1998 Chevrolet Camaro & Pontiac Firebird Service Manual Volume 2

1998 Chevrolet Camaro
and Pontiac Firebird

Service Manual
Volume 2
This manual provides information on the diagnosis, the service procedures, the adjustments,
and the specifications for the 1998 Chevrolet Camara and Pontiac Firebird. This is the second
edition of the 1998 Chevrolet Camara and Pontiac Firebird Service Manual. This manual
contains new and updated information that will help you diagnose and service vehicles. If you
are in the possession of the early edition of this manual GMP/98-F Volumes 1, 2, and 3 please
DISCARD it because the information is outdated.
Information on transmission unit repair (overhaul) can be found in the 1998
Transmission/Transaxle/Transfer Case Unit Repair Manual (TURM), GMPT/98-TURM, available
separately. The TURM manual contains information on automatic and manual transmissions,
including the fluid flow and circuit description information.
The technicians who understand the material in this manual and in the appropriate Dealer
Service Bulletins better serve the vehicle owners.
When this manual refers to a brand name, a part number, or a specific tool, you may use an
.
equivalent product in place of the recommended item. All information, illustrations, and
specifications in this manual are based on the latest product information available at the time of
publication approval. General Motors reserves the right to make changes at any time without
notice.
TABLE OF CONTENTS
Volume 1
Volume 2
Preface ................................................................ 1
Preface ................................................................ 1
Cautions and Notices
. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. ... .. .. 3
.. .. .. .. . .. .. .. .. .. .. ... ... .. .. . .. .. .. .. . 3
General Information ....................................... 0-1
Steering ............................................................ 2-1
General Information ......................................... 0-3

Maintenance and Lubrication ......................... 0-33
Vibration Diagnosis and Correction ................ 0-45
Power Steering System .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 2-3

Steering Wheel and Column - Tilt ................. 2-51
HVAC ................................................................ 1-1

HVAC System - Manual
.. .. .. .. .. .. .. .. .. .. .. .. ... ... .. .. 1-3
Body and Accessories .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 8-1

Lighting Systems ........................................... 8-15
Wipers/Washer Systems .............................. 8-161
Entertainment .............................................. 8-195
Wiring Systems ........................................... 8-282
Body Control System ................................... 8-425
Instrument Panel, Gauges and Console ....... 8-467
Keyless Entry .. . .. ... . .. .. .. ... .. .. .. .. .. . .. .. .. .. .. .. .. .. . 8-545
Horns .......................................................... 8-560
Theft Deterrent .. . .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. . .. . .. . .. .. 8-569
Cruise Control ............................................. 8-601
Retained Accessory Power .......................... 8-640
Exterior Trim ............................................... 8-647
Waterleaks .................................................. 8-658
Air/Wind Noise ............................................ 8-665
Squeaks and Rattles .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. 8-667
Stationary Windows .. .. .. .. .. .. .. . .. .. . .. . .. .. .. ... .. .. . 8-683
Bumpers ..................................................... 8-712
Body Front End ........................................... 8-734
Doors .......................................................... 8-771
Roof ............................................................ 8-825
Seats ... .. . .. .. . .. .. ... .. ... ..... .... . .. ...... .. .. .. ... ... ... .. 8-896
Interior Trim ................................................ 8-939
Body Rear End .. .. .. ... .. .. .. .. .. .. . .. .. . .. .. .. .. .. .. . .. . 8-955
Plastic Panel Information and Repair ........... 8-987
PainVCoatings ........................................... 8-1014
Frame and Underbody ............................... 8-1022
Collision Repair ......................................... 8-1080
Restraints ......................................................... 9-1

Seat Belts .. .. . .. .. .. ... .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. .. ... . 9-3
SIR ............................................................... 9-20
INDEX ....................................................... .INDEX-1
Suspension .. .. .. ... ... ... ... ... .. ...... ...... .. .. ... .... ..... ... 3-1
Suspension General Diagnosis .. .. .. .. .. .. .. .. .. .. .. .. 3-3
Wheel Alignment ............................................. 3-7
Front Suspension .......................................... 3-12
Rear Suspension .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 3-43
Tires and Wheels .......................................... 3-58
Driveline/Axle .................................................. 4-1

Propeller Shaft . .. .. . .. .. . .. .. .. .. .. ... . .. . .. ... .. . . .. .. .. ... .. 4-3
Rear Drive Axle .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. . 4-23
Brakes .............................................................. 5-1

Hydraulic Brakes .. .. . .. . .. . .. .. .. . .. . .. .. . .. ... .. ... . . ... ... . 5-5
Disc Brakes .. . .. .. ... .. .. .. . .. .. .. ... . . .. .. .. .. . .. . .. .. .. ... . 5-68
Park Brake . .. . .. .. .. . .. .. . .. .. . .. . .. .. .. . . .. .. . .. .. .. . .. .. ... . 5-92
Anti lock Brake System .. .. .. .. .. . .. . .. .. .. ... .. .. .. .. . 5-108
INDEX ........................................................ INDEX-1

Volume 3
Preface ................................................................ 1
.. .. .. ... .. .. . .. .. .. .. . .. .. .. .. .. .. .. .. .. 3
Engine .............................................................. 6-1

Engine
Engine
Engine
Engine
Engine
Engine
Engine
Mechanical - 3.8L ............. ,................ 6-13

Mechanical - 5.7L ............................ 6-229
Cooling ............................................ 6-580
Electrical .. .. .. . .. . .. .. .. . .. . .. . .. . ... .. ... .. . ... . 6-665
Controls - 3.8L ................................ 6-725
Controls - 5.7L .............................. 6-1247
Exhaust ......................................... 6-1900
Transmission/Transaxle .. .. ... .... ... ...... ... .... .. .. . 7-1

Manual Transmission - M49 ............................ 7-5
Manual Transmission - MM6 ......................... 7-28
Automatic Transmission - 4L60-E .................. 7-56
Clutch
......................................................... 7-359
INDEX ........................................................INDEX-1
Steering
Table of Contents 2-1
Section 2
Steering
Power Steering System ..................................2-3
Specifications ..................................................2-3
Fastener Tightening Specifications ................. 2-3
Fluid Specifications ........................................2-3
Visual Identification .........................................2-4
Power Steering Pump Disassembled View ....................................2-4
Power Steering Gear - Disassembled View .... 2-5
Diagnostic Information and Procedures ......... 2-6
Power Steering System Inspection ................. 2-6
Hissing Noise In Steering Gear ...................... 2-7
Rattle in Rack and Pinion .............................. 2-7
Power Steering Gear and Pump Leaks .......... 2-7
Seal Replacement Recommendations ............ 2-9
Power Steering System Test Procedure ....... 2-10
Power Steering System Test ........................ 2-11
Rattle or Chuckle Noise in Steering Gear .... 2-12
Excessive Wheel Kickback or Loose
Steering ....................................................2-12
Increase in Effort While Turning Steering
Wheel .......................................................2-12
Poor Return of Steering Wheel .................... 2-12
Steering Wheel Surges/Jerks While Turning ... 2-12
Steering Wheel Kickback ............................. 2-13
Steering Effort Hard in Both Directions ......... 2-13
Too Much Play in Steering .......................... 2-13
Wander or Poor Steering Stability ................ 2-13
Vehicle Leads to One Side or the Other ...... 2-13
Foaming, Milky-Appearing PS Fluid, Low
in Level .................................................... 2-14
Low Oil Pressure Due to Steering Gear ....... 2-14
Low Oil Pressure Due to Steering Pump ..... 2-14
Groan Noise in Steering Pump .................... 2-14
Growl Noise in Steering Pump ..................... 2-14
Whine Noise in Steering Pump .................... 2-15
Repair Instructions ........................................2-15
Remote Power Steering Fluid Reservoir
Replacement ............................................2-15
Remote PS Fluid Reservoir Bracket
Replacement ............................................2-16
Power Steering Pulley Replacement ............. 2-17
Power Steering Pump Replacement
(3800 VIN K) ............................................2-18
(5.7L VIN G) ............................................ 2-19
Power Steering Reservoir Replacement Off Vehicle ...............................................2-20
Power Steering Pump Flow Control Valve
Replacement - Off Vehicle
(Control Valve) .........................................2-21

Replacement - Off Vehicle (Return Tube) .... 2-22
Power Steering Pump Disassemble .............. 2-23
Power Steering Pump Drive Shaft Seal
Replacement - Off Vehicle ........................ 2-23
Power Steering Pump Assemble ..................2-23
Power Steering Pump Front Bracket
Replacement ............................................2-24
Power Steering Pump Rear Bracket
Replacement ............................................2-24
Checking and Adding Power Steering Fluid .... 2-25
Bleeding Power Steering System ................. 2-25
Flushing the Power Steering System ............2-27
Power Steering Hoses Replacement ............ 2-28
Tie Rod End Replacement - Outer - Ott
Vehicle .....................................................2-30
Rack and Pinion Boot Replacement - Ott
Vehicle .....................................................2-33
Power Steering Cooler Replacement ............ 2-36
Power Steering Gear Replacement
(3.BL VIN G) ............................................2-37
(5.7L VIN K) ........................................ ,.... 2-40
Rack Bearing Preload Adjustment - Off
Vehicle .....................................................2-42
Tie Rod Replacement - Inner ....................... 2-42
Steering Gear Cylinder Pipe Assemblies/
0-Ring Seals Replacement-Off Vehicle ..... 2-44
Steering Gear Stub Shaft Seals and
Bearing Replacement - Ott Vehicle ........... 2-46
Description and Operation ............................ 2-49
Power Steering Pump Description ................ 2-49
Power Steering Gear Description ................. 2-49
Seal Replacement Recommendations .......... 2-49
Special Tools and Equipment ....................... 2-50
Steering Wheel and Column - Tilt ............... 2-51

Specifications ................................................2-51
Fastener Tightening Specifications ............... 2-51
Visual Identification .......................................2-52
Steering Column - Disassembled View ......... 2-52
Schematic and Routing Diagrams ................ 2-54
Tilt Wheel/Column Schematic References .... 2-54
Tilt Wheel/Column Schematic Icons ............. 2-54
Automatic Transmission Shift Lock Control
Schematics ...............................................2-55
Component Locator ....................................... 2-56
Tilt Wheel/Column Components ................... 2-56
Tilt Wheel/Column Component Views ...........2-57
2-2 Table of Contents

Tilt Wheel/Column Connector End Views ..... 2-58
Diagnostic Information and Procedures ....... 2-58
System Check ..........................................2-58
Inoperative ...............................................2-59
Always On With Ignition in RUN ............... 2-60
Lock System Does Not Unlock .................... 2-60
Lock System Does Not Lock ........................ 2-61
Key Cannot Be Removed in the Off Lock
Position .................................................... 2-61
Lock Cylinder Can Be Removed Without
Depressing Retainer ................................. 2-61
High Lock Effort Between the Off Lock
Positions .................................................. 2-61
High Lock Effort ........................................... 2-61
Diagnosis .................................................2-62
Noise in Steering Column ............................ 2-62
High Steering Shaft Effort ............................ 2-62
Looseness in Steering Column ..................... 2-62
Lower Housing Scraping Upper Housing ...... 2-62
Loose Steering Wheel ..................................2-63
Loose Steering Wheel
(Every Other Tilt Position) ........................ 2-63
Steering Wheel Does Not Lock in Any Tilt
Position .................................................... 2-63
Steering Wheel Not Returning to Top Tilt
Position ....................................................2-63
Noise When Tilting Steering Column ............ 2-63
Turn Signal Does Not Indicate Lane
Change .................................................... 2-63
Turn Signal Does Not Stay in Turn
Position ....................................................2-64
Turn Signal Does Not Cancel ...................... 2-64
Turn Signal Difficult to Operate .................... 2-64
Hazard Switch Cannot Be Turned Off .......... 2-64
Hazard Switch Does Not Stay On ................ 2-65
Ignition Switch Electrical System Does
Not Operate ............................................. 2-65
Ignition Switch Does Not Turn ..................... 2-65
Ignition Switch Cannot Be Set Correctly ....... 2-65
Ignition Switch Replacement - On Vehicle .... 2-66
Multifunction Turn Signal Lever
Replacement - On Vehicle ......................... 2-68
Hazard Warning Switch Replacement On Vehicle ............................................... 2-69
Tilt Lever Replacement - On Vehicle ........... 2-69
Steering Wheel Inflater Module
Replacement ............................................ 2-70
Hom Switch Replacement - On Vehicle
(Pontiac) ................................................... 2-72
Hom Switch Replacement - On Vehicle
(Chevrolet) ................................................2-72
Steering Wheel Control Switch Assembly
Replacement ............................................2-73
Steering Wheel Replacement ....................... 2-74
Steering Shaft Coupling Replacement .......... 2-75
Steering
Steering Column Replacement ..................... 2-77
Steering Column Disassembly/Assembly Off Vehicle ...............................................2-79
Ignition and Key Alarm Switch Assembly Off Vehicle ...............................................2-81
Tilt Spring - Disassemble - Off Vehicle ........ 2-85
Tilt Spring - Assemble - Off Vehicle ............. 2-87
Turn Signal and Multifunction Switch
Assembly - Disassemble - Off Vehicle ...... 2-88
Assembly - Assemble - Off Vehicle .......... 2-89
Ignition Switch Assembly - Disassemble Off Vehicle ...............................................2-91
Ignition Switch Assembly - Assemble Off Vehicle ...............................................2-91
Dimmer Switch Assembly - Disassemble Off Vehicle ...............................................2-92
Dimmer Switch Assembly - Assemble Off Vehicle ...............................................2-92
Windshield Wiper and Washer Switch
Assembly - Disassemble - Off Vehicle ...... 2-93
Assembly - Assemble - Off Vehicle .......... 2-94
Steering Column Lock Cylinder Set Disassemble - Off Vehicle ........................ 2-95
Steering Column Lock Cylinder Set Assemble - Off Vehicle ............................. 2-95
Turn Signal Cancel Cam and Upper
Bearing Inner Race - Disassemble Off Vehicle ...............................................2-95
Bearing Inner Race - Assemble - Off
Vehicle .....................................................2-96
Steering Column Jacket - Disassemble Off Vehicle ...............................................2-97
Steering Column Jacket - Assemble Off Vehicle ............................................... 2-98
Lock Housing Assembly - Disassemble - /
Off Vehicle .............................................2-100
Lock Housing Assembly - Assemble Off Vehicle .............................................2-101
Steering Shaft, Lower Bearing, and
Jacket - Disassemble - Off Vehicle ......... 2-103
Steering Shaft, Lower Bearing, and
Jacket - Assemble - Off Vehicle ............. 2-105
Steering Column Accident Damage ff Vehicle ................................................2-107
Description and Operation .......................... 2-109
Steering Wheel and Column Description .... 2-109
Ignition Lock System Description ................ 2-110
Automatic Transmission Shift Lock
Control Description ................................. 2-11 O
Control Circuit Description ....................... 2-110
Supplemental Inflatable Restraint
Description .............................................2-11 O
Special Tools and Equipment ..................... 2-111
Steering
Power Steering System

Specifications
Fastener Tightening Specifications
Specification
Application
Hydraulic Pump Control Fitting-to-Power Steering Pump
Power Steering Fluid Reservoir Bolt/Screw (5.7L VIN G)
Metric
English
75Nm
55 lb ft
10 Nm
891bin
50Nm
37 lb ft
Power Steering Gear Bolt/Screw
85 N-m
63 lb ft
Power Steering Gear Inlet Hose Fitting-to-Power Steering Gear
28 Nm
21 lb ft
Power Steering Gear Inlet Hose Fitting-to-Power Steering Pump
28Nm
21 lb ft
Power Steering Gear Outlet Hose Fitting-to-Power Steering Gear
28Nm
21 lb ft
Power Steering Fluid Reservoir Bracket Bolt/Screw (3800 VINK)
Power Steering Pump Bolt/Screw (5.7L VIN G)
25Nm
18 lb ft
Power Steering Pump Nut (3800 VIN K)
30Nm
23 lb ft
Power Steering Pump Rear Bracket Bolt/Screw (5.7L VIN G)
50N-m
37 lb ft
Fluid Specifications
Application
Type of Material
GM Part Number
1050017
Warm Climate
Power Steering Fluid
Cold Climate (see note)
Power Steering Fluid
Important: Drain and refill the system prior to using this fluid.
or
1052884
or equivalent meeting
GM Specification 998501 O
12345867
or
12345866
2-3
2-4 Power Steering System
Steering
Visual Identification
Power Steering Pump Disassembled View
Power Steering Pump
391549
Legend
(1) Hydraulic Pump Housing Assembly
(2) Flow Control Spring
(3) Control Valve Assembly
(4) 0-ring Seal

(5) 0-ring Union Fitting
Steering
2-5
Power Steering Gear - Disassembled View

Power Rack and Pinion - End Take Off
441305
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Lubrication Fitting
Hexagon Slotted Nut
Cotter Pin
Tie Rod Seal
Outer Tie Rod Assembly
Hexagon Jam Nut
Tie Rod End Clamp
Rack and Pinion Boot
Boot Clamp
Inner Tie Rod Assembly
Adjuster Plug Lock Nut
Shock Dampener Ring
Mounting Bracket Assembly
Mounting Grommet
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
(28)
Cylinder Line (Left Hand) Assembly

Cylinder Line (Right Hand) Assembly
0-Ring Seal
0-Ring Seal
Seal Adapter
Retaining Ring
Stub Shaft Seal
Annulus Bearing Assen,bly
Hexagon Lock Nut
Dust Cover
Rack and Pinion (Partial) Gear Assembly
Shock Dampener Ring
Inner Tie Rod Assembly
Boot Clamp
2-6
Steering

(29)
(30)
(31)
(32)
Rack and Pinion Boot

Tie Rod End Clamp
Hexagon Jam Nut
Outer Tie Rod Assembly
(33)
(34)
(35)
(36)
Cotter Pin
Hexagon Slotted Nut
Tie Rod Seal
Lubrication Fitting
Diagnostic Information and Procedures

Power Steering System Inspection
Tools Required
J 5176-E Power Steering Pressure
Tester 0-2000 psi
J 5176-9218 mm Power Steering Gauge Adapter
If you suspect a hydraulic or mechanical malfunction of
one of the following components, perform this
procedure in order to determine the cause:
The power steering pump
The power steering gear
1. Place a drain pan under the remote reservoir.
2. Disconnect the outlet hose at the remote reservoir.
3. Connect a spare pressure hose to the remote
reservoir.
Important: Test the power steering system using the

J 5176-E. Testing the power steering system with
the J 25323-A will measure the flow rate and
the pressure.
4. Connect the J 5176-E and the J 5176-92 to the
following hoses:
The outlet hose
The spare pressure hose
5. Open the valve on the J 5176-E.
6. Start the engine.
Allow the engine to reach a normal operating
temperature.
7. Ensure that the engine is at idle and that the
valve on the J 5176-E is open.
8. Read the pressure reading.
Important: The pressure should be no more
than 1 050 kPa (150 psi).
9. If the pressure is more than 1 050 kPa (150 psi),
perform the following steps:
Inspect the hoses for restrictions.
Inspect the popper valve on the steering gear
for the proper installation.
Notice: Do not leave the valve fully closed for more
than 5 seconds, or the pump could be damaged
internally.
10. Fully close the valve on the J 5176-E three times.
Record the pressure readings each time.
The power steering pump is functioning properly
when the pressure readings fall within the
following range:
Each reading is at least 6 895 kPa (1,000 psi).
The 3 readings are within 345 kPa (50 psi)
of each other.
11. The power steering pump control valve is sticking

if the following conditions exist:
The pressure readings are at least
6 895 kPa (1,000 psi).
The pressure readings are not within 345 kPa
(50 psi) of each other.
12. If the pressure readings indicate that there is a
sticking flow control valve, perform the
following steps:
12.1. Remove the flow control valve.
12.2. Clean the flow control valve.
Remove any burrs using a crocus cloth of
fine hone.
12.3. Flush the system if the system contains
any contamination.
13. If the pressure readings are less than 6 895 kPa
(1,000 psi), complete the following steps:
13.1. Replace the flow control valve.
13.2. Retest the flow control valve.
13.3. If the pressure is still below 6 895 kPa
(1,000 psi), replace the following
components:
The rotor
The vanes
14. If the pressure readings are within specifications,

perform the following procedure:
14 .1 . With the flow control valve open, have an
assistant turn the steering wheel to
both sides.
14.2. Record the highest pressures.
14.3. Compare the pressure with the highest
pump pressures that you recorded earlier.
15. If the pressure at both stops is not the same as
the maximum pressure previously recorded, then
the steering gear is leaking internally.
Repair the steering gear if the steering gear is
leaking internally.
16. Turn off the engine.
17. Remove the J 5176-E and J 5176-92.
Notice: Refer to Fastener Notice in Cautions and
Notices.
18. Connect the outlet hose to the remote reservoir.
Tighten
Tighten the hydraulic pump hose fitting nut to
28 N,m (21 lb ft).
19. Bleed the power steering system. Refer to

Bleeding Power Steering System.
Steering
2-7
Hissing Noise In Steering Gear

Problem
Action
DEFINITION:
A hissing noise is commonly heard when the steering wheel is turned and the vehicle is not moving. The noise especially
noticeable if the brakes are applied. A replacement gear will also have a slight noise, and is not always a cure for the
condition.
There is a hissing noise in the
steering gear.
Inspect for loose intermediate steering shaft universal joints.

If the noise is very objectionable, replace the steering gear.
Rattle in Rack and Pinion

Problem
There is a rattling noise.
Action
Inspect for the following conditions:
Contact between the outlet (pressure) hose and the frame
Loose tie rod ends
Loose steering gear attachment
A loose pinion shaft
A rattling noise occurs when driving

over bumps.
Inspect the front brake linings for the following conditions:

A loose fit
Missing antirattle clips
Power Steering Gear and Pump Le~ks

Determine if any of the following conditions exist:
- The vehicle leaks fluid onto the garage floor.
- Fluid leaks are visible on the steering

gear or the pump.
- There is a growling noise when you are
parking the vehicle.
- There is a growling noise when the engine
is cold.
- The power steering does not operate when
you are parking the vehicle.
- The vehicle requires excessive steering
effort.
Inspect for an overfilled power steering fluid
reservoir.
Inspect for fluid aeration and overflow.
Inspect the hose connections.
Identify the exact point of system leakage. Refer
to External Leakage Check in this section.
The point from which fluid is dripping is not
necessarily the point where the system is
leaking from.
External Leakage Check

Use this procedure in order to help identify the exact
location of a leak. Some leaks can be easily
located, but seepage type leaks may be more difficult
to locate. To locate seepage leaks use the following
method:
1. Turn the engine off.
2. Wipe the complete power steering system dry.
291852
3. On vehicles with a 3800 engine, inspect the fluid

level in the power steering fluid reservoir (1 ).
Adjust the fluid level as necessary.
2-8
Steering
13. Replace the hydraulic pump fluid reservoir if you
detect these conditions.
291855
14. Torque the steering gear pipe fitting seat to

specifications.
If leakage persists, replace the steering gear pipe
seal (0-ring).
291841
4. On vehicles with a 5.7L engine, inspect the fluid

level in the power steering fluid reservoir (1 ).
Adjust the fluid level as necessary.
6. Turn the steering wheel from stop to stop
several times:
Do not hold the steering wheel at a stop for
any length of time.
Holding the steering wheel at a stop may
damage the power steering pump (3).
Search for the seepage while an assistant
operates the steering wheel.
7. Find the exact location of the leak.
Repair any leaks that you find.
8. Replace the driveshaft seal (4).
9. Ensure that the driveshaft is clean and free of
pitting at point 4.
10. Inspect the fluid level.
Determine if leakage persists under the following
conditions:
The fluid level is correct.
The hydraulic pump reservoir cap is tight.
11. Replace the hydraulic pump reservoir cap if
leakage persists.
12. Inspect the hydraulic pump fluid reservoir for the
following conditions:
Cracks
Bending
291858
15. Replace the gear with a partial steering gear.

16. If you observe leakage between the torsion bar
and the steering gear pinion shaft, replace the
gear with a partial steering gear.
Steering
2-9
291861
17. Determine if the following conditions exist:

You observe a leakage at the driver side.
The leakage is not affected by the direction of
the turn.
18. If the above conditions exist, replace the steering
You observe a leakage at the steering
gear housing end.
The fluid spurts when bottomed in a left turn.

291841
23. Tighten the following components to

specifications:
The hydraulic pump hose fitting.
The hydraulic pump hose fitting nut.
24. Replace the hydraulic pump seal (0-ring) if
leakage persists.
Seal Replacement Recommendations

Lip Seals
Lip seals seal the rotating shafts. The lip seals require
special treatment. Lip seals are used on the hydraulic
pump shaft of the power steering pump. When the
lip seals leak complete the following steps:
1. Inspect the sealing surfaces.
2. Thoroughly clean the sealing surfaces.
3. Replace the seal(s).
Replace the shaft if you find pitting. If there is slight
corrosion in the lip seal contact zone, clean the surface
of the shaft with crocus cloth. Replace the shaft only if
you cannot stop the leakage by smoothing the shaft
with crocus cloth.
0-Ring Seals
291864

You observe leakage at point 2
You observe leakage at point 3
When you remove a part which forms a sealing

surface for an 0-ring complete the following steps:
1. Remove the original 0-ring seal.
2. Replace the original 0-ring seal with a new
0-ring seal.
Lubricate all of the new 0-ring seals with power
steering fluid in order to ease the installation.
2-10
Power Steering System Test Procedure

Tools Required
Tester 0-2000 psi
Flow Rate and Presssure Gauge Power
Steering System Analyzer
J 29525 Power Steering Analyzer 18 mmAdapter
one of the following components, perform this
1. Place a drain pan under the reservoir.
2. Disconnect the outlet hose at the reservoir.
3. Connect a spare pressure hose to the reservoir.
Important: Test the power steering system using
the J 5176-E. Testing the power steering system with
the will also measure the flow rate as well as the
pressure.
4. Connect the J 5176-E and the J 5176-92 or the
Flow Rate and Presssure Gauge and the J 29525
to the following hoses:
The outlet hose
5. Open the valve on the J 5176-E or the Flow Rate
and Presssure Gauge.
6. Start the engine and allow to reach a normal
operating temperature.
valve on the J 5176-E or is open.
than 5 seconds. or the pump could be damaged
internally.
10. Fully close the valve on the J 5176-E or the Flow
Rate and Presssure Gauge 3 times.
following range:
of each other.
Steering
11. The power steering pump control valve is sticking
if the following conditions exist:
The pressure readings are at
least 6 895 kPa (1,300 psi).
following steps:
12.1. Remove the flow control valve.

fine hone.
12.3. Flush the system if the system contains
any contamination.
components:
The rotor
The vanes
14. If the pressure readings are within specifications,
14.1. With the flow control valve open, have an
both sides.
14.2. Record the highest pressures.

leaking internally.
16. Tum off the engine.
17. Remove the J S 176-E and the J 5176-92 or the
Flow Rate and Presssure Gauge and the.
J29525.
Notices.
Tighten
28 Nm (21 lb ft).
Bleeding Power Steering System in Power
Steering.
I~
Steering
Power Steering System Test
Tools Required
Tester 0-2000 psi
Flow Rate and Presssure Gauge Power
Steering System Analyzer
J 29525 Power Steering Analyzer 18 mmAdapter
one of the following components, periorm this
1. Place a drain pan under the reservoir.
2. Disconnect the outlet hose at the reservoir.
3. Connect a spare pressure hose to the reservoir.
Important: Test the power steering system using
the J 5176-E. Testing the power steering system with
the will also measure the flow rate as well as the
pressure.
4. Connect the J 5176-E and the J 5176-92 or the
Flow Rate and Presssure Gauge and the J ~9525
to the following hoses:
The outlet hose
5. Open the valve on the J 5176-E or the Flow Rate
and Presssure Gauge.
6. Start the engine and allow to reach a normal
operating temperature.
valve on the J 5176-E or is open.
than 5 seconds, or the pump. could be damaged
internally.
1O. Fully close the valve on the J 5176-E or the Flow
Rate and Presssure Gauge 3 times.
following range:
of each other.
Power S~eering System
2-11
11 . The power steering pump control valve is sticking

if the following conditions eX:ist: ..
The pressure readings are at
least 6 895 kPa (1,300 psi).
following steps:
12.1 . .Remove the flow control valve.
fine hone.
12.. 3. Flush the system if the system contains
any contamination.
components:
The rotor
The vanes
14. If the pressure readings are within. specifications,
14.1. With the flow control valve open, have an

both sides.
14.2. Record the highest pressures,
leaking internally.
16. Turn off the engine.

17. Remove the J 5176-E and the J 5176-92 or the
Flow Rate and Presssure Gauge and the
J29525.
Notices.
Tighten
28 N-m (21 lb ft).
Bleeding Power Steering System in Power.
Steering.
Steering
Rattle or Chuckle Noise in Steering Gear

Problem
There is a rattling noise.
A rattling noise occurs when driving

over bumps.
Action
Contact between the outlet (pressure) hose and the frame
Loose tie rod ends
Loose steering gear attachment
A loose pinion shaft
Inspect the front brake linings for the following conditions:
A loose fit
Missing antirattle clips
Excessive Wheel Kickback or Loose Steering

Problem
There is excessive steering wheel
kickback or loose steering.
Action
Inspect the steering system for the following conditions:
Air in the power steering system
Loose steering gear adjustment
Loose tie rod ends
A worn wheel bearing
A loose coupling on the stabilizer
A loose thrust bearing preload adjustment
A worn pipe fitting seat
Increase in Effort While Turning Steering Wheel

Problem
Action
There is a momentary increase in
effort when turning the steering wheel
High internal leakage
fast to the right or left.
A sticking or damaged steering gear valve spool
Insufficient pump pressure
A low fluid level
Poor Return of Steering Wheel

Problem
The steering wheel has poor
return ability.
Action
Incorrect caster setting
A bind in the following components:
- The control arm ball stud
- The steering column
- The intermediate steering shaft joints
A misadjusted steering gear
An incorrect steering gear valve spool
Steeri ng Wheel Surges/Je rks Wh"I1e T urning

Problem
The steering wheel surges or jerks.
Action
Inspect the vehicle for the following conditions:
A defective tire
A bad tire
A sluggish steering gear valve spool
A serpentine drive belt which is in one of the following conditions:
- Loose
- Soaked with oil
I~
Steering
2-13
Steering Wheel Kickback

Problem
There is kickback in the

steering wheel.
Action

A loose steering gear mounting
Loose or worn joints from the steering column to the steering gear
Loose tie rod ends
A worn or missing pipe fitting seat
A worn wheel bearing
Misadjusted steering gear
'
Steering Effort Hard in Both Directions

Problem
The steering is hard.
Action
Perform the test on the hydraulic system. Refer to Power Steering System Test
Procedure.
Inspect the steering system:for the following conditions:
- Misadjusted steering gear
- A bind or catch in the steering gear
- A loose ~teering gear mounting
- A faulty pipe fitting seat
Too Much Play in Steering

Problem
There is too much play in the

steering wheel.
Action

A loose steering gear mounting
Loose or worn joints from the steering column to the steering gear
Wander or Poor Steering, Stability

Action
Problem
There is a wander or poor stability in

the steering.

Mismatched tires
Uneven tires
Worn shock absorbers
A loose stabilizer shaft
A broken spring
A sagging spring
A misaligned tire and wheel
Vehicle Leads to One Side or the Other

Problem
The vehicle pulls or leads.
Action

A misaligned front tire and wheel
Mismatched tires
Uneven tires
Broken springs
Sagging springs
Radial tire lead/pull
An unbalanced steering gear valve spool
A dragging front brake
2-14
Steering
Power Steerieg System

Foaming, Milky-Appearing PS Fluid, Low in Level
Problem
The following conditions exist:
The fluid is foamy or milky.
The fluid level is low.
The fluid pressure is low.
Action
Inspect for air in the fluid.

Inspect tor an internal pump leak.
Extremely cold temperatures will cause air bubbles if the fluid level is low.
If the fluid level is correct and the pump still foams, perform the following steps:
- Remove the reservoir.
- Inspect the reservoir for cracks.
If the reservoir is cracked, replace the reservoir.
Low Oil Pressure Due to Steering Gear

Problem
There is low pressure due to the
steering gear.
Action
Inspect the steering gear for the following conditions:
A scored housing bore
Leakage at one of the following areas:
- The valve rings
- The seals
Low Oil Pressure Due to Steering Pump

Problem
There is low pressure due to the
power steering pump.
Action
A stuck or inoperative flow control valve
A pressure plate that is not flat against the ring
An extremely worn ring
Scoring on one of the following components:
- The pressure plate
- The thrust plate
- The rotor
Vanes sticking in the rotor slots
A break or crack on one of the following components:
- The thrust plate
- The pressure plate
A high internal leakage
Groan Noise in Steering Pump

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

Problem
There is a growling noise in the
power steering pump.
Action
Inspect the system for the following conditions:
Excessive back pressure that is caused by one of the following conditions:
- A restricted hose
- A restricted steering gear
Scoring on one of the following components:
- The pressure plates
- The thrust plate
- The rotor
A worn ring
Steering
2-15
Whine Noise in Steering Pump

Problem
Action
There is a whining noise in the power Inspect the system for scoring on one of the following components:
steering pump.
.The power steering pump shaft bushing
The pressure plates
The vanes
Repair Instructions
Remote Power Steering Fluid Reservoir
Replacement
Removal Procedure
1. Place a drain pan under the reservoir (1 ).
2. Remove the cap from the reservoir (1 ).
3. Remove the reservoir (1) from the bracket (2).
4. Disconnect the reservoir and outlet hoses (4 & 6)
from the reservoir (1 ).
5. Remove the power steering fluid reservoir (1 ).
290572
Installation Procedure
1. Connect the reservoir and outlet hoses (4 & 6) to
the reservoir (1 ).
2. Install the reservoir (1) to the bracket (2).
3. Refill the reservoir and Install the cap to the
reservoir.
4. Remove drain pan.
290572
2-16
Steering
Remote PS Fluid Reservoir Bracket

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

6. Remove the nuts (2).
290571
Notices.
1. Install the nuts (2).
Tighten
Tighten the nuts to 12 N-m (107 lb in).
2. Install the bolVscrew (1 ).
Tighten
Tighten the bolVscrew to 50 N,m (37 lb ft).
3. Install the electrical harness to the bracket (3).
4. Lower the vehicle.
290571
Steering
2-17
5. Install the reservoir (1) to the bracket (2).
290572
Power Steering Pulley Replacement

Removal Procedure
Tools Required
J 25034-C Pulley Pump Remover
1. Remove the air intake resonator and mass airflow
assembly (LS1 only).

2. Remove the serpentine belt.
3. Use the J 25034-C in order to remove the
steering pulley from the power steering pump.
354410
Tools Required
J 25033-C Pulley Pump Installer.
Important:
3.8 Liter Engine: Ensure that the face of the pulley
hub is flush with the end of the pump shaft before
you apply a load to the pulley hub.
5.7 Liter Engine: Ensure that the pulley hub
shoulder bottoms out completely on the pulley
shaft before you apply a load to the pulley hub.
Ensure that the pulley goes on snug when
installing the pulley with the special tool. If the
pulley installs onto the pump shaft too easily, it will
not relay engine power to the pump and should
be replaced.
1. Use the J 25033-C in order to install the power
steering pulley (1) to the power steering pump (2).
290557
2-18
Steering
2. Install the air intake resonator and mass airflow

assembly (LS1 only).
3. Install the serpentine belt.
4. Check power steering operation and visibly check
pulley for any irregular wobble when operating.

(3800 VINK)
Removal Procedure
1. Place a drain pan under the power steering
pump (1 ).
3. Remove the front air intake duct.
4. Remove the pulley from the power steering
pump (1 ). Refer to Power Steering Pulley
Replacement.
5. Disconnect the inlet hose (3) from the power
steering pump (1 ).
6. Disconnect the reservoir hose (2) from the power
steering pump (1).
354420
7. Remove the power steering pump nuts.

8. Remove the power steering pump.
2
290569
Steering
2-19
1. Position the power steering pump onto the
mounting studs.

Notices.
2. Tighten the power steering pump nuts.
Tighten
Tighten the bolts/screws to 30 N,m (23 lb ft).
290569
3. Connect the inlet hose to the power steering

pump (2).
4. Connect the reservoir hose (2) to the power
steering pump (1 ).
5. Install the pulley to the power steering pump (1).
Refer to Power Steering Pulley Replacement.
6. Install the front air intake duct.
8. Refill and bleed the power steering system. Refer
to Bleeding Power Steering System.
2
354420

(5.7L VIN G)
Removal Procedure
1. Place a drain pan under the power steering
pump(1).
2. Remove the air intake resonator and mass airflow
assembly.
4. Remove the power steering pump pulley. Refer to
Power Steering Pulley Replacement.
5. Remove the outlet hose and the clamp from the
reservoir (This allows fluid to drain from reservoir).
6. Remove the inlet hose fitting from the pump.
7. Remove power steering pump attaching bolts (4)
and power steering pump front brace (3) from
pump (1).
290570
2-20
Steering
8. Remove pump (1) from rear bracket (2).
9. Remove reservoir from pump. Refer to Power
Steering Reservoir Replacement.
1. Install reservoir to pump. Refer to Power Steering
Reservoir Replacement.
Notices.
2. Install pump (1 ), pump front brace (3), and
attaching bolts (4) to rear bracket (2).
3.
4.
5.
290570
6.
7.
8.
9.
Tighten
Tighten the bolts/screws to 25 Nm (18 lb ft).
Install the inlet hose fitting from pump.
Tighten
Tighten the fitting to 28 Nm (21 lb ft).
Install the outlet hose and clamp to reservoir.
Install the power steering pump pulley. Refer to
Install the serpentine belt.
Install the air intake resonator and mass airflow
assembly.
Remove drain pan.
Refill and bleed the power steering system. Refer
to Bleeding Power Steering System.
Power Steering Reservoir Replacement Off Vehicle

Removal Procedure
1. Remove power steering pump (LS1 only). Refer
to Power Steering Pump Replacement
(5. 7L VIN G).
2. Remove the retainer clips from the sides of the
pump/reservoir assembly.
Important: It will be necessary to use a flat-head

screwdriver to slightly pry up the retainer clip tabs to
allow the clips to slide from the assembly.
3. Remove reservoir and seal from pump.
1 . Install the reservoir and seal to pump.
Important: Seal may be reused if in good condition.

Examine for any visible deterioration and if
present, replace seal.
2. Slide retainer clips onto pump/reservoir assembly.
Important: Ensure that retainer clip tabs lock down
into their mating groove in the pump. When fully
installed, the clips should "click" as they reach the fully
installed position.
3. Install the power steering pump (LS1 only). Refer
(5. lL VIN G).
4. Refill and bleed power steering system. Refer to
Steering
Replacement - Off Vehicle (Control Valve)
"~
Removal Procedure
1. Remove power steering pump assembly. Refer to
Power Steering Pump Replacement (3800 VIN K)
for 3.BL V6 or Power Steering Pump Replacement
(5.7L VIN G) for 5.7L VB.
2. Remove powers steering gear inlet hose (1) from
hydraulic pump fitting (2).
3. Remove hydraulic pump fitting (2) and 0-ring
seal (3) from pump (6).
Power Steering System 2-21

1
Important: The flow control valve must be installed in

the same orientation it was in when removed or
flow control and pressure relief will be affected.
4. Remove the flow control valve (4) and valve
spring (5) from pump (6) cavity using magnet.
Important: Do not disassemble the flow control
valve (4).
5. Inspect flow control valve (4) for free movement
within housing bore. If sticking occurs, check for
burrs and clean as necessary. If necessary,
replace flow control valve (4).
354417
1. Install the valve spring (5) and flow control
valve (4) into pump (6) cavity.
Important: The flow control valve (4) should be
installed face out, away from contact with the valve
spring (5).
2. Install new 0-ring (3) to fitting (2).
Notices.
'
Important: Lubricate 0-ring seal (3) with power

steering fluid.
3. Hand start fitting (2) and 0-ring seal (3) to
pump (6). Once fitting is seated by hand,
then tighten.
Tighten
Fitting to 75Nm (55 lb. ft.).
4. Install inlet hose (1) to fitting (2).
Tighten
Inlet hose (1) to 2BNm (21 lb. ft.).
5. Install the power steering pump assembly. Refer
(3800 VIN K) for 3.BL V6 or Power Steering Pump
Replacement (5.7L VIN G) for 5.7L VB.
Fill
reservoir with fluid and bleed system. Refer to
6.
Steering.
354417
2-22
Steering

Replacement - Off Vehicle (Return Tube)
Disassembly Procedure
Important: Handle the pump with care. Do not carry
the hydraulic pump housing assembly (1) by the return
tube (2).
Important: Replace the hydraulic pump housing

assembly (1) if the return tube (2) is cracked or loose.
Do not attempt to repair the hydraulic pump housing
assembly (1 ).
1. Inspect the return tube (2) on hydraulic pump
housing assembly (1).
391544
2. Remove the 0-ring union fitting (5) from the

hydraulic pump housing assembly (1 ).
3. Remove the 0-ring seal (4) from the 0-ring union
fitting (5).
4. Remove the control valve assembly (3).
5. Remove the flow control spring (2).
391535
Assembly Procedure
1. Install the flow control spring (2) to the hydraulic
pump housing assembly (1 ).
2. Install the control valve assembly (3).
3. Lubricate the 0-ring seal (4) with power

steering fluid.
4. Install the 0-ring seal (4) on to the 0-ring union
fitting (5).
Notice: Refer to Fastener Notice

5. Install the 0-ring union fitting (5) into the hydraulic
pump housing assembly (1 ).
Tighten
Tighten the 0-ring union fitting (5) to
75 N-m (55 lb ft).
391535
Steering
Power Steering Pump Disassemble
1. Use the punch in the access hole in order to
remove the retaining ring.
2. Push gently on the drive shaft in order to remove
the following internal components of the pump
housing:
The end cover
The 0-ring seal
The pressure plate spring
The pressure plate
3. Remove the following components from the drive
shaft subassembly:
The pump rotor
The thrust plate
The drive shaft
The shaft retaining ring.
The pump ring and the vane.
4. Remove the 0-ring from the pump housing.
5. Remove the dowel pins.
6. Remove the drive shaft seal.
7. Remove the following components from the
pressure plate:
The end cover
The pressure plate spring
The 0-ring
8. Remove the pump ring and the vanes from the
drive shaft subassembly.
9. Remove the shaft retaining ring from the
drive shaft.
10. Remove the pump rotor and the thrust plate from
the drive shaft.
11 . Clean all of the parts in power steering fluid.
12. Dry the parts.
13. Adjust the following components:
The pressure plate
The pump ring
The rotor
The vanes
The thrust plate
The drive shaft
14. Inspect and replace the components if the
components have the following conditions:
Scoring
Pitting
Chatter marks
2-23
Power Steering Pump Drive Shaft Seal

Replacement - Off Vehicle
Removal Procedure
Tools Required
J 7728 Shaft Oil Seal Installer
1. Remove the pump assembly from the vehicle, if
necessary for access.
2. Protect the drive shaft with the shim stock.
3. Use a small chisel in order to remove the seal.
4. Discard the seal.
1. Lubricate the new drive shaft seal with power
steering fluid.
2. Use the J 7728 in order to install the .new drive
shaft seal.
3. Install the pump assembly to the vehicle, if
removed.
Power Steering Pump Assemble

Assembly Procedure
1. Lubricate the new drive shaft seal with power
steering fluid:
2. Use the J 7728 in order to install the drive shaft
seal into the pump housing.
3. Install the pump ring dowel pins into the pump
housing.
4. Install the thrust pJate and the pump rotor to the
drive shaft.
5. Install the new shaft retaining ring onto the

drive shaft.
6. Install the drive shaft subassembly into the pump
housing.
7. Install the vanes into the pump rotor.
8. Install the pump ring into the pump housing.
Ensure that the holes are positioned correctly
onto the dowel pins.
9. Lubricate the new 0-ring with power steering fluid.
10. Install the 0-ring into the groove in the pump
housing.
11. Install the pressure plate.
12. Install the pressure plate spring.
13. Lubricate the.new 0-ring with power steering fluid.
14. Install the 0-ring into the end cover.
15. Lubricate the outer edge of the end cover with
power steering fluid.
16. Press the end cover into the pump housing.
17. Install the retaining ring into the groove in the
'
pump housing.
Ensure that the ring opening is near the apcess
hole in,the pump housing.
2-24
Steering
Power Steering Pump Front Bracket

Replacement
Removal Procedure
1. Place drain pan under pump (1 ).
2. Remove air intake resonator and mass airflow
sensor assembly.
4. Remove the power steering pump pulley from the
pump. Refer to Power Steering Pulley
Replacement.
5. Support pump assembly with mechanics wire.
Important: The front power steering pump bracket can

be removed without the complete disconnection of
the pump. The hydraulic hoses do not need to
be disconnected.
6. Power steering pump attaching bolts (4) and front
power steering pump bracket (3).
290570
1. Power steering pump attaching bolts (4) and front
power steering pump bracket (3).
2. Remove the mechanics wire used for support.
3. Install the power steering pump pulley to the
pump. Refer to Power Steering Pulley
Replacement.
5. Install the air intake resonator and mass airflow
sensor assembly.
6. Remove drain pan and verify power steering
operation.
290570
Power Steering Pump Rear Bracket

Replacement
Removal Procedure
1. Remove the power steering pump (LS1 only).
Refer to Power Steering Pump Replacement
(5. 7L VIN G).
2. Remove the rear power steering pump bracket

bolts (3).
3. Remove the rear power steering pump bracket (2)
from cylinder head (1 ).
2
354413
Steering
2-25
1. Install the rear power steering pump bracket (2) to
cylinder head (1 ).
Notice: Refer to Fastener Notice in Cuations and
Notices.
2. Install the rear power steering pump bracket
bolts (3).
Tighten
Bolts (3) to 50 N-m(37 lb ft.).
3. Install the power steering pump (LS1 only). Refer
(5. 7L VIN G).
2
354413
Checking and Adding Power Steering

Fluid
Notice: When adding fluid or making a complete fluid
change, always use the proper fluid. Failure to use
the proper fluid will cause hose and seal damage and
fluid leaks. Refer to Power Steering Fluid
Recommendations in this section.
The fluid level is indicated by marks on the fluid level
indicator. The fluid level indicator is located on the
reservoir cap.
If the fluid is about 77C (170F), the fluid level
should be at the H mark.
If the fluid is about 21 C (70F), the fluid level
should be at the C mark.
Bleeding Power Steering System

Reasons For Bleeding
Bleeding the power steering system prevents the
following situations:
Improper power steering system operation
Power steering pump damage
Power steering system noise
When To Bleed
Bleed the power steering system in the following
situations:
When replacing any power steering system
component.
When disconnecting the power steering fluid line.
When power steering system noise exists.
171727
226
Steering

Inspections Before Bleeding
Inspect the following parts before bleeding the power

steering system:
1. The power steering, hoses must not contact any
other part of the vehicle. Power steering system
noise could be caused by the power steering
hoses touching the frame or the engine.
2. The power steering hoses for tight connections.
Loose connections could cause fluid leaks or
allow air to enter the power steering system.
3. The accessory drive belt tightness.
4. Check power steering pulley for looseness or
damage. The pulley must not wobble while the
engine runs.
Bleeding Procedure
172547
Important: Do not remove the key from the ignition

after turning the ignition OFF. If the key is removed
from the ignition the electronic column lock will
engage.
1. Turn OFF the ignition.
2. Raise the front wheels oft the ground.
3. Turn the steering wheel completely to the left.
4. Fill the fluid reservoir to the Full Cold level (1 ).
Leave the reservoir cap oft.
5. Turn the steering wheel from lock to lock at
least 20 times.
6. Have an c1ssistant check the following conditions
while turning the steering wheel:
The power steering fluid level
The power steering fluid for bubbles
7. Turn the steering wheel from lock to lock at least
40 time if the power steering system has either of
the following components:
A long power steering return line
A power steering fluid cooler
8. Check the fluid constantly while turning the wheel.
9. Trapped air may cause the power steering fluid
to overflow. Thoroughly clean up any spilled fluid.
10. Maintain the fluid level at the Full Cold mark (1 ).
11. The fluid must be tree of bubbles.
If bubbles exist, check the connections again and
repair as necessary. Repeat steps 5, 6 and 7
tor turning the steering wheel while checking the
power steering fluid.
13. Maintain the power steering fluid level while the
engine idles.
14. Reinstall the cap.
15. Return the wheels to the center.
16. Lower the front wheels to the ground.
17. Keep the engine running for two minutes.
18. Turn the steering wheel in both directions.
Steering
19. If all the following conditions exist, the procedure
is complete:
20. If any of the following conditions do not exist,
proceed to Special Conditions For Bleeding:
The system has smooth power assist
The system has noiseless operation
The power steering fluid is filled to the
proper level
There are no system leaks
The power steering fluid is not discolored and
is free of bubbles and foam
2-27
6. If the noise persists, repair or replace the power

steering pump.
7. Repeat the bleeding procedure.
,Partial Fluid Replacement
2. Allow the engine to reach to operating
temperature.
3. If the nofse persists, repair or replace the power
steering pump.
Special Conditions For Bleeding
Flushing the Power Steering System
If the power steering fluid is discolored or there is

foam or bubbles, proceed with the following
instructions:
Notice: When adding fluid or making a complete fluid

change, always use the proper fluid. Failure to use
the proper fluid will cause hose and seal damage and
fluid leaks. Refer to Power Steering Fluid
Recommendations in this section.
1. Raise and support the front of the vehicle. Ensure
that the tires and wheels are free to turn. Refer to
Lifting and Jacking the Vehicle in General
Information.
Discolored, Foam or Bubbles in the Power Steering

Fluid
1. Turn OFF the ignition.
Wait two minutes.
2. Recheck the hose connections.
4. Maintain the power steering fluid level with the
engine idling (1 ).
5. Install the cap.
6. Return the wheels to center.
7. Lower the front wheels to the ground.
8. Keep the engine running for two minutes.
9. Turn the steering wheel in both directions.
10. If the condition continues, check and repair or
replace the following:
The return hose clamps and 0-rings
The pressure hose 0-rings
The steering gear cylinder line 0-rings
11. Fill the power steering system.
Noise In Power Steering System
If the power steering pump emits a whine or a groan,
proceed through the following instructions:
2. Recheck the hoses for contact with the
following areas:
The frame
The engine
3. If no contact is found, follow the following method
for cool down.
Normal Cool Down
1. Turn OFF the engine.
2. Wait for the power steering system to cool.
3. Install the reservoir cap.
5. Allow the engine to reach to operating
temperature.
Important: Position the inlet hose or the reservoir

hose toward a larg~ container in order to catch any
draining fluid.
2. Remove the reservoir hose at the fluid reservoir
inlet connector.
3. Plug the fluid inlet connector port on the fluid
reservoir.
4. While an assistant is filling the fluid reservoir with
fluid, start the engine.

Run the engine at idle.
Notice: Do not hold the steering wheel against the
stops while flushing the power steering system.
Holding the steering wheel against the wheel stops
will cause high system pressure, overheating,
and damage to the power steering pump and/or gear.
5. Turn the steering wheel from stop to stop.
6. Continue to drain the reservoir until all of the old
fluid is cleared from the power steering system.
7. Add approximately 0.94 liters (1 quart) of new fluid
in order to flush the system.
8. Inspect the fluid that is draining while you are
refilling the fluid reservoir.
Do not reuse any drained fluid.
9. If necessary, perform the following steps:
Replace all of the lines.
Disassemble and clean the system
components.
Replace the system components.
1O. Unplug the reservoir hose at the fluid reservoir
inlet connector.
11. Turn the engine off.
12. Fill the fluid reservoir to the C mark on the fluid
level indicator.
228
Steering
Power Steering Hoses Replacement

1
Removal Procedure
1. Place drain pan(s) under vehicle steering gear
and pump.
2. Raise and suitably support vehicle. Refer to Lifting
and Jacking the Vehicle in General Information.
3. Remove power steering gear inlet (3) and
outlet (2) hoses from steering gear (1 ).
':'/['?r~
2
354423
4. Lower vehicle.
Power Steering Pulley Replacement for L36 V6 or
Power Steering Pulley Replacement for LS1 VS.
7. Remove inlet hose fitting (3) from pump (1)
(L36 shown, LS1 similar).
354420
Steering
2-29
Important: If vehicle is equipped with a power

steering cooler (LS1 only), outlet hose and cooler
hose (if replacing) must be removed from the power
steering cooler as the cooler is installed in the
outlet hose (return back to reservoir).
8. Remove outlet hose (4) from reservoir ( LS1 with

cooler shown, remote-mount reservoir on L36).
354416
Important: Inlet and outlet hoses must be oriented so
as adequate clearance is maintained between both
hoses and surrounding components to prevent chafing.
Use minimum clearance of 12 mm (.47 inch). The
outlet hose must not be twisted during installation. Do
not bend or distort inlet and outlet hoses to make
installation easier. Failure to follow these procedures
could result in component damage.
1. Install outlet hose (4) to reservoir ( LS1 with
cooler shown, remote-mount reservoir on
L36). (Pump mounted on LS1, body mounted
on L36)
354416
2-30
Steering
2. Install inlet hose fitting (3) to pump (1)
354420
3. Install the power steering pump pulley. Refer to

Power Steering Pulley Replacement for L36 V6 or
Power Steering Pulley Replacement for LS1 V8.
6. Install inlet and outlet hoses (2&3) to steering
gear (1 ).
,..,..._--:~//,,
I
;:r~~
Tighten
Inlet hose (3) to 28N-m (2J lb. ft.).
Outlet hose (2) to 28Nm (21 lb. ft.).
7. Lower vehicle.
8. Remove drain pan ..
Steering.
..._
~~S~ti[O
3
354423
Tie Rod End Replacement - Outer - Off

Vehicle
Tools Required
J 24319-01 Universal Steering Linkage Puller
1. Pull the cotter pin (3) and the hex slotted nut (2)
from outer tie rod assembly (1 ).
423439
Steering
2-31
2. Loosen the jam nut (2) on the inner tie rod

assembly (1).
297349
3. Remove -the outer tie rod assembly (2) from the

steering knuckle (1) using J 24319-01.
297353
4. Remove the outer tie rod assembly (3) from the

inner tie rod assembly (1).
297358
2-32
Steering

Assembly Procedure
1. Connect the outer tie rod assembly (3) to the

inner tie rod (1 ). Do not tighten the jam nut (2) .
297355
2. Connect the outer tie rod assembly (2) to the

steering knuckle (1 ).
2
297628
3. Connect the hex slotted nut (2) to the outer tie rod
stud (1 ).
,y

Notices.
Tighten
Tighten the hex slotted nut (2) to 47 Nm (35 lb ft).
Align the cotter pin slot by tightening the hex
slotted nut (2) up to 1/6 additional turn, or
70 N-m (52 lb ft) maximum. Do not back off the
hex slotted nut (2) for the cotter pin (3) insertion.
4. Install the cotter pin (3) into the hole in the tie
rod stud.
~
I
423439
Steering
/~
2-33
Important: Be sure the rac.k and pinion boot is not

twisted or puckered during toe adjustment.
5. Adjust toe by turning the inner tie rod. Follow
recommended manufacturer specifications;
refer to Front Toe Adjustment.
Tighten
Tighten the hex jam nut against the outer tie rod
to 68 N-m (50 lb ft).
Rack and Pinion Boot Replacement - Off

Vehicle
Tools Required
J 22610 Service Boot Clamp Installer
1. Remove the outer tie rod. Refer to Tie Rod End
Replacement - Outer - Off Vehicle.
2. Remove the hex jam nut (2) from the inner tie rod
assembly (1 ).
297360
3. Remove the tie rod end clamp (2) from the rack
and pinion boot (1).
297362
2-34
Steering
4. Remove the boot clamp (1) from the rack and

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

rack and pinion gear assembly.
6. Discard the boot clamp.
7. Inspect the rack and pinion boot (1) for damage.
8. Look for gear oil leakage inside the rack and
pinion boot (1 ).
9. Drain the oil.
10. Clean the rack and pinion boot (1) with solvent.
'
~
~
1
..
441311
Assembly Procedure
Tools Required
J 22610 Service Boot Clamp Installer
1. Install the new boot clamp (2) onto the rack and
pinion boot (1 ).
297362
Steering
2-35
2. Prior to rack and pinion boot installation, apply

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

boot (2) with J 22610.
6. Crimp the boot clamp (1 ).
7. Pinch the pliers together on the rack and pinion
boot (2) in order to install the tie rod end clamp.
J 22610
441313
8. Install the hex jam nut (2) to the. inner tie rod
assembly (1).
9. Assemble the outer tie rod assembly. Refer to Tie
Rod End Replacement - Outer - Off Vehicle.
2
297638
2-36
Steering
Power Steering Cooler Replacement

Removal Procedure
1. Place drain pan under vehicle under cooler.
2. Drain engine coolant from engine. Refer to
Draining and Filling Cooling System (VB) for
5.7L VB in Engine Cooling.
3. Remove power steering gear outlet hoses (3) and
clips from cooler (1 ).
4. Remove hose clamps from radiator hoses at
cooler (1).
5. Remove radiator hoses from cooler (1 ).
6. Remove cooler (1) from radiator support bracket.
354416
1. Install cooler (1) to radiator support bracket.
354416
Important: Ensure that the cooler is installed with the

"ENGINE" marking pointed toward the engine and
the "RADIATOR" marking pointing toward the radiator
(drivers side of the vehicle).
Alignment marks on cooler should align with alignment

marks on radiator hoses so cooler is properly
positioned (Power steering circuit outlets pointing
straight down).
2. Install radiator hoses to cooler (1 ).
3. Install radiator hose clamps to radiator hoses at
cooler.
4. Install the power steering gear outlet hoses (3)
and clips to the cooler (1 ).
5. Refill engine with coolant. Refer to Draining and
Filling Cooling System (VB) for 5.7L VB in Engine
Cooling.
6. Refill and bleed power the power steering system.
Refer to Bleeding Power Steering System in
Power Steering.
Steering
{3.SL VIN G)
-~
2-37
Removal Procedure
1. Place drain pan(s) under vehicle under steering
gear and pump.
and Jacking the Vehicle
3. Remove power steering gear inlet (3) and
outlet (2) hoses from steering gear (1 ).
4. Lower vehicle.
Power Steering Pulley Replacement in General
Information.
,_-
-~
-
I
9,._.
;: . -..:::: _...\
t[[~
2
354423
7. Remove inlet hose fitting (3) from pump (1)

354420
Steering
8. Remove outlet hose from reservoir ( LS1 with

cooler shown, remote-mount reservoir on L36).
Important: If vehicle is equipped with a power steering

cooler (LS1 only), outlet hose and cooler hose
(if replacing) must be removed from the power steering
cooler as the cooler is installed in the outlet hose
(return back to reservoir).
354416
1. Install outlet hose to reservoir ( LS1 with cooler

shown. remote-mount reservoir on L36). (Pump
mounted on LS 1. body mounted on L36)
Important: Inlet and outlet hoses must be oriented so
as adequate clearance is maintained between both
hoses and surrounding components to prevent chafing.
Use minimum clearance of 12 mm (.47 inch). The
outlet hose must not be twisted during installation. Do
not bend or distort inlet and outlet hoses to make
installation easier. Failure to follow these procedures
could result in component damage.
354416
Steering
2-39
2. Install inlet hose fitting (3) to pump (1)

354420
3. Install the power steering pump pulley. Refer to

6. Install inlet and outlet hoses (2&3) to steering
gear (1).
Tighten
Inlet hose (3) to 28N-m (21 lb. ft.).
Outlet hose (2) to 28Nm (21 lb. ft.).
7. Lower vehicle.
8. Remove drain pan.
2
354423
2-40

1
Steering
(5.7L VINK)
Removal Procedure
290561
1. Remove the air intake resonator.

2. Remove the serpentine belt. Refer to Drive Belt
Replacement (Accessory) or Drive Belt
Replacement (AIC) in Engine Mechanical - 5.7L.
3. Support the engine with a hydraulic jack.
5. Remove the tires and wheels. Refer to Wheel
Removal in Tires and Wheels.
6. Place a drain pan under the steering gear (5).
7. Disconnect the steering gear outer tie rods.
8. Remove the generator. Refer to Generator
Replacement (5. 7L VB) in Engine Electrical.
9. Remove the left-side engine mount through bolt.
11. Raise the engine with the hydraulic jack.
12. Disconnect the following hoses from the steering
gear (5):
The power steering gear inlet hose
The power steering gear outlet hose
13. Remove the steering gear flexible coupling from
the steering gear (5). Refer to Steering Shaft
Coupling Replacement in Steering Wheel
and Column.
14. Remove the nuts (4) and bolts/screws (1 ).
15. Remove the steering gear (5).
Steering
241
1. Position the steering gear (5) to the
crossmember (2).
2. Adjust the steering gear (5).
Ensure that the steering aligns as straight as
possible with the steering gear coupling shaft.
3. Hand start the bolts/screws (1) and nuts (4).
4. Position the back-up wrench to the nuts (4).

Notices.
Tighten
Tighten the bolVscrews to 85 N-m (63 lb ft).
5. Install the steering gear flexible coupling to the
steering gear. Refer to Steering Shaft Coupling
Replacement in Steering Wheel and. Column.
6.
7.
8.
9.
~
10.
11.
12.
13.
14.
15.
16.
17.
18.
Tighten
Tighten the bolts/screws to 47 N-m (35 lb ft).
Connect the following hoses to the steering
gear (5).
The power steering gear inlet hose
The power steering gear outlet hose
Lower the vehicle. Allow the vehicle to stay
slightly above the ground while the tires and
wheels are not installed.
Lower the engine with the hydraulic jack.
Raise and suitably support the vehicle. Refer to
Lifting and Jacking the Vehicle.
Install the left side engine mount through-bolt.
Install the generator. Refer to Generator
Replacement (5.7L VB) in Engine Electrical.
Connect the steering gear outer tie rods to the
steering knuckles.
Install the tire and wheels. Refer to Wheel
Installation in Tires and Wheels.
Lower the vehicle.
Remove the hydraulic jack supporting the engine.
Install the serpentine belt. Refer to Drive Belt
Replacement (Accessory) or Drive Belt
Replacement (AIC) in Engine Mechanical - 5.7L.
Install the air intake resonator.
Refill and bleed the power steering system. Refer
to Bleeding Power Steering System in Power
Steering System.
290561
2-42
Steering
Rack Bearing Preload Adjustment - Off
Vehicle
Adjustment Procedure
1. Loosen the adjuster plug lock nut (1 ).
2. Turn the adjuster plug clockwise until the adjuster
plug bottoms in the gear assembly.
3. Turn the adjuster plug back 50 degrees
to 70 degrees (approximately one flat).
4. Install the adjuster plug lock nut (1) to the
adjuster plug.

Notices.
Tighten
Hold the adjuster plug stationary while tightening
the adjuster plug lock nut (1) 75 Nm (55 lb ft).
423455
Tie Rod Replacement - Inner

1. To remove the rack and pinion boot; refer to Rack
and Pinion Boot Replacement - Off Vehicle.
297376
Important: The rack must be held during removal and

installation of the inner tie rod to prevent damage to
the rack.
Remove the shock dampener (2) from the inner
tie rod assembly (5).
2. Slide the shock dampener (2) back on the
rack (1 ).
3. Remove the inner tie rod assembly (5) from the
rack assembly (1) as follows:
3.1. Place a wrench on flats of rack
assembly (3).
3.2. Place another wrench on the flats of the
inner tie rod housing (4).
3.3. Rotate the inner tie rod housing (4)
counterclockwise until the inner tie
rod (5) separates from the rack (1 ).
Steering
2..43
4. Remove the old Loctite from the threads (2) of

the rack (1) and the inner tie rod (3).
297389
Assembly Procedure
Important: The rack must be held during removal and
installation of the inner tie rod to prevent damage to
the rack.
1. Slide the shock dampener (2) forward onto the
rack (1 ).
Important: Threads must be clean prior to Loctite
application. Check Loctite (or equivalen~ container for
expiration date. Use only enough Loctite to evenly
coat threads.
2. Apply Loctite 262 (or equivalent) to the inner tie

rod threads.
3. Attach the inner tie rod (6) on the rack (1) as
follows:
3.1 . Place a wrench on the flats of the rack
assembly (3).
3.2. Place a torque wrench (5) on the flats of
the inner tie rod housing (4).
Notices.
Tighten
Inner tie rod to 100 Nm (74 lb ft).
297392
2-44
Steering
4. Slide the shock dampener (2) over the inner tie

rod housing (3) until the front lip of the shock
dampener (2) bottoms against the inner tie
rod housing (3).
5. To assemble the rack and pinion boot; refer to
Rack and Pinion Boot Replacement - Off
Vehicle.
297398
Steering Gear Cylinder Pipe

Assemblies/0-Ring Seals Replacement Off Vehicle
1. Loosen both cylinder line fittings (1) on the
cylinder end of the gear assembly (2).
2. Loosen both fittings on the cylinder line
assemblies (3) at the valve end of the gear
assembly (2).
423409
3. Remove both cylinder line assemblies (1) from the

rack and pinion gear assembly (2).
423417
Steering
2-45
4. Remove the 0-ring seals (1) from the valve end

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

the cylinder lines.
Important: Carefully align the threads on all of the
fittings.
Finger tighten the fittings in order to avoid
stripping and cross-threading the fittings.
-~
423421
2-46
Steering
4. Install the cylinder line assemblies (1) to the gear

assembly (2).
Notices.
Tighten
Valve end fittings to 16.9 Nm (12.6 lb ft). Cylinder
end fittings to 27 N-m (20 lb ft).
Important: Flush and bleed power steering system

(hoses, reservoir and cooler lines) with power steering
fluid GM Part #1050017 (or equivalent meeting GM
Specification #9985010).
Flush and bleed power steering system. Refer to
423417
Steering Gear Stub Shaft Seals and

Bearing Replacement - Off Vehicle
1. Remove the adjuster plug lock nut (5) from the
adjuster plug (4).
2. Remove the adjuster plug (4) from the gear
assembly (1 ).
3. Remove the adjuster spring (3) and the rack
bearing (2).
423457
4. Remove the retaining ring (1) from the valve bore

of the rack and pinion gear assembly (2).
5. Remove the dust cover (4) from the bottom of the
rack and pinion gear assembly (2).
Important: Hold the stub shaft in order to prevent
damage to the pinion teeth.
6. Remove the hex lock nut (3) from the lower end
of the pinion and valve assembly while holding
the stub shaft with a 14 mm crowfoot wrench .
423458
Steering
2-47
Important: When performing the following procedure,

do not remove pinion and valve assembly from the
rack and pinion gear assembly (5). P,ress the
pinion and valve assembly only far enough to allow
removal of the stub shaft bearing annulus (2) and the
stub shaft seal (2).
7. Using an arbor press (1), press on the threaded

end of the pinion until removal of the following
items is possible:
7.1. The stub shaft (4)
7.2. The stub shaft seal (3)
7.3. The stub shaft bearing annulus
assembly (2)
Assembly Procedure
Tools Required
J 29810 Stub Shaft Seal Protector
Important: Hold the stub shaft in order to prevent
damage to the pinion teeth.
1. lnstail the hex lock nut (1) onto the pinion while
holding the valve stub shaft.
2. Install the dust cover (2) to the rack and pinion
gear assembly.
423460
3. Install the stub shaft bearing annulus assembly (1}

onto the valve stub shaft (2).
423461
2-48
Steering
4. Install the J 29810 onto the valve stub shaft.

5. Lubricate the stub shaft seal (2) with grease.
6. Install the stub shaft seal (2) into the rack
and pinion gear assembly.
7. Install the retaining ring (1) into the groove in the
rack and pinion gear assembly.
423462
423457
8. Lubricate the following items with lithium base

grease:
8.1. The rack bearing (2)
8.2. The adjuster spring (3)
8.3. The adjuster plug (4)
9. Install the following items into the gear assembly:
9.1. The rack bearing (2)
9.2. The adjuster spring (3)
9.3. The adjuster plug (4)
10. Turn the adjuster plug (4) clockwise onto the rack
and pinion gear assembly (1) until the adjuster
plug (4) bottoms in the rack and pinion gear
assembly (1 ), then tum the adjuster plug (4)
back 50 degrees to 70 degrees.
11. Inspect the rotational torque on the pinion. The
maximum pinion preload torque is
1.8 N-m (16 lb in).
12. Install the adjuster plug lock nut (5) to the adjuster
plug (4).

Notices.
Tighten
Finger tighten the adjuster plug lock nut (5) while
holding the adjuster plug (4) stationary.
Steering
Power.Steering System
2-49
Description and Operation

Power Steering. Pump Description
The power steering gear includes the following major
internal components:
The power steering gear pinion and valve shaft
The steering gear rack and piston
The inner tie rods
The outer tie rods
The steering gear rack and piston is supported at the
ends in the steering gear housing. The steering
gear rack and piston is sealed in order to prevent
leakage across the piston. The pinion and valve
intersects with the rack and piston and meshes directly
with the teeth of the rack and piston.
Manual steering is always available during the
When the engine is not running
In the event of power steering pump failure
In the event of serpentine belt failure
Steering effort is increased when the above conditions
exists.
The power steering pump provides hydraulic pressure
and fluid flow in order to move the gear components.
Tt'fiS action occurs when the vehicle is parked or
moving. The valve directs pressurized fluid during a
steering maneuver. The fluid travels through the
external steel cylinder lines in'order to act on the rack
and piston. When the vehicle is turned right, the
steering valve opens and routes pressurized fluid to
the left side of the piston. At the same time, the v.alve
allows fluid to escape from the right side of the
piston and return to the valve area. The fluid pressure
is converted into a mechanical force which is applied
to the piston. This difference in force across the piston
causes the rack to move to the right. The opposite
action occurs when the gear is turned to the left.
The effort to steer the vehicle is created by the
pressure difference at the piston when the following
conditions exist:
The power steering pump (3) provides pressurized
fluid to the gear.
The valve is operating correctly.
Power Steering Gear Description

The power steering gear includes the following major
internal components:
The power steering gear pinion and valve shaft
The steering gear rack and piston
The inner tie rods
The outer tie rods
The steering gear rack and piston is supported at the

ends in the steering gear housing. The steering
gear rack and piston is sealed in order to prevent
leakage across the piston. The pinion and valve
intersects with the rack and piston and meshes directly
with the teeth of the rack and piston.
Manual steering is always available during the
When the engine is not running
In the event of power steering pump failure
In the event of serpentine belt failure
Steering effort is increased when the above conditions
exists ..
The power steering pump provides hydraulic pressure
and fluid flow in order to move the gear components.
This action occurs when the vehicle is parked or
moving. The valve directs pressurized fluid during a
steering maneuver. The fluid travels through the
external steel cylinder lines in order to act on the rack
and piston. When the vehicle is turned right, the
steering valve opens and routes pressurized fluid to
the left side of the piston. At the same time, the valve
allows fluid to escape from the right side of the
piston and return to the valve area. The fluid pressure
is converted into a .mechanical force which is applied
to the piston. This difference in force across the piston
causes the rack to move to the right. The opposite
action occurs when the gear is turned to the left.
The effort to steer the vehicle is created by the
pressure difference at the piston when the following
conditions exist:
The power steering pump (3) provides pressurized
fluid to the gear.
The valve is operating correctly.
Seal Replacement Recommendations

Lip Seals
Lip seals, which seal rotating shafts, require special
treatment. This type of seal is used on the hydraulic
pump shaft of the pump. When leakage occurs in this
area, always replace the seal or seals, after
inspecting and thoroughly cleaning the sealing
surface. Replace the shaft if pitting is found. If
corrcsion in the lip seal contact zone is slight, clean
the surface of the shaft with crocus cloth. Replace the
shaft only if the leakage cannot be stopped by
smoothing with crocus cloth first.
0-Ring Seals
Whenever a part which forms a, sealing surface for an
0-ring is removed, the 0-ring seal should also be
removed and replaced with a 0-ring seal. Lubricate all
new 0-rings with fresh power steering fluid to ease
installation.
2-50
Steering
Special Tools and Equipment

Tool Number/ Description
Illustration
Illustration
J 5176-E
J 25034-8
Power Steering Pressure

Tester
Power Steering Pump Pulley

Remover
675
65360
J 5176-92
J 25323-A

Adapter
Pressure Tester
337279
293487
J 25033-8
J 29525-92
Power Steering Pump Pulley

Installer

Adapter
676
J 7728
Shaft Oil Seal Installer
6218
Steering
Steering Wheel and Column - Tilt

Specifications
Specification
Application
Metric
English
351bin
Hazard Warning Switch Knob Bolt/Screw
4Nm
0.7N,m
Hydraulic Pump Fitting
75Nm
55 lb ft
Hydraulic Pump Hose Fitting
28Nm
21 lb ft
Ignition Switch Bolt/Screw
2.5Nm
221bin
Inflatable Restraint Steering Wheel Mounting Plate Bolt/Screw

(Pontiac Only)
1.9 Nm
171bin
Intermediate Steering Shaft-to-Steering Column Bolt/Screw
47N,m
35 lb ft
Dimmer and Ignition Switch Bolts/Screws
61bin
Intermediate Steering Shaft-to-Steering Gear Bolt/Screw
47N-m
35 lb ft
Power Steering Gear Pipe Fitting Seat
21 lb ft
Radio Control Switch Bolt/Screw (Pontiac Only)
28Nm
1.9 N,m
171bin
Steering Column Bolts/Screws
18 N,m
14 lb ft
Steering Column Guide Bolt/Screw
25Nm
18 lb ft
Steering Column Upper Support Nuts
25Nm
18 lb ft
Steering Wheel Bolt/Screw (Pontiac Only)
2.8Nm
251bin
Steering Wheel Horn Switch Contact Plate Shoulder Bolt/Screw

(Pontiac Only)
2.8Nm
251bin
Steering Wheel Nut
43Nm
32 lb ft
Steering Wheel-to-Inflatable Restraint Steering Wheel Module

Bolts/Screw (Chevrolet Only)
2.8Nm
251bin
Steering Wheel-to-Steering Wheel Horn Switch Bolts/Screws

(Chevrolet Only)
1.9 N-m
171bin
2-51
2-52
Steering
Steering Column - Disassembled View
Tilt Steering Column
590268
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
Flanged Prevailing Torque Nut

Retaining Ring
SIR Coil Assembly
Wave Washer
Bearing Retainer
Connector Shroud
Shaft Lock Shield Assembly
Turn Signal Cancel Cam Assembly
Upper Bearing Spring
Pan Head 6-Lobed Socket Screw
Round Washer Head Screw
Signal Switch Arm Assembly
Turn Signal Switch Assembly
(14)
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
Upper Bearing Inner Race Seat

Inner Race
Pan Head 6--Lobed Socket Screw
Buzzer Switch Assembly
Lock Retaining Screw
Lock Housing Cover and Sleeve Assembly
Steering Column Lock Cylinder Set
Dimmer Switch Rod Actuator
Switch Actuator Pivot Pin
Pivot and Pulse Switch Assembly
Column Housing Cover End Base Plate
Column Housing Cover End Cap
Wiring Protector
Steering
(27)
(28)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
(43)
(44)
(45)
(46)
(47)
(48)
Steering Column Housing Assembly

Bearing Assembly
Lock Bolt
Lock Bolt Spring
Steering Wheel Lock Shoe
Steering Wheel Lock Shoe
Wire Protector Shield
Drive Shaft
Dowel Pin
Pivot Pin
Shoe Spring
Release Lever Spring
Release Lever Pin
Shoe Release Lever
Bearing Assembly
Switch Actuator Rack
Rack Preload Spring
Steering Column Housing
Pivot Pin
Switch Actuator Sector
Hexagon Washer Head Screw
Spring Guide
Steering Wheel and Column - Ti.It

(49)
(50)
(51)
(52)
(53)
(54)
(55)
(56)
(57)
(58)
(59)
(60}
(61)
(62)
(63)
(64)
(65)
(66)
(67)
(68}
(69)
(70)
2-53
Wheel Tilt Spring

Spring Retainer
Race and Upper Shaft Assembly
Centering Sphere
Joint Preload Spring
Lower Steering Shaft Assembly
Steering Shaft Assembly
Hexagon Washer Head Tapping Screw
Steering Column Housing Support Assembly
Steering Column Housing Shroud
Steering Column Jacket Assembly
Lower Bearing Adapter
Bearing Assembly
Bearing Adapter Retainer
Lower Bearing Adapter Clip
Ignition Switch Assembly
Flat Head Screw
Dimmer Switch Assembly
Hexagon Washer Head Tapping Screw
Dimmer Switch Rod
Washer Head Screw
Ignition Switch Rod Actuator Assembly
2-54
Steering
Schematic and Routing Diagrams

Tilt Wheel/Column Schematic References
Section Number Subsection Number
Reference on Schematic
Engine Controls Cell 21, 22
5.::..c...Engine Controls
Fuse Block Details Cell 11
8-Wiring Systems
Ground Distribution Cell 14
8-Wiring Systems
Power Distribution Cell 1O
8-Wiring Systems
Release Systems Cell 134
8-Body Rear End
Tilt Wheel/Column Schematic Icons

Icon
Icon Definition
Refer to ESD Notice in Cautions and Notices.
19384
Refer to SIR Service Precautions Caution in Cautions and Notices.
19386
Refer to OBD II Symbol Description Notice in Cautions and Notices.
19385
.en
Automatic Transmission Shift Lock Control Schem~tics (Cell 138)

jHot In RUN, Bulb Test And START
C1)
. - - - - - - - - - - - - ., IP
I Power
I
Fuse Block
Details
ee1111
' - - - - - -... H4
I 11!
!Loe
GAUGES
IGN
: Fuse
9
~~':
(Not~sedl I Block
Disbibution
: Cell10
!Esc!
;-------~:~~:1::
A{C2
r
:
I
Brake
Depressed
-
1Brake Transmission .,
Shift Interlock Switch :
. (Normally closed)
I
L.-------
______ ...
Stoplamp
Switch
Assembly
BIC2
0'.35 DK GRN/WH~ 1135
'-f 11
1
1
I
L -
'Brake
Transmission
1Shift Interlock
1
Solenoid (BTSI)
1(Gear select.or can

I not be shifted when
..1
_ .TAN/WHT
05
816
.
Powertrain. Control
Cell 21 (Y8 VIN G)
.0.5 ORN/BLK 434

: : ORN/BLK
5234
solenoid is energized)
A
Hatch Release
Relay
Cell134
Folding Top
Relay with (ETA)
~ Module (PCM)
0.35 ORN/BLK 434
0.5 TAN/WHT 816

52$9
Isolation
Diode (BTSI)
'
'" - -;;--.
- "'." - - - ,p.ark Neutral
I Position
I
: ~ P ..
I
(1A)
R..N . ,._ ..eD_,,2.
8237
Powertraln Control
~ Module (PCM)
Cell 22 (Y6 VIN K)
. en
C1)
C1)
:switch
::!.
::::,
co
:E
::r
t_-- . ~ ---~ j
A"'
C1)
0.5 BLKJWHT I 451
!.
0.8 BLK/WHT1451
c.
r------~-------~S~5
Ground
Distnbution
Cell14
T
f
~-
::::,
F C220
C)
E"
0.8BLK/WHT
iJ
L~---~----~-~-
~
f
::!
;::;:
-------------,
N
I
4s3ss.2
u,
I U,
2-56
Steering
Component Locator
Tilt Wheel/Column Components
Name
Brake Transmission
Shift Interlock
(BTSI) Diode
Location
In instrument panel harness, main branch,
approximately 6 cm from body control
module (BCM) breakout
Locator View
-
Connector End View

-
Brake Transmission
Shift Interlock (BTSI)
Solenoid
In console, forward of shift control lever
Tilt Wheel/Column
Component Views in
Steering Wheel and
Column-Tilt
IP Fuse Block
On the left end of the instrument panel

carrier
Instrument Cluster
Component Views in
Instrument Panel,
Guages and Console
Under the console, on the base of the shift

control lever
Tilt Wheel/Column
Component Views in
Steering Wheel and
Column-Tilt
Stop Lamp Switch
Mounted on the brake pedal bracket
Cruise Control
Component Views in
Cruise Control
Antilock Brakes System

Connector End Views in
Antilock Brake System
Stop Lamp!TCC Switch

(Automatic)
Park Neutral Position

Switch
Tilt Wheel/Column
Steering Wheel and
Column-Tilt
Lighting Systems
Lighting Systems
lnline Harness Connector
End Views in Wiring
Systems
C220 (10 cavities)
Instrument panel to engine harness, under

the right side of the instrument panel,
behind the knee bolster
Harness Routing Views in

Wiring Systems
G110 (V6 VINK)
In the front of the engine, bolted to the

pulley above the A/C clutch connector

Wiring Systems
G110 (VB VIN G)
Attached to the rear of the left

cylinder head

Wiring Systems
P110
Right side in the dash panel, engine to the

passenger compartment

Wiring Systems
8110 (V6 VINK)
In the engine harness, approximately 4 cm

(2 in) from the powertrain control module
(PCM) breakout
8110 (VB VIN G)
In the engine harness, main branch,

approximately 19 cm (7 in) from the
powertrain control module (PCM) breakout
8206
In the instrument panel harness, at the

rear compartment lid release relay
breakout
8215
In the instrument panel harness, main

branch, approximately 11 cm (4 in) from
the antenna cable breakout
8234 (Automatic)
Instrument panel harness, main branch,

approximately 5 cm (2 in) from body
control module (BCM) breakout
8237 (Automatic)

approximately 6 cm (2 in) from body
8239 (Automatic)
instrument panel harness, main branch,

approximately 1 cm (0.5 in) from body
Steering
Steering Wheel and Column - Tilt 2-57
Tilt Wheel/Column Component Views

Under Console, Right Side (Automatic Transmission)
3
483480
Legend
(01) Shift Control Lever
(02) Brake Transmossion Shift Interrupt (BTSI)
Solenoid
(03) Park/Neutral Position Switch
(04) Park Brake

(05) Park Brake Switch
2-58
Steering
Steering .Wheel and Column - lilt
Tilt Wheel/Column Connector End Views
Brake Transmission Shift Interlock (BTSI)

Solenoid
280768
Connector Part
Information
1205-2832
2 Way F Metrf-Pack
150 S.eries (BLK)
Pin
Wire Color
Circuit
No.
TAN/WHT
816
DKGRN/
WHT
1135
Function
Park Neutral position

Power feed

Automatic Transmission Shift Lock Control System Check
Step
Action
1. Place the gearshift selector into

the PARK position.
1
2. Turn the ignition switch to the

RUN position.
3. Depress the brake pedal
and hold.
4. Move the gearshift selector to
the NEUTRAL position.
1. Place the gearshift selector into
the PARK position.
2. Remove all foot pressure from
the brake pedal.
3. Attempt to move the gearshift
selector from PARK to the
NEUTRAL position.
Normal Result(s)
Abnormal Result(s)*
Brake transmission interlock solenoid Automatic Transmission Shift Lock

disengages and allows driver to move Control Always On With Ignition
gearshift selector from PARK to
in RUN
NEUTRAL.
Gearshift selector does not move

from the PARK position.

Control Inoperative
* Refer to the appropriate symptom diagnostic table for the applicable abnormal result.
Steering
2.:.59
Automatic Transmission Shift Lock Control Inoperative

Step
--"'
1
Action
Check for engine DTCs.

Are any engine DTCs present?
Value(s)
Yes
No
Go to A
Powertrain On
Board Diagnostic
(OBD)
System Check
Go to Step 2
Go to Step 3
Go to Automatic
Transmission
Shift Lock
Control
System Check
Go to Step 4
Go to Step 9
Go to Step 5
Go to Step 6
Was the entire BTSI system check performed?
1. Make sure the park neutral position switch is in the

PARK position.
2. Disconnect the brake transmission shift interlock
(BTSI) solenoid connector.
3. Turn the ignition switch to the RUN position.
4. Connect a test light from the brake transmission shift
interlock solenoid connector terminal B to ground.
Is the test light on?
Connect a test light between the brake transmission shift

interlock solenoid connector terminals A and B.
Replace the BTSI solenoid. Refer to BTSI Solenoid

Replacement
Is the repair complete?
Inspect the hatch release system tor proper operation.

Does the hatch release system operate properly?
Repair the open in circuit 816 between the BTSI solenoid

and 8239.
Repair a poor connection or an open in circuit 434

between 8239 and 8234.
Backprobe the stoplamp switch assembly connector C2

terminal B with a test light to ground ..
Repair the open in circuit 1135 between the stoplamp

switch assembly and the BT81 solenoid.
--
10
11
12
13
14
Backprobe the stoplamp switch assembly connector C2

terminal A with a test light to ground.
Replace the stoplamp switch assembly. Refer to Stop/amp
Switch Replacement
Repair the open in circuit 39 between the stoplamp switch
assembly and 8206.
1. Turn the ignition switch to the OFF position.
2. Reconnect all connectors/components removed.
Have all repairs been made?
Go to_ Step 14
Go to Step 7
Go to Step B
Go to Step 14
Go to Step 14
Go to Step 10
Go to Step 11
Go to Step 14
Go to Step 12
Go to Step 13
Go to Step 14
Go to Step 14
Go to Automatic
Transmission
Shift Lock Control
System Check
2-60
Steering

Automatic Transmission Shift Lock Control Always On With Ignition in RUN
Value(s)
Action
Step
Yes
No
Go to Step 2
Go to Automatic
Transmission
Shift Lock
Control
System Check
Go to Step 3
Go to Step 4
Was the entire BTSI System Check performed?
1. Disconnect the stoplamp switch assembly

connector C2.
3. Backprobe the brake transmission shift interlock
(BTSI) solenoid terminal B with a test light to ground.
Repair the short to B+ in circuit 1135.


2. Reconnect the stoplamp switch assembly
connector C2.
4. Backprobe the brake transmission shift interlock
solenoid terminal B with a test light to ground.
5. Depress the brake pedal.
Replace the stoplamp switch assembly. Refer to Stop/amp

Switch Replacement
Replace the BTSI solenoid. Refer to BTSI Solenoid

Replacement

2. Reconnect all connectors/components disconnected.
Have all repairs been made?
Go to Step 7
Go to Step 5
Go to Step 6
Go to Step 7
Go to Step 7
Go to Automatic
Transmission
Shift Lock Control
System Check
Lock System Does Not Unlock

Problem
The lock system will not unlock.
Action
Inspect the lock

A collapsed
A damaged
A damaged
A damaged
A damaged
A damaged
A damaged
system for the following conditions:

shear flange on the sector shaft
lock bolt
lock cylinder
housing
sector
rack
or incorrectly cut key
Steering

Lock System Does Not Lock
Problem
Action
The lock system will not lock.
Inspect the lock system for the following conditions:

A broken or worn lock bolt spring
A damaged sector
A damaged lock cylinder
A burr on the lock bolt
A damaged housing
A damaged rack
Interference between the bowl and the rack coupling
A stuck ignition switch
A restricted actuator rod
An incorrectly installed sector
Key Cannot Be Removed in the Off Lock Position

Problem
Action
The key cannot be removed in the

OFF-LOCK position.
Inspect the column for the following conditions:

An incorrectly set ignition
Lock Cylinder Can Be Removed Without Depressing Retainer

Problem
Action
The lock cylinder can be removed

without depressing the retainer.
Inspect the lock cylinder for a missing lock cylinder retaining screw.
High Lock Effort Between the Off Lock Positions

Action
Problem
High effort is required in the lock
cylinder between the OFF and
OFF-LOCK positions.
Inspect the lock cylinder for a distorted rack.
High Lock Effort

Action
Problem
High lock effort is required.
Inspect the system steering for the following. conditions:

A damaged ignition switch
A broken or deformed rack preload spring
Burrs on the following components:
- The sector
-The rack
- The housing
- The support
- The actuator rod coupling
A bent sector shaft
A damaged rack
A damaged or misadjusted park lock cable
Misalignment of the housing to the cover
A distorted coupling slot in the rack
A
A
A
A
bent actuator rod

bent ignition switch mounting bracket
restricted actuator rod
worn or damaged key
2-61
2-62
Steering
Automatic Transmission Shift Lock Control Diagnosis

Problem
Action
The transmission does not shift out of Refer to Automatic Transmission Shift Lock Control Inoperative
PARK with the brake pedal
depressed and the ignition switch in
the RUN position.
The transmission shifts out of the
Refer to Automatic Transmission Shift Lock Control Always On With Ignition in RUN
PARK position with the ignition switch
in the RUN position and the brake
pedal not depressed.
Noise in Steering Column

Problem
Action
There is noise in the steering column. Inspect the steering column for the following conditions:
Loose joints from the steering column to the steering gear
An incorrectly aligned steering column
An unlubricated horn contact ring
A lack of grease on the bearings

Loose sight shields
A worn or broken upper or lower steering shaft bearing
An unseated lock plate retainer ring
An unlubricated spherical joint
High Steering Shaft Effort

Problem
Action
High steering shaft effort is required.
A misaligned steering column

An improperly installed or deformed dust seal
A damaged upper or lower steering shaft bearing
A flash on the inside diameter of the shift tube
A tight universal joint
Looseness in Steering Column

Problem
There is a lash in the steering
column.
Action
Inspect the steering column for the following conditions:
Loose bolts/screws on the upper and lower bracket mounting of the instrument
panel (IP)-to-steering column
Broken weld nuts on the jacket
A sheared IP upper bracket capsule
Loose shoes in the housing

Loose pivot pins
A loose lock pin in the housing support
Loose housing support bolts/screws
Loose bolts/screws on the steering column upper and lower bracket-to-jacket
Loose bolts/screws on the lower bracket-to-adapter and bearing mounting
Lower Housing Scraping Upper Housing

Problem
The housing scrapes the bowl.
Action
A bent bowl
A bowl that is not concentric to the hub
An improperly installed cover and housing end cap
'Steering
Steering 1Wheel and.Colur,1n ~,TUt .2:..53

Loose Steedng Wheel
Problem
Action
The steering wheel is loose.

Excessive clearance between the holes in the housing or housing support and
the pivoi pin diameters
A damaged anti-lash spring in the spheres
A missing anti-lash spring in the spheres
The steering shaft upper bearing is not seated in the housing
A missing steering shaft upper bearing inner race
Lo.ose housing support be.Its/screws
A missing bearing preload spring
IA broken bearing
prelqc;3.d spring
Loose Steering Wheel (Every Other Tilt Position)

Problem
..
.Action
The steering wheel is loose in every

other tilt position.

A loose fit between the shoe and the pivot pins
The shoe is not free in the slot.
Steering Wheel Does Not Lock in Any Tilt Position

Problem
Action
The steering column does not lock in

any tilt position.

A seized shoe on the pivot pin
Burrs or dirt on the shoe grooves
A weak shoe lock spring
A broken shoe lock spring
Steering Wheel Not Returning to Top Tilt Position

Action
Problem
The steering wheel fails to return to

the top tilt position.

Bound up. pivot pins
A broken wheel tilt spring
A weak wheel tilt spring
Tight turn signal switch wires
Noise When Tilting Steering Column

Action
Problem
Inspect the steering column' for the following conditions:
There is noise when tilting the

steering column.
Worn upper tilt bumpers

Rubbing of the shoe lock spring in the housing
.
Turn Signal Does Not Indicate Lane Change

Action
Problem
The turn signal does not indicate a

lane change.
Inspect the steering column forthe following conditions:
A broken lane change pressure pad
A broken lane change spring hanger

A broken lane change spring
A missing lane change spring
A misplaced lane change spring
A jammed base
Jammed wires
..
'
.
..
2-64
Steering
Turn Signal Does Not Stay in Turn Position

Action
Problem
The turn signal does not stay in the

turn position.

Foreign material impeding the movement of the yoke
Loose parts impeding the movement of the yoke
A broken detent
A broken canceling spring
A missing detent
A missing canceling spring
Replace the switch if none of the above conditions are found.
Turn Signal Does Not Cancel

Problem
The turn signal does not cancel.
Action

Loose switch mounting screws
A broken switch
Broken anchor bosses
A broken detent
A missing detent
An out-of-position detent
A broken return
A missing return
An out-of-position return
A broken canceling spring
A missing canceling spring
An out-of-position canceling spring
A worn canceling cam
Turn Signal Difficult to Operate

Problem
The turn signal is difficult to operate.
Action

A loose turn signal switch arm
Loose springs
Misplaced springs
Foreign parts or material
Loose turn signal switch mounting screws
Replace the switch if the following conditions exist:
A broken yoke
A distorted yoke
Hazard Switch Cannot Be Turned Off

Problem
The hazard switch cannot be

turned off.
Action
1. Inspect for foreign material between the hazard support canceling leg and
the yoke.
2. Replace the turn signal switch if no foreign material is found.
Steering
Steering Wheel and Column -Tilt

Hazard Switct, Does Not Stay On
Problem
Action
The hazard switch will not stay on or

is difficult to turn off.
1. Inspect the steering column for the following conditions:

A loosEl turn signal switch
Interference with other components
Interference from foreign material
2. Replace the turn signal switch if none of the above conditions are found.
Ignition Switch Electrical System Does Not Operate

Problem
The electrical system does not

function properly.
Action

An improperly adjusted ignition switch
A loose connector at. the ignition switch
Ignition Switch Does Not Turn

Problem
The ignition switch does not turn.
Action

An improperly adjusted ignition switch
A loose connector at the ignition switch
Ignition Switch Cannot Be Set Correctly

Problem
The ignition switch cannot be

correctly set.
Action

A deformed switch actuator rod
A sector to rack engaged in the wrong tooth
2-65
2-66
Steering
Steering Wheel and Coluom - Tilt
Repair Instructions
Ignition Switch Reptacement - On Vehicle
1
Removal Procedure
1. Remove the left-hand instrument panel insulator.
2. Remove the instrument panel driver knee

bolster and deflector. Refer to Knee Bolster
Replacement in Instrument Panel, Gauges and
Console.
3. Disable the SIR system. Refer to Disabling the
SIR System in SIR.
4. Ensure that the following components are in the
LOCK (1) position:
The steering column lock
The ignition cylinder
5. Remove the steering column upper support nuts
from the steering column support. Refer to
Steering Column Replacement.
290208
6. Remove the lower column (8).

7. Remove the electrical connectors from the
dimmer switch (5).
8. Remove the electrical connectors from the ignition
switch (7).
9. Remove the bolts/screws (4).
10. Remove the dimmer switch actuator rod (3)
11. Remove the dimmer switch (5).
12. Remove the bolVscrew (6).
13. Remove the ignition switch actuator rod (2).
14. Remove the ignition switch (7).
15. Remove the automatic transmission park lock
cable, if equipped.
290273
Steering
2-67
1. Install the automatic park lock cable1 if equipped.
2. Complete the following steps in ord.er to ensure
that the ignition switch (2) is in the LOCK (1)
position:
2.1. Move the switch slider to the extreme right
position.
2.2. Move the slider one detent to the left.
3. Ensure that the following components are in the
LOCK position:
The steering column lock

The ignition cylinder
290208
4. Install the ignition switch (7) to the jacket (1 ).

5. Install the ignition switch actuator rod (3) to the
ignition switch.
Notices.
6. Install the bolVscrew (6).
Tighten
Tighten the bolVscrew (6) to 2.5 N-m (22 lb in).
7. Position the dimmer switch (5) to the ignition
switch (7).
8. Install the bolts/screws.
9. Complete the following procedures in order to
adjust the dimmer switch:
9.1. Press the switch mechanism slightly in
order to insert the 3/32-inch drill bit.
9.2. Move the dimmer switch in order to remove
the lash.
Tighten
Tighten the bolts/scr~w to 4 N-m. (35 lb in).

10. Install the dimmer switch actu'ator rod (2).
11. Install the electrical connectors to the dimmer
switch (5).
12. Install the electrical connector to the ignition
switch (7).
13. Raise the column.
14. Install the steering column upper support nots to
the steering column support. Refer to Steering
Column Replacement.
15. Enable the SIB. Refer to Enabling the SIR
System in SIR.
16. Install th.e instrument panel driver knee bolster
and deflector.
17. Install the left-hand instrument panel insulator.
290273
2-68
Steering
Multifunction Turn Signal Lever
Replacement - On Vehicle
Removal Procedure
1. Remove the steering column tilt wheel release

lever, if equipped with cruise control. Refer to
Tilt Lever Replacement - On Vehicle.
2. Remove the access cover, if equipped with cruise
control.
3. Disconnect the electrical connectors (4, 5), if
equipped with cruise control.
290193
4. Grasp the lever firmly (1).

5. Pull the lever (1) straight out in order to remove
the lever.
29C, 92
1. Position the tang (2) on the lever (1) to the
notch (3) in the column (4).
Important: Ensure that the wiper switch is in the OFF
position before you install the lever.
2. Install the lever (1) to the column (4).
290192
Important: Ensure that the lever (1) is fully seated.

3. Install the electrical connectors, if equipped
with cruise control.
4. Install the access cover, if equipped with cruise
control.
5. Install the steering column tilt wheel release lever,
if equipped with cruise control. Refer to Tilt Lever
Replacement - On Vehicle.
Steering
2-69
Hazard Warning Switch Replacement - On

Vehicle
Removal Procedure
Do not remove the steering column in order to replace
the hazard warning switch. Refer to Tilt Steering
Column Unit Repair.
1. Remove the bolt/screw (4).
2. Remove the button (3).
3. Remove the spring (2).
4. Remove the knob (1 ).
290205
1. Install the knob (1 ).
2. Install the spring (2).
3. Install the button (3).
Notices.
4. Install the bolt/screw (4).
Tighten
Tighten the bolt/screw to 0.7 Nm (6 lb in).
290205
Tilt Lever Replacement - On Vehicle

Removal Procedure
1. Firmly grip the tilt wheel release lever (3).
2. Twist the lever (3) counterclockwise.
290197
2-70
Steering

1. Firmly grip the tilt wheel release lever (3).

2. Twist the lever (3) clockwise.
290197
Steering Wheel lnflator Module

Replacement
Removal Procedure
1. Disable the SIR. Refer to Disabling the SIR
System in SIR.
2. Use a number 30 TORx driver, or the equivalent,
in order to loosen the bolts/screws (4) from the
back of the steering wheel (1 ).
3. Remove the inflatable restraint steering wheel
module (3) from the steering wheel (1 ).
290386
4. Disconnect the SIR coil electrical connector and

retainer from the inflatable restraint steering wheel
module (1).
5. Remove the radio control switch electrical
connector from the inflatable restraint steering
wheel module (1 ), if equipped.
6. Remove the horn lead from the column.
290462
Steering
Steering Wheel and Column .. Tilt. 2-71
1. Install the horn lead to the column (5).
2. Install the radio control switch electrical connector
to the inflatable restraint steering wheel module, if
equipped.
290386
3. Install the SIR coil electrical connector and

retainer to the inflatable restraint steering wheel
module (3).
4. Insert a thick section of wire into the existing
retainers in order to secure the SIR coil
electrical connector to the steering wheel.
Important: Ensure that the wiring is not exposed or
trapped between inflatable restraint steering wheel
module and the steering wheel.
5. Position the inflatable restraint steering wheel
module to the steering wheel.
Notices.
Tighten
Tighten the bolts/screws to 2.8 N-m (25 lb in).
7. Enable the SIR system. Refer to Enabling the SIR
System in SIR.
290462
2-72
Steering
Horn Switch Replacement - On Vehicle

(Pontiac)
Removal Procedure
module (1 ). Refer to Steering Wheel lnflator
Module Replacement.
2. Remove the horn wiring connector from the
steering column.
3. Remove the bolts/screws (6).
4. Remove the horn switch (2) from the steering
wheel (4).
4
290329
1. Position the horn switch (2) to the steering
wheel (4).

Notices.
2. Install the bolts/screws (6).
Tighten
Tighten the bolts/screws (6) to 1.9 N-m (17 lb in) .
3. Install the horn wiring connector to the steering
column.
4. Install the inflatable restraint steering wheel
module (1 ). Refer to Steering Wheel lnflator
Module Replacement.
290329
Horn Switch Replacement - On Vehicle

(Chevrolet)
Removal Procedure
module (4). Refer to Steering Wheel lnflator
Module Replacement.
2. Remove the bolt/screw (3).
3. Use the following steps in order to remove the
horn switch (2) from the inflatable restraint
steering wheel module (4):
3.1. Lift up on the edge of the module cover at
the horn button. This action provides
access to the horn switches.
3.2. Press the lock tang.
3.3. Remove the horn switch (2).
3.4. Repeat the above steps in order to remove
the remaining horn switch.
290190
Steering
Steering Whe~I and Column .. Tift
2-73
1. Use the following steps in order to install., the horn
switch (2) to the inflatable restraint steering Wheel
module (4).
1.1. Lift up on the edge of the module cover at
the horn button.
1.2. Install the horn switch (2).
1.3. Repeat the above steps for the remaining
horn switch.

Notices.
2. Install the bolt/screw (3).
Tighten
Tighten the bolt/screw (3) to 1.9 N-m (17 lb in).
Module Replacement.
290190

Replacement
Removal Procedure
Module Replacement.
2. Remove the radio control wire harness retainer.
3. Pry out the radio control switch (5) at the
lower edge.
4. Remove the radio control switch (5) from the

steering wheel (7).
5. Remove the wire harness connector (3) from the
control(s).
5
290322
1. Install the wire harness connector (3) to the
control(s).
2. Install the radio control switch (5) to the steering
wheel (7).
3. Install the radio control wire harness retainer.
Module Replacement.
3
6
5
290322
Steering
2-74 Steering Wheel and Column - Tilt

Steering Wheel Replacement
Removal Procedure
5
290184
Tools Required
J 1859-A Steering Wheel Puller
J 38720 Steering Wheel Puller Bolts
module. Refer to Steering Wheel lnflator Module
Replacement.
2. Remove the nut (3).
3. Remove the horn lead (5).
Notice: When removing the steering wheel, use only
the specified steering wheel puller. Under no
conditions should the end of the steering column shaft
be hammered on, as hammering could loosen the
plastic injections which maintain steering column
rigidity.
Notice: When attaching J 1859-A and J 38720 to the
steering wheel, use care to prevent threading
J 39720 (bolts) all the way through the steering wheel
hub into the SIR coil and damaging the SIR coil.
4. Use a J 1859-A and a J 38720 in order to remove
the steering wheel (2).
5. Remove the steering wheel horn switch.
2
1. Route the SIR coil electrical connector to the

steering wheel (2).
2. Install the steering wheel horn switch.
Important: Align the tooth on the steering wheel with

the block tooth on the steering column shaft within
one female serration.
3. Install the steering wheel (2).
4. Install the horn lead (5).
Notices.
5. Install the nut (3).
Tighten
Tighten the nut to 43 N-m (32 lb ft).
module. Refer to Steering Wheel lnflator
Module Replacement.
290184
Steering
Steering Wheel and Column- Tilt
2-75
Steering Shaft Coupling Replacement
Removal Procedure
Notice: The vehicle's wheels must be in a
straight-ahead position and the key must be in a
LOCK position when removing or installing the steering
column. Failure to do so may cause the SIR coil
assembly to become uncentered and may result in
unneeded SIR system repairs.
1. Remove the clamp (11) from the boot (12).
2. Remove the boot (12) from the shaft (5).
3. Remove the bolt/screw (10) from the gear (8).
4. Remove the shaft (5) from the gear (8).
5. Remove the shield (14) from the shaft (5) and
column (3) on 5.7L VIN G only.
6. Remove the bolt/screw (3) from the column (3).
7. Remove the shaft (5) from the column (3).
290411
2-76
Steering
Steering Wheel and Column Tilt

1. Position the shaft (5) to the column (3).

Notices.
Tighten
Tighten the bolVscrew (3) to 47 Nm (35 lb ft).
3. Position the shaft (5) to the gear (8).
5.
6.
7.
8.
Tighten
Tighten the bolVscrew (10) to 47 Nm (35 lb ft).
Install the boot (12) to the shaft (5).
Use a clamp (11) in order to secure the boot to
the shaft.
Position the shield (14) to the shaft (5) and
column (3) on 5.7L VIN G only.
On 5.7L VIN G only, insert the button into the hole
in the column (3) in order to install the shield (14) .
290411
Steering
2-77
Steering Column Replacement

Removal Procedure
LOCK position when .removing or installing the steering
Notice: When the steering column is removed from
the vehicle, it is extremely susceptible to damage.
Dropping the column on its end could collapse
the steering shaft or loosen plastic injections that keep
the column rigid. Leaning on the column could
cause steering column jacket to bend or deform. Any
of the above conditions could impair column
assembly's collapsible design. If the steering wheel
must be removed, .use only the specified steering
wheel puller and steering wheel puller bolts. Never
hammer on the end of the steering shaft because
hammering could loosen plastic injections that keep
the column right.
1. Remove the left instrument panel insulator.
2. Remove the instrument panel driver knee bolster
and deflector.
SIR System in SIR
4. Remove the steering wheel, if the column is to be
replaced. Refer toSteering Wheel Replacement.
5. Remove the intermediate steering shaft bolt/screw
from the steering gear coupling shaft and column.
6. Remove the bolts/screws (2) that attach the
cover (7) to the dash panel.

8. Remove the cover (7) from the dash panel.
9. Disconnect the electrical connectors.
10. Remove the nuts (5) and shims (6) from the
steering column support.
11 . Remove the automatic transmission park lock
cable from the ignition switch, if equipped.
12. Remove the column (3) from the vehicle.
290448
2-78
Steering

Notice: If a service replacement steering column is

being installed, do not remove the antirotation pin until
after the column has been connected to the steering
gear. Removing the antirotation pin before the column
is connected to the steering gear may damage the
SIR coil.
1. Position the column (3) into the vehicle.
2. Install the automatic transmission park lock cable
to the ignition switch, if equipped. Refer to
Automatic Transmission, On-Vehicle Service.

Notices.
3. Install the shims (6) and the nuts (5) to the
290294
4.
5.
6.
7.
8.
9.
10.
11.
12.
Tighten
Tighten the nuts to 25 N,m (18 lb ft).
Install the intermediate steering shaft bolt/screw to
the steering gear coupling shaft. Refer to Steering
Gear Coupling Shaft.
Install the cover to the dash. Install the bolt/screws
in the following order:
5.1. Install the lower (3) bolt/screw.
5.2. Install the outboard (4) bolt/screw.
5.3. Install the inboard (2) bolt/screw.
Position the cover to the dash panel.
Connect the electrical connectors.
Install the bolts/screws.
Tighten
Tighten the bolts/screws to 18 Nm (14 lb ft).
Install the steering wheel, if column is replaced.
Refer to Steering Wheel Replacement.
Enable the SIR system. Refer to Enabling the SIR
System in SIR.
Install the instrument panel driver knee bolster
and deflector.
Install the left instrument panel insulator.
Steering
2-79
Steering Column Disassembly/Assembly Off Vehicle

Removal Procedure
LOCK position when removing or installing the steering
Notice: When the steering column is removed from
the vehicle, it is extremely susceptible to damage.
Dropping the column on its end could collapse
the steering shaft or loosen plastic injections that keep
the column rigid. Leaning on the column could
cause steering column jacket to bend or deform. Any
of the above conditions could impair column
assembly's collapsible design. If the steering wheel
must be removed, use only the specified steering
wheel puller and steering wheel puller bolts. Never
hammer on the end of the steering shaft because
hammering could loosen plastic injections that keep
the column right.
1. Remove the left-hand instrument panel insulator.
Refer to Insulator Replacement - IP (Left Side) in
Instrument Panel, Gages and Console.
2. Remove the instrument panel driver knee bolster
and deflector. Refer to Knee Bolster Replacement
in Instrument Panel, Gauges and Console.
SIR System in SIR.
4. Remove the steering wheel, if the column is to be
replaced. Refer to Steering Wheel Replacement.
5. Remove the intermediate steering shaft bolt/screw
from the steering gear coupling shaft and crnumn.
Refer to Steering Gear Coupling Shaft.
7. Remove the cover (7) from the dash panel.
9. Remove the nuts (5) and shims (6) from the
10. Remove the automatic transmission park lock
cable from the ignition switch, if equipped.
Refer to Automatic Transmission, On-Vehicle
Service.
11 . Remove the column (3) from the vehicle.
290448
2-80
Steering
Steering Wheel and Co.lumn - Tilt

Notice: If a service replacement steering column is

being installed, do not remove the antirotation pin until
after the column has been connected to the steering
gear. Removing the antirotation pin before the column
is connected to the steering gear may damage the
SIR coil.
1. Position the column (3) into the vehicle.
2. Install the automatlc transmission park lock cable
to the ignition switch, if equipped. Refer to
Automatic Transmission, On-Vehicle Service.

