1996 Chevrolet Camaro & Pontiac Firebird Service Manual Volume 1

1996 CHEVROLET CAMARO AND PONTIAC FIREBIRD SERVICE MA\JUAL
CONTENTS - BOOK 1
-::.
TABLE OF CONTENTS
SECTION
GENERAL INFORMATION
General Information
Maintenance and Lubrication
Vibration Diagnosis
OA
OB
OC
HEATING AND AIR CONDITIONING

Heater and Ventilation
Heater, Ventilation and Air Conditioning
Manual Control Air Cor;iditioning
HD6/HR6-HE Air Conditioning .
Compressor Service or Unit Repair
V5 Air Conditioning Compressor
Service or Unit Repair R-134a
1/1A
18
181
102
103
STEERING, SUSPENSION, TIRES AND WHEELS

Diagnosis
Wheel Alignment
Power Steering Gear and Pump
On-Vehicle Service
Power Steering Gear Unit Repair
Power Steering Pump Unit Repair
Front Suspension
Rear Suspension
Tires and Wheels
Steering Wheel and Column
On-Vehicle Service
SuP./:lemental Inflatable Restraint (SIR)
!It Steering Column Unit Repair
FINAL DRIVE
Propeller Shaft
Rear Axle
BRAKES
Brakes
Master Cylinder
Front Disc Brakes
Rear Disc Brakes
Duo-Servo Drum Brakes
Vacuum Booster System
Antilock Brake System
Antilock Brake System with Traction
Control System
Parking Brake
3
3A
38
3B1A
3818
3C
3D
3E
3F
3F5B
4A
48
5
5A
581
582
5C2
501
5E1
5E2
5F
ENGINE
General Information and Mechanical Diagnosis
5.7 Liter VS Engine On-Vehicle
Service RPO LT1 - VIN P
5.7 Liter VS Engine Unit Repair
RPO LT1 - VIN P
3800 Engine On-Vehicle Service
L36 (VINK)
3800 Engine Unit Repair L36 (VIN K)
Cooling and Radiator
6
6A3A
6A3B
6ABA
6A8B
68
TABLE OF CONTENTS
Eng,ine Fuel
Engine Electrical
Battery
Cranking System
Charging System
Ignition System
Engine Wiring
Exhaust System
TRANSMISSION
For Unit Repair, see 1996 Transmission/
Transaxle/Transfer Case Unit Repair
Manual
Automatic and Manual Transmission
Automatic Transmission On-Vehicle
Service
HYDRA-MATIC 4L60-E Automatic
Transmission Diagnosis RPO M30
(See Book 2)
Manual Transmission On-Vehicle

Service RPO MM6 and M49
Clutch
ELECTRICAL BODY AND CHASSIS
Lighting Systems and Horns
Instrument Panel, Gages and Console
Body Control Module
Windshield Wiper/Washer System
ACCESSORIES
Audio Systems
Cruise Control
Theft Deterrent Systems
Engine Coolant Heater
Supplemental Inflatable Restraint (SIR)
System
Remote Keyless Entry
BODY SERVICE
General Body Service
Stationary Windows
Body Dim.ensions and Underbody
.
Bumpers
Body Front End
Doors
Rear Quarters
Body Rear End
Roof and Folding Top
Seats and Carpet
Seat Belts
BODY STRUCTURE
Structural Body Repair and Dimensions
ALPHABETICAL INDEX
SECTION
6C
6D
601
602
603
604
605
6F
7
7A
78
7C
8
SB
SC
SD
SE
9A
98
9D
9E
9J
t 9K
10
10-1
10-2
10-3
10-4
10-5
10-6
10-7
10-8
10-9
0-10
0-11
11
.. 11\.DEX
CONTENTS - BOOK 2
TABLE OF CONTENTS
ENGINE
Driveability & Emissions - General Information
Driveability & Emissions - Fuel Injection
(Port) (3800)
Driveability & Emissions - Sequential Multiport
Fuel lniection !SF!) !5.7L)
TRANSMISSION
HYDRA-MATIC 4L60-E Automatic Transmission
Diagnoeis RPO M30
SECTION
6E
6E3 (3800)
6E3 (5.7L)
TABLE OF CONTENTS
7A:-14A1
Diagnostic Trouble Codes 5.7L VIN P (LT1)
7A-14A2

Electrical Diagnosis
7A-14A
SECTION
Diagnostic Trouble Codes 3.BL VIN K (L36)
BA
1-------------------------+------1\
ALPHABETICAL INDEX
INDEX-1
GENERAL INFORMATION
OA-1
SECTION OA
GENERAL INFORMATION
CONTENTS
Supplemental Inflatable Restraint
(SIR) Handling ............................................... OA-1
Disconnecting the Battery Negative Cable ........... OA-1
Handling Electrostatic Discharge (ESD)
Sensitive Parts ................................. :.............. OA-1
Special Tool Ordering Information........................ OA-2
Body 'Identification ................................................. OA-2
Federal Vehicle Theft Prevention Standard .......... OA-2
Vehicle Identification Number ............................... OA-2
Model Identification ............................................... OA-4
Engine Identification .............................................. OA-4
Transmission Usage ................................................ OA-4
Transmission Identification ............... ;................. ;.. OA-4
Differential Ratios and Tire Information .............. OA-4
General Vehicle Lifting and Jacking ...................O. OA-4
Lock Cylinder Coding ........................................... OA-8
Key Identification and Usage ........................... OA-8

Cutting Keys ..................................................... OA-8
Replacement Lock Cylinders ............................ OA-8
Assembling and Coding Lock Cylinders ......... OA-8
Metric Fasteners .................................................... OA-10
Fastener Strength Identification ....... '. .................... OA-10
Prevailing Torque Fasteners .................................. OA-10
Recommendations for Reuse ............................ OA-10
English-Metric Conversions .................................. OA-11
Decimal and Metric Equivalents .......................... OA-11
Abbreviations and Symbols .................................. OA-15
Replacement Labels ..............................................OA-18
Service Parts Identification Label ........................ OA-18
Option Codes ........................................................ OA-18
Option and Process Codes .................................... OA-19
SUPPLEMENTAL INFLATABLE RESTF,IAINT ,

(SIR) HANDLING
HANDLING ELECTROSTATIC DISCHARGE

{ESD) SENSITIVE PARTS
CAUTION: This. vehicle is equipped with

Supplemental Inflatable Restraint {SIR).
Refer to CAUTIONS in Section 9J under
"On-Vehicle Service" and the SIR
Component and Wiring Location view in
Section 9J before performing service .on
or around SIR components or wiring.
Failure to follow CAUTIONS could result
in possible air bag deployment, personal
injury, or unneeded SIR system repairs.
SIR equipped vehicles can be identified by:
Steering wheel hub marked "INFLATABLE
.
RESTRAINT."
"INFLATABLE RESTRAINT" mdicator lamp in
instrument cluster.
Code "2," "3" or "5" for the seventh digit of the
vehicle identification number (VIN).
DISCONNECTING THE BATTERY

NEGATIVE CABLE
CAUTION: Before removing or installing
any electrical unit or when a tool or
equipment could easily come in contact
with "live" exposed electrical terminals,
disconnect the battery negative cable
assembly to help prevent personal injury
and/or damage to the vehicle or
components. Unless instructed
otherwise, the ignition switch must be in
the "OFF" or "LOCK" position.
Figure 1
Many solid state electrical components can be
damaged by Electrostatic Discharge (ESD). Some will
display a label as shown in Figure 1 but many will
not.
NOTICE: In order to avoid possibly damaging

any components, observe the following:
1. Body movement produces an electrostatic charge.
To discharge personal Static electricity, touch a
ground point (metal) on the vehicle. This should
be done any time you:
Slide across the vehicle seat.
Sit down. or get up.
Do any walking.
2. Do not touch exposed electric terminals on
components or connectors with your fingers or
any tools. Remember the connector you are
checking might be tied into a circuit that could be
damaged by electrostatic discharge.
3. When using a screwdriver or similar tool to
disconnect a connector, never let the tool come in
contact with or come between the exposed
terminals.
4. Never jumper, ground or use test equipment
probes on any components or connectors unless
specified in diagnosis. When using test equipment,
always connect the ground lead first.
OA..;2
GENERAL INFORMATION
vehicle identification number (VIN) sequence number.
Refer to "Vehicle Identification Number" in this
section.
Paint codes, trim numbers, seat option codes and
other body information are included on the Service
Parts Identification Label. Refer to "Service Parts
Identification Label" in this section.
NOTICE
FEDERAL VEHICLE THEFT PREVENTION

STANDARD
ANTlTHEFT LABELING
CONTENTS SENSITIVE
TO
STATIC ELECTRICITY
01-2195
FS0010A
Figure 1 - ESD Sensitive Parts Label
5. Do not remove the solid state component from its

protective packaging until you are ready to install
the part.
6. Always touch the solid state component's package
to a ground before opening. Solid state
components can also be damaged if:
They are bumped or dropped.
They are laid on any metal work benches
or components that operated electrically,
such as a radio, TV or oscilloscope.
Solid state .components also can be damaged if
they are bumped or dropped, or if they are laid on a
metal work bench or on an electrically operated item
such as a radio, a TV or an oscilloscope.
SPECIAL TOOL ORDERING INFORMATION

Special service tools that are shown in this
service manual that have tool product numbers
beginning with "J" or "BT" are available for
worldwide distribution from:
Kent-Moore SPX Corporation
29784 Little Mack
Roseville, MI 48066-2298
Phone: 1-800-345-2233
Monday through Friday
8:00 a.m. through 8:00 p.m. EST
Telex: 244040 KMTR UR
Fax: 1-800-578-7375
BODY IDENTIFICATION
A body identification tag is attached to the
vehicle on the center of the radiator tie. The tag gives
a schedule number and the. last four digits of the
Federal law requires General Motors to place a

vehicle identification number (VIN) label on certain
parts of selected vehicles.
The purpose of the standard is to reduce motor
vehicle thefts by making parts removed from stolen
vehicles easier to trace and recover.
The label is permanently attached to an interior
surface of the part and displays the complete VIN..
The label on a replacement part contains the letter
"R", the manufacturer's logo and the symbol "DOT."
rn
Important
THESE LABELS ARE NOT TO BE DEFACED,

REMOVED OR COVERED. The labels must be
shielded from paint, rustproofing and undercoating
(dealer preparation included).
NOTICE: The anti-,theft label found on most
major body panels m~st be masked prior to
painting, rustproofing, .undercoating, etc. The
mask must be removed following the above
operations. Failure to keep the label clean and
readable may result in liability for a violation of
Federal Vehicle Theft Prevention Standard, and
subject the vehicle owner to possible suspicion
that the part was stolen.
The parts involved:
Front and rear bumpers.
Hood.
Right and left front doors.
Right and left quarter panels.
Rear compartment lid/hatch.
Right and left front. fenders.
Certification on driver's door qualifies as a theft
prevention label. Refer to SECTIONS 10-4,
10-5, 10-6 and 10-7 for further information.
VEHICLE IDENTIFICATION NUMBER

Figures 2 through 4
The vehicle identification number (VIN) legally

identifies the vehicle. A VIN plate is attached to the
upper left of the instrument panel and can be seen
from outside the vehicle. Each sequential unit number
is prefixed by letters and numbers that are explained
in Figure 2. The VIN also appears on the Vehicle
Certificate of Title and Registration.
------1
GENERAL INFORMATION OA-3
Vehicle Identification Number
1G1 FP 3 2 K O T 2 100001
PLANT SEQUENCE NUMBER

VINPOSITTONS
#12 THROUGH #17
~
G.M. MAKE IDENTIFIERS
VIN POSITIONS #1,2,3
USE CANADA
MAKE
CODE
CODE
CHEVROLET
PONTIAC
1G1
1G2
G.M. PLANT CODES

VINPOSITTON #11
2
2G1
2G2
MODEL YEAR CODES

. VIN POSITTON #10.
SERIES AND MODEL TABLE

VIN POSITIONS #4AND #5
#4
CAR
LINE
#5
SERIES CHEVROLET
p
CAMARO SPORT COUPE
FIREBIRD
FORMULA/TRANS AM
CODE
VEAR .
1995
1996
CHECK
DIGIT
VIN
POSITION #9
DIVISION
VIN
RPO
CODE CODE
K
p
ENGINE CODES
VIN POSITION #8
FUEL DISPL
MFT.
ENG.
lYPE SYSTEM (LITERS) DIVISION
L36
V6
MFI
3.8
MCO
LT1
V8
MFI
5.7
MCD
CODE
1
TWO DOOR COUPE/SEDAN
TWO DOOR HATCHBACK
TWO DOOR CONVERTIBLE
ST. THERESE
CODE.
DESCRliPTION
ACTIVE (MANUAL) BELTS
ACTIVE (MANUAL) BELTS WITH DRIVER

AND PASSENGER INFLATABLE
RESTRAINT SYSTEM
ACTIVE MANUAL BELTS WITH DRIVER INFLATABLE

RESTRAINT SYSTEM
PASSIVE (AUTOMATIC) BELTS
PASSIVE (AUTOMATIC) BELTS WITH DRIVER

INFLATABLE RESTRAINT SYSTEM
PASSIVE (AUTOMATIC) BELTS WITH DRIVER

AND PASSENGER INFLATABLE RESTRAINT SYSTEM
0203H
FS0020A
Figure 2 VIN Codes
OA-4
GENERAL INFORMATION
A derivative of the VIN is stamped on the

engine and transmission. The code gives the model
year, plant of manufacture and a sequence number that
also indicates the car division. A VIN number is also
stamped on the frame.
A bar code VIN is also on the vehicle
identification plate.
VIN NUMBER PLATE

LOCATION
MODEL IDENTIFICATION
Models (series) and body styles for the current
year are listed in Figure 2.
01-2815
F80030A
ENGINE IDENTIFICATION
Figures 2 and 4 thro/i(J~ 6
Figure 3 VIN Plate Location
The VIN code /(Figure 2,) provides detailed

engine information by tht\ engi11:e code letter located
on the vehicle identification plate. J
Stick-on-labels attached to the engine indicate
the engine unit number and code. 'These labels also
contain bar codes for in-plant identification.
Engines are stamped with an engine
identification number which identifies the assembly
plant, the month produced, the day produced and the
engine type code.
All engines and transmissions are stamped with
a VIN derivative, created from the complete VIN.
Refer to "Vehicle Identification Number" in this
section. The stamping contains nine positions. Position
1 is the GM car division identifier. Position 2 is the
model year code. Position 3 is the car assembly plant
code. P?sitions 4 through ,9 contain the assembly plant
sequential number of the vehicle (Figure 4).
. If .the en~ine in the ve~icle is the original
engme, ~ormation can be der~ved from the eighth
VIN position letter or number (Figure 2). To determine
if the engine is original, compare the VIN and the
VIN derivative. The VIN derivative should be the
same as positions 3 and 10 through 17 of the VIN.
TRANSMISSION USAGE
Figure 7
~ra!lsmission usage . affects axle usage. The
transmission usage chart hsts each engine with the
axles and transmissions used for each.
TRANSMISSION IDENTIFICATION
Vehicle Identification Number
G 1 F P 3 2 S O S 2 100001
Diron
MrelT
Y~ar
Plant of
Manutacture
1
Sequence
,------'
'
I
Number
"--1 S 2 100001
VIN Derivative
012&15
FS0040A
Figure 4 VIN Derivative (Typical)
transmission identification number is located either on

the. tr~s~ssion case or the bell housing. The VIN
denvat1ve 1s created from the complete VIN and is
stamped in either of 2 places (Figure 8). Refer to
"Vehicle Identification Number" in this section. For
more information on rear axle differential ratio codes
refer to SECTION 4B.
'
DIFFERENTIAL RATIOS AND TIRE

INFORMATION
For differential ratios, refer to SECTION 4B.
For tire information, refer to SECTION 3E.
Figures B and 9
GENERAL VEHICLE LIFTING AND

JACKING
The ~a!ls~ssioI?, has. two identifying stampings:

the transm1ss1on 1dent1ficat1on and the VIN derivative.
The transmission identification number gives the
tr.ansmission model and when it was made. On the
automatic transmission, the transmission identification
numbe! ~s located on the plate on the automatic
transm1ss1on case. On the manual transmission, the
Figure 10
CAUTION: T.o help avoid personal injury,
always use Jack stands when working on
or under any vehicle that is supported
only by a jack.
GENERAL INFORMATION
OA-5
c
B
c
A
A
B
C
D
E
VS
VB
VIN DERIVATIVE {PRIMARY)
VIN DERIVATIVE (OPTIONAL)
ENGINE ID NUMBER VERIFICATION LABEL
LOCATED ON OIL PAN
012895
FS0050A
Figure 5 Engine Identification Locations (Typical)
E;ngine Identification Number
00
00
000
Type Code
Source Code
F - Fllnt Motor
v- Flint Engine
T-Tonawand11
s- Saginaw Parts
K-GM or Canada LTD.
M-GM of Mexico
H-Hydra- Matte
Month Produced
01 January
02February
Day Produced
12 December
012895
FS0080A
Figure 6 Engine Identification Number
Engine
TRANSMISSION USAGE
Axle (RPO-Ratio)
3.8L, V6 (VIN K)
GU4-3.08, GUS-3.23, GU6-3.42
5.7L, V8 (VIN P)
GU2-2.73, GUS-3.23, GU6-3.42
Transmission
M49 Borg-Warner Manual 5-Speed
M30 Hydra-Matic 4L60-E
M49 Borg-Warner Manual 5-Speed
MM6 Borg-Warner Manual 6-Speed
M30 Hydra-Matic 4L60-E
T5362
Figure 7 - Transmission Usage Chart
OA-6
GENERAL INFORMATION
(
JULIAN DATE
(OR DAY OF THE YEAR)
HYORA-MATIC 4L60-E
CALENDAR
YEAR
5 = 1995
TRANSMISSION 1.0.
LOCATION
SHIFT BUILT
A, B OR J = FIRST SHIFT
C, H OR W = SECOND SHIFT
0121Ml5
FS0080A
Figure 8 Hydra-Matic 4L60-E Transmission 1.0. Location
CAUTION: To help avoid personal injury

when a vehicle 1s on a hoist, provide
additional support for the vehicle at the
opposite end from which components are
being removed. The additional support
will reduce the possibility of the vehicle's
falling off the hoist. When removing
major components from the vehicle while
the vehicle is on a hoist, the vehicle
frame should be chained to the hoist
pads at the same end as the removed
components to prevent tip-off. Failure to
follow these precautionary measures
could result in vehicle damage, serious
personal injury or death.
NOTICE: When jacking or lifting a vehicle at

the frame side rails or other prescribed lift
points, be certain that lift pads do not contact
the catalytic converter, brake pipes or fuel lines.
Such contact may result in damage or
unsatisfactory vehicle performance.
B
A
B
C
D
SIX-SPEED
FIVE-SPEED
PRIMARY LOCATION
SECONDARY LOCATION
01-2895
FSOOIOA
Figure 9 - Manual Transmissi,on Identification
When a vehicle is lifted with a vehicle jack or

floor jack, the wheels at the opposite end should be
blocked. J ackstands should be used to provide
additional support. Jackstands should be placed under
either the frame, the front suspension crossmember or
the axle.
A USING FRAME CONTACT HQilST REARWARD OF

FRONT TIRE
B USIN,G FRAME CONTACT HOIST FORWARD OF
REAR TIRE
C USING SUSPENSION CONTACT HOIST UNDER
FRONT LOWER CONTROL ARM
D USING SUSPENSION CONTACT HOIST LIFTING
ON REAR AXLE
012195
FS0100A
Figure 10 Vehicl,e Lifting Points
OA-8
GENERAL INFORMATION
The vehicle should be on a clean, hard, level

surface before any lifting procedure begins. All lifting
equipment must meet weight standards and be in good
working order. Make sure all vehicle loads are equally
distributed and secure. If the only support for the
vehicle is at the frame side rails, make sure the lifting
equipment does not put too much stress on: or weaken
the frame side rails.
Recommended vehicle lifting points are shown
in Figure 10. If any .other hoist methods are used, take
special care not to damage the fuel tank, filler neck,
exhaust system or underbody.
8[iJ
1UM Of' IXCELlf'-Ct:
111111
... ..
123456
. .
1 2 J 4 5
A
A POSITION
B LEVELS
LOCK CYLINDER COD,ING
01261115
FS0110A
Figure 11 Key Code Diagram
Key Identification and Usage

Figure 11
The lock cylinder keyway is designed so that
other model keys will not enter a current model lock
cylinder. Two non-interchangeable keys are used.
Square-headed key is used in the ignition lock
cylinder.
Oval-headed key is used in all other lock
cylinders.
Key identification is obtained from the
four-character key code stamped on the knockout
portion of the key head and from an identification
letter stamped on the key shank. After the code
number has been recorded by the owner, the plugs
should be knocked out of the key head. Using these
numbers, owners of key-cutting equipment can
determine the lock combination by consulting a code
list available from equipment suppliers. If the key
code numbers are not available from records or from
the knockout plug, the lock combination (tumbler
numbers and position) can be determined by laying the
key on the diagram (Figure 11 ). For information on
the square-headed ignition key and lock cylinder, refer
to SECTION 9D.
Cutting Keys
Figure 11
1. Determine special code from the code list or key
code diagram.
2. Cut a blank key to proper level for each of six
tumbler positions or according to directions
supplied by the key-cutting equipment
manufacturer.
3. Check key operation in lock cylinder.
Replacement Lock Cylinders

Figure 12
Lock cylinders (3) are available from service
parts warehouses completely coded and with a new
key. The new lock cylinder (3) has a locking bar
staked in place. Tumblers (1) and springs are also
available and must be assembled into the lock cylinder
(3) according to the key code.
1 TUMBLER
2 CYLINDER HEAD, LOCK
3 CYLINDER, LOCK
4 SIDE BAR
01261115
FS0120A
Figure 12 Lock Cylinder Components
Assembling and Coding Lock Cylinders

ALL LOCK CYLINDERS EXCEPT REAR STOWAGE
COMPARTMENT
Figures 11 through 14
Tumblers (1) for all locks are shaped exactly
alike, with the exception of the notch position on one
side. As the key is inserted in the lock cylinder (3),
tumblers ( 1) are lowered to the correct height so that
notches on each tumbler (1) are at the same level.
When the notches on all six tumblers line up, the side
bar (4) is pushed into the notches by two small
springs. This allows the lock cylinder (3) to turn in its
bore. Five types of tumblers (1) are used to make the
various lock combinations. Each tumbler (1) is coded
according to a number, one through five, stamped on
its side.
I+;+!
Assemble
1. Determine tumbler numbers and arrangement.

With the numerical key code, use code list
provided by the key cutting equipment supplier.
Without the numerical key code or without the
code list, refer to Figure 11.
A. Lay key on the key code diagram. Be sure key
is outlined by the diagram.
B. Start with position number one. Find and
record the lowest level (tumbler number) that
is visible. Repeat for each of the remaining
five positions.
GENERAL INFORMATION
2. Tumblers ( 1) in their . proper slots in the order
called for by the code (Figure 12).
OA-9
Start with position number .one, nearest open end

or lock cylinder head (2).
3. Tumblers (1) by pulling side bar (4) out with
fingers.
4. One tumbler spring (6) above each tumbler (1).
5. Spring retainer (5) so that end prongs slide into
slots at each end of lock cylinder (3).
A STAKE POINTS FOR RETAINER

5 RETAINER, SPRING
Press spring retainer (5) down (Figure 13).

6. Insert key into lock cylinder (3) to check for
proper installation.
01H95
FS0130A
Figure 13 - Installing Spring Retainer
Side bar (4) will drop down if tumblers (1) are

installed properly. If incorrectly assembled, take
apart and assemble correctly.
2
NOTICE: Use leather or wood at each vise

jaw to prevent damage to the cylinder.
1
7. Remove key and secure lock cylinder (3) in a vise

with spring retainer (5) exposed.
A. Stake spring retainer (5) securely in place at each

.end. Use a suitable staking tool and stake cylinder
metal. over the spring retainer (5).
B. Black lock cylinders should be lubricated with
Multi-Purpose Lubricant (GM PIN 12345120 or
equivalent) or light machine oil. AH other lock
cylinders should be lubricated with a general
purpose silicone lubricant.
1 TUMBLER
4 SIDE BAR
5 RETAINER, SPRING
6 SPRING, TUMBLER
01H95
FS0140A
Figure 14 - Installing Tumblers
REAR STOWAGE COMPARTMENT LOCK

CYLINDER
Figures 12, 14 and 15

A lock cylinder with snap-in tumblers (1) is used
for the rear stowage compartment lock. The lock
cylinder has four or five tumbler positions. The
number one or two position (closest to the lock
cylinder head (2)) is a brass retainer tumbler. The two
through five positions or three through five positions
are standard. tumbler positions depending upon
cylinder type. Therefore, only the last four or five
tumbler combinations are required.
!+!+!
Assemble
1. Determine tumbler numbers and arrangement as

previously described and install tumblers (1).
2. After installation, tap tumblers (1) flush with the
cylinder.
WOODEN BLOCK
Figure 15 Locking Tumblers in Place
01H95
FS0150A
OA-10
GENERAL INFORMATION
the head of each bolt/screw to identify the strength
class. Some metric nuts are marked with strength
identification numbers on the nut face (Figure 17).
Correct replacement bolts/screws and nuts are
available through General Motors Service Parts
Operation (GMSPO). Many metric fasteners available
in the aftermarket parts channels were designed to
metric standards of countries other than the United
States. The fasteners may have different strength or
thread pitch and may not have the numbered head
marking system. The metric fasteners used on GM
products are designed to new international standards
that might not be used by some non-domestic
bolt/screw and nut suppliers.
METRIC FASTENERS
Figure 16
NOTICE: Always use the correct fastener in
the correct location. When you replace a
fastener, use ONLY the exact part number for
that application. General Motors will call out
those fasteners that require a replacement after
removal. General Motors will also call out the
fasteners that require thread lockers or thread
sealant. UNLESS OTHERWISE SPECIFIED, do
not use supplemental coatings (paints, greases,
or other corrosion inhibitors) on threaded
fasteners or fastener joint interfaces. Generally,
such coatings adversely affect the fastener
torque and the joint clamping force, and may
damage the fastener. When you install fasteners,
use the correct tightening sequence and
specifications. Following these instructions can
help you avoid damage to parts and systems.
PREVAILING TORQUE FASTENERS

Figures 18 and 19
A prevailing torque nut is designed to develop
an interference between the nut and bolt/screw threads.
This interference is usually created by distortion of the
top of an all-metal nut or by a nylon patch in the
threads in the middle of a hex flat. In other cases, a
nylon insert may be used (Figure 18).
A prevailing torque bolt/screw is designed to
develop an interference between the bolt/screw and nut
threads or between the bolt/screw and tapped hole
threads. This interference is created by distorting some
of the threads or by using a nylon patch or adhesive
(Figure 18).
Rusty or damaged bolts/screws and nuts should

be replaced with new parts of the same strength class.
Clean, unrusted bolts/screws and nuts can be reused.
Be sure to use the following recommendations:
Many fasteners are metric. Metric fasteners may

be close in dimension to well-known english fasteners
in the inch system. Replacement fasteners must be the
correct nominal diameter, thread pitch and strength.
Original equipment metric fasteners, except for
exposed bumper bolts and other beauty bolts and
cross-recess head screws, have numbers on their heads
that identify them as metric. Cross-recess head screws
can be identified by a Posidriv or Type IA
cross-recess. Either type of cross-recess screwdriver
can be used to remove Posidriv recess head screws,
but Type lA will perform better.
Metric and english thread notations differ
slightly. For example, the thread major diameter of a
1/4-20 bolt/screw is 1/4 inch, and the bolt/screw has
20 threads per inch. The thread major diameter of an
M6.0xl bolt/screw is 6.0 mm, and the bolt/screw has
1 mm between threads.
Recommendations for Reuse

1. Clean, unrusted prevailing torque nuts and bolts
may be reused as follows:
A. Clean dirt and other foreign material from nut
or bolt.
B. Inspect nut or bolt to assure there are no
cracks, elongation, or other signs of abuse or
over tightening. (If there is any doubt, replace
with a new prevailing torque fastener.)
C. Assemble parts and hand st3;rt nut or bolt.
D. Observe that, before faster seats, it develops
torque per the chart in Figure 19. (If there is
any doubt, replace with a new prevailing
torque fastener.)
FASTENER STRENGTH IDENTIFICATION

Figure 17
Most commonly used metric fastener strength
property classes are 9.8 and 10.9. The class
identification is embossed on the head of each
bolt/screw. English fastener strength property classes
range from grade 2 to 8. Radial lines are embossed on
ENGLISH
1/4
THREAD MAJOR
DIAMETER IN INCHES
METRIC
M6.0
20
NUMBER OF THREADS
PER INCH
THREAD MAJOR DIAMETER

IN MIWMETERS
1
DISTANCE BETWEEN
THREADS IN MILLIMETERS
I
THREAD PITCH
Figure 16 - Thread Notation
GENERAL INFORMATION
GRADE 5
(GM 280-M)
GRADE 2
(GM 200-M)
GRADE 7
(GM 290-M)
GRADE 8
(GM 300-M)
OA-11
NUT STRENGTH
IDENTIFICATION
ENGLISH (INCH) SOL TS/SCREWS - IDENTIFICATION MARKS CORRESPOND TO

BOLT/SCREW STRENGTH - INCREASING NUMBERS REPRESENT INCREASING STRENGTH.
METRIC BOLTS/SCREWS - IDENTIFICATION CLASS NUMBERS CORRESPOND TO SOLT /SCREW

STRENGTH - INCREASING NUMBERS REPRESENT INCREASING STRENGTH.
012tl95
FS0170A
Figure 17 Fastener Strength Markings
ENGLISH-METRIC CONVERSIONS
Figure 20
CENTER TOP
LOCK
LOCK
NYLON
PATCH
NYLON
WASHER
INSERT
NYLON
INSERT
To convert english units to metric units, multiply

the english units by the conversion factor shown in
Figure 20. To convert metric units to english units,
divide the metric units by the conversion factor shown
in Figure 20.
DECIMAL AND METRIC EQUIVALENTS

ORV
ADHESIVE
COATING
THREAD
PROFILE
DEFORMED
NYLON
STRIP
OUT OF
ROUND
THREAD
AREA
012tl95
FS0180A
Figure 18 - Prevailing Torque Nuts and Bolts/Screws
E. Tighten fastener to torque specified in

appropriate section of this manual.
2. Bolts and nuts which are rusty or damaged should
be replaced with new parts.
Figure 21
Inch-to-millimeter decimal equivalents are shown
in Figure 21.
OA-12
GENERAL INFORMATION
FASTENER
TYPE
Nuts and All
Metal Bolts/SCreWS
Adhesive or Nylon
Coated Bolls/Screws
FASTENER
TYPE
Nuts and All
Metal Bolts/Screws
Adhesive or Nylon
Coated Bolts/Screws
TORQUE
UNITS
Nm
lb.In.
Nm
lb.In.
TORQUE
UNITS
Nm
lb.In.
Nm
lb.In.
METRIC-SIZE FASTENERS
6
0.4
4
0.4
4
6.3
0.4
4
0.4
4
.250
.312
0.6
5
0.6
5
0.4
4
0.4
4
8
0.8
7
0.6
5
10
1.4
12
1.2
1.4
12
1.0
9
1.8
16
1.4
12
12
2.2
19
1.6
14
14
3.0
27
2.4
21
16
4.2
37
3.4
30
20
7.0
62
5.6
50
2.4
21
1.8
16
3.2
28
2.6
23
.625
4.2
37
3.4
30
.750
6.2
11
INCH-SIZE FASTENERS
.375 .437 .500 .562
55
5.2
49
06-22-H
FS0190A
Figure 19 - Prevailing Torque Fastener Specifications
GENERAL INFORMATION
Multip,ly
by
to get equivalent
number of:
Multiply
by
LENGTH
25.4
Inch
ACCELERATION
Foot/sec
0.3048
meter/sec (rn/s2 )
meters (m)
Inch/sec
0.0254
meter/sec'
Pound-Inch
0.11298
newton-meters (Nm)
Pound-foot
1.3558
newton 1-meters
Horsepower
0.746
0.3048
Yard
0.9144
meters
Mille
1.609
kilometers (km)
TORQUE
AREA
645.2
miUimeters2 (mm')
6.45
centimeters' (cm
Foot'
0.0929
meters (m')
Yard'
0.836.1
meters'
2
)
POWER
---
16387.
kilowatts (kW)
PRESSURE OR STRESS
VOLUME
Inch"
to get equlvalent
number of:
Miillimeter (mm)
Foot
Inch'
OA-13
mm
cm
Inches of water
0.2491
kilopascals (kPa)
0.0164
liters (L)
Pounds/sq. in.
6.895
kilopascals
Quart
0.9464
liters
GaHon
3.7854
l:iters
Yard"
0.7646
meters (m")
16.397
ENERGY OR WORK
1055.
BTU
0.4536
Pound
907.18
Ton
Ton
'
0.907
1.3558
Pound-foot
MASS
kilograms (kg)
Kilowatt-hour
3600000.
Joules (J)
joules
joules (J = one W.s)
or 3.6 x 10
kilograms (kg)
tonne (t)
LIGHT
FORCE
Kiilogram
9.807
newtons (N)
Ounce
0.2780
newtons
Pound
4.448
newtons
Foot Candle
10.764
Miles/hour
1.609 3
lumens/meter' (lrn/m')
VELOCITY
kilometers/hr. (km/h)
TEMPERATURE
To convert Celsius temperature
to Fahrenheit temperature, use formula:
F = 9/5 ('C + 32)
To convert Fahrenheit temperature

to Celsius temperature, use formula:
= 5/9 CF - 32)
FUEL PERFORMANCE
235.215 + Miles/gal = liters/100 Kilometers
C8758
Figure 20 - English/SI Metric Conversion Table
OA-14
GENERAL INFORMATION
DECIMAL AND METRIC EQUIVALENTS
Fractional
Inch
1/64
1/32
3/64
1/16
5/64
3/32
7/64
1/8
9/64
5/32
11/64
3/16
13/64
7/32
15/64
1/4
17/64
9/'J2
19/64
5/16
21/64
11/32.
23/64
3/8
25/64
13/32
27/64
7/16
29/64
15/32
31/64
1/2
Decimal
Inch
Metric
mm.
.015625
.03125 ....
.046875 ...
.0625 .....
.078125 ....
.09375 ....
.109375 ....
.125 ......
.140625 ....
.15625 ....
.171875 .
.1875 .....
.203125 ....
.21876 ....
234375 ...
.250 ......
.265625
.28125 ....
.296876 ....
.3125
.328125 ..
.34375
.359375 ....
.375 ......
.390625
.40625
.421875 ....
.4375 .....
.453125
.46875
.484375 ....
.500
.39,688
<ii
. . ...
ID
....
It
ID
.79375
1.19062
1.58750
1.98437
2.38125
2.77812
3.1750
3.57187
3.96875
4.36562
4.76250
5.15937
5.56625
5.95312
6.36000
6.74687
7.14375
7.54062
7.93750
8.33437
8.73125
9.12812
9.52600
9.92187
10.31875
10.71562
11.11250
11.60937
11.90625
12.30312
12.70000
Fractional .
Inch
33/64
17/32
36/64
9/16
37/64
19/32
39/64
5/8
41/64
21/32.
43/64
11/16
45/64
23/32
47/64
3/4
49/64
26/32
51/64
13/16
53/64
27/32
56/64
7/8
57/64
29/32
59/64
15/16
61/64
31/32
63/64
1
Metric
mm.
Decimal
Inch
.515625
.53125 ....
.546875 , ..
.5625 . . ' .
.578125 ...
.59375 ...
.609376
'
.626
.640625 ...
.66625 ....
.671875 ...
.6875 ., ...
.703125 ...
.71875 ...
.734375 ...
.750
.766625 ...
.78125 ....
.796875 ..
.8125 ... '
.828125 ...
.84375 ....
.859376 ...
.876 . ....
.890625
.90625 ....
.921875
.9375
.953125
.96875 ....
.984375 ...
1.00
0
..
Cl
...
...
...
It
It
13.09687
13.49375
13.89062
14.28750
14.68437
15.08125
15.47812
15.81500
16.27187
16.66875
17.06562
17.46250
17.85937
18.25625
18.66312
19.05000
19.44687
19.84375
20.24062
20.63750
21.03437
21.43125
21.82812
22.22500
22.62187
23.01875
23.41662
23.81260
24.20937
24.60625
25.00312
25.40000
OMfflIIS
FS0210A
(
Fi,gure 21 - Inch-to-Millimeter Decimal Equivalents
GENERAL INFORMATION
OA-15
ABBREVIATIONS AND SYMBOLS

The following abbreviations and symbols may
appear in this manual.
A
A - Ampere(s)
ABS - Antilock Brake System
AJC - Air Conditioning
AC - Alternating Current
ACC - Automatic Climate Control
ACL - Air Cleaner
ACR4 - Air Conditioning Refrigerant, Recovery,
Recycling, Recharging
AID - Analog-to-Digital
AJF - Air/Fuel (Ratio)
AIR - Secondary Air Injection
ALC - Automatic Level Control
AM/FM - Amplitude Modulation/Frequency
Modulation
API - American Petroleum Institute
APT - Adjustable Part Throttle
ARS - Automatic Restraint System
asm - assembly
ASR - Acceleration Slip Regulation
AJT - Automatic Transmission/Transaxle
AT<; - Automatic Temperature Control
ATDC - After Top Dead Center
Auto - Automatic
avg - average
AWD - All Wheel Drive
AWG - American Wire Gage
B
B+ - Battery Positive
B- - Battery Negative
BARO - Barometric (pressure)
bat - battery
BCM - Body Control Module
BHP - Brake Horsepower
BP - Back Pressure
BTDC - Before Top Dead Center
BTSI - Brake Transmission Shift Interlock
Btu - British thermal units
c
c - Degrees Celsius
CAC - Charge Air Cooler
Cam - Camshaft
CCOT - Cycling Clutch Orifice Tube
CD - Compact Disc
CE - Commutator End
CEAB - Cold Engine Air Bleed
CEMF - Counter Electromotive Force
cfm - cubic feet per minute
cg - center of gravity
CID - Cubic Inch Displacement
CKP - Crankshaft Position
CKT - Circuit
CL - Closed Loop
cm3 - cubic centimeters
CMP - Camshaft Position
CO - Carbon Monoxide
C02 - Carbon Dioxide
Conn - Connector
CPA - Connector Position Assurance
CPS - Central Power Supply
CPU - Central Processing Unit
CRT - Cathode Ray Tube
CRTC - Cathode Ray Tube Controller
CS - Charging System
CTP - Closed Throttle Position
cu ft or ft3 - cubic foot, or feet
cu in or in3 - cubic inch, or inches
CV - Constant Velocity (joint)
Cyl - Cylinder(s)
D
dB - decibels
dBA - decibels on A-weighted scale
DC - Direct Current
DE - Drive End
DEC - Digital Electronic Controller
DERM - Diagnostic Energy Reserve Module
DI - Distributor Ignition
dia - diameter
DIC - Driver Information Center
Diff - Differential
DLC - Data Link Connector
DOHC - Dual Overhead Camshafts
DRL - Daytime Running Lamps
DTC - Diagnostic Trouble Code
DVM - Digital Voltmeter
DVOM - Digital Volt/Ohmmeter
E
EBCM - Electronic Brake Control Module
EBTCM - Electronic Brake and Traction Control
Module
ECC - Electronic Climate Control
ECI - Extended Compressor at Idle
ECM - Engine Control Module
ECS - Emission Control System
ECT - Engine Coolant Temperature
EEPROM - Electronically Erasable
Programmable Read Only Memory
EEVIR - Evaporator Equalized Values in
Receiver
EFE - Early Fuel Evaporation
EGR - Exhaust Gas Recirculation
EI - Electronic Ignition
ELC - Electronic Level Control
EMF - Electromotive Force
Eng - Engine
EPA - Environmental Protection Agency
EPR - Exhaust Pressure Regulator
OA-16
GENERAL INFORMATION
EPROM - Erasable Programmable Read Only

Memory
ESD - Electrostatic Discharge
ETC - Electronic Temperature Control
ETCC - Electronic Touch Climate Control
ETR - Electronically Tuned Receiver
EVAP - Evaporative Emission
Exh - Exhaust
F
~F - Degrees Fahrenheit
FC - Fan Control
FDC - Fuel Data Center
FED - Federal (all states except California)
FEDS - Fuel Enable Data Stream
FI - Fuel Injection
FMVSS - Federal Motor Vehicle Safety
Standards
ft - foot, feet
FT - Fuel Trim
4WAL - Four Wheel Antilock
4WD - Four Wheel Drive
FWD - Front Wheel Drive
G
g - gravitational acceleration, grams
GA - Gage
gal - gallon
gas - gasoline
GCW - Gross Combination Weight
Gen - Generator
GL - Gear Lubricant
GM - General Motors
GM SPO - General Motors Service Parts
Operations
gnd - ground
gpm - gallons per minute
GVWR - Gross Vehicle Weight Rating
H
H - Hydrogen
H20 - Water
Harn - Harness
HC - Hydrocarbons
H/CMPR - High Compression
HD - Heavy Duty
HDC - Heavy Duty Cooling
hex - hexagon
Hg - Mercury
Hi Alt - High Altitude
H02S - Heated Oxygen Sensor
hp - horsepower
HPL - High Pressure Liquid
HPS - High Performance System
HPV - High Pressure Vapor
HUD - Head-Up Display
HVAC - Heater-Vent-Air Conditioning
HVACM - Heater-Vent-Air Conditioning Module
HVM - Heater Vent Module
Hz - Hertz
IAC - Idle Air Control

IAT - Intake Air Temperature
IC - Ignition Control I Integrated Circuit
ICM - Ignition Control Module
ID - Inside Diameter, Identification
IDI - Integrated Direct Ignition
ign - ignition
ILC - Idle Load Compensator
in. - inch(es)
INJ - Injection
1/P - Instrument Panel
ISC - Idle Speed Control
ISO - International Standards Organization
ISS - Input Shaft Speed
K
KAM - Keep Alive Memory
kg - kilogram
kHz - kilohertz
km - kilometer
km/h - kilometers per hour
km/L - kilometers per liter
kPa - kilopascals
KS - Knock Sensor
kV - kilovolts
L
L - Liter
L4 - Four Cylinder Engine, In-Line
lb. ft. - pound feet (torque)
lb. in - pound inch (torque)
LCD - Liquid Crystal Display
LED - Light Emitting Diode
LF - Left Front
LH - Left Hand
LR - Left Rear
lt - left
LTPWS - Low Tire Pressure Warning System
M
MAF - Mass Air Flow
Man - Manual
MAP - Manifold Absolute Pressure
Max - Maximum
MIC - Mixture Control
MDP - Manifold Differential Pressure
MFI - Multi-port Fuel Injection
mi - miles
MIL - Malfunction Indicator Lamp
min - minimum
mL - milliliters
mm - millimeters
mpg - miles per gallon
mph - miles per hour
ms - millisecond
MST - Manifold Surface Temperature
MIT - Manual Transmission/Transaxle
MV - Megavolt
mV - millivolt
GENERAL INFORMATION
N
NC - Normally Closed
NEG - Negative
Neu - Neutral
NLGI - National Lubricating Grease Institute
N.m - Newton-meters (torque)
NO - Normally Open
NOx - Oxides of Nitrogen
NPTC - National Pipe Thread Coarse
NPTF - National Pipe Thread Fine
0
02 - Oxygen
02S - Oxygen Sensor
OBD - On-Board Diagnostic
OBD II - On-Board Diagnostic II
OC - Oxidation Converter (Catalytic)
OD - Outside Diameter
OE - Original Equipment
OEM - Original Equipment Manufacturer
OHC - Overhead Camshaft
OL - Open Loop
ORC - Oxidation Reduction Converter
(Catalytic)
oz - ounce(s)
p
PAG - Polyalkylene Glycol
PAIR - Pulsed Secondary Air Injection
PASS-Key - Personalized Automotive Security
System
P/B - Power Brakes
PCM - Powertrain Control Module
PCS - Pressure Control Solenoid
PCV - Positive Crankcase Ventilation
PKE - Passive Keyless Entry
PM - Permanent Magnet (Generator)
PIN - Part Number
PNP - Park/Neutral Position
POA - Pilot Operated Absolute (Valve)
POS - Positive
POT - Potentiometer (Variable Resistor)
ppm - parts per million
PROM - Programmable Read Only Memory
PS - Power Steering
PSP - Power Steering Pressure
psi - pounds per square inch
psia - pounds per square inch absolute
psig - pounds per square inch gage
pt - pint
PWM - Pulse Width Modulated
Q
qt - quart(s)
OA-17
R
R-12 - Refrigerant-12
R-134a - Refrigerant-134a
RAM - Random Access Memory (non
permanent memory devise, memory contents are
lost when power is removed)
RAP - Retained Accessory Power
Ref - Reference
RF - Right Front
RFI - Radio Frequency Interference
RH - Right Hand
ROM - Read Only Memory (permanent memory
devise, memory contents are retained when
power is removed)
RPM - Engine Speed (Revolutions Per Minute)
RPO - Regular Production Option
RR - Right Rear
rt - right
RTD - Real Time Damping
RTV - Room Temperature Vulcanizing (sealer)
RWD - Rear Wheel Drive
s
s - second(s)
SAE - Society of Automotive Engineers
SC - Supercharger
SCB - Supercharger Bypass
SDM - Sensing and Diagnostic Module
SEO - Special Equipment Option
SFI - Sequential Multiport Fuel Injection
SI - System International (modern version of
metric system)
SIR - Supplemental Inflatable Restraint
sol - solenoid
S02 - Sulfur Dioxide
SPO - Service Parts Operations
sq ft, ft2 - square foot(feet)
sq in, in2 - square inch(es)
ST - Scan Tool
syn - synchronizer
T
Tach - Tachometer
TBI - Throttle Body Fuel Injection
TC - Turbocharger
TCC - Torque Converter Clutch
TCS - Traction Control System
TDC - Top Dead Center
TEMP - Temperature
Term - Terminal
TFT - Transmission Fluid Temperature
THM - Turbo Hydra-Matic
TP - Throttle Position
TPA - Terminal Positive Assurance
TR - Transmission Range
TRANS - Transmission/Transaxle
TV - Throttle Valve
TVRS - Television and Radio Suppression
TVV - Thermal Vacuum Valve
TWC - Three Way Converter (Catalytic)
OA-18
GENERAL INFORMATION
TWC+OC - Three Way + Oxidation Converter

(Catalytic)
TXV - Thermal Expansion Valve
u
UART - Universal Asynchronous Receive and
Transmit
U-joint - Universal Joint
UTD - Universal Theft Deterrent
v
V - Volt(s), Voltage
V6 - Six Cylinder Engine
V8 - Eight Cylinder Engine
Vac - Vacuum
VATS - Vehicle Anti-Theft System
VDV - Vacuum Delay Valve
vel - velocity
VF - Vacuum Fluorescent
VIN - Vehicle Identification Number
VMV - Vacuum Modulator Valve
VSS - Vehicle Speed Sensor
w
W/B - Wheel Base
WOT - Wide Open Throttle
WIS - Windshield
WSS - Wheel Speed Sensor
WU-OC - Warm Up Oxidation Converter
(Catalytic)
WU-TWC - Warm Up Three Way Converter
(Catalytic)
x
X-valve - Expansion valve
y
yd - yard
z
Zn - zinc
REPLACEMENT LABELS
Replacement labels are available through GM
Service Parts Operations for the following:
Vehicle Emission Control Information (Exhaust
Emission Tune Up)
Spare Wheel Caution
Superlight Shock Absorber Information
Jacking
Spare Tire Storage
Serpentine Belt Routing (when it is a separate
label)
Engine Fan Caution
IRS/SIR Service Caution
e Odometer Reset
These and other labels will be found in the
Standard Parts Catalog.
The Vehicle Certification Label, Trre Pressure
Placard and Service Parts Identification Label are
NOT available as service parts.
SERVICE PARTS IDENTIFICATION LABEL

Figure 22
The Service Parts Identification Label has been
developed and placed on the vehicle to aid service and
parts personnel in identifying parts and options
originally installed on the vehicle. The label is
attached to the inside of the instrument panel
compartment.
OPTION CODES
Vehicle options are identified on the Service
Parts Identification Label by option codes. Option
codes are three-digit combinations of letters and
numbers. They identify equipment installed on the
vehicle, and trim and paint colors. Refer to "Option
and Process Codes" in this section ..
4i9tliiiRDINOJUl@OMl-11ll(ii;Jj~c)'J~
1G4BN6371NW400001
AG9 A90 848 C09 033 E9Z LC3 N81
AUE BMO .884 C49 864 F40 MX1 MNI
A01 BSI 893 C60 085 GU2 M31 POI
A42 832 896 DF3 E5Z K19 NA5 DJW
A52 833 C04 DIC ESE K64
TFl9 UF7 U26 U81 ZXS

TIS UN3 U29 VE& 41A
T63 UN9 U35 N30 42L
T87 UPS U76 YT9 420
4BN69
42T 809
6PA
609
601
WA8358 SILVER LOWER

WA7888 DARK BLUE UPPER
PAINT ALANTIC PROMOTION TWO TONE
/BASE COAT- CLEAR COAT
A VEHICLE IDENTIFICATION NUMBER (VIN)

B ENGINEERING MODEL NUMBER (CAR DIVISION,
CARLINE AND BODY SlYLE)
C SPECIAL ORDER PAINTS
D lYPE OF PAINT TECHNOLOGY
E LOWER EXTERIOR PAINT COLOR
F UPPER EXTERIOR PAINT COLOR

G ACCENT COLOR
H VINYL TOP
J INTERIOR TRIM AND DECOR LEVEL
K OPTION CONTENT
01-28-95
B80230A
Figure 22 - Service Parts Identification Label
OPTION AND PROCESS CODES

AG1
AG4
AH3
AKS
AN4
AQ9
AUO
AU3
A31
A90
B35
B84
CC1
C41
C49
C60
009
OE4
OG7
OLS
035
082
FE2
FE9
Adjuster, 6-Way Power, Driver Seat

Adjuster, 2-Way Manual, Driver Seat
Adjuster, 4-Way Manual, Driver Seat
Restraint System Front Seat, Inflatable, Driver
and Passenger
Restraint Provisions, Child
Seat, Passenger and Driver, Recline
Lock Control, Remote Entry
Lock, Side Door, Electric
Window, Power Operated, Side
Lock, Rear Compartment Lid, Remote Control,
Electric
Floor Mats, Rear, Carpeted Insert
Exterior Molding, Body Side
Roof Hatch, Removable Glass Panels
HVAC System, Heater
Defogger, Rear Window Electric
HVAC System, Air Conditioner, Manual
Control
Mirror, Outside, LH and RH,. Remote Control,
Electric, Breakaway, Painted
Sunshade, Removable Hatch Roof
Mirror, Outside LH & RH, Remote Control,
Electric, Painted
Decal, Roadside Service Information
Mirror, Outside LH Remote, RH Manual,
Painted
Paint Special
Suspension System, Ride Handling
Certification Emission, Federal
F41
GU2
GU4
GUS
GU6
GSO
ILO
IL2
IPB
IP2
J41
J65
KG9
KOS
K34
K68
LT1
L36
MM5
MM6
MN6
MXO
Suspensions System, Firm Ride Handling, Front

and Rear
Axle, Rear 2. 73 Ratio
Axle, Rear 3.08 Ratio
Axle, Rear Positraction (Limited Slip)
Trim, Interior Design
Seat, Leather Sport Front Bucket, Driver and
Passenger, Reclining
Brake System, Power, Front Disc, Rear Drum,
Cast Iron
Brake System, Power, Front and Rear Disc
Generator, 140 Amp
Heater, Engine Block
Cruise Control, Automatic Electronic
Generator, 105 Amp
Engine, 5.7L (V8) MFI
Engine, 3.8L (V6) MFI
Transmission - 5-Speed Manual (Merchandising
Option)
Transmission, Manual, 6-Speed, Borg-Warner,
85 mm, 2.66 1st, 0.50 6th, 0/D
Transmission - 6-Speed Manual (Merchandising
Option)
Transmission - Automatic 0/D (Merchandising
Option)
OA..20
GENERAL INFORMATION
M30 Transmission - Automatic, 4-Speed, 4L60-E,

Electronic
M49 Transmission, Manual, 5-Speed, Borg-Warner,
77 mm, 3.75 1st, 0.76 5th, 0/D Emission
NB6 Emission System - California Requirements,
Tier 1
NC3 Tailpipe Modifications
NF2 Emission System- Federal Requirement, Tier 1
NK3 Steering Wheel, Sport, Soft Rim, Simulated
Leather
NP5 Steering Wheel, Leather Wrapped
NW9 ASR-Traction Control
N36 Steering Wheel, 4 Spokes, Sport
N60 Wheel, Aluminum, Painted
N92 Cover, Wheel, Bolt-on
N96 Wheel, 16 x 8, Cast Aluminum
N98 Wheel, Chrome, Var 2
POS Wheel, Chrome, Var 1
P08 Cover, Wheel, Super Deluxe
QA7 Wheel, 16 x 7.5, Aluminum
QB3 Wheel, 16 x 7.5, Steel
.
QEA Tire, P215/60R16 BW R/Pe ST TL AL2 94T
QFZ Tire, P245/50ZR16 BW RIPE ST TL AL3
Qil Tire, P215/60R16 BW RIPE ST TL AL3 94H
QLC Tire, P245/50ZR16/N BL RIPE ST TL HW4
STE Plant Code-St. Therese, PQ, GM of Canada
TR7 Headlamps, Automatic Control Leveling System
T39 Lamp Turn Signal, Auxiliary
T43 Spoiler, Rear
T61 Lighting- Daytime Running
T96 Lamp, Fog
UA6 Theft Deterrent System
UB3 Instrument Cluster, Oil, Coolant, Temperature,
Volts, Trip Odometer, Tachometer
UK2 Lever, Directional Signal, Multifunction
UK3 Electronic System Accessory Control
UN6 Radio, AM/FM Stereo, Se~k/Scan, Auto
Reverse Music Search Cassette, Clock, ETR
UQO Speaker System 4, Dual Front Door Mounted,
Standard Range Quarter/Shelf
UU8 Radio, AM/FM Stereo, Seek/Scan, Auto
Reverse Music Search Cassette, HPS, Clock,
ETR
UlC Radio, AM/FM Stereo, Seek/Scan, Compact
Disc, Clock, ETR
UlT Radio, AM/FM Stereo, Seek/Scan, Compact
Disc, HPS, Clock, ETR
U18 Speedometer Instrument, Kilometers
U19 Speedometer Instrument, Kilometers and Miles,
Kilometer Odometer
U62 Speaker System 4, Dual Coax Front, Dual
Coaxial Package Shelf
U65 Speaker System 5, Dual Front Door Mtd, Dual
Ext Range Sail Panel, Single Rear
Compartment
U73 Antenna, Fixed
U75 Antenna, Power
VG8 Label, Vehicle, Notice To Buyer
VHS Plate, Vehicle Identification
VK3 License Plate, Front Mounting Package
VP6 Noise Control
WS6 Performance Package - Formula/Trans Am
W51 Entertainment System - Radio, AM/FM Stereo,
Seek/Scan, Cassette, 4 Speaker System Standard Range

Cassette, Equalizer, 4 Speaker System - Coaxial
Compact Disc, Equalizer, 4 Speaker System Coaxial
.
.W54 .Entertainment System - Radio, AM/FM Stereo,
Cassette, Equalizer, 10 Speaker System,
Amplifier
wss Entertainment System - Radio, AM/FM Stereo,
Compact Disc, Equalizer, 10 Speaker System,
Amplifier
W57 Entertainment .System ~ Radio, AM/FM Stereo,
Cassette, Equalizer, 4 Speaker System - Coaxial
Compact Disc, Equalizer, 4 Speaker System Coaxial
Cassette, Equalizer, 6 Speaker System, Dual
Front Door Tweeters/Woofers, Extended Range
Shelf
W66 Merchandised Package - Formula
Compact Disc, Equalizer, 6 Speaker System,
Dual Front Door Tweeters/Woofers, Extended
Range Shelf
Y81 Merchandised Package - Firebird
Y82 Merchandised Package - Trans Am, Base Coupe
Y84 Merchandised Package - Trans Am
Y87 Merchandised Package - Performance
Enhancement
Z28 Merchandised Package - Special Performance
Z49 Canadian Modifications
OlU Primary Color Exterior, Special
OSQ Molding Color, Cyclamen
osu Primary Color Exterior, Cyclamen
lLE Performance Package Components
101 Interior Trim - Arctic White
lOT Top Color - Arctic White
102 Trim Combination Leather, Arctic White
lOQ Molding Color - Arctic White
lOU Primary Color - Exterior, Arctic White
12B Trim Combination - Cloth, Graphite
12D Trim Combination - Cloth, Graphite
121 Interior Trim - Graphite
122 Trim Combination - Leather, Graphite
13Q Molding Color - Bright Silver Metallic
13U Primary Color Exterior - Bright Silver Metallic
14B Trim Combination - Cloth, Lt. Gray
141 Interior Trim - Lt. Gray
37Q Molding Color - Dark Bright Teal Metallic
37U Primary Color Exterior - Dark Bright Teal
Metallic
41Q Molding Color - Black
41T Top Color '- Black
41U Primary Color "' Exterior, Black
48U Primary Color Exterior - Dark Yellow Green
Metallic
52B Trim Combination, Cloth, Lt. Neutral
52D Trim Combination, Cloth, Lt. Neutral
521 Interior Trim, Lt. Neutral
522 Trim Combination, Leather, Lt. Neutral
56T Top Color, Med. Neutral II
701
Interior Trim - Torch Red
702 Trim Combination Leather, Torch Red
GENERAL INFORMATION
73B
731
79Q
790
80Q
800
8Xl
81Q
810
96Q
960
Trim Combination Cloth - Flame Red

