the sensor. The
7X sensor is connected directly to the ignition control module (ICM). The sensor wiring includes 2 circuits, a
CKP senor signal circuit, and a low reference circuit. The ICM uses the 7X signal to determine the engine
position and speed. There are no DTCs to diagnose the CKP sensor B. This CKP sensor system diagnosis is
used to diagnose a fault with the CKP sensor B and the CKP sensor B circuits.
Crankshaft Position Sensor (CKP) System Diagnosis

Connector End View Reference: Engine Controls Component Views , Engine Controls Connector
End Views , or Powertrain Control Module (PCM) Connector End Views
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
1. Disconnect the crankshaft position (CKP)
sensor A.
2. Observe the 3X crank sensor parameter
2 with a scan tool. -
Go to
Does the scan tool display a 3X crank sensor Intermittent
RPM ? Conditions Go to Step 3
2. Disconnect the CKP sensor B connector
from the ignition control module (ICM).
3. Probe the CKP sensor signal circuit of the
3 CKP sensor B with a test lamp connected -
to battery voltage. Refer to Probing
Electrical Connectors in Wiring Systems.

4 2. Probe the CKP sensor signal circuit of the -
CKP sensor B with a test lamp connected
to a good ground. Refer to Probing
Electrical Connectors in Wiring Systems.
Measure the resistance from the CKP sensor
signal circuit to the low reference circuit of the
800-1200
5 CKP sensor B with a DMM. Refer to Circuit
ohms
Testing in Wiring Systems.
Test the CKP sensor B circuits for high
6 -
Repair the short to ground in the CKP sensor
signal circuit. Refer to Wiring Repairs in
7 -
Wiring Systems.
Repair the short to voltage in the CKP sensor
signal circuit. Refer to Wiring Repairs in
8 -
Wiring Systems.
Test the CKP sensor B circuits for the following
conditions:
An open
The CKP sensor signal shorted to the low
9 reference -

Wiring Systems.
at the ICM. Refer to Testing for Intermittent
10 Conditions and Poor Connections and -
at the CKP sensor. Refer to Testing for
11 -
Systems.
1. Remove the CKP sensor B. Refer to

Crankshaft Position (CKP) Sensor
Replacement (24X CKP Sensor) .
2. Visually inspect the CKP sensor B for the
Physical damage
Excessive play or looseness
Foreign material passing between
12 the CKP sensor B and the reluctor -
wheel
Electromagnetic interference (EI) in
the CKP sensor B circuits

Inspect the crankshaft reluctor wheel for the
Physical damage
Excessive end play or looseness
13 Improper installation -
Refer to Crankshaft and Bearings Cleaning

and Inspection in Engine Mechanical.
Replace the CKP sensor B. Refer to Crankshaft
Position (CKP) Sensor Replacement (24X
14 -
CKP Sensor) .
Replace the ICM. Refer to Ignition Control
15 Module Replacement . -
2. Turn the ignition OFF for 30 seconds.
3. Start the engine and operate the vehicle.
16 4. Observe the malfunction indicator lamp -
(MIL), vehicle performance, and
driveability.
Does the vehicle operate normally, with no MIL? System OK Go to Step 2
INSPECTION/MAINTENANCE (I/M) SYSTEM CHECK
Description
Several states require that a vehicle pass on-board diagnostic (OBD) system tests and the
inspection/maintenance (I/M) emission inspection in order to renew license plates. This is accomplished by
viewing the I/M System Status display on a scan tool. Using a scan tool, the technician can observe the I/M
System Status in order to verify that the vehicle meets the criteria that comply with the local area requirements.
Conditions for Updating the I/M System Status
Each system monitor requires at least one, and sometimes several diagnostic tests. The result of each test is
reported by a DTC. A system monitor is complete when either all of the DTCs comprising the monitor have
Run and Passed, or when any one of the DTCs comprising the monitor has illuminated the malfunction
indicator lamp (MIL). Once the system monitor is complete, the I/M System Status display will indicate YES in
the Completed column.
For example, when the heated oxygen sensor (HO2S) Heater Status indicates YES, either all of the oxygen
sensor heater tests have passed or one of the tests has illuminated the MIL. If the vehicle has 4 heated oxygen
sensors, either all four heater circuit tests have passed or one of the heater circuit tests has illuminated the MIL.
The I/M System Status will indicate NO under the Completed column when any of the required tests for that
system have not run. The following is a list of conditions that would set the I/M System Status indicator to NO:
The vehicle is new from the factory and has not yet been driven through the necessary drive conditions to
complete the tests.
The battery has been disconnected or discharged below operating voltage.
The control module power or ground has been interrupted.
The control module has been reprogrammed.
The control module DTCs have been cleared.
Monitored Emission Control Systems
The OBD II System monitors all emission control systems that are on-board. Not all vehicles have a full
complement of emission control systems. For example, a vehicle may not be equipped with secondary air
injection (AIR) or exhaust gas recirculation (EGR). The OBD II regulations require monitoring of the
following:
The air conditioning system

The catalytic converter efficiency
Comprehensive component monitoring - Emission related inputs and outputs
The evaporative emissions (EVAP) system
The EGR System
The fuel delivery system
Heated catalyst monitoring
Misfire monitoring
The oxygen sensor system (O2S or HO2S)
The oxygen sensor heater system (HO2S heater)
For the specific DTCs required for each system, refer to Inspection/Maintenance (I/M) System DTC Table.
Systems such as fuel delivery, misfire, and comprehensive components may not be listed in a system status list.
These tests run continuously and do not require an I/M System Status indicator.
Inspection/Maintenance (I/M) System Check

Step Action Yes No
1. Perform the Diagnostic System Check -
Vehicle in Vehicle DTC Information.
IMPORTANT:
Many DTC related repairs will instruct the
technician to clear the DTC information.
This procedure will reset ALL of the I/M
System Status indicators to NO, and
1 require performing the I/M Complete
System Set Procedure.
2. Repair any DTCs or driveability concerns that

would prevent the I/M System Status tests
from completing.
Did you find and repair a DTC or driveability

concern? Go to Step 3 Go to Step 2
1. Review any service bulletins for software
updates that may prevent
inspection/maintenance (I/M) readiness.
2 2. Perform any reprogramming or repairs Go to
indicated by the service bulletins. Inspection/Maintenance
(I/M) Complete System
Was a reprogramming or repair service required? Set Procedure Go to Step 3
Observe the I/M System Status display with a scan Go to Go to the I/M
tool. Inspection/Maintenance System Set
3
Is more than one test indicating a NO status? (I/M) Complete System Procedure for the
Set Procedure indicated system
INSPECTION/MAINTENANCE (I/M) COMPLETE SYSTEM SET PROCEDURE
Description
The purpose of the inspection/maintenance (I/M) complete system set procedure is to satisfy the enable criteria
necessary to execute all of the I/M readiness diagnostics, and complete the trips for those particular diagnostics.
When all diagnostic tests are completed, the I/M System Status indicators are set to YES. Perform this test
when more than one or all of the I/M System Status indicators are set to NO.
Conditions for Running
Cold Start
The barometric pressure (BARO) is more than 74 kPa.
The engine coolant temperature (ECT) is below 35C (95F).
The intake air temperature (IAT) is below 35C (95F).
The difference between the IAT and the ECT is 6C (10.8F) or less.
The fuel level is between 15-85 percent.
Diagnostic Aids
Rough road conditions may prevent some of the tests from running. Extreme high or low ambient temperatures
may prevent tests such as heated oxygen sensor (HO2S) Heater and evaporative emission (EVAP) System from
initiating. If a step is interrupted before completion, perform the remaining portion of the set procedures. Any
portion of the set procedure that requires the engine at operating temperature may be repeated. This allows most
of the diagnostics to run and the remaining tests can be performed using the individual System Set Procedures.
The scan tool can be used to monitor each of the I/M System Status indicators during the I/M complete system
set procedure. When all of the indicators for a test step have updated to YES, testing can move on to the next
step, even if the remaining portion of the test is not complete. For example, step 3 is designed to run the EVAP,
secondary air injection (AIR), and HO2S tests. The procedure instructs the technician to operate the vehicle in
the enable conditions for 6 minutes. If all 3 tests have updated to YES within 4 minutes, it is not necessary to
continue with the enable conditions and testing can advance to the next step.
Test Description
2: This step is to run the HO2S Heater Tests and initiate the EVAP System Test. Preprogramming the
scan tool will reduce the amount of time the oxygen sensor heaters operate while verifying the enable
criteria.
3: This step is to run the EVAP, AIR and the Oxygen Sensor Tests. The EVAP Test begins once the
engine coolant reaches a calibrated temperature. The AIR Test, if equipped, begins shortly after Closed
Loop and the indicated speed is achieved. The Oxygen Sensor Tests begin once the engine is at operating
temperature, in Closed Loop Fuel Control, and a calibrated amount of time has elapsed.
4: This step is to run the exhaust gas recirculation (EGR) Tests. The EGR Tests are run during a gradual
deceleration with a closed throttle. The vehicle speed is required in order to maintain a high, steady
manifold absolute pressure (MAP) signal.
5: This step is to run the Catalyst Tests. This test runs during the idle period immediately following a
cruise period that meets a minimum calibrated RPM and time period.
7: The I/M System Status only reports on whether or not a diagnostic has run, not what the outcome of
the test was. If any emission related DTC sets after the tests are complete, the DTC will require diagnosis.
Inspection/Maintenance (I/M) Complete System Set Procedure

Did you perform the
Go to
Inspection/Maintenance (I/M) System Inspection/Maintenance
1 -
Check? Go to Step 2 (I/M) System Check
IMPORTANT:
Whenever the ignition is turned
ON, ignition positive voltage is
supplied to the heated oxygen
sensor (HO2S) heaters. After
verifying the enable criteria, turn
OFF the ignition for approximately
5 minutes to allow the sensors to
cool before continuing with the
test. Once the engine is started,
DO NOT turn the engine OFF for
the remaining portion of the set
procedure.
1. Preprogram the scan tool with the

vehicle information before the
2 ignition is turned ON. 2 minutes
2. Ensure the vehicle is within the
Conditions for Running specified in
the supporting text.
3. Turn OFF all of the accessories, e.g.,
A/C, blower fan, etc.
4. Set the vehicle parking brake.
5. Verify the transmission is in Park for
automatic transmissions and Neutral
for manual transmissions.
6. Start the engine and allow it to idle
for the specified time.
Is the action complete? Go to Step 3 -

CAUTION:
Refer to Road Test Caution in Cautions
and Notices.
In order for the next group of tests to run,

the vehicle must operate in the following
conditions:
3 -
1. Acceleration at part throttle to 72
km/h (45 mph) with this speed
maintained until the engine reaches
operating temperature-This may be
up to 10 minutes depending on the
start up coolant temperature.
2. Continued operation under these
conditions for an additional 3
minutes

CAUTION:
and Notices.

conditions:
1. Accelerate to 89 km/h (55 mph) with

this speed maintained for one
additional minute.
4 2. Decelerate to 48 km/h (30 mph) -
while the following criteria is
maintained:
The throttle is closed
There is NO brake application

on either manual or automatic
transmission
There is NO clutch actuation
on a manual transmission
There is NO manual downshift

CAUTION:
and Notices.

conditions:
5 1. Acceleration at part throttle to 90 -

maintained for 5 minutes.
2. Deceleration to 0 km/h (0 mph).
3. Engine idling for 2 minutes while
the following criteria is maintained:
Service brake depressed
Automatic transmission in
drive
Manual transmission in
neutral with the clutch pedal
depressed

Observe the I/M System Status display Go to the I/M System Set
with a scan tool. Procedure for the
6 -
Did all of the I/M System Status indicators indicated systems that
update to YES? Go to Step 7 have not passed
Observe the Emission Related DTC Go to
portion of the I/M System Status display Diagnostic
with a scan tool. Trouble Code
7 Does the scan tool indicate any Emission - (DTC) List -
Related DTCs set? Vehicle in
Vehicle DTC
INSPECTION/MAINTENANCE (I/M) SYSTEM DTC TABLE
IMPORTANT: Not all vehicles will have every diagnostic trouble code (DTC) listed in each
section. For example, a vehicle may have only 2 oxygen sensors or 1 catalyst.
Only those DTCs applicable to the vehicle are required to update each System
Status to YES. Refer to the appropriate service manual to determine which
DTCs are supported for each vehicle.
Inspection/Maintenance (I/M) System DTC Table

System DTCs Required to Set System Status to YES
Catalyst DTC P0420 Catalyst System Low Efficiency
EVAP DTC P0442 Evaporative Emission (EVAP) System Small Leak Detected
DTC P0446 Evaporative Emission (EVAP) Vent System Performance
DTC P0455 Evaporative Emission (EVAP) System Large Leak Detected
DTC P0496 Evaporative Emission (EVAP) System Flow During Non-Purge
Oxygen Sensor DTC P0133 HO2S Slow Response Bank 1 Sensor 1
DTC P0140 HO2S Circuit Insufficient Activity Bank 1 Sensor 2
DTC P1133 HO2S Insufficient Switching Bank 1 Sensor 1
DTC P1134 HO2S Transition Time Ratio Bank 1 Sensor 1
DTC P2A01 HO2S Circuit Closed Loop (CL) Performance Bank 1 Sensor 2
Oxygen Sensor Heater DTC P0135 HO2S Heater Performance Bank 1 Sensor 1
DTC P0141 HO2S Circuit Low Voltage Bank 1 Sensor 2
INSPECTION/MAINTENANCE (I/M) CATALYST SYSTEM SET PROCEDURE
Description
The purpose of this test is to satisfy the enable criteria necessary to execute inspection/maintenance (I/M)
readiness diagnostics for the catalyst system. The test may be used to set the I/M System Status indicators to
YES. The I/M System Status display on the scan tool provides an indication of whether the control module has
completed the required tests. The I/M System Status does not indicate that the tests have passed or failed. When
all of the diagnostics for a specific system have run and passed, the I/M System Status will update to YES. If a
test for a specific system has failed, the I/M System Status will update to YES, indicating a determination was
made even if all of the other tests for that system have not run.
The engine has been running longer than 10 minutes.

The engine load must be stable.
The idle air control (IAC) position parameter does not change more than 5 counts.
The throttle position (TP) is below 1.5 percent.
The short term fuel trim (FT) is between -20 and +20 percent.
The transaxle is in drive for automatic transaxle, or in neutral for manual transaxle with the clutch pedal
depressed.
The engine coolant temperature (ECT) is between 75-126C (167-258.8F).
The engine is in Closed Loop fuel control.
The battery voltage is more than 10.7 volts.
The intake air temperature (IAT) is between -20 and +100C (-4 and +212F).
The difference between the engine speed and the desired engine speed is less than 200 RPM.
The mass air flow (MAF) is between 3-10 grams per second.
Diagnostic Aids
The control module runs a maximum of 6 tests per trip until the Catalyst System Status updates to YES. If the
status does not update, the test outlined in this procedure can be repeated until the I/M System Status updates to
YES.
If there is an impending failure, the system may require more time to run the diagnostic than was allotted in the
set procedure. If the test does not run after numerous attempts and no DTC is set, review the appropriate scan
tool data list and the service information for an indication of why the test does not complete. Some tests may
abort due to changes in the conditions while the test is running. For example, changes in engine load such as a
cooling fan or A/C compressor clutch turning ON may cause the test to abort.
Inspection/Maintenance (I/M) Catalyst System Set Procedure

Step Action Yes No
Did you perform the Inspection/Maintenance (I/M) Go to
1 System Check? Inspection/Maintenance
Go to Step 2 (I/M) System Check
1. Ensure the vehicle is within the Conditions
for Running specified in the supporting text.
2. Turn OFF all of the accessories, e.g., A/C,
blower fan, etc.
3. Start the engine and allow it to idle for 5
minutes.
CAUTION:
Refer to Road Test Caution in Cautions and
Notices.
IMPORTANT:
In order for this test to run, the vehicle
must operate in the following conditions:
2
Acceleration at part throttle to 90
maintained for 5 minutes
Deceleration to 0 km/h (0 mph)
Engine idling for 2 minutes while the
following criteria is maintained:
Service brake pressed
Automatic transmission in
Drive
4. Observe the I/M System Status display with a

scan tool.
Did the catalyst System Status update to YES? Go to Step 5 Go to Step 3

Observe the DTC Information with a scan tool. Go to Diagnostic
Does the scan tool indicate any failed DTCs? Trouble Code
3 (DTC) List -
Vehicle in Vehicle
1. Refer to the Inspection/Maintenance (I/M)
System DTC Table to determine which
DTCs are required to run in order to complete
this test.
2. Observe the Not Ran Since Code Cleared
display with a scan tool.
4
3. Determine which of the DTCs required for a
YES status has not run.
4. Enter the DTC number in the specific DTC
menu of the scan tool.
Running the DTC, located in the supporting
text for the diagnostic table of the DTC.
6. Repeat the procedure until the scan tool
indicates the diagnostic test has run.
7. Repeat steps 4-6 for any additional required
DTCs that have not run.
scan tool.
Did the catalyst System Status update to YES? Go to Step 5 Go to Diagnostic Aids
Observe the emission related DTC portion of the Go to Diagnostic
I/M System Status display with a scan tool. Trouble Code
5 Does the scan tool indicate any emission related (DTC) List -
DTCs set? Vehicle in Vehicle
INSPECTION/MAINTENANCE (I/M) EXHAUST GAS RECIRCULATION (EGR) SYSTEM SET

PROCEDURE
Description
readiness diagnostics for the exhaust gas recirculation (EGR) system. The test may be used to set the I/M
System Status indicators to YES. The I/M System Status display on the scan tool provides an indication of
whether the control module has completed the required tests. The I/M System Status does not indicate that the
tests have passed or failed. When all of the diagnostics for a specific system have run and passed, the I/M
System Status will update to YES. If a test for a specific system has failed, the I/M System Status will update to
YES, indicating a determination was made even if all of the other tests for that system have not run.
The barometric pressure is more than 74 kPa.

The ignition 1 voltage is between 11-18 volts.
The intake air temperature (IAT) is between 0-100C (32-212F).
The A/C Relay Command parameter does not change.
The Current Gear parameter does not change.
The engine coolant temperature (ECT) is more than 75C (167F).
The engine speed is between 1,050-1,400 RPM.
The manifold absolute pressure (MAP) is between 15-70 kPa.
The mass air flow (MAF) sensor does not change more than 2 grams per second.
The throttle position (TP) sensor is less than one percent.
The vehicle speed is more than 48 km/h (30 mph) during deceleration.
The idle air control (IAC) position does not change more than 5 counts when the above conditions are
met.
Diagnostic Aids
The control module only runs the EGR Active Tests during a gradual deceleration with a closed throttle and a
vehicle speed above 48 km/h (30 mph). Several deceleration cycles may be necessary in order to accumulate a
sufficient number of EGR flow samples. The procedure outlined in the table is for a clear, flat road. If the
procedure is performed on a road with a slight down hill grade, the test may acquire the necessary sample
counters in one or two decel trips. If the test is interrupted during the procedure, it may take more than three
deceleration cycles to complete the test. If the status does not update, the test outlined in this procedure can be
repeated until the I/M System Status updates to YES.
If a diagnostic test is difficult to run, observe the I/M System Status display while maintaining the necessary
enable conditions until the System Status updates to YES.
Inspection/Maintenance (I/M) Exhaust Gas Recirculation (EGR) System Set Procedure

Step Action Yes No
blower fan, etc.
minutes.
CAUTION:
2 Notices.
IMPORTANT:
Acceleration at part throttle to 89

maintained for 1 minute
Decelerate to 48 km/h (30 mph) while
the following criteria is maintained:
The throttle is closed
There is NO brake application
There is NO clutch actuation on
a manual transmission
There is NO manual downshift

scan tool.
Did the EGR System Status update to YES? Go to Step 5 Go to Step 3

3 (DTC) List -
Vehicle in Vehicle
this test.
2. With a scan tool, observe the Not Ran Since
Code Cleared display.
4. Enter the DTC number in the Specific DTC
4 5. Operate the vehicle within the Conditions for
scan tool.
Did the EGR System Status update to YES? Go to Step 5 Go to Diagnostic Aids
Observe the Emission Related DTC portion of the Go to Diagnostic
5 Does the scan tool indicate any Emission Related (DTC) List -
INSPECTION/MAINTENANCE (I/M) EVAPORATIVE EMISSION (EVAP) SYSTEM SET

PROCEDURE
Description
readiness diagnostics for the evaporative emission (EVAP) system. The test may be used to set the I/M System
Status indicators to YES. The I/M System Status display on the scan tool indicates whether or not the control
module has completed the required test. The required test is complete when either all of the DTCs comprising
the test have run and passed, or when any one of the DTCs comprising the test has illuminated the malfunction
indicator lamp (MIL). Once the test is complete, the I/M System Status display will indicate YES in the
completed column. Performing a visual inspection prior to running the EVAP test may prevent having to repeat
the test due to the fact that a failed or aborted test will require the vehicle to cool down in order to meet the
enable criteria to run another test.

The engine coolant temperature (ECT) is between 4-30C (39-86F).
The fuel level is between 15-85 percent.
The intake air temperature (IAT) is between 4-30C (39-86F).
The startup ECT and IAT are within 9C (16F) of each other.
The vehicle speed sensor (VSS) is less than 121 km/h (75 mph).
Diagnostic Aids
Extreme high or low ambient temperatures may prevent the EVAP System Tests from initiating.
Inspection/Maintenance (I/M) Evaporative Emission (EVAP) System Set Procedure

Step Action Yes No
Did you perform the Inspection/Maintenance Go to
1 (I/M) System Check? Inspection/Maintenance
Select Special Functions on a scan tool.
2 Does the Special Functions list include
Service Bay Tests? Go to Step 3 Go to Step 5
Perform the Service Bay Test. Refer to
3 Service Bay Test.
Did the evaporative emission (EVAP) system
pass the Service Bay Test? Go to Step 8 Go to Step 4
1. Observe the Service Bay Test on the
scan tool for an indication of why the
test did not pass, e.g., a failed DTC, test
aborted, etc.
4 2. Refer to the appropriate service
information for diagnosis and repair of Go to
the condition, as necessary. Inspection/Maintenance
(I/M) Complete System
Is the action complete? Set Procedure -
Conditions for Running as specified in
IMPORTANT:
Once the engine is started, DO NOT
turn the engine OFF for the remainder
of the procedure until the test is
complete.
3. Start the engine and idle for 2 minutes.
CAUTION:
Refer to Road Test Caution in
5
IMPORTANT:
In order for this test to run, the
vehicle must operate in the following
conditions:
4. Acceleration at part throttle to 72 km/h

(45 mph) with this speed maintained
until the engine reaches operating
temperature. This may be up to 10
minutes depending on the start up
coolant temperature.
5. Continue the operating conditions for
an additional 3 minutes after the engine
reaches operating temperature, or until
the I/M System Status indicator updates
to YES.
Did the EVAP System Status update to YES? Go to Step 8 Go to Step 6
Observe the DTC information with a scan Go to Diagnostic
tool. Trouble Code (DTC)
6
Does the scan tool indicate any failed DTCs? List - Vehicle in Vehicle
1. Refer to the Inspection/Maintenance
(I/M) System DTC Table to determine
which DTCs are required to run in order
to complete this test.
2. Observe the Not Ran Since Code
Cleared display with a scan tool.
3. Determine which of the DTCs required
for a YES status has not run.
4. Enter the DTC number in the Specific
DTC menu of the scan tool.
7 5. Operate the vehicle within the
Conditions for Running the DTC,
located in the supporting text for the
diagnostic table of the DTC.
7. Repeat steps 4-6 for any additional
required DTCs that have not run.
8. Observe the I/M System Status display
with a scan tool.
Did the EVAP System Status update to YES? Go to Step 8 Go to Diagnostic Aids
Observe the Emission Related DTC portion of
the I/M System Status display with a scan Go to Diagnostic
8 tool. Trouble Code (DTC)
Does the scan tool indicate any Emission List - Vehicle in Vehicle
Related DTCs set? DTC Information System OK
INSPECTION/MAINTENANCE (I/M) HEATED OXYGEN SENSOR/OXYGEN SENSOR (HO2S/O2S)

SYSTEM SET PROCEDURE
Description
readiness diagnostics for the oxygen sensor (O2S, HO2S) system. The test may be used to set the I/M System
Status to YES. The I/M System Status display on the scan tool provides an indication of whether the control
module has completed the required tests. The I/M System Status does not indicate that the tests have passed or
failed. When all of the diagnostics for a specific system have run and passed, the I/M System Status will update
to YES. If a test for a specific system has failed, the I/M System Status will update to YES, indicating a
determination was made, even if all of the other tests for that system have not run.
The engine coolant temperature (ECT) is less than 35C (95F).

The engine is running in Closed Loop fuel control.
The engine has been running for more than 1 minute.
The engine speed is between 1,300-3,000 RPM.
The throttle position (TP) sensor is more than 2 percent.
The vehicle speed sensor (VSS) is between 33-120 km/h (20-75 mph).
The short term fuel trim is between 97.5-102.5.
The intake air temperature (IAT) is less than 35C (95F).
The startup engine coolant temperature (ECT) and IAT are within 6C (10.8F) of each other.
Diagnostic Aids
Inspection/Maintenance (I/M) Heated Oxygen Sensor/Oxygen Sensor (HO2S/O2S) System Set Procedure
Step Action Yes No
blower fan, etc.
minute.
2
CAUTION:
Notices.
IMPORTANT:
4. Acceleration at part throttle to 75-90 km/h
(45-55 mph) with this speed maintained for 6
minutes or until the I/M System Status
updates to YES.
Manual transmissions, either 5 or 6 speed,

may require operation in 4th or 5th gear
respectively, in order for this test to run.
5. Review the I/M System Status display with a

scan tool.
Did the HO2S/O2S System Status update to YES?

3 (DTC) List -
Vehicle in Vehicle
this test.
2. Observe the Not Ran Since Code Cleared
4. Enter the DTC number in the Specific DTC
scan tool.
Did the HO2S/O2S System Status update to YES? Go to Step 5 Go to Diagnostic Aids
Observe the Emission Related DTC portion of the Go to Diagnostic
5 Does the scan tool indicate any Emission Related (DTC) List -
INSPECTION/MAINTENANCE (I/M) HEATED OXYGEN SENSOR (HO2S) HEATER SYSTEM SET
PROCEDURE
Description
readiness diagnostics for the heated oxygen sensor (HO2S) system. The test may be used to set the I/M System
Status to YES. The I/M System Status display on the scan tool provides an indication of whether the control
module has completed the required tests. The I/M System Status does not indicate that the tests have passed or
failed. When all of the diagnostics for a specific system have run and passed, the I/M System Status will update
to YES. If a test for a specific system has failed, the I/M System Status will update to YES, indicating a
determination was made, even if all of the other tests for that system have not run.

The intake air temperature (IAT) is less than 35C (95F).
The difference between the IAT and the ECT is less than 6C (10.8F).
The engine speed is between 600-3,000 RPM.
Diagnostic Aids
The HO2S Heater Tests will normally run within the 2 minutes allotted in the procedure. If there is an
indeterminate condition, the test may take up to 8 minutes on some vehicles before a decision of pass or fail is
made. If the test does not update to YES, it may have failed or aborted due to the loss of enabling conditions.
Extremely high ambient temperatures may prevent the HO2S Heater Test from initiating.
Inspection/Maintenance (I/M) Heated Oxygen Sensor (HO2S) Heater System Set Procedure
Did you perform the Go to
1 Inspection/Maintenance (I/M) System - Inspection/Maintenance
Check? Go to Step 2 (I/M) System Check
IMPORTANT:
Whenever the ignition is turned ON,
ignition positive voltage is supplied
to the heated oxygen sensor
(HO2S) heaters. After verifying the
enable criteria, turn OFF the
ignition for approximately 5
minutes to allow the sensors to
cool before continuing with the
test.
1. Preprogram the scan tool with the

vehicle information before the
ignition is turned ON.
Conditions for Running as specified
in the supporting text.
3. Set the vehicle parking brake.
2 2 minutes
4. Verify the transmission is in Park for
automatic transmissions and Neutral
for manual transmissions.
6. Start the engine and allow it to idle
for the specified time or until the I/M
System Status indicator updates to
YES.
Did the HO2S Heater System Status update

to YES? Go to Step 5 Go to Step 3
Observe the DTC information with a scan Go to
tool. Diagnostic
Does the scan tool indicate any failed Trouble Code
3 DTCs? - (DTC) List -
Vehicle in
Vehicle DTC
Information Go to Step 4
1. Refer to the Inspection/Maintenance
(I/M) System DTC Table to
determine which DTCs are required
to run in order to complete this test.
2. Observe the Not Ran Since Code
Cleared display with a scan tool.
4 3. Determine which of the DTCs -
required for a YES status has not run.
4. Enter the DTC number in the Specific
DTC menu of the scan tool.
5. Operate the vehicle within the
Conditions for Running the DTC,
located in the supporting text for the
diagnostic table of the DTC.
6. Repeat the procedure until the scan
tool indicates the diagnostic test has
run.
7. Repeat steps 4-6 for any additional
required DTCs that have not run.
8. Observe the I/M System Status
Did the HO2S Heater System Status update

to YES? Go to Step 5 Go to Diagnostic Aids
Observe the Emission Related DTC portion Go to
of the I/M System Status display with a Diagnostic
scan tool. Trouble Code
5 Does the scan tool indicate any Emission - (DTC) List -
Related DTCs set? Vehicle in
Vehicle DTC
SERVICE BAY TEST
Description
The evaporative emission (EVAP) Service Bay Test raises the engine coolant temperature (ECT) threshold so
that the temperature sensitive EVAP diagnosis tests can run while in service environments. When the EVAP
tests are run the service bay test will indicate a pass or will indicate a specific DTC has failed. The EVAP
service bay test can be used to verify an existing condition and verify that the EVAP system is OK after a repair
is completed.
Conditions for Running the Test
IMPORTANT: The following conditions must be met in order to enable the Service Bay Test:
The ignition is ON.

The fuel level is 15-85 percent of capacity.
The vehicle speed is less than 4.8 km/h (3 mph).
Stored DTCs have been cleared.
Test Procedure

2. With a scan tool, select the service bay test in the special functions menu.
3. Follow the instructions on the scan tool.
4. Check DTCs with a scan tool.
5. Continue with the published service manual diagnostic DTC procedure.
Specifications & Drive Belt Routing - Aztek & Rendezvous
IDENTIFICATION
Series (1) Model
"B" Aztek & Rendezvous
ADJUSTMENTS

systems have completed a relearn cycle. See appropriate COMPUTER
RELEARN PROCEDURES article in GENERAL INFORMATION before
disconnecting battery.
BELT ADJUSTMENT
Serpentine Belt (1)
(1) Serpentine belt tension is maintained automatically by a spring-tensioned idler pulley. No adjustment
is necessary.
DRIVE BELT ROUTING & ALIGNMENT
NOTE: For serpentine belt routing, see underhood label or refer to appropriate
illustrations. See Fig. 1 or Fig. 2 .
AZTEK & RENDEZVOUS (3.4L)

Fig. 1: Serpentine Belt Routing (3.4L Aztek & Rendezvous)
RENDEZVOUS (3.6L)
Fig. 2: Serpentine Belt Routing (3.6L Rendezvous)
COOLING SYSTEM SPECIFICATIONS
NOTE: For engine cooling system specifications, see appropriate SPECIFICATIONS

article in GENERAL INFORMATION.
Engine Cooling - Aztek & Rendezvous
SPECIFICATIONS

Specification
A/C Condenser Mounting Bolts 6 N.m 53 lb in
A/C Condenser Tube Clip Bolt 2.5 N.m 22 lb in
Coolant Heater Bolt 2 N.m 18 lb in
Cooling Fan Motor Screws 6 N.m 53 lb in
Cooling Fan Nut 6 N.m 53 lb in
Cooling Fan Shroud Bolts 6 N.m 53 lb in
Discharge Hose to Condenser Nut 16 N.m 12 lb ft
Evaporator Inlet Tube to Condenser Bolt 16 N.m 12 lb ft
Radiator Bracket Bolts 24 N.m 18 lb ft
Radiator Lower Air Deflector Bolts 20 N.m 15 lb ft
Radiator Upper Mount Bolts 10 N.m 89 lb in
Thermostat Bypass Pipe Bolt 11 N.m 98 lb in
Thermostat Bypass Pipe Nut 25 N.m 18 lb ft
Thermostat Housing Bolts 25 N.m 18 lb ft
Water Pump Bolts 10 N.m 89 lb in
Water Pump Pulley Bolts 25 N.m 18 lb ft

ENGINE COOLING SCHEMATICS
Fig. 1: Cooling Fans
Fig. 2: Indicators, Sensors
COMPONENT LOCATOR
COOLING SYSTEM COMPONENT VIEWS
Fig. 3: Cooling System Component View
Callouts For Fig. 3

1 Cooling Fan-Left
2 Cooling Fan-Right
COOLING SYSTEM CONNECTOR END VIEWS
Cooling Fan - Left

12033769
2-Way F Metri-Pack 630 Series Sealed P2S (BK)

WH 504 Cooling Fan Motor Ground (LA1)
A
RD 504 Cooling Fan Motor Ground (LY7)
GY 532 Cooling Fan Motor Supply Voltage (LA1)
B
BK 532 Cooling Fan Motor Supply Voltage (LY7)
Cooling Fan - Right
12033769
2-Way F Metri-Pack 630 Series Sealed P2S (BK)

BK 1250 Ground (LA1)
A
RD 1250 Ground (LY7)
L- BU 409 Cooling Fan Motor Supply Voltage (LA1)
B
BK 409 Cooling Fan Motor Supply Voltage (LY7)

DIAGNOSTIC STARTING POINT - ENGINE COOLING
Begin the system diagnosis with the diagnostic system check. Refer to Diagnostic System Check - Vehicle in
Vehicle DTC Information. The Diagnostic System Check - Vehicle will provide the following information:

The ability of the control modules to communicate through the serial data circuits
The use of the Diagnostic System Check - Vehicle will identify the correct procedure for diagnosing the system
and where the procedure is located.
Powertrain Control Module (PCM) 3.4 Liter LA1

The scan tool displays a Commanded State of None, Off or
On. This allows you to communicate with the powertrain
Fans Low Speed Fan Relays control module (PCM) and activate or deactivate the
cooling fan 1 relay, manually turning the low speed fans On
and Off.
On. This allows you to communicate with the PCM to
activate or deactivate the cooling fan 1 relay, manually
Fans High Speed Fan Relays
turning the low speed fans On. After a 3 second delay the
PCM will activate the cooling fan 2 relay and the cooling
fan 3 relay. This turns the high speed fans On and Off.
Engine Control Module (ECM) 3.6L LY7

On. This allows you to communicate with the electronic
Fan Relay 1 Fan Relays control module (ECM) and activate or deactivate the
cooling fan 1 relay, manually turning the low speed fans On
and Off.
Fan Relays 2 and 3 Fan Relays The scan tool displays a Commanded State of None, Off or
On. This allows you to communicate with the ECM to
activate or deactivate the cooling fan 2 and 3 relays,
manually turning the medium speed fans On.
On. This allows you to communicate with the ECM to
Fan Relays 1, 2 and 3 Fan Relays
activate or deactivate the cooling fan 1, 2 and 3 relays,
manually turning the high speed fans On.
SCAN TOOL DATA LIST
Powertrain Control Module (PCM) 3.4 Liter LA1

Engine Idling/Radiator Hose Hot/Closed Throttle/Park or Neutral/Closed Loop/Accessories Off
Engine Data 1 and
ECT Sensor Degrees Varies
Engine Data 2
OK/Fault/Invalid
FC Relay 1 Command Engine Data 2 OK
State
OK/Fault/Invalid
FC Relay 2 and 3 Command Engine Data 2 OK
State
Engine Control Module (ECM) 3.6L LY7

Engine Idling/Radiator Hose Hot/Closed Throttle/Park or Neutral/Closed Loop/Accessories Off
Engine Data 1,
ECT Sensor Engine Data 2 and Degrees Varies
Cooling/HVAC Data
OK/Fault/Invalid
FC Relay 1 Command Cooling/HVAC Data OK
State
OK/Fault/Invalid
FC Relay 2 and 3 Command Cooling/HVAC Data OK
State
ECT
The scan tool displays -40 to +151C (-40 to +304F). The Engine Coolant Temperature (ECT) sensor is
mounted in the coolant stream. The PCM/ECM applies 5 volts to the ECT sensor circuit. The sensor is a
thermistor which changes internal resistance as temperature changes. When the sensor is cold (internal
resistance high), the PCM/ECM monitors a high signal voltage and interprets it as a cold engine. As the
sensor warms (internal resistance decreases), the voltage signal decreases and the PCM/ECM interprets
the lower voltage as a warm engine.
FC Relay 1 Command
The scan tool displays OK or Fault. This parameter indicates the state of the driver circuit for this device.
FC Relay 2 and 3 Command
DTC P0480, P0481, P0691, P0692, P0693, OR P0694
Circuit Description
Battery positive voltage is supplied to the cooling fan 1 relay from the COOL FAN #1 fuse. The powertrain
control module (PCM) or engine control module (ECM) controls the cooling fan 1 relay by grounding the low
speed cooling fan relay control circuit via an internal solid state device called a driver.
Battery positive voltage is supplied to the cooling fan 2 relay and the cooling fan 3 or S/P relay from the COOL
FAN #2 fuse. The PCM/ECM controls the relays by grounding the high speed cooling fan relay control circuit.
When the PCM/ECM is commanding a relay ON, the voltage potential of the control circuit should be low, near
0 volts. When the PCM/ECM is commanding the control circuit to a relay, the voltage potential of the circuit
should be high, near battery voltage. If the fault detection circuit senses a voltage other than what is expected,
the DTC will set.
The PCM/ECM will monitor the control circuit for the following:
A short to ground
A short to voltage
An open circuit
An open relay coil
An internally shorted or excessively low resistance relay coil
When the PCM/ECM detects any of the above conditions, the DTC will set and the affected driver will be
disabled.
DTC Descriptors
DTC P0480 Cooling Fan 1 Relay Control Circuit

DTC P0481 Cooling Fan 2 and 3 or S/P Relay Control Circuit
DTC P0691 Cooling Fan 1 Relay Control Circuit Low Voltage
DTC P0692 Cooling Fan 1 Relay Control Circuit High Voltage
DTC P0693 Cooling Fan 2 and 3 or S/P Relay Control Circuit Low Voltage
DTC P0694 Cooling Fan 2 and 3 or S/P Relay Control Circuit High Voltage
The ignition is ON
System voltage is between 9-18 volts.
The relay control circuit is transitioned from OFF to ON or ON to OFF.
The PCM/ECM detects an open, a short to ground, or a short to voltage on the cooling fan relay control
circuit.
The above conditions are present for at least 30 seconds.
The PCM/ECM will illuminate the malfunction indicator lamp (MIL) during the second consecutive trip
in which the diagnostic test has been run and failed.
The PCM/ECM will store conditions which were present when the DTC set as Freeze Frame and Failure
Records data.
The PCM/ECM will turn OFF the MIL during the third consecutive trip in which the diagnostic has been
run and passed.
The History DTC will clear after 40 consecutive warm-up cycles have occurred without a malfunction.
The DTC can be cleared by using the scan tool.
Diagnostic Aids
If the condition is not present, refer to Testing for Intermittent Conditions and Poor Connections in
Wiring Systems.
Review the Freeze Frame/Failure Records vehicle mileage since the diagnostic test last failed. This may
help determine how often the condition that caused the DTC to be set occurs.
Test Description
2: Listen for an audible click when the cooling fan 1 relay operates. Command both the ON and OFF
states. Repeat the commands as necessary.
3: Listen for an audible click when the cooling fan 2 and cooling fan 3 or S/P relays operate. Command
both the ON and OFF states. Repeat the commands as necessary.
4: This step tests for voltage at the coil side of the cooling fan 1 relay. The COOL FAN #1 fuse supplies
battery positive voltage to the coil side of the cooling fan 1 relay.
DTC P0480, P0481, P0691, P0692, P0693, or P0694

Step Action Yes No
Schematic Reference: Engine Cooling Schematics

Connector End View Reference: Cooling System Connector End Views
Did you perform the Diagnostic System Check - Vehicle? Go to Diagnostic
System Check -
1
Vehicle in Vehicle
3. With a scan tool, command the Fans Low Speed
2 ON and OFF.
Does the cooling fan 1 relay turn ON and OFF with each
3. With a scan tool, command the Fans High Speed
3 ON and OFF.
Do the cooling fan 2 and the cooling fan 3 or S/P relays Go to Diagnostic
turn ON and OFF with each command? Aids Go to Step 6
2. Disconnect the cooling fan 1 relay.
4 4. Probe the battery positive voltage circuit of the
cooling fan 1 relay with a test lamp that is

1. Connect a test lamp between the control circuit of
the cooling fan 1 relay and the battery positive
voltage circuit of the cooling fan 1 relay.
5 2. With a scan tool, command the Fans Low Speed
ON and OFF.

2. Disconnect the cooling fan 3 or S/P relay.
6
cooling fan 3 or S/P relay with a test lamp that is
the cooling fan 3 or S/P relay and the battery
positive voltage circuit of the cooling fan 3 or S/P
relay.
7 2. With a scan tool, command the Fans High Speed
ON and OFF.

3. Turn ON the ignition with the engine OFF.
the cooling fan 2 relay and the battery positive
8 voltage circuit of the cooling fan 2 relay.
5. With a scan tool, command the Fans High Speed
ON and OFF.

9
Test the control circuit of the appropriate relay for a short
to voltage or an open. Refer to Circuit Testing and
10
Test the control circuit of the appropriate relay for a short
to ground. Refer to Circuit Testing and Wiring Repairs
11
in Wiring Systems.
Inspect for poor connections at the cooling fan 1 relay.
12
Connections and Connector Repairs in Wiring Systems.
13
Inspect for poor connections at the cooling fan 3 or S/P
relay. Refer to Testing for Intermittent Conditions and
14 Poor Connections andConnector Repairs in Wiring
Systems.
the powertrain control module (PCM)/engine control
module (ECM). Refer to Testing for Intermittent
15
Repair the battery positive voltage circuit. Refer to
Replace the cooling fan 1 relay.
17
18
Replace the cooling fan 3 or S/P relay.
19
Replace the PCM/ECM. Refer to Control Module
20
text.
DTC P1258
Circuit Description
The powertrain control module (PCM) or engine control module (ECM) uses the engine coolant temperature
(ECT) sensor to monitor the engine for an over temperature condition. This condition occurs when the coolant
temperature is above 131C (268F). When an over temperature condition is present, DTC P1258 will set. The
PCM/ECM will disable 2 groups of 4 cylinders by turning OFF the fuel injectors. By switching between the 2
groups of cylinders, the PCM/ECM is able to reduce the temperature of the coolant.
DTC Descriptors
P1258 Engine Coolant Overtemperature - Protection Mode Active
The ignition is ON.

The PCM/ECM detects an engine metal over temperature.

The PCM/ECM will illuminate the malfunction indicator Lamp (MIL) during the first trip in which the
diagnostic test has been run and failed.
The PCM/ECM will signal the instrument panel cluster (IPC) to turn ON the Service Engine Soon
indicator.
The PCM/ECM will alternately disable 2 groups of 4 cylinders by turning OFF the fuel injectors.
The PCM/ECM will store conditions which were present when the DTC set as Freeze Frame and Failure
Records data.
A history DTC is stored.
The PCM/ECM will turn the MIL OFF after 3 consecutive trips that the diagnostic has been run and
passed.
The history DTC will clear after 40 consecutive warm-up cycles have occurred without a malfunction.
The DTC can be cleared by using the scan tool Clear DTC Information function.
DTC P1258
Step Action Yes No
1
Vehicle in Vehicle
Check the engine cooling fans for proper operation. Go to Engine Go to Symptoms -
2
Are the engine cooling fans operative? Overheating Engine Cooling
SYMPTOMS - ENGINE COOLING
IMPORTANT: Review the system operation in order to familiarize yourself with the system
functions. Refer to Cooling System Description and Operation.
Inspect for aftermarket devices which could affect the operation of the Cooling System. Refer to
cause the symptom.
Inspect the surge tank reservoir for the proper coolant level.
Intermittent
Symptom List
Engine Coolant Temperature Indicator Always On

Coolant Heater Inoperative
Engine Overheating
Loss of Coolant
Thermostat Diagnosis
Engine Fails To Reach Normal Operating Temperature
ENGINE COOLANT TEMPERATURE INDICATOR ALWAYS ON
Engine Coolant Temperature Indicator Always On

Step Action Yes No
1
Vehicle in Vehicle
Start the engine. Go to Testing for
Does the engine coolant temperature indicator Intermittent
2 illuminate? Conditions and
Poor Connections
With the scan tool, observe the engine coolant
temperature parameter in the powertrain control
module (PCM) or engine control module (ECM) data
3 list.
Does the scan tool indicate that the coolant
temperature is within the temperature range shown on Go to Engine
the temperature gage? Overheating Go to Step 4
Replace the instrument panel cluster (IPC). Refer to
Control Module References in Computer/Integrating
4 -
5
COOLING FAN ALWAYS ON

Step Action Yes No
Schematic Reference: Engine Cooling Schematics, HVAC Schematics , in HVAC Systems -
Automatic or HVAC Schematics in HVAC Systems - Manual
DEFINITION: One or both engine cooling fan motors run continuously in high or low speed.
1
Vehicle in Vehicle
Turn ON the ignition, with the engine OFF. Go to Testing for
Are one or both cooling fans ON? Intermittent
2 Conditions and
Poor Connections
3 Are both cooling fans running continuously? Go to Step 4 Go to Step 6
Are both cooling fans running continuously in high
4
speed? Go to Step 5 Go to Step 7
Test the low reference circuit of the A/C refrigerant
pressure sensor for an open. Refer to Circuit Testing
5
Remove the cool fan 3 or S/P relay.
6
Did the right cooling fan turn OFF? Go to Step 10 Go to Step 8
Remove the cool fan 1 relay.
7
Did the cooling fans turn OFF? Go to Step 12 Go to Step 9
Remove the cool fan 2 relay.
8
Did the right cooling fan turn OFF? Go to Step 13 Go to Step 11
Repair the short to voltage in the left cooling fan motor
supply voltage circuit. Refer to Wiring Repairs in
9 -
Wiring Systems.
Repair the short to voltage in the left cooling fan low
reference circuit. Refer to Wiring Repairs in Wiring
10 -
Systems.
Repair the short to voltage in the right cooling fan
motor supply voltage circuit. Refer to Wiring Repairs
11 -
in Wiring Systems.
Inspect for poor connections at the cool fan 1 relay.
Repairs.
Inspect for poor connections at the cool fan 2 relay.
Repairs.
Inspect for poor connections at the A/C refrigerant
pressure sensor. Refer to Testing for Intermittent
Repairs in Wiring Repairs.
Replace the cool fan 1 relay.
15 -
Replace the cool fan 2 relay.
16 -
Replace the A/C refrigerant pressure sensor. Refer to
Air Conditioning (A/C) Refrigerant Pressure
17 Sensor Replacement in Heating, Ventilation, and Air -
Conditioning.
18
COOLING FAN INOPERATIVE

Step Action Yes No
Schematic Reference: Engine Cooling Schematics
DEFINITION: One or both cooling fan motors are inoperative in either high, low, or both speeds.
1
Vehicle in Vehicle
3. With a scan tool, command the Fans Low Speed
2 ON and OFF.
Do the low speed engine cooling fans turn ON and

OFF with each command? Go to Step 3 Go to Step 4
IMPORTANT:
A 3 second delay occurs before the powertrain
control module (PCM)/engine control module (ECM)
changes the cooling fan speed. Go to Testing for
3
Intermittent
With a scan tool, command the Fans High Speed ON Conditions and
and OFF.Do the high speed engine cooling fans turn Poor Connections
ON and OFF with each command? in Wiring Systems Go to Step 11
IMPORTANT:
Do NOT remove the 20-amp fused jumper wire
connected during this step. Use a second 20-
amp fused jumper wire while performing the
following steps.
4 1. Disconnect the cooling fan 1 relay.

2. Connect the first 20-amp fused jumper between
the battery positive voltage circuit of the cooling
fan 1 relay and the cooling fan motor supply
voltage circuit of the cooling fan 1 relay.
Do both cooling fans operate in low speed? Go to Step 13 Go to Step 5

1. Disconnect the cooling fan S/P relay.
2. Connect the second 20-amp fused jumper
between the left cooling fan motor low reference
5 circuit of the cooling fan 2 relay and the right
cooling fan motor supply voltage circuit of the
cooling fan 2 relay.
Do both cooling fans operate in low speed? Go to Step 14 Go to Step 6

Reconnect the second 20-amp fused jumper between
the battery positive voltage circuit of the cooling fan 2
6 relay and the cooling fan motor supply voltage circuit
of the cooling fan 2 relay.
Does the right cooling fan operate in high speed? Go to Step 9 Go to Step 7
1. Install the cooling fan 2 relay.
2. Disconnect the right cooling fan electrical
connector.
3. Reconnect the second 20-amp fused jumper wire
7 from the cooling fan motor supply voltage
circuit of the right cooling fan electrical
connector to the cooling fan motor ground
circuit of the right cooling fan electrical
connector.
Does the left cooling fan operate in high speed? Go to Step 16 Go to Step 8
Reconnect the second 20-amp fused jumper wire from
the cooling fan motor supply voltage circuit of the
8
right cooling fan electrical connector to a good ground.
Does the left cooling fan operate in high speed? Go to Step 20 Go to Step 21
1. Install the cooling fan 2 relay.
2. Disconnect the left cooling fan electrical
connector.
3. Reconnect the second 20-amp fused jumper wire
9 from cooling fan motor supply voltage circuit of
the left cooling fan electrical connector to the
cooling fan low reference circuit of the left
cooling fan electrical connector.
Reconnect the second 20-amp fused jumper wire from
battery positive voltage to the left cooling fan low
10 reference circuit of the left cooling fan electrical
connector.
11 Does the right cooling fan operate in high speed? Go to Step 12 Go to Step 15
2. Connect a 20-amp fused jumper between the left
cooling fan low reference circuit of the cooling
12 fan 2 relay and the ground circuit of the cooling
fan 2 relay.
Does the left cooling fan operate properly in high

speed? Go to Step 14 Go to Step 19
Systems.
Systems.
Inspect for poor connections at the cooling fan 3 or S/P
relay. Refer to Testing for Intermittent Conditions
15 and Poor Connections andConnector Repairs in
Wiring Systems.
of the right cooling fan. Refer to Testing for
of the left cooling fan. Refer to Testing for
Repair the left cooling fan motor supply voltage
18 circuit. Refer to Wiring Repairs in Wiring Systems. -
Repair the left cooling fan motor ground circuit. Refer
19 to Wiring Repairs in Wiring Systems. -
Repair the right cooling fan motor ground circuit.
20 Refer to Wiring Repairs in Wiring Systems. -
Repair the right cooling fan motor supply voltage
21 circuit. Refer to Wiring Repairs in Wiring Systems. -
Repair the left cooling fan low reference circuit. Refer
22 to Wiring Repairs in Wiring Systems. -
23 -
24 -
Replace the cooling fan 3 or S/P relay.
25 -
Replace the right cooling fan. Refer to Cooling Fan
26 Motor Replacement - Electric. -
Replace the left cooling fan. Refer to Cooling Fan
27 Motor Replacement - Electric. -
28
ENGINE OVERHEATING
Engine Overheating
Step Action Yes No
DEFINITION: Either of the following conditions indicate a probable engine overheat condition.
The engine temperature gauge is in the red (overheat) zone and/or the engine temperature indicator
is ON.
Hot engine coolant overflows from the coolant recovery reservoir and/or radiator cap onto the
ground while the engine is running.
1. Inspect and fill the cooling system as necessary.

Refer to Draining and Filling Cooling System.
1 2. Inspect the cooling system for leaks as necessary.
3. Repair the cooling system leaks as necessary.
Has the inspection/repair been performed? Go to Step 2 -

1. Start the engine and allow the engine to run at Go to Engine
approximately 1200 RPM. Coolant
2. Use the Scan Tool in order to verify the overheat Temperature Gage
2 condition. Inaccurate or
Inoperative in
Does the Scan Tool verify the engine overheat Instrument Panel,
condition? Go to Step 3 Gauges and Console
1. Verify that the cooling fans are operating
properly.
3 2. Repair the cooling fan system as necessary.
Does the engine still overheat? Go to Step 4 System OK

Perform the following inspections:
Inspect the radiator and the A/C condenser

cooling fins for debris or any other obstruction.
Inspect the drive belt system and the drive belt
tensioner for proper operation in order to ensure
that the coolant pump is rotating properly.
Inspect for a loose, damaged, and/or missing air
4
deflector(s). Refer to Radiator Air Baffle
Assemblies and Deflectors.
Check for a pinched or kinked cooling system
hose.
Repair the systems as necessary.

CAUTION:
As long as there is pressure in the cooling system,
the temperature can be considerably higher than the
boiling temperature of the solution in the radiator
without causing the solution to boil. Removal of the
pressure cap while the engine is hot and pressure is
high will cause the solution to boil instantaneously -
possibly with explosive force - spewing the solution
over the engine, fenders and the person removing
5 the cap.
Inspect the thermostat for proper operation. Refer to

Thermostat Diagnosis.Is the thermostat operating
properly? Go to Step 7 Go to Step 6
Replace the thermostat. Refer to Thermostat
Replacement (LA1) or Thermostat Replacement
6
(LY7).
IMPORTANT:
Excessive coolant freeze point protection MAY
cause the coolant to boil at low temperatures.
1. Inspect for the proper coolant concentration

(mixture). Correct the coolant concentration as
necessary.
7
2. Remove the radiator cap.
3. Start the engine and inspect for a steady and
constant flow of air bubbles in the engine
coolant.
Is there a steady and constant flow of air bubbles in the

engine coolant? Go to Step 8 Go to Step 9
The probable cause of the engine overheat is
combustion chamber gasses leaking into the cooling
system. This condition is usually caused by the
following:
A faulty cylinder head gasket

A faulty cylinder head
8 A faulty engine block
Verify this condition by using spark plug electrodes or

the porcelain surrounding the spark plug electrodes that
exhibit signs of coolant. Replace the engine internal
component(s) as necessary in order to repair the engine
internal coolant leak.
The engine overheat may be caused by a cooling
system blockage. Flush the cooling system. Refer to
9 Flushing.
IMPORTANT:
It is VERY unlikely that the water pump is the cause
of the overheat condition.
10
If NONE of the cooling system passages are restricted,
replace the coolant pump. Refer to Water Pump
Replacement (LA1) or Water Pump Replacement
(LY7).Does the engine still overheat? Go to Step 1 System OK
LOSS OF COOLANT
Loss of Coolant
Step Action Yes No
DEFINITION: The cooling system is loosing coolant either internally or externally.
Were you sent here from Symptoms or another Go to Symptoms -
1
diagnostic table? Go to Step 2 Engine Cooling
Repair any present DTCs. Refer to Diagnostic System
2 Check - Vehicle in Vehicle DTC Information.
Inspect the coolant level.
3
Is the coolant at the proper level? Go to Step 6 Go to Step 4
Fill the cooling system to the proper level. Refer to
4 Draining and Filling Cooling System.
If the engine is suspected to have a coolant leak into a
5 cylinder, the coolant can hydraulically lock the engine.
Does the engine crankshaft rotate? Go to Step 6 Go to Step 26
Engine overheating can cause a loss of coolant.
6
Is the engine overheating? Go to Step 27 Go to Step 7
Extended operation with a low coolant level can cause
7 engine internal component failure.
Is the engine knocking? Go to Step 29 Go to Step 8
1. Idle the engine at normal operating temperature.
2. Inspect for heavy, white smoke coming out of the
8 exhaust pipe.
Is a heavy, white smoke present from the exhaust pipe? Go to Step 9 Go to Step 10
Coolant in the exhaust system creates a distinctive,
burning coolant odor in the exhaust.
9 Condensation in the exhaust system can cause an
odorless, white smoke during engine warm up.
Does the white smoke have a burning coolant type
odor? Go to Step 28 Go to Step 10
With the engine idling, inspect the coolant recovery
system.
10
Does the coolant recovery system discharge coolant
while the engine is idling? Go to Step 15 Go to Step 11
Visually inspect the hoses, pipes, and hose clamps at
the following locations:
The coolant bypass

The coolant reservoir
11
The heater core
The radiator
Are any of the hoses, clamps, or pipes leaking? Go to Step 20 Go to Step 12

Visually inspect the following components:
The block heater

The coolant pressure cap
The core plugs
The cylinder head gaskets
The engine block
12
The intake manifold
The radiator
The thermostat housing
The water pump
Are any of the listed components leaking? Go to Step 20 Go to Step 13

1. Pressure test the cooling system. Refer to
Cooling System Leak Testing.
2. With the cooling system pressurized, visually
13 inspect the components listed in the previous
steps.
Are any leaks present? Go to Step 20 Go to Step 14

Pressure test the coolant pressure cap. Refer to
14 Pressure Cap Testing.
Does the coolant pressure cap hold pressure? Go to Step 16 Go to Step 21
Pressure test the coolant pressure cap. Refer to
15 Pressure Cap Testing.
Does the coolant pressure cap hold pressure? Go to Step 30 Go to Step 21
A coolant smell inside of the vehicle

Coolant in the HVAC module assembly drain
tube
16
Coolant on the vehicle floor covering near the
HVAC module assembly
Is coolant present? Go to Step 22 Go to Step 17

Inspect the underside of the engine oil fill cap for a
17 gray/white milky substance.
Is there a milky substance under the oil fill cap? Go to Step 18 Go to Step 19
Inspect the engine oil fluid level indicator for a
gray/white milky substance.
18
Is there a milky substance on the engine oil fluid level
indicator? Go to Step 28 Go to Step 19
Inspect the automatic transmission oil fluid level
indicator, if equipped, for a gray/white milky
19 substance.
Is there a milky substance on the automatic
transmission fluid level indicator? Go to Step 23 Go to Step 31
Repair or replace the leaking component. Refer to the
20 appropriate repair.
Replace the coolant pressure cap.
21
Replace the heater core. Refer to Heater Core
Replacement (LA1) in Heating, Ventilation and Air
22
Conditioning.
1. Remove the transmission oil cooler lines from
the radiator.
2. Pressure test the cooling system. Refer to
23 Cooling System Leak Testing.
3. Inspect the transmission oil cooler for coolant.
Is coolant present? Go to Step 24 Go to Step 25

1. Replace the radiator. Refer to Radiator
Replacement (LA1).
24 2. Service the automatic transmission. Refer to
Engine Coolant/Water in Transmission in
Automatic Transmission - 4T65-E.
Is the repair complete?
Go to Step 31 -
Install the cooler lines to the radiator.
25
Repair the engine no crank condition. Refer to Engine
Will Not Crank - Crankshaft Will Not Rotate in
26
Engine Mechanical - 3.4L.
Repair the engine overheating condition. Refer to
27 Engine Overheating.
Repair the engine internal coolant leak. Refer to the
following procedure:
Coolant in Combustion Chamber in Engine

Mechanical - 3.4L
28
Coolant in Engine Oil in Engine Mechanical -
3.4L

Repair the engine knock. Refer to Lower Engine
Noise, Regardless of Engine Speed in Engine
29
Mechanical - 3.4L.
Repair the combustion pressure in the cooling system
problem. Refer to Cylinder Leakage Test in Engine
30
Mechanical - 3.4L.
31
THERMOSTAT DIAGNOSIS
Tools Required
J 24731 Tempil Stick. See Special Tools.
Use one of the following procedures in testing for a malfunctioning thermostat.
Thermostat Test Procedure Using Tempil Sticks
The coolant thermostat can be tested using a temperature (tempil) stick. The temperature stick is a pencil like
device. It has a wax material containing certain chemicals which melt at a given temperature. Temperature
sticks can be used to determine a thermostat's operating range, by rubbing 87C (188F) and 97C (206F)
sticks on the thermostat housing.
1. Use a tempil stick in order to find the opening and the closing temperatures of the coolant thermostat.
J 24731-188 tempil stick melts at 87C (188F). The thermostat should begin to open.
J 24731-206 tempil stick melts at 97C (206F). The thermostat should be fully open.
2. Replace the coolant thermostat if it does not operate properly between this temperature range.
COOLANT HEATER INOPERATIVE
Coolant Heater Inoperative

Step Action Yes No
Did you perform the necessary inspections? Go to Symptoms -
1
Go to Step 2 Engine Cooling
Test the engine coolant heater power supply cord for
an open or short to ground. Refer to Circuit Testing in
2
Wiring Systems.
Replace the engine coolant heater power supply cord.
Refer to Coolant Heater Cord Replacement (LA1) or
3 -
Coolant Heater Cord Replacement (LY7).
of the engine coolant heater. Refer to Testing for
Replace the engine coolant heater. Refer to Coolant
Heater Replacement (LA1) or Coolant Heater
5 -
Replacement (LY7).
6
ENGINE FAILS TO REACH NORMAL OPERATING TEMPERATURE
Engine Fails To Reach Normal Operating Temperature

Step Action Yes No
1. Ensure that the cooling system is full.
2. Allow the engine/radiator cap to cool.
1 4. Turn the air conditioning system off.
5. Inspect the engine cooling fan(s)
Is either engine cooling fan on? Go to Step 2 Go to Step 3

1. Diagnose and repair the cooling fan system.
2. Verify the customer complaint.
2
Does the engine still fail to reach normal operating
temperature? Go to Step 3 System OK
Install the Scan Tool to the DLC. Compare the Scan
Tool coolant temperature reading to the I/P cluster
3 coolant temperature.
Is the I/P cluster coolant temperature close to the Scan
Tool coolant temperature? Go to Step 5 Go to Step 4
1. Diagnose and repair the coolant temperature gage
system. Refer to Engine Coolant Temperature
Gage Inaccurate or Inoperative in Instrument
Panel Gauges and Console.
4
2. Verify the customer complaint.

CAUTION:
As long as there is pressure in the cooling system,
the temperature can be considerably higher than the
boiling temperature of the solution in the radiator
without causing the solution to boil. Removal of the
pressure cap while the engine is hot and pressure is
high will cause the solution to boil instantaneously -
5 possibly with explosive force - spewing the solution
over the engine, fenders and the person removing
the cap.
Inspect the thermostat for proper operation. Refer to

Thermostat Diagnosis.Is the thermostat operating
properly? Go to Step 1 Go to Step 6
1. Replace the thermostat. Refer to Thermostat
Replacement (LA1) or Thermostat
Replacement (LY7).
6 2. Verify the customer complaint.

PRESSURE CAP TESTING
Tools Required
J 24460-01 Cooling System Pressure Tester. See Special Tools.

CAUTION: To avoid being burned, do not remove the radiator cap or surge tank
cap while the engine is hot. The cooling system will release scalding
fluid and steam under pressure if radiator cap or surge tank cap is
removed while the engine and radiator are still hot.
1. Remove the pressure cap.

2. Wash the pressure cap sealing surface with water.
Fig. 4: Identifying J 24460-01

3. Use the J 24460-01 in order to test the pressure cap. See Special Tools.
4. Test the pressure cap for the following conditions:
Pressure release when the J 24460-01 exceeds the pressure rating of the pressure cap. See Special
Tools.
Maintain the rated pressure for at least 10 seconds.
Note the rate of pressure loss.

5. Replace the pressure cap under the following conditions:
The pressure cap does not release pressure which exceeds the rated pressure of the cap.
The pressure cap does not hold the rated pressure.
COOLING SYSTEM LEAK TESTING
Tools Required
J 24460-01 Cooling System Pressure Tester. See Special Tools.
CAUTION: Under pressure, the temperature of the solution in the radiator can be
considerably higher, without boiling. Removing the radiator cap
while the engine is hot (pressure is high), will cause the solution to
boil instantaneously, with explosive force. The solution will spew out
over the engine, fenders, and the person removing the cap. Serious
bodily injury may result. Flammable antifreeze, such as alcohol, is
not recommended for use at any time. Flammable antifreeze could
cause a serious fire.
CAUTION: In order to help avoid being burned, do not remove the radiator cap
while the engine and the radiator are hot. Scalding fluid and steam
can be blown out under pressure if the cap is removed too soon.
1. Remove the pressure cap.

2. Test the operation of the pressure cap. Refer to Pressure Cap Testing.
3. Wash the pressure cap mating surface with water.
Fig. 5: Pressure Testing Cooling System Using J 24460-01
4. Use the J 24460-01 in order to apply pressure to the cooling system. See Special Tools.
Do not exceed the pressure cap rating.
5. The cooling system should hold the rated pressure for at least 2 minutes.
Observe the gage for any pressure loss.
6. Repair any leaks as required.
REPAIR INSTRUCTIONS
DRAINING AND FILLING COOLING SYSTEM
Draining Procedure
Tools Required
J 26568 Coolant and Battery Tester. See Special Tools.
CAUTION: To avoid being burned, do not remove the radiator cap or surge tank cap
while the engine is hot. The cooling system will release scalding fluid and
steam under pressure if radiator cap or surge tank cap is removed while
the engine and radiator are still hot.
IMPORTANT: Draining the cooling system with the pressure cap installed will siphon
the coolant from the overflow tank.
1. Remove the coolant pressure cap.

3. Place a drain pan under the drain cock.
4. Open the radiator drain cock.
5. Drain the cooling system.
6. If a complete engine block drain is required LA1 engine, remove the engine block drain plugs.
7. If a complete engine block drain is required LY7 engine, remove the starter motor. Refer to Starter
Motor Replacement (LA1) or Starter Motor Replacement (LY7) in Engine Electrical.
8. If a complete engine block drain is required LY7 engine, remove the engine block drain plugs.
9. Inspect the coolant.
10. Follow the appropriate procedure based on the condition of the coolant.
Normal in appearance - follow the filling procedure.
Discolored - follow the flush procedure. Refer to:Flushing .
Filling Procedure
1. Close the radiator drain cock.

2. If the engine block drain plugs were removed from the LA1 or LY7 engine, perform the following:
Apply pipe sealer to the drain plugs.
Install the drain plugs.
Tighten: Tighten the drain plugs to 22 N.m (16 lb ft).
3. If the engine block was drained LY7 engine, install the starter motor. Refer to Starter Motor
Replacement (LA1) or Starter Motor Replacement (LY7) in Engine Electrical.
5. Open the cooling system bleeder screws.
IMPORTANT: Use a 50/50 mixture of DEX-COOL antifreeze and clean, drinkable water.
6. Slowly fill the cooling system with a 50/50 coolant mixture. Refer to Capacities - Approximate Fluid .
7. Close the cooling system bleeder screws.
8. Install the coolant pressure cap.
10. Run the engine at 2000 - 2500 RPM until the engine reaches normal operating temperature.
11. Allow the engine to idle for 3 minutes.
12. Shut the engine off.
13. Allow the engine to cool.
14. Top off the coolant as necessary.
15. Inspect the concentration of the engine coolant. Using theJ 26568 . See Special Tools.
16. Rinse away any excess coolant from the engine and the engine compartment.
FLUSHING
Flushing Procedure
IMPORTANT: Do not use a chemical flush.
Store used coolant in the proper manner, such as in a used engine coolant holding tank. Do not pour used
coolant down a drain. Ethylene glycol antifreeze is a very toxic chemical. Do not dispose of coolant into the
sewer system or ground water. This is illegal and ecologically unsound.
Various methods and equipment can be used to flush the cooling system. If special equipment is used, such as a
back flusher, follow the manufacturer's instruction. Always remove the thermostat before flushing the cooling
system.
When the cooling system becomes contaminated, the cooling system should be flushed thoroughly to remove
the contaminants before the engine is seriously damaged.
1. Drain the cooling system. Refer to Draining and Filling Cooling System.
2. Remove the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement.
3. Clean and flush the coolant recovery reservoir with clean, drinkable water.
4. Install the coolant recovery reservoir. Refer to Coolant Recovery Reservoir Replacement.
5. Follow the drain and fill procedure using only clean, drinkable water. Refer to Draining and Filling
Cooling System.
6. Run the engine for 20 minutes.
7. Stop the engine.
9. Repeat the procedure if necessary, until the fluid is nearly colorless.
10. Fill the cooling system. Refer to Draining and Filling Cooling System.
RADIATOR CLEANING
CAUTION: NEVER spray water on a hot radiator. The resulting steam could cause
personal injury.
NOTE: The radiator fins are necessary for good heat transfer. Do not brush the fins.
This may cause damage to the fins, reducing heat transfer.
IMPORTANT: Remove bugs, leaves, dirt and other debris by blowing compressed air
through the engine side of the radiator.
Some conditions may require the use of warm water and a mild detergent.
Clean the A/C condenser fins.
Clean between the A/C condenser and radiator.
Clean the radiator cooling fins.
Straighten any damaged cooling fins.
COOLANT RECOVERY RESERVOIR REPLACEMENT
Tools Required
J 38185 Hose Clamp Pliers. See Special Tools.
Removal Procedure
1. Reposition the reservoir hose clamp at the radiator overflow fitting using the J 38185 . See Special Tools.
2. Remove the reservoir hose at the radiator overflow fitting.
Fig. 6: View Of Coolant Reservoir
3. Remove the reservoir mounting clip.

4. Remove the coolant reservoir.
1. Install the coolant reservoir.

Fig. 7: View Of Coolant Reservoir
2. Install the reservoir mounting clip.

3. Connect the reservoir hose to the radiator overflow fitting.
4. Reposition the reservoir hose clamp to secure the hose using the J 38185 . See Special Tools.
5. Fill the coolant reservoir. Refer to Draining and Filling Cooling System.
RADIATOR HOSE REPLACEMENT - INLET (LA1)
Tools Required
Removal Procedure
Fig. 8: Identifying Radiator Hose Clamp

2. Reposition the hose clamp at the radiator using the J 38185 . See Special Tools.
3. Disconnect the radiator inlet hose from the radiator.
4. Reposition the hose clamp at the thermostat housing using the J 38185 . See Special Tools.
5. Disconnect the radiator inlet hose from the thermostat housing.
6. Remove the radiator inlet hose.
Fig. 9: Identifying Radiator Hose Clamp

1. Install the radiator inlet hose.

2. Connect the radiator inlet hose to the radiator.
3. Reposition the hose clamp at the radiator to secure the hose using theJ 38185 . See Special Tools.
4. Connect the radiator inlet hose to the thermostat housing.
5. Reposition the hose clamp at the thermostat housing to secure the hose using theJ 38185 . See Special
Tools.
RADIATOR HOSE REPLACEMENT - OUTLET (LA1)
Tools Required
Removal Procedure
Fig. 10: View Of Radiator Outlet Hose
2. Reposition the hose clamp at the water pump housing using the J 38185 . See Special Tools.
3. Disconnect the radiator outlet hose from the water pump housing.
5. Disconnect the radiator outlet hose from the radiator.
6. Remove the radiator outlet hose.

1. Install the radiator outlet hose.

2. Connect the radiator outlet hose to the radiator.
3. Reposition the hose clamp at the radiator to secure the hose using the J 38185 . See Special Tools.
4. Connect the radiator outlet hose to the water pump housing.
5. Reposition the hose clamp at the water pump housing to secure the hose using the J 38185 . See Special
Tools.
THROTTLE BODY HEATER HOSE REPLACEMENT - INLET
Tools Required
Removal Procedure
1. Remove the air cleaner duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.4L.
2. Remove the throttle cable bracket in order to gain access to the throttle body heater hose clamp.
3. Drain the coolant until the coolant level is below the throttle body heater hoses. Refer to Draining and
Filling Cooling System.
4. Use the J 38185 in order to remove the hose clamp. See Special Tools.
Fig. 12: View Of Throttle Body Heater Inlet Hose
5. Remove the throttle body heater inlet hose.
Fig. 13: Checking Throttle Body Heater Inlet Hose Clearances
1. Install the throttle body heater inlet hose.

2. Use the J 38185 in order to install the hose clamps. See Special Tools.
5. Install the air cleaner duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.4L.
THROTTLE BODY HEATER HOSE REPLACEMENT - OUTLET
Tools Required
Removal Procedure
1. Remove the air cleaner duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.4L.
2. Drain the coolant until the coolant level is below the throttle body heater hoses. Refer to Draining and
3. Use the J 38185 in order to remove the hose clamp. See Special Tools.
Fig. 14: View Of Throttle Body Heater Inlet Hose

4. Remove the throttle body heater outlet hose.

Fig. 15: Checking Throttle Body Heater Inlet Hose Clearances

1. Install the throttle body heater outlet hose.

2. Use the J 38185 in order to install the hose clamps. See Special Tools.
4. Install the air cleaner duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.4L.
FAN REPLACEMENT
Removal Procedure
CAUTION: Refer to Electric Coolant Fan Caution in Cautions and Notices.
CAUTION: Refer to Damaged Fan Blade Caution in Cautions and Notices.
IMPORTANT: If abnormal noise or vibration is felt from the engine compartment, inspect and
clean any foreign material from the cooling fan blades.
1. Turn the ignition off.

2. Remove the cooling fans with the cooling fan shroud. Refer to Cooling Fan Replacement - Electric
(LA1).
IMPORTANT: Turn the cooling fan nut clockwise to loosen.
3. Remove the cooling fan nut.

Fig. 16: Identifying Cooling Fans
4. Remove the cooling fan.
1. Install the cooling fan.
IMPORTANT: Turn the cooling fan nut counterclockwise to tighten.
2. Install the cooling fan nut.
Tighten: Tighten the nut to 6 N.m (53 lb in).
3. Install the cooling fans with the cooling fan shroud. Refer to Cooling Fan Replacement - Electric
(LA1).
COOLING FAN REPLACEMENT - ELECTRIC (LA1)
Tools Required
Removal Procedure
1. Remove the air cleaner and duct assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 3.4L.
Fig. 18: Locating Cooling Fan Harness Electrical Connector
2. Remove the cooling fan harness electrical connector.

3. Remove right side diagonal brace. Refer to Brace Replacement - Front Fender Upper Diagonal -
Right in Body Front End.
Fig. 19: Identifying Engine Mount Strut Bracket Brace Bolts
4. Loosen the engine mount strut nuts.

5. Remove the engine mount strut bracket brace bolts from the upper radiator support and rotate the struts
and brackets rearward.
6. Remove upper radiator hose. Refer to Radiator Hose Replacement - Inlet (LA1)
Fig. 20: View Of Radiator Upper Mount Bolts
7. Remove the radiator upper mount bolts (1).

8. Remove the radiator upper mounts.
9. Remove the cooling fan shroud bolts.
10. Reposition the coolant overflow hose clamp at the radiator using the J 38185 . See Special Tools.
11. Disconnect and reposition the coolant overflow hose.
12. Disconnect the upper TOC line from the radiator. Refer to Transmission Fluid Cooler Line Quick
Connect Fitting in Automatic Transaxle - 4T65-E.
14. Disconnect the TOC lines from the fan module retainer clip.
Fig. 21: Locating Engine Wiring Harness Retainers At The Engine Harness Bracket
16. Disconnect the engine wiring harness retainers at the engine harness bracket.
17. Reposition the engine wiring harness.
18. Remove the cooling fans with the cooling fan shroud.
Fig. 22: Locating Engine Wiring Harness Retainers At The Engine Harness Bracket
1. Install the cooling fans with the cooling fan shroud.

2. Reposition the engine wiring harness.
3. Connect the engine wiring harness retainers at the engine harness bracket.
5. Connect the TOC lines to the fan module retainer clip.
7. Connect the upper TOC line to the radiator. Refer to Transmission Fluid Cooler Line Quick Connect
Fitting in Automatic Transaxle - 4T65-E.
Fig. 23: View Of Radiator Upper Mount Bolts
8. Install the cooling fan shroud bolts.
9. Install the radiator upper mounts.

10. Install the radiator upper mount bolts (1).
11. Install the coolant overflow hose to the radiator.

12. Reposition the hose clamp to secure the coolant overflow hose using the J 38185 . See Special Tools.
13. Install the upper radiator hose. Refer to Radiator Hose Replacement - Inlet (LA1).
Fig. 24: Identifying Engine Mount Strut Bracket Brace Bolts
14. Position the engine mount struts brackets flush with the upper radiator support.
15. Install the engine mount strut bracket brace bolts to the upper radiator support.
Tighten: Tighten bolts to 28 N.m (21 lb ft).
16. Tighten the engine mount strut nuts.
Tighten: Tighten the nuts to 48 N.m (35 lb ft).
17. Install right side diagonal brace. Refer to Brace Replacement - Front Fender Upper Diagonal - Right
in Body Front End.
Fig. 25: Locating Cooling Fan Harness Electrical Connector
18. Install the cooling fan harness electrical connector.

19. Install the air cleaner and duct assembly. Refer to Air Cleaner Assembly Replacement in Engine
Controls - 3.4L.
COOLING FAN MOTOR REPLACEMENT - ELECTRIC
Removal Procedure

IMPORTANT: If abnormal noise or vibration is felt from the engine compartment,

inspect and clean any foreign material from the cooling fan blades.
1. Turn the ignition off.

2. Remove the cooling fan and shroud assembly. Refer to Cooling Fan Replacement - Electric (LA1).
IMPORTANT: Turn the cooling fan nut clockwise to loosen.
3. Remove the cooling fan nut.

4. Remove the cooling fan from the shroud.

5. Disconnect the electrical connector from the cooling fan motor.
Fig. 27: Locating Cooling Fan Motor Screws

6. Remove the screws from the cooling fan motor.

7. Remove the cooling fan motor.
1. Install the cooling fan motor.
2. Install the screws to the cooling fan motor.
3. Connect the electrical connector to the cooling fan motor.

4. Install the cooling fan to the shroud.
IMPORTANT: Turn the cooling fan nut counterclockwise to tighten.
5. Install the cooling fan nut.
6. Install the cooling fan and shroud assembly. Refer to Cooling Fan Replacement - Electric (LA1).
THERMOSTAT REPLACEMENT (LA1)

Tools Required
Removal Procedure
Controls - 3.4L.
2. Drain the coolant until the coolant level is below the thermostat. Refer to Draining and Filling Cooling
System.
3. Remove the crossover exhaust pipe. Refer to Exhaust Crossover Pipe Replacement (LA1) or Exhaust
Crossover Pipe Replacement (LY7) in Engine Exhaust.
4. Remove the radiator hose from the thermostat housing.
Fig. 30: Water Outlet Housing & Bolts

5. Remove the thermostat housing bolts and clean any sealer from the bolt threads.
6. Remove the thermostat housing and gasket.
Fig. 31: View Of Thermostat (3.4L)

8. Clean the mating surfaces.

2. Install the thermostat housing and gasket.

Fig. 34: Identifying Radiator Inlet Hose & Water Outlet Housing
3. Install the thermostat housing bolts.

4. Install the radiator hose to the thermostat housing.
5. Install the crossover exhaust pipe. Refer to Exhaust Crossover Pipe Replacement (LA1) or Exhaust
Controls - 3.4L.
THERMOSTAT REPLACEMENT (LY7)
Removal Procedure
Fig. 35: View Of Thermostat (LY7)
1. Remove the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls-3.6L (LY7).
2. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement .
3. Remove the heater pipes. Refer to Heater Pipes Replacement (LY7) in Heating, Ventilation and Air
Conditioning.
IMPORTANT: Use a universal or swivel socket with a long extension in order to remove
the bolts.
4. Remove the coolant inlet pipe. Refer to Coolant Pipe Replacement - Inlet.
IMPORTANT: Use a universal or swivel socket with a long extension in order to remove
the bolts.
5. Remove the thermostat bolts and the thermostat.

6. Clean the thermostat and heater pipe sealing surfaces.
Fig. 36: View Of Thermostat (LY7)
1. Install a NEW thermostat gasket.

2. Install the thermostat and gasket.

3. Install the thermostat bolts.
4. Install the coolant inlet pipe. Refer to Coolant Pipe Replacement - Inlet.
5. Install the heater pipes. Refer to Heater Pipes Replacement (LY7) in Heating, Ventilation and Air
Conditioning.
6. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement .
7. Install the air cleaner. Refer to Air Cleaner Assembly Replacement in Engine Controls-3.6L (LY7).
WATER OUTLET HOUSING REPLACEMENT (LA1)
Tools Required
Removal Procedure
Controls-3.4L.
2. Drain the coolant until the coolant level is below the thermostat. Refer to Draining and Filling Cooling
System.
3. Remove the crossover exhaust pipe. Refer to Exhaust Crossover Pipe Replacement (LA1) or Exhaust
4. Remove the radiator hose from the thermostat housing.
5. Remove the thermostat housing bolts and clean any sealer from the bolt threads.
6. Remove the thermostat housing and gasket.

8. Clean the mating surfaces.

2. Install the thermostat housing and gasket.

3. Install RTV sealer (GM P/N 1052366 or the equivalent) to the thermostat housing bolt threads.
Fig. 41: Identifying Radiator Inlet Hose & Water Outlet Housing
4. Install the thermostat housing bolts.

5. Install the radiator hose to the thermostat housing.
6. Install the crossover exhaust pipe. Refer to Exhaust Crossover Pipe Replacement (LA1) or Exhaust
Controls-3.4L.
COOLANT PIPE REPLACEMENT - INLET
Removal Procedure
Fig. 42: View Of Water Coolant Inlet Pipe Bolts & Coolant Inlet Pipe
1. Drain the coolant until the coolant level is below the lower radiator hose. Refer to Draining and Filling
Cooling System.
2. Remove the lower radiator hose from the coolant inlet pipe. Refer to Radiator Hose Replacement -
Outlet (LA1).
3. Remove the water coolant inlet pipe bolts and the coolant inlet pipe.
4. Remove and discard the coolant inlet pipe seal.
Fig. 43: View Of Water Coolant Inlet Pipe Bolts & Coolant Inlet Pipe
1. Install the NEW coolant inlet pipe seal.
2. Install the coolant inlet pipe bolts.
Tighten
Tighten the water outlet upper bolt (2) to 23 N.m (17 lb ft).
Tighten the water outlet lower bolt (1) to 50 N.m (37 lb ft).
3. Install the lower radiator hose to the coolant inlet pipe. Refer to Radiator Hose Replacement - Inlet
(LA1).
THERMOSTAT BYPASS PIPES REPLACEMENT
Tools Required
Removal Procedure
2. Remove the spark plug wire harness from the thermostat bypass pipe.
3. Remove the air inlet duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.4L.
4. Remove the upper radiator hose from the thermostat housing.
5. Disconnect the left engine mount strut from the engine.
6. Remove the heater hose from the bypass pipe.
Fig. 44: Locating Heater Pipe Nut
7. Remove the thermostat bypass pipe to throttle body nut.

Fig. 45: Identifying Thermostat Bypass Pipes
8. Use the J 38185 in order to remove the thermostat bypass pipe hose clamps (1,5). See Special Tools.
9. Remove the thermostat bypass pipe to cylinder head nut (3).
10. Remove the thermostat bypass pipe bolt (4).
Fig. 46: Removing/Installing Thermostat Bypass Pipe Hose
11. Remove the thermostat bypass pipe hose.

12. Remove the thermostat bypass pipe.
1. Apply engine coolant to the bypass pipe seal in order to ease installation.
2. Install the thermostat bypass pipe.
Fig. 47: Removing/Installing Thermostat Bypass Pipe Hose
3. Install the thermostat bypass pipe hose.

Fig. 48: Identifying Thermostat Bypass Pipes
4. Install the thermostat bypass pipe hose clamp (5).
5. Install the thermostat bypass pipe bolt (4).
Tighten: Tighten the thermostat bypass pipe bolt to 11 N.m (98 lb in).
6. Install the thermostat bypass pipe to cylinder head nut (3).
Tighten: Tighten the thermostat bypass pipe nut to 25 N.m (18 lb ft).
7. Install the thermostat bypass pipe to throttle body hose clamps (1).
Fig. 49: Locating Heater Pipe Nut

8. Install the thermostat bypass pipe to throttle body nut.
Tighten: Tighten the thermostat bypass pipe nut to 25 N.m (18 lb ft).
9. Install the heater hose to the bypass pipe.

10. Install the left engine mount strut to the engine.
11. Install the upper radiator hose to the engine.
12. Install the air inlet duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.4L.
13. Install the spark plug wire harness to the thermostat bypass pipe.
WATER PUMP REPLACEMENT (LA1)
Removal Procedure
1 Drain the cooling system until the coolant is below the level of the water pump Refer to Draining and
Fig. 50: Locating Drive Belt Guard

2. Remove the drive belt guard.

3. Loosen the water pump pulley bolts.
4. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.4L.
Fig. 51: View Of Water Pump Pulley


Fig. 52: Identifying Water Pump & Gasket

10. Clean the water pump mating surfaces.
Fig. 53: Identifying Water Pump & Gasket



6. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.4L.
Tighten: Tighten the water pump pulley bolts to 25 N.m (18 lb in).
Fig. 55: Locating Drive Belt Guard
7. Install the drive belt guard.

WATER PUMP REPLACEMENT (LY7)

Tools Required
EN 46104 Water Pump Pulley Holding Tool
Removal Procedure
1. Drain the cooling system until the coolant is below the water pump. Refer to Draining and Filling
Cooling System.
2. Remove the accessory drive belt from the water pump. Refer to Drive Belt Replacement in Engine
Mechanical - 3.6L (LY7).
Fig. 56: Securing Water Pump Pulley With EN 46104

3. Use the EN 46104 in order to retain the water pump pulley.

4. Remove the water pump pulley bolts and the water pump pulley.
Fig. 58: Identifying Water Pump Components

7. Remove and discard the water pump gasket.
8. Clean the water pump sealing surfaces.
Fig. 59: Identifying Water Pump Components
1. Install the NEW water pump gasket.

Tighten: Tighten the water pump bolts to 10 N.m (89 lb in).


Fig. 61: Securing Water Pump Pulley With EN 46104
5. Use the EN 46104 in order to retain the water pump pulley.

Tighten: Tighten the water pump pulley bolts to 12 N.m (106 lb in).
7. Install the accessory drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.6L (LY7).
FAN SHROUD REPLACEMENT (LA1)

Removal Procedure
IMPORTANT: If abnormal noise or vibration is felt from the engine compartment,

inspect and clean any foreign material from the cooling fan blades.
1. Remove the cooling fan assembly including the shroud. Refer to Cooling Fan Replacement - Electric
(LA1).
IMPORTANT: Turn the cooling fan nuts clockwise to loosen.
2. Remove the cooling fan nuts.

3. Remove the cooling fans from the shroud.
4. Disconnect the fan motor electrical connectors.

5. Remove the fan motor screws.
6. Remove the fan motors from the cooling fan shroud.
Fig. 64: Locating Heat Shield On Cooling Fan Shroud
7. Remove the heat shields from the cooling fan shroud.
Fig. 65: Locating Heat Shield On Cooling Fan Shroud
1. Install the heat shields to the cooling fan shroud.

2. Install the fan motors to the cooling fan shroud.
3. Install the screws to the cooling fan motor.
4. Connect the cooling fan motor electrical connectors.

5. Install the cooling fans to the shroud.
IMPORTANT: Turn the cooling fan nuts counterclockwise to tighten.
6. Install the cooling fan nuts.
Tighten: Tighten the nuts to 6 N.m (53 lb in).
7. Install the cooling fan assembly including the shroud. Refer to Cooling Fan Replacement - Electric
(LA1).
RADIATOR REPLACEMENT (LA1)
Tools Required

J 39400-A Halogen Leak Detector. See Special Tools.
Removal Procedure
1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging in
Heating, Ventilation and Air Conditioning.
3. Remove the cooling fans with the cooling fan shroud. Refer to Cooling Fan Replacement - Electric
(LA1).
4. Reposition the hose clamp at the water pump housing using the J 38185 . See Special Tools.
5. Disconnect the radiator outlet hose from the water pump housing.
8. Disconnect the radiator outlet hose from the radiator.
9. Remove the radiator outlet hose.
10. Disconnect the lower TOC line from the radiator. Refer to Transmission Fluid Cooler Line Quick
Connect Fitting in Automatic Transaxle - 4T65-E.
Fig. 69: Locating A/C Discharge Hose From Condenser Block
12. Remove the nut which secures the A/C discharge hose to the condenser block.
13. Disconnect the A/C discharge hose from the condenser block.
14. Remove and discard the sealing washer.
IMPORTANT: Cap or tape off the open A/C hose immediately to prevent system
contamination.
15. Cap or tape off the A/C discharge hose.
Fig. 70: Identifying Evaporator Inlet Tube To Condenser Block

16. Remove the bolt which secures the evaporator inlet tube to the condenser block.
17. Disconnect the evaporator inlet tube from the condenser block.
18. Cap or tape off the evaporator inlet tube.
Fig. 71: View Of Radiator And Condenser Assembly

19. Remove the radiator and condenser assembly.

20. Remove the condenser tube clip bolt.
21. Remove the condenser mounting bolts.
22. Remove the condenser from the radiator.
Fig. 72: View Of Radiator And Condenser Assembly
1. Install the condenser to the radiator.
2. Install the mounting bolts that secure the condenser to the radiator.
3. Install the condenser tube clip bolt.
Tighten: Tighten the bolt to 2.5 N.m (22 lb in).
4. Install the radiator and condenser assembly.

5. Remove the cap or the tape from the evaporator inlet tube.
6. Install a new seal washer to the evaporator inlet tube. Refer to Sealing Washer Replacement .
Fig. 73: Identifying Evaporator Inlet Tube To Condenser Block

7. Install the evaporator inlet tube and the bolt to the condenser block.
Tighten: Tighten bolt to 16 N.m (12 lb ft).
8. Remove the cap or the tape from the A/C discharge hose.
9. Install a new sealing washer to the A/C discharge hose. Refer to Sealing Washer Replacement .
Fig. 74: Locating A/C Discharge Hose From Condenser Block
10. Install the A/C discharge hose and the nut to the condenser block.

12. Connect the lower TOC line to the radiator. Refer to Transmission Fluid Cooler Line Quick Connect
Fitting in Automatic Transaxle - 4T65-E.

13. Install the radiator outlet hose.

14. Connect the radiator outlet hose to the radiator.
15. Reposition the hose clamp at the radiator to secure the hose using the J 38185 . See Special Tools.
17. Connect the radiator outlet hose to the water pump housing.
18. Reposition the hose clamp at the water pump housing to secure the hose using the J 38185 . See Special
Tools.
19. Install the cooling fans with the cooling fan shroud. Refer to Cooling Fan Replacement - Electric
(LA1).
21. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging in Heating,
Ventilation and Air Conditioning.
22. Leak test the fittings of the component using the J 39400-A . See Special Tools.
23. Inspect the transmission fluid level. Refer to Transmission Fluid Checking Procedure in Automatic
Transaxle - 4T65-E.
RADIATOR AIR BAFFLE ASSEMBLIES AND DEFLECTORS
Removal Procedure
Fig. 76: View Of Lower Air Deflector/Baffle
2. Remove the air baffle bolts.

3. Remove the air baffle.
1. Install the air baffle.

Fig. 77: View Of Lower Air Deflector/Baffle
2. Install the air baffle bolts.
COOLANT HEATER REPLACEMENT (LA1)
Removal Procedure
1. Drain the engine cooling system. Refer to Draining and Filling Cooling System.
3. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
4. Remove the right engine splash shield. Refer to Splash Shield Replacement - Engine in Body Front
End.
Fig. 78: View Of Engine Coolant Heater Cord

5. Remove the engine coolant heater cord from the engine coolant heater.
6. Loosen the coolant heater bolt.
Fig. 79: Identifying Coolant Heater (LA1)

7. Remove the coolant heater.
1. Apply GM P/N United States 12346004, GM P/N Canada 10953480 or equivalent to the coolant heater
seal and the coolant heater hole.
Fig. 80: Aligning Coolant Heater Element (LA1)

2. Ensure that the coolant heater element is horizontal and pointed toward the front of the engine.
The 3 o'clock position (2) is DESIRED.
The 2 o'clock position (1) and the 4 o'clock position (3) are acceptable.
Fig. 81: Identifying Coolant Heater (LA1)
3. Install the coolant heater.
4. Install the coolant heater bolt.
Tighten: Tighten the bolt to 2 N.m (18 lb in).

NOTE: The heater cord must not touch the engine, hot pipes, manifold, or any
moving parts. Route the cord to the left front of the engine compartment
securing with tie straps as necessary to prevent damage.
5 Install the engine coolant heater cord to the engine coolant heater
6. Install the right engine splash shield. Refer to Splash Shield Replacement - Engine in Body Front End.
7. Install the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
9. Fill the engine cooling system. Refer to Draining and Filling Cooling System.
COOLANT HEATER REPLACEMENT (LY7)
Removal Procedure
2. Remove the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
Fig. 83: View Of Coolant Heater (LY7)

4. Remove the coolant heater.
Fig. 84: View Of Coolant Heater (LY7)

1. Install the coolant heater.

2. Install the engine coolant heater cord to the engine coolant heater.
3. Install the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
COOLANT HEATER CORD REPLACEMENT (LA1)
Removal Procedure
Fig. 85: Identifying Coolant Heater Cord (LA1)
IMPORTANT: The strap that secures the coolant heater cord to the diagonal brace is
reusable. Do NOT cut this strap in order to remove it.
1. Press the coolant heater strap retainer tab in order to remove coolant heater cord strap.
2. Use wire cutters in order to remove the remaining coolant heater cord straps from the engine wiring
harness.
Fig. 86: Locating 3 Coolant Heater Cord Lower Straps
4. Use wire cutters in order to remove the 3 coolant heater cord lower straps (1) from the engine wiring
harness.
5. Remove the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
6. Remove the right engine splash shield. Refer to Splash Shield Replacement - Engine in Body Front
End.
8. Remove the engine coolant heater cord.
1. Install the engine coolant heater cord to the engine coolant heater.
NOTE: The heater cord must not touch the engine, hot pipes, manifold, or any
moving parts. Route the cord to the left front of the engine compartment
securing with tie straps as necessary to prevent damage.
2. Properly route the coolant heater cord.
Fig. 89: Locating 3 Coolant Heater Cord Lower Straps

3. Install new tie straps (1) in order to secure the coolant heater cord to the engine wiring harness.
4. Install the right engine splash shield. Refer to Splash Shield Replacement - Engine in Body Front End.
5. Install the right front wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
Fig. 90: Identifying Coolant Heater Cord (LA1)
7. Install the reusable strap in order to secure the coolant heater cord to the diagonal brace.
COOLANT HEATER CORD REPLACEMENT (LY7)
Removal Procedure
Fig. 91: View Of Coolant Heater Cord (LY7)
1. Remove the air inlet duct. Refer to Air Cleaner Intake Duct Replacement Engine Controls - 3.6L
(LY7).
2. Remove the coolant (block) heater cord from the transmission fill tube.
4. Remove the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
5. Remove the engine coolant (block) heater cord from the engine coolant heater.
6. Remove the engine coolant (block) heater cord.
Fig. 92: View Of Coolant Heater Cord (LY7)
1. Install the engine coolant (block) heater cord above the transmission.
2. Install the engine coolant (block) heater cord to the engine coolant heater.
3. Install the catalytic converter. Refer to Catalytic Converter Replacement in Engine Exhaust.
5. Install the coolant (block) heater cord to the transmission fill tube.
6. Install the air inlet duct. Refer to Air Cleaner Intake Duct Replacement Engine Controls - 3.6L (LY7).

COOLING SYSTEM DESCRIPTION AND OPERATION
Cooling Fan Control
The engine cooling fan system is controlled by the body control module (BCM) and the powertrain control
module (PCM) or engine control module (ECM). The BCM performs the calculations as to how long, when and
what speed the cooling fans should turn on. The BCM then sends a class 2 message to the PCM/ECM to engage
the cooling fan relays. If there is a malfunction with the BCM, the PCM/ECM will control the engine cooling
fans independently. The engine cooling system consists of 2 electrical cooling fans and 3 fan relays. The relays
are arranged in a series/parallel configuration that allows the PCM/ECM to operate both fans together at low or
high speeds. The cooling fans and fan relays receive battery positive voltage from the underhood accessory
wiring junction block. The ground path is provided at G100.
During low speed operation, the PCM/ECM supplies the ground path for the low speed fan relay through the
low speed cooling fan relay control circuit. This energizes the cooling fan 1 relay coil, closes the relay contacts,
and supplies battery positive voltage from the cool fan 1 fuse through the cooling fan motor supply voltage
circuit to the left cooling fan. The ground path for the left cooling fan is through the cooling fan 2 relay and the
right cooling fan. The result is a series circuit with both fans running at low speed.
During high speed operation the PCM/ECM supplies the ground path for the cooling fan 1 relay through the
low speed cooling fan relay control circuit. After a 3-second delay, the PCM/ECM supplies a ground path for
the cooling fan 3 or S/P relay and the cooling fan 2 relay through the high speed cooling fan relay control
circuit. This energizes the cooling fan 2 relay coil, closes the relay contacts, and provides a ground path for the
left cooling fan. At the same time the cooling fan 2 relay coil is energized closing the relay contacts and
provides battery positive voltage from the cool fan 2 fuse on the cooling fan motor supply voltage circuit to the
right cooling fan. During high speed fan operation, both engine cooling fans have there own ground path. The
result is a parallel circuit with both fans running at high speed.
The BCM and PCM/ECM command Low Speed Fans on under the following conditions:
Engine coolant temperature exceeds approximately 106C (223F).

A/C refrigerant pressure exceeds 1 310 kPa (190 psi).
After the vehicle is shut off if the engine coolant temperature at key-off is greater than 140C (284F) and
system voltage is more than 12 volts. The fans will stay on for approximately 3 minutes.
The BCM and PCM/ECM command High Speed Fans on under the following conditions:
Engine coolant temperature reaches 110C (230F).

A/C refrigerant pressure exceeds 1 655 kPa (240 psi).
When certain DTCs set.
Engine Coolant Indicator(s)
Hot Coolant Temp
The instrument panel cluster (IPC) illuminates the hot coolant temp indicator in the message center when the
PCM determines that the coolant temperature is greater than 128C (262F). The IPC receives a class 2 message
from the PCM requesting illumination.
Reduced Engine Power
The IPC displays REDUCED ENGINE POWER message when the IPC detects a reduced engine power
condition from the PCM. The IPC receives a class 2 message from the PCM requesting illumination when the
engine temperature reaches 110C (230F).
Coolant Heater
The optional engine coolant heater (RPO K05) is rated at 400 watts and supplies 1365 btu/hr. The engine
coolant heater operates using 110-volt AC external power and is designed to warm the coolant in the engine
block area for improved starting in very cold weather -29C (-20F). The coolant heater helps reduce fuel
consumption when a cold engine is warming up. The unit is equipped with a detachable AC power cord. A
weather shield is provided to protect the plug when not in use.
Cooling System
The cooling system's function is to maintain an efficient engine operating temperature during all engine speeds
and operating conditions. The cooling system is designed to remove approximately one-third of the heat
produced by the burning of the air-fuel mixture. When the engine is cold, the system cools slowly or not at all.
This allows the engine to warm quickly.
Cooling Cycle
Coolant is drawn from the radiator outlet and into the water pump inlet by the water pump. Coolant will then be
pumped through the water pump outlet and into the engine block. In the engine block, the coolant circulates
through the water jackets surrounding the cylinders, where the radiator absorbs heat.
Some coolant is also pumped from the water pump to the heater core, then back to the water pump. This
provides the passenger compartment with heat and defrost.
The coolant is then forced through the cylinder head gasket openings and into the cylinder heads. In the cylinder
heads, the coolant flows through the water jackets surrounding the combustion chambers and valve seats, where
the radiator absorbs additional heat.
Coolant is also directed to the throttle body, where the coolant circulates through passages in the casting.
During initial start up, the coolant assists in warming the throttle body. During normal operating temperatures,
the coolant assists in keeping the throttle body cool.
From the cylinder heads, the coolant is then forced to the thermostat. The flow of coolant will either be stopped
at the thermostat until the engine is warmed, or the coolant will flow through the thermostat and into the
radiator where the radiator is cooled and the coolant cycle is completed.
Operation of the cooling system requires proper functioning of all cooling system components. The cooling
system consists of the following components:
Coolant
The engine coolant is a solution made up of a 50/50 mixture of DEX-COOL and clean drinkable water. The
coolant solution carries excess heat away from the engine to the radiator, where the heat is dissipated to the
atmosphere.
When the coolant temperature is below 91C (195F), the thermostat valve remains closed. This prevents
circulation of the coolant to the radiator and allows the engine to warm up quickly. After the coolant
temperature reaches 91C (195F), the thermostat valve will open. The coolant is then allowed to circulate
through the thermostat to the radiator where the engine heat is dissipated to the atmosphere. The thermostat also
provides a restriction in the cooling system, even after it has opened. This restriction creates a pressure
difference which prevents cavitation at the water pump and forces coolant to circulate through the engine block.
Radiator
The radiator is a heat exchanger. It consists of a core and two tanks. The aluminum core is a crossflow tube and
fin design. This is a series of tubes that extend side to side from the inlet tank to the outlet tank. Fins are placed
around the outside of the tubes to improve heat transfer from the coolant to the atmosphere. The inlet and outlet
tanks are molded with a high temperature, nylon reinforced plastic. A high temperature rubber gasket seals the
tank flange edge. The tanks are clamped to the core with clinch tabs. The tabs are part of the aluminum header
at each end of the core. The radiator also has a drain cock which is located in the bottom of the left hand tank.
The drain cock includes the drain cock and drain cock seal.
The radiator removes heat from the coolant passing through it. The fins on the core absorb heat from the coolant
passing through the tubes. As air passes between the fins, it absorbs heat and cools the coolant.
During vehicle use, the coolant heats and expands. The coolant that is displaced by this expansion flows into the
surge tank. As the coolant circulates, air is allowed to exit. This is an advantage to the cooling system. Coolant
without bubbles absorbs heat much better than coolant with bubbles.
Pressure Cap
The pressure cap is a cap that seals and pressurizes the cooling system. It contains a blow off or pressure valve
and a vacuum or atmospheric valve. The pressure valve is held against the seat by a spring of predetermined
strength, which protects the radiator by relieving pressure if it exceeds 15 psi. The vacuum valve is held against
the seat by a spring, which permits opening of the valve to relieve vacuum created in the cooling system as the
radiator cools off. The vacuum, if not relieved, might cause the radiator to collapse.
The pressure cap allows pressure in the cooling system to build up. As the pressure builds, the boiling point of
the coolant goes up as well. Therefore, the coolant can be safely run at a temperature much higher than the
boiling point of the coolant at atmospheric pressure. The hotter the coolant is, the faster the heat moves from the
radiator to the cooler, passing air. The pressure in the cooling system can get too high, however. When the
pressure exceeds the strength of the spring, the pressure valve rises so that the excess pressure can escape. As
the engine cools down, the temperature of the coolant drops and a vacuum is created in the cooling system. This
vacuum causes the vacuum valve to open, allowing outside air into the cooling system. This equalizes the
pressure in the cooling system with atmospheric pressure, preventing the radiator from collapsing.
Coolant Recovery System
The coolant recovery system consists of a plastic coolant recovery reservoir and overflow tube The recovery
reservoir is also called a recovery tank or expansion tank. This reservoir is partially filled with coolant and is
connected to the radiator fill neck with the overflow tube. Coolant can flow back and forth between the radiator
and the reservoir.
In effect, a cooling system with a coolant recovery reservoir is a closed system. When the pressure in the
cooling system gets too high, the pressure valve opens in the pressure cap. This allows the coolant, which has
expanded due to being heated, is allowed to flow through the overflow tube and into the recovery reservoir. As
the engine cools down, the temperature of the coolant drops and a vacuum is created in the cooling system. This
vacuum opens the vacuum valve in the pressure cap, allowing some of the coolant in the reservoir to be
siphoned back into the radiator. Under normal operating conditions, coolant is not lost. Although the coolant
level in the recovery reservoir goes up and down, the radiator and cooling system are kept full. An advantage to
using a coolant recovery reservoir is that most of the air bubbles are eliminated from the cooling system.
Coolant without bubbles absorbs heat much better than coolant with bubbles.
Air Baffles and Seals
The cooling system uses deflectors, air baffles and air seals to increase system cooling. Deflectors are installed
under the vehicle to redirect airflow beneath the vehicle to flow through the radiator and increase cooling. Air
baffles are also used to direct airflow into the radiator and increase cooling. Air seals prevent air from bypassing
the radiator and A/C condenser. Air seals also prevent recirculation of the air for better hot weather cooling and
A/C condenser performance.
The transmission oil pump, pumps the fluid through the transmission oil cooler feed line to the oil cooler. The
fluid then flows down through the cooler while the engine coolant absorbs heat from the fluid. The fluid is then
pumped through the transmission oil cooler return line, to the transmission.
Water Pump
The water pump is a centrifugal vane impeller type pump. The pump consists of a housing with coolant inlet
and outlet passages and an impeller. The impeller is a flat plate mounted on the pump shaft with a series of flat
or curved blades or vanes. When the impeller rotates, the coolant between the vanes is thrown outward by
centrifugal force. The impeller shaft is supported by one or more sealed bearings. These sealed bearings never
need to be lubricated. With a sealed bearing, grease cannot leak out, and dirt and water cannot get in.
The purpose of the water pump is to circulate coolant throughout the cooling system. The water pump is driven
by the crankshaft via the drive belt.
Thermostat
The thermostat is a coolant flow control component. It's purpose is to regulate the operating temperature of the
engine. It utilizes a temperature sensitive wax-pellet element. The element connects to a valve through a piston.
When the element is heated, it expands and exerts pressure against a rubber diaphragm. This pressure forces the
valve to open. As the element is cooled, it contracts. This contraction allows a spring to push the valve closed.
Engine Oil Cooler
The engine oil cooler is a heat exchanger. It is located inside the left side end tank of the radiator. The engine oil
temperature is controlled by the temperature of the engine coolant that surrounds the oil cooler in the radiator.
The engine oil pump, pumps the oil through the engine oil cooler line to the oil cooler. The oil then flows
through the cooler where the engine coolant absorbs heat from the oil. The oil is then pumped through the oil
cooler return line, to the oil filter, to the engine block oil system.
Transmission Oil Cooler
The transmission oil cooler is a heat exchanger. It is located inside the right side end tank of the radiator. The
transmission fluid temperature is regulated by the temperature of the engine coolant that surrounds the oil cooler
as the transmission fluid passes down through the cooler.

SPECIAL TOOLS
Special Tools
J 24460-O1
Cooling System Pressure Tester
J 24731
Tempilstick
J 26568
Coolant and Battery Fluid Tester
J 38185
Hose Clamp Pliers
J 39400-A
Halogen Leak Detector
Engine Electrical - Aztek & Rendezvous
SPECIFICATIONS

Specification
Battery Ground (Negative) Cable Nut to Transaxle Stud 25 N.m 18 lb ft
Battery Ground (Negative) Cable to Inner Fender Bolt 5 N.m 44 lb in
Battery Hold-Down Retainer Bolt 25 N.m 18 lb ft
Battery Positive Cable to Underhood Electrical Center Nut 10 N.m 89 lb in
Battery Terminal Bolt 16 N.m 12 lb ft
Battery Tray Bolt 10 N.m 89 lb in
Generator B+ Terminal Nut 13 N.m 115 lb in
Generator Bolt 50 N.m 37 lb ft
Generator Bracket Bolt 50 N.m 37 lb ft
Starter Motor Bolt 47 N.m 35 lb ft
Starter Motor BAT Terminal Nut 10 N.m 89 lb in
Starter Motor S Terminal Nut 3 N.m 27 lb in
BATTERY USAGE
Battery Usage
Cold Cranking Amperage (CCA) 600 A (LA1)
690 A (LY7)
Reserve Capacity 115 Minutes
Replacement Model Number 78A-72
GENERATOR USAGE
Generator Usage
3.4L w/ K68
Generator Model Valeo SG10
Rated Output 105 A
Load Test Output 73 A
3.4L w/ KG7
Generator Model Valeo SG12
Rated Output 125 A
Load Test Output 87 A

STARTING AND CHARGING SCHEMATICS
Fig. 1: Engine Cranking

Fig. 2: Charging Control, Indicator
COMPONENT LOCATOR
ENGINE ELECTRICAL COMPONENT VIEWS
Fig. 3: Lower Front Of Engine Component View (LA1)
Callouts For Fig. 3

1 Crankshaft Position (CKP) Sensor A Connector and Bracket
2 Knock Sensor (KS) Connector
3 Engine Oil Pressure (EOP) Switch Connector
4 Starter Solenoid
5 Starter Motor
6 Fusible Links (Starter)
7 A/C Compressor Clutch Diode
Fig. 4: LH Side of Engine Component View (LA1)
Callouts For Fig. 4

1 Generator
2 Ignition Control Module (ICM)
3 Heated Oxygen Sensor (HO2S) 1
4 Ignition Coils
Fig. 5: Starter Component View
Callouts For Fig. 5

1 To A/C Compressor Clutch
2 Positive Battery Cable
3 Starter Solenoid
4 Starter Solenoid Ground
5 Starter
6 Battery Positive
ENGINE ELECTRICAL CONNECTOR END VIEWS
Generator (LA1)
12186568

A - - Not Used
B RD 225 Generator Turn On Signal
C-D - - Not Used
Generator (LY7)
15355066
4-Way F Metri-Pack 150 Series (BG)

A - - Not Used
B OG 225 Generator Turn On Signal
C GY 23 Generator Field Duty Cycle Signal
D - - Not Used

DIAGNOSTIC STARTING POINT - ENGINE ELECTRICAL


The powertrain control module (PCM) commands the
Engine Output generator OFF by removing the 5-volt reference signal
GEN L-Terminal Controls/ GEN L- from the L terminal of the voltage regulator when you
Terminal select Off. The generator will then stop generating an
output voltage.
Engine Output The engine control module (ECM) grounds the starter relay
Starter Relay Control Controls/Starter Relay control circuit when ON is selected. When Off is selected,
Control ground is removed from the circuit.
SCAN TOOL DATA LIST
Body Control Module (BCM)

Ignition ON/Engine OFF
Electronics Battery Fd Data Volts 12.6 Volts
None/Load 1//Load
Load Shed Inputs None
2/Load 3
Inadvertent Power Relay Outputs On/Off Off
Load Management Relay Outputs On/Off Off
Powertrain Control Module (PCM 3.4L LA1)

Crank Request Signal Engine Data 2 Yes/No No
GEN F-Terminal Signal Engine Data 2 % 0%
GEN L-Terminal Signal Command Engine Data 2 On/Off Off
Ignition 1 Signal Engine Data 1 Volts 12.6 Volts
Fault/OK/Invalid
Starter Enable Relay Circuit Status Output Driver Data State OK
Starter Relay Command Engine Data 2 On/Off Off
Engine Control Module (ECM 3.6L LY7)

Crank Request Signal Electrical/Theft Data Yes/No No
GEN F-Terminal Signal Electrical/Theft Data % 0%
GEN L-Terminal Signal Command Electrical/Theft Data On/Off Off
Ignition 1 Signal Electrical/Theft Data Volts 12.6 Volts
Starter Relay Command Electrical/Theft Data On/Off Off
Crank Request Signal
The scan tool displays Yes/No. The scan tool displays No until the ignition is placed into the START
position then Yes is displayed.
Electronics Battery FD
The scan tool displays 0-20 Volts. The scan tool displays the voltage as received on the battery positive
voltage E circuit of the BCM.
GEN F-Terminal Signal
The scan tool displays 0%-100%. The scan tool displays 0%-10% until the engine is started and the PCM
receives a signal from the generator then OK is displayed.
GEN L-Terminal Signal Command
The scan tool displays On/Off. The scan tool displays Off until the engine is running, then the PCM
supplies then the percentage value varies depending on electrical loads
Ignition 1 Signal
The scan tool displays 0-20 Volts. The scan tool displays the voltage as received on the Ignition 1 circuit
to the PCM.
Inadvertent Power Relay
The scan tool displays On/Off. The scan tool displays On when the key is in the ACCY. or ON position.
Load Management Relay
The scan tool displays On/Off. The scan tool displays On unless the BCM has entered Load Management
or Idle Boost.
Load Shed
The scan tool displays None/Load 1/Load 2/Load 3. The scan tool displays None unless Load
management has been entered.
Starter Enable Relay Circuit Status
The scan tool displays Fault/OK/Invalid State. The scan tool displays Fault until the ignition is placed
into the START position then OK is displayed.
Starter Relay Command
The scan tool displays ON/OFF. The scan tool displays Off until the ignition is placed into the CRANK
position, then it reads On.
DTC B1327
Circuit Description
The body control module (BCM) monitors the battery positive voltage and battery negative circuit voltage to
determine if it is between 9-15 volts and sends this information out as a class 2 message to the vehicle theft
deterrent (VTD).
DTC Descriptor
DTC B1327 Device Power Circuit Low
This DTC shall run only if the BCM has power, ground, and the ignition is not in START mode.
This DTC shall be set as current when the voltage falls below 9 volts for 1.2 milliseconds.

A message shall be sent out on the class 2 lines to illuminate the charge indicator and security lamp.
In order to clear the DTC from a current status, the voltage shall be greater than 9.54 volts for 1,200
milliseconds.
Test Description
3: This step tests for the proper operation of the complete circuit.
4: This step tests for the proper operation of the signal input circuit.
DTC B1327
Schematic Reference: Theft Deterrent System Schematics in Theft Deterrent
Connector End View Reference: Computer/Integrating Systems Connector End Views in
Computer/Integrating Systems
Vehicle? Diagnostic
System Check -
1 -
Vehicle in
Vehicle DTC
OFF.
3. With a scan tool, observe the Electronic
2 Battery FD in the body control module 9V
(BCM) data list.
Does the scan tool indicate the battery voltage is Go to Charging

greater than the specified value? Go to Step 3 System Test
Replace the vehicle theft deterrent (VTD). Refer
to Theft Deterrent Control Module
3 -
Replacement in Theft Deterrent.

4 DTCs. -
for Running the DTC as specified in the
supporting text.
DTC B1328
Circuit Description
The body control module (BCM) has an internal voltage sensor with a dedicated circuit that monitors the
battery positive voltage circuit to determine if it is below 18 volts.
DTC Descriptor
DTC B1328 Device Power Circuit High
This DTC shall run only if no communication codes are set.
The ignition positive voltage level is greater than 18 volts for approximately 1/2 second or more.
The BCM sets a DTC and disables the following state of health (SOH) DTCs:
DTC U1096
DTC U1255
DTC U1300
DTC U1301
The BCM illuminates the charge lamp indicator.
The battery positive voltage level is less than 17.9 volts for approximately 1/2 second.
A history DTC clears after 100 malfunction free ignition cycles.
The BCM receives the clear code command from the scan tool.
Diagnostic Aids
This DTC may set when the vehicle is placed on a battery charger, on fast charge, for a long period of time.
DTC B1328
System Check
1 -
- Vehicle in
Vehicle DTC
3. With a scan tool, observe the
Electronics Battery Fd parameter in
2 the body control module (BCM) 18 V
data list.
Does the scan tool indicate the battery

voltage is greater than the specified
Measure the voltage across the battery
terminals. Go to
3 18 V
Is the battery voltage greater than the Charging
specified value? System Test Go to Step 4
Replace the BCM. Refer to Control
Module References in
4 Computer/Integrating Systems for -
1. Use the scan tool in order to clear
the DTCs.
2. Operate the vehicle within the
5 Conditions for Running the DTC as
specified in the supporting text.
System
Does the DTC reset? Go to Step 2 OK
DTC P0560
Circuit Description
The powertrain control module (PCM) monitors the system voltage to make sure that the voltage stays within
the proper range. Damage to components, and incorrect data input can occur when the voltage is out of range.
The PCM monitors the system voltage over an extended length of time. If the PCM detects a system voltage
outside an expected range for the calibrated length of time, DTC P0560 will set.
DTC Descriptor
DTC P0560 System Voltage
System voltage below 9 volts or above 16 volts

Engine speed above 650 RPM
Vehicle speed below 40 km/h (25 mph)
The PCM detects a system voltage out of range for 30 seconds.
The PCM will not illuminate the malfunction indicator lamp (MIL).
The PCM will command a message to be displayed.
The PCM will store conditions which were present when the DTC set as Failure Records data only.
The PCM will command the message OFF after one trip in which the diagnostic test has been run and
passed.
DTC P0560
Step Action Value Yes No
Schematic Reference: Engine Controls Schematics in Engine Controls - 3.4L
Connector End View Reference: Engine Controls Connector End Views in Engine Controls - 3.4L
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC

2 supporting text. -
Go to Testing
3. Using the scan tool, observe the Specific for
DTC Information for DTC P0560 until the Intermittent
test runs. Conditions and
Does the scan tool indicate that DTC P0560 has Poor
passed this ignition cycle? Connections in
OFF.
3. With a scan tool, observe the Ignition 1
3 Signal parameter in the powertrain control 9-16 V
module (PCM) data list.
Does the scan tool indicate that the Ignition 1

Signal parameter is within the specified range? Go to Step 7 Go to Step 4
Using a scan tool, compare the battery voltage
with the Ignition 1 Signal parameter in the PCM
data list.
4 0.5 V
Is the battery voltage and PCM Ignition 1
readings different by more than the value Go to Charging
specified? Go to Step 5 System Test
Test the battery positive voltage circuit of the
PCM for a high resistance or open. Refer to
Systems.
6 -
Systems.
7 -
1. Review and record the scan tool Failure
Records data.
DTC.
supporting text.
4. Using the scan tool, observe the Specific
DTC Information for DTC P0560 until the
test runs.
Does the scan tool indicate that DTC P0560
failed this ignition? Go to Step 3 System OK
DTC P0562
Circuit Description
The engine control module (ECM) checks the system voltage to make sure that the voltage stays within the
proper range. Damage to components, and incorrect input can occur when the voltage is out of range. The ECM
monitors the system voltage over an extended length of time. If the ECM detects an excessively low system
voltage, DTC P0562 will set.
DTC Descriptor
DTC P0562 System Voltage Low
Engine speed above 1500 RPM.

System voltage between 9.5-18 volts.
The ECM detects a system voltage below 10 volts for 5 seconds.
The ECM will command a message to be displayed.

The ECM will not illuminate the malfunction indicator lamp (MIL).
The ECM will store conditions which were present when the DTC set as Fail Records data only.
The ECM will command the message OFF after one trip in which the diagnostic test has been run and
passed.
DTC P0562
Schematic Reference: Engine Controls Schematics in Engine Controls - 3.6L (LY7)
Connector End View Reference: Engine Control Module (ECM) Connector End Views in Engine
Controls - 3.6L (LY7)
Go to
Diagnostic
Did you perform the Diagnostic System Check - System Check
1 -
Vehicle ? - Vehicle in
Vehicle DTC
3. Raise the engine speed above 1500 RPM.
2 Signal parameter in the engine control 10.5 V
module (ECM) data list.

Signal parameter is greater than the specified
Using a scan tool compare the Battery Voltage
Signal parameter in the body control module
(BCM) data list with the Ignition 1 Signal
3 parameter in the ECM data list. 0.5 V
Is the Battery Voltage and Ignition 1 Signal
parameter readings different by more than the Go to Charging
value specified? Go to Step 4 System Test
ECM for a high resistance. Refer to Circuit
4 -
connector of the ECM. Refer to Testing for
andConnector Repairs in Wiring Systems.
6 -
1. Review and record the scan tool Fail
Records data.
7 -
supporting text.
test runs.

DTC P0563
Circuit Description
The engine control module (ECM) checks the system voltage to make sure that the voltage stays within the
proper range. Damage to components, and incorrect input can occur when the voltage is out of range. The ECM
monitors the system voltage over an extended length of time. If the ECM detects an excessively high system
voltage, DTC P0563 will set.
DTC Descriptor
DTC P0563 System Voltage High
Engine speed above 1,500 RPM

System voltage between 9.5-18 volts
The ECM detects a system voltage above 16 volts for less than 1 second.
The ECM will command a message to be displayed.

The ECM will store conditions which were present when the DTC set as Failure Records data only.
The ECM will command the message OFF after one trip in which the diagnostic test has been run and
passed.
DTC P0563
Go to
Diagnostic
Did you perform the Diagnostic System Check - System Check
1 -
Vehicle ? - Vehicle in
Vehicle DTC
3. Raise the engine speed above 1,500 RPM.
2 16 V
Signal parameter in the engine control
module (ECM) data list.

Signal parameter is less than the specified value? Go to Step 4 Go to Step 3
Using a scan tool, compare the Battery Voltage
parameter in the body control module (BCM)
data list with the Ignition 1 Signal parameter in
3 the engine control module (ECM) data list. 0.8 V
Is the Battery Voltage and Ignition 1 Signal
parameter readings different by more than the Go to Charging
value specified? Go to Step 4 System Test
4 -
Records data.
5 supporting text. -
test runs.

DTC P0615
Circuit Description
The engine control module (ECM) supplies a ground path for the STARTER relay when start enable has been
requested. The ECM monitors this circuit for conditions that are incorrect for the commanded state. If the ECM
detects an improper circuit condition, STARTER relay DTC P0615 will set.
DTC Descriptor
DTC P0615 Starter Relay Control Circuit
The ECM detects an improper voltage level on the output circuit that controls the starter relay.
The condition exists for at least 2 seconds.
The ECM will store the conditions present when the DTC set as Fail Records data only.
Diagnostic Aids
Ignition system DTCs set with the ignition switch in the Crank position if the starter relay or the starter is
inoperative. When the ECM enables starter operation, the ECM also initiates the diagnostic test routines for
DTCs P0335, P0340, and P0385. If a condition exists which prevents the engine from cranking, the ECM will
not receive signal input from the crankshaft position (CKP) and camshaft position (CMP) sensors, and the
DTCs will set.
Reviewing the Fail Records vehicle mileage since the diagnostic test last failed may assist in diagnosing the
condition. The information may help determine how often the condition that set the DTC occurs.
Test Description
2: Listen for an audible click when the starter relay operates. Press the ignition switch back and forth
from the ON to Crank positions. Repeat this as necessary.
3: Tests for voltage at the coil side of the starter relay. The ECM IGN fuse supplies power to the coil side
of the starter relay.
4: Verifies that the ECM is providing ground to the starter relay.
5: Tests if ground is constantly being applied to the starter relay.
DTC P0615
Step Action Yes No
Schematic Reference: Starting and Charging Schematics
Go to Diagnostic
1
Vehicle ? Vehicle in Vehicle
2 3. Press the ignition back and forth from the ON to Intermittent
Crank positions. Conditions and
Poor Connections
Does the starter relay click with each command? in Wiring Systems Go to Step 3
2. Disconnect the starter relay.
3 4. Connect a test lamp between the battery positive
voltage of the starter relay coil circuit and a good
ground.

voltage of the starter relay coil circuit and the
control circuit of the starter relay.
4 2. Turn the ignition back and forth from the ON to
Crank positions.

Test the control circuit of the starter relay for a short to
voltage or an open. Refer to Circuit Testing and
5
Inspect for poor connections at the starter relay. Refer
6 Systems.
Inspect for poor connections at the engine control
Repair the battery positive voltage circuit of the starter
8 relay. Refer to Connector Repairs in Wiring Systems.
Replace the starter relay.
9
Did you complete the replacement. Go to Step 11 -
10
1. Review and record scan tool Fail Records data.
2. Clear DTCs.
3. Operate vehicle within Fail Records conditions
as noted.
11
4. Using a scan tool, monitor the Specific DTC
Information for DTC P0615.
Does the scan tool indicate DTC P0615 failed this

ignition? Go to Step 2 System OK
DTC P0616
Circuit Description
The engine control module (ECM) supplies a ground path for the starter relay when start enable has been
detects an improper circuit condition, starter relay DTC P0616 will set.
DTC Descriptor
DTC P0616 Starter Relay Control Circuit Low Voltage

DTC P0616
Step Action Yes No
Go to Diagnostic
1
Vehicle ? Vehicle in Vehicle
running the DTC.
2 3. Using the scan tool, observe the specific DTC Go to Testing for
information for DTC P0616 until the test runs. Intermittent
Conditions and
Does the scan tool indicate that DTC P0616 has passed Poor Connections
this ignition cycle? in Wiring Systems Go to Step 3
Test the control circuit of the starter relay for a short to
ground. Refer to Circuit Testing and Wiring Repairs
3
in Wiring Systems.
5
1. Review and record the scan tool Fail Records
data.
6 text.
4. Using the scan tool, observe the Specific DTC
Information for DTC P0616 until the test runs.
Does the scan tool indicate that DTC P0616 failed this
DTC P0617
Circuit Description
The engine control module (ECM) supplies a ground path for the starter relay when start enable has been
detects an improper circuit condition, starter relay DTC P0617 will set.
DTC Descriptor
DTC P0617 Starter Relay Control Circuit High Voltage

DTC P0617
Step Action Yes No
Go to Diagnostic
1
running the DTC.
2 3. Using the scan tool, observe the specific DTC Go to Testing for
information for DTC P0617 until the test runs. Intermittent
Conditions and
Does the scan tool indicate that DTC P0617 has passed Poor Connections
this ignition cycle? in Wiring Systems Go to Step 3
Test the control circuit of the Starter relay for a short to
battery. Refer to Circuit Testing and Wiring Repairs
3
in Wiring Systems.
5
1. Review and record the scan tool Fail Records
data.
6 running the DTC.
4. Using the scan tool, observe the specific DTC
information for DTC P0617 until the test runs.
Does the scan tool indicate that DTC P0617 failed this
DTC P0620
Circuit Description
The powertrain control module (PCM) uses the generator turn on signal circuit to control the generator. A high
side driver within the PCM allows the PCM to turn the generator ON and OFF. When generator operation is
desired, the PCM sends a 5-volt signal to the voltage regulator via the generator turn on signal circuit. This
causes the voltage regulator to begin controlling the generator field circuit. Once the Generator is enabled by the
PCM, the voltage regulator controls generator output independently of the PCM. Under certain operating
conditions, the PCM can turn OFF the generator by turning OFF the 5-volt signal on the generator turn on
signal circuit. The PCM has fault detection circuitry which monitors the state of the generator turn on signal
circuit. If the fault detection circuit senses a voltage other than what is expected, this DTC will set. The voltage
regulator also contains fault detection circuitry. If the regulator detects a problem, the regulator will ground the
generator turn on signal circuit, pulling the voltage low. This also causes the PCM to set the DTC.
DTC Descriptor
DTC P0620 Generator Performance
The generator turn on signal circuit voltage is low while the PCM is commanding the generator ON.
The above condition is present for more than 30 seconds.
OR
The engine RPM is less than 2,500.

The above conditions are present for more than 30 seconds.
The PCM stores the DTC information into memory when the diagnostic runs and fails.
The PCM records the operating conditions at the time the diagnostic fails. The PCM stores this
The PCM sends a class 2 message to the instrument panel cluster (IPC) to illuminate the charge indicator.
A History DTC will clear after forty consecutive warm-up cycles, if no failures are reported by this or any
other non-emission related diagnostic.
The current DTC will clear when the diagnostic runs and does not fail.
Use a scan tool in order to clear the MIL diagnostic trouble code.
DTC P0620
Step Action Yes No
Connector End View Reference: Engine Electrical Connector End Views or Engine Controls
Connector End Views in Engine Controls - 3.4L
System Check -
1
Vehicle in Vehicle
2 3. With a scan tool, monitor the DTC Information for Intermittent
DTC P0620 in Engine Controls. Conditions and
Poor Connections
Does the scan tool indicate that DTC P0620 has passed? in Wiring Systems Go to Step 3
Test the generator turn on signal circuit for a short to
ground. Refer to Circuit Testing and Wiring Repairs in
3
Wiring Systems.
the powertrain control module (PCM). Refer to
4
Replace the PCM. Refer to Control Module References
in Computer/Integrating Systems for replacement, setup,
5
and programming.
Is the action complete? Go to Step 6 Go to Step 6
1. Review and record the scan tool Fail Records data.
2. Clear any DTCs.
3. Operate the vehicle within the Fail Records
conditions as noted.
6
4. Using a scan tool, monitor the Specific DTC info
for this DTC.
Does the scan tool indicate that this DTC failed this
DTC P0625
Circuit Description
The engine control module (ECM) uses the generator field duty cycle signal circuit to monitor the duty cycle of
the generator and fault indication. The generator field duty cycle signal circuit connects to the high side of the
field winding in the generator. A pulse width modulated (PWM) high side driver in the voltage regulator turns
the field winding ON and OFF. The ECM uses the PWM signal input to determine the generator load on the
engine. This allows the ECM to adjust the idle speed to compensate for high electrical loads.
The ECM monitors the state of the generator field duty cycle signal circuit. When the engine is running, the
ECM should detect a duty cycle that varies up to 100 percent. The ECM monitors the PWM signal using a key
ON test and a RUN test. During the tests, if the ECM detects an out of range PWM signal, a DTC will set.
When the DTC sets, the ECM will send a class 2 serial data message to the instrument panel cluster (IPC) and
driver information center (DIC) to illuminate the charge indicator or display a charging message.
DTC Descriptor
DTC P0625 Generator F-Terminal Circuit Low Voltage
No generator, crankshaft position (CKP) sensors, or camshaft position (CMP) sensor DTCs are set.
The engine is less than 3,000 RPM.
The generator has not been commanded OFF by the ECM or scan tool.
The ECM detects a PWM signal less than 5 percent for at least 15 seconds.
The ECM will store the conditions present when the DTC set as Failure Records data only.
The ECM will send a class 2 serial data message to the IPC and DIC to illuminate the charge indicator or
display a charging message.
The conditions for setting DTC P0625 are not present.

DTC P0625
Go to
1 Vehicle? - Diagnostic
System Check
- Vehicle in
Vehicle DTC
3. With a scan tool, observe the GEN-F Go to Testing
Terminal Signal parameter in the engine for
2 control module (ECM) data list. 5-100%
Intermittent
Conditions and
Does the scan tool indicate that the GEN-F Poor
Terminal parameter is within the specified Connections in
range? Wiring Systems Go to Step 3
2. Disconnect the generator harness
connector.
OFF.
4. Connect a test lamp to battery positive
3 voltage and repeatedly probe the generator -
field duty cycle signal circuit in the
harness connector while monitoring the
GEN-F Terminal Signal parameter on the
scan tool.
Is the GEN-F Terminal Signal parameter

affected? Go to Step 5 Go to Step 4
Test the generator field duty cycle signal circuit
for a short to ground or open. Refer to Circuit
Systems.
Test the battery positive voltage cable for an
open or high resistance. Refer to Circuit
Systems.
connector of the generator. Refer to Connector
6 -
Repairs in Wiring Systems. Go to Charging
Did you find and correct the condition? Go to Step 9 System Test
connector of the ECM. Refer to Connector
7 -
8 -
Records data.
DTC.
9 for running DTC P0625. -
4. Using the scan tool, observe the specific
DTC information for DTC P0625 until the
test runs.

failed? Go to Step 2 System OK
DTC P0626
Circuit Description
The engine control module (ECM) uses the generator field duty cycle signal circuit to monitor the duty cycle of
the generator and fault indication. The generator field duty cycle signal circuit connects to the high side of the
field winding in the generator. A pulse width modulated (PWM) high side driver in the voltage regulator turns
the field winding ON and OFF. The ECM uses the PWM signal input to determine the generator load on the
engine. This allows the ECM to adjust the idle speed to compensate for high electrical loads.
The ECM monitors the state of the generator field duty cycle signal circuit. When the key in the ON position,
with the engine OFF, the ECM should detect a duty cycle that is 0 percent.
The ECM monitors the PWM signal using a key ON test and a RUN test. During the tests, if the ECM detects
an out of range PWM signal, a DTC will set.
DTC Descriptor
This Diagnostic procedure supports the following DTC:
DTC P0626 Generator F- Terminal Circuit High Voltage
No generator, crankshaft position (CKP) sensors, or camshaft position (CMP) sensor DTCs are set.
The engine is not running.
The key is in the ON position.
The ECM detects a PWM signal greater than 5 percent for at least 15 seconds.
The ECM will store the conditions present when the DTC set as Failure Records data only.
The ECM will send a class 2 serial data message to the instrument panel cluster (IPC) and driver
information center (DIC) to illuminate the charge indicator or display a charging message.
The conditions for setting DTC P0626 are not present.

DTC P0626
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
OFF
3. With a scan tool, observe the GEN-F Go to Testing
2 Terminal Signal parameter in the engine 0-5% for
control module (ECM) data list. Intermittent
Conditions and
Does the scan tool indicate that the GEN-F Poor
Terminal parameter is within the specified Connections in
range? Wiring Systems Go to Step 3
connector.
3 3. Turn ON the ignition, with the engine -
OFF.
4. Connect a test lamp to battery positive
voltage and repeatedly probe the generator
field duty cycle signal circuit in the
harness connector while monitoring the
GEN-F Terminal Signal parameter on the
scan tool.
Is the GEN-F Terminal Signal parameter

affected? Go to Step 5 Go to Step 4
Test the generator field duty cycle signal circuit
for a short to battery voltage. Refer to Circuit
Systems.
5 -
Repairs in Wiring Systems. Go to Charging
Did you find and correct the condition? Go to Step 8 System Test
connector of the ECM. Refer to Connector
6 -
7 -
Records data.
DTC.
8 for Running the DTC. -
4. Using the scan tool, observe the specific
DTC information for DTC P0626 until the
test runs.

failed? Go to Step 2 System OK
DTC P1668
Circuit Description
The engine control module (ECM) uses the generator turn-on signal circuit to control the voltage output of the
generator. When a different voltage is desired, the ECM will change the pulse width modulation (PWM) signal
to the voltage regulator via the generator turn-on signal circuit. This causes the voltage regulator to the voltage
output of the generator. The ECM has fault detection circuitry which monitors the state of the generator turn-on
signal circuit. If the fault detection circuit senses a voltage other than what is expected, this DTC will set. The
voltage regulator also contains fault detection circuitry. If the regulator detects a problem, the regulator will
ground the generator turn-on signal circuit, pulling the voltage low. This also causes the ECM to set the DTC.
DTC Descriptor
DTC P1668 Generator L-Terminal Control Circuit
Key ON Test
The key is in the ON position for 5 seconds.

The engine is OFF.
Engine Run Test

The engine speed is less than 3000 RPM.
Key ON Test
The ECM detects a high signal voltage on the generator turn on signal circuit for at least 5 seconds.
The engine must be started.
During the RUN test, the ECM detects a low signal voltage on the generator turn on signal circuit for at least 5
seconds.
The ECM sends a class 2 message to the instrument panel cluster (IPC) to illuminate the charge indicator
and/or turn on a message.
DTC P1668
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
OFF.
3. Wait 5 seconds.
4. Start the engine. Go to Testing
2 -
5. With a scan tool, monitor the DTC for
information for DTC P1668 in Engine Intermittent
Controls. Conditions and
Poor
Does the scan tool indicate that DTC P1668 has Connections in
passed? Wiring Systems Go to Step 3
1. Turn OFF the engine.
connector.
3 4. With a DMM measure the pulse width 15-87%
modulation (PWM) signal between the
generator turn on signal circuit and
ground.
Is the PWM signal within the specified value? Go to Step 5 Go to Step 4

Test the generator turn on signal circuit for a
short or open. Refer to Circuit Testing and
4 -
Test the generator battery positive voltage output
circuit for a high resistance or open. Refer to
Systems.
6 -
connector of the engine control module (ECM).
7 -
in Wiring Systems.
Replace the generator. Refer to Generator
Replacement (LA1) or Generator
8 -
Replacement (LY7).
9 -
DTCs.
supporting text.
SYMPTOMS - ENGINE ELECTRICAL
Perform the Diagnostic System Check - Vehicle in Vehicle DTC information before using the Symptom
Review the system descriptions and operations in order to familiarize yourself with the system functions.
Refer to one of the following system operations:
Battery Description and Operation
Starting System Description and Operation
Charging System Description and Operation
Inspect for aftermarket devices which could affect the operation of the starting and charging systems.
Refer to Checking Aftermarket Accessories in Wiring Systems.
cause the symptom.
Intermittent
Symptom List
Battery Inspection/Test
Battery Electrical Drain/Parasitic Load Test
Battery Common Causes of Failure
Charging System Test
Charge Indicator Always On
Charge Indicator Inoperative
Generator Noise Diagnosis
Starter Solenoid Does Not Click
Starter Solenoid Clicks, Engine Does Not Crank
Engine Cranks Slowly
Starter Motor Noise Diagnosis
BATTERY INSPECTION/TEST
Tools Required
J 42000 Battery Tester. See Special Tools.
Diagnostic Aids
CAUTION: Refer to Battery Disconnect Caution in Cautions and Notices.
IMPORTANT: The battery test using the J 42000 requires correct connections to the battery
terminals. See Special Tools. A failure to obtain the correct connections during
the test may result in a failed test on a good battery.
Follow these instructions in order to avoid an incorrect diagnosis because of connections:
If testing the vehicle with the battery cables still connected, wiggle the J 42000 clips on the terminal bolt.
See Special Tools. This may cut through any coating or through any oxidation that may be present on the
bolt.
Even new bolts contain a protective coating that may insulate or cause a resistance in the test circuit.
If correct connections to the battery terminal bolts in the vehicle are in doubt, perform the following
steps:
Disconnect the negative battery cable.
Disconnect the positive battery cable.
Install the test adapters on the terminals.
Follow the instructions for an Out-of-Vehicle test.
If the tester displays a REPLACE BATTERY or BAD CELL-REPLACE result for a battery tested in the
vehicle with the battery cables connected, perform the following steps:
Disconnect the negative battery cable.
Disconnect the positive battery cable.
Install the tester adapters.
Follow the instructions for an Out-of-Vehicle test.
Replace the battery only if the Out-of-Vehicle test shows a REPLACE BATTERY or BAD CELL-
REPLACE result. This prevents battery replacements that are due only to faulty battery cable
connections.
Use the correct terminal adapters.
Do not use any common bolts or a combination of bolts, nuts, and or washers as adapters when testing the
battery.
Use the test adapters that are provided with the J 42000 or P/N 12303040 terminal adapters. See Special
Tools. If the adapters that are provided with the J 42000 require replacement, use P/N 12303040. See
Special Tools. Any other adapter may not contact the correct areas of the battery terminal, causing a
resistance that may result in an invalid battery test result.
Battery Inspection/Test
CAUTION:
Refer to Battery Disconnect Caution in Cautions and Notices.
IMPORTANT:
Always write the test code displayed by the tester on the repair order for any warranty
purposes. The number is a unique code that describes the test data for a particular battery at
a particular time. The test code may occasionally repeat when you retest the same battery.
More often, each test will result in a different code. If the battery is replaced due to failing the
test, only an Out-of-Vehicle test code is valid for warranty purposes.
Inspect the battery for a cracked, broken, or
damaged case, which may be indicated by
1 -
battery acid leakage.
Is the battery OK? Go to Step 2 Go to Step 15
Compare the cold cranking amperage (CCA)
and reserve capacity (RC) of the battery to the
original battery or original equipment (OE)
specification. Refer to Battery Usage.
2 Does the battery meet or exceed the -
specifications? Go to Step 3 Go to Step 15
2. Attempt to rotate the negative battery
3 cable connector clockwise with light -
finger pressure.
Does the negative connector rotate? Go to Step 4 Go to Step 5

Use a torque wrench in order to verify the
torque to loosen the negative battery terminal 10 N.m (88
4
bolt. lb in)
Is the torque above the specified value? Go to Step 9 Go to Step 8
Attempt to rotate the positive battery cable
connector clockwise with light finger
5 -
pressure.
Does the positive connector rotate? Go to Step 7 Go to Step 6
IMPORTANT:
Ensure that all of the electrical loads are
turned OFF.
1. Install the J 42000 Battery Tester. See

Special Tools.
2. Follow the directions supplied with the
6 -
tester for an In-Vehicle test.
3. Follow any directions displayed on the
tester.
4. If the tester calls for charging the
battery, refer to Battery Charging.
Did the tester pass the battery? Go to Step 14 Go to Step 8

Use a torque wrench in order to verify the
torque to loosen the positive battery terminal 10 N.m (88
7
bolt. lb in)
Is the torque above the specified value? Go to Step 10 Go to Step 8

2. Disconnect the positive battery cable.
3. Clean and wire brush the lead face of
8 both battery terminals and the metal -
contact rings in both cable connectors.
4. Remove the bolts from the cable
connectors in order to provide access to
the connector rings as needed.
5. If either of the battery terminals or the
cable rings are excessively damaged or
corroded, replace as needed.

2. Inspect for the following conditions and
repair as needed:
The cable bolt is too long or
deformed at the end.
9 There is foreign material present
inside the nut in the battery
terminal
Damage to the battery terminal
face or cable connector ring

1. Disconnect the positive battery cable.
2. Inspect for the following conditions and
repair as needed:
The cable bolt is too long or
deformed at the end
10 There is foreign material present -
inside the nut in the battery
terminal
Damage to the battery terminal
face or cable connector ring
IMPORTANT:
Ensure that both battery cables are
disconnected and proper adapters are
installed in the battery terminals.
11 1. Install the J 42000 . See Special Tools. -

2. Follow the directions supplied with the
tester for an Out-of-Vehicle test.
3. Follow any directions displayed on the
tester.
4. If the tester calls for charging the
battery, refer to Battery Charging.
Did the tester pass the battery? Go to Step 12 Go to Step 15
1. Press the CODE button on the J 42000 .
See Special Tools.
12 2. For warranty purposes, write the
displayed code on the repair order.
Did you complete this action? Go to Step 13 -

1. Connect the positive battery cable to the
battery's positive terminal.
NOTE:
Refer to Fastener Notice in Cautions
and Notices.
15 N.m (11
13 2. Tighten the positive battery cable bolt to
lb ft)
the specified value.
3. Connect the negative battery cable to
the battery negative terminal.
4. Tighten the negative battery cable bolt
to the specified value.
Are the cable bolts properly tightened? Battery OK -

1. Press the CODE button on the J 42000 .
See Special Tools.
14 2. For warranty purposes, write the
displayed code on the repair order.
Did you complete the replacement? Battery OK -

Replace the battery. Refer to Battery
15 Replacement. -
Did you complete the replacement? Battery OK -
BATTERY CHARGING
Tools Required
J 42000 Battery Tester. See Special Tools.
For best results, use an automatic taper-rate battery charger with a voltage capability of 16 volts.
The charging area should be well ventilated.
Do not charge a battery that appears to be frozen. Allow the battery to warm to room temperature and test
it using the J 42000 before charging. See Special Tools.
Battery State of Charge
IMPORTANT: Using voltage to determine the batteries state of charge (SOC) is only accurate
after the battery has been at rest for 24 hours. This is enough time for the acid
in each cell to equalize. If the battery has been charged or discharged in the
past 24 hours, the battery SOC will only be an estimate.
The maintenance-free batteries SOC is estimated by reading the voltage of the battery across the battery
terminals. Because the voltage is affected by current flow into or out of the battery, the engine must be stopped
and all electrical loads turned OFF, including parasitic loads, when checking the voltage. The voltage can also
be affected if the battery has just been charged or discharged, so it is important to consider what has happened
to the battery in the time just before testing. Use the following procedure to determine the batteries SOC:
1. Be sure all electrical loads are turned OFF.

2. Determine whether the battery has been used in a vehicle or charged within the past 12 hours.
If the answer is no, the terminal voltage will be stabilized and no action is necessary before reading
the voltage. Skip to step 3.
If the answer is yes, terminal voltage will not be stabilized and you should wait 12 hours since the
last time the battery was used.
3. Estimate the battery temperature by determining the average temperature to which the battery has been
exposed for the past 12 hours.
IMPORTANT: The table is accurate to 10 percent only after the battery has been at rest
for 12 hours.
4. Measure the battery voltage at the battery terminals. Refer to the following table to determine the SOC
according to the estimated battery temperature:
Battery Charging
Battery Voltage % Charge at 0C (32F) % Charge at 25C (75F)
12.75 V 100% 100%
12.7 V 100% 90%
12.6 V 90% 75%
12.45 V 75% 65%
12.2 V 65% 45%
12.0 V 40% 20%
Use the SOC information as follows:
A battery with a SOC that is below 65 percent must always be recharged before returning it to service or
continuing storage.
A battery with a SOC that is 65 percent or greater is generally considered to be charged enough in order
to be returned to normal service or in order to continue storage. However, if the battery is being used in
slow traffic or with short drive times, or if the temperature is very hot or very cold, the battery should be
fully charged, to at least 90 percent, before returning it to service or continuing storage.
Charging Time Required
The time required to charge a battery will vary depending upon the following factors:
The battery charger capacity - The higher the charger amperage, the less time it will take to charge the
battery.
The SOC of the battery - A completely discharged battery requires more than twice as much charging
time as a half charged battery. In a discharged battery with a voltage below 11 volts, the battery has a
very high internal resistance and may only accept a very low current at first. Later, as the charging current
causes the acid content to increase in the electrolyte, the charging current will increase. Extremely
discharged batteries may not activate the reversed voltage protection in some chargers. Refer to the
manufacturer's instructions for operating this circuitry.
The temperature of the battery - The colder the battery is, the more time it takes to recharge the battery.
The charging current accepted by a cold battery is very low at first. As the battery warms, the charging
current will increase.
Charging Procedure
NOTE: Turn OFF the ignition when connecting or disconnecting the battery cables, the
battery charger or the jumper cables. Failure to do so may damage the PCM or
other electronic components.
When charging side-terminal batteries with the battery cables connected, connect the charger to the positive
cable bolt and to a ground located away from the battery. When charging side-terminal batteries with the battery
cables disconnected, install the battery side terminal adapters and connect the charger to the adapters.
Tighten: Tighten the battery side terminal adapters to 15 N.m (11 lb ft).
Use the following procedure to charge the battery:
1. Turn OFF the charger.