Notices.
3. Install the shims (6) and the nuts (5) to the
290294
Tighten
Tighten the nuts to 25 N-m (18 lb ft).
4. Install the intermediate steering shaft bolt/screw to
the steering gear coupling shaft. Refer to Steering
Gear Coupling Shaft.
Important: When you install the cover (1) to the dash,
install the bolts/screws in the following order:
4.1. The lower (3) bolt/screw
4.2. The outboard (4) bolt/screw
4.3. The inboard (2) bolt/screw
5. Position the cover to the dash panel.
6. Connect the electrical connectors.
8.
9.
10.
11.
Tighten
Install the steering wheel, if column is replaced.
Refer to Steering Wheel Replacement.
Enable the SIR system. Refer to Enabling the SIR
System in SIR.
Install the instrument panel driver knee bolster
and deflector. Refer to Knee Bolster Replacement
in Instrument Panel, Gages and Console.
Install the left-hand instrument panel insulator.
Refer to Insulator Replacement - IP (Left Side)
in Instrument Panel, Gages and Console.
Steering
2-81
Ignition and Key Alarm Switch Assembly Off Vehicle

Reminder Operates With the Key Out, Stops
When Driver Door is Closed
Use the following inspection procedure when the
reminder continues to operate with the key out, but
stops when the driver's door is closed:
1. Inspect for chips or foreign material in the lock
cylinder bore.
2. Inspect for a sticky lock cylinder actuator tip.
3. Inspect for a damaged or broken
reminder switch (1 ).
Reminder Does Not Sound With the Key in

Lock Cylinder, Driver Door Open
Use the following inspection procedure when the
reminder does not sound when the key is fully inserted
in the lock cylinder and the driver's door is open:
1. Inspect the reminder in order to determine if power
is available. Refer to Engine Electrical.
2. Use the following steps in order to inspect the
chassis wiring for an open circuit:
Separate the chassis connector (2) from the
column connector.
Connect the female contacts of terminals E
and Fon the chassis connector. You may
use a bent paper clip as a jumper.
Repair the chassis wiring if the reminder
sounds.
Continue with this inspection procedure if the
reminder does not sound.
3. Use a multimeter (or test light) in order to inspect
the continuity between the male E and F column
connector contacts.
4. Push the key all of the way into the lock cylinder.
5. The function is normal if there is continuity
when the key is in and no continuity when the key
is out.
6. If there is no continuity, the fault is in the column.
Continue with this inspection procedure.
290088
290095
2-82
290060
Steering
probes of the reminder switch (1). This inspection
will ensure that there is good contact with pads
on the signal switch:
7.1. Disassemble the upper end of the column
until the turn signal switch mounting
bolts/screws have been removed.
7.2. Lift the turn signal switch in order to gain
access to the probes.
7.3. Bend the probes, if needed.
7.4. Replace the turn signal switch.
7.5. Tighten the three bolts/screws.
7.6. Use a multimeter (or test light) in order to
inspect the continuity between the male E
and F column connector contacts.
7.7. Push the key all of the way into the lock
cylinder.
7.8. The function is normal if there is continuity
when the key is in and no continuity when
the key is out.
7.9. If there is no continuity, the fault is in the
column. Continue with this inspection
procedure.
turn signal switch wiring for a short or a fault.
8.1 . Connect the male contacts of terminals E
and F of the column connector (2) with a
jumper.
8.2. Use a multimeter in order to inspect the key
reminder switch pads on the turn signal
switch.
8.3. The function is normal if there is continuity.
8.4. Replace the turn signal switch if there is
no continuity.
2
290105
$teering
9. If you have not found the problem, use the
following steps in order to inspect the continuity of
the key reminder switch probes:
9.1. Connect a multimeter to the probes on the
reminder switch.
9.2. Fully insert the key into the lock cylinder (2).
9.3. Remove the key from the lock cylinder (2).
9.4. The function is normal when the following
conditions exist:
There is continuity when the key is in
the lock.
There is no continuity when the key is
out of the lock.
9.5. If the function is normal, repeat steps 3
through 9.
9.6. If there is no continuity, the fault is in the
lock cylinder (2) or the reminder switch.
10. Inspect the lock cylinder (2) for the following
obstructions which may prevent actuator tip
function:
Chips
Burrs
Other foreign material
11. If foreign materials are found, use the following
steps in order to remove the materials:
11 .1. Ensure that the key is removed or the lock
cylinder is in the RUN position before you
remove the lock cylinder .
11.2. Remove the chips, burrs or foreign
material.
11.3. Reassembly and reinspect the lock
cylinder.
12. Use the following procedure to inspect the lock
cylinder for damage:
12.1. Remove the lock cylinder.
12.2. Push the key all of the way in.
12.3. Turn the key to the RUN position.
12.4. Remove the key.
12.5. Ensure that the lock cylinder actuator tip
extends and retracts smoothly.
12.6. Ensure that the total extension of the tip is
1.27 mm (0.050 inch).
12,7. Replace the lock cylinder if it does not
meet the above specifications.
12.8. Reassemble the lock cylinder.
12.9 .. Return to Step 4 in order to reinspect the
lock cylinder.
reminder switch if it appears to be good but will
not operate:
13.1. Connect the multimeter leads to the
reminder switch probes on the reminder
switch.
13.2. Press on the actuator pad until the switch
points touch.
13.3. Replace the reminder switch if there is no
continuity.
2-83
375025
2
290107
2-84
Steering
reminder switch contact gap:
14.1 . Connect the reminder switch leads (4) to
the reminder switch probes on the
reminder switch (3).
14.2. Press a 0.76 mm (0.030 inch) wire plug
gage with a flat piece of stock onto the
actuator pad.
290101
15. If contact is not made (continuity), decrease the

switch contact gap until a positive contact is made.
16. Use the following procedure in order to inspect

the reminder gap switch. Ensure that the positive
contact gap is set at 0.76 mm (0.030 inch).
16.1. Use a 0.63 mm (0.025 inch) plug gap wire
beneath a flat stock. Increase the switch
contact gap if contact is made (continuity).
16.2. The reminder switch is set properly when
the switch contact will touch 0.76 mm
(0.0030 inch) wire but not 0.63 mm
(0.025 inch) wire.
2
290303
Steering
Steering Wheel and Column - Ti1t
2..95
Determine if the following conditions exist:

The reminder keeps operating with the key in the
lock cylinder.
The driver's door is open or closed.
The reminder ceases when the key is removed.
Complete the following steps if the above
conditions exist:
1. Inspect for a misadjusted or inoperative door jamb
switch on the driver's side.
2. Inspect for a shorted wire from the signal switch
to the door jamb switch.
This condition indicates that the lock cylinder
or reminder switch is at fault.
To verify this, inspect for continuity at the
E and F male column connector contacts with
the key removed from the lock cylinder.
If continuity exists, the fault is in the column.
Insert a key into the lock. Turn the lock toward
the START position. If the reminder stops
when the key is in the RUN position or when it
is turned past the RUN position, toward the
START position, the problem is a sticky
lock cylinder actuator.
3. For further diagnosis of the key reminder, refer to
Engine Electrical.
Tilt Spring - Disassemble - Off Vehicle

Tool Required
J 39246 Tilt Spring Compressor
1. Remove the lock housing cover and sleeve
assembly. Refer to Lock Housing Assembly Disassemble - Off Vehicle.
2. Seat the counterbore of J 39246 over the steering
shaft assembly (1 ).
Caution: The tilt spring and spring guide are under
pressure and could become a projectile. Exercise
caution when removing or installing the tilt
spring and spring guide as bodily injury may
result.
3. Thread and seat the standard hexagon nut (2)
onto the steering shaft assembly (1 ).
4. Thread the hexagon nut (2) until it contacts the
block of J 39246.
343839
2-86
Steering
5. Insert the square end (2) of J 39246 into the
spring retainer (1) and seat.
343842
6. Rotate the tool bolt clockwise with the wrench

until it contacts the surface of the tool block.
7. Make a 114 turn counter clockwise to the hexagon
section on the end of the tool bolt.
8. Unscrew the tool bolt until the wheel tilt spring
and the spring retainer (1) are free.
9. Remove the spring retainer (2) from the steering

column housing assembly.
10. Remove the wheel tilt spring (1) from the steering
11. Remove the spring guide (3) from the steering
343856
Steering
Steering, Wheel and Column, -Tilt
.2-..a7
Tilt Spring - Assemble - Off Vehicle

Assembly Procedure
Tool Required
J 39246 Tilt Spring Compressor .
1. Install the spring guide (3)to the steering column
housing assembly.
2. Lubricate the wheel tilt spring (1) with lithium
grease.
3. Install the wheel tilt spring (1) to the steering
4. Install the spring retainer (2) to the steering
343856
5. Seat the counterbore of J 39246 over the steering

shaft assembly (1 ).
6. Thread and seat the standard hexagon nut (2)
onto the steering shaft assembly (1 ).
7. Thread the hexagon nut (2) until it contacts the
block of J 39246.
343839
8. Insert the square end (2) of J 39246 into the

spring retainer (1) and seat.
343842
2-88
Steering
Steering Wheel and Column ~ Tl1t
9. Rotate, the tool bolt clockwise with a wrench. unti.l

it contacts the surface of the tool block.
10. Make a % turn counter clockwise to the hexagon
section on the end of the tool bolt.
11. Unscrew the tool bolt until the wheel tilt spring
and the spring retainer (1) are free.
12. Remove J 39246.
13. Install the lock housing cover and sleeve
assembly. Refer to Lock Housing Assembly
- Assemble - Off Vehicle.
343845
Tum Signal and MultHunctlon Switch

Assembly - Disassemble - Off Vehicle
315,11,2
1. Remove the tilt lever. Refer to Tilt Lever

2. Remove the multifunction lever. Refer to
Multifunction Tum Signal Lever Replacement - On
Vehicle.
3. Remove the hazard knob. Refer to Hazard
Warning Switch Replacement - On Vehicle.
4. Remove the tum signal cancel cam assembly.
Refer to Inflatable Restraint Steering Wheel
Module Coil - Disassemble - Off Vehicle.
5. Remove the round washer head screw (2) from
the signal switch ann assembly (3).
6. Pry out the signal switch ann assembly (3) from
the lock housing cover and sleeve assembly.
7. Remove the 3 pan head 6 lobed socket screws (1)
from the tum signal switch assembly.
Steering
289
8. In order to remove the turn signal switch

assembly, use the following steps.
8.1. Remove the steering column wire
harness strap.
8.2. Remove the wiring protector.
354116
9. Disconnect the terminal connector from the turn

signal switch assembly connector.
10. Remove the terminal connector from the dimmer
switch assembly.
11. Pull the turn signal switch assembly connector
through the steering column, if needed.
343824

Assembly - Assemble - Off Vehicle
Assembly Procedure
1. Thread the turn signal switch assembly connector
through the lock housing cover and sleeve
assembly, if the connector is hanging.
343961
2-90
Steering

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

switch assembly connector.
7. Install the terminal connector to the dimmer switch
assembly.
343824
8. Pull the turn signal switch assembly connector

towards the base of the column.
9. Insert the wiring protector into the steering column

bracket.
10. Insert the steering column wire harness into the
steering column wire harness strap.
11. Install the turn signal cancel cam assembly. Refer
to Turn Signal Cancel Cam and Upper Bearing
Inner Race - Assemble - Off Vehicle.
---1
12. Install the tilt lever. Refer to Tilt Lever
i...=::::.::-
13. Install the multifunction lever. Refer to
Multifunction Turn Signal Lever Replacement - On

Vehicle.
14. Install the hazard knob. Refer to Hazard Warning
Switch Replacement - On Vehicle.
354116
Steering
2-91
Ignition Switch Assembly - Disassemble Off Vehicle

1. Remove the dimmer switch assembly. Refer to
Dimmer Switch Assembly - Disassemble - Off
Vehicle.
2. Remove the flat head screw (1) from the ignition
switch assembly (2).
3. Slide the vehicle wire harness from the ignition
4. Remove the ignition switch assembly (2) from the
ignition switch actuator assembly.
5. Remove the ignition switch assembly (2) from the
steering column jacket assembly.
393976
Ignition Switch Assembly - Assemble - Off

Vehicle
Assembly Procedure
1. Install the vehicle wire harness into the ignition
2. Install the ignition switch assembly (2) onto the
steering column jacket assembly.
3. Install the ignition switch assembly (2) to the
ignition switch actuator assembly.
4. Install the flat head screw (1) to the ignition switch
assembly (2).
5. Tighten the flat head screw (1) finger tight.
393976
6. Move the ignition switch assembly slider (2) to the

far right position.
7. Move the ignition switch assembly slider (2)
detent to the left. This is the "OFF LOCK" position.
8. Install a 3/32 inch drill bit into the hole on
the ignition switch assembly (1) to limit travel.
9. Push against the ignition switch actuator assembly
to limit all the lash.
10. Tighten the flat head screw.
Tighten
Tighten the flat head screw to 4 Nm (35 lb in).
11. Install the dimmer switch assembly. Refer to
Dimmer Switch Assembly - Assemble - Off
Vehicle .
358702
2..92
Steering
Steering Wheel and Column~ Tilt
Dimmer Switch Assembly - Disassemble Off Vehicle

393978
Tools Required
J 42640 Steering Column Anti Rotation Pin
J 41352 Modular Column Holding Fixture
1. Insert the steering column and J 41352 into
a vise.
2. Insert J 42640 into the column.
3. Remove the hexagon washer head tapping
screw (1) from the dimmer switch assembly (3).
4. Remove the washer head screw (2) from the
dimmer switch assembly (3).
5. Remove the dimmer switch rod from the dimmer
6. Remove the dimmer switch assembly (3) from the
ignition switch assembly (4).
7. Remove the dimmer switch assembly (3) from the
. vehicle wire harness.
Dimmer Switch Assembly - Assemble - Off

Vehicle
Assembly Procedure
Tools Required
J 42640 Steering Column Anti Rotation Pin
J 41352 Modular Column Holding Fixture
1. Install the dimmer switch assembly (3) to the
ignition switch assembly (4).
2. Install the hexagon washer head tapping screw (1)
to the dimmer switch assembly (3).
3. Tighten the hexagon washer head tapping
screw (1) finger tight.
4. Install the washer head screw (2) to the dimmer
5. Tighten the washer head screw (2) finger tight.
6. Insert the dimmer switch rod into the slot on
the dimmer switch assembly (3).
393978
Steering
Steering Wheel and
Column .. Tilt 2'"93
7. Adjust the dimmer switch assembly (1) following

these steps:
7.1. Install a 3/32 inch drill bit into the hole (1)
on the dimmer switch assembly to limit
travel.
7.2. Position the dimmer switch assembly onto
the column and push it against the dimmer
switch actuator rod to remove all the lash.
7.3. Remove the drill bit.
358700
8. Tighten the hexagon washer head screw (1 ).
Tighten
Tighten the hexagon washer head screw to
2.5 Nm (22 lb in).
9. Tighten the washer head screw (2).
Tighten
Tighten the washer head screw to 4 Nm (35 lb in).
10. Insert the vehicle wire harness into the dimmer
11. Remove the steering column and J 41352 from
the vise.
12. Remove J 42640 from the column.
393978

Assembly - Disassemble - Off Vehicle
assembly. Refer to Lock Housing Assembly Disassemble - Off Vehicle.
2. Remove the switch actuator pivot pin (2) from the
pivot and pulse switch assembly (1 ).
3. If removal of the pivot and pulse switch
assembly (1) is not needed let the pivot and pulse
switch assembly (1) hang freely.
343835
2-94
Steering
4. Remove the pivot and pulse switch assembly (1)
from the lock housing cover and sleeve assembly
following these steps:
4.1. Remove the wire protector shield.
4.2. Remove the pivot and pulse switch
assembly connector from the bulk head
connector.
4.3. Pull the wire harness through the steering
column.
Important: Use care not to damage the wires when

pulling the pivot and pulse switch assembly wire
harness through the steering column.

Assembly - Assemble - Off Vehicle
Assembly Procedure
1. Install the pivot and pulse switch assembly to the
lock housing cover and sleeve assembly.
2. Lubricate the switch actuator pivot pin (2) with
lithium grease.
3. Install the switch actuator pivot pin (2) into the
4. Install the switch actuator pivot pin (2) into the
lock housing cover and sleeve assembly.
5. Pull the pivot and pulse switch assembly wire
343861
Important: Use care not to damage the wires when

pulling the pivot and pulse switch assembly wire
6. Install the pivot and pulse switch assembly
connector to the bulkhead connector.
7. Install the wire protector shield.
8. Install the lock housing cover and sleeve
assembly. Refer to Lock Housing Assembly
Steering
Steering Wheel'and .Column - Tilt
2.:95
Steering Column Lock Cylinder Set Disassemble - Off Vehicle

1. Remove the turn signal switch assembly. Refer to
Turn Signal and Multifunction Switch Assembly Disassemble - Off Vehicle.
2. Put the key in the "LOCK" position.
3. Remove the lock retaining screw (2) from the lock
housing cover and sleeve assembly.
4. Remove the steering column lock cylinder set (1)
from the lock housing cover and sleeve assembly.
354104
Steering Column Lock Cylinder Set Assemble - Off Vehicle

Assembly Procedure
1. Install the steering column lock cylinder set (1)
into the lock housing cover and sleeve assembly.
Notice: Refer to Fastener Notice in Cautions

and Notices.
2. Install the lock retaining screw (2) into the lock
housing cover and sleeve assembly.
Tighten
Tighten the lock retaining screw to
2.5 Nm (22 lb in).
3. Install the turn signal switch assembly. Refer to
Turn Signal and Multifunction Switch Assembly Assemble - Off Vehicle.
354104

Bearing Inner Race - Disassemble - Off
Vehicle
Tools Required
J 23653-SIR Lock Plate Compressor
1. Remove the SIR coil assembly. Refer to Inflatable
Restraint Steering Wheel Module Coil Disassemble - Off Vehicle.
2. Compress the shaft lock using J 23653-SIR.
3. Remove the bearing retainer (1) from the steering
shaft assembly.
4. Dispose of the bearing retainer (1 ).
5. Remove J 23653-SIR.
343728
296
Steering
6. Remove the following 3 parts from the steering

shaft assembly:
6.1. Remove the shaft lock (1).
6.2. Remove the turn signal cancel cam
assembly (2).
6.3. Remove the upper bearing spring (3).
344003
7. Remove the following 2 parts from the steering

shaft assembly:
7.1. Remove the upper bearing inner race
seat (1 ).
7.2. Remove the inner race (2).
344004

Bearing Inner Race - Assemble - Off
Vehicle
Assembly Procedure
Tools Required
J 23653-SIR Lock Plate Compressor
1. Install the following 2 parts onto the steering shaft
assembly:
1.1. Lubricate the inner race (2) with lithium
grease.
1.2. Install the inner race (2).
1.3. Install the upper bearing inner race seat (1 ) .
343818
Steering
Steering,,Wheel and Colul'.l'ln - Tiit 297
2. Install the following 3 parts onto the steeting shaft

assembly,
2.1. Install the upper bearing spring (3) .
2.2. Lubricate the turn signal cancel cam
assembly (2) with lithium grease.
2.3. Install the turn signal cancel cam
assembly (2).
2.4. Install the shaft lock (1).
343821
3. Install the new bearing retainer (1) using

J 23653-SIR.
4. Seat the bearing retainer (1) in the groove on the
steering shaft assembly.
5. Remove J 23653-SIR.
6. Install the SIR coil assembly. Refer to Inflatable
Restraint Steering Wheel Module Coil - Assemble
- Off Vehicle .
343728
Steering olumn Jacket - Disassemble Off Vehicle

Tools Required
J 38639 Steering Column Housing Bearing
Installer
J 8092 Driver Handle
J 22635 Lock. Shoe and Release Lever Pin
Remover and Installer
J 21854-01 Pivot PinRemoveF
1 . Remove the tilt spring assembly. Refer fo Tiit
Spring - Disassemble ~ Off Vehicle.
2. Remove 2 pivot pins (1) using J 21854:..01:
343869
2-98
Steering Wheel and Column - . Tilt
Steering
3. Use the tilt lever (2) to pull back on the steering
column housing assembly (1) to release.
4. Remove the tilt lever (2).
344138
5. Disassemble the steering column housing

assembly, if needed:
5.1. Remove the bearing assembly (12).
5.2. Remove the wire protector shield (9).
5.3. Remove the switch actuator rack (17) and
the rack preload spring (16).
5.4. Remove the drive shaft (8).
5.5. Remove the switch actuator sector (13).
5.6. Release the release lever pin (3)
using J 22635.
5.7. Remove the shoe release lever (2).
5.8. Remove the release lever spring (4).
5.9. Remove the dowel pin (7).
5.10. Remove the steering wheel lock
shoes (10) and (11) using J 22635 and the
shoe springs (5).
5.11. Remove the bearing assembly (1 ).
12
~/
15
354085
Steering Column Jacket - Assemble - Off

Vehicle
Assembly Procedure
12
Tools Required
J 38639 Steering Column Housing Bearing
Installer
J 22635 Lock Shoe and Release Lever Pin
Remover and Installer
1. To assemble the steering column housing
assembly if needed:
2. Install the bearing assembly (1)
3. Install the shoe springs (5).
4. Install the steering wheel lock shoes (10) and (11).
5. Install the dowel pin (7).
6. Install the release lever spring (4).
~/
354085
Steering
Steering Wheel and Column .-Tilt 2-99
7.
8.
9.
10.
11.
12.
Install the shoe release lever (2).

Install the release lever pin (3) using J 22635.
Install the drive shaft (8).
Install the switch actuator sector (13).
Install the rack preload spring (16).
Install the switch actuator rack (17) to the switch
actuator sector (13).
13. Install the bearing assembly (12) using J 8092
and J 38639.
14. Install the wire protector shield (9).
Important: If the steering column housing assembly
has been staked (2) 3 times by the pivot pins (1) it
must be replaced.
15. Install the steering column housing assembly.
354605
16. Install the steering column housing assembly

following these steps:
16.1. Install the tilt lever (2) and use it to pull
back on the steering column housing
assembly (1) to mount on the steering
column housing support assembly.
16.2. Position the steering column housing
assembly ( 1) onto the steering column
housing support assembly.
16.3. Align the switch actuator rack with the pin
on the end of the ignition switch actuator
assembly.
16.4. Pull back on the tilt lever (2) to position
the steering column housing assembly (1 ).
16.5. Push the steering column housing
assembly (1) into the steering column
housing support assembly.
16.6. Release the tilt lever (2) to lock the
steering wheel lock shoes and the
dowel pin.
16.7. Remove the tilt lever (2) .
344138
2-100
Steering
17. Install 2 pivot pins (1 ).
18. Press the 2 pivot pins (1) until they are firmly
seated.
19. Stake the steering column housing assembly
in 3 places.
20. Install the tilt spring assembly. Refer to Tilt Spring
352626
Lock Housing Assembly - Disassemble Off Vehicle

1. Remove the steering column lock cylinder set.
Refer to Steering Column Lock Cylinder Set Disassemble - Off Vehicle.
2. Remove the column housing cover end cap (2).
Remove the cruise control connector (3) from the
base plate (1) and disconnect.
i..---
3. Remove 3 pan head 6-lobed socket screws (1)

from the lock housing cover and sleeve assembly.
3
343832
Steering
2-101

assembly (1 ).
Remove the column housing cover end base
plate (3) and the dimmer switch rod actuator (4).
5. Remove the wire protector shield.
343833
6. Remove the switch actuator pivot pin (2) from the

343835
Lock Housing Assembly - Assemble - Off

Vehicle
Assembly Procedure
1. Install the switch actuator pivot pin (2) to the pivot
and pulse dimmer switch assembly (1 ).
2. Install the wire protector shield.
343861
2-102
Steering
3. Align the lock housing cover and sleeve
assembly (1) onto the steering column.
4. Lubricate the dimmer switch rod actuator (3) with
lithium grease.
5. Install the dimmer switch rod actuator (3) to the
column housing cover end base plate (2).
6. Install the column housing cover end base
plate (2) to the lock housing cover and sleeve
assembly (1 ).
Important: The bottom edge of the dimmer switch rod

actuator must rest on the bend in the dimmer
switch rod.
343866

Notices.
7. Install the 3 pan head 6-lobed socket screws (1 ).
Tighten
Tighten the 3 pan head 6-lobed socket screws to
9 N-m (80 lb in).
3
343832
8. Mount the cruise control connector (3) on the

base plate (1 ).
9. Install the column housing cover end cap (2).
10. Install the steering column lock cylinder set. Refer

to Turn Signal and Multifunction Switch Assembly
1-----2
343830
Steering
2-103
Steering Shaft, Lower Bearing, and Jacket

- Disassemble - Off Vehicle
Tools Required
J 23072 Shift Tube Remover
1. Remove the steering column housing assembly.
Refer to Steering Column Jacket - Disassemble Off Vehicle.
2. Remove the following 3 items from the steering
column jacket assembly:
2.1. Remove the steering shaft seal (4).
2.2. Remove the sensor retainer (3).
2.3. Remove the steering wheel speed sensor
assembly (2) from the adapter and bearing
assembly (1 ).
388560
3. Remove the following 4 items from the steering

column jacket assembly:
3.1. Remove the lower spring retainer (1).
3.2. Dispose of the lower spring retainer (1 ).
3.3. Remove the lower bearing spring (2).
3.4. Remove the lower bearing seat (3).
2
343874
4. Remove the adapter and bearing assembly (1).
343881
2-104
Steering
5. Remove the steering shaft assembly from the
steering column. :
343889
6. Tilt the race and upper shaft assembly (1)

90 degrees from the lower steering shaft
assembly (2) to disengage.
7. Separate the race and upper shaft assembly (1)
from the lower steering shaft assembly (2).
8. Remove the ignition switch assembly. Refer to
Ignition Switch Assembly - Disassemble - Off
Vehicle
306318
9. Remove the 4 support screws (t).

10. Remove the steering column housing support
assembly (2).
390527
Steering
Steering Wheel and co1u,rm - Tilt
2-105
11. Remove the lock plate (1).

12. Remove the steering column shroud (2) from the
steering column jacket assembly (G),,
390526
Steering Shaft, Lower Bearing, and Jacket

- Assemble - Off Vehicle
Assembly Procedure
Tools Required
J 23072 Shift Tube Remover
1. Install the steering column shroud (2) to the
steering column jacket assembly (3).
2. Install the lock plate (1 ).
390526
3. Install the steering column housing support

assembly (2).

Notices.
4. Install the 4 support screws (1) to the steering
column housing assembly (2).
Tighten
Tighten the 4 support screws to 9 Nm (80 lb in).
5. Install the ignition switch assembly. Refer
to Ignition Switch Assembly - Assemble Off Vehicle.
390527
2-106
Steering
6. Lubricate the exposed area of the race and upper
shaft assembly (1) .
7. Install the race and upper shaft assembly (1) to
the lower steering shaft assembly (2).
8. Align the mark on the race and upper shaft
assembly (1) to the mark on the lower steering
shaft assembly (2).
9. Tilt the race and upper shaft assembly (1)
90 degrees to the lower steering shaft
assembly (2) to engage.
306318
10. Install the steering shaft assembly to the steering

column.
343889
11. Install the adapter and bearing assembly (1 ).
343881
Steering
2-107
12. Install the following 3 items to the steering column

jacket assembly:
12.1. Install the lower bearing seat (3).
12.2. Install the lower bearing spring (2) .
12.3. Install the lower spring retainer (1 ).
343874
13. Install the following 3 items to the steering column

jacket assembly:
13.1. Install the steering wheel speed sensor
assembly (2) to the adapter and bearing
assembly (1 ).
13.2. Install the sensor retainer (3).
13.3. Install the steering shaft seal (4).
14. Install the steering column housing assembly.
Refer to Steering Column Jacket - Assemble Off Vehicle.
388560
Steering Column Accident Damage - Off

Vehicle
Inspection Procedure
Vehicles involved in accidents resulting in frame
damage, major body or sheet metal damage, or
where the steering column has been impacted, or
where supplemental inflatable restraint systems
deployed may also have a damaged or misaligned
steering column.
Check the capsules on the steering column
bracket assembly. All capsules must be securely
seated in the bracket slots and checked for
any loose conditions when pushed or pulled
by hand.
303713
2-108 Steering Wlleel and Column - Tilt
324MM
Steering
Observe how the. bracket is attached to the jacket
assembly.
- If the capsules are not securely seated and
the bracket is bolted to the jacket assembly,
replace only the bracket.
- If the capsules are not securely seated and
the bracket is welded to the jacket assembly,
replace only the jacket assembly.
Check for jacket assembly collapse by measuring
the distance from the lower edge of the upper
jacket to a defined point on the lower jacket.
Replace the jacket assembly if the measured
dimensions are not within specifications.
392279
Visually inspect the steering shaft for sheared

injected plastic. If the steering shaft shows
sheared plastic, replace the steering shaft.
Any frame damage that could cause a bent
steering shaft must have the steering shaft runout
checked. Using a dial indicator (1) at the lower
end of the steering shaft, rotate the steering wheel.
The runout must not exceed 1.60 mm (0.0625 in).
303724
Stee.ring
Steering;Wheel andCOlulJ'ln,- Tilt
2-1'09

Steering Wheel and Column Description
12
2 .
19
24
23
290365
The locking, energy-absorbing column (20) includes

the following three features in addition to the steering
function:
In a front-end collision, the energy-absorbing
column is designed to collapse. This action
minimizes the possibility of driver injury.
The steering column lock and ignition cylinder are
mounted on the column.
When locked, the column-mounted lock prevents
the operation of both the ignition and steering.
This action acts as a theft deterrent.
The turn signal controls the turn signals.
The headlamp dimmer switch controls the headlamp
high beam.
The windshield washer and wiper lever (16) controls

the windshield washer and wipers.
The cruise control actuator controls the cruise control,
if equipped.
In order to ensure energy-absorbing action, complete
the following steps:
Use only specified bolts/screws and nuts.
Tighten the bolts/screws and nuts to the specified
torque.
Apply a thin coat of lithium grease to all friction
points during reassembly.
2..110 Steering Wheel and Column .. Tilt

Handle the column with care when removing the
column.
Do not use a steering wheel puller other than the
one recommended.
Do not hit the end of the steering gear coupling
shaft (26) sharply.
Do not lean on the column.
Do not drop the column.
Disregarding the above suggestions could shear or
loosen the plastic fasteners that keep the column rigid.
Ignition Lock System Description

The automatic transmission uses a park lock system.
This system uses a flexible automatic transmission
park lock cable. The cable is attached at one end to
ttie automatic transmission control lever and at
ttie other end to the ignition switch. The ignition switch
is mounted to the column where it actuates a locking
pin. The locking pin engages an ignition switch
sliding contact when the lever is in the REVERSE
position. This action does not allow the ignition switch
to move to the LOCK position.
With the lever in PARK and the ignition switch slider in
LOCK, the following actions occur:
The locking pin engages a cam on the cable.
The locking pin prevents the lever from moving
into another position.
Vehicles with a manual transmission have a steering
column key release lever. A manual transmission
clutch start switch is also used. Depress the clutch in
order to crank the engine.

Control Description
the brake transmission shift interlock (BTSI) system
prevents the driver from shifting out of the PARK
position without simultaneously pressing the brake
pedal. When energized, the BTSI solenoid locks the
automatic transmission control lever.
When pressure is applied to the brake pedal, the
following actions occur:
The BTSI solenoid is de-energized.
Steering
Control Circuit Description
The brake/transmission shift interlock requires that the
brake pedal be depressed and the ignition switch
be placed in the RUN or START position before the
transmission may be shifted from the park position.
When the transmission is shifted from the park position
and the ignition switch is in RUN or START, current
flows from the GAUGES Fuse 9, through the stoplamp
switch, through the brake/transmission shift interlock
solenoid, and through the contacts of the park/neutral
position switch (closed in park/neutral) to ground
G110. The solenoid is energized preventing the
transmission from being shifted into another gear.
When the brake pedal is depressed, the
normally-closed contacts in the stoplamp switch open.
Current flow is interrupted and the brake/transmission
shift interlock solenoid is de-energized. The
transmission may then be shifted to another gear.
Once the transmission is shifted to another gear
(except neutral), the contacts in the park/neutral switch
are open and no current can flow to energize the
solenoid when the brake pedal is released.
Supplemental Inflatable Restraint

Description
The supplemental inflatable restraint (SIR) helps
supplement the protection offered by the driver's seat
belt. This is accomplished by deploying an air bag
from the center of the steering wheel during frontal
crashes. The air bag deploys when the
following conditions exist:
When the vehicle is involved in a frontal crash of
sufficient force.
When the crash site is up to 30 degrees off the
centerline.
The steering column is collapsible. Inspect the
steering column after an accident has occurred
whether or not the air bag deployed.
The following components are the SIR system
components in the steering wheel and steering column:
Inflatable restraint steering wheel module
The SIR coil
Refer to SIR System Component Description and
Definitions in Supplemental Inflatable Restraint (SIR)
for a detailed description of these components.
The BTSI releases the automatic transmission

control lever.
Steering
2-111

Illustration
Illustration
J 1859-A
J 5176-E
Steering Wheel Puller

Tester
802
65360
J 5176-92
J 38720
Steering Wheel Puller Bolts

Tester Adapter
293487
280232
2-112 Steering Wheel and
Column - Tilt
Steering
BLANK
Table of Contents
Suspension
3-1
Section 3
Suspension
Suspension General Diagnosis ..................... 3-3
Specifications .................................................. 3-3
Trim Height Specifications ..............................3-3
Vehicle Leads/Pulls ........................................ 3-3
Abnormal or Excessive Tire Wear .................. 3-4
Struts or Shock Absorbers Weak ................... 3-5
Struts or Shock Absorbers Noisy ................... 3-5
Struts or Shock Absorbers Leak .................... 3-5
Low or Uneven Trim Height ........................... 3-6
Description and Operation ..............................3-6
General Description ....................................... 3-6
Wheel Alignment .............................................. 3- 7

Specifications .................................................. 3-7
Wheel Alignment Specifications ...................... 3-7
Preliminary Alignment Inspection .................... 3-7
Repair Instructions .......................................... 3-8
Measuring Wheel Alignment ........................... 3-8
Front Caster and Camber Adjustment ............ 3-8
Front Toe Adjustment .................................... 3-9
Rear Thrust Angle Adjustment ....................... 3-9
Description and Operation ............................ 3-1 O
Caster Description ....................................... 3-1 O
Camber Description ..................................... 3-1 O
Toe Description ............................................ 3-11
Front Suspension .......................................... 3-12

Specifications ................................................ 3-12
Front Suspension Components .................... 3-13
Ball Stud Check ........................................... 3-14
Repair Instructions ........................................ 3-15
Wheel Hub Bolt Replacement ...................... 3-15
Stabilizer Shaft Replacement ....................... 3-16
Stabilizer Shaft Link Replacement ................ 3-17

Upper Ball Joint Replacement ...................... 3-17
Lower Ball Joint Replacement ...................... 3-19
Wheel Bearing/Hub Replacement - Front ..... 3-21
Steering Knuckle Replacement ..................... 3-22
Upper Control Arm Replacement .................. 3-24
Upper Control Arm Bushings
Replacement ............................................3-26
Lower Control Arm Replacement .................. 3-28
Lower Control Arm Bushings
Replacement (Front) ................................. 3-29
Replacement (Rear) .................................. 3-30
Shock Absorber Replacement ...................... 3-32
General Description .....................................3-39
Rear Suspension ............................................ 3-43

Specifications ................................................ 3-43
Rear Suspension Components ..................... 3-44
Bumper Replacement ................................... 3-45
Rear Axle Lower Control Arm
Replacement ............................................ 3-46
Bushings Replace ..................................... 3-46
Torque Arm Replacement ............................ 3-47
Stabilizer Shaft Replacement ....................... 3-49
Stabilizer Shaft Link Replacement ................ 3-50
Shock Absorber Replacement ...................... 3-51
Coil Spring Replacement ..............................3-52
Coil Spring Insulators Replacement .............. 3-53
Track Bar Replacement ............................... 3-54
General Description ..................................... 3-56
3-2
Table of Contents
Tires and Wheels ...........................................3-58

Specifications ................................................3-58
Tire and Wheel Specifications ...................... 3-58
Wheel Mounting Surface Check ................... 3-59
Aluminum Wheel Hub Cap Replacement ...... 3-60
Aluminum Wheel Porosity Repair ................. 3-60
Aluminum Wheel Refinishing ........................ 3-60
Wheel Removal ...........................................3-61
Suspension
Wheel Installation .........................................3-62
Tire Repair ..................................................3-63
Compact Spare Tire Replacement ................ 3-63
Tire Mounting and Dismounting .................... 3-64
Tire Rotation ................................................ 3-65
.Description and Operation ............................ 3-66
Tires Description ..........................................3-66
Tire Chain Usage Description ...................... 3-67
P-Metric Sized Tires Description .................. 3-67
Tire Placard Description ............................... 3-68
Wheels Description ...................................... 3-68
Suspension
Suspension General Diagnosis 3-3
Suspension General Diagnosis
Specifications
Trim Height Specifications
A
Suspension
Tire
mm
in
mm
in
mm
in
F41
235-55
420
16.5
204
8.0
30
1.2
235-55
420
16.5
204
8.0
31
1.2
245-50
420
16.5
204
8.0
37
1.5
FE2
Trim Height Specifications

B
Suspension
Tire
mm
in
mm
in
mm
in
F41
235-55
367
14.4
208
8.4
118
4.6
235-55
367
14.4
208
8.4
118
4.6
245-50
367
14.4
208
8.4
125
4.9
FE2

Vehicle Leads/Pulls
Lead/pull is the deviation of the vehicle from a straight

path on a level road with no pressure on the steering
wheel. Lead is usually caused by the following
conditions:
Poor tire construction
Uneven brake assemblies
Improper tire and wheel alignment In the front
tires (rear tires will not cause lead)
Tire construction can be a cause of lead in a vehicle.

An example of this is placement of the belt.
Off-center belts on radial tires can cause the tire to
develop a side force while rolling straight down
the road, and the tire will tend to roll like a cone.
Use the lead/pull correction table in order to verify that
improper tire and wheel alignment is not mistaken
for tire lead.
Vehicle Leads/Pulls
Step
1
Action
Road test the vehicle in order to verify the complaint
Does the vehicle lead/pull to either the left or to the right?
Value(s)
Yes
Go to Step2
No
1. Adjust the tire pressure to specification (30 psi).

2
2. Check for proper trim heights.

3. Check brakes for drag.
4. Road test the vehicle.
210 kPa
(30 psi)
Does the vehicle still lead/pull in the same direction?
Vehicle lead or pull is to the left.

1. Replace the left front tire with a known good tire.

1. Replace the left rear tire with a known good tire.

Vehicle lead or pull is to the right.
1. Replace the right front tire with a known good tire.
If left. go to
Step 3
If right, go to
Step4
Go to Steps
Go to Step 8
Go to Step 6
Go to Step 9
Go to Step 7
Go to Step 10
Suspension
3-4 Suspension General Diagnosis

Vehicle Leads/Pulls (cont'd)
Value(s)
Action
Step
6
1. Replace the right rear tire with a known good tire.

Perform vehicle alignment. Refer to Measuring Wheel

Alignment in Wheel Alignment.
Is alignment within specifications?
Replace the left front tire.

Replace the right front tire.

10
Replace the left rear tire.

11
Replace the right rear tire.

12
Perform vehicle alignment. Refer to Measuring Wheel

Alignment in Wheel Alignment.
Is repair complete?
13
14
Vehicle lead/pullis to the left.

1. Set the left caster to top specification. Set the right
caster 1 degree less. Refer to Wheel Alignment
Specifications.
Does the vehicle still lead/pull?
Vehicle lead/pull is to the right.

1. Set the right caster to top specification. Set the left
caster 1 degree less. Refer to Wheel Alignment
Specifications.
1. On the side opposite to the lead/pull, decrease the

caster 1 degree until lead/pull is eliminated. Do not
exceed 2 degree cross caster.
The cause of the problem is worn or bent suspension

components. Replace as necessary.
Have you replaced the parts?
16
17
Abnormal or Excessive Tire Wear

Irregular or premature tire wear has many causes,
including the folrowing:
Incorrect inflation pressure
Lack of regular rotation
Driving habits
Improper tire and wheel alignment
If tire and wheel alignment is reset due to a tire wear
condition, always rest the toe as close to zero
degrees as the specification allows.
No
Go to Step 7
Go to Step 11
Go to Step 13
Go to Step 12
Go to Step 1
.
Go to Step 1
Go to Step 1
Go to Step 1..
Go to Step 1
1. Change the caster setting.

Does the vehicle lead/pull to either the left or to the right?
15
Yes
If left, go to
Step 14
If right, go to
Step 15
Go to Step 16
System OK
Go to Step 16
System OK
Go to Step 17
System OK
System OK
Rotate the tires if you notice any of the following

conditions:
Front and rear tire wear is unequal
The tread of any tire wear is uneven
Left and right fron tire wear is unequal
Check tire and wheel alignment if you notice any of
the following conditions:
Left and right fron tire wear is unequal
The tread of any front tire wear is uneven
The front tire treads have a scuffed appearance
with ''feather'' edges on one side of the tread
ribs or blocks
Suspension
Suspension General Diagnosis 3-5
Struts or Shock Absorbers Weak
Struts or Shock Absorbers Noisy
Important: The single-tube shock absorbers are

highly gas pressurized and require a force of
445 N (100 lb) to initiate shock absorber rod
movement. Do not dent or puncture the shock
absorber assemblies, or they must be replaced.

445 N (100 lb) in order to initiate shock absorber rod
movement. Be careful not to dent or puncture the
shock absorber assemblies, or they must be replaced.
1. Check all of the mountings for proper tightening.
A loose mounting will cause a noise.
2. If all mountings are intact, test each shock
absorber in turn by quickly pushing down,
then lifting up, on the corner of the bumper nearest
to the shock absorber which you are checking.
2.1 . Use the same amount of effort on each test
and notice the resistance on compression
and rebound.
2.2. Repeat this test on a similar vehicle having
acceptable ride quality. The shock
absorbers on both vehicles should provide
the same feeling of resistance. If you
notice much difference between the two
vehicles, continue with the next step.
3. Remove the suspected shock absorber.
4. Shake the shock absorber and listen for loose
metallic parts inside the shock absorber body.
If you hear a suspicious noise, replace the shock
absorber.
5. Turn the shock absorber so that the loser mount
is up and the upper mount and rod are down.
Slowly compress the shock absorber. Do not allow
the chromed portion of the shock absorber rod to pass below the black seal cover.
6. Replace the shock absorber if you encounter a
seize condition with more than 25 mm (1 in) of
the chromed portion of the shock absorber
rod exposed above the seal cover.
1. Check and adjust the tire pressures to those

pressures shown on the tire placard.
2. Notice the load conditions in effect when the
vehicle is driven under normal conditions.
3. If practical, ride with the owner in order to be sure
that you understand the complaint before
proceeding to the next step.
4. Test each shock absorber in turn by quickly
pushing down, then lifting up, on the corner of the
bumper nearest to the shock absorber which
you are checking.
4. 1. Use the same amount of effort on each test
and notice the resistance on compression
and rebound.
4.2. Repeat this test on a similar vehicle having
acceptable ride quality. The shock
absorbers on both vehicles should provide
the same feeling of resistance. If you
notice much difference between the two
vehicles, continue with the next step.
5. Support the vehicle in order to expose the shock
mounts.
6. Remove the shock absorber assemblies.
Caution: The shock absorbers are highly

pressurized. Be sure to properly disassemble
module or personal injury could result.
7. Disassemble the plastic dust tube.
8. Remove the shock absorber rod washer.
Important: Do not fully compress the shock absorber.
Shock absorbers are highly gas charged and will
extend when released.
9. Turn the shock absorber to that the lower mount
is up and the upper mount is down. Compress the
shock absorber against the ground at various
rates of speed through approximately one-half of
the length of the exposed chromed shock
absorber rod:
Rear -
75 mm (3 in)
Front -
50 mm (2 in)
10. Compare the right and the left shock absorbers

for compression resistance and rebound speed:
The right and the left shock absorbers
should feel comparable.
Differences between the front and the rear
shock absorbers are normal.
If you are doubtful about the condition of any
shock absorber, compare with a shock
absorber known to be good.
Struts or Shock Absorbers Leak

445 N (100 lb) in order to initiate shock absorber rod
movement. Be careful not to dent or puncture the
shock absorber assemblies. or they must be replaced.
1. Fully extend the shock absorbers with the tires
and the wheels unsupported in order to expose
the seat cover area for inspection.
2. Look for signs of leaks at the top of the shock
absorber:
A small amount of fluid in not cause for
replacement. The seal permits some seepage
to lubricate the shock absorber rod.
You can easily determine a leaking shock
absorber because an excessive amount of fluid
will cover the shock absorber.
3. Replace a leaking shock absorber.
3-6
Suspension General Diagnosis
Suspension
Low or Uneven Trim Height

Incorrect trim heights can produce symptoms similar
to those produced tire and wheel misalignment. Check
trim heights whenever you diagnose steering and
vibration complaints.
In order to measure the trim heights accurately, use
the following check list:
Tires should be at their correct pressure as shown
on the tire placard and up to vehicle capacity
The fuel tank should be full
The vehicle should have no additional weight or
passengers
Seats should be in the full back position
The rear compartment should be empty, except
for a spare tire and jack and a simulated fuel
load if required
The vehicle should be on a known level floor
All doors, hood, and rear compartment lid should
be closed
All dimensions are measured vertical to the ground. In
order to be considered correct, trim heights should
be within +/-10 mm (0.4 in).
Measuring "Z", "J", and "A" Dimensions

1 . Lift the front bumper of the vehicle approximately
38 mm (1-1/2 in). Gently remove your hands and
let the vehicle settle.
Repeat the operation for a total of 2 times.
4. Verify the trim heights. Refer to Trim Height

Specifications.
5. Correct the trim heights as necessary.
Measuring "D", "K", and "B" Dimensions
-------6
5
'
2
156342
Repeat the procedure described in the preceding

section using the rear bumper.

General Description
156337
After the second time, measure the "Z', "J",

and "A" dimensions.
2. Push the front bumper down approximately
38 mm (1-1/2 in). Gently remove your hands
and let the vehicle rise on its own.
Repeat the operation tor a total of 2 times.
After the second time, measure the "Z",
"J", and "A" dimensions.
3. Calculate the trim heights. Trim heights are the
average of the high and the low measurements.
Since the problems in steering, suspension, tires and

wheels involve several systems, you must consider
all of these systems whenever you diagnose a
complaint. In order to avoid using the wrong symptom,
always road test the vehicle first. Proceed with the
following preliminary checks and correct any
substandard conditions which you may find.
Inspect tor the following conditions:
Wrong pressure and uneven tire wear
Loose connections or wear on joints from the
steering column to the steering gear
Loose or damaged parts on the front and on the
rear suspension or on the steering gear
Out-of-round or out-of-balance tires, bent wheels,
and loose or rough wheel bearings
Leaks in the power steering system. Also check
the power steering fluid level and check the
accessory drive belt tor proper condition and
tension.
Wheel Alignment
Suspension
3-7
Wheel Alignment
,9
11
Specifications
Wheel Alignment Specifications
Specification
Set
Check
Front Caster
5.00.5 degrees
5.0+1.0 degrees
Cross Caster (Front)
0.00.7 degrees
0.0+0.7 degrees
Application
a
Front Camber
0.40.5 degrees
0.4+1.0 degrees
Cross Camber (Front)
0.00.7 degrees
0.0+0.7 degrees
Individual Toe (Front)
0.00.1 degrees
0.0+0.1 degrees
Total Toe (Front)
0.00.2 degrees
0.0+0.2 degrees
Steering Wheel Angle (Front)
0.03.5 degrees
0.0+3.5 degrees
Rear Camber
0.00.6 degrees
O.Q+1.6 degrees
Cross Camber (Rear)
0.00.6 degrees
0.0+0.6 degrees
Total Toe (Rear)
0.00.3 degrees
0.0+0.3 degrees
0.0+0.15 degrees
0.0+0.15 degrees
Rear Thrust ,A.ngle

Specification
Application
Steering Linkage Tie Rod Adjust Nut
Diagnostic Information and

Procedures
Preliminary Alignment Inspection
Steering and vibration complaints are not always the
result of improper alignment. Another possibility is
tire lead. Tire lead is a condition due to worn or
improperly manufactured tires. Tire lead is the vehicle
deviation from a straight path on a level road
without pressure on the steering wheel. In order to
determine if the vehicle has a tire lead problem, refer
to Vehicle Leads/Pu/ls in Suspension General
Diagnosis.
Before making any adjustment that will affect the tire
and wheel alignment, make the following inspections to
ensure correct alignment readings and alignment
adjustments.
Inspect all tires for proper inflation pressures. Also
verify that all the tires have nearly even
tread wear.
Inspect the control arm ball studs. If the studs are
loose, correct them before adjusting the tire and
wheel alignment. Refer to Ball Stud Check in Front
Suspension.
Check the tire rod ends. If the ends are loose,
correct them before adjusting the tire and
wheel alignment. Refer to Power Steering System
Inspection.
Check the tires and wheels for runout. Refer to
Tire and Wheel Runout Measurement.
Metric
47N-m
I
I
English
35 lb ft
Inspect the vehicle trim height. If the height is out

of limits and a correction is to be made, make
the correction before adjusting the alignment.
Refer to Trim Height Specifications in Specification
General Diagnosis for the trim height chart.
Inspect the steering gear for looseness at
the frame.
Inspect the control arms for loose bushings.
Inspect the stabilizer shaft for loose or
missing parts.
Inspect the shock absorber and springs for
improper operation.
Inspect the suspension and steering components
for damage. Replace parts as necessary.
Inspect the vehicle for stability. The fuel tank
should be full, or the vehicle should have
compensating ballast.
Jounce the vehicle lightly three times in the rear
and three times in the front.
Give consideration to excess loads such as tool
boxes, sample cases, etc. If these items are normally
carried in the vehicle, they should remain in the
vehicle during alignment adjustments.
Give consideration also to the condition of the
equipment being used to adjust the alignment. Verify
that you, follow the equipment manufacturer's
instructions. Regardless of the equipment used to
adjust the alignment, the vehicle must be on a level
surface, both front to rear and side to side.
Suspension
3-8 Wheel Alignment
Repair Instruction$
Measuring Wheel Alignment.
Satisfactory vehicle operation may occur over a wide
range of alignment settings. If settings vary beyond
the specifications, correct the alignment angles.
1. Measure th~ front alignment angles.
2. Install the alignment equipment according to the
manufacturer's instructions.
3. Jounce the. front and rear bumpers iightly three
times to normalize the suspension prior to
measuring the angles.
4. Measure the alignment angles and record the
readings: H adjustments are required, make the
adjustments in the order. of camber,
caster and toe.
Front Caster and Camber Adjustment

Tools Required
J 38658.Caster/Camber Adjusting Tool
1. Jounce front bumper three times to allow vehicle
to return to normal height before making any
adjustments in caster.
2. Raise and sui\~bly support vehicle. Refer to Lifting
and Jacking the Vehicle inGeneral Information.
3; Loosen front lower control arm nuts.
4. Install J 38658 to slot holes in lower control
arm (2) and frontcrossmember (1).
5. Adjust camber by rotating turnbuckle on J 38658.
5.1. Rotating turnbuckle clockwise will increase
camber.
5.2. Rotating turnbuckle counterclockwise will
decrease camber.
208361
6. Install J 38658 to slot holes in lower control

arm (1) and front crossmember (2).
6.1. Rotating turnbuckle clockwise will increase
caster.
6.2. Rotating turnbuckle .counterclockwise will
decrease caster.
7. Adjust caster by rotating turnbuckle on J 38658.
8. Remove J 38658 from slot holes.

Notices.
9. Tighten front lower control arm nuts.
Tighten
Tighten the front lower control arm nuts to
100 N-m (74 lb ft).
10. Lower vehicle. Refer to Lifting and Jacking the
Vehicle in General lnfqrmation.
J 38658
208366
Suspension
Wheel Alignment
3-9
Front Toe Adjustment

1. Ensure that the steering wheel is set in a
straight-ahead position within 3.5 degrees.
2. Make toe adjustments separately at each
individual tire and wheel.
3. Loosen the nut (4) on the inner tie rod.
4. Adjust the toe to specification by turning the inner
tie rod. Refer to Wheel Alignment Specifications.

and Notices.
5. Verify that the steering gear boot seal is not
twisted.
Tighten
Tighten the nut to 47 N-m (35 lb ft).
6. Check the toe alignment specifications for
adjustment. Readjust the assembly by repeating
steps if necessary. Refer to Wheel Alignment
Specifications.
Rear Thrust Angle Adjustment

If the thrust angle is not within specifications, inspect
the lower control arms for damage. If the control
arms are not damaged, check the frame dimensions.
Refer to Dimensions - Body and Dimensions Frame.
180302
3-10
Suspension
Wheel Alignment
Camber Description
Caster Description
--
....
180281
82220
Caster is the tilting of the front steering axis (at the top)
either forward or backward (3) from the vertical (1 ).
A backward tilt is positive (+) and a forward tilt is
negative(-). Caster influences the directional control of
the steering but does not affect the tire wear and is
adjustable only at the front tires and wheels.
Camber is the tilting of the front tires and wheels (1)

from the vertical (2) as viewed from the front of
the vehicle. When the tires and wheels tilt outward (1)
at the top, the camber is positive(+). When the
tires and wheels tilt inward at the top, the camber is
negative (-). The amount of the tilt is measured in
degrees from the vertical and is called the camber
angle. The camber setting influences directional control
and tire wear.
360
+..__0--
!/
105 1020
30\
90
270
270
90
-=I_
180
143180
Caster is affected by the vehicle height. Therefore it is

important to keep the body at the designated trim
height. Overloading of the vehicle, or a weak sagging
rear spring will affect the caster. When the rear of
the vehicle is lower than the designated trim height, the
front suspension moves to a more positive caster. If
the rear of the vehicle is higher than the designated
trim height, the front suspension moves to a less
positive caster. For trim height information, refer to
Trim Height Specifications in Suspension General
Diagnosis.
82221
When the tires and the wheels are set to a positive

camber angle (1 ), they will tend to roll in a path that is
away from the vehicle's true path. The effect of
each tire and wheel tends to cancel the other. The
suspension geometry and the camber setting are
designed to keep the tire tread surface perpendicular
(flat) on the road through the full range of suspension
travel.
Suspension
Wheel Alignment
Toe Description
3-11
l--J \
5
180285
82222
Toe is the measurement of how much the front tires

and wheels are turned in or out (5) from a
straight-ahead position (4). When the tires and the .
wheels are turned in, toe is positive (+). When the tires
and the wheels are turned out, toe is negative (-).
the actual amount of toe is normally only a fraction of
a degree. The purpose of toe is to ensure that the
tires and the wheels roll parallel by compensating for
the slight tolerances or play that exist within the
suspension components .
You can also measure total toe, which is the

relationship or difference between the front toe
dimension (1) and the rear toe dimension (2). Total
toe indicates the tire-to-tire relationship, but does
not indicate the relationship of a tire to the vehicle
centerline. Toe also serves to offset the small
deflections of the tire and the wheel support system
which occur when the vehicle is rolling forward.
In other words, even when the tires and wheels are
set to toe in slightly when the vehicle is standing still,
the tires tend to roll parallel on the road when the
vehicle is moving. Toe affects tire wear.
3-12
Suspension
Front Suspension
Front Suspension
Specifications
Specification
Application
Metric
English
Front Lower Control Arm-To-Front Crossmember Nut (Horizontal)
100 N-m
74 lb ft
Front Lower,Control Arm-To-Front Crossmember Nut (Vertical)
115 N-m
85 lb ft
Front Lower Control Arm-To-Front Lower Control Arm Ball Stud Nut
110 N-m
81 lb ft
Front Shock Absorber Bolt/Screw
65Nm
48 lb ft
Front Shock Absorber Lower Bracket Nut
65Nm
48 lb ft
Front Shock Absorber Upper Mount Bolt/Screw
50Nm
37 lb ft
Front Shock Absorber Upper Mount Nut
43N-m
32 lb ft
55Nm
41 lb ft
23N-m
17 lb ft
Front Stabilizer Shaft Link Nut
23N-m
17 lb ft
Front Upper Control Arm-To-Front Upper Control Arm Ball Stud Nut
53Nm
39 lb ft
Front Upper Control Arm-To-Front Upper Control Arm Support Nut
98N-m
72 lb ft
Front Wheel Bolt/Screw
86N-m
63 lb ft
Front Stabilizer Shaft Bracket Bolt/Screw

Front Stabilizer Shaft Link
,<
Front Suspension
Suspension
3-.ts
Component Locator
Front Suspension Components
29
22
18
26
17~
:l
I
16
15
13
11
L
7
181103
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
Arm, Front Upper Control

Stud, Front Upper Control Arm Ball
Nut, Front Shock Absorber Lower Bracket
Nut, Front Upper Control Arm
Pin, Front Upper Control Arm Cotter
Knuckle and Hub, Steering
Hub, Front Wheel
Stud, Front Lower Control Arm Ball
Arm, Front Lower Control
Bolt/Screw, Front Shock Absorber
Link, Front Stabilizer Shaft
Sleeve, Front Stabilizer Shaft Link
(13) Bolt/Screw, Front Stabilizer Shaft

Insulator Clamp
(15) Clamp, Front Stabilizer Shaft Insulator
(16) Stabilizer Shaft, Front
(17) Nut, Front Stabilizer Shaft Link
(18) Insulator, Front Stabilizer Shaft
(19) Bolt/Screw, Front Lower Control Arm
(20) Nut, Front Lower Control Arm
(22) Crossmember, Front
(23) Bolt/Screw, Front Lower Control Arm
(25) Pin, Front Lower Control Arm Cotter
3-14
(26)
(27)
(28)
(29)
Front Suspension
Suspension
Absorber, Front Shock

Spring, Front
Mount, Front Upper Shock Absorber
Support, Front Upper Control Arm
(30) Nut, Front Shock Absorber Upper

(31) Bolt/Screw, Front Shock Absorber
Upper Mount

Ball Stud Check
Important:
The vehicle must be stable and should not rock

on the floor stands.
Wipe the ball joints clean and check the seals for
cuts or tears. If the seal is cut or torn, you
MUST replace the ball joint.
1. Raise the vehicle and position the floor stands
under both lower control arms as near as
possible to each ball stud. Refer to Lifting and
190281
3. Pry between the lower control arm and the

steering knuckle while reading the dial indicator.
Vertical deflection on the dial indicator should
not exceed 1.19 mm (0.046875 in).
4. If the dial indicator reading exceeds
1.19 mm (0.046875 in), replace the ball stud.
5. Anytime the ball stud is disconnected from the
steering knuckle, check for looseness. If you are
able to twist the ball stud in its socket with
your fingers, replace the ball stud.
2009
2. Position the dial indicator against the wheel

rim (1 ).
Suspension
Front Suspension
3-15
Repair Instructions
Wheel Hub Bolt Replacement
Removal Procedure
J 6627-A
Tool Required
J 6627-A Wheel Stud Remover
1. Raise and suitably support the vehicle. Refer to
Information.
2. Remove the tire and wheel assembly. Refer to
Wheel Removal in Tires and Wheels.
3. Install tool J 6627-A onto the wheel stud and hub.
4. Turn the forcing screw in until the stud is pushed
out of the wheel hub.
65316
1. Place the new stud (3) in the wheel hub.
2. Place some washers (1) onto the wheel stud.
3. With the flat side of the wheel nut (2) against the
washers, tighten the wheel nut until the wheel
stud head seats against the wheel hub flange .
Important: Make sure that the wheel stud is fully

seated against the wheel hub flange.
4. Remove the wheel nut and washers.
5. Install the tire and wheel assembly. Refer to
Wheel Installation in Tires and Wheels.
65317
3-16
Suspension
Front Suspension
Stabilizer Shaft Replacement
Removal Procedure

Information.
2. Remove the stabilizer shaft link. Refer to Stabilizer
Shaft Link Replacement.
3. Remove the bolts (4).
4. Remove the clamps (5).
5. Remove the stabilizer shaft (7).
6. Remove the insulators (6).
7. Remove the bolts (2).
8. Remove the brackets (3).
181093
1. Position the brackets (3) to the side rail.
Notices.
2. Hand start the bolts (2).
Tighten
Tighten the bolts to 55 Nm (41 lb ft).
Important: The slit of the insulator must face the front

of the vehicle.
3. Place the insulators (6) over the stabilizer
shaft (7).
4. Position the clamps (5) over the insulators at the
stabilizer shaft (7).
5. Install the bolts (4).
Tighten
Tighten the bolts to 55 Nm (41 lb ft).
6. Install the stabilizer shaft link. Refer to Stabilizer
181093
Suspension
Front Suspension
3-17
Stabilizer Shaft Link Replacement

-
Removal Procedure
Information.
2. Remove the nut (7).
3. Remove the link (3),
181095
1. Install the sleeve (5) between the lower control
arm (4) and the stabilizer shaft (6).
2. Install the link (3) through the lower control
arm (4), the sleeve (5), and the stabilizer shaft (6).
and Notices.
3. Install the nut (7)
Tighten
Tighten the nut (7) to 23 Nm (17 lb ft).
Upper Ball Joint Replacement

Removal Procedure
Tools Required
J 39549 Ball Joint!fie Rod Separator
Information.
2. Remove the special security wheel lock nut, if
equipped. Use the special security wheel lock
key which is located in the front floor console.
3. Remove the tire and the wheel. Refer to Wheel
1832
3-18
Front .Suspension
Suspension
Important: The floor jack must remain under the
shock absorber mounting location on the lower control
arm during removal and installation in order to hold
the spring and lower control arm in position.
4. Place a floor jack under the shock absorber
mounting location on the lower control arm.
5. Loosen the ball stud from the steering knuckle.
6. Remove the cotter pin and the nut.
7. Support the steering knuckle with floor stands.
8. Use the J 39549 in order to separate the ball stud
from the upper control arm.
9. With the upper control arm in the raised position,
drill out four rivets approximately 6 mm (0.25 in)
deep using a Va inch drill bit.
10. Drill off the rivet heads using a 112 inch drill bit.
1833
11. Punch out the rivets using a small punch.

12. Remove the ball stud.
1834
Suspension
Front Suspension
3-19
-~
1. Position the new ball stud and install the four

service kit bolts/screws and nuts. Use the
specifications in the ball stud kit.
2. Remove the temporary support from the steering
knuckle, then connect the ball stud to the steering
knuckle.
3. Hand start the nut.
4. Install the nut enough in order to align the slot
with the stud hole.
5. Install the cotter pin.
6. Install the floor jack to the spring seat.
7. Install the tire and the wheel. Refer to Wheel
8. Install the special security wheel lock nut, if
equipped. Use the special security wheel lock key
which is located in the front floor console.
181076
Lower Ball Joint Replacement

Removal Procedure
Tools Required
J 39549 Ball Joint/Tie Rod Separator
J 9519-7 Ball Joint Remover
J 9519-9 Ball Joint Installer
J 9519-18 Ball Joint Pressing Screw
J 9519-23 Ball Joint C-Clamp
1. Raise and suitably support the vehicle with floor
stands under the frame. Refer to Lifting and
4. Place a floor jack under the lower control arm (1 ).
5. Remove the lower control arm cotter pin and
loosen the lower control arm nut.
181072
3-20
Front Suspension
Suspension
J 9519-18
Important: The floor jack must remain under the

shock absorber mounting location on the lower control
arm during removal and installation in order to hold
the spring and the lower control arm in position .
6. Use the J 39549 in order to separate the ball
stud (1) from the steering knuckle (3).
7. Use J 9519-7, J 9519-18 and J 9519-23 in order
to press the ball stud out of the lower control arm.
1
181070
1. Position the ball stud into the lower control
arm (1), then press in using J 9519-9, J 9519-18
and J 9519-23 until the ball stud bottoms on
the lower control arm.
2. The ball stud must firmly press into the lower
control arm. If the ball stud does not fit firmly
into the lower control arm, replace the lower
control arm.
J 9519-9
181071
3. Install the ball stud (1) to the steering knuckle (3).

Notices.
Important: Tighten the lower control arm nut enough
in order to align the nut slot with the stud hole.

Never loosen the nut in order to align the nut slot with
the stud hole.
4. Hand start the lower control arm nut.
Tighten
Tighten the lower control arm nut to
110 Nm (81 lb ft).
5. Install the lower control arm cotter pin.
6. Remove the floor jack from under the shock

absorber mounting location on the lower
control arm.
7. Install the tire and wheel. Refer to Wheel

181072
Suspension
FrontSuspension
3-21

9. Check the wheel alignment. Refer to Measuring
Wheel Alignment in Wheel Alignment.
Wheel Bearing/Hub Replacement - Front

Removal Procedure
1 . Raise and suitably support the vehicle. Refer to
Information.
3. Remove the Tire and Wheel. Refer to Wheel
4. Remove the brake caliper (3). Refer to Brake
Caliper Replacement (Front) in Disc Brakes.
5. Remove the brake rotor (5). Refer to Brake Rotor
Replacement (Front) in Disc Brakes.
6. Disconnect the wheel speed sensor electrical
connector and set the connector aside. Refer
to Wheel Speed Sensor Replacement (Front) in
Antilock Brake System.
7. Remove the bolts/screws (6) from the hub (4).
8. Pull the hub from the spindle.
1s1on
1. Position the hub (4) to the spindle.

Notices.
2. Install the bolts and the screws (6).
Tighten
Important: Ensure that the wheel speed sensor
electrical connector is reconnected to the wheel speed
sensor wire bracket (8) and to the wheel speed
sensor. Otherwise the wires may be damaged.
3. Connect the wheel speed sensor electrical
connector. Refer to Wheel Speed Sensor
Replacement (Front) in Antilock Brake System.
4. Install the brake rotor (5). Refer to Brake Rotor
5. Install the brake caliper (3). Refer to Brake
Caliper Replacement (Front) in Disc Brakes.
1s1on
3-22
Suspension
Front Suspension
Steering Knuckle Replacement
Removal Procedure
13
3
181096
1. Support the vehicle. Raise the vehicle. Refer to

Information.
3. Remove the tire and wheel. Refer to Wheel
Removal in Tire and Wheels.
4. Remove the brake caliper and set the caliper
aside. Refer to Brake Caliper Replacement
(Front) in Disc Brakes.
5. Remove the brake rotor. Refer to Brake Rotor
6. Remove the wheel speed sensor electrical
connector and move aside. Refer to Wheel Speed
Sensor Replacement (Front) in Antilock Brake
System.
7. Remove the front wheel hub from the steering
knuckle. Refer to Wheel Bearing/Hub
Replacement - Front.
8. Remove the power steering gear from the
steering knuckle. Refer to Power Steering
Gear Replacement (3.BL VIN G) or Power
Steering Gear Replacement (5. 7L VIN K) in Power
Steering System.
10. Remove the front shock absorber bolts. Refer to
Shock Absorber Replacement.
Separate
the lower ball stud from the steering
11.
knuckle. Refer to Lower Ball Joint Replacement.
12. Remove the lower control arm from the steering
knuckle. Refer to Lower Control Arm
Replacement.
13. Separate the upper ball stud from the steering
knuckle. Refer to Upper Ball Joint Replacement
and Lower Ball Joint Replacement.
14. Remove the steering knuckle from the upper
control arm. Refer to Upper Control Arm
Replacement.
15. Remove the steering knuckle (5) and the hubs (6).
Suspension
Front ,suspension
3-23
1. Position the steering knuckle (5) and the hubs (6)
to the upper e:ontrol arm (1 ).
2. Install the upper ball stud (2) to the steering
'knuckle. Refer to Lower Ball Joint Replacement.
3. Position the steering knuckle (5) to the lower
control arm. Refer to Lower Control Arm
Replacement.
4. Install the lower ball stud (7) to the steering
knuckle. Refer to Lower Ball Joint Replacement.
5. Install the front shock absorber bolts. Refer
to Shock Absorber Replacement.
6. Install the stabilizer shaft link. Refer to Stabilizer
7. Install the power steering gear to the steering
knuckle. Refer to Power Steering Gear
Replacement (3.BL VIN G) or Power Steering
Gear Replacement (5. 7L VIN K) in Power Steering
System.
8. Install the front wheel hub (6) to the steering
knuckle. Refer to Wheel Bearing/Hub
Replacement - Front.
Important: Ensure that the wheel speed sensor
electrical connector is reconnected to the wheel speed
sensor wire bracket and to the wheel speed sensor.
or else the wires may be damaged.
9. Install the wheel speed sensor electrical
connector. Refer to Wheel Speed Sensor
Replacement (Front) in Antilock Brake System .
10. Install the brake rotor. Refer to Brake Rotor
11. Install the brake caliper. Refer to Brake Caliper
12. Install the tire and wheel. Refer to Wheel
Install
the special security wheel lock nut, if
13.
15. Check the wheel toe-in alignment. Refer to Front
Toe Adjustment in Wheel Alignment.
181096
3-24
Front Suspension
Suspension
Upper Control Arm Replacement
Removal Procedure
181097
1. Remove the brake mc!,ster cylinder nuts (driver

side only). Refer to Master Cylinder Replacement
in Hydraulic Brakes.
2. Move the brake master cylinder asid,e (driver side
only). Refer to Master Cylinder Replacement in
Hydraulic Brakes.
3. Remove the shock absorber upper mounting
bolts/screws (15) and the nuts (14).
8. Remove the front shock absorber bolts/screws.
Refer to Shock Absorber Replacement.
9. Separate the upper ball st.ud (2) from the steering
knuckle (6). Refer to Lower Ball Joint
Replacement.
10. Remove the steering knuckle from the. upper
control arm (1 ).
11. Remove the upper control arm and the shock
absorber from the vehicle.
12. Support the steering knuckle with floor stands.
13. Remove the upper control arm from the shock
absorber.
Suspension
Front Suspension
3-25
1. Position the upper control arm (1) to the shock
absorber (8).

Notices.
2. Install the front upper control arm bolts/screws
and the nuts (12)(11 ).
3.
4.
5.
6.
7.
8.
Notice: Turning the shock absorber while tightening

the nut may damage the shock absorber. In order
to prevent damage, keep the shock absorber in
a stationary position while tightening the nut.
9. Install the shock absorber mounting nuts and the
bolts/screws.
10.
11.
12.
13.
14.
Tighten
Tighten the nqts to 98 N-m (72 lb ft).
Install the upper control arm and the shock
absorber to the vehicle.
Position the steering knuckle (6) to the upper
control arm.
Install the upper ball stud to the steering knuckle.
Refer to Upper Ball Joint Replacement.
Remove the floor stands from the steering
knuckle.
Install the front shock absorber bolts/screws.
Install the stabilizer shaft link. Refer to Stabilizer
Tighten
Tighten the nuts (14) to 43 Nm (32 lb ft).
Tighten the bolts/screws (15) to
50 N-m (37 lb ft).
Install the tire and the wheel. Refer to Wheel
Install the special security wheel lock nut, if
Lower the vehicle.
Position the brake master cylinder (driver side
Hydraulic Brakes.
Install the brake master cylinder nuts (driver side
Hydraulic Brakes .
181097
3-26
Front Suspension
Suspension
Upper Control Arm Bushings Replacement
Removal Procedure
J 39872
J 21474-5
181098
Tools Required
J 21474-5 Control Arm Bushing Receiver
J 21474-18 Upper Control Arm Nut
J 21474-19 Upper Control Arm Screw
J 39872 Half Moon Spacer
J 39930 Upper Control Arm Bushing
Receiver/Installer
Service the upper control arm bushing separately from
the upper control arm.
1. Remove the upper control arm. Refer to Upper
Control Arm Replacement.
2. Remove the bolts/screws and the nuts.
3. Separate the front upper control arm from the
upper control arm support.
4. Perform the following procedure in order to
remove the upper control arm bushing from
the upper control arm (2):
4.1. Thread J 21474-19 through J 39930 (the
three tangs on J 39930 should be against
the screw head).
4.2. Thread J 21474-19 through the inside of the
upper control arm bushing (you may need
to wiggle J 21474-19 until the tool slides
through the bushing).
4.3. Run the smaller end of J 21474-5 onto
J 21474-19, then place the thrust
washer (1) on J21474-19with the seams
facing toward J 21474-5.
4.4. Install J 39872 around the outside of the
bushing in order to avoid metal distortion
during removal.
4.5. Ensure that both J 39930 and J 21474-5
line up property, then install J 21474-18 on
J 21474-19.
4.6. Tighten J 21474-19 and J 21474-18 until
the bushing is pushed all the way out
(making a popping noise).
Suspension
Front Suspension
3-27
1. Perform the following procedure in order to install
the upper control arm bushings:
1.1. Secure the control arm tightly in a vise,
then thread J 21474-19 through J 39930
(the three tangs on J 39930 should
face away from the screw head).
1.2. Install a new upper control arm bushing
onto J 21474-19 with the three indentations
facing toward the three tangs on J 39930.
1.3. Install the threaded end of J 21474-19 into
the upper control arm from the outer side of
the control arm.
1.4. Install J 21474-5 onto J 21474-19 from the
inside of the control arm.
1.5. Install the thrust washer (2) onto J 21474-19
with the seam facing toward the control arm
bushing.
during removal.
1.7. Install J 21474-18 onto J 21474-19,
ensuring that the three tangs prongs
on J 39930 fit into the indentations of the
bushing.
1.8. Tighten until the bushing is flush with the
control arm.
2. Install the front upper control arm to the front
upper control arm support .

Notices.
3. Install the bolts/screws and nuts.
Tighten
Tighten the nuts to 98 Nm (72 lb ft).
4. Install the upper control arm. Refer to Upper
J 21474-5
J 21474-18
1
181100
3-28
Suspension
Front Suspension
Lower Control Arm Replacement

Removal Procedure
Information.
4. Remove the power steering gear from the
steering knuckle. Refer to Power Steering
Gear Replacement (3.BL VIN G) or Power
Steering Gear Replacement (5. 7L VIN K) in Power
Steering System.
5. Remove the stabilizer shaft link (7). Refer to
Stabilizer Shaft Link Replacement.
6. Remove the shock absorber (19) and spring (21)
from the lower control arm (5). Refer to Shock
Absorber Replacement.
7. Separate the lower control arm ball stud (4) from
the steering knuckle (2). Refer to Lower Ball Joint
Replacement.
8. Remove the lower control arm from the steering
knuckle.
9. Remove the bolts/screws and nuts.
10. Remove the lower control arm.
181078
1. Position the lower control arm (5) to the
crossmember (15).

Notices.
2. Hand tighten the bolts/screws and nuts.
Tighten
Tighten the nuts {12) to 115 N-m (85 lb ft).
Tighten the nuts {13) to 100 N-m (74 lb ft).
3. Position the lower control arm to the steering
knuckle (2).
Important: Tighten the nut enough in order to align
the slot with the stud hole. Never loosen the nut
in order to align the slot with the hole.
4. Hand start the nut.
Tighten
Tighten the nut (17) to 110 N-m (81 lb ft).
5. Install the cotter pin (18).
6. Install the lower control arm to the shock
absorber (19) and spring (21 ). Refer to Shock
Absorber Replacement.
7. Install the stabilizer shaft link (7). Refer to
181078
Suspension
Front Suspension
3-29
8. Install the power steering gear to the steering

knuckle. Refer to Power Steering Gear
Replacement (3.8L VIN G) or Power Steering
Gear Replacement (5. 7L VIN K) in Power Steering
System.
12. Perform a wheel alignment. Refer to Measuring
Wheel Alignment in Wheel Alignment.

Replacement (Front)
J 21474-5
Tools Required
J 21474-3 Lower Control Arm Bushing Screw
J 21474-4 Lower Control Arm Bushing Nut
J 39875 Half Moon Spacer
J 39876 Lower Control Arm Bushing Receiver
1. Remove the lower control arm. Refer to Lower
2. Perform the following procedure in order to
remove the lower control arm front bushing
from the lower control arm (1 ):
2.1. Place J 21474-3 through the large end of
J 21474-6.
2.2. Thread J 21474-3 through the front bushing
and push J 21474-3 through the open end
of J 39876.
2.3. Place the thrust washer onto J 21474-3 with
the seam facing toward the front bushing.
during removal.
2.5. Ensure that all tools properly line up with
the front bushing and the control arm (1 ),
then install J 21474-4 and tighten until
the bushing is pushed all the way out
(the bushing makes a popping noise upon
removal) .
(
181079
3-30
Front Suspension
Suspension
Assembly Procedure
181080
1. Perform the following steps in order to install the

lower control arm front bushing:
1.1. Thread J 21474-3 through J 21474-5.
1.2. Install J 21474-3 through the new front
bushing and into the lower control arm (2).
1.3. Thread J 21474-3 and accessories into the
front lower control arm.
1.4. Install J 39876 onto J 21474-3 with the
open end of J 39876 facing toward the
control arm.
during installation.
1.6. Place the thrust washer (1) onto the
threaded end of J 21474-3 with the
seam facing toward the control arm.
1.7. Ensure that all tools properly line up with
the front bushing and the control arm, then
install J 21474-4 onto J 21474-3.
1.8. Tighten J 21474-4 and J 21474-3 until the
bushing becomes flush with the control arm.
2. Install the lower control arm. Refer to Lower

Replacement (Rear)
J 39931
Tools Required
J 21474-3 Lower Control Arm Bushing Screw
J 21474-4 Lower Control Arm Bushing Nut
Remove the lower control arm. Refer to Lower
2. Perform the following steps in order to remove the
lower control arm rear bushing from the lower
control arm (1 ):
2.1. Install J 39874 onto J 21474-3 with the
sealed end of J 39874 facing the head of
the screw.
2.2. Run the J 21474-3 through the control arm
bushing, the control arm and into the small
end of J 39931.
2.3. Install the thrust washer onto J 21474-3
with the seam facing toward the control arm.
2.4. Install J 21474-4 onto J 21474-3 and ensure
that all parts are lined up with the control
arm bushing.
2.5. Tighten until you are able to remove the
control arm bushing (the bushing may make
a popping noise upon removal).
1.
181081
Suspension
Front Suspension
3-31
Assembly Procedure
1. Perform the following steps in order to install the
lower control arm rear bushing:
1.1. Secure the lower control arm (2) in a vise,
then place J 21474-3 through the small end
of J 39931.
1.2. Install J 21474-3 through the new rear
bushing, then through the closed end of
the rear lower control arm.
1.3. Place the small end of J 21474-5 onto
J 21474-3.
1.4. Install the thrust washer (1) onto J 21474-3
with the seam of the washer facing toward
the control arm.
1.5. Ensure that all the tools are lined up with
the bushing and the control arm, and that
the window is facing straight up and
visible on J 39931.
1.6. Install J 21474-4 onto J 21474-3 and tighten
until the rubber protrusion on the J 39931
side bottoms out against J 39931.
2. Install the lower control arm. Refer to Lower
J 39931
181082
3-32
Suspension
Front Suspension
Shock Absorber Replacement
Removal Procedure
Tools Requireq
J 34013-B Strut Spring Compressor
J 34013-114 Modular Shock Compressor Adapter
J 3401388 Strut Compressor Adapter
J 39642 Modular Shock Nut Removal Set,
15 mm (0.60 in)
J 34013-115 Modular Alignment Rod
1 . Remove. the driver-side brake master cylinder
nuts. Refer to Master Cylinder Replacement in
Hydraulic Brakes.
2. Move the brake master cylinder aside (qriver-side
Hydraulic Brakes.
3. Remove the bolts/screws (18) and the nuts (17).
4. Raise and suitably support the vehicle. Refer
to Lifting and Jacking the Vehicle in General
Information.
8. Remove the lower shock absorber bracket
mounting nuts (3).
9. Remove the lower shock absorber mounting
bolts/screws (11 ).
10. Separate the lower ball stud (10) from the
steering knuckle (6). Refer to Lower Ball
Joint Replacement.
181083
Important: Use chalk or paint in order to mark (do not

scribe) the lower mount location relative to the
upper mount location before removing the shock
absorber.
11. Remove the shock absorber (13) and the
spring (14).
Suspension
Tools Required
J 34013-8 Strut Spring Compressor
J 34013-88 Strut Compressor Adapter
15 mm (0.60 in)
1. Install J 34013-114 and J 34013-8.
Front Suspension
3-33
J 34013-114
J 34013-88
J 34013-B.
181087
2. Use wing nuts in order to secure the tool to

mounting holes C-H (lower left corner) and P
(upper right corner) for driver-side shock absorber,
and to secure the tool to mounting holes A-X-P
(upper left corner) and C-H (lower right corner) for
the passenger-side shock absorber.
J-N-L
Nave Twln-c.n
181084
3-34
Front Suspension
Suspension
Important: Ensure that J 34013-114 and J 34013-88
align so that these tools may open and close together.
If J 34013-114 and J 34013-88 do not align properly,
the tools will not open.
3. Install J 34013-114 and J 34013-88
181088
Important: Ensure that the top of the shock absorber

is flat against J 34013-114. The shock absorber is not
aligned correctly if the shock absorber does not lie
flat against the tool.
4. Install the driver side shock absorber (2) to the

top of J 34013-114
181089
5. Install the passenger side shock absorber (2) to

the top of J 34013-114.
J 34013-B
181090
Suspension
Front Suspension
3.:.35
6. Install the shock absorber (1) into J 34013-114

and J 34013-88.
7. Close J 34013-114 and J 34013-88 and install the
locking pin.
Important: Ensure that the mounting ears of the

shock absorber are facing downward, toward the rear
of J 34013-8 or the shock absorber will not align
properly.
8. Turn the screw on J 34013-8 counterclockwise in
order to raise the shock absorber up to
J 34013-114. Ensure that the studs go through
the guide holes in J 34013-114, and that the top of
the shock absorber is flat against the tool.
Caution: Do not over compress the spring. Severe
overloading may cause tool failure which could
result in bodily injury.
9. Compress the front spring approximately
13 mm (0.50 in) or three or four complete turns of
the screw on J 34013-114.
10. Insert J 39642-1 on the shock absorber nut, then
insert J 39642-2 through J 39642-1 in order to
hold the shock absorber rod in place.
11. Remove the shock absorber nut with J 39642-1
while holding the shock absorber rod from
rotating with J 39642-2.
12. Discard the shock absorber nut.
13. Turn J 34013-8 clockwise in order to fully relieve
spring pressure.
Assembly Procedure
Tools Required
J 34013-8 Strut Spring Compressor
J 34013-88 Strut Compressor Adapter
15 mm (0.60 in)
1. Install J34013-114to J34013-8.
181088
J 34013-114
J 34013-88
J 34013-B
181087
3-36
Suspension
Front Suspension
2. Use wing nuts in order to secure J 34013114 to

J 34013-8 mounting holes C-H (lower left corner)
and P (upper right corner) for the driver-side
shock absorber and in order to secure
J 34013-114 to J 34013-8 mounting holes A-X-P
(upper left corner) and C-H (lower right corner)
for the passenger-side shock absorber.
3. Install J 34013-114 and J 34013-88.
J 34013- B Strut Spring Compressor

Read Instruction Sheet J 34013 29l29A
Before Using
C-H-E/K
J-N-L
Nova Twin-Cam
181084
4. Install the shock absorber (1) to J 34013-114 and

J 34013-88.
Important:
Ensure that the mounting ears of the shock
absorber are facing downward, toward the rear of
J 34013-8 or the shock absorber will not align
property.
Use chalk or paint in order to mark (do not scribe)
the lower mount location relative to the upper
mount location before removing the shock
absorber, or the shock absorber cannot be
reinstalled.
5. Close J 34013-114 and J 34013-88 and engage
the locking pin.
6. Ensure that the upper and lower spring seats are
positioned correctly.
181088
Important: Ensure that the top of the shock absorber

is flat against J 34013-114. The shock absorber
will not align properly if the shock absorber does not
lie flat against the tool.
7. Install the shock absorber to the top of
J 34013-114
Important: Only turn the screw until the shock
absorber secures itself in J 34013-8. Do not load the
spring.
8. Turn the screw on J 34013-8 counterclockwise in
order to raise the shock absorber up to
J 34013-114 without compressing the spring.
Suspension
Important: Ensure that J 34013-115 is straight with
the shock absorber. If J 34013-115 is angled,
repeat steps 1 through 5 until the tool is straight.
9. Place J 34013-115 down th rough the top
of J 34013-8 through the top of the shock
absorber and onto the top of the shock
absorber rod.
Caution: Do not over compress the spring. Severe
overloading may cause tool failure which could
result in bodily injury.
10. Turn the operating screw clockwise in order to
compress the spring until the threaded portion
of the shock absorber rod is through the top of the
shock absorber.
11. Remove J 34013-115.
Important: When installing the front shock absorber

nut, always replace with a new shock absorber
nut. Never reinstall the original nut.
12. Insert the new shock absorber nut on the shock
absorber rod.
13. Place J 39642-1 on the shock absorber nut.
the nut may damage the shock absorber. In order
to prevent damage, keep the shock absorber in
a stationary position while tightening the nut.
14. Insert J 39642-2 through J 39642-1 and tighten
the shock absorber nut.
15. Tighten the shock absorber nut while holding onto
J 39642 (J 39642-2).
16. Remove the shock absorber from J 34013-8.
Front Suspension
3,;37
Suspension
3-38 Front Suspension

1. Position the shock absorber (13) and spring (14)

to the lower control arm (12).

Notices.
2. Install the bolts/screws and the nuts.
3.
4.
5.
6.
7.
8.
9.
10.
Tighten
Tighten the bolts/screws and the nuts to.
65 N-m (48 lb ft).
Install the lower ball stud (10) to the steering
knuckle (6). Refer to Lower Ball Joint
Replacement.
Install the stabilizer shaft link. Refer to Stabilizer
Install the tire and the wheel. Refer to Wheel
Install the special security wheel lock nut, if
Lower the vehicle.
Hand tighten the bolts/screws and the nuts.
Tighten
Tighten the nuts to 43 N-m (32 lb ft).
Position the brake master cylinder (driver-side
Hydraulic Brakes.
Install the brake master cylinder nuts. (driver-side
Hydraulic Brakes.
181083
Front Suspension 3,;39
Suspension

General Description
29
22
4
18
26
~~
I
16
15
13
11
L
7
181103
The short/long arm front suspension design allows

each wheel to compensate for changes in the
road surface level without appreciably affecting the
opposite wheel. Each wheel independently connects to
the frame by the following:
A steering knuckle (6)
A wheel hub (7)
A shock absorber (26) and spring (27)
Upper and lower ball studs (2, 8)
Upper and lower control arms (1, 9)
The steering knuckle and hubs (6, 7) move in a
prescribed three-dimensional arc. The front wheels are
held in proper relationship to each other by the two
front tie rods. The front tie rods connect to steering
arms on the knuckles and to the steering gear.
Springs (27) mount to the lower control arms (9). Direct

acting shock absorbers (26) provide ride control. The
upper portion of the shock absorber connects to the
front upper shock absorber mount (28). The upper
mount (28) extends through the upper control arm
support (29) and the center wheelhouse. The upper
mount attaches with two bolts/screws (31) and two
nuts (30).
The stabilizer shaft (16) controls idle roll of the front
suspension. The stabilizer shaft mounts to the
stabilizer shaft insulators (18). These insulators attach
to the frame side rails by stabilizer shaft brackets.
The ends of the stabilizer shaft (16) connect to
the lower control arms (9) by stabilizer shaft links (11)
and are isolated by bushings.
3-40
Suspension
Front Suspensi.on
I
The inner ends of the lower control arm (9) have

pressed-in bushings. Bolts (19) pass through
the bushings and attach the lower control arm (9) to
the crossmember (22).
Illustration ' '
''
The upper ball stud (2) is riveted to the upper control

arm (1 ). This stud attaches to the steering knuckle (6)
with a nut (4) and cotter pin (5). The control arm bolts to
the shock absorber (26) through an upper control arm
support (29) which attaches to the body.
The lower ball stud (8) is press fit into the lower control
arm (9) and attaches to the steering knuckle (6) with a
nut (24) and a cotter pin (25).
Tool Number/Description
J 34013-114
Modular Shock Compressor
Adapter
181112
Rubber seals are provided at ball sockets in order to

keep dirt and moisture from entering the stud and
damaging the bearing surfaces.

Illustration
J 34013-115
Modular Shock
Alignment Rod
181114
J 24292-B
Ball Joint Remover
J 39549
Ball Joint/Tie Rod Separator
181107
181116
J 34013-B
Strut Spring Compressor
J 39876
Lower Control Arm Bushing .
Receiver
144083
181119
J 34013-88
Strut Compressor Adapter
J 39930
Upper Control Arm Bushing
Receiver/Installer
176280
181122
Front Suspension
Suspension
Illustration
Illustration
J 39931
J 9519-23
Lower Control Arm Bushing

Receiver
Ball Joint C-clamp
153090
181124
J 39642
Modular Shock Nut Removal
Set, 15 mm (0.60 in)
J 6627-A
Wheel Stud Remover
153085
181126
J 39872
Half Moon Spacer
J 9519-7
Ball Joint Remover
181134
153086
J 39874
J 9519-9
Lower Control Arm Bushing

Receiver
Ball Joint Installer
181136
181128
()
)]}JJjj;)))JjjJiJJJ}D
153089
3-41
J 39875
Half Moon Spacer
J 9519-18
Ball Joint Pressing Screw
181138
342
Front Suspension
Illustration
Suspension
Illustration .
J 21474-3
J 21474-6
Lower Control Arm

Bushing Screw
Control Arm Bushing

Receiver
181139
181140
J 21474-4
J 2147<!--18
Upper Control Arm Nut
Lower Control Arm

Bushing Nut
156973
2018
J 21474-5
Control Arm Bushing
Receiver
144086
J 21474-19
Upper Control Arm Screw
2019
Suspension
Rear Suspension 3-43
Rear Suspension
Specifications
Specification
Metric
English
Rear Axle Bumper BolVScrew
Application
27N-m
20 lb ft
Rear Axle Lower Control Arm BolVScrew
108 N-m
80 lb ft
Rear Axle Lower Control Arm Nut
82N-m
60 lb ft
Rear Axle Tie Rod Bracket-to-Left-Hand Brace Bracket BolVScrew
47N-m
35 lb ft
Rear Axle Tie Rod Bracket-to-Left-Hand Brace Bracket Nut
82N-m
61 lb ft
Rear Axle Tie Rod Bracket-to-Right-Hand Brace Bracket Nut
82N-m
61 lb ft
Rear Axle Torque Arm BolVScrew
30Nm
96 lb ft
Rear Axle Torque Arm Bracket Nut
41 N-m
30 lb ft
Rear Axle Torque Arm Inner Bracket BolVScrew (Automatic and Manual
Transmission)
50N,m
37 lb ft
Rear Axle Torque Arm Inner Bracket BolVScrew (Upper)

(AutomaticTransmission Only)
50N-m
37 lb ft
Rear Axle Torque Arm Nut
132 N-m
97 lb ft
Rear Axle Torque Arm Outer Bracket BolVScrew
27N-m
20 lb ft
Rear Axle Torque Arm Vibration Dampener Nut
50N-m
37 lb ft
Rear Shock Absorber Nut (Lower)
90 N-m
66 lb ft
Rear Shock Absorber Nut (Upper)
17N-m
13 lb ft
Rear Stabilizer Shaft Insulator Clamp Nut
24N-m
18 lb ft
Rear Stabilizer Shaft Link BolVScrew
23N-m
17 lb ft
Rear Stabilizer Shaft Link Nut
22N-m
16 lb ft
3-44
Rear Suspension
Suspension
Component Locator
Rear Suspension Col'f'ponents
181184
Legend
(1)
(2)
(3)
(4)
(5)
(6)
Rear
Rear
Rear
Rear
Rear
Rear
Axle Tie Rod

Axle Tie Rod Bracket Brace
Spring Upper Insulator
Spring
Stabilizer Shaft
Axle Lower Control Arm
(7)
(8)
(9)
(10)
(11)
Floor Panel
Rear Axle Torque Arm
Propeller Shaft
Rear Shock Absorbe
Rear Axler
Rear Suspension
Suspension
3-45
Repair Instructions
Bumper Replacement
Removal Procedure
The rear suspension jounce bumper is located on the
frame, above the rear axle housing.
Information.
2. Support the rear axle (3).
3. Remove the bolts and screws (4).
4. Remove the bumper (2).
181230
1. Install the bumper (2). Install the bumper
spacer (WS6 only).
Notices.
2. Install the bolts and the screws (4).
Tighten
Tighten the bolts and the screws (4) to
27 N-m (20 lb ft).
3. Remove the rear axle support.
181230
3-46
Rear Suspension
Suspen"Sion
Replacement
Removal Procedure
Important: If you replace both of the lower control

arms, remove and replace one arm at a time in order
to prevent the rear axle from rolling or slipping
sideways.
Information.
2. Support the rear axle (1 ).
3. Remove the bolts and screws (5), the nuts (2)
and the washers (4) from the rear axle.
4. Remove the bolts and screws (5), the nuts (2)
and the washers (4) from the underbody pan.
5. Remove the lower control arm (3).
3---
181238
1. Position the lower control arm (3) to the rear
axle (1) and the underbody pan
Important: Do not tighten the bolts and screws (5)
and the nuts (2) unless the suspension is at the curb
height position.
Notices.
2. Install the bolts and screws (5), the nuts (2) and
the washers (4) to the rear axle (1) from the
inboard side out.
Tighten
Tighten the bolts and screws (5) to
108 N-m (74 lb ft).
181238

Bushings Replace
1
Removal Procedure
Tools Required
J 21474-5 Receiver
J 21474-20 Installer
J 21474-23 Remover
Important: If you are replacing both lower control
arms, remove and replace one control arm at a time in
order to prevent the rear axle from rolling or slipping
sideways.
Information.
2. Support the rear axle.
181231
Rear Suspensioh
Suspension
3..47
3. Remove the Lower Control Arm. Refer to Rear

Axle Lower Control Arm Replacement.
4. Place J 21474-5 over the flanged side of the
bushing.
5. Using the arbor press, place the large outside
diameter of the J 21474-23 in contact with the
outside diameter of the outer sleeve in order
to force the bushing out of the arm.
1. Install the reverse tool.
2. Place J 21474-5 over the flanged side of the
bushing.
3. Install the bushing into position using J 21474-20.
4. Install the lower control arm. Refer to Rear Axle
Lower Control Arm Replacement.

J 21474-5
181233
Torque Arm Replacement
Removal Procedure
Important: When raising the vehicle, support the
vehicle by the frame, allowing the suspension to fully
extend (unloaded).
Information.
2. Support the rear axle (1) with an adjustable lifting
device.
3. Remove the torque arm from the propeller shaft, if
equipped with two-piece propeller shaft.
4. Remove the bolts and screws (2), the washers (3)
and the nuts (4) from the rear axle (1).
~
4
181239
3-48
Rear Suspension
Suspension
5. Remove the bolts and screws (3, 7 and 8) and
the nuts (5) from the automatic transmission, if
equipped.
6. Remove the outer bracket (9).
7. Remove the inner bracket (10).

8. Remove the torque arm (6).
181240
1. Position the inner bracket (2) through the
transmission.
2. Position the outer bracket (3) to the inner
bracket (2) and loosely install the nuts (7) and the
bolts and screws (5 and 6).
3. Insert the torque arm (4) into the

brackets (2 and 3).

Notices.
4. Install the nuts (7) and the bolts and
screws (5 and 6).
181241
Tighten
50 Nm (37 lb ft).
27 Nm (20 lb ft).
5. Position the torque arm (5) to the rear axle (1 ).
6. Install the bolts and screws (2), the washers (3)

and the nuts (4).
Tighten
7. Install the torque arm to the propeller shaft, if
equipped with a two piece propeller shaft.
Refer to Propeller Shaft Replacement - One Piece
or Propeller Shaft Replacement - Two Piece in
Propeller Shaft.
8. Install the rear axle support.
181239
Rear Suspension
Suspension
3..49
Removal Procedure
Information.
2. Remove the nut (1 ).
,
3. Remove the link (3). Refer to Stabilizer Shaft Link
Replacement.
181244
4. Remove
nuts (4).
5. Remove
6. Remove
7. Remove
8. Remove
the bolts and screws (1) and the

the
the
the
the
clamp (3).
insulator (7).
bracket (6).
stabilizer shaft (5).
~
181243
Important: Install the rear stabilizer shaft with the
bend of the shaft facing down.
Important: The slit of the shaft insulator must face the

rear of the vehicle.
1. Place the insulator (7) over the stabilizer shaft (5).
2. Position the clamp (3) to the insulator (7) and
the stabilizer shaft (5).
3. Position the bracket (6) to the rear axle (2).
4. Install the bolts and screws (1) and the nuts (4).
~
181243
3-50
Suspension
Rear Suspension
Notice: Refer to Fastener Notice in Cautions and ,

Notices.
5. Install the stabilizer shaft link nut. Refer to
Tighten
Tighten the nuts (4) to 24 N:m (18 lb ft).
6. Install the link. Refer to Stabilizer Shaft Link
Replacement
Stabilizer Shaft Link Replacement

Removal Procedure
---------
Information.
2. Remove the
3. Remove the
4. Remove the
5. Remove the
nut (1 ).
link (3).
bolts and screws (2).
bracket (5).
181244
1. Position the bracket (5) to the underbody pan.
\ \~,
:--- ~ I

and Notices.
2. Install the bolts and screws (2)
Tighten
Tighten the bolts and
23 N-m (17 lb ft).
screws (2) to
3. Position the link (3) to the brack~t (5).

4. Install the link (3) and the nut (1).
Tighten
Tighten the link (3) and the nut (1) to
22 N-m (16 lb ft).
5. Lower the vehicie.
181244
Suspension
Rear Suspension
3-51

Removal Procedure
1. Fold down the seatback frame.
2. Remove the quarter trim panel.
3. Pull the folding carpet back.
Notice: The rear axle must be supported before
removing the nut in order to avoid possible damage to
the break hose lines, the tie rod and the
propeller shaft.
Information.
5. Support the rear axle (8).
6. Remove the nut (1 ).
7. Remove the retainer (2) and the upper
insulator (3).
8. Remove the retainer (2) and the lower
insulator (5).
9. Remove the nut (7) from the rear axle (8).
10. Remove the shock absorber (6).
181246
1. Position the shock absorber (6) to the rear
axle (8).
Notices.
2. Install the nut (7).
Tighten
Tighten the nut (7) to 90 N-m (66 lb ft).
3. Install the lower insulator (5) and the retainer (2)
to the shock absorber (6).
4. Position the shock absorber (6) through the
underbody pan and seat the insulator.
5. Install the upper insulator (3) and the retainer (2)
to the shock absorber (6).
the nut could damage the shock absorber. In order to
prevent damage, keep the shock absorber stationary
while you tighten the nut.
6. Hand start the nut (1 ).
Tighten
9. Pull the folding carpet down into position.
10. Install the quarter trim panel.
11. Fold the seatback frame into an upright position.
181246
3-52
Suspension
Rear Suspension
Coil Spring Replacement
Removal Procedure
Important: When raising the vehicle, support the

vehicle by the frame, allowing the suspension to fully
extend (unloaded).
Information.
device.
3. Remove the shock absorber nut from the
rear axle.
Notice: Do not suspend rear axle by brake hoses.

Damage to hoses could result.
4. Lower the rear axle (2).
5. Remove the upper insulator (3).
6. Remove the rear spring (1 ).
181234
Important: The lower end of the rear spring should be
facing forward.
Do not chip or damage the corrosion protection

coating on the rear spring. Avoid contact with hard
steel. If the coating is chipped or damaged, replace the
rear spring.
1. Install the rear spring (1) to the rear axle (2).
2. Install the upper insulator (3) to the rear spring
housing (4).
3. Raise the rear axle (2).
4. Install the shock absorber nuts to the rear axle.
181234
Suspension
Rear Suspension
3-53
Coil Spring Insulators Replacement

Removal Procedure
Important: When raising the vehicle, do not use twin
post type hoists.
Information.
device (2).
175241
3. Remove the shock absorber nuts from the rear

axle. Refer to Shock Absorber Replacement.
4. Lower the rear axle (2).
5. Remove the upper insulator (3).
181234
3-54
Suspension
Rear Suspension
1. Position the upper insulator (3), to the spring

seat (4).
2. Install the rear spring and the upper insulator.
Refer to Coil Spring Replacement.
3. Raise the rear axle (2).
4. Install the shock absorber nut to the rear axle.

181234
Track Bar Replacement

Removal Procedure
2.
3.
4.
5.

Information.
Support the rear axle (2).
Remove the bolt or screw (6) and the nut (8).
Remove the bolts and screws (7 and 1O) and the
nuts (9).
Remove the tie rod (5).
6. Remove the brace (4).
181235
Suspension
Rear Suspension
3-:55
1. Position the brace- (4) to the right-hand underbody
brace bracket.
2. Hand tighten the bolt or screw (10) and the
nut (9).
3. Position the tie rod (5) to the right-hand underbody
brace bracket.
4. Hand tighten the other bolt or screw (10) and the
other nut (9).

Notices.
5. Install the bolts and screws (7 and 10) and the
nuts (9).
Tighten
47 N-m (35 lb ft).
Tighten the nuts (9) to 82 N-m (61 lb ft).
6. Install the bolt or screw (6) and the nut (8).
Tighten
7. Install the rear axle support.
181235
3-56
Rear Suspension
Suspension
General Description
181184
The rear axle (11) attaches to the vehicle with a

link suspension system.
The rear axle housing connects to the floor
panel (7) by two lower control arms (6) and a
tie rod (1 ). A single torque arm (8) is used in
place of an upper control arm.
The torque arm rigidly mounts to the rear axle
housing at the rear.
The torque arm mounts through a torque arm
bushing at the front.
On some vehicles, the torque arm (8) also mounts
to the two piece propeller shaft center support
bearing (9) with two bolts or screws.
The rear springs (4) support the weight of the
vehicle.
The rear shock absorbers (10) mount to the rear

of the axle housing and provide ride control. A
rear stabilizer shaft (5) is also part of the
suspension system.
The rear shock absorbers (10) mount at the
bottom with a nut to brackets welded to the rear of
the rear axle housing. The shock absorbers
mount at the top of the floor panel with a nut.
The only service that the rear shock absorbers
require is replacement for the following
conditions:
- Loss of resistance
- Damage or leaking fluid
For rear shock absorber diagnosis.
Rear Suspension
Suspension

Illustration
J 21474-5
Bushing Receiver
3288
J 21474-20
Bushing Installer
2020
J 21474-23
Bushing Remover
2021
3-57
a.;58
Suspension
Tires and Wheels
Tires and Wheels
Specifications
Tire and Wheel Specifications
Maximum Radial Runout
Specification
Application
Aluminum Wheels
Steel Wheels
Metric
English
0.76
0.030
1.01
0.040
Maximum Lateral Runout

Aluminum Wheels
0.76
0.030
Steel Wheels
1.14
0.045
Compact Spare
420
60
Front/Rear
210
30
Tire Pressures

Specification
Application
Metric
English
Jack Stowage Bolt/Screw
6.5Nm
581bin
Wheel Nut- M12 x 1.5
140 N-m
100 lb ft
Wheel Nut Cap - 16 x 8 Aluminum Wheel
6Nm
531bin
Wheel Trim Cover (Chevrolet)
6Nm
531bin
Tires and Wheels
Suspension
3-59

Wheel Mounting Surface Check
It is necessary to replace any wheels which are bent,
dented, or which have excessive lateral or radial
runout. Also, wheels with runout greater than specified
may cause objectionable vibrations.
981
3. Inspect the mounting wheel/nut holes for damage

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

Place the straight edge on the wheel inboard
mounting surface. Try to rock the straight edge up
and down within the mounting surface.
.......
.......
980
980
2. Repeat this procedure on at least three or four

different positions on the inboard mounting
surface.
The outer ring of the mounting surface
normally is raised above everything inside the
mounting surface.
The mounting surface will be raised above the
outer ring if the wheel mounting surface has
been bent on a tire changer.
Notice: The use of non-GM original equipment wheels

may cause:
Damage to the wheel bearing, the wheel fasteners
and the wheel
Tire damage caused by the modified clearance to
the adjacent vehicle components
Adverse vehicle steering stability caused by the
modified scrub radius
Damage to the vehicle caused by the modified
ground clearance
Speedometer and odometer inaccuracy
3-60
Tires and Wheels
Important:
Replacement wheels must be equivalent to the
original equipment wheels in the following ways:
- Load capacity
- Wheel diameter
- Rim width
- Wheel offset
- Mounting configuration
A wheel of incorrect size or type may effect the
- Wheel and hub-bearing life
- Brake cooling
- Speedometer/odometer calibration
- Vehicle ground clearance
- Tire clearance to the body and the chassis
4. Replace the wheel if the wheel is bent. Replace
the wheel if the wheel/nut boss area is cracked.
identify steel wheels with a 2 or 3 letter code stamped
into the rim near the valve stem. Aluminum wheels
have the code, the part number, and the manufacturer
identification cast into the back side of the wheel.
Repair Instructions
Aluminum Wheel Hub Cap Replacement
Removal Procedure
Use the following procedure in order to remove the
hub cap:
1. Insert a flat-bladed tool into the slot between the
rim and the hub cap.
2. With the tool in position, pry off the hub cap.
3. Remove the hub cap.
Install the hub cap.
Use a rubber mallet in order to fully seat the hub cap
into the rim.
Aluminum Wheel Porosity Repair

Removal Procedure
Information.
Removal
3. Locate the leaking areas by inflating the tire to
280 kPa (40 psi) and dipping the tire and the
wheel into a water bath.
4. Mark the leak areas
5. Mark the tire at the valve stem.
Suspension
6. Remove the tire from the wheel. Refer to Tire
Mounting and Dismounting.
7. Scuff the inside rim surface at the leak area with a
number 80 grit sandpaper.
8. Clean the area with a general purpose cleaner
such as 3M part number 08984 or the equivalent.
9. Apply 3 mm (1/8 in) thick layer of
adhesive/sealant, GM P/N 1052366 or the
equivalent, to the leak test area. Allow six hours
of drying time.
1. Install the tire to the wheel. Refer to Tire Mounting
and Dismounting.
2. Align the matchmark on the tire with the
valve stem.
3. Pressurize the tire to 280 kPa (40 psi) and inspect
for leaks.
4. Adjust the tire pressure in order to meet the
specifications on the tire placard.
5. Balance the tires and wheels.
Installation.
Aluminum Wheel Refinishing

A protective clearcoat and/or base color is applied to
the surface of the original equipment cast aluminum
wheels. The use of improper balance weights
and frequent, repeated automatic car wash cleaning
may cause surface degradation. Frequent automatic
car wash cleaning may abrade or wear off the
factory applied protective clearcoat and base color.
This can happen at facilities using aggressive
silicon carbide tipped tire brushes to clean whitewalls
and tires. Once the protective clearcoat is damaged,
exposure to caustic cleaners and/or road salt
causes further degradation.
The refinishing of aluminum wheels requires that the
wheel surface is a plastic media that has been blasted
in order to remove the old clearcoat or paint. Do not
re-machine or use chemical strippers in order to
ensure repair durability. The service procedure details
how to strip, clean and recoat the aluminum wheel
rims that are affected by the above condition.
Required Materials
There are three different paint systems that can be
used to refinish aluminum wheels. The following
products have shown the required repair durability:
System 1: DuPont Products
System 2: PPG Products
System 3: Spies Hecker
The above products are the only paint systems
that meet General Motors
specification 435M-A336.
Tires and Wheels
Suspension
Color Selection
Important: Refer to and follow the individual formula
and process provided by the manufacturer of each
specific paint system. Use the products in the list as a
system. Do not mix other manufacturers' product
lines with the required materials of a given system.
Products listed in this manual have shown the required
durability, and are the only paint systems that meet
General Motors specification 435m-a336.
For body color selection and verification, refer to the
paint manufacturer's color book. For color uniformity it
is recommended that all four wheels, and their
center caps be refinished.
Service Procedure
Caution: To avoid serious personal injury when
applying any two part component paint system,
follow the specific precautions provided by
the paint manufacturer. Failure to follow these
precautions may cause lung irritation and allergic
respiratory reaction.
1. Remove the wheel(s) from the vehicle. Refer to
Wheel Removal. Tires may remain mounted on
the wheel.
2. Remove the balance weights and mark their

location on the tire. Record the weight of the
balance weights for re-installation.
3. Wipe the excess grease dirt from the wheels
using a wax and grease remover.
4. Blast the wheels' plastic media to remove old
paint or clearcoat.
Important: Do not re-machine or use chemical
strippers on aluminum wheels. Do not use re-clear
coating on aluminum wheels in order to ensure repair
durability.
5. Mask off the wheels and the tires.
6. Refer to the individual formula process provided
by the manufacturer of each specific paint
system.
7. Follow the specific painting procedure.
8. Unmask the tires and the wheels.
9. Install the new coated balance weights at the
locations marked on the tires.
10. Clean all the wheel mounting surfaces of any of
Corrosion
Overspray
Dirt
11. Install the wheels onto the vehicle. Refer to Wheel
Installation.
Wheel Removal
Caution: If penetrating oil gets on the vertical
surfaces between the wheel and the rotor or drum,
it could cause the wheel to work loose as the
vehicle is driven, resulting in a loss of control and
an injury accident.
3-61
Notice: Improperly tightened wheel nuts can lead to

brake pulsation and rotor damage. To avoid expensive
brake repairs, evenly tighten the wheel nuts in the
proper torque specification.
Notice: NEVER use heat to loosen a tight wheel. It
can shorten the life of the wheel, wheel nuts and wheel
bearings. Excessive force, such as hammering the
wheel or tire, can also cause damage and is not
recommended. Slight tapping of the tire side wall, such
as with one's hand or a rubber mallet, is normally
acceptable.
Important: Penetrating oil has not been found to be
effective in removing tight wheels. However, if
used. you should apply the oil sparingly on the wheel
centerhole area only.
Sometimes the wheels can be difficult to remove due
to foreign material or a tight fit between the wheel
centerhole and the rotor. Excessive force such
as hammering the wheel or the tire can cause damage.
Slight tapping on the tire sidewall using a large
rubber mallet is acceptable.
You can remove the wheel without damage through
the following steps:
1. Retighten all the wheel nuts on the affected
wheel. Then loosen each nut two turns. Rock
the vehicle from side to side. If this is not effective,
go to step 2.
2. Rock the vehicle from Drive and Reverse allowing
the vehicle to move several feet in each direction.
Apply quick. hard pressure on the brake pedal
in order to loosen the wheel. If the wheel still does
not loosen. then rock the vehicle again from
side to side as hard as possible using one or more
persons body weight. If the wheel is still tight,
repeat the procedure.
Removal Procedure
1. Raise the vehicle. Support the vehicle. Refer to

Information.
2. Remove the wheel nut cap, if equipped.
3. Remove the hub cap or the wheel trim cover.
4. Remove the special security lock nut, if equipped.
Use a special security wheel lock key located in
the front floor console.
5. Remove the wheel nuts.
6. Mark the location of the tires and the wheels to
the hub.
7. Remove the tire and the wheel.
Caution: Refer to Buildup of Corrosion Removal

Caution in Cautions and Notices.
8. Clean the following components:
The wheel nuts
The bolts
The wheel
The brake drum or rotor mounting surfaces
3-62
Suspension
Tires and Wheels

Wheel Installation
Caution: Never use oil or grease on studs or nuts.

Tighten the wheel nuts with your fingers until
they are snug. Then, tighten the nuts (in the
sequence shown) to the fastener tightening
specification shown in Specifications in this
Section. Improperly tightened wheel nuts could
eventually allow the wheel to come off while
the vehicle is moving, possibly causing loss of
control, personal injury, and property damage.
1. Install the tire and the wheel.