Interior Trim - Flame Red
Molding Color - Mystic Teal Pearl
Primary Color Exterior - Mystic Teal Pearl
Molding Color Medium - Quasar Blue Metallic
Primary Color - Exterior, Medium Quasar Blue
Metallic
Vehicle Label, Fasten Seat Belt
Molding Color - Bright Red
Primary Color Exterior - Bright Red
Molding Color, Cayenne Red
Primary Color, Exterior, Cayenne Red, Metallic
OA-21
OA-22
GENERAL INFORMATION
BLANK
MAINTENANCE AND LUBRICATION
081
SECTION OB

CONTENTS
Scheduled Maintenance Service ............................. OB-1
Normal Vehicle Use ............................................ OB-1
Selecting the Right Schedule .............................. OB-1
Maintenance Schedule I ...................................... OB-1
Maintenance Schedule II .................................... OB-4
Explanation of Scheduled Maintenance
Services ............................................................ OB-7
Engine Oil and Oil Filter Change .................. OB-7
Chassis Lubrication ......................................... OB-8
Tire and Wheel Inspection and Rotation ....... OB-8
Serpentine Drive Belt Inspection .................... OB-8
Cooling System Service .................................. OB-8
Front Wheel Bearing Repack ......................... OB-8
Transmission Service....................................... OB-8
Spark Plug Replacement.. ............................... OB-8
Spark Plug Wire Inspection ............................ OB-8
SCHEDULED MAINTENANCE
SERVICE
NORMAL VEHICLE USE
The maintenance instructions contained in the
Mainte.nance Schedules are based on the assumption
that the vehicle will be used as designed:
To carry passengers and cargo within the
limitation indicated on the vehicle's Tire Placard
located on the edge of the driver's door.
On reasonable road surfaces within legal operating
limits.
On unleaded gasoline.
SELECTING THE RIGHT SCHEDULE

Determine which of the two schedules is right
for this vehicle. Refer to definitions of maintenance
schedules below:
SCHEDULE I DEFINITION
..
Follow this maintenance schedule ONLY if none
of the conditions from Maintenance Schedule II is
true.
Driving a vehicle with a fully warmed engine
under highway conditions causes engine oil to break
down slower.
Air Cleaner and Crankcase Ventilation Filter

Replacement .............................................. OB-9
Fuel Tank, Cap and Lines Inspection .......... OB-9
Owner Inspection and Services ............................ OB-9
While Operating the Vehicle ............................ OB-9
At Each Fuel Fill. ............................................. OB-9
At Least Monthly .............................................. OB-9
At Least 1\vice a Year ..................................... OB-9
At Least Annually ............................................. OB-10
Each Time Oil Is Changed............................... OB-11
Recommended Fluids and Lubricants .................. OB-12
Maintenance Items ................................................ OB-12
Approximate Fluid Capacities .............................. OB-13
Wheel Nut Torque ................................................ OB-13
Rear Axle Housing Drain/Fill Plug Torque ......... OB-13
Belt Tension Specifications .................................. OB-13
Tire Pressure Specifications .................................. OB-13
SCHEDULE II DEFINITION
Follow Maintenance Schedule II if any one of

these conditions apply to this vehicle:
Most trips are less than 5 to 10 miles (8 to
16 km). This is particularly important when
outside temperatures are below freezing.
Most trips include extensive idling (such as
frequent driving in stop and go traffic).
Most .trips are through dusty areas.
Frequent trailer towing. Do not exceed trailering
limits. See the Owner's Manual for details.
If. the vehicle is used for delivery service, police,
taxi, or other commercial application.
One of the reasons this schedule should be
followed under any of these conditions is that these
conditions cause engine oil to break down sooner.
O
MAINTENANCE SCHEDULE I
The services shown in this schedule up to
100,000 miles (166 000 km) should be performed after
100,000 miles (166 000 km) at the same intervals.
Footnotes
t The U.S. Environmental Protection Agency or

the. California Air Resources Board has determined
that the failure to perform this maintenance item will
not nullify the emission warranty or limit recall
liability prior to the completion of vehicle useful life.
We, however, urge that all recommended maintenance
services be performed at the indicated intervals and
the maintenance be recorded.
OB-2
7,500 Miles (12,500 km)

Change engine oil and filter (or ev~ry_ 12 months,
whichever occurs first). An Em1ss1on Control
Service.
Lubricate the steering linkage. Lubricate the
transmission shift linkage (or every 12 months,
whichever occurs first).
Rotate tires. Refer to "Tire and Wheel Inspection
and Rotation" in this section for proper rotation
pattern and additional information.
15,000 Miles (25 000 km)

Change engine oil and filter (or every 12 months,
whichever occurs first). An Emission Control
Service.
Change automatic transmission fluid and filter if
the vehicle is mainly driven under one or more of
these conditions:
-
In heavy city traffic where the outside

temperature regularly reaches 90F (32C) or
higher.
- On hilly or mountainous terrain.
- When doing frequent trailer towing.
- Uses such as found in taxi, police or delivery
service.
If the vehicle is not used under any of these
conditions, the automatic fluid and filter do not
require changing.
22,500 Miles (37,500 km)

Service.
30,000 Miles (50 000 km)

Service .
Replace air cleaner filter. An Emission Control
Service.
Inspect fuel tank, cap and lines for damage or
leaks. Inspect fuel cap gasket for any damage.
Replace parts as needed. An Emission Control
Service.

these conditions:
-

temperature regularly .reaches 90F (32C) or
higher.
- When doing frequent trailer towing .
service.
require changing.
37,500 Miles (62,500 km)

Service.
45,000 Miles (75 000 km)

Service.
these conditions:

higher.
- When doing frequent trailer towing .
- Uses sch as found in taxi, police or delivery
service.
require changing .
52,500 Miles (87,500 km)

Service.
transmission shift linkage (or .. every 12 months,

60,000 Miles (100 000 km)
Service.
Inspect serpentine drive belt.
Service.
Service.t
these conditions:
- In heavy city traffic where the outside
higher.
service.
require changing.
67,500 Miles (112,500 km)

Change engine oil and. filter (or every 12 months,
Service.
75,000 Miles (125 000 km)

Service.
Change. automatic transmission fluid and filter if
these conditions:
higher.
083

service.
require changing.
82,500 Miles (137,500 km)

Service.
90,000 Miles (150 000 km)

Service.
Service.
Service.t
Change automatic. transmission fluid and filter if
these conditions:
higher.
service.
require changing.
97,500 Miles (162,500 km)

Service.
OB-4
100,000 Miles (166 000 km)

Drain, flush and refill cooling system (or every
60 months since last service, whichever occurs
first). Refer to "Cooling System Service" in this
section. An Emission Control Service.
Inspect spark plug wires. An Emission Control
Service.t
Replace spark plugs. An Emission Control
Service.
these conditions:
higher.
service.
require changing.
MAINTENANCE SCHEDULE II
The services shown in this schedule up to
100,000 miles (166 000 km) should be performed after
100,000 miles (166 000 km) at the same intervals.
Footnotes
t The U.S. Environmental Protection Agency or
the California Air Resources Board has determined
that the failure to perform this maintenance item will
not nullify the emission warranty or limit recall
liability prior to the completion of the vehicle's useful
life. We, however, urge that all recommended
maintenance services be performed at the indicated
intervals and the maintenance .be recorded.
3,000 Miles (5 000 km)

Service.
6,000 Miles (10 000 km)

Service.
9,000 Miles (15 000 km)

Service.
12,000 Miles (20 000 km)

Service.
15,000 Miles (25 000 km)

Service.
Inspect air cleaner filter if the vehicle is driven in
dusty conditions. Replace filter if necessary. An
Emission Control Service.
these conditions:
higher.
service.
require changing.
18,000 Miles (30 000 km)

Service.
21,000 Miles (35 000 km)

Service.
24,000 Miles (40 000 km)

Service.
whichever occurs first);
27,000 Miles (45 000 km)

Service.
30,000 Miles (50
ooo
km)

Service.
Replace air cleaner filter. Replace filter more
often under dusty conditions. An Emission
Control Service.
Inspect fuel cap gasket for any damage. Replace
parts as needed. An Emission Control Service.
these conditions:
~

higher.
-----" Uses such as found in taxi, police or delivery
service.
require changing.
33,000 Miles (55 000 km)

Service.
36,000 Miles (60 000 km)

Service.
39,000 Miles (65 000 km)

Service.
42,000 Miles (70 000 km)
, Change engine oil and filter (or every 3 months,

Service.
OB-5
45,000 Miles (75 000 km)

Service.
these conditions:
higher.
service.
If the vehicle is not . used under any of these

conditions, the automatic fluid and filter. do not
require changing.
48,000 Miles (80 000 km)

whichever occurs first). An .Emission Control
Service.
50,000 Miles (83 000 km)

Change automatic transmission fluid . and filter if
these conditions:
-

higher.
service.
require changing.
51,000 Miles (85 000 km)

Service.
54,000 Miles (90 000 km)

Service.
08-6
57,000 Miles (95 000 km)

Service.
60,000 Miles (100 000 km)

Service.
Inspect serpentine drive belt.
Control Service.
Service.
these conditions:

higher.
service.
require changing.
63,000 Miles (105 000 km)

Change .engine oil and filter (or every 3 months,
Service.
66,000 Miles (110 000 km)

Service.
69,000 Miles (115 000 km)

Service.
72,000 Miles (120 000 km)

Service.
75,000 Miles (125 000 km)

Service.
these conditions:
temperature regularly reaches 90 F (32 C) or
higher.

service.
require changing.
78,000 Miles (130 000 km)

Service.
81,000 Miles (135 000 km)

Service.
84,000 Miles (140 000 km)

Service.
87,000 Miles (145 000 km)

Service.

90,000 Miles (150 000 km)
Service.
Control Service.
Service.t
these conditions:

higher.
service.
require changing.
93,000 Miles (155 000 km)

Service.
96,000 Miles (160 000 km)

Service.
99,000 Miles (165 000 km)

Service.
100,000 Miles (166 000 km)

Drain, flush and refill cooling system (or every 60
months since last service, whichever occurs first).
Refer to "Cooling System Service" in this
section. An Emission Control Service.
Inspect spark plug wires. An Emission Control
Service.t
Replace spark plugs. An Emission Control
Service.
these conditions:
08-7

higher.
service.
require changing.
EXPLANATION OF SCHEDULED
MAINTENANCE SERVICES
The following text and illustrations (Figures 1
and 2) give details of the required maintenance
services.
Engine Oil and Oil Filter Change

Figure 1
Oils recommended can be identified by looking
for the "Starburst" symbol. This symbol indicates that
the oil has been certified by the American Petroleum
Institute (API). Do not use any oil which does not
carry this Starburst symbol.
Engine oil viscosity (thickness) has an effect on
fuel economy and cold-weather operation (starting and
oil flow). Lower viscosity engine oils can provide
better fuel economy and cold-weather performance;
however, higher temperature weather conditions
require higher viscosity engine oils for satisfactory
lubrication. Using oils of any viscosity other
than those recommended could result in
engine damage.
When choosing an oil, consider the range of
temperatures the vehicle will be operated in before the
next oil change. Then, select the recommended oil
viscosity from the chart (Figure 1).
HOT
LOOK FOR
WEATHER ONE OF THESE
f
1111
.31
INI
+2'1
+&a
.,.1,
'4
+lQ
-7
-11
was
SAE ,ow.30
SAE5W30
PREFERRED
COLD
WEATHER
IF NEITHER SAE IW-30 NOR SAE fllW-3Q
GRADE OILS ARE AVAIWLE, SAE 30 GRADE
MAY BE USED AT TEMPERATURES ABOVE
40 DEGREES F 14 DEGREES C).
DO NOT USE SAE 111\V~, W 211\VSO OR
ANY OTHER BRIIDE OIL NOT RECOMMENDED.
01-23-95
FS0030B
Figure 1 - Engine Oil Viscosity Recommendation
OEM3 MAINTENANCE AND LUBRICATION

Chassis lubrication
Serpentine Drive Belt Inspection
Lubricate steering linkage and transmission shift

linkage.
Inspect drive belt for cracks or fraying. If

sections of the drive belt are missing, the drive belt
should be replaced. Refer to SECTION 6A3A or
SECTION 6A8A.
Tire and Wheel Inspection and Rotation

Figure 2
Cooling System Service
Check tires for abnormal wear or damage. To

equalize wear and obtain maximum tire life, rotate as
shown in Figure 2.
If the vehicle is equipped with P245/50ZR16
size tires, special rotation provisions must be followed
because the tires are directional. See Figure 2 for the
recommended rotation. Directional tires have
color-coded arrows on both sides of the sidewall
pointing in the direction the tires must roll for the
correct performance.
If irregular or premature wear exists, check
wheel alignment. Also, check for damaged wheels. Do
not include the compact spare tire in rotation.
While the tire and wheels are removed, perform
the brake systems inspection specified. Refer to "Each
Time Oil Is Changed" in this section.
Drain, flush and refill system with

DEX-COOL (orange-colored, silicate free) engine
coolant every 160 000 km (100,000 miles) or five
years. Refer to "Recommended Fluids and
Lubricants" in this section, or SECTION 6B. Inspect
hoses. Clean radiator, con.denser, pressure cap and
neck. Pressure test cooling system and pressure cap.
II]
Important
If silicate coolant is added to the system,

premature engine, heater core or radiator corrosion
may result. In addition, the coolant will require
change sooner at 50 000 km (30,000 miles) or
24 months.
Front Wheel Bearing Repack

The front wheel bearings are not serviceable.
Complete replacement of the front wheel bearing hubs
is required.
Transmission Service
For the manual transmission, fluid does not
require changing. Refer to SECTION 7B for more
information.
For the automatic transmission, change both the
fluid and the filter every 25 000 km (15,000 miles) if
these conditions:
ffi]
lI Il
B
A NORMAL FOUR-WHEEL ROTATION PATIERN FOR TIRES
DESIGNED TO ROLL IN EITHER DIRECTION
8 SPECIAL FOUR-WHEEL ROTATION PATIERN FOR
DIRECTIONAL TIRES DESIGNED TO ROLL MAINLY IN ONE
DIRECTION
IMPORTANT: DO NOT INCLUDE COMPACT SPARE TIRE
ASSEMBLY IN ROTATION.
Figure 2 - Recommended Tire Rotation Pattern
In heavy city traffic where outside temperature

regularly reaches 32C (90F) or higher..
On hilly or mountainous terrain.
Frequent trailer towing. Do not exceed trail~g
limits. See the Owner's Manual or dealership
trailering brochure for details.
Used for delivery service, police, taxi or other
commercial applications.
conditions, the automatic transmission fluid and filter
do not require changing. Refer to SECTION 7A for
more information.
Spark Plug Replacement

Replace spark plugs every 160 000 km (100,000
miles) on the 3800 (VIN K) engine and on the 5.7L
(VIN P) engine with type listed. Refer to
"Maintenance Items" in this section.
Spark Plug Wire Inspection

Clean wires and inspect for burns, cracks or
other damage. Check the wire boot fit at the ignition
distributor and/or ignition distributor coil, and at the
spark plugs. Replace the wires as needed.

Air Cleaner and Crankcase Ventilation
Filter Replacement
. Replace the air cleaner filter every 50 000 km
(30,000 miles) or 36 months, whichever comes first.
Replace more often under dusty conditions.
Fuel Tank, Cap and Lines Inspection

leaks. Inspect fuel cap gasket for an even filler neck
imprint or any damage. Inspect injections. Replace
parts as needed. Periodic replacement of the fuel filter
is not required.
OWNER INSPECTION AND

SERVICES
Listed below are vehicle inspections and services
that should be made by either the owner or a qualified
technician at the frequencies indicated to help ensure
proper safety, emission systems performance and
dependability of the vehicle. Whenever repairs are
necessary, have them completed at once.
Any safety related or emissions related
components that could have been damaged in an
accident should be inspected and all needed repairs
should be performed before operating the vehicle.
WHILE OPERATING THE VEHICLE

Automatic transmission shift indicator
operation -Make sure the indicator points to the gear
chosen.
Hom operation - Blow the horn. occasionally
to make sure it works. Check all button locations.
Brake system operation - Be alert to
abnormal sounds, increased brake pedal travel or
repeated pulling to one side when braking. Also, if the
brake warning lamp or antilock brake ,system warning
lamp goes on or flashes, something may be wrong
with part of the brake system.
Exhaust system operation - Be alert to any
changes in the sound of the system or any smell of
fumes. These are signs the system may be leaking or
overheating. Have it inspected and repaired at once.
Tires, wheels and alignment operation Be alert to a vibration of the steering wheel or seat at
normal highway speeds. This may mean a wheel
balance is needed. Also, a pull right or left on a
straight and level road may show the .need for a tire
pressure adjustment or a wheel alignment.
Steering system operation - Be alert to
changes in steering action. An inspection is needed
when the steering wheel is harder to turn, or has too
much free play, or if unusual sounds are noted when
turning or parking.
Headlamp capsule aim - Take note of the
light pattern occasionally. If beams seem to be
improperly aimed, headlamps should be checked and
adjusted as necessary.
AT EACH FUEL FILL

A fluid loss in any system (except windshield
washer) may indicate a problem. Have the system
inspected and repaired at once.
08-9
Engine oil level - Check level and add oil if

necessary. The best time to check the engine oil level
is. when the_ oil is warm. After stopping the engine
with the vehicle on a level surface, wait a few minutes
for the oil to drain back to the oil pan. Pull out the oil
level indicator and wipe it clean. Push the oil level
indicator back down all the way. Pull out the oil level
indicator keeping the tip down, and look at the oil
level on it.
Add oil, if needed, to keep the oil level above
the "ADD" line and within the cross-hatched
operati~g range area. ~void overfilling the engine
smce this may cause engme damage. Push the oil level
indicator back down all the way after taking the
reading.
If you check the oil level when the oil is cold,
do not run the engine first The cold oil will not drain
back to the pan fast enough to give a true oil level.
Engine coolant level and condition - Check
engine coolant level in the coolant reservoir and add
coolant if necessary.
Windshield washer solvent level - Check
washer solvent level in reservoir and add solvent if
necessary.
Hood latch operation - When opening the
hood, note the operation of the secondary latch. It
should keep the hood from opening all the way when
the primary latch is released. Make sure that the hood
closes firmly.
AT LEAST MONTHLY
Tire and wheel inspection and pressure
check - Check tires for abnormal wear or damage.
Also check for damaged wheels. Pressure should be
checked when tires are "cold." Maintain pressures as
shown in "Tire Pressure Specifications" in this
section, or the Tire Placard on the driver's door.
lamp operation - Check operation of the
license plate lamp, sidemarker lamps, headlamps
(including high beams), fog lamps, parking lamps,
taillamps, brake lamps (including the center
high-mounted stoplamp), turn signals, backup lamps,
hazard warning flasher and interior lamps.
Fluid leak check - Periodically inspect the
surface beneath the vehicle for water, oil, fuel or other
fluids after the vehicle has been parked for a while.
Water dripping from the air conditioning system after
use is normal. The cause of fuel leaks or fumes should
be found and corrected at once.
AT LEAST TWICE A YEAR

Power steering system reservoir level Check and keep at proper level. Refer to
SECTION 3B1B.
Brake master cylinder reservoir level Check fluid. Refer to SECTION SA. Keep fluid at
proper level. A low fluid level can indicate worn disc
brake pads which may need to be serviced. Also refer
to SECTION 5El.
Hydraulic clutch reservoir level - Check
and keep at proper level. Refer to SECTION 7C. A
fluid loss in this system could indicate a problem.
OB-10
Weatherstrip lubrication - Clean the surface

and then apply a thin film of silicone grease, GM
PIN 12345579 or equivalent, using a clean cloth.
Throttle linkage inspection - Throttle system
(includes accelerator and cruise control) should operate
freely without hesitation between full closed and wide
open throttle.
rn
Important
Accelerator and cruise control cables should not

be lubricated under any condition. Throttle system
components causing hesitation or sticking should
be replaced.
Inspect for the following:
Missing parts such as retainers or clips.
Interference of linkage or cable conduit to
critical components such as fuel lines, brake
pipes, harness leads, etc.
Proximity of cable to exhaust system and other
heat sources; check for melting and/or
discoloration.
Cable kinking, maintain generous bend radii of
cables.
Clearance of throttle system moving parts
throughout their travel from other stationary
components.
Damage of components due to cable kinking,
severe kinking, severe abrasion, mis-alignment,
etc.
If any of the above conditions exists; notify your
dealer for a recommended rerouting, adjustment, or
replacement.
AT LEAST ANNUALLY
CAUTION: Before checking the holding
ability of the parking brake and automatic
transmission park mechanism, park on a
fairly steep hill with enough room for
movement in the downhill direction. To
reduce the risk of personal injury or
property damage, be prepared to apply
the regular brakes promptly if the vehicle
begins to move.
Parking brake and transmission park
mechanism operation - To check the parking
brake, with the engine running, parking brake set and
transmission in "NEUTRAL," slowly remove foot
pressure from the regular brake pedal until the vehicle
is held only by the parking brake.
To check the automatic transmission park
mechanism holding ability, release all brakes after
shifting the transmission to "PARK."
CAUTION: Before performing the

following transmission neutral start
switch check, be sure to have enough
room around the vehicle. Then, firmly
apply both the parking brake and the
regular brakes. Do not use the
accelerator pedal. If the engine starts, be
ready to turn off the ignition promptly.
Take these precautions because the
vehicle could move without warning and
possibly cause personal injury or
property damage.
Transmission neutral start switch operation - On
automatic transmission vehicles, try to start the engine
in each gear. The starter should crank only in
"PARK" or "NEUTRAL."
On manual transmission vehicles, place the shift
lever in "NEUTRAL," push the clutch pedal halfway
and try to start. The starter should crank only when
the clutch pedal is fully depressed.
Steering column lock operation - While
parked, try to turn the key to "LOCK" in each gear
range. On vehicles with automatic transmissions, the
key should tum to "LOCK" only when the gear
selector is in "PARK." On vehicles with key release
button, try to turn to "LOCK" without depressing the
button. The key should turn to "LOCK" only with the
key button depressed.
Seatback latch operation - Be sure seatbacks
latch on those vehicles with folding seats using
mechanical latches.
Lap and shoulder belts condition .and

operation -Inspect belt system, including webbing,
buckles, latch plates, retractor, guide loops and
anchors.
Movable head restraint operation - Make
sure movable head restraints stay in the desired
position.
Seatback recliner operation (if equipped) Make sure the recliner is holding by pushing and
pulling on the top of the seatback while it is reclined.
Spare tire and jack storage - Be alert to
rattles in rear of the vehicle. Make sure the spare tire,
all jacking equipment and any covers or doors are
securely stowed at all times. Oil the jack screw
mechanism after each use.
Key lock service - Lubricate the key lock
cylinder (except instrument panel compartment lock).
Body lubrication service - Lubricate all body
door hinges, including the hood, fuel door and rear
compartment hinges and latches, the instrument panel
compartment door, and any folding seat hardware.
Lubricate all pivot points in the headlamp door,
including the spring links for each door.
Underbody flushing - At least every spring,
flush from the underbody any corrosive materials used
for ice and snow removal and dust control. Use plain
water. Take care to thoroughly clean any areas where
mud or other debris can collect. Sediment packed in
closed areas of the vehicle should be loosened before
being flushed.

Engine cooling system - Inspect coolant and
freeze protection. Keep coolant at the proper mixture
for proper freeze protection, corrosion inhibitor level
and best engine operating temperature. Inspect hoses
and replace if cracked, swollen or deteriorated. Clean
outside of radiator and air conditioning condenser.
Wash filler cap and neck. To help ensure proper
operation, a pressure test of both the cooling system
and cap is also recommended.
EACH TIME OIL IS CHANGED

Automatic transmission fluid level Maintain level within operating range on the oil level
indicator. Refer to SECTION 7A.
Manual transmission - Check fluid level and
add as required. Refer to SECTION 7B ..
Brake systems inspection - For
convenience, the following should be done when
wheels are removed for rotation: Inspect lines and
hoses for proper hookup, binding, leaks, cracks,
chafing, etc. Inspect disc brake pads for wear and
rotors for surface condition. Also inspect drum brake
linings for wear and cracks. Inspect other brake parts,
including drums, wheel cylinders, parking brake, etc.,
at the same time. The parking brake is self-adjusting
and no manual adjustment is required.
II]
Important
Inspect brakes rriore often if habit or conditions

result in frequent braking.
Steering and suspension inspection \
Inspect front and rear suspension and steering system

for damaged, loose or missing parts, signs of wear or
lack of lubrication. Inspect power steering lines and
hoses for proper hookup, binding, leaks, cracks,
chafing, etc.
OB-11
Exhaust system inspection - Inspect

complete system, including catalytic converter. Inspect
body near the exhaust system. Look for broken,
damaged, missing or out-of-position parts as well as
open seams, holes, loose connections and other
conditions which could cause a heat buildup in the
floor pan or could let exhaust fumes seep into the
trunk or passenger compartment. Check heat shields.
Tighten connections or replace parts as necessary.
Throttle linkage inspection - Inspect for
interference, binding, and damaged or missing parts.
Serpentine drive belt - Inspect drive belt for
cracks, fraying, wear and proper tension. Drive belts
cannot be adjusted. Replace tensioner or drive belt as
needed. Refer to SECTION 6A3A or
SECTION 6A8A.
Rear axle - Check fluid level and add if
needed. To check or add fluid, hoist vehicle at
suspension contact points. Refer to SECTION OA.
Keep vehicle level. Clean dirt or foreign material from
around drain/fill plug opening before removing the
plug. Maintain fluid level .from flush with bottom of
opening to no lower than 14 mm (9/16 inch) below
opening.. Always replace drain/fill plug. Tighten to
35 N.m (26 lb. ft.).
If the vehicle is used to tow a trailer; change
lubricant every 12 500 krri (7,500 miles) in either type
differential.
Limited slip differentials should have fluid
drained and refilled at the first 12 500 km (7,500
miles). Be sure to add limited slip additive. Refer to
"Recommended Fluids and Lubricants" in this section.
0812
RECOMMENDED FLUIDS AND LUBRICANTS

Engine oil. - GM Goodwrench motor oil or equivalent with API "Starburst" of recommended viscosity.
Engine coolant - 50150 mixture of water (preferably distilled) and ethylene glycol based DEX-COOL
(orange-colored, silicate free) engine coolant meeting GM Specification 6277M (GM PIN 12346290).
Hydraulic brake system - Delco-Supreme 11 brake fluid (GM PIN 1052535) DOT-3 brake fluid.
Hydraulic clutch system - Hydraulic clutch fluid (GM PIN 12345347 or equivalent).
Power steering system - Power steering fluid meeting requirements of GM 9985010 (GM PIN 1050017,
GM PIN 1052884 or equivalent). In cold climates use GM PIN 12345867, GM PIN 12345866 or equivalent.
(System should be drained and refilled prior to using this fluid).
.
Automatic transmission - DEXRON-III (GM PIN 12346143) automatic transmission fluid.

Automatic transmission shift linkage - Engine oil.
Clutch linkage pivot points - Engine oil.
Manual transmission DEXRON-111 (GM PIN 12346143) automatic transmission fluid.
Manual transmission shift linkage - Chassis lubricant meeting requirements of NLGI Grade 2, Category
LB or GC-LB (GM PIN 1052497).
.
Key lock cylinders (except instrument panel compartment lock) - Lubricate with Superlube
Lubricant (GM PIN 12346241). Do not use aerosols.
Weatherstrips - Dielectric silicone grease (GM PIN 12345579 or equivalent).
..
Standard differential rear axle - SAE 80W-90 GL-5 gear lubricant or axle lubricant (GM PIN 12345977,
or equivalent).
Limited slip differential rear axle - All models require 59 ml (2 fl. oz.) of limited slip differential
additive lubricant (GM PIN 1052358 or equivalent) and axle lubricant (GM PIN 12345977).
Windshield washer solvent - GM Optikleen Washer Solvent (GM PIN 1051515 or equivalent).
Hood latch and pivots - Engine oil.
Hood latch release pawl - Chassis lubricant meeting requirements of NLGI Grade 2, Category LB or
GC-LB (GM PIN 1052497).
Hood and door hinges, hatchback lid hinge and linkage. Headlamp doors, if equipped. Rear
folding seat. Fuel door hinge. Rear compartment lid hinges. - Superlube Lubricant (GIM
PIN 12346241).
MAIN'TENANCE ITEMS
Air Cleaner Filter
All VIN .................................................................................................................................. AC Type A1163C
Engine Oil Filter
3800 (VIN K) ............................................................................................................................. AC Type PF47
5.7L (VIN P) .............................................................................................................................. AC Type PF25
Fuel Filter
3800 (VIN K) .......................................................................................................................... AC Type GF627
5.7L (VIN P) ........................................................................................................................... AC Type GF578
PCV Valve
3800 (VIN K) ....................................................................................................................... AC Type CV892C
5.7L (VIN P) ........................................................................................................................ AC Type CV895C
Spark Plugs and Gap
3800 (VIN K) .................................................................................... AC Type 41-921 1.52 mm (0.060 inch)
5.7L (VIN P) ..................................................................................... AC Type 41-943 1.24 mm (0.050 inch)
08-13
APPROXIMATE FLUID CAPACITIES

Air Conditioning
3800 (VIN K) ......................................................................................................... R-134a - 0.77 kg (1.7 lbs.)
5.7L (VIN P) .......................................................................................................... R-134a - 0.91 kg (2.0 lbs.)
Engine Crankcase
Without Filter Change (All VIN) ......................................................................................... 3.8 liters (4.0 qt.)
With Filter Change
3800 (VIN K) ................................................................................................................... 4.3 liters (4.5 qt.)
5.7L (VIN P) ..................................................................................................................... 4.7 liters (5.0 qt.)
Fuel Tank .............................................................................................................................. 58.7 liters (15.5 gal.)
Transmission
Manual - Drain and Refill and Overhaul
Five-Speed ......................................................................................................................... 3.2 liters (6.8 pt.)
Six-Speed ........................................................................................................................... 3.8 liters (8.0 pt.)
Automatic (HYDRA-MATIC 4L60-E)
3800 (VIN K) Drain & Refill ....................................................................................... 4.7 liters (10.0 pt.)
3800 (VIN K) Overhaul ................................................................................................. 7. 9 liters (16.7 pt.)
5.7L (VIN P) Drain and Refill ...................................................................................... 4.7 liters (10.0 pt.)
5.7L (VIN P) Overhaul ................................................................................................ 10.6 liters (22.4 pt.)
Cooling System
3800 (VINK)
With Automatic Transmission ....................................................................................... 11.6 liters (12.3 qt.)
With Manual Transmission ............................................................................................ 11.8 liters (12.5 qt.)
5.7L (VIN P)
With Automatic Transmission ...................................................................................... 14.3 liters (15.1 qt.)
With Manual Transmission ........................................................................................... 14.5 liters (15.3 qt.)
Rear Axle - Drain and Refill .................................................................................................... 1.7 liters (3.5 pt.)
Rear Axle (Limited Slip Differential) - Additive ........................................................... 59 milliliters (2 fl. oz.)
The capacities shown here are approximate. Add fluid as necessary to bring to appropriate level.
WHEEL NUT TORQUE

Wheel Nuts .......................................................................................................................... 140 N.m (100 lb. ft.)
REAR AXLE HOUSING DRAIN/FILL PLUG TORQUE

Drain/Fill Plug ......................................................................................................................... 35 N.m (26 lb. ft.)
BELT TENSION SPECIFICATIONS

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

Compact Spare ............................................................................................................................. 420 kPa (60 ps~)
Front and Rear - All ................................................................................................................... 210 kPa (30 psi)
0814 MAINTENANCE AND LUBRICATION
BLANK
(
VIBRATION DIAGNOSIS
OC-1
SECTION OC
)
VIBRATION DIAGNOSIS
NOTICE: Always use the correct fastener in the correct location. When you replace a fastener, use ONLY the
exact part number for that application. General Motors will call out thos.e fasteners that require a replacement
after removal. General Motors will also call out the fasteners that require thread lockers or thread sealant.
UNLESS OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion
inhibitors) on threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener
torque and joint clamping force, and may damage the fastener. When you install fasteners, use the correct
sequence and tightening specifications. Following these instructions can help you avoid damage to parts and
~~-
CONTENTS
General Description ................................................. OC-1
Vibration .............................................................. oc.:.1
Diagnosis ................................................................. OC-1
Reed Tachometer ................................................. OC-1
Electronic Vibration Analyzer (EVA) ................. OC-2
Classifying a Vibration Complaint ..................... OC-3
Road Test. ............................................................ OC-3
Vehicle Speed Sensitive ...................................... OC-4
Engine Speed Sensitive ....................................... OC-:4
Torque Sensitive .................................................. OC-4
Jounce or Load Sensitive.................................... OC-4
On-Vehicle Service.................................................. OC-5

Engine Speed Sensitive Only ............................. OC-5
Vehicle Speed Sensitive Only ............................ OC-5
Torque and Vehicle Speed Sensitive .................. OC-6
Torque and Engine Speed Sensitive................... OC-6
Propeller Shaft. .................................................... OC-6
Propeller Shaft Runout ................................... OC-6
Propeller Shaft Balance .................................. OC-6
Universal Joints ................................................... OC-7
Driveline Angles ................................................. OC-7
Special Tools ........................................................... OC-7
GENERAL DESCRIPTION
DIAGNOSIS
VIBRATION
REED TACHOMETER
Among the problems encountered in the

development and servicing of a vehicle, vibration
conditions are perhaps the most difficult to identify
and correct This difficulty arises since the vibration
the driver feels or hears is generally not the source of
the problem, but rather a component responding to
some external excitation, e.g., the steering wheel may
vibrate due to the unbalance of a wheel, the engine,
etc. Also, the source of the excitation may be built
into the operation of the vehicle, and therefore cannot
be eliminated (vehicle is normal) as in the case of the
power pulses from the engine.
Vibration is a back and forth oscillation that can
be seen, heard or felt. A vibration results from a
system (group of parts) responding to an alternating
excitation, the resulting motion being transmitted
either visually (can be seen), audibly (c;an be heard) or
physically (can be felt) to the occupants. A vehicle
imbalance or misalignment. is usually the cause of a
vibration;
There are three ways to correct a vibration:
Figures 1 and 2
1. Eliminate the source of the vibration.

2. Interrupt the transfer path.
3. Stop the responder from responding;
To .. aid in the diagnosis of vibrations, a reed

tachometer can be used to identify the frequency of a
rotational component with a repetitive vibration
(Figure 1).
MBS0010C
Figure 1-Reed Tachometer
OC-2
VIBRATION DIAGNOSIS
1ST ORDER VIBRATION

(ONCE PER REVOLUTION)
90
1ao
270
360
2ND ORDER VIBRATION

(TWICE PER REVOLUTION)
MBS00200
Figure 2-0rder of Vibration
The Biddle Frahm Reed Tachometer, or

equivalent, measures vibration in cycles per minute
(CPM). It consists of two rows of reeds. Each row is
designed to vibrate at a particular frequency.
If you can match the rotational speed of a
particular component with the frequency reading of the
reed tachometer, you will know in which area to
concentrate your efforts for repairs. Each component
on a vehicle will vibrate at a natural frequency. This
frequency acts like a fingerprint and will identify a
component. For a particular component, this frequency
will vary with vehicle speed and/or engine speed.
These frequency relationships exist for all vibrations
that occur in a vehicle, and understanding these
relationships can often solve difficult vibration
problems.
The reed tachometer should be placed on the top
of the instrument panel for ease of. viewing and for
effective pickup of a vibration.
Some components may induce more than one
vibration at a given speed. These multiple vibrations
are referred to as the order of vibration. The order of
vibration refers to the number of disturbances created
by one rotation of a component. For example, a tire
with one heavy spot will produce one. disturbance each
rotation, a first order vibration (Figure 2). An
oval-shaped tire will produce two disturbances each
rotation, a second order vibration. (Figure 2).
In general, the suspect component should be
isolated to verify the cause of a vibration before parts
are replaced. For a first order tire vibration, the
responsible component can be anything which rotates
at wheel and tire speed (i.e., wheels, tires, brake
rotors, brake drums). These can be serviced or

replaced with known good parts to identify the
component causing the vibration. Once verified, the
component can be balanced or replaced as necessary.
Using a reed tachometer in a vehicle will take
some practice. One of the more important things to be
aware of when using the reed tachometer for the first
time is that the reeds are very sensitive and will pick
up many low amplitude vibrations. These will appear
as slight movements of many reeds, and do not
correspond to any particular component. Reed
movement that corresponds to a vibrating component
will be greater in amplitude, traveling the full range of
the viewing area.. Reed vibration will also change as
engine speed or vehicle speed changes.
ELECTRONIC VIBRATION ANALYZER

(EVA)
Figure 3
The Electronic Vibration Analyzer (EVA)
J 38792 speeds up the diagnosis of vibrations
(Figure 3). The EVA displays three predominant
frequencies and their amplitudes in order from the
strongest to the weakest.
The EVA is equipped with a vibration sensor
that can be plugged into either input A or input B on
the front of the EVA. The vibration sensor can be
mounted almost anywhere on the vehicle using a
magnet or adhesive putty. There is a trigger wire on
the front of the EVA that a strobe light can be
attached to for driveshaft balancing.
VIBRATION DIAGNOSIS
OC-3
ROAD TEST
The road test is a very beneficial way to help the
technician locate the vibration. If possible, the owner
of the vehicle should be present for the road test to
help point out the vibration complaint.. The importance
of riding in the vehicle with the owner cannot be
overemphasized. If the condition is normal, and no
corrective action is needed, the owner should be told
so immediately. A normal condition can be
demonstrated with other vehicles, pointing out that
similar vehicles have the same condition. To help
diagnose and isolate the source of a vibration, it is
important to road test the vehicle and use a systematic
approach in narrowing. down the possible causes of a
vibration.
[1J
290080758
Figure 3-Electronic Vibration Analyzer (EVA)
[I]
Important
The vibration sensor is marked with the word

"UP" on one side. Mount the sensor in the
horizontal position with the "UP" identification
facing up. Mount the sensor as close as possible
to the source of the vibration. Refer to the EVA
instruction manual for information about sensor
calibration.
'
CLASSIFYING A VIBRATION COMPLAINT

There are several excitation sources and many
responding systems which may cause an annoying
vibration. The first step is to identify the individual
vibration complaints by systematically classifying
them, during a road test, into one or more of the
following categories:
1. Vehicle speed sensitive.
2. Engine speed sensitive.
3. Torque sensitive.
4. Jounce (load) sensitive.
In the process of classifying vibration problems
in terms of these four sensitivity categories, you will
find that many problems fit more than one of the
categories. These four sensitivity categories can be
combined into a list of five possible combinations into
which a majority. of vibration problems will fall:
A. Engine speed sensitive only.
B. Vehicle speed sensitive only.
C. Torque sensitive and vehicle speed sensitive.
D. Torque sensitive and engine speed sensitive.
E. Torque sensitive, vehicle speed sensitive and
jounce sensitive.
Since each of the categories has specific
vibrations associated with it, determining which
category(ies) the vibration falls into will give direction
to the proper area for analysis of the problem. This
will eliminate many components that cannot be the
cause, and will focus attention on only those items
that can contribute to the specific condition
encountered.
Important
Before road testing the vehicle, check the

following:
A. Tires for correct inflation pressure. Refer to
the tire placard affixed to the driver's door
jamb for tire inflation specifications.
B. Vehicle for correct load conditions. Refer to
the tire placard affixed to the driver's door
jamb for vehicle load specifications.
C. Wheel nuts for proper torque. Refer to
SECTION 3E.
D. Engine mounts for proper torque. Refer to
SECTION 6A3A or 6A8A.
E. All universal joint fasteners for tightness and
correct torque. Refer to SECTION 4A.
When did the vibration start?
Did the vibration start after a repair?
- Exhaust system
- Undercoating
- Tire repair or replacement
- Wheel alignment
- Engine repair
-Other
The following questions should be used as a
basic outline during the road test. These questions will
enable you to eliminate many components and focus
attention on only those items that can be responsible
for the vibration complaint.
Is it a noise? Can it be heard as well as felt?
What type of noise is it?
-Buzz
-Moan
-Rattle
-Squeak
-Shudder
Where can the vibration be felt?
-Seat
-Floor
- Steering Wheel
Does the vibration occur on smooth or rough
roads?
When does the vibration occur?
OC-4 VIBRATION DIAGNOSIS

Four major component groups are usually the
cause of, or are related to the vibration:
1. Engine and mounts.
2. Clutch and transmission.
3. Tires, wheels, brake drums and rotors.
4. Propeller shaft and universal joints .
The following list contains items that may cause
vibration:
!L!
Inspect
1. Wheel alignment. Refer to SECTION 3A for

wheel alignment specifications.
2. Tire treads for blisters or separations.
3. Tire or wheel for proper balance. Refer to
SECTION 3E for specifications.
4. Brake drum or rotor for damage or deformation.
5. Tie rod ends for wear.
6. Trim height. Refer to SECTION 3 for trim height
specifications.
7. Lower ball joints for wear or damage.
8. Wheel for excessive runout. Refer to
SECTION 3E for wheel runout specifications.
9. Tire and wheel assembly for excessive lateral or
radial runout. Refer to SECTION 3 for runout
specifications.
10. Universal joints for looseness or damage.
COAST TEST
Drive the vehicle past the vibration speed, shift

into neutral and coast back through the vibration
speed. In this test two kinds of vibrations normally
occur: a shaking or a buzzing. A shaking vibration is
usually caused by tires or a wheel and brake drum/disc
assembly problem. A buzzing vibration is usually
caused by a driveline problem.
VEHICLE SPEED SENSITIVE

Tool Required:
TK-0-A TECH 1 Tester
Most vibration complaints are vehicle
speed sensitive. The frequency of the excitation
depends on the speed of the vehicle. To
determine if a given problem is vehicle speed
sensitive:
1. Connect a TECH 1 to the Data Link Connector
(DLC) and display engine rpm. Refer to the
TECH 1 operator's guide.
2. Drive the vehicle in high gear and record the
vehicle speed and the engine speed at which the
problem occurs.
3. Shift the vehicle into the next lowest gear and
again record the vehicle speed and engine speed
at which the problem occurs.
4. If the problem occurs at the same vehicle speed
as when the vehicle was in high gear, the
vibration is vehicle speed sensitive.
ENGINE SPEED SENSITIVE

Tool Required:
Another group of vibration complaints are
engine speed sensitive. The frequency of the
excitation depends only on the speed of the
engine, independent of the vehicle speed. To
determine if a given problem is engine speed
sensitive:
problem occurs.
3. Shift the vehicle into the next lowest gear and
again record the vehicle speed and engine speed
at which the problem occurs.
4. If the problem occurs at the same engine speed as
when the vehicle was in high gear, the vibration is
engine speed sensitive.
TORQUE SENSITIVE
Tool Required:
A torque sensitive problem is one which
increases in intensity as the torque (power)
output of the engine increases. The intensity of
the vibration increases as the throttle opening is
increased. To determine if a given problem is
torque sensitive:
problem occurs.
3. Observe the disturbance while varying the throttle
position. That is, drive the vehicle with steady
throttle, slowly increasing to heavy throttle by
going uphill or applying the brakes while
increasing the throttle opening and then slowly
decreasing to minimum throttle by coasting
through the disturbance.
4. If the disturbance becomes more severe as the
throttle opening is increased, the vibration is
torque sensitive.
JOUNCE OR LOAD SENSITIVE
A jounce or load sensitive problem is one which
varies in intensity as the height of the vehicle changes
with respect to the surface of the road. The intensity
varies as the front struts are extended or compressed.
To determine if a given problem is jounce or load
sensitive:
1. Drive the vehicle a number of times, changing the
load each time and observing the disturbance.
2. Drive the vehicle over a road that dips in such a
way that it causes the front of the vehicle to move
up and down in relation to the surface of the road.
Keeping a constant throttle, observe the
disturbance.
VIBRATION DIAGNOSIS
3. If the condition varies depending on the passenger
load (or varies as the front of the vehicle moves
up and down), the problem is jounce or load
sensitive.
Jounce sensitive vibrations may also be torque or
engine speed sensitive.
ON-VEHICLE SERVICE
ENGINE SPEED SENSITIVE ONLY
Problems in this category may be duplicated

with the vehicle stopped and the transmission in
neutral by running the engine at the speed which the
disturbance was felt during the road test. All additional
appraisals can thus .be made under this "free engine"
condition.
Engine speed sensitive problems can be due to
the belt or engine-driven accessories (generator, A/C
compressor, coolant pump, power steering pump). To
isolate the offending component, first check the torque
on all accessory bracket fasteners. Also, check the
condition and tension of the drive belts. If any
abnormal conditions are found, correct and retest for
the vibration problem.
For generator fastener torque specifications, refer
to SECTION 603. For A/C compressor fastener torque
specifications, refer to SECTION lB. For coolant
pump fastener torque specifications, refer to SECTION
6B. For power steering pump fastener torque
specifications, refer to SECTION 3B.
If the vibration occurs after all accessory drive

belts and fasteners have been properly adjusted and
tightened, the accessory may have an internal problem
such as bad bearings, bent shafts or imbalance. Repair
or replace unsatisfactory parts until all accessories run
smoothly.
If all accessories run smoothly and the vibration
problem still exists, check for basic engine imbalance
due to a defective or loose flywheel. For flywheel
torque specifications, refer to SECTION 7A or 7B.
Also, on automatic transmission equipped vehicles,
check for a defective or loose torque converter. For
torque converter specifications, refer to SECTION 7A.
If the vibration occurred after a major engine overhaul,
the cause may be internal. For engine mechanical
diagnosis, refer to SECTION 6.
AIC compressor problems can be diagnosed by
turning the compressor off and on. while the vibration
condition is being experienced. Refer to SECTION 1B
for air conditioning service procedures.
VEHICLE SPEED SENSITIVE ONLY

Figure 4
Vehicle speed sensitive vibration problems are
usually related to tire and wheel imbalance or runout.
Low speed vibrations, those occurring at less than 64
km/h (40 mph), are usually runout related. Highway
speed vibrations, those speeds above 64 km/h (40
mph), can be caused by either imbalance or runout.
For wheel and tire balancing procedures, refer to
SECTION 3E. To investigate the possibility of wheel
SUSPENSION MOVEMENT
(Loaded Runout)
,,-'
,----.. --~ ,,____-..... ____ _-,,,
SMOOTH ROAD
CAUSED BY
TIRE OUT
OF
ROUND
OC-5
TIRE
STIFFNESS
VARIATION
Figure 4-Causes of Vibrations
RIM BENT
OR
OUT OF ROUND
OC-6
VIBRATION DIAGNOSIS
or tire runout, refer to SECTION 3. If a vibration

remains after dynamic balancing, it can be caused by
three things (Figure 4):
1. Tire runout.
2. Wheel runout.
3. Tire stiffness variations.
For service procedures concerning these three
problems, refer. to SECTION 3.
Another condition that is vehicle speed sensitive
is a problem called "radial tire waddle." This
condition is caused by a steel belt not being straight
within the tire, or by excessive lateral runout of the
tire or wheel. The vehicle can be road tested to
determine which end of the vehicle has the faulty tire.
If the waddle tire is on the rear, the rear end of the
vehicle will shake from side to side or "waddle."
From the driver's seat it feels as though someone is
pushing on the side of the vehicle. For "radial tire
waddle" service procedures, refer to SECTION 3.
TORQUE AND VEHICLE SPEED

SENSITIVE
The only excitations which are both vehicle
speed sensitive and torque sensitive (and possibly
jounce sensitive) are disturbances caused by improper
driveline angles wl)ich are a result of incorrect trim
height or faulty universal joints. Check for the
following:
Worn or damaged universal joints. The universal
joints should pivot smoothly. If universal joint
binds or appears tight, replace the universal joint
as an assembly. Refer to SECTION 4A for
universal joint service procedures.
Correct trim height. Refer to SECTION 3.
TORQUE AND ENGINE SPEED SENSITIVE
Vibration problems likely to be encountered in
this class are as follows:
A. Engine-driven accessories (generator, A/C
compressor, coolant pump, power steering pump).
Engine-driven accessories generally do not
present a problem if all fasteners are tightened
to specifications and their respective drive
belts are adjusted to proper tension. Also
check physical conditio'l of the drive belts.
Visually inspect each accessory to ensure that
the brackets installed are complete and
properly assembled.
For generator fastener torque specifications,
refer to SECTION 603. For A/C compressor
fastener torque specifications, refer to
SECTION lB. For coolant pump fastener
torque specifications, refer to SECTION 6B.
For power steering pump torque specifications,
B. Engine/transmission contacting the engine cradle
or body.
Inspect the vehicle to be certain that neither.
the engine or transmission is contacting the
engine cradle or body. If any irregularities are
revealed during inspection, correct and retest
on the road.
C. Exhaust system components.
Visually inspect the exhaust manifold,

intermediate pipe/muffler, forward
pipe/catalytic converter and tailpipe for
sufficient clearance of all points, at least 13
mm (0.51 inch) in all directions. Be
particularly certain that sufficient clearance
exists in all directions. during engine torque
load.
A majority of exhaust system problems are
due to "bound up" conditions. Loosen all
joints in the entire system and rest the pipes
on floor stands while each clamp and bolt is
tightened to specifications. Refer to
SECTION 6F for proper exhaust system torque
specifications.
Be certain that the end of the tailpipe is below
the surface of the rear bumper fascia.
After inspecting the exhaust system and
making any corrections, retest on the road,
PROPELLER SHAFT
Driveline vibrations will generally be a, high
speed vibration associated with a "buzz" or a
"shudder" occurring in the 72 to 88 km/h (45 to
55 mph) range. A majority of the vibration is
experienced on either acceleration or deceleration.
Driveline vibrations emanate from four general areas:
1. Propeller shaft balance.
2. Propeller shaft runout.
3. Driveline angles.
4. Joint phasing.
Most driveline vibrations that are associated with
a "buzz" or a "shudder" type vibration will also have
a high frequency reading on the reed tachometer or
Electronic Vibration Analyzer (EVA). Refer to "Reed
Tachometer" or " Electronic Vibration Analyzer
(EVA)" earlier in this section.
Propeller Shaft: Runout
If a noise vibration is present in the vehicle
driveline, the propeller shaft may be bent or out of
round due to damage. Inspect the propeller shaft for
dents or other damage. The propeller shaft and its
components must be "true" or turning with an
absolute minimum amount of lateral movement. Refer
to SECTION 4A for propeller shaft runout
specifications.
Propeller Shaft: Balance

If balance weights are loose or nussmg, the
propeller shaft must be balanced or replaced. Refer to
SECTION 4A for propeller shaft balance check
procedures. Excessive looseness or wear at the
propeller shaft sliding yoke splines may also cause a
propeller shaft to be unbalanced. For propeller shaft
inspections procedures, refer to SECTION 4A. Inspect
propeller shaft and universal joints for mud buildup,
undercoating buildup or loose fasteners.
VIBRATION DIAGNOSIS
UNIVERSAL JOINTS
Faulty universal joints can be another cause for
driveline vibrations. If a universal joint is suspected of
producing a rattling or knocking noise, the u~i~ersal
joint may be worn or loose. Make a prehmmary
inspection by grasping the propeller shaft toward the
end near the suspected universal joint and rotate it
back and forth, then, move the propeller shaft in an up
and down direction while feeling for any looseness. If
the propeller shaft shows excessive movement, the
universal joint should be removed and inspected for
wear or damage. Refer to SECTION 4A for universal
joint diagnosis and service procedures.
OC-7
DRIVELINE ANGLES
Vibrations due to improper driveline angles are
caused by either incorrect trim height or faulty
universal joints. Incorrect trim height can lead to
excessive universal joint angles. Refer to SECTION 3
for trim height specifications. Faulty universal joints
can lead to incorrect driveline angles. Refer to
SECTION 4A for universal joint angle measurement
procedures.
SPECIAL TOOLS
ITJ
TECH 1 MODULAR DIAGNOSTIC SYSTEM
[I]
ELECTRONIC VIBRATION ANALVZER

MBT0040C
OC-8
VIBRATION DIAGNOSIS
BLANK
HEATER AND VENTILATION
1A1
SECTION 1
HEATING AND AIR CONDITIONING

CONTENTS
Heater and Ventilation ................................. Section lA
Heater, Ventilation and Air Conditioning ... Section 1B
Manual Control Air Conditioning ............. Section 1B 1
HD6/HR6-HE Air Conditioning Compressor Service

or Unit Repair R-134a .......................... Section 1D2
VS Air Conditioning Compressor Service or Unit
Repair R-134a ........................................ Section ID3
SECTION 1A
exact part number for that application. General Motors will call out those fasteners that require a replacement
after removal. General Motors. will also call out the fasteners that require thread lockers or thread sealant.
torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the correct
tightening sequence and specifications. Following these instructions can help you avoid damage to parts and
systems.
CONTENTS
General Description ........................................ , ....... lA-1
Base Heater System ........................................... lA-1
Controls ............................................................... lA-2
Temperature Control Knob ............................ lA-2
Mode Control Knob ....................................... lA-2
Blower Motor Speed Control Knob .............. lA-3
Air Distribution System ..................................... lA-3
Vacuum System .............................................. lA-3
Temperature Valve and Heater Core ............. lA-4
Mode Valve Housing ..................................... lA-4
Air Outlets ...................................................... lA-6
Ventilation ....................................................... lA-6
Diagnosis ................................................................ lA-6
Functional Test ................................................... lA-6
Heater Output. Temperature Check .................... lA-8
Insufficient Heating or Defrosting ..................... lA-8
High or Low Heater Control Effort .................. lA-9
Blower Motor Noise .......................................... lA-9
Excessive Heat ................................................... 1A-9
On-Vehicle Service................................................ lA-9

Adjustments and Repairs .................................. lA-9
Temperature Control Cable Adjustment.. ..... lA-9
Replacement Procedures ................................... lA-9
Control and Vacuum Selector Valve and/or
Blower Motor Switch ............................... lA-9
Control Lamp Bulb ....................................... lA-10
Temperature Control Cable ........................... lA-16
Blower Motor Resistor ................................. lA-17
Blower Motor and Blower Motor Fan ........ lA-17
Vacuum Harness ............................................ lA-18
Vacuum Tank ................................................. lA-18
Vacuum Actuators ......................................... lA-19
Air Deflectors ................................................ lA-20
Heater Hose and Heater Hose Pipes ........... lA-20
Heater Core ................................................... lA-22
Specifications ......................................................... 1A-25
Fastener Tightening Specifications ................... lA-25
Electrical Specifications .................................... 1A-25
GENERAL DESCRIPTION
the base of the windshield into the heater module ( 1)

by the blower motor fan (18).
Within the heater module (1), the air is heated as
required and then routed through ducts to the proper
outlets for discharge into the passenger compartment.
A control (2) in the instrument panel allows the
operator to control blower motor speed, mode of
operation and the temperature of the air coming from
the heater system.
BASE HEATER SYSTEM

Figures 1 through 5
The base heater system provides heating,
ventilation, side window defogging and windshield
defrosting. Outside air is drawn from the plenum at
1A2 HEATER AND VENTILATION

The heater module ( 1) contains components that
heat the air flowing through it and direct the air to the
proper ducts and outlets. The heater module (1) is a
single unit, including the blower motor (6), that is
mounted to the rear surface of tlle dash front panel in
front of the instrument panel.
Hot coolant from the engine's cooling system is
directed through the heater core (14) and returned to
the cooling system when the engine is running. The
heater core (14) transfers heat from the coolant to the
air passing through the heater core fins. There is no
hot water shut off valve in the heater system to
prevent flow of coolant through the heater core (14).
CONTROLS
Figures 1 through 5
Temperature Control Knob

The temperature control knob is the middle knob
in the control. It regulates the temperature of the air
being discharged into the passenger compartment from
the heater or ventilation system.. The temperature
control knob controls the position of a "door" called
the temperature valve in the heater module. The
temperature valve governs the relative amounts of
heated and unheated air discharged from the heater
system. Full warm, full cool or any intermediate
temperature mixture can be selected by moving the
knob to the right (red area) for warm air and to the
left (blue area) for cool air or anywhere in between.
Mode Control Knob

Figures 2 and 3
Three knobs in the instrument panel allow a

front seat occupant to operate the heating and
ventilation. These knobs are in the control, in the
center of the instrument panel, just above or below the
radio, depending on the vehicle; To the left of the
blower motor speed control knob is the control button
for the electric rear window defogger (Pontiac only)
The controls are lit when the headlamps are on.
Electrical power is provided by the instrument panel
lighting circuit. The control lamp is in parallel with
the instrument cluster bulbs, the radio dial bulb and
certain other interior illumination bulbs. Brightness of
the dial illumination is controlled by the dimmer
control of the headlamp switch. For electrical circuit
diagrams and more information, refer to
SECTION 8A.
The right knob, called the mode control knob, is

a rotary vacuum switch that regulates airflow from the
outlets by routing engine vacuum to vacuum actuators
at the heater module. The mode control knob also
controls an electrical switch that supplies power to
operate the blower motor for specific mode selections.
A choice of six operating modes can be selected
by turning the mode control knob in the control. From
left to right, the six modes are "OFF", Vent, Bi-level,
Heater, Blend and Defrost.
"OFF" MODE
When the mode control knob is in the "OFF"

position, no electrical power is supplied to the blower
motor. A limited flow of air, caused by movement of
the vehicle, may come from the defrost outlet and the
floor outlets. This is the only mode in which the
blower motor will not operate.
VENT MODE .
. Wi~ ~e m~de control knob in the vent position,

outside arr 1s dehvered through the instrument panel
outlets to ventilate the vehicle. If preferred, the air
may be warmed by setting the temperature control
knob to the desired temperature.
Bl-LEVEL MODE
1
2
3
4
6
7
8
g
10
11
12
13
MODULE, HEATER
CONTROL
VALVE, VENT MODE
VALVE, Bl-LEVEL MODE
MOTOR, BLOWER
KNOB, MODE CONTROL
KNOB, TEMPERATURE CONTROL
KNOB, BLOWER MOTOR SPEED CONTROL
ACTUATOR, Bl-LEVEL MOOE VALVE
ACTUATOR, DEFROSTER/HEATER VALVE
OUTLET, FLOOR AIR
HARNESS, VACUUM
01-27-fllS
FS0011A
Figure 1 - Heater Modul,e and Controls
With the mode control knob in the bi-level

position, electrical power is supplied to the blower
motor. Ou~s~de air is drawn in anq heated (depending
on the pos1t10n of the temperature control knob). Then
the airflow is split between the instrument panel
outlets and the floor outlets. Blower motor speed may
be varied.
HEATER MODE
With the mode control knob in the heater

position, outside air is drawn into the vehicle, heated
(depending on the position of the temperature control
knob) and directed to the floor air outlets. A small
amount of air is routed to the windshield through the
defrost outlet.
Blower motor speed may be varied as in other
operating modes.