2. Ensure that all of the battery terminal connections are clean and tight.
3. Connect the charger positive lead to the battery positive terminal on the battery or the remote jumper stud
underhood.
NOTE: Do not connect the negative charger lead to the housings of other vehicle
electrical accessories or equipment. The action of the battery charger may
damage such equipment.
4. Connect the negative charger lead to a solid engine ground or to a ground stud in the engine compartment
that is connected directly to the battery negative terminal, but away from the battery. If the negative
battery cable is disconnected and a terminal adapter is being used, connect directly to the adapter.
5. Turn ON the charger and set to the highest setting for normal charging.
6. Inspect the battery every half hour after starting the battery charger.
Charge the battery until the taper-rate charger indicates that the battery is fully charged.
Estimate the battery temperature by feeling the side of the battery. If it feels hot to the touch or its
temperature is over 45C (125F), discontinue charging and allow the battery to cool before
resuming charging.
7. After charging, test the battery. Refer to Battery Inspection/Test.
BATTERY ELECTRICAL DRAIN/PARASITIC LOAD TEST
Tools Required
J 38758 Parasitic Draw Test Switch. See Special Tools.
Diagnostic Aids
Be sure to rule out any possible obvious influences, such as customer error or aftermarket equipment.
Customer driving habits, such as regular short trips. This does not allow enough time to properly charge
the battery. Refer to Battery Description and Operation.
Verify that the battery and charging system are in proper working order. Refer to Battery Charging and
Charging System Test.
A battery discharging for no apparent reason while the vehicle is parked can be caused by an intermittent
draw, such as a module waking up, or a continuous draw, such as a dome light or stuck relay.
Some systems and modules such as OnStar, and regulated voltage control (RVC), if equipped, are
designed to wake-up, perform a task, and go back asleep at regular intervals. Refer to Body Control
System Description and Operation in Computer/Integrating Systems for the system or modules
description and operation.
Remote keyless entry (RKE) will wake up due to an outside input. Refer to Keyless Entry System
Description and Operation in Keyless Entry.
IMPORTANT: The battery specification listed below is a generic specification. Refer to

Battery Usage when testing the battery.
The battery run down time will vary depending on cold cranking amperage (CCA) and reserve capacity
(RC). If the CCA and RC are higher, then the battery run down time would be longer. If the CCA and RC
are lower, then the battery run down time would be shorter. The graph below indicates roughly how many
days a 690 CCA battery with at 110 min. RC (60.5 AH) starting at 80 percent state of charge will last
with a constant current draw until it reaches 50 percent state of charge. Differences in battery rating and
temperature will affect the results.
Battery Electrical Drain/Parasitic Load Test

Current Drain Days
25 mA 30.5
50 mA 16.5
75 mA 11
100 mA 8.25
250 mA 3.3
500 mA 1.65
750 mA 1
1A 0.8
2A 0.4
NOTE: Do not turn the parasitic draw test switch to the OFF position with the engine
running. Damage will occur to the vehicle's electrical system.
NOTE: The test switch must be in the ON position when removing the fuses in order to
maintain continuity in the electrical system. This avoids damaging the digital
multimeter due to accidental overloading, such as a door being opened to
change a fuse.
IMPORTANT: The switch knob (1) on the J 38758 is marked ON and OFF. See Special Tools.
When the switch knob is in the ON position, the circuit is closed and electrical
current will pass through the switch. When the switch knob is in the OFF
position, the circuit is open and electrical current will not pass through the
switch.
1. Disconnect the battery negative cable from the battery negative terminal.
2. Install the male end of the J 38758 to the battery ground terminal. See Special Tools.
3. Turn the J 38758 knob to the OFF position. See Special Tools.
4. Install the battery negative cable to the female end of the J 38758 . See Special Tools.
5. Connect a 10-amp fused jumper wire to the test switch tool terminals.
6. Turn the J 38758 knob to the ON position. See Special Tools.
7. Road test the vehicle and activate ALL of the accessories, including the radio and air conditioning. This
may take up to 30 minutes.
8. Park the vehicle. Turn the ignition switch to the OFF position and remove the ignition switch key.
9. Turn the J 38758 knob to the OFF position. See Special Tools. The current now flows through the
jumper wire.
10. Wait 1 minute. If the fuse blows, install an inductive ammeter and go to step 20.
11. Remove the fused jumper wire.
12. Set a digital multimeter to the 10A scale.
13 Connect the digital multimeter to the test switch tool terminals
14. Turn the J 38758 knob to the OFF position. See Special Tools. The current flows now through the digital
multimeter.
15. Wait 1 minute. Check and record the current reading.
1. When there is a current reading on 2A or less, turn the J 38758 knob to the ON position. See
Special Tools. The electrical current will now pass through the switch.
2. Then switch the digital multimeter down to the 2A scale for a more accurate reading when the J
38758 knob is turned OFF. See Special Tools.
16. Turn the J 38758 knob to the OFF position. See Special Tools. Wait 15 minutes for most vehicles.
17. Check and record the current reading.
18. Note the battery reserve capacity, amp hour rating. Refer to Battery Usage.
1. Divide the reserve capacity by 4, amp hour rating by 2.4.
2. Compare this to the multimeter milliampere reading taken in the previous step. The parasitic
current drain should not exceed this number. Example: If a battery has a reserve capacity of 100
minutes, (60 A/H) the current drain should not exceed 25 mA.
19. If excessive current drain is not found at this time and there are no other apparent causes, complete the
following:
20. Using the MIN/MAX function of the digital multimeter, monitor the parasitic drain overnight or during
the day. This will determine if something has been activated during that time frame.
NOTE: The test switch must be in the ON position when removing the fuses in
order to maintain continuity in the electrical system. This avoids damaging
the digital multimeter due to accidental overloading, such as a door being
opened to change a fuse.
IMPORTANT: Removing fuses, relays, and connectors to determine the failure area may
wake up modules. You must wait for these modules to go to sleep or use
the sleep function on the scan tool.
21. When the vehicle has an unacceptable amount of parasitic current drain, remove each fuse one at a time
until the current drain falls to an acceptable level. This will indicate which circuit is causing the drain.
Refer to Power Distribution Schematics in Wiring Systems to diagnose exactly which part of the
suspect circuit is causing the parasitic drain. In some cases a non-fused circuit or component, such as a
relay, is the cause of excessive parasitic current drain.
22. Repeat the parasitic current drain test procedure after any repair has been completed to make sure that the
parasitic current drain is at an acceptable level.
23. When the cause of the excessive current drain has been located and repaired, remove the J 38758 . See
Special Tools.
24. Connect the battery negative cable to the battery negative terminal.
BATTERY COMMON CAUSES OF FAILURE
A battery is not designed to last forever. With proper care, however, the battery will provide years of good
service. If the battery tests good but still fails to perform well, the following are some of the more common
causes:
A vehicle accessory was left on overnight.

The driving speeds have been slow with frequent stops, stop-and-go driving, with many electrical
accessories in use, particularly air conditioning, headlights, wipers, heated rear window, cellular
telephone, etc.
The electrical load has exceeded the generator output, particularly with the addition of aftermarket
equipment.
Existing conditions in the charging system, including the following possibilities:
A slipping belt
A bad generator
The battery has not been properly maintained, including a loose battery hold down or missing battery
insulator if used.
There are mechanical conditions in the electrical system, such as a short or a pinched wire, attributing to
power failure. Refer to General Electrical Diagnosis Procedures in Wiring Systems.
Electrolyte Freezing
The freezing point of electrolyte depends on its specific gravity. A fully charged battery will not freeze until the
ambient temperature gets below -54C (-65F). However, a battery with a low state of charge may freeze at
temperatures as high as -7C (20F). Since freezing may ruin a battery, the battery should be protected against
freezing by keeping it properly charged. As long as the green eye is visible in the hydrometer, the freezing point
of the battery will be somewhere below -32C (-25F).
Battery Protection During Vehicle Storage
Certain devices on the vehicle maintain a small continuous current drain, parasitic load, on the battery. A
battery that is not used for an extended period of time will discharge. Eventually permanent damage will result.
Discharged batteries will also freeze in cold weather. Refer to Battery Inspection/Test.
In order to maintain the battery state of charge while storing the vehicle for more than 30 days:
1. Ensure that the green dot is visible in the built-in hydrometer.
2. Disconnect the battery ground cable to protect the battery from discharge by parasitic current drains.
When the battery cannot be disconnected:
1. Maintain a high state of charge.

2. Establish a regular schedule for recharging the battery every 20-45 days.
A battery that has remained in a discharged state for a long period of time is difficult to recharge or may be
permanently damaged.
JUMP STARTING IN CASE OF EMERGENCY
CAUTION: Batteries produce explosive gases. Batteries contain corrosive acid.

Batteries supply levels of electrical current high enough to cause burns.
Therefore, in order to reduce the risk of personal injury while working near
a battery, observe the following guidelines:
Always shield your eyes.

Avoid leaning over the battery whenever possible.
Do not expose the battery to open flames or sparks.
Do not allow battery acid to contact the eyes or the skin.
Flush any contacted areas with water immediately and
thoroughly.
Get medical help.
NOTE: This vehicle has a 12 volt, negative ground electrical system. Make sure the
vehicle or equipment being used to jump start the engine is also 12 volt,
negative ground. Use of any other type of system will damage the vehicle's
electrical components.
1. Position the vehicle with the booster battery so that the jumper cables will reach.
Do not let the 2 vehicles touch.
Make sure that the jumper cables do not have loose ends, or missing insulation.
2. Place an automatic transmission in PARK. If equipped with a manual transmission, place in NEUTRAL
and block the wheels.
3. Turn OFF all electrical loads on both vehicles that are not needed.
4. Turn OFF the ignition on both vehicles.
Fig. 6: Identifying Proper Jumper Cable Connection
5. Connect the red positive (+) cable to the battery positive (+) terminal (2) of the vehicle with the
discharged battery.
Use a remote positive (+) terminal if the vehicle has one.

6. Connect the red positive (+) cable to the positive (+) terminal (1) of the booster battery.
Use a remote positive (+) terminal if the vehicle has one.
7. Connect the black negative (-) cable to the negative (-) terminal (3) of the booster battery.
CAUTION: Do not connect a jumper cable directly to the negative terminal of a

discharged battery to prevent sparking and possible explosion of
battery gases.
8. The final connection is made to a heavy, unpainted metal engine part (4) of the vehicle with the
discharged battery.
This final attachment must be at least 46 cm (18 in) away from the dead battery.
9. Start the engine of the vehicle that is providing the boost.
NOTE: Never operate the starter motor more than 15 seconds at a time without
pausing in order to allow it to cool for at least 2 minutes. Overheating will
damage the starter motor.
10. Crank the engine of the vehicle with the discharged battery.
11. The black negative (-) cable must be first disconnected from the vehicle that was boosted (4).
12. Disconnect the black negative (-) cable from the negative (-) terminal (3) of the booster battery.
NOTE: Do not let the cable end touch any metal. Damage to the battery and other
components may result.
13. Disconnect the red positive (+) cable from the positive (+) terminal (1) of the booster battery.
14. Disconnect the red positive (+) cable from the remote positive (+) terminal (2) of the vehicle with the
discharged battery.
CHARGING SYSTEM TEST
Charging System Test

Vehicle? Diagnostic
System Check -
1 -
Vehicle in
Vehicle DTC
IMPORTANT:
The battery must be above a 70 percent state
of charge.
2 - Go to Battery
Did you perform the Battery Inspection Test? Go to Step 3 Inspection/Test
3. With a scan tool, command the GEN-L
3 Terminal OFF and ON. -
4. Observe the Ignition 1 Signal parameter.
Does the voltage change with each command? Go to Step 4 Go to Step 8

1. Turn ON the following accessories:
Headlights-High beams
A/C on Max
Blower fan-ON high
4 Heated seats, if equipped 12-15.5 V

2. With a scan tool, observe the ignition 1
signal parameter in the engine data list.
3. Increase engine speed to 2,500 RPM.
Is the voltage within the specified value? Go to Step 5 Go to Step 6

1. Turn OFF all accessories.
CAUTION:
Make sure that the load is completely
turned off before connecting or
disconnecting a carbon pile load tester
to the battery. Otherwise, sparking
could ignite battery gasses which are
extremely flammable and may explode
violently.
5 -
3. Connect a carbon pile tester to the vehicle.
IMPORTANT:
When measuring generator output
current, be sure the inductive probe
encircles the generator output wire.
4. Connect an inductive ammeter probe to the

output circuit of the generator.
Terminal ON.
7. Increase engine speed to 2,500 RPM.
8. Adjust the carbon pile as necessary in
order to obtain the maximum current
output.
Is the generator output greater than or equal to

the load test value as specified in Generator
Usage ? System OK Go to Step 7
6 Is the voltage measured greater than 15.5 volts? - Go to Step 12 Go to Step 7
1. Leave the vehicle accessories ON or
maintain load test value.
2. Maintain engine speed at 2,500 RPM.
3. Measure the voltage between the generator
7 output terminal and the generator metal B+
housing.
Is the voltage measured equal to the specified

OFF.
connector.
3. Measure the voltage between the generator 4.7 V
8 turn ON signal circuit and ground. 0V
Terminal ON and OFF.
Does the voltage measure greater than the first

value ON and near the second value OFF? Go to Step 14 Go to Step 11
1. Maintain the engine speed at 2,500 RPM
and continue to operate the generator at the
load test value.
2. Measure the voltage drop from the battery
9 negative terminal to the metal housing of 0.5 V
the generator. Refer to Circuit Testing
Is the voltage measured less than the specified

1. Maintain the engine speed at 2,500 RPM
and continue to operate the generator at the
load test value.
2. Measure the voltage drop from the output
terminal of the generator to the positive
terminal on the battery. Refer to Circuit
10 Testing and Wiring Repairs in Wiring 0.5 V
Systems.
Is the voltage measured less than the specified

Test the generator turn on signal circuit for a
short or open. Refer to Circuit Testing and
11 -
Test the generator battery voltage sense circuit, if
equipped, for an open or high resistance. Refer to
Systems.
connector of the powertrain control module
(PCM). Refer to Testing for Intermittent
13 -
Inspect for poor connections at the generator.
14 and Poor Connections and Connector Repairs -
in Wiring Systems.
Repair the high resistance or open in the ground
circuit of the generator. Refer to Wiring Repairs
15 -
in Wiring Systems.
Repair the high resistance or open in the
generator output circuit. Refer to Wiring
16 -
17 -
Replace the generator. Refer to Generator
Replacement (LA1) or Generator
18 -
Replacement (LY7).
Operate the vehicle in order to verify the repair.
19 -
CHARGE INDICATOR ALWAYS ON
Charge Indicator Always On

Vehicle? Diagnostic
System Check -
1 -
Vehicle in
Vehicle DTC
Start the engine. Go to Testing
Does the battery charge indicator remain for
illuminated after the 5 second bulb check? Intermittent
2 - Conditions and
Poor
Connections in
Go to Step 3 Wiring Systems
1. Install a scan tool
Signal parameter in the powertrain control
3 module (PCM) data list. 10-15 V
Does the voltage measure within the normal Go to Charging

operating range? Go to Step 4 System Test
Replace the instrument panel cluster (IPC). Refer
setup, and programming
5 -
CHARGE INDICATOR INOPERATIVE
Charge Indicator Inoperative

Step Action Yes No
System Check -
1
Vehicle in Vehicle
3. Observe the battery charge indicator on the Go to Testing for
2 instrument cluster (IPC) during the bulb check. Intermittent
Conditions and
Does the battery charge indicator illuminate during the Poor Connections
bulb check? in Wiring Systems Go to Step 3
Replace the IPC. Refer to Control Module References in
Computer/Integrating Systems for replacement, setup,
3
and programming.
4
GENERATOR NOISE DIAGNOSIS
Diagnostic Aids
Noise from a generator may be due to electrical or mechanical noise. Electrical noise, magnetic whine, usually
varies with the electrical load placed on the generator and is a normal operating characteristic of all generators.
When diagnosing a noisy generator, it is important to remember that loose or misaligned components around
the generator may transmit the noise into the passenger compartment and that replacing the generator may not
solve the problem.
Generator Noise Diagnosis

Step Action Yes No
Test the generator for proper operation using the
1 Generator Tester. Refer to Charging System Test.
Is the generator operating properly? Go to Step 2 Go to Step 11
1. Start the engine. Verify that the noise can be heard.
3. Disconnect the 4-way connector from the generator.
2 4. Start the engine.
5. Listen for the noise.
Has the noise stopped? Go to Step 11 Go to Step 3

2. Remove the drive belt. Refer to Drive Belt
Replacement in Engine Mechanical - 3.4L.
3 3. Spin the generator pulley by hand.
Does the generator shaft spin smoothly and without any

roughness or grinding noise? Go to Step 4 Go to Step 11
Inspect the generator for a loose pulley and/or pulley nut.
4 Is the generator pulley or pulley nut loose? Go to Step 11 Go to Step 5
1. Loosen all of the generator mounting bolts.
2. Tighten the generator mounting bolts to
specifications and in the proper sequence, if
necessary. Refer to Generator Replacement (LA1)
or Generator Replacement (LY7).
5
3. Install the drive belt. Refer to Drive Belt
Replacement in Engine Mechanical - 3.4L.
Has the noise decreased or stopped? System OK Go to Step 6

Inspect the generator for the following conditions:
Strained or stretched electrical connections.

Hoses or other vehicle equipment resting on the
6 generator (which may cause the noise to be
transmitted into the passenger compartment).
Are any electrical connections pulling on the generator or

are any hoses, etc. resting on the generator? Go to Step 7 Go to Step 8
1. Reroute the electrical connections to relieve the
tension.
7 2. Reroute the hoses, etc. away from the generator.

Inspect the drive belt for proper tension. Refer to in
8 Engine Mechanical - 3.4L.
Is the drive belt loose? Go to Step 9 Go to Step 10
1. Replace the drive belt tensioner. Refer to Drive Belt
Tensioner Replacement in Engine Mechanical -
3.4L.
9

Compare the vehicle with a known good vehicle.
10
Do both vehicles make the same noise? System OK Go to Step 11
IMPORTANT:
If no definite generator problems were found, be sure
that all other possible sources of objectionable noise
are eliminated before replacing the generator.
Replacing the generator may not change the noise level
if the noise is a normal characteristic of the generator
or the generator mounting.
11
Replace the generator. Refer to Generator Replacement
(LA1) or Generator Replacement (LY7).Has the noise
decreased or stopped? Go to Step 12 -
12
STARTER SOLENOID DOES NOT CLICK
Starter Solenoid Does Not Click

Step Action Yes No
Connector End View Reference: Master Electrical Component List in Wiring Systems
System Check -
1
Vehicle in Vehicle
Turn the ignition switch to the START position. Go to Testing for
Does the engine crank? Intermittent
2 Conditions and
Poor Connections
IMPORTANT:
A flashing or illuminated security lamp indicates a
theft deterrent malfunction. A theft deterrent Go to Diagnostic
3 malfunction may disable starter operation. System Check -
Vehicle in Vehicle
Is the security lamp flashing? DTC Information Go to Step 4
3. With a scan tool, observe the Crank Request Signal
4 parameter in the powertrain control module (PCM)
data list.
4. Turn the ignition switch to the START position.
Does the scan tool display Yes? Go to Step 5 Go to Step 14

Turn the ignition switch to the START position.
5
Does the starter relay click? Go to Step 6 Go to Step 9
6 2. Disconnect the starter relay.
voltage circuit of the starter relay switch circuit and
a good ground.

Connect a 30-amp fused jumper between the battery
positive voltage circuit of the starter relay switch circuit
7
and the supply voltage circuit of the starter solenoid.
Does the engine crank? Go to Step 19 Go to Step 8
8 Does the fuse in the jumper open? Go to Step 15 Go to Step 16
2. Disconnect the starter relay.
9 4. Connect a test lamp between the battery positive
voltage circuit of the starter relay coil and a good
ground.

voltage circuit of the starter relay coil and the
control circuit of the starter relay.
10

Turn the ignition to the START position.
11
2. Disconnect the park neutral position (PNP) switch.
3. Connect a 3-amp fused jumper between the PNP
12 switch signal circuit and the ignition 1 voltage
circuit of the PNP switch.

Connect a test lamp between the ignition 1 voltage circuit
13 of the PNP switch and a good ground.
2. Disconnect the PCM.
14 3. Connect a test lamp between the crank request
signal circuit of the PCM and a good ground.
4. Turn the ignition to the start position.
Test the supply voltage circuit of the starter solenoid for a
15
Test the supply voltage circuit of the starter solenoid for a
high resistance or open. Refer to Circuit Testing and
16
Test the control circuit of the starter relay for a high
resistance or open. Refer to Circuit Testing and Wiring
17
Test the crank request circuit of the PCM for a high
resistance or open. Refer to Circuit Testing and Wiring
18
Inspect for poor connections at the starter relay. Refer to
19
Inspect the PNP switch for proper operation.
20
Inspect for poor connection at the PNP switch. Refer to
21
Inspect for poor connections at the PCM. Refer to
22
Inspect for poor connections at the starter solenoid. Refer
23
Inspect for poor connections at the ignition switch. Refer
24
Repair the high resistance or open in the battery positive
voltage circuit of the starter relay switch. Refer to Wiring
25
Repair the short to ground in the control circuit of the
26 starter relay. Refer to Wiring Repairs in Wiring
Systems.
Repair the high resistance or open in the park/neutral
signal circuit of the PNP switch. Refer to Wiring
27
Repair the high resistance or open in the ignition 1 circuit
of the PNP switch. Refer to Wiring Repairs in Wiring
28
Systems.
Replace the starter relay.
29
Replace the neutral safety switch.
30
Replace the PCM. Refer to Control Module References
in Computer/Integrating Systems for replacement, setup,
31
and programming.
Replace the starter motor. Refer to Starter Motor
Replacement (LA1) or Starter Motor Replacement
32
(LY7).
34
STARTER SOLENOID CLICKS, ENGINE DOES NOT CRANK
Test Description
The step below refers to the test step on the diagnostic table.
3: Inspect the engine for mechanical failure, or the binding of driven components including driveline
related components.
Starter Solenoid Clicks, Engine Does Not Crank

Step Action Yes No
Connector End View Reference: Engine Electrical Connector End Views
System Check -
1
Vehicle in Vehicle
Turn the ignition to the START position. Go to Starter
Does the starter solenoid click only one time? Solenoid Does Not
2
Go to Step 3 Click
Inspect the engine and the belt drive system for Go to Engine Will
mechanical binding (seized engine, seized generator). Not Crank -
Does the engine move freely? Crankshaft Will
3
Not Rotate in
Engine Mechanical
Go to Step 4 - 3.4L
battery and the starter motor for an open or high
4 resistance. Refer to Circuit Testing and Wiring Repairs
in Wiring Systems.
Test the ground circuit between the battery and the starter
motor for an open or high resistance. Refer to Circuit
5
Inspect for poor connections at the starter. Refer to
6
7
(LY7).
8
ENGINE CRANKS SLOWLY
Inspect the following items:
Battery - Perform the Battery Inspection/Test. Refer to Battery Inspection/Test.

Wiring - Inspect the wiring for damage. Inspect all connections to the starter motor, the solenoid, the
battery, and all ground connections. Refer to Circuit Testing , Wiring Repairs , Testing for
Intermittent Conditions and Poor Connections , and Connector Repairs in Wiring Systems.
Engine - Verify that the engine is not seized.
If the battery, the wiring, and the engine are functioning properly, and the engine continues to crank slowly,
replace the starter motor. Refer to Starter Motor Replacement (LA1) or Starter Motor Replacement (LY7).
STARTER MOTOR NOISE DIAGNOSIS
Diagnostic Aids
Inspect the flywheel ring gear for damage or unusual wear.
Shim the starter as required.
In order to add pinion to ring gear clearance, a full size shim must be used. Do not shim only one starter
mounting bolt. There are 3 shims available in different shapes for clearance. All are 1 mm (0.039 in)
thick.
Starter Motor Noise Diagnosis

Step Action Yes No
System Check -
1
Vehicle in Vehicle
Start the engine. Go to Testing for
Does the starter operate normally? Intermittent
2 Conditions and
Poor Connections
Start the engine while listening to the starter motor turn.
Is there a loud whoop, it may sound like a siren if the
3 engine is revved while the starter is engaged, after the
engine starts, but while the starter is still held in the
engaged position? Go to Step 6 Go to Step 4
Do you hear a rumble, a growl, or in some cases, a knock
4 as the starter is coasting down to a stop after starting the
engine? Go to Step 7 Go to Step 5
IMPORTANT:
This is often diagnosed as a starter drive gear hang-in
or a weak solenoid.
5
When the engine is cranked, do you hear a high-pitched
whine after the engine cranks and starts normally? Go to Step 8 Go to Step 7
Inspect the flywheel ring gear for the following:
Chipped gear teeth

Missing gear teeth
6
Milled teeth
Is the flywheel bent or does it have damaged teeth? Go to Step 9 Go to Step 10

1. Remove the starter motor. Refer to Starter Motor
Replacement (LA1) or Starter Motor
7 Replacement (LY7).
2. Inspect the starter motor bushings and clutch gear.
Does the clutch gear have chipped or milled teeth or worn
bushings? Go to Step 10 Go to Step 9
1. Shim the starter motor away from the flywheel by
adding shims between the starter motor and the
engine block one at a time.
8 2. Flywheel runout may make this noise appear to be
intermittent.

Replace the flywheel. Refer to Engine Flywheel
9 Replacement in Engine Mechanical - 3.4L.
10
(LY7).
11
REPAIR INSTRUCTIONS
BATTERY NEGATIVE CABLE DISCONNECT/CONNECT PROCEDURE (LA1)
Removal Procedure
1. Record all of the customer's radio station presets.

2. Turn off all the lamps and accessories.
Fig. 7: View Of Battery Ground (Negative) Cable And Bolt
4. Remove the battery ground (negative) cable and bolt from the battery.
Fig. 8: View Of Battery Ground (Negative) Cable And Bolt
IMPORTANT: Clean any existing corrosion from the battery terminal bolt flange and the
battery cable end.
1. Install the battery ground (negative) cable and bolt to the battery.
Tighten: Tighten the battery terminal bolt to 16 N.m (12 lb ft).
2. Program all of the customer's radio station presets and set the radio clock to the current time.
BATTERY NEGATIVE CABLE REPLACEMENT (LA1)
Removal Procedure
IMPORTANT: When replacing battery cables, be sure to use battery cables that are the same
type, gauge and length.
1. Remove the battery ground (negative) cable from the battery. Refer to Battery Negative Cable
Disconnect/Connect Procedure (LA1).
Fig. 9: Locating Battery Ground (Negative) Cable Bolt

2. Remove the battery ground (negative) cable bolt from the core support.
4. Remove the lower radiator baffle. Refer to Radiator Air Baffle Assemblies and Deflectors in Engine
Cooling.
5. Remove the battery cable conduit from the conduit retainers.
6. Remove the battery cable from the conduit.
Fig. 10: View Of Battery Ground (Negative) Cable Nut & Cable From Transaxle Stud
7. Remove the battery ground (negative) cable nut and cable from the transaxle stud.
9. Remove the battery ground (negative) cable from the vehicle.
1. Install the battery ground (negative) cable to the vehicle.

3. Install the battery ground (negative) cable and nut to the transaxle stud.
4. Install the battery cable to the conduit.

5. Install the battery cable conduit to the conduit retainers.
6. Install the lower radiator baffle. Refer to Radiator Air Baffle Assemblies and Deflectors in Engine
Cooling.
8. Install the battery ground (negative) cable and bolt to the inner fender.
9. Install the battery ground (negative) cable to the battery. Refer to Battery Negative Cable
BATTERY NEGATIVE CABLE REPLACEMENT (LY7)
Removal Procedure
2. Remove the battery ground (negative) cable bolt from the core support.
Cooling.
6. Remove the battery cable from the conduit.
Fig. 14: Locating Battery Ground (Negative) Cable Bolt & Cable At Engine Block
7. Remove the battery ground (negative) cable bolt and cable from the engine block.
9. Remove the battery ground (negative) cable from the vehicle.
1. Install the battery ground (negative) cable to the vehicle.

Fig. 15: Locating Battery Ground (Negative) Cable Bolt & Cable At Engine Block
3. Install the battery ground (negative) cable and bolt to the engine block.
4. Install the battery cable to the conduit.

Cooling.

8. Install the battery ground (negative) cable and bolt to the core support.
Tighten: Tighten the battery ground (negative) cable at core support bolt to 5 N.m (44 lb in).
BATTERY POSITIVE CABLE REPLACEMENT (LA1)
Removal Procedure
When replacing battery cables, be sure to use replacement cables that are the same type, gauge and length.
Fig. 17: Identifying Battery Positive Cable

2. Remove the battery positive cable from the battery.

Fig. 18: Locating Battery Positive Cable Nut & Cable
3. Remove the battery positive cable nut and cable from the underhood electrical center.
4. Remove the battery positive cable nut and cable from the generator.
Cooling.
8. Remove the starter motor BAT terminal nut from the starter motor.
9. Remove the battery positive cable from the starter motor BAT terminal.
11. Remove the battery positive cable from the vehicle.
1. Install the battery positive cable to the vehicle.

3. Install the battery positive cable and nut to the starter motor BAT terminal.
4. Install the battery positive cable to the conduit.

Cooling.
8. Connect the battery positive cable to the generator. Refer to Generator Replacement (LA1) or
Generator Replacement (LY7).
9. Install the battery positive cable and nut to the underhood electrical center.

Fig. 22: Identifying Battery Positive Cable
10. Install the battery positive cable and bolt to the battery.
BATTERY POSITIVE CABLE REPLACEMENT (LY7)
Removal Procedure
When replacing battery cables, be sure to use replacement cables that are the same type, gage and length.
Fig. 23: View Of Battery Positive Cable

2. Loosen the battery terminal nut.

4. Remove the battery positive cable nut and cable from the underhood electrical center.
Fig. 25: Identifying Battery Positive Cable Nut And Cable At The Generator
5. Remove the battery positive cable nut and cable from the generator.
Cooling.
9. Remove the starter motor BAT terminal nut from the starter motor.
10. Remove the battery positive cable from the starter motor BAT terminal.
12. Remove the battery positive cable from the vehicle.
1. Install the battery positive cable to the vehicle.

3. Install the battery positive cable and nut to the starter motor BAT terminal.
Tighten: Tighten the starter motor BAT terminal nut to 13 N.m (115 lb in).
4. Install the battery positive cable to the conduit.

Cooling.
8. Connect the battery positive cable to the generator. Refer to Generator Replacement (LA1) or
Generator Replacement (LY7).
9. Install the battery positive cable and nut to the underhood electrical center.

Fig. 28: View Of Battery Positive Cable
10. Install the battery positive cable to the battery.
Tighten: Tighten the battery terminal nut to 9 N.m (80 lb in).
BATTERY REPLACEMENT
Removal Procedure
CAUTION: Batteries generate hydrogen gas, which is extremely flammable and may
explode violently if ignited by a spark or a flame. Battery acid is extremely
corrosive and causes severe personal injury if the acid comes into contact
with the skin, and blindness if the acid comes into contact with the eyes.
In order to avoid severe personal injury, use extreme caution when
servicing the battery or battery-related components.
1. Remove and reposition the underhood electrical center. Refer to Underhood Electrical Center or
Junction Block Replacement in Wiring Systems.
2. Remove the front end sheet metal diagonal brace. Refer to Brace Replacement - Front Fender Upper
Diagonal - Right in Body Front End.
Fig. 29: View Of Battery
5. Remove the battery hold down retainer.
IMPORTANT: Do not tip the battery more than 40 degrees.
6. Remove the battery.

Fig. 30: Identifying Battery Insulator
7. Remove the battery insulator from the battery.
Fig. 31: Identifying Battery Insulator
1. Install the battery insulator to the battery.

Fig. 32: View Of Battery
IMPORTANT: Do not tip the battery more than 40 degrees.
2. Install the battery and ensure that the battery is positioned properly in the battery tray.
3. Install the battery hold down retainer.
4. Install the battery hold down retainer bolt.

5. Install the battery positive cable and bolt to the battery.
7. Install the front end sheet metal diagonal brace. Refer to Brace Replacement - Front Fender Upper
Diagonal - Right in Body Front End.
8. Install the underhood electrical center. Refer to Underhood Electrical Center or Junction Block
Replacement in Wiring Systems.
BATTERY TRAY REPLACEMENT
Removal Procedure
1. Remove the battery. Refer to Battery Replacement.

Fig. 33: Identifying Battery Tray & Bolts
2. Remove the battery tray bolts.

3. Remove the battery tray.
Fig. 34: Identifying Battery Tray & Bolts
1. Install the battery tray.
2. Install the battery tray bolts.
Tighten: Tighten the battery tray bolts to 10 N.m (89 lb in).
3. Install the battery. Refer to Battery Replacement.

STARTER MOTOR REPLACEMENT (LA1)
Removal Procedure
IMPORTANT: This vehicle uses the PG260 F1 starter motor. The starter motor is serviced
only as a complete unit.
1. Disconnect the battery ground (negative) cable from the battery. Refer to Battery Negative Cable
3. Remove radiator air baffle assembly. Refer to Radiator Air Baffle Assemblies and Deflectors in Engine
Cooling.
Fig. 35: View Of Starter Motor BAT Terminal Nut And Electrical Leads (LA1)
4. Remove the starter motor BAT terminal nut and electrical leads.
5. Remove the starter motor S terminal nut and electrical lead.
6. Remove the torque converter cover. Refer to Torque Converter Cover Replacement (LA1) in
Automatic Transaxle - 4T65-E.
Fig. 36: Locating Starter Motor & Bolts (LA1)

7. Remove the starter motor bolts.

Fig. 37: Locating Starter Motor & Bolts (LA1)

2. Install the starter motor bolts.

Tighten: Tighten the starter motor bolts to 47 N.m (35 lb ft).
3. Install the torque converter cover. Refer to Torque Converter Cover Replacement (LA1) in Automatic
Transaxle - 4T65-E.
Fig. 38: View Of Starter Motor BAT Terminal Nut And Electrical Leads (LA1)
4. Install the starter motor S terminal electrical lead and nut.
Tighten: Tighten the starter motor solenoid S terminal nut to 3 N.m (27 lb in).
5. Install the starter motor BAT terminal electrical leads and nut.
Tighten: Tighten the starter motor solenoid BAT terminal nut to 10 N.m (89 lb in).
6. Install radiator air baffle assembly. Refer to Radiator Air Baffle Assemblies and Deflectors in Engine
Cooling.
STARTER MOTOR REPLACEMENT (LY7)
Removal Procedure
3. Remove the radiator air baffle. Refer to Radiator Air Baffle Assemblies and Deflectors in Engine
Cooling.
Fig. 39: Identifying Starter Motor BAT Terminal Nut (LY7)

4. Remove the starter motor BAT terminal nut and electrical leads.
Fig. 40: Locating Starter Motor & Bolts (LY7)

5. Remove the starter motor bolts.

Fig. 41: Locating Starter Motor & Bolts (LY7)
2. Install the starter motor bolts.
Tighten: Tighten the starter motor bolts to 50 N.m (37 lb ft).

Fig. 42: Identifying Starter Motor BAT Terminal Nut (LY7)
3. Install the starter motor S terminal electrical connector.

4. Install the battery positive cable and the BAT terminal nut to the starter motor BAT terminal.
Tighten: Tighten the starter motor BAT terminal nut to 13 N.m (115 lb in).
5. Install radiator air baffle assembly. Refer to Radiator Air Baffle Assemblies and Deflectors in Engine
Cooling.
GENERATOR BRACKET REPLACEMENT
Removal Procedure
1. Remove the generator. Refer to Generator Replacement (LA1) or Generator Replacement (LY7).
2. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement in Engine Mechanical-
3.4L.
Fig. 43: View Of Generator Bracket & Bolts

3. Remove the generator bracket bolts.

Fig. 44: View Of Generator Bracket & Bolts
Tighten: Tighten the generator bracket bolts in the sequence shown to 50 N.m (37 lb ft).
3. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement in Engine Mechanical-3.4L.
4. Install the generator. Refer to Generator Replacement (LA1) or Generator Replacement (LY7).
GENERATOR REPLACEMENT (LA1)
Removal Procedure
2. Rotate and secure the engine forward to access rear generator bolts. Refer to Rotating the Engine for
Service Access in Engine Mechanical - 3.4L.
Fig. 45: View Of Generator Electrical Leads, Connectors & Terminal Nut
3. Remove the generator B+ terminal nut.

4. Remove the generator B+ lead.
5. Remove the generator electrical connector.
6. Remove the drive belt from the generator. Refer to Drive Belt Replacement in Engine Mechanical -
3.4L.
Fig. 46: Locating Generator Front Bolt
7. Remove the generator front bolt.

Fig. 47: Identifying Generator Rear Bolts
8. Remove the generator rear bolts.

Fig. 48: Aligning Generator To Generator Bracket
9. Remove the generator from the generator bracket and position the generator above the drive axle.
10. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement in Engine Mechanical-
3.4L.
11. Remove the generator bracket. Refer to Generator Bracket Replacement.
12. Remove the power steering pipes from the power steering pipe retainer.
13. Remove the fuel pressure test port (Schrader valve) cap from the fuel injector rail.
IMPORTANT: Do not disconnect the power steering pipes from the power steering
pump.
14. Remove the power steering pump and reposition the power steering pump in front of the timing chain
cover in order to provide access for the generator. Refer to Power Steering Pump Replacement (LA1 )
or Power Steering Pump Replacement (LY7) in Power Steering System.
15. Remove electrical harness from retainer on right fender well and position aside.
16. Remove the generator from the vehicle.
1. Install the generator to the vehicle and position the generator above the drive axle.
2. Install electrical harness to retainer on right fender well.
3. Install the power steering pump to the engine. Refer to Power Steering Pump Replacement (LA1 ) or
Power Steering Pump Replacement (LY7) in Power Steering System.
4. Install the fuel pressure test port (Schrader valve) cap to the fuel injector rail.
5. Install the power steering pipes from the power steering pipe retainer.
6. Install the generator bracket. Refer to Generator Bracket Replacement.
7. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement in Engine Mechanical -
3.4L.
Fig. 49: Aligning Generator To Generator Bracket
8. Install the generator to the generator bracket and position the generator above the drive axle.
9. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement in Engine Mechanical -
3.4L.
10. Install the generator to the generator bracket.
Fig. 50: Locating Generator Front Bolt
11. Install the generator front bolt.

Fig. 51: Identifying Generator Rear Bolts
12. Install the generator rear bolts.
Tighten: Tighten the generator bolts to 50 N.m (37 lb ft).
13. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.4L.
Fig. 52: View Of Generator Electrical Leads, Connectors & Terminal Nut
14. Install the generator electrical connector.

15. Install the generator B+ lead.
16. Install the generator B+ terminal nut.
Tighten: Tighten the generator B+ terminal nut to 13 N.m (115 lb in).
17. Rotate the engine rearward and install the engine mount strut bracket bolts. Refer to Rotating the Engine
for Service Access in Engine Mechanical - 3.4L.
GENERATOR REPLACEMENT (LY7)
Removal Procedure
2. Remove the torque struts and rotate the engine in order to provide access to remove the generator. Refer
to and in Engine Mechanical - 3.6L (LY7).
3. Remove the generator B+ terminal nut and the battery cable from the generator.
Fig. 54: Locating Generator Electrical Connector
4. Disconnect the generator electrical connector.

5. Remove the drive belt from the generator. Refer to Drive Belt Replacement in Engine Mechanical - 3.6L
(LY7).
6. Remove the idler pulley. Refer to Drive Belt Idler Pulley Replacement in Engine Mechanical - 3.6L
(LY7).
Fig. 55: View Of Generator Bolts

7. Remove the generator bolts.

8. Remove the generator from the vehicle.
Fig. 56: View Of Generator Bolts
1. Install the generator to the vehicle.
2. Install the generator bolts.
Tighten: Tighten the generator bolts to 50 N.m (37 lb ft).
3. Install the idler pulley. Refer to Drive Belt Idler Pulley Replacement in Engine Mechanical - 3.6L
(LY7).
4. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical - 3.6L (LY7).
Fig. 57: Locating Generator Electrical Connector
5. Connect the generator electrical connector.

6. Install the battery cable and the generator B+ terminal nut to the generator.
Tighten: Tighten the generator B+ terminal nut 20 N.m (15 lb ft).
7. Install the torque struts. Refer to and in Engine Mechanical - 3.6L (LY7).
8. Connect the battery ground (negative) cable to the battery. Refer to Battery Negative Cable

BATTERY DESCRIPTION AND OPERATION
Fig. 59: Battery Warning Label

CAUTION: Batteries produce explosive gases, contain corrosive acid, and supply
levels of electrical current high enough to cause burns. Therefore, to
reduce the risk of personal injury when working near a battery:
Always shield your eyes and avoid leaning over the battery whenever
possible.
Do not expose the battery to open flames or sparks.
Do not allow the battery electrolyte to contact the eyes or the skin.
Flush immediately and thoroughly any contacted areas with water
and get medical help.
Follow each step of the jump starting procedure in order.
Treat both the booster and the discharged batteries carefully when
using the jumper cables.
IMPORTANT: Because of the materials used in the manufacture of automotive lead-acid

batteries, dealers and service shops that handle them are subject to various
regulations issued by OSHA, EPA, DOT, and various state or local agencies.
Other regulations may also apply in other locations. Always know and follow
these regulations when handling batteries.
Batteries that are no longer wanted must be disposed of by an approved battery recycler and must never be
thrown in the trash or sent to a landfill.
Batteries that are not part of the vehicle itself, not the battery under the hood, must only be transported on
public streets for business purposes via approved hazardous material transportation procedures.
Battery storage, charging, and testing facilities in repair shops must meet various requirements for ventilation,
safety equipment, material segregation, etc.
The maintenance-free battery is standard. There are no vent plugs in the cover. The battery is completely sealed
except for 2 small vent holes in the side. These vent holes allow the small amount of gas that is produced in the
battery to escape.
The battery has 3 functions as a major source of energy:
Engine cranking
Voltage stabilizer
Alternate source of energy with generator overload
The battery specification label, example below, contains information about the following:
The test ratings

The original equipment catalog number
The recommended replacement model number
Fig. 60: View Of Battery Specification Label
Battery Ratings
A battery may have 3 ratings:
Amp hour
Reserve capacity
Cold cranking amperage
When a battery is replaced, use a battery with similar ratings. Refer to the battery specification label on the
original battery or refer to Battery Usage.
Amp Hour
The amp hour rating of a battery is the amount of time it takes a fully charged battery, being discharged at a
constant rate of 1 amperes and a constant temperature of 27C (80F), to reach a terminal voltage of 10.5 volts.
Refer to Battery Usage for the amp hour rating of the original equipment battery.
Reserve Capacity
Reserve capacity is the amount of time in minutes it takes a fully charged battery, being discharged at a constant
rate of 25 amperes and a constant temperature of 27C (80F), to reach a terminal voltage of 10.5 volts. Refer to
Battery Usage for the reserve capacity rating of the original equipment battery.
Cold Cranking Amperage
The cold cranking amperage is an indication of the ability of the battery to crank the engine at cold
temperatures. The cold cranking amperage rating is the minimum amperage the battery must maintain for 30
seconds at -18C (0F) while maintaining at least 7.2 volts. Refer to Battery Usage for the cold cranking
amperage rating for this vehicle.
CHARGING SYSTEM DESCRIPTION AND OPERATION
Generator
The Valeo SG10 and SG12 generators are electrically similar to earlier models. The generators feature the
following major components:
The delta stator

The rectifier bridge
The rotor with slip rings and brushes
A conventional pulley
Dual internal fans
The regulator
The pulley and the fan cool the slip ring and the frame.
The generators feature permanently lubricated bearings. Service should only include tightening of mount
components. Otherwise, replace the generator as a complete unit.
Regulator
The voltage regulator controls the rotor field current in order to limit the system voltage. When the field current
is on, the regulator switches the current on and off at a rate of 400 cycles per second in order to perform the
following functions:
Radio noise control

Obtain the correct average current needed for proper system voltage control
At high speeds, the on-time may be 10 percent with the off-time at 90 percent. At low speeds, the on-time may
be 90 percent and the off-time 10 percent.
Circuit Description
The generator provides voltage to operate the vehicle's electrical system and to charge its battery. A magnetic
field is created when current flows through the rotor. This field rotates as the rotor is driven by the engine,
creating an AC voltage in the stator windings. The AC voltage is converted to DC by the rectifier bridge and is
supplied to the electrical system at the battery terminal.
When the engine is running, the generator turn-on signal is sent to the generator from the engine control module
(ECM), turning on the regulator. The generator's voltage regulator controls current to the rotor, thereby
controlling the output voltage. The rotor current is proportional to the electrical pulse width supplied by the
regulator. When the engine is started, the regulator senses generator rotation by detecting AC voltage at the
stator through an internal wire. Once the engine is running, the regulator varies the field current by controlling
the pulse width. This regulates the generator output voltage for proper battery charging and electrical system
operation. The generator F terminal is connected internally to the voltage regulator and externally to the ECM.
When the voltage regulator detects a charging system problem, it grounds this circuit to signal the ECM that a
problem exists. The ECM monitors the generator field duty cycle signal circuit. The system voltage sense
circuit receives B+ voltage at the body control module (BCM). This voltage is used by the regulator as the
reference for system voltage control.
When the ignition switch is turned to RUN, the charge indicator turns on for a few seconds (bulb check), then
turns off. The ECM commands the bulb of the charge indicator on by sending a class 2 serial data line message
to the instrument panel cluster (IPC) when the ECM detects a charging system problem.
Charge Indicator
The instrument panel cluster (IPC) illuminates the battery indicator in the message center when the following
occurs:
The engine control module (ECM) detects that the generator output is less than 11 volts or greater than 16
volts. The IPC receives a class 2 message from the ECM requesting illumination.
The ignition is ON, with the engine OFF.
Regulated Voltage Control (RVC)
The LY7 engine comes equipped with GEN II RVC. Regulated voltage control (RVC) is used to more
accurately control the amount of voltage put into the battery based upon the battery state of charge (SOC) and
battery temperature.
The main components of the RVC system is a new voltage regulator, the body control module (BCM ), and the
engine control module (ECM).
Voltage regulator - uses a pulse width modulation (PWM) signal on the generator L-terminal circuit
instead of a 5-volt reference signal from the ECM to determine voltage output of the generator.
ECM - controls the PWM signal to the regulator and provides diagnostics for the generator L-terminal
and generator F-terminal. It also provides feedback of the generator F-terminal to the BCM for its
calculations.
BCM - calculates an estimate of the battery SOC and battery temperature based upon, battery voltage and
internal calibrations. When the BCM has determined what voltage the battery should receive, a message
is sent to the ECM. This message tells the ECM what percentage to set the PWM signal at.
With RVC in closed loop control of the generator, it can vary the voltage at the battery from 13.4 volts, battery
temperature above 70C (158F) and battery SOC 95 percent or higher, to 14.9 volts, battery temperature below
-30C (-22F) and battery SOC 65 percent or lower. If RVC looses control of the generator because of a failure
the voltage regulator will default to 13.9 volts at the battery and function as a normal generator.
Circuit Description (LY7)
The generator provides voltage to operate the vehicle's electrical system and to charge its battery. A magnetic
field is created when current flows through the rotor. This field rotates as the rotor is driven by the engine,
creating an AC voltage in the stator windings. The AC voltage is converted to DC by the rectifier bridge and is
supplied to the electrical system at the battery terminal.
When the engine is running, The ECM sends a PWM signal to the voltage regulator. The generator's voltage
regulator then controls the current to the rotor according to the PWM signal received, thereby controlling the
output voltage. The rotor current is proportional to the electrical pulse width supplied by the regulator. The
PWM signal may vary between 12 percent and 88 percent. The lower the PWM signal percentage the lower the
generator voltage output will be. Below 12 percent and above 88 percent the voltage regulator defaults to 13.9
volts. This generator is self starting and does not require voltage on the L-terminal circuit to initiate battery
charging. This also means that the generator cannot be commanded OFF with the scan tool. When the voltage
regulator detects a charging system problem, it grounds the generator L-terminal circuit to signal the ECM that
a problem exists. The ECM also monitors the generator field duty cycle signal circuit for failures.
STARTING SYSTEM DESCRIPTION AND OPERATION
The PG-260 D is a non-repairable starter motor. It has pole pieces that are arranged around the armature. Both
solenoid windings are energized. The pull-in winding circuit is completed to the ground through the starter
motor. The windings work together magnetically to pull and hold in the plunger. The plunger moves the shift
lever. This action causes the starter drive assembly to rotate on the armature shaft spline as it engages with the
flywheel ring gear on the engine. Moving at the same time, the plunger also closes the solenoid switch contacts
in the starter solenoid. Full battery voltage is applied directly to the starter motor and it cranks the engine.
As soon as the solenoid switch contacts close, current stops flowing thorough the pull-in winding because
battery voltage is applied to both ends of the windings. The hold-in winding remains energized; its magnetic
field is strong enough to hold the plunger, shift lever, starter drive assembly, and solenoid switch contacts in
place to continue cranking the engine. When the engine starts, pinion overrun protects the armature from
excessive speed until the switch is opened.
When the ignition switch is released from the START position, the CRANK relay opens and battery voltage is
removed from the starter solenoid S terminal. Current flows from the motor contacts through both windings to
the ground at the end of the hold-in winding. However, the direction of the current flow through the pull-in
winding is now opposite the direction of the current flow when the winding was first energized.
The magnetic fields of the pull-in and hold-in windings now oppose one another. This action of the windings,
along with the help of the return spring, causes the starter drive assembly to disengage and the solenoid switch
contacts to open simultaneously. As soon as the contacts open, the starter circuit is turned off.
Circuit Description
Moving the ignition switch to the START position sends a 12 V signal to the PCM Ignition Crank Sense. The
PCM then grounds the control circuit, which travels through the Park Neutral Position switch, of the CRANK
relay. When the CRANK relay is energized it allows voltage to the starter solenoid S terminal.
LOAD SHED SYSTEM DESCRIPTION AND OPERATION
Electrical Load Management
Electrical load management is designed to maintain battery voltage and covers more than load-shed. The body
control module (BCM) will request increases in idle speed from the powertrain control module (PCM), when
the vehicle is in park or neutral, as well as turn off loads in order to manage the electrical system and preserve
the vehicle electrical power availability. The BCM calculates the battery temperature, voltage and charging rate
at all times while the engine is running.
The BCM calculates the battery temperature by factoring in:
The current intake manifold air temperature compared to the last temperature recorded when the ignition
switch was turned OFF
The current battery voltage compared to the last battery voltage recorded when the ignition switch was
turned OFF
The length of time since the last battery temperature calculation
If the calculated battery temperature is below -15C (5F), the BCM institutes steps to control the load.
The BCM makes constant voltage measurements. If the BCM detects a low voltage steps are taken to control
the load.
The BCM calculates the net charge rate on the electrical system by making constant voltage measurements and
using the measurements to calculate the charge rate in amp/hours. If the BCM detects a negative charge rate for
the battery, the BCM institutes steps to control the load.
The BCM will turn off loads, called the load-shed function, in order to preserve the vehicle electrical system
operation. The criteria used by the PMM to regulate this electrical load management are outlined below:
Load Shed System Description and Operation

Battery
Temperature Battery Voltage Amp-hour
Function Calculation Calculation Calculation Action Taken
First level Idle
Idle Boost 1 Start <-15C (5F) - -
boost requested
Battery has a net First level Idle
Idle Boost 1 Start - -
loss of 0.6 AH boost requested
Idle Boost 1 End >-15C (5F) loss of less than 0.2 boost request
AH cancelled
Idle Boost 1 End - 14.0 V loss of less than 0.2 boost request
AH cancelled
Controlled outputs
Battery has a net
Load Shed 1 Start - - cycled OFF for 20%
loss of 1.6 AH
of their cycle
Battery has a net
Load Shed 1 End - - loss of less than 0.8 Clear Load Shed 1
AH
Battery has a net Second level Idle
Battery has a net Second level Idle
Idle Boost 2 End - - loss of less than 2.0 boost request
AH cancelled
Battery has a net Third level Idle
Third level Idle
Idle Boost 3 Start - <10.9 V -
boost requested
Battery has a net Third level Idle
Idle Boost 3 End - >13.0 V loss of less than 6.0 boost request
AH cancelled
Controlled outputs
Battery has a net
Load Shed 2 Start - - cycled OFF for 50%
loss of 12.0 AH
of their cycle
Battery has a net
Load Shed 2 End - - loss of less than Clear Load Shed 2
10.5 AH
Controlled outputs
cycled OFF for
100% of their cycle,
Battery has a net
Load Shed 3 Start - <11.9 V Battery Indicator or
loss of 20.0 AH
Battery Saver
Indicator ON
request sent
Controlled outputs
cycled OFF for
100% of their cycle,
Battery Indicator or
Load Shed 3 Start - <10.9 V -
Battery Saver
Indicator ON
request sent
Battery has a net
Load Shed 3 End - >13.0 V loss of less than Clear Load Shed 3
15.0 AH
Each load management function, either idle boost or load-shed, is discrete. No two functions are implemented at
the same time.
During each load management function, the BCM checks the battery temperature, battery voltage and amp-hour
calculations and determines if a different power management function should be implemented.
The highest loads on the electrical system are the resistance load of heating elements. The BCM controls the
heating elements in the outside rear view mirrors, the rear window and the heated seats, either directly or by
sending messages to the module controlling power to these devices.
Idle Boost Functions
The BCM sends a serial data request to the PCM to increase the idle speed. The PCM then adjusts the idle
speed by using a special program and idle speed ramp calculations in order to prevent driveability and safety
concerns. The idle speed boost and cancel function will vary from one moment to another. This happens
because the PCM responds to changes in the inputs from the sensors used to control the powertrain.
Load-Shed
This vehicle uses the following load-shed actions:
Load Shed System Description and Operation

Load Shed Level Affected Systems Action Taken
Load-Shed Level 0 No systems affected Normal operation
Heated Outside Rear View Cycled at 80% duty cycle, OFF for
Mirrors, Heated Rear Window / 4 of every 20 second cycle.
Rear Window Defrost, Heated Indicator and timer not affected.
Seats
No messages or indicators are
Load-Shed Level 1 displayed. Data (DPID) indicating
that the Load-Shed 1 was entered
Message Center, Instrument is stored and may be accessed with
Cluster a scan tool. DPID will reset after
40 ignition switch cycles with no
repeated load-shed 1 action or with
a battery disconnection.
Heated Outside Rear View Cycled at 50% duty cycle, OFF for
Mirrors, Heated Rear Window / 10 of every 20 second cycle.
Rear Window Defrost, Heated Indicator and timer not affected.
Seats
"Battery Saver Action" message or
flashing indicators is displayed.
Load-Shed Level 2 Data (DPID) indicating that the
Load-Shed 2 was entered is stored
Message Center, Instrument
and may be accessed with a scan
Cluster
tool. DPID will reset after 40
ignition switch cycles with no
repeated load-shed 2 action or with
a battery disconnection.
Heated Outside Rear View Turned OFF. Indicator and timer
Mirrors, Heated Rear Window / are not affected. The indicators
Rear Window Defrost, Heated and timers are not controlled by
Seats the BCM. The operator must turn
ON system when load-shed level is
exited. System will not respond to
operator input until current load-
shed level is exited. This system
will respond to only one Load-
Shed Level 3 command per
ignition switch cycle.
Load-Shed Level 3 Message Center, Instrument "Battery Saver Action" message is
Cluster displayed. Battery / Charging
System Failure icon is illuminated.
Chime may be activated constantly
until the load-shed level is exited.
Data (DPID) indicating that the
Load-Shed Level 3 was entered is
stored and may be accessed with a
scan tool. DPID will reset after 40
ignition switch cycles with no
repeated Load-Shed 3 actions or
with a battery disconnection.

SPECIAL TOOLS
Special Tools
J 38758
Parasitic Draw Test Switch
J 42000
Battery Tester
Engine Mechanical - 3.4L - Aztek & Rendezvous
SPECIFICATIONS

Specification
Accelerator Control Cable Bracket Bolt/Nut 10 N.m 89 lb in
Camshaft Position Sensor Bolt 10 N.m 89 lb in
Camshaft Sprocket Bolt 140 N.m 103 lb ft
Camshaft Thrust Plate Screw 10 N.m 89 lb in
Connecting Rod Bearing Cap Nut
First Pass 20 N.m 15 lb ft
Final Pass 75 degrees
Coolant Drain Plug 19 N.m 14 lb ft
Coolant Temperature Sensor 23 N.m 17 lb ft
Crankshaft Balancer Bolt
Crankshaft Main Bearing Cap Bolt/Stud
Crankshaft Oil Deflector Nut 25 N.m 18 lb ft
Crankshaft Position Sensor Bolt - Front Cover 10 N.m 89 lb in
Crankshaft Position Sensor Stud - Side of Engine
11 N.m 98 lb in
Block
Crankshaft Position Sensor Shield Nut 11 N.m 98 lb in
Crankshaft Position Sensor Wiring Bracket Bolt 27 N.m 20 lb ft
Cylinder Head Bolt
Drive Belt Tensioner Bolt 50 N.m 37 lb ft
EGR Valve Pipe to Exhaust Manifold Nut 25 N.m 18 lb ft
EGR Valve Pipe to EGR Valve Bolt 25 N.m 18 lb ft
EGR Valve to Upper Intake Manifold Bolt 30 N.m 22 lb ft
Engine Front Cover Bolt
Large Bolt 55 N.m 41 lb ft
Medium Bolt 55 N.m 41 lb ft
Small Bolt 27 N.m 20 lb ft
Engine Mount Bracket to Engine Block Bolt - AWD 85 N.m 63 lb ft
Engine Mount Bracket to Oil Pan 58 N.m 43 lb ft
Engine Mount to Engine Mount Bracket Nut 53 N.m 39 lb ft
Engine Mount to Engine Oil Pan Bolts 58 N.m 43 lb ft
Engine Mount to Frame Bolts 47 N.m 35 lb ft
Engine Mount to Lower Nut 47 N.m 35 lb ft
Engine Mount Strut and A/C Compressor Bracket
50 N.m 37 lb ft
Bolt
Engine Mount Strut Bolt 48 N.m 35 lb ft
Engine Mount Strut Bracket Bolt, Left 70 N.m 52 lb ft
Engine Mount Strut Bracket Bolt, Right 50 N.m 37 lb ft
Engine Mount Strut Bracket Bolt to Radiator
26 N.m 19 lb ft
Support, Upper
Engine Mount Strut and Generator Bracket Bolt 50 N.m 37 lb ft
Engine Mount Strut and Lift Bracket Bolt - Engine
70 N.m 52 lb ft
Lift Rear
Engine Mount Strut Nut 48 N.m 35 lb ft
Engine Mount Strut and Support Bracket
Large Bolt 55 N.m 41 lb ft
Medium Bolt 55 N.m 41 lb ft
Small Bolt 27 N.m 20 lb ft
Engine Mount Strut to Upper Bracket Bolt 48 N.m 36 lb ft
Engine Mount Strut to Engine Mount Strut Bracket
48 N.m 36 lb ft
Nut
Engine Mount Upper Nut 53 N.m 39 lb ft
Engine Oil Pressure Indicator Switch 16 N.m 12 lb ft
Engine Wiring Harness Bracket Bolt 13 N.m 110 lb in
Exhaust Manifold Heat Shield Bolt 10 N.m 89 lb in
Exhaust Manifold Nut 16 N.m 12 lb ft
Exhaust Manifold Stud 18 N.m 13 lb ft
Flywheel Bolt 71 N.m 52 lb ft
Fuel Feed and Return Pipe Bracket Stud 50 N.m 37 lb ft
Fuel Feed and Return Pipe Retaining Clip Bolt 8 N.m 71 lb in
Fuel Feed and Return Pipe Retaining Clip Nut 25 N.m 18 lb ft
Fuel Feed Pipe To Fuel Injector Rail Nut 17 N.m 13 lb ft
Fuel Injector Rail Bolt 10 N.m 89 lb in
Fuel Pipe Clip Bolt 8 N.m 71 lb in
Heated Oxygen Sensor 42 N.m 31 lb ft
Heater Inlet Pipe Nut 25 N.m 18 lb ft
Heater Inlet Pipe Stud 50 N.m 37 lb ft
Ignition Coil Bracket Bolt/Nut/Stud 25 N.m 18 lb ft
Intake Manifold Coolant Pipe Bolt 10 N.m 89 lb in
Knock Sensor 19 N.m 14 lb ft
Left Engine Mount Strut Bracket to Engine Bolts 50 N.m 37 lb ft
Lower Intake Manifold Bolt - Center
First Pass 7 N.m 62 lb in
Final Pass 13 N.m 115 lb in
Lower Intake Manifold Bolt - Corner
First Pass 13 N.m 115 lb in
Final Pass 25 N.m 18 lb ft
MAP Sensor Bolt 5 N.m 44 lb in
MAP Sensor Bracket Bolt 25 N.m 18 lb ft
Oil Filter 30 N.m 22 lb ft
Oil Filter Bypass Hole Plug 19 N.m 14 lb ft
Oil Filter Fitting 39 N.m 29 lb ft
Oil Gallery Plug - 1/4 inch 19 N.m 14 lb ft
Oil Gallery Plug - 3/8 inch 33 N.m 24 lb ft
Oil Level Indicator Tube Bolt 25 N.m 18 lb ft
Oil Level Sensor Bolt 10 N.m 89 lb in
Oil Pan Bolt 25 N.m 18 lb ft
Oil Pan Drain Plug 25 N.m 18 lb ft
Oil Pan Side Bolt 50 N.m 37 lb ft
Oil Pump Cover Bolt 10 N.m 89 lb in
Oil Pump Drive Clamp Bolt 36 N.m 27 lb ft
Oil Pump Mounting Bolt 41 N.m 30 lb ft
Right Engine Mount Strut Bracket to Engine Bolts 70 N.m 52 lb ft
Spark Plug - Initial Installation 20 N.m 15 lb ft
Spark Plug - After Initial Installation 15 N.m 13 lb ft
Thermostat Bypass Pipe to Engine Front Cover Bolt 12 N.m 106 lb in
Thermostat Bypass Pipe to Throttle Body Nut 25 N.m 18 lb ft
Throttle Body Bolt/Stud 25 N.m 18 lb ft
Timing Chain Dampener Bolt 21 N.m 15 lb ft
Upper Engine Mount Strut Bracket to Upper
28 N.m 21 lb in
Radiator Support Bolts
Upper Intake Manifold Bolt/Stud 25 N.m 18 lb ft
Valve Lifter Guide Bolt 10 N.m 89 lb in
Valve Rocker Arm Bolt 32 N.m 24 lb ft
Valve Rocker Arm Cover Bolt 10 N.m 89 lb in
Water Outlet Bolt 25 N.m 18 lb ft
Water Pump Bolt 11 N.m 98 lb in
Water Pump Pulley Bolt 25 N.m 18 lb ft
ENGINE MECHANICAL SPECIFICATIONS
Engine Mechanical Specifications

Specification
General Data
Engine Type 60 degree V-6
Displacement 3.4L 204 cu in
RPO LA1
VIN E
Bore 92 mm 3.62 in
Stroke 84 mm 3.31 in
Compression Ratio 9.6:1
Firing Order 1-2-3-4-5-6
Spark Plug Gap 1.52 mm 0.60 in
Block
Camshaft Bearing Bore Diameter - Front and 51.03-51.08 mm 2.009-2.011 in
Rear
Camshaft Bearing Bore Diameter - Middle #2, 50.77-50.82 mm 1.999-2.001 in
#3
72.1535-72.0695
Crankshaft Main Bearing Bore Diameter 2.840-2.841 in
mm
Crankshaft Main Bearing Bore Out-of-Round 0.008 mm 0.00031 in
Cylinder Bore Diameter - Production 92.020-92.038 mm 3.622-3.623 in
Cylinder Bore Diameter - Service 92.020-92.038 mm 3.622-3.623 in
Cylinder Bore Out-of-Round - Diametral - 0.020 mm 0.0008 in
Production
Cylinder Bore Out-of-Round - Diametral - 0.025 mm 0.001 in
Service
Cylinder Bore Taper - Production 0.020 mm 0.0008 in
Cylinder Bore Taper - Service 0.025 mm 0.001 in
Cylinder Head Deck Height 224 mm 8.818 in
0.05 mm per 152
Cylinder Head Deck Surface Flatness 0.0019 in per 6 in
mm
Valve Lifter Bore Diameter 21.417-21.455 mm 0.843-0.844 in
Camshaft
Camshaft Bearing Inside Diameter 47.523-47.549 mm 1.871-1.872 in
Camshaft Journal Diameter 47.45-47.48 mm 1.868-1.869 in
Camshaft Journal Out-of-Round 0.025 mm 0.001 in
Camshaft Lobe Lift - Exhaust 6.9263 mm 0.2727 in
Camshaft Lobe Lift - Intake 6.9263 mm 0.2727 in
Cooling System
Capacity 12.4 liters 13.1 quarts
Thermostat Full Open Temperature 195 degrees
Connecting Rod
Connecting Rod Bearing Clearance 0.18-0.062 mm 0.0007-0.017 in
Connecting Rod Bore Diameter 53.962-53.978 mm 2.124-2.125 in
Connecting Rod Bore Out-of-Round 0.008 mm 0.0002 in
Connecting Rod Length - Center to Center 144.75-144.81 mm 5.69-5.70 in
Connecting Rod Side Clearance 0.25-0.37 mm 0.010-0.015 in
Crankshaft
Connecting Rod Journal Diameter 50.768-50.784 mm 1.9987-1.9994 in
Connecting Rod Journal Out-of-Round 0.005 mm 0.0002 in
Connecting Rod Journal Taper 0.005 mm 0.0002 in
Connecting Rod Journal Width 21.92-22.08 mm 0.863-0.869 in
Crankshaft End Play 0.060-0.210 mm 0.0024-0.0083 in
Crankshaft Main Bearing Journal Width 23.9-24.1 mm 0.941-0.949 in
Crankshaft Main Bearing Clearance - Except 0.019-0.064 mm 0.0008-0.0025 in
#3
Crankshaft Main Bearing Clearance - #3 0.032-0.077 mm 0.0012-0.0030 in
Thrust Bearing
Crankshaft Main Journal Diameter 67.239-67.257 mm 2.6473-2.6483 in
Crankshaft Main Journal Out-of-Round 0.005 mm 0.0002 in
Crankshaft Main Journal Taper 0.005 mm 0.0002 in
Crankshaft Rear Flange Runout 0.04 mm 0.0016 in
Cylinder Head
Combustion Chamber Depth - at Measurement 2.2 mm 0.087 in
Point
Surface Finish - Maximum 2.8 RA
0.08 mm per 152
Surface Flatness - Block Deck 0.003 in per 6 in
mm
Surface Flatness - Exhaust Manifold Deck 0.1 mm 0.004 in
Surface Flatness - Intake Manifold Deck 0.1 mm 0.004 in
Valve Guide Bore - Exhaust 8.01 mm 0.315 in
Valve Guide Bore - Intake 8.01 mm 0.315 in
Valve Guide Installed Height 16.6 mm 0.654 in
Lubrication System
Oil Capacity - with Filter 4.3 liters 4.5 quarts
Oil Capacity - without Filter 3.8 liters 4.0 quarts
Oil Pressure - @ 1850 RPM 414 kPa 60 psi
Oil Pump
Gear Diameter 38.05-38.10 mm 1.498-1.500 in
Gear Pocket - Depth 30.52-30.58 mm 1.202-1.204 in
Gear Pocket - Diameter 38.176-38.226 mm 1.503-1.505 in
Gears Lash 0.094-0.195 mm 0.0037-0.0077 mm
Relief Valve-to-Bore Clearance 0.038-0.089 mm 0.0015-0.0035 in
Piston Ring End Gap
First Compression Ring 0.15-0.36 mm 0.006-0.014 in
Second Compression Ring 0.48-0.74 mm 0.0188-0.0291 in
Oil Control Ring 0.25-0.77 mm 0.0098-0.0303 in
Piston Ring to Groove Clearance
Oil Control Ring 0.07-0.095 mm 0.0028-0.0037 in
Piston Ring Thickness
Oil Control Ring - Maximum 2.960 mm 0.116 in
Piston
Piston Diameter - production - cylinder 1-4 91.985-92.003 mm 3.621-3.622 in
Piston Diameter - service limit - cylinder 1-4 91.945 mm 3.619 in
Piston Diameter - production - cylinder 5-6 91.99-92.028 mm 3.621-3.623 in
Piston Diameter - service limit - cylinder 5-6 91.945 mm 3.619 in
Piston Pin Bore Diameter 23.005-23.010 mm 0.9057-0.9059 in
Piston Ring Groove Width - First 1.23-1.25 mm 0.048-0.049 in
Piston Ring Groove Width - Second 1.53-1.55 mm 0.060-0.061 in
Piston Ring Groove Width - Oil Control 3.03-3.055 mm 0.119-0.120 in
Piston to Bore Clearance - production - 1-4 0.17-0.053 mm 0.0006-0.0020 in
Piston to Bore Clearance - service limit- 1-4 0.093 mm 0.0036 in
Piston to Bore Clearance - production - 5-6 -0.008-0.048 mm -0.0003-0.0018 in
Piston to Bore Clearance - service limit- 5-6 0.093 mm 0.0036 in
Pin
Piston Pin Clearance to Connecting Rod Bore - -0.047 to -0.019 -0.0019 to -0.0007
Press Fit mm in
0.00031-0.00063
Piston Pin Clearance to Piston Pin Bore 0.008-0.016 mm
in
Piston Pin Diameter 22.994-22.997 mm 0.9053-0.9054 in
Valves
Valve Face Angle 45 degrees
Valve Seat Angle 46 degrees
Valve Seat Depth - Intake - from deck face 7.9-8.1 mm 0.311-0.318 in
Valve Seat Depth - Exhaust - from deck face 8.9-9.1 mm 0.350-0.358 in
Valve Seat Runout 0.037 mm 0.0015 in
Valve Seat Width - Intake 1.55-1.80 mm 0.061-0.071 in
Valve Seat Width - Exhaust 1.70-2.0 mm 0.067-0.079 in
Valve Stem-to-Guide Clearance 0.026-0.068 mm 0.0010-0.0027 in
Valve Lifters/Push Rods
Push Rod Length - Intake 146.0 mm 5.75 in
Push Rod Length - Exhaust 152.5 mm 6.0 in
Valve Springs
Valve Spring Free Length 48.5 mm 1.89 in
Valve Spring Installed Height 43.2 mm 1.701 in
Valve Spring Load - Closed 320 N @ 43.2 mm 75 lb @ 1.701 in
Valve Spring Load - Open 1036 N @ 32 mm 230 lb @ 1.260 in
Valve Spring Total Number of Coils 6.55
SEALERS, ADHESIVES, AND LUBRICANTS
Sealers, Adhesives, and Lubricants

GM Part Number
United Canada
Application Type of Material States
Accelerator Control Cable Bracket Bolt
10953489
Threads Threadlock 12345382
Camshaft Rear Bearing Hole Plug Sealant 12377901 10953504
Coolant Drain Plug Sealant 12346004 10953480
Coolant Temperature Sensor Threads Sealant 12346004 10953480
Crankshaft Balancer Keyway Sealant 12346141 10953433
Crankshaft Position Sensor Bolt/Stud
10953489
Threads Threadlock 12345382
Engine Block Coolant Drain Plug Threads Sealant 12346004 10953480
Engine Block Oil Gallery Plug Threads Sealant 12346004 10953480
Engine Front Cover Bolt Threads Sealant 12346004 10953480
Engine Front Cover Gasket Lower Tabs Sealant 12346004 10953480
Engine Oil 10W-30 Oil 12345616 993182
Engine Oil Cooler Fitting Threads Sealant 12346004 10953480
Engine Oil Supplement Lubricant 1052367 992869
Intake Manifold Bolt Threads - Upper and
Threadlock 12345382 10953489
Lower
Intake Manifold Coolant Pipe Sealant 12345493 10953488
Intake Manifold to Engine Block Mating
Sealant 10953433
Surface 12346141
Knock Sensor Threads Sealant 12346004 10953480
Oil Filter Bypass Hole Plug Threads Sealant 12346004 10953480
Oil Pan Surface at Rear Crankshaft Main
Sealant 10953433
Bearing Cap 12346141
Oil Pressure Switch Threads Sealant 12346004 10953480
Oil Pump Suction Pipe Sealant 12346004 10953480
Piston and Piston Pin 10W-30 Oil 12345616 993182
Rear Crankshaft Main Bearing Cap Sealant 1052942 10953466
Throttle Body Bolt and Stud Threadlock 12345382 10953489
Valve Lifter Guide Bolt Threads Threadlock 12345382 10953489
Valve Rocker Arm Cover Notch at
Cylinder Head and Lower Intake Sealant 10953433
Manifold 12346141
Valve Lifter and Camshaft Prelube Lubricant 12345501 992704
COMPONENT LOCATOR
DISASSEMBLED VIEWS
Fig. 1: Upper Intake Manifold and Components Disassembled View

Callouts For Fig. 1

305 Thermostat Bypass Hose Clamp
305 Thermostat Bypass Hose Clamp
306 Thermostat Bypass Hose
307 Thermostat Bypass Pipe Seal
308 Thermostat Bypass Pipe Bolt - to Front Cover
309 Thermostat Bypass Pipe
310 Thermostat Bypass Pipe Nut
500 Upper Intake Manifold
501 Upper Intake Manifold Stud
503 Accelerator Control Cable Bracket
504 Idle Air Control Valve
505 MAP Sensor Bracket
506 MAP Sensor
507 Throttle Position Sensor
508 Upper Intake Manifold Bolt
509 Spark Plug Wire Support Bracket
513 Throttle Body Gasket
514 Throttle Body
515 Throttle Body Bolt
516 Upper Intake Manifold Gasket
524 Idle Air Control Valve Bolt
525 Valve Rocker Cover Seal
526 Valve Rocker Cover
530 Oil Fill Cap
531 PCV Valve
532 PCV Valve Grommet
533 PCV Tube - Foul Air
535 Throttle Position Sensor Bolt
545 Oil Fill Cap Seal
550 Throttle Body Stud
552 Throttle Body Heater Hose - Outlet
553 Throttle Body Heater Hose - Inlet
554 Throttle Body Heater Hose Clamp
Throttle Body Heater Hose Clamp
555 Accelerator Control Cable Bracket Bolt
556 Accelerator Control Cable Bracket Nut
566 PCV Valve Retainer
610 Exhaust Crossover Pipe
611 EGR Pipe Bolt - to EGR
612 EGR Pipe
613 EGR Valve Bolt
614 EGR Valve
615 EGR Valve Gasket - to Intake Manifold
617 Exhaust Crossover Pipe Stud
618 Exhaust Crossover Pipe Nut
619 Exhaust Crossover Pipe Heat Shield
620 Exhaust Crossover Pipe Heat Shield Bolt
700 Ignition Coil Assembly
701 Ignition Coil Assembly Stud
702 Ignition Coil Assembly Nut
703 Ignition Coil Assembly Bolt
704 Spark Plug Wire Harness - Front
705 Spark Plug Wire Support
711 Ignition Coil
715 Spark Plug Wire Harness - Rear
716 Ignition Coil Bolt
722 Wire Support Bracket
723 Wire Support Bracket - SAI Only
724 EVAP Purge Valve
725 EVAP Purge Valve Bolt
728 EVAP Purge Valve Bracket
Fig. 2: Lower Intake Manifold, Cylinder Head and Components Disassembled View
Callouts For Fig. 2

200 Cylinder Head
200 Cylinder Head
201 Valve Seal
202 Valve Spring
203 Valve Spring Cap
204 Valve Stem Key
205 Valve Pushrod - Exhaust
206 Valve Rocker Arm
207 Valve Rocker Arm Bolt
208 Cylinder Head Bolt - Medium
209 Cylinder Head Bolt - Short
212 Spark Plug
213 Exhaust Valve
214 Intake Valve
215 Cylinder Head Gasket
215 Cylinder Head Gasket
216 Cylinder Head Locating Pin
228 Drive Belt Tensioner Bolt
229 Drive Belt Tensioner
230 Generator Bracket Bolt - Short
231 Generator Bracket Bolt - Medium
232 Generator Bracket Bolt - Long
233 Generator Bracket
234 Engine Lift Bracket - Front
238 Heater Inlet Pipe Stud
239 Heater Inlet Pipe
240 Heater Inlet Pipe Nut
241 Heater Inlet Pipe Seal
242 Cylinder Head Expansion Plug
242 Cylinder Head Expansion Plug
243 Valve Guide
244 Valve Seat - Exhaust
245 Valve Seat - Intake
246 Valve Pushrod - Intake
248 Cylinder Head Bolt - Long
249 Engine Mount Strut and A/C Compressor Bracket Bolt - Short
250 Engine Mount Strut and A/C Compressor Bracket
251 Engine Mount Strut and A/C Compressor Bracket Bolt - Long
252 Engine Mount Strut and Engine Lift Bracket
253 Engine Mount Strut and Engine Lift Bracket Bolt
254 Fuel Feed and Return Pipe Bracket
255 Fuel Feed and Return Pipe Clip
256 Fuel Feed and Return Pipe Clip Bolt
Thermostat
313 Thermostat Seal
314 Water Outlet Housing
315 Water Outlet Housing Bolt
316 Water Outlet Housing Fitting
517 Fuel Rail Bolt
518 Fuel Rail
519 Fuel Injector Seal
519 Fuel Injector Seal
520 Lower Intake Manifold Bolt - Long
521 Lower Intake Manifold
522 Lower Intake Manifold Bolt - Short
523 Lower Intake Manifold Gasket
525 Valve Rocker Cover Seal
526 Valve Rocker Cover
527 Valve Rocker Cover Bolt
528 Valve Rocker Cover Bolt Grommet
529 Vacuum Harness
548 Fuel Injector Retaining Clip
549 Fuel Injector
557 Fuel Rail Service Port Cap
558 Fuel Rail Service Port Schrader Valve
559 Fuel Pressure Regulator
560 Fuel Pressure Regulator Bolt
561 Fuel Feed Pipe
562 Ruel Return Pipe
567 Fuel Feed Pipe Seal
600 Exhaust Manifold - Left
601 Exhaust Manifold - Right
602 Exhaust Manifold Heat Shield - Right - Upper
603 Exhaust Manifold Heat Shield Bolt
603 Exhaust Manifold Heat Shield Bolt
604 Exhaust Manifold Gasket
604 Exhaust Manifold Gasket
605 Exhaust Manifold Stud
Heated Oxygen Sensor
607 Exhaust Manifold Nut
608 Exhaust Manifold Heat Shield - Left
616 Exhaust Manifold Heat Shield - Right - Lower
700 Ignition Coil Assembly
Fig. 3: Engine Block and Components Disassembled View

Callouts For Fig. 3

100 Engine Block
101 Camshaft Rear Bearing Hole Plug
102 Engine Block Oil Gallery Plug - Rear - Large
103 Engine Block Oil Gallery Plug - Rear - Small
104 Transmission Locating Pin
105 Engine Block Coolant Drain Hole Plug
106 Oil Filter Bypass Hole Plug
107 Engine Block Oil Gallery Plug - Front - Press Fit
108 Engine Block Plug
110 Engine Block Oil Gallery Plug - Front - Small
111 Crankshaft Rear Oil Seal
126 Connecting Rod Bearing Cap Nut
127 Connecting Rod Bearing Cap
128 Connecting Rod Bearing
129 Connecting Rod
130 Piston Pin
131 Piston
132 Piston Ring - Oil Control
133 Piston Ring - Compression - Lower
134 Piston Ring - Compression - Upper
137 Engine Block Oil Gallery Plug - Front - Large
217 Timing Chain
218 Camshaft Sprocket Bolt
219 Camshaft Sprocket
220 Camshaft Thrust Plate Bolt
221 Camshaft Thrust Plate
222 Camshaft
223 Camshaft Bearing - 1 and 4
224 Camshaft Bearing - 2 and 3
225 Timing Chain Dampener
226 Timing Chain Dampener Bolt
227 Crankshaft Sprocket
235 Valve Lifter Guide Bolt
236 Valve Lifter Guide
237 Valve Lifter
300 Water Pump
Water Pump Gasket
302 Water Pump Pulley Bolt
303 Water Pump Pulley
304 Water Pump Bolt
410 Oil Pump Drive Bolt
411 Oil Pump Drive Clamp
412 Oil Pump Drive
418 Oil Filter Bypass Valve
421 Oil Filter
440 Oil Pump Drive Seal
444 Oil Filter Fitting
536 Engine Front Cover Bolt - Large
538 Engine Front Cover
539 Engine Front Cover Gasket
540 Engine Front Cover Bolt - Small
541 Engine Front Cover Bolt - Medium
542 Crankshaft Front Oil Seal
543 Crankshaft Balancer
544 Crankshaft Balancer Bolt
551 Front Cover Locating Pins
706 Camshaft Position Sensor Bolt
707 Camshaft Position Sensor
708 Camshaft Position Sensor Seal
709 Engine Oil Pressure Sensor
710 Knock Sensor
712 Crankshaft Position Sensor Stud
713 Crankshaft Position Sensor - Engine Block
714 Crankshaft Position Sensor Seal
717 Crankshaft Position Sensor - Front Cover
718 Crankshaft Position Sensor Wire Harness Bracket - Small
719 Crankshaft Position Sensor Wire Harness Bracket - Large
720 Crankshaft Position Sensor Wire Harness Bracket Bolt
721 Crankshaft Position Sensor Bolt - Front Cover
726 Crankshaft Position Sensor Heat Shield
727 Crankshaft Position Sensor Heat Shield Nut
Fig. 4: Crankshaft and Components Disassembled View
Callouts For Fig. 4

112 Flywheel
114 Flywheel Bolt
115 Crankshaft Upper Bearing - 1 and 4
116 Crankshaft Upper Bearing - 2
117 Crankshaft Upper Bearing - 3
118 Crankshaft
119 Crankshaft Balancer Key
120 Crankshaft Lower Bearing - 2
121 Crankshaft Lower Bearing - 1 and 4
122 Crankshaft Bearing Cap - 1
123 Crankshaft Bearing Cap Stud
124 Crankshaft Bearing Cap - 4
125 Crankshaft Bearing
135 Crankshaft Lower Bearing - 3
136 Crankshaft Bearing Cap - 2 and 3
400 Oil Pan
401 Oil Pan Gasket
402 Oil Pan Bolt - to Engine Block
403 Oil Pan Drain Plug
404 Crankshaft Oil Deflector Nut
405 Crankshaft Oil Deflector
406 Oil Pump Locating Pin
407 Oil Pump Shaft
408 Oil Pump
409 Oil Pump Bolt
413 Oil Level Indicator Tube
414 Oil Level Indicator Tube Bolt
415 Oil Level Indicator
416 Oil Pan Drain Plug Seal
417 Oil Level Indicator Seal
426 Oil Pan Bolt - Side of Pan
Fig. 5: Locating Vehicle Identification Number - VIN
The Vehicle Identification Number - VIN derivative (1) for 3100 LG8 and 3400 LA1 is stamped
or laser etched on the left side rear of the engine block. The Vehicle Identification Number - VIN
derivative is nine digits long and can be used to determine if a vehicle contains the original
engine.
The first digit identifies the division.

The second digit identifies the model year.
The third digit identifies the assembly plant.
The fourth through ninth digits are the last six digits of the Vehicle Identification Number -
VIN.

DIAGNOSTIC STARTING POINT - ENGINE MECHANICAL
Begin the system diagnosis by reviewing the Disassembled Views, Engine Component
Description, Drive Belt System Description, Lubrication Description, and New Product
Information. Reviewing the description and operation information will help you determine the
correct symptom diagnostic procedure when a malfunction exists. Reviewing the description and
operation information will also help you determine if the condition described by the customer is
normal operation. Refer to Symptoms - Engine Mechanical in order to identify the correct
SYMPTOMS - ENGINE MECHANICAL
Strategy Based Diagnostics
1. Perform Diagnostic System Check - Engine Controls in Engine Controls before using the
symptom tables if applicable.
2. Review the system operations in order to familiarize yourself with the system functions.
Refer to Disassembled Views, Engine Component Description, Drive Belt System
Description, Lubrication Description, and New Product Information.
All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform
approach for repairing all systems. The diagnostic flow may always be used in order to resolve a
system problem. The diagnostic flow is the place to start when repairs are necessary. For a
detailed explanation, refer to Strategy Based Diagnosis in General Information.
Inspect for aftermarket devices which could affect the operation of the Engine. Refer to
Inspect the easily accessible or visible system components for obvious damage or conditions
which could cause the symptom.
Check for the correct oil level, proper oil viscosity, and correct filter application.
Verify the exact operating conditions under which the concern exists. Note factors such as
engine RPM, ambient temperature, engine temperature, amount of engine warm-up time,
and other specifics.
Compare the engine sounds if applicable to a known good engine and make sure you are not
trying to correct a normal condition.
Intermittent
Test the vehicle under the same conditions that the customer reported in order to verify the system
is operating properly.
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the
symptom:
Base Engine Misfire without Internal Engine Noises

Base Engine Misfire with Abnormal Internal Lower Engine Noises
Base Engine Misfire with Abnormal Valve Train Noise
Base Engine Misfire with Coolant Consumption
Base Engine Misfire with Excessive Oil Consumption
Engine Compression Test
Engine Noise on Start-Up, but Only Lasting a Few Seconds
Upper Engine Noise, Regardless of Engine Speed
Lower Engine Noise, Regardless of Engine Speed
Engine Noise Under Load
Engine Will Not Crank - Crankshaft Will Not Rotate
Oil Consumption Diagnosis
Oil Pressure Diagnosis and Testing
Oil Leak Diagnosis
Drive Belt Chirping Diagnosis
Drive Belt Squeal Diagnosis
Drive Belt Whine Diagnosis
Drive Belt Rumbling Diagnosis
Drive Belt Vibration Diagnosis
Drive Belt Falls Off Diagnosis
Drive Belt Excessive Wear Diagnosis
Drive Belt Tensioner Diagnosis
Base Engine Misfire without Internal Engine Noises

Cause Correction
Abnormalities consist of severe cracking, Replace the drive belt. Refer to Drive Belt
bumps, or missing areas in the accessory Tensioner Replacement.
drive belt
Abnormalities in the accessory drive system
and/or components may cause engine RPM
variations and lead to a misfire DTC. A
misfire code may be present without an
actual misfire condition.
Worn, damaged, or mis-aligned accessory Inspect the components, and repair or replace
drive components or excessive pulley runout as required.
may lead to a misfire DTC.
A misfire code may be present without an
Loose or improperly installed engine Repair or replace the flywheel and/or
flywheel or crankshaft balancer balancer as required. Refer to Engine
A misfire code may be present without an Flywheel Replacement or Crankshaft
actual misfire condition. Balancer Replacement.
Restricted exhaust system Repair or replace as required.
A severe restriction in the exhaust flow can
cause significant loss of engine performance
and may set a DTC. Possible causes of
restrictions include collapsed or dented pipes
or plugged mufflers and/or catalytic
converters.
Improperly installed or damaged vacuum Repair or replace as required.
hoses
Improper sealing between the intake Replace the intake manifold, gaskets, cylinder
manifold and cylinder heads or throttle body. heads, and/or throttle body as required.
Worn or loose rocker arms Replace the valve rocker arms as required.
The rocker arm bearing end caps and/or
needle bearings should be intact and in the
proper position.
Worn or bent pushrods Replace the pushrods.
Stuck valves Repair or replace as required.
Carbon buildup on the valve stem can cause
the valve not to close properly.
Excessively worn or mis-aligned timing chain Replace the timing chain and sprockets as
required.
Worn camshaft lobes Replace the camshaft and valve lifters.
Excessive oil pressure Perform an oil pressure test. Refer to
A lubrication system with excessive oil Oil Pressure Diagnosis and Testing.
pressure may lead to excessive valve lifter
Repair or replace the oil pump as
pump-up and loss of compression.
required.
Faulty cylinder head gaskets and/or cracking Inspect for spark plugs saturated by
or other damage to the cylinder heads and coolant. Refer to Spark Plug
engine block cooling system passages. Refer Inspection in Engine Controls.
to Diagnostic Starting Point - Engine
Inspect the cylinder heads, engine block,
Cooling .
and/or head gaskets.
Coolant consumption may or may not cause
Repair or replace as required.
the engine to overheat.
Worn Piston Rings Inspect the spark plugs for oil deposits.
Oil consumption may or may not cause the Refer to Spark Plug Inspection in
engine to misfire. Engine Controls.
Inspect the cylinders for a loss of
compression. Refer to Engine
Compression Test.
Perform cylinder leak down and
compression testing to identify the
cause.
Base Engine Misfire with Abnormal Internal Lower Engine Noises

Cause Correction
Abnormalities consist of severe cracking, Replace the drive belt. Refer to Drive Belt
bumps or missing areas in the accessory drive Tensioner Replacement.
belt
Abnormalities in the accessory drive system
and/or components may cause engine RPM
variations, noises similar to a faulty lower
engine and also lead to a misfire condition. A
misfire code may be present without an
Worn, damaged, or mis-aligned accessory Inspect the components, repair or replace as
drive components or excessive pulley runout required.
A misfire code may be present without an
Loose or improperly installed engine Repair or replace the flywheel and/or
flywheel or crankshaft balancer balancer as required.
A misfire code may be present without an Refer to Engine Flywheel Replacement or
actual misfire condition. Crankshaft Balancer Replacement.
Compression Test.
compression testing to determine the
cause.
Worn Crankshaft Thrust Bearings Replace the crankshaft and bearings as

Severely worn thrust surfaces on the required.
crankshaft and/or thrust bearing may permit
fore and aft movement of the crankshaft and
create a DTC without an actual misfire
condition.
Base Engine Misfire with Abnormal Valve Train Noise

Cause Correction
Worn or loose rocker arms Replace the valve rocker arms as required.
The rocker arm bearing end caps and/or
needle bearings should intact within the
rocker arm assembly.
Worn or bent pushrods Replace the pushrods.
Stuck valves Repair or replace as required.
Carbon buildup on the valve stem can cause
the valve not to close properly.
Excessively worn or mis-aligned timing chain Replace the timing chain and sprockets as
required.
Worn camshaft lobes Replace the camshaft and valve lifters.
Sticking lifters Replace as required.
Base Engine Misfire with Coolant Consumption

Cause Correction
Faulty cylinder head gaskets and/or cracking Inspect for spark plugs saturated by
or other damage to the cylinder heads and coolant. Refer to Spark Plug
engine block cooling system passages. Inspection in Engine Controls.
ReferDiagnostic Starting Point - Engine
Perform a cylinder leak down test.
Cooling .
Inspect the cylinder heads and engine
Coolant consumption may or may not cause
the engine to overheat. block for damage to the coolant
passages and/or a faulty head gasket.
Base Engine Misfire with Excessive Oil Consumption

Cause Correction
Worn valves, valve guides and/or valve stem Inspect the spark plugs for oil deposits.
oil seals Refer to Spark Plug Inspection in
Engine Controls.
Compression Test.
compression testing to determine the
cause.
Worn or faulty lower intake manifold gaskets Replace as required.
Engine Noise on Start-Up, but Only Lasting a Few Seconds

Cause Correction
Incorrect oil filter without anti-drainback Install the correct oil filter.
feature
Incorrect oil viscosity 1. Drain the oil.
2. Install the correct viscosity oil.
Worn crankshaft thrust bearing Inspect the thrust bearing and
crankshaft.
High valve lifter leak down rate Replace the lifters as required.
Upper Engine Noise, Regardless of Engine Speed

Cause Correction
Low oil pressure Perform an oil pressure test. Refer to
Oil Pressure Diagnosis and Testing.
Loose and/or worn valve rocker arm Inspect the valve rocker arm stud, nut,
attachments or bolt.
Worn valve rocker arm Replace the valve rocker arm.

Bent or damaged push rod Inspect the following components, and
replace as required:
The valve rocker arm

The valve push rod
The valve lifter
Improper lubrication to the valve rocker arms Inspect the following components, and repair
or replace as required:
The valve rocker arm
The valve push rod
The valve lifter
The oil filter bypass valve
The oil pump and pump screen
The engine block oil galleries
Broken valve spring Replace the valve spring.

Worn and/or damaged valve rotators Replace the valve rotators as required.
Worn or dirty valve lifters Replace the valve lifters.
Stretched or broken timing chain and/or Replace the timing chain and sprockets.
damaged sprocket teeth
Worn timing chain tensioner if applicable Replace the timing chain tensioners as
required.
Worn engine camshaft lobes Inspect the engine camshaft lobes.
Replace the camshaft and valve lifters as
required.
Damaged, broken, or dirty, balance shaft Inspect the following components, and repair
sprocket teeth if applicable as required:
The balance shaft gear

The camshaft gear
The balance shaft rear bushing
Worn valve guides or valve stems Inspect the following components, and repair
as required:
The valves
The valve guides
Stuck Valves Inspect the following components, and repair

Carbon on the valve stem or valve seat may as required:
cause the valve to stay open
The valves
The valve guides
Lower Engine Noise, Regardless of Engine Speed

Cause Correction
Repair or replace damaged components
as required.
Worn accessory drive components Inspect the accessory drive system.
Abnormalities such as severe cracking, bumps
or missing areas in the accessory drive belt
and/or misalignment of system components.
Loose or damaged crankshaft balancer Inspect the crankshaft balancer.
Detonation or spark knock Verify the correct operation of the ignition

controls system. Refer to Electronic Ignition
(EI) System Description in Engine
Controls.
Loose torque converter bolts Inspect the torque converter bolts and
flywheel.
Loose or damaged flywheel Repair or replace the flywheel.

Damaged oil pan, contacting the oil pump Inspect the oil pan.
screen
Inspect the oil pump screen.
An oil pan that has been damaged may
improperly position the oil pump screen, Repair or replace as required.
preventing proper oil flow to the oil pump.
Oil pump screen loose, damaged or restricted Inspect the oil pump screen.
Excessive piston-to-cylinder bore clearance Inspect the piston and cylinder bore.
Repair as required.
Excessive piston pin-to-bore clearance Inspect the piston, piston pin, and the
connecting rod.
Excessive connecting rod bearing clearance Inspect the following components, and repair
as required:
The connecting rod bearings

The connecting rods
The crankshaft
The crankshaft journals
Excessive crankshaft bearing clearance Inspect the following components, and repair
as required:
The crankshaft bearings

Incorrect piston, piston pin and connecting Verify the pistons, piston pins and
rod installation connecting rods are installed correctly.
Pistons must be installed with the mark or
Repair as required.
dimple on the top of the piston facing the
front of the engine. Piston pins must be
centered in the connecting rod pin bore.
Engine Noise Under Load

Cause Correction
Detonation or spark knock Verify the correct operation of the ignition

controls. Refer to Electronic Ignition (EI)
System Description in Engine Controls.
Loose torque converter bolts Inspect the torque converter bolts and
flywheel.
Repair as required.
Cracked flywheel automatic transmission Inspect the flywheel bolts and flywheel.
Repair as required.
Excessive connecting rod bearing clearance Inspect the following components, and repair
as required:
The connecting rod bearings

The connecting rods
The crankshaft
Excessive crankshaft bearing clearance Inspect the following components, and repair
as required:
The crankshaft bearings

The cylinder block crankshaft bearing
bore
Engine Will Not Crank - Crankshaft Will Not Rotate

Cause Correction
Seized accessory drive system component 1. Remove accessory drive belt or belts.
2. Rotate crankshaft by hand at the
balancer or flywheel location.
Hydraulically locked cylinder 1. Remove spark plugs and check for
fluid.
Coolant/antifreeze in cylinder
2. Inspect for broken head gasket or
Oil in cylinder gaskets.
Fuel in cylinder 3. Inspect for cracked engine block or
cylinder head.
4. Inspect for a sticking fuel injector
and/or leaking fuel regulator.
Seized automatic transmission torque 1. Remove the torque converter bolts.
converter
2. Rotate crankshaft by hand at the
balancer or flywheel location.
Broken timing chain and/or timing chain gears 1. Inspect timing chain and gears.
2. Repair as required.
Seized balance shaft bearing if equipped 1. Inspect balance shaft bearings.
Material in cylinder 1. Inspect cylinder for damaged
components and/or foreign materials.
Broken valve
2. Repair or replace as required.
Piston material
Foreign material
Seized crankshaft or connecting rod bearings 1. Inspect crankshaft and connecting rod
bearings.
Bent or broken connecting rod 1. Inspect connecting rods.
Broken crankshaft 1. Inspect crankshaft.
COOLANT IN COMBUSTION CHAMBER
Coolant in Combustion Chamber

Cause Correction
DEFINITION: Excessive white smoke and/or coolant type odor coming from the exhaust
pipe may indicate coolant in the combustion chamber. Low coolant levels, an inoperative
cooling fan, or a faulty thermostat may lead to an "overtemperature" condition which may
cause engine component damage.
1. A slower than normal cranking speed may indicate coolant entering the combustion
chamber. Refer to Engine Will Not Crank - Crankshaft Will Not Rotate.
2. Remove the spark plugs and inspect for spark plugs saturated by coolant or coolant in
the cylinder bore.
3. Inspect by performing a Cylinder Leakage Test. During this test, excessive air
bubbles within the coolant may indicate a faulty gasket or damaged component.
4. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on
the engine block, with low compression, may indicate a failed cylinder head gasket.
Refer to Engine Compression Test.
Cracked intake manifold or failed gasket Replace the components as required.
Faulty cylinder head gasket Replace the head gasket and components as
required. Refer to Cylinder Head Cleaning
and Inspection and Cylinder Head
Replacement - Left or Cylinder Head
Replacement - Right.
Warped cylinder head Machine the cylinder head to the proper
flatness, if applicable and replace the cylinder
head gasket. Refer to Cylinder Head
Cracked cylinder head Replace the cylinder head and gasket.
Cracked cylinder liner or engine block Replace the components as required.
Cylinder head or engine block porosity Replace the components as required.
COOLANT IN ENGINE OIL
Coolant in Engine Oil

Cause Correction
DEFINITION: Foamy or discolored oil or an engine oil "overfill" condition may indicate
coolant entering the engine crankcase. Low coolant levels, an inoperative cooling fan, or a
faulty thermostat may lead to an "overtemperature" condition which may cause engine
component damage. Contaminated engine oil and oil filter should be changed.
1. Inspect the oil for excessive foaming or an overfill condition. Oil diluted by coolant
may not properly lubricate the crankshaft bearings and may lead to component
damage. Refer to Lower Engine Noise, Regardless of Engine Speed.
2. Inspect by performing a Cylinder Leakage Test. During this test, excessive air
bubbles within the cooling system may indicate a faulty gasket or damaged
component.
3. Inspect by performing a cylinder compression test. Two cylinders "side-by-side" on
the engine block with low compression may indicate a failed cylinder head gasket.
Refer to Engine Compression Test.
Faulty external engine oil cooler Replace the components as required.
Faulty cylinder head gasket Replace the head gasket and components as
required. Refer to Cylinder Head Cleaning
and Inspection and Cylinder Head
Warped cylinder head Machine the cylinder head to proper flatness,
if applicable, and replace the cylinder head
gasket. Refer to Cylinder Head
Cracked cylinder head Replace the cylinder head and gasket.
Cracked cylinder liner or engine block Replace the components as required.
Cylinder head, block, or manifold porosity Replace the components as required.
Faulty or damaged lower intake gaskets Replace the components as required.
A compression pressure test of the engine cylinders determines the condition of the rings, the
valves, and the head gasket.
IMPORTANT: Remove the Powertrain Control Module (PCM) and the

ignition fuses from the I/P fuse block. Refer to Electrical
Center Identification Views in Wiring Systems.
1. Disable the ignition.

2. Disable the fuel systems.
3. Remove the spark plugs from all the cylinders.
4. Remove the air duct from the throttle body.
5. Block the throttle plate in the open position.
6. Measure the engine compression, using the following procedure:
1. Firmly install the compression gauge to the spark plug hole.
2. Have an assistant crank the engine through at least 4 compression strokes in the testing
cylinder.
3. Record the readings on the gauge at each stroke.
4. Disconnect the gauge.
5. Repeat the compression test for each cylinder.
7. Record the compression readings from all of the cylinders.
The lowest reading should not be less than 70 percent of the highest reading.
No cylinder reading should be less than 689 kPa (100 psi).
8. The following list contains examples of the possible measurements:

When the compression measurement is normal, the compression builds up quickly and
evenly to the specified compression on each cylinder.
When the compression is low on the first stroke and tends to build up on the following
strokes, but does not reach the normal compression, the piston rings may be the cause.
If the compression improves considerably with the addition of three squirts of oil, the
piston rings may be the cause.
When the compression is low on the first stroke and does not build up in the following
strokes, the valves may be the cause.
The addition of oil does not affect the compression, the valves may be the cause.
When the compression is low on two adjacent cylinders, or coolant is present in the
crankcase, the head gasket may be the cause.
9. Remove the block from the throttle plate.
10. Install the air duct to the throttle body.
12. Install the Powertrain Control Module (PCM) fuse.
13. Install the ignition fuse to the I/P fuse block.
CYLINDER LEAKAGE TEST
Tools Required
J 35667-A Cylinder Head Leakdown Tester. See Special Tools and Equipment.
Testing Procedure
With the use of air pressure, a cylinder leakage test will aid in the diagnosis. Use the cylinder
leakage test in conjunction with the engine compression test in order to isolate the cause of
leaking cylinders.
CAUTION: Refer to Battery Disconnect Caution in Cautions and

Notices.

2. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Controls.
3. Install the J 35667-A . See Special Tools and Equipment.
4. Measure each cylinder on the compression stroke, with both valves closed.
IMPORTANT: Hold the crankshaft balancer bolt in order to prevent piston

movement.
5. Apply air pressure, using the J 35667-A . See Special Tools and Equipment. Refer to the
manufacturer's instructions.
6. Record the cylinder leakage readings for each cylinder.
IMPORTANT: Normal cylinder leakage is from 12 to 18 percent.

Make a note of any cylinder with more leakage than the
other cylinders.
Any cylinder with 30 percent leakage or more requires
service.
7. Inspect the 4 primary areas in order to properly diagnose a leaking cylinder.

8. If air is heard from the intake or exhaust system, perform the following procedure:
Remove the valve rocker arm cover of the suspect cylinder head.
Ensure that both valves are closed.
Inspect the cylinder head for a broken valve spring.
Remove and inspect the suspect cylinder head. Refer to Cylinder Head Cleaning
and Inspection.
9. If air is heard from the crankcase system at the crankcase oil filler tube, perform the
1. Remove the piston from the suspect cylinder.
2. Inspect the piston and connecting rod assembly. Refer to Piston, Connecting Rod,
and Bearings Cleaning and Inspection.
3. Inspect the engine block. Refer to Engine Block Cleaning and Inspection.
10. If bubbles are found in the radiator, perform the following procedure:
Remove and inspect both cylinder heads. Refer to Cylinder Head Cleaning and
Inspection.
Inspect the engine block. Refer to Engine Block Cleaning and Inspection.
11. Remove the J 35667-A . See Special Tools and Equipment.

12. Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls.
13. Connect the negative battery cable. Refer to Battery Disconnect Caution in Cautions and
Notices.
An engine that has excessive oil consumption uses 0.9 L (1 qt) of oil, or more, within 3 200 km
(2,000 mi). The following list indicates the conditions and corrections of excessive oil
consumption:
An improperly read oil level indicator dipstick

Inspect the oil level while the vehicle is parked on a level surface.
Allow adequate drain-down time.
Improper oil viscosity
Use the recommended SAE viscosity for prevailing temperatures.

Continuous high-speed driving
Severe hauling, such as a trailer. This causes decreased oil mileage.
A malfunctioning crankcase ventilation system
External oil leaks
Tighten the bolts, as needed.
Replace the gaskets and seals, as needed.
Worn or omitted valve guides and/or valve stem seals

Ream the guides.
Install oversized service valves and/or new valve stem seals.
Broken or worn piston rings

Improperly installed or unseated piston rings
Improperly installed or improperly fitted piston
Plugged cylinder head gasket oil drain holes
Damaged intake gaskets
Low or No Oil Pressure
The following conditions may cause low or no oil pressure:
Low oil level
Fill to the full mark on the oil level indicator.
Incorrect or malfunctioning oil pressure switch
Replace the oil pressure switch.
Incorrect or malfunctioning oil pressure gage
Replace the oil pressure gage.
Improper oil viscosity or diluted oil

Install oil of proper viscosity for expected temperature.
Install new oil if the oil is diluted.
A worn or dirty oil pump

Clean or replace the oil pump.
A plugged oil filter
Replace the oil filter.
A loose or plugged oil pickup screen
Replace the oil pickup screen.
A hole in the oil pickup tube
Replace the oil pickup tube.
Excessive bearing clearance
Replace the bearings.
Cracked, porous, or plugged oil gallery
Repair or replace the engine block.
Missing or improperly installed gallery plugs
Install or repair the plugs as needed.
A stuck pressure regulator valve

Inspect the pressure regulator valve for sticking in the bore.
Inspect the bore for scoring and burrs.
A worn or poorly machined camshaft
Replace the camshaft.
Worn valve guides
Repair the valve guides as needed.

Oil Pressure Testing
Tools Required
J 25087-C Oil Pressure Tester

Test Procedure
If the vehicle has low oil pressure complete the following steps:
1. Inspect the oil level.

2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
4. Assemble the plunger valve in the large hole of the J 25087-C base. Insert the hose in the
small hole of the J 25087-C base. Connect the gage to the end of the hose.
5. Insert the flat side of the rubber plug in the bypass valve without depressing the bypass
valve.
6. Install the J 25087-C on the filter mounting pad.
8. Inspect the overall oil pressure, the oil pressure switch, and for noisy lifters. Ensure that the
engine is at operating temperature before inspecting the oil pressure. The oil pressure should
be approximately 414 kPa (60 psi) at 1,850 RPM using 5W-30 engine oil.
9. If adequate oil pressure is indicated, test the oil pressure switch.
10. If a low reading is indicated, press the valve on the tester base in order to isolate the oil
pump and/or its components from the lubricating system. An adequate reading at this time
indicates a good pump and the previous low pressure was due to worn bearings, etc. A low
reading while pressing the valve indicates a faulty pump.
OIL LEAK DIAGNOSIS
Tools Required
J 28428-E High Intensity Black Light Kit

Diagnosis Procedure
You may repair most fluid leaks by first visually locating the leak, repairing or replacing the
component, or by resealing the gasket surface. Once the leak is identified, determine the cause of
the leak. Repair the leak and the cause of leak.
Locating and Identifying the Leak
Use the visual inspection method in order to determine if the leaking fluid is one of the following
items:
Engine oil
Transmission fluid
Brake fluid
Some other fluid
Engine coolant
Fuel
Visual Inspection Method
Complete the following steps in order to perform the visual inspection method:
1. Bring the vehicle to normal operating temperature.

6. Inspect for leaks at sealing surfaces, fittings, or from cracked or damaged components.
7. If you cannot locate the leak, perform the following steps:
2. Operate the vehicle for several miles at normal operation temperature and at varying
speeds.
8. If you still cannot locate the leak, use the powder method or the black light and dye method.
Powder Method

2. Apply an aerosol-type powder, baby powder, foot powder, etc., to the suspected area.
3. Operate the vehicle for several miles at normal operation temperature and at varying speeds.
4. Identify the type of fluid, and the approximate location of the leak, from the discolorations
in the powder surface.
5. Visually inspect the suspected area. Use a small mirror to assist in looking at hard to see
areas.
Refer to Possible Causes for Leaks if necessary.

Black Light and Dye Method
A dye and light kit is available for finding leaks.
1. Use the J 28428-E or the equivalent. Refer to the manufacturer's instructions when using the
tool.
2. Visually inspect the suspected area. Use a small mirror if necessary
Refer to Possible Causes for Leaks if necessary.

Possible Causes for Leaks
Inspect the vehicle for the following conditions:
Higher than recommended fluid levels

Higher than recommended fluid pressures
Plugged or malfunctioning fluid filters or pressure bypass valves
Plugged or malfunctioning engine ventilation system
Improperly tightened or damaged fasteners
Cracked or porous components
Improper sealants or gaskets where required
Improper sealant or gasket installation
Damaged or worn gaskets or seals
Damaged or worn sealing surfaces
CRANKCASE VENTILATION SYSTEM INSPECTION/DIAGNOSIS
1. Disconnect the PCV hose.

3. Check for vacuum at the hose. If there is no vacuum, check for a plugged hose or manifold
port. Check for a hose that collapses when blocked (vacuum applied). Replace the plugged
or the deteriorated hoses.
4. Allow the engine to idle at normal operating temperature.
5. Remove the engine oil dipstick and install a vacuum gage on the dipstick tube.
6. Block off the PCV system fresh air intake passage.
7. Run the engine at 1500 RPM for 30 seconds, then read vacuum gage while engine is running
at 1500 RPM.
If vacuum is present, this indicates that the crankcase ventilation system is functioning
properly.
If no vacuum is indicated, the engine may not be sealed and is drawing in outside air.
Check the valve covers, the oil pan gasket or other sealing areas for leaks.
If the vacuum gage registers a pressure, or if a vacuum gage is pushed out of dipstick
tube, check for a plugged PCV port, a plugged hose or an excessive engine blow-by.
Diagnostic Aids
The symptom may be intermittent due to moisture on the drive belt(s) or the pulleys. It may be
necessary to spray a small amount of water on the drive belt(s) in order to duplicate the customers
concern. If spraying water on the drive belt(s) duplicates the symptom, cleaning the belt pulleys
may be the probable solution.
A loose or improper installation of a body component, a suspension component, or other items of

the vehicle may cause the chirping noise.
Test Description
2: The noise may not be engine related. This step is to verify that the engine is making the
noise. If the engine is not making the noise do not proceed further with this table.
3: The noise may be an internal engine noise. Removing the drive belt and operating the
engine for a brief period will verify the noise is related to the drive belt. When removing the
drive belt(s) the water pump may not be operating and the engine may overheat. Also DTCs
may set when the engine is operating with the drive belt removed.
4: Inspect all drive belt pulleys for pilling. Pilling is the small balls or pills or it may be
strings in the drive belt grooves from the accumulation of rubber dust.
6: Misalignment of the pulleys may be caused from improper mounting of the accessory
drive component, incorrect installation of the accessory drive component pulley, or the
pulley bent inward or outward from a previous repair. Test for a misalign pulley using a
straight edge in the pulley grooves across two or three pulleys. If a misalign pulley is found
refer to that accessory drive component for the proper installation procedure for that pulley.
10: Inspecting of the fasteners can eliminate the possibility that a wrong bolt, nut, spacer, or
washer was installed.
12: Inspecting the pulleys for being bent should include inspecting for a dent or other
damage to the pulleys that would prevent the drive belt from not seating properly in all of
the pulley grooves or on the smooth surface of a pulley when the back side of the belt is
used to drive the pulley.
14: Replacing the drive belt when it is not damaged or there is not excessive pilling will
only be a temporary repair.
Drive Belt Chirping Diagnosis

Step Action Yes No
NOTE:
Refer to Belt Dressing Notice in Cautions and Notices.
DEFINITION: The following items are indications of chirping:
A high pitched noise that is heard once per revolution of the drive belt or a pulley.
It usually occurs on cold damp mornings.
Did you review the Symptoms - Engine Go to

Mechanical operation and perform the necessary Symptoms -
1
inspections? Engine
Go to Step 2 Mechanical
Verify that there is a chirping noise. Go to
2
Does the engine make the chirping noise? Go to Step 3 Diagnostic Aids
Go to Engine
Replacement
Noise on Start-
2. Operate the engine for no longer than 30 to Up, but Only
40 seconds. Lasting a Few
Seconds,
Does the chirping noise still exist?
Upper Engine
3 Noise,
Regardless of
Engine Speed,
Lower Engine
Noise,
Regardless of
Engine Speed,
or Engine
Noise Under
Load Go to Step 4
Inspect for severe pilling exceeding 1/3 of the belt
4 groove depth.
Does the belt grooves have pilling? Go to Step 5 Go to Step 6
Clean the drive belt pulleys with a suitable wire
5 brush.
Did you complete the repair? Go to Step 15 Go to Step 6
Inspect for misalignment of the pulleys.
6
Are any of the pulleys misaligned? Go to Step 7 Go to Step 8
Replace or repair any misaligned pulleys.
7
Inspect for bent or cracked brackets.
8
Did you find any bent or cracked brackets? Go to Step 9 Go to Step 10
Replace any bent or cracked brackets.
9
Inspect for improper, loose or missing fasteners.
10
1. Tighten any loose fasteners.
2. Replace any improper or missing fasteners.
11 Refer to Fastener Tightening
Specifications.

Inspect for a bent pulley.
12
Replace the bent pulley.
13
Replace the drive belt. Refer to Drive Belt
14 Replacement. Go to
Did you complete the repair? Go to Step 15 Diagnostic Aids
15
Diagnostic Aids
A loose or improper installation of a body component, a suspension component, or other items of
the vehicle may cause the squeal noise.
If the noise is intermittent, verify the accessory drive components by varying their loads making
sure they are operated to their maximum capacity. An overcharged A/C system, power steering
system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect.
Test Description
2: The noise may not be engine related. This step is to verify that the engine is making the
noise. If the engine is not making the noise do not proceed further with this table
3: The noise may be an internal engine noise. Removing the drive belt and operating the
engine for a brief period will verify the squeal noise is the drive belt(s) or an accessory
drive component. When removing the drive belt the water pump may not be operating and
the engine may overheat. Also DTCs may set when the engine is operating with the drive
belt removed.
4: This test is to verify that an accessory drive component does not have a seized bearing.
With the belt remove test the bearings in the accessory drive components for turning
smoothly. Also test the accessory drive components with the engine operating by varying the
load on the components to verify that the components operate properly.
5: This test is to verify that the drive belt tensioner operates properly. If the drive belt
tensioner is not operating properly, proper belt tension may not be achieved to keep the
drive belt from slipping which could cause a squeal noise.
6: This test is to verify that the drive belt(s) is not too long, which would prevent the drive
belt tensioner from working properly. Also if an incorrect length drive belt was installed, it
may not be routed properly and may be turning an accessory drive component in the wrong
direction.
refer to that accessory drive component for the proper installation procedure for that pulley.
8: This test is to verify that the pulleys are the correct diameter or width. Using a known
good vehicle compare the pulley sizes.
Drive Belt Squeal Diagnosis

Step Action Yes No
NOTE:
DEFINITION: The following items are indications of drive belt squeal:
A loud screeching noise that is caused by a slipping drive belt (this is unusual for a
drive belt with multiple ribs)
The noise occurs when a heavy load is applied to the drive belt, such as an air
conditioning compressor engagement snapping the throttle, or slipping on a seized
pulley or a faulty accessory drive component.
1
inspections? Engine
Verify that there is a squeal noise. Go to
2
Does the engine make the squeal noise? Go to Step 3 Diagnostic Aids
1. Remove the drive belt(s). Refer to Drive Go to Engine
Belt Replacement. Noise on Start-
Up, but Only
2. Operate the engine for no longer than 30 to
Lasting a Few
40 seconds.
Seconds,
Does the noise still exist? Upper Engine
Noise,
Regardless of
3
Engine Speed,
Lower Engine
Noise,
Regardless of
Engine Speed,
or Engine
Noise Under
Load Go to Step 4
Inspect for an accessory drive component seized
4 bearing or a faulty accessory drive component.
Test the drive belt tensioner for proper operation.
5 Refer to Drive Belt Tensioner Diagnosis.
Inspect for the correct drive belt length. Refer to
Drive Belt Replacement.
6
Inspect for misalignment of a pulley.
7
Inspect for the correct pulley size. Go to
8
9
Diagnostic Aids
The drive belt(s) will not cause the whine noise.
If the whine noise is intermittent, verify the accessory drive components by varying their loads
making sure they are operated to their maximum capacity. Such items but not limited to may be
an A/C system overcharged, the power steering system restricted or the wrong fluid, or the
generator failing.
Test Description
3: This test is to verify that the noise is being caused by the drive belt(s) or the accessory
drive components. When removing the drive belt the water pump may not be operating and
the engine may overheat. Also DTCs may set when the engine is operating with the drive
belt removed.
4: The inspection should include checking the drive belt tensioner and the drive belt idler
pulley bearings. The drive belt(s) may have to be installed and the accessory drive
components operated separately by varying their loads. Refer to the suspected accessory
drive component for the proper inspection and replacement procedure.
Drive Belt Whine Diagnosis

Step Action Yes No
NOTE:
DEFINITION: A high pitched continuous noise that may be caused by an accessory drive
component failed bearing.
1
inspections? Engine
Verify that there is a whine noise. Go to
2
Does the engine make the whine noise? Go to Step 3 Diagnostic Aids
1. Remove the drive belt. Refer to Drive Belt Go to Engine
Replacement. Noise on Start-
Up, but Only
Lasting a Few
40 seconds.
Seconds,
Does the whine noise still exist? Upper Engine
Noise,
Regardless of
3
Engine Speed,
Lower Engine
Noise,
Regardless of
Engine Speed,
or Engine
Noise Under
Load Go to Step 4
Inspect for a failed accessory drive component
4 bearing. Go to
Did you find and repair the condition? Go to Step 5 Diagnostic Aids
5
Did you correct the condition? System OK -
Diagnostic Aids
Vibration from the engine operating may cause a body component or another part of the vehicle
to make rumbling noise.
The drive belt(s) may have a condition that can not be seen or felt. Sometimes replacing the drive
belt may be the only repair for the symptom.
If replacing the drive belt(s), completing the diagnostic table, and the noise is only heard when
the drive belt(s) is installed, there might be an accessory drive component with a failure. Varying
the load on the different accessory drive components may aid in identifying which component is
causing the rumbling noise.
Test Description
2: This test is to verify that the symptom is present during diagnosing. Other vehicle
components may cause a similar symptom.
3: This test is to verify that the drive belt(s) is causing the rumbling noise. Rumbling noise
may be confused with an internal engine noise due to the similarity in the description.
Remove only one drive belt at a time if the vehicle has multiple drive belts. When removing
the drive belt the water pump may not be operating and the engine may overheat. Also
DTCs may set when the engine is operating with the drive belt removed.
4: Inspecting the drive belt(s) is to ensure that it is not causing a the noise. Small cracks
across the ribs of the drive belt will not cause the noise. Belt separation is identified by the
plys of the belt separating and may be seen at the edge of the belt our felt as a lump in the
belt.
5: Small amounts of pilling is normal condition and acceptable. When the pilling is severe
the drive belt does not have a smooth surface for proper operation.
Drive Belt Rumbling Diagnosis

Step Action Yes No
NOTE:
DEFINITION:
A low pitch tapping, knocking, or thumping noise heard at or just above idle.
Heard once per revolution of the drive belt or a pulley.
Rumbling may be caused from:
Pilling, the accumulation of rubber dust that forms small balls (pills) or strings in
the drive belt pulley groove
The separation of the drive belt
A damaged drive belt
Did you review the Symptoms - Engine

Go to
1 Mechanical operation and perform the necessary Symptoms -
inspections?
Engine
Verify that there is a rumbling noise. Go to
2
Does the engine make the rumbling noise? Go to Step 3 Diagnostic Aids
1. Remove the drive belt. Refer to Drive Belt Go to Engine
Replacement. Noise on Start-
Up, but Only
Lasting a Few
40 seconds.
Seconds,
Does the rumbling noise still exist? Upper Engine
Noise,
Regardless of
3
Engine Speed,
Lower Engine
Noise,
Regardless of
Engine Speed,
or Engine
Noise Under
Load Go to Step 4
Inspect the drive belt(s) for damage, separation,
4 or sections of missing ribs.
Did you find any of these conditions? Go to Step 7 Go to Step 5
Inspect for severe pilling of more than 1/3 of the
5 drive belt pulley grooves.
Did you find severe pilling? Go to Step 6 Go to Step 7
1. Clean the drive belt pulleys using a suitable
wire brush.
6 2. Reinstall the drive belt. Refer to Drive Belt
Replacement.

Install a new drive belt. Refer to Drive Belt
7 Replacement.
Operate the system in order to verify the repair. Go to
8
Did you correct the condition? System OK Diagnostic Aids

Diagnostic Aids
The accessory drive components can have an affect on engine vibration. Such as but not limited to
the A/C system over charged, the power steering system restricted or the incorrect fluid, or an
extra load on the generator. To help identify an intermittent or an improper condition, vary the
loads on the accessory drive components.
Test Description
2: This test is to verify that the symptom is present during diagnosing. Other vehicle
components may cause a similar symptom such as the exhaust system, or the drivetrain.
3: This test is to verify that the drive belt(s) or accessory drive components may be causing
the vibration. When removing the drive belt the water pump may not be operating and the
engine may overheat. Also DTCs may set when the engine is operating with the drive belt
removed.
4: The drive belt(s) may cause a vibration. While the drive belt(s) is removed this is the best
time to inspect the condition of the belt.
washer was installed.
8: This step should only be performed if the water pump is driven by the drive belt. Inspect
the water pump shaft for being bent. Also inspect the water pump bearings for smoothness
and excessive play. Compare the water pump with a known good water pump.
9: Accessory drive component brackets that are bent, cracked, or loose may put extra strain
on that accessory component causing it to vibrate.
Drive Belt Vibration Diagnosis

Step Action Yes No
NOTE:
DEFINITION: The following items are indications of drive belt vibration:
The vibration is engine-speed related.

The vibration may be sensitive to accessory load.

Go to
inspections?
Engine
Verify that the vibration is engine related. Go to
2
Does the engine make the vibration? Go to Step 3 Diagnostic Aids
1. Remove the drive belt. Refer to Drive Belt Go to
Replacement. Diagnostic
Starting Point
- Vibration
3 40 seconds.
Diagnosis and
Does the engine still make the vibration? Correction in
Vibration and
Diagnosis Go to Step 4
Inspect the drive belt for wear, damage, debris
4 build-up and missing drive belt ribs.
5 Replacement.
6
Tighten any loose fasteners.
Replace improper or missing fasteners. Refer to
7
Fastener Tightening Specifications.
Inspect for a bent water pump shaft, if the water
pump is belt driven. Refer to Water Pump
8 Replacement (LA1) or Water Pump
Replacement (LY7) in Engine Cooling.
Inspect for bent or cracked brackets. Go to
9
10
Diagnostic Aids
If the drive belt(s) repeatedly falls off the drive belt pulleys, this is because of pulley
misalignment.
An extra load that is quickly applied on released by an accessory drive component may cause the
drive belt to fall off the pulleys. Verify the accessory drive components operate properly.
If the drive belt(s) is the incorrect length, the drive belt tensioner may not keep the proper tension
on the drive belt.
Test Description
2: This inspection is to verify the condition of the drive belt. Damage may of occurred to
the drive belt when the drive belt fell off. The drive belt may of been damaged, which
caused the drive belt to fall off. Inspect the belt for cuts, tears, sections of ribs missing, or
damaged belt plys.
refer to that accessory drive component for the proper installation procedure of that pulley.
5: Inspecting the pulleys for being bent should include inspecting for a dent or other damage
to the pulleys that would prevent the drive belt from not seating properly in all of the pulley
grooves or on the smooth surface of a pulley when the back side of the belt is used to drive
the pulley.
6: Accessory drive component brackets that are bent or cracked may will let the drive belt
fall off.
washer was installed. Missing. loose, or the wrong fasteners may cause pulley misalignment
from the bracket moving under load. Over tightening of the fasteners may cause
misalignment of the accessory component bracket.
Drive Belt Falls Off Diagnosis

Step Action Yes No
NOTE:
DEFINITION: The drive belt falls off the pulleys or may not ride correctly on the pulleys.
Go to
inspections?
Engine
Inspect for a damaged drive belt.
2
3 Replacement.
Does the drive belt continue to fall off? Go to Step 4 System OK
Inspect for misalignment of the pulleys.
4
Did you find and repair the condition? Go to Step 12 Go to Step 5
Inspect for a bent or dented pulley.
5
Inspect for a bent or a cracked bracket.
6
7
Did you find loose or missing fasteners? Go to Step 8 Go to Step 9
1. Tighten any loose fasteners. Refer to
Fastener Tightening Specifications.
8 2. Replace improper or missing fasteners.

Test the drive belt tensioner for operating
correctly. Refer to Drive Belt Tensioner
9
Diagnosis.
Does the drive belt tensioner operate correctly? Go to Step 11 Go to Step 10
Replace the drive belt tensioner. Refer to Drive
10 Belt Tensioner Replacement.
Inspect for failed drive belt idler and drive belt
11 tensioner pulley bearings. Go to
12
Diagnostic Aids
Excessive wear on a drive belt(s) is usually caused by an incorrect installation or the wrong drive
belt for the application.
Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably
cause the drive belt(s) to make a noise or to fall off.
Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the
drive belt(s) fall off.
Test Description
2: The inspection is to verify the drive belt(s) is correctly installed on all of the drive belt
pulleys. Wear on the drive belt(s) may be caused by mis-positioning the drive belt(s) by one
groove on a pulley.
3: The installation of a drive belt that is two wide or two narrow will cause wear on the
drive belt. The drive belt ribs should match all of the grooves on all of the pulleys.
4: This inspection is to verify the drive belt(s) is not contacting any parts of the engine or
body while the engine is operating. There should be sufficient clearance when the drive belt
accessory drive components load varies. The drive belt(s) should not come in contact with
an engine or a body component when snapping the throttle.
Drive Belt Excessive Wear Diagnosis

Step Action Yes No
NOTE:
DEFINITION: Wear at the outside ribs of the drive belt due to an incorrectly installed
drive belt.
1
inspections? Engine
Inspect the drive belt for the proper installation.
2 Refer to Drive Belt Replacement.
Did you find this condition? Go to Step 5 Go to Step 3
Inspect for the proper drive belt.
3
Did you find this condition? Go to Step 5 Go to Step 4
Inspect for the drive belt rubbing against a
4 bracket, hose, or wiring harness. Go to
Replace the drive belt. Refer to Drive Belt
5 Replacement.
6
Drive Belt Tensioner Diagnosis

Step Action Yes No
Replacement.
1 2. Inspect the drive belt tensioner pulley.
Is the drive belt tensioner pulley loose or

misaligned? Go to Step 4 Go to Step 2
Rotate the drive belt tensioner.
2 Does the tensioner rotate without any unusual
resistance or binding? Go to Step 3 Go to Step 4
1. Use a torque wrench in order to measure the
torque required to move the tensioner off of
the stop.
2. Use a torque wrench on a known good
3 tensioner in order to measure the torque
required to move the tensioner off of the stop.
Is the first torque reading within 10% of the

second torque reading? System OK Go to Step 4
Replace the drive belt tensioner. Refer to Drive
4 Belt Tensioner Replacement.
Is the repair complete? System OK -
REPAIR INSTRUCTIONS
DRIVE BELT REPLACEMENT
Removal Procedure
Fig. 6: Rotating Drive Belt Tensioner
1. Rotate the drive belt tensioner in order to release the pressure on the drive belt.
2. Remove the drive belt.
Fig. 7: Rotating Drive Belt Tensioner
1. Install the drive belt to all of the pulleys except the generator pulley.
2. Rotate the drive belt tensioner in order to install the drive belt over the generator pulley.
Fig. 8: Illustrating Proper Alignment Of Drive Belt
IMPORTANT: Ensure that the drive belt is aligned into the proper grooves
of the accessory drive belt pulleys.
3. Ensure that the drive belt is properly routed.
DRIVE BELT TENSIONER REPLACEMENT
Removal Procedure
1. Remove the drive belt. Refer to Drive Belt Replacement.
Fig. 9: Identifying Drive Belt Tensioner Assembly


Fig. 10: Identifying Drive Belt Tensioner Assembly

3. Install the drive belt. Refer to Drive Belt Replacement.
DRIVE BELT IDLER PULLEY REPLACEMENT - UPPER
Removal Procedure

Fig. 11: Locating Drive Belt Idler Pulley
2. Remove the drive belt idler pulley bolt.

3. Remove the drive belt idler pulley.
Fig. 12: Locating Drive Belt Idler Pulley

1. Install the drive belt idler pulley.
2. Install the drive belt idler pulley bolt.
Tighten: Tighten the drive belt idler pulley bolt to 50 N.m (37 lb ft).
ENGINE MOUNT INSPECTION
NOTE: In order to avoid oil pan damage and possible engine failure, insert
a block of wood that spans the width of the oil pan bottom between
the oil pan and the jack support.
IMPORTANT: Before replacing any engine mount due to suspected fluid

loss, verify that the source of the fluid is the engine mount,
not the engine or accessories.
1. Raise the engine in order to remove the weight from the engine mount and create slight
tension in the rubber.
2. Observe the engine mount while raising the engine. Replace the engine mount if the engine
mount exhibits any of the following conditions:
The hard rubber surface is covered with heat check cracks.
The rubber is separated from the metal plate of the engine mount.
The rubber is split through the center of the engine mount.
3. If there is movement between the metal plate of the engine mount and its attaching points,
lower the engine on the engine mount. Tighten the bolts or nuts attaching the engine mount
to the frame or engine mount bracket. Refer to Engine Mount Bracket Replacement.
ENGINE SUPPORT FIXTURE
Tools Required
J 28467-34 Lift Hook Wing Nut and Washer (2). See Special Tools and Equipment.
J 28467-6A Bracket Assembly (2). See Special Tools and Equipment.
J 28467-7A Bolt Hook (2). See Special Tools and Equipment.
J 28467-500 Engine Support Fixture. See Special Tools and Equipment.
J 28467-B Universal Engine Support Fixture. See Special Tools and Equipment.
J 45057 Engine Support Bar Assembly. See Special Tools and Equipment.
J 45057-2 Lower Support Bar. See Special Tools and Equipment.
1. Remove the right engine mount strut. Refer to Engine Mount Strut Replacement - Right.
Fig. 13: View Of J 45057

2. Install the J 45057 to the right engine mount strut bracket (1). See Special Tools and
Equipment.
Fig. 14: Installing J 45057 To Left Side Engine Lift Bracket

3. Install the J 45057 to the left side engine lift bracket. See Special Tools and Equipment.
Fig. 15: View of J 45057 Installed To Right Side Engine Lift Bracket
4. Install the J 45057 to the right rear engine lift bracket. See Special Tools and Equipment.
5. For Buick vehicles, remove the headlamps. Refer to Headlamp Assembly or Headlamp
Bulb Replacement (Aztek) or Headlamp Assembly or Headlamp Bulb Replacement
(Rendezvous) in Lighting Systems.
6. Disconnect the hood strut assist rods from the fenders.
7. Carefully open and secure the hood in a 90 degree position.
Fig. 16: Identifying J 28467-B & J 28467-3
8. Install a J 28467-B and retention pin to each end of theJ 28467-500 beam (2). See Special
Tools and Equipment.
Fig. 17: View Of Engine Lift Bracket
9. Position the J 28467-B to the left and right side inner fender rails in order to install the J
28467-500 . See Special Tools and Equipment.
Fig. 18: View Of Lift Hook Assembly
10. Assemble the following to create 2 lift hook assemblies as shown:

J 28467-34 . See Special Tools and Equipment.
J 28467-6A . See Special Tools and Equipment.

J 28467-7A . See Special Tools and Equipment.
Fig. 19: View Of Lift Hook & Bracket Assembly At Longitudinal Mounted Cross
Bar
11. Install the 2 lift hook assemblies (1) to the J 45057-2 (2). See Special Tools and
Equipment.
Fig. 20: View Of Right Side Lift Hook Assembly
12. Install the right side lift hook assembly to the right side hole in the J 45057 (2). See Special
Fig. 21: View Of Left Side Lift Hook Assembly
13. Install the left side lift hook assembly to the left side hole in the J 45057 (2). See Special
14. Gently tighten the J 28467-34 lift hook wing nuts. See Special Tools and Equipment.
16. Remove the lower air baffle. Refer to Radiator Air Baffle Assemblies and Deflectors in
Engine Cooling.
17. Remove the engine mount left bolt.
Fig. 22: Locating J 45057-2
18. Install the J 45057-2 to the radiator core support. See Special Tools and Equipment.
19. Use the engine mount bolt to install the J 45057-2 to the engine. See Special Tools and
Equipment.
Fig. 23: Ensuring Proper Assembly Of J 45057-2
20. Ensure that the J 45057-2 is assembled properly and hand tighten the fasteners. See Special
ENGINE MOUNT REPLACEMENT
Removal Procedure
1. Disconnect the battery ground (negative) cable. Refer to Battery Negative Cable
Disconnect/Connect Procedure (LA1) or Battery Negative Cable Disconnect/Connect
Procedure (LY7) in Engine Electrical.
2. Remove the throttle body air inlet duct. Refer to Air Cleaner Intake Duct Replacement
in Engine Controls - 3.4L.
3. Remove the engine mount struts. Refer to Engine Mount Strut Replacement - Left or
Engine Mount Strut Replacement - Right.
Information.
5. Remove the three-way catalytic converter pipe from the engine right side exhaust manifold.
Refer to Catalytic Converter Replacement in Engine Exhaust.
6. Remove the right front wheel and tire. Refer to Tire and Wheel Removal and
Installation in Tires and Wheels.
7. Remove the right engine splash shield. Refer to Splash Shield Replacement - Engine in
Body Front End.
Fig. 24: Identifying Engine Mount Lower Nuts

8. Remove the engine mount lower nuts.
Fig. 25: Engine Mount Bracket To Oil Pan Bolts

NOTE: In order to avoid oil pan damage and possible engine failure,
insert a block of wood that spans the width of the oil pan
bottom between the oil pan and the jack support.
9. Use a utility stand and a block of wood in order to raise the engine.
10. For FWD, remove the engine mount bracket-to-oil pan bolts.
Fig. 26: View Of Engine Mount Bracket-To-Oil Pan Bolts

11. For AWD, remove the engine mount bracket-to-oil pan bolts (1).
12. For AWD, remove the engine mount bracket-to engine bolts (2).
13. Remove the engine mount and the engine mount bracket.
Fig. 27: Identifying Engine Mount Upper Nuts

15. Remove the engine mount from the engine mount bracket.

1. Install the engine mount to the engine mount bracket.

Tighten: Tighten the engine mount upper nuts to 53 N.m (39 lb ft).
Fig. 29: Engine Mount Bracket To Oil Pan Bolts
3. Install the engine mount bracket with the engine mount to the oil pan.
4. For FWD, install the engine mount bracket-to-oil pan bolts.
Tighten: Tighten the engine mount bracket bolts to 58 N.m (43 lb ft).
Fig. 30: View Of Engine Mount Bracket-To-Oil Pan Bolts
5. Fro AWD, install the engine mount bracket-to-oil pan bolts. Hand tighten only.
6. For AWD, install the engine mount-to-engine bolt (2).

7. Use the utility stand in order to lower the engine.
Fig. 31: Identifying Engine Mount Lower Nuts

8. Install the engine mount lower nuts.
Tighten: Tighten the engine mount lower nuts to 47 N.m (35 lb ft).
9. Install the right engine splash shield. Refer to Splash Shield Replacement - Engine in
Body Front End.
10. Install the right front wheel and tire. Refer to Tire and Wheel Removal and Installation
in Tires and Wheels.
11. Connect the three-way catalytic converter pipe to the engine right side exhaust manifold.
Refer to Catalytic Converter Replacement in Engine Exhaust.
13. Install the engine mount struts. Refer to Engine Mount Strut Replacement - Left and
14. Install the throttle body air inlet duct. Refer to Air Cleaner Element Replacement in
Engine Controls - 3.4L.
15. Connect the battery ground (negative) cable. Refer to Battery Negative Cable
ENGINE MOUNT BRACKET REPLACEMENT
Removal Procedure
1. Remove the engine mount. Refer to Engine Mount Replacement.


Tighten: Tighten the engine mount upper nuts to 53 N.m (39 lb ft).
3. Install the engine mount. Refer to Engine Mount Replacement.
ENGINE MOUNT STRUT REPLACEMENT - LEFT
Removal Procedure
Fig. 34: Locating Bolt & Nut For Engine Mount Strut At Left Engine Mount Strut
Bracket
1. Remove the bolt and the nut from the engine mount strut at the left engine mount strut
bracket on the engine.
Fig. 35: View Of Bolt & Nut For Engine Mount Strut At Engine Mount Strut
Bracket On Upper Radiator Support
2. Remove the bolt and the nut from the engine mount strut at the engine mount strut bracket
on the upper radiator support.
Hardness
Splitting
Cracking

2. Install the bolt and the nut to the engine mount strut at the engine mount strut bracket on the
upper radiator support. HAND TIGHTEN ONLY.
Bracket
3. Install the bolt and the nut to the engine mount strut at the left engine mount strut bracket on
the engine.
Tighten: Tighten bolt engine mount strut nuts to 48 N.m (35 lb ft).
ENGINE MOUNT STRUT REPLACEMENT - RIGHT
Removal Procedure
Fig. 38: Locating Bolt & Nut For Engine Mount Strut At Right Engine Mount Strut
Bracket
1. Remove the bolt and the nut from the engine mount strut at the right engine mount strut
bracket on the engine.
2. Remove the bolt and the nut from the engine mount strut at the engine mount strut bracket
on the upper radiator support.
Hardness
Splitting
Cracking

2. Install the bolt and the nut to the engine mount strut at the engine mount strut bracket on the
upper radiator support. HAND TIGHTEN ONLY.
Bracket
3. Install the bolt and the nut to the engine mount strut at the right engine mount strut bracket
on the engine.
Tighten: Tighten both engine mount strut nuts to 48 N.m (35 lb ft).
ENGINE MOUNT STRUT BRACKET REPLACEMENT - LEFT
Removal Procedure
Bracket
1. Remove the left engine mount strut from the left engine mount strut bracket. Refer to
Engine Mount Strut Replacement - Left.
2. Remove the thermostat housing. Refer to Thermostat Replacement (LA1) or Thermostat
Fig. 43: View Of Engine Mount Strut Bracket Bolts

3. Remove the engine mount strut bracket bolts from the left engine mount strut bracket to the
cylinder head.
4. Remove the left engine mount strut bracket.
Fig. 44: View Of Engine Mount Strut Bracket Bolts
1. Install the left engine mount strut bracket.
2. Install the engine mount strut bracket bolts through the engine mount strut bracket to the
cylinder head.
Tighten: Tighten the engine mount strut bracket bolts to 70 N.m (52 lb ft).
3. Install the thermostat housing. Refer to Thermostat Replacement (LA1) or Thermostat

Bracket
4. Install the left engine mount strut to the left engine mount strut bracket. Refer to Engine
Mount Strut Replacement - Left.
ENGINE MOUNT STRUT BRACKET REPLACEMENT - RIGHT
Removal Procedure
Bracket
1. Remove the right engine mount strut from the right engine mount strut bracket. Refer to
Fig. 47: Identifying Engine Mount Strut Bracket Bolt
Information.
3. Remove the lower radiator baffle. Refer to Radiator Air Baffle Assemblies and
Deflectors in Engine Cooling.
Fig. 48: Locating Air Conditioning Compressor Mounting Bolts
4. Remove the air conditioning compressor mounting bolts. Refer to Compressor

Replacement in Heating, Ventilation and Air Conditioning.
5. Remove and set the air conditioning compressor aside.
Fig. 49: View Of Lower Engine Mount Strut Bracket Bolt
6. Remove the lower engine mount strut bracket bolt from the right engine mount strut bracket.
8. Remove the vertical engine mount strut bracket bolt from the right engine mount strut
bracket.
9. Remove the right engine mount strut bracket.
Fig. 50: View Of Lower Engine Mount Strut Bracket Bolt
1. Position the right engine mount strut bracket over the pin locator.
2. Install the vertical engine mount strut bracket bolt through the right engine mount strut
bracket to the cylinder head.
Tighten: Tighten the engine mount strut bracket bolt to 50 N.m (37 lb ft).
Information.
4. Install the engine mount strut bracket lower bolt through the right engine mount strut
bracket into the cylinder block.
Tighten: Tighten the engine mount strut bracket bolt to 50 N.m (37 lb ft).
5. Install the air conditioning compressor. Refer to Compressor Replacement in Heating,

6. Install the lower radiator baffle. Refer to Radiator Air Baffle Assemblies and Deflectors
in Engine Cooling.
Bracket
8. Install the right engine mount strut to the right engine mount strut bracket. Refer to Engine
Mount Strut Replacement - Right.
ENGINE MOUNT STRUT BRACKET REPLACEMENT - UPPER RADIATOR SUPPORT
Removal Procedure
1. Remove the engine mount strut from the engine mount strut bracket at the upper radiator
support. Refer to Engine Mount Strut Replacement - Left and/or Engine Mount Strut
Fig. 53: Engine Mount Strut Bracket Bolts

2. Remove the engine mount strut bracket bolts from the upper radiator support.
3. Remove the engine mount strut bracket from the upper radiator support.
Fig. 54: Engine Mount Strut Bracket Bolts
1. Position the engine mount strut bracket over the upper radiator support. Ensure that the
engine mount strut bracket and the engine mount strut are aligned to the proper holes of the
upper radiator support.
2. Install the engine mount strut bracket bolts to the upper radiator support.
Tighten: Tighten the engine mount strut bracket bolts to 26 N.m (19 lb ft).
3. Install the engine mount strut to the engine mount strut bracket at the upper radiator support.
Refer to Engine Mount Strut Replacement - Left and/or Engine Mount Strut
OIL FILTER ADAPTER AND BYPASS VALVE ASSEMBLY REPLACEMENT
Removal Procedure
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in
2. Remove the oil filter. Refer to Engine Oil and Oil Filter Replacement.
Fig. 56: Oil Filter Bypass Hole Plug

3. Remove oil filter bypass hole plug.
Fig. 57: View Of Oil Filter Bypass Valve

4. Insert a flat-bladed tool into the oil filter bypass hole and force the bypass valve (1 ) out.
Fig. 58: Oil Filter Bypass Valve
5. Remove the oil filter bypass valve.

Fig. 59: Identifying Oil Filter Adapter
6. If necessary, remove the oil filter adapter.

Fig. 60: Identifying Oil Filter Adapter
1. If removed, install the oil filter adapter.
Tighten: Tighten the oil filter adapter to 39 N.m (29 lb ft).

Fig. 61: Oil Filter Bypass Valve

3. Install the oil filter bypass valve (1) to the proper depth.
Fig. 63: Oil Filter Bypass Hole Plug
4. Install oil filter bypass hole plug.
Tighten: Tighten the oil filter bypass hole plug to 19 N.m (14 lb ft).
5. Install the oil filter. Refer to Engine Oil and Oil Filter Replacement.
7. Inspect and correct the engine oil level as necessary. Refer to Fluid and Lubricant
Recommendations and Explanation of Scheduled Services in Maintenance and
Lubrication.
OIL LEVEL INDICATOR AND TUBE REPLACEMENT

Removal Procedure
Fig. 64: View Of Oil Level Indicator Tube Bolt And Tube
1. Remove the oil level indicator.

2. Remove the oil level indicator tube bolt and tube.
If you are unable to remove the oil level indicator tube, perform the following steps:
1. Apply penetrating oil to the bottom of the oil level indicator tube.
2. Move the oil level indicator tube back and forth in order to loosen the oil level
indicator tube.
1. Clean the oil level indicator tube.

2. Apply GM sealant P/N 12345739 or equivalent around the oil level indicator tube 12.7 mm
(0.50 in) below the bead.
Fig. 65: View Of Oil Level Indicator Tube Bolt And Tube
3. Install the oil level indicator tube and bolt.
Tighten: Tighten bolt to 25 N.m (18 lb ft.)
4. Install the oil level indicator.
INTAKE MANIFOLD REPLACEMENT - UPPER
Removal Procedure
IMPORTANT: The fuel injector wiring harness connectors must be connected to

their respective fuel injectors. Failure to connect the fuel injector
connectors to their respective fuel injectors may result in
excessive exhaust emissions and poor engine performance.
1. Drain the engine coolant from the cooling system. Refer to Draining and Filling Cooling
System in Engine Cooling.
3. Remove the accelerator control and cruise control cables with bracket from the throttle
body. Refer to Accelerator Controls Cable Replacement in Engine Controls - 3.4L.
4. Disconnect the wiring harness connectors from the following throttle body components:
Throttle Position (TP) sensor
Idle Air Control (IAC) valve
5. Disconnect the engine left side spark plug wires. Refer to Spark Plug Wire Replacement
in Engine Electrical.
6. Disconnect the engine left side spark plug wire harness attachment clip. Refer to Spark
Plug Wire Replacement in Engine Electrical.
7. Disconnect the throttle body heater hoses. Refer to Throttle Body Heater Hose
Replacement - Inlet and Throttle Body Heater Hose Replacement - Outlet in Engine
Cooling.
Fig. 66: Vacuum Hoses To EVAP Purge Valve
8. Disconnect the vacuum hoses from the evaporative emission (EVAP) canister purge
solenoid valve.
9. Remove the EVAP canister purge solenoid valve. Refer to Evaporative Emission (EVAP)
Canister Purge Solenoid Valve Replacement in Engine Controls - 3.4L.
Fig. 67: Locating Ignition Coil Bracket

10. Remove the ignition coil bracket.
Fig. 68: View Of Manifold Air Pressure (MAP) Sensor

11. Disconnect the wiring harness from the manifold air pressure (MAP) sensor.
Fig. 69: Locating Vacuum Harness
12. Disconnect the vacuum harness from the MAP sensor and the upper intake manifold.
Fig. 70: Identifying Emission Control Vacuum Harness
13. Disconnect and remove the emission control vacuum harness.

14. Disconnect the vacuum brake booster hose from the upper intake manifold.
15. Disconnect the vacuum hose connections from the upper intake manifold:
Heating, Ventilation and Air Conditioning (HVAC) vacuum source hose
16. Remove the exhaust gas recirculation (EGR) valve. Refer to Exhaust Gas Recirculation
(EGR) Valve Replacement in Engine Controls - 3.4L.
17. Remove the MAP sensor and the bracket. Refer to Manifold Absolute Pressure (MAP)
Sensor Replacement in Engine Controls - 3.4L.
18. Remove generator through bolt bracket.
Fig. 71: View Of Upper Intake Manifold Studs And Bolts

19. Remove the upper intake manifold studs and bolts.

Fig. 72: Upper Intake Manifold
20. Remove the upper intake manifold.

Fig. 73: View Of Throttle Body
21. If replacing the intake manifold, remove the throttle body. Refer to Throttle Body
Assembly Replacement in Engine Controls - 3.4L.
Fig. 74: Identifying Upper Intake Manifold Gasket
22. Remove the upper intake manifold gasket.

23. Clean and inspect the upper intake manifold. Refer to Intake Manifold Cleaning and
Inspection - Upper in the Engine Unit Repair Manual.
1. If removed, install the throttle body. Refer to Throttle Body Assembly Replacement in
Fig. 76: Identifying Upper Intake Manifold Gasket
2. Install the upper intake manifold gasket.

Fig. 77: Upper Intake Manifold

Fig. 78: View Of Upper Intake Manifold Studs And Bolts
4. Install the MAP sensor and the bracket. Refer to Manifold Absolute Pressure (MAP)
Sensor Replacement in Engine Controls - 3.4L.
5. Install the upper intake manifold studs and bolts.
Tighten: Tighten bolts to 25 N.m (18 lb ft.)
6. Install generator through bolt bracket.

7. Install the EGR valve. Refer to Exhaust Gas Recirculation (EGR) Valve Replacement
8. Connect the vacuum hose connections to the upper intake manifold:
Heater and air conditioning vacuum source hose
9. Connect the vacuum brake booster hose to the upper intake manifold.
Fig. 79: Identifying Emission Control Vacuum Harness

10. Install and connect the emission control vacuum harness.

Fig. 80: Locating Vacuum Harness
11. Connect the vacuum hose to the MAP sensor and the upper intake manifold.
Fig. 81: View Of Manifold Air Pressure (MAP) Sensor
12. Connect the wiring harness to the MAP sensor.

13. Install the ignition coil bracket with the coils.

14. Install the EVAP canister purge solenoid valve. Refer to Evaporative Emission (EVAP)

15. Connect the vacuum hoses to the EVAP canister purge solenoid valve.
16. Connect the throttle body heater hoses. Refer to Throttle Body Heater Hose
Replacement - Inlet and Throttle Body Heater Hose Replacement - Outlet in Engine
Cooling.
17. Connect the engine left side spark plug wire harness attachment clip. Refer to Spark Plug
Wire Replacement in Engine Electrical.
18. Connect the engine left side spark plug wires. Refer to Spark Plug Wire Replacement in
Engine Electrical.
19. Connect the wiring harness connectors to the throttle body. Refer to Throttle Body
Assembly Replacement in Engine Controls - 3.4L.
20. Install the accelerator control and cruise control cables with bracket to the throttle body.
Refer to Accelerator Controls Cable Replacement in Engine Controls - 3.4L.
21. Install the throttle body air inlet duct. Refer to Air Cleaner Intake Duct Replacement in
22. Fill the cooling system with engine coolant. Refer to Draining and Filling Cooling
INTAKE MANIFOLD REPLACEMENT - LOWER
Removal Procedure
1. Remove the upper intake manifold. Refer to Intake Manifold Replacement - Upper.
2. Remove the engine left side valve rocker arm cover. Refer to Valve Rocker Arm Cover
Replacement - Left.
3. Remove the engine right side valve rocker arm cover. Refer to Valve Rocker Arm Cover
Fig. 84: ECT Sensor Electrical Connector
4. Disconnect the wiring harness from the engine coolant temperature (ECT) sensor.
Fig. 85: Locating Fuel Injector, Manifold Air Pressure (MAP) & ECT Wiring
Harness
IMPORTANT: Use masking tape or another appropriate method in order to

identify each fuel injector wiring harness connector cylinder
number.
5. Disconnect and remove the fuel injector, manifold air pressure (MAP) and ECT wiring
harness.
6. Remove the fuel feed and return pipe from the fuel injector rail. Refer to Fuel Hose/Pipes
Replacement - Engine Compartment in Engine Controls-3.4L.
Fig. 86: Fuel Feed & Return Pipe Retaining Clip
Fig. 87: View Of Fuel Injector Rail Assembly

10. Remove the fuel injector rail with the fuel injectors.
IMPORTANT: Do NOT disconnect the power steering pipes or hoses from

the power steering pump.
11. Remove the power steering pump from the front engine cover and reposition. Refer to
Power Steering Pump Replacement (LA1 ) or Power Steering Pump Replacement
(LY7) in Power Steering System.
12. Disconnect the heater inlet pipe with heater hose from the lower intake manifold and
reposition. Refer to Heater Pipe Replacement - Inlet in Heating, Ventilation and Air
Conditioning.
13. Disconnect the inlet radiator hose from the engine. Refer to Radiator Hose Replacement -
Inlet (LA1) or Radiator Hose Replacement - Inlet (LY7) in Engine Cooling.
Fig. 88: Identifying Thermostat Bypass Hose

14. Disconnect the thermostat bypass hose from the lower intake manifold pipe.
Fig. 89: View Of Lower Intake Manifold Bolts


Fig. 90: Identifying Lower Intake Manifold

17. Loosen the valve rocker arms and remove the push rods. Refer to Valve Rocker Arm and
Push Rod Removal.
18. Remove the lower intake manifold gaskets and seals.
19. Clean the lower intake manifold gasket and seal surfaces on the cylinder heads and the
engine block.
20. Clean and inspect the lower intake manifold. Refer to Intake Manifold Cleaning and
Inspection - Lower.
21. If you are replacing the lower intake manifold, perform the following steps:
Remove the ECT sensor. Refer to Engine Coolant Temperature (ECT) Sensor
Replacement in Engine Controls-3.4L.
Remove the thermostat. Refer to Thermostat Replacement (LA1) or Thermostat
1. If you are replacing the lower intake manifold, perform the following steps.
Install the ECT sensor. Refer to Engine Coolant Temperature (ECT) Sensor
Replacement in Engine Controls - 3.4L.
Install the thermostat. Refer to Thermostat Replacement (LA1) or Thermostat
Fig. 91: Lower Intake Manifold
IMPORTANT: All gasket-mating surfaces need to be free of oil, and foreign

material. Use GM P/N 12346139 (Canadian P/N 10953463) or
equivalent to clean surfaces.