2. Install the wheel nuts.

Notices.
equipped. Use a special security wheel lock
key located in the front floor console.
Tighten
Tighten the nut in increments of 27 N-m (20 lb ft)
in sequence up to 140 Nm (100 lb ft).
4. Install the hub cap or the wheel trim cover, if
equipped.
Tighten
Tighten the wheel trim cover to 6 Nm (53 lb in).
5. Install the wheel nut cap, if equipped.
70082
Tires and Wheels
Suspension
Tire Repair
There are many different materials and techniques on
the market used in order to repair tires. Not all of
the materials and techniques work on some types of
tires. Tire manufacturers have published detailed
instructions on how and when to repair tires. Obtain
the instructions from the manufacturer. Do not
repair the compact spare tire.
Compact Spare Tire Replacement
3-63
Caution: To avoid serious personal injury, do not

stand over tire when inflating. The bead may
break when the bead snaps over the safety hump.
Do not exceed 220 kPa (32 psi) pressure when
inflating any tire if beads are not seated. If
220 kPa (32 psi) pressure will not seat the beads,
deflate, relubricate the beads and reinflate.
Overinflation may cause the bead to break and
cause serious personal injury.
Measure the compact spare inflation pressure
periodically and maintain the inflation pressure at
420 kPa (60 psi). You can mount or dismount the tire
from the wheel using present tire-changing equipment
procedures. As with other tires, the beads should
completely seat at 280 kPa (40 psi).
156984
Important: Use of the compact spare may result in

activating a wheel sensor fault code. This will result in
an Antilock warning lamp turning on and deactivation
of the antilock brake system. After replacing the
compact spare, the recycling ignition switch will reset
the system.
Notice: If the compact spare is used as a rear tire. do

not drive faster than 80 km/h (50 mph). Damage to
the rear axle may occur if the compact spare is driven
faster than 80 km/h (50 mph). This speed limitation
does not apply when the compact spare is used as a
front tire.
Some vehicles are equipped with a high-pressure
compact spare. The compact spare uses a narrow
4 inch wide rim, although the wheel diameter is usually
one inch larger than the road wheels.
Notice: The compact spare wheel should not be used
with standard tires, snow tires. wheel covers or trim
rings. If such use is attempted, damage to these items
or other parts of the vehicle may occur. The compact
spare should be used only on vehicles that offer it
as original equipment.
231482
Notice: Do not take the vehicle through an automatic

car wash with the compact spare installed. The
vehicle may get caught, which could result in property
damage.
The compact spare weighs less than standard tires
and handles more easily when the need arises.
Measure the inflation pressure as soon as is practical
after installing the compact spare. Adjust the
pressure to 420 kPa (60 psi). Only an authorized tire
dealer should replace a compact spare.
Suspension
3-64 Tires and Wheels

Tire Mounting and Dismounting
Important: Do not lubricate the tire beads or wheel

rim with the lubricant containing s.ilicone. Silicone
will allow the tire to rotate on the wheel rim, throwing
the tire and wheel out of balance.
Clean the rim bead seats with a wire brush or a
coarse steel wool to remove old rubber and light rust
or corrosion. Before mounting or dismounting a
tire, the bead area should be well-lubricated with
GM P/N 9985555 (50% lubricant and 50% water) or
equivalent.
Caution: To avoid serious personal injury, do not

stand over tire when inflating. The bead may
break when the bead snaps over the safety hump.
Do not exceed 220 kPa (32 psi) pressure when
inflating any tire if beads are not seated. If
220 kPa (32 psi) pressure will not seat the beads,
deflate, relubricate the beads and reinflate.
Overinflation may cause the bead to break and
cause serious personal injury.
70081
Use a tire changing machine in order to mount or

dismount tires. Follow the equipment manufacturer's
instructions. Do not use hand tools or tire irons to
change the tire as they may damage the tire beads,
wheel rim or flanges.
Notice: Damage to either the tire bead or the wheel

mounting holes can result from the use of improper
wheel attachment or tire mounting procedures. It takes
up to 70 seconds tor all of the air to completely
exhaust from a large tire. Failure to follow the proper
procedures could cause the tire changer to put
enough force on the tire to bend the wheel at the
mounting surface. Such damage may result in vibration
and/or shimmy, and under severe usage lead to
wheel cracking.
After mounting the tire, inflate the tire so that the

beads are completely seated. Never exceed
280 kPa (40 psi).
Important: When mounting blackwall tires, be sure
that the TPC specification number faces the outboard
side of the vehicle.
Install the valve stem and inflate the tire to the
pressure specified on the tire placard. Inspect the
locating rings of the tire in order to determine that the
rings show around the rim flanges on both sides of
the wheel.
Suspension
Tires and Wheels
3-65
Tire Rotation
In order to equalize tire wear, rotate the tires at
intervals specified in Maintenance and Lubrication
in General Information. If you notice uneven
tire wear, investigate the cause. Refer to Rotating
the Tires for the only recommended method of
tire and wheel rotation.
Due to design, radial tires tend to wear faster in
the shoulder area, particularly in drive locations.
Radial tires in non-drive locations may develop
and irregular wear pattern that can generate
tire noise. This wear makes regular rotation
especially important.
Always use a four-wheel rotation. After rotation,
be sure to measure wheel nut torque and set
the tire pressure. Never use oil or grease on the
wheel bolts or nuts.
On vehicles with P245/50ZR16 tires, follow
special rotation provisions because the tires are
directional. refer to Rotating the Tires For the
recommended rotation.
Rotate the tires. If you have directional tires, be
sure the color-coded arrows on the tires roll.
Balance the tires and wheels using a
polyester-coated clip-on wheel balancing weights.
Adjust the tire pressures and tighten the wheel
nuts to the specified torque. Refer to Wheel
Removal and Wheel Installation .
231490
8-66
Tires and Wheels
Suspension

Tires Description
Install new tires in pairs on the.same axle.

If it is necessary to replace only one tire, the tire
should be paired with the tire having the most
tread in order to equalize the braking traction.
Replace the tires under the following conditions:
Tires are worn to a point where 1.6 mm (1.16 in)

or less tre.ad remains, or the cord fabric shows.
To help detect this condition, tires have built-in
tread wear indicators that appear between
the tread grooves when the tread is worn to
1.6 mm (1/16 in) or less.
Replace the tire when the indicators appear iri
two or more adjacent grooves at three spots
around the tire.
The tread or sidewall is. damaged in on of the
following ways:
70080
A tire performance criteria (TPC) specification

number is molded in the sidewall near the tire size
of all original equipment tires.
The TPC specification number ensures that the
tire meets GM's performance standards for the
- Traction
- Endurance
- Dimension
- Noise
- Handling
- Rolling resistance
A specific TPC number is usually assigned to
each tire size.
The following characteristics on replacement tires
should be the same as on the original tires:
- Load range
- Speed Rating
- Construction
Replace the original tires with tires of the same
TPC specification number.
Use of any other tire size or type may affect the
- Ride
- Handling
- Speedometer/odometer calibration
- Antilock brake system
- Vehicle ground clearance
- Tire clearance to body and chassis
The tread or sidewall is cracked or either cut or

snagged deeply enough to expose the cord or the
fabric.
- The tread or sidewall is cracked.
- The tread or sidewall is cut deeply enough in
order to expose the cord or the fabric.
- The tread or sidewall is snagged deeply
enough in order to expose the cord or
the fabric.
One of the following conditions exists in the tire:
- A bump
- A bulge
- A split
Slight sidewall indentations are normal and
should not affect the ride.
One of the following conditions exists in the tire:
- A puncture
- A cut
- Other damage that cannot be correctly
repaired because of the size or location
of the damage.
Tires and Wheels
Suspension
Tire Chain Usage Description
Notice: Tire chains should not be used with
P245/50ZR16 or P235/55R16 tires. The chains could
damage the vehicle. Tire chains are only
recommended for emergency use or when required
by law.
Due to limited tire-to-body clearance on certain
vehicles, tire chain usage recommendations are
published in the Owner's Manual. When chains are
needed, most current GM vehicles require
SAE Class S tire chains. These are also designated
as 1100 Series, Type PL tire chains. These chains are
specially designed to limit the fly off effect that
occurs when the tire and the wheel rotate.
Manufacturers of tire chains have a specific chain size
for each tire and wheel in order to ensure proper fit
when installing the chains. Therefore, the vehicle
owner must obtain specific chains for the tires
and wheels on which the chains are to be used. Do
not use rubber adjusters in order to take up the slack
or clearance in chains which are loose due to
incorrect size. Always follow the chain manufacturer's
installation instructions.
The use of chains may adversely affect vehicle
handling. When driving with chains installed, remember
the following driving tips:
3;.57
P-Metric Sized Tires Description
p 245 I SOR 16 95S
TIRE TYPE
P-PASSENGER
T-TEMPORARY
SECTION
WIDTH
SPEED SYMBOL
RIM
(MILLIMETERS)
DIAMETER
235
245
(lt-.CHES)
275
ASPECT
RATIO
(SECTION HEIGHT)
(SECTION WIOTI-<)
55
50
40
'6
,.,
'I
CONSTRUCTION
TYPE
R-~_I\O'AL
B-31AS-BEL TEO
>D AGOt-.AL(BIAS)
SECIO\ -+-----+----.t
w10-1-
Adjust your speed to the road conditions

Avoid sharp turns
Adhere to the following tips in order to help prevent
chain damage to the vehicle:
Install chains on rear tires and wheels as tightly
as possible. Then tighten the chains again
after driving 0.4-0.8 km (%-112 mi). The use of
chains on front tires and wheels is not
recommended. The chains may contact and
possibly damage the vehicle if the chains are used
on front wheels. If you do use chains on front
tires and wheels, allow for enough clearance.
Do not exceed 70 km/h (45 mph), or the chain
manufacturer's speed limit, whichever is lower.
Drive in a restrained manner and avoid the
following road conditions:
- Large bumps
- Potholes
- Severe turns
- Other maneuvers that may cause tires and
wheels to bounce up and down
Follow any other instructions of the chain
manufacturer which do not disagree with this
section. Additional specific information is published
in the Owner's Manual.
70078
All GM vehicles now use passenger-metric (P-metric)

sized tires. P-metric tires are available in the
following two load ranges:
Standard load with 210 kPa (30 psi) maximum
pressure
Extra load with 240 pKa (35 psi) maximum
pressure
Most P-metric tire sizes do not have exact
corresponding alpha-numeric tire sizes. For example,
a P205/75A15 is not exactly equal in size and
load carrying capacity to an FR78-15. Replacement
tires should be of the same TPC specification number
as those originally on the vehicle. If the TPC
specification number is the same then the following
conditions are the same:
The size
The load range
The construction
If you must replace the P-metric tires with other sizes,
consult a tire dealer. A tire company can best
recommend the closest match of alpha-numeric to
P-metric sizes within their own tire lines.
The metric term for tire pressure is the kilopascal
(kPa). Tire pressure may be printed in both kPa and
pounds per square inch (psi). One psi equals 6.9 kPa.
Refer to Tire Placard or Tire and Wheel Specifications
for tire pressures.
3-68
Tires and Wheels
Tire Placard Description

The tire placard is permanently located on the rear
face of the driver's door. The tire placecard should be
referred to for tire information. The placard lists the
following specifications:
The maximum vehicle load
The tire size (including the spare)
The cold inflation pressure (including the spare)
Wheels Description
Replace wheels under the following conditions:
The wheels are bent
The wheels have dents
The wheels have excessive lateral or radial runout
The wheels leak air through the wheel welds
The wheels have elongated bolt holes
The wheel nuts will not stay tight
Wheels with runout that is greater than specified may
cause objectionable vibrations.
Suspension
Replacement wheels must be equivalent to the
original equipment wheels in the following ways:
Load capacity
Diameter
Rim width
Offset configuration
Mounting configuration
A wheel of the incorrect size or type may affect the
following:
The wheel life
The bearing life
The break cooling
The speedometer/odometer calibration
The antilock brake system
The vehicle ground clearance
The tire clearance to the body and the chassis
A two or three-letter code identifies steel wheels. The
two or three-letter code is stamped into the front
side of the rim near the valve stem. Aluminum wheels
have the code, the part number and the manufacturer
ID cast into the inboard side.
Driveline/Axle
Table of Contents
4-1
Section 4
Drivel ine/Axle
Propeller Shaft .................................................4-3
Specifications ................................................. .4-3
Fastener Tightening Specifications ................ .4-3
Propeller Shaft Runout Specifications ............. 4-3
Diagnostic Information and Procedures ........ .4-4
Propeller Shaft Diagnosis
(Runout Measurement) .............................. .4-4
(Drive Gear Pinion Yoke Runout) ............... 4-5
Leak at Front Slip Yoke ................................ .4-6
Roughness or Vibration ................................ .4-6
Ping, Snap, or Click Noise ............................ .4-8
Knock or Clunk Noise .................................... 4-8
Scraping Noise ............................................. .4-8
Shudder on Acceleration at Low Speed ........ .4-9
Repair Instructions ....................................... .4-1 o
Propeller Shaft Replacement - One Piece .... 4-1 O
Propeller Shaft Replacement - Two Piece ... .4-12
Universal Joints Replacement ...................... 4-16
Propeller Shaft Description ........................... 4-20
Propeller Shaft Phasing Description ............ .4-21
Universal Joint Description .......................... .4-21
Center Bearing Description .......................... 4-21
Special Tools and Equipment ...................... .4-22
Rear Drive Axle ............................................. .4-23
Specifications ............................................... .4-23
Fastener Tightening Specifications .............. .4-23
Rear Axle Specifications
(General Specifications) ............................ 4-23

(Bearing Shim Thickness) .........................4-23
Rear Axle Usage .........................................4-24
Pinion Bearing and Differential Bearing
Pre load .....................................................4-24
Noise Diagnosis ...........................................4-25
General Information ..................................... 4-26
Repair Instructions ....................................... .4-28
Lubricant Level Check ................................ .4-28
Rear Axle Housing Cover and Gasket
Replacement ............................................4-28
Rear Axle - Disassemble ............................. 4-28
Pinion Depth Adjustment ..............................4-29
Rear Axle - Assemble .................................. 4-32
Axle Shaft Replacement ............................... 4-32
Oil Seal and/or Bearing Replacement .......... 4-34
Pinion Oil Seal Replacement (And Yoke) ..... 4-36
Inspection Before Disassembly .....................4-39
Pinion and Ring Gear Inspection ..................4-40
Bearings Inspection ...................................... 4-43
Differential Case Assembly .......................... 4-44
Differential Side Bearing Preload
Adjustment ...............................................4-48
Backlash Adjustment .................................... 4-50
Gear Tooth Contact Pattern Check .............. 4-51
Rear Axle Replacement .............................. .4-54
Drive Pinion Installation ............................... .4-55
Description and Operation ........................... .4-60
Rear Axle Description ................................. .4-60
Drivel ine/Axle
BLANK
Propeller Shaft 4-3
Driveline/Axle
Propeller-shaft
Specifications
Specification
Metric
English
Propeller Shaft BolVScrew
Application
22Nm
16 lb ft
Propeller Shaft-To-Center Support Bearing BolVScrew
50Nm
37 lb ft
Propeller Shaft Runout Specifications

Specfflcatlon
Application
Propeller Shaft Runout
Metric
1.40mm
English
0.055 in
4-4
Driveline/Axle
Propeller Shaft

(Runout Measurement)
Tools Required
J 8001 Dial Indicator Set

Important: The driveline components on this vehicle
have been factory balanced. System balancing
provides a smoother running driveline operation.
Be sure to observe and accurately reference mark the

positions of all of the driveline components relative
to the propeller shaft and to the rear axle before
disassembly.
The following components must be reference marked
before disassembly:
The propeller shaft

The rear axle
The drive pinion gear yoke
Be sure to reassemble all of the components in the
exact relationship to each other that existed before
disassembly.
Be sure to follow the following specifications during
reassembly in order to maintain the factory balance of
the components:
164325
4. For a one-piece propeller shaft, take the readings

at the following points:
The center runout measurement point (1)
The rear runout measurement point (2)
The front runout measurement point (4)
The published specifications

The torque values
Any measurements made prior to disassembly
Important: A bent propeller shaft may cause noise or
vibrations at high speeds.
Rough handling or a collision may cause damage to

the propeller shaft.
Inspect for propeller shaft straightness
1. Place the transmission range selector lever in the
NEUTRAL position.
2. Raise the vehicle on a twin point hoist. Suitably
support the vehicle.
Ensure that the following conditions are met:

The vehicle is supported on the rear axle
housing
The rear wheels can rotate freely
Refer to Lifting and Jacking the Vehicle in
General Information.
3. Use one of the following arrangements in order to
prepare the J 8001 for use:
Mount the J 8001
Ensure that the moveable support is high
enough in order to permit contact of the
indicator button with the propeller shaft.
Mount the J 8001 onto a magnetic base.
Attach the base to a smooth place on
the underbody of the vehicle.
180316
5. For a two-piece propeller shaft, take the readings

at the following points:
The center runout measurement point (1)
The rear runout measurement point (2)
The front runout measurement point (3)
6. Turn a rear wheel in order to rotate the
propeller shaft.
Inspect for runout.
Driveline/Axle
Propeller Shaft
7. If the runout exceeds 1.40 mm (0.055 in),

complete the following steps:
7.1. Disconnect the propeller shaft at the
differential drive pinion gear yoke.
7.2. Rotate the propeller shaft 180 degrees.
7.3. Reinstall the propeller shaft.
8. Inspect for runout.
If the runout still exceeds 1.40 mm (0.055 in),
measure the differential drive pinion gear
yoke runout.
Refer to Propeller Shaft Diagnosis (Drive Gear
Pinion Yoke Runout).
9. If the runout still exceeds 1.40 mm (0.055 in),
inspect for vibrations or noise.
If necessary, replace the propeller shaft. Refer to
Propeller Shaft Replacement - One Piece or
Propeller Shaft Replacement - Two Piece.

(Drive Gear Pinion Yoke Runout)
Tools Required
J 35819 Runout Gage

J 35819-100 Runout Gage Adapter Sleeves
1. Raise the vehicle on a twin post hoist. Suitably
support the vehicle.
The vehicle is supported on the rear axle
housing
The rear wheels can rotate freely
General Information
2. Remove the propeller shaft.
or Propeller Shaft Replacement - Two Piece.
4-5
3. Use the J 8001, the J 35819 and the J 35819-100

in order to measure the pinion gear yoke runout.
Record the runout.
Mark the high point and the low point of the pinion
gear yoke.
4. If the pinion gear yoke runout is 0.15 mm
(0.006 in) or less, remove the pinion gear
yoke balance weight, if the pinion gear yoke
balance weight is used.
No further action is required.
5. No further action is required if the following
circumstances exist:
The pinion gear yoke runout is between
0.15--0.28 mm (0.006-0.011 in)
The balance weight is near or at the low point
of pinion gear runout
If the balance weight is not near or at the low
point of pinion gear runout, remove the
weight.
6. No further action is required if the following
circumstances exist:
The pinion gear yoke runout is between
0.28-0.38 mm (0.011-0.015 in)
The balance weight is near or at the low point
of pinion gear runout
7. If the balance weight is not at or near the low
point of the pinion gear runout, complete the
following steps:
7 .1. Remove the weight.

7.2. Rotate the pinion gear yoke until the runout
is 0.25 mm (0.010 in) or less.
8. If a runout of 0.25 mm (0.010 in) or less cannot
be attained, complete the following steps:
Important: Service replacement differential pinion
gear yokes may be equipped with balance weights. Do
not remove these weights.
8.1. Install a new differential pinion gear yoke.

Refer to Pinion Oil Seal Replacement
(And Yoke) in Rear Drive Axle.
8.2. Inspect again in order to determine if the
runout is 0.25 mm (0.010 in) or less.
9. Install the propeller shaft.

or Propeller Shaft Replacement - Two Piece.
J 8001-4
J 8001-3
164321
4-6
Driveline/Axle
Propeller Shaft
Leak at Front Slip Yoke
Step
Value(s)
Action
Yes
No
Go to Step2
Go to Step 3
Go to Step 3
System OK
Go to Step4
Go to Step 5
Go to Step5
System OK
Important: An occasional drop of fluid from the slip yoke is normal.
Inspect the outside surface of the slip yoke for roughness.

Is the outside surface of the slip yoke rough?
Important: An occasional drop of fluid from the slip yoke
is normal.
Replace the yoke.
Is there still a leak at the front slip yoke?
Inspect the seal for cuts caused by burrs on the slip yoke.
Are there cuts on the seal?

is normal.
Replace the seal.
Inspect the rear transmission oil seal for damage.

Is the rear transmission oil seal damaged?

is normal.
Replace the rear transmission oil seal. Add fluid if fluid is
needed.
Go to Step 6
System OK
Roughness or Vibration
Step
Action
Inspect the propeller shaft for the following conditions:
Bending
Damage
Is the propeller shaft bent or damaged?
Value(s)
Yes
No
Go to Step2
Go to Step 3
Go to Step3
System OK
Go to Step4
Go to.Step 5
Go to Steps
System OK
Go to Step 6
Go to Step 7
Go to Step 7
System OK
Go to Step 8
Go to Step 9
Go to Step 9
System OK
Go to Step 10
Go to Step 11
Go to Step 11
System OK
Replace the propeller shaft.

Is there still roughness or vibration?
Inspect for undercoating on the propeller shaft.

Is there undercoating on the propeller shaft?
Remove the undercoating from the propetler shaft.

Inspect the tires for the following conditions:

Unbalance
5
Vibration during vehicle operation at a speed of

48-80 km/h (30-50 mph)
Do the above conditions exist?
Balance the tires.

Inspect the universal joints for tightness.

Are the universal joints tight?
If the universal joints are equipped with snap rings, tap on

the yokes with a hammer in order to free up the universal
joints.
If the joints cannot be freed up or if the joints feel rough,
replace the joints.
Inspect the universal joints for wear.

Are any of the universal joints worn?
10
Replace the worn universal joint(s).

Propeller Shaft 4-7
Driveline/Axle
Roughness or Vibration (cont'd)
Step
Action
Value(s)
Inspect the fixed yoke for bending and inspect the flange
for excessive runout.
Does either of the above conditions exist?
12
Replace the fixed yoke.

13
Inspect the propeller shaft for lack of balance.

Is the propeller shaft unbalanced?
14
Inspect for the missing balance weight on the propeller

shaft. Rotate the shaft 180 degrees on the fixed yoke.
15
Inspect the universal joint for incorrect angle placement.

Is the universal joint at an incorrect angle?
16
Correct the universal joint angle.

17
Inspect the yokes and the flanges for the following

conditions:
Damage
Distortion
Are the yokes and/or the flanges damaged or distorted?
18
Replace the yokes and/or the flanges.

19
Inspect the shaft for yokes that are out of phase.

Are the yokes out of phase on the shaft?
20
Replace the propeller shaft if the propeller shaft is a

one-piece shaft.
Reindex the propeller shaft if the propeller shaft is a
two-piece shaft.
Inspect for driveline vibration during vehicle operation at a

speed of 80 km/h (50 mph).
Is there driveline vibration at the specified speed?
Inspect the propeller shaft runout.

Inspect for missing balance weights on the propeller shaft.
Is there driveline vibration at the specified speed?
11
21
22
Yes
No
Go to Step 12
Go to Step 13
Go to Step 13
System OK
Go to Step 14
Go to Step 15
Go to Step 15
System OK
Go to Step 16
Go to Step 17
Go to Step 17
System OK
Go to Step 18
Go to Step 19
Go to Step 19
System OK
Go toStep20
Go to Step21
Go to Step 21
System OK
Go to Step22
System OK
4-8
Drive line/Axle
Propeller Shaft
Ping, Snap, or Click Noise
Step
Value(s)
Action
Yes
No
DEFINITION: A ping, a snap or a clicking noise in the driveline that is usually heard during initial load after the transmission
is in gear.
Inspect the rear axle lower control arm for loose
bolts/screws.
Are there loose bolts/screws in the lower control arm?
Tighten the bolts/screws to the specified torque. Refer to

Rear Suspension in Suspension.
Is there still a ping, a snap or a clicking noise?
Inspect the universal joints for the following conditions:

Wear
Damage
Are any of the universal joints worn or damaged?
Replace the worn or damaged universal joint(s).

Is t.here still a ping, a snap or a clicking noise?
Inspect the fixed yoke in order to determine if the fixed

yoke is loose.
Is the fixed yoke loose?
Tighten the drive pinion gear nut to the specified torque.

Refer to Fastener Tightening Specifications.
Is there still a ping, a snap or a clicking noise?
Go to Step2
Go to Step 3
Go to Step3
System OK
Go to Step 4
Go to Step 5
Go to Step 5
System OK
Go to Step 6
System OK
Knock or Clunk Noise

Step
Value(s)
Action
Yes
No
DEFINITION, A knock or a clunking noise in the driveline that occurs during operation of the vehicle in high gear or during
coasting in neutral at a speed of 16 km/h (10 mph.)
Inspect the universal joints for the following conditions:
Damage
Wear
Are any of the universal joints damaged or worn?
Replace the worn or damaged universal joint(s).

Is there still a knock or a clunking noise?
Inspect the differential side gears for wear.

Are any of the differential side gears worn?
Replace the worn differential side gear(s)?

Is there still a knock or a clunking noise?
Go to Step2
Go to Step 3
Go to Step3
System OK
Go to Step4
System OK
Scraping Noise
Value(s)
Yes
No
Is the vehicle equipped wi1h drum brakes?
Go to Step2
Go to Step 4
Inspect the backing plate for contact with the brake drum.
Is there contact between the brake drum and the
backing plate?
Go to Step 3
Go to Step 4
Replace the brake drum or the backing plate.

Is there still a scraping noise?
Go to Step 4
System OK
Inspect the pinion flange and the center support bearing

for rubbing.
Is there rubbing between the pinion flange and the center
support bearing?
Correct the interference.

Is there still a scraping noise?
Step
Action
Go to Step5
-
System OK
Propeller Shaft
Drive line/Axle
4-9
Shudder on Acceleration at Low Speed

Step
Action
Value(s)
Yes
No
Go to Step2
Go to Step 3
Go to Step 3
Go to Step5
Go to Step 4
Go to Step 5
Go to Step 5
System OK
DEFINITION: A shudder during acceleration from 0-24 km/h (0-15 mph)

Inspect the universal joint angle in order to determine of
the universal joint angle is incorrectly set or excessive.
Is the universal joint angle incorrectly set or excessive?
Add or remove transmission mount shims as needed.

Is there a shudder during acceleration?
Inspect the flanges for loose or missing bolts/screws?

Are there loose or missing bolts/screws in the flanges?
Replace or tighten the bolts/screws to the specified torque.

Inspect the universal joints for wear.

Are the universal joints worn?
Replace the worn universal joints.

Go to Step 6
System OK
4-10 Propeller Shaft
Driveline/Axle
Repair Instructions
Propeller Shaft Replacement - One Piece
Removal Procedure
Notice: Do not strike or drop the propeller shaft, or
allow the universal joints to bend to extreme angles, as
internal joint damage might occur.
Information.
2. Mark the relationship of the propeller shaft (2) to
the pinion gear yoke (t).
180335
3. Remove the propeller shaft bolts/screws (2).

4. Remove the propeller shaft retainers.
Important: Support the propeller shaft during removal.

propeller shaft:
5.1. Withdraw the slip yoke (3) from the
transmission.
5.2. Move the propeller shaft (1) rearward and
pass the propeller shaft under the
housing (2).
If the bearing caps are loose, tape the
bearing caps together in order to prevent
dropping and losing the needle roller
bearings.
6. Inspect the transmission output shaft splines
for burrs.
180341
Driveline/Axle
Propeller Shaft
4-11
7. Inspect the outer diameter of the slip yoke (1)

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

joint cap connecting surface for the following
conditions:
Burrs
Foreign material
180344
Notice: The propeller shaft must be supported
carefully during handling to avoid jamming or bending
of parts.
Important: Do not place any tool between the
propeller shaft slip yoke and the splines. Placing any
tool between the propeller shaft slip yoke and the
splines may cause damage to the
transmission oil seal.
1. Lubricate the slip yoke with chassis lubricant.
2. Install the slip yoke onto the transmission
output shaft.
Important: Be sure to align the mark on the pinion
gear yoke with the mark on the propeller shaft.
3. Install the rear of the propeller shaft (2) to the
pinion gear yoke (1 ).
180335
4-12
Driveline/Axle
Propeller Shaft
4. Install the rear universal joint to the pinion

gear yoke.
Ensure that the bearing caps are properly seated .
5. Install the propeller shaft retainers (1 ).
Notices.
6. Install the propeller shaft bolts/screws (2).
Tighten
Tighten the propeller shaft bolts/screws evenly to
22 N-m (16 lb ft).
1
180340
Propeller Shaft Replacement - Two Piece

Removal Procedure
Notice: Do not strike or drop the propeller shaft, or
allow the universal joints to bend to extreme angles, as
internal joint damage might occur.
Important: The two-piece propeller shaft and the

center support bearing used with the 3800 (VINK)
engine are not serviceable separately. The propeller
shaft and the support bearing should be replaced as a
complete assembly only.
Information.
2. Mark the relationship of the propeller shaft (2) to
the pinion gear yoke (1 ).
180337
Propeller Shaft 4-13
Driveline/Axle
3. Remove the bolts/screws (4) from the center
support bearing (3).
torque arm (2):
The center support bearing (3)
The washers (1)
180339
5. Remove the propeller shaft bolts/screws (2).

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

propeller shaft:
7.1. Withdraw the slip yoke (3) from the
transmission.
7.2. Move the propeller shaft (1 and 4) rearward
and pass the propeller shaft under the
housing (2).
If the bearing caps are loose, tape the
bearing caps together in order to prevent
dropping and losing the needle roller
bearings.
8. Inspect the transmission output shaft splines
for burrs.
3
180342
4-14
Propeller Shaft
Drive line/Axle
9. Inspect the outer diameter of the slip yoke (1)
for burrs.
10. Inspect the outer splines of the slip yoke (1) for
Damage
Twisting
Wear
11. Inspect the relationship of the outer splines of the
slip yoke to the transmission output shaft splines.
The outer splines of the slip yoke should meet
the following requirements:
The outer splines should agree in number with
the transmission output shaft splines.
The outer splines should fit with the
transmission output shaft splines.
180343
12. Inspect the pinion gear yoke (1) at the universal

joint cap connecting surface for the following
conditions:
Burrs
Foreign material
180344
Notice: The propeller shaft must be supported
carefully during handling to avoid jamming or bending
of parts.
Important: Do not place any tool between the
propeller shaft slip yoke and the splines. Placing any
tool between the propeller shaft slip yoke and the
splines may cause damage to the
transmission oil seal.
1. Lubricate the slip yoke with chassis lubricant.
2. Install the slip yoke onto the transmission
output shaft.
Important: Be sure to align the mark on the pinion
gear yoke with the mark on the propeller shaft.
3. Install the rear of the propeller shaft (2) to the
pinion gear yoke (1 ).
180337
Driveline/Axle
Propeller Shaft
4-15
4. Install the rear universal joint to the pinion

gear yoke.
Ensure that the bearing caps are properly seated.
5. Install tlie propeller shaft retainers (1 ).
Notices.
6. Install the propeller shaft bolts/screws (2).
Tighten
Tighten the propeller shaft bolts/screws evenly to
22 N,m (16 lb ft).
7. Install the following components to the torque

arm (2):
The washers (1)
The center support bearing (3)
Install the bolts/screws (4) to the center
support bearing.
Tighten
Tighten the propeller shaft-to-center support
bearing bolts/screws to 50 N-m (37 lb ft).
180339
4-16
Drive line/Axle
Propeller Shaft
Universal Joints Replacement

Tools Required
J 9522-3 U-Joint Bearing Separator
J 9522-5 U-Joint Bearing Spacer Remover
Notice: Never clamp propeller shaft tubing in a vise.

Clamping propeller shaft tubing in a vise could dent or
deform the tube causing an imbalance or unsafe
condition. Always clamp on one of the yokes
and support the shaft horizontally. Avoid damaging the
slip yoke sealing surface. Nicks may damage the
bushing or cut the lip seal.
Important: Nylon injected ring universal joints cannot

be reassembled. Replace nylon injected ring
universal joints with external snap ring universal joints.
When reassembling a propeller shaft, always install
a complete propeller shaft universal joint service kit.
1237
This kit includes the following components:

One pregreased spider (8)
Four service bearing caps with seals (7)
One needle roller bearing (4)
Delrin round washers (3)
Delrin flat washers (5)
Grease
Four retainer rings (2)
Ensure that the seals (7) are in place on the service
bearing caps (1) during handling. The seals will
hold the needle roller bearings (4) in place during
handling.
Important: There are no bearing retainer grooves in

production bearing caps. Production bearing caps
cannot be reused.
1. Support the propeller shaft in a horizontal position
that is aligned with the base plate of a press.
2. Place the universal joint so that the lower ear of
the shaft yoke is supported on a 29 mm (1.125 in)
socket (2).
3. Use the following procedure in order to remove
the lower bearing cap from the yoke ear:
3.1 . Place the J 9522-3 on the open horizontal
bearing cap.
3.2. Press the lower bearing cap out of the
yoke ear.
This process shears the nylon injected ring
on the lower bearing cap.
1222
Drive line/Axle
Propeller Shaft
4-17
4. If the bearing cap (1) is not completely removed,

use the following steps in order to completely
remov,e the bearing cap:
4.1 . Lift the J 9522-3
4.2. Insert the J 9522-5 between the seal and
the bearing cap (1 ).
4.3. Press the bearing cap (1) out of the yoke.
5. Rotate the propeller shaft.
5.1. Repeat Step 3 in order to shear the
opposite nylon injected ring.
5.2. Repeat Step 4 in order to remove the
opposite bearing cap from the yoke.
6. If the front universal joint is being replaced, use
the above procedure in order to remove the two
bearing caps from the propeller shaft slip yoke.
164308
7. Remcwe the spider from the yoke.

8. Clean the yoke in the area that will hold the
retainer ring in order to ensure proper assembly.
9. Clean all of the sheared nylon from the universal
joint cup bore.
Important: Do not loosen or damage the dust seals.
If the dust seals are loose or damaged, replace

the entire universal joint.
Important: These universal joints are designed for
extended life and do not require periodic inspections or
lubrication.
When these joints are taken apart, repack the bearing.

Lubricate the reservoir at the end of the trunnions
with chassis lubricant or linkage joint lubricant.
10. Remove the U-joint spider bearing retainer rings.
If the retainer ring does not snap readily out of the
grooves, lightly tap the end of the bearing cap
in order to relieve the pressure against the retainer
ring. After relieving the pressure, remove the
retainer ring.
11 . Support the propeller shaft in a horizontal position
that aligns with the base plate of a press .
--~
1237
4-18
Drive line/Axle
Propeller Shaft
12. Place the universal joint so the ear of the yoke is

supported on a 28.6 mm (1.125 in) socket (2).
13. Use the following procedure in order to remove
the lower bearing cap from the yoke ear:
13.1. Place the J 9522-3 on the open horizontal
bearing cap.
13.2. Press the lower bearing cap out of the
yoke ear.
J 9522-3
1222
14. If the bearing cap (1) is not completely removed,

use the following steps in order to completely
remove the bearing cap:
14.1. Lift the J 9522-3.
14.2. Insert the J 9522-5 between the seal and
the bearing cap (1 ).
14.3. Press the bearing cap (1) out of the yoke.
15. Rotate the propeller shaft.
Press the opposite bearing cap out of the yoke.
16. Remove the spider from the yoke.
164308
Assembly Procedure
1. Install one bearing cap partially into one side of
the yoke.
Rotate the yoke so that this yoke ear is on the
bottom.
2. Insert the J 9522-3 in order to seat the trunnion in
the bearing cap.
3. Repeat Steps 1 and 2 in order to partially install
the opposite bearing cap.
4. Inspect both trunnions in order to ensure their
straight positioning into the bearing caps (1 ).
5. Press against the two opposite bearing caps while
working the spider in order to ensure free
movement of the trunnions in the bearings .
1223
Driveline/Axle
Propeller Shaft
4-.19
6. Inspect the needle roller bearing for binding.

If binding exists, one or more of the needle roller
bearings may have tipped under the end of
the relevant trunnion.
7. Stop pressing on the bearing caps when one
bearing retainer groove clears inside of the yoke.
1237
8. Press the U-joint spider bearing retainer ring

into place.
1225
9. Continue pressing on the retainer ring until the

opposite side of the ring can be snapped
into place.
If necessary, strike the yoke with a hammer in
order to facilitate seating of the retainer rings.
(Striking the yoke with a hammer slightly springs
the yoke ears.)
10. Repeat the above procedure for the other half of
the universal joint.
1226
4-20
Propeller Shaft
Driveline/Axle

Propeller Shaft Description
~--1~--;ll
156377
3649
One Piece Propeller Shaft

Important: When undercoating a vehicle, keep the
propeller shaft free from undercoating material.
Undercoating or any other foreign material will upset
the propeller shaft balance and may produce
serious vibrations.
The propeller shaft is a hollow shaft or tube that

connects the transmission to the differential. The
propeller shaft connects to the transmission with a
splined slip yoke and connects to the rear axle with an
universal joint.
Propeller shafts have universal joints at each end in
order to accommodate angle variations between
the transmission and rear axle, and the rear axle
position caused by suspension motion. All propeller
shafts are the balanced tubular type.
Two Piece Propeller Shaft

Vehicles equipped with the 3800 (VIN K) engine and
the 5-speed manual transmission (M49) are
equipped with a two-piece propeller shaft assembly.
The two-piece shaft assembly consists of a front
propeller shaft, a rear propeller shaft, and a center
support bearing. The center support bearing prevents
angular movement (or "whipping") of the propeller
shaft. The support bearing is a ball bearing type. The
support bearing mounts in a rubber cushion. The
rubber cushion mounts to the torque arm.
The bearing is prelubricated and sealed by the
manufacturer.
The spline coupling has internal splines which accept
the rear propeller shaft.
The 5.7L (VIN G) engine is equipped with a one-piece

propeller shaft of either stamped steel design or a
lightweight aluminum.
156961
A propeller shaft joint (sometimes referred to as

constant velocity joint) is located on the front of the
rear propeller shaft. The propeller shaft joint fits
into the spline coupling of the front propeller shaft.
Driveline/Axle
Propeller Shaft
The propeller shaft joint (or constant velocity joint)

allows adjustment of the propeller shaft angle without
interrupting the power flow. The up and down
movement of the vehicle requires the above action.
Vehicles with two or more propeller shafts use a center
bearing. The center bearing is usually near the rear
of the front propeller shaft. The slip joint is at the
forward end of the rear propeller shaft.
Propeller Shaft Phasing Description

The propeller shaft is designed and built with the yoke
lugs (ears) in line with each other which produces
the smoothest running shaft possible. A propeller shaft
designed with built in yoke lugs in line is known as
in-phase.
An out of phase propeller shaft often causes vibration.
The propeller shaft generates vibration from speeding
up and slowing down each time the universal joint
goes around. The vibration is the same as a person
snapping a rope and watching the wave reaction
flow to the end. An in phase propeller shaft is similar
to two persons snapping a rope at the same time
and watching the waves meet and cancel each other
out. A total cancellation of vibration produces a
smooth flow of power in the drive line. Since phasing
of a propeller shaft is between the front and center
universal joints, you must reference mark the front and
rear propeller shafts before removal in order to
ensure proper phasing upon reinstallation. Some
splined shaft slip yokes are keyed in order to ensure
proper phasing.
4-21
The trunnion bearings used in universal joints are the

needle roller type. Round bearing cups hold the
needle rollers in place on the trunnions. Either snap
rings or injected plastic hold the bearing cups
in the yokes.
The Original Equipment Manufacturer (OEM) universal
joints are lubricated for life and cannot be lubricated
on the vehicle. A seNice kit which consists of a spider
with bearing assemblies and snap rings may be
installed if a universal joint becomes worn or noisy. If
it is necessary to repair a universal joint, you must
remove the propeller shaft from the vehicle. Avoid
jamming, bending, or over-angulating any parts of the
propeller shaft assembly. Avoid damaging the
propeller weld yokes and slip yoke ears upon
installation or removal of U-joints.
Center Bearing Description
Universal Joint Description
1236
Center bearings support the driveline when using two

or more propeller shafts. The center bearing is a
ball bearing mounted in a rubber cushion that attaches
to a frame crossmember. The manufacturer
prelubricates and seals the bearing. The cushion
allows vertical motion at the driveline and helps isolate
the vehicle from vibration.
1237
Universal joints are designed to handle the effects of

various loadings and rear axle windup during
acceleration and braking. Within the designed angle
variations, the universal joint operates efficiently
and safely. When the design angle changes or is
exceeded, the operational life of the joint may
decrease.
4-22
Driveline/Axle
Propeller Shaft

Illustration
Illustration
J 23498-20
J 8001
Driveshaft Inclinometer
Adapter
Dial Indicator Set
180348
25473
J 9522-3
J 35819
U-Joint Bearing Separator
Runout Gage
1512
803
J 9522-5
U-Joint Bearing Spacer
Remover
[)[)
J 35819-100
Runout Gage Adapter
Sleeves
180346
805
J 23498-A
Driveshaft Inclinometer
8224
Rear Drive Axle
Drive line/Axle
4...23
Rear Drive Axle

Specifications
Specification
Application
Metric
English
Important: Use a reliable torque wrench in order to tighten the parts listed. A reliable torque wrench will ensure proper
tightening of the parts without straining or distorting the parts. The following specifications are for clean and lightly-lubricated
threads only. Dry or dirty threads produce increased friction. Friction prevents the measurement of tightness.
Differential Carrier Bearing Cap Bolt/Screw
75 N-m
55 lb ft
Differential Drive Pinion Gear Setting Gauge Nut
2.3Nm
201bin
Differential Pinion Gear Shaft Lock Bolt/Screw
36 N-m
27 lb ft
Differential Ring Gear Bolt/Screw
120 N-m
89 lb ft
Rear Axle Housing Cover Bolt/Screw
30N-m
22 lb ft
Rear Axle Housing Drain Plug
35Nm
26 lb ft
Sensor Plug Mounting Bolt/Screw
10N-m
891bin
Wheel Bolt
140 N-m
100 lb ft
Wheel Speed Sensor Mounting Plug
10 N-m
891bin
Rear Axle Specifications (General Specifications)

Specification
Application
Metric
Rear Axle Type
English
Sem,-Floatmg Hyphoid
Through 4 Arms
Drive and Torque

Ring and Drive Pinion Gear Set Type
Hyphoid
Rear Axle Lubricant Capacity
1.65 L
3.5 pt.
Rear Axle Lubricant

Synthetic 75W-90 Gear lubricant (GM
P/N 12378261). meeting GM
specification 9986115. or equivalent
Standard and Limited Slip Differential

Limited Slip Differential Additive (GM P/N 1052358)

(Bearing Shim Thickness)
4 fl. oz.
Production Differential Bearing Shim

Thickness (Standard Spacer) (cont'd)
Production Differential Bearing Shim

Thickness (Standard Spacer)
Metric
118 ml
English
DEFINITION: The total thickness of both the production

differential bearing shims removed.
10.57 mm
0.416 in
10.92 mm
0.430 in
11.18 mm
0.440 in
11.43 mm
0.450 in
11.68 mm
0.460 in
11.94 mm
Metric
English
13.21 mm
0.520 in
13.46 mm
0.530 in
13.97 mm
0.550 in
Service Differential Bearing Shim Thickness

(Standard Spacer)
Metric
English
DEFINITION: The total thickness of the service

differential bearing shims to be used as a starting point.
1.52 mm
0.060 in
1.78mm
0.070 in
0.470 in
2.03 mm
0.080 in
12.19 mm
0.480 in
2.29 mm
0.090 in
12.45 mm
0.490 in
2.54 mm
0.100 in
12.70 mm
0.500 in
2.79 mm
0.110 in
12.95 mm
0.51 O in
3.05 mm
0.120 in
4-24
Driveline/Axle
Rear Drive Axle

(Standard Spacer) (cont'd)

(Standard Spacer) (cont'd)
Metric
English
Metric
English
3.30 mm
0.130 in
4.06 mm
0.160 in
3.56 mm
0.140 in
4.32 mm
0.170 in
3.81 mm
0.150 in
4.83 mm
0.190 in
Rear Axle Usage

Rear Brake
Teeth Ring
Gear: Pinion
194
(7 5/8")
Disc
42:13
GU5
194
(7 5/8")
Disc
42:13
3.08
GU4
194
(7 5/8")
Disc
40:13
4-SPD
Automatic
(M30)
3.42
GU6
194
(7 5/8")
Disc
41:12
5.7L-V8 (LT1)
6-SPD
Automatic
(MM6)
3.42
GU6
194
(7 5/8")
Disc
41 :12
5.7L-V8 (LT1)
6-SPD
Automatic
(MM6)
3.42
GU6
194
(7 5/8")
Disc
41 :12
5.7L-V8 (LT1)
4-SPD
Automatic
(M30)
2.73
GU2
194
(7 5/8")
Disc
41:15
5.7L-V8 (LT1)
4-SPD
Automatic
(M30)
3.23
GU5
194
(7 5/8")
Disc
42:13
Rear Axle
Ratio
Rear Axle RPO
Engine (RPO)
Transmission
3800-V6 (L36)
5-SPD
Manual (M49)
3.23
GU5
3800-V6 (L36)
5-SPD
Manual (M49)
3.23
3800-V6 (L36)
4-SPD
Automatic
(M30)
3800-V6 (L36)
Ring Gear
Diameter
Pinion Bearing and Differential Bearing Preload

Specification
Metric
English
New Bearings
(Rotating Torque With a New Seal)
1.7-3.4 N-m
15-301bin
Used Bearings
1.0-1.7 N-m
10-151bin
New Bearings
3.6-6.2 Nm
32-55 lb in
Used Bearings
1.8-3.1 N-m
16-28 lb in
0.13-0.23 mm
(0.005-0.009 in)
Application
Differential Drive Pinion Gear Inner and Outer Bearing Preload
(Measured at the Drive Pinion Gear Nut)
Total Preload
(Measured at the Drive Pinion Gear Nut)
Differential Ring Gear-to Differential

Drive Pinion Gear Backlash
Drive line/Axle
Rear Drive Axle
4-25

Noise Diagnosis
Many noises that are reported as coming from the
rear axle actually originate from other components.
Any of the following components may be the source of
noises that are reported as coming from the rear axle:
The tires and wheels
The road surfaces
The wheel bearings
The engine
The transmission
The muffler
The body
Thoroughly inspect for the source of the noise before
disassembling the rear axle. Noise that originates
in other places cannot be corrected by adjustment or
replacement of rear axle components. Rear axle
differential gears are not absolutely quiet (like
any other mechanical devices). Rear axle differential
gears should be accepted as commercially quiet
unless some abnormal noise exists.
Use the following procedure in order to inspect for
axle noise under standard conditions:
1. Measure the rear axle lubricant in order to ensure
the correct level.
2. Drive the vehicle far enough in order to thoroughly
warm up the rear axle lubricant.
Select a level asphalt road. A level asphalt road
will reduce tire noise and body drumming.
3. Note the speed at which the noise occurs.
4. Stop the vehicle.
5. Determine if the exhaust muffler roar or other
engine conditions cause the noise:
5.1. Place the transmission range selector lever
in NEUTRAL
5.2. Run the engine slowly up and down
through the engine speeds that correspond
to the speed at which the noise was
most pronounced.
6. Determine if the tires cause the noise:
Temporarily inflate all of the tires to
approximately 345 kpa (50 psi).
This will alter the noise caused by the tires,
but will not affect the noise made by
the rear axle.
Test drive the vehicle. Coast at speeds under
48 km/h (30 mph).
The following characteristics of tire and rear
axle noise may help in determining if the tires
cause the noise:
Rear axle noise usually stops when the
vehicle is coasting at speeds under
48 km/h (30 mph).
Tire noise usually continues. The tone of
the tire noise becomes lower as the
speed of the vehicle is reduced.
Rear axle noise usually sounds different

during driving and during coasting. Tire
noise remains the same during
driving and during coasting.
Exhaust and axle noises change during
sudden acceleration and deceleration.
Tire noise remains constant during
sudden changes in vehicle speed.
Tire noise is the most noticeable at the
speeds of 32 to 48 km/h (20 to 30 mph).
Tire noises changes on different
road surfaces, but rear axle noise does
not. Drive the vehicle over smooth
pavement or dirt roads (not gravel) with
the tires at normal pressure. If the
noise is caused by the tires, it will
noticeably change or disappear and
reappear with the road surface.
7. Determine if loose or rough front wheel inner or
outer bearings cause the noise.
The following characteristics of noise caused by
loose or rough front wheel inner or outer bearings
may help in determining if loose or rough
bearings cause the noise:
Loose or rough front wheel inner or outer bearings
will cause a noise which may be confused with
rear axle noise. Noise in the above components
does not change when comparing drive and coast.
the noise in the above components to diminish.
Applying the brake pedal while holding the speed
constant removes some of the weight off the
bearing. Use the following procedure in order to
test the front inner and outer bearings for noise:
Noise in front wheel inner or outer bearings
does not change between drive and coast.
Light application of the brake pedal while
holding the vehicie speed steady takes
some weight off of the bearings. This action
will often cause noise in front wheel inner
or outer bearings to diminish.
Use the following steps in order to determine if
the front wheel inner and outer bearings
are loose:
7.1. Jack up the tires and the wheels.
7.2. Spin or shake the tires and the
wheels in order to determine if the
bearings are loose.
8. Rear axle noise is dampened when the rear
suspension rubber bushings and the spring
insulators are correctly installed.
Determine if any metallic contact exists between
The spring and the spring opening in the
underbody
The lower control arm bushings and the
underbody or axle housing brackets
Metal-to-metal contact at these points may
increase road noise and normal axle noise.
4-26
Driveline/Axle
Rear Drive Axle
Rear Axle Noises
Backlash Clunk
After verifying that a noise exists in the rear axle,

determine the type of the noise. D'etermining the type
of the rear axle noise will aid in repair.
One of the following conditions may cause excessive

backlash clunk with acceleration and deceleration:
A worn differential drive pinion gear shaft
A worn differential case
Excessive clearance between the following
components:
- The rear axle shaft splines and the side gear
splines
- The side gear hub and the counterbore in
the case
A worn differential drive pinion gear and worn side
gear teeth
Worn differential pinion gear thrust washers
Excessive differential ring gear-to-differential drive
pinion gear backlash
Replace the worn components as necessary. Select
close fitting replacement parts.
Adjust the differential ring gear-to-differential drive
pinion gear backlash. Refer to Backlash Adjustment
Gear Noise
Gear noise (whine) is audible from 32-89 km/h
(20- 55 mph) under the following driving conditions:
Drive - Acceleration or heavy pull
Road Load - The vehicle driving load or the
constant speed
Float - Using enough throttle in order to keep the
vehicle from driving the engine, the vehicle slows
down gradually but the engine still pulls slightly.
Coast - The throttle closes and the vehicle is
in gear.
Gear noise is most noticeable when the vehicle is
operating at the following speeds:
64-80 km/h (40-50 mph)
97-105 km/h (6Q-65 mph)
Bearing Noise
Poor bearings generally produce a rough growl or
grating sound, rather than the whine typical of
gear noise.
Bearing noise frequently "wow-wows" at constant .
RPMs. This noise may indicate that the. following
components are faulty:
The differential drive pinion gear
The side bearings
The "wow-wow" bearing noise may be confused with
rear w~eel bec1.ring noise. Inspect and replace as
necessary.
Rear Wheel Bearing Noise

The noise that is produced by a rough rear wheel
bearing is evident under the following conditions:
The vehicle is coasting at low speeds
The transmission range selector lever is in
NEUTRAL
The bearing noise may diminish with gentle braking.
Use the following steps in order to determine if a noise
is caused by a rough rear wheel bearing:
1. Raise the rear tires and wheels.
2. Spin the rear tires and wheel by hand.
3. Listen at the hubs for evidence of rough (noisy)
rear wheel bearings.
Knock At Low Speeds

One of the following conditions may cause a knock at
low speeds:
A worn universal joint
A worn or oversized side gear hub counterbore in
the differential case
Inspect and replace the above components as
necessary.
General Information
Limited Slip Rear Axle
The following conditions usually indicate improper
operation:
Clutch slippage
Clutch grabbing
Clutch slippage or grabbing may produce a chatter or
a whirring sound.
A chatter or a whirring sound does not necessarily
indicate inoperative components. Excessive wheel spin
that occurs when the cones are not sufficiently
lubricated may cause a similar sound. (Excessive
wheel spin could occur during rapid acceleration, with
one tire and wheel on a dry surface and the other
tire and wheel on a slippery surface, such as ice.)
Both tires and wheels rotate at equal speeds while the
vehicle is being driven straight ahead. An equal
driving force is delivered to each tire and wheel during
straight ahead driving.
The inside tire and wheel requires extra driving force
when the vehicle is being driven around a corner.
This extra driving force causes slippage in
the clutch cone.
The operational life of the limited slip unit depends
upon equal rotation of both the tires and the wheels
during straight ahead operation.
If the rotation of the wheels and the tires is not equal
during straight ahead operation, the limited slip
unit will function as if the vehicle were cornering. This
will impose constant slippage on the clutch and will
cause abnormal wear on the clutch cones.
Driveline/Axle
Rear Drive Axle
Checking Limited Slip Operation

Tools Required
J 2619-01 Slide Hammer
J 21579 Axle Shaft Remover
1. If the vehicle is equipped with an automatic
transmission, place the transmission range
selector lever in PARK with the parking brake
lever released.
If the vehicle is equipped with a manual
transmission, place the vehicle in gear.
2. Raise both of the rear tires and wheels off
the floor.
Refer to Lifting and Jacking the Vehicle in General
Information.
J 21579
164014
3. Install the J 21579, the 12.7 x 330.0 mm

(1/2 x 13 in) adapter from the J 2619-01 (1), and a
torque wrench (2).
4. Measure the torque required in order to rotate one
tire and wheel.
The torque should measure between
169-305 N,m (125-225 lb ft).
5. Place the automatic transmission range selector
level in NEUTRAL.
6. Lower one rear tire and wheel to the ground.
7. Measure the torque required in order to rotate the
raised tire and wheel.
The torque should measure between
58-91 N-m (43-67 lb ft).
8. Install the tire and the wheel.
Refer to Wheel Installation in nres and Wheels.
9. Replace the differential case if any of the above
measurements do not fall within specifications .
4-27
4-28
Driveline/Axle
Rear Drive Axle
Repair Instructions
Lubricant Level Check
Information.
2. Clean any dirt or foreign material from around the
rear axle housing drain plug.
3. Remove the rear axle housing drain plug.

4. Ensure that the axle lubricant level is within the
following range:
1. Install a new rear axle housing cover gasket.
Refer to Rear Axle With ABS and With Drum
Brakes or Rear Axle With ABS and TCS
2. Install a new rear axle housing cover.
3. Install the park brake cable guides.
Notices.
No higher than the bottom of the plug opening
4. Install the rear axle housing cover bolts/screws
No lower than 15 mm (9/16 in) below the

plug opening
(20 or 18).
Tighten
Tighten the rear axle housing cover bolts/screws
(20 or 18) in a crosswise pattern to
30 N-m (22 lb ft).
5. Fill the lubricant. Refer to Lubricant Level Check
5. If necessary, add to or replace the axle lubricant.

Use Synthetic 75W-90 gear lubricant (GM
P/N 12378261), meeting GM
specification 9986115, or equivalent.
6. If the vehicle has a limited slip differential, add

118 ml (4 fl oz) of limited slip differential additive.

and Notices.
7. Install the rear axle housing drain plug.

Tighten
Tighten the rear axle housing drain plug to
35 N-m (26 lb ft).
Rear Axle Housing Cover and Gasket

Replacement
Removal Procedure
Lifting and Jacking the Vehicle
2. Clean all of the dirt from the area of the rear axle
housing cover before removing the cover.
3. Remove the following components:
The rear axle housing cover bolts/screws
The parking brake cable guides
4. Pry the rear axle housing cover loose.
Remove the rear axle housing cover. Refer to
Rear Axle With ABS and With Drum Brakes
or Rear Axle With ABS and TCS
5. Drain the lubricant.

6. Remove the rear axle housing cover gasket.
7. Clean both of the gasket sealing surfaces.
Rear Axle - Disassemble

Important: It is not necessary to remove the rear axle
assembly for overhaul of the rear axle components
as this can be done in vehicle. If the rear axle housing
is being replaced, the rear axle assembly should be
removed from the vehicle and overhauled on the
bench. If the rear axle housing is damaged, use the
following procedure in order to remove and install
the rear axle housing:
2. Support rear axle with stands and/or
hydraulic jack.
3. Remove rear torque arm. Refer to Torque Arm
Replacement
4. Remove propeller shaft from vehicle. Refer to
5. If the rear axle housing is being replaced, remove
the rear axle assembly from the vehicle. Refer to
Rear Axle Replacement
6. Remove the rear axle cover and gasket from
housing. Refer to Rear Axle Housing Cover
and Gasket Replacement
7. Remove the axle shafts. Refer to Axle Shaft
Replacement
8. Remove the differential case from housing. Refer
to Differential Case Assembly
9. Remove the differential drive pinion gear and
bearing races from housing. Refer to Drive
Pinion Installation
10. Inspect all components for excessive wear and
replace as necessary.
Driveline/Axle
Rear Drive Axle
4-29
Pinion Depth Adjustment
Removal Procedure
1. Disassemble the differential case.
Refer to Differential Case Assembly
2. Remove the differential drive pinion gear inner
bearing.
Refer to Drive Pinion Installation
3. Clean the following components:
3.1. All of the components of the gauge
3.2. The differential bearing bore
3.3. The inner and outer drive pinion gear
bearing cups
4. Lubricate the inner (14 or 12) and the outer (7)
drive pinion gear bearings.
Use one of the following lubricants:
Axle lubricant
SAE 80W-90 GL-5 gear lubricant or an
equivalent
Tools Required
J 23597-1 Arbor
J 23597-11 Gauge Plate
J 21777-40 Rear Pilot Washer
J 21777-42 Front Pilot Washer
J 21777-43 Stud Assembly-Bolt
J 21777-45 Side Bearing Discs
Use a pinion setting gauge in order to measure
differential drive pinion gear depth. The gauge provides
a normal or zero pinion as a gauging reference.
1. Install the J 21777-40, the J 21777-42, the
J 21777-43, and the J 21777-45
2. Install the J 23597-11.
3. Install the J 21777-42 into the rear axle housing.
Notices.
4. Install the drive pinion gear setting gauge nut into
the rear axle housing.
(Refer to Rear Axle With ABS and With Drum
Tighten
Tighten the differential drive pinion gear setting
gauge nut to 2.3 Nm (20 lb in).
5. Rotate the J 23597-11 in order to seat the
following components:
The differential drive pinion gear outer
bearing (2)
The differential drive pinion gear inner
bearing (1)
164276
4-30
Rear Drive Axre
Drive Ii ne/Axle
6. Mount the J 8001 onto the J 23597-1.
7. Preload the dial indicator against the plunger
about 1.27 mm (0.050 in).
8. Install the J 21777-45 onto the J 23597-11.
Position this unit into the rear axle housing (10).
Brakes or Rear Axle With ABS and TCS.
9. Install the following components:
J.21777-45
,54343
The carrier bearing caps (3)

The bearing cap bolts/screws (2)
Tighten
Tighten the differential carrier bearing cap
bolt/screws (2) to 75 N-m (55 lb ft).
10. Use the following steps in order to measure the
differential drive pinion gear depth:
10.1. Rotate the J 23597-1 slowly back and
forth until the J 8001 reads the greatest
deflection.
The deflection is the point where the needle
changes direction.
10.2. At the point of deflection, set the J 8001
to zero.
10.3. Repeat the rocking action in order to verify
the zero setting.
10.4. After obtaining the zero setting, rotate the
J 23597-1 until the plunger no longer
touches the J 23597-11.
This action provides the gauge reference of
a zero or nominal drive pinion gear.
10.5. Use the following information in order to
select the correct shim:
Record the J 8001 reading at the pointer
position.
The required drive pinion gear shim
thickness is equal to the J 8001 reading.
For example, if the pointer moved
counterclockwise 1.70 mm (0.067 in) to
a dial reading of 0.84 mm (0.033 in),
a shim thickness of 0.84 mm (0.033 in)
is required.
Drive pinion gear shims are available
in 0.03--0.94 mm (0.001-0.037 in).
The thickness of each shim is etched on
the flat surface of the shim.
Driveline/Axle
11. Loosen the J 21777-43.
12. Remove all of the special tools from the rear axle
housing.
13. Remove the inner (1) and the outer (2) drive
pinion gear bearings from the rear axle housing.
14. Install the correct drive pinion gear shim on the
drive pinion gear.
15. Use the following steps in order to set the proper
drive pinion gear depth:
15.1. Use the set-up dimension determined by
the J 8001 as a starting point.
15.2. Perform a ring gear tooth pattern test in
order to fine tune the drive pinion
gear depth.
The test may indicate additional necessary
drive pinion gear shim changes.
Refer to Pinion and Ring Gear Inspection.
The drive pinion gear inner bearing
The drive pinion gear outer bearing
Refer to Drive Pinion Installation
17. Assemble the differential case.
Refer to Differential Case Assembly.
18. Measure the total preload at the drive pinion gear
nut bearings.
The preload should measure within the following
specifications:
With new inner and outer drive pinion gear
bearings and a new drive pinion gear
seal (6), the preload should measure
3.6-6.2 N-m (32-55 lb in).
With used inner and outer drive pinion gear
bearings and a new drive pinion gear
seal (6), the preload should measure
1.8-3.1 N-m (16-28 lb in) when rotating with a
new drive pinion gear seal (6).
Brakes or Rear Axle With ABS and TCS .
Rear Drive Axle
4..31
164276
4-32
Rear Drive Axle
Driveline/Axle
Rear Axle - Assemble
1. Inspect all components for excessive wear and
replace as necessary.
2. Perform pinion depth measurement and
adjustment. Refer to Pinion Depth Adjustment
3. Install the differential drive pinion gear, bearing
races, and new pinion seal from housing. Refer
to Drive Pinion Installation
4. Install the differential case to housing. Refer to
Differential Case Assembly
5. Perform side bearing preload adjustment and
measurement. Refer to Differential Side Bearing
Preload Adjustment
6. Perform a backlash adjustment and measurement.
Refer to Backlash Adjustment
7. Install the axle shafts. Refer to Axle Shaft
Replacement
8. Perform Gear Tooth Contact Pattern Check. Refer
to Gear Tooth Contact Pattern Check
9. Install the r~ar axle cover and gasket to the
housing. Refer to Rear Axle Housing Cover
and Gasket Replacement
10. If the rear axle housing was replaced, install the
rear axle assembly into the vehicle. Refer to Rear
Axle Replacement
11. Install the propeller shaft to the vehicle. Refer to
12. Install rear torque arm. Refer to Torque Arm
Replacement
13. Remove stand and/or hydraulic jack from
rear axle.
15. Road test the vehicle and inspect for leaks.
Axle Shaft Replacement

Removal Procedure
Tools Required
J 39446 ABS Exciter Ring Protector Kit
1 . Remove the rear tire and wheel. Refer to Wheel
Removal
2. Remove the rear brake rotor. Refer to Brake
Rotor Replacement (Rear)
3. Remove the rear axle housing cover.
Refer to Rear Axle Housing Cover and Gasket
Replacement
4. Install a J 39446 onto the speed sensor reluctor
wheel (6) on vehicles that are equipped with
non-traction control axles.
5. Remove the pinion gear shaft lock bolt/screw (5)
from the differential case.
6
164023
Rear Drive Axle
Driveline/Axle
4-33
6. Remove the pinion gear shaft (8) from the

differential case (9).
Refer to Rear Axle With ABS Differential Assembly
or Rear Axle With ABS and TCS: Differential
Assembly.
7. Push the flanged end of the axle shaft into the
rear axle housing (7) in order to access the rear
axle shaft lock.
Remove the rear axle shaft lock (1 ).
Important: Do not damage the rear wheel speed

sensor reluctor wheel (30) during axle shaft removal
on vehicles that are equipped with traction control.
The rear wheel speed sensor reluctor wheel is located
on the axle shaft (29).
If the rear wheel speed sensor reluctor wheel is
damaged, replace the rear axle shaft.
Remove the rear axle shaft (27 or 29) from the
rear axle housing (10).
1. Install the rear axle shaft (27 or 29) into place.

The splines on the end of the axle shaft
(27 or 29) do not damage the rear wheel
bearing seal (23 or 21 ).
The splines on the end of the axle shaft
(27 or 29) engage with splines of the
differential side gear (11 ).
Refer to Rear Axle With ABS Differential
Assembly or Rear Axle With ABS and TCS:
Differential Assembly.
2. Install the rear axle shaft lock (1 ).
Push the axle shaft (27 or 29) outward so that the
rear axle shaft lock seats in the counterbore of
the differential side gear.
6
164023
3. Install the pinion gear shaft (8) through the

The differential case (9)
The pinion gear thrust washers (12)
The pinion gears (11)
Align the hole in the pinion gear shaft (8) with
the rear axle shaft lock bolt/screw hole in
the differential case (9).
4-34
Drive line/Axle
Rear Drive Axle

Notices.
4. Coat the pinion gear shaft lock bolt/screw (5) with
Loctite 242 or an equivalent.
Install the pinion gear shaft lock bolt/screw (5).
5.
6.
7.
8.
Tighten
Tighten the differential pinion gear shaft lock
bolt/screw (5) to 36 N-m (27 lb ft).
Remove the J 39446 from the speed sensor
reluctor wheel (6) if the vehicle has a standard
rear axle.
If a new speed sensor reluctor wheel (6) was
installed, remove and discard the plastic covering.
Install the rear axle housing cover.
Replacement.
,fnstall the rear brake rotor. Refer to Brake Rotor
Replacement (Rear)
Install the rear tire and the rear wheel. Refer to
Wheel Removal
Oil Seal and/or Bearing Replacement

Removal Procedure
164285
Tools Required
J 2619-01 Slide Hammer
J 22813-01 Axle Bearing Remover
1. Remove the rear axle shaft. Refer to Axle Shaft
Replacement.
2. If the vehicle has a rear brake backing plate,
remove the rear brake backing plate.
3. if the vehicle has a rear brake caliper anchor
bracket and mounting plate, remove the rear
brake caliper anchor bracket and mounting plate.
Refer to Brake Caliper Replacement (Rear) in
Disc Brakes.
4. Place a pry bar behind the steel case of the
seal (3).
Use the pry bar in order to remove the rear wheel
bearing seal (3} from the rear axle housing (2).
Do not damage the housing (2).
Rear Drive Axle
Driveline/Axle
5. Insert the J 22813-01 into the bore.
Position the J 22813-01 behind the rear wheel
bearing so that the tangs on the tool engage the
bearing outer race.
6. Use the J 2619-01 in order to remove the rear
wheel bearing.
4-35
J 22813-01
Tools Required
J 23765 Axle Bearing Installer
J 23771 Axle Oil Seal Installer
1. Lubricate the new rear wheel bearing ( 1).
Axle lubricant
SAE BOW-90 GL-5 gear lubricant or an
equivalent
J 2619-01
228698
2. Use the J 23765 and the J 8092 in order to install

the rear wheel bearing.
Ensure that the tool bottoms against the shoulder
in the rear axle housing.
3. Lubricate the sealing lips.
Axle lubricant
SAE BOW-90 GL-5 gear lubricant or an
equivalent
4. Position the rear wheel bearing seal onto the
J 23771
5. Use the J 23771 in order to direct the bearing
seal (3) into the housing bore.
6. Install the rear wheel bearing seal into place.
Ensure that the rear wheel bearing seal is
flush with the axle tube.
7. Install the rear brake caliper mounting plate.
8. Install the rear axle shaft. Refer to Axle Shaft
Replacement
9. Inspect for correct operation of the rear axle.
164285
J 23771
228693
4-36
Rear Drive Axle
Driveline/Axle
Pinion Oil Seal Replacement (And Yoke}
Removal Procedure
164053
Tools Required
J 8614-01 Pinion Flange Remover'and Installer
2. Remove the propeller shaft.
or Propeller Shaft Replacement - Two Piece
3. Mark the position of the following components
before disassembly:
(This action will ensure that the correct drive
pinion gear inner and outer bearing preload can
be maintained.)
The drive pinion gear yoke (1)
The drive pinion gear (16 or 14)
The drive pinion gear nut (1)
Refer to Rep[ Axle With ABS and With Drum
4. Use the J 8614-01 in order to remove the
following components:.
The drive pinion gear washer (2)
Use a suitable container in order to hold any
fluid that may drain from the rear axle.
J 8614-01
164050
Driveline/Axle
5. Use the J 8614-01 in order to remove the drive
pinion gear yoke (1 ) .
Rear Drive ,Axle
4,;-37
J 8614-2
164041
Important: Do not damage the rear axle housing

when removing the drive pinion gear seal.
6. Use a blunt chisel in order to drive the drive

pinion gear seal (1) out of the rear axle housing.
Remove the drive pinion gear seal (1 ).
7. Inspect the drive pinion gear seal (6) surface of
the drive pinion gear yoke (3) for the following
conditions:
Tool marks
Nicks
Damage, such as a groove worn by the drive
pinion gear seal.
8. If the drive pinion gear yoke (3) is damaged,
replace the drive pinion gear yoke.
9. Inspect the housing bore for burrs.
Burrs might cause leaks around the outer
diameter (OD) of the drive pinion gear seal (1 ).
Remove any burrs that might cause leaks around
the outer diameter (OD) of the drive pinion
gear seal (1 ).
164048
4-38
Driveline/Axle
Rear Drive Axle

Tools Required
J 8614-01 Pinion Flange Remover and Installer
J 23911 Pinion Oil Seal Installer
1. Use the J 23911 in order to install a new drive
pinion gear seal (1 ).
2. Apply chassis lubricant or an equivalent to the
The outside diameter of the drive pinion gear
yoke (3)
The sealing lip of the new drive pinion gear
seal (6)
164048
3. Install the drive pinion gear yoke (1 ).

J 8614-2
The drive pinion gear washer (2)

Finger tighten the drive pinion gear nut.
164041
\
J 8614-01
164oso
5. While holding the drive pinion gear yoke (1 ), use

the following specifications:
Use the following steps in order to tighten the
drive pinion gear nut:
5.1. Hold the drive pinion gear yoke.
Use the J 8614-01 in order to tighten the
drive pinion gear nut to the position that was
marked.
5.2. Use the J 8614-01 in order to tighten the
drive pinion gear nut to 1.59 mm (1/16 inch)
beyond the alignment mark.
6. Install the propeller shaft.
or Propeller Shaft Replacement - Two Piece
7. Measure the rear axle lubricant level.
Add lubricant, if lubricant is required.
Refer to Lubricant Level Check
9. Inspect for correct operation of the rear axle.
Driveline/Axle
Inspection Before Disassembly
Tools Required
J 39446 ABS Exciter Ring Protector
Important: Use the J 39446 in order to prevent
damage to the rear wheel speed sensor reluctor wheel
when removing components within the rear axle
housing on veflicles with standard rear axles.
Important: The driveline components in this vehicle
are factory system balanced. System balancing
provides a smoother running driveline operation.
Observe and reference mark the positions of all of the
driveline components relative to the propeller shaft
and rear axle prior to assembly.
The following driveline components are relative to the
propeller shaft and rear axle:
The propeller shaft
The rear axle
The differential drive pinion gear yoke
The output shaft
Be sure to reassemble all of the components in the
exact relationship to each other that existed before the
components were disassembled.
Ensure that the published specifications and torque
values and any measurements made prior to
disassembly are followed during assembly. These
specifications must be followed in order to maintain the
factory balance of the components.
When a new differential ring gear and a new drive
pinion gear are installed, replace the original
drive pinion gear yoke with a service drive pinion gear
yoke. Refer to Pinion Oil Seal Replacement
(And Yoke).
Advise the owner to avoid the following actions for the
first 80 km (50 miles) of driving after the replacement
of the drive pinion gear yoke:
Rapid acceleration
Driving at speeds faster than 80 km/h (50 mph)
Use the following steps in order to clean and inspect
the rear axle components whenever the rear axle
is taken apart for service:
For vehicles equipped with standard non-traction
control rear axles, select the correct ABS exciter
ring from the J 39446.
Attach the correct ABS exciter ring protector to
the speed sensor reluctor wheel.
Clean all of the differential bearings thoroughly in
clean solvent.
Visually inspect the bearings.
Minute scratches and pits that appear on the
rollers and the races at low mileage are caused
the initial preload.
Do not replace bearings that have minute
scratches and pits on the rollers and the races at
low mileage.
Inspect the bearings by feel:
1. Ensure that the bearings are oiled.
2. Rotate the bearings. Apply as much hand
pressure as possible.
The bearings should feel smooth.
Rear Drive Axle
4-39
Inspect the sealing surface of the differential drive

pinion gear yoke for the following conditions:
- Nicks
- Burrs
- Rough tool marks
These conditions may cause damage to the
differential drive pinion gear seal. Damage
to the seal may result in an oil leak.
Replace the differential drive pinion gear seal if
it is damaged. Refer to Pinion Oil Seal
Replacement (And Yoke).
Inspect the housing bore for burrs.
Burrs may cause leaks around the OD (outside
diameter) of the drive pinion gear seal.
Remove any burrs that are found.
Inspect the following components for excessive
wear and scoring:
The differential ring gear
The drive pinion gear teeth
If excessive wear or scoring exists, replace
both of the above gears. Refer to Pinion
and Ring Gear Inspection.
Inspect the following components for
unusual wear:
- The differential drive pinion gear shaft
- The differential drive pinion gear
- The side gear
- The differential pinion gear thrust washers
Pry against the shoulder at the puller recess in
the differential case in order to inspect the
press fit of the differential bearing inner race on
the differential case hub.
Ensure that the differential bearings are press fit
onto the hub.
Inspect the rear axle for the following conditions:
- Chipped bearings
- Loose (lapped-in) bearings
- Chipped gears
The above conditions indicate that foreign
material is present. If any of the above
conditions are found, clean the rear axle
housing.
On vehicles with standard non-traction control rear
axles, inspect the speed sensor reluctor wheel for
- Chipped teeth
- Missing teeth
- Looseness
- Wobble
Replace the speed sensor reluctor wheel if the
speed sensor reluctor wheel is damaged.
Refer to Wheel Speed Sensor Ring
Replacement (Without Traction Control) and
Wheel Speed Sensor Ring Replacement (With
Traction Control).
Driveline/Axle
4-40 Rear. Drive Axle
Pinion and Ring Gear Inspection
164018
Inspect the rear axle before disassembly: A close

inspection of the rear axle and the report of the
malfunction will aid in determining the type of repairs
or adjustments that are necessary.
The following conditions may cause' rear axle noise:
Improper backlash
The differential drive pinion gear inner bearing
pre load
The differential drive pinion gear outer bearing
pre load
The differential side bearing preload
Any combination of the above items
Measure the following items before removing the
differential case from the housing:
The backlash
The total differential
preload
c
The tooth contact pattern
Record and analyze the above measurements before
removing the differential case from the housing.
Do not allow foreign matter (such as dirt or sand) near
the rear axle. The presence of foreign matter in the
rear axle may cause rear axle failure.
Differentiat Ring Gear Tooth Nomenclature

The drive side (5) of the differential ring gear
tooth curves outward, or is convex.
The coast ,side (3) of the differential rlng gear tooth
curves inward, or is concave.
The toe end (2) of.the differential ring gear tooth is the
end that is nearest to the center of the differential
ring gear.
The heel end (1) of the differential ring gear tooth is
the end that is farthest away from the center of
the differential ring gear. The toe end of the tooth is
smaller than the heel end.
Effects Of Increasing Load On Tooth Contact

Pattern
1
The load on the differential ring and the drive pinion

gear is increased during vehicle acceleration.
An increased load on the differential ring and the drive
pinion gear may cause the tooth contact to spread
out. Under a very heavy load, the tooth contact may
extend from the near to the near heel on the drive side.
Increasingly heavier loads cause the following
changes in tooth contact:
The entire contact tends to shift toward the heel
The entire contact becomes broader with
respect to the tops and the bottoms of the teeth
The following tooth contact pattern test will recreate
the effects of a light load. For this reason, the patterns
that will be obtained by the following test will only
extend to about half of their potential expansion .
7560
Driveline/Axle
It is important to note tha:t the contact pattern is
centrally located up and down on the face of the
differential ring gear teeth .
The following.conditions may cause a change in the
tooth contact pattern under a load:
A drive pinon gear is insufficiently preloaded
The differential bearings are insufficiently
preloaded
Adjustments Affecting Tooth Contact

The following two adjustments will affect the tooth
contact pattern:
An adjustment to the backlash
An adjustment to the position of the drive pinion
gear in the rear axle housing
The effects of bearing preloads are not readily
apparent on hand-loaded tooth contact pattern tests.
Differential bearing shims can be used in order to
adjust the backlash. The shims move the entire
differential closer to or farther from the drive
pinion gear.
Bearing shims can also be used in order to set the
differential bearing preload.
Make the following changes in order to increase
the backlash:
- Increase the thickness of the right
bearings shim
- Decrease the thickness of the left
bearing shim
Make the following changes in order to decrease
the backlash:
- Decrease the thickness of the right
bearings shim
- Increase the thickness of the left
bearing shim
The position of the drive pinion gear can be adjusted
by changing the thickness of the shims between
The drive pinion gear head
The race of the differential drive pinion gear inner
bearing
The drive pinion gear shim is used in the rear axle in
order to compensate for manufacturing tolerances.
Increasing the shim thickness moves the drive
pinion gear closer to the centerline of the
differential ring gear.
Decreasing shim thickness moves the drive pinion
gear farther away from the centerline of the
Rear Drive Axle
4-41
4-42
Rear Drive Axle
Driveline/Axle
Effects Of Differential Drive Pinion Gear
Position On Tooth Pattern
The following tooth contact pattern exists when the
differential drive pinion gear is too far away from
the centerline of the differential ring gear:
High heel (2) contact on the drive side (4)
High toe (1) contact on the coast side (3)
Decreasing backlash in order to move the differential
drive pinion gear closer to the centerline of the
differential ring gear will cause the following tooth
contact pattern:
High heel (2) contact on the drive side (4) moves
down and toward the toe (1 ).
High toe (1) contact on the coast side (3) moves
down and toward the heel (2).
7566
The following tooth contact pattern exists when the

differential drive pinion gear is too close to the
centerline of the differential ring gear:
Low toe (1) contact on the drive side (4)
Low heel (2) contact on the coast side (3)
7579
Rear Drive Axle
Driveline/Axle
4-43
Increasing backlash in order to move the differential

drive pinion gear further away from the centerline of
the differential ring gear will cause the following
tooth contact pattern to exist:
Low toe contact on the drive side (4) moves up
and toward the heel (2).
Low heel contact on the coast side (3) moves up
and toward the toe (1 ).
7566
Bearings Inspection
Carefully and thoroughly inspect all drive unit parts
before assembly. Thorough inspection of the
drive parts for wear or stress with subsequent
replacement of worn parts eliminates costly drive
component repair after assembly.
Important: Bearings and cups are matched sets .
Replace both bearing and cup when either part
requires replacement.
Oil the bearings. Inspect the bearings for smooth
rotation.
Inspect the bearing rollers for wear.
Inspect the bearing cups for wear, cracks,
brinelling, and scoring .
4-44
Rear Drive Axle
Drivetine/Axle
Differential Case Assembly
Removal Procedure
J 39446
164239
1. Remove the rear axle shafts.

Refer to Axle Shaft Replacement.
2. On vehicles with standard non-traction control
rear axles, remove the sensor plug mounting
bolt/screw from the wheel speed sensor.
Brakes
3. On vehicles with standard non-traction control
rear axles, remove the wheel speed sensor.
Carefully place the wheel speed sensor along the
side of the rear axle housing.
Brakes
4. Remove the differential carrier bearing cap
bolts/screws.
Assembly
Important: Mark the differential carrier bearing caps

R and L. This will ensure that they can be reassembled
into their original positions.
Place the following components with the marked right
and left differential bearings caps:
The right and left bearing outer races of the
differential (side) bearings
The bearing shims
This will ensure that they can be reassembled into
their original positions.
5. Remove the .differential bearing shims.
,,
Assembly
Notice: Be careful when prying the differential case

out of the axle housing to prevent damage of the cover
gasket surface. Support the differential case during
removal to prevent case from falling and being
damaged.
Important: Before removing the differential case from
the rear axle housing, measure the differential ring
gear-to-differential drive pinion gear backlash.
6. Remove the differential case from the rear axle
housing.
Driveline/Axle
Rear Drive Axle
4-45
Tools Required
J 22888-20 Differential Side Bearing Remover
J 8107-2 Differential Side Bearing Remover Plug
1. Use the J 22888-20 and the J 8107-2 in order to
remove the differential (side) bearing from the
differential case.
(If removing an Auburn type limited slip differential
case, skip Step 2.
2. Remove the fol.lowing components from the
differential case:
The upper and lower pinion gears
The pinion thrust washer
The left and right pinion gears
The differential side gear thrust washers
Mark the pinion gears and the differential case
so the pinion gears may be reinstalled in
the original positions.
Differential Assembly
3. Remove all of the ring gear bolts/screws from the
differential case.
The differential ring gear bolts/screws are the
left-hand thread type bolts/screws.
Discard the ring gear bolts/screws.
Assembly
4. Use a brass drift and a hammer in order to drive
the ring gear from the differential case.
Do not pry between the ring gear, the speed
sensor reluctor wheel and the differential case if
the ring gear tightly attached.
Assembly
Important: Replace the speed sensor reluctor wheel if
the speed sensor reluctor wheel is removed from
vehicles with standard rear axles.

5. Use a brass hammer in order to remove the speed
sensor reluctor wheel (14).
6. Discard the speed sensor reluctor wheel.
164234
4-46
Driveline/Axle
Rear Drive Axle

Assembly Procedure
J 39446
Tools Required
J 21465-13 Driver Handle Extension
J 25299 Differential Side Bearing Installer
1. Lubricate all of the components of the differential
before assembly.
Axle lubricant
SAE 80W-90 GL-5 gear lubricant or an
equivalent
2. Clean the connecting surfaces of the ring gear
and the differential case.
Assembly
3
164241
Caution: Once the speed sensor reluctor wheel

has been removed from the differential case, a new
speed sensor reluctor wheel must be installed.
The press fit may be lost if the speed sensor
reluctor wheel is used more than once. This would
allow the speed sensor reluctor wheel to rotate
freely on the differential case causing a significant
reduction in performance of the antilock brake
system, which could result in bodily injury.
3. On vehicles with a non-traction control rear axle,
place the speed sensor reluctor wheel over the
differential case on the ring gear side.
Install the speed sensor reluctor wheel.
4. On vehicles with a non-traction control rear axle,
position the ring gear over the speed sensor
reluctor wheel.
Install the ring gear (2),
5. Install two ring gear bolts/screws into opposite
sides of the ring gear.
(If converting to an Auburn type limited slip
differential case, skip to Step 12.

Notices.
6. Install the remaining new ring gear bolts/screws.
Finger tighten the new ring gear bolts/screws.
Tighten
Tighten the differential ring gear bolts/screws
alternately in progressive stages to
120 N-m (89 lb ft).
7. Position the side gear thrust washers over the
side gear hubs.
If the original side gear thrust washers are being
installed, install the side gear thrust washers
in their original positions.
Assembly
Drive line/Axle
Rear Drive Axle
4-47
8. Install the pinion gears into the differential case.

If the original pinion gears are being installed,
install the pinion gears in their original positions .
Assembly
9. Position one upper or lower pinion gear (without a
pinion thrust washer) between the left pinion gear
and the right pinion gear.
Rotate the pinion gears until one of the upper or
lower pinion gears is opposite the loading opening
in the differential case.
Assembly
10. Position the other pinion gear between the left
and the right pinion side gears so that the
pinion gear shaft holes are aligned.
Rotate the pinion gears until the holes in the
upper and the lower pinion gears are aligned with
the holes in the differential case.
11 . Rotate the upper and the lower pinion gears back
toward the loading opening enough to permit
sliding in the pinion thrust washers.
Assembly
12. Use the J 8092, the J 21465-13 and the J 25299
in order to install the differential bearings (1) to
the differential case.
J25299
164242
4-48
Rear Drive Axle
Tools Required
J 25588 Side Bearing Shim Installer
1. Install the differential case into the rear axle
housing.
Assembly
Important:
Do not reinstall the production bearing shims.
The production bearing shims may break
when tapped by a hammer.
Service bearing shims are reusable.
The differential bearings must have the original
outer races in place when the bearings are
reused. Refer to Differential Side Bearing Preload
Adjustment.
Ensure that the bearing shim packs remain in
each shim pack's proper position (right side or
left side).
2. Use the following steps in order to install the
differential bearing shims:
2.1. Select the correct left side bearing shim.
The bearing shim must be 0.10 mm
(0.004 in) thicker than the shim that was
removed from the left side.
2.2. Insert the left side bearing shim pack
between the spacer and the left
bearing race.
2.3. Loosely install the carrier bearing cap.
Assembly or Rear Axle With ABS and
TCS: Differential Assembly
2.4. Select the correct right side bearing shim.
The bearing shim must be 0.1 O mm
(0.004 inch) thicker than the shim that was
removed from the right side.
2.5. Insert the bearing shim between the spacer
and the right bearing race.
2.6. Use the J 25588 in order to drive the right
bearing shim into position.
Notices.
3. Install the differential bearing cap bolts/screws (5).
Assembly
Tighten
bolts/screws to 75 Nm (55 lb ft).
4. Measure the backlash.
Correct the backlash as necessary.
Drive line/Axle
5. Install the rear axle shafts.
Refer to Axle Shaft Replacement
The wheel speed sensor
The wheel speed sensor mounting bolt/screw
Assembly
Tighten
Tighten the wheel speed sensor mounting
plug bolt/screw to 10 N,m (89 lb in).
Differential Side Bearing Preload

P,djustment
Perform the differential bearing preload adjustment
before installing the drive pinion gear.
Refer to Rear Axle With ABS and With Drum Brakes
or Rear Axle With ABS and TCS.
If the drive pinion gear is installed, remove the
ring gear.
Refer to Differential Case Assembly.
Change the thickness of both the right and the left
bearing shims by an equal amount in order to adjust
differential bearing preload.
Refer to Rear Axle With ABS Differential Assembly or
Rear Axle With ABS and TCS: Differential Assembly.
Changing the thickness of both of the bearing
shims equally will ensure that the original backlash
remains constant.
Production bearing shims are cast iron. Production
bearing shims (1) vary in thickness from 5.33-6.91 mm
(0.210-0.272 in) in increments of 0.05 mm (0.002 in).
Assembly.
Steel service bearing shims are available from
1.02-2.08 mm (0.040-0.082 inch) in increments of
0.05 mm (0.002 in).
Rear Axle With ABS and TCS: Differential Assembly
Standard service bearing spacers are
4.32 mm (0.170 inch) thick.
Refer to Production Differential Bearing Shim
Thickness (Standard Spacer) and Service Differential
Bearing Shim Thickness (Standard Spacer) in
Rear Axle Specifications (General Specifications)
Driveline/Axle
Important:
Do not reinstall the production bearing shims.

The production bearing shims may break
when tapped by a hammer.
Service bearing shims are reusable.
The differential bearings must have the original
outer races in place when the bearings are
reused.
1. Determine the approximate required thickness of
the replacement bearing shims.
Measure each production bearing shim (1) or
each service bearing spacer and each
bearing shim pack.
Assembly
2. Determine the necessary service bearing shims.
Select a starting point in service bearing shim
thickness.
Refer to Service Differential Bearing Shim
Thickness (Standard Spacer) in Rear Axle
Specifications (General Specifications)
3. Position the following components into the rear
axle housing:
The differential case
The differential bearing outer races
4. Slip the correct service bearing spacer between
each differential bearing race and the rear axle
housing.
Ensure that the chamfered edge of the service
bearing spacer is placed against the rear
axle housing.
Assembly
Notice: Install the left side bearing cap loosely so the
differential case may be moved while checking
adjustments. Another differential bearing cap
bolt/screw can be added in the lower right side
differential bearing cap hole. This will prevent the case
from dropping while making shim adjustments.
5. Select one or two bearing shims.
Refer to Service Differential Bearing Shim
Thickness in Rear Axle Specifications (General
Specifications) for the correct total thickness.
6. Position the shims between the right side of the
differential bearing race and the service bearing
spacer.
The right side of the differential bearing race
The service bearing spacer
Ensure that the left side differential bearing
race and the bearing spacer are against the left
side of the rear axle housing.
Rear Drive Axle
4..49
7. Insert progressively larger feeler gauge sizes

between the right bearing shim and service
bearing spacer until a noticeable increase in drag
exists .
Assembly
The following measurements are examples of
progressively larger feeler gauge sizes:
0.25 mm (0.010 in)
0.30 mm (0.01 in)
0.36 mm (0.01 in)
8. Push a feeler gauge downward until the end of
the gauge touches the rear axle housing bore.
This position will ensure an accurate reading.
Correct feeler gauge thickness exists at the point
just before additional drag begins.
9. Rotate the differential case (9) while using the
feeler gauge in order to ensure an even reading.
Assembly
The weight of the differential case against the
rear axle housing (10) causes the original
light drag.
Differential bearing preload causes the
additional drag.
Starting with a thin feeler gauge obtains a
sense of feel that is necessary in order to
recognize the beginning of the preload.
Recognizing the beginning of the preload is
necessary in order to obtain zero clearance.
Work the differential case (9) in, out and to the
left in order to insert the feeler gauge.
10. Remove the following components from the rear
axle housing:
The left side differential bearing cap
The left side bearing shim
11. Add the following measurements in order to
obtain the size of the total shim pack that is
needed with no preload on the differential
bearings (3)
The feeler gauge reading measured in Step 7.
The thickness of the bearing shims that
were installed in Step 4.
4-50 Rear Drive Ax1e
Driveline/Axle
12. Select two bearing shims of approximately equal
size. The total thickness of the two shims must be
equal to the value obtained in Step 9.
When installing the differential case into the rear
axle housing, install the above bearing
shims (1) between the following components:
Each differential bearing race
Each service bearing spacer
The additional preload will be added after the
differential case is installed.
13. Install the ring gear if the drive pinion gear is in
position.
Backlash Adjustment
J 8001
164245
Tools Required
Replacement
2. Rotate the differential case (1) several times in
order to seat the bearings.
3. Mount the J 8001.
4. Use a small button on the indicator stem in order
to make contact with the near heel end of
the tooth.
5. Set the J 8001 so that the following condit.ions
are met:
The stem is in line with the gear rotation
The stem is perpendicular to the tooth angle
6. Measure the backlash at three or four points
around the ring gear (3).
Hold the drive pinion gear stationary when
checking backlash.
7. The lash must not vary over 0.05 mm (0.002 in)
around the ring gear (3).
If the variation is over 0.05 mm (0.002 in), inspect
for the following conditions:
Burrs
Uneven bolting condi,ions
A distorted case flange
Correct the conditions as necessary.
8. The backlash at the point of minimum lash should
be between 0.13-0.23 mm (0.00-0.009 in) for all
new gears.
Adjust the backlash as necessary by increasing
the thickness of one bearing shim and decreasing
the thickness of the other bearing shim by the
same amount.
Transfer 0.05 mm (0.002 in) in bearing shim
thickness for .each 0.03' mm (0.001 in) change in
backlash desired.
Driveline/Axle
Rear Drive Axle
4-51
For example, use the following steps in order to

decrease the backlash by 0.03 mm (0.001 in):
8.1 . Decrease the thickness of the right bearing
shim by 0.05 mm (0.002 in).
8.2. Increase the thickness of the left bearing
shim by 0.05 mm (0.002 in).
Refer to Differential Side Bearing Preload
Adjustment tor further information.
9. Install the rear axle housing cover.
Replacement
Gear Tooth Contact Pattern Check

Tooth Contact Pattern Test
Tools Required
J 39446 ABS Exciter Ring Protector Kit
Notice: It is very important that tooth contact be
tested after the differential is taken apart. Variations in
the differential or differential drive pinion gear inner
bearing may cause the differential drive pinion gear to
be too tar away from, or close to, the differential
ring gear. Therefore, the tooth contact pattern must be
tested and corrected, (if necessary) to prevent
gear noise.
1. Clean all of the dirt from the area of the rear axle
housing cover before removing the rear axle
housing cover.
Replacement.
3. Wipe the oil out of the rear axle housing.
4. Carefully clean each tooth of the ring gear.
Assembly
5. Select the correct exciter ring protector from the
J 39446
Attach the exciter ring protector to the speed
sensor reluctor wheel on vehicles with non-traction
control rear axles only.
Assembly.
6. Use a medium stiff brush in order to apply a
mixture of gear marking compound sparingly
to all of the ring gear teeth.
Visibility of the area of the differential drive pinion
gear contact identifies proper usage when a
hand load is applied.
180'
4-52
Rear Drive Axle
Driveline/Axle
Notices.
7. Tighten the differential carrier bearing cap
bolts/screws.
Tighten
bolts/screw to 75 Nm (55 lb ft).
Assembly
8. Apply the park brake until a torque of 54-70 N-m

(40-52 lb ft) is required in order to turn the drive
pinion gear (16 or 14).
Important: A test made without loading the gears will
not give a satisfactory pattern.
9. Use the following procedure in order to obtain a
ring gear tooth contact pattern:
9.1. Tum the pinion gear yoke with a wrench so
that the ring gear rotates one full revolution.
9.2. Reverse the rotation so that the ring gear
rotates one revolution in the opposite
direction.
10. Inspect the differential ring gear teeth for a low
flank contact pattern (2).
11 . Decrease the differential drive pinion gear bearing
shim thickness in order to repair low flank contact
if a low flank contact pattern (2) exists.
Decreasing the differential drive pinion gear shim
thickness moves the smaller diameter of the
differential drive pinion gear contact (2) out toward
the differential ring gear center line (1 ).
12. Inspect the differential ring gear teeth for a heel

contact pattern (1 ).
13. Decrease the backlash in order to repair heel
contact if a heel contact pattern (1) exists.
Decreasing the backlash moves the area of
differential drive pinion gear contact (1) toward
the toe.
180095
Drive Ii ne/Axle
Rear Drive Axle
4-53
14. Inspect the differential ring gear teeth for a high

face contact pattern (2).
15. Increase the differential drive pinion gear bearing
shim thickness in order to repair high face contact
if a high face contact pattern (2) exists.
Increasing the differential drive pinion gear shim
thickness moves the area of differential drive
pinion gear contact (2) out toward the differential
ring gear center line (1 ).
180094
16. Inspect the differential ring gear teeth for a toe

contact pattern (1 ).
17. Increase the backlash in order to repair heel
contact if a toe contact pattern (1) exists.
Increasing the backlash moves the area of
differential drive pinion gear contact (1) toward
the heel.
180093
18. Inspect the differential ring gear teeth for a

desired tooth contact pattern (1 ).
19. Verify that the area of differential drive pinion gear
contact (1) remains in the center of the differential
ring gear tooth.
20. If the differential ring gear tooth pattern is
acceptable, remove the J 39446.
21. Install the rear axle housing cover.
Replacement
180092
4-54
Rear Drive Axle
Driveline/Axle
Rear Axle Replacement
Removal Procedure
1. Use the aid of a helper in order to install the rear

axle housing (10).
2. Install the rear axle lower control arms. Refer to
Rear Axle Lower Control Arm Replacement
3. Install the rear axle torque arm. Refer to Torque
Arm Replacement
4. Connect the electrical connectors to the rear
wheel sensor.
5. Install the parking brake cables to the rear axle
housing.
6. Install the rear springs. Refer to Coil Spring
Replacement
7. Install the rear brake (center) hose to the rear
brake hose junction block.
8. Install the rear axle track bar. Refer to Track Bar
Replacement
9. Install the rear shock absorbers. Refer to Shock
Absorber Replacement
10. Remove the lifting device from the rear axle
housing.
11. Install the rear stabilizer shaft. Refer to Stabilizer
Shaft Replacement
12. Install the propeller shaft. Refer to Propeller Shaft
Replacement - One Piece or Propeller Shaft
Replacement - Two Piece
13. Bleed the brake system. Refer to Hydraulic Brake
System Bleeding (Manual Bleed)
14. Install the rear tires and wheels. Refer to Wheel
Removal
1. Remove the rear tires and wheels. Refer to Wheel

Removal
2. Remove the propeller shaft. Refer to Propeller
Shaft Replacement - One Piece or Propeller
Shaft Replacement - Two Piece
3. Remove the rear stabilizer shaft. Refer to
4. Use an adjustable lifting device in order to support
the rear axle housing (10).
5. Remove the rear shock absorbers. Refer to Shock
Absorber Replacement
6. Remove the rear axle track bar. Refer to Track
Bar Replacement
7. Remove the rear brake (center) hose from the
rear brake hose junction block.
8. Remove the rear springs. Refer to Coil Spring
Replacement
9. Remove the parking brake cables from the rear
axle housing.
10. If the vehicle is equipped with disc brakes,
disconnect the electrical connectors from the rear
wheel sensor.
11. Remove the rear axle torque arm. Refer to
12. Remove the rear axle lower control arm. Refer to
Rear Axle Lower Control Arm Replacement
13. Use the aid of a helper in order to remove the
rear axle housing.
Oriveline/Axle
Rear Drive Axle
4-55
Drive Pinion Installation

Removal Procedure
Tools Required
J 22536 Pinion Driver
1. Remove the differential case.
2. Measure the differential drive pinion gear inner
and outer bearing preload.
3. If no preload reading exists, then inspect for
looseness of the drive pinion gear by shaking.
The following conditions may cause looseness:
A worn drive pinion gear yoke
Defective inner or outer drive pinion gear
bearings
4. If the rear axle was opened for an extended
period with very loose inner and outer drive
pinion gear bearings, the following components
will require replacement:
The ring gear
The drive pinion gear
5. Remove the differential drive pinion gear yoke (1 ).
Refer to Pinion Oil Seal Replacement (And Yoke)
6. Install the J 22536
164053
164249
Driveline,IAxle
7. Use the J 22536 in order to install the drive pinion
gear (1).
Apply heavy hand pressure on the J 22536 toward
the rear axle housing in order to keep the outer
drive pinion gear bearing seated,
The outer drive pinion gear bearing must remain
seated in order to avoid damage to the
outer race.
164254
Outer Bearing Removal Procedure

1. Remove the differential diive pinion gear seal
from the rear axle housing.
2. Remove the drive pinion ~ r outer bearing from

Brakes
Rear Axle With ABS and
3. Use a punch iri 'order to remove the drive pinion
gear outer bearing race fromthe rear axle :
housing, if the drive pinion gear outer. bearing is
.
being replaced.
or
res
Place the punch into the slots in the rear axle

housing.
Brakes or Rear Axle With ABS and
res
1
164261
Inner Bearing Removal Procedure

Tools Required
J 22912-01 Rear Pinion Bearing Cone Remover
1. Remove the drive pinion gear bearing spacer from
the drive pinion gear.
Discard the drive pinion gear bearing spacer.
2. Use a punch in order to remove the drive pinion
gear inner bearing race from the rear axle
housing, if the inner drive pinion gear bearing is
being replaced.
Place the punch into the slots in the rear axle
housing.
3. Use the J 22912-01 in order to drive the inner
drive pinion gear bearing from the drive
pinion gear.
res
res
res
Driveline/Axle
Rear Drive.Axle 4-57
Inner Bearing Installation Procedure
Tools Required
J 29609 Rear Pinion Bearing Cup Installer
J 5590 Rear Pinion Bearing Cone Installer
1 . Use the J 5590 in order to install the inner drive
pinion gear bearing (1) onto the drive pinion
gear (2).
164265
2. Use the J 8092 and the J 29609 in order to drive
the inner bearing race (1) into the rear axle

housing, if the inner drive pinion gear bearing was
replaced.
3. Install the new drive pinion gear bearing
spacer (8) onto the drive pinion gear.
Brakes or Rear Axle With ABS and TCS .
164270
Outer Bearing Installation Procedure
Tools Required
J 7817 Front Pinion Bearing Cup Installer
1. Use the in J 8092 and the J 7817 in order to
install the drive pinion gear outer bearing race
into the rear axle housing if the pinion gear outer
bearing race is removed.
2. Install the drive pinion gear outer bearing into the
rear axle housing ..
3. Install the differential drive pinion gear seal.
J8092
164257
4-5a Rear Drive Axle
Driveline/Atle
Tools Required
164048
J 23911 Front Pinion Bearing Cup Installer

1. If a new ring gear and a new drive pinion gear will
be installed, measure the differential drive pinion
gear depth.
(Refer to Pinion Depth Adjustment.)
2. Install the drive pinion gear into the rear axle
housing.
3. Use the J 23911 in order to install the new drive
pinion gear seal.
4. Apply pinion gear seal lubricant or an equivalent
to the drive pinion gear yoke and to the
sealing lip of the drive pinon gear seal.
5. Install the drive pinion gear yoke.
6. Install the drive pinion gear washer and nut.
Finger tighten the drive pinion gear
washer and nut.
7. Perform the following actions in order to tighten
the drive pinion gear nut.
Hold the drive pinion gear yoke in place .
Rotate the drive pinion gear in order to seat
the inner and outer drive pinion gear
bearings.
While rotating the drive pinion gear, tighten the
drive pinion gear nut until the end play is
taken up.
Important: Preload specifications are being

approached when the following conditions occur:
The holder will no longer pivot fre,ely as the drive
pinion gear rotates.
No further end play exists
Do not attempt further tightening until after
measuring the preload if the above
conditions exist.
Driveline/Axle
Important: Exceeding the preload specifications will
compress the collapsible drive pinion gear bearing
spacer too far. Refer to Rear Axle With ABS and With
Drum Brakes or Rear Axle With ABS and TCS
This conditions will require the installation of a new

spacer.
8. Set the preload to the following specifications on
the inner and outer drive pinion gear bearings:
1.7-3.4 N-m (15-30 lb in) on new.inner and
outer drive pinion gear bearings
1.0-1.7 N-m (10-15 lb in) on used inner and
outer drive pinion gear beatings
9. Rotate the drive pinion gear several times.
Ensure that the inner and outer drive pinion gear
bearings seat.
10. Carefully tighten the drive pinion gear nut.
11. Continue to gradually tighten the drive pinion
gear nut.
Measure the preload after each tightening.
(Additional tightening of the drive pinion gear nut
may add additional torque.
12. Measure the preload again .
13. Reset the preload to specifications if the preload
decreased by rotating the drive pinion gear.
14. Install the differential case.
Rear Drive Axle
4-59
4-60
Rear Drive Ax!e
Driveline/Axle

Rear Axle Description
Standard Rear Axle
The standard rear axle is a semi-floating hyphoid
rear axle.
The rear axle housing carries the vehicle weight.
or Rear Axle With ABS and TCS.
The rear axle is designed for use with the following
components:
An open driveline
Coil springs
The rear axle has a hyphoid type differential ring gear.
or Rear Axle With ABS and TCS: Differential Assembly
The centerline of the differential drive pinion gear is
located below the centerline of the hyphoid type
The rear axle housing encloses all of the components
that are necessary for transmitting power from the
propeller shaft to the rear wheels and tires. Bolts
attach the rear axle housing cover to the back of the
rear axle housing.
The rear axle housing cover is removable in order to
permit service of the differential case without
removing the entire axle from the vehicle.
A universal joint connects the rear end of the propeller
shaft to the drive pinion gear yoke.
The drive pinion gear yoke has a splined end that fits
over the drive pinion gear.
The splined end of the drive pinion gear yoke also
drives the pinion gear.
Two preloaded tapered drive pinion gear bearings
support the drive pinion gear in the rear axle housing.
The races of the following components are press fit
into the rear axle housing:
The inner drive pinion gear bearing
The inner drive pinion gear bearing press fits onto
the drive pinion gear.
The races of the inner drive pinion gear bearing and

the outer pinion gear bearing press against shoulders
recessed in the rear axle housing (10).
Tightening the drive pinion gear nut compresses a
collapsible drive pinion gear spacer. The collaspsable
drive pinion gear spacer bears against the following
components:
The outer drive pinion gear bearing
A shoulder on the drive pinion gear

The drive pinion gear spacer (8) performs the following
actions:
Enables automatic bearing preload adjustment.
Maintains a preload on .the inner drive pinion gear
bearing.
Maintains. a pre load on the outer drive pinion gear
bearing.
Placing selective driye pinion gear shims between the
following components enables adjustment of the
fore-and-aft position of the drive pinion gear:
The head of the drive pinion gear
The inner drive pinion gear bearing
The differential case is one piece.
Two differential side bearings support the differential

case in the rear axle housing.
The differential side bearings are preloaded by
the insertion of differential bearing shims (1) between
The differential side bearings
The rear axle housing
Assembly
Vary the shim thickness from side to side positions the
differential case for proper differential ring
gear-to-differential drive pinion gear backlash.
Bolts attach the differential ring gear to the
differential case.
The outer pinion gear bearing

The outer drive pinion gear bearing combines a
light press fit to a close sliding fit on the yoke end
of the drive pinion gear).
Driveline/Axle
The following components have splined bores used for
driving the axle shaft:
The left differential pinion gear
The right differential pinion gear
The position of the above components permits them to
turn in counterbored cavities of the differential
case (9). The following components have
smooth bores:
The upper differential pinion gear
The lower differential pinion gear
Assembly
The differential pinion gear shaft holds the above
components in position. The differential pinion gear
shaft mounts and locks in the differential case. All four
of the gears mesh with each other.
The following components turn freely on the pinion
gear shaft:
The upper differential pinion gear
The lower differential pinion gear

Assembly
The above components act as idler gears when the
rear wheels turn at different speeds.
The following components back the differential
pinion gears:
Differential pinion thrust washers
Differential side gear thrust washers
Assembly
Vehicles that are equipped with the standard rear axle
with the antilock brake system (ABS) have a rear
wheel speed sensor reluctor wheel (14) press fit to the
differential case (8).
A wheel speed sensor (12 or 26) is bolted to the top of
The sensor provides wheel speed information to
the electronic brake control module (EBCM). Refer to
ABS!TCS System Description in Antilock Brakes
System for more information.
Rear Drive Axle
4-61
The rear wheel speed sensor reluctor wheels are an

integral part of the rear axle shaft (27 or 29) on
vehicles that contain the following components:
The limited slip rear axle
The antilock brake system (ABS)
Brakes
Traction control
Refer to Rear Axle With ABS and TCS: Differential
Assembly
The rear wheel speed sensor reluctor wheels are not
separately serviceable.
The wheel speed sensor (12 or 26) mounts to the rear
brake caliper mounting plate (24).
Bolts attach the rear brake caliper mounting plate
(24 or 5) to the rear axle shaft (29).
Refer to Rear Axle With ABS and TCS or Rear Axle
With ABS: Disc Brake Assembly
The wheel speed sensor provides wheel speed
information to the electronic brake control module
(EBCM). Refer to ABS!TCS System Description
in Antilock Brakes System for more information.
Operation
When the vehicle turns a corner, the differential allows
the outer rear tire and wheel to turn faster than the
inner tire and wheel.
The inner tire and wheel move more slowly than the
outer tire and wheel. The inner tire and wheel slows its
(side) differential pinion gear. The side differential
pinion gear is slowed because the axle shaft is splined
to the side gear.
The differential pinion gears roll around the slowed
(side) differential pinion gear. This action causes
the other differential pinion gear and tire and wheel to
move faster.
4-62
Rear Drive Axle
Driveline/Axle
Limited Slip Rear Axle
Rear Axle Identification
164279
Limited slip rear axles have several definite operating

characteristics. An understanding of these
characteristics is necessary in order to aid diagnostics.
The energizing force comes from the thrust side of
the gears. A free spinning tire and wheel may not have
the level resistance to driving torque required to
apply the clutch packs and the cones.
If the above condition occurs, applying the parking
brake a few notches will provide enough resistance to
energize the cones.
Energizing the cones is independent of acceleration. A
very slow application of the throttle on starting is
recommended to provide maximum traction by
preventing break away of either rear tire and wheel.
All the rear axle components (except for the differential
cases) from the following vehicles are interchangeable:
Vehicles with the limited slip rear axle
Vehicles with the standard rear axle
The slip rear axle differential case is similar in all
respects to the standard differential case, with
the addition of cone clutches splined to each side
gear. The Auburn limited slip differential case is
non-serviceable. The differential cases of the two
vehicles are not interchangeable. The Auburn limited
slip differential case must be replaced as a complete
assembly. The following procedures are the same
for both the Auburn limited slip differential case and the
standard rear axle differential case:
Removal of the differential case
Replacement of the differential case
Service of the side bearings
Service of the ring gear
5794
It is necessary to know the rear axle identification

code (1) and the manufacturer's code (2) before
adjusting or repairing the following components:
The repair axle shafts
The differential
The following information is stamped onto the forward
side of the right axle tube or on a metal tag on the
housing cover (19 or 17):
Rear axle ratio
Differential type
Manufacturer (2)
Build date (3)
RPO codes for the rear axle are also printed on the
service parts identification label.
Maintenance and Lubrication

Refer to Lubricant Level Check tor information on
measuring or adding lubricant.
Drain and refill the lubricant on vehicles with limited
slip differentials at the first 12 500 km (7,500 miles).
If the vehicle pulls a trailer, drain and refill the lubricant
every 12 500 km (7,500 miles), with either type of
differential.
Rear Dtive Axle
Driveline/Axle
4;,,53

Illustration
Illustration
J 2619-01
Slide Hammer With V2 X 13
Adapter
25473
982
c___--Bo
J 5590
Rear Pinion Bearing Cone
Installer
J 8092
Driver Handle
7016
5335
J 8001
Dial Indicator Set
J 8017-2
J 6627-A
Differential Side Bearing

Remover Plug
Wheel Stud Remover
5322
65363
J 8614-01
Pinion Flange Remover and
Installer
J 7817
Front Pinion Bearing Cup
Installer
12439
1507
464
Drive line/Axle
Rear Drive Axle

Illustration
Illustration
J 21777-45
J 21465-13
Pinion Setting Gauge-Side

Bearing Discs
Driver Handle Extension
9879
44782
J 21579
Axle Shaft Remover
(-----_o~_____,o
J 22536
Pinion Driver
180153
180151
J 21777-40
Pinion Setting Gauge-Rear
Pilot Washer
9876
J 22813-01
Axle Bearing Remover
1508
J 21777-42
Pinion Setting Gauge-Front
Pilot Washer
J 22888-20A
Remover
5114
9878
J 21777-43
J 22912-01
Pinion Setting Gauge-Stud

Assembly Bolt
Rear Pinion Bearing Cone

Remover
994
Rear Drive Axle
Driveline/Axle
Illustration
Illustration
J 25299
J 23597-1

Installer
Pinion Setting Gauge-Arbor
5323
9880
J 23597-11
J 25588
Pinion Setting
Gauge-Gauge Plate
Side Bearing Shim Installer
18()155
9881
J 29609
Rear Pinion Bearing Cup
Installer
J 23765
Axle Bearing Installer
180157
1511
J 39446
ABS Exciter Ring
Protector Kit
J 23771
Axle Oil Seal Installer
180158
1510
J 23911
Pinion Oil Seal Installer
1509
4'-65
466
Driveline/Axle
Rear Drive Axle
BLANK
Brakes
Table of Contents 5-1
Section 5
Brakes
Hydraulic Brakes .............................................. 5-5
Specifications .................................................. 5-5
Brake System Specifications .......................... 5-5
Schematic and Routing Diagrams .................. 5-6
Hydraulic Brakes Schematic References ........ 5-6
Hydraulic Brakes Schematic Icons ................. 5-6
Brake Warning System Schematics ................ 5-7
Component Locator ........................................5-8
Hydraulic Brakes Components ....................... 5-8
Hydraulic Brakes Component Views ............... 5-9
Brake Warning System Check ..................... 5-12
Brake Warning Indicator Always On ............. 5-12
Brake Warning Indicator Inoperative
(With Park Brake Set) .............................. 5-13
(With Low Brake Fluid Level) .................... 5-14
(With Antilock Brake System Failure) ........ 5-14
Brake System Testing .................................. 5-15
Brake System Diagnosis .............................. 5-15
Brake Pedal Travel ...................................... 5-25
Brake Fluid Leaks ........................................ 5-25
Master Cylinder Diagnosis ............................ 5-26
Master Cylinder Reservoir Filling .................. 5-26
Master Cylinder Reservoir Replacement ....... 5-27
Master Cylinder Replacement ....................... 5-28
Master Cylinder Bench Bleeding .................. 5-29
Brake Pedal Replacement ............................ 5-30
Brake Pedal Bracket Replacement ............... 5-34
Brake Pipe Replacement .............................. 5-38
ISO Flares Replacement .............................. 5-38
Brake Hose Replacement - Front ................. 5-39
Brake Hose Replacement - Rear
(Rear Brake Hose) ...................................5-41
(Center, w/o Tractn Cntrl, Disc) ................ 5-42
(Center, w/Traction Control) ...................... 5-44
Hydraulic Brake System Bleeding
(Manual Bleed) .........................................5-46
(Pressure Bleed) ....................................... 5-49
Hydraulic Brake System Flushing
(ABS w/o Traction Control) ....................... 5-53
(ABS w/Traction Control) .......................... 5-55
Vacuum Brake Booster Replacement ........... 5-57