This mode is the normal selection for cold
weather operation unless the windshield must be
cleared of heavy frost.
BLEND MODE
With the mode control knob in blend position,

outside air is drawn into the vehicle, heated
knob) and split between the defrost outlet and the
floor air outlets.
DEFROST MODE
With the mode control knob in the defrost

position, outside air is drawn into the vehicle, heated
knob) and directed to the defrost outlet. A small
amount of air is routed to the floor air outlets. Blower
motor speed may be varied.
SIDE WINDOW DEFOGGING
In all modes except "OFF" and vent, air is

supplied to the side window defrost outlets, located at
the end of the instrument panel upper trim pad.
Blower Motor Speed Control Knob

With the ignition switch in the "RUN" position,
the blower motor runs in all mode control knob
positions except "OFF. " Blower motor speed is
controlled by a four-position electrical blower switch
7
8
9
156
1A-3
at the left side of the control. The blower switch

provides a choice of low blower motor speed, two
medium blower motor speeds and a high blower motor
speed.
The circuit to the blower motor is completed to

ground at the instrument panel through the instrument
panel wiring harness. Refer to SECTION 8A.
AIR DISTRIBUTION SYSTEM

Air enters the heater module where it is heated
as necessary before being sent to the proper outlets for
discharge into the passenger compartment Within the
heater module, valves ("doors") guide, the airflow in
response to the positions of the temperature control
knob and the mode control knob in the control.
Vacuum System
Figure 6
All valves in the heater module except the
temperature valve are controlled by engine vacuum
drawn from the vacuum tank in the engine
compartment. The vacuum is routed . by a vacuum
selector valve in the control to spring-loaded vacuum
actuators on the heater module. Vacuum stored in the
vacuum tank is prevented from bleeding back to its
source during conditions of low engine manifold
vacuum (acceleration, hard pulling, etc.) by a check
valve in the vacuum line.
The vacuum selector valve in the control is
controlled by the mode control knob. For each mode
control knob position, the vacuum selector valve
directs vacuum to specific hoses to overcome the force
KNOB,MODECONTROL
KNOB, TEMPERATURE CONTROL
KNOB. BLOWER MOTOR SPEED CONTROL
KNOB, REAR WINDOW DEFOGGER
012715
FS0021A
Figure 2 Controls (Pontiac)
157 KNOB, MODE CONTROL

158 KNOB, TEMPERATURE CONTROL
159 KNOB, BLOWER MOTOR SPEED CONTROL
158
Figure 3 Controls (Chevrolet)
0127111
FS0031A
1A-4
of the spring within the appropriate vacuum actuators.

The vacuum selector valve also vents (to normal air
pressure) the hoses to each remaining vacuum
actuator, allowing the actuator's spring to expand. This
results in the valves being properly positioned for the
selected operating mode.
The bi-level and vent valves have two-position
vacuum actuators. When vacuum is directed to either
actuator's vacuum chamber, the vacuum pulls in a
flexible diaphragm that forms one wall of the
chamber. This draws a movable shaft attached to the
diaphragm. 'fl?.e shaft is linked to the corresponding
valve, and it operates the valve when vacuum is
applied.
When the vacuum chamber is vented to normal

air pressure, an external spring moves the shaft back
to its original position. The shaft, in turn, returns the
valve to its original position.
The defroster/heater valve has a three-position
mode valve actuator with two vacuum hoses and two
vacuum chambers, one at each end of the actuator. In
effect, the three-position mode valve actuator acts like
a pair of two-position actuators placed end-to-end.
When vacuum is directed to either chamber, that
chamber's diaphragm moves the mode valve operating
linkage from its centered position to one extreme of
travel. Venting that chamber while directing vacuum to
the opposite chamber causes the linkage to move to its
opposite extreme. Venting both chambers allows
external torsion springs to center the linkage. The
center position of the defroster/heater valve creates the
blend mode.
Temperature Valve and Heater Core

Figure 4
The temperature of the air discharged from the

heater system is regulated by controlling the relative
amounts of warm and cool air that are mixed together
downstream from the heater core area. The part of the
total airflow that is allowed to pass through the heater
core (14) is governed by the position of the
temperature valve (16).
Hot coolant from the engine's cooling system is
directed through the heater core (14). The heater core
(14) transfers heat from the coolant to the air passing
through the heater core fins.
Mode Valve Housing

After the heated and unheated airflows are
mixed, the combined airflow comes to the mode valve
housing. In vent mode, the vent mode valve actuator is
engaged as well as the bi-level mode valve actuator.
This directs all the air to the instrument panel outlets.
In bi-level mode, the vent mode valve remains
closed (allowing air to the defroster/heater door); while
the bi-level mode valve opens, allowing air to the
instrument panel outlets. The defroster/heater door
directs air to the floor air outlets. A small amount of
air goes to the side window defrost outlets.
In heater mode, both the vent and bi-level doors
remain closed and the defroster/heater door moves up,
dire~ting most of the air to the floor air outlets.
6
D
F
\
G
G
A OUTSIDE AIR
8 PLENUM
CHEATED AIR
D UNHEATED AIR
E
F
G
H
TO INSTRUMENT PANEL OUTLETS

TO FLOOR OUTLETS
TO WINDSHIELD DEFROSTER OUTLETS
TO SIDE WINDOW DEFOGGER OUTLETS
1
3
4
6
14
15
16
MODULE, HEATER
VALVE, VENT MODE
MOTOR, BLOWER
CORE, HEATER
VALVE, DEFROSTER/HEATER
VALVE, TEMPERATURE
0127-SIS
FS0041A
Figure 4 - Heater Module Schematics
1A-5
17
11
15
A
A
B
C
0
E
F
G
H
COMPONENT LOCATIONS
"Bl-LEVEL" MODE AIRFLOW
"VENT" MOOE AIRFLOW
"HEATER" MODE AIRFLOW
"DEFROST" MODE AIRFLOW
"BLEND" MOOE AIRFLOW
OUTSIDE AIR
J TO FLOOR AIR OUTLET
K TO WINDSHIELD DEFROSTER NOZZLES
L,
3
4
10
11
15
17
18
19
TO SIDE WINDOW DEFOGGER OUTLETS

VALVE, VENT MODE
ACTUATOR, Bl-LEVEL MODE VALVE
VALVE, DEFROSTER/HEATER
HEATER
FAN, BLOWER MOTOR
ACTUATOR, VENT MODE VALVE
01-27-95
FS0051A
Figure 5 - Operating Mode Airflow Distribution
1A-6

E
A
B
D
E
F
G
H
2
10
11
19
20
BLACK HOSE
ORANGE HOSE
YELLOW HOSE
GREEN HOSE
VIOLET HOSE
TO VACUUM SOURCE
RED HOSE
CONTROL
ACTUATOR, Bl-LEVEL MODE VALVE
ACTUATOR, VENT MODE VALVE
TANK, VACUUM
012795
FSOOl1A
Figure 6 Vacuum Circuit
In blend mode, both chambers of the

heater/defrost actuator are vented and the
heater/defrost valve moves to a mid-position allowing
air up to the defroster and down to the heater outlet.
Both the vent and bi-level doors remain closed.
In defrost mode, the heater/defrost valve moves
down and forces the air up to the defroster outlet. A
small amount of air still flows to the heater outlet
because of a fixed bleed.
Air Outlets
Figures 7 and 8
There are adjustable high-level air outlets in the
instrument panel. In addition, there are two side
window defrost outlets, one at each end of the
instrument panel. All outlets are fed by the air
distributor.
Ventilation
Figure 9
The air distribution system provides fresh air
ventilation for the passenger compartment in all
operating modes. Even in the "OFF" mode, fresh
outside air is forced into the air distribution system by
the forward movement of the vehicle.
After being warmed to the desired temperature,
the air is discharged from the outlets. When all
windows are closed, the addition of outside air builds
a slight positive pressure within the passenger

compartment. The pressure forces stale air to leave the
vehicle through a pressure relief valve near the left
side quarter panel in front of the rear fascia.
DIAGNOSIS
FUNCTIONAL TEST
The following operational test sequence will aid
in determining whether the heater system is working
properly. Coolant temperature should be close to 90C
(194F).
PREPARATION
Engine should be started and allowed to idle for

about 20 minutes or until thennostat is open.
TEST
1. Set mode control knob to bi-level, temperature
control knob all the way to the left and blower

switch to "HIGH."
Air at nearly the same temperature as outside
air should come from all outlets.
2. Set mode control knob to vent.
Air at nearly the same temperature as outside
air should come from instrument panel outlets.
Air should not come from floor outlets,
defroster nozzle or side window defogger
outlets.
1A-7
24
12
21
22
23
24
12
OUTLET, FLOOR AIR

OUTLET, LEFT-HAND
DEFOGGER, SIDE WINDOW
OUTLET, CENTER
OUTLET, RIGHT-HAND
012795
F80071A
Figure 7 Air Outlets - (Pontiac)
)
163
160
164
161
0
162
12
160
161
162
163
164
OUTLET, FLOOR AIR

DEFOGGER, SIDE WINDOW
OUTLET, LEFT-HAND EYEBROW
OUTLET,LEFTHANO DRIVER
OUTLET, RIGHT-HAND EYEBROW
OUTLET, RIGHT-HAND PASSENGER
12
165 OUTLET, LEFT-HAND PASSENGER
012795
F80081A
)
Figure 8 Air Outlets (Chevrolet)
1A-8

HEATER OUTPUT TEMPERATURE CHECK
A
Figure 10
The heat output of the heater system can be
checked with the following procedure.
A PLENUM
25 VALVE, PRESSURE RELIEF
012715
FSOOl1A
Figure 9 Flow-Through Ventilation (Typical)
3. Move mode control knob to the heater position.

Most of the air. should come from floor outlets
with remainder coming out of defroster nozzle
and defogger outlets.
Air should not come from instrument panel
outlets in heater position.
All air from heater system should be at nearly
the same temperature as outside air.
4. Move the mode control knob from heater position
to the blend position. Air should come equally
from the defroster nozzle and the heater outlet
with some air coming from the side window
defogger.
5. Move mode control knob from blend position to
defrost position.
Most of the air should be discharged onto the
windshield from the defroster nozzle.
A small amount of air should also be
discharged from floor outlets.
6. Move mode control knob back to bi-level position
and rotate temperature control knob clockwise to
full hot.
Air should come from instrument panel
outlets, and its temperature should climb
rapidly to approximately 55C (131F) or
higher, depending upon outside air
temperature. For a more precise heater output
temperature check, refer to "Heater Output
Temperature Check" in the following
procedure.
Defroster nozzle airflow should diminish and
airflow from floor outlets may increase
slightly.
7. Rotate temperature control knob counterclockwise
to full cold and check to be sure air temperature
drops back to nearly the temperature of the
outside air once again.
8. Slowly tum blower motor speed control knob
toward "OFF," stopping briefly at each
intermediate position to feel the reduction of
airflow.
Both airflow and blower noise should reduce
noticeably at each intermediate step.
-1sc
24c
-4C
1oc
OUTSIDE AIR
TEMPERATURE
(0F) (25F) (50F) (75F)
43c
soc
HEATER AIR
60c
66C
IBMPERATURE* (ll0F) (125F) (140.F) (tsoF)
* Temperature at floor air outlet assembly
controls at
"HI" blower, "HEATER" mode and full warm,
engine at operating temperature and vehicle speed of
48 km/h (30 mph).
Tl677
Figure 10, Heater Output Temperature Chart
PREPARATION
With the engine sufficiently cool, the radiator

cap should be removed and the engine started and
allowed to idle (3800 V6 only). Heater controls should
be set to heater mode, temperature control knob turned
all the way to full hot and "HIGH" blower speed.
When coolant flow in the radiator is visible through
the filler neck, the radiator cap should be installed
(3800 V6 only).
rn
Important
Do not remove radiator cap on 5.7L V8 engine

while running.
TEMPERATURE CHECK
When the engine is warmed up (after

approximately 20 minutes of operation), the vehicle
should be driven. An accurate thermometer should be
used to determine the temperature of the outside air
and the temperature of the air discharged at the floor
outlets with the vehicle being driven at 48 km/h (30
mph). Minimum acceptable heater output temperatures
. at four different outside air temperatures are shown in
Figure 10.
Minimum acceptable heater output temperatures
for outside air temperatures other than those shown in
Figure 10 can be approximated by using the
Fahrenheit scale and rounding off the outside air
temperature to the nearest 5. For every additional 5
of outside temperature, an additional l.8 of heater
output temperature should be allowed when the
outside temperature is below 50F. An additional l .6
of heater output temperature should be allowed for
every 5 of outside temperature when the outside
temperature is above .50.
INSUFFICIENT HEATING OR DEFROSTING

The most likely causes of insufficient heating
outside the heater system include a low coolant level,
a faulty thermostat, a partially or fully clogged heater
1A-9
core or heater hose, an obstruction to air circulation

(often under the front seat) or an air leak past a faulty
seal into the passenger compartment. For an organized
diagnosis procedure, refer to Figures 12 and 13.
HIGH OR LOW HEATER CONTROL

EFFORT
27
A kinked control cable, a binding valve or a

faulty control are possible causes of excessive
temperature control knob effort. For an organized
diagnosis procedure, refer to Figure 14.
FULL
HOT
FULL
COLD
BLOWER MOTOR NOISE

A constant air rush noise is typical of all heater
systems when operating on "HIGH" blower speed.
Some systems and modes may be worse than others. If
possible, check a similar vehicle to determine whether
the noise is typical or excessive. For diagnosis of
excessive blower motor noise, refer to Figures 15
and 16.
EXCESSIVE HEAT
A
5
27
29
The most likely cause of excessive heat from the

heater system is a disconnected, mis-adjusted or
nonfunctional temperature control cable. Refer to
"Temperature Control Cable Adjustment" or
"Temperature Control Cable" in this section. A hot air
leak from the engine compartment to the blower inlet
is also a remote possibility.
0127-lts
FS0251A
Figure 11 Temperature Control Cable Adjustment
ON-VEHICLE SERVICE
ADJUSTMENTS AND REPAIRS
Temperature Control Cable Adjustment

Figure 11
!+-.I
Remove or Disconnect
1. Right instrument panel insulator. Refer to

SECTION 8C.
2. Temperature control cable from heater module.
Refer to "Temperature Control Cable" in this
section.
[I]
Important
With the cable still attached to the HVAC

control, cycle the temperature knob between
full cold and full hot. If a binding occurs, or
the cable does not rotate freely, the cable must
be replaced. Refer to "Temperature Control
Cable" in this section.
3. Set the temperature control knob to the detent
position half way between full cold and full hot.
!L"!
)
Inspect
Note the position of the control cable pulley

(29).
- If the control cable pulley (29) is skewed
5-10 degrees toward the full cold side, no
adjustment is necessary.
CORRECT CABLE POSITION

CABLE, TEMPERATURE CONTROL
SPRING, TEMPERATURE CONTROL CABLE
PULLEY, TEMPERATURE CONTROL CABLE
If the control cable pulley (29) is skewed
toward the full hot side, adjustment of the

control cable is necessary.
4. Spring (27) from control cable pulley (29).
5. Control cable pulley 5-10 degrees toward .full
cold.
!-.+!
Install or Connect
NOTICE: Refer to "Notice" on page lA-1.

1. Spring (27). to control cable pulley (29).
2. Temperature control cable to heater module. Refer
to "Temperature Control Cable" in this section.
SECTION 8C.
REPLACEMENT PROCEDURES
Control and Vacuum Selector Valve and/or

Blower Motor Switch
Figures 2, 3, 17 and 18
!+-.!
1. Control trim plate (Pontiac only).

Pull control trim plate rearward and off
instrument panel lower trim pad.
2. Upper instrument panel cover panel (Chevrolet
only).
1A-10
3. Cluster trim plate (Chevrolet only). Refer to

SECTION 8C.
4. Heater and air conditioning control bolts/screws
(26).
5. Control (2 or 162).
Pull control (2 or 162) out far enough to reach
the vacuum, electrical and temperature control
cable connections.
6. Blower motor switch connector.
7. Vacuum harness connector from vacuum selector
valve.
8. Temperature control cable from control (2 or 162).
While releasing temperature control cable clips
from control, pry temperature control cable
with small screwdriver from control
(2 or 162).
9. Vacuum selector valve, if necessary.
Remove two retaining screws and remove
vacuum selector valve.
10. Blower motor switch, if necessary.
A. Remove blower motor speed control knob
(9 or 159) and retaining bolt/screw.
B. Remove blower motor switch.
ILI
Inspect
Electrical terminals for corrosion. Remove

corrosion or replace component as necessary.
Temperature and mode knobs for freedom of
movement. Lubricate, repair or replace as
necessary.
Temperature control cable for kinks, binding and
other damage. Adjust, repair or replace as
necessary.
!++!
Install or Connect
NOTICE:
Refer to "Notice" on page lA-1.
1. Blower motor switch, if removed.

A. Hold blower motor switch in position and
install bolt/screw.
B. Install blower motor speed control knob (9 or
159).
2. Vacuum selector valve and retaining screws, if
removed.
3. Temperature control cable.
A. Slip temperature control cable into position on
lever arm. Align shaft with temperature control
cable slot.
B. Press temperature control cable clip into slot in
control (2 or 162). Make sure all three clips
are in place.
4. Vacuum harness connector to vacuum selector
valve.
5. Blower motor switch connector.
(26).
l~I
8.
9.
10.
11.
Tighten
Heater and air conditioning control

bolts/screws (26) to 1.9 N,m (17 lb. in.).
Control trim plate (Pontiac only).
Hold control trim plate in position and press it
forward to engage four retaining clips.
Cluster trim plate (Chevrolet only). Refer to
SECTION 8C.
Upper instrument panel cover panel (Chevmlet
only).
Test operation of temperature control knob, mode
control knob and blower motor switch.
Control lamp Bulb

Figures 17 and 18
l++i

Pull control trim plate forward and off
SECTION 8C.
(26).
control lamp bulb socket.
5. Bulb and socket by twisting socket.
6. Bulb from socket.
Pull bulb straight out from socket.
lL!
Inspect
Control lamp bulb socket for corrosion and

damage. Clean or replace as necessary.
Wires for damage and secure connection to bulb
socket. Repair or replace as necessary.
i++j
Install or Connect
NOTICE:
1. New bulb.
Push bulb straight into socket.
2. Bulb and socket by twisting socket into place.
4. Heater and air conditioning bolts/screws (26).
!~I
Tighten

bolts/screws (26) to 1.9 N.m (17 lb. in.).
rearward to engage four retaining clips.
SECTION 8C.
7. Test operation of control lamp bulb.
1A-11
INSUFFICIENT HEATING OR DEFROSTING

CHECK FOR LOW COOLANT LEVEL, LOOSE OR WORN BELTS,
LEAKING OR KINKED HOSES, LOSS OF RADIATOR CAP
PRESSURE SEAL,
I
ADJUST THE HEATER CONTROLS TO "HEATER" MODE, "HIGH"
BLOWER SPEED AND FULL "WARM."
I
WITH VEHICLE IDLING, CHECK THE AIR FLOW OUT OF THE
FLOOR AIR OUTLET AND CHECK OUTLET ATTACHMENT.
I
u
HIGH AIRFLOW.
I
SPEED
CHANGE.
ffl
CHECK BLOWER
SPEEDS FOR AIRFLOW
CHANGE.
LOW OR NO AIRFLOW,
NO SPEED
CHANGE.
RUN THE FUNCTIONAL TEST IN

THIS SECTION. IF THE PROBLEM IS
NOT RESOLVED, CHECK THE
AIRFLOW FROM DEFROSTER AND
VENT OUTLETS.
I
CHECK BLOWER
SWITCH AND RESISTOR
ASSEMBLY. REPAIR AS
NECESSARY.
HIGH AIRFLOW FROM

DEFROSTER OR VENT
OUTLETS.
m
LOW OR NO AIRFLOW
FROM DEFROSTER OR
VENT OUTLETS.
CHECK VACUUM
SYSTEM. REPAIR AS
REQUIRED.
SWITCH THE MODE

CONTROL KNOB TO
"DEFROST" AND
CHECK AIRFLOW
DEFROSTER AIRFLOW
CORRECT.
RUN THE HEATER

OUTPUT TEMPERATURE
CHECK IN THIS
SECTION.
HEATER OUTPUT
TEMPERATURE CORRECT
CONTINUED
CHECK FLOOR AIR

OUTLET FOR
OBSTRUCTIONS.
CHECK BLOWER
SPEEDS FOR AIRFLOW
CHANGE.
ffl
I
I
LOW OR NO
DEFROSTER AIRFLOW.
HEATER OUTPUT
TEMPERATURE LOW
I
CONTINUED
,l.,
I I
I
NO SPEED
CHANGE.
CHECK BLOWER
SWITCH AND RESISTOR
ASSEMBLY. REPAIR AS
NECESSARY.
SPEED
CHANGE.
CHECK FOR AIRFLOW

OBSTRUCTIONS AT
BLOWER INLET AND
PLENUM.
CONTINUED
C8753
Figure 12 Insufficient Heating or Defrosting Diagnostic Procedure (1 of 2)
1A-12
INSUFFICIENT HEATING OR DEFROSTING (Continued)
HEATER OUTPUT
TEMPERATURE LOW
CHECK FOR AIRFLOW

OBSTRUCTIONS AT
BLOWER INLET AND
PLENUM.
WITH THE IGNITION SWITCH IN "RUN"

AND THE BLOWER ON LOW, ROTATE THE
TEMPERATURE CONTROL KNOB TO THE
MID-POSITION, THEN RAPIDLY TO FULL
"HOT." LISTEN FOR VALVE SLAM AT THE
END OF CONTROL KNOB ROTATION.
NO OBSTRUCTIONS AT
BLOWER INLET OR
PLENUM.
HEATER OUTPUT
TEMPERATURE CORRECT
CHECK VEHICLE FOR COLD AIR

LEAKS AT COWL, HEATER CASE
AND VENTS. CHECK UNDER
SEAT FOR OBSTRUCTIONS.
VALVE SLAM.
NO VALVE SLAM.
CHECK THE TEMPERATURE
CONTROL CABLE ASSEMBLY
FOR PROPER ATTACHMENT AT
CONTROL ASSEMBLY AND
HEATER MODULE ASSEMBLY.
REPAIR AS NECESSARY.
WITH THE BLOWER ON "HIGH,"

MOVE THE TEMPERATURE
CONTROL KNOB FROM FULL
"WARM" TO FULL "COOL" AND
LISTEN FOR AIRFLOW CHANGE.
WITH THE TEMPERATURE VALVE

FULL "WARM," START THE
VEHICLE. CHECK THE
TEMPERATURE o,F THE HEATER
INLET AND OUTLET HOSES BY
FEEL. THE AIR TEMPERATURE
AROUND THE HOSES MUST BE
AT LEAST 24"C (85"F).
STILL NO VALVE SLAM.
CHECK THE
TEMPERATURE
VALVE, CABLES
AND CONTROL,
REPLACE AS
REQUIRED.
REPLACE
TEMPERATURE
CONTROL CABLE
ASSEMBLY.
HOT INLET AND WARM

OUTLET.
BOTH WARM.
CHECK THE
THERMOSTAT FOR
PROPER INSTALLATION
AND SEATING.
BACK FLUSH HEATER

CORE, DRAIN AND
REPLACE COOLANT.
RETEST.
INCORRECT.
REINSTALL AND
RECHECK.
CORRECT.
REPLACE
THERMOSTAT.
BOTH HOSES
WARM.
HOT INLET AND WARM

OUTLET HOSES.
REPLACE
HEATER CORE.
RETEST AND
VERIFY
SYMPTOMS.
CHECK FOR
AIRFLOW
OBSTRUCTION
BETWEEN THE
BLOWER AND
THE SYSTEM
OUTLETS.
C8754
Figure 13 Insufficient Heating or Defrosting Diagnostic Procedure (2 of 2)
1A-13
TEMPERATURE CONTROL EFFORT
CHECK TEMPERATURE CONTROL

EFFORTWITH BLOWER OFF.
EXCESSIVE EFFORT.
PROPER EFFORT.
CHECK CABLE FOR ROUTING, A

KINK, WIRING INTERFERENCE OR
OTHER INSTRUMENT PANEL
INTERFERENCE.
PROBLEM NOT FOUND.
REMOVE CABLE FROM

TEMPERATURE VALVE
AND CYCLE VALVE
MANUALLY. CHECK
FOR VALVE BINDING.
NO CONTROL PROBLEM.
PROBLEM FOUND.
REPAIR AS
NECESSARY.
EFFORT TOO LOW.

TEMPERATURE VALVE
MOVES ON HIGH
BLOWER.
REMOVE CABLE FROM

CONTROL AND CHECK TO
SEE THAT CONTROL HAS
DETENTS.
DETENTS.
NO DETENTS.
REPLACE
CONTROL.
REPLACE CABLE.
NO VALVE BIND.
VALVE BIND.
CHECK FOR CONTROL

BINDING.
LUBRICATE VALVE AND

RECHECK.
CONTROL BINDS.
NO CONTROL BIND.
REMOVE CABLE AND

RECHECK CONROL
FOR BINDING.
REINSTALL AND
RECHECK
CLEARANCES TO DASH
COMPONENTS.
CONTROL BINDS.
REPLACE
CONTROL.
OK
CHECK TEMPERATURE
VALVE FOR SHAFT
ALIGNMENT, BENT
SHAFT OR VALVE,
WARPED CASE. REPAIR
AS NECESSARY.
NO CONTROL BIND.
REPLACE
CABLE(S).
C8755
Figure 14 - Temperature Control Effort Diagnostic Procedure
BLOWER MOTOR ASSEMBLY NOISE
CHECK ALL ELECTRICAL CONNECTIONS AND GROUNDS FOR

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

INTERMITTENT. MAY OCCUR AT COLD
AMBIENTS AND LOW BLOWER MOTOR
ASSEMBLY SPEEDS. TYPICAL NOISE IS AN
OBJECTIONABLE SQUEAL/SCREECH.
NOISE IS CONSTANT BUT

LESSENS WITH BLOWER
MOTOR ASS.EMBLY SPEED
REDUCTION. TYPICAL NOISES
ARE WHINE, TICK/CLICK,
FLUTTER OR SCRAPE.
I
CHECK FOR MOTOR ASSEMBLY AND
BLOWER IMPELLER VIBRATION AT EACH
BLOWER MOTOR ASSEMBLY SPEED BY
FEELING THE BLOWER MOTOR COVER,
NO EXCESS VIBRATION.
NOISE IS CONSTANT AT
HIGH BLOWER MOTOR
ASSEMBLY SPEEDS IN
CERTAIN MODES BUT
CAN BE ELIMINATED AT
LOWER BLOWER
MOTOR ASSEMBLY
SPEEDS OR IN OTHER
MODES. TYPICAL
NOISES ARE FLUTTER
OR RUMBLE.
VIBRATION EXCESSIVE.
I
REMOVE BLOWER MOTOR
ASSEMBLY AND BLOWER
IMPELLER AND CHECK FOR
FOREIGN MATERIAL AT THE
ORIFICE OF THE BLOWER INLET
I
PROBLEM
FOUND.
PROBLEM STILL
EXISTS
EXAMINE BLOWER
IMi'ELLER FOR WEAR
SPORTS,CRACKED
BLADES OR HUB, AND
ALIGNMENT. EXAMINE
BLOWER CASE FOR
WEAR SPOTS.
REPAIR OR REPLACE
AS NECESSARY AND
RECHECK.
PROBLEM STILL
EXISTS.
CONTINUED
,l
PROBLEM
FOUND.
CONTINUED
REPLACE BLOWER
IMPELLER AND
RECHECK.
C8756
Figure 15 Blower Motor Noise Diagnostic Procedure (1 of 2)
1A-15
BLOWER MOTOR ASSEMBLY NOISE (Continued)
CONTINUED
CONTINUED
I
REPLACE BLOWER
MOTOR ASSEMBLY AND
BLOWER IMPELLER
AND RECHECK.
NOISE IS CONSTANT AT HIGH

BLOWER MOTOR ASSEMBLY
SPEEDS IN CERTAIN MODES BUT
CAN BE ELIMINATED AT LOWER
BLOWER MOTOR ASSEMBLY
SPEEDS OR IN OTHER MODES.
I
I
PROBLEM
FOUND.
PROBLEM
STILL EXISTS.
I
REINSTALL ORIGINAL
BLOWER MOTOR
ASSEMBLY
AT HIGH BLOWER MOTOR ASSEMBLY SPEED, CHECK

FOR NOISE AT TEMPERATURE SELECTIONS
(INCLUDING DEFROSTER OPERATION).
I
NOISE IN ALL MODES
AND IN ALL
TEMPERATURE
SETTINGS.
I
CHECK SYSTEM FOR
OBSTRUCTIONS OR
FOREIGN MATERIALS
BETWEEN THE
BLOWER IMPELLER
AND THE
TEMPERATURE VALVE.
REMOVE, REPAIR OR
REPLACE AS
NECESSARY AND
RECHECK.
I
NOISE IN ALL MODES
BUT NOT ALL
TEMPERATURE
SETTINGS.
I
CHECK TEMPERATURE
VALVE SEALS. REPAIR
OR REPLACE AS
NECESSARY AND
RECHECK.
NOISE ONLY IN
"DEFROST" OR
"HEATER" MODE.
NOISE ONLY IN "VENT"

OR "A/C" MODE.
I
CHECK DUCTS FOR
OBSTRUCTIONS OR
FOREIGN MATERIALS
AND REMOVE. CHECK
DEFROSTER VALVE
FUNCTION. REPAIR OR
REPLACE AS
NECESSARY AND
RECHECK.
CHECK DUCTS FOR

OBSTRUCTIONS OR
FOREIGN MATERIALS
AND REMOVE. CHECK
DEFROSTER VALVE
SEALS. REPAIR OR
REPLACE AS
NECESSARY AND
RECHECK.
C8757
Figure 16 - Blower Motor Noise Diagnostic Procedure (2 of 2)
1A-16 HEATER AND VENTILATION

7. Temperature control cable (5).
Temperature Control Cable
While releasing temperature control cable clips

from control (2 or 162), pry temperature
control cable with small screwdriver from
control (2 or 162).
l++I

SECTION 8C.
2. Temperature control cable (5) at heater module
(1).
!++!
Install or Connect
NOTICE: Refer to "Notice" on page lA-1.
Remove temperature control cable bolt/screw

(28).

Pull control cable trim plate rearward and off
SECTION 8C.
(26).
temperature control cable connection.
1. Temperature control cable (5) to control (2 or

162).
A. Slip temperature control cable into position
over lever arm. Align shaft with temperature
control cable slot.
B. Press temperature control cable clip into slot in
control (2 or 162). Make sure all three clips
are in place.
(26);
2 CONTROL
26 BOLT/SCREW, HEATER AND AIR CONDITIONING
CONTROL
26
01-27-95
FS0181A
Figure 17 - Heater Control Removed - (Pontiac)
26 BOLT/SCREW, HEATER AND AIR CONDITIONING CONTROL

162 CONTROL
169 TRIM PLATE, CLUSTER
162
26
Figure 18 - Heater Control Removed - (Chevrolet)
01-27-95
FS0171A
HEATER AND VENTILATION . 1A-17
A
1
2
5
28
SNAPS
MODULE, HEATER
CONTROL
CABLE, TEMPERATURE CONTROL
BOLT/SCREW, TEMPERATURE CONTROL CABLE
5
0127915
FS01B1A
!~I
Figure 19 Temperature Control Cable
Tighten

bolts/screws (26) to 1.9 N.m (17 lb. in.).
forward to engage four retaining clips.
SECTION 8C.
6. Temperature control cable (5) at heater module (1)
with temperature control cable bolt/screw (28).
!~!
Tighten
Temperature control cable bolt/screw (28) to

1.9 N.m (17 lb. in.).
SECTION SC.
5. Blower motor resistor (30).
!++!
Install or Connect
NOTICE:
1. Blower motor resistor (30) and blower motor

resistor bolt/screw (31).
!~!
Tighten
Blower motor resistor bolt/ screw (31) to

2 N.m (18 lb. in.).
2. Carpet.
SECTION SC.
4. Test blower motor operation at all four speeds.
Blower Motor and Blower Motor Fan
Blower Motor Resistor
Figure 21
Figure 20
l++l
!+-+!
1. Key from ignition to assure that switch will

remain in "OFF."
SECTION SC.
3. Pull carpet away from heater module.
4. Blower motor resistor bolt/screw (31).
1. Key from ignition switch to assure that switch

will remain "OFF."
2. Right instrument panel insulator and side trim
panel. Refer to SECTION 8C.
3. Blower motor bolts/screws (32).
Blower motor (6) and blower motor fan (18)
will drop down.
1A18 . HEATER AND VENTILATION
!LI
Inspect
Blower motor terminals for corrosion. Clean

corrosion from terminals or replace blower motor
(6) as necessary.
F!ang~ of blower motor (6). for damage or
distortion that could cause an arr leak. Repair as
necessary.
Blower motor fan (18) for damage and distortion.
Repair or replace as necessary.
I++!
Install or Connect
@--NOTICE: Refer to "Notice" on page lA-1.

30 RESISTOR, BLOWER MOTOR
012795
31 BOLT/SCREW, BLOWER MOTOR RESISTOR
FS0191A
1. Blower motor (6).
Figure 20 - Blower Motor Resistor Removed
Guide blower motor (6) and blower motor fan

(18) into position, being careful not to catch
blower motor fan (18) on protruding parts.
2. Blower motor bolts/screws (32).
I~!
Tighten
Blower motor bolts/screws (32) to 2.3 N.m

(20 lb. in.).
3. Right instrument panel insulator and side trim
4. Check blower operation.
-_::::.~ \
It is not necessary to replace an entire vacuum

harnes~ in case of a localized leakage or hose collapse.
A reparr can be made by cutting the hose and inserting
a plastic retainer.
I++!
1. Open ins~ment panel compartment and push in

on both sides of compartment. This will cause
compartment to "drop" open completely for
access to vacuum harness.
2. Vacuum hose connectors at vacuum actuators.
Trace each vacuum hose to its actuator on
heater module (1), noting its routing for
reference during installation.
3. Pry apart vacuum interconnect and remove
harness through instrument panel compartment.
!L!
Inspect
Vacuum hoses for leaks by attempting to blow

through hose while covering opposite end with a
fingertip. Replace any hose that leaks.
Vacuum switches and connecting hose at control
for leaks and proper function. Replace faulty
components.
18
!.
, ~
32
Vacuum Harness
Figure 22
6 MOTOR, BLOWER
18 FAN, BLOWER MOTOR
32 SOLT/SCREW,
-~ .
BLOWER MOTOR
~
6
01-27-95
FS0201A
Figure 21 - Blower Motor and Blower Motor Fan Removed
l++!
Install or Connect
1. Vacuum harness.
2. Vacuum hose connectors to vacuum actuators.
Be sure connectors are snapped securely in
place.
3. Push in on sides of instrument panel compartment
and return it to its normal position.
Vacuum Tank
The vacuum tank that supplies the heater
vacuum system is an oblong-shaped tank mounted
below the front right-hand engine rail.
!++!
1. Raise and suitably support vehicle. Refer to

SECTION OA.
2. Right lower side air baffle.
3. Vacuum line from lower connection.
4. 1\vo vacuum tank mounting bolts/screws from top
of vacuum tank.
5. Vacuum tank.
!++!
Bl-LEVEL MODE VALVE
Install or Connect
NOTICE:
1. Vacuum tank and vacuum tank mounting

bolts/screws.
!~!
1A-19
Tighten
Vacuum tank mounting bolts/screws to

2.5 N,m (22 lb. in.).
2. Vacuum line to lower connection.
3. Right lower side air baffle.
4. Lower vehicle.
!++!
1. Front floor console. Refer to SECTION 8C.

2. Floor air outlet.
3. Bi-level mode valve linkage bolt/screw from
linkage.
4. Bi-level mode valve actuator (10).
Unsnap bi-level mode valve actuator (10).
l++!
Install or Connect
NOTICE:
Vacuum Actuators
Figure 22
1. Bi-level mode valve actuator (10).
DEFROSTER/HEATER VALVE
Snap bi-level mode valve actuator (10) into

place.
2. Bi-level mode valve linkage bolt/screw to linkage.
!++!
1. Instrument panel. Refer to SECTION 8C.

2. Defroster/heater valve actuator ( 11) from linkage.
!++!
Install or Connect
1. Defroster/heater valve actuator (11) to linkage.

!~!
Tighten
Bi-level mode valve linkage bolt/screw to

2.3 N.m (20 lb. in.).
3. Floor air outlet.
13
19
10
A VACUUM HARNESS CONNECTORS, MAIN HARNESS

TO ENGINE COMPARTMENT HARNESS
B CONNECTOR, ELECTRICAL
1 MODULE, HEATER
2 CONTROL
10 ACTUATOR, Bl-LEVEL MOOE
11 ACTUATOR, DEFROSTER/HEATER VALVE
13 HARNESS, VACUUM
19 ACTUATOR, VENT MODE VALVE
47 ACTUATOR, AIR INLET VALVE
012791
FS0211A
Figure 22 Vacuum Harness
1A20
VENT MODE VALVE
!++I
Chevrolet
-

2. Vent mode valve linkage bolt/screw.
3. Vent mode valve actuator (19).
Disconnect linkage from vent mode valve
actuator (19).
I++!
Install or Connect
NOTICE:
The left (driver's side) upper air deflectors can

be removed by gently pushing in on the
inboard edges of the deflector until it unseats
from its snap. Gently pry the outboard snap
with a small screwdriver until the outlet is
free. The left (driver's side) lower air deflector
is part of the knee bolster. Refer to
SECTION 8C. The right (passenger side) air
deflectors can be removed by gently prying the
outboard edges with a wide flat bladed tool.
The outlets are snapped on either side to the
deflector housing.
Heater Hose and Heater Hose Pipes

Figures 23 and 24
1. Vent mode valve actuator (19).

Connect linkage to vent mode valve actuator
(19).
2. Vent mode valve linkage bolt/screw.
l~I
Tighten
Vent mode valve linkage bolt/screw to 2.3 N.m

(20 lb. in.).
AIR INLET VALVE
!++I
1. Insulator from both sides of vehicle.

2. Instrument panel compartment. Refer to
SECTION 8C.
3. Heater module cover.
4. Vacuum hose.
5. Air inlet valve actuator from linkage,
!Hl
Install or Connect
1.
2.
3.
4.
Air inlet valve actuator to linkage.

Vacuum hose.
Heater module cover.
Instrument panel compartment. Refer to
SECTION 8C.
5. Insulator to both sides of vehicle.
Air Deflectors
The heater hose inlet pipe (37) and heater hose

outlet pipe (36) extend forward from the dash front
panel next to the heater module. The heater hose inlet
pipe (37) is toward the left side of the vehicle from
the heater hose outlet pipe (36).
On the 3800 (VIN K) engine, the heated coolant
supply for the heater comes from a quick connect
fitting (33) at the serpentine belt tensioner, just below
the generator. A tube from the fitting extends across
the front of the engine and connects to a heater inlet
pipe (37) that is mounted on the right side rail in the
engine compartment. The rear end of the pipe is
connected to a short inlet hose that leads to the heater
core.
On the 5.7L (VIN K) engine, the heated coolant
supply for the heater comes from a fitting at the water
pump.
On both engines, the heater hose outlet pipe (36)
discharges coolant to a short heater outlet hose that is
connected to a pipe mounted on the right side rail in
the engine compartment. The forward end of the pipe
is connected to an outlet hose that crosses in front of
the engine and feeds the coolant into the water pump
5.7L (VIN K) or the serpentine drive belt tensioner
3800 (VIN K).
3800 (VIN K)
Figure 23
!++!
1. Engine coolant
Drain enough coolant into a clean container
for reuse.
Pontiac
-
The right (passenger's side) and three center

air deflectors of the heater system can be
removed by closing the deflector and then
gently easing the deflector and housing from
the instrument panel. The left-hand (driver's
side) air deflector is part of the instrument
panel cluster trim plate. Refer to
SECTION 8C.
NOTICE: The heater core can be damaged if

excessive force is applied on the core pipes
during hose removal.
NOTICE: Heater hose quick connect fittings
(27) are designed to be removed by hand. Do
not attempt to pry quick connect fittings from
the drive belt tensioner or damage may result.
1A21
27
FITTING, QUICK CONNECT SNAP

BOLT/SCREW, HEATER INLET AND OUTLET PIPE
33 HOSE, HEATER INLET
34 CLAMP, HEATER OUTLET
36 PIPE, HEATER HOSE OUTLET
37 PIPE, HEATER HOSE INLET
146 HOSE, HEATER OUTLET
29
29
012795
FS0211B
Figure 23 - Heater Hose and Heater Hose Pipes 3800 (VIN K)
1A-22
2. Heater hoses and heater hose pipes (33 and 146)

If replacing only heater hose, cut the crimp at
heater hose pipe and replace it with a worm
gear clamp.
A. Twist and pull quick connect fittings (27)
from drive belt tensioner.
Discard 0-rings.
B. Squeeze clamps with pliers and slide
clamps away from heater core fittings.
C. Bolt/screw (29) mounting heater hose pipes
(36 and 37) to side rail.
D. Remove heater hose and heater hose pipes
from heater core by gently twisting and
pulling.
!++I
Install or Connect
NOTICE:
Refer to "Notice" on page lB-1.
1. Heater hose and heater hose pipes (33 and 146)

A. Squeeze clamp ends and slip new hose clamps
over ends of heater hoses.
B. Install heater hoses to heater core.
Apply rubber lubricant to inside diameter
of hoses, if necessary.
C. Bolt/screw (29) mounting heater hose pipes
(36 and 37) to side rail.
!~I
Tighten
Heater inlet and outlet pipe bolt/screw (29)

to 14 N.m (10 lb. ft.).
D. 0-rings to quick connect fittings.
E. Snap quick connect fittings to drive belt
tensioner.
Pull back on quick connect fittings to
verify proper connector engagement.
2. Engine coolant.
Use coolant drained earlier only if it is
uncontaminated. Discard contaminated coolant
and add fresh 50/50 coolant and water
mixture. Refer to "Recommended Fluids or
Lubricants" in SECTION OB.
jL!
Inspect
Be sure installed hose does not sag or rub

against other components. Adjust or support
hose as necessary to correct hose position.
Operate engine and check hose installation for
leaks.
Check coolant level after engine has been
warmed up. Add coolant as necessary.
5.7l (VINK)
NOTICE: The heater core can be damaged if

excessive force is applied on the core pipes
2. Heater hose (33).

A. Squeeze clamps with pliers and slide clamps
(34 and 35 or 151 and 152) away from
fittings.
B. Remove heater hose (33) by twisting and
pulling. If hose will not come off heater hose
inlet pipe (37) or outlet pipe (36) easily with
this method, cut off hose forward of heater
hose pipes. Then cut hose remaining on pipes
lengthwise to remove it.
C. Remove and discard hose clamps (34 and 35
or 151 and 152) if hose (33) is to be reused.
!++I
Install or Connect
1. Heater hose (33). If old hoses are being reused,
replace original hose clamps with worm-gear

clamps.
A. Cut replacement hose(s) to same length as
original hose(s), if necessary.
B. If replacing rubber hoses, remove aluminum
crimp and replace it with worm-gear clamps.
C. Apply rubber lubricant to inside diameter of
hose(s), if desired.
D. Squeeze clamp ends and slip new hose clamp
(34, 35, 151 or 152) over one end of heater
hose. Push hose onto fitting with twisting
motion. Hose end should be 1.0 mm
(0.04 inch) away from touching nearest surface
(dash front panel, fitting hex head, etc.).
E. Install clamp (34, 35, 151 or 152) beyond any
bead around fitting, but not closer than
3.0 mm (0.12 inch) to nearest surface (dash
front panel, fitting hex head, etc.).
F. Repeat hose and clamp installation procedure
at other end of hose.
2. Engine coolant.
Use coolant drained earlier only if it is
uncontaminated. Discard contaminated coolant
and add fresh 50/50 coolant and water
mixture.
!LI
Inspect
Be sure installed hose does not sag or rub against

other components. Adjust or support hose as
necessary to correct hose position.
Operate engine and .check hose installation for
leaks.
Check coolant level after engine has been warmed
up. Add coolant as necessary.
Figure 24
Heater Core
Figure 25
!++I
!++I
1. Engine coolant.
Drain enough coolant into a clean container
for reuse.
1. Hose pipe clamp bolt/screw (45) and hose pipe

clamp (44).
Clamp off heater hoses.
1A-23
40
151
154
150
38
36
PIPE, HEATER HOSE OUTLET

PIPE, HEATER HOSE INLET
38 VALVE, FLOW CONTROL
40 VALVE, BLEED
150 HOSE, HEATER INLET
151 CLAMP, HEATER OUTLET FRONT HOSE
152 CLAMP, HEATER INLET FRONT HOSE
153 PIPE, HEATER INLET
154 PIPE, HEATER OUTLET
155 HOSE, HEATER OUTLET
37
0518-H
FT0231A
Figure 24 - Heater Hose and Heater Hose Pipes 5. 7L (VIN K)
:5~
44~
41
14
A SEALS
MODULE, HEATER
14 CORE. HEATER
41 BOLT/SCREW, HEATER MODULE
42 SOLT/SCREW, HEATER CORE
43 CLAMP, HEATER CORE
44 CLAMP, HEATER HOSE PIPE
45 BOLT/SCREW . HEATER HOSE PIPE
46 COVER, HEATER MODULE
~\q----43
!VIEWA
42~
012795
FS0241A
Figure 25 Heater Core Removed
NOTICE: Heater core can be damaged if too

much force is applied .to heater core pipes
2. Heater hose from heater core pipes.
3. Open instrument panel compartment. Push in on
sides of compartment to release it to reach heater
core.
4. Heater module bolts/screws (41).
For vehicles equipped with A/C, remove air
conditioning evaporator temperature sensor
from heater and air conditioning cover and
remove air inlet valve actuator.
6. Heater core bolt/screw (42) and heater core
clamp (43).
7. Heater core (14).
Carefully pull heater core toward you.
!++!
Install or Connect
NOTICE:
1. Heater core (14).
rn
Important
Lubricate heater pipes for good seal.

Be sure seals around heater pipes remain in
place when installing.
To verify that seal is installed correctly,

observe seal from inside engine compartment.
If seal leaks, apply sealer GM PIN 3012078
between heater core pipes and evaporator
housing.
2. Heater core bolt/screw ( 42) and heater core
clamp (43).
!~!
Tighten
Heater core bolt/screw to 1.8 N.m (16 lb. in.).

3. Hose pipe clamp bolt/screw (45) and hose pipe
clamp (44).
Unclamp heater hoses.
!~!
Tighten
Hose pipe clamp bolt/screw (45) to 1.8 N.m

(16 lb. in.).
4. Heater hose to heater core pipes.
6. Heater module bolts/screws (41).
!~!
Tighten
Heater module bolts/screws (41) to 2 N.m

(18 lb. in.).
For 5. 7L (VIN K) vehicles, install air
conditioning evaporator temperature sensor to
heater core cover and install air inlet valve
actuator.

7. Coolant.
A. Fill cooling system.
B. Operate engine and check for leaks at heater
core pipes.
1A-25
C. Check coolant level after engine has been

warmed up. Add coolant as necessary.
8. Instrument panel compartment.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Bi-Level Mode Valve Linkage Bolt/Screw ........................................................................... 2.3 N,m (20 lb.
Blower Motor Bolt/Screw ...................................................................................................... 2.3 N.m (20 lb.
Blower Motor Resistor Bolt/Screw ........................................................................................... 2 N.m (18 lb.
Heater and A/C Control Bolt/Screw ...................................................................................... 1.9 N,m (17 lb.
Heater Core Bolt/Screw .......................................................................................................... 1.8 N.m (16 lb.
Heater Hose Pipe Bolt/Screw................................................................................................. 1.8 N.m (16 lb.
Heater Inlet and Outlet Pipe Bolt/Screw ................................................................................ 14 N.m (10 lb.
Heater Module Bolt/Screw ........................................................................................................ 2 N.m (18 lb.
Hose Pipe Clamp Bolt/Screw................................................................................................. 1.8 N.m (16 lb.
Temperature Control Cable Bolt/Screw ................................................................................. 1.9 N,m (17 lb.
Vacuum Tank Mounting Bolt/Screw ...................................................................................... 2.5 N,m (22 lb.
Vent Mode Valve Linkage Bolt/Screw .................................................................................. 2.3 N.m (20 lb.
in.)
in.)
in.)
in.)
in.)
in.)
ft.)
in.)
in.)
in.)
in.)
in.)
ELECTRICAL SPECIFICATIONS
Blower Motor Fuse (Labeled "HVAC") .................................................................................. 20 Amp. (Yellow)
HVAC Control Lamp Fuse (Labeled "IP DIMMER") ....... ,.......................................................... 5 Amp. (Tan)
HVAC Control Lamp Bulb Number .......................... ,. ....................................................................................... 37
1A26
BLANK
(
HEATER, VENTILATION AND AIR CONDITIONING
1B-1
SECTION 18
HEATER, VENTILATION AND AIR

CONDITIONING
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "On-Vehicle Service" and the SIR Component and Wiring
Location view in Section 9J before performing service on or around SIR components or wiring.
Failure to follow CAUTIONS could result in possible air bag deployment, personal injury, or
unneeded SIR system repairs.
exact part number for that application. General Motors will call out those fasteners that require a. replacement
UNLESS OTHERWISE SPECIFIED, do .not use supplemental coatings (paints, greases, or other corrosion
systems.
CONTENTS
General Description ............................................... 1B-2

System Operation ................................. ;........ lB-2
Heater System ......................... Refer to Section lA
Air Distribution ...... Refer to Sections lA and 1B 1
Refrigeration System ......................................... lB-2
Refrigerant-134a ............................................ 1B-2
VDOT A/C System ........................................... lB-3
TXV A/C System .............................................. lB-3
Air Conditioning Accumulator ..................... lB-3
Air Conditioning Receiver and
Dehydrator ................................................. 18-3
Air Conditioning Compressor ....................... lB-5
Air Conditioning Condenser ......................... lB-5
Engine Electric Coolant Fans ....................... lB-5
Air Conditioning Evaporator Tube
Orifice ........................................................ lB-5
Thermostatic Expansion Valve ..................... lB-7
Air Conditioning Evaporator ........................ lB-8
Air Conditioning Compressor Pressure
Relief Valve ............................................... lB-8
Relays and Switches ......................................... lB-8
Blower Motor Relay ..................................... 18-8
Air Conditioning Compressor Relay ............ lB-8
Air Conditioning Refrigerant Pressure
Sensor ........................................................ 1B-8
Air Conditioning Evaporator Temperature
Sensor ........................................................ lB-8
Diagnosis ............................................................... 1B-8
Air Distribution System ........ Refer to Section 1B 1
Blower Motor ..................... Refer to Section SA-63
Compressor Circuit......... Refer to Section 6E3-C10
Refrigeration System/Insufficient
Cooling ............................... Refer to Section 1B 1
Heater System/Insufficient
Heating ................................. Refer to Section lA
Leak-Testing the Refrigeration System ............ lB-8

Electric Halogen Leak Detector ................... 1B-9
Fluorescent Leak Detector ............................ 1B-9
Liquid Leak Detectors and Pressure
Testing ....................................................... 18-9
Eliminating Air Conditioning Odor ................. 1B-10
On-Vehicle Service................................................ lB-11
Refrigeration System Services .......................... 1B-11
Replacing 0-Rings ........................................ lB-11
Handling Refrigerant-134a ............................ 1B-11
Handling Refrigerant Lines and Fittings ...... lB-12
Maintaining Chemical Stability in the
Refrigeration System ................................. 18-12
Refrigerant Recovery and Recycling, Adding
Oil, Evacuating and Recharging
Procedures ..................................................... lB-13
General Description ...................................... 1B-13
Station (ACR4) Setup and Maintenance ...... lB-13
Refrigerant Recovery .................................... 1B-14
Evacuation ..................................................... 1B-16
AJC System Oil Charge Replenishing ......... lB-17
Refrigerant Oil Distribution .......................... lB-17
Refrigerant Oil Loss Due to a Large
Leak ........................................................... lB-17
Compressor System ....................................... I B-18
Charging the A/C System (Engine Off) ...... lB-18
Replacement Procedures ................................... 1B-19
Blower Motor and Fan ......... Refer to Section lA
Air Ducts and Deflector
Outlets ................................ Refer to Section lA
Vacuum Tank......................... Refer to Section IA
Heater Hoses and Pipes ........ Refer to Section lA
Air Conditioning Compressor and
Condenser Hose ........................................ lB-19
Air Conditioning Accumulator Hose ........... lB-23
19.;2
Air Conditioning Receiver and Dehydrator

Tube ........................................................... lB-23
Air Conditioning Evaporator Tube ............... lB-24
Orifice ........................................................ lB-25
Thermostatic Expansion Valve ...................... lB-25
Air Conditioning Accumulator ..................... lB-25
Dehydrator ................................................. IB-26
Sensor .............................. Refer to Section 1B 1
Air Conditioning Condenser ........ ;................ lB-27
Air Conditioning Compressor ....................... lB-27
GENERAL DESCRIPTION
Air Conditioning Refrigerant Service

Valve Core ................................................. lB-30
Air Conditioning Compressor Front
Bracket ....................................................... IB-30
Generator and Air Conditioning Compressor
and Power Steering Pump Bracket .......... lB-31
Compressor On-Vehicle Minor Component
Replacement .............................................. lB-31
-Specifications ......................................................... lB-32
General Specifications ....................................... lB-32
Fastener Tightening Specifications ................... lB-32
Fitting Tightening Specifications ...................... lB-32
Special Tools ......................................................... lB-33
REFRIGERATION SYSTEM
Figures 1 through 4
HEATER, VENTILATION AND AIR

CONDITIONING SYSTEM OPERATION
NOTICE: The refrigeration system on this
vehicle uses R-134a which is not compatible
with refrigerant R-12. Before servicing the
system always make sure the proper servicing
equipment is used or the system could become
severely damaged. Always refer to the service
text and manufacturer instructions included with
service equipment before proceeding.
The air conditioning system (C60) delivers air
that has been heated or cooled and dehumidified for
occupant comfort. It also provides power ventilation,
windshield and side window defrosting.
During most operating conditions, outside air is
drawn through the heater and air conditioning module
by the blower motor. Additional outside air is also
forced into the vehicle by forward movement of the
vehicle.
Within the evaporator module, air is pushed by
the blower motor through the evaporator, then through
the heater core depending on the temperature valve
position, then into the passenger compartment. For air
conditioning or defroster operation at ambient
temperatures above 7C (45F),the refrigeration system
will chill the evaporator to almost freezing. As the air
passes through the evaporator, the air temperature
drops which causes the moisture in the air to condense
on the evaporator core fins. This moisture leaves the
vehicle by gravity feed through a drain hole,
dehumidifying the vehicle.
From the evaporator, some or all of the air may
pass through the heater core, which is warmed by
engine coolant. Any of the air which is not to be
heated will mix with the heated air before entering the
passenger compartment.
When maximum air conditioning mode is
selected, most of the air entering the blower motor is
taken from the passenger compartment (re-circulated)
where it is most likely to be cooler than the outside
air. Only outside air is used in all other modes.
Refrigerant-134a
CAUTION: Avoid breathing A/C
Refrigerant-134a and lubricant vapor or
mist. Exposure may irritate eyes, nose,
and throat. To remove R-134a from the
A/C system, use service equipment
certified to meet the requirements of SAE
J2210 (R-134a recycling equipment). If
accidental system discharge occurs,
ventilate work area before resuming
service. Additional health and safety
information may be obtained from
refrigerant and lubricant manufacturers.
Like the coolant in the engine cooling system,
the refrigerant is the substance in the air conditioning
system that absorbs, carries and then releases heat.
Although various substances are used as refrigerants in
other types of refrigeration systems, past automotive
air conditioning systems used a type called
Refrigerant-12 (R-12).
This vehicle uses a new type of refrigerant
called Refrigerant-134a (R-134a). It is a non-toxic,
non-flammable, clear, colorless, liquefied gas.
While the R-134a A/C system is very similar to
an R-12 A/C system, the differences in the refrigerant,
lubricants, and service equipment are important.
NOTICE: R-134a refrigerant is not compatible

with R-12 refrigerant in an air conditioning
system. R-12 in a R-134a system will cause
compressor failure, refrigerant oil sludge or poor
air conditioning system performance.
Refrigerant-134a carries a charge of a special
lubricating oil, polyalkylene glycol (PAG)
refrigerant oil. GM PAG refrigerant oil will
have a slight blue tint. The oil is hydroscopic
(absorbs water from the atmosphere) and should
be stored in closed containers.
Use only polyalkylene glycol (PAG) synthetic
refrigerant oil for internal circulation through
the R-134a A/C system and only mineral base
525 viscosity refrigerant oil on fittings threads
and 0-rings. If lubricants other than those
specified are used, compressor failure and/or
fitting seizure is likely to occur.