3. Install the push rods and tighten the valve rocker arms. Refer to Valve Rocker Arm and
Push Rod Installation.
4. With the gaskets in place apply a small drop 8-10 mm (0.31-0.39 in) of RTV sealer GM
P/N 12346286 (Canadian P/N 10953472) or equivalent to the 4 corners of the intake
manifold to block joint (1).
5. Connect the 2 small drops with a bead of RTV sealer that is between 8-10 mm (0.31-0.39
in) wide and 3.0-5.0 mm (0.12-0.20 in) thick (2).
7. Apply sealer GM P/N 12345382, (Canadian P/N 10953489) or the equivalent to the lower
intake manifold bolt threads.

NOTE: Maximum gasket performance is achieved when using new

fasteners, which contain a thread-locking patch. If the
fasteners are not replaced, a thread locking chemical must be
applied to the fastener threads. Failure to replace the fasteners
or apply a thread-locking chemical MAY reduce gasket sealing
capability.
IMPORTANT: All lower intake manifold bolts need to be cleaned, free of

any foreign material, and reused only if new bolts are
unavailable. Use GM P/N 12345382 (Canadian P/N 10953489)
or equivalent and apply to the old intake manifold bolt
threads.
IMPORTANT: Manufacturer recommends the center bolts be fully torqued

before the diagonal bolts to assure proper seal ability.
IMPORTANT: Lower intake manifold bolts in location 6 and 7 should be

torqued to specification using a crows foot type tool.
Tighten:
1. Tighten the lower intake manifold bolts in sequence to 7 N.m (62 lb in) on the first
pass.
2. Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 13 N.m (115 lb in)
on the final pass.
3. Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence to 25 N.m (18 lb ft) on
the final pass.
Fig. 93: Identifying Thermostat Bypass Hose
9. Connect the thermostat bypass hose to the lower intake manifold pipe.
10. Connect the inlet radiator hose to the engine. Refer to Radiator Hose Replacement - Inlet
(LA1) or Radiator Hose Replacement - Inlet (LY7) in Engine Cooling.
11. Connect the heater inlet pipe to the lower intake manifold. Refer to Heater Pipe
Replacement - Inlet in Heating, Ventilation and Air Conditioning.
12. Install the power steering pump to the front engine cover. Refer to Power Steering Pump
Replacement (LA1 ) or Power Steering Pump Replacement (LY7) in Power Steering
System.

13. Install the fuel injector rail. Refer to Fuel Rail Assembly Replacement in Engine Controls
- 3.4L.
14. Connect the fuel feed and return pipe to the fuel injector rail. Refer to Fuel Hose/Pipes
Replacement - Engine Compartment in Engine Controls-3.4L.

Tighten: Tighten the fuel feed and return pipe retaining clip bolt to 8 N.m (71 lb in).
Fig. 96: Locating Fuel Injector, Manifold Air Pressure (MAP) & ECT Wiring
Harness
IMPORTANT: The fuel injector wiring harness connectors must be

connected to their respective fuel injectors. Failure to
connect the fuel injector connectors to their respective fuel
injectors may result in excessive exhaust emissions and
poor engine performance.
17. Install and connect the fuel injector, MAP and ECT wiring harness.
Fig. 97: ECT Sensor Electrical Connector
18. Install the wiring harness to the ECT sensor.

19. Install the engine right side valve rocker arm cover. Refer to Valve Rocker Arm Cover
Replacement - Left.
20. Install the engine left side valve rocker arm cover. Refer to Valve Rocker Arm Cover
Replacement - Left.
21. Install the upper intake manifold. Refer to Intake Manifold Replacement - Upper.
POSITIVE CRANKCASE VENTILATION (PCV) VALVE REPLACEMENT
Removal Procedure
Fig. 98: PVC Valve, Vacuum Hoses & Fuel Pressure Regulator
1. Disconnect the vacuum hose from positive crankcase ventilation valve (2).
2. Remove the positive crankcase ventilation valve.
Fig. 99: PVC Valve, Vacuum Hoses & Fuel Pressure Regulator
1. Install the positive crankcase ventilation valve (2).

2. Connect the vacuum hose to positive crankcase ventilation valve.
VALVE ROCKER ARM COVER REPLACEMENT - LEFT
Removal Procedure
1. Remove the right engine strut mount. Refer to Engine Mount Strut Replacement - Right.
2. Remove the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement in
Engine Cooling.
3. Remove the PCV valve from valve rocker arm cover.
NOTE: Valve rocker arm cover gasket and sealant must be carefully
trimmed away from lower intake manifold gasket. Failure to do
so will damage the lower intake manifold gasket, causing a
severe oil leak.
Fig. 100: View Of Valve Rocker Arm Cover - Right

IMPORTANT: When removing the valve rocker arm cover, make sure the
gasket stays in place attached to the cylinder head.
5. Remove the valve rocker arm cover. Bump the end of the valve rocker arm cover with the
palm of your hand or a soft rubber mallet if the cover adheres to the cylinder head.
Fig. 101: Identifying Cylinder Head To Lower Intake Manifold Joint

6. Trim valve cover gasket and sealant away from lower intake manifold gasket at the cylinder
head to lower intake manifold joints (1).
7. Remove the valve cover gasket.
8. Clean the sealing surface on the cylinder head with degreaser.
9. Clean the valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and
Inspection.

IMPORTANT: All gasket mating surfaces need to be free of oil and foreign
material. Use GM P/N 12346139 (Canadian P/N 88901148), or
equivalent, at the cylinder head to lower intake manifold
joint.
IMPORTANT: Apply sealant GM P/N 12378521 (Canadian P/N 88901148), or

equivalent, at the cylinder head lower intake joint.
1. Apply sealant at the cylinder head to lower intake manifold joints (1).
2. Install the valve rocker arm cover gasket into valve rocker arm cover. Ensure that the gasket
is properly seated in the groove of the valve rocker arm cover.

Tighten: Tighten bolts to 10 N.m (89 lb in).
4. Install the PCV valve to valve rocker arm cover.

5. Install the thermostat bypass pipe. Refer to Thermostat Bypass Pipes Replacement in
Engine Cooling.
6. Install the right engine mount strut. Refer to Engine Mount Strut Replacement - Right.
VALVE ROCKER ARM COVER REPLACEMENT - RIGHT

Removal Procedure

2. Remove the generator. Refer to Generator Replacement (LA1) or Generator
Replacement (LY7) in Engine Electrical.
3. Remove the generator bracket. Refer to Generator Bracket Replacement in Engine
Electrical.
4. Disconnect the engine right side spark plug wires. Refer to Spark Plug Wire Replacement
in Engine Controls - 3.4 L.
5. Disconnect the vacuum hoses from the evaporative emissions (EVAP) canister purge
solenoid valve.
6. Remove the EVAP canister purge solenoid valve. Refer to Evaporative Emission (EVAP)

7. Remove the ignition module bracket with the coils.
8. Remove the vacuum hose from the grommet in the engine right side valve rocker arm cover.

severe oil leak.
IMPORTANT: When removing the valve rocker arm cover, make sure the
10. Remove the valve rocker. Bump the end of the valve rocker arm cover with the palm of
your hand or a soft rubber mallet if the cover adheres to the cylinder head.
11. Trim the valve cover gasket and sealant away from lower intake manifold gasket at the
cylinder head to lower intake manifold joints (1).
12. Remove the valve cover gasket.
13. Clean the sealing surface on the cylinder head with degreaser.
14. Clean the valve rocker arm cover. Refer to Valve Rocker Arm Cover Cleaning and
Inspection in the Engine Unit Repair Manual.
IMPORTANT: All gasket mating surfaces need to be free of oil and foreign
IMPORTANT: Apply sealant GM P/N 12378521 (Canadian P/N 88901148), or

equivalent, at the cylinder head to lower intake manifold
joint.
1. Apply sealant at the cylinder head to lower intake manifold joint (1).
2. Install the valve rocker arm cover gasket into the valve rocker arm cover. Ensure that the
gasket is properly seated in the groove of the valve rocker arm cover.
3. Install valve rocker arm cover.
5. Install the vacuum hose to the grommet in the engine right side valve rocker arm cover.
6. Install the ignition module bracket with the coils.

7. Install the EVAP canister purge solenoid valve. Refer to Evaporative Emission (EVAP)

8. Connect the vacuum hoses from the EVAP canister purge solenoid valve.
9. Connect the engine right side spark plug wires. Refer to Spark Plug Wire Replacement in
10. Install the generator bracket. Refer to Generator Bracket Replacement in Engine
Electrical.
11. Install the generator. Refer to Generator Replacement (LA1) or Generator
VALVE ROCKER ARM AND PUSH ROD REPLACEMENT
Removal Procedure
1. Remove the valve rocker arm cover(s). Refer to Valve Rocker Arm Cover Replacement -
Left or Valve Rocker Arm Cover Replacement - Right.
Fig. 112: View Of Valve Rocker Arm

2. Remove the valve rocker arm bolt(s).
3. Remove the valve rocker arm(s).
IMPORTANT: Place the valve train parts in a rack in order to ensure that
they are installed in the same location from which they were
removed. Intake pushrods are yellow and measure 144.18 mm
(5.68 in) long. Exhaust pushrods are green and measure
152.51 mm (6.0 in) long.
IMPORTANT: Use care when removing the pushrods. Ensure that they do
not fall down into the lifter valley.
4. Remove the pushrod(s).

5. Clean and inspect the valve train components. Refer to Valve Rocker Arm and Push
Rods Cleaning and Inspection in the Engine Unit Repair Manual.
1. Install the pushrod(s) and the valve rocker arm(s). Refer to Valve Rocker Arm and Push
Rod Installation in the Engine Unit Repair Manual.
2. Install the valve rocker arm cover(s). Refer to Valve Rocker Arm Cover Replacement -
Left.
VALVE STEM OIL SEAL AND VALVE SPRING REPLACEMENT
Tools Required
J 22794 Spark Plug Port Adapter. See Special Tools and Equipment.
Removal Procedure
IMPORTANT: Before you remove the valve keys, rotate the engine so
that the piston in the cylinder you are working on is at
(TDC) top dead center. This will eliminate the possibility
of the valve accidentally falling inside the cylinder.
Do not loosen or remove the spark plug when the engine
is hot.
Loosen the spark plug, and clean any dirt and debris
from the spark plug recess area before removing.
1. Remove the spark plug. Refer to Spark Plug Replacement in Engine Controls - 3.4 L.
2. Install the J 22794 into the spark plug port. See Special Tools and Equipment. Apply
compressed air in order to hold the valves in place.
3. Remove the rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement.
Fig. 114: Compressing Valve Springs
4. Compress the valve spring with the J 38606 .

Fig. 115: Valve Locks, Caps, Seats & Spring
5. Remove the valve keys.

6. Remove the valve cap.
7. Remove the valve spring.
8. Inspect the valve spring for damage. Replace the spring if it is damaged. Refer to Cylinder
Head Cleaning and Inspection in the Engine Unit Repair Manual.
9. Remove the spring seat/valve stem oil seal.
1. Install the valve stem oil seal/spring seat.

Use a suitable driver.
Press over the valve guide boss.
2. Install the valve spring.

3. Install the valve cap.
4. Use the J 38606 in order to compress the valve spring. See Special Tools and Equipment.
5. Install the valve keys. If necessary, hold the valve keys in place with grease.
6. Remove the J 38606 in order to release the valve spring. See Special Tools and
Equipment.
7. Ensure that the valve keys are seated.
8. Install the valve rocker arm. Refer to Valve Rocker Arm and Push Rod Replacement.
9. Release the air pressure and remove the J 22794 . See Special Tools and Equipment.
10. Install the spark plug. Refer to Spark Plug Replacement in Engine Controls - 3.4 L.
VALVE LIFTER REPLACEMENT
Removal Procedure
1. Remove the engine left side valve rocker arm cover. Refer to Valve Rocker Arm Cover
Replacement - Left.
2. Remove the engine right side valve rocker arm cover. Refer to Valve Rocker Arm Cover
3. Remove the upper intake manifold. Refer to Intake Manifold Replacement - Lower.
4. Remove the lower intake manifold. Refer to Intake Manifold Replacement - Upper.
5. Remove the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod
Replacement.
Fig. 118: View Of Lifter Guide
6. Remove the lifter guide bolts.

7. Remove the lifter guide.
IMPORTANT: Place the valve train parts in a rack in order to ensure that
they are installed in the same location from which they were
removed.
8. Remove the lifter(s).

9. Clean and inspect the valve lifter(s). Refer to Valve Lifters Cleaning and Inspection in
the Engine Unit Repair Manual.
Fig. 119: View Of Lifter Guide
IMPORTANT: Install the lifters to the same location from which they were
removed.
1. Install the lifters and the lifter guide. Refer to Valve Lifter Installation in the Engine Unit
Repair Manual.
2. Install the valve rocker arms and pushrods. Refer to Valve Rocker Arm and Push Rod
Replacement.
3. Install the lower intake manifold. Refer to Intake Manifold Replacement - Lower
5. Install the engine right side valve rocker arm cover. Refer to Valve Rocker Arm Cover
Replacement - Left.
6. Install the engine left side valve rocker arm cover. Refer to Valve Rocker Arm Cover
Replacement - Left.
CRANKSHAFT BALANCER REPLACEMENT
Tools Required
J 24420-C Crankshaft Balancer Puller. See Special Tools and Equipment.

J 29113 Crankshaft Balancer Installer. See Special Tools and Equipment.
Removal Procedure

Information.
3. Remove the right front tire and wheel. Refer to Tire and Wheel Removal and
4. Remove the right engine splash shield. Refer to Splash Shield Replacement - Engine in
Body Front End.
5. Install a utility stand beneath the frame right side rail in order to support the
frame/powertrain.
6. Remove the two frame right side bolts.
7. Use the utility stand to lower the frame enough to provide access to the crankshaft balancer.
Fig. 120: Installing Crankshaft Washer & Bolt
NOTE: The inertial weight section of the crankshaft balancer is

assembled to the hub with a rubber type material. The correct
installation procedures (with the proper tool) must be followed
or movement of the inertial weight section of the hub will
destroy the tuning of the crankshaft balancer.
8. Remove and DISCARD the crankshaft balancer bolt.

Fig. 121: Identifying J 24420-C
9. Remove the crankshaft balancer using the J 24420-C . See Special Tools and Equipment.
10. Clean and inspect the crankshaft balancer. Refer to Crankshaft Balancer Cleaning and
Inspection.
Fig. 122: Installing Crankshaft Balancer Using J 29113
1. Apply sealer GM P/N 12345739 or the equivalent to the keyway of the crankshaft balancer.
2. Install the crankshaft balancer into position over the key in the crankshaft.
3. Use the J 29113 in order to install the crankshaft balancer to the crankshaft. See Special
4. Remove the J 29113 from the crankshaft balancer. See Special Tools and Equipment.
5. Install the crankshaft balancer washer and the NEW crankshaft balancer bolt.
Tighten:
1. Tighten the bolt to 70 N.m (52 lb ft).
2. Use a torque angle meter in order to rotate the bolt 72 degrees.
6. Use the utility stand in order to raise the frame/powertrain.

7. Install the frame right side bolts. Refer to Frame Replacement - Front (W/AWD) or
Frame Replacement - Front (W/FWD) in Frame and Underbody.
8. Install the engine splash shield. Refer to Splash Shield Replacement - Engine in Body
Front End.
9. Install the right front tire and wheel. Refer to Tire and Wheel Removal and Installation
in Tires and Wheels.
OIL PAN REPLACEMENT
Tools Required
J 39505 Torque Wrench Adapter. See Special Tools and Equipment.

J 45057-2 Lower Support Bar. See Special Tools and Equipment.
Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Negative Cable

2. Remove the right engine mount strut from the engine. Refer to Engine Mount Strut
3. Install the engine support fixture. Refer to Engine Support Fixture.
Information.
5. Remove the A/C compressor bolts and reposition the compressor in order to gain access to
the oil pan. Refer to Compressor Replacement in HVAC Systems - Manual.
6. Disconnect the catalytic converter from the exhaust manifold. Refer to Catalytic
Converter Replacement in Engine Exhaust.
7. Remove the frame. Refer to Frame Replacement - Front (W/AWD) or Frame
Replacement - Front (W/FWD) in Frame and Underbody.
8. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement.
Fig. 124: View Of Oil Level Sensor Electrical Connector
9. Disconnect the oil level sensor electrical connector.

10. Remove the starter motor. Refer to Starter Motor Replacement (LA1) or Starter Motor
11. If the vehicle is equipped with All-Wheel-Drive (AWD), remove the transfer case brace.
Refer to Support Brace Replacement (LA1) or Support Brace Replacement (LY7) in
Transfer Case - Steyr.
12. Remove the transaxle brace. Refer to Automatic Transmission Brace Replacement
(LA1) or Automatic Transmission Brace Replacement (LY7) in Automatic Transaxle -
4T65-E.
Fig. 125: Securing Transfer Case/Transmission Case Extension Housing
13. Install one end of a suitable utility strap to the transmission.

If the vehicle is equipped with All-Wheel-Drive (AWD), carefully wrap the utility
strap around the transfer case.
If the vehicle is equipped with Front-Wheel-Drive (FWD), carefully wrap the utility
strap around the transmission case extension housing.
14. Install the opposite end of the utility strap to a suitable underbody structure.
15. Tighten the utility strap in order to prevent movement of the powertrain.
16. Remove the J 45057-2 lower support bar. See Special Tools and Equipment.
17. Remove the engine mount with the engine mount bracket from the oil pan. Refer to Engine
Mount Bracket Replacement.
IMPORTANT: Use the J 39505 in order to remove the engine right side oil
pan side bolts. See Special Tools and Equipment.
18. Remove the oil pan and the oil pan gasket. Refer to Oil Pan Removal.
19. Clean the oil pan and the engine block gasket surface. Refer to Oil Pan Cleaning and
Inspection.
IMPORTANT: Ensure that the transaxle brace is in position prior to
installing the oil pan.
Use the J 39505 in order to install the engine right side
oil pan side bolts. See Special Tools and Equipment.
1. Install the oil pan gasket and the oil pan. Refer to Oil Pan Installation.
2. Install the transaxle brace. Refer to Automatic Transmission Brace Replacement (LA1)
or Automatic Transmission Brace Replacement (LY7) in Automatic Transaxle - 4T65-
E.
3. Install the engine mount with the engine mount bracket to the oil pan. Refer to Engine
Mount Bracket Replacement.
4. Install the J 45057-2 lower support bar. See Special Tools and Equipment.
5. Remove the utility strap.
6. If the vehicle is equipped with All-Wheel-Drive (AWD), install the transfer case brace.
Refer to Support Brace Replacement (LA1) or Support Brace Replacement (LY7) in
Transfer Case - Steyr.
7. Install the starter motor. Refer to Starter Motor Replacement (LA1) or Starter Motor
8. Connect the oil level sensor electrical connector.

9. Install the frame. Refer to Frame Replacement - Front (W/AWD) or Frame
10. Connect the catalytic converter to the exhaust manifold. Refer to Catalytic Converter
Replacement in Engine Exhaust.
11. Install the A/C compressor. Refer to Compressor Replacement in HVAC Systems -
Manual.
13. Remove the engine support fixture. Refer to Engine Support Fixture.
14. Install the right engine mount strut to the engine. Refer to Engine Mount Strut
15. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement.
16. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect
Procedure (LA1) or Battery Negative Cable Disconnect/Connect Procedure (LY7) in
Engine Electrical.
ENGINE OIL PRESSURE SENSOR AND/OR SWITCH REPLACEMENT
Removal Procedure
1. Remove the battery negative cable from the battery. Refer to Battery Negative Cable
3. Remove the electrical connector from the engine oil pressure sensor.
Fig. 130: View Of Oil Pressure Switch

Fig. 131: View Of Oil Pressure Switch
Tighten: Tighten the switch to 16 N.m (12 lb ft).
2. Install the electrical connector to the engine oil pressure switch.

4. Install the battery negative cable to the battery. Refer to Battery Negative Cable
ENGINE OIL LEVEL SENSOR AND/OR SWITCH REPLACEMENT
Removal Procedure
Information.
2. Drain the oil from the oil pan.

3. Disconnect the electrical connector from the oil level sensor.

Fig. 133: Identifying Oil Level Sensor & Bolt

5. Remove the oil level sensor from the oil pan.
Fig. 134: Identifying Oil Level Sensor & Bolt
1. Install the oil level sensor to the oil pan.

3. Connect the electrical connector to the oil level sensor.

5. Ensure that the engine oil is filled to the proper level.
CRANKSHAFT OIL DEFLECTOR REPLACEMENT
Removal Procedure
1. Remove the oil pan. Refer to Oil Pan Replacement.

Fig. 136: Locating Crankshaft Oil Deflector & Nuts

Fig. 137: Locating Crankshaft Oil Deflector & Nuts

Tighten: Tighten the crankshaft oil deflector nuts to 25 N.m (18 lb ft).
3. Install the oil pan. Refer to Oil Pan Replacement.
OIL PUMP REPLACEMENT
Removal Procedure
1. Remove the oil pan. Refer to Oil Pan Replacement.

Fig. 138: Removing Oil Pump & Oil Pump Drive Shaft

Fig. 139: View Of Crankshaft Oil Deflector & Nuts

6. Inspect the oil pump driveshaft at both ends for rounding of the corners.
7. Inspect the oil pump. Refer to Oil Pump Disassemble, Oil Pump Cleaning and
Inspection, and Oil Pump Assemble in Engine Unit Repair Manual.
IMPORTANT: Rotate the oil pump driveshaft as necessary in order to

obtain the engagement with the oil pump drive.

3. Install the oil pump and oil pump drive shaft.

4. Install the oil pump bolt.
Tighten: Tighten the oil pump bolt to 41 N.m (30 lb ft).
5. Install the oil pan. Refer to Oil Pan Replacement.
OIL PUMP DRIVE REPLACEMENT
Removal Procedure
1. Remove the upper intake manifold. Refer to Intake Manifold Replacement - Upper.
2. Disconnect the fuel feed and return pipe from the fuel injector rail. Refer to Fuel
Hose/Pipes Replacement - Engine Compartment in Engine Controls - 3.4L.
Fig. 142: View Of Oil Pump Drive


1. Apply prelube GM P/N 1052365 or the equivalent to the oil pump drive gear.
Tighten: Tighten the oil pump drive gear clamp bolt to 36 N.m (27 lb ft).
6. Connect the fuel feed and return pipe to the fuel injector rail. Refer to Fuel Hose/Pipes
Replacement - Engine Compartment in Engine Controls - 3.4L.
CRANKSHAFT FRONT OIL SEAL REPLACEMENT
Tools Required
J 35468 Crankshaft Front Oil Seal Installer. See Special Tools and Equipment.
Removal Procedure
1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement.

2. Pry out the crankshaft front oil seal using a suitable tool. Use care not to damage the engine
front cover or the crankshaft.
3. Inspect the crankshaft, the crankshaft balancer and the engine front cover for wear and/or
damage. Replace the components as necessary. Refer to the following procedures:
Crankshaft Balancer Cleaning and Inspection
Engine Front Cover Cleaning and Inspection
Fig. 145: Installing Crankshaft Front Oil Seal

1. Align the J 35468 and the crankshaft front oil seal with the engine front cover and
crankshaft. See Special Tools and Equipment.
2. Install the crankshaft front oil seal using the J 35468 and a suitable tool. See Special Tools
and Equipment.
3. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
ENGINE FRONT COVER REPLACEMENT
Removal Procedure
1. Drain the engine cooling system. Refer to Draining and Filling Cooling System in Engine
Cooling.
3. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
4. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
5. Remove the power steering pump with lines. Move the power steering pump aside. Refer to
Power Steering Pump Replacement (LA1 ) or Power Steering Pump Replacement
(LY7) in Power Steering System.
6. Disconnect the thermostat bypass pipe from the engine front cover. Refer to Thermostat
Bypass Pipes Replacement in Engine Cooling.
7. Disconnect the radiator outlet hose from the front cover. Refer to Radiator Hose
Replacement - Outlet (LA1) or Radiator Hose Replacement - Outlet (LY7) in Engine
Cooling.
8. Remove the coolant pump pulley. Refer to Water Pump Replacement (LA1) or Water
Pump Replacement (LY7) in Engine Cooling.
Fig. 146: View Of Crankshaft Position Sensor Wiring Harness Bracket
9. Remove the crankshaft position sensor wiring harness bracket from the engine front cover.
10. Remove oil pan. Refer to Oil Pan Replacement.
Fig. 147: Removing/Installing Engine Front Cover
11. Remove the engine front cover bolts (1,2,3).

14. Clean the engine front cover and engine block gasket sealing surfaces. Refer to Engine
Front Cover Cleaning and Inspection in the Engine Unit Repair Manual.
15. Inspect the engine front cover for damage to the engine front cover, crankshaft front oil seal
or the gasket sealing surface. Refer to Engine Front Cover Cleaning and Inspection in
the Engine Unit Repair Manual.
Fig. 148: Locating Drive Belt Shield
16. If you are replacing the engine front cover, remove the drive belt shield.
17. If you are replacing the engine front cover, remove the crankshaft position sensor from the
engine front cover. Refer to Crankshaft Position (CKP) Sensor Replacement (24X
CKP Sensor) or Crankshaft Position (CKP) Sensor Replacement (7X CKP Sensor)
in Engine Controls-3.4L.
18. If you are replacing the engine front cover, remove the coolant pump from the engine front
cover. Refer to Water Pump Replacement (LA1) or Water Pump Replacement (LY7)
in Engine Cooling.
1. If removed, install the coolant pump to the engine front cover. Refer to Water Pump
Replacement (LA1) or Water Pump Replacement (LY7) in Engine Cooling.
2. If removed, install the crankshaft position sensor to the engine front cover. Refer to
Crankshaft Position (CKP) Sensor Replacement (24X CKP Sensor) or Crankshaft
Position (CKP) Sensor Replacement (7X CKP Sensor) in Engine Controls-3.4L.
Fig. 149: Locating Drive Belt Shield

3. If removed, install the drive belt shield.

4. Install the drive belt shield bolt.
Tighten: Tighten the drive belt shield bolt to 10 N.m (89 lb in).
Fig. 150: Applying Sealer To Lower Tabs Of Engine Front Cover Gasket

6. Apply sealer GM P/N 12346004, (Canadian P/N 10953480) or equivalent to both sides of
the lower tabs of the engine front cover gasket, and the engine front cover bolts.

Tighten: Tighten the engine front cover bolts (2) to 55 N.m (41 lb ft).
Fig. 152: Crankshaft Position Sensor Wiring Bracket

Tighten: Tighten the crankshaft position sensor wiring bracket bolt to 27 N.m (20 lb ft).
13. Install the coolant pump pulley. Refer to Water Pump Replacement (LA1) or Water
Pump Replacement (LY7) in Engine Cooling.
14. Connect the radiator outlet hose to the coolant pump. Refer to Radiator Hose
Cooling.
15. Connect the thermostat bypass pipe to the engine front cover. Refer to Thermostat Bypass
Pipes Replacement in Engine Cooling.
16. Install the power steering pump with lines. Refer to Power Steering Pump Replacement
(LA1 ) or Power Steering Pump Replacement (LY7) in Power Steering System.
17. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
18. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
19. Fill the engine with new engine oil. Refer to Engine Oil and Oil Filter Replacement.
TIMING CHAIN AND SPROCKETS REPLACEMENT
Removal Procedure
1. Remove the engine front cover. Refer to Engine Front Cover Replacement.
Fig. 153: Aligning The Dowel In The Camshaft With The Dowel Hole In The
Camshaft Sprocket
2. Align the crankshaft timing mark (2) to the timing mark on the bottom of the timing chain
dampener (1).
3. Align the timing mark on the camshaft gear (4) with the timing mark on top of the timing
chain dampener (3).
Fig. 154: Identifying Camshaft Sprocket Bolt


Fig. 155: View Of Crankshaft Sprocket

Fig. 156: View Of Timing Chain Dampener & Bolts

9. Clean and inspect the timing chain and gears. Refer to Timing Chain and Sprockets
Cleaning and Inspection in the Engine Unit Repair Manual.

2. Apply prelube GM P/N 1052365 or the equivalent to the crankshaft sprocket thrust surface.
Tighten: Tighten the timing chain dampener bolt to 21 N.m (15 lb ft).
Fig. 159: Aligning The Dowel In The Camshaft With The Dowel Hole In The
Camshaft Sprocket
dampener (1).
6. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain
to the crankshaft gear.
chain dampener (3).
Fig. 160: Identifying Camshaft Sprocket Bolt

11. Install the engine front cover. Refer to Engine Front Cover Replacement.
CYLINDER HEAD REPLACEMENT - LEFT

Tools Required
J 45059 Torque Angel Meter. See Special Tools and Equipment.

Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Negative Cable

Procedure (LY7)
Information.
3. Drain the cooling system. Refer to Draining and Filling Cooling System in Engine
Cooling.
6. Remove the lower intake manifold. Refer to Intake Manifold Replacement - Lower.
7. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement
(LA1) or Exhaust Crossover Pipe Replacement (LY7) in Engine Exhaust.
8. Remove the pushrods and valve rocker arms. Refer to Valve Rocker Arm and Push Rod
Replacement.
9. Remove the engine mount strut bracket. Refer to Engine Mount Strut Bracket
Replacement - Left.
10. Remove the oil level indicator tube. Refer to Oil Level Indicator and Tube
Replacement.
Fig. 161: View Of Cylinder Head

Fig. 162: View Of Cylinder Head Gasket And Alignment Pins


Remove the exhaust manifold. Refer to Exhaust Manifold Replacement - Left
(LA1) or Exhaust Manifold Replacement - Left (LY7) in Engine Exhaust.
Remove the spark plugs from the cylinder head. Refer to Spark Plug Replacement in

Install the exhaust manifold to the cylinder head. Refer to Exhaust Manifold
Replacement - Left (LA1) or Exhaust Manifold Replacement - Left (LY7) in
Engine Exhaust.
Install the spark plugs to the cylinder head. Refer to Spark Plug Replacement in
2. Install the new cylinder head gasket.

3. Install the engine left side exhaust manifold. Refer to Exhaust Manifold Replacement -
Left (LA1) or Exhaust Manifold Replacement - Left (LY7) .
4. Install the spark plugs. Refer to Spark Plug Replacement in Engine Controls - 3.4L.

Fig. 165: View Of Cylinder Head Bolt Tightening Sequence
Tighten:
1. Tighten the bolts in the sequence shown to 60 N.m (44 lb ft),
2. Using the J 45059 , torque the cylinder head bolts in sequence, an additional 95
degrees. See Special Tools and Equipment.
7. Install the oil level indicator tube. Refer to Oil Level Indicator and Tube Replacement.
8. Install the engine mount strut bracket. Refer to Engine Mount Strut Bracket
Replacement - Left.
9. Install the pushrods and valve rocker arms. Refer to Valve Rocker Arm and Push Rod
Replacement.
10. Install the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement (LA1)
or Exhaust Crossover Pipe Replacement (LY7) in Engine Exhaust.
11. Install the lower intake manifold. Refer to Intake Manifold Replacement - Lower.
Procedure (LY7)
14. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
CYLINDER HEAD REPLACEMENT - RIGHT
Tools Required
J 45059 Torque Angle Meter. See Special Tools and Equipment.

Removal Procedure
1. Disconnect the battery negative cable from the battery. Refer to Battery Negative Cable
Information.
Cooling.
6. Remove the lower intake manifold. Refer to Intake Manifold Replacement - Lower.
7. Remove the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement
(LA1) or Exhaust Crossover Pipe Replacement (LY7) in Engine Exhaust.
8. Remove the pushrods and valve rocker arms. Refer to Valve Rocker Arm and Push Rod
Replacement.



Remove the exhaust manifold. Refer to Exhaust Manifold Replacement - Right
(LA1) or Exhaust Manifold Replacement - Right (LY7) in Engine Exhaust.
Remove the spark plugs from the cylinder head. Refer to Spark Plug Replacement in

Install the exhaust manifold to the cylinder head. Refer to Exhaust Manifold
Replacement - Right (LA1) or Exhaust Manifold Replacement - Right (LY7) in
Engine Exhaust.
Install the spark plugs to the cylinder head. Refer to Spark Plug Replacement in


Tighten:
1. Tighten the bolts in the sequence shown to 60 N.m (44 lb ft),
2. Using the J 45059 , torque the cylinder head bolts in sequence, an additional 95
degrees. See Special Tools and Equipment.
5. Install the exhaust crossover pipe. Refer to Exhaust Crossover Pipe Replacement (LA1)
or Exhaust Crossover Pipe Replacement (LY7) in Engine Exhaust.
6. Install the pushrods and valve rocker arms. Refer to Valve Rocker Arm and Push Rod
Replacement.
7. Install the lower intake manifold. Refer to Intake Manifold Replacement - Lower.
10. Fill the cooling system. Refer to Draining and Filling Cooling System in Engine Cooling.
ENGINE FLYWHEEL REPLACEMENT
Removal Procedure
Fig. 171: Identifying Engine Flywheel & Components

1. Remove the automatic transaxle. Refer to Transmission Replacement (LA1) or

Transmission Replacement (LY7) in Automatic Transaxle - 4T65-E.
2. Remove the engine flywheel bolts and flywheel.
3. Clean the engine flywheel bolt threads and bolt holes.
4. Clean and inspect the engine flywheel. Refer to Engine Flywheel Cleaning and
Inspection.
Fig. 172: Identifying Engine Flywheel & Components
1. Install the engine flywheel and bolts
2. Install the automatic transaxle. Refer to Transmission Replacement (LA1) or

Transmission Replacement (LY7) in Automatic Transaxle - 4T65-E.
CRANKSHAFT REAR OIL SEAL REPLACEMENT
Tools Required
J 34686 Rear Main Seal Installer. See Special Tools and Equipment.
Removal Procedure
1. Remove the engine flywheel. Refer to Engine Flywheel Replacement.
IMPORTANT: Do not damage the crankshaft outside diameter (OD) surface

or the chamfer while using the pry tool.
2. Insert a screwdriver or a similar tool at an angle through the dust lip.

3. Pry the seal out by moving the handle of the tool towards the end of the crankshaft pilot. Pry
around the seal as required until you remove the seal.
4. Inspect the inner diameter (ID) of bore for nicks or burrs. Repair the bore if needed.
5. Inspect the crankshaft for burrs or nicks on the sealing surfaces. Repair or replace the
crankshaft as needed.
NOTE: Do not apply or use any oil lubrication on the crankshaft rear oil
seal, or the seal installer. Do not touch the sealing lip of the oil seal
once the protective sleeve is removed. Doing so will
damage/deform the seal.
NOTE: Clean the crankshaft sealing surface with a clean, lint free towel.
Inspect lead-in edge of crankshaft for burrs/sharp edges that could
damage the rear main oil seal. Remove burrs/sharp edges with
crocus cloth before proceeding.
Fig. 174: Installing Crankshaft Rear Oil Seal

IMPORTANT: Notice the direction of the rear oil seal. The new design is a
reverse style as opposed to what has been used in the past.
"THIS SIDE OUT" has been stamped into the seal as shown in
the Carefully remove the protection sleeve from the new
crankshaft rear oil seal graphic.
1. Carefully remove the protection sleeve from the new crankshaft rear oil seal.
2. Install the crankshaft rear oil seal onto the J34686 by sliding the crankshaft rear oil seal
over the mandrel using a twisting motion until the back of the crankshaft rear oil seal
bottoms squarely against the collar of the tool.
3. Perform the following steps in order to install the crankshaft rear oil seal.
Align the dowel pin of the J 34686 with the dowel pin in the crankshaft. See Special
Attach the J 34686 to the crankshaft by hand, or tighten the attaching screws to 5 N.
See Special Tools and Equipment.m (45 lb in).
Turn the T-handle of the J 34686 in order to engage allow the collar to push the seal
into the bore. See Special Tools and Equipment. Turn the handle until the collar is
tight against the engine block. Ensure that the seal is seated properly.
Loosen the T-handle until the T-handle comes to a stop.
Remove the attaching screws.
4. Install the flywheel. Refer to Engine Flywheel Replacement.
CAMSHAFT REAR BEARING HOLE PLUG REPLACEMENT
Removal Procedure
1. Remove the engine flywheel. Refer to Engine Flywheel Replacement.

Fig. 175: View Of Camshaft Rear Bearing Hole Plug

Fig. 176: View Of Camshaft Rear Bearing Hole Plug
1. Coat the camshaft rear bearing hole plug with sealer. Use sealer GM P/N 12345493 or
equivalent.
2. Use an impact wrench socket and a hammer in order to install the camshaft rear bearing hole
plug.
Fig. 177: Illustrating Proper Camshaft Rear Bearing Plug Specifications

3. Ensure that the camshaft rear bearing plug is installed to specifications.

4. Install the engine flywheel. Refer to Engine Flywheel Replacement.
ENGINE REPLACEMENT
Removal Procedure
1. Disconnect the negative battery cable. Refer to Battery Negative Cable

3. Remove the cruise control cable from the engine and reposition the cable away from the
engine. Refer to Cruise Control Cable Replacement in Cruise Control.
CAUTION: In order to avoid possible injury or vehicle damage,

always replace the accelerator control cable with a NEW
cable whenever you remove the engine from the vehicle.
In order to avoid cruise control cable damage, position
the cable out of the way while you remove or install the
engine. Do not pry or lean against the cruise control
cable and do not kink the cable. You must replace a
damaged cable.
4. Remove and discard the accelerator control cable from the engine and reposition the cable
away from the engine. Refer to Accelerator Controls Cable Replacement in Engine
Controls - 3.4L.
Cooling.
6. Disconnect the radiator hoses from the engine. Refer to Radiator Hose Replacement -
Inlet (LA1) or Radiator Hose Replacement - Inlet (LY7) and Radiator Hose
Cooling.
7. Disconnect the heater hoses from the engine. Refer to Heater Hose Replacement - Inlet
(LA1) or Heater Hose Replacement - Inlet (LY7) and Heater Hose Replacement -
Outlet (LA1) or Heater Hose Replacement - Outlet (LY7) in HVAC Systems - Manual.
8. Remove the engine mount struts. Refer to Engine Mount Strut Replacement - Left and
IMPORTANT: Relieve the fuel pressure. Refer to Fuel Pressure Relief

Procedure in Engine Controls - 3.4L.
9. Disconnect the fuel lines at quick connects. Refer to Fuel Hose/Pipes Replacement -
Engine Compartment in Engine Controls - 3.4L.
10. Remove the upper engine wiring harness from engine and transmission.
11. Remove the vacuum hoses from the engine. Refer to Emission Hose Routing Diagram in
12. Remove the vacuum brake booster hose.
13. Remove the automatic transaxle range selector cable. Refer to Automatic Transmission
Range Selector Cable Replacement in Automatic Transaxle - 4T65-E.
Information.
16. Remove the lower engine wiring harness from engine and transmission.
17. Remove the three-way catalytic converter. Refer to Catalytic Converter Replacement in
Engine Exhaust.
18. Remove rear propshaft. Refer to Propeller Shaft Replacement in Driveline/Axle-
Propeller Shaft. (AWD Only)
19. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation in
Tires and Wheels.
20. Remove lower radiator baffle assembly.
21. Remove the engine splash shields. Refer to Splash Shield Replacement - Engine in Body
Front End.
22. Remove the stabilizer shaft links from the lower control arms. Refer to Stabilizer Shaft
Link Replacement in Front Suspension.
23. Remove the tie rod ends from the steering knuckles. Refer to Steering Knuckle
Replacement in Front Suspension.
24. Remove the lower ball joints from the knuckles. Refer to Lower Ball Joint Replacement
in Front Suspension.
25. Remove the transaxle cooler lines and bracket from the transaxle. Refer to Automatic
Transmission Oil Cooler Hose Replacement in Automatic Transaxle - 4T65-E.
26. Remove A/C compressor bolts and position compressor aside.
27. Disconnect the drive axles from the transaxle. Refer to Wheel Drive Shaft Replacement -
Front in Drive Axle.
28. Secure the drive axles to the steering knuckle/struts.
CAUTION: Failure to disconnect the intermediate shaft from the rack

and pinion steering gear stub shaft can result in damage
to the steering gear and/or intermediate shaft. This
damage may cause loss of steering control which could
result in an accident and possible personal injury
29. Remove the intermediate shaft pinch bolt from the steering gear. Refer to Intermediate
Steering Shaft Replacement in Steering Wheel and Column.
Fig. 178: Identifying Utility Stand

31. Remove the frame bolts. Refer to Frame Replacement - Front (W/AWD) or Frame
32. Raise the vehicle in order to separate the powertrain/frame assembly from the vehicle.
33. Remove starter. Refer to Starter Motor Replacement (LA1) or Starter Motor
34. Remove the engine flywheel to torque converter bolts.
Fig. 179: View of Transaxle To Engine Mounting

35. Install engine hoist to engine.

36. Remove engine mount to frame nuts.
37. Remove the engine-to-transaxle bolts (3, 4, 5, 6) and studs (1, 2).
38. Separate and remove the engine from the transaxle/frame and install to the engine stand.
Fig. 180: View of Transaxle To Engine Mounting
1. Remove engine from engine stand.

2. Install and align the engine to the transaxle/frame.
3. Install the engine-to-transaxle bolts (3, 4, 5, 6) and studs (1, 2).
Tighten: Tighten the bolts (3, 4, 5, 6) and studs (1, 2) to 75 N.m (55 lb ft).
4. Install engine mount to frame nuts.
Tighten: Tighten nuts to 43 N.m (32 lb ft).
5. Remove engine hoist from engine.

6. Install the engine flywheel to torque converter bolts.
7. Install starter. Refer to Starter Motor Replacement (LA1) or Starter Motor

8. Position the transaxle table with the powertrain/frame under the vehicle.

10. Install the new frame bolts. Refer to Frame Replacement - Front (W/AWD) or Frame
Information.
12. Remove the transaxle table.
CAUTION: When installing the intermediate shaft make sure that the
shaft is seated prior to pinch bolt installation. If the pinch
bolt is inserted into the coupling before shaft installation,
the two mating shafts may disengage. Disengagement of
the two mating shafts will cause loss of steering control
which could result in personal injury.
13. Install the intermediate shaft pinch bolt to steering gear. Refer to Intermediate Steering
Shaft Replacement in Steering Wheel and Column.
14. Install the drive axles to the transaxle. Refer to Wheel Drive Shaft Replacement - Front
in Drive Axle.
15. Install the transaxle cooler lines and bracket to the transaxle. Refer to Automatic
Transmission Oil Cooler Hose Replacement in Automatic Transaxle - 4T65-E.
16. Install A/C compressor and bolts.
17. Install the lower ball joints to the knuckles. Refer to Lower Ball Joint Replacement in
Front Suspension.
18. Install the tie rod ends to the steering knuckles. Refer to Steering Knuckle Replacement
19. Install the stabilizer shaft links to the lower control arms. Refer to Stabilizer Shaft Link
20. Install the engine splash shields. Refer to Splash Shield Replacement - Engine in Body
Front End.
21. Install lower radiator baffle.
22. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation in
Tires and Wheels.
23. Install the three-way catalytic converter. Refer to Catalytic Converter Replacement in
Engine Exhaust.
24. Install the lower engine wiring harness to engine and transmission.
25. Install rear propshaft. Refer to Propeller Shaft Replacement in Driveline/Axle-Propeller
Shaft. (AWD Only)
27. Install the automatic transaxle range selector cable. Refer to Automatic Transmission
Range Selector Cable Replacement in Automatic Transaxle - 4T65-E.
28. Install the vacuum brake booster hose.
29. Install the vacuum hoses to the engine. Refer to Emission Hose Routing Diagram in
30. Install the upper engine wiring harness to engine and transmission.
31. Install the fuel lines at quick connects. Refer to Fuel Hose/Pipes Replacement - Engine
Compartment in Engine Controls - 3.4L.
32. Install the engine mount struts. Refer to Engine Mount Strut Replacement - Left and
33. Connect the heater hoses to the engine. Refer to Heater Hose Replacement - Inlet (LA1)
or Heater Hose Replacement - Inlet (LY7) and Heater Hose Replacement - Outlet
(LA1) or Heater Hose Replacement - Outlet (LY7) in HVAC Systems - Manual.
34. Connect the radiator hoses to the engine. Refer to Radiator Hose Replacement - Inlet
(LA1) or Radiator Hose Replacement - Inlet (LY7) and Radiator Hose Replacement -
Outlet (LA1) or Radiator Hose Replacement - Outlet (LY7) in Engine Cooling.
CAUTION: In order to avoid possible injury or vehicle damage,

always replace the accelerator control cable with a NEW
cable whenever you remove the engine from the vehicle.
In order to avoid cruise control cable damage, position
the cable out of the way while you remove or install the
engine. Do not pry or lean against the cruise control
cable and do not kink the cable. You must replace a
damaged cable.
35. Install the NEW accelerator control cable to the engine. Refer to Accelerator Controls
Cable Replacement in Engine Controls - 3.4L.
36. Install the cruise control cable to the engine. Refer to Cruise Control Cable Replacement
in Cruise Control.
37. Install the throttle body air inlet duct. Refer to Air Cleaner Intake Duct Replacement in
39. Adjust the transaxle fluid level. Refer to the following information:
Capacities - Approximate Fluid in Maintenance and Lubrication
Fluid and Lubricant Recommendations in Maintenance and Lubrication
40. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement.
41. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect
Procedure (LA1) or Battery Negative Cable Disconnect/Connect Procedure (LY7) in
Engine Electrical.
42. Perform the CKP system variation learn procedure. Refer to CKP System Variation
Learn Procedure in Engine Controls - 3.4L.
43. Inspect for proper fluid levels and possible fluid leaks.
ENGINE OIL AND OIL FILTER REPLACEMENT
Removal Procedure
Information.
2. Position the oil drain pan under the engine oil drain plug.
Fig. 182: View Of Engine Oil Drain Plug
3. Remove the engine oil drain plug.

4. Clean and inspect the engine oil drain plug, repair or replace if necessary.
5. Clean and inspect the engine oil drain plug sealing surface on the oil pan, repair or replace
oil pan if necessary.
Fig. 183: View Of Oil Filter

7. Clean and inspect the oil filter sealing area.
1. Lightly oil the replacement oil filter gasket with clean oil and install the new oil filter.
Fig. 184: View Of Oil Filter
2. Install the new oil filter. Refer to Maintenance Items in Maintenance and Lubrication.
Tighten: Tighten the new oil filter to 3/4 to 1 full turn, after the oil filter gasket contacts
the oil filter mounting surface.
3. Install the engine oil drain plug.
Tighten: Tighten the engine oil drain plug to 25 N.m (18 lb ft).
4. Remove the oil drain pan.

6. Fill the engine with new engine oil. Refer to the following information in Maintenance and
Lubrication.
Capacities - Approximate Fluid
Fluid and Lubricant Recommendations
Explanation of Scheduled Services
DRAINING FLUIDS AND OIL FILTER REMOVAL

1. Remove the oil pan drain plug.
2. Drain the engine oil.
Fig. 187: Removing/Installing Oil Filter


Fig. 188: Locating Left Coolant Drain Plug
4. Remove the coolant drain plug from the left side, if applicable.
Fig. 189: Locating Right Coolant Drain Plug
5. Remove the coolant drain plug from the right side.

6. Drain the coolant.
CRANKSHAFT BALANCER REMOVAL
Tools Required
J 24420-C Harmonic Balancer Puller. See Special Tools and Equipment.

Removal Procedure
1. Remove the crankshaft balancer retaining bolt and washer.

Fig. 191: Identifying J 24420-C
2. Remove the crankshaft balancer using the J 24420-C . See Special Tools and Equipment.
ENGINE FLYWHEEL REMOVAL

Fig. 192: View Of Engine Flywheel
1. Remove the flywheel bolts.

2. Remove the flywheel.
DRIVE BELT TENSIONER REMOVAL

Fig. 193: Drive Belt Tensioner

ENGINE MOUNT STRUT AND AIR CONDITIONING COMPRESSOR BRACKET REMOVAL

Fig. 194: Removing Engine Mount Strut & A/C Compressor Bracket
1. Remove the engine mount strut and A/C compressor bracket bolts.
2. Remove the engine mount strut and A/C compressor bracket.
ENGINE MOUNT STRUT AND ENGINE LIFT BRACKET REMOVAL

Fig. 195: Engine Mount Strut & Lift Bracket
1. Remove the engine mount strut and lift bracket bolts.

2. Remove the engine mount strut and lift bracket.
ENGINE LIFT BRACKET AND GENERATOR BRACKET REMOVAL

Fig. 196: View Of Engine Lift Bracket & Generator Bracket
1. Remove the generator bracket bolts (1-3).

3. Remove the front engine lift bracket.
OIL LEVEL INDICATOR AND TUBE REMOVAL

Fig. 197: Thermostat Bypass Pipe & Components
1. Remove the thermostat bypass pipe to throttle body nut (2).

2. Remove the thermostat bypass pipe to throttle body hose clamps (1).
3. Remove the thermostat bypass pipe to engine front cover bolt (4).
4. Remove the thermostat bypass pipe hose clamp (5) and hose from pipe.
5. Remove the thermostat bypass pipe (3).
Fig. 198: Locating Oil Level Indicator And Oil Level Indicator Tube
6. Remove the oil level indicator tube bolt.

7. Remove the oil level indicator and oil level indicator tube.
OIL FILTER ADAPTER REMOVAL

1. Remove the oil filter bypass hole plug.
IMPORTANT: Do not remove the oil filter fitting unless replacement or

repair is needed.
2. Remove the oil filter fitting, if necessary.
IMPORTANT: Do not pry against the threads in oil filter bypass hole when
removing the bypass valve.
3. Remove the oil filter bypass valve, by prying out with a suitable tool.
EXHAUST MANIFOLD REMOVAL - LEFT
Fig. 200: View Of Exhaust Manifold Heat Shield & Bolts - Left

4. Remove the exhaust manifold heat shield.
Fig. 201: View Of Exhaust Manifold & Exhaust Manifold Gasket - Left

EXHAUST MANIFOLD REMOVAL - RIGHT

Fig. 202: Identifying Heated Oxygen Sensor

3. Remove the EGR pipe from the exhaust manifold.
4. Remove the heated oxygen sensor.
Fig. 203: View Of Right Exhaust Manifold Heat Shields & Bolts

6. Remove the exhaust manifold heat shields.
Fig. 204: Right Exhaust Manifold (3.4L)

WATER OUTLET AND THERMOSTAT REMOVAL

1. Remove the water outlet bolts.

2. Remove the water outlet.
Fig. 206: Locating Thermostat
VALVE ROCKER ARM COVER REMOVAL - LEFT

Fig. 207: View Of Valve Rocker Arm Cover - Left
severe oil leak.
IMPORTANT: When removing the valve rocker arm cover make sure the

VALVE ROCKER ARM COVER REMOVAL - RIGHT

Fig. 209: Electric Ignition Control Module
1. Remove the electronic ignition control module nuts and bolts.

2. Remove the electronic ignition control module.
3. Remove the electronic ignition control module studs.
severe oil leak.
IMPORTANT: When removing the valve rocker arm cover make sure the

INTAKE MANIFOLD REMOVAL - UPPER

Fig. 212: View Of MAP Sensor & Bolts
1. Remove the manifold absolute pressure (MAP) sensor electrical connector.

2. Remove the MAP sensor bolts (1).
3. Remove the MAP sensor from bracket.
4. Remove the MAP sensor bracket and bracket bolt (1, 2).
Fig. 213: Locating Exhaust Gas Recirculation (EGR) Valve Pipe
5. Remove the exhaust gas recirculation (EGR) valve pipe and bolt from the EGR valve.
6. Remove the EGR valve bolts.
7. Remove the EGR valve and gasket.
Fig. 214: Vacuum Harness Assembly
8. Remove the vacuum harness assembly.

Fig. 215: View Of Accelerator Cable Bracket & Bracket Bolts
9. Remove the accelerator cable bracket and bracket bolts.

Fig. 216: View Of Upper Intake Manifold & Gaskets
10. Remove the purge valve bracket bolt, hose and valve assembly.
11. Remove the throttle body bolts.
12. Remove the throttle body and gasket.
13. Remove the upper intake manifold bolts.
14. Remove the upper intake manifold and gaskets.
INTAKE MANIFOLD REMOVAL - LOWER


4. Remove the fuel injector rail assembly.
Fig. 219: View Of Heater Inlet Pipe & Nut
5. Remove the heater inlet pipe nut.

6. Remove the heater inlet pipe.
Fig. 220: View Of Lower Intake Manifold & Bolts

VALVE ROCKER ARM AND PUSH ROD REMOVAL

1. Remove the valve rocker arm bolts.
IMPORTANT: Place the valve train components in a rack in order to ensure

that the components are installed in the same location from
which they were removed.
2. Remove the valve rocker arms.

Fig. 222: Removing/Installing Push Rods
3. Remove the push rods.

The intake push rods measure 146 mm (5.75 in).
The exhaust push rods measure 152.51 mm (6.0 in).

Fig. 223: Intake Manifold Gaskets
4. Remove the intake manifold gaskets.
VALVE LIFTER REMOVAL

Fig. 224: View Of Valve Lifters & Lifter Guides
1. Remove the valve lifter guide bolts.

2. Remove the valve lifter guides.
IMPORTANT: Once removed, place the valve lifters in an organized order

so the valve lifters can be installed into the original
locations.
3. Remove the valve lifters.
WATER PUMP REMOVAL


Fig. 226: View Of Water Pump Assembly & Bolts

CYLINDER HEAD REMOVAL - LEFT

1. Remove the cylinder head bolts and discard.


4. Remove the cylinder head locator dowel pins if required.
CYLINDER HEAD REMOVAL - RIGHT

1. Remove the cylinder head bolts and discard.


4. Remove the cylinder head locator dowel pins if required.
OIL PAN REMOVAL

Fig. 231: View Of Oil Pan & Bolts
1. Remove the oil pan side bolts.

2. Remove the oil pan bolts.
3. Remove the oil pan.
4. Remove the oil pan gasket.
OIL PUMP REMOVAL


OIL PUMP DRIVE REMOVAL


CRANKSHAFT FRONT OIL SEAL REMOVAL

Pry out the crankshaft front oil seal using a suitable tool. Use care not to damage the engine front
cover or the crankshaft.
ENGINE FRONT COVER REMOVAL

1. Remove the crankshaft position sensor wiring bracket bolt.

2. Remove the crankshaft position sensor wiring bracket.
3. Remove the engine front cover bolts (1), (2), and (3).
TIMING CHAIN AND SPROCKETS REMOVAL

Fig. 238: View Of Timing Chain & Camshaft Sprocket



CAMSHAFT REMOVAL
Fig. 241: Identifying Camshaft Position Sensor And Sensor Bolt
1. Remove the camshaft position sensor and sensor bolt.

Fig. 242: View Of Camshaft Thrust Plate
2. Remove the camshaft thrust plate screws.

3. Remove the camshaft thrust plate.
Fig. 243: View Of Camshaft
NOTE: All camshaft journals are the same diameter, so care must be
used in removing or installing the camshaft to avoid damage to
the camshaft bearings.
4. Complete the following steps in order to remove the camshaft:

1. Install a large screwdriver in the camshaft bolt hole. Do not damage the threads.
2. Carefully rotate and pull the camshaft out of the camshaft bearings.
PISTON, CONNECTING ROD, AND BEARING REMOVAL
Tools Required
J 24270 Ridge Reamer. See Special Tools and Equipment.

J 5239 Connecting Rod Bolt Guide. See Special Tools and Equipment.
Fig. 244: Removing Cylinder Bore Ring Ridge
1. Mark the piston with the number of the cylinder from which the piston is being removed.
2. Mark the connecting rod and the connecting rod cap in order to ensure correct assembly.
NOTE: If there is a pronounced ridge at the top of the piston travel, the
ridge must be removed with a ridge reamer before the piston
and connecting rod assembly are removed. Applying force may
break the piston rings or damage the piston.
3. Use the J 24270 in order to remove the cylinder bore ring ridge. See Special Tools and
Equipment.
Complete the following steps:
1. Turn the crankshaft until the piston is at the bottom of the stroke.
2. Cover the piston with a cloth.
3. Remove the cylinder ring ridge.
4. Turn the crankshaft until the piston is at the top of the stroke.
5. Remove the cloth.
6. Remove the metal shavings from the cylinder and piston.
Fig. 245: View Of Connecting Rod & Piston Assembly
4. Remove the connecting rod nuts and cap.

5. Remove the connecting rod cap and bearing half.
NOTE: Install thread protector in order to avoid damage to the

crankshaft journal.
6. Install J 5239 onto the connecting rod bolts. See Special Tools and Equipment.
7. Remove the connecting rod and piston assembly.
8. Push out the assembly using a suitable tool.
CRANKSHAFT REAR OIL SEAL REMOVAL

1. Remove the crankshaft rear oil seal.
IMPORTANT: Do not damage the crankshaft or seal bore.
2. Pry out the crankshaft rear oil seal out using a suitable tool.
CRANKSHAFT AND BEARINGS REMOVAL
Fig. 247: View Of Crankshaft Position Sensor & Stud

1. Remove the crankshaft position sensor heat shield nut and heat shield.
2. Remove the crankshaft position sensor stud.
3. Remove the crankshaft position sensor from the side of the block.
Fig. 248: View Of Crankshaft, Main Bearings And Bearing Caps
4. Remove the crankshaft main bearing cap bolt and studs.

5. Remove the crankshaft main bearing caps and lower crankshaft main bearing halves.
IMPORTANT: Use Care when handling the crankshaft. Avoid damage to the
crankshaft position sensor reluctor wheel teeth. Nicks, burrs
or other damage to the teeth may effect On-board
Diagnostics (OBD) II system performance.
6. Remove the crankshaft.

7. Remove the upper crankshaft main bearing halves.
CAMSHAFT BEARING REMOVAL
Tools Required

Removal Procedure
Fig. 249: Camshaft Bearing Service Set
1. Select the expander assembly and driving washer.

2. Assemble the J 33049 .
Fig. 250: Removing/Installation Camshaft Inner Bearing Using J 33049
3. Drive out the camshaft bearings. Use the J 33049 .
ENGINE BLOCK DISASSEMBLE


Fig. 252: Identifying Rear Oil Gallery Plugs
2. Remove the rear oil gallery plugs (1, 2, 3).

Fig. 253: Front Oil Gallery Plugs
3. Remove the front oil gallery plugs (1, 2).

4. Remove all of the remaining engine block plugs.
5. Remove the knock sensor.

Fig. 255: View Of Engine Oil Pressure Switch
ENGINE BLOCK CLEANING AND INSPECTION
Tools Required
J 8001 Dial Indicator Set

J 8087 Cylinder Bore Gage. See Special Tools and Equipment.
Fig. 256: View Of Gasket Mating Surfaces
1. Clean the sealing material from the gasket mating surfaces.

2. Boil the engine block in caustic solution.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.
5. Clean the blind holes.
6. Spray the cylinder bores and the machined surfaces with engine oil.
7. Inspect the threaded holes.
8. Clean the holes with a tap. Drill out the holes and install thread inserts, as needed.
Fig. 257: Testing Block Deck Surface For Flatness

9. Use a straight edge and a feeler gauge in order to test the deck surface for flatness. Replace
the block if it is outside of the specification limit.
10. Inspect the oil pan rail for nicks.
Inspect the front cover attaching area for nicks.
Use a flat mill file in order to remove any nicks.
Fig. 258: Inspect Mating Surfaces Of Transmission Case

11. Inspect the mating surfaces of the transmission case.
NOTE: A broken flywheel may result if the transmission case mating

surface is not flat.
12. Use the following procedure in order to measure the engine block flange runout at the 6
mounting bolt hole bosses:
1. Temporarily install the crankshaft. Measure the crankshaft flange runout.
2. Hold the J 8001 gage plate flat against the crankshaft flange.
3. Place the dial indicator stem on the transmission mounting bolt hole boss. Set the
indicator to 0.
4. Record the readings obtained from all of the bolt hole bosses. The measurements
should not vary more than 0.25 mm (0.010 in).
5. Retest the crankshaft flange runout if the readings vary more than 0.25 mm (0.010 in).
If the crankshaft flange runout is not within the specification, replace the engine block.

IMPORTANT: Perform the following inspections, and reconditioning if

necessary, with the crankshaft main bearing caps installed
and tightened to specification.
13. Inspect the crankshaft main bearing bores. Use the J 8087 in order to measure the bearing
bore concentricity and alignment at the following locations:
The camshaft
The crankshaft
14. Replace the engine block if the bores are out of specification.
Fig. 260: Inspecting Cylinder Bores Using J 8087

15. Use the J 8087 in order to inspect the cylinder bores. See Special Tools and Equipment.
Inspect the bores for the following conditions:
Wear
Taper
Runout
Ridging
IMPORTANT: If the bore is worn beyond the limits, refit the bore with 0.5
mm (0.02 in) oversized pistons.
16. Leave sufficient material in order to allow honing when fitting the piston.
CYLINDER BORING AND HONING
Boring Procedure
1. Before honing or boring, measure all of the new pistons. Select the smallest piston for the
piston fitting. Slightly varied pistons in a set may provide correction, if the first piston is too
loosely fitted.
2. Before using any type of boring bar, file the top of the engine block to remove any dirt or
burrs. If the cylinder block is not straight, the boring bar may be tilted, causing the bored
cylinder wall to have incorrect right angles to the crankshaft.
3. Carefully follow the instructions furnished by the manufacturer regarding use of equipment.
4. Install all crankshaft main bearing caps to specification when boring cylinders. Cover or
tape the crankshaft bearings and other internal parts to protect these parts during the boring
or honing operation.
5. Leave 0.03 mm (0.001 in) on the diameter for finish honing when performing the final cut
with a boring bar. Carefully perform the honing and boring operation to maintain the
specified clearances between pistons, rings, and cylinder bores.
Honing Procedure
1. Follow the manufacturer's recommendations for use, cleaning, and lubrication when honing
the cylinders. Use only clean, sharp stones of the proper grade for the amount of material to
be removed. Dull, dirty stones cut unevenly and generate excessive heat. When using coarse
or medium-grade stones, leave sufficient metal so all stone marks may be removed with the
fine stones used for finishing to provide the proper clearance.
2. During the honing operation, thoroughly clean the cylinder bore. Check for the correct
piston fit.
Fig. 261: Identifying Cylinder Bore Cross Hatch Pattern
3. Make full strokes in the cylinder to eliminate taper. Repeatedly check the measurement at
the top, the middle, and the bottom of the cylinder bore.
NOTE: Handle the pistons with care. Do not force the pistons through
the cylinder until you hone the cylinder to the correct size. The
piston can be distorted through careless handling.
4. When finish honing a cylinder bore to fit a piston, move the hone up and down at a
sufficient speed to obtain a fine and uniform surface finish in a cross hatch pattern.
5. The finish marks should be clean but not sharp. The finish marks should be free from
imbedded particles and torn or folded metal.
6. Determine the finish hone cylinder measurement by measuring the piston to be installed, and
by adding the average of the clearance specification. Measure the block and the piston at
normal room temperature.
7. True up the refinished cylinder bores. Final hone each cylinder bore to remove all stone or
cutter marks.
8. After final honing and before the piston is checked for fit, clean the bores with hot water
and detergent. Scrub the bores with a stiff bristle brush and rinse the bores thoroughly with
hot water. Do not allow any abrasive material to remain in the cylinder bores. This abrasive
material will wear the new rings, the cylinder bores, and the bearings lubricated by the
contaminated oil. After washing dry the bore.
9. Permanently mark the piston for the cylinder to which the piston has been fitted.
10. Apply clean engine oil to each bore to prevent rusting.
ENGINE BLOCK ASSEMBLE

1. Apply sealer GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the oil
pressure switch threads.
Tighten: Tighten the engine oil pressure switch to 16 N.m (12 lb ft).
3. Apply sealer GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the knock
sensor threads.
4. Install the knock sensor.
Tighten: Tighten the knock sensor to 19 N.m (14 lb ft).
Fig. 264: Front Oil Gallery Plugs

5. Apply sealer GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the front
oil gallery plug threads (1 and 2).
Tighten: Tighten the oil gallery plug (1) to 19 N.m (14 lb ft).

Tighten: Tighten the oil gallery plug (2) to 33 N.m (24 lb ft).
Fig. 265: Locating Rear Oil Gallery Plugs

8. Apply sealer GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the rear oil
gallery plug threads (1 and 4).
Tighten: Tighten the oil gallery plugs (1 and 4) to 19 N.m (14 lb ft).

Tighten: Tighten the oil gallery plugs (2 and 3) to 33 N.m (24 lb ft).
11. Apply sealer GM P/N United States 12346004, GM P/N Canada 10953480 or the
equivalent to the engine block plugs.
12. Install the remaining engine block plugs.
Fig. 266: Locating Left Coolant Drain Plug

13. Apply sealant GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the
coolant drain plug threads.
14. Install the left coolant drain plug.
Tighten: Tighten the coolant drain plug to 19 N.m (14 lb ft).
Fig. 267: Locating Right Coolant Drain Plug

15. Apply sealant GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the
coolant drain plug threads.
16. Install the right coolant drain plug.
Tighten: Tighten the coolant drain plug to 19 N.m (14 lb ft).
CRANKSHAFT AND BEARINGS CLEANING AND INSPECTION

Tools Required

J 45059 Angle Meter. See Special Tools and Equipment.
Fig. 268: View Of Crankshaft & Bearings

IMPORTANT: Use care when handling the crankshaft. Avoid damage to the
crankshaft position sensor reluctor wheel teeth. Nicks, burrs
or other damage to the teeth may effect on-board diagnostics
(OBD) 2 system performance.
1. Clean the crankshaft of the following elements:

Oil
Sludge
Carbon
2. Inspect the crankshaft oil passages for obstructions.

Fig. 269: Inspecting Crankshaft Keyway
3. Inspect the crankshaft keyway for the following conditions:

A worn crankshaft key (1)
A worn crankshaft keyway (2)
4. Inspect the crankshaft threads (3) for damage.

Fig. 270: Identifying Different Crankshaft Journal Wear Patterns
IMPORTANT: If cracks, severe gouges or burned spots are found, replace

the crankshaft. Remove slight roughness using a fine
polishing cloth soaked in clean engine oil. Remove any burrs
using a fine oil stone.
5. Inspect the crankshaft bearing journals and the crankshaft thrust surfaces for the following
conditions:
Wear without any grooves or scratches (1)
Grooves or scoring (2)
Scratches or excessive wear (3)
Pitting or embedded bearing material (4) - Inspect the corresponding crankshaft

bearing inserts for embedded material and determine the source of the material.
Fig. 271: View Of Crankshaft Bearings
6. The crankshaft bearings are the precision insert type.

7. Inspect the outer surfaces of the crankshaft bearings for the following conditions:
Wear-surface wear indicates either movement of the insert, or high spots in the
surrounding material - spot wear.
Looseness or rotation indicated by flattened tangs and wear grooves

Fig. 272: Identifying Crankshaft Bearing Craters Or Pockets
IMPORTANT: Note the location of the crankshaft main bearing high spots.
If the spots are not in line, the crankshaft is bent. Replace the
crankshaft.
8. Inspect the crankshaft main bearings for craters or pockets. Flattened sections on the
crankshaft bearing halves also indicate fatigue.
9. Inspect the thrust surfaces of the main thrust bearing for the following conditions:
Wear
Grooving-Grooves are caused by irregularities of the crankshaft thrust surface.

Fig. 273: Identifying Connecting Rod Bearing Scoring Or Discoloration
10. Inspect the crankshaft bearings for excessive scoring or discoloration.

11. Inspect the crankshaft main bearings for dirt or imbedded debris.
Fig. 274: Crankshaft Bearing Polished Sections (Improper Seating)
12. Inspect the crankshaft main bearings for improper seating indicated by bright, polished
sections.
13. Inspect the crankshaft bearings for uneven side-to-side wear. This may indicate a bent
crankshaft or a tapered bearing journal.
IMPORTANT: If crankshaft bearing failure is due to conditions other than

normal wear, investigate the cause of the condition. Inspect
the crankshaft or connecting rod bearing bores.
14. Inspect the connecting rod bearing bores or crankshaft main bearing bores using the
1. Tighten the bearing cap to specification.
2. Use the J 8087 in order to measure the bearing bore for taper and out-of-round.
Record the readings for bearing selection.
3. No taper or out-of-round should exist.
Bearing Selection
Measure the bearing clearance to determine the correct replacement bearing insert size. There are
two methods to measure bearing clearance. Method A gives more reliable results and is preferred.
Method A yields measurement from which the bearing clearance can be computed.
Method B yields the bearing clearance directly. Method B does not give any indication of
bearing run-out.
Method A
Fig. 276: Measuring Crankshaft Bearing Journal Diameter

IMPORTANT: Do not mix inserts of different nominal size in the same

bearing bore.
1. Measure the crankshaft bearing journal diameter with a micrometer in several places, 90
degrees apart. Average the measurements.
2. Measure the crankshaft bearing journal taper and runout.
3. Install the crankshaft bearing inserts. Tighten the bearing cap bolts to specification using J
45059 . See Special Tools and Equipment.
4. Measure the connecting rod inside diameter in the same direction as the length of the rod
with an inside micrometer.
5. Measure the crankshaft main bearing inside diameter with an inside micrometer.
7. If the specified clearances cannot be met, the crankshaft journals must be reconditioned and
undersized bearing inserts installed.
Method B
Fig. 277: Measuring Gaging Plastic
IMPORTANT: Do not mix inserts of different nominal size in the same

bearing bore.
1. Clean the used bearing inserts.

2. Install the used bearing inserts.
3. Place a piece of gaging plastic across the entire bearing width.
4. Install the bearing caps.
NOTE: In order to prevent the possibility of cylinder block or
crankshaft bearing cap damage, the crankshaft bearing caps
are tapped into the cylinder block cavity using a brass, lead, or
a leather mallet before the attaching bolts are installed. Do not
use attaching bolts to pull the crankshaft bearing caps into the
seats. Failure to use this process may damage a cylinder block
or a bearing cap.
5. Install the bearing cap bolts to specification using J 45059 . See Special Tools and
Equipment.
IMPORTANT: Do not rotate the crankshaft.
6. Remove the bearing cap, leaving the gaging plastic in place. It does not matter whether the
gaging plastic adheres to the journal or to the bearing cap.
7. Measure the gaging plastic at its widest point with the scale printed on the gaging plastic
package.
8. Remove the gaging plastic.

Fig. 278: Inspecting Crankshaft Balancer Sealing Area
Inspect the crankshaft balancer sealing area for grooves (1).

Inspect the crankshaft balancer belt ribs for dents or damage.
Replace the crankshaft balancer if necessary.
ENGINE FLYWHEEL CLEANING AND INSPECTION

Fig. 279: Inspecting Engine Flywheel
Inspect the engine flywheel for cracks.

Inspect the engine flywheel teeth for damage.
Replace the engine flywheel if necessary.
PISTON AND CONNECTING ROD DISASSEMBLE
Tools Required

Fig. 280: View Of Removing/Installing Piston Rings

IMPORTANT: This procedure is to be used for oversized pistons only.

Standard size pistons are supplied as an assembly
consisting of a piston, piston pin, connecting rod and piston
rings.
1. Using piston ring pliers, remove the piston rings from the piston.
Fig. 281: Installing J 24086-310 Into J 24086-10
2. Install fork insert J 24086-310 into fixture J 24086-10 piston pin remover/installer base,
which are part of J 24086-C .
Fig. 282: View Of J 24086-107 & J 24086-88A

3. Install the piston and connecting rod assembly onto J 24086-10.

4. Install the J 24086-107 onto the piston pin and J 24086-88A through the fixture and onto J
24086-107, which are part of J 24086-C .
Fig. 283: View Of J 24086-88A

NOTE: After the installer hub bottoms on the support assembly, do not
exceed 35 000 kPa (5,000 psi) pressure, this could cause
damage to the tool.
5. Press the piston pin from the piston and connecting rod assembly.
6. The piston and pin are a matched set and are not to be serviced separately. Mark, sort
organize the piston and the matching piston pin.
PISTON, CONNECTING ROD, AND BEARINGS CLEANING AND INSPECTION
Tools Required

Cleaning and Inspection Procedure
Fig. 284: Cleaning The Piston Ring Grooves With Suitable Ring Groove Cleaning
Tool
CAUTION: Bodily injury may occur if the cleaning solvent is inhaled

or exposed to the skin.
IMPORTANT: Measurement of all components should be taken with the
components at room temperature. Do not use a wire brush in
order to clean any part of the piston or connecting rod
assembly.
IMPORTANT: Some steps in this procedure may reflect on a disassembled

oversized piston. Others will only apply to the standard size
pistons that are NOT to be disassembled.
1. Clean the piston and connecting rod in solvent.

2. Dry off the piston and connecting rod with compressed air.
3. Clean the piston ring grooves with a suitable ring groove cleaning tool.
4. Clean the piston oil lubrication holes and slots.
Fig. 285: Identifying Piston Damage Inspection Areas
5. Inspect the piston for the following:

Eroded areas (1) on the top of the piston
Scuffed or damaged skirt (2)
Damage to the pin bore (3)
Cracks in the piston ring lands, the piston skirt, or the pin bosses
Piston ring grooves for nicks, burrs, or other warpage which may cause the piston ring
to bind
6. Inspect the piston pin for scoring, wear or other damage.
Fig. 286: Inserting Piston Ring Into Ring Groove

7. Measure the piston ring-to-piston ring groove side clearance.

1. Insert the edge of the piston ring into the piston ring groove.
2. Roll the piston ring completely around the piston ring groove.
If binding is caused by distorted piston ring groove, replace the piston.
If binding is caused by a distorted piston ring, replace the piston ring.

Fig. 287: Measuring Piston Ring Side Clearance
8. Measure the piston ring side clearance with a feeler gage.

9. If the side clearance is too small try another ring set.
10. If the proper piston ring-to-piston ring groove clearance cannot be achieved, replace the
piston and pin assembly.
Proper ring-to-piston ring groove clearance for the top ring is 0.03-0.076 mm (0.001-
0.003 in).
Proper ring-to-piston ring groove clearance for the second ring is 0.04-0.078 mm
(0.002-0.003 in).
Fig. 288: Measuring Piston Pin Diameter
11. Measure the piston pin diameter using a micrometer.

Fig. 289: Measuring The Piston Pin Bore
IMPORTANT: When fitting pistons, consider both the pistons and the
cylinder bore conditions together. Production and service
pistons have the same nominal weight and may be
intermixed without affecting engine balance. If necessary,
used pistons may be fitted selectively to any cylinder of the
engine, providing the pistons are in good condition and the
same weight. Do not cut oversize pistons down or the engine
balance may be affected. Finish hone when selecting the
pistons.
12. Measure the piston pin bore using an inside micrometer.

13. Subtract the piston pin diameter from the piston pin bore diameter in order to determine the
piston pin-to-piston pin bore clearance.
14. Piston-to-piston pin bore clearance must measure 0.008-0.016 mm (0.0003-0.0006 in).
Replace the piston and the piston pin if the piston and the piston pin are not within
specifications.
Fig. 290: Measuring Piston Diameter

15. Measure the piston diameter with a micrometer at a right angle to the piston bore with the
piston pin removed, and record the measurement. Measure the piston at 43 mm (1.692 in)
from dome of piston. Piston diameter must measure no less than 93.960 mm (3.699 in).
Replace the piston and the pin as an assembly if the piston is not within specifications.
Fig. 291: Measuring Cylinder Bore
16. Measure the cylinder bore, using J 8087 .

Fig. 292: Measuring Bore Gauge With Micrometer
17. Measure the J 8087 . Record this reading.

18. Subtract the diameter of the piston from the diameter of the cylinder bore to determine the
piston-to-bore clearance. The cylinder bore clearance must be no more than 0.080 mm
(0.003 in).
19. If a used piston is not acceptable, inspect the service piston size and determine if a new
piston may be selected. Service pistons are available in standard and 0.5 mm (0.012 in)
oversize.
20. When a piston has been selected, mark the piston in order to identify the cylinder for which
the piston was fitted.
Fig. 293: View Of Connecting Rod
21. Inspect the connecting rod for an out-of-round bearing bore. If the out-of-round
measurement exceeds 0.005 mm (0.0002 in) the connecting rod must be replaced.
Fig. 294: Identifying Twisted Connecting Rod
22. Inspect the connecting rod for twisting.

1. Install the connecting rod cap.
2. Place the connecting rod assembly on a checking fixture. Inspect the assembly for
bending or twisting.
3. Do not attempt to straighten the connecting rod. Ensure that the connecting rod meets
The connecting rods are not bent more than 0.18 mm (0.007 in).
The connecting rods are not twisted more than 0.38 mm (0.0015 in).
Replace any bent or twisted connecting rods.
Inspect the new connecting rods before using the new rods.
23. Inspect the connecting rod for damage to the bearing cap and bolt threads.
Fig. 295: Measuring Piston Ring End Gap
24. Measure the piston compression ring end gap.
IMPORTANT: Fit each compression ring to the cylinder in which it will

be used.
1. Place the compression ring into the cylinder bore.

2. Push the compression ring into the bottom of the cylinder bore to approximately 6.5
mm (0.25 in) above ring travel. The ring must be square to the cylinder wall.
3. Use a feeler gage in order to measure the end gap. The first compression ring end gap
must measure 0.18-0.39 mm (0.007-0.015 in), the second compression ring must
measure 0.48-0.74 mm (0.019-0.029 in).
4. Select another size ring set if the end gap exceeds specifications. If ring gap clearance
is below specifications, increase the gap by carefully filing off excess material.
Fig. 296: Identifying Crankshaft Bearing Craters Or Pockets

25. Inspect the connecting rod bearings for craters or pockets. Flattened sections on the
connecting rod bearing halves may indicate fatigue.
Fig. 297: Identifying Connecting Rod Bearing Scoring Or Discoloration
26. Inspect the connecting rod bearings for excess scoring or discoloration.
27. Inspect the connecting rod bearings for dirt or debris imbedded into the connecting rod
bearing halves.
Fig. 298: Crankshaft Bearing Polished Sections (Improper Seating)
28. Inspect the connecting rod bearings for improper seating indicated by bright, polished
sections of the bearings.
29. Inspect the inside of the connecting rod bearing and the outside diameter of the connecting
rod bearing journal for wear. This indicates high spots.
PISTON AND CONNECTING ROD ASSEMBLE
Tools Required

Assembly Procedure
Fig. 299: Installing J 24086-310 Into J 24086-10
IMPORTANT: This procedure is to be used for oversized pistons only.

Standard size pistons are supplied as an assembly
consisting of a piston, piston pin, connecting rod and piston
rings. Assemble the piston for the specific cylinder with the
connecting rod for the corresponding crankshaft journal.
1. Install fork insert J 24086-310 into fixture J 24086-10, which are part of J 24086-C .
Fig. 300: Assemble J 24086-C With Piston Assembly

2. Lubricate the piston pin with clean engine oil.
IMPORTANT: Ensure that the marks on the piston and connecting rod are
aligned the same as when removed. If installing a new piston,
ensure that the arrow on top faces towards the front of the
engine. If no identification marks were made during
disassembly, ensure that the flat area on the bottom of the
piston pin skirt is aligned with the small dimple above the
connecting rod crankshaft bearing bore.
3. Assemble the piston, connecting rod and adapter J 24086-6A and install onto fixture J
24086-10, which are part of J 24086-C .
Fig. 301: Closeup View Of J 24086-9
4. Adjust installation pin J 24086-9 to G-4.

Fig. 302: View Of J 24086-9
NOTE: After the installer hub bottoms on the support assembly, do not
exceed 35 000 kPa (5,000 psi) pressure, this could cause
damage to the tool.
5. Insert pin J 24086-9 through fixture J 24086-10, which are part of J 24086-C and to the
piston pin.
6. Press pin J 24086-9 until it bottoms on fixture J 24086-10.
Fig. 303: View Of Removing/Installing Piston Rings

NOTE: Use a piston ring expander to install the piston rings. The rings
may be damaged if expanded more than necessary.
IMPORTANT: To provide an effective compression seal, the ring gaps must

be staggered a minimum of 90 degrees.
7. Using piston ring pliers, install the piston rings onto the piston.
1. Install the oil control ring spacer into the bottom groove of the piston.
2. Install the lower oil control ring. The oil control rings do not have a dimple or
orientation mark and may be installed in either direction.
3. Install the upper oil control ring.
4. Install the middle compression ring with the dot facing up.
5. Install the top compression ring in either direction. The ring has no orientation
markings.
CAMSHAFT AND BEARINGS CLEANING AND INSPECTION
Tools Required
J 7872 Magnetic Base Dial Indicator Set. See Special Tools and Equipment.
1. Clean the camshaft with cleaning solvent.

Fig. 304: Inspecting Camshaft
CAUTION: Refer to Cleaning Solvent Caution in Cautions and

Notices.
2. Inspect the camshaft for the following conditions:

Scored camshaft bearing journals (1)
Damaged camshaft lobes (2)
Damaged camshaft sprocket locator pins (3)
Damaged threads (4)
Damage to the camshaft reluctor tooth (5)

Fig. 305: Measure Camshaft Journals With Micrometer
3. Measure the camshaft journals using a micrometer.
If the camshaft journals are not within specifications, replace the camshaft.
Fig. 306: Measuring Camshaft With J 7872
4. Measure the camshaft runout using the J 7872 . See Special Tools and Equipment.
1. Mount the camshaft in V-blocks between the centers.
2. Use the J 7872 in order to measure the intermediate camshaft journal. See Special
5. Measure the camshaft lobe lift using the J 7872 . See Special Tools and Equipment.
1. Lubricate the camshaft using GM P/N United States 12345501, GM P/N Canada
992704 or the equivalent.
2. Set the camshaft on V-blocks.
3. Use the J 7872 in order to measure the lobe lift. See Special Tools and Equipment.
6. If the runout or lobe lift is not within specifications, replace the camshaft.
TIMING CHAIN AND SPROCKETS CLEANING AND INSPECTION

Fig. 307: Identifying Damaged Sprocket Teeth
Inspect the timing chain sprockets for teeth that are worn (1), broken (2), or chipped (3).
Inspect the timing chain for binding or stretching.
Inspect the timing chain dampener for excessive wear or cracks.
Replace the timing chain and sprockets as needed.
VALVE LIFTERS CLEANING AND INSPECTION
1. Clean the valve lifters in cleaning solvent.
CAUTION: Refer to Safety Glasses Caution in Cautions and Notices.

2. Dry the valve lifters with compressed air.
Fig. 308: Inspecting Areas Of Valve Lifters

3. Inspect the valve lifters for the following:

Bent or broken clip (1)
Worn push rod socket (2)

Scuffed or worn sides (3)
If the valve lifter shows wear, inspect the engine block lifter bores for wear or
damage.
Flat spots on the roller (4)

Loose or damaged pin (5)
Plugged oil hole (6)
Worn or damaged roller bearing

Fig. 309: View Of Valve Lifter Guides
4. Inspect the valve lifter guides for the following:

For cracks or damage
Excessive wear in the lifter mounting bores
VALVE ROCKER ARM AND PUSH RODS CLEANING AND INSPECTION

Notices.
1. Clean the valve rocker arms and push rods in cleaning solvent.
2. Dry the valve rocker arms and push rods with compressed air.
Fig. 310: Identifying Valve Rocker Arm

3. Inspect the valve rocker arms for the following conditions:

Excessive wear at the valve contact or push rod socket area (1)
A loose or damaged pin (2)
A worn or damaged roller bearing (2)
The bolt threads for damage
Fig. 311: Inspecting Push Rods

IMPORTANT: Keep the push rods in order. The intake and exhaust are
different lengths.
4. Inspect the push rods for the following conditions:

Straightness using a straight edge (1)
Excessive wear on the push rod ends (3)
Clogging of the oil passage (2)
CYLINDER HEAD DISASSEMBLE

Tools Required
J 38606 Valve Spring Compressor. See Special Tools and Equipment.

Fig. 312: Removing/Installing Fuel Line Bracket

IMPORTANT: Ensure that the valve train components are marked,

organized or sorted when disassembling the cylinder head.
Install the valve train components in the original location
from which the components were removed.
1. Remove the fuel line bracket bolt and stud.

2. Remove the fuel line bracket.
NOTE: Do not damage the valve guide. Remove any burrs that have
formed at the key groove by chamfering the valve stem with an
oil stone or a file.
3. Compress the valve springs using the J 38606 . See Special Tools and Equipment.
4. Remove the valve spring cap keys.

5. Remove the valve spring caps.
6. Remove the valve springs.
7. Remove the valves.
8. Remove the valve stem oil seals and spring seats as an assembly.
CYLINDER HEAD CLEANING AND INSPECTION
Tools Required
J 8089 Carbon Removing Brush. See Special Tools and Equipment.

J 9666 Valve Spring Tester
Fig. 315: View Of Cylinder Head Gasket
1. Inspect the cylinder head gasket and the mating surfaces. Inspect for leaks, corrosion, and
blowby.
2. If the gasket failed, determine the cause. The following conditions may cause gasket failure:
A loose or warped cylinder head

Missing, off location, or not fully seated dowel pins
Low torque on the cylinder head bolts
Cylinder head bolts with the incorrect length
A warped engine block surface
Scratched surfaces
Excessive intake manifold torque
Cracked engine block threaded holes
Fig. 316: Removing Carbon From Combustion Chambers

IMPORTANT: Do not scuff the chamber.
3. Use the J 8089 in order to remove the carbon from the combustion chambers. See Special
4. Clean the following components:
The gasket surfaces
Do not use a motorized brush on any gasket sealing surface.
Valve stems and heads on a buffing wheel

The bolt hole threads
Remove all dirt, debris, or threadlocking material from the bolt holes.
Fig. 317: Inspecting Cylinder Head Mating Surfaces For Flatness
5. Inspect the cylinder head mating surfaces for flatness. Replace the cylinder head if it is
outside of the specification limit.
6. Inspect the cylinder head for cracks.
7. Inspect the cylinder head deck for corrosion. Do not attempt to weld the cylinder head. If
the cylinder head is damaged, replace the cylinder head.
Fig. 318: Inspecting Valve Spring For Squareness
8. Inspect the valve springs for squareness.

Fig. 319: Measuring Valve Spring Tension
9. Use the J 9666 in order to measure the valve spring tension.
Replace the spring if the spring tension is not within specification.
VALVE GUIDE REAMING/VALVE AND SEAT GRINDING
Tools Required
J 8520 Camshaft Lobe Lift Indicator Set. See Special Tools and Equipment.
Reaming/Grinding Procedure
Fig. 320: Identifying Inspection Points For Valves Damage

1. Inspect the valves for the following conditions:

A worn margin (2)
A bent stem (3)
A worn or scored stem (4)
A worn key groove (5)
A worn stem tip (6)
Fig. 321: Inspecting Valve Face For Burning, Pitting & Cracking
2. Inspect the valve face for the following conditions:

Worn margin (4)
No margin (1)
Pitted surfaces (2)
3. Inspect the valve seats for a loose fit in the cylinder head.
Fig. 322: Inspecting For Excessive Valve Stem To Guide Clearance
NOTE: Proper valve stem-to-valve guide clearance is necessary for

proper engine operation and component life. Excessive
clearance may cause a noisy valve train, premature valve stem
oil seal failure, excessive oil consumption and related
component damage. Insufficient clearance may cause a noisy
valve train, rough engine operation or sticking valves that may
lead to related component damage. Failure to inspect valve
stem-to-valve guide clearance and repair or replace necessary
components may lead to extensive engine damage.
IMPORTANT: Excessive valve stem-to guide clearance may cause the

A noisy valve train

Premature valve stem oil seal wear
Component damage
Excessive engine oil consumption
4. Inspect for excessive valve stem (1) to guide (2) clearance.

5. Use a dial indicator in order to measure the valve stem-to-guide clearance. Complete the
following steps:
1. Install the valve into the guide.
2. Install the J 8520 onto the cylinder head. See Special Tools and Equipment.
3. Locate the dial indicator so that the movement of the valve stem from side to side,
crosswise to the cylinder head, will cause a direct movement on the indicator stem.
4. Ensure that the indicator stem contacts the side of the valve stem just above the valve
guide.
5. Drop the valve head about 2 mm (1/8 in) off the valve seat.
6. Use light pressure and move the valve stem side to side in order to obtain a clearance
reading.
7. If the valve stem to guide clearance is not within specification, replace the valve
and/or repair the guide in order to obtain the proper clearances.
Fig. 324: Reaming Valve Guides For Oversize Valves

IMPORTANT: Replace a valve stem that has excessive scoring or wear. A

valve guide that is worn and has excessive stem-to-guide
clearance may need to be sleeved.
6. Ream the valve guides for oversize valves if the clearance exceeds the specifications.
Fig. 325: Reaming Valve Guide
IMPORTANT: Follow the manufacturers instructions when using valve

guide reamers, sleeves, and installers.
7. Ream the valve guide in order to obtain the proper specification.

IMPORTANT: Valves that are pitted must be refaced to the proper angle.
Replace valve stems that show excessive wear, or replace
valves that are warped. Several different types of equipment
are available for refacing valves and valve seats. Follow the
manufacturers recommendations when performing these
procedures.
8. Inspect the valves for excessive scoring.

Fig. 327: Inspecting Valve Margin
9. Inspect the valve face.
Replace the valve if the valve margin is not within specifications after grinding.
10. Reface pitted valves on a valve refacing machine in order to ensure the correct relationship
between the head and the stem.
IMPORTANT: Reconditioning the valve seats is very important. Ensure

perfect seating of the valves in the engine in order to deliver
optimum power and performance. Clean the valve guides of
all debris and dirt before grinding the valve seat.
11. Recondition the valve seats after reaming the valve guide bores or installing the new valve
guides.
12. The valve seats should be concentric to within 0.05 mm (0.031 in) total indicator reading.
CYLINDER HEAD ASSEMBLE
Tools Required
J 38606 Valve Spring Compressor. See Special Tools and Equipment.

Assembly Procedure
IMPORTANT: Use oversize valve stem seals if you install oversize valves.
1. Lubricate the valve stem with clean engine oil.

2. Install the valves.
3. Lightly lap the reconditioned valves into the valve seat.
4. Install the valve stem oil seals.
5. Install the valve springs.
6. Install the valve spring caps.
7. Compress the valve springs using the J 38606 . See Special Tools and Equipment.
8. Install the valve spring cap keys.
Hold the valves in place with grease, if necessary.
9. Release the valve springs.

10. Ensure that the valve locks are seated.
11. Measure valve spring installed height.
12. If the valve spring installed height is not within specifications install 0.25 mm (0.010 in)
rocker arm shims as needed. If more than 2 shims are needed replace the cylinder head or
valve.
Fig. 330: Removing/Installing Fuel Line Bracket

NOTE: In order to avoid damage, install the spark plugs after the
cylinder head has been installed on the engine.
13. Install the fuel line bracket.
14. Install the fuel line bracket bolt or stud.
Tighten: Tighten the fuel line bracket bolt or stud to 50 N.m (37 lb ft).
OIL PUMP DISASSEMBLE
Fig. 331: View Of Oil Pump Driveshaft & Oil Pump Driveshaft Retainer
1. Remove the oil pump driveshaft and oil pump driveshaft retainer.
Fig. 332: View Of Oil Pump Screen
IMPORTANT: DO NOT remove the oil pump screen from the pipe. The pipe
and oil pump screen are serviced as a complete assembly.
2. Remove the oil pump screen, if necessary.

The oil pump screen has a press fit into the oil pump cover.
Fig. 333: View Of Oil Pump Cover Bolts

3. Remove the oil pump cover bolts.

Fig. 334: View Of Oil Pump Cover
4. Remove the oil pump cover.

Fig. 335: View Of Oil Pump Drive Gear & Driven Gear
5. Remove the oil pump drive gear and the oil pump driven gear.
6. Matchmark the gear teeth for assembly.
Fig. 336: View Of Oil Pump Pressure Relief Valve, Spring & Spring Straight Pin
CAUTION: In some models, the pressure regulator valve spring is

under pressure. Remove the retaining pin carefully in
order to avoid bodily injury.
7. Remove the following items:

1. The oil pump pressure relief valve spring straight pin.
2. The oil pump pressure relief spring.
Notices.
3. The oil pump pressure relief valve. If the valve is stuck, soak the pump housing in
cleaning solvent.
OIL PUMP CLEANING AND INSPECTION

Fig. 337: Inspecting Oil Pump Housing & Gears, Idler Shaft, & Drive Gear Shaft

Notices.
1. Clean all parts of sludge, oil, and varnish by soaking in cleaning solvent.
2. Inspect for foreign material and determine the source of the foreign material.
3. Inspect the pump housing and cover for the following conditions:
Cracks or casting imperfections
Scoring (3)
Damaged threads
4. Do not attempt to repair the pump housing.
Replace the pump housing.
5. Inspect the oil pump gears for the following conditions:

Scoring (1)
Excessive wear (2)
6. Inspect the idler shaft for looseness or scoring (4).
If loose or damaged, replace the oil pump.
7. Inspect the drive gear shaft for looseness or scoring (5).

Fig. 338: View Of Pressure Regulator Valve & Spring
8. Inspect the pressure regulator valve for the following conditions:

Scoring
Sticking
Burrs may be removed using a fine oil stone.
9. Inspect the pressure regulator valve spring for the following conditions:
Loss of tension
Bending
10. Inspect the suction pipe and screen assembly for the following conditions:
Looseness
If the suction pipe is loose, bent or has been removed, replace the pump body cover
and suction pipe.
Broken wire mesh or screen
Fig. 339: Measuring Oil Pump Gear Lash

11. Measure the oil pump gear lash. Install the gears, and measure in several places.
Fig. 340: Checking Oil Pump Housing Gear Pocket
12. Measure the oil pump housing gear pocket (1, 2).
Fig. 341: View Of Oil Pump Gears
13. Measure the oil pump gears (1, 2).

Fig. 342: Measuring Oil Pump Gear Side Clearance
IMPORTANT: When deciding pump serviceability based on end clearance,

consider depth of the wear pattern in the pump cover.
14. Measure the oil pump gear side clearance.
OIL PUMP ASSEMBLE
Tools Required
J 21882 Oil Suction Pipe Installer. See Special Tools and Equipment.
1. Lubricate all the internal oil pump parts using engine oil during assembly.
Fig. 343: View Of Oil Pump Drive Gear & Driven Gear
2. Install the oil pump gears.
Fig. 344: View Of Oil Pump Cover

3. Install the oil pump cover.
4. Install the oil pump cover bolts.
Tighten: Tighten the oil pump cover bolts to 10 N.m (89 lb in).
Fig. 345: View Of Pressure Regulator Valve & Spring

5. Install the pressure regulator valve.

6. Install the pressure regulator spring.
7. Install the cotter pin.
IMPORTANT: Make sure the cotter pin is properly secured.
8. Apply sealer GM P/N 12346004, (Canadian P/N 10953480) or the equivalent to the new
suction pipe.
9. Tap the new suction pipe into place using a plastic hammer. Use the J 21882 for 5/8 inch
pipe or J 22144 for 3/4 inch pipe. See Special Tools and Equipment.
Fig. 346: Crankshaft Position Sensor

1. Remove the crankshaft position sensor bolts from the engine front cover.
2. Remove the crankshaft position sensor.
Fig. 347: View Of Engine Front Cover


Notices.
3. Clean the engine front cover with cleaning solvent.

4. Inspect the engine front cover sealing surfaces for damage.
5. Inspect the engine front cover threaded holes.
6. Repair or replace the engine front cover as necessary.
Fig. 348: Crankshaft Position Sensor

7. Install the crankshaft position sensor to the engine front cover.

8. Install the crankshaft position sensor bolts. Apply threadlock GM P/N United States
12345382, GM P/N Canada 10953489 or the equivalent to the threads.
Tighten: Tighten the crankshaft position sensor bolts to 10 N.m (89 lb in).
VALVE ROCKER ARM COVER CLEANING AND INSPECTION
Fig. 349: View Of Valve Rocker Arm Covers

1. Remove all rubber grommets from the valve rocker arm covers.
2. Inspect the rubber grommets, if cracked or torn replace.
CAUTION: Bodily injury may occur if the cleaning solvent is inhaled

or exposed to the skin.
3. Clean the valve rocker arm covers with GM P/N 12346139 (Canadian P/N 88901247) or
equivalent.
4. Dry the valve rocker arm covers with compressed air.
5. Inspect the valve rocker arm covers for damage and replace if necessary.
6. Install all rubber grommets into the valve rocker arm covers.
OIL PAN CLEANING AND INSPECTION
Fig. 350: Oil Pan

2. Remove the oil level sensor.

Notices.
3. Clean the oil pan in solvent. Remove all sludge and debris from the bottom of the oil pan.
4. Inspect the oil pan sealing surfaces for damage.
Replace the oil pan if necessary.
5. Install the oil level sensor.
Tighten: Tighten the oil level sensor bolt to 10 N.m (89 lb in).
INTAKE MANIFOLD CLEANING AND INSPECTION - LOWER
Tools Required
Fig. 351: Engine Coolant Temperature Sensor
1. Remove the engine coolant temperature sensor.

Fig. 352: Identifying Intake Manifold Coolant Pipe
2. Remove the intake manifold coolant pipe bolt, if required.

3. Remove the intake manifold coolant pipe, if required.
Fig. 353: View Of Intake Manifold
IMPORTANT: Use GM P/N 12346139 (Canadian P/N 10953463) or equivalent

to clean the intake manifold mating surfaces.
4. Clean the intake manifold gasket mating surfaces.

5. Clean the fuel injector bores.
6. Inspect the threaded holes for damage.
7. Inspect the intake manifold mating surfaces for damage.
Repair or replace the intake manifold as necessary.

8. Apply sealant GM P/N 12345493 (Canadian P/N 10953488) to the end of a new intake
manifold coolant pipe.
9. Install the intake manifold coolant pipe using the J 21882 . See Special Tools and
Equipment.
10. Install the intake manifold coolant pipe bolt.

Tighten: Tighten the intake manifold coolant pipe bolt to 10 N.m (89 lb in).
Fig. 355: Engine Coolant Temperature Sensor

11. Apply sealant GM P/N 12346004 (Canadian P/N 10953480) or equivalent to the threads of
the engine coolant temperature sensor.
12. Install the engine coolant temperature sensor.
Tighten: Tighten the engine coolant temperature sensor to 23 N.m (17 lb ft).
INTAKE MANIFOLD CLEANING AND INSPECTION - UPPER
Fig. 356: Accelerator Control Cable Bracket
1. Remove the accelerator control cable bracket bolts (1, 2) and the nut (3).
2. Remove the accelerator control cable bracket.

3. Remove the throttle body bolt and stud.

4. Remove the throttle body.
5. Remove the throttle body gasket.
Fig. 358: Inspecting Intake Manifold
6. Clean the intake manifold gasket surfaces.

7. Clean the intake manifold bolts and studs.
8. Inspect the intake manifold mating surfaces for nicks or cracks.
Replace the intake manifold if damaged.

9. Install the throttle body gasket.

10. Install the throttle body.
11. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) to the threads.
12. Install the throttle body bolt and stud.
Tighten: Tighten the throttle body bolt and stud to 25 N.m (18 lb ft).
Fig. 360: Accelerator Control Cable Bracket
13. Install the accelerator control cable bracket.
14. Install the accelerator control cable bracket bolts and nut.
Tighten: Tighten the accelerator control cable bracket bolts in sequence (1, 2, 3) to 10 N.m
(89 lb in).
EXHAUST MANIFOLD CLEANING AND INSPECTION
Fig. 361: Inspecting Exhaust Manifold

1. Inspect the exhaust manifold mating surface for flatness.

2. Inspect the exhaust manifold for cracks or damage.
Replace the exhaust manifold if necessary.
WATER PUMP CLEANING AND INSPECTION

1. Remove all gasket material from the sealing surface.

2. Inspect the water pump impeller for damage.
3. Inspect the water pump shaft for looseness.
4. Replace the water pump if necessary.
THREAD REPAIR
General purpose thread repair kits are available commercially.

Fig. 363: Drilling & Tapping Damaged Threads
IMPORTANT: Refer to the thread repair kit manufacturer's instructions

regarding the size of the drill and which tap to use.
Always avoid any buildup of chips. Back out the tap every
few turns and remove the chips.
1. Determine the size, the pitch, and the depth of the damaged thread.
2. Adjust the stop collars on the cutting tool as needed. Tap the stop collars to the required
depth.
3. Drill out the damaged thread.
4. Remove the chips.
5. Apply clean engine oil to the top thread.
6. Use the tap in order to cut new thread.
7. Clean the thread.
Fig. 364: Installing Thread Insert

8. Screw the thread insert onto the mandrel of the thread insert installer. Engage the tang of the
thread insert onto the end of the mandrel.
IMPORTANT: The thread insert should be flush to 1 turn below the surface.
9. Lubricate the thread insert with clean engine oil - except when installing in aluminum - and
install the thread insert.
10. If the tang of the thread insert does not break off when backing out the thread insert
installer, break off the tang using a drift punch.
SERVICE PRIOR TO ASSEMBLY
Dirt will cause premature wear of the rebuilt engine. Clean all of the components. Use the proper
tools in order to measure components when inspecting for excessive wear. Repair or replace the
components that are not within the manufacturers specification. When components are reinstalled
into an engine, return the components to their original location, position, and direction. During
assembly, lubricate all of the moving parts with clean engine oil or engine assembly lubricant
unless otherwise specified. This will provide initial lubrication when the engine is first started.
ENGINE PRELUBING
Tools Required
J 45299 Engine Preluber. See Special Tools and Equipment.

Prelubing Procedure
IMPORTANT: A constant/continuous flow of clean engine oil is required in

order to properly prime the engine. Be sure to use an
approved engine oil as specified in the owners manual.
1. Remove the engine oil filter, fill with clean engine oil.

Tighten: Tighten the oil filter to 30 N.m (22 lb ft).
3. Locate the oil pressure sensor on left side of engine and remove.
4. Install the 1/4 inch adapter P/N 509373.
Fig. 366: Identifying Engine Preluber J 45299

5. Install the flexible hose to the adapter and open the valve.
6. Pump the handle on J 45299 to flow a minimum of 1-2 quarts of engine oil. See Special
Tools and Equipment. Observe the flow of engine oil through the flexible hose and into
the engine assembly.
7. Close the valve and remove the flexible hose and adapter from the engine.
8. Install the oil pressure sensor.
Tighten: Tighten the oil pressure sensor to 16 N.m (12 lb ft).
9. Top off the engine oil to the proper level.
CAMSHAFT BEARING INSTALLATION
Tools Required
J 33049 Camshaft Bearing Remover/Installer. See Special Tools and Equipment.

Fig. 367: Camshaft Bearing Service Set
1. Assemble the J 33049 according to the manufacturer's instructions. See Special Tools and
Equipment.
Fig. 368: Removing/Installation Camshaft Inner Bearing Using J 33049
NOTE: Severe engine damage may result if the oil holes are not
correctly aligned.
2. Install the camshaft bearings in the following order:

1. Index the camshaft bearing oil holes with the engine block oil passages.
2. Place the bearing on the J 33049 . See Special Tools and Equipment.
3. Install the third camshaft bearing.
4. Install the second camshaft bearing.
5. Install the outer camshaft bearings.
3. Apply sealer GM P/N United States 12377901, GM P/N Canada 10953504 or the
equivalent to the camshaft rear bearing hole plug.
4. Install the camshaft rear bearing hole plug.
CRANKSHAFT AND BEARINGS INSTALLATION
Tools Required
Fig. 370: View Of Crankshaft, Main Bearings And Bearing Caps

IMPORTANT: Ensure that the crankshaft bearing cap bolt holes and the
crankshaft bearing cap mating surfaces are clean and dry.
1. Dip the crankshaft bearing cap bolts in clean engine oil.
NOTE: Upper and lower inserts may be different. Do not obstruct any
oil passages.
2. Place the crankshaft bearing inserts into the crankshaft bearing cap and into the engine
block.
IMPORTANT: The crankshaft bearing inserts will project slightly when put
into place. Ensure that the bearing inserts project an equal
distance on both sides. Ensure that the insert tangs are
engaged.
3. Lubricate the crankshaft main bearing surface with clean engine oil.
4. Install the crankshaft.
NOTE: In order to prevent the possibility of cylinder block or

crankshaft bearing cap damage, the crankshaft bearing caps
are tapped into the cylinder block cavity using a brass, lead, or
a leather mallet before the attaching bolts are installed. Do not
use attaching bolts to pull the crankshaft bearing caps into the
seats. Failure to use this process may damage a cylinder block
or a bearing cap.
5. Install the crankshaft main bearing caps. Apply a small amount of sealer GM P/N 1052942
(Canadian P/N 10953466) to the rear of the #4 crankshaft main bearing cap sealing surface.
6. Install the crankshaft main bearing cap bolts.
Tighten: Use the J 45059 in order to tighten the crankshaft main bearing cap bolts to 50 N.
See Special Tools and Equipment.m (37 lb ft) plus 77 degrees.
Fig. 371: Measuring Crankshaft End Play
7. Measure the crankshaft end play.

1. Thrust the crankshaft forward or rearward.
2. Insert a feeler gage between the number 3 crankshaft bearing and the bearing surface
of the crankshaft and measure the bearing clearance. The proper crankshaft end play
clearance is 0.06-0.21 mm (0.002-0.008 in).
3. If the bearing clearance is not within specifications, inspect the thrust surfaces for
nicks, gouges or raised metal. Minor imperfections may be removed with a fine stone.
Fig. 372: View Of Crankshaft Position Sensor & Stud
8. Install the crankshaft position sensor into the side of the engine block.
9. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or the equivalent to the
crankshaft position sensor stud threads.
10. Install the crankshaft position sensor stud.
Tighten: Tighten the crankshaft position sensor stud to 11 N.m (98 lb in).
11. Install the crankshaft position sensor shield and nut.
Tighten: Tighten the crankshaft position sensor shield nut to 11 N.m (98 lb in).
CRANKSHAFT REAR OIL SEAL INSTALLATION

Tools Required
J 34686 Rear Main Seal Installer. See Special Tools and Equipment.
Fig. 373: Installing Crankshaft Rear Oil Seal

NOTE: Do not apply or use any oil lubrication on the crankshaft rear
oil seal, or the seal installer. Do not touch the sealing lip of the
oil seal once the protective sleeve is removed. Doing so will
damage/deform the seal.
NOTE: Clean the crankshaft sealing surface with a clean, lint free
towel. Inspect lead-in edge of crankshaft for burrs/sharp edges
that could damage the rear main oil seal. Remove burrs/sharp
edges with crocus cloth before proceeding.
IMPORTANT: Notice the direction of the rear oil seal. The new design seal
is a reverse style as opposed to what has been used in the
past. "THIS SIDE OUT" has been stamped into the seal as
shown in the graphic.
1. Carefully remove the protection sleeve from the new crankshaft rear oil seal.
2. Install the crankshaft rear oil seal onto the J 34686 by sliding the crankshaft rear oil seal
over the mandrel using a twisting motion until the back of the crankshaft rear oil seal
bottoms squarely against the collar of the tool. See Special Tools and Equipment.
1. Align the dowel pin of the J 34686 with the dowel pin in the crankshaft. See Special
2. Attach the J 34686 to the crankshaft by hand, or tighten attaching screws to 5 N. See
Special Tools and Equipment.m (45 lb in).
3. Turn the T-handle of the J 34686 in order to engage allow the collar to push the seal
into the bore. See Special Tools and Equipment.
Turn the handle until the collar is tight against the engine block. Ensure that the seal is
seated properly.
4. Loosen the T-handle until the T-handle comes to a stop.

5. Remove the attaching screws.
PISTON, CONNECTING ROD, AND BEARING INSTALLATION
Tools Required
J 5239 Connecting Rod Bolt Guide. See Special Tools and Equipment.
J 8037 Piston Ring Compressor. See Special Tools and Equipment.
Fig. 374: View Of Piston Assembly
IMPORTANT: The piston and cylinder bore have been measured and the
bore has been sized for the proper clearance. Install the
piston and connecting rod assembly into the proper cylinder
bore. The piston alignment mark MUST face the front of the
engine block.
1. Lightly lubricate the following components with clean engine oil:
The piston
The piston rings
The cylinder bore
The bearing surfaces
2. Stagger the oil control ring end gaps a minimum of 90 degrees.

3. Stagger the compression ring end gaps a minimum of 25 mm (1.0 in).
4. Install the J 8037 onto the piston and compress the piston rings. See Special Tools and
Equipment.
Fig. 375: Protecting Crankshaft Journals Using J 5239
IMPORTANT: The piston alignment mark MUST be facing the front of the
engine block.
5. Install the J 5239 on the connecting rod bolts. See Special Tools and Equipment.
Fig. 376: Installing Piston & Connecting Rod Assembly Into Cylinder
6. Install the piston and connecting rod assembly into the proper cylinder bore.
7. Hold the piston ring compressor firmly against the engine block. Using a wooden hammer
handle, lightly tap the top of the piston until all of the piston rings enter the cylinder bore.
Fig. 377: View Of Connecting Rod & Piston Assembly
8. Guide the connecting rod end onto the crankshaft journal.

9. Install the bearing, cap, and nuts.
Tighten:
1. Tighten the connecting rod bearing cap nuts a first pass to 20 N.m (15 lb ft).
2. Tighten the connecting rod bearing cap nuts a second pass to 75 degrees using the J
Fig. 378: Measuring Connecting Rod Side Clearance
10. With the pistons and connecting rods installed, use a soft faced mallet and lightly tap each
connecting rod assembly parallel to the crankpin to make sure that the rods have side
clearance.
11. Measure the connecting rod side clearance using a feeler gage or dial indicator. Connecting
rod side clearance should be within 0.18-0.44 mm (0.007-0.017 in).
CAMSHAFT INSTALLATION
Fig. 379: View Of Camshaft

1. Coat the camshaft journals with clean engine oil.

2. Coat the camshaft lobes with prelube GM P/N United States 12345501, GM P/N Canada
992704 or the equivalent.
3. Install the camshaft using the following procedure:
1. Install a large screwdriver into the camshaft bolt hole for support. Do not damage the
threads.
2. Rotate the camshaft while installing the camshaft into the camshaft bearings.
Fig. 380: View Of Camshaft Thrust Plate

4. Install the camshaft thrust plate.
5. Install the camshaft thrust plate screws.

Tighten: Tighten the camshaft thrust plate screws to 10 N.m (89 lb in).
Fig. 381: View Of Camshaft Position Sensor

6. Install the camshaft position sensor.

7. Install the camshaft position sensor bolt.
Tighten: Tighten the camshaft position sensor bolt to 10 N.m (89 lb in).
TIMING CHAIN AND SPROCKETS INSTALLATION


2. Apply prelube GM P/N United States 12345501, GM P/N Canada 992704 or the equivalent
to the crankshaft sprocket thrust surface.
Tighten: Tighten the timing chain dampener bolt to 21 N.m (15 lb ft).
Fig. 384: Locating Timing Marks
dampener (1).
6. Hold the camshaft sprocket with the timing chain hanging down and install the timing chain
to the crankshaft gear.
chain dampener (3).
Fig. 385: View Of Timing Chain & Camshaft Sprocket

ENGINE FRONT COVER INSTALLATION

Fig. 386: Applying Sealer To Lower Tabs Of Engine Front Cover Gasket

2. Apply sealer GM P/N 12346004, (Canadian P/N 10953480) or equivalent to both sides of
the lower tabs of the engine front cover gasket, and the engine front cover bolts. Apply the
sealer no less than 5.0 mm (0.20 in) wide.



Tighten: Tighten the crankshaft position sensor wiring bracket bolt to 27 N.m (20 lb ft).
CRANKSHAFT FRONT OIL SEAL INSTALLATION
Tools Required
J 35468 Cover Aligner and Seal Installer. See Special Tools and Equipment.
Fig. 389: Installing Crankshaft Front Oil Seal

1. Align the J 35468 and the crankshaft front oil seal with the engine front cover and
crankshaft. See Special Tools and Equipment.
2. Install the crankshaft front oil seal using the J 35468 and a suitable tool. See Special Tools
and Equipment.
OIL PUMP DRIVE INSTALLATION

1. Apply prelube GM P/N United States 12345501, GM P/N Canada 992704 or the equivalent
to the oil pump drive gear.
Tighten: Tighten the oil pump drive gear clamp bolt to 36 N.m (27 lb ft).
OIL PUMP INSTALLATION

Tighten: Tighten the crankshaft oil deflector nuts to 25 N.m (18 lb ft).
Fig. 392: Oil Pump
IMPORTANT: Do not reuse the oil pump driveshaft retainer. During

assembly, install a NEW oil pump driveshaft retainer.
3. Install the oil pump.
4. Position the oil pump onto the pins.
5. Install the oil pump bolt attaching the oil pump to the rear crankshaft bearing cap.
Tighten: Tighten the oil pump bolt to 41 N.m (30 lb ft).
OIL PAN INSTALLATION
Fig. 393: Illustrating Proper Sealer Application

1. Apply sealer GM P/N 12346141 (Canadian P/N 10953433) or the equivalent to both sides
of the crankshaft rear main bearing cap (1). Press sealer into gap using a putty knife.
Fig. 394: View Of Oil Pan & Bolts
2. Install the oil pan gasket.

3. Install the oil pan.
NOTE: Refer to Fastener Notice In Cautions and Notices.

4. Install the oil pan bolts.
Tighten: Tighten the oil pan bolts to 25 N.m (18 lb ft).
5. Install the oil pan side bolts.
Tighten: Tighten the oil pan side bolts to 50 N.m (37 lb ft).
CYLINDER HEAD INSTALLATION - LEFT
Tools Required

NOTE: This component uses torque-to-yield bolts. When servicing this

component do not reuse the bolts, New torque-to-yield bolts
must be installed. Reusing used torque-to-yield bolts will not
provide proper bolt torque and clamp load. Failure to install
NEW torque-to-yield bolts may lead to engine damage.
Fig. 396: Removing/Installing Cylinder Head


Tighten:
1. Tighten the cylinder head bolts a first pass in sequence to 60 N.m (44 lb ft).
2. Tighten the cylinder head bolts a final pass in sequence to 95 degrees using the J
CYLINDER HEAD INSTALLATION - RIGHT
Tools Required

NOTE: This component uses torque-to-yield bolts. When servicing this

component do not reuse the bolts, New torque-to-yield bolts
must be installed. Reusing used torque-to-yield bolts will not
provide proper bolt torque and clamp load. Failure to install
NEW torque-to-yield bolts may lead to engine damage.
Fig. 399: Removing/Installing Cylinder Head


Tighten:
1. Tighten the cylinder head bolts a first pass in sequence to 60 N.m (44 lb ft).
2. Tighten the cylinder head bolts a final pass in sequence to 95 degrees using the J
WATER PUMP INSTALLATION


Tighten: Tighten the water pump bolts to 11 N.m (98 lb in).


Tighten: Tighten the water pump pulley bolts to 25 N.m (18 lb ft).
VALVE LIFTER INSTALLATION

Fig. 403: View Of Valve Lifters & Lifter Guides
1. Coat the valve lifters using prelube GM P/N 12345501 (Canadian P/N 992704) or the
equivalent.
2. Install the valve lifters in their original locations.
3. Apply threadlock GM P/N 12345382 (Canadian P/N 10953489) or the equivalent to the
threads.

4. Install the valve lifter guides and guide bolts.
Tighten: Tighten the valve lifter guide bolts to 10 N.m (89 lb in).
VALVE ROCKER ARM AND PUSH ROD INSTALLATION
Fig. 404: Intake Manifold Gaskets

IMPORTANT: All gasket mating surfaces must be free of oil and foreign
Fig. 405: Removing/Installing Push Rods

2. Coat the ends of the push rods using prelube GM P/N 12345501 (Canadian P/N 992704) or
the equivalent.
IMPORTANT: The intake valve push rods measure 146.0 mm (5.75 in) in
length. The exhaust valve push rods measure 152.5 mm (6.0
in) in length.
3. Install the push rods in their original location.

4. Coat the rocker arm friction surfaces using prelube GM P/N 12345501 (Canadian P/N
992704) or the equivalent.
IMPORTANT: Shims may be required under the valve rocker arm pedestals
if reconditioning has been performed on the cylinder head or
its components.
5. Install the valve rocker arms in their original positions.

6. Install the valve rocker arm bolts.
Tighten: Tighten the valve rocker arm bolts to 32 N.m (24 lb ft).
INTAKE MANIFOLD INSTALLATION - LOWER
Fig. 407: Lower Intake Manifold

IMPORTANT: All gasket-mating surfaces need to be free of oil, and foreign

2. With gaskets in place apply a small drop 8-10 mm (0.31-0.39 in) of RTV sealer GM P/N
12346141 (Canadian P/N 10953433) or equivalent to the 4 corners of the intake manifold
to block joint (1).
3. Connect the 2 small drops with a bead of RTV sealer that is between 8-10 mm (0.31-0.39
in) wide and 3.0-5.0 mm (0.12-0.20 in) thick (2).

NOTE: Maximum gasket performance is achieved when using new

fasteners, which contain a thread-locking patch. If the
fasteners are not replaced, a thread locking chemical must be
applied to the fastener threads. Failure to replace the fasteners
or apply a thread-locking chemical MAY reduce gasket sealing
capability.
IMPORTANT: All lower intake manifold bolts need to be cleaned, free of

any foreign material, and reused only if new bolts are
unavailable. Use GM P/N 12345382 (Canadian P/N 10953489)
or equivalent and apply to the old intake manifold bolt
threads.
IMPORTANT: Manufacturer recommends the center bolts be fully torqued

before the diagonal bolts to assure proper seal ability.
IMPORTANT: Lower intake manifold bolts in location 6 and 7 should be

torqued to specification using a crows foot type tool.
Tighten:
1. Tighten the lower intake manifold bolts (1, 2, 3, 4) in sequence to 7 N.m (62 lb in) on
the first pass.
on the first pass.
on the final pass.
4. Tighten the lower intake manifold bolts (5, 6, 7, 8) in sequence to 25 N.m (18 lb ft) on
the final pass.
Fig. 409: View Of Heater Inlet Pipe & Nut
6. Install the heater inlet pipe.

7. Install the heater inlet pipe nut.
Tighten: Tighten the heater inlet pipe nut to 25 N.m (18 lb ft).
IMPORTANT: Do not use the fuel injector O-ring seals twice. Install NEW
fuel injector O-ring seals during assembly.
IMPORTANT: Do not press on the fuel pressure regulator valve when

installing the fuel injector rail assembly.
8. Install the fuel injector rail assembly.
1. Install the fuel injector O-rings using GM P/N 12345616, (Canadian P/N 993182) or
equivalent.
2. Install the injector nozzles into the lower intake manifold injector bores.
3. Press on the injector rail using the palms of both hands until the injectors are fully
seated.
9. Install the fuel injector rail bolts.
Tighten: Tighten the fuel injector rail bolts to 10 N.m (89 lb in).

IMPORTANT: Do not use the fuel injector O-ring seals twice. Install NEW
fuel injector O-ring seals during assembly.
Tighten: Tighten the fuel feed and return pipe retaining clip bolt to 8 N.m (71 lb in).
INTAKE MANIFOLD INSTALLATION - UPPER

Fig. 412: View Of Upper Intake Manifold & Gaskets
1. Install the upper intake manifold gaskets.

3. Install the upper intake manifold bolts and studs. Apply threadlock GM P/N 12345382
(Canadian P/N 10953489) to the threads.
Tighten: Tighten the upper intake manifold bolts and studs to 25 N.m (18 lb ft).
Fig. 413: Identifying Exhaust Gas Recirculation (EGR) Valve Pipe & Bolt
4. Install the exhaust gas recirculation (EGR) valve pipe and bolt to the EGR.
Tighten: Tighten the EGR valve pipe bolt to 25 N.m (18 lb ft).
5. Install the EGR valve.
6. Install the EGR valve bolts.
Tighten: Tighten the EGR valve bolts to 25 N.m (18 lb ft).
Fig. 414: View Of MAP Sensor & Bolts

7. Install the manifold absolute pressure (MAP) sensor bracket and bolt.
Tighten: Tighten the MAP sensor bracket bolt to 25 N.m (18 lb ft).
8. Install the MAP sensor (1, 2).
9. Install the MAP sensor bolts (1).
Tighten: Tighten the MAP sensor bolts to 5 N.m (44 lb in).
10. Install the MAP sensor electrical connector.
Fig. 415: Locating Vacuum Lines

11. Install the vacuum lines to the upper intake manifold.

13. Install the throttle cable bracket bolts.
Tighten: Tighten the throttle cable bracket bolts to 13 N.m (115 lb in).
VALVE ROCKER ARM COVER INSTALLATION - RIGHT

IMPORTANT: All gasket-mating surfaces need to be free of oil and

foreign material. Use GM P/N 12378392 or equivalent to
clean surfaces.
Apply sealant GM P/N 12378521 (Canadian P/N 88901148)
or equivalent at the cylinder head to lower intake
manifold joint.
1. Install a NEW gasket to the valve rocker arm cover. Ensure that the gasket is properly
seated in the groove of the valve rocker arm cover.
2. Apply sealant GM P/N 12378521, (Canadian P/N 88901148) or the equivalent to the joint
surfaces (1) where the cylinder head and intake manifold meet.

Tighten: Tighten the valve rocker arm cover bolts to 10 N.m (89 lb in).
Fig. 418: Vacuum Harness Assembly
5. Install the vacuum lines from the upper intake manifold.

Fig. 419: Electric Ignition Control Module
6. Install the ignition coil studs.
Tighten: Tighten the ignition coil studs to 25 N.m (18 lb ft).

7. Install the electronic ignition control module.
8. Install the electronic ignition control module nuts and bolts.
Tighten: Tighten the electronic ignition control module nuts and bolts to 25 N.m (18 lb ft).
VALVE ROCKER ARM COVER INSTALLATION - LEFT

IMPORTANT: All gasket-mating surfaces need to be free of oil and

foreign material. Use GM P/N 12378392 or equivalent to
clean surfaces.
Apply sealant GM P/N 12378521 (Canadian P/N 88901148)
or equivalent at the cylinder head to lower intake
manifold joint.
1. Install a NEW gasket to the valve rocker arm cover. Ensure that the gasket is properly
seated in the groove of the valve rocker arm cover.
2. Apply sealant GM P/N 12378521, (Canadian P/N 88901148) or the equivalent to the joint
surfaces (1) where the cylinder head and intake manifold meet.
Fig. 421: View Of Valve Rocker Arm Cover - Left

Tighten: Tighten the valve rocker arm cover bolts to 10 N.m (89 lb in).
WATER OUTLET AND THERMOSTAT INSTALLATION
Fig. 422: Locating Thermostat


2. Install the water outlet.
3. Install the water outlet bolts.
Tighten: Tighten the water outlet bolts to 25 N.m (18 lb ft).
EXHAUST MANIFOLD INSTALLATION - LEFT

Fig. 424: View Of Exhaust Manifold & Exhaust Manifold Gasket - Left
Tighten: Tighten the exhaust manifold studs to 18 N.m (13 lb ft).

4. Install the exhaust manifold nuts.
Tighten: Tighten the exhaust manifold nuts working from the center outward to 16 N.m (12
lb ft).
5. Install the left side spark plugs.
Tighten:
Tighten the spark plugs to 20 N.m (15 lb ft) when installing spark plugs into a new
cylinder head.
Fig. 425: View Of Exhaust Manifold Heat Shield & Bolts - Left
6. Install the exhaust manifold heat shield.

Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
EXHAUST MANIFOLD INSTALLATION - RIGHT
Fig. 426: Right Exhaust Manifold (3.4L)

Tighten: Tighten the exhaust manifold studs to 18 N.m (13 lb ft).

4. Install the exhaust manifold nuts.
Tighten: Tighten the exhaust manifold nuts working from the center out to 16 N.m (12 lb
ft).
5. Install the right side spark plugs.
Tighten:
Tighten the spark plugs to 20 N.m (15 lb ft) when installing spark plugs into a new
cylinder head.
6. Install the spark plug wires on to the spark plugs.

Fig. 427: View Of Right Exhaust Manifold Heat Shields & Bolts
7. Install the lower exhaust manifold heat shield.

8. Install the upper exhaust manifold heat shield.
Tighten: Tighten the exhaust manifold heat shield bolts to 10 N.m (89 lb in).
Fig. 428: Identifying Heated Oxygen Sensor
10. Coat the threads of the heated oxygen sensor with anti seize compound.
11. Install the heated oxygen sensor.
Tighten: Tighten the heated oxygen sensor to 42 N.m (31 lb ft).
12. Install the spark plug wires.
OIL FILTER ADAPTER INSTALLATION

2. Install the oil filter fitting, if necessary.
Tighten: Tighten the oil filter fitting to 39 N.m (29 lb ft).

3. Install the oil filter bypass valve plug. Apply sealer GM P/N 12345739 (Canadian P/N
10953541) or the equivalent to the threads.
Tighten: Tighten the oil filter bypass valve plug to 19 N.m (14 lb ft).
Fig. 430: Removing/Installing Oil Filter

Tighten: Tighten the oil filter to 30 N.m (22 lb ft).

OIL LEVEL INDICATOR AND TUBE INSTALLATION
Fig. 431: Removing/Installing Oil Level Indicator & Oil Level Indicator Tube
1. Install the oil level indicator and oil level indicator tube.
2. Install the oil level indicator tube bolt.
Tighten: Tighten the oil level indicator tube bolt to 25 N.m (18 lb ft).
3. Install the thermostat bypass pipe (3).
Fig. 432: Thermostat Bypass Pipe & Components

4. Install the thermostat bypass pipe (3) and hose clamp (5).
5. Install the thermostat bypass pipe to engine front cover bolt (4).
Tighten: Tighten the thermostat bypass pipe to engine front cover bolt to 11 N.m (98 lb in).
6. Install the thermostat bypass pipe (3) to throttle body hose clamps (1).
7. Install the thermostat bypass pipe to throttle body nut (2).
Tighten: Tighten the thermostat bypass pipe to throttle body nut to 25 N.m (18 lb ft).
ENGINE LIFT BRACKET AND GENERATOR BRACKET INSTALLATION
Fig. 433: View Of Engine Lift Bracket & Generator Bracket

1. Install the front engine lift hook.


Tighten: Tighten the generator bracket bolts in sequence (1, 2, 3) to 50 N.m (37 lb ft).
ENGINE MOUNT STRUT AND ENGINE LIFT BRACKET INSTALLATION
Fig. 434: Engine Mount Strut & Lift Bracket

1. Install the engine mount strut and lift bracket.
2. Install the engine mount strut and lift bracket bolts.

Tighten: Tighten the engine mount strut and lift bracket bolts to 70 N.m (52 lb ft).
ENGINE MOUNT STRUT AND AIR CONDITIONING COMPRESSOR BRACKET INSTA

INSTALLATION
Fig. 435: Removing Engine Mount Strut & A/C Compressor Bracket
1. Install the engine mount strut and A/C Compressor bracket.

2. Install the engine mount strut and A/C Compressor bracket bolts.
Tighten: Tighten the engine mount strut and lift bracket bolts to 50 N.m (37 lb ft).
DRIVE BELT TENSIONER INSTALLATION
Fig. 436: Drive Belt Tensioner

Tighten: Tighten the drive belt tensioner bolt to 50 N.m (37 lb ft).
ENGINE FLYWHEEL INSTALLATION
Fig. 437: View Of Engine Flywheel

1. Install the flywheel.
2. Install the flywheel bolts.
Tighten: Tighten the flywheel bolts to 70 N.m (52 lb ft).
CRANKSHAFT BALANCER INSTALLATION
Tools Required
J 29113 Crankshaft Balancer Installer. See Special Tools and Equipment.

Fig. 438: Installing Crankshaft Balancer Using J 29113
1. Apply sealer GM P/N 12346141, (Canadian P/N 10953433) or the equivalent to the
keyway of the crankshaft balancer.
2. Place the crankshaft balancer into position over the key in the crankshaft.
3. Install the J 29113 onto the crankshaft. See Special Tools and Equipment.
4. Pull the crankshaft balancer into position.
5. Remove the J 29113 from the crankshaft balancer. See Special Tools and Equipment.

NOTE: Do NOT use a power-assisted tool with the special tool in order
to remove or install this component. You cannot properly
control the alignment of this component using a power-
assisted tool, and this can damage the component.
6. Install the crankshaft balancer washer and bolt.
Tighten:
Tighten the crankshaft balancer bolt a first pass to 70 N.m (52 lb ft).
Tighten the crankshaft balancer bolt a second pass to 85 degrees using the J 45059 .
See Special Tools and Equipment.
ROTATING THE ENGINE FOR SERVICE ACCESS
Tools Required
J 41131 Engine Tilter Strap. See Special Tools and Equipment.

Rotation Procedure
3. Shift the transaxle into Neutral.
4. Remove the engine mount strut bolts. Swing the engine mount struts aside.
5. Install the J 41131 . See Special Tools and Equipment.

6. Pull on the engine in order to rotate the engine forward.
7. Tighten the J 41131 . See Special Tools and Equipment.
CRANKCASE VENTILATION SYSTEM DESCRIPTION
General Description
Fig. 441: Crankcase Ventilation System Flow Diagram

A crankcase ventilation system is used to consume crankcase vapors in the combustion process
instead of venting them to atmosphere. Fresh air from the throttle body is supplied to the
crankcase, mixed with blow by gases and then passed through a PCV valve into the intake
manifold.
Operation
Fig. 442: Crankcase Ventilation System Flow Diagram
The primary control is through the positive crankcase ventilation (PCV) valve which meters the
flow at a rate depending on inlet vacuum. To maintain idle quality, the PCV valve restricts the
flow when inlet vacuum is high. If abnormal operating conditions arise, the system is designed to
allow excessive amounts of blow by gases to back flow through the crankcase vent into the
throttle body to be consumed by normal combustion.
Results of Incorrect Operation
A plugged valve may cause the following conditions:
Rough idle
Stalling or slow idle speed
Oil leaks
Sludge in engine
A leaking valve would cause:
Rough idle
Stalling
High idle speed
Functional Check of PCV valve
If an engine is idling rough, check for a clogged PCV valve. Replace if required. Use the
1. Remove PCV valve from intake manifold.

2. Shake valve and listen for the rattle of needle inside the valve.
3. If valve does not rattle, replace valve.
With this system, any blow-by in excess of the system capacity (from a badly worn engine,
sustained heavy load, etc.) is exhausted into the intake manifold and is drawn into the engine.
Proper operation of the crankcase ventilation system is dependent upon a sealed engine. If oil
sludging or dilution is noted, and the crankcase ventilation system is functioning properly, check
engine for possible cause and correct to ensure that system will function as intended.
DRIVE BELT SYSTEM DESCRIPTION
The drive belt system consists of the following components:

The drive belt
The drive belt tensioner
The drive belt idler pulley
The crankshaft balancer pulley
The accessory drive component mounting brackets
The accessory drive components
The power steering pump, if belt driven
The generator
The A/C compressor, if equipped
The engine cooling fan, if belt driven
The water pump, if belt driven
The vacuum pump, if equipped
The air compressor, if equipped
The drive belt system may use one belt or two belts. The drive belt is thin so that it can bend
backwards and has several ribs to match the grooves in the pulleys. There also may be a V-belt
style belt used to drive certain accessory drive components. The drive belts are made of different
types of rubbers (chloroprene or EPDM) and have different layers or plys containing either fiber
cloth or cords for reinforcement.
Both sides of the drive belt may be used to drive the different accessory drive components. When
the back side of the drive belt is used to drive a pulley, the pulley is smooth.
The drive belt is pulled by the crankshaft balancer pulley across the accessory drive component
pulleys. The spring loaded drive belt tensioner keeps constant tension on the drive belt to prevent
the drive belt from slipping. The drive belt tensioner arm will move when loads are applied to the
drive belt by the accessory drive components and the crankshaft.
The drive belt system may have an idler pulley, which is used to add wrap to the adjacent pulleys.
Some systems use an idler pulley in place of an accessory drive component when the vehicle is
not equipped with the accessory.
ENGINE COMPONENT DESCRIPTION
The cylinder block is made of cast alloy iron. The cylinder block has 6 cylinders that are
arranged in a V shape. There are 3 cylinders in each bank. The cylinder banks are set at a 60
degree angle from each other.
Starting from the front of the engine, the left bank cylinders are 1, 3, 5. The right bank cylinders
are 2, 4, 6.
Four main bearings support the crankshaft. The crankshaft is retained by the bearing caps. The
bearing caps are machined with the block for proper alignment and clearances. The main bearing
caps are drilled and tapped for the structural oil pan side bolts.
The aluminum cylinder heads have individual intake and exhaust ports for each cylinder. The
valve guides are pressed in. The roller rocker arms are located on a pedestal in a slot in the
cylinder head. The roller rocker arms are retained on individual threaded bolts.
The crankshaft is cast nodular iron with deep rolled fillets on all 6 crankpins and all 4 main
journals. Four steel-backed aluminum bearings are used. The #3 bearing is the end-thrust bearing.
The camshaft is made from a new metal composite design. The camshaft profile is a hydraulic
roller design. The camshaft is supported by 4 journals. The camshaft includes an oil pump drive
gear.
The pistons are cast aluminum using 2 compression rings and 1 oil control ring. The piston pin is
offset 0.8 mm (0.031 in) towards the major thrust side. This placement allows for a gradual
change in thrust pressure against the cylinder wall as the piston travels its path. The pins are
chromium steel. The pins have a floating fit in the pistons. The pins are retained in the connecting
rods by a press fit.
The 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.
A roller rocker type valve train is used. Motion is transmitted from the camshaft through the
hydraulic roller lifter and from the pushrod to the roller rocker arm. The rocker arm pivots on the
needle roller bearings. The rocker arm transmits the camshaft motion to the valve. The rocker arm
pedestal is located in a slot in the cylinder head. The rocker arm is retained in the cylinder head
by a bolt. The pushrod is located by the rocker arm.
The intake manifold is a 2-piece cast aluminum unit. The intake manifold centrally supports a fuel
rail with 6 fuel injectors.
The exhaust manifolds are cast nodular iron.
NEW PRODUCT INFORMATION
The purpose of New Product Information is to highlight or indicate important product changes
from the previous model year.
Changes may include one or more of the following items:
A component comparison from the previous year

Fastener changes
Torque values and/or fastener tightening strategies
Changed engine specifications
New sealants and/or adhesives
Disassembly and assembly procedure revisions
Engine mechanical diagnostic procedure revisions
New special tools required
Component Comparison
The MAP sensor and bracket have been revised.
The engine oil cooler has been deleted.

Fastener Changes
No fastener changes for 2004.

Lower intake manifold strategy is now:
Center bolts:
First Pass 7 N.m (62 lb in)
Final Pass 13 N.m (115 lb in)
Corner bolts:
First Pass 13 N.m (115 lb in)
Final Pass 25 N.m (18 lb ft)
A new Engine Mechanical Specifications chart has been implemented into the 2004 service
manual.
Engine sealers have been revised.
Disassembly and Assembly Procedure Revisions
No Revisions for 2004.

Engine Mechanical Diagnostic Procedure Revisions
No Revisions for 2004.

New Special Tools Required
J 45059 Angle Meter has been applied to 2004 books.
LUBRICATION DESCRIPTION
Fig. 443: Front View
Full pressure lubrication, through a full flow oil filter, is furnished by a gear type oil pump. The
oil is drawn up through the pickup screen and the tube. The oil passes through the pump to the oil
filter.
The oil filter is a full flow paper element unit. An oil filter bypass is used in order to ensure oil
supply during the following conditions:
On a cold start
If the filter is plugged
If the filter develops excessive pressure drop
The bypass is designed to open at 69-83 kPa (10-12 psi).
A priority oil delivery system supplies oil first to the crankshaft journals. The oil from the
crankshaft main bearings is supplied to the connecting rod bearings by intersecting the passages
drilled in the crankshaft. The passages supply the oil to the crankshaft main bearings and the
camshaft bearings through the intersecting vertical drilled holes. The oil passages from the
camshaft journals supply oil to the hydraulic lifters.
The hydraulic lifters pump oil up through the pushrods to the rocker arms. The cast dams in the
crankcase casting direct the oil that drains back from the rocker arms in order to supply the
camshaft lobes. The camshaft chain drive is lubricated by indirect oil splash.
Fig. 444: Rear View
Fig. 445: Right View
CLEANLINESS AND CARE
An automobile engine is a combination of many of the following surfaces:

Machined
Honed
Polished
Lapped
The tolerances of these surfaces are measured in the ten-thousandths of an inch. When you service
any internal engine part, cleanliness and care are important. Apply a liberal coating of engine oil
to the friction areas during assembly in order to protect and lubricate the surfaces on initial
operation. Throughout this section, practice proper cleaning and protection procedures to the
machined surfaces and to the friction areas.
NOTE: Engine damage may result if an abrasive paper, pad, or motorized

wire brush is used to clean any engine gasket surfaces.
Whenever you remove the valve train components, keep the components in order. Follow this
procedure in order to install the components in the same locations and with the same mating
surfaces as when removed.
Disconnect the negative battery cables before you perform any major work on the engine. For
more information on the disconnection of the battery, refer to Engine Electrical.
SEPARATING PARTS
In addition to the room temperature vulcanizing (RTV) sealant's sealing capabilities, the RTV
sealants may form an adhesive bond between the components. This may make the components
difficult to remove or to separate. If possible, bump the components sideways rather than using
prying tools in order to remove the components. This technique prevents damage when the
bonding strength of the RTV sealant is stronger than the component itself. Perform bumping at the
bends or at the reinforced areas in order to prevent part distortion.
REPLACING ENGINE GASKETS
1. Do not reuse any gasket unless otherwise specified. Reusable gaskets will be identified in
the service procedure. Do not apply sealant to any gasket or sealing surface unless called out
in the service procedure.
2. Use a rubber mallet in order to separate components. Bump the part sideways in order to
loosen the components. Perform the bumping at the bends or at the reinforced areas in order
to prevent the distortion of components.
IMPORTANT: Do not use any other method or technique in order to remove

the gasket material from a components.
Do not use the following items in order to clean the gasket
surfaces:
Abrasive pads
Sand paper
Power tools
These methods of cleaning may damage the component.

Abrasive pads also produce a fine grit that the oil filter
cannot remove from the oil. This grit is abrasive and may
cause internal engine damage.
3. Remove all of the gasket and the sealing material from the component using a plastic or a
wood scraper. Do not gouge or scrape the sealing surfaces.
IMPORTANT: Do not allow the sealant to enter any blind threaded holes.
The sealant may cause the following conditions:

4. When assembling components, use only the sealant specified in the service procedure.
Ensure that the sealing surfaces are clean and free of debris or oil. When applying sealant to
a component, apply a bead size as specified in the service procedure.
5. Tighten the bolts to the specifications.
USE OF ROOM TEMPERATURE VULCANIZING (RTV) AND ANAEROBIC SEALER
The following 2 types of sealer are commonly used in engines:
The RTV sealer

The anaerobic gasket eliminator sealer
Follow the service procedure instructions. Use the correct sealer in the proper place in order to
prevent oil leaks. Do not interchange the 2 types of sealers. Use the sealer recommended in the
service procedure.
Applying RTV Sealer
Do not use the room temperature vulcanizing (RTV) sealant in areas where extreme
temperatures are expected. These areas include the following locations:
The exhaust manifold
The head gasket
The other surfaces where gasket eliminator is specified
Use a rubber mallet in order to separate the components sealed with RTV sealant. Bump the
part sideways in order to shear the RTV sealer. Perform the bumping at the bends or the
reinforced areas in order to prevent distortion of the components. The RTV sealant is
weaker in shear (lateral) strength than in tensile (vertical) strength.
IMPORTANT: Do not use any other method or technique in order to remove

the gasket material from a component.
Abrasive pads
Sand Paper
Power tools
Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is
abrasive and may cause internal engine damage.
Remove all of the gasket material from the component using a plastic or a wood scraper.
Use Loctite brand gasket remover P/N 4MA or the equivalent. Follow all of the safety
recommendations and the directions that are on the container.
IMPORTANT: Do not allow the sealer to enter the blind threaded holes.
The sealer may cause the following conditions:

Apply the RTV sealant to a clean surface. Use a bead size as specified in the procedure.
Apply the bead to the inside of any bolt holes.
Assemble the components while the RTV sealant is still wet (within 3 minutes). Do not wait
for the RTV sealant to skin over.
IMPORTANT: Do not overtighten the bolts.
Tighten the bolts to specifications.

Applying Anaerobic Sealer
The anaerobic gasket eliminator hardens in the absence of air. This type of sealer is used where 2
rigid parts (such as castings) are assembled together. When 2 rigid parts are disassembled and no
sealer or gasket is readily noticeable, the parts were probably assembled using a gasket
eliminator.
IMPORTANT: Do not use any other method or technique in order to remove the
gasket material from a component.
Abrasive pads
Sand paper
Power tools
Abrasive pads also produce a fine grit that the oil filter cannot remove from the oil. This grit is
abrasive and may cause internal engine damage.
Remove all of the gasket material from the component using a plastic or a wood scraper.
Use Loctite brand gasket remover P/N 4MA or the equivalent. Follow all of the safety
recommendations and the directions that are on the container.
Apply a continuous bead of the gasket eliminator to 1 flange. Clean and dry any surfaces
that you will reseal.
IMPORTANT: Anaerobic sealed joints that are partially torqued and

allowed to cure more than 5 minutes may result in incorrect
shimming and sealing of the joint.
Do not allow the sealer to enter the blind threaded holes. The sealer may cause the
Spread the sealer evenly in order to get a uniform coating on the sealing surface.
Tighten the bolts to the specifications.
Remove the excess sealer from the outside of the joint.
TOOLS AND EQUIPMENT
Work in a clean and well-lit area. Have the following components available before you begin to
work:
A suitable parts cleaning tank

A compressed air supply
Trays, in order to keep the parts and the fasteners organized
An adequate set of hand tools
An approved engine repair stand will prevent personal injury or damage to the engine
components. The special tools are designed in order to quickly and safely accomplish the
operations for which the tools are intended. Using the tools will minimize possible damage to the
engine components. Precision measuring tools are required for the inspection of certain critical
components. Torque wrenches are needed for the correct assembly of various parts.

SPECIAL TOOLS
Special Tools
J 5239
Connecting Rod Bolt Guide
J 7872
Magnetic Base Dial Indicator Set
J 8001
Dial Indicator Set
J 8037
Piston Ring Compressor
J 8087
Cylinder Bore Gage
J 8089
Carbon Removing Brush
J 8520
Camshaft Lobe Lift Indicator Set
J 9666
Valve Spring Tester
J 21882
Oil Suction Pipe Installer
J 22144
Oil Suction Pipe Installer
J 22794
Spark Plug Port Adapter
J 24086-C
Piston Pin Remover and Installer Set
J 24270
Ridge Reamer
J 24420-C
Harmonic Balancer Puller
J 25087-C
Oil Pressure Tester and Pump Primer
J 28428-E
High Intensity Black Light Kit
J 28467-B
Universal Engine Support Fixture
J 28467-6A
Bracket Assembly
J 28467-7A
Bolt Hook
J 28467-34
Lift Hook Wing Nut Washer
J 28467-500
Engine Support Fixture
J 29113
Crankshaft Balancer Installer
J 33049
Camshaft Bearing Remover/Installer
J 34686
Rear Main Seal Installer
J 35468
Crankshaft Front Oil Seal Installer
J 35667-A
Cylinder Head Leakdown Tester
J 38606
Valve Spring Compressor
J 39505
Torque Wrench Adapter
J 41131
Engine Tilt Strap
J 45057
Engine Support Bar Assembly
J 45057-2
Lower Engine Support Bar
J 45059
Angle Meter
J 45299
Engine Preluber
On-Vehicle Adjustments - Trucks - Except Tracker
ENGINE MECHANICAL
Before performing any on-vehicle adjustments to fuel or ignition systems, ensure engine mechanical condition
is okay.
VALVE CLEARANCE
NOTE: All engines are equipped with hydraulic lifters, except for 6.6L diesel engine.
Adjustments are not required. The 6.6L diesel engine is equipped with
mechanical roller lifters. Adjustment is not required as routine service.
Adjustment is only performed after disassembly of engine components. See
6.6L V8 DIESEL in ENGINES.
IGNITION TIMING (GASOLINE)
NOTE: On all models, ignition timing is controlled by control module and is not
adjustable.
INJECTION PUMP TIMING (DIESEL)
NOTE: Injection pump timing is not adjustable on 6.6L diesel engine.
IDLE SPEED & MIXTURE

GASOLINE ENGINES
NOTE: DO NOT attempt to adjust idle mixture and idle speed. Both are controlled by
Powertrain Control Module (PCM). Incorrect idle speeds are normally caused by
dirty throttle plate or vacuum leaks. Ensure all vacuum components are
functioning properly.
DIESEL ENGINES
NOTE: Diesel engines are equipped with electronic fuel injection in which PCM
controls all fuel delivery modes based on inputs from APP, ECT and BARO
sensors. Idle speed is not adjustable.