Vacuum Brake Booster Hose
Replacement ............................................ 5-59
Vacuum Brake Booster Check Valve
Replacement ............................................ 5-60
Stoplamp Switch Replacement ..................... 5-61
Stoplamp Switch Adjustment ........................ 5-63
Master Cylinder Description ......................... 5-64
Brake Fluid and Brake Fluid Handling .......... 5-65
Vacuum Brake Booster Description .............. 5-65
Brake Warning System Description .............. 5-66
Brake Warning System Circuit
Description ............................................... 5-67
Disc Brakes .....................................................5-68

Specifications ................................................5-68
Fastener Tightening Specifications (Front) .... 5-68
Fastener Tightening Specifications (Rear) .... 5-68
Component Specifications ............................ 5-68
Brake Rotor Thickness Variation Check ....... 5-69
Brake Rotor Lateral Runout Check ............... 5-69
Brake Rotor Tolerance ................................. 5-69
Brake Pad Inspection ................................... 5-70
Brake Pads Repfacement (Front) ................. 5-70
Brake Pads Replacement (Rear) .................. 5-72
Burnishing Pads and Rotors ........................ 5-73
Brake Caliper Replacement (Rear) ............... 5-73
Brake Caliper Replacement (Front) .............. 5-76
Brake Caliper Inspection .............................. 5-78
Brake Caliper Overhaul (Front) .................... 5-78
Brake Caliper Overhaul (Rear) ..................... 5-81
Brake Caliper Bracket
Replacement (Rear) .................................. 5-84
Brake Caliper Bracket
Replacement (Front) ................................. 5-84
Brake Rotor Replacement (Front) ................. 5-85
Brake Rotor Replacement (Rear) ................. 5-86
Refinishing Brake Rotors (Rear) ................... 5-87
Refinishing Brake Rotors (Front) .................. 5-89
Disc Brakes System Description (Rear) ........ 5-90
Disc Brakes System Description (Front) ....... 5-90

Park Brake ......................................................5-92
Specifications ................................................5-92
Park Brake Shoe Replacement .................... 5-92
Park Brake Shoe Adjustment .......................5-9.3
Park Brake Lever Replacement .................... 5-94
Park Brake Cable Replacement (Front) ........ 5-97
Park Brake Cable Replacement
(Rear W/Disc Brakes) ............................. 5-100
Disabling the Park Brake Automatic
Adjuster .................................................. 5-103
Enabling the Park Brake Automatic
Adjuster .................................................. 5-104
Brake Drum Inspection ............................... 5-104
Backing Plate Replacement ........................ 5-104
Park Brake Actuator Replacement .............. 5-105
System Description ....................................5-106
Antilock Brake System ................................ 5-108
Specifications .......................................... ,... 5-108
Fastener Tightening Specifications ............. 5-108
GM SPO Group Numbers .......................... 5-108
Schematic and Routing Diagrams .............. 5-109
BPMV Hydraulic Flow Chart
.
(Without TCS) ........................................ ,5.:109
BPMV Hydraulic Flow Chart (With Tcsr .... 5-'110
Antilock Brakes System Schematic
References ............................................. 5-111
Schematic Icons ..................................... 5.:111
ABS/TCS Schematics ............. ,................... 5-112
Component Locator .....................................5-120
Antilock Brakes System Components ......... 5-120
Component Views ...................................5-123
Antilock Brakes System Connector
End Views ..............................................5-128
Diagnostic Information and Procedures ..... 5-133
Self-Diagnostics .........................................5-133
Displaying OTCs ........................................5-133
Clearing OTCs ..........................................5-133
lntermittents and Poor Connections ............ 5-133
Initialization Sequence ................................5-133
Scan Tool Diagnostics ...............................5-133
Electromagnetic Interference ...................... 5-135
A Diagnostic System Check .......................5-136
OTC C0035 LF Wheel Speed Circuit
Malfunction .............................................5-139
Range/Performance ................................5-142
OTC C0040 RF Wheel Speed Circuit
Malfunction .............................................5-145
OTC C0045 LR Wheel Speed Circuit
Malfunction ................. ; ..........................5-151
.Brakes
OTC C0046 LR Wheel Speed Circuit
Range/Performance ................................ 5-154
OTC C0050 RR Wheel Speed Circuit
Malfunction ............................................. 5-157
. OTC C0055 Rear Wheel Speed Circuit
Malfunction .............................................5-163
OTC C0056 Rear Wheel Speed CKT
OTC C0060 LF ABS Solenoid #1 Circuit
Malfunction ..............................................5-169
OTC C0065 LF ABS Solenoid #2 Circuit
Malfunction .............................................5-171
OTC C0070 RF ABS Solenoid .#.1 Circuit
Malfunction ......................................~ ....... 5-173
OTC C0075 RF Ass Solenoid #2 Circuit
Malfunction ............................ , ................ 5-175
OTC C0080 LR ABS Solenoid #1 Ci.rcu.it
Malfunction .............................................5-177
OTC C0085 LR ABS Solenoid #2 Circuit
Malfunction .. : ................... :...................... 5-179
OTC C0090 RR ABS Solenoid #1 Circuit
Malfunction ........................... :; .... :... : ....... 181
OTC C0095 RR ABS Solenoid #2 Circuit .
Malfunction .............................. : .. :.......... :5-183
OTC C0100 Rear ABS Solenoid #1 Circuit .
Malfunction ............................................. 5-185
OTC C0105 Rear ABS Solenoid #2 Circuit
Malfunction ...................... :...................... 5-187
OTC C011 O Pump Motor Circuit
Malfunction ....................': ........................ 5-189
OTC C0121 Valve Relay Circuit
Malfunction ......................................... :: :.. 5-192
OTC C0161 ABS/TCS Brake Switch Cir,ci!Jit
Malfunction .............................. ; .............. 5-195
OTC C0166 TCS Priming Line Valve CKT
Malfunction ............................................ :;6~ 198
OTC C0171 TCS Pilot Valve Circuit
Malfunction ................... ; .............. ,.. ,.; ..... 5-200
OTC C0181 Throttle Reduction-Motor CKT
Malfunction ......................................s,, .... 5-202
OTC C0182 Throttle Beduction Motor CKT .
Range Pert ............................................ ,5-205
OTC C0236 TCS RPM Signal Circuit
Malfunction ................................. , ... - ...... 5-207
OTC C0237 TCS Throttle. Position Signal .
Malfunction .......................... :.................. $-21 o
OTC C0238 TCS TP Sensor Comparison
Malfunction .............................................5-212
OTC C0239 TCS Spark Retard Monitoring
Malfunction .............................................S-214
OTC C0245 Wheel Speed Sensor .
Frequency Error ............................ , .......... 5-216
OTC C0266 ADS Controller Malfunction ..... 5-219
OTC C0550 ECU Malfunction ..................... 5-222
OTC C0896 Device Voltage Range/
Performance ........................................... 5-223
OTC C0901 Device #2 Voltage Low ........... 5-225
OTC U1304 Lost Communication with
UART System ............................ :............ 5-227
s~
Brakes
TCS Off Indicator On with No DTC Set ...... 5-229
TCS Off Indicator Inoperative with No
DTC Set .................................................5-231
ASR Indicator On with No DTC Set ........... 5-233
ASR Indicator Inoperative with No
DTC Set ................................................. 5-235
No Communication with EBCM/EBTCM ...... 5-237
ABS Indicator On No DTC Set ................... 5-239
ABS Indicator Inoperative with No
DTC Set ................................................. 5-241
Low Traction Indicator Always On .............. 5-243
Low Traction Indicator Inoperative .............. 5-245
Repair Instructions ......................................5-247
Electronic Brake Control Module (EBCM)
Replacement ...........................................5-247
Accelerator and Servo Control Module
(ASM) Replacement ................................ 5-250
Brake Pressure Modulator Valve
Replacement ........................................... 5-251
Adjuster Assembly Replacement ................ 5-253
Cable Adjustment Procedure ...................... 5-255
Wheel Speed Sensor Replacement
(Rear without Traction Control) ............... 5-255
(Rear with Traction Control) .................... 5-256
Table of Contents
5-3
Wheel Speed Sensor

Replacement (Front) ............................... 5-257
Wheel Speed Sensor Jumper Harness
Replacement (Rear with Traction
Control) .................................................. 5-257
Replacement (Rear without Traction
Control) ..................................................5-258
Replacement (Front Left) ........................ 5-258
Replacement (Front Right) ...................... 5-259
Wheel Speed Sensor Ring Replacement
(Without Traction Control) ....................... 5-260
(With Traction Control) ............................ 5-260
Traction Control Switch Replacement ......... 5-260
Service Precautions ................................... 5-260
General System Description ....................... 5-260
Abbreviations and Definitions ..................... 5-260
Basic Knowledge Required ......................... 5-260
ABS/TCS System Description ..................... 5-261
ABS/TCS System Operation ....................... 5-262
Brakes
BLANK
Brakes
Hydraulic Brakes
Hydraulic Brakes
Specifications
Specification
Metric
English
Brake Master Cylinder Nut
29 Nrn
21 lb ft
Brake Pedal Bracket Bolt/Screw
25N-m
18 lb ft
Application
Brake Pedal Nuts
20N-m
15 lb ft
Brake Pedal Pivot Nut
54N-m
40 lb ft
Clutch Master Cylinder Nut
27N-m
20 lb ft
Front Brake Hose Clip Bolt/Screw
13 N-m
115 lb in
Front Brake Hose Fitting
44N-m
32 lb ft
Master Cylinder Tube Nut
32N-m
24 lb ft
Negative Battery Cable
15 N-m
11 lb ft
Rear Brake (Center) Hose Fitting Bolt/Screw
21 N-m
15 lb ft
Rear Brake Front Pipe to Rear Brake (Center) Hose
15 N-m
. 11 lb ft
Rear Brake Hose Fitting
44N-m
32 lb ft
Rear Brake Pipe to Rear Brake (Center) Hose
24N-m
18 lb ft
Rear Brake Pipe to Rear Brake Hose
17 N-m
13 lb ft
Brake System Specifications
Specification
Application
Brake Pedal Travel (see note)
Metric
English
51-89 mm
2.0-3.5 in
19mm
0.75 in
13mm
0.50 in
Brake Pipe Clearance (Minimum)

Moving Components
Vibrating Components
Hydraulic Brake (Glycol) Fluid
GM P/N 1052535 or equivalent DOT-3 fluid
Note: Brake pedal travel maximum with 445 N (100 lb) of force applied to the pedal with the engine running at idle.
5-5
5-6
Hydraulic Brakes
Brakes

Hydraulic Brakes Schematic References
Section Number - Subsection Name
Fuse Block Details Cell 11
8-Wiring Systems
Ground Distribution Cell 14
8-Wiring Systems
Power DiWfipution Cell 1O
8-Wiring Systems
Release Systems Cell 134
8--::sody Rear End
Hydraulic Brakes Schematic Icons

Icon
Icon Definition
19384
Brake Warning System Schematics
!Ho<IORIJN,""'T"'o,STAJrr!
r - - -
I Power .
II
""''
- - - - - - - - .Electronic
I
Brake
Brake
I
.
Indicator I Control
IP
Fuse
I Block
II
- - - - ,
GAGES
I
.....
"'
<OA
II
" ' I
____
- - - - - ~;PNK 39
- - - - - - , Instrument
cluster
Release
Syatema
Cell 134
'\
.......
0.35 TAN/WHT
I 33
-J-,
D ,lC2
r -
I Park
I Brake
I Input
,. _ _ _ _
I Daytime
Running
I lamps (DAL)
I
.. Module
EIC2
0.35 LT BL~ 1134
rz]
Park
Brake
Switch
(Closedwl
-=- park brake on)
AS
rlf:
P100
0.35 TAN,WH; 33
C200A
C200D
Bek
f 1.:~1on
,~~
0.35 TAN/WHT
133
o.35111.K eao
r- - -
C2000
C200B
"'
Indicator
Lamp Driver
Module
0.35 TAN/WHT133
82
el
I T
(Q)) (0)
lndlomlof
~--------~--""
A10
0.35 TAN~T 133
8228
!Esc
0.35 YEL/BLK 1471
: ,:,... .
Symbol For Z44t
0.35 TAN/WHT I 33
!Loe I
P100
0.35 PNK 39
NKl 39
lndicatorl,
Gagee
I Module
I (EBCM)
1
I ,A
~------~
16JC1
0.35 YEL/BLK 1471
8206
A5
---I""""
I
I
IN~- I
~- 0.35P
S155t- - ,
s21e
l,so! 5*" I
0.35 BU< 1
~BLK
.,Brake
I
I Fluid
I
I ---:11 Level
a.. - ;.i Indicator
$113t--J
8 '( Sensor
3 BU< I 150
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a.
"'I
c
c,
m
"'I
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I 3BLK 850
''
''
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s
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G200
507601
I .......
5-8
Hydraulic Brakes
Brakes
Component Locator
Hydraulic Brakes Components
Name
Brake Fluid Level
Indicator Sensor
Brake Malfunction
Indicator Lamp Driver
Module
Location
Part of the master cylinder
Behind the center of the IP, near the HVAC
control
Daytime Running Lamps Mounted behind the radio and the HVAC
(DAL) Module
control, left of the IP compartment
Mounted with the brake pressure
Electronic Brake Control
modulator valve (BPMV) on top of the left
Module (EBCM)
front frame rail
Locator View
-
Connector End View

-
HVAC Component Views

Connector End Views
Instrument Cluster
Component Views
Lighting Systems
Connector End Views

Connector End Views
On the left end of the IP carrier
Instrument Cluster
Component Views
Instrument Cluster
On the left side of the IP
Instrument Cluster
Component Views
Park Brake Switch
Below the center console, at the base of

the park brake lever
Harness Routing Views
C200B (18 cavities)
Forward lamp to IP harness, between the

left kick panel and the steering column

End Views
C200D (48 cavities)
Part of the IP harness, between the left

kick panel and the steering column

End Views
G106
Attached to the top left side of the radiator

support
G200
Near the left A pillar bolted to the IP

mounting stud behind the kick panel
P100
Left side in the dash panel, engine to the

8113
In the forward lamp harness approximately

7 cm (2.8 in) from the engine coolant
fans/cruise control module breakout
8155
In the forward lamp harness,

approximately 27 cm (10.6 in) from the
engine coolant fans/cruise control module
breakout
8206
In the IP harness. at the rear compartment

lid release relay breakout
8216
In the IP harness, main branch,

approximately 10 cm (3.9 in) from the
instrument cluster breakout
8228
In the IP harness, main branch,

approximately 20 cm (7.9 in) from the rear
compartment lid release relay breakout
IP Fuse Block
Instrument Cluster
Component Views
Brakes
Hydraulic Brakes 5-9
Hydraulic Brakes Component Views

Under Console, Right Side (Automatic Transmission)
508183
Legend
(1) Shift Control Lever
(2) Brake Transmission Shift Interrupt (BTSI)
Solenoid
(3) Park/Neutral Position Switch
(4) Park Brake

5-10
Hydraulic Brakes
Brakes
Center of the Instrument Panel
11
510598
Legend
(01)
(02)
(03)
(04)
HVAC Control Connector C3

IP Wiring Harness
Brake Malfunction Indicator Lamp Driver
Module
(05) HVAC Control Connector C4
(06) Rear Defogger Switch
(07)
(08)
(09)
(10)
(11)
Blower Switch
HVAC Control
HVAC Control Selector Switch
Rear Defogger Timer/Relay
Hydraulic Brakes
5-11
Under Console, Left Side (Manual Transmission)
508189
Legend

(2) Park Brake
(3) G202
(4) Seat Belt Switch Connector
(5) Inflatable Restraint Sensing and Diagnostic
(SOM) Module
(6) Ash Tray Lamp
IP Wiring Harness
Convertible Top Switch Connector
(9) Cigar Lighter Connector
( 10) Traction Control Switch Connector (Pont)
( 11) Auxiliary Power Connector
(7)
(8)
5-12
Brakes
Hydraulic Brakes

Brake Warning System Check
Step
Action
Normal Result(s)
Abnormal Result(s)*
1. Release the park brake.

RUN position, with the
engine off.
The BRAKE indicator lights for

approximately 3 seconds, then
goes out.
The BRAKE indicator remains ON

with the ignition switch in RUN and
the park brake released. Refer to
Brake Warning Indicator Always On.
The BRAKE indicator lights.

RUN position.
2. Apply the park brake.
The BRAKE indicator does not light

with the park brake set. Refer to
(With Park Brake Set).
Brake fluid level low, or ABS failure.
The BRAKE indicator lights.
The BRAKE indicator does not

light with a low brake fluid level.
Refer to Brake Warning Indicator
Inoperative (With Low Brake
Fluid Level).
The BRAKE indicator does not
light with Antilock Brake System
failure. Refer to Brake Warning
Indicator Inoperative (With
Antilock Brake System Failure).
* Refer to the appropriate symptom diagnostic table for the applicable abnormal result.
Brake Warning Indicator Always On

Step
Action
Value(s)
Yes
No
Important:
In order to prevent misdiagnosis. inspect for electronic brake control module (EBCM) diagnostic trouble codes (DTCs) .
Refer to ABS A Diagnostic System Check.
Inspect the master brake cylinder fluid level prior to performing this diagnosis.
1. Turn the ignition switch to RUN.
2. Backprobe with a fused jumper between the
electronic brake control module (EBCM) connector C1
terminal 16 and ground.
Did the BRAKE indicator go out?
Backprobe with a fused jumper between the brake

malfunction indicator lamp driver module connector
terminal C and ground.
Disconnect the brake malfunction indicator lamp driver

module.
Disconnect the brake fluid level indicator sensor.

Disconnect the park brake switch.

Disconnect the daytime running lights (DRL) module

connector C2.
1. Inspect for a short to ground in CKT 1134.

2. If OK, replace the DRL module.
Go to ABS A
Diagnostic
System Check
Go to Step2
Go to Step 9
Go to Step 3
Go to Step 10
Go to Step 4
Go to Step 11
Go to Step 5
Go to Step 12
Go to Step 6
Go to Step 7
Go to Step 8
System OK
Brakes

Brake Warning Indicator Always On (cont'd)
Step
Action
1. Inspect for a short to ground in CKT 33, including the

rear compartment lid release relay if equipped with a
manual transmission.
2. If OK, replace the instrument cluster. Refer to IP
Cluster Replacement.
Value(s)
Yes
No
System OK
1. Inspect for a short to voltage in CKT 1471 between

the lamp driver module and the electronic brake
control module (EBCM).
2. If OK, repair an open or a poor connection in

CKT 1471 between the lamp driver module and
the EBCM.
System OK
10
Replace the lamp driver module.

11
Replace the park brake fluid level indicator sensor.

12
1. Inspect the park brake switch for mechanical

interference.
2. If OK, replace the switch.
System OK
System OK
Step
System OK
Brake Warning Indicator Inoperative (With Park Brake Set)

Action
Yatue(s)
Yes
2. Disconnect the park brake switch.
3. Connect a fused jumper from the park brake switch
connector to ground.
Does the BRAKE indicator light?
1. Disconnect the daytime running lights module (DAL)

connector C2.
2. Connect a fused jumper from DRL module
connector C2 terminal D to ground.
Repair an open in CKT 33 between the DRL module

and 8228.
No
Go to Step4
Go to Step2
Go to Steps
Go to Step 3
System OK
1. Inspect for a poor connection at the park brake

switch.
4
2. Inspect for mechanical interference at the park brake

switch.
3. If OK, replace the park brake switch.

1. Inspect for an open in CKT 1134 between the park

brake switch and the DRL module.
2. Inspect for a poor connection at the DRL module
connector C2.
3. If OK, replace the DRL module.
System OK
System OK
Brakes
5-14 Hydraulic Brakes

Brake Warning Indicator. Inoperative (With Low Brake Fluid Level)
Step
Action
Value(s)
1. Disconnect the brake fluid level indicator sensor.

2. Connect a fused jumper from sensor connector
terminal A to ground.
Repair an open or a poor connection in CKT 33 between

the brake fluid level indicator sensor and 8228.
1. Inspect for a poor connection at the brake fluid level

indicator sensor.
2. Inspect for an open in CKT 150 between the sensor
and 8155.
3. If OK, replace the brake fluid level indicator sensor.
No.
Yes
Go to Step 3
Go to Step2
System OK
System OK
Brake Warning Indicator Inoperative (With Antilock Brake System Failure)

Value(s)
Step
Action
1. Disconnect the brake malfunction indicator lamp

driver module.
2. Connect a fused jumper from the lamp driver module
connector terminal E to ground.
Connect a fused jumper from the lamp driver module

connector terminal E to terminal D.
Connect a test lamp from the lamp driver module

connector terminal B to terminal D.
Does the test lamp light?
Disconnect the electronic brake control module (EBCM)

connector C1.
1. Inspect for a short to ground in CKT 1471 between

the lamp driver module and the EBCM.
2. If OK, replace the lamp driver module.
Repair an open in CKT 33 between the lamp driver

module and 8228.

module and 8216.

module and 8206.
Yes
No
Go to Step2
Go to Step6
Go to Step 3
Go to Step 7
Go to Step4
Go to StepB
Go to ABS A
Diagnostic
System Check
Go to Steps
System OK
System OK
System OK
System OK
Hydraulic Brakes
Brakes
Brake System Testing
Test the brakes on a roadway that meets all of the
Dry
Clean
Reasonably smooth
Level
Test the brakes at different vehicle speeds with both
light and heavy brake pedal force.
515
Do not test the brakes on a roadway with the following

conditions because the tires will not grip the road
equally:
Wet
Greasy
Covered with loose dirt
Do not test the brakes on a crowned roadway because
the weight of the vehicle will be thrown toward the
wheels on one side.
Do not test the brakes on a rough roadway because
the wheels will tend to bounce.
Brake System Diagnosis

Symptom
Improper Brake Pedal Travel
Causes
Leaking brake line or connection. Refer to Brake
Fluid Leaks.
Leaking piston seal. Refer to Brake Caliper Overhaul
(Front) or Brake Caliper Overhaul (Rear).
Leaking master cylinder (internal). Replace the master
cylinder. Refer to Master Cylinder Replacement.
Air in brake system. Refer to Hydraulic Brake System
Bleeding (Manual Bleed) or Hydraulic Brake System
Bleeding (Pressure Bleed).
Contaminated or improper brake fluid. Refer to Brake
Fluid and Brake Fluid Handling.
Leaking vacuum or booster system. Refer to Vacuum
Brake Booster Replacement.
Damaged vacuum booster. Refer to Vacuum Brake
Booster Replacement.
Uneven brake lining wear. Refer to Brake Pad
Inspection in Disc Brakes.
Brake lining damage by abuse. Refer to Brake Pad
Improper thickness variation in rotor. Refer to Brake
Rotor Thickness Variation Check.
Excessive lateral runout in rotor. Refer to Brake Rotor
Lateral Runout Check.
Brake assembly attachments loose (including splash
shield). Refer to Brake Caliper Inspection in
Disc Brakes.
Improperly adjusted stoplamp switch or cruise control
vacuum dump. Refer to Stop/amp Switch Adjustment.
Incorrect vacuum booster pushrod length. Refer to
Vacuum Brake Booster Replacement in
Hydraulic Brakes.
Low brake fluid. Refer to Master Cylinder Reservoir
Filling.
Improper rear brake adjustment. Refer to Park Brake
Shoe Adjustment in Parl< Brake.
Low engine vacuum. Refer to Engine Compression Test
in Engine Mechanical-3.BL or Engine Compression Test
in Engine Mechanical-5.7L.
5-16
Hydraulic. Brakes
Brakes
Brake System Diagnosis {cont'd)
Symptom
Brake Pedal Travel Gradually Increases
Causes

Fluid Leaks.
Leaking master cylinder (internal). Replace master
Restricted passage in the vacuum booster. Refer to

Vacuum Brake Booster Replacement.
Restrictad brake fluid passage. Refer to Hydraulic Brake
System Flushing (ABS w!o Traction Control) or Hydraulic.
Brake System Flushing (ABS w/Traction Control) in
Hydraulic Brakes.
Excessive Brake Pedal Effort

Brake Booster Replacement in Hydraulic Brakes.
Vacuum Brake Booster Replacement in Hydraulic
Brakes.
Worn out brake lining. Refer to Brake Pad Inspection in
Disc Brakes.
Glazed brake lining. Refer to Brake Pad Inspection in
Disc Brakes.
Incorrect brake lining material. Refer to Brake Pad
Contaminated brake lining. Refer to Brake Pad
Improper rotor surface finish. Refer to Refinishing Brake
Rotors (Rear) or Refinishing Brake Rotors (Front) in
Disc Brakes.
Restricted brake fluid passage. Refer to Hydraulic Brake

System Flushing (ABS w/o Traction Control) or Hydraulic
Hydraulic Brakes.
Brake pedal linkage interference or binding. Refer to
Brake Pedal Travel in Hydraulic Brakes.
Operator riding the brake pedal. Refer to Brake Pad
in Engine Mechanical-3.8 L or Engine Compression Test
in Engine Mechanical-5. 7L.
Excessive vehicle loading. Refer to Brake Pad
Rotor corroded. Refer to Brake Caliper Inspection in
Disc Brakes.
ABS modulator RR piston seized. Refer to Brake
Pressure Modulator Valve Replacement in Antilock
Brake System.
Hydraulic Brakes
Brakes
5-17
Brake System Diagnosis (cont'd)

Symptom
Excessive Braking Action
Causes

Disc Brakes.
Disc Brakes.
Scored rotor. Refer to Refinishing Brake Rotors (Front).
shield). Refer to Brake Caliper Inspection in Disc
Brakes.
Poor drum surface finish.
Brakes Slow To Respond
Air in the brake system. Refer to Hydraulic Brake

System Bleeding (Manual Bleed) or Hydraulic Brake
System Bleeding (Pressure Bleed).
Brake Booster Replacement in Hydraulic Brakes.
Brakes.
Disc Brakes.
Restncted brake fluid passage. Refer to Hydraulic Brake
System Flushing (ABS wlo Traction Control) or Hydraulic
Hydraulic Brakes.
Sticking caliper or caliper pistons. Refer to Brake Caliper
Overhaul (Front) or Brake Caliper Overhaul (Rear).
in Engine Mechanical-3.8 L or Engine Compression Test
in Engine Mechanical-5.?L.
5-18
Hydraulic Brakes
Bfakes
Caus~s
Symptom
Brakes Slow To Release

Brakes.
Hydraulic Brakes.
'
Sticking caliper or caliper pistons. Refer to Brake Caliper '

Parking brake not releasing. Refer to Park Brake Shoe
Adjustment in Park Brake.
Caliper to knuckle clearance. Refer to Brake Caliper
Brakes Drag

Lateral Runout Check a.
Brakes.
Brake System Flushing (ABS w!Traction Control) in
Hydraulic Brakes.

Brakes.
I
I'
Loose front suspension parts. Refer to Front Suspension

Components in Front Suspension.
Operator riding the brake pedal. Refer to Brake Pad
Sticking caliper or caliper pistons. Refer' to Brake Caliper
Adjustment in Parle Brake.
Shoe Adjustment in Park Brake.
Parking brake cables seized. Refer to Park Brake Shoe
Brakes
Hydraulic Brakes 5.. 19

Symptom
Uneven Braking Action (Side to Side)
Causes
Disc Brakes.
Disc Brakes.
Disc Brakes.
Scored rotor. Refer to Refinishing Brake Rotors (Front)
or Refinishing Brake Rotors (Rear).
Brakes.
Brake System Flushing (ABS w!Traction Control) in
Hydraulic Brakes.
Incorrect front wheel alignment. Refer to Preliminary
Alignment Inspection in Wheel Alignment.
Incorrect tire pressure. Refer to Tire and Wheel
Specifications in Tires and Wheels.
Rotor corroded. Refer to Refinishing Brake Rotors
(Rear) or Refinishing Brake Rotors (Front) in Disc
Brakes.
5-20
Hydraulic Brakes
Brakes
Symptom
Uneven Braking Action (F~?nt to Rear)
Causes

Fluid Leaks.
Disc Brakes.

Disc Brakes.
Disc Brakes.
Brakes.
Hydraulic Brakes.
Filling.
Excessive Vehicle Loading. Refer to Brake Pad
Brake System.
Brakes

Symptom
Causes
Scraping Noise from Brakes

Disc Brakes.
Brakes.
Brakes.
Brakes Squeak without Application

Disc Brakes.
Disc Brakes.
Scored Rotor. Refer to Refinishing Brake Rotors (Front)
Brakes.
Brakes Squeak During Application

Disc Brakes.
Disc Brakes.
Brakes.
522
Brakes
Hydraulic Brakes
Brake"System :.Diagnosis (cont'd)
Symptom
',,
Causes
'
Brakes Chatter (Roughness)
Scored rotor. Refer to Brake Caliper Inspection in

Disc Brakes.
shield). Refer to Brake Caliper Inspection in
Disc Brakes.
'
Loose front suspension parts. Refer to OTC P0138

H02S Circuit High Voltage Sensor2 in Front
Suspension.
Out-of-balance wheel assembly. Refer to Balancing
Tires and Wheels in Vibration Diagnosis and Correction.
Improperly torqued wheel nuts. Refer to Wheel
Rotor corroded. Refer to Brake Pad Inspection in
Hydraulic Brakes.
Grease or dirt on the rotor. Refer to Brake Pad
Brakes Groan at the End of Stop
Incorrect lining material. Refer to Brake Pad Inspection

in Disc Brakes.
Grease or dirt on the rotor. Refer to Brake Pad
1,
Brake Warning Lamp ON

Ruid Leaks.
Ruid and Brake Ruid Handling.
Parking brake switch circuit grounded. Refer to Park
Brake Lever Replacement in Park Brake.
Parking brake not releasing. Refer to Parl< Brake Shoe
Filling.
''
Hydraulic Brakes
Brakes
5-23

Symptom
Premature Lining Wear Out
Causes

Fluid Leaks.
in Disc Brakes.
Brake lining damaged by abuse. Refer to Brake Pad
Brakes.
Operator riding brake pedal. Refer to Brake Pad
Parking brake cable seized. Refer to Park Brake Shoe
Brake System.
Parking Brake Won't Hold

Disc Brakes.
in Disc Brakes.
Brake lining damaged by abuse. Refer to Brake Pad
Disc Brakes.
Parking Brake Won't Release

5-24
Brakes
Hydraulic Brakes
Symptom
Brake Pulsation
Causes

in Disc Brakes.
Brake linings damaged by abuse. Refer to Brake Pad
Loose front suspension parts. Refer to OTC P0138
H02S Circuit High Voltage Sensor2 in Front
Suspension.
Out-of-balance wheel assembly. Refer to Balancing
Tires and Wheels in Vibration Diagnosis and Correction.
Improperly torqued wheel nuts. Refer to Wheel
(Rear) or Refinishing Brake Rotors (Front) in Hydraulic
Brakes.
Brake Pulls

Disc Brakes.
in Disc Brakes.
Brake linings damaged by abuse. Refer to Brake Pad
Hydraulic Brakes.
Hydraulic Brakes.
Incorrect front wheel alignment. Refer to Preliminary
Alignment Inspection in Wheel Alignment.
Incorrect tire pressure. Refer to Tire and Wheel
Specifications in Tires and Wheels.
Brakes.
Brakes
Brake Pedal Travel
Tools Required
J 28662Brake Pedal Effort Gage
One of .the following conditions may be the cause of
most low brake pedal problems:
Air in the brake system. Bleed the system until the
air is purged. Refer to Hydraulic Brake System
Bleeding (Manual Bleed) or Hydraulic Brake
System Bleeding (Pressure Bleed).
Misadjusted rear drum brakes. Inspect the rear
brake adjustment.
The following conditions may be other less frequent
causes of excessive brake pedal travel:
Incorrect pushrod length
Malfunctioning rear brake shoe adjusters
Excessively worn pads
Brake hydraulic system leakage
One of the following conditions is usually the cause of
high brake pedal .effort problems:
Low engine vacuum
Vacuum leak
Improperly functioning vacuum booster
1. Install the J 28662 onto the brake pedal.
2. Hook the end.of the tape measure over the top
edge of the pedal.
3. Measure the distance from the top edge of the
pedal to the rim of the steering wheel.
4. Block the tires and the wheels.
5. Run the engine at idle.
6. Put the range selector lever in NEUTRAL.
7. Apply 445 N (100 lb) of force to the brake pedal.
8. Remeasure t/le distance from the top edge of
the pedaf to the rim of the steering wheel. The
difference between both of the readings is
the actual brake pedal travel. The brake pedal
travel should be between 51-89 mm (2.0-3.5 in).
9. If the brake pedal travel is more than
specifications, refer to Improper Brake Pedal
Travel in Brake System Diagnosis.
Brake Fluid Leaks

1. Run the engine at idle.
2. Put the range selector lever in NEUTRAL.
3. Depress the brake pedal. Hold the brake pedal
with constant foot pressure.
Hydraulic Brakes
5-25
4. If the pedal gradually falls away with constant

pressure, the brake hydraulic system may be
leaking. Inspect the hydraulic system for
any suspected leaks.
5. Inspect the master cylinder fluid level.
A slight drop in the master cylinder reservoir
level results from normal pad wear. The
reservoir may be as low as 25.4 mm (1.0 in)
from the top if the pads are worn. This
condition is not abnormal.
An abnormally low level in the reservoir
indicates a leak in the system. The brake
hydraulic system may be leaking either
internally or externally. Refer to Brake System
Diagnosis. The system may appear to pass
this test but still have a slight leakage.
6. Inspect the brake pipe and the brake hose
connections for brake fluid leaks.
7. If any leaks are found, replace the hose or

the pipe.
8. If any hoses or pipes are replaced, inspect the
connecting brake component for damage. If
damage is found. rebuild or replace the
component.
9. Inspect the brake caliper boots and rear wheel
cylinder boots for leaks.
10. If any leaks are found. rebuild or replace the part
in question. Refer to Brake Caliper Overhaul
Brake Hose and Pipe Inspection

Notice: Do not allow components to hang from the
flexible brake hoses as damage to the hoses
may occur. Some brake hoses have protective rings
or covers to prevent direct contact of the hose
with other chassis parts. Besides causing possible
structural damage to the hose, excessive tension could
cause the hose rings to move out of their proper
locations.
Inspect the brake hoses at least twice a year for the
Road hazard damage
Cracks
Chafing of the outer cover
Leaks
Blisters
Use a light and a mirror for an adequate inspection.
Replace any hoses with any of the above conditions.
S-26
Hydraulic Brakes
Brakes
Master Cylinder Diagnosis
Brake Master Cylinder Check
1. Inspect for cracks in the master cylinder body .
2. Inspect for brake fluid around the master cylinder.
A leak exists if there is at least one drop
of fluid.
A damp condition is not abnormal.
3. Inspect for binding brake pedal linkage.
4. If the pedal linkage is correct, remove the master
cylinder reservoir cap. Inspect for the following
conditions:
A distorted or swollen master cylinder reservoir
diaphragm
Swollen primary or secondary piston seal(s)
5. If a swollen diaphragm or secondary piston seal(s)
are found, substandard or contaminated brake
fluid is the probable cause. If the fluid is
contaminated, use the following procedure:
5.1 . Disassemble and clean the serviceable
components.
5.2. Replace all of the non-serviceable rubber
components.
5.3. Flush all ofthe brake pipes and the hoses.
In order to diagnose malfunctions in the master
cylinder, refer to Brake System Diagnosis.
Repair Instructions
Master Cylinder Reservoir Filling
Filling The Master Cylinder Reservoir
182425
Caution: Use only SUPREME 11 or equivalent

DOT 3 brake fluid from a clean, sealed container.
Do not use fluid from an open container that
may be contaminated with water. Improper or
contaminated fluid will result in damage to
components or loss of bralclng, with possible
personal injury.
Ensure that the master cylinder reservoir (2) is kept
properly filled. An adequate reserve of brake fluid will
prevent air from entering the brake hydraulic system.
However, because heat absorbed from the brakes and
the engine expands the brake fluid, do not overfill
the reservoir.
A drop in the brake fluid level is normal as the pads
wear. If the master cylinder reservoir is filled before
new pads are installed, brake fluid may spill over once
the new pads are in place. Unless there is a leak in
the brake hydraulic system, or the brake hydraulic
system has been serviced, do not top off the master
cylinder reservoir.
Clean the master cylinder reservoir cap thoroughly
before removal in order to avoid contaminating
the reservoir. Remove the reservoir cap and the
reservoir diaphragm.
Add brake fluid to the reservoir in order to bring the
fluid level to the fill line. The fill line is located
inside the neck of the reservoir fill opening (1 ).
B.rakes
Hydraulic Brakes
5-27
Master Cylinder Reservoir Replacement

1
Removal Procedure
1. Remove the master cylinder (5). Refer to Master
Cylinder Replacement
Notice: Do not overtighten vise, or damage to the
master cylinder will result.
2. Clamp the flange on the master cylinder body
in a vise.
3. Drive out the master cylinder reservoir pins (13).
Use a 1/8-inch punch.
4. Remove the master cylinder reservoir (3) by
pulling the reservoir straight up and away from
the cylinder body.
5. Remove the master cylinder reservoir
grommets (14) from the grooves in the reservoir.
Discard the grommets.
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.
182445
1. Lubricate the new grommets (14) and the grooves
in the reservoir. Use clean brake fluid.
2. Insert the grommets into the grooves in the
reservoir. Verify that the grommets are properly
seated.
3. Connect the reservoir to the master cylinder body.
Use your hand in order to press the reservoir
straight down into the cylinder body.
4. Drive in the master cylinder reservoir pins in order
to retain the reservoir.
5. Install the master cylinder. Refer to Master
Cylinder Replacement
182445
5-28
Brakes
Hydraulic Brakes
Master Cylinder Replacement
Removal Procedure
1. Remove the brake fluid from the reservoir.

Discard the old fluid.
2. Remove the brake combination valve pipes in
order to prevent fluid loss and contamination.
3. Remove the master cylinder nuts.
4. Remove the master cylinder.
222987
1. Bench bleed the master cylinder. Refer to Master
Cylinder Bench Bleeding
2. Install the master cylinder.
Notices.
3. Install the master cylinder nuts.
222901
Tighten
Tighten the brake master cylinder nuts to
29 N,m (21 lb ft).
4. Fill the master cylinder reservoir. Refer to Master
Cylinder Reservoir Filling.
5. Install the brake combination valve pipes onto the
master cylinder one at a time. Complete the
following steps:
5.1. Remove the locally fabricated plugs.
5.2. Install the brake pipe fitting finger tight.
5.3. Have an assistant depress the brake pedal
in order to remove air at the loose brake
pipe fittings.
Tighten
Tighten the brake combination valve pipe
fittings to 32 Nm (24 lb ft).
5.4. Have an assistant quickly release and
pump the brake pedal several times.
5.5. If the brake pedal remains high and firm,
start the vehicle. If the brake pedal still
feels firm, test drive the vehicle.
If the brake pedal feels soft or spongy,
bleed the entire brake hydraulic system.
Refer to Hydraulic Brake System Bleeding
(Manual Bleed)
Brakes
Master Cylinder Bench Bleeding
Brake Master Cylinder Bench Bleeding
Materials Required
One 11 x 1 .5 mm tube fitting nut
One 12 x 1 .0 mm tube fitting nut
Two pieces of 4.75 mm (0.187 in) brake pipe,
approximately 50 mm (1.969 in) long
1. Fabricate two plugs in order to plug the master
cylinder outlet ports. Use the following procedure:
1.1 . Fashion two ISO flares on one end of
each tube. Refer to ISO Flares
Replacement.
1.2. Install the nuts onto the flared tubes.
1.3. One at a time, place approximately 13 mm
(0.51 in) of the unflared tube end in a vise.
1.4. Compress the end of the tube with the vise
in order to collapse the tube.
1.5. Bend the tube to a 90 degree angle.
1.6. Remove the tube from the vise.
1.7. Put the tube back in the vise. Fold the tube
end against itself in order to form an
air-tight seal.
2. Plug the master cylinder outlet ports with the
fabricated plugs.
Notice: Do not overtighten vise, or damage to the

master cylinder will result.
Hydraulic Brakes 5~29 \

3. Place shop towels around the. master cylinder in
order to absorb the bled fluid.
4. Mount the master cylinder in a vise. Tilt the front
end of the master cylinder down slightly.
5. Fill the master cylinder with clean brake fluid.
Important: As air bleeds from the brake master
cylinder, resistance to primary piston strokes will
increase, not allowing a full stroke.
6. Using a tool with a smooth, rounded end, 'stroke
the primary piston about 25 mm (0.948 in)
several times.
7. Reposition the master cylinder in the vise. Tilt the
master cylinder slightly up.
8. Stroke the primary piston several times.
9. Reposition the brake master cylinder in the vise.
Level the master cylinder.
10. Loosen the fabricated plugs one at a time.
11. Push the primary piston into the master cylinder
bore in order to force the air out of the master
cylinder.
Important: In order to prevent air from sucking back
into the master cylinder, tighten the fabricated
plugs before allowing the primary piston to return to its
original position.
12. Repeat the previous 6 steps until no air escapes
past the plugs.
13. Install the master cylinder into the vehicle. Refer
to Master Cylinder Replacement
5-30
Brakes
Hydraulic.Brakes
Brake Pedal. Replacement
Removal Procedure
Caution: Refer to Battery Disconnect Caution in

Cautions and Notices.
1. Disconnect the negative battery cable.
2. Remove the left side instrument panel insulator.
Refer tolnsulator Replacement - IP (Left Side) in
lnstrumentPanel, Gauges, and Console.
3. Remove the Electronic Brake Control Module
(EBCM). Refer to Electronic Brake Control
Module (EBCM) Replacement in Antilock Brakes.
4. Remove the following components from the brake
pedal pin (1 O):
The brake pedal pushrod pin retainer (7)
The brake pedal pushrod (8)
The ,brake pedal pushrod washer (11)
182817
Brakes
Hydraulic Brakes
5-31
5. Remove the brake pedal pivot nut (12).

6. Slide out the brake pedal pivot bolt/screw (2)
partway in order to give enough clearance in
order to remove the brake pedal (7).
7. Remove the brake pedal (7).
8. Remove the brake pedal pivot bushings (10) from
the brake pedal (7), if necessary.
9. Remove the brake pedal pivot spacer (8) from the
brake pedal (7), if necessary.
10. Clean all the components. Use a suitable solvent.
11. Inspect all the components for wear. Repair or
replace the components as needed.
5
182814
S:.32
Brakes
Hydraulic Brakes
1. Install the brake pedal pivot spacer {8) to the

brake pedal (7), if removed.
2. Install the brake pedal pivot bushings (10) to the
brake pedal (7), if removed.
-
3. Install the brake pedal (7).

4. Lubricate the brake pedal pivot bolt/screw (2) with
chassis lubricant.
Notice: Refer to Fastener Notice in Cautions arid

Nbtices.
5. Install the brake pedal pivot bolt/screw (2) and the
brake pedal pivot nut (12}: -
Tighten
Tighten the brake pedal pivot nut (12) to
54 N-m (40 lb ft).
182814
Brakes
Hydraulic Brakes
5-33.
6. Lubricate the brake pedal:pin (10) with chassis .,

lubricant.
7. Install the following components to the brake
pedal pin (10):
The brake pedal pushrod washer (11)
8. Install the Electronic Brake Control Module
(EBCM). Refer to Electronic Brake Control Module
(8CM) Replacement in Antilock_Brakes.
9. Install the left side instrument panel insulator.
in Instrument Panel, Gauges, and Console.
10. Connect the negative battery cable.
Tighten
Tighten the negative battery cable to
15 N-m (11 lb ft).
11 . Adjust the following components. Refer to
Stop/amp Switch Adjustment.
Cruise control release switch
Stoplamp and TCC switch
Cruise control clutch switch or cruise control
clutch anticipate switch
182817
5-34
Brakes
Hydraulic Brakes
Brake Pedal Bracket Replacement
Removal Procedure
Caution: Refer to Battery Disconnect Caution in

Cautions and Notices.
1. Disconnect the negative battery cable.
Instrument Panel, Gauges, and Console.
3. Remove the Electronic Brake Control Module
(EBCM). Refer to Electronic Brake Control
Module (EBCM) Replacement in Antilock Brakes.
4. Remove the following components from the pedal
with the bracket. Refer to Stop/amp Switch
Replacement.
Stoplamp and Torque Converter Clutch (TCC)
switch
5. Remove the clutch start switch from the brake
pedal with the bracket, if equipped with a
manual transmission.
6. Remove the accelerator pedal (11 ). Refer to
Accelerator Controls Pedal Replacement or
Accelerator Controls Pedal Replacement in Engine
Controls.
7. Remove the following components from the brake
pedal pin (9):
The brake pedal pushrod washer (4)
11
5
182814
Brakes
Hydraulic Brakes
5-35
8. Remove the clutch pedal lever pin retainer (4) and

the clutch pushrod (5) from the clutch pedal
pin (6), if equipped with a manual transmission.
9. Remove the brake pedal nuts (3) and the brake
pedal bracket bolts/screws (1 ).
10. Remove the clutch master cylinder nuts (13), if
equipped with a manual transmission.
11. Remove the brake pedal with the bracket (16).
182817
5-36
Brakes
Hydraulic Brakes
Important: When installing the brake pedal with the

bracket, ensure that the dash panel insulator material
does not get pinched between the brake pedal and
the dash panel.
1. Install the brake pedal with the bracket (13) .
5
182814
Brakes
2. Install the clutch master cylinder nuts (13), if


Notices.
3. Install the brake pedal nuts (3) and brake pedal
bracket bolts/screws (1 ).
4.
5.
6.
7.
8.
9.
1O.
11.
12.
Hydraulic Brakes 5~37
Tighten
Tighten the clutch master cylinder nuts (13) to
27 Nm (20 lb ft), if equipped with a manual
transmission.
Tighten the brake pedal nuts (3) to 20 N-m
( 15 lb ft). Use the following sequence:
Inboard upper, Outboard lower, Outboard
upper, Inboard lower.
Tighten the brake pedal bracket
bolts/screws (1) to 25 N-m (18 lb ft).
Install the accelerator pedal (14). Refer to
Accelerator Controls Pedal Replacement or
Accelerator Controls Pedal Replacement in Engine
Controls.
Lubricate the clutch pedal pin (6) with chassis
lubricant.
Install the clutch pedal lever pin retainer (4) and
the clutch master cylinder pushrod (5) to the
clutch pedal pin (6), if equipped with a manual
transmission.
Lubricate the brake pedal pin (10) with chassis
lubricant.
Install the following components to the brake
pedal pin:
The brake pedal pushrod pin retainer
The brake pedal pushrod
The brake pedal pushrod washer
Install the following components to the pedal with
the bracket (16). Refer to Stop/amp Switch
Replacement.
Install the Electronic Brake Control Module
(EBCM). Refer to Electronic Brake Control Module
(EBCM) Replacement in Antilock Brakes.
Install the clutch start switch to the brake pedal
with the bracket, if equipped with a manual
transmission.
Install the left side instrument panel insulator.
in Instrument Panel, Gauges, and Console .
182817
5-38 Hydraulic Brakes
Brakes
13. Connect the negative battery cable.
Tighten
Tighten the negative battery cable to
15 Nm (11 lb ft).
14. Adjust the following components. Refer to
Brake Pipe Replacement

Refer to Master Cylinder Description Master
Cylinder Description
for an illustration depicting the brake pipe layout
and locations. Brake pipes that are to be
locally fabricated, should only be ISO flared, and
not double lap flared. For more information on
ISO flares, refer to ISO Flares Replacement ISO
Flare Replacement.
Rear brake front pipes (mid) should not be locally
fabricated. These pipes should be ordered
through your GM parts dealer.
ISO Flares Replacement

Tools Required
J 29803-A ISO Flaring Kit
63927
Important: Do not use ISO flares for the rear brake

pipe connections to the rear wheel cylinders.
1. Obtain the recommended tubing and steel fitting
nuts of the correct size. Use the outside diameter
of the tubing in order to specify the size.
2. Cut the tubing to length. Determine the correct
length by using string in order to measure the
old brake pipe. Add 3 mm (0.125 in) for
each ISO flare.
3. Cut the end square.
4. Chamfer the inside and outside diameter of the
tubing. Use a de-burring tool.
5. Remove all traces of lubricant from the tubing.
6. ISO flare the tubing ends. Use the J 29803-A.
7. Install the fittings on the tubing.
8. Clamp the flaring tool body (1) in a vise.
9. Select the correct size collet and forming
mandrel (3) for the tube size used.
10. Insert the proper forming mandrel (3) into the
tool body (1 ).
11. Hold the mandrel (3) in place with your finger.
12. Thread in the forcing screw (2) until the screw
makes contact and begins to move the forming
mandrel (3).
13. When contact is made, turn back the forcing
screw (2) one complete turn.
Brakes
14. Slide the clamping nut (1) over the tubing into the
correct collet (2). Leave approximately 19 mm
(0. 750 in) of the tubing extending out of
the collet (2).
15. Insert the tubing into the tool body. Ensure that
the tube end contacts the face of the forming
mandrel.
16. Tighten the clamping nut (1) into the tool body
very tight in order to prevent the tube from
pushing out.
17. Wrench tighten the forcing screw in until the
screw bottoms. Do not overtighten the forcing
screw or the flare may become oversized.
Hydraulic Brakes
5-39
J 29803-A
63931
18. Back the clamping nut out of the tool body.

Disassemble the clamping nut and collet.
19. The flare is now ready for use.
20. Bend the new brake pipe in order to match the
old pipe. Use a tube bender.
Maintain a minimum clearance of 19 mm
(0.750 in) from all moving components, unless
the brake pipe is clipped to the component.
Maintain a minimum clearance of 13 mm
(0.50 in) from all vibrating components, unless
the brake pipe is clipped to the component.
For armor wrapped pipe, contact is permissible
if there is no relative movement between the
pipe and the contact surface.
63933
Brake Hose Replacement - Front

Removal Procedure
Removal
2. Clean all dirt and foreign material from the front
brake hose and the front brake hose fitting.
3. Remove the front brake pipe from the front
brake hose.
Use a backup wrench on the hose fitting.
Do not bend the front brake hose bracket or
front brake pipe.
4. Remove the brake hose retainer from the hose
fitting at the brake hose bracket.
5. Remove the brake hose from the brake hose
bracket.
5-40
t:tydraulic Brakesi
Brakes
6. Remove the following components from the front
brake caliper (5):
The brake hose fitting (4)
The brake hose bolt (3)
Two brake hose fitting gaskets
Discard the two old brake hose fitting gaskets.
1. Lubricate the brake hose bolt (3) threads with

clean brake fluid.
2. Install the following components to the front

caliper (5):
The brake hose bolt (3)
Two new brake hose fitting gaskets

Notices.
3. Ensure that the hose fitting flange engages the

front caliper orientation ledge.
Tighten
Tighten the front brake hose bolt (3) to
40 N-m (30 lb ft).
4. Install the brake hose into the brake hose

bracket (2). Ensure that there are no kinks in- the
brake hose.
5. Install the brake hose retainer at the brake hose
bracket.
6. Install the front brake pipe to the brake hose .
7. Install the brake hose retainer.
8. Secure the retainer to the brake hose bracket

using the screw.
'82786
Use a backup wrench on the hose fitting.

Ensure that the brake hose does not contact
any part of the suspension.
Inspect the hose in the extreme right and

extreme left tum conditions.
Tighten
Tighten the front brake hose clip
bolt/screw (6) to 13 Nm (115 lb in).
9. Bleed the brake hydraulic system. Refer to

Hydraulic Brake System Bleeding (Manual Bleed)
or Hydraulic Brake System Bleeding
(Pressure Bleed).
10. Install the tire and the Wheel. Refer to
Wheel Removal
Brakes
Hydraulic'Brakes 5-41'
Brake Hose ~eplacement - Rear

(Rear Brake Hose)
Removal Procedure
1. Remove the wheel and the tire. Refer to Wheel
Removal
2. Clean all dirt and foreign material from the hose

and fitting (4).
3. Remove the rear brake hose (2) from the rear
brake pipe (3).
Use a backup wrench on the hose fitting (2).
Do not bend the rear brake hose bracket or the
rear brake pipe (3).
4. Remove the rear brake hose retainer (1) from the
brake hose bracket and the rear brake hose (2).
5. Remove the following components from the rear
brake caliper (5):
The brake hose fitting bolt (4)

Two brake hose fitting gaskets.
Discard the brake hose fitting gaskets.
222984
The rear brake hose (2)
1 . Lubricate the bolt fitting threads. Use clean
brake fluid.
2. Install the following components to the rear brake
caliper (5):
Two new brake hose fitting gaskets
The rear brake hose (2)

Notices.
3. Ensure that the hose fitting flange engages the
caliper orientation ledge.
Tighten
Tighten the rear brake hose fitting (4) to
40 N-m (30 lb ft).
4. Install the rear brake hose retainer (1) to the
brake hose bracket and the brake hose (2).
5. Install the rear brake hose (2) to the rear
brake pipe (3).
Use a backup wrench on the hose fitting (2).
Do not bend the brake hose bracket or
the brake pipe (3).
Tighten
Tighten the rear brake pipe (3) to the brake
hose (2) to 17 N-m (13 lb ft).
6. Bleed the hydraulic brake system. Refer to
or Hydraulic Brake System Bleeding
(Pressure Bleed)
7. Install the wheel and the tire. Refer to Wheel
Removal
222984
5-42
Hydraulic Brakes
Brakes
(Center, w/o Tractn Cntrl, Disc)
Removal Procedure
Jacking the Vehicle
2. Clean all dirt and foreign material from the brake
hose (3) and the brake pipe fittings.
3. Remove the rear brake front pipe (2) from the
brake hose (3).
Use a backup wrench on the brake hose
fitting.
Do not bend the brake hose bracket (6) or the
brake front pipe (2).
4. Remove the brake hose retainer (7) from the
brake hose bracket (6) and the brake hose (3).
5. Remove the rear brake hose (3).
6. Remove the left rear pipe (1) and the right rear
pipe (5) from the hose (3). Do not bend the left
rear pipe (1) or the right rear pipe (5).
7. Note the position of the brake hose (3) for proper
location during installation.
8. Remove the rear brake hose fitting bolt/screw (8)
and the brake hose (3) from the rear axle (4) .
184635
Brakes
Notice: Refer to Fastener Notice in Cautions ahd
Notices.
1. Install the brake hose (3) and the brake hose
fitting bolt/screw (8) to the rear axle (4).
Tighten
Tighten the rear brake (center) hose fitting
bolt/screw (8) to 21 N-m (15 lb ft).
2. Install the left rear pipe (1) and the right rear
pipe (5) to the brake hose (3).
Tighten
Tighten the left rear pipe (1) and the right rear
pipe (5) at the rear brake (center) hose (3) to
24 Nm (18 lb ft).
Tighten the left r.ear pipe (1) and the right rear
pipe (5) at the left hand brake hose to
17Nm (131bft).
3. Install the brake hose (3) into the brake hose
bracket (6). Ensure that the brake hose (3) is
properly seated and not twisted.
4. Install the rear brake hose retainer (7) to the rear
brake hose bracket (6) and the brake hose (3).
5. Install the rear brake front pipe (2) to the
brake hose (3).
Use a backup wrench on the brake hose (3).
Do not bend the brake hose bracket (6) or
the rear brake front pipe (2).
Tighten
Tighten the rear brake front pipe (2) to the
rear brake (center) hose (3) to
15 N-m (11 lb ft).
Hydraulic Brakes
5-43
5-44
Hydraulic Brakes
Brakes
(Center, w/Traction Control)
Removal Procedure
2. Clean all dirt and foreign material from the brake
hose and the brake pipe fittings.
3. Remove the right rear brake pipe (6) or the left
rear brake pipe (7) from the rear brake
hoses (3 or 4).
fittings.
Do not bend 1he rear brake hose bracket (10)
or the brake pipes (6 or 7).
4. Remove the rear brake pipe clips (8 or 9) from
the brake hose bracket (10) and the rear brake
hoses (3 or 4).
5. Remove the left rear brake pipe (2) or the right
rear brake pipe (5) from the rear brake
hoses (3 or 4).
fittings.
Do not bend the rear brake hose bracket (1) or

the rear brake pipes (2 or 5).
6. Remove the rear brake pipe clips (8 or 9) from
the brake hose bracket (1) and the rear brake
hoses (3 or 4).
7. Remove the rear brake hoses (3 or 4).
182798
Brakes
Hydraulic .Brakes
5-45
1. Install the rear brake hose (3 or 4).
2. Install the rear brake pipe clips (8 or 9) to the
brake hose bracket (1) and the rear brake
hoses (3 or 4). Ensure that the rear brake
hoses (3 or 4) are properly seated and not twisted.
and Notices.
3. Install the rear brake pipes (2 or 5) to the rear
brake hoses (3 or 4).
fittings.
Do not bend the bracket (1) or the rear brake
pipes (2 or 5).
Tighten
Tighten the rear brake pipes (2 or 5) to the
rear brake hoses (3 or 4) to 17 N-m (13 lb ft).
4. Install the rear brake pipe clips (8 or 9) to the rear
brake hose bracket (10) and the rear brake
hoses (3 or 4). Ensure that the rear brake
hoses (3 or 4) are properly seated and not twisted.
5. Install the right rear brake pipe (6) or the left rear
brake pipe (7) to the rear brake hose (3 or 4).
fittings.
Do not bend the rear brake hose bracket ( 10)
or the brake pipes (6 or 7).
Tighten
Tighten the right rear brake pipe (6) or the
left rear brake pipe (7) to the rear brake
hoses (3 or 4) to 17 N-m (13 lb ft).
(Pressure Bleed).
182798
5-46
Hydraulic Brakes
Hydraulic Brake System Bleeding (Manual

Bleed)
Notice: If any brake component is repaired or replaced
such that air is allowed to enter the brake system,
the entire bleeding procedure must be followed.
Notice: Use only DOT 3 brake fluid from a clean,
sealed container. Do not use any fluid from a container
which is wet with water. Do not use DOT 5 silicone
brake fluid. Improper brake fluid, mineral oil or water in
the fluid may cause the brake fluid to boil or the
rubber components to deteriorate. Keep all fluid
containers capped to prevent contamination.
Notice: Avoid spilling brake fluid on any of the
vehicle's painted surfaces, wiring, cables, or electric
connectors. Brake fluid will damage the paint and
the electrical connections. If any fluid is spilled on the
vehicle, flush the area to lessen the damage.
Notice: Prior to bleeding the brakes, the front and
rear displacement cylinder pistons must be returned to
the topmost position. The preferred method uses a
Scan Tool to perform the rehoming procedure. If
a Scan Tool is not available, the second procedure
may be used, but it is extremely important that
the procedure be followed exactly as outlined.
Pressure Bleeding
Tools Required
J 35589 Bleeding Adapter
Notice: Pressure bleeding equipment must be of the
diaphragm type. It must have a rubber diaphragm
between the air supply and the brake fluid to prevent
air, moisture, and other contaminants from entering
the hydraulic system.
1. Clean the fluid reservoir cover and the

2.
3.
4.
5.
6.
7.
surrounding area.
Remove the fluid reservoir cover.
Inspect the brake fluid reservoir level. Refer to
Master Cylinder Reservoir Filling. Add clean
brake fluid as required.
Install the J 35589 to the brake fluid reservoir.
Install the J 35589 to the pressure bleeding
equipment.
Adjust the pressure bleed equipment to
35-70 kPa (5-10 psi). Wait approximately
30 seconds in order to ensure that there is no
leakage.
Adjust the pressure bleed equipment to
205-240 kPa (30-35 psi).
Brakes
8. Complete the following procedures with the
pressure bleeding equipment connected and
pressurized:
8. 1. Attach a clear plastic bleeder hose to the
rearward bleeder valve on the ABS
hydraulic modulator.
Submerge the opposite hose end in a clean
container partially filled with clean
brake fluid.
8.2. Slowly open the bleeder valve. Allow the
fluid to flow until no air is seen in the fluid.
8.3. Close the valve when the fluid flows without
any air bubbles.
Important:
Use a shop cloth in order to catch escaping
brake fluid.
Prevent the fluid from running down the motor
pack base or into the electrical connector.
Do not allow brake fluid to contact any painted
surfaces as surface damage will occur.
If brake fluid does contact any surface, flush the
surface with water in order to lessen the
damage.
8.4. Repeat the previous three steps until no air
bubbles are present.
8.5. Relocate the bleeder hose on the forward
ABS hydraulic modulator bleeder valve.
brake fluid.
any air bubbles.
Notice: Fastener Notice in Cautions and Notices.

8.8. Repeat the previous two steps until no
air bubbles are present.
Tighten
Tighten the ABS hydraulic modulator
bleeder valves to 9 Nm (80 lb in).
9. Bleed the master cylinder brake connections with
the pressure bleeding equipment connected and
pressurized. Use the following procedure:
9. 1. Slowly loosen the forward brake pipe tube
nut on the master cylinder. Inspect for air in
the escaping fluid.
9.2. When the air flow ceases, immediately
tighten the tube nut.
Tighten
Tighten the master cylinder tube nut to
32 Nm (24 lb ft).
9.3. Repeat the previous two steps for the
rearward master cylinder brake pipe
connection.
Brakes
Hydraulic Brakes
10. Bleed the brake combination valve with the

1O.1. Slowly loosen the forward brake pipe tube
nut on the brake combination valve.
Inspect for air in the escaping fluid.
Tighten
Tighten the brake combination valve tube
nut to 18 Nm (13 lb ft).
rearward brake combination valve pipe
connection.
11. Bleed the ABS hydraulic _modulator b~ake
connections with the pressure bleeding equipment
connected and pressurized. Use the following
procedure:
11 .1 . Slowly loosen the forward brake pipe tube
nut on the ABS hydraulic modulator.
Tighten
Tighten the ABS hydraulic modulator tube
nut to modulator to 32 N-m (24 lb ft).

remaining ABS hydraulic modulator brake
pipe connections. Move from the front
to the rear.
Vehicle Lifting and Jacking in General Information.
13. Bleed the rear wheel brakes. Use the following
procedure:
13.1. Attach a clear plastic bleeder hose to the
right rear wheel bleeder valve.
brake fluid.
fluid to flow.
13.3. Close the valve when the fluid begins to
flow without any air bubbles. Tap lightly on
the caliper or backing plate in order to
dislodge any trapped air bubbles.
13.4. Relocate the bleeder hose to the left rear
wheel bleeder valve.
brake fluid.
Then, repeat the previous two steps.
14. Remove the pressure bleeding equipment.

15. Attach a clear plastic bleeder hose to the right
front wheel bleeder valve.
container partially filled with clean brake fluid.
16. Turn the ignition to RUN. Leave the engine OFF.
5-47
17. Open the bleeder valve. Apply the brake until the
red BRAKE warning lamp turns ON. This action
shuttles the brake pressure differential
warning valve .
Important: Do not reapply the brakes after closing the
bleeder valve.
18. Close the bleeder valve.
19. Reapply pressure to the pressure bleeding
equipment.
20. Turn the ignition OFF.
22. Repeat the entire pressure bleeding procedure for
the ABS hydraulic modulator.
24. Repeat the entire pressure bleeding procedure for
the rear wheel brakes.
25. Bleed the front wheel brakes. Use the following
procedure:
right front wheel bleeder valve.
brake fluid.
fluid to flow.
the caliper in order to dislodge any
trapped air bubbles.
25.4. Relocate the bleeder hose to the left front
brake fluid.
27. Remove the pressure bleeding equipment,
including the J 35589.
28. Inspect the brake fluid level in the reservoir. Fill
the reservoir to the proper level if necessary.
29. Reinstall the brake fluid reservoir cap.
30. Tum the ignition to the RUN position. Apply the
brake pedal with moderate force and hold. Note
the pedal travel and feel.
30.1. If the pedal feels firm and constant and
pedal travel is not excessive, start the
engine.
30.2. With the engine running, recheck the
pedal travel.
30.3. If the pedal is still firm and constant and
pedal travel is not excessive, road test the
vehicle .
Make several normal (non-ABS) stops from
a moderate speed in order to ensure
proper brake system function. Allow
adequate cooling time between stops.
5..43 Hydrauli~il:Jrakes
Brakes
31. If the pedal feels soft or has excessive travel

either initially or after the engine is started,
repeat previous steps.
32. Road test the vehicle. Make several normal
: (nqn-ABS) stop~ from a moderate speed in
order to ensure proper brake system function.
Allow adequate cooling time between stops.
Manual Bleeding
Important: In the following procedure, use a suitable
container or shop cloths in order to catch and
prevent the brake fluid from contacting any painted
surfaces.
1. Clean the brake fluid reservoir cover and the
surrounding area.
2. Remove the brake fluid reservoir cover.

3. Inspect the brake fluid level. Fill the reservoir to
the correct level if necessary.
'
\''
.'
4. Install the brake fluid reservoir cover.
5. Prime the ABS brake modulator. Use the following

procedure:
5.1 . 'Attach a clear plastic bleeder hose to the

hydraulic modulatbr.
brake fluid.
5.2. Slowly open the rearward bleeder valve one

half to one full turn.
5.3. Depress the brake pedal. Hold the pedal

until the fluid begins to flow.
5.4. Close the valve. Release the brake pedal.

5.5. Repeat the previous three steps until
air bubbles are no longer present.
Important: Once the fluid is visibly flowing from both
AB? hydraulic modulator bleeder valves, the ~BS
brake modulator is sufficiently full of fluid. However, it
may not be completely purged of air. At this point,
move to the wheel brakes and bleed the brakes. This
ensures that the lowest points in the system are
completely free of air. The ABS brake modulator may
then be purged of any remaining air.

brake fluid.
Then, repeat the previous four steps.

the reservoir to the correct level, if necessary.
9. Raise the vehicte. Support the vehicle. Refer to
Important: The bleed sequence is as follows:
right rear, left front, right front, left rear.
procedure:
bleeder valve at each wheel.Submerge the
opposite hose end in a clean container
partially filled with clean brake fluid.
10.2. Open the bleeder valve.
10.3. Slowly depress the brake pedal.
10.4. Glqse the valve. Slowly release the
brake pedal.
10.5. Wait 5 seconds.
10.6. Repeat the previous four steps until the
brake pedal feels firm and no air bubbles
are visible in the bleeder hose.
Tap lightly on the caliper or braking plate
using a rubber mallet in order to assist
in freeing any trapped air.
the reservoir to the correct level if necessary .
15. Bleed th& ABS hydraulic modulator. Use the
following procedure:
hydra~lic modulator.
brake fluid.
15.2. Depress the brake pedal with
moderate force.
15.3. Slowly open the rearw,ard bleeder valve
one half to one full turn. Allow the fluid
to flow.
15.4. Close the valve. Slowly release the
brake pedal.
15.6. Repeat the previous four steps until air
bubbles are no !onger visible in the
bleeder hose.
ABS hydraulic .modulator bleeder valve.
brake fluid.
Then, repeat the previous five. steps.
Tighten
bleeder valves to 9 Nm (80 lb in).
Brakes
Hydraulic Brakes
Pressure Bleeding

the reservoir to the correct level if necessary.
Tools Required

Apply the brake pedal with moderate force
and hold. Note the pedal travel and feel.
engine.
pedal travel.
19.3. If the pedal still feels firm and constant
and pedal travel is not excessive, road
test the vehicle.
20. If pedal feel is soft or has excessive travel either

initially or after starting the engine, repeat previous
steps until firm pedal is attained.

(non-ABS) stops from a moderate speed in

(Pressure Bleed)
Notice: If any brake component is repaired or replaced
such that air is allowed to enter the brake system,
the entire bleeding procedure must be followed.
Notice: Use only DOT 3 brake fluid from a clean.
Notice: Prior to bleeding the brakes, the front and rear

displacement cylinder pistons, on the ABS hydraulic
modulator, must be returned to the topmost position.
The TCS hydraulic modulator must be rehomed a
minimum of 4 full times. This method uses a Tech 1 to
perform the rehoming procedure. You will not be able to
bleed this system without the Tech 1.
5-49

Notice: Pressure bleeding equipment must be of the
diaphragm type. It must have a rubber diaphragm
between the air supply and the brake fluid to prevent
air, moisture, and other contaminants from entering
the hydraulic system.

surrounding area.
2. Remove the fluid reservoir cover.
3. Inspect the brake fluid reservoir level. Refer to
Master Cylinder Reservoir Filling. Add clean
brake fluid as required.
4. Install the J 35589 to the brake fluid reservoir.
5. Install the J 35589 to the pressure bleeding
equipment.
6. Adjust the pressure bleed equipment to
35-70 kPa (5-10 psi). Wait approximately
30 seconds in order to ensure that there is no
leakage.
7. Adjust the pressure bleed equipment to

205-240 kPa (30-35 psi).
8. Complete the following procedure with the
pressurized:

brake fluid.
any air bubbles.
Important:
Use a shop cloth in order to catch escaping
brake fluid.
Prevent the fluid from running down the motor
pack base or into the electrical connector.
Do not allow brake fluid to contact any painted
surfaces as surface damage will occur.
If brake fluid does contact any surface, flush the
surface with water in order to lessen the
damage.
8.4. Repeat the previous two steps until no air
bubbles are present.
5-50
Brakes
Hydraulic Brakes
Notice: Fastener Notice in Cautions and Notices.

Repeat the above procedure.
brake fluid.
Then, repeat the previous three steps.
Tighten
bleeder valves to 9 N-m (80 lb in).
9. Bleed the master cylinder brake connections with

the pressure bleeding equipment connected and
9.1. Slowly loosen the forward brake pipe tube
nut on the master cylinder. Inspect for air in
the escaping fluid.
Tighten
Tighten the master cylinder tube nut to
32 Nm (24 lb ft).
rearward master cylinder brake pipe
connection.
10. Bleed the brake combination valve connections
with the pressure bleeding equipment connected
and pressurized. Use the following procedure:
10.1. Slowly loosen the forward brake pipe tube
nut on the brake combination valve.
Tighten
Tighten the brake combination valve tube
nut to 18 Nm (13 lb ft).
rearward brake combination valve pipe
connection.
11 . Bleed the ABS hydraulic modulator brake
procedure:
11 .1 . Slowly loosen the forward brake pipe tube
nut on the ABS hydraulic modulator.
11 .2. When the air flow ceases, immediately
Tighten
Tighten the ABS hydraulic modulator tube
nut to modulator to 32 N-m (24 lb ft).
11 .3. Repeat the previous two steps for the
remaining ABS hydraulic modulator brake
pipe connections. Move from the front
to the rear.
12. Bleed the TCS hydraulic modulator brake

procedure:
12.1 . Slowly loosen the forward brake pipe tube
nut on the TCS hydraulic modulator.
Tighten
Tighten the TCS hydraulic modulator tube
nut to 32 N-m (24 lb ft).
remaining TCS hydraulic modulator brake
pipe connections.
procedure:
brake fluid.
fluid to flow.
brake fluid.

15. Remove the pressure to the pressure bleeding
equipment.
16. Attach a clear plastic bleeder hose to the right
front wheel bleeder valve.
container partially filled with clean brake fluid.
17. Tum the ignition to RUN. Leave the engine OFF.
18. Open the bleeder valve. Apply the brake until
the red BRAKE warning lamp turns ON. This
action shuttles the brake pressure
differential warning valve.
Important: Do not reapply the brakes after closing the
bleeder valve.
19. Close the bleeder valve.
20. Reapply pressure to the pressure bleeding
equipment.
21. Turn the ignition OFF.
23. Repeat the entire bleeding procedure for the ABS
Brakes

25. Repeat the bleeding procedure for the rear wheel
brakes.
26. Bleed the front wheel brakes. Use the following
procedure:
right front wheel bl~eder valve.
brake fluid.
fluid to flow.
26.3. Close the valve when fluid begins to flow
without any air bubbles. Tap lightly on the
caliper in order to dislodge any trapped
air bubbles.
26.4. Relocate the bleeder hose to the left front
brake fluid.
Important: Follow this procedure in order to ensure

that all air is removed from the TCS hydraulic
modulator.
27. Bleed the rear wheel brakes only. Use the
brake fluid.
fluid to flow.
brake fluid.
29. Remove the pressure bleeding equipment,
including the J 35589.
the reservoir to the proper level if necessary.
31. Reinstall the brake fluid reservoir cap.

32. Turn the ignition to the RUN position. Apply the
brake pedal with moderate force and hold. Note
the pedal travel and feel.
engine.
pedal travel.
32.3. If the pedal is still firm and constant and
pedal travel is not excessive, road test the
vehicle.
33. If the pedal feels soft or has excessive travel
either initially or after the engine is started,
repeat the previous steps until pedal is firm.
Manual Bleeding

Important: In the following procedure, use a suitable

container or shop cloths in order to catch and
prevent the brake fluid from contacting any painted
surfaces.
1. Clean the brake fluid reservoir cover and the
surrounding area.
3. Inspect the brake fluid level. Fill the reservoir to
the correct level if necessary.
5. Prime the ABS brake modulator. Use the following
procedure:
brake fluid.
5.3. Depress the brake pedal. Hold the pedal
until the fluid begins to flow .
5-52
Hydraulic Btakes
Important: Once the fluid is visibly flowing from both

ABS hydraulic modulator bleeder valves,. the ABS
brake modulator is sufficiently full of fluid. However, it
may not be completely purged of air. At this point,
move to the wheel brakes and bleed the brakes. This
ensures that the lowest points in the system are
completely free of air. The ABS brake modulator may
then be purged of any remaining air.
5.5. Repeat the previous three steps until air
bubbles are no longer present.
brake fluid.
Then, repeat the previous four steps.

the reservoir to the correct level, if necessary.
Important: Bleed Sequence: Right rear, left front, right
front, rightrear
10. Bleed the wheel brakes in the sequence shown
above. Use the following procedure:
bleeder valve at each wheel.
brake fluid.
brake pedal.
10.5. Wait 5 seconds. Tap lightly on the caliper
or braking plate with a rubber mallet in
order to assist in freeing any trapped air.
10.6. Repeat the previous four steps until the
brake pedal feels firm at half travel and no
air bubbles are visible in the bleeder hose.
11. Continuing with the scan tool, press ENTER in
order to initialize the TCS modulator for bleeding.
Follow the instructions on the scan tool as
directed.
Important: Follow this procedure in order to ensure
that all air is removed from the TCS hydraulic
modulator.
12. Bleed the rear wheel brakes only. Use the
procedure below:

brake fluid.
Btakes
12.2. Slowly open the bleeder valve. '
12.3. Slowly depress the braki{pedal.
12.4. Close the valve when ttle fluid begins to
12.5. Relocate the bleeder hose to the left. rear
brake fluid.
Then, repeat the previous three steps.
14. Remove the brake fluid reservoir cover. '
15. Inspect the brake flLJid level in the ..reservoir. Fill
16 .. .Install the bra,ke fluid Jeservoir .cover,
17. Bleed the ABS hydraulic modulator. Use the
following procedurEjl:
17 .1 . Attach a clear plastic bleeder hose to the
hydraulic mpdulator.
Submerge the opposite hose end in a c.lean
brake fluid:
17 .2. Depress the brake pedal with
moderate force:
17 .3. Slowly open the rearward bleeder valve
one half to one full turn. Allow the fluid
to flow.
brake pedal.
17.6. Repeat the previous four steps uritil air
bubbles are no longer visible in the
bleeder hose.

Notices.
17.7. Relocate the bl.eedei:,hose on the forward
ABS hydraulic modul_ator bleeder valve.
Submerge the opposite hose. end in a clean
brake fluid.
Then, repeat the previous five steps.
Tighten
bleeder valves to 9 N-m (80 lb in).
18. Remove the brake fluid reservoir cover ..

Brake$
Hydraulic Brakes
21 ..Turn the ignition switch to the RUN position.

Apply the brake pedal with moderate force
and hold. Note the pedal travel and feel.
21.1 . If the pedal feels firm and constant and
engine.
pedal travel.
21.3. If the pedal still feels firm and constant
and pedal travel is not excessive, road
test the vehicle.
22. If pedal feels soft or has excessive travel either

initially or after starting the engine, repeat
previous procedures:
5-53
Flushing Preparation
Notice: The flushing prep procedure must be
performed prior to using "Pressure Flush" or "Manual
Flush" procedures.
Important: Do not place your foot on the brake pedal
through this entire procedure unless specifically
directed to do so.
1. Remove your foot from the brake pedal.
3. Allow the engine to run for at least 10 seconds.
Observe the amber ABS warning lamp.
4. If the amber ABS warning lamps turn ON and
stay ON after 1O seconds, stop the flushing
procedure.
5. If the amber ABS warning lamps tum ON for
approximately 3 seconds, then tum OFF and
stay OFF. tum the ignition OFF.
6. Repeat the previous five steps one more time.
7. Flush the entire brake system. Use the Pressure
Flush procedure or the Manual Flush procedure.
Pressure Flush

(ABS w/o Traction Control)
Tools Required
Notice: Use only DOT 3 brake fluid from a clean.

Notice: Pressure Bleeding equipment can be used to

perform the flush procedure. The pressure bleeding
equipment used for flushing must be of the diaphragm
type. It must a have a rubber diaphragm between
the air supply and the brake fluid to prevent air,
moisture. and other contaminants from entering the
hydraulic system.
Important:
It evidence of contamination is present in the
vehicle's brake fluid, flush the entire brake system.
Use one of the following procedures below.
After flushing the entire brake system, replace all
rubber components.
Replace the following components:
- Brake hoses
- Master cylinder rubber parts
- Brake caliper and wheel cylinder boots
and seals
- Combination valve
- ABS hydraulic modulator
Refer to the appropriate replacement procedures.
After replacing all rubber components, re-flush
the entire brake system by performing one of
the following procedures.
After performing the second flushing procedure,
perform a complete system bleed. Refer to
Flush the system if there is any doubt about the
condition of the fluid in the system or if the fluid
used contains the slightest trace of mineral oil (from
such things as engine oil, transmission fluid, etc.)

surrounding area.
3. Remove any remaining brake fluid in the reservoir.
4. Refill the reservoir with clean DOT 3 brake fluid
to the proper level.
equipment.
7. Adjust the pressure bleeding equipment to
35-70 kPa (5-10 psi). Wait for approximately
30 seconds in order to ensure that there is
no leakage.
205-240 kPa (30-35 psi).
9. After connecting the pressure bleeding equipment
and pressurizing the system, perform the
following steps:
9.1. Attach a clear plastic hose to the rearward
bleeder valve on the ABS hydraulic
modulator.
Place the other end of the hose in a
container in order to collect the draining
brake fluid. Do not submerge the hose end
into the fluid.
5-54
Brakes
Hydraulic Brakes
fluid to flow until clean brake fluid flows or
until at least 118 ml (4 oz) of fluid
accumulates.
9.3. Close the valve.
9.4. Repeat the previous three steps for the
forward bleeder valve until clean brake
fluid flows or until at least 118 ml (4 oz) of
fluid accumulates.

Notices.
Tighten
The ABS hydraulic modulator bleeder valve
to 9 N-m (80 lb in).
10. Raiseand suitably support the vehicle. Refer to
Important: Flush sequence: Right rear, left front, right
front, left rear.
11. Flush the wheel brakes in the sequence shown
11 .1 . Attach the bleeder hose to the bleeder
valve at each wheel.
Place the other end into a container in

order to collect the draining brake fluid. Do
not submerge the hose end into the fluid.

fluid to flow.
11.3. Close the valve when clean brake fluid
begins to flow or at least 235 ml (8 oz) of
fluid accumulates.
6.1 . Attach a clear plastic bleeder hose to the

into the fluid.
6.3. Depress the brake pedal until the fluid
begins to flow.
Repeat the previous two steps until clean
brake fluid flows or at least 118 ml (4 oz) of
fluid accumulates.
Notices.
6.5. Repeat the previous four steps for the
fluid flows or at least 118 ml (4 oz) of fluid
accumulates.
Tighten
Tighten the ABS brake modulator bleeder
valves to 9 N-m (80 lb in).
9. Replace the brake fluid reservoir cover.

13. Remove the bleeder adapter.

front, left rear.
14. Replace all the rubber components listed in

Flushing Procedure in this section.
11 . Flush the wheel brakes in the above sequence.

Use the following procedure:
15. Repeat the flushing preparation and the flushing

procedure one more time.
17. Install the brake fluid reservoir cap.
18. Bleed the entire brake hydraulic system. Refer to
(Manual Bleed).
Manual Flush
Important: Use a suitable container or shop rags in
order to catch fluid and prevent the fluid from
contacting any painted surfaces.

11 .3. Slowly depress the brake pedal.
brake pedal.
clean brake fluid flows or at least 235 ml
(8 oz) of fluid accumulates.

13. Replace all the rubber components listed under


6. Use the following procedure in order to flush the
ABS hydraulic modulator:
11 .1. Attach the bleeder hose to the bleeder

not submerge the hose end in the fluid.

surrounding area.
16. Replace the brake fluid reservoir cap.

Brakes
(ABS w/Traction Control)
Important:
If evidence of contamination is present in the
vehicle's brake fluid, flush the entire brake system.
Use one of the following procedures:
After flushing the entire brake system, replace all
rubber components.
Replace the following components:
- Brake hoses
- Master cylinder rubber parts
- Brake caliper and wheel cylinder boots
and seals
- Combination valve
- ABS hydraulic modulator
- TCS hydraulic modulator
- ABS solenoids
Refer to the appropriate replacement procedures.
After replacing all rubber components, re-flush
the entire brake system by performing one of
the following procedures.
After performing the second flushing procedure,
perform a complete system bleed. Refer to

(Pressure Bleed)
Flush the system if there is any doubt about the
condition of the fluid in the system or if the fluid
used contains the slightest trace of mineral
oil (from such things as engine oil,
transmission fluid, etc.)
Flushing Preparation
Notice: The flushing prep procedure must be
performed prior to using "Pressure Flush" or WManual
Flush" procedures.
Important: Do not place your foot on the brake pedal
through this entire procedure unless specifically
directed to do so.
1. Remove your foot from the brake pedal.

3. Allow the engine to run for at least 1O seconds.
Observe the amber ABS and TCS warning lamp.
4. If the ABS or TCS warning lamps turn ON and

stay ON after 10 seconds, stop the flushing
procedure.
5. If the ABS or TCS warning lamps turn ON for
approximately 3 seconds, then turn OFF and
stay OFF, turn the ignition OFF.

6. Repeat the previous five steps one more time.
7. Flush the entire brake system. Use the Pressure

Flush procedure or the Manual Flush procedure.
Pressure Flush
Tools Required

Notice: Pressure Bleeding equipment can be used to
perform the flush procedure. The pressure bleeding
equipment used for flushing must be of the diaphragm
type. It must a have a rubber diaphragm between
the air supply and the brake fluid to prevent air,
moisture, and other contaminants from entering the
hydraulic system.
1 . Clean the fluid reservoir cover and the
surrounding area.

equipment.
35-70 kPa (5-10 psi). Wait for approximately
30 seconds in order to ensure that there is
no leakage.

205-240 kPa (30-35 psi).
9. After connecting the pressure bleeding equipment

and pressurizing the system. perfonn the
following steps:
9 .1 . Attach a dear plastic hose to the rearward

bleeder valve on the ABS hydraulic
modulator.
into the fluid.
fluid to flow until clean brake fluid flows or
until at least 118 ml (4 oz) of fluid
accumulates.
9.3. Close the valve.

Notices.
9.4. Repeat the previous three steps for the

fluid flows or until at least 118 ml (4 oz) of
fluid accumulates.
Tighten
The ABS hydraulic modulator bleeder valve
to 9 Nm (80 lb in).
Information.
5-56
Hydraulic Brakes

front, left rear.
11.1. Attach the bleeder hose to the bleeder
Place the other hose end into a container in
order to collect the draining brake fluid.
Do not submerge the hose end
into the fluid.
fluid to flow.
11.3. Close the valve when clean brake fluid
begins to flow or at least 235 ml (8 oz) of
fluid accumulates.
13. Remove the J 35589.
14. Replace all the rubber components listed in
17. Install the brake fluid reservoir cap.
18. Bleed the entire bra:ke hydraulic system. Refer to
(Pressure Bleed)
Manual Flush
Important: Use a suitable container or shop rags in
order to catch fluid and prevent the fluid from
contacting any painted surfaces.
surrounding area.
4. Refill the reservoir With clean DOT 3 brake fluid
6. Flush the ABS hydraulic modulator. Use the
6. 1. Attach a clear plastic bleeder hose to the
into the fluid.
Brakes
6.2. Slowly open the' rearward bleeder valve one
6.3. Depress the brake pedal until the fluid
begins to flow.
6.5. Repeat the previous three ,steps until
6.6. Repeat the previous five steps for the
fluid flows or at least 118 ml (4 oz) of fluid
accumulates.
Tighten
Tighten the ABS brake modulator bleeder
valves to 9 N-m (80 lb in).
9. Replace the brake fluid reservoir cover.
1o. Raise and suitably support the vehicle. Refer to
Important: Wheel position flush sequence: Right rear,
left front, right front, left rear.
11.1. Attach the bleeder hose, to the bleeder
not submerge the hose end in fluid.
brake pedal.
13. Replace all the rubber components listed under
16. Replace the brake fluid reservoir cap.
,
(Pressure Bleed)
,Brakes
Hydraulic Brakes
5-57
Vacuum Brake Booster Replacement
Removal Procedure
1. Remove the hood rear seal.
2. Remove the air inlet screen. Refer to Air Inlet
Grille Panel Replacement in Body Front End.
3. Remove the brake booster vacuum hose
clamp (9) and the vacuum hose (8) from the check
valve (4).
4. Remove the master cylinder nuts (7) attaching the
master cylinder (6) to the brake booster (1 ).
5. Remove the master cylinder from the brake
booster.
Move the master cylinder forward and toward
the driver's side in order to provide clearance
for the booster. Moving the master cylinder
will flex the brake pipes slightly.
Do not bend or distort the brake pipes.
Instrument Panel, Gauges and Console.
7. Remove the brake pedal nuts (3) attaching the
brake booster to the brake pedal with bracket (6).
8. On vehicles equipped with manual transmissions,
loosen the clutch master cylinder nuts (5).
9. Remove the brake booster pushrod (8) from the
brake pedal lever pin.
From inside the vehicle, remove the brake
pedal pushrod retainer (7) and the
pushrod washer (4).
Tilt the entire brake booster slightly in order to
work the brake booster pushrod (8) off the
brake pedal pin. Do no put undue side
pressure on the pushrod.
4
184981
184982
5-58
Hydraulic Brakes
Brakes
10. Remove the power brake booster (1) from the
vehicle.
4
184981
1. Install the power brake booster (1) onto the

vehicle.
2. Install the brake booster pushrod (8) onto the

brake pedal lever pin (1 ).
Tiit the entire brake booster slightly in order to
work the brake booster pushrod (8) onto the
brake pedal pin. Do not put undue side
pressure on the pushrod.
From inside the vehicle, install the brake pedal
pushrod washer (4) and the pushrod
retainer (7).
Notices.
3. Install the brake pedal nuts.
184982
Tighten
Tighten the brake pedal nuts to 20 N-m (15 lb ft)
in the following sequence:
3.1. Inboard upper
3.2. Outboard lower
3.3. Outboard upper
3.4. Inboard lower
Hydraulic Brakes
Brakes
4. On vehicles equipped with manual transmissions,

tighten the clutch master cylinder nuts (5).
Tighten
Tighten the clutch master cylinder nuts to
27 N-m (20 lb ft).
5. Install the master cylinder (6) onto the brake
booster (1 ).
6. Install the master cylinder nuts attaching the
master cylinder to the brake booster.
7.
8.
9.
10.
Tighten
Tighten the brake master cylinder nuts to
29 Nm (21 lb ft).
Connect the vacuum hose (8) and the clamp (9)
to the check valve (10).
Install the left hand instrument panel insulator.
Refer to Insulator Replacement - IP {Left Side)
Install the transmission fluid filler tube. Refer to
Filler Tube Replacement (VB) or Filler Tube
Replacement (V6) in Automatic Transaxle.
Install the air inlet screens. Refer to Air Inlet Grille
Panel Replacement in Body Front End.
10
5-59
184981
Vacuum Brake Booster Hose Replacement
Removal Procedure
1. Reposition the brake booster vacuum hose
clamps.
2. Remove the hose clamp from the engine side of
the vacuum hose, if equipped.
3. Remove the power brake booster vacuum hose
from the engine fitting and the vacuum
check valve.
4. Remove the vacuum hose.
222997
5-60
Brakes
Hydraulic Brakes
1. Install the vacuum hose.
2. Connect the power brake booster vacuum hose to

the engine fitting and the vacuum check valve.
3. Install the hose clamp to the engine side of the
vacuum hose. if equipped.
4. Reposition the brake booster vacuum hose
clamps.
222997

Replacement
Removal Procedure
Important: The vacuum check valve and the grommet
may be inspected and serviced without removing
the booster from the vehicle.
1. Disconnect the damp (3) and the vacuum
hose (4) from the vacuum check valve (2) .
2. Remove the check valve (2) and the grommet (1 ).
3. Inspect the grommet and the vacuum hose for
Cuts
5
184963
Nicks
Excessive wear
Replace the grommet or vacuum hose if
damage is evident.
4. Clean all the parts in denatured alcohol.
5. Dry all the parts. Use non-lubricated
compressed air.
Hydraulic Brakes
Brakes
5;.,s1
1. Lubricate the inner and outer diameters of the

grommet (1 ). Use a thin layer of silicone grease .
2. Install the grommet and the check valve (2).
3. Connect the vacuum hose (4) and the clamp (3)
to the vacuum check valve.(2).
5
184983
Stoplamp Switch Replacement
r-------------,
-----1
Removal Procedure

3. Remove the following components from the pedal
with the bracket (1):
Cruise control release switch (2)
Stoplamp and TCC switch (3)
Cruise control clutch switch (4) or cruise
control clutch anticipate switch (6)
__________ ...
.. OPTIONAL
182813
5-62
Brakes
Hydraulic Brakes
r------------,
lk-::;-,'----1
1. Install the following components to the pedal with

the bracket (1 ):
2. Connect the electrical connectors.
3. Install the left side instrument panel insulator.
4. Adjust the following components. Refer to
6
OPTIONAL
'-----------"
5283
Hydraulic Brakes
Brakes
Stoplamp Switch Adjustment
,.------------.,
-----1
Notice: Proper stoplamp switch adjustment is

essential. Improper stoplamp switch adjustment may
cause brake drag, heat buildup and excessive brake
lining wear.
1. Adjust the cruise control release switch (2) and
the stoplamp and Torque Converter Clutch
(TCC) switch (3) at the same time.
2. Adjust the cruise control clutch switch (4) or the
cruise control clutch anticipate switch (6) after the
clutch pedal is installed.
3. Depress the brake or the clutch pedal.
4. Insert the following switches into the pedal with
the bracket until the retainers on the switches
are fully seated:
Important: Apply the proper amount of force to the

brake pedal during adjustment.
Too much force may damage the vacuum
booster.
Too little force may cause the brakes to drag.
5. Slowly pull the brake or clutch pedal rearward
with a force of 222 N (50 lbs) until clicking
sounds are no longer heard. At this point, the
retainers on the switches will be adjusted.
6. Measure the cruise control release switch (2).
7. Measure the stoplamp and TCC switch (3).
8. The switch contacts should be open at 25.4 mm
(1.0 in) or less of pedal travel. The switch contacts
should occur at the same time or before the
onset of braking. The brake pedal travel can be
up to 25.4 mm (1.0 in) before the cruise control
system disengages.
5-63
,. ~ -L_ -----,
4
__________ ...
.. OPTIONAL
182813
,'5-64
Hydraulic Brakes
Brakes
Description and Oper~tion

Master Cylinder Description
Master Cylinder
, Important:
Replace all 61 the components that are included in
the repair kits used to service this master cylinder.
Lubricate the rubber parts in order to ease
assembly. Use clean brake fluid.
Do not use lubricated compressed air on the
brake parts. This action may cause damage to the
rubber components.
If you remove or disconnect any hydraulic part,
you may have to bleed all or part of the brake
system.
The specified torque values are for dry,
non-lubricated fasteners.
Perform the service operations on a clean bench
that (s free from all mineral oil materials.
The master cylinder has an aluminum body and a

plastic reservoir. The brake system is a conventional
front-to-rear split system. The master cylinder
primary piston provides the fluid pressure to lhe front
disc brakes. The secondary piston provides the
fluid pressure to the rear disc brakes. If pressure is
lost from either system, the remaining system will
function in order to stop the vehicle.
Brake Master Cylinder Reservoir

The reservoir has a minimum and maximum fluid level
indicator marks. The fluid level in~icator marks are
located inside the neck of the reservoir fill opening.
Remove the reservoir cap in order to view
these indicator marks.
, Brake Pipe Routing and Location
186982
Brake pipe location and routing can be found in the

attached graphic. For brake pipe replacement, refer to
Brake Pipe Replacement For information on flaring
new brake pipes, refer to ISO Flares Replacement.
Brakes
Hydraulic Brakes
5;;;55
Brake Fluid and Brake Fluid Handling
Substandard or Contaminated Brake Fluid

DQT 3 brake fluid from a clean, sealed container.
components or loss of braking, with possible
personal injury.

DOT 3 brake fluid from a clean, sealed container.
components or loss of braking, with possible
personal injury.

Important:
Do not re-use fluid accumulated during brake

hydraulic system bleeding.
Store brake fluid in a closed container.
Reseal brake fluid containers immediately
after use.
Do not use fluid left in an open or improperly
sealed container. Fluid left in an open or
improperly sealed container absorbs moisture and
may become contaminated.
If rubber deterioration is evident, complete the
1. Disassemble all hydraulic parts.
2. Wash all the hydraulic parts with alcohol.
3. Dry the parts with compressed air before

reassembly in order to keep alcohol out of
the system.
4. Replace all the rubber parts in the system,
including the following components:
Brake hoses
Master cylinder rubber parts
Brake caliper boots and seals
Wheel cylinder boots and seals
5. Replace the combination valve and the brake
pressure modulator valve. Refer to Brake
Pressure Modulator Valve Replacement. Both
valves have rubber components inside which are
not serviceable.
6. Inspect the pads for brake fluid. If excessive
brake fluid is present, replace the pads.
Vacuum Brake Booster Description

Important:
Do not use lubricated compressed air on the
brake parts. This action may result in damage to
the rubber parts.
Replace all of the components that are included in
the repair kits used to service this booster.
Lubricate the rubber parts in order to ease
assembly. Use silicone grease.
If you remove or disconnect any hydraulic
component, bleed all or part of the brake system.
The specified torque values are for dry,
non-lubricated fasteners.
This vacuum booster is a tandem vacuum suspended
unit. When the service brakes are released, the
tandem vacuum booster operates with vacuum on
both sides of the diaphragm. When the brakes
are applied, air at atmospheric pressure is admitted to
one side of each diaphragm. This draws air from
the booster through the vacuum check valve to the
vacuum source. The internal components of this
booster cannot be serviced. Do not unstake and
separate the housing. Separating the housing
will cause permanent deformation of the booster and
prevent the booster from holding the proper volume.
5-66
Brakes
Hydraulic Brakes
Brake Warning System Description
Routing
Brake
The brake system uses a single red BRAKE warning
lamp located in the instrument cluster. When the
ignition switch is in the START position, the BRAKE.
warning lamp should turn on. When the ignition switch
is retunis to the RUN position, the BRAKE warning
lamp should turn off.
The following conditions activate the BRAKE
warning lamp:
The parking brake is applied. The lamp should. be
on when the parking brake is applied and the
ignition switch is ON.
The brake pressure differential warning switch
detects a failure.
The BRAKE warning lamp remains on while
cranking the engine. This indicates that the circuit
is operating properly.
222997
Brake booster vacuum hose routing in the 3800

V6 series engine.
222994
Power brake booster vacuum hose routing in the 5.7L

V8 series engine.
Anti lock
The Antilock Brake System (ABS) uses three
indicator lamps:
The red BRAKE warning lamp
An amber ABS INOP indicator lamp
An amber LOW TRAC indicator lamp
The lamps operate normally under the following
conditions:
When the ignition is turned to the RUN position,
prior to starting the ehgine, the amber ABS
INOP indicator lamp should tum on and the red
BRAKE warning lamp should flash.
While the engine is cranked, the red BRAKE
warning lamp and the amber ABS INOP indicator
lamp should tum on. The amber LOW TRAC
indicator lamp may tum on and off.
When the engine is started, the amber ABS INOP
lamp and the red BRAKE lamp should turn off.
The amber LOW TRAC indicator lamp may turn on
and off.
The operation of the three lamps is an important part
of the Antilock Brake System (ABS) diagnosis. A
malfunction is present if the warning/indicator lamps
turn on while driving the vehicle. If the warning
lamps do not turn on under normal conditions as
described above, service the lamps as soon as
possible. For further information regarding the
operation of the warning/indicator lamps for the
Antilock Brake System (ABS), refer to A Diagnostic
System Check.
Hydraulic Brakes
Brakes
Brake Warning System Circuit Description
Circuit Operation

Illustration
When the ignition switch is turned to RUN, BULB

TEST or START, voltage is applied to the instrument
cluster through CKT 39 from gauges Fuse 9. The
brake indicator receives a ground through CKT 33 by
one of the following components:
J 28662
Brake Pedal Effort Gage
The park brake switch

The brake malfunction indicator lamp driver
module
From the electronic brake control module
The brake fluid level indicator sensor
When the ignition switch is turned to RUN, CKT 33 is
grounded through the brake malfunction indicator
module. The brake indicator illuminates for
approximately 3 seconds. When the park brake is set
the park brake switch closes, grounding CKT 33
through the park brake switch. If the brake fluid level
in the brake master cylinder reaches an unacceptably
low level, the brake fluid level indicator sensor
applies a ground to CKT 33. For more information on
when the brake malfunction indicator lamp driver
module will ground CKT 33, refer to Antilock Brake
System.
5-67
1006
J 29803-A
ISO Flaring Kit
1089
J 35589
Bleeding Adapter
153149
5,.59
Disc Brakes
Brakes
Disc Brakes
Specifications
Fastener Tightening Specifications (Front)
Specification
Application
Metric
English
Bleeder Valve
13 N-m
115 lb in
Brake Hose Bolt
40Nm
30 lb ft
Brake Caliper Mounting Bracket Bolt
225 N-m
160 N-m
Caliper Guide Pin Bolt
31 N-m
23 lb ft
Wheel Nut
140 N-m
100 lb ft
Fastener Tightening Specifications (Rear)

Specification
Metric
English
Bleeder Valve
12 N-m
1061bin
Brake Hose Bolt
40N-m
30 lb.ft
Application
Caliper Bolt
Caliper Mounting Plate Bolt
37N-m
27lb ft
225 N-m
160 lb ft
..
Component Specifications
Specification
Application
Metric
English
Front Brakes
Discard Thickness (see note)
30.7 mm
1.209 in
0.13 mm
0.005 in
Minimum Thickness After Refinish
31.08 mm
1.223 in
31.08mm
1.223 in
Minimum Wear Thickness
..
..
- .-,.."
-.
""?t
.,
-" I
z-1
32mm
1.26 in
0.013mm
0.0005 in
24.7mm
0.97 in
0.15mm
0.006 in
Minimum Wear Thickness
25.02mm
0.985 in
Minimum Thickness After Refinish
25.02mm
0.985 in
Rear Axle Shaft Flange
0.05mm
0.002 in
0.013 mm
0.0005 in
Rotor Thickness (new)

Thickness Variation
Rear Brakes
Discard Thickness
Thickness Variation
All brake rotors have a discard dimension cast into the rotor. Replace any rotor that does not meet this specification. After
refinishing the rotor, replace any rotor that does not meet the maximum or minimum thickness after refinish specifications .
Disc .Brakes
Brakes
5-69

Brake Rotor Thickness Variation Check
Measure the rotor thickness at four or more points
around the circumference of the rotor in order .
to inspect the thickness variation. Use a micrometer
calibrated in ten-thousandths of an inch. Inspect each
measurement at the same distance from the edge
of the rotor.
A rotor that varies in thickness by more than0.013 mm
(0.0005 in) may cause pedal pulsation or front end
vibration during brake applications. Refinish or replace
a rotor that does not meet the above specifications.
Brake Rotor Lateral Runout Check

Removal Procedure
Tools Required
Notice: Any time the brake rotor is separated from the
wheel bearing flange, clean any rust or foreign
material from the mating surfaces of the wheel bearing
flange and the rotor. Failure to do so can result in
increased lateral runout of the rotor and brake
pulsation.
5. Turn the rotor one complete revolution.Jnspect

the runout indicated on the dial. If the TIA
exceeds 0.15 mm (0.006 in), refinish or replace
the rotor.
In some cases, excessive lateral runout of the
rotor may be improved by indexing the rotor on the
hub. one or two bolt positions from the original
position. Indexing the rotor requires removal and
installation of the front brake caliper. For
removal of the front brake rotor, refer to Brake
Rotor Replacement (Front). For rear brake
rotor replacement. refer to Brake Rotor
Replacement (Rear).
If the lateral runout cannot be corrected by
indexing the front rotor. inspect the hub and the
front wheel bearing for excessive lateral runout or
looseness. If the hub lateral runout exceeds
0.040 mm (0 015 in 1. replace the hub and bearing.
Refer to Brake Rotor Replacement (Front) or
Brake Pads Replacement (Rear). If lateral runout
of the hub and bearing is within specifications,
refinish or replace the rotor as necessary.
If the lateral runout cannot be corrected by
indexing the rear rotor. inspect the rear axle shaft
flange for excessrve lateral runout. If the axle
flange lateral runout exceeds 0.040 mm (0.015 in),
replace the axle shaft Refer to Propeller Shaft
Replacement One Piece or Propeller Shaft
Replacement Two Piece. If lateral runout of the
axle flange hub is within specifications, refinish
or replace the rotor as necessary.
Brake Rotor Tolerance
1. Clean the rotor surface (1).

Notices.
2. Reinstall the wheel nuts (2) in order to retain
the rotor.
Tighten
Tighten the wheel nuts in a star pattern to
140 N-m (100 lb ft).
3. Fasten the J 8001 to the steering knuckle for front
or to the brake mounting flange on the rear axle
for rear so that the indicator button contacts
the rotor surface about 13 mm (0.5 in) from the
rotor edge.
4. Set the J 8001 to zero.
Tolerances of the braking surfaces for the following

conditions are held closely during the manufacture of
the brake rotor:
Flatness
Parallelism
Lateral runout
The maintenance of close tolerances on the shape of
the braking surfaces is neceSSftt"Y in order to
prevent brake roughness or pulsation. The surface
finish must be held to a specified range of a 60 degree
radius of roughness or less. A new rotor conforms
to the above specifications, as will a correctly
refinished rotor. For front brake rotors, refer to
Refinishing Brake Rotors (Front). For erear brake rotors,
refer to Refinfshing Brake Rotors (Rear). Control of
the braking surface finish will eliminate the following
probiems:
Hard pedal application
Excessive brake fade
Pulls
Erratic performance.
Control of the braking surface finish will improve
lining life.
Light scoring of the rotor surfaees not exceeding
1.5 mm (0.060 in) in depth is not detrimental to brake
operation. Normal use may cause light scoring.
5-70
Brakes
Disc Brakes
Repair Instructions
t1
0
tJ
H
1
Brake Pad Inspection
B
t1
D
n
2
125
Inspect the disc brake pads at least twice a year

when the wheels are removed for rotation, etc.
Inspect both ends of the outer pad by looking in at
each end of the caliper. The highest rate of wear
normally occurs at the ends.
Inspect the thickness of the inner pad in order to
ensure that it has not worn prematurely. Look
through the window in the top of the caliper
in order to view the inner pad.
Both front and rear disc brakes have wear
indicators that makes a noise when the pads wear
below specifications. The wear indicator is an
integral part of the outer pad. When the pad
is worn, the wear indicator contacts the rotor and
produces a warning noise as indicated in the
illustration.
Replace the pads when the thickness is worn to
within 0.76 mm (0.030 in) of the shoe. Replace
all pads in axle sets.
Measure the flatness of the inner and outer pads.
Place the pad surfaces together and measure
the gap between the surfaces. If more
than 0.13 mm (0.005 in) gap exists midway
between the attaching lugs, replace the pads .
Brake Pads Replacement (Front)

Removal Procedure
1. Remove two-thirds of the brake fluid from the
master cylinder reservoir.
Lifting and Jacking the Vehicle.
3. Remove the tire and wheel assembly. Refer to
Wheel Removal.
4. Install a C-clamp onto the front brake caliper and
tighten until the caliper pistons bottom in the
caliper housing. Verify that the C-clamp is centrally
positioned on both the caliper housing and the
brake pad. This provides an even clamping force
on both pistons and should prevent the pistons
from becoming wedged in their bores due to
uneven clamping force.
5. Remove front brake caliper. Refer to Brake
Caliper Replacement (Front)
6. Remove the inner and outer brake pads from the
caliper mounting plate.
Use a screwdriver if necessary to remove the
pads from their installed position.
1. Inspect the caliper guide pins for free movement
in the caliper mounting plate.
181856
Brakes
Disc Brakes 5-71
8. Inspect the caliper guide pin boots for proper

seating in the retaining groove of the caliper
guide pin and the rear caliper mounting plate.
9. Replace the caliper guide pins and/or guide pin
boots if any of the following conditions exist:
Excessive Corrosion
Excessive Wear
Visible Damage
Important: Use GM replacement brake pads for all
GM vehicles in order to maintain the balance in
performance between the front and rear brakes. GM
replacement brake parts are carefully selected in order
to guarantee minimum stopping distance and
maximum controllability over the full range of operating
conditions. Installing front or rear brake pads not
recommended by GM may change the intended
performance, wear characteristics, and brake balance
of the vehicle.
1. Install the inner and outer pads into the caliper
mounting plate.Ensure that the wear sensor is at
the trailing edge of the outer brake pad when
the wheel is rotating forward. If the wear sensor is
not at the trailing edge, the outer brake pad is
on the wrong side.
2. Install the front brake caliper. Refer to Brake
Notices.
3. Install the caliper mounting pin bolts.
4.
5.
6.
7.
8.
9.
Tighten
Tighten the mounting pin bolts to 31 N-m (23 lb ft).
With the engine running, pump the brake
pedal slowly and firmly until the inner and outer
brake pads are positioned against rotor
(firm pedal).
Install the tire and wheel assembly. Refer to
Wheel Removal
Lower the vehicle. Refer to Lifting and Jacking the
Vehicle
Refill the master cylinder to the proper level with
clean, fresh brake fluid.
Inspect the hydraulic brake system for brake
fluid leaks.
Burnish the new pads. Refer to Burnishing Pads
and Rotors in this section.
171937
5-72
Brakes
Disc Brakes.
Brake Pads Replacement (Rear)
Removal Procedure

master cylinder.
Removal
4. Install two wheel nuts in order to retain the rotor.
5. Position a C-clamp (2) over the catiper
housing (1 ).
6. Tighten the C-clamp until the caliper piston
bottoms in the base of the brake caliper.Verify that
one end of the C-clamp rests oh the brake hose
fitting bolt/screw and the other end rests
against the outer pad .
. 181856
7. Remove the rear brake caliper from the mounting

plate. Refer to Brake Caliper Replacement (Rear)
Ensure that weight of caliper is adequately
supported.
8. Remove the inner and outer brake pads (2) from
the mounting plate (1 ).
9. Clean all the residue from the shoe guide surfaces
on the caliper mounting plate and the rear brake
caliper.
10. Inspect the caliper guide pins for free movement
11. Inspect the caliper guide pin boot for proper
seating in the retaining groove of the guide pin and
the caliper mounting plate. Replace the caliper
guide pins or the guide pin boots, if corrosion or
damage exists. Refer to Brake Caliper
Overhaul(FronQ
221494
Important:
Install the inner pad with wear sensor near the
piston.
Ensure that the wear sensor is on the leading
edge of the inner pad during forward wheel
rotation. If the wear sensor is not on the leading
edge, use the other inner pad in the
replacement kit.
Replace the inner and outer pads in axle sets only.
1. Install new inner and outer pads (2) into
mounting plate (1).
221494
Disc Brakes
Brakes
5-73
2. Install the rear brake caliper to the mounting

plate. Refer to Brake Caliper
Replacement (Rear)
3. Remove the wheel nuts securing the rotor.
4. Install the tire and wheel. Refer to Wheel Removal
6. With engine running, pump brake pedal until
brake pads are positioned against rotor
(firm brake pedal).
7. Verify that there are no leaks in the brake
hydraulic system.
8. Burnish the new pads. Refer to Burnishing Pads
and Rotors in this section.
Burnishing Pads and Rotors

Burnish the new braking surface after the brake pads
have been replaced and the rotors have been
refinished or replaced.
Burnishing "breaks in" the new pads or rotors.
Burnishing also removes light corrosion on the rotors.
Burnish the brakes by making 20 stops from
48 km/h (30 mph) using medium to firm pressure on
the brake pedal. Allow 0.8 km (0.5 miles) between
stops in order to avoid overheating the brakes.
Brake Caliper Replacement (Rear)

Removal Procedure
Removal
3. Install two wheel nuts in order to secure the rotor.
4. Complete the following steps if you are removing
the caliper (5) from the vehicle:
4.1 . Remove the brake hose bolt attaching the
brake hose fitting (4).
4.2. Remove the following items:
The copper gaskets
Discard the copper gaskets.
The brake hose from the caliper
4.3. Plug the openings in the caliper housing
and the hose in order to prevent loss or
contamination of the brake fluid.
222984
5-74
Disc Brakes
Brakes
5. Remove the brake caliper guide pin bolts and
discard.
6. Remove the rear brake caliper (3) from the inner
and outer pads (2) and mounting plate (1 ) .
If the caliper is not being removed from the vehicle
for unit repair, suspend the caliper from the rear
suspension using a fabricated wire hook.
221490
7. Remove the inner and outer brake pads (2) from
8.
9.
10.
11.
221494
12.
13.
the mounting plate (1) if the following

conditions exist:
The brake pads are also being replaced.
The brake caliper mounting plate is also being
removed.
Inspect the caliper guide pins for free movement
Inspect the caliper guide pin boot for proper
seating in the retaining groove of the caliper guide
pin and the rear caliper mounting plate.
Replace the guide pins or guide pin boots if the
following conditions exist:
Excessive Corrosion
Significant Wear
Visible Damage
Lubricate the inner diameters of the caliper bolt
bushings with silicone grease. Also lubricate the
caliper bolts with silicone grease.
Inspect the inner and outer pads for wear.
Inspect the in_ner and outer pads for
maximum taper.
Maximum taper of the rear brake pads is
0.15 mm (0.006 in).
If the pads are tapered beyond the maximum
specification, replace the inner and outer
pads as a complete set only.
Brakes
Disc Brakes 5-75
1. Install the inner and outer pads (2) into the
mounting plate (1 ).
2. Install the rear brake caliper (3) over the brake

pads (2) and into the caliper mounting plate (1 ).