VDOT A/C SYSTEM
3800 VINK
The Variable Displacement Orifice Tube

(VDOT) air conditioning system employs a VS
compressor that can match the automotive air
conditioning demand under all conditions without
cycling. The basic compressor mechanism is a variable
angle wobble-plate with axially oriented cylinders. The
control of the compressor displacement is a bellows
actuated control valve located in the rear head of the
compressor that senses suction pressure. The
wobble-plate angle and compressor displacement are
controlled by the crankcase-suction pressure
differential. When the A/C capacity demand is high,
the suction pressure will be above the control point;
the valve will maintain a bleed from the crankcase to
suction; no crankcase-suction pressure differential; and
the compressor will have maximum displacement.
When the A/C capacity demand is lower and the
suction pressure reaches the control point, the valve
will bleed discharge gas into the crankcase and close
off a passage from the crankcase to the suction
plenum. The angle of the wobble-plate is controlled by
a force balance on the five pistons. A slight elevation
of tie crankcase-suction pressure differential creates a
total force on the pistons resulting in a movement
about the wobble-plate pivot pin that reduces the plate
angle.
The compressor has a unique lubrication system.
The crankcase-suction bleed is routed through the
rotating wobble-plate for lubrication of the
wobble-plate bearing. The rotation acts as an oil
separator, which removes some of the oil from the
crankcase-suction bleed, rerouting it to the crankcase
where it can lubricate the compressor mechanism.
The compressor, depending upon engine usage,
is cut-off under certain conditions, such as wide-open
throttle, low idle speed, low air temperature and high
power steering loads. The VS compressor has a
mechanical destroker that will begin to destroke during
engine speeds of 3,000 -3,800 RPM.
When the engine is turned "OFF" with the A/C
system operating, the refrigerant in the system will
flow from the high pressure side of the evaporator
tube orifice to the low pressure side until the pressure
is equalized. This may be detected as a faint sound of
liq1id flowing (hissing) for 30 to 60 seconds and is a
normal condition.
A/C Electrical System diagnosis is found in
ELECTRICAL DIAGNOSIS (SECTION 8A-63 and
8A-64).
TXV A/C SYSTEM

5.7L VIN P
The Thermostatic Expansion Valve (TXV)

refrigerant system, on 5. 7L VIN P equipped vehicles,
is designed to cycle the compressor on and off to
maintain desired cooling and to prevent evaporator
freeze. Passenger compartment comfort is maintained
by the temperature lever on the control.
1B-3
Control of the refrigeration cycle (on and off

operation of the compressor) is done with the
evaporator temperature sensor. The evaporator
temperature sensor is a freeze protection device for the
evaporator. When the air conditioning mode (max,
norm, bi-level, defrost) is selected, voltage is supplied
to the compressor clutch coil. When evaporator
temperature approaches the freezing point (the low
setting of the switch), the switch opens the compressor
clutch circuit and disengages the clutch. The
compressor remains disengaged until the temperature
rises above a preset temperature. As the temperature
rises and reaches a preset point, the switch closes,
re-energizing the clutch coil. This cycling continues
and attempts to maintain evaporator temperature at
1C (33 F) with slight variation due to outside air
temperature and humidity. Because of this cycling,
some slight increases and decreases of engine
speed/power may be noticed under certain conditions.
This is normal as the system is designed to cycle to
maintain desired cooling, thus preventing evaporator
freeze-up. The thermostatic expansion valve (TXV)
regulates the flow of liquid refrigerant into the
evaporator. Its operation reduces the pressure and
temperature of the refrigerant flowing to the
evaporator.
The compressor, depending upon engine usage,
is also cut off under certain other conditions such as
wide-open throttle, low idle speed and low air
temperature.
AIC Electrical System diagnosis is found in
ELECTRICAL DIAGNOSIS (SECTION 8A-63 and
8A-64).
Air Conditioning Accumulator

3800 VINK
The accumulator is located on the right side

wheelhouse panel, just downstream from the
evaporator. It functions as a moisture separator that
receives refrigerant liquid and refrigerant oil from the
evaporator.
At the bottom of the accumulator is the
desiccant, which acts as a drying agent for moisture
that may have entered the system.

5.7L VIN P
The receiver and dehydrator is located on the

right side wheelhouse panel, just downstream from the
condenser. It functions as a moisture separator that
receives refrigerant liquid and refrigerant oil from the
condenser. It only allows refrigerant liquid and a small
amount of oil to continue on to the thermostatic
expansion valve.
At the bottom of the receiver and dehydrator is
the desiccant, which acts as a drying agent for
moisture that may have entered the system. A filter is
also located near the bottom of the receiver and
dehydrator outlet pipe to keep any particles from
plugging the thermostatic expansion valve.
1B-4

42
Id
22~
I
21-1
20~/
33
11-16-94
FS0221B
Figure 1 - Refrigeration System Components (3800 VIN K)
2
3
4
6
7
8
9
10
11
12
13
14
16
MODULE, HEATER AND AIR CONDITIONING

EVAPORATOR
COMPRESSOR, AIR CONDITIONING
CONDENSER, AIR CONDITIONING
ACCUMULATOR, AIR CONDITIONING
EVAPORATOR, AIR CONDITIONING
HOSE, AIR CONDITIONING COMPRESSOR
ANO CONDENSER
HOSE, ACCUMULATOR
TUBE. AIR CONDITIONING EVAPORATOR
BRACKET, AIR CONDITIONING ACCUMULATOR
SOLT /SCREW, AIR CONDITIONING
ACCUMULATOR CLAMP
SOLT /SCREW, AIR CONDITIONING
ACCUMULATOR BRACKET
0-RING, AIR CONDITIONING EVAPORATOR TUBE
0-RING, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE
0-RING, AIR CONDITIONING ACCUMULATOR HOSE
17
18
20
21
22
23
26
27
28
33
38
1B-5
0-RING, AIR CONDITIONING COMPRESSOR AND

CONDENSER HOSE
SEAL, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE
0-RING, AIR CONDITIONING REFRIGERANT
PRESSURE SENSOR
VAL VE, AIR CONDITIONING REFRIGERANT
PRESSURE SENSOR
SENSOR, AIR CONDITIONING REFRIGERANT
PRESSURE SENSOR
CORE, AIR CONDITIONING REFRIGERANT SERVICE VALVE
CAP, AIR CONDITIONING REFRIGERANT CHARGE VALVE
SOLT/SCREW, AIR CONDITIONING EVAPORATOR TUBE
SOLT/SCREW, AIR CONDITIONING COMPRESSOR ANO
CONDENSER HOSE
RETAINER, RADIATOR AIR UPPER BAFFLE
SOLT/SCREW. AIR CONDITIONING COMPRESSOR
11-11-14
FS0231B
Figure 2 - Refrigeration System Components -Legend (3800 VIN K)
Air Conditioning Compressor

The air conditioning compressor is driven by a
belt from the engine crankshaft through the
compressor clutch pulley. The compressor pulley
rotates freely, without turning the compressor shaft,
until an electromagnetic clutch coil is energized. When
voltage is applied to energize the clutch coil, a clutch
plate and hub is drawn rearward toward the pulley.
The magnetic force locks the clutch plate and pulley
together as one unit to drive the compressor shaft. For
unit repair information, refer to SECTION 1D2 or
SECTION 1D3.
Air Conditioning Condenser

The air conditioning condenser in front of the
radiator is made up of coils, which carry the
refrigerant and cooling fins to provide rapid transfer of
heat. The air passing through the condenser cools the
high-pressure refrigerant vapor, causing it to condense
into a liquid.
Engine Electric Coolant Fans
Coolant fan operation is crucial to the proper

.operation of the air conditioning system. The coolant
fans ensures the proper amount of air flow across the
condenser throughout the vehicle operating range.
Fan operation should be checked during any air

conditioning diagnosis procedure. Special attention
should be given to the fan whenever excessive high
side pressures are encountered.
Air Conditioning Evaporator Tube Orifice

3800 VINK
Figure 5
The plastic tube, with its mesh screen and
orifice, is located just forward of the evaporator fitting
between the condenser outlet and evaporator inlet. It
provides a restriction to the high-pressure liquid
refrigerant in the liquid line, metering the flow of
refrigerant to the evaporator as a vapor. The
evaporator tube orifice is protected from contamination
by filter screens on both inlet and outlet sides.
When system diagnostics indicate a restricted
evaporator tube orifice, it may not be necessary to
replace the tube. Metal chips, flakes or slivers found
on the screen may be removed with compressed air
and the evaporator tube orifice may be reused if:
The plastic frame is not broken .
The brass expansion tube is not damaged or
plugged.
The screen material is not torn.
The screen is not plugged with fine gritty
material.
1B-6
18
11
,4
12
33
013095
FS0011B
Figure 3 Refrigeration System Components (5. 7L VIN P)

20 0-RING, AIR CONDITIONING REFRIGERANT
1 MODULE, HEATER ANO AIR CONDITIONING

2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
1B-7
EVAPORATOR
RECEIVER ANO DEHYDRATOR, AIR
CONDITIONING
VAL VE, AIR CONDITIONING
THERMOSTATIC EXPANSION
HOSE, AIR CONDITIONING COMPRESSOR
ANO CONDENSER
TUBE, AIR CONDITIONING RECEIVED DEHYDRATOR
TUBE, AIR CONDITIONING RECEIVER DEHYDRATOR
BRACKET, AIR CONDITIONING RECEIVER DEHYDRATOR
BOLT/SCREW, AIR CONDITIONING RECEIVER
DEHYDRATOR CLAMP
BOLT/SCREW, AIR CONDITIONING RECEIVER
DEHYDRATOR BRACKET
0-RING, AIR CONDITIONING RECEIVER DEHYDRATOR
TUBE
0-RING, AIR CONDITIONING EVAPORATOR TUBE
SEAL, AIR CONDITIONING EVAPORATOR TUBE
SEAL, AIR CONDITIONING COMPRESSOR ANO
CONDENSER HOSE
0-RING, AIR CONDITIONING CONDENSER FITIING
SEAL, AIR CONDITIONING COMPRESSOR HOSE
PRESSURE SENSOR
21 VAL VE, AIR CONDITIONING REFRIGERANT

PRESSURE SENSOR
22 SENSOR, AIR CONDITIONING

REFRIGERANT PRESSURE
23 CORE, AIR CONDITIONING REFRIGERANT SERVICE

VALVE
26 CAP, Al,R CONDITIONING REFRIGERANT CHARGE

VALVE
27 BOLT/SCREW, AIR CONDITIONING RECEIVER

DEHYDRATOR TUBE
28 BOLT/SCREW, AIR CONDITIONING COMPRESSOR AND

CONDENSER HOSE
29 SOLT/SCREW, AIR CONDITIONING THERMOSTATIC

EXPANSION VAL VE
30 BOLT/SCREW, AIR CONDITIONING COMPRESSOR ANO

CONDENSER HOSE CLIP BRACKET
32 BRACKET, AIR CONDITIONING COMPRESSOR HOSE

CLIP
33 RETAINER, RADIATOR AIR UPPER BAFFLE

34 STRAP, AIR CONDITIONING COMPRESSOR ANO
CONDENSER HOSE
38 SOLT/SCREW, AIR CONDITIONING COMPRESSOR

42 GASKET, EVAPORATOR BLOCK
01-30-95
FS0021B
Figure 4 - Refrigeration System Components -Legend (5.7L VIN P)
14
A LONG SCREEN (INLET-INSTALL TOWARD

CONDENSER)
8 0-RING
C SHORT SCREEN (OUTLET-INSTALL TOWARD
EVAPORATOR)
10-10-94
14 TUBE, EXPANSION
D80021B
c
F
Figure 5 - Air Conditioning Evaporator Tube Orifice (3800

VINK)
E
Thermostatic Expansion Valve
5.7L VIN P
Figure 6
The purpose of the thermostatic expansion valve
is to regulate the flow of refrigerant through the
evaporator to optimize its cooling performance. This is
accomplished by monitoring the refrigerant conditions
at the evaporator outlet and adjusting the inlet flow
accordingly. This assures that all the liquid is
evaporated before it is returned to the compressor.
A
B
C
D
POWER DOME
THERMAL-SIDE PRESSURE
AIR CONDITIONING SYSTEM LOW-SIDE PRESSURE
FROM AIR CONDITIONING RECEIVER AND
DEHYDRATOR {HIGH SIDE)
E TO AIR CONDITIONING EVAPORATOR (LOW SIDE)
F FROM AIR CONDITIONING EVAPORATOR
G TO AIR CONDITIONING COMPRESSOR
12-08-94
FS0031B
Figure 6 - Thermostatic Expansion Valve (5.7L VIN P)
1B-8
The refrigerant flow is controlled by the

movement of a shaft that pushes a ball from its seat.
As the ball is unseated, more flow is allowed through
the evaporator. Shaft movement is controlled by the
power dome which has two separate sides. The
thermal side of the power dome is sealed and charged
with refrigerant. The system side of the power dome is
exposed to the pressure of the evaporator outlet or low
side. Refrigerant exiting the evaporator flows over part
of the thermal side of the power dome. The sealed
refrigerant in the thermal side responds to the
temperature changes of the refrigerant flowing out of
the evaporator. As the refrigerant temperature rises, the
pressure of the thermal side increases.
If the pressure on the thermal side of the power
dome is greater than the pressure on the system side
(the evaporator outlet or low-side pressure), the shaft
moves down and pushes the ball off the seat allowing
more refrigerant flow through the evaporator. Wh~n
the opposite is true, the shaft moves up and re-seats
the ball reducing flow. A spring at the bottom of the
thermostatic expansion valve is not adjustable.
Although the thermostatic expansion valve
controls evaporator refrigerant flow, air conditioning
capacity control (to prevent ice build-up) is managed
by compressor cycling which is controlled by the
powertrain control module (PCM).
Air Conditioning Evaporator

The evaporator is a device which cools and
dehumidifies the air before it enters the vehicle.
High-pressure refrigerant flows through the
thermostatic expansion valve (5.7L VIN P) or the
orifice tube (3800 VIN K) and becomes low-pressure
refrigerant before entering the evaporator. The heat in
the air passing through the evaporator core is lost to
the cooler surface of the core, thereby cooling the air.
As the process of heat loss from the air to the
evaporator core surface is taking place, any moisture
(humidity) in the air condenses on the outside of the
evaporator core and is drained off as water.

Relief Valve
The compressor is equipped with a pressure
relief valve which is placed in the system as a safety
factor. Under certain conditions, the refrigerant on the
discharge side may exceed the designed operating
pressure. To prevent system damage, the valve is
designed to open automatically at approximately 3036
kPa (440 psi). Any condition that causes this valve to
open should be corrected, and the refrigerant oil
should be replaced as necessary. The air conditioning
refrigerant pressure sensor should also be checked for
proper calibration. Refer to SECTION 6E3 (DTC 61).
RELAYS AND SWITCHES

Blower Motor Relay
The blower motor relay is used to provide
battery voltage to the blower motor only during high
blower motor speed. The blower motor resistor is used
to provide power to the blower motor in all other
speed settings. The blower motor relay is located

under the instrument panel. Refer to SECTION 8A-63
for more information.
Air Conditioning Compressor Relay

The air conditioning compressor relay is used to
provide battery voltage to the compressor clutch coil.
The relay is controlled by the powertrain control
module (PCM) only. The relay is located in the
underhood electrical center. Refer to SECTION 8A-64
for more information.
Air Conc:litioning Refrigerant Pressure

Sensor.
The NC refrigerant pressure sensor attached to
the air conditioning evaporator liquid line, senses
refrigerant pressure on the air conditioning system
high-side. The refrigerant pressure status is sent to the
PCM. The purpose of this sensor is to inform the
PCM of high-side pressure status so the PCM can:
Control cooling fan operation.
Prevent compressor operation if ambient
temperatures are too cold.
Disable the compressor before high-side pressure
becomes too high.
Diagnosis of compressor controls.
Refer to SECTION 8A-64 for more information.
Air Conditioning Evaporator Temperature

Sensor
5.7L VIN P
The air conditioning evaporator temperature

sensor mounted to the heater and air conditioning
evaporator module has a probe inserted into the
evaporator which measures evaporator temperature and
sends a signal to the PCM. Within the probe is a
thermistor which varies output according to
temperature. The purpose of this sensor is to inform
the PCM of the evaporator temperature so the
compressor can be disabled before the evaporator
freezes. The evaporator temperature sensor is a solid
state device, do not attempt to measure resistance.
Measuring resistance across pins can cause sensor
damage. Refer to SECTION 8A-64 for more
information.
DIAGNOSIS
LEAK-TESTING THE REFRIGERATION
SYSTEM
A refrigerant leak test should be performed on
the system whenever a leak is suspected due to system
indication of low charge or after any service operation
which disturbs the components, lines, or connections.
Many methods and special tools are available for this
purpose; however, no matter which tool is used, care
and diligence are the biggest keys to success.
1B-9
Electric Halogen Leak Detector

Figures 7 and 8
Tool Required:
J 39400 Halogen Leak Detector
This type of leak detector has been found to
be the most useful tool in locating refrigerant leaks.
The J 39400 is a small unit which operates on
12 volts de and provides an audible signal which
increases in frequency when leaking refrigerant is
detected. There are three settings: one for R-12, one
for R-134a, and one for gross leaks. The gross leak
setting is for isolating very large leaks already
found at one of the other two settings. Care must be
taken that the instrument is properly calibrated, per
the included instructions, and that it is used at the
proper setting for the type of refrigerant in .the
system being tested.
)
A SERVICE FITIING VALVE
EVAPORATOR CORE
Because the evaporator core is contained in a

closed module and is inaccessible to leak detectors, it
is one of the most difficult parts of the air
conditioning system to check for leaks. To leak-test
the evaporator core:
J 39400
l. Turn the blower motor on to high for 15 or more

seconds then shut it
2. Wait 10 minutes.
3. Remove blower motor resistor. Refer to
SECTION lA.
4. Insert the leak detector probe into the resistor
opening. If the detector goes to a solid alarm, a
leak has been found.
off.
B REFRIGERANT LINE
COMPRESSOR AND BLOCK FITTING
J 39400
1. Blow shop air behind and in front of the

compressor clutch/pulley for at least 15 seconds.
2. Probe the compressor area. If the detector goes to
a solid alarm, a leak has been found.
J39400
C REFRIGERANT PRESSURE SENSOR OR

COMPRESSOR LOW PRESSURE CUT-OFF SWITCH
Ol-3011
FSOOSIB
Ol3011
F800418
Figure 7 - Electric Halogen Leak Detector
Figure 8 - Checking for Refrigerant Leaks
1B-10 HEATER, VENTILATION AND AIR CONDITIONING
Fluorescent Leak Detector

Tools Required:
J 41447 Tracer Dye
J 41436 Tracer Dye Injector
J 28428 High Intensity Black Light
R-134a refrigerant is uniquely different from
R-12 refrigerant used in the past and may require
additional methods to detect leaks. The R-134a
molecule is smaller than the R-12 molecule and can
leak through smaller openings. Also, R-134a
refrigerant does not contain chlorine which the
electronic leak detectors found very easy to identify.
The tracer dye method is meant to be used in
conjunction with the electronic leak detector and
will pinpoint smaller leaks undetected by using the
electronic leak detector. R-134a tracer dye requires
time. Depending upon the leak rate, it may take
only minutes or up to 7 days of compressor
operation for the leak to become visible.
DYE INJECTION
Charged A/C systems can be injected with tracer

dye by using J 41436 Tracer Dye Injector along
with the instructions provided.
Discharged A/C systems can have the tracer dye
added by use of replaced components or by
injecting the dye with the ACR4.
lIJ
important
Tracer Dye PIN J 41447 has been developed to be

used only with R-134a equipped vehicles or
vehicles that have been retrofitted from R-12 to
R-134a systems.
Only J 41447 tracer dye is recommended for use
in the R-134a system. Use of other products may
affect system reliability and cause premature
compressor failure.
Use only a 1/4 oz. charge of tracer dye. Larger
amounts may compromise the reliability of the
AIC system.
Place tracer dye notice label on shock tower next
to R-134a cparging label on accumulator.
CAUTION: R134a service equipment or

vehicle A/C systems should not be
pressure tested or leak-tested with
compressed air. Some mixtures of
air/R-134a have been shown to be
combustible at elevated pressures. These
mixtures are potentially dangerous and
may result in fire or explosion causing
injury or property damage. Additional
health and safety information may be
obtained from refrigerant and lubricant
manufacturers.
ELIMINATING AIR CONDITIONING ODOR

Tool Required:
J 36645 A/C Evaporator Cleaning Gun
Some vehicles may experience odors emitted
from the air conditioning system primarily at start
up in hot, humid climates. This odor may be the
result of debris in the evaporator module case
and/or microbial growth on the evaporator core. To
eliminate this condition, the following equipment
and procedure should be used.
CAUTION: This procedure should only be

performed on a cold vehicle to prevent
the disinfectant from coming in contact
with hot enqine components which could
cause irritating vapors. to form.
Disinfectant can cause substantial, but
temporary, eye injury. Do not get in eyes
or on clothing. Wash thoroughly with
soap and water after handling
disinfectant. If disinfectant gets into
eyes, hold eyelids open and flush with a
steady, gentle stream of water for fifteen
minutes. Obtain medical attention if
irritation persists.
rn
1.
2.
Clean
After adding tracer dye, clean service valves and

surfaces of residual dye with GM Engine
Degreaser GM PIN 1050436 or equivalent to
prevent any future false diagnosis.
3.
Liquid Leak Detectors and Pressure

Testing
Due to their lack of sensitivity, liquid/bubble
leak detectors have very limited usefulness and are not
recommended.
4.
Important
This procedure will eliminate debris or

microbial growth which can cause odors but
will not keep such debris or microbes present
in the environment from causing a recurrence
of the problem.
Remove heater core. Refer to SECTION lA.
Check evaporator module case for debris, remove
any debris present. If debris is imbedded into
evaporator core face and cannot be removed, the
core will have to be removed from vehicle and
cleaned. If a large amount of debris is present in
evaporator module case, the air inlet screen will
require sealing around the windshield wiper post
holes and fender edges.
Place drain pan with at least a two-liter
(two-quart) capacity below evaporator drain hole
to collect disinfectant and rinse water runoff.
The evaporator drain hole is located at the
bottom of the evaporator lower case
approximately 25 mm (1 inch) from the dash
panel (engine compartment side).
Connect battery charger to avoid draining battery
during cleaning procedure.

5. Position pedestal fan and turn it on high speed to
provide cross ventilation during cleaning
procedure.
6. Turn ignition switch to the "RUN" position but
do not start vehicle.
7. Set heater and air conditioning control to "LOW"
blower motor speed, full "HOT" and
"HEATER."
8. Open all windows and doors and exit vehicle.
9. Pour small bottle of two-part GM Goodwrench air
conditioning system disinfectant kit, GM
PIN 25533404 or equivalent, into large bottle.
Seal and invert large container once or twice to
mix contents.
10. Use J 36645 or equivalent siphon-type
parts-cleaning spray gun capable of delivering
60 ml (2 ounces) per minute of liquid when
driven with 552 to 621 kPa (80 to 90 psi) of
compressed air. Insert nozzle of spray gun through
heater core opening and insert siphon hose into
container of disinfectant. Direct spray toward
evaporator face taking extra care to ensure
. adequate coverage of the corners and edges,
completely saturating the entire core. Use entire
container of solution.
11. Turn ignition switch to the "OFF" position and
allow core to soak for five minutes.
12. Check underneath vehicle to verify proper drain
operation. If necessary, unclog and increase drain
plug hole with a rat-tail file.
13. Turn the ignition switch to the "RUN" position
but do not start vehicle.
14. Thoroughly rinse evaporator core with one liter
(one quart) of clean water using spray gun to
remove any disinfectant residue.
15. Turn ignition switch to the "OFF" position and
install heater core. Refer to SECTION lA.
16. Dispose of disinfectant and rinse water runoff
collected in drain pan in an approved mariner.
ON-VEHICLE SERVICE
REFRIGERATION SYSTEM SERVICES
Replacing 0-Rings
Install new GM-approvedservice replacement air
conditioning 0-rings when a joint or a fitting is
installed, except when the 0-rings are provided on
new replacement components. Unless service
replacement 0-rings of the specified part numbers are
used, excessive leakage of Refrigerant-134a may
occur. Refer to the part number for identification, not
to the former color-coating method of identification,
because some formerly color-coated service
replacement 0-rings may be black.
.
Air conditioning 0-rings should be coated with
mineral base 525 viscosity refrigerant oil just before
installation and should be slipped onto the flange tube
to assure proper locating and sealing. To prevent the
possibility of swelling and a reduction in sealing
effectiveness, 0-rings should not be allowed to soak in
1B-11
refrigerant oil. Before installation, the 0-rings and the

fittings should be examined to ensure that they have
not been nicked or deformed. Nicked or deformed
parts must be replaced or excessive refrigerant leakage
may result.
Handling Refrigerant-134a
The air conditioning system in this vehicle
contains Refrigerant-134a (R-134a). This chemical
mixture requires special handling procedures to avoid
personal injury.
Always wear goggles and wrap a clean cloth
around fittings, va.lves, and connections when
performing work that involves opening the refrigerant
system. Always work in a well ventilated area and
avoid breathing. any refrigerant fumes. Do not weld or
steam clean on or near any vehicle-installed air
conditioning lines or components.
If R-134a should come in contact with any part
of the body, flush the exposed area with water and
immediately seek medical attention.
refrigerant and lubricant vapor or mist.
Exposure may irritate eyes, nose, and
throat. To remove R-134a from the A/C
system, use service equipment certified
to meet the requirements of SAE J221 O
or SAE J2209. If accidental system
discharge occurs, ventilate work area
before resuming service. Additional
health and safety information may be
obtained from refrigerant and lubricant
manufacturers.
Do not store or heat refrigerant
containers above 52C (125F).
Do not heat a refrigerant container with
an open flame; if container warming is
required, place the bottom of the
container in a pail of warm water.
Do not intentionally drop, puncture, or
incinerate refrigerant containers.
Refrigerant will displace oxygen,
therefore be certain to work in well
ventilated areas to prevent suffocation.
If it is necessary to carry a container of
"Dot CFR" Refr1gerant-134a in a vehicle,
it should not be carried in the passenger
compartment. Only containers that meet
DOT SPEC 4BA or 4BW should be used.
NOTICE: R-12 refrigerant and R-134a
refrigerant must never be mixed, even in the
smallest of amounts, as they are incompatible
with each other. If the refrigerants are mixed,
compressor failure is likely to occur.
the R-134a A/C system and only mineral base
525 viscosity refrigerant oil on fitting threads
1B-12
Do not introduce compressed air to any

refrigerant container or refrigerant component, because
contamination will occur.
Before attempting any service which requires
opening refrigeration system lines or components, refer
to "Handling of Refrigerant Lines and Fittings" and
"Maintaining Chemical Stability" that follow.
Carefully follow the instructions for refrigerant
recovery and recycling, adding oil, evacuating, and
recharging the refrigeration system.
All Refrigerant-134a disposable (colored blue)
containers are shipped with a heavy metal screw cap
to protect the valve and safety plug of the container
from damage. It is good practice to replace the cap
after each use of the container to continue protection.
Handling Refrigerant lines and Fittings

CAUTION: For personal protection,
goggles should be worn and a clean
cloth wrapped around fittings, valves and
connections when doing work that
includes opening the refrigeration
system. If Refrigerant-134a comes in
contact with any part of the body, severe
frostbite and personal injury can result.
The exposed area should be flushed
immediately with cold water and prompt
medical help should be obtained.
All metal tubing lines should be free of dents or
kinks to prevent loss of system capacity due to
line restriction.
The flexible hose lines should never be bent to a
radius of less than four times the diameter of the
hose.
The flexible hose lines should never to allowed to
come within a distance of 635 mm (2 1/2 inches)
of the exhaust manifold.
Flexible hose lines should be inspected regularly
for leaks or brittleness and replaced with new
lines if deterioration or leaking is found.
When disconnecting any fitting in the refrigeration
system, the system must first be discharged of all
Refrigerant-134a. Refer to "Refrigerant Recovery
and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
Once a refrigerant line is opened to the
atmosphere, it should be capped or taped
immediately to prevent entry of moisture and dirt.
The use of the proper wrenches when making
connections on 0-ring fittings is important. The
opposing fitting should always be backed up with
a wrench to prevent distortion of connecting lines
or components. Tighten all tubing connections to
the specified torque for the fitting. Too little or
too much torque when tightening can result in
loose joints or deformed joint parts. Either
condition can result in refrigerant leakage and an
inoperative air conditioning system. Refer to
"Fitting Tightening Specifications" at the end of
this section.
0-rings and seals must be in perfect condition. A

burr or piece of dirt may cause a refrigerant leak.
Install new 0-rings that have been lubricated with
mineral base 525 viscosity refrigerant oil. Do not
use PAG oil.
Keep polyalkylene glycol (PAG) refrigerant oil off
fitting threads. Long term contact of PAG oil on
threads may cause future difficulties. Flush
threads of fittings with mineralbase 525 viscosity
refrigerant oil. Do not use PAG oil. Do not wipe
threads .with a cloth.
Maintaining Chemical Stability in the

Refrigeration System
The efficient operation and life of the air
conditioning system is dependent upon the chemical
stability of the refrigeration system. When foreign
materials such as dirt, air, or moisture, contaminate the
refrigeration system, the stability of the
Refrigerant-134a and polyalkylene glycol (PAG)
synthetic refrigerant oil will change. Contaminants will
also affect pressure-temperature relationship, reduce
efficient operation and possibly cause interior
corrosion and abnormal wear of moving parts.
The following general practices should be
observed to ensure the chemical stability in the
system:
Before breaking a .. refrigerant connection, .wipe
away any dirt. or oil to reduce the possibility of
dirt entering the system. Both sides of the
connection should be capped, plugged or taped as
soon as possible to prevent the entry of dirt,
foreign material and moisture.
Keep tools clean and dry. This includes the
manifold gage set and replacement parts.
When adding polyalkylene glycol (PAG) synthetic
refrigerant oil, the transfer device and container
should be exceptionally clean and dry to assure
that refrigerant oil remains as moisture-free as
possible.
When it is necessary to "open" an A/C system,

have everything needed ready and handy so that
as little time as possible will be required to
perform the operation. Do not leave the A/C
system open any longer than is necessary.
Any time the A/C system has been "opened," it
should be properly evacuated before recharging
with Refrigerant-134a.
All service parts are dehydrated and sealed prior
to shipping. They should remain sealed until just
prior to making connections. All parts should be
at room temperature before uncapping. This
prevents condensation of moisture from the air
entering the system. If for any reason caps are
removed but the connections are not made, parts
should be resealed as soon as possible.

REFRIGERANT RECOVERY AND
RECYCLING, ADDING Oil, EVACUATING
AND RECHARGING PROCEDURES
1B-13
General Description
B
Figure 9
The J 39500 air conditioning refrigerant

recovery, recycling and recharging (ACR4) system
removes Refrigerant-134a from the vehicle A/C
system, recycles and recharges all with one hook-up.
Single pass filtering during recovery cycle, plus
automatic multiple pass filtering during evacuation
cycle assures constant supply of clean/dry refrigerant
for AJC system charging.
NOTICE: R-12 and R-134a require separate

and non-interchangeable sets of recovery,
recycling, and recharging equipment, because
the refrigerants and lubricants are not
compatible and cannot be mixed even in the
smallest amounts. Do not attempt to use one set
of equipment for both R-12 and R-134a, as all
equipment contains residual amounts of
refrigerant and/or lubricant, which will result in
contamination, and damage to the
recovery/recycle equipment. Adapters to convert
from one size fitting to the other must never be
used; refrigerant/lubricant contamination will
occur and system failure may result.
E
A
B
C
D
E
F
G
H
I
J
K
L
M
BOTTLE, OIL STORAGE

VALVE, OIL DRAIN
HOSE, BLUE
HOSE, RED
BOTTLE, OIL CATCH
HOSE, YELLOW
BOTTLE, SELECTED OIL
HOSE, LOW SIDE (BLUE)
COUPLER, QUICK DISCONNECT, LOW SIDE
COUPLER, QUICK DISCONNECT, HIGH SIDE
HOSE, HIGH SIDE IRED)
GROMMETS
VALVE, OIL INJECTION
01-3095
FSOOIS'll!!I
Figure 9 Complete Operational Setup
CONTROL PANEL FUNCTIONS
Station (ACR4) Setup and Maintenance
Figures 10 and 11
INITIAL SETUP
Refer to the manufacturer instructions for all

initial setup procedures.
OPERATION SETUP
Figure 9
CAUTION: Always wear goggles and

gloves when doing work that involves
opening the refrigeration system. If liquid
refrigerant comes into contact with the
skin or eyes, injury may result
CAUTION: Use only authorized 23 kg
(50-pound) refillable refrigerant tanks
(J 39500-50). Use of other tanks could
cause personal injury and void the
warranty.
NOTICE:
Refrigerant-134a systems have

special fittings (per SAE specifications) to avoid
cross-contamination with Refrigerant-12
systems. Do. not attempt to adapt this unit to
Refrigerant. . 12 systems as severe system, failure
will result.
Connect high-side (red) and low-side (blue)
hoses to the ACR4 unit. Be sure to route hoses
through hose reel bracket grommets.
This section explains the functions of the various

compon~nts of the unit control panel (Figure 10).
Main Power Switch, - supplies electrical power

to the control panel.
Beeper - emits an audible tone to alert the

operator to unit operating functions.
Digital Display - shows the time programmed

for vacuum and the weight of refrigerant
programmed for recharging.
Low-Side Manifold Gage - when connected to
an A/C system, this gage shows the system
low-side pressure.
High-Side Manifold Gage - when connected to
an A/C system, this gage shows the system
high-side pressure.
Moisture Indicator - shows if the refrigerant is
wet or dry.
low-Side Valve - connects the low side of the
A/C system to the unit.
High-Side Valve - connects the high side of the
A/C system to the unit.
In addition to the number keys, the control panel
contains special keys that accomplish specific
operating functions (Figure 11).
RECYCLE - activates the recycling sequence.