GASOLINE ENGINES (EXCEPT 8.1L)
NOTE: Throttle position sensors are not adjustable.
DIESEL ENGINES & 8.1L GASOLINE ENGINE
Throttle control is electronic with no mechanical link from engine to accelerator pedal. PCM monitors position
of accelerator pedal based on signals from a non-adjustable Accelerator Pedal Position (APP) module. APP
module is mounted near accelerator pedal.
Basic Diagnostic Procedures - 3.4L Aztek & Rendezvous
INTRODUCTION
Before proceeding with basic diagnostic procedures, ensure testing procedure is followed, as some systems
which may result in a no-start condition may cause a Diagnostic Trouble Codes (DTC) to be stored in the
Powertrain Control Module (PCM). See DIAGNOSTIC STARTING POINT - ENGINE CONTROLS under
SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article.
If no-start condition still exists after checking and repairing all DTCs, perform a careful and complete visual
inspection. Many problems result from mechanical breakdowns, poor electrical connections or
damaged/misrouted vacuum hoses. See VISUAL INSPECTION under PRELIMINARY INSPECTION &
ADJUSTMENTS. Before condemning the computerized system, perform each test listed in this article.
NOTE: Perform all voltage tests with a Digital Volt-Ohmmeter (DVOM) with a minimum
10-megohm input impedance, unless stated otherwise in test procedure.
PRELIMINARY INSPECTION & ADJUSTMENTS

VISUAL INSPECTION
Visually inspect all electrical wiring. Look for chafed, stretched, cut or pinched wiring. Ensure electrical
connectors fit tightly and are not corroded. Ensure vacuum hoses are properly routed and not pinched or cut. If
necessary, see VACUUM DIAGRAMS - AZTEK & RENDEZVOUS article to verify routing and
connections. Inspect air induction system for possible vacuum leaks.
MECHANICAL INSPECTION
Cylinder Compression Pressure
Check engine mechanical condition with compression gauge, vacuum gauge, or engine analyzer. See engine
analyzer manual for specific instructions. For compression specifications, see ENGINE COMPRESSION
SPECIFICATIONS table. Install and tighten spark plugs to 11 ft. lbs (15 N.m).
ENGINE COMPRESSION SPECIFICATIONS

Application Specification - psi (kPa)
Normal Compression Pressure (1)
Minimum Compression Pressure (1)
Compression Variance (2)
(1) Lowest compression reading should not be less than 70 percent of highest compression reading. No
cylinder compression reading should be less than 100 psi (689.5 kPa).
(2) Information is not available from manufacturer.
Cylinder Combustion Pressure Leakage
1. Disconnect negative battery cable. Remove spark plugs. Install Cylinder Head Leakdown Tester (J-
35667-A). Measure each cylinder on the compression stroke, with both valves closed.
NOTE: Hold crankshaft balancer bolt in order to prevent piston movement.
2. Apply air pressure to cylinder leakdown tester. Record the cylinder leakage readings for each cylinder.
Normal cylinder leakage is from 12 to 18 percent. Make note of any cylinder with more leakage than the
other cylinders. Any cylinder with 30 percent leakage or more requires service.
3. Inspect the following primary areas in order to properly diagnose a leaking cylinder.
If air is heard from the intake or exhaust system, remove valve rocker arm cover of the suspect
cylinder head. Ensure that both valves are closed. Inspect cylinder head for a broken valve spring or
remove and inspect suspect cylinder head.
If air is heard from the crankcase system at the crankcase oil filler tube, remove piston from suspect
cylinder. Inspect piston and connecting rod assembly. Inspect engine block.
If bubbles are observed in the radiator, remove and inspect both cylinder heads. Inspect engine
block.
4. After performing test, remove leakdown tester. Install spark plugs and reconnect negative battery cable.
Exhaust System Backpressure
Before replacing any components, check exhaust system for restrictions. Use vacuum gauge or low-pressure (0-
5 psi) gauge to check exhaust system.
If vacuum gauge is used, connect vacuum gauge hose to intake manifold vacuum port and start engine. Observe
vacuum gauge. Partially open throttle and hold steady. If vacuum gauge reading slowly drops after stabilizing,
exhaust system should be checked for restriction. If using low pressure gauge, connect gauge in the following
manner:
Check At Oxygen Sensor - Remove oxygen sensor. Install backpressure tester in place of oxygen sensor.
After test is completed, coat oxygen sensor threads with anti-seize compound before installation.
Diagnosis
1. Start engine and allow it to reach normal operating temperature. Increase engine speed to 2000-2500
RPM and note gauge. If reading exceeds 1.25 psi (.09 kg/cm2 ), exhaust system is restricted.
2. Check exhaust system for collapsed pipe, heat distress and possible internal muffler failure. If none of
these conditions exist, check for restricted catalytic converter. Replace as necessary.
NO-START DIAGNOSIS
NOTE: For terminal and circuit identification, see WIRING DIAGRAMS

Definition - No-start is defined as engine cranks properly, but does not start. Engine may fire a few times.
NO-START - ENGINE CRANKS OKAY
Preliminary Checks
Before performing the following tests, check battery condition, engine cranking speed and for adequate fuel in
tank. Perform diagnostic system check following any repairs. See DIAGNOSTIC SYSTEM CHECK -
ENGINE CONTROLS under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - 3.4L AZTEK &
RENDEZVOUS article.
Test Description
The numbers below refer to the step numbers in the diagnostic procedure.
3 - This step determines if ignition relay is providing listed fuses with voltage.
5 - This step determines if the fuel pump is operating electrically.
6 - If all the Cylinder Injector Circuit Status parameters display FAULT, this indicates a condition with
the injector supply voltage circuit.
Diagnostic Procedures
1. Perform diagnostic system check. See DIAGNOSTIC SYSTEM CHECK -- ENGINE CONTROLS
under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS
article. After performing diagnostic system check, go to next step.
2. Turn ignition on, with engine off. Using scan tool, check for DTCs. If DTCs P0101, P0230, P0336,
P0601, P0602, P1626, P1630 or P1631 are set, diagnose DTCs. See DIAGNOSTIC TROUBLE CODE
DEFINITIONS in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article. If DTC(s) are not
set, go to next step.
3. Using a test light, probe both sides of the following fuses: ELEC, ENG and Fuel INJ fuses. Does test light
illuminate on at least one side of the fuses listed? If yes, go to next step. If no, diagnose or replace
ignition relay.
4. Turn ignition off. Disconnect a spark plug wire. Install a Spark Tester (J 26792) to spark plug wire.
Attempt to start engine. Is spark present at spark tester? If yes, go to next step. If no, diagnose electronic
ignition system. See IGNITION SYSTEMS .
5. Using scan tool, command fuel pump ON. Does the fuel pump turn on? If yes, go to next step. If no,
diagnose fuel pump electrical circuit. See FUEL SYSTEMS .
6. While monitoring the cylinder 1-6 injector circuit status parameters with scan tool, crank engine. Do all
of the Cylinder Injector Circuit Status parameters display OK while cranking the engine? If yes, go to
next step. If no, diagnose fuel injector. See FUEL INJECTOR COIL TEST under FUEL SYSTEMS in
SYSTEM & COMPONENT TESTING - 3.4L AZTEK & RENDEZVOUS article.
7. Turn ignition off. Reinstall all disconnected components. Install Fuel Pressure Gauge (J 34730-1A). Turn
ignition on, with engine off. Using scan tool, command fuel pump on. Is fuel pressure within 52-59 psi
(358-405 kPa)? If yes, go to next step. If no, perform fuel system diagnosis. See FUEL SYSTEMS .
8. Check for collapsed air intake duct, restricted air filter element, fouled spark plugs, engine mechanical
condition or restricted exhaust system. Check ECT sensor value (ECT sensor is NOT close to actual
engine temperature), compare MAP/BARO parameters to another vehicle (parameters should be close in
value) or check TP sensor for being stuck in range. Did you find and correct the condition? If yes, go to
next step. If no, problem is intermittent.
9. Using scan tool, clear any DTCs that are set. Attempt to start engine. Does engine start and continue to
operate? If yes, go to next step. If engine does not start, go to step 2 .
10. Allow engine to reach operating temperature. Observe DTC information on scan tool. Does the scan tool
display any DTCs that you have not diagnosed? If yes, diagnose affected DTC. See DIAGNOSTIC
TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS
article. If no, system is okay.
FUEL SYSTEMS
FUEL SYSTEM PRESSURE RELEASE
WARNING: Remove fuel tank cap and release fuel system pressure before servicing
any fuel injection-related components. After releasing fuel system
pressure, a small amount of fuel may be released when servicing fuel
lines, fuel pump or fuel connections. Cover the fuel system components
with a shop towel before disconnection. DO NOT allow fuel to contact
engine or electrical components.
CAUTION: Fuel system is under pressure. Pressure must be released prior to

servicing fuel system.
Loosen retaining bolt on intake manifold sight shield at top of engine. Remove intake manifold sight shield
from top of engine. Disconnect negative battery cable. Loosen fuel filler cap. Install Fuel Pressure Gauge
Fitting Adapter (J-34730-262) to fuel pressure test port connection. Install Fuel Pressure Gauge (J-34730-1A) to
fuel pressure gauge fitting adapter on fuel rail. Wrap a shop towel around pressure connection when installing
fuel pressure gauge to absorb fuel leakage. Place gauge bleed hose into an approved gasoline container. Open
bleed valve to release fuel pressure.
FUEL SYSTEM PRESSURE TEST
System Description
PCM turns on the in-tank fuel pump when ignition is on. The fuel pump will remain on as long as engine is
cranking or running and PCM is receiving ignition reference pulses. If there are no ignition reference pulses,
PCM will turn the fuel pump off 2 seconds after ignition is turned on or 2 seconds after engine stops running.
The fuel pump is attached to fuel sender assembly and is designed to provide fuel at a pressure above the
pressure needed by the fuel injectors. A fuel pressure regulator, attached to fuel rail, keeps fuel available to fuel
injectors at a regulated pressure. Unused fuel is returned to fuel tank by a separate fuel return pipe.
Test Description
The numbers below refer to step numbers in the diagnostic procedure.
2 - This step verifies that the fuel pump is operating.

4 - This step tests for an internal fuel leak. If the fuel pressure drops during this test, then an internal loss
of pressure is indicated.
6 - This step tests the fuel pressure regulator. The fuel pressure regulator is controlled by engine vacuum.
With engine vacuum applied, pressure should drop the specified value.
9 - This step inspects the fuel pressure regulator for a fuel leak from the vacuum port. If fuel leaks from
the fuel pressure regulator while fuel pump is commanded ON, replace fuel pressure regulator.
10 - This step tests for a loss of fuel pressure between the fuel feed pipe shut off adapter and fuel pump.
11 - This step tests for a leaking fuel injector or fuel pressure regulator. If fuel pressure remains constant
during this test, fuel injectors are not leaking fuel.
14 - This step tests for a restricted fuel return pipe. If fuel pressure is within the specified values, a
restriction in the fuel return pipe is indicated.
16 - This step determines if fuel pressure regulator or fuel pump is the cause of the low fuel pressure. If
pressure rises above the specified value, fuel pump is okay.
18 - This step verifies that a circuit condition is not the cause of a fuel pressure concern. Inspect all fuel
pump electrical circuits thoroughly.
1. Perform diagnostic system check. See DIAGNOSTIC SYSTEM CHECK - ENGINE CONTROLS
2. Turn ignition on, with engine off. Using scan tool, command fuel pump on. Does the fuel pump operate?
If yes, go to next step. If no, diagnose fuel pump electrical circuit. See FUEL PUMP ELECTRICAL
CIRCUIT DIAGNOSIS under FUEL SYSTEMS in SYSTEM & COMPONENT TESTING - 3.4L
3. Turn ignition off. Turn off all accessories. Install Fuel Pressure Gauge (J-34730-1A) and Fuel Pressure
Gauge Fitting Adapter (J-34730-262). Turn ignition on, with engine off. Using scan tool, command fuel
pump (fuel pump runs for about 2 seconds) in order to obtain the highest possible fuel pressure. DO NOT
start engine. Observe fuel pressure gauge with fuel pump commanded on. Is fuel pressure within 52-59
psi (358-405 kPa)? If yes, go to next step. If no, go to step 12 .
4. Monitor fuel pressure gauge for one minute. Does the fuel pressure drop more than 5 psi (34 kPa)? If yes,
go to step 9 . If no, go to next step.
5. Relieve fuel pressure to 10 psi (69 kPa). Monitor fuel pressure gauge for 5 minutes. Does fuel pressure
drop more than 2 psi (14 kPa)? If yes, go to step 24 . If no, go to next step.
6. Turn ignition off for 15 seconds. Turn ignition on, with engine off. Monitor fuel pressure gauge. Start
engine. Does fuel pressure drop by 3-10 psi (21-69 kPa) when engine is started? If yes, go to next step. If
no, go to step 8 .
7. Operate the vehicle within the conditions of the customers concern. Monitor fuel related parameters with
a scan tool. Do any of the scan tool parameters indicate a lean condition? If yes, go to step 17 . If no, see
DIAGNOSTIC SYSTEM CHECK - ENGINE CONTROLS under SELF-DIAGNOSTICS - 3.4L
8. Disconnect vacuum hose from fuel pressure regulator. Monitor fuel pressure gauge. Operate engine at
idle. Using a hand-held vacuum pump, apply 12-14 in. Hg (34-47 kPa) to fuel pressure regulator. Does
fuel pressure drop to 3-10 psi (21-69 kPa) when vacuum is applied? If yes, go to step 21 . If no, go to step
23 .
9. Turn ignition off. Remove vacuum hose from fuel pressure regulator. Turn ignition on, with engine off.
Using scan tool, command fuel pump on. Inspect for fuel leak from fuel pressure regulator vacuum port.
Is fuel pressure regulator leaking fuel? If yes, go to step 23 . If no, go to next step.
10. Turn ignition off. Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect fuel
feed hose and fuel return hose from fuel rail pipes. Install a Fuel Line Shut-Off Adapters (J-37287)
between fuel hoses and the fuel rail pipes. Open valves on fuel pipe shut-off adapters. Turn ignition on,
with engine off. Command fuel pump on using scan tool. Obtain highest possible fuel pressure. Bleed air
from fuel pressure gauge. Close fuel feed pipe shut-off valve. Monitor fuel pressure gauge for one
minute. Does fuel pressure remain constant? If yes, go to step 19 . If no, go to next step.
11. Turn ignition off. Open fuel feed pipe shut-off valve. Turn ignition on, with engine off. Command fuel
pump ON and then OFF with scan tool. Close fuel return pipe shut-off valve. Monitor fuel pressure gauge
for one minute. Does the fuel pressure remain constant? If yes, go to step 23 . If no, go to step 20 .
12. Is fuel pressure greater than 59 psi (427 kPa)? If yes, go to step 14 . If no, go to next step.
13. Is fuel pressure greater than zero psi? If yes, go to step 16 . If no, go to step 17 .
14. Turn ignition off. Relieve fuel pressure. Disconnect fuel return hose from fuel rail return pipe. Attach a
length of flexible fuel hose to fuel rail outlet passage. Place open end of the flexible fuel hose into an
approved gasoline container. Turn ignition on, with engine off. Using scan tool, monitor fuel pressure
gauge while fuel pump is operating. Is fuel pressure within 52-59 psi (358-405 kPa)? If yes, go to step
22 . If no, go to next step.
15. Inspect the fuel rail return pipe and fuel rail outlet passage for a restriction. Did you find and correct the
condition? If yes, go to step 25 . If no, go to step 23 .
16. Turn ignition off. Relieve fuel pressure. Disconnect fuel return hose from fuel rail return pipe. Install a
Fuel Line Shut-Off Adapters (J-37287) between fuel return pipe and fuel rail. Open valve in the fuel pipe
shut-off adapter. Turn ignition on, with engine off. Bleed air from fuel system. Monitor fuel pressure
gauge. DO NOT allow fuel pressure to exceed 75 psi (517 kPa). Excessive pressure may damage fuel
system. Slowly close valve in fuel return pipe shut-off adapter. Command fuel pump on with scan tool.
Does the fuel pressure rise to greater than 52 psi (358 kPa)? If yes, go to step 23 . If no, go to next step.
17. Inspect fuel filter and fuel feed pipe for restriction. Did you find and correct the condition? If yes, go to
step 25 . If no, go to next step.
18. Inspect the harness connectors and ground circuits of the fuel pump for poor connections. Did you find
and correct the condition? If yes, go to step 25 . If no, go to next step.
19. Remove the fuel sender assembly. Inspect fuel pump flex hose for damage, fuel pump harness connectors
for poor connections, fuel strainer for a restriction or contaminates in fuel tank Did you find and correct
the condition? If yes, go to step 25 . If no, go to step 24 .
20. Turn ignition off. Raise fuel rail with fuel lines connected. Turn ignition on, with engine off. Command
fuel pump on with scan tool. Locate and replace the leaking fuel injector. After repairs, go to step 25 .
21. Repair vacuum source to fuel pressure regulator. After repairs, go to step 25 .
22. Locate and repair restricted fuel return line. After repairs, go to step 25 .
23. Replace fuel pressure regulator. After replacing fuel pressure regulator, go to step 25 .
24. Replace fuel pump. After replacing fuel pump, go to next step.
25. Operate the system in order to verify the repair. Did you correct the condition? If yes, system is okay. If
no, go to step 3 .
IGNITION SYSTEMS
NOTE: For additional ignition system and component diagnosis, see IGNITION
SYSTEMS in SYSTEM & COMPONENT TESTING - 3.4L AZTEK & RENDEZVOUS
article.
For testing procedures and specifications, perform appropriate diagnostic test. See DIAGNOSTIC TROUBLE
CODE DEFINITIONS in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article.
For testing procedures and specifications, perform appropriate diagnostic test. See DIAGNOSTIC TROUBLE
CODE DEFINITIONS in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article.
ELECTRONIC IGNITION SYSTEM

Fig. 1: Electronic Ignition Electrical Schematic
Circuit Description
The Ignition Control (IC) module has independent power and ground circuits. The circuits between the IC
module and the PCM consist of the IC timing signal, IC timing control, low resolution engine speed signal and
a low reference signal.
The IC module sends 3X signals to the PCM. The IC module controls the timing advance during engine
cranking. The timing advance changes to PCM control after the PCM receives the second 3X signal and after
the PCM applies 5 volts to the IC timing signal circuit.
Diagnostic Aids
An arcing spark plug wire or an arcing ignition coil to the IC module may cause a stall, misfire or a no-start
condition.
2. Attempt to start the engine. Does engine start and run? If yes, go to next step. If no, go to step 4 .
3. Disconnect the Crankshaft Position Sensor (CKP) sensor "B" connector from the Ignition Control Module
(ICM). ICM control module is located on top of rear valve cover. CKP sensor "B" is located on right side
of engine block. See Fig. 3 . Measure the resistance from the CKP sensor 1 signal circuit to the low
reference circuit of the CKP sensor "B" with a DVOM. See Fig. 1 . Is the resistance within 800-1200
ohms? If yes, go to next step. If no, go to step 28 .
4. Disconnect the CKP sensor "A". CKP sensor "A" is located on front of engine, near crankshaft pulley.
See Fig. 2 . Observe the 3X crank sensor parameter with a scan tool. Crank the engine. Does the scan tool
indicate a 3X crank sensor signal present? If yes, go to next step. If no, go to step 11 .
5. Reconnect the CKP sensor "A". Test for spark at each cylinder with a Spark Tester (J-26792). Did you
observe any non-sparking cylinders? If yes, go to next step. If no, go to step 9 .
6. Inspect and test the affected cylinder spark plug wires, ignition coils and spark plugs for a short to ground
or an arching to ground. If carbon tracking or corrosion is present, replace both components that are
affected. Did you find and correct the condition? If yes, go to step 32 . If no, go to next step.
7. Test the resistance of the spark plug wires. Is resistance more than 3000 ohms per foot? If yes, go to step
8. Measure the secondary resistance of the ignition coils. Is the resistance 5000-8000 ohms? If yes, go to
step 25 . If no, go to step 29 .
9. Inspect the spark plug wires for proper routing and for the correct firing order. If any spark plug wires are
found to be misrouted, reroute as necessary. Did you find and correct the condition? If yes, go to step 32 .
If no, go to next step.
10. Remove spark plugs. Inspect spark plugs. Did you find the problem? If yes, go to step 31 . If no, see
DIAGNOSTIC AIDS .
11. Connect the CKP sensor "A". Disconnect the IC module. Turn ignition on. Connect a test light between
the IC module ignition 1 voltage circuit and a good ground. See Fig. 1 . Does the test light illuminate? If
yes, go to next step. If no, go to step 24 .
12. Connect a test light between the IC module ignition 1 voltage circuit and the IC module ground circuit.
Does the test light illuminate? If yes, go to next step. If no, go to step 26 .
13. Test for an intermittent and for a poor connection at the ICM. Did you find and correct the condition? If
yes, go to step 32 . If no, go to next step.
14. Disconnect the CKP sensor "B" connector from the ICM. Probe the CKP sensor 1 signal circuit of the
CKP sensor "B" with a test light connected to battery voltage. Does the test light illuminate? If yes, go to
15. Probe the CKP sensor 1 signal circuit of the CKP sensor "B" with a test light connected to a good ground.
Does the test light illuminate? If yes, go to step 18 . If no, go to next step.
16. Ensure the battery voltage is within specifications. Measure the voltage from the CKP sensor 1 signal
circuit and the low reference circuit of the CKP sensor "B" with DVOM at the ICM harness connector.
Crank the engine while observing the AC scale. Is the voltage greater than 200 mV? If yes, go to step 27 .
If no, go to step 19 .
17. Test the CKP sensor 1 signal circuit for a short to ground. Did you find and correct the condition? If yes,
go to step 32 . If no, go to step 20 .
18. Test the CKP sensor 1 signal circuit for a short to ground. Did you find and correct the condition? If yes,
go to step 32 . If no, go to step 20 .
19. Test the CKP sensor "B" circuits for an open or CKP sensor 1 signal and low reference circuit shorted
together. Did you find and correct the condition? If yes, go to step 32 . If no, go to next step.
20. Test for an intermittent and for a poor connection at the ICM. Did you find and correct the condition? If
yes, go to step 32 . If no, go to next step.
21. Test for an intermittent and for a poor connection at the CKP sensor. Did you find and correct the
condition? If yes, go to step 32 . If no, go to next step.
22. Remove CKP sensor. Visually inspect the CKP sensor for physical damage, excessive play or looseness,
improper installation, foreign material passing between the CKP sensor and reluctor wheel or wiring
routed too closely to secondary ignition components. Did you find and correct the condition? If yes, go to
23. Visually inspect the reluctor wheel for foreign material passing between the CKP sensor and reluctor
wheel, physical damage, excessive end play or looseness, improper installation, or excessive air gap
between CKP sensor and reluctor wheel. Did you find and correct the condition? If yes, go to step 32 . If
no, go to step 28 .
24. Repair the open or the short to ground in the IC module ignition 1 voltage circuit. Replace fuse, if
necessary. After repairs, go to step 32 .
25. Remove the coils associated with the cylinder that did not have spark. Connect a test light across the
ignition module primary circuit, between the ICM terminals for the coils. Observe the test light while
cranking the engine. Does the test light flash continuously while the engine is being cranked? If yes, go to
26. Repair open in the IC module ground circuit. After repairs, go to step 32 .
27. Replace IC module. After replacing module, go to step 32 .
28. Replace CKP sensor "B". After replacing sensor, go to step 32 .
29. Replace affected ignition coil(s). After replacing ignition coil(s), go to step 32 .
30. Replace spark plug wires. After replacing spark plug wires, go to step 32 .
31. Replace spark plugs. After replacing spark plugs, go to next step.
32. Turn ignition off for 30 seconds. Start engine and operate vehicle. Observe the MIL, vehicle performance
and driveability. Does the vehicle operate normally, with no MIL? If yes, system is okay. If no, go to step
2.
IGNITION RELAY
See IGNITION RELAY under MODULES, MOTORS, RELAYS & SOLENOIDS in SYSTEM &
COMPONENT TESTING - 3.4L AZTEK & RENDEZVOUS article.
IDLE SPEED & IGNITION TIMING

Idle speed and ignition timing are controlled by PCM. Incorrect idle speed are normally caused by dirty throttle
plate or vacuum leaks. Ensure all vacuum components are functioning properly.
WIRING DIAGRAMS
AZTEK
For wiring diagrams, see ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article in
ELECTRICAL.
RENDEZVOUS
ELECTRICAL.
System & Component Testing - 3.4L Aztek & Rendezvous
INTRODUCTION
Before testing separate components or systems, follow proper workflow. See DIAGNOSTIC STARTING
POINT - ENGINE CONTROLS under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - 3.4L
AZTEK & RENDEZVOUS article. If no Diagnostic Trouble Codes (DTC) are present and a no-start condition
exists, proceed to NO-START DIAGNOSIS in BASIC DIAGNOSTIC PROCEDURES - 3.4L AZTEK &
RENDEZVOUS article. If no DTCs are present and a driveability condition exists, proceed to SYMPTOMS in
TROUBLE SHOOTING - NO CODES - 3.4L AZTEK & RENDEZVOUS article for diagnosis by symptom
(i.e., ROUGH IDLE, ENGINE STALLS, etc.).
NOTE: Testing individual components does not isolate shorts or opens. Perform all
voltage tests with a Digital Volt-Ohmmeter (DVOM) with a minimum 10-megohm
input impedance, unless stated otherwise in test procedure. Use ohmmeter to
isolate wiring harness shorts or opens.
COMPONENT LOCATIONS
NOTE: For component locations, refer to COMPONENT LOCATIONS table or

illustrations. See Fig. 1 -Fig. 11 .
COMPONENT LOCATIONS
Component Location
Body Control Module Inside Center Console, Above Fuse Block
Camshaft Position Sensor Right Side Of Engine, Above A/C Compressor Clutch
Crankshaft Position Sensor (7x) Lower Rear Of Engine
Crankshaft Position Sensor (24x) Right Front Side Of Engine, Behind Harmonic Balancer
Data Link Connector Below Steering Column, Bottom Of Knee Bolster
Engine Coolant Temperature Sensor Top Left Of Engine
Engine Oil Level Switch Right Side Of Engine Oil Pan
Engine Oil Pressure Indicator Switch Front Of Engine, Above Starter
EVAP Canister Purge Solenoid Top Rear Of Engine, Between EGR Valve & Throttle
Body Assembly
EVAP Canister Vent Solenoid Below Center Of Vehicle, Near Fuel Tank
Exhaust Gas Recirculation Valve Top Left Side Of Engine, Left Of Manifold
Fuel Injectors Top Of Engine, At Each Cylinder Intake Port
Fuel Pump Relay In Underhood Fuse Block
Fuel Tank Pressure Sensor Inside Fuel Tank
Heated Oxygen Sensor No. 1 Rear Of Engine, In Exhaust Manifold
Heated Oxygen Sensor No. 2 In Exhaust System, Rear Of Catalytic Converter
Idle Air Control Valve Top Of Engine, Top Of Throttle Body
Ignition Control Module Top Center Rear Of Engine
Intake Air Temperature Sensor Left Side Of Engine Compartment, On Air Intake Duct,
Near Throttle Body
Knock Sensor Front Of Engine, Above Starter
Manifold Absolute Pressure Sensor Right Top Of Engine
Mass Airflow Sensor In Air Cleaner Duct, Left Front Side Of Engine
Compartment
Powertrain Control Module Engine Compartment, Secured In Air Cleaner Assembly
Secondary AIR Injection Pump Front Of Vehicle, Behind Left Fog Light, Below Horn
Secondary AIR Injection Solenoid Lower Rear Of Engine
Throttle Position Sensor Top Of Engine, On Rear Side Of Throttle Assembly
Vehicle Speed Sensor Lower Right Rear Of Engine Compartment, Mounted To
Right Side Of Transaxle
Fig. 1: Locating Camshaft Position Sensor
Fig. 4: Locating Engine Coolant Temperature Sensor
Fig. 5: Locating EVAP Canister, EVAP Vent Solenoid & Fuel Tank Pressure Sensor
Fig. 6: Locating EVAP Purge Solenoid
Fig. 7: Locating Idle Air Control Valve & TP Sensor
Fig. 8: Locating Intake Air Temperature & Mass Airflow Sensors
Fig. 9: Locating Knock Sensor
Fig. 10: Locating MAP Sensor
Fig. 11: Locating Secondary Air Injection Pump
COMPUTERIZED ENGINE CONTROLS
NOTE: For component locations, see COMPONENT LOCATIONS .
NOTE: To identify circuits referenced in the following ground and power tests, see
WIRING DIAGRAMS or Fig. 12 -Fig. 17 .
Ground Circuits
Check PCM connectors for corroded or loose connections. Repair as necessary. Disconnect PCM connectors.
Using DVOM, measure resistance between negative battery terminal and ground terminals at PCM harness
connector. If resistance is more than 5 ohms, repair open in affected ground circuit. If resistance is 5 ohms or
less, ground circuits are okay.
Power Circuits
1. Check PCM connectors for corroded or loose connections. Repair as necessary. Disconnect PCM
connectors. Using DVOM, check for battery voltage between chassis ground and continuous power
terminal(s) at PCM harness connector(s). See WIRING DIAGRAMS . If battery voltage is present, go to
next step. If battery voltage is not present, check for open fuse or fusible link. If fuse or fusible link is
okay, check for open in wire between PCM terminal and power source.
2. Turn ignition switch to RUN position. Using DVOM, check for battery voltage between chassis ground
and ignition power terminals at PCM harness connector(s). If battery voltage is present, power circuits are
okay. If battery voltage is not present, check IGN fuse. If fuse is okay, check for an open in wire between
battery and ignition switch, and between ignition switch and PCM terminal. If wiring is okay, check for a
defective ignition switch.
PCM Harness Resistance
Turn ignition switch to LOCK position. Disconnect PCM and appropriate component harness connectors.
Check for open or short circuits between appropriate PCM harness connector terminal and appropriate
component harness connector terminal. See WIRING DIAGRAMS . If harness is open or shorted, repair as
necessary.
Fig. 12: Identifying PCM Connector C1 Terminals (1 Of 3)

SENSORS & SWITCHES

NOTE: For additional sensor testing specifications, see SENSOR OPERATING RANGE
CHARTS - TRUCKS article.
Manufacturer does not provide testing procedures for many individual systems and components. For sensor and
switch testing not listed, perform related DTC testing procedure. See DIAGNOSTIC TROUBLE CODE
DEFINITIONS in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article.
BAROMETRIC PRESSURE SENSOR
A malfunction in Barometric Pressure (BARO) sensor can set a DTC. For testing procedures and specifications,
perform appropriate diagnostic test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-
A malfunction in Camshaft Position (CMP) sensor can set a DTC. For testing procedures and specifications,
A malfunction in Crankshaft Position (CKP) sensor can set a DTC. For testing procedures and specifications,
ENGINE COOLANT TEMPERATURE SENSOR
A malfunction in Engine Coolant Temperature (ECT) sensor circuit can set a DTC. For testing procedures and
specifications, perform appropriate diagnostic test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in
SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article. An out-of-calibration ECT sensor may not
set a DTC. Use the following procedure to test sensor calibration.
Disconnect ECT sensor harness connector. See COMPONENT LOCATIONS . Using DVOM, measure
resistance of ECT sensor at specified temperatures. See SENSOR TEMPERATURE VS RESISTANCE
table. Resistance should be high when engine is cold and drop as engine warms. With vehicle sitting overnight,
IAT sensor and ECT sensor should have close to the same resistance reading. If resistance is not within
specification, replace ECT sensor.
SENSOR TEMPERATURE VS RESISTANCE

Temperature - F (C) (1) Ohms
302 (150) 47
284 (140) 60
266 (130) 77
248 (120) 100
230 (110) 132
212 (100) 177
194 (90) 241
176 (80) 332
158 (70) 467
140 (60) 667
122 (50) 973
113 (45) 1188
104 (40) 1459
95 (35) 1802
86 (30) 2238
77 (25) 2796
68 (20) 3520
59 (15) 4450
50 (10) 5670
41 (5) 7280
32 (0) 9420
23 (-5) 12,300
14 (-10) 16,180
5 (-15) 21,450
-4 (-20) 28,680
-22 (-30) 52,700
-40 (-40) 100,700
(1) Measure resistance across sensor terminals.
FUEL LEVEL SENSOR
A malfunction in fuel level sensor circuit can set a DTC. For testing procedures and specifications, perform
appropriate diagnostic test. See DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS
- 3.4L AZTEK & RENDEZVOUS article.
A Fuel Tank Pressure (FTP) sensor circuit can set a DTC. For testing procedures and specifications, perform
HEATED OXYGEN SENSOR
A malfunction in Heated Oxygen Sensor (HO2S) circuit can set a DTC. For testing procedures and
SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article.
INTAKE AIR TEMPERATURE SENSOR
A malfunction in IAT sensor circuit can set a DTC. For testing procedures and specifications, perform
- 3.4L AZTEK & RENDEZVOUS article. An out-of-calibration IAT sensor may not set a DTC. Use the
following procedure to test sensor calibration.
Disconnect IAT sensor harness connector. See COMPONENT LOCATIONS . Using DVOM, measure
resistance of IAT sensor at specified temperatures. See SENSOR TEMPERATURE VS RESISTANCE table.
Resistance should be high when air temperature is cold and drop as air temperature warms. With vehicle sitting
overnight, ECT sensor and IAT sensor should have close to the same resistance reading. If resistance is not
within specification, replace IAT sensor.
KNOCK SENSOR
A malfunction in Knock Sensor (KS) circuit can set a DTC. For testing procedures and specifications, perform
MANIFOLD ABSOLUTE PRESSURE SENSOR
A malfunction in Manifold Absolute Pressure (MAP) sensor circuit can set a DTC. For testing procedures and
SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article.
MASS AIRFLOW SENSOR
A malfunction in Mass Airflow (MAF) sensor circuit can set a DTC. For testing procedures and specifications,
NOTE: Throttle Position (TP) sensor is not adjustable. Replace TP sensor as

necessary.
A malfunction in TP sensor circuit can set a DTC. For testing procedures and specifications, perform
TRANSMISSION RANGE SWITCH
See appropriate DIAGNOSIS article in AUTOMATIC TRANSMISSIONS.

VEHICLE SPEED SENSOR
MODULES, MOTORS, RELAYS & SOLENOIDS
NOTE: Manufacturer does not provide testing procedures for many individual systems
and components. For module, motor, relay and solenoid testing not listed,
perform related DTC testing procedure. See DIAGNOSTIC TROUBLE CODE
A/C COMPRESSOR CLUTCH RELAY
See appropriate AUTOMATIC A/C-HEATER SYSTEMS or MANUAL A/C-HEATER SYSTEMS article in

AIR CONDITIONING & HEATING.
FUEL PUMP RELAY
See FUEL PUMP ELECTRICAL CIRCUIT DIAGNOSIS under FUEL SYSTEMS.
See IDLE AIR CONTROL SYSTEM DIAGNOSIS under IDLE CONTROL SYSTEM.
IGNITION RELAY
Circuit Description
The ignition relay is normally an open relay. The relay armature is held in the open position by spring tension.
When the ignition switch is turned to the RUN or START position, current will flow through the relay coil. A
wire connected to the other end of the relay coil completes the path to ground. The electromagnetic field created
by the relay coil overcomes the spring tension and moves the armature, allowing the relay contacts to close.
The closed relay contacts allow current to flow from the battery to the ENG CONTROLS fuse, Fuel INJ fuse,
ELEC ENG fuse, O2 Sensors fuse, TRANS SOL fuse, ABS fuse and AWD fuse. Fuses are located in
underhood fuse/relay block. See Fig. 18 .
When the ignition switch is turned off, the electromagnetic field collapses. This action allows the spring tension
to move the armature away from the relay contacts, which interrupts current flow to the fuses.
If ignition relay fails to close, the engine will crank but will not run. The class 2 communications will be
available with the use of a scan tool.
Fig. 18: Identifying Underhood Fuse/Relay Block
1. Perform diagnostic system check. See DIAGNOSTIC SYSTEM CHECK - ENGINE CONTROLS under
SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article.
After performing diagnostic system check, go to next step.
2. Turn ignition on, with engine off. Remove the underhood junction block cover. Probe the following fuses
with a test light that is connected to a good ground; ENG CONTROLS fuse, FUEL INJ fuse, ELEC ENG
fuse, O2 SENSORS fuse, TRANS SOL fuse, ABS fuse and AWD fuse. See Fig. 18 . Does the test light
illuminate on at least one test point of each fuse? If yes, go to next step. If no, go to step 11 .
3. Turn ignition off. Probe both test points of the FUEL INJ fuse with a test light that is connected to a good
ground. Does the test light illuminate on either test point of the fuse? If yes, go to next step. If no, go to
step 43 .
4. Turn ignition off. Remove ignition relay from the underhood junction block. Probe both test points of the
10-amp IGN 1 fuse in the underhood junction block with a test light connected to a good ground. Does
the test light illuminate on any of the fuse test points? If yes, go to step 7 . If no, go to next step.
5. Test the ignition relay load circuit bus bar of the underhood junction block between the ignition relay and
the fuses to the circuit components for a short to battery positive voltage. Did you find and correct the
condition? If yes, go to step 42 . If no, go to next step.
6. Turn ignition off. Remove the following fuses from the underhood junction block: ENG CONTROLS
fuse, FUEL INJ fuse, ELEC ENG fuse, O2 SENSORS fuse, TRANS SOL fuse, ABS fuse and AWD fuse.
Probe all these fuse terminals in the underhood junction block with a test light that is connected to a good
ground. Does the test light illuminate at any of the fuse terminals? If yes, diagnose engine electrical
system. If no, go to step 39 .
7. Turn ignition off. Disconnect the ignition switch electrical connector. Connect a 20-amp fused jumper
wire from the battery positive voltage wire terminal at the ignition switch harness connector to the battery
positive voltage terminal at the ignition switch. Probe the ignition 1 voltage terminal of the ignition
switch with a test light that is connected to a good ground. Does the test light illuminate? If yes, go to step
8. Turn ignition off. Disconnect negative battery cable at the battery. Disconnect the console junction block
electrical connector that contains the ignition 1 voltage circuit from the ignition switch. Connect the
negative battery cable to the battery. Probe the ignition 1 voltage circuit between the ignition switch and
the console junction block at the console junction block electrical connector with a test light that is
connected to a good ground. Does the test light illuminate? If yes, go to step 35 . If no, go to next step.
9. Turn ignition off. Disconnect negative battery cable at the battery. Disconnect the underhood junction
block electrical connector that contains the ignition 1 voltage circuit for the ignition relay. Connect the
negative battery cable to the battery. Probe the ignition 1 voltage circuit of the ignition relay at the
underhood junction block electrical connector with a test light that is connected to a good ground. Does
the test light illuminate? If yes, go to step 38 . If no, go to next step.
10. Test the ignition 1 voltage bus bar circuit for the ignition relay in the console junction block for a short to
battery positive voltage. Did you find a condition? If yes, go to step 41 . If no, go to step 42 .
11. Turn ignition off. Probe both test points of the 20-amp IGN 3 fuse in the underhood junction block with a
test light that is connected to a good ground. See Fig. 18 . Does the test light illuminate on both test
points of the fuse? If yes, go to step 19 . If no, go to next step.
12. Does the test light illuminate on one test point of the 20-amp IGN 3 fuse? If yes, go to next step. If no, go
to step 28 .
13. Test the battery positive voltage circuit between the underhood junction block and the ignition switch for
a short to ground. Did you find and correct the condition? If yes, go to step 43 . If no, go to next step.
14. Test the ignition 1 voltage circuit between the ignition switch and the console junction block for a short to
ground. Did you find and correct the condition? If yes, go to step 43 . If no, go to next step.
15. Test the ignition 1 voltage circuit between the console junction block and the underhood junction block
for a short to ground. Did you find and correct the condition? If yes, go to step 43 . If no, go to next step.
16. Test the ignition 1 voltage bus bar circuit of the console junction block between the ignition switch and
the underhood junction block for a short to ground. Did you find a condition? If yes, go to step 41 . If no,
go to next step.
17. Test the ignition 1 voltage bus bar circuit of the underhood junction block up to the 10-amp IGN 1 fuse
for a short to ground. Did you find a condition? If yes, go to step 42 . If no, go to next step.
18. Test the battery positive voltage bus bar circuit of the underhood junction block from the 20-amp IGN 3
fuse for a short to ground. Did you find a condition? If yes, go to step 42 . If no, go to step 40 .
19. Turn ignition on, with engine off. Probe both test points of the 10-amp IGN 1 fuse in the underhood
junction block with a test light that is connected to a good ground. Does the test light illuminate on both
test points of the fuse? If yes, go to step 29 . If no, go to next step.
20. Does the test light illuminate on one test point of the 10-amp IGN 1 fuse? If yes, go to step 27 . If no, go
to next step.
21. Turn ignition on, with engine off. Probe the ignition 1 voltage circuit at the ignition switch electrical
connector with a test light that is connected to a good ground. Does the test light illuminate? If yes, go to
22. Test the battery positive voltage circuit between the underhood junction block and the ignition switch for
a high resistance or an open. Did you find and correct a condition? If yes, go to step 43 . If no, go to next
step.
23. Turn ignition off. Probe the mounting stud for the battery positive terminal at the underhood junction
block with a test light that is connected to a good ground. Does the test light illuminate? If yes, go to step
40 . If no, diagnose engine electrical system.
24. Turn ignition on, with engine off. Probe the ignition 1 voltage circuit for the ignition relay at the console
junction block electrical connector that leads from the ignition switch with a test light that is connected to
a good ground. Does the test light illuminate? If yes, go to next step. If no, go to step 36 .
25. Turn ignition on, with engine off. Probe the ignition 1 voltage circuit for the ignition relay at the console
junction block electrical connector that leads to the underhood junction block with a test light that is
connected to a good ground. Does test light illuminate? If yes, go to next step. If no, go to step 41 .
26. Turn ignition off. Disconnect the negative battery cable at the battery. Disconnect the underhood junction
block electrical connector that contains the ignition 1 voltage circuit for the ignition relay. Connect the
negative battery cable at the battery. Turn ignition on, with engine off. Probe the ignition 1 voltage circuit
at the underhood junction block electrical connector with a test light that is connected to a good ground.
Does the test light illuminate? If yes, go to step 42 . If no, go to step 37 .
27. Test the ignition 1 voltage bus bar circuit of the underhood junction block between the 10-amp IGN 1
fuse and the ignition relay for a short to ground. Did you find a condition? If yes, go to step 42 . If no, go
to step 39 .
28. Turn ignition off. Probe the mounting stud for the battery positive cable at the underhood junction block
with a test light that is connected to a good ground. Does the test light illuminate? If yes, go to step 42 . If
no, diagnose engine electrical system.
29. Turn ignition off. Remove the ignition relay with the J 43244 from the underhood junction block. Probe
the battery positive voltage circuit of the ignition relay at the underhood junction block with a test light
that is connected to a good ground. Does the test light illuminate? If yes, go to next step. If no, go to step
42 .
30. Turn ignition on, with engine off. Probe the ignition 1 voltage circuit of the ignition relay at the
underhood junction block with a test light that is connected to a good ground. Does the test light
illuminate? Is yes, go to next step. If no, go to step 42 .
31. Turn ignition on, with engine off. Probe the coil ground circuit of the ignition relay at the underhood
junction block with a test light that is connected to battery voltage. Does the test light illuminate? If yes,
go to step 33 . If no, go to next step.
32. Turn ignition off. Disconnect the negative battery cable at the battery. Disconnect the underhood junction
block electrical connectors. Test the coil ground circuit wire of the ignition relay at the underhood
junction block electrical connector for a high resistance or an open. Did you find and correct the
33. Turn ignition off. Jumper the ignition relay battery positive voltage circuit and the ignition relay load
circuit together at the underhood junction block with a 20-amp fused jumper wire. Probe the following
fuses with a test light that is connected to a good ground: ENG CONTROLS fuse, FUEL INJ fuse, O2
SENSORS fuse, TRANS SOL fuse, ABS fuse and AWD fuse. Does the test light illuminate on at least
one test point of each fuse? If yes, go to next step. If no, go to step 42 .
34. Test for an intermittent and for a poor connection at the underhood junction block, ignition relay
connector location. Did you find a condition? If yes, go to step 42 . If no, go to step 39 .
35. Repair the short to battery positive voltage in the ignition 1 voltage circuit between the ignition switch
and the console junction block. After repairs, go to step 43 .
36. Repair the high resistance or an open in the ignition 1 voltage circuit between the console junction block
and the ignition switch. After repairs, go to step 43 .
37. Repair the high resistance or an open in the ignition 1 voltage circuit between the console junction block
and the underhood junction block. After repairs, go to step 43 .
38. Repair the short to battery positive voltage in the ignition 1 voltage circuit between the console junction
block and the underhood junction block electrical connector. After repairs, go to step 43 .
39. Replace ignition relay. After replacing relay, go to step 43 .
40. Replace ignition switch. After replacing ignition switch, go to step 43 .
41. Replace console junction block. After replacing junction block, go to step 43 .
42. Replace the underhood junction center. After replacing junction center, go to next step.
43. Replace any open fuses. Turn ignition off for 30 seconds. Attempt to start the engine. Does the engine
start and run? If yes, go to next step. If no, go to NO-START - ENGINE CRANKS OKAY under NO-
START in BASIC DIAGNOSTIC PROCEDURES - 3.4L AZTEK & RENDEZVOUS article.
44. Using scan tool, clear DTCs. Operate the vehicle for 5 minutes. Does a DTC set during this ignition
cycle? If yes, diagnose affected DTC(s). See DIAGNOSTIC TROUBLE CODE DEFINITIONS in
SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article. If no DTCs are set, system is okay.
TORQUE CONVERTER CLUTCH SOLENOID
FUEL SYSTEMS
FUEL INJECTOR BALANCE TEST WITH SPECIAL TOOL
Test Description
The numbers below refer to step numbers in diagnostic procedure.
3 - Engine Coolant Temperature (ECT) must be below operating temperature in order to avoid irregular
6 - If pressure drop value for each fuel injector is within 1.5 psi (10 kPa) of average pressure drop value,
fuel injectors are flowing properly. Calculate pressure drop value for each fuel injector by subtracting
second pressure reading from first pressure reading. See Fig. 19 .
Fig. 19: Injector Balance Test Example
1. Perform Diagnostic System Check - Engine Controls. See DIAGNOSTIC SYSTEM CHECK -
ENGINE CONTROLS under SELF-DIAGNOSTIC SYSTEM in SELF-DIAGNOSTICS - 3.4L AZTEK
& RENDEZVOUS article. After performing Diagnostic System Check - Engine Controls, go to next step.
2. Perform FUEL INJECTOR COIL TEST . After performing Fuel Injector Coil Test, go to next step.
NOTE: DO NOT perform this test if ECT is greater than 201F (94C).
3. Observe ECT parameter with scan tool. Does scan tool indicate ECT parameter is less than 201F (94
C)? If yes, go to next step. If no, allow engine to cool before proceeding.
NOTE: Verify there is adequate fuel in fuel tank before proceeding with this step.
Fuel pump may need to be commanded ON a few times, in order to obtain
highest possible fuel pressure reading. DO NOT allow engine to start.
4. Turn ignition off. Turn off all accessories. Install fuel pressure gauge. Turn ignition on, with engine off.
Command fuel pump ON with scan tool. Observe fuel pressure gauge, with fuel pump commanded ON.
Is fuel pressure within 52-59 psi (358-405 kPa)? If yes, go to next step. If no, go to FUEL SYSTEM
PRESSURE TEST under FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 3.4L AZTEK
& RENDEZVOUS article.
NOTE: Fuel pressure may vary slightly when fuel pump stops operating. After fuel
pump stops operating, fuel pressure should stabilize and remain constant.
5. Monitor fuel pressure gauge for one minute. Does fuel pressure decrease by more than 5 psi (34 kPa)? If
yes, go to FUEL SYSTEM PRESSURE TEST under FUEL SYSTEMS in BASIC DIAGNOSTIC
PROCEDURES - 3.4L AZTEK & RENDEZVOUS article. If no, go to next step.
NOTE: Fuel pressure may rise after fuel injector stops pulsing. Record fuel
pressure value immediately after fuel injector stops pulsing. DO NOT
record higher fuel pressure value.
6. Connect Fuel Injector Coil/Balance Tester (J-39021), Injector Test Adapter Box (J-39021-210), and Fuel
Injector Test Harness (J-39021-410) to fuel injector multi-way connector. Set amperage supply selector
switch on fuel injector tester to Balance Test .5-2.5-amp position. Command fuel pump ON and then OFF
with scan tool. Record fuel pressure indicated by fuel pressure gauge after fuel pressure stabilizes. This is
first pressure reading. Energize fuel injector by depressing "Push to Start Test" button on fuel injector
tester. Record fuel pressure indicated by fuel pressure gauge after fuel injector has stopped pulsing. This
is second pressure reading. Repeat this step for each fuel injector. Subtract second pressure reading from
first pressure reading for one fuel injector. Result is pressure drop value. See Fig. 19 . Obtain a pressure
drop value for each fuel injector. Add all individual pressure drop values. This is total pressure drop.
Divide total pressure drop by number of fuel injectors. This is average pressure drop. Does any fuel
injector have a pressure drop value more than average pressure drop or less than average pressure drop by
1.5 psi (10 kPa)? If yes, go to next step. If no, go to SYMPTOMS in TROUBLE SHOOTING - NO
CODES - 3.4L AZTEK & RENDEZVOUS article.
7. Replace affected fuel injectors. After repairs, go to next step.
8. Operate system in order to verify repair. Does a driveability condition still exist? If yes, go to
SYMPTOMS in TROUBLE SHOOTING - NO CODES - 3.4L AZTEK & RENDEZVOUS article. If no,
system is okay.
FUEL INJECTOR BALANCE TEST WITH TECH 2
Circuit Description
Scan tool first energizes fuel pump and then injectors for a precise amount of time allowing a measured amount
of fuel into manifold. This causes a drop in system fuel pressure that can be recorded and used to compare each
injector.
Test Description
3 - Engine Coolant Temperature (ECT) must be below operating temperature in order to avoid irregular
4 - Fuel pressure should be within specified range. If fuel pressure is not within specified range, see
FUEL SYSTEM PRESSURE TEST under FUEL SYSTEMS in BASIC DIAGNOSTIC
PROCEDURES - 3.4L AZTEK & RENDEZVOUS article.
5 - Fuel pressure should reach a steady value. If fuel pressure does not stabilize, see FUEL SYSTEM
6 - If pressure drop value for each fuel injector is within 1.5 psi (10 kPa) of average pressure drop value,
fuel injectors are flowing properly. Calculate pressure drop value for each fuel injector by subtracting
second pressure reading from first pressure reading. See Fig. 19 .
2. Perform FUEL INJECTOR COIL TEST . After performing Fuel Injector Coil Test, go to next step.
NOTE: DO NOT perform this test if ECT is above 201F (94C).
3. Observe ECT parameter with scan tool. Does scan tool indicate ECT parameter is less than 201F (94
C)? If yes, go to next step. If no, allow engine to cool before proceeding.
NOTE: Verify there is adequate fuel in fuel tank before proceeding with this step.
Fuel pump may need to be commanded ON a few times, in order to obtain
highest possible fuel pressure reading. DO NOT allow engine to start.
4. Turn ignition off. Turn off all accessories. Install fuel pressure gauge. Turn ignition on, with engine off.
Command fuel pump ON with scan tool. Observe fuel pressure gauge, with fuel pump commanded ON.
Is fuel pressure within 52-59 psi (358-405 kPa)? If yes, go to next step. If no, go to FUEL SYSTEM
NOTE: Fuel pressure may vary slightly when fuel pump stops operating. After fuel
pump stops operating, fuel pressure should stabilize and remain constant.
5. Monitor fuel pressure gauge for one minute. Does fuel pressure decrease by more than 5 psi (34 kPa)? If
yes, go to FUEL SYSTEM PRESSURE TEST under FUEL SYSTEMS in BASIC DIAGNOSTIC
PROCEDURES - 3.4L AZTEK & RENDEZVOUS article. If no, go to next step.
NOTE: Fuel pressure may rise after fuel injector stops pulsing. Record fuel
pressure value immediately after fuel injector stops pulsing. DO NOT
record higher fuel pressure value.
6. With scan tool, select Fuel Injector Balance Test function, within Special Functions menu. Select an
injector to be tested. Press Enter. This will prime fuel system. Record fuel pressure indicated by fuel
pressure gauge after fuel pressure stabilizes. This is first pressure reading. Energize fuel injector by
depressing Pulse Injector button on scan tool. This will energize injector and decrease fuel pressure.
Record fuel pressure indicated by fuel pressure gauge after fuel injector has stopped pulsing. This is
second pressure reading. Press Enter again to bring you back to Select Injector screen. Repeat this step for
each fuel injector. Subtract second pressure reading from first pressure reading for one fuel injector.
Result is pressure drop value. Obtain a pressure drop value for each fuel injector. Add all individual
pressure drop values. This is total pressure drop. Divide total pressure drop by number of fuel injectors.
This is average pressure drop. Does any fuel injector have a pressure drop value that is more than average
pressure drop or less than average pressure drop by 1.5 psi (10 kPa)? If yes, go to next step. If no, go to
SYMPTOMS in TROUBLE SHOOTING - NO CODES - 3.4L AZTEK & RENDEZVOUS article.
7. Replace affected fuel injectors. After repairs, go to next step.
8. Operate system in order to verify repair. Does a driveability condition still exist? If yes, go to
SYMPTOMS in TROUBLE SHOOTING - NO CODES - 3.4L AZTEK & RENDEZVOUS article. If no,
system is okay.
FUEL INJECTOR COIL TEST
Circuit Description
The PCM enables appropriate fuel injector on intake stroke for each cylinder. A voltage is supplied directly to
fuel injectors. PCM controls each fuel injector by grounding Control circuit via a solid state device called a
driver. A fuel injector coil winding resistance that is too high or too low, will affect engine driveability. A Fuel
Injector Control circuit DTC may not set, but a misfire may be apparent. Fuel injector coil windings are affected
by temperature. Resistance of fuel injector coil windings will increase as temperature of fuel injector increases.
Diagnostic Aids
Monitoring misfire current counters or misfire graph, may help isolate fuel injector that is causing
condition.
Operating vehicle over a wide temperature range may help isolate fuel injector that is causing condition.
Perform fuel injector coil test within conditions of customer's concern. A fuel injector condition may only
be apparent at a certain temperature, or under certain conditions.
If fuel injector coil test does not isolate condition, perform fuel injector balance test. See FUEL
INJECTOR BALANCE TEST WITH SPECIAL TOOL or FUEL INJECTOR BALANCE TEST
WITH TECH 2 .
Test Description
3 - This step tests each fuel injector resistance within a specific temperature range. If any fuel injectors
display a resistance outside of specified value, replace fuel injector.
4 - This step determines if all fuel injectors are within 3 ohms of each other. If highest resistance value is
within 3 ohms of lowest resistance value, then all fuel injector coil windings are okay.
6 - This step determines if the ignition 1 voltage circuit under the intake plenum is causing the concern.
8 - This step determines which fuel injector is faulty. After subtracting highest and lowest resistance
values from average value, replace fuel injector that has greatest resistance difference from average.
2. Observe Engine Coolant Temperature (ECT) parameter with scan tool. Is ECT value within 50-90F (10-
32C)? If yes, go to next step. If no, go to step 4 .
3. Disconnect fuel injector multi-way harness connector. With DVOM, measure resistance of each fuel
injector between Ignition Feed circuit and Fuel Injector Control circuit, at multi-way connector. See
WIRING DIAGRAMS . Do any fuel injectors display a resistance outside 11-14 ohms? If yes, go to step
5 . If no, go to DIAGNOSTIC AIDS .
4. Disconnect fuel injector multi-way harness connector. With DVOM, measure resistance of each fuel
injector between Ignition Feed circuit and Fuel Injector Control circuit, at multi-way connector. Record
each fuel injector value. Subtract lowest resistance value from highest resistance value. Is difference 3
ohms or less? If yes, go to FUEL INJECTOR BALANCE TEST WITH SPECIAL TOOL or FUEL
INJECTOR BALANCE TEST WITH TECH 2 . If no, go to step 8 .
5. Remove upper intake manifold. After removing upper intake manifold, go to next step.
6. Using a DVOM, measure resistance of the ignition 1 voltage circuit between the multi-way connector and
affected fuel injector connector. Is resistance more than 5 ohms? If yes, go to next step. If no, go to step
9.
7. Repair open or high resistance in the ignition 1 voltage circuit. After repairs, go to step 11 .
8. Add all of the fuel injector resistance values to obtain a total resistance value. Divide the total resistance
value by the number of fuel injectors to obtain an average resistance value. Subtract the lowest and the
highest individual fuel injector resistance values from the average resistance value. Replace fuel injector
that displays the greatest resistance difference, above or below the average. After replacing injector(s), go
to step 11 .
9. Test for an intermittent and for a poor connection at the affected fuel injector. Did you find and correct
the condition? If yes, go to step 11 . If no, go to next step.
10. Replace any fuel injectors that are out of the specified range of 11-14 ohms. After replacing injector(s),
go to next step.
no, go to step 2 .
FUEL PUMP ELECTRICAL CIRCUIT DIAGNOSIS

Fig. 20: Fuel System Electrical Schematic
Circuit Description
When ignition is turned on, the control module enables the fuel pump relay to turn on. The fuel pump remains
on as long as engine is cranking or running and control module receives ignition reference pulses. If there are no
ignition reference pulses, the control module shuts the fuel pump off within 2 seconds after ignition was turned
on or if engine stops.
Diagnostic Aids
Listen for an audible hiss from fuel pump when fuel pump relay is commanded on. A vibration in the fuel feed
line when fuel pump relay is commanded on indicates that the fuel pump is operating.
Test Description
The numbers below refer to the step numbers on the diagnostic procedure.
2 - Command both the ON and OFF states. Repeat the commands as necessary.
3 - This step determines if the condition is located on the coil side or the switch side of the circuit.
4 - This step verifies that the PCM is providing voltage to the fuel pump relay.
5 - This step tests for an open in the fuel pump relay ground circuit.
6 - This step determines if a voltage is constantly being applied to the fuel pump relay.
12 - This tests for a grounded fuel pump supply voltage circuit. The fuel pump fuse supplies power to fuel
pump. Disconnecting the fuel pump in-line harness connector isolates the fuel pump supply voltage
circuit.
15 - This step jumps the fuel pump relay in order to activate the fuel pump.
16 - This step tests for an open in the fuel pump feed circuit between the in-line connector and the fuel
pump relay.
17 - This step tests for an open or high resistance in the fuel pump ground circuit.
20 - This step determines if the condition with the circuit is intermittent. If the fuse does not open, inspect
the supply voltage circuit between the fuse and the fuel pump for an intermittent condition.
2. Turn ignition on, with engine off. Using scan tool, command the fuel pump relay ON and OFF. Does the
fuel pump turn ON and OFF? If yes, problem is intermittent. If yes, go to next step.
3. Using scan tool, command fuel pump relay ON and OFF. Do you hear a click when you command the
fuel pump relay ON and OFF? If yes, go to step 9 . If no, go to next step.
4. Turn ignition off. Disconnect fuel pump relay, located in underhood fuse/relay block. Turn ignition on,
with engine off. Probe control circuit of the fuel pump relay with a test light that is connected to a good
ground. See Fig. 20 . With scan tool, command the fuel pump ON and OFF. Does the test light turn ON
and OFF? If yes, go to next step. If no, go to step 6 .
5. Connect the test light between the control circuit of the fuel pump relay and the ground circuit of the fuel
pump relay. With a scan tool, command the fuel pump ON and OFF. Does test light turn ON and OFF? If
yes, go to step 21 . If no, go to step 24 .
6. Does the test light remain illuminated with each command? If yes, go to next step. If no, go to step 8 .
7. Test the control circuit of the fuel pump relay for a short to voltage. Did you find and correct the
8. Test control circuit of the fuel pump relay for a short to ground or an open. Did you find and correct the
9. Turn ignition on, with engine off. Does the fuel pump operate continuously? If yes, go to next step. If no,
go to step 11 .
10. Turn ignition off. Disconnect fuel pump relay, located in underhood fuse/relay block. Turn ignition on,
with engine off. Does the fuel pump operate continuously? If yes, go to step 23 . If no, go to step 27 .
11. Is the fuel pump fuse open? If yes, go to next step. If no, go to step 14 .
12. Disconnect the fuel pump harness in-line connector, located near fuel tank. Test the fuel pump supply
voltage circuit for a short to ground. See Fig. 20 . Replace fuel pump fuse, if necessary. Did you find and
correct the condition? If yes, go to step 29 . If no, go to next step.
13. Lower fuel tank, if necessary. Test or inspect the fuel tank electrical harness for damage or grounded
circuit. Replace the fuel pump fuse, if necessary. Did you find and correct the condition? If yes, go to step
29 . If no, go to step 20 .
14. Turn ignition off. Disconnect fuel pump relay. Turn ignition on, with engine off. Probe the battery
positive voltage circuit of the fuel pump relay with a test light connected to a good ground. Does the test
light illuminate? If yes, go to next step. If no, go to step 25 .
15. Connect a 10-amp fused jumper wire between the battery positive voltage circuit and fuel pump supply
voltage circuit in the fuel pump cavity. Does the fuel pump operate? If yes, go to step 21 . If no, go to
next step.
16. Disconnect the fuel pump harness in-line connector located near the fuel tank. Test the fuel pump supply
voltage circuit for an open or high resistance between the fuel pump relay and the in-line connector. Did
you find and correct the condition? If yes, go to step 29 . If no, go to next step.
17. Test the ground circuit of the fuel pump for an open or high resistance between the body pass-through
connector and the ground. Did you find and correct the condition? If yes, go to step 29 . If no, go to next
step.
18. Inspect for poor connections at the fuel pump in-line connector to the body pass-through connector. Did
you find and correct the condition? If yes, go to step 29 . If no, go to next step.
19. Lower fuel tank. Test or inspect the fuel tank electrical harness for damage or open circuit. Did you find
and correct the condition? If yes, go to step 29 . If no, go to step 26.
20. Connect all disconnected components. Install a new fuel pump fuse. With a scan tool, command the fuel
pump ON. Is the fuel pump fuse open? If yes, go to step 26 . If no, problem is intermittent.
21. Inspect for poor connections at the fuel pump relay. Did you find and correct the condition? If yes, go to
22. Inspect for poor connections at PCM harness. Did you find and correct the condition? If yes, go to step
29 . If no, go to step 28 .
23. Repair fuel pump supply voltage circuit for a short to voltage. After repairs, go to step 29 .
24. Repair fuel pump relay ground circuit for an open ground. After repairs, go to step 29 .
25. Repair battery positive voltage circuit of the fuel pump relay for an open. After repairs, go to step 29 .
26. Replace fuel pump. After replacing fuel pump, go to step 29 .
27. Replace fuel pump relay. After replacing relay, go to step 29 .
28. Replace PCM. See appropriate REMOVAL & INSTALLATION article. Perform PCM programing. After
replacing PCM, go to next step.
no, go to step 2 .
FUEL SYSTEM PRESSURE TEST
NOTE: For fuel system pressure testing, see FUEL SYSTEM PRESSURE TEST under
FUEL SYSTEMS in BASIC DIAGNOSTIC PROCEDURES - 3.4L AZTEK &
RENDEZVOUS article.
FUEL TANK LEAK TEST

Description
Fuel Tank Leak Test is used to locate any fuel or fuel vapor escaping fuel tank area. Fuel vapors escaping above
fuel level will be detected when Evaporative (EVAP) emission diagnostics complete one test cycle. Malfunction
Indicator Light (MIL) will illuminate after EVAP diagnostics complete 2 test cycles.
Diagnostic Aids
Operate vehicle under condition of customer's concern. Under high temperature conditions fuel vapors
may increase to a point of EVAP canister vapor saturation. Fuel vapors would then be released into
atmosphere. Once engine is running and EVAP purge is enabled, all fuel vapor release would be
eliminated.
Test for fuel leaking in fuel tank, rear tank if equipped, and fuel feed and return pipes.
Test for fuel vapor leaks in fuel tank, fill limiter vent valve and rollover valves, fuel fill pipe, hose and
fuel fill cap, fuel sender housing and seal, Fuel Tank Pressure (FTP) sensor seal and EVAP vapor pipe.
Movement of EVAP pipes or fuel pipes may help find an intermittent condition.
Test Description
The numbers below refer to step numbers in diagnostic procedures.
1 - Perform this procedure in order to determine that no EVAP diagnostic DTC is present.
3 - This test is to locate fuel leakage in fuel lines.
4 - This tests for fuel leaks below fuel tank fuel level.
5 - This test is to locate fuel vapors escaping above fuel level in fuel tank.
NOTE: Before performing this procedure, place a dry chemical (class B) fire
extinguisher near work area.
2. Raise vehicle. Inspect fuel tank and fuel pipes for damage or external leaks. Did you find fuel leaking
from fuel tank? If yes, go to step 7 . If no, go to next step.
3. Turn ignition on, with engine off. Using scan tool, command fuel pump ON. Inspect for fuel leaking from
fuel pipes. Did fuel leak from fuel pipes? If yes, go to step 8 . If no, go to next step.
4. Install Fuel Tank Cap Adapter (J-41415-40). Connect EVAP Pressure/Purge Diagnostic Station (J-41413)
to fuel tank cap adapter. With scan tool, seal EVAP system. DO NOT exceed 15 in. H2O. With EVAP
pressure/purge diagnostic station, pressurize fuel tank. Did fuel leak from fuel tank? If yes, go to step 7 .
NOTE: Fuel tank may need to be partially lowered during this step.
5. With EVAP pressure/purge diagnostic station, maintain pressure in fuel tank. With Ultrasonic Leak
Detector (J-41416), test for leaks above fuel level in following locations:
Fuel tank, fill limiter vent valve, pressure relief valve and rollover valves.
Fuel sender housing and fuel sender seal.
Fuel Tank Pressure (FTP) sensor seal.
EVAP vapor pipes.
Fuel fill pipe and hose.
Did you locate a fuel leak? If yes, go to next step. If no, see DIAGNOSTIC AIDS .
6. Repair system as necessary. After repairs, system is okay.

7. Replace fuel tank. After repairs, system is okay.
8. Replace leaking fuel pipe. After repairs, system is okay.
IDLE CONTROL SYSTEM
IDLE AIR CONTROL SYSTEM DIAGNOSIS
Description
Engine idle speed is controlled by Idle Air Control (IAC) valve. IAC valve is on throttle body. IAC valve pintle
moves in and out of an idle air passage bore to control air flow around throttle plate. IAC valve consists of a
movable pintle, driven by a gear attached to a 2 phase bi-polar permanent magnet electric motor called a stepper
motor. The stepper motor is capable of highly accurate rotation, or of movement, called steps. The stepper
motor has 2 separate windings that are called coils. Each coil is fed by 2 circuits from PCM. When PCM
changes polarity of a coil, stepper motor moves one step. PCM uses a predetermined number of counts to
determine IAC pintle position. Observe IAC counts with scan tool. IAC counts will increment up or down as
PCM attempts to change IAC valve pintle position. An IAC Reset will occur when ignition key is turned OFF.
First, PCM will seat IAC pintle in idle air passage bore. Second, PCM will retract pintle a predetermined
number of counts to allow for efficient engine start-up. If engine idle speed is out of range for a calibrated
period of time, an idle speed DTC may set.
Diagnostic Aids
High resistance in an IAC valve control circuit.

The correct PCV valve, properly installed and proper operation of the PCV valve.
Proper operation and installation of all air intake components.
Proper installation and operation of the MAF sensor.
A tampered with or damaged throttle stop screw.
A tampered with or damaged throttle plate, throttle shaft, throttle linkage, or cruise control linkage, if
equipped.
A skewed high TP sensor.
Excessive deposits in IAC passage or on IAC pintle.
Excessive deposits in the throttle bore or on the throttle plate.
Vacuum leaks.
A high or unstable idle condition could be caused by a non-IAC system problem that cannot be overcome
by the IAC valve.
An intermittent condition.
Test Description
5 - This test will determine ability of PCM and IAC valve circuits to control IAC valve.
7 - This test will determine ability of PCM to provide IAC valve circuits with ground. On a normally
operating system, test light should not flash while IAC counts are incrementing.
NOTE: Ensure engine speed stabilizes with each commanded RPM change to
determine if engine speed stays within specifications.
2. Set parking brake and block drive wheels. Install scan tool. Start engine. Turn all accessories off. Using
scan tool RPM control function, slowly increment engine speed to 1700 RPM, then to 600 RPM. Then to
1700 RPM. Exit RPM control function. Did the engine speed stabilize within 100 RPM less than the
commanded engine speed or within 150 RPM above the commanded RPM? If yes, see DIAGNOSTIC
AIDS . If no, go to next step.
3. Turn ignition off. Disconnect IAC valve harness connector. See WIRING DIAGRAMS . Connect IAC
System Motor Analyzer (J-37027-A) to IAC valve. Start engine. Using IAC system motor analyzer,
command IAC valve in until about 600 RPM is reached and then command IAC valve out until about
1700 RPM is reached. Return engine RPM to desired idle as indicated on scan tool data list. Did the
engine speed steadily decrease to near 600 RPM and steadily increase to near 1700 RPM when the IAC
valve was commanded in and out? If yes, go to step 5 . If no, go to next step.
4. Did you observe an excessively high idle condition that could not be controlled with the IAC motor driver
during the last test? If yes, go to step 11 . If no, go to step 12 .
5. Using a test light connected to ground, probe one IAC valve circuit at IAC valve harness connector. See
WIRING DIAGRAMS . Start engine. Using IAC system motor analyzer, command low RPM while
observing scan tool until IAC counts start to increment, then command high RPM until IAC counts start
to increment. Observe test light while incrementing IAC counts. Return engine to idle as indicated on
scan tool data list. Repeat procedure for other three IAC valve circuits. Did the test light remain ON,
never flashing, while the IAC counts where incrementing at any of the IAC valve circuits during the
above test? If yes, go to step 10 . If no, go to next step.
6. Did the test light remain OFF, never flashing, while the IAC counts where incrementing at any of the IAC
valve circuits during the above test? If yes, go to step 9 . If no, go to next step.
7. Using Connector Test Adapter Kit (J-35616-A) connect a test light between IAC coil "A" low circuit and
IAC coil "A" high circuit at IAC valve harness connector. Using IAC system motor driver, command low
RPM while observing scan tool until IAC counts start to increment, then command high RPM until IAC
counts start to increment. Observe test light while incrementing IAC counts. Return engine speed to
desired idle as indicated on scan tool data list. Repeat procedure on IAC coil "B" low circuit and IAC coil
"B" high circuit. Did the test light stay illuminated, never flashing, while the IAC counts where
incrementing during the above test? If yes, go to next step. If no, go to step 17 .
8. Check for poor connection at IAC valve harness connector. Did you find and correct the condition? If
yes, go to step 18 . If no, go to step 13 .
9. Turn ignition off. Disconnect PCM harness connectors. With a DVOM, test the circuit where the test light
remained off for the following:
An open circuit.
A short to ground.
A short to another IAC valve circuit.
Did you find and correct the condition? If yes, go to step 18 . If no, go to step 13 .
10. Turn ignition on. With a DVOM, test the circuit where the test light remained illuminated for the
following:
A short to voltage.
A short to another IAC valve circuit.
11. Visually and physically inspect for the following:

Throttle body damage and tampering.
Skewed TP sensor signal.
Throttle lever screw tampering (if equipped).
Vacuum leaks.
Faulty, incorrectly installed PCV valve and hose (if equipped).
Throttle shaft binding.
Throttle linkage or cruise control linkage binding (if equipped).
Remove IAC valve. Inspect for the following:

Clogged IAC passage
Excessive deposits on throttle plate.
Excessive deposits in throttle bore.
Excessive deposits on IAC valve pintle.
12. Visually and physically inspect for the following:

Throttle body damage and tampering.
Throttle lever screw tampering (if equipped).
Restricted air intake system.
Excessive deposits on throttle plate.
Excessive deposits in throttle bore.
Remove IAC valve and inspect for excessive deposits on IAC valve pintle and in IAC valve
passage.
Repair as necessary. Did you find and correct the condition? If yes, go to step 18 . If no, go to step 15 .
13. Check for poor PCM harness connections. Did you find and correct the condition? If yes, go to step 18 .
14. Disconnect the PCM harness connectors. With a DVOM, test all IAC valve circuits for high resistance.
15. Check for poor IAC valve harness connection. Did you find and correct the condition? If yes, go to step
16. Replace IAC valve. After repairs, go to step 18 .
17. Replace PCM. See appropriate REMOVAL & INSTALLATION article. Perform PCM relearn
procedures. After repairs, go to next step.
18. Reconnect any disconnected components. Use the scan tool to clear any DTCs that may have set. Turn
OFF the ignition for 30 seconds. Operate the vehicle within conditions to verify the repair. Did you verify
the repair? If yes, go to next step. If no, go to step 2 .
19. With a scan tool, observe the stored information in Capture Info. Does the scan tool display any DTCs
that you have not diagnosed? If yes, see DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-
DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article. If no, system is okay.
Fig. 21: Identifying Idle Air Control Valve Connector Terminals
IGNITION SYSTEMS
NOTE: For ignition system testing, perform related DTC testing procedure. See
DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 3.4L
NOTE: For a no-start problem, refer to NO-START DIAGNOSIS in BASIC DIAGNOSTIC

PROCEDURES - 3.4L AZTEK & RENDEZVOUS article.
See CAMSHAFT POSITION SENSOR under SENSORS & SWITCHES.
See CRANKSHAFT POSITION SENSOR under SENSORS & SWITCHES.
EMISSION SYSTEMS & SUB-SYSTEMS
NOTE: For emission and sub-system testing not listed, perform related DTC testing
procedure. DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS
AIR INJECTION
Electric AIR Pump
NOTE: For electric AIR pump testing, perform related DTC testing procedure. See
DIAGNOSTIC TROUBLE CODE DEFINITIONS in SELF-DIAGNOSTICS - 3.4L
EXHAUST GAS RECIRCULATION
NOTE: For EGR system diagnosis, see appropriate INSPECTION/MAINTENANCE

PROCEDURES under DRIVE CYCLES in SELF-DIAGNOSTICS - 3.4L AZTEK &
RENDEZVOUS article.
FUEL EVAPORATION
NOTE: Ensure all vacuum line and EVAP system components are not damaged or
missing before proceeding with this test.
EVAP Control System Diagnosis
For EVAP control system diagnosis, see appropriate INSPECTION/MAINTENANCE PROCEDURES under
DRIVE CYCLES in SELF-DIAGNOSTICS - 3.4L AZTEK & RENDEZVOUS article.
POSITIVE CRANKCASE VENTILATION

Required Service
The PCV system may require service for obstructions if any of the following conditions exist:
Rough idle.
Stalling or low idle speed.
Oil leaks.
Oil in air cleaner.
Sludge in engine.
A leaking PCV valve or hose could cause:
Rough idle.
Stalling.
High idle speed.
If engine idles rough, check for clogged PCV valve, or for plugged or broken PCV hoses BEFORE adjusting
idle. Check PCV valve application to ensure valve is fitted. Replace PCV valve if required.
Checking PCV Valve Function
1. Disconnect PCV valve vacuum hose from cylinder head cover. Run engine at idle. Place thumb over open
end of PCV valve vacuum hose to check for vacuum. If vacuum does not exist, check for obstruction in
source vacuum supply. If source vacuum supply is okay, replace PCV valve.
2. Turn ignition off. Remove PCV valve. Shake valve and listen for rattle of check valve inside PCV valve.
If a clear rattle is not heard, replace PCV valve.
3. Visually inspect valve for varnish or deposits that may make PCV valve operation sticky or restricted, or
cause incomplete seating of valve. Replace as necessary.
4. Engine must be sealed for PCV system to function as designed. If leakage, sludging or dilution of oil is
noted and PCV system is functioning properly, check engine for cause and repair as required to ensure
PCV system will continue to function properly.
5. An engine operating without any crankcase ventilation can be damaged, so it is important to replace PCV
valve and air cleaner breather (if equipped) at regular intervals (at least every 30,000 miles). Check all
hoses and clamps for failure or deterioration.
MISCELLANEOUS CONTROLS
NOTE: Although some of the controlled devices listed here are not technically engine
performance components, they can affect driveability if they malfunction.
Manufacturer does not provide testing procedures for many individual systems and components. For system and
component testing not listed, perform related DTC testing procedure. See DIAGNOSTIC TROUBLE CODE
A/C COMPRESSOR CLUTCH CONTROLS
NOTE: For A/C compressor clutch circuit testing, see appropriate AUTOMATIC A/C-
HEATER SYSTEMS or MANUAL A/C-HEATER SYSTEMS article in AIR
CONDITIONING & HEATING. See appropriate SYSTEM WIRING DIAGRAMS
article in ELECTRICAL for terminal and wire color identification.
ELECTRIC COOLING FAN CONTROL
NOTE: For electric cooling fan circuit testing, see ELECTRIC COOLING FANS article in
AIR CONDITIONING & HEATING. See appropriate SYSTEM WIRING DIAGRAMS
article in ELECTRICAL for terminal and wire color identification.
TRANSMISSION
NOTE: For transmission electronic controls and component testing, see appropriate
DIAGNOSIS article in AUTOMATIC TRANSMISSIONS. For component circuit
identification, see appropriate SYSTEM WIRING DIAGRAMS article in
ELECTRICAL.
WIRING DIAGRAMS
AZTEK
ELECTRICAL.
RENDEZVOUS
ELECTRICAL.
Vacuum Diagrams - Aztek & Rendezvous
INTRODUCTION
This article contains underhood views or schematics of vacuum hose routing. Use these vacuum diagrams as a
guide during the visual inspection in appropriate BASIC DIAGNOSTIC PROCEDURES article. This will assist
in identifying improperly routed vacuum hoses which may cause driveability and/or computer-indicated
malfunctions. Always verify vacuum hose routing using underhood emission and vacuum label (if equipped) for
specific applications.
NOTE: If underhood vacuum label and diagram in manual differ, underhood label
should always take precedent, unless it is suspected of not being correct
application.
VACUUM DIAGRAMS
VACUUM HOSE ROUTING
Fig. 1: Vacuum Hose Routing
EVAPORATIVE EMISSIONS (EVAP) HOSE ROUTING

Fig. 2: EVAP Hose Routing
Entertainment - Aztek & Rendezvous
SPECIFICATIONS

Specification
Amplifier Bolt 2 N.m 18 lb in
Antenna Base Bolt 3 N.m 27 lb in
Antenna Cable Extension to Roof Screw 3.2 N.m 28 lb in
Auto Control Rear Cargo Screw 2 N.m 18 lb in
DVD Player Retaining Bolts 9 N.m 80 lb in
Overhead Speaker Screws 3.2 N.m 28 lb in
Radio Screws 2.5 N.m 22 lb in
Speaker Screws 3.2 N.m 28 lb in
Support Bracket Screw 2 N.m 18 lb in
Trim Panel Screw 2 N.m 18 lb in
Video Cassette Player Mounting Bracket 2 N.m 18 lb in
Video Cassette Storage Bolts 2 N.m 18 lb in
Video Cassette Storage Screws 2 N.m 18 lb in
XM Digital Radio Receiver Nuts 4 N.m 35 lb in

RADIO/AUDIO SYSTEM SCHEMATICS
Fig. 1: Radio System (U96) - Pontiac
Fig. 2: Radio W/Rear Seat Audio Controls (U96 w/U32) - Pontiac
Fig. 3: Uplevel Radio W/O Rear Seat Audio Controls (UQ3) - Pontiac
Fig. 4: Uplevel Radio W/Rear Seat Audio Controls (UQ3 w/U32) - Pontiac
Fig. 5: Radio Speakers (UQ3) - Pontiac
Fig. 6: Radio System (U96) - Buick
Fig. 7: Radio W/Rear Seat Audio Controls (U96 w/U32) - Buick
Fig. 8: Uplevel Radio W/O Rear Seat Audio Controls (UQ3) - Buick
Fig. 9: Uplevel Radio W/Rear Seat Audio Controls (UQ3 w/U32) - Buick
Fig. 10: Radio Speakers (UQ3) - Buick
Fig. 11: Digital Radio Receiver w/U2K
Fig. 12: Digital Radio Receiver (w/U2K and UE1)
STEERING WHEEL CONTROLS SCHEMATICS

Fig. 13: Steering Wheel and Tailgate Controls - Pontiac
Fig. 14: Steering Wheel Controls - Buick
VIDEO SYSTEM SCHEMATICS

Fig. 15: Video System
COMPONENT LOCATOR
ENTERTAINMENT COMPONENT VIEWS

8 Cigar Lighter
11 Radio
12 Ignition Switch
Fig. 17: Instrument Panel Location View - Buick


1 Headlamp Switch
2 Turn Signal Switch/Multifunction Switch
3 Hazard Switch
4 Instrument Panel Cluster (IPC)
5 Automatic Transmission Shift Lever
6 Radio
8 Alarm LED
9 Fuse Block - Center Console
10 Center Console Switchbank
12 Steering Wheel Controls - Right
13 Ignition Switch
14 Head Up Display (HUD) Switch and Driver Information Center (DIC) Switch
15 Steering Wheel Controls - Left
Fig. 18: Door Trim Panel Location View - Rendezvous


1 Tweeter - RF (LF Similar)
2 Speaker - RF (LF, LR, RR Similar)
Fig. 19: Door Trim Panel Location View - Aztek


1 Tweeter - RF (LF Similar)
2 Speaker - RF (LF, LR, RR Similar)
Fig. 20: Driver Side Control Location View - Pontiac

1 Headlamp Switch
2 Steering Wheel Controls
3 Driver Information Center
Fig. 21: Cargo Area Location View - Left

1 Tailgate Audio Controls
2 Subwoofer
3 Aux Outlet-Rear
4 Auto Level Control (ALC) Inflator Air Switch
Fig. 22: Behind I/P Compartment Location View

1 Digital Radio Reciever
Fig. 23: Rear Seat Audio (RSA) Location View

1 Rear Seat Audio (RSA)
Fig. 24: Digital Video Disc (DVD) Display Screen Location View

1 DVD Display Screen
2 Overhead Console
ENTERTAINMENT CONNECTOR END VIEWS
Audio Amplifier - C1 (UQ3)

12110626
8-Way F Metri-Pack 280 Series Flexlock (WH)

A - - Not Used
B OG 926 Amplifier Present Signal
C-D - - Not Used
PU 493 Rear Seat Audio Enable Signal
E
PU 493 Rear Seat Audio Enable Signal (Buick)
F PU 927 Amplifier Control
G OG 2040 Battery Positive Voltage
H BK/WH 351 Ground
Audio Amplifier - C2 (UQ3)

12110088
24-Way F Micro-Pack 100 Series (GY)

A1 L-GN/BK 1794 Left Rear Subwoofer Speaker Output (-)
A2 D-BU/WH 346 Left Rear Subwoofer Speaker Output (+)
A3 L- BU/BK 315 Right Rear Subwoofer Speaker Output (-)
A4 D-GN 1795 Right Rear Subwoofer Speaker Output (+)
Left Rear Midrange Speaker Output (-)
WH 1959
(Pontiac)
A5
Left Front Tweeter Speaker Output (-)
YE 1956
(Buick)
Left Rear Midrange Speaker Output (+)
TN 1859
(Pontiac)
A6
Left Front Tweeter Speaker Output (+)
BK 1856
(Buick)
Right Rear Midrange Speaker Output (-)
RD 1955
(Pontiac)
A7
Right Front Tweeter Speaker Output (-)
PU 1952
(Buick)
Right Rear Midrange Speaker Output (+)
TN 1855
(Pontiac)
A8
Right Front Tweeter Speaker Output (+)
L-GN 1852
(Buick)
D-BU 46 Right Rear Speaker Output (+) (Pontiac)
A9
L-GN 200 Right Front Speaker Output (+) (Buick)
L-BU 115 Right Rear Speaker Output (-) (Pontiac)
A10
D-GN 117 Right Front Speaker Output (-) (Buick)
BN 199 Left Rear Speaker Output (+) (Pontiac)
A11
TN 201 Left Front Speaker Output (+) (Buick)
YE 116 Left Rear Speaker Output (-) (Pontiac)
A12
GY 118 Left Front Speaker Output (-) (Buick)
Right Rear Low Level Audio Signal (-)
BK/WH 1946
(Pontiac)
B1
Right Front Low Level Audio Signal (-)
L-GN 1948
(Buick)
Right Rear Low Level Audio Signal (+)
D-BU 546
(Pontiac)
B2
Right Front Low Level Audio Signal (+)
L-GN 512
(Buick)
Left Rear Low Level Audio Signal (-)
BN 1999
B3 (Pontiac)
D-GN 1947 Left Front Low Level Audio Signal (-)
(Buick)
Left Rear Low Level Audio Signal (+)
BN 599
(Pontiac)
B4
Left Front Low Level Audio Signal (+)
TN 511
(Buick)
Right Front Low Level Audio Signal (-)
L-GN 1948
(Pontiac)
B5
Right Rear Low Level Audio Signal (-)
BK/WH 1946
(Buick)
Right Front Low Level Audio Signal (+)
L-GN/BK 512
(Pontiac)
B6
Right Rear Low Level Audio Signal (+)
D-BU 546
(Buick)
Left Front Low Level Audio Signal (-)
D-GN 1947
(Pontiac)
B7
Left Rear Low Level Audio Signal (-)
BN 1999
(Buick)
Left Front Low Level Audio Signal (+)
TN 511
(Pontiac)
B8
Left Rear Low Level Audio Signal (+)
BK/WH 599
(Buick)
L-GN 200 Right Front Speaker Output (+) (Pontiac)
B9
D-BU 46 Right Rear Speaker Output (+) (Buick)
D-GN 117 Right Front Speaker Output (-) (Pontiac)
B10
L-BU 115 Right Rear Speaker Output (-) (Buick)
TN 201 Left Front Speaker Output (+) (Pontiac)
B11
BN 199 Left Rear Speaker Output (+) (Buick)
GY 118 Left Front Speaker Output (-) (Pontiac)
B12
YE 116 Left Rear Speaker Output (-) (Buick)
Digital Radio Receiver (U2K)

15394150
16-Way F Metri-Pack (GY)

1 - - Not Used
2 BN/WH 367 Remote Radio Left Audio Signal
3 D-GN/WH 368 Remote Radio Right Audio Signal
4-8 - - Not Used
9 BK 351 Ground
10 BK/WH 372 Remote Radio Audio Output (-)
11 BARE 7814 Drain Wire
12-14 - - Not Used
15 TN 9807 Class 2 Serial Data
Radio - C1
12110088

A1 OG 1044 Radio Class 2 Serial Data
A2 - - Not Used
A3 PU 493 Rear Seat Audio Enable Signal (UQ3)
A4-A5 - - Not Used
A6 PU 1375 Remote Radio Control Supply Voltage
A7 D-BU 1796 Steering Wheel Controls Signal
TN 201 Left Front Speaker Output (+) (w/o UQ3)
A8 Left Front Low Level Audio Signal (+)
TN 511
(UQ3)
GY 118 Left Front Speaker Output (-) (w/o UQ3)
A9 Left Front Low Level Audio Signal (-)
D-GN 1947
(UQ3)
L-BU 115 Right Rear Speaker Output (-) (w/o UQ3)
A10 Right Rear Low Level Audio Signal (-)
BK 1946
(UQ3)
D-BU 46 Right Rear Speaker Output (+) (w/o UQ3)
A11 Right Rear Low Level Audio Signal (+)
D-BU 546
(UQ3)
A12 BK/WH 351 Ground
B1 OG 5640 Battery Positive Voltage
B2 - - Not Used
B3 PU 927 Amplifier Control (UQ3)
B4 GY 8 Instrument Panel Lamp Supply Voltage - 1
B5 BK 1450 Ground
B6 OG 926 Amplifier Present Signal (UQ3)
B7 L-GN 1011 Remote Radio Control Signal (RSA)
BN 199 Left Rear Speaker Output (+) (w/o UQ3)
B8
BN/WH 599 Left Rear Low Level Audio Signal (+) (UQ3)
YE 116 Left Rear Speaker Output (-) (w/o UQ3)
B9
BN 1999 Left Rear Low Level Audio Signal (-) (UQ3)
D-GN 117 Right Front Speaker Output (-) (w/o UQ3)
B10 Right Front Low Level Audio Signal (-)
L-GN 1948
(UQ3)
L-GN 200 Right Front Speaker Output (+) (w/o UQ3)
B11 Right Front Low Level Audio Signal (+)
L-GN/BK 512
(UQ3)
B12 - - Not Used
Radio - C2 (UE1/UQ3/UK6)
12064799
12-Way F Micro-Pack 100 Series (BK)

A-B - - Not Used
C BARE 814 Drain Wire (U32)
D - - Not Used
E D-GN 389 Vehicle Speed Signal
F-G - - Not Used
H D-GN/WH 368 Remote Radio Right Audio Signal
J BN/WH 367 Remote Radio Left Audio Signal
K BK/WH 372 Remote Radio Audio Output (-)
L BK/WH 9372 Remote Radio Audio Output (-)
M BN/WH 9367 Remote Radio Left Audio Signal
Rear Seat Audio Control (UQ3/UK6)
12110259
16-Way F Micro-Pack 100 Series (GN)

A1 BK 1946 Right Rear Low Level Audio Signal (-)
A2 D-BU 546 Right Rear Low Level Audio Signal (+)
A3 BN 1999 Left Rear Low Level Audio Signal (-)
A4 BN 599 Left Rear Low Level Audio Signal (+)
A5 L-GN 1011 Remote Radio Control Signal
A6 GY 8 Instrument Panel Lamp Supply Voltage
A7 - - Not Used
A8 PU 1375 Remote Radio Control Supply Voltage
B1 L-BU 115 Right Rear Speaker Output (-) (Base Radio)
B2 D-BU 46 Right Rear Speaker Output (+) (Base Radio)
B3 YE 116 Left Rear Speaker Output (-) (Base Radio)
B4 BN 199 Left Rear Speaker Output (+) (Base Radio)
B5 PU 493 Rear Seat Audio Enable Signal
B6 BK 650 Ground
B7 - - Not Used
B8 BN 9 Park Lamp Supply Voltage
Rear Seat Entertainment (RSE) Assembly (U32)

15341086
12-Way F Multi-Lock Series (BK)

1 - - Not Used
2 PK 1045 VCM Class 2 Serial Data
3-4 - - Not Used
5 D-GN/WH 368 Remote Radio Right Audio Signal
6 BN/WH 367 Remote Radio Left Audio Signal
7 BK/WH 351 Ground
8 - - Not Used
10-11 - - Not Used
12 BK/WH 372 Remote Audio Output (-)
Speaker - LF Door
12186847
2-Way F Metri-Pack 150 Series (WH)

A GY 118 Left Front Speaker Output (-)
B TN 201 Left Front Speaker Output (+)
Speaker - LR Door
12052832

A YE 116 Left Rear Speaker Output (-)
B BN 199 Left Rear Speaker Output (+)
Speaker - LR (Pontiac UQ3 Only)
12064760

A L-GN/BK 1794 Left or Rear Subwoofer Speaker Output (-)
B D-BU/WH 346 Left Subwoofer Speaker Output (+)
C WH 1959 Left Rear Midrange Speaker Output (-)
D TN 1859 Left Rear Midrange Speaker Output (+)
Speaker - LR Subwoofer (Buick UQ3)
12052832
A L-GN/BK 1794 Left Subwoofer Speaker Output (-)
B D-BU/WH 346 Left Subwoofer Speaker Output (-)
Speaker - RF Door
12186847
2-Way F Metri-Pack 150 Series (WH)

A D-GN 117 Right Front Speaker Output (-)
B L-GN 200 Right Front Speaker Output (+)
Speaker - RR Door
12052832

A L-BU 115 Right Rear Speaker Output (-)
B D-BU 46 Right Rear Speaker Output (+)
Speaker - RR (Pontiac UQ3 Only)
12064760

A L-BU/BK 315 Right Subwoofer Speaker Output (-)
B D-GN 1795 Right Subwoofer Speaker Output (+)
C RD 1955 Right Rear Midrange Speaker Output (-)
D TN 1855 Right Rear Midrange Speaker Output (+)
Speaker - RR Subwoofer (Buick UQ3)

12052832

A L-BU/BK 315 Right Subwoofer Speaker Output (-)
B D-GN 1795 Right Subwoofer Speaker Output (+)
Steering Wheel Controls - Left (UK3)
50579405
5-Way F (BK)

1 D-BU 1796 Steering Wheel Controls Signal
2 - - Not Used
3 BK 350 Ground
4 YE/BK 1458 Instrument Panel Lamp Supply Voltage - 4
Steering Wheel Controls - Right (UK3)
50579406
6-Way F (BK)

1 PU 1375 Remote Radio Control Supply Voltage
3 GY/BK 14 Instrument Panel Lamp Supply Voltage - 4
4 - - Not Used
5 BK 350 Ground
Tailgate Audio Controls (Pontiac W/UQ3)

12092162

A PU 1375 Remote Radio Control Supply Voltage
B - - Not Used
C D-BU 1796 Steering Wheel Controls Signal
D - - Not Used
Tweeter - LF Door
12052832

A GY 118 Left Front Speaker Output (-)
B TN 201 Left Front Speaker Output (+)
Tweeter - RF Door
12052832

A D-GN 117 Right Front Speaker Output (-)
B L-GN 200 Right Front Speaker Output (+)

DIAGNOSTIC STARTING POINT - ENTERTAINMENT

SCAN TOOL DATA LIST
Radio / Integrated Radio Control (IRC)

Ignition ON/Engine OFF/Radio ON
8 Digit GM Part Number Module Information Numeric Varies
Antenna Signal System Configuration dBuV Varies
Amplifier System Configuration Present/Not Present Varies
Band Number System Configuration FM1/ FM2/ AM Varies
Calibration ID Module Information Numeric Varies
Cassette Cut Tape Cassette Information Numeric Varies
Cassette Load/Unload Error Cassette Information Numeric Varies
Cassette Inserted Cassette Information Yes/No Varies
Cassette Metal Cassette Information Metal/Not Metal Varies
Cassette Side Cassette Information Bottom/Top Varies
Cassette Tight Tape Cassette Information Numeric Varies
CD Focus Errors CD Information Numeric Varies
CD Load/Unload Errors CD Information Numeric Varies
CD Tracking Errors CD Information Numeric Varies
CD Inserted CD Information Yes/No Varies
1 (2 if the memory 2
Driver Number System Configuration 1/2 button has been
activated)
Julian Date of Build Module Information Numeric Varies
New VIN Counter System Configuration Numeric Varies
Phone System Configuration Present/Not Present Varies
Preset 1-6, if active
Preset 1-6/Not a
Preset Control System Configuration radio station is a
Preset
preset
PROM ID Module Information Numeric Varies
Sequence Number Module Information Numeric Varies
Single CD Track Number CD Information Numeric Varies
Off/ Tuner/ CD/
Source System Configuration Varies
Cassette
Yes/No/ Learn VIN
Theft Armed System Configuration Varies
Number
Theft Lock System Configuration Locked/Unlocked Unlocked
Total Cassette Hours Cassette Information Hrs. Varies
Total CD Hours CD Information Hrs. Varies
Total Radio Hours Module Information Hrs. Varies
Year Module Built Module Information Numeric Varies
Digital Radio Receiver

Operating Conditions: Ignition ON/Engine OFF/Radio ON
ID
8-Digit GM Part Number Information/Module Numeric Varies
Information
Battery Voltage Data Volts Varies
ID Information/DSP
Day - Varies
Software Version ID
ID Information/XM
Day - Varies
Software Version ID
Digital Radio Antenna Data Millivolts Varies
Ignition Counter Data Numeric Varies
ID
Julian Date Of Build Information/Module Numeric Varies
Information
ID Information/DSP
Month - Varies
Software Version ID
ID Information/XM
Month - Varies
Software Version ID
Power Mode Data - run
ID Information/DSP
Software Version - Varies
Software Version ID
ID Information/XM
Software Version - Varies
Software Version ID
ID Information/DSP
Year - Varies
Software Version ID
ID Information/XM
Year - Varies
Software Version ID
ID
Year Module Built Information/Module - Varies
Information
ID
Electronic Serial Number Information/Electronic Alphanumeric Varies
Serial Number
The scan tool displays an 8-digit alphanumeric number. This is part number of the module.
Antenna Signal
The scan tool displays 0-300. The signal from the antenna is measured in dBuV.
Band Number
The scan tool displays AM/FM/FM1. This is the current band setting.
Calibration ID
The scan tool displays 0-9999. This number designates what calibrations the radio contains.
Cassette Cut Tape
The scan tool displays 0-999. This is the number of cut tape errors the radio has recorded.
Cassette Load/Unload Errors
The scan tool displays 0-999. This is the number of cassette loading and unloading errors the radio has
recorded.
Cassette Tight Tape
The scan tool displays 0-999. This is the number of cassette tight tape errors the radio has recorded.
CD Focus Errors
The scan tool displays 0-999. This is the number of CD focus errors the radio has recorded.
CD Load/Unload Errors
The scan tool displays 0-999. This is the number of CD loading and unloading errors the radio has
recorded.
CD Tracking Errors
The scan tool displays 0-999. This is the number of CD tracking errors the radio has recorded.
Driver Number
The scan tool displays 1-2. This is the memory position the driver has selected as received by Class 2
lines.
Julian Date of Build
The scan tool displays 0-999. This is the month and year that the module was built.
PROM ID
The scan tool displays 0-9999. This is the identification number of the radios internal PROM.
Preset Control
The scan tool displays a preset number 1-6. This is the preset number when the radio is on a preset
station.
Theft Armed
The scan tool displays Yes/No/Learned VIN Number. The scan tool displays Yes when the theft mode
has been turned ON by recognizing a valid VIN #.
Theft Lock
The scan tool displays Yes/No. The scan tool displays Yes when the radio receives the incorrect VIN
number from the PCM across Class 2 lines.
Total Cassette Hours
The scan tool displays 0-999 hrs. This is the total number of hours the cassette player has been used.
Total CD Hours
The scan tool displays 0-999 hrs. This is the total number of hours the CD player has been used.
Total Radio Hours
The scan tool displays 0-999 hrs. This is the total number of hours the radio has been used.
Year Module Built
The scan tool displays a 1990-2020. This is the production year the module was manufactured.
Digital Radio Antenna
The scan tool displays millivolts. This parameter indicates the amount of current being used by the digital
radio antenna by measuring the voltage drop across an internal resistor. Typical value is 1200-1800 mV.
DTC B1001
Circuit Description
Each time the ignition cycles from OFF to ON, the radio receives VIN data over the class 2 communication
circuit. If the VIN data in the radio memory matches the VIN data it receives over the class 2 communication
circuit, the radio will operate normally.
DTC Descriptor
DTC B1001 Option Configuration Error

The DTC is run when the radio is turned from OFF to ON.
Battery voltage is between 9-16 volts.
Installing a radio from a different vehicle platform or installing a new body control module (BCM) and not
entering the correct setup information with the scan tool.
The radio does not function properly. The radio displays "CAL".
Installing a radio from another vehicle of the same platform or a new radio of the same platform.
Installing a new BCM setup properly with the correct VIN for that vehicle.
The DTC status will turn to history when the above criteria is met. The scan tool can now clear the history
DTC, or the scan tool will automatically clear after 100 consecutive fault free ignition cycles.
Test Description
2: Clear all DTCs and cycle the ignition in order to verify that the DTC did not falsely set.
3: Clear all DTCs after the repair procedure is complete.
DTC B1001
Step Action Yes No
1
Vehicle in Vehicle
3. With the scan tool, perform the radio setup
2 procedure. Refer to Radio Setup.

Replace the radio. Refer to Control Module
DTC B1025, B1035, B1045, OR B1055
Circuit Description
When the radio is powered up, the radio supplies low level audio signals to the speakers. If the vehicle is
equipped with an audio amplifier, the amplifier will boost the signal sent to the speakers.
DTC Descriptors
DTC B1025 Audio Output 1 Circuit

The test is performed when the radio switches from OFF to ON. The radio will continue to test for the fault
once every 0.5 seconds.
The radio sets a current status for this DTC when a short to ground or voltage is detected on any of the speaker
channels for 1.5 seconds.
No sound is present from one or more of the speakers.
The fault condition is not present for 5 seconds.
Test Description
2: This step verifies that the DTC is still present.

3: This step isolates the fault condition.
DTC B1025, B1035, B1045, or B1055

Step Action Yes No
Schematic Reference: Radio/Audio System Schematics
Connector End View Reference: Entertainment Connector End Views
1
Vehicle in Vehicle
2 3. With the scan tool, monitor the DTC Information Intermittent
for DTC B1025. Conditions and
Poor Connections
Does the scan tool indicate that DTC B1025 is current? Go to Step 3 in Wiring Systems
Test the speaker outputs from the radio for a short to
ground or voltage. Refer to Circuit Testing and
3
of the radio. Refer to Testing for Intermittent
5
6
DTC B1259
Circuit Description
The digital radio antenna is connected to the digital radio receiver (DRR) by 2 coax cables. One coax carries the
satellite signal, the other coax carries the terrestrial signal. The antenna cable for the satellite antenna also
provides a path for D.C. current for powering the antenna.
DTC Descriptor
DTC B1259 Antenna Ground Circuit
This test is run every 300 milliseconds.

The DRR detects an antenna fault.
The radio displays "No XM Signal."
The condition must be corrected.

The DTC clears after 100 malfunction free ignition cycles.
Test Description
2: Early design modules support the mV reading while later design modules support the mA reading.
3: Due to current limiting capabilities in the module, an antenna cable shorted to ground could still show
1200-1800 mV.
DTC B1259
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
With a scan tool, observe the digital radio
antenna in the digital radio receiver (DRR) data 1200-1800
2 list. mV or 42-118
Does the scan tool indicate that the digital radio mA
antenna is within the specified range? Go to Step 3 Go to Step 4
Test the antenna cables for a short to ground.
3 -
Wiring Systems.
1. Disconnect the antenna cables from the

4 DRR. 4.5-5.5 V
2. Measure the voltage from the center
conductor of the inboard antenna connector
on the DRR to one of the case screws.
Test the antenna cables for an open or a high
5 -
Inspect for poor connections at the DRR. Refer to
6 Connections and Connector Repairs in Wiring -
Systems.
Replace the DRR. Refer to Control Module
7 -
Inspect for poor connections at the digital radio
antenna. Refer to Testing for Intermittent
8 Conditions and Poor Connections and -
Replace the digital radio antenna. Refer to
9 Antenna Replacement - Digital Radio. -
DTCs.
supporting text.
DTC B1780
Circuit Description
Each time the ignition cycles from OFF to ON, the radio receives VIN data over the class 2 communication
circuit. If the VIN data in the radio memory matches the VIN data the radio receives over the class 2
communication circuit, the radio will operate normally.
DTC Descriptor
DTC B1780 Seat Motor 4 Circuit

The DTC is run when the radio is turned from OFF to ON.
Battery voltage is between 9-16 volts.
Installing a radio from another vehicle or installing a new body control module (BCM) and not entering the
correct VIN information with the scan tool.
The radio does not function. The radio displays "LOC".
When installing a radio from another vehicle of the same platform, clear the VIN data using the scan tool.
Installing a new BCM setup properly with the correct VIN for that vehicle.
The DTC status will turn to history when the above criteria is met. The scan tool can now clear the history DTC
or the scan tool will clear automatically after 100 consecutive fault free ignition cycles.
Test Description
2: Clear all DTCs and radio theft information. Cycle the ignition in order for the radio to learn the VIN.
3: Clear all DTCs after the repair procedure is complete.
DTC B1780
Step Action Yes No
1
Vehicle in Vehicle
3. With the scan tool clear the radio theft
2 information.
Does the DTC Reset? Go to Step 3 System OK

SYMPTOMS - ENTERTAINMENT
IMPORTANT: 1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC

Information, before using the Symptom Tables in order to verify that all of
the following conditions are true:

system functions. Refer to Radio/Audio System Description and
Operation.
Inspect for aftermarket devices which may affect the operation of the Radio/Audio System. Refer to
Inspect for easily accessible or visible system components for obvious damage or conditions which may
cause the symptom.
Intermittent
Symptom List
Radio Poor Reception

Digital Radio Poor or No Reception
Audio Distortion - One or More Speakers
Audio Too Loud at Low Settings
Radio Controls Inoperative - Rear Seat
Rear Seat Audio Power Indicator Always On
Tape Player Weak, Slow, or Garbled Output
Steering Wheel Controls Inoperative
Tailgate Audio Controls Inoperative
Speakers Inoperative - One or More
Video Entertainment System Troubleshooting Hints
Radio Audio Inoperative at Rear Seat Audio (RSA) Control
AUDIO SYSTEM TROUBLESHOOTING HINTS
Many conditions that affect radio operation may be corrected without removing the radio from the car. Verify
the condition, and follow the diagnostic procedures in order to isolate and correct the condition. In order to
properly diagnose any audio system problems, ensure that you have a fully charged battery.
Preliminary Inspections
Tools Required
J 39916-A CD and Cassette Diagnostic Audio Kit
IMPORTANT: When testing the audio system for poor reception or noise, the vehicle
should be outside away from metal buildings and utility lines, with the
hood and rear compartment closed.
Inspect for any aftermarket equipment that may have been installed on the vehicle. If aftermarket
equipment is found, disconnect the equipment and verify that the audio noise is still present.
Verify that the antenna connector and the antenna coaxial cable are clean and tight.
For reception concerns, first determine if the customer is within the listening area of the stations they are
attempting to receive.
Stations at the lower end of the FM band are more susceptible to audio noises than stations at the higher
end.
If the noise is only from one speaker, inspect for the following items before speaker replacement:
Isolate the noise using the J 39916-A .
Inspect the speaker connections in order to ensure they are clean and tight. Refer to Testing for
Inspect for a loose or incorrectly installed speaker or surrounding trim. Loose trim may cause a
buzz or flutter which sounds like a malfunctioning speaker.
Ignition noise on the FM band may be an indication of an ignition system problem.
Verify that all vehicle grounds are clean, tight, and free of corrosion.
Inspect the rear defogger grid lines for large breaks or dark spots.
Inspect the connections at the radio antenna module, if equipped, in order to ensure that they are clean
and tight.
Compare the customers vehicle to another of similar model and audio system in order to determine if the
condition is abnormal.
Identifying Concerns
1. In order to isolate the source of the noise/poor reception, identify the ignition switch position that the
concern is most noticeable:
1. Turn the ignition switch to the accessory position.
2. Turn ON the radio.
3. Seek up 88 to 108 FM then 550 to 1600 AM.
4. Record the number of valid radio stations where the tuner stops.
5. Repeat these steps with the ignition ON, and the engine OFF, then repeat the steps again with the
engine running.
2. Return the ignition switch to the position that the concern was most noticeable.
3. Remove the fuses or circuit breakers, one at a time, until the noise has been eliminated.
4. Identify what systems or components are powered by the fuse.
5. Reinstall all fuses and circuit breakers.
6. Disconnect the components powered by the fuse, one at a time, until the concern has been eliminated.
Corrective Action
Inspect the ground integrity of the component or system causing the noise.
Malfunctioning and marginal components such as relays and solenoids may cause noise and/or poor
reception.
Always use a braided ground strap when applying additional grounds and keep the ground strap as short
as possible.
If the noise source is found to be coming from the vehicle harness:
Route the antenna cable separately from the wire harness that is emitting the noise.
Use aluminum or nickel tape in order to shield the antenna cable. Try variations of the following
repairs:
Try adding only aluminum or nickel tape before adding a ground strap to the tape.
Wrap a ground strap 360 degrees around the tape, securing the other end of the strap to
chassis ground.
IMPORTANT: When installing suppression devices, signal wires such as sensor and
communication circuits should not be suppressed. Battery and ignition
voltage circuits are the best choices for suppressing.
Capacitors work best on switch pops and low frequency noise.

Filters work best on high frequency whines and static.
After adding any suppression device, inspect all of the vehicle systems, including those not related to the
audio system, for proper operation and function.
Whenever possible, make a test harness that includes filters or capacitors. Always inspect the
effectiveness and operation before permanent installation.
If an audible pop is caused due to operating a switch, perform the following repairs as necessary:
Add a capacitor across the contacts of the switch.
Add a capacitor from the battery positive voltage (B+) side of the switch to chassis ground.
Add a capacitor from the ground side of the switch to chassis ground.
Use the following available noise suppression devices:
220 micro farad (50 volt) capacitor GM P/N 1227895
This works well for ignition system related noise.
0.47 micro farad capacitor GM P/N 1227894
This works well for switches and relays.
Feed through capacitor GM P/N 477371
This works well for high current situations.
Filter package GM P/N 1224205
This works well for low current situations.
Fuel pump suppressor GM P/N 25027405

21 inch braided ground strap GM P/N 8910791
19 inch braided ground strap GM P/N 6286800
10.5 inch braided ground strap GM P/N 6287160
8.5 inch braided ground strap GM P/N 12091511
Generator Whine Concerns
1. Inspect the ground terminal and cable for high resistance.

2. Inspect the generator and brackets for loose or coated mounting bolts.
3. Verify that the ground straps between the engine and the frame are clean and tight.
4. If the noise is still present, inspect the charging system for proper operation. Refer to Diagnostic System
Check - Vehicle in Vehicle DTC Information.
5. Install a filter GM P/N 1224205 in the battery voltage feed circuit to the radio.
6. If the noise is not eliminated, install the filter in each following variation:
Install the filter with the single wire side toward the radio and the ground wire attached to chassis
ground.
Remove the ground to the filter.
Reverse the filter so that the two-wire side is toward the radio with the ground wire attached to
chassis ground.
Remove the ground from the filter.
7. If the filter GM P/N 1224205 causes a delay when turning the radio ON or OFF, or other problems,
remove the filter and install a 0.47 micro farad capacitor to chassis ground.
8. Before reassembling the vehicle, remove any unneeded filters.
9. Test the functionality of all the vehicle systems, including those not related to the audio system, for
proper operation and function.
RADIO POOR RECEPTION
Diagnostic System Check - Entertainment System
Always perform the Radio/Audio System Diagnostic System Check before proceeding with these diagnostic
procedures. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information.
Using a Test Antenna
Use a test mast antenna to quickly check for poor vehicle antenna operation. Unplug antenna lead-in connector
from radio receiver and plug a test antenna into radio. Make sure the test antenna base is grounded to the
vehicle chassis and keep hands off the mast. Check radio reception in an area away from electrical
interferences. Tune to several weak and strong AM and FM stations. If the radio reception improved, the
problem exists with the vehicle antenna and/or lead-in cable. If the reception is still poor, refer to Audio System
Troubleshooting Hints.
Antenna Ground Test
IMPORTANT: Always zero out the DMM before taking a resistance measurement in order to
ensure an accurate reading.

2. Disconnect the antenna lead-in connector from the radio receiver.
3. Measure the resistance from the negative battery cable to the coaxial cable, outer conductor, connector.
4. The resistance measured should be 0.20 ohms or less.
5. Test the following when the resistance is greater than 0.20 ohms.
Base of the antenna for a poor connection to body ground.
The coaxial cable interconnects for a poor connection or corrosion.
Test for an open or high resistance from the battery negative cable to the body. Refer to Circuit
6. After finding and correcting the condition, operate the system in order to verify the repair.
Antenna Coaxial Cable Testing
Use the appropriate chart and diagram to test the antenna coaxial cable resistances for the antenna system on the
vehicle. Refer to the table when testing the antenna and/or lead-in cable.
Fig. 25: Identifying Mast Antenna System Components

1 Negative Battery Cable
2 Coaxial Cable Conductor - Radio End
3 Coaxial Cable Metal Outer Shield - Radio End
4 Coaxial Cable Metal Outer Shield - Antenna End
5 Coaxial Cable Conductor - Antenna End
6 Antenna Base
7 Antenna Mast
8 Antenna Coaxial Cable

Ohmmeter Probes At Points Resistance Measured In Ohms
1 and 3 Less than 0.2
1 and 2 Infinite
1 and 5 Infinite
1 and 7 Infinite
2 and 3 Infinite
2 and 4 Infinite
2 and 6 Infinite
3 and 5 Infinite
3 and 7 Infinite
1. Measure the resistance from the coax center conductor to antenna mast, ohmmeter probes at points 2 and
7.
2. Total resistance from end to end of center conductor-ohmmeter probes at points 2 and 5:
RG-58/RG-59 type cable - less than 0.20 ohms per foot
RG-62/RG-62M type cable - less than 3.5 ohms per foot
3. When checking the resistance, cautiously wiggle the lead-in tip and cable. Refer to Testing for
4. Replace the antenna and/or lead-in cable when the above readings are not obtained. Refer to Antenna
Cable Replacement for service procedure.
Power Type Antennas
The following chart and diagram show ohmmeter readings which should be obtained.
Fig. 26: Power Antenna System

1 Top Antenna Mast Section
2 Middle Antenna Mast Section
3 Antenna Metal Housing Case
4 Body Ground
5 Antenna Lead-in Connector, Outer
6 Antenna Lead-in Connector, Inner
7 Lower Antenna Mast Section

Ohmmeter Probes At Points Resistance Measured In Ohms
1 and 4 Infinite
2 and 4 Infinite
7 and 4 Infinite
Refer to the table when testing the power antenna.

2. Measure the resistance at the points specified in the table.
3. With the ohmmeter probes fastened to each point, wiggle the separate mast section and antenna housing
case.
4. The resistance readings specified in the table should always be obtained. Test and/or replace the
following when the resistance readings are out of specification.
Replace antenna mast section.
Test the ground for an open or high resistance. Refer to Circuit Testing andWiring Repairs in
Wiring Systems.
5. After finding and correcting the antenna condition, make sure the antenna lead-in connector is corrosion
free and properly fastened.
6. Operate the system in order to verify the repair.
Windshield Type Antennas
Inspect the antenna connector wire at base of windshield. Make sure the wire is not pinched or broken and is
fully seated into the lead-in receptacle.
Inspect dipole wires within the windshield for breaks. Use the figure and table for the mast antenna as a guide to
test for continuity within the antenna coaxial cable. Repair or replace any portion of the coaxial cable that does
not meet the resistance measurements. If test antenna indicates radio is OK and lead-in checks fine, the
windshield may need to be replaced. A defective windshield antenna results in loss of sensitivity, particularly
on AM.
Fig. 27: Windshield Antenna System


1 Antenna Coaxial Lead-in Connector
2 Radio Chassis
3 Window Antenna Grid, Front or Rear
4 Window Glass, Front or Rear
5 Antenna Module
6 Antenna Coaxial Lead-in Connector
Rear Defogger Antenna System
IMPORTANT: The following information lists the most probable cause of the concern to the
least probable cause followed by the appropriate test for that condition. If the
test leads to the replacement of a component, always inspect for a poor
connection before proceeding with the replacement. Refer to Testing for
Intermittent Conditions and Poor Connections and Connector Repairs in Wiring
Systems.
This antenna system uses the existing rear defogger grid as an antenna. Using the defogger as an antenna
requires the circuitry in the radio antenna module to decouple the RF from the DC heater current.
Perform the Antenna System Test and test the antenna coax cable prior to performing the following tests.
1. The radio antenna module is not grounded properly. The module grounding screws should be clean and
tight. Measure the resistance from the antenna module base plate to a good ground. Resistance should be
0.20 ohms or less. Find and correct the condition if the resistance is out of specification.
2. The antenna relay coil supply voltage circuit to the radio antenna module is open or shorted to ground.
Test the antenna relay coil supply voltage circuit for an open or short to ground. Refer to Circuit Testing
3. Defective radio antenna module. Replace the radio antenna module.
4. No antenna relay coil supply voltage output from the radio. Disconnect the radio antenna module
connector. Turn ON the radio and measure the voltage from the antenna relay coil supply voltage circuit
of the radio to a good ground. Voltage measured should be near 12 volts. If no voltage is measured,
replace the radio. Refer to Radio Replacement for service procedure.
5. If noise is present when the rear defogger is on, inspect the rear defogger grid for breaks. Repair as
necessary.
Diversity Antenna System
test leads to the replacement of a component, always inspect for a poor
Systems.
This antenna system uses two antennas to form a diversity system. The primary antenna is part of the rear
window. The primary antenna receives both AM and FM signals. The secondary antenna is located on the
passenger side of the windshield. The secondary antenna receives only FM signals. The radio antenna module
processes the antenna reception signals and phase aligns them to create one strong signal.
Perform the Antenna System Test and test the antenna coax cable prior to performing the following tests.
1. The radio antenna module is not grounded properly. The module grounding screws should be clean and
tight. Measure the resistance from the antenna module base plate to a good ground. Resistance should be
0.20 ohms or less. Find and correct the condition if the resistance is out of specification.
2. The antenna enable signal circuit to the radio antenna module is open or shorted to ground. Test the
antenna enable signal circuit for an open or short to ground. Refer to Circuit Testing and Wiring
3. The FM composite signal circuit to the radio antenna module is open or shorted to ground. Test the FM
composite signal circuit for an open or short to ground. Refer to Circuit Testing and Wiring Repairs in
Wiring Systems.
4. Improper retention of the antenna cable in the floating retainer. Poor or no connection with the radio will
result when the radio is installed if the antenna cable is not properly attached in the floating retainer.
Inspect the antenna cable for movement in the floating retainer. Replace the antenna cable if movement is
found. Refer to Antenna Cable Replacement for service procedure.
5. Defective radio antenna module. Replace radio antenna module.
6. No FM composite signal voltage output from the radio. Disconnect the radio antenna module connector.
Turn ON the radio and tune the radio to the FM band. Measure the voltage from the FM composite signal
circuit of the radio antenna module to a good ground. Voltage measured should be near 8 volts. If no
voltage is measured, replace the radio. Refer to Radio Replacement for service procedure.
DIGITAL RADIO POOR OR NO RECEPTION
Digital Radio Poor or No Reception

Did you perform the Diagnostic System Check Go to
- Vehicle? Diagnostic
System Check -
1 -
Vehicle in
Vehicle DTC
1. Make sure the vehicle is outside in an
area with an unobstructed view of the
southern sky.
2 OFF. -
4. Tune the radio to satellite channel 1.
Is the reception clear? Go to Step 3 Go to Step 5

Tune the radio to several other satellite Go to Audio
channels. System
3 -
Is the reception clear? Troubleshooting
Hints Go to Step 4
Contact XM at 1-800-556-3600 to verify
customer account status or possible network
4 -
problems.
Contact XM at 1-800-556-3600 to verify
5 possible network problems. -
With a scan tool, observe the digital radio
1200-1800
antenna in the digital radio receiver data list.
6 mV or 42-
Does the scan tool indicate that the digital radio
118 mA
antenna is within the specified range? Go to Step 10 Go to Step 7
1. Disconnect the antenna cables from the
digital radio receiver.
2. Measure the voltage from the center
conductor of the inboard antenna
7 connector on the digital radio receiver to 4.5-5.5 V
one of the case screws.

Test the antenna cables for an open, short, or
high resistance. Refer to Testing for
Replace the antenna cable.
9 -
receiver (DRR). Refer to Testing for
antenna. Refer to Testing for Intermittent
11 Conditions and Poor Connections in Wiring -
Systems.
Replace the DRR. Refer to Control Module
References in Computer/Integrating Systems
12 -
Replace the digital radio antenna. Refer to
13 Antenna Replacement - Digital Radio. -
14 Operate the system in order to verify the repair. -
AUDIO DISTORTION - ONE OR MORE SPEAKERS
Audio Distortion - One or More Speakers

Step Action Yes No
Schematic Reference: Radio/Audio System Schematics and Video System Schematics
Connector End View Reference: Entertainment Connector End Views
DEFINITION: This table is used for vehicles equipped with an audio amplifier.
1
Vehicle in Vehicle
3. Adjust the fade and balance controls to mid
2 range. Go to Testing for
4. Insert the tape or CD from the J 39916-A CD Intermittent
and Cassette Diagnostic Audio Kit. Conditions and
Poor Connections
Can audio distortion be heard from any speaker? Go to Step 3 in Wiring Systems
Test the appropriate speaker output circuits between
the radio and the audio amplifier for an open or high
Is the vehicle equipped with rear seat entertainment
4
(U32) ? Go to Step 5 Go to Step 6
Test the video entertainment circuits:
Remote playback device

Left and right audio circuits
Remote playback device common audio circuit
5 For the following:
An open
A short to ground
A short to B+

Wiring Systems.
of the speaker. Refer to Testing for Intermittent
Replace the speaker. Refer to Speaker Replacement
7 Reference. -
8
AUDIO TOO LOUD AT LOW SETTINGS
Audio Too Loud at Low Settings

Step Action Yes No
1
Vehicle in Vehicle
3. Insert the tape or CD from the J 39916-A CD and
2 Cassette Diagnostic Audio Kit. Go to Testing for
4. Adjust the volume to the lowest setting that can Intermittent
be heard. Conditions and
Poor Connections
Is the audio too loud for the lowest setting? Go to Step 3 in Wiring Systems
3. With a scan tool, observe the Amplifier
3 parameter in the System Configuration data list.
Does the scan tool indicate that the Amplifier is Not

Present? Go to Step 5 Go to Step 4
Compare the volume to a similar vehicle with the same
4 audio system.
Are both vehicles the same? System OK Go to Step 7
Test the amplifier present signal circuit for an open or
5 high resistance. Refer to Circuit Testing and Wiring
2. Disconnect the audio amplifier connector. Refer
to Amplifier Replacement.
3. Connect a 3-amp fused jumper between the
6 amplifier present signal circuit of the audio
amplifier and a good ground.
Does the scan tool indicate that the Amplifier is

Present? Go to Step 8 Go to Step 7
of the radio. Refer to Testing for Intermittent
of the audio amplifier. Refer to Testing for
9
Replace the audio amplifier. Refer to Amplifier
10 Replacement.
11
RADIO CONTROLS INOPERATIVE - REAR SEAT
Radio Controls Inoperative - Rear Seat

DEFINITION: With the radio operating normally, the volume greatly increases when the rear seat audio
(RSA) power button is pressed ON.
Vehicle? Diagnostic
System Check -
1 -
Vehicle in
Vehicle DTC
OFF.
3. Adjust the fade and balance controls to Go to Testing
2 mid range. - for
4. Press the power button on the rear seat Intermittent
audio (RSA) controller. Conditions and
Poor
Does the volume increase greatly when the RSA Connections in
power button is pressed ON? Go to Step 3 Wiring Systems
2. Remove the radio. Refer to Radio
Replacement.
OFF.
3 12 V
5. Press the power button on the RSA
controller.
6. Measure the voltage from the RSA enable
circuit of the radio to ground.

connector of the radio. Refer to Testing for
4 -
Systems.
5 Is the vehicle equipped with an audio amplifier? - Go to Step 7 Go to Step 8
6 -
connector C1 of the audio amplifier. Refer to
7 -
Systems.
Test the RSA enable circuit between the RSA
8 controller and the radio for an open or for a short -
to ground. Refer to Circuit Testing and Wiring
connector of the RSA controller. Refer to
9 -
Systems.
Replace the RSA controller. Refer to Audio
Control Replacement - Second Seat (Aztek) or
10 Audio Control Replacement - Second Seat -
(Rendezvous).
11 -
REAR SEAT AUDIO POWER INDICATOR ALWAYS ON
Rear Seat Audio Power Indicator Always On

Step Action Yes No
1
Vehicle in Vehicle
3. Press the rear seat audio (RSA) control power
2 button ON and then OFF. Go to Testing for
4. Observe the indicator after pressing the power Intermittent
button OFF. Conditions and
Poor Connections
Is the power indicator illuminated? Go to Step 3 in Wiring Systems
Test the RSA enable circuit of the RSA control for a
short to voltage. Refer to Circuit Testing and to
3
of the RSA control. Refer to Testing for Intermittent
4 Conditions and Poor Connections and to Connector
Replace the RSA control. Refer to Audio Control
5 Replacement - Second Seat (Aztek) or Audio
Control Replacement - Second Seat (Rendezvous).
6
TAPE PLAYER WEAK, SLOW, OR GARBLED OUTPUT
Tape Player Weak, Slow, or Garbled Output

Step Action Yes No
1
Vehicle in Vehicle
Use the J 39916-A CD and Cassette Diagnostic Audio
2 Kit in order to perform the motor speed test.
Is the cassette motor speed correct? Go to Step 3 Go to Step 4
Use the J 39916-A in order to clean the cassette player.
3
4
5
STEERING WHEEL CONTROLS INOPERATIVE
Steering Wheel Controls Inoperative

Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
OFF.
Go to Testing
2. Turn ON the radio. for
2 3. Operate all of the steering wheel control - Intermittent
(SWC) buttons. Conditions and
Poor
Do all of the steering wheel control buttons Connections in
operate properly? Wiring Systems Go to Step 3
CAUTION:
Refer to SIR Caution in Cautions and
Notices.
1. Disable the SIR. Refer to SIR Disabling

and Enabling Zone 3 in SIR.
2. Disconnect the SWC connector.
OFF.
5. Measure the voltage from the supply
voltage circuit of the remote radio control
to ground.

1. Measure the resistance from the remote
radio control supply voltage circuit of the
SWC to the steering wheel controls signal
circuit of the SWC.
2. Press the following steering wheel control
buttons and record the resistance values: 1270 ohms
Volume Up 1564 ohms
Volume Down 1912 ohms
2387 ohms
4 Play
3102 ohms
Mute 4282 ohms
Seek Up 6652 ohms
Seek Down
13,632 ohms
AM/FM
Pre-Set
Do the recorded resistances measure near the

specified values? Go to Step 6 Go to Step 7
Test the remote radio control supply voltage
circuit between the SWC harness connector and
the radio for an open, for a high resistance, or for
5 -
a short. Refer to Circuit Testing and to Wiring
1. Disconnect the radio connector. Refer to
Radio Replacement.
2. Test the steering wheel controls signal
circuit between the SWC harness
connector and the radio connector for an
open, for a high resistance, or for a short.
6 Refer to Circuit Testing and to Wiring -

connector of the SWC. Refer to Testing for
7 -
Connections and to Connector Repairs in
Wiring Systems.
8 -
Connections and to Connector Repairs in
Wiring Systems.
Replace the SWC switch. Refer to Steering
Wheel Control Switch Assembly Replacement
9 -
in Steering Wheel and Column.
10 -
11 -
TAILGATE AUDIO CONTROLS INOPERATIVE
Tailgate Audio Controls Inoperative

Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
OFF.
Go to Testing
2. Turn ON the radio. for
3. Operate all of the tailgate audio control Intermittent
buttons. Conditions and
Poor
2 -
Do all of the tailgate audio control buttons Connections in
operate properly? Wiring Systems Go to Step 3
2. Disconnect the tailgate audio controls
connector. Refer to Audio Control
Replacement - Rear Quarter for service
procedure.
3 OFF. 9.5 V
5. Measure the voltage from the remote radio
control supply voltage circuit of the radio
to a good ground.

1. Measure the resistance from the remote
radio control supply voltage circuit of the
tailgate audio controls and the steering
wheel controls signal circuit of the tailgate
audio controls.
2. Press the following tailgate audio control
buttons and record the resistance values: 1270 ohms
Volume Up
1564 ohms
1912 ohms
Volume Down
2387 ohms
4
Play 3102 ohms
Mute 4282 ohms
6652 ohms
Seek Up
13,632 ohms
Seek Down
AM/FM
Pre-Set
Do the recorded resistances measure near the

circuit between the tailgate audio controls
harness connector and the radio for an open,
5 -
high resistance or short. Refer to Circuit
1. Disconnect the radio connector. Refer to
Radio Replacement for service
procedure.
2. Test the steering wheel controls signal
circuit between the tailgate audio controls
6 harness connector and the radio connector -
for an open, high resistance or short. Refer
to Circuit Testing and Wiring Repairs in
Wiring Systems.

connector of the tailgate audio controls. Refer to
7 -
Systems.
8 -
Systems.
Replace the tailgate audio controls. Refer to
Audio Control Replacement - Rear Quarter
9 -
for service procedure.
10 -
11 -
SPEAKERS INOPERATIVE - ONE OR MORE
Diagnostic System Check - Entertainment System
Always perform the Entertainment System Diagnostic System Check before proceeding with these diagnostic
procedures. Refer to Diagnostic System Check - Vehicle in Vehicle DTC Information.
All Speakers Inoperative

list leads to the replacement of a component, always inspect for a poor
Systems.
With RPO U96
1. Speaker output shorted-Test all speaker outputs for a short. Refer to Circuit Testing and Wiring Repairs
in Wiring Systems.
2. Defective radio-Replace the radio. Refer to Radio Replacement.
With RPO UQ3
1. Battery positive voltage circuit to the amplifier open-Test the battery positive voltage circuit to the
amplifier for an open. Refer to Circuit Testing and Wiring Repairs in Wiring Systems.
2. Low level audio signal circuit shorted-Test all low level audio signal circuits for a short to ground or
short to voltage. Refer to Circuit Testing and Wiring Repairs in Wiring Systems.
3. Radio ON signal circuit open or shorted to ground-Test the radio ON signal circuit for an open or short to
ground. Refer to Circuit Testing and Wiring Repairs in Wiring Systems.
4. Entertainment and comfort serial data circuit shorted to voltage-Test the entertainment and comfort serial
data circuit for a short to voltage. Refer to Circuit Testing and Wiring Repairs in Wiring Systems.
5. No low level audio output from the radio-Test for any AC voltage between the left front low level audio
signal circuits at the amplifier harness connector, disconnected with the radio volume adjusted to 50
percent. If no AC voltage is present, replace the radio. Refer to Radio Replacement.
6. No audio output from the amplifier-Replace the amplifier. Refer to Amplifier Replacement.
One Speaker Inoperative
least probable cause. If the list leads to the replacement of a component,
always inspect for a poor connection before proceeding with replacement.
Refer to Testing for Intermittent Conditions and Poor Connections and
With RPO U96
1. Speaker output open-Test the appropriate speaker output circuits for an open. Refer to Circuit Testing
2. No audio output from the radio-Test for any AC voltage between the appropriate speaker output circuits
at the speaker harness connector, disconnected with the radio volume adjusted to an audible level. If AC
voltage is present, replace the speaker. Refer to Speaker Replacement Reference. If no AC voltage is
present, replace the radio. Refer to Radio Replacement.
With RPO UQ3
1. Speaker output circuit from amplifier open or shorted-Test the appropriate speaker output circuits for an
open or short. Refer to Circuit Testing and Wiring Repairs in Wiring Systems.
2. Low level audio circuit open-Test the appropriate low level audio circuit for an open. Refer to Circuit
3. No low level audio output from the radio-Test for any AC voltage between the appropriate low level
audio signal circuits at the amplifier harness connector, disconnected with the radio volume adjusted to an
audible level. If no AC voltage is present, replace the radio. Refer to Radio Replacement.
4. No audio output from the amplifier-Test for any AC voltage between the appropriate speaker output
circuits at the speaker harness connector, disconnected with the radio volume adjusted to an audible level.
If AC voltage is present, replace the speaker. Refer to Speaker Replacement Reference. If no AC
voltage is present, replace the amplifier. Refer to Amplifier Replacement.
All Speakers on One Channel Inoperative Only on Digital Radio
Systems.
1. Right or left audio signal circuit open or shorted-Test all audio signal circuits for an open or short. Refer
to Circuit Testing and Wiring Repairs in Wiring Systems.
2. No audio output from the digital radio receiver-Replace the digital radio receiver. Refer to Receiver
Replacement - Digital Radio.
All Speakers Inoperative Only on Digital Radio
Systems.
1. Right or left audio signal circuit shorted to battery positive voltage-Test all audio signal circuits for a
short to battery positive voltage. Refer to Circuit Testing and Wiring Repairs in Wiring Systems.
2. No audio output from the digital radio receiver-Replace the digital radio receiver. Refer to Receiver
Replacement - Digital Radio.
Speakers - Reduced Volume
least probable cause. If the list leads to the replacement of a component,
always inspect for a poor connection before proceeding with replacement.
Refer to Testing for Intermittent Conditions and Poor Connections and
With RPO U96
1. Speaker output circuit high resistance-Test the appropriate speaker output circuits for high resistance.
Refer to Circuit Testing and Wiring Repairs in Wiring Systems.
2. Defective speaker-Replace the appropriate speaker. Refer to Speaker Replacement Reference.
With RPO UQ3
1. Speaker output circuit high resistance-Test the appropriate speaker output circuits for high resistance.
Refer to Circuit Testing and Wiring Repairs in Wiring Systems.
2. Low level audio circuit open-Test the appropriate low level audio circuit for an open. Refer to Circuit
3. Defective speaker-Replace the appropriate speaker. Refer to Speaker Replacement Reference.
VIDEO ENTERTAINMENT SYSTEM TROUBLESHOOTING HINTS
Schematic Reference: Video System Schematics
Many conditions that affect video system operation may be corrected without removing the radio, the
digital video disc (DVD) player or the video entertainment overhead console from the vehicle. Make sure
to understand all features of system operation before beginning the diagnosis of the system. Verify the
condition and follow the diagnostic procedures in order to isolate and correct the condition.
Be sure the vehicle battery is fully charged before beginning video entertainment system diagnosis.
Video or Audio Distortion
The manufacturing process for producing DVD's does not have the same quality control processes in place that
compact disk manufacturing does. If there are video or audio quality problems with an individual DVD, try
playing that disk in another DVD player. If the quality is poor for both players, return the disk to the place of
purchase and request an exchange. If the quality problem is only seen in one of the players, examine the disk for
scratches dirt or smudges and attempt to clean the disk with one of the disk cleaning systems that are
commercially available.
Video or audio distortion during auxiliary playback can often be attributed to the DC to AC inverter that is used
to power the auxiliary device. The power inverters tend to introduce noisy signals into the vehicle electrical
system.
Video Entertainment System Wireless Headphone Inoperative
least probable cause followed by the appropriate test for that condition.
1. Volume control on the wireless headphone set is turned all the way down. Adjust the volume control on
the headphones.
2. Dead batteries in the wireless headphone set. Turn on power to the headphone set. If the headset indicator
does not turn on, replace the batteries in the headset as needed.
3. Faulty headphone set. Test the operation of the system using a known good headphone set. If operation is
OK, replace the vehicle headphone set.
Video Entertainment System Remote Control Inoperative
The buttons on the video remote control do not operate the video disc player but the buttons on the video disc
player operate normally.
least probable cause followed by the appropriate test for that condition.
1. Dead batteries in the video remote control. Replace the dead batteries.
2. Faulty remote control. Test the operation of the system using a known good remote control. If operation
is OK, replace the remote control.
RADIO AUDIO INOPERATIVE AT REAR SEAT AUDIO (RSA) CONTROL
Radio Audio Inoperative at Rear Seat Audio (RSA) Control

DEFINITION: The rear seat audio (RSA) does not provide audio controls when using the headphones.
The RSA power button indicator does not illuminate.
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
OFF.
3. Install the headphones. Go to Testing
2 - for
4. Press the power button on the RSA Intermittent
control. Conditions and
5. Operate all of the RSA control buttons. Poor
Connections in
Do all the RSA controls operate properly? Wiring Systems Go to Step 3
2. Remove the RSA control. Refer to Audio
Control Replacement - Second Seat
(Aztek) or Audio Control Replacement -
Second Seat (Rendezvous).
3 OFF. 9.5 V
control supply voltage circuit of the RSA
control to ground.

Test the ground circuit of the RSA control for an
open or high resistance. Refer to Circuit
4 Testing and to Wiring Repairs in Wiring -
Systems.
circuit for an open or for a short to ground. Refer
5 to Circuit Testing and to Wiring Repairs in -
Wiring Systems.
OFF.
control signal circuit of the RSA control to
ground.
4. Press the following RSA control buttons 2.5 V
and record the voltage values: 2.0 V
4.0 V
6 Seek Up
3.5 V
Seek Down 3.0 V
AM/FM 4.5 V
Tape/CD
PSET
PWR
Do the recorded voltages measure near the

Inspect for a poor connections at the harness
7 Connections and to Wiring Repairs in Wiring -
Systems.
2. Remove the radio. Refer to Radio
Replacement.
OFF.
control signal circuit of the radio to 2.5 V
ground. 2.0 V
6. Press the following RSA control buttons 4.0 V
8
and record the voltage values: 3.5 V
Seek Up 3.0 V
4.5 V
Seek Down
AM/FM
Tape/CD
PSET
PWR
Do the recorded voltages measure near the

connector of the RSA control. Refer to Testing
9 -
Connections and to Wiring Repairs in Wiring
Systems.
10 -
Test the remote radio control signal circuit for an
open or for a short to ground. Refer to Circuit
11 Testing and to Wiring Repairs in Wiring -
Systems.
Did you correct the condition? Go to Step 13 -
Replace the RSA control. Refer to Audio
12 Control Replacement - Second Seat (Aztek) or -
Audio Control Replacement - Second Seat
(Rendezvous).
13 -
RADIO SETUP
IMPORTANT: The Radio Setup option does not contain a submenu. Radio Setup will
configure the following systems:
Steering wheel controls

Learn VIN
DTCs
Class 2 radio messages
The radio setup procedure will also clear the following messages:
CAL
CAL ERROR
CALIBRATE
To setup a new radio for the vehicle, perform a VIN Relearn, located in the Special Functions section on the
scan tool. Cycle the ignition when complete.
If the radio is not properly setup, the radio will display a locked message (LOC) or Calibrate.
Radio Tuner Calibration
IMPORTANT: The Country Code option does not contain a submenu. Country Code sets the
point of sale, or origin, in the radio in order to calibrate the tuner for the
country that the vehicle will be used in.
To calibrate the radio, select COUNTRY CODE under the Special Functions menu on the scan tool.
Radio Chime Volume Selection
IMPORTANT: The Loud Chime Volume option and Chime Level option does not contain a
submenu. This selection is used for setting the volume when the radio is
replaced.
To set the chime volume, select CHIME SETTINGS under the Special Functions screen and follow correct
menu headings.
DIGITAL RADIO RECEIVER SETUP

IMPORTANT: The digital radio receiver setup option does not contain a submenu. Digital
radio receiver setup will configure the following systems:
DTCs
GMLAN and class 2 radio messages
To setup the digital radio receiver, complete the setup procedure under the Special Functions menu of the scan
tool, then cycle ignition.
XM Activation
IMPORTANT: After replacement of an XM receiver, call XM radio to deactivate the receiver

that has been removed from the vehicle and activate the new XM radio receiver.
The vehicle must be parked in view of a satellite within 24 hours after an
activation call.
1. Turn the radio ON, tune to the XM channel 0, and record the radio ID. The radio ID will be needed for
activation of the new receiver.
2. Call XM radio at 1-800-556-3600 to deactivate the faulty receiver and activate the new receiver.
3. Park the vehicle outside in an area with an unobstructed view of the southern sky.
4. Leave the vehicle outside with the ignition switch in the ACC position and the radio on for 30 minutes to
activate XM service.
5. Once activated, the radio will receive the remaining XM channels.
SPEAKER REPLACEMENT REFERENCE
Speaker Replacement Reference

Component Repair Instruction
Front Lower Speaker Refer to Speaker Replacement - Front Lower
Front Upper Speaker Refer to Speaker Replacement - Front Upper
Rear Door Speaker Refer to Speaker Replacement - Rear Door
Rear Speaker Refer to Speaker Replacement - Rear (Aztek)
REPAIR INSTRUCTIONS
RADIO REPLACEMENT
Removal Procedure
Fig. 28: Identifying Radio Screws
1. Remove the instrument accessory panel trim plate. Refer to Trim Plate Replacement - Instrument
Panel (I/P) Accessory or to Trim Plate Bezel Replacement - Instrument Panel (I/P) Cluster (Aztek)
or Trim Plate Bezel Replacement - Instrument Panel (I/P) Cluster (Rendezvous) in Instrument Panel,
Gages and Console.
2. Remove the radio screws.
Fig. 29: View Of Radio Electrical/Audio/Coaxial Electrical Connectors
3. Pull the radio away from the instrument panel (I/P).

4. Disconnect the electrical/audio electrical connectors from the radio.
5. Disconnect the coaxial cable connector from the radio.
6. Remove the radio.
Fig. 30: View Of Radio Electrical/Audio/Coaxial Electrical Connectors
1. Connect the coaxial cable connector to the radio.

2. Connect the electrical/audio connectors to the radio.
3. Install the radio to the I/P.
IMPORTANT: If the radio locator tab is difficult to align to the I/P locator opening, pull
the radio toward you and reposition the antenna cable.
Align the radio control locator tab to the I/P locator hole while carefully pressing the radio into the I/P
until fully seated.
Fig. 31: Identifying Radio Screws
4. Install the radio screws.
Tighten: Tighten the radio screws to 2.5 N.m (22 lb in).
5. Install the I/P accessory trim plate. Refer to Trim Plate Replacement - Instrument Panel (I/P)
Accessory or to Trim Plate Bezel Replacement - Instrument Panel (I/P) Cluster (Aztek) or Trim
Plate Bezel Replacement - Instrument Panel (I/P) Cluster (Rendezvous) in Instrument Panel, Gages
and Console.
6. Perform the radio set-up procedure. Refer to Radio Setup.
RECEIVER REPLACEMENT - DIGITAL RADIO
Removal Procedure
IMPORTANT: Do not exchange digital radio receivers between vehicles. Exchanging

digital receivers between vehicles will activate the digital radio Theftlock.
"XM Theftlock" will be displayed.
1. Remove the I/P compartment. Refer to Compartment Replacement - Instrument Panel (I/P) in
Fig. 32: View Of Radio Wiring Harness

2. Remove the receiver bracket nuts.

3. Remove the receiver from the bracket.
4. Disengage the electrical connector and the antenna connectors from the XM radio receiver.
Fig. 33: Identifying XM Digital Radio Receiver
5. Remove the XM digital radio receiver from the vehicle.
Fig. 34: View Of Radio Wiring Harness
1. Install the XM digital radio receiver to the receiver bracket.
2. Install the radio receiver nuts.
Tighten: Tighten the nuts to 4 N.m (35 lb in).

Fig. 35: Identifying XM Digital Radio Receiver
3. Connect the electrical connector and the antenna connectors to the XM radio receiver.
4. Install the I/P compartment. Refer to Compartment Replacement - Instrument Panel (I/P) in
5. Perform the setup procedure for the digital radio receiver. Refer to Digital Radio Receiver Setup.
AMPLIFIER REPLACEMENT
Removal Procedure
1. Remove the left instrument panel (IP) insulator. Refer to Closeout/Insulator Panel Replacement - Left
in Instrument Panel, Gages, and Console.
Fig. 36: Locating Amplifier

2. Push in the retaining tab to release the amplifier.

3. Slide the amplifier out of the bracket.
5. Remove the amplifier from the vehicle.
1. Connect the electrical connectors to the amplifier.

Fig. 37: Locating Amplifier
2. Align the pins on the amplifier to the slots on the bracket.

3. Slide the amplifier forward until the lock tab is seated.
4. Install the left IP insulator. Refer to Closeout/Insulator Panel Replacement - Left in Instrument Panel,
Gages, and Console
ANTENNA REPLACEMENT - DIGITAL RADIO
Removal Procedure
Fig. 38: View Of Antenna Base Cable Connectors
1. Remove the headliner. Refer to Headliner Replacement (Rendezvous) in Interior Trim.

2. Disconnect the antenna cables from the antenna base cable connectors.
Fig. 39: Identifying Antenna Base Bolt
3. Remove the antenna base bolt.

Fig. 40: Antenna Base & Cable Connectors
4. Disengage the retainers at the inside of the roof.

Fig. 41: View Of Antenna Base Assembly
5. Remove the antenna base assembly.
Fig. 42: Antenna Base & Cable Connectors
1. Route the antenna base cables through the roof opening.

Fig. 43: View Of Antenna Base Cable Connectors
2. Install the antenna base to the roof.

Fig. 44: Identifying Antenna Base Bolt
3. Secure the antenna base with the bolt.
4. Connect the antenna cables to the antenna base cable connectors.

5. Install the headliner. Refer to Headliner Replacement (Rendezvous) in Interior Trim.
ANTENNA CABLE REPLACEMENT
Removal Procedure
IMPORTANT: These procedures are applicable to both of the antenna cables in this
vehicle.
1. Remove the radio. Refer to Radio Replacement.

2. Remove the sunshade. Refer to Sunshade Replacement in Interior Trim.
3. Remove the sunshade anchor. Refer to Sunshade Anchor Replacement in Interior Trim.
4. Remove the trim panel from the right cowl side. Refer to Trim Panel Replacement - Cowl Side in
Interior Trim.
5. Remove the garnish molding from the windshield. Refer to Garnish Molding Replacement -
Windshield Pillar in Interior Trim.
Fig. 45: Locating Antenna Cable Extension To Roof Retaining Bolt
6. Remove the bolt that secures the antenna cable extension to the roof. This bolt is located under the right
front corner of the headliner.
Fig. 46: Identifying Antenna Cable To Instrument Panel Carrier
7. Remove the antenna cable from the instrument panel carrier.

Fig. 47: Identifying Antenna Cable/Antenna Cable Extension
8. Remove the following components from the vehicle:

The antenna cable
The antenna cable extension
Fig. 48: Identifying Antenna Cable/Antenna Cable Extension
1. Install the following components to the vehicle:

The antenna cable
The antenna cable extension

Fig. 49: Identifying Antenna Cable To Instrument Panel Carrier
2. Install the antenna cable to the instrument panel carrier.

Fig. 50: Locating Antenna Cable Extension To Roof Retaining Bolt
3. Install the bolt which secures the antenna cable extension to the roof.
4. Install the trim panel at the right cowl side. Refer to Trim Panel Replacement - Cowl Side in Interior
Trim.
5. Install the garnish molding to the windshield. Refer to Garnish Molding Replacement - Windshield
Pillar in Interior Trim.
6. Install the sunshade anchor. Refer to Sunshade Anchor Replacement in Interior Trim.
7. Install the sunshade. Refer to Sunshade Replacement in Interior Trim.
8. Install the radio. Refer to Radio Replacement.
COAXIAL CABLE REPLACEMENT - DIGITAL RADIO
Removal Procedure
Fig. 51: View Of Antenna Cable

1. Remove the headliner. Refer to Headliner Replacement (Rendezvous) in Interior Trim.

2. Disconnect the antenna cable from the antenna base cable connector.
3. Remove the antenna cable retainer clips.
Fig. 52: Locating Cable Connectors Inside Of Instrument Panel (I/P)
4. Open the right side end cap from the instrument panel (I/P) to disconnect the cable connectors.
5. Disconnect the antenna cable from the digital radio receiver.
6. Remove the antenna cable retainers from the receiver bracket.
7. Remove the antenna cable.
Fig. 53: View Of Antenna Cable
1. Install the antenna cable retainers to the receiver bracket.

2. Connect the antenna cable to the digital radio receiver.
Fig. 54: Locating Cable Connectors Inside Of Instrument Panel (I/P)
3. Install the cable connectors to the right side end cap on the I/P.
4. Install the right rear compartment trim panel.
Fig. 55: View Of Antenna Base Assembly
5. Install the antenna cable retainer clips.

6. Connect the antenna cable to the antenna base cable connector.
7. Install the headliner. Refer to Headliner Replacement (Rendezvous) in Interior Trim.
SPEAKER REPLACEMENT - FRONT LOWER
Removal Procedure
Trim Panel Replacement - Side Front Door (Rendezvous) in Doors.
2. Remove the front door water deflector. Refer to Water Deflector Replacement - Front Door in Doors.
3. Remove the speaker screws.
4. Disconnect the wire harness from the speaker.
Fig. 56: View Of Speaker - Door
5. Remove the speaker.
1. Connect the wire harness to the speaker.
2. Install the speaker screws.
Tighten: Tighten the screws to 3.2 N.m (28 lb in)
3. Install the front door water deflector. Refer to Water Deflector Replacement - Front Door in Doors.
Panel Replacement - Side Front Door (Rendezvous) in Doors.
SPEAKER REPLACEMENT - FRONT UPPER
Removal Procedure
Fig. 58: View Of Speaker Components - Front Upper
1. Remove the front door trim panel assembly in order to expose the speaker. Refer to Trim Panel
Replacement - Side Front Door (Aztek) or Trim Panel Replacement - Side Front Door
(Rendezvous) in Doors.
2. Remove the speaker screws.
3. Disconnect the wire harness from the speaker.
Fig. 59: View Of Speaker Components - Front Upper
1. Install the speaker to the door trim panel assembly.
Tighten: Tighten the speaker screws to 3.2 N.m 28 lb in).
2. Connect the wire harness to the speaker.

3. Install the trim panel assembly to the front door. Refer to Trim Panel Replacement - Side Front Door
(Aztek) or Trim Panel Replacement - Side Front Door (Rendezvous) in Doors.
SPEAKER REPLACEMENT - REAR DOOR
Removal Procedure
Fig. 60: Identifying Rear Door Trim Panel

Panel Replacement - Side Rear Door (Rendezvous) in Doors.
2. Remove the screws from the speaker.
3. Disconnect the electrical connector from the speaker.
4. Remove the speaker from the rear door.
1. Connect the electrical connector to the rear door speaker.

Fig. 63: Identifying Rear Door Trim Panel
2. Align the speaker to the rear door and install the screws.
Tighten: Tighten the speaker screws to 3.2 N.m (28 lb in).
Panel Replacement - Side Rear Door (Rendezvous) in Doors.
SPEAKER REPLACEMENT - REAR (AZTEK)
Removal Procedure
1. Remove the rear quarter trim. Refer to Trim Panel Replacement - Rear Quarter Lower (Aztek) or
Trim Panel Replacement - Rear Quarter Lower (Rendezvous) in Interior Trim.
Fig. 64: View Of Rear Speaker Assembly
2. Remove the speaker bolts.

3. Disconnect the electrical connectors from the speaker.
Fig. 65: View Of Rear Speaker Assembly
1. Connect the electrical connector to the rear radio speaker.

2. Install the rear radio speaker.
3. Install the speaker screws.
4. Install the rear quarter trim. Refer to Trim Panel Replacement - Rear Quarter Lower (Aztek) or Trim
Panel Replacement - Rear Quarter Lower (Rendezvous) in Interior Trim.
AUDIO CONTROL REPLACEMENT - SECOND SEAT (AZTEK)

Removal Procedure
Fig. 66: Locating Second Seat Audio Control

1. Using a flat-bladed tool, gently pry the second seat audio control out from the overhead console.
Fig. 67: Identifying Second Seat Audio Control Electrical Connector
Fig. 68: Identifying Second Seat Audio Control Electrical Connector

2. Align the second seat control to the overhead console.
Fig. 69: Locating Second Seat Audio Control
3. Gently install the second seat control into the overhead console by pushing forward and inward.
AUDIO CONTROL REPLACEMENT - SECOND SEAT (RENDEZVOUS)
Removal Procedure
Fig. 70: View Of Front Armrest
1. Raise the front armrest.