Notices.
3. Install new brake caliper guide pin bolts.
Tighten
Tighten the brake caliper guide pin bolts to
37 Nm (72 lb ft).
4. Install the following components, if removed:
The brake hose
The new brake hose fitting gaskets
5. Install the brake hose fitting bolt.
6.
7.
8.
9.
1o.
Tighten
Tighten the brake hose fitting bolt to
30 N-m (22 lb ft).
Bleed the brake hydraulic system, if the brake
hose fitting was removed. Refer to Hydraulic
Brake System Bleeding (Manual Bleed)
Install tires and wheels. Refer to Wheel Installation
Lower the vehicle.
While the engine is running, pump the brake
pedal slowly and firmly three times in order to
seat the inner and outer pads.
Check the brake hydraulic system for leaks.
221490
5-76
Disc Brakes
Brakes
Brake Caliper Replacement (Front)
Removal Procedure
181856

master cylinder.
Removal
4. Push the piston into the housing bore in order to
provide clearance between the pads and the rotor.
4.1. Install a large C-clamp (2) over the top of
the caliper housing (1) and against the back
of the outboard pad.
4.2. Slowly tighten the C-clamp until the piston
is pushed into the caliper bore enough to
slide the caliper off the rotor. Do not
overtighten the C-clamp. Overtightening the
C-clamp will deform the outboard shoe.
5. Complete the following steps if the caliper is being
removed from the vehicle for overhaul or
replacement:
5.1 . Remove the brake hose bolt attaching the
brake hose fitting to the caliper.
5.2. Remove the following components:
The brake hose fitting
The copper gaskets
Discard the copper gaskets.
The brake hose from the caliper
5.3. Plug the openings in the caliper housing
and the hose in order to prevent loss or
contamination of the brake fluid.
6. If the caliper is being removed for service of the
mounting plate or the brake pads, do not
disconnect the inlet fitting.
63952
7. Remove the brake caliper guide pin bolts.

8. Remove the caliper housing from the rotor and
the knuckle.
If the caliper is not being removed from the
vehicle, suspend the caliper from the front
suspension using a fabricated wire hook.
63984
Brakes
Disc Brakes
5'77
9. Inspect the following parts for corrosion, cuts,

nicks or blockage. Replace any damaged parts.
The caliper guide pin bolts (6)
The caliper guide pin bushings
If corrosion and/or excessive wear is found,
use new parts, including bushings, when
installing the caliper. Do not attempt to polish
away corrosion.
142260
1. Lubricate the inner diameters of the caliper bolt
bushings (2) with silicone grease.
2. Lubricate the caliper bolts (1 ). Use silicone
grease. Do not lubricate the threads.
3. Inspect the caliper guide pins.

The caliper pin should slide through the pin
bushings and caliper pin bores using only
hand pressure.
If greater force is required, remove the caliper
pin and the bushings.
4. Inspect the mounting bores (4) for corrosion.
If corrosion exists, remove the corrosion
using a 1-inch wheel cylinder brush.
Clean the mounting bores using clean
denatured alcohol.
5. Replace the caliper pin and bushir.gs. Refer to
Brake Caliper Overhaul (Front)
142246
6. Install the caliper onto the mounting plate

and pads.

Notices.
7. Install the front brake caliper guide pin bolts.
Tighten
Tighten the front brake caliper guide pin bolts to
31 Nm (23 lb ft).
63984
5-78
Disc Brakes
Brakes
8. If the following components were removed, install
them onto the caliper housing using new copper
gaskets:
The brake hose
Tighten
Tighten the front brake hose fitting to
40 N-m (30 lb ft).
Removal
63952
Important: If the brake hose was removed, bleed the

caliper. Refer to Hydraulic Brake System Bleeding
(Manual Bleed)
11. Fill the master cylinder reservoir to the proper
level with clean brake fluid.
12. With engine running, pump brake pedal until firm
brake pedal is attained.
13. Check for leaks.
Brake Caliper Inspection

Check the calipers for outward signs of leaking fluid
and cracked or damaged piston boots. Also check for
excessive corrosion in the brake pad guiding
surface. All other types of caliper inspections should
be performed during unit repair.
Brake Caliper Overhaul (Front)

Important:
Replace all the components included in the repair
kits used to service this brake caliper.
Lubricate the rubber parts with clean brake fluid to
make assembly easier.
If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or
part of the brake system.
Replace the brake pads in axle sets only.
The torque values specified are for dry,
unlubricated fasteners.
Perform the service operations on a clean bench,
free from all mineral oil materials.
63980
Brakes
Disc Brakes 5-79
Caution: Do not place your fingers in front of the

piston in order to catch or protect the piston while
applying compressed air. This could result in
serious injury.
1. Remove the brake caliper from the vehicle. Refer

to Brake Caliper Replacement (Front)
2. Remove the pistons by directing compressed air
into the brake hose inlet fitting port of the brake
caliper housing.
171956
3. Remove the piston boots.

4. Remove the piston seals.
171964
5. Remove the brake caliper bleed screw cap.

6. Remove the brake caliper bleed screw.
7. Inspect the brake caliper bores and piston seal
grooves for scoring and corrosion. If badly
scored or corroded around the piston seal area,
replace the brake caliper housing.
171971
siso;
Brakes
Dis' .erakes
8. Inspect the brake calipermounting bracket guide

surfaces for corrosion and wear. Remove and
replace the brake caliper mounting bracket
if necessary.
9. Clean all the residue from the brake pad guiding
surfaces on the brake caliper housing and Uie
brake caliper mounting bracket.
10. Clean all the parts not included in the repair kit
with denatured alcohol.
11. Dry all the parts with filtered unlubricated
compressed air.
12. Blow out all passages in the brake caliper housing
and the brake caliper bleeder valve.
171985
Assembly Procedure
Notice: Refer to Fastener No#ce in Cautions and
Notices.
1. Install the brake caliper bleed screw.
Tighten
Tighten the brake caliper bleed screw to
12 N-m (106 lb in).
2. Install the brake caliper bleed screw cap.
171971
3. Lubricate the new piston seals and the brake

caliper bore seal grooves with brake f~uid.
4. Install new seals into the brake caliper bore seal-:
grooves.
5. Make sure the seals are not twisted.
6. Lubricate the brake caliper bores and the pistons
with brake fluid.
7. Install the boot and piston.
7.1. Install the boot over the end of the piston
so that the fold will face toward the brake
caliper housing piston bore opening.
7.2. Seat the boot into the brake caliper bore
groove and slide the piston into the brake
caliper bore.
7.3. Push down the piston to the bottom of the
brake caliper bore.
171964
Brakes
Disc Brakes 5-81
7.4. Make sure the boot is properly seated into

the piston groove and into the groove in the
brake caliper bore.
7.5. Repeat Steps 5 and 6 for the remaining
piston.
8. Install the brake caliper to the vehicle. Refer to
Brake Caliper Replacement (Front)
Brake Caliper Overhaul (Rear)

Important:
Replace all the components included in the repair
kits used to service this brake caliper.
Lubricate the rubber parts with clean brake fluid to
make assembly easier.
If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or
part of the brake system.
Replace the brake pads in axle sets only.
The torque values specified are for dry,
unlubricated fasteners.
Perform the service operations on a clean bench,
free from all mineral oil materials .
63982
Caution: Do not place your fingers in front of the

piston in order to catch or protect the piston while
applying compressed air. This could result in
serious injury.
1. Remove the brake caliper from the vehicle. Refer

to Brake Caliper Replacement (Rear)
2. Remove the piston by directing compressed air
into the brake hose inlet fitting port of the brake
caliper housing.
171956
Brakes
5-82 Disc Brakes

3. Remove the piston boot.
4. Remove the piston seal.
171975
5. Remove the brake caliper bleed screw cap.

6. Remove the brake caliper bleed screw.
7. Inspect the brake caliper bore and piston seal
groove tor scoring and corrosion. If badly scored
or corroded around the piston seal area,
replace the brake caliper housing.
171977
8. Inspect the brake caliper mounting bracket guide

surfaces for corrosion and wear. Remove and
replace the brake caliper mounting bracket
if necessary.
9. Clean all the residue from the brake pad guiding
surfaces on the brake caliper housing and the
brake caliper mounting bracket.
10. Clean all the parts not included in the repair kit
with denatured alcohol.
11. Dry all the parts with filtered unlubricated
compressed air.
12. Blow out all passages in the brake caliper housing
and the brake caliper bleeder valve.
171985
Brakes
Disc Brakes
5-83
Assembly Procedure
Notices.
1. Install the brake caliper bleed screw.
Tighten
Tighten the brake caliper bleed screw to
12 N-m (106 lb in).
2. Install the brake caliper bleed screw cap.
171977
1. Lubricate the new piston seal and the brake

2.
3.
4.
5.
6.
caliper bore seal groove with brake fluid.

Install the new seal into the brake caliper bore
seal groove.
Make sure the seal is not twisted.
Lubricate the brake caliper bore and the piston
with brake fluid.
Install the boot and piston.
5.1. Install the boot over the end of the piston
so that the fold will face toward the brake
caliper housing piston bore opening.
5.2. Seat the boot into the brake caliper bore
groove and slide the piston into the brake
caliper bore.
5.3. Push down the piston to the bottom of the
brake caliper bore.
5.4. Make sure the boot is properly seated into
the piston groove and into the groove in the
brake caliper bore.
5.5. Repeat Steps 5 and 6 for the remaining
piston.
Install the brake caliper to the vehicle. Refer to
Brake Caliper Replacement (Rear)
171983
5"!84
Disc Brakes
Brakes
Brake Caliper Bracket Replacement(Rear)
Removal Procedure
1. Remove the inner and outer brake pads. Refer to
Brake Pads Replacemenf(Rear)
,
Caution: These fasteners MUST be replaced With

new fasteners anytime they become loose or
are removed. Failure to replace these fasteners
after they become looseorare removed'maycause
loss of vehicle control and personal injury.
2. Remove the caliper bracket bolts (2).
3. Remove the caliper bracket (1 ).
177036
1. Lubricate the following components with silicone
grease:
New bolt boots
New bushings
2. Install the following components into the caliper
bracket (1 ):
The bolt boots (2)
The bushings
Notices.
3. Install the caliper bracket with the .bracket bolts.
Tighten
Tighten the caliper bolts to 225 N-rn (166 lb ft).
4. Install the inner and outer brake pads. Refer to
Brake Pads Replacement (Rear)
177063
Brake Caliper Bracket Reptacement

(Front)
Removal Procedure'
1. Remove the inner and outer pads. Refer to Brake
Pads Replacement (Front)
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. Remove the caliper bracket bolts (2).
3. Remove the caliper bracket (1 ).
177036
Disc Brakes
Brakes
bracket (1 ):
The boot bolts (2)
The bushings
5. Inspect the bracket ,1) for cracks.
6. Replace the bracket (1) if necessary.
5;.a5
177068
1. Lubricate the following components with silicone
grease:
New bolt boots
New bushings
2. Install the following components into the caliper
bracket (1 ):
The bolt boots (2)
The bushings
Notices.
3. Install the caliper bracket with the bracket bolts.
Tighten
Tighten the caliper bolts to 225 N-m {166 lb ft).
4. Install the inner and outer brake pads. Refer to
Brake Pads Replacement (Front)
177063
Brake Rotor Replacement (Front)

Removal Procedure
Removal
3. Remove the front brake caliper. Refer to Brake
4. Remove the caliper mounting bracket bolts and
bracket.
5. Remove the brake rotor from the wheel hub.
6. Clean the metal contact surfaces between
the brake rotor and the hub bearing flange.
63987
5-86
Brakes
Disc Brakes
1. Install the brake rotor onto the wheel hub.

2. Install the caliper mounting bracket and bolts.
3. Install the front brake caliper. Refer to Brake
Installation
6. Pump brake pedal several times until firm.
63987
Brake Rotor Replacement (Rear}

Removal Procedure
The rear brake rotor can be removed without
separating the caliper from the mounting plate (remove
as an assembly).
2. Remove the tire and the wheel. Refer to
Wheel Removal
3. Remove the rear brake caliper (2) and mounting
bracket and support with locally fabricated
hook (1 ). Refer to Brake Caliper .
Replacement (Rear)
18186'
4. Remove the brake rotor from the wheel hub .
221499
Brakes
Disc Brakes
5-87
Notice: Any new rotor must have the protective
coating removed from the friction surfaces before being
placed in service. Use Goodwrench Brake Parts
Cleaner P/N 12345754 or the 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.
1. Install the brake rotor onto the wheel hub.
2. Install the rear brake caliper and mounting plate
assembly. Refer to Brake Caliper
Replacement (Rear)
Removal
5. Pump the brake pedal several times until the
pedal is firm.
221499
Refinishing Brake Rotors (Rear)

Important: DO NOT refinish brake rotors when
performing routine brake maintenance, such as
replacing worn disc brake pads. Refinish a rotor ONLY
under the following circumstances:
There is a complaint of brake pulsation.
There is scoring greater than 1.5 mm (0.060 in).
All brake rotors have a minimum thickness dimension
cast into the rotor. This dimension is not a minimum
refinishing dimension. The minimum refinishing
dimension is larger than the discard dimension. Do not
use a brake rotor that, after refinishing, will not meet
the minimum thickness shown on the rotor. Always use
a new rotor. Refer to Component Specifications.
Accurate control of the rotor tolerance is necessary for
proper performance of the disc brakes. Machine the
rotor using precise equipment. Service the machining
equipment on a regular basis. Follow the
manufacturer's recommended maintenance procedure.
Ensure that the following tool accessories are in
good condition when refinishing the rotors:
The attaching adapters
The tool holders
The vibration dampeners
The tool bits
Always use sharp cutting tools and bits. Replace
cutting bits using equipment that is recommended by
the manufacturer. Dull or worn tools leave a poor
surface finish which will affect braking performance.
Always use anti-chatter silencer attachments when
refinishing braking surfaces. The attachments eliminate
tool chatter and will result in a better surface finish.
Ensure that the adapters are clean and free of nicks.
s~as
::Disc ,,,..,._
Brakes
.
Brakes
, fn order to correct brake pulsation, refinish rotors

using an on-vehicle brake lathe. Follow the equipment
manufacturer's recommended specifications and
procedure.
Important: Remove any rust and scale from the rotor
and spindle hub mating surfaces. Failure to do so
may' introduce excessive 19teral runol,!t IN,hen the rotor
. is mounted on the brake lathe, or when the rotor is
reinstalled on the spindle hub.
.
;
.,
'
,:''
The following two proceClltJres are recommended and

achieve adequate fSSYltS USingJwo different
.
off-vehicle disc brake lathes. If ,any other''lathe is used,
follow that lathe's i_nstructions a11d recommendations:
./!'
: Ammco Brake Lathe

R9ugh_Cut
_fil1is!1 Cut
Spindle Speed
150 rpm
150 rpm
Depth of Cut
(per side)
0.15 mm0.64 mm
(0.006 in0.025 in)
0.10 mm0.15 mm
(0.004 in0.006 in)
Cross Feed
(per rev.)
0.25 mm
(0.01 O in)
0.05 mm
(0.002 in)
Vibration
Dampener
Yes
Yes
Sand Brake Rotor

(Swirl Pattern)
No
Yes
..
Removal Procedure
1. lnspectall the mounting hardware.tor the following
conditions:
Rust
Nicks
Dirt
Abnormal wear
For proper results, ensure that all components
are ~r;i._good condition and clean.
2. Inspect the rotor:
. Measure the lateral runout. Refer'to Brake
Rotor Lateral Runout Check.
, Measure the thickness. variation. Refer to
Brake Rotor Thickness Variation Check.
Ensure that the mounting surface of the rotor
is clean and freeJrom rust and nicks.
3. Mount the J 37160-A on a spindle arbor.
Use a suitable combination of spacers or
collets in order to tighten the J 37160-A to
the arbor;
W1"1en using lathe$,_Wit'1 a 7/8~inch spindle
arbor, use the J 3716(J-50 _with the J 37160-A
'' ~,the j 37.160~50iS:'not required .with:lathes
using a 1-inch spir,idle, a(bor.
Notice: Refer, to Fast~ner Notice.in Cautions and
Notices .
4. M~unt the rotor onto the J 3n6o-A
,Mount ttie clamp plate to the rotor using the
.. enclosed bolts/screws.
The rotor may be installed and removed while
the J 37160-A is mounted on the machine
spindle.
Tighten
Tighten the rotor mounting adapter nuts in
. a cross pattern to 34 N-m (23 lb ft).
5: Install the anti-chatter silencer onto the rotor.
6. Set the spindle speed to ~pproximately 150 RPM
(or mid.:range).
7. While the' machine is running, bring th~ tool bit up
and touch off.
Stop the machine.
Inspect the witness mark. If the witness mark
goes 3/4 of the way around>the rotor is
mounted properly.
_.. Continue turning the rot9r using normal
methods in order to resurface the rotor.
8. If the witness mark does not go 3/4 of the way
. around, repeat the above steps. , :
>
l'
Accu Turn Brake Lathe

1. Locate the deepest score. Tum the rotor
micrometer knob until the tool bit bottoms out at
the deepest point of the score.
2. Zero the scale and back out the tool bit.
3. Advance the cutter handwheel until the bits have
cleared the inner edges of the rotor face.
4. Adjust the micrometer knobs for approximately
0.127 mm (0.005 in) more than the first reading.
Use this method in order to resurface the
rotor in one cut.
Finish Cut
Spindle Speed
105 rpm
Depth of Cut
As necessary
Cross Feed (per rev.)
0.08 mm (0.003 in)
Vibration Dampener
Yes
Rotor Mounting Adapter

Tools Required
J 37160-A Rotor Mounting Adapter

J 37160-50 Rotor Mounting Adapter Sleeve
Important: Verify that the mounting surfaces of these

components are clean and free from nicks, burrs
or rust.
, ......
!,,-
Nc:m~irec~ional 'Finishing
Ensure thc1.t th~ rotor surface is. nonctirectional by
dressing the rotor sud~_ces. Use a non-directional rotor
finisher such as the 54-433179 Non-Directional
Rotor Refinisher listed in the GM Dealer Equipment
Catalog, or a suitable equivalent.
If the brake lathe is not equipped with an adequate
nondirectional finishing tool, use a sanding block with
150 grit aluminum oxide sandpaper.
Brakes
Disc Brakes
589
With the rotor turning at the equipment manufacturer's

highest recommended cutting speed, sand each
rotor surface, for a minimum of .60 seconds using
moderate pressure;
The following two procedures are recommended and

achieve adequate results using two different
off-vehicle disc brake lathes. If any other lathe is used,
follow that lathe's instructions and recommendations:
After the rotor has been sanded, clean each surface

with denatured alcohol or a suitable brake cleaner.
Ammco Brake Lathe
Important: Replace any rotor that does not meetthe

minimum thickness specification recommended t;>y
the manufacturer. Do not resurface new brake rotors.
New brake rotors are manufactured with the proper
surface finish.
The finished rotor surface should be as close as
possible hthat of a new rotor: Failure to obtain the
best possible rotor finish may affect braking
performance:
Refinishing Brake Rotors (Front)

Important: DO NOT refinish brake rotors when
performing routine brake maintenance, such as
replacing worn disc brake pads. Refinish a rotor ONLY
under t.he following,.circumstances:
There is a complaint of brake pulsation.
There is scoring greater than 1.5 mm (0.060 in).
All brake rotors have a minimum thickness dimension
cast into the rotor. This dimension is not a minimum
refinishing dimension. The minimum refinishing
dimension is larger than the discard dimension. Do not
use a brake rotor that, after refinishing, will not meet
the minimum thickness shown on the rotor. Replace it
with a new rotor. Refer to Component Specifications.
Accurate control of the rotor tolerance is necessary
for proper performance of the disc brakes. Machine the
rotor using precise equipment. Service machining
equipment on a regular basis. Follow the
manufacturer's recommended maintenance procedure.
Ensure that the following tool accessories are in
good condition when refinishing the rotors:
The attaching adapters
Rough Cut
Finish Cut
Spindle Speed
150 rpm
150 rpm
Depth of Cut
(per side)
0.15 mm0.64 mm
(0.006 in0.025 in)
0.10 mm0.15 mm
(0.004 in0.006 in)
Cross Feed
(per rev.)
0.25 mm
(0.01 O in)
0.05 mm
(0.002 in)
Vibration
Dampener
Yes
Yes
Sand Brake Rotor

(Swirl Pattern)
No
Yes
Accu Turn Brake Lathe

1 . Locate the deepest score and turn the rotor
micrometer knob until the tool bit bottoms out
at the deepest point of the score.
2. Zero the scale and back out the tool bit.
3. Advance the cutter handwheel until the bits have

cleared the inner edges of the rotor face.
4. Adjust the micrometer knobs for approximately
0.127 mm (0.005 in) more than the first reading.
Use this method in order to resurface the
rotor in one cut.
Finish Cut
Spindle Speed
105 rpm
Depth of Cut
As necessary
Cross Feed (per rev.)
0.08 mm (0.003 in)
Vibration Dampener
Yes
The tool holders
Nondirectional Finishing
The vibration dampeners
Ensure that the rotor surface is nondirectional by

dressing the rotor surfaces. Use a non-directional rotor
finisher such as the 54-433179 Non-Directional
Rotor Refinisher listed in the GM Dealer Equipment
Catalog, or a suitable equivalent.
The tool bits

Always use sharp cutting tools and bits. Replace
cutting bits using equipmentrecommended by
the manufacturer. Dull or worn tools leave a poor
surface finish which will affect braking performance.
Always use anti-chatter silencer attachments when
refinishing braking surfaces. The attachments eliminate
tool chatter and will result in a better surface finish.
Ensure that the adapters are clean and free of nicks.
In order to correct brake pulsation, refinish the
rotors using an on-vehicle brake lathe. Follow the
equipment manufacturer's recommended specifications
and procedure.
Important: Remove any rust and scale from the rotor
and spindle hub mating surfaces. Failure to do so
may introduce excessive lateral runout when the rotor
is mounted on the brake lathe, or when the rotor is
reinstalled on the spindle hub.
If the brake lathe is not equipped with an adequate

nondirectional finishing tool, use a sanding block with
150 grit aluminum oxide sandpaper.
With the rotor turning at the equipment manufacturer's
highest recommended cutting speed, sand each
rotor surface for a minimum of 60 seconds using
moderate pressure.
After the rotor has been sanded, clean each surface
with denatured alcohol or a suitable brake cleaner.
5-90
Disc Brakes
Brakes
Important: Replace any rotor that does not meet the

minimum thickness specification recommended by
the manufacturer. Do not resurface new brake rotors.
New brake rotors are manufactured with the proper
surface finish.
The finished rotor surface should be as close as
possible, to that of a new rotor. Failure to obtain the
best possible rotor finish may affect braking
performance.
Description and Operation.

Disc Brakes System Description (Rear)
Rear. Brake Rotor
The rear brake rotor is a composite cast iron ventilated
rotor. The rear brake rotor has a stamped sheet
metal flange which is insert cast. The internal fins or
vanes between the friction surfaces radiate from
the center of the rotor to the outer edge of the rotor.
This design enables the rotor to act as its
own cooling fan.
Rear Brake Caliper
Applying the brake pedal creates hydraulic pressure.

This pressure exerts equally against.the bottom of the
piston and against the bottom of the cylinder bore. The
pressure applied to the piston transmits to the brake
pads (16, 18). The brake pads clamp down on the rotor,
creating friction in order to stop the car.
Application of the parking brake causes the following
components to move outward:
The pushrod (23)
The actuating collar (10)
The clamp rod (19)
The outward motion of the above components causes
the caliper to move inward. Inward motion of the
caliper forces the brake pads against the rotor in order
to hold the vehicle in place. The parking brake
mechanism is completely independent of the hydraulic
braking system.
Disc Brakes System Description (Front)

Front Brake Rotor
The front brake rotor is a machined, cast iron
ventilated rotor. The rotor is cast with cooling fins
between the friction surfaces. The internal fins
or vanes radiate from the center of the rotor to the
outer edge of the rotor. This design enables the rotor
to act as its own cooling fan.
Front Brake Caliper
181875
The rear brake caliper has a single piston (9) in an

aluminum housing (1 ). The housing is suspended in an
anchor bracket (4) on two guide pins (2). The caliper
mounts to the steering knuckle with two mounting bolts.
63980
The aluminum dual piston front caliper used on this

vehicle is mounted onto the front brake caliper
mounting plate, and ultimately to the steering knuckle.
Disc Brakes
Brakes
Applying the brake pedal creates hydraulic pressure.
This pressure exerts equally against the bottom of
the pistons and against the bottom of the cylinder
bores. The pressure applied to the pistons transmits to
the inner pad and forces the pad against the inner
rotor surface. The pressure applied to the bottom of
the cylinders forces the caliper to slide in the
caliper bolt bushings toward the center of the vehicle.
This movement forces the outer section of the
caliper against the back of the outer pad and presses
the pad against the outer rotor surface. As hydraulic
pressure builds, the pads press against the rotor
surface with increasing force. The increasing force
causes the vehicle to stop. In addition, it is this sliding
action that allows a disc brake caliper to compensate
for wear of the inner and outer pads. If upon
inspection, it is found that one pad is significantly
thicker or thinner than its counterpart, it would be an
indication that the caliper is not sliding freely, and
therefore not self-adjusting as it is should.
5-91

Illustration
J 36349
Front Dust Boot Seal
Installer
,77284
J 8001
Dial Indicator Set
The brake caliper piston seals, while sealing the

hydraulic circuit at the wheels, have a second function.
These seals, while firmly mounted in their channels,
do distort very slightly under brake actuation. When the
brakes are applied, the movement of the pistons out
of the caliper bores distort the piston seals. When
the brake pedal is released, the piston returns only as
far as the seal was distorted. While this distortion
of the seal shape is very minimal, it is enough to allow
the brake pads to retract very slightly so as to
eliminate any significant drag of the brakes.
J 37704
Disc Brake Lathe
J 37160-A
Brake Rotor Mounting
Adapter
155093
5-92
Patk Brake
Brakes
Park Brake
Specifications
Specification
Metric
English
Park Brake Indicator Switch Screw
2.8Nm
251b.in
Park Brake Lever Bolt
12 N-m
1061bin
Application
Repair Instructions
Park Brake Shoe Replacement
Removal Procedure
1. Remove the brake rotor. Refer to. Brake Rotor
Replacement (Rear).
2. Rotate the parkiri,g brake adjusting nut until the
adjuster is in closed (fully) seated position.
3. Remove the parking brake shoe assembly .
64007
Brakes
Park Brake i5-93
1. Install the parking brake shoe assembly.
2. Adjust the parking brake shoe to drum clearance.
Refer to Park Brake Shoe Adjustment
Replacement (Rear).
64007
Park Brake Shoe Adjustment

Tools Required
J 21177-A Drum to Brake Shoe Clearance Gauge
Important:
Adjustments are not normally necessary after
replacing the park brake lever or cables. The park
brake is adjusted automatically by pulling on
the park brake lever.
Never operate the park brake lever while the rotor
is removed.
1. Remove the brake rotor. Refer to Brake Rotor
Replacement (Rear).
2. Check for excessive scoring or wear. If scored
excessively, replace rotor. Refer to Brake Rotor
Replacement (Rear). Do not refinish parking brake
surface.
Important: If the gap between the adjuster nut and
screw exceeds 5mm during the adjustment procedure,
the brake shoe assembly must be replaced.
3. Adjust the parking brake shoe to drum clearance
to 0.38mm (0.15 in.) using J 21177-A.
4. Center the brake shoe.
5. Measure the brake shoe lining diameter across
the horizontal centerline using J 21177-A.
The diameter should measure 189.6mm
to 189.Bmm
6. Install the brake rotor.
7. Install two wheel nuts to retain the rotor.
Tighten
Tighten the wheel nuts finger tight. Do not
overtighten.
8. Cycle the park brake lever three times .
9. Rotate the rotor and check for drag.
If drag is present recheck and adjust the shoe to
drum clearance.
10. Install the rotor. Refer to Brake Rotor
Replacement (Rear)
5-94
Brakes
Park Brake
Park Brake Lever Replacement
Removal Procedure
Notice: Do not lubricate the parking brake cables.

Lubrication may damage the plastic coating on
the parking brake cables.
If the park brake lever does not fully return, lubricate
the following parts using chassis lubricant or the
equivalent:
The adjust pawl pin
The handle ratchet
The adjusting ratchet
182184
Tools Required
J 37043 Parking Brake Cable Release Tool
1. Remove the front floor console. Refer to Console
Replacement - Front Floor in Instrument Panel,
Gauges and Console.
2. Disconnect the electrical connector from the park
brake indicator switch (6).
3. Remove the park brake indicator switch screw
and the park brake indicator switch (6) from the
park brake lever (1 ).
4. With the park brake lever (1) in the up position,
remove the park brake lever spring (2).
5. With the park brake lever (1) in the down position,
rotate the adjuster arm toward the front of the
vehicle until a 3 mm metal pin can be inserted into
the hole.
5.1 . Remove and discard the remaining piece of
plastic shear pin.
5.2. Insert a 3 mm metal pin into the hole,
locking out the self adjuster.
Park Brake
Brakes
7. Remove the rear cables from the park brake
cable equalizer (6).
9. Bend back the cable retainer tab on the pulley.
10. Remove the barrel-shaped front cable end
fitting from the adjuster track on the pulley.
5-95
182198
11. Remove the park brake lever bolts (3) and the
park brake lever (1) from the floor pan.
12. Use the J 37043 in order to remove the par1<
brake front cable (4) from the par1< brake
lever (1 ).
182184
5-96
Brakes
Park Brake
1. Connect the park brake front cable (4) to the park

brake lever (1 ).

Notices.
2. Connect the park brake lever (1) and the park
brake lever bolts (3) to the floor pan.
Tighten
Tighten the park brake lever bolts (3) to
12 Nm (106 lb in).
3. Connect the park brake indicator switch screw
and the park brake indicator switch (6) to the
park brake lever (1 ).
Tighten
Tighten the park brake indicator switch screw to
2.8 N,m (25 lb in).
4. Connect the electrical connector to the park brake
indicator switch (6).
182184
5. Connect the barrel-shaped front cable end fitting

to the adjuster track on the pulley.
6. Bend the cable retainer tab to the original position
on the pulley.
7. If the rear cables were not disconnected from the
equalizer, skip to step 11.
8. Raise the vehicle. Suitably support the vehicle.
General Information.
9. Connect the rear cables to the equalizer (6).
182198
Brakes
Park Brake
5-97
11. Rotate the adjuster arm toward the rear of the

vehicle and completely raise the park brake
lever (1).
12. Install the park brake spring (2).
13. Remove the 3 mm metal pin from the hole.
14. Cycle the park brake lever three times.
15. Install the front floor console. Refer to Console
Gauges and Console.
182184
Park Brake Cable Replacement (Front)

Removal Procedure
Notice: Use care when performing service operations
on or around parking brake cables. Damage to the
plastic coating will reduce corrosion protection and if
the damaged area passes through the seal,
increased parking brake effort could result. Contacting
the coating with sharp-edged tools, or with sharp
surfaces of the vehicle underbody, should be avoided.
Tools Required
Gauges and Console.
2. Remove the park brake spring (2) while the park
brake lever (1) is in the up position.
3. While the park brake lever (1) is in the down
position, rotate the adjuster arm toward the
front of the vehicle until a 3 mm metal pin can be
inserted into the hole.
3.1. Remove the remaining piece of plastic
shear pin from the hole.
3.2. Insert a 3 mm metal pin into the hole,
locking out the self adjuster.
4. Pull back on the park brake lever completely.
182184
5-98
.Brakes
Park Brake
5. Raise and suitably supporMhe vehicle . .Refer to

Lifting and Jaal<ing the Vehicle
6. Remove the rear cables (2) from the equalizer (1 ) .
214860
7. Use the J 37043 in order to remove the fitting of

the park brake front cable (4) from the bracket.
8. Remove the grommet (5) from the cavity in the
underbody.
10. Bend back the cable retainer tab on the pulley.
11 . Remove the barrel-shaped front cable end
fitting from the adjuster track on the pulley .
12. Use the J 37043 in order to remove the park
b,:al<e front ~le. (4). fr0Jl1 th.e ~~ braJ(e
leve~(1):

13. Remove the park brake front cable(4):from the '
floor plan.
182184
Brakes
Park Brake 5-99
1. Install the park brake front cable (4)and the
grommet (5) into the slot in the floor pan. Use
the following procedure in order to install the
grommet into the floor pan:
1.1 . Use soapy water as a lubricant.
1.2. Feed the forward end of the grommet (5)
into the slot.
1.3. Use a small, curved, flat-ended pry bar in
order to gently press the rearward end of
the grommet (5) into the slot.
1.4. Ensure that the grommet (5) is properly
seated in the slot in the floor pan.
2. Connect the front park brake cable (4) to the park
brake lever (1 ).
3. Install the barrel-shaped front cable end fitting into
the adjuster track on the pulley.
4. Bend the cable retainer tab to the original position
on the pulley.
5. Ensure that the park brake lever (1) is in the
down position.
182184
7. Connect the rear cables (2) to the equalizer (1 ).

214860
5-100
Brakes
Park Brake
9. Install the park brake spring (2) while the park .

brake lever (1) is in the up position.
10. Remove the 3 mm metal pin from the hole.
11. Cycle the park brake lever (1) three times.
Gauges and Console.
182184
Park Brake cable Replacement

(Rear W/Disc Brakes)
Removal Procedure
Tools Required
1. Fully disengage the park brake lever. Ensure that
the handle is down and that the brake indicator
lamp is not lit. If the park brake lever is partially
engaged, it will not be possible to pull the
equalizer rearward later in this procedure.
Information.
3. Remove the rear park brake cables (2) from the
park brake cable equalizer (1 ).
214860
Park Brake
Brakes
5-101
4. Pull the park brake cable equalizer rearward in

order to gain the necessary park brake
cable slack.
4.1. Insert a fabricated spacer (1) in order to
hold the park brake cable equalizer
in place.
4.2. Remove the rear cable from the park brake
equalizer.
182210
5. Remove the rear cable from the underbody

bracket.
Use the J 37043 in order to compress the retainer
fingers on the casing and pull the rear cable
from the underbody bracket.
6. Pull the park brake rear cable (3) through the
guide (2) that is installed on the rear axle
housing.
7. Remove the rear tire and wheel. Refer to Wheel
Removal
3
214857
8. Remove the rear cable (1) from the park brake

actuator lever (2) and the park brake cable
bracket. Complete the following procedure:
8.1 . Pull all the park brake cable slack to the
caliper end of the park brake cable.
8.2. Remove the rear cable from the tang on the
park brake actuator lever (2).
2
214859
5-102
Brakes
Park Brake
9. Use the J 37043 in order to compress the retainer

fingers on the cable casing (1) and pull the rear
cable from the cable bracket (2).
2
214854
1. Install the rear cable (1) to the park brake
actuator lever (2) and the park brake cable
bracket.
214859
2. Install the rear cable (1) to the park brake cable

bracket (2).
3. Seat the retainer fingers into the park brake cable
bracket.
2
214854
Park Brake
Brakes
5-103
4. Install the rear tire and wheel. Refer to Wheel

Removal
5. Pull the rear cable (3) through the park brake
cable guides (2) on the rear axle housing (3).
6. Install the rear cable into the underbody bracket.
If the tie strap was removed, install a new tie
strap in the place of the original tie strap.
7. Connect the rear park brake cable to the park
brake cable equalizer (6).
3
214857
8. Remove the fabricated spacer.

10. Cycle the park brake lever three times.
182210

Adjuster
2. Remove the rear tire and wheel assembly. Refer
to Wheel Removal
3. Disconnect the park brake cable from the park
brake lever.
Gauges and Console.
6. With the assistance of another technician, pull the
disconnected park brake cable downward until it
is fully extended and install a rivet, drill bit,
zip tie or cotter key through the lined up holes in
the park brake lever. Do not overextend
the cable.
.............
ru
....
64001
s-104
Park Brake
Brakes
Adjuster
1 . Connect the park brake cable to the park
brake lever.
2. Remove the rivet, drill bit, zip tie, cotter key from
the park brake lever.
Gauges and Console.
4. Raise the vehicle.

Notices.
5. Install the tire and wheel assembly. Refer to
Wheel Installation in Tires and Wheels.
54001
Tighten
Tighten the wheel nuts in sequence to
140 N-m (100 lb ft).
7. Cycle the park brake lever up and down three
times for auto adjustment.
Brake Drum Inspection

Refinishing Rear Brake Rotor Parking Brake
Surface
The rear brake rotor parking brake contact surface
should not be refinished. If the parking brake system
can't effectively hold the vehicle, and all other
parking brake components are functioning properly,
replace the rotor. Refer to Brake Rotor Replacement
(Rear). In addition, If the parking brake surface is
excessively scored (vehicle driven with parking
brake on), replace the rotor.
Backing Plate Replacement

Removal Procedure
1. Remove parking brake shoe. Refer to Park Brake
Shoe Replacement
2. Remove parking brake actuator. Refer to Park
Brake Actuator Replacement
3. Remove brake backing plate bolts.
4. Remove brake backing plate from axle.
1. Install brake backing plate to axle.
Notices.
2. Install brake backing plate bolts.
Tighten
Tighten brake backing plate bolts to
58 N-m(43 lb ft.).
3. Install parking brake actuator. Refer to Park Brake
Actuator Replacement
4. Install parking brake shoe. Refer to Park Brake
Shoe Replacement
Brakes
Park Brake
5-105
Park Brake Actuator Replacement

Removal Procedure
1. Remove the rear brake rotor. Refer to Brake
Rotor Replacement (Rear)
2. Rotate the parking brake adjuster nut until the bolt
is in the closed position.
3. Remove the parking brake shoe.
4. Remove the two actuator mounting bolts.

5. Remove the actuator assembly from the brake
backing plate .
1. Apply grease to positions 1 and 2. Do not apply
grease to position 3 .
64006
5...106
Park Brake
Brakes
2. Install the a,ctvator toJhe brake, Qacking plate.
Notice: Refer to Fastener Notice. in Cautions and
Notices.
3. Install the actuator mounting bolts.
Tighten
Tighten the actuator mounting bolts to
70 Nm (52 lb ft).
4. Install the parking brake shoe.
5. Adjust the parking brake. Refer to Park Brake
Shoe Adjustment
Replacement (Rear)
64007
Description anct operation

System Description
Park Brake System
The park brake system for this vehicle has been
changed and now contains the "drum and hat" parking
brake system instead of the previous system which
relied on the disc braker caliper for parking brake
system operation. The park brake system allows a
mechanical application of the rear parking brake shoes
to the inner rotor surface by pulling the park brake
lever. When the park brake system is applied,
the effort with which the brake lever is moved is
transmitted to the rear brake shoes by the cables
which this forces the rear brake shoes outward against
the inner rotor surface.
Park Brake Lever

This vehicle is equipped with a self-adjusting park
brake lever. This mechanism automatically takes up
any slack in the cables and provides.,the cor;rect "'
amount of tension in the cables when the system is
engaged. The park brake cables cannot be manually
adjusted. When operating correctly; the rear park
brake actuator applies force to the rear brake shoe and
forces it against the inner rotor surface. When the
parking brake lever is released, the parking brakes will
fully return to their mechanical stops eliminating any
drag on the brake rotor.
Park Brake 5-107
Brakes
Park Brake Cables
The park brake system uses the following three
separate cables:

Illustration
The front cable

The left rear cable
The right rear cable
The left and~right rear c~bles are joined to the front
cable at the park brake cable equalizer. This vehicle is
equipped with coated park brake cables. The cable
is coated with a plastic material which slides over the
plastic seals inside the conduit end fittings. The
plastic material coating is for corrosion protection, and
reduced park brake effort.
BRAKE Warning Lamp

The. red BRAKE warning lamp illuminates when
the ignition switch is in the START position
and the park brake lever is applied or is not iully
released.
The park brake warning switch is located on the
park brake lever.
The park brake lever will ground the BRAKE
warning lamp circuit and cause the BRAKE
warning lamp to illuminate.
J 37043
Parking Brake Cable
Release Tool
157368
5-108
Brakes
Specifications
Specification
Application
Metric
English
Brake Pipe Fittings At Brake Pressure Modulator Valve (BPMV)
15 Nm
11 lb.ft.
Brake Pressure Modulator Valve Bracket Bolt/nut
10N:m
?lb.ft.
Brake Pressure Modulator Valve Bracket Nut to Brake Pressure

Modulator Valve
12Nm
8 lb.ft.
Electronic Brake and Traction Control Module (EBCM/EBTCM) to Brake

Pressure Modulator Valve Bolt/Screw
2.9Nm
26 lb.in.
Wheel Speed Sensor Mounting Bolt
10 Nm
89 lb. in.
Adjuster Assembly Attaching Nuts
25.Nm
19 lb. ft.
GM SPO Group Numbers

Application
GM SPO Group Number
4.730
Brake Pressure Modulator Valve Bracket
4.730
Electronic Brake and Traction Control Module
4.720
Stoplamp Switch
2.447
Wheel Speed Sensor
4.710
4.720
Brakes
5-109

BPMV Hydraulic Flow Chart (Without TCS)
1
19
2
4
15
8
14
13
11
12
REAR AXLE
FRONT LEFT
FRONT RIGHT
215234
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Master Cylinder
Front Brake Pipe
Check Valve
Damping Chamber
Pump
Pressure Accumulator
Right Front Inlet Valve
Left Front Inlet Valve
Right Front Outlet Valve
(10)
( 11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Right Front Rotor

Left Front Outlet Valve
Left Front Rotor
Rear Rotors
Rear Outlet Valve
Rear Inlet Valve
Damping Chamber
Check Valve
5-U O Antilock Brake System

,.
Brakes
'~
BPMV Hydraulic Flow Chart (With TCS)
23
25
5
21
9
Rear
Left
Rear
Right
10
Front
Left
215251
Legend
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Master Cylinder
Front Brake Pipes
Check Valve
Damping Chamber
Pump
Right Front Inlet Valve
Left Front Inlet Valve
Right Front Outlet Valve
Right Front Rotor
Left Front Outlet Valve
Left Front Rotor
Right Rear Rotor
Right Rear Outlet Valve
(15)
(16)
(17)
(18)
(19)
(20)
(21)
(22)
(23)
(24)
(25)
(26)
(27)
Left Rear Rotor

Left Rear Outlet Valve
Right Rear Inlet Valve
Left Rear Inlet Valve
Check Valve
Pump
Check Valve
Damping Chamber
Isolation Valve
Prime Valve
Internal Damper
Rear Brake Pipes
Brakes
5-111
Antilock Brakes System Schematic References
Section Number Subsection Name
Brake Warning Cell 41
5-Brakes
a-Cruise Control
Cruise Control Cell 34
a-Wiring Systems
Data Link Connector - Cell 50
a-Lighting
Exterior Lights - Cell 110

Fuse Block Details - Cell 11
a-Wiring Systems
8-Wiring Systems
Ground Distribution - Cell 14

Instrument Cluster - Cell 81
8-lnstrument Panel, Gauges and

Console
Power Distribution - Cell 10
8-Wiring Systems
Antilock Brakes System Schematic Icons

Icon Deftnilion
Icon
19384
Refer to OBD II Symbol Description Notice in Cautions and Notices .
19385
ABS/TCS Schematics (Antilock Brakes-Power and Ground)

Data Link
Connector
!Hot In RUN, BULB TEST And STARTj
~ -
'" - - - - - - - - - - - - - - - - - - - - - - -....-P;we-;- - ., Underhood

ABSBATT1
ABS BATT 2 Distribution I Electrical
L4
L2
MaxiFuse
MaxiFuse Cell 10
I Center 1
40A
50A
I
K4
I H9
________ ...
._
Power
., Underhood
Distribution : Electrical
cen 10
Center 2
I
ABS IGN ill)

MiniFuse
10A
..I _ ________ ...I

IH10
5 RED 1802
-
-.-----_-_-_-_-_,___ _ _ _ Power
J11
I
I J10
ABS BATI
MiniFuse
25A
------
._
J9
JS
I
I
Positive
Voltage
Battery
________ ...
IDEsc!
0
(')
m
...
I
(DLC)
Cell50
P100
0.8 PNK 739
:::s
::::!:.
CJ)
'<
en
co
0.35 TAN 800
0.35TAN
8184 ---8-00---~
0.35 TAN 800
14
13
., Underhood
Distribution I Electrical
een 10
I Center 1
I
Fuse Block
Details
Cell 11
30RN 440
'" Battery -
TCS BATT
MiniFuse
20A
)>
0.35 TAN 800

0.35TAN
8225 - - - - - - - ,
800
0.35 TAN 800
A12 C200D
Data Link
Connector
C200A
3 RED 302
~
IL0 c I
(DLC)
Positive
Voltage
I
I
QJ.
-
v - - - - - - - - - 12
Solenoid
Valve
24
Ignition
- -
Positive
Voltage
C1
serial Data -
(UART)
., Electronic
I Brake
I Control
Control
Relay
I Module
I (EBCM)
:.\lJ.sU .~ .iu /0.sU ~t_o____ ~_;~

Left
Front
Inlet
Solenoid
Valve
Brake
Pressure
Modulator
Valve
(BPMV)
Left
Front
Oudet
Solenoid
Valve
Right
Front
Inlet
Solenoid
Valve
Right
Front
Oudet
Solenoid
Valve
Rear
Inlet
Solenoid
Valve
Rear
Oudet
Solenoid
Valve
Pump
Motor
1 C2
12
3BLK
------
15
C1
150
2 BLK 651
8113
--,
I
I
Solenoid Coila Are

Part Of The Bectronlc
Brake Control Modula
(EBCM)
Ground
Distribution
Cell14
T
3BLK
G106
...Im
-=- G101
C'D
202149
en
ABSITCS Schematics (Antilock Brakes-IP Indicators)
iHot In RUN, BULB TEST And START

r - - - - - - - -
I
I
Not
used
G3
I
I H4
iHot At All Timesi
-P;~ - - - - - - - - ,1/P
GAUGES
Fuse 9
10A
H3
STOP/HAZARD I Fuse
Fuse 1
I Block
20A
I
Distribution
Cell 10
L-
- -
---------------------------------------
Fuse Block
Details
Cell11
r-
I Instrument +-----------------+---------------,
I Cluster
BRAKE
~ LOW TRAC
I Cell S1
I
Warning
Indicator
I
I
(0)((D)
ASS INOP
Indicator
Amber
Instrument
I Cluster
B C1
I })
0.8 LT BLU 20
I .1 ..~
Indicator
Amber
I~
Red
....-.........- - - - - - - : r - - - ,
7-
26
r,
LOWTRAC Brake
Indicator
Malfunction I . -f Control
Indicator
I
Lamp Driver I
-=I
Module
cell 110
l?
ABSINOP Indicator
....f Control
-=-
0.8 LT BLU 20
C200A
C200D
P100
0.8 LT BLU 20
S154 _ _ _o_.8_L_T_B_LU
_ _.
20
o. 8 LT BLU 20
-
BRAKE
Indicator
... T Control
_._
~
~
J.
(Normally
open)
Cruise
Control
Cell34
C1
St;la-;;;p-1- ~
Switch
Signal
I
I
..,,.
I
L-----------16 -Z------------..1
C1
._c__..________. 4~
Exterior
Lights
A4
? -----------------------------~
- -
C1)
u,
0.8 LT BLU 20
~-------------MO
M6I ----~71 --~----J
537
0.35 LT GRN 867
________
8243---------------------~
I
I
0.35 DK BLU
0.8 ORN
140
Stop
Lamp
Switch
0.35
PNK 39 0.35
0.35 DK BLU 1537
TAN/WHT 33
0.35 LT GAN 867
.----.
A9
A3 C200D
.
..
- -f.C200A
8228
------P100
0.35
TAN/WHT 33
.a
0c
0
! Esc!
A C1
39
-
0.8 ORN 140
8206--------------------------,
r -
OJ
IL
0.8 PNK 39
Electronic
Brake
Control
Module
(EBCM)
_.
~
~
0.35 YEL/BLK 1471

P100
0.35 BLK 650
----
8216
3BLK 650
/
Ground
Distribution
Cell14
.,.
~----..J
AS
C200A
C2000
0.35 YEL/BLK 1471
-=- G200
L-----------------------------------------------------------------------------------------------------------------------:2=02~7~52
(11
.1.
.....
c,.)
ABS/TCS Schematics (Antilock Brakes-Wheel Speed Sensors)
123-ilri.:. 12:92,.
Left
Front
Right
Front
0.8 LTBLU 830
!Loe
Sensor,
Rear
0.5BLK 884
c
C1
~
~
,:~
0.5WHT 885
0.8 LT BLU 872
[S]
131=~
0.8YEL 833
0.8YEL 873
U'I
I
D C405C
--------
01 C405B
0.35BLK 884
B C120
0.35RED 885
B C130
A15
O.SYEL 873
A14
--------
C200D
C200A
-------
P100
0.5TAN 833
0.5DKGRN 872
0.5 LTBLU 830
0.5 BLK 884

0.5 RED 885
21
: - _T-;..;
I
I
I
.._ Low
20
;;_-.;.--=
'VVv
High
Left Front Wheel
Speed Sensor
22
.t
Low
'VVv
tt""
Right Front Wheel

8peecl Senior
........
"'""
r--:
23C1
~r-:-.;.--=-;..; ;;.-;;.-1-=-;..; ;;.-.;.--= I ~: ;;.--= -~;;.-;;.--=~I ;;.-~ --= ~-;;.

Wv
Low
RNr Wheel
Speed Sensor
i~:onlc
.l
...
Control
I Module
I (EBCM)
I
~-----------------------------~---------~,:~
202754
...I,
...I,
)>
:s
::::!:.
0n
m
....
m
fa
Cl)
'<
(I)
ci
3
ABSITCS Schematics (Antilock BrakeslTracticm Control-Power and Ground)
!Hot In RUN, BULB TEST And START!
Data Link
Connector
Underhood
r - - - ,Underhood
(DLC)
: H9
ABS IGN
een 10
I Center 1
MlnlFuse
eeu 10
Center 2
9
I
IH10 10A
I
0.35TAN
800
I
I
I
_
_ _0_.35_T_A_N_,
L8225
800
0.8 PNK 739
0.35TAN 800
A12 C2000
DataUnk
Underhood
Connector
C200A
TCS BATT
(DLC)
Cell 10
I Center 1 s1a1--o.:..':.:;;8...:.P...:.N..:.;K..:._--1A
Cell SO
P100
I
739
0.35TAN 800
8184 _ _ _
_ _ __,
0.35TAN
800
0.8 PNK 739
.__-_-_-_-_-_-__-_-_-_-_-P;:,; - ,
ABSBATT1
L.2
40A
K2
MaxlFuse
... -
ABS BATT 2
MaxiFuse
50A
________ .
5 RED 1802
3 RED 302
...
!Loe
ABS
~~n:use
30RN 440
D,)
f
u,
~
~
[B
--------J
----------------------------P~;
-,
BATT
r -...
: J11
I J10
-P-;~ -
m
"'I
,:~
:n_ruse .
Electronic
Brake And Traction
Control Module
(EBCM/EBTCM)
0.35TAN 800
?~
~~
r-------------------------------------------------------------------,
l
13
I
I
I
-----~~
Battery
Positive
Voltage
---------------------------------------~
Battery
l 2V
Positive
Voltage
____________________________
Solenokl
Valve
C1
Serial Data
(UART)
Ignition
Poafflve
Voltage
I
I
I
Control
--- Relay
1~
I
I
I
I
I
I
I
12V
--1
ASV1
Left
Left
Righi
IAft
IAft
Righi
1-----------------------------------------------------------------------....a---------------------------2
SOienoid
Solenoid
Front
Front
Front
Front
Rell'
Rell'
"RNr
Righi
USV1
Vetve
Inlet
Outlet
Inlet
Outlet
Inlet
Oldlll
Solenoid
Valve
Solenoid
Valve
Solenoid
Valve
Soltnold
Outlet
Solenoid
Inlet
Solenoid
Valve
Solenoid
Solenoid
Valve
Val\19
Vtwe
VM
Vrlve
Motor
Control
Relay
-~---l-~0_!!!1<!._~
C2 12
15 C1
0n
3 BLK 150
""
m
2 BLK 651
$113
Brake
Pressure
Modulator
Valve
(BPMV)
- -,
I
Solenoid Colle Are

Part OI The Electronic
Brake Control Module
l>
::,
:::::!:.
.CJ)
(EBCM)
CD
G101
202756
CJ1
I
.....
.....
CJ1
ABSITCS Schematics (Antilock Brakes!Traction Control-IP Indicators)

! Hot In RUN, BULB TEST And START!
r - - - - - - - - I
I
I
Not
used
G3
H3
GAUGES
Fuse 9
10A
;o~r -
! Hot At All Times!

- - - -
Distribution
Cell 10
(J1
STOP/HAZARD
Fuse 1
20A
I H4
!Loe
"'1/P
I Fuse
I Block
I
L-
-------------------------------------------
0.8 PNK 39
/
..--
Fuse Block
Details
Cell11
0.8 ORN 140
Instrument
Cluster
Red
I
I
TCSOFF
Indicator
Amber
B C1
I
I
0.8 LT BLU 20
3~- ---~-;~-~~:~Iwii~~-~: 1~--"~~ ~~J;s,2
Brake
Warning...- cen41
A3 C200D
--------- C200A
P100
------0.35 DK BLU 1537
0.35
0.35 LT GRN 867
Cruise
DKBLU
Control -1-53_7_ _ 8278
0.35
TAN/WHT 33
)>
::::,
~
~
'~
@
en
'<
tn
(I)
C200A
C200D
P100
0.8 LT BLU 20
8154
0.8 LT BLU 20
~
34
0.8 LT BLU
20
Cruise
Control
Cell 34
Cell34
. - - - - - - - - . . - - - , Brake 0.35 DK BLU 1537

26
Malfunction
Indicator
r
I
Lamp Driver
Indicator
7-LOW_TRAC_ -J-
Modulo
....C__.._ _ _
0.-35-B_L_K.......6-50
8216
,!~ _,, ~
- - _...,.
3 BLK 650
Distribution
ce1114
~---.....;...J
=
.
_
,
.
:
-------0::v:~-t;~ -----------------------f''""
ABSINOP- Indicator
J""""
- - - BRAKE
f)
[i
C1
St;l;,p-,- - - - - - - - - - - ..1 Electronic

switch
Brake And Traction
~;~
:~M/EBTCM)
A5
C200A
C200D
0.35 YEL/BLK 1471
m
...
G200
202759
::!:
0
A4
A9
8228
0.8 LT BLU 20
0
! Esc!
0.8 LT BLU 20
-------- ----- -------- -----J
0.35
PNK 39 0.35
TAN/WHT
(Normally
open)
O>
8243
I
I
..,,.....,......,........
L.----A10
AI
Exterior
Lights
Cell 110
Stop
Lamp
Switch
..I
ChevroleU
ASR
Pontiac
0.80RN
140
A C1
~
r-------------- -------------------I
llnstrument - - - - - - - - - - - - - - - - - - - - - - - ,
I Cluster
BRAKE
A LOWTRAC
ABSINOP
Pages
Warning
Indicator
Indicator
I ea-01-1,3
Indicator
Amber
Amber
I
-----~
I
......
......
r -
ABSfTCS Schematics (Antilock Brakes!Traction Control-Accelerator Control)

-
- -
.,
Electronic
!Hot At All Times!
I Brake And Traction

I Control Module
1 (EBCM/EBTCM)
:~-T~~;-:-~-~--,r--~~;;~=1~~::~-~~-:~: ~1[.- ------~
0.35
ORN/BLK 463
--------
P100
C101
$120
C212
30
0.5 TAN/BLK 4640.5
35
Retard
Output
I
:
C212
E C211
P100
0.8 BLK/WHT 151

0.8 BLK/WHT 151
W~~r~.8 W:T15600.B
D C212
B
56
--------
1 WHT 560
1 WHT 560
C211
Electrical
: Center 1
--------"'
1540
0.8 ORN
1540
1540
0::1561
F C212
C212
0.8 ORN
ORN 1540
24
1g;"iu;; -
P100
C211
- ~;; - Potltlve
Voltage
1540
51
Battery - - - - ., Accelerator
Positive
Voltage
I And Servo
: Control
,!~
l>
:::s
:::::!:
1 GRY 561
5204
0
C')
1 GRY 561
-""
...m
D>
5205
2 WHT 560 2 GRY 561
en
P100
A
G102
~
- - - -
0.8 PNK 1739~-~
o:1 1.a
5209----~
3 BLK/WHT 151
Voltage
~ _ _ _ _ ~o~n~ _ _ _ _9r~u~ ____ ~J- ___ j_ _ _ _ _

0.8 BLK/W::1151
1
0.8 BLK/WHT 151
eeu 1o
~r~;e
-1 I
E_J __J?_j __________________ ~~itt
B
Poattlve
55
Distribution
:n:use
. . . . - - - - - 5203
~~N
I Control
-Sl~na~ - - - - - - - - - - -
0.8 ORN
81
~~
- - -P-;;we-; - ., Underhood
I
rcs BATT
C2
37
'-~
~l~~;ent
eeu
1
I J9
1 JS
- - - - r~"';, - ., Powertraln
ORN/BLK 463
35
-
0.35 WHT
121
0.35 WHT 121
C1
-rcs spa-;i; I
0.8 PNK 739
0.35 WHT 121
0.35
GRY/BLK 1687
r -
t.-3.f
~
'<
u,
CD
Accelerator
Control And
...__ _ ___. Adjuster
(J1
.....
.....
I
202761
.......
ABSITCS Schematics {Antilock BrakeslTraction Control-Traction Control Switch)

lHot In RUNi
,------
:;:~on
I
I Cell10
I
I...
F1
0.8BRN 141
..., __
:nsor
_____ ____ ..
E1
-r- -:~:r
0.8 BRN 141
r-o-----~~
g[~HT
451
C200D
C200B
0.35
PPL.JWHT 1572
----,
I Module
[S]
~
~
,!,
Throttle
Position (TP)
Sensor
0.35 DK BLU I417 0.5 GRYI596

0.5 BLK1452
40
41
43
" - - - - - - - - - - - - - - - - - - - ., Accelerator
I
I And Servo
0.35 PPUWHT 1572
I
I Control
A13
C200D
C200A
0.8
BLK/WHT 461
._ -35 - - - - - - - 37- - - - - - - - -
P100
F C220
Module
J
0.5 TAN/BU<I464 0.5 ORN/BLKI463

C
A C~2
P100
0.5 TAN/BU<
T~---~~~-~~~~~~KT4~00
(ASM)
~T-__________
8110
3 BLK 451
G110
17 _____________1~ ___________
-~lc1
" - - - - - - - - - - - - - - - - - - - - - - - - - - - - ., Electronic
I
I
I Control
I...
J ~
(EBCM/EBTCM)
~
'116.
202763
ex,
>
:::,
0
(')
tu
"'I
D>
u,
'<
tn
CD
0.36 DK BL~~~t3:-~:t-____ o:~-~~+~~
0.35
BRN/WHT 1571
8~5
~ensor:i
!Loe I
B
0.35 BLK 452
8119
0.35 BLK 452
K C100
0.35 GRY 596
P P ~ 1572_________ D5
Sensor
It .. fl
0.35DKBLU 417
. _ ----j----- ---J
F E 0.36 BI
=~-~23(l _1(t:
TP
,
- - "'' 12
43
0.350KBLU 417 0.35 GAY 596
$118
0.35 BLK 452
0.35 DKBLU 417
5116
0.35GRY 596
0.35
PPUWHT 1572
$207
Tl
t_-_:~ _! j_- -_--- --- - --
I Fuse
I Bl k
I OC
TURN B/IJ
Fuse2
20A
" - - - - - - - - - - - - - - - - - - - - - - - - - - ., Powertrain
:
sv
: Control
----,1/P
c.n
......
......
ABSITCS Schematics (Antilock Brakes!Traction Control-Wheel Speed Sensors)
@
@
1~2. 1r--?;12.
Left
Front
A'
B'
Right
Front
@
1ae.
Left
Rear
0.8 BLK 884
,_
0.8YEL 873
0.8YEL 833
[SJ
0.8WHT 883
C405C
C405B
0.35WHT 883
- - - - - - - _. -i
A10
0.5TAN 833
0.5 LT BLU 830
ff
ti)
0.35BRN 882
A14
0.5 YEL 873
0.8 BRN 882
0.35RED 885
B C130
a,
m
Right
Rear
81
0.35 BLK 884

C120
c --------D
A
--------B
-------------C1
01
A1
0.8 LTBLU 872
--------B
0.8RED 885
.)
0.8LTBLU 830
@
131=..
!Loe I
A11
--------
C200D
C200A
0.5 DK GRN 872

0.5WHT 883
0.5 RED 885
l>
:::::,
=::::!:.
__1
0n
0.5 BLK 884
0.5BRN 882
--r-----r- ------1-----r--------r-----r--------r-----1--21
______ ,?9
-----------~
vv,.,
->-
I_
I _l Low
1 -=I
High
Left Front Wheel
Speed Sensor
_l
-=-
-------~- ------------~~ ------~
Low
vv,.,
->
High
Right Front Wheel
Speed Sensor
vv,.,
High
Left Rear Wheel
Speed Senaor
_____________ )
Low
_l
.,..
E-
-------~ C1
vv,.,
High
Low
Right Rear Wheel
Speed Sensor
_l
-=-
a,
;
ff
~ :~=o~~ Traction
en
'<
ti)
'Control
I Module
I (EBCM/EBTCM)
I
CD
~------------------------------------------------------J,~
UI
I
202765
....
....
CD
5-120
Brakes
Component Locator
Antilock Brakes System Components
Name
Location
Locator View
Connector End View
Accelerator and Servo

Control Module (ASM)
Under the left side of the instrument panel,

near the kick panel

Connector End Views
Anti/ock Brakes System

Component Views

Connector End Views
HVAC Component Views

Connector End Views
Accelerator Control and In engine compartment, forward of the

Adjuster
right front wheelhouse
Brake Malfunction
Indicator Lamp Driver
Module
Brake Pressure
Modulator
Valve (BPMV)
Behind the center of the instrument panel

near the HV AC control
Mounted to the left front frame rail
Cruise Control Module
Mounted to the left frame rail. forward of

the wheelhouse
Cruise Control
Component Views
Cruise Control Connector

End Views
Data Link
Connector (DLC)
Under the instrument panel, right of the

steering column
Instrument Cluster
Component Views
Power and Grounding

Connector End Views
Mounted with brake pressure modulator

valve on the top of the left front frame rail

Component Views

Connector End Views
Electronic Brake Control Mounted with brake pressure modulator

Module (EBTCM)
valve on the top of the left front frame rail

Component Views

Connector End Views
Instrument Cluster
Connector End Views
Electronic Brake and

Traction Control
Module (EBTCM)
Instrument Cluster
On the left side of the instrument panel
Instrument Cluster
Component Views
IP Fuse Block
On the left end of the 1nstrumert panel

carrier
Instrument Cluster
Component Vtews
Under the consc e. c~ :he oase ol tne sr1tt

control lever
Tilt Wheel Column

Component Views
Park Neutral Position

Switch
Powertrain Control
Module (PCM)
(V6 VINK)
On the r:gn: S':::e c' '."e engine

compartr,,er:. ea c :"e ,.,hee""ouse
Power and Grouncing

Component Views
PCM Connector
End Views
Powertrain Control
Module (PCM)
(V8 VIN G)
Qr_ !r"'\e ,...g~~ s :;e 8' !!""e er1gine

ccrnpa-:re"'.. ea of the I'. heelhouse
Power and Grounding

Component v,ews
PCM Connector
End Views
Stop Lamp Switch
Cruise Control
Compcment Views

Connector End Views
Throttle Position (TP)

Sensor (V6 VIN K)
Mounted to the front of the throttle body
Engine Controls
Component Views
Engine Controls
Connector End Views

Sensor (V8 VIN G)
Mounted to the front of tlle throttle body
In the center of the instrument panel,

above the HVAC control
Lighting Systems
Component Views

Connector End Views
Traction Control Switch

(Pontiac)
On the left side of the upper console
Lighting Systems
Component Views

Connector End Views
Underhood Electrical
Center 1
On the Left front corner of the engine

compartment
Power and Grounding

Component Views
Underhood Electrical
Center 2
On the left front corner of the engine

compartment
Power and Grounding

Component Views
Wheel Speed Sensor,

Lett Front
Middle of left front steering knuckle
Ant(lock Brakes System

Connector End Views
Wheel Speed Sensor,

Left Rear
Mounted to rear backing plate of

wheel disc

Connector End Views
Wheel Speed Sensor,

Rear (without NW9)
Top of rear differential
Wheel Speed Sensor,

Right Front
Middle of right front steering knuckle
Engine Controls
Connector End Views

(Chevrolet)

Connector End Views
Connector End Views
Brakes
5-121
Antilock Brakes System Components (cont'd)
Name
Locator View
Connector End View
Mounted to rear backing plate of

wheel disc

Connector End Views
C100 (10 cavities)
Engine to forward lamp harness, in the

engine compartment, above the right
wheelhouse

End Views
C120 (2 cavities)
Forward lamp to wheel speed sensor

jumper harness, mounted to left frame rail
C200A ( 17 cavities)
Forward lamp to instrument panel harness,

behind the left kick panel and steering
column

End Views
C200B ( 18 cavities)
Forward lamp to instrument panel harness,

between the left kick panel and the
steering column

End Views
C200D (48 cavities)
Part of the instrument panel harness,

between the left kick panel and the
steering column

End Views
C211 (8 cavities)
Forward lamp to traction control module

jumper harness, under the left side of the
instrument panel, near the kick panel

End Views
C212 (10 cavities)
Forward lamp to traction control module

jumper harness, under the left side of the
instrument panel, near the kick panel

End Views
C220 (10 cavities)
Instrument panel to engine harness, under

the right side of the instrument panel,
behind the knee bolster

End Views
C4058 (16 cavities)
Instrument panel harness pass through

connector, forward of the rear axle

End Views
C405C (4 cavities)
Rear wheel speed sensor jumper to the

instrument panel harness pass through
connector, forward of the rear axle to the
speed sensor (ABS)

End Views
G101
In the engine compartment, attached to

the front of the left wheelhouse
G106
Attached to the top left side of the radiator

support
G110 (V6 VINK)
In the front of the engine, bolted to the

pulley above the NC clutch connector
G110 (V8 VIN G)
Attached to the rear of the left

cylinder head
G305
Bolted to the left rocker panel at the floor

pan bar 3
P100
Left side in the dash panel, engine to the

P110
Right side in the dash panel, engine to the

8113
In the forward lamp harness approximately

7 cm (3 in) from the engine coolant
tans/cruise control
8116 (V8 VIN G)
Engine harness, approximately 9 cm (4 in)

from manifold absolute pressure (MAP)
sensor breakout
8118 (V8 VIN G)
Engine harness, approximately 15 cm

(6 in) from manifold absolute pressure
(MAP) sensor breakout
8119 (V8 VIN G)

(Automatic
Transmission)
Engine harness, main branch,

approximately 8 cm (3 in) from automatic
transmission breakout
Wheel Speed Sensor,

Right Rear
Location

End Views
5-122
Brakes
Antilock Brakes System Components (cont'd)

Name
Location
Locator View
Connector End View
Engine harness, main branch,

approximately 9 cm (4 in) from vehicle
speed sensor breakout
Engine harness, main. branch, 8 cm (3 in)

from powertrain control module (PCM)
breakout
8154
Forward lamp harness, approximately

13 cm (5 in) from C120 (left front wheel
speed sensor) breakout
8181

approximately 20 cm (8 in) from the UH
electrical center 1 breakout
8184

approximately 5 cm (2 in) from the UH
electrical center 1 breakout
8203
In the forward lamp harness, main branch,

approximately 4 cm from C211/C212
breakout, toward C200
8204
Forward lamp harness, main branch, at

C211 /C212 breakout
8205
Forward lamp harness, main branch,

approximately 4 cm (2 in) from C211 /C212
breakout, toward P100
8206
Instrument panel, at rear compartment lid

release relay breakout
8207

branch, approximately 4 cm (2 in) from the
data link connector (DLC) breakout
8209
Forward lamp harness, main branch,

approximately 11 cm (5 in) from
C211 /C212 breakout, toward P100
8215

the antenna cable breakout
8216

the instrument cluster breakout
8217

branch, approximately 18 cm [l in) from
the body control module (BCM) breakout
8225
Instrument panel harness, approximately

6 cm (2 in) from blower motor breakout
8228

approximately 20 cm {8 in) from rear
compartment lid release relay breakout
8243
Instrument panel harness, approximately

9 cm (4 in) from G200 breakout
8278
Forward lamp harness, approximately

7 cm (3 in) into C215 breakout
8119 (VB VIN G)

(Manual Transmission)
8120 (VB VIN G)
..
"
Brakes
Antilock Brake System 5-123
Antilock Brakes System Component

Views
Right Front Engine Compartment
497421
Legend
(1) Right Front Wheelhouse
(2) Accelerator Control and Adjuster
(3) Forward Lamp Harness
5-124
Antilock BrakeSystem
Brakes
Inside of Left Steering Knuckle
497423
Legend
(1) Front Wheel
(2) Left Front Wheel Speed Sensor
(3) Lower Control Arm

(4) Brake Line
(Right side similar)
Brakes
5-125
Front of Center Console
498125
Legend
(1) Console
(3) Folding Top Switch
(4) Cigar Lighter
-5-126 Antilock Brake System
Brakes
Lower Left Front of the Engine Compartment
497425
Legend
(1) Brake Pressure Modulator Valve (BPMV)
(2) Electronic Brake Control Module (EBCM)
(3) Left Front Frame Rail
Brakes
5-127
Rear Axle and Differential (With Traction Control)
497520
Legend
(1) Right Rear Wheel Speed Sensor

(2) Right Rear Wheel Speed Sensor
(3) Left Rear Wheel Speed Sensor Connector

(4) Rear Axle
5-128
Brakes
Accelerator Control and Adjuster
Antilock Brakes System Connector

End Views

1
28
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29
68721
Connector Part
Information
1530-0027
2 Way F Metri-Pack 280 (BLK)
235270
Connector Part
Information
1218-6485
55 Way F (NAT)
Pin
Wire Color
Circuit
No.
PNK
739
Battery Feed
22
WHT
560
Accelerator Control and

Adjuster Motor Feed
24
ORN
1540
Battery Feed
26
GRY
561

Adjuster Motor Return
28
BLK/WHT
151
Ground
Pin
Wire Color
Circuit
No.
WHT
560

Adjuster Signal - High
GRY
561

Adjuster Signal - Low
Function
35
TAN/BLK
464
Traction Control System

Signal - Torque Delivered
37
ORN/BLK
463

Signal - Torque Desired
40
DKBLU
417
Throttle Position Sensor

Signal
41
GRY
596
Throttle Position
Sensor 5V Reference
43
BLK
452

Return
49
WHT
560

Adjuster Motor Feed
51
ORN
1540
Battery Feed
53
GRY
561

Adjuster Motor Return
55
BLK/WHT
151
Ground
Function
Brake Malfuntion Indicator Lamp Driver

Module
'\.
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62420
Connector Part
Information
Pin
Wire Color
1201-0488
6 Way PC Edgeboard STD (BLK)
Circuit
No.
Function
Not Used
PNK
39
Ignition Feed
YEUBLK
1471
BRAKE Indicator Control
BLK
650
Ground
TAN/WHT
33
BRAKE Indicator Control
Not Used
Brakes

Data Link Connector
Electronic Brake Control Module (EBCM)

11
5-129
I -
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30
20
68793
Connector Part
Information
Pin
Wire Color
1211-0250
16 Way F Metri-Pack
150 Series (BLK)
Circuit
No.
Function
Serial Data Signal Class B
PPL
1807
BLK
BLK/WHT
650
451
Ground
5
9
TAN
Serial Data Signal - UART
16
ORN
800
540
231364
Connector Part
Information
Pin
Wire Color
1219-1490
30 Way F GT 150 Series
Sealed (BLK)
Circuit
No.
DKGRN
872
TAN
833
Wheel Speed Sensor

Return - Right Front
LTBLU
20
Stop Lamp Feed
LTGRN
867
8
12
13
14
PNK
BLK
739
150
Ground
RED
302
Battery Feed
ORN
440
Battery Feed
15
BLK
651
Ground
16
YELBLK
1471
Brake Warning Indicator

Lamp Feed - Secondary
20
LT BLU
830
Wheel Speed Sensor

Signal - Left Front
21
YEL
873
Wheel Speed Sensor

Return - Left Front
22
BLK
884
Wheel Speed Sensor

Signal - Rear
23
RED
885
Wheel Speed Sensor

Return - Rear
24
TAN
800
26
DKBLU
1537
ABS Indicator Lamp

Output
Ground
Battery Feed
Function
Wheel Speed Sensor
Signal - Right Front
ABS Failure Indicator

Lamp Output
Ignition Feed
5-130
Antilock Brake, System
Brakes
Electronic Brake,and Traction Control

Module (EBTCM)
Electronic Brake and ,Traction Control

Module (EBTCM) (cont'd)
11
11
~DDDDDDDDD~
30
~D[]f][JODDDD~
20
.. ..
r-
30
20
231364
Connector Part
Information
Pin
Wire Color
1219-1490
Sealed (BLK)
Circuit
No.
Function
231364
1219-1,490
s~~le<;f'(BLK)
Connector Part
Information
Pin
Wire Color
Circuit
..
No'.
Function
24
TAN
800
BAN
882
Wheel Speed Sensor

Signal - Right Rear
WHT
883
Wheel Speed Sensor

Return - Right Rear
26
DKBLU
1537
ABS Indicator Lamp

Output
DKGRN
872
Wheel Speed Sensor

Signal - Right Front
27
ORN/BLK
463
TAN
833
Wheel Speed Sensor

Return - Right Front
Tractkln control system "

Signal - Requested TPS
Position
LT BLU
20
Stop Lamp Feed
LTGRN
867
ABS Failure Indicator

Lamp Output
PNK
739
Ignition Feed
TAN/BLK
464

Signal - Delivered TPS
Position
11 ,
WHT
BLK
RED
121
150
302
Tachometer Signal
12
13
14.
15
ORN
440
Battery Feed.
BLK
651
Ground
YEUBLK
1471
Brake Warning tndicatoi

Lamp Feed - Secondary
16
Stop Lamp Switch
Ground
Battery Feed
17
BRN/WHT
1571

Switch Signal
18
PPUWHT
1572

Indicator Lamp Output Failure
19
GRY/BLK
1687
Ignition Retard Signal
20
LT BLU
830
Wheel Speed Sensor

Signal - Left Front
21
YEL
873
Wheel Speed Sensor

Return - Left Front
22
BLK
884
Wheel Speed Sensor

Signal - Left Rear
23
RED
885
Wheel Speed Sensor

Return - Left Rear
I I i
...-
DD
I
73251
Connector Part
Information
Pin
Wire Color
ORN
LT BLU
1203-3701
2 Way F Metri-Pack
280 Series (GRV)
Circuit
No.
140
20
Function
Battery Feed
Stoplamp Switch Signal
Brakes
5-131
Traction Control Switch (cont'd)
Throttle Position (TP) Sensor
Connector Part
Information
Pin
Wire Color
1211-0192
3 Way F Metri-Pack
150 Series Pull. To Seat {BLK)
Circuit
No.
Function
596
BLK
452
Sensor Ground
417
Throttle PositiOn Sensor

Signal
DKBLU
12177195
6-Way F Metri-Pack {Black)
Circuit
No.
Wire Color
Function
Not Used

Sensor 5V Reference
GRY
Connector Part
Information
Pin
BRN/WHT
1571
Traction control system

switch signal
BLK/WHT
451
Engine control module

ground
Wheel.Speed Sensor, Left Front
304345
62485
35437
304345
Connector Part
Information
12177195
6-Way F Metri-Pack {Black)
Pin
Wire Color
Circuit
No.
BRN
141
Fuse output-ignition 3type Ill fuse
PPUWHT
1572
Traction control system

indicator lamp
output-failure
GRY
Function
Instrument panel
lamp feed
Connector. Part
Information
1205-2644
2 Way F Metri-Pack 150
Sealed (GRY)
Pin
Wire Color
Circuit
No.
YEL
873
Left Front Wheel Speed

Sensor Signal - Low
BLU
830
Left Front Wheel Speed

Sensor Signal - High
Function
5-132
Brakes
Wheel Speed Sensor, Left Rear (With NW9)
Wheel Speed Sensor, Right Rear

(With NW9)
35437
Connector Part
Information
35437
1205-2644
Sealed (GRY)
Connector Part
Information
Pin
Wire Color
Circuit
No.
RED
885
Left Rear Wheel Speed

Sensor Signal - Low
884
Left Rear Wheel Speed

BLK
Function
Wheel Speed Sensor, Right Front
Pin
Wire Color
1205-2644
Sealed (GRY)
Circuit
No.
Function
WHT
883
Right Rear Wheel Speed

Sensor Signal - Low
BRN
882
Right Rear Wheel Speed

Wheel Speed Sensor, Rear (Without NW9)
35437
Connector Part
Information
Pin
Wire Color
1205-2644
Sealed (GAY)
Circuit
No.
Function
YEL
833
Right Front Wheel Speed

Sensor Signal - Low
BLU
872
Right Front Wheel Speed

35437
Connector Part
Information
Pin
Wire Color
1205-2644
Sealed (LT GRY)
Circuit
No.
Function
BLK
884
Rear Wheel Speed

WHT
885
Rear Wheel Speed

Sensor Signal - Low
Brakes
5-133

Self-Diagnostics
Scan Tool Diagnostics
The EBCM/EBTCM performs system self-diagnostics,

and can detect and often isolate system malfunctions.
When a malfunction is detected the EBCM/EBTCM
sets a Diagnostic Trouble Code (DTC). The DTC
represents the malfunction, and may turn on the
Antilock Indicator, Red BRAKE Warning Indicator, and
Traction Control indicators (if equipped), and may
disable the ABS/TCS functions as necessary for the
duration of the ignition cycle.
Refer to the Scan Tool Manual for complete

information on scan tool diagnostics.
Displaying DTCs
The EBCM/EBTCM can display the DTC(s) through
the use of a scan tool.
Diagnostic Trouble Codes (DTC)
The Diagnostic Trouble Codes (DTC) function has

three modes that are described below:
DTC Information: In this mode, current or history
DTC(s) stored by the EBCM/EBTCM can be
displayed.
Enhanced Data: In this mode, DTC data for
current or history DTC(s) is displayed. This data
includes the following information at the time when
the DTC(s) was set:
Clearing DTCs
Brake switch status
The DTCs in the EBCM/EBTCM memory are erased

in one of two ways:
Scan tool method.
Ignition cycle default. This requires 100 ignition
cycles to pass with no detection of the DTC.
TCS switch status
Important: After DTC C0036, C0041, C0046, C0051,

C0056, and C0110 are cleared by ignition cycle
default the vehicle must be driven above 12 Km/h
(8 mph) for the ABS/TCS indicator(s) to turn off.
Whichever method is used, be sure to verify proper
system operation and absence of DTCs when the
clearing procedure is completed.
DTCs cannot be cleared by unplugging the
EBCM/EBTCM, disconnecting the battery cables, or
by turning the ignition OFF (except on the 100th cycle
of ignition cycle default without the malfunction
reappearing).
lntermittents and Poor Connections

Most intermittents are caused by faulty electrical
connections or wiring, although a sticking relay
or solenoid can occasionally be at fault. Refer to
Troubleshooting Procedures Cell 4 in Electrical
Diagnosis for a detailed explanation of how to locate
and repair intermittent conditions.
Initialization Sequence
The EBCM/EBTCM performs the Initialization test
once each ignition cycle, when the vehicle speed
reaches 6 Km/h (4 mph) and the EBCM/EBTCM does
not see a brake switch input, if the EBCM/EBTCM
sees a brake switch input the initialization test
runs when the vehicle speed reaches 15 Km/h
(9 mph). The Initialization sequence cycles each valve
solenoid and the pump motor (as well as the
necessary relays) to check component operation. If
any error is detected, the EBCM/EBTCM will set
a DTC. The Initialization sequence may be heard and
felt while it is taking place, and is considered part
of normal operation.
ABS activity status

TCS activity status
Vehicle speed
The number drive cycles since the DTC
was set
Clear DTC Information: In this mode, current or
history DTC(s) stored by the EBCM/EBTCM
can be cleared.
Data Display
The Data Display function contains two sets of menus.

The menus available depend on the number and
type of systems on the vehicle and are listed below:
Data Display (ABS)
Data Display (TCS)
A brief description of all ABS/TCS data parameters
available on the scan tool are listed below:
ABS Data:
- Left Front Wheel Speed-scan tool displays:
Km/h I MPH-Display shows actual
wheel speed.
- Right Front Wheel Speed-scan tool
displays: Km/h I MPH-Display shows actual
wheel speed.
- Rear Wheel Speed-scan tool displays:
wheel speed.
- Brake Switch-scan tool displays:
Applied/Released-This parameter indicates
the state of the brake switch.
- Valve Relay State-scan tool displays:
On/Off-This parameter indicates the state of
the valve relay.
- Pump Monitor State-scan tool displays:
the return pump relay.
5-134
Anti1ock Brake System
TCS Data:
- Left Front Wheel Speed-scan tool displays:
wheel speed.
- Right Front Wheel Speed-scan tool
displays: Km/h I MPH-Display shows actual
wheel speed.
- Left Rear Wheel Speed-scan tool displays:
wheel speed.
- Right Rear Wheel Speed-scan tool displays:
wheel speed.
- Engine Speed-scan tool displays:
O to 10200 RPM-This is essentially a digital
tachometer display.
- Throttle Angle-scan tool displays in percent
of throttle open.
- Brake Switch-scan tool displays:
Applied/Released-This parameter indicates
the state of the brake switch.
- TCS Switch State-scan tool displays:
the traction control switch.
- Valve Relay State-scan tool displays:
the valve relay.
- Pump Monitor State-scan tool displays:
the return pump relay.
- Vehicle Speed-scan tool displays: Km/h I
MPH-Display shows actual vehicle speed.
- TCS Status EBTCM-scan tool displays:
lnable/Disable- This parameter indicates
the state of the TCS based on if the operator
has disabled TCS by pressing the TCS
On/Off switch, or if the TCS is disabled
because of a malfunction.
- TCS State EBTCM-scan tool displays:
Active/Inactive-This parameter indicates if
the TCS is currently in a TCS event or not.
Snapshot
In this test mode, the scan tool can captures the data
listed in the data displays before and after a
snapshot-triggering condition which may or may not
set a OTC.
Brakes
Special Functions
In this test mode, the scan tool can be used to
perform functional tests on the ABS/TCS which help
verify proper operation. Malfunction conditions
can be further identified by testing and observing the
test results. DTCs must be cleared before any
tests in Special Functions can be performed. In a
vehicle equipped with ABS/TCS, the Special Functions
are grouped as following:
ABS
- Automated Test
- Solenoid Tests (for all inlet and outlet
solenoid valves)
- Lamp Tests
- ABS Warning Lamp
- Low Trac Lamp
TCS
- TCS Test
- Lamp Tests-TCS OFF Lamp (ASR if
vehicle is a Chevrolet)
- TP Sensor Replacement
The Special Functions are detailed below.
Automated Test
The Automated Test cycles each valve solenoid and
the pump motor (as well as the necessary relays)
to check component operation. If a malfunction
is detected, the EBCM/EBTCM will set DTCs, which
will be displayed upon completion of the test. Perform
the test as follows:
1. Ignition OFF.
2. Install the scan tool.
3. Turn ignition to RUN.
4. Select the scan tool's Special Functions.
5. Select the Automated Test.
6. Run the Automated Test.
7. Note any DTCs set.
Solenoid Tests (Inlet Valves)

The Solenoid Test for inlet valves activates the selected
wheel circuit Inlet valve placing it in the pressure hold
position. When in the pressure hold position, the valve
will not allow master cylinder pressure to be delivered to
the hydraulic wheel circuit. This is done under ABS
operating conditions because the EBCM/EBTCM has
determined that the wheel is moving too slowly, so it
holds additional master cylinder pressure from it in an
attempt to allow it to rotate at an appropriate speed.
Brakes
The scan tool commands the valve to close, which

should allow the technician to spin the wheel even
though an assistant is applying pressure to the brake
pedal. Perform the test as follows:
1. Ignition OFF.
4. Raise vehicle such that wheels are about 6 inches
off the floor with the transmission in neutral.
5. Select the scan tool's Special Functions.
6. Select Valve Solenoid Test. Have an assistant
command Hold Pressure with the scan tool.
7. Have the assistant press and hold the
brake pedal.
8. Attempt to move the wheel being tested by hand;
it should move even though the assistant is
applying pressure to the brake pedal. The wheels
may be difficult to turn by hand, but can be
moved if the system is working properly.
Solenoid Tests (Outlet Valves)
The Solenoid Tests for the outlet valves activates the

selected hydraulic wheel circuit valves, placing
them in the pressure reduce position. When in the
pressure reduce position, the valve will allow wheel
caliper pressure to be returned to the master cylinder
circuit. This is done under ABS operating conditions
because the EBCM/EBTCM has determined that
the wheel is moving too slowly, and holding additional
master cylinder pressure from it has not allowed it
to rotate at an appropriate speed. The scan tool
commands the valves to these positions which should
allow the technician to spin the wheel even though
an assistant is applying pressure to the brake pedal.
Perform the test as follows:
1. Ignition OFF.
4. Raise vehicle such that wheels are about 6 inches
5. Have an assistant press and hold the brake pedal.
6. Select the scan tools Special Functions.
7. Select Valve Solenoid Test. Have the assistant
command Release Pressure with the scan tool.
8. Attempt to move the wheel being tested by hand;
it should move even though the assistant is
applying pressure to the brake pedal. The wheels
may be difficult to turn by hand, but can be
moved if the system is working properly .
5-135
Traction Control System Test

This test runs the pump motor and appropriate
solenoid valves to apply fluid pressure to the rear
wheel circuits.
Perform the test as follows (this test does NOT require
an assistant):
1. Ignition OFF.
4. Raise vehicle so that wheels are about 6 inches
6. Select TCS Test.
7. Command the TCS Test on with the scan tool.
The pump motor will tum on for approximately
25 seconds.
8. Attempt to move each rear wheel by hand, they
should not move, due to the pump motor running
and applying pressure to the rear wheels.
TP Sensor Replacement
This procedure must be run anytime the TP sensor is
replaced on a vehicle that has Traction Control
(RPO NW9). The TP sensor replacement allows the
Accelerator and Servo Control Module (ASM) to
relearn the new TP sensor position.
1. Ignition OFF.
3. Tum ignition to RUN.
5. Select TP Sensor Replacement.
6. Follow the scan tool menus until the procedure is
completed.
Electromagnetic Interference
Due to the sensitivity of electronics to Electromagnetic
Interference (EMI), the following checks should be
performed if an intermittent malfunction is suspected.
1. Check for proper installation of wiring harnesses
resulting from add-on options.
2. Check for proper routing of front wheel speed
sensor wiring near spark plug wires.
5136
Brakes
A Diagnostic System Check

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14
24
Battery - - - Positive
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Positive
Voltage
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Banery
G101
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Electronic
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C1
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415659
Circuit Description
The EBCM/EBTCM Diagnostic System Check is an
organized approach to identify problems associated
with the EBCM/EBTCM. This check must be the
starting point for any EBCM/EBTCM complaint, and
will direct you to the next logical step in diagnosing the
complaint. The EBCM/EBTCM 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.
Diagnostic Aids
An intermittent failure in the electronic system
may be very difficult to detect and to accurately
diagnose. The EBCM/EBTCM test for different
malfunctions under different vehicle conditions. For
this reason, a thorough test drive is often
needed in order to repeat a malfunction. If the
system malfunction is not repeated during the test
drive, a good description of the complaint may be

very useful in locating an intermittent malfunction.
Faulty electrical connections or wiring causes
most intermitting problems. When an intermitting
condition is suspected, check the suspected
circuits for the following conditions:
- Poor mating of connector halves or backed
out terminals
- Improperly formed or damaged terminals
- Wire chafing
- Poor wire to terminal connections
- Dirty or corroded terminals
- Damage to connector bodies
If the OTC is a history OTC, the problem may be
intermittent. Perform the tests shown while
moving related wiring and connectors. This can
often cause the malfunction to occur. Perform
a thorough inspection of all related wiring
and connectors pertaining to the history OTC
stored. Refer to Troubleshooting Procedures
Cell 4 in Electrical Diagnosis.
Brakes
5-137
A Diagnostic System Check
Step
Action
1. Reconnect all previously disconnected components.

2. Cycle the ignition switch from the OFF to RUN
position, engine off.
3. Plug a scan tool into the Diagnostic Link
Connector (DLC).
Does the scan tool communicate with the EBCM/EBTCM?
Does the scan tool communicate with other modules on

the UART serial data line?
1. Unplug the scan tool from the DLC.

2. Cycle the ignition switch from the RUN to OFF to
START position.
3. Carefully drive the vehicle above 24 Km/h (15 mph)
for several minutes.
Value(s)
Go to Step 3
Go to Step 2
Go to No
Communication
with
EBCMIEBTCM
Go to Data Link
Cell 50 in
Electrical
Diagnosis
Go to Applicable
OTC Table
Go to Step 4
Go to Step 6
Go to Step 5
Go to ABS
Indicator On No
OTC Set
Go to ABS
Indicator
Inoperative with
No OTC Set
Go to Step 8
Go to Step 7
Does the ABS Indicator turn on, then turn off after several
seconds?
Does the ABS Indicator stay on?
Cycle the ignition switch from the RUN to OFF to RUN

Does the Low Traction Indicator tum on. then tum off after
several seconds?
Does the Low Traction Indicator stay on?
7
8
Is this vehicle equipped with Traction Control?
Is this vehicle a Chevrolet?
10

Does the ASR Indicator turn on, then turn off after several
seconds?
Go to Low
Traction
Indicator
Always On
Go to Low
Traction Indicator
Inoperative
Go to Step 14
Go to Step 10
Go to Step 12
Go to Step 14
Go to Step 11
Go to ASR
Indicator On with
No OTC Set
Go to ASR
Indicator
Inoperative with
No OTC Set
12

Does the TCS Off Indicator turn on, then turn off after
several seconds?
Go to Step 14
Go to Step 13
Go to TCS Off
Indicator On with
No OTC Set
Go to TCS Off
Indicator
Inoperative with
No OTC Set
Does the TCS Off indicator stay on?
13
Go to Step 9
Does the ASR Indicator stay on?

11
No
4. Leave the vehicle running and plug the scan tool into
the DLC.
5. With the scan tool read ABS/TCS DTC(s)
Are there any current Diagnostic Trouble Codes?
1. Remove the scan tool from the DLC.
2. Cycle the ignition switch from the RUN to OFF to
RUN position, engine off.
Yes
5-138
Brakes
A Diagnostic System Check (cont'd)

Step
14
15
Action
Are there any history DTC(s)?

1. Refer to the appropriate OTC table for the
history OTC.
2. Read the diagnostic aids and conditions for setting
the OTC.
position.
4. Carefully drive the vehicle above 24 Km/h (15 mph)
for several minutes.
5. Leave the vehicle running and plug the scan tool into
the DLC.
6. With the scan tool read the ABS/TCS DTC(s).
Did the history OTC set as a current OTC while the vehicle
was being driven?
Value(s)
-
Yes
No
Go to Step 15
System OK
Go to Applicable
OTC Table
System OK
Brakes
5-139
DTC C0035 LF Wheel SpeedCircuit Malfunction
LFWheel
Speed
Sensor
0.8 YEL 873
@11
(M;-1
L..l!.J
0.8 LT BLU 830
B
0.5 LT BLU 830
0.5 YEL 873
C120
,.------------1---;:;.;,- -f 1---,
20
I
I
I
I
21
C1
LFWheel
Speed Sensor
Signal
"="
Electronic Brake And Traction

I Control Module
I (EBCM/EBTCM)
I ~
I ~<>~&
~------------------------~
Circuit Description
The speed sensor used on this vehicle is a multiple
pole magnetic pickup. This sensor produces an
AC signal that the EBCM/EBTCM uses the frequency
from to calculate the wheel speed.
Conditions for Setting the DTC

The DTC can be set any time the ignition is in the
RUN position and the EBCM/EBTCM detects an open
or a short to voltage.
Action Taken When the DTC Sets
A malfunction DTC stores.

The ABS/TCS disables.
The amber ABS/TCS indicator(s) turn on.
The Red BRAKE Warning indicator could turn on.
Conditions for Clearing the DTC

The condition responsible for setting the DTC no
longer exists and the scan tool Clear DTCs
function is used.
100 ignition cycles pass with no DTC(s) detected.
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 conditio_ns:
Backed out terminals

Improper mating
Broken locks
Improperly formed or damaged terminals
Poor terminal~to-wiring connections
Physical damage to the wiring harness
213272
The following conditions may cause an intermittent

malfunction:
- A poor connection
- Rubbed-through wire insulation
- A broken wire inside the insulation
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 suspeGted 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.
If an intermittent malfunction exists refer to
Diagnosis for further diagnosis.
Front Wheel Speed Sensor Resistance

The following table contains resistance values for the
front wheel speed sensors at varying sensor
temperatures for use in diagnosis. The values are
approximate and should be used as a guideline
for diagnosis.
5-140
Brakes

Malfunction
Test Description
The numbers below refer to step numbers on the
diagnostic table.
Sensor
Temperature
(OF)
Sensor
Resistance
{Ohms)
-34 to 4
-30 to 40
800 to 1100
5 to 43
41 to 11 O
950 to 1300
13. Checks for a short to voltage in the WSS CKT.
44 to 93
111 to 200
1100 to 1600
Sensor
Temperature (C)
6. This step checks for an open in the WSS or

WSS CKT.
OTC C0035 LF Wheel Speed Circuit Malfunction

Step
Action
Value(s)
Yes
No
Was the Diagnostic System Check performed?
Go to Step 2
Go to A
Diagnostic
System Check
Inspect the WSS for physical damage.

Is physical damage of the WSS evident?
Go to Step 3
Go to Step 4
Replace the WSS. Refer to Wheel Bearing/Hub

Replacement - Front in Front Suspension.
Is the replacement complete?
Go to Step 18
Inspect the jumper harness for physical damage.

Is physical damage of the jumper harness evident?
Go to Step 5
Replace the jumper harness. Refer to Wheel Speed

Sensor Jumper Harness Replacement (Front Left).
Go to Step 18
Go to Step 6
2. Disconnect the EBCM/EBTCM connector C1.

3. Install the J 39700 Universal Pinout Box using the
J 39700-530 cable adapter to the EBCM/EBTCM
harness connector C1 only.
4. Using J 39200 DMM, measure the resistance
between terminals 20 and 21 of J 39700.
Is the resistance within the range specified in the value(s)
column?
800-1600
Go to Step 13
Go to Step 7
800-1600
Go to Step 8
Go to Step 3
Go to Step 10
Go to Step 9
1. Disconnect the Wheel Speed Sensor.

between terminals A and B of the Wheel Speed
Sensor Connector.
column?
Using J 39200 DMM, measure the resistance between

terminal 20 of J 39700 and terminal B of the WSS harness
connector.
column?
Repair CKT 830 for an open or high resistance. Refer to

Repair Procedures Cell 5 in Electrical Diagnosis. If an
open or high resistance is found in the jumper harness,
replace the jumper harness. Refer to Wheel Speed Sensor
Jumper Harness Replacement (Front Left).
Go to Step 18
10

terminal 21 of J 39700 and terminal A of the WSS harness
connector.
column?
o-5n
Go to Step 12
0-5!1
Go to Step 11
Brakes
5-141
DTC C0035 LF Wheel Speed Circuit Malfunction (cont'd)

Step
11
Action
Jumper Harness Replacement (Front Left).
Value(s)
Yes
No
Go to Step 18
Go to Step 18
Above 1V
Go to Step 14
12
Malfunction is intermittent. Inspect all connectors and

harnesses for damage that may result in an open or high
resistance when connected. Refer to Repair Procedures
2. Turn the ignition switch to the RUN position,
engine off.
13
3. Using J 39200 DMM, measure the voltage at

terminal 20 of J 39700.
Go to Step 15
Is the voltage within the range specified in the value(s)

column?
14
Repair CKT 830 for a short to voltage. Refer to Repair

Procedures Cell 5 in Electrical Diagnosis. If a short to
voltage is found in the jumper harness, replace the jumper
harness. Refer to Wheel Speed Sensor Jumper Harness
Replacement (Front Left).
Go to Step 18
15
16
Using J 39200 DMM. measure the voltage at terminal 21

of J 39700.
column?
voltage is found in the jumper harness. replace the jumper
Above 1V
Go to Step 16
Go to Step 17
Go to Step 18
Go to A
Dia.gnostic
System Check
Go to Step 2

17
Replace the EBCM/EBTCM. Refer to Electronic Brake

Control Module (EBCM) Replacement.
2. Using a scan tool clear the OTC.
18

4. Carefully drive the vehicle above 12 Km/h (8 mph) for
several minutes.
Does the OTC reset as a current OTC?
Go to A
Dia.gnostic
System Check
5-142
Antilock B.rake System
Brakes
DTC C0036 LF Wheel Speed Circuit Range/Performance

LFWheel
Speed
Sensor
0.8 YEL 873
@11
Ll:iJ
0.8 LT BLU 830
B
0.5 LT BLU 830
0.5 YEL 873
r- ----------20
21
C120
C1
I
I
LF;~~----
Speed Sensor
Signal
.,,.
--
-:=~=~Traction
II
~------------------------~
Circuit Description

The DTC will set if one wheel speed = O and the
other WSS are greater than 40 Km/h (25 mph)
for 10 ms, or if the EBCM/EBTCM detects a short
to ground.
The DTC will set if during drive off, one wheel
speed = 0, and the other WSS are greater than
12 Km/h (7.5 mph).

A malfunction OTC stores.

The condition responsible for setting the OTC no
function is used.
Important: After the DTC is cleared by ignition
cycle default, the vehicle must be driven above
12 Km/h (8 mph) for the ABS/TCS indicator{s) to
turn off.
Diagnostic Aids
,.
~
213272

causing the complaint for the following conditions:
- Backed out terminals
- Improper mating
- Broken locks
- Improperly fanned or damaged terminals
- Poor terminal-to-wiring connections
- Physical damage to the wiring harness
malfunction:
- A poor connection
- A broken wire ingjde the insulation
ABS/TCS indicator is on on4y during moist
for signs of water intrusion. If the OTC is not
1. Spray the suspected area with a five
solution.
harness.
Brakes

for diagnosis.
Test Description
The number(s) below refer to the step number(s) on
the diagnostic table.
DTC C0036 LF Wheel Speed Circuit

Range/Performance
Sensor
Temperature (C)
Sensor
Temperature
(OF)
Sensor
Resistance
(Ohms)
-34 to 4
-30 to 40
800 to 1100
5 to 43
41 to 110
950 to 1300
44 to 93
111 to 200
1100 to 1600
Step
5-143
6. This step checks for the proper resistance in

the WSS.
7. This step checks for the proper WSS output.
DTC C0036 LF Wheel Speed Circuit Range/Performance

Action
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check

Go to Step 3
Go to Step 4
Go to Step 16


4

Go to Step 5

Sensor Jumper Harness Replacement (Front Left).
Go to Step 16
1. Disconnect the WSS connector directly at the WSS.

between terminals A and B of the WSS.
800-1600
Go to Step 6
Go to Step 7
Go to Step 3
Above 100 mV
Go to Step 8
Go to Step 3
Using J 39200 DMM, measure the resistance between the

WSS terminal A and ground.
column?
OL (infinite)
Go to Step 9
Go to Step 3
1. Disconnect the EBCM/EBTCM harness connector C1.

Is the resistance within the range specified in the values
column?
OL (infinite)
Go to Step 11
Go to Step 10

column?
1. With the J 39200 DMM still connected to the WSS
select the mV AC scale.
7
2. Spin the wheel as fast as you can by hand while

monitoring the AC output.
Is the AC voltage within the range specified in the value(s)
column?
5-144
Brakes
DTC C0036 LF Wheel Speed Circuit Range/Performance (cont'd)

Step
Action
10
Repair short between CKT(s) 830 and 873. Refer to

Repair Procedures Cell 5 in Electrical Diagnosis. If a short
between wheel speed sensor circuits is found in the
jumper harness, replace the jumper harness. Refer to
11

terminals 20 and 15 of J 39700.
column?
12
Repair CKT 830 for a short to ground. Refer to Repair

ground is found in the jumper harness, replace the jumper
13

column?
14

Go to Step 16
15

Go to A
Diagnostic
System Check
Go to Step 2
16
1.
2.
3.
4.
Reconnect all previously disconnected components.