RECOVER - activates the recovery sequence.
1B-14
,-f-1
~ ~~
0CDC!l8
~~~8
A
B
C
D
E
F
G
H
I
RECYCLE
(IJ@) [[) E)
~
'61 Cm)
l:!J '51
~ ~ @[)
I-~~
FILTER
0@8
~-, lnlo
Gm)
~~
DISPLAY, DIGITAL
GAGE, LOW SIDE
BEEPER
GAGE, HIGH SIDE
VALVE, HIGH SIDE
INDICATOR, MOISTURE
VALVE, LOW SIDE
KEYPAD
SWITCH, MAIN POWER
( '"'')
01-30-95
FS0071B
01-3095
FS0081B
Figure 11 - Keypad Functions
Figure 1O - Control Panel
SHIFT/RESET - activates "shifted" position of

keys on the keypad and resets the program mode.
FILTER - automatically recovers and evacuates to
57 kPa (17 inches Hg) vacuum from the filter and
low side of the unit.
CHG - automatically charges the NC system with
the programmed amount of refrigerant.
HOLD/CONT - interrupts the automatic cycle in
the "HOLD" position, and then resumes functions
in the "CONT" position. Press this button once
for "HOLD" and again for "CONT."
VACUUM - activates the vacuum and automatic
recycling sequence.
ENTER - enters programmed data into the unit
control memory.
DIGITAL DISPLAY FUNCTIONS
For information regarding the functions of the

digital display, refer to the manufacturer instructions.
MAINTENANCE
Refer to manufacturer instructions for all

maintenance procedures.
Refrigerant Recovery
Tools Required:
J 39500 Air Conditioning Refrigerant
Recovery, Recycling and Recharging
(ACR4) System
J 39500-50 50 lb. Refillable Recovery Tank
[I]
Important
Use only the 23 kg (50-pound) unit refrigerant

tank (J 39500-50) designed for the ACR4. The
unit overfill limitation mechanism has been
calibrated specifically for use with this tank,
and the tank valves are set up specifically for
use with the unit.
Connect battery charger to vehicle battery to
prevent battery drain:
1. Attach the high-side (red) hose with the quick
disconnect coupler to the high-side refrigerant
service valve fitting of the vehicle NC system.
This valve is located ,in the .. receiver and
dehydrator tube, between the receiver and
dehydrator and the condenser. Open ,the coupler
valve after attachment.
1B-15
6. Slowly open the oil drain valve to see if the oil

separator contains oil (Figure 9).
If any oil drains into the catch bottle at the
bottom of the unit, allow it to drain until there
is no more oil in the separator.
7. Close the oil drain valve.
CJ
mmo
mros
mmo
11>80
CLL
OISPI.AV
11]
0.00
Important
Blower motor setting to "HIGH" will increase

the rate at which refrigerant can be recovered.
11. Press "RECOVER" on the . keypad. Before
recovery begins, the unit will clear itself of
refrigerant "CL-L" will appear on the display.
The cleaning process takes from thirty seconds to
three minutes to complete (Figure 12).
CPL
DISPLAY
7.5*
)
01-30-95
FS00911B
Figure 12 - Refrigerant Recovery
2. Attach the low-side (blue) hose with the quick

disconnect coupler to the low-side refrigerant
charge valve fitting of the vehicle A/C system.
This valve is located in the compressor and
condenser hose, between the compressor and the
thermostatic expansion valve. Open the coupler
valve after attachment.
3. Check the high-side and low-side gages on the
unit control panel to be sure the A/C system has
pressure. If there is no pressure, there is no
refrigerant in the system to recover.
II]
Dispose of the oil in the catch bottle in an

appropriate manner and return the bottle to its
place on the unit.
8. Plug the unit into the proper voltage outlet and
turn on the "MAIN POWER" switch.
9. Start engine and run for one minute with A/C
system "ON" in order to stabilize system.
10. Turn ignition switch "OFF," then back to
"RUN," and blower motor to "HIGH." A battery
charger should be connected to prevent battery
drain.
Important
If there is no refrigerant in the A/C system, do

not continue with the recovery operation. Air
will be drawn into the recovery tank.
4. Open both the high-side and the low-side valves
on the control panel (Figure 10).
5. Open both the red "GAS" (vapor) and the blue
"LIQUID" valves on the tank.
11]
Important
Maintain A/C blower motor on "HIGH"

during recovery operation.
12. When cleaning is complete. The unit will
automatically start recovery, and the control panel
display will show the unit is in the "RECOVER"
mode of the "AUTOMATIC" cycle. Also, the
weight of refrigerant being recovered will be
displayed.
13. The compressor shuts off automatically when
initial recovery has occurred, at approximately
57 kPa (17 inches Hg) vacuum.
14. At the end of the initial recovery process, the
display shows "CPL" and then alternately flashes
the weight of refrigerant recovered and "OIL/OZ"
("OIL/GMS ").
11]
Important
A small amount of A/C system lubricating oil

polyalkylene glycol (PAG) might be removed
with the refrigerant during recovery. The
amount of oil removed (often there will be
none) will vary greatly depending on a variety
of conditions of the vehicle being serviced.
The ACR4 separates the oil from the
refrigerant.
The "OIL/OZ" ("OIL/GMS") flashing is a
reminder to always drain the recovered oil at
this time. The same amount of oil must be
replaced in to the A/C system later when the
system is recharged with refrigerant.
18-16
15. Slowly open the oil drain valve and drain the oil
into the calibrated oil catch bottle at the bottom of
the unit (Figure 9).
16. After the oil is completely drained, close the
valve.
17. Read and record the amount of oil removed in the
catch bottle.
18. Dispose of the recovered oil in an appropriate
manner. Never reuse this oil.
19. Check the control panel "LOW-SIDE GAGE."
120
DISPLAY
HOLD/CONT
If the A/C system has maintained a vacuum,

the recovery is complete.
20. If the "LOW-SIDE GAGE" pressure rises above
"O," this indicates the presence of more
refrigerant in the system. In this case, press the
"HOLD/CONT" key on the keypad to recover the
additional refrigerant. Repeat this step as needed
until the system maintains vacuum for two
minutes.
[I]
OJGJ(]Q
CD
(!)(1)(!)0
0@80
Important
r@o@
If the display flashes "FULL" during the
recovery process, and the unit shuts off, the

unit tank is full.
An empty unit tank (J 39500-50) must be
installed to accommodate additional
refrigerant, before proceeding to the next step
in the recovery operation. Do not use any
other kind of tank.
It is possible to lower the amount of
refrigerant in the unit tank by charging other
vehicles.
Evacuation
Figures 13 and 14
The ACR4 unit tank must contain sufficient
R-134a refrigerant for A/C system charging. Check the
amount of refrigerant in the tank by simultaneously
pressing "RESET" and "ENTER" on the keypad to
enter the diagnostic mode. Once in the diagnostic
mode, press "7". When "7" is pressed, the ACR4
unit will display the amount of R-134a refrigerant
available in the tank. If less than 3.6 kg (8 pounds) is
displayed, add new refrigerant to the tank. Refer to the
manufacturer's instructions for adding refrigerant.
AUTOMATIC
15.0
VACUUM
RECYCLE
MINUTES
01-30-86
FS01018
Figure 13 - System Evacuation (1 of 2)
A LOW SIDE VALVE OPEN

B HIGH SIDE VALVE OPEN
013085
FS0111B
Figure 14 - System Evacuation (2 of 2)
1. With the high side and low side hoses connected

to the vehicle A/C system, open both the
high-side (red) and the low-side (blue) valves on
the unit control panel.
2. Open both the red "GAS" (vapor) and the blue
"LIQUID" valves on the tank.
[I]
Important
To remove all the air and properly dry the A/C

system, the unit automatically goes to a
pre-programmed evacuation time.
It is possible to evacuate longer. Press keys to
enter time desired. New entry will show on the
display. Press "ENTER," the display will
blink indicating input of data (Figure 13).
3. Press "VACUUM" to start the vacuum pump.
The display counts down the vacuum time to zero
to indicate operation time remaining. The display
reads "RECYCLE" five seconds after the vacuum
pump starts and continues while the process takes
place.
[I]
DISPLAY
lmpo,rtant
Automatic refrigerant recycling during each

evacuation is a feature of the ACR 4 system.
No action is required by the technician.

The control panel "MOISTURE
INDICATOR" must be green during recycling
verifying refrigerant moisture content is within
specifications. Yellow indicates a set condition
requiring a filter/drier cartridge change. See
the manufacturer instructions for this
procedure.
Non-condensable gases (mostly air) are
automatically vented from the tank during the
recycling process. An audible sound of
pressure release may be heard as this happens.
This is a normal function.
4. At approximately the 12-minute mark on the
display (pump has run for three minutes), press
"HOLD/CONT" key to stop vacuum pump
(Figure 15).
A. A "O" vacuum reading indicates a major
system leak. Repair leak and restart evacuation
procedure.
B. If a vacuum reading of 91-101 kPa
(27-30 inches of Hg) is indicated, close the
low-side and high-side valves. Observe the
vacuum level for a few minutes as a leak
check of the A/C system. If vacuum is not
maintained, find and repair the A/C system
leak before continuing.
C. If a vacuum reading of 91-101 kPa
(27-30 inches of Hg) is maintained, open the
high-side and low-side valves and press the
"HOLD/CONT" key to restart the vacuum
pump.
5. When the vacuum sequence has run the
programmed time, the display shows. "CPL" to
indicate that evacuation is complete.
[I]
Important
The vacuum pump oil must be changed

frequently.
When the pump has run for a total time of ten
hours, the message "OIL" will flash on the
control panel display as a reminder to change
the oil.
If the "OIL" warning flashes during operation,
press "CONT" and change the oil before the
next operation. See the manufacturer
instructions for this procedure.
A/C System Oil Charge Replenishing

If oil was removed from the A/C system during
the recovery process or due to component replacement,
it must be replenished at this time. Refer to
"Refrigerant Oil Distribution" that follows for proper
oil capacities.
1. Select the graduated bottle of replenishing

polyalkylene glycol (PAG) synthetic refrigerant oil
(GM PIN 12345923 or equivalent).
2. Adjust the 0-ring around the PAG oil bottle to the
required oil charge level. Example: If bottle oil
level is at 4 ounces and 1/2 ounce of oil is
required, adjust 0-rings to 3 1/2 ounces as final
level mark.
1B-17
3. Install the bottle on the oil injection system on the

back of the unit.
rn
Important
Keep the oil bottles tightly capped at all times

to keep out moisture and contamination.
Do not open the oil injection valve while there
is positive pressure in the A/C system. This
will result in oil blow-back through the bottle
vent. A/C system vacuum is required for this
operation.
Never let the oil level drop below the pick-up
tube while charging or replenishing. This will
allow air into the A/C system.
4. Open the valve at the top of the plastic container
and watch the level of oil being drawn into the
system.
5. Close the valve when the required oil charge has
been pulled into the system.
Refrigerant Oil Distribution

Compressor systems require 240 ml (8 fluid
ounces) of polyalkylene glycol (PAG) synthetic
refrigerant oil (GM PIN 12345923 or equivalent).
During component replacement and conditions stated,
new oil quantities should be added to the system as
follows:
Compressor replaced.
-
If less than 30 ml (1 fluid ounce) is drained,

add 60 ml (2 fluid ounces).
- If more than 30 ml (1 fluid ounce) is drained,
add same amount.
Receiver and dehydrator replaced.
-
Add 30 ml ( 1 fluid ounce) more than what

was drained from old receiver and dehydrator.
Evaporator replaced.
- Add 90 ml (3 fluid ounces) oil.
Condenser replaced.
-
Add 30 ml (1 fluid ounce) oil.
Refrigerant Oil Loss Due to a Large Leak

If the refrigerant charge is abruptly lost due to a
large refrigerant leak, approximately 90 ml (3 fluid
ounces) of refrigerant oil will be carried out of the
system suspended in the refrigerant. Any failure that
caused an abrupt refrigerant discharge will experience
this oil loss. Failures that allow the refrigerant to seep
or bleed off over tune do not experience this oil loss.
Upon replacement of a component which caused
a large refrigerant leak, add 90 ml (3 fluid ounces) of
new polyalkylene glycol (PAG) synthetic refrigerant
oil (GM PIN 12345923 or equivalent) plus the
required amount of oil for the particular component
(as outlined above).
Add the oil directly to the replaced component if
possible. If the oil cannot easily be added to the
replaced part, add the oil to the receiver and
dehydrator.
1B-18
The normal blue tint of the PAG oil may not be

seen once the vehicle's A/C system has been run. Be
sure to use the GM-approved PAG oil for this system.
Compressor System
Up to 120 ml (4 fluid ounces) of oil can collect
in the crankcase. Therefore, it is important when
replacing a compressor that the oil in the old
compressor crankcase be drained and measured
(discard the oil after recording the amount).
All replacement compressors will be shipped
with approximately 240 ml (8 fluid ounces) of oil in
the crankcase. The oil must be drained and retained.
Then replace the oil in the same amount as previously
recorded from the old compressor.
Charging the A/C System (Engine Off)

rn
1.
2.
3.
4.
Important
The A/C system must be evacuated prior to

charging.
Check that the "LB/KG" switch on the back
of the unit to be sure it is set for the desired
units of weight system (operate switch with
main power "OFF").
Close the low-side valve on the control panel.
Open the high-side valve on the control panel.
Press "CHG" on the keypad to be sure the unit is
in the program mode.
Enter the amount of refrigerant charge to charge
the A/C system by pressing the appropriate
number keys. Be sure to use correct unit of
weight (pounds or kg).
rn
mmm
ru
l!)(D(!)8
0@(!)0
ENTER
I-
1-;D.D
ll
DIS~Y
1.9
.....
DISPLAY
CPL
DISPLAY
A LOW SIDE VALVE CLOSED

B HIGH SIDE VALVE OPEN
0130H
FS01218
Important
Figure 15 System Charging (1 of 2)
Charge A/C system with amounts of R-134a

specified. Do not overcharge.
Charge A/C system (C60) as follows:
- 3800 VIN K to 0.77 kg (1.7 lbs.).
- 5.7L VIN P to 0.91 kg (2.0 lbs.).
5. Press "ENTER."
A blink of the display indicates the charge
amount is in the unit memory.
6. Press "CHG" on the keyboard to begin the
charging process.
7. The display shows "AUTOMATIC" and the
amount of refrigerant programmed for charging.
The display counts down to zero as the
charging process proceeds.
At the end of the process, the display shows
"CPL.''
rn
CHG
Important
If the transfer of refrigerant stops before

complete, refer to "Unsuccessful Transfer"
that follows.
Successful Transfer Complete

1. Close the high-side valve on the unit control panel
(both valves should now be closed).
2. Start the vehicle and the A/C system and let run
until the readings on the high-side and low-side
gages stabilize. Compare readings, outlet
temperatures and ambient temperature and
humidity to the "Air Conditioning Performance
Chart" in SECTION lBl.
3. With the A/C system running, close the high-side
coupler valve and disconnect the high-side (red)
hose from the vehicle.
4. Open both the high-side and low-side valves on
the control panel.
5. Refrigerant from both hoses will be drawn quickly
into the A/C system through the low-side (blue)
hose.
6. Close the low-side coupler valve and disconnect
from the vehicle.
J---.
HOLD/CONT
11
[J(D(IJ
mmmo
.____~f:-f- ~SHIFT/RESET
AUTOMATIC
1.0
CHARGE
LBS.
3. Add refrigerant to the tank following the

manufacturer instructions, and refer to
"Evacuation" in this section.
REPLACEMENT PROCEDURES
CAUTION: For personal protection,
goggles should be worn and a clean
cloth wrapped around fittings, valves and
connections when doing work that
includes opening the refrigeration
system. If Refrigerant-134a comes in
contact with any part of the body, severe
frostbite and personal injury can result.
The exposed area should be flushed
immediately with cold water and prompt
medical help should be obtained.
NOTICE: Tighten all tubing connections to
the specified torque for the fitting. Too little or
too much torque when tightening can result in
loose joints or deformed joint parts. Either
condition can result in refrigerant leakage and
an inoperative air conditioning system. Refer to
"Fitting Tightening Specifications" at the end
of this section.
DISPLAY
A BEEPER
8 HIGH SIDE VALVE CLOSED
C LOW SIDE VALVE OPEN
18-19
07-10-95
FSl131B
Figure 16 - System Charging (2 of 2)
Unsuccessful Transfer
On rare occasions, the total charge does not
transfer to the vehicle A/C system. There are two
reasons why this can occur.
1. If the transfer is too slow because the pressure in
the unit tank and the vehicle A/C system are
about the same, the unit will emit an audible
signal and the display shows the weight remaining
for transfer. In this case:
A. Close the high-side valve (Figure 16).

B. Open the low-side valve.
C. Start the vehicle A/C system, and press
"HOLD/CONT" on the keyboard. This will
put the remainder of the charge into the A/C
system.
D. Continue with the previous procedure,
"Successful Transfer Complete."
2. If the transfer will not complete and the display
shows "CHECK REFRIGERANT," there is not
enough refrigerant in the tank to complete the
process. This condition requires the recovery of
the partial charge of refrigerant in the vehicle A/C
system and another complete evacuation and
charge procedure.
A. Press "HOLD/CONT" on the keypad to
interrupt the cycle.
B. Press "RESET" to reset the unit.
C. Recover the refrigerant that has been charged
into the system, refer to "Refrigerant
Recovery" in this section.

Condenser Hose
3800 VINK
Figures 1, 2 and 17
E3
1. Recover refrigerant. Refer to "Refrigerant

Recovery and Recycling, Adding Oil, Evacuating
and Recharging Procedures" in this section.
2. Compressor and condenser hose fitting at
accumulator (4).
Use back-up wrench to hold accumulator
fitting while loosening compressor and
condenser hose fitting.
Discard 0-ring (14).
SECTION OA.
4. Bolt/screw (28).
condenser (3).
Use back-up wrench to hold condenser fitting
while loosening compressor and condenser
hose fitting.
Discard 0-ring (17)
6. Lower vehicle.
7. Compressor and condenser hose (7).
Discard seals (18).
i++! .Install or Connect

NOTICE:
1B-20
A SLEEVE, AIR CONDITIONING COMPRESSOR AND

CONDENSER HOSE
B ORIFICE TUBE LOCATION
2 COMPRESSOR, AIR CONDITIONING
4 ACCUMULATOR, AIR CONDITIONING
6 EVAPORATOR, AIR CONDITIONING
7 HOSE, AIR CONDITIONING COMPRESSOR
AND CONDENSER
9 TUBE, EVAPORATOR
13 0-RING, AIR CONDITIONING EVAPORATOR TUBE
14 0-RING, AIR CONDITIONING COMPRESSOR
AND CONDENSER HOSE
16 0-RING, AIR CONDITIONING ACCUMULATOR
HOSE
17 0-RING, AIR CONDITIONING COMPRESSOR

AND CONDENSER HOSE
18 SEAL, AIR CONDITIONING COMPRESSOR AND

CONDENSER HOSE
22 SENSOR, REFRIGERANT PRESSURE SENSOR

27 BOLT/SCREW, AIR CONDITIONING EVAPORATOR
TUBE
28 BOLT/SCREW, AIR CONDITIONING COMPRESSOR

AND CONDENSER HOSE
58 NUT, AIR CONDITIONING ACCUMULATOR

HOSE BRACKET
59 BRACKET, AIR CONDITIONING ACCUMULATOR

HOSE
Figure 17 Refrigerant Lines and Hoses (3800 VIN K)
10-17-14
FS0241B

1. Clean fittings with mineral base 525 viscosity
refrigerant oil.
Lightly coat seals (18) with mineral base 525
viscosity refrigerant oil.
2. Compressor and condenser hose (7) into position.
3. Raise vehicle.
4. 0-ring (17) to compressor and condenser hose (7).
Coat 0-ring (17) with mineral base 525
5. Compressor and condenser hose fitting to
condenser (3).
!~I
Tighten
Compressor and condenser hose fitting to

28 N.m (21 lb. ft.).
6. Seals (18) to compressor and condenser hose (7).
7. Bolt/screw (28).
i~I
Tighten
Bolt/screw (28) to 33 N,m (24 lb. ft.).

8. Lower vehicle.
accumulator (4).
l~I
Tighten

48 N.m (36 lb. ft.).
11. Charge A/C system. Refer to "Refrigerant
12. Leak-test fittings. Refer to "Leak-Testing the
Refrigeration System" in this section.
5.7L VIN P
Figures 3, 4 and 18
(++I
l. Recover refrigerant. Refer to "Refrigerant

2. Strap (34) from compressor and condenser hose
(7).
3. Compressor and. condenser hose fitting at
thermostatic expansion valve (6).
o Discard seal (16).
SECTION OA.
condenser (3).
Use a back-up wrench to hold condenser
fitting while loosening compressor and
1B-21
6. Bolt/screw (30).
7. Compressor. Refer to "Air Conditioning
Compressor" in this section.
8. Compressor and condenser hose (7).
Discard seals (18).
l++I
Install or Connect
NOTICE:

refrigerant oil.
Do not allow refrigerant oil to enter A/C
system.
2. Seals (18) to compressor and condenser hose (7).
Lightly coat seals (18) with mineral base 525
3. Compressor and condenser hose (7) into position.
4. Compressor. Refer to "Air Conditioning
Compressor" in this section.
condenser (3).
!~I
Tighten

27 N.m (20 lb. ft.).
7. Bolt/screw (30).
I~)
Tighten
Bolt/screw (30) t() 10 N,m (89 lb. in.).

8. Lower vehicle.
9. Seal (16) to compressor and condenser hose
fitting.
Lightly coat seal (16) with mineral base 525
l~I
Tighten

37 N,m (27 lb. ft.).
11. Strap (34) to compressor and condenser hose (7).
18-22
18
28
jv1Ewe I
17
oo
IVIEWA
W:A
~
3
~46
jVIEWCj
A VERTICAL REFERENCE LINE

3 CONDENSER, AIR CONDITIONING
4 RECEIVER DEHYDRATOR, AIR
CONDITIONING
15 VALVE, Al R CONDITIONING
THERMOSTATIC EXPANSION
7 HOSE, AIR CONDITIONING COMPRESSOR
AND CONDENSER
8 TUBE.AIR CONDITIONING EVAPORATOR
Sl TUBE, AIR CONDITIONING RECEIVER
DEHYDRATOR
13 0-RING, AIR CONDITIONING RECEIVER DEHYDRATOR
TUBE
14 ORING, Al,R CONDITIONING EVAPORATOR TUBE
16 SEAL, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE
1
17 0-RING, AIR CONDITIONING CONDENSER FITTING

18 SEAL, AIR CONDITIONING HOSE
27 BOLT/SCREW, AIR CONDITIONING RECEIVER
DEHYDRATOR TUBE
28 BOLTISCREW, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE
29 BOLT/SCREW, AIR CONDITIONING THERMOSTATIC
EXPANSION VALVE
30 BOLT/SCREW, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE CLIP BRACKET
32 BRACKET, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE CLIP
34 STRAP, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE
46. VALVE, AIR CONDITIONING REFRIGERANT CHARGE
91-38-95
Fsot41B
Figure 18 - Refrigerant Lines and Hoses (5.7L VIN P)

Air Conditioning Accumulator Hose
3800 VINK
Figures 1, 2 and 17
!+-+!

Tube
5.7L VIN P
Figures 3, 4 and 18

and Recharging Procedures'' in this section.
2. Nut (58) mounting accumulator hose bracket (59)
to shock absorber stud.
3. Accumulator hose fitting at evaporator (6).
Use back-up wrench to hold evaporator fitting
while loosening compressor and condenser
hose fitting.
4. Accumulator hose fitting at accumulator (4).
fitting while loosening accumulator hose
fitting.
Discard 0-rings (16).
5. Accumulator hose (8).
!-++l
1B-23
Install or Connect
!+-+!

CAUTION: Refer to "Caution" under

"Disconnecting the Battery Negative
Cable" in SECTION OA.
2. Battery negative cable.
3. Bolt/screw (27).
4. Receiver and dehydrator tube fitting at receiver
and dehydrator (4).
Use a back-up wrench to hold receiver and
dehydrator port while loosening receiver and
dehydrator tube fitting.
5. Receiver and dehydrator tube (9).
NOTICE: Refer to "Notice" on page lB-1.

refrigerant oil.
2. 0-rings (16) to accumulator hose.
Lightly coat 0-rings (16) with mineral base
525 viscosity refrigerant oil.
3. Accumulator hose (8).
4. Accumulator hose fitting to accumulator ( 4).
!~!
Tighten
Accumulator hose fitting to 48 N ,m

(36 lb. ft.).
5. Accumulator hose fitting to evaporator (6).
!~!
Tighten
Accumulator hose fitting to 38 N ,m

(28 lb. ft.).
6. Nut (58) mounting accumulator hose bracket (59)
to shock absorber stud.
!~!
Tighten
Nut (58) to 8 N.m (71 lb. in.).

7; Charge A/C system. Refer to "Refrigerant
I-++!
Install or Connect

refrigerant oil.
system.
2. 0-rings (13) to receiver and dehydrator tube (9).
Lightly coat 0-rings (13) with mineral base
4. Bolt/screw (27).
Do not tighten at this time.
5. Receiver and dehydrator tube fitting to receiver
and dehydrator ( 4).
l~I
Tighten
Receiver and dehydrator tube fitting to 27 N.m

(20 lb. ft.).
1B-24

3800 VINK
Figures 1, 2 and 17
!+-+!


3. Electrical connector at refrigerant pressure sensor
(22).
4. Evaporator tube fitting at evaporator (6).
Use back-up wrench to hold evaporator fitting
while loosening evaporator tube fitting.
5. Bolt/screw (27).
6. Evaporator tube (9).
l++I
Install or Connect
NOTICE:
1. Clean evaporator tube fittings with mineral base

2. 0-rings (13) to evaporator tube (9).
Lightly coat 0-rings with mineral base 525
3. Evaporator tube fitting to evaporator (6).
4. Bolt/screw (27).
I~!
5.
6.
7.
8.
Tighten
Bolt/screw to 16 N,m (12 lb. ft.).

Evaporator tube fitting to 38 N.m (28 lb. ft).
Electrical connector to refrigerant pressure
sensor (22).
Battery negative cable.
Charge A/C system. Refer to "Refrigerant
Leak-test fittings. Refer to "Leak-Testing the
5.7L VIN P
Figures 3, 4 and 18
!+-+I

2. Electrical connector at refrigerant pressure sensor

(22).
3. Strap (34) from evaporator tube (8).
4. Receiver and dehydrator tube. Refer to "Air
Conditioning Receiver and Dehydrator Tube" in
this section.
5. Bolt/screw (12).
6. Evaporator tube fitting at receiver and
dehydrator (4).
dehydl'.ator port while loosening evaporator
tube fitting.
7. Evaporator tube fitting at thermostatic expansion
valve (6).
8. Evaporator tube (8).
!++!
Install or Connect

1. Clean evaporator tube fittings with mineral base
Do not allow refrigerant oil to enter evaporator
tube (8).
2. 0-rings to evaporator tube (8).
Lightly coat 0-rings with mineral base 525
3. Evaporator tube fitting at thermostatic expansion
valve (6).
4. Evaporator tube fitting at receiver and dehydrator
(4).
!~!
Tighten
Evaporator tube fitting at receiver and

dehydrator (4) to 7 N.m (62 lb. in.).
Evaporator tube fitting at thermostatic
expansion valve (6) to 18 N.m (13 lb. ft.).
5. Bolt/screw (12).
j~!
Tighten
Bolt/screw (12) to 14 N.m (10 lb. ft.).

this section.
7. Strap (34) to evaporator tube (8).
8. Electrical connector at refrigerant pressure
sensor (22).

3800 VINK
Figures 5 and 17
!+ ..! Remove or Disconnect

2. A/C evaporator tube. Refer to "Air Conditioning
Evaporator Tube" in this section.
3. Orifice from A/C evaporator tube.
!++!
Install or Connect
NOTICE:
1. Orifice in A/C evaporator tube (9).
rn
Important
Install long screen inlet end toward condenser.

2. AJC evaporator tube. Refer to "Air Conditioning
Recovery and. Recycling, Adding Oil, Evacuating

5.7L VIN P
Figures 3, 4 and 18
!++!

2. Evaporator tube. Refer to "Air Conditioning
Discard seal (16).
4. Bolts/screws (29).
5. Thermostatkexpansion valve (6).
6. Seals (15) from evaporator (5).
Discard seals (15).
!++-!
lnstali or Connect
NOTICE:
l. Seals (15) to evaporator (5).

Lightly coat seals with mineral base 525
2. Thermostatic expansion valve (6).
1B-25
I~!
Tighten
Bolts/screws (29) to 7 N.m (62 lb. in.).

4. Clean compressor and condenser hose fitting with
mineral base 525 viscosity refrigerant oil.
system.
5. Seal (16) to compressor and condenser hose (7).
Lightly coat seal with mineral base 525
l~!
Tighten

37 N.m (27 lb. ft.).
7. Evaporator tube. Refer to "Air Conditioning
Air Conditioning Accumulator

3800 VINK
Figures 1, 2 and 17
l++I

3. A/C compressor and condenser hose fitting at
accumulator (4).

fitting while loosening A/C compressor and
4. Accumulator hose fitting at accumulator (4).
fitting while loosening .evaporator tube fitting.
5. Bolt/screw (11) at accumulator bracket (10).
6. Accumulator (4) from bracket (10).
Discard 0-rings (14 and 16)
!++I
Install or Connect
NOTICE:
1. If accumulator is being replaced, drain and

measure amount of PAG oil in old accumulator.
Add the drained amount plus 30 ml ( 1 fluid
ounce) more of new PAG oil to new accumulator.
1B-26
2. Accumulator (4) to bracket (10).

refrigerant oil.
4. 0-ring (16) to accumulator hose.
Lightly coat 0-ring (16) with mineral base 525
5. Accumulator hose fitting to accumulator (4).
l~I
Tighten
Accumulator hose fitting to 48 N .m

(36 lb. ft.).
6. Bolt/screw (11) to accumulator bracket (10).
I~!
Tighten
Bolt/screw (11) to 9 N.m (80 lb. in.).

7. 0-ring (14) to NC compressor and condenser
hose fitting.
8. NC compressor and condenser hose fitting to
accumulator (4).
!~!
Tighten
NC compressor and condenser hose fitting to

48 N.m (36 lb. ft.).


5.7L VIN P
Figures 3, 4 and 18
!++!
Remove o,r Disconnect

3. Bolt/screw (27).
4. Receiver and dehydrator tube fitting at receiver
and dehydrator (4).
dehydrator port while loosening receiver and
dehydrator tube fitting.
6. Bolt/screw (11) at receiver and dehydrator bracket
clamp.
7. Evaporator tube fitting at receiver and dehydrator

(4).
dehydrator port while loosening evaporator
tube fitting.
8. Receiver and dehydrator (4) from bracket (10).
!++!
Install or Connect

1. If receiver and dehydrator is being replaced, drain
and measure amount of PAG oil in old receiver
and dehydrator. Add the drained amount plus 30
ml (1 fluid ounce) more of new PAG oil to new
receiver and dehydrator.
2. Receiver and dehydrator (4) to bracket (10).
refrigerant oil.
Do not allow refrigerant oil to enter NC
system.
4. 0-ring (14) to evaporator tube (8).
5. Evaporator tube fitting to receiver and dehydrator
(4).
!~!
Tighten
Evaporator tube fitting to 7 N.m (62 lb. in.).

6. Bolt/screw (11) at receiver and dehydrator bracket
clamp.
!~!
Tighten

7. 0-rings (13) to receiver and dehydrator tube (9).
9. Bolt/screw (27).
10. Receiver and dehydrator tube fitting to receiver
and dehydrator (4).
!~I
Tighten
Receiver and dehydrator tube fitting to 27 N.m

(20 lb. ft.).
10. Condenser (3) from radiator (47).

Disconnect retaining tangs from grooves.

Figures 1 through 4, and 19
!+-+!
!-++!

2. Air intake duct. Refer to SECTION 6E3.
3. Air cleaner. Refer to SECTION 6E3.
4. Upper radiator shroud. Refer to SECTION 6B.
SECTION OA.
6. Hose (7) at condenser (3).
7. Lower vehicle.
this section.
9. Radiator air upper baffle from condenser, if
necessary. Refer to SECTION 6B.
Install or Connect
NOTICE:
[I]
2.
3.
5.
6.
7.
3
~~/A
B C
Tighten
Hose fitting to 27 N.m (20 lb. ft.).

Lower vehicle.
Upper radiator shroud. Refer to SECTION 6B.
Air cleaner. Refer to SECTION 6E3.
Air intake duct. Refer to SECTION 6E3.
Charge A/C system. Refer to "Refrigerant
8.
9.
10.
11.
12.
47
VIEW
Important
If a retaining groove breaks, install the

condenser finger to locate and drill a small
hole into the existing boss. Use appropriate
screw to fasten finger to the tab. Do not
puncture radiator coolant tank when doing this
procedure.
Radiator air upper baffle to condenser, if removed.
Refer to SECTION 6B.
Receiver and dehydrator tube. Refer to "Air
this section.
Raise and suitably support vehicle. Refer to
SECTION OA.
Clean hose fitting and condenser fitting with
mineral base 525 viscosity refrigerant oil.
system.
0-ring. (17) to hose (7).
Lightly coat 0-ring with mineral base 525
Hose (7) to condenser (3).
!~!
~~
I BI
1. Condenser (3) to radiator (47).

Retaining tangs must be fully seated in
grooves (Figure 19).
4.
1B-27
47

3800 VINK
A
B
C
3
47
TANG, CONDENSER RETAINING

GROOVE
CONDENSER TIBE
RADIATOR
Figures 1, 2, and 20
[I]
0130N
FB0111B
Figure 19 - Condenser
Important
Compressor related noise is generally A/C

system related and not always the compressor
itself. Prior to replacing compressor, refer to
"A/C System Noise Diagnosis" in
SECTION 1B 1.
1B-28
61
38

38 SOLT/SCREW, AIR CONDITIONING COMPRESSOR
44
55
57
60
61
62
SOLT/SCREW, AIR CONDITIONING COMPRESSOR

REAR BRACKET
SOLT/SCREW, AIR CONDITIONING COMPRESSOR BRACKET
SOLT/SCREW, AIR CONDITIONING COMPRESSOR BRACKET
BRACKET, AIR CONDITIONING COMPRESSOR
BRACKET, AIR CONDITIONING COMPRESSOR REAR
SOLT/SCREW, AIR CONDITIONING COMPRESSOR REAR
BRACKET
INDICATES TIGHTENING SEQUENCE
..571]
04-19-85
FT0261B
Figure 20 - Air Conditioning Compressor Mounting and Brackets (3800 VIN K)
!+-+!

2. Serpentine drive belt.. Refer to SECTION 6A8A.
3. Electrical connector at compressor (2).
SECTION OA.
5. Bolt/screw (28).
6. Hose (7) from compressor (2).
Discard seals (18).

7. Battery positive cable nut from stud (44).
8. Stud (44).
9.Compressor (2).
11. Bolts/screws (62) and rear bracket (61), if
necessary.
!-++!
Install or Connect

1. Polyalkaline glycol (PAG) refrigerant oil.
If compressor is being replaced, drain

refrigerant oil from both defective compressor
and new compressor. Oil must be drained
through the crankcase drain plug and
suction/discharge ports. Measure amount
removed from defective compressor. If
measured amount is less than 30 ml (1 fluid
ounce), add 60 ml (2 fluid ounces) to new
replacement compressor. If more than 30 ml (1
fluid ounce) is drained from defective
compressor, add same amount to new
compressor. Use PAG refrigerant oil only.
2. Rear bracket (61) and bolts/screws (62), if
removed.
!~!
Tighten
Bolts/screws (62) to 25 N,m (19 lb. ft.).

3. Compressor (2).
!~!
Tighten
12. Serpentine drive belt. Refer to SECTION 6A8A.

14. Leak-test NC system. Refer to "Leak-Testing the
5.7L VIN P

5. Stud (44).
!~!
Tighten
[I]
!~I .Tighten
Nut to 25 N.m (18 lb. ft.).
7. Seals (18) to NC compressor and condenser hose
(7).
8. Hose (7) to compressor (2).
9. Bolt/screw (28).
Tighten

10. Lower vehicle.
11. Electrical connector to compressor (2).
Important
Compressor related noise is generally A/C

system related and not always the compressor
itself. Prior to replacing compressor, refer to
"A/C System Noise Diagnosis" in
SECTION 1B 1.
Stud (44) to 50 N.m (37 lb. ft.).

6. Battery positive cable and nut to stud (44).
l~l
18-29
l++l

SECTION OA.
3. Serpentine drive belt and tensioner. Refer to
SECTION 6A3A.
4. Bolt/screw (30).
5. Bolt/screw (28).
6. Hose (7) from compressor (2).
Discard seals (18).
32

32 BRACKET, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE CLIP
38 BOLT/SCREW; AIR CONDITIONING COMPRESSOR
39 BOLT/SCREW, AIR CONDITIONING COMPRESSOR REAR
BRACKET
40 BRACKET, AIR CONDITIONING COMPRESSOR REAR
41 BOLT/SCREW, AIR CONDITIONING COMPRESSOR REAR
BRACKET
41
IVIEWA!
Figure 21 - Air Conditioning Compressor Mounting and Bracket (5.7L VIN P)
01-30N
F801118
1B-30
7. Transmission oil cooler pipes at engine, if

necessary. Refer to SECTION 7A.
8. Bolt/screw (41).
10. Electrical connector and compressor (2).
11. Bolts/screws {39) and bracket (40), if necessary.
!Hi
15. Leak-test A/C system. Refer to "Leak-Testing the

Air Conditioning Refrigerant Service Valve

Core
Figures 1 through 4
Install or Connect
NOTICE:
1. Polyalkaline glycol (PAG) refrigerant oil.

If compressor (2) is being replaced, drain
refrigerant oil from both defective compressor
and new replacement compressor. Measure
amount removed from defective compressor. If
measured amount is less than 30 ml (1 fluid
ounce), add 60 ml (2 fluid ounces) to new
replacement compressor. If more that . 30 ml
(1 fluid ounce) is drained from defective
compressor add same amount to new
compressor. Use PAG refrigerant oil GM
PIN 12345923 or equivalent.
2. Bracket (40) and bolts/screws (39), if removed.
!~I
Tighten
Bolts/screws (39) to 25 N.m (18 lb. ft.).

3. Compressor (2).
!~!
Tighten

5. Bolt/screw (41).
l~I
Tighten

7. Transmission oil cooler pipes at engine, if
necessary. Refer to SECTION 7A.
8. Seals (18) to hose (7).
9. Hose (7) to compressor (2).
10. Bolt/screw (28).
~ Tighten
!~I
Tool Requifed:
J 39923 Valve Core Remover and Installer
J 34611-A Valve Core Remover and Installer
Tighten

12. Serpentine drive belt and tensioner. Refer to
SECTION 6A3A.
13. Lower vehicle.
!++!
1. Valve cap (26).

3. Valve core (23) using J 39923 or J 346U-A.
!++j
Install or Connect
1. Valve core (23) using J 39923 or J 34611-A.

and Recharging Procedures'' in. this section.
3. Leak-test A/C system. Refer to "Leak-Testing the
4. Valve cap (26).
Air Conditioning Compressor Front

Bracket
3800 VINK
Figure 20
SECTION OA.
4. Battery positive cable nut from stud (44).
5. Stud (44).
. 7. Compressor (2) forward to allow access to
bracket.
8. Bolts/screws (55 and 57).
9. Bracket (60).
!++!
Install or Connect

1. Bracket (60).
!~I
-
Tighten
In sequence (Figure 20).

1B-31
3. Position compressor (2).

!~I
Tighten

5. Stud (44).
!~I. Tighten
Stud (44) to 50 N.m (37 lb. ft.).
6. Battery positive cable and nut to stud (44).
!~!
Tighten

7. Lower vehicle.
8. Electrical connector to compressor (2).
Generator and Air Conditioning

Compressor and Power Steering Pump
Bracket
5.7L VIN P
Figure 22
l+-+I
1. Generator. Refer to SECTION 6D3.

2. Power steering pump. Refer to SECTION 3B.
3. Air conditioning compressor. Refer to "Air
Conditioning Compressor" in this section.
4. Bolts/screws (49, 50, 51 and 52).
5. Spark plug wire support (53).
6. Bracket (48).
I++!
Install or Connect
1. Bracket (48).
2. Spark plug wire support (53).
3. Bolts/screws (49, 50, 51 and 52) loosely.
I~!
Tighten
In sequence:
- Bolt/screw (49) to 33 N.m (24 lb. ft.).
4. Air conditioning compressor. Refer to "Air
Conditioning Compressor" in this section.
7. Bleed power steering system. Refer to
SECTION 3B.
so
48 BRACKET, GENERATOR AND AIR
CONDITIONING COMPRESSOR AND POWER STEERING
PUMP
49 BOLT/SCREW, GENERATOR BRACKET
53 SUPPORT, SPARK PLUG WIRE
54 ENGINE (S.7L LT1)
01-3011
F80t818
Figure 22 Generator and Air Conditioning Compressor

and Power Steering Pump Bracket (5.7L VIN P)
9. Leak-test A/C fitting at rear of compressor. Refer

to "Leak-Testing the Refrigeration System" in
this section.
Compressor On-Vehicle Minor Component

Replacement
Due to the limited clearance on the 5.7L VIN P
engine, it is recommended that the compressor be
serviced after the compressor is removed from the
vehicle. Vehicles with 3800 VIN K engines have
clearance to service compressor minor components
on-vehicle. For component replacement procedures,
refer to SECTION 1D2 or 1D3.
18-32
SPECIFICATIONS
GENERAL SPECIFICATIONS
AIC System 0-Ring and Fitting Lubricant.. ...... 525 Viscosity Mineral Oil, GM PIN 12301108 or equivalent
A/C System Internal Lubricant (Including

Compressor) ......... Polyalkylene Glycol (PAG) Synthetic Refrigerant Oil GM PIN 12345923 or equivalent
AIC System R-134a Charge Capacity
3800 VIN K ............................................................................................................................. 0'.77 kg (1.7 lb.)
5.7L VIN P .............................................................................................................................. 0.91 kg (2.0 lb.)

Air Conditioning Accumulator Hose Bracket Nut (To Shock Absorber Stud,
3800 VIN K) ............................................................................................................................ 8 N.m (71 lb. in.)
Air Conditioning Compressor Bolts/Screws (Rear Bracket to Compressor,
3800 VIN K) ........................................................................................................................... 25 N.m (19 lb. ft.)
Air Conditioning Compressor Bolts/Screws (To Front Bracket, 5.7L VIN P) ................. 50 N.m (37 lb. ft.)
Air Conditioning Compressor and Condenser Hose Bolt/Screw (To Compressor,
All Engines) ......................................................................................................................... 33 N.m (24 lb. ft.)
Air Conditioning Compressor and Condenser Hose Clip Bracket Bolt/Screw
(5.7L VIN P) ..................................................................................................... ;.................. 10 N.m {89 lb. in.)
Air Conditioning Compressor Front Bracket Bolts/Screws (3800 VIN K) ......................... Refer To Procedure
Air Conditioning Compressor Low Pressure Cutoff Switch .................................................. 6 N.m (53 lb. in.)
Air Conditioning Compressor Rear Bracket Bolts/Screws
(To Compressor, All Engines) ............................................................................................. 25 N.m (18 lb. ft.)
Air Conditioning Compressor Rear Bracket Bolt/Screw (To 5.7L VIN P) .......................... 33 N.m (24 lb. ft.)
Air Conditioning Compressor Rear Bracket Stud (To 3800 VIN K) ................................... 50 N,m (37 lb. ft.)
Air Conditioning Evaporator Tube Bolt/Screw (To Condenser, 3800 VIN K) .................... 16 N.m (12 lb. ft.)
Air Conditioning Receiver and Dehydrator/Accumulator Bracket Bolt/Screw ..................... 14 N.m (10 lb. ft.)
Air Conditioning Receiver and Dehydrator/Accumulator Bracket Clamp Bolt/Screw .......... 9 N,m (80 lb. in.)
Air Conditioning Receiver and Dehydrator Tube Bolt/Screw ................................................. 16 N.m (12 lb.ft.)
Air Conditioning Refrigerant Pressure Sensor ........................................................................ 6 N.m (53 lb. in.)
Thermostatic Expansion Valve Bolt/Screw (5.7L VIN P) ...................................................... 7 N.m (62 lb. in.)
Generator Bracket Bolt/Screw (5.7L VIN P) ......................................................................... 33 N.m (24 lb. ft.)
Generator Bracket Stud (5.7L VIN P) .................................................................................... 33 N,m (24 lb. ft.)
FITTING TIGHTENING SPECIFICATIONS

Air Conditioning Accumulator Hose Fitting (At Accumulator) ............................................ 48 N.m (36 lb. ft.)
Air Conditioning Accumulator Hose Fitting (At Evaporator) ............................................... 38 N,m (28 lb. ft.)
Air Conditioning Compressor and Condenser Hose Fitting (At Condenser) ....................... 27 N.m (20 lb. ft.)
Air Conditioning Compressor and Condenser Hose Fitting (At Accumulator) .................... 48 N.m (36 lb. ft.)
Air Conditioning Compressor and Condenser Hose Fitting
(At Thermostatic Expansion Valve) .................................................................................... 37 N.m (27 lb. ft.)
Air Conditioning Evaporator Tube Fitting (At Evaporator) .................................................. 38 N.m (28 lb. ft.)
Air Conditioning Evaporator Tube Fitting (At Receiver and Dehydrator) ............................ 7 N.m (62 lb~ in.)
Air Conditioning Evaporator Tube Fitting (At Thermostatic Expansion Valve) .................. 18 N.m (13 lb. ft.)
Air Conditioning Receiver and Dehydrator Tube Fitting (At Receiver and Dehydrator) ... 27 N,m (20 lb. ft.)
1 B-33
SPECIAL TOOLS
J 39400
J 34611-A
OR
J39923
J 39500
J 36645
J 6742-03
J 39183-C
7
J 39500-50
1
2
3
4
HALOGEN LEAK DETECTOR

VALVE CORE REMOVER AND INSTALLER
PRECISION THERMOMETER
AIR CONDITIONING REFRIGERANT RECOVERY,
RECYCLING ANO RECHARGING (ACR4) SYSTEM
5 AIR CONDITIONING EVAPORATOR CLEANING GUN
6 R-1340 MANIFOLD GAUGE SET
7 50 LB REFILLABLE RECOVERY TANK
1B-34
J 41447
10
J 41436
J 28428-E
8 R134A TRACER DYE (24-1/4 OZ. BOTILES)

9 TRACER DYE INJECTOR
10 HIGH INTENSITY BLACK LIGHT
04-o3-95
FT0211B
MANUAL CONTROL AIR CONDITIONING
181-1
SECTION 181
MANUAL CONTROL AIR COND I NIN

CAUTIONS
Section 9J under "On-Vehicle Service" and the SIR Component and Wiring
in
systems.
CONTENTS
General Description ............................................. 1B 1-1
Overview .......................................................... 1B 1-1
HVAC Control ................................................. lBl-3
Temperature Control.. .................................. lBl-3
Mode Control .............................................. lBl-4
Blower Motor Speed Con.trol.. ................... lB 1-4
Air Distribution System .................................. lB 1-5
Vacuum System ........................................... lBl-5
Other Components ....................................... lBl-5
Air Inlet Valve ............................................ lBl-5
Blower Motor and Evaporator .................... lB 1-5
Temperature Valve and Heater Core .......... lB 1-5
Bi-Level Valve............................................. lBl-8
Heater and Defrost Valve ........................... lB 1-8
Ducts and Outlets ........................................ lBl-9
Ventilation .................................................... 1B 1-9
Refrigeration System ....................................... lB 1-9
Refrigerant R-134a ...................................... 1Bl-11
Air Conditioning Compressor ..................... lB 1-11
Air Conditioning Condenser ....................... 1B 1-11
Tube Orifice ................................................. 1B 1-11
Thermostatic Expansion Valve .................... lB 1-11
Air Conditioning Evaporator....................... I B 1-12
Air Conditioning Accumulator/Receiver
and Dehydrator ............................................ 1B 1-12
Diagnosis ............................................................. lBl-12
Functional Test ................................................ 1B 1-12
Insufficient Cooling Check ............................. 1B 1-13

Insufficient Heat Check ............ Refer to Section lA
Improper Air Delivery .................................... lBl-13
NC System Noise Diagnosis ......................... lBl-17
NC System Diagnostic Charts ....................... 1B 1-17
NC Performance Test .................................... 1B 1-17
VDOT A/C System Diagnostic Charts .......... 1B 1~ 19
On-Vehicle Service .............................................. lBl-27
Refrigeration System Services ... Refer to Section 1B
Control and Components .......... Refer to Section lA
Temperature Control Cable ....... Refer to Section lA
Blower Motor Resistor ............. Refer to Section 1A
Blower Motor Relay ....................................... 1B 1-27
Air Conditioning Compressor Relay .............. 1B 1-27
Temperature Sensor ..................................... lBl-27
Air Conditioning Refrigerant
Pressure Sensor ........................................... lBl-27
Vacuum Hose Harness .............. Refer to Section lA
Vacuum Actuators ..................... Refer to Section lA
Heater Core ............................... Refer to Section lA
Air Conditioning Evaporator .......................... 1B 1-28
Specifications ....................................................... lBl-31
General Specifications ..................................... lBl-31
Component Tightening Specifications ............ lB 1-31
Special Tools ....................................................... 1B 1-31
GENERAL DESCRIPTION
During most operating conditions, outside air is

drawn through the heater and air conditioning module
by the blower motor. Additional outside air is also
forced into the vehicle by forward movement of the
vehicle.
Within the heater and air conditioning evaporator
module, air is pushed by the blower motor through the
evaporator, then through the heater core, depending on
the temperature valve setting, and into the passenger
OVERVIEW
Figures 1 through 3
The air conditioning system (C60) delivers air
that has been heated or cooled and dehumidified for
occupant comfort. It also provides power ventilation,
and windshield defrosting and side window defogging.
1812 MANUAL CONTROL AIR CONDITIONING
(
J
c
A BLOWER MOTOR SPEED CONTROL
8 TEMPERATURE CONTROL
C
D
E
F
"OFF" MODE
"MAX A/C" MODE
"NORMAL A/C" MODE
"Bl-LEVEL A/C" MODE
G
H
I
J
"VENT" MODE
"HEATER" MODE
"DEFROST BLEND" MODE
"DEFROST" MODE
CONTROL, HEATER AND AIR
CONDITIONING
01-lHl-95
FS0011B1
Figure 1 - Heater and Air Conditioning Control - (Chevrolet)
2
F
A LOWER BLOWER MOTOR SPEED

B MEDIUM 1 BLOWER MOTOR SPEED
C MEDIUM 2 BLOWER MOTOR SPEED
D HIGH BLOWER MOTOR SPEED
E TEMPERATURECONTROL
F "OFF" MOOE
G "MAX A/C" MODE
H "NORMAL A/C" MOOE
I
J
I<
L
M
"Bl-LEVEL A/C" MODE

vENP MOOE
HEATER" MODE
"DEFROST MOOE
1 CONTROL, HEATER.AND AIR CONDITIONING
2 SWITCH, REAR WINDOW DEFOGGER
01-28-95
FSO<mBt
Figure 2 - Heater and Air Conditioning Control - (Pontiac)
181-3
R
7
rr
c
A TO WINDSHIELD DEFROST OUTLET

13 TO SIDE WINDOW DEFROST OUTLETS
C TO FLOOR OUTLETS
D TO INSTRUMENT PANEL OUTLETS
E FROM PLENUM AREA !OUTSIDE AIRJ
F FROM INSIDE VEHICLE (RECIRCULATED AIR)
G SMALLPASSAGE

4
5
6
7
8
9
10
11
CORE. HEATER
MOTOR, BLOWER
VALVE, TEMPERATURE
VALVE, HEATER AND DEFROST
VALVE, Bl-LEVEL
VALVE, UPPER MODE
VALVE, AIR INLET
MODULE, HEATER AND AIR CONDITIONING
EVAPORATOR
01-26-95
FS0031B1
Figure 3 - Air Distribution System
compartment. For air conditioning or defroster

operation at ambient temperatures above 7C (45F),
the refrigeration system will chill the evaporator to
almost freezing. As the air passes through the
evaporator, the air temperature drops which causes
moisture in the air to condense on the evaporator core
fins. This moisture leaves the vehicle by gravity feed
through a drain hole, dehumidifying the. vehicle.
From the evaporator, some or all of the air may
pass through the heater core, which is warmed by
engine coolant. Any of the air which is not to be
heated will mix with the heated air before entering the
passenger compartment.
When maximum air conditioning mode is
selected, most of the air entering the blower motor is
taken from the passenger compartment (re-circulated)
where it is most likely to be cooler than the outside
air. Only outside air is used in all other modes.
HVAC CONTROL
Temperature Control
Figures 1 and 2
The temperature control is mechanically linked
to the air temperature valve (door) by a temperature
control cable. Rotating the temperature control
clockwise allows more of the incoming or
re-circulated air to flow through the heater core, thus
increasing the air temperature entering the vehicle.
Rotating the temperature control counterclockwise
decreases air flow through the heater core, thus
decreasing the air temperature entering the vehicle.
1814 MANUAL CONTROL AIR CONDITIONING

Mode Control
"HEATER" MODE
Figures 1 and 2
The "HEATER" setting functions the same as

the "VENT" setting, except most of the air is
discharged through the floor outlets with a small
amount discharged through the defroster outlets. The
"HEATER" mode is the normal selection for cold
weather operation unless windshield defrosting or side
window defogging is required.
The mode control has eight settings: "OFF,"

"MAX," "A/C," "BI-LEVEL A/C," "VENT,"
"HEATER," "DEFROST BLEND," and
"DEFROST." Some settings are symbols on the heater
and air conditioning control (1). These symbols are
identified in Figures 1 and 2. Each setting is described
below.
"OFF" MODE
At this setting, electrical power is not supplied

to the blower motor and A/C is not requested to the
powertrain control module (PCM). A small amount of
air which is forced into the heater and air conditioning
module by forward movement of the vehicle will still
be discharged through the heater and defrost outlets.
This is the only mode in which the blower motor does
not operate.
The "DEFROST BLEND" setting allows

operation of the blower motor and sends an A/C
request signal to the PCM for compressor operation.
During this setting, air is discharged through the
defroster and floor air outlets. This setting allows
greater passenger comfort than "DEFROST" but is
not as effective in defrosting the windshield and side
windows.
''DEFROST" MODE
"MAX" A/C MODE
The "MAX" A/C setting is one of five settings

which requests A/C operation to the PCM. At this
setting the blower motor will operate in one of the
four blower motor speed control settings and air will
be discharged from the instrument panel air outlets
only.
To provide maximum. air conditioning, most of
the air entering the heater and air conditioning module
is taken from the vehicle interior (re-circulated) where
it is most likely cooler than the outside air. This is the
only mode in which air is re-circulated, all other
modes use outside air only. This setting would be most
useful during conditions of high temperature and
humidity, or when the outside air may have an
objectionable odor.
NORMAL "A/C" MODE
The normal "A/C" setting functions the same as

"MAX" A/C setting, except only outside air enters the
module. There may be a slight reduction of blower
noise compared to "MAX" A/C mode because the
re-circulation valve (door) is closed.
"Bl-LEVEL A/C" MODE
The "BI-LEVEL A/C" setting requests A/C to

the PCM and allows the blower motor to operate in
one of four settings. Only outside air enters the
module and air is distributed through the instrument
panel outlets and the floor outlets with a small amount
to the defrost outlet.
"VENT" MODE
The "VENT" setting does not request A/C to

the PCM but allows the blower motor to operate
normally. This is one of two economy modes (other
than "OFF") in which A/C is not requested. Air is
discharged through the instrument panel outlets only.
The "DEFROST" setting functions the same as

"DEFROST BLEND" setting except most of the air is
discharged through the defroster outlets with a small
amount going through the heater and side window
defoggers.
Blower Motor Speed Control

Figures 1 and 2
With the ignition switch in the "RUN" position,
the blower motor runs in all mode control positions
except "OFF." Blower motor speed is controlled by a
four-position electrical blower motor speed control
switch at the left side of the control. The blower
motor speed control switch provides a choice of a low
blower motor speed, two medium speeds, and a high
speed.
Electrical power is routed from the HVAC fuse
number 3 in the fuse block to the mode control
switch. The mode control switch breaks the. circuit
when it is in the "OFF" position, and closes the
circuit in all other positions.
From the mode control switch, the circuit then
goes to the blower motor speed control switch. When
the blower motor speed control switch is in "LOW,"
voltage is conducted to the resistor. At the resistor, the
voltage passes through all three resistors and is
reduced to provide the low blower motor speed.
When the blower switch is in either of the two
medium speed positions, it closes to send voltage
through either two or one of the resistors in the
resistor. Because the current follows the path of least
resistance, the circuit branch leading directly to all
three resistors becomes ineffective and the current
bypasses either one or two resistors, depending upon
which medium speed position is selected. The reduced
resistance increases current flow and blower motor
speed.

When the blower motor speed control switch is
in the "HIGH" position, it energizes the high blower
relay and power is taken from a separate circuit that is
protected by a fusible link. This separate power circuit
is "hot" at all times and has the capacity to handle the
current demands of the blower motor at high speed.
The circuit to the blower motor is completed to
ground at the instrument panel through the instrument
panel wiring harness. Refer to SECTION 8A for more
electrical information.
AIR DISTRIBUTION SYSTEM

Figures 3 through 6
Air enters the heater and air conditioning
evaporator module where it . may be cooled for air
conditioning or defrost modes, and then heated as
necessary before being sent to the proper outlets for
discharge into the passenger compartment. Within the
heater and air conditioning evaporator module, valves
(doors) guide the airflow in response to the position of
the mode control.
Vacuum System
All valves in the heater and air conditioning
evaporator module except the temperature valve are
controlled by engine vacuum drawn from the vacuum
tank, mounted to the right side body rail, just behind
the radiator support. The vacuum is routed by a
vacuum selector valve in the control to spring-loaded
vacuum actuators on the heater and air conditioning
evaporator module. Vacuum stored in the vacuum tank
is prevented from bleeding back to its source during
conditions of low engine manifold vacuum
(acceleration, hard pulling, etc.) by a check valve in
the vacuum source hose.
The vacuum selector valve in the control is
controlled by the mode control. For each mode control
position, the vacuum selector valve directs vacuum to
specific hoses to overcome the force of the spring
within the appropriate vacuum actuators. The vacuum
selector valve also vents the hoses to each remaining
vacuum actuator to normal air pressure, allowing the
actuator spring to expand. This results in the valves
(doors) being properly positioned for the selected
operating mode.
The heater and defrost valve uses a
three-position vacuum actuator. A three-position
vacuum actuator has a diaphragm with a spring on
both sides. At rest (no vacuum applied) the diaphragm
will be in a mid-position, allowing for a "blend"
mode. When vacuum is applied to either end of the
diaphragm, the diaphragm will move the heater and
defrost valve to either stop, which will direct airflow
to either the defroster outlets or the floor outlets.
When air is directed to the floor outlets, as in
"HEATER" mode, a small amount of air still bleeds
through the defroster outlets to help eliminate
re-fogging of the windshield.
181-5
Other Components
Other components of the air distribution system
include the plenum, the blower motor, the evaporator
and the heater core. The plenum provides a source of
outside air to the system. The blower motor draws air
from the plenum or from the vehicle interior into the
heater and air conditioning evaporator module and
forces it through the air distribution system to the
outlets. The evaporator is a part of the refrigeration.
system. It cools the air from the blower motor when
operating in an air conditioning or defrosting mode.
The heater core provides heat which can be used to
warm the air downstream from the evaporator.
Air Inlet Valve

The first valve in the air distribution system is
the air inlet valve. This two-position valve controls the
two air entrances which feed air to the blower motor.
When "MAX" A/C mode is selected, vacuum is
applied to the air inlet vacuum actuator and the air
inlet valve opens the entrance which supplies inside
air from the passenger compartment. In this position,
the air inlet valve partially closes the entrance for
outside air so only a slight amount can enter.
Re-circulating the cooled air inside the passenger
compartment when outside temperature is very high
gives a faster cool down to a more comfortable
temperature.
When any other operating mode (including
"OFF") is selected, the air inlet vacuum actuator is
vented to normal air pressure and the air inlet valve
completely closes off the entrance for inside air. Only
fresh outside air is used in the system in these modes.
Blower Motor and Evaporator

In any operating mode except "OFF," the
blower motor draws in air from the plenum and
pushes it through the evaporator. When any air
conditioning or defrost mode is selected, the air
conditioning refrigeration system chills the core of the
evaporator to slightly above freezing temperature. This
cools the airflow and causes excess humidity to
condense on the fins of the evaporator. The condensed
moisture drips to the bottom of the case and drains out
through a hole that lets the water fall on the road
surface below the vehicle. From the evaporator, the air
flows toward the temperature valve and heater core.
Temperature Valve and Heater Core

The temperature control in the control is linked
to the temperature valve by a flexible control cable.
When the temperature control is rotated fully
counterclockwise to the full "COLD" position, the
temperature valve is held snugly against the air
entrance to the heater core. This causes all of the
airflow from the evaporator to bypass the heater core
and there is no heat transfer.
As the temperature control is moved clockwise
away from the full "COLD" position, the temperature
valve begins to direct some air to the heater core to
allow some air to flow through it. The farther the
temperature control is rotated clockwise, the more the
temperature valve directs air through the heater core.
181-6 MANUAL CONTROL AIR CONDITIONING

60
11
12
13
18
19
21
23
50
52
53
54
55
56
57
58
60
61
62
66
MODULE, HEATER AND AIR CONDITIONING EVAPORATOR

DUCT, INSTRUMENT PANEL CENTER AIR OUTLET
SCREW, INSTRUMENT PANEL CENTER AIR OUTLET DUCT
DISTRIBUTOR, WINDSHIELD DEFROSTER NOZZLE AND AIR
DUCT, SIDE WINDOW DEFOGGER OUTLET (LEFT SIDE)
DUCT, INSTRUMENT PANEL OUTER AIR OUTLET (RIGHT SIDE)
GRILLE. SIDE WINDOW DEFOGGER OUTLET
OUTLET, INSTRUMENT PANEL CENTER AIR
SCREW, AIR DISTRIBUTOR DUCT
SCREW, FLOOR AIR OUTLET DUCT
DUCT, FLOOR AIR OUTLET
SCREW, INSTRUMENT PANEL OUTER AIR OUTLET DUCT
OUTLET, INSTRUMENT UPPER OUTER AIR (RIGHT SIDE)
OUTLET, INSTRUMENT PANEL OUTER AIR (LEFT SIDE)
CARRIER, INSTRUMENT PANEL
DUCT, INSTRUMENT PANEL OUTER AIR OUTLET (LEFT SIDE)
OUTLET, INSTRUMENT PANEL CENTER AIR
PANEL, INSTRUMENT
Figure 4 Air Ducts and Outlets (Chevrolet)
01289S
FS0041B1
181-7
11 MODULE, HEATER ANO AIR CONDITIONING

EVAPORATOR
18 DISTRIBUTOR, WINDSHIELD DEFROSTER NOZZLE
AND AIR
21 DUCT, SIDE WINDOW DEFOGGER OUTLET (LEFT SIDE)
23 DUCT, INSTRUMENT PANEL OUTER AIR OUTLET
50 GRILLE. SIDE WINDOW DEFOGGER OUTLET
51 OUTLET, INSTRUMENT PANEL OUTER AIR
52 OUTLET, INSTRUMENT PANEL CENTER AIR
53 SCREW, AIR DISTRIBUTOR DUCT
54 SCREW, FLOOR AIR OUTLET DUCT
55 DUCT, FLOOR AIR OUTLET
56 SCREW, INSTRUMENT PANEL OUTER AIR OUTLET
DUCT
60 CARRIER, INSTRUMENT PANEL
012191
F80051B1
Figure 5 Air Ducts and Outlets (Pontiac)
181-8
36
37
34
B MULTl-CONNECTOR
C TO VACUUM SOURCE
32 ACTUATOR, HEATER AND DEFROST
VACUUM
33 ACTUATOR, Bl-LEVEL VACUUM
34 ACTUATOR, UPPER AND LOWER MODE
VACUUM
35 ACTUATOR, AIR INLET VACUUM
36 VALVE, CONTROL VACUUM SELECTOR
37 TANK, VACUUM
38 VALVE. VACUUM CHECK
32
33
35
38
O P G Y
B
RURERL
A R E L E A
NPELDc
G L N O
K
E E
W
01-2fl-95
FS0081B1
Figure 6 - Vacuum Circuit Diagram
Heating a greater proportion of the total airflow in this

manner results in a warmer discharge of air because
the heated and unheated air flows join and are mixed
together thoroughly beyond the heater core.
When the temperature lever is rotated fully
clockwise to the full "HOT" position, the temperature
valve blocks off the passage that allows air to bypass
the heater core and causes all of the airflow to pass
through the heater core.
When the bi-level valve (8) is opened by the

upper mode valve (9) vacuum actuator, as in "MAX"
A/C, normal "A/C" and "VENT" modes both valves
move at the same time, directing all airflow through
the instrument panel outlets.
Bi-Level Valve
The heater and defrost valve (7) is operated by a

three-position heater and defrost vacuum actuator. At
its "at rest" (no vacuum applied to either side)
position, the heater and defrost valve (7) is positioned
to allow airflow through both the floor outlets and
defroster outlets, as when in "DEFROST BLEND"
mode. During the "DEFROST" mode, vacuum is
applied to one side of the heater and defrost vacuum
actuator, causing the heater and defrost valve (7) to
direct all airflow to the defroster outlets. A small
passage within the heater and air conditioning
evaporator module (11) will allow some air to bleed
Figure 3
The bi-level valve (8) at its "at rest" (no
vacuum) position, allows no air to the instrument
panel outlets. The bi-level valve (8) can be opened by
either the bi-level valve vacuum actuator or the upper
mode valve vacuum actuator. When opened by the
bi-level valve vacuum actuator, as in "BI-LEVEL
AJC" air will exit the instrument panel outlets, floor
outlets and a small amount will exit the defroster
outlets.
Heater and Defrost Valve

Figure 3
181-9
out the floor outlets. During the "HEATER" mode,

vacuum is applied to the opposite side of the heater
and defrost vacuum actuator causing the heater and
defrost valve (7) to direct all airflow to the floor
outlets with a small bleed to the defroster outlets.
Ducts and Outlets

Figures 4 and 5
There are adjustable outlets in the instrument
panel. In addition, there are two side windo.w defrost
outlets, one at each end of the instrument panel. All
outlets are fed by the air distributor.
Heated or cooled air can be directed to the
windshield through the air distributor and through the
floor air outlet duct.
Ventilation
Figure 7
The air distribution system provides fresh air
ventilation for the passenger compar~men! ~n ~11
operating modes. A small amount of outside air is still
provided in the "MAX" NC mode while most of the
air is re-circulated. Even in the "OFF" mode, fresh
outside air is forced into the air distribution system by
the forward movement of the vehicle.
After being warmed or cooled to the desired
temperature, the air is discharged fr~~ the outl~ts.
When all windows are closed, the addition of outside
air builds a slight positive pressure within th_e
passenger compartment. The pressure forces. stale air
to leave the vehicle through a pressure relief valve,
near the left side quarter panel, behind the rear fascia.
REFRIGERATION SYSTEM
Figures 8 and 9
The refrigeration system cools the air .flow~g
through the air distribution system durmg au
conditioning operation. It also operates when the
"DEFROST" or "DEFROST BLEND" mode is
selected, dehumidifying the air to aid in fog removal
from the windshield. Refrigeration system components
and their functions are as follows:
Refrigerant circulates through t~e r~frigeration
system to absorb heat from the air .bemg _cooled,
and to give off the heat to the air outside the
vehicle. The refrigerant also carries a polyalkylene
glycol (PAG) refrigerant oil throughout the
system, primarily to lubricate parts of the
compressor.
An engine-driven compressor pumps the
refrigerant through the refrigeration system.
A condenser cools the refrigerant in the same way
that the engine cooling system radiator cools the
engine coolant.
A receiver and dehydrator (5.7L VIN P) dries and
filters the refrigerant. It also separates the liquid
and the vapor to provide only liquid to the
thermostatic expansion valve.
24
A PLENUM AREA
24 VALVE, PRESSURE RELIEF
01-28-95
FS0071B'I
Figure 7 - Ventilation Airflow (Typical)
A accumulator (3800 VIN K) functions as a

moisture separator that receives refrigerant liquid
and refrigerant oil from the evaporator. At the
bottom of the accumulator is the desiccant, which
acts as a drying agent for moisture that may have
entered the system.
Lines (metal tubes and nylon-core composite
hoses) and leak-resistant connectors join the
compressor, condenser, accumulator/receiver and
dehydrator, evaporator and other components to
provide a closed-loop circuit for the refrigerant.
The NC refrigerant pressure sensor attached to
the air conditioning evaporator line and senses
refrigerant pressure on the air conditioning .system
high side. One purpose of the A/C refngerant
pressure sensor is to inform the PCM of hig~ side
refrigerant pressure status so the PCM can disable
the compressor before pressure becomes too high.
The high side pressure signal is also used by the
PCM for NC diagnosis.
The evaporator tube orifice (3800 VIN K)
provides a ~estriction to the high-pre~sm:e li9uid
refrigerant m the evaporator tube (hqmd hne),
metering the flow of refrigerant to the evaporator
as a low-pressure liquid.
The thermostatic expansion valve (5.7L VIN P)
lowers the pressure of the refrigerant from the
receiver and dehydrator by metering the flow.
This prepares the refrigerant to pick up heat.
An evaporator absorbs heat from the moving air
and passes it on to the refrigerant inside the core
of the evaporator. This causes the refrigerant to
boil and leave the evaporator as a vapor.
The air conditioning evaporator temperature
sensor (5.7L VIN P) mounted to the heater and air
conditioning evaporator module has a probe
inserted into the evaporator which measures
evaporator temperature and sends a signal to the
PCM. Within the probe is a thermistor which
varies resistance according to temperature. The
evaporator temperature sensor is a soli~ state
device and resistance cannot be measured directly.
One purpose of this temperature sensor is to
inform the PCM of the evaporator temperature so
the compressor can be disabled before the
evaporator freezes. The temperature sensor is also
used by the PCM for NC diagnosis.
1 COMPRESSOR
2 CONDENSER
3 EVAPORATOR
4 ACCUMUlATOR
8. LIQUID LINE
9 PRESSURE RELIEF
VALVE
5 OESSICANT BAG
6 OIL BLEED HOLE
7 EXPANSION TUBE
(ORIFICE)
-HIGH PRESSURE LIQUID

c:=HIGH PRESSURE VAPOf;
LOW PRESSURE LIQUID

LOW PRESSURE VAPOR
5-3-94
WR0031B
Figure 8 - Refrigeration System Schematic (3800 VIN K)
25
....
29
....
30
A PROBE, AIR CONDITIONING EVAPORATOR TEMPERATURE

SENSOR
25 SENSOR, AIR CONDITIONING EVAPORATOR
TEMPERATURE
26 SENSOR, AIR CONDITIONING REFRIGERANT
PRESSURE
28
29
30
31

CONDENSER. AIR CONDITIONING
RECEIVER DEHYDRATOR, AIR CONDITIONING
VALVE, AIR CONDITIONING THERMOSTATIC
EXPANSION
01-2895
FS0081B1
(
Figure 9 Refrigeration System Schematic (5. 7L VIN P)

Refrigerant-134a
Refrigerant-134a and lubricant vapor or
mist. Exposure may irritate eyes, nose,
and throat. To remove R-134a from the
A/C system, use service. equipment
certified to meet the requirements of SAE
J221 O (R-134a recycling equipment). If
accidental system discharge occurs,
ventilate work area before. resuming
service. Additional health and safety
information may be obtained from
refrigerant and lubricant manufacturers.
Like the coolant in the engine cooling system,
the refrigerant is the substance in the air conditioning
system that absorbs, carries and then releases heat.
Past automotive air conditioning systems used a type
\
called Refrigerant-12 (R-12).
This vehicle uses a new type of refrigerant
called Refrigerant-J34a (R-134a). It is a non-toxic,
non-flammable, clear colorless liquefied gas.
While the R-134a AJC system is very similar to
an R-12 A/C system, the differences in the refrigerant,
lubricants, and service equipment are important
NOTICE: R-134a refrigerant is not compatible

with R-12 refrigerant in an air conqitioning
system. R-12 in a R-134a system will cause
compressor failure, refrigerant oil sludge or poor
air conditioning system performance.
Refrigerant-134a carries a charge of a special
lubricating oil, polyalky lene glycol (PAG)
refrigerant oil. GM PAG refrigerant oil will
have a slight blue tint. The oil is hydroscopic
(absorbs water from the atmosphere) and should
be stored in closed containers.
the R-134A A/C system and only mineral base
525 viscosity refrigerant oil ~n fittings threads

The compressor is belt driven from the engine
crankshaft through the compressor clutch pulley. The
compressor pulley rotates without driving the
compressor shaft until an electromagnetic clutch coil is
energized. When voltage is applied to energize the
clutch coil, the clutch plate and hub is drawn rearward
toward the pulley. The magnetic force locks the clutch
plate and pulley together as one unit to drive the
compressor shaft.
As the compressor shaft is driven, the
compressor compresses the low-pressure refrigerant
vapor from the evaporator into a high-pressure,
high-temperature vapor. Carried with the refrigerant is
the refrigerant oil which is used to lubricate the
compressor.
181-11
The compressor has a unique lubrication system.

The crankcase-suction bleed is routed through the
rotating wobble-plate for lubrication of the
wobble-plate bearing. The rotation acts as an oil
separator, which removes some of the oil .from the
crankcase-suction bleed, rerouting it to the crankcase
Up to 118 ml (4 fluid ounces) of oil can collect
in the crankcase. Therefore, it is important when
replacing. a compressor that the oil in the old
compressor crankcase be drained and measured
(discard after recording amount).
All replacement compressors from service parts
will have 237 ml (8 fluid ounces) of oil in the
crankcase. The oil must be drained and retained. Then
replace the oil in the same amount as previously
recorded from the old compressor. For compressor
overhaul, refer to SECTION 102 or SECTION 103.

The high-pressure refrigerant line from the
compressor goes to the condenser. The condenser, is made