2. Remove 2 screws that secure the rear console trim plate.
Fig. 71: Locating Audio Control Electrical Connectors
3. Pull the trim plate away from the console.

Fig. 72: View Of Second Seat Audio Control
5. Press the back of the audio control to release the control from the trim plate.
6. Remove the second seat audio control.
Fig. 73: View Of Second Seat Audio Control
1. Press the second seat audio control into the rear console trim plate.
2. Connect the electrical connectors to the audio control
Fig. 74: Locating Audio Control Electrical Connectors
3. Press the trim plate onto the center console.

Fig. 75: View Of Front Armrest
4. Install 2 screws that secure the rear console trim plate.

5. Close the front armrest.
AUDIO CONTROL REPLACEMENT - REAR QUARTER
Removal Procedure
1. Remove the trim panel. Refer to Trim Panel Replacement - Rear Quarter Lower (Aztek) or Trim
Panel Replacement - Rear Quarter Lower (Rendezvous) .
Fig. 76: Expanded View Of Rear Cargo Audio Control


3. Remove the screws which retain the rear cargo audio control.
Fig. 77: Identifying Rear Cargo Audio Control
4. Remove the rear cargo audio control from the trim panel.
1. Align the rear cargo audio control to the trim panel.

Fig. 78: Identifying Rear Cargo Audio Control
2. Install the screws.

Fig. 79: Expanded View Of Rear Cargo Audio Control

4. Install the rear trim panel. Refer to Trim Panel Replacement - Rear Quarter Lower (Aztek) or Trim
Panel Replacement - Rear Quarter Lower (Rendezvous) .
DVD PLAYER REPLACEMENT
Removal Procedure
IMPORTANT: Components of the DVD player cannot be serviced separately. Replace as

an assembly.
1. Move the screen to the open position.

Fig. 80: Identifying Rear Screw Cover
2. Open the rear screw cover using a flat-bladed tool.

Fig. 81: Locating 4 Retaining Bolts
3. Remove the 4 retaining bolts.

4. With one hand holding the DVD player assembly, pull down the retainer from the bracket.
Fig. 82: View Of DVD Player Assembly
5. Allow the DVD player assembly to come to rest on the hook.

Fig. 83: Identifying DVD Player Wiring Harness & Connector
IMPORTANT: Observe the routing of the wiring harness (2).
6. Disconnect the wire connector (1).

7. Slightly lift up the DVD player assembly so that the hook can be removed from its resting position.
8. Remove the DVD player from the vehicle.
Fig. 84: View Of DVD Player Assembly
1. Install the DVD player hook (1) into the hook opening.
Fig. 85: Identifying DVD Player Wiring Harness & Connector
IMPORTANT: Ensure the harness is routed to the right side of the large plastic pin (2) as
shown.
2. Connect the wire connector (1) to the DVD player assembly.

3. Install the harness retainer to the panel.
4. Swing the rear part of the assembly to the headliner so that the retainer is seated.
Fig. 86: Locating 4 Retaining Bolts
5. Install the rear retaining bolts.

Fig. 87: Locating DVD Player Front Retaining Bolts
6. Move the screen to the open position.

7. Install the front retaining bolts (2).
8. Close the rear screw cover.

RADIO/AUDIO SYSTEM DESCRIPTION AND OPERATION
The entertainment system on this vehicle is configured with either a base or an uplevel system. Both the base
and uplevel systems contain a radio, antenna, speakers, and on some vehicle lines an audio amplifier and/or rear
seat audio (RSA).
The uplevel system differs from the base level system by providing the customer with enhanced audio system
features. Some of those features may include the radio data system (RDS), extended range speakers, an audio
amplifier, or an uplevel amplifier, RSA, video entertainment system and a remote playback device.
The following list shows the radios available for this vehicle:
Uplevel Radio (U1N) - AM/FM Stereo, Cassette with Programmable Equalizer and RDS
Uplevel Radio (U1P ) - AM/FM Stereo, CD with Programmable Equalizer and RDS
Uplevel Radio (U1Q) - AM/FM Stereo, Cassette, CD with Programmable Equalizer, Rear Seat Audio
(RSA) System and RDS
Uplevel Radio (UC6) - AM/FM, Integral Multi Disc CD Changer (IMCX) with Programmable Equalizer,
Rear Seat Audio (RSA) System and RDS
Radio Features
Controls Uplevel U1N Uplevel U1P Uplevel U1Q Uplevel IMDX UC6
Push the
Power Push the PWR/VOL knob to turn the radio ON. VOLUME/PWR knob
to turn the radio ON.
The volume is
adjusted by rotating
Volume The volume is adjusted by rotating the PWR/VOL knob.
the VOLUME/PWR
knob.
Press the SCV button (U1N, U1P, U1Q) or AUTO VOL (UC6).
Speed Compensated Adjust the SCV by pressing the SCV or AUTO VOL until the desired volume
Volume (SCV) setting appears on the display. Three settings are available; LOW, MEDIUM, and
HIGH.
Turn the
Tune Turn the TUNE/SELECT/RCL knob. TUNE/RCL/P-TYPE
knob.
Seek Momentarily press the SEEK/SCAN button.
Scan Hold the SEEK/SCAN button at least 2 seconds until a beep is heard.
Presets Six AM, Six FM1 and Six FM2
Preset Saving Press and hold desired button until an audible beep is heard.
Preset Scan Press and hold SEEK at least 4 seconds until a double beep is heard.
Press and hold the HR or MN button until an audible beep indicates the time set
mode has been entered. Once the beep is heard, the time can be set by tapping each
Set Clock
button to incrementally adjust the time. Holding down each button will rapidly
change the time.
Recall Push the TUNE/SELECT/RCL knob. Push the

TUNE/RCL/P-TYPE
knob.
Steering Wheel and/or Tailgate Audio Controls only.
Mute Press the MUTE button to silence the system. Press it again, or any other radio
button, to restore the sound.
Push the AUDIO
Press the BAL/FADE button to select and adjust w/SELECT knob to select and
Fade or Balance
knob. adjust w/AUDIO
knob.
Push the AUDIO
Bass, Treble or Press the TONE button to select and adjust w/SELECT knob to select and
Midrange knob. adjust w/AUDIO
knob.
Programmable Press the AUTO EQ or EQ button to choose and program preset bass and treble
Equalizer equalization settings.
Cassette Features
Uplevel IMDX
Controls Uplevel U1N Uplevel U1P Uplevel U1Q UC6
Play/Stop TAPE AUX button CD TAPE button
Eject Eject button Eject button
Forward Preset button 1 Preset button 1
Side Preset button 2 Preset button 2
Dolby Sound Preset button 6 Preset button 6
Reverse Preset button 4 Preset button 4
Auto Reverse Yes Yes
N/A N/A
Press the up or down
arrow on
Previous arrow on
SEEK/SCAN
SEEK/SCAN button.
button.
arrow on
Next arrow on
SEEK/SCAN
SEEK/SCAN button.
button.
Compact Disc Features

Controls Uplevel U1N Uplevel U1P Uplevel U1Q Uplevel IMDX UC6
Play/Stop CD AUX button CD TAPE button CD AUX button
Eject Press the EJECT button. Press the CD button.
Press the arrow on
Forward Press preset button 1
the FWD button.
N/A
Press the arrow on
Reverse Press preset button 4
the REV button.
Press the down arrow on SEEK/SCAN Press the left arrow

button. on SEEK/SCAN
Previous
button.
Press the right arrow
Press the up arrow on SEEK/SCAN
Next on SEEK/SCAN
button.
button.
Press the RPT
Repeat N/A
button.
Random Press preset button 3 or RDM button.
Each item in the list below represents topics covered in detail below.
AM/FM Reception
Antenna
Audio Amplifier
Theft Deterrent
Integral Multi Disc CD Changer (IMDX)
Remote Playback Device
Rear Seat Audio (RSA)
Radio Data System (RDS)
Steering Wheel and Tailgate Audio Controls
Tape/CD Player Error Messages
AM/FM Reception
Radio Signal
The radio signal is sent from a broadcast station and is then received by an antenna. The strength of the signal
received depends on the following:
The power output, or wattage of the broadcasting station

The location of the vehicle, or receiver relative to the broadcast tower.
Obstacles between the tower and the receiver
Atmospheric conditions
What band, AM or FM the station is broadcasting
Type of antenna and the ground plane
AM Reception
The AM band has a lower frequency range than the FM band. These longer wavelengths:
Bend around obstacles

Follow the curvature of the earth
May reflect off the ionosphere-skip
The AM frequencies have longer range due to the ground wave. The ground wave follows the curvature of the
earth and is affected by its conductivity. Greater conductivity equates to less signal loss thus transmission over
water is better than over land. The AM band has a range of 80-320 km (50-200 miles).
FM Reception
The shorter wavelengths of the higher frequency FM band:
Reflect off obstacles

Are absorbed by the ground
Penetrate the ionosphere
Broadcasts in the FM band are limited to "line of sight" reception which is typically 40 km (25 miles). Even
when out of a direct line of sight, the signal may be reflected into areas that would be in a "shadow" otherwise.
Factors which affect the line of sight include:
Height of the broadcast antenna

Height of the receiving antenna
Terrain and buildings in the broadcast path
XM Reception
XM satellite radio provides digital radio reception. The XM signal is broadcast from two satellites and, where
necessary, terrestrial repeaters. The high power satellites allow the antenna to receive the XM signal even when
foliage and other partial obstructions block the antennas view of the satellite. Terrestrial repeaters are used in
dense urban areas. These repeaters will receive the satellite signal and re-broadcast them at much higher power
levels in order to ensure reception in areas with densely packed tall buildings.
Antenna
The antenna is comprised of a very thin metal grid which is permanently affixed to the top center of the
windshield. If the antenna becomes damaged, the windshield must be replaced.
Audio Amplifier
The purpose of an amplifier is to increase the power of a voltage or current signal. The output signal of an
amplifier may consist of the same frequencies as the input signal or it may consist of only a portion of the
frequencies of the input signal, as in the case of a subwoofer or a mid-range amplifier.
When the radio is turned on, the radio sends a voltage signal to the audio amplifier via the amplifier control
circuit. The amplifier present signal circuit allows the radio to recognize that an amplifier is present. Once the
radio detects the amplifier, the radio will output low level audio signals to the amplifier. With the amplifier
enabled, the signal that drives the speakers is now amplified.
Theft Deterrent
The "Theftlock" theft deterrent system is a feature on all base and uplevel radios. There is no need to program a
security code into the radio as in past model years. The theft deterrent system now utilizes class 2 serial data to
determine if the radio is in the appropriate vehicle. Each time the radio receives the "run" power mode message,
it compares the VIN information it has stored to the VIN information received from a module on the class 2
serial data circuit responsible for transmitting that information. If a mis-match occurs, the radio display will
indicate to the user the radio is locked. Once this takes place, a DTC will set, the radio will not respond to any
button presses and become inoperative. The 2 scenarios able to cause this condition are:
A radio is installed from another vehicle

A module which communicates on the class 2 serial data circuit which supplies VIN information to the
radio is replaced and not properly setup with the correct VIN information for that vehicle
The only way to unlock the radio is by using a scan tool. Always refer to the table in this section to diagnose the
"Theftlock" DTC for further information.
Integral Multi Disc CD Changer (IMDX [Uplevel])
The Integral Multi Disc CD Changer has the capability of storing and playing up to 6 compact discs. The
Integral Multi Disc CD Changer has a shock-absorbing system. Only under extreme operating temperatures or
severe shock or vibration should the compact disc player skip or mute. If the customer travels an abnormally
rough road, a skip condition may be normal. Test drive the vehicle on a normal road with a known good CD. If
the condition is still present, replace the radio.
The use of CD lens cleaner discs is not advised, due to the risk of contaminating the lens of the CD optics with
lubricants internal to the CD mechanism.
Single Disc Loading
To operate the Integral Multi Disc CD Changer in the single play mode, press and release the LOAD button and
wait for the LED to the right of the disc door to turn green. Load a disc when the LED turns green. If the radio
is ON, the disc will begin to play automatically. If the radio is OFF, press the LOAD button for the disc to play.
Multi Disc Loading
To operate the Multi Disc CD Changer in the multi disc mode, press and hold the LOAD button for 2 seconds.
An audible beep will be heard and the LED to the right of the disc door begins to flash. The radio will also
display the message "INSERT CD". When the LED stops flashing and turns green, load a disc. Once the disc is
loaded the LED begins to flash again. The radio will also display the message "MULTI LOAD" to indicate the
multi load mode has been initiated and the changer will begin accepting a disc for however many empty slots
there may be. When the LED stops flashing and turns green, load another disc. Repeat this procedure to
continue loading discs. The CD changer holds up to 6 discs.
When the changer is full, 6 discs are loaded, and the LOAD button is pressed, 3 audible beeps are heard and the
message "CHANGER FULL" is displayed.
To play one of the CD's, press one of the preset buttons.
Removing CDs
Use the eject button, the button labeled CD to remove a disc or discs.
Perform the following to eject:
To remove a single disc, press and release the CD button. The message "REMOVE CD" is displayed.
To remove multiple discs, press and release the CD button for 2 seconds. An audible beep is heard and
the LED to the right of the disc door begins to flash indicating a disc is being ejected. The message
"REMOVE CD" is displayed.
IMPORTANT: Pressing the CD button repeatedly, causes the radio receiver's 25 second eject
timer to reset at each press of the button. This will cause the receiver to not
eject a disc until the 25 second time period has elapsed.
Song List Feature
The Multi Disc CD Changer has a feature called Song List. This feature is capable of saving 20 track selections
to a play list.
To save tracks into Song List, perform the following :
1. The disc player must be ON with at least one disc loaded.

2. The message "S-LIST" should not be displayed on the radio. If "S-LIST" is present, press the SONG
LIST button to turn it OFF.
3. Select the desired disc by pressing the numbered push-button and then use the SEEK right arrow button
to locate the track that you want to save. The track will begin to play.
4. Press and hold the SONG LIST button for 2 or more seconds to save the track into memory. When SONG
LIST is pressed an audible beep is heard. After 2 seconds of pressing SONG LIST continually, 2 audible
beeps will sound to confirm that the track has been saved. The message "TRACK ADD" is displayed.
5. Repeat steps 3 and 4 for saving other selections.
To play the Song List press the SONG LIST button. One beep is heard and "S-LIST" appears on the display.
The recorded tracks will begin to play in the order that they were saved.
To delete tracks from the Song List.
1. The disc player must be on.

2. Press the SONG LIST button. The message "S-LIST" appears on the display.
3. Press the SEEK button to locate desired track to be deleted.
4. Press and hold the SONG LIST button for 2 seconds. After 2 seconds, 2 beeps are heard confirming that
the track has been deleted. The message "TRACK DELETE" is displayed.
To delete the entire Song List.
1. The disc player must be on.

2. Press the SONG LIST button. The message "S-LIST" appears on display.
3. Press the SEEK button to locate desired track to be deleted.
4. Press and hold the SONG LIST button for more than 4 seconds. After 2 seconds, a beep will be heard
followed by 2 beeps and a final beep after 4 seconds. The message "S-LIST EMPTY" appears on the
display.
Remote Playback Device
The remote playback device is either installed at the factory or in some instances it is dealer installed. There are
3 types of remote playback devices, a multi disc remote CD changer, a single disc CD player and a cassette
player. All 3 devices have a wiring harness which plugs into the back of the radio. The radio controls and
communicates with the remote playback device through an entertainment and comfort (E & C) or Class 2
communication circuit.
Remote CD Changer (CDX)
The remote CD changer allows for multiple compact disks to be played continuously without having to
manually change compact discs. Normal size discs may be played using the slots supplied in the magazine. The
magazine must first be loaded with discs before it can played. To load CDs, insert the CDs from bottom to top,
placing the discs in the magazine label side up. If a disc is loaded label side down, the disc will not play and an
error will occur. Care should be used to align and insert the disc into one disc tray only. Repeat this procedure
for loading all of the discs in the magazine. Once the discs are loaded into the magazine, push the magazine into
the changer in the direction of the arrow marked on the magazine. When the CD magazine is loaded, the
changer will begin checking for discs in the magazine. This will continue for up to one and a half minutes,
depending on the number of discs loaded. To eject the magazine from the player, push the CD changer door.
The door will open. Then press the eject button. NOTICE: If the CD magazine fails to eject after the EJECT
button has been pressed, do not attempt to pry the magazine from the CD changer. Whenever a CD magazine
with discs is loaded in the changer, the CD changer symbol will appear on the radio display. If the CD changer
is checking the magazine for CDs, the CD symbol will flash on the display until the changer is ready to play.
Rear Seat Audio (RSA)
The rear seat audio (RSA) control allows the rear seat passengers to listen to a different music source than the
front seat passengers. For example, the rear seat passengers may listen to the cassette or CD through
headphones while the driver listens to the radio through the front speakers. The rear seat passengers have
control of the volume for each headphone. The primary radio controls always override the RSA controls.
The remote radio control supply voltage circuit, from the radio, supplies voltage to the RSA control when the
radio is ON. When the RSA control is turned ON, a voltage signal is sent back to the radio on the RSA enable
circuit. After receiving the voltage signal, the radio is enabled to control RSA audio functions. The radio
controls RSA functions through the remote radio control signal (RUI2) circuit, some vehicles may use a class 2
communication circuit. When the radio receives the enable signal the rear speakers are muted. This allows the
user to listen to the audio through the headphones.
Seek (SEEK)
Press the SEEK button in order to seek to the next higher or lower station. The sound will mute when seeking
another frequency. The SEEK button is inactive when the front radio is in the SEEK mode.
Power (PWR)
Press the PWR push button in order to turn the rear seat audio system ON or OFF. The rear speakers mute when
the power is turned ON. The rear seat audio functions are operable even when the primary radio power is OFF.
Band Switching (AM/FM)
Press the AM/FM push button in order to select between (AM and FM) or (AM, FM1 and FM2) for radios with
2 FM bands. The selection appears on the display. If the front passengers are already listening to AM-FM, the
rear seat audio controller will not switch between the bands and cannot change the frequency.
Source Switching (TAPE CD)
Press the TAPE CD push button in order to activate the source switching feature. There must be a cassette tape
and/or compact disc in the player.
Preset Program (P.SET PROG)
Press the P.SET PROG button in order to select between pre-programmed station presets. The front passenger
must be listening to something different for the P.SET PROG to operate.
Volume (VOL)
Rotate the volume control in order to increase or decrease the volume. The top VOL knob controls the top
headphone and the bottom VOL knob controls the bottom headphone.
Radio Data System (RDS)
All uplevel audio systems are equipped with technology known as the radio data system (RDS). RDS is a
system that sends data along with the audio of the FM station you are currently tuned to. RDS is a standard that
defines how a FM broadcast station may send digital data along with the audio program. Think of it as a one-
way wireless modem, allowing the broadcaster to send information about his program to your receiver.
RDS data is carried in what is known as a "subcarrier". A subcarrier is a frequency that the FM broadcaster is
authorized to use to send data or other audio programs that are not audible in the main audio program. RDS
information can be used to display program information and to control the radio.
To receive the RDS signal, all that is needed is an FM receiver with a RDS circuit. A special integrated circuit
capable of dealing with the RDS signal is in the RDS circuit and passes it along to the receiver's microprocessor
where it is decoded and acted upon.
RDS Basic Information

RDS functions are provided in the FM broadcast band only.
RDS functions will only work with FM broadcast stations that are broadcasting RDS data.
Not all FM Broadcast stations broadcast RDS data or offer all of the RDS services.
RDS functions may not work properly when reception is weak, reception is of poor quality, or RDS is not
implemented properly by the FM Broadcaster.
In some cases, a radio station broadcasting incorrect information may cause the RDS features of the radio to
appear to work improperly.
Displaying RDS Information
The RDS feature is always on. When tuned to a non-RDS station, the radio will display frequency information
as you would normally expect. When tuned to a RDS station, the radio can operate as follows:
The radio will change from displaying the frequency of the FM station to displaying the call letters of the
station or display the nickname of the station.
Display the type of program.
Display general information such as artist and song title, call in phone numbers, etc.
Viewing and Selecting RDS Information for Display
Press the TUNE knob once for less then 2 seconds when the radio displays the program service (PS) name and
the frequency of the station will be displayed. Press the knob again, and the program type (P-Type) will be
displayed. Pressed again, and the program type (PTY) name will be displayed, if the broadcaster is broadcasting
one. The PTY name is an 8-character name that the broadcaster may use to further identify the type of
programming currently being broadcast. Should you decide that Frequency, P-Type or PTY name is more
desirable to display when tuned to an RDS station than the PS name, press the TUNE knob until the desired
information is displayed, then press and hold for more than 2 seconds. A beep should be heard and the radio
will now display the selected information whenever tuned to an RDS broadcaster. The radio will display
frequency for all non-RDS broadcast stations.
Using RDS Program Types to Tune Radio
Listed are several ways on how to tune your radio using RDS program types.
The radio will now be configured to tune based on RDS data rather than frequency.
A Fast Way to Find a RDS Station In Your Listening Area
1. Press the PROG TYPE or P-TYPE button, the radio displays the current P-Type to search for.
2. Rotate the TUNE knob until the radio displays "ANY TYPE". Press the PROG TYPE or P-TYPE button
again and the radio will now seek the first RDS Broadcaster of any kind that it can find in the FM band.
Finding a RDS Station By Specific Program Type

1. Press the PROG TYPE or P-TYPE button, the radio will display the current P-Type to search for.
2. Rotate the TUNE knob until the desired program type is shown in the display.
3. Press the PROG TYPE or P-TYPE button and the radio will now seek the first RDS Broadcaster of the
selected P-Type.
If the radio cannot find the desired P-Type, the radio displays "NONE" and will return to the last station you
were listening to.
Using the INFO Feature
When the INFO icon appears in the radio display, a new text message is available for viewing. These text
messages are from the RDS broadcaster to the listening public and may be general information such as artist
and song title, call in phone numbers, etc.
How to view the INFO message
To view the message when the INFO icon appears, press the INFO button to display the text message. If
you do not press the INFO button again, the text message will automatically be displayed 8 characters at a
time, 3 seconds between updates.
To view the text message faster, press the INFO button for less than 1 second to scroll through the
message at your own speed.
The INFO icon disappears as soon as you press the INFO button. The INFO icon will appear when a new
different message is received.
To view the most recent received message, press the INFO icon at any time even if the icon does not
appear in the display.
Controlling the Radio
RDS can control the radio when data the receiver can use responds to timely information performing the
following:
Interrupt the playback of your cassette or CD for traffic or emergency bulletins.

Search for stations by type of program.
Automatically follow networked programming from transmitter to transmitter as you travel from one
listening area to another.
Set your clock to the time that the RDS broadcast station broadcasts.
Using the RDS Traffic Feature
Some RDS broadcasters may carry traffic information programming to inform you of current traffic conditions
in your listening area and is indicated by the TRAF icon in the radio display. RDS enables the broadcaster to get
this information to you even when you are listening to a tape or compact disc. This feature can be enabled or
disabled by the listener. Press the TRAF button to find a station that claims to carry traffic information. You
may do this even when playing a cassette tape or compact disc. This action will operate in the background
without interrupting the current playback. If the radio is not currently tuned to an RDS traffic station, the radio
will immediately seek an RDS traffic station. If the radio finds an RDS traffic station, the "TRAF" icon will
appear on the radio display as will brackets around the [TRAF] icon. If the radio cannot find an RDS traffic
station after searching through the entire FM band, the radio will display "NO TRAFFIC".
Traffic Interrupt Feature
Whenever the TRAF icon is displayed, the current FM station may also broadcast traffic announcements.
Traffic announcements are reports of the current traffic conditions in the listening area of the tuned FM
broadcasters.
Your radio can interrupt the playback of a cassette or compact disc by use of the traffic interrupt feature. The
traffic interrupt feature is enabled when the TRAF icon is displayed.
If the broadcaster sends out a traffic announcement while you are listening to FM or in the playback mode,
"TRAFFIC" will be displayed on the radio and the audio from the broadcaster will be heard. At the conclusion
of the traffic announcement, the radio will return to the previous playback mode.
During the time the radio displays "TRAFFIC", you can adjust the volume of the traffic announcement. This
will be the volume at which all future traffic announcements will be heard.
You can also interrupt a traffic announcement interrupt by pressing the TRAF button.
RDS Program Type Interrupts
When the program type feature is ON, all program types may be selected as interrupts. Perform the following to
select a program type as an interrupt.

2. Select the program type.
3. Press and hold the program type button, labeled PROG TYPE or P-TYPE, for 2 seconds while the
program type is displayed.
When an interrupt is set, the display shows the program type followed by an asterisk and the brackets around
the [P-TYPE] icon are illuminated.
To turn an interrupt OFF:
1. Select a program type marked as an interrupt.

2. Press and hold the program type button, labeled PROG TYPE or P-TYPE, for 2 seconds. The program
type will be unmarked by turning OFF the asterisk. If no other program type interrupts are set, the
brackets around the [P-TYPE] icon are also turned off.
When a program type interrupt is set, the radio will wait for the current FM RDS station to change its program
type to one of those selected as an interrupt. When the station program type changes to a program type interrupt
setting then the interrupt is activated. If the radio is in a playback mode, an interrupt will cause the radio to
switch to the FM band, display the program type followed by "INT", and adjust the volume to the last active
interrupt volume. If the radio is in the FM mode when an interrupt occurs, only the volume will change. The
radio resumes the mode that was active prior to the interrupt, when an interrupt ends. An interrupt in progress
may be canceled by pressing the program type button or a mode button.
During a national or local emergency, a special program type interrupt message "ALERT!" is displayed. This
special announcement will cancel all other RDS features that are in progress, such as a traffic announcement.
Alternate Frequency (AF) Switching
RDS permits broadcaster's to send information to the radio that allows the radio to automatically switch
frequency to the best quality station in that broadcaster's network.
Since the radio is displaying the broadcaster call letters or nickname, the listener will not see the frequency
during an AF switch unless you have changed the default display to be frequency instead of Program Service
name.
To enable or disable AF switching perform the following:
Press and hold the AM/FM button for 2 seconds or more.

The radio will display AF ON or AF OFF depending on the current condition of AF and a confirmation
beep will be heard.
When AF is enabled and you recall a RDS station stored on preset, the radio determines if the station stored is
of acceptable quality. If not, the radio checks all available AF's for your station. If the radio fails to locate your
program, AF SEARCH will be displayed as the radio scans across the band looking for your program or an
affiliated network. If the radio cannot find the original station or an acceptable alternate frequency NOT
FOUND will be displayed and the radio returns to the original frequency for the preset.
RDS Clock Time
Broadcasters can choose to send clock time information in the RDS data. This information can be used to
update the clock time on the radio. RDS clock time is broadcast once a minute. To set the clock using RDS
clock data perform the following:
Press and hold the HR and MIN buttons together for 2 or more seconds to update the time.
The display will show UPDATED after receiving the broadcasted time data.
If the broadcaster is not broadcasting the time data, the radio will display NO UPDATE and the time
remains unchanged.
Steering Wheel and Tailgate Audio Controls
Some audio functions are available using the steering wheel controls and/or tailgate audio controls. The steering
wheel and tailgate audio controls are actually a resistor network which consists of multiple momentary contact
switches and a series of resistors. The switches and resistor network is arranged so that each switch has a
different resistance value. When a switch is pressed, a voltage drop occurs in the resistor network which
produces a specific voltage value unique to the switch selected. These specific voltage values allow the radio to
identify which switch has been pressed. The radio responds just as if the corresponding radio front panel button
had been pressed.
The radio supplies voltage to the switches via the remote radio control supply voltage circuit, RSA/SWC power.
The specific voltage signal from the switch is returned to the radio on the steering wheel controls signal circuit,
RUI 1.
Tape/CD Player Error Messages
The radio displays an error when any of the following occurs.
The radio will display error codes for the tape player and integral CD player.
The radio will display the following tape player error codes for tight tape, broken tape, and wrapped tape.
If these conditions are detected, the radio will switch to the radio mode and eject the tape. The error code
will be displayed for 5 seconds, followed by the tuner display, then the default.
E10-Tight tape.
E11-Broken tape.
E14-Wrapped tape.
The radio will display the following integral CD player error codes. If one of these problems is detected,
the unit will switch to the radio mode and eject the CD. The display will show TOD, if the unit is OFF, or
display the radio frequency for 5 seconds, then the default, if the unit is on.
E20-Optics focus error, maybe due to moisture.
E21-Optics loss of tracking control, maybe due to blemishes on disc.
E22-Load/Unload motor problem.
E23-Communication problem.
XM Satellite Radio
XM is a national satellite radio service that offers up to 100 coast to coast channels including music, news,
sports, talk and children's programming. XM provides digital quality audio and text information, including song
title and artist name. A service fee is required in order to receive the XM service. For more information, contact
XM at www.xmradio.com or call 1-800-852-9696.
Digital Radio Receiver
The radio controls communicate with the digital radio receiver via the class 2 communication circuit. The
digital radio receiver sends remote radio audio signals to the radio.
Viewing Messages
Press the DISP or RCL button while in XM mode to view various pieces of information related to the current
song or channel. By pressing and releasing the DISP or RCL button, you may view four different categories of
information: Artist Name/Feature, Song/Program Title, Channel Category, and other Additional Information
that may be broadcast on that channel. Additional Information messages may not always be available. If an
Additional Information message is being broadcast on the tuned channel, the INFO icon will appear on the
display. Each of the four information types may have multiple pages of text. To reach a category, press and
release the DISP or RCL button consecutively until the desired type is displayed. If there are multiple pages of
text for the selected information type, the radio will automatically display all the pages for that type at a rate of
approximately one page every three seconds before timing out and returning to the default display. You may
override this feature by pressing the DISP or RCL button to review all of the pages at your own pace.
XM Advisory Messages
Radio Display Message Condition
Updating Updating encryption code
No Signal Loss of signal
Loading XM Acquiring channel audio (after 4 second delay)
CH Off Air Channel not in service
CH Unavail Channel no longer available
No Info Artist Name/Feature not available
No Info Song/Program Title not available
No Info Category name not available
Not Found No channel available for the chosen category
No Info No text/informational message available
XM Locked Theft Lock active
Radio ID Electronic serial number (ESN) channel 0
Radio ID not known (should only be if hardware
Unknown
failure
Chk XMRcvr Hardware failure
Technical Information for MP3 Player (US8)
The US8 radio will play both standard audio CDs and CD-Rs. The CD-Rs may contain standard audio format
(*.cda) or compressed audio in the *.mp3 format.
Customers who make their own music CD-Rs should be aware of the following:
The files can be recorded on a CD-R disc with a maximum capacity of 700 MB.
The MP3 files must be recorded onto the disc in either a fixed bit rate (32 kbps, 40 kbps, 48 kbps, 56
kbps, 64 kbps, 80 kbps, 96 kbps, 112 kbps, 128 kbps, 160 kbps, 192 kbps, 224 kbps, 256 kbps, and 320
kbps), or in a variable bit rate.
Discs recorded in either one session or in multiple sessions will play. Playlists, such as those created with
popular MP3 software, are also supported.
ID3 tag information is available during playback, providing the information was recorded with ID3 tags,
version 1 or version 2. CD text information is not available with the US8 radio.
The radio does not play mixed media CDs (those that contain files in both the *.mp3 and the *.cda
format).
The radio will not play CD-Rs that contain formats of compressed audio other than *.mp3 (such as
*.wma, *.asf, or *.aac).
The radio will support a maximum of 50 folders, 50 playlists, 10 sessions, and 255 files. If the
information on the disc exceeds these numbers, anything over the maximum allowable will be ignored.
Files that are not in the *.mp3 format will not play, but do count toward the maximum number of files.
The files or playlists can be arranged in folders, up to 11 layers deep (folders within folders, within
folders, etc.). Anything more than 11 layers deep will be ignored.
Long names (on files, folders, playlists) or combination of large number of folders and files or playlists
may cause player not to be able to read up to the max numbers of folders, playlists, files, or sessions, due
to memory limitations. Customers are encouraged to keep shorter names and minimize folder depth for
ease of operation.
If these guidelines are not followed, a customer recorded CD may not play. Note that the radio has no ability to
record *.mp3 files or any audio to a CD-R, it has only the ability to read information on a CD-R.
VIDEO ENTERTAINMENT SYSTEM DESCRIPTION AND OPERATION
Rear Seat Entertainment System

Fig. 88: Rear Seat Entertainment System
The rear seat entertainment (RSE) system augments the vehicle's in-dash audio system with:
A Digital Versatile Disc (DVD) player

A video display screen
Two sets of wireless infrared headphones
A remote control and
Stereo audio and video inputs in the overhead console for playing an auxiliary device
DVD Player
Fig. 89: DVD Player

1 Eject Button
2 Enter Button
3 Menu Navigation Buttons
4 DVD Menu Button
5 Video Screen Display Menu Button
6 Play / Pause Button
7 Stop Button
8 Source Button
9 Power Button
The DVD player and the video display screen are located in the overhead console. The DVD player can be
controlled by both the buttons on the DVD player and by the buttons on the remote control. The DVD player
power may be turned on when the ignition is in the run, accessory, or retained accessory power (RAP) power
modes. DVDs are manufactured with different region codes based on the country in which they are sold.
Therefore, the RSE system DVD player is only compatible with the region code where the vehicle is sold. The
DVD region code is printed on the jacket of most DVDs. The DVD player will also play audio CDs. Home
recorded CDs, CD-R or CD-RW formats, will not play in this DVD player.
DVD Player Buttons
The following buttons operate the DVD player.
Eject
Press this button to eject the DVD or CD media.
Enter
Press this button to select items within a menu.
Menu Navigation
Use the arrow keys to navigate through a menu. The up arrow will skip to the next chapter or track; the
down arrow acts as a previous chapter or track access key; the right arrow acts as fast forward, and the
left arrow acts as rewind.
Menu
Press this button to access the DVD menu. This button does not operate with media other than DVD.
Display Menu
Press this button to modify the video screen display characteristics.
Play / Pause
Press this button to turn the DVD player on to play media, pause media, and to toggle between play and
pause of media.
Stop
Press this button to stop play of media in the DVD player.
Source
Press this button to toggle between DVD player and auxiliary source.
Power
Press this button to turn the RSE system power On or Off.
Playing a Disc
To play a disc, gently insert the disc with the label side up, into the loading slot. The DVD player will continue
to load the disc and the player will automatically start if the vehicle ignition is in an enabled power mode. If a
disc is already in the player, press the play/pause button on the face of the DVD player or on the remote control.
Some DVDs will not allow the user to fast forward or skip the copyright or previews. Some DVDs will
automatically begin to play after the previews have finished. If the DVD does not begin to play the main title,
refer to the on-screen instructions, and press play on the DVD player buttons or on the remote control.
Stopping and Resuming Play
To stop a disc, press and release the stop/eject button on the DVD player or the remote control. To resume
playback, press the play/pause button on the DVD player or the remote control. The movie should resume play
from where it was stopped. If the disc has been ejected, or if the stop button has been pressed 2 times, the disc
will resume play at the beginning of the main title.
Ejecting the Disc
Press the eject button on the DVD player to eject the disc.
If a disc is ejected from the DVD player but is not removed, the DVD player will reload the disc within 25 to 30
seconds. The disc will then be stored in the DVD player. The DVD player will not resume play of this disc
automatically upon its reload.
DVD Messages
The following errors may be displayed on the video screen monitor.
Disc Format Error
This message will be displayed if a disc is inserted upside down, the disc is not able to be read, or if the
disc format is not compatible with the DVD player.
Load / Eject Error
This message will be displayed if the disc is not able to properly load or eject.
Disc Play Error
This message will be displayed if the DVD player cannot play the disc. Severely damaged discs will
cause this error.
Region Code Error

This message will be displayed if the region code of the DVD media is not compatible with the DVD
player.
No Disc
This message will be displayed if the play button is pressed and there is no disc in the DVD player.
Fig. 90: Parental Control


1 Auxiliary Inputs
2 Parental Control Button
3 DVD Screen Latch
Parental Control Button
This button is located on the forward part of the DVD console, near the driver of the vehicle. Press this button
while media is playing in the DVD player to freeze the video and mute the audio. The video screen will display
the message Parental Control ON and the power indicator light on the DVD player will flash at one-second
intervals. While in this mode, all other button operations from the remote control and the DVD player, with the
exception of the eject function, will be disabled. The driver will then be able to gain the attention of the rear seat
passengers. Press this button again to restore normal operation of the DVD player. This button may also be used
to turn the DVD power on and automatically resume play of the media within the DVD player if the vehicle is
in an enabled power mode.
Video Screen
To use the video screen, push forward on the release latch and the screen will be free to rotate down. Adjust the
screen's position as desired. The display menu button will allow different screen display modes, such as normal,
full screen, zoom or cinema. When the video screen is not in use, push it up into its latched position.
The DVD player and video screen will continue to operate when the screen is in either the up (closed) or down
(viewing) position. The video screen contains the infrared transmitters for the wireless headphones as well as
the infrared receiver for the remote control. Therefore, if the screen is in the closed position the infrared signals
will not be available for the operation of the headphones and the remote control.
Avoid directly touching the video screen, as damage may occur.
Remote Control
To use the remote control, aim it at the infrared window below the video screen and press the desired remote
control button. Direct sunlight or very bright light may affect the ability of the entertainment system to receive
signals from the remote control. If the remote control does not seem to be working, the batteries may need to be
replaced. Objects blocking the line of sight may affect the function of the remote control.
Remote Control Buttons
DVD Player Power On / Off
Press this button to turn the RSE system power On or Off.
RSERC Illumination
Press this button to turn the remote control backlight ON.
Title
Press this button to return the DVD media to the root menu of the DVD.
Menu
Press this button to access the DVD menu. This button does not operate with media other than DVD.
Display Menu
Press this button to modify the video screen display characteristics.
Return
The return button shall operate only when a DVD is being played and a menu is active. The return
function allows the user to exit the current active menu and return to the previous superior menu.
Enter
Press this button to select items within a menu.
Audio
Pressing this button shall call-up a menu that shall operate only when a DVD is being played. The format
and content of this function is defined by the disc and is dependent on the disc.
Angle
Subtitle
Source
Press this button to toggle between DVD player and auxiliary source.
Fast Forward
Press this button to fast forward the DVD in 5x speed. To stop fast forwarding, press this button again.
This button may not work when the DVD is playing the copyright or the preview.
Fast Reverse
Press this button to fast rewind the DVD in 5x speed. To stop fast rewinding, press this button again. This
button may not work when the DVD is playing the copyright or the preview.
Previous Track/Chapter
Press this button to return to the start of the current track/chapter. Press this button again to backup to the
previous track/chapter. This button may not work when the DVD is playing the copyright material.
Next Track/Chapter
Press this button to advance to the beginning of the next track/chapter. The button may not work when the
DVD is playing copyright material.
Stop
Press this button to stop play of media in the DVD player
Play / Pause
Press this button to turn the DVD player on, to play media, to pause media, and to toggle between play
and pause of media.
Cancel
Pressing this button within 3 seconds of inputting a numeric selection shall clear all numeric inputs.
Numeric Keypad
The RSERC numeric keypad shall provide the operator with the capability of direct chapter / title / track
number selection.
Menu Navigation
Use the arrow keys to navigate through a menu. The up arrow will skip to the next chapter or track; the
down arrow acts as a previous chapter or track access key; the right arrow acts as fast forward, and the
left arrow acts as rewind.
Battery Replacement
To change the batteries, do the following:
1. Remove the battery compartment door located on the bottom of the remote control.
2. Remove the batteries from the compartment.
3. Replace the 2 AA-size batteries in the proper orientation.
If the remote control is to be stored for a long period of time, remove the batteries and keep them in a cool, dry
place. Do not store the remote control in heat or direct sunlight. This could damage the remote control and
would not be covered by your vehicle warranty. Keep the remote control stored in a cool, dry place.
Wireless Headphones
The RSE system includes 2 sets of wireless infrared headphones.
Each set of headphones has an ON/OFF control. To use the headphones activate the ON/OFF control. A red
indicator light will illuminate on the headphones. If the light does not illuminate, the batteries may need to be
replaced. See Battery Replacement in this section for more information. To turn the headphones OFF activate
the ON/OFF control once again.
Each set of headphones has a rotary volume control. To adjust the volume, adjust this control. The headphones
will automatically turn OFF if they lose the infrared signal from the system for approximately 4 minutes in
order to preserve their battery power. The signal may be lost if the system is turned off or if the headphones are
out of range of the infrared signal transmitters that are located below the video display screen.
Battery Replacement
To change the batteries, do the following:
1. Loosen the screw on the battery compartment door located on the LEFT headphone earpiece.
2. Remove the batteries from the compartment.
3. Replace the 2 AAA-size batteries in the proper orientation.
If the headphones are to be stored for a long period of time, remove the batteries and keep them in a cool, dry
place. Do not store the headphones in heat or direct sunlight. This could damage the headphones and would not
be covered by your vehicle warranty. Keep the headphones stored in a cool, dry place.
Stereo RCA Jacks
The RCA jacks are located on the forward portion of the overhead console next to the parental control button.
The RCA jacks allow you to connect audio and video from an auxiliary device such as a camcorder or a video
game player to your RSE system just as you would to a standard television. Standard RCA cables are needed to
connect the auxiliary device to the RCA jacks. The yellow connector transmits video while the red and white
connectors transmit right and left stereo audio respectively. Please refer to the manufacturer's instructions for
proper connection of your auxiliary device.
To use the auxiliary inputs on the RSE system, connect an external auxiliary device to the color-coded RCA
jacks and turn both the auxiliary device and the RSE system power on. If the RSE system had been previously
in the DVD player mode, the user will need to press the SRCE button on the faceplate or remote control to
change to the auxiliary mode. Successive actuations of the SRCE button will toggle the RSE system between
the auxiliary and DVD player modes.
Audio Output
Audio from the RSE system DVD player or auxiliary inputs may be heard through the following possible
sources:
Wireless infrared headphones

Vehicle speakers
Vehicle wired headphone jacks on rear seat audio controller (if equipped)
The RSE system will always transmit the audio signal by infrared to the wireless headphones, if there is audio
available. The RSE system is capable of outputting audio to the vehicle speakers by pressing the CD button on
the vehicle's radio. The RSE system may be selected as an audio source on the radio if the RSE system power is
on. Once the RSE system is selected as an audio source on the radio you may adjust the speaker volume on the
radio to control the volume of the audio to the speakers. If the RSE system power is not on, the RSE system will
not be an available source on the radio head unit. Please refer to the operating instructions for the vehicle radio
for more information on its operation.
The RSE system is capable of outputting audio to the wired headphone jacks on the rear seat audio controller if
the vehicle is so equipped. The RSE system may be selected as an audio source on the Rear Seat Audio
controller if the RSE system power is on. Please refer to the operating instructions for the Rear Seat Audio
Controller for more information on its operation.
Exterior Trim - Aztek & Rendezvous
SPECIFICATIONS

Specification
Front Fascia Screws 2 N.m 18 lb in
Front Wheel Opening Molding Screws 2 N.m 18 lb in
Hood Emblem Nuts 2 N.m 18 lb in
Lift Gate Lower Molding Screws 2 N.m 18 lb in
Lift Gate Upper Molding Screws 2 N.m 18 lb in
Rear Door Body Side Molding Screw 6 N.m 53 lb in
Rear Wheel Opening Molding Screws 2 N.m 18 lb in
Rocker Molding Screw 6 N.m 53 lb in
REPAIR INSTRUCTIONS
EMBLEM/NAMEPLATE REPLACEMENT - DOOR (AZTEK)
Tools Required
J 25070 Heat Gun
Removal Procedure
IMPORTANT: Use the tape for protection and alignment marks for alignment of the new
emblem.
1. Apply tape to the area around the door emblem.

2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface.
3. Apply the heat using a circular motion for about 30 seconds.
NOTE: Refer to Exterior Trim Emblem Removal Notice in Cautions and Notices.
4. Remove the emblem/nameplate from the door surface using a plastic, flat-bladed tool.
Fig. 1: Adhesive Removal Tool
5. Remove all adhesive from the door panel surface and the back of the emblem/nameplate using 3M
scotch brite molding adhesive remover disk 3M P/N 07501 or equivalent.
6. Clean the door surface using varnish makers and painters (VMP) naptha.
Fig. 2: Identifying Location Of Emblem/Nameplate (Aztek)
1. If the location of the emblem/nameplate has not been marked apply tape and use the following
dimensions:
Dimension (a) is 41 mm (1.625 in) from the rear door edge to the emblem/nameplate.
Dimension (b) is 146 mm (5.750 in) from the feature line on the door to the bottom of the
emblem/nameplate.
2. Warm the door surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21C
(70F).
IMPORTANT: Do not touch the adhesive backing of the emblem/nameplate.
3. Remove the backing from the front end of the emblem/nameplate.

4. Press the emblem/nameplate to the door panel surface while continuing to remove the backing.
5. Hand roll the emblem/nameplate to the door panel to ensure proper adhesion.
6. Inspect the emblem/nameplate for bonding.
7. Remove the tape from the area around the door emblem.
EMBLEM/NAMEPLATE REPLACEMENT - DOOR (RENDEZVOUS)
Tools Required
J 25070 Heat Gun
Removal Procedure
Fig. 3: Using J 25070 To Apply Heat

emblem.
1. Apply tape to the area around the door emblem.

2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6.0 in) from the surface.
3. Apply the heat using a circular motion for about 30 seconds.
4. Remove the emblem/nameplate from the door surface using a plastic, flat-bladed tool.

5. Remove all adhesive from the door panel surface and the back of the emblem/nameplate using 3M
scotch brite molding adhesive remover disk 3M P/N 07501 or equivalent.
6. Clean the door surface using varnish makers and painters (VMP) naptha.
Fig. 5: View Of Emblem/Nameplate (Rendezvous)

1. If the location of the emblem/nameplate has not been marked apply tape and use the following
dimensions:
Dimension (a) is 19.5 mm (0.78 in) above the feature line on the door.
Dimension (b) is 68.7 mm (2.7 in) from the front edge of the door.
Fig. 6: Using J 25070 To Apply Heat
2. Warm the door surface with a heat gun J 25070 152 mm (6.0 in) from the surface to a minimum of 21C
(70F).

4. Press the emblem/nameplate to the door panel surface while continuing to remove the backing.
5. Hand roll the emblem/nameplate to the door panel to ensure proper adhesion.
7. Remove the tape from the area around the door emblem.
EMBLEM/NAMEPLATE REPLACEMENT - LIFTGATE (AZTEK)
Tools Required
J 25070 Heat Gun
Removal Procedure
emblem/nameplate.
1. Apply tape to the area around the liftgate emblem/nameplate.

2. Heat the emblem/nameplate, using a heat gun J 25070 152 mm (6 in) from the surface.
Apply the heat using a circular motion for about 30 seconds.
3. Remove the emblem/nameplate from the liftgate surface using a plastic, flat-bladed tool.
4. Remove all adhesive from the liftgate surface and the back of the emblem/nameplate using 3M scotch
brite molding adhesive remover disk 3M P/N 07501 or equivalent.
5. Clean the liftgate surface using Varnish Makers and Painters (VMP) naptha.
1. Mark the tape with the measurement for the proper location of the emblem.
2. Warm the liftgate surface with a heat gun J 25070 152 mm (6 in) from the surface to a minimum of 21C
(70F).
Fig. 8: Clearances For Proper Location Of Emblem (Aztek)

4. Press the emblem/nameplate to the liftgate surface while continuing to remove the backing.
5. Hand roll the emblem/nameplate to the liftgate to ensure proper adhesion.
7. Remove the tape from the area around the liftgate emblem.
EMBLEM/NAMEPLATE REPLACEMENT - LIFTGATE (RENDEZVOUS)
Tools Required
J 25070 Heat Gun
Removal Procedure
1. When replacing an emblem/nameplate do the following:

1. Use tape to protect the mounting surface during removal.
2. Use tape for alignment marks for installation of the emblem/nameplate.
2. To remove an emblem/nameplate, heat the emblem/nameplate using a J 25070 .
3. Apply the heat using a circular motion for about 30 seconds holding the J 25070 approximately 152 mm
(6 in) from the surface.

4. Use a plastic, flat-bladed tool to remove the emblem/nameplate from the panel surface.
5. When replacing, remove all adhesive as follows:
For body panels use a 3M Scotch Brite molding adhesive remover disk 3M P/N 07501 or
equivalent.
For plastic panels use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a 50/50
mixture by volume of isopropyl alcohol and water to remove the adhesive.
IMPORTANT: Apply the emblem/nameplate in an environment that is free from dust or

other dirt that could come into contact with the sticky backing. Foreign
material may cause improper adhesion.
1. Clean the area where the emblem/nameplate will be installed.
Use a lint free cloth and Varnish Makers and Painters (VMP) naphtha or a 50/50 mixture by volume of
isopropyl alcohol and water to clean the area.
2. Dry the area thoroughly.

3. If the location of the emblem/nameplate has not been marked, apply tape and mark the location as shown
below.
Fig. 10: View Of CX Emblem (Rendezvous)
4. For the CX emblem/nameplate install to the following dimensions:

Dimension (a) is 19.05 mm (0.750 in) from the top of the lift gate lower molding to the bottom of
the emblem/nameplate.
Dimension (b) is 53.975 mm (2.125 in) from the side of the emblem/nameplate to the right edge of
the lift gate.
Fig. 11: Installation Measurements Of CXL Emblem (Rendezvous)
5. For the CXL emblem/nameplate install to the following dimensions:

Dimension (a) is 19.05 mm (0.750 in) from the top of the lift gate lower molding to the bottom of
Dimension (b) is 53.975 mm (2.125 in) from the side of the emblem/nameplate to the right edge of
the lift gate.
Fig. 12: Identifying VERSATRAK AWD Emblem/Nameplate Placement (Rendezvous)
6. For the VERSATRAK AWD emblem/nameplate install to the following dimensions:

Dimension (a) is 58.750 mm (2.313 in) from the left edge of the lift gate to the side of the
emblem/nameplate.
Dimension (b) is 19.05 mm (0.750 in) from the top of the lift gate lower molding to the bottom of
7. Heat the mounting surface to approximately 27-41C (80-105F) using the J 25070 , if necessary.
8. Ensure that the temperature of the emblem/nameplate is approximately 29-32C (85-90F).
IMPORTANT: Do not touch the adhesive backing on the emblem/nameplate.
9. Remove the protective liner from the back of the emblem/nameplate.

10. Position the emblem/nameplate to the location marks and press the emblem/nameplate to the mounting
surface.
11. Apply equal pressure along the emblem/nameplate to uniformly bond the item to the mounting surface.
12. Remove the protective tape from the mounting surface.
EMBLEM REPLACEMENT - GRILLE
Removal Procedure
Fig. 13: View Of Back Of Grille Emblem

1. Remove the grille from the front fascia. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille
Replacement (Rendezvous) in Bumpers.
2. Remove the nut from the back of the grille emblem.
Fig. 14: Locating Grille Emblem
3. Remove the emblem from the grille.
Fig. 15: Locating Grille Emblem
1. Position the emblem to the grille.

Fig. 16: View Of Back Of Grille Emblem
2. Install the nut to the grille emblem.
3. Install the grille to the front fascia. Refer to Fascia Grille Replacement (Aztek) or Fascia Grille
Replacement (Rendezvous) in Bumpers.
EMBLEM REPLACEMENT - HOOD
Tools Required
J 25070 Heat Gun
Removal Procedure
Fig. 17: Locating Hood Emblem Mounting Nuts
1. Apply masking tape to the area around the hood emblem to protect the finish.
2. Open the hood.
3. Remove the nuts from the back of the hood emblem.
4. To remove the emblem from the hood, heat the emblem using the J 25070 152 mm (6.0 in) from the
surface.
5. Apply heat in a circular motion for about 30 seconds.
6. Use a plastic, flat bladed tool to lift or remove the emblem from the hood.
7. Remove any adhesive from the hood using a 3M Scotch Brite molding adhesive remover disk P/N
07501 or equivalent.
1. Heat the hood emblem and mounting surface to approximately 21C (70F) using the J 25070 , if
necessary.
IMPORTANT: Apply the emblem/nameplate in an environment that is free from dust or

other dirt that could come into contact with the sticky backing. Foreign
material may cause improper adhesion. Do not touch the adhesive
backing on the emblem/nameplate.
2. Remove the protective liner from the back of the hood emblem.
Fig. 19: Locating Hood Emblem Mounting Nuts

3. Position the hood emblem locating pins to the holes in the hood.
4. Apply equal pressure along the emblem to uniformly bond the emblem to the hood.
5. Install the hood emblem nuts to the hood emblem.
Tighten: Tighten the nuts to 2.0 N.m (18 lb in).
6. Remove the masking tape from the hood.

7. Close the hood.
MOLDING REPLACEMENT - FRONT WHEEL OPENING (AZTEK)
Removal Procedure
1. Remove the front wheel liner. Refer to Front Fender Liner Replacement in Body Front End.
2. Remove the bolts from the corner of the front fascia. Refer to Fascia Replacement - Front Bumper -
Upper (Aztek) or Fascia Replacement - Front Bumper - Upper (Rendezvous) in Bumpers.
Fig. 20: View Of Front Wheel Opening Molding Screws (Aztek)

3. Remove the screws from the front wheel opening molding.

4. Pull the corner of the front fascia outward to access the front retainer on the wheel opening molding.
Fig. 21: Identifying Wheel Opening Molding (Aztek)
5. Use a thin, plastic flat-bladed tool between the fender and the molding to help release the retainers.
Remove the molding from the fender.
Fig. 22: Identifying Wheel Opening Molding (Aztek)
1. Position the molding to the fender.

2. Align the push-in retainers to the holes in the fender.
3. Press the molding to the fender until all of the retainers are fully seated.
Fig. 23: View Of Front Wheel Opening Molding Screws (Aztek)
4. Install the screws to the front wheel opening molding.
5. Install the bolts to the corner of the front fascia. Refer to Fascia Replacement - Front Bumper - Upper
(Aztek) or Fascia Replacement - Front Bumper - Upper (Rendezvous) in Bumpers.
6. Install the front wheel liner. Refer to Front Fender Liner Replacement in Body Front End.
MOLDING REPLACEMENT - FRONT WHEEL OPENING (RENDEZVOUS)
Removal Procedure
Fig. 24: Locating Front Wheel Opening Molding Screws (Rendezvous)

1. Remove the screws from the front wheel opening molding.

Fig. 25: Pulling Outward On Front Fascia (Rendezvous)
2. Remove the screws from the front corner of the fascia.

3. Pull outward on the corner of the front fascia to access the front wheel opening molding retainer.
Fig. 26: Front Wheel Opening Molding (Rendezvous)
4. A thin, plastic flat-bladed tool may be used between the fender and molding to help release the retainers.
Remove the front wheel opening molding from the fender.

Fig. 27: Wheel Opening Molding Retainers (Rendezvous)
5. Remove the wheel opening molding retainers from the molding, if necessary.
Fig. 28: Wheel Opening Molding Retainers (Rendezvous)
1. Install the wheel opening molding retainers to the molding, if removed.

Fig. 29: Front Wheel Opening Molding (Rendezvous)
2. Position the front wheel opening molding to the fender.

3. Align the push-in retainers to the holes in the fender.
4. Press the front wheel opening molding to the fender until all of the retainers are fully seated.
Fig. 30: Locating Front Wheel Opening Molding Screws (Rendezvous)
5. Install the front wheel opening molding screws to the front wheel opening molding.

Fig. 31: Pulling Outward On Front Fascia (Rendezvous)
6. Press the corner of the front fascia to the fender to seat the retainer.
7. Install the screws to the corner of the front fascia.
MOLDING REPLACEMENT - REAR WHEEL OPENING
Removal Procedure
Fig. 32: View Of Rear Wheel Opening Molding
1. Remove the screws from the rear wheel opening molding.

2. Pull the upper edge of the rear wheel opening molding out, to release the retainers.
3. A thin, plastic flat-bladed tool may be used between the molding and the body to help release the wheel
opening molding retainers.
4. Remove the rear wheel opening molding from the vehicle.
Fig. 33: View Of Rear Wheel Opening Molding
1. Position the rear wheel opening molding to the rear quarter panel.
2. Align the wheel opening molding retainers to the holes in the rear quarter panel.
3. Press the molding to the rear quarter panel until all of the retainers are fully seated.
4. Install the wheel opening molding screws.
Tighten: Tighten the wheel opening molding screws to 2 N.m (18 lb in).
MOLDING REPLACEMENT - FRONT DOOR BODY SIDE (AZTEK)
Tools Required
J 25070 Heat Gun
Removal Procedure
Fig. 34: Using J 25070 Heat Gun To Remove Door Side Molding
1. Use a heat gun J 25070 .

Fig. 35: Removing Front Door body Side Molding (Aztek)
2. Use a plastic, flat-bladed tool to remove the upper edge of the front door body side molding from the
surface.
Fig. 36: Locating Front Door body Side Molding Retainers (Aztek)
3. Pull the upper edge of the front door body side molding out, in order to release the retainers.
4. Remove the front door body side molding from the door.
Fig. 37: Drilling Pilot Hole In Center Retainer Pins
5. Drill a small hole into the center of the center retainer pins of the support retainer.
Fig. 38: Installing Screws Into Center Retainer Pin
6. Install a small screw into the hole in the center retainer pin.
Fig. 39: Removing Center Retainer Pin
7. Remove the center retainer pin using small pliers and pulling out the center retainer pin.
Fig. 40: Identifying Front Door Body Side Molding Support
8. Remove the front door body side molding support from the door.
9. Remove all adhesive from the rear door body panel using 3M ScotchBrite molding adhesive remover
disk 3M P/N 07501 or equivalent.
10. Clean the rear door panel surface using Varnish Makers and Painters (VMP) naphtha and allow to air dry.
1. Position the support retainer with the notch down and the retainers to the holes in the door panel.
2. Install in the center pins of the retainers using a small hammer.

Fig. 44: Aligning Front Door Body Side Molding To Retainer Support (Aztek)

4. Position the lower flange of the front door body side molding to the retainer support and align the tab to
the notch in the retainer support.
IMPORTANT: Do not touch the adhesive backing on the molding.
5. Remove the protective liner from the back side of the door body side molding.
6. Position the upper edge of the front door body side molding retainer clips to the holes in the door panel.
7. Install the retainer clips to the door panel by pressing in until fully seated.
8. Install the upper edge of the front door body side molding by applying pressure to the entire length of the
molding starting at the center and working outward to ensure a maximum bond to the door panel.
MOLDING REPLACEMENT - FRONT DOOR BODY SIDE (RENDEZVOUS)
Removal Procedure

Fig. 45: View Of Front Door Body Side Molding (Rendezvous)
2. A thin, plastic flat-bladed tool may be used between the molding and the door to help release the
retainers.
Pull the upper edge of the front door body side molding out, in order to release the retainers.
3. Remove the front door body side molding from the door.
4. Drill a small hole into the center of the center retainer pins of the support retainer.
Fig. 47: Installing Screws Into Center Retainer Pin

Fig. 48: Removing Center Retainer Pin
7. Remove the front door body side molding support from the door.
1. Position the support retainer with the notch down and the retainers to the holes in the door panel.

3. Position the lower flange of the front door body side molding to the retainer support and align the tab to
4. Position the upper edge of the front door body side molding retainer clips to the holes in the door panel.
MOLDING REPLACEMENT - REAR DOOR BODY SIDE (AZTEK)

Tools Required
J 25070 Heat Gun
Removal Procedure
Fig. 52: Locating Rear Door Body Side Molding Rear Edge Screws
2. Remove the screws from the rear edge of the rear door body side molding.
Fig. 53: Using J 25070 Heat Gun To Remove Rear Door Molding

Fig. 54: View Of Rear Door Body Side Molding
4. Use a plastic, flat-bladed tool to remove the upper edge of the rear door body side molding from the
surface.
Fig. 55: Identifying Rear Door Body Side Molding Retainers
5. Pull the upper edge of the rear door body side molding out, to release the retainers.
6. Remove the rear door body side molding from the door.
Fig. 56: Drilling Center Retainer Pin
7. Drill a small hole into the center of the center retainer pins of the lower support retainer.
Fig. 57: Placing Small Screw In Center Retainer Pin
Fig. 58: Removing Center Retainer Pin Using Pliers
Fig. 59: View Of Rear Door Body Side Molding Lower Support
10. Remove the rear door body side molding lower support from the door.
Fig. 60: Drilling Into Center Retainer Pins Of Rear Support Retainer
11. Drill a small hole into the center of the center retainer pins of the rear support retainer.
Fig. 61: Installing Small Screw Into Center Retainer Pin
Fig. 62: Pulling Out Center Retainer Pin
Fig. 63: View Of Rear Door Body Side Molding Rear Support
14. Remove the rear door body side molding rear support from the door.
1. Position the lower support retainer with the notch down and the retainers to the holes in the door panel.
Fig. 66: Installing Center Pins In Retainer

Fig. 67: View Of Rear Door Body Side Molding Rear Support
Fig. 68: Inserting Center Pins In Rear Support Retainer

Fig. 69: Aligning Rear Door Body Side Molding
5. Use a heat gunJ 25070 .

6. Position the lower flange of the rear door body side molding to the retainer support and align the tab to
7. Remove the protective liner from the back side of the door body side molding.
8. Position the upper edge of the rear door body side molding retainer clips to the holes in the door panel.
10. Install the upper edge of the rear door body side molding by applying pressure to the entire length of the
molding starting at the center and working outward to ensure a maximum bond to the door panel.
Fig. 70: Locating Rear Door Body Side Molding Rear Edge Screws
11. Install the screws to the rear edge of the rear door body side molding.
MOLDING REPLACEMENT - REAR DOOR BODY SIDE (RENDEZVOUS)
Removal Procedure

2. Pull the upper edge of the rear door body side molding out, to release the retainers.
3. A thin, plastic flat-bladed tool may be used between the door and the molding to help release the
retainers.
Remove the rear door body side molding from the door.
Fig. 72: Drilling Center Retainer Pin


4. Drill a small hole into the center of the center retainer pins of the lower support retainer.
Fig. 73: Removing Center Retainer Pin Using Pliers

7. Remove the rear door body side molding lower support from the door.
Fig. 76: Installing Center Pins In Retainer

3. Position the lower edge of the molding to the lower door retainer.
4. Align the door molding retainers to the holes in the door.
5. Press the molding to the door until the retainers are fully seated.
MOLDING REPLACEMENT - LIFTGATE UPPER
Removal Procedure
1. Remove the lift gate applique. Refer to Liftgate Applique Replacement in Body Rear End.
2. Remove the lift gate handle. Refer to Handle Replacement - Endgate in Body Rear End.
3. Remove the lift gate lower molding. Refer to Molding Replacement - Liftgate Lower.
Fig. 78: Locating Lift Gate Upper Molding Screws

4. Remove the screws from the lift gate upper molding.

Fig. 79: Removing Lift Gate Upper Molding
5. Remove the lift gate upper molding from the lift gate.
Fig. 80: Locating Lift Gate Upper Molding Screws
1. Position the lift gate upper molding to the lift gate.
2. Install the lift gate upper molding screws.
Tighten: Tighten the screws to 2.0 N.m (18 lb in).
3. Install the lift gate lower molding. Refer to Molding Replacement - Liftgate Lower.
4. Install the lift gate applique. Refer to Liftgate Applique Replacement in Body Rear End.
5. Install the lift gate handle. Refer to Handle Replacement - Endgate in Body Rear End.
MOLDING REPLACEMENT - LIFTGATE LOWER
Removal Procedure
Fig. 81: View Of Open Lift Gate
1. Raise the rear life gate.

2. Remove the screws from the lift gate lower molding.
Fig. 82: Identifying Lift Gate Lower Molding
3. Remove the lower molding from the lift gate.
Fig. 83: Identifying Lift Gate Lower Molding
1. Align the lift gate lower molding to the tabs in the upper molding.
Fig. 84: View Of Open Lift Gate
2. Install the lift gate lower molding screws.
3. Close the rear lift gate.
MOLDING REPLACEMENT - REAR QUARTER
Tools Required
J 25070 Heat Gun
Removal Procedure
Fig. 85: Locating Rear Quarter Panel Molding Push-In Retainers

2. Remove the push-in retainers from the inside rear edge of the rear quarter panel molding.
Fig. 86: Heating Rear Quarter Panel Molding

Fig. 87: View Of Rear Quarter Panel Molding
4. Use a plastic, flat-bladed tool to remove the upper edge of the rear quarter panel molding from the
surface.
Fig. 88: Locating Rear Quarter Panel Molding Retainers
5. Pull the upper edge of the rear quarter panel molding out, to release the retainers.
6. Remove the rear quarter panel molding from the door.
Fig. 89: Identifying D-Pillar Push-In Retainer Nuts
7. Remove the push-in retainer nuts from the D-pillar, if required.

Fig. 91: Identifying D-Pillar Push-In Retainer Nuts
1. Install the push-in retainer nuts to the D-pillar, if required.

Fig. 92: Locating Rear Quarter Panel Molding Retainers
3. Remove the protective liner from the back side of the rear quarter panel molding.
4. Position the rear quarter panel molding to the rear quarter panel.
5. Install rear quarter panel molding starting at the D-pillar and working forward and locating the push-in
retainers to the rear quarter panel, pressing rear quarter panel molding into place until fully seated.
6. Install the upper edge of the rear quarter panel molding by applying pressure to the entire length of the
molding starting at the rear and working forward in order to ensure a maximum bond to the rear quarter
panel.
Fig. 93: Locating Rear Quarter Panel Molding Push-In Retainers

7. Install the push-in retainers to the inside rear edge of the rear quarter panel molding.
MOLDING REPLACEMENT - ROCKER PANEL
Removal Procedure
Fig. 94: View Of Rocker Panel Push-In Retainers
1. Remove the screw from the front of the rocker panel molding.
2. Remove the top edge of the rocker panel molding by pulling off to release the push-in retainers.
3. Release the push-in retainers from the lower rocker panel molding using a small flat-bladed tool inserted
between the rocker panel molding and the retainer.
4. Remove the rocker panel molding from the rocker panel.
Fig. 95: Locating Rocker Molding Push-In Retainers

1. Position the rocker molding to the holes in the rocker panel.

2. Install the rocker molding starting to the first net hole (1) then the second net hole (2) and then the third
net hole (3). Press the push-in retainers into place until fully seated.
3. Install the push-in retainers to the lower rocker molding, pressing into place until fully seated.

Fig. 96: View Of Rocker Panel Push-In Retainers
4. Install the rocker molding screw to the rocker molding.
MOLDING REPLACEMENT - REAR PANEL
Tools Required
J 25070 Heat Gun

Removal Procedure
1. Remove the license plate.

2. Remove the license lamp. Refer to License Lamp Replacement (Aztek) or License Lamp Replacement
Fig. 97: Using J 25070 Heat Gun To Remove Rear Body Panel Molding

Fig. 98: Identifying Rear Body Panel Molding
4. Use a plastic, flat-bladed tool to remove the upper edge of the rear body panel molding from the surface.
Fig. 99: Rear Body Panel Molding Retainers
5. Pull the upper edge of the rear body panel molding out, to release the retainers.
6. Remove the rear body panel molding from the endgate.
7. Remove all adhesive from the endgate using 3M ScotchBrite molding adhesive remover disk 3M
P/N 07501 or equivalent.
8. Clean the endgate surface using Varnish Makers and Painters (VMP) naphtha and allow to air dry.
Fig. 101: Rear Body Panel Molding Retainers

2. Position the lower flange of the rear body panel molding to the hem flange of the endgate, pulling upward
and forward to align the retainer clips to the holes in the endgate.
3. Remove the protective liner from the back side of the rear body panel molding.
4. Position the upper edge of the rear body panel molding retainer clips to the holes in the endgate.
5. Install the retainer clips to the endgate by pressing in until fully seated.
6. Install the upper edge of the rear body panel molding by applying pressure to the entire length of the
molding starting at the center and working outward in order to ensure a maximum bond to the endgate.
7. Install the license lamp. Refer to License Lamp Replacement (Aztek) or License Lamp Replacement
8. Install the license plate.
DECAL AND STRIPE REPLACEMENT
Stripes or Decals
The stripes and decals adhere to a painted surface using pressure sensitive adhesive.
The use of a wetting solution aids the technician in lifting and positioning the stripe or decal during the
installation. The wetting solution ensures a better bond between the stripe or decal and the panel assembly. Use
a wetting solution when applying large stripe and decal packages.
Complete the following procedures before you apply a stripe or a decal:
Metal repair or refinishing after a collision

Painting the underlying surface
Maintain a temperature 21-38C (70-100F) on the body surfaces and the decals prior to installation. The decal
requires auxiliary heat sources in order to warm the body surfaces and decals. If the temperature is below 21C
(70F) the decal may not adhere to the body surface properly.
IMPORTANT: You may apply stripes or decals using the dry method. Use the wet method if
the dry method does not result in a bubble free application. This may be the
case in large graphics packages.
Use the wet method in order to apply the stripes or decals that are applied on
flexible surfaces (fascias, etc.). This will reduce the formation of bubbles under
the decal due to the outgassing potential of the flexible materials.
Use the following equipment and materials in order to apply a stripe or a decal:
A wetting solution
A foaming type of window cleaner that does not contain ammonia.
A silicone, wax and grease remover

Varnish Makers and Painters (VM&P) naphtha
Isopropyl alcohol
A squeegee
75-100 mm (3-4 in) wide
Made of plastic or hard rubber

Remove the burrs from any sharp or rough edges in order to prevent scratching of the stripe or
decal.
A water bucket and sponge or spray bottle

Sandpaper
800 grit or finer
Wet or dry type
A heat gun or heat lamp

A clean, lint-free wiping cloth
A sharp knife or razor blade
A pair of scissors
A fine pin or needle
A marking pencil
Stripe or Decal Removal
1. Remove the following components:

Necessary moldings or trim panel
Molding attaching clips
Handles
Sidemarker lamps
Other stripe or decal overlapping parts
2. Clean the following areas as needed:

The repair surfaces
The adjacent panels
The openings
3. Use 3M ScotchBrite molding adhesive remover disk 3M P/N 07501 or equivalent in order to remove
the stripe or decal from the body panel.
4. Use Varnish Makers and Painters (VM&P) naphtha in order to remove all traces of adhesive residue from
the painted surfaces.
Stripe or Decal Installation - Wet Method
1. Prepare the surface.
IMPORTANT: Remove any imperfections that would appear through the stripe or decal
if the area has been refinished.
Clean the painted surface using the following types of removers:
Silicone
Wax
Grease
2. Clean the area where the stripe or decal will be applied using a 50/50 mixture of isopropyl alcohol and
water.
3. Wipe the panel surface using a clean cloth while the solvent is still wet. Allow the panel surface to dry.
4. Apply the wetting solution to the area where you are installing the stripe or decal.
Application of a soapy wetting solution on the top side of the stripe or decal will ease the pull of the
squeegee on the stripe or decal and help to eliminate damage.
IMPORTANT: Do not touch the adhesive backing of the stripes.
Apply the wetting solution on the adhesive side of the stripe or decal.
Remove the backing material of the stripe or the decal as needed.
5. Apply the strip or decal to the panel. The wetting solution will allow movement for proper positioning on
the panel surface.
6. Working from the center where possible, squeegee the stripe or decal into position. Apply additional
wetting solution as needed in order to ease installation.
7. Apply heat to the stripe or decal at the recessed areas. Press the stripe or decal into the recess in order to
obtain a firm bond.
8. Use adequate light reflection in order to inspect the stripe or decal from a critical angle. This technique
detects any irregularities that may have developed during the installation.
IMPORTANT: Do not use a razor blade or a knife edge in order to pierce the air bubbles.
Remove all air bubbles by piercing the bubble with one of the following items:
A safety pin
A needle
A tool with the same size piercing tip
9. Pierce the bubble on the outer edge. Force the air out through the opposite edge using the blade of the
squeegee.
10. Install any previously removed components. Clean the components as needed.

SPECIAL TOOLS
Special Tools
J 25070
Heat Gun
Frame & Underbody - Aztek & Rendezvous
SPECIFICATIONS

Specification
Frame Bolt - Front 155 N.m 114 lb ft
Frame Bolt - Rear 240 N.m 177 lb ft
Rear Crossover Mounting Nuts 130 N.m 96 lb ft
Rear Suspension Support Bolt 105 N.m 77 lb ft
Trailer Hitch To Vehicle Bolts 101 N.m 75 lb ft
REPAIR INSTRUCTIONS
FRAME REPLACEMENT - FRONT (W/AWD)
Removal Procedure
1. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.6L (LY7)
or Engine Support Fixture in Engine Mechanical - 3.4L.
3. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
4. Remove the front engine splash shield. Refer to Splash Shield Replacement - Engine in Body Front
End.
5. Remove the stabilizer shaft. Refer to Stabilizer Shaft Replacement in Front Suspension.
6. Remove the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
7. Remove the catalytic converter pipe. Refer to Catalytic Converter Replacement in Engine Exhaust.
8. Remove the power steering gear. Refer to Power Steering Gear Replacement in Power Steering
System.
9. Remove the inner fender liner enough to gain access to the front frame bolts. Refer to Front Fender
Liner Replacement in Exterior Trim.
10. Disconnect the power steering cooler pipe from the pressure hose. Refer to Power Steering Cooler
Pipe/Hose Replacement in Power Steering System.
11. Disconnect the front wheel speed sensor harness connectors.
12. Disconnect the front wheel speed sensor wiring harnesses from the lower control arms.
13. Disconnect the lower control arm from the steering knuckles. Refer to Steering Knuckle Replacement
Fig. 1: Supporting Frame & Powertrain

14. Use the utility stand in order to raise the frame and powertrain.
15. Install the frame rear bolts. Refer to Frame Replacement - Front (W/AWD) or Frame Replacement -
Front (W/FWD).
16. Remove the utility stand from the frame.
17. Remove the engine mount nuts.
18. Remove the transaxle mount nuts.
Fig. 2: View Of Utility Stand Supporting Powertrain At Transfer Case
19. Use a utility stand in order to support the powertrain at the transfer case.
Fig. 3: Locating Frame To Body Bolts
20. Remove frame to body bolts.

21. Use the utility stand in order to lower the frame and powertrain.
22. Provide clearance for the frame to pass to the PTU.
23. Remove the frame from the vehicle. The frame will be around the utility stand.
Fig. 4: View Of Transmission Stand Supporting Powertrain
24. Use a transmission stand to support the powertrain.

Fig. 5: Freeing Frame From Utility Stand
25. Remove the utility stand in order to free the frame from the utility stand.
26. If you are REPLACING the frame, perform the following steps:
1. Remove the frame insulators from the frame. Refer to Frame Cushion or Insulator Replacement
- Front.
2. Remove the lower control arms from the frame. Refer to Lower Control Arm Replacement in
Front Suspension.
3 Remove the power steering cooler pipes from the frame Refer to Power Steering Cooler

1. Install the power steering cooler pipes to the frame. Refer to Power Steering Cooler Pipe/Hose
Replacement in Power Steering System.
2. Install the lower control arms to the frame. Refer to Lower Control Arm Replacement in Front
Suspension.
3. Install the frame insulators to the frame. Refer to Frame Cushion or Insulator Replacement -
Front.
Fig. 6: View Of Transmission Stand Supporting Powertrain
2. Use a utility stand with the frame around it to support the powertrain.
Fig. 7: View Of Utility Stand Supporting Powertrain At Transfer Case
3. Remove the transmission stand from the powertrain.

4. Install the frame to the vehicle.
5. Use the utility stand to raise the frame and powertrain.
IMPORTANT: Ensure that the alignment pins remain installed during the frame
installation.
6. Insert two 19 mm (0.75 in) diameter X 203 mm (8 in) long guide pins or drill bits into the frame right side
alignment holes in order to align the frame.

7. Install the frame to chassis front bolts.
8. Install the frame to chassis rear bolts.
9. Remove the alignment pins from the frame.

10. Install the transaxle mount nuts.
11. Install the engine mount nuts.

12. Remove the utility stand from the powertrain.
Fig. 9: Supporting Frame & Powertrain

13. Use a utility stand to support the frame.

14. Remove the rear frame bolts.
15. Use the utility stand in order to lower the frame and powertrain.
16. Connect the wheel speed sensor wiring harnesses to the lower control arms.
17. Connect the wheel speed sensor harness connectors.
18. Connect the lower control arms to the steering knuckles. Refer to Steering Knuckle Replacement in
Front Suspension.
19. Connect the power steering cooler pipe to the pressure hose. Refer to Power Steering Cooler Pipe/Hose
20. Install front fender liner. Refer to Front Fender Liner Replacement in Exterior Trim.
21. Install the power steering gear. Refer to Power Steering Gear Replacement in Power Steering System.
22. Install the catalytic converter pipe. Refer to Catalytic Converter Replacement in Engine Exhaust.
23. Install the propeller shaft. Refer to Propeller Shaft Replacement in Propeller Shaft.
24. Install the stabilizer shaft. Refer to Stabilizer Shaft Replacement in Front Suspension.
25. Install the front engine splash shield. Refer to Splash Shield Replacement - Engine in Body Front End.
26. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
28. Remove the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.4L or
Engine Support Fixture in Engine Mechanical - 3.6L (LY7).
FRAME REPLACEMENT - FRONT (W/FWD)
Tools Required
J 39580 Universal Engine Support Table. See Special Tools.
Removal Procedure
1. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.4L or
3. Remove the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
4. Remove the front engine splash shield. Refer to Splash Shield Replacement - Engine in Body Front
End.
5. Remove the stabilizer shaft. Refer to Stabilizer Shaft Replacement in Front Suspension.
6. Remove the power steering gear. Refer to Power Steering Gear Replacement in Power Steering
System.
7. Remove the inner fender liner enough to gain access to the front frame bolts. Refer to Front Fender
Liner Replacement in Exterior Trim.
8. Disconnect the power steering cooler pipe from the pressure hose. Refer to Power Steering Cooler
9. Disconnect the front wheel speed sensor harness connectors.
10. Disconnect the front wheel speed sensor wiring harnesses from the lower control arms.
11. Disconnect the lower control arm from the steering knuckles. Refer to Steering Knuckle Replacement
12. Remove the engine mount nuts.
13. Remove the transaxle mount nuts.
14. Lower the vehicle until the frame contacts the J 39580 . See Special Tools.
15. Remove frame to body bolts.

16. Raise the vehicle in order to separate the frame from the vehicle.
1. Remove the frame insulators from the frame. Refer to Frame Cushion or Insulator Replacement
- Front.
2. Remove the lower control arms from the frame. Refer to Lower Control Arm Replacement in
Front Suspension.
3. Remove the power steering cooler pipe from the frame. Refer to Power Steering Cooler

1. Install the power steering cooler pipe to the frame. Refer to Power Steering Cooler Pipe/Hose
2. Install the lower control arms to the frame. Refer to Lower Control Arm Replacement in Front
Suspension.
3. Install the frame insulators to the frame. Refer to Frame Cushion or Insulator Replacement -
Front.
2. Position the J 39580 with the frame under the vehicle. See Special Tools.

IMPORTANT: Ensure that the power steering cooler line does not become trapped by
the engine mount during this step.
3. Lower the vehicle until the frame is close to the vehicle.
IMPORTANT: Ensure that the alignment pins remain installed during the frame
installation.
4. Insert two 19 mm (0.75 in) diameter X 203 mm (8 in) long guide pins or drill bits into the frame right side
alignment holes in order to align the frame.

5. Install the frame to chassis front bolts.
6. Install the frame to chassis rear bolts.
7. Remove the alignment pins from the frame.

8. Install the transaxle mount nuts.

9. Install the engine mount nuts.
10. Connect the lower control arms to the steering knuckles. Refer to Steering Knuckle Replacement in
Front Suspension.
11. Connect the wheel speed sensor wiring harnesses to the lower control arms.
12. Connect the wheel speed sensor harness connectors.
13. Connect the power steering cooler pipe to the pressure hose. Refer to Power Steering Cooler Pipe/Hose
14. Install front fender liner. Refer to Front Fender Liner Replacement in Exterior Trim.
15. Install the power steering gear. Refer to Power Steering Gear Replacement in Power Steering System.
16. Install the stabilizer shaft. Refer to Stabilizer Shaft Replacement in Front Suspension.
17. Install the front engine splash shield. Refer to Splash Shield Replacement - Engine in Body Front End.
18. Install the front tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
20. Remove the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.4L and
CROSSMEMBER REPLACEMENT - REAR SUSPENSION
Removal Procedure
2. Remove the tire and the wheel. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
3. Support the rear differential carrier using a utility stand.
Fig. 14: View Of Rear Differential Carrier Mounting Bolts
4. Remove the rear differential carrier mounting bolts (5) from the rear crossmember. Refer to Differential
Replacement in Rear Drive Axle.
5. Remove the rear suspension knuckle. Refer to Knuckle Replacement (All Wheel Drive) in Rear
Suspension.
6. Disconnect the wheel speed sensor harness from the lower control arm and from the rear cross member.
7. Remove the rivets that attach the park brake cable to the rear crossmember.
8. Remove the automatic level control (ALC) height sensor and link from the crossmember bar and lower
control arm. Refer to Automatic Level Control Sensor Replacement in Automatic Level Control.
9. Secure the ALC wiring harness out of the way.
10. Using a utility jack, support the rear crossmember.
11. Remove the rear crossmember mounting bolts.
Fig. 15: View Of Rear Crossmember

12. Lower the rear crossmember.

13. Remove the rear stabilizer shaft. Refer to Stabilizer Shaft Replacement (All Wheel Drive) in Rear
Suspension.
14. Remove the rear axle upper control arms from the rear crossmember. Refer to Rear Axle Upper Control
Arm Replacement (All Wheel Drive) in Rear Suspension.
15. Remove the rear axle lower control arms from the rear crossmember. Refer to Rear Axle Lower Control
16. Remove the tie rods from the rear crossmember. Refer to Tie Rod Replacement (Front Wheel Drive) or
Tie Rod Replacement (All Wheel Drive) in Rear Suspension.
1. Install the tie rods to the crossmember. Refer to Tie Rod Replacement (Front Wheel Drive) or Tie Rod
Replacement (All Wheel Drive) in Rear Suspension.
2 Install the rear axle lower control arms onto the rear crossmember Refer to Rear Axle Lower Control
3. Install the rear axle upper control arms onto the rear crossmember. Refer to Rear Axle Upper Control
4. Install the rear stabilizer shaft onto the rear crossmember. Refer to Stabilizer Shaft Replacement (All
Wheel Drive) in Rear Suspension.
Fig. 16: Raising Rear Crossmember

5. Raise the rear crossmember.

6. Align the rear crossmember using guide pins through the rail holes (1).
7. Install the rear crossmember mounting bolts.
8. Tighten the mounting bolts.
Tighten: Tighten the rear crossmember mounting bolts to 130 N.m (96 lb ft).
9. Install the ALC height sensor onto the crossmember and lower control arm. Refer to Automatic Level
Control Sensor Replacement in Automatic Level Control.
Fig. 17: View Of Rear Differential Carrier Mounting Bolts

10. Install the rear differential carrier mounting bolts (5). Refer to Differential Replacement in Rear Drive
Axle.
11. Attach the parking brake cable onto the rear crossmember. Refer to Park Brake Cable Replacement -
Left Rear (Disc) or Park Brake Cable Replacement - Left Rear (Drum) and Park Brake Cable
Replacement - Right Rear (Disc) or Park Brake Cable Replacement - Right Rear (Drum) in Park
Brake.
12. Connect the wheel speed sensor harness onto the rear crossmember and the lower control arm.
13. Install the rear suspension knuckle. Refer to Knuckle Replacement (All Wheel Drive) in Rear
Suspension.
16. Inspect the rear wheel alignment and adjust as necessary. Refer to Measuring Wheel Alignment in
Wheel Alignment.
FRAME CUSHION OR INSULATOR REPLACEMENT - FRONT
Tools Required
J 45296 Frame Insulator Remover/Installer. See Special Tools.
Removal Procedure
2. Disconnect the steering intermediate shaft. Refer to Intermediate Steering Shaft Replacement in
3. Install a jackstand under the center of the frame, between the front frame insulators.
Fig. 18: View Of Front Frame Bolts And Retainers
4. Remove the front frame bolts and retainers.

5. Lower the front of the frame.
6. Remove the frame front upper insulators.
Fig. 19: View Of Frame Front Upper Insulators
7. Install the J 45296 to the front frame insulator you are removing. See Special Tools.
8. Using J 45296 , remove the front frame insulator from the frame. See Special Tools.
1. Clean the front frame insulator opening.

2. Apply a thin coat of rubber lubricant GM P/N 1051717, Canadian P/N 5728223, or equivalent to the
inside of the front frame insulator opening.
3. Apply a thin coat of rubber lubricant GM P/N 1051717, Canadian P/N 5728223, or equivalent to the front
frame insulator.
Fig. 20: Aligning The Front Frame Insulator
4. Align the front frame insulator to the front frame opening with the front frame alignment tabs facing to
the front.
5. Using J 45296 , install the front frame insulator to the front frame. See Special Tools.
Fig. 21: View Of Front Frame Bolts And Retainers
6. Install the frame front upper insulators.

7. Raise the front of the frame.
8. Install the front frame bolts and retainers.
Tighten: Tighten the front frame bolts to 155 N.m (114 lb ft).
9. Remove the jackstand.

10. Connect the steering intermediate shaft. Refer to Intermediate Steering Shaft Replacement in Steering
Wheel and Column.
FRAME CUSHION OR INSULATOR REPLACEMENT - REAR
Removal Procedure
IMPORTANT: In order to remove any frame insulator, loosen the adjacent frame
insulators to permit the frame to separate from the body. Do not break the
fan shroud or damage the frame attachments, such as steering hoses and
brake pipes during the replacement of body mounts.
When installing a body mount, ensure the lower insulator is seated into
the frame. The lower insulator should not be loose. The spacer and the
corresponding upper insulator is pressed into the lower insulator thus
squeezing the frame. The bolt is then inserted through the mount,
capturing the lower retainer. The body mount components prevent
contact of the frame to the body.
When clamping by the mount, ensure the surfaces are clean and dry. If
the frame insulator bolt does not screw in smoothly, run a tap through the
frame crossmember nut in the body in order to remove foreign material.
Ensure the tap does not punch through the underbody.
Whenever the body is moved in relation to the frame, disconnect the
intermediate shaft from the rack and pinion steering gear and stub shaft.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle Vehicle Lifting and
Jacking in General Information.
Fig. 22: View Of Rear Frame
2. Remove the intermediate shaft from the steering gear stub shaft. Refer to Intermediate Steering Shaft
Replacement in Power Steering.
3. Install a utility stand to the rear of the frame.
4. Remove the rear frame bolts.
5. Lower the rear of the frame.
6. Remove the upper and lower insulators from the rear of the frame as a set.
Fig. 23: View Of Rear Frame
1. Apply a thin coat of rubber lubricant GM P/N 1051717, Canadian P/N 5728223, to inside surface of
lower insulator and to top surface of upper insulator.
2. Install the upper and lower insulators to the rear of the frame as a set.
3. Raise the rear of the frame.
4. Install the rear frame bolts.
Tighten: Tighten the rear frame bolts to 240 N.m (177 lb ft).
5. Remove the utility stand.

6. Install the intermediate shaft to the steering gear stub shaft. Refer to Intermediate Steering Shaft
Replacement in Power Steering
TRAILER HITCH REPLACEMENT
Removal Procedure
2. Remove the rear fascia. Refer to Fascia Replacement - Rear Bumper (Aztek) or Fascia Replacement -
Rear Bumper (Rendezvous) in Bumpers.
3. Remove the rear energy absorber. Refer to Energy Absorber Replacement - Rear (Aztek) or Energy
Absorber Replacement - Rear (Rendezvous) in Bumpers.
4. Remove the rear impact bar. Refer to Impact Bar Replacement - Rear Bumper in Bumpers.
Fig. 27: Identifying Trailer Hitch Assembly
5. Remove the trailer hitch assembly.
Fig. 28: Identifying Trailer Hitch Assembly
1. Install the trailer hitch to the vehicle.

2. Install bolts to frame rail.
Tighten: Tighten to 101 N.m (75 lb ft)

3. Install the rear impact bar. Refer to Impact Bar Replacement - Rear Bumper in Bumpers.
4. Install the rear energy absorbers. Refer to Energy Absorber Replacement - Rear (Aztek) or Energy
Absorber Replacement - Rear (Rendezvous) in Bumpers.
5. Install the rear fascia. Refer to Fascia Replacement - Rear Bumper (Aztek) or Fascia Replacement -
Rear Bumper (Rendezvous) in Bumpers.

SPECIAL TOOLS
Special Tools
J 39580
Universal Engine Support Table
J 45296
Frame Insulator Remover/Installer
Front Suspension - Aztek & Rendezvous
SPECIFICATIONS

Specification
ABS Bracket Bolt 10 N.m 7 lb ft
Ball Joint Retaining Nuts 68 N.m 50 lb ft
Ball Stud Castle Nut (Lower Control Arm) 55 N.m 40 lb ft
Lower Control Arm Nuts (at Frame) * 104 N.m 77 lb ft
Stabilizer Shaft Insulator Bracket Bolts 48 N.m 35 lb in
Stabilizer Shaft Link Nut 23 N.m 17 lb ft
Strut To Knuckle Bolts 123 N.m 90 lb ft
Strut Shaft Nut * 85 N.m 63 lb ft
Strut Upper Nuts 41 N.m 30 lb ft
Wheel Bearing/Hub Bolts (NEW ONLY) 130 N.m 96 lb ft
* This is a prevailing torque type fastener. This fastener may be reused ONLY if:
The fastener and its counterpart are clean and free from rust
The fastener develops a specified amount of torque (drag) against its counterpart prior to the
fastener seating
Refer to the appropriate service procedure for the prevailing torque value.
If the fastener does not meet these criteria, REPLACE the fastener.
REPAIR INSTRUCTIONS
STABILIZER SHAFT REPLACEMENT
Removal Procedure
2. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
3. Remove the stabilizer shaft links. Refer to Stabilizer Shaft Link Replacement.
Fig. 1: View Of Left And Right Stabilizer Shaft Insulators And Brackets
4. Remove the left and right stabilizer shaft insulators and brackets. Refer to Stabilizer Shaft Insulator
Replacement.
Fig. 2: Identifying Stabilizer Shaft
5. Remove the stabilizer shaft from the right side of the vehicle.
Fig. 3: Identifying Stabilizer Shaft
1. Install the stabilizer shaft to the vehicle from the right side of the vehicle.
2. Install the stabilizer shaft insulators (4) and brackets. Refer to Stabilizer Shaft Insulator Replacement.
3. Install the left and right stabilizer shaft links. Refer to Stabilizer Shaft Link Replacement.
4. Install the tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
STABILIZER SHAFT LINK REPLACEMENT
Removal Procedure
Fig. 5: View Of Stabilizer Bar Links

2. Remove the stabilizer shaft link bolt and nut.

3. Use a pry bar in order to remove the stabilizer shaft link insulators and the spacer.
1. Use a pry bar in order to install the stabilizer shaft link insulators and the spacer.

2. Install the stabilizer shaft link and insulators.

3. Install the stabilizer shaft link bolt and nut.
Tighten: Tighten the stabilizer shaft link nut to 23 N.m (17 lb ft).
STABILIZER SHAFT INSULATOR REPLACEMENT
Removal Procedure
2. Remove the tires. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
3. Remove the side stabilizer shaft insulator bracket bolts.

4. Use a pry bar in order to remove the stabilizer shaft insulator brackets.
5. Remove the stabilizer shaft insulators (4).
1. Install the stabilizer shaft insulator.
2. Ensure that the stabilizer shaft insulator locating tabs (3) align with the indentations in the frame (2).
3. Install the left and right side stabilizer shaft insulator brackets.
4. Install the left and right side stabilizer shaft insulator bracket bolts.
Tighten: Tighten the stabilizer shaft insulator bracket bolts to 48 N.m (35 lb in).
5. Install the front tires. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
LOWER BALL JOINT REPLACEMENT
Removal Procedure
2. Remove the tires and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
3. Remove the lower control arm. Refer to Lower Control Arm Replacement.
4. Secure the lower control arm in a vice.
Fig. 9: Drilling Out Lower Ball Joint Rivet Heads
5. Drill out the rivet heads from the lower control arm.
Fig. 10: Using Hammer & Drift To Remove Lower Ball Joint Rivets
6. Use a hammer and a drift punch in order to remove the rivets from the lower control arm.
Fig. 11: Removing/Installing Lower Ball Joint
7. Remove the ball joint from the lower control arm.
Fig. 12: Removing/Installing Lower Ball Joint
1. Install the ball joint to the lower control arm.

Fig. 13: Identifying Ball Joint Retaining Nuts
2. Install the new ball joint bolts facing downward, away from the ball stud.
3. Install the new ball joint retaining nuts.

Tighten: Tighten the ball joint retaining nuts to 68 N.m (50 lb ft).
4. Install the lower control arm. Refer to Lower Control Arm Replacement.
5. Install the tire and wheels. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
7. Align the front suspension. Refer to Measuring Wheel Alignment in Wheel Alignment.
WHEEL BEARING/HUB REPLACEMENT - FRONT
Tools Required
J 28733-B Front Hub Spindle Remover
Removal Procedure
Fig. 14: Locating Front Wheel Speed Sensor Electrical Connector

4. Remove the wheel speed sensor electrical connector from the bracket.
5. Remove the wheel drive shaft nut. Refer to Wheel Drive Shaft Replacement - Front in Wheel Drive
Shafts.
6. Remove the brake rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes.
Fig. 15: Using J 28733-B To Push Wheel Drive Shaft Out Of Wheel Bearing/Hub
7. Install the J 28733-B to the wheel bearing/hub.

8. Use the J 28733-B in order to push the wheel drive shaft out of the wheel bearing/hub.
Fig. 16: View Of Wheel Bearing/Hub & Splash Shield
CAUTION: These fasteners MUST be replaced with new fasteners anytime they
become loose or are removed. Failure to replace these fasteners after
they become loose or are removed may cause loss of vehicle control
and personal injury.
9. Remove and discard the wheel bearing/hub bolts.
IMPORTANT: Ensure that the wheel drive shaft outer seal (boot) is not damaged.
10. Remove the wheel bearing/hub.
Fig. 17: View Of Wheel Bearing/Hub & Splash Shield
1. Install the wheel bearing/hub.
2. Install NEW wheel bearing/hub bolts.
Tighten: Tighten the new wheel bearing/hub bolts to 130 N.m (96 lb ft).
3. Install the brake rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes.
4. Install the wheel drive shaft nut. Refer to Wheel Drive Shaft Replacement - Front in Wheel Drive
Shafts.
IMPORTANT: Ensure that the connector clip engages the bracket properly.
5. Install the wheel speed sensor electrical connector to the bracket.
Fig. 18: Locating Front Wheel Speed Sensor Electrical Connector


STEERING KNUCKLE REPLACEMENT
Tools Required
J 24319-B Universal Steering Linkage Puller. See Special Tools.
Removal Procedure
Wheels.
3. Remove the front wheel drive shaft bearing. Refer to Wheel Bearing/Hub Replacement - Front.
4. Remove the front lower control arm ball stud. Refer to Lower Control Arm Replacement.
5. Remove the outer tie rod end from the steering knuckle. Refer to Rack and Pinion Outer Tie Rod End
6. Remove the bolt retaining the ABS harness bracket to the steering knuckle.
Fig. 19: Scribing Strut To Knuckle
7. Scribe the strut to the knuckle.

Fig. 20: View Of Steering Knuckle To Strut Bolts
8. Remove the bolts connecting the strut to the knuckle.

9. Remove the knuckle from the vehicle.
1. Install the knuckle to the vehicle.

2. Install the bolts which connect the strut to the knuckle. Hand tighten only.
3. Connect the front lower control arm ball stud to knuckle. Refer to Lower Control Arm Replacement.
4. Attach the ABS bracket to the steering knuckle.
Tighten: Tighten the ABS bracket bolt to 10 N.m (7 lb ft).
5. Install the outer tie rod to the steering knuckle. Refer to Rack and Pinion Outer Tie Rod End
6. Install the front wheel drive shaft bearing. Refer to Wheel Bearing/Hub Replacement - Front.
7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and
Wheels.
9. Measure and adjust the front alignment. Refer to Front Camber Adjustment in Wheel Alignment.
LOWER CONTROL ARM REPLACEMENT
Tools Required
J 41820 Ball Stud/Joint Separator. See Special Tools.
Removal Procedure
NOTE: Use only the recommended tools for separating the ball joint from the knuckle.
Do NOT hammer or pry the ball joint from the knuckle. Failure to use the
recommended tools may cause damage to the ball joint and seal.
IMPORTANT: Use the ignition key in order to unlock the steering column.
1. Turn the steering wheel in order to move the front of the applicable wheel to the outboard most position
in order to allow for tool access to the lower control arm ball stud nut.
IMPORTANT: Use only a frame-contact type vehicle lift or a floor jack at the
recommended lift points. Do NOT use a suspension-contact type vehicle
lift. Do NOT lift the front of the vehicle by the lower control arms.
Fig. 22: Locating Wheel Speed Sensor Wiring Harness On Lower Control Arm
4. Disconnect the wheel speed sensor wiring harness from the lower control arm.
5. Remove the stabilizer shaft link. Refer to Stabilizer Shaft Link Replacement.
Fig. 23: Identifying Ball Stud Cotter Pin
6. Remove the cotter pin (1) from the ball stud (3).
7. Loosen the ball stud nut. Do not remove the ball stud nut.
Fig. 24: Separating Ball Stud From Steering Knuckle
8. Install the J 41820 over the ball stud nut and the steering knuckle as shown. See Special Tools.
9. Rotate the ball stud nut counterclockwise in order to separate the ball stud from the steering knuckle.
Fig. 25: View Of Lower Control Arm Bolts And Nuts
10. Remove the lower control arm bolts and nuts.

11. Remove the lower control arm.
Fig. 26: View Of Lower Control Arm Bolts And Nuts
1. Install the lower control arm.

2. Install the control arm bolts and nuts. Hand tighten only.
IMPORTANT: Align the ball stud cotter pin hole parallel to the knuckle in order to ease
the cotter pin installation.
3. Install the ball stud to the knuckle.
4. Install the ball stud castle nut.

Tighten: Tighten the ball stud castle nut to 55 N.m (40 lb ft).
Fig. 27: Aligning Ball Stud Castle Nut Slot To The Ball Stud Cotter Pin Hole
IMPORTANT: Do not loosen the ball stud nut in order to align the ball stud nut slots to
the ball stud cotter pin hole.
5. If necessary, tighten the ball stud castle nut in order to align the ball stud castle nut slot (1) to the ball stud
cotter pin hole (2) as shown.
Fig. 28: Securing Cotter Pin In Ball Joint Castle Nut
IMPORTANT: Ensure that the cotter pin ends do not contact the ABS sensor connector
or the drive axle.
6. Install a new cotter pin and bend the ends as shown in either example.
7. Install the stabilizer shaft link. Refer to Stabilizer Shaft Link Replacement.
Fig. 29: Locating Wheel Speed Sensor Wiring Harness On Lower Control Arm
8. Install the wheel speed sensor harness to the lower control arm.
IMPORTANT: This is a prevailing torque type fastener. This fastener may be reused only
if:
The fastener and its counterpart are clean and free from rust
The fastener develops 3 N.m (27 lb in) of torque (drag) against its
counterpart prior to the fastener seating
If the fastener does not meet these criteria, REPLACE the fastener.
9. Install the lower control arm nuts.
Tighten: Tighten the lower control arm nuts to 104 N.m (77 lb ft).
LOWER CONTROL ARM BUSHINGS REPLACEMENT
Tools Required
J 23444-A High Pressure Lubricant. See Special Tools.

J 21474-01 Control Arm Bushing Service Set. See Special Tools.
Removal Procedure
1. Remove the lower control arm. Refer to Lower Control Arm Replacement.
2. Secure the lower control arm in a vice.
Fig. 30: Identifying Flat Edge Of The Bushing Flange
IMPORTANT: The lower control arm vertical bushing MUST be installed in the same
position which it was removed in order to maintain the original vehicle
ride, handling and road feel.
3. Mark the lower control arm along the flat edge of the bushing flange (1).
Fig. 31: View Of J 21474-01
IMPORTANT: Apply J 23444-A (or equivalent high pressure lubricant) to the threads of
the . See Special Tools. J 21474-27 .
4. Assemble the following bushing tools as shown.

5. Tighten the J 21474-4 until the bushing is removed from the control arm.
6. Disassemble the bushing tools.
Fig. 32: Identifying Flat Edge Of The Bushing Flange
IMPORTANT: The lower control arm vertical bushing MUST be installed in the same
position which it was removed in order to maintain the original vehicle
ride, handling and road feel.
1. Align the flat edge of the bushing flange to the mark in the control arm (1).
2. Insert the bushing into the control arm.
Fig. 33: Illustrating Proper Installation Of Bushing Tools
IMPORTANT: Apply J 23444-A (or equivalent high pressure lubricant) to the threads of
the . See Special Tools. J 21474-27 .
3. Assemble the bushing tools as shown.

4. Tighten the J 21474-4 until the bushing is fully seated in the control arm.
5. Disassemble the bushing tools.
6. Install the lower control arm. Refer to Lower Control Arm Replacement.
WHEEL STUD REPLACEMENT
Tools Required
J 35917 Ball Joint Remover. See Special Tools.
Removal Procedure
CAUTION: If you are replacing the wheel(s), the wheel stud(s), the wheel nut(s) or the
wheel bolt(s), install only new GM original equipment parts. Installation of
used parts or non-GM original equipment parts may cause the wheel to
loosen, loss of tire air pressure, poor vehicle handling and loss of vehicle
control resulting in personal injury.
3. Remove the brake rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes.
Fig. 34: Identifying J 35917 To Press The Wheel Stud From The Bearing/Hub
4. Use the J 35917 in order to press the wheel stud (1) from the bearing/hub (2). See Special Tools.
1. Install a new wheel stud from the back side of the bearing/hub.
Fig. 35: Installing Wheel Stud
2. Install three flat washers (1) to the wheel stud (3).

3. Install a hex nut (2) to the wheel stud (3).
Fig. 36: Seating Stud Head Fully In Bearing/Hub Flange
4. Tighten the hex nut until the stud head is fully seated in the bearing/hub flange.
5. Remove the hex nut and the washers from the wheel stud.
6. Install the brake rotor. Refer to Brake Rotor Replacement - Front in Disc Brakes.
STRUT ASSEMBLY REPLACEMENT
Removal Procedure
1. Remove wiper module. Refer to Wiper Motor Module Replacement

Fig. 37: Identifying Upper Strut Mounting Nuts
2. Remove the upper strut mounting nuts.

5. Scribe the strut to the steering knuckle.

6. Remove the strut lower mounting bolts and nuts.

7. Remove the strut.
1. Install the strut to the vehicle.

Fig. 40: Identifying Upper Strut Mounting Nuts
2. Install the strut upper nuts.
Tighten: Tighten the strut upper nuts to 41 N.m (30 lb ft).
3. Install the wiper module refer to Wiper Motor Module Replacement

4. Install the strut lower bolts and nuts. Hand tighten only.
6. Inspect and adjust the camber as necessary. Refer to Front Camber Adjustment in Wheel Alignment.
SUSPENSION SHOCK/STRUT DISPOSAL

CAUTION: Gas charged shock absorbers contain high pressure gas. Do not remove
the snap ring from inside the top of the tube. If the snap ring is removed,
the contents of the shock absorber will come out with extreme force which
may result in personal injury.
CAUTION: To prevent personal injury, wear safety glasses when centerpunching and
drilling the shock absorber. Use care not to puncture the shock absorber
tube with the centerpunch.
Fig. 43: Drilling Hole In Shock Absorber At Centerpunched Locations
1. Make an indentation 10 mm (0.4 in) from the bottom (4) of the tube (3) using a centerpunch.
2. Clamp the shock absorber in a vise horizontally with the shock absorber rod (1) completely extended.
3. Drill a hole in the shock absorber at the centerpunch (4) using a 5 mm (3/16 in) drill bit. Gas or a gas/oil
mixture will exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain
the escaping oil.
4. Make an indentation in the middle (2) of the tube (3) with a centerpunch.
5. Drill a second hole in the shock absorber at the centerpunch (2) using a 5 mm (3/16 in) drill bit. Oil will
exhaust when the drill bit penetrates the shock absorber. Use shop towels in order to contain the escaping
oil.
6. Remove the shock absorber from the vise. Hold the shock absorber over a drain pan horizontally with the
holes down. Move the rod (1) in and out of the tube (3) to completely drain the oil from the shock
absorber.
STRUT, STRUT COMPONENT AND/OR SPRING REPLACEMENT
Tools Required
J 42991 Strut Rod Nut Socket. See Special Tools.

J 45400 Strut Spring Compressor. See Special Tools.
1. Remove the strut from the vehicle. Refer to Strut Assembly Replacement.
Fig. 44: Compressing/Releasing Lower Part Of Shock Spring
2. Install the strut (2) in the J 45400 (1). See Special Tools.
IMPORTANT: The spring is compressed when the strut moves freely.

Fig. 45: View Of Compressor Forcing Screw & Coil Spring
3. Turn the spring compressor forcing screw (1) until the coil spring (2) is compressed.
4. Use a 45 TORX socket in order to hold the strut shaft. Use the J 42991 to remove the upper strut mount
nut. See Special Tools.
5. Remove the strut from the J 45400 . See Special Tools.
6. Loosen the compressor forcing screw (1) until the upper strut mount and coil spring (2) may be removed.
7. Remove the upper strut mount and the coil spring from the J 45400 . See Special Tools.
Assembly Procedure
1. Install the coil spring and upper strut mount to the J 45400 . See Special Tools.
Fig. 46: View Of Compressor Forcing Screw & Coil Spring

2. Turn the spring compressor forcing screw (1) until the coil spring is compressed.
3. Install the strut to the coil spring and upper strut mount.
4. Loosely install the strut retaining nut.
5. Use a 45 TORX socket in order to hold the strut shaft. Use the J 42991 to install the upper strut mount
nut. See Special Tools.
Tighten: Tighten the strut mount nut to 85 N.m (63 lb ft).
6. Remove the strut from the J 45400 . See Special Tools.

7. Install the strut to the vehicle. Refer to Strut Assembly Replacement.

FRONT SUSPENSION DESCRIPTION AND OPERATION
The front suspension has 2 primary purposes:
Isolate the driver from irregularities in the road surface.

Define the ride and handling characteristics of the vehicle.
The front suspension absorbs the impact of the tires travelling over irregular road surfaces and dissipates this
energy throughout the suspension system. This process isolates the vehicle occupants from the road surface.
The rate at which the suspension dissipates the energy and the amount of energy that is absorbed is how the
suspension defines the vehicles ride characteristics. Ride characteristics are designed into the suspension system
and are not adjustable. The ride characteristics are mentioned in this description in order to aid in the
understanding of the functions of the suspension system. The suspension system must allow for the vertical
movement of the tire and wheel assembly as the vehicle travels over irregular road surfaces while maintaining
the tire's horizontal relationship to the road.
This requires that the steering knuckle be suspended between a lower control arm and a strut assembly. The
lower control arm attaches from the steering knuckle at the outermost point of the control arm. The attachment
is through a ball and socket type joint. The innermost end of the control arm attached at 2 points to the vehicle
frame through semi-rigid bushings. The upper portion of the steering knuckle is attached to a strut assembly.
The strut assembly then connects to the vehicle body by way of an upper bearing. The steering knuckle is
allowed to travel up and down independent of the vehicle body structure and frame.
This up and down motion of the steering knuckle as the vehicle travels over bumps is absorbed predominantly
by the coil spring. This spring is retained under tension over the strut assembly. A strut is used in conjunction
with this system in order to dampen out the oscillations of the coil spring. A strut is a basic hydraulic cylinder.
The strut is filled with oil and has a moveable shaft that connects to a piston inside the strut. Valves inside the
shock absorber offer resistance to oil flow and consequently inhibit rapid movement of the piston and shaft.
Each end of the shock absorber is connected in such a fashion to utilize this recoil action of a spring alone. Each
end of the strut is designed as the connection point of the suspension system to the vehicle and acts as the coil
spring seat. This allows the strut to utilize the dampening action to reduce the recoil of a spring alone. The
lower control arm is allowed to pivot at the vehicle frame in a vertical fashion. The ball joint allows the steering
knuckle to maintain the perpendicular relationship to the road surface.
Front suspensions systems utilize a stabilizer shaft. The stabilizer bar connects between the left and right lower
control arm assemblies through the stabilizer link and stabilizer shaft insulators. This bar controls the amount of
independent movement of the suspension when the vehicle turns. Limiting the independent movement defines
the vehicles handling characteristics on turns.

SPECIAL TOOLS
Special Tools
J 21474-01
Control Arm Bushing Set
J 23444-A
High Pressure Lubricant
J 24319-B
Universal Steering Linkage Puller
J 28733-B
Spindle Remover
J 35917
Ball Joint Remover
J 41820
Ball Joint/Stud Separator
J 42991
Strut Rod Nut Socket
J 45400
Strut Compressor
Front
DESCRIPTION
The front suspension is a combination strut and spring design. The control arms pivot at the frame. See Fig. 1 .
The frame has isolation mounts to the body and conventional rubber bushings for control arm pivots. The upper
end of the strut is isolated by a rubber mount, and contains a bearing to allow for wheel turning.
The lower end of the steering knuckle pivots on a ball joint riveted to the control arm. The ball joint is fastened
to the steering knuckle with a pinch bolt.
Fig. 1: Exploded View Of Front Suspension (Typical)
ADJUSTMENTS & INSPECTION

WHEEL ALIGNMENT
NOTE: See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL

ALIGNMENT.
FRONT WHEEL BEARINGS
Front bearings are pre-adjusted and lubricated, requiring no routine maintenance or adjustment. Front wheel
bearings are serviceable only by complete replacement of hub and bearing assembly.
RIDE HEIGHT
NOTE: See appropriate SPECIFICATIONS & PROCEDURES article in WHEEL

ALIGNMENT.
BALL JOINT CHECKING
Raise and support vehicle. Allow suspension to hang freely. Inspect ball joint seals for cracks or tears. Replace
ball joint if seal is damaged. Grasp tire at top and bottom. Move top of tire using an in-and-out motion. Note
horizontal movement of the knuckle relative to the control arm. Replace ball joint if any looseness exists. Ball
stud tightness in steering knuckle boss should be checked by shaking wheel and looking for looseness at stud
end. Repair or replace as necessary.

BALL JOINT
Removal
CAUTION: When servicing suspension, use Inner Drive Joint Seal Protector (J-
34754). Modify protector by removing 3 tabs on inside surface. DO NOT
overextend drive axle joints, or internal parts may separate.
1. Raise and support vehicle. Place jackstands under frame. Lower vehicle slightly so weight of vehicle rests
on jackstands and not control arms. Remove front wheel assemblies.
2. Remove ball joint nut. Remove ball joint from steering knuckle using Ball Joint Separator (J-41820).
3. Drill out ball joint retaining rivets. DO NOT damage drive axle seals when removing rivets. Loosen
stabilizer bar bushing assembly nut. Remove ball joint from control arm.
Installation
1. Install ball joint in control arm. Install and tighten retaining bolts as shown in instructions included with
ball joint kit. Position steering knuckle over ball joint.
2. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE
SPECIFICATIONS . Lower vehicle and check wheel alignment. See appropriate SPECIFICATIONS &
PROCEDURES article in WHEEL ALIGNMENT.
STEERING KNUCKLE
Removal
1. Raise and support vehicle. Place jackstands under frame. Lower vehicle slightly so that weight of vehicle
rests on jackstands and not on control arms. Remove front wheel assemblies.
CAUTION: Do not overextend drive axle joints, or internal parts may separate.
2. Disconnect stabilizer bar from control arm. See STABILIZER BAR & BUSHING ASSEMBLY .
Remove hub and bearing assembly. See WHEEL HUB/ROTOR & BEARINGS . Remove ball joint
castle nut and separate ball joint from steering knuckle. See BALL JOINT .
3. With a sharp tool, scribe reference marks on steering knuckle along lower strut radius for reassembly.
Remove strut-to-steering knuckle retaining bolts. Remove steering knuckle.
Installation
1. Install NEW bearing seal (if removed). Install steering knuckle to strut ensuring scribe marks on steering
knuckle align with strut and mounting bracket. Position steering knuckle over ball joint and install castle
nut.
2. To complete installation, reverse removal procedure. Tighten bolts and nuts to specification. See
TORQUE SPECIFICATIONS . Lower vehicle and check wheel alignment. See appropriate
SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.
WHEEL HUB/ROTOR & BEARINGS
Removal
rests on jackstands and not on control arms. Remove front wheel assemblies. Disconnect wheel speed
sensor and remove from wiring harness. Install Inner Drive Joint Seal Protector (J-34754 - modified) on
drive axle joints.
2. Remove hub-to-drive axle nut and washer. See Fig. 2 . Remove brake caliper. DO NOT disconnect
brakeline. Support caliper to prevent brake hose damage.
3. Remove rotor. Using Front Hub Spindle Remover (J-28733-B), separate hub from drive axle shaft.
Remove hub and bearing retaining bolts. Remove splash shield, hub and bearing assembly and "O" ring.
Using punch, tap seal toward engine. Using side cutters, cut seal off of drive axle after seal has been
removed from steering knuckle.
Installation
1. Using Inner Hub Seal Installer (J-28671 or J-34657-A), install NEW seal into steering knuckle from
wheel side of steering knuckle. Lubricate seal with grease.
2. Install "O" ring on hub and bearing assembly. See Fig. 2 . Hub and bearing are replaced as an assembly.
DO NOT damage seal during hub and bearing assembly installation.
3. Install hub and bearing assembly into steering knuckle. Install rotor. Install brake caliper. Install hub-to-
drive axle nut and washer. To complete installation, reverse removal procedure. Tighten bolts and nuts to
specification. See TORQUE SPECIFICATIONS . Lower vehicle. Check wheel alignment. See
appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.
Fig. 2: Exploded View Of Hub & Bearing Assembly

STRUT ASSEMBLY
Removal
1. Remove upper strut-to-body mount nuts. Raise and support vehicle. Place jackstands under frame. Lower
vehicle slightly so that weight of vehicle rests on jackstands and not on control arms. Remove front wheel
assemblies. Install Inner Drive Joint Seal Protector (J-34754 - modified) on drive axle joints.
CAUTION: Support steering knuckle/hub and bearing assembly during strut

removal to prevent tension from being applied to brake hose. Do not
overextend drive axle joints.
2. Remove brakeline bracket from strut. Scribe strut-to-mounting bracket outline on steering knuckle for
reassembly reference. Remove lower strut-to-steering knuckle bolts and remove strut assembly from
vehicle. DO NOT chip or scratch coil spring coating. Support steering knuckle/hub and bearing assembly
to prevent overextending drive axle joints.
Disassembly
CAUTION: Do not chip or crack coil spring coating. Coil spring damage may
occur if coating is damaged.
1. Mount Strut Compressor (J-34013-B) in Holding Fixture (J-3289-20). Mount strut assembly into strut
compressor. Wear eye protection while performing this operation. Compress strut to about 1/2 its height.
DO NOT bottom spring or strut rod. Using a socket, hold strut rod stationary while removing nut from
top of rod.
2. Install Guide Rod (J-34013-197) on strut rod to guide rod down through bearing cap of strut mount while
decompressing strut spring. Remove strut and spring from compressor.
Reassembly
1. Install strut mount into strut compressor, if removed. Mount strut into compressor. Extend strut rod and
attach Rod Clamp (J-34013-20) onto lower portion of strut rod.
2. Install components onto strut rod. Ensure flat side of upper spring seat is aligned with lower strut-to-
steering knuckle mounting flange. Install Guide Rod (J-34013-197) to center components on strut rod.
Remove guide rod when threads are visible on strut rod.
3. Install strut rod nut. Using a socket, hold strut rod stationary while tightening nut on top of strut rod. See
TORQUE SPECIFICATIONS . Remove rod clamp.
Installation
Install upper strut onto body. Install lower strut to steering knuckle ensuring scribe marks on steering knuckle
align with strut and mounting bracket. To complete installation, reverse removal procedure. Tighten bolts to
specification. See TORQUE SPECIFICATIONS . Lower vehicle and check wheel alignment. See appropriate
SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.
CONTROL ARM
Removal
rests on jackstands and not on control arms. Remove front wheel assemblies. Disconnect ABS wheel
speed sensor.
2. Remove stabilizer bar from control arm. See STABILIZER BAR & BUSHING ASSEMBLY . Remove
castle nut and separate ball joint from steering knuckle using Ball Joint Separator (J-41820). See BALL
JOINT . Remove control arm mounting bolts and remove control arm.
Installation
NOTE: Control arm bolts must be tightened to specification with vehicle weight on
control arms.
To install, reverse removal procedure. Tighten control arm bolts with vehicle weight on control arms. Tighten
bolts to specification. See TORQUE SPECIFICATIONS . Lower vehicle and check wheel alignment. See
appropriate SPECIFICATIONS & PROCEDURES article in WHEEL ALIGNMENT.
CONTROL ARM BUSHINGS
Remove control arm. See CONTROL ARM . Bushing replacement requires the following bushing removal
tools:
J 21474-01 Control Arm Bushing Service Set.

J 34126 Driven Sprocket Support Bearing Installer.
J 35379 Front Knuckle Support.
J 21474-4 Service Tool.
1. Secure lower control arm in vise. Assemble bushing removal tools. See Fig. 3 .
2. Tighten service tool until bushing is removed from control arm.
NOTE: Lower control arm vertical bushing must be installed into original position
from which it was removed in order to maintain original vehicle ride,
handling and road feel.
3. Insert bushing into control arm. Assemble bushing installation tool.

4. Tighten service tool until bushing is fully seated into control arm.
5. To complete procedure, install lower control arm. See CONTROL ARM .
Fig. 3: Removing/Installing Lower Control Arm Vertical Bushing
STABILIZER BAR & BUSHING ASSEMBLY
Removal
Raise and support vehicle. Allow suspension to hang freely. Remove stabilizer bar links from control arms.
Remove stabilizer bar reinforcement plates from frame. Remove stabilizer bar and bushings from vehicle.
Inspect and replace all rubber bushings showing signs of wear, damage or deterioration.
Installation
To install, reverse removal procedure. Install bushings with slit facing toward front of vehicle. During
installation, loosely assemble all fasteners and ensure stabilizer bar is centered from side to side. Tighten bolts
and nuts to specification. See TORQUE SPECIFICATIONS .
Ball Joint Castle Nut 40 (54)
Ball Joint Nuts 50 (68)
Brake Caliper Bolt 63 (85)
Hub & Bearing Retaining Bolt 96 (130)
Lower Control Arm Nuts 83 (113)
Stabilizer Bar Insulator Bracket Bolts 35 (47)
Stabilizer Bar Link Nut 17 (23)
Strut Lower Nuts 90 (122)
Strut Mounting Nuts 30 (41)
Strut Shaft Nut 63 (85)
Fuses & Circuit Breakers
IDENTIFICATION

battery.
CENTER CONSOLE FUSE BLOCK
NOTE: Center console fuse block is on the right side of the center console. See Fig. 1 .
Fig. 1: Locating Center Console Fuse Block
Fig. 2: Identifying Center Console Fuse Block Components
Fig. 3: Center Console Fuse Block Legend (1 of 3)

UNDERHOOD FUSE BLOCK
NOTE: Underhood fuse block is located on the right side of the engine compartment,
next top washer fluid reservoir. See Fig. 6 .
Fig. 6: Locating Underhood Fuse Block
Fig. 7: Identifying Underhood Fuse Block Components
Fig. 8: Underhood Fuse Block Legend (1 of 3)
Horns - Aztek & Rendezvous
SPECIFICATIONS

Specification
Horn Bracket Bolt 10 N.m 89 lb in

HORNS SCHEMATIC ICONS
Horns Schematic Icons

Icon Icon Definition
CAUTION:
When performing service on or near the SIR
components or the SIR wiring, the SIR system
must be disabled. Refer to SIR Disabling and
Enabling Zones. Failure to observe the correct
procedure could cause deployment of the SIR
components, personal injury, or unnecessary
SIR system repairs.
HORNS SCHEMATICS
Fig. 1: Horns
COMPONENT LOCATOR
HORNS COMPONENT VIEWS
Fig. 2: Horn Component View - Right
Callouts For Fig. 2

1 Horn - Right
HORNS CONNECTOR END VIEWS
Horn - Left (Low Note)

12052644
2-Way F Metri-Pack 150 Series Sealed (GY)

A BK 1350 Ground
B D-GN 29 Horn Control
Horn - Right (High Note)
12052644
2-Way F Metri-Pack 150 Series Sealed (GY)

A BK 1250 Ground
B D-GN 29 Horn Control
DIAGNOSTIC STARTING POINT - HORNS


The horn may be activated momentarily using the scan tool.
When commanded the body control module (BCM) will
Horn Output Output Control
ground the horn relay control circuit energizing the horn
relay causing the horn to sound.
SCAN TOOL DATA LIST
The Horns Scan Tool Data List contains all of the horn related parameters that are available on the scan tool.
The parameters in the list are arranged in alphabetical order. The column, "Data List," indicates the location of
the parameter within the scan tool menu selections. Use the Horns Scan Tool Data List as directed by a
diagnostic table or in order to supplement the diagnostic procedures. Begin all of the diagnostic procedures with
Diagnostic System Check - Vehicle in Vehicle DTC Information.
Use the Scan Tool Data List only after the following is determined:
customer concern.
first row of the Scan Tool Data List table. Comparison of the parameter values from the suspect vehicle with the
Typical Data Values may reveal the source of the customer concern.
Scan Tool Data List

Ignition 0 Data Volts Varies
Horn Relay Outputs On/Off Off
Ignition 0
The scan tool displays the current state of the battery in volts.
Horn Relay
The scan tool displays the commanded state of the horn relay. The scan tool displays on when the BCM
allows the horn relay to go to ground to activate the horn. The BCM will command this state when the
PANIC button on the keyless entry transmitter is activated or when there is an unauthorized entry into the
vehicle.
DTC B2752
Circuit Description
The vehicle horn is activated whenever ground is applied to the horn relay coil through the horn relay control
circuit. Ground may be applied by either of the following:
The body control module (BCM)

The horn switch
DTC Descriptor
DTC B2752 Horn Relay Coil Circuit Low
The BCM commands the horn relay to energize.
The BCM detects a short to ground in the horn relay control circuit for approximately 300 milliseconds.
The horn will remain on at all times.


A current DTC will clear when the fault is no longer present and the ignition switch is cycled.
A history DTC will clear after 100 consecutive ignition cycles without a fault present.
A scan tool may be used to clear history and current DTCs.
Diagnostic Aids
Always begin diagnosis with the first DTC listed on the scan tool.
The scan tool must display DTC B2752 as a current code before performing these diagnostics.
Inspect for a sticking horn pad and or switch.
Perform a visual inspection for loose or poor connections at all related components.
Refer to Testing for Intermittent Conditions and Poor Connections in Wiring Systems.
Test Description
2: Listen for an audible click when the horn relay operates. Command both the ON and OFF states.
Repeat the commands as necessary.
3: Tests for voltage at the coil side of the horn relay. The HORN fuse supplies power to the coil side of
the horn relay.
4: Verifies that the BCM is providing ground to the horn relay.
5: Tests if ground is constantly being applied to the horn relay.
DTC B2752
Step Action Yes No
Schematic Reference: Horns Schematics
1
Vehicle in Vehicle
3. With a scan tool, command the horn relay ON
2 and OFF.
Does the horn relay turn ON and OFF with each Go to Diagnostic
command? Aids Go to Step 3
2. Disconnect the horn relay.
horn relay coil with a test lamp that is connected
to a good ground.

1. Connect a test lamp between the horn relay
control circuit and the battery positive voltage
circuit of the horn relay coil.
4 2. With a scan tool, command the horn relay ON
and OFF.

5
Test the horn relay control circuit for an open. Refer to
6
Systems.
Test the horn relay control circuit for a short to ground.
7
Wiring Systems.
Inspect for poor connections at the horn relay. Refer to
Systems.
Repair the battery positive voltage circuit of the horn
relay coil. Refer to Wiring Repairs in Wiring
10
Systems.
Replace the horn relay.
11
12
text.
SYMPTOMS - HORNS
IMPORTANT: The following steps must be completed before using the symptom tables:
1. Perform Diagnostic System Check - Vehicle in Vehicle DTC Information, before using the symptom
tables in order to verify that all of the following are true:
2. Review the system operation in order to familiarize yourself with the system functions. Refer to Horns
System Description and Operation .
Inspect for aftermarket devices which could affect the operation of the horn system. Refer to Checking
cause the symptom.
Perform the following if a horn buzzes or has a harsh tone:
Inspect for debris in the joint where the horn fastens to the vehicle.
Test the torque of the horn mounting hardware. The horn mounting hardware should be tightened to
a torque of 10 N.m (7 lb ft).
Intermittent
Symptom List
Horns Always On
Horns Inoperative
Horns Inoperative - One Horn
Horns - Poor Tone
HORNS ALWAYS ON
Test Description
4: Tests if ground is constantly being applied to the horn relay.

5: The horn relay control circuit includes the horn switch. The horn switch is part of the inflatable
restraint steering wheel module. The horn switch must be tested for a short to ground when testing the
relay control circuit.
Horns Always On
Step Action Yes No
1
Vehicle in Vehicle
2. Turn the ignition ON, with the engine OFF. Go to Testing for
2 3. With a scan tool, command the body control Intermittent
module (BCM) Horn Output ON and OFF. Conditions and
Poor Connections
Is the horn on at all times? Go to Step 3 in Wiring Systems
3 2. Disconnect the horn relay.
Is the horn on at all times? Go to Step 8 Go to Step 4

voltage circuit of the horn relay coil and the horn relay
4
control circuit.
IMPORTANT:
The horn switch is part of the inflatable restraint
steering wheel module. Refer to Inflatable Restraint
Steering Wheel Module Replacement (Aztek) or
Inflatable Restraint Steering Wheel Module
Replacement (Rendezvous) in SIR.
5 1. To disable the SIR system, refer to SIR

Disabling and Enabling Zone 3 in SIR.
2. Test the horn relay control circuit for a short to

6 Testing for Intermittent Conditions and Poor
Connections andConnector Repairs in Wiring
Systems.
Repair the short to voltage in the horn control circuit.
8
Wiring Systems.
9
10
Operate the horn.
11
Does the horn operate properly? System OK Go to Step 1
HORNS INOPERATIVE
Test Description
4: Verifies that the body control module (BCM) is providing ground to the horn relay.
5: Tests for voltage at the battery positive voltage terminal of the horn relay coil.
7: Tests for voltage at the battery positive voltage terminal of the horn relay switch. The HORN fuse
supplies power to the battery positive voltage terminal of the horn relay switch.
13: The horn needs maximum current flow to operate properly. A high resistance, greater than 0.5 ohm,
in the horn control circuit or the horn ground circuit could cause operating problems with the horn.
Inspect the circuits for faults that would restrict current flow.
15: The horn relay control circuit includes the horn switch. The horn switch is part of the inflatable
restraint steering wheel module. The horn switch must be tested for a high resistance, an open or a short
to voltage when testing the relay control circuit.
Horns Inoperative
Step Action Yes No
1
Vehicle in Vehicle
Depress the horn switch.
2
Does the horn operate? Go to Step 3 Go to Step 5
3 3. With a scan tool, command the body control Intermittent
module (BCM) Horn Output ON and OFF. Conditions and
Poor Connections
Does the horn operate? in Wiring Systems Go to Step 4
Test the BCM portion of the horn relay control circuit
for a high resistance or an open. Refer to Circuit
4
2. Disconnect the horn relay.
5 voltage circuit of the horn relay coil and a good
ground.

voltage circuit of the horn relay coil and the horn
relay control circuit.
6
2. Depress and hold the horn switch.

voltage circuit of the horn relay switch and a good
7
ground.
Momentarily connect a 15-amp fused jumper wire
between the battery positive voltage circuit of the horn
8
relay switch and the horn control circuit.
Do the horns operate? Go to Step 12 Go to Step 9
1. Reconnect the horn relay.
2. Disconnect either horn connector.
3. Connect a test lamp between the horn control
9 circuit and a good ground.

10 circuit and the horn ground circuit.
Systems.
IMPORTANT:
A resistance as low as 0.5ohm could cause
operating problems with the horn.
13
Repair the high resistance in the horn control circuit or
the horn ground circuit. Refer to Circuit Testing and
Wiring Repairs in Wiring Systems.Did you complete
the repair? Go to Step 21 -
Repair the open or high resistance in the battery
positive voltage circuit of the horn relay coil. Refer to
Systems.
IMPORTANT:
The horn switch is part of the inflatable restraint
steering wheel module. Refer to Inflatable Restraint
Steering Wheel Module Replacement (Aztek) or
Inflatable Restraint Steering Wheel Module
Replacement (Rendezvous) in SIR.
15 1. To disable the SIR system, refer to SIR

Disabling and Enabling Zone 3 in SIR.
2. Repair the open or short to voltage in the horn
relay control circuit. Refer to Circuit Testing

Repair the open or high resistance in the battery
positive voltage circuit of the horn relay switch. Refer
16 to Circuit Testing andWiring Repairs in Wiring
Systems.
Repair the open or high resistance in the horn control
circuit. Refer to Circuit Testing and Wiring Repairs
in Wiring Systems.
17
Repair the open or high resistance in the horn ground
18
in Wiring Systems.
19
20
Operate the horn.
21
HORNS INOPERATIVE - ONE HORN
Test Description
The number below refer to the step number on the diagnostic table.
9: The horns need maximum current flow to operate properly. A high resistance, greater than 0.5 ohm, in
the horn control circuit or the horn ground circuit could cause operating problems with the horns. Inspect
the circuits for faults that would restrict current flow.
Horns Inoperative - One Horn

Step Action Yes No
DEFINITION: This diagnostic procedure is for use with systems that have multiple horns in which one
of the horns is inoperative.
1
Vehicle in Vehicle
Depress the horn switch. Go to Testing for
Do all of the horns operate? Intermittent
2 Conditions and
Poor Connections
1. Disconnect the inoperative horn.

circuit and the horn ground circuit.
4 2. Depress and hold the horn switch.

Inspect for poor connections at the inoperative horn.
Systems.
1. Connect a 15-amp fused jumper wire between
the positive battery terminal and the control
terminal of the horn.
6 2. Connect another jumper wire between the
negative battery terminal and the ground
terminal of the horn.
Does the horn sound? Go to Step 9 Go to Step 10

Repair the open or poor connection in the horn control
7
in Wiring Systems.
Repair the open or poor connection in the horn ground
8
in Wiring Systems.
the horn ground circuit of the horn. Refer to Circuit
9
Replace the inoperative horn. Refer to Horn
10 Replacement .
Operate the horns.
11
Do the horns operate properly? System OK Go to Step 1
HORNS - POOR TONE
Horns - Poor Tone

Step Action Yes No
1
Vehicle in Vehicle
Depress the horn switch. Go to Symptoms -
2
Does the horn have a harsh tone or buzzing? Go to Step 3 Horns
1. Test the horn mounting hardware for adequate
torque. Refer to Fastener Tightening
Specifications .
3 2. Inspect the horn for debris in the joint where the
horn attaches to the vehicle.

1. Disconnect the horn connector.
2. Connect a 15-amp fuse jumper wire between the
positive battery terminal and the control terminal
of the horn.
4 3. Connect another jumper wire between the
negative battery terminal and the ground terminal
of the horn.
Does the horn have a harsh tone or buzzing? Go to Step 6 Go to Step 5

the horn ground circuit. Refer to Circuit Testing and
5
Replace the horn. Refer to Horn Replacement .
6
Operate the horn.
7
REPAIR INSTRUCTIONS
HORN REPLACEMENT
Removal Procedure
1. Remove the right and/or left headlamp. Refer to Headlamp Assembly or Headlamp Bulb Replacement
Fig. 3: View Of Horn Electrical Connector
2. Disconnect the horn electrical connector.

Fig. 4: Identifying Horn Bracket Bolt
3. Remove the horn bracket bolt.

Fig. 5: View Of Horn
4. Remove the horn from the front bumper impact bar.
Fig. 6: View Of Horn
1. Position the horn to the front bumper impact bar; position the horn anti-rotation tab onto the tab on the
front bumper impact bar.
Fig. 7: Identifying Horn Bracket Bolt
2. Install the horn bracket bolt.

Fig. 8: Locating Horn Electrical Connector
3. Connect the horn electrical connector.

4. Install the right and/or left headlamp. Refer to Headlamp Assembly or Headlamp Bulb Replacement

HORNS SYSTEM DESCRIPTION AND OPERATION
System Description
The horn system consists of the following components:
The horn fuse

The horn relay
The horn switch, the horn switch is part of the inflatable restraint steering wheel module
The horn, vehicle may be equipped with a one or two horn system
The body control module (BCM)
System Operation
The vehicle horn system is activated under the following conditions:
The horn switch is depressed.

The body control module (BCM) commands the horn on. The BCM commands the horn on under any of
When the content theft deterrent system detects a vehicle intrusion. For further information refer to
Content Theft Deterrent (CTD) Description and Operation in Theft Deterrent.
When the panic button is depressed on the remote control door lock transmitter. For further
information refer to Content Theft Deterrent (CTD) Description and Operation in Theft
Deterrent.
When the keyless entry system is used to lock the vehicle, a horn chirp may sound to notify the
driver that the vehicle has been locked. The notification feature may be enabled or disabled through
personalization. For further information refer to Keyless Entry System Description and
Operation in Keyless Entry.
When the OnStar(R) system is used to sound the horn. For further information refer to OnStar
Description and Operation in Cellular Communication.
Circuit Operation
Battery positive voltage is applied at all times to the horn relay coil and the horn relay switch. Pressing the horn
switch applies ground to the horn relay control circuit. The BCM may also apply ground to the horn relay
control circuit as described above. When the horn relay control circuit is grounded, the horn relay is energized
and battery positive voltage is applied to the horn through the horn control circuit. The horn sounds as long as
ground is applied to the horn relay control circuit.
Automatic A/C-Heater Systems - Aztek & Rendezvous
SPECIFICATIONS
Fig. 1: Fastener Tightening Specifications Table

SENSOR RESISTANCE TABLE (OUTSIDE AIR TEMPERATURE)

Fig. 2: Sensor Resistance Table (Outside Air Temperature)
SENSOR RESISTANCE TABLE (EVAPORATOR TEMPERATURE)

Fig. 3: Sensor Resistance Table (Evaporator Temperature)

HVAC SCHEMATICS (POWER, GROUND AND BLOWER CONTROLS)
Fig. 4: HVAC Schematics (Power, Ground And Blower Controls)
HVAC SCHEMATICS (A/C COMPRESSOR CONTROLS)

Fig. 5: HVAC Schematics (A/C Compressor Controls)
HVAC SCHEMATICS (AIR DELIVERY CONTROLS)

Fig. 6: HVAC Schematics (Air Delivery Controls)
COMPONENT LOCATOR
HVAC COMPONENT VIEWS
Instrument Panel and Center Console - Pontiac

Fig. 7: Locating Components Instrument Panel And Center Console - Pontiac
Instrument Panel - Buick

Fig. 8: Locating Components Instrument Panel - Buick
LH Side of Engine
Fig. 9: Identifying Water Pump And A/C Compressor
HVAC CONNECTOR END VIEWS
A/C Compressor Clutch

Fig. 10: Identifying A/C Compressor Clutch Connector End

Fig. 11: Identifying A/C Refrigerant Pressure Sensor Connector End
Air Temperature Actuator - Left

Fig. 12: Identifying Air Temperature Actuator - Left Connector End
Air Temperature Actuator - Right - CJ3

Fig. 13: Identifying Air Temperature Actuator - Right - CJ3 Connector End
Blower Motor Resistor Assembly

Fig. 14: Identifying Blower Motor Resistor Assembly Connector End
Evaporator Temperature Sensor
Fig. 15: Identifying Evaporator Temperature Sensor Connector End

HVAC Control Module - C1

Fig. 16: Identifying HVAC Control Module - C1 Connector End

Fig. 17: Identifying HVAC Control Module - C2 Connector End
Mode Actuator
Fig. 18: Identifying Mode Actuator Connector End
Recirculation Actuator
Fig. 19: Identifying Recirculation Actuator Connector End

DIAGNOSTIC SYSTEM CHECK - HVAC SYSTEMS - AUTOMATIC
Test Description
The numbers below refer to the step numbers on the diagnostic table
3. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a
total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular
condition.
5. Determine if the HVAC Control Module, Body Control Module or Powertrain Control Module have
set DTCs which may affect HVAC operation are present.
6. The presence of DTCs which begin with "U" indicate some other module is not communicating. The
specified procedure will compile all the available information before tests are performed.
7. Answer Yes if the first 3 characters of the DTC name begins with B10; regardless of the last 2
characters.
DIAGNOSTIC SYSTEM CHECK - HVAC SYSTEMS - AUTOMATIC

Fig. 20: Automatic HVAC System Diagnosis (Steps 1-6)
Fig. 21: Automatic HVAC System Diagnosis (Steps 7-9)
HVAC Control Module Scan Tool Output Controls
Fig. 22: HVAC Control Module Scan Tool Output Controls

PCM Scan Tool Output Controls
Fig. 23: PCM Scan Tool Output Controls

SCAN TOOL DATA LIST

BCM Scan Tool Data List
Fig. 24: BCM Scan Tool Data List

HVAC Control Module Scan Tool Data List
Fig. 25: HVAC Control Module Scan Tool Data List

PCM Scan Tool Data List

Fig. 26: PCM Scan Tool Data List
The HVAC Scan Tool Data Definitions contain a brief description of all the scan tool parameters. This list is in
alphanumeric order.
A/C High Side Pressure: The scan tool displays -103 to +3119 kPa (-14 to +452 psi). This parameter
represents the A/C refrigerant pressure sensor voltage signal converted to pressure.
A/C High Side Pressure: The scan tool displays 0.00-5.00 Volts. This parameter represents the A/C refrigerant
pressure sensor signal.
A/C Off For WOT: The scan tool displays Yes or No. Yes indicates that the PCM has disabled the A/C
compressor because the TP sensor signal is at wide open throttle.
A/C Pressure Disable: The scan tool displays Yes or No. Yes indicates that the PCM has disabled the A/C
compressor due to excessive refrigerant pressure.
A/C Request: The scan tool displays Yes or No. The PCM uses the A/C request signal in order to determine if
A/C compressor operation is being requested by the HVAC control module.
A/C Request Signal: The scan tool displays Yes or No. The PCM uses the A/C request signal in order to
determine if A/C compressor operation is being requested by the HVAC control module.
A/C Relay Command: The scan tool displays On or Off. Represents the PCM commanded state of the A/C
compressor clutch relay. The A/C compressor clutch should be engaged when Commanded A/C displays On.
Ambient Air Temperature: The scan tool displays -50 to +87.5C (-58 to +189.5F). The output of the
ambient air temperature sensor.
Auto Mode: The scan tool displays On or Off. When in Auto mode the scan tool displays On. When in Manual
mode the scan tool displays Off.
Auto Button: The scan tool displays On or Off. When the AUTO button is pressed the scan tool displays On.
When released, the scan tool displays Off.
Blower Speed: The scan tool displays 0 to 8 bars. When the blower motor is commanded off the scan tool
displays 0. When the blower motor controls are placed in the maximum speed setting the scan tool displays 8
bars. This coincides with the HVAC control module display.
Evaporator Temp: This data displays -40 to 87.5C (-40 to 189.5F). The output of the evaporator temperature
sensor.
Fan Down Button: The scan tool displays On or Off. When the Blower Speed Control Down button is pressed
the scan tool displays On. When released, the scan tool displays Off.
Fan Up Button: The scan tool displays On or Off. When the Blower Speed Control Up button is pressed the
scan tool displays On. When released, the scan tool displays Off.
Front Defrost Button: The scan tool displays On or Off. When the Front Defrost button is pressed the scan
tool displays On. When released, the scan tool displays Off.
Inside Air Temperature: The scan tool displays -50 to +87.5C (-58 to +189.5F). The output of the inside air
temperature sensor.
Left Temp Door Position: The scan tool displays 0 to 195 counts. The signal output from the feedback pot on
the actuator.
Mode Button: The scan tool displays On or Off. When the Mode button is pressed the scan tool displays On.
Mode Door Position: The scan tool displays Vent, Mix-Blend, Floor, Bi- Level or Defrost. The current
operating mode of the HVAC system.
Off Button: The scan tool displays On or Off. When the Off button is pressed the scan tool displays On. When
released, the scan tool displays Off.
Rear Defrost Button: The scan tool displays On or Off. When the Rear Defrost button is pressed the scan tool
displays On. When released, the scan tool displays Off.
Recirculate Button: The scan tool displays On or Off. When the Recirculate button is pressed the scan tool
Recirculation Mode: The scan tool displays Ambient Air or Recirculate. The current operating state of the
recirculation door.
Right Temp Door Position: The scan tool displays 0 to 195 counts. The signal output from the feedback pot on
the actuator.
Selected Air Mode: The scan tool displays Warm Up, Defrost or Off. The current operating mode of the
HVAC system.
Sun Load Sensor: The scan tool displays 0 to 255 counts. The signal output from the Sun Load Sensor.
Vent Button: The scan tool displays On or Off. When the Vent button is pressed the scan tool displays On.
DIAGNOSTIC TROUBLE CODE (DTC) LIST
Fig. 27: Diagnostic Trouble Code (DTC) List

DTC B0165 OR B0166
Circuit Description
The HVAC control module monitors the passenger compartment inside air temperature through an inside air
temperature sensor. The inside air temperature sensor is a integral part of the HVAC control module. When the
air is cold, the sensor resistance and the signal voltage are high. When the air is warm, the sensor resistance and
the signal voltage are low.
The ignition is turned ON.
The HVAC control module detects the signal circuit is less than 0.09 volts.
The HVAC control module detects the signal circuit is more than 4.90 volts.
The DTC is stored in DTC information.

The HVAC control module will continue to monitor the reference signal of the inside air temperature
sensor.

The DTC will become history if the HVAC control module no longer detects a condition.
The history DTC clears after 50 fault free ignition cycles.
The DTC can be cleared with a scan tool.
Diagnostic Aids
If the condition is not present, refer to TESTING FOR INTERMITTENT AND POOR CONNECTIONS .
DTC B0165 OR B0166
Fig. 28: DTC B0165 Or B0166 Diagnosis

DTC B0233
Circuit Description
The mode actuator is an electronic device that incorporates a stepper motor and feedback potentiometer. The
HVAC control module controls the mode door position by sending a control signal to the actuator. The signal's
value is dependent upon the desired mode selected by the vehicle occupants. As the actuator moves, the
potentiometer produces the actual door position signal that is sent to the HVAC control module. The HVAC
control module continues to command the actuator to move until the desired and actual values are equal. The
door directs airflow through the outlets as selected by the vehicles occupants.
The HVAC control module commands the actuator through it's full range. The HVAC control module stores the
learned minimum and maximum position values. The travel range value is calculated by subtracting the
minimum and maximum position values. Then the HVAC control module compares the travel range, minimum
and maximum values to calibrated value ranges. If the travel range value is less than or equal to the maximum
calibrated limit and greater than or equal to the minimum calibrated limit, then the calibration is considered
successful. The HVAC control module continuously compares the actual actuator position to the calibrated
minimum and maximum position values.
The ignition is ON.

Ignition voltage is between 9-16 volts.
Mode actuator position signal is less than 5 counts.

Mode actuator position signal is more than 194 counts.
The mode actuators total travel range is less than or greater than the calibrated limits.

The HVAC control module will continue to make use of whatever travel range is still available.
If the HVAC control no longer detects a failure, then the DTC will become history.
The history DTC will clear after 50 ignition cycles without a failure.
Diagnostic Aids
A damaged or broken mode door and or actuator can cause this DTC to set.
If the Mode actuator travels beyond it's calibrated limits the DTC will set.
DTC B0233
Fig. 29: DTC B0233 Diagnosis (Steps 1-4)
DTC B0408 OR B0418
Circuit Description
The HVAC control module commands the air temperature actuator movement with one of three voltage signals
applied to the air temperature door control circuit. A low voltage of 0 volts moves the air temperature door
toward full hot. A voltage of 2.5 volts stops the actuator. A high voltage of 5 volts moves the air temperature
door toward full cold. The HVAC control module determines the current position of the actuator by monitoring
the feedback voltage of the air temperature door position signal circuit. The feedback potentiometer position is a
function of the actuator position. A high voltage indicates a full cold air temperature door position. A low
voltage indicates a full hot air temperature door position. The HVAC control module controls the air
temperature door position in order to maintain the selected air temperature.

The air temperature position signal is less than 5 counts.

The air temperature position signal is greater than 194 counts.
The air temperature actuator actual total travel range max-min is less than or greater than the range limits.
The HVAC control module will continue to make use of whatever air temperature actuator travel range is
still available.
The DTC will become history if the HVAC control module no longer detects a failure.
The history DTC will clear after 50 fault free ignition cycles.
Diagnostic Aids
A damaged or broken air temperature actuator or mode door can cause this DTC to set.
If the condition is not present refer to TESTING FOR INTERMITTENT AND POOR
CONNECTIONS .
DTC B0408 OR B0418

Fig. 31: DTC B0408 Or B0418 Diagnosis (Steps 1-5)
Fig. 32: DTC B0408 Or B0418 Diagnosis (Steps 6-15)
DTC B3933
Circuit Description
The HVAC control module monitors the temperature of the refrigerant through the evaporator via a evaporator
temperature sensor. When the refrigerant temperature is low the sensor resistance and the signal voltage are
high. When the refrigerant temperature is high the sensor resistance and the signal voltage are low.
The sensor works in conjunction with a switch to meter the flow of refrigerant therefore preventing the freezing
of moisture that condenses on the evaporator. An evaporator with too little refrigerant will starve causing
insufficient cooling. An evaporator flooded with refrigerant will also cause poor cooling when there is too much
liquid refrigerant that cannot vaporize quickly.
The HVAC control module detects the signal circuit is less than 5 counts (0.09 V).
The HVAC control module will store the trouble code in memory.
A default value will be used for the sensor data by the HVAC control module to allow the A/C system to
operate.
Diagnostic Aids
Test Description
3. Tests for the proper operation of the circuit in the high voltage range.
4. Tests for the proper operation of the circuit in the low voltage range. If the fuse in the jumper opens
when you perform this test, the signal circuit is shorted to voltage.
DTC B3933
DTC P0530
Circuit Description
The powertrain control module (PCM) monitors the high side refrigerant pressure via a A/C refrigerant pressure
sensor. When the pressure is high the signal voltage is high. When the pressure is low the signal voltage is low.
When pressure is high the PCM commands the cooling fans on. When pressure is too high or too low the PCM
will not allow the A/C compressor clutch to engage.