Using a scan tool clear the DTC.
Remove the scan tool from the DLC.
Carefully drive vehicle above 12 Km/h (8 mph) for
several minutes.
Value(s)
Yes
Go to Step 16
OL (infinite)
Go to Step 13
OL (infinite)
Go to Step 16
Go to Step 15
No
Go to Step 12
Go to Step 14
Go to A
Diagnostic
System Check
Brakes
5-145
DTC C0040 RF Wheel Speed Circuit Malfunction

RF Wheel
Speed
Sensor
0.8 YEL 833
@11
0.8 LT BLU 872
C130
0.5 DK GAN 872

3
4
0.5 TAN 833

5 C1 (ABS)
5 C1 (ABS!TCS)
r - - - - - - - - - - - - ~
- - - - - - - ,BectronicBrakeAndTraction
I
High
I Control Module
I
I
I
I (EBCM/EBTCM)
Low
~~
~~~:': Sensor
-=-
I~
I ~
~------------------------J
Circuit Description

The OTC can be set any time the ignition is in the
RUN position and the EBCM/EBTCM detects an open
or a short to voltage.

The amber ABS/TCS indicator(s) tum on.
The Red BRAKE Warning indicator could tum on.

function is used.
Diagnostic Aids
-

Improper mating
Broken locks
Poor terminal-to-wiring connections
213274

malfunction:
- A poor connection

environmental conditions (rain. snow, vehicle
wash). inspect all the wheel speed sensor circuitry
current. clear aJI DTCs and simulate the effects of
solution.
harness.

for diagnosis.
5-146
Brakes
DTC C0040 RF Wheel Speed Circuit

Malfunction
Test Description
diagnostic table.
Sensor
Temperature (C)
Sensor
Temperature
(OF)
Sensor
Resistance
(Ohms)
-34 to 4
-30 to 40
800 to 1100
5 to 43
41 to 110
950 to 1300
44 to 93
111 to 200
1100 to 1600

WSS CKT.
OTC C0040 RF Wheel Speed Circuit Malfunction

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check

Go to Step 3
Go to Step 4

Go to Step 18

Go to Step 5

Sensor Jumper Harness Replacement (Front Right).
Go to Step 18
800-1600 Q
Go to Step 13
Go to Step 7
800-16000
Go to Step 8
Go to Step 3
0-50
Go to Step 10
Go to Step 9
Go to Step 6


harness connector Cl only.
between terminals 4 and 5 of J 39700 if the vehicle is
equipped with Traction Control. If the vehicle is not
equipped with Traction Control then measure the
resistance between terminals 3 and 5 of J 39700.
column?
2. Using J 39200 OMM, measure the resistance
Sensor Connector.
column?
connector if the vehicle is equipped with Traction Control.
If the vehicle is not equipped with Traction Control
measure the resistance between terminal 3 of J 39700 and
terminal B of the WSS harness connector.

column?
Brakes
5-147
DTC C0040 RF Wheel Speed Circuit Malfunction (cont'd)
Step
Action

Jumper Harness Replacement (Front Right).
10
Using J 39200 DMM, measure the resistance between.

terminal 5 of J 39700 and terminal A of ttie WSS harness
connector.
column?
11

Jumper Harness Replacement (Front Right).
Value(s)
0-5Q
Yes
Go to Step 18
Go to Step 12
No
Go to Step 11
Go to Step 18
Go to Step 18
12

13

engine off.
terminal 4 of J 39700 if the vehicle is equipped with
Traction Control. If the vehicle is not equipped with
Traction Control measure the voltage at terminal 3
of J 39700.
column?
14

Replacement (Front Right).
15
Using J 39200 DMM, measure the voltage at terminal 5

of J 39700.
Is the voltage within the range specified in the valueis1
column?
16

voltage is found in the jumper harness. replace the Jumper
Above 1V
Go to Step 14
Go to Step 18
Above 1V
Go to Step 16
Go to Step 15
Go to Step 17
Go to Step 18
Go to A
Diagnostic
System Check
Go to Step 2

17


18

several minutes.
Go to A
Diagnostic
System Check
5-148
Brakes
DTC C0041 RF Wheel Speed Circuit Range/Performance

RF Wheel
Speed
Sensor
0.8YEL 833
@11
0.8 LT BLU 872
----------
0.5 DKGRN 872

3
4
C130
0.5TAN 833
I
I
C1 (ABS)
C1 (ABS/TCS)
---------- ~
- - - - - - - ,ElectronicBrakeAndTraction
High
I Control Module
Low
I (EBCM/EBTCM)
I
I
Speed Sensor
Signal
r - - - - - - - - - - -
5
5
~~
..-
I~
I ~
L------------------------J
Circuit Description

for 1O ms, or if the EBCM/EBTCM detects a short
to ground.
speed= 0, and the other WSS are greater than
12 Km/h (7.5 mph).


function is used.
cycle default, the vehicle must be driven above 12
Km/h (8 mph) for the ABS/TCS indicator(s) to turn off.
Diagnostic Aids
~
213274

- Improper mating
- Broken locks
malfunction:
- A poor connection
solution.
harness.
Brakes
5-149

Range/Performance

approximate and should be used as a guideline for
diagnosis.
Sensor
Temperature (C)
Sensor
Temperature
(OF)
Sensor
Resistance
(Ohms)
-34 to 4
-30 to 40
800 to 1100
5 to 43
41 to 11 O
950 to 1300
44to 93
111 to 200
1100 to 1600
Test Description
the WSS.
OTC C0041 RF Wheel Speed Circuit Range/Performance

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check

Go to Step 3
Go to Step 4
Go to Step 16


4

Go to Step 5

Sensor Jumper Harness Replacement (Front Right).
Go to Step 16

800-1600
Go to Step 6
Go to Step 7
Go to Step 3
Above 100 mV
Go to Step 8
Go to Step 3
OL (infinite)
Go to Step 9
Go to Step 3
OL (infinite)
Go to Step 11
Go to Step 10

column?

column?
column?
between terminals 4 and 5 of J 39700 if the vehicle is
equipped with Traction Control. If the vehicle is not
equipped with traction control measure the resistance
column?
5-150
Brakes
OTC C0041 RF Wheel Speed Circuit Range/Performance (cont'd)

Value(s)
Step
Action
10

11

terminals 4 and 15 of J 39700 if the vehicle is equipped
with Traction Control. If the vehicle is not equipped with
traction control measure the resistance between
column?
12

13

column?
14

Go to Step 16
15

Goto A
Diagnostjc
System Check
Go to Step2
16

2. Using a scan tool clear the DTC.
4. Carefully drive vehicle above 12 Km/h (8 mph) for
several minutes.
Yes
Go to Step 16
OL (infinite)
Go to Step 13
OL (infinite)
Go to Step 16
Go to Step 15
No
Go to Step 12
Go to Step 14
Go to A
Diagnostic
System Check
Does the DTC reset as a current DTC?
Brakes
5-151
DTC C0045 LR Wheel Speed Circuit Malfunction

LR Wheel
Speed
Sensor
@[ ir
0.5 RED r...

,A 885
1
I
I
C405C
C4Q5B
0.5 BLK I I
v
884
I
I
I
C1
I
I
I
I
I
I
I
IL 0 c
D1 ~D
0.35RED 885
884
A15
C200D
1#-- ~~~~
0.5 BLK
22
r - - -
- -
- -
- -
- - -
I
I
I
I
~~5-
23
---------- - - - -
- -
C1
HOS~
Low
LRWhNI
Speed Sensor
Signal
.,,.
- ., Electronic Brake And Traction
I Control Module
I (EBCM/EBTCM)
I ~
I
~
L-----------------------J
Circuit Description
The speed sensor used on this vehicle is a single
point magnetic pickup. This sensor produces an
AC signal that the EBTCM uses the frequency from to
calculate the wheel speed.

RUN position and the EBTCM detects an open or a
short to voltage.

The Red BRAKE Warning indicator turns on.

function is used.
Diagnostic Aids
- Improper mating
- Broken locks
213276

malfunction:
- A poor connection
solution.
harness.
Rear Wheel Speed Sensor Resistance

rear wheel speed sensors at varying sensor
for diagnosis.
5-152
Brakes
DTC C0045 LR Wheel Speed Circuit

Malfunction
Test Description
diagnostic table.
Sensor
Temperature
(OF)
Sensor
Resistance
(Ohms)
-34 to 4
-30 to 40
2032 to 3107
5 to 43
41 to 11 O
2417 to 3615
44 to 93
111 to 200
2812 to 4266
Sensor
Temperature ( C)
0

WSS CKT.
DTC C0045 LR Wheel Speed Circuit Malfunction

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check

Go to Step 3
Go to Step 4
Replace the WSS. Refer to Wheel Speed Sensor

Replacement (Rear with Traction Control).
Go to Step 18

Go to Step 5

Sensor Jumper Harness Replacement
(Rear with Traction Control).
Go to Step 18

2. Disconnect the EBTCM connector C1.
J 39700-530 cable adapter to the EBTCM harness
connector C1 only.
column?
2032-4266Q
Go to Step 13
Go to Step 7

2. Using J 39200 DMM. measure the resistance
Sensor Connector.
column?
2032-4266.n
Go to Step 8
Go to Step 3
0-5Q
Go to Step 10
Go to Step 9

connector.
Go to Step 6
ls the resistance within the range specified in the value(s)

column?

Repair Procedures Cell 5 in Electrical Diagnosis. If an open
or high resistance is found in the jumper harness, replace
the jumper harness. Refer to Wheel Speed Sensor Jumper
Harness Replacement (Rear with Traction Control).
Go to Step 18
10

connector.
column?
0-5Q
Go to Step 12
Go to Step 11
Brakes
5-153
DTC C0045 LR Wheel Speed Circuit Malfunction (cont'd)

Step
11
Action
Value(s)
Yes
No
Go to Step 18
Go to Step 18
12

2. Turn the ignition switch to the RUN position, engine off.
13

Above 1V
Go to Step 14
Go to Step 15

column?
14

Go to Step 18
15
16
Using J 39200 DMM, measure the voltage at terminal 23 of

J 39700.
column?
Above 1V
Goto Step 16
Go to Step 17
Go to Step 18
Goto A
Diagnostic
System Check
GotoStep2

17
Replace the EBTCM. Refer to Electronic Brake Control

Module (EBCM) Replacement.

18

several minutes.
Goto A
Diagnostic
System Check
5.,.154
Brakes
Antilock Brake.System
DTC C0046 LR Wheel Sp~ed Circuit Range/Performance

LR Wheel
Speed
Sensor
0.5 RED
885
@11
Llil
0.5 BLK
884
C1
0.35 RED 885
u.~ :~
884
A15
C200D
O.SBLKY~~~
-,. -------------r---. ;_-- i _,
22
HIOh
23 C1
---------_l_
I
I
Low
LRWMel
.
Speed Sensor
Signal
_
EleC1ronlc Brake And Traction

I Control Module
I (EBCM/EBTCM)
I .._
~
I .'1,6
L----------------------~J
.Circuit Description
.calculate the. wheel speed.

for 10 ms, or if the EBTCM detects a short
to ground.
12 Km/h (7.5 rnph).
.Action Taken When the DTC Sets


function is used.
12 Km/h (8 mph) for the ABS/TCS indicator(s) to
turn off.
Diagnostic Aids
- Improper mating
213276
Broken locks
The following conditions may cause. an intermittent

malfunction:
- A poor connection

Add two teaspoons of. salt to twelve ounces
solution.
harness.

for diagnosis.
Antil.ock Brake System
Brakes
DTC C0046 LR Wheel Speed Circuit
Range/Performance
5-155
Test Description
Sensor
Temperature (C)
Sensor
Temperature
(OF)
Sensor
Resistance
(Ohms)
-34 to 4
-30 to 40
2032 to 3107
5 to 43
41 to 11 O
2417 to 3615

the WSS.
44 to 93
111 to 200
2812 to 4266

DTC C0046 LR Wheel Speed Circuit Range/Performance

Action
Step
Value(s)
Yes
No
Was the Diagnostic System Check perforrned?
Go to Step 2
Go to A
Diagnostic
System Check

Go to Step 3
Go to Step 4

Go to Step 16

Go to Step 5

Go to Step 16

2 . Using J 39200 DMM, measure the resistance
column?
2032--4266 n
Go to Step 7
Go to Step 3
Above 100 mV
Go to Step 8
Go to Step 3
OL (infinite)
Go to Step 9
Go to Step 3
OL (infinite)
Go to Step 11
Go to Step 10
Go to Step 6

7
10

column?
column?
column?
Repair Procedures Cell 5 in Electrical Diagnosis. If a
Wheel Speed Sensor Jumper Harness Replacement (Rear
with Traction Control).
Go to Step 16
5-156
Brakes
DTC C0046 LR Wheel Speed Circuit Range/Performance (cont'd)

Step
Action
11

column?
12

13

column?
Value(s)
Yes
No
OL (infinite)
Go to Step 13
Go to Step 12
OL (infinite)
Go to Step 16
Go to Step 15
Go to Step 14
14

Go to Step 16
15

Go to A
Diagnostic
System Check
16

4. Carefully drive vehicle above 12 Km/h (8 mph) for
several minutes.
Go to Step2
Go to A
Diagnostic
System Check
Brakes
5-157
DTC C0050 RR Wheel Speed Circuit Malfunction

RR Wheel
Speed
Sensor
r:
A
C405B
0.8 WHT C405C
,.....
883
\/
r A1
@[ IIL [___!:
_+-+--,
0.8 BLK
882
0.35WHT 883
J \
B >.B1
v
0.35 BRN 882
A10,
A11
C200D
~.~-~~~
0.5 B R
-2- N
~ -~~OOA
1
r - - -
- -
- -
- -
- -
I
I
I
I
3
---------- - - - -
- - -
C1
-
- , Electronic Brake And Traction
High~
Low
RRWheel
~ig~ Sensor
I Control Module
I (EBCM/EBTCM)
I ~
I~
L----------------------J
Circuit Description

The OTC can be set any time the ignition is in the
RUN position and the EBTCM detects an open or a
short to voltage.
Action Taken When the OTC Sets

The ABS!TCS disables.
The amber ABS!TCS indicator(s) turn on.

function is used.
Diagnostic Aids
- Improper mating
- Broken locks
213278

malfunction:
- A poor connection
ABS!TCS indicator is on only during moist
solution.
3. If the OTC returns, replace the suspected
harness.

for diagnosis.
5-158
Brakes
DTC COOSO RR Wheel Speed Circuit

Malfunction

diagnostic table.
(OF)
Sensor
Resistance
(Ohms)
-34 to 4
-30 to 40
2032 to 3107
5 to 43
41 to 110
2417 to 3615
44 to 93
111 to 200
2812 to 4266
Sensor
Temperature (C)
Sensor
Temperature
Test Description

WSS CKT.
DTC COOSO RR Wheel Speed Circuit Malfunction

Action
Step
1

Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Go to Step 3
Go to Step 4
Go to Step 18

4

Go to Step 5.
Go to Step 18
Go to Step 6


connector C1 only.
2032-42660
Go .to Step 13
Go to Step 7
2032-426&1
Go to Step 8
Go to Step 3
0-50
Go to Step 10
Go to Step 9


column?
7

Sensor Connector.
column?

connector.
column?

Go to Step 18
0-5Q
Go to Step 12
Go to Step 11
10

connector.
column?
Brakes
5-159
DTC COOSO RR Wheel Speed Circuit Malfunction (cont'd)

Step
11
Action
Jumper Harness Replacement (Rear with Traction Control).
Value(s)
Yes
No
Go to Step 18
Go to Step 18
12

13

2. Turn the ignition switch to the RUN position, engine off.
Above 1V
Go to Step 14
Go to Step 15

column?
14

voltage is found in the jumper harness, replace the i:..rnper
Go to Step 18
15
16
Using J 39200 DMM, measure the voltage at terr'l:~a 3

of J 39700.
Is the voltage within the range specified in the .a :...e s
column?
Repair CKT 883 for a short to voltage. Refer:::: Re::;a '
Procedures Cell 5 in Electrical Diagnosis. If a s:-:::r: ::::
voltage is found in the jumper harness. 'ec:ra:::e :~e ;J-rper
harness. Refer to Wheel Speed Sensor Jurnoe Ha '"ess
Replacement (Rear with Traction Cont-011.
Above 1V
Go to Step 16
Go to Step 17
Go to Step 18
Goto A
Diagnostic
System Check
Go to Step2
17
Replace the EBTCM. Reier to Electronic 8,a-<e C::"'.'C'

Is the replacement cornpiete?
18
1.
2.
3.
4.
Reconnect all prev1ous1y disconnected com::;c"e":s.

Carefully drive the vehicle above 12 Km "h 18 moh 1 'or

several minutes.
Goto A
Diagnostic
System Check
5-160
Brakes
OTC C0051 RR Wheel Speed Circuit Range/Performance

RR Wheel
Speed
Sensor
@[
rl
~A
C405B
0.8WHT C405C
A~- A1
883
I
I
I
I
I
I
I
I
I
I
L...,
}B
0.8 BLK
882
0.35WHT 883
),
A11 ~ C200D
0.5BAN~:.~31:200A
---------1
- -
- - - -
'-
81
0.35BRN 882
A10,
r -
I
I
I
II
!Loe
.....
l'
- -
I
I
I
I
C1
- - -
- -
- - -
,ElectronicBrakeAndTraction
- ~ I Control Module
Low
I (EBCM/EBTCM)
RRWheel
I ~
Speed Sensor
-=- I
~
~----------------------J
Circuit Description

The DTC will set if one wheel speed = 0 and the
for 1O ms, or if the EBTCM detects a short
to ground.
12 Km/h (7.5 mph).


function is used.

turn off.
Diagnostic Aids
Signal
213278

- Backed out tenninals
- Improper mating
- Broken locks
malfunction:
- A poor connection

solution.
3. If the OTC returns, replace the suspected
harness.
Brakes
5-161

Range/Performance

for diagnosis.
Sensor
Temperature (C)
Sensor
Temperature
(OF)
Sensor
Resistance
(Ohms)
-34 to 4
-30 to 40
2032 to 3107
5 to 43
41 to 110
2417 to 3615
44 to 93
111 to 200
2812 to 4266
Test Description
the WSS.
OTC C0051 RR Wheel Speed Circuit Range/Performance

Step
Action
Value(s)
Yes
No
Go to Step2
Goto A
Diagnostic
System Check

Go to Step 3
Go to Step 4

Go to Step 16

Go to Step 5
Go to Step 6

Sensor Jumper Harness Replacement (Rear with Traction
Control).
Go to Step 16
2032-4266 n
Go to Step 7
Go to Step 3

column?
Above 100 mV
Go to Step B
Go to Step 3

column?
OL (infinite)
Go to Step 9
Go to Step 3

column?
OL (infinite)
Go to Step 11
Go to Step 10

6

column?
5-162
Brakes
OTC C0051 RR Wheel Speed Circuit Range/Performance (cont'd)

Step
10
Action

Wheel Speed Sensor Jumper Harness Replacement
Value(s)
Yes
Go to Step 16
OL (infinite)
Go to Step 13
No

11

column?
12

13

column?
Go to Step 16
Go to Step 12
OL (infinite)
Go to Step 15
14

Replacement (Rear with Traction Control}.
Go to Step 16
15

Go to A
Diagnostic
System Check
Go to Step 2
16
1.
2.
3.
4.

several minutes.
Go to Step 14
Go to A
Diagnostic
System Check
Brakes
5-163
OTC C0055 Rear Wheel Speed Circuit Malfunction

Rear
Wheel
Speed
Sensor
,s
0.5WHT
885
C405C
C405B
I
I
IL 0 c
D D1
1
I
II
0.35 RED 885
0.5 BLK
884
[SJ
N
C1
0.35 BLK1884
A15
A14
C200D
C200A
.. - - - - - - - - - - - - - - - - , Electronic Brake
I
High~
control Module
I
I (EBCM)
I
Rear Wheel
I ~
I
-=I~
=Sensor
L----------------~
Circuit Description
point magnetic pickup. This sensor produces an AC
signal that the EBCM uses the frequency from to

RUN position and the EBCM detects an open or
a short to voltage.

The ABS disables.
The amber ABS indicator turns on.

function is used.
Diagnostic Aids
-

Improper mating
Broken locks
213280

malfunction:
- A poor connection
ABS indicator is on only during moist
environmental conditions (rain. snow, vehicle
wash). inspect all the wheel speed sensor circuitry
current. clear all DTCs and simulate the effects of
solution.
surfaces (bumps. turns. etc.) above 40 km/h
harness.

for diagnosis.
5-164
Brakes
DTC C0055 Rear Wheel Speed Circuit

Malfunction
Test Description
diagnostic table.
(OF)
Sensor
Resistance
(Ohms)
-34 to 4
-30 to 40
763 to 1110
5 to 43
41 to 110
908 to 1292
44 to 93
111 to 200
1057 to 1525
Sensor
Temperature (C)
Sensor
Temperature

WSS CKT.
DTC C0055 Rear Wheel Speed Circuit Malfunction

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check

Go to Step 3
Go to Step 4
Go to Step 18
Go to Step 5
Go to Step 18

2. Disconnect the EBCM connector C1.
J 39700-530 cable adapter to the EBCM harness
connector C1 only.
column?
763-1525Q
Go to Step 13
Go to Step

Sensor Connector.
column?
763-1525Q
Go to Step 8
Go to Step 3

connector.
column?
o-5n
Go to Step 10
Go to Step 9

Jumper Harness Replacement (Rear without
Traction Control).
Go to Step 18
10

connector.
column?
o-5n
Go to Step 12
Go to Step 11

Replacement (Rear without Traction Control).

4
Inspect the jumper harness tor physical damage.

Sensor Jumper Harness Replacement (Rear without
Traction Control).
Go to Step 6
7.,
Brakes
S.;165
DTC C0055 Rear Wheel Speed Circuit Malfunction (cont'd)

Step
Action
11

Jumper Harness Replacement (Rear without
Traction Control).
Go to Step 18
12

Go to Step 18
13

engine off.
column?
14

15

of J 39700.
column?
16

Go to Step 18
17
Replace the EBCM. Refer to Wheel Speed Sensor Jumper

Harness Replacement (Rear without Traction Control).
Go to A
Diagnostic
System Check
Go to Step 2
Value(s)
Above 1V
Above 1V
Yes
Go to Step 14
Go to Step 18
Go to Step 16

18

several minutes.
Does the OTC reset as a current DTC?
No
Go to Step 15
Go to Step 17
Go to A
Diagnostic
System Check
5-166
Brakes
OTC C0056 Rear Wheel Speed CKT Range/Performance

Rear
Wheel
Speed
Sensor
{D}
B
I
IL 0 c
0.5WHT
885
[S]
II
0.35 RED 885

A
0.5 BLK
884
C C1
0.35 BLK1884
A15
A14
C200D
C200A
'" - - - - - - - - - - - - - - - - , Electronic Brake

I
High~
I Control Module
I
Low
I (EBCM)
I
Rear Wheel
Speed Sensor
I
-=-
L----------------J
Signal
Circuit Description
AC signal that the EBCM uses the frequency from to

The OTC will set if one wheel speed = O and the
for 10 ms, or if the EBCM detects a short to
ground.
The DTC will set if during drive off. one wheel
12 Km/h (7.5 mph).

The ABS disables.
The amber ABS indicator turns on.

function is used.
turn off.
Diagnostic Aids
.A.
. -....
~
213280

- Improper mating
- Broken locks
malfunction:
- A poor connection
ABS indicator is on only during moist
solution.
harness.
Brakes
DTC C0056 Rear Wheel Speed CKT

Range/Performance

for diagnosis.
Sensor
Temperature (C)
Sensor
Temperature
(OF)
Sensor
Resistance
(Ohms)
-34 to 4
-30 to 40
763 to 1110
5 to 43
41 to 110
908 to 1292
44 to 93
111 to 200
1057 to 1525
Test Description
the WSS.
DTC C0056 Rear Wheel Speed CKT Range/Performance

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check

Go to Step 3
Go to Step 4
Go to Step 16
Go to Step 5
Go to Step 16


4


Sensor Jumper Harness Replacement (Rear without
Traction Control).

column?

2. Spin the rear wheel as fast as you can by hand while
column?
Go to Step 6
Go to Step 7
Go to Step 3
Above 100 mV
Go to Step 8
Go to Step 3

column?
OL (infinite)
Go to Step 9
Go to Step 3

column?
OL (infinite)
Go to Step 11
Go to Step 10
763-1525
5.;168
Antil'ock 'Brake System
Brakes
DTC C0056 Rear Wheel Speed CKT Range/Performance (cont'd)

Step
10
Action
Repair Procedures Cell 5 in El~ctrical Diagnosis. If a short
between wheel speed. circuits is found in the jumper
harness, replace the jumper harness. Refer to Wheel
Speed Sensor Jumper Harness Replacement
(Hear without Traction Control).
Value(s)
Yes
Go to Step 16
OL (infinite)
Go to Step 13
No
11
12

column?
Go to Step 16
OL (infinite)
Go to Step 15
Go to Step 12
13
14

column?
Procedures Cell 5 in 8ectrical Diagnosis. If a short to
Go to Step 16
Go to A
. Diagnostic
System Check
Go to Step 2
Go to Step 14
15
16
Replace the EBCM. Refer to Electronic Brake Control

1.
2.
3.
4.

Using a scan tool clear the OTC.
several minutes.
Go to A
Diagnostic
System Check
Brakes
5-169
DTC C0060 LF ABS Solenoid #1 Circuit Malfunction
~~:: r
i
1
ORNI44:8 PNK
14
Voltage
='[ -----------i------------------- rn
_ !zM/EBTC~
8
739
C1
Voltage
~ ~::,ro~ Traction
~~,~~
Valve Contn:JI
Relay Control
---.
Control
I Module
Solenold Valve
I
~------------------------------~--------J
I
Solenoid Valve
I
15 C1
---.
Groird
~------------------------------J
Brake Pressure
Modulator Valve
(BPMV)
2 BLK 651
.... G101
213283
Circuit Description
The Inlet valve solenoid circuits are supplied with
battery power when the ignition is in the run position.
The EBCM/EBTCM controls the valve functions by
grounding the circuit when necessary.

The EBCM/EBTCM senses a discrepancy such as an
open, short to ground, or short to voltage in the
circuit.

A malfunction DTC is stored.
ABS/TCS disabled
ABS/TCS Indicators are turned on.
The Red BRAKE Warning Indicator turns on .

Condition for DTC is no longer present and scan
tool clear DTC function is used.
100 ignition cycles pass with no DTC detected.
Test Description
Diagnostic Table.
2. This step determines if the DTC is current.
5-170
Brakes

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check

2. Install a scan tool.
engine off.
4. Using the scan tool run the Automated test.
Does OTC C0060 reset as a current OTC?
Go to Step 3
Go to A
Diagnostic
System Check

Go to A
Diagnostic
System Check
Brakes
5-171
OTC C0065 LF ABS Solenoid #2 Circuit Malfunction
Power
Distribution
Cell10
3 ORN
14
" - Ignition
- Positive
Voltage
144:8
PNK 739
8
C1
f - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,I Electronic
-;...: =-e_a_tt_e-.._7
., _
l
r-r----~
Positive
Voltage
SOienoid Valve
Relay Control
ill
Brake And Traction

Control
Module
I (EBCM/EBTCM)
I
I
Solenoid Valve
Control Relay
Sok3nouj
Valve Control
4~
~------------------------------~--------J
~------------------------------J
:
.,,.
I
I
---.
Solenoid Valve
GrOLrld
15
C1
Brake Pressure
Modulator Valve
(BPMV)
2 BLI< 651
G101
213283
Circuit Description
The Outlet valve solenoid circuits are supplied with
battery power when the ignition is in the RUN position.

circuit.

ABS/TCS disabled
The Red BRAKE Warning Indicator turns on.
Conditions for Clearing the OTC

Condition for OTC is no longer present and scan
tool clear OTC function is used.
100 ignition cycles pass with no OTC detected.
Test Description
Diagnostic Table.
5-172
Brakes

Step
Action
Value(s)
Yes
No
Go to Step2
Go to A
Diagnostic
System Check

engine off.
Go to Step 3
Goto A
Diagnostic
System Check

Control ModLJle (EBCM) Replacement.
Go to A
Diagnostic
System Check
Brakes
5-,173
OTC C0070 RF ABS Solenoid #1 Circuit Malfunction

Power
Distribution
Cell 10
ORNI44:8 PNK
14
r--lgnition
Positive
Voltage
I
I
739
-------8 C1
- Battery f - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - " Electronic

Positive
Voltage
SOlenoldValve
Relay Control
....-----Solenoid
rn

I
v_.,.
l~7S~
Caou- -
V&Jve Control
.,,.
....
Con1r01
Module
(fts,d
~------------------------------~--------J
~------------------------------J
I
I
Solauoid VaNe
15
C1
Brake Pressure
Modulator Valve
(BPMV)
2 BU< 651
G101
213283
Circuit Description

circuit.

A malfunction OTC is stored.
ABS/TCS disabled

100 ignition cydes pass with no OTC detected.
Test Description
Diagnostic Table.
2. This step determines if the OTC is current.
5-174
Brakes

Action
Step
1

engine off.
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Go to Step 3
Go to A
Diagnostic
System Check
Go to A
Diagnostic
System Check
Value(s)


Brakes
5-175
ORNI44:s PNK
14
.. -
- Ignition
Positive
Voltage
8
- - -B-att_e_ry_
Positive
Voltage
739
C1
f_ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,I Electronic
rn
I Module
I (EBCM/EBTCM)
.......- - - - - - . Solenoid Valve

Control Relay
Solenoid Valve
Relay Control
Brake And Traction
Control
So~noo
Valve Control
,!~
---1
~--------------------------- ---~--------J
I
I
I
GrDlrld
Solenoid Valve
15
C1
~------------------------------J
Brake Pressure
Modulator Valve
(BPMV)
2 BU< 651
.,,. G101
213283
Circuit Description
Conditions for Setting the OTC

circuit.

ABS/TCS disabled

Test Description
Diagnostic Table.
S-176
AotilQck Brake System
.Brakes
DTC C0075 RF ABS Solenoid #2 Circuit Malfunction

Step
Action
Value(s)
Yes
No
Go to Step2
G'O to A
Diagnostic
System Check

engine off.
Does DTC C0075 reset as a current DTC?
Go to Step 3
Go to A
Diagnostic
System Check
Go to A
Diagnostic
System Check

Brakes
5-177
OTC COOBO LR ABS Solenoid #1 Circuit Malfunction

wer
Distribution
Cflll10
Ir---= ,.----------- 1- ---- -- ---- -- -0.8PNK 739
3 ORN 440
~
I
I
14
~:v':,
Voltage
C1
I
I
:
I.
Voltage
Solenoid Valve
---~~~Traclioo
I
I
Solenoid Valve
Control Relay
Module
I (EBCM/EBTCM)
I ~
Solenoid
Valve ConlJOI
Relay Control
Control
.416
~------------------------------~--------~
~------------------------------~
---..
---..
Solenoid Valve
9rolnl
15
C1
Brake Pressure
Modulator Valve
(BPMV)
2 BU< 651
.,,. G101
213283
Circuit Description
The EBTCM controls the valve functions by

The EBTCM senses a discrepancy such as an open,
short to ground, or short to voltage in the circuit.

ABS/TCS disabled

Test Description
Diagnostic Table.
5-178 Antilock Brake System

DTC
Step
1
cooao LR ABS Solenoid #1

Action
Brakes
Circuit Malfunction
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Go to Step 3
Go to A
Diagnostic
System Check
Go to A
Diagnostic
System Check

engine off.
Brakes
. AntilockBrake System
5-179
OTC C0085 LR ABS Solenoid #2 Circuit Malfunction
II-
0.8PNK 739
o~~
r "ig;"io-;;
I Positive
I Voltage
I
l
I
~-o- ___ ~ C1
Battery f - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - "'I Electronic
_._ m
Positive
Voltage
I.
I
I
l:::MIEBTCM)
Solenokl Valve
eo,..,.,., Valve Control
Relay Control
Brake And Traction

Control
Module
~------------------------------~--------J
---.
---..
Solauoid Valve
Grolm
15
C1
~------------------------------J
Brake Pressure
Modulator Valve
(BPMV)
2 BU< 651
... G101
213283
Circuit Description
The EBTCM controls the valve functions by grounding
the circuit when necessary.


ABS/TCS disabled

Test Description
Diagnostic Table.
5-180
Antilo,ck Brake ,$ystem

OTC C0085 LR ABS Solenoid#2,CircuitMalfunctio.n
..
..
"
Step
Action
Value(s)
. Yes.
No
Go to Step2
. Goto A
; Diagnostic
System Check

engine off.
. ,4. Using. the scan tool run the Automated test.
Does OTC C0085 reset as a current DTC?
Go to Step 3
Goto A
Diagnostic
System Check

... ..
..
.,.
"''.
'
Go to A
Diagnostic
System Check
,.
Antilock Brake SystE!m
Brakes
5-181
DTC C0090 RR ABS Solenoid #1 Circuit Malfunction

er
Distribution
Cell 10
ORNI44:8 PNK
~:: I"':
14
Voltage
739
C1
f -----------
Voltage
.n
11
1------------------
":::"co":
~~=~Traction
I
C.. LJ
Control
I Module
l'.:!:M,1;BTC~
Solenoid Valve
c,-~ ::*'ea,,,
....
Grotm
~------------------------------~--------J
I
Solenoid Valve
I
15 C1
I
~------------------------------J
Brake Pressure
Modulator Valve
(BPMV)
2 BLK 651
-=- G101
213283
Circuit Description
The EBTCM controls the valve functions by


ABS/TCS disabled

Test Description
Diagnostic Table.
5-182
Antilock Brake.System
Brakes
OTC C0090 RR ABS Solenoid #1 Circuit Malfunction

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Go to Step 3
Go to A
Diagnostic
System Check
"

engine off.
Go to A
Diagnostic
System Check
Brakes
5-183
Ir---ru
0.8 PNK 739
3 ORN 440
14
r
I
Ignition
Positive
Voltage
8 C1
-;a~e:;
Positive
Voltage
f - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,I Electronic
l
Brake And Traction
I 1
I Control
I
.
i!M/EBTCM)
Co"""""'"'""""'
Valve Control
Relay Control
Module
Solenoid Valve
-....
---..
Groim
~------------------------------~--------J
~------------------------------J
I
Solenoid Valve
15
C1
Brake Pressure
Modulator Valve
(BPMV)
2 BU< 651
G101
213283
Circuit Description
The EBTCM controls the valve functions by grounding


ABsrrcs disabled
ABsrrcs Indicators are turned on.

Test Description
Diagnostic Table.
5-184
AntHock Brake System
Brakes

Step
.value(s)
Action
No
Go to Step 2
Goto A
Diagnostic
Sy$IBm Check
Go to Step 3
Goto A
Diagnostic
System Check
Yes

engine off.
Does OTC 00095 reset as a current OTC?
Go to A
Diagnostic
System Check
Btakes
Antilock Brake system
5-185
DTC C0100 Rear ABS Solenoid #1 Circuit Malfunction
so~:I
~~=I-=f-----------1------------------~:oo~Traction
wer
Distribution
Cell 10
0.8PNK 739
~-o- ___ ~
Voltage
C1
Voltage
I
I
::
I
Solenoid Valve
Relay Control
ill
---1
:~
I
Valve Control
(EBCMJEBTCM)
I .....
Solenoid
---.
Control
I Module
Solenoid Valve
Control Relay
~------------------------------~--------J
~------------------------------J
I
Solenoid Valve
15
C1
Brake Pressure
Modulator Valve
(BPMV)
2 BU< 651
.,... G101
213283
Circuit Description
The Inlet valve solenoid circuit is supplied with battery
power when the ignition is in the run position. The
EBCM controls the valve functions by grounding the
circuit when necessary.

The EBCM senses a discrepancy such as an open,

ABSfrCS disabled
ABsrrcs Indicators are turned on.

Test Description
Diagnostic Table.
5-18& Antilock Brake System
Brakes
DTC C0100 Rear Aa.S Solenoid #1 Circuit Malfunction

Action
Step
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Go to Step 3
Go to A
Diagnostic
System Check
1
2

engine off.

3
Repace the EBCM. Refer to Electronic Brake Control

Go to A
Diagnostic
System Check
Brakes
5187
0.8 PNK 739
3 ORN 440
14
" lg;;iio;;'
Positive
Voltage
8 C1
------- Battery f Positive
Voltage
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,I Electronic
Brake And Traction
ru ._. ., --
I Control
I
Module
- - - - - ~ Solenoid Valve
Solenoid Valve
Relay Control
---1
.,,.
i:::MIEBT~
Valve Control
.,,.
Ground
~------------------------------~--------J
I
15 C1
Solenoid Valve
~------------------------------J
Brake Pressure
Modulator Valve
(BPMV)
2 BU< 651
.,,. G101
213283
Circuit Description
The Outlet valve solenoid circuit is supplied with
The EBCM controls the valve functions by grounding

The EBCM senses a discrepancy such as an open,

ABS!fCS disabled
ABS!fCS Indicators are turned on.

Test Description
Diagnostic Table.
5-~ 88
Aotil,ocl( Brake System
Brakes

Step
AcUon
Value(s)
No
Go to Step 2
Go to A
Diagnostic
System Check
Go to Step 3
Go to A
Diagnostic
System Check
Yes

engine off.
Repace the EBCM. Refer to Electronic Brake Control

Goto A
Diagnostic
System Check
'
Brakes
5-189
DTC C011 O Pump Motor Circuit Malfunction
!Hot At All Times!

r -
1
, L4
ABS BATT 1
IK4
MaxiFuse
40A
r-
1Center
ce1110
I
..
L-
----------J
_________ ...
Fuse Block
Details
Cell 11
s1a1---
3 RED 302
0.8PNK 739
8 C1
13
I
I
I
- -
Ignition -
. . - - - - - - - ' Pooitive
Voltage
Motor
Contr~
Relay
------
T-
I
I
Electronic
Brake And
Traction Control
I Module
: (EBCM/EBTCM)
:~
Pump
Motor
Relay
l_$_-.- --- ~-~ 1~ ~~1,:

...
-2~ ~ , - - - - - - - - - - - - - _
I
I
Pump
--------,
Power
I
ABS IGN
Distribution
MiniFuse Cell 10
I
10A
I
0.8 PNK 739
r- - - - - - - - - - - - - - Batteiy
I
Pooitive ' - - - - - - - - - - ~
I
Voltage
!Hot In RUN, Bulb Test And START
;r- - ,Underhood
Control
1y- ~2
-3
~-----"'
.,,. G101
Brake Pressure
Modulator Valve
213285
Circuit Description
The pump motor is an integral part of the BPMV, while
the pump motor relay is integral to the EBCM/EBTCM.
The pump motor relay is not engaged during normal
system operation. When ABS or TCS operation
is required the EBCM/EBTCM activates the pump
motor relay and battery power is provided to
the pump motor.

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.

G106
(BPMV)
The ABsrrcs disables .

The amber ABSffCS indicator(s) turn on.

function is used.
Important: After the DTC is cleared using ignition
12 Km/h (8 mph) for the ABSffCS indicator(s) to
tum off.
Diagnostic Aids
- Improper mating
- Broken locks
5-190

malfunction:
- A poor connection
Brakes
Test Description
diagnostic table.
4. This step checks for a short to ground in CKT 302.
1o. This step checks for an open in CKT 302.
OTC C0110 Pump Motor Circuit Malfunction

Action
Step
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Inspect the 40A ABS BATT 1 Maxifuse, in the Underhood

Electrical Center 1.
Go to Step 7
Go to Step 3
Go to Step 16
Go to Step 4
Go to Step 5
Go to Step 12
Go to Step 6
Is the fuse OK?
1. Install a new 40A ABS BATI Maxifuse.

position, engine OFF.
3. Using a scan tool in ABS/TCS Special Functions
attempt to run the AUTOMATED test.
4. Recheck the 40A ABS BATT 1 Maxifuse fuse.
Is the fuse OK?
1.
2.
3.
4.
Turn the Ignition switch to the OFF position.

Remove the 40A ABS BATT 1 Maxifuse.
Disconnect the EBCM/EBTCM connector C1.
Connect the J 39700 Universal Pinout Box using the
harness connector only.
column?
1. Disconnect the EBCM/EBTCM pump motor

connector C2.
2. Connect a 1QA fused jumper wire between the pump
motor connector C2 terminal 1 and battery voltage.
3. Connect a jumper wire between the pump motor
connector C2 terminal 2 and ground. Only attempt to
run the pump motor for 5 seconds.
4. Disconnect the jumper wires.
5. Inspect the 10A fuse in the jumper wire.
Is the fuse OK?
Go to Step 11
Replace the BPMV. Refer to Brake Pressure Modulator

Valve Replacement.
Go to Step 16
OL (infinite)
1. Turn the Ignition switch to the OFF position.

3. Connect J 39700 Universal Pinout Box using the

J 39700-530 cable adaptor to the EBCM/EBTCM
column?
0-5Q
Go to Step 9
Go to Step B
Brakes
5-191
DTC C0110 Pump Motor Circuit Malfunction (cont'd)

Step
Action
Value(s)
Yes
No

Repair Procedures Cell 5 in Electrical Diagnosis.
1. Install the fuse if removed.

2. Using J 39200 DMM, measure the voltage at the
40A ABS BATI 1 Maxifuse by probing between the
fuse test terminals and a good ground.
column?
Battery volts
Go to Step 10
Go to Power
Distribution
Cell 10 in
Electrical
Diagnosis
10

of J 39700.
column?
Battery volts
Go to Step 14
Go to Step 13
11
Replace EBCM/EBTCM. Refer to Electronic Brake Control

Go to A
Diagnostic
System Check
12
Repair short to ground in CKT 302. Refer to Repair

Procedures Cell 5 in Electrical Diagnosis.
Go to Step 16
13
Repair open in CKT 302. Refer to Repair Procedures

Go to Step 16
Go to Step 15
Go to Step 6
Go to Step 11
Go to Step 6
Go to Step 2
Go to A
Diagnostic
System Check
14
1. Disconnect the EBCM/EBTCM pump motor

connector C2.
2. Connect a 1QA fused jumper wire between the pump
motor connector C2 terminal 1 and battery voltage.
3. Connect a jumper wire between the pump motor
connector C2 terminal 2 and ground. Only attempt to
run the pump motor for 5 seconds.
4. Disconnect the jumper wires.
5. Inspect the 1OA fuse in the jumper wire.
Go to Step 16
Is the fuse OK?
15
1. Zero the J 39200 DMM leads.

between terminals 1 and 2 of the pump motor
connector C2.
Q-4Q

column?
16

Carefully drive the vehicle above 12 Km/h (8 mph) for
several minutes.
1.
2.
3.
4.
5-192
Brakes
Antiloc~ Brake System
DTC
C0121
Valve Relay Circuit Malfunction
.
.
'
IHot At All Tlmesi

r 1
L2
1
ABS BATT 2
MaxiFuse
11<2
50A
I.
P;we-; - , Underhood
fHot in RUN, Bulb Test And START
r 1
He
1
IHtO
1 Center 1
cen 10
I..
~-------""
~-
,.... ,.... -
ABS IGN
MiniFuse
10A
P;;; - ~Underhood
Distribution
Cell to
Electrical
I Center 2
_________ ...I
I
~
~
,5 RED 1802
r-
1.. J11
I
,.... -
ABS BATT
MlnlFuse
-;;
;e;- - , Underhood
Distribution I
I
Cell to
..I _ _________ ...I

I J10
r
I
I
I
I
I
I
I
2!tA
Electrical
Center 1
30RN 440
14 C1
... e":u;. . - - - - . - - - -
0.8 PNK 739
2 BLK 651
Positive ~ - - - - - , - . , . . - - - - - - - ,
C1
lgn1tin- - ..... Gr~~d - - ,

Positive
.--+------+-, Solenoid
Voltage
15
8
- - - - - - - - .. - -
Voltage
Valve
Control
----- -
Relay
(EBCM/
EBTCM)
SOienoid
----T
I
I
.._
-=-
Valve
Control
Electronic
Brake
And
Traction
Control
Module
Solenoid
-.. -T Valve
,t Relay
-
J. .
Control
I- - - - - - - - - - - - - - - - - - - - -. - - - - - -,- - - - - - - - - - - ..I
I
Solenoid
I Brake Pressure
.
.
I
va1ve
I Modulator Valve
i. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ .a (BPMV)
,.
-=- G101
213289
Circuit Description
The solenoid valve relay supplies power to the
solenoid valve coils in the EBCM/EBTCM. The
solenoid valve relay, located in the EBCM/EBTCM, 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.

OTC C0121 will set anytime the solenoid valve
relay is commanded on and the EBCM/EBTCM
does not see battery voltage at the solenoid valves.
OTC C0121 will set anytime the EBCM/EBTCM
commands the solenoid valve relay off and battery
voltage is still present at the solenoid valves.

The amber ABS/TCS indicator(s) tum on.

The condition responsible tor setting the OTC no
function is used.
Diagnostic Aids
- Improper mating
- Broken locks
The fottowing conditions may cause an intermittent
malfunction:
- A poor connection
The solenoid valve relay is an integral part of the
EBCM/EBTCM and is not serviced separately.
Brakes
51'93
Test Description
The numbers below refer to the step numbers on the
diagnostic table.
13. This step checks for an open in CKT 440.
DTC C0121 Valve Relay Circuit Malfunction

Step
Action
Value(s)
Yes
No
Go to Step2
Go to A
Diagnostic
System Check
Inspect the ABS BATI 2 Maxifuse in the Underhood

electrical Center 1.
Is the fuse OK?
Go to Step 4
Go to Step 3
1. Install a new ABS BATT 2 fuse.

2. Inspect the ABS BATT 2 fuse.
Is the fuse OK?
Go to A
Diagnostic
System Check
Go to Step 9
Inspect the ABS BATI Minifuse in the Underhood

electrical Center 1.
Is the fuse OK?
Go to Step 10
Go to Step 5
1. Install a new ABS BATT fuse.

2. Inspect the ABS BATT fuse.
Is the fuse OK?
Go to A
Diagnostic
System Check
Go to Step 6
OL (infinite)
Go to Step 7
Go to Step 8
1.
2.
3.
4.
Turn the ignition switch to the OFF position.

Remove the ABS BATT Minifuse.
Connect the J 39700 Universal Pinout Box using the
5. Using the J 39200 DMM, measure the resistance
between the J 39700 terminals 14 and 15.
Is the resistance within specifications?

Go to A
Diagnostic
System Check
Repair the short to ground in CKT 440. Refer to Repair

Is the circuit repair complete?
Go to A
Diagnostic
System Check

Go to A
Diagnostic
System Check
10
Using the J 39200 DMM, probe between the ABS BATI 2

fuse test terminals and a good ground in order to measure
the voltage.
Is the voltage within specifications?
Battery voltage
Go to Step 11
Go to Power
Distribution
Cell 10 in
Electrical
Diagnosis
11
Using the J 39200 DMM, probe between the ABS BATI

Minifuse test terminals and a good ground in order to
measure the voltage.
Battery voltage
Go to Step 13
Go to Step 12
12
Repair the open or high resistance in CKT 1802. Refer to

Go to A
Diagnostic
System Check
S-194 Antilock Brake System
Brakes
DTC C0121 Valve Relay Circuit Malfunction (cont'd)

Step
13
Action

3. Connect the J 39700 Universal Pinout Box using the
engine off.
Value(s)
Yes
No
Battery voltage
Go to Step 7
Go to Step 14
5. Using the J 39200 DMM, measure the voltage at

terminal 14 of the J 39700.
14

Go to A
Diagnostic
System Check
Brakes
5-195
DTC C0161 ABS/TCS Brake Switch Circuit Malfunction
. ----1-
!Hot At All Times !
I Power
I Distribution H1
I Cell10
G1
------,1p
I
STOP/HAZARD
Fuse1
20A
I
I
I
1.-----______ . I.
0.8 ORN 140

A
Fuse
BlQCk
0.8 ORN
Exterior
140
Cell110
Lights
C1
r-]- ~ Stoplamp
Switch
1
1. - ...:y
0.8 LT BLU 20
I---' I (Closed with

.1
pedal depressed)
B C1
0.8 LT BLU 20
$243-----------------------0.8 LT BLU 20
A4 C200A
C200D
P100
8154
0.8 LT BLU 20
0.8 LT BLU
20
C1
'"s7o;a;p1-,I Electronic
I switch
Brake And Traction
I Control
1Modu~
I Input
1
I
I
I (EBCM/EBTCM)
I
.._
,-,
1.------..1~
213295
Circuit Description
The Stoplamp Switch is a normally open switch, when
the brake pedal is depressed the EBCM/EBTCM will
sense battery voltage. This allows the EBCM/EBTCM to
determine the state of the brake lamps.

EBCM/EBTCM detects battery voltage at all times.
EBCM/EBTCM never detects battery voltage
from CKT 20.
Both brake lamps are faulty.

DTC C0161 is set.
ABS and TCS remains active.

function is used.
Diagnostic Aids

- Improper mating
- Broken locks
malfunction:
- A poor connection
Test Description
diagnostic table.
5. This step checks for voltage at the EBCM/EBTCM.
11. This step checks the Stoplamp switch.
5-196
Brakes
DTC C0161 ABS/TCS Brake Switch Circuit Malfunction

Action
Step
1
2
3
4

Observe the rear brake lamps.
Are the brake lamps off?
Disconnect the Stoplamp Switch connector C1.
Are the brake lamps on?
Press the brake pedal.
Do the brake lights come on?
Value(s)
Yes
No
Go to Step2
Go to A
Diagnostic
System Check
Go to Step 4
Go to Step 3
Go to Step 18
Go to Step 12
Go to Step 5
Go to Step 8
Go to Step 6
Go to Step 7


Battery voltage
4. Using the J 39200 DMM, measure the voltage at the

J 39700 terminal 6 while an assistant presses the
brake pedal.

Go to A
Diagnostic
System Check
Go to A
Diagnostic
System Check
Go to Step 9
Go to Step 13
Go to Step 11
Go to Step 10
Check the STOP/HAZARD fuse in the 1/P Fuse Block.

Is the fuse OK?
1. Disconnect the Stoplamp Switch connector C 1.

Stoplamp Switch harness connector terminal A.
Battery voltage

10
Repair the open in CKT 140. Refer to Repair Procedures

Go to A
Diagnostic
System Check
Go to Step 12
Go to A
Diagnostic
System Check
Go to Step 15
Go to A
Diagnostic
System Check
Go to A
Diagnostic
System Check
11
Connect a fused jumper wire between the Stoplamp

Switch harness connector terminals A and B.
Go to Step 7
Do the brake lamps come on?

12
13
Adjust or repair the Stoplamp Switch as necessary.

1. Replace the STOP/HAZARD fuse. (Do not press the
brake pedal.)
2. Check the STOP/HAZARD fuse.
Go to Step 14
Is the fuse OK?

14

1. Press the brake pedal.
15

Is the fuse OK?
Go to Step 16
Brakes
Step
OTC C0161 ABSffCS Brake Switch Circuit Malfunction (cont'd)

Value(s)
Yes
Action
5-197
No
16
1. Turn the ignition switch to the OFF position .

2. Disconnect the EBCM/EBTCM.
3. Replace the fuse.
4. Depress the brake pedal.
Is the fuse OK?
Go to Step6
17

Goto A
Diagnostic
System Check
18

Goto A
Diagnostic
System Check
Go to Step 17
5-198
Brakes
DTC C0166 TCS Priming Line Valve CKT Malfunction
Ir-
0.8PNK 739
3 ORN 440
14
r
I
Ignition
Positive
Voltage
-------8
Battery
Positive
Voltage
C1
f - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,I Electronic
Brake And Traction
I l
I Control
I
':::-0:
Module
Solenoid Valve
11
(__.
LJ
'"'" ~ :w-Cc<ma
---.
(!MIEBTCM)
Groood
~------------------------------~--------J
I
Solenoid Valve
I
15 C1
I
~------------------------------J
Brake Pressure
Modulator Valve
(BPMV)
2 BU< 651
.... G101
213283
Circuit Description
The TCS Prime valve solenoid circuits are supplied
with battery power when the ignition is in the RUN
position. The EBTCM controls the valve functions by


Test Description
Diagnostic Table.

ABS/TCS disabled
Brakes
5-199
OTC C0166 TCS Priming Line Valve CKT Malfunction
Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check

engine off.
Go to Step 3
Go to A
Diagnostic
System Check

Go to A
Diagnostic
System Check
5-200
Brakes
Antnock Brake System
DTC C0171 TCS Pilot Valve Circuit Malfunetion
[El
Ir~::r-----------1--------------~~~=ru ~~~~~ izM~

0.8PNK 739
3 ORN 440
14
~ )~~
I
!.
I
Voltage
8 C1
Voltage
I.
---~=~Traction
Control
I Module
Solenoid Valve
~------------------------------~--------J
.,,.
Sola11oid Valve
.,,.
Groim
15
C1
~------------------------------J
Brake Pressure
Modulator Valve
(BPMV)
2 BU< 651
.... G101
213283
Circuit Description
The Master Cylinder Isolation valve solenoid circuits
are supplied with battery power when the ignition is in
the RUN position. The EBTCM controls the valve
functions by grounding the circuit when necessary.


Test Description
Diagnostic Table.

ABS/TCS disabled
Brakes
5-201
DTC C0171 TCS Pilot Valve Circuit Malfunction
Step
Action

engine off.
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Go to Step 3
Go to A
Diagnostic
System Check
Go to A
Diagnostic
System Check

3

Module (EBCM) Replacement
5-202
Brakes
DTC C0181 Throttle Reduction Motor CKT Malfunction

r -
I
I
I
I
ADS Motor Control
Accelerator
I And Servo
I Control
I Module (ASM)
.,
I ~
ADS Motor Control
l__ l____ I____ J___l____l____ l___ j""4

o.aw!~r560
D C212
491
0.8WHT 560
531
0.8
GRY 561
B ,,------D C211
O.BG::1561
F C212
1 GRY 561
1 WHT 560
1 GRY 561
1 WHT 560
---------8204
8205
2WHT 560
2 GRY 561
- - - ~~ P100
B
Accelerator
Control And
Adjuster
213284
Circuit Description
Diagnostic Aids
Identifies an adjuster assembly motor circuit that is

shorted to ground, shorted to voltage. or an open
circuit. This malfunction will not allow the adjuster
assembly motor to be controlled at the commanded
current rate or will cause the driver circuit to allow
current directly to ground.
Thoroughly inspect any circuitry that may be causing

the complaint for the following conditions:
- Improper mating
- Broken locks
malfunction:
- A poor connection
Diagnosis.

OTC C0181 can set anytime the ignition switch is in
the RUN position and the EBTCM detects an
open, short to ground, or a short to voltage.

- A malfunction OTC stores
- The TCS disables
- The amber TCS indicator turns on

function is used.
Test Description
4. This step checks for a short to ground.
8. This step checks for an open.
14. This step checks for a short to voltage.
Brakes
5-203
OTC C0181 Throttle Reduction Motor CKT Malfunction

Step
Action
Value(s)
-
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Go to Step 4
Go to Step 3

2. Disconnect the Accelerator Control and Adjuster
connector.
3. Disconnect all cables from the Accelerator Control
and Adjuster.
4. Rotate Adjuster by hand fully, then release and allow
to return to the stop. Repeat this procedure
three times.
5. Zero the leads on the J 39200 DMM.
between the Accelerator Control and Adjuster
connector terminals A and B.
column?
Replace the Accelerator Control and Adjuster. Refer to
Brake Pressure Modulator Valve Replacement.
1. Disconnect the ASM harness connector.

2. Using J 39200 DMM measure the resistance between
the ASM harness connector terminals 22 and 28.
0.5-10Q
OL (infinite)
Go to A
Diagnostic
System Check
Go to Step 6
Go to Step 5

column?

Using J 39200 DMM measure the resistance between the

ASM harness connector terminals 26 and 28.
column?

Using the J 39200 DMM. measure the resistance between

the ASM harness connector terminal 22 and the
Accelerator Adjuster harness connector terminal A.
column?
Repair CKT 560 for an open. Refer to Repair Procedures

10
Using the J 39200 DMM, measure the resistance between

Accelerator Adjuster harness connector terminal A.
column?
0-5Q
Go to Step 11
Go to Step 9
11

Accelerator Adjuster harness connector terminal B.
column?
0-5Q
Go to Step 13
Go to Step 12
12

OL !Infinite)
0-5n
Go to A
Diagnostic
System Check
Go to Step 8
Go to A
Diagnostic
System Check
Go to Step 10
Go to A
Diagnostic
System Check
Go to A
Diagnostic
System Check
Go to Step 7
Go to Step 9
5..204
Brakes
DTC C0181 Throttle Reduction Motor CKT Malfunction (cont'd)

Step
Action
Value(s)
Yes
No
13

Accelerator Adjuster harness connector terminal B.
column?
0-5Q
Go to Step 14
Go to Step 12
Above 1V
Go to Step 15
Go to Step 16

engine off.
14

ASM harness connector terminal 22.
column?
15

16
Using the J 39200 DMM, measure the voltage at the ASM

harness connector terminal 26.
column?
17

Go to A
Diagnostic
System Check
18
Replace the ASM.

Go to A
Diagnostic
System Check
Above 1V
Go to A
Diagnostic
System Check
Go to Step 17
Go to Step 18
Brakes
5205
DTC C0182 Throttle Reduction Motor CKT Range Perf

... - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - , Accelerator
I
I And Servo
I
I Control
I
I Module (ASM)
l__ l__ ~_l=_l_ __l__~J~__ l___ ]A

491 531
221 560
.
0 .8 WHT
0.8 WHT 560
261
0.8
C212
0.8 GRY 561
GRY 561
D C211
,------
1 GRY 561
1 GAY 561
1 WHT 560
1 WHT 560
..___ _ _ _ _ _ _ _ 8204
C212
8205
2WHT 560
2 GRY 561
--r
~P100
Accelerator
Control And
Adjuster
213284
Circuit Description
The throttle position signal is used by the ASM to
control the actual throttle position that is requested by
the EBTCM. The EBTCM compares the Delivered
throttle position sensor value that is sent from the ASM
to the throttle position sensor value sent from the
PCM over the UART serial data line.

OTC C0182 will set if the ASM delivers current greater
than 18 amps to the Accelerator Control and Adjuster
for more than three seconds without the cable
adjuster reaching its desired position.

The TCS is disabled.
Conditions for Ctear1ng the OTC

100 ignition cycles have passed with no DTC(s)
detected.
Diagnostic Aids
If an intermittent malfunction exists refer to General
Electrical Diagnosis in Wiring Systems.
Test Description
4. This step checks if DTC C0181 is the cause for
OTC C0182 for setting.
5. This step checks if OTC C0182 is a current fault.
Brakes
OTC C0182 Throttle Reduction Motor CKT Range Perf

Action
Step
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Inspect all Accelerator Control and Adjuster cables and

linkages for any obvious problems that could cause
binding or sticking.
Were any problems found?
Go to Step 3
Go to Step 4
Repair as necessary.
Go to A
Diagnostic
System Check
Go to
OTC C0181
Throttle
Reduction Motor
CKT Malfunction
Go to Step 5
Go to Step 6
Go to A
Diagnostic
System Check
Go to A
Diagnostic
System Check
Is OTC C0181 also set as a current OTC?
1. Using a scan tool clear OTC C0182.

2. Raise the rear of the vehicle so that both rear wheel
are approximately 6 inches off the floor.
4. Using a scan tool in TCS Data List monitor the
Throttle Angle
5.
6.
7.
8.
Press the brake pedal.

Put vehicle in gear.
Release the brake pedal.
Depress and hold the Accelerator pedal between 15

and 45 for at least four seconds.
Did OTC C0182 reset as a current OTC?
6
Replace the Accelerator Control and Adjuster. Refer to

Brake Pressure Modulator Valve Replacement.
Brakes
5-207
DTC C0236 TCS RPM Signal Circuit Malfunction
11
r - - - - - - - - - - - - - - - - - - , Electronic
'
I
I
J
~
Spark
Tachometer
Retard
Input
tcontrol
L.
Module
: (EBCM/EBTCM)
I
..... - - - - - - - - - - - - - - - - - : - . . ,
19
11
0.35 GRY/WHT 1687
Brake And Traction
I Control
...
C1
0.35 WHT 121
. C101
G.~ C105
0.35 WHT 121
0.35 WHT
$120 - -121
---
0.35 GRY/WHT 1687
ntrurent
c.JSter
Cell a,
0.35 WHT 121

30 ., C1
35
C2
~--r~------~--~;----~=:m
I
I
I
PWM Out
Tachometar I Module
I
I (PCM)
Output
_____ :et:d~g:'I____________ ~ ,!"

TCS Spark
A
415667
Circuit Description
Diagnostic Aids
The RPM signal circuit provides the EBTCM with an

indication of engine RPM to help determine TCS
control methods and rates when a TCS event
takes place.
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.

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

The TCS indicator is turned on.
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 drive cycles have passed with no DTC(s)
detected.
Test Description
2. If the instrument panel tachometer is working
properly. the cause of the malfunction is most
likely between S120 and the EBTCM, or the
EBTCM itself.
10. At this point, the PCM is likely causing the
malfunction. Refer to the appropriate
OBD system check.
Brakes

OTC C0236 TCS RPM Signal Circuit Malfunction
Step
Action
1
...
'
1. Start the engine .

2. Vary the engine RPM with the throttle while observing
the 1/P tachometer.
Does the 1/P tachometer work properly as the engine RPM
changes?
Value{s)

2. Disconnect the PCM connector C2 from the PCM.
3. Disconnect the EBTCM connector C1 from
the EBTCM.
4. Install the J 39700 Universal Breakout Box with the
J 39700-530 Cable Adapter to the EBTCM
harness only.
5. Use a J 39200 DMM to measure the resistance
between the PCM harness connector C2 terminal 10
and the J 39700 Universal Breakout Box terminal 11.
Is the resistance within the specified range?
<Hin
1. Inspect the PCM connector for the following:

Inspect for damage.
Inspect for poor terminal contact.
Inspect for corrosion.
2. Inspect the EBTCM connector for the following:
Inspect for damage.
Inspect for poor terminal contact.
Inspect for corrosion.
3. Ensure both the PCM connector and the EBTCM
connector are properly retained when connected.
Are the following signs present on either connector:
Is poor terminal contact present?
Is corrosion present?
Is damaged terminals present?
Go to Step 2
Go to A
Diagnostic
System Check
Go to Step 3
Go to Step 4
Go to Step 9
Go to Step 11
Go to Step 5
Gb to St~p 12
CHiil
1. Turn the ignition switch to the RUN position

2. Use a J 39200 DMM to measure the voltage between
the J 39700 Universal Breakout Box terminal 11 and
terminal 15.
Is the voltage within the specified range?
No

2. Disconnect the PCM connector C2 from the PCM.
3. Disconnect the EBTCM connector C1 from
the EBTCM.
4. Install the J 39700 Universal Breakout Box with the
J 39700-530 Cable Adapter to the EBTCM
harness only.
between the PCM harness connector C2 terminal 10
and the J 39700 Universal Breakout Box terminal 11.
Use a J 39200 DMM to measure the resistance between

the J 39700 Universal Breakout Box terminal 11 and
terminal 15.
Yes
OL (Infinite)
Go to Step 6
Go to Step 13
0-2V
.
Go to Step 7
Go to Step 14
"
Go to Step 15
Go to Step 8
Brakes
AntilQck Brake System
5-209
OTC C0236 TCS RPM Signal Circuit Malfunction (cont'd)

Action
Step
Value(s)
Yes
No
Go to Step 10
Go to A
Diagnostic
System Check
1. Reconnect all the connectors.

2. Using the scan tool clear the OTC.
3. Disconnect the scan tool from the DLC.

Did OTC C0236 reset?

9

Go to A
Diagnostic
System Check
10
Suspect PCM. Refer to Engine Controls.

Go to A
Diagnostic
System Check
11
Repair an open in CKT 121 between 8120 and the

EBTCM harness connector terminal 11. Refer to Repair
Go to A
Diagnostic
System Check
Go to A
Diagnostic
System Check
12
Repair an open in CKT 121 between 8120 and the PCM

harness connector C2 terminal 10. Refer to Repair
13
Repair a short to ground in CKT 121. Refer to Repair

Go to A
Diagnostic
System Check
14
Repair a short to voltage in CKT 121. Refer to Repair

Go to A
Diagnostic
System Check
Replace all the terminals or replace the connectors that

exhibit signs of the following:
That exhibit signs of poor terminal contact.
15
That exhibit signs of corrosion.

That exhibit signs of damaged terminals.
Refer to Repair Procedures Cell 5 in Electrical Diagnosis.
Go to A
Diagnostic
System Check
Brakes
5-21 O Antilock Brake System

DTC C0237 TCS Throttle Position Signal Malfunction
iHotAtAIITimes!
~ P;w; - - Distribution L4
I C 1110
ABS B
ATT1
MaxiFuse
1.-----
40A
I e
I
- - - - - - - - - - - ~ Underhood ~ -
s TT
Electrical
AB BA 2 1 C t
1
MaxiFuse I en er
L2
K2
____ ...
50A
H9
1.- ________
5 RED 1802
0.8 PNK 739
0.35TAN 800
$225-------------,
3 RED 302
r -
I Power
I Distribution
Cell 10
J11
I
I
J10
0.35TAN 800
Underhood
.
ABS BATT I Electrical
MiniFuse Center 1
-
.,
26 A
~~
0.8PNK
Accelerator And
Servo Control
739
Module (ASM)
P100
0.35TAN 800
~84 ....----.....J
0.8 PNK 739
30RN 440
2 BLK 651
0.35TAN 800
13
~ Ground
I
I
I
I
i. -
C200D
C200A
A12
L----------..1
15
24
14
Battery - - - -
Battery - - - - - - - - - - Ignition
Positive
Voltage
Positive
Voltage
- -
- -
- -
- -
Positive
Voltage
C1
Serial - -
Dala
Une
(UART)
- - - - - P-;w; - ~ Underhood
A~~ IGN Distribution I Electrical
Mm1Fuse
Cell10
C t 2
10 A
I en er
g Data Link
..I
Connector
(DLC)
Electronic
Brake And
I Traction
I Control
I Module
I (EBCM/
..1 EBTCM)
l~'\.
G101
415659
Circuit Description
the EBTCM.

OTC C0237 will set if the ASM is not receiving a
reference voltage.
OTC C0237 will set if the reference signal is
outside of a specified range.

The amber TCS indicator will turn on.

detected.
Diagnostic Aids
General Electrical Diagnosis in Wiring Systems.
Test Description
7. This step checks for an open in CKT 452 .
Brakes
5-211
DTC C0237 TCS Throttle Position Signal Malfunction
Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Go to A
Powertrain On
Board Diagnostic
(OBD) System
Check in Engine
Controls
Go to Step 3
Go to Step 5
Go to Step 4
1
Are any PCM TPS DTC(s) set?
2

2. Disconnect the PCM connector C2.
3. Disconnect the TPS connector.
4. Disconnect the ASM connector.

5. Using the J 39200 DMM, measure the resistance
between terminal 40 of the ASM harness connector
and the TPS harness connector terminal C.
0-5Q

column?
4


terminal 41 of the ASM harness connector and the TPS
harness connector terminal A.

Repair Procedures Cell 5 in Electrical Diagnosis .
terminal 43 of the ASM harness connector and the TPS
harness connector terminal B.
Go to Step 7
-
Go to Step 9
Replace the ASM. Refer to Accelerator and Servo Control

Module (ASM) Replacement.
Go to Step 8
Go to A
Diagnostic
System Check
Go to A
Diagnostic
System Check

9
Go to A
Diagnostic
System Check
Go to Step 6
0-SQ

column?
0-5Q

column?
6
Go to A
Diagnostic
System Check
5-212
Brakes
OTC C0238 TCS TP Sensor Comparison Malfunction

!HotAtAIITimesi
.. - - - - I Power
L4
I g:r~~utlon
I
I
K4
____ _
...
.. 1 H9
1
40A
...I
____ ..
SOA
5 RED 1802
- - - - ABS IGN
MiniFuse
10 A
I H8
P-;_;w;; - "' Underhood

1
Distribution Electrical
1 Center 2
cen 10
I
I
_ ________ ..
0.8 PNK 739
Data Link
Connector
(DLC)
0.35 TAN 800
8225---------1
3 RED 302
.-P-ow- - I
er
Distribution
I Cell 10
I
I...
- - - - - - - - - - - "' Underhood
1Electrical
L2
AB~ BATT1
~ BATT 2 1 Center 1
Max1Fuse
K2
MaxiFuse <Bl I
J11
J10
0.35TAN 800
C200D
- - - "'Underhood
I
.
ABS BATT Electrical
MiniFuse I Center 1
25 A
I
A12
__________ ..I
$1~
C200A
Accelerator And
Servo Control
Module (ASM)
0.8 PNK
739
P100
0.35TAN 800
$184----------'
0.8 PNK 739
3 ORN 440
2 BLK 651
15
.-I
0.35TAN 800
13
Ground
I
I
14
Battery Positive
Voltage
Battery Positive
Voltage
Ct
24
Ignition Positive
Voltage
Serial - -
D8III
Ln
(UART)
"' Electronic
1Brake And
I Traction
I Control
IModlJle
l~W
L -
...
EBTCM)
~
'1,6
G101
415659
Circuit Description
the EBTCM. The EBTCM compares the Delivered
throttle position sensor value that is sent from the ASM
to the throttle position sensor value sent from the
PCM over the UART serial data line.

DTC C0238 will set if the EBTCM detects a difference
between the PCM throttle position and the throttle
position sent from the ASM.


detected.
Diagnostic Aids
General Electrical Diagnosis in Wiring Systems.
Test Description
2. This step checks if the PCM detected a fault.
Brakes
5-213
OTC C0238 TCS TP Sensor Comparison .Malfunction
Step
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Go to Engine
Controls
System Check
Go to Step 3
Go to Step 4
Go to A
Diagnostic
System Check
Are any PCM TPS DTCs set?
Value(s)

1
Action
1.
2.
3.
4.

Disconnect the scan tool.
Turn the ignition switch to the RUN position,
engine off.

Go to A
Diagnostic
System Check
5-214
Brakes
DTC C0239 TCS Spark Retard Monitoring Malfunction

~
1
I
- - - - - - - - - - - - - - - - - - ., Electronic
Jt
Spark
Retard
Control
Tachometer ]
Input
Brake And Traction
I
I
Control
Module
_
(EBCM/EBTCM)
~--,,.----------~
-------------------, ---J
19
11 C1
I
I
I
1
0.35 GRY/WHT 1687
0.35 WHT 121
C101
G , C105
'
0.35 WHT 121

0.35 WHT . ,
121
$120
0.35 GRY/WHT 1687
Instrument
Cluster
Cell81
0.35 WHT 121
:-3~licJ.,------~c~i ;,;,:,.: ]6,o;:rin

I
PWM Out
LJ
Output
TCS Spark
_ _ _ _ _ ~et:d ~19:1 _ _ _ _ _ _ _ _ _ _ _ _
Module
(PCM)
f.t
~~
415667
Circuit Description
Spark Retard is simultaneously controlled by the
EBTCM and the PCM. The PCM supplies a 12 volt
pull up voltage. This voltage is monitored by the PCM,
the EBTCM requests spark retard by pulling the
voltage low.

DTC C0239 can be set anytime when the EBTCM
senses a short to ground, a short to battery voltage, or
an open in CKT 1687.

The ABS/TCS is disabled.
The Red BRAKE Warning indicator turn on.

detected.
Diagnostic Aids
If an intermittent malfunction exists refer to General
Electrical Diagnosis Cell 4 in Wiring Systems.
Test Description
2. This step checks for the pull up voltage from
the PCM.
3. This step checks for a short to voltage.
6. This step checks for a short to ground.
Brakes
5-215
DTC C0239 TCS Spark Retard Monitoring Malfunction

Action
Step
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Go to Step 3
Go to Step 6
Go to Step 4
Go to Step 5

-

connector C1 only.
engine off.
column?
Battery volts

engine off.
column?
Above 1V

Go to A
Diagnostic
System Check

Go to A
Diagnostic
System Check

column?

OL (infinite)
Go to Step 8
-

terminal 19 of J 39700 and terminal 53 of the PCM
connector C2.
column?
0-50
Go to Step 10
Go to Step 9
Go to A
Diagnostic
System Check
Go to A
Diagnostic
System Check
Suspect the PCM. Refer to Engine Controls.

10
Go to A
Diagnostic
System Check
Go to Step 7
5-216
Brakes
OTC C0245 Wheel Speed Sensor Frequency Error

RF Wheel Speed
Sensor
LF Wheel Speed
Sensor
0.8YEL 873
0.8
LT BLU 830
0.8YEL 833
A C120
RR Wheel Speed
Sensor
(ABS/TCS)
(ABS/TCS)
C1
01
WHT 883
A
A15
A14
A10
----------
0.5 BLK 884
GRN 872
0.5BRN 882
0.35
0.5 BU< 884
0.5
B
Ai ~---~-A1
B1
RED 885
0.5
DK
O.BWHT 883
0.35
A C130
B'
0.8BU< 882
0.5 BU< 884

0.5 RED 885
0.8
LT
BLU 872
LR Wheel Speed
Sensor
A11 C200D
-. - - - - - ~ C200A
0.5 BLK 882
r--;~~r-,----~----H;h~--~----H;r-~.y---..;r-1r~
= . = . = LT BLU 830
0.5 RED 885
0.5TAN 833
0.5 WHT 883
0.5 YEL 873
20
21
(ABS)
(ABS/TCS)
22
----- --------- ------ ----------
23
------
3
----------1 '-----~
C1
Traction
~eel
sensor
L -
~~
RF Wheel
LR Wheel
...
-~- -
I Control Module
I (EBCM/EBTCM)
RR Wheel
~~
,:~
231377
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 EBTCM uses the frequency from to

The EBTCM detects a deviation between the left
and right rear wheel speeds of greater than 6km/h
(3.75 mph) at a vehicle speed of less
than 1OOKm/h (62 mph) on vehicles equipped
with TCS.
The EBCM/EBTCM detects a deviation between
the left and right front wheel speeds of greater
than 1OKm/h (6.25 mph) at a vehicle speed of less
than 100Km/h (62 mph).
The EBTCM detects a deviation between the left

and right rear wheel speeds of greater than 6 %
of the vehicle speed at greater than 100 km/h
(62 mph) on vehicles equipped with TCS ..
The EBCM/EBTCM detects a deviation between
the left and right front wheel speeds of greater
than 4 km/h plus 6 % of the vehicle speed
at greater than 100 km/h (62 mph).
This DTC will set when the EBCM/EBTCM cannot
specifically identify which wheel speed sensor is
causing the malfunction. If the EBCM/EBTCM 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.
Br:akes


function is used.
Diagnostic Aids

- Improper mating
- Broken locks
- Poor terminal-to-Wiring connections
malfunction:
- A poor connection
5-217

solution.
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
diagnostic table.
2. If DTC C0245 is a history code, this step checks if
a specific Wheel Speed Circuit Malfunction DTC
is set concurrentty with OTC 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 C0245 Wheel Speed Sensor Frequency Error

Step
1
Action
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Go to OTC Table
Go to Step 3
Go to Step 4
Go to Step 5
Go to Step 14
Value(s)
Is the following DTC{s) set concurrently with a history

DTC C0245?
DTC
OTC
DTC
OTC
C0036
C0041
C0046
C0051
DTC C0056
3
4

Replace the WSS.

Go to Step 6
Replace the jumper harness.

Go to Step 14
Check for Proper routing of the wheel speed sensor

harness. Check that the wheel speed sensor harness is
routed away from the spark plug wires.
Is the wheel speed sensor harness properly routed?
Go to Step 9
Go to Step 7
-
Go to Step B
5-218
Brakes

OTC C0245 Wheel Speed Sensor Frequency Error (cont'd)
Action
Step
8
Reroute the wheel speed sensor harness away from the

spark plug wires.
Value(s)
Yes
No
Go to Step 14
Go to Step 10
Go to A
Diagnostic
System Check
Go to Step 13
Go to A
Diagnostic
System Check
Go to A
Diagnostic
System Check
Go to Step 2
Is the reroute complete?

3. Set the scan tool to Snap Shot Auto Trigger mode

and monitor the wheel speed sensors.
Go to Step 11

several minutes
Did the scan tool trigger on any of the wheel speed
sensors?
10
Note which wheel speed sensor triggered the scan tool.

Follow the appropriate Wheel Speed Sensor Malfunction
OTC table for the wheel speed sensor that triggered. Refer
to OTC Table.

11

3. Remove the scan tool from the OLC.
Go to Step 12

several minutes.
12

13


14
3. Remove the scan tool frcm the OLC.

4. Carefully drive the vehicle above 12 Krn h 18 mph) for
several minutes.
Go to A
Diagnostic
System Check
Brakes
5-219
OTC C0266 ADS Controller Malfunction
-d -
r -Req- -
Accelerator
IAdS
Delivered
n ervo
I
TPS Position
Control
Output
I Module
-ill.fl-: (ASM)
ueste
TPS Position
Input
12V
~-ill.fl-
~
~
f\.t_
>
37-]- - - - 35 -]- - - ~
I
L
PWM
1-
PWM
.J
0.35 ORN/BU< 463
0.35
TAN/BLK 464
C C212
,---------0.35 ORN/BU< 463
0.35
TAN/BU< 464
~~ - - - -- - - ~~ P100
2 BU< 651
1s
r -
l ___ ?? ,. ________ ~
-
I
I
I
! -{
C1
-
-ill.fl-
-ill.fl-
PWM
PWM
~
TPS P06dion
~ - - - - Output---
.lJ G101
1
2V
~~
Electronic
1I Brake And
Traction
I Control
I Module
I (EBCM/EBTCM)
Input----~
>
~
213300
Circuit Description
This circuit monitors the Delivered Trottle Position
Input for proper operation.

OTC C0266 can set anytime the ignition is in the RUN
position and the EBTCM does not recieve a Delivered
Throttle Position Input.

The TCS is disabled
The traction control indicator is turned on

The condition for the OTC is no longer present
and the scan tool clear OTC function is used
100 ignition cycles have passed with no DTCs
detected
Diagnostic Aids
Thoroughly inspect the wiring and the connectors.
Failure to carefully and fully inspect the wiring
and the connectors can result in misdiagnosis.
Misdiagnosis may cause replacement of parts
without repairing the malfunction.
If an intermittent malfunction exists, refer to
Diagnosis.
Test Description
diagnostic table.
3. This step checks for a good ground.
5. This step checks for proper voltage.
5-220
Antjlock Brake System
Step
Action
Brakes
OTC C0266 ADS Controller Malfunction

Vatue(s)

1. Turn the ignition switch to. the OFF position.
3. Inspect the ASM harness connector and the
connector for damage or corrosion.
Is there any evidence of damage or corrosion?

the ASM harness connector terminal 28 and a good
ground.

ground.I
Go to Step 2
Go to A
Diagnostic
System Check
Go to Step 7
Go to Step 3
Go to Step 4
Go to Step 8
Go to Steps
Go to StepB
Go to Step 10
Go to Step 6
o-5 n
o~sn
s the resistance within specifications?

1. Turn the ignition switch to the RUN position with the
engine off.
2. Measure the voltage between the ASM harness
connector terminals 1 and 28.

Are the repairs complete?
No
Yes
Battery volts
Go to A
Diagnostic
System Check
Go to A
Diagnostic
System Check

Go to A
Diagnostic
System Check
Replace the ASM. Refer to Accelerator and Servo Control

Module (ASM) Replacement.
Goto A
Diagnostic
System Check
10

J39700-530 cable adapter to the EBTCM harness
connector C1 only.
column?
Go to Step 12
Go to Step 11
11

12

terminal 9 of J 39700 and terminal 35 of the ASM harness
connector.
column?
OL (infinite)
Goto A
Diagnostic
System Check
o-5n
Go to Step 14
Go to Step 13
Brakes
5-221
DTC C0266 ADS Controller Malfunction (cont'd)

Step
Action
13

14

engine off.
column?
15

Value(s)
Yes
Go to A
Diagnostic
System Check
No
Above 1V
Go to Step 15
-
Go to A
Diagnostic
System Check
Go to Step 9
5-222
Brakes
DTC C0550 ECU Malfunction
P:v; - - - - - - - - - - - - - - ~ Underhood
I Distribution L4
I Cell 10
K4
I...
____ _
ABS BAIT 1
MaxiFuse
40A
L2
K2
ABS BATT 2 I
MaxiFuse I
so A
...I
____
Electrical
Center 1
- - - - ~~n~~:
I HS
I H8
I
10 A
P-;;w; - ~ Underhood
g:iir\~utlon I
I
I
________ ...
"-
5 RED 1802
0.8 PNK 739
,. P:w; - - - - - - - - .,1Underhood
ABS BATT Electrical
MiniFuse 1 Center 1
25 A
I
J11
: Distribution
Cell 10
I
I
J10
"----------..!
'" -
0.35 TAN 800

14
13
Battery Positive
Voltage
I
I
I
I
P100
0.35 TAN 800

S184 - - - - - - '
2 BLK 651
15
Data Link
Connector
(DLC)
Modula (ASM)
0.8 PNK 739
3 ORN 440
Accelerator And
Servo Control
0.8 PNK
739
~~
Electrical
Center 2
0.35 TAN 800

$225 - - - - - - - ,
0.35TAN 800
C200D
A12 C200A
3 RED 302
~ Ground
C1
24
Battery Positive
Voltage
Ignition
Positive
Voltage
Serial Data
Line
(UARn
!Hot In RUN, Bulb Test And START !
!Hot At All Times!
G101
Electronic
Brake And
I Traction
I Control
IModu~
I (EBCM/
..1 EBTCM)
'~
415659
Circuit Description
This DTC identifies a malfunction within the

EBCM/EBTCM.

DTC C0550 is set when an internal EBCM/EBTCM
malfunction exists.


OTC C0550 ECU Malfunction

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Are any other DTC(s) present besides C0550?
Go to DTC Table
Go to Step 3

Go to A
Diagnostic
System Check
Brakes
5-223
OTC C0896 Device Voltage Range/Performance
!Hot At AIITimesi
.. - - - - I Power
L4
I g:r~~utlon
K4
____ _
I
....
!Hottn RUN, Bulb Test And START !
- - - - - - - - - - - "' Underhood .. I
1 Electrical
L2
H9
AB~ BATT1
AB~ BATT 2 I Center
I
1
Max1Fuse
40 A
MaxiFuse
K2
____
50A
- - - - ABS IGN
MiniFuse
I H8
10 A
P-;;w; - "'Underhood
I
Distribution Electrical
ce1110
I Center 2
.. _ ________
...
5 RED 1802
0.8 PNK 739
..I
ce1110
J11
"'
0.35 TAN 800

C200D
Underhood
1
Electrical
MiniFuse 1 Center 1
ABS BATT
J10
25 A
Data Link
Connector
(DLC)
0.35 TAN 800

8225 - - - - - - - .
3 RED 302
.. P:;w: - I Distribution
...I
A12
__________ ...
8181
C200A
Accelerator And
0.8 PNK
739
Servo Control
P100
Module (ASM)
0.35TAN 800
8184 _ _ _ _ ___,
0.8 PNK 739
3 ORN 440
2 BLK 651
15
I"
13
Ground
I
I
I
I
-
14
Battery Positive
Voltage
.. -
0.35TAN 800
Bat!Ell)I Positive
Voltage
24
Ignition
Electronic
Brake And
I Traction
I Control
I Module
I (EBCM/
..1 EBTCM)
"I
Data
une
(UART)
PosJttve
Voltage
C1
Serial - -
,~~
G101
415659
Circuit Description
The EBCM/EBTCM 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/EBTCM also
monitors for high voltage conditions which could
damage the EBCM/EBTCM.

The EBCM/EBTCM operating voltage falls
below 9.4 volts out of ABS/TCS control, or
8.8 volts during ABS/TCS control.
The EBCM/EBTCM 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 condition for the DTC is no longer present,
the scan tool Clear DTCs function is used.
detected.
Diagnostic Aids
- Improper mating
- Broken locks
malfunction:
- A poor connection
5-224
Brakes
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.
DTC C0896 Device Voltage Range/Performance

Step
Action
Was a Diagnostic System Check performed?
1.
2.
3.
4.
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Go to Step 4
Go to Step 3
Go to Step 5
Go to Charging
System Check in
Engine Electrical
Go to Step 6
Go to Step 5
Go to Step 10
Go to A
Diagnostic
System Check
Go to Step B
Go to Step 7
Turn all the accessories off.

Install a scan tool.
Start the engine.
Use the scan tool to monitor the battery voltage while

running the engine at approximately 2000 RPM.
Is the monitored battery voltage within the
specified range?
0-17.4 V
Use a J 39200 DMM to measure the voltage between the

battery positive terminal and ground.
0-17.4 V
Continue to monitor the battery voltage with the scan tool

while running the engine at approximately 2000 RPM.
Is the monitored battery voltage within the
specified range?
0-9.4 V

5
2. Disconnect the scan tool if still connected.

3. Test drive the vehicle above 6 km/h (3.5 mph).

3. Install the J 39700 Universal Pinout Box with the
J 39700-530 Cable Adapter to the EBCM/EBTCM
between the J 39700 terminal 15 and a good ground.
Repair open or high resistance in CKT 651. Refer to

ls the repair complete?

2. Use a J 39200 DMM to measure the voltage between
the J 39700 terminal 8 and 15.

2. Reconnect the EBCM/EBTCM connector C1.
3. Disconnect the scan tool if the scan tool is still
connected.
4. Test drive the vehicle above 6 km/h (3.5 mph).
0-50

Goto A
Diagnostic
System Check
Go to Step 9
Go to Charging
System Check in
Engine Electrical
Go to Step 10
Go to A
Diagnostic
System Check
Above 9.4 Volts
10
Go to A
Diagnostic
System Check
Brakes
5-225
DTC C0901 Device #2 Voltage Low
l Hot In RUN, BULB TEST And START l

" - - T - - - - :- - - - - " Underhood
H9
.Power
'Electnca
, I
ABS IGN
01strlbu11on
I Center 2
I
MiniFuse
een 10
I
I
...
HS
__
10A
I
I
---------~
0.8 PNK 739
1
r
lg~ - - - - - - - - - - - - - - - " Accelerator
I
I
I And
Posmve
voltage
1
I
1. -
Ground
-
Ground
28 ,, - - - -
55 ' - -
0.8 BLK/WHT 151
Servo
' Control
1Module
1
(ASM)
~
.1
0.8 BLKJWHT 151
S209-----0.8 BLKJWHT 151
.!J. G102
257215
Circuit Description
This circuit monitors the voltage level available to the
ASM. If the voltage drops below 7.5 volts, full
performance of the traction control system cannot be
guaranteed.

DTC C0901 can set anytime the ignition is in the
RUN position and ignition voltage is less than 7.5 volts

The TCS is disabled
The traction control indicator is turned on

The condition for the DTC is no longer present
and the scan tool clear DTC function is used
100 ignition cycles have passed with no DTCs
detected
Diagnostic Aids
Inspect for other low voltage conditions.
Test the charging system. Refer to Charging
System Check in Engine Electrical.
The following conditions are other possible causes
of low system voltage:
- A charging system malfunction
- Excessive parasitic drain
- A weak battery
- A faulty system ground
Diagnosis.
Test Description
diagnostic table.
4. This step checks for a good ground.
6. This step checks for proper voltage voltage.
5-226
Brakes
DTC C0901 Device #2 Voltage Low

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Check the Charging System. Refer to Charging System

Check in Engine Electrical.
Is the charging system OK?
Go to Step 3
Go to Charging
System Check in
Engine Electrical

3. Inspect the ASM harness connector and the
connector for damage or corrosion.
Is there any evidence of damage or corrosion?
Go to Step 7
Go to Step 4

ground.
o-5 n
Go to Step 5
Go to Step 8

ground.
s the resistance within specifications?
o-5 n
Go to Step 6
Go to Step 8
More than 7.5 V
Go to Step 9
Go to Battery
Charging in
Engine Electrical
1. Turn the ignition switch to the RUN position with the

6
engine off.
2. Measure the voltage between the ASM harness
connector terminals 1 and 28.
Are the repairs complete?
Go to A
Diagnostic
System Check

Go to A
Diagnostic
System Check

Go to A
Diagnostic
System Check
Brakes
5-227
DTC U1304 Lost Communication with UART System

Data Link
Connector
(DLC)
9 ,.,
0.35 TAN 800

_ _ _ _ _0_.35_T_A_N_~
8225
800
0.35TAN 800
C200D
A12 ,i,C200A
OataUnk
Connector (Ol.C)
Cell SO
~~P100
0.35TAN 800
0.35 TAN
800
$184 - - - - - - - - ~
0.35 TAN 800
24
r -
C1
~"'i~- - , Electronic
(UART)
I
I
I

I ContrO,
I Module
I (EBCMIEBTCM)
L-------.1
~
213296
Circuit Description
The UART serial data line allows information to be
exchanged from module to module as needed. This is
done by the PCM, the PCM requests and sends all
the information that is transmitted on the UART line.

OTC U1304 can be set anytime the ignition is in the
RUN position and the EBTCM does not recieve a
$90 message from the PCM for 6 seconds.

The amber TCS indicator is turned on.

function is used.
Diagnostic Aids

- Improper mating
- Broken locks
malfunction:
- A poor connection
Test Description
4. This step checks for a short to battery voltage in
CKT 800.
5-228
Brakes

DTC U1304 Lost Communication with UART System
Step
Action

1
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Go to Step 4
Go to Step 3


column?


engine off.
column?
Repair CKT 800 for a short to battery voltage. Refer to


2. Disconnect the PCM. If the vehicle is equipped
with a V8 disconnect the PCM connector C4.
If the vehicle is equipped with a V6 disconnect the
PCM connector C1.
3. Using J 39200 DMM measure the resistance between
the J 39700 terminal 24 and the PCM terminal 30 if
the vehicle is equipped with a V8 or terminal 15 if the
vehicle is equipped with a V6.
OL (infinite)
Go to A
Diagnostic
System Check
Battery voltage
Go to Step 5
Go to A
Diagnostic
System Check
Go to Step 6
0-2Q

column?
Go to Step 8
Go to Step 7

Go to A
Diagnostic
System Check

Goto A
Diagnostic
System Check
Brakes
5-229
TCS Off Indicator On with No DTC Set

!HotlnRUNi
P;w;;; - - - - - - - - - - - - - , 1/P
I Distribution
C&ll 10
I
F1
~-----Fu-se-B-loc_k_
0.8 BRN
Details
Cell il
TURN B/U
Fuse 2
20 A
E1
G3
GAGES I
Fuse 9 I
10 A
I
H3
----------~
141
0.35
39
PNK
----S207
0.8 BRN 141
-------0_____ :JEI _______BI
i:i'o.;'entary -
Switch
(TCS)
'l- - - , Traction
A,,J, I Control
I Switch
J __ ~
F
0.35
0.35
0.35 BLKJWHT 451 BRN/WHT 1571
PPL/WHT 1572
A13
C4 C200D
,... - S215
------------ C200A
g~K/WHT 451
~~r
ASR
Ci) !
Pontiac:
~~
lI~
:~----~~---l
~=:
Iv!,
0.35 PPl/WHT 1572
C200A
F
C220
0.35
PPL/WHT 1572
Cell 14
0.8
I BLK/WHT
L
lnStrument
0.35 PPL/WHT ~;~OD
Ground
Distribution
I
I
(!j
A5 ; - - - - - - - - - - - , Instrument
L------<,
!Chewoletl : Cluster
fuse
Block
ii:O :-u;;
'!. -~~-~-~!]; ~~""'~~ - -:::=ooA:IT<actioo
5 BLKJWHT 451
I
I
1~
G110 1
I Control
1 Module
I (EBCM/EBTCM)
~----------------J
~
213310
Circuit Description
The TCS Off indicator is controlled by the EBTCM.
The EBTCM supplies the ground to CKT 1572 in order
to keep the indicator off. When CKT 1572 looses
ground at the EBTCM, the TCS Off indicator turns on.
When the EBTCM sees the traction control switch
voltage go low it turn the TCS Off indicator on
and disables traction control.
Diagnostic Aids

- Improper mating
- Broken locks
- lmproperty formed or damaged terminals
malfunction:
- A poor connection
Test Description
3. This step checks for an internal EBTCM
malfunction.
5-230
Step
Action
Brakes
TCS Off Indicator On with No DTC Set

Value(s)
Yes
No
DEFINITION: TCS Off indicator is on and traction control was not turned off. There are no DTCs set.
1
Go to Step 2
Go to A
Diagnostic
System Check
Go to Step 3
Go to Step 8
Go to Step 4
Go to Step 5
Go to A
Diagnostic
System Check

engine off.
2. Using a scan tool enter TCS Data List.
2
3. While monitoring the TCS On/Off switch status, press

and release the TCS On/Off switch.
Does the switch status change from pressed to released

as the TCS switch is pressed and released?
J 39700-530 cable adapter to connector C1 only.
3
4. Connect a fused jumper wire between terminals 18

and 15 of J 39700.
engine off.
Does the TCS Off Indicator turn off?

1. Tum the ignition switch to the OFF position.

2. Disconnect the Instrument Cluster connector. Refer to
Instrument Cluster Cell 81 in Electrical Diagnosis for
connector pinout
5

between terminals 18 of J 39700 and the Instrument
Cluster harness connector terminal AB.
0-5Q
Go to Step 7
Go to Step 6

column?

Goto A
Diagnostic
System Check
Go to A
Diagnostic
System Check
OL (infinite)
Go to Step 4

7
Suspect the Instrument Panel. Refer to Instrument Panel in


8

Go to Step 9

column?
Repair CKT 1571 for a short to ground, being sure to

check the traction control switch for a short. Refer to
Go to A
Diagnostic
System Check
Brakes
5-231
TCS Off Indicator Inoperative with No DTC Set

!Hot In RUN!
,. - - - - I Power
I g:r\~l.ltion
I
I..
- - - - - - - - - - "'1/P
F1
TURN B/U
Fuse 2
G3
20A
H3
_______________ ..,I
0.8 BAN 141

0.35 PNK 39
AS ,. - - - - - - - - - - - , Instrument
1 Cluster
----S207
'-------<
!Chevrolet! I
..&.
0.8 BAN 141
Fuse Block
Details
Cell11
~=~~rt
-1~ --1
..
F
(!)
(TCS)
PPL/WHT
C4
-----------0.35 PPL/WHT
$215
0.8
~ BLK/WHT 451
Ground
Distribution
Cell 14
t1
g~~r
~6~~~~r
0.8
\:ti
..
TCS OFF
Indicator
Amber
I
I
I
,-~
---___________
..,
AB
1572
C200D
C200A
0.35 PPL/WHT 1572
1572
C200D
C200A
C220
1
P 00
ASA
~ ! Pontiac ! 1~
I Switch
-----...
0.35
EI -------~-0.35 BI
y
0.35 BLK/WHT 451 BRN/WHT 1571

A13
.- -
Instrument
~CJ-------
GAGES I fuse
Fuse 9 I Block
10 A
I
0.35
rl-v
2
PPL/WHT 1572
1
]_: -~-;...-~-)~;~:~~- - - ,Electronic
BLKJWHT 451
:
Control P
$110 1
T
5 Bl.KJWHT 451
1
G110 1.. ________________
.t
: Brake
And Traction
Control
..._
,.
I Module
..,1(EBCM/EBTCM) ~
I
213310
Circuit Description
The TCS Off indicator is controlled by the EBTCM.
The EBTCM supplies the ground to CKT 1572 in order
ground at the EBTCM, the TCS Off indicator turns on.
voltage go low it turn the TCS Off indicator on
and disables traction control.
Diagnostic Aids
- Improper mating
- Broken locks

malfunction:
- A poor connection
Test Description
malfunction.
5. This step checks for a short to ground in
CKT 1572.
5-232
Brakes
TCS Off Indicator Inoperative with No OTC Set

Step
Action
Value(s)
Yes
No
DEFINITION: TCS Off indicator is inoperative when attempting to disable traction control.
1
Go to Step 2
Go to A
Diagnostic
System Check

engine off.
Go to Step 3
Go to Step B

engine off.
Does the TCS Off Indicator turn on?
Go to Step 4
Go to Step 5

Go to A
Diagnostic
System Check

connector pinout.
column?
OL (infinite)
Go to Step 7

Goto ABS
Diagnostic
System Check

Go to A
Diagnostic
System Check

between terminals 17 and 15 of J 39700 while an
assistant presses the TCS On/Off switch.
column?
Repair CKT 1571 or 451 for an open or high resistance,

being sure to check the traction control switch for an open.
0-5Q
Go to Step 4
Go to A
Diagnostic
System Check
Go to Step 6
Go to Step 9
Brakes
5-233
ASR Indicator On with No DTC Set
----------,wfuse
lHotln RUN!
r----I Power
Distribution
I eet110
I
F1
E1
TURN BN
Fuse 2
G3
GAGES I
Fuse 9
20A
H3
10A
L----- ----------J
r-rFu-sa..,....oc-.-k-,
Details
cen 11
Block
--------
0.8 BAN 141

0.35 PNK 39
8207
0.8 BAN 141
~~-
--1;-~l~:r:
~ l_ _--_?j:~ ----_
f __ JEI
BI
F
0.35
0.35
0.35 BLK/WHT 451 BAN/WHT 1571
PPL/WHT
A13
C4
.- 8215
-----------0.35 PPL/WHT
I 0.8
D5
~ BLK/WHT 451
F
C220
P100
17
QI-,
C..81
.TCSOf'F. I
~=:
~----~~---1
0.35 PPl.J'MfT 1572
C2000
C200A
0.35
PPLJWHT 1572
- - - - - - - ~~ C1
-f
Conb'ol
...
: Module
Traction
I (EBCMJEBTCM)
~m~----------------~
~....
""1t.
213310
Circuit Description
The ASR indicator is controlled by the EBTCM. The
EBTCM supplies the ground to CKT 1572 in order
ground at the EBTCM, the ASR indicator turns on.
voltage go low it tum the ASR indicator on and
disables traction control.
Diagnostic Aids
- Improper mating
- Broken locks
@iei,roieti
-9 I Poni8C: fl Mli\
1572
C200D
C200A
1572
ruv- - - - - -,-~; - - :=:"~
I g~K/WHT 451
L 8110
5 BLK/WHT 451
:
A5 r - - - - - - - - - - - , Instrument
IE
l
I Cluster
I
t
I ~
I 1n1tnmen1
ASR
I
~


malfunction:
- A poor connection
Test Description
malfunction.
5-234
Brakes
ASR Indicator On with No DTC Set

Step
Action
Value(s)
Yes
No
DEFINITION: ASR indicator is on and traction control was not turned off. There are no DTCs set.
1
Go to Step 2
Go to A
Diagnostic
System Check
Go to Step 3
Go to Step 8
Go to Step 4
Go to Step 5
Go to A
Diagnostic
System Check

engine off.

2


and 15 of J 39700.
engine off.
Does the ASR Indicator turn off?


connector pinout.

Cluster harness connector terminal AS.
0-5!1
Go to Step 7
Go to Step 6

column?
6

Go to A
Diagnostic
System Check
Go to A
Diagnostic
System Check

7


8

OL (infinite)
Go to Step 4
Go to Step 9

column?
Repair CKT 1571 for a short to ground, being sure to

check the traction control switch for a short. Refer to
Go to A
Diagnostic
System Check
Brakes
5-235
ASR Indicator Inoperative with No DTC Set

!Hot In RUN!
rP;w;--I Distribution
F1
I C&ll 10
I
E1
----------,1/P
TURN B/U
Fuse 2
20 A
GAGES I
Fuse 9 I
10 A
I
G3
H3
Fuse
Block
----------~
~----0.8 BAN
141
0.35 PNK 39
AS " - - - - - - - - - - - ., Instrument
1
~:~\~
- - - - 8207
~-----<
l""'--'etl C>luster
~;;:.:...:._ _.
0.8 BAN 141
."' ..... "' . 1
......
Fu-se""'B....
oc..,...,
-----.
Instrument
Cluster
Cell81
~0
- - - -- - -f~~ntary- I
(TOS)
-1:~6~~~~1n
A?'
\:i;I
,1
Ground
Distribution
Cell 14
F C220
P100
I g~K/WHT 451
L
5110
5 BLK/WHT 451
G110
-u
17
~::or
TCSOFF
I Switch
1
1
~i~:~11~~ ~
o.35 BLK/W;~ :1- g:~~:~r1~7~ A13

C4
.- - 8215
-----------0.35 PPL/WHT
I 0.8
05
~ BLK/WHT 451
ASR
(!}/;' I Pontiac I
Solid State
I , ......
I~
I
1
1
~ - - - - AB- - - - - - ~
C200D
C200A
0.35 PPLJWHT 1572
1572
C200D
C200A
O35
PPWWHT 1572
_______ ~~
C1
v- - - - - -; ~~ ~ - - ~=~Traction
Conl'OI
Control
1
I
1
.i.
1Module
1(EBCMIEBTCM) ~
..I ________________
Jt
213310
Circuit Description
The ASR indicator is controlled by the EBTCM. The
EBTCM supplies the ground to CKT 1572 in order
ground at the EBTCM, the ASR indicator turns on.
voltage go low it turn the ASR indicator on and
disables traction control.
Diagnostic Aids
- Improper mating
- Broken locks
'"'" Improperly formed or damaged terminals


malfunction:
- A poor connection
Test Description
malfunction.
CKT 1572.
5-236
Step
Action
Brakes
ASR Indicator Inoperative with No OTC Set

Value(s)
Yes
No
DEFINITION: ASR indicator is inoperative when attempting to disable traction control.

1
Go to Step 2
Go to A
Diagnostic
System Check

engine off.
Go to Step 3
Go to Step B
Go to Step 4
Go to Step 5
Go to A
Diagnostic
System Check

engine off.
Does the ASR Indicator turn on?

4



connector pinout.
OL (infinite)
Go to Step 7
Go to Step 6

column?

Go to A
Diagnostic
System Check

Go to A
Diagnostic
System Check

between terminals 17 and 15 of J 39700 while an
assistant presses the TCS On/Off switch.
column?
Repair CKT 1571 or 451 for an open or high resistance,

being sure to check the traction control switch for an open.
0-50
Go to Step4
Go to A
Diagnostic
System Check
Go to Step 9
Brakes
5-237
No Communication with EBCM/EBTCM

lHotAtAUTimes!
" - - - - I Power
4
I Distribution L
I Cell 10
K4
____ _
..I
!Hot In RUN, Bulb Test And START !
- - - - - - - - - - - ., Underhood " I
L2
Electrical
ABS BATT1
ABS BATT 2 I Center 1
MaxiFuse
MaxlFuse <Bl
K2
.. _ ________ ..
____
SOA
40A
- - - - - - - - ., Underhood
Power
I El
"cal
ABS IGN
Distribution
ectn
MiniFuse
Cell 10
I Center 2
...I
10 A
5 RED 1802
0.8 PNK 739
0.35TAN 800
C200D
A12 C200A
" - - - - - - - - - - ., Underhood
1Power
IEIect"
Distribution
J11
ABS BATT
ricaI
I ce1110
MiniFuse I Center 1
J10
25 A
L----------..1
Accelerator And
Servo Control
Module (ASM)
0.8 PNK
~~
739
P100
0.35TAN 800
S184 ...- - - - -
0.8 PNK 739
3 ORN 440
Data Link
Connector
(DLC)
0.35TAN 800
8225 ...- - - - - - ,
3 RED 302
I
I
2 BLK 651
0.35TAN 800
15
13
14
8 ____________________ .?~ C1
" - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ., Electronic
Ground Battery
Battery
Ignition
Serial
I B k And
I
I
Positive
Voltage
Positive
Voltage
I
I
I
L -
ra e
Data
Une
(UART)
Positive
Voltage
I Traction
I Control
I Module
I (EBCM/
-
...
EBTCM)
G101
415659
Circuit Description
Diagnostic Aids
The UART serial data link allows information to be

exchanged from module to module as needed. This is
done by the PCM, the PCM requests and sends all
the information that is transmitted on the UART
line. When a scan tool is connected to the UART line
it takes over for the PCM and sends and requests
the needed information.

Diagnosis.
No Communication with EBCM/EBTCM

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
DEFINITION: Scan tool can not communicate with the EBCM/EBTCM.

1
Turn the Ignition switch to the RUN position with the

engine off.
Can the scan tool communicate with other modules on the
UART serial data line, such as the PCM?
Go to Step 3
Go to Data Link
Connector
Cell 50 in
Electrical
Diagnosis
Inspect the 10A ABS IGN fuse in the Underhood Electrical

Center 2.
Is the fuse OK?
Go to Step 4
Go to Step 6
5-238
Brakes
No Communication with EBCM/EBTCM (cont'd)

Step
Action
1. Install the fuses if removed.

engine off.
3. Using J 39200 DMM, measure the voltage at the
1OA ABS IGN fuse by probing between the fuse test
terminals and a good ground.
Is the voltage within the range specified within the value(s)
column?

3. Connect the J 39700 Universal Pinout Box using
the J 39700-25 to the EBCM/EBTCM harness
connector C1 only.
between J 39700 terminal 15 and a good ground.
column?
1. Install a new 10A ABS IGN fuse.

3. Recheck the fuse.
Is the fuse OK?
Yes
No
Battery Volts
Go to Step 5
Go to Power
Distribution
Cell 10 in
Electrical
Diagnosis
0 - 2Q
Go to Step 10
Go to Step 9
Go to A
Diagnostic
System Check
Go to Step 7
Go to Step 12
Go to Step B
1.
2.
3.
4.
10
11
12

Remove the 1OA ABS IGN fuse.
Connect the J 39700 Universal Pinout Box using
the J 39700-25 to the EBCM/EBTCM harness
connector C1 only.
column?
Value(s)

Repair CKT 651 or G101 for an open or high resistance.
engine off.
2. Using J 39200 DMM. measure the voltage between
J 39700 terminals 8 and 15.
column?
13

2. Using J 39200 DMM, measure the resistance between
the J 39700 terminal 24 and the DLC terminal 9.
Is the resistance within the range specified i the values
column?
14

OL (infinite)
Go to A
Diagnostic
System Check
Go to A
Diagnostic
System Check
Battery Volts
13
Go to Step 11
Go to A
Diagnostic
System Check
Go to A
Diagnostic
System Check
0-2Q
Go to Step 12
Goto A
Diagnostic
System Check
Go to Step 14
Brakes
5-239
ABS Indicator On No DTC Set
iHot In RUN, Bulb Test And START

r- I
I G3
Im
I
...
GAGES
Fuse 9
f'I':-1
- - - .,
Power
I
Distribution I
Cell 10
WA
I
I
Instrument
Cluster ~
IP
Fuse
Block
:E~-1:.:---~1:::~-----c:.:,!j rsi
: I-- I --------~:
_ --- . ____ .,
0.8 PNK 39
I
I
S206
Warning
Indicator
~-----
PNK 39
-:-=~-~n_g_
Cell
41
A9
r- -
0.35 YEL/BLK 147'1

A5
S216
C2000 I
C200A I
P100
G200
C200D
0.35 LT GRN 867
-1------1---7
26
3 BLK
I
I
-me::
A3
0.35 DK BLUf,5-3~- ____
......___..._ _.
Indicator
~ Amber
0.35 LT GRN 867
~~:~a~~~on
0.35 BLK 650
0.35 DK :(~r1537
0.35 A10
TAN/WHT 33
Lamp Driver
Module
Solid
State
~--- -----817
B
E
- - - - - - - - Brake
- - - - - - - - -...
Indicator
Amber
(G)((D)
8228
0.35
0.35
TAN/WHT 33
0.35PNK 39
0.35 YELJBLK 147'1
~
16
C1
LOW TRAC
---f
.t.
Indicator
Control
----T
.t.
.,Electronic
ABSINOP I Bak A d
Indicator
r e n
I
Control
Traction Control
. __ Control
I Module
I (EBCM/EBTCM)
I ~
- .;;; - - - - - - - - - - - - - - -
~~
BRAKE
Indicator
C1
213307
Circuit Description
The ABS indicator is controlled by the EBCM/EBTCM.
The EBCM/EBTCM supplies the ground to CKT 867 in
order to keep the indicator off. When CKT 867
looses ground at the EBCM/EBTCM, the ABS indicator
turns on.
Diagnostic Aids
- Improper mating
- Broken locks

malfunction:
- A poor connection
Test Description
2. This step checks for an internal EBCM/EBTCM
malfunction.
Brakes
ABS Indicator On No DTC Set
Step
Value(s)
Action
Yes
. I
No
DEFINITION: ABS Indicator is on with no DTCs.
Go to Step 2
Go to A
Diagnostic
System Check

3. install the J 39700 Universal Pinout Box using the
and 15 of J 39700.
Does the ABS Indicator turn off?
Go to Step 3
Go to $tep 4

..
-

connector pinout.
Cluster harness connector terminal 817.
column?
o-5n
Go to A
Diagnostic
System Check
Go to Step6
Go to Step 5
..

Goto A
Diagnostic
System Check
Suspect the Instrument Panel. Refer to Instrument Panel

Goto A
Diagnostic
System Check
'-c:
Brakes
5-241
ABS Indicator Inoperative with No OTC Set

!Hot In AUN, Bulb Test And START
'" -
I
I G3
I~
I
'--
Instrument
Cluster
- - - "'."' - - - - , IP
Power
I
GAGES
Distribution I Fuse
Fuse 9
CeH 10
Block
WA
0.35 PNK 39
rEt
________
...
0.8 PNK 39
22
;3-9_ _ _ _ _ _8_ _ _8
-c.:----1~~-~----
-1~~,:.-:
(J)
(J)
Warning
1141
Solid
Indicator
817
TAN/WHT 33
0.35 DK t(BI1537
0.35 LT GRN 867
A9
~~:~a~~~on
A3
0.35 DK BLUJ,5~~- ____
C200D
-mC:~:OA
0.35 LT GAN 867
~~~l~river
------- ~
J.
0.35YEL/BLK 1471
AS
S216
0.35 YEL/BLK
'" -------1------1----,
I
-----1---------,
3 BLK
Indicator
0.35 A 0
B
E
.........- - - - - . - -..... Brake
......................- -
L2w
_I _(,~~ J_
::_-~---:~-_j
:!~ng
ce
0.35 BLK 650
(J)
~IN
_1__. [ _- - _
0.35
TAN/WHT 33
~~
AS
1
I
C2000 I
C200A I
1:;~oo
1~6
26
Indicator
-*
T Control
... Control
1
C1 z -
Electronic
And
I Brake
Traction Control
I Module
I (EBCM/EBTCM)
ABS INOP I
Indicator
---T control
BRAKE
Indicator
C1
LOW TRAC
- - - - - - - - - - - - - -
J.
~~
G200
213307
Circuit Description
The ABS indicator is controlled by the EBCM/EBTCM.
The EBCM/EBTCM supplies the ground to CKT 867 in
order to keep the indicator off. When CKT 867
looses ground at the EBCM/EBTCM, the ABS indicator
turns on.
Diagnostic Aids
- Improper mating
- Broken locks

malfunction:
- A poor connection
Test Description
malfunction.
Brakes
ABS Indicator Inoperative with No DTC Set

Step
Action
Value(s)
Yes
No
DEFINITION: ABS Indicator never comes on.

1
Go to Step 2
Go to A
Diagnostic
System Check

Does the ABS Indicator come on?
Go to Step 3
Go to Step 4

Go to A
Diagnostic
System Check

connector pinout.
column?

Goto A
Diagnostic
System Check

Go to A
Diagnostic
System Check
OL (infinite)
Go to Step 6
Go to Step 5
Brakes
5-243
Low Traction Indicator Always On
,. -
I
I
Instrument
Cluster
- - - - - - - - , IP
G3
I~
I
Power
I
Distribution I Fuse
GAGES
Fuse 9
Cen 10
WA
Block
L-
0.35 PNK 39
--------.1
: ~,;rt
0.8 PNK 39
: I (r( I
<!)
s2os--~~~~~~~~__.
$228
0.35
PNK 39
-1:.:---~t
Q))
I
Brake
0.35
<!)
Warning
[SJ
oc
~w-~- - - -
-1~
Indicator
Solid
<!)
Amber
State
~.~:1 [SJ
Red
Indicator
Amber
L----- ------- -----817 --------.1
Warning
...............
--. 0.35 A10
0.35 DK :(~ 11537
Cell41
TAN/WHT 33
0.35 LT GRN 867
TAN/WHT 33
E
A9
Brake
Malfunction
Indicator
Lamp Driver
Module
0.35 BLK 650
0.35 LT GRN 867
'" -------1------1----
3BLK
26
1
0.35 YEL/BLK 1471
I
A5 C200D I
S216
C200A I
0.35 YEL/BLK
C200D
0.35 DK BLUf5~~- ____ -mC:A
A3
1:;~oo
1~6
E
.1
C1 z
C1
"Electronic
ABS INOP I B ak A d
Indicator
r e n
LOW TRAC
Indicator
Control
1
Traction Control
1
Module
I (EBCM/EBTCM)
I ~
- - - - - - - - - - - - - - -
~~
BRAKE
- __
Indicator
---1eon1ro1
_
--1Contro1
_
-
G200
213307
Circuit Description
The LOW TRAC Indicator is controlled by the
EBCM/EBTCM. When the EBCM/EBTCM detects a
low traction condition it supplies a ground for
CKT 1537 turning on the LOW TRAC Indicator.
Diagnostic Aids
- Improper mating
- Broken locks

malfunction:
- A poor connection
Test Description
2. This step checks for an internal
EBCM/EBTCM short.
CKT 1537.
5-244
Brakes
Low Traction Indicator Always On

Step
Action
Value(s)
Yes
No
DEFINITION: LOW TRAC Indicator On without a low traction condition.

1
Go to Step 2
Go to A
Diagnostic
System Check

Is the LOW TRAC Indicator off?
Go to Step 3
Go to Step 4

Go to A
Diagnostic
System Check

connector pinout.
column?
OL (infinite)
Go to Step 6

Go to A
Diagnostic
System Check

Go to A
Diagnostic
System Check
Go to Step 5
Brakes
5-245
Low Traction Indicator Inoperative

" -
- - - - - - - - ., IP
Power
I
Distribution I Fuse
Cell 10
Block
I
GAGES
Fuse 9
10A
~- --------J
0.8 PNK 39
8228
0.35
PNK 39
0.35 PNK 39
:~;: ,-r;.=--- -1~~-~---- -1~~1:0P-:
: I cr(CD) I
@
Warning
Indicator
Solid
Amber
State
Indicator
Amber
Red
Brake
Warning
0.35
A0
Cell41
0.35 DK
A9
Brake
Malfunction
Indicator
Lamp Driver
Module
0.35 DK
0.35
BLK 650
BLUj,5-3~- ____
C200D
-me:::
0.35 LT GRN 867
0.35 YEL/BLK 1471
A5
0.35 YEL/BLK
G200
C1
,.- ------;- ----- ---1

----T
I
S216
3BLK
A3
26
~"
L2w
~-----1 ------- -----817 --------J

.....,...._,;...-..., 0.35
t(B 11537
1
TANJWHT 33
0.35 LT GRN 867
TAN/WHT 33
B
A~,
A5
s2os-------------------'
Instrument f"C'"l
Cluster ~
I
I
C2000 I
C200A I
P100 ~
1471 16
BRAKE
Indicator
"Electronic
ABS INOP I B al< And

Indicator
r e
LOW TRAC
Indicator
1Contro1
Control
.t.-
I Traction Control
I Module
I
(EBCM/EBTCM)
I J.
_ z _______________ ~ .M6
. __ Control
C1
213307
Circuit Description
The LOW TRAC Indicator is controlled by the
EBCM/EBTCM. When the EBCM/EBTCM detects a
low traction condition it supplies a ground for
CKT 1537 turning on the LOW TRAC Indicator.
Diagnostic Aids
- Improper mating
- Broken locks

malfunction:
- A poor connection
Test Description
malfunction.
5-246
Brakes
Low Traction Indicator Inoperative

Step
Action
Value(s)
Yes
No
Go to Step 2
Go to A
Diagnostic
System Check
Go to Step 3
Go to Step 4
Go to A
Diagnostic
System Check
o-5n
Go to Step 6
DEFINITION: LOW TRAC Indicator never comes on.

1


and 15 of J 39700.
Does the LOW TRAC Indicator come on?


connector pinout.

Cluster harness connector terminal A 16.
Go to Step 5

column?
5

Go to A
Diagnostic
System Check

in Instrument Panel. Gauges and Console.
Go to A
Diagnostic
System Check
Brakes
5-247
Repair Instructions
Electronic Brake Control Module {EBCM)
Replacement
Removal Procedure
Notice: To prevent equipment damage, never connect
or disconnect the wiring harness connection from
the EBCM with the ignition switch in the ON position.
2. Pull out lock tab from the EBCM/EBTCM harness
connector.
3. Disconnect the EBTCM harness connector (6).
3
213428
4. Disconnect the pump motor connector (3) at the

bottom of the EBCM/EBTCM.
5. Remove the six EBCM/EBTCM to BPMV
screws (2) and discard.
6. Separate the EBCM/EBTCM (1) from the
BPMV (5) by gently pulling apart until separated.
Important: Be careful not to damage seal. Do not pry

apart using a tool.
Important: Care must be taken not to damage the
solenoid valves when the EBCM/EBTCM is removed
from the BPMV.
4
213438
5-248
Brakes
7. If equipped with ABS only, remove one wave

spring (1) between the EBCM and BPMV and
discard.
Important: Note the location and the orientation of the
wave spring in order to aid during installation.
255233
8. If equipped with ABS/TCS remove two wave

springs (1) between the EBTCM and BPMV and
discard.
Important: Note the location and the orientation of the
wave springs in order to aid during installation .
255236
Important: Only the new wave spring(s) and screws
supplied with the new EBCM/EBTCM should be used.
1. Clean the BPMV gasket surface with alcohol
using a clean rag.
2. If equipped with ABS only, install one wave
spring (1) between the EBCM and BPMV.
Use location and orientation noted during removal.
255233
Brakes
5-249
3. If equipped with ABS/TCS, install two wave

springs (1) between the EBTCM and BPMV. Use
locations and orientation noted during removal.
255236
4. Install the EBCM/EBTCM (1) to the BPMV (5).

Notices.
Tighten
Tighten the top four mounting screws (2) to
2.9 N-m (26 lb in.). Tighten screws in an X pattern.
Tighten
Tighten the bottom two mounting screws (2) to
2.9 Nm (26 lb. in.).
5. Connect the pump motor connector (3) to the
bottom of the EBTCM.
3
4
213438
6. Connect the EBCM/EBTCM harness connector.