up of coils which carry hot refrigerant vapor routed from
the compressor. Thin cooling fins on the coils transfer
heat. to the air passing through the condenser. This cools
the high-pressure refrigerant vapor and causes it to
condense into a high-pressure liquid.

3800. VINK
.. The plastic expansion tube, with its mesh screen

and orifice, is located just forward of the evaporator
fitting between the condenser outlet and evaporator
inlet. It provides a restriction to the high-pressure
liquid refrigerant in the liquid line, metering the flow
of refrigerant to the evaporator as a vapor. The
expansion tube and orifice are protected from
contamination by filter screens on both inlet and outlet
sides.
When system diagnostics indicate a restricted
expansion tube, it may not be necessary to replace the
tube. Metal chips, flakes or slivers found on the screen
may be removed with compressed air and the
expansion tube may be reused if:
The plastic frame is not broken.
The brass expansion tube is not damaged or
plugged.
The screen material is not tom.
The screen is not plugged with fine gritty
material.

5.7L VIN P
The thermostatic expansion valve controls the

flow of refrigerant in the air conditioning system. The
valve is a mechanical device and does not control
compressor cycling. The valve replaces the orifice tube
used in the VOOT air conditioning systems. It
functions by sensing pressure and temperature on the
low side of the system and then meters the high side
of the system to achieve optimal refrigeration
performance.
181-12
DIAGNOSIS

Air passing through the evaporator gives off
some of its heat to the evaporator core fins when the
refrigeration system is operating. Refer to "Air
Distribution System" in this section. The heat is
conducted through the thin metal walls of the
evaporator core to the low-pressure liquid refrigerant
flowing through the evaporator core tubes, causing the
refrigerant to boil and vaporize. The refrigerant leaves
the evaporator as a low-pressure vapor, carrying off
the heat it absorbed from the. evaporator surfaces.
Air Conditioning Accumulator/Receiver and

Dehydrator
The accumulator (VDOT system) and receiver
and dehydrator (TXV system) serve as a refrigerant
storage container. A bag of desiccant {a moisture
absorbing material) in the base collects and holds any
traces of moisture in the refrigerant that could
otherwise create problems such as corrosion or
freezing in the refrigeration system.
Recent improvements in refrigerant hose
materials and the increased. use of metal lines have
reduced the chances of moisture entering the
refrigerant system. The accumulator/receiver and
dehydrator should be replaced if leaking as a result of
perforation, damaged 0-ring seat or damaged threads.
If the system has been opened to outside air for an
extended period, the desiccant may be moisture
saturated and the component should be replaced.
FUNCTIONAL TEST
The following operational test sequence will aid

in determining whether the air conditioning electrical,
air, vacuum and refrigeration systems are working
properly. Temperature of the air should be at least
l6C (60F). The air conditioning system can not be
properly tested unless it is at least this warm.
The engine should be .started and allowed to idle
for about 20 minutes or until the engine cooling
system thermostat is open.
Perform steps 1-9 on Figure 10 and compare
vehicle response to the normal system response shown
on the chart. If vehicle does not respond correctly
during any of these steps, begin diagnosis as noted
below:
Insufficient heating. Refer to SECTION IA.
Insufficient cooling. Refer to "Insufficient
Cooling Check" in this section.
Improper air delivery. Refer to "Improper Air
Delivery" in this section.
Blower motor inoperative or incorrect speed.
Refer to SECTION 8A.
HIA'l'IIII AND All! COMIITIONING

CONT'IIOL AIIIIMILY 8ETT1NO
lilDIIE COlffllOI.
llYBIIETTIIIII
Siii'
Figure 10
IYITIM RESPONSl
'IBlll'BIAllm lllllWBI IICll'III IUIWBI M111111

AHEMII.T
Clllll1IOL IIWBI
ASSlMIII.Y
IINID
IWfl'Clt
mTIIIGI
HlATPI
DEfllllffll
MIC
DUTUII
OUTUTI
aunm
COMMINTS
tlllTI.EI'
11MPUATUIIE
Off
COLD
LOW
OFF
NO AIRFLOW
NOAIR FLOW
NO AIRFLOW
MAX NC
COLD
LOW
LOW
NO.AIAFLDW
AIRFLOW
NO AIRFLOW
A.E
AT LEAST ll'CIZD'FICOOLElllllAN
AMlllfflT
MAX NC
COLD
lDWTD HIGH
LDWTOHIDH
r-lDAIRFLDW
AIRFLOW
NO AIRFLOW
B.E
AT LEAST ll'C tZD'fl COOt.ER llfAN

AMBIENT
NORMAi.NC
MID-IAHIIE
HIGH
1116H
NOAIRFLIIW
AIRFLOW
NOAIIR.IIW
IUOllll.YWARM
Ill-LEVEi.NC
COLD
HIGH
H1GH
AIRFLOW
AIRFLOW
MINIMUMAIR
FLOW
AT LEAST Il'C IZD'FI COOLER TllAN
VENT
COLD
HIGH
HIGH
NDAIIIFLDW
AIRFLOW
NDAIRR.OW
AM81ENT
HEATER
HOT
HIGH
HIGH
AIIIR.OW
NDAIRR.DW
MINIMUMAIR
FLOW
A.C.D
AT LEAST 4l'C 11:ll'fl
DEFROSTER
HOT
HIGH
HIGH
AIRFLOW
NOAlnFLOW
Amn.ow
A.O
AT LEAST 4l'C llZD'Fl
HOT
HIGH
HIGH
MINIMUM AIR
ND AIRFLOW
AIRFLOW
A.D
AT LEAST 4l'C 11:lll'FI
BLEND
DEFROST
AMBIENT
AMIIISfT
FLOW
A
I
C
D
E
ENGAGEMENT o~ DETENT MUST BE FELT IN EAOI MODE CONTIIOL LEVER smlNG.

A NOTICEAIII.E ILOWEA MOTOII ASSEMBLY SPEED INCIEASE MUST OCC\111 FIIOM LOW, MEDIUM LOW. MEDIUM HIGH ANO HIGH.
TEMPERATURE LEVEii MUST TRAVEL FROM FULL COLD TO FULL HOT,
All! FLOW MUST Al.SO IE PRESENT AT SIDE WINDOW OEl'OGGEII OUTLETS.
INSTRUMENT PANEL OUTUml MUST HOLD THEIR POSITION DURING HIGH BLOWER MOTOR ASSEMBLY &PEED BUT BHDULD IE MOVEAIILE rN HANO.
012195
FS009181
Figure 10 - Functional Test
181-13
PERFORM ON BOARD DIAGNOSTIC SYSTEM CHECK. REFEFI

TO SECTION 6E3.
ARE ANY PCM DIAGNOSTIC TROUBLE CODES DISPLAYED?
NO
YES
OPEN DOORS AND HOOD TO NEUTRALIZE VEHICLE

INTERNAL TEMPERATURE WITH SHOP TEMPERATURE,
INSTALL J 39183-C (R134A MANIFOLD GAGE SET) OR
J 39500-GM (ACR' SYSTEM) ON VEHICLE. REFER TO
SECTION 18.
IS LOW SIDE STATIC (ENGINE NOT RUNNING)
PRESSURE ABOVE 310 kPa (45 psi)?
NO
REPAIR DIAGNOSTIC TROUBLE

CODES. REFER TO SECTION 6E3.
YES
LEAK TEST A/C SYSTEM USING J 39400. REFER TO SECTION 1 B.

AFTER REPAIRS HAVE BEEN MADE, CHARGE SYSTEM WITH
PROPER AMOUNT OF R134A. REFER TO SECTION 18.
PERFORM "AIR CONDITIONING PERFORMANCE TEST" IN THIS
SECTION.
PERFORM "AIR CONDITIONING

PERFORMANCE TEST" IN THIS
SECTION.
C10551
Figure 11 - Insufficient Cooling Check
INSUFFICIENT COOLING CHECK

Figure 11
To help eliminate any . possible mis-diagnosis,
"Functional Test" must be performed first. Insufficient
cooling could be caused by one of several reasons.
When the air conditioning compressor is inoperative,
proper diagnosis of insufficient cooling must begin
with an "On Board Diagnostic System Check" of the
PCM. Refer to SECTION 6E3.
IMPROPER AIR DELIVERY

SYSTEM DESCRIPTION
The air distribution system is operated

completely by vacuum, except for the electrically
powered blower motor (5)~ Engine vacuum is routed
through a vacuum check valve (38) then to the control
vacuum selector valve (36) and to the vacuum tank
(37). The vacuum check valve (38) is used to prevent
vacuum loss due to heavy acceleration or steep uphill
traveling.
When vacuum is applied to a vacuum actuator
(5), the air valve (door) moves to its correct position.
PRELIMINARY INSPECTION
1. Inspect vacuum lines at engine and vacuum check

valve (38) for proper connection.
2. Disconnect vacuum line leading to engine at
vacuum check valve (38). Start engine and check
for presence of vacuum, if no vacuum is present,
repair as required.
3. Disconnect vacuum line leading to vacuum tank (37)
at vacuum check valve (38). Using hand vacuum
pump, apply vacuum to vacuum line leading to
vacuum tank (37). If vacuum does not hold, replace
vacuum line and/or vacuum tank (37).
4. Disconnect vacuum line leading to control (1) at
vacuum check valve (38). Apply vacuum to check
valve port. If vacuum does not hold, replace
vacuum check valve (38).
5. Quickly rotate temperature control from "FULL
COLD" to "FULL HOT" several times. Listen
for temperature valve (6) to seat in both positions.
If the sound indicates that the temperature valve
(6) is not fully seating or opening, check the
temperature control cable for proper operation. If
problem persists, check that the. temperature valve
door operates freely wi.th the blower off.
6. Make sure vacuum line seals are positioned
correctly at vacuum line multi-connector above
right-hand sound insulator panel.
7. Perform diagnosis. Refer to Figure 13.
MODE CONTROL VACUUM

VALVE POSITIONS
OFF
MAX NC
NORMAL NC
Bl-LEVEL NC
VENT
HEATER
HEATER/DEFROST BLEND
DEFROSTER
2
3
4
5
6
7
8
38
36
V:l
32
_______ ..,:
~GREEN
~
.
35
'
A
B
C
D
E
F
G
H
J
1
3
TO WINDSHIELD DEFROST OUTLETS

TO SIDE WINDOW DEFROST OUTLETS
TO FLOOR OUTLETS
FROM PLENUM AREA (OUTSIDE AIR)
FROM INSIDE VEHICLE (RECIRCULATED AIR)
TO ENGINE (VACUUM SOURCE)
PARTIALLY OPEN (WITH NO VACUUM)
TEMPERATURE CONTROL
MODE, CONTROL VACUUM LOGIC DISPLAY
4
5
6
32
33
34
35
36
37
38
CORE, HEATER
MOTOR, BLOWER
VAL VE, TEMPERATURE
ACTUATOR, HEATER AND DEFROST VACUUM
ACTUATOR, Bl-LEVEL VACUUM
ACTUATOR, UPPER AND LOWER MODE VACUUM
ACTUATOR, AIR INLET VACUUM
VALVE, CONTROL VACUUM SELECTOR
TANK, VACUUM
VALVE, VACUUM CHECK
Ol-26-95
FS0111:B1
Figure 12 - Improper Air Delivery Vacuum Schematic
...
.
181-15
PERFORM PRELIMINARY INSPECTION .

SET MODE SELECTOR VALVE IN THE "OFF" POSITION .
DISCONNECT VACUUM LINE AT CHECK VALVE .
USING A HAND VACUUM PUMP, APPLY VACUUM
TO VACUUM LINE LEADING TO MODE
SELECTOR VALVE.
DOES VACUUM HOLD?
I
I
NO
I
CHECK BLACK VACUUM

LINE LEADING TO MODE
SELECTOR VALVE. IF LINE IS
CONNECTED AND WORKING
PROPERLY REPLACE MODE
SELECTOR VALVE.
YES
I
APPLY VACUUM TO VACUUM LINE LEADING TO

MODE SELECTOR VALVE AND CHECK IN EACH SETIING
("MAX" A/C TO "DEFROST").
DOES VACUUM HOLD IN EVERY SETIING?
B
I
.
..
APPLY VACUUM TO
ORANGE VACUUM
LINE.
DOES BLOWER MOTOR
ASSEMBLY AIR FLOW NOISE
INCREASE?
YES
SYSTEM
OK.
.
.
.
NO
I
DISCONNECT VACUUM LINE MULTI-CONNECTOR

AT MODE SELECTOR VALVE.
APPLY VACUUM TO EACH LINE AT MULTI
CONNECTOR CONTROLLED BY THE MODE SELECTOR
VALVE AT A SETIING WHERE VACUUM DID
NOT HOLD.
IS A VACUUM LEAK PRESENT AT ONE OR
MORE LINES?
YES
NO
YES
DISCONNECT VACUUM LINE MULTl-CONNECTOR

UNDER RIGHT SIDE SOUND INSULATOR.
TURN IGNITION SWITCH TO "RUN" POSITION
(ENGINE NOT RUNNING).
SELECT "HIGH" BLOWER MOTOR ASSEMBLY SPEED.
APPLY VACUUM TO EACH VACUUM LINE INDIVIDUALLY
(EXCEPT BLACK AND ORANGE LINE) AND CHECK
FOR AIR FLOW AT THE PROPER OUTLETS.
REFER TO "DIAGNOSTIC AID CHART" BELOW.
DOES AIR FLOW AT PROPER OUTLETS?
-i
YES
NO
I
REPAIR OR REPLACE VACUUM LINE

AND/OR VACUUM ACTUATOR.
REFER TO SECTION 1A.
REPAIR OR REPLACE ACTUATOR

LINKAGE AND/OR AIR VALVE (DOOR).
DIAGNOSTIC AID CHART
NO
REPLACE MODE SELECTOR

VALVE. REFER TO SECTION 1A.
REPAIR OR REPLACE AIR

INLET VACUUM ACTUATOR
LINKAGE AND/OR AIR
INLET VALVE.
APPLY VACUUM TO:
AIR FLOW SHOULD BE DIVERTED TO:
RED VACUUM LINE

YELLOW VACUUM LINE
INSTRUMENT PANEL OUTLETS ONLY

=SIDE WINDOW DEFOGGER AND FLOOR
OUTLETS
SIDE WINDOW DEFOGGER. FLOOR AND .
INSTRUMENT PANEL OUTLETS
WINDSHIELD AND SIDE WINDOW
DEFOGGER OUTLETS
BLOWER MOTOR ASSEMBLY AIR NOISE
INCREASE
ALL OUTLETS EXCEPT INSTRUMENT PANEL
PURPLE VACUUM LINE

GREEN VACUUM LINE
ORANGE VACUUM LINE
NO VACUUM LINES (ALL
LINES VENTED TO
ATMOSPHERE)
0203915
FS0121BI
Figure 13 Improper Air Delivery Diagnostic Chart
ROTATE TEMPERATURE KNOB FROM "FULL COLD" TO

"FULL HOT" AND BACK TO "FULL COLD". LISTEN FOR
TEMPERATURE VALVE TO SEAT IN BOTH "FULL HOT"
AND "FULL COLD" POSITION (A "THUD" NOISE SHOULD
BE HEARD.
DOES TEMPERATURE VALVE SEAT IN BOTH POSITIONS?
YES
NO
DISCONNECT TEMPERATURE CABLE AT HEATER AND

EVAPORATOR MODULE.
ROTATE TEMPERATURE LEVER FROM "FULL HOT" TO "FULL
COLD" WHILE WATCHING CABLE END.
DOES CABLE END ROTATE WHEN TEMPERATURE LEVER IS
ROTATED?
PARK VEHICLE INDOORS

CLOSE DOORS AND WINDOWS.
SELECT "FULL COLD, MAX A/C" MODE AND
"HIGH" BLOWER MOTOR SPEED.
PLACE VEHICLE IN PARK (AUTOMATIC
TRANSMISSION) AND SET PARKING BRAKE
(MANUAL OR AUTOMATIC TRANSMISSION).
START ENGINE.
DOES COMPRESSOR ENGAGE?
YES
INSTALL TECH 1 WITH

POWERTRAIN CARTRIDGE.
SELECT "FIELD SERVICE" MODE.
ENERGIZE COOLING FANS USING
TECH 1.
CHECK COOLING FAN OPERATION:
ARE BOTH COOLING FANS
OPERATING?
I
I
NO
NO
REPAIR OR REPLACE
TEMPERATURE CABLE
AS NECESSARY.
REFER TO SECTION 6E3

FOR A/C COMPRESSOR
CIRCUIT DIAGNOSIS.
YES
MANUALLY ROTATE
TEMPERATURE VALVE BY HAND.
DOES TEMPERATURE VALVE
ROTATE EASILY TO BOTH THE
"FULL HOT" AND "FULL .COLD"
POSITION WITH APPROXIMATELY
50 DEGREES OF TRAVEL?
I
I
YES
ADJUST OR REPLACE
TEMPERATURE CABLE.
NO
I
REPAIR OR REPLACE
HEATER AND
EVAPORATOR MODULE.
NO
REPAIR COOLING FAN

CIRCUIT.
REFER TO SECTION
6E3C12.
YES
INSTALL J 39183C (R134a MANIFOLD GAGE SET) OR J 39500-GM (ACR'

SYSTEM) ONTO VEHICLE. REFER TO SECTION 1B.
INSTALL J 674203 (PRECISION THERMOMETER) OR EQUIVALENT INTO CENTER
INSTRUMENT PANEL OUTLET.
WITH VEHICLE RUNNING IN "MAX A/C" MODE, "FULL COLD" AND "HIGH"
BLOWER MOTOR SPEED FOR 2 MINUTES AT ENGINE IDLE, RECORD THE
FOLLOWING INFORMATION:
AJC SYSTEM HIGH AND LOW SIDE PRESSURE
EVAPORATOR TEMPERATURE USING TECH 1 (LT1 ONLY).
AMBIENT TEMPERATURE AND HUMIDITY
COMPARE WITH AIR CONDITIONING PERFORMANCE CHART.
IS VEHICLE A/C PERFORMANCE WITHIN SPECIFICATIONS?
I
NO
(5.7L LT1 ENGINE)

REFER TO
"REFRIGERANT
SYSTEM DIAGNOSIS
CHART" IN THIS
SECTION.
YES
ISYSTEM OK. I
(3800 L36 ENGINE) REFER TO
"VDOT A/C SYSTEM DIAGNOSTIC
CHARTS" IN THIS SECTION.
C8078
Figure 14 - A/C Performance Test

A/C PERFORMANCE TEST
A/C SYSTEM NOISE DIAGNOSIS

IMPORTANT: Feel lines, hoses, brackets
during diagnosis. Many noises may stop
while being contacted.
TYPE
Vibration/Rattle
Moan
Screech
POTENTIAL CAUSE
Belt mis-aligned in groove.
Belt Tensioner.
Lines/Hoses contacting other
components.
Brackets loose.
Other Drive Components.
Check related Bulletins.
Improper NC Charge.
Other Drive Components.
Loose or mis-aligned bracket.
Lines/Hoses contacting other
components.
Serpentine Belt.
Compressor Bearings.
Compressor Clutch.
T5568
A/C SYSTEM DIAGNOSTIC CHARTS

For diagnosis of typical A/C problems, first refer
to "AJC Performance Test" (Figure 14). For additional
diagnosis of VDOT A/C problems, refer to Figures 17
through 24.
Tools Required:
J 39500 ACR 4 System or
J 39183-C R-134a Manifold Gauge Set
J 67 42-03 Precision Thermometer
(or Equivalent)
Before performing the air conditioning
performance test, a functional test should be made
to assure that the air distribution system valves are
functioning properly to route all the air passing
through the evaporator to the outlets. Refer to
"Functional Test" in this section.
Performance testing provides a measure of air
conditioning system operating efficiency by
measuring and comparing pressures at the
high-pressure and low-pressure sides of the
refrigeration system, the temperature of the air
being discharged into the passenger compartment,
and the evaporator temperature.
Start with the air conditioning performance
test in Figure 14, and compare vehicle air
conditioning system performance with the chart in
Figure 15. If system performance is not within
specifications, proceed to the refrigeration system
diagnostic chart in Figure 16 to pinpoint the
problem.
GAGE PRESSURES
TEMPERATURE
HUMIDITY
21-2rc
181-17
CENTER
OUTLET
TEMP
LOW
(V6)
LOW
(V8)
HIGH
LESS TIIAN 50%
165-234 kPa
(24-34 psi)
110-165 kPa
(16-24 psi)
793-1310 kPa
(115-190 psi)
(70 -80F)
HIGHER TIIAN
50%
172-255 kPa
(25-37 psi)
145-200 kPa
(21-29 psi)
793-1379 kPa
(115-200 psi)
27_33c
LESS TIIAN 50%
193-262 kPa
(28-38 psi)
131-207 kPa
(19-30 psi)
965-1482 kPa
(140-215 psi)
(so -90F)
HIGHER TIIAN
50%
207-276 kPa
(30-40 psi)
1034-1620 kPa
(150-235 psi)
33-3sc
LESS TIIAN 40%
234-296 kPa
(34-43 psi)
165-269 kPa
(24-39 psi)
172-290 kPa
(25-42 psi)
3 -9c
(38-48F)
4_13c
(40-55F)
3_13c
(38-55F)
r-1sc
(45-65F)
1138-1793 kPa
(165-260 psi)
(45 -63F)
(90 -100F)
HIGHER TIIAN
40%
251-331 kPa
(36-48 psi)
234-296 kPa
(34-43 psi)
3g_44c
LESS TIIAN 20%
276-338 kPa
(40-49 psi)
(l00-ll0F)
HIGHER TIIAN
20%
296-359 kPa
(43-52 psi)
255-296 kPa
(37-43 psi)
262-352 kPa
(38-51 psi)
1276-1862 kPa
(185-270 psi)
1448-2000 kPa
(210-290 psi)
1517-2137 kPa
(220-310 psi)
13-20C
(55-68F)
12-18c
(53 -64F)
14-21C
(S8-70F)
r-11c
EVAP
ASSEMBLY
TEMP
DISPLAYED ON
TECH 1
(V8)
1-6C
(33 -43F)
2-10c
(35-50F)
1-10c
(33 -50F)
4-16c
(40 -60F)
4-14C
(40-58F)
10-18C
(S0-65F)
9-16c
(48 -6l 0F)
13-18c
(55-65F)
T5523
Figure 15 - A/C Performance Chart
PERFORM AIR CONDITIONING PERFORMANCE TEST BEFORE REFRIGERATION SYSTEM DIAGNOSIS

CONDITIONS
CENTER
OUTI.Er
TEMP
LOW SIDE
PRESSURE
HIGH SIDE
PRESSURE
TECH1
EVAPORATOR
TEMPERATURE
OKOR HIGH
OK ORLOW
OK ORLOW
HIGHER
POSSIBLE
FAULT
LOW REFRIGERANT RECOVER, MEASURE AND RECHARGE A/C

CHARGE
SYSTEM. REFER TO SECTION 18.
RECEIVER AND
CHECK FOR PRESSURE DIFFERANCE
GREATER THAN 138 kPa (20 PSI) BETWEEN
DEHYDRATOR
TECH 1AND HIGH GAUGE, REPLACE
ASSEMBLY
PLUGGED
RECEIVER AND DEHYDRATOR ASSEMBLY.
DEBRIS PLUGGING
THERMOSTATIC
EXPANSION VALVE
INOPERATIVE
THERMOSTATIC
EXPANSION VALVE
HIGHER
HIGHER
HIGHER
HIGHER
LOW
HIGHER
HIGH
HIGHER
OK
OK
HIGH
OK
OK
OK ORLOW
OK
LOW
CORRECTIVE ACTION
CLEAN THERMOSTATIC EXPANSION

VALVE.
TEST THERMOSTATIC EXPANSION VALVE.
SET NC BLOWER ON LOW ANO REV
ENGINE TO 1,500 RPM. IF LOW GAGE GOES
OR REMAINS ABOVE 193 kPa (28 PSI),
THERMOSTATIC EXPANSION VALVE IS STUCK
OPEN; REPLACE IT. IF LOW GAGE GOES
BELOW 138 kPa (20 PSI) SYSTEM OK.
EVAPORATOR
TEMPERATURE
SENSOR OUT OF
POSITION
REINSTALL EVAPORATOR TEMPERATURE

SENSOR. REFER TO "AIR CONDITIONING
EVAPORATOR TEMPERATURE SENSOR
ASSEMBLY" IN THIS SECTION.
A/C COMPRESSOR
FAULT
INOPERATIVE
THERMOSTATIC
EXPANSION VALVE
PERFORM COMPRESSOR TEST

TEST THERMOSTATIC EXPANSION VALVE.
SET NC BLOWER ON LOW AND REV
ENGINE TO 1,500 RPM. IF LOW GAGE GOES
OR REMAINS ABOVE 193 kPa (28 PSI},
THERMOSTATIC EXPANSION VALVE IS STUCK
OPEN; REPLACE IT. IF LOW GAGE GOES
BELOW 138 kPa (20 PSI) SYSTEM OK.
CLEAN, REMOVE RESTRICTION.
CONOENSOR AIR
RESTRICTION
CONDENSORAIR
RECIRCULATION
HIGH REFRIGER
ANT CHARGE
TOO MUCH
REFRIGERANT OIL
FAN PROBLEMS
CHECK FLOW DIRECTION, RELAY, ETC.
CIRCUIT FAULT
PERFORM A/C ELECTRICAL CIRCUITTEST.
INSTALL OR REPOSITION AIR CONTROL

BAFFLES.
RECOVER, MEASURE AND RECHARGE A/C
SYSTEM. REFER TO SECTION 1B.
FLUSH A/C SYSTEM. REFER TO SECTION 18.
0126H
IFS0151B1
Figure 16- Refrigeration System Diagnostic Chart (5.7L VIN P)
181-19
Diagnostic Procedures
For
Variable Displacement Orifice Tube (VDOT)
3800 L36 Engine
The procedures in the following charts will help you diagnose VS compressor and
VDOT refrigerant system problems causing insufficient cooling. They must be used
in conjunction with other appropriate service manual information.
The VS compressor is a variable displacement compressor which matches air
conditioning demand by changing its stroke, instead of cycling its clutch. A control
valve located in the rear head of the compressor senses compressor low side
pressure and causes the compressor mechanism to change stroke. This
compressor is also equipped with a RPM triggered destroking mechanism that
allows the compressor to function at reduced stroke during high RPM operation.
Because the V5 compressor always runs and the system does not cycle, these
diagnostic procedures differ from those used for fixed displacement systems. By
using these procedures, you will avoid needlessly replacing A/C components.
STEP 1 -
Preliminary Checks
Repair the following as necessary. If discharge air temperature with A/C on is

normal after making the following repairs, the system is operating properly.
A/C fuse.
A/C blower operation.
Temperature door or cable adjustment. Move temp. door knob from cold to hot.
Listen for temp. door hitting (thud noise) at each end. Adjust as necessary.
(Cable operated temp. door only.).
Clutch coil connections/relay.
Compressor belt. Replace if damaged or missing.
Engine cooling fan operation (both fans) and proper air flow direction.
Check outer surfaces of radiator and condenser cores to be sure air flow is not
blocked by dirt, leaves or other foreign material. Be sure to check between the
condenser and radiator as well as the outer surfaces.
Restriction in evaporator core or condenser core, or kinks in hoses, tubes, etc.
Dealer Technical Bulletins for updates on A/C System.
C7945
Figure 17 - VDOT A/C System Diagnostic Charts (1 of 8)
STEP 2 -
Checking Refrigerant Charge
Note: Before proceeding with this step, pressure gages must be properly callbrated, the ambient air temperature must be 15.5"C
(60'F) or above, and the engine must be warmed to operating temperature.
IGNITION KEY IN
OFI" POSITION.
CONNECT HIGH AND

LOW SIDE
PRESSURE GAGES.
PRESSURES
SHOULD BE
APPROXIMATELY
EQUAL.
BOTH PRESSURES ABOVE

345 kPa (50 psi). OK.
BOTH PRESSURES
BELOW 69 kPa (10 psi).
ADD .45 Kg (1 LB.) of
R134a. LEAK CHECK
SYSTEM. REPAIR LEAK.
BOTH PRESSURES BETWEEN

69 AND 345 kPa (10 AND 50
psi). LEAK CHECK SYSTEM.
REPAIR LEAK.
EVACUATE AND
CHARGE SYSTEM.
BOTH PRESSURES ABOVE

345 kPa (50 psi). OK.
DO STEP 3.
C7946
Figure 18 VDOT A/C System Diagnostic Charts (2 of 8)
STEP 3 -
Checking Comp.ressor Clutch /Engagement
RUN ENGINE AT IDLE. SET

A/C CONTROLS TO: NORM
A/C MODE, HIGH BLOWER
AND TEMP. TO FULL COLD.
i,.........-,,....,.,......_....,_.......,....._..,...,..._,,_""'"'1 CLUTCH ENGAGES.
OBSERVE FOR LOUD KNOCKING NOISE

FROM COMPRESSOR AND/OR A BELT
SLIPPAGE CONDITION (CYCLE
COMPRESSOR ON AND OFF TO VERIFY
SOURCE OF NOISE).
CLUTCH DOES NOT

ENGAGE.
TURN OFF THE

IGNITION SWITCH.
DISCONNECT CLUTCH WIRES AT

COMPRESSOR. CONNECT A JUMPER WIRE
FROM GROUND TO ONE COMPRESSOR
CLUTCH TERMINAL. CONNECT A
FUSED-JUMPER WIRE FROM THE
POSITIVE BATTERY POST TO THE OTHER
COMPRESSOR CLUTCH TERMINAL.
NO COMPRESSOR
NOISE/BELT SLIPPAGE.
COMPRESSOR NOISE/BELT
SLIPPAGE OBSERVED.
BELT SLIPPAGE.
CLUTCH DOES NOT

ENGAGE.
CLUTCH DOES
ENGAGE.
REPLACE CLUTCH
COIL.
REPAIR ELECTRICAL
CIRCUIT TO THE
COMPRESSOR CLUTCH
. RUN ENGINE AT IDLE. SET A/C

CONTROLS TO: NORM A/C
MODE, HIGH BLOWER AND
TEMP. TO FULL COLD.
COMPRESSOR NOISE.
CORRECT CONDITION.
CHECK A/C LINES AND

HOSES FOR CONTACT WITH
OTHER COMPONENTS OR
BODY PANELS.
EVACUATE AND
CHARGE SYSTEM.
REPOSITION OR
REPLACE.
CLUTCH ENGAGES. OK.

REFER TO "A/C SYSTEM
NOISE DIAGNOSIS CHART"
IN THIS SECTION.
COMPRESSOR NOISE?
DO STEP 4.
DO STEP 4.
NO
REPLACE
COMPRESSOR.
DO STEP 4.
C7947
181-22
STEP 4 -
Checking System Performance
II] IMPORTANT:
THIS TEST WAS DESIGNED FOR TYPICAL GARAGE CONDITIONS: 2132"C (7090'F) AND NO
SUN LOAD. NORMAL DISCHARGE AIR TEMPERATURE IS TYPICALLY AT LEAST 7'C (20"F)
COOLER THAN AMBIENT TEMPERATURE. FOLLOW THIS TEST EXACTLY. IT IS DESIGNED TO
CREATE ENOUGH COOLING LOAD TO CAUSE THE VS TO OPERATE AT FULL STROKE. THIS
IS ABSOLUTELY NECESSARY FOR ACCURATE TEST RESULTS.
CLOSE ALL VEHICLE WINDOWS.AND DOORS. SET A/C CONTROLS TO "NORM" A/C MODE,
HIGH BLOWER AND TEMP. TO FULL COLD. RUN ENGINE AT IDLE FOR 5 MINUTES.
FEEL LIQUID LINE ON BOTH SIDES OF ORIFICE (EXPANSION) TUBE.
SAME TEMPERATURE.
RECOVER REFRIGERANT.
ORIFICE (EXPANSION) TUBE MISSING

AND/OR ORIFICE ORING MISSING.
AND/OR HIGH SIDE RESTRICTION.
INSTALL ORIFICE
(EXPANSION) TUBE OR
REPAIR RESTRICTION.
NOTICEABLE TEMPERATURE
DIFFERENCE.
RECORD LOW AND HIGH SIDE PRESSURES

AFTER A/C SYSTEM HAS BEEN
OPERATING FOR 5 MINUTES OR MORE. ON
ENGINES WITH COOLING FANS THAT
CYCLE. TAKE PRESSURE READINGS WITH
ENGINE COOLING FAN ON.
LOCATE THE INTERSECTION OF THE LOW

AND HIGH SIDE PRESSURES ON THE
.. DIAGNOSTIC CHART (5 OF 8).
EVACUATE AND
CHARGE SYSTEM.
LEAK TEST.
CONTINUE TESTING
WITH NEXT CHART.
NOTE DISCHARGE AIR
TEMPERATURE. IS IT
WITHIN SPECIFICATIONS?
END
FOLLOW STEP 4
AGAIN.
C7948

STEP 4 -
181-23
Continued
10090L
0
80-
70-
LEFT
RIGHT
w
I
D
E
I,
60-
R
E
s
s
u
R
E
NORMAL
50-
------
4030-
20-
10100
200
300
400
HIGH SIDE PRESSURE

FIGURE 1
HUMIDITY AND TEMPERATURE VARIABLES CAN CREATE BORDERLINE DIAGNOSTIC

CONDITIONS. IF THE DIAGNOSTIC CHART "FIGURE 1" DIRECTS YOU TO FOLLOW
PROCEDURES IN ONE STEP, BUT THOSE PROCEDURES DO NOT LEAD YOU TO CORRECT
THE PROBLEM, FOLLOW THE PROCEDURES FOR THE OTHER STEP.
LOW AND HIGH SIDE

PRESSURES INTERSECT IN
THE LEFT AREA OF THE
CHART. DO STEP 6.
LOW AND HIGH SIDE

PRESSURES INTERSECT IN
THE RIGHT AREA OF THE
CHART. DO STEP 5.
LOW AND HIGH SIDE PRESSURES INTERSECT IN THE WHITE AREA OF THE CHART.
NORMAL AREA MEANS ALL COMPONENTS OF THE REFRIGERANT SYSTEM ARE
FUNCTIONING PROPERLY. IF INSUFFICIENT COOLING EXISTS, AIR HANDLING
SYSTEM IS AT FAULT.
C7949
181-24
(
STEP 5 -
Right Area Diagnosis and Service
ENGINE STILL RUNNING. SET A/C CONTROLS TO: NORM A/C MODE, HIGH BLOWER AND
TEMP. TO FULL COLD. CLOSE VEHICLE WINDOWS AND DOORS. OPEN HOOD. BOTH
ENGINE COOLING FANS MUST BE OPERATING.
FEEL LIQUID LINE BETWEEN CONDENSER AND ORIFICE (EXPANSION) TUBE. IS IT COLD?
REFRIGERANT OVERCHARGE OR
AIR IN SYSTEM.
CHECK FOR RESTRICTED AIR

FLOW AT CONDENSER AND/OR
FAN OPERATION.
REPAIR FAN(S).
REMOVE RESTRICTION.
EVACUATE AND CHARGE SYSTEM.
C7950
STEP 6 -
181-25
Left Area Diagnosis and Service
AAE COMPRESSOR HIGH AND LOW SIDE PRESSURES WITHIN

287 kPa (30 psi) OF EACH OTHER?
NO
IS LOW SIDE PRESSURE 172241 kPa

(27 TO 38 psi).
YES
NO
LIQUID LINE COLD BEFORE ORIFICE?
NO
RUN ENGINE AT 3,000 RPM. SET
A/C CONTROLS TO: HIGH BLOWER
AND TEMP. TO FULL COLD. CLOSE
VEHICLE WINDOWS AND DOORS.
CYCLE MODE LEVER FROM VENT
TO A/C EVERY 20 SECONDS FOR 3
MINUTES.
.
CHECK FOR
RESTRICTION IN
LIQUID LINE BEFORE
ORIFICE. REPLACE OR
REPAIR.
REFRIGERANT UNDER-CHARGED.
ADD 0.40 kg (14 oz.) OF
REFRIGERANT TO SYSTEM. DOES
COOLING PERFORMANCE
IMPROVE?
ARE COMPRESSOR HIGH AND LOW

SIDE PRESSURES WITHIN 207 kPa
(30 psi) OF EACH OTHER?
NO
IS PRESSURE RISE SLOW ON

BOTH GAGES (COMPRESSOR
SUCTION LINE WARM AND
DISCHARGE LINE VERY HOT)?
RECOVER
REFRIGERANT.
CHECK ORIFICE
(EXPANSION)
TUBE. IF
PLUGGED,
REMOVE. CLEAR
LINES. REPLACE
ORIFICE
(EXPANSION)
TUBE. IF ONLY
LIGHT DEBRIS IS
PRESENT, CLEAN
TUBE WITH SHOP
AIR AND REUSE.
YES
ENGINE OFF. WITH

COMPRESSOR CLUTCH
DISENGAGED, DOES
COMPRESSOR CLUTCH
DRIVER (NOT PULLEY)
TURN FREELY BY HAND?
YES
IF FOUND,
REPAIR
REFRIGERAN
LEAK. IF NO
LEAK IS
FOUND,
CONTINUED.
NO
CHECK FOR RAPID RISE

IN LOW SIDE PRESSURE
BETWEEN 3,000-3,800
ENGINE RPM.
DO STEP 4.
REPLACE COMPRESSOR.
LEAK TEST.
PERFOAM CONTROL VALVE

DIAGNOSIS. DO STEP 7.
DO STEP 4.
C7951
181-26
STEP 7 -
Control Valve Diagnosis
[]] IMPORTANT:
FOLLOW THIS TEST PROCEDURE EXACTLY. IT IS DESIGNED TO CREATE A LOW COOLING
LOAD TO CAUSE THE VS COMPRESSOR TO OPERATE AT LESS THAN FULL STROKE. THIS IS
ABSOLUTELY NECESSARY FOR ACCURATE TEST RESULTS.
RUN ENGINE FOR 5 MINUTES AT 2,000 RPM. SET AIC CONTROLS TO: MAX.
AIC MODE, LOW BLOWER AND TEMP. TO FULL COLD. CLOSE VEHICLE
WINDOWS AND DOORS. OPEN HOOD.
IS LOW SIDE PRESSURE

172-241 kPa (25 TO 35 psi)?
NO
YES
REPLACE CONTROL VALVE.
LEAK TEST,
DO STEP 4.
C7952
18127
ON-VEHICLE SERVICE
3
35
BLOWER MOTOR RELAY

The blower motor relay is located under the
instrument panel. Refer to electrical diagnosis
SECTION 8A.
AIR CONDITIONING COMPRESSOR RELAY

The air conditioning compressor relay is located
in the underhood electrical center. Refer to electrical
diagnosis SECTION 8A.
AIR CONDITIONING EVAPORATOR

TEMPERATURE SENSOR
5.7L VIN P
Figures 25 and 26
!++!
1. Heater core. Refer to SECTION IA.

2. Evaporator temperature sensor electrical
connector.
3. Evaporator temperature sensor probe from
evaporator.
Use needle-nose pliers to pull probe straight

out.
4. Evaporator temperature sensor (25) from heater
and air conditioning evaporator module (11).
O
!++!
11
A PROBE
B GROMMET
C PERFORATION FOR AIR CONDITIONING EVAPORATOR
REMOVAL
D SERVICE PROBE LOCATION
11 MODULE, HEATER AND AIR CONDITIONING
EVAPORATOR
TEMPERATURE
35 ACTUATOR, AIR INLET VACUUM
Remove grommet with evaporator temperature

sensor (25).
Install or Connect
1. Evaporator temperature sensor (25) to heater and

air conditioning evaporator module (11).
Seat grommet in heater and air conditioning
module (11).
II]
Important
Do not insert probe into existing hole. Use

alternate location near the existing hole shown
in the condensate screen and . insert probe
straight into evaporator. If probe is not inserted
straight into evaporator, incorrect evaporator
temperature reading may result, causing
evaporator freeze-up.
2. Evaporator temperature sensor probe straight into
evaporator in new location near previous location.
3. Evaporator temperature sensor electrical
connector.
4. Heater core. Refer to SECTION lA.
O
25
01-2195
FS0161B1
Figure 25 Air Conditioning Evaporator Temperature

Sensor (5.7L VIN P)
AIR CONDITIONING REFRIGERANT

PRESSURE SENSOR
Figure 27
!++I
1. Electrical connector at sensor (26).

2. Sensor (26) and seal (39).
e Sensor (26) is mounted on a Schrader type
valve so it is not necessary to discharge the
refrigeration system.
Discard seal (39).
I++!
Install or Connect
NOTICE: Refer to "Notice" on page lBl-1.

1. New seal (39) to sensor fitting.
Coat seal (39) with mineral base 525 viscosity
refrigerant oil.
2. Sensor (26).
181-28
!~!
c
Tighten
Sensor (26) to 6 N.m (53 lb. in.).

3. Electrical connector to sensor (26).
AIR CONDITIONING EVAPORATOR
!++!
A
A SERVICE PROBE LOCATION

B AIR CONDITIONING EVAPORATOR TUBE PLATE
C CONDENSATE SCREEN
D BARBS
012895
FS017181
Figure 26 Air Conditioning Evaporator Temperature

Sensor Installation (5.7L VIN P)
1. Discharge refrigerant into a recovery station.

Refer to SECTION lB.
2. Right-hand instrument panel sound insulator
3. Heater hoses at heater core. Refer to
SECTION lA.
SECTION 8C.
6. Air conditioning evaporator temperature sensor.
Refer to "Air Conditioning Evaporator
Temperature Sensor" in this section.
7. Temperature control cable at temperature valve
case. Refer to SECTION lA.
8. Bolts/screws (48) located in engine compartment
from temperature valve case (42).
9. Temperature valve case (42).
Slide case (42) downward to disengage upper
case clip.
Remove from under the instrument panel.
10. Thermostatic expansion valve. Refer to
SECTION lB.
rn
Important
Remove perforated section of heater and air

conditioning evaporator module as one piece
(it will be reused).
Water can leak onto carpeting when doing this

procedure. It is recommended that a mat be
placed on passenger side floor.
11. Using a small hand saw, remove perforated
section of heater and air conditioning evaporator
module (Figure 25).
26 SENSOR, AIR CONDITIONING REFRIGERANT
PRESSURE
39 SEAL, AIR CONDITIONING REFRIGERANT PRESSURE
SENSOR
63 HOSE, AIR CONDITIONING COMPRESSOR ANO
CONDENSER
64 TUBE, AIR CONDITIONING EVAPORATOR
01H95
FS018181
Figure 27 Air Conditioning Refrigerant Sensor (Typical)
rn
Important
This piece of material is required to keep

condensate from draining inside vehicle.
12. Bolts/ screws ( 41) retaining air conditioning
evaporator (3).
13. Air conditioning evaporator (3) from heater and
air conditioning module (11).
Slide evaporator (3) to the left, then pull out
through the opening enlarged in step 11.
A SNAP, TEMPERATURE VALVE CASE

4 CORE, HEATER
TEMPERATURE (5.7L LTl ENGINE)
42 CASE, TEMPERATURE VAL VE
43 CLAMP, HEATER CORE TUBE
44 CASE, AIR CONDITIONING EVAPORATOR UPPER
45 CASE, AIR CONDITIONING EVAPORATOR LOWER
46 CASE, AIR DISTRIBUTOR UPPER
47 COVER, HEATER AND AIR CONDITIONING EVAPORATOR
CASE
48 BOLT/SCREW, TEMPERATURE VALVE CASE
EVAPORATOR CASE OVER
59 BOLT/SCREW, HEATER CORE TUBE CLAMP
65 CLAMP, AIR CONDITIONING EVAPORATOR
66 SEAL, HEATER PIPE
67 BRACKET, HEATER CORE
68 BOLT/SCREW, HEATER CORE
69 GROMMET, TEMPERATURE SENSOR (5. 7L LTl ENGINE)
181-29
lv1EwAI
012iH
FS0111B1
Figure 28 Air Conditioning Evaporator and Components
181 30
!++I
Install or Connect
NOTICE:
Refer to "Notice" on page lBl-1.
1. Transfer condensate screen to new evaporator (3).

2. Install new evaporator core gasket in same
position as original with appropriate adhesive.
3. Air conditioning evaporator (3) to heater and air
conditioning module (11).
Insert evaporator (3) into module (11) through
the opening enlarged during removal, slide to
the right until fully seated.
4. Bolts/screws (41) to air conditioning evaporator
(3).
5. Thermostatic expansion valve. Refer to SECTION

lB.
6. Apply sealer GM PIN 3012078 (do not use epoxy
glue) between evaporator (3) and evaporator upper
and lower case ( 44 and 45) just behind
thermostatic expansion valve to prevent air entry
from the engine compartment into .the passenger
compartment.
7. Position perforated section of heater and air
conditioning evaporator module and use epoxy
glue to adhere it to module. After epoxy dries, use
thumb to grade sealant on inside and outside to
ensure water-tight seal.
8. Temperature valve case (42).

Install from under instrument panel.
Slide case (42) upward into position until
upper clip engages.
Engage snap on left edge of temperature valve
case (42) to distributor case (46).
9. Bolts/screws (48) .to temperature valve case (42).
l~I Tighten
Bolts/screws (48) evenly to compress flange
seaL
10. Temperature control cable at temperature valve
case. Refer to SECTION lA.
11. Air conditioning evaporator temperature sensor.
Refer to "Air Conditioning Evaporator
Temperature Sensor" in this section.
13. Instrument panel compartment. Refer to.
SECTION 8C.
14. Heater hoses to heater core. Refer to SECTION
lA.
15. Right-hand instrument panel sound insulator
16. Fill radiator and bleed cooling system. Refer to
SECTION 6B.
17. Refrigerant oil into evaporator (3), if necessary.
If installing new evaporator (3), add 89 ml (3
fluid ounces) of polyalkylene glycol (PAG)
synthetic refrigerant oil, GM PIN 12345923.
181-31
SPECIFICATIONS
NC System 0-ring and Fitting Lubricant ............................ Mineral Base 525 Viscosity Refrigerant Oil, GM
PIN 12301108 or equivalent
NC System Internal Lubricant (Including Compressor) .......................... Polyalkylene Glycol (PAG) Synthetic
Refrigerant Oil, GM PIN 12345923 or equivalent
NC System R-134a Capacity
3800 VIN K ........................................................................................................................... 0.77 kg (1.7 lbs.)
5.7L VIN P ............................................................................................................................. 0.91 kg (2.0 lbs.)
COMPONENT TIGHTENING SPECIFICATIONS

Air Conditioning Refrigerant Pressure Sensor ......................................................................... 6 N.m (53 lb. in.)
SPECIAL TOOLS
2.
4.
J 39183-C
1. R-12 ANO R-134a HALOGEN LEAK DETECTOR

2. AIR CONDITIONING REFRIGERANT RECOVERY,
RECYCLING ANO RECHARGING SYSTEM (ACR)
3. PRECISION THERMOMETER
4. R-134a MANIFOLD GAUGE SET
OMl895
FS0201,B1
BLANK
HD6/HT6 AIR CONDITIONING COMPRESSOR 1D2-1
SECTION 102
HD6/HT6
AIR CONDITIONING C
PRESS R
SERVICE OR UNIT REPAIR R-134a
CAUTIONS in Section 9J under ON-VEHICLE SERVICE: and the SIR Component and Wiring Location
view in Section 9J before performing service on or around SIR components or wiring. Failure to
follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a
fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not
available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread
locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above
conditions are not followed, parts or system damage could result.
CONTENTS
General Description ...........................

Metric Thread Size Information ...............
UnitRepair ..................................
Minor Compressor
Repair Procedures ..........................
Compressor Clutch Plate and
Hub Assembly ..........................
Compressor Clutch Rotor and/or Bearing ......
Compressor Clutch Coil ...................
1D2-1
m2:..:.3
1D2-3
1D2-3
1D2-3
1D2-4
1D2-7
Major Compressor
Repair Procedures .......................... 1D2-8
Compressor Shaft Seal Replacement ......... 1D2-8
Seal Leak Detection ...................... 1D2-8
CompressorPressureReliefValve .......... 1D2-10
Control Switches ........................ 1D2- ll
Compressor Leak Testing ................. 1D2-11
Bench-Check Procedures ............... 1D2-l l
Special Tools ........................... 1D2-l 2
GENERAL DESCRIPTION
The HD6/HT6 Automotive Conditioning Compressor
and Clutch Assembly is a lightweight, six cylinder axial design
consisting of three double ended pistons and weighs 5.8 kg
(12.7 lbs.)
[II
There are two clutch driver designs for these

compressors. The clutch driver without a torque cushion and
the clutch driver having a thin torque cushion (Fig. 1).
Service compressors are supplied with either the control
switches assembled in the rear head or a plug may be found
where a control switch is required. If the service compressor
requires control switches, the plug may be removed from the
appropriate rear head switch cavity of the replaced compressor
and assembled as prescribed in this manual.
Fig. 1 Clutch Driver Designs
When servicing the compressor, keep dirt or foreign

material from getting on or into the compressor parts and system.
Clean tools and a clean work area are important for proper service.
The compressor connections and the outside of the compressor
should be cleaned before any "on vehicle" repairs, or before
removal of the compressor. The parts must be kept clean at all
times and any parts to be reassembled should be cleaned with
trichloroethane, naphtha, stoddard solvent, kerosene or equivalent
and dried with dry air. When necessary to use a cloth on any part,
it should be of a non-lint producing type.
Although this compressor is the same for all vehicle

applications, there are differences in installations, mounting
brackets, pulleys, torque cushions and switches, none of which
will affect the following overhaul procedures.
The operations described below are based on bench

overhaul with the compressor removed from the vehicle,
except as noted. They have been prepared in order of
accessibility of the components. When a compressor is
removed from the vehicle for servicing, the amount of PAG
lubricant remaining in the compressor should be drained,
[I}
WITHOUT TORQUE
CUSHION
(ID
TORQUE
CUSHION
1D2-2 HD6/HT6 AIR CONDITIONING COMPRESSOR
[I]
1-
CLUTCH DRIVER
2-
ROTOR BEARING
RETAINER
3-
PULLEY BEARING
4 - PULLEY
5-
CLUTCH COIL
ASSEMBLY
6-
SHAFT SEAL PARTS
7-
PUMP ASSEMBLY
8-
SWITCH 0-RING
9-
SYSTEM CONTROL
SWITCH
O o. . --m
10 - HIGH PRESSURE
RELIEF VALVE
11 -
RETAINER RING SWITCH
12 -
SUCTION/DISCHARGE
PORT SEALING
WASHERS
13 -
SPECIAL 134a SUCTION

PORT
14 -
SPECIAL 134a
DISCHARGE PORT
6..
~}
DII-A....
Af
'/J ~--Eu
00
m_ _ __
Compressor -
Rear Head
As Viewed In DlrecUon of Arrow ''/!>:.'

Fig. 2 Compressor Components - Disassembly
[ill
HD6/HT6 AIR CONDITIONING COMPRESSOR 102-3

measured and recorded. This PAG lubricant should then be
discarded and an equal amount of new PAG lubricant added to
the compressor.
The service compressor is shipped with 240 ml (8 oz.) of
PAG lubricant. This lubricant should be drained and retained
for use as replacement lubricant when service procedures
require addition of new lubricant to compressor. NOTE:
Replace only with GM approved PAG oil P/N 12345923.
Most minor repair procedures may be done on the
vehicle without discharging the system. Major repair
procedures require thatthe system be discharged ofrefrigerant.
METRIC THREAD SIZE INFORMATION

1.
Compressor to mounting bracket bolts.

Front
M 10 x 1.5 - 6H
Rear
M8 x 1.25-6H
2.
Suction-discharge port screw.

MlOx 1.5-6H
3.
Compressor shaft.
M9 x 1.25-6H
4.
Internal hub-clutch drive assembly.

M22x 1.5-6H
UNIT REPAIR
center screw into the remover body to remove the clutch
MINOR COMPRESSOR REPAIR
plate and hub assembly (Fig. 3).
PROCEDURES
THE
FOLLOWING
OPERATIONS
TO
THE
COMPRESSOR CLUTCH PLATE AND HUB, ROTOR
AND BEARING, AND COIL ARE COVERED AS
"MINOR" BECAUSE THEY MAY BE PERFORMED
WITHOUT FIRST RECOVERING REFRIGERANT
FROM THE SYSTEM OR REMOVING THE
COMPRESSOR FROM THE VEHICLE.
The Compressor Shaft Seal assembly, control switches,
and Pressure Relief Valve may also be serviced WITHOUT
REMOVING THE compressor from the vehicle but these
operations are covered later in this section as MAJOR REPAIR
PROCEDURES because the system must be reclaimed,
evacuated and recharged to complete service.
Illustrations used in describing these operations show the

compressor removed from the vehicle only to more clearly
illustrate the various operations.
When servicing the compressor, remove only the parts
that preliminary diagnosis shows are in rieed of service. Refer
to Figures 2 and 5 for information relative to part names and
location.
3.
I +I
1.
2.
3.
NOTICE: Do not drive or pound on the clutch hub or

shaft. Internal damage to compressor may result. The
forcing tip on J 33013-B remover-installer center screw
must be flat or the end of the shaft/axial plate assembly
will be damaged.
Remove the shaft key and retain for reassembly.
Install or Connect
Install the shaft key into the hub key groove (Fig. 4).
Allow the key to project approximately 3.2mm (118")
out of the keyway. The shaft key is curved slightly to
provide an interference fit in the hub key groove.
Be sure the frictional surface of the clutch plate and the
clutch rotor are clean before installing the clutch plate
and hub assembly.
Align the shaft key with the shaft keyway and place the
clutch plate and the hub assembly onto the compressor
shaft.
Removal and installation of external compressor parts,

and disassembly and assembly of internal parts, must be
performed on a clean workbench. The work area, tools and
parts must be kept clean at all times.
COMPRESSOR CLUTCH PLATE AND HUB

ASSEMBLY
I +I Remove or Disconnect
1.
2.
Clamp the holding fixture J 33026 in a vise and attach

compressor to holding fixture with thumb screws
J 33026-1 (Fig. 3).
With center screw forcing tip in place to thrust against
the end of the shaft, thread the Clutch Plate and Hub
Assembly Installer-Remover J 33013-B into the hub.
Hold the body of the remover with a wrench and tum the
DJ J 33013-B HUB AND

CLUTCH DRIVE PLATE
ASM. REMOVER
(I] J 33026-1
THUMB
[]'J J 33026 HOLDING

FIXTURE
IT] CLUTCH PLATE

AND HUB ASM.
SCREW
G60070-1D2-C-R1
Fig. 3 Clutch Plate and Hub Assembly Removal
102-4 HD6/HT6 AIR CONDITIONING COMPRESSOR

NOTICE: If the center screw is threaded fully onto
the end of the compressor shaft. or if the body of the
installer is held and the center screw is rotated, the key
will wedge and will break the clutch hub.
(J] CLUTCH PLATE AND HUB ASSY.

[I) CLUTCH PULLEY ROTOR
(]] SHAFT KEVWAY
(TI SHAFT KEV

G60080-1D2-EK
Fig. 4 Shaft Key, Clutch Plate/Hub Installation
4.
5.
Remove the forcing tip on J 33013-B clutch plate and

hub assembly installer-remover center screw and
reverse the body direction on the center screw, as shown
in Figure 5.
Install the clutch plate and hub installer-remover
J 33013-B with bearing as shown in Figure 8.
The body of the J 33013-B installer-remover should be
backed off sufficiently to allow the center screw to be
threaded onto the end of the compressor shaft.
6.
Hold the center screw with a wrench. Tighten the hex

portion of the installer-remover J 33013-B body to press
the hub onto the shaft. Tighten the body several turns,
remove the installer and check to see that the shaft
key is still in place in the keyway before

installing the clutch plate and hub assembly to
its final position. The air gap between frictional
surfaces of the clutch plate and clutch rotor should be
0.50-0.76mm (.020-.030").
OJ
J 33013-B DRIVE
PLATE INSTALLER
DRIVE PLATE
INSTALLER BEARING
[I)
AIR GAP (0.20"0.30") 0.50-0.76n,m
CLUTCH PLATE
AND HUBASM.
G60090-1D2-C-R1
Fig. 5 Installing Clutch Plate & Hub Assembly
7.
Remove installer J 33013-B, check for proper positioning

of the shaft key (even or slightly above the clutch hub).
8.
Spin the pulley rotor by hand to see that the rotor is not
rubbing the clutch drive plate.
COMPRESSOR CLUTCH ROTOR AND/OR

BEARING
1.
Remove the clutch plate and hub assembly as described

previously.
2.
Remove rotor and bearing assembly retaining ring, using

snap ring pliers J 6083 (Fig. 6).
J 41552 PULLEY ROTOR

AND BEARING PULLER
G60120-1D2-EK-R1
Fig. 8 Removing Pulley Rotor and Bearing Assembly
OJ J 6083
PLIERS
[!] PULLEY
ROTOR
[!) RETAINING
RING
G60060-1D2-C-R1
Fig. 6 Installing-Removing Pulley Rotor & Bearing Assembly

Retaining Ring
(Il
II) J 33023-A PULLEY [I)J 41552 PULLER

ROTOR AND
.BEARING PULLl;R
GUIDE
ENGAGES IN INNER
CIRCLE OF SLOTS
IN ROTOR
4.
Hold the J 41552 puller in place and tighten the puller

screw against the puller guide to remove the pulley rotor
and bearing assembly.
5.
To prevent damage to the pulley rotor during bearing

removal the rotor hub must be properly supported.
PULLEY ROTOR
FACE DOWN'"
II)
J 9398~A BEARING
REMOVER
[!)
J 29886 DRIVER
HANDLE
Fig. 9 Pulley Rotor Bearing Removal
Fig. 7 Installing Pulley Rotor/Bearing Puller Guide
Install pulley rotor and bearing puller guide J 33023-A

to the front head (Fig. 7) and install J 41552 pulley rotor
and bearing puller down into the inner circle of slots in
therotor. Tum the J 41552 puller clockwise in the slots in
the rotor (Fig. 8).
[!)
G60130-1D2-C-R1
G60110-1D2-C-R1
3.
J 41552 (LESS
FORCING SCREW)
INVERTED AND
USED .TO SUPPORT
HUB OF ROTOR
FOR BEARING
REMOVAL. PULLER
TANGS ENGAGED
IN ROTOR .SLOTS.
Remove the forcing screw from J 41552 puller and, with

the puller tangs still engaged in the rotor slots, invert the
assembly onto a solid flat surface or blocks as shown in
Figure 9.
6.
Drive the bearing out of the rotor hub with rotor bearing
remover J 9398-A and J 29886 universal handle (Fig. 9).
NOTICE: It is not necessary to remove the staking in

front of the bearing to remove the bearing, however, it
will be necessary to file away the old stake. metal for
proper clearance for the new bearing to be installed into
the rotor bore or the bearing may be damaged.
OJ
[I]
J 33019-1 BEARING STAKING GUIDE
RUBBER BAND
J 33019-2BEARING STAKING PIN

G60150-1D2-EK-R1
Fig. 11 Staking Bearing In Rotor Hub Bore
(I]
J 29886 DRIVER
HANDLE
(II
J 21352-A
SUPPORT BLOCK
(!]
PULLEY
ROTOR
J 9481-A BEARING
INSTALLER
G60140-1 D2-C-R1
Fig. 1O Installing Pulley Rotor Bearing
E3
1.
Install or Connect
Place the pulley rotor on the J 21352-A support block to
fully support the rotor hub during bearing installation
(Fig. 10).
NOTICE: DO NOT support the rotor by resting the

pulley rim on a flat surface during the bearing
installation or the rotor face will be bent.
2.
3.
4.
Align the new bearing squarely with the hub bore and
using puller and bearing installer J 9481-A with
universal handle J 29886, drive the bearing fully into the
hub (Fig. 10) ..The installer will apply force to the outer
race of the bearing, if used as shown.
Place bearing staking guide J 33019-1 and bearing
staking pin J 33019-2 in the hub bore as shown in
Figure 11. Shift the rotor and bearing assembly on the
J 21352-A support block to give full support of the hub
under the staking pin location. A heavy-duty rubber
band may be used to hold the stake pin in the guide (Fig.
11), and the stake pin should be properly positioned in
the guide after each impact on the pin.
520016-102
Fig. 12 Bearing Staked in Place
5.
With the compressor mounted to the J 33026 holding

fixture, position the rotor and bearing assembly on the
front head (Fig. 13).
6.
Position the J 330.17 pulley, rotor and bearing installer

and J 33023-A puller pilot directly over the inner race of
the bearing (Fig. 13).
7.
Position puller crossbar J 8433-1 on the puller pilqt

J 33023-A and assemble the two J 33026-2 through bolts
and washers through the puller bar slots and thread them
into the J 33026 holding fixture (Fig. 13). The thread of
the through bolts should engage the full thickness of the
holding fixture.
8.
Tighten the center screw in the J 8433-'-l puller crossbar

to force the pulley rotor and bearing assembly onto the
compressor front head. (Fig. 13). Should the
J 33017 pulley rotor and bearing installer slip off direct
in-line contact with the inner.race of the bearing, loosen
the J 8433-1 center forcing screw and realign the
installer and pilot so that the J 33017 installer will
properly clear the front head.
9.
Install rotor and bearing assembly retainer ring, using

10.
Reinstall clutch plate and hub assembly as described

previously.
Using care to preventpersonal injury, strike the staking

pin with a hammer until a metal stake, similar to the
original, is formed down to but not touching the
bearing.
Noisy bearing operation and reduced bearing life may
result if outer bearing .race is deformed while staking,
The stake metal should not contact the outer race of the
bearing. Stake three places 120 degrees apart as shown in
Figure 12.
J 8433-3 SCREW
J 33023-A PULLER PILOT
J 33026-2 THROUGH BOLTS

PULLEY ROTOR
(!]
1-J 84333 SCA EW

2-CLUTCH COi L
ASSEMBLY
J 33017 PULLEY ROTOR AND BEARING INSTALLER

J 8433-1 CROSS BAR
3-J 33024 CLUTCH

COIL INSTALLER
4-J 84331 PULLER

CROSS BAR
G60170-1D2-C-R1
520019-1D2-R1
Fig. 13 Installing Pulley Rotor and Bearing Assembly
Fig. 15 Installing Clutch Coil Assembly
)
COMPRESSOR CLUTCH COIL
I I
1.
Perform Steps 1 through 4 of "Clutch Rotor and/or

Bearings" removal procedure. Mark clutch coil
terminal location on compressor front head.
2.
Install J 33023-A puller pilot on front head of

compressor (Fig. 14). Also install J 8433-1 puller
crossbar with J 33025 puller legs as shown in Figure 14.
3.
Tighten J 8433-3 forcing screw against the puller pilot to

remove the clutch coil.
I I
(i] J 8433-3 SCREW
(!] MARK COIL TERMINAL
LOCATION ON HEAD
(]] CLUTCH COIL .
ASSEMBLY
mJ
.
[!)
Place the clutch coil assembly on the front head with the
terminals positioned at the "marked" location.
2.
Place the J 33024 clutch coil installer over the internal

opening of the clutch coil housing and align installer
with the compressor front head.
3.
Center the J 8433-1 puller crossbar in the countersunk

center hole of the J 33024 clutch coil installer. Install the
J 33026-2 through bolts and washers through the
crossbar slots and thread them into the holding fixture
J 33026 to full fixture thickness (Fig. 15).
4.
Tum the center forcing screw of the J 8433-1 puller

crossbar to force the clutch coil onto the front head. Be
sure clutch coil and J 33024 installer stay "in-line"
during installation.
(i] J 33025 PULLER

LEG
G60180-1 D2-C-R1
Fig. 14 Clutch Coil Assembly Removal
Install or Connect
1.
8433-1 PULLER
CROSS BAR
J 33023-A
PULLER PILOT
1 D2-8 HD6/HT6 AIR CONDITIONING COMPRESSOR
1 - FRONT HEAD SURFACE

1-CLUTCH COIL
3-STAKE IN FRONT
HEAD (3 PLACES)
2-DRIFT PUNCH
2 - STAKE FRONT HEAD 0.28-0.35MM

11
DEEP(0.10-015 )
520020-102
Fig. 16 Staking Clutch Coil to Front Head
5.
520021-102
Fig. 17 Details of Stakes in Front Head for Clutch Coil
When coil is fully seated on the front head, use a l/8 11

diameter drift punch and stake the front head at three
places 120 degrees apart (Fig. 16), to ensure clutch coil
remains in position.
6.
3 - CLUTCH
COIL
HOUSING
Stake size should be only one-half the area of the

punch tip and be only approximately
0.28-0.35mm (.010-.015") deep (Fig. 17).
Install rotor and bearing assembly and the clutch plate

and hub assembly as described previously.
1 - STEEL SHELL
2 - DOUBLE LIP SEAL
(
520033-101
Fig. 18 Compressor Shaft Seal
MAJOR COMPRESSOR REPAIR

PROCEDURES
When replacing the shaft seal assembly (Fig. 18),
pressure relief valve or control switches (Fig. 19), it will be
necessary to recover the refrigerant. Other than clutch repair
procedures, the same holds true for any disassembly of the
compressor.
SUCTION PORT
DISCHARGE PORT
MOUNTING BOSS (3)
[I]coNTROL
SWITCHES
[!] PRESSURE
RELIEF VALVE
A clean workbench covered with a sheet of clean paper,

and a place (clean trays, etc.) for all parts being removed and
replaced is important, as is the use of proper clean service tools.
NOTICE: Any attempt to use makeshift or
inadequate service tools or equipment may result in
damage and/or improper compressor operation.
All parts required for servicing the internal compressor
are protected by a preservative process and packaged in a
manner which will eliminate the necessity of cleaning,
washing or flushing of the parts. The parts can be used in the
internal assembly just as they are removed from the service
package. Seals and protective packaging should be left
intact until just prior to installation.
If the compressor rear head, front head or cylinder and
shaft assembly is to be serviced or replaced, the oil in the
compressor must be drained, measured, recorded and replaced.
520020-1 02-R 1
Fig. 19 Compressor- Rear Head
COMPRESSOR SHAFT SEAL

REPLACEMENT
Seal Leak Detection
A shaft seal should not be changed because of small
amounts of oil found on an adjacent surface but only after
actual refrigerant leakage is found using an approved leak
detector, J 39400 or equivalent.
I+ +I Remove or Disconnect
1.
Recover the refrigerant using J 39500-GM.
2.
Loosen and reposition compressor in mounting brackets,

if necessary.
3.
Remove clutch plate and hub assembly from compressor

as described in minor repairs.
4.
Remove the shaft .seal retainer ring, using snap ring

pliers J 5403 (Fig. 21).
5.
Thoroughly clean inside of. compressor neck area

surrounding the shaft, the exposed portion of the seal, the
retainer ring groove and the shaft itself. Any dirt or
foreign material getting into compressor may cause
damage.
6.
Fully engage the knurled tangs of Seal RemoverInstaller J 23128-A into the recessed portion of the Seal
by turning the handle clockwise. Remove the Seal from
the compressor with a rotary-pulling motion (Fig. 22).
Discard the seal. The handle must be hand- tightened
securely. Do not use a wrench or pliers.
7.
Remove and discard the seal seat 0-ring from the

compressor neck using 0-ring remover J 9553-01,
Figure 20.
8.
Recheck the shaft and inside of the compressor neck for

dirt or foreign material and be sure these areas are
perfectly clean before instaUing new parts.
fiJ
Clean
Thoroughly clean 0-ring seal groove in front head.
NOTICE: Seals should not be re-used. Always use a

new specification service seal. on rebuild (Fig. 18). Be
sure that the seal to be installed is not scratched or
damaged in anyway. Make sure that the seal seat and seal
are free of lint and dirt that could damage the seal surface
or prevent sealing.
I+ +I Install or Conn~ct
[TI
(!]
SEAL
J 23128-A
rn
l!)
J 9553-01
0-RING
J 33011
(!]
J 34614
Fig. 20 Removing and Installing Shaft Seal and 0-Ring
1.
Dip the new seal seat 0-ring in clean 525 viscosity

refrigerant oil and assemble onto 0-ring installer
J 33011, Figure 20.
2.
Insert the 0-ring installer J 33011 into the compressor

neck until the installer "bottoms". Lower the moveable
slide of the 0-ring installer to release the 0-ring into the
seal 0-ring lower groove. (The compressor neck top
groove is for the shaft seal retainer ring.) Rotate the
installer to seat the 0-ring and remove the installer.
3.
Dip the new seal in clean 525 viscosity refrigerant oil and
assemble seal to Seal Installer J 23128-A, by turning
handle clockwise. The stamped steel case side of the
lip seal must be engaged with knurled tangs of installer
so that flared-out side of lip seal is facing and
installed towards the compressor. Install seal protector
J 34614, in the seal lip and place over the compressor
shaft, Figure 22, and push the seal in place with a
rotary motion or place the seal protector J 34014 over
end of compressor shaft, Figure 22, and slide the new
QJ J 5403
SNAP RING
PLIERS
4.
Install the new seal retainer ring with its flat side against
the Seal, using Snap-Ring Pliers J 5403. See Figure 21.
Use the sleeve from 0-ring installer J 33011 to pressi11on
the seal retainer ring so that it snaps into its groove.
5.
To leak test, install compressor leak test fixture

J 39893 on rear head of compressor and connect gage
charging lines and J 39500-GM Refrigerant Recovery
System. Pressurize suction and high-side of compressor
with R-134a Refrigerant. Temporarily install (M9 x 1.25
thread on shaft) nut and, with the compressor in
horizontal position, rotate the compressor shaft in
normal direction of rotation several turns by hand. Leak
test the seal area and correct and leak found. Recover the
refrigerant. Remove shaft nut.
6.
Remove any excess oil resulting from installing the new

seal parts from the shaft and inside the compressor neck.
7.
Install the clutch plate and hub assembly as described in

minor repair procedures.
8.
Reinstall compressor belt and tighten bracket.
9.
Evacuate and charge the refrigerant system.
COMPRESSOR PRESSURE RELIEF VALVE
SEAL SEAT
RETAINER
RING
I I
G60060-1D2-C-R1
Fig. 21 Removing or Installing Shaft Seal

Retaining Ring
1.
Recover the refrigerant using J 39500-GM.
2.
Remove old pressure relief valve (Fig. 19).
I +I
seal onto the shaft with a rotary motion until it stops.
Take care not to dislodge the 0-ring. Be sure the seal
makes good contact with the 0-ring. Disengage the
installer from the seal and remove the installer
J 23128-A and the seal protector J 34614.
NOTICE: Handling and care of seal protector is

important. If seal protector is nicked or the bottom
flared, the new seal may be damaged during installation.
[!)
-[!)
ONE-PIECE SEAL
J 23128-A
lI)
Install or Connect
1.
Clean valve seat area on rear head.
2.
Lubricate 0-ring of new pressure relief valve and 0-ring

assembly with new 525 viscosity refrigerant oil. Install
new valve and torque in place, 9.0 Nm (6.1 lbs.-ft.)
3.
Evacuate and recharge the system.
4.
Leak test system.
J 34614 SHAFT SEAL
PROTECTOR
G60250-1 D2-C-R1

CONTROL SWITCHES
6.
If an external leak is present, perform the necessary

corrective measures and recheck for leaks to make
certain the leak has been corrected.
7.
Recover the refrigerant.
8.
Disconnect both hoses from the test plate J 39893.
9.
Add 90 ml (3 oz.) new PAG lubricant to the compressor

assembly. Rotate the complete compressor assembly
(not the crankshaft or drive plate hub) slowly several
turns to distribute oil to all cylinder and piston areas.
10.
Install a M9 x 1.25 threaded nut on the compressor

crankshaft if the drive plate and clutch assembly are not
installed.
11.
Using a box-end wrench or socket and handle, rotate the

compressor crankshaft or clutch drive plate on the
crankshaft several turns to insure piston assembly to
cylinder wall lubrication.
12.
Using J 39500-GM Refrigerant Recovery System,

connect J 9893 the charging station high-pressure line to
the test plate high-side connector.
13.
Using J 39500-GM Refrigerant Recovery System,

connect the charging station low-pressure line to the low
pressure port of the test plate J 39893. Oil will drain out
of the compressor suction port if the compressor is
positioned with the suction port downward.
14.
Attach the compressor to the J 33026 holding fixture and

mount the compressor in a vise so that the compressor
will be in a horizontal position and the shaft can be
turned with a wrench.
15.
Using a wrench, rotate the compressor crankshaft or

drive plate hub ten complete revolutions at a speed of
approximately one-revolution per second. Turning the
compressor at less than one-revolution per second can
result in a lower pump-up pressure and disqualify a good
pumping compressor.
16.
Observe the reading on high-pressure gage at the

completion of the tenth revolution of the compressor.
The pressure reading for a good pumping compressor
should be 690 kPa (100 psi) or above. A pressure reading
of less than 620 kPa (90 psi) would indicate one or more
suction and/or discharge valves leaking an internal leak,
or an inoperative valve, and the refrigerant must be
recovered and the compressor disassembled and
checked for cause of leak. Repair as needed, reassemble
and repeat the pump-up test. Externally leak test.
17.
When the pressure pump-up test is completed, recover

the refrigerant from the high-side and remove the test
plate J 39893.
18.
Tilt the compressor so that the compressor suction and

discharge ports are down. Drain the PAG lubricant from
the compressor.
19.
Allow the compressor to drain for 10 minutes, then refill

with the proper amount of PAG lubricant, per oil balance
procedure in section lB of the service manual. The PAG
lubricant may be poured into the suction port. If further
assembly .or: processing is required, a shipping plate or
test plate J 39893 should be installed to keep out air, dirt
and moisture until the compressor is installed.
Figure 20
E3
1.
Recover the refrigerant.
2.
Disconnect the electrical connector from the switch in

the rear head of compressor.
3.
Remove the switch retaining ring using J 5403 internal

snap ring pliers.
4.
5.
Remove the switch from the compressor.

Remove old 0-ring seal from the switch cavity using
J 9553-01 0-ring removal tool.

If existing control switch is reinstalled in the compressor,
a new 0-ring seal must be used and preferably a new retainer
ring should also be used. A new switch kit has the 0-ring and
retainer ring included.
E3
Install or Connect
1.
Check switch cavity and 0-ring groove in the rear head

for dirt or foreign material and clean as necessary. Install
a new 0-ring coated with . clean refrigerant oil into
groove in switch cavity.
2.
Lubricate the control switch housing with clean

refrigerant oil and carefully insert switch into switch
cavity until switch bottoms in cavity.
3.
Using J 9533-1 snap ring pliers install switch retaining

ring with high point of curved sides adjacent to switch
housing. Be sure retaining ring is properly seated in
switch cavity retaining groove. Leak test according to
bench test procedure.
COMPRESSOR LEAK TESTING

(EXTERNAL AND INTERNAL)
Bench-Check Procedure
1.
Install test plate J 39893 on rear head of compressor.
2.
Using J 39500-GM Refrigerant Recovery System, attach

center hose of manifold gage set on charging ~tation to a
refrigerant drum standing in an upright drum.
3.
Connect charging station high and low pressure lines to

corresponding fittings on test plate J 39893. Suction port
(low-side) of compressor has large internal opening.
Discharge port (high-side) has smaller internal opening
into compressor and deeper recess.
4.
Open low pressure control, high pressure control and

refrigerant control on charging station . to allow
refrigerant vapor to flow into compressor.
5.
Using a leak detector, check for leaks at pressure relief

valve, rear head switch location, compressor front and
rear head seals, center cylinder seal, through bolt head
gaskets and compressor shaft seal. After checking, shut
off low pressure control and high-pressure control on
charging station.
102 ... 12 HD6/HT6 AIR CONDITIONING COMPRESSOR
DJ
@l
1-
13- J 33013
HUB & DRIVE PLATE REMOVER

& INSTALLER
14- J 39500-GM
R134a NC REFRIGERANT RECOVERY,

RECYCLING AND RECHARGING
SYSTEM (ACR4)
15- J 33017
PULLEY & BEARING ASSEMBLY

INSTALLER
16- J 33019
BEARING STAKING TOOL
17- J 41552
PULLEY PULLER
18- J 34614
SHAFT SEAL PROTECTOR
"O" RING REMOVER
19- J 33023
PULLER PILOT
PRESSURE TESTING CONNECTOR
20- J 33024
CLUTCH COIL INSTALLER ADAPTER
SEAL SEAT REMOVER &

INSTALLER
21 -
CLUTCH COIL PULLER LEGS
J 5403
SNAP RING PLIERS
2-J6083
SNAP RING PLIERS
3 - J 29886
DRIVER HANDLE
4 - J 8433-1
PULLER BAR
5 - J 8433-3
FORCING SCREW
6-
J 9398-A
BEARING REMOVER
7-
J 9481-A
BEARING INSTALLER
8-
J 9553-01
9-
J 39893
10- J 23128-A
J 33025
22- J 34992
COMPRESSOR HOLDING FIXTU~E
11 -
J 21352-A
SUPPORT BLOCK
23- J 39400
LEAK DETECTOR
12 -
J 33011
"O" RING INSTALLER
24- J 39037
HIGH-SIDE CHARGE VALVE SOCKET
Fig. 23 Compressor Overhaul -
Special Tools
V5 AIR .CONDITIONING COMPRESSOR 103-1
SECTION 103
VS AIR CONDITIONING
COMPRESSOR SERVICE OR
UNIT REPAIR R-134a
CAUTION: Thi~ vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under ON-VEHICLE SERVICE and the SIR Component and Wiring Location
view in Section 9J before performing service on or around SIR components or wiring. Failure to
follow CAUTIONS could result in possible air. bag deployment, personal injury, or. otherwise
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a
fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not
available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread
locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above
conditions are not followed, parts or system damage could result.
CONTENTS
General Description ........................... 1D3-1

V5 Compressor - Theory of Operation .......... 1D3-1
Metric Thread Size Information ............... 1D3-2
Unit Repair ................ , ................. 1D3-2
Minor V5 Compressor Repair Procedures ........ 1D3-2
Compressor Clutch Plate and
Hub Assembly .................... , ..... 1D3-2
Compressor Clutch Rotor and/or Bearing ...... 1D3-5
Compressor Clutch Coil ................... '1D3-7
Major VS Compressor Repair Procedures ........ 1D3-8

Compressor Shaft Seal Replacement ......... 1D3-9
Seal Leak Detection .................... 1D3-9
Compressor Pressure Relief Valve .......... 1D3-10
Compressor Control Switches .............. 1D3-10
Compressor Control Valve Assembly ........ 1D3-11
Compressor Leak Testing (External) ......... 1D3-12
Compressor- Special Tools ............... 1D3-13
GENERAL DESCRIPTION
. Vehicles using the VS compressor (Fig. 1) may have
differences between installations in the mounting .brackets,
drive systems, pulleys, connections, and system capacities.
Basic overhaul procedures are similar between compressors
used on different vehicles.
Fig. 1 V5 Compressor, V-Groove Pulley
When servicing the compressor, keep dirt and foreign

material from getting on or into the compressor parts and
system. Clean tools and a clean work area are important for
proper service. The compressor connections and the outside of
the compressor should be cleaned before any "on-vehicle"
repairs, or before removal of the compressor. The parts must be
kept clean at all times and any parts to be reassembled should
be cleaned with naphtha, stoddard solvent, kerosene or
equivalent solvent and dried with dry air. Use only lint free
cloths to wipe parts.
The operations described below are based on bench
overhaul with the compressor removed from the car, except as
noted. They have been prepared in order of accessibility of the
components.
When a compressor is removed from the car for
servicing, the amount of PAG Lubricant remaining in the
compressor should be drained, measured and recorded. This
PAG Lubricant should then be discarded and an equal amount
of new PAG Lubricant added to the compressor.
NOTICE: Upto 120 ml (4 oz.) of PAG Lubricant can
collect in the crankcase; Therefore, it is important when
replacing a compressor that the PAG Lubricant in the old
compressor crankcase be drained thru the drain plug and
measured (discard after recording amount).
All replacement compressors will be shipped with 270 ml
(9 oz.) of PAG Lubricant in the crankcase. This lubricant must be
drained and retained. Then replace the lubricant in the same
amount as previously recorded from the old compressor. NOTE:
Replace only with GM approved PAG Lubricant PIN 12345923.
V5 COMPRESSOR - THEORY OF
OPERATION
The V5 is a variable displacement compressor that can
match the automotive air conditioning demand under all
conditions without cycling. The basic compressor mechanism
is a variable angle wobble-plate with five axially oriented
103-2 VS AIR CONDITIONING COMPRESSOR

cylinders. The center of control of the compressor
displacement is a bellows actuated control valve located in the
rear head of the compressor that senses compressor suction
pressure. The wobble-plate angle and compressor
displacement are controlled by the crankcase-suction pressure
differential. When the A/C capacity demand is high, the
suction pressure will be above the control point; the valve will
maintain a bleed from crankcase to suction: no
crankcase-suction pressure differential; and the compressor
will have maximum displacement. When the A/C capacity
demand is lower and the suction pressure reaches the control
point, the valve will bleed discharge gas into the crankcase and
close off a passage from the crankcase to the suction plenum.
The angle of the wobble-plate is controlled by a force balance
on the five pistons. A slight elevation of the crankcase-suction
pressure differential creates a total force on the pistons
resulting in a movement about the wobble-plate pivot pin that
reduces the plate angle.
The compressor has a unique lubrication system. The

crankcase-suction bleed is routed through the rotating
wobble-plate for lubrication of the wobble-plate bearing. The
rotation acts as an oil separator. which removes some of the oil
from the crankcase-suction bleed, rerouting it to the crankcase
METRIC THREAD SIZE INFORMATION

1.
2.
Compressor to mounting bracket bolts.

Front
MlO x 1.5 - 6H
Rear
M8 x 1.25 - 6H
MlO x 1.25 - 6H
Suc:tion-discharge port screw.
MlOx 1.5-6H
3.
Compressor shaft.
4.
M9 x 1.25-6H
Internal hub-clutch drive assembly.
M22 x 1.5-6H
UNIT REPAIR
MINOR PROCEDURES
COMPRESSOR REPAIR
Illustrations used in the following operations show the
compressor removed from the car for easier viewing. Refer to
Air Conditioning (Section lB) for compressor removal where
necessary.
When servicing the compressor, remove only the parts
that preliminary diagnosis show in need of service.
Removal and installation of external compressor parts,
and disassembly and assembly of internal parts, must be
performed on a clean workbench. The work area, tools and
parts must be kept clean at all times.
COMPRESSOR CLUTCH PLATE AND HUB

ASSEMBLY
1.
2.
3.
4.
Clamp the holding fixture J 34992 in a vise and attach

compressor to holding fixture with thumb screws
J 34992-1 (Fig. 4).
Keep the clutch hub and drive plate assembly from
turning by using the clutch hub holding tool
J 33027-A. Remove the shaft nut using shaft nut socket
J 33022 (Fig. 4).
Thread the Clutch Plate and Hub Assembly Remover
J 33013-B into the hub. Hold the body of the remover
with a wrench and tum the center screw into the remover
body to remove the clutch plate and hub assembly
(Fig. 5).
Remove the shaft key and retain for reassembly.
I +I Install or Connect
1.
2.
3.
NOTICE: Do not drive or pound on the clutch hub or

shaft. Internal damage to compressor may result.
1 - CLUTCH COIL TERMINALS

2 - HIGH PRESSURE RELIEF VALVE
4.
3 - HIGH SIDE LOW PRESSURE SWITCH (If equipped)

4 - HIGH SIDE CUT-OFF SWITCH (If equipped)
5 - COMPRESSOR CONTROL VALVE
Fig. 2 V5 Compressor Rear Head Details
Install the shaft key into the hub key groove (Fig. 6).
Allow the key to project approximately 3.2 mm (1/8")
out of the keyway. The shaft key is curved slightly to
provide an interference fit in the hub key groove.
Be sure the frictional surface of the clutch plate and the
clutch rotor are clean before installing the clutch plate
and hub assembly.
Align the shaft key with the shaft keyway and place the
clutch plate an.d the hub assembly onto the compressor
shaft
5.
Remove the J 33013-B remover-installer center screw

and reverse the body direction on the center screw as
shown in Figure 7.
Install the clutch plate and hub installer J 33013-B with
bearing as shown in Figure 7.
The body of the J 33013-B installer should be backed off
sufficiently to allow the center screw to be threaded onto
the end of the compressor shaft.
VS AIR CONDITIONING COMPRESSOR 1D3-3
1-
DUST COVER &

SCREWS (SPECIAL
APPLICATIONS)
2-SHAFTNUT
3-
CLUTCH HUB KEY
4 - CLUTCH DRIVER
..,.___[I]
5-
DUST SEAL (SPECIAL

APPLICATIONS)
<111,111(111---(2]
6-
PULLEY BEARING
RETAINER
7-
PULLEY BEARING
8 - WEEPAGE SEAL - FELT

WASHER (SPECIAL
APPLICATIONS)
9-
PULLEY ROTOR
10- CLUTCHCOILASM.
11 - SHAFT SEAL PARTS
12-SERVICE
COMPRESSOR
WITHOUT CLUTCH
~~~
0
IT]
v f)
[2J
@]
''A"
13 - COMPRESSOR
CONTROL.VALVE ASM.
14 -
RETAINER RING
CONTROL VALVE
15 -
HIGH PRESSURE
RELIEFVALVE
16 -
RETAINER RING
SWITCH
17 -
SYSTEM CONTROL
SWITCHES
1B- SUCTION PORT