A/C has been requested.
The PCM detects the signal circuit is less than 5 counts (0.09 volt) or more than 250 counts (4.90 volts).
The condition exists for 20 seconds.
The PCM will not illuminate the Malfunction Indicator Lamp (MIL).
The PCM stores the failure records.
The A/C compressor clutch is disabled.
The DTC will become history if the PCM no longer detects a failure.
The history DTC will clear after 40 fault-free ignition cycles.
Diagnostic Aids
If the condition is not present refer to TESTING FOR INTERMITTENT AND POOR CONNECTIONS .
Test Description
4. If the pressure signal voltage stays high after disconnecting the pressure sensor electrical connector, the
signal circuit is shorted to voltage, or the PCM is faulty.
7. Tests for a high resistance or for an open in the ground circuit.
16. This vehicle is equipped with a PCM which utilizes an Electrically Erasable Programmable Read
Only Memory (EEPROM). Before you replace the PCM, program the new PCM.
DTC P0530
Fig. 35: DTC P0530 Diagnosis (Steps 1-8)
Fig. 36: DTC P0530 Diagnosis (Steps 9-17)
DTCP1546
Ignition voltage is supplied directly to the A/C compressor clutch relay. The powertrain control module (PCM)
controls the relay by grounding the control circuit of the A/C clutch relay through an internal solid state device.
This device is called a driver. The driver supplies the ground for the component that is being controlled. Each
driver has a fault line which is monitored by the PCM. When the PCM commands a component ON, the voltage
of the control circuit should be near 0 volts. When the PCM commands the control circuit to a component OFF,
the voltage potential of the circuit should be near battery voltage. If the fault detection circuit senses an
unexpected voltage, this DTC will set.
The PCM will monitor the control circuit to the A/C clutch relay for the following conditions:
A short to ground
A short to voltage
An open circuit
An open relay coil
A relay coil that is shorted internally or which has a very low resistance
If the PCM detects any of these malfunctions, this DTC is set, and the affected driver is disabled.
The ignition voltage is between 9.0-18.0 volts.
A short to ground, an open circuit, or a short to battery voltage is detected on the control circuit to the
A/C clutch relay.
The condition is present for at least 30 seconds.
The PCM will store those conditions which were present when the DTC set. These conditions are
recorded as Failure Records data only.
This information will not be stored as Freeze Frame data.
A history DTC will clear after 50 consecutive fault free ignitions have occurred without a malfunction.
The DTC can be cleared by using a scan tool.
Diagnostic Aids
Important: Inspect PCM engine grounds for being secure and clean.
If DTC P1546 cannot be duplicated, review the Failure Records. Observe the vehicle mileage since the
diagnostic test last failed. This may help to determine how often the condition which caused the DTC to set
occurs. This may assist in diagnosing the condition.
Test Description
The numbers below refer to the step numbers on the diagnostic table:
2. Listen for an audible click when the relay operates.
Command the ON and the OFF states. Repeat the commands as necessary.
12. The PCM utilizes Electrically Erasable Programmable Read Only Memory (EEPROM).
Program the new PCM before you replace the PCM.
DTC P1546
Fig. 37: DTC P1546 Diagnosis
SYMPTOMS - HVAC SYSTEMS - AUTOMATIC

Important: The following steps must be completed before using the symptom tables.
1. Perform the DIAGNOSTIC SYSTEM CHECK - HVAC SYSTEMS - AUTOMATIC before using the
Symptom Tables in order to verify that all of the following are true:
2. Review the system operation in order to familiarize yourself with the system functions. Refer to:
AIR DELIVERY DESCRIPTION AND OPERATION
AIR TEMPERATURE DESCRIPTION AND OPERATION
Inspect for aftermarket devices which could affect the operation of the HVAC System. Refer to
CHECKING AFTERMARKET ACCESSORIES .
cause the symptom.
Verify the A/C compressor clutch turns freely and is not seized.
Verify that the customer is using the correct key to enable personalization and is not inadvertently
activating steering wheel or passenger HVAC controls.
The A/C compressor will not operate in cold outside air temperatures. Refer to AIR TEMPERATURE
The following conditions may cause window fogging:
Wet carpet or mats
High humidity
Interior water leak
Blocked A/C evaporator drain tube
Maximum passenger capacity
Blocked body pressure relief valves
Inspect the air distribution system for causes of reduced air flow:
Obstructed or dirty passenger compartment air filter, if equipped
Blocked or damaged air inlet or outlet vents
Intermittent
INTERMITTENT AND POOR CONNECTIONS .
Symptom List
HVAC COMPRESSOR CLUTCH DOES NOT ENGAGE

HVAC COMPRESSOR CLUTCH DOES NOT DISENGAGE
Blower Motor Always on, see Fig. 44
Blower Motor Inoperative, see Fig. 45
BLOWER MOTOR MALFUNCTION
TOO HOT IN VEHICLE
TOO COLD IN VEHICLE
AIR DELIVERY IMPROPER
AIR RECIRCULATION MALFUNCTION
LEAK TESTING
DEFROSTING INSUFFICIENT
NOISE DIAGNOSIS - BLOWER MOTOR
NOISE DIAGNOSIS - AIR CONDITIONING (A/C) SYSTEM
ODOR DIAGNOSIS
NOISE DIAGNOSIS - HVAC MODULE
OUTSIDE AIR TEMPERATURE DISPLAY INACCURATE OR INOPERATIVE
Diagnostic Aids
The Mitsubishi scroll type A/C compressor carries an internal thermal cut off switch. The thermal cut off switch
normal operation is to open and disable the compressor under extreme load and temperatures above 155C
(311F). The internal thermal cut off switch is non-serviceable.
Test Description
2. The A/C compressor relay output is disabled if engine coolant temperature is above 121C (250F).
The engine coolant indicator will illuminate at this temperature.
3. Pressing the center of the left side driver temperature control switch and setting the air temperature
control switch in a cold setting activates A/C operation. For the purpose of this and future steps where
A/C operation is necessary, bi-level mode is used for consistent testing.
6. The HVAC control module is inoperative when the module does not respond to any operator control
requests to enable the A/C compressor. The blower motor may still operate independent of the A/C
controls.

Fig. 38: HVAC Compressor Clutch Does Not Engage Diagnosis (Steps 1-4)
Fig. 42: HVAC Compressor Clutch Does Not Disengage Diagnosis (Steps 1-5)
BLOWER MOTOR ALWAYS ON

Fig. 44: Blower Motor Always On Diagnosis
BLOWER MOTOR INOPERATIVE

Fig. 45: Blower Motor Inoperative Diagnosis (Steps 1-9)
Test Description
2. This step will determine if one or more blower speeds are inoperative.
3. This step determines if the HVAC control module and blower motor control processor are attempting
to control the blower motor speed.
5. The measured voltage on the blower speed control circuit should steadily increase from 0 V to 8.0 V as
the blower speed is adjusted from the minimum speed position to the maximum speed position.
Fig. 47: Blower Motor Malfunction Diagnosis (Steps 1-7)
TOO HOT IN VEHICLE
Diagnostic Aids
Test Description
7. This test is to ensure A/C system is operating normally.

10. The aspirator tube connects to the rear of the HVAC control module. The aspirator tube is used to
draw air past the inside air temperature sensor.
Fig. 49: Too Hot in Vehicle Diagnosis (Steps 1-7)
Fig. 50: Too Hot In Vehicle Diagnosis (Steps 8-17)
Fig. 51: Too Hot In Vehicle Diagnosis (Steps 18-21)
TOO COLD IN VEHICLE
Test Description
The step numbers below refer to the step numbers on the diagnostic table
3. This checks for A/C compressor clutch always on.

7. This test is to insure cooling system is operating normally.
10. The aspirator tube connects to the rear of the HVAC control module. The aspirator tube is used to
Fig. 52: Too Cold In Vehicle Diagnosis (Steps 1-9)
Fig. 53: Too Cold In Vehicle Diagnosis (Steps 10-21)
Test Description
3. This step tests for a blower motor that does not operate regardless of the desired blower motor speed.
4. This step tests for a blower motor that operates, yet does not accurately respond to the desired blower
motor speed.
5. The HVAC control module is inoperative when the it does not respond to any operator requests.
This step verifies that there is power to the HVAC control assembly.
13. The voltage will vary between 0-5 volts during normal operation. The HVAC control assembly
connector must be connected during this step.
Fig. 54: Air Delivery Improper Diagnosis (Steps 1-10)
Fig. 57: Air Recirculation Malfunction Diagnosis (Steps 1-6)


REPAIR INSTRUCTIONS
HVAC CONTROL MODULE REPLACEMENT
Removal Procedure
1. Remove the I/P cluster trim plate bezel. Refer to TRIM PLATE BEZEL REPLACEMENT --
INSTRUMENT PANEL (I/P) CLUSTER (AZTEK) or TRIM PLATE BEZEL REPLACEMENT --
INSTRUMENT PANEL (I/P) CLUSTER (RENDEZVOUS) .
2. Remove the HVAC control module retaining screws.
Fig. 59: Removing HVAC Control Module Retaining Screws
3. Pull the HVAC control module out from the I/P.

4. Disconnect the aspirator hose (1) from the HVAC control module.
5. Disconnect the electrical connector from the HVAC control module.
6. Remove the HVAC control module.
Fig. 60: Disconnecting Aspirator Hose From HVAC Control Module
1. Connect the electrical connector to the HVAC control module.

2. Connect the aspirator hose (1) to the HVAC control module.
3. Install the HVAC control module to the I/P.
Fig. 61: Connecting Aspirator Hose To HVAC Control Module
4. Install the HVAC control module retaining screws.
Tighten
Tighten the screws to 2.5 N.m (22 Ib. in).
5. Install the I/P cluster trim plate bezel. Refer to TRIM PLATE BEZEL REPLACEMENT --
Fig. 62: Installing HVAC Control Module Retaining Screws
BLOWER MOTOR CONTROL PROCESSOR REPLACEMENT
Removal Procedure
1. Remove the right side I/P insulator. Refer to CLOSEOUT/INSULATOR PANEL REPLACEMENT --
RIGHT .
2. Disconnect the blower motor electrical connector.
3. Remove the blower motor mounting screws.
4. Remove the blower motor from the HVAC module assembly.
Fig. 63: Disconnecting Blower Motor Electrical Connector
5. Disconnect the electrical connector from the blower motor control processor assembly.
Fig. 64: Disconnecting Electrical Connector From Blower Motor Control Processor Assembly
6. Remove the forward blower control processor mounting screws.

7. Remove the rearward blower control processor mounting screw.
8. Remove the blower control processor assembly from the HVAC module assembly.
Fig. 65: Removing Blower Control Processor Assembly From HVAC Module Assembly
1. Install the blower motor control processor assembly to the HVAC module assembly.
2. Install the rearward mounting screw.
Tighten
Tighten the screw to 1 8 N m (16 Ib in)

3. Install the forward mounting screws.
Tighten
Fig. 66: Installing Blower Control Processor Assembly From HVAC Module Assembly
4. Connect the electrical connector to the blower control processor assembly.

5. Install the blower motor to the HVAC module assembly.
6. Install the blower motor mounting screws.
Tighten
Tighten the screws to 1.8 N.m (16 lb ft).
Fig. 67: Connecting Electrical Connector To Blower Control Processor Assembly

7. Connect the blower motor electrical connector.

8. Install the right side I/P insulator. Refer to CLOSEOUT/INSULATOR PANEL REPLACEMENT --
RIGHT .
Fig. 68: Connecting Blower Motor Electrical Connector
RECIRCULATION ACTUATOR REPLACEMENT
Removal Procedure
1. Remove the upper I/P trim pad. Refer to TRIM PAD REPLACEMENT -- INSTRUMENT PANEL
(I/P) UPPER (AZTEK) or TRIM PAD REPLACEMENT -- INSTRUMENT PANEL (I/P) UPPER
(RENDEZVOUS) .
2. Disconnect the recirculation actuator electrical connector.
Fig. 69: Disconnecting Recirculation Actuator Electrical Connector
3. Remove the mounting screws from the recirculation actuator.

4. Remove the recirculation actuator.
Fig. 70: Removing Mounting Screws And Recirculation Actuator
1. Install the recirculation actuator.

2. Install the recirculation actuator mounting screws.
Tighten

Fig. 71: Installing Mounting Screws And Recirculation Actuator
3. Connect the recirculation actuator electrical connector.

4. Install the upper I/P trim pad. Refer to TRIM PAD REPLACEMENT -- INSTRUMENT PANEL (I/P)
UPPER (AZTEK) or TRIM PAD REPLACEMENT -- INSTRUMENT PANEL (I/P) UPPER
(RENDEZVOUS) .
Fig. 72: Connecting Recirculation Actuator Electrical Connector
MODE ACTUATOR REPLACEMENT
Removal Procedure
1. Remove the knee bolster from the instrument panel (I/P). Refer to KNEE BOLSTER
REPLACEMENT .
2. Disconnect the mode actuator electrical connector.
Important: Count the number of threads showing from the tip of the mode actuator push rod to the end
of the retainer clip.
3. Open the mode actuator push rod retainer clip (1) with a small flat-bladed screwdriver.
4. Disconnect the mode actuator push rod (2) from the retainer clip (1).
Fig. 73: Disconnecting Mode Actuator Push Rod From Retainer Clip
Important: Disconnect the I/P wiring harness clip from the I/P support bracket to help access the mode
actuator screws.
5. Disconnect the I/P wiring harness clip from the I/P support bracket.
6. Remove the mode actuator mounting screws.
7. Remove the mode door actuator.
Fig. 74: Removing Mode Actuator Mounting Screws
1. Install the mode actuator.

2. Install the mode actuator mounting screws.
Tighten
3. Connect the I/P wiring harness clip to the I/P support bracket.
Fig. 75: Installing Mode Actuator Mounting Screws
Important: Align the counted number of threads on the mode actuator push rod (2) with the tip of the
retainer clip (1).
4. Connect the mode actuator push rod (2) to the retainer clip (1).
5. Close the push rod retainer clip (1).
6. Connect the mode actuator electrical connector.
7. Install the knee bolster. Refer to KNEE BOLSTER REPLACEMENT .
Fig. 76: Connecting Mode Actuator Push Rod To Retainer Clip
AIR TEMPERATURE ACTUATOR REPLACEMENT - RIGHT
Removal Procedure
1. Remove the I/P compartment. Refer to COMPARTMENT REPLACEMENT -- INSTRUMENT

PANEL (I/P) .
2. Disconnect and remove the right hand temperature door lever spring (2).
3. Disconnect and remove the right hand temperature lever (1) from the right hand temperature door.
Fig. 77: Disconnecting And Removing Right Hand Temperature Door Lever Spring
4. Disconnect the right hand temperature actuator electrical connector.

Fig. 78: Disconnecting Right Hand Temperature Actuator Electrical Connector
5. Remove the right hand temperature actuator mounting screws.

6. Remove the right hand temperature actuator.
Fig. 79: Removing Right Hand Temperature Actuator Mounting Screws
1. Install the right hand temperature actuator.

2. Install the right hand temperature actuator mounting screws.
Tighten

Fig. 80: Installing Right Hand Temperature Actuator Mounting Screw
3. Connect the right hand temperature actuator electrical connector.

Fig. 81: Connecting Right Hand Temperature Actuator Electrical Connector
Important: Align the pin on the right hand air temperature actuator with the slot in the right hand
temperature door lever.
4. Install the right hand temperature lever (1) to the right hand temperature door.
5. Connect the right hand temperature door lever spring (2) to the right hand temperature door lever (1) and
HVAC module case.
6. Install the I/P compartment. Refer to COMPARTMENT REPLACEMENT -- INSTRUMENT
PANEL (I/P) .
Fig. 82: Connecting Right Hand Temperature Door Lever Spring
AIR TEMPERATURE ACTUATOR REPLACEMENT - LEFT
Removal Procedure
1. Remove the knee bolster. Refer to KNEE BOLSTER REPLACEMENT .
Important: The HVAC controls must be set to the vent mode to position the defroster door lever for
access to the air temperature actuator.
2. Set the HVAC controls to the vent mode to position the defroster door lever.
3. Remove the left hand temperature door lever bolt (3) from the HVAC module.
4. Disconnect and remove the left hand temperature door lever spring (2).
5. Disconnect and remove the left hand temperature door lever (1) from the left hand temperature door.
Fig. 83: Removing Left Hand Temperature Door Lever Bolt And Spring
6. Disconnect the left hand air temperature actuator electrical connector.

Fig. 84: Disconnecting Left Hand Air Temperature Actuator Electrical Connector
7. Remove the left hand air temperature actuator mounting screws.

8. Remove the left hand air temperature actuator.
Fig. 85: Removing Left Hand Air Temperature Actuator Mounting Screws
1. Install the left hand air temperature actuator.

2. Install the left hand air temperature actuator mounting screws.
Tighten

Fig. 86: Installing Left Hand Air Temperature Actuator Mounting Screws
3. Connect the left hand air temperature actuator electrical connector.

Fig. 87: Connecting Left Hand Air Temperature Actuator Electrical Connector
Important: Align the pin on the left hand air temperature actuator with the slot in the left hand
4. Install the left hand temperature door lever (1) to the left hand temperature door.
5. Connect the left hand temperature door lever spring (2) to the left hand temperature door lever (1) and
HVAC module case.
6. Install the left hand temperature door lever bolt (3) to the HVAC module case.
Tighten
Tighten the bolt to 0.9 N.m (8 Ib. in).

Fig. 88: Installing Left Hand Temperature Door Lever Bolt And Spring
ASPIRATOR REPLACEMENT
Removal Procedure
1. Remove the IP carrier. Refer to INSTRUMENT PANEL (I/P) CARRIER REPLACEMENT .

2. Remove the aspirator hose mounting screw.
3. Disconnect the aspirator hose from the aspirator duct adapter (1).
4. Remove the aspirator hose from the HVAC module.
Fig. 89: Removing Aspirator Hose Mounting Screw And Hose
1. Install the aspirator hose to the HVAC module.

2. Install the aspirator hose retaining screw.
Tighten
Tighten the screw 0.9 N.m (8 Ib. in).
3. Connect the aspirator hose to the aspirator duct adapter (1).

4. Install the IP carrier. Refer to INSTRUMENT PANEL (I/P) CARRIER REPLACEMENT .
Fig. 90: Installing Aspirator Hose Mounting Screw And Hose

AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT
Tools Required
J 38778 Door Trim Pad Clip Remover
Removal Procedure
1. Open the hood.
2. Disconnect the electrical connector from the ambient air temperature sensor.
Fig. 91: Disconnecting Electrical Connector From Ambient Air Temperature Sensor
3. Use J 38778 to disconnect the wiring harness retainer which secures the ambient air temperature sensor to
the hood latch support.
4. Remove the ambient air temperature sensor from the wiring harness retainer.
5. Remove the ambient air temperature sensor from the vehicle.
Fig. 92: Removing Ambient Air Temperature Sensor From Vehicle
1. Install the ambient air temperature sensor on the wiring harness retainer.
2. Install the wiring harness push-in retainer which secures the ambient air temperature sensor to the hood
latch support.
3. Connect the electrical connector to the ambient air temperature sensor.
Fig. 93: Connecting Electrical Connector To Ambient Air Temperature Sensor
SUN LOAD SENSOR REPLACEMENT
Removal Procedure
1. Remove the windshield garnish molding. Refer to GARNISH MOLDING REPLACEMENT --

WINDSHIELD PILLAR .
Important: Remove the I/P upper trim panel slowly, the retainer clips could possibly fall into the I/P.
2. Lift the I/P upper trim panel up approximately 51 mm (2 in) and pull rearward to release I/P upper trim
panel retainers.
3. Lift the I/P upper trim panel to access sun load sensor.
4. Disconnect the sunload sensor electrical connector.
5. Remove the sun load sensor.
Fig. 94: Lifting I/P Upper Trim Panel To Access Sun Load Sensor
1. Install sun load sensor.

2. Connect the sunload sensor electrical connector.
3. Align the I/P upper trim locating pins and the retainers to the slots in the I/P.
Fig. 95: Connecting Sunload Sensor Electrical Connector
4. Push forward and down on the I/P upper trim panel to lock into place.
5. Install the windshield garnish molding. Refer to GARNISH MOLDING REPLACEMENT --
WINDSHIELD PILLAR .
Fig. 96: Pushing Forward And Down On I/P Upper Trim Panel To Lock Into Place

The air delivery description and operation is divided into five areas:
HVAC Control Components

Air Speed
Air Delivery
Recirculation Operation
Automatic Operation
HVAC Control Module
The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to
maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the
control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all
HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle
mode master, provides a device on signal. The control module supports the following features:
Fig. 97: Feature & Availability Table

Mode Actuator
The mode actuator is a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition
3 voltage, low reference, control, 5 volt reference and position signal circuits enable the actuator to operate. The
control circuit uses either a 0, 2.5 or 5 volt signal to command the actuator movement. When the actuator is at
rest, the control circuit value is 2.5 volts. A 0 or 5 volt control signal commands the actuator movement in
opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door
position signal between 0-5 volts.
The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal
voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, the control
signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the
commanded value. As the actuator shaft rotates the changing position signal is sent to the module. Once the
position signal and the commanded value are the same, the module changes the control signal to 2.5 volts.
The recirculation actuator is a 3 wire bi-directional electric motor. Ignition 3 voltage, ground and control
circuits enable the actuator to operate. The control circuit is either grounded or opened during normal operation.
If the control circuit is grounded, then the shaft rotates in the opposite direction than it would if the circuit was
opened. The actuator shaft rotates until the limit is reached. If the module needs to reverse the direction of
rotation, then the control circuit's state is reversed. The open circuits are held at ignition 3 voltage from the
actuator. The module will maintain the control circuit's state until a new position is needed.
The blower motor control processor is an interface between the HVAC control module and the blower motor.
The blower motor speed control, Blower motor speed signal, battery positive voltage and ground circuits enable
the control processor to operate. The HVAC control module sends the commanded blower motor speed to the
control processor through a 0 to 12-volt linear ramped blower motor speed control circuit. As the blower motor
speed control voltage increases, the blower motor speed increases. The control processor sends the actual
blower speed to the control module through a 0 to 12-volt blower motor speed signal circuit. The processor
supplies 12volts to the blower motor through the blower motor voltage supply circuit. The control processor
uses the blower motor ground as a low side control to adjust the blower motor speed.
Air Speed
The blower motor forces air to circulate within the vehicle's interior. The vehicle operator determines the
blower motor's speed by placing the blower motor switch in a desired speed position or by selecting automatic
operation. In manual operation, once a blower speed is selected, the blower speed remains constant until a new
speed is selected. In automatic operation, the HVAC control module will determine what blower speed is
necessary in order to achieve or maintain a desired temperature.
OFF Mode
Press the passenger temperature knob to turn off the HVAC control module. When the vehicle is moving, air
flowing over the vehicle increases the air pressure just ahead of the windshield. This forces air into the ambient
air into the HVAC module and out through the floor and windshield outlets. Since the A/C compressor is not
running, the incoming air may be warmed but not cooled. Recirculation is not adjustable in OFF mode.
Purge Operation
If the ambient air temperature is less than 2 C (35 F) and the coolant temperature is less than 10 C (50 F), then a
75-second purge will occur. The purge will begin as soon as the coolant temperature reaches 4 C (40 F). The
mode door will move to the defrost position and the blower motor will be near half speed.
Air Distribution
The HVAC control module controls the mode actuator in order to distribute airflow to a desired outlet. The
mode switch provides the vehicle operator with the ability to override the automatic setting. When the mode
door is moved to the defrost position, the A/C compressor clutch engages and the recirculation actuator will be
moved to the outside air position. Regardless of the mode setting, a small amount of air will be diverted to the
defrost ducts to reduce windshield fogging. This vehicle may be equipped with a passenger compartment air
filter. When VENT is pressed, the following will occur:
The recirculation actuator will be placed in the outside air position

The A/C compressor will be commanded off
The mode is adjustable
After a malfunction occurs to the mode actuator it is driven to the Defrost position. On start-up, the HVAC
control module will place the mode door in the last selected position.
The HVAC control module controls the air intake through the recirculation actuator. Recirculation is only
available when the HVAC control module is in Panel or Bi-level. The recirculation mode will stay on and the
recirculation indicator will illuminate until either outside air or a non-recirculation mode is selected. When the
recirculation actuator sees an open in the control circuit, the actuator will default to the recirculation position.
Automatic Operation
In automatic operation, the HVAC control module will maintain the comfort level inside of the vehicle by
controlling the A/C compressor clutch, the blower motor, the air temperature actuators, mode actuator and
recirculation. To place the HVAC system in Automatic mode you must set the temperature and press the drivers
temperature knob. Once the desired temperature is reached, the blower motor, mode, recirculation and
temperature actuators will automatically be adjusted to maintain the temperature selected. The HVAC control
module performs the following functions to maintain the desired air temperature:
Monitor the following sensors:

Inside air temperature sensor
Ambient air temperature sensor
Sunload sensor
Regulate blower motor speed

Position the air temperature actuator
Position the mode actuator
Position the recirculation actuator
Request A/C operation
The air temperature controls are divided in 5 primary areas:

Heating and A/C Operation
Automatic Operation
Engine Coolant
A/C Cycle
HVAC CONTROL COMPONENTS

HVAC Control Module
The HVAC control module works in a dual role operating both air temperature and A/C operation from the
drivers side switch. The HVAC control module is a class 2 device that interfaces between the operator and the
HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit
provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage
circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM),
which is the vehicle mode master, provides a device on signal. The control module supports the following
features:
Fig. 98: Feature & Availability Table

Air Temperature Actuator
The air temperature actuator is a 5-wire bi-directional electric motor that incorporates a feedback potentiometer.
Ignition 3 voltage, low reference control, 5-volt reference and position signal circuits enable the actuator to
operate. The control circuit uses either a 0, 2.5 or 5-volt signal to command the actuator movement. When the
actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5-volt control signal commands the actuator
movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact
changes the door position signal between 0-5 volts. The HVAC control module uses a range of 0-255 counts to
index the actuator position. When the module sets a commanded, or targeted, value, the control signal is
changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the
Inside Air Temperature Sensor
Replacement of the inside air temperature sensor means replacing the HVAC control module. The inside air
temperature sensor is an integral part of the HVAC control module. The HVAC control module monitors the
passenger compartment inside air temperature through an inside air temperature sensor. When the air is cold,
the sensor resistance and the signal voltage are high. When the air is warm, the sensor resistance and the signal
voltage are low. The HVAC control module requests A/C compressor clutch engagement and controls the air
temperature actuator door positions in order to maintain the selected air temperature. The HVAC control
module sends out a 5-volt reference signal to the inside air temperature sensor over the 5-volt reference circuit.
A thermistor varies the reference voltage back to the HVAC control module through the low reference circuit.
The A/C refrigerant pressure sensor is a 3-wire piezoelectric pressure transducer. A 5-volt reference, low
reference, and signal circuits enable the sensor to operate. The A/C pressure signal can be between 0-5 volts.
When the A/C refrigerant pressure is low, the signal value is near 0 volts. When the A/C refrigerant pressure is
high, the signal value is near 5 volts.
The A/C refrigerant pressure sensor protects the A/C system from operating when an excessively high or low
pressure condition exists. The PCM disables the compressor clutch under the following conditions:
A/C pressure is more than 2979 kPa (432 psi). The clutch will be enabled after the pressure decreases to
less than 1510 kPa (219 psi).
A/C pressure is less than 186 kPa (27 psi). The clutch will be enabled after the pressure increases to more
than 207 kPa (30 psi).
The A/C system is protected by the evaporator temperature sensor. The sensor located on the evaporator core
provides the HVAC control module with the surface temperature of the evaporator core. If the evaporator
temperature sensor reads a temperature of 0C (32F), the HVAC control module will turn off the A/C
compressor clutch until evaporator temperatures reach 2C (36F).
The ambient air temperature sensor is a 2-wire negative temperature co-efficient thermistor. The vehicle uses
the following air temperature sensors:
Ambient
Inside
A 5-volt reference and signal circuit enables the sensor to operate. As the air temperature surrounding the sensor
increases, the sensor resistance decreases.
The sensor operates within a temperature range of -40C (-40F) to 60C (140F). The HVAC control module
receives a class 2 message from the instrument panel cluster (IPC). The ambient air temperature sensor is
mounted in the forward engine area of the vehicle. In this position, it is exposed to the airflow through the grill
before it reaches the radiators. The sensor signal varies between 0 to 5 volts. The HVAC control module
converts the signal to a working temperature range.
If the HVAC control module detects a faulty class 2 signal, then the control module software will use a
defaulted air temperature value.
The default action ensures that the HVAC system can adjust the inside air temperature near the desired
temperature until the system is fixed.
The ambient air temperature is updated and displayed under the following conditions:
Fig. 99: Ambient Air Temperature Condition Display Table

Sunload Sensor
The sunload sensor is a 2-wire photo diode. Low reference and signal circuits enable the sensor to operate. As
the light shining upon the sensor gets brighter, the sensor conductance increases. The sensor signal decreases as
the conductance increases. The sensor operates within an intensity range between completely dark and bright.
The sensor signal varies between 0-5 volts. The HVAC control module converts the signal to a range between
0-255 counts.
The sunload sensor provides the HVAC control module a measurement of the amount of light shining on the
vehicle. Bright, or high intensity, light causes the vehicles inside temperature to increase. The HVAC system
compensates for the increased temperature by diverting additional cool air into the vehicle. If the HVAC control
module detects a malfunctioning sensor, then the control module software will use a defaulted sunload valve.
temperature until the condition is fixed. A resistance check of the sunload sensor should not be performed as it
will damage the sensor.
The purpose of the heating and A/C system is to provide heated and cooled air to the interior of the vehicle. The
A/C system will also remove humidity from the interior and reduce windshield fogging. The vehicle operator
can determine the passenger compartment temperature by adjusting the air temperature switch. Regardless of
the temperature setting, the following can effect the rate that the HVAC system can achieve the desired
temperature:
Recirculation actuator setting

Difference between inside and desired temperature
Difference between ambient and desired temperature
Blower motor speed setting
Mode setting
The control module makes the following actions when automatic operation is not selected, and an air
temperature setting is selected:
When the air temperature switch is placed in the warmest position, the control module commands the air
temperature door to divert maximum air past the heater core.
When the air temperature switch is placed in the coldest position, the control module commands the air
temperature door to direct air to bypass the heater core.
When the air temperature switch is placed between the warmest and coldest positions, the control module
monitors the following sensor inputs to determine the air temperature door position that diverts the
appropriate amount of air through the heater core in order to achieve the desired temperature:
Sunload
Ambient temperature
Inside temperature
The following shows what blower motor, recirculation actuator, and mode actuator adjustments are made for
each air temperature switch selection:
The A/C system can be engaged by either pressing the driver temperature switch or during automatic operation.
The A/C display will illuminate on the HVAC control module display board when the driver temperature switch
is pressed. The control module sends a class 2 A/C request message to the powertrain control module (PCM).
The HVAC system uses a scroll compressor that incorporates a thermal switch that opens once the compressor
temperature is more than 155C (311F). The thermal switch is a non-serviceable item. The following
conditions must be met in order for the PCM to turn on the compressor clutch:
HVAC control module

Ambient temperature more than 0C (32F)
Evaporator Temperature more than 2C (36F)
BCM
Battery voltage between 9-16 volts
A/C request from the HVAC control module
PCM
Engine coolant temperature (ECT) is less than 125C(257F)
Engine RPM is below 5000 RPM
A/C Pressure is between 1510-2979 kPa (219-432 psi)
Once engaged, the compressor clutch will be disengaged for the following conditions:
Compressor thermal switch is opened

Throttle position is 100 percent
A/C Pressure is more than 2979 kPa (432 psi)
A/C Pressure is less than 1510 kPa (219 psi)
Engine coolant temperature (ECT) is more than 125C (257F)
Engine speed is more than 5500 RPM
Transmission shift
PCM detects excessive torque load
PCM detects insufficient idle quality
PCM detects a hard launch
When the compressor clutch disengages, the compressor clutch diode protects the electrical system from a
voltage spike.
Dual Zone Operation
The HVAC control module uses dual rotary temperature switches. The dual zone controls allows for maximum
temperature offset and comfort between the driver and passenger. It is possible to select maximum airflow over
the evaporator core with one dual zone switch along with maximum airflow over the heater core with the other
dual zone switch. Each air temperature actuator is independent from the other and the passenger side is not
limited in it's range of temperature offset.
Automatic Operation

Sunload sensor

Engine Coolant
Engine coolant is the essential element of the heating system. The thermostat controls the normal operating
temperature of the engine. The thermostat also creates a restriction for the cooling system that promotes a
positive coolant flow and helps prevent cavitation.
Coolant enters the heater core through the inlet heater hose, in a pressurized state. The heater core is located
inside the HVAC module. The ambient air drawn through the HVAC module absorbs the heat of the coolant
flowing through the heater core. The HVAC module distributes heated air to the passenger compartment for
consistent passenger comfort.
Opening or closing the HVAC module temperature door controls the amount of heat delivered to the passenger
compartment. The coolant exits the heater core through the return heater hose and is recirculated back through
the engine cooling system.
A/C Cycle
Refrigerant is the key element in an air conditioning system. R-134a is presently the only EPA approved
refrigerant for automotive use. R-134a is a very low temperature gas that can transfer the undesirable heat and
moisture from the passenger compartment to the outside air.
A Mitsubishi scroll compressor is used on this model year vehicle. The A/C compressor is belt driven and
operates when the magnetic clutch is engaged. The compressor builds pressure on the vapor refrigerant.
Compressing the refrigerant also adds heat to the refrigerant. The refrigerant is discharged from the compressor,
through the discharge hose, and forced to flow to the condenser and then through the balance of the A/C system.
The A/C system is mechanically protected with the use of a high pressure relief valve. If the high pressure
switch were to fail or if the refrigerant system becomes restricted and refrigerant pressure continued to rise, the
high pressure relief will pop open and release refrigerant from the system.
Compressed refrigerant enters the condenser in a high temperature, high pressure vapor state. As the refrigerant
flows through the condenser, the heat of the refrigerant is transferred to the ambient air passing through the
condenser. Cooling the refrigerant causes the refrigerant to condense and change from a vapor to a liquid state.
The condenser is located in front of the radiator for maximum heat transfer. The condenser is made of
aluminum tubing and aluminum cooling fins, which allows rapid heat transfer for the refrigerant. The semi-
cooled liquid refrigerant exits the condenser and flows through the liquid line, to the TXV.
The TXV is located at the evaporator inlet. The TXV is the dividing point for the high and the low pressure
sides of the A/C system. As the refrigerant passes through the TXV, the pressure on the refrigerant is lowered.
Due to the pressure differential on the liquid refrigerant, the refrigerant will begin to boil at the TXV. The TXV
also meters the amount of liquid refrigerant that can flow into the evaporator.
Refrigerant exiting the TXV flows into the evaporator core in a low pressure, liquid state. Ambient air is drawn
through the HVAC module and passes through the evaporator core. Warm and moist air will cause the liquid
refrigerant boil inside of the evaporator core. The boiling refrigerant absorbs the moisture and heat from the
ambient air. The refrigerant exits the evaporator through the suction line and back to the compressor, in a vapor
state, and completing the A/C cycle of heat removal. At the compressor, the refrigerant is compressed again and
the cycle of heat removal is repeated.
The conditioned air is distributed through the HVAC module for passenger comfort. The heat and moisture
removed from the passenger compartment will also change form, or condense, and is discharged from the
HVAC module as water.

Fig. 100: Special Tools & Equipment Table (1 Of 2)
Fig. 101: Special Tools & Equipment Table (2 Of 2)
SPECIFICATIONS
SPECIFICATIONS
Compressor Type Mitsubishi ASTN
Compressor Belt Tension (1)
System Oil Capacity (2) 7.4 ozs.

Refrigerant (R-134a) Capacity 26.8 ozs.
System Operating Pressures (3)
High Side 158-191 psi (10.9-13.2
kg/cm2 )
Low Side 29-36 psi (1.9-2.4 kg/cm2 )
(1) Belt tension is adjusted automatically.
(2) Use PAG Refrigerant Oil (Part No. 12345923).
(3) Specification is with ambient temperature at 80F (27C), and relative humidity at 60 percent.
WARNING: To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.
A/C COMPRESSOR TEMPERATURE SWITCH
The A/C compressor clutch is protected from an overheating condition by a A/C compressor temperature switch
mounted at rear of compressor. The switch is wired internally and is not serviceable. Switch shuts off
compressor when temperatures reach 311F (155C) and allows the clutch to engage again when temperatures
are less than 257F (125C).
A/C REFRIGERANT PRESSURE SENSOR
The A/C system is protected by A/C refrigerant pressure sensor. The input to the PCM from the sensor is
variable and is dependent upon pressure inside refrigerant. A higher pressure results in a higher voltage output.
The A/C pressure is constantly monitored in order to allow the A/C compressor clutch to disengage as needed.
If refrigerant line pressures exceeds 432 psi (2979 kPa), the PCM will turn off the A/C compressor clutch until
pressure lowers to 219 psi (1510 kPa). If line pressures fall below 186 kPa (27 psi), the PCM will turn off the
A/C compressor clutch until pressure increases to 30 psi (207 kPa).
A 5-volt reference signal is sent out over the 5-volt reference circuit, from the PCM, to the A/C refrigerant
pressure sensor. The PCM monitors A/C pressure by sending out a separate 5-volt signal on the A/C pressure
sensor signal circuit. Ground for the A/C refrigerant pressure sensor is provided by the low reference circuit.
AIR TEMPERATURE ACTUATOR
When a desired temperature setting is selected, a variable resistor is used to determine the mode door position
signal value. The resistor changes the 12-volt signal coming into the actuator and varies the voltage to move the
actuator into the proper position, based on the signal from Heater Ventilation Air Conditioning (HVAC) control
module. The motor opens left air temperature actuator to a position to divert sufficient air past the heater core to
achieve the desired vehicle temperature. Ground is provided to left air temperature actuator by the ground
circuit.
BLOWER MOTOR
OFF
The blower motor will only operate in any switch position other than OFF, as long as ignition switch is on. The
blower motor OFF input is connected in series with the HVAC control module by the off blower motor control
circuit.
Low Speed
When low speed is selected, the HVAC control module applies voltage to blower motor resistor assembly
through the low blower motor control circuit. Voltage is divided between 4 resistors, a blower relay, and the
blower motor to obtain desired speed.
Medium-Low Speed
When medium-low (M1) speed is selected, the HVAC control module applies voltage to blower motor resistor
assembly through the M1 blower motor control circuit. Voltage is divided between 3 resistors, a blower relay,
and the blower motor to obtain desired speed.
Medium Speed
When medium speed (M2) speed is selected, the HVAC control module applies voltage to the blower motor
resistor assembly through the M2 blower motor control circuit. Voltage is divided between 2 resistors, a blower
relay, and the blower motor to obtain desired speed.
Medium-High Speed
When medium-high (M3) speed is selected, the HVAC control module applies voltage to the blower motor
resistor assembly through the M3 blower motor control circuit. Voltage is divided between one resistor, a
blower relay, and the blower motor to obtain desired speed.
High Speed
When high speed is selected, the HVAC control module applies voltage to the blower motor resistor assembly
through the high blower motor control circuit. The voltage energizes the blower relay, causing the blower motor
to be connected directly to battery voltage.
EVAPORATOR TEMPERATURE SENSOR
The A/C system is protected by evaporator temperature sensor (mounted on evaporator core). This sensor
provides the HVAC control module with the surface temperature of the evaporator core. If evaporator
temperature sensor reads a temperature of 32F (0C), the HVAC control module will turn off A/C compressor
clutch until evaporator temperatures reach 36F (2C).
The HVAC control module sends out a 5-volt reference signal to evaporator temperature sensor over the 5-volt
reference circuit. A thermistor varies the reference voltage back to the HVAC control module through the low
reference circuit.
HVAC CONTROL MODULE
OFF Mode
When OFF is selected, the Heater Ventilation Air Conditioning (HVAC) control module applies voltage to
blower switch off input (within HVAC control module) through the off blower motor control circuit. When
HVAC control module receives this input, any A/C request will be cancelled and the A/C request LED will turn
off. Fresh air will be brought in from the outside, the LED indicator will not illuminate.
A/C Mode
The A/C system is activated by placing mode switch in any position and pressing the A/C switch. The A/C
system operates regardless of temperature setting. The PCM will operate A/C system without any driver input.
The PCM will command the A/C compressor clutch on to reduce moisture inside of vehicle. The A/C
compressor is on, even in cool weather conditions, to keep moisture from fogging the windshield. The A/C
LED will not illuminate unless the driver presses A/C switch on HVAC control module. The A/C system may
be running without the A/C LED indicator being lit.
Regardless of selected A/C setting, a request is made to the PCM to turn on A/C compressor on the class 2
serial data circuit. The request is made by the HVAC control module to the Body Control Module (BCM)
through the A/C request signal circuit when the A/C switch grounds the 12-volt signal from the BCM. The
BCM then sends a class 2 message to the PCM on the BCM class 2 serial data circuit. The PCM grounds the
clutch relay control circuit and engages the A/C compressor clutch.
The PCM turns on A/C compressor by providing a path to ground through the A/C clutch relay control circuit
for the A/C compressor clutch relay. Power is provided to the A/C compressor clutch relay internally through
the underhood junction block. Once the relay closes, battery voltage is provided to A/C compressor clutch
through the A/C compressor clutch supply voltage circuit. Whenever A/C compressor is turned off, the A/C
compressor clutch diode, located in the underhood junction block, prevents voltage spikes. The ground circuit
provides a path to ground for the compressor and relay. The A/C clutch relay control circuit is grounded
internally within the PCM.
Dual-Zone Mode
Vehicles with dual-zone climate controls will have an additional air temperature actuator. The Heater
Ventilation Air Conditioning (HVAC) control module will have dual sliding temperature switches instead of the
rotary temperature switch.
When a desired temperature setting is selected, a variable resistor is used to determine temperature door
position signal value. The resistor changes the 12-volt signal coming into actuator and varies the voltage to
move actuator into the proper position, based on the signal from HVAC control module. The motor opens right
air temperature actuator to a position to divert sufficient air past the heater core to achieve the desired vehicle
temperature. When the air temperature actuator sees an open in the control circuit, the actuator defaults to 6
volts and positions air temperature door mid-range.
The dual-zone climate controls allows for maximum temperature offset between driver and passenger. It is
possible to select maximum airflow over evaporator core with one dual-zone switch, along with maximum
airflow over heater core with the other dual-zone switch. Each air temperature actuator is independent from the
other.
Heater Mode
When a desired temperature setting is selected, a variable resistor is used to determine the temperature door
position signal value. The resistor changes the 12-volt signal coming into actuator and varies the voltage to
move the actuator into the proper position, based on the signal from HVAC control module. The motor opens
the left air temperature actuator to a position to divert sufficient air past the heater core to achieve the desired
temperature. When mode actuator sees an open in the control circuit, the actuator defaults to 6 volts and
positions air temperature door mid-range.
Recirculated Air Mode
When recirculation switch is pressed, a signal is sent from Heater Ventilation Air Conditioning (HVAC) control
module to the recirculation actuator through the recirculation door control circuit. When signal is received, the
recirculation actuator moves into recirculated air mode. This brings air from inside the vehicle instead of fresh
air from the outside. Recirculation is only available when HVAC control module is in vent or bi-level positions.
Recirculated air mode will stay on and the LED will illuminate until either outside air or a non-recirculated air
mode is selected. When the recirculation actuator sees an open in the control circuit, the actuator will default to
recirculated air position.
THERMOSTATIC EXPANSION VALVE
The semi-cooled liquid refrigerant exits the condenser and flows through the liquid line, to the Thermal
Expansion Valve (TXV). The TXV is located at the evaporator inlet. The TXV is the dividing point for the high
and the low pressure sides of the A/C system. As the refrigerant passes through the TXV, the pressure on the
refrigerant is lowered. Due to the pressure differential on the liquid refrigerant, the refrigerant will begin to boil
at the TXV. The TXV also meters the amount of liquid refrigerant that can flow into the evaporator. Refrigerant
exiting the TXV flows into the evaporator core in a low pressure, liquid state.
TROUBLE SHOOTING
NOTE: For additional trouble shooting information, see MANUAL A/C-HEATER
SYSTEMS - TROUBLE SHOOTING article.
DIAGNOSTIC SYSTEM CHECK
1. Install scan tool to DLC connector. Turn ignition on. If scan tool communicates with vehicle, retrieve any
PCM or BCM Diagnostic Trouble Codes (DTCs) that are related to HVAC system. No HVAC related
DTCs should be stored. If DTCs are stored, go to appropriate DTC table to diagnose. For PCM DTCs, go
to appropriate SELF-DIAGNOSTICS article in ENGINE PERFORMANCE. For BCM DTCs, go to
appropriate BODY CONTROL MODULES article in ACCESSORIES & EQUIPMENT.
2. Turn ignition switch to OFF position. Remove scan tool from DLC. Start engine and bring to operating
temperature. Close all doors, windows and hood. Turn mode control knob to upper (vent) position. Turn
blower switch to position No. 3 (medium-2) and turn temperature control to full hot (Red) position. Make
sure that A/C is in OFF position. Depress non-recirculated (fresh) air button and ensure LED comes on.
Install thermometer into upper air outlet. The A/C compressor should be off and hot air should be
discharged from vent outlets at medium speed. Air temperature should be 145-155F (63-69C) with
ambient (outside) temperature at 70-75F (21-24C).
3. With all others settings left alone, set temperature to full cold position. Depress A/C button to turn LED
on. Depress recirculated air button and ensure LED comes on. A/C compressor should be on and cold air
should be discharged from vent outlets at medium speed. Air temperature should be approximately 30F
(18C) lower than ambient temperature.
4. With all others settings left alone, turn A/C off. Depress non-recirculated (fresh) air button and ensure
LED comes on. A/C compressor should turn off and ambient air should be discharged from vent outlets at
medium speed. Check bi-level, floor, defog and defrost modes. If system does not operate as specified, go
to appropriate symptom test. See SYMPTOM TESTS .
SYMPTOM TESTS
AIR DELIVERY INCORRECT
1. Turn ignition on, engine off. Place blower motor switch in OFF position. If blower motor is off, go to
next step. If blower motor is off, problem is intermittent.
2. Place blower motor switch in each speed position. If blower motor operates in any speed position, go to
next step. If blower motor does not operate in any speed position, go to BLOWER MOTOR
INOPERATIVE .
3. If blower motor operates in each speed position, to next step. If blower motor does not operate in each
speed position, go to BLOWER MOTOR MALFUNCTION .
4. If all HVAC control module controls except for blower motor are inoperative, go to step 13 . If all
controls are not inoperative, go to next step.
5. Place blower motor switch in maximum speed position. Place mode switch in vent position. Place
recirculation switch in ON position. Observe recirculation door. Place outside air switch in ON position.
If recirculation door moves from recirculation to outside air position, go to next step. If recirculation door
does not move, go to AIR RECIRCULATION MALFUNCTION .
6. Place blower motor switch in maximum speed position. Place mode switch in each mode position. If air
flows with sufficient volume from proper air distribution outlets for each selected mode position, problem
is intermittent. If air does not flow with sufficient volume, go to next step.
7. Check air delivery system for dirty HVAC air filter, obstructed airflow, air leaks, and misaligned air
ducts. Repair as necessary. If all components are okay, go to next step.
8. Check mode door and mode actuator for misaligned mode actuator, broken or binding linkages,
obstruction preventing mode actuator from operating within full range of motion, missing or misaligned
seals. Repair components as necessary. If components are okay, go to next step.
9. Turn ignition off. Disconnect mode actuator. Turn ignition on, engine off. Probe ignition voltage circuit
of mode actuator with a test light connected to ground. If test light illuminates, go to next step. If test light
does not illuminate, go to step 19 .
10. Check ground circuit of mode actuator for an open or high resistance. If wiring is okay, go to next step.
11. Measure voltage between mode door control circuit of mode actuator and ground. Observe mode door
control circuit voltage. Place mode switch in each mode position. If voltage measures near specified
values for each mode position, go to step 17 . See MODE SWITCH VOLTAGE SPECIFICATIONS
table. If voltages are not to specification, go to next step
12. Check mode door control circuit of mode actuator for an open, high resistance, short to ground, or short
to voltage. If wiring is okay, go to step 18 .
13. Check ignition voltage circuit of HVAC control module for an open or high resistance. If wiring is okay,
go to next step.
14. Check battery positive voltage circuit of HVAC control module for an open or high resistance. If wiring
is okay, go to next step.
15. Check ground circuit of HVAC control module for an open or high resistance. If wiring is okay, go to
next step.
16. Check blower motor control circuit of HVAC control module for a short to voltage. If wiring is okay, go
to step 18 .
17. Check for poor connections at harness connector of mode actuator. If connections are okay, go to step
20 .
18. Check for poor connections at harness connector of HVAC control module. If connections are okay, go to
step 21 .
19. Repair ignition voltage circuit of mode actuator.
20. Replace mode actuator. See MODE ACTUATOR under REMOVAL & INSTALLATION.
21. Replace HVAC control module. See HVAC CONTROL MODULE under REMOVAL &
INSTALLATION.
MODE SWITCH VOLTAGE SPECIFICATIONS

Switch Position Volts
Vent .2
Bi-Level 3.1
Floor 5.9
Mix-Blend: 8.9
Defrost: 11.8
1. Turn ignition on, engine off. Place blower motor switch in maximum speed position. Place mode switch
in vent position. Place recirculation switch in ON position. Observe recirculation door. Place outside air
switch in ON position. If recirculation door moves from recirculation to outside air position, problem is
intermittent. If recirculation door does not move, go to next step.
2. Except for blower motor speed, if all functions of HVAC control module are inoperative, go to step 8 . If
all functions are not inoperative, go to next step.
3. Turn ignition off. Disconnect recirculation actuator. Turn ignition on, engine off. Probe ignition voltage
circuit of recirculation actuator with a test light connected to ground. If test light illuminates, go to next
step. If test light does not illuminate, go to step 14 .
4. Check ground circuit of recirculation actuator for an open or high resistance. If wiring is okay, go to next
step.
5. Reconnect recirculation actuator. Disconnect HVAC control module. Observe recirculation door. Connect
3-amp fused jumper wire between recirculation door control circuit and ground circuit. If recirculation
door moves into outside air position, go to step 13 . If door does not move to outside air position, go to
next step.
6. Check recirculation door control circuit of recirculation actuator for an open, high resistance, short to
ground, or short to voltage. If wiring is okay, go to next step.
7. Check recirculation door and recirculation actuator for misaligned recirculation actuator, broken or
binding linkages or recirculation door, obstruction preventing recirculation actuator from operating within
full range of motion, missing or misaligned seals to recirculation door. Repair as necessary. If
components are okay, go to step 12 .
8. Check ignition voltage circuit of HVAC control module for an open or high resistance. If wiring is okay,
to next step.
9. Check battery positive voltage circuit of HVAC control module for an open or high resistance. If wiring
10. Check ground circuit of HVAC control module for an open or high resistance. If wiring is okay, go to
next step.
11. Check blower motor control circuit of HVAC control module for a short to voltage. If wiring is okay, go
to step 13 .
12. Check for poor connections at harness connector of recirculation actuator. If connections are okay, go to
step 15 .
step 16 .
14. Repair ignition voltage circuit of recirculation actuator. See WIRING DIAGRAMS .
15. Replace recirculation actuator. See RECIRCULATION ACTUATOR under REMOVAL &
INSTALLATION.
16. Replace HVAC control module. See HVAC CONTROL MODULE .
1. Turn ignition on, engine off. Place blower motor switch in OFF position. If blower motor is off, problem
is intermittent. If blower is not off, go to step 2 .
2. Ensure blower motor switch is off. Turn ignition off. Disconnect blower motor resistor assembly
connector. Turn ignition on, engine off. Probe each blower motor control circuit with a test light
connected to ground. If test light illuminates while connected to any blower motor control circuits, go to
next step. If test light does not come on, go to step 4 .
3. Check appropriate blower motor control circuit for a short to voltage. If wiring is okay, go to step 5 .
4. Check for poor connections at harness connectors of blower motor resistor assembly. If connections are
okay, 6 .
step 7 .
6. Replace blower motor resistor assembly. See BLOWER MOTOR RESISTOR/RELAY under
INSTALLATION.
1. Turn ignition on, engine off. Place mode switch in vent position. Place blower motor switch in each speed
position. If blower motor operates in any speed position, problem is intermittent. If blower motor does not
operate in any speed position, go to next step.
2. Turn ignition off. Disconnect blower motor. Turn ignition on, engine off. Connect test light between
blower motor supply voltage circuit and ground. Place blower motor switch in minimum speed position.
If test light comes on, go to next step. If test light does not come on, go to step 5 .
3. Connect test light between blower motor supply voltage circuit and blower motor ground circuit. If test
light comes on, go to step 7 . If test light does not come on, go to next step.
4. Check ground circuit of blower motor resistor assembly for an open or high resistance. If wiring is okay,
go to step 8 .
5. Turn ignition off. Disconnect blower motor resistor assembly connector. Turn ignition on, engine off.
Place blower motor switch in minimum speed position. Connect test light between blower motor control
circuit of blower motor resistor assembly and ground. If test light illuminates, go to step 8 . If test light
does not illuminate, go to next step.
6. Turn ignition off. Disconnect HVAC control module connector. Turn ignition on, engine off. Connect test
light between ignition voltage circuit of HVAC control module and ground. If test light illuminates, go to
step 9 . If test light does not illuminate, go to step 10 .
7. Check for poor connections at harness connector of blower motor. If connections are okay, go to step 11 .
8. Check for poor connections at harness connector of blower motor resistor assembly. If connections are
okay, go to step 12 .
step 13 .
10. Repair ignition voltage circuit of HVAC control module.
11. Replace blower motor. See BLOWER MOTOR under REMOVAL & INSTALLATION.
INSTALLATION.
1. Turn ignition on, engine off. Place mode switch in vent position. Place blower motor switch in each speed
position. If blower motor operates in each speed position, problem is intermittent. If blower motor does
not operate in each speed position, go to next step.
2. Turn ignition off. Disconnect blower motor. Turn ignition on, engine off. Connect test light between
blower motor supply voltage circuit and ground. Place blower motor switch in each speed position. If test
light illuminates when blower motor switch is in each speed position, go to step 6 . If test light does not
illuminate when blower motor switch is in each speed position, go to next step.
3. Turn ignition off. Disconnect blower motor resistor assembly connector. Turn ignition on, engine off.
Connect test light between battery positive voltage circuit of blower motor resistor assembly and ground.
If test light illuminates, go to next step. If test light does not illuminate, go to step 9 .
4. Ensure blower motor switch is in correct speed position for blower motor control circuit being tested.
Probe each blower motor control circuit with a test light connected to ground. Place blower motor switch
in appropriate speed position for blower motor control circuit being tested. If test light illuminates when
blower motor switch is in each speed position, go to step 7 . If test light does not illuminate, go to next
step.
5. Check suspect blower motor control circuit for an open circuit. If wiring is okay, go to step 8 .
6. Check for poor connections at harness connector of blower motor assembly. If connections are okay, go
to step 10 .
7. Check for poor connections at harness connectors of blower motor resistor assembly. If connections are
step 12 .
9. Repair battery positive voltage circuit of blower motor resistor assembly. See WIRING DIAGRAMS .
10. Replace blower motor. See BLOWER MOTOR under REMOVAL & INSTALLATION.
INSTALLATION.
COMPRESSOR CLUTCH DOES NOT DISENGAGE
A/C compressor operates (does not disengage), go to next step. If A/C compressor does not operate,
problem is intermittent.
2. Using scan tool, observe A/C request signal parameter in powertrain control module data list. If scan tool
indicates A/C request signal parameter is YES, go to next step. If parameter is not YES, go to step 5 .
3. Check A/C request signal circuit for a short to ground. See WIRING DIAGRAMS . If wiring is okay, go
to next step.
4. Turn ignition off. Disconnect A/C high-pressure switch. Start engine. Using scan tool, observe A/C
request signal parameter. If scan tool indicates A/C request signal parameter is YES, go to step 12 . If
parameter is not YES, go to step 11 .
on and off with each command, go to next step. If relay does not turn on and off with each command, go
to step 8 .
6. Remove A/C compressor clutch relay. If A/C compressor is on, go to step 9 . If A/C compressor is not on,
go to next step.
7. Measure resistance between switch side A/C compressor clutch relay terminals. If infinite resistance is
present, go to next step. If infinite resistance is not present, go to step 10 .
8. Check A/C clutch relay control circuit for a short to ground. If wiring is okay, go to step 12 .
9. Check A/C compressor clutch supply voltage circuit for a short to voltage. If wiring is okay, go to step
14 .
10. Check for poor connections at A/C compressor clutch relay. If connections are okay, go to step 13 .
step 15 .
12. Check for poor connections at harness connector of Powertrain Control Module (PCM). If connections
are okay, go to step 16 .
13. Replace A/C compressor clutch relay. See Fig. 1 .
14. Replace A/C compressor clutch.
INSTALLATION.
16. Replace PCM. See POWERTRAIN CONTROL MODULE under REMOVAL & INSTALLATION.
COMPRESSOR CLUTCH DOES NOT ENGAGE
1. Ensure ambient air temperature is greater than 38F (3C). Start engine. Place blower motor switch in
maximum speed position. Place A/C request switch in ON position. Place air temperature switch in
coldest position. If A/C compressor clutch engages, problem is intermittent. If clutch does not engage, go
to next step.
operating, allow A/C system to equalize for approximately 2 minutes. Turn ignition off. Record ambient
air temperature at vehicle. Record readings of low and high side static pressures. Compare low and high
side pressure values with allowable limits for recorded ambient air temperature. See A/C PRESSURE
SPECIFICATIONS table. If low and high side pressure values are within allowable limits for recorded
ambient air temperature, and within 15 psi (1.03 kg/cm2 ) of each other, go to next step. If low and high
side pressure values are not within allowable limits for recorded ambient air temperature, and not within
15 psi (1.03 kg/cm2 ) of each other, check system for leaks.
A/C PRESSURE SPECIFICATIONS

Ambient Temp. High Side Pressure Low Side Pressure -
- F (C) (1) - psi (kg/cm2 ) psi (kg/cm2 )
66-75 160-199 (11.0-13.7) 29-36 (1.9-2.4)
76-85 158-191 (10.9-13.2) 29-36 (1.9-2.4)
86-95 171-223 (11.8-15.4) 34-45 (2.3-3.1)
(1) Relative humidity at 40-60 percent.
3. Turn ignition on, engine off. Using scan tool, observe A/C HIGH SIDE pressure sensor parameter in
powertrain data list Compare pressure values with specifications for ambient air temperature. If pressure
values within specification for ambient air temperature, and within 15 psi (1.03 kg/cm2 ) of each other, go
to next step. If pressure values are not within specification, go to step 22 .
4. If HVAC control module is inoperative, go to step 17 . If control module is operative, go to next step.
5. Start engine. Using scan tool, observe A/C request signal parameter in powertrain control module data
list. Place air temperature switch in coldest position. Place A/C request switch in ON position. If scan tool
indicates A/C request signal parameter is YES, go to step 11 . If scan tool does not indicate parameter is
YES, go to next step.
6. If A/C request indicator illuminates, go to next step. If indicator does not illuminate, go to step 31 .
7. Turn ignition off. Test A/C request signal circuit for a short to ground, high resistance, or an open. If
wiring is okay, go to next step.
8. Disconnect evaporator temperature sensor located in evaporator. Measure resistance of evaporator
temperature sensor. See EVAPORATOR TEMPERATURE SENSOR SPECIFICATIONS table. If
resistances are to specification, go to next step. If resistances are not to specification, go to step 29 .
EVAPORATOR TEMPERATURE SENSOR SPECIFICATIONS

Ambient Temp. - F (C) Resistance (K/Ohms)
-22 (-30) 52.78
-13 (-25) 39.81
-4 (-20) 30.37
5 (-15) 23.41
14 (-10) 18.04
23 (-5) 14.32
32 (0) 11.36
41 (5) 9.08
50 (10) 7.34
59 (15) 5.94
68 (20) 4.87
77 (25) 4.00
86 (30) 3.31
95 (35) 2.79
104 (40) 2.29
113 (45) 1.96
122 (50) 1.85
9. Check evaporator temperature signal circuit for a short to ground, high resistance, or an open. See
WIRING DIAGRAMS . If wiring is okay, go to next step.
10. Check low reference circuit for a short to ground, high resistance, or an open. If wiring is okay, go to step
26 .
on and off with each command, go to step 15 . If relay does not turn on and off with each command, go to
next step.
12. Turn ignition off. Disconnect A/C compressor clutch relay. Turn ignition on, engine off. Probe coil side
voltage supply circuit of A/C compressor clutch relay with a test light connected to ground. If test light
illuminates, go to next step. If test light does not illuminate, go to step 25 .
13. Connect test light between control circuit of A/C compressor clutch relay and coil side voltage supply
circuit of A/C compressor clutch relay. Using scan tool, command A/C compressor clutch relay on and
off. If test light turns on and off with each command, go to step 28 . If test light does not turn on and off
14. If test light remains illuminated with each command, go to step 20 . If test light does not remain
illuminated with each command, go to step 19 .
15. Turn ignition off. Disconnect A/C compressor clutch relay. Probe switch side voltage supply circuit of
A/C compressor clutch relay with a test light connected to ground. If test light comes on, go to next step.
If test light does not come on, go to step 24 .
16. Connect 10-amp fused jumper wire between switch side voltage circuit of A/C compressor clutch relay
and A/C compressor clutch supply voltage circuit of A/C compressor clutch. Turn ignition on, engine off.
If A/C compressor clutch engages, go to step 28 . If compressor clutch does not engage, go to step 21 .
17. Check ignition voltage circuit of HVAC control module for a short to ground, high resistance, or an open.
See WIRING DIAGRAMS . If wiring is okay, go to next step.
18. Check ground circuit of HVAC control module for an open. If wiring is okay, go to step 31 .
19. Check control circuit of A/C compressor clutch relay for an open. If wiring is okay, go to step 32 .
20. Check control circuit of A/C compressor clutch relay for a short to ground. If wiring is okay, go to step
32 .
21. Check A/C compressor clutch supply voltage circuit at A/C compressor clutch for a short to ground, high
resistance, or an open. If wiring is okay, go to step 23 .
22. Check ground circuit of A/C pressure sensor for an open. If wiring is okay, go to step 27 .
23. Check ground circuit of A/C compressor clutch for high resistance or an open. If wiring is okay, go to
step 30 .
24. Repair switch side voltage supply circuit of A/C compressor clutch relay. See WIRING DIAGRAMS .
25. Repair coil side voltage supply circuit of A/C compressor clutch relay.
26. Check blower motor control OFF circuit for a short to voltage. If wiring is okay, go to step 31 .
27. Check for poor connections at harness connector of A/C high pressure sensor. If connections are okay, go
to step 33 .
29. Check for poor connections at harness connector of evaporator temperature sensor. If connections are
30. Check for poor connections at harness connector of A/C compressor clutch. If connections are okay, go to
step 36 .
step 37 .
32. Check for poor connections at harness connector of Powertrain Control Module (PCM). If connections
are okay, go to step 38 .
33. Replace A/C high pressure switch.
34. Replace evaporator temperature sensor. See EVAPORATOR TEMPERATURE SENSOR under
36. Replace A/C compressor clutch coil. See COMPRESSOR SERVICING article in GENERAL
SERVICING.
INSTALLATION.
TOO COLD IN VEHICLE
1. Turn ignition on, engine off. Place blower motor switch in each speed position. If blower motor operates,
go to next step. If blower motor does not operate, go to BLOWER MOTOR INOPERATIVE .
2. If blower motor operate when blower motor switch is in each speed position, go to next step. If blower
motor does not operate, go to BLOWER MOTOR MALFUNCTION .
3. Except for blower motor speed, if all functions of HVAC control module are inoperative, go to step 12 . If
all functions are not inoperative, go to next step.
4. Inspect cooling system for low coolant level, loose or worn accessory drive belt, leaking radiator hose or
heater hoses, kinked radiator hose or heater hoses, missing radiator cap pressure seal, or leaking radiator
cap. Repair as necessary. If all components are okay, go to next step.
5. Start engine. Place blower switch in OFF position. Place A/C request switch in OFF position. If A/C
compressor operate, go to COMPRESSOR CLUTCH DOES NOT ENGAGE . If A/C compressor does
not operate, go to next step.
6. Observe air temperature actuator drive shaft. Adjust air temperature switch. If air temperature actuator
drive shaft rotate, go to next step. If drive shaft does not rotate, go to step 8 .
7. Check air temperature door and air temperature actuator for misaligned air temperature actuator, broken
or binding linkages or air temperature door, obstruction preventing air temperature door from operating
within full range of motion, missing or misaligned seals to air temperature door. Repair components as
necessary.
8. Check ignition voltage circuit of air temperature actuator for an open circuit or a high resistance. If wiring
is okay, go to step 9 .
9. Check ground circuit of air temperature actuator for an open circuit. If wiring is okay, go to next step.
10. Check air temperature door control circuit of air temperature actuator for an open, high resistance, short
to ground, or short to voltage. If wiring is okay, go to next step.
11. Ensure HVAC control module connector is connected. Turn ignition on, engine off. Measure voltage
between air temperature door control circuit of air temperature actuator and ground. Place air temperature
switch from coldest to warmest position. If voltage measures about zero volts at cold and 12 volts at hot,
go to step 16 . If voltages are not to specification, go to step 18 .
12. Check ignition voltage circuit of HVAC control module for an open or a high resistance. If wiring is
okay, go to next step.
13. Check battery positive voltage circuit of HVAC control module for an open or a high resistance. If wiring
14. Check blower motor control OFF circuit of HVAC control module for a short to voltage. If wiring is
okay, go to next step.
15. Check ground circuit of HVAC control module for an open circuit. If wiring is okay, go to step 18 .
16. Check for poor connections at harness connector of air temperature actuator. If connections are okay, go
to next step.
17. Check air temperature actuator, door and any attaching linkage for binding or a condition preventing
drive shaft rotation. Repair as necessary. If components are okay, go to step 19 .
step 20 .
19. Replace air temperature actuator. See AIR TEMPERATURE ACTUATOR .
20. Replace HVAC control module. See HVAC CONTROL MODULE .
TOO HOT IN VEHICLE
1. Turn ignition on, engine off. Place blower motor switch in each speed position. If blower motor operates
in any of speed position, problem is intermittent. If blower motor does not operate in any speed position,
go to next step.
2. If blower motor operates in each speed position, go to next step. If blower motor does not operate in each
speed position, go to BLOWER MOTOR MALFUNCTION .
3. If vehicle is too hot when A/C cooling is desired, go to next step. If vehicle is too hot when A/C cooling
is not desired, go to step 6 .
4. Ensure ambient air temperature is greater than 38F (3C). Start engine. Place blower motor switch in
maximum speed position. Place mode switch in vent position. Place A/C request switch in ON position.
Place left and right temperature switches in coldest position. If A/C compressor operates, go to next step.
If A/C compressor does not operate, go to COMPRESSOR CLUTCH DOES NOT ENGAGE .
5. Check A/C system performance. See A/C SYSTEM PERFORMANCE under SYSTEM TEST. If
performance is not okay, go to next step.
6. Observe drive shaft of air temperature actuator. Place air temperature switch from coldest to warmest
position. If air temperature actuator drive shaft rotates, go to next step. If shaft does not rotate, go to step
8.
or binding linkages, obstruction preventing air temperature door from operating within full range of
motion, missing seals or misaligned seals to air temperature door. Repair components as necessary.
8. Check ignition voltage circuit of air temperature actuator for an open or high resistance. If wiring is okay,
go to next step.
9. Check ground circuit of air temperature actuator for an open. If wiring is okay, go to next step.
10. Check air temperature door control circuit of air temperature actuator for an open, high resistance, short
to ground, or short to voltage. If wiring is okay, go to next step.
11. Ensure HVAC control module connector is connected. Turn ignition on, engine off. Measure voltage
between air temperature door control circuit of air temperature actuator and ground. Place air temperature
switch from coldest to warmest position. If voltage measures about zero volts at cold and 12 volts at hot,
go to next step. If voltages are not to specification, go to step 14 .
12. Check for poor connections at harness connector of air temperature actuator. If connections are okay, go
to next step.
or binding linkages, obstruction preventing air temperature door from operating within full range of
motion, missing seals or misaligned seals. If all components are okay, go to step 15 .
step 16 .
15. Replace air temperature actuator. See AIR TEMPERATURE ACTUATOR under REMOVAL &
INSTALLATION.
INSTALLATION.
SELF-DIAGNOSTICS
RETRIEVING DIAGNOSTIC TROUBLE CODES
NOTE: Diagnostic Trouble Codes (DTCs) can only be displayed using a scan tool.
Turn ignition switch to ON position. Connect scan tool to Data Link Connector (DLC). DLC is located under
instrument panel, near steering column. Retrieve DTCs following scan tool manufacturer's instructions. See
DIAGNOSTIC TROUBLE CODES table. See appropriate DTC test procedure. To diagnose a non-DTC
related concern, see SYMPTOM TESTS . Clear DTC after completing repairs. See CLEARING TROUBLE
CODES .
DIAGNOSTIC TROUBLE CODES

DTC Fault
P0530 A/C Pressure Sensor
P1546 A/C Relay
CLEARING DIAGNOSTIC TROUBLE CODES
DTCs can be cleared using scan tool or by ignition cycle default. If no DTCs occur for 50 drive cycles (ignition
switch cycled on and off 50 times), existing history DTCs will be cleared from programmer memory.
DIAGNOSTIC TESTS
DTC P0530: A/C PRESSURE SENSOR
1. Ensure ambient air temperature is greater than 38F (3C). Turn ignition off. Check A/C compressor for
free rotation. Start engine. Place HVAC control module in OFF position. If A/C compressor operates, go
to COMPRESSOR CLUTCH DOES NOT DISENGAGE under SYMPTOM TESTS. If A/C
compressor does not operate, go to next step.
2. Install scan tool. Turn ignition on, engine off. Using scan tool, observe A/C HIGH PRESSURE
PARAMETER in powertrain control module engine data 2 list. If scan tool indicates A/C HIGH SIDE
PRESSURE parameter is within .1-4.9 volts, check PCM grounds. If parameter is not within .1-4.9 volts,
go to next step.
3. Turn ignition off. Disconnect A/C refrigerant pressure sensor. Turn ignition on, engine off. Using scan
tool, observe A/C HIGH SIDE PRESSURE parameter. If scan tool indicates A/C HIGH SIDE
PRESSURE parameter is less than .1 volt, go to next step. If parameter is greater than .1 volt, go to step
10 .
4. Turn ignition off. Connect 3-amp fused jumper wire between 5-volt reference circuit of A/C refrigerant
pressure sensor and A/C refrigerant pressure sensor signal circuit of A/C refrigerant pressure sensor. Turn
ignition on, engine off. Using scan tool, observe A/C HIGH SIDE PRESSURE parameter. If scan tool
indicates A/C HIGH SIDE PRESSURE parameter is greater than 4.9 volts, go to next step. If parameter is
greater than 4.9 volts, go to step 8 .
5. Disconnect fused jumper wire. Measure voltage between 5-volt reference circuit of A/C refrigerant
pressure sensor and ground circuit of A/C refrigerant pressure sensor. If voltage measures less than 5
volts, go to next step. If voltage is greater than 5 volts, go to step 7 .
6. Turn ignition off. Measure resistance between ground circuit of A/C refrigerant pressure sensor and
ground. If resistance is less than 5 ohms, go to step 12 . If resistance is greater than 5 ohms, go to step 11 .
7. Check 5-volt reference circuit of A/C refrigerant pressure sensor for short to voltage. See WIRING
DIAGRAMS . If wiring is okay, go to step 13 .
8. Check 5-volt reference circuit of A/C refrigerant pressure sensor for a short to ground, high resistance, or
an open. If wiring is okay, go to step 9 .
9. Check A/C refrigerant pressure sensor signal circuit of A/C refrigerant pressure sensor for a short to
ground, high resistance, or an open. If wiring is okay, go to step 13 .
10. Check A/C refrigerant sensor signal circuit of A/C refrigerant pressure sensor for a short to voltage. If
wiring is okay, go to step 13 .
11. Disconnect PCM. Check ground circuit of A/C refrigerant pressure sensor for high resistance or an open.
If wiring is okay, go to step 13 .
12. Check for poor connections at harness connector of A/C refrigerant pressure sensor. If wiring is okay, go
to step 14 .
13. Check for poor connections at harness connector of PCM. If wiring is okay, go to step 15 .
14. Replace A/C refrigerant pressure sensor.
DTC P1546: A/C RELAY
1. Install scan tool. Start engine. Using scan tool, command A/C compressor clutch relay on and off. If A/C
compressor clutch relay turns on and off with each command, problem is intermittent. Check system for
poor connections and grounds. If relay does turn on and off, go to next step.
2. Turn ignition off. Disconnect A/C compressor clutch relay. Turn ignition on, engine off. Probe coil feed
circuit of A/C compressor clutch relay using a test light connected to ground. If test light comes on, go to
next step. If test light does not come on, go to step 9 .
3. Connect test light between A/C clutch relay control circuit of A/C compressor clutch relay and coil feed
circuit of A/C compressor clutch relay. Using scan tool, command A/C compressor clutch relay on and
off. If test light turns on and off with each command, go to step 7 . If test light does not turn on and off
4. If test light remain on with each command, go to step 6 . If test light does not remain on, go to next step.
5. Check A/C clutch relay control circuit of A/C compressor clutch relay for a short to voltage or an open. If
wiring is okay, go to step 8 .
6. Check A/C clutch relay control circuit of A/C compressor clutch relay for a short to ground. If wiring is
8. Check for poor connections at PCM. Repair connections as necessary. If connections are okay, go to step
11 .
9. Repair coil feed circuit of A/C compressor clutch relay.
Fig. 1: Removing A/C Relay
SYSTEM TESTS
A/C SYSTEM PERFORMANCE
NOTE: Before proceeding with A/C system performance test, perform On-Board
Diagnostic (OBD) system check. If DTC P0530 or DTC P1546 is displayed, repair
DTC according to procedures. See appropriate SELF-DIAGNOSTICS article in
ENGINE PERFORMANCE.
1. Park vehicle out of direct sunlight. Open windows to equalize temperatures. Open hood and install A/C
manifold gauge set. Route gauge hoses over rear hood seal and close hood. Record ambient temperature
and relative humidity at time of test. Close all doors and windows.
2. Set A/C mode control to A/C, blower motor to high speed, and temperature control to full cold. Open A/C
outlets. Insert thermometer into right center A/C outlet. Place transaxle in Park or Neutral position. Start
and run engine at 2000 RPM.
3. Operate A/C system until A/C outlet air temperature is at its lowest (about 3 minutes). Record outlet air
temperature and high-side and low-side pressures. Turn engine off. See A/C SYSTEM
PERFORMANCE SPECIFICATIONS or A/C SYSTEM PRESSURE SPECIFICATIONS tables.
4. If system temperatures and pressures are not as specified, ensure outer surfaces and area between radiator
and condenser cores are free of dirt, leaves or other foreign material that could block airflow. Ensure
evaporator and condenser cores are free of restrictions. Check air ducts for leaks or restrictions. Low air
duct airflow could indicate a restricted evaporator core.
5. Check for kinked hoses and tubes. Check for refrigerant leaks. Check for compressor clutch slippage or
improper drive belt tension. Check for a plugged accumulator or orifice tube. Perform repairs as
necessary. Ensure system is operating properly.
A/C SYSTEM PERFORMANCE SPECIFICATIONS(1)

Ambient Temp. - F (C) Outlet Air Temp. - F (C)
65 (18) 48 (9)
75 (23) 54 (12)
85 (29) 59 (15)
95 (35) 65 (18)
(1) Specifications are with relative humidity at 60 percent and engine speed at 2000 RPM.
A/C SYSTEM PRESSURE SPECIFICATIONS(1)

Ambient Temp. - F (
C) Low-Side Pressure - psi (kg/cm2 ) High-Side Pressure - psi (kg/cm2 )
95 (35) 34-45 (2.3-3.1) 187-254 (12.9-17.5)
85 (29) 34-45 (2.3-3.1) 165-229 (11.4-15.8)
75 (23) 29-36 (2.0-2.4) 160-199 (1.1-1.3)
65 (18) 29-33 (1.9-2.2) 160-178 (1.1-1.2)
(1) Specifications are with relative humidity at 60 percent and engine speed at 2000 RPM.
WARNING: To avoid injury from accidental air bag deployment, read and carefully
follow all SERVICE PRECAUTIONS and DISABLING & ACTIVATING AIR
BAG SYSTEM procedures in AIR BAG SYSTEM SAFETY article in
GENERAL SERVICING.
A/C COMPRESSOR
1. Disconnect negative battery cable. Discharge A/C system, using approved refrigerant recovery/recycling
equipment. Turn steering wheel to right. Raise and support vehicle. Remove right engine splash shield.
Release drive belt tensioner and remove belt from compressor pulley. Remove air baffle bolts. Remove
air baffle.
2. Disconnect electrical connector from compressor. Disconnect engine harness electrical connector.
Reposition engine harness away from compressor. Remove suction hose nut. Disconnect suction hose
from compressor. Immediately cap all openings on compressor and refrigerant lines to prevent
contamination. Remove suction hose. Remove discharge hose nut. Disconnect discharge hose from
compressor. Remove and discard sealing washers. Remove compressor mounting bolts. Remove
compressor.
3. To install, reverse removal procedure. Use new sealing washers. Lightly coat all seals with refrigerant oil.
Tighten bolts as specified. See TORQUE SPECIFICATIONS .
A/C-HEATER MODULE
NOTE: Some vehicles may require windshield removal for removal of A/C-heater
module as instrument panel inner bolt interferes with windshield.
equipment. Drain cooling system. Remove left wiper arm linkage nuts. Reposition left wiper arm linkage
for access. Close defroster door to allow clearance during defroster duct removal. Set HVAC controls in
vent setting to close defroster door. Remove blower motor. See BLOWER MOTOR .
2. Disconnect electrical connector from blower motor resistor. Disconnect electrical connector from
evaporator temperature sensor. Disconnect all HVAC actuator electrical connectors. Remove cross-
vehicle beam. See INSTRUMENT PANEL .
3. Remove evaporator outlet tube nut. Disconnect evaporator outlet tube. Disconnect evaporator inlet tube.
Reposition inlet heater hose clamp. Disconnect inlet heater hose from heater core. Reposition outlet
heater hose clamp. Disconnect outlet heater hose from heater core. Remove A/C-heater module to dash
panel sound barrier nuts. Remove A/C-heater module assembly from cowl. See Fig. 2 .
4. To install, reverse removal procedure. Use new A/C-heater module seals. Lightly coat all "O" rings with
refrigerant oil. Tighten all bolts, nuts, and screws to specification. See TORQUE SPECIFICATIONS .
Fig. 2: Exploded View Of A/C-Heater Module
AIR TEMPERATURE ACTUATOR
Removal & Installation (Left)
Remove left instrument panel insulator. Disconnect left temperature actuator electrical connector. Remove left
temperature actuator mounting screws. Disengage actuator linkage by rotating actuator toward steering column.
Remove left temperature actuator.
Removal & Installation (Right)
Remove glove box. Disconnect right temperature actuator electrical connector. Remove right temperature
actuator mounting screws. Remove right temperature actuator.
BLOWER MOTOR
Disconnect negative battery cable. Remove right side instrument panel insulator. Disconnect electrical
connector from blower motor. Remove blower motor mounting screws. Remove blower motor from A/C-heater
module assembly. To install, reverse removal procedure. Tighten blower motor mounting screws as specified.
See TORQUE SPECIFICATIONS .
BLOWER MOTOR RESISTOR/RELAY
1. Remove right instrument panel insulator. Disconnect blower motor electrical connector. Remove blower
motor mounting screws. Remove blower motor from A/C-heater module assembly. Disconnect electrical
connector from blower motor resistor assembly. Loosen only both forward blower resistor assembly
mounting screws.
NOTE: Blower motor resistor assembly mounting holes are slotted.
2. Loosen forward blower resistor assembly mounting screws. Remove rear blower resistor assembly
mounting screw. Remove blower motor resistor assembly from A/C-heater module assembly. To install,
reverse removal procedure. Tighten blower motor resistor/relay mounting screws.
CONDENSER
equipment. Remove left and right front fender upper diagonal braces. Remove air cleaner assembly.
Remove evaporator inlet tube to condenser fitting bolt. Disconnect evaporator inlet tube from condenser.
Remove discharge hose to condenser fitting nut. Seal all open A/C lines.
2. Disconnect discharge hose from condenser. Remove radiator. Remove condenser pipe-to-radiator
mounting bolt. Remove condenser-to-radiator mounting bolts. Remove condenser from radiator. Remove
receiver-drier upper bracket bolts. Remove receiver-drier-to-condenser mounting bolts. Disconnect
receiver-drier from condenser. Discard sealing washers.
3. To install, reverse removal procedure. Replace "O" rings and lightly coat with refrigerant oil. Tighten all
bolts, nuts, and screws to specification. See TORQUE SPECIFICATIONS .
EVAPORATOR
NOTE: Some vehicles may require windshield removal for evaporator removal as
instrument panel inner bolt interferes with windshield.

1. Remove A/C-heater module. See A/C-HEATER MODULE . Remove air inlet housing screws. Remove
air inlet housing from A/C-heater module. Remove right A/C-heater module assembly mounting bracket
screws. Remove right A/C-heater module assembly mounting bracket. Remove upper A/C-heater module
assembly retaining screw.
NOTE: A/C-heater module assembly retaining screw is located under A/C-heater

module assembly mounting bracket.
2. Remove A/C-heater module assembly-to-dash panel sound barrier seal. Remove lower A/C-heater
module assembly retaining screws. Remove heater core cover screws. Remove heater core cover. Remove
heater core pipe retaining screw. Remove heater core. Remove A/C-heater module assembly retaining
screw. Separate upper and lower A/C-heater module halves. Remove evaporator core from upper A/C-
heater module case half.
3. To install, reverse removal procedure. Use new evaporator and A/C-heater module seals. Lightly coat all
"O" rings with refrigerant oil. Tighten all bolts, nuts, and screws to specification. See TORQUE
SPECIFICATIONS .
EVAPORATOR TEMPERATURE SENSOR
Remove evaporator. See EVAPORATOR . Remove evaporator temperature sensor from evaporator. To install,
reverse removal procedure. Ensure evaporator temperature sensor is installed approximately 1.4" from side and
2" from bottom corner of evaporator.
HEATER CORE
1. Drain cooling system. Remove wiper module. Disconnect brake booster vacuum hose and lay aside.
Remove air cleaner cover and intake tube. Disconnect throttle and cruise control cables from mounting
bracket. Disconnect throttle and cruise control cables. Remove transmission fluid filler tube. Disconnect
both heater hose quick-disconnect couplings from inlet and outlet pipes.
2. Disconnect both heater hose clamps from heater hoses. Remove heater hoses from heater core. Cap heater
core inlet and outlet pipes to prevent coolant spillage inside of vehicle. Cap heater core pipes. Remove
right instrument panel insulator. Remove left instrument panel insulator. Remove center console. Remove
automatic transmission range selector.
3. Remove console bracket. Remove floor duct brace. Remove floor duct. Remove screws retaining heater
outlet duct. Remove heater outlet duct. Remove instrument panel harness-to-heater core cover tie strap.
Remove screws retaining heater core cover. Remove heater core cover. Remove heater core pipe retaining
clamp screw. Remove heater core from A/C-heater module. To install, reverse removal procedure.
HVAC CONTROL MODULE

Remove instrument panel accessory trim plate. Remove Heater Ventilation Air Conditioning (HVAC) control
module (A/C-heater control panel) retaining screws. See Fig. 3 . Pull HVAC control module straight out from
instrument panel. Disconnect HVAC control module electrical connectors. Push HVAC control module into
instrument panel opening. To install, reverse removal procedure.
Fig. 3: Removing HVAC Control Module

INSTRUMENT PANEL
NOTE: Some vehicles may require windshield removal for evaporator removal as
instrument panel inner bolt interferes with windshield.
1. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING.
Disconnect negative battery cable. Remove windshield garnish molding from windshield pillar by pulling
windshield garnish molding to release retainers. Remove windshield garnish molding from windshield
pillar. Remove upper trim panel slowly, as retainer clips could possibly fall into instrument panel. Lift
instrument panel upper trim panel about 2" and pull rearward to release retainers.
2. Remove daytime running light ambient light sensor. Remove instrument panel upper trim panel. Remove
brake pedal bracket and reinforcement. Route transmission shift cable through cross-vehicle beam.
Release retaining clips from instrument panel wiring harness and position wiring harness out of way.
3. Remove bolts retaining HVAC module (A/C-heater module) to cross-vehicle beam. See Fig. 4 . Remove
left cross vehicle ground wire. Remove right cross vehicle ground wires. Unbolt cross vehicle anchor.
4. Unclip antenna cable from cross-vehicle beam. Remove HVAC bracket from cross-vehicle beam bracket.
Remove heads up display bracket (if equipped). Remove bolts retaining cross-vehicle beam to left and
right hinge pillars.
5. If inner bolt cannot be removed because of interference with windshield, gently bend bolt stem when bolt
is removed from cross-vehicle beam. Discard bolt. Remove cross-vehicle beam from vehicle through
main wire harness. Remove front defroster duct.
6. To install, reverse removal procedure. Tighten all bolts, nuts, and screws to specification. See TORQUE
SPECIFICATIONS .
Fig. 4: Exploded View Of Instrument Panel Carrier & Air Distribution Ducts
MODE ACTUATOR
Remove left instrument panel insulator. Remove knee bolster from instrument panel. Disconnect mode actuator
electrical connector. Disconnect actuator pushrod retainer clip from mode door lever. Disconnect actuator
pushrod from mode door lever. Remove mode actuator mounting screws. Remove mode door actuator. To
install, reverse removal procedure.
POLLEN FILTERS
Open glove box. Remove inside rear glove box door. Open A/C-heater module assembly access door. Pull out
and remove right passenger compartment air filter. Slide left passenger compartment air filter to opening. Pull
out and remove left passenger compartment air filter. To install, reverse removal procedure.
NOTE: When replacing PCM it is important to transfer broadcast code and production
number to new PCM label, not to PCM case.
1. Turn ignition off. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL
SERVICING. Disconnect negative battery cable. Remove left sheet metal diagonal brace. Remove air
cleaner assembly cover and lift PCM from assembly. Disconnect harness connectors from PCM. Remove
PCM from engine compartment
2. To install, reverse removal procedure. Program PCM. See COMPUTER RELEARN PROCEDURES
article in GENERAL INFORMATION in ENGINE PERFORMANCE.
RECIRCULATION ACTUATOR
Remove upper instrument panel trim pad. Disconnect recirculation actuator electrical connector. Remove
mounting screws from recirculation actuator. Remove recirculation actuator.
TEMPERATURE VALVE ELECTRIC ACTUATOR
Remove left instrument panel sound insulator. Disconnect temperature valve electric actuator connector.
Remove screws and temperature valve electric actuator. To install, reverse removal procedure.
A/C Compressor Mounting Bolts 37 (50)
A/C Filter Flare Nut 11 (15)
Air Baffle Bolts 15 (20)
Compressor Hose Block Fitting-To-Accumulator Bolt (1) 11 (16)
Compressor Hose Block Fitting-To-Compressor Bolt 20 (27)
Cross-Vehicle Beam Bolts 18 (25)
INCH Lbs. (N.m)
A/C-Heater Module Screws 89 (10)
Actuator Screws 89 (10)
Air Inlet Housing Screws 89 (10)
Blower Motor Mounting Screws 15 (20)
Condenser Bolts 53 (6)
(1) Use new sealing washers or "O" rings lightly coated with clean refrigerant oil.
WIRING DIAGRAMS
Fig. 5: Manual A/C-Heater System Wiring Diagram (2001 Aztek)
Manual A/C-Heater - Aztek & Rendezvous
SPECIFICATIONS
Fig. 1: Fastener Tightening Specifications Chart

SENSOR RESISTANCE TABLE

Fig. 2: Sensor Resistance Specification Chart

Fig. 3: HVAC Blower Controls Wiring Diagram
Fig. 4: HVAC Compressor Control Wiring Diagram
Fig. 5: HVAC Schematics Air Delivery & Temperature Control Wiring Diagram
COMPONENT LOCATOR
Instrument Panel and Center Console - Pontiac

Fig. 6: Identifying HVAC Components
Instrument Panel - Buick

Fig. 7: Identifying Instruments Panel Components
LH Side of Engine
Fig. 8: Identifying LH Side Engine Components

Fig. 9: Identifying A/C Compressor Clutch Connector

Fig. 10: Identifying A/C Refrigerant Pressure Sensor Connector

Fig. 11: Identifying Air Temperature Actuator - Left Connector

Fig. 12: Identifying Air Temperature Actuator - Right - CJ3 Connector

Fig. 13: Blower Motor Resistor Assembly Connector<
Fig. 14: Identifying Evaporator Temperature Sensor Connector


Fig. 15: Identifying HVAC Control Module - C1 Connector

Fig. 16: Identifying HVAC Control Module - C2 Connector
Mode Actuator
Fig. 17: Identifying Mode Actuator Connector
Fig. 18: Identifying Recirculation Actuator Connector

DIAGNOSTIC SYSTEM CHECK - HVAC SYSTEMS - MANUAL
Test Description
3. Lack of communication may be due to a partial malfunction of the class 2 serial data circuit or due to a
total malfunction of the class 2 serial data circuit. The specified procedure will determine the particular
condition.
4. Determine if the Powertrain Control Module has set DTCs which may affect HVAC operation are
present.
5. The presence of DTCs which begin with "U" indicate some other module is not communicating. The
specified procedure will compile all the available information before tests are performed.
Diagnostic System Check - HVAC Systems - Manual
Fig. 19: Diagnostic Manual HVAC Systems Specification Chart


Fig. 20: PCM Scan Tool Output Controls Chart
SCAN TOOL DATA LIST
Fig. 21: BCM Scan Tool Data List Specification Chart

Fig. 22: PCM Scan Tool Data List Specification Chart

8 Digit GM Part Number: The scan tool displays the part number for service identification.
A/C High Side Pressure: The scan tool displays -103 to +3119 kPa (-14 to +452 psi). This parameter
represents the A/C refrigerant pressure sensor voltage signal converted to pressure.
A/C High Side Pressure: The scan tool displays 0.00-5.00 Volts. This parameter represents the A/C refrigerant
pressure sensor signal.
A/C Off For WOT: The scan tool displays Yes or No. Yes indicates that the PCM has disabled the A/C
compressor because the TP sensor signal is at wide open throttle.
A/C Pressure Disable: The scan tool displays Yes or No. Yes indicates that the PCM has disabled the A/C
compressor due to excessive refrigerant pressure.
A/C Relay Circuit Status: The scan tool displays OK or Fault. This parameter indicates the state of the driver
circuit for this device.
A/C Relay Command: The scan tool displays On or Off. Represents the PCM commanded state of the A/C
compressor clutch relay control circuit. The A/C compressor clutch should be engaged when Commanded A/C
displays On.
A/C Request Signal: The scan tool displays Yes or No. The PCM uses the A/C request signal in order to
determine if A/C compressor operation is being requested by the BCM.
A/C Switch: The scan tool displays Active or Inactive. Displays the state of the A/C request signal circuit from
the HVAC control module to the BCM.
ECT Sensor: The scan tool range is -39C to +140C (-38F to +284F). Displays the temperature of the
engine coolant.
Diagnostic Trouble Code (DTC) List
Fig. 23: DTC Chart

DTC P0530
Circuit Description

The PCM will not illuminate the Malfunction Indicator Lamp (MIL).
Diagnostic Aids
If the condition is not present refer to TESTING FOR INTERMITTENT AND POOR CONNECTIONS .
Test Description
4. If the pressure signal voltage stays high after disconnecting the pressure sensor electrical connector, the
7. Tests for a high resistance or for an open in the ground circuit.
16. This vehicle is equipped with a PCM which utilizes an Electrically Erasable Programmable Read
Only Memory (EEPROM). Before you replace the PCM, program the new PCM.
DTC P0530
Fig. 24: DTC P0530 Diagnostic (Steps 1-8)
Fig. 25: DTC P0530 Diagnostic (Steps 9-17)
DTC P1546
Circuit Description
A short to ground
A short to voltage
An open circuit
An open relay coil
The ignition voltage is between 9.0-18.0 volts.
A/C clutch relay.
recorded as Failure Records data only. This information will not be stored as Freeze Frame data.
A history DTC will clear after 40 consecutive warm-up cycles have occurred without a malfunction.
Diagnostic Aids
Important: Inspect PCM engine grounds for being secure and clean.
If the condition is intermittent, refer to TESTING FOR INTERMITTENT AND POOR CONNECTIONS .
Test Description
2. Listen for an audible click when the relay operates. Command the ON and the OFF states. Repeat the
commands as necessary.
12. The PCM utilizes Electrically Erasable Programmable Read Only Memory (EEPROM). Program the
new PCM before you replace the PCM.
DTC P1546
Fig. 26: DTC P1546 Diagnostic
SYMPTOMS - HVAC SYSTEMS - MANUAL
Important: Review the system operation in order to learn the system functions. Refer to the following
procedures:
VISUAL/PHYSICAL INSPECTION
Inspect for aftermarket devices which could affect the operation of the HVAC System. Refer to
CHECKING AFTERMARKET ACCESSORIES .
Inspect the system components which are easily accessible or visible for obvious damage or for
conditions which could cause the symptom.
The A/C compressor will not operate in cold, outside air temperatures. Refer to AIR TEMPERATURE
A wet carpet
High humidity
An interior water leak
A blocked drain tube to the A/C evaporator
Inspect the air distribution system for causes of reduced airflow:

An obstructed or dirty passenger compartment air filter
Blocked or damaged air vents
Intermittent
INTERMITTENT AND POOR CONNECTIONS .
Symptom List
Refer to one of the following symptom diagnostic procedures:

Blower Motor Inoperative, see Fig. 35
Blower Motor Malfunction, see Fig. 37
TOO HOT IN VEHICLE
TOO COLD IN VEHICLE
LEAK TESTING
DEFROSTING INSUFFICIENT
NOISE DIAGNOSIS - BLOWER MOTOR
NOISE DIAGNOSIS - AIR CONDITIONING (A/C) SYSTEM
NOISE DIAGNOSIS - HVAC MODULE
ODOR DIAGNOSIS
Diagnostic Aids
Test Description
2. The A/C compressor relay output is disabled if engine coolant temperature is above 121C (250F).
3. Place the mode switch in any position except OFF, and place the air temperature control switch in a
cold setting. Use the bi-level mode for consistent testing of the A/C system operation.
6. The HVAC control module is inoperative if the module does not respond to any operator control
requests.
40. The evaporator temperature sensor is replaced as part of the evaporator core.
HVAC Compressor Clutch Does Not Engage

Fig. 27: HVAC Compressor Clutch Does Not Engage Diagnosis (Steps 1-4
HVAC Compressor Clutch Does Not Disengage

Test Description
2. This step checks for continuous operation of the blower motor.
3. This step tests for a short to voltage in the blower motor control circuits.
Fig. 34: Blower Motor Always On Diagnosis




TOO HOT IN VEHICLE
Diagnostic Aids
Test Description
12. The voltage will vary between 0-12 volts during normal operation. The HVAC control module
Too Hot in Vehicle

TOO COLD IN VEHICLE
Test Description
12. The voltage will vary between 0-12 volts during normal operation. The HVAC control module
Too Cold in Vehicle

Fig. 42: Too Cold in Vehicle Diagnosis (Steps 1-8)
Test Description
12. The measured voltage should be near the specified values for each mode position.
Two ignition 3 voltage circuits supply the HVAC control module. Test the ignition 3 voltage circuit that
does not supply the blower motor switch.
Air Delivery Improper

Test Description
9. The HVAC control module is supplied by 2 ignition-3 voltage circuits. Test the ignition-3 voltage
circuit that does not supply the blower motor switch.
Air Recirculation Malfunction

RE-CALIBRATING ACTUATORS
Use the following steps to perform the calibration update:

2. Remove the battery positive voltage circuit fuse of the HVAC Control Module.
Important: The module memory will not clear if the battery positive voltage circuit fuse is installed in
less than 60 seconds.
3. Wait 60 seconds.
4. Install the fuse.
REPAIR INSTRUCTIONS
HVAC CONTROL MODULE REPLACEMENT (BUICK)
Removal Procedure
1. Remove the I/P cluster trim plate bezel. Refer to TRIM PLATE BEZEL REPLACEMENT --
3. Pull the HVAC control module straight out from the I/P.
4. Disconnect the HVAC control module electrical connector.
Fig. 51: Pulling HVAC Control Module Straight From I/P
Important: The key should be in the off position when connecting the HVAC control module electrical
connector to ensure proper calibration.
1. Connect the HVAC control module electrical connector.

2. Install the HVAC control module into the I/P opening.
Fig. 52: Installing HVAC Control Module Into I/P Opening

Tighten
Tighten the screws to 2.5 N.m (22 lb in).
4. Install the IP cluster trim plate bezel. Refer to TRIM PLATE BEZEL REPLACEMENT --
Important: Do not adjust any controls on the HVAC control module while the HVAC control module is
self-calibrating. If interrupted, improper HVAC performance will result.
The engine must be running for proper calibration to occur.

5. Start and allow the engine to run for a least one minute.
HVAC CONTROL MODULE REPLACEMENT (PONTIAC)
Removal Procedure
1. Remove the I/P accessory trim plate. Refer to TRIM PLATE REPLACEMENT -- INSTRUMENT
PANEL (I/P) ACCESSORY (AZTEK) .
4. Disconnect the HVAC control module electrical connectors.
Fig. 55: Pulling HVAC Control Module From I/P
Important: The key should be in the off position when connecting the HVAC control module electrical
connector to ensure proper calibration.
1. Connect the HVAC control module electrical connectors.

2. Push the HVAC control module into I/P opening.
Fig. 56: Installing HVAC Control Module Into I/P

Tighten
4. Install the I/P accessory trim plate. Refer to TRIM PLATE REPLACEMENT -- INSTRUMENT
PANEL (I/P) ACCESSORY (AZTEK) .
Important: Do not adjust any controls on the HVAC control module while the HVAC control module is
self-calibrating. If interrupted, improper HVAC performance will result.
AIR TEMPERATURE ACTUATOR REPLACEMENT
Removal Procedure
3. Remove the temperature door lever bolt (3) from the HVAC module.
4. Disconnect and remove the temperature door lever spring (2).
5. Disconnect and remove the temperature door lever (1) from the temperature door.
Fig. 58: Removing Temperature Door Lever Bolt
6. Disconnect the air temperature actuator electrical connector.

Fig. 59: Disconnecting Air Temperature Actuator Electrical Connector
7. Remove the air temperature actuator mounting screws.

8. Remove the air temperature actuator.
Fig. 60: Removing Air Temperature Actuator Mounting Screws
1. Install the air temperature actuator.

2. Install the air temperature actuator mounting screws.
Tighten

Fig. 61: Installing Air Temperature Actuator Mounting Screws
3. Connect the air temperature actuator electrical connector.

Fig. 62: Connecting Air Temperature Actuator Electrical Connector
Important: Align the pin on the air temperature actuator with the slot in the temperature door lever.
4. Install the temperature door lever (1) to the temperature door.

5. Connect the temperature door lever spring (2) to the temperature door lever (1) and HVAC module case.
6. Install the temperature door lever bolt (3) to the HVAC module case.
Tighten
Tighten the bolt to 0.9 N.m (8 lb in).

8. Recalibrate the actuators. Refer to RE-CALIBRATING ACTUATORS .
Fig. 63: Installing Temperature Door Lever Bolt
Removal Procedure
1. Remove the instrument panel (I/P) compartment. Refer to COMPARTMENT REPLACEMENT --

INSTRUMENT PANEL (I/P) .
Fig. 64: Replacing Air Temperature Actuator Right


Fig. 66: Removing Right Hand Temperature Actuator

Tighten

Fig. 67: Installing Right Hand Temperature Actuator

Important: Align the pin on the right hand air temperature actuator with the slot in the right hand
HVAC module case.
6. Install the I/P compartment. Refer to COMPARTMENT REPLACEMENT -- INSTRUMENT
PANEL (I/P) .
Fig. 69: Connecting Right Hand Temperature Door Lever Spring
Removal Procedure
Fig. 70: Replacing Air Temperature Actuator Left


Fig. 71: Disconnecting Left Hand Air Temperature Actuator Electrical Connector

Fig. 72: Removing Left Hand Air Temperature Actuator Mounting Screws

Tighten

Fig. 73: Installing Left Hand Air Temperature Actuator Mounting Screws

Fig. 74: Connecting Left Hand Air Temperature Actuator Electrical Connector
Important: Align the pin on the left hand air temperature actuator with the slot in the left hand
HVAC module case.
Tighten
Tighten the bolt to 0.9 N.m (8 lb in).

Fig. 75: Connecting Left Hand Temperature Door Lever Spring
Removal Procedure
1. Remove the knee bolster from the instrument panel. Refer to KNEE BOLSTER REPLACEMENT .
Important: Disconnect the I/P wiring harness clip from the I/P support bracket to help access the mode
actuator screws.
Important: Count the number of threads showing from the tip of the mode actuator push rod to the end
of the retainer clip.
Fig. 76: Replacing Mode Actuator

Fig. 77: Removing Mode Actuator Mounting Screws

Tighten

Fig. 78: Installing Mode Actuator Mounting Screws
Important: Align the counted number of threads on the mode actuator push rod (2) with the tip of the
retainer clip (1).
Fig. 79: Connecting Mode Actuator Electrical Connector
Removal Procedure
1. Remove the upper I/P trim pad. Refer to TRIM PAD REPLACEMENT -- INSTRUMENT PANEL
(I/P) UPPER (AZTEK) or TRIM PLATE BEZEL REPLACEMENT -- INSTRUMENT PANEL
(I/P) UPPER (RENDEZVOUS) .
Fig. 80: Replacing Recirculation Actuator

Fig. 81: Removing Mounting Screws From Recirculation Actuator

Tighten

Fig. 82: Installing Recirculation Actuator Mounting Screws

4. Install the upper I/P trim pad. Refer to TRIM PAD REPLACEMENT -- INSTRUMENT PANEL (I/P)
UPPER (AZTEK) or TRIM PLATE BEZEL REPLACEMENT -- INSTRUMENT PANEL (I/P)
UPPER (RENDEZVOUS) .
Fig. 83: Connecting Recirculation Actuator Electrical Connector

The air delivery description and operation is divided into four areas:

Air Speed
Air Delivery
HVAC Control Module
The HVAC control module is a non-class 2 device that interfaces between the operator and the HVAC system
to maintain air temperature and distribution settings. The ignition 3 and battery positive voltage circuits provide
power to the control module. The control module supports the following features:
Fig. 84: HVAC Control Module Features
Mode Actuator
The mode actuator is a 3 wire bi-directional electric motor. Ignition 3 voltage, ground and control circuits
enable the actuator to operate. The control circuit uses a 0-12 volt linear-ramped signal to command the actuator
movement. The 0 and 12 volt control values represent the opposite limits of the actuator range of motion. The
values in between 0 and 12 volts correspond to the positions between the limits. When the HVAC control
module sets a commanded, or targeted, value, the control signal is set to a value between 0-12 volts. The
actuator shaft rotates until the commanded position is reached. The module will maintain the control value until
a new commanded value is needed.
Air Speed
The HVAC control assembly applies voltage to the blower motor control circuit that corresponds to the selected
blower speed. The resistors and the blower motor are in a series circuit. The following list represents the
number of resistors in series with the blower motor per particular speed request:
Low speed-4 resistors

Medium 1 speed-3 resistors
Medium 3 speed-1 resistor
When the operator requests High speed, the HVAC control assembly applies voltage to the blower motor relay
through the high blower motor control circuit. The voltage energizes the blower motor relay, connecting the
blower motor to battery positive voltage.
Off Mode
When the OFF position is selected, the HVAC control module applies voltage to the blower switch off input
within the HVAC control module through the off blower motor control circuit. When the HVAC control
module receives this input, any A/C request will be cancelled and the A/C request LED will turn off. Fresh air
will still be brought in from the outside, but the LED indicator will not illuminate.
Air Delivery
The HVAC control module controls the mode actuator in order to distribute airflow to a desired outlet.
When the mode door is moved to the defrost position, the A/C compressor clutch engages and the recirculation
actuator will be moved to the outside air position. Regardless of the mode setting, a small amount of air will be
diverted to the defrost ducts to reduce windshield fogging. When the mode actuator sees an open in the control
circuit, the actuator defaults to 6 volts and positions the mode door to the floor position. On start-up, the HVAC
available when the HVAC control module is in Vent or Bi-level. The operator must activate the blower for
Recirculation operation. When the recirculation actuator sees an open in the control circuit, the actuator will
default to the recirculation position.
The four primary areas of air controls are:

Engine Coolant
A/C Cycle
HVAC Control Module
Fig. 85: HVAC Control Features
The air temperature actuator is a 3 wire bi-directional electric motor. Ignition 3 voltage, ground and control
circuits enable the actuator to operate. The control circuit uses a 0-12 volt linear-ramped signal to command the
actuator movement. The 0 and 12 volt control values represent the opposite limits of the actuator range of
motion. The values in between 0 and 12 volts correspond to the positions between the limits.
When the HVAC control module sets a commanded, or targeted, value, the control signal sets to a value
between 0-12 volts. Actuator shaft rotation is the results of a commanded position input by the vehicle operator.
With a new actuator commanded value action, the maintained actuator control value is changed.
The A/C refrigerant pressure sensor is a 3 wire piezoelectric pressure transducer. A 5 volt reference, low
The evaporator temperature sensor protects the A/C system. The sensor located on the evaporator core provides
the HVAC control module with the surface temperature of the evaporator core. If the evaporator temperature
sensor reads a temperature of 0C (32F), the HVAC control module will turn off the A/C compressor clutch
until evaporator temperatures reach 2C (36F).
A/C system will also remove humidity from the interior and reduce windshield fogging.
The vehicle operator can determine the passenger compartment temperature by adjusting the air temperature
switch. Regardless of the temperature setting, the following can effect the rate that the HVAC system can
achieve the desired temperature:

Mode setting
The control module takes the following actions when a mode operation is selected, and an air temperature
setting is selected:
The A/C system can be engaged by pressing the A/C switch. The A/C switch will illuminate when the A/C
switch is pressed to the on position. The control module sends a discreet A/C request message to the body
control module (BCM) which sends a class 2 message to the powertrain control module (PCM).
temperature is more than 155C (311F).
The following conditions must be met in order for the PCM to turn on the compressor clutch:
HVAC control module

BCM
Battery voltage between 9 - 16 volts
PCM
Engine coolant temperature (ECT) is less than 125C (257F)
Engine RPM is below 5,000 RPM

A/C Pressure is between 1510 - 2979 kPa (219 - 432 psi)

Throttle position is 100%
Engine speed is more than 5,500 RPM
Transmission shift
PCM detects a hard launch condition
voltage spike.
Engine Coolant
Engine coolant is the important element of the heating system. The thermostat controls the normal engine
operating coolant temperature. The thermostat also creates a restriction for the cooling system that promotes a
flowing through the heater core. Heated air distribution to the passenger compartment, through the HVAC
module maintains passenger comfort.
Opening or closing the HVAC module temperature door controls heat delivered to the passenger compartment.
The coolant exits the heater core through the return heater hose and recirculates back through the engine cooling
system.
A/C Cycle
refrigerant boil inside of the evaporator core.
The boiling refrigerant absorbs the moisture and heat from the ambient air. The refrigerant exits the evaporator
through the suction line and back to the compressor, in a vapor state, and completing the A/C cycle of heat
removal. At the compressor, the refrigerant is compressed again and the cycle of heat removal is repeated.

Fig. 86: Identifying Special Tools & Equipments
HVAC Systems - Automatic - Aztek & Rendezvous
SPECIFICATIONS

Specification
Actuator Retaining Screws, All 1.6 N.m 14 lb in
HVAC Control Module Retaining Screws 2.5 N.m 22 lb in
Temperature Door Lever Bolt 0.9 N.m 8 lb in
SENSOR RESISTANCE TABLE (OUTSIDE AIR TEMPERATURE)
Sensor Resistance Table (Outside Air Temperature)

C / F Outside Resistance (ohms)
Temperature vs. Resistance Values-Approximate
-40 96121.4 ohms
-30 / -22 52765.8 ohms
-20 / -4 30371.3 ohms
-10 / -14 18230.8 ohms
0 / 32 11360.0 ohms
10 / 50 7319.2 ohms
20 / 68 4859.2 ohms
30 / 86 3314.5 ohms
40 / 104 2316.7 ohms
50 / 122 1655.6 ohms
60 / 140 1207.2 ohms
70 / 158 896.7 ohms
80 / 176 677.3 ohms
SENSOR RESISTANCE TABLE (EVAPORATOR TEMPERATURE)
Sensor Resistance Table (Evaporator Temperature)

Evaporator Temperature Sensor Resistance
C / F (ohms)
-30 / -22 52.78 K
-25 / -13 39.81 K
-20 / -4 30.37 K
-15 / 5 23.41 K
-10 / 14 18.04 K
-5 / 23 14.32 K
0 / 32 11.36 K
5 / 41 9.08 K
10 / 50 7.34 K
15 / 59 5.94 K
20 / 68 4.87 K
25 / 77 4.00 K
30 / 86 3.31 K
35 / 95 2.79 K
40 / 104 2.29 K
45 / 113 1.96 K
50 / 122 1.85 K

HVAC SCHEMATICS
Fig. 1: Power, Ground and Blower Controls

Fig. 2: A/C Compressor Controls - 3.4L

Fig. 3: A/C Compressor Controls - 3.6L
Fig. 4: Air Delivery Controls - Early Production
Fig. 5: Air Delivery Controls - Late Production
COMPONENT LOCATOR
Fig. 6: A/C Refrigerant Pressure Sensor Component View
Callouts For Fig. 6

1 A/C Refrigerant Pressure Sensor (under Air Cleaner Housing)
Fig. 7: Under the Right Side of the Instrument Panel Component View
Callouts For Fig. 7

1 Blower Motor
2 Blower Motor Resistor (CJ2)/Blower Motor Processor (CJ3)
3 Auxiliary Power Drop Connector
Fig. 8: HVAC Air Plenum Component View
Callouts For Fig. 8

1 Recirculation Actuator
2 Air Temperature Actuator - Right (CJ3, CJ2)
3 HVAC Module Case
4 Mode Actuator
5 Air Temperature Actuator - Left (CJ3, CJ2)
Callouts For Fig. 9

8 Cigar Lighter
11 Radio
12 Ignition Switch


1 Headlamp Switch
3 Hazard Switch
6 Radio
8 Alarm LED
13 Ignition Switch
Fig. 11: Front of Engine Component View - LA1


1 Water Pump
2 Engine Oil Level Switch
3 Engine Oil Pressure (EOP) Switch
4 A/C Compressor and A/C Compressor Clutch
Fig. 12: LF of the Engine Component View - 3.6L (LY7)


1 A/C Compressor Clutch Connector
2 A/C Compressor
3 A/C Compressor Clutch

15326801
2-Way F GT 150 Series (L-GY)

A D-GN 59 A/C Compressor Clutch Supply Voltage
BK 1050 Ground (3.4L)
B
BK 1450 Ground (3.6L)
12110192

A BK 2751 Low Reference
B GY 2700 5-Volt Reference
C RD/BK 380 A/C Refrigerant Pressure Sensor Signal
12064978

1 BN 241 Ignition 3 Voltage
2 D-BU 1199 Left Air Temperature Door Control
3 BK 150 Ground
4 - - Not Used
5 L-BU 733 Left Air Temperature Door Position Signal
6 GY 598 5-Volt Reference
Air Temperature Actuator - Right

12064993

6 WH/BK 1236 Right Air Temperature Door Control
7 BK 150 Ground
8 - - Not Used
9 D-BU 1646 Right Air Temperature Door Position Signal
Blower Motor
12084957

A RD - Blower Motor Supply Voltage
B BK - Ground

12105056
4-Way F (BK)

1 RD 442 Battery Positive Voltage
2 OG 761 Blower Motor Speed Signal
3 GY/BK 754 Blower Motor Speed Control
4 BK 150 Ground
12052832
A WH 2622 Evaporator Temperature Sensor Signal
B BK 552 Low Reference
HVAC Control Module
12110206
24-Way F Micro-Pack 100 Series (L-BU)

A1 BK 552 Low Reference
A2 - - Not Used
A3 WH 2622 Evaporator Temperature Sensor Signal
A4 L-BU/BK 590 Sunload Sensor Signal
A5-A6 - - Not Used
A7 GY/BK 754 Blower Motor Speed Control
A8 OG 761 Blower Motor Speed Signal
A9 - - Not Used
A10 BK 150 Ground
A11 BN 241 Ignition 3 Voltage
A12 OG 640 Battery Positive Voltage
B1 D-BU 1646 Right Air Temperature Door Position Signal
B2 L-BU 733 Left Air Temperature Door Position Signal
B3 YE/BK 713 Mode Door Position Signal
B4 GY 598 5-Volt Reference
B5 WH/BK 1236 Right Air Temperature Door Control
B6 D-BU 1199 Left Air Temperature Door Control
B7 TN 2273 Mode Door Control
B8 TN/BK 2274 Recirculation Door Control
B9 WH 1038 Class 2 Serial Data
B10 - - Not Used
B11 WH 193 Rear Defog Relay Control
B12 GY 8 Instrument Panel Lamp Supply Voltage
Mode Actuator
12064993

6 TN 2273 Mode Door Control
7 BK 150 Ground
8 - - Not Used
9 YE/BK 713 Mode Door Position Signal
12064993

6 TN/BK 2274 Recirculation Door Control
7 BK 150 Ground
8-10 - - Not Used
Sunload Sensor
15316639
2-Way F (BK)

1 L-BU/BK 590 Sunload Sensor Signal
2 BK 552 Low Reference

HVAC Control Module Scan Tool Output Controls

The HVAC control module sends out a A/C request signal
A/C Request Output Control to turn on the A/C compressor when you select ON. The
request signal should stay active until commanded OFF.
The HVAC control module commands the blower motor on
to maximum speed when you select ON. The HVAC
Blower Motor Output Control
control module commands the blower motor to low speed
when you select OFF.
IMPORTANT:
You must exit the Defrost Mode menu to return to
normal operating mode.
Defrost Mode Miscellaneous Test
When you select ON, the HVAC control module goes into
defrost mode.
IMPORTANT:
You must exit the Heater Mode menu to return to normal
operating mode.
Heater Mode Miscellaneous Test
heater mode.
The HVAC control module commands the left air
temperature actuator towards 198 counts when you select
Left Mix Motor HVAC Motors ON. The HVAC control module commands the left air
temperature actuator towards 0 counts when commanded
OFF.
The HVAC control module commands the air inlet door to
the recirculation position when you select ON. The HVAC
Recirculation Door HVAC Motors
control module commands the air inlet door to the ambient
air position when you select OFF.
The HVAC control module commands the right air
temperature actuator towards 0 counts when you select ON.
Right Mix Motor HVAC Motors The HVAC control module commands the right air
temperature actuator towards 195 counts when you select
OFF.
IMPORTANT:
You must exit the Vent Mode menu to return to normal
operating mode.
Vent Mode Miscellaneous Test
vent mode.

The PCM energizes the A/C compressor clutch relay when
Engine Output
A/C Relay you select ON. The A/C compressor clutch should remain
Controls
engaged until commanded OFF.
SCAN TOOL DATA LIST

Operating Conditions: Engine idling, A/C ON, ambient air temperature between 22-27C (70-80F)
A/C Switch Inputs On/Off varies
HVAC Control Module Scan Tool Data List

AC Request Outputs Yes/No varies
Ambient Air Temp Data C/F varies
Auto Mode Outputs On/Off varies
Auto Button Inputs On/Off varies
Blower Speed Outputs 0 Thru 8 Bars varies
Evaporator Temp Data C/F varies
Fan Down Button Inputs On/Off varies
Fan Up Button Inputs On/Off varies
Front Defrost Button Inputs On/Off varies
Inside Air Temperature Data C/F varies
Left Temp Door Position Outputs Counts varies
Mode Button Inputs On/Off varies
Vent/ Mix-Blend/
Mode Door Position Outputs Floor/ Bi-Level/ varies
Defrost
Off Button Inputs On/Off varies
Rear Defrost Button Inputs On/Off varies
Recirculate Button Inputs On/Off varies
Ambient
Recirculation Mode Outputs varies
Air/Recirculate
Right Temp Door Position Outputs Counts varies
Selected Air Mode Outputs Warm Up/Defrost/Off varies
Sun Load Sensor Data Counts varies
Vent Button Inputs On/Off varies
PCM Scan Tool Data List 3.4L (LA1)

A/C Off for WOT Engine Data 2 Yes/No varies
A/C Pressure Disable Engine Data 2 Yes/No varies
A/C High Side Pressure Engine Data 2 kPa/Psi varies
A/C High Side Pressure Engine Data 2 Volts varies
Engine Data 2/ EGR
A/C Relay Command On/Off varies
Data/ Misfire Data
A/C Request Signal Engine Data 2 Yes/No varies
ECM Scan Tool Data List 3.6L (LY7)

A/C Off for WOT Cooling/HVAC Data Yes/No varies
A/C Pressure Disable Cooling/HVAC Data Yes/No varies
A/C High Side Pressure Cooling/HVAC Data Volts varies
A/C Relay Command Cooling/HVAC Data On/Off varies
A/C Request Signal Cooling/HVAC Data Yes/No varies
The HVAC Scan Tool Data Definitions contain a brief description of all the scan tool parameters. This list is in
alphanumeric order.
A/C High Side Pressure
The scan tool displays -103 to +3119 kPa (-14 to +452 psi). This parameter represents the A/C refrigerant
pressure sensor voltage signal converted to pressure.
The scan tool displays 0.00-5.00 Volts. This parameter represents the A/C refrigerant pressure sensor
signal.
A/C Off For WOT
The scan tool displays Yes or No. Yes indicates that the PCM/ECM has disabled the A/C compressor
because the TP sensor signal is at wide open throttle.
A/C Pressure Disable
The scan tool displays Yes or No. Yes indicates that the PCM/ECM has disabled the A/C compressor due
to excessive refrigerant pressure.
A/C Request
The scan tool displays Yes or No. The PCM/ECM uses the A/C request signal in order to determine if
A/C Request Signal
The scan tool displays Yes or No. The PCM/ECM uses the A/C request signal in order to determine if
A/C Relay Command
The scan tool displays On or Off. Represents the PCM/ECM commanded state of the A/C compressor
clutch relay. The A/C compressor clutch should be engaged when Commanded A/C displays On.
Ambient Air Temperature
The scan tool displays -50 to +87.5C (-58 to +189.5F). The output of the ambient air temperature
sensor.
Auto Mode
The scan tool displays On or Off. When in Auto mode the scan tool displays On. When in Manual mode
the scan tool displays Off.
Auto Button
The scan tool displays On or Off. When the AUTO button is pressed the scan tool displays On. When
Blower Speed
The scan tool displays 0 to 8 bars. When the blower motor is commanded off the scan tool displays 0.
When the blower motor controls are placed in the maximum speed setting the scan tool displays 8 bars.
This coincides with the HVAC control module display.
Evaporator Temp
This data displays -40 to 87.5C (-40 to 189.5F). The output of the evaporator temperature sensor.
Fan Down Button
The scan tool displays On or Off. When the Blower Speed Control Down button is pressed the scan tool
Fan Up Button
The scan tool displays On or Off. When the Blower Speed Control Up button is pressed the scan tool
Front Defrost Button
The scan tool displays On or Off. When the Front Defrost button is pressed the scan tool displays On.
Inside Air Temperature
The scan tool displays -50 to +87.5C (-58 to +189.5F). The output of the inside air temperature sensor.
Left Temp Door Position
The scan tool displays 0 to 195 counts. The signal output from the feedback pot on the actuator.
Mode Button
The scan tool displays On or Off. When the Mode button is pressed the scan tool displays On. When
Mode Door Position
The scan tool displays Vent, Mix-Blend, Floor, Bi-Level or Defrost. The current operating mode of the
HVAC system.
Off Button
The scan tool displays On or Off. When the Off button is pressed the scan tool displays On. When
Rear Defrost Button
The scan tool displays On or Off. When the Rear Defrost button is pressed the scan tool displays On.
Recirculate Button
The scan tool displays On or Off. When the Recirculate button is pressed the scan tool displays On. When
Recirculation Mode
The scan tool displays Ambient Air or Recirculate. The current operating state of the recirculation door.
Right Temp Door Position
The scan tool displays 0 to 195 counts. The signal output from the feedback pot on the actuator.
Selected Air Mode
The scan tool displays Warm Up, Defrost or Off. The current operating mode of the HVAC system.
Sun Load Sensor
The scan tool displays 0 to 255 counts. The signal output from the Sun Load Sensor.
Vent Button
The scan tool displays On or Off. When the Vent button is pressed the scan tool displays On. When
DTC B0165 OR B0166
Circuit Description
The HVAC control module monitors the passenger compartment inside air temperature through an inside air
temperature sensor. The inside air temperature sensor is a integral part of the HVAC control module. When the
air is cold, the sensor resistance and the signal voltage are high. When the air is warm, the sensor resistance and
the signal voltage are low.
DTC Descriptors
DTC B0165 Passenger Compartment Temp Sensor 1 left Circuit Low

DTC B0166 Passenger Compartment Temp Sensor 1 left Circuit High
The HVAC control module detects the signal circuit is less than 0.09 volts.
The HVAC control module detects the signal circuit is more than 4.9 volts.

The HVAC control module will continue to monitor the reference signal of the inside air temperature
sensor.
The DTC will become history if the HVAC control module no longer detects a condition.
The history DTC clears after 50 fault-free ignition cycles.
Diagnostic Aids
If the condition is not present, refer to Testing for Intermittent Conditions and Poor Connections in Wiring
Systems.
DTC B0165 or B0166

Step Action Yes No
Schematic Reference: HVAC Schematics
Connector End View Reference: HVAC Connector End Views
1
Vehicle in Vehicle
2. With a scan tool, observe the Vehicle DTC list.
2 Refer to Diagnostic Trouble Code (DTC) List -
Vehicle in Vehicle DTC Information.
Go to Diagnostic
Does the scan tool indicate the DTC is current? Go to Step 3 Aids
Test the ignition 3 voltage circuit of the HVAC control
module for an open or a high resistance. Refer to
Systems.
Test the ground circuit of the HVAC control module
4
the HVAC control module. Refer to Testing for
Replace the HVAC control module. Refer to Control
Module References in Computer/Integrating Systems
6 -
2. Operate the vehicle according to the Conditions
7 for Running the DTC.
Does the DTC set again? Go to Step 2 System OK
DTC B0233
Circuit Description
The mode actuator is an electronic device that incorporates a stepper motor and feedback potentiometer. The
HVAC control module controls the mode door position by sending a control signal to the actuator. The signal's
value is dependent upon the desired mode selected by the vehicle occupants. As the actuator moves, the
potentiometer produces the actual door position signal that is sent to the HVAC control module. The HVAC
control module continues to command the actuator to move until the desired and actual values are equal. The
door directs airflow through the outlets as selected by the vehicles occupants.
The HVAC control module commands the actuator through it's full range. The HVAC control module stores the
learned minimum and maximum position values. The travel range value is calculated by subtracting the
minimum and maximum position values. Then the HVAC control module compares the travel range, minimum
and maximum values to calibrated value ranges. If the travel range value is less than or equal to the maximum
calibrated limit and greater than or equal to the minimum calibrated limit, then the calibration is considered
successful. The HVAC control module continuously compares the actual actuator position to the calibrated
minimum and maximum position values.
DTC Descriptors
B0233 Air Flow Control Circuit
The ignition is ON.

Mode actuator position signal is less than 5 counts.

Mode actuator position signal is more than 194 counts.
The mode actuators total travel range is less than or greater than the calibrated limits.

The HVAC control module will continue to make use of whatever travel range is still available.
If the HVAC control no longer detects a failure, then the DTC will become history.
The history DTC will clear after 50 ignition cycles without a failure.
Diagnostic Aids
A damaged or broken mode door and or actuator can cause this DTC to set.
If the Mode actuator travels beyond it's calibrated limits the DTC will set.
DTC B0233
Vehicle? Diagnostic
System Check -
1 -
Vehicle in
Vehicle DTC
1. Observe the mode actuator drive shaft.
2. Place the mode control in each mode
2 position. -
Does the mode actuator drive shaft rotate for

each selected position? Go to Step 3 Go to Step 4
Inspect the mode door and the mode actuator for
the following:
Incorrectly installed mode actuator

3 Broken or binding linkages or mode door -
Obstruction that prevents the mode door Go to Testing
from operating within its full range of for
motion Intermittent
Conditions and
Poor
Did you find and correct the condition? Connections in
Test the ignition 3 voltage circuit of the mode
actuator for an open or a high resistance. Refer
4 to Circuit Testing andWiring Repairs in -
Wiring Systems.
Test the ground circuit of the mode actuator for
5 -
Test the 5-volt reference circuit of the mode
actuator for an open, a high resistance, short to
6 ground, or a short to voltage. Refer to Circuit -
Test the mode door position signal circuit of the
mode actuator for an open, a high resistance,
short to ground, or a short to voltage. Refer to
7 -
Systems.
Test the mode door control circuit of the mode
IMPORTANT:
The mode actuator connector and the HVAC
controller connector must be connected to
correctly perform the test.

OFF.
2. Backprobe and monitor the voltage from
the mode door position signal circuit of the
9 -
mode actuator to a good ground.
between the mode door control circuit and
the 5-volt reference circuit of the mode
actuator, this drives the motor to FLR.
4. Remove and reconnect the jumper wire
the ground circuit of the mode actuator,
this drives the motor to DEF.
Does the mode actuator drive shaft rotate and

does the voltage change? Go to Step 10 Go to Step 11
1. Backprobe the mode actuator connector
terminal in order to measure the voltage
from the mode door control circuit to a
good ground. 0 V toward
2. Place the mode control in each mode DEF
position. 5 V toward
10
FLR
Does the voltage measure near the specified 2.5 V
value when airflow moves toward DEF, near the stationary
specified value when airflow moves toward
FLR, and near the specified value when
stationary? Go to Step 11 Go to Step 12
connector of the mode actuator. Refer to Testing
11 -
Systems.
connector of the HVAC control assembly. Refer
to Testing for Intermittent Conditions and
12 -
Poor Connections and Connector Repairs in
Wiring Systems.
Replace the mode actuator. Refer to Mode
13 Actuator Replacement. -
Replace the HVAC control module. Refer to
15 -
DTC B0408 OR B0418
Circuit Description
The HVAC control module commands the air temperature actuator movement with one of three voltage signals
applied to the air temperature door control circuit. A low voltage of 0 volts moves the air temperature door
toward full hot A voltage of 2 5 volts stops the actuator A high voltage of 5 volts moves the air temperature
door toward full cold. The HVAC control module determines the current position of the actuator by monitoring
the feedback voltage of the air temperature door position signal circuit. The feedback potentiometer position is a
function of the actuator position. A high voltage indicates a full cold air temperature door position. A low
voltage indicates a full hot air temperature door position. The HVAC control module controls the air
temperature door position in order to maintain the selected air temperature.
DTC Descriptors
DTC B0408 Temperature Control 1 Main Circuit

DTC B0418 Temperature Control 2 Passenger Circuit

The air temperature position signal is less than 5 counts.

The air temperature position signal is greater than 194 counts.
The air temperature actuator actual total travel range max/min is less than or greater than the range limits.
The HVAC control module will continue to make use of whatever air temperature actuator travel range is
still available.
Diagnostic Aids
A damaged or broken air temperature actuator or mode door can cause this DTC to set.
If the condition is not present, refer to Testing for Intermittent Conditions and Poor Connections in
Wiring Systems.
DTC B0408 or B0418

Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
1. Observe the air temperature actuator drive
shaft.
2. Place the air temperature control in the
2 Full Hot and Full Cold position. -
Does the air temperature actuator drive shaft

rotate for each selected position? Go to Step 3 Go to Step 4
Inspect the air temperature actuator for the
An incorrectly installed air temperature

actuator
Air temperature actuator broken or binding
3 linkages -
An obstruction that prevents the air
temperature actuator from operating
within its full range of motion
Go to
Test the ignition 3 voltage circuit of the air
temperature actuator for an open or a high
4 resistance. Refer to Circuit Testing or Wiring -
Test the ground circuit of the air temperature
actuator for an open. Refer to Circuit Testing
5 -
Test the 5-volt reference circuit of the air
temperature actuator for an open, a high
resistance, short to ground, or a short to voltage.
6 -
Wiring Systems.
Test the air temperature position signal circuit of
the air temperature actuator for an open, a high
resistance, a short to ground, or a short to
voltage. Refer to Circuit Testing and Wiring
7 Repairs in Wiring Systems. -
Test the air temperature control circuit of the air
8 -
IMPORTANT:
The air temperature actuator connector and
the HVAC controller connector must be
connected to correctly perform the test.

OFF.
the air temperature position signal circuit
of the air temperature actuator to a good
ground.
9 -
between the air temperature control circuit
and the 5-volt reference circuit of the air
temperature actuator.
between the air temperature control circuit
and the ground circuit of the air
Does the air temperature actuator drive shaft

rotate and does the voltage change? Go to Step 10 Go to Step 11
1. Backprobe the air temperature actuator
connector terminal in order to measure the
voltage from the air temperature control
circuit to a good ground.
0V
2. Place the air temperature control in each decreasing
10 temperature position. 5 V increasing
2.5 V
Does the voltage measure near the specified stationary
value when airflow moves toward Full Cold
decreasing, near the specified value when
airflow moves toward Full Hot increasing, and
near the specified value when stationary? Go to Step 11 Go to Step 12
connector of the air temperature actuator. Refer
11 -
Wiring Systems.
connector of the HVAC control module. Refer to
12 -
Systems.
Replace the air temperature actuator. Refer to
Air Temperature Actuator Replacement -
13 Left or Air Temperature Actuator - -
15 -
DTC B3933
Circuit Description
The HVAC control module monitors the temperature of the refrigerant through the evaporator via a evaporator
temperature sensor. When the refrigerant temperature is low the sensor resistance and the signal voltage are
high. When the refrigerant temperature is high the sensor resistance and the signal voltage are low. The sensor
works in conjunction with a switch to meter the flow of refrigerant therefore preventing the freezing of moisture
that condenses on the evaporator. An evaporator with too little refrigerant will starve causing insufficient
cooling. An evaporator flooded with refrigerant will also cause poor cooling when there is too much liquid
refrigerant that cannot vaporize quickly.
DTC Descriptors
B3933 Air Conditioning (A/C) Evaporator Temperature Sensor Circuit

The HVAC control module detects the signal circuit is less than 5 counts (0.09 volts).
The HVAC control module will store the trouble code in memory.
A default value will be used for the sensor data by the HVAC control module to allow the A/C system to
operate.
Diagnostic Aids
Systems.
Test Description
3: Tests for the proper operation of the circuit in the high voltage range.
4: Tests for the proper operation of the circuit in the low voltage range. If the fuse in the jumper opens
when you perform this test, the signal circuit is shorted to voltage.
DTC B3933
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
OFF. -50 to +143
2 3. With a scan tool, observe the Evaporator C (-58 to
Temp parameter in the Heating, +290F)
Ventilation and Air Conditioning data list.
Does the scan tool indicate that the Evaporator Go to

Temp parameter is within the specified range? Diagnostic Aids Go to Step 3
2. Disconnect the evaporator temperature
sensor
OFF.
3 -43C (-45F)
4. With a scan tool, observe the Evaporator
Temp parameter.
Does the scan tool indicate that the Evaporator

Temp sensor parameter is equal to the specified
between the signal circuit of the
evaporator temperature sensor and the low
reference circuit of the evaporator
temperature sensor.
3. Turn ON the ignition, with the engine 144C (291
4
OFF. F)
4. With a scan tool, observe the Evaporator
Temp parameter.
Does the scan tool indicate that the

EvaporatorTemp parameter is equal to the
Test the signal circuit of the evaporator
temperature sensor for a short to ground. Refer to
Systems.
Test the signal circuit of the evaporator
temperature sensor for a short to voltage, a high
6 resistance, or an open. Refer to Circuit Testing -
Test the low reference circuit of the evaporator
temperature sensor for a high resistance or an
7 open. Refer to Circuit Testing and Wiring -
connector of the evaporator temperature sensor.
8 in Wiring Systems. -
9 -
Systems.
Replace the evaporator temperature sensor. Refer
to Evaporator Temperature Sensor
10 Replacement in Heating, Ventilation and Air -
Conditioning.
DTCs.
supporting text.
DTC P0530
Circuit Description
The powertrain control module (PCM) or engine control module (ECM) monitors the high side refrigerant
pressure via an A/C refrigerant pressure sensor. The PCM/ECM supplies a 5-volt reference and a low reference
to the sensor. Changes in the A/C refrigerant pressure cause the A/C refrigerant pressure sensor signal to the
PCM/ECM to vary. When the pressure is high, the signal voltage is high. When the pressure is low, the signal
voltage is low. When pressure is high, the PCM commands the cooling fans ON. When pressure is too high or
too low, the PCM/ECM will not allow the A/C compressor clutch to engage.
DTC Descriptor
DTC P0530 Air Conditioning (A/C) Refrigerant Pressure Sensor Signal Circuit Too Low or Too High

The PCM/ECM detects the signal circuit is less than 5 counts (0.09 volt) or more than 250 counts (4.9
volts).
The PCM/ECM will not illuminate the malfunction indicator lamp (MIL).
The PCM/ECM stores the Failure Records.
The DTC will become history if the PCM/ECM no longer detects a failure.
Diagnostic Aids
Systems.
Test Description
4: If the pressure signal voltage stays high after disconnecting the pressure sensor electrical connector, the
signal circuit is shorted to voltage, or the PCM/ECM is faulty.
7: This step tests for a high resistance or for an open in the ground circuit.
16: This vehicle is equipped with a PCM/ECM which utilizes an electrically erasable programmable read-
only memory (EEPROM). Before you replace the PCM/ECM, program the new PCM/ECM.
DTC P0530
Vehicle? Go to
1 - Diagnostic
System Check
- Vehicle in
Vehicle DTC
IMPORTANT:
The ambient air temperature must be above 3
C (38F).

2. Inspect the A/C compressor for free
2 -
rotation operation.
4. Place the HVAC control module in the Go to HVAC
OFF position. Compressor
Clutch Does
Does the A/C compressor operate? Not Disengage Go to Step 3
OFF.
3. Observe the A/C High Side Pressure
parameter in the powertrain control
3 module (PCM)/engine control module 0.1-4.9 V
(ECM) Engine Data-2 list with a scan tool.
Does the scan tool indicate that the A/C High

Side Pressure parameter is within the specified Go to
range? Diagnostic Aids Go to Step 4
2. Disconnect the A/C refrigerant pressure
sensor.
OFF.
4 0.1 V
4. With a scan tool, observe the A/C High
Side Pressure parameter.

Side Pressure parameter is less than the specified
5 the signal circuit of the A/C refrigerant 4.9 V
pressure sensor.
OFF.

Side Pressure parameter is greater than the
reference circuit of the A/C refrigerant
6 pressure sensor and the ground circuit of 5V
the A/C refrigerant pressure sensor.
Is the voltage measurement less than the

7 pressure sensor to a good ground. 5 ohms
Is the resistance measurement near the specified

Test the 5-volt reference circuit of the A/C
refrigerant pressure sensor for a short to voltage.
Wiring Systems.
refrigerant pressure sensor for a short to ground,
for a high resistance, or for an open. Refer to
9 -
Systems.
Test the signal circuit of the A/C refrigerant
pressure sensor for a short to ground, for a high
resistance, or for an open. Refer to Circuit
10 -
Systems.
pressure sensor for a short to voltage. Refer to
Systems.
1. Disconnect the PCM/ECM.
2. Test the low reference circuit of the A/C
refrigerant pressure sensor for high
resistance or for an open. Refer to Testing
12 for Intermittent Conditions and Poor -
Connections and Wiring Repairs in
Wiring Systems.

Inspect for bad connections at the harness
connector of the A/C refrigerant pressure sensor.
13 -
in Wiring Systems.
connector of the PCM/ECM. Refer to Testing
14 -
Systems.
Replace the A/C refrigerant pressure sensor.
Refer to Air Conditioning (A/C) Refrigerant
15 Pressure Sensor Replacement in Heating, - -
Replace the PCM/ECM. Refer to Control
Module References in Computer/Integrating
16 Systems for replacement, setup, and - -
programming.
supporting text.
DTC P0645
or engine control module (ECM) controls the relay by grounding the control circuit of the A/C clutch relay
through an internal solid state device. This device is called a driver. The driver supplies the ground for the
component that is being controlled. Each driver has a fault line which is monitored by the PCM/ECM. When
the PCM/ECM commands a component ON, the voltage of the control circuit should be near 0 volts. When the
PCM/ECM commands the control circuit to a component OFF, the voltage potential of the circuit should be
near battery voltage. If the fault detection circuit senses an unexpected voltage, this DTC will set.
The PCM/ECM will monitor the control circuit to the A/C clutch relay for the following conditions:
A short to ground
A short to voltage
An open circuit
An open relay coil
If the PCM/ECM detects any of these malfunctions, this DTC is set, and the affected driver is disabled.
DTC Descriptor
DTC P0645 Air Conditioning (A/C) Clutch Relay Control Circuit.
The ignition voltage is between 9-18 volts.
A/C clutch relay.
The PCM/ECM will not illuminate the malfunction indicator lamp (MIL).
The PCM/ECM will store those conditions which were present when the DTC set. These conditions are
A history DTC will clear after 50 consecutive fault-free ignitions have occurred without a malfunction.
Diagnostic Aids
IMPORTANT: Inspect PCM/ECM engine grounds for being secure and clean.
Systems.
Test Description
2: Listen for an audible click when the relay operates. Command the ON and the OFF states. Repeat the
12: The PCM/ECM utilizes electrically erasable programmable read-only memory (EEPROM). Program
the new PCM/ECM before you replace the PCM/ECM.
DTC P0645
Step Action Yes No
1
Vehicle in Vehicle
3. With a scan tool, command the A/C compressor
2 clutch relay ON and OFF.
Does the clutch relay turn ON and OFF with each Go to Diagnostic
2. Disconnect the A/C compressor clutch relay.
3 4. Probe the coil feed circuit of the A/C compressor
clutch relay using a test lamp which is connected
to a good ground.

of the A/C compressor clutch relay and the coil
4 feed circuit of the A/C compressor clutch relay.
clutch relay ON and OFF.
5
Test the control circuit of the A/C compressor clutch
relay for a short to voltage or for an open. Refer to
Systems.
relay for a short to ground. Refer to Circuit Testing
7
Inspect for poor connections at the A/C compressor
clutch relay. Refer to Testing for Intermittent
Inspect for poor connections at the powertrain control
module (PCM)/engine control module (ECM). Refer to
9
Systems.
Repair the coil feed circuit of the A/C compressor
clutch relay. Refer to Wiring Repairs in Wiring
10 -
Systems.
Replace the A/C compressor clutch relay. Refer to
Compressor Relay Replacement in Heating,
11 -
12 -
13 for Running the DTC, which are specified in the
supporting text.
SYMPTOMS - HVAC SYSTEMS - AUTOMATIC

1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information before using the Symptom
2. Review the system operation in order to familiarize yourself with the system functions. Refer to:
Air Delivery Description and Operation
Air Temperature Description and Operation
Inspect for aftermarket devices which could affect the operation of the HVAC System. Refer to Checking
cause the symptom.
Verify that the customer is using the correct key to enable personalization and is not inadvertently
activating steering wheel or passenger HVAC controls.
The A/C compressor will not operate in cold outside air temperatures. Refer to Air Temperature
Description and Operation.
Wet carpet or mats
High humidity
Interior water leak
Blocked A/C evaporator drain tube
Inspect the air distribution system for causes of reduced air flow:
Obstructed or dirty passenger compartment air filter, if equipped
Blocked or damaged air inlet or outlet vents
Intermittent
Symptom List

Blower Motor Always On
Blower Motor Inoperative
Blower Motor Malfunction
Too Hot in Vehicle
Too Cold in Vehicle
Leak Testing in Heating, Ventilation and Air Conditioning
Defrosting Insufficient in Heating, Ventilation and Air Conditioning
Noise Diagnosis - Blower Motor in Heating, Ventilation and Air Conditioning
Noise Diagnosis - Air Conditioning (A/C) System in Heating, Ventilation and Air Conditioning
Noise Diagnosis - HVAC Module in Heating, Ventilation and Air Conditioning
Odor Diagnosis in Heating, Ventilation and Air Conditioning
Outside Air Temperature Display Inaccurate or Inoperative in Instrument Panel, Gages, and Console
Diagnostic Aids
Test Description
2: The A/C compressor relay output is disabled if engine coolant temperature (ECT) is above 121C
(250F). The engine coolant indicator will illuminate at this temperature.
3: Pressing the center of the left side driver temperature control switch and setting the air temperature
control switch in a cold setting activates A/C operation. For the purpose of this and future steps where
A/C operation is necessary, believe mode is used for consistent testing.
6: The HVAC control module is inoperative when the module does not respond to any operator control
requests to enable the A/C compressor. The blower motor may still operate independent of the A/C
controls.

Step Action Yes No
DEFINITION: The A/C compressor clutch will not engage when an A/C request has been made and a
powertrain DTC has not been set.
1
Vehicle in Vehicle
1. Start the engine. Go to Engine
Coolant
2. Observe the coolant temperature indicator. Temperature
2
Indicator Always
Is the engine coolant temperature (ECT) indicator On in Engine
illuminated? Cooling Go to Step 3
IMPORTANT:
For A/C compressor operation, ambient air
temperature must be above 3C (38F).

2. Place the blower motor switch in the maximum
3 speed position.
3. Press the drivers side temperature control
switch. Go to Testing for
4. Place the driver side temperature control in the Intermittent
coldest position. Conditions and
Poor Connections
Does the A/C compressor operate? in Wiring Systems Go to Step 4
1. Park the vehicle inside or in the shade.
2. Open the windows in order to ventilate the
interior of the vehicle.
3. If the A/C system was operating, then allow the
A/C system to equalize for approximately 2
minutes.
4. Turn OFF the ignition switch.
5. Install the J 43600 ACR 2000 Air Conditioning
Service Center.
4
6. Record the ambient air temperature at the
vehicle.
7. Record readings of the low and high side
STATIC pressures.
8. Compare the low and high side pressure values
with the allowable limits for the recorded
ambient air temperature. Refer to Air
Conditioning (A/C) System Performance
Test .
Are the low and high side pressure values within the Go to Leak Testing
allowable limits for the recorded ambient air in Heating,
temperature, and within 103 kPa (15 psi) of each Ventilation and Air
other? Go to Step 5 Conditioning
2. With a scan tool, observe the A/C high side
pressure sensor parameter in the Powertrain
Data List.
5 3. Compare the A/C high side pressure on the scan
tool to the high side pressure value on the J
43600 .
Are the high side pressure values within the 103 kPa
(15 psi) of each other? Go to Step 6 Go to Step 16
IMPORTANT:
The HVAC control module is inoperative when the
module does not respond to any operator control
6 requests.
Is the HVAC control module inoperative? Go to Step 15 Go to Step 7

2. With a scan tool, observe the A/C Request
Signal parameter in the Powertrain Data List.
3. Place the air temperature switch in the coldest
7 position.
4. Press the drivers side temperature control
switch.
Does the scan tool indicate that the A/C Request

Signal parameter is YES? Go to Step 8 Go to Step 27
With a scan tool, observe the A/C Relay Command
Parameter in the Powertrain Data List.
8
Does the scan tool indicate that the A/C Relay
Command parameter is ON? Go to Step 9 Go to Step 28
With a scan tool, command the A/C compressor clutch
relay ON and OFF.
9
Does the A/C compressor clutch relay turn ON and
OFF with each command? Go to Step 13 Go to Step 10
4. Probe the coil side voltage supply circuit of the
A/C compressor clutch relay with a test lamp

side voltage supply circuit of the A/C
compressor clutch relay.
11 2. With a scan tool, command the A/C compressor

12
3. Probe the switch side voltage supply circuit of
13 the A/C compressor clutch relay with a test lamp

1. Connect a 10-amp fused jumper wire between
the switch side voltage circuit of the A/C
compressor clutch relay and the A/C compressor
clutch supply voltage circuit of the A/C
14
compressor clutch.
Does the A/C compressor clutch engage? Go to Step 25 Go to Step 20

module for a short to ground, a high resistance, or an
15 open. Refer to Circuit Testing and Wiring Repairs in
Wiring Systems.
Test the ground circuit of the A/C pressure sensor for
16
17
relay for an open. Refer to Circuit Testing and
18
19
Test the A/C compressor clutch supply voltage circuit
at the A/C compressor clutch for a short to ground, a
20 high resistance, or an open. Refer to Circuit Testing
Test the ground circuit of the A/C compressor clutch
for a high resistance or an open. Refer to Circuit
21
Repair the switch side voltage supply circuit of the
A/C compressor clutch relay. Refer to Wiring Repairs
22 -
in Wiring Systems.
Repair the coil side voltage supply circuit of the A/C
compressor clutch relay. Refer to Wiring Repairs in
23 -
Wiring Systems.
of the A/C high pressure sensor. Refer to Testing for
of the A/C compressor clutch. Refer to Testing for
of the HVAC control module. Refer to Testing for
of the powertrain control module (PCM) or engine
control module (ECM). Refer to Testing for
Replace the A/C high pressure switch. Refer to Air
Conditioning (A/C) Refrigerant Pressure Sensor
29 Replacement in Heating, Ventilation and Air -
Conditioning.
30 -
Replace the A/C compressor. Refer to Compressor
Replacement in Heating, Ventilation and Air
31 -
Conditioning.
32 -
33 -
34

DEFINITION: The A/C compressor clutch will not disengage when an A/C request has not been made
and a powertrain DTC has not been set.
Vehicle? Diagnostic
System Check -
1 -
Vehicle in
Vehicle DTC
Go to Testing
2 2. Turn OFF the HVAC controls. - for
Intermittent
Does the A/C compressor operate? Conditions and
Poor
Connections in
With a scan tool, observe the A/C Relay
Command Parameter in the Powertrain Data List.
3 -
Does the scan tool indicate that the A/C Relay
Command Parameter is ON? Go to Step 4 Go to Step 5
With a scan tool, observe the A/C Request Signal
parameter in the Powertrain Data List.
4 -
Does the scan tool indicate that the A/C Request
Signal parameter is YES? Go to Step 10 Go to Step 11
Remove the A/C compressor clutch relay.
5 -
Does the A/C compressor clutch turn OFF? Go to Step 6 Go to Step 8
Measure the resistance between the switch side
A/C compressor clutch relay terminals.
6 infinity
Does the resistance measurement equal the
Test the A/C clutch relay control circuit for a
short to ground. Refer to Circuit Testing and
7 -
Test the A/C compressor clutch supply voltage
8 -
Inspect for poor connections at the A/C
compressor clutch relay. Refer to Testing for
9 -
Systems.
10 -
Systems.
11 -
Replace the A/C compressor clutch relay. Refer
12 to Compressor Relay Replacement in Heating, - -
Replace the A/C compressor. Refer to
Compressor Replacement in Heating,
13 - -
Replace the PCM/ECM. Refer to Control
Module References in Computer/Integrating
15 Systems for replacement, setup, and - -
programming.
16 -

Step Action Yes No
DEFINITION: The blower motor is ON while the HVAC control is in the OFF position.
1
Vehicle in Vehicle
Intermittent
2 2. Turn OFF the HVAC controls. Conditions and
Poor Connections
Is the blower motor OFF? in Wiring Systems Go to Step 3
Disconnect the HVAC control module.
3
Does the blower motor continue to operate? Go to Step 4 Go to Step 8
Inspect or test the blower motor control circuit
between the blower motor and the blower module for a
Test the blower motor speed control circuit between
the HVAC control module and blower motor control
5 processor for a short to voltage. Refer to Circuit
Test the blower motor speed signal circuit for a short
to ground or an open. Refer to Circuit Testing and
6
of the blower motor control processor. Refer to
7
Systems.
Replace the blower motor control processor. Refer to
9 Blower Motor Control Processor Replacement. -
10 -
11

DEFINITION: The blower motor is inoperative in all speed positions.
System Check
1 -
- Vehicle in
Vehicle DTC
1. Turn ON the ignition, with the
engine OFF.
2 2. Place the blower switch in each -
speed position.
Go to Blower
Does the blower motor operate in any Motor
speed position? Malfunction Go to Step 3
2. Disconnect the blower motor
connector.
3. Turn ON the ignition, with the
engine OFF.
4. Connect a test lamp between the
3 blower motor supply voltage circuit -
and the blower motor control
circuit.
5. Place the blower switch in the
maximum speed position.