Push in lock tab.
engine off.
8. Perform the A Diagnostic System Check
3
213428
5-250
Brakes
(ASM). Replacement
Removal Procedure
1. Disconnect the fasteners on the lower sound
insulator panel under the steering column.
2. Remove the lower sound insulator panel from the
vehicle.
3. Remove the left side kick panel on vehicles
4. Remove the bolt attaching the ASM bracket to the
upper 1/P.
5. Remove the push in retainer attaching the ASM
bracket to the side wall.
6. Remove the ASM bracket along with the ASM
from the mounting place (1,2).
7. Disconnect the ASM harness connector).
8. Remove the ASM to ASM bracket mounting
screws (3).
9. Remove the ASM and ASM bracket from the
vehicle (1,2).
213425
1. Install the ASM to the ASM mounting
bracket (1,2).
2. Install the ASM to ASM bracket screws (3).
3. Connect the ASM harness connector.
4. Install the ASM and ASM bracket in the
mounting place.
5. Install the push in retainer attaching the ASM
bracket to the side wall.
6. Install the bolt attaching the ASM bracket to the
upper 1/P.
7. Install the left side kick panel on vehicles equipped
with a manual transmission.
8. Install the lower sound insulator panel in the
vehicle.
9. Install the fasteners on the lower sound insulator
panel under the steering column.
213425
Brakes
5-251

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. Disconnect the EBCM/EBTCM harness
connector (6).
Important: Note the locations of the brake pipes in
order to aid in installation.
3. Disconnect the brake pipes from the BPMV.
213428
4. Remove the two nuts that connect the BPMV to

the BPMV bracket (3).
Notice: When removing the brake pressure modulator

valve, protect the vehicle exterior from possible
brake fluid spillage. Brake fluid can cause damage to
painted surfaces.
5. Remove the BPMV and EBCM/EBTCM as an
assembly from the vehicle (5).
255229
5-252
Brakes
1. Install BPMV and EBCM/EBTCM as an assembly
into the BPMV bracket (2).
2. Install the two BPMV bracket nuts (3).
Tighten
Tighten the.two BPMV to BPMV bracket nuts to
12 N-m (8 lb ft.)
Important: If a new BPMV is being installed, remove

the shipping plugs from the valve openings in the
compartment during the next step.
Important: Use the locations noted during removal.
255229
Caution: Make sure brake pipes are correctly

connected to brake pressure modulator valve. If
brake pipes are switched by mistake, wheel lockup
will occur and personal injury may result. The
only two ways this condition can be detected are
by using a Scan Tool or by doing an Antilock stop.
3. Install the brake pipes on to the BPMV.

Tighten
Tighten the brake pipe fittings to 15 N-m (11 lb ft).
4. Connect the EBCM/EBTCM harness
connector (6).
engine off.
6. Perform the A Diagnostic System Check
3
213428
Brakes
Adjuster Assembly Replacement
Removal Procedure
Important: The adjuster assembly cables must always

be adjusted each time the adjuster assembly is
removed and/or replaced to ensure optimum system
periormance. Refer to Cable Adjustment Procedure.
1. Remove the adjuster assembly splash cover.
2. Remove the cable cam cover.
3. Disconnect the adjuster assembly electrical
connector.
4. Remove the nuts attaching the adjuster assembly
to the bracket.
213434
5. Remove the cables from the adjuster assembly.
213407
5-254
Brakes
1. Install the cables to the adjuster assembly .
213407
2. Install the adjuster assembly to the mounting

bracket (3).
3. Install the adjuster assembly attaching nuts.
4.
5.
6.
7.
Tighten
Tighten the adjuster assembly attaching nuts to
25 Nm (18 lb. ft.).
Connect the adjuster assembly electrical
connector.
Adjust the adjuster assembly cables. Refer to
Cable Adjustment Procedure.
Install the cable cam cover.
Install the adjuster assembly splash cover.
213434
Brakes
5-255
Cable Adjustment Procedure

The throttle body, accelerator pedal, and cruise control
cables must be fully installed before making
adjustments.
1. Remove the throttle body lever cover.
2. Unlock the throttle body cable and cruise control
cable adjuster (1 ).
3. Hold throttle body lever firmly at stop/idle position.
4. Pull the throttle body cable assembly just
rearward of the adjuster lock to remove
slack from cable.
Important: Do not disturb cable after removing slack.
5. Lock the throttle body cable adjuster (1 ).
6. Hold throttle body lever firmly at stop/idle position.
7. Pull the cruise control cable assembly just
rearward of the adjuster lock to remove
slack from cable.
Important: Do not disturb cable after removing slack.
8. Lock the throttle body cable adjuster (1 ).
213432
Important: Cables should never be adjusted so tight

that tension from the cable will not allow the throttle
to close completely. If the cable is adjusted to tight, the
cable will prevent the engine from returning to idle
and will cause unstable idle quality.
Using a scan tool check the throttle angle. When the
accelerator is fully depressed the throttle angle
should read 100 percent. When the accelerator is
released the throttle angle should read O percent. If
proper results are not obtained check cables for kinks
or damage and repeat procedure.

(Rear without Traction Control)
Removal Procedure
1. Remove the wheel speed sensor connector.
2. Clean all dirt and debris from sensor
housing/sensor interface area.
3. Remove the Wheel Speed Sensor bolt (3).
4. Remove the Wheel Speed Sensor (4).
213402
5-256
Brakes

1. Install the Wheel Speed Sensor (4).

2. Install the Wheel Speed Sensor mounting bolt (3) .
Tighten
Tighten the bolt to 10 N-m (89 lb.in)
3. Install the wheel speed sensor connector.
213402

(Rear with Traction Contr~I)
Removal Procedure
1. Remove the wheel speed sensor connector (2).
2. Clean all dirt and debris from sensor
housing/sensor interface area.
3. Remove the Wheel Speed Sensor attaching bolt.
4. Remove the Wheel Speed Sensor (1).
213413
1. Install the Wheel Speed Sensor (1 ).
2. Install the Wheel Speed Sensor attaching bolt.
Tighten
Tighten the bolt to 1O N-m (89 lb.in)
3. Install the wheel speed sensor connector (2) .
213413
Brakes
5-257
Wheel Speed Sensor Replacement (Front)

1. Refer to Wheel Bearing/Hub Replacement Front in Front Suspension.
2. After the replacement procedure is complete refer
to A Diagnostic System Check.

Replacement (Rear with Traction Control)
Removal Procedure
1. Remove the wheel speed sensor connectors (2,3).
2. Remove the jumper harness grommet from the
retainer.
3. Remove the upper jumper harness connector
from the rear body pass-thru connector.
213413
1. Install the upper jumper harness connector from
the rear body pass-thru connector.
2. Install the jumper harness grommet to the
retainer.
3. Install the wheel speed sensor connectors (2,3).
213413
5-258
Brakes
Replacement (Rear without Traction
Control)
Removal Procedure
2. Remove the rear wheel speed sensor jumper
harness grommet from retainer (1 ).
3. Remove the upper harness connector from rear
body pass-thru connector.
213402
1. Install the upper harness connector from rear
body pass-thru connector.
2. Install the rear wheel speed sensor jumper
harness grommet from retainer (1 ).
3. Install the wheel speed sensor connector .

Replacement (Front Left)
Removal Procedure
2. Remove the jumper harness from the
retaining clip.
3. Remove the grommet retainer at the inner tender.
4. Remove the transmission cable retainer and
various harnesses from restraints at left strut
tower to access jumper harness connector.
5. Remove the upper jumper harness connector.
6. Pull the grommet through inner tender pass-thru
and remove jumper harness.
213395
Brakes
''
5-259
1. Route the new.jumper harness through inner
fender pass-thru .
2. Install the upper jumper harness connector.
3. Install the transmission cable retainer and various
harnesses to restraints that may have been
disconnected to access jumper harness.
4. Install the grommet retainer at the inner fender.
5. Install the jumper harness from the retaining clip.
213395

Replacement (Front Right)
Removal Procedure
2. Remove the jumper harness from the
retaining clip.
3. Remove the grommet retainer at the inner fender.
4. Remove the harness cover from the right
strut tower.
5. Remove the upper jumper harness connector.
6. Pull the grommet through inner fender pass-thru
and remove jumper harness.
213395
1. Route the new jumper harness through inner
fender pass-thru.
2. Install the upper jumper harness connector.
3. Install the harness cover on the right strut tower.
4. Install the grommet retainer at the inner fender.
5. Install the jumper harness from the retaining clip.
213395
5-260

(Without Traction Control)
The rear wheel speed sensor reluctor ring is located in
the differential case. If the reluctor ring is determined
to be damaged and must be replaced refer to
Differential case in Rear Axle.

(With Traction Control)
The rear wheel speed sensor reluctor rings are an
integral part of the rear axle shafts. If it has been
determined they must be replaced refer to Axle Shaft
in Rear Axle.
Brakes
General System Description
The purpose of the Bosch 5.3 Antilock Brake System
(ABS) is to minimize wheel slip during heavy
braking. The Bosch 5.3 _performs .this function by
monitoring the speed of each wheel and controlling
the brake fluid pressure to each wheel independently
during a braking event. This allows the driver to
retain directional stability and better steering capability.
The Traction Control System (TCS) also monitors
rear wheel speed and compares the speed to
the speed of the front wheel. If excessive rear wheel
speed is detected in either rear wheels the TCS will be
activated.
Abbreviations and Definitions

Traction Control Switch Replacement
ABS:
Refer to Traction Control Switch Replacement in

ASM:
BPMV:
B+:

Battery Voltage
CKT:
Circuit
Service Precautions
DLC:
Data Link Connector
ABS/TCS System Service Precautions
DTC:
Diagnostic Trouble Code
Observe the following general precautions during any

ABS!TCS service. Failure to adhere to these
precautions may result in ABS!TCS system damage.
1. Unplug the EBCM/EBTCM harness connector
before performing electric welding procedures.
2. Carefully note the routing of the ABS!TCS wiring
and wiring components during removal. The
ABS!TCS components are extremely sensitive to
EMI (electromagnetic interference). Proper
mounting is critical during component service.
3. Do not use a quick charger for engine starting or
for battery charging with the battery still
connected. Brake failure or ABS!TCS component
damage may result.
4. Disconnect the battery with the ignition off.
5. Disconnect the EBCM/EBTCM connector with the
ignition off.
6. Do not attempt to repair the BPMV or any other
non serviceable ABS!TCS components where
noted in this section. Many ABS/TCS components
are serviceable by component replacement only.
7. Do not hang the suspension components from the
WSS cables. The cables may be damaged.
8. Do not subject the EBCM/EBTCM to temperatures
of more than 85C (184F).
9. Do not use petroleum based fluids in the master
cylinder. Do not use any containers previously
used for petroleum based fluids. Petroleum causes
swelling and distortion of the rubber components
in the hydraulic brake system, resulting in
water entering the system and lowering the fluid
boiling point.
10. Inspect the ABS!TCS system after service using a
scan tool.
Digital Multimeter
DMM:
Electronic Brake Control Module
EBCM:
EBD:
Electronic Brakeforce Distribution
EBTCM:
Module
IPC:
Electronic Brake and Traction Control
Instrument Panel Cluster
PCM:
Powertrain Control Module
TCS:
WSS:
Wheel Speed Sensor
Basic Knowledge Required

Before using this section, it is important that you have
a basic knowledge of the following items. Without
this basic knowledge, it will be difficult to use
the diagnostic procedures contained in this section.
If you need a review of basic electrical troubleshooting
knowledge, Refer to Troubleshooting Procedures
Cell 4 in Electrical Diagnosis. Additionally,
electrical/electronic courses are offered through
General Motors Service Training.
Basic Electrical Circuits

You should understand the basic theory of
electricity and know the meaning of voltage,
currrent (amperes) and resistance (ohms).
You should understand what happens in a circuit
with an open or shorted wire.
You should be able to read and understand a
wiring diagram.
Brakes
Use of Circuit Testing Tools
You should be familiar with the Digital Multimeter
(DMM) J 39200, and be familiar with the meter
controls and how to use them correctly.
You should be able to measure voltage, resistance
and current.
You should know how to use jumper wires to
bypass components for testing circuits.
Important: When measuring the resistance to ground
of circuit or component, make sure to use a solid,
unpainted chassis ground or the negative battery
terminal.
ABS/TCS System Description

Brake Pressure Modulator Valve (BPMV)
The Brake Pressure Modulator Valve (BPMV) mounted
on the left side of the engine compartment, provides
brake fluid modulation for each of the individual wheel
circuits as required during Antilock braking. During
the Antilock mode, the BPMV can maintain or reduce
brake fluid pressure independent of the pressure
generated in the master cylinder. The BPMV does not
provide more pressure than is applied by the master
cylinder during braking.
The BPMV supplies Electronic Brakeforce Distribution

(EBD). This function takes the place of the
proportioning valve(s).
With the exception of the EBCM/EBTCM, the Brake
Pressure Modulator Valve (BPMV) is an integral,
non-serviceable component. The BPMV should never
be disassembled.
If the vehicle is not equipped with traction control the
BPMV uses a three circuit configuration with a
front-rear split. Individual circuits are provided for the
left front and right front wheels, and the rear wheels
use one circuit.
If the vehicle is equipped with traction control the
BPMV uses a four circuit configuration with a front-rear
split. Individual circuits are provided for the left front
and right front wheels, and left rear and right rear
wheels.
The BPMV consists of several other components
which are described as follows:
Pump Motor
The BPMV contains a motor driven recirculation
pump. The pump serves two purposes: 1) During
ABS Reduce Pressure events, it transfers fluid from
the brake calipers back to the master cylinder;
and 2) During traction control, it transfers fluid from
the master cylinder reservoir to the rear brake calipers.
The pump and motor are located within the BPMV
and are not serviced separately.
5-261
ABS Valves
The ABS valves decrease or maintain brake fluid
pressure at the individual wheel circuits. If the vehicle
is not equipped with traction control there are
three Inlet, and three Outlet solenoid valves. If the
vehicle is equipped with traction control there are four
Inlet, and tour Outlet solenoid valves. The solenoid
valves maintain, increase, or decrease brake fluid
pressure to the individual wheel circuits. The
EBCM/EBTCM commands the valves to their correct
position during an antilock or traction event. During
antilock mode, the pressure in each hydraulic
circuit can be held or released by activating the
appropriate valves. The normal state of the inlet valves
is open, while the normal state of the Outlet valves
is closed. This allows direct master cylinder pressure
to the brakes during normal braking. The ABS
valves are located within the BPMV and are not
serviced separately.
TCS Master Cylinder Isolation Valves
If the vehicle is equipped with Traction Control there is
one TCS Master Cylinder Isolation Valve within the
BPMV. This valves isolates the master cylinder so the
pump motor can build brake fluid pressure for the
rear brakes during a traction event.
TCS Prime Valves
If the vehicle is equipped with Traction Control there is
one TCS prime valve within the BPMV. This valves
allow the pump to draw fluid from the master cylinder
reservoir, through the compensating ports in the
master cylinder bore.
Electronic Brake And Traction Control Module

The EBCM/EBTCM performs the following primary
functions:
Detects wheel slip tendencies
Detects wheel speed differences
Controls the brake system while in the antilock or
traction control mode
Controls the Electronic Brakeforce
Distribution (EBD)
Monitors the system for proper electrical operation
The EBCM/EBTCM also controls the display of
the ABS and traction control DTCs while in diagnostic
mode. The EBCM/EBTCM continuously checks the
speed of each wheel in order to determine if any wheel
is beginning to slip. If a wheel slip tendency is
detected, the EBCM/EBTCM commands the
appropriate valve positions to modulate the brake fluid
pressure in some or all of the hydraulic circuits.
This action prevents wheel slip and provides optimum
braking. The EBCM/EBTCM continues to control
pressure in the individual hydraulic circuits until
a slipping tendency is no longer present. The
EBCM/EBTCM continuously monitors the ABS/TCS for
proper operation. If an error is detected, the
EBCM/EBTCM can disable the ABS/TCS and turn on
the ABS or TCS OFF Indicators in the IPC.
5-262
Wheel Speed Sensors

A wheel speed sensor is located at each front wheel
bearing assembly. If the vehicle is equipped with
traction control a wheel speed sensor is located at
each rear wheel bearing assembly. If the vehicle is not
equipped With traction control then a single rear
wheel speed sensor is located in the differential
housing. The sensors use AC voltage in order to
transmit wheel speed information to the
EBCM/EBTCM. Passing a toothed sensor ring past a
stationary sensor causes the magnetic induction
that generates the voltage. A pair of wires carries the
signal to the EBCM/EBTCM. The wheel speed
sensors are located in their respective assemblies and
are not adjustable.
Traction Control System ON/OFF Switch

The Traction Control On/Off Switch is a momentary on
switch that allows the driver to shut off the TCS for
personal or diagnostic reasons. Turning the switch to
off places the TCS in the passive mode while
maintaining ABS functions. With the TCS system on,
pressing the switch disables the TCS and the
TRACTION OFF indicator turns on.
Stoplamp Switch
The stoplamp switch is an input to the EBCM/EBTCM.
The EBCM/EBTCM uses the stoplamp switch in
order to tell when the brake pedal is being applied.
ABSITCS System Operation

When wheel slip is noted during a brake application,
the ABS will enter Antilock mode. During Antilock
braking, hydraulic pressure in the individual wheel
circuits is controlled to prevent any wheel from
slipping. If the vehicle is equipped with traction control
a separate hydraulic line and specific solenoid
valves are provided for each wheel. If the vehicle is
not equipped with traction control then both front
wheels have a separate hydraulic line and specific
solenoid valves, the rear wheels have only one
hydraulic line controlled by one set of solenoid valves.
The ABS can decrease, hold, or increase hydraulic
pressure to each wheel brake. However, it cannot
increase hydraulic pressure above the amount which
is transmitted by the master cylinder during braking.
During Antilock braking, a series of rapid pulsation's
will be felt in the brake pedal. These pulsation's
are caused by the rapid changes in position of the
individual solenoid valves as they respond to
their desired wheel speed. This pedal pulsation is
present during Antilock braking and will 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 rapidly cycle. During
Antilock braking on dry pavement, the tires may make
intermittent chirping noises as they approach
slipping. These noises and pedal pulsation's should be
considered normal during Antilock operation.
Brakes
Vehicles equipped with ABS may be stopped by
applying normal force to the brake pedal. Brake pedal
operation during normal braking should be no
different than previous systems. Maintaining a constant
force on the pedal will provide the shortest stopping
distance while maintaining vehicle stability.
Pressure Hold
When the EBCM/EBTCM senses the wheel slip, the
EBCM/EBTCM closes the Inlet valve and keeps
the Outlet valve closed in the BPMV in order to isolate
the system. This holds the pressure steady on the
brake so that the hydraulic pressure does not increase
or decrease.
Pressure Decrease
If during the pressure hold mode the EBCM/EBTCM
still senses wheel slip, the EBCM/EBTCM will
decrease the pressure to the brake. The Inlet valve is
left 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 cyclinder.
Pressure Increase
If during the pressure hold or the pressure decrease
mode the EBCM/EBTCM senses that the wheel speed
is too fast, the EBCM/EBTCM will increase the
pressure to the brake. The Inlet is opened and the
Outlet valve is closed. The increased pressure comes
from the master cylinder and is related to the
pressure applied to the brake pedal.
Traction Control
Traction control will not have any effect on the
operation of the vehicle until the control module
detects one or both of the rear wheels rotating faster
than the front wheels. At this time the Electronic
Brake and Traction Control Module (EBTCM) will
request the Powertrain Control Module (PCM) to retard
timing. If the EBTCM continues to detect the rear
wheel are rotating faster than the front it will request
the ASM to reduce the throttle angle. The last measure
taken to control the rear wheel is for the EBTCM to
apply the rear brakes, thus reducing torque to the rear
wheels. Once the rear wheels begin to rotate at the
same speed as the front wheels, the system will return
full control to the driver. During Traction Control
mode, if the brake is applied to only one rear wheel,
most of the torque from the engine will be directed
to the other rear wheel which will improve the traction
of the vehicle.
The braking is accomplished by closing the TCS
Master Cylinder Isolating Valve, this isolates the
master cylinder from the rest of the system. The TCS
Prime valve opens to allow the pump to get brake
fluid to build pressure for braking. The drive wheel
circuit solenoids are energized as needed to allow for
pressure hold, pressure increase, or pressure
decrease.
The TCS may be deactivated by the driver if desired.
In order to deactivate the TCS with the engine
running, depress the TCS On/Off switch. The system
will remain deactivated until the ignition switch is
cycled, or the switch is pressed again.
Brakes
5-263
Tires with ABS!TCS
ASR Indicator (Chevrolet)
The compact spare tire rotates faster than the others.

The EBCM/EBTCM compensates for this faster
rotation. Refer to Tires and Wheels in Suspension for
information on replacement tires.
The ASR Indicator (Chevrolet only) is located in the

instrument cluster and will illuminate if a malfunction in
the traction control system is detected by the
(EBTCM). The ASR Indicator informs the driver that a
condition exists which results in turning off traction.
Conditions for the ASR Indicator to turn on are
as follows:
1. Traction control malfunction detected. As
previously described, the ASR Indicator turns on
when a problem has been found in the traction
control system. The ASR Indicator indicates that
traction control has been disabled.
2. Instrument Panel Cluster bulb check. When the
ignition is turned to RUN, the ASR Indicator will
turn on for approximately three seconds and then
turn off.
Replacement Tires
The tire size is important for the performance of the
ABS/TCS. The replacement tires should be the
same size load range and construction as the original
tires. Replace the tires in axle sets and only with
tires of the same tire performance criteria specification
number. Use of any other tire size or type may
seriously affect ABS/TCS operation. For information
on replacement tires for this vehicle, Refer to Tires and
Wheels in Suspension.
BRAKE Warning Indicator

The red BRAKE Indicator in the instrument cluster will
illuminate to warn the driver of conditions in the
brake system which may result in reduced braking
ability. The red BRAKE indicator will also illuminate
when the park brake is applied. The BRAKE warning
Indicator will stay illuminated until the condition
has been repaired, or the park brake is released. Refer
to Brake System Testing in Hydraulic Brakes.
ABS Indicator
The ABS is located in the instrument cluster and will

illuminate if a malfunction in the ABS is detected by the
(EBCM/EBTCM). The ABS Indicator informs the driver
that a condition exists which results in turning off
the Antilock brake and traction control function
if equipped. If only the ABS Indicator is on, normal
braking with full power assist is available. If the BRAKE
and Antilock Indicators are on, a problem may exist
in the hydraulic brake system. Refer to Brake System
Testing in Hydraulic Brakes. Conditions for the
Antilock Indicator to turn on are as follows:
1. ABS malfunction detected. As previously
described, the ABS Indicator turns on when
a problem has been found in the ABS. The ABS
Indicator indicates that the ABS and TCS if
equipped have been disabled.
ignition is turned to RUN, the ABS Indicator will
turn off.
Illumination of the BRAKE warning Indicator
may indicate reduced braking ability.
Illumination of the ABS Indicator without the
BRAKE warning Indicator on indicates only
that Antilock braking is no longer available.
Power assisted braking without Antilock control
is still available.
Refer to Brake System Testing in Hydraulic
Brakes for diagnosis of any condition which
causes the BRAKE warning Indicator to
illuminate.
TCS Off Indicator (Pontiac)

The TCS Off Indicator (Pontiac only) is located in the
instrument cluster and will illuminate if a malfunction
in the traction control system is detected by the
(EBTCM). The TCS Off Indicator informs the driver
that a condition exists which results in turning off
traction. Conditions for the TCS Off Indicator to turn
on are as follows:
1. Traction control malfunction detected. As
previously described, the TCS Off Indicator turns
on when a problem has been found in the
traction control system. The TCS Off Indicator
indicates that traction control has been disabled.
ignition is turned to RUN, the TCS Off Indicator
will turn on for approximately three seconds
and then turn off.
Low Trac Indicator

The Low Trac Indicator is located in the instrument
cluster and will illuminate when the EBCM/EBTCM
detects a low traction condition. Conditions for the Low
Trac Indicator to tum on are as follows:
ignition is turned to RUN, the ASR Indicator will
turn off.
2. The EBCM/EBTCM detects an antilock braking
condition.
3. The EBTCM detects a traction control condition.
5-264
Brakes

Illustration
Illustration
J 39700
Universal Pinout Box
98818
J 39200
Digital Multimeter
3430
J 39700-530
Cable Adapter
96824
J 35616-A
Connector Test Adapter Kit
8917
Tech 2 Scan Tool
39438
INDEX
A
Abbreviations and Their Meanings ..................... 0-20
(ASM) Replacement ........................ 5-250
Accelerator Controls
Cable Replacement (3.8L) .......................... 6-1169
Cable Replacement (5.7L) .......................... 6-1802
Pedal Replacement (3.8L) .......................... 6-1170
Pedal Replacement (5.7L) .......................... 6-1804
Acid Rain ...................................................... 8-1020
Actuator
Air Inlet Replacement (A/C - Manual) ........... 1-106
Defroster Replacement (A/C - Manual) ......... 1-107
Heater/Bi-Level Vacuum Replacement
(A/C - Manual) ............................... 1-108
Vent Replacement (A/C - Manual) ................ 1-106
Actuator Replacement
Liftgate Lock . .. .. .. .. .. .. . . .. .. .. .. ... .. .. . .... .. .. ... . .. .. . 8-980
Release .. .. .. .. .. .. .. .. . .. ... .. .. .. .. .. .. ... . .. ... . ... ... . .. . . 8-981
Adjustment
Rack Bearing Preload - Power Steering ......... 2-42
Adjustments
Backlash Adjustment
Rear Drive Axle .......................................... 4-50
Clutch Pressure Plate .................................. 7-381
Pinion Depth Adjustment
Rear Drive Axle .......................................... 4-29
Side Bearing Preload Adjustment
Rear Drive Axle .......................................... 4-48
AIR
Check Valve/Pipe Replacement
Bank1 (5.7L) ........................................... 6-1853
Bank2 (5.7L) ........................................... 6-1852
Air Baffle Assemblies and Deflectors
(Engine Cooling) .................. 6-652, 6-653
Air Cleaner
Assembly Replacement (5.7L) .................... 6-1859
Element Replacement (3.8L) ...................... 6-1219
Element Replacement (5.7L) ...................... 6-1858
Intake Duct Replacement (3.8L) ................. 6-1220
Air Conditioning
Diagnosis
Request Circuit (5.7L) ............................. 6-1750
Air Deflector Replacement
Radiator ........................................................8-761
Air Inlet Actuator Replacement
(A/C - Manual) ... . .. .. .. .. .. .. ... .. .. .. . .. . .. 1-106
Air Inlet Grille Panel Replacement ................... 8-762
Air Outlet Replacement - Right Defogger
(A/C - Manual) ............................... 1-110
Air Wind/Noise
Diagnosis
Air Pressure Test ..................................... 8-665
Air/Wind Noise
Diagnosis
Air/Wind Noise .......................................... 8-665
Soap Suds or Bubble Test ....................... 8-665
Tracing Powder or Chalk Test .................. 8-665
Alignment
Checking Frame to Body Alignment ........... 8-1041
Alignment Checking
Aluminum Wheel
Hub Cap Replacement ................................... 3-60
Porosity Repair .. .. .. .. .. .. .. .. ... .. ... .. ... ... .. .. .. .. .. .. .. 3-60
Refinishing ..................................................... 3-60
Amplifier Replacement .. .. .. .. ... .. ... .. .. .. .. .. 8-244, 8-245
Antenna
Schematic
Power .. .. ... .. .. .. .. .. .. . ... .. .. .. .. .. . .. ... .. .. .. .. .. .. .. .. 8-205
Antenna Mast Cleaning .. .. .. .. .. .. . ... ... .. .. .. . .. .. .. .. . 8-256
Antenna Mast Replacement
Fixed ........................................................... 8-253
Power .......................................................... 8-254
Antenna Motor Replacement .. .. .. .. ... .. .. .. .. ... .. .. . 8-255
Antenna Replacement
Fixed .. .. . . .. ... .. .. .. .. ... .. .. ... .. .... ... ... .. .. ... .. .. . .. . ... 8-254
Antenna System Check
Power .......................................................... 8-218
ABS!TCS Schematics .. .. ... .. ... ... .. . .. .. . .. .. .. .. . .. . 5-112
Adjuster Assembly Replacement ................... 5-253
BPMV Hydraulic Flow Chart .............. 5-109, 5-110
Replacement .................................. 5-251
Cable Adjustment Procedure ........................ 5-255
Component Locations ................................... 5-120
Component Views ........................................ 5-123
Connector End Views .. .. . . .. . ... .. .. .. .. .. .. .. .. ... .. .. 5-128
Diagnostic
TCS Off Indicator On with No DTC Set ..... 5-229
Description
Abbreviations and Definitions .. .. . .. . .. .. .. .. .. .. 5-260
ABS!TCS System ..................................... 5-261
ABS!TCS System Operation .. .. . ... .. .. .. ... ... . 5-262
Basic Knowledge Required ....................... 5-260
General . ... . ... .. .. .. ... .. .. .. . .. . .. . ... . .. .. ... . .. ... . .. .. 5-260
Service Precautions .................................. 5-260
Diagnosis
ABS Indicator Inoperative with
No DTC Set .................................... 5-241
ABS Indicator On No DTC Set .................. 5-239
ASR Indicator Inoperative with
No DTC Set .. ... .. .. .. .. .. .. .. .. .. .. ... .. .. .. .. 5-235
ASR Indicator On with No OTC Set .......... 5-233
Clearing Diagnostic Trouble Codes ........... 5-133
Diagnostic System Check .. .. .. ... .. ... .. .. .. .. .. . 5-136
Displaying Diagnostic Trouble Codes ........ 5-133
Electromagnetic Interference .. .. .. .. .. ... .. .. .. .. 5-135
Initialization Sequence .............................. 5-133
lntermittents and Poor Connections .......... 5-133
Low Traction Indicator Inoperative ............. 5-245
Low Traction Indicator On
All of the Time .. . . .. .. .. . .. .. .. .. .. .. .. .. .. .. 5-243
No Communication with EBCM/EBTCM .... 5-237
Scan Tool Diagnostics ... .. . .. .. .. .. .. ... .. .. .. ... .. 5-133
Self-Diagnostics ........................................ 5-133
TCS Indicator Inoperative with
No DTC Set .................................... 5-231
Electronic Brake Control Module
Replacement .. .. ... .. .. . ... . . ... ... . .. ... . .. .. 5-247
GM SPO Group Numbers ............................ 5-108
Schematic
ABS Schematic Icons .. .. ... . .. ... .. .. .. .. . .. .. .. .. . 5-111
ABS Schematic References ...................... 5-111
2
Antilock Brake System (cont.)
Special Tools ............................................... 5-264
Specifications
Fastener Tightening .................................. 5-108
Wheel Speed Sensor
Jumper Harness Replacement ...... 5-257, 5-258,
5-259
Ring Replacement .................................... 5-260
Wheel Speed Sensor Replacement .... 5-255, 5-256,
5-257
Anti-Theft Labeling ............................................ 0-11
Arm Blade Replacement .. .. .. . .. .. .. .. .. .. .. .. .. .. ... . ... 8-180
Arrows and Symbols, Description ........................ 0-4
Ashtray Lamp Bulb Replacement ..................... 8-130
Ashtray Replacement . .. .. .. .. ... .. .. .. . ... .. .. .. . .. ... .. .. 8-506
Assist Rod Ball Stud Replacement
Hood ........................................................... 8-756
Assist Rod Replacement
Hood ........................................................... 8-755
Audible Warnings
Diagnosis
Diagnostic System Check ......................... 8-496
Fasten Safety Belt Chime Always On ....... 8-497
Fasten Safety Belt Chime Inoperative ....... 8-497
Key-in Ignition Chime On with LF Door
Closed ............................................ 8-499
Key-in-Ignition Chime Always On .............. 8-498
Key-In-Ignition Chime Inoperative .............. 8-498
Lights On Chime Inoperative .................... 8-499
Lights On Chime On with Ignition in Run ..... 8-499
Auto Trans Shift Lock Control
Description
Circuit (Tilt Column) .................................. 2-110
Diagnosis
Always On With Ignition in RUN ................. 2-60
Inoperative ................................................. 2-59
System Check ............................................ 2-58
Diagnosis (Tilt Column) .................................. 2-62
Auto Trans Shift Lock Control Schematics
Steering Wheel/Column - lilt ......................... 2-55
Automatic Transmission - 4L60-E
2-4 Servo ..................................................... 7-266
Accumulator Assembly ................................. 7-294
Brake Transmission Shift Interlock
Solenoid Replacement .................... 7-245
Case Extension Assembly Installation ........... 7-292
Component Location .................................... 7-324
Component Location Table .................... 7-79, 7-81
Control and Shift Solenoids Replacement ..... 7-284
Description
Diagnosis ................................................. 7-318
Electrical Connector Description ................ 7-323
Electronic Component ............................... 7-319
Preliminary Checking Procedure ............... 7-317
Torque Converter Clutch Electrical
Controls .. .. .. .. . .. .. ... .. .. .. . .. .. ... .. .. . .. . .. .. 7-322
Transmission ID Information ..................... 7-316
Diagnosis
1st Gear Range Only-No Upshift .............. 7-235
2nd Gear Start . .. . .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. . 7-240
2nd Gear Start Switch and Indicator
Lamp Circuit Check ........................ 7-220
2nd/3rd Gears Only or 1st/4th
Gears Only ..................................... 7-237
INDEX
Automatic Transmission - 4L60-E (cont.)
Diagnosis (cont.)
3-2 Flare or Tie-Up ................................... 7-237
Component Resistance .. .. .. .. .. .. .. . .. . .. .. .. ... .. 7-230
Delay in Drive and Reverse ...................... 7-241
Drives in Neutral ....................................... 7-240
Electrical/Garage Shift Procedure .............. 7-224
Electronic Component Malfunctions ........... 7-233
Fluid Leak . .. .. .. .. .. ... . .. ... .. . ... .. .. .. .. .. .. .. .. .. .. .. 7-242
Flywheel/Torque Converter
Vibration Test ................................. 7-226
Functional Test Procedure .......................... 7-72
Harsh Garage Shift ................................... 7-239
Harsh Shifts ............................................. 7-234
Inaccurate Shift Points .............................. 7-235
Line Pressure Check Procedure ............... 7-223
No 2-3 Shift or 2-3 Shift Slips,
Rough or Hunting ........................... 7-236
No 3-4 Shift, Slips or Rough 3-4 Shift ...... 7-237
No Drive in All Ranges ............................. 7-241
No Overrun Braking - Manual 3-2-1 .......... 7-239
No Park . .. .. .. .. .. ... . ... .. .. .. .. . .. ... .. .. .. .. .. .. .. .. .. .. 7-240
No Part Throttle or Delayed Downshifts .... 7-238
No Reverse or Slips in Reverse ............... 7-238
No Torque Converter Clutch Apply ........... 7-239
No Torque Converter Clutch Release ....... 7-240
Noise and Vibration Analysis .................... 7-226
Oil Out the Vent ....................................... 7-241
Oil Pressure High or Low ......................... 7-234
Ratcheting Noise . .. .. .. .. .. .. .. ... .. . ... .. . .. .. .. ... .. 7-241
Road Test Procedure ............................... 7-224
Slipping or Rough 1-2 Shift ...................... 7-236
Slips in 1st Gear ....................................... 7-235
Third Gear Only ....................................... 7-237
Torque Converter Clutch ........................... 7-226
Torque Converter Clutch Shudder .... 7-227, 7-240
Transmission Fluid Checking Procedure .... 7-222
Transmission Fluid Pressure Valve Position
Switch Resistance Check ................ 7-231
Vibration in Reverse and Whining
Noise in Park ................................. 7-241
Wiring Harness Check .............................. 7-228
Do Not Use Air Tools ................................... 7-315
Electronic Component Views .......................... 7-83
Extension Housing Rear Oil Seal ................. 7-291
Filler Tube Replacement .................... 7-271, 7-273
Floor Shift Control Replacement ................... 7-252
Fluid/Filter Changing .................................... 7-255
lnline Harness Connector End View ............... 7-84
Internal Connector End Views ........................ 7-85
Oil Cooler Flushing ...................................... 7-314
Oil Cooler Line Replacement ....................... 7-258
Park Lock Cable Replacement ..................... 7-246
Park/Neutral Position Switch Replacement . .. 7-253
Parts Cleaning and Inspection ...................... 7-244
Pressure Regulator Replacement ................. 7-269
Replacement ..................................... 7-301, 7-307
Schematic
Controls Schematic Diagrams ..................... 7-74
Schematic Icon Table ................................. 7-73
Schematic Reference Table ........................ 7-73
Shift Cable Replacement .............................. 7-249
Special Tools ............................................... 7-356
INDEX
Automatic Transmission - 4L60-E (cont.)

Specifications
Diagnostic Trouble Code (OTC)
Identification ............................ 7-64, 7-67
Fastener Tightening .................................... 7-56
Fluid Capacity ............................................ 7-69
Line Pressure ............................................. 7-71
Range Reference Table .............................. 7-70
Scan Tool Data Definitions ................ 7-60, 7-62
Scan Tool Data Value Examples ....... 7-57, 7-58
Shift Solenoid Valve State and
Gear Ratio ....................................... 7-70
Shift Speed Table ....................................... 7-70
Temperature vs Resistance ........................ 7-56
TFP Manual Valve Position Switch Logic ....... 7-71
Torque Converter Clutch PWM Solenoid, TCC
Solenoid, and Wiring Harness .......... 7-287
Torque Converter Cover Replacement ......... 7-275,
7-276
Valve Body and Pressure Switch
Replacement . .. .. .. .. .. .. .. . ... .. .. .. .. .. .. .. . 7-278
Vehicle Speed Sensor Replacement ............. 7-299
Automatic Transmission- 4L60-E
Diagnosis
Front Oil Leak .......................................... 7-241
No Drive in Drive Range .......................... 7-241
Automatic Transmission 4- L60-E
General Information ...................................... 7-317
Automatic Transmission 4L60-E
Description
Fluid Checking Procedure ......................... 7-317
Axle Replacement
Rear Drive Axle ............................................. 4-54
8
Balancing Tires and Wheels .............................. 0-66
Ball Joint Replacement, Lower Front
Suspension ....................................... 3-19
Ball Joint Replacement, Upper Front
Suspension ....................................... 3-17
Basecoat/Clearcoat Paint Systems ................. 8-1016
Battery
Cable Replacement ........................... 6-695, 6-700
Charging ...................................................... 6-691
Common Causes of Failure ......................... 6-675
Description . . ... .. . .. .. .. ... .. .. .. .. . ... .. .. . ... .. .. .. .. .. . .. . 6-720
Hydrometer Displays Dark or Yellow Dot ...... 6-676
Is Undercharged or Overcharge ................... 6-679
Jump Starting in Case of Emergency ........... 6-692
Load Test - Parasitic .................................... 6-676
Negative Cable Disconnect .......................... 6-693
Replacement . .. . .. .. .. ... .. .. .. .. . . .. .. . .. ... .. .. .. .. .. .. . .. 6-689
Battery Temperature vs Minimum Voltage ........ 6-666
Battery Usage Specifications ........................... 6-665
Belt, Drive, Diagnosis ...................................... 6-258
Belt, Drive, Diagnosis (3.8L) .............................. 6-28
Belt, Drive, Replacement (3.8L) ......................... 6-34
Belt, Drive, Replacement (5.7L) ............ 6-267, 6-269
Belt Reveal Molding Replacement ........ 8-950, 8-951
Bezel Replacement
IP Cluster .......................................... 8-502, 8-503
Blade Element Cleaning .................................. 8-193

Blower
Diagnosis
High Speed Inoperative (A/C - Manual) ...... 1-20
Inoperative at Any Speed (A/C - Manual) ...... 1-17
Low Speed Inoperative (A/C - Manual) ....... 1-18
Operates at High Speed Only
(A/C - Manual) ................................. 1-19
Operates Continuously (A/C - Manual) ........ 1-20
Operates in One Speed Only
(A/C - Manual) ................................. 1-19
Motor and Fan Assembly Replacement
(A/C - Manual) ................................. 1-92
Resistor Replacement (A/C - Manual) ............ 1-92
Blower Motor
Description
Controls Circuit (A/C - Manual) ................. 1-127
Relay Replacement (A/C - Manual) ................ 1-91
Body Control Module Programming/RPO
Configuration .................................. 8-465
Body Control Module Replacement .................. 8-463
Body Control System
Body Control Module Component Views ....... 8-439
Body Control Module Components .. .. .. .. .. ... .. 8-436
Body Control Module Connector
End Views . .. .. ... . .. .. .. .. .. .. .. .. ... .. . .. ... .. 8-440
Description
Circuit ....................................................... 8-465
Diagnosis
Clearing DTCs .. .. .. .. . ... .. ... . ... . .. ... .. .. . ... . ... .. . 8-443
Displaying DTCs ... . ... ... .. . .. .. .. .. .. ... ... .. .. .. .. .. 8-442
DTC List .. .. .. .. .. . ... . .. .. ... .. .. ... .. .. . . .. .... .. .. . .. .. . 8-443
lntenninents and Poor Connections .......... 8-442
Schematics
Body Control Module ..................... 8-426, 8-431
Body Control Module Schematic Icons ...... 8-425
Body Control Module Schematic
References .. .. ... .. .. .. .. . .. .. ... .. .. .. . ... .. .. 8-425
Body Dimensions ........................................... 8-1023
Body Front End
Description
General .................................................... 8-770
Specifications
Body Measurements ............. 8-1042, 8-1050, 8-1059
Body Rear End
Component Views . .. .. .. .. .. .. .. .. .. .. .. . .... . .. .. .. .. .. . 8-960
Components ................................................. 8-958
Connector End Views ................................... 8-962
Description .. .. .. .. .. .. .. .. .. ... . ... .. .. . ... . .. ... . ... .. .. .. . . 8-986
Rear Compartment Lid Release Circuit ..... 8-986
Schematic
Schematic Icons ....................................... 8-955
Schematic References .............................. 8-955
Special Tools ............................................... 8-986
Body Side
Door Molding Replacement .......................... 8-653
Brake Booster
Hose Replacement . . .. ... . . .. .. .. . ... . .. .. ... .. .. .. .. .. . .. 5-59
Brake Caliper
Bracket Replacement ..................................... 5-84
Inspection ...................................................... 5-78
INDEX
4
Brake Caliper (cont.)
Overhaul ............................................... 5-78, 5-81
Replacement .. .. .. ... .. .. . .. .. .. ... .. .. .. .. .. .. .. . ... 5-73, 5-76
Brake Pad Inspection ........................................ 5-70
Brake Pads Replacement ......................... 5-70, 5-72
Brake Pedal Bracket Replacement .. .. . .. .. .. .. .. ... .. 5-34
Brake Pedal Replacement . ... .. . ... .. .. ... .. .. .. . .. .. ... . . 5-30
Brake Pedal Travel
Hydraulic Brakes ............................................ 5-25
Brake Rotor
Refinishing ............................................ 5-87, 5-89
Brake Rotor Replacement ........................ 5-85, 5-86
Brake System Diagnosis
Brake System Testing
Brake Vacuum Brake Booster
Description . . .. .. ... .. .. .. .. .. .. .. .. ... .. .. .. ... . .. .. .. .. .. ... . . 5-65
Brake Warning System
Schematics . .. .. .. . .. .. .. .. .. .. .. ... .. . .. . .. .. .. . .. . .. . .. .. .. .. .. 5-7
Bumper Replacement
Rear Suspension ........................................... 3-45
Bumpers
Air Deflector Replacement
Front Fascia ............................................. 8-713
Description
Bumper and Fascia .................................. 8-733
Energy Absorber Replacement
Front ............................................. 8-721, 8-722
Rear .............................................. 8-730, 8-731
Fascia Grille Replacement
Front Lower .............................................. 8-720
Fascia Replacement
Front ............................................. 8-714, 8-716
Rear .. .. .. .. .. . .. ... .. .. .. ... . ... . .. .. .. . .. .. .. .. . 8-723, 8-726
Impact Bar Replacement
Front ........................................................ 8-720
Rear ......................................................... 8-732
License Bracket Replacement
Rear ......................................................... 8-723
License Pocket Cover Replacement
Front ........................................................ 8-719
Specifications
c
Cable Replacement
Accelerator Controls (3.8L) ......................... 6-1169
Accelerator Controls (5. 7L) ......................... 6-1802
Hood Latch Release .................................... 8-751
Cage Nut Service, Damaged ......................... 8-1077
Camshaft Position Sensor
Replacement (3.8L) ....................... 6-1214
Camshaft Position Sensor
Replacement (5.7L) ....................... 6-1848
Cargo Area Trim Front Panel
Replacement ........................ 8-940, 8-941
Cargo Area Trim Side Panel Replacement . .. ... . 8-942
Carper Replacement
Rear Center Trim Panel Carpet .. ... .. . . 8-945, 8-946
Carpet Replacement .. .. .. .. .. ... . ... . .. .. ... .. .. .. .. .. .. ... 8-944
Cassette Player
Cleaning Tape Head and Capstan ................ 8-246
Caster and Camber Adjustment, Front ................ 3-8

Catalytic Converter Replacement . .. .. .. .. .. . .. .. .. . 6-1902
CD Changer Replacement
Remote ............................................. 8-247, 8-249
Charging System
Circuit Description ........................................ 6-722
Charging System Check .................................. 6-672
Charging System Description ........................... 6-721
Cigarette Lighter Replacement IP .................... 8-511
Cleaning
Fabric Trim .................................................. 8-954
Glass Surfaces ............................................ 8-954
Removal of Specific Stains .......................... 8-954
Cleaning Agents . ... .. .... .. ... . . .. .. ... .. .. .. .. ... .. .. . .. . ... 8-954
Cleaning Leather Trim ..................................... 8-953
Cleaning The Headliner ................................... 8-954
Cleaning Vinyl Trim ......................................... 8-953
Clearcoat Repair without Repainting .............. 8-1019
Clearcoat Thickness ...................................... 8-1021
Clutch
Actuator Cylinder Replacement .................... 7-373
Anticipate Switch Replacement ..................... 7-375
Clutch Pressure Plate Adjustment ................ 7-381
Clutch Pressure Plate and Clutch Driven
Plate Replacement ............... 7-379, 7-380
Description
Clutch Driven Members ............................ 7-383
Clutch Driving Members ............................ 7-383
Clutch Operating Members ....................... 7-383
Principal Components ............................... 7-383
Diagnosis
Does Not Disengage ................................ 7-360
Grabbing (Chattering) ............................... 7-361
Noisy During Engagement ........................ 7-363
Pedal Hard to Push .. .. .. .. . .. .. .. . ... .. .. . .. ... .. ... 7-363
Pedal Spongy .. .. .. .. .. . .. .. .. .. .. .. . .. .. ... . .. . ... .. ... 7-364
Pedal Squeaky . .. . .. .. .. .. .. .. .. .. .. .. .. .. ... . .. .. ... .. 7-364
Pedal Stays on Floor (Clutch
Disengaged) ................................... 7-363
Preliminary Checking Procedure ............... 7-359
Rapid Driven Plate Wear ... . .. .. .. . ... .. . ... . .. . .. 7-365
Rattle (Trans Click) ................................... 7-362
Release Bearing Noisy w/Clutch
Engaged .. .. .. ... .. . .. ... . .. .. .. .. ... .. . .. .. ... .. 7-362
Slipping .................................................... 7-361
Spin Down Time ....................................... 7-360
Housing Replacement . .. .. . .. .. .. .. .. . .. ... . .. . .. . .. . .. 7-378
Hydraulic Clutch Bleeding ............................ 7-374
Master Cylinder Replacement ....................... 7-371
Pedal Position Switch Replacement ............. 7-376
Pedal Replacement .. .. .. .. .. .. .. . .. .. .. .. . .. .. . ... . ... .. 7-366
Pilot Bearing Replacement ........................... 7-378
Release Bearing Replacement ..................... 7-382
Special Tools ............................................... 7-384
Specifications
Sealers, Adhesives and Lubricants ........... 7-359
Clutch Anticipate Switch Replacement (3.8L) .... 6-1218
Coding Keys and Lock Cylinders ....................... 0-25
Coil Spring Insulators Replacement, Rear ......... 3-53
INDEX
Coil Spring Replacement
Rear Suspension . .. .. ... . ... .. .. .. .. . ... ... .. . .. ... . .. .. .. . 3-52
Coin Holder Replacement
Front Floor Console ..................................... 8-526
Collision Repair
Radiator Support
Description . .. .. ... . .. ... .. .. .. .. .. .. . ... .. .. .. .. ... .. .. . 8-1112
Compact Disc Care and Cleaning ................... 8-251
Compressor
Clutch Coil Removal (A/C - Manual) . .. .. 1-50, 1-52
Clutch Plate and Hub Assembly Removal
(A/C - Manual) .. .. .. ... . .. ... .. .. .. . .. 1-46, 1-47
Clutch Plate/Hub Assembly Install
(A/C - Manual) ........................ 1-59, 1-60
Clutch Rotor and/or Bearing Install
(A/C - Manual) ........................ 1-61, 1-64
Clutch Rotor and/or Bearing Removal
(A/C - Manual) .. .. .. . ... ... . .. .. ... . .. 1-48, 1-49
Compressor Clutch Coil Install
(A/C - Manual) . .. .. .. ... .. .. .. . ... .. .. 1-65, 1-67
Control Switches Install (A/C - Manual) .......... 1-71
Control Switches Removal (A/C - Manual) ..... 1-58
Control Valve Assembly Install
(A/C - Manual) . . .. .. . ... .. ... . .. .. ... . .. .. .. .. . 1-58
Control Valve Assembly Removal
(A/C - Manual) ................................. 1-53
Hose Assembly Replacement
(A/C - Manual) ........................ 1-77, 1-79
Leak Testing (A/C - Manual) . .. . .... . ... .. .. . ... . .. .. . 1-72
Mounting Bracket Replacement
(A/C - Manual) .. . .. . ... ... . .. .. .. .. .. . 1-73, 1-76
Pressure Relief Valve Install
(A/C - Manual) ................................. 1-71
Pressure Relief Valve Removal
(A/C - Manual) .. . .. .. ... .. . ... .. . .. . .. .. .. .. .. . 1-57
Replacement (A/C - Manual) ................. 1-40. 1-43
Shaft Seal Install (A/C - Manual) .......... 1-67. 1-69
Shaft Seal Removal (A/C - Manual) ...... 1-54. 1-56
Condenser Replacement (A/C - Manual) ... ... . ... . 1-85
Console
Armrest Replacement
Front Floor ............................................... 8-523
Coin Holder Replacement
Front Floor ............................................... 8-526
Cup Holder Replacement
Front Floor ............................................... 8-525
Power Accessory Port Replacement
Front Floor ............................................... 8-524
Replacement
Front Floor ............................................... 8-521
Trim Plate Replacement .................... 8-517, 8-520
Control Arm Bushings Replacement
Rear Suspension . ... .. .. ... . .. .. .. .. . .... .. .. . .. .. .. .. ... . . 3-46
Control Arm Bushings Replacement, Upper ....... 3-26
Control Arm, Lower, Bushings
Replacement ........................... 3-29, 3-30
Control Arm Replacement
Rear Axle Lower ............................................ 3-46
Control Arm Replacement, Lower ...................... 3-28
Control Arm Replacement, Upper ...................... 3-24
Control Assembly
Replacement (A/C - Manual) ........................ 1-101
5
Conversion Table
English/Metric .................................................. 0-3
Coolant
Description .. .. .. .. .. .. .. . ... .. .. .. .. .. .. .. . .. .. ... .. .. .. .. .. . 6-664
Heater Description ....................................... 6-660
Level Sensor Replacement
(Engine Cooling) ............................. 6-644
Recovery Pipe Replacement
(Engine Cooling) ............................. 6-602
Recovery Reservoir Replacement
(Engine Cooling) ............................. 6-598
Recovery System Description . .. .. .. .. .. .. .. ... .. . .. 6-660
Coolant Heater
Cord Replacement (Engine Cooling) ... 6-657, 6-658
Coolant Heater Replacement
(Engine Cooling) ................. : 6-654, 6-655
Cooling System Draining and Filling ..... 6-592, 6-595
Courtesy Lamp Replacement
Rear Quarter .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .. . 8-142
Cover Replacement
Trim Panel Opening ..................................... 8-966
Crankcase Ventilation System ........................ 6-1893
Crankcase Ventilation System
Inspection (3.8L) ........................... 6-1219
Crankshaft Position Sensor
Replacement (3.8L) ....................... 6-1213
Crankshaft Position Sensor
Replacement (5.7L) ....................... 6-1846
Crankshaft Position System Variation Learn
Procedure (3.8L) ........................... 6-1157
Crankshaft Position System Variation Learn
Procedure (5. 7L) ........................... 6-1789
Crossmember Brace Replacement
Front .......................................................... 8-1068
Crossmember Replacement ........................... 8-1070
Cruise Control
Cable Adjustment . .. .. .. ... . .. ... . .. .. .. .. .. ... .. .. .. . ... . 8-632
Cable Replacement ........................... 8-617, 8-621
Component Locations .. ... .. .. .. .. . .. .. ... .. .. .. .. . ... .. 8-604
Component Views . .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. . .. .. .. . 8-605
Connector End Views . ... .. .. .. .. .. . .. ... .. .. .. .. .. .. .. . 8-608
Description
System Circuit ............................... 8-638, 8-639
System Description ................................... 8-636
System Operation .. .. .. .. ... . .. .. .. .. .. ... .. . .. .. .. .. . 8-636
Diagnosis
Does Not Resume, Accelerate, or
Tap Up or Down ............................ 8-613
Inoperative ................................................ 8-609
System Check .. ... . ... .. .. .. .. .. .. .. . .. ... .. .. .. .. .. .. . 8-609
Module Replacement ................................... 8-614
Multifunction Lever Replacement .................. 8-632
Release Switch Adjustment .. .. . ... .. .. .. .. .. .. .. .. .. 8-635
Release Switch Replacement .. ... . .. ... .. .. .. .. .. . . 8-634
Schematic
Icons ........................................................ 8-601
References ............................................... 8-601
Schematics . .. .. .. .. .. .. .. .. .. .. .. .. ... . .. .. .. ... .. .. . .. .. .. . 8-602
Specifications
Cup Holder Replacement
Front Floor Console ..................................... 8-525
INDEX
D
Daytime Running Lamps
Ambient Light Sensor Replacement ... .. .. .. .. .. . 8-137
Control Module Replacement ....................... 8-135
Decimal and Metric Equivalents .......................... 0-3
Definition of Caution, Notice and Important ............ 3
Defogger
Right Air Outlet Replacement
(A/C - Manual) ............................... 1-110
Defroster Actuator Replacement
(A/C - Manual} .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 1-107
Description of Arrows and Symbols . .. .. .. ... .. .. .. . ... . 0-4
Diagnosis
Ball Stud Check .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 3-14
Low or Uneven Trim Height ............................. 3-6
Strategy Based Diagnosis .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 0-31
Tire Wear, Abnormal or Excessive ................... 3-4
Vehicle Leads/Pulls .......................................... 3-3
Diagnostic Work Sheets .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. . 0-5
Disc Brakes
Brake Caliper
Inspection ................................................... 5-78
Overhaul ........................................... 5-78, 5-81
Replacement ..................................... 5-73, 5-76
Brake Rotor Replacement ..................... 5-85, 5-86
Burnishing Pads and Rotors .......................... 5-73
Description .. .. .. .. .. .. .. .. .. .. .. .. ... .. . .. .. .. .. .. ... . ... .. .. .. 5-90
Diagnosis
Brake Rotor Lateral Runout Check ............. 5-69
Brake Rotor Thickness Variation Check ...... 5-69
Brake Rotor Tolerance ............................... 5-69
Refinishing Brake Rotors ....................... 5-87, 5-89
Special Tools ................................................. 5-91
Specifications
Component . .. ... .. .. .. .. .. . ... . ... .. .. . ... .. .. .. .. .. .. .. .. . 5-68
Dome and Reading Lamp Bulb
Replacement .................................. 8-130
Dome Lamp Replacement ............................... 8-143
Door Lamp Replacement ...................... 8-139, 8-140
Door Lock Switch Replacement ............ 8-799, 8-800
Door Locks
Diagnosis
Power Door Locks .................................... 8-790
Inoperative ............................................ 8-790
Lock Inoperative, Lock Operates ........... 8-790
Unlock Inoperative, Lock Operates ........ 8-790
Power Door Locks Switch Lock
Function Inoperative ....................... 8-791
One ...................................................... 8-791
Power Door Locks Switch Unlock
Function Inoperative ....................... 8-791
One ...................................................... 8-791
Door Opening Frame Replacement Side ....... 8-1097,
8-1098, 8-1100
Door Replacement
Fuel Filler .................................................... 8-970
Door Service ................................................. 8-1103
Door Sill Plate Replacement .. .. .. .. .. .. .. . .. .. . .. .. . .. . 8-943
Doors
Description
Power Door Locks Circuit ......................... 8-823
Power Mirrors Circuit ................................ 8-824
Doors (cont.)
Description (cont.)
Power Windows Circuit ............................. 8-823
Diagnosis
One Mirror Inoperative in Up/Down
Direction .............................. 8-794, 8-795
Outside Mirrors System Check .................. 8-785
Power Door Locks System Check . ... .. . .. ... . 8-784
Power Windows System Check ................ 8-784
Door Handle Replacement
Inside ....................................................... 8-81 O
Outside .. .. .. .. .. .. .. . . .. ... . .. .... . . ... . . .. .. .. .. .. .. . ... .. 8-809
Door Hinge Replacement .................. 8-807, 8-808
Door Replacement .. .. .. .. . .. .. .. ... .. .. .. .. .. .. .. . .. ... . 8-806
Door Seal Replacement ............................... 8-819
Lock Actuator Replacement .. .. .. .. . .. .. .. .. .. .. . .. .. 8-813
Lock Replacement ....................................... 8-812
Lock Striker Adjustment ............................... 8-814
Mirror Face Replacement .................. 8-822, 8-823
Mirrors Replacement .................................... 8-821
Power Door Systems Component Views ... ... 8-779
Power Door Systems Components ............... 8-777
Power Door Systems Connector
End Views .. ... .. .. .... .. ... .. .. .. .. ... .. .. ... .. 8-783
Pull Handle Replacement ............................. 8-802
Schematic
Door Locks . .. . ... ... .. .. .. ... .. .. .. .. .. . .. .. .. .. .. ... ... . 8-774
Outside Mirrors ......................................... 8-775
Power Door Systems Schematic Icons .. .. .. 8-772
Power Door Systems Schematic
References ..................................... 8-772
Power Windows ........................................ 8-773
Special Tools .. .. .. .. .. ... .. .. .. ... . .. .. .. .. .. .. .. . ... .. . .. . 8-824
Specifications
Striker Replacement ..................................... 8-814
Trim Panel Replacement
Door ......................................................... 8-804
Water Deflector Replacement
Door ......................................................... 8-805
Weatherstrip Replacement
Door ......................................................... 8-820
Window Regulator Motor Replacement ......... 8-816
Window Regulator Replacement ................... 8-815
Window Replacement ................................... 8-817
Drain Channel Replacement ............................ 8-879
Drain Cock
Replacement (Engine Cooling) ..................... 6-646
Draining and Filling Cooling System
(Engine Cooling) .................. 6-592, 6-595
Drive Belt
Replacement (5.7l) ........................... 6-267, 6-269
Tensioner Replacement (5.7L) ........... 6-272, 6-273
Drive Belt Diagnosis .. .. .. .. . .. .. .. ... .. .. .. .. .. .. .. .. . . .... 6-258
Drive Belt Diagnosis - 3.8L ............................... 6-28
Drive Belt Replacement - 3.8L .......................... 6-34
Drive Tension Specifications ............ 0-33, 5-33, 5-76
DTC 12 .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. . .. .. .. . .. .. .. .. .. . . 8-444
DTC 21/31 ....................................................... 8-446
DTC 22/32 ............................................ 8-448, 8-450
DTC 23/33 .. .. .. .. .. .. .. .. .. .. ... . .. .. .. .. .. ... .. .. .. . ... .. .. . .. . 8-452
DTC 24/34 . . .. ... .. .. . .. ... .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. .. . . 8-454
DTC 25/35 ....................................................... 8-456
DTC 41 ... .. .. .. .. .. .. .. .. ... . ... .. .. .. .. . .. ... ... . .. .. .. .. .. .. .. . 8-458
INDEX
DTC 42 .. .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. . .. ... . ... .. .. . ... . .. .. .. 8-459
DTC 43 .. .. ... . .. .. ... . .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. . ... .. . .. .. 8-460
DTC 44 ... . ... .. .. . ... . .. .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. 8-461
DTC 45 . .. .. .. .. .. .. . ... .. . .. ... .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. . .. 8-462
DTC 55 . .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .. . .. .. .. ... . ... .. . .. .. .. . 8-463
DTC 81015 ....................................................... 9-40
DTC81016 ....................................................... 9-44
DTC81017 ....................................................... 9-47
DTC 81018 ....................................................... 9-51
DTC 81019 ....................................................... 9-54
DTC 81021 ....................................................... 9-56
DTC 81022 . .. .. .. .. . .. .. .. .. ... . .. ... . .. .. .. .. .. .. .. .. .. . .. .. .. .. 9-60
DTC 81024 .. . .. .. .. .. . ... . .. ... . .. ... . .. .. .. .. ... .. . .. .. .. . ... . .. 9-64
DTC 81025 .. .. . .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. ... .. .. . .. .. .. .. .. . 9-67
DTC 81026 ....................................................... 9-70
DTC 81051 ....................................................... 9-74
DTC 81053 ....................................................... 9-75
DTC 81061 ....................................................... 9-76
DTC 81071 ....................................................... 9-77
DTC C0035 . .. .. .. .. .. .. . .. ... .. . ... . .. .. .. .. .. .. .. .. .. .. .. .. . .. 5-139
DTC C0036 . .. .. .. .. .. .. .. . .... . .. .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. 5-142
DTC C0040 .. .. . ... . .. .. .. .. ... . .. .. .. . ... . .. .. ... . ... . .. .. .. . .. 5-145
DTC C0041 ..................................................... 5-148
DTC C0045 ..................................................... 5-151
DTC C0046 .. .. .. .. .. .. .. .. . ... .. .. . .. .. .. .. .. ... . .. .. .. .. .. .. . . 5-154
DTC C0050 ..................................................... 5-157
DTC C0051 ..................................................... 5-160
DTC C0055 . .. .. .. .. .. . .. .. .. .. ... . .. .. .. .. .. .. .. .. .. .. .. . .. .. .. 5-163
DTC C0056 . .. .. .. .. .. .. . .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. . ... . .. 5-166
DTC C0060 . .. .. .. .. .. .. . ... .. .. .. . .. .. .. .. .. .. ... . .. .. .. .. .. .. . 5-169
DTC C0065 ..................................................... 5-171
DTC C0070 .. .. .. .. .. .. . .. .. ... . ... . .. .. .. .. . .. ... .. .. .. .. .. . .. . 5-173
DTC C0075 ..................................................... 5-175
DTC C0080 .. .. .. .. .. . .. .. .. ... .. .. . .. .. .. .. .. ... .. . ... . .. .. .. . . 5- 177
DTC C0085 . . .. ... .. . .. .. .. . ... .. .. .. .. . .. .. .. ... .. .. .. .. . .. .. . . 5- 179
DTC C0090 ..................................................... 5-181
DTC C0095 . .. .. .. .. .. . .. .. .. ... .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. .. 5-183
DTC C0100 ..................................................... 5-185
DTC C0105 ..................................................... 5-187
DTC C0110 ..................................................... 5-189
DTC C0121 ..................................................... 5-192
DTC C0161 ..................................................... 5-195
DTC C0166 ..................................................... 5-198
DTC C0171 ..................................................... 5-200
DTC C0181 ..................................................... 5-202
DTC C0182 ..................................................... 5-205
DTC C0236 ..................................................... 5-207
DTC C0237 ..................................................... 5-210
DTC C0238 ..................................................... 5-212
DTC C0239 ..................................................... 5-214
DTC C0245 ..................................................... 5-216
DTC C0266 ..................................................... 5-219
DTC C0550 ..................................................... 5-222
DTC C0901 ..................................................... 5-225
DTC C0896 . .. .. .. .. .. .. . .. ... .. .. .. .. . ... .. . .. ... .. .. .. . .. .. .. 5-223
DTC P0101 ..................................................... 6-795
DTC P0101 ................................................... 6-1334
DTC P0102 ..................................................... 6-799
DTC P0102 ................................................... 6-1339
DTC P0103 ......................................... 6-802, 6-1344
DTC P0107 ......................................... 6-805, 6-1348
DTC P0108 ......................................... 6-808, 6-1352
DTC P0112 ...................................................... 6-811
DTC P0112 .................................................... 6-1356
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
OTC
DTC
OTC
DTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
DTC
OTC
OTC
OTC
OTC
OTC
DTC
OTC
OTC
OTC
OTC
DTC
DTC
DTC
DTC
DTC
DTC
DTC
OTC
OTC
OTC
DTC
P0113
P0117
P0118
P0121
P0122
P0123
P0125
P0131
P0132
P0133
P0134
P0135
P0137
P0138
P0140
P0141
P0143
P0144
P0146
P0147
P0151
P0152
P0152
P0153
P0154
P0154
P0155
P0157
P0158
P0160
P0161
P0171
P0172
P0174
P0175
P0175
P0201
P0202
P0203
P0204
P0205
P0206
P0218
P0230
P0300
P0325
P0327
P0327
P0332
P0332
P0335
P0336
P0341
P0342
P0343
P0351
P0352
P0353
P0354
P0355
P0356
P0357
P0358
P0401
......................................... 6-813, 6-1359

......................................... 6-816, 6-1363
......................................... 6-818, 6-1366
......................................... 6-821, 6-1370
......................................... 6-824, 6-1374
......................................... 6-827, 6-1378
......................................... 6-830, 6-1382
......................................... 6-833, 6-1385
......................................... 6-836, 6-1389
......................................... 6-839, 6-1393
......................................... 6-842, 6-1397
......................................... 6-845, 6-1401
................................................... 6-1405
................................................... 6-1409
................................................... 6-1413
................................................... 6-1417
..................................................... 6-848
..................................................... 6-851
..................................................... 6-854
..................................................... 6-857
......................................... 6-860, 6-1421
..................................................... 6-863
................................................... 6-1425
......................................... 6-866, 6-1429
..................................................... 6-869
................................................. 6-1433
........................................ 6-872, 6-1437
.. .. ................................ 6-1440
.................................... 6-1444
.........
.. ................................ 6-1448
. . .................................. 6-1452
.
. ........................... 6-876, 6-1456
......................... 6-880, 6-1459
........................................ 6-884, 6-1462
..................................................... 6-887
................................................... 6-1465
..................................................... 6-890
..................................................... 6-893
..................................................... 6-896
..................................................... 6-899
. . ... .. .. .. .. .. .. . ... .. .. .. .. . ... .. .. .. .. . . .. .. .. . .. . 6-902
. .. ... .. . .. .. .. .. .. .. ... .. .. . .. .. .. .. . .. ... .. .. .. .. . . 6-905
.............................................. 7-87, 7-89
......................................... 6-908, 6-1468
......................................... 6-911, 6-1472
......................................... 6-916, 6-1478
..................................................... 6-918
................................................... 6-1479
..................................................... 6-921
. .. .. .. .. .. .. .. .. .. .. ... .. . .. .. . ... .. .. . ... .. .. .. .. 6-1483
. .. .. ... . ... . .. .. .. .. ... .. . .. .. .. .. .. .. ... . .. .. .. .. 6-1487
......................................... 6-924, 6-1491
.. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6-927, 6-1494
................................................... 6-1497
................................................... 6-1503
................................................... 6-1509
................................................... 6-1513
................................................... 6-1517
................................................... 6-1521
... .. .. .. .. .. .. .. .. .. ... .. .. . .. .. .. .. .. . ... .. .. .. . . 6-1525
. .. ... . .. ... .. . .. .. .. ... .. .. . .. .. .. .. .. .. .. .. .. .. .. 6-1529
................................................... 6-1533
.. . ... .. .. .. .. .. .. . .. ... .. .. .. . .. .. .. .. ... . .. .. .. .. 6-1537
..................................................... 6-932
INDEX
8
OTC P0401
OTC P0403
OTC P0404
OTC P0404
OTC P0405
OTC P0410
OTC P0412
OTC P0418
OTC P0420
OTC P0430
OTC P0440
OTC P0442
OTC P0443
OTC P0446
OTC P0449
OTC P0452
OTC P0452
OTC P0453
OTC P0453
OTC P0461
OTC P0462
OTC P0463
OTC P0480
OTC P0481
OTC P0500
OTC P0502
OTC P0503
OTC P0506
OTC P0506
OTC P0507
OTC P0507
OTC P0530
OTC P0560
OTC P0562
OTC P0563
OTC P0601
OTC P0602
OTC P0604
OTC P0608
OTC P0650
OTC P0654
OTC P0656
OTC P0704
OTC P0705
OTC P0706
OTC P0711
OTC P0712
OTC P0713
OTC P0719
OTC P0724
OTC P0740
OTC P0742
OTC P0748
OTC P0751
OTC P0753
OTC P0756
OTC P0758
OTC P0785
OTC P0801
OTC P0803
OTC P0804
OTC P1106
OTC P1107
OTC P1111
................................................... 6-1541
. .. .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. .. .. . ... . ... .. . .. . 6-934
.. . .. .. ... .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. ... .. .. 6-1543
. .. .. .. .. .. .. .. .. .. .. .. . .. ... .. .. .. . .. .. .. .. ... .. . .. . 6-938
......................................... 6-942, 6-1547
................................................... 6-1551
................................................... 6-1557
................................................... 6-1561
......................................... 6-946, 6-1565
. . .. .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. ... .. . 6-1567
......................................... 6-949, 6-1569
.. .. .. .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6-954, 6-157 4
.. . .. .. ... .. .. .. .. . .. .. .. ... .. . .. .. .. .. .. . .. ... ... . 6-1579
......................................... 6-958, 6-1583
. .. .. .. .. ... .. . .. .. .. .. .. .. .. .. .. . ... .. . .. .. ... .. .. 6-1587
.. .. .. ... .. .. .. .. .. .. . .. .. ... .. .. . .. .. .. .. .. .. .. .. .. . 6-962
................................................... 6-1591
.. .. .. .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. ... .. .. . .. 6-965
................................................... 6-1596
.. .. .. . .... . .. .. .. .. .. .. .. .. .. .. . ... .. . .. .. .. ... .. . 6-1600
.. . .. ... .. .. .. .. .. .. . ... . ... .. . ... .. .. . .. .. .. .. ... . 6-1603
. .. .. .. .. ... .. .. . .. .. .. .. ... . .. .. .. .. .. .. .. . ... .. .. 6-1606
................................................... 6-1610
................................................... 6-1613
......................................... 6-968, 6-1616
.............................................. 7-92, 7-95
............................................ 7-98, 7-101
. .. .. ... .. .. .. .. . ... . .. .. ... .. .. .. . .. .. .. .. .. ... . .. .. 6-970
................................................... 6-1619
. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. .. .. .. . .. ... .. .. .. . . 6-973
. .. .. .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. .. 6-1622
......................................... 6-976, 6-1625
. . .. .. .. ... .. . .. .. .. .. .. .. .. ... . .. .. .. .. .. .. ... . .. .. . 6-979
.. .. .. ... .. . ... . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 6-1628
................................................... 6-1631
......................................... 6-982, 6-1633
......................................... 6-983, 6-1634
. .. .. .. .. ... .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. . .... . .. 6-1635
. .. .. .. .. ... .. . .. .. .. .. .. .. .. .. .. . ... . ... . .. .... . .. 6-1636
. .. .. .. .. .. .. .. .. .. . ... . .. ... .. .. . .. .. .. .. .. ... .. .. 6-1639
. .. . .. ... .. .. .. .. . .. ... . .. .. .. .. .. .. .. .. .. .. .. ... .. 6-1642
.. .. .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. .. .. . .. ... ... . . 6-1645
.. .. . .... .. . .. .. .. .. .. .. . ... . ... .. . .. .. .. .. .. .. .. .. .. 6-984
..................................................... 6-987
..................................................... 6-991
........................................... 7-104, 7-108
........................................... 7-112, 7-116
........................................... 7-120, 7-124
........................................... 7-128, 7-131
........................................... 7-134, 7-136
........................................... 7-138, 7-141
........................................... 7-144, 7-147
........................................... 7-150, 7-154
........................................... 7-158, 7-161
........................................... 7-164, 7-168
........................................... 7-172, 7-175
........................................... 7-178, 7-182
........................................... 7-186, 7-190
................................................... 6-1649
.. .. .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. ... .. . 6-1653
. ... . .. ... .. .. .. .. . .. .. ... .. .. .. .. .. . .. .. .. .. ... . .. 6-1656
...................................................... 6-994
...................................................... 6-996
...................................................... 6-998
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
OTC
P1111 .................................................... 6-1659

P1112 .................................................... 6-1662
P1112 .................................................... 6-1000
P1114 .................................................... 6-1665
P1114 .................................................... 6-1002
P1115 ....................................... 6-1004, 6-1668
P1121 .................................................... 6-1671
P1121 .................................................... 6-1006
P1122 ....................................... 6-1008, 6-1674
P1133 ....................................... 6-1010, 6-1677
P1134 ....................................... 6-1013, 6-1681
P1153 .................................................... 6-1685
P1153 .................................................... 6-1016
P1154 .................................................... 6-1689
P1154 .................................................... 6-1019
P1258 ................................................... 6-1693
P1336 ....................................... 6-1022, 6-1695
P1351 ................................................... 6-1024
P1352 ................................................... 6-1026
P1361 ................................................... 6-1028
P1362 ................................................... 6-1031
P1374 ................................................... 6-1034
P1380 ....................................... 6-1037, 6-1698
P1381 ................................................... 6-1038
P1404 ....................................... 6-1040, 6-1699
P1415 ................................................... 6-1703
P1416 ................................................... 6-1706
P1441 ....................................... 6-1043, 6-1709
P1539 ................................................... 6-1711
P1545 ................................................... 6-1714
P1546 ................................................... 6-1718
P1554 ................................................... 6-1047
P1626 ....................................... 6-1049, 6-1721
P1629 ................................................... 6-1052
P1635 ....................................... 6-1054, 6-1724
P1639 ................................................... 6-1727
P1639 ................................................... 6-1058
P1641 ................................................... 6-1060
P1651 ................................................... 6-1066
P1652 ................................................... 6-1070
P1653 ................................................... 6-1074
P1662 ................................................... 6-1077
P1663 ................................................... 6-1080
P1665 ................................................... 6-1083
P1671 ................................................... 6-1086
P1672 ................................................... 6-1089
P1676 ................................................... 6-1092
P1810 ........................................... 7-194, 7-198
P1860 ........................................... 7-202, 7-206
P1870 ........................................... 7-210, 7-215
U 1304 .. .. .. .. .. ... .. .. .. .. .. .. .. .. .. . .. .. .. . .. .. .. .. ... .. . 5-227
E
Emblem Replacement
Front Bumper Fascia ................................... 8-652
End gate Latch Replacement .. .. .. .. .. .. .. .. .. .. . .. . .. .. 8-979
Engine Compression Test ................................ 6-252
Engine Compression Test (3.8L) ........................ 6-20
Engine Controls - 3.8L
Component Views ........................................ 6-763
Components . .. .. .. ... .. .. .. .. .. .. .. .. ... .. . .. .. ... .. .. . .. . .. 6-758
INDEX
Engine Controls - 3.8L (cont.)

Description
Air Intake System ................................... 6-1243
Crankcase Ventilation System (3.8L) ....... 6-1243
Electric Engine Cooling Fan .................... 6-1227
Electronic Ignition System .. .. .. .. .. .. .. .. .. .. .. . 6-1236
EVAP Control System (3.8L) ................... 6-1234
Exhaust Gas Recirculation
System (3.8L) ............................... 6-1242
Fuel Metering Modes of Operation .......... 6-1231
Fuel Metering System
Component (3.8L) ......................... 6-1232
Fuel Supply Component .......................... 6-1227
Information Sensors/Switches .................. 6-1221
Diagnosis
Alcohol/Contaminants-in-Fuel ................... 6-1148
Backfire .................................................. 6-1110
Cranks but Does Not Run ........................ 6-784
Cuts Out, Misses .................................... 6-1104
Data Link Connector ................................. 6-782
Detonation/Spark Knock .......................... 6-1101
Dieseling, Run-On ................................... 6-1110
Electric Cooling Fan ............................... 6-1124
Engine Oil Level Sensor/Switch .. .. .. .. .. .. .. 6-1133
EV AP Control System .. .. .. . .. .. .. .. .. .. .. ... .. .. . 6-1149
Fuel Injector Balance Test ...................... 6-1141
Fuel Injector Coil Test ............................ 6-1144
ECT Between 10-35 .. .. .. .. .. .. .. . .. .. .. . .. .. .. 6-1144
ECT Outside 10-35 ............................. 6-1146
Fuel Pump Relay Circuit ........................... 6-791
Fuel System ............................................. 6-794
Fuel System Pressure Test ..................... 6-1135
Fuel Tank Leak Check ............................ 6-1148
Fuel Tank Vent Valve ............................. 6-1148
Hard Start . .. .. .. .. .. ... .. .. . .. .. .. .. ... . .. . .. .. . .. .. .. .. 6-1095
Hesitation, Sag, Stumble ......................... 6-1102
Idle Air Control System ........................... 6-1152
Intermittent Condition .............................. 6-1095
Lack of Power, Sluggishness, or
Sponginess ................................... 6-1099
No Malfunction Indicator Lamp .................. 6-780
Poor Fuel Economy ................................ 6-1106
Powertrain Control Module ...................... 6-1113
Powertrain Control Module Controlled
Air Conditioning ............................ 6-1118
Warning Lamps ............................ 6-1114
Powertrain On Board Diagnosis
System Check .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . 6-778
Restricted Exhaust System Check .. . .. ... .. 6-1112
Rough, Unstable, or Incorrect Idle,
Stalling ......................................... 6-1108
Surges/Chuggles ..................................... 6-1097
Powertrain Control Module Connector
End Views . ... .. .. .. .. .. . .. .. .. .. . .. .. . .. .. .. .. . 6-767
Schematic
Emission Hose Routing Diagram ............... 6-741
Icons ........................................................ 6-742
References . .. . .. .. ... .. .. .. .. .. .. .. .. .. . ... .. .. .. .. . .. .. . 6-742
Schematics .. .. .. . ... . .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . 6-743
Special Tools .............................................. 6-1244
Specifications
DTC List . .. . .. . .. .. .. .. .. . . .. .. .. .. . . .. .. .. .. .. .. .. .. .. .. . . 6-736
9
Specifications (cont.)
Fuel System ............................................. 6-739
GM SPO Group Numbers ......................... 6-740
Scan Tool Data Definitions ....................... 6-731
Scan Tool Data List .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6-726
Temperature vs Resistance ...................... 6-725
Engine Controls - 5.7L
Component Views .. .. ... .. .. .. . .. ... . .. .. .. .. . .. .. .. . .. 6-1286
Components . .. .. .. .. ... . .. .. . .. .. .. . ... . .. .. .. ... .. . ... .. . 6-1281
Connector End Views ................................. 6-1304
Description .. .. .. . ... .. .. .. . ... .. .. .. .. .. . ... . .. ... .. .. .. .. . 6-1893
Air Intake System ................................... 6-1895
Electric Engine Cooling Fan .................... 6-1876
Electronic Ignition System ....................... 6-1886
EVAP Control System .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 6-1884
Exhaust Gas Recirculation System .......... 6-1892
Fuel Metering Modes of Operation .......... 6-1879
Fuel Metering System Component .......... 6-1880
Fuel Supply Component .......................... 6-1877
Information Sensors/Switches .. .. .. .. .. .. .. .. .. 6-1869
Knock Sensor System .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 6-1889
Long Term Fuel Trim .............................. 6-1883
Air Conditioning ............................ 6-1876
Secondary Air Injection System ............... 6-1890
Short Term Fuel Trim ............................. 6-1883
Speed Density System .. .. .. .. ... .. .. .. . ... .. . ... . 6-1883
Diagnosis
Air Conditioning ...................................... 6-1750
Request Circuit .................................... 6-1750
Air Conditioning Refrigerant Pressure
Sensor .......................................... 6-1753
Alcohol/Contaminants-in-Fuel ................... 61781
Backfire .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 6-17 46
Cuts Out, Misses .................................... 6-1740
Data Link Connector ............................... 6-1315
Detonation/Spark Knock . .. .. .. .. . .. .. .. . .. .. .. .. . 6-1738
Dieseling, Run-On ................................... 6-1746
Electric Cooling Fan ............................... 6-1756
Electronic Ignition System ....................... 6-1782
Engine Cranks but Does Not Run ........... 6-1318
Engine Oil Level Sensor/Switch .............. 6-1766
Fuel Injector Balance Test ...................... 6-1771
Fuel Injector Circuit ................................. 6-1778
Fuel Injector Coil Test ............................ 6-1774
ECT Between 10-35 ............................ 6-1774
ECT Outside 10-35 ............................. 6-1776
Fuel Pump Relay Circuit ......................... 6-1324
Fuel System ........................................... 6-1329
Fuel Tank Leak Check ............................ 6-1781
Fuel Tank Vent Valve ............................. 6-1781
Hard Start . .. .. .. .. .. .. .. .. ... .. . .. .. .. .. .. .. ... . .. ... .. . 6-1734
Hesitation, Sag, Stumble ......................... 6-1739
Ignition Relay .......................................... 6-1321
Inspection/Maintenance Status Reset
Procedure ..................................... 6-1785
Lack of Power, Sluggishness, or
Sponginess . ... .. .. .. .. ... .. . .. . .. .. .. . .. .. .. . 6-1737
Low Engine Oil Level Indicator ............... 6-1769
Park/Neutral Position Switch ................... 6-1763
Poor Fuel Economy ................................ 6-1742
Powertrain On Board Diagnostic
System Check .............................. 6-1312
10
Diagnosis (cont.)
Restricted Exhaust System Check .......... 6-1749
Rough, Unstable, or Incorrect Idle,
Stalling ......................................... 6-1744
Surges/Chuggles ..................................... 6-1735
Symptoms .............................................. 6-1733
Emission Hose Routing Diagram ................ 6-1261
Powertrain Control Module Connector
End Views .................................... 6-1300
Schematic
Icons ...................................................... 6-1262
References . ... .. .. .. .. ... . .. .. ... .. . ... .. .. .. .. . ... .. .. 6-1262
Schematics .. .. ... .. .. .. .. .. .. .. .. .. .. .. ... . ... . .. .. ... . . .. 6-1263
Special Tools .............................................. 6-1897
Specifications
OTC List ................................................. 6-1256
Fastener Tightening ................................ 6-1247
Fuel System ........................................... 6-1259
GM SPO Group Numbers ....................... 6-1260
Scan Tool Data Definitions ..................... 6-1251
Scan Tool Data List . ... .. .. . ... .. . ... .. ... .. . ... .. . 6-1248
Temperature vs Resistance ..................... 6-1247
Engine Coolant Temperature Sensor
Replacement (3.8L) ....................... 6-1158
Engine Coolant Temperature Sensor
Replacement (5.7L) ....................... 6-1790
Engine Coolant Temperature Sensor Replacement
(Engine Cooling) .................. 6-645, 6-646
Engine Cooling
Components .. .. ... . ... . ... .. . .. .. .. .... . .. .. .. . ... .. .. . . .. .. 6-584
Description
Air Baffles and Seals ................................ 6-663
Coolant .. .. ... .. .. .. .. .. .. ... . .. ... . ... .. . .. .. .. .. ... .. .. ... 6-664
Coolant Heater . .. .. .. .. .. .. ... .. .. . .. .. .. .. .. .. ... .. .. . 6-660
Coolant Recovery System .. .. .. .. . .. .. .. .. ... .. .. . 6-660
Cooling Fan Relay .................................... 6-663
Cooling System ........................................ 6-660
Electric Engine Cooling Fan ...................... 6-663
Engine Coolant Temperature Sensor ........ 6-663
Low Coolant Sensor . ... . ... .. .. . ... . ... . ... . .. .... . . 6-664
Radiator Assembly .................................... 6-661
Radiator Filler/Pressure Cap Assembly ..... 6-662
Thermostat .. .. .. .. .. .. .. .. .. . .... . .. .. .. .. .. .. .. ... . .. ... 6-663
Throttle Body Coolant System .................. 6-660
Water Pump ............................................. 6-663
Diagnosis
Coolant Concentration Testing .. ... . ... .. .. .. .. . 6-589
Cooling System Leak Testing ................... 6-590
Engine Fails To Reach Normal
Operating Temperature ................... 6-588
Loss of Coolant .. .. .. .. .. .. ... .. . .. .. .. .. .. ... . .. . .. .. . 6-587
Overheating .............................................. 6-586
Pressure Cap Testing ............................... 6-591
Thermostat . ... .. .. .. .. .. .. .. . ... . . .. .. ... . .. .. .. .. ... .. .. 6-588
Schematic
Cooling Fan .............................................. 6-582
Cooling System Icons ............................... 6-581
Cooling System References ...................... 6-581
Special Tools ............................................... 6-664
Specifications
INDEX
Engine Cooling (cont.)
Specifications Engine Cooling System .......... 6-580
Engine Diagnosis
Exhaust Leakage ....................................... 6-1901
Engine Electric
Specifications
Engine Electrical
Component Locations . .. .. .. .. .. ... .. . ... . .. .. .. .. .. ... . 6-670
Description
Battery ...................................................... 6-720
Charging System ...................................... 6-721
Charging System Circuit ........................... 6-722
Charging System Operation Charging
System .. ... .. .. .. .. .. . ... ... . .. .. .. .. .. .. .. .. .. .. 6-722
Operation .............................................. 6-722
Ignition System .............................. 6-722, 6-723
Starting System Circuit ............................. 6-720
Diagnosis
Battery Hydrometer Displays Dark or
Yellow Dot . .. . .. .. ... . .. .. ... . .. .. .. .. .. .. .. ... . 6-676
Battery Is Undercharged or
Overcharged . . .. .. ... .. .. .. .. .. .. .. .. . ... .. .. .. 6-679
Charging System Check ........................... 6-672
Common Causes of Battery Failure .......... 6-675
Engine Cranks/Cranks Slowly, but
Does Not Start . ... . .. ... .. .. .. .. . .. .. .. .. ... . 6-674
Generator Assembly Check ...................... 6-681
Parasitic Load Test - Parasitic .. .. .. ... . .. . .... . 6-676
Spark Plug Visual ..................................... 6-682
Spark Plug Wire Harness ......................... 6-684
Starter No Load Test .............. ; ................. 6-675
Starter Solenoid Does Not Click .. . ... .. .. . ... . 6-672
Starting System Check ............................. 6-671
Generator Brace Replacement ..................... 6-706
Generator Bracket Replacement ................... 6-705
Generator Replacement . . ... .. .. .. .. .. .. .. .. 6-707, 6-709
Ignition Coil and Ignition Control Module
Replacement .................................. 6-718
Ignition Coil Replacement ............................. 6-716
Schematic
Starting and Charging ............................... 6-668
Starting and Charging Icons . .. . .. .. .. .. .. .. ... . . 6-667
Starting and Charging References ............ 6-667
Spark Plug Replacement .............................. 6-715
Spark Plug Wire Ha mess Replacement ....... 6-711,
6-714
Special Tools ............................................... 6-724
Specifications
Battery Temperature vs Voltage Drop ....... 6-666
Battery Usage Table ................................. 6-665
Generator Usage Table ............................ 6-666
Starter Motor Usage Table ....................... 6-666
Starting and Charging Connector
End Views ...................................... 6-671
Engine Exhaust
Catalytic Converter Replacement ................ 6-1902
Converter Hanger Assembly
Replacement ....... 6-1917, 6-1919, 6-1920
Converter Heat Shield Replacement ........... 6-1924
Description
Exhaust System .. .. . ... .. .. .. . .... .. . .. .. .. ... .. . ... . 6-1929
INDEX
Engine Exhaust (cont.)

Diagnosis
Exhaust Noise ........................................ 6-1901
Internal Muffler Rattles/Loss of Power ..... 6-1900
Exhaust Pipe and Muffler Heat Shields
Replacement . .. . .. .. .. ... . .. ... . ... . ... . .. .. . 6-1926
Heat Shield Replacement ........................... 6-1925
Muffler Hangers Replacement ........ 6-1921, 6-1923
Muffler Replacement .................................. 6-1913
Oxidation Catalytic Converter
Replacement .................... 6-1905, 6-1908
Specifications
GM SPO Group Numbers ....................... 6-1900
Engine Flywheel
Replacement (5.7L) ...................................... 6-374
Engine ID and Partial VIN Location ..................... 0-8
Engine Mechanical - 3.8L
Balance Shaft
Bearing and/or Bushing Installation ........... 6-198
Bearing and/or Bushing Removal .............. 6-197
Clean and Inspect .................................... 6-197
Installation (Off-Vehicle) ............................ 6-203
Balance Shaft Removal (Off-Vehicle) ............ 6-165
Camshaft
Bearing Installation (Off-Vehicle) ............... 6-185
Bearing Removal (Off-Vehicle) .................. 6-183
Camshaft and Bearings Clean and
Inspect (Off-Vehicle) ....................... 6-184
Removal (Off-Vehicle) ............................... 6-165
Replacement ... . .. .. .. . .. . .. .. .. .. .. .. .. ... .. . .. .. .. . ... 6-1 O1
Crankshaft
Balancer Clean and Inspect ...................... 6-176
Balancer Installation (Off-Vehicle) ... 6-210, 6-211
Balancer Removal (Off-Vehicle) ................ 6-161
Balancer Replacement ................................ 6-83
Cranksahft and Bearings Removal
(Off-Vehicle) ................................... 6-169
Crankshaft and Bearings Clean and
Inspect (Off-Vehicle) ....................... 6-173
Crankshaft and Bearings Installation
(Off-Vehicle) ................................... 6-199
Front Oil Seal Installation (Off-Vehicle) ..... 6-210
Front Oil Seal Removal (Off-Vehicle) ........ 6-162
Front Oil Seal Replacement ........................ 6-86
Rear Oil Seal and Housing Installation
(Off-Vehicle) ................................... 6-205
Rear Oil Seal and Housing Removal
(Off-Vehicle) ................................... 6-167
Rear Oil Seal and Housing
Replacement . .. ... .. . .. .. . ... ... . ... . ... . .. .. . 6-116
Rear Oil Seal Installation (Off-Vehicle) ...... 6-206
Rear Oil Seal Removal (Off-Vehicle) ......... 6-166
Rear Oil Seal Replacement ...................... 6-116
Cylinder Boring and Honing ......................... 6-172
Cylinder Head
Assemble .. .. .. .. . .. .. ... . .. .. .. .. .. .. .. .. .. ... .. . .. .. .. .. 6-192
Clean and Inspect .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . 6-187
Disassemble .. .. .. .. ... .. . .. .. .. .. .. .. .. .. ... . .. .. .. .. . .. 6-186
Replacement . .. .. .. . ... .. .. .. .. .. . ... .. . ... .. . 6-103, 6-105
11
Engine Mechanical - 3.8L (cont.)
Description
Cleanliness and Care ............................... 6-223
Components ............................................. 6-221
Installation Precautions ............................. 6-225
Lubrication ................................................ 6-222
Replacing Engine Gaskets ........................ 6-224
Separating Parts ....................................... 6-225
Thread Repair .......................................... 6-223
Tools and Equipment ................................ 6-225
Use of ATV and Anaerobic Sealer ............ 6-224
Diagnosis
Base Engine Misfire ................................... 6-18
Cylinder Leakage Test ................................ 6-28
Drive Belt ................................................... 6-28
Engine Compression Test ........................... 6-20
Engine Noise ..................................... 6-20, 6-23
Oil Consumption ......................................... 6-25
Oil Leak ..................................................... 6-26
Oil Pressure Diagnosis and Testing ............ 6-25
Disassembled Views .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. . 6-29
Draining Fluids and Oil Filter Removal
(Off-Vehicle) .................................... 6-152
Drive Belt
Replacement - 3.8L .................................... 6-34
Tensioner Installation (Off-Vehicle) ............ 6-219
Tensioner Removal (Off-Vehicle) ............... 6-154
Tensioner Replacement .. .. .. .. .. ... . .... .. . .. .. .. . .. 6-35
Engine Block
Clean and Inspect (Off-Vehicle) ................ 6-170
Plug Installation (Off-Vehicle) .................... 6-199
Plug Removal (Off-Vehicle) ....................... 6-170
Engine Flywheel
Engine Front Cover Clean and Inspect ........ 6-197
Engine Front Cover Installation
(Off-Vehicle) .................................... 6-209
Engine Front Cover Removal (Off-Vehicle) ... 6-162
Engine Front Cover Replacement .................. 6-86
Engine Mount
Inspection ................................................... 6-36
Replacement .. .. .. .. .. . ... .. .. .. .. . .. .. .. ... .. .. .. .. . ... .. 6-37
Engine Oil and Oil Filter Replacement ......... 6-151
Engine Replacement .................................... 6-118
Exhaust Manifold
Installation (Off-Vehicle) ................. 6-213, 6-215
Removal (Off-Vehicle) .................... 6-157, 6-158
Replacement .. .. .. .. .. . .. .. .. .. .. .. .. ... .. . .. .. .. 6-57, 6-64
Flywheel
Replacement ............................................ 6-114
Flywheel Clean and Inspect ......................... 6-177
Flywheel Removal (Off-Vehicle) .................... 6-153
Intake Manifold
Replacement ..................................... 6-46, 6-56
Oil Filter
Adapter and Valve Assembly
Installation (Off-Vehicle) .................. 6-208
12
Oil Filter (cont.)
Adapter and Valve Assembly
Replacement . .. .. . .. ... .. .. .. . .. .. ... .. .. .. .. .. . 6-96
Oil Filter Adapter and Valve Assembly
Removal (Off-Vehicle) ..................... 6-163
Oil Level Indicator and Tube Installation
(Off-Vehicle) .................................... 6-219
Oil Level Indicator and Tube Removal
(Off-Vehicle) .................................... 6-154
Oil Level Indicator and Tube Replacement ..... 6-45
Oil Pan
Oil Pan Removal (Off-Vehicle) ...................... 6-167
Oil Pan Replacement .. .. . ... .. ... . .. .. .. .. .. .. . .... . .. . 6-107
Oil Pump
Cover and Gear Set Installation
(Off-Vehicle) ................................... 6-208
Cover and Gear Set Replacement . . .. .... . .. ... 6-96
Pipe and Screen Assembly Installation ..... 6-202
Pipe and Screen Assembly Removal
(Off-Vehicle) ................................... 6-168
Pipe and Screen Assembly
Replacement . .. .. .. ... .. . .. .. .. .. .. .. .. ... . .. . 6-113
Oil Pump Cover and Gear Set Removal
(Off-Vehicle) .................................... 6-163
Piston and Connecting Rod Assemble .......... 6-182
Piston and Connecting Rod Disassemble ..... 6-177
Piston, Connecting Rod, and Bearing
Installation ...................................... 6-201
Removal (Off-Vehicle) ..................... 6-168
Piston, Connecting Rod and Bearings
Clean/Inspect .................................. 6-178
Piston Selection .. .. .. .. .. .. .. . .... . .. .. .. .. .. .. .. . ... .. .. . 6-180
Rear Oil Seal Replacement .. . .. .. .. .. .. . .. ... .. ... . . 6-116
Service Prior to Assembly ............................ 6-198
Special Tools ............................................... 6-226
Specifications
GM SPO Group Numbers ........................... 6-17
Specifications . ... .. .. .. . .. .. .. .. .. ... . .. .. .. .. .. .. .. ... .. .. .. . 6-14
Sealers, Adhesives, and Lubricants ............ 6-18
Timing Chain
Timing Chain and Sprockets Clean and
Inspect .. .. .. .. .. .. .. . ... .. .. ... .. .. . .. .. . . .. ... .. 6-185
Timing Chain and Sprockets Installation
(Off-Vehicle) ................................... 6-207
Timing Chain and Sprockets Removal
(Off-Vehicle) ................................... 6-164
Timing Chain and Sprockets
Replacement .................................. 6-100
Valve
Rocker Arm and Push Rod Removal
(Off-Vehicle) ................................... 6-160
Valve Guide ReamingNalve and Seat
Grinding ......................................... 6-189
Valve Lifter Installation (Off-Vehicle) ............. 6-211
Valve Lifter Removal (Off-Vehicle) ................ 6-161
Valve Lifter Replacement .. .. ... ... .. .. .. ... . ... .. .. .. .. 6-82
Valve Lifters and Guides Clean and
Inspect .. .. .. .. .. .. . .. ... .. .. .. . .. ... .. . .. ... .. .. . 6-186
INDEX
Valve Rocker Arm and Push Rod
Installation (Off-Vehicle) .................. 6-212
Replacement .. .. . ... .. . .... . .. .. .. . ... .. .. . ... .. 6-77
Valve Rocker Arm and Push Rods Clean
and Inspect .................................... 6-186
Valve Rocker Arm Cover Clean and
Inspect . ... .... . . .. .. .. . .. .. ... . ... . .. ... . .. .. .. .. 6-194
Valve Rocker Arm Cover Installation
(Off-Vehicle) .................................... 6-213
Valve Rocker Arm Cover Removal
(Off-Vehicle) ......................... 6-159, 6-160
Valve Rocker Arm Cover Replacement .... 6-70, 6-74
Valve Stem Oil Seal and Valve Spring
Replacement .................................... 6-79
Water Outlet
Water Outlet Removal (Off-Vehicle) .............. 6-154
Water Pump
Removal (Off-Vehicle) ....... , ....................... 6-155
Engine Mechanical - 5. 7L
Balancer, Crankshaft, Replacement . .. .. .. .. .. .. . 6-339
Camshaft
Bearing Installation ................................... 6-481
Bearing Removal ........................... 6-474, 6-476
Camshaft and Bearings Clean and
Inspect ........................................... 6-478
Replacement ............................................ 6-371
Crankshaft
Balancer Clean and Inspect ...................... 6-462
Balancer Installation (Off-Vehicle) .............. 6-557
Balancer Removal (Off-Vehicle) ................ 6-411
Balancer Replacement .. .. .. .. ... .. .. .. .. . ... . .. .. .. 6-339
Crankshaft and Bearings Clean
and Inspect ............... 6-446, 6-456, 6-460
Crankshaft and Bearings Installation
(Off-Vehicle) ................................... 6-518
Crankshaft and Bearings Removal
(Off-Vehicle) ................................... 6-437
Front Oil Seal Installation (Off-Vehicle) ..... 6-533
Front Oil Seal Replacement ...................... 6-346
Rear Oil Seal Installation (Off-Vehicle) ...... 6-530
Rear Oil Seal Replacement ... . ... .. .. . . .. .. .. .. . 6-357
Cylinder Boring and Honing (Off-Vehicle) ..... 6-444
Cylinder Head
Assemble .. . .. .. . .. . .. .. .. .. . .. .. .. .. .. .. ... .. .. . . .. .. .. .. 6-493
Clean and Inspect .. . .. .. .. . ... .. . .. ... .. . .. .. . .. ... .. 6-487
Disassemble . . .. . .. .. . . .. .. .. . ... .. .. .. .. .. . ... .. . .. ... .. 6-485
Replacement .................................. 6-328, 6-331
Description
Cleanliness and Care ............................... 6-572
Engine Components . .. .. .. .. .. .. .. .. .. .. .. .. . .. .... . 6-560
Identification ............................................. 6-562
Lubrication ................................................ 6-563
New Product Information .......................... 6-561
13
INDEX
Description (cont.)
Replacing Engine Gaskets ........................
Separating Parts .......................................
Thread Repair ..........................................
Tools and Equipment ................................
Use of RTV and Anaerobic Sealer ............
Diagnosis
Base Engine Misfire ..................................
Drive Belt .................................................
Engine Compression Test .........................
Engine Noise ............................................
Oil Consumption .......................................
Oil Leak ...................................................
Oil Pressure Diagnosis and Testing ..........
Valve Train ...............................................
Disassembled Views .. .. .. .. .. .. . ... .. ... . .. .. ... . .. .. . .
Draining Fluids and Oil Filter Removal
(Off-Vehicle) ....................................
Drive Belt
Idler Pulley Replacement ............... 6-270,
Replacement .................................. 6-267,
Tensioner Replacement ................. 6-272,
Engine Block
Clean and Inspect (Off-Vehicle) ................
Engine Block Plug Installation ......................
Engine Block Plug Removal (Off-Vehicle) .....
Engine Mount
Replacement .................................. 6-274,
Engine Set-Up and Testing ..........................
Exhaust Manifold
Clean and Inspect ....................................
Installation (Off-Vehicle) ................. 6-553,
Removal (Off-Vehicle) .................... 6-413,
Replacement .................................. 6-315,
Flywheel
Installation (Off-Vehicle) ............................
Removal (Off-Vehicle) ...............................
Front Cover
Replacement ............................................
Front Cover Removal (Off-Vehicle) ...............
Fuel Rail and Injectors Installation
(Off-Vehicle) ....................................
Fuel Rail and Injectors Removal
(Off-Vehicle) ....................................
Intake Manifold
Replacement ............................................
Oil and Oil Filter Change .............................
Oil Filter
Oil Filter, Adapter, Pan Cover
Installation (Off-Vehicle) ..................
Oil Filter, Adapter and Pan Cover
Removal (Off-Vehicle) .....................
Oil Level Indicator and Tube
Replacement . . .. ... . ... .. . ... .. .. .. ... ... .. .. . ... .. . ... .
6-573
6-57 4
6-564
6-574
6-573
6-250
6-258
6-252
6-252
6-255
6-256
6-256
6-254
6-259
6-409
6-271
6-269
6-273
6-443
6-515
6-440
6-277
6-559
6-512
6-554
6-414
6-321
6-462
6-556
6-412
6-502
6-530
6-348
6-431
6-551
6-417
6-509
6-547
6-418
6-281
6-408
6-536
6-428
6-556
6-413
6-311

Oil Pan
Replacement ... . .. .. .. .. ... . .. .. .. .. .. .. .. ... .. . .. .. .. ..
Oil Pump
Assemble .................................................
Disassemble . .. .. .. ... . .. .. .. .. ... .. . .. .. .. .. . .. .. . .. .. ..
Oil Pump, Pump Screen and Deflector
Replacement . .. .. ... .. .. . .. .. .. .. . . ... . .. .. . . .
Piston and Connecting Rod Assemble ..........
Piston and Connecting Rod Disassemble .. .. .
Piston, Connecting Rod and Bearings
Clean/Inspect ............ 6-465, 6-467,
Piston Selection ...........................................
Rear Cover
Clean and Inspect .. .. .. .. .. . .. .. . .. ... .. .. .. .. .. . .. ..
Replacement . .. .. ... . .. .. .. .. ... .. . .. .. .. .. .. ... . .. .. .. .
Replacement .. .. .. .. . .. ... . ... .. .. .. .. .. .. . .. .. ... .. .. .. . .. .
Service Prior to Assembly ............................
Special Tools ...............................................
Specifications
Engine Mechanical ...................................
Fastener Tightening ..................................
GM SPO Group Numbers .........................
Sealers, Adhesives, and Lubricants ..........
Thread Repair ..........................................
Throttle Body Installation (Off-Vehicle) ..........
Throttle Body Removal (Off-Vehicle) .............
Timing Chain
Timing Chain and Sprockets Clean
and Inspect ....................................
Timing Chain and Sprockets Installation
(Off-Vehicle) ...................................
Timing Chain and Sprockets Removal
(Off-Vehicle) ...................................
Timing Chain and Sprockets
Replacement .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. ..
Valley Cover
Valley Cover Removal (Off-Vehicle) ..............
Valley Cover Replacement .. .. .. .. .. .. . ... .. . ... .. .. .
Valve Guide Reaming/Valve and Seat
Grinding .........................................
Valve Lifter
Replacement .. .. .. .. .. .. ... . .. ... .. . .. .. .. ... . .. .. .. .. ..
6-506
6-533
6-429
6-360
6-500
6-498
6-496
6-526
6-432
6-369
6-471
6-463
6-521
6-435
6-470
6-470
6-503
6-527
6-431
6-358
6-376
6-515
6-575
6-231
6-229
6-234
6-236
6-237
6-551
6-416
6-482
6-524
6-433
6-370
6-503
6-545
6-421
6-297
6-488
6-537
6-427
6-339
14
Valve Lifters and Guides Clean
and Inspect .................................... 6-484
Installation (Off-Vehicle) .. .. .. .. .. .. .. .. .. .. ... .. .. . 6-541
Removal ................................................... 6-424
Replacement . .. .. .. .. .. .. .. . ... .. .. .. .. .. .. .. .. .. .. .. .. . 6-307
Engine Mechanical - 57L
Valve Rocker Arm and Push Rods
Clean and Inspect .. .. .. .. .. .. .. .. .. .. .. .. .. . .. . .. .. .. 6-483
Engine Mechanical - 5. 7L
Valve Rocker Arm Cover
Replacement .................................. 6-299, 6-302
Valve Stem Oil Seal and Valve Spring
Replacement . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 6-308
Vapor Vent Pipe
Vapor Vent Pipe Clean and Inspect ............. 6-514
Vapor Vent Pipe Removal (Off-Vehicle) ........ 6-421
Vapor Vent Pipe Replacement ...................... 6-296
Water Pump
Clean and Inspect .. .. .. .. ... .. .. .. .. .. . .. .. .. .. .. .. .. 6-514
Installation (Off-Vehicle) .. .. .. .. .. .. .. .. .. .. .. . .. .. . 6-552
Engine Mount
Replacement (3.8L) ........................................ 6-37
Replacement (5.7L) ........................... 6-27 4, 6-277
Engine Oil and Oil Filter Change (5.7L) ........... 6-408
Engine Oil and Oil Filter
Replacement (3.8L) ........................ 6-151
Engine Oil Life Monitor Reset
Procedure (5.7L) ........................... 6-1861
Engine Oil Pressure Sensor/Switch
Replacement (3.8L) ....................... 6-1209
Engine Replacement (3.8L) ............................. 6-118
Engine Replacement (5.7L) ............................. 6-376
English/Metric Conversion Table .......................... 0-3
Entertainment
Amplifier Replacement ....................... 8-244. 8-245
Antenna Mast Cleaning ................................ 8-256
Antenna Mast Replacement
Fixed ........................................................ 8-253
Power ....................................................... 8-254
Antenna Module Replacement
Fixed ........................................................ 8-254
Antenna Motor Replacement ........................ 8-255
Cassette Player
Cleaning Tape Head and Capstan ............ 8-246
CD Changer Replacement
Remote .......................................... 8-247, 8-249
Compact Disc Care and Cleaning ................ 8-251
Component Locations . .. .. .. ... .. .. . .. ... . .. .. .. .. ... .. . 8-206
Component Views .. .. .. .. .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. 8-209
Description
Compact Disc Player Operation ................ 8-277
Power Antenna System ............................ 8-281
Power Antenna System Circuit .................. 8-281
Radio Controls Operation ... 8-267, 8-268, 8-271,
8-274, 8-276
Radio/Audio System ....................... 8-265, 8-266
INDEX
Entertainment (cont.)
Description (cont.)
Radio/Audio System Circuit ....................... 8-280
Steering Wheel Controls System Circuit .... 8-281
Steering Wheel Controls System
Operation ....................................... 8-280
Theftlock Operation ................................... 8-279
Diagnosis
Antenna Inoperative .................................. 8-227
Antenna Poor Reception ........................... 8-223
Compact Disc Inoperative ......................... 8-221
General Radio Noise . .. .. .. .. .. .. .. . .. .. .. .. . .. .. . .. 8-222
Power Antenna System Check .................. 8-218
Radio Display Inoperative, No Sound
from Speakers .. .. .. ... .. .. .. .. . .. ... . .. .. .. .. 8-219
Radio Display Inoperative, Speakers
Operative ........................................ 8-218
Radio Illuminate Inoperative with Park
Lamps On ...................................... 8-219
Radio Memory Inoperative ........................ 8-218
Radio/Audio System Check ....................... 8-217
Speaker General ...................................... 8-228
Speakers Inoperative ................................ 8-229
One or More ........ 8-229, 8-230, 8-231, 8-232,
8-233, 8-234, 8-235,
8-236, 8-237, 8-238
Subwoofer ............................................. 8-239
Steering Wheel Control System Check ..... 8-218
Steering Wheel Controls Illumination
Inoperative ...................................... 8-226
Steering Wheel Controls Inoperative ......... 8-225
Tape Player Inoperative ............................ 8-220
Radio Replacement ........................... 8-240, 8-242
Schematic
Icons ........................................................ 8-195
Power Antenna ......................................... 8-205
Radio/Audio System ................................. 8-196
References ............................................... 8-195
Steering Wheel Controls ........................... 8-204
Speaker Grille Replacement
Rear .............................................. 8-263, 8-264
Speaker Replacement ....................... 8-257, 8-258
Rear ......................................................... 8-259
Special Tools ............................................... 8-281
Specifications
Steering Wheel Control Switches
Replacement .................................. 8-251
EVAP
Canister Purge Solenoid Valve
Replacement (3.8L) ....................... 6-1209
Canister Purge Solenoid Valve
Replacement (5.7L) ....................... 6-1842
Canister Replacement (3.8L) ...................... 6-1211
Canister Replacement (5.7L) ...................... 6-1844
System Cleaning (5.7L) .............................. 6-1845
Vent Valve Replacement (3.8L) .................. 6-1210
Vent Valve Replacement (5. 7L) .................. 6-1843
Evaporator Core Replacement
(A/C - Manual) .. .. .. .. .. . .. .. . .. .. .. . . .. ... . .. . 1-93
Evaporator Tube Replacement
(A/C - Manual) ................................. 1-81
Exhaust Gas Recirculation
Pipe Replacement (5. 7L) ............................ 6-1857
INDEX
15
Exhaust Gas Recirculation (cont.)