SCREEN
19 -
0-RING SWITCH
20 -
SPECIAL 134A
SUCTION PORT
21 -
SPECIAL 134A
DISCHARGE PORT
COMPRESSOR - REAR HEAD
AS VIEWED IN DIRECTION
OF ARROW ''Pi'
Fig. 3 Compressor Components - Disassembled View
1 D3.;..4 VS AIR CONDITIONING COMPRESSOR
1 - J 34992 COMPRESSOR HOLDING FIXTURE

2 - CLUTCH PLATE AND HUB ASM.
3 - J 33022NUT SOCKET
1 - CLUTCH PLATE AND HUB
4 - J 33027-A CLUTCH HUB HOLDING TOOL
2 - SHAFT KEY
5 - J 34992 THUMB SCREW

Fig. 4 Removing Shaft Nut
3 - SHAFT KEYWAY
4 - CLUTCH PULLEY ROTOR
Fig. 6 Shaft Key, Clutch Plate/Hub Installation
1 - CLUTCH PLATE AND HUB ASSEMBLY

2 - J 33013-8 HUB AND CLUTCH DRIVE
PLATE ASSEMBLY REMOVER
1 - CLUTCH PLATE AND HUB ASSEMBLY

2 - J 33013-8 DRIVE PLATE INSTALLER
3 - J 34992-1 THUMB SCREW
3 - DRIVE PLATE INSTALLER BEARING
4 - J 34992 HOLDING FIXTURE
4 - AIR GAP (.015-.020") 0.40-0.50mm
Fig. 5 Clutch Plate and Hub Assembly Removal
Fig. 7 Installing Clutch Plate & Hub Assembly
VS AIR CONDITIONING COMPRESSOR 103-5
1 - J 8083 PLIERS
2 - PULLEY ROTOR
3 - RETAINING RING
Fig. 10 Removing Pulley Rotor and Bearing Assembly
Fig. 8 Removing Pulley Rotor & Bearing Assembly

Retaining Ring
6.
7.
8.
1 - J 33020 PULLER ENGAGES IN INNER

CIRCLE OF SLOTS IN ROTOR
2 - J 33023-A PULLEY ROTOR AND
BEARING PULLER GUIDE
Fig. 9 Installing Pulley Rotor/Bearing Puller Guide
Hold the center screw with a wrench. Tighten the hex

portion of the installer J 33013-B body to press the hub
onto the shaft. Tighten the body several turns, remove
the installer and check to see that the shaft key is still in
place in the keyway before installing the clutch plate
and hub assembly to its final position. The air gap
between frictional surfaces of the clutch plate and clutch
rotor should be 0.40-0.50mm (0.015-0.020").
If the center screw is threaded fully onto the end of

the compressor shaft, or if the body of the installer
is held and the center screw is rotated, the key will
assume the position as shown in Figure 6 and will
break the clutch hub.
Remove installer J 33013-B, check for proper
positioning of the shaft key (even or slightly above the
clutch hub). Install the shaft nut. Hold the clutch plate
and hub assembly with clutch hub holding tool
J 33027-A and using shaft nut socket J 33022, tighten the
nut against the crankshaft shoulder to 16.5 Nm
(12 lbs.ft.) torque, using a 17.5 Nm (12.5 lbs.ft.) torque
wrench.
Spin the pulley rotor by hand to see that the rotor is not
rubbing the clutch drive plate.
COMPRESSOR CLUTCH ROTOR AND/OR

BEARING
I +I
1.
2.
Remove the clutch plate and hub assembly as described
previously.
Remove rotor and bearing assembly retaining ring, using
1 - J 33020 (LESS
FORCING SCREW)
INVERTED AND USED
TO SUPPORT HUB OF
ROTOR FOR BEARING
REMOVAL, PULLER
TANGS ENGAGED IN
ROTOR SLOTS
2 - PULLEY ROTOR
"FACE DOWN"
3 - J 8398-A BEARING
REMOVER
1 - J 8092 DRIVER
HANDLE
4 - J 8092 DRIVER
HANDLE
2 - J 21352 SUPPORT
BLOCK
Fig. 12 Installing Pulley Rotor Bearing
Fig. 11 Pulley Rotor Bearing Removal
3.
4.
5.
Install pulley rotor and bearing puller guide J 33023-A

to the front head (Fig. 9) and install J 33020 pulley rotor
and bearing puller down into the inner circle of slots in
the rotor. Tum the J 33020 puller clockwise in the slots to
engage the puller tangs with the segments between the
slots in the rotor (Fig. 10).
Hold the J 33020 puller in place and tighten the puller
screw against the puller guide to remove the pulley rotor
and bearing assembly.
NOTICE: Do Not support the rotor by resting the

pulley rim on a flat surface during the bearing
installation or the rotor face will be bent.
2.
Align the new bearing squarely with the hub bore and
using puller and bearing installer J 9481-A with
universal handle J 29886, drive the bearing fully into the
hub (Fig. 12). The installer will apply force to the outer
race of the bearing if used as shown.
3.
Place bearing staking guide J 33019-1 and bearing

staking pin J 33019 in the hub bore as shown in Figure 13.
Shift the rotor and bearing assembly on the
J 21352-A support block to give full support of the hub
under the staking pin location. A heavy-duty rubber band
may be used to hold the stake pin in the guide (Fig. 13),
and the stake pin should be properly positioned in the
guide after each impact on the pin.
4.
Using care to prevent personal injury, strike the staking

pin with a hammer until a metal stake, similar to the
original, is formed down to but not touching the
bearing.
To prevent damage to the pulley rotor during bearing

removal the rotor hub must be properly supported.
Remove the forcing screw from J 33020 puller and, with
the puller tangs still engaged in the rotor slots, invert the
assembly onto a solid flat surface or blocks as shown in
Figute 11.
6.
Drive the bearing out of the rotor hub with rotor bearing
remover J 9398~A and J 29886 universal handle
(Fig. 11).
NOTICE: It is not necessary to remove the staking in

front of the bearing to remove the bearing, however, it
will be necessary to file away the old stake metal for
proper clearance for the new bearing to be installed into
the rotor bore or the bearing may be damaged.
E3
1.
The stake metal should not contact the outer face of the
bearing.to prevent the possibility of distorting the outer
race. Stake three (3) places 120 apart as shown in
Figure 14.
5.
With the compressor mounted to the J 34992 holding

fixture, position the rotor and bearing assembly on the
front head (Fig. 15).
6.
Position the J 33017 pulley rotor and bearing installer

and J 33023-A puller pilot directly over the inner race of
the bearing (Fig. 15).
Install or Connect
Place the pulley rotor on the J 21352-A support block to
fully support the rotor hub during bearing installation
(Fig. 12).
3 - PULLEY ROTOR
4 - J 9481-A BEARING
INSTALLER
V5AIR CONDITIONING COMPRESSOR 103-7

1 - J 33019
BEARING
STAKING
GUIDE
2- RUBBER
BAND
3- J 33019
BEARING
STAKING
PIN
Fig. 13 Staking Bearing In Rotor Hub Bore
STAKE THREE
LOCATIONS
120 APART
=::::~~~:-:--7 (3)
1 - J 8433-3 SCREW
2 - J 8433-1 PULLER CROSS BAR
3 - J 33025 PULLER LEG
4 - J 33023-A PULLER PILOT
5 - CLUTCH COIL ASSEMBLY
6 - MARK COIL TERMINAL LOCATION

ON HEAD
Fig. 16 Clutch Coil Assembly Removal
Fig. 14 Bearing Staked In Place
7.
Position puller crossbar J 8433-1 on the puller pilot

J 33023-A and assemble the two J 34992-2 through bolts
and washers through the puller bar slots and thread them
into the J 34992 holding fixture (Fig. 15). The thread of
the through bolts should engage the full thickness of the
holding fixture.
8.
Tighten the center screw in the J 8433-1 puller crossbar

to force the pulley rotor and bearing assembly onto the
compressor front head (Fig. 15). Should the J 33017
pulley rotor and bearing installer slip off direct in-line
contact with the inner face of the bearing, loosen the
J 8433-3 center forcing screw and realign the installer
and pilot so that the J 33017 installer will properly clear
the front head.
9.
Install rotor and bearing assembly retainer ring, using

10.
Reinstall clutch plate and hub assembly as described

previously.
COMPRESSOR CLUTCH COil

1 - PULLEY ROTOR
2 - J 33017 PULLEY ROTOR
3 - J 8433-1 PULLER BAR
I+ I
1.
Perform Steps 1 through 4 of "Clutch Rotor and/or

Bearings" removal procedure. Mark clutch coil terminal
location on compressor front head.
2.
Install J 33023-A puller pilot on front head of

compressor (Fig. 16). Also install J 8433-1 puller
crossbar with J 33025 puller legs as shown in Figure 16.
3.
Tighten J 8433-3 forcing screw against the puller pilot to

remove the clutch coil.
4 - J 8433-3 FORCING SCREW

5 - J 33023-A PULLER PILOT
6 - J 34992 COMPRESSOR HOLDING FIXTURE
Fig. 15 Installing Pulley Rotor and Bearing Assembly
MAJOR COMPRESSOR REPAIR

PROCEDURES
When replacing the shaft seal assembly (Fig. 20),
pressure relief valve or rear head mounted pressure switches
(Fig. 2), even if the compressor remains on the vehicle during
the operation, it will be necessary to discharge the systen of
refrigerant.
Other than clutch repair procedures, the same holds true
for any disassembly of the compressor.
A clean workbench covered with a sheet of clean paper,
and a place (clean trays, etc.) for all parts being removed and
replaced is important, as is the use of the proper, clean service
tools.
NOTICE: Any attempt to use makeshift or
inadequate service tools or equipment may result in
damage and/or improper compressor operation.
1234-
J 8433-3 SCREW
J 8433 PULLER CROSS BAR
J 33024 CLUTCH COIL INSTALLER
CLUTCH COIL ASSEMBLY
Fig. 17 Installing Clutch Coil Assembly
E3
Place the clutch coil assembly on the front head with the
terminals positioned at the "marked" location.
2.
Place the J 33024 clutch coil installer over the internal

opening of the clutch coil housing and align installer
with the compressor front head.
3.
Center the J 8433-1 puller crossbar in the countersunk

center hole of the J 33024 clutch coil installer. Install the
J 34992-2 through bolts and washers through the
crossbar slots and thread them, into the holding fixture
J 34992 to full fixture thickness (Fig. 17).
4.
Tum the center forcing screw of the J 8433-1 puller

crossbar to force the clutch coil onto the front head. Be
sure clutch coil and J 33024 installer stay "in-line"
5.
When coil is fully seated on the front head, use a l/8 11

diameter drift punch and stake the front head at three (3)
places 120 apart (Fig. 18), to ensure clutch coil
remaining in position.
7.
If the compressor rear head, front head or cylinder and

shaft assembly is to be serviced or replaced, the oil in the
compressor must be drained, measured, recorded and replaced.
Install or Connect
1.
6.
All parts required for servicing the internal compressor

are protected by a preservative process and packaged in a
manner which will eliminate the necessity of cleating,
washing or flushing of the parts. The parts can be used it the
internal assembly just as they are removed from the service
package. Seals and protective packaging should be left
intact until just prior to installation.
Stake size should be only one half the area of the

punch tip and only approximately 0.28-0.35mm
(.010--.015") deep (Fig. 19).
Install rotor and bearing assembly and the clutch plate

and hub assembly according as described previously.
Install shaft nut.
1 - CLUTCH COIL
2 - DRIFT PUNCH
3 - STAKE IN FRONT
HEAD (3 PLACES)
Fig. 18 Staking Clutch Coil To Front Head
V5 AIR CONDITIONING COMPRESSOR 103-9

COMPRESSOR SHAFT SEAL
REPLACEMENT
6.
Fully engage the knurled tangs of seal remover-installer

J 23128-A into the recessed portion of the seal by turning
the handle clockwise. Remove the seal from the
compressor with a rotary-pulling motion (Fig. 24).
Discard the seal. The handle should be hand-tightened
securely. Do not use a wrench or pliers.
7.
Remove and discard the seal 0-ring from the compressor

neck using 0-ring remover J 9553-01 (Fig. 22).
8.
Recheck the shaft and inside of the compressor neck for

dirt or foreign material and be sure these areas are
perfectly clean before installing new parts.
Seal Leak Detection

A shaft seal should not be. changed because of small
amounts of oil found on an adjacent surface. The seal is
designed to leak some oil for lubrication purposes. A shaft seal
should be changed only when a large amount of sprayed oil is
found, and only after actual refrigerant leakage is found by
using an approved leak detector, J 39400 or equivalent.
fiJ
1.
Clean
Thoroughly clean seal 0-ring groove in front head.
NOTICE: Seals should not be re-used. Always use a

new specification service seal kit (Fig. 20). Be sure that
the seal to be installed is not scratched or damaged in any
way. Make sure that the seal is free of lint and dirt that
could damage the seal surface or prevent sealing.
1 - FRONT HEAD SURFACE
3 - CLUTCH
COIL
2 - STAKE FRONT HEAD
0.28-0.35MM DEEP (.010-.015")
HOUSING
1.
Dip the new seal 0-ring in clean 525 viscosity refrigerant

oil and assemble onto 0-ring installer J 33011. (Fig. 23)
"New".
2.
Insert the 0-ring installer J 33011 into the compressor

neck until the installer "bottoms." Lower the moveable
slide of the 0-ring installer to release the 0-ring into the
seal 0-ring lower groove. (The compressor neck top
groove is for the shaft seal retainer ring.) Rotate the
installer to seat the 0-ring and remove the installer.
3.
Dip the new seal in clean 525 viscosity refrigerant oil and
assemble seal to Seal Installer J 23128-A, by turning
handle clockwise. The stamped steel case side of the
lip seal must be engaged with knurled tangs of installer
so that flared-out side of lip seal is facing and installed
towards the compressor. Install shaft seal protector
J 34614 on the lip seal, Figure 25. Place the seal protector
J 34614 over end of compressor shaft, and slide the new
seal onto the shaft with a rotary motion until it stops.
Take care not to dislodge the 0-ring. Be sure the seal
makes good contact with the 0-ring. Disengage the
installer from the seal and remove the installer
J 23128-A and theshaft seal protector J 34614.
Fig. 19 Details of Stakes In Front Head for Clutch Coil
1 - STEEL SHELL
2 - DOUBLE LIP SEAL
Fig. 20 Compressor Shaft Seal
I+ I Remove or Disconnect
1.
Recover refrigerant using J 39500-GM.
2.
Loosen and reposition compressor in mounting brackets.
3.
Remove clutch plate and hub assembly from compressor

as described in minor repairs.
4.
Remove the shaft seal retainer ring, using snap ring

pliers J 5403 (Fig. 21).
5.
Thoroughly clean inside of compressor neck area

surrounding the shaft, the exposed portion of the seal, the
shaft itself and 0-ring groove. Any dirt or foreign
material getting into compressor may cause damage.
NOTICE: Handling and care of seal protector is

important. If seal protector is nicked or the bottom
flared, the new seal may be damaged during installation.
4.
Install the new seal retainer ring with its flat side against
the seal, using snap-ring pliers J 5403 (Fig. 21). Use the
sleeve from 0-ring installer J 33011 to press in on the
seal retainer ring so that it snaps into its groove.
5.
To leak test, install compressor leak test fixture

J 39893 on rear head of compressor and connect gage
charging lines using J 39500-GM Refrigerant Recovery
System. Pressurize suction and high-side of compressor
with R134a Refrigerant. Temporarily install the shaft nut
and, with the compressor in horizontal position. rotate
the compressor shaft in normal direction of rotation
several turns by hand. Leak test the seal area and correct
any leak found. Recover refrigerant. Remove shaft nut.
1.
Clean valve seat area on rear head.
2.
Lubricate 0-ring of new pressure relief valve and 0-ring

assembly with new 525 viscosity refrigerant oil. Install
new valve and torque in place, 9.0 Nm (6.1 lbs.ft.).
3.
Evacuate and recharge. the system.
4.
Leak test system.
COMPRESSOR CONTROL SWITCHES
I+ I Remove or Disconnect
1 - J 5403 SNAP RING PLIERS
1.
Recover refrigerant using J 39500-GM
2.
Disconnect the electrical connector from the switch in

the rear head of the compressor (Fig. 3).
3.
Remove the switch retaining ring (Fig. 3), using J 5403

internal snap ring pliers.
4.
Remove switch from compressor.
5.
Remove old 0-ring seal from switch cavity using

J 9553-01 0-ring removal tool or equivalent.
2 - SEAL RETAINER RING
Retaining Ring
6.
Remove any excess oil resulting from installing the new

seal parts from the shaft and inside the compressor neck.
7.
Install the clutch plate and hub.assembly as described in

minor repair procedures.
8.
Reinstall the compressor, belt and tighten bracket.
9.
Evacuate and charge the refrigerant system using

J 39500-GM.
COMPRESSOR PRESSURE RELIEF VALVE
E:3
1.
Check switch cavity and 0-ring groove in the rear head

for dirt or foreign material and clean as necessary. Install
new 0-ring coated with clean 525 viscosity refrigerant
oil into groove in switch cavity.
2.
Lubricate the switch housing with clean 525 viscosity

refrigerant oil and carefully insert switch into switch
cavity until switch "bottoms" in cavity.
Using J 5403 snap ring pliers, install switch retaining
ring with high point of curved sides adjacent to the
switch housing. Be sure retaining ring is properly seated
in the switch cavity retainer ring groove.
Leak test referring to "Compressor Leak Testing" in this
section.
3.
1. .. Recover refrigerant using J 39500-GM.

2.
NOTICE: If existing switch will be reinstalled in

compressor, a new 0-ring seal must be used and
preferably a new retainer ring should also be used. A new
switch kit has the 0-ring and retainer ring included.
Remove old pressure relief valve (Fig. 2).
4.
5.
1 - SHAFT SEAL O~RING
1 - J 23128-A SEAL REMOVER

AND INSTALLER
2 - J 9553-01 0-RING REMOVER
2- SEAL
Fig. 24 Removing Shaft Seal
Fig. 22 Removing Shaft Seal 0-Ring
)
COMPRESSOR CONTROL VALVE
ASSEMBLY
I I
1.
Recover refrigerant using J 39500-GM.
2.
Remove control valve retaining ring using J 5403

internal snap ring pliers.
3.
Remove control valve assembly.
1 - 0-RING
2 - J 33011
Fig. 23 Installing Shaft Seal 0-Ring
1.
When reassembling control valve, coat 0-rings with 525

viscosity refrigeration oil and push in place with thumb
pressure.
2.
Using J 5403 snap ring pliers, install valve retaining ring

with high point of curved sides against valve housing. Be
sure retaining ring is properly seated in ring groove.
3.
4.
Leak test referring to "Compressor Leak Testing" in this

section.

4.
If an external leak is present, perform the necessary

corrective measures and recheck for leaks to make
certain the leak has been corrected.
5.
Recover refrigerant
6.
Disconnect hoses from the test plate J 39893 and remove

test plate.
J 34614 SEAL PROTECTOR

Fig. 25 Lip Seal Installed on Seal Protector
COMPRESSOR LEAK TESTING

(EXTERNAL)
I.
2.
3.
With sealing washers in place, install test plate 139893

on rear head of compressor and connect gage charging
lines and J 39500-GM.
Pressurize suction and high-side of compressor with
Rl34a refrigerant. With the compressor in horizontal
position, rotate the compressor shaft in normal direction
of rotation several turns by hand.
Using leak detector J 39400, check for leaks at pressure
relief valve, rear head switch location, compressor front
and rear head seals, through bolt head gaskets and
compressor shaft seal.
1 - LEAK TEST
ADAPTER
J-39893
2 - HIGH
PRESSURE
CUT-OFF
SWITCH
Fig. 26 Compressor Leak Testing Fixture
~O
G~
J 5403
SNAP RING PLIERS
2 - J6083
1-
SNAP RING PLIERS
3-J8092
DRIVER HANDLE
4 - J 8433-1
PULLER BAR
5 - J 8433-3
15 -
J 33017
PULLEY & BEARING ASSEMBLY

INSTALLER
16- J 39500-GM
R134a NC REFRIGERANT RECOVERY,

RECYCLING AND RECHARGING
SYSTEM (ACR4)
FORCING SCREW
17- J 33019
BEARING STAKING TOOL
6 - J 9393-A
SEAL SEAT INSTALLER
18- J 33020 -
PULLEY PULLER
7 - J 9398-A
BEARING REMOVER
19- J 34614
SHAFT SEAL PROTECTOR
8 - J 9481-A
BEARING INSTALLER
20- J 33022
SHAFT NUT SOCKET
9 - J 9553-01
0-RING REMOVER
21 -
PULLER PILOT
10- J 39893
PRESSURE TESTING CONNECTOR
22- J 33024
CLUTCH COIL INSTALLER
11 -
SEAL SEAT INSTALLER &

REMOVER
J 23128-A
12- J 21352-A
SUPPORT BLOCK
13- J 33011
0-RING INSTALLER
14- J 33013-8
HUB & DRIVE PLATE REMOVER

AND INSTALLER
J 33023-A
23- J 33025
CLUTCH COIL PULLER LEGS
24- J 34992
COMPRESSOR HOLDING FIXTURE
25 -
CLUTCH HUB HOLDING TOOL
J 33027-A
26- J 39400
LEAK DETECTOR
27- J 39037
HIGH-SIDE CHARGE VALVE SOCKET
Fig. 27 VS Compressor -
Special Tools
103-14 V5 AIR CONDITIONING COMPRESSOR
BLANK
STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3-1
SECTION 3
STEERING, SUSPENSION,
WHEELS
RES AND
CONTENTS
Steering, Suspension, Tires and Wheels
Diagnosis ..................................................... Section 3
Wheel Alignment ......................................... Section 3A
Power Steering Gear and Pump
On-Vehicle Service .................................. Section 3B
Power Steering Gear Unit Repair ........... Section 3B1A
Power Steering Pump Unit Repair .......... Section 3B1B
Front Suspension .......................................... Section 3C
Rear Suspension ........................................... Section 3D

Tires and Wheels .......................................... Section 3E
Steering Wheel and Column
On-Vehicle Service ................................... Section 3F
(SIR) Tilt Steering Column
Unit Repair .......................................... Section 3F5B
SECTION 3
STEERING, SUSPENSION, RES AND

WHEELS DIAGN SIS
CAUTION: This vehicle -is equipped with Supplemental . Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
otherwise unneeded SIR system repairs.
systems.
CONTENTS
General Description ................................................. 3-2
General Diagnosis ................................................... 3-2
Power Steering Gear Diagnosis ................ ;............. 3-5
Power Steering Pump Diagnosis ............................ 3-6
Steering Column. Diagnosis .................................... 3-7
Lock System ........................................................ 3-7
Steering Colunnn .................................................. 3-9
Turn Signal Switch .................... :........................ 3-10
Ignition Switch ............ ,............................ u, .......... 3-12
.Key Reminder ............. ::.............. ;....................... 3-13
Column-Mounted Dimmer Switch ..................... 3-15
Pivot and Switch ................................................. 3-15

Power Steering Gear and Pump Leaks .................. 3-16
General Procedure ............................................... 3-16
External Leakage Check ..................................... 3-16
Seal Replacement Recommendations ..................... 3-16
Lip Seals ............................................................. 3-16
0-Ring Seals ....................................................... 3-16
Power Steering System Test ProcedUI'e :' .. 3-16
Shock Absorbers ::t!:'..~ ........... 3-18
Weak .................................... :; ............ t'~~............ 3-18
Noisy ......................... :...... :.................. :.;i.~: 3-18
3-2
STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS
Leaks .................................................................... 3-19

Tires ......................................................................... 3-19
Irregular or Premature Wear ............................... 3-19
Tread Wear Indicators ......................................... 3-19
Tire Waddle Complaint.. ..................................... 3-19
Radial Tire Lead/Pull .......................................... 3-20
Vibration .................................................................. 3-20
Road Test. ............................................................ 3-20
Tire and Wheel Balance ..................................... 3-20
Runout Check ...................................................... 3-20

Tire Force Variation Check ................................ 3-23
Substitution Method ............................................ 3-23
Tapered Roller Bearing Diagnosis .......................... 3-23
Trim Height ............................................................. 3-25
Specifications ........................................................... 3-27
Fastener Tightening Specifications ..................... 3-27
Special Tools ........................................................... 3-27
GENERAL DESCRIPTION
Loose or damaged parts on the front and rear

suspension or steering gear.
Out-of-round or out-of-balance tires, bent wheels
and loose and/or rough wheel bearing.
Leaks in power steering system. Also check the
power steering fluid level and the accessory drive
belt condition and tension. Refer to "Power
Steering Pump Diagnosis" in this section.
The following symptom diagnosis tables may
help you find the cause of a problem. The tables list a
number of symptoms, along with associated possible
causes. More information on any particular listing can
be found in the sections referenced in the "Refer To"
column.
Since the problems in steering, suspension, tire

and wheels involve several systems, they must all be
considered when diagnosing a complaint. To avoid
using the wrong symptom, always road test the vehicle
first. Proceed with the following preliminary checks
and correct any substandard conditions which are
found.
!L)
Inspect
Wrong pressure and uneven wear on tires.

Loose connections or wear on joints from the
steering column to the steering gear.
GENERAL DIAGNOSIS
SYMPTON
POSSIBLE CAUSE
REFER TO (SECTION)
BODY/CHASSIS GENERAL
Vehicle Pulls or Leads
Misaligned front tire and wheel.
3A
Mismatched or uneven tires.
3E
Broken or sagging springs.
3C, 3D
Radial tire lead/pull.

Unbalanced steering gear valve
spool.
Dragging front brake.
Shimmy, Shake or Vibration
3E
3B, 3B1A
5
Bent tire and wheel rim.
3E
Excessive tire and wheel runout.
3E
Out-of-balance tire or wheel.
3E
Excessive wheel bolt runout.
3E
Excessive brake drum or brake

rotor imbalance.
Worn steering linkage components.
3B1A
Worn lower control arm ball stud.
3C
Excessive loaded radial runout of

tire.
3E
Worn suspension bushings.
3C, 3D
Blister or bump on tire.

Out-of-balance propeller shaft.
Foreign material lodged in wheel
rim.
4A
STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3-3

SYMPTON
Abnonnal Noise at Front End
POSSIBLE CAUSE
REFER TO (SECTION)
Damaged suspension components.
3C, 30
3BlA, 3C, 30
Worn control arm bushings or

steering linkage.
Loose stabilizer shaft or broken
stabilizer shaft links.
Loose or improper torque to wheel
nuts.
Loose suspension bolts/screws.
Misadjusted steering gear.
Worn shock absorber or mountings.
Improperly positioned spring.
3C, 30
3E
3C, 3D
3B, 3B1A
3C, 30
3C, 30
Scuffed tires.
Low or Uneven Trim Height
Broken, incorrect, or sagging

spring.
3C, 30
Overloaded vehicle.
Body Leans or Sways in Comers
Suspension Bottoms
"Dog" Tracking
Loose stabilizer shaft or broken

stabilizer shaft links.
3C, 30
Worn shock absorber or mountings.
3C, 30
Broken or ~agging spring.

Overloaded vehicle.
3C, 30
Overloaded vehicle.
Worn shock absorber.
Incorrect, broken or sagging spring.
3C, 30
Damaged rear control arm or worn

control arm bushing.
30
3C, 30
Bent rear axle.
TIRES/WHEELS GENERAL
Abnonnal or Excessive Tire Wear
Misaligned tire and wheel.
3A, 3E
Excessive toe.
Sagging or broken spring.
3A
3C, 30

Worn shock absorber.
3E
3C, 30
Hard driving.
Wheel Tramp
Tire not rotated.
3E
Low or excessive inflation

pressure.
Bent suspension components.
3E
3C, 30
3E
Improper shock absorber action.

Blister or bump on tires.
3C, 30
34

SYMPTON
Cupped Tires
POSSIBLE CAUSE
Weak shock absorbers.
Worn wheel bearing.
STEERING/STEERING WHEEL
GENERAL
Poor Returnability
Too Much Play in Steering
Wander or Poor Steering Stability
Steering Wheel Kickback
3E
3C, 30
3C
Excessive tire or wheel runout.
3E
Worn control arm ball stud.

Loose steering gear adjustment.
3C
Incorrect caster .setting.

Bind in control arm ball stud.
3~, 3B1A
3A
Bind in steering column.
3C
3F, 3F5B
3B, 3B1A
Incorrect steering gear valve spool.
3B, 3B1A
Intermediate steering shaft joints

binding.
Hard Steering
REFER TO (SECTION)
3B
Hydraulic system - Perfonn test as

outlined in "Power Steering Test
Procedure" in this section.
3B, 3B1A
Bind or catch in steering gear.

Loose steering gear mounting.
3B, 3B1A
3B, 3B1A
Faulty pipe fitting seat.
3B, 3B1A
3B, 3B1A
Loose or worn joints from steering

column to steering gear.
3B, 3B1A
3B, 3B1A
Mismatched or uneven tires.

Worn shock absorbers.
3C, 30
Loose stabilizer shaft.
3C, 30
Broken or sagging spring.
3C, 30
3B, 3B1A
3A, 3E
Air in power steering system.

3B
3B, 3B1A
Loose or worn joints from steering

column to steering gear.
3B, 3BlA, 3F
Loose tie rod ends.

Worn or missing pipe fitting seat.
3B1A
3B, 3B1A
Worn wheel bearing.

3B, 3B1A
(
Steering Wheel Surges or Jerks
Bad or defective tire.