Test the battery positive voltage circuit of
the blower motor control processor for an
open, high resistance or short to ground.
4 -
Refer to Circuit Testing and Wiring
Test the ground circuit of the blower
motor control processor for an open or
5 high resistance. Refer to Circuit Testing -
IMPORTANT:
The blower motor control processor
connector and the HVAC control
module connectors must be connected
to correctly perform the test.
1. Backprobe and measure the voltage

from the blower speed control 2.0 V OFF
6 circuit at the HVAC control module 8.0 V ON
to a good ground.
2. With a scan tool, command the
blower motor ON and OFF.
Does the voltage measure near the

specified values for each commanded
state? Go to Step 7 Go to Step 9
Test the blower motor voltage supply
circuit between the blower motor and the
7 blower motor control processor for an
open, short to ground. Refer to Circuit Go
Testing and Wiring Repairs in Wiring to
Systems. Step
Did you find and correct the condition? Go to Step 16 8
Test the blower speed control circuit
between the blower motor and the blower
motor control processor for an open, short Go
8
to voltage. Refer to Circuit Testing and to
Wiring Repairs in Wiring Systems. Step
Test the blower speed control circuit of
the HVAC control module for an open,
short to ground or short to voltage. Refer Go
9
to Circuit Testing and Wiring Repairs to
in Wiring Systems. Step
Inspect for poor connections at the
harness connector of the blower motor.
Refer to Testing for Intermittent
10 -
harness connector of the blower motor
control processor. Refer to Testing for
Wiring Systems.
harness connector of the HVAC control
module. Refer to Testing for
Wiring Systems.
Replace the blower motor. Refer to
Blower Motor Replacement in Heating,
13 - -
Replace the blower motor control
processor. Refer to Blower Motor
14 - -
Control Processor Replacement.
Replace the HVAC control module. Refer
15 to Control Module References in - -
Computer/Integrating Systems for
Operate the system in order to verify the
16 repair. -
Test Description
2: This step will determine if one or more blower speeds are inoperative.
3: This step determines if the HVAC control module and blower motor control processor are attempting
to control the blower motor speed.
5: The measured voltage on the blower speed control circuit should steadily increase from 0-8 volts as the
blower speed is adjusted from the minimum speed position to the maximum speed position.

DEFINITION: The blower motor operates in at least one, but not all, speed positions.
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
1. Turn ON the ignition, with the engine Go to Testing
OFF. for
2. Place the blower motor switch in each Intermittent
2 speed position. - Conditions and
Poor
Does the blower motor operate at the desired Connections in
speeds? Wiring Systems Go to Step 3
2. Disconnect the blower motor connector.
3 OFF. -
4. Connect a test lamp between the blower
motor supply voltage circuit and the
blower motor control circuit.
5. Adjust the blower motor switch from the
minimum speed position to the maximum
speed position.
Does the test lamp illuminate and increase

intensity? Go to Step 8 Go to Step 4
Test the battery positive voltage circuit and
ground circuit of the blower motor control
processor for high resistance. Refer to Circuit
4 -
Systems.
IMPORTANT:
The blower motor control processor and
HVAC control module connectors must be
connected to correctly perform the test.
1. Backprobe and measure the voltage from

the blower speed control circuit at the
5 HVAC control module to a good ground. 0-8.0 V
2. Gradually adjust the blower motor switch
from the minimum speed position to the
Does the measured voltage continuously

increase between the specified values? Go to Step 7 Go to Step 6
Test the blower motor speed control circuit for
an short to voltage. Refer to Circuit Testing and
6 -
Test the blower motor speed signal circuit for an -
short to voltage, open or short to ground. Refer
7 to Circuit Testing and Wiring Repairs in
Wiring Systems.
connector of the blower motor. Refer to Testing
8 -
Systems.
connector of the blower motor control processor.
9 Refer to Testing for Intermittent Conditions -
in Wiring Systems.
10 -
Systems.
Replace the blower motor. Refer to Blower
Motor Replacement in Heating, Ventilation and
11 - -
Air Conditioning.
Replace the blower motor control processor.
Refer to Blower Motor Control Processor
12 - -
Replacement.
14 -
TOO HOT IN VEHICLE
Diagnostic Aids
Test Description
7: This test is to ensure A/C system is operating normally.

10: The aspirator tube connects to the rear of the HVAC control module. The aspirator tube is used to
Too Hot in Vehicle

DEFINITION: The temperature cannot be adjusted, or the cooling is insufficient.
Vehicle? Diagnostic
System Check -
1 -
Vehicle in
Vehicle DTC
2. Turn ON the ignition, with the engine Go to
OFF. Diagnostic
2 3. Observe the DTC List in Vehicle DTC - Trouble Code
Information. (DTC) List -
Vehicle in
Does the scan tool display any DTC B0165, Vehicle DTC
B0166, B0408, B0418, or B0233? Information Go to Step 3
IMPORTANT:
Ambient air temperature must be above 3C
(38F).

2. Turn ON the HVAC controls.
3 -
3. Place the drivers temperature knob in the
coldest position.
4. Place the HVAC control head in the Go to HVAC
AUTO position. Compressor
Clutch Does
Does the A/C compressor operate? Go to Step 4 Not Engage
Place the blower motor switch in each speed
position. Go to Blower
4 -
Does the blower motor operate in any of the Motor
speed positions? Go to Step 5 Inoperative
Does the blower motor operate in the desired Go to Blower
5 speeds? - Motor
Go to Step 6 Malfunction
1. Place the blower motor switch in the
2. Place the mode switch in the panel
6 position. -
3. Place the recirculation switch in the ON
and OFF positions. Go to Air
Recirculation
Does the recirculation door operate properly? Go to Step 7 Malfunction
Perform the A/C system performance test. Refer
to Air Conditioning (A/C) System
Performance Test in Heating, Ventilation and
7 Air Conditioning. -
1. Turn ON the ignition, with engine OFF.
2. With a scan tool, command the right and
left air temperature actuators Hot and
Cold.
8 3. Observe the Right Temp Door Position -
and the Left Temp Door Position
parameters.
Do the counts change when actuators are

1. Install a thermometer near the inside air
temperature sensor.
2. With a scan tool, observe the Inside Air
Temp data parameters in the Heating and
9 Air Conditioning Data list. -
Does the scan tool indicate the sensor

temperature are within 3C (5F) of the
thermometer temperatures? Go to Step 11 Go to Step 10
Inspect for a blocked aspirator tube of the
10 HVAC control module. -
3. Cover the sunload sensor.
5. Adjust the driver side temperature to 22C
(72F).
11 230 Counts
6. With a scan tool, observe the Sunload
Sensor data parameter in the Heating and
Air Condition data list.
Does the scan tool indicate that the Sunload

Sensor parameter is greater than the specified
1. Uncover the sunload sensor.
12 2. Direct a light source at the sunload sensor. -
Does the voltage change? System OK Go to Step 16

Test the suspect actuator door control circuit for
a short to voltage, a short to ground, an open, or
13 high resistance. Refer to Circuit Testing and -
Test the suspect actuator ignition 3 voltage
circuit for a short to ground, an open, or high
14 resistance. Refer to Circuit Testing and -
connector of the suspect air temperature
actuator. Refer to Testing for Intermittent
15 -
connector of the sunload sensor. Refer to
16 -
Systems.
connector of the HVAC control module. Refer
17 -
Wiring Systems.
Replace the sunload sensor. Refer to Sun Load
18 Sensor Replacement. - -
Replace the suspect air temperature actuator.
Refer to Air Temperature Actuator
19 Replacement - Right or Air Temperature - -
Actuator Replacement - Left.
21 -
TOO COLD IN VEHICLE

Test Description
The step numbers below refer to the step numbers on the diagnostic table.
3: This checks for A/C compressor clutch always ON.

7: This test is to ensure the cooling system is operating normally.
10: The aspirator tube connects to the rear of the HVAC control module. The aspirator tube is used to
Too Cold in Vehicle

DEFINITION: The temperature cannot be adjusted, or the heating is insufficient.
Did you perform Diagnostic System Check - Go to
Vehicle? Diagnostic
System Check -
1 -
Vehicle in
Vehicle DTC
Go to
2. Turn ON the ignition, with the engine Diagnostic
OFF. Trouble Code
2 3. Observe the DTC List. -
(DTC) List -
Vehicle in
Does the scan tool display any DTC B0165, Vehicle DTC
B0166, B0408, B0418, or B0233? Information Go to Step 3
1. Start the engine. Go to HVAC
3 2. Turn OFF the HVAC controls. - Compressor
Clutch Does
4 -
Does the blower motor operate in the desired Go to Blower
5 speeds? - Motor
6 2. Place the mode switch in the vent -
position.
and OFF positions. Go to Air
Recirculation
Does the recirculation door operate properly? Go to Step 7 Malfunction
Perform the heater performance diagnostic.
Refer to Heating Performance Diagnostic in
7 -
1. Turn ON the ignition, with engine OFF.
2. With a scan tool, command the right and
left air temperature actuators Hot and
Cold.
8 3. Observe the Right Temp Door Position -
and the Left Temp Door Position
parameters.
Do the counts change when the actuators are

1. Install a thermometer near the inside air
temperature sensor.
2. With a scan tool, observe the Inside Air
Temp data parameters in the Heating and
9 Air Conditioning Data list. -
Does the scan tool indicate the sensor

temperature are within 3C (5F) of the
thermometer temperatures? Go to Step 11 Go to Step 10
Inspect for a blocked aspirator tube of the
10 HVAC control module. -
3. Cover the sunload sensor.
5. Adjust the driver side temperature to 22C
(72F).
11 230 Counts
6. With a scan tool, observe the Sunload
Sensor data parameter in the Heating and
Air Condition data list.
Does the scan tool indicate that the Sunload

1. Uncover the sunload sensor.
2. Direct a light source at the sunload sensor.
12 -
Does the voltage change? System OK Go to Step 16
Test the suspect actuator door control circuit for
a short to voltage, a short to ground, an open, or
13 high resistance. Refer to Circuit Testing and -
Test the suspect actuator ignition 3 voltage
circuit for a short to ground, an open, or high
14 resistance. Refer to Circuit Testing and -
connector of the suspect air temperature
actuator. Refer to Testing for Intermittent
15 -
connector of the sunload sensor. Refer to
16 -
Systems.
17 -
Wiring Systems.
Replace the sunload sensor. Refer to Sun Load
18 Sensor Replacement. - -
IMPORTANT:
Perform the recalibration procedure for the air
temperature actuator
19 Replace the suspect air temperature actuator. - -

Replacement - Right or Air Temperature
Actuator Replacement - Left.Did you
complete the replacement? Go to Step 21
20 Control Module References in - -
Computer/Integrating Systems.
21 -
Test Description
3: This step tests for a blower motor that does not operate regardless of the desired blower motor speed.
4: This step tests for a blower motor that operates, yet does not accurately respond to the desired blower
motor speed.
5: The HVAC control module is inoperative when the it does not respond to any operator requests. This
step verifies that there is power to the HVAC control assembly.
13: The voltage will vary between 0-5 volts during normal operation. The HVAC control assembly

DEFINITION: Air does not flow correctly from the air distribution outlets.
Vehicle? Diagnostic
System Check -
1 -
Vehicle in
Vehicle DTC
OFF.
2 2. Place the blower control in the OFF -
Motor Always
Is the blower motor OFF? Go to Step 3 On
Place the blower control in each speed position. Go to Blower
3 Does the blower motor operate at all? - Motor
Go to Step 4 Inoperative
Does the blower motor operate correctly for each Go to Blower
4 speed position? - Motor
5 Is the HVAC control module inoperative? - Go to Step 16 Go to Step 6
1. Observe the mode actuator drive shaft.
2. Place the mode control in each mode
position.
6 -
Does the mode actuator drive shaft rotate for
each selected position? Go to Step 7 Go to Step 8
the following:
Incorrectly installed mode actuator

Broken or binding linkages or mode door Go to Testing
7 Obstruction that prevents the mode door - for
from operating within its full range of Intermittent
motion Conditions and
Poor
Connections in
Did you find and correct the condition? Go to Step 23 Wiring Systems
Test the ignition 3 voltage circuit of the mode
actuator for an open or a high resistance. Refer
Wiring Systems.
9 -
Test the 5-volt reference circuit of the mode
Test the mode door position signal circuit of the
mode actuator for an open, a high resistance,
short to ground, or a short to voltage. Refer to
11 -
Systems.
IMPORTANT:
The mode actuator connector and the HVAC
controller connector must be connected to
correctly perform the test.
OFF.
the mode door position signal circuit of the
mode actuator to a good ground.
13 the 5-volt reference circuit of the mode -
actuator, this drives the motor to FLR.
the ground circuit of the mode actuator,
this drives the motor to DEF.
Does the mode actuator drive shaft rotate and

does the voltage change? Go to Step 14 Go to Step 18
1. Backprobe the mode actuator connector
terminal in order to measure the voltage
from the mode door control circuit to a
good ground. 0 V toward
2. Place the mode control in each mode DEF
position. 5 V toward
14
FLR
Does the voltage measure near the specified 2.5 V
value when airflow moves toward DEF, near the stationary
specified value when airflow moves toward
FLR, and near the specified value when
stationary? Go to Step 15 Go to Step 20
Inspect the mode door for a mechanical failure
or a condition that allows excessive travel to the
15 -
door.
Test the ignition 3 voltage circuit of the HVAC
controller for an open, a high resistance or a
Test the ground circuit of the HVAC controller
for an open. Refer to Circuit Testing and
17 -
connector of the mode actuator. Refer to Testing
18 -
Systems.
1. Inspect the mode door and any attaching
linkage for any binding.
2. Inspect the ductwork for any debris that
19 would prevent air flow through the -
ductwork.

connector of the HVAC control assembly. Refer
20 -
Wiring Systems.
21 Actuator Replacement. -
23 -

DEFINITION: Air recirculation is inoperative or is always ON.
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
OFF.
2 2. With a scan tool observe the Recirculate -
Mode Parameter.
3. Place the recirculation switch in the
recirculate position.
Does the scan tool indicate that the recirculation

switch changes state? Go to Step 3 Go to Step 11
2. Disconnect the recirculation actuator.
3. Turn On the ignition, with the engine OFF.
3 4. Probe the ignition 3 voltage circuit of the -
recirculation actuator with a test lamp that
is connected to a good ground.

Test the low reference circuit of the recirculation
actuator for an open or high resistance. Refer to
4 Circuit Testing andWiring Repairs in Wiring -
Systems.
1. Measure the voltage from the door control
circuit of the recirculation actuator to a
good ground.
2. Place the recirculation switch in the 0 volts
5
outside air position. outside air

circuit of the recirculation actuator to a
good ground.
6 2. Place the recirculation switch in the recirc 12 volts recirc
position.

Test the recirculation door control circuit of the
recirculation actuator for an open, a high
7 -
Repair the ignition 3 voltage circuit of the
recirculation actuator. Refer to Wiring Repairs
8 - -
in Wiring Systems.
Inspect the recirculation door and the
recirculation actuator for the following
conditions:
A misaligned recirculation actuator

Broken or binding linkages
A broken or binding recirculation door
9 An obstruction that prevents the -
recirculation door from operating within its
full range of motion
Missing seals to the recirculation door
Misaligned seals to the recirculation door

connector of the recirculation actuator. Refer to
10 -
Systems.
11 -
Systems.
Replace the recirculation actuator. Refer to
12 Recirculation Actuator Replacement. - -
14 -
REPAIR INSTRUCTIONS
HVAC CONTROL MODULE REPLACEMENT
Removal Procedure
1. Remove the I/P cluster trim plate bezel. Refer to Trim Plate Bezel Replacement - Instrument Panel
(I/P) Cluster (Aztek) or Trim Plate Bezel Replacement - Instrument Panel (I/P) Cluster
(Rendezvous) in Instrument Panel, Gages and Console.
Fig. 13: View Of HVAC Control Module Retaining Screws


3. Pull the HVAC control module out from the I/P.
Fig. 14: Locating Aspirator Hose
4. Disconnect the aspirator hose (1) from the HVAC control module.
5. Disconnect the electrical connector from the HVAC control module.
6. Remove the HVAC control module.
1. Connect the electrical connector to the HVAC control module.

Fig. 15: Locating Aspirator Hose
2. Connect the aspirator hose (1) to the HVAC control module.

3. Install the HVAC control module to the I/P.
Fig. 16: View Of HVAC Control Module Retaining Screws
5. Install the I/P cluster trim plate bezel. Refer to Trim Plate Bezel Replacement - Instrument Panel (I/P)
Cluster (Aztek) or Trim Plate Bezel Replacement - Instrument Panel (I/P) Cluster (Rendezvous) in
BLOWER MOTOR CONTROL PROCESSOR REPLACEMENT
Removal Procedure
1. Remove the right side I/P insulator. Refer to Closeout/Insulator Panel Replacement - Right in
Fig. 17: Blower Motor & Electrical Connector

2. Disconnect the blower motor electrical connector.

3. Remove the blower motor mounting screws.
4. Remove the blower motor from the HVAC module assembly.
Fig. 18: Locating Electrical Connector From The Blower Motor Resistor
5. Disconnect the electrical connector from the blower motor control processor assembly.
6. Remove the forward blower control processor mounting screws.
7. Remove the rearward blower control processor mounting screw.
Fig. 19: View Of Blower Motor Resistor Assembly
8. Remove the blower control processor assembly from the HVAC module assembly.
Fig. 20: View Of Blower Motor Resistor Assembly
1. Install the blower motor control processor assembly to the HVAC module assembly.
2. Install the rearward mounting screw.
Tighten: Tighten the screw to 1.8 N.m (16 lb in).

3. Install the forward mounting screws.
Fig. 21: Locating Electrical Connector From The Blower Motor Resistor
4. Connect the electrical connector to the blower control processor assembly.

5. Install the blower motor to the HVAC module assembly.
6. Install the blower motor mounting screws.

Fig. 22: Blower Motor & Electrical Connector
7. Connect the blower motor electrical connector.

8. Install the right side I/P insulator. Refer to Closeout/Insulator Panel Replacement - Right in Instrument
Panel, Gages and Console.
Removal Procedure
1. Remove the upper I/P trim pad. Refer to Trim Pad Replacement - Instrument Panel (I/P) Upper
(Aztek) or Trim Pad Replacement - Instrument Panel (I/P) Upper (Rendezvous) in Instrument Panel,
Gages and Console.
Fig. 23: Locating Actuator Connector

Fig. 24: View Of Mounting Screws On The Recirculation Actuator



4. Install the upper I/P trim pad. Refer to Compartment Replacement - Instrument Panel (I/P) in
Removal Procedure
1. Remove the knee bolster from the instrument panel (I/P). Refer to Knee Bolster Replacement in
IMPORTANT: Count the number of threads showing from the tip of the mode actuator
push rod to the end of the retainer clip.
Fig. 27: Identifying Push Rod Retainer Clip
IMPORTANT: Disconnect the I/P wiring harness clip from the I/P support bracket to help
access the mode actuator screws.
Fig. 28: Locating Mode Actuator Mounting Screws

IMPORTANT: Align the counted number of threads on the mode actuator push rod (2)
with the tip of the retainer clip (1).
7. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages and Console.
Removal Procedure
1. Remove the I/P compartment. Refer to Compartment Replacement - Instrument Panel (I/P) in
Fig. 31: Locating Right Hand Temperature Door Lever Spring

Fig. 33: View Of HVAC Module


IMPORTANT: Align the pin on the right hand air temperature actuator with the slot in the
right hand temperature door lever.
HVAC module case.

Removal Procedure
1. Remove the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages and Console.
IMPORTANT: The HVAC controls must be set to the vent mode to position the defroster
door lever for access to the air temperature actuator.
Fig. 37: Locating Air Temperature Door Components

3 Remove the left hand temperature door lever bolt (3) from the HVAC module


Fig. 39: Identifying Air Temperature Actuator Mounting Screws


IMPORTANT: Align the pin on the left hand air temperature actuator with the slot in the
left hand temperature door lever.
HVAC module case.
ASPIRATOR REPLACEMENT
Removal Procedure
Fig. 43: View Of Aspirator Hose Mounting Screw

1. Remove the I/P carrier. Refer to Instrument Panel (I/P) Carrier Replacement in Instrument Panel,
Gages and Console.
2. Remove the aspirator hose mounting screw.
3. Disconnect the aspirator hose from the aspirator duct adapter (1).
4. Remove the aspirator hose from the HVAC module.
Fig. 44: View Of Aspirator Hose Mounting Screw
1. Install the aspirator hose to the HVAC module.
2. Install the aspirator hose retaining screw.
Tighten: Tighten the screw 0.9 N.m (8 lb in).
3. Connect the aspirator hose to the aspirator duct adapter (1).

4. Install the I/P carrier. Refer to Instrument Panel (I/P) Carrier Replacement in Instrument Panel, Gages
and Console.
AMBIENT AIR TEMPERATURE SENSOR REPLACEMENT
Tools Required
J 38778 Door Trim Pad Clip Remover
Removal Procedure
Fig. 45: Identifying Electrical Connector From The Ambient Air Temperature Sensor
1. Open the hood.

2. Disconnect the electrical connector from the ambient air temperature sensor.
3. Use J 38778 to disconnect the wiring harness retainer which secures the ambient air temperature sensor to
the hood latch support.
4. Remove the ambient air temperature sensor from the wiring harness retainer.
5. Remove the ambient air temperature sensor from the vehicle.
1. Install the ambient air temperature sensor on the wiring harness retainer.
2. Install the wiring harness push-in retainer which secures the ambient air temperature sensor to the hood
latch support.
Fig. 47: Identifying Electrical Connector From The Ambient Air Temperature Sensor
3. Connect the electrical connector to the ambient air temperature sensor.
SUN LOAD SENSOR REPLACEMENT
Removal Procedure
1. Remove the windshield garnish molding. Refer to Garnish Molding Replacement - Windshield Pillar
in Interior Trim.
IMPORTANT: Remove the I/P upper trim panel slowly, the retainer clips could possibly
fall into the I/P.
Fig. 48: View Of Instrument Panel (I/P) Upper Trim Panel Components
2. Lift the I/P upper trim panel up approximately 51 mm (2 in) and pull rearward to release I/P upper trim
panel retainers.
3. Lift the I/P upper trim panel to access sun load sensor.
4. Disconnect the sunload sensor electrical connector.
5. Remove the sun load sensor.
1. Install sun load sensor.

2. Connect the sunload sensor electrical connector.
Fig. 49: Identifying Sun Load & Ambient Light Sensors

3. Align the I/P upper trim locating pins and the retainers to the slots in the I/P.
Fig. 50: View Of Instrument Panel (I/P) Upper Trim Panel Components
4. Push forward and down on the I/P upper trim panel to lock into place.
5. Install the windshield garnish molding. Refer to Garnish Molding Replacement - Windshield Pillar in
Interior Trim.

The air delivery description and operation is divided into five areas:
Air Speed
Air Delivery
Automatic Operation
HVAC Control Module
The HVAC control module is a class 2 device that interfaces between the operator and the HVAC system to
maintain air temperature and distribution settings. The battery positive voltage circuit provides power that the
control module uses for keep alive memory (KAM). If the battery positive voltage circuit loses power, all
HVAC DTCs and settings will be erased from KAM. The body control module (BCM), which is the vehicle
mode master, provides a device on signal. The control module supports the following features:

Feature Availability
Afterblow No
Purge Yes
Personalization No
Actuator Calibration No
Mode Actuator
The mode actuator is a 5 wire bi-directional electric motor that incorporates a feedback potentiometer. Ignition
3 voltage, low reference, control, 5 volt reference and position signal circuits enable the actuator to operate. The
control circuit uses either a 0, 2.5 or 5 volt signal to command the actuator movement. When the actuator is at
rest, the control circuit value is 2.5 volts. A 0 or 5 volt control signal commands the actuator movement in
opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact changes the door
position signal between 0-5 volts.
The HVAC control module uses a range of 0-255 counts to index the actuator position. The door position signal
voltage is converted to a 0-255 count range. When the module sets a commanded, or targeted, value, the control
signal is changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the
The blower motor control processor is an interface between the HVAC control module and the blower motor.
The blower motor speed control, Blower motor speed signal, battery positive voltage and ground circuits enable
the control processor to operate. The HVAC control module sends the commanded blower motor speed to the
control processor through a 0 to 12-volt linear ramped blower motor speed control circuit. As the blower motor
speed control voltage increases, the blower motor speed increases. The control processor sends the actual
blower speed to the control module through a 0 to 12-volt blower motor speed signal circuit. The processor
supplies 12volts to the blower motor through the blower motor voltage supply circuit. The control processor
uses the blower motor ground as a low side control to adjust the blower motor speed.
Air Speed
The blower motor forces air to circulate within the vehicle's interior. The vehicle operator determines the
blower motor's speed by placing the blower motor switch in a desired speed position or by selecting automatic
operation. In manual operation, once a blower speed is selected, the blower speed remains constant until a new
speed is selected. In automatic operation, the HVAC control module will determine what blower speed is
necessary in order to achieve or maintain a desired temperature.
OFF Mode
Press the passenger temperature knob to turn off the HVAC control module. When the vehicle is moving, air
flowing over the vehicle increases the air pressure just ahead of the windshield. This forces air into the ambient
air into the HVAC module and out through the floor and windshield outlets. Since the A/C compressor is not
running, the incoming air may be warmed but not cooled. Recirculation is not adjustable in OFF mode.
Purge Operation
If the ambient air temperature is less than 2 C (35 F) and the coolant temperature is less than 10 C (50 F), then a
75-second purge will occur. The purge will begin as soon as the coolant temperature reaches 4 C (40 F). The
mode door will move to the defrost position and the blower motor will be near half speed.
Air Distribution
The HVAC control module controls the mode actuator in order to distribute airflow to a desired outlet. The
mode switch provides the vehicle operator with the ability to override the automatic setting. When the mode
door is moved to the defrost position, the A/C compressor clutch engages and the recirculation actuator will be
moved to the outside air position. Regardless of the mode setting, a small amount of air will be diverted to the
defrost ducts to reduce windshield fogging. This vehicle may be equipped with a passenger compartment air
filter. When VENT is pressed, the following will occur:
The recirculation actuator will be placed in the outside air position

The A/C compressor will be commanded off
The mode is adjustable
After a malfunction occurs to the mode actuator it is driven to the Defrost position. On startup, the HVAC
available when the HVAC control module is in Panel or Bi-level. The recirculation mode will stay on and the
recirculation indicator will illuminate until either outside air or a non-recirculation mode is selected. When the
recirculation actuator sees an open in the control circuit, the actuator will default to the recirculation position.
Automatic Operation

Sunload sensor

The air temperature controls are divided in 5 primary areas:
HVAC control components

Heating and A/C operation
Automatic operation
Engine coolant
A/C cycle
HVAC Control Module
The HVAC control module works in a dual role operating both air temperature and A/C operation from the
driver side switch. The HVAC control module is a class 2 device that interfaces between the operator and the
HVAC system to maintain air temperature and distribution settings. The battery positive voltage circuit
provides power that the control module uses for keep alive memory (KAM). If the battery positive voltage
circuit loses power, all HVAC DTCs and settings will be erased from KAM. The body control module (BCM),
which is the vehicle mode master, provides a device on signal. The control module supports the following
features:

Afterblow No
Purge Yes
Personalization No
Actuator Calibration No
The air temperature actuator is a 5-wire bi-directional electric motor that incorporates a feedback potentiometer.
Ignition 3 voltage, low reference control, 5-volt reference, and position signal circuits enable the actuator to
operate. The control circuit uses either a 0, 2.5, or 5-volt signal to command the actuator movement. When the
actuator is at rest, the control circuit value is 2.5 volts. A 0 or 5-volt control signal commands the actuator
movement in opposite directions. When the actuator shaft rotates, the potentiometer's adjustable contact
changes the door position signal between 0-5 volts. The HVAC control module uses a range of 0-255 counts to
index the actuator position. When the module sets a commanded, or targeted, value, the control signal is
changed to either 0 or 5 volts depending upon the direction that the actuator needs to rotate to reach the
Inside Air Temperature Sensor
Replacement of the inside air temperature sensor means replacing the HVAC control module. The inside air
temperature sensor is an integral part of the HVAC control module. The HVAC control module monitors the
passenger compartment inside air temperature through an inside air temperature sensor. When the air is cold,
the sensor resistance and the signal voltage are high. When the air is warm, the sensor resistance and the signal
voltage are low. The HVAC control module requests A/C compressor clutch engagement and controls the air
temperature actuator door positions in order to maintain the selected air temperature. The HVAC control
module sends out a 5-volt reference signal to the inside air temperature sensor over the 5-volt reference circuit.
A thermistor varies the reference voltage back to the HVAC control module through the low reference circuit.
A/C pressure is more than 2 979 kPa (432 psi). The clutch will be enabled after the pressure decreases to
less than 1 510 kPa (219 psi).
The A/C system is protected by the evaporator temperature sensor. The sensor located on the evaporator core
provides the HVAC control module with the surface temperature of the evaporator core. If the evaporator
temperature sensor reads a temperature of 0C (32F), the HVAC control module will turn OFF the A/C
compressor clutch until evaporator temperatures reach 2C (36F).
The ambient air temperature sensor is a 2-wire negative temperature co-efficient thermistor. The vehicle uses
the following air temperature sensors:
Ambient
Inside
A 5-volt reference and signal circuit enables the sensor to operate. As the air temperature surrounding the sensor
increases, the sensor resistance decreases.
The sensor operates within a temperature range of -40C to +60C (-40F to +140F). The HVAC control
module receives a class 2 message from the instrument panel cluster (IPC). The ambient air temperature sensor
is mounted in the forward engine area of the vehicle. In this position, it is exposed to the airflow through the
grill before it reaches the radiators. The sensor signal varies between 0-5 volts. The HVAC control module
converts the signal to a working temperature range.
If the HVAC control module detects a faulty class 2 signal, then the control module software will use a
defaulted air temperature value.
temperature until the system is fixed.
The ambient air temperature is updated and displayed under the following conditions:

Conditions Display
At Ignition 3 Key ON
If the engine off time is less than 3 hours Displays outside actual temperature
Displays last temperature recorded before Ignition 3
If engine off time is greater than 3 hours.
key OFF
When Ignition 3 is ON
If vehicle speed is greater than 10 mph (for at least 5 Displays last temperature displayed plus 2 percent
minutes) and outside actual temperature is greater of the difference between the displayed and actual
than displayed temperatures (updated every second)
If vehicle speed is greater than 10 mph (for at least 5 Displays last temperature displayed minus 25
minutes) and outside actual temperature is less than percent of the difference between the displayed and
displayed actual temperatures (updated every second)
If outside actual temperature is less than the
Displays last temperature displayed while driving
displayed temperature and vehicle speed is less than
above 10 mph
10 mph
At Ignition 3 Key OFF displayed temperature is stored into memory.
Sunload Sensor
The sunload sensor is a 2-wire photo diode. Low reference and signal circuits enable the sensor to operate. As
the light shining upon the sensor gets brighter, the sensor conductance increases. The sensor signal decreases as
the conductance increases. The sensor operates within an intensity range between completely dark and bright.
The sensor signal varies between 0-5 volts. The HVAC control module converts the signal to a range between
0-255 counts.
The sunload sensor provides the HVAC control module a measurement of the amount of light shining on the
vehicle. Bright, or high intensity, light causes the vehicles inside temperature to increase. The HVAC system
compensates for the increased temperature by diverting additional cool air into the vehicle. If the HVAC control
module detects a malfunctioning sensor, then the control module software will use a defaulted sunload valve.
temperature until the condition is fixed. A resistance check of the sunload sensor should not be performed as it
will damage the sensor.
A/C system will also remove humidity from the interior and reduce windshield fogging. The vehicle operator
temperature:

Mode setting
The control module makes the following actions when automatic operation is not selected, and an air
temperature setting is selected:
When the air temperature switch is placed between the warmest and coldest positions, the control module
monitors the following sensor inputs to determine the air temperature door position that diverts the
appropriate amount of air through the heater core in order to achieve the desired temperature:
Sunload
Ambient temperature
Inside temperature
The following shows what blower motor, recirculation actuator, and mode actuator adjustments are made for
each air temperature switch selection:
The A/C system can be engaged by either pressing the driver temperature switch or during automatic operation.
The A/C display will illuminate on the HVAC control module display board when the driver temperature switch
is pressed. The control module sends a class 2 A/C request message to the powertrain control module (PCM).
temperature is more than 155C (311F). The thermal switch is a non-serviceable item. The following
conditions must be met in order for the PCM/ECM to turn on the compressor clutch:
HVAC control module

Evaporator temperature more than 2C (36F)
BCM
Battery voltage between 9-16 volts
PCM/ECM
Engine RPM is below 5,000 RPM.
A/C pressure is between 1 510-2 979 kPa (219-432 psi).
The compressor thermal switch is opened.

The throttle position is 100 percent.
A/C pressure is more than 2 979 kPa (432 psi).
A/C pressure is less than 1 510 kPa (219 psi).
The ECT is more than 125C (257F).
Engine speed is more than 5,500 RPM.
Transmission shift
The PCM/ECM detects excessive torque load.
The PCM/ECM detects insufficient idle quality.
The PCM/ECM detects a hard launch.
voltage spike.
Dual Zone Operation
The HVAC control module uses dual rotary temperature switches. The dual zone controls allows for maximum
temperature offset and comfort between the driver and passenger. It is possible to select maximum airflow over
the evaporator core with one dual zone switch along with maximum airflow over the heater core with the other
dual zone switch. Each air temperature actuator is independent from the other and the passenger side is not
limited in it's range of temperature offset.
Automatic Operation

Sunload sensor
Regulate blower motor speed.

Position the air temperature actuator.
Position the mode actuator.
Position the recirculation actuator.
Request A/C operation.
Engine Coolant
Engine coolant is the essential element of the heating system. The thermostat controls the normal operating
temperature of the engine. The thermostat also creates a restriction for the cooling system that promotes a
flowing through the heater core. The HVAC module distributes heated air to the passenger compartment for
consistent passenger comfort. Opening or closing the HVAC module temperature door controls the amount of
heat delivered to the passenger compartment. The coolant exits the heater core through the return heater hose
and is recirculated back through the engine cooling system.
A/C Cycle
refrigerant boil inside of the evaporator core. The boiling refrigerant absorbs heat from the ambient air and
draws moisture onto the evaporator. The refrigerant exits the evaporator through the suction line and back to the
compressor, in a vapor state, and completing the A/C cycle of heat removal. At the compressor, the refrigerant
is compressed again and the cycle of heat removal is repeated.

SPECIAL TOOLS
Special Tools
J 34142-B
Test Light
J 35616-A
Connector Test Adapter Kit
J 38778
Door Trim Pad Clip Remover
J 39200
Digital Multimeter
J 43600
ACR 2000 Air Conditioning Service Center
7000081
Tech 2 Kit
HVAC Systems - Manual - Aztek & Rendezvous
SPECIFICATIONS

Specification
Actuator Retaining Screws, All 1.6 N.m 14 lb in
HVAC Control Module Retaining Screws 2.5 N.m 22 lb in
Temperature Door Lever Bolt 0.9 N.m 8 lb in
SENSOR RESISTANCE TABLE
Sensor Resistance Table

Evaporator Temperature Sensor Resistance
C / F (ohms)
-30 / -22 52.78 K
-25 / -13 39.81 K
-20 / -4 30.37 K
-15 / 5 23.41 K
-10 / 14 18.04 K
-5 / 23 14.32 K
0 / 32 11.36 K
5 / 41 9.08 K
10 / 50 7.34 K
15 / 59 5.94 K
20 / 68 4.87 K
25 / 77 4.00 K
30 / 86 3.31 K
35 / 95 2.79 K
40 / 104 2.29 K
45 / 113 1.96 K
50 / 122 1.85 K

HVAC SCHEMATICS
Fig. 1: Blower Controls
Fig. 2: A/C Compressor Controls
Fig. 3: Air Delivery and Temperature Controls - Early Production Pontiac
Fig. 4: Air Delivery and Temperature Controls - Early Production Buick
Fig. 5: Air Delivery and Temperature Controls - Late Production
COMPONENT LOCATOR
Fig. 6: A/C Refrigerant Pressure Sensor Component View
Callouts For Fig. 6

1 A/C Refrigerant Pressure Sensor (under Air Cleaner Housing)
Fig. 7: Under the Right Side of the Instrument Panel Component View
Callouts For Fig. 7

1 Blower Motor
2 Blower Motor Resistor (CJ2)/Blower Motor Processor (CJ3)
3 Auxiliary Power Drop Connector
Fig. 8: HVAC Air Plenum Component View
Callouts For Fig. 8

1 Recirculation Actuator
2 Air Temperature Actuator - Right (CJ3, CJ2)
3 HVAC Module Case
4 Mode Actuator
5 Air Temperature Actuator - Left (CJ3, CJ2)
Callouts For Fig. 9

8 Cigar Lighter
11 Radio
12 Ignition Switch


1 Headlamp Switch
3 Hazard Switch
6 Radio
8 Alarm LED
13 Ignition Switch
Fig. 11: Front of Engine Component View - LA1


1 Water Pump
2 Engine Oil Level Switch
3 Engine Oil Pressure (EOP) Switch
4 A/C Compressor and A/C Compressor Clutch
Fig. 12: LF of the Engine Component View - 3.6L (LY7)


1 A/C Compressor Clutch Connector
2 A/C Compressor
3 A/C Compressor Clutch

15326801
2-Way F GT 150 Series (L-GY)

A D-GN 59 A/C Compressor Clutch Supply Voltage
B BK 1050 Ground
12110192

A BK 2751 Low Reference
B GY 2700 5-Volt Reference
C RD/BK 380 A/C Refrigerant Pressure Sensor Signal
12064978

1-2 - - Not Used
3 BK 150 Ground
4 D-BU 1199 Left Air Temperature Door Control
5 - - Not Used
12064993

5-6 - - Not Used
7 BK 150 Ground
8 WH/BK 1236 Right Air Temperature Door Control
9 - - Not Used
Blower Motor
12084957

A RD - Blower Motor Supply Voltage
B BK - Ground

12052854

A TN 63 Medium 1 Blower Motor Control
B YE 60 Low Blower Motor Control
C PU 73 Medium 3 Blower Motor Control
D L-BU 72 Medium 2 Blower Motor Control
E BK 150 Ground
F OG 52 High Blower Motor Control
G RD 442 Battery Positive Voltage
12052832

A WH 2622 Evaporator Temperature Sensor Signal
B BK 552 Low Reference

12084994

A1 OG 640 Battery Positive Voltage
A2 BN 241 Ignition 3 Voltage
A3 BN 9 Park Lamp Supply Voltage
A4 WH 193 Rear Defog Relay Control
A5 TN/BK 2274 Recirculation Door Control
A6 D-GN/WH 762 A/C Request Signal
A7 TN 2273 Mode Door Control
A8 D-BU 1199 Left Air Temperature Door Control
B1 BK 150 Ground
B2 BK 552 Low Reference
B3 WH 2622 Evaporator Temperature Sensor Signal
B5 D-GN 71 Off Blower Motor Control
B6 WH/BK 1236 Right Air Temperature Door Control
B7-B8 - - Not Used

12064998

A D-GN 71 OFF Blower Motor Control
B BN 41 Ignition 3 Voltage
C OG 52 High Blower Motor Control
D - - Not Used
E PU 73 Medium 3 Blower Motor Control
F L-BU 72 Medium 2 Blower Motor Control
G TN 63 Medium 1 Blower Motor Control
H YE 60 Low Blower Motor Control
Mode Actuator

12064993
5-6 - - Not Used
7 BK 150 Ground
8 TN 2273 Mode Door Control
9 - - Not Used
12064993

6 TN/BK 2274 Recirculation Door Control
7 BK 150 Ground
8-10 - - Not Used


The PCM actuates the A/C compressor clutch relay when
A/C Relay Command - you select ON. The A/C compressor clutch should remain
engaged until commanded OFF.
SCAN TOOL DATA LIST

Operating Conditions: Ignition ON/Engine OFF
8-Digit GM Part Number Module Information 8-Digit Alphanumeric varies
A/C Switch Inputs Active/Inactive varies

A/C High Side Pressure Engine Data 2 kPa/psi 420 kPa (61 psi)
A/C High Side Pressure Engine Data 2 volts 0.8 volts
A/C Off For WOT Engine Data 2 Yes/No No
A/C Pressure Disable Engine Data 2 Yes/No No
A/C Relay Circuit Status Output Driver Data OK/Fault OK
Engine Data
A/C Relay Command On/Off Off
1/Engine Data 2
A/C Request Signal Engine Data 2 Yes/No varies
Engine Data
ECT Sensor C/F varies
1/Engine Data 2
The scan tool displays the part number for service identification.
The scan tool displays -103 to +3119 kPa (-14 to +452 psi). This parameter represents the A/C refrigerant
pressure sensor voltage signal converted to pressure.
The scan tool displays 0.00-5.00 Volts. This parameter represents the A/C refrigerant pressure sensor
signal.
A/C Off For WOT
The scan tool displays Yes or No. Yes indicates that the PCM has disabled the A/C compressor because
the TP sensor signal is at wide open throttle.
A/C Pressure Disable

The scan tool displays Yes or No. Yes indicates that the PCM has disabled the A/C compressor due to
excessive refrigerant pressure.
A/C Relay Circuit Status
A/C Relay Command
The scan tool displays On or Off. Represents the PCM commanded state of the A/C compressor clutch
relay control circuit. The A/C compressor clutch should be engaged when Commanded A/C displays On.
A/C Request Signal
The scan tool displays Yes or No. The PCM uses the A/C request signal in order to determine if A/C
compressor operation is being requested by the BCM.
A/C Switch
The scan tool displays Active or Inactive. Displays the state of the A/C request signal circuit from the
HVAC control module to the BCM.
ECT Sensor
The scan tool range is -39C to +140C (-38F to +284F). Displays the temperature of the engine
coolant.
DTC P0530
Circuit Description

Diagnostic Aids
If the condition is not present refer to Testing for Intermittent Conditions and Poor Connections in Wiring
Systems.
Test Description
4: If the pressure signal voltage stays high after disconnecting the pressure sensor electrical connector, the
7: Tests for a high resistance or for an open in the ground circuit.
16: This vehicle is equipped with a PCM which utilizes an electrically erasable programmable read only
memory (EEPROM). Before you replace the PCM, program the new PCM.
DTC P0530
Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
IMPORTANT:
The ambient air temperature must be above 3
C (38F).
2 -
2. Inspect the A/C compressor for free
rotation operation.
4. Place the HVAC control module in the Go to HVAC
OFF position. Compressor
Clutch Does
OFF.
3 Side Pressure parameter in the PCM 0.1-4.9 V
Engine Data-2 list.

Side Pressure parameter is within the specified Go to
range? Diagnostic Aids Go to Step 4
2. Disconnect the A/C refrigerant pressure
sensor.
OFF.
4 0.1 V

Side Pressure parameter is less than the specified
the signal circuit of the A/C refrigerant
pressure sensor.
5 OFF. 4.9 V

Side Pressure parameter is greater than the
pressure sensor and the ground circuit of
the A/C refrigerant pressure sensor.
6 5.0 V
Is the voltage measurement less than the
7 pressure sensor to a good ground. 5 ohms
Is the resistance measurement near the specified

refrigerant pressure sensor for a short to voltage.
Wiring Systems.
refrigerant pressure sensor for a short to ground,
for a high resistance, or for an open. Refer to
9 -
Systems.
pressure sensor for a short to ground, for a high
resistance, or for an open. Refer to Circuit
10 -
Systems.
pressure sensor for a short to voltage. Refer to
Systems.
(PCM).
2. Test the low reference circuit of the A/C
refrigerant pressure sensor for high
12 resistance or for an open. Refer to Testing -
Connections and Wiring Repairs in
Wiring Systems.

connector of the A/C refrigerant pressure sensor.
13 and Poor Connections and Connector Repairs -
in Wiring Systems.
14 -
Systems.
Replace the A/C refrigerant pressure sensor.
Refer to Air Conditioning (A/C) Refrigerant
15 Pressure Sensor Replacement in Heating, -
16 -
DTCs.
17 for Running, as specified in the supporting -
text.
DTC P0645
Circuit Description
A short to ground
A short to voltage
An open circuit
An open relay coil
The ignition voltage is between 9-18 volts.
A/C clutch relay.
Diagnostic Aids
IMPORTANT: Inspect PCM engine grounds for being secure and clean.
If the condition is intermittent, refer to Testing for Intermittent Conditions and Poor Connections .
Test Description
2: Listen for an audible click when the relay operates. Command the ON and the OFF states. Repeat the
12: The PCM utilizes electrically erasable programmable read only memory (EEPROM). Program the
new PCM before you replace the PCM.
DTC P0645
Step Action Yes No
1
Vehicle in Vehicle
Does the clutch relay turn ON and OFF with each Go to Diagnostic
3 4. Probe the coil feed circuit of the A/C compressor
clutch relay using a test lamp which is connected
to a good ground.

feed circuit of the A/C compressor clutch relay.
4 2. With a scan tool, command the A/C compressor

5
relay for a short to voltage or for an open. Refer to
Systems.
7
Inspect for bad connections at the A/C compressor
8
Inspect for bad connections at the powertrain control
module (PCM). Refer to Testing for Intermittent
Repair the coil feed circuit of the A/C compressor
clutch relay. Refer to Wiring Repairs in Wiring
10
Systems.
11
Ventilation, and Air Conditioning..
12
13 for Running in the DTC, which are specified in
SYMPTOMS - HVAC SYSTEMS - MANUAL
IMPORTANT: Review the system operation in order to learn the system functions. Refer to
the following procedures:

Inspect for aftermarket devices which could affect the operation of the HVAC System. Refer to Checking
Inspect the system components which are easily accessible or visible for obvious damage or for
conditions which could cause the symptom.
The A/C compressor will not operate in cold, outside air temperatures. Refer to Air Temperature
Description and Operation.
A wet carpet
High humidity
An interior water leak
A blocked drain tube to the A/C evaporator
Inspect the air distribution system for causes of reduced airflow:

An obstructed or dirty passenger compartment air filter
Blocked or damaged air vents
Intermittent
Symptom List
Refer to one of the following symptom diagnostic procedures:

Too Hot in Vehicle
Too Cold in Vehicle
Leak Testing in Heating, Ventilation and Air Conditioning
Defrosting Insufficient in Heating, Ventilation and Air Conditioning
Noise Diagnosis - Blower Motor in Heating, Ventilation and Air Conditioning
Noise Diagnosis - Air Conditioning (A/C) System in Heating, Ventilation and Air Conditioning
Noise Diagnosis - HVAC Module in Heating, Ventilation and Air Conditioning
Odor Diagnosis in Heating, Ventilation and Air Conditioning
Diagnostic Aids
Test Description
2: The A/C compressor relay output is disabled if engine coolant temperature is above 121C (250F).
3: Place the mode switch in any position except OFF, and place the air temperature control switch in a
cold setting. Use the bi-level mode for consistent testing of the A/C system operation.
6: The HVAC control module is inoperative if the module does not respond to any operator control
requests.
40: The evaporator temperature sensor is replaced as part of the evaporator core.

Step Action Yes No
DEFINITION: The A/C compressor clutch will not engage if an A/C request has been made, and a
powertrain DTC has not been set.
1
Vehicle in Vehicle
1. Start the engine. Go to Engine
Coolant
2. Observe the coolant temperature indicator. Temperature
2
Indicator Always
Is the engine coolant temperature indicator On in Engine
illuminated? Cooling Go to Step 3
IMPORTANT:
For A/C compressor operation, the ambient air

2. Place the blower motor switch in the maximum
3
speed position.
3. Place the A/C request switch in the ON position. Go to Testing for
4. Place the air temperature switch in the coldest Intermittent
position. Conditions and
Poor Connections
Does the A/C compressor clutch engage? in Wiring Systems Go to Step 4
1. Park the vehicle inside or out of direct sunlight.
2. Open the window in order to ventilate the
interior of the vehicle.
3. If the A/C system was operating, then wait for
approximately 2 minutes.
5. Install the J 43600 ACR 2000 Air Conditioning
Service Center.
6. Record the ambient air temperature at the
vehicle.
4
7. Record readings of the low and high side
STATIC pressures.
8. Compare the low side pressure values and the
high side pressure values with the allowable
limits for the recorded ambient air temperature.
Refer to Air Conditioning (A/C) System
Performance Test .
Go to Leak Testing
Are the pressure values within the allowable limits for in Heating,
the recorded ambient air temperature, and within 103 Ventilation and Air
kPa (15 psi) of each other? Go to Step 5 Conditioning
2. With a scan tool, observe the A/C High Side
pressure sensor parameter in the powertrain data
list.
5 3. Compare the pressure values with the
specifications for the ambient air temperature.
Are the pressure values within specifications for the

ambient air temperature, and within 103 kPa (15 psi)
of each other? Go to Step 6 Go to Step 27
6 Is the HVAC control module inoperative? Go to Step 19 Go to Step 7
2. With a scan tool, observe the A/C request signal
parameter in the Powertrain data list.
7 position.
4. Place the A/C request switch in the ON position.
Does the scan tool indicate that the A/C request signal
parameter is YES? Go to Step 14 Go to Step 8

2. With a scan tool, observe the A/C switch
parameter in the Body Control Module (BCM)
data list.
8 position.
4. Place the A/C request switch in the ON position.
Does the scan tool indicate that the A/C switch

parameter is Active? Go to Step 9 Go to Step 22
9 Does the A/C request indicator illuminate? Go to Step 10 Go to Step 31
2. Test the A/C request signal circuit for a short to
voltage, for a high resistance, or for an open.
Wiring Systems.

1. Disconnect the evaporator temperature sensor.
2. Measure the resistance of the evaporator
temperature sensor. Refer to Sensor Resistance
11 Table.
Is the resistance measurement near the values specified

in the sensor resistance table? Go to Step 12 Go to Step 34
Test the evaporator temperature signal circuit for a
short to ground, for a high resistance, or for an open.
Wiring Systems.
Test the low reference circuit for a short to ground, for
a high resistance, or for an open. Refer to Circuit
13
With a scan tool, command the A/C compressor clutch
relay ON and OFF.
14
Does the clutch relay turn ON and OFF with each
4. Probe the coil side of the voltage supply circuit
ground.
and the coil side of the voltage supply circuit.

17
3. Probe the switch side of the voltage supply
18 circuit with a test lamp that is connected to a
good ground.

switch side voltage circuit of the clutch relay
and the supply voltage circuit of the clutch.
19
Does the A/C compressor clutch engage? Go to Step 33 Go to Step 26

module for a short to ground, for a high resistance, or
20 for an open. Refer to Circuit Testing and Wiring
21
2. Place the A/C request in the ON position.
22 3. Measure the voltage on the request circuit at the
BCM to a good ground.
Does the value measure near battery voltage? Go to Step 37 Go to Step 23
Test the A/C request signal circuit for a high

23 resistance, an open, or a short to ground. Refer to
Systems.
relay for an open. Refer to Circuit Testing and
24
25
Test the supply voltage circuit at the A/C compressor
clutch for a short to ground, for a high resistance, or
26 for an open. Refer to Circuit Testing and Wiring
Test the ground circuit of the A/C pressure sensor for
27
Test the ground circuit of the A/C compressor clutch
for a high resistance or for an open. Refer to Circuit
28
Repair the switch side voltage supply circuit of the
A/C compressor clutch relay. Refer to Wiring
29 -
Repair the coil side of the voltage supply circuit of the
A/C compressor clutch relay. Refer to Wiring
30 -
Test the off blower motor control circuit for a short to
voltage. Refer to Circuit Testing and Wiring Repairs
31
in Wiring Systems.
of the A/C high pressure sensor. Refer to Testing for
of the evaporator temperature sensor. Refer to Testing
for Intermittent Conditions and Poor Connections
34
of the A/C compressor clutch. Refer to Testing for
of the powertrain control module (PCM). Refer to
38
Systems.
Replace the A/C refrigerant pressure sensor. Refer to
Air Conditioning (A/C) Refrigerant Pressure
39 Sensor Replacement in Heating, Ventilation and Air -
Conditioning.
Replace the evaporator temperature sensor. Refer to
Evaporator Core Replacement in Heating,
40 -
41 -
Replace the A/C compressor clutch coil. Refer to
Compressor Replacement in Heating, Ventilation
42 -
and Air Conditioning.
Replace the HVAC control module. Refer to HVAC
Control Module Replacement (Buick) or HVAC
43 -
Control Module Replacement (Pontiac).
44 -
45 -
46

DEFINITION: The A/C compressor clutch will not disengage when an A/C request has not been made
and a powertrain DTC has not been set.
Vehicle? Diagnostic
System Check -
1 -
Vehicle in
Vehicle DTC
Go to Testing
2. Place the blower motor switch in the OFF for
position. Intermittent
2 3. Place the A/C request switch in the OFF -
Conditions and
position. Poor
Connections in
Does the A/C compressor operate? Go to Step 3 Wiring Systems
With a scan tool, observe the A/C request signal
parameter in the Powertrain data list.
3 -
Does the scan tool indicate that the A/C request
signal parameter is YES? Go to Step 4 Go to Step 6
Test the A/C request signal circuit for a short to
4 -
2. Disconnect the A/C high pressure switch.
4. With a scan tool, observe the A/C request
signal parameter.
5 -
Does the scan tool indicate that the A/C request
signal parameter is YES? Go to Step 13 Go to Step 12
With a scan tool, command the A/C compressor
6 -
Does the A/C compressor clutch relay turn ON
and OFF with each command? Go to Step 7 Go to Step 9
Remove the A/C compressor clutch relay.
7 -
Is the A/C compressor ON? Go to Step 10 Go to Step 8
Measure the resistance between the switch side
A/C compressor clutch relay terminals.
8 infinity
Does the resistance measurement equal the
Test the A/C clutch relay control circuit for a
short to ground. Refer to Circuit Testing and
9 -
Test the A/C compressor clutch supply voltage
10 -
Inspect for poor connections at the A/C
compressor clutch relay. Refer to Testing for
11 -
Systems.
12 -
Systems.
13 -
Replace the A/C compressor clutch relay. Refer
to Compressor Relay Replacement in Heating,
14 - -
Replace the A/C compressor clutch. Refer to
Compressor Replacement in Heating,
15 - -
17 - -
18 -
Test Description
2: This step checks for continuous operation of the blower motor.

3: This step tests for a short to voltage in the blower motor control circuits.

Step Action Yes No
DEFINITION: The blower motor is ON while the blower motor switch is in the OFF position.
1
Vehicle in Vehicle
2. Place the blower motor switch in the OFF Intermittent
2 position. Conditions and
Poor Connections
Is the blower motor OFF? in Wiring Systems Go to Step 3
IMPORTANT:
The blower motor switch must remain in the OFF
position during this step.

2. Disconnect the resistor assembly connector.
4. Probe each control circuit with a test lamp that is
3 connected to a good ground.
Does the test lamp illuminate while the lamp is

connected to any of the blower motor control circuits? Go to Step 4 Go to Step 5
Test the appropriate control circuit for a short to
voltage. Refer to Circuit Testing and Wiring Repairs
4
in Wiring Systems.
Inspect for bad harness connections at the blower
motor resistor assembly. Refer to Testing for
Inspect for bad harness connections to the HVAC
control module. Refer to Testing for Intermittent
Replace the blower motor resistor assembly. Refer to
Blower Motor Resistor Assembly Replacement in
7 -
8 -
9

Step Action Yes No
DEFINITION: The blower motor does not operate in every speed position.
1
Vehicle in Vehicle
2. Place the mode switch in the vent position. Go to Testing for
3. Place the blower motor switch in each speed Intermittent
2 position. Conditions and
Poor Connections
Does the blower motor operate in each speed position? in Wiring Systems Go to Step 3
2. Disconnect the blower motor.
4. Connect a test lamp between the supply voltage
5. Place the blower motor switch in the minimum
speed position.

Connect a test lamp between the supply voltage circuit
4 and the ground circuit.
Test the ground circuit of the resistor assembly for an
open or for a high resistance. Refer to Circuit Testing
5
2. Disconnect the resistor assembly connector.
4. Place the blower motor switch in the minimum
6 speed position.
5. Connect a test lamp between the low blower
motor control circuit of the resistor assembly and
a good ground.

2. Disconnect the HVAC control module connector
C2.
7
voltage circuit of the HVAC control module, and
a good ground.

Inspect for bad connections at the harness connector of
the blower motor. Refer to Testing for Intermittent
the blower motor resistor assembly. Refer to Testing
Repair the ignition 3 voltage circuit of the HVAC
control module. Refer to Wiring Repairs in Wiring
11 -
Systems.
Replace the blower motor. Refer to Blower Motor
12 -
Conditioning.
13 -
14 -
15

Step Action Yes No
DEFINITION: The blower motor operates in at least one, but not in every speed position.
1
Vehicle in Vehicle
2. Place the mode switch in the vent position.
3. Place the blower motor switch in each speed Go to Testing for
position. Intermittent
2 Conditions and
Does the blower motor operate in each speed position? Poor Connections
2. Disconnect the blower motor.
4. Connect a test lamp between the supply voltage
3 circuit of the blower motor and a good ground.
5. Place the blower motor switch in each speed
position.
Does the test lamp illuminate when the blower motor

switch is in each speed position? Go to Step 7 Go to Step 4
2. Disconnect the blower motor resistor assembly
connector.
4
voltage circuit of the blower motor resistor
assembly and a good ground.

IMPORTANT:
The blower motor switch must be in the correct
speed position for the blower motor control circuit
being tested.
1. Probe each blower motor control circuit with a

5 test lamp that connects to a good ground.
2. Place the blower motor switch in the appropriate
speed position for the control circuit being
tested.
Does the test lamp illuminate when the blower motor

switch is in each speed position? Go to Step 8 Go to Step 6
Test the suspected control circuit for an open. Refer to
6
Systems.
the blower motor assembly. Refer to Testing for
Inspect for bad connections at the harness connectors
of the blower motor resistor assembly. Refer to
8
Systems.
Repair the battery positive voltage circuit of the blower
motor resistor assembly. Refer to Wiring Repairs in
10 -
Wiring Systems.
Replace the blower motor. Refer to Blower Motor
11 -
Conditioning.
12 -
13 -
14
TOO HOT IN VEHICLE
Diagnostic Aids
Test Description
12: The voltage will vary between 0-12 volts during normal operation. The HVAC control module
Too Hot in Vehicle

DEFINITION: The temperature cannot be adjusted, or the cooling is insufficient during A/C operation.
IMPORTANT: Go to
Both the left and the right air temperature Diagnostic
controls are diagnosed in this table. System Check -
1 -
Vehicle in
Did you perform the Diagnostic System Check - Vehicle DTC
Vehicle? Go to Step 2 Information
OFF.
2. Place the blower motor switch in each
2 speed position. -
Go to Blower
Does the blower motor operate in each speed Go to Blower
3 position? - Motor
Does the Too Hot in Vehicle concern occur when
4 -
A/C cooling is desired? Go to Step 5 Go to Step 7
IMPORTANT:
For A/C compressor operation, the ambient air

5 3. Place the mode switch in the VENT -
position.
4. Place the A/C request switch in the ON
position.
5. Place both temperature switches in the Go to HVAC
coldest position. Compressor
Clutch Does
Does the A/C compressor operate? Go to Step 6 Not Engage
Perform the refrigerant system performance test.
Refer to Air Conditioning (A/C) System
6 Performance Test in Heating, Ventilation and -
Air Conditioning.
1. Observe the drive shaft of the air
2. Place the air temperature switch from the
7 coldest to the warmest position. -
Does the drive shaft of the air temperature

actuator rotate? Go to Step 8 Go to Step 9
Inspect the air temperature door and the air
temperature actuator for the following
conditions:
A misaligned air temperature actuator-

Replacement.
Broken or binding linkages or air
temperature door
8 -
temperature door from operating within
the full range of motion
Go to Testing
Missing seals to the air temperature door for
Misaligned seals to the air temperature Intermittent
door Conditions and
Poor
Connections in
Did you find and correct the condition? Go to Step 18 Wiring Systems
temperature actuator for an open or for a high
9 resistance. Refer to Circuit Testing and Wiring -
10 -
Test the control circuit of the air temperature
actuator for an open, for a high resistance, for a
short to ground, or for a short to voltage. Refer to
11 -
Systems.
IMPORTANT:
Ensure that the HVAC control module
connector is connected during this step in
order to avoid misdiagnosis.

OFF.
circuit of the air temperature actuator to a 0 V at cold
12
good ground. 12 V at hot
coldest position to the warmest position.
Is the voltage within the specified values with a

smooth transition between cold and hot? Go to Step 13 Go to Step 15
13 -
Wiring Systems.
conditions:

Replacement.
temperature door
14 -
Missing seals to the air temperature door
Misaligned seals to the air temperature
door

15 -
Systems.
Right or Air Temperature Actuator
16 Replacement - Left. - -
18 -
TOO COLD IN VEHICLE
Test Description
12: The voltage will vary between 0-12 volts during normal operation. The HVAC control module
Too Cold in Vehicle

DEFINITION: The temperature cannot be adjusted, or the heating is insufficient.
IMPORTANT: Go to
Both the left and the right air temperature Diagnostic
controls are diagnosed in this table. System Check -
1 -
Vehicle in
Did you perform the Diagnostic System Check - Vehicle DTC
Vehicle? Go to Step 2 Information
OFF.
2. Place the blower motor switch in each
2 speed position. -
Go to Blower
3 position? - Motor
Except for the blower motor speed, are all of the
4 functions of the HVAC control module -
Inspect the cooling system for the following
conditions:
A low coolant level

A loose or worn accessory drive belt
A leaking radiator hose or heater hoses
5 -
A kinked radiator hose or heater hoses
A missing radiator cap pressure seal
A leaking radiator cap

2. Place the blower switch in the OFF
position.
6 3. Place the A/C request switch in the OFF -
Go to HVAC
position. Compressor
Clutch Does
1. Observe the drive shaft to the air
7 2. Adjust the air temperature switch. -
Does the drive shaft of the air temperature

actuator rotate? Go to Step 8 Go to Step 9
conditions:

Replacement.
temperature door
8 -
Missing seals to the air temperature door
Misaligned seals to the air temperature
door
Go to Heating
Performance
Did you find and correct the condition? Go to Step 22 Diagnostic
temperature actuator for an open or for a high
9 resistance. Refer to Circuit Testing andWiring -
10 -
Test the door control circuit of the air
11 -
IMPORTANT:
Ensure that the HVAC control module
connector is connected during this step in
order to avoid misdiagnosis.

OFF.
12 2. Measure the voltage from the door control 0 V at cold
circuit of the air temperature actuator to a 12 V at hot
good ground.
coldest position to the warmest position.
Is the voltage measurement within the specified

values with a smooth transition between cold
and hot? Go to Step 17 Go to Step 19
control module for an open or for a high
HVAC control module for an open or for a high
Test the blower motor control OFF circuit of the
15 HVAC control module for a short to voltage. -
Wiring Systems.
Test the ground circuit of the HVAC control
module for an open. Refer to Circuit Testing
16 -
17
Wiring Systems.
Inspect the air temperature actuator, door and
any attaching linkage for binding or a condition
18 -
that prevents drive shaft rotation.
19 -
Wiring Systems.
20 Right or Air Temperature Actuator - -
Replacement - Left.
22 -
Test Description
12: The measured voltage should be near the specified values for each mode position.
14: Two ignition 3 voltage circuits supply the HVAC control module. Test the ignition 3 voltage circuit
that does not supply the blower motor switch.
DEFINITION: Air does not flow correctly from the air distribution outlets.
Vehicle? Diagnostic
System Check -
1 -
Vehicle in
Vehicle DTC
OFF.
2 2. Place the blower motor switch in the OFF -
Motor Always
Is the blower motor OFF? Go to Step 3 On
3 -
Does the blower motor operate in any speed Motor
position? Go to Step 4 Inoperative
4 position? - Motor
Are all of the HVAC control module controls
5 -
except for the blower motor inoperative? Go to Step 14 Go to Step 6
2. Place the mode switch in the vent
position.
6 position. -
4. Observe the recirculation door.
5. Place the outside air switch in the ON
position.
Go to Air
Does the recirculation door move from the Recirculation
recirculation to the outside air position? Go to Step 7 Malfunction
7 2. Place the mode switch in each mode - Go to Testing
position. for
Intermittent
Conditions and
Does air flow sufficiently from the proper air Poor
distribution outlets for each selected mode Connections in
position? Wiring Systems Go to Step 8
Inspect the air delivery system for the following
conditions:
A dirty HVAC air filter, if applicable

An obstruction to the airflow
8 -
Air leaks
Misaligned air ducts

A misaligned mode actuator-Refer to

Mode Actuator Replacement.
Broken or binding linkages or mode door
An obstruction that prevents the mode
9 -
actuator from operating within the full
range of motion
Missing seals to the mode door
Misaligned seals to the mode door

2. Disconnect the mode actuator.
OFF.
10 -
4. Probe the ignition 3 voltage circuit of the
mode actuator with a test lamp that is

an open or for a high resistance. Refer to
Systems.
2. Reconnect the mode actuator.
3. Turn ON the ignition with the engine
OFF.
4. Measure the voltage from the mode door Vent: 0.2V,
control circuit of the mode actuator to a Bi-Level:
good ground. 3.1V, Floor:
12 5. Observe the control circuit voltage of the 5.0V Mix-
mode door. Blend: 8.9V,
Defrost:
6. Place the mode switch in each mode 11.8V
position.

values for each mode position? Go to Step 18 Go to Step 13
actuator for an open, a high resistance, a short to
ground, or a short to voltage. Refer to Circuit
13 --
Systems.
control module for an open or for a high
HVAC control module for an open or for a high
Test the ground circuit of the HVAC control
module for an open or for a high resistance.
16 Refer to Circuit Testing and Wiring Repairs -
in Wiring Systems.
Test the off blower motor control circuit of the
HVAC control module for a short to voltage.
17 Refer to Circuit Testing and Wiring Repairs -
in Wiring Systems.
connector of the mode actuator. Refer to
18 -
Systems.
19 -
Wiring Systems.
Repair the ignition 3 voltage circuit of the mode
actuator. Refer to Wiring Repairs in Wiring
20 - -
Systems.
21 Actuator Replacement. - -
23 -
Test Description
9: The HVAC control module is supplied by 2 ignition 3 voltage circuits. Test the ignition 3 voltage
circuit that does not supply the blower motor switch.

Step Action Yes No
DEFINITION: Air recirculation is inoperative or is always ON.
1
Vehicle in Vehicle
2. Place the blower motor switch at the maximum
speed position.
2
3. Place the mode switch in the vent position.
position.
5. Observe the recirculation door. Go to Testing for
6. Place the ambient air switch in the ON position. Intermittent
Conditions and
Does the recirculation door move from the Poor Connections
recirculation to the outside air position? in Wiring Systems Go to Step 3
Except for the blower motor speed, are all of the
3
functions of the HVAC control module inoperative? Go to Step 9 Go to Step 4
2. Disconnect the recirculation actuator.
4 4. Probe the ignition 3 voltage circuit of the
recirculation actuator with a test lamp that is

Test the ground circuit of the recirculation actuator for
an open or for a high resistance. Refer to Circuit
5
1. Reconnect the recirculation actuator.
2. Disconnect the HVAC control module.
3. Observe the recirculation door.
6
recirculation door control circuit and the ground
circuit.
Does the recirculation door move into the outside air

position? Go to Step 14 Go to Step 7
Test the door control circuit of the recirculation
actuator for an open, for a high resistance, for a short
7 to ground, or for a short to voltage. Refer to Circuit
Inspect the recirculation door and the recirculation
actuator for the following conditions:
A misaligned recirculation actuator-Refer to

8 Recirculation Actuator Replacement.
Broken or binding linkages or recirculation door
An obstruction that prevents the recirculation
actuator from operating within the full range of
motion
Missing seals to the recirculation door
Misaligned seals to the recirculation door

module for an open or for a high resistance. Refer to
Systems.
Test the battery positive voltage circuit of the HVAC
control module for an open or for a high resistance.
Wiring Systems.
for an open or for a high resistance. Refer to Circuit
11
Test the off blower motor control circuit of the HVAC
control module for a short to voltage. Refer to Circuit
12
the recirculation actuator. Refer to Testing for
Repair the ignition 3 voltage circuit of the recirculation
15 actuator. Refer to Wiring Repairs in Wiring Systems. -
Replace the recirculation actuator. Refer to
16 Recirculation Actuator Replacement. -
17 -
18
RE-CALIBRATING ACTUATORS
Use the following steps to perform the calibration update:

2. Remove the battery positive voltage circuit fuse of the HVAC Control Module.
IMPORTANT: The module memory will not clear if the battery positive voltage circuit
fuse is installed in less than 60 seconds.
3. Wait 60 seconds.
4. Install the fuse.
REPAIR INSTRUCTIONS
HVAC CONTROL MODULE REPLACEMENT (BUICK)
Removal Procedure
1. Remove the I/P cluster trim plate bezel. Refer to Trim Plate Bezel Replacement - Instrument Panel
(I/P) Cluster (Aztek) or Trim Plate Bezel Replacement - Instrument Panel (I/P) Cluster
(Rendezvous) in Instrument Panel, Gages and Console.
Fig. 13: Locating HVAC Control Module Retaining Screws (Buick)

Fig. 14: View Of HVAC Control Module (Buick)
4. Disconnect the HVAC control module electrical connector.
IMPORTANT: The key should be in the off position when connecting the HVAC control
module electrical connector to ensure proper calibration.
1. Connect the HVAC control module electrical connector.

Fig. 15: View Of HVAC Control Module (Buick)
2. Install the HVAC control module into the I/P opening.
Fig. 16: Locating HVAC Control Module Retaining Screws (Buick)


4. Install the IP cluster trim plate bezel. Refer to Trim Plate Bezel Replacement - Instrument Panel (I/P)
Cluster (Aztek) or Trim Plate Bezel Replacement - Instrument Panel (I/P) Cluster (Rendezvous) in
IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC
control module is self-calibrating. If interrupted, improper HVAC
performance will result.
HVAC CONTROL MODULE REPLACEMENT (PONTIAC)
Removal Procedure
1. Remove the I/P accessory trim plate. Refer to Trim Plate Replacement - Instrument Panel (I/P)
Accessory in Instrument Panel, Gages and Console.
Fig. 17: View Of HVAC Control Module Retaining Screws (Pontiac)

Fig. 18: HVAC Control Module (Pontiac)
4. Disconnect the HVAC control module electrical connectors.
IMPORTANT: The key should be in the off position when connecting the HVAC control
module electrical connector to ensure proper calibration.
1. Connect the HVAC control module electrical connectors.

Fig. 19: HVAC Control Module (Pontiac)
2. Push the HVAC control module into I/P opening.
Fig. 20: View Of HVAC Control Module Retaining Screws (Pontiac)

4. Install the I/P accessory trim plate. Refer to Trim Plate Replacement - Instrument Panel (I/P)
Accessory in Instrument Panel, Gages, and Console.
IMPORTANT: Do not adjust any controls on the HVAC control module while the HVAC
control module is self-calibrating. If interrupted, improper HVAC
performance will result.
AIR TEMPERATURE ACTUATOR REPLACEMENT
Removal Procedure
3. Remove the temperature door lever bolt (3) from the HVAC module.
4. Disconnect and remove the temperature door lever spring (2).
5. Disconnect and remove the temperature door lever (1) from the temperature door.
6. Disconnect the air temperature actuator electrical connector.

7. Remove the air temperature actuator mounting screws.

8. Remove the air temperature actuator.
1. Install the air temperature actuator.
2. Install the air temperature actuator mounting screws.

3. Connect the air temperature actuator electrical connector.
IMPORTANT: Align the pin on the air temperature actuator with the slot in the
4. Install the temperature door lever (1) to the temperature door.

5. Connect the temperature door lever spring (2) to the temperature door lever (1) and HVAC module case.
6. Install the temperature door lever bolt (3) to the HVAC module case.
8. Recalibrate the actuators. Refer to Re-Calibrating Actuators.

Removal Procedure
1. Remove the instrument panel (I/P) compartment. Refer to Compartment Replacement - Instrument
Panel (I/P) in Instrument Panel, Gages and Console.




IMPORTANT: Align the pin on the right hand air temperature actuator with the slot in the
right hand temperature door lever.
HVAC module case.
Removal Procedure





IMPORTANT: Align the pin on the left hand air temperature actuator with the slot in the
left hand temperature door lever.
HVAC module case.
Removal Procedure
1. Remove the knee bolster from the instrument panel. Refer to Knee Bolster Replacement in Instrument
IMPORTANT: Disconnect the I/P wiring harness clip from the I/P support bracket to help
access the mode actuator screws.
IMPORTANT: Count the number of threads showing from the tip of the mode actuator
push rod to the end of the retainer clip.

IMPORTANT: Align the counted number of threads on the mode actuator push rod (2)
with the tip of the retainer clip (1).
Removal Procedure
1. Remove the upper I/P trim pad. Refer to Trim Pad Replacement - Instrument Panel (I/P) Upper
(Aztek) or Trim Pad Replacement - Instrument Panel (I/P) Upper (Rendezvous) in Instrument Panel,
Gages and Console.





4. Install the upper I/P trim pad. Refer to Compartment Replacement - Instrument Panel (I/P) in

The air delivery description and operation is divided into four areas:

Air Speed
Air Delivery
HVAC Control Module


Afterblow No
Purge No
Personalization No
Actuator Calibration Yes
Mode Actuator
The mode actuator is a 3 wire bi-directional electric motor. Ignition 3 voltage, ground and control circuits
enable the actuator to operate. The control circuit uses a 0-12 volt linear-ramped signal to command the actuator
movement. The 0 and 12 volt control values represent the opposite limits of the actuator range of motion. The
values in between 0 and 12 volts correspond to the positions between the limits. When the HVAC control
module sets a commanded, or targeted, value, the control signal is set to a value between 0-12 volts. The
actuator shaft rotates until the commanded position is reached. The module will maintain the control value until
a new commanded value is needed.
Air Speed
The HVAC control assembly applies voltage to the blower motor control circuit that corresponds to the selected
blower speed. The resistors and the blower motor are in a series circuit. The following list represents the
number of resistors in series with the blower motor per particular speed request:
Low speed-4 resistors

Medium 3 speed-1 resistor
When the operator requests High speed, the HVAC control assembly applies voltage to the blower motor relay
through the high blower motor control circuit. The voltage energizes the blower motor relay, connecting the
blower motor to battery positive voltage.
Off Mode
When the OFF position is selected, the HVAC control module applies voltage to the blower switch off input
within the HVAC control module through the off blower motor control circuit. When the HVAC control
module receives this input, any A/C request will be cancelled and the A/C request LED will turn off. Fresh air
will still be brought in from the outside, but the LED indicator will not illuminate.
Air Delivery
The HVAC control module controls the mode actuator in order to distribute airflow to a desired outlet. When
the mode door is moved to the defrost position, the A/C compressor clutch engages and the recirculation
actuator will be moved to the outside air position. Regardless of the mode setting, a small amount of air will be
diverted to the defrost ducts to reduce windshield fogging. When the mode actuator sees an open in the control
circuit, the actuator defaults to 6 volts and positions the mode door to the floor position. On startup, the HVAC
available when the HVAC control module is in Vent or Bi-level. The operator must activate the blower for
Recirculation operation. When the recirculation actuator sees an open in the control circuit, the actuator will
default to the recirculation position.
The four primary areas of air controls are:

Engine Coolant
A/C Cycle
HVAC Control Module
The HVAC control module is a non-class 2 device that interfaces between the operator and the HVAC System

Afterblow No
Purge No
Personalization No
Actuator Calibration Yes

The air temperature actuator is a 3 wire bi-directional electric motor. Ignition 3-voltage, ground and control
circuits enable the actuator to operate. The control circuit uses a 0-12 volt linear-ramped signal to command the
actuator movement. The 0 and 12-volt control values represent the opposite limits of the actuator range of
motion. The values in between 0 and 12 volts correspond to the positions between the limits.
When the HVAC control module sets a commanded, or targeted, value, the control signal sets to a value
between 0-12 volts. Actuator shaft rotation is the results of a commanded position input by the vehicle operator.
With a new actuator commanded value action, the maintained actuator control value is changed.
pressure condition exists. The powertrain control module (PCM) disables the compressor clutch under the
The evaporator temperature sensor protects the A/C system. The sensor located on the evaporator core provides
the HVAC control module with the surface temperature of the evaporator core. If the evaporator temperature
sensor reads a temperature of 0C (32F), the HVAC control module will turn off the A/C compressor clutch
until evaporator temperatures reach 2C (36F).
The purpose of the heating and A/C System is to provide heated and cooled air to the interior of the vehicle. The
A/C System will also remove humidity from the interior and reduce windshield fogging. The vehicle operator
temperature:

Mode setting
The control module takes the following actions when a mode operation is selected, and an air temperature
setting is selected:
The A/C system can be engaged by pressing the A/C switch. The A/C switch will illuminate when the A/C
switch is pressed to the on position. The control module sends an A/C request message to the body control
module (BCM) which sends a class 2 message to the powertrain control module (PCM). The HVAC System
uses a scroll compressor that incorporates a thermal switch that opens once the compressor temperature is more
than 155C (311F). The following conditions must be met in order for the PCM to turn on the compressor
clutch:
HVAC control module

BCM
Battery voltage between 9 - 16 volts
PCM
Engine coolant temperature (ECT) is less than 125C (257F)
Engine RPM is below 5,000 RPM
A/C Pressure is between 1510 - 2979 kPa (219 - 432 psi)

Throttle position is 100%
Engine speed is more than 5,500 RPM
Transmission shift
PCM detects a hard launch condition
voltage spike.
Engine Coolant
Engine coolant is the important element of the heating system. The thermostat controls the normal engine
operating coolant temperature. The thermostat also creates a restriction for the cooling system that promotes a
flowing through the heater core. Heated air distribution to the passenger compartment, through the HVAC
module maintains passenger comfort. Opening or closing the HVAC module temperature door controls heat
delivered to the passenger compartment. The coolant exits the heater core through the return heater hose and
recirculates back through the engine cooling system.
A/C Cycle
refrigerant boil inside of the evaporator core. The boiling refrigerant absorbs heat from the ambient air and
draws moisture onto the evaporator. The refrigerant exits the evaporator through the suction line and back to the
compressor, in a vapor state, and completing the A/C cycle of heat removal. At the compressor, the refrigerant
is compressed again and the cycle of heat removal is repeated.

SPECIAL TOOLS
Special Tools
J 43600
ACR 2000 Air Conditioning Service
7000081
Tech 2 Kit
Hydraulic Brakes - Aztek & Rendezvous
SPECIFICATIONS

Specification
Brake Booster Mounting Nuts 25 N.m 18 lb ft
Brake Hose Fitting Bolt at Front Brake Caliper 54 N.m 40 lb ft
Brake Hose Fitting Bolt at Rear Brake Caliper 43 N.m 32 lb ft
Brake Pedal Brace Bolts 10 N.m 89 lb in
Brake Pedal Brace Nuts 10 N.m 89 lb in
Brake Pedal Bracket Nuts 5 N.m 44 lb in
Brake Pipe at Flexible Brake Hose Tube Nuts 21 N.m 15 lb ft
Brake Pipe at Master Cylinder to Proportion Valve 15 N.m 11 lb ft
Brake Pipe at Master Cylinder Tube Nuts 15 N.m 11 lb ft
Brake Pipe to Proportion Valve 21 N.m 15 lb ft
Master Cylinder Mounting Nuts 25 N.m 18 lb ft
BRAKE COMPONENT SPECIFICATIONS
Brake Component Specifications

Specification
Brake Caliper Bleeder Valve (Front) 13 N.m 115 lb in
Brake Caliper Bleeder Valve (Rear) 11 N.m 97 lb in
Drum Brake Wheel Cylinder Bleeder Valve 7 N.m 62 lb in
BRAKE SYSTEM SPECIFICATIONS
Brake System Specifications

Specification
Brake Pedal Maximum Travel
Specification with 445 N (100 lbs) of force
applied to the brake pedal, the ignition OFF, 74 mm 2.91 in
and the brake booster power reserve depleted.

BRAKE WARNING SYSTEM SCHEMATICS
Fig. 1: Brake Warning System Schematic

COMPONENT LOCATOR
HYDRAULIC BRAKES COMPONENT VIEWS
Fig. 2: Lower LF of the Passenger Compartment Component View
Callouts For Fig. 2

1 Park Brake Switch
2 I/P Wiring Harness
3 Park Brake Switch Connector
4 Parking Brake
Fig. 3: LR Engine Compartment Component View
Callouts For Fig. 3

HYDRAULIC BRAKES CONNECTOR END VIEWS
Brake Fluid Level Switch Connector End View

12162195
2-Way F 150.2 SER (BLK)

A BLK 1550 Ground
B TAN/WHT 33 Brake Fluid Level Switch Signal
Park Brake Switch Connector End View
12004267
1-Way F 56 Series Lock Type (BLK)

A ORN/BLK 233 Park Brake Switch Signal

DIAGNOSTIC STARTING POINT - HYDRAULIC BRAKES
Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the
Description and Operation information will help you determine the correct symptom diagnostic
procedure when a malfunction exists. Reviewing the Description and Operation information will
also help you determine if the condition described by the customer is normal operation. Refer to
Symptoms - Hydraulic Brakes in order to identify the correct procedure for diagnosing the
system and where the procedure is located.
SCAN TOOL DATA LIST
Instrument Cluster (IPC) Scan Tool Data List

Ignition ON, engine OFF, brake fluid level normal, and park brake released.
Typical Data
Inputs for Analog
Park Brake Switch Off/On Off
Dash
Brake Fluid Level
Scan tool displays: OK or Low. The status of the brake fluid level sensor signal.
Park Brake Switch
Scan tool displays: Off/On - Display indicates if the red BRAKE warning indicator is
currently ON.
SYMPTOMS - HYDRAULIC BRAKES
IMPORTANT: The following steps must be completed before using the symptom
tables.
1. Perform the Brake System Vehicle Road Test before using

the hydraulic brake symptom tables in order to duplicate the
customer's concern.
2. Review the system operation in order to familiarize yourself
with the system functions. Refer to the following:
Brake Warning System Description and Operation
Hydraulic Brake System Description and Operation
Brake Assist System Description and Operation
Disc Brake System Description and Operation in Disc

Brakes
Inspect for aftermarket devices which could affect the operation of the Hydraulic Brake
System. Refer to Checking Aftermarket Accessories in Wiring Systems.
Inspect the easily accessible or visible system components for obvious damage or conditions
which could cause the symptom.
Intermittent
Faulty electrical connections or wiring may be the cause of intermittent conditions. Refer to
Symptom List
Refer to a symptom diagnostic procedure from the following list in order to diagnose the
symptom:
Brake Warning Indicator Always On

Brake Warning Indicator Inoperative
Brake Pulsation
Braking Action Uneven - Pulls to One Side
Braking Action Uneven - Front to Rear
Brake Pedal Excessive Travel
Brake Pedal Excessive Effort
Brake System Slow Release
Brake Fluid Loss

Test Description
7: If the fuse in the jumper opens when you perform this test, the signal circuit of the brake
fluid level switch is shorted to voltage.

Step Action Yes No
Schematic Reference:Brake Warning System Schematics
Connector End Views Reference: Hydraulic Brakes Connector End Views or
Instrument Panel, Gages, and Console Connector End Views or Body Control
System Connector End Views
Did you review the hydraulic brakes operation Go to
and perform the necessary inspection? Symptoms -
1
Hydraulic
Go to Step 2 Brakes
Inspect the brake fluid level. Go to Brake
2
Is the brake fluid level OK? Go to Step 3 Fluid Loss
2. Disengage the park brake.
3. With a scan tool, observe the Park Brake
3 Switch parameter in the BCM Inputs data
list.
Does the scan tool indicate that the Park Brake

Switch parameter is Inactive? Go to Step 4 Go to Step 5
With a scan tool, observe the Brake Warning
Lamp parameter in the IPC Inputs data list.
4
Does the scan tool indicate that the Brake
Warning Lamp parameter is ON? Go to Step 12 Go to Step 6
1. Disconnect the park brake warning lamp
switch.
2. With a scan tool, observe the Park Brake
5 Switch parameter.
Does the scan tool indicate that the Park Brake

Switch parameter is Inactive? Go to Step 9 Go to Step 7
1. Disconnect the brake fluid level switch.
2. With a scan tool, observe the Brake Warning
6 Lamp parameter.
Does the scan tool indicate that the Brake

Warning Lamp parameter is ON? Go to Step 10 Go to Step 8
2. Test the signal circuit of the park brake
warning lamp switch for a short to ground.
7 Refer to Circuit Testing and Wiring

2. Test the signal circuit of the brake fluid level
switch for a short to ground. Refer to
8 Circuit Testing and Wiring Repairs in
Wiring Systems.

connector of the park brake warning lamp switch.
9
in Wiring Systems.
connector of the brake fluid level switch. Refer to
10
Systems.
connector of the Body Control Module. Refer to
11
Systems.
connector of the instrument Panel cluster. Refer to
12
Systems.
Replace the park brake warning lamp switch.
Refer to Stop Lamp Switch Replacement in
13
Park Brake.
Replace the brake fluid level switch. Refer to
Master Cylinder Fluid Level Sensor
14
Replacement.
Replace the Body Control Module. Refer to Body
Control Module Replacement in Body Control
15
System.
Replace the instrument cluster (IPC). Refer to
16
17

Step Action Yes No
Schematic Reference: Brake Warning System Schematics Connector End Views
Reference: Hydraulic Brakes Connector End Views or Instrument Panel, Gages, and
Console Connector End Views or Body Control System Connector End Views
Did you review the hydraulic brakes operation Go to
and perform the necessary inspection? Symptoms -
1
Hydraulic
Go to Step 2 Brakes
2. Observe the brake warning indicator.
Does the brake warning indicator illuminate
2 briefly during the bulb check? Go to Step 3 Go to Step 11
3 2. Apply the park brake.
Does the brake warning indicator illuminate? Go to Step 4 Go to Step 7

1. Turn OFF the ignition
2. Release park brake.
3. Disconnect the brake fluid level indicator
switch
4
4. Connect a 3A fused jumper wire between
the signal circuit of the brake fluid level
indicator switch and a good ground.

Inspect for poor connections or a poor ground at
5 the brake fluid level indicator switch.
Inspect brake fluid level indicator switch for Go to Testing
proper operation. for
Does brake fluid level indicator switch work Intermittent
6 properly? Conditions and
Poor
Connections in
1. Disconnect the park brake warning lamp
switch.
2. Connect a 3A fused jumper wire between
7 the signal circuit of the park brake warning
lamp switch and ground.

2. Disconnect the body control module.
8
3. Test the signal circuit of the park brake
warning lamp switch for a high resistance or
an open. Refer to Circuit Testing and

2. Disconnect the instrument panel cluster.
Test the signal circuit of the brake fluid

9 level indicator switch for a high resistance
or an open. Refer to Circuit Testing and

Inspect for poor connections or a poor case
ground at the park brake warning lamp switch.
10
in Wiring Systems.
connector of the instrument cluster. Refer to
11
Systems.
connector of the Body Control Module. Refer to
12
Systems.
Replace the park brake warning lamp switch.
Refer to Stop Lamp Switch Replacement in
13
Park Brake.
Replace the instrument cluster. Refer to
14
Replace the brake fluid level indicator switch.
Refer to Master Cylinder Fluid Level Sensor
15
Replacement.
Replace the Body Control Module. Refer to
Body Control Module Replacement in Body
16
Control System.
17
BRAKE PULSATION
Test Description
2: Suspension components that are not operating properly may cause a disturbance to the
vehicle during application of the brake system.
3: Antilock brake system operation could produce feedback through the brake pedal during
application of the brake system.
Brake Pulsation
Step Action Yes No
Were you sent here from the Hydraulic Brake Go to Diagnostic
Symptom table? Starting Point -
1
Hydraulic
Go to Step 2 Brakes
Inspect the suspension system for proper
operation. Refer to Diagnostic Starting Point
2 - Suspension General Diagnosis in
Suspension General Diagnosis.
Inspect the antilock brake system for proper
3 - Antilock Brake System in Antilock Brake
System.
Inspect the disc brake system for proper
operation. Refer to Disc Brake System
4
Diagnosis.
Inspect the drum brake system, if equipped, for
proper operation. Refer to Drum Brake
5
System Diagnosis.
Inspect the hydraulic brake system for proper Go to Diagnostic
operation. Refer to Hydraulic Brake System Starting Point -
6
Diagnosis. Hydraulic
Did you find and correct a condition? Go to Step 7 Brakes
Road test the vehicle in order to confirm proper
operation. Refer to Brake System Vehicle
7
Road Test.
Is the condition still present? Go to Step 2 System OK
BRAKE SYSTEM NOISE
Brake System Noise

Step Action Yes No
1
Hydraulic
Go to Step 2 Brakes
2
Diagnosis.
3
System Diagnosis.
Inspect the brake assist system for proper
operation. Refer to Brake Assist System
4
Diagnosis.
Inspect the hydraulic brake system for proper
operation. Refer to Hydraulic Brake System
5 Diagnosis.
Is the vehicle equipped with a drum-in-rotor
6
type of park brake system? Go to Step 7 Go to Step 9
Ensure the park brake shoes are not adjusted too
tightly, possibly causing a noise under certain
7
conditions.
Are the park brake shoes adjusted too tightly? Go to Step 8 Go to Step 9
1. Clean and inspect the park brake shoes for
excessive wear and/or damage.
2. Inspect the drum portion of the rotors for
excessive wear, blueing discoloration, heat
8 spots, and excessive radial runout.
3. If any of these conditions are present,
replace the affected components.
4. Adjust the park brake system.

Inspect the park brake system for proper Go to Diagnostic
operation. Refer to Park Brake System Starting Point -
9
Diagnosis in Park Brake. Hydraulic
10
Road Test.
BRAKING ACTION UNEVEN - PULLS TO ONE SIDE
Test Description
3: Steering components that are not operating properly may cause a disturbance to the
Step Action Yes No
1
Hydraulic
Go to Step 2 Brakes
Inspect the steering system for proper operation.
Refer to Diagnostic Starting Point - Power
3 Steering System (w/o Electro-Hydraulic
Steering) in Power Steering System.
4
Diagnosis.
5
Diagnosis.
Inspect the drum brake system, if equipped, for Go to Diagnostic
proper operation. Refer to Drum Brake Starting Point -
6
System Diagnosis. Hydraulic
7
Road Test.
BRAKING ACTION UNEVEN - FRONT TO REAR
Test Description
The number below refer to the step number on the diagnostic table:

Step Action Yes No
1
Hydraulic
Go to Step 2 Brakes
3
Diagnosis.
4
Diagnosis.
5
System Diagnosis.
Inspect the brake assist system for proper Go to Diagnostic
operation. Refer to Brake Assist System Starting Point -
6
7
Road Test.

Step Action Yes No
Symptom Table? Starting Point -
1
Hydraulic
Go to Step 2 Brakes
Inspect for proper brake pedal travel. Refer to
Brake Pedal Travel Measurement and
2 Inspection.
Is the brake pedal travel distance within the
acceptable limits? Go to Step 5 Go to Step 3
1. Inspect for worn, missing, misaligned, bent
or damaged brake pedal system
components.
For the brake pedal pushrod
component inspection, refer to Brake
Pedal Pushrod Inspection.
Inspect the brake pedal bushings for
excessive wear and/or damage and
inspect the brake pedal for a bent
and/or damaged condition.
2. Replace the brake pedal system
components that are worn, missing,
3 misaligned, bent or damaged, refer to the
following procedure(s) as necessary.
Brake Pedal Assembly
Replacement
Replacement (3.4L) or Vacuum
Brake Booster Replacement (3.6L
LY7) (for pedal pushrod
replacement)
Did you find and replace any worn, missing,

misaligned, bent or damaged brake pedal system
components? Go to Step 4 Go to Step 5
Reinspect for proper brake pedal travel. Refer
4 to Brake Pedal Travel Measurement and
Inspection.
5
Diagnosis.
6
System Diagnosis.
7
Diagnosis.
Inspect the brake assist system for proper Go to Diagnostic
operation. Refer to Brake Assist System Starting Point -
8
Road test the vehicle to confirm proper
9
Road Test.

Step Action Yes No
1
Hydraulic
Go to Step 2 Brakes
2
Diagnosis.
3 operation. Refer to Hydraulic Brake System
Diagnosis.
4
Diagnosis.
Inspect the drum brake system, if equipped, for Go to Diagnostic
proper operation. Refer to Drum Brake Starting Point -
5
System Diagnosis. Hydraulic
6
Road Test.
BRAKES DRAG
Brakes Drag
Step Action Yes No
1
Hydraulic
Go to Step 2 Brakes
Is the vehicle equipped with an adjustable stop
2 lamp switch and/or an adjustable cruise control
release switch? Go to Step 3 Go to Step 4
1. Inspect the stop lamp switch for proper
adjustment to ensure that the brake pedal is
fully releasing.
3 2. Inspect the cruise control release switch, if
equipped, for proper adjustment to ensure
that the brake pedal is fully releasing.

4
System Diagnosis.
Is the vehicle equipped with a drum-in-rotor
5 type of park brake system? Go to Step 6 Go to Step 8
tightly, possibly causing drag under certain
6
conditions.
excessive wear, blueing discoloration, heat
spots, and excessive radial runout.
7
3. If any of these conditions are present,
replace the affected components.

Inspect the park brake system for proper
operation. Refer to Park Brake System
8
Diagnosis in Park Brake.
9
Diagnosis.
1. Separate the brake booster pushrod from
the brake pedal.
2. Inspect the brake corners to determine if
10 the brake drag condition is still present.
Do the brake corners still exhibit the brake drag

Replace the brake pedal assembly.
11 -
1. Separate the master cylinder from the

brake booster. Do not disconnect any
12 brake pipes.
2. Inspect the brake corners to determine if
the brake drag condition is still present.
Replace the brake booster assembly.
13 -
Inspect the hydraulic brake system for proper Go to Diagnostic
operation. Refer to Hydraulic Brake System Starting Point -
14
1. Install or connect components that were
removed or disconnected during diagnosis.
2. Road test the vehicle in order to confirm
15 proper operation. Refer to Brake System
Vehicle Road Test.

Step Action Yes No
1
Hydraulic
Go to Step 2 Brakes
2
Diagnosis.
3
Diagnosis.
4
System Diagnosis.
Inspect the disc brake system for proper Go to Diagnostic
operation. Refer to Disc Brake System Starting Point -
5
6
Road Test.
BRAKE FLUID LOSS
Brake Fluid Loss

Step Action Yes No
1
Hydraulic
Go to Step 2 Brakes
2
Diagnosis.
3
Diagnosis.
4
System Diagnosis.
1. Separate the master cylinder from the
vacuum brake booster. Do not disconnect
any brake pipes. Refer to Master
Cylinder Replacement.
5 2. Inspect the rear of the master cylinder for a
brake fluid leak.
3. Inspect for brake fluid in the vacuum brake Go to Diagnostic
booster. Starting Point -
Hydraulic
Did you find a brake fluid leak? Go to Step 6 Brakes
Replace the brake master cylinder and the
vacuum brake booster. Refer to Master
Cylinder Replacement and Vacuum Brake
6 Booster Replacement (3.4L) or Vacuum -
Brake Booster Replacement (3.6L LY7).
1. Install or connect components that were
removed or disconnected during diagnosis.
2. Road test the vehicle to confirm proper
7 operation. Refer to Brake System
Vehicle Road Test.
DISC BRAKE SYSTEM DIAGNOSIS
Test Description
9: Lubricant leaks from non-brake system components may come in contact with and
contaminate brake system components.
10: Lubricant leaks from non-brake system components may come in contact with and
contaminate brake system components.
13: Disc brake rotor thickness variation that exceeds the maximum acceptable level can
cause brake pulsation.
17: Disc brake rotor thickness variation that exceeds the maximum acceptable level can
cause brake pulsation.
20: Disc brake rotor assembled lateral runout (LRO) that exceeds the maximum acceptable
level can lead to thickness variation.
Disc Brake System Diagnosis

Step Action Yes No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the
DISC brake system in order to determine if the DISC brake system is operating properly.
You will be directed by the appropriate Symptom table to go to other brake system
diagnostic tables as appropriate.
Were you sent here from a Brake Symptom Go to Diagnostic
table? Starting Point -
1
Hydraulic
Go to Step 2 Brakes
Visually inspect the disc brake pads for the
Refer to Brake Pad Inspection in Disc Brakes.
Lining thickness below specifications

Uneven and/or abnormal wear - edge-to-
edge and/or side-to-side
2 Looseness or damage - including pad
hardware
Evidence of contamination from an
external substance
Did you find any conditions to indicate a

concern with any of the front and/or rear disc
brake pads? Go to Step 3 Go to Step 12
Are any of the front and/or rear disc brake pads
3
contaminated? Go to Step 8 Go to Step 4
4
worn unevenly? Go to Step 7 Go to Step 5
5
and/or pad hardware loose or damaged? Go to Step 7 Go to Step 6
1. Remove and inspect the worn disc brake
pads for glazing, looseness, heat spots or
damage.
2. Replace the worn disc brake pads as a
complete axle set. Refer to Brake Pads
6 Replacement - Front and/or Brake Pads -
Replacement - Rear , if equipped, in
Disc Brakes.
Did you complete the inspection and

replacement? Go to Step 12
NOTE:
Support the brake caliper with heavy
mechanic's wire, or equivalent, whenever it is
separated from its mount and the hydraulic
flexible brake hose is still connected. Failure
to support the caliper in this manner will
cause the flexible brake hose to bear the
weight of the caliper, which may cause
damage to the brake hose and in turn may
IMPORTANT:
Do NOT disconnect the hydraulic brake flex
hoses from the calipers.
1. Remove the front and/or rear disc brake

calipers, as appropriate, from the mounting
brackets and support the calipers. Refer to
Brake Caliper Replacement - Front
and/or Brake Caliper Replacement -
Rear , if equipped, in Disc Brakes.
2. Inspect the disc brake caliper mounting
7 bracket and the mounting/sliding hardware -
for the following conditions:
Refer to Disc Brake Mounting and

Hardware Inspection - Front and/or
Disc Brake Mounting and Hardware
Inspection - Rear , if equipped, in Disc
Brakes.
Binding or seized hardware

Worn, damaged or missing hardware
components
Loose, bent, cracked, or damaged
caliper mounting bracket
3. Replace components as required. Refer to
the following procedures in Disc Brakes,
as required:
Brake Caliper Bracket
Replacement - Front
Brake Caliper Bracket
Replacement - Rear , if equipped
Disc Brake Hardware
Replacement - Front
Disc Brake Hardware
Replacement - Rear , if equipped
4. Replace the unevenly-worn, loose or
damaged disc brake pads as a complete
axle set. Refer to Brake Pads
Replacement - Front and/or Brake Pads
Disc Brakes.

1. Inspect the disc brake calipers, brake hoses
and brake pipes for evidence of an external
brake fluid leak.
2. Replace any components found to be
leaking brake fluid. Refer to the following
procedures as required:
Brake Caliper Overhaul - Front or
Brake Caliper Replacement -
Front in Disc Brakes
Brake Caliper Overhaul - Rear or
8 Brake Caliper Replacement -
Rear , if equipped, in Disc Brakes
Brake Hose Replacement - Front
Brake Hose Replacement - Rear

(Disc Brake) or Brake Hose
Replacement - Rear (Drum
Brake)
Brake Pipe Replacement
Did you find and correct the source of the leak

causing contamination of the pads? Go to Step 11 Go to Step 9
1. Inspect the wheel drive shaft outer seals
for damage and evidence of a grease leak.
2. Replace any wheel drive shaft seal that is
found to be leaking grease which may be
the source of the contamination to the
pads. Refer to Wheel Drive Shaft Outer
9 Joint and Seal Replacement - Front
and/or Wheel Drive Shaft Outer Joint
and Seal Replacement - Rear in Wheel
Drive Shafts.

causing contamination of the pads? Go to Step 11 Go to Step 10
1. Inspect the automatic transmission cooling
system lines, if equipped, for damage and
evidence of an external fluid leak which
may be the source of the contamination to
the pads.
2. Inspect the power steering system hoses for
damage and evidence of an external fluid
10 leak which may be the source of the -
contamination to the pads.
3. Replace any components found to be
leaking fluid which may be the source of
the contamination to the pads.

causing contamination of the pads? Go to Step 11
1. Clean the remaining disc brake system
components to remove any traces of the
contaminant.
NOTE:
to support the caliper in this manner will
cause the flexible brake hose to bear the
weight of the caliper, which may cause
damage to the brake hose and in turn may
IMPORTANT:
2. Remove the front and/or rear disc brake

calipers, as appropriate, from the mounting
brackets and support the calipers. Refer to
and/or Brake Caliper Replacement -
Rear , if equipped, in Disc Brakes.
3. Inspect the disc brake caliper
mounting/sliding hardware for the
Refer to Disc Brake Mounting and

Hardware Inspection - Front and/or
11 Disc Brake Mounting and Hardware -
Inspection - Rear , if equipped, in Disc
Brakes.

Distorted, worn, damaged or missing
hardware components
4. Replace the caliper mounting/sliding
hardware components as required. Refer to
Disc Brake Hardware Replacement -
Front and/or Disc Brake Hardware
Disc Brakes.
5. Replace the contaminated disc brake pads
as a complete axle set. Refer to Brake
Pads Replacement - Front and/or Brake
Pads Replacement - Rear , if equipped,
in Disc Brakes.
Go to Step 12
Did you complete the cleaning, inspection and
replacement?
1. Check the thickness of each of the disc
brake rotors.
IMPORTANT:
Make the following determination AND
ANSWER the question INDIVIDUALLY for
EACH rotor.
12 2. Make a determination for each brake rotor

if the rotor can be REFINISHED and
REMAIN ABOVE the minimum
requirements.
Refer to Brake Rotor Thickness

Measurement in Disc Brakes.Does the disc
brake rotor meet the minimum requirements for
REFINISHING? Go to Step 13 Go to Step 16
IMPORTANT:
Perform the following inspection AND ANSWER the
question INDIVIDUALLY for EACH rotor.
Inspect each of the disc brake rotors for

13 thickness variation that exceeds the maximum
acceptable level. Refer to Brake Rotor
Thickness Variation Measurement in Disc
Brakes.Does the brake rotor exhibit thickness
variation that exceeds the maximum acceptable
level? Go to Step 15 Go to Step 14
1. Inspect each of the disc brake rotors for
the following surface and wear conditions:
Refer to Brake Rotor Surface and Wear

Inspection in Disc Brakes.

Deep or excessive scoring beyond
maximum acceptable level
IMPORTANT:
EACH rotor.
14 2. Make a determination for each brake rotor

if the rotor requires refinishing based upon
the results of the inspection.
If the brake rotor exhibits any of the

conditions listed previously, it requires
refinishing.
Does the brake rotor require REFINISHING? Go to Step 15 Go to Step 20

1. Refinish the brake rotor. Refer to Brake
Rotor Refinishing in Disc Brakes.
2. Inspect the brake rotor thickness. Refer to
15 Brake Rotor Thickness Measurement
in Disc Brakes.
Were you able to REFINISH the brake rotor

within the minimum requirements? Go to Step 20 Go to Step 19
Is the brake rotor at or below the DISCARD
16
requirements? Go to Step 19 Go to Step 17
IMPORTANT:

17 thickness variation that exceeds the maximum
acceptable level. Refer to Brake Rotor
Thickness Variation Measurement in Disc
Brakes.Does the brake rotor exhibit thickness
variation that exceeds the maximum acceptable
level? Go to Step 19 Go to Step 18
1. Inspect each of the disc brake rotors for

the following surface and wear conditions:


IMPORTANT:
18 Make the following determination AND
EACH rotor.
2. Make a determination for each brake rotor

if the rotor requires replacement based
upon the results of the inspection.
If the brake rotor exhibits any of the

conditions listed previously, it requires
replacement.
Does the brake rotor require

REPLACEMENT? Go to Step 19 Go to Step 20
IMPORTANT:
Whenever a brake rotor is replaced, the assembled
lateral runout (LRO) of the rotor must be measured
to ensure optimum performance of the disc brakes.
19 -
Replace the brake rotor. Refer to Brake Rotor
Replacement - Front or Brake Rotor
Replacement - Rear , if equipped, in Disc
Brakes.Did you complete the replacement? Go to Step 22
IMPORTANT:

assembled lateral runout (LRO) that exceeds the
maximum acceptable level. Refer to Brake
Rotor Assembled Lateral Runout (LRO)
20
Measurement in Disc Brakes.Does the brake
rotor exhibit assembled LRO that exceeds the
maximum acceptable level? Go to Step 21 Go to Step 22
Correct the LRO for each brake rotor that was
determined to have LRO exceeding the
maximum acceptable level. Refer to Brake
21 -
Rotor Assembled Lateral Runout (LRO)
Correction in Disc Brakes.
Did you complete the operation? Go to Step 22
Install or connect components that were Disc Brake
removed or disconnected during diagnosis. System OK
22 -
Did you complete the operation? Return to
Symptom Table
DRUM BRAKE SYSTEM DIAGNOSIS
Test Description
The number below refers to the step number on the diagnostic table:
18: Drum brake backing plates that come in contact with brake drums may cause brake
system noise.
Drum Brake System Diagnosis

Step Action Yes No
DRUM brake system in order to determine if the DRUM brake system is operating
properly. You will be directed by the appropriate Symptom table to go to other brake
system diagnostic tables as appropriate.
table? Starting Point -
1
Hydraulic
Go to Step 2 Brakes
1. Remove the brake drums. Refer to Brake
Drum Replacement in Drum Brakes.
2. Inspect the drum brake shoes for the
Uneven and/or abnormal wear - edge-

to-edge and/or side-to-side
Contamination from an external
2 substance
Looseness, damage, glazing, or
incorrect lining material
Did you find any conditions to indicate a

concern with any of the drum brake shoes? Go to Step 3 Go to Step 7
3 Are any of the brake shoes contaminated? Go to Step 4 Go to Step 5
1. Inspect the wheel cylinders for evidence of
an external brake fluid leak.
2. Replace any wheel cylinder that is found to
4 be leaking brake fluid. Refer to Wheel -
Cylinder Replacement in Drum Brakes.

1. Inspect the drum brake hardware for any
components which are worn, damaged,
discolored due to stress, broken or missing.
Refer to Drum Brake Hardware
Inspection in Drum Brakes.
2. Replace components as required. Refer to
5 Drum Brake Hardware Replacement in -
Drum Brakes.
3. Replace the drum brake shoes. Refer to
Brake Shoe Replacement in Drum
Brakes.

1. Clean the remaining drum brake system
contaminant.
3. Replace the drum brake hardware
components as required. Refer to Drum
6 Brake Hardware Replacement in Drum -
Brakes.
4. Replace the contaminated brake shoes.
Refer to Brake Shoe Replacement in
Drum Brakes.

7 2. Replace components as required. Refer to -
Drum Brake Hardware Replacement in
Drum Brakes.
Did you complete the inspection and, if

necessary, the replacement? Go to Step 8
1. Check the diameter of each of the brake
drums.
IMPORTANT:
8 EACH drum.
2. Make a determination for each brake drum

if the drum can be REFINISHED and
REMAIN ABOVE the minimum
requirements.
Refer to Brake Drum Diameter
Measurement in Drum Brakes.Does the brake
drum meet the minimum requirements for
REFINISHING? Go to Step 9 Go to Step 11
1. Inspect each of the brake drums for the
following surface and wear conditions:
Refer to Brake Drum Surface and Wear



Deep or excessive scoring
beyond maximum acceptable
level
Radial runout beyond maximum
9 acceptable level
IMPORTANT:
EACH drum.

if the drum requires refinishing based upon
the results of the inspection.
If the brake drum exhibits any of the

following conditions, it requires
refinishing.
Drum exhibits one or more of the

Braking Surface Conditions listed
previously
Drum is beyond the acceptable level
in one or more of the Braking Surface
Wear Conditions listed previously
Does the brake drum require REFINISHING? Go to Step 10 Go to Step 14

1. Refinish the brake drum. Refer to Brake
Drum Refinishing in Drum Brakes.
2. Inspect the brake drum diameter. Refer to
10 Brake Drum Diameter Measurement in
Drum Brakes.
Were you able to REFINISH the brake drum

within the minimum requirements? Go to Step 14 Go to Step 13
Is the brake drum at or below the DISCARD
11
1. Inspect each of the brake drums for the



12
Deep or excessive scoring
beyond maximum acceptable
level
acceptable level
IMPORTANT:
EACH drum.
if the drum requires replacement based
upon the results of the inspection.
If a brake drum exhibits any of the

following conditions, it requires
replacement.
Drum exhibits one or more of the

Braking Surface Conditions listed
previously
Drum is beyond the acceptable level
in one or more of the Braking Surface
Wear Conditions listed previously
Does the brake drum require REPLACEMENT? Go to Step 13 Go to Step 14

Replace the brake drum. Refer to Brake Drum
13 Replacement in Drum Brakes. -
Inspect the brake shoes for proper adjustment.
Refer to Drum Brake Adjustment in Drum
14
Brakes.
Are the brake shoes adjusted properly? Go to Step 18 Go to Step 15
Inspect the components of the brake drum
adjustment hardware system for free movement
and correct operation. Refer to Drum Brake
15 Adjusting Hardware Inspection in Drum
Brakes.
Do the drum brake adjusting hardware
components operate freely and correctly? Go to Step 17 Go to Step 16
Replace the drum brake adjusting hardware
components as necessary. Refer to Drum Brake
16 Adjusting Hardware Replacement in Drum -
Brakes.
Adjust the drum brake shoes. Refer to Drum
17 Brake Adjustment in Drum Brakes. Return to
Were you able to complete the adjustment? Go to Step 20 Symptom Table
Inspect the drum brake backing plate for the
following:
Excessive wear or rust

18 Damage and/or evidence of contact with
the brake drum
Does the drum brake backing plate exhibit any

of these conditions? Go to Step 19 Go to Step 20
Repair or replace the drum brake backing plate
as necessary. Refer to Drum Brake Backing
19 -
Plate Replacement in Drum Brakes.
Did you complete the repair or replacement? Go to Step 20
Install or connect components that were Drum Brake
20 -
Symptom Table
HYDRAULIC BRAKE SYSTEM DIAGNOSIS
Hydraulic Brake System Diagnosis

Step Action Yes No
HYDRAULIC brake system in order to determine if the HYDRAULIC brake system is
operating properly. You will be directed by the appropriate Symptom table to go to other
brake system diagnostic tables as appropriate.
Were you sent here from a Brake Symptom Go to
table? Diagnostic
1 Starting Point -
Hydraulic
Go to Step 2 Brakes
Inspect and adjust the brake fluid level in the
brake master cylinder. Refer to Master
2
Cylinder Reservoir Filling.
Was the brake fluid level low? Go to Step 3 Go to Step 4
1. Inspect the brake fluid for the following
conditions, indicating brake fluid
contamination:
Fluid separation, indicating two types
of fluid are present
Swirled appearance - oil-based
substance
Layered appearance - silicone-
based substance
Fluid discoloration
Cloudy appearance - moisture

3
Dark appearance/suspended
particles in fluid - dirt, rust,
corrosion, brake dust
2. Inspect the master cylinder reservoir cap
diaphragm and the reservoir-to-master
cylinder grommets for swelling, indicating
fluid contamination.
Do any of the above conditions exist? Go to Step 5 Go to Step 6

conditions, indicating brake fluid
contamination:
Fluid separation, indicating two types
of fluid are present
substance
Layered appearance - silicone-
based substance
4 Fluid discoloration
Dark appearance/suspended
particles in fluid - dirt, rust,
corrosion, brake dust
diaphragm and the reservoir-to-master
cylinder grommets for swelling, indicating
fluid contamination.
1. Flush the hydraulic brake system. Refer to
Hydraulic Brake System Flushing.
2. If the brake fluid WAS contaminated with
an oil-based or a silicone-based fluid,
indicated by fluid separation and/or a
swollen master cylinder reservoir cap
diaphragm and/or swollen reservoir-to-
master cylinder grommets, perform the
following steps. Refer to the procedures
indicated.
1. Remove ALL of the following
components listed. Each component
contains internal rubber seals/linings
which have been contaminated.
2. Clean out the hydraulic brake pipes
using denatured alcohol, or equivalent.
3. Dry the brake pipes using non-
lubricated, filtered air.
5 4. Repair or replace ALL of the -
following components listed. Each
component contains internal rubber
seals/linings which have been
contaminated.
Master Cylinder Overhaul or
Master Cylinder Replacement
Brake master cylinder reservoir:
Clean the brake master cylinder
reservoir using denatured
alcohol, or equivalent, then dry
the reservoir using non-
lubricated, filtered air, or if
necessary, replace the brake
Replace the brake master
cylinder reservoir cap
diaphragm.
Brake Hose Replacement -
Front
Brake Hose Replacement -
Rear (Disc Brake) or Brake
Hose Replacement - Rear
(Drum Brake)
Brake Caliper Overhaul -
Front or Brake Caliper
Replacement - Front in Disc
Brakes
Brake Caliper Overhaul -
Rear or Brake Caliper
Replacement - Rear , if
equipped, in Disc Brakes
Wheel Cylinder Replacement ,
if equipped, in Drum Brakes
Brake Pressure Modulator
Valve (BPMV) Replacement
in Antilock Brake System
3. If the brake fluid was NOT contaminated
with an oil-based fluid, but WAS
contaminated with water or dirt, rust,
corrosion, and/or brake dust, replace the
brake master cylinder reservoir cap
diaphragm which may have allowed
moisture or dirt to enter the system.
4. Refill and bleed the hydraulic brake system.
Refer to Hydraulic Brake System
Bleeding (Manual) or Hydraulic Brake
System Bleeding (Pressure).
Did you complete the operation and any required

repairs and/or replacements? Go to Step 9
1. Inspect the following hydraulic brake
system components for external fluid leaks.
Repair or replace any of the components
found to be leaking brake fluid. Refer to the
appropriate procedures:
Brake master cylinder reservoir cap

diaphragm

Replacement - Rear (Drum Brake)

in Disc Brakes
6 Wheel Cylinder Replacement , if
equipped, in Drum Brakes
Brake Pressure Modulator Valve
(BPMV) Replacement in Antilock
Brake System
2. If you repaired or replaced any of the brake
system components listed, bleed the
hydraulic brake system. Refer to Hydraulic
Brake System Bleeding (Manual) or
Hydraulic Brake System Bleeding
(Pressure). While bleeding the hydraulic
brake system, observe for the following
conditions:
The presence of air in the system at a
bleeder valve location other than at
the repair location, except if the brake
master cylinder was replaced
An unrestricted and even flow of
brake fluid per axle during the
bleeding procedure

Was there air in the system at a bleeder valve
7 location other than at the repair location, except
if the brake master cylinder was replaced? Go to Step 19 Go to Step 8
Was the flow of brake fluid unrestricted and even
8
per axle during the bleeding procedure? Go to Step 9 Go to Step 10
Inspect the hydraulic function of the brake
calipers/wheel cylinders for proper operation.
Refer to Hydraulic Brake Component
9
Operation Visual Inspection.
Was the hydraulic function of the brake
calipers/wheel cylinders operating properly? Go to Step 21 Go to Step 14
Was the flow of brake fluid restricted or uneven
10 through front axle hydraulic components during
the bleeding procedure? Go to Step 13 Go to Step 11
Was the flow of brake fluid restricted or uneven
11 through rear axle hydraulic components during -
the bleeding procedure? Go to Step 17
calipers/wheel cylinders for proper operation.
Refer to Hydraulic Brake Component
12
Operation Visual Inspection.
Was the hydraulic function of the brake
calipers/wheel cylinders operating properly? Go to Step 15 Go to Step 13
Determine if the brake caliper is restricting the
flow of brake fluid and/or not operating
properly:
1. Raise and support the vehicle. Refer to

Lifting and Jacking the Vehicle in
13 General Information.
2. Remove the tire and wheel assemblies.
Refer to Tire and Wheel Removal and
3. Open the suspected caliper bleeder valve.
4. Using a large C-clamp, compress the caliper
piston and observe for an unrestricted flow
of brake fluid and for free movement of the
caliper piston.
5. Close the caliper bleeder valve.
Was the flow of brake fluid unrestricted and did

the caliper piston move freely? Go to Step 17 Go to Step 14
Repair or replace any brake caliper/wheel
cylinder that was not operating properly. Refer
to the appropriate procedure.

Brake Caliper Replacement - Front in
Disc Brakes
14 Brake Caliper Overhaul - Rear or Brake -
Caliper Replacement - Rear , if
Wheel Cylinder Replacement , if
Did you complete the repair and/or replacement? Go to Step 21

Bleed the hydraulic brake system to observe for
the presence of air in the system and to observe
for an unrestricted and even flow of brake fluid
per axle during the bleeding procedure. Refer to
15
Hydraulic Brake System Bleeding (Manual)
or Hydraulic Brake System Bleeding
(Pressure).
Was there air in the system? Go to Step 19 Go to Step 16
Was the flow of brake fluid unrestricted and even
16
per axle during the bleeding procedure? Go to Step 21 Go to Step 17
1. Inspect the hydraulic brake pipes and
flexible brake hoses for signs of a fluid
restriction; such as being bent, kinked,
pinched or damaged. Refer to Brake Pipe
and Hose Inspection.
2. Replace any of the hydraulic brake pipes
and/or flexible brake hoses found to be
bent, kinked, pinched, or damaged. Refer to
the following procedures as necessary:

17 Replacement - Rear (Drum Brake)
3. If none of the hydraulic brake pipes or

flexible brake hoses were visibly bent,
kinked, pinched, or damaged, replace the
hydraulic brake flex hose at the restricted
location.

Replace the brake pressure modulator valve
(BPMV), in order to correct the hydraulic brake
dynamic rear proportioning mechanical
18 operation. Refer to Brake Pressure Modulator -
Valve (BPMV) Replacement in Antilock
Brake System.
1. Inspect the hydraulic brake system
components for brake fluid seepage at a seal
and/or fitting location, which may have
drawn air into the system.
2. Inspect the hydraulic brake system
components for evidence of a recent repair,
19 which may have introduced air into the
system.
3. Repair or replace any of the components
found to be installed incorrectly or seeping
brake fluid.

1. Inspect the brake master cylinder for
internal fluid leaks. Refer to Brake System
Internal Leak Test.
2. Repair or replace the brake master cylinder
if it is found to be leaking brake fluid
20 internally. Refer to Master Cylinder
Overhaul or Master Cylinder
Replacement.
Return to
Did you find and correct a condition? Go to Step 21 Symptom Table
Install or connect components that were removed Hydraulic Brake
or disconnected during diagnosis. System OK
21 -
Symptom Table
BRAKE ASSIST SYSTEM DIAGNOSIS
Brake Assist System Diagnosis

Step Action Yes No
brake ASSIST system in order to determine if the brake ASSIST system is operating
properly. You will be directed by the appropriate Symptom Table to go to other brake
system diagnostic tables as appropriate.
Table? Starting Point -
1
Hydraulic
Go to Step 2 Brakes
Inspect for proper brake pedal travel. Refer to
Brake Pedal Travel Measurement and
2 Inspection.
1. Inspect for worn, missing, misaligned, bent
or damaged brake pedal system
components.
For the brake pedal pushrod
component inspection, refer to
Brake Pedal Pushrod Inspection.
excessive wear and/or damage and
inspect the brake pedal for a
misaligned, bent and/or damaged
condition.
2. Replace the brake pedal system
components that are worn, missing,
misaligned, bent or damaged, refer to the
following procedures as necessary.
Brake Pedal Assembly
3 Replacement
Replacement (3.4L) or Vacuum
Brake Booster Replacement (3.6L
LY7) (for a bent or damaged pedal
pushrod replacement)

Reinspect for proper brake pedal travel. Refer
to Brake Pedal Travel Measurement and
4 Inspection.
Check the engine vacuum source that supplies Go to Diagnostic
vacuum to the vacuum brake booster. Refer to Starting Point -
Brake System Vacuum Source Test. Engine
5 Is the vacuum reading within the acceptable Mechanical in
limits? Engine
Mechanical -
Go to Step 6 3.4L
During the vacuum source inspection, did the
6
vacuum booster check valve operate properly? Go to Step 8 Go to Step 7
Replace the vacuum booster check valve. Refer
to Vacuum Brake Booster Check Valve
7 -
and/or Hose Replacement.
1. Pump the brake pedal several times until
the brake pedal becomes hard.
2. Maintain moderate foot pressure on the
brake pedal and start the engine. Observe
8 pedal operation.
Did the brake pedal drop slightly, then remain

firm after the engine was started? Go to Step 9 Go to Step 12
1. Release the brake pedal.
2. Turn the ignition OFF, then wait 15
seconds.
3. Pump the brake pedal two times to check
for vacuum booster available vacuum
reserve. Observe pedal effort.
9
(If operating properly, the vacuum brake
booster should maintain assist for at least
two pedal applications.)
Did the brake pedal effort increase

significantly? Go to Step 12 Go to Step 10
Inspect the brake pedal pushrod and the brake
pedal for misalignment, a bent condition and/or
10 damage.
Is the brake pedal pushrod and/or the brake
pedal misaligned, bent or damaged? Go to Step 11 Go to Step 13
Replace the brake pedal pushrod and/or the
brake pedal, as necessary. Refer to the
following procedure(s).
Brake Pedal Assembly Replacement

11 Vacuum Brake Booster Replacement -
(3.4L) or Vacuum Brake Booster
Replacement (3.6L LY7) (for a bent or
damaged pedal pushrod replacement)

Replace the vacuum brake booster. Refer to
Vacuum Brake Booster Replacement (3.4L)
or Vacuum Brake Booster Replacement
12 -
(3.6L LY7).
Install or connect any components that were Brake Assist
13 -
Symptom Table
BRAKE SYSTEM VEHICLE ROAD TEST
1. Visually inspect easily accessible brake system components for obvious damage and/or leaks
which may indicate that the vehicle should not be driven until further inspections have been
completed.
2. Inspect the brake master cylinder reservoir fluid level and adjust only if necessary for brake
system road testing. Refer to Master Cylinder Reservoir Filling.
4. Inspect the tire tread patterns to ensure that they are the same or very similar, especially per
axle.
Road Testing Procedure
CAUTION: Road test a vehicle under safe conditions and while obeying
all traffic laws. Do not attempt any maneuvers that could
jeopardize vehicle control. Failure to adhere to these
precautions could lead to serious personal injury and vehicle
damage.

3. If the brake system warning lamp remains illuminated, DO NOT proceed to test drive the
vehicle until it is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes.
4. Select a smooth, dry, clean and level road or large lot that is as free of traffic and obstacles
as possible for brake system low speed road testing.
5. With the transmission in PARK, lightly apply the brake pedal. Observe both the pedal feel
and the pedal travel.
6. If the brake pedal apply felt spongy, or the pedal travel was excessive, DO NOT drive the
vehicle until it is repaired.
7. If the brake pedal apply did not feel spongy and the pedal travel was not excessive, proceed
to step 8.
9. While continuing to apply the brakes, shift the transmission into DRIVE, release the brakes
and allow the engine to idle the vehicle away from the stopped position. Observe for a slow
release of the brake system.
10. With the aid of an assistant to observe the vehicle's performance from outside of the vehicle,
drive the vehicle at a low speed and lightly apply the brakes while driving past the assistant.
Have the assistant observe for brake system noise from the side of the vehicle closest to
them, while you observe both the pedal effort and the pedal travel.
11. If the brake pedal apply effort was excessive, or the pedal travel was excessive, DO NOT
continue to test drive the vehicle until it is repaired.
12. If the brake pedal apply effort was not excessive and the pedal travel was not excessive,
proceed to step 13.
13. Drive the vehicle in the opposite direction, at the same low speed and lightly apply the
brakes while driving past the assistant. Have the assistant observe for brake system noise
from the side of the vehicle closest to him.
14. Drive the vehicle at a low speed and shift the transmission into NEUTRAL without applying
the brakes. Observe for a rapid deceleration in vehicle speed, indicating possible brake
drag.
15. Select a smooth, dry, clean and level road that is as free of heavy traffic as possible for
brake system moderate speed road testing.
16. Drive the vehicle at a moderate speed. Observe for a pull and/or incorrect tracking of the
vehicle without the brakes applied.
17. While continuing to drive the vehicle at a moderate speed, perform several light applies of
the brakes. Observe the pedal effort and the pedal travel, observe for brake system noise,
pulsation and/or brake drag.
19. If the brake pedal apply effort was not excessive and the pedal travel was not excessive,
proceed to step 20.
20. While continuing to drive the vehicle at a moderate speed, perform several moderate applies
of the brakes. Observe the pedal effort and the pedal travel, observe for brake system
pulsation and/or uneven braking action - either side to side, or front to rear.
A small amount of vehicle front end dip is expected during a moderate apply of the brakes.
BRAKE PEDAL TRAVEL MEASUREMENT AND INSPECTION
Tools Required
J 28662 Brake Pedal Effort Gauge. See Special Tools and Equipment.
Measurement and Inspection Procedure
1. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake
pedal becomes firm, in order to deplete the brake booster power reserve.
2. Install the J 28662 to the brake pedal. See Special Tools and Equipment.
3. Measure and record the distance (1) from the brake pedal to the rim of the steering wheel;
note the points of measurement.
4. Apply and maintain the brakes with 445 N (100 lb) of force to the brake pedal, as indicated
on the J 28662 . See Special Tools and Equipment.
5. While maintaining 445 N (100 lb) of force to the brake pedal, measure and record the
distance (2) from the same point on the brake pedal to the same point on the rim of the
steering wheel.
6. Release the brakes and repeat steps 4 and 5 to obtain a second measurement. After obtaining
a second measurement, proceed to step 7.
7. Average the first and second measurements recorded during the two applies of the brakes.
8. Subtract the initial measurement, unapplied (1), from the averaged, applied measurement
(2) to obtain the brake pedal travel distance.
Specification: Maximum brake pedal travel (measured with the ignition OFF, brake
booster power assist depleted, and the brakes cool): 74 mm (2.91 in).
BRAKE SYSTEM VACUUM SOURCE TEST
3. Start the engine and allow the engine to idle until normal operating temperatures are
reached.
4. Check to see if the engine vacuum reading is within the specified normal engine vacuum
range.
Specification: 47-68 kPa (14-20 in Hg)

6. If the engine vacuum reading is within the specified normal range, proceed to step 10.
7. If the engine vacuum reading is NOT within the specified normal range, inspect the engine
vacuum hose for the following conditions.
Tight connection to the engine
Collapse, deformation or contamination
Cracks, cuts, dry-rot
8. If any of these conditions were found with the engine vacuum hose, replace the hose, then
repeat steps 2-4.
9. If none of these conditions were found with the engine vacuum hose, then there is an engine
vacuum source problem, check the engine vacuum system.
13. Start the engine and allow the engine to idle until normal operating temperatures are
reached.
15. Check to see if the engine vacuum reading is maintained within the specified normal engine
vacuum range.
16. If the engine vacuum reading is maintained within the specified normal range, proceed to
step 18.
17. If the engine vacuum reading is NOT maintained within the specified normal range, replace
the brake booster check valve, then repeat steps 11-15.
Firm connection to the vacuum brake booster
Deformation or contamination
BRAKE SYSTEM EXTERNAL LEAK INSPECTION
NOTE: Refer to Brake Fluid Effects on Paint and Electrical Components

1. In order to inspect for external brake fluid leaks, first check the fluid level in the master
cylinder.
While a slight brake fluid level drop can be considered a normal condition due to brake
lining wear, a very low level may indicate a brake fluid leak in the hydraulic system.
2. If the fluid level is abnormally low, adjust the brake fluid level. Refer to Master Cylinder
Reservoir Filling.
4. Apply constant, moderate foot pressure to the brake pedal.
If the brake pedal gradually falls away while under foot pressure, there may be a brake fluid
leak.

6. Visually inspect the following brake system components for brake fluid leaks, excessive
corrosion, and damage. Give particular attention to all brake pipe and flexible hose
connections to ensure that there are not any slight brake fluid leaks - even though the brake
pedal may feel firm and hold steady:
Master cylinder brake pipe fittings
All brake pipe connections
Brake pipes
Brake hoses and connections
Brake calipers and/or wheel cylinders, if equipped
7. While slight dampness around the master cylinder reservoir can be considered acceptable,
brake fluid leaking from any of the brake system components requires immediate attention.
If any of these components exhibit signs of brake fluid leakage, repair or replace those
components. After the repair or replacement, reinspect the hydraulic brake system to assure
proper function.
BRAKE SYSTEM INTERNAL LEAK TEST


2. Apply light, steady pressure to the brake pedal. Observe both the brake pedal feel and
travel.
4. If the brake pedal apply felt spongy, but the brake pedal travel was not excessive, perform
the following steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak
Inspection.
2. Pressure bleed the brake system in order to purge any air that may be trapped in the
system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake
Fig. 5: Cross Sectional View Of Brake Master Cylinder
5. If the brake pedal apply did not feel spongy, but the brake pedal travel was excessive,
perform the following steps:
1. Loosen the master cylinder-to-brake power booster mounting nuts.
2. Carefully pull the master cylinder away from the brake power booster just enough to
inspect the mounting surface of the master cylinder.
3. Inspect the master cylinder mounting surface at the primary piston (2) for brake fluid
leaks.
6. If the master cylinder exhibits any leakage around the primary piston (2), then the primary
piston primary seal (4) and/or secondary seal (3) is leaking and the master cylinder requires
overhaul or replacement.
7. If the master cylinder primary piston (2) does not exhibit any leakage, pressure bleed the
brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic
Brake System Bleeding (Pressure).
8. If the brake pedal apply did not feel spongy, and the brake pedal travel was initially steady
and not excessive, but then gradually fell, then the master cylinder requires overhaul or
replacement due to an internal leak past the secondary piston (1) from the secondary piston
primary seal (6) or secondary seal (5).
9. If the brake pedal apply did not feel spongy, and the brake pedal travel was initially steady
and not excessive, then fell slightly, then became steady again, then the brake pressure
modulator valve (BPMV) may be leaking internally, and may require replacement.
HYDRAULIC BRAKE COMPONENT OPERATION VISUAL INSPECTION
Disc Brake
Fig. 6: Identifying Brake Caliper/Pad Inspection Areas
1. With the tire and wheel assemblies removed and the brake rotors retained by wheel lug nuts,
visually inspect the caliper piston dust boot (2) sealing area to ensure that there are no brake
fluid leaks.
2. If any evidence of a brake fluid leak is present, the brake caliper requires overhaul or
replacement.
3. While the brake system is at rest (4), observe the position of the caliper piston (1) in relation
to the caliper housing.
4. Have an assistant apply and release the brake pedal several times while you observe the
operation of the hydraulic brake caliper.
1. Observe the caliper piston (1) for unrestricted and even movement during each apply
of the brake system (5).
2. Observe the caliper piston (1) for an unrestricted and even return motion during each
release of the brake system (6).
5. If the caliper piston (1) did not exhibit unrestricted and even movement during brake system
apply and/or release, the piston square seal (3) may be worn or damaged and the caliper
may require overhaul or replacement.
Drum Brake
Fig. 7: Identifying Areas To Press To Compress Wheel Cylinder Pistons
1. With the rear tire and wheel assemblies and the brake drums removed, visually inspect the
wheel cylinder pistons boot sealing areas to ensure that there are no brake fluid leaks.
2. If any evidence of a brake fluid leak is present, the brake wheel cylinder requires
replacement.
3. Using firm hand pressure, simultaneously and evenly apply force on both brake shoes in
order to compress the wheel cylinder pistons into their bore.
5. If one or both of the wheel cylinder pistons did not exhibit unrestricted and even movement
during apply and/or release of force, the wheel cylinder may require replacement.
BRAKE PIPE AND HOSE INSPECTION

Kinks, improper routing, missing or damaged retainers
Leaking fittings, excessive corrosion
2. If any of the brake pipes exhibited any of the conditions listed, then the identified pipe, or
pipes, require replacement.
3. Ensure that the vehicle axles are properly supported at ride height in order to maintain the
proper relationship of the flexible brake hoses to the chassis.
Fig. 8: Identifying Flexible Brake Hose Failure Conditions
Kinks (1), improper routing, twists, chafing, missing or damaged retainers
Leaking connections, cracking, dry-rot, blisters, bulges
5. If any of the flexible brake hoses exhibited any of the conditions listed, then the identified
flexible brake hose, or hoses require replacement.
6. Squeeze the flexible brake hoses with firm finger pressure to check for soft spots (2),
indicating an internal restriction. Check the entire length of each flexible brake hose.
7. If any of the flexible brake hoses were found to have soft spots (2), then the identified
flexible brake hose, or hoses require replacement.
BRAKE PEDAL PUSHROD INSPECTION

Fig. 9: View of Brake Pedal Pushrod
1. Disconnect the brake pedal pushrod (1) from the brake pedal.
2. Inspect the brake pedal pushrod eyelet bushing (2), if equipped, for cracks and/or excessive
wear.
3. Reposition the pedal pushrod boot (3) toward the front of the vehicle to expose as much of
the pedal pushrod (1) as possible.
4. Inspect the brake pedal pushrod (1) for straightness.
5. If the brake pedal pushrod eyelet bushing (2) exhibited cracks and/or excessive wear, then
the bushing requires replacement.
6. If the brake pedal pushrod (1) is not straight, then the pushrod requires replacement.
7. Return the pedal pushrod boot (3) to its original position on the pedal pushrod (1).
8. Connect the brake pedal pushrod (1) to the brake pedal.
REPAIR INSTRUCTIONS
MASTER CYLINDER RESERVOIR FILLING
NOTE: When adding fluid to the brake master cylinder reservoir, use only
Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or
equivalent DOT-3 brake fluid from a clean, sealed brake fluid
container. The use of any type of fluid other than the recommended
type of brake fluid, may cause contamination which could result in
damage to the internal rubber seals and/or rubber linings of
hydraulic brake system components.

2. If the brake fluid level is at or below the half-full point during routine fluid checks, the
brake system should be inspected for wear and possible brake fluid leaks.
3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an
inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may
be topped-off up to the maximum-fill level.
4. If brake system service was just completed, the brake fluid may be topped-off up to the
maximum-fill level.
5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended
under normal conditions.
6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the
reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use
only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-
3 brake fluid from a clean, sealed brake fluid container.
MASTER CYLINDER RESERVOIR REPLACEMENT
Removal Procedure

1. Remove the master cylinder. Refer to Master Cylinder Replacement.
NOTE: Do not overtighten vise, or damage to the master cylinder will

result.
2. Clamp the flange on the master cylinder body in a vise. Do not clamp the master cylinder
body.
Fig. 10: Removing/Installing Reservoir Retaining Pins
3. Drive out the spring pins. Use a suitable punch. Do not damage the reservoir or the cylinder
body when pushing out the pins.
Fig. 11: View Of Master Cylinder Reservoir Components

4. Remove the reservoir body (3) by pulling the body straight up and away from the cylinder
body.
5. Remove the O-rings (4) from the grooves in the reservoir.
1. Lubricate the new O-rings and the reservoir-to-housing fittings. Use clean brake fluid.
2. Insert the O-rings (4) into the grooves in the reservoir. Ensure that the O-rings are properly
seated.
3. Install the reservoir (3) to the master cylinder body. Use your hand in order to push the
reservoir straight down into the body.
4. Install the spring pins in order to retain the reservoir. Do not damage the reservoir or the
cylinder body.
5. Install the master cylinder. Refer to Master Cylinder Replacement.
MASTER CYLINDER REPLACEMENT
Removal procedure

Fig. 14: View Of Master Cylinder Reservoir


4. Remove the master cylinder.
6. Remove the master cylinder reservoir. Refer to Master Cylinder Reservoir Replacement.

1. Install the master cylinder reservoir. Refer to Master Cylinder Reservoir Replacement.
2. Bench bleed the master cylinder prior to installation. Refer to Master Cylinder Bench
Bleeding.
3. Install the master cylinder.
4. Install the master cylinder mounting nuts.
Tighten: Tighten the master cylinder mounting nuts to 25 N.m (18 lb ft).

6. Connect the brake pipes to the master cylinder.
Tighten: Tighten the master cylinder tube nuts to 15 N.m (11 lb ft).
7. Fill the master cylinder reservoir with brake fluid. Refer to Master Cylinder Reservoir
Filling.
8. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual) or
Hydraulic Brake System Bleeding (Pressure).
MASTER CYLINDER OVERHAUL

1. Remove the brake master cylinder from the vehicle. Refer to Master Cylinder
Replacement.
2. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of
the primary piston is accessible.
3. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to
removing the cap and diaphragm.
5. Inspect the reservoir cap and diaphragm for the following conditions. If any of these
conditions are present, replace the affected components.
Cuts or cracks
Nicks or deformation
6. Remove the master cylinder reservoir from the master cylinder. Refer to Master Cylinder
Reservoir Replacement.
7. Using a smooth, round-ended tool, depress the primary piston (2) and remove the piston
retainer.
9. Plug the cylinder inlet ports and the rear outlet port. Apply low pressure, non-lubricated,
filtered air into the front outlet port, in order the remove the secondary piston (1) with the
primary (6) and secondary (5) seals, and the return spring.
10. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer from
the secondary piston.
Assembly Procedure
IMPORTANT: Do not use abrasives to clean the brake master cylinder bore.
1. Clean the interior and exterior of the master cylinder, the secondary piston (1), and the
return spring in denatured alcohol, or equivalent.
2. Inspect the master cylinder bore, inlet and outlet ports, the secondary piston (1), and the
return spring for cracks, scoring, pitting, and/or corrosion. Replace the master cylinder if
any of these conditions exist.
4. Lubricate the master cylinder bore, the secondary piston (1), the return spring, and all of the
individual overhaul components with Delco Supreme 11, GM P/N 12377967 (Canadian
P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container.
5. Assemble the lubricated, new primary seal (6) and retainer, and new secondary seal (5) onto
the secondary piston.
6. Install the lubricated return spring and secondary piston assembly (1) into the cylinder bore.
7. Install the lubricated, new primary piston assembly (2) into the cylinder bore.
8. Using a smooth, round-ended tool, depress the primary piston (2) and install the new piston
retainer.
9. Install the master cylinder reservoir to the master cylinder. Refer to Master Cylinder
11. Install the master cylinder to the vehicle. Refer to Master Cylinder Replacement.

Fig. 18: Bleeding Master Cylinder
1. Secure the mounting flange of the brake master cylinder in a bench vise so that the rear of
the primary piston is accessible.
3. Install suitable fittings to the master cylinder ports that match the type of flare seat required
and also provide for hose attachment.
4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the
hoses into the master cylinder reservoir.
5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11,
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean,
sealed brake fluid container.
6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are
fully submerged in the brake fluid.
7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will
travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from
the ports.
As air is bled from the primary and secondary pistons, the effort required to depress the
primary piston will increase and the amount of travel will decrease.
8. Continue to depress and release the primary piston until fluid flows freely from the ports
with no evidence of air bubbles.
11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the
master cylinder with a clean shop cloth to prevent brake fluid spills.
MASTER CYLINDER FLUID LEVEL SENSOR REPLACEMENT
Removal Procedure
Fig. 19: Identifying Master Cylinder Fluid Level Sensor Electrical Connector
1. Disconnect the electrical connector (2) from the fluid level sensor (1).
Fig. 20: Removing Brake Fluid Level Sensor
2. Remove the fluid level sensor (1). Use needle nose pliers in order to compress the switch
locking tabs at the outboard side of the master cylinder.
Fig. 21: Locating Master Cylinder Fluid Level Sensor
1. Install the fluid level sensor (1) until the locking tabs snap into place.
2. Connect the electrical connector to the fluid level sensor (1).
BRAKE PEDAL ASSEMBLY REPLACEMENT
Removal Procedure
1. Disable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.
2. Remove the left side insulator panel. Refer to Closeout/Insulator Panel Replacement -
Left in Instrument Panel, Gages and Console.
Fig. 22: Locating Brake Pedal Assembly Components
3. Remove the booster push rod (2) from the brake pedal (1).
4. Disconnect the electrical connectors from the cruise control release if equipped and stop
lamp switch.
5. Remove the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages
and Console.
6. Remove the brake booster mounting nuts (3).
Fig. 23: Identifying Brake Pedal Assembly Components
7. Remove the brake pedal bracket mounting nuts (2).

8. Remove the upper mounting nuts (1) from the brake pedal brace (4).
9. Remove the brake pedal with the bracket (3).
10. Remove the brake pedal brace (4) from the bracket.
Fig. 24: Locating Stop Lamp Switch & Cruise Control Switch
11. Remove the cruise control release switch (3), if equipped, and the stop lamp switch (1) from
the brake pedal with the bracket (2).
1. Install the cruise control release switch (3), if equipped, and the stop lamp switch (1) to the
brake pedal with the bracket (2).
2. Install the brake pedal brace (4) with the mounting nuts (1) to the bracket.
Tighten: Tighten the nuts (1) to 10 N.m (89 lb in).
3. Install the brake pedal with the bracket (3).

4. Install the upper mounting bolt for the brake pedal brace (4).
5. Install the brake pedal bracket mounting nuts (2).
Tighten: Tighten the nuts (2) to 25 N.m (18 lb ft).

6. Install the brake booster mounting nuts (3).

7. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages
and Console.
8. Connect the electrical connectors to the cruise control release if equipped and stop lamp
switch.
9. Install the booster push rod (2) to the brake pedal (1).
10. Adjust the stop lamp switch and the cruise control release switch if equipped. Refer to Stop
Lamp Switch Adjustment in Lighting System.
11. Install the left side insulator panel. Refer to Closeout/Insulator Panel Replacement -
Left in Instrument Panel, Gages and Console.
12. Enable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.
PROPORTIONING VALVE REPLACEMENT
Removal Procedure

IMPORTANT: Note the locations of the brake pipes in order to aid in

installation.
Fig. 28: View Of Brake Pipes To Proportioning Valve

Fig. 29: Locating Master Cylinder Brake Pipes From Proportion Valve

1. Install the proportion valve to bracket and install retaining nuts.
Tighten: Tighten the nuts 10 N.m (84 lb in).

4. Bleed brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic
BRAKE PIPE REPLACEMENT
Tools Required
J 45405 Pipe Flaring Tool Kit. See Special Tools and Equipment.
Replacement Procedure
CAUTION: Always use double walled steel brake pipe when replacing
brake pipes. The use of any other pipe is not recommended
and may cause brake system failure. Carefully route and
retain replacement brake pipes. Always use the correct
fasteners and the original location for replacement brake
pipes. Failure to properly route and retain brake pipes may
cause damage to the brake pipes and cause brake system
failure.

IMPORTANT: When servicing brake pipes, note the following:
If sectioning brake pipe, use replacement pipe of the same

type and outside diameter.
Use fittings of the appropriate size and type.
Only create flares of the same type or design as originally
equipped on the vehicle.
Fig. 32: Sectioning Brake Pipe Using Pipe Cutter
1. Inspect the section of brake pipe to be replaced.

2. Release the brake pipe to be replaced from the retainers, as required.
3. Select an appropriate location to section the brake pipe, if necessary.
Allow adequate clearance in order to maneuver the J 45405 . See Special Tools and
Equipment.
Avoid sectioning the brake pipe at bends or mounting points.
4. Using a string or wire, measure the length of the pipe to be replaced including all pipe
bends.
5. Add to the measurement taken the appropriate additional length required for each flare to
be created.
Specification: 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe
IMPORTANT: Ensure that the brake pipe end to be flared is cut at a square,
90 degree angle to the pipe length.
6. Using the pipe cutter included in the J 45405 , carefully cut the brake pipe squarely to the
measured length. See Special Tools and Equipment.
7. Remove the sectioned brake pipe from the vehicle.
8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside
diameter determines brake pipe size.
Fig. 33: Stripping Nylon Coating From Brake Pipe Ends
9. Strip the nylon coating from the brake pipe ends to be flared, if necessary.
Select the appropriate blade on the coating stripping tool included in the J 45405 , by
unthreading the blade block from the stripping tool and installing the block with the
desired blade facing the tool rollers. See Special Tools and Equipment.
Specification: 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe
Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge
on the tool rollers.
While holding the brake pipe firmly against the stripping tool roller ledges, rotate the
thumbwheel of the tool until the blade contacts the brake pipe coated surface.
IMPORTANT: Do not gouge the metal surface of the brake pipe.
Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end
remains against the tool roller ledges.
After each successive revolution of the stripping tool, carefully rotate the thumbwheel
of the tool clockwise, in order to continue stripping the coating from the brake pipe
until the metal pipe surface is exposed.
Loosen the thumbwheel of the tool and remove the brake pipe.
IMPORTANT: Ensure that all loose remnants of the nylon coating have
been removed from the brake pipe.
Inspect the stripped end of the brake pipe to ensure that the proper amount of coating
has been removed.
Fig. 34: Chamfering Pipe Using De-Burring Tool

10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the
J 45405 . See Special Tools and Equipment.
11. Install the tube nuts on the brake pipe, noting their orientation.
12. Clean the brake pipe and the J 45405 of lubricant, contaminants, and debris. See Special
Fig. 35: Installing Die Halves Into Die Cage

13. Loosen the die clamping screw of the J 45405 . See Special Tools and Equipment.
14. Select the corresponding die set and install the die halves into the die cage with the full, flat
face of one die facing the clamping screw, and the counterbores of both dies facing the
forming ram.
Fig. 36: View Of Clamping Screw & Unused Die
15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold
firmly against the counterbored face of the dies.
16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is
seated against the flat surface of the unused die (1).
17. Remove the unused die (1).
18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage.
19. Firmly hand tighten the clamping screw (2) against the dies.
Fig. 37: Rotating J 45405 To Bottom Against Die Cage
20. Select the appropriate forming mandrel and place into the forming ram.
21. Rotate the hydraulic fluid control valve clockwise to the closed position.
22. Rotate the body of the J 45405 until it bottoms against the die cage. See Special Tools and
Equipment.
Fig. 38: Bottoming Forming Mandrel Against Clamping Dies Using Pipe Flaring
Tool
23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the
lever of the J 45405 until the forming mandrel bottoms against the clamping dies. See
Special Tools and Equipment.
24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the
hydraulic forming ram to retract.
25. Loosen the die clamping screw and remove the dies and pipe.
26. If necessary, lightly tap the dies until the die halves separate.
Fig. 39: Inspecting Brake Pipe Flare Diameter
27. Inspect the brake pipe flare for correct shape and diameter (a).
Specification: 7.10 mm (0.279 in) +/- 0.18 mm (0.007 in) flare diameter for 4.76 mm
(3/16 in) diameter pipe
28. If necessary, using the removed section of pipe as a template, shape the new pipe with a
suitable brake pipe bending tool.
IMPORTANT: When installing the pipe, maintain a clearance of 19 mm (3/4

in) from all moving or vibrating components.
29. Install the pipe to the vehicle with the appropriate brake pipe unions as required.
30. If previously released, secure the brake pipe to the retainers.
31. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual)
or Hydraulic Brake System Bleeding (Pressure).
32. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and
applying the brakes.
BRAKE HOSE REPLACEMENT - FRONT
Removal Procedure

Information.
2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
Fig. 40: Locating Brake Hose Retainer
IMPORTANT: Install a rubber cap or plug to the exposed brake pipe fitting
end in order to prevent brake fluid loss and contamination.
4. Remove the brake pipe fitting (1) from the brake hose (3).
5. Use a flat-bladed tool in order to remove the brake hose retainer (4) from the brake hose
(3).
6. Remove the brake hose (3) from the brake hose bracket (2).
Fig. 41: Removing/Installing Brake Hose At Brake Caliper
7. Remove the brake hose bolt (4) from the brake caliper (2).
8. Remove the brake hose (5) from the brake caliper (2).
9. Remove and discard the two copper brake hose gaskets (3). These gaskets may be stuck to
the brake caliper and/or the brake hose end.
10. Install a rubber plug into the brake hose bolt hole of the brake caliper in order to prevent
brake fluid loss and contamination.

2. Assemble the brake hose bolt (4) and the NEW copper brake hose gaskets (3) to the brake
hose (5).
3. Install the brake hose bolt (4) to the brake caliper (2).
Tighten: Tighten the brake hose bolt to 54 N.m (40 lb ft).

NOTE: Make sure the brake hose is not twisted or kinked after
installation. Damage to the hose could result.
IMPORTANT: Use the stripe on the brake hose in order to align the brake
4. Install the brake hose (3) to the brake hose bracket (2).
5. Install the brake hose retainer (4) to the brake hose (3).
7. Install the brake pipe fitting (1) to the brake hose (3).
Tighten: Tighten the brake pipe fitting to 21 N.m (15 lb ft).
9. Install the tire and wheel. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
BRAKE HOSE REPLACEMENT - REAR (DISC BRAKE)
Removal Procedure

Information.
2. Remove the wheel and tire. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
Fig. 44: Identifying Brake Hose Retainer
IMPORTANT: Install a rubber cap or plug to the exposed brake pipe fitting
end in order to prevent brake fluid loss and contamination.
5. Use a flat-bladed tool in order to remove the brake hose retainer (4) from the brake hose
(3).
7. Remove the brake hose bolt from the brake caliper (1).
9. Remove and discard the two copper brake hose gasket. These gaskets may be stuck to the
brake caliper and/or the brake hose end (3).
10. Install a rubber plug into the brake hose bolt hole of the brake caliper in order to prevent
brake fluid loss and contamination.