System Cleaning (5. 7L) .............................. 6-1858
Valve Replacement (3.8L) .......................... 6-1217
Valve Replacement (5.7L) ................ ,......... 6-1856
Exhaust Manifold
Replacement (3.8L) ............................... 6-57, 6-64
Exhaust Manifold Replacement (5. 7L) ... 6-315, 6-321
Exterior Lamps
Diagnosis ................................................... 8-80
Lamps Inoperative .......................... 8-80, 8-81
Exterior Trim
Description
Adhesive Retained Molding and
Emblem .......................................... 8-657
Molding/Nameplates Replacement .... 8-647, 8-648,
8-649, 8-650, 8-651
Washing and Waxing ................................... 8-656
Weld Stud Replacement .. . .. .. .. .. ... .. .. .. .. . .. .. .. . . 8-656
F
Fan
Cooling Fan Relay Description ..................... 6-663
Cooling Fan Relay Replacement
(Engine Cooling) ............................. 6-622
Electric Cooling Fan Motor Replacement
(Engine Cooling) ............................. 6-621
Electric Cooling Fan Replacement
(Engine Cooling) ............................. 6-616
Electric Engine Cooling Fan Description ....... 6-663
Shroud Replacement (Engine Cooling) ......... 6-647
Fasteners .......................................................... 0-14
Filter Replacement
In-Line Fuel (3.8L) ..................................... 6-1181
In-Line Fuel (5.7L) ..................................... 6-1813
Finish Panel Replacement
Upper Rear Trim .......................................... 8-949
Floor Panel Reinforcement Replacement ....... 8-1067
Fluid Capacities, Approximate ............................ 0-33
Fluids and Lubricants, Recommended ............... 0-33
Flushing (Engine Cooling) ............................... 6-598
Flywheel Replacement (3.8L) .......................... 6-114
Fog Lamp
Aiming Procedure ........................................ 8-124
Replacement
Front ................................... 8-118, 8-120, 8-121
Rear .............................................. 8-122. 8-123
Switch Replacement .......................... 8-133. 8-134
Fog Lamp Bulb Replacement .......................... 8-124
Folding Top
Arm Replacement ........................................ 8-87 4
Bow Link Replacement ................................ 8-844
Front Side Rail Link Replacement ................ 8-865
Pivot Bracket Replacement .......................... 8-861
Side Front Weatherstrip Replacement .......... 8-888
Side Rail Assembly Replacement ................. 8-873
Side Rail Link Replacement ......................... 8-853
Side Rail Replacement ................................. 8-846
Stowage Compartment Lid Latch Replace .... 8-883
Weatherstrip Retainer Replacement .............. 8-887
Folding Top Adjustment ................................... 8-864
Folding Top Bow Replacement ........................ 8-837
Folding Top Hose Replacement
Power . .. ... .. .. .. .. .. .. .. . .. ... .. .. .. .. . ... .. .. .. .. .. .. .. . .. .. . 8-836
Folding Top Pump with Motor Replacement ..... 8-835

Frame
Floor Panel Reinforcement Replacement .... 8-1067
Frame and Underbody
Description
Centerline ............................................... 8-1078
Datum .................................................... 8-1078
General .................................................. 8-1079
Diagnosis
Alignment Checking ................................ 8-1041
Checking Frame to Body Alignment ........ 8-1041
Special Tools .. .. .. .. .. .. .. .. ... .. . .. .. .. ... . .. ... . .. ... .. . 8-1079
Specifications
Asymmetrical Reference Points ............... 8-1040
Body Dimensions .................................... 8-1023
Symmetrical Reference Points ................ 8-1040
Frame Dimensions ........................................ 8-1032
Front .................................................... 8-133, 8-134
Front Bumper Fascia Emblem Replacement .... 8-652
Front Fender
Rear Side Molding Replacement .................. 8-653
Front Oil Seal Replacement (5.7L) .................. 6-346
Front Suspension
Component Locations .................................... 3-13
Description
General ...................................................... 3-39
Diagnosis
Ball Stud Check .. .. .. . ... .. . .. .. .. .. .. .. ... .. . .. .. . .. . .. 3-14
Special Tools ................................................. 3-40
Specifications
Front Weatherstrip Replacement ...................... 8-890
Fuel Filler Door Replacement .......................... 8-970
Fuel Filler Pocket Replacement ....................... 8-970
Fuel Filter Replacement, In-Line (3.8L) .......... 6-1181
Fuel Filter Replacement, In-Line (5.7L) .......... 6-1813
Fuel Hose/Pipe
Replacement
Filter to Tank (3.8L) ................................ 6-1200
Fuel Hose/Pipes
Assembly Replacement (5.7L) .................... 6-1833
Replacement
Engine Compartment (3.8L) .................... 6-1201
Filter to Engine (3.8L) ............................. 6-1194
Fuel Hose/Pipes Replacement
Chassis (5.7L) ............................................ 6-1826
Engine Compartment (5. 7L) ........................ 6-1832
Fuel Injector Replacement (3.8L) ................... 6-1207
Fuel Injector Replacement (5.7L) ................... 6-1839
Fuel Level Sensor Replacement (3.8L) .......... 6-1193
Fuel Pressure Connection Valve
Replacement (5.7L) ....................... 6-1836
Fuel Pressure Regulator Replacement (3.8L) ... 6-1206
Fuel Pressure Relief Procedure (3.8L) ........... 6-1175
Fuel Pressure Relief Procedure (5. 7L) ........... 6-1807
Fuel Pulse Dampener Replacement (5.7L) ..... 6-1826
Fuel Pump Relay Replacement (3.8L) ........... 6-1208
Fuel Pump Relay Replacement (5. 7L) ........... 6-1841
Fuel Pump Strainer Replacement (3.8L) ........ 6-1192
Fuel Rail Assembly Replacement (3.8L) ......... 6-1204
Fuel Rail Assembly Replacement (5. 7L) ......... 6-1836
Fuel Sender Assembly
Replacement (5.7L) ............................... .... 6 1823
16
INDEX
Fuel Sender Assembly (cont.)

Service (5.7L) ............................................
Fuel Sender Assembly Replacement (3.8L) ....
Fuel Sender Assembly Service (3.8L) ............
Fuel System Cleaning (3.8L) .........................
Fuel System Cleaning (5.7L) .........................
Fuel Tank
Draining Procedure (3.8L) ..........................
Draining Procedure (5.7L) ..........................
Pressure Sensor Replacement (3.8L) .........
Pressure Sensor Replacement (5.7L) .........
Replacement (3.8L) ....................................
Replacement (5.7L) ....................................
Vent Valve Replacement (3.8L) ..................
Vent Valve Replacement (5.7L) ..................
6-1824
6-1190
6-1191
6-1203
6-1835
6-1182
6-1814
6-1189
6-1822
6-1183
6-1815
6-1188
6-1821
G
Garnish Molding Replacement
Liftgate . .. .. .. .. .. ... .. .. .. .. .. .. .. .. .. ... .. . .. .. .. ... . ... .. .. . 8-984
Upper Pillar .................................................. 8-948
Windshield Pillar .......................................... 8-947
General Description
Suspension Diagnosis ...................................... 3-6
Generator
Assembly Check .......................................... 6-681
Brace Replacement .. .. .. .. .. . . ... .. . .. ... . .. .. ... .. .. .. . 6-706
Bracket Replacement . .. .. .. .. ... . .. .. .. .. .. .. .. .. . .. .. . 6-705
Replacement ..................................... 6-707, 6-709
Generator Usage .. .. .. .. .. .. .. .. .. .. . .. .. . .. .. ... . .. ... .. . ... 6-666
Glass Surface Cleaning ................................... 8-954
Anti lock Brake System ................................. 5-108
H
Hard Top Headliner Replacement .................... 8-833
Hazard Lamp
Flasher Replacement ................................... 8-139
Headlamp
Aiming .............................................. 8-114, 8-118
Bezel Replacement ...................................... 8-112
Bracket Replacement ........................ 8-759, 8-760
Bulb Replacement . .. . .. .. ... . ... .. .. . ... .. .. . .. .. ... .. ... 8-109
Door Module Replacement ........................... 8-113
Housing Panel Replacement ........................ 8-757
Opening Door Adjustment ............................ 8-111
Opening Door Replacement ......................... 8-109
Replacement ..................................... 8-104, 8-106
Switch Replacement ..................................... 8-131
Headlight
Leveling Schematic ........................................ 8-29
Headlights
Door Schematics .. .. .. . .. .. . .. .. .. .. .. ... . .. .. .. . .. .. .. .. . . 8-28
Schematics ........................................... 8-18, 8-19
Headlights - DRL Schematics ................... 8-20, 8-24
Headliner Cleaning .......................................... 8-954
Headliner Replacement
Hard Top ..................................................... 8-833
Headrest Replacement
Front Seat ................................................... 8-930
Heat Excessive (A/C - Manual) .. .. .. .. . .. .. . .. .. .. .. .. . 1-33
Heat Shield Replacement
Converter ................................................... 6-1924
Heat Shield Replacement (cont.)

Exhaust Pipe and Muffler ........................... 6-1926
Heater
Pipes Replacement (A/C - Manual) .. .. .. . 1-97, 1-99
Heater Core Replacement .. .. .. .. .. .. .. .. . .. .. .. ... . .. .. .. 1-96
Heater Replacement-Engine (Block)
Coolant .. .. .. .. .. . .. .. . .. .. .. .. .. ... . .. 6-654, 6-655
Heater/Bi-Level Vacuum Actuator
Replacement (A/C - Manual) .......... 1-108
Heating Insufficient (A/C - Manual) .. .. .. .. . .. .. .. .. .. . 1-30
High Mounted Stop Lamp
Replacement ........................ 8-143, 8-145
Hinge Cover Replacement
Hood ........................................................... 8-739
Hinge Pillar Trim Replacement ........................ 8-939
Hinge Replacement
Hood ........................................................... 8-743
Rear Compartment Lid .. .. . .. .. .. .. .. .. .. .. . 8-977, 8-978
Rear Lift Window .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. .. . 8-976
Hood
Adjustment ................................................... 8-735
Air Extractor Replacement ................. 8-740, 8-742
Assist Rod Ball Stud Replacement .. .. .. .. . .. .. .. 8-756
Assist Rod Replacement .............................. 8-755
Bumper Replacement .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. 8-736
Close Out Filler Replacement .. .. .. . .. .. .. .. .. .. .. .. 8-739
Hinge Cover Replacement ........................... 8-739
Hinge Replacement ...................................... 8-743
Insulator Replacement .................................. 8-754
Latch Release Cable Replacement ............... 8-751
Latch Replacement
Primary ..................................................... 8-746
Secondary .. . .. .. ... .. ... . .. .. .. .. ... .. .. .. .. . ... .. .. . ... . 8-750
Replacement . .. .. .. ... .. .. .. .. . .. ... .. .. .. .. .. .. .. .. .. .. .. .. 8-736
Hood Rear Seal Replacement .. . .. .. .. .. .. .. .. .. .. .. .. 8-763
Hook Replacement, Tow ................... 8-1074, 8-1076
Horn Replacement ........................................... 8-566
Horns
Component Locations .. .. ... .. . .. .. ... . .. .. .. .. ... .. .. .. 8-562
Connector End Views .. .. .. .. .. . .. .. ... ... . .. .. .. .. .. .. . 8-563
Description
Circuit ....................................................... 8-568
Operation ................................................. 8-568
Diagnosis
Homs Always on .. .. ... .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. 8-565
Homs Inoperative ..................................... 8-563
System Check .. . ... .. . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . . 8-563
Relay Replacement .. . .. ... .. . .. .. .. . ... .. . ... . .. ... .. . .. 8-567
Schematic
Icons ........................................................ 8-560
References .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. . 8-560
Schematics . .. .. .. ... .. . ... .. .. . ... . ... ... . ... . .. .. .. . ... .. .. 8-561
Specifications
Fastener Tightening .. . .. .. .. .. . .. .. . .. . .. .. .. .. . .. .. . 8-560
Hose Routing Diagram
Emission (5.7L) .......................................... 6-1261
Hose Routing Diagram, Emission (3.8L) .......... 6-741
Hose-Inlet, Replacement, Radiator ........ 6-603, 6-606
Hose-Outlet, Replacement, Radiator ..... 6-609, 6-612
How to Obtain Replacement Labels .................. 0-14
How to Use Diagnostic Tables .. .. .. .. .. .. . .. .. . .. .. . .. 8-289
Hub Cap
Aluminum Wheel Hub Cap Replacement ........ 3-60
Hub/Wheel Bearing Replacement, Front ............ 3-21
INDEX
HVAC - Manual
Description .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... .. . .. . .. .. .. . .. 1-119
Handling of Refrigerant Lines and
Fittings . .. .. .. . . .. .. .. .. .. .. . .. ... ... . .. .. .. .. .. .. 1-119
Accumulator Replacement .............................. 1-90
Air Distributor Duct Replacement .................. 1-109
Air Inlet Actuator Replacement ..................... 1-106
Air Outlet Replacement - Floor .. .. .. .. . ... .. . ... . .. 1-110
Air Outlet Replacement - Right Defogger ..... 1-11 O
Air Outlet Replacement - Side Window .. .. .. .. 1-111
Blower Control Schematic .. .. ... .. .. .. .. .. . .. .. .. .. . ... . 1-5
Blower Motor and Fan Assembly
Replacement .. .. . ... . .. .. .. ... .. .. . ... .. . .. .. .. . 1-92
Blower Motor Relay Replacement .................. 1-91
Blower Motor Resistor Replacement ............... 1-92
Component Locations .. .. .. . .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. . 1-8
Component Views . .. .. .. .. .. .. .. . .. ... .. . . .. .. .. .. .. .. . .. .. 1-10
Compressor Control Module Replacement ...... 1-83
Compressor Control Schematic .. .. .. ... .. .. .. . .. .. .. .. 1-6
Compressor Hose Assembly
Replacement ........................... 1-77, 1-79
Compressor Mounting Bracket
Replacement .. .. .. .. .. .. .. .. .. .. . .. .. .. 1-73, 1-76
Compressor Replacement .. .. .. .. .. .. .. .. .. .. . 1-40, 1-43
Condenser Replacement . . .. .. .. .. .. .. . . ... . ... . .. .. .. .. 1-85
Connector End Views .................................... 1-14
Control Assembly Replacement .. .. .. .. .. .. .. .. .. .. 1-101
Defroster Actuator Replacement ................... 1-107
Description
A/C System .. .. .. . ... ... . .. .. .. .. .. .. .. .. . . .. . . .. .. .. .. .. 1-115
Accumulator . . .. .. .. .. ... . .. .. .. .. .. .. .. ... . .. . .. . .. .. .. .. 1-120
Air Distribution System ............................. 1-116
Blower Controls Circuit ............................. 1-127
Blower Motor . ... . .. ... .. .. . .. .. ... . .. .. .. ... .. .. . .. .. .. . 1-125
Compressor . .. .. .. .. ... . ... . .. ... . .. .. .. ... .. .. .. .. .. . .. . 1-122
Condenser . . ... . .. .. .. ... . ... . .. .. .. .. .. . ... .. . . .. .. . .. . . . 1-120
Control Assembly . .. .. .. .. .. . ... . .. ... .. .. .. .. .. .. .. .. . 1-123
Evaporator .. .. . .. .. ... . ... .. . .. ... . .. .. .. .. ... . .. .. .. . . . .. 1-120
Expansion (Orifice) Tube .......................... 1-120
Handling A/C Compressor ........................ 1-119
Handling Compressor Oil .. .. .. .. .. .. .. .. ... .. .. .. . 1-118
Handling R-134a ....................................... 1-118
Heater Core ............................................. 1-121
High Pressure Relief Valve ....................... 1-123
Maintaining Chemical Stability .. .... .. .. ... .. .. .. 1-119
0-Ring ...................................................... 1-127
Refrigerant Oil Distribution ........................ 1-125
Refrigerant Pressure Sensor ..................... 1-127
Refrigerant R-134a . ... .. . ... .. . .. . .. ... .. .. . .. .. .. . . . 1-118
Refrigeration System .. ... . .. .. .. .. .. ... .. .. . .. .. .. .. . 1-117
Relays and Switches .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1-127
Vacuum Hose Harness ............................. 1-126
Diagnosis
Air Delivery Improper .................................. 1-34
Blower Control System Check .................... 1-16
Cooling Insufficient - A/C Inoperative .......... 1-33
Functional Check .. .. .. .. .. .. .. . .. .. .. .. .. .. . .. .. .. .. . .. . 1-14
Heat Excessive . . .. .. .. ... .. .. . .. .. .. .. ... .. .. .. ... .. . .. .. 1-33
Heating Insufficient . .. .. .. .. . ... .. .. .. .. .. .. .. .. .. . . .. . . 1-30
Leak Testing .............................................. 1-23
Noise ......................................................... 1-36
Odor ........................................................... 1-38
Refrigerant System Checks .. .. .. .. .. .. .. .. .. .. .. .. 1-23
System Performance Test .......................... 1-21
17
HVAC - Manual (cont.)
Diagnosis (cont.)
Temperature Control Inoperative ................. 1-37
VDOT A/C System .. .. .. .. .. .. . .. . .. . .. .. .. .. . .. .. .. .. . 1-25
Evaporator Core Replacement .. .. . .. .. .. .. .. .. .. . .. . 1-93
Evaporator Tube Replacement ....................... 1-81
Expansion (Orifice) Tube ................................ 1-83
Heater Core Replacement .. .. .. .. . .. . .. .. .. .. .. .. .. .. .. 1-96
Heater Pipes Replacement .................... 1-97, 1-99
Heater/Bi-Level Vacuum Actuator
Replacement . .. . . ... .. . .. .. .. .. .. . . .. .. .. .. .. . 1-108
IP Air Outlet Ducts Replacement .................. 1-108
Odor Correction . .. .. .. . .. .. . .. .. .. . ... .. .. .. .. .. . ... .. .. .. . . 1-38
0-Ring Replacement ...................................... 1-72
Refrigerant Pressure Sensor Replacement ..... 1-84
Refrigerant Recovery ..................................... 1-39
Schematic Icons .............................................. 1-4
Service Ports Replacement .. .. .. .. .. .. .. .. .. .. .. . .. .. . 1-82
Special Tools ............................................... 1-128
Specifications
Fastener Tightening .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. ... .. .. . 1-3
Refrigerant Oil Distribution ............................ 1-4
System Capacities . .. .. .. .. .. .. .. .. .. . .. ... . .. . .. .. .. .. .. . 1-3
Temperature Control Cable .. .. .. .. .. .. .. .. .. .. .. .. .. 1-104
Temperature Control Cable Replacement ..... 1-103
Vacuum Hose Harness Replacement
(A/C - Manual) ..................... 1-113, 1-114
Vacuum Tank Replacement
(A/C - Manual) ............................... 1-112
Vent Actuator Replacement . .. .. .. .. .. . .. . .. . .. .. . .. . 1-106
HVAC Control Lamp Replacement .. .. . .. .. .. .. .. .. .. 8-141
Hydraulic Brake System
Component . .. .. .. .. .. .. . .. .. ... .. .. . .. ... . .. .. ... .. .. .. . ... . ... . 5-8
Schematic
References ................................................... 5-6
Hydraulic Brakes
Description
Brake Fluid and Brake Fluid Handling .. .. .. . . 5-65
Brake Warning System ............................... 5-66
Brake Warning System Circuit .................... 5-67
Master Cylinder .......................................... 5-64
Vacuum Brake Booster ............................... 5-65
Diagnosis
Brake Fluid Leaks .. . .. .. . .. .. .. .. .. . .. .... . .. .. .. .. .. .. 5-25
Brake Pedal Travel ..................................... 5-25
Brake System .. .. .. . .. .. .. ... .. .. .. . .. . .. .. .. .. .. ... .. .. .. 5-15
Brake System Testing ................................ 5-15
Brake Warning Indicator Always On ........... 5-12
Brake Warning Indicator Inoperative .... 5-13, 5-14
Brake Warning System Check .................... 5-12
Master Cylinder Diagnosis .......................... 5-26
Front Brake Hose Replacement ..................... 5-39
ISO Flares Replacement ................................ 5-38
Pipe Replacement . .. .. .. .. . .. .. .. . .. .. .. .. .. .. .. .. .. .. .. ... 5-38
Rear Brake Hose Replacement .... 5-41, 5-42, 5-44
Special Tools .. . .. . .. ... . .. .. .. .. . .. . .. .. .. .. .. .. ... . .. .. .. .. . 5-67
Specifications
Brake System ............................................... 5-5
Fastener Tightening ...................................... 5-5
System Bleeding ................................... 5-46, 5-49
System Flushing ................................... 5-53, 5-55
Replacement .. .. . . .. .. .. .. .. .. . .. ... .. .. .. .. .. .. 5-60
INDEX
18
Hydraulic Brakes (cont.)
Vacuum Brake Booster Hose
Replacement .. .. . .. .. ... .. .. .. .. . ... .. .. .. .. .. . . 5-59
Vacuum Brake Booster Replacement ............. 5-57
Hydraulic Brakes System
Schematic
Icons ............................................................ 5-6
Hydraulic Brake System
Component Views ............................................ 5-9
I
Identification, Vehicle ........................................... 0-5
Idle Air Control Valve Replacement (3.8L) ...... 6-1166
Idle Air Control Valve Replacement (5.7L) ...... 6-1801
Idle Learn Procedure (5. 7L} ........................... 6-1789
Ignition Coil
Replacement ................................................ 6-716
Ignition Coil and Ignition Control Module
Replacement .................................. 6-718
Ignition Coil(s) Replacement (3.8L} ................ 6-1212
Ignition Control Module Replacement (3.8L) ..... 6-1212
Ignition System
Description ........................................ 6-722, 6-723
Important, Caution and Notice, Definition of ........... 3
Instrument Cluster
Description
Circuit ....................................................... 8-540
Gauge Operation ...................................... 8-537
General .................................................... 8-536
Indicator Operation ................................... 8-538
Instrument Panel
Carrier ......................................................... 8-527
Cigarette Lighter Replacement ..................... 8-511
Cluster Replacement .................................... 8-504
Compartment Lamp Replacement ................ 8-141
Compartment Latch Replacement ................. 8-514
Compartment Lock Cylinder Replacement .... 8-516
Description
Odometer Repair Label ............................. 8-536
Insulator Replacement .................................. 8-534
Storage Compartment Door Replacement ..... 8-513
Upper Trim Pad Replacement ...................... 8-500
Instrument Panel Compartment Lamp
Inoperative ..................................................... 8-97
Instrument Panel, Gauges and Console
Audible Warnings Component Locations ....... 8-495
Audible Warnings Connector End Views ....... 8-496
Description
Audible Warnings ...................................... 8-542
Audible Warnings Circuit ........................... 8-542
Console ... . .. ... . .. ... .. .. .. . .. ... . .. ... .. .. . .. .. ... . . .. . .. 8-543
Diagnosis
CHECK GAGES Indicator Always On ....... 8-485
CHECK GAGES Indicator Inoperative ....... 8-485
Engine Coolant Temperature Gauge
Always Cold .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. 8-482
Always Hot ..................................... 8-482
Inaccurate or Inoperative ................ 8-483
Engine Oil Pressure Gauge
Always High ................................... 8-483
Instrument Panel, Gauges and Console (cont.)

Diagnosis (cont.)
Engine Oil Pressure Gauge
G~~g~.. j~~~~~~~t~
8 484
Engin/~ti~e~~:r~ ..
....... or Inoperative ................................. 8-484
Fasten Safety Belt Indicator Always On .... 8-486
Fasten Safety Belt Indicator Inoperative .... 8-486
Fuel Gauge Inaccurate or Inoperative ., ..... 8-484
Instrument Cluster .................................... 8-480
System Check . .. .. . .. ... . .. .. ... .. . ... .. .. .. .. . .. ... 8-480
Low Engine Coolant Indicator
Always On . .. .. . .. .. ... . .. ... .. .. .. .. .. . .. .. .. . . 8-487
Low Engine Coolant Indicator
Inoperative ...................................... 8-488
Low Engine Oil Level Indicator
Always On .. . .. .. . ... .. .. . ... .. .. .. .. . .. .. .. .. . . 8-488
Low Engine Oil Level Indicator
Inoperative ...................................... 8-489
Speedometer and/or Odometer
Inoperative ...................................... 8-490
Speedometer Inaccurate (J 38522
Available) ....................................... 8-489
Tachometer Inaccurate or Inoperative ....... 8-491
Instrument Cluster Component Locations ..... 8-473
Instrument Cluster Component Views ........... 8-475
Instrument Cluster Connector End Views ..... 8-479
Schematic
Audible Warnings Schematic Icons ........... 8-492
Audible Warnings Schematic
References ..................................... 8-492
Instrument Cluster Schematic Icons .......... 8-468
Instrument Cluster Schematic
References .. .. .. .. .. ... .. .. .. .. .. .. .. ... .. .. .. . 8-468
Schematics
Audible Warnings ...................................... 8-493
Instrument Cluster .................................... 8-469
Analog .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. .. .. . .. . .. .. . ... .. 8-469
Special Tools ............................................... 8-544
Specifications
Instrument Panel Service Precautions .............. 8-500
Intake Air Temperature Sensor
Replacement (3.8L) ....................... 6-1165
Intake Air Temperature Sensor
Replacement (5.7L} ....................... 6-1800
Interior Trim
Specifications
J
Jacking and Lifting ............................................ 0-28
K
Key Coding and Lock Cylinders ........................ 0-25
Keyless Entry
Component Location .................................... 8-549
Description
Remote Keyless Entry General . . .. .. ... . .. .. .. . 8-559
Remote Key less Entry System Circuit ....... 8-557
Remote Keyless Entry System
Operation .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. ... .. 8-556
19
INDEX
Keyless Entry (cont.)
Diagnosis
Courtesy Lamps Inoperative With
Transmitter ..................................... 8-554
Door Lock/Unlock Inoperative ................... 8-554
Right Front ............................................ 8-554
Door Unlock Inoperative with
Transmitter ..................................... 8-553
All ......................................................... 8-553
Doors Lock Inoperative with Transmitter ... 8-553
All ......................................................... 8-553
Doors Lock/Unlock Inoperative .................. 8-554
Left Front .............................................. 8-554
Rear Release Inoperative with
Transmitter ..................................... 8-553
Remote Keyless Entry System Does Not
Change Customization Modes ......... 8-552
Remote Keyless Entry System
Inoperative ...................................... 8-551
System Check .......................................... 8-551
Transmitter Test ....................................... 8-552
Schematic
Icons ........................................................ 8-545
References ............................................... 8-545
Schematics . ... . .. .. .. .. ... . .. .. .. .. .. .. . .. ... .. .. .. .. .. .. . .. 8-546
Knee Bolster
Bracket Replacement ................................... 8-532
Knee Bolster Replacement .............................. 8-509
Knock Sensor Replacement (3.8L) ................. 6-1215
Knock Sensor Replacement (5.7L) ................. 6-1849
Knock Sensor System Description (3.8L) ....... 6-1240
L
Label
Anti-Theft Labeling ......................................... 0-11
Service Parts ID ............................................ 0-12
Label, Vehicle Certification .................................. 0-6
Labels
Replacement, How to Obtain ......................... 0-14
Latch Replacement
Endgate ....................................................... 8-979
Hood Primary ............................................... 8-746
Hood Secondary .......................................... 8-750
License Lamp Replacement ............................. 8-14 7
Lift Off Panel
Adjustment ................................................... 8-886
Weatherstrip Replacement ............................ 8-893
Weatherstrip Retainer Replacement .............. 8-894
Lift Off Panel Replacement .............................. 8-881
Lift Window Panel Adjustment
Rear ............................................................ 8-971
Lift Window Panel Hinge Replacement
Rear ............................................................ 8-976
Lift Window Panel Opening Weatherstrip
Replacement
Rear ............................................................ 8-985
Lift Window Panel Replacement
Rear ............................................................ 8-972
Liftgate Garnish Molding Replacement ............. 8-984
Lift gate Lock Actuator Replacement .. ... .. .. .. .. . .. . 8-980

Liftgate Lock Cylinder Replacement ................. 8-978
Liftgate Trim Panel Replacement ..................... 8-965
Lifting and Jacking ............................................ 0-28
Lift-Out Panel
Mounting Hardware Replacement ................. 8-882
Replacement .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. ... .. .. .. .. .. .. 8-882
Lighting Systems
Component Locations . ... .. . .. .. . ... .. . .. ... .. .. .. .. .. . .. 8-49
Component Views .......................................... 8-57
Description ................................................... 8-154
Backup Lights Circuit ................................ 8-159
Daytime Running Lamps Circuit ................ 8-157
Exterior Lights Circuit ............................... 8-158
Fog Lights Circuit .......................... 8-157, 8-158
Headlight Doors Circuit ............................. 8-158
Headlight Leveling Circuit ......................... 8-158
Headlights Circuit ...................................... 8-156
Interior Lights Circuit ................................. 8-159
Interior Lights Dimming Circuit .................. 8-160
Diagnosis
Backup Lamp Inoperative - One ................. 8-73
Backup Lamps Always On .......................... 8-73
Backup Lamps Inoperative .......................... 8-71
Backup Lights System Check ..................... 8-69
Courtesy Lamps Always On ....................... 8-74
Courtesy Lamps Inoperative ....................... 8-75
Courtesy Lamps Inoperative IP
Dimmer Switch ................................. 8-75
Courtesy Lamps Inoperative with
Doors Ajar ............................... 8-76, 8-77
Courtesy Lamps Inoperative with
Rear Compartment Lid Open ............ 8-78
Courtesy/Reading Lamps Always On .......... 8-79
Courtesy/Reading Lamps Inoperative .......... 8-79
Courtesy/Reading Lamps Inoperative
with Lamp Switch ............................. 8-75
Daytime Running Lamps Inoperative,
Headlamp Switch Operates
Normally ........................................... 8-79
Daytime Running Lamps On With Park
Brake Applied ................................... 8-92
Daytime Running Lamps System Check ..... 8-67
Daytime Running Lamps Turn Off. with
Ignition On (Park Brake Applied) ...... 8-92
Exterior Lights System Check ..................... 8-68
Fog Lamp Indicator Inoperative ......... 8-85, 8-86
Fog Lamps Always On ...................... 8-81, 8-82
Fog Lamps Inoperative - All .............. 8-82, 8-83
Fog Lamps Inoperative - One ..................... 8-85
Fog Lights System Check ........................... 8-68
Hazard Lamps Inoperative .......................... 8-86
Headlamps Do Not Switch Intensity ............ 8-91
Headlamps Inoperative ............................... 8-88
High Beams ............................................ 8-88
Low Beams .................................... 8-87, 8-88
One Lamp ............................................... 8-89
Headlamps Inoperative In Low Light
Conditions ........................................ 8-90
Headlamps On in Day Light Conditions ...... 8-90
20
Lighting Systems (cont.)
Diagnosis (cont.)
Headlight Do Not Close .............................. 8-93
Headlight Doors Inoperative - One Door ..... 8-93
Headlight Doors System Check .................. 8-68
Headlight Leveling Inoperative .................... 8-95
Headlight Leveling Inoperative Actuator Switch Illumination .............. 8-96
Headlight Leveling Inoperative One Actuator .................................... 8-94
Headlight Leveling System Check ............... 8-68
Headlight System Check ............................. 8-67
High Beam Indicator Inoperative ................. 8-96
Instrument Panel Compartment Lamp
Inoperative ....................................... 8-97
Instrument Panel Lamps Do Not Dim ......... 8-97
Instrument Panel Lamps Inoperative ........... 8-98
Instrument Panel Lamps
Inoperative - One ............................. 8-98
Interior Lights Dimming System Check ....... 8-71
Interior Lights System Check ...................... 8-69
Stop Lamps Always On .. ... .. .. . .. . .. .. .. .. . .. .. . ... 8-99
Stop Lamps Inoperative .............................. 8-99
All ........................................................... 8-99
Center High Mounted ............................ 8-100
CHMSL Operative ................................. 8-100
Turn Signal and Hazard Lamps
Inoperative ...................................... 8-101
Turn Signal Indicators Inoperative ............. 8-102
Left ....................................................... 8-103
Turn Signal Lamp Always On ................... 8-102
One Side . .. .. .. ... . .. .. . .. ... . . .. .. .. .. .. .. .. .. .. .. .. . 8-102
Turn Signal Lamps Inoperative ................. 8-101
Schematic
Backup Lights ............................................. 8-41
Exterior Lights .......................... 8-30, 8-35, 8-38
Fog Lights .. .. .. ... . .. .. ... . .. ... .. . .. .. .. .. .. .. .. .. .. ... . .. 8-25
Headlight Doors .......................................... 8-28
Headlight Leveling ...................................... 8-29
Headlights ......................................... 8-18, 8-19
Headlights - Daytime Running
Lamps ..................................... 8-20, 8-24
Icons .......................................................... 8-17
Interior Lights .................................... 8-42, 8-44
Interior Lights Dimming ............................... 8-46
References . .. ... . .. .. .. .. .. .. ... . .. .. .. .. .. .. .. .. .. .. .. .. .. 8-17
Special Tools ............................................... 8-160
Specifications
Bulb Usage ................................................ 8-16
Lock Actuator Replacement
Liftgate . .. .. .. .. .. . .. .. .. . .. ... . ... . ... . ... . ... . ... .. .. ... .. ... 8-980
Lock Cylinder Replacement
Liftgate . . .. .. .. .. ... .. .. .. . ... . .. .. ... .. .. . ... . .. ... .. . .... .. .. 8-978
Lock Cylinders and Key Coding ........................ 0-25
Lock Striker Replacement
Rear Compartment Lid ................................. 8-982
Long Trip/Highway Maintenance Schedule ......... 0-37
Lubricants and Fluids Recommended ................ 0-33
Luggage Screen Support Replacement ............ 8-947
Lumbar Bladder Replacement .......................... 8-924
Lumbar Motor Replacement ............................. 8-922
INDEX
M
Maintenance Schedule Long Trip/Highway ......... 0-37
Maintenance and Lubrication
Inspections and Other Services ...................... 0-41
Maintenance Items ......................................... 0-34
Maintenance Schedule ................................... 0-34
Periodic Maintenance Inspections .......... 0-43, 0-44
Maintenance Items ... .. .. .. . .. ... . ... . ... .. .. .. .. . .. ... . ... .. . 0-34
Maintenance Lubrication
Explanation of Scheduled Services .. .. .. .. .. ... . .. 0-39
Maintenance Schedule, Short Trip/City .............. 0-35
Manifold Absolute Pressure Sensor
Replacement (3.8L) ....................... 6-1160
Manifold Absolute Pressure Sensor
Replacement (5.7L) ....................... 6-1792
Maintenance Schedule .. .. .. .. .. .. . .. .. . .. .. .. . .. ... . ... . .. . 0-34
Manual Transmission - MM6
Control Lever Handle Assembly ..................... 7-39
Manual Transmission - M49
Backup Lamp Switch .......................................7-15
Control Assembly ... .. . .. ... . .. .. .. .. .. ... .. . .. .. .. .. .. .. . . . 7-11
Control Lever Boot Assembly ... . .. .. .. .. .. .. .. .. .. .. . 7-12
Diagnosis
Gear Clash When Shifting Gears ................. 7-6
Transmission Does Not Shift into
One Gear ........................................... 7-7
Transmission Jumps Out Of Gear ................ 7-6
Transmission Locked in One Gear ............... 7-7
Transmission Noisy ...................................... 7-6
Transmission Shifts Hard .............................. 7-5
Fluid Level Check ............................................ 7-8
Mains haft Rear Oil Seal .. . ... .. .. .. .. .. .. . ... .. . .. ... .. . 7-14
Oil Drain and Fill ........................................... 7-18
Replacement . .. . .. . .. .. .. .. .. .. . . .. .. .. .. .. .. .. . . .. .. 7-19, 7-22
Shift Control Closeout Boot Replacement ....... 7-13
Shift Control Knob Replacement .. . ... .. .. . .. ... .. .. 7-14
Special Tools
Special Tools ............................................. 7-27
Specifications
Lubrication . .. .. ... .. . .. .. .. .. .. .. ... .. .. . .. .. .. .. .. .. .. .. .. .. 7-5
Support and Mount Assembly . .. .. .. .. .. .. . .. .. ... .. .. . 7-9
Vehicle Speed Sensor ... .. . .. .. .. ... .. .. . ... . .. .. .. ... . .. 7-17
Manual Transmission - MM6
Backup Lamp Switch Replacement .. . .. .. .. ... .. .. 7-41
Control Assembly .. .. .. .. .. .. .. . ... .. .. .. .. .. . .. .. ... . ... .. . 7-36
Control Lever Boot Assembly .. .. .. .. .. .. .. . .. .. .. ... . 7-37
Diagnosis
Clunk on Acceleration or Deceleration ........ 7-31
Gear Clash When Shifting Gears ................ 7-29
Oil Leak . .. .. .. .. .. ... .. . .. .. .. ... . ... .. .. . .. . . .. .. .. .. ... .. . 7-32
Transmission Does Not Shift into
One Gear . .. . .. ... .. .. .. . ... .. .. .. .. . .. ... . ... .. .. 7-30
Transmission Jumps Out of Gear ............... 7-30
Transmission Locked in One Gear .............. 7-31
Transmission Noisy .................................... 7-30
Transmission Shifts Hard ............................ 7-28
Transmission Shifts Hard into Reverse ....... 7-29
1
7 33
~
Replacement .. .. .. .. .. .. ... .. . .. .. .. .. .. ... . ... . 7-45
Mainshaft Rear Oil Seal . .. .. . .. .. .. . .. .. .. .. .. .. ... .. .. . 7-41
Oil Drain and Fill ........................................... 7-46
~! ~~~=~v~~~iks"i~itts~i~~~id
INDEX
21
Manual Transmission - MM6 (cont.)

Replacement ......................................... 7-47, 7-51
Reverse Lockout Solenoid
Replacement (MM6) ......................... 7-44
Shift Control Closeout Boot Replacement . .. . .. . 7-38
Shift Control Knob Replacement .. ... . .. .. .. .. .. .. .. 7-40
Special Tools
Special Tools ............................................. 7-55
Specifications
Fastener Tightening Specifications .............. 7-28
Lubrication .................................................. 7-28
Vehicle Speed Sensor Replacement ............... 7-43
Vent Tube Replacement ................................. 7-47
Manual Transmission (M49)
Description .. .. .. .. . ... .. .. .. .. .. .. .. .. .. .. . ... .. .. .. . .. .. .. .. .. 7-26
Manual Transmission (MM6)
Description ............. ,. .. .. .. .. .. .. .. . .. .... . .. .. . .. .. .. .. .. . 7-54
Marker Lamp
Bulb Replacement
Side ......................................................... 8-126
Replacement
Side ......................................................... 8-125
Mass Air Flow Sensor Replacement (3.8L) .... 6-1159
Mass Air Flow Sensor Replacement (5.7L) .... 6-1791
Master Cylinder
Bench Bleeding ............................................. 5-29
Replacement . .. .. .. .. .. .. .. .. .. .. .. .. .. . .. ... .. .. .. .. . ... . .. .. 5-28
Reservoir Filling ............................................. 5-26
Reservoir Replacement .................................. 5-27
Meanings of Abbreviations ................................. 0-20
Mirror Face Replacement ..................... 8-822, 8-823
Mirror Replacement
Door ............................................................ 8-821
Mirrors
Diagnosis
Power Mirrors Inoperative ......................... 8-791
One ............................................ 8-792, 8-793
Power Mirrors Inoperative in Left
and Right Direction ......................... 8-796
One ............................................ 8-796, 8-797
Power Mirror Switch Replacement ................ 8-801
Molding Replacement
Belt Reveal ....................................... 8-950, 8-951
Body Side Door .. . ... .. .. .. .. .. .. . .. .. .. .. ... .. .. . .. .. .. .. 8-653
Liftgate Garnish .. .. .. .. ... . ... . .. .. .. .. .. . ... .. .. .. .. .. .. . 8-984
Rear Quarter ................................................ 8-654
Rocker Panel .. . .. .. .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. .. ... ... 8-655
Upper Pillar Garnish .................................... 8-948
Windshield Pillar Garnish ............................. 8-947
Mount, Engine, Replacement (5.7L) ...... 6-274, 6-277
N
Noise Diagnosis
Instrument Panel .................... 8-668,
Noise Diagnosis
Door .................................................
Front of Vehicle .................................
Rear of Vehicle ........... 8-677, 8-678,
Roof ....................................... 8-674,
Seat ..................................................
Under Vehicle ...................................
Notice, Caution and Important, Definition
8-669, 8-670
8-673, 8-674
8-667, 8-668
8-679, 8-680
8-675, 8-676
8-671, 8-672
8-680, 8-681
of ........... 3
0
Oil Consumption Diagnosis (3.8L) ..................... 6-25
Ordering Information, Special Tools ..................... 0-5
Oxygen Sensor Replacement,
Heated Bank .. .. .. .. .. .. .. .. . .. . 6-1794, 6-1797
Oxygen Sensor Replacement,
Heated (3.8L) ............................... 6-1161
p
Paint Coatings
Environmental Fallout
Acid Rain ................................................ 8-1020
Paint Gauges ................................................ 8-1021
Paint/Coatings
Anti-Corrosion Treatment and Repair .......... 8-1016
Basecoat/Clearcoat Paint Systems ............. 8-1016
Clearcoat Repair without Repainting ........... 8-1019
Paint Identification ...................................... 8-1019
Specifications
Clearcoat Repair - 3M Products .............. 8-1014
Clearcoat Repair - Meguiar Products ...... 8-1015
Painting
Clearcoat Thickness ................................... 8-1021
Rail Dust Damage Repair .......................... 8-1021
Panel Information and Repair
Specifications
Repair Materials ....................................... 8-987
Flexible Plastic Part ............................... 8-987
Rigid Plastic Part .................................. 8-987
Panel Repair
Backing Patch Fabrication ............................ 8-998
Gouge or Puncture ...................................... 8-989
Partial . .. .. .. .. ... .. . .. .. .. .. .. ... .. .. .. . .. .. ... . .. .. .. ... . .. .. . 8-993
Plastic Structure ......................................... 8-1004
Panel Replacement
Air Inlet Grille .............................................. 8-762
Complete .. ... .. .. .. .. . .. .. .. ... .. .. .. .. ... . .. . .. ... .. . .. .. .. . 8-997
Front Side ......................................... 8-764, 8-767
Quarter .. .. .. .. .. .. .. ... . .. . .. . ... ... .. .. . .. ... .. 8-1105, 8-1108
Rear End . ... ... . .. .. .. .. .. .. ... .. .. .. .. . .. .. . .. . .. 8-983, 8-984
Rocker . . .. .. .... .. . .. ... . .. .. . .... ... . .. . .. . .. ... .. . .. . . .. .. . 8-1094
Upper Rear Trim Finish ................................ 8-949
Wheelhouse . .. .. . .. .. .. ... .. .... .. . ... . .. . .. .. .. ... . .. .. .. . . 8-769
Panels, Plastic ................................................ 8-988
Park Brake
Actuator Replacement . . ... .. .. .. . .. .. ... .. .. . .. .. .. .. . . 5-105
Backing Plate Replacement . .. .. .. ... . .. .. . ... .. .. . .. 5-104
Brake Drum Inspection ................................. 5-104
Cable Replacement ............................. 5-97, 5-100
Description
System .. .. .. .. ... . .. . ... .. .. .. .. . ... .. . ... . .. ... .. .. . . ... . . 5-106
Adjuster .......................................... 5-103
Adjuster .. ... .. .. . ... . ... .. ... ... . . .... .. .. . . .. ... 5-104
Lever Replacement ........................................ 5-94
Shoe Adjustment .. . .. .. .. .. ... . ... .. . .. .. .. . .. ... .. .. .. .. . .. 5-93
Shoe Replacement .. . .. .. .. .. . .. . .. ... . ... . .. .. .. .. .. .. .. . 5-92
Special Tools .. . .. .. .. .. .. .. ... .. . .. .. .. .. .. . .. ... .. .. .. . .. . 5-107
Specifications
Park/Turn Signal Lamp Bulb Replacement ....... 8-129
22
Park!Turn Signal Lamps Replacement .... 8-126, 8-128
Pedal Replacement
Plastic Panel Information and Repair
Description
Handling Precautions For Plastic ............. 8-1013
How to Identify Plastic Parts ................... 8-1011
Plastic Identification and Refinishing
Systems ....................................... 8-1011
Plastic Repair Precautions ...................... 8-1013
Plastic Panels .. .. ... .. . .. ... .. . .. .. .. ... .. . .. .. .. .. .. .. .. .. .. . 8-988
Plastic Repair Instructions ............................... 8-988
Plate Replacement
Door Sill ...................................................... 8-943
Power Door Lock Switch
Replacement ........................ 8-799, 8-800
Power Folding Top Bow Replacement ............. 8-837
Power Folding Top Cylinder Replacement ........ 8-836
Power Folding Top Pump with Motor
Replacement . .. . ... .. .. .. .. . ... . .. .. .. ... .. .. . 8-835
Power Folding Top System Check ................... 8-829
Power Mirror Switch Replacement ................... 8-801
Power Mirrors
Diagnosis
Inoperative ................................................ 8-791
One ............................................ 8-792, 8-793
Inoperative in Left and Right Direction ...... 8-796
One ............................................ 8-796, 8-797
Power Steering
Bleeding the System ...................................... 2-25
Checking and Adding Fluid ............................ 2-25
Control Valve Replacement ................... 2-21, 2-22
Cooler Replacement . .. .. . .. ... .. . .. . .. . .. ... ... . ... .... .. 2-36
Cylinder Line Assemblies/0-Ring Seals .......... 2-44
Description
Gear ........................................................... 2-49
Pump ......................................................... 2-49
Seal Replacement Recommendations ......... 2-49
Diagnosis
Excessive Wheel Kickback or
Loose Steering ................................. 2-12
Foaming, Milky-Appearing PS Fluid.
Low in Level .................................... 2-14
Gear and Pump Leaks .. .. .. . .. .. .. . .. .. .. .. .. .. .. . .. .. 2-7
Groan Noise in Steering Pump ................... 2-14
Growl Noise in Steering Pump ................... 2-14
Hissing Noise in Steering Gear .................... 2-6
Increase in Effort While Turning .................. 2-12
Low Oil Pressure Due to
Steering Gear ................................... 2-14
Low Oil Pressure Due to
Steering Pump ................................. 2-14
Poor Return of Steering Wheel ................... 2-12
Rattle Noise in Rack and Pinion ................... 2-7
Rattle or Chuckle Noise In
Steering Gear ................................... 2-11
Seal Replacement Recommendations . .. .. . ... . . 2-9
Steering Effort Hard in Both Directions ....... 2-13
Steering Wheel Kickback ............................ 2-13
System Inspection ........................................ 2-6
System Test ... .. .. .. .. .. . ... .. .. .. .. . ... .. .. . .. .. . .. .. .. . . 2-11
System Test Procedure .............................. 2-10
Too Much Play in Steering ......................... 2-13
INDEX
Power Steering (cont.)
Diagnosis (cont.)
Vehicle Leads to One Side
or the Other ..................................... 2-13
Wander or Poor Steering Stability ............... 2-13
Wheel Surges or Jerks While Turning ........ 2-12
Whine Noise in Steering Pump ................... 2-15
Drive Shaft Seal Replacement ....................... 2-23
Flushing the System ...................................... 2-27
Gear Disassembled View ................................. 2-5
Gear Replacement ................................ 2-37, 2-40
Hoses Replacement ....................................... 2-28
Inner Tie Rod Replacement ........................... 2-42
Pinion Seals and Bearing Annulus
Replacement . .. .. .. .. .. ... .. .. .. .. . ... .. .. .. .. .. 2-46
Pulley Replacement ....................................... 2-17
Pump Front Bracket Replacement .................. 2-24
Pump Rear Bracket Replacement .................. 2-24
Pump Replacement ............................... 2-18, 2-19
Rack and Pinion Boot Replacement ............... 2-33
Rack Bearing Pre load .................................... 2-42
Remote Fluid Reservoir Bracket
Replacement .................................... 2-16
Remote Fluid Reservoir Replacement ............ 2-15
Reservoir Replacement .................................. 2-20
Special Tools ................................................. 2-50
Specifications
Fluid Specifications ....................................... 2-3
Tie Rod End Replacement - Outer ................. 2-30
Unit Repair
Pump Assemble ......................................... 2-23
Power Steering Pump
Disassembled View .. .. .. . .. . .. .. . .. .. .. .. .. ... .. .. .. .. .. .. .. 2-4
Unit Repair
Pump Disassemble ..................................... 2-23
Power Window
Switch Replacement .. .. .. .. .. .. . .. .. .. .. .. .. . 8-798, 8-799
Power Windows
Diagnosis
Inoperative ................................................ 8-786
Express Function ................................... 8-786
From LF Switch .................................... 8-789
From RF Switch .................................... 8-789
Left Front .............................................. 8-787
RF from LF Switch .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . .. 8-788
Right Front ............................................ 8-788
Power Windows Inoperative ...................... 8-786
All ......................................................... 8-786
Powertrain Control Module
Air Conditioning Control Diagnosis (3.8L) ...... 6-1118
Connector End Views (3.8L) ........................ 6-767
Connector End Views (5.7L) ....................... 6-1300
Controlled Air Conditioning
Description (3.8L) ......................... 6-1226
Controlled Warning Lamps
Description (3.8L) ......................... 6-1226
Description (3.8L) ....................................... 6-1221
Description (5.7L) ....................................... 6-1862
Diagnosis (3.8L) ......................................... 6-1113
Replacement/Programming (3.8L) ............... 6-1155
Replacement/Programming (5.7L) ............... 6-1786
Warning Lamps Control Diagnosis (3.8L) .... 6-1114
23
INDEX
PoWertrain Control Module Idle Learn

Procedure (5. 7L) ........................... 6-1789
Programming Additional Keys-Theft
Deterrent .. .. ... .. .. . ... .. .. . .. .. ... .. .. .. . .. ... . 8-593
Programming/Replacement
Powertrain Control Module (3.8L) ............... 6-1155
Powertrain Control Module (5.7L) ............... 6-1786
Programming/Synchronization .......................... 8-556
Keyless Entry Transmitter ............................. 8-556
Propeller Shaft
Description ........... ,. . ... .. .. . ... .. .. .. . .. .. . .. .. .. .. .. .. . .. . 4-20
Center Bearing ........................................... 421
Phasing ...................................................... A-21
Universal Joint ............................................ 4-21
Diagnosis .. ... . ... . .. .. .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 4-4, 4-5
Leak at Front Slip Yoke ............................... 4-5
Noise ........................................................... 4-8
Knock or Clunk Noise ............................... 4-8
Noise ........................................................... 4-8
Ping, Snap, or Click Noise ........................ 4-8
Noise ........................................................... 4-8
Scraping Noise ......................................... 4-8
Roughness or Vibration .. .. .. ... . .. . . .. ... . .. ... . .. ... . 4-6
Shudder on Acceleration at Low Speed ........ 4-9
Propeller Shaft Replacement, On~-Piece ........ 4-10
Propeller Shaft Replacement, Two-Piece ........ 4-12
Special Tools ................................................. 4-22
Specifications
Run out Specifications ................................... 4-3
Universal Joints Replacement ........................ 4-16
Propeller Shaft Balancing Weight Amounts ........ 0-45
Propeller Shaft Runout Specifications ................ 0-45
Proper Use of Torque Wrenches ....................... 0-18
Q
Quarter Panel Replacement .............. 8-1105,
Quick Connect Fitting Service
Metal Collar (3.8L) .....................................
Metal Collar (5.7L) .....................................
Plastic Collar (3.8L) ....................................
Plastic Collar (5.7L) ....................................
81108
6-1175
6-1808
6-1178
6-1811
Radiator
Air Baffle Assemblies and Deflectors
(Engine Cooling) ................. , 6-652, 6-653
Air Deflector Replacement ............................ 8-761
Assembly Description ................................... 6-661
Cleaning (Engine Cooling) ............................ 6-598
Filler/Pressure Cap Assembly Description ..... 6-662
Inlet Hose Replacement
(Engine Cooling) .................. 6-603, 6-606
Outlet Hose Replacement
(Engine Cooling) .................. 6-609, 6-612
Support Replacement (Engine Cooling) ........ 6-631
Radiator Support Description .............. : .......... 8-1112
Radio Replacement .............................. 8-240, 8-242

Radio/Audio
System Check ............................................. 8-217
System Schematic .. . .. .. ... .. .. .. .. .. .. . ... ... . .. ... . .. . 8-196
Rail Replacement
Side ........................................................... 8-1093
Upper ........................................................ 8-1080
Rail Sectioning
Lower ........................................................ 8-1088
Rail Sub-Assembly Replacement Front Lower .................................. 8-1091
Rear Compartment Lamp Replacement . .. ... . . ... 8-153
Rear Compartment Lid Applique
Replacement .. .. ... .. . ... .. . .. .. ... .. .. .. .. .. . 8-967
Rear Compartment Lid Hinge
Replacement ........................ 8-977, 8-978
Rear Compartment Lid Lock Striker
Replacement .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . . 8-982
Rear Compartment Lid Release Inoperative ..... 8-962
Rear Compartment Lid Release
System Check .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . 8-962
Rear Compartment Lid Replacement .... 8-974, 8-975
Rear Compartment Lid Switch Replacement . ... 8-965
Rear Crankshaft Oil Seal
Replacement (5.7L) ........................ 6-357
Rear Drive Axle
Axle Replacement .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 4-54
Axle Shaft Replacement ................................. 4-32
Description
Rear Axle .. ... . .. .. .. .. .. ... .. .. .. .. .. .. .. .. .... .. . . .. .. .. .. 4-60
Diagnosis
General Information .................................... 4-26
Noise Diagnosis ......................................... 4-25
Drive Pinion Installation .................................. 4-55
Lubricant Level Check ................................... 4-28
Oil Deal and/or Bearing Replacement ............ 4-34
Pinion Oil Seal Replacement ......................... 4-36
Rear Cover and Gasket Replacement .. . .. .. .. .. . 4-28
Special Tools .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . 4-63
Specifications
Pinion Bearing and Differential Bearing
Preload ............................................ 4-24
Rear Axle .. .. . .. .. .. .. .. .. .. .. .. .. . .. .. . .. .. . .. .. .. .. .. .. .. . 4-23
Rear Axle Usage .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 4-24
Unit Repair
Backlash Adjustment .. .. .. . .. .. .. .. .. .. ... .. . .. .. .. .. . 4-50
Bearings Inspection .................................... 4-43
Differential Case Assembly .. .. .. .. .. .. .. .. .. .. .. .. . 4-44
Gear Tooth Contact Pattern Check ............. 4-51
Inspection Before Disassembly .. .. .. .. .. .. .. .. .. . 4-39
Pinion and Ring Gear Inspection ................ 4-40
Pinion Depth Adjustment ............................ 4-29
Rear Axle Disassemble .. .. .. .. .. .. .. . .. .. . .. .. .. .. .. 4-28
Side Bearing Preload Adjustment .. .. ... .. .. . .. . 4-48
Rear Drive Axle
Unit Repair
Rear Axle Assemble .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. 4-32
Rear End Panel Replacement .............. 8-983, 8-984
Rear Lift Window
Replacement ................................................ 8-701
24
Rear Quarter
Molding Replacement .. .. .. .. ... .. .. . ... .. .. . ... .. ... .. . 8-654
Rear Suspension .. .. .. .. .. . ... . .. .. ... .. .. .. .. .. .. .. .. ... .. .. .. 3-54
Rear Suspension
Component Locations .. .. .. .. .. ... .. .. .. .. .. .. .. ... .. . .. . 3-44
Special Tools .. .. ... .. .. .. . .. .. ... .. .. .. .. .. .. .. .. .. ... .. .. .. . 3-57
Specifications
Rear Window
Defogger Braided Lead Wire .. .. ... . .. .. .. . .. .. . ... . 8-709
Rearview Mirror
Replacement .. ... . .. .. ... . .. .. .. .. ... ... . .. .. ... .. .. . ... .. .. 8-694
Support Replacement . .. .. .... ... .. .. .. .. ... . .. .. ... .. .. 8-695
Relay
Blower Motor Relay Replacement
(A/C - Manual) ................................. 1-91
Compressor Relay Replacement
(A/C - Manual) . .. .... ... . . ... .. ... .. . .. .. .. .. . . 1-83
Cooling Fan Relay Description ..................... 6-663
Fuel Pump Relay Replacement (5.7L) ........ 6-1841
Horn Relay Replacement .. ... . .. .. .. ... . .. .. . .. . ... . . 8-567
Theft Deterrent Relay Replacement .............. 8-590
Release Actuator Replacement ........................ 8-981
Release Systems
Diagnosis
Rear Compartment Lid Release
System Check ... . .. ... .. .. .. ... . .. .. ... .. .. . . 8-962
Schematics . ... . ... .. .. .. .. .. .. .. ... .... .. . .. .. ... . .... .. . .. . 8-956
Replacement ........................................ 6-684, 6-686
Retained Accessory Power
Component Locations .. .. .. .. ... .. . .. ... .. .. . .. .... . .. .. 8-643
Description
Circuit ....................................................... 8-646
Diagnosis
RAP Inoperative ....................................... 8-645
RAP On After Timeout .... .. .. ... .. .. .. .. . .. ... .. .. . 8-645
System Check .. .. ... . .. . .. ... ... .. . .. ... .. .. .. ..... .. .. 8-644
Schematic
Icons ........................................................ 8-640
References ............................................... 8-640
Schematics . .. ... .. .. .. .. .. .. .. .. .. .... .. .. ... . .. . 8-641. 8-642
Rocker Panel
Molding Replacement ................................... 8-655
Rocker Panel Replacement .... . .. .. .. . ... .. ... ... . .. . 8-1094
Roof
Description
Power Folding Top Circuit ........................ 8-895
Diagnosis
Power Folding Top Does Not Close .......... 8-831
Power Folding Top Does Not Open .......... 8-830
Power Folding Top System Check ............ 8-829
Lift Off Panel Replacement .......................... 8-881
Power Roof Systems Component
Locations . .. .. .. ... . .. ... .. ... . ... . .. .. ..... ... . . 8-827
Power Roof Systems Component Views ... .. .. 8-828
Power Roof Systems Connector
End Views ... .. . .. .. ... .. .. .. .. .. .. .. ... .. .. .. .. 8-829
Schematic
Power Folding Top ................................... 8-826
Power Roof Systems Schematic Icons . .. ... 8-826
Power Roof Systems Schematic
References .. . .. .. ... .. .. .. .. .. .. ... . .. ... .. .. .. 8-825
Specifications
INDEX
Roof Outer Replacement ............................... 8-1105
RPO Code List ................................................. 0-12
s
Scan Tool
Does Not Communicate with Class 2
Data Line ....................................... 8-381
Does Not Communicate with
UART Data Line ............................. 8-379
Inoperative ................................................... 8-379
Schematic
Backup Lights .. .. ... .. .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. ... .. .. 8-41
Exterior Lights .............................. 8-30, 8-35, 8-38
Fog Lights ..................................................... 8-25
Headlight Doors ............................................. 8-28
Headlight Leveling ......................................... 8-29
Headlights - Daytime Running Lamps ... 8-20, 8-24
Instrument Cluster
Analog . .. . .. ... . .. ... .. .. .. .. .. .. .. .. ... .. . .. .. .. .. .. .. ... .. 8-469
Interior Lights ........................................ 8-42, 8-44
Interior Lights Dimming .................................. 8-46
Power Folding Top ....................................... 8-826
Schematics
Audible Warnings .. ... .. .. . .. .. .. .. .. . .. .. .. .. .. .. .. . ... .. 8-493
Steering Wheel/Column - Tilt ...................... 2-55
Body Control Module ......................... 8-426, 8-431
Cruise Control .............................................. 8-602
Defogger .. .. . .. ... . .. ... .. .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. .. .. .. 8-684
Door Locks . ... . .. .. ... .. .. .. .. .. . .. ... . . .. .. .. .. .. .. .. .. .. .. 8-77 4
Engine Controls (3.8L) . .. .. .. . .. ... .. .. .. .. .. .. . .. .... . 6-743
Engine Controls (5.7L) ............................... 6-1263
Fuse Block Details ....................................... 8-318
schematics
Ground Distribution ...................................... 8-330
Schematics
Headlights ... . ... . .. ... .. .. .. .. .. .. .. .. ... ... .. .... .. .. 8-18, 8-19
Horns ........................................................... 8-561
Keyless Entry .. . ..... .. ... .. . .. .. ... .. . ... . ... .. .. .. . .. .. .. . 8-546
Lumbar Support . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... . ... . 8-898
Outside Mirrors .. .... .. . .. .. . . . ... . ... .. .. . .. ... .. . .. .. ... . 8-775
Power Distribution ........................................ 8-314
Power Seats . .. .. .. . . .. ... . .. .. .. .. ... .. .. .. .. . .. ... . .. ... .. 8-897
Power Windows ... . ... .. ... .. .. .. .. ... . .. .. ... . .. .. .. ... .. 8-773
Release Systems .. .. .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. . .... 8-956
Retained Accessory Power .. .. .. .. . ... .. .. 8-641, 8-642
SIR ................................................................ 9-23
Theft Deterrent . .. .. .. .. .. .. .. ... . .. .. ... . .. .. .. .. .. .. .. .. .. 8-570
Seal Replacement
Hood Rear .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... . .. .. .. ... . .. .. ... . . 8-763
Seat Adjuster Mechanism Replacement
Power .. .. ... . .. .. .. .. ... . ... .. . .. .... .. ... .. .. . .. .. .. ... . .. ... . 8-928
Seat Back Latch Replacement
Rear Folding .. . .. ... .. . ... .. .. .. . .. ... .. .. .. .. .. .. .. .. . ... .. 8-936
Seat Back Latch Striker Replacement
Rear Folding ................................................ 8-936
Seat Back Replacement
Rear Split Folding ........................................ 8-934
Seat Belt
Child Seat Restraint System Belt Kit ..... 9-17, 9-18
Seat Belt Buckle Replacement
Left Front ........................................................ 9-5
Right Front ...................................................... 9-8
INDEX
Seat Belt Retractor Replacement

Left Front ................................................. 9-5, 9-7
Rear ..................................................... 9-12, 9-13
Right Front ............................................. 9-9, 9-1 O
Seat Belt Side Buckle Replacement
Rear .............................................................. 9-11
Seat Belts
Description
System Operation . .. .. .. .. .. .. .. ... . ... .. ... ... .. .. . .. .. 9-19
Diagnosis
Seat Belt Service Precautions . .... . .. .. .. .. .. . .. ... 9-4
Emergency Locking Retractor Checks .............. 9-4
Seat Belt Checks .. .. ... .. .. .. .. .. .. .. .. ... .. .. .. .. . .. .. .. .. .. 9-3
Specifications
Seats
Description
Front Seats .............................................. 8-937
Power Lumbar Circuit ............................... 8-938
Power Seat .. .. .. . ... .. .. .. .. .. ... .. . .. ... ... . .. .. .. .. ... 8-938
Systems Circuit Description ................... 8-938
Rear Seats .. .. .. .. .. ... .. .. . .. ... . .. .. .... . ... .. .. .. . .. .. 8-938
Diagnosis
Lumbar Support Does Not Move
Up or Down . .. .. .. .. .. .. .. .. .. ... .. .. . .. .. ... .. 8-906
Lumbar Support Inoperative ...................... 8-906
Lumbar Support Inoperative
in One Direction ............................. 8-907
Lumbar Support System Check .. .. .. ... . .. .. .. 8-902
Power Seat Adjuster Does Not Move
Vertically ......................................... 8-902
Power Seat Does Not Move Forward/
Rearward .. .. ... . .. .. .. .. .. .. .. ... ... . .. .. ... ... . 8-903
Power Seat Does Not Tilt Forward . .. ... .. ... 8-904
Power Seat Does Not Tilt Rearward ......... 8-905
Power Seat Inoperative ............................. 8-903
Power Seat Systems Check .. .. ... . .. ... ... . .. .. 8-902
Headrest Replacement
Front Seat ................................................ 8-930
Lumbar Bladder Replacement ...................... 8-924
Lumbar Motor Replacement ......................... 8-922
Power Recliner Replacement
Front Seat ................................................ 8-917
Power Seat Systems Component Views ....... 8-900
Power Seat Systems Components ............... 8-899
Schematic
Power Seat Systems Schematic Icons ... .. . 8-896
Power Seat Systems Schematic
References ..................................... 8-896
Schematics
Lumbar Support ........................................ 8-898
Power Seats ... . . ... .. .. .. .. .. ... . .. ... . .. ... .. . . ... .. .. . 8-897
Seat Back Hinge/Recliner Mechanism
Replacement
Front ........................................................ 8-916
Seat Back Recliner Mechanism
Replacement
Front ........................................................ 8-921
Seat Back Replacement
Front ........................................................ 8-914
Seat Cushion Cover Replacement
Front ........................................................ 8-913
Seat Cushion Trim Cover and Pad
Replacement .................................. 8-913
25
Seats (cont.)
Seat Replacement
Bucket ........................................... 8-908, 8-909
Front Bucket .................................. 8-910, 8-911
Power with Adjuster ....................... 8-925, 8-926
Shoulder Restraint Guide Replacement
Rear Seat .. .. .. .. . .. .. .. . ... .. .. .. ... .. .. . . ... . 8-934, 8-935
Specifications
Secondary Air Injection
Pump Relay Replacement (5.7L) ................ 6-1854
Pump Replacement (5. 7L) .......................... 6-1850
Solenoid Relay Replacement (5.7L) ............ 6-1854
Secondary Air Injection Bleed Valve
Solenoid Replacement (5.7L) ........ 6-1855
Service Parts ID Label ...................................... 0-12
Shelf Trim Panel Replacement
Rear ............................................................ 8-952
Rear Suspension . . ... .. . ... .. .. .. . .. .. .. . . .. ... .. .. .. . .. .. . 3-51
Shock Absorber Replacement, Front .................. 3-32
Short Trip/City Maintenance Schedule ............... 0-35
Shoulder Belt Replacement
Rear .............................................................. 9-15
Side Marker Lamp Replacement .. ... .. . ... .. .. .. .. .. . 8-151
Side Weatherstrip Retainer Protector
and Seal . ... . .. ... .. .. . ... . .. .. . .. . ... .. . .. . . .. . 8-894
SIR
AIR BAG Warning Lamp Replacement ........... 9-89
Component Views . . . . . . . . .. . . . . . . .. .. .. .. .. . . . . .. . . .. .. . . . . 9-25
Components . .. .. .. .. .. . ... .. .. .. ... .. .. .. ... .. .. ... . .. .. . .. .. 9-24
Connector End Views .. .. .. .. .. .. .. . ... .. .. .. .. .. .. .. . .. . 9-26
Description
Special Tools . . ... . .. .. .. .. .. .. .. .. .. .. ... . .... . .. . .. ... . 9-110
System Component Description and
Definitions . .. . .. ... .. .. . .. .. .. .. .. . .. . . . ... .. .. .. 9-107
System Operation . .. .. .. .. .. . . .. .. .. .. .. .. .. .. .. .. .. .. 9-106
Description (Tilt Column) .............................. 2-11 O
Diagnosis
AIR BAG Warning Lamp Comes
On Steady . ... .. ... . .. .. .. .. .. .. .. ... . .. ... . .. .. .. 9-32
AIR BAG Warning Lamp
Does Not Come On .. .. .. .. .. .. .. .. .. .. .. .. . 9-36
Diagnostic System Check .. .. . .. .. .. .. . .. ... . ... .. . . 9-28
General Diagnosis .. .. .. . . .. .. .. . .. ... .. . .. ... .. .. .. .. .. 9-27
lntennittents and Poor Connections . . .. .. . .. . .. 9-27
SOM Integrity Check .. . . .. . .. .. .. .. .. .. .. .. . . .. . .. . .. . 9-30
Disabling the SIR System .............................. 9-79
Enabling the SIR System ............................... 9-81
General Service Instructions .......................... 9-83
Inflatable Restraint Instrument Panel
lnflator Module Replacement ............ 9-86
Inflatable Restraint Sensing and
Diagnostic Module Replacement . .. . .. . 9-84
Inflatable Restraint Steering Wheel
Module Coil Replacement . .. ... .. . .. .. ... . 9-89
Inflatable Restraint Steering Wheel
Module Replacement . .. .. ... .. .. .. .. .. . .. .. . 9-89
lnflator Module Handling, Shipping, and
Scrapping ......................................... 9-94
Repairs and Inspections Required After
an Accident . . ... .. .. .. .. .. .. .. .. . .. ... .. .. .. .. .. . 9-93
Schematics ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . ... ... . .. .. .. .. .. . 9-23
Icons .......................................................... 9-22
26
SIR (cont.)
Schematics (cont.)
References .. .. ... . .. .. .. .. ... . ... .. .. . ... .. . .. .. ... .. .. .. .. 9-22
Service Precautions .. .. .. .. .. .. .. ... .. . ... . .. .. ... .. .. .. .. 9-79
Special Tools ............................................... 9-111
Specifications
GM SPO Group Numbers ........................... 9-21
Scan Tool Data Definitions ......................... 9-21
Scan Tool Data List ................................... 9-20
Wiring Repair ................................................. 9-89
Solenoid
Brake Transmission Shift Interlock
Solenoid Replacement
Automatic Transmission (4L60-E) .............. 7-245
Control and Shift Solenoids Replacement
Automatic Transmission (4L60-E) .............. 7-284
Torque Converter Clutch PWM Solenoid, TCC
Solenoid, and Wiring Harness
Automatic Transmission (4L60-E) ............. 7-287
Spare Tire Replacement
Compact . ... . .. ... .. .. .. .. .. . .. .. ... .. .. .. .. .. .. .. .. .. .. ... . .. .. 3-63
Spark Plug
Replacement ................................................ 6-715
Visual Diagnosis .......................................... 6-682
Wire Harness Diagnosis ............................... 6-684
Speaker Grille Replacement
Rear ................................................. 8-263, 8-264
Speaker Replacement .......................... 8-257, 8-258
Front
Entertainment ........................................... 8-258
Rear ............................................................. 8-259
Special Tools
Anti lock Brake System ................................. 5-264
Automatic Transmission (4L60-E} . . .. ... . ... ... .. . 7-356
Body Rear End . ... .. .. .. .. .. .. ... .. ... .. .. .. . .. .. .. .. ... .. 8-986
Clutch .......................................................... 7-384
Disc Brakes ................................................... 5-91
Doors ........................................................... 8-824
Engine Cooling ............................................ 6-664
Engine Electrical .......................................... 6-724
Engine Mechanical (3.8L) ............................. 6-226
Entertainment ............................................... 8-281
Front Suspension ........... .; .............................. 3-40
General Information ....................................... 0-32
HVAC - Manual ............................................ 1-128
Instrument Panel, Gauges and Console ....... 8-544
Lighting Systems .......................................... 8-160
Park Brake .................................................. 5-107
Power Steering .............................................. 2-50
Propeller Shaft .. .. .. .. .. .. .. .. .. .. .. .. .. ... . .. .. .. .. ... .. . .. . 4-22
Rear Drive Axle . . ... .. . . .. ... . ... ... . . .... . .. .. . ... ... . .. .. . 4-63
Hear Suspension ........................................... 3-57
SIR .............................................................. 9-111
Stationary Windows ...................................... 8-711
Steering Wheel/Column - Tilt ........................ 2-111
Theft Deterrent . . .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. ... . .. ... 8-600
Vibration Diagnosis . . .. .. .. .. ... .. .. .. . .. .. .. .. ... .. .. .. .. . 0-98
Wipers/Washer Systems ............................... 8-194
INDEX
Special Tools Ordering Information ...................... 0-5
Specifications
Scan Tool Data Definitions
Engine Controls (5. 7L) ............................ 6-1251
Specifications
Approximate Fluid Capacities ......................... 0-33
Battery Temperature vs Voltage Drop ........... 6-666
Battery Usage . .. ... .. . ... . ... . ... . ... .. .. .. .. .. .. .. .. .. .. .. 6665
Body Dimensions ....................................... 8-1023
Brake System
Hydraulic Brakes ........................... ,. . ... . ... .. .. . 5-5
Components
Disc Brakes ................................................ 568
Diagnostic Trouble Code (DTC) Identification
Automatic Transmission (4L60-E) ....... 7-64, 7-67
Drive Belt Tension .......................................... o;.33
DTC List
Engine Controls (3.8L) .............................. 6-736
Engine Controls (5. 7L) ............................ 6-1256
Engine Cooling System
Engine Cooling .............. : ...................... ,... 6-580
Engine Mechanical (3.8L) ............................... 6-14
Fastener Tightening
3.8L ........................................................... 6-13
Anti lock Brake System .............................. 5-108
Automatic Transmission .............................. 7-56
4L60-E . .. .. .. ... .. .. . .. ... . ... .. .. .. .. .. .... .. .. .. .. ... .. . 7-56
Bumpers ................................................... 8-712
Clutch . .. .. ... .. ... ... .. .. ... . .. .. .. .. ... .... .. .. . ... . ... .. .. 7-359
Cruise Control .......................................... 8-601
Disc Brakes ................................................ 5-68
Doors ................................... :. . .. .. .. . ... .. .. .. . 8-771
Engine Control (3.8L) . ... .. .. .. .. .. .. .. .. .. . ... ... . . 6-725
Engine Controls (5.7L) ............................ 6-1247
Engine Cooling . .... .. .. .. .. .. .. ... . .. .. .. .. .. .. .. ... .. . 6-580
Engine Electrical . ... . .. .. .. .. .. .. .. .. ... . ... . .. .. .... .. 6-665
Engine Exhaust .. .. .. .. .. .. .. . ... .. .. .. .. .. . ... . .. ... 6-1900
Entertainment . ... ... .. . .. .. .. .. .. ... . .. .. .. ... .. .. .. .. .. . 8-195
Frame and Underbody ............................ 8-1022
Front Suspension . .. .. .. .. . . .... .. .. .. .. .. .. .... ... ... .. 3-12
Homs ....................................................... 8-560
HVAC - Manual .. .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. . .. .. .. 1-3
Hydraulic Brakes .. .... .. .. .. .. .. .. .. .. .. . .... . .. . ... ... . .. 5-5
Instrument Panel, Gauges and Console ... . 8-467
Interior Trim .............................................. 8-939
Lighting Systems .. ... .. ... .. .. .... .. .. . ... .. .. .... .. .. . . 8-15
Manual Transmission .................................... 7-5
M49 .......................................................... 7-5
MM6 ....................................................... 7-28
Park Brake . .. .. ... .. .. . .. .. ... .. ... .. .. . ... ... .. ... .. .. .. .. 5-92
Power Steering . .. .. .. .. .. .. .. .. ... .. .. .. .. . .. ... . ... .. .. .. . 2-3
Propeller Shaft ............................................. 4-3
Rear Drive Axle .......................................... 4-23
Rear Suspension . .. .. .. .. .. ... . .... . .. .. .. .. .. ... ... .. .. 3-43
Roof ......................................................... 8-825
Seat Belts . .. .. ... .. .. .. .. .. .. .. .. .. ... .. .. . ... . ... .. .. .. .. .. . 9-3
Seats .. .. . .. .. .. ... .. .. .. .. .. .. .. .. .. ... .. .. .. . ... . .. . .. .. .. . 8-896
SIR ............................................................. 9-20
Stationary Windows .................................. 8-683
Steering Wheel/Column - Tilt ...................... 2-51
Theft Deterrent ......................................... 8-569
Ti res and Wheels .. .. .. .. .. . .. ... ... . .. .. .. .. ... . ... . ... 3-58
Wheel Alignment .......................................... 3-7
INDEX
Fastener Tightening (cont.)
Wipers/Washer System ............................. 8-161
Fastener Tightening (5.7L) ........................... 6-229
Body Front End ........................................ 8-734
Fluid Capacity
Automatic Transmission .............................. 7-69
4L60-E .................................................... 7-69
Fluid Specifications
Power Steering ............................................. 2-3
Frame Dimensions ..................................... 8-1032
Fuel System
Generator Usage ... . ... .. .. .. .. .. .. . .. ... .. .. .. .. .. . .. .. 6-666
Engine Cooling ......................................... 6-580
Engine Electrical ....................................... 6-666
Engine Exhaust ...................................... 6-1900
Engine Mechanical (3.8L) ........................... 6-17
Engine Mechanical (5.7L) ......................... 6-234
SIR ............................................................ 9-21
Lubrication
Manual Transmission (M49) .......................... 7-5
Manual Transmission (MM6) ....................... 7-28
Pinion Bearing and Differential Bearing Preload
Rear Drive Axle .......................................... 4-24
Propeller Shaft Balancing Weight Amounts ..... 0-45
Propeller Shaft Runout ................................... 0-45
Range Reference Table
Automatic Transmission (4L60-E) ................ 7-70
Rear Axle Usage .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 4-24
Recommend Fluids and Lubricants ................ 0-33
Refrigerant Oil Distribution
HV AC - Manual .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1-4
Runout Specifications
Propeller Shaft ............................................. 4-3
Scan Tool Data Definitions
SIR ............................................................ 9-21
Scan Tool Data List
SIR ............................................................ 9-20
Scan Tool Data Value Examples
Sealers, Adhesives and Lubricants
Clutch ....................................................... 7-359
Sealers, Adhesives, and Lubricants
Engine Mechanical (3.8L) ........................... 6-18
Shift Solenoid Valve State and Gear Ratio
Shift Speed Table
Starter Motor Usage .................................... 6-666
System Capacities
HVAC - Manual .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 1-3
Temperature vs Resistance
27
Temperature vs Resistance (cont.)
Engine Control (5.7L) .............................. 6-1247
Thread Repair
Tire Inflation Pressure .................................... 0-34
Tires and Wheels ........................................... 3-58
Trim Height
Trim Height Specifications ............................ 3-3
Wheel Alignment .............................................. 3-7
Spoiler Replacement
Rear ................................................. 8-968, 8-969
Spring Insulators Replacement, Rear Coil ......... 3-53
Spring Replacement
Coil
Rear Suspension ........................................ 3-52
Squeaks and Rattles
Description
Noise . .. .. ... .. .. .. .. .. .. .. .. . .. .. . .. .. ... . .. .. ... .. ... .. .. . . 8-682
Diagnosis .. ... .. .. .. .. .. .. .. ... . ... .. .. .. .. . .. .. .. . .. .. .. ... .. 8-667
Stabilizer Shaft
Link Replacement .......................................... 3-16
Stabilizer Shaft Link Replacement ..................... 3-17
Rear Suspension . .. .. . .. ... .. .. .. .. .. .. .. .. .. . . .. ... .. . .. .. 3-50
Rear Suspension ... .. .. .. .. .. .. .. .. ... .. . ... . ... .. .. .. .. .. . 3-49
Stains Removal ............................................... 8-954
Starter
Diagnosis
No Load Test ........................................... 6-675
Solenoid Does Not Click .. .. .. .. .. . ... .. .. . .. . . .. .. 6-672
Starter Motor ........................................ 6-684, 6-686
Shield Replacement ..................................... 6-688
Starter Motor Usage ........................................ 6-666
Starting System
Circuit Description ........................................ 6-720
Starting System Check .................................... 6-671
Stationary Windows
Bus Bar Lead Terminal Repair ..................... 8-709
Component Locations ................................... 8-685
Component Views ........................................ 8-686
Description
Adhesive Service Kit Description ............... 8-71 O
Extended Method Description ................... 8-710
General .................................................... 8-710
Rear Window Defogger ............................. 8-710
Rear Window Defogger Circuit .................. 8-711
Rear Window Defogger Operation ............. 8-711
Reveal Molding ......................................... 8-71 O
Short Method Description .......................... 8-710
Diagnosis
Defogger Always On - Rear .. .. .. .. .. .. .. .. .. .. . 8-688
Defogger Grid Lines ................................. 8-690
Defogger Indicator Always On . .. .. .. ... .. . .. .. . 8-690
Defogger Indicator Inoperative .................. 8-690
Defogger Inoperative - Rear ..................... 8-689
Defogger System Check . .. . .. .. .. .. .. .. .. .. .. . .. .. 8-688
Grid Line Repair .......................................... 8-707
Schematic
Icons ........................................................ 8-683
References . .. .. .. . ... .. .. .. .. ... .. . .. .. .. .. .. . ... .. .. .. .. 8-683
28
Stationary Windows (cont.)
Schematics
Defogger .................................................. 8-684
Special Tools ............................................... 8-711
Specifications
Window Cleaning ......................................... 8-707
Window Polishing ......................................... 8-706
Steering Column
Overhaul
Turn Signal Cancel Cam, Upper
Bearing Inner Race Assemble .......... 2-96
Steering Knuckle Replacement .......................... 3-22
Steering Wheel Control Schematic .. .. ... . ... .. .. .. . 8-204
Replacement .. .. .. .. .. .. .. .. ... . .. .. .. .. ... .. . 8-251
Steering Wheel Control System Check ............ 8-218
Steering Wheel/Column - Tilt
Component Locations .. .. .. . ... .. .. .. .. .. . .. ... .. .. .. ... . 2-56
Component Views .. . .. .. ... . ... .. .. .. .. .. .. .. . ... .. ... .. .. . 2-57
Description
Auto Trans Shift Lock Control ................... 2-110
Auto Trans Shift Lock Control Circuit ........ 2-110
Ignition Lock System ................................ 2-110
Steering Wheel and Column ..................... 2-109
Supplemental Inflatable Restraint .............. 2-110
Diagnosis
Auto Trans Shift Lock Control Always
On With Ignition in RUN ................... 2-60
Inoperative ....................................... 2-59
Auto Trans Shift Lock Control System ........ 2-62
Auto Trans Shift Lock Control System
Check .............................................. 2-58
Hazard Switch Does Not Stay On
Wheel/Column .................................. 2-65
Hazard Warning Cannot Be Turned Off ...... 2-64
High Lock Effort ......................................... 2-61
High Lock Effort Between the Off Lock
Positions .......................................... 2-61
High Steering Shaft Effort ........................... 2-62
Housing Scraping Bowl ............................... 2-62
Ignition Switch Cannot Be Set Correctly ..... 2-65
Ignition Switch Does Not Tum .................... 2-65
Ignition Switch Electrical System Does
Not Operate . .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. .. . 2-65
Key Cannot Be Removed in the Off
Lock Position .................................... 2-61
Lash In Steering Column ............................ 2-62
Lock Cylinder Can Be Removed
Without Depressing Retainer ............ 2-61
Lock System Does Not Lock .. .. .. .. .. .. ... .. .. .. . 2-60
Lock System Does Not Unlock ................... 2-60
Loose Steering Wheel ................................ 2-63
Loose Steering Wheel (Every Other Tilt
Position) ........................................... 2-63
Noise in Steering Column ........................... 2-62
Noise When Tilting Steering Column .......... 2-63
Steering Wheel Does Not Lock in Any
Tilt Position ...................................... 2-63
Steering Wheel Not Returning to Top
Tilt Position ...................................... 2-63
Turn Signal Difficult to Operate ................... 2-64
INDEX
Steering Wheel/Column - Tilt (cont.)
Diagnosis (cont.)
Turn Signal Does Not Cancel ..................... 2-64
Turn Signal Does Not Indicate Lane
Change ... .. .. .. . ... .. .. .. .. .. ... . .. ... . .. .. ... .. .. 2-63
Turn Signal Does Not Stay in Turn
Position ... .. .. . .. ... .. .. .. .. .. ... .. . ... . .. ... . ... .. 2-64
Flexible Coupling Replacement ...................... 2-75
Hazard Warning Switch Replacement ............. 2-69
Horn Switch Replacement . .. .. ... .. . ... .. .. .. .. .. .. .. .. 2-72
Ignition Switch Replacement . ... .. .. .. .. .. .. . .. .. ... .. 2-66
lnflator Module Replacement .......................... 2-70
Replacement .. .. .. ... .. .. .. . .. ... .. .. .. .. .. ... . ... . ... . .. ... .. 2-77
Schematic
Icons .......................................................... 2-54
References . .. .. ... .. .. .. . .. ... .. .. .. .. .... . .. .. . .. ... .. .. .. 2-54
Special Tools .. . .. ... .. .. .. .. ... .. . ... .. .. .. .. .. ... . .. .. .. .. 2-111
Specifications
Replacement .. . .. ... .. . .... .. .. .. .. .. . ... .. .. . .. 2-73
Steering Wheel Replacement . ... . .. .. ... .. . .. .. . .. .. . 2-74
Tilt Lever Replacement .. . ... . .. ... ... .. .. .. . .. ... . ... . .. 2-69
Assembly - Disassemble ................... 2-88
Turn Signal Multifunction Signal Lever
Replacement . .. .. .. .. .. ... .. .. .. .. .. .. .. ... . ... . 2-68
Unit Repair
Dimmer Switch Assembly - Assemble ... . .. .. . 2-92
Dimmer Switch Assembly Disassemble .. ... . .. .. .. .... .. . .. .. .. .. .. ... .. .. . 2-92
Disassembly/Assembly ................................ 2-79
Housing - Assemble ................................... 2-98
Ignition and Key Alarm Switch
Assembly ......................................... 2-81
Ignition Switch Assembly - Assemble .......... 2-91
Ignition Switch Assembly - Disassemble ..... 2-91
Lock Cylinder Set - Assemble .. . ... .. . .. . .. . .. .. . 2-95
Lock Cylinder Set - Disassemble . .. .. .. .. . ... .. . 2-95
Lock Housing Assembly - Assemble ......... 2-101
Lock Housing Assembly - Disassemble ... .. 2-100
Pivot and Pulse Switch Assembly Assemble .. .. .. .. ... .. .. . .... .. . ... . .. .. ... . ... .. . 2-94
Pivot and Pulse Switch Assembly Disassemble .. .. .. .. .. ... .. .. ... . .. ... .. . .. ... .. . 2-93
Steering Column Accident Damage .. .. .. .. . .. 2-107
Steering Shaft, Lower Bearing, JacketAssemble . . ... . ... . ... .. .. .. .. .. ... . .. .. .. .. ... . 2-105
Steering Shaft, Lower Bearing, JacketDisassemble . . .. .. ... .. .. .. ... .. .. .. . .. .. ... .. . 2-103
Tilt Spring - Assemble . .. .. .. ... .. .. .. .. .. .. .. .. .. ... . 2-87
Tilt Spring - Disassemble . .. .. . .. .. .. .. .. .. .. .. .. .. .. 2-85
Turn Signal and Multifun'ction Switch
Assembly - Assemble . .. .. .. .. .. .. .. .. ... .. . 2-89
Turn Signal Cancel Cam, Upper
Bearing Inner Race Disassemble ...... 2-95
Disassembled View ... .. .. .. .. ... .. .. .. .. .. .. .. .. ... . .. 2-52
Steering Wheel/Column Tilt
Unit Repair
Housing - Disassemble .. .. .. ... .. .. .. .. .. .. .. .. .. ... . 2-97
Stop Lamp Bulb Replacement
High Mounted ................................... 8-143, 8-145
29
INDEX
Stoplamp Switch
Adjustment . .. .. .. .. .. .. .. ... . .. ... .. .. . .. .. ... .. .. .. . .. ... . .. .. 5-63
Replacement .................................................. 5-61
Strategy Based Diagnosis ................................. 0-31
Striker Replacement
Rear Compartment Lid Lock . .. .. .. . . ... .. . .. .. .. .. . 8-982
Struts or Shock Absorbers
Diagnosis
Leak ............................................................. 3-5
Noisy ........................................................... 3-5
Weak ........................................................... 3-5
Sunshade Panel Replacement ......................... 8-880
Suspension
Description
General ........................................................ 3-6
Diagnosis
Abnormal or Excessive Tire Wear ................ 3-4
Low or Uneven Trim Height ......................... 3-6
Struts or Shack Absorbers Weak .................. 3-5
Struts or Shock Absorbers Leak ................... 3-5
Struts or Shock Absorbers Noisy .................. 3-5
Vehicle Leads/Pulls ...................................... 3-3
Front
Description . .. .. .. .. .. ... . .. ... .. .. . .. .. ... .. .. .. . .. .. .. .. .. 3-39
General . .. .. .. .. .. .. .. ... .. .. .. .. . .. .. ... .. .. .. . .. ... . .. .. 3-39
Rear
Component Locations .. .. .. . ... .. .. .. .. ... . .. .. .. . .. .. 3-44
Description . .. .. .. .. .. .. ... . ... .. . .. ... . .. . .. ... .. .. .. .. .. .. 3-56
General . .. .. .. .. .. .. .. .. .. .... .. .. .. .. .. . .. .. .. . .. ... . .. .. 3-56
Switch
Clutch Anticipate Switch Replacement .......... 7-375
Clutch Pedal Position Switch
Replacement .................................. 7-376
Cruise Release Switch Adjustment ............... 8-635
Cruise Release Switch Replacement ............ 8-634
Fog Lamp Switch Replacement ......... 8-133, 8-134
Hazard Warning Switch Replacement
(Tilt Column) ..................................... 2-69
Headlamp Switch Replacement .................... 8-131
Horn Switch Replacement (Tilt Column) ......... 2-72
Ignition and Key Alarm Switch Assembly
(Tilt Column) ..................................... 2-81
Ignition Switch Replacement (Tilt Column) ...... 2-66
IP Compartment Lamp Switch
Replacement . . .. ... . .. .. .. ... . . .. ... . .. .. .. .. . 8-526
Park/Neutral Position Switch Replacement
Automatic Transmission - 4L60-E ............. 7-253
Power Door Lock Switch
Replacement ........................ 8-799, 8-800
Power Mirror Switch Replacement ................ 8-801
Power Window Switch Replacement ... 8-798, 8-799
Rear Compartment Lid Switch
Replacement .. .. ... . .. .. .. .. ... .. .. . ... . .. .. .. 8-965
Replacement (Tilt Column) ................ 2-73
Replacement .. .. .. .. .. .. .. .. ... . .. ... .. . ... . .. 8-251
Stoplamp Switch Adjustment .......................... 5-63
Stoplamp Switch Replacement . .. ... ... . .. . .. .... ... . 5-61
Valve Body and Pressure Switch
Replacement
Automatic Transmission - 4L60-E ............. 7-278
Switches
Traction Control Switch Replacement ........... 5-260
T
Tail Lamp Replacement ........................ 8-149,
Temperature Control Cable Adjustment
(A/C - Manual) ... ... ... . .. .. .. ... . .. ... .. . .. .
Temperature Sensor Description-Engine
Coolant .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. . .. .. ...
Tensioner, Drive Belt,
Replacement (5.7L) .............. 6-272,
Theft Deterrent
Diagnosis
System Feature Customization
Inoperative ......................................
Theft Deterrent
Component Locations .. .. .. ... .. . .. .. .. .. ... .. . .. .. .. ...
Component Views ... .. .. .. .. .. .. .. .. .. .. .. ... .. ... .. .. .. .
Connector End Views ...................................
Description
Content Theft Deterrent . .. .. .. .. ... . ... . .. .. ... .. . .
Content Theft Deterrent Circuit .................
Content Theft Deterrent Operation .. .. .. .. .. ..
Vehicle Theft Deterrent .............................
Vehicle Theft Deterrent Circuit ..................
Vehicle Theft Deterrent Operation .............
Diagnosis
Content Theft Deterrent Alarm Mode
Always On ... . ... .. .. .. .. .. .. .. . ... .. .. .. .. ... ..
Content Theft Deterrent Alarm Mode
Inoperative ......................................
Horn Inoperative in CDT Alarm Mode .......
Ignition Lock Cylinder Test .......................
lntermittents and Poor Connections ..........
Lights Inoperative in CDT Alarm Mode .....
SECURITY Indicator Inoperative ...............
SECURITY Indicator Off,
Engine Cranks ................................
SECURITY Indicator Off, Engine Does
Not Crank .. . .. .. .... .. ... . .. .... .. ... .. .. .. .. .. .
SECURITY Indicator On Engine Starts .....
Shock Sensor Inoperative .........................
System Check ..........................................
Content ... .. . .. .. .. ... .. .. .. .. .. .. .. .. ... ... ... .. ... .. ..
Vehicle ..................................................
Feature Customization .................................
Ignition Lock Cylinder Replacement ..............
Pass Key Programming ...............................
Programming Additional Keys .......................
Programming Replacement Keys, Ignition
Cylinder, or Powertrain Control
Module .. .. .. . .. .. ... .. . .. .. .. .. .. . .. .. .. .. ... .. ..
Relay Replacement .. .. .. .. . ... .. ... .. .. ... .. .. .. .. .. .. ..
Schematic
Icons ........................................................
References ...............................................
Schematics .. . .. .. .. .. .. ... . .. .. .. ... .. . .. .. .. ... .. .. .. ... . ..
Shock Sensor Replacement . ... .... .. .. .. . .. .. ... . ..
Special Tools ...............................................
Specifications
Thermostat
Description .. .. .. .. . .. .. .. .. ... .. .. .. .. .. .. .. . ... .. ... . .. .. .. .
Housing Replacement
(Engine Cooling) .................. 6-623,
Replacement (Engine Cooling) .......... 6-627,
8-150
1-104
6-663
6-273
8-587
8-57 4
8-576
8-577
8-596
8-598
8-596
8-598
8-600
8-598
8-585
8-585
8-586
8-581
8-577
8-586
8-584
8-582
8-582
8-584
8-587
8-578
8-578
8-580
8-594
8-591
8-587
8-593
8-594
8-590
8-569
8-569
8-570
8-592
8-600
8-569
6-663
6-625
6-629
IND.EX
30
Thread Inserts ................................................... 0-17
Throttle Body
Assembly Replacement (5.7L} .................... 6-1804
Coolant System Description .. .. .. . . .. .. .. .. .. .. . .. .. 6,-660
Throttle Body Air Inlet Screen
Replacement (3.8L} ....................... 6-1174
Throttle Body Assembly Replacement (3.8L) .... 6-1171
Throttle Body Heater
Inlet Hose Replacement (Engine Cooling) .... 6-614
Outlet Hose Replacement
(Engine Cooling) ............................. 6-615
Replacement (3.8L) ....................... 6-1163
Replacement (5. 7L) ....................... 6-1800
Thrust Angle Adjustment, Rear ............................ 3-9
Tire
Chain Usage Description ............................... 3-67
Description .. .. .. .. .. ... . ... . ... . ... ... .. .. . .. .. .. .. .. ... .. .. .. . 3-66
Mounting and Dismounting ............................. 3-64
Placard Description ........................................ 3-68
Replacement
Compact Spare .......................... , .. .. .. .. . . .. . . . 3-63
Rotation ,......... :.. ............................................ 3-65
Tire and Wheel Balancing ................................. 0-66
Tire Inflation Pressure Specifications ................. 0-34
Tire Placard ........................................................ 0-7
Tire Repair ........................................................ 3-63
TiteWear
Abnormal or Excessive . .. .. . .. .. .. .. .. .. .. .. . .. .. .. . .. .. .. 3-4
Tires and Wheels
Description ..................................................... 3-66
Chain Usage .............................................. 3-67
P-Metric Sized Tires ................................... 3-67
Tire Placard ................................................ 3-68
Wheels .. .. . .. .. ... .. .. .. .. .. .. ... .. .. .. . .. ... .. . . .. .. . . .. .. .. 3-68
Diagnosis
Wheel Mounting Surface Checl< . .. . .. .. ... ... . .. . 3-59
Specifications .. . .... . . .. . .. .. ... .. .. .. .. .. .. .. .. .. .. .. . .. .. . .. 3-58
Wheel Installation ........................................... 3-62
Wheel Removal . .. .. .. . .. ... .. .. .. .. .. ... . .. .. .. .. ... .. .. . .. 3-61
Toe Adjustment, Front . .. .. .. . .. .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. . 3-9
Rear Suspension . .. .. . .. ... .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. . 3-47
Torque Wrenches
Proper Use . .. .. .. ... .. .. .. . .. .. ... .. .. .. .. .. .. ... . .. ... .. .. .. . 0-18
Tow Hook Replacement .................... 8-1074, 8-1076
Track Bar Replacement ......... ,........................... 3-54
Traction Control Switch Replacement .............. 5-260
Transmission Floor Shift Control Indicator '
Lamp Replacement ......................... 8-142
Transmission ID and Partial VIN Location ......... 0-10
Transmission (MM6)
Support and Mount Assembly (MM6} ............. 7-34
Transmission Support Replacement .....'.......... 8-1065
Transmission Usage .......................................... 0-11
Transmitter
Battery Replacement
Keyless Entry .. . ... .. .. .. . .. ... . . .. .. .. .. .. .. .. .. ... ... . 8-555
Trim Cleaning
Fabric .......................................................... 8-954
trim Cleaning
. Vinyl .. ... .. . .. .. .. ... . ... .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. .. ..
Trim Panel Carper Replacement
Rear Center ...................................... 8-945,
Trim Panel Opening Cover Replacement .........
Cargo Area Side .........................................
IP Accessory ..................................... 8-506,
Liftgate . .. .. .. .. .. .. .. ... .. . ... .. .. .. . .. .... . .. .. .. .. .. .. .. ... .
Shelf
Rear . . .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. . . .. .. ... . .. .. ... .. .
Cargo Area Front .............................. 8-940,
Trim Replacement
Hinge Pillar ..................................................
Turn Signal
. Flasher Replacement .. .. .. .. .. .. ... . ... . ... . .. .. ... .. ..
8-953
8-946
&966
8-942
8-508
8-965
8-952
8-941
8-939
8-138
u
Underbody Inspection ........................'. ........... 8-1077
Upper Garnish Molding Replacement ............... 8-948
Upper Rear Trim Finish Panel Replacement ....... 8-949
v
Vacuum Brake Booster
Check Valve Replacement .. ... ... . .. .. ... .. . .. .... . . .. 5-60
Replacement . .. .. .. ... .. .. . .. .. ... . ... .. .. .. .. .. .. .. .. .. ... .. . 5-57
Vacuum Hose Harness Replacement
(A/C - Manual) ...... : .............. 1-113, 1-114
Vacuum Tank Replacement (A/C - Manual) ..... 1-112
Vapor Vent Pipe
Clean and Inspect (5.7L) , ............................. 6-514
Vapor Vent Pipe Replacement (5.7L) ............... 6-296
Vehicle Certification Label ................................... 0-6
Vehicle Identification ............................................ 0-5
Vehicle Speed Sensor
Manual Transmission - M49 ........................... 7-17
Vehicle Speed Sensor Replacement
Automatic Transmission - 4L60-E ................. 7-299
Manual Transmission (MM6) .......................... 7-43
Vent Actuator Replacement (A/C - Manual) ..... 1-106
Vibration Diagnosis
Balancing Tires and Wheels .......... ,................ Q-66
Classifying the Vibration . .. .. .. . .... .. . . .. .. .. . .. .. .... . . 0-49
Correcting Driveline Vibration RWD and 4WD ................................ 0-71
Correcting Non-Uniform Tires ........................ 0-70
Correcting Tire and Wheel Vibration . .. .. .. . .... .. . 0-62
Driveline Vibration Analysis .......... , ................. 0-53
Engine Related Vibration .... ,. . ... .. .. .. .. . .. ... . .. ... .. 0-58
General Description ..................................... 0-87
General Service Precautions ........ ,................. 0-62
Road Test .......................................... , ........... 0-47
Special Tools .......................... :...................... 0-98
Tire and Wheel Vibration ............................... 0-52
Vibration Diagnosis . .. .. .. ... .. .. . .. ... ... . . .. .. ... . .. .. . .. 0-45
Wheel Runout Measurement . ... .. .. .. .. .. .. .. . .. .... . 0-52
VIN Derivative ..................................................... 0-6
VIN, Partial, Location and Engine ID ................... 0-8
31
INDEX
w
Washer
Pump Replacement ...................................... 8-178
Solvent Container Replacement .. .. . ... .. . .. .. .. .. 8-176
Water Pump
Clean and Inspect ........................................ 6-514
Description . .. .. .. .. .. .. ... . .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. . . 6-663
Replacement (Engine Cooling) .......... 6-634, 6-636
Waterleaks
Body Waterleak Repair ................................ 8-662
Diagnosis
Air Hose Test ........................................... 8-660
Body Waterleak Repair ............................. 8-658
Dust Leaks ............................................... 8-661
Generalized Testing .................................. 8-659
Localized Testing (Spot Testing) ............... 8-659
Test Preparation .. ... .. .. . ... . ... . .. ... .. .. .. .. .. . ... . . 8-658
Water Hose Test : 8-660
Specifications
Recommended Materials ........................... 8-658
Stationary Window Waterleak Repair ............ 8-664
Weatherstrip Waterleak Repair ..................... 8-663
Weatherstrip Replacement
Door ............................................................ 8-820
Folding Top Side Rear ................................. 8-888
Front ............................................................ 8-890
Lift Off Panel . .. .. .. .. ... .. .. .. . .. ... .. . .. ... . .. . .. .. .. . .. .. 8-893
Rear Lift Window Panel Opening ................. 8-985
Weatherstrip Retainer Protector and Seal
Side ............................................................. 8-894
Weatherstrip Retainer Replacement
Folding Top .................................................. 8-887
Lift Off Panel .. ... . .. ... .. . .. .. .. .. ... . .. .. .. . ... .. .. . .. .. .. 8-894
Wheel
Installation
Tires and Wheels ....................................... 3-62
Removal
Tires and Wheels ....................................... 3-61
Wheel Alignment
Description
Camber . . .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. ... .. .. .. . .. .. ... .. . 3-10
Caster ........................................................ 3-10
Toe ............................................................ 3-11
Diagnosis
Preliminary Alignment Inspection .................. 3-7
Front Caster and Camber Adjustment .............. 3-8
Front Toe Adjustment ....................................... 3-9
Measuring ........................................................ 3-8
Rear Thrust Angle Adjustment .......................... 3-9
Specifications . .. ... . .. ... .. .. .. .. . ... .. .. .. .. .. .. ... .. . .. . ... ... 3-7
Wheel Bearing/Hub Replacement - Front ........... 3-21
Wheel Hub Bolt Replacement ............................ 3-15
Wheelhouse
Panel Replacement . ... .. .. . ... .. . .. .. .. . .. .. .. .. .. .. .. .. 8-769
Wheelhouse Replacement
Front . .. ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. 8-1083, 8-1086
Rear .. .. .. .. .. .. .. .. .. . .. . .. .. .. .. .. .. .. .. . ... ... .. .. .. . .. ... . 8-1110
Wheels
Description . .. .. .. .. . ... . ... .. . ... .. .. .. . .. .... . .. .. .. .. .. .. .. .. 3-68
Wind noise
Exterior ... . .. .. .. .. .. .. .. .. ... . .. .. .. .. .. .. .. ... .. . ... .. . .. .. .. 8-666
Interior ......................................................... 8-666
Window Regulator Motor Replacement

Door ............................................................
Window Regulator Replacement ......................
Window Replacement
Door ............................................................
Windows
Diagnosis
Power Windows Inoperative ......................
All .........................................................
Express Function ...................................
From LF Switch ....................................
From RF Switch ....................................
Left Front ..............................................
RF from LF Switch ................................
Right Front ............................................
Power Window Switch
Replacement ........................ 8-798,
Windshield
Reveal Molding Replacement .......................
Side Garnish Molding
Replacement . .. . ... . .. ... . ... . .. ... . 8-692,
Windshield Glass Cleaning ..............................
Windshield Pillar Garnish Molding
Replacement ..................................
Windshield Replacement .................................
Wiper .. . .. ... .. .. .. .. .. .. . ... .. .. .. .. .. .. ... . .. . ... . .. .. . .. .. . ... ..
Arm Replacement ... . .. .. .. .. ... . ... . . .. . . .. .. .. . .. . .... .
Blade Element Replacement ........................
Chatter Repair .............................................
Motor Cover Replacement ............................
Motor Replacement ......................................
Transmission Replacement ...........................
Wiper Blade Element Cleaning . .. ... ... ... .. . .... .. ...
Wipers/Washer Systems
Component Locations . . .. .. .. ... .. .. . ... ... . .. .. .. .. .. ..
Component Views .. .. .. . .. . .. .. .. .. ... .. .. ... .. .. . ... . .. .
Connector End Views . ... . .. ... .. .. .. . .. .. .. .. ... . ... .. .
Description
System Operation . .. ... . .. ... .. .. .. . ... ... ... .. .. .. .. .
Windshield Wipers/Washer System . .. .. . .. .. .
Diagnosis
System Check .. ... . .. ... .. . ... .. . .. .. .. ... .. .. . ... . .. ..
Washer Always On . ... .. .. .. . ... . .. .. ... .. .. .. .. .. .. .
Washer Pump Inoperative .........................
Wiper Always On ......................................
Wiper Arm Tip Pressure Check, Blade
Element Check . .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .
Wiper Blades Do Not Park with
Switch Off . . .. .. ... .. . .. .. .. .. .. . ... .. .. .. .. . ... .
Wipers Delay Mode Inoperative ................
Wipers High Mode Inoperative,
Low Mode Operates .. .. ... .. . .. .. .. ... . ...
Wipers Inoperative ....................................
All Modes .. .. . .. .. .. .. ... . .. .. .. .. ... . . ... .. ... . .. .. . ..
Wipers Mist, Delay, and Low Modes
Inoperative ......................................
Schematic
Icons ........................................................
References . .. .. . ... . .. .. ... .. . .. .. .. .. .. .. .. .. .. .. .. .. .. .
Schematics Pulse .. .. . .. ... .. .. .. . .. .. .. .. ... .. . .. .. .. .. .
Special Tools ...............................................
Specifications
8-816
8-815
8-817
8-786
8-786
8-786
8-789
8-789
8-787
8-788
8-788
8-799
8-691
8-693
8-193
8-947
8-697
8-180
8-179
8-181
8-193
8-182
8-183
8-188
8-193
8-163
8-164
8-166
8-194
8-193
8-167
8-174
8-173
8-171
8-175
8-172
8-168
8-169
8-167
8-167
8-170
8-161
8-161
8-162
8-194
8-161
INDEX
32
Wiring System
Electrical Center Identification ......................
Wiring Systems
Description
Data Link Connector Circuit ......................
Harness Routing Views .............................
lnline Harness Connector End Views ........
Diagnosis .....................................................
Checking Aftermarket Accessories ............
Circuit Protection ......................................
Circuit Breakers .....................................
Fuses ....................................................
Fusible Links .........................................
Connector Position Assurance Locks ........
Connector Repairs ....................................
Data Link Connector (DLC) System
Check . ... .. .. .. .. .. . .. .. ... .. . ... . .. ... . .. .. .. .. ..
Electrical Symbols ....................................
Flat Wire Repairs .....................................
General Electrical Diagnosis Procedures .....
H02S Wiring Repairs ...............................
How to Use Circuit Descriptions ...............
How to Use Component Location
Tables ............................................
How to Use Component Location Views ......
How to Use Connector End Views ............
How to Use Diagnostic System Checks ....
How to Use Electrical Diagnosis . .. .. .. .. .. .. ..
How to Use Electrical Schematics .. ... . ... .. .
How to Use Schematic Icon Tables ..........
How to Use Schematic Reference
Tables ............................................
lntermittents and Poor Connections ..........
Passenger Car Zoning ..............................
Probing Electrical Connectors ...................
Pull to Seat Connectors ............................
Push to Seat Connectors ..........................
Repairing Connector Terminals .................
Repairing Damaged Wire Insulation ..........
Scan Tool Does Not Communicate with
Class 2 Data Line ..........................
8-369
8-382
8-401
8-383
8-289
8-298
8-302
8-302
8-301
8-302
8-310
8-310
8-378
8-291
8-309
8-296
8-307
8-290
8-287
8-288
8-289
8-289
8-285
8-286
8-287
8-287
8-297
8-291
8-299
8-311
8-310
8-312
8-302
8-381
Wiring Systems (cont.)

Diagnosis (cont.)
Scan Tool Does Not Communicate with
UART Data Line ............................. 8-379
Scan Tool Inoperative ............................... 8-379
SIR Wiring Repairs ................................... 8-307
Splicing Copper Wire Using Splice Clips ..... 8-302
Splicing Copper Wire Using Splice
Sleeves .. ... .. .. .. .. . ... .. . ... .. .. . ... .. .. .. . ... . 8-304
Splicing lnline Harness Diodes .................. 8-306
Splicing Twisted or Shielded Cable .. .. .. .. ... 8-305
Symptom Diagnostic Example .. .. .. .. . ... .. .. .. . 8-296
Terminal Position Assurance Locks ........... 8-310
Testing for Continuity ................................ 8-300
Testing for Electrical lntermittents ............. 8-301
Testing for Short to Ground ...................... 8-300
Testing for Voltage ................................... 8-299
Testing for Voltage Drop ........................... 8-300
Troubleshooting with a Digital
Multimeter ....................................... 8-298
Troubleshooting with a Short Finder ......... 8-299
Troubleshooting with a Test Light ............. 8-298
Using Connector Test Adapters ................ 8-299
Using Fused Jumper Wires ....................... 8-299
Weather Pack Connectors ........................ 8-311
Where to Find Electrical Schematics ......... 8-282
Wiring Repairs .......................................... 8-301
Power and Grounding Component Views ..... 8-367
Power and Grounding Components .............. 8-344
Power and Grounding Connector
End Views ...................................... 8-375
Schematics
Data Link Connector (DLC) Schematics ...... 8-376
Fuse Block Details .................................... 8-318
Ground Distribution ................................... 8-330
Power and Grounding Schematic Icons .... 8-313
Power and Grounding Schematic
References ..................................... 8-313
Power Distribution ..................................... 8-314
Work Sheets, Diagnostic .. .. .. ... .. . ... .. . ... . .. ... . .. .. ... .. 0-5

1998 Chevrolet Camaro &amp; Pontiac Firebird Service Manual Volume 2

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1998 Chevrolet Camaro &amp; Pontiac Firebird Service Manual Volume 2

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1998 Chevrolet Camaro

and Pontiac Firebird

Cautions and Notices

Cautions and Notices

General Information ....................................... 0-1

Steering ............................................................ 2-1

General Information ......................................... 0-3

Power Steering System .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 2-3

HVAC ................................................................ 1-1

.. .. .. .. .. .. .. .. .. .. .. .. ... ... .. .. 1-3

Body and Accessories .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 8-1

Restraints ......................................................... 9-1

INDEX ....................................................... .INDEX-1

Driveline/Axle .................................................. 4-1

Brakes .............................................................. 5-1

INDEX ........................................................ INDEX-1

Engine .............................................................. 6-1

Mechanical - 3.8L ............. ,................ 6-13

Transmission/Transaxle .. .. ... .... ... ...... ... .... .. .. . 7-1

Table of Contents 2-1

Power Steering Pump Flow Control Valve

Steering Wheel and Column - Tilt ............... 2-51

2-2 Table of Contents

Power Steering System

Power Steering System

Power Steering Gear Bolt/Screw

Power Steering Gear Inlet Hose Fitting-to-Power Steering Gear

Power Steering Gear Inlet Hose Fitting-to-Power Steering Pump

Power Steering Gear Outlet Hose Fitting-to-Power Steering Gear

Power Steering Fluid Reservoir Bracket Bolt/Screw (3800 VINK)

Power Steering Pump Bolt/Screw (5.7L VIN G)

Power Steering Pump Nut (3800 VIN K)

Power Steering Pump Rear Bracket Bolt/Screw (5.7L VIN G)

Power Steering Fluid

Cold Climate (see note)

Power Steering Fluid

2-4 Power Steering System

Power Steering Pump

(4) 0-ring Seal

Power Steering System

Power Steering Gear - Disassembled View

Cylinder Line (Left Hand) Assembly

Power Steering System

Rack and Pinion Boot

Diagnostic Information and Procedures

Important: Test the power steering system using the

11. The power steering pump control valve is sticking

14. If the pressure readings are within specifications,

19. Bleed the power steering system. Refer to

Power Steering System

Hissing Noise In Steering Gear

Inspect for loose intermediate steering shaft universal joints.

Rattle in Rack and Pinion

A rattling noise occurs when driving

Inspect the front brake linings for the following conditions:

Power Steering Gear and Pump Le~ks

- Fluid leaks are visible on the steering

External Leakage Check

3. On vehicles with a 3800 engine, inspect the fluid

Power Steering System

14. Torque the steering gear pipe fitting seat to

4. On vehicles with a 5.7L engine, inspect the fluid

15. Replace the gear with a partial steering gear.

Power Steering System

1998 Chevrolet Camaro & Pontiac Firebird Service Manual Volume 2

1998 Chevrolet Camaro & Pontiac Firebird Service Manual Volume 2