2. Assemble the brake hose bolt and the NEW copper brake hose gaskets to the brake hose (2).
3. Install the brake hose bolt to the brake caliper (1).
NOTE: Make sure the brake hose is not twisted or kinked after
installation. Damage to the hose could result.
IMPORTANT: Use the stripe on the brake hose in order to align the brake

7. Install the brake pipe fitting (1) to the brake hose.
9. Install the wheel and tire. Refer to Tire and Wheel Removal and Installation in Tires
and Wheels.
BRAKE HOSE REPLACEMENT - REAR (DRUM BRAKE)
Removal Procedure

Fig. 48: Identifying Rear Brake Pipes From Brake Hose
3. Remove the brake pipes (1) from the brake hose (2).
6. Remove the hose.
IMPORTANT: Ensure that there are no kinks in the brake hose.

1. Align the hose fitting with the notch in the brackets.


4. Install the brake pipes (1) to the brake hose.

HYDRAULIC BRAKE SYSTEM BLEEDING (MANUAL)

pedal effort increases significantly, in order to deplete the brake booster power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you
disconnected the brake pipes from the master cylinder, you must perform the following
steps:
1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If
necessary, add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or
If removal of the reservoir cap and diaphragm is necessary, clean the outside of the
reservoir on and around the cap prior to removal.
2. With the rear brake pipe installed securely to the master cylinder, loosen and separate
the front brake pipe from the front port of the brake master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the master
cylinder.
4. Reconnect the brake pipe to the master cylinder port and tighten securely.
5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on
the pedal.
6. Loosen the same brake pipe to purge air from the open port of the master cylinder.
7. Tighten the brake pipe, then have the assistant slowly release the brake pedal.
8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of
the master cylinder.
9. With the front brake pipe installed securely to the master cylinder, after all air has
been purged from the front port of the master cylinder, loosen and separate the rear
brake pipe from the master cylinder, then repeat steps 3.3-3.8.
10. After completing the final master cylinder port bleeding procedure, ensure that both of
the brake pipe-to-master cylinder fittings are properly tightened.
4. Fill the brake master cylinder reservoir with Delco Supreme 11, GM P/N 12377967
(Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid
container. Ensure that the brake master cylinder reservoir remains at least half-full during
this bleeding procedure. Add fluid as needed to maintain the proper level.
Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap
and diaphragm.
5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder
valve.
7. Submerge the open end of the transparent hose into a transparent container partially filled
with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-
8. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the
pedal.
11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic
circuit.
12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has
been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the
LEFT FRONT wheel hydraulic circuit bleeder valve.
13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7-11.
14. With the left front wheel hydraulic circuit bleeder valve tightened securely, after all air has
been purged from the left front hydraulic circuit, install a proper box-end wrench onto the
LEFT REAR wheel hydraulic circuit bleeder valve.
16. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has
been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the
RIGHT FRONT wheel hydraulic circuit bleeder valve.
18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of
the 4 wheel hydraulic circuit bleeder valves are properly tightened.
19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11,
IMPORTANT: If it is determined that air was induced into the system

upstream of the ABS modulator prior to servicing, the ABS
Automated Bleed Procedure must be performed.
21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still
feels spongy after repeating the bleeding procedure, perform the following steps:
Inspection.
2. Pressure bleed the hydraulic brake system in order to purge any air that may still be
trapped in the system.
22. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning
lamp remains illuminated.
IMPORTANT: DO NOT allow the vehicle to be driven until it is diagnosed

and repaired.
23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic
Brakes.
HYDRAULIC BRAKE SYSTEM BLEEDING (PRESSURE)
Tools Required
J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent. See Special Tools and
Equipment.
J 35589-A Master Cylinder Bleeder Adapter. See Special Tools and Equipment.

pedal effort increases significantly, in order to deplete the brake booster power reserve.
3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you
disconnected the brake pipes from the master cylinder, you must perform the following
steps:
1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If
necessary, add Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or
If removal of the reservoir cap and diaphragm is necessary, clean the outside of the
reservoir on and around the cap prior to removal.
2. With the rear brake pipe installed securely to the master cylinder, loosen and separate
the front brake pipe from the front port of the brake master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the master
cylinder.
5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on
the pedal.
8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of
the master cylinder.
9. With the front brake pipe installed securely to the master cylinder, after all air has
been purged from the front port of the master cylinder, loosen and separate the rear
brake pipe from the master cylinder, then repeat steps 3.3-3.8.
10. After completing the final master cylinder port bleeding procedure, ensure that both of
the brake pipe-to-master cylinder fittings are properly tightened.
Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap
and diaphragm.
5. Install the J 35589-A to the brake master cylinder reservoir. See Special Tools and
Equipment.
6. Check the brake fluid level in the J 29532 , or equivalent. Add Delco Supreme 11, GM
P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean,
sealed brake fluid container as necessary to bring the level to approximately the half-full
point.
7. Connect the J 29532 , or equivalent, to the J 35589-A . See Special Tools and
Equipment.
8. Charge the J 29532 , or equivalent, air tank to 175-205 kPa (25-30 psi).
9. Open the J 29532 , or equivalent, fluid tank valve to allow pressurized brake fluid to enter
the brake system.
10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to
ensure that there are no existing external brake fluid leaks.
Any brake fluid leaks identified require repair prior to completing this procedure.
11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder
valve.
13. Submerge the open end of the transparent hose into a transparent container partially filled
with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-
14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow
until air bubbles stop flowing from the bleeder, then tighten the bleeder valve.
15. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has
been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the
LEFT FRONT wheel hydraulic circuit bleeder valve.
17. With the left front wheel hydraulic circuit bleeder valve tightened securely, after all air has
been purged from the left front hydraulic circuit, install a proper box-end wrench onto the
LEFT REAR wheel hydraulic circuit bleeder valve.
19. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has
been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the
RIGHT FRONT wheel hydraulic circuit bleeder valve
21. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of
the 4 wheel hydraulic circuit bleeder valves are properly tightened.
22. Close the J 29532 , or equivalent, fluid tank valve, then disconnect the J 29532 , or
equivalent, from the J 35589-A .
23. Remove the J 35589-A from the brake master cylinder reservoir. See Special Tools and
Equipment.
IMPORTANT: If it is determined that air was induced into the system

upstream of the ABS modulator prior to servicing, the ABS
Automated Bleed Procedure must be performed.
26. If the brake pedal feels spongy, perform the following steps:
Inspection.
2. Using a scan tool, perform the antilock brake system automated bleeding procedure to
remove any air that may have been trapped in the BPMV. Refer to ABS Automated
Bleed Procedure in Antilock Brake System.
27. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning
lamp remains illuminated.
IMPORTANT: DO NOT allow the vehicle to be driven until it is diagnosed

and repaired.
28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic
Brakes.

Fluid separation, indicating two types of fluid are present; a substance other than the
recommended brake fluid has been introduced into the brake hydraulic system
Swirled appearance - oil-based substance
Layered appearance - silicone-based substance
Fluid discoloration, indicating the presence of moisture or particles that have been
introduced into the brake hydraulic system
Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust
2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder
grommets for swelling, indicating brake fluid contamination.
3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance,
indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm
and/or swollen reservoir-to-master cylinder grommets, perform the following:
1. Remove ALL of the following components listed from the vehicle. Each component
contains internal rubber seals/linings which have been contaminated by the
contaminated brake fluid in the brake hydraulic system.
Refer to the procedures indicated:

Brake Hose Replacement - Rear (Disc Brake) or Brake Hose Replacement -

Rear (Drum Brake)
Brake Caliper Replacement - Front in Disc Brakes
Brake Caliper Replacement - Rear , if equipped, in Disc Brakes
Wheel Cylinder Replacement , if equipped, in Drum Brakes
Brake Pressure Modulator Valve (BPMV) Replacement in Antilock Brake

System
2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent.
3. Dry the brake pipes using non-lubricated, filtered air.
4. Repair or replace ALL of the following components listed and install them to the
vehicle. Each component contains internal rubber seals/linings which have been
contaminated by the contaminated brake fluid in the brake hydraulic system.
Master Cylinder Overhaul or Master Cylinder Replacement; also perform

the following:
Clean the brake master cylinder reservoir using denatured alcohol, or equivalent,
then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for
cracks and/or damage and replace if necessary. Refer to Master Cylinder
Replace the brake master cylinder reservoir cap diaphragm.

Brake Hose Replacement - Rear (Disc Brake) or Brake Hose Replacement -
Rear (Drum Brake)
Brake Caliper Overhaul - Front or Brake Caliper Replacement - Front in
Disc Brakes
Brake Caliper Overhaul - Rear or Brake Caliper Replacement - Rear , if
Brake Pressure Modulator Valve (BPMV) Replacement in Antilock Brake

System
4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance,
but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the
brake master cylinder reservoir cap diaphragm. The diaphragm may have allowed the
moisture or particles to enter the hydraulic system.
6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder
reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to
Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding
(Pressure).
VACUUM BRAKE BOOSTER REPLACEMENT (3.4L)
Removal Procedure
1. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in

Engine Cooling.
2. Relieve fuel line pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls -
3.4L.
3. Remove the left front cross brace. Refer to Brace Replacement - Front Fender Upper
Diagonal - Left in Body Front End.
4. Remove the powertrain control module (PCM) cover from the air cleaner housing.
5. Remove the PCM and set aside. It is not necessary to disconnect electrical. Refer to
Powertrain Control Module (PCM) Replacement in Engine Controls - 3.4L.
6. Remove the air cleaner and the duct. Refer to Air Cleaner Assembly Replacement in
7. Remove the fuel lines from the pipes and the vapor line. Refer to Fuel Hose/Pipes
8. Disconnect the fluid level sensor switch from the brake master cylinder.
9. Disconnect the brake lines from the master cylinder and remove the master cylinder. Refer
to Master Cylinder Replacement.
Fig. 50: Locating Vacuum Hose From Vacuum Check Valve

11. Unclip the wire harness from the ABS module bracket and disconnect the electrical
connector at the ABS module.
12. Remove the brake lines from the ABS module.
13. Remove the ABS module and bracket. Refer to Brake Pressure Modulator Valve
(BPMV) Replacement in Antilock Brake System.
NOTE: When disconnecting the pushrod from the brake pedal, the
brake pedal must be held stationary or damage to the brake
switch may result.
14. Remove the booster push rod retaining clip and washer (2) from the brake pedal assembly.
15. Remove the brake booster push rod (2) from the brake pedal (1).
Fig. 52: View Of Vacuum Brake Booster Components

CAUTION: When replacing the power booster brake, make sure that the
cruise control cable is not routed between the booster and the
cowl. If the cable is damaged or pinched, it must be replaced.
Failure to do this could result in personal injury.
NOTE: Proper stoplamp switch adjustment is essential. Improper stoplamp

switch adjustment may cause brake drag, heat buildup and
excessive brake lining wear.

1. Install the brake booster and position to the cowl and the mounting plate.
2. Install the brake booster mounting nuts.
Tighten: Tighten the brake booster mounting nuts to 25 N.m (18 lb ft).
3. Install the brake booster push rod (2) to the brake pedal (1).
5. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment in Lighting
Systems.
6. Install the ABS module bracket and module. Refer to Brake Pressure Modulator Valve
7. Connect the brake lines to the module.
8. Connect the electrical connector to the ABS module and clip the electrical harness to the
bracket.
10. Install the brake master cylinder and connect the brake lines. Refer to Master Cylinder
Replacement.
11. Connect the fluid level sensor switch on the master cylinder.
12. Install the fuel lines to the pipes and the vapor line. Refer to Fuel Hose/Pipes
13. Install the air cleaner and duct assembly. Refer to Air Cleaner Assembly Replacement in
14. Install the PCM. Refer to Powertrain Control Module (PCM) Replacement in Engine
Controls - 3.4L.
15. Install the PCM cover.
16. Install the left front cross brace. Refer to Brace Replacement - Front Fender Upper
17. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in
Engine Cooling.
VACUUM BRAKE BOOSTER REPLACEMENT (3.6L LY7)
Removal Procedure
1. Lift the coolant reservoir up and away from the left front cross brace.
2. Remove the left front cross brace. Refer to Brace Replacement - Front Fender Upper
3. Remove the engine control module (ECM) cover from the air cleaner housing.
4. Remove the ECM and set aside. It is not necessary to disconnect electrical. Refer to Engine
Control Module (ECM) Replacement in Engine Controls - 3.6L (LY7).
5. Remove the air cleaner and the duct. Refer to Air Cleaner Assembly Replacement in
Engine Controls - 3.6L (LY7).
6. Remove the fuel line retaining bolt from the intake manifold.
8. Disconnect the brake lines from the master cylinder and remove the master cylinder. Refer
to Master Cylinder Replacement.
10. Remove the ABS module and bracket. Refer to Brake Pressure Modulator Valve
11. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical
- 3.6L (LY7).
Information.
13. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and
Fig. 55: Locating Left Front Fender Liner

14. Remove the left front fender liner.
15. Remove the left ball joint from the steering knuckle. Refer to Lower Control Arm

16. Remove the stabilizer bar links. Refer to Stabilizer Shaft Link Replacement in Front
Suspension.
17. Remove the steering gear mounting bolts.
Fig. 57: Locating Left Side Frame To Body Bolts
18. Remove the 2 left side frame to body bolts.
IMPORTANT: DO NOT remove the frame to body bolts on the right side.
19. Loosen, but do not remove, the right frame to body bolts.
20. Position an oil drain pan under the transmission.
IMPORTANT: Insure that all pipes, hoses, and wires are clear and not
being bound or stressed when lowering the frame.

22. Using the engine support fixture, lower the powertrain.
23. Remove the transmission filler tube. Refer to Fluid Filler Tube Replacement (LA1) or
Fluid Filler Tube Replacement (LY7) in Automatic Transaxle - 4T65-E.
24. Disconnect the fuel pipe retainer from the wheelhouse stud.

NOTE: When disconnecting the pushrod from the brake pedal, the
brake pedal must be held stationary or damage to the brake
switch may result.

CAUTION: When replacing the power booster brake, make sure that the
cruise control cable is not routed between the booster and the
cowl. If the cable is damaged or pinched, it must be replaced.
Failure to do this could result in personal injury.
NOTE: Proper stoplamp switch adjustment is essential. Improper stoplamp

switch adjustment may cause brake drag, heat buildup and
excessive brake lining wear.

5. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment in Lighting
Systems.
6. Connect the fuel pipe retainer to the wheelhouse stud.
7. Install the transmission filler tube. Refer to Fluid Filler Tube Replacement (LA1) or
Fluid Filler Tube Replacement (LY7) in Automatic Transaxle - 4T65-E.
8. Using the engine support fixture, raise the powertrain to its original position.
10. Using an appropriate jack, raise the left side of the frame so that the frame to body bolts can
be installed.
Fig. 62: Locating Left Side Frame To Body Bolts

11. Install the frame to body bolts.
Tighten:
Tighten the front bolts to 155 N.m (114 lb ft).
Tighten the rear bolts to 240 N.m (177 lb ft).
12. Remove the jackstand and oil drain pan.

13. Install the steering gear mounting bolts.

14. Install the stabilizer bar links. Refer to Stabilizer Shaft Link Replacement in Front
Suspension.
15. Install the ball joint to the steering knuckle. Refer to Lower Control Arm Replacement in
Front Suspension.
Fig. 64: Locating Left Front Fender Liner
16. Install the left front fender liner.

17. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and
19. Remove the engine support fixture.
20. Install ABS module bracket and module. Refer to Brake Pressure Modulator Valve
22. Install the brake master cylinder and connect the brake lines. Refer to Master Cylinder
Replacement.
23. Connect fluid level sensor switch on the master cylinder.
24. Install the fuel line retaining bolt to the intake manifold.
25. Install the air cleaner and duct assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls - 3.6L (LY7).
26. Install the ECM. Refer to Engine Control Module (ECM) Replacement in Engine
Controls - 3.6L (LY7).
27. Install the ECM cover.
28. Install the left front cross brace. Refer to Brace Replacement - Front Fender Upper
29. Reposition the coolant reservoir to the left front cross brace.
VACUUM BRAKE BOOSTER CHECK VALVE AND/OR HOSE REPLACEMENT
Removal Procedure

Fig. 66: View Of Vacuum Brake Booster Check Valve And Vacuum Brake Booster
Hose
3. Remove the vacuum hose (1) from the vacuum brake booster check valve (2).

Fig. 68: View Of Vacuum Brake Booster Check Valve And Vacuum Brake Booster
Hose
3. Install the vacuum hose (1) to the vacuum brake booster check valve (2).

BRAKE FLUID AND BRAKE 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.
If ingested-consult a physician immediately.
CAUTION: Use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N
992667), or equivalent DOT 3 brake fluid from a clean, sealed
container. Do not use fluid from an open container that may
be contaminated with water. Improper or contaminated fluid
could result in damage to components, or loss of braking,
with possible injury.
NOTE: When filling the master cylinder, use only Delco Supreme 11, GM
P/N 12377967 (Canadian P/N 992667), or equivalent DOT 3 brake
fluid. Do not use a container which has been used for petroleum
based fluids, or a container which is wet with water. Petroleum
based fluids will cause swelling and distortion of rubber parts in
the hydraulic brake system, and water will mix with brake fluid,
lowering the boiling point. Keep all fluid containers capped to
prevent contamination.
NOTE: Brake fluid will damage electrical connections and painted

surfaces. Use shop cloths, suitable containers, and fender covers
to prevent brake fluid from contacting these areas. Always re-seal
and wipe off brake fluid containers to prevent spills.
NOTE: Avoid spilling brake fluid on any of the vehicle's painted surfaces,
wiring, cables or electrical connectors. Brake fluid will damage
paint and electrical connections. If any fluid is spilled on the
vehicle, immediately flush the area with water to minimize the
potential for damage.
NOTE: Power steering fluid, engine oil, brake fluid, or any mineral based
fluids cannot be mixed. If brake seals contact power steering fluid
or steering seals contact brake fluid, seal damage will result.
IMPORTANT: Do not reuse the brake fluid collected during the hydraulic
brake system bleeding.
Always store brake fluid in a closed container.
Reseal brake fluid containers immediately after use.
Do not use brake fluid left in an open container.
Do not use brake fluid left in an improperly sealed container.
Do not use the following fluids in the hydraulic brake system:
Automatic transmission fluid
DOT 5 silicone hydraulic brake fluid

BRAKE WARNING SYSTEM DESCRIPTION AND OPERATION
The IPC detects a low brake fluid condition. The IPC receives a discrete input from the
brake fluid level switch requesting illumination.
The IPC detects the park brake is engaged. The IPC receives a discrete input from the park
brake switch requesting illumination.
The IPC performs the displays test at the start of each ignition cycle. The indicator
illuminates for approximately 3 seconds.
HYDRAULIC BRAKE SYSTEM DESCRIPTION AND OPERATION
Converts mechanical input force into hydraulic output pressure.

Hydraulic output pressure is distributed from the master cylinder through two hydraulic
circuits, supplying diagonally-opposed wheel apply circuits.
Regulates brake fluid pressure delivered to hydraulic brake wheel circuits, in order to
control the distribution of braking force.
Pressure balance control is achieved through dynamic rear proportioning (DRP), which is a
function of the ABS modulator. Refer to ABS Description and Operation in Antilock
Brake System for specific information on the operation of DRP.

System Operation
Mechanical force is converted into hydraulic pressure by the master cylinder, regulated to meet
braking system demands by the pressure balance control system, and delivered to the hydraulic
brake wheel circuits by the pipes and flexible hoses. The wheel apply components then convert
the hydraulic pressure back into mechanical force which presses linings against rotating brake
system components.
BRAKE ASSIST SYSTEM DESCRIPTION AND OPERATION
Brake Pedal
Brake Pedal Pushrod
Uses source vacuum to decrease effort required by driver when applying brake system input
force.
When brake system input force is applied, air at atmospheric pressure is admitted to the rear
of both vacuum diaphragms, providing a decrease in brake pedal effort required. When
input force is removed, vacuum replaces atmospheric pressure within the booster.
Vacuum Source
System Operation
Brake system input force is multiplied by the brake pedal and transferred by the pedal pushrod to
the hydraulic brake master cylinder. Effort required to apply the brake system is reduced by the
vacuum brake booster.

SPECIAL TOOLS
Special Tools
J 28662
Brake Pedal Effort Gauge
J 29532
Diaphragm Pressure Bleeder
J 35589-A
Master Cylinder Bleeder Adapter
J 45405
Pipe Flaring Tool Kit
Hydraulic Brakes - Aztek & Rendezvous
SPECIFICATIONS

Specification
Brake Booster Mounting Nuts 25 N.m 18 lb ft
Brake Hose Fitting Bolt at Front Brake Caliper 54 N.m 40 lb ft
Brake Hose Fitting Bolt at Rear Brake Caliper 43 N.m 32 lb ft
Brake Pedal Brace Bolts 10 N.m 89 lb in
Brake Pedal Brace Nuts 10 N.m 89 lb in
Brake Pedal Bracket Nuts 5 N.m 44 lb in
Brake Pipe at Flexible Brake Hose Tube Nuts 21 N.m 15 lb ft
Brake Pipe at Master Cylinder to Proportion Valve 15 N.m 11 lb ft
Brake Pipe at Master Cylinder Tube Nuts 15 N.m 11 lb ft
Brake Pipe to Proportion Valve 21 N.m 15 lb ft
Master Cylinder Mounting Nuts 25 N.m 18 lb ft
BRAKE COMPONENT SPECIFICATIONS
Brake Component Specifications

Specification
Brake Caliper Bleeder Valve (Front) 13 N.m 115 lb in
Brake Caliper Bleeder Valve (Rear) 11 N.m 97 lb in
Drum Brake Wheel Cylinder Bleeder Valve 7 N.m 62 lb in
BRAKE SYSTEM SPECIFICATIONS
Brake System Specifications

Specification
Brake Pedal Maximum Travel
Specification with 445 N (100 lbs) of force applied to 74 mm 2.91 in

the brake pedal, the ignition OFF, and the brake
booster power reserve depleted.
BRAKE WARNING SYSTEM SCHEMATICS
Fig. 1: Brake Warning System

COMPONENT LOCATOR
HYDRAULIC BRAKES COMPONENT VIEWS
Fig. 2: Lower LF of the Passenger Compartment Component View
Callouts For Fig. 2

1 Park Brake Switch
2 I/P Wiring Harness
3 Park Brake Switch Connector
4 Parking Brake
Callouts For Fig. 3

HYDRAULIC BRAKES CONNECTOR END VIEWS
Brake Fluid Level Switch

12162195
2-Way F 150.2 SER (BK)

A BK 1550 Ground
B TN/WH 33 Brake Fluid Level Switch Signal
Park Brake Switch
12004267
1-Way F 56 Series Lock Type (BK)

A OG/BK 233 Park Brake Switch Signal

DIAGNOSTIC STARTING POINT - HYDRAULIC BRAKES
Begin the system diagnosis by reviewing the system Description and Operation. Reviewing the Description and
Operation information will help you determine the correct symptom diagnostic procedure when a malfunction
exists. Reviewing the Description and Operation information will also help you determine if the condition
described by the customer is normal operation. Refer to Symptoms - Hydraulic Brakes in order to identify the
correct procedure for diagnosing the system and where the procedure is located.
SCAN TOOL DATA LIST
Instrument Cluster (IPC)

Ignition ON, engine OFF, brake fluid level normal, and park brake released.
Inputs for Analog
Park Brake Switch Off/On Off
Dash
Brake Fluid Level
Scan tool displays: OK or Low. The status of the brake fluid level sensor signal.
Park Brake Switch
Scan tool displays: Off/On - Display indicates if the red BRAKE warning indicator is currently ON.
SYMPTOMS - HYDRAULIC BRAKES
1. Perform the Brake System Vehicle Road Test before using the hydraulic
brake symptom tables in order to duplicate the customer's concern.
system functions. Refer to the following:
Brake Warning System Description and Operation
Hydraulic Brake System Description and Operation
Brake Assist System Description and Operation
Disc Brake System Description and Operation in Disc Brakes

Inspect for aftermarket devices which could affect the operation of the Hydraulic Brake System. Refer to
cause the symptom.
Intermittent
Symptom List

Brake Pulsation
Brake Fluid Loss
Test Description
7: If the fuse in the jumper opens when you perform this test, the signal circuit of the brake fluid level
switch is shorted to voltage.

Step Action Yes No
Schematic Reference: Brake Warning System Schematics
Connector End Views Reference: Hydraulic Brakes Connector End Views, Instrument Panel,
Gages, and Console Connector End Views in Instrument Panel, Gages, and Console or

1 System Check -
Vehicle?
Vehicle in Vehicle
Inspect the brake fluid level. Go to Brake Fluid
2
Is the brake fluid level OK? Go to Step 3 Loss
2. Disengage the park brake.
3. With a scan tool, observe the Park Brake Switch
3 parameter in the BCM Inputs data list.
Does the scan tool indicate that the Park Brake Switch
parameter is Inactive? Go to Step 4 Go to Step 5
With a scan tool, observe the Brake Warning Lamp
parameter in the IPC Inputs data list.
4
Does the scan tool indicate that the Brake Warning
Lamp parameter is ON? Go to Step 12 Go to Step 6
1. Disconnect the park brake warning lamp switch.
2. With a scan tool, observe the Park Brake Switch
5 parameter.
Does the scan tool indicate that the Park Brake Switch
parameter is Inactive? Go to Step 9 Go to Step 7
1. Disconnect the brake fluid level switch.
2. With a scan tool, observe the Brake Warning
6 Lamp parameter.
Does the scan tool indicate that the Brake Warning

Lamp parameter is ON? Go to Step 10 Go to Step 8
2. Test the signal circuit of the park brake warning
lamp switch for a short to ground. Refer to
Systems.

2. Test the signal circuit of the brake fluid level
8 switch for a short to ground. Refer to Circuit

of the park brake warning lamp switch. Refer to
9
Systems.
of the brake fluid level switch. Refer to Testing for
of the Body Control Module. Refer to Testing for
Replace the park brake warning lamp switch. Refer to
13 Stop Lamp Switch Replacement in Park Brake.
Replace the brake fluid level switch. Refer to Master
14 Cylinder Fluid Level Sensor Replacement.
Replace the body control module (BCM). Refer to
Control Module References in Computer/Integrating
15
16
17

Step Action Yes No
Schematic Reference: Brake Warning System Schematics
Connector End Views Reference: Hydraulic Brakes Connector End Views, Instrument Panel,
Gages, and Console Connector End Views in Instrument Panel, Gages, and Console or

1 System Check -
Vehicle?
Vehicle in Vehicle
2. Observe the brake warning indicator.
2
Does the brake warning indicator illuminate briefly
during the bulb check? Go to Step 3 Go to Step 11
3 2. Apply the park brake.

2. Release park brake.
3. Disconnect the brake fluid level indicator switch.
4 4. Connect a 3-amp fused jumper wire between the
signal circuit of the brake fluid level indicator
switch and a good ground.

Inspect for poor connections or a poor ground at the
5 brake fluid level indicator switch.
Inspect brake fluid level indicator switch for proper Go to Testing for
operation. Intermittent
6 Does brake fluid level indicator switch work properly? Conditions and
Poor Connections
1. Disconnect the park brake warning lamp switch.
2. Connect a 3-amp fused jumper wire between the
7 signal circuit of the park brake warning lamp
switch and ground.

2. Disconnect the body control module (BCM).
3. Test the signal circuit of the park brake warning
8 lamp switch for a high resistance or an open.
Wiring Systems.

2. Disconnect the instrument panel cluster (IPC).
Test the signal circuit of the brake fluid level

9 indicator switch for a high resistance or an open.
Wiring Systems.

Inspect for poor connections or a poor case ground at
the park brake warning lamp switch. Refer to Testing
of the instrument cluster. Refer to Testing for
Replace the park brake warning lamp switch. Refer to
13 Stop Lamp Switch Replacement in Park Brake.
14
Replace the brake fluid level indicator switch. Refer to
15 Master Cylinder Fluid Level Sensor Replacement.
16
17
BRAKE PULSATION
Test Description
2: Suspension components that are not operating properly may cause a disturbance to the vehicle during
3: Antilock brake system operation could produce feedback through the brake pedal during application of
the brake system.
Brake Pulsation
Step Action Yes No
1 Symptom table? Starting Point -
Go to Step 2 Hydraulic Brakes
Inspect the suspension system for proper operation.
Refer to Diagnostic Starting Point - Suspension
2
General Diagnosis in Suspension General Diagnosis.
Inspect the antilock brake system for proper operation.
Refer to Diagnostic Starting Point - Antilock Brake
3
System in Antilock Brake System.
Inspect the disc brake system for proper operation.
4 Refer to Disc Brake System Diagnosis.
Inspect the drum brake system, if equipped, for proper
5 operation. Refer to Drum Brake System Diagnosis.
operation. Refer to Hydraulic Brake System Go to Diagnostic
6
Diagnosis. Starting Point -
Did you find and correct a condition? Go to Step 7 Hydraulic Brakes
7 operation. Refer to Brake System Vehicle Road Test.
BRAKE SYSTEM NOISE
Brake System Noise

Step Action Yes No
Inspect the brake assist system for proper operation.
4 Refer to Brake Assist System Diagnosis.
5
Diagnosis.
Is the vehicle equipped with a drum-in-rotor type of
6
park brake system? Go to Step 7 Go to Step 9
tightly, possibly causing a noise under certain
7
conditions.
excessive wear, blueing discoloration, heat spots,
and excessive radial runout.
8
3. If any of these conditions are present, replace the
affected components.

Inspect the park brake system for proper operation. Go to Diagnostic
9 Refer to Park Brake System Diagnosis in Park Brake. Starting Point -
BRAKING ACTION UNEVEN - PULLS TO ONE SIDE
Test Description
3: Steering components that are not operating properly may cause a disturbance to the vehicle during

Step Action Yes No
Were you sent here from the Hydraulic Brake
Go to Diagnostic
1
2
Inspect the steering system for proper operation. Refer
to Diagnostic Starting Point - Power Steering
3 System (w/o Electro-Hydraulic Steering) in Power
Steering System.
4
Diagnosis.
Inspect the drum brake system, if equipped, for proper Go to Diagnostic
6 operation. Refer to Drum Brake System Diagnosis. Starting Point -
BRAKING ACTION UNEVEN - FRONT TO REAR
Test Description
The number below refer to the step number on the diagnostic table:

Step Action Yes No
2
3 operation. Refer to Hydraulic Brake System
Diagnosis.
Inspect the brake assist system for proper operation. Go to Diagnostic
6 Refer to Brake Assist System Diagnosis. Starting Point -

Step Action Yes No
Were you sent here from the Hydraulic Brake Symptom Go to Diagnostic
1 Table? Starting Point -
Inspect for proper brake pedal travel. Refer to Brake
Pedal Travel Measurement and Inspection.
2
Is the brake pedal travel distance within the acceptable
limits? Go to Step 5 Go to Step 3
1. Inspect for worn, missing, misaligned, bent or
damaged brake pedal system components.
For the brake pedal pushrod component
inspection, refer to Brake Pedal Pushrod
Inspection .
excessive wear and/or damage and inspect
the brake pedal for a bent and/or damaged
condition.
3
2. Replace the brake pedal system components that
are worn, missing, misaligned, bent or damaged,
refer to the following procedure(s) as necessary.
Vacuum Brake Booster Replacement

(3.4L)Vacuum Brake Booster
Replacement (3.6L LY7) (for pedal
pushrod replacement)
Reinspect for proper brake pedal travel. Refer to Brake
4
Inspect the hydraulic brake system for proper operation.
5 Refer to Hydraulic Brake System Diagnosis.
Inspect the brake assist system for proper operation. Go to Diagnostic
8 Refer to Brake Assist System Diagnosis. Starting Point -
Road test the vehicle to confirm proper operation. Refer
9 to Brake System Vehicle Road Test.

Step Action Yes No
2 Refer to Brake Assist System Diagnosis.
3
Diagnosis.
Inspect the drum brake system, if equipped, for proper Go to Diagnostic
5 operation. Refer to Drum Brake System Diagnosis. Starting Point -
Road test the vehicle to confirm proper operation.
6 Refer to Brake System Vehicle Road Test.
BRAKES DRAG
Brakes Drag
Step Action Yes No
Is the vehicle equipped with an adjustable stop lamp
2 switch and/or an adjustable cruise control release
switch? Go to Step 3 Go to Step 4
1. Inspect the stop lamp switch for proper
adjustment to ensure that the brake pedal is fully
releasing.
3 2. Inspect the cruise control release switch, if
equipped, for proper adjustment to ensure that
the brake pedal is fully releasing.

Is the vehicle equipped with a drum-in-rotor type of
5
park brake system? Go to Step 6 Go to Step 8
6 tightly, possibly causing drag under certain conditions.
excessive wear, blueing discoloration, heat spots,
and excessive radial runout.
7
3. If any of these conditions are present, replace the
affected components.

Inspect the park brake system for proper operation.
8 Refer to Park Brake System Diagnosis in Park Brake.
1. Separate the brake booster pushrod from the
brake pedal.
2. Inspect the brake corners to determine if the
10 brake drag condition is still present.

Replace the brake pedal assembly.
11 -
1. Separate the master cylinder from the brake
booster. Do not disconnect any brake pipes.
2. Inspect the brake corners to determine if the
12 brake drag condition is still present.

Replace the brake booster assembly.
13 -
operation. Refer to Hydraulic Brake System Go to Diagnostic
14
Diagnosis. Starting Point -
1. Install or connect components that were removed
or disconnected during diagnosis.
2. Road test the vehicle in order to confirm proper
15 operation. Refer to Brake System Vehicle Road
Test.

Step Action Yes No
2
Diagnosis.
Refer to Brake Assist System Diagnosis.
3
Inspect the disc brake system for proper operation. Go to Diagnostic
5 Refer to Disc Brake System Diagnosis. Starting Point -
Road test the vehicle to confirm proper operation.
BRAKE FLUID LOSS
Brake Fluid Loss

Step Action Yes No
Were you sent here from the Hydraulic Brake Symptom Go to Diagnostic
1 table? Starting Point -
Inspect the hydraulic brake system for proper operation.
2 Refer to Hydraulic Brake System Diagnosis.
1. Separate the master cylinder from the vacuum
brake booster. Do not disconnect any brake
pipes. Refer to Master Cylinder Replacement.
2. Inspect the rear of the master cylinder for a brake
5 fluid leak.
3. Inspect for brake fluid in the vacuum brake
booster. Go to Diagnostic
Starting Point -
Did you find a brake fluid leak? Go to Step 6 Hydraulic Brakes
Replace the brake master cylinder and the vacuum
brake booster. Refer to Master Cylinder Replacement
6 and Vacuum Brake Booster Replacement (3.4L) or -
Vacuum Brake Booster Replacement (3.6L LY7).
1. Install or connect components that were removed

or disconnected during diagnosis.
2. Road test the vehicle to confirm proper operation.
DISC BRAKE SYSTEM DIAGNOSIS
Test Description
9: Lubricant leaks from non-brake system components may come in contact with and contaminate brake
system components.
10: Lubricant leaks from non-brake system components may come in contact with and contaminate brake
system components.
13: Disc brake rotor thickness variation that exceeds the maximum acceptable level can cause brake
pulsation.
17: Disc brake rotor thickness variation that exceeds the maximum acceptable level can cause brake
pulsation.
20: Disc brake rotor assembled lateral runout (LRO) that exceeds the maximum acceptable level can lead
to thickness variation.
Disc Brake System Diagnosis

Step Action Yes No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the DISC brake
system in order to determine if the DISC brake system is operating properly. You will be directed by the
appropriate Symptom table to go to other brake system diagnostic tables as appropriate.
Were you sent here from a Brake Symptom table? Go to Diagnostic
1 Starting Point -
Visually inspect the disc brake pads for the following
conditions:
Refer to Brake Pad Inspection in Disc Brakes.

Uneven and/or abnormal wear - edge-to-edge
2 and/or side-to-side
Looseness or damage - including pad hardware
Evidence of contamination from an external
substance
Did you find any conditions to indicate a concern with
any of the front and/or rear disc brake pads? Go to Step 3 Go to Step 12
3
contaminated? Go to Step 8 Go to Step 4
Are any of the front and/or rear disc brake pads worn
4
unevenly? Go to Step 7 Go to Step 5
Are any of the front and/or rear disc brake pads and/or
5
pad hardware loose or damaged? Go to Step 7 Go to Step 6
1. Remove and inspect the worn disc brake pads for
glazing, looseness, heat spots or damage.
2. Replace the worn disc brake pads as a complete
6 axle set. Refer to Brake Pads Replacement - -
Front and/or Brake Pads Replacement - Rear ,
if equipped, in Disc Brakes.
Did you complete the inspection and replacement? Go to Step 12

NOTE:
to support the caliper in this manner will cause
the flexible brake hose to bear the weight of
the caliper, which may cause damage to the
brake hose and in turn may cause a brake fluid
leak.
IMPORTANT:
7 -
1. Remove the front and/or rear disc brake calipers,
as appropriate, from the mounting brackets and
support the calipers. Refer to Brake Caliper
Replacement - Front and/or Brake Caliper
Brakes.
2. Inspect the disc brake caliper mounting bracket
and the mounting/sliding hardware for the
Refer to Disc Brake Mounting and Hardware

Inspection - Front and/or Disc Brake
Mounting and Hardware Inspection - Rear , if
equipped, in Disc Brakes.
Worn, damaged or missing hardware
components
Loose, bent, cracked, or damaged caliper
mounting bracket
3. Replace components as required. Refer to the
following procedures in Disc Brakes, as required:
Brake Caliper Bracket Replacement -
Front
Brake Caliper Bracket Replacement -
Rear , if equipped
Front
Rear , if equipped
4. Replace the unevenly-worn, loose or damaged
disc brake pads as a complete axle set. Refer to
Brake Pads Replacement - Front and/or Brake
Pads Replacement - Rear , if equipped, in Disc
Brakes.

1. Inspect the disc brake calipers, brake hoses and
brake pipes for evidence of an external brake
fluid leak.
2. Replace any components found to be leaking
brake fluid. Refer to the following procedures as
required:
Disc Brakes
Brake Caliper Overhaul - Rear or Brake
8
Caliper Replacement - Rear , if
Brake Hose Replacement - Rear (Disc

Brake)Brake Hose Replacement - Rear
(Drum Brake)
Did you find and correct the source of the leak causing
contamination of the pads? Go to Step 11 Go to Step 9
1. Inspect the wheel drive shaft outer seals for
damage and evidence of a grease leak.
2. Replace any wheel drive shaft seal that is found
to be leaking grease which may be the source of
the contamination to the pads. Refer to Wheel
9 Drive Shaft Outer Joint and Seal Replacement
- Front and/or Wheel Drive Shaft Outer Joint
and Seal Replacement - Rear in Wheel Drive
Shafts.
contamination of the pads? Go to Step 11 Go to Step 10
1. Inspect the automatic transmission cooling
system lines, if equipped, for damage and
evidence of an external fluid leak which may be
the source of the contamination to the pads.
2. Inspect the power steering system hoses for
damage and evidence of an external fluid leak
10 which may be the source of the contamination to -
the pads.
3. Replace any components found to be leaking
fluid which may be the source of the
contamination to the pads.
contamination of the pads? Go to Step 11
1. Clean the remaining disc brake system
contaminant.
NOTE:
to support the caliper in this manner will cause
the flexible brake hose to bear the weight of
the caliper, which may cause damage to the
brake hose and in turn may cause a brake fluid
leak.
IMPORTANT:
2. Remove the front and/or rear disc brake calipers,
as appropriate, from the mounting brackets and
support the calipers. Refer to Brake Caliper
Replacement - Front and/or Brake Caliper
Brakes.
3. Inspect the disc brake caliper mounting/sliding
hardware for the following conditions:
Refer to Disc Brake Mounting and Hardware

Inspection - Front and/or Disc Brake
Mounting and Hardware Inspection - Rear , if

11 -
Distorted, worn, damaged or missing
hardware components
4. Replace the caliper mounting/sliding hardware
components as required. Refer to Disc Brake
Hardware Replacement - Front and/or Disc
Brake Hardware Replacement - Rear , if
5. Replace the contaminated disc brake pads as a
complete axle set. Refer to Brake Pads
Replacement - Front and/or Brake Pads
Brakes.

1. Check the thickness of each of the disc brake
rotors.
IMPORTANT:
EACH rotor.
12
2. Make a determination for each brake rotor if the
rotor can be REFINISHED and REMAIN
ABOVE the minimum requirements.
Refer to Brake Rotor Thickness Measurement in

Disc Brakes.Does the disc brake rotor meet the
minimum requirements for REFINISHING? Go to Step 13 Go to Step 16
IMPORTANT:
13 Inspect each of the disc brake rotors for thickness

variation that exceeds the maximum acceptable level.
Refer to Brake Rotor Thickness Variation
Measurement in Disc Brakes.Does the brake rotor
exhibit thickness variation that exceeds the maximum
acceptable level? Go to Step 15 Go to Step 14
1. Inspect each of the disc brake rotors for the


14
IMPORTANT:
EACH rotor.

rotor requires refinishing based upon the results
of the inspection.
If the brake rotor exhibits any of the conditions

listed previously, it requires refinishing.
Does the brake rotor require REFINISHING? Go to Step 15 Go to Step 20

1. Refinish the brake rotor. Refer to Brake Rotor
Refinishing in Disc Brakes.
2. Inspect the brake rotor thickness. Refer to Brake
15 Rotor Thickness Measurement in Disc Brakes.
Were you able to REFINISH the brake rotor within the

minimum requirements? Go to Step 20 Go to Step 19
Is the brake rotor at or below the DISCARD
16
IMPORTANT:
17 Inspect each of the disc brake rotors for thickness

variation that exceeds the maximum acceptable level.
Refer to Brake Rotor Thickness Variation
Measurement in Disc Brakes.Does the brake rotor
exhibit thickness variation that exceeds the maximum
acceptable level? Go to Step 19 Go to Step 18
1. Inspect each of the disc brake rotors for the


18
IMPORTANT:
EACH rotor.

rotor requires replacement based upon the results
of the inspection.
If the brake rotor exhibits any of the conditions

listed previously, it requires replacement.
Does the brake rotor require REPLACEMENT? Go to Step 19 Go to Step 20

IMPORTANT:
Whenever a brake rotor is replaced, the assembled
lateral runout (LRO) of the rotor must be measured
to ensure optimum performance of the disc brakes.
19 -
Replace the brake rotor. Refer to Brake Rotor
Replacement - Front or Brake Rotor Replacement -
Rear , if equipped, in Disc Brakes.Did you complete
the replacement? Go to Step 22
IMPORTANT:
Inspect each of the disc brake rotors for assembled

20 lateral runout (LRO) that exceeds the maximum
acceptable level. Refer to Brake Rotor Assembled
Lateral Runout (LRO) Measurement in Disc
Brakes.Does the brake rotor exhibit assembled LRO
that exceeds the maximum acceptable level? Go to Step 21 Go to Step 22
Correct the LRO for each brake rotor that was
determined to have LRO exceeding the maximum
21 acceptable level. Refer to Brake Rotor Assembled -
Lateral Runout (LRO) Correction in Disc Brakes.
Did you complete the operation? Go to Step 22
Install or connect components that were removed or Disc Brake System
disconnected during diagnosis. OK
22 -
Did you complete the operation? Return to Symptom
Table
DRUM BRAKE SYSTEM DIAGNOSIS
Test Description
The number below refers to the step number on the diagnostic table:
18: Drum brake backing plates that come in contact with brake drums may cause brake system noise.
Drum Brake System Diagnosis

Step Action Yes No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the DRUM brake
system in order to determine if the DRUM brake system is operating properly. You will be directed by
the appropriate Symptom table to go to other brake system diagnostic tables as appropriate.
1 Starting Point -
1. Remove the brake drums. Refer to Brake Drum
Replacement in Drum Brakes.
2. Inspect the drum brake shoes for the following
conditions:
2
Uneven and/or abnormal wear - edge-to-
edge and/or side-to-side
Contamination from an external substance
Looseness, damage, glazing, or incorrect

lining material
Did you find any conditions to indicate a concern with

any of the drum brake shoes? Go to Step 3 Go to Step 7
3 Are any of the brake shoes contaminated? Go to Step 4 Go to Step 5
1. Inspect the wheel cylinders for evidence of an
external brake fluid leak.
2. Replace any wheel cylinder that is found to be
4 leaking brake fluid. Refer to Wheel Cylinder -

discolored due to stress, broken or missing. Refer
to Drum Brake Hardware Inspection in Drum
Brakes.
5 2. Replace components as required. Refer to Drum -
Brake Hardware Replacement in Drum Brakes.
3. Replace the drum brake shoes. Refer to Brake
Shoe Replacement in Drum Brakes.

1. Clean the remaining drum brake system
contaminant.
Brakes.
6 -
3. Replace the drum brake hardware components as
required. Refer to Drum Brake Hardware
4. Replace the contaminated brake shoes. Refer to
Brake Shoe Replacement in Drum Brakes.

Brakes.
2. Replace components as required. Refer to Drum
7 Brake Hardware Replacement in Drum Brakes. -
Did you complete the inspection and, if necessary, the
1. Check the diameter of each of the brake drums.
IMPORTANT:
EACH drum.
8
2. Make a determination for each brake drum if the
drum can be REFINISHED and REMAIN
ABOVE the minimum requirements.
Refer to Brake Drum Diameter Measurement in

Drum Brakes.Does the brake drum meet the minimum
requirements for REFINISHING? Go to Step 9 Go to Step 11
1. Inspect each of the brake drums for the following
surface and wear conditions:


9 Braking Surface Wear Conditions

acceptable level
IMPORTANT:
EACH drum.

drum requires refinishing based upon the results
of the inspection.
If the brake drum exhibits any of the following

conditions, it requires refinishing.
Drum exhibits one or more of the Braking

Surface Conditions listed previously
Drum is beyond the acceptable level in one
or more of the Braking Surface Wear
Conditions listed previously
Does the brake drum require REFINISHING? Go to Step 10 Go to Step 14

1. Refinish the brake drum. Refer to Brake Drum
Refinishing in Drum Brakes.
2. Inspect the brake drum diameter. Refer to Brake
10 Drum Diameter Measurement in Drum Brakes.
Were you able to REFINISH the brake drum within the

minimum requirements? Go to Step 14 Go to Step 13
Is the brake drum at or below the DISCARD
11
1. Inspect each of the brake drums for the following
surface and wear conditions:


12 Missing balance weights

acceptable level
IMPORTANT:
EACH drum.
drum requires replacement based upon the results
of the inspection.
If a brake drum exhibits any of the following

conditions, it requires replacement.
Drum exhibits one or more of the Braking

Surface Conditions listed previously
Drum is beyond the acceptable level in one
or more of the Braking Surface Wear
Conditions listed previously
Does the brake drum require REPLACEMENT? Go to Step 13 Go to Step 14

Replace the brake drum. Refer to Brake Drum
13 Replacement in Drum Brakes. -
Inspect the brake shoes for proper adjustment. Refer to
14 Drum Brake Adjustment in Drum Brakes.
Are the brake shoes adjusted properly? Go to Step 18 Go to Step 15
Inspect the components of the brake drum adjustment
hardware system for free movement and correct
operation. Refer to Drum Brake Adjusting Hardware
15
Do the drum brake adjusting hardware components
operate freely and correctly? Go to Step 17 Go to Step 16
Replace the drum brake adjusting hardware components
as necessary. Refer to Drum Brake Adjusting
16 -
Hardware Replacement in Drum Brakes.
Adjust the drum brake shoes. Refer to Drum Brake
17 Adjustment in Drum Brakes. Return to Symptom
Were you able to complete the adjustment? Go to Step 20 Table
Inspect the drum brake backing plate for the following:
Excessive wear or rust

Damage and/or evidence of contact with the
18 brake drum
Does the drum brake backing plate exhibit any of these

conditions? Go to Step 19 Go to Step 20
Repair or replace the drum brake backing plate as
19 necessary. Refer to Drum Brake Backing Plate -
Did you complete the repair or replacement? Go to Step 20
Install or connect components that were removed or Drum Brake
disconnected during diagnosis. System OK
20 -
Table
HYDRAULIC BRAKE SYSTEM DIAGNOSIS
Hydraulic Brake System Diagnosis

Step Action Yes No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the HYDRAULIC
brake system in order to determine if the HYDRAULIC brake system is operating properly. You will be
directed by the appropriate Symptom table to go to other brake system diagnostic tables as appropriate.
1 Starting Point -
Inspect and adjust the brake fluid level in the brake
master cylinder. Refer to Master Cylinder Reservoir
2
Filling.
Was the brake fluid level low? Go to Step 3 Go to Step 4
conditions, indicating brake fluid contamination:
Fluid separation, indicating two types of
fluid are present
substance
Layered appearance - silicone-based
substance
Fluid discoloration
3
Dark appearance/ suspended particles

in fluid - dirt, rust, corrosion, brake
dust
diaphragm and the reservoir-to-master cylinder
grommets for swelling, indicating fluid
contamination.

conditions, indicating brake fluid contamination:
Fluid separation, indicating two types of
fluid are present
substance
Layered appearance - silicone-based
substance
Fluid discoloration
Dark appearance/ suspended particles

4
in fluid - dirt, rust, corrosion, brake
dust
diaphragm and the reservoir-to-master cylinder
grommets for swelling, indicating fluid
contamination.

1. Flush the hydraulic brake system. Refer to
Hydraulic Brake System Flushing.
2. If the brake fluid WAS contaminated with an oil-
based or a silicone-based fluid, indicated by fluid
separation and/or a swollen master cylinder
reservoir cap diaphragm and/or swollen reservoir-
to-master cylinder grommets, perform the
following steps. Refer to the procedures
indicated.
1. Remove ALL of the following components
listed. Each component contains internal
rubber seals/linings which have been
contaminated.
2. Clean out the hydraulic brake pipes using
3. Dry the brake pipes using non-lubricated,
filtered air.
4. Repair or replace ALL of the following
components listed. Each component
contains internal rubber seals/linings which
have been contaminated.
Brake master cylinder reservoir:
Clean the brake master cylinder
reservoir using denatured alcohol, or
equivalent, then dry the reservoir
using non-lubricated, filtered air, or
if necessary, replace the brake master
cylinder reservoir.
Replace the brake master cylinder
reservoir cap diaphragm.

(Disc Brake)Brake Hose
Replacement - Rear (Drum Brake)
Front in Disc Brakes
5 equipped, in Drum Brakes -

(BPMV) Replacement in Antilock
Brake System
3. If the brake fluid was NOT contaminated with an
oil-based fluid, but WAS contaminated with
water or dirt, rust, corrosion, and/or brake dust,
replace the brake master cylinder reservoir cap
diaphragm which may have allowed moisture or
dirt to enter the system.
4. Refill and bleed the hydraulic brake system.
Refer to Hydraulic Brake System Bleeding
(Manual) or Hydraulic Brake System Bleeding
(Pressure).
Did you complete the operation and any required

repairs and/or replacements? Go to Step 9
1. Inspect the following hydraulic brake system
components for external fluid leaks. Repair or
replace any of the components found to be
leaking brake fluid. Refer to the appropriate
procedures:
Master Cylinder Overhaul or Master
Cylinder Replacement
Brake master cylinder reservoir cap

diaphragm

Brake Hose Replacement - Rear (Disc
(Drum Brake)

Disc Brakes
Caliper Replacement - Rear , if equipped,
in Disc Brakes
(BPMV) Replacement in Antilock Brake
System
6
2. If you repaired or replaced any of the brake
system components listed, bleed the hydraulic
brake system. Refer to Hydraulic Brake System
Bleeding (Manual) or Hydraulic Brake System
Bleeding (Pressure). While bleeding the
hydraulic brake system, observe for the following
conditions:
The presence of air in the system at a
bleeder valve location other than at the
repair location, except if the brake master
cylinder was replaced
An unrestricted and even flow of brake
fluid per axle during the bleeding
procedure

Was there air in the system at a bleeder valve location
7 other than at the repair location, except if the brake
master cylinder was replaced? Go to Step 19 Go to Step 8
Was the flow of brake fluid unrestricted and even per
8
axle during the bleeding procedure? Go to Step 9 Go to Step 10
calipers/wheel cylinders for proper operation. Refer to
Hydraulic Brake Component Operation Visual
9
Inspection.
Was the hydraulic function of the brake calipers/wheel
cylinders operating properly? Go to Step 21 Go to Step 14
Was the flow of brake fluid restricted or uneven through
10 front axle hydraulic components during the bleeding
procedure? Go to Step 13 Go to Step 11
Was the flow of brake fluid restricted or uneven through
11 rear axle hydraulic components during the bleeding -
procedure? Go to Step 17
calipers/wheel cylinders for proper operation. Refer to
Hydraulic Brake Component Operation Visual
12
Inspection.
Was the hydraulic function of the brake calipers/wheel
cylinders operating properly? Go to Step 15 Go to Step 13
Determine if the brake caliper is restricting the flow of
brake fluid and/or not operating properly:
1. Raise and support the vehicle. Refer to Lifting

and Jacking the Vehicle in General Information.
2. Remove the tire and wheel assemblies. Refer to
Tire and Wheel Removal and Installation in
Tires and Wheels.
3. Open the suspected caliper bleeder valve.
13
4. Using a large C-clamp, compress the caliper
piston and observe for an unrestricted flow of
brake fluid and for free movement of the caliper
piston.
5. Close the caliper bleeder valve.
Was the flow of brake fluid unrestricted and did the

caliper piston move freely? Go to Step 17 Go to Step 14
Repair or replace any brake caliper/wheel cylinder that
was not operating properly. Refer to the appropriate
procedure.
Brake Caliper Overhaul - Front or Brake

Caliper Replacement - Front in Disc Brakes
14 -
Caliper Replacement - Rear , if equipped, in
Disc Brakes
Wheel Cylinder Replacement , if equipped, in
Drum Brakes
Did you complete the repair and/or replacement? Go to Step 21

Bleed the hydraulic brake system to observe for the
presence of air in the system and to observe for an
unrestricted and even flow of brake fluid per axle
during the bleeding procedure. Refer to Hydraulic
Brake System Bleeding (Manual) or Hydraulic
15
Was there air in the system? Go to Step 19 Go to Step 16
Was the flow of brake fluid unrestricted and even per
16
axle during the bleeding procedure? Go to Step 21 Go to Step 17
1. Inspect the hydraulic brake pipes and flexible
brake hoses for signs of a fluid restriction; such as
being bent, kinked, pinched or damaged. Refer to
Brake Pipe and Hose Inspection.
2. Replace any of the hydraulic brake pipes and/or
flexible brake hoses found to be bent, kinked,
pinched, or damaged. Refer to the following
procedures as necessary:
17 Brake Hose Replacement - Rear (Disc
(Drum Brake)
3. If none of the hydraulic brake pipes or flexible

brake hoses were visibly bent, kinked, pinched, or
damaged, replace the hydraulic brake flex hose at
the restricted location.

Replace the brake pressure modulator valve (BPMV), in
order to correct the hydraulic brake dynamic rear
proportioning mechanical operation. Refer to Brake
18 -
Pressure Modulator Valve (BPMV) Replacement in
Antilock Brake System.
1. Inspect the hydraulic brake system components
for brake fluid seepage at a seal and/or fitting
location, which may have drawn air into the
system.
2. Inspect the hydraulic brake system components
19 for evidence of a recent repair, which may have
introduced air into the system.
3. Repair or replace any of the components found to
be installed incorrectly or seeping brake fluid.

1. Inspect the brake master cylinder for internal
fluid leaks. Refer to Brake System Internal
Leak Test.
2. Repair or replace the brake master cylinder if it is
found to be leaking brake fluid internally. Refer
20 to Master Cylinder Overhaul or Master
Return to Symptom
Did you find and correct a condition? Go to Step 21 Table
Install or connect components that were removed or Hydraulic Brake
disconnected during diagnosis. System OK
21 -
Table
BRAKE ASSIST SYSTEM DIAGNOSIS
Brake Assist System Diagnosis

Step Action Yes No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the brake ASSIST
system in order to determine if the brake ASSIST system is operating properly. You will be directed by
the appropriate Symptom Table to go to other brake system diagnostic tables as appropriate.
Were you sent here from a Brake Symptom Table? Go to Diagnostic
1 Starting Point -
Inspect for proper brake pedal travel. Refer to Brake
2
1. Inspect for worn, missing, misaligned, bent or
damaged brake pedal system components.
For the brake pedal pushrod component
inspection, refer to Brake Pedal Pushrod
Inspection .
excessive wear and/or damage and inspect
the brake pedal for a misaligned, bent
and/or damaged condition.
3
2. Replace the brake pedal system components that
are worn, missing, misaligned, bent or damaged,
refer to the following procedures as necessary.
Vacuum Brake Booster Replacement

(3.4L)Vacuum Brake Booster
Replacement (3.6L LY7) (for a bent or
damaged pedal pushrod replacement)
Reinspect for proper brake pedal travel. Refer to Brake
4
Check the engine vacuum source that supplies vacuum Go to Diagnostic
to the vacuum brake booster. Refer to Brake System Starting Point -
5 Vacuum Source Test. Engine Mechanical
Is the vacuum reading within the acceptable limits? in Engine
Go to Step 6 Mechanical - 3.4L
During the vacuum source inspection, did the vacuum
6
booster check valve operate properly? Go to Step 8 Go to Step 7
Replace the vacuum booster check valve. Refer to
Vacuum Brake Booster Check Valve and/or Hose
7 -
Replacement.
1. Pump the brake pedal several times until the
brake pedal becomes hard.
2. Maintain moderate foot pressure on the brake
8 pedal and start the engine. Observe pedal
operation.
Did the brake pedal drop slightly, then remain firm

after the engine was started? Go to Step 9 Go to Step 12
1. Release the brake pedal.
2. Turn the ignition OFF, then wait 15 seconds.
3. Pump the brake pedal two times to check for
vacuum booster available vacuum reserve.
Observe pedal effort.
9
(If operating properly, the vacuum brake booster
should maintain assist for at least two pedal
applications.)
Did the brake pedal effort increase significantly? Go to Step 12 Go to Step 10

Inspect the brake pedal pushrod and the brake pedal for
misalignment, a bent condition and/or damage.
10
Is the brake pedal pushrod and/or the brake pedal
misaligned, bent or damaged? Go to Step 11 Go to Step 13
Replace the brake pedal pushrod and/or the brake
pedal, as necessary. Refer to the following procedure
(s).
Vacuum Brake Booster Replacement (3.4L) or
Vacuum Brake Booster Replacement (3.6L
11 LY7) (for a bent or damaged pedal pushrod -
replacement)

Replace the vacuum brake booster. Refer to Vacuum
Brake Booster Replacement (3.4L) or Vacuum
12 -
Brake Booster Replacement (3.6L LY7).
Install or connect any components that were removed Brake Assist
or disconnected during diagnosis. System OK
13 -
Table
BRAKE SYSTEM VEHICLE ROAD TEST
1. Visually inspect easily accessible brake system components for obvious damage and/or leaks which may
indicate that the vehicle should not be driven until further inspections have been completed.
2. Inspect the brake master cylinder reservoir fluid level and adjust only if necessary for brake system road
testing. Refer to Master Cylinder Reservoir Filling.
4. Inspect the tire tread patterns to ensure that they are the same or very similar, especially per axle.
Road Testing Procedure
CAUTION: Road test a vehicle under safe conditions and while obeying all traffic

3. If the brake system warning lamp remains illuminated, DO NOT proceed to test drive the vehicle until it
is diagnosed and repaired. Refer to Symptoms - Hydraulic Brakes.
4. Select a smooth, dry, clean and level road or large lot that is as free of traffic and obstacles as possible for
brake system low speed road testing.
5. With the transmission in PARK, lightly apply the brake pedal. Observe both the pedal feel and the pedal
travel.
6. If the brake pedal apply felt spongy, or the pedal travel was excessive, DO NOT drive the vehicle until it
is repaired.
7. If the brake pedal apply did not feel spongy and the pedal travel was not excessive, proceed to step 8.
9. While continuing to apply the brakes, shift the transmission into DRIVE, release the brakes and allow the
engine to idle the vehicle away from the stopped position. Observe for a slow release of the brake system.
10. With the aid of an assistant to observe the vehicle's performance from outside of the vehicle, drive the
vehicle at a low speed and lightly apply the brakes while driving past the assistant. Have the assistant
observe for brake system noise from the side of the vehicle closest to them, while you observe both the
pedal effort and the pedal travel.
12. If the brake pedal apply effort was not excessive and the pedal travel was not excessive, proceed to step
13.
13. Drive the vehicle in the opposite direction, at the same low speed and lightly apply the brakes while
driving past the assistant. Have the assistant observe for brake system noise from the side of the vehicle
closest to him.
14. Drive the vehicle at a low speed and shift the transmission into NEUTRAL without applying the brakes.
Observe for a rapid deceleration in vehicle speed, indicating possible brake drag.
15. Select a smooth, dry, clean and level road that is as free of heavy traffic as possible for brake system
moderate speed road testing.
16. Drive the vehicle at a moderate speed. Observe for a pull and/or incorrect tracking of the vehicle without
the brakes applied.
17. While continuing to drive the vehicle at a moderate speed, perform several light applies of the brakes.
Observe the pedal effort and the pedal travel, observe for brake system noise, pulsation and/or brake drag.
19. If the brake pedal apply effort was not excessive and the pedal travel was not excessive, proceed to step
20.
20. While continuing to drive the vehicle at a moderate speed, perform several moderate applies of the
brakes. Observe the pedal effort and the pedal travel, observe for brake system pulsation and/or uneven
braking action - either side to side, or front to rear.
A small amount of vehicle front end dip is expected during a moderate apply of the brakes.
BRAKE PEDAL TRAVEL MEASUREMENT AND INSPECTION
Tools Required
J 28662 Brake Pedal Effort Gauge. See Special Tools.

1. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes
firm, in order to deplete the brake booster power reserve.
2. Install the J 28662 to the brake pedal. See Special Tools.

3. Measure and record the distance (1) from the brake pedal to the rim of the steering wheel; note the points
of measurement.
4. Apply and maintain the brakes with 445 N (100 lb) of force to the brake pedal, as indicated on the J
28662 . See Special Tools.
5. While maintaining 445 N (100 lb) of force to the brake pedal, measure and record the distance (2) from
the same point on the brake pedal to the same point on the rim of the steering wheel.
6. Release the brakes and repeat steps 4 and 5 to obtain a second measurement. After obtaining a second
measurement, proceed to step 7.
7. Average the first and second measurements recorded during the two applies of the brakes.
8. Subtract the initial measurement, unapplied (1), from the averaged, applied measurement (2) to obtain the
brake pedal travel distance.
Specification: Maximum brake pedal travel (measured with the ignition OFF, brake booster power assist
depleted, and the brakes cool): 74 mm (2.91 in).
BRAKE SYSTEM VACUUM SOURCE TEST
4. Check to see if the engine vacuum reading is within the specified normal engine vacuum range.

6. If the engine vacuum reading is within the specified normal range, proceed to step 10.
7. If the engine vacuum reading is NOT within the specified normal range, inspect the engine vacuum hose
for the following conditions.
Tight connection to the engine
Collapse, deformation or contamination
8. If any of these conditions were found with the engine vacuum hose, replace the hose, then repeat steps 2-
4.
9. If none of these conditions were found with the engine vacuum hose, then there is an engine vacuum
source problem, check the engine vacuum system.
15. Check to see if the engine vacuum reading is maintained within the specified normal engine vacuum
range.
16. If the engine vacuum reading is maintained within the specified normal range, proceed to step 18.
17. If the engine vacuum reading is NOT maintained within the specified normal range, replace the brake
booster check valve then repeat steps 11-15
Firm connection to the vacuum brake booster
Deformation or contamination
BRAKE SYSTEM EXTERNAL LEAK INSPECTION
1. In order to inspect for external brake fluid leaks, first check the fluid level in the master cylinder.
While a slight brake fluid level drop can be considered a normal condition due to brake lining wear, a
very low level may indicate a brake fluid leak in the hydraulic system.
2. If the fluid level is abnormally low, adjust the brake fluid level. Refer to Master Cylinder Reservoir
Filling.
4. Apply constant, moderate foot pressure to the brake pedal.
If the brake pedal gradually falls away while under foot pressure, there may be a brake fluid leak.

6. Visually inspect the following brake system components for brake fluid leaks, excessive corrosion, and
damage. Give particular attention to all brake pipe and flexible hose connections to ensure that there are
not any slight brake fluid leaks - even though the brake pedal may feel firm and hold steady:
Master cylinder brake pipe fittings
All brake pipe connections
Brake pipes
Brake hoses and connections
Brake calipers and/or wheel cylinders, if equipped
7. While slight dampness around the master cylinder reservoir can be considered acceptable, brake fluid
leaking from any of the brake system components requires immediate attention. If any of these
components exhibit signs of brake fluid leakage, repair or replace those components. After the repair or
replacement, reinspect the hydraulic brake system to assure proper function.
BRAKE SYSTEM INTERNAL LEAK TEST


2. Apply light, steady pressure to the brake pedal. Observe both the brake pedal feel and travel.
4. If the brake pedal apply felt spongy, but the brake pedal travel was not excessive, perform the following
steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection .
2. Pressure bleed the brake system in order to purge any air that may be trapped in the system. Refer
to Hydraulic Brake System Bleeding (Manual)Hydraulic Brake System Bleeding (Pressure) .
5. If the brake pedal apply did not feel spongy, but the brake pedal travel was excessive, perform the
following steps:
1. Loosen the master cylinder-to-brake power booster mounting nuts.
2. Carefully pull the master cylinder away from the brake power booster just enough to inspect the
mounting surface of the master cylinder.
3. Inspect the master cylinder mounting surface at the primary piston (2) for brake fluid leaks.
6. If the master cylinder exhibits any leakage around the primary piston (2), then the primary piston primary
seal (4) and/or secondary seal (3) is leaking and the master cylinder requires overhaul or replacement.
7. If the master cylinder primary piston (2) does not exhibit any leakage, pressure bleed the brake system.
Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System Bleeding
(Pressure).
excessive, but then gradually fell, then the master cylinder requires overhaul or replacement due to an
internal leak past the secondary piston (1) from the secondary piston primary seal (6) or secondary seal
(5).
excessive, then fell slightly, then became steady again, then the brake pressure modulator valve (BPMV)
may be leaking internally, and may require replacement.
HYDRAULIC BRAKE COMPONENT OPERATION VISUAL INSPECTION
Disc Brake
Fig. 6: Identifying Brake Caliper/Pad Inspection Areas
1. With the tire and wheel assemblies removed and the brake rotors retained by wheel lug nuts, visually
inspect the caliper piston dust boot (2) sealing area to ensure that there are no brake fluid leaks.
2. If any evidence of a brake fluid leak is present, the brake caliper requires overhaul or replacement.
3. While the brake system is at rest (4), observe the position of the caliper piston (1) in relation to the caliper
housing.
4. Have an assistant apply and release the brake pedal several times while you observe the operation of the
hydraulic brake caliper.
1. Observe the caliper piston (1) for unrestricted and even movement during each apply of the brake
system (5).
2. Observe the caliper piston (1) for an unrestricted and even return motion during each release of the
brake system (6).
5. If the caliper piston (1) did not exhibit unrestricted and even movement during brake system apply and/or
release, the piston square seal (3) may be worn or damaged and the caliper may require overhaul or
replacement.
Drum Brake
Fig. 7: Identifying Areas To Press To Compress Wheel Cylinder Pistons
1. With the rear tire and wheel assemblies and the brake drums removed, visually inspect the wheel cylinder
pistons boot sealing areas to ensure that there are no brake fluid leaks.
2. If any evidence of a brake fluid leak is present, the brake wheel cylinder requires replacement.
3. Using firm hand pressure, simultaneously and evenly apply force on both brake shoes in order to
compress the wheel cylinder pistons into their bore.
5. If one or both of the wheel cylinder pistons did not exhibit unrestricted and even movement during apply
and/or release of force, the wheel cylinder may require replacement.
BRAKE PIPE AND HOSE INSPECTION
Kinks, improper routing, missing or damaged retainers
Leaking fittings, excessive corrosion
2. If any of the brake pipes exhibited any of the conditions listed, then the identified pipe, or pipes, require
replacement.
3. Ensure that the vehicle axles are properly supported at ride height in order to maintain the proper
relationship of the flexible brake hoses to the chassis.
Fig. 8: Identifying Flexible Brake Hose Failure Conditions
Kinks (1), improper routing, twists, chafing, missing or damaged retainers
Leaking connections, cracking, dry-rot, blisters, bulges
5. If any of the flexible brake hoses exhibited any of the conditions listed, then the identified flexible brake
hose, or hoses require replacement.
6. Squeeze the flexible brake hoses with firm finger pressure to check for soft spots (2), indicating an
internal restriction. Check the entire length of each flexible brake hose.
7. If any of the flexible brake hoses were found to have soft spots (2), then the identified flexible brake hose,
or hoses require replacement.
BRAKE PEDAL PUSHROD INSPECTION
Fig. 9: View of Brake Pedal Pushrod

1. Disconnect the brake pedal pushrod (1) from the brake pedal.
2. Inspect the brake pedal pushrod eyelet bushing (2), if equipped, for cracks and/or excessive wear.
3. Reposition the pedal pushrod boot (3) toward the front of the vehicle to expose as much of the pedal
pushrod (1) as possible.
4. Inspect the brake pedal pushrod (1) for straightness.
5. If the brake pedal pushrod eyelet bushing (2) exhibited cracks and/or excessive wear, then the bushing
requires replacement.
6. If the brake pedal pushrod (1) is not straight, then the pushrod requires replacement.
7. Return the pedal pushrod boot (3) to its original position on the pedal pushrod (1).
8. Connect the brake pedal pushrod (1) to the brake pedal.
REPAIR INSTRUCTIONS
MASTER CYLINDER RESERVOIR FILLING
NOTE: When adding fluid to the brake master cylinder reservoir, use only Delco
Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3
brake fluid from a clean, sealed brake fluid container. The use of any type of
fluid other than the recommended type of brake fluid, may cause contamination
which could result in damage to the internal rubber seals and/or rubber linings
of hydraulic brake system components.
2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system
should be inspected for wear and possible brake fluid leaks.
3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of
the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the
maximum-fill level.
4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill
level.
5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal
conditions.
6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and
around the reservoir cap prior to removing the cap and diaphragm. Use only Delco Supreme 11, GM
P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid
container.
MASTER CYLINDER RESERVOIR REPLACEMENT
Removal Procedure
1. Remove the master cylinder. Refer to Master Cylinder Replacement.
NOTE: Do not overtighten vise, or damage to the master cylinder will result.
2. Clamp the flange on the master cylinder body in a vise. Do not clamp the master cylinder body.
3. Drive out the spring pins. Use a suitable punch. Do not damage the reservoir or the cylinder body when
pushing out the pins.
4. Remove the reservoir body (3) by pulling the body straight up and away from the cylinder body.
5. Remove the O-rings (4) from the grooves in the reservoir.

1. Lubricate the new O-rings and the reservoir-to-housing fittings. Use clean brake fluid.
2. Insert the O-rings (4) into the grooves in the reservoir. Ensure that the O-rings are properly seated.
3. Install the reservoir (3) to the master cylinder body. Use your hand in order to push the reservoir straight
down into the body.
4. Install the spring pins in order to retain the reservoir. Do not damage the reservoir or the cylinder body.
5. Install the master cylinder. Refer to Master Cylinder Replacement.
MASTER CYLINDER REPLACEMENT
Removal procedure



4. Remove the master cylinder.
6. Remove the master cylinder reservoir. Refer to Master Cylinder Reservoir Replacement.

1. Install the master cylinder reservoir. Refer to Master Cylinder Reservoir Replacement.
2. Bench bleed the master cylinder prior to installation. Refer to Master Cylinder Bench Bleeding.
3. Install the master cylinder.
4. Install the master cylinder mounting nuts.

Tighten: Tighten the master cylinder mounting nuts to 25 N.m (18 lb ft).

6. Connect the brake pipes to the master cylinder.
Tighten: Tighten the master cylinder tube nuts to 15 N.m (11 lb ft).
7. Fill the master cylinder reservoir with brake fluid. Refer to Master Cylinder Reservoir Filling.
MASTER CYLINDER OVERHAUL
1. Remove the brake master cylinder from the vehicle. Refer to Master Cylinder Replacement.
3. Clean the outside of the master cylinder reservoir on and around the reservoir cap prior to removing the
cap and diaphragm.
5. Inspect the reservoir cap and diaphragm for the following conditions. If any of these conditions are
present, replace the affected components.
Cuts or cracks
Nicks or deformation
6. Remove the master cylinder reservoir from the master cylinder. Refer to Master Cylinder Reservoir
Replacement.
7. Using a smooth, round-ended tool, depress the primary piston (2) and remove the piston retainer.
9. Plug the cylinder inlet ports and the rear outlet port. Apply low pressure, non-lubricated, filtered air into
the front outlet port, in order the remove the secondary piston (1) with the primary (6) and secondary (5)
seals, and the return spring.
10. Discard the primary piston assembly, the piston retainer, and the seals and seal retainer from the
secondary piston.
Assembly Procedure

IMPORTANT: Do not use abrasives to clean the brake master cylinder bore.
1. Clean the interior and exterior of the master cylinder, the secondary piston (1), and the return spring in
2. Inspect the master cylinder bore, inlet and outlet ports, the secondary piston (1), and the return spring for
cracks, scoring, pitting, and/or corrosion. Replace the master cylinder if any of these conditions exist.
4. Lubricate the master cylinder bore, the secondary piston (1), the return spring, and all of the individual
overhaul components with Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or
5. Assemble the lubricated, new primary seal (6) and retainer, and new secondary seal (5) onto the
secondary piston.
6. Install the lubricated return spring and secondary piston assembly (1) into the cylinder bore.
7. Install the lubricated, new primary piston assembly (2) into the cylinder bore.
8. Using a smooth, round-ended tool, depress the primary piston (2) and install the new piston retainer.
9. Install the master cylinder reservoir to the master cylinder. Refer to Master Cylinder Reservoir
Replacement.
11. Install the master cylinder to the vehicle. Refer to Master Cylinder Replacement.
Fig. 18: Bleeding Master Cylinder
3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also
provide for hose attachment.
4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the
5. Fill the master cylinder reservoir to at least the half-way point with Delco Supreme 11, GM P/N
container.
6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully
submerged in the brake fluid.
7 Using a smooth round-ended tool depress and release the primary piston as far as it will travel a depth
of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports.
As air is bled from the primary and secondary pistons, the effort required to depress the primary piston
will increase and the amount of travel will decrease.
8. Continue to depress and release the primary piston until fluid flows freely from the ports with no
evidence of air bubbles.
11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder
with a clean shop cloth to prevent brake fluid spills.
MASTER CYLINDER FLUID LEVEL SENSOR REPLACEMENT
Removal Procedure
Fig. 19: Identifying Master Cylinder Fluid Level Sensor Electrical Connector
1. Disconnect the electrical connector (2) from the fluid level sensor (1).
Fig. 20: Removing Brake Fluid Level Sensor
2. Remove the fluid level sensor (1). Use needle nose pliers in order to compress the switch locking tabs at
the outboard side of the master cylinder.
Fig. 21: Locating Master Cylinder Fluid Level Sensor
1. Install the fluid level sensor (1) until the locking tabs snap into place.
2. Connect the electrical connector to the fluid level sensor (1).
BRAKE PEDAL ASSEMBLY REPLACEMENT
Removal Procedure
1. Disable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.
2. Remove the left side insulator panel. Refer to Closeout/Insulator Panel Replacement - Left in
3. Remove the booster push rod (2) from the brake pedal (1).
4. Disconnect the electrical connectors from the cruise control release if equipped and stop lamp switch.
6. Remove the brake booster mounting nuts (3).
7. Remove the brake pedal bracket mounting nuts (2).

8. Remove the upper mounting nuts (1) from the brake pedal brace (4).
9. Remove the brake pedal with the bracket (3).
10. Remove the brake pedal brace (4) from the bracket.
11. Remove the cruise control release switch (3), if equipped, and the stop lamp switch (1) from the brake
pedal with the bracket (2).
1. Install the cruise control release switch (3), if equipped, and the stop lamp switch (1) to the brake pedal
with the bracket (2).
2. Install the brake pedal brace (4) with the mounting nuts (1) to the bracket.
Tighten: Tighten the nuts (1) to 10 N.m (89 lb in).
3. Install the brake pedal with the bracket (3).

4. Install the upper mounting bolt for the brake pedal brace (4).

5. Install the brake pedal bracket mounting nuts (2).

6. Install the brake booster mounting nuts (3).
8. Connect the electrical connectors to the cruise control release if equipped and stop lamp switch.
9. Install the booster push rod (2) to the brake pedal (1).
10. Adjust the stop lamp switch and the cruise control release switch if equipped. Refer to Stop Lamp
Switch Adjustment in Lighting System.
11. Install the left side insulator panel. Refer to Closeout/Insulator Panel Replacement - Left in Instrument
12. Enable the SIR system. Refer to SIR Disabling and Enabling Zones in SIR.
PROPORTIONING VALVE REPLACEMENT
Removal Procedure
IMPORTANT: Note the locations of the brake pipes in order to aid in installation.


1. Install the proportion valve to bracket and install retaining nuts.
Tighten: Tighten the nuts 10 N.m (84 lb in).

4. Bleed brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic Brake System
Bleeding (Pressure).
BRAKE PIPE REPLACEMENT

Tools Required
J 45405 Pipe Flaring Tool Kit. See Special Tools.
CAUTION: Always use double walled steel brake pipe when replacing brake pipes.
The use of any other pipe is not recommended and may cause brake
system failure. Carefully route and retain replacement brake pipes. Always
use the correct fasteners and the original location for replacement brake
pipes. Failure to properly route and retain brake pipes may cause damage
to the brake pipes and cause brake system failure.
IMPORTANT: When servicing brake pipes, note the following:
If sectioning brake pipe, use replacement pipe of the same type and
outside diameter.
Use fittings of the appropriate size and type.
Only create flares of the same type or design as originally equipped on
the vehicle.
Fig. 32: Sectioning Brake Pipe Using Pipe Cutter
1. Inspect the section of brake pipe to be replaced.

2. Release the brake pipe to be replaced from the retainers, as required.
3. Select an appropriate location to section the brake pipe, if necessary.
Allow adequate clearance in order to maneuver the J 45405 . See Special Tools.
Avoid sectioning the brake pipe at bends or mounting points.
4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends.
5. Add to the measurement taken the appropriate additional length required for each flare to be created.
IMPORTANT: Ensure that the brake pipe end to be flared is cut at a square, 90 degree
angle to the pipe length.
6. Using the pipe cutter included in the J 45405 , carefully cut the brake pipe squarely to the measured
length. See Special Tools.
7. Remove the sectioned brake pipe from the vehicle.
8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter
determines brake pipe size.
Fig. 33: Stripping Nylon Coating From Brake Pipe Ends

9 Strip the nylon coating from the brake pipe ends to be flared if necessary
Select the appropriate blade on the coating stripping tool included in the J 45405 , by unthreading
the blade block from the stripping tool and installing the block with the desired blade facing the
tool rollers. See Special Tools.
Specification: 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe
Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool
rollers.
While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel
of the tool until the blade contacts the brake pipe coated surface.
IMPORTANT: Do not gouge the metal surface of the brake pipe.
Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against
the tool roller ledges.
After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool
clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe
surface is exposed.
Loosen the thumbwheel of the tool and remove the brake pipe.
IMPORTANT: Ensure that all loose remnants of the nylon coating have been
removed from the brake pipe.
Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been
removed.
Fig. 34: Chamfering Pipe Using De-Burring Tool
10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the J 45405 . See
Special Tools.
11. Install the tube nuts on the brake pipe, noting their orientation.
12. Clean the brake pipe and the J 45405 of lubricant, contaminants, and debris. See Special Tools.
Fig. 35: Installing Die Halves Into Die Cage
13. Loosen the die clamping screw of the J 45405 . See Special Tools.
14. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one
die facing the clamping screw, and the counterbores of both dies facing the forming ram.
Fig. 36: View Of Clamping Screw & Unused Die
15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against
the counterbored face of the dies.
16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against
the flat surface of the unused die (1).
17. Remove the unused die (1).
18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage.
19. Firmly hand tighten the clamping screw (2) against the dies.
Fig. 37: Rotating J 45405 To Bottom Against Die Cage
20. Select the appropriate forming mandrel and place into the forming ram.
21. Rotate the hydraulic fluid control valve clockwise to the closed position.
22. Rotate the body of the J 45405 until it bottoms against the die cage. See Special Tools.
Fig. 38: Bottoming Forming Mandrel Against Clamping Dies Using Pipe Flaring Tool
23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the J
45405 until the forming mandrel bottoms against the clamping dies. See Special Tools.
24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic
forming ram to retract.
25. Loosen the die clamping screw and remove the dies and pipe.
26. If necessary, lightly tap the dies until the die halves separate.
Fig. 39: Inspecting Brake Pipe Flare Diameter
27. Inspect the brake pipe flare for correct shape and diameter (a).
Specification: 7.10 mm (0.279 in) +/- 0.18 mm (0.007 in) flare diameter for 4.76 mm (3/16 in) diameter
pipe
28. If necessary, using the removed section of pipe as a template, shape the new pipe with a suitable brake
pipe bending tool.
IMPORTANT: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all
moving or vibrating components.
29. Install the pipe to the vehicle with the appropriate brake pipe unions as required.
30. If previously released, secure the brake pipe to the retainers.
31. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual) or Hydraulic
32. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the
brakes.
BRAKE HOSE REPLACEMENT - FRONT
Removal Procedure
IMPORTANT: Install a rubber cap or plug to the exposed brake pipe fitting end in order
to prevent brake fluid loss and contamination.
5. Use a flat-bladed tool in order to remove the brake hose retainer (4) from the brake hose (3).
7. Remove the brake hose bolt (4) from the brake caliper (2).
and contamination.
3. Install the brake hose bolt (4) to the brake caliper (2).

NOTE: Make sure the brake hose is not twisted or kinked after installation.
Damage to the hose could result.
IMPORTANT: Use the stripe on the brake hose in order to align the brake hose with the
notch in the brake hose bracket.
7. Install the brake pipe fitting (1) to the brake hose (3).
BRAKE HOSE REPLACEMENT - REAR (DISC BRAKE)
Removal Procedure
2. Remove the wheel and tire. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
IMPORTANT: Install a rubber cap or plug to the exposed brake pipe fitting end in order
to prevent brake fluid loss and contamination.
5. Use a flat-bladed tool in order to remove the brake hose retainer (4) from the brake hose (3).
7. Remove the brake hose bolt from the brake caliper (1).
9. Remove and discard the two copper brake hose gasket. These gaskets may be stuck to the brake caliper
and/or the brake hose end (3).
and contamination.

2. Assemble the brake hose bolt and the NEW copper brake hose gaskets to the brake hose (2).
3. Install the brake hose bolt to the brake caliper (1).
NOTE: Make sure the brake hose is not twisted or kinked after installation.
Damage to the hose could result.
IMPORTANT: Use the stripe on the brake hose in order to align the brake hose with the
notch in the brake hose bracket.

7. Install the brake pipe fitting (1) to the brake hose.
9. Install the wheel and tire. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
BRAKE HOSE REPLACEMENT - REAR (DRUM BRAKE)
Removal Procedure
3. Remove the brake pipes (1) from the brake hose (2).
6. Remove the hose.
IMPORTANT: Ensure that there are no kinks in the brake hose.
1. Align the hose fitting with the notch in the brackets.


4. Install the brake pipes (1) to the brake hose.
HYDRAULIC BRAKE SYSTEM BLEEDING (MANUAL)
1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add
Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid
from a clean, sealed brake fluid container.
If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and
around the cap prior to removal.
2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front
3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder.
8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master
cylinder.
9. With the front brake pipe installed securely to the master cylinder, after all air has been purged
cylinder, then repeat steps 3.3-3.8.
10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake
4. Fill the brake master cylinder reservoir with Delco Supreme 11, GM P/N 12377967 (Canadian P/N
992667), or equivalent DOT-3 brake fluid from a clean, sealed brake fluid container. Ensure that the
brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as
needed to maintain the proper level.
Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and
diaphragm.
Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean,
11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the same wheel hydraulic circuit.
19. Fill the brake master cylinder reservoir to the maximum-fill level with Delco Supreme 11, GM P/N
container.
IMPORTANT: If it is determined that air was induced into the system upstream of the
ABS modulator prior to servicing, the ABS Automated Bleed Procedure
must be performed.
21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy
after repeating the bleeding procedure, perform the following steps:
2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the
system.
illuminated.
IMPORTANT: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
23. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes.
HYDRAULIC BRAKE SYSTEM BLEEDING (PRESSURE)
Tools Required
J 29532 Diaphragm Type Brake Pressure Bleeder, or equivalent. See Special Tools.
J 35589-A Master Cylinder Bleeder Adapter. See Special Tools.
1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add
Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid
from a clean, sealed brake fluid container.
If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and
around the cap prior to removal.
2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front
3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder.
8. Wait 15 seconds, then repeat steps 3.3-3.7 until all air is purged from the same port of the master
cylinder.
9. With the front brake pipe installed securely to the master cylinder, after all air has been purged
cylinder, then repeat steps 3.3-3.8.
10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake
container.
Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and
diaphragm.
5. Install the J 35589-A to the brake master cylinder reservoir. See Special Tools.
6. Check the brake fluid level in the J 29532 , or equivalent. See Special Tools. Add Delco Supreme 11,
GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean, sealed brake
fluid container as necessary to bring the level to approximately the half-full point.
7. Connect the J 29532 , or equivalent, to the J 35589-A . See Special Tools.
8. Charge the J 29532 , or equivalent, air tank to 175-205 kPa (25-30 psi). See Special Tools.
9. Open the J 29532 , or equivalent, fluid tank valve to allow pressurized brake fluid to enter the brake
system. See Special Tools.
10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system in order to ensure that
there are no existing external brake fluid leaks.
Any brake fluid leaks identified require repair prior to completing this procedure.
Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or equivalent DOT-3 brake fluid from a clean,
14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit. Allow fluid to flow until air
bubbles stop flowing from the bleeder, then tighten the bleeder valve.
hydraulic circuit bleeder valve
22. Close the J 29532 , or equivalent, fluid tank valve, then disconnect the J 29532 , or equivalent, from the J
35589-A . See Special Tools.
23. Remove the J 35589-A from the brake master cylinder reservoir. See Special Tools.
container.
IMPORTANT: If it is determined that air was induced into the system upstream of the
ABS modulator prior to servicing, the ABS Automated Bleed Procedure
must be performed.
26. If the brake pedal feels spongy, perform the following steps:
2. Using a scan tool, perform the antilock brake system automated bleeding procedure to remove any
air that may have been trapped in the BPMV. Refer to ABS Automated Bleed Procedure in
Antilock Brake System.
illuminated.
IMPORTANT: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.
28. If the brake system warning lamp remains illuminated, refer to Symptoms - Hydraulic Brakes.

Fluid separation, indicating two types of fluid are present; a substance other than the recommended
brake fluid has been introduced into the brake hydraulic system
Swirled appearance - oil-based substance
Layered appearance - silicone-based substance
Fluid discoloration, indicating the presence of moisture or particles that have been introduced into
the brake hydraulic system
Dark appearance/suspended particles in fluid - dirt, rust, corrosion, brake dust
2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for
swelling, indicating brake fluid contamination.
3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid
separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master
cylinder grommets, perform the following:
1. Remove ALL of the following components listed from the vehicle. Each component contains
internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the
brake hydraulic system.

Brake Hose Replacement - Rear (Disc Brake)Brake Hose Replacement - Rear (Drum
Brake)
Brake Caliper Replacement - Front in Disc Brakes
Brake Caliper Replacement - Rear , if equipped, in Disc Brakes
Brake Pressure Modulator Valve (BPMV) Replacement in Antilock Brake System
2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent.
3. Dry the brake pipes using non-lubricated, filtered air.
4. Repair or replace ALL of the following components listed and install them to the vehicle. Each
component contains internal rubber seals/linings which have been contaminated by the
contaminated brake fluid in the brake hydraulic system.
Master Cylinder Overhaul or Master Cylinder Replacement ; also perform the following:
Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the
reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and
replace if necessary. Refer to Master Cylinder Reservoir Replacement .
Replace the brake master cylinder reservoir cap diaphragm.

Brake Hose Replacement - Rear (Disc Brake)Brake Hose Replacement - Rear (Drum
Brake)
Brake Caliper Overhaul - Front or Brake Caliper Replacement - Front in Disc Brakes
Brake Caliper Overhaul - Rear or Brake Caliper Replacement - Rear , if equipped, in

Disc Brakes
Brake Pressure Modulator Valve (BPMV) Replacement in Antilock Brake System
4. If the brake fluid was NOT contaminated with an oil-based or a silicone-based substance, but WAS
contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder
reservoir cap diaphragm. The diaphragm may have allowed the moisture or particles to enter the
hydraulic system.
container.
6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled
to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System
Bleeding (Manual) or Hydraulic Brake System Bleeding (Pressure).
VACUUM BRAKE BOOSTER REPLACEMENT (3.4L)
Removal Procedure
1. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
2. Relieve fuel line pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls - 3.4L.
3. Remove the left front cross brace. Refer to Brace Replacement - Front Fender Upper Diagonal - Left
in Body Front End.
4. Remove the powertrain control module (PCM) cover from the air cleaner housing.
5. Remove the PCM and set aside. It is not necessary to disconnect electrical. Refer to Powertrain Control
Module (PCM) Replacement in Engine Controls - 3.4L.
6. Remove the air cleaner and the duct. Refer to Air Cleaner Assembly Replacement in Engine Controls -
3.4L.
7. Remove the fuel lines from the pipes and the vapor line. Refer to Fuel Hose/Pipes Replacement -
Engine Compartment in Engine Controls - 3.4L.
9. Disconnect the brake lines from the master cylinder and remove the master cylinder. Refer to Master

11. Unclip the wire harness from the ABS module bracket and disconnect the electrical connector at the ABS
module.
12. Remove the brake lines from the ABS module.
13. Remove the ABS module and bracket. Refer to Brake Pressure Modulator Valve (BPMV)
Replacement in Antilock Brake System.

CAUTION: When replacing the power booster brake, make sure that the cruise
in personal injury.

wear.
5. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment in Lighting Systems.
6. Install the ABS module bracket and module. Refer to Brake Pressure Modulator Valve (BPMV)
7. Connect the brake lines to the module.
8. Connect the electrical connector to the ABS module and clip the electrical harness to the bracket.
10. Install the brake master cylinder and connect the brake lines. Refer to Master Cylinder Replacement.
11. Connect the fluid level sensor switch on the master cylinder.
12. Install the fuel lines to the pipes and the vapor line. Refer to Fuel Hose/Pipes Replacement - Engine
Compartment in Engine Controls - 3.4L.
Controls - 3.4L.
14. Install the PCM. Refer to Powertrain Control Module (PCM) Replacement in Engine Controls - 3.4L.
15. Install the PCM cover.
16. Install the left front cross brace. Refer to Brace Replacement - Front Fender Upper Diagonal - Left in
Body Front End.
17. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
VACUUM BRAKE BOOSTER REPLACEMENT (3.6L LY7)
Removal Procedure
1. Lift the coolant reservoir up and away from the left front cross brace.
2. Remove the left front cross brace. Refer to Brace Replacement - Front Fender Upper Diagonal - Left
in Body Front End.
3. Remove the engine control module (ECM) cover from the air cleaner housing.
4. Remove the ECM and set aside. It is not necessary to disconnect electrical. Refer to Engine Control
Module (ECM) Replacement in Engine Controls - 3.6L (LY7).
5. Remove the air cleaner and the duct. Refer to Air Cleaner Assembly Replacement in Engine Controls -
3.6L (LY7).
6. Remove the fuel line retaining bolt from the intake manifold.
8. Disconnect the brake lines from the master cylinder and remove the master cylinder. Refer to Master
10. Remove the ABS module and bracket. Refer to Brake Pressure Modulator Valve (BPMV)
11. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.6L (LY7).
13. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in
Tires and Wheels.
14. Remove the left front fender liner.

15. Remove the left ball joint from the steering knuckle. Refer to Lower Control Arm Replacement in
Front Suspension.
16. Remove the stabilizer bar links. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
17. Remove the steering gear mounting bolts.
18. Remove the 2 left side frame to body bolts.
IMPORTANT: DO NOT remove the frame to body bolts on the right side.
19. Loosen, but do not remove, the right frame to body bolts.
20. Position an oil drain pan under the transmission.
IMPORTANT: Insure that all pipes, hoses, and wires are clear and not being bound or
stressed when lowering the frame.

22. Using the engine support fixture, lower the powertrain.
23. Remove the transmission filler tube. Refer to Fluid Filler Tube Replacement (LA1) in Automatic
Transaxle - 4T65-E.
24. Disconnect the fuel pipe retainer from the wheelhouse stud.

CAUTION: When replacing the power booster brake, make sure that the cruise
in personal injury.

wear.
5. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment in Lighting Systems.
6. Connect the fuel pipe retainer to the wheelhouse stud.
7. Install the transmission filler tube. Refer to Fluid Filler Tube Replacement (LA1) in Automatic
Transaxle - 4T65-E.
8. Using the engine support fixture, raise the powertrain to its original position.
10. Using an appropriate jack, raise the left side of the frame so that the frame to body bolts can be installed.
11. Install the frame to body bolts.
Tighten:
Tighten the front bolts to 155 N.m (114 lb ft).
Tighten the rear bolts to 240 N.m (177 lb ft).
12. Remove the jackstand and oil drain pan.

13. Install the steering gear mounting bolts.

14. Install the stabilizer bar links. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
15. Install the ball joint to the steering knuckle. Refer to Lower Control Arm Replacement in Front
Suspension.
16. Install the left front fender liner.

17. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in
Tires and Wheels.
19. Remove the engine support fixture.
20. Install ABS module bracket and module. Refer to Brake Pressure Modulator Valve (BPMV)
22. Install the brake master cylinder and connect the brake lines. Refer to Master Cylinder Replacement.
23. Connect fluid level sensor switch on the master cylinder.
24. Install the fuel line retaining bolt to the intake manifold.
Controls - 3.6L (LY7).
26. Install the ECM. Refer to Engine Control Module (ECM) Replacement in Engine Controls - 3.6L
(LY7).
27. Install the ECM cover.
28. Install the left front cross brace. Refer to Brace Replacement - Front Fender Upper Diagonal - Left in
Body Front End.
29. Reposition the coolant reservoir to the left front cross brace.
VACUUM BRAKE BOOSTER CHECK VALVE AND/OR HOSE REPLACEMENT
Removal Procedure

Fig. 66: View Of Vacuum Brake Booster Check Valve And Vacuum Brake Booster Hose
3. Remove the vacuum hose (1) from the vacuum brake booster check valve (2).

Fig. 68: View Of Vacuum Brake Booster Check Valve And Vacuum Brake Booster Hose
3. Install the vacuum hose (1) to the vacuum brake booster check valve (2).

BRAKE FLUID AND BRAKE 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.
If ingested-consult a physician immediately.
CAUTION: Use only Delco Supreme 11, GM P/N 12377967 (Canadian P/N 992667), or
equivalent DOT 3 brake fluid from a clean, sealed container. Do not use
fluid from an open container that may be contaminated with water.
Improper or contaminated fluid could result in damage to components, or
loss of braking, with possible injury.
NOTE: When filling the master cylinder, use only Delco Supreme 11, GM P/N 12377967
(Canadian P/N 992667), or equivalent DOT 3 brake fluid. Do not use a container
which has been used for petroleum based fluids, or a container which is wet
with water. Petroleum based fluids will cause swelling and distortion of rubber
parts in the hydraulic brake system, and water will mix with brake fluid,
lowering the boiling point. Keep all fluid containers capped to prevent
contamination.
NOTE: Brake fluid will damage electrical connections and painted surfaces. Use shop
cloths, suitable containers, and fender covers to prevent brake fluid from
contacting these areas. Always re-seal and wipe off brake fluid containers to
prevent spills.
NOTE: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring,
cables or electrical connectors. Brake fluid will damage paint and electrical
connections. If any fluid is spilled on the vehicle, immediately flush the area
with water to minimize the potential for damage.
NOTE: Power steering fluid, engine oil, brake fluid, or any mineral based fluids cannot
be mixed. If brake seals contact power steering fluid or steering seals contact
brake fluid, seal damage will result.
IMPORTANT: Do not reuse the brake fluid collected during the hydraulic brake system
bleeding.
Always store brake fluid in a closed container.
Reseal brake fluid containers immediately after use.
Do not use brake fluid left in an open container.
Do not use brake fluid left in an improperly sealed container.
Do not use the following fluids in the hydraulic brake system:
Automatic transmission fluid
DOT 5 silicone hydraulic brake fluid
BRAKE WARNING SYSTEM DESCRIPTION AND OPERATION
The IPC detects a low brake fluid condition. The IPC receives a discrete input from the brake fluid level
switch requesting illumination.
The IPC detects the park brake is engaged. The IPC receives a discrete input from the park brake switch
HYDRAULIC BRAKE SYSTEM DESCRIPTION AND OPERATION
Converts mechanical input force into hydraulic output pressure.

Hydraulic output pressure is distributed from the master cylinder through two hydraulic circuits,
supplying diagonally-opposed wheel apply circuits.
Regulates brake fluid pressure delivered to hydraulic brake wheel circuits, in order to control the
distribution of braking force.
Pressure balance control is achieved through dynamic rear proportioning (DRP), which is a function of
the ABS modulator. Refer to ABS Description and Operation in Antilock Brake System for specific
information on the operation of DRP.
System Operation
Mechanical force is converted into hydraulic pressure by the master cylinder, regulated to meet braking system
demands by the pressure balance control system, and delivered to the hydraulic brake wheel circuits by the
pipes and flexible hoses. The wheel apply components then convert the hydraulic pressure back into mechanical
force which presses linings against rotating brake system components.
BRAKE ASSIST SYSTEM DESCRIPTION AND OPERATION
Brake Pedal
Brake Pedal Pushrod
Uses source vacuum to decrease effort required by driver when applying brake system input force.
When brake system input force is applied, air at atmospheric pressure is admitted to the rear of both
vacuum diaphragms, providing a decrease in brake pedal effort required. When input force is removed,
vacuum replaces atmospheric pressure within the booster.
Vacuum Source
System Operation
Brake system input force is multiplied by the brake pedal and transferred by the pedal pushrod to the hydraulic
brake master cylinder. Effort required to apply the brake system is reduced by the vacuum brake booster.

SPECIAL TOOLS
Special Tools
J 28662
Brake Pedal Effort Gauge
J 29532
Diaphragm Pressure Bleeder
J 35589-A
Master Cylinder Bleeder Adapter
J 45405
Pipe Flaring Tool Kit
Instrument Panel, Gages, & Console - Aztek & Rendezvous
SPECIFICATIONS

Specification
Air Distribution Extension Duct Bolts 2 N.m 18 lb in
Arm Rest Screws 2 N.m 18 lb in
Assist Handle Nuts 8 N.m 71 lb in
Audio System Bolts 2 N.m 18 lb in
Cross Car Beam at Hinge Pillars Bolts 25 N.m 18 lb ft
Data Link Connector Bolts 2 N.m 18 lb in
Front Floor Console Front Mounting Point Bolts 6 N.m 53 lb in
Front Floor Console Rear of Storage Compartment Base
6 N.m 53 lb in
Bolts
Front Floor Console Rear of Transaxle Shift Lever Bolts 6 N.m 53 lb in
Heads Up Display Bolts 2 N.m 18 lb in
Heater A/C Control Bolts 2 N.m 18 lb in
Hood Release Handle Base Bolts 2 N.m 18 lb in
Instrument Panel Cluster Bolts 2 N.m 18 lb in
Instrument Panel Cluster Trim Plate Bolts 2 N.m 18 lb in
Instrument Panel Compartment Bolts 2 N.m 18 lb in
Instrument Panel Compartment Door Retractor Cord Bolt 2 N.m 18 lb in
Instrument Panel Compartment Hinge Bolts 4 N.m 35 lb in
Instrument Panel Compartment Latch Bolts 2 N.m 18 lb in
Instrument Panel Forward Extension Compartment Bolts 2 N.m 18 lb in
Instrument Panel Trim Pad at Lower Hinge Pillars Bolts 20 N.m 15 lb ft
Instrument Panel Trim Pad at Windshield Bolts 5 N.m 44 lb in
Overhead Console Screws 2 N.m 18 lb in
Steering Column Bracket Bolts 6 N.m 53 lb in
Trim Plate Screws 2 N.m 18 lb in
FUEL LEVEL SPECIFICATIONS
The information in this table is intended for use with the J 33431-C Signal Generator and Instrument Panel
Tester. See Special Tools. The fuel level sensor values represent the test values to be used on the Signal
Generator to drive the fuel gage display to the indicated positions. Vehicles that require more than one fuel level
sensor calculate gage position from many possible resistance combinations of fuel levels between the two tanks.
Therefore, the values in the table may not correlate directly to readings taken from the vehicle primary or
secondary sending units.
The values in the table are approximate values based on information obtained from properly operating vehicles.
Actual results may vary slightly.
Fuel Level Specifications

Fuel Gage Display Resistance Sender Voltage Fuel Level
E 40-57 ohms 1.0V 0-8%
1/4 99-101 ohms 1.3V 28%
1/2 139 ohms 1.8V 49-51%
3/4 178 ohms 2.2V 71%
F 217-250 ohms 2.5V 91-100%
Low Fuel Indicator On 67-73 ohms 1.1V 11-13%

INSTRUMENT CLUSTER SCHEMATICS
Fig. 1: Power, Ground, Serial Data and Message Center

Fig. 2: Indicators
Fig. 3: Engine Oil Pressure (EOP) Sensor, Engine Oil Level Sensor and Indicator
Fig. 4: Gages - 3.4L
Fig. 5: Gages - 3.6L
Fig. 6: Driver Information Center (DIC)
HEAD UP DISPLAY SCHEMATICS

Fig. 7: Head Up Display
AUDIBLE WARNINGS SCHEMATICS

Fig. 8: Audible Warnings
COMPONENT LOCATOR
INSTRUMENT PANEL, GAGES, AND CONSOLE COMPONENT VIEWS
Callouts For Fig. 9

8 Cigar Lighter
11 Radio
12 Ignition Switch


1 Headlamp Switch
3 Hazard Switch
6 Radio
8 Alarm LED
13 Ignition Switch
Fig. 11: Steering Column Component View - Pontiac


1 Upper Trim Cover
2 Upper Bearing
3 Upper Bearing Seat
4 Steering Shaft Upper Bearing Spring
5 Inflatable Restraint Steering Wheel Module Coil
6 Bearing Retainer
7 Steering Wheel Nut
8 Trim Cover Protector
9 Sleeve
10 Cover, Housing Trim Extension
11 Lower Trim Cover Screws
12 Lower Trim Cover
13 Tilt Lever
14 Tilt Lever Spring
15 Tilt Lever Bolt
17 Lower Trim Cover Screw
18 Lower Tilt Head Mounting Bolts
19 Lower Tilt Head
20 Tilt Head Pivot Pins
21 Steering Column Jacket Assembly
22 Adapter and Bearing Assembly
23 Lower Bearing Seat
24 Lower Bearing Retainer
25 Wire Harness Retainer
26 Wire Harness Assembly
27 Shaft Assembly
28 Multifunction Switch
29 Tilt Head Springs
30 Multifunction Switch Screws
31 Trim Cover Screw
32 Actuator, Automatic Transmission Shift Lock Control
33 Ignition Switch
34 Ignition Key Alarm Switch
35 Upper Tilt Head
36 Theft Deterrent Module
Fig. 12: Steering Column Component View - Buick

1 Upper Trim Cover
2 Upper Bearing
3 Upper Bearing Seat
4 Steering Shaft Upper Bearing Spring
5 Bearing Retainer
6 Inflatable Restraint Steering Wheel Module Coil
7 Steering Wheel Nut
8 Trim Cover Protector
9 Sleeve
10 Cover, Housing Trim Extension
11 Lower Trim Cover Screws
12 Lower Trim Cover
13 Tilt Lever
15 Tilt Lever Bolt
17 Lower Trim Cover Screw
18 Lower Tilt Head Mounting Bolts
19 Lower Tilt Head
20 Tilt Head Pivot Pins
21 Steering Column Jacket Assembly
22 Adapter and Bearing Assembly
23 Lower Bearing Seat
24 Lower Bearing Retainer
25 Wire Harness Retainer
26 Wire Harness Assembly
27 Shaft Assembly
28 Multifunction Switch
29 Tilt Head Springs
30 Multifunction Switch Screws
31 Trim Cover Screw
32 Ignition Switch
33 Ignition Key Alarm
34 Upper Tilt Head
35 Theft Deterrent Module
36 Control Assembly
37 Shift Lever Pivot Pin
38 Pivot Pin Bolt
39 Lower Shift Lever Bushing
40 Upper Shift Lever Bushing
41 Steering Column Boot
42 Shift Lever
43 Shift Lever Screw
44 Shift Lever Pin
45 Shift Lever Spring
Fig. 13: Theft Deterrent Control Module Component View

1 Theft Deterrent Control Module
2 Ignition Key Housing
3 Key Warning Switch
Fig. 14: Lower Front Of Engine (LA1) Component View

1 Crankshaft Position (CKP) Sensor A Connector and Bracket
2 Knock Sensor (KS) Connector
3 Engine Oil Pressure (EOP) Switch Connector
4 Fusible Links (Starter)
5 A/C Compressor Clutch Diode
Fig. 15: Fuel Tank Component View

1 Fuel Pump and Sender Assembly
2 Fuel Pump
3 Canister Vent Solenoid
4 EVAP Canister
5 Fuel Level Sender
INSTRUMENT PANEL, GAGES, AND CONSOLE CONNECTOR END VIEWS
Ambient Air Temperature Sensor (UH9/CJ2)

12052641

A L-GN/BK 735 Ambient Air Temperature Sensor Signal
B YE 61 Low Reference
Driver Information Center (DIC) Switch (UH6)
12064993

5 GY 8 Instrument Panel Lamp Supply Voltage
6 BK 1450 Ground
7 BK 1550 Ground
8 PK 893 DIC Select Menu Switch Signal
9 D-GN/WH 1358 DIC Switch Signal
10 - - Not Used
Head Up Display (HUD) Switch (UH6)
12064978

1 GY 8 Instrument Panel Lamp Supply Voltage
2 BK 1450 Ground
3 BK 1550 Ground
4 YE 621 HUD Image Up Signal
5 BN 620 HUD Image Down Signal
6 WH 717 Illuminated Display Signal
Head Up Display (HUD) (UH6)

12064799

A BK 1550 Ground
B BK 1450 Ground
C OG 5240 Battery Positive Voltage
D L-BU 14 Left Turn Signal Lamps Supply Voltage
E D-BU 15 Right Turn Signal Lamps Supply Voltage
F WH 717 Illuminated Display Signal
G BK 9936 Class 2 Serial Data
H YE 621 HUD Image Up Signal
J BN 620 HUD Image Down Signal
K-L - - Not Used
M BN 241 Ignition 3 Voltage
Instrument Panel Cluster (IPC) - Pontiac

12110088

A1 - - Not Used
A2 BN/WH 419 MIL Control
A3 D-BU 15 Right Turn Signal Lamps Supply Voltage
A4 L-BU 14 Left Turn Signal Lamps Supply Voltage
A5 TN/WH 33 Brake Fluid Level Switch Signal
A6 D-GN/WH 1358 DIC Switch Signal (UH9)
A7 PK 893 DIC Select Menu Switch Signal (UH9)
A8 TN 185 Low Washer Fluid Indicator Signal
A9-A11 - - Not Used
Ambient Air Temperature Sensor Signal
A12 L-GN/BK 735
(UH9)
B2 YE 61 Low Reference (UH9)
B3 BK 1550 Ground
B4 PU 1500 Ignition 0 Voltage
B5-B6 - - Not Used
B7 BK 1450 Ground
B9 GY 1036 IPC Class 2 Serial Data
B10-B12 - - Not Used
Instrument Panel Cluster (IPC) - Buick

12110088

A1 D-BU 15 Right Turn Signal Lamps Supply Voltage
A2 TN/WH 33 Brake Fluid Level Switch Signal
A3 TN 185 Low Washer Fluid Indicator Signal
A4 PK 893 DIC Select Menue Switch Signal
A5 D-GN/WH 1358 DIC Switch Signal
A6-A8 - - Not Used
A9 L-GN/BK 735 Ambient Air Temperature Sensor Signal
A10 L-BU 14 Left Turn Signal Lamps Supply Voltage
A11 BN/WH 419 MIL Control
A12 - - Not Used
B1 GY 1036 IPC Class 2 Serial Data
B2 - - Not Used
B4 - - Not Used
B5 BK 1450 Ground
B6 - - Not Used
B7 PU 1500 Ignition 0 Voltage
B8 - - Not Used
B9 BK 1550 Ground
B10 YE 61 Low Reference
B11 - - Not Used
Ignition Key Alarm Switch

12059254
2-Way M Metri-Pack 150 Series (L-GN)

A L-GN 80 Key In Ignition Switch Signal
B BK 1550 Ground

DIAGNOSTIC STARTING POINT - INSTRUMENT PANEL, GAGES AND CONSOLE
Begin the Instrument Panel (I/P) System diagnosis with Diagnostic System Check - Vehicle in Vehicle DTC
Information. The Diagnostic System Check will provide the following information:


The IPC commands this gage to sweep to its maximum
Coolant Gage Sweep Special Functions:
when you select UP. Then the gage is commanded to sweep
Test IPC Gages
to its minimum when you select DOWN.
Fuel Gage Sweep Special Functions: when you select UP. Then the gage is commanded to sweep
Test IPC Gages to its minimum when you select DOWN.
The IPC illuminates the following indicators when you
select On:
Antilock
Air Bag
Brake
Cruise
High Beam
Left Turn Signal
Special Functions: Low Brake Fluid
Lamp Test Low Coolant Level
Lamp Test
Low Washer Fluid

Right Turn Signal
Seat Belt
TCS Off
The indicators should illuminate until commanded Off.

The IPC Tech 2 display will also change the states of
Ignition 0, the DIC Reset switch, the DIC Mode switch, and
the Trip Odometer Reset switch.
Speed Gage Sweep Special Functions:
Test IPC Gages
Tach Gage Sweep Special Functions:
Test IPC Gages
SCAN TOOL DATA LIST
The scan tool data lists contain all the instrument panel, gages, and console related parameters that are available
on the scan tool. The parameters in the list are arranged in order as they appear on the scan tool. The data list
column indicates the location of the parameter within the scan tool menu selections.
Use the scan tool data lists as directed by a diagnostic table or in order to supplement the diagnostic procedures.
Begin all of the diagnostic procedures with Diagnostic System Check - Vehicle in Vehicle DTC Information.
Use the scan tool data lists only after the following is determined:
The DTC or symptom procedure indicated by the diagnostic system check does not resolve the customer
concern.
The typical data values are obtained from a properly operating vehicle under the conditions specified in the first
row of the scan tool data list table. Comparison of the parameter values from the suspect vehicle with the typical
data values may reveal the source of the customer concern.
Body Control Module (BCM)

Door Ajar Switches Inputs Active/Inactive Inactive
Driver Door Open Sw Inputs Active/Inactive Inactive
Headlamp Switch Inputs Active/Inactive Inactive
Ignition 0 Inputs Active/Inactive Active
Ignition 1 Inputs Active/Inactive Active
Key In Ignition Inputs Active/Inactive Active
Liftgate Ajar Switch Inputs Active/Inactive Inactive
Park Brake Switch Inputs Active/Inactive Inactive
Parklamp Switch Inputs Active/Inactive Inactive
Instrument Panel Cluster (IPC)

Operating Conditions: Ignition ON/Engine OFF, Lights OFF, Turn Signals OFF, Park Brake Set,
Seat Belt Unbuckled
8 Digit GM Part Number Module Information - Varies
Air Bag Lamp Inputs On/Off On
Ambient Temperature Data C (F) Varies
Antilock Lamp Inputs On/Off Off
Brake Lamp Inputs On/Off On
Cruise Lamp Inputs On/Off Off
DIC Mode Button Inputs On/Off Off
DIC Reset Button Inputs On/Off Off
High Beam Lamp Inputs On/Off Off
Ignition 0 Data Volts 9-16 Volts (varies)
Ignition 0 Inputs On/Off On
Left Turn Signal Inputs On/Off Off
Low Brake Fluid Inputs OK/Low OK
Low Coolant Level Inputs OK/Low OK
Low Washer Fluid Inputs OK/Low OK
Odometer Data miles (kilometers) Varies
PROM ID Module Information - Varies
Revision Level Module Information - Varies
Right Turn Signal Inputs On/Off Off
Seat Belt Lamp Inputs On/Off On
Software Release Level Module Information - Varies
TCS Off Lamp Inputs On/Off Off
Trip Odometer Reset Inputs On/Released Released
Powertrain 3.4L
Engine Data 1
Engine Data 2
EGR Data Varies with engine
ECT Sensor Celsius (Fahrenheit)
EVAP Data temperature
Fuel Trim Data
Misfire Data
Engine Oil Level Switch Engine Data 2 OK/Low OK
Engine Oil Life Remaining Engine Data 2 % Varies
Engine Oil Pressure Switch Engine Data 2 OK/Low OK
Engine Data 1
Engine Data 2
EGR Data
EVAP Data Within 50 RPM of
Engine Speed RPM
Fuel Trim Data actual engine speed
Misfire Data
TAC Data
Cruise Control Data
Fuel Level Sensor EVAP Data Volts 0-5 V (Varies)
Fuel Tank Level Remaining EVAP Data % Varies
Engine Data 1
Engine Data 2
EGR Data
Ignition 1 Signal EVAP Data Volts 9-16 V (Varies)
Fuel Trim Data
Misfire Data
Cruise Control Data
MIL Command Engine Data 2 On/Off Off
Engine Data 1
Engine Data 2
EGR Data
EVAP Data
Vehicle Speed Sensor km/h (mph) 0 km/h (0 mph)
Fuel Trim Data
Misfire Data
TAC Data
Cruise Control Data
Powertrain 3.6L
Typical Data
Cruise Control Active IPC Data Yes/No No
Current Gear IPC Data Park/Reverse/Neutral/Drive/3rd/2nd/1st Park
Engine Data 1
Engine Data 2 Varies with
ECT Sensor EVAP Data Celsius (Fahrenheit) engine
Fuel Trim Data temperature
IPC Data
Engine Oil Level Switch IPC Data OK/Low OK
Engine Oil Pressure Sensor IPC Data OK/Low OK
Engine Oil Pressure Sensor IPC Data kPa (psi) Varies
Engine Data 1
Engine Data 2 Within 50 RPM of
Engine Speed EVAP Data RPM actual engine
Fuel Trim Data speed
IPC Data
EVAP Data
Fuel Level Sensor Volts 0-5 V (Varies)
IPC Data
Fuel Level Sensor IPC Data Volts 0-5 V (Varies)
Engine Data 1
Fuel Tank Level Remaining EVAP Data Gallons (Liters) Varies
IPC Data
17.8 Gallons (67.3
Fuel Tank Rated Capacity EVAP Data Gallons (Liters)
Liters)
Engine Data 1
Engine Data 2
Ignition 0 Signal On/Off On
EVAP Data
IPC Data
Engine Data 1
Engine Data 2
Ignition 1 Signal On/Off On
EVAP Data
IPC Data
Ignition 1 Signal Fuel Trim Data Volts 9-16 V (Varies)
Engine Data 1
MIL Command Engine Data 2 On/Off Off
IPC Data
Engine Data 1
Engine Data 2
Reduced Engine Power EVAP Data Active/Inactive Inactive
Fuel Trim Data
IPC Data
Engine Data 1
Vehicle Speed Sensor Engine Data 2 km/h (mph) 0 km/h (0 mph)
IPC Data
8-Digit GM Part Number
The scan tool displays the GM eight digit part number of the instrument panel cluster (IPC).
Air Bag Lamp
The scan tool displays On/Off. The state of the air bag lamp as commanded by the IPC. The IPC receives
a class 2 message from the sensing and diagnostic module (SDM).
Ambient Temperature
The scan tool displays 0-100C. The measured temperature from the ambient outside air temperature
sensor to the IPC.
Antilock Lamp
The scan tool displays On/Off. The state of the antilock lamp as commanded by the IPC. The IPC
receives a class 2 message from the electronic brake control module (EBCM).
Brake Lamp
The scan tool displays On/Off. The state of the brake lamp as commanded by the IPC. The IPC receives a
class 2 message from the body control module (BCM).
The scan tool displays Yes or No. The state of the cruise control indicator as commanded by the ECM.
Cruise Lamp
The scan tool displays On or Off. The state of the cruise control indicator as commanded by the
ECM/powertrain control module (PCM).
Current Gear
The scan tool displays the current gear of the vehicle. This is the state of the PRNDL range as
communicated to the IPC by the ECM. The value of this data corresponds to the PRNDL display.
DIC Mode Button

The scan tool displays On/Off. The state of the DIC mode button detected by the IPC from the DIC
switch (low input).
DIC Reset Button
The scan tool displays On/Off. The state of the DIC reset button detected by the IPC from the DIC switch
(low input).
ECT Sensor
The scan tool displays -39 to +140C (-38 to +284F). This is the engine coolant temperature as
monitored by the ECM/PCM. The voltage is inversely proportional to the engine coolant temperature.
Engine Oil Level Switch
The scan tool displays OK/Low. The PCM monitors the signal circuit of the engine oil level switch,
where an open switch is displayed as Low (low engine oil level).
Engine Oil Life Remaining
The scan tool displays 0-100%. The PCM calculates the remaining engine oil life.
Engine Oil Pressure Sensor
The scan tool displays 0-5 volts. The ECM monitors the engine oil pressure sensor signal circuit where a
low voltage indicates low pressure.
Engine Oil Pressure Sensor
The scan tool displays pressure in kPa (psi). The ECM monitors the engine oil pressure sensor signal
circuit.
Engine Oil Pressure Switch
The scan tool displays OK/Low. The PCM monitors the signal circuit of the engine oil pressure switch,
where an open switch is displayed as OK.
Engine Speed
The scan tool displays 0- 9999 RPM. The IPC receives the engine speed from the ECM/PCM via the
engine speed signal circuit.
Fuel Level Sensor
The scan tool displays 0-5 volts. The ECM/PCM monitors the fuel level sensor signal circuit where 0
volts is an empty tank.
Fuel Tank Level Remaining
The scan tool displays gallons (liters). This is the amount of fuel remaining in the fuel tank as determined
by the ECM.
Fuel Tank Level Remaining
The scan tool displays 0-100%. The scan tool displays in percentage the amount of fuel remaining in the
fuel tank as determined by the PCM.
High Beam Lamp
The scan tool displays On/Off. The state of the high beam lamp as commanded by the IPC. The IPC
receives a class 2 message from the BCM.
Ignition 0
The scan tool displays 0-25.5 volts. The voltage measured from the ignition 0 positive voltage circuit at
the IPC.
Ignition 0
The scan tool displays On/Off. The state of the ignition 0 positive voltage circuit detected by the IPC
when the ignition is turned ON.
Ignition 0 Signal
The scan tool displays On or Off. The state of the ignition 0 voltage circuit as monitored by the ECM.
Ignition 1 Signal
The scan tool displays On or Off. The state of the ignition 1 voltage circuit as monitored by the ECM.
Ignition 1 Signal
The scan tool displays 0-16 V. The ignition 1 signal represents the system voltage detected by the
ECM/PCM at the ignition voltage circuit.
Key In Ignition
The scan tool displays Active/Inactive. When the key is in the ignition switch, the scan tool will display
Active.
Left Turn Signal
The scan tool displays On/Off. The state of left turn signal input detected by the IPC from the turn hazard
flasher (high input). The indicator turns on when the switch is closed.
Low Brake Fluid
The scan tool displays OK/Low. The state of the low brake fluid input detected by the IPC from the brake
fluid switch (low input).
Low Coolant Level
The scan tool displays OK/Low. The state of the low coolant level input detected by the IPC from the
engine coolant level sensor (low input).
Low Washer Fluid
The scan tool displays OK/Low. The state of the low washer fluid input detected by the IPC from the
washer fluid switch (low input).
MIL (Malfunction Indicator Lamp) Command
The scan tool displays On or Off. This is the commanded state of the MIL (Malfunction Indicator Lamp)
by the ECM/PCM.
Odometer
The scan tool displays 0-999999.9 miles. The IPC calculates the mileage to determine the odometer
value.
PROM ID
The scan tool displays the four digit number of the PROM incorporated into the IPC.
Reduced Engine Power
The scan tool displays Inactive or Active. This is the state of the Reduced Engine Power indicator as
monitored by the ECM.
Revision Level
The scan tool displays the revision level of the software in the IPC.
Right Turn Signal
The scan tool displays On/Off. The state of right turn signal input detected by the IPC from the turn
hazard flasher (high input). The indicator turns on when the switch is closed.
Seat Belt Lamp

The scan tool displays On/Off. The state of the seat belt lamp as commanded by the IPC. The IPC
receives a class 2 message from the SDM.
Software Release Level
The scan tool displays the original release level of the software in the IPC.
TCS Off Lamp
The scan tool displays On/Off. The state of the TCS off lamp as commanded by the IPC. The IPC
receives a class 2 message from the EBCM.
Trip Odometer Reset
The scan tool displays On/Released. The state of trip odometer reset switch detected by the IPC from the
internal trip odometer reset switch.
Vehicle Speed Sensor
The scan tool displays 0-255 km/h (0-159 mph). The IPC obtains vehicle speed data from the PCM on a
dedicated input. The PCM is responsible for calculating correct vehicle speed data.
DTC B1369
Circuit Description
The instrument panel cluster (IPC) monitors the ignition 0 voltage circuit when the ignition switch is in either
the ON position or the OFF position. If the IPC senses that the ignition 0 voltage circuit is low for greater than 3
seconds, DTC B1369 is set.
DTC Descriptor
DTC B1369 Device Ignition 0 (UNLOCK, ON, and START) Circuit Open

At least 3 seconds has elapsed since the ignition switch was cycled ON.
The ignition 0 input is low during power up or while in RUN for greater than 3 seconds.

The IPC stores DTC B1369 in memory.
The IPC will store conditions which were present when the DTC set as Failure Records data only. The
information will not be stored as Freeze Frame data.
A current DTC B1369 will clear when the malfunction is no longer present and the ignition switch is
cycled.
A history DTC B1369 will be cleared after 100 ignition cycles with no current codes active during the
100 ignition cycles.
The IPC receives the clear code command from the scan tool.
Diagnostic Aids
If the DTC is a history DTC, the problem may be intermittent. Refer to Testing for Intermittent Conditions
Test Description
3: This step determines if the ignition 0 voltage circuit is open or shorted to ground.
DTC B1369
Step Action Yes No
Schematic Reference: Instrument Cluster Schematics
1
Vehicle in Vehicle
2. Turn the ignition ON.
3. With the scan tool, observe the Ignition 0 Go to Testing for
2 parameter in the instrument panel cluster (IPC) Intermittent
Inputs data list. Conditions and
Poor Connections
Does the scan tool display On? in Wiring Systems Go to Step 3
Test the ignition 0 voltage circuit for an open or a short
to ground. Refer to Circuit Testing and to Wiring
3
4 of the IPC. Refer to Testing for Intermittent
Conditions and Poor Connections and to Connector
5
6 Running the DTC.
DTC B2823 OR B3574
Circuit Description
The instrument panel cluster (IPC) monitors the signal circuit of the internal trip odometer reset switch in order
to change odometer displays and to reset the odometer value. The IPC detects a switch activation when the
signal circuit is low.
DTC Descriptors
DTC B2823 Trip Odometer Reset Switch Circuit Low

DTC B3574 Trip Odometer A or B (trip odometer 1 or 2) Select Switch Circuit Low
The IPC must have normal operating battery voltage.
The IPC detects that the trip odometer reset switch signal circuit is low for greater than 60 seconds.
The IPC ignores the trip odometer reset switch signal circuit. The IPC sets DTC B2823.
A history DTC B2823 will clear after a complete ignition cycle.

Diagnostic Aids
The IPC will store the code as current only as long as the failure exists. An intermittent failure will be
stored as a history DTC B2823.
If DTC B2823 is set only in history, press and release the trip reset switch several times in order to verify
the customer concern.
DTC B2823 or B3574

Step Action Yes No
1
Vehicle in Vehicle
3. With a scan tool, observe the Trip Reset Switch
2 parameter in the instrument panel cluster (IPC)
data list.

1. Press and release the trip odometer reset switch.
2. With a scan tool, observe the Trip Reset Switch
3 parameter.
Does the Trip Reset Switch parameter change state and Go to Diagnostic
does the odometer change from season to trip? Aids Go to Step 4
4
5 Running the DTC.
DTC B2838, B3564, B3569, OR B3752
Circuit Description
The instrument panel cluster (IPC) monitors the driver information center (DIC) mode switch and the DIC reset
switch in order to perform certain functions. The IPC detects a switch activation when the signal circuit is low.
DTC Descriptors
DTC B2838 Driver Information Center (DIC) Reset Switch Circuit Low
DTC B3564 Driver Information Center (DIC) Mode Switch Circuit Low
DTC B3569 Driver Information Center (DIC) Select Switch Circuit Low
DTC B3752 Driver Information Center (DIC) On or Off Signal Circuit Low
The IPC must have normal operating battery voltage.
B2838
The IPC detects that the reset switch signal circuit is low for greater than 60 seconds.
B3564
The IPC detects that the mode switch signal circuit is low for greater than 60 seconds.
The IPC ignores the DIC mode switch or the DIC reset switch.
A current DTC B3564 or B2838 will clear after a complete ignition cycle if the fault is no longer present.
Diagnostic Aids
The IPC will store the code as current only as long as the failure exists. An intermittent failure will be
stored as a history DTC B3564 or B2838.
If DTC B3564 or B2838 is set only in history, press and release the DIC mode B3564 or reset B2838
switch several times in order to verify the customer concern.
DTC B2838, B3564, B3569, or B3752

Step Action Yes No
1
Vehicle in Vehicle
3. With a scan tool, observe the driver information
center (DIC) Mode button or the DIC Reset
2 Button parameter in the instrument panel cluster
(IPC) inputs data list.
Go to Diagnostic
Disconnect the DIC switch.
3 Does the suspected DIC switch parameter display
Inactive? Go to Step 6 Go to Step 4
Test the signal circuit of the suspected DIC switch for a
4
5
Replace the DIC switch. Refer to Driver Information
Center Switch Replacement (Rendezvous) or Driver
6
Information Center Switch Replacement (Aztek).
7 Running the DTC.
DTC B2961
Circuit Description
The body control module (BCM) uses a key in ignition input in order to control certain features in the vehicle.
These features are in the following systems:
Content theft deterrent (CTD), if equipped

Audible warnings
Automatic door locks (ADL)
The ignition switch switches the key in ignition input circuit to ground when you fully insert the ignition key
into the ignition switch. This in turn pulls the BCM key in ignition input low.
DTC Descriptor
DTC B2961 Key In Ignition Circuit
The ignition is on.
The ignition 0 input is active, high signal and the key in ignition input is inactive, high signal.
The conditions above must be present for more than 0.3 seconds.
The DTC becomes history when the fault is no longer present.

A history DTC will clear after 100 consecutive ignition cycles if the condition for the malfunction is no
longer present.
The BCM receives the clear code command from the scan tool.
DTC B2961
Step Action Yes No
Schematic Reference: Audible Warnings Schematics
1
Vehicle in Vehicle
3. With the scan tool, observe the Key In Ignition Go to Testing for
2 parameter in the body control module (BCM) Intermittent
data list. Conditions and
Poor Connections
Does the Key In Ignition parameter display Active? in Wiring Systems Go to Step 3
2. Disconnect the BCM connector C0.
3 3. Connect a test lamp between the key in ignition
input circuit and battery positive voltage.
Test the key in ignition input circuit for an open, for a
high resistance, or for a short to voltage. Refer to
Systems.
Test the ground circuit of the key in ignition switch for
an open or a high resistance. Refer to Circuit Testing
5
of the ignition switch. Refer to Testing for
9
text.
DTC P0461
Circuit Description
The fuel level sender changes resistance based on fuel level. The engine control module (ECM) monitors the
signal circuit of the fuel level sender in order to determine fuel level. When the fuel tank is full, the sender
resistance is high and the ECM senses a high signal voltage. When the fuel tank is empty, the sender resistance
is low and the ECM senses a low signal voltage. The ECM uses the signal circuit of the fuel level sender in
order to calculate the total remaining fuel percent in the tank. The ECM sends the fuel level percent via the class
2 serial data circuit to the instrument cluster in order to control the fuel gage. The fuel level information is also
used for misfire and EVAP diagnostics.
This diagnostic tests for a stuck primary fuel level sensor signal. The ECM sets this DTC if the primary fuel
level sensor signal appears to be stuck based on a lack of signal variation expected during normal operation.
DTC Descriptor
DTC P0461 Fuel Level Sensor Performance

No other fuel level sensor signal failure is present.
The ECM does not detect a change in fuel level in the primary fuel tank of at least 1.0L (0.246 gal).
The difference between fuel consumed by the engine and a change in fuel level signal exceeds 46%.
The fuel gage defaults to empty.

The driver information center (DIC) displays the FUEL LEVEL LOW message.
The ECM records the operating conditions at the time that the diagnostic test fails. The ECM displays the
failure information in the Failure Records on the scan tool.
The ECM receives the clear code command from the scan tool.
Diagnostic Aids
Use the Freeze Frame/Failure Records data in order to locate an intermittent condition. If you cannot
duplicate the DTC, the information included in the Freeze Frame/Failure Records data may help in
determining the number of miles since the DTC set. The Fail Counter and Pass Counter can also help in
determining the number of ignition cycles that the diagnostic test reported a pass and/or fail. Operate the
vehicle within the same freeze frame conditions, including those for RPM, for engine load, for vehicle
speed, for temperature, and for others. This will isolate at what point the DTC failed.
DTC P0461
Step Action Yes No
1
Vehicle in Vehicle
1. Remove the primary fuel level sender.
2. Inspect for the following items:
The fuel level sensor is stuck, perhaps due
2 to an interference with the fuel strainer.

The fuel tank contains foreign material, for
instance, ice.

Replace the primary fuel level sensor. Refer to Fuel
3 Level Sensor Replacement in Engine Controls - 3.6L.
text.
DTC P0462 (3.4L)
Circuit Description
The fuel level sender changes resistance based on fuel level. The powertrain control module (PCM) monitors
the signal circuit of the fuel level sender in order to determine fuel level. When the fuel tank is full, the sender
resistance is high and the PCM senses a high signal voltage. When the fuel tank is empty, the sender resistance
is low and the PCM senses a low signal voltage. The PCM uses the signal circuit of the fuel level sender in
order to calculate the total remaining fuel (percent) in the tank. The PCM sends the fuel level percent via the
class 2 serial data circuit to the instrument cluster in order to control the fuel gage. The fuel level information is
also used for misfire and evaporative emission (EVAP) diagnostics.
DTC Descriptor
DTC P0462 Fuel Level Sensor Circuit Low Voltage
The ignition is ON.

The fuel level signal is less than 0.4 volts.


The Check Gages indicator illuminates.
The PCM records the operating conditions at the time the diagnostic fails. The PCM displays the failure
information in the Failure Records on the scan tool.
The history DTC clears after 40 malfunction-free warm-up cycles.
The PCM receives the clear code command from the scan tool.
Diagnostic Aids
Use the Freeze Frame and/or Failure Records data in order to locate an intermittent condition. If you
cannot duplicate the DTC, the information included in the Freeze Frame and/or Failure Records data may
aid in determining the number of miles since the DTC set. The Fail Counter and Pass Counter can also
aid in determining the number of ignition cycles that the diagnostic reported a pass and/or fail. Operate
the vehicle within the same freeze frame conditions (RPM, engine load, vehicle speed, temperature, etc.).
This will isolate when the DTC failed.
Test Description
DTC P0462 (3.4L)

Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
OFF.
3. With a scan tool, observe the Fuel Level
2 Sensor parameter in the powertrain control 0.5 V
module (PCM) evaporative emission
(EVAP) Data, data list.
Does the scan tool indicate that the Fuel Level Go to

Sensor parameter is less than the specified value? Go to Step 3 Diagnostic Aids
2. Disconnect C305/C305C.
OFF.
3 4. With a scan tool, observe the Fuel Level 4.5 V
Sensor parameter.
Does the scan tool indicate that the Fuel Level

Test the signal circuit of the fuel level sender for
4 -
a short to ground between C305/C305C and the
5 fuel level sender. Refer to Circuit Testing and -
connector of the fuel level sender. Refer to
6 -
Systems.
Replace the fuel level sender. Refer to Fuel
Level Sensor Replacement in Engine Controls -
8 -
3.4L.
9 -
DTCs.
supporting text.
DTC P0462 (3.6L)
Circuit Description
order to calculate the total remaining fuel (percent) in the tank. The ECM sends the fuel level percent via the
DTC Descriptor
DTC P0462 Fuel Level Sensor Circuit Low Voltage

The system voltage is between 10.5-18 volts.
The fuel level signal is less than 0.25 volts.


The ECM records the operating conditions at the time the diagnostic fails. The ECM displays the failure
Diagnostic Aids
the vehicle within the same freeze frame conditions (RPM, engine load, vehicle speed, temperature, etc.).
This will isolate when the DTC failed.
Test Description
DTC P0462 (3.6L)

Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
OFF.
2 Sensor parameter in the engine control 0.35 V
module (ECM) evaporative emission
Does the scan tool indicate that the Fuel Level Go to

Sensor parameter is less than the specified value? Go to Step 3 Diagnostic Aids
OFF.
3 Sensor parameter. 4.2 V

4 -
a short to ground between C305/C305C and the
5 fuel level sender. Refer to Circuit Testing and -
6 -
Systems.
8 -
3.6L (LY7).
9 -
DTCs.
supporting text.

DTC P0463 (3.4L)
Circuit Description
The fuel level sender changes resistance based on fuel level. The powertrain control module (PCM) monitors
the signal circuit of the fuel level sender in order to determine fuel level. When the fuel tank is full, the sender
resistance is high and the PCM senses a high signal voltage. When the fuel tank is empty, the sender resistance
is low and the PCM senses a low signal voltage. The PCM uses the signal circuit of the fuel level sender in
order to calculate the total remaining fuel (percent) in the tank. The PCM sends the fuel level percent via the
DTC Descriptor
DTC P0463 Fuel Level Sensor Circuit High Voltage
The ignition is ON.

The fuel level signal is greater than 3 volts.


The PCM records the operating conditions at the time the diagnostic fails. The PCM displays the failure
Diagnostic Aids
the vehicle within the same freeze frame conditions (RPM, load, vehicle speed, temperature, etc.). This
will isolate when the DTC failed.
Test Description
3: Tests for the proper operation of the circuit in the low voltage range.
DTC P0463 (3.4L)

Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
OFF.
Sensor parameter in the powertrain control
2 module (PCM) evaporative emission 4.5 V

Sensor parameter is greater than the specified Go to
value? Go to Step 3 Diagnostic Aids
between the signal circuit of the fuel level
sender and the low reference circuit of the
fuel level sender (male terminal side).
OFF.
Sensor parameter.

Sensor parameter is less than the specified value? Go to Step 6 Go to Step 4
an open, a high resistance, or a short to voltage.
Wiring Systems.
Test the low reference circuit of the fuel level
sender for an open, a high resistance, or a short to
5 voltage. Refer to Circuit Testing and Wiring -
an open, a high resistance, or a short to voltage
between C305/C305C and the fuel level sender.
6 -
Wiring Systems.
voltage between C305/C305C and the fuel level
7 -
sender. Refer to Circuit Testing and Wiring
8 -
Systems.
10 -
3.4L.
11 -
DTCs.
12 2. Operate the vehicle within the Conditions -
supporting text.
DTC P0463 (3.6L)
Circuit Description
order to calculate the total remaining fuel (percent) in the tank. The ECM sends the fuel level percent via the
DTC Descriptor
DTC P0463 Fuel Level Sensor Circuit High Voltage

The system voltage is between 10.5-18 volts.
The fuel level signal is greater than 3.2 volts.


The ECM records the operating conditions at the time the diagnostic fails. The ECM displays the failure
Diagnostic Aids
the vehicle within the same freeze frame conditions (RPM, load, vehicle speed, temperature, etc.). This
will isolate when the DTC failed.
Test Description
3: Tests for the proper operation of the circuit in the low voltage range.
DTC P0463 (3.6L)

Vehicle? Diagnostic
System Check
1 -
- Vehicle in
Vehicle DTC
OFF.
Sensor parameter in the engine control
2 module (ECM) evaporative emission 4.2 V

Sensor parameter is greater than the specified Go to
value? Go to Step 3 Diagnostic Aids
between the signal circuit of the fuel level
3 sender and the low reference circuit of the 0.35 V
fuel level sender (male terminal side).
OFF.
Sensor parameter.

Sensor parameter is less than the specified value? Go to Step 6 Go to Step 4
an open, a high resistance, or a short to voltage.
Wiring Systems.
5 voltage. Refer to Circuit Testing and Wiring -
an open, a high resistance, or a short to voltage
between C305/C305C and the fuel level sender.
6 -
Wiring Systems.
voltage between C305/C305C and the fuel level
7 -
sender. Refer to Circuit Testing and Wiring
8 -
Systems.
10 -
3.6L (LY7).
11 -
DTCs.
supporting text.
DTC P0520
Circuit Description
The engine oil pressure (EOP) switch is a normally closed switch that opens with the proper oil pressure. With
the ignition switch turned ON and the engine not running, the powertrain control module (PCM) should detect a
low signal voltage input. With the engine running, the pressure switch opens, and the PCM should detect a high
signal voltage input. The PCM tests the state of the EOP circuit with the ignition switch turned ON, and the
engine turned OFF. If the PCM detects a high voltage input on the EOP signal circuit, DTC P1189 will set.
DTC Descriptor
DTC P0520 Engine Oil Pressure (EOP) Switch Circuit
The ignition is ON, with the engine OFF.

DTCs P0117, P0118, P1111, and P1114 are not set.
The PCM detects that the EOP switch signal circuit is high.
The above condition is present for greater than 10 seconds.
The PCM will store conditions which were present when the DTC set as Fail Records data only. The
information will not be stored as Freeze Frame data.
DTC P0520
Step Action Yes No
1
Vehicle in Vehicle
IMPORTANT:
Do not turn the key to the crank position or engage
the starter at any time during diagnosis.

2 2. With a scan tool, observe the Engine Oil Pressure
Switch parameter in the PCM Engine Data 2 data Go to Testing for
list. Intermittent
Conditions and
Does the Engine Oil Pressure Switch parameter display Poor Connections
OK? Go to Step 3 in Wiring Systems
1. Disconnect the engine oil pressure (EOP) switch
connector.
2. Connect a fused jumper between the EOP switch
signal circuit and a good ground.
3 3. With a scan tool, observe the Engine Oil Pressure
Switch parameter in the PCM Engine Data 2 data
list.
Does the Engine Oil Pressure Switch parameter display

Low? Go to Step 6 Go to Step 4
Test the EOP signal circuit for an open, for a high
resistance, or for a short to voltage. Refer to Circuit
4
Inspect for poor connections at the powertrain control
module (PCM). Refer to Testing for Intermittent
Inspect for poor connections at the EOP switch. Refer
Systems.
Replace the EOP switch. Refer to Engine Oil Pressure
7 Sensor and/or Switch Replacement in Engine
Mechanical - 3.4L.
8
text.
DTC P2066
Circuit Description
order to calculate the total remaining fuel percent in the tank. The ECM sends the fuel level percent via the class
2 serial data circuit to the instrument cluster in order to control the fuel gage. The fuel level information is also
used for misfire and EVAP diagnostics.
This diagnostic tests for a stuck primary fuel level sensor signal. The ECM sets this DTC if the primary fuel
level sensor signal appears to be stuck based on a lack of signal variation expected during normal operation.
DTC Descriptor
DTC P2066 Fuel Level Sensor 2 Performance

No other fuel level sensor signal failure is present.
The ECM does not detect a change in fuel level in the primary fuel tank of at least 1.0L (0.246 gal).
The difference between fuel consumed by the engine and a change in fuel level signal exceeds 46%.

The driver information center (DIC) displays the FUEL LEVEL LOW message.
The ECM records the operating conditions at the time that the diagnostic test fails. The ECM displays the
failure information in the Failure Records on the scan tool.
Diagnostic Aids
Use the Freeze Frame/Failure Records data in order to locate an intermittent condition. If you cannot
duplicate the DTC, the information included in the Freeze Frame/Failure Records data may help in
determining the number of miles since the DTC set. The Fail Counter and Pass Counter can also help in
determining the number of ignition cycles that the diagnostic test reported a pass and/or fail. Operate the
vehicle within the same freeze frame conditions, including those for RPM, for engine load, for vehicle
speed, for temperature, and for others. This will isolate at what point the DTC failed.
For diagnosis refer to DTC P0461.
SYMPTOMS - INSTRUMENT PANEL, GAGES AND CONSOLE
1. Perform the Diagnostic System Check - Vehicle in Vehicle DTC Information before using the symptom
tables in order to verify that all of the following are true:
The modules can communicate via the serial data link.
2. Review the system operation in order to familiarize yourself with the system functions. Refer to the
following:
Instrument Panel Cluster (IPC) Description and Operation
Indicator/Warning Message Description and Operation
Driver Information Center (DIC) Description and Operation
Head Up Display (HUD) Description and Operation
Audible Warnings Description and Operation
Inspect for aftermarket devices which could affect the operation of the instrument cluster, the driver
information display, or the audible warnings. Refer to Checking Aftermarket Accessories in Wiring
Systems.
cause the symptom.
For any indicator or message relating to fluid level, perform a visual inspection of the fluid level before
beginning diagnosis.
Verify that the indicators and message display works properly during the displays check.
Intermittent
Symptom List
Audible Warnings
Chime Always On
Chime Inoperative
Driver Information Center (DIC)
Driver Information Center (DIC) Temperature Display Always Reads SC

Driver Information Center (DIC) Temperature Display Always Reads OC
Outside Air Temperature Display Inaccurate or Inoperative
Driver Information Center (DIC) Compass Inaccurate or C Displayed
Driver Information Center (DIC) Switch(es) Inoperative
Gages
Engine Coolant Temperature Gage Inaccurate or Inoperative

Fuel Gage Inaccurate or Inoperative
Odometer Trip/Reset Switch Inoperative
Speedometer and/or Odometer Inaccurate or Inoperative
Tachometer Inaccurate or Inoperative
Heads Up Display
Head Up Display (HUD) Inoperative

Head Up Display (HUD) Turn Signal Indicator Inoperative - Left/Right
Head Up Display (HUD) Image Adjustment Inoperative
Head Up Display (HUD) Intensity Does Not Vary
Indicators
ABS Indicator Always On in ABS

ABS Indicator Inoperative in ABS
Air Bag Indicator Circuit Malfunction in SIR
Brake Warning Indicator Always On in Hydraulic Brakes
Brake Warning Indicator Inoperative in Hydraulic Brakes
Change Engine Oil Indicator Always On
Change Engine Oil Indicator Inoperative
Charge Indicator Always On in Engine Electrical
Charge Indicator Inoperative in Engine Electrical
Door Ajar Indicator Malfunction in Doors
Engine Coolant Temperature Indicator Always On in Engine Cooling
Engine Oil Pressure Indicator Always On
High Beam Indicator Inoperative in Lighting Systems
Low Engine Oil Level Indicator Always On
For LOW FUEL indicator refer to Fuel Gage Inaccurate or Inoperative
Low Traction Indicator Always On in ABS
Low Traction Indicator Inoperative in ABS
Low Washer Fluid Indicator Malfunction in Wipers/Washer Systems
Malfunction Indicator Lamp (MIL) Always On in Engine Controls
Malfunction Indicator Lamp (MIL) Inoperative in Engine Controls
Park Lamp Out Indicator Inoperative in Lighting Systems
Rear Hatch/Gate Ajar Indicator Malfunction in Body Rear End
Seat Belt Indicator Circuit Malfunction in Seat Belts
Security Indicator LED Inoperative in Theft Deterrent
Traction Off Indicator Always On in ABS
Traction Off Indicator Inoperative in ABS
Turn Signal Lamps and/or Indicators Inoperative in Lighting Systems
ENGINE COOLANT TEMPERATURE GAGE INACCURATE OR INOPERATIVE
Engine Coolant Temperature Gage Inaccurate or Inoperative

Vehicle? Go to
Diagnostic
System Check
- Vehicle in
1 -
Vehicle DTC
2. Turn ON the ignition, with the engine Go to Testing
OFF. for
2 3. With the scan tool, perform the coolant - Intermittent
gage sweep test. Conditions and
Poor
Does the engine coolant temperature gage move Connections in
up and down when commanded? Wiring Systems Go to Step

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2005-2007 Buick Rendezvous

MODEL IDENTIFICATION (CARS)

MODEL IDENTIFICATION (LIGHT TRUCKS & VANS)

A/C CLUTCH RELAY LOCATION (CARS)

A/C COMPRESSOR CLUTCH CONTROLS (LIGHT TRUCKS & VANS)

RWD Trucks & Vans

A/C CLUTCH RELAY LOCATION (LIGHT TRUCKS & VANS)

A/C CLUTCH CIRCUIT DIAGNOSIS (CARS)

NOTE: Vehicles may be equipped with a PCM using an Electronically Erasable

2.2L & 2.4L: CAVALIER & SUNFIRE (2000)

A hot engine restart.

DTC P0530 or U1016 are set.

Diagnostic System Check

2.2L & 2.4L: CAVALIER & SUNFIRE (2001)

A hot engine restart.

DTC P0530 or U1016 are set.

Diagnostic System Check

Compressor Clutch Does Not Engage

Compressor Clutch Does Not Disengage

2.4L, 3.1L & 3.4L: ALERO, GRAND AM & MALIBU

A hot engine restart.

DTC P0530 or U1016 are set.

Diagnostic System Check

Compressor Clutch Does Not Engage

Compressor Clutch Does Not Disengage

Description (A/C Request Circuit)

Description (A/C Load Signal Circuit)

Description (A/C Compressor Control Circuit)

Diagnostic System Check

Compressor Clutch Does Not Engage

Compressor Clutch Does Not Disengage

3.1L, 3.5L & 3.8L: CENTURY, INTRIGUE & REGAL

Throttle angle is greater than 90 percent.

Diagnostic System Check

Compressor Clutch Does Not Engage (Automatic A/C)

Compressor Clutch Does Not Engage (Manual A/C)

Compressor Clutch Does Not Disengage (Automatic A/C)

Compressor Clutch Does Not Disengage (Manual A/C)

3.1L & 3.8L: GRAND PRIX

Diagnostic System Check

Compressor Does Not Engage

Compressor Does Not Disengage

Throttle angle is greater than 96 percent.

Diagnostic System Check

3.4L & 3.8L: IMPALA & MONTE CARLO

Throttle position is more than 96 percent.

Diagnostic System Check

Compressor Clutch Does Not Engage

Compressor Clutch Does Not Disengage

3.5L & 4.0L: AURORA

Compressor Clutch Does Not Engage

3.8L: BONNEVILLE & LESABRE

Disengages when air conditioning is not requested.

Under normal operating conditions, the following events occur:

Diagnostic System Check (Manual A/C)

Compressor Clutch Does Not Engage (Automatic A/C)

Compressor Clutch Does Not Engage (Manual A/C)

Compressor Clutch Does Not Disengage (Automatic A/C)

Compressor Clutch Does Not Disengage (Manual A/C)

3.8L: PARK AVENUE

Disengages when air conditioning is not requested.

Under normal operating conditions, the following events occur:

Diagnostic System Check