Sluggish steering gear valve spool.
3B, 3B1A
STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 35

SYMPTON
POSSIBLE CAUSE
REFER TO (SECTION)
Loose or oil soaked serpentine

drive belt.
3B, 3B1A
3B
RIDE
Too Soft (Vehicles with FE2 suspension
are designed for soft ride.)
Too Harsh
Incorrect shock absorbers.
3C, 30
Incorrect or sagging spring.
3C, 30
Incorrect shock absorbers.
3C, 30
3C, 30
Incorrect springs.
Incorrect tires or tire pressure.
3E
POWER STEERING GEAR 'DIAGNOSIS

SYMPTON
Hissing Noise
Rattle Noise (If rattle occurs when

driving over bumps, check front brake
linings for loose fit and missing
antirattle clips.)
POSSIBLE CAUSE
This is commonly heard when the
steering wheel is turned and
vehicle is not moving, and
especially so if brakes are applied.
If noise is very objectionable,
replace service gear.
(A replacement gear will also have
a slight noise, and is not always a
cure for the condition.)
3B, 3B1A
Loose intermediate steering shaft

universal joints.
3B
Outlet (pressure) hose contacting

frame.
3B, 3B1A
Loose tie rod ends.
3B1A
3B, 3B1A
3B, 3B1A
Loose steering gear attachment.

Loose pinion shaft.
Poor Return of Steering Wheel to
Center
REFER TO (SECTION)
Misaligned front tire and wheel.

Worn whee.I bearing,
Binding tie rod ends.
Binding control arm ball stud.
Steering wheel rubbing against tum
signal switch housing.
Tight or frozen steering gear
coupling shaft.
3A
3C
3B1A
3C
3F
3B, 3B1A
3F
3-6

SYMPTON
Momentary Increase in Effort When

Turning Steering Wheel Fast to Right
or Left
Steering Wheel Surges or Jerks When

Turning with Engine Running,
Especially During Parking
Excessive Steering Wheel Kickback or

Loose Steering
POSSIBLE CAUSE
REFER TO (SECTION)
Sticky or plugged steering gear

valve spool.
3B, 3B1A
High internal leakage.
3B, 3BlA, 3B1B
Sticking or damaged steering gear

valve spool.
3B, 3B1A
Insufficient pump pressure.
3B, 3B1B
Low fluid level.
3B, 3B1B
3B, 3B1B
Sticky flow control.
3B, 3B1B

Loose steering gear adjustment.
Loose tie rod ends.
3B
3B, 3B1A
3B1A
3C
Worn wheel bearing.
Hard Steering or Lack of Assist,

Especially During Parking
Coupling loose on stabilize.
3B, 3C
Loose thrust bearing preload

adjustment.
3B, 3B1A
Worn pipe fitting seat.
3B, 3B1A
Brake applied while turning

steering wheel.
3F
Damaged or worn steering gear

coupling shaft.
Sticky flow control valve.
3B, 3B1B
3B, 3B1B
Excessive internal pump leakage.
3B, 3B1B
Excessive internal steering gear

leakage.
3B, 3B1A
POWER STEERING PUMP DIAGNOSIS

SYMPTON
Foamy, Milky Fluid, Low Fluid Level,
Low Pressure
POSSIBLE CAUSE
Air in fluid.
Internal pump leakage.
Extremely cold temperatures will
cause air bubbles if fluid level is
low.
REFER TO (SECTION) 38, 381 B

POSSIBLE CAUSE
SYMPTON
37
REFER TO (SECTION) 38, 381 B
If fluid level is correct and pump

still foams, remove remote
reservoir and check it for cracks. If
cracked, replace remote reservoir.
Stuck or inoperative flow control

valve.
Low Pressure Due to Pump
Pressure plate not flat against ring.

Extremely worn ring.
Scored pressure plate, thrust plate
or rotor.
Vanes sticking in rotor slots.
Cracked or broken thrust plate or
pressure plate.
High internal leakage.
Low Pressure Due to Steering Gear
Scored housing bore.

Leakage at valve rings or seals.
Growling Noise in Pump
Restricted hoses or steering gear

causing excessive back pressure.
Scored pressure plates, thrust plate
or rotor.
Groaning Noise in Pump
Worn ring.
Air in fluid.
Low fluid level.
Loose pump mounting.
Whining Noise in Pump
Scored pump shaft bushing.

Scored pressure. plates and vanes.
STEERING COLUMN DIAGNOSIS

SYMPTON
POSSIBL.E CAUSE
REFER TO SECTION 3F, 3FSB
(except where noted)

LOCK SYSTEM
Will Not Unlock
Collapsed shear flange on sector

shaft.
Damaged lock bolt.
Damaged lock cylinder.
Damaged housing.
Damaged sector.
Damaged rack.
Damaged or incorrectly cut key.
3-8

SYMPTON
Will Not Lock
POSSIBLE CAUSE
REFER TO SECTION 3F, 3F5B

Broken or worn lock bolt spring.

Damaged sector.
Burr on lock bolt.
Damaged housing.
Damaged rack.
Interference between bowl and rack
coupling.
Stuck ignition switch.
Restricted actuator rod.
Incorrectly installed sector.
High Lock Effort

Damaged ignition switch.
Broken or deformed rack preload
spring.
Burrs or sector, rack, housing,
support or actuator rod coupling.
Bent sector shaft.
Damaged rack.
Park lock cable damaged or
misadjusted.
Extreme misalignment of housing
to cover.
Distorted coupling slot in. rack.
Bent actuator rod.
Bent ignition switch mounting
bracket.
Restricted actuator rod.
Worn or damaged key.
Will Stick in "START"
Deformed actuator rod.

Check items under "High Lock
Effort."
Key Cannot Be Removed in

"OFF-LOCK"
Incorrectly set ignition.

Lock Cylinder Can Be Removed
Missing lock cylinder retaining

screw.
High Effort in Lock Cylinder Between

"OFF" and "OFF-LOCK"
Distorted rack.
Lock Bolt Hits Shaft in "OFF" and
Incorrectly set ignition switch.
"PARK"

SYMPTON
POSSIBLE CAUSE

STEERING COLUMN
Noise in Steering Column
Loose joints from steering column

to steering gear.
3B, 3BIA
Incorrectly aligned steering column.

Unlubricated horn contact ring.
Lack of grease on bearings.
OB
OB
Loose sight shields.

Worn or broken upper or lower
steering shaft bearing.
Unseated lock plate retainer ring.
Unlubricated spherical joint.
High Steering Shaft Effort
OB
Misaligned steering column.

Improperly installed or deforms
dust seal.
Damaged upper or lower steering
shaft bearing.
Flash on inside diameter of shift
tube.
Tight universal joint.
Lash in Steering Column
Loose JJP-to-steering column upper

and lower bracket mounting
bolts/screws.
Broken weld nuts on jacket.
Sheared JJP upper bracket capsule.
Loose shoes in housing.
Loose pivot pins.
Loose lock pin in housing support.
Loose housing support
bolts/screws.
Loose steering column upper and
lower bracket-to-jacket
bolts/screws.
Loose lower bracket-to-adapter and
bearing mounting bolts/screws.
Housing Scraping Bowl
Bent bowl or bowl not concentric

with hub.
Improperly installed cover and
housing end cap.
Loose Steering Wheel
Excessive clearance between holes

in housing support or housing and
pivot pin diameters.
Damaged or missing anti-lash
spring in spheres.
Steering shaft upper bearing not
seated in housing.
39
4A
310

SYMPTON
POSSIBLE CAUSE
REFER TO SECTION 3F, 3F5,B

Missing steering shaft upper

bearing inner race.
Loose housing support
bolts/screws.
Missing or broken bearing preload
spring.
Loose Steering Wheel (Every Other Tilt
Position)
Loose fit between shoe and pivot

pins.
Shoe not free in slot.
Steering Column Not Locking in Any

Tilt Position
Shoe seized on pivot pin.

Burrs or dirt on shoe grooves.
Weak or broken shoe lock spring.
Steering Wheel Fails to return to Top

Tilt Position
Bound up pivot pins.

Broken or weak wheel tilt spring.
Tight turn signal switch wires.
Noise When Tilting Steering Column
Worn upper tilt bumpers.

Shoe lock spring rubbing in
housing.
TURN SIGNAL SWITCH
This diagnosis covers mechanical problems only. For tum signal switch electrical diagnosis, refer to SECTION 8A.
Tum Signal Will Not Stay in Tum
Position
Foriegn material or loose parts

impeding movement of yoke.
Broken or missing detent or
canceling spring.
None of the above; replace switch.
Tum Signal Will Not Cancel
Loose switch mounting screws.

Broken switch or anchor bosses.
Broken, missing or out-of-position
detent, return or canceling spring.
Worn canceling cam.
Tum Signal Difficult to Operate
Loose tum signal switch arm.

Broken or distorted yoke; replace
switch.
Loose or misplaced springs.
Foreign parts and/or material.
Loose tum signal switch mounting
screws.

SYMPTON
Turn Signal Will Not Indicate Lane
Change
POSSIBLE CAUSE
Broken lane change pressure pad
or spring hanger.
Broken, missing or misplaced lane
change spring.
Jammed base or wires.
Hazard Switch Cannot Be Turned

"OFF"
Foreign material between hazard

support canceling leg and yoke.
If no foreign material is found,
replace turn signal switch.
Hazard Switch Will Not Stay "ON" or

Difficult to Turn "OFF"
Loose turn signal switch.

Interference with other components.
Foreign material interference.
None of the above; replace turn
signal switch.
No Turn Signal Lamps
Electrical failure in chassis harness.

Inoperative turn signal flasher.
Loose chassis-to-column connector.
Disconnect chassis-to-column
connector and connect new turn
signal switch to chassis and
operate switch by hand.
- If vehicle lamps now operate
normally, turn signal switch is
inoperative.
- If vehicle lamps do not operate,
refer to SECTION 8A.
Turn Indicator Lamps "ON," But Not

Flashing
Inoperative turn signal flasher.

Loose chassis-to-column
connection.
Inoperative turn signal switch.
To determine if turn signal switch
is inoperative, substitute new turn
signal switch into circuit and
operate switch by hand. If vehicle
lamps operate normally, turn signal
switch is inoperative.
Front or Rear Turn Signal Lamps Not

Flashing
Burned-out or damaged turn signal

bulb.
High resistance connection to
ground at bulb socket.
311

312

SYMPTON
POSSIBLE CAUSE
REFER TO SECT[ON 3F1 3F5B

Loose chassis-to-column connector.

connector and connect new turn
- If tum signal lamps are now
"ON" and flashing, turn signal
switch is inoperative.
- If vehicle lamps do not operate,
refer to SECTION 8A.
No Tum Indicator Panel Lamps
Burned out bulbs or opens/grounds

in wiring harness from front tum
signal bulb socket to indicator
lights. Refer to SECTION 8A.
Stoplamp Not "ON" When Tum

Indicated
Loose chassis-to-column
connection.
connector and connect new tum
---' If lamps now work nonnally,
tum signal .switch is
inoperative. - If lamps do not flash, check
wiring harness. Refer to
SECTION 8A.
IGNITION SWITCH
Electrical System Will Not Function

Improperly adjusted ignition
switch.
Loose connector at ignition switch.
Switch Will Not Tum

Improperly adjusted ignition
switch.
Loose connector at ignition switch.
Switch Will Not Tum

Switch Cannot Be Set Correctly
Deformed switch actuator rod.

Sector to rack engaged in wrong
tooth.
STEERING, SUSPENSION, TIRES A~D WHEELS DIAGNOSIS
313
KEV REMINDER
B
REMINDER CONTINUES TO OPERATE WITH KEY
OUT, BUT STQPS WHEN DRIVER'S DOOR IS
CLOSED
!L!
Inspect
Chips, foreign material in lock cylinder bore.

Sticky lock cylinder actuator tip.
Damaged or broken reminder switch (3).
A TESTLEADS
B PADS, REMINDER SWITCH
012595
F80033
Figure 3 Checking Reminder Switch Pads
A BENT PAPER CLIP

B CONTACTS
1 CONNECTOR. CHASSIS
01-2495
F80013
Figure 1 - Checking Reminder at Chassis Connector
A TEST LEADS
3 SWITCH, REMINDER
01259S
FS0043
Figure 4 - Checking Reminder Switch
REMINDER DOES NOT SOUND WITH KEY FULLY

INSERTED IN LOCK CYLINDER AND THE
DRIVER'S DOOR OPEN
!LI
A TESTLEADS
2 CONNECTOR, COLUMN
Inspect
NOTICE: If you are using a multimeter to

check continuity with voltage present in circuits,
be sure to use a voltage setting. A multimeter
set on a resistance scale will be damaged by the
voltage from live circuits.
01-25-95
FS0023
Figure 2 - Checking Reminder at Column Connector
.1. Reminder to see if power is available. Refer to

SECTION 8A.
3-14
STEERING, SUSPENSION, TIRES AND WHEELS .DIAGNOSIS
(
4
A ACTUATOR TIP RETRACTED

4 CYLINDER, LOCK
Figure 5 Lock cylinder Actuator Key Removed
A TESTLEADS
B STRAIGHT EDGE
C GAGE, PLUG
3 SWITCH, REMINDER
01-2595
FS0083
Figure 8 Checking Contact Gap
A ACTUATOR TIP EXTENDED

4 CYLINDER, LOCK
OM2515
FS0083
Figure 6 - Lock Cylinder Actuator Key in Place

B
A SCREWDRIVER
3 SWITCH, REMINDER
Figure 9 - Decreasing Switch Contact Gap
A
8
C
3
TESTLEADS
SCREWDRIVER
PAD.ACTUATOR
SWITCH, REMINDER
0Mt515
FS0073
Figure 7 Checking Key Reminder Switch Continuity
2. Chassis wiring for open circuit.

A. Separate chassis connector (1) from column
connector (2).
B. Connect female contacts of terminals "E" and
"F" on chassis connector (1). A bent paper
clip will work as a jumper.
If reminder sounds, repair chassis wiring.
If reminder does not sound, go to step 3.
3. Continuity between male "E" and "F" column
connector co]J.tacts with a multimeter (or test
light).
A. Push key all the way into lock cylinder (4).
If there is continuity when key is in, and
off when key is out, function is normal.
If there is no continuity, fault is in column.
Go to step 4.
A
A SCREWDRIVER
3 SWITCH, REMINDER
012515
FS0103
Figure 1O Increasing Switch Contact Gap
4. Probes of reminder switch (3) .to ensure good

contact with pads on signal switch.
A. Disassemble upper end of column until turn
signal switch mounting bolts/screws have been
removed.
B. Lift turn signal switch to gain access to
probes.

C. Bend probes, if needed, then replace tum
signal switch and tighten three bolts/screws.
D. Check function as in step 3.
5. Tum signal switch wiring for short or fault.
A. Connect male contacts of terminals "E" and
"F of column connector (2) with a jumper.
B. Check key reminder switch pads on turn signal
switch with multimeter.
If there is continuity, function is normal.
If there is no continuity, replace turn signal
switch.
6. Continuity of check key reminder switch probes,
if problem has not been found.
A. Connect a multimeter to probes on reminder
switch (3).
B. Fully insert and remove key from lock
cylinder (4).
.
If there is continuity when key is in lock
cylinder (4) and no continuity when key is
out, function is normal. Retrace diagnostic
steps starting at step 3.
If there is no continuity, fault is in lock
cylinder (4) or reminder switch (3).
7. Lock cylinder (4) for chips, burrs, or foreign
material that may prevent actuator tip function.
A. Key must be removed, or lock cylinder (4)
must be in "RUN" position, before lock
cylinder can be removed.
B. Remove chips, burrs or foreign material.
C. Reassemble and recheck (step 6).
8. Lock cylinder for damage.
A. With lock cylinder removed, push key all the
way in, tum to "RUN" position and then
remove it.
The lock cylinder actuator tip should
extend and retract smoothly. Total
extension of tip should be 1.27 mm
(0.050 inch).
If not, replace lock cylinder (4).
Reassemble and recheck per step 4.
9. Reminder switch (3) if it appears good but will
not operate.
A. Connect multimeter leads to reminder switch
probes on reminder switch.
B. Press on actuator pad until switch points touch.
C. If there is no continuity, replace reminder
switch.
10. Reminder switch contact gap.
A. Connect multimeter leads to reminder switch
probes on reminder switch (3).
B. Press a 0.76 mm (0.030-inch) wire type plug
gage with a flat piece of stock onto actuator
pad.
If contact is not made (no continuity),
decrease switch contact gap until positive
contact is made.
11. Reminder switch contact gap,. with positive
contact gap set at 0.76 mm (0.030 inch) as
outlined above.
A. Use a 0.63 mm (0.025-inch) plug gap wire
beneath flat stock.
If contact is made (continuity), increase
switch contact gap.
3-15
B. Reminder switch (3) is set properly when

switch contact will touch 0.76 mm
(0.0030-inch) wire but not 0.63 mm
(0.025-inch) wire.
Reminder Keeps Operating with Key in

lock Cylinder, Driver's Door Open or
Closed; Ceases When Key is Removed
!LI
Inspect
Misadjusted or inoperative door jamb switch on

driver's side.
Shorted wire from signal switch to door jamb
switch.
A. This condition indicates lock cylinder (4) or
reminder switch (3) is at fault. To verify,
check for continuity at "E" and "F" male
column connector contacts, with key removed
from lock cylinder .(4).
If continuity exits, fault is in column.
B. Insert key into lock, then tum lock toward
"START" position.
If reminder stops when key is in "RUN"
position or when it is turned past "RUN"
toward "START," problem is a sticky lock
cylinder actuator.
For further diagnosis of key reminder, refer to
SECTION 8A.
COLUMN-MOUNTED DIMMER SWITCH

NO "LOW" OR "HIGH" BEAM
!L!
Inspect
1. Loose connector at dimmer switch.

2. Improper adjustment.
3. Internally damaged or worn switch. Refer to
SECTION 8A.
Check continuity on switch at light green and
tan switch terminals by pushing in plunger all
the way. A click should be heard.
- If there is no continuity, replace dimmer
switch.
- I f there is continuity, refer to
SECTION 8A.
PIVOT AND SWITCH

SWITCH INOPERATIVE: NO "LOW", "HIGH",
AND/OR "WASH"
!L!
Inspect
1. Loose body-to-switch connector.

2. Broken or damaged switch.
3. Internally damaged or worn switch.
Connect a new switch without removing old
one.
--,- If system functions, replace switch.
- If system doesn't function, refer to
SECTION 8A.
3-16
POWER STEERING .GEAR AND

PUMP LEAKS
GENERAL PROCEDURE
!LI
Inspect
For these common complaints about the power

steering system:
-
Fluid leakage on garage floor.

Fluid leaks visible on steering gear or pump.
Growling noise, especially when parking of
when engine is cold.
- Loss of power steering when parking.
- Excessive steering effort required.
For an overfilled reservoir.
For fluid aeration and overflow.
Hose connections.
Identify exact point of leakage. Refer to "External
Leakage Check" in this section.
-
Point from which fluid is dripping is not

necessarily point where system is leaking. It is
important to identify exact point of leakage.
EXTERNAL LEAKAGE CHECK
0-RING SEALS
Whenever a part which forms a sealing surface
for an 0-ring is removed, the 0-ring seal should also
be replaced with a new 0-ring seal. Lubricate all new
0-ring seals with power steering fluid to ease.
POWER STEERING SYSTEM TEST

PROCEDURE
Tools Required:
J 5176-E Power Steering Pressure Tester
0-2000 PSI and
J 5176-92 18 mm Power Steering Gauge
Adapter
J 25323-B Power Steering System Analyzer
J 29525-92 Power Steering Analyzer 18 mm
Adapter
If a hydraulic or mechanical malfunction of
the pump or power steering gear. or power steering
gear is suspected, perform the following procedure
to determine the cause.
NOTICE:
Refer to "Notice" on page 3-1.
1. Place drain pan under remote reservoir.

2. Disconnect outlet hose at remote reservoir.
3. Connect spare pressure hose to remote reservoir.
[I) Important
Figure 11
This procedure will help identify exact location
of leak. Some leaks can easily be located but seepage
type leaks may be more difficult. To locate seepage
leaks, use the following method:
1. With engine off, wipe dry complete power
steering system.
2. Check fluid level. Adjust fluid level as necessary.
3. Start engine, then turn steering wheel from stop to
stop several times.
Do not hold it at a stop for any length of time
as this can damage pump (5).
It is easier for someone else to operate steering
wheel while you search for seepage.
4. Find exact location of leak and repair.
SEAL REPLACEMENT
RECOMMENDATIONS
LIP SEALS
Lip seals, which seal rotating shafts, require
special treatment. This type of seal is used on the
hydraulic pump shaft and the pinion shaft of the
steering gear. When leakage occurs in this area,
always replace the seal or seals, after inspecting and
thoroughly cleaning the sealing surfaces. Replace the
shaft if pitting is found. If corrosion in the lip seal
contact zone is slight, clean the surface of the shaft
with crocus cloth. Replace the hydraulic pump shaft of
complete gear only if the leakage cannot be stopped
by smoothing with crocus cloth first.
4.
5.
6.
7.
The power steering system may be tested

using J 5176-D or J 25325-A. Testing ,vith
J 25323-A will measure flow rate as well as
pressure.
Connect J 5176-D and J 5176-92 or J 25323-A
and J 29525-92 to outlet hose and spare pressure
hose.
Open valve on J 5176-D or J 25323-A.
Start engine and allow engine to reach normal
operating temperature.
With engine at idle and valve open on J 5176-D
or J 25323-A, pressure should be no more than 1
050 kPa (150 psi).
[I)
Important
If pressure is more than 7 240 kPa (150 psi),

check the hoses for restrictions and popper
valve on steering gear for proper.
NOTICE: Do not leave the valve fully closed
for more than 5 seconds as the pump could be
damaged.
8. Fully close valve on J 5176-D or J 25323-A three
times and record pressure reading each time. Each
reading should show at least 6 895 kPa
(1,000 psi). The three readings should be within
345 kPa (50 psi) of each other.
If pressure readings are high enough and are

within 345 kPa (50 psi) of each other, pump is
functioning properly.
317
D
6
A 3800 L36 ENGINE

B 5. 7L LTl ENGINE
C REPLACE DRIVESHAFT SEAL. MAKE CERTAIN THAT
DRIVESHAf'T IS CLEAN AND FREE OF PITTING
IN AREA
D CHEO< FLUID LEVEL. IF LEAKAGE PERSISTS WITH THE
LEVEL CORRECT AND HYDRAULIC PUMP RESERVOIR CAP
TIGHT, REPLACE HYDRAULIC PUMP RESERVOIR CAP.
E IF A CRAO<ED OR BENT HYDRAULIC PUMP FLUID
RESERVOIR IS DETECTED, REPLACE HYDRAULIC
PUMP FLUID RESERVOIR.
F TORQUE STEERING GEAR PIPE FITTING SEAT TO
SPEOFICATIONS. IF LEAKAGE PERSISTS, REPLACE
STEERING GEAR PIPE SEAL (0-RING).
G REPLACE GEAR WITH PARTIAL STEERING GEAR.
H IF LEAKAGE IS OBSERVED BETWEEN TORSION BAR
AND STEERING GEAR PINION SHAFT, REPLACE
WITH PARTIAL STEERING GEAR.
I IF LEAKAGE IS OBSERVED AT DRIVER SIDE AND IS

NOT AFFECTED BY DIIRECTION OF TIJRN, REPLACE
WITH PARTIAL STEERING GEAR.
J IF" LEAKAGE IS OBSERVED AT STEERING GEAR
HOUSING END AND SPURTS WHEN BOTTOMED IN
LEFT TURN, REPLACE 'MTH PARTIAL STEERING
GEAR.
K IF LEAKAGE IS OBSERVED AT THESE POINTS,
REPLACE WITH PARTIAL STEERING GEAR.
L TORQUE HYDRAULIC PUMP FITTING AND HYDRAULIC
PUMP HOSE FITTING NUT TO SPECIFICATIONS. IF
LEAKAGE PERSISTS, REPLACE HYDRAULIC PUMP
SEAL (0-RING).
5 PUMP, POWER STEERING
6 RESERVOIR, POWER STEERING FLUID
7 HOSE, POWER STEERING FLUID OUTLET
8 GEAR, POWER STEERING
012711
F80113
Figure 11 - Power Steering Gear and Pump Leak Diagnosis
3-18
STEERING,. SUSPENSION, TIRES AND WHEELS DIAGNOSIS
If pressure readings are high enough but are

not within 345 kPa (50 psi) of each other,
control valve in pump is sticking.
A. Remove valve, clean it and remove any
burrs using crocus cloth of fine hone.
B. If system contains some contamination,
flush it.
If pressure readings are less than 6 895 kPa
(1,000 psi), replace flow control valve and
recheck.
- If pressures are still low, replace rotor and
vanes.
9. If pump checks to specification, leave valve open
and turn steering wheel (or have someone else
turn it) to both sides.
Record highest pressures and compare with
highest pump pressure recorded earlier.
- If pressure at both stops is not same as
maximum pressure; steering gear is leaking
internally and must be repaired.
10. Turn off engine.
11. Remove J 5176-D and J 5176-92 or J 25323-A
and J 29525-92.
12. Connect outlet hose to remote reservoir.
l~I
Tighten
Hydraulic pump hose fitting nut to 28 N.m

(21 lb. ft.).
SECTION 3B.
SHOCK ABSORBERS
The following procedure includes both
on-vehicle and bench checks to be done when
evaluating performance of shock absorber assemblies.
[I)
Important
The single-tube shock absorbers are highly gas

pressurized and require a force of 445 N
(100 pounds) to initiate shock absorber rod
movement. Be careful not to dent or puncture the
shock absorber assemblies, or they must be
replaced.
WEAK
1. Check and adjust tire pressures to pressures
shown on tire placard.

2. Note load conditions under which vehicle is
normally driven.
3. If practical, ride with owner to be sure you
understand complaint before proceeding to next
step.
4. Test each shock absorber in tum by quickly
pushing down, then lifting up, comer of the
bumper nearest the shock absorber being checked.
A. Use same amount of effort on each test and
note resistance on compression and rebound.
B. Compare this with a similar vehicle having
acceptable ride quality.
Shock absorbers on both vehicles should

provide the same feeling of resistance. If
there is much difference between the two
vehicles, go to next step.
5. Support vehicle to expose shock mounts.
6. Remove shock absorber assemblies. Refer to
SECTION 3C.
CAUTION: The shock absorbers are

highly pressurized. Be sure to properly
disassemble module or personal injury
could result.
7. Disassemble plastic dust tube.
8. Remove shock absorber rod washer.
rn
Important
Do not fully compress shock absorber. Shock

absorbers are highly gas charged and will
extend when released.
9. Turn shock absorber so lower mount is up and
upper mount is down .
Compress shock absorber against ground at
various rates of speed through approximately
one-half the length of the exposed chromed
shock absorber rod (75 mm (3 inches) - rear;
50 mm (2 inches) - front).
10. Compare right and left shock absorbers for
compression resistance and rebound speed.
Right and left shock absorbers should feel
comparable.
Differences between front and rear shock
absorbers are normal.
If in doubt about condition, compare with a
shock absorber known to be good.
NOISY
1. Check all mountings for proper tightening.
A loose mounting will cause a noise.
2. If all mountings are intact, jounce vehicle as in
step 4 in "Weak" above to isolate suspected unit.
3. If practical, ride with owner to be sure you
understand complaint, before proceeding to next
step.
4. Remove suspected shock absorber. Refer to
SECTION 3C.
5. Shake shock absorber and listen for loose metallic
parts inside shock absorber body.
If suspicious noise is heard, replace shock
absorber.
6. Turn shock absorber so lower mount is up and
upper mount and rod is down.
Slowly compress shock absorber. Do not allow
chromed portion of shock absorber rod to pass
below black seal cover.
7. Replace shock absorber if seize is encountered
with more than 25 mm (1 inch) of chromed
portion of shock absorber rod exposed above seal
cover.
3-19
LEAKS
1. Fully extend shock absorbers (tire and wheels
unsupported) to expose seal cover area for
inspection.
2. Look for signs of leaks at top of shock absorber.
A small amount of fluid is not cause for
replacement. The seal permits some seepage to
lubricate the shock absorber rod.
A leaking shock absorber can easily be found
because there will be an excessive amount of
fluid on shock absorber.
3.. A leaking shock absorber must be replaced.
TIRES
01-25-95
A WEAR. INDICATORS
FS0123
IRREGULAR OR PREMATURE WEAR

Figures 12 and 13
Figure 12 - Tread Wear Indicators
Irregular or premature tire wear has many

causes. Some of them are: incorrect inflation
pressures, lack of regular rotation, driving habits, or
improper tire and wheel assignment. If tire and wheel
alignment is reset due to a tire wear condition, always
reset. toe as close to zero degrees as the specification
allows.
Rotate tires if following conditions are noted:
Front and rear tire wear is unequal.

Uneven wear exists across tread of any tire.
Left and right front tire wear is unequal.
Check tire and wheel alignment if following
conditions are noted:
Left and right front tire wear is unequal.

Wear is uneven across tread of any front tire.
Front tire treads have a scuffed appearance with
"feather" edges on one side of tread ribs or
blocks.
TREAD WEAR INDICATORS

Figure 12
The original equipment tires have built-in tread
wear indicators to show when the tires should be
replaced. These indicators will appear as 12.7 mm
(1/2-inch) wide bands when the tire tread depth
becomes 1.6 mm (1116 inch). When the indicators
appear in 2 or more grooves at 3 locations, replace the
tire.
TIRE WADDLE COMPLAINT
A HARD CORNERING, UNDER INFLATION OR LACK OF

ROTATION
B EXCESSIVE TOE ON THE NON-DRIVE AXLE OR LACK OF
ROTATION
C HEAVY ACCELERATION ON DRIVE AXLE, EXCESSIVE
TOE ON DRIVE AXLE ASSEMBLY OR LACK OF ROTATION
Figure 14
Tire waddle is side-to-side movement at the
front and/or rear of the vehicle. It can be caused by
the steel belt not being straight within the tire; or by
excessive lateral runout of the tire or wheel. It is most
noticeable at low speed, about 8 to 48 km/h (5 to
30 rriph). It may also appear as a ride roughness at 80
to 113 km/h (50 to 70 mph).
012595
FS0133
Figure 13 - Tire Wear Diagnosis
320
VIBRATION
Figures 16 and 17
!L!
0125115
FS0143
Figure 14 Tire Waddle
The vehicle can be road tested to see which end

of the vehicle has the faulty tire. If the tire causing the
tire waddle is on the rear, the rear end of the vehicle
will waddle. From the driver's seat, it feels as if
someone is pushing on the side of the vehicle.
If the faulty tire is on the front, the tire waddle
is more easily seen. The front sheet metal appears to
be moving back and forth. It feels as if the driver's
seat is the pivot point in the vehicle.
A more time-consuming method of determining
the faulty tire is substituting tire and wheels that are
known to be good. Follow these steps:
1. Drive vehicle to determine if tire waddle is
coming from front or rear.
2. Install tire and wheels known to be good from a
similar vehicle in place of those on end of vehicle
which is vibrating.
If tire waddle cannot be isolated to front or
rear, start with rear tires.
3. Road .test again.
If improvement is noted, install original tire
and wheels one at a time until faulty tire is
found.
If no improvement is noted, install tires known
to be good in place of all four. Then, install
originals one at a time until faulty tire is
found.
RADIAL TIRE LEAD/PULL

Figure 15
Lead/pull is the deviation of the vehicle from a
straight path on a level road with no pressure on the
steering wheel.
Lead is usually caused by:
Poor tire construction.
Uneven brake assemblies.
Improper tire and wheel alignment.
The way in which a tire is built can produce
lead in a vehicle. An example of this is placement of
the belt. Off-center belts on radial tires can cause the
tire to develop aside force while rolling straight down
the road and the tire will tend to roll like a cone.
The lead/pull correction chart should be used to
make sure that the front tire and wheel alignment is
not mistaken for tire lead (Figure 15). Wheel
alignment, Refer to SECTION 3A.
Rear tires will not cause lead.
Inspect
Improper tire inflation pressure.

Bent rims from pothole or curb impact.
Faulty tires, such as tread distortions, separations,
or bulges.
- Slight sidewall indentations are normal and
will not affect ride.
- Sidewall bulges are not normal and indicate
impact damage.
Mud or tar build-up on tire or wheel.
Replacement tire and wheel does not conform to
original part, or is of lesser quality or substitute
design.
Loose or missing balance weights or wheel nuts.
Irregular or excessive tire wear.
Bent or faulty drive axle.
ROAD TEST
Before performing any work or testing, always
road test the vehicle. Warming up the. tires is
necessary to eliminate any flat spotting. For vibrations
that appear to be engine related, refer to SECTION 6.
A road test is also necessary to determine the speed at
which the vibration occurs. Low-speed vibration at
speeds less than 64 km/h (40 mph) is usually related
to runo.ut. High-speed vibration. at speeds greater than
64 km/h (40 mph) is usually the result of imbalance,
but may be a product of both runout and imbalance.
TIRE AND WHEEL BALANCE

Before removing the tire and wheel from the
vehicle, mark the wheel bolt nearest the valve stem for
future .reference. Also mark the vehicle position (left
front, etc.) on each tire.
Balance is the easiest procedure to perform and
should be done first if the vibration occurs at highway
speeds. An off-vehicle, two-plane dynamic balance
should be performed first. This will correct any
imbalance in the tire and wheel. An on.-vehicle finish
balance may also be required. This may offset brake
drum, rotor, drive axle, or wheel cover imbalance.
If balance does not correct the highway speed
vibration, or if the vibration occurs at low speeds,
runout may be the probable cause. Runout is the term
used when components are checked for symmetry.
Runout can be caused by the drive axle, the bearing,
or the way the wheel attaches to the vehicle.
RUNOUT CHECK
This procedure may be stopped at whatever
point the acceptable level of runout is reached.
1. Measure free runout of tire and wheel on vehicle
using a dial indicator with a roller wheel.
Lateral runout (side to side) should be
measured on tires sidewall as close to tread
shoulder as possible.
321
RADIAL TIRE LEAD/PULL CORRECTION CHART

Adiust the pressure to
specifications (on-Tire Placardf.
OK
Check for proper trim heights.

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

direction.
OK
Vehicle leadsfpulls opposite

direction.
Probable cause is front ti,re and

wheel assembly alignment. Check
caster-camber-toe.
Probable cause is tires.

Swap left front tire and wheel
assembly with left rear tire and
wheel assembly.
Road Test
Alignment not within specifications.
Vehicle Still Leads
Adjust front tire and wheel assembly

alignment to specifications.
Swap right front tire and wheel

assembly with right rear tire
and wheel assembly.
OK
Replace left rear ti,re.
Road Test
OK
Vehicle still leads.
Replace right rear tire.
Alignment Within Specifications

Change caster s,etting.
Leads Right
Leads Left
Set right caster at top spec. set

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

right caster 1 less.
Road Test
Still Leads Left

Continue decreasing right caster
until puU is eliminated.
Still Leads Right

Continue decreasing left caster
until pull is eliminated.
DO NOT exceed 2 cross caster.
OMISH
FS0153
Figure i 5 Radial Tire Lead/Pull Diagnosis
322
VIBRATION COMPLAINT DIAGNOSIS
(
Visual inspection
Road test to verify

complaint.
OK
Low speed below 64

km/h(40mphl
High speed above 64

km/h 140 mphl
On-vehicle
runout check
Off-vehicle dynamic
balance
Not OK
Not OK
Off-vehicle
runout check
On-vehicle dynamic
balance
Not OK
OK
Not OK
OK
Index assemblies on
wheel studs.
Match mount tke

on wheel assembly
Not OK
Replace
tke.
OK
OK
Not OK
Measure and
replace wheel assembly.
Measure axle assembly or

brake rotor runout.
OK
Not OK
Replace brake rotor or

axle shaft.
OK
Off-vehicle dynamic
balance
OK
Not OK
On-vehicle finish
balance
Not OK
Check for engine d,rive

line imbalance.
012585
F80183
Figure 16 Wheel and Tire Vibration
TIIRE OUT OF ROUND
TIRE STIFFNESS VARIATION
3-23
RIM BENT OR OUT OF ROUND

01-25-15
FSCl173
Figure 17 - Causes of Vibration/Runout
Radial runout ( up and down) should be

measured on center tread rib.
- S?me tread desi~ns may require wrapping a
piece of tape tightly around center tread
circumference for better dial indicator
contact.
2. Disregard any instantaneous indicator needle
jumps due to sidewall depressions, tread blocks,
etc.
3. Record total indicator reading, and location of
high point of turnout.
4. If radial or lateral runout exceeds 1.52 mm
(0.060 inch), mount tire and wheel on a dynamic
balance machine and re-measure runout.
Make sure wheel is centered on machine by
wheel center pilot hole.
5. Record total indicator reading, and location of the
high point of runout.
6. If radial or lateral runout exceeds 1.27 mm
(0.050 inch), break down and rotate tire on rim
180 degrees.
In many cases, rotating tire on wheel will
bring runout to an acceptable range.
Whenever a tire is rotated on the wheel, in this
way, the must be re-balanced.
7. Re-inflate, mount on dynamic balance machine
and re-measure runout.
8. Record total indicator reading and location of high
point of runout.
9. If radial or lateral runout still exceeds 1.27 mm
(0.050 inch) and high point has moved
approximately 180 degrees, following tire around
rim, tire is faulty and should be replaced.
10. If second high point still exceeds 1.27 mm
(0.050 inch) and is close to original high point,
relative to the rim, wheel is faulty and should be
replaced.
A. Before replacing tire and wheel, break down
and measure wheel separately.
B. Replace wheel if radial runout exceeds
1.02 mm (0.040 inch), or lateral runout
exceeds 1.14 mm (0.045 inch).
11. If runout of tire and wheel is within limits when
measured off the vehicle, yet exceeds the limits
when measured on the vehicle, the attachment of
tire and wheel to hub is probable cause.
12. Rotate two wheel bolts and recheck runout.
Several positions may have to be tried to find

best location.
13. If runout can not be reduced to an acceptable
level remove tire and wheel and measure hub
stud 'runout.
14. If runout exceeds 0.76 mm (0.030 inch), replace
hub or drive axle shaft.
TIRE FORCE VARIATION CHECK

Tire stiffness variation, or loaded radial runout
can also cause a vibration. However, this is difficult to
measure without a tire problem detector or a loaded
radial runout buffer.
The tire problem detector is simply a roller drum
that slowly rotates the tire, while under load, (mounted
on the vehicle) measuring spindle movement.
The loaded radial runout buffer is a more
automated machine that slowly rotates the tire under
load with a roller drum off the vehicle and measures
the tire's stiffness. It will then "match" the tire to the
wheel by buffing off small amounts of rubber from the
outer tread rows at the stiff spot. This procedure is
usually effective, especially when used as a measuring
device and for fine buffing only. This equipment
requires careful use. Do not remove too much rubber.
Because this equipment is not always available,
the most basic procedure of measuring free runout
with a dial indicator, as previously detailed, is usually
more practical. The free runout of the tire will usually
correspond with the tire's stiff spot.
SUBSTITUTION METHOD
Install a known good set of tire and wheels. If
these correct the vibration, the original tire and wheels
should be reinstalled one at a time until the vibration
returns.
TAPERED ROLLER BEARING DIAGNOSIS

Figure 18
When diagnosing a bearing condition:
1. Consider general condition of all parts during
disassembly and inspection.
2. Identify bearing problem (Figure 18).
3. After identifying bearing problem, refer to
diagnostic chart to identify cause and
appropriate repair procedures.
3-24
~~
A
@ ~~
E
Q)~
@llHmB
~'
\l ~-tt
\1
H
~~~ ~~ ~~/
,l!!.,...___!- - ~
au
K
8Jffil
M
GOOD BEARING
ETCHING
CAGEWEAR
HEATDISCOLORATION
BENTCAGE
MISALIGNMENT
ABRASIVE ROLLER WEAR
STAIN DISCOLORATION
SENTCAGE
INDENTATIONS
CRACKED INNER RACE
GALLING
ABRASIVE STEPWEAR
FATIGUE SPALLING
SMEARS
BRINELLING
FRETTAGE
Figure 18 Tapered Rolller Bearing Diagnosis

TRIIM HEIGHT
Figure 19
Incorrect trim heights can produce symptoms

similar to those produced when there is a problem
with the tire and wheel alignment. Trim heights should
be checked when diagnosing steering and vibration
complaints (Figure 19).
In order to measure trim height accurately, make
sure:
Tires are at correct pressure as shown on tire
placard "up to vehicle capacity."
Fuel tank is full.
Vehicle has no additional weight or passengers.
Seats are in full back position.
Rear compartment is empty except for spare
tire and jack and simulated fuel load if
required.
Vehicle is on a known level floor.
All doors, hood and rear compartment lid are
closed.
All dimensions shown on Figure 19 are
measured vertical to the ground. Trim heights should
be within +/- 10 mm (0.4 inch) to be considered
correct.
3-25
MEASURING "Z," "J" AND A" DIMENSIONS
1. Lift front bumper of vehicle up approximately

38 mm (1 1/2 inches). Gently remove hands and
let vehicle settle.
A. Repeat operation for a total of 2 times.
B. After second time, measure "Z," "J" and "A"
dimensions.
2. Push front bumper down approximately 38 nun:
(1 1/2 inches). Gently remove hands and let
vehicle rise on its own.
A. Repeat operation for a total of 2 times.
B. Measure "Z," "J" and "A" dimensions.
3. Calculate trim heights.
Trim heights are average of high and low
measurements.
4. Verify trim heights with Figure 19.
5. Correct trim heights as necessary.
MEASURING ''D,'' "K" AND "B" DIMENSIONS
Repeat procedure as described for "Measuring

"Z," "J" and "A" Dimensions using the rear bumper
and measuring "D," "K" and "B" at the appropriate
times.
3-26
CENTERLINE
828mm
(17.24")
REAR AXLE
ASSEMBLY
(32.59"}
FRONT AXLE
ASSEMBLY
REAR BUMPER
BRACKET BOLT/SCR!W
11----
LOWEST
POINT OF
ROCKER PANEL
TOP OF REAR AXLE

ASSEMBLY BRACKET
ROCKER
INNER
PANEL
DISTANCE
TO
GROUND
(J
&Kl
LGROUND
SECTION A-A
REAR AXLE
ASSEMBLY
CENTER OF FRONT LOWER
CONTROL ARM - FRONT
LOWER CONTROL ARM
BUSHING BOLT/SCREW HEAD
!VIEWA!
LOWEST POINT ON
FRONT LOWER CONTROL
ARM BALL STUD
ASSEMBLY (EXCLUD1ING
GREASE FITTING)
IVIEWB!
(LEFT-HAND SHOWNI
SUSPENSION
F41
FE2
TIRE
215-60
235-55
236-55
245-50
mm inch
m,mlnch
nun 1,nch
mm inllh
mm inch
inmlnch
420 16.5
420 16.5
420 16.5
420 16.5
367
367
367
367
32
-30
31
37
m 4.8
118 4.6
118 4.6
125 4.9
204 8.0
204 8.0
204 8.0
204 8.0
208 8.2
208 8.4
208 8.4
208 8.4
14.4
14.4
14.4
14.4
1.3
1.2
1.2
1.6
NOTE: Trim heights should be within 10 mm (0.4 inch).

G12515
FS0113
(
Figure 19 Trim Height Diagnosis
3-27
SPECIFICATIONS
Hydraulic Pump Fitting ........................................................................................................... 75 N.m (55 lb. ft.)
Hydraulic Pump Hose Fitting ................................................................................................. 28 N.m (21 lb. ft.)
Power Steering Gear Pipe Fitting Seat.. ................................................................................. 28 N.m (21 lb. ft.)
SPECIAL TOOLS
1. ~ J 5 1 7 0 - 0
3.
r~J517692
2.
J 29525-92
1.
2.
3.
4.
POWER STEERING PRESSURE TESTER 0-2000 PSI

POWER STEERING SYSTEM ANALYZER
POWER STEERING PRESSURE TESTER ADAPTER
POWER STEERING ANALYZER 18 mm ADAPTER
4.
01-25-115
FS0203
328
BLANK
(
WHEEL ALIGNMENT
3A1
SECTION 3A
WHEEL ALIGNMENT
systems.
CONTENTS
General Description ................................................ 3A-1
Caster ................................................................... 3A-1
Camber ................................................................. 3A-1
Toe ....................................................................... 3A-l
Thrust Angle ....................................................... 3A-3
Preliminary Inspections ...................................... 3A-3
Diagnosis .......................................... Refer to Section 3
On-Vehicle Service ................................................. 3A-4
Measuring Front Alignment Angles .................. 3A-4
Front Camber and Caster Adjustment ............... 3A-4

Front Toe Adjustment ......................................... 3A-4
Measuring Rear Alignment Angles ................... .3A-5
Rear Thrust Angle Adjustment .......................... 3A-6
Specifications ........................................................... 3A-6
Tire and Wheel Alignment Specifications ......... 3A-6
Fastener Tightening Specifications ..................... 3A-6
Special Tools ........................................................... 3A-7
GENERAL DESCRIPTION
at the top, the camber is positive (+). when the tires

and wheels tilt inward at the top, the camber is
negative (-). The amount of tilt is measured in degrees
from the vertical and is called the camber angle.
Camber setting influences directional control and tire
wear.
When tires and wheels are set to a positive
camber angle, they will tend to roll in a path away
from the vehicle's true path. The effect of each tire
and wheel tends to cancel the other. The suspension
geometry and camber setting are designed to keep the
tire tread flat on the road through bumps or dips.
Tire and wheel alignment refers to the angular

relationship between the tires and wheels, the
suspension attaching parts and the ground.
CASTER
Figures 1 and 2
Caster is the tilting of the front steering axis (at

the top) either forward or backward from the vertical.
A backward tilt is positive (+) and a forward tilt is
negative (-). Caster influences directional control of
the steering but does not affect tire wear and is
adjustable only at the front tires and wheels.
Caster is affected by vehicle height, therefore, it
is important to keep the body at its designated trim
height. Overloading the vehicle or a weak or sagging
rear spring will affect caster. When the rear of the
vehicle is lower than its designated trim height, the
front suspension moves to a more positive caster. If
the rear of the vehicle is higher than its designated
trim height, the front suspension moves to a less
positive caster. For trim height information, refer to
SECTION 3.
CAMBER
Figures 1 and 3
Camber is the tilting of the front tires and

wheels from the vertical when viewed from the front
of the vehicle. When the tires and wheels tilt outward
TOE
Figures 1 and 4
Toe is a measurement of how much the front

tires and wheels are turned in or out from a
straight-ahead position. When the tires and wheels are
turned in, toe is positive (+). When the tires and
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
wheels roll parallel.
Toe also serves to offset the small deflections of
the tire and 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 or out
slightly when the vehicle is standing still, they tend to
roll parallel on the road when the vehicle is moving.
Toe affects tire wear.
3A2 WHEEL ALIGNMENT

K
~FRT
A CASTER
B CAMBER
C TOE
D VERTICAL
E NEGATIVE CASTER ANGLE
F POSITIVE CASTER ANGLE
G CENTERLINE OF TIRE AND WHEEL
H LOWER INBOARD CORNER OF LOWER CONTROL ARM
BALL STUD
J POSITIVE CAMBER ANG,LE
K
L.
M
N
P
Q
1
2
3
CENTERLINE OF VEHICLE
CENTERLINE OF BOLT/SCREW HEAD
TRIM HEIGHT
CENTERLINE OF FRONT TIRE AND WHEEL
POSITIVE WHEEL TOE-IN ANGLE CONE TIRE AND
WHEEL)
NEGATIVE CAMBER ANGLE
FRAME
CROSSMEMBER, FRONT
ARM, FRONT LOWER CONTROL
01-23-15
FS0013A
Figure 1 - Caster, Camber and Toe
(
I
A CASTER IS POSITIVE WHEN LOWER CONTROL BALL

STUD IS AHEAD OR PULLING THE SPINDLE
B CASTER IS NEGATIVE WHEN THE LOWER CONTROL
BALL STUD IS BEHIND OR PUSHING THE
SPINDLE
C SPINDLE
D VERTICAL
4 STUD, FRONT LOWER CONTROL ARM BALL
Figure 2 - Caster
11-23-ts
FS0023A
WHEEL ALIGNMENT
3A-3
THRUST ANGLE
-------''A''-------
Figure 5
The front tires and wheels aim or steer the

vehicle, but the rear tires and wheels control tracking.
This tracking action i.s relative to thrust angle. Thrust
angle is defined as the path that the rear tires and
wheels will take. Ideally, the thrust angle is
geometrically aligned with the body centerline.
FRT
PRELIMINARY INSPECTIONS
Steering and vibration complaints are not always
the result of improper alignment. Another possibility is
tire "lead" due to worn or improperly manufactured
tires. "Lead" is the vehicle deviation from a straight
path on a level road without pressure on the steering
wheel. To determine of the vehicle has a tire lead
problem, refer to SECTION 3.
Before making any adjustment affecting tire and
wheel alignment, make the following inspections to
ensure correct alignment readings and alignment
adjustments.
!L!
Inspect
All tires for proper inflation pressures. Also check

that all tires have about the same tread wear.
Control arm ball studs. If they are loose, correct
them before adjusting tire and wheel alignment.
Refer to SECTION 3C.
i,.------- "B"
-------
DIMENSION "A" SHOULD BE LESS THAN "B"

012315
FS0043A
Figure 4 Toe
Tie rod ends. If they are loose, correct them

before adjusting tire and wheel alignment. Refer
to SECTION 3B.
Runout of tires and wheels. Refer to SECTION 3.
Vehicle trim height. If out of limits and a
correction is to be made, do so before adjusting
alignment. Refer to SECTION 3 for trim height
chart.
Steering gear for looseness at frame.
Control arms for loose bushings.
Stabilizer shaft for loose or missing parts.
Improperly operating shock absorber and springs.
Suspension and steering components for damage.
Replace parts as necessary.
Vehicle for stability. The fuel tank should be full,
or the vehicle should have compensating ballast.
Jounce vehicle lightly three times rear and three
times front.
Consideration must be given 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.
E
-- --c
B
A. A CYLINDER WILL ROLL STRAIGHT AHEAD
B A CONE WILL ROLL IN A CIRCLE TOWARD THE SMALL
END .
C TIRE CONTACTS THE ROAD SURFACE
D POSITIVE CAMBER ANGLE
5 VERTICAL
01-:Z39S
F80033A
Figure 3 Camber
A
B
C
D
E
THRUST ANGLE
THRUST LINE - OFF CENTER
GEOMETRIC CENTERLINE
REAR TOE-OUT CONOfflON
REAR TOE-IN CONDITION
Figure 5 Thrust Angle
0
012395
FS00&3A
3A-4
WHEEL ALIGNMENT
Consideration should also be given to the

condition of the equipment being used to adjust
alignment. Be sure to follow the equipment
manufacturer's instructions. Regardless of the
equipment used to adjust alignment, the vehicle must
be on a level surface, both front-to-rear and
side-to-side.
ON-VEHICLE SERVICE
MEASURING FRONT ALIGNMENT ANGLES
Satisfactory vehicle operation may occur over a
wide range of alignment settings. However, should the
settings vary beyond the specifications shown at the
end of this section, the alignment angles should be
corrected.
!@!
2 CROSSMEMBER. FRONT
3 ARM, FRONT LOWER CONTROL
Measure
01-23-IS
FSOGe3A
Figure 6 - Front Camber Adjustment
Front alignment angles.

A. Install alignment equipment according to the
manufacturer's instructions.
B. Jounce the front and rear bumpers lightly three
times to normalize suspension prior to
measuring angles.
. .
C. Measure alignment angles and record the
readings. If adjustments are required, make
them in the following order: camber, caster,
and toe.
FRONT CAMBER AND CASTER

ADJUSTMENT
Figures 6 and 7
Tool Required:
J 38658. Camber/Caster Adjuster
2 CROSSMEMBER, FRONT
Adjust
1. Jounce front bumper three times to allow vehicle

to return to normal height before making any
adjustments in caster.
SECTION OA.
3. Loosen front lower control arm nuts. Refer to
SECTION 3C.
4. Install J 38658 to slot holes in lower control
arm (3) and front crossmember (2) (Figure 6).
5. Camber by rotating turnbuckle on J 38658.
Rotating turnbuckle clockwise will increase
camber.
Rotating turnbuckle counterclockwise will
decrease camber.
6. Install J 38658 to slot holes in lower control arm
(3) and front crossmember (2) (Figure 7).
7. Caster by rotating turnbuckle on J 38658.
Rotating turnbuckle clockwise will increase
caster.
Rotating turnbuckle counterclockwise will
decrease caster.
01-2395
FS0073A
Figure 7 - Front Caster Adjustment
8. Remove J 38658 from slot holes.

9. Tighten front lower control arm nuts. Refer to
SECTION 3C.
10. Lower vehicle.
FRONT TOE ADJUSTMENT

Figure 8
Adjust
NOTICE:
Refer to "Notice" on page .3A-1.
Toe
A. Make sure steering wheel is set in a
straight-ahead position within 3.5 degrees.
B. Toe adjustments are made separately at each
individual tire and wheel.
C. Loosen nut (8) on inner tie rod (7).
WHEEL ALIGNMENT 3A-5

D. Toe to specification by turning inner tie
rod (7). Refer to "Alignment Specifications" in
this section.
Left and right toe adjustment should be
equal within 0.2 degrees.
E. Make sure steering gear boot seal is not
twisted.
!~!
Nut (7) to 47 N,m (35 lb. ft.).

F. Check specifications for adjustment. Readjust
by repeating steps if necessary.
5
6
7
8
KNUCKLE, STEERING
ROD, STEERING LINKAGE OUTER TIE
ROD 1 STEERING LINKAGE INNE~ TIE
NUT, STEERING LINKAGE TIE ROD
ADJUST
9 BOOT, STEERING GEAR
MEASURING REAR ALIGNMENT ANGLES

Figure 9
012395
FS0083A
After front tire and wheel alignment has been

completed, the rear alignment angles should be
checked if there is excessive rear tire wear or tires and
wheels do not track properly. Rear tires and wheels
(14) should be parallel to and the same distance from
the vehicle's centerline;
Figure 8 Front Toe Adjustment
13
13
13
------------
Tighten
-\
l\
F
E
~G
"-t
E
14
14
14
A
A RIGHT SIDE OF REAR AXLE IS FORWARD
I'S
C
D
E
F
G
H
J
13
14
!TOE-OUT OF LEFT TIRE AND WHEEL AND

TOE-IN OF RIGHT TIRE AND WHEEL}
RIGHT SPINDLE IS NOT PERPENDICULAR TO
CENTERLINE OF VEHICLE
REAR VIEW OF REAR AXLE SAG
TOPVIEW
CENTERLINE OF TIRE ANO WHEEL
PERPENDICULAR TO CENTERLINE OF VEHICLE
PARALI.EL TO CENTERLINE OF VEHICLE
DEVIATION OF TOE FROM CENTERLINE OF VEHICLE
NEGATIVE CAMBER ANGLE
FRONT TIRE AND WHEEL
REAR TIRE AND WHEEL
Figure 9 Rear Tires and Wheels
012395
FS0093A
3A-6
WHEEL ALIGNMENT
If tires do not track correctly after a front tire

and wheel alignment, no amount of adjustment will
correct the problem. Poor tracking or excessive rear
tire wear after a front tire and wheel alignment usually
indicates that the axle housing, frame or suspension
arms have been bent.
Rear alignment angles can be checked as
follows:
!~!
D. Check amount of toe - which should be

0.0 degrees 0.3 degrees.
When using an alignment machine to
measure toe-out, the measurement will read
as toe-in on the scale.
When checking toe-in with a tram gage,
the measurement will read correctly as
toe-out. However, when using a tram gage,
it will still be necessary to perform steps A
and B to check camber.
Measure
Rear alignment angles.

A. Back vehicle squarely onto alignment machine.
B. Compensate for tire and wheel runout the
same as for checking front tire and wheel
toe-in.
C. Check camber reading - which should be
0.0 degrees 0.6 degrees.
REAR THRUST ANGLE ADJUSTMENT

If the thrust angle is not within specifications,
inspect the upper and lower control arms for damage.
If the control arms are not damaged, then check the
frame dimensions. Refer to SECTION 10-3.
SPECIFICATIONS
TIRE AND WHEEL ALIGNMENT SPECIFICATIONS
FRONT
Caster
Set .................................................................................................................................................. 5.0
Check ............................................................................................................................................. 5.0
Cross Caster
Set .................................................................................................................................................. 0.0
Ca;S,:~k ..................................................................................................................................... ;....... o.o
Set ............................................................................................................................................ ..... 0.4
Check ............................................................................................................................................. 0.4
Cross Camber
Set .................................................................................................................................................. 0.0
Check ............................................................................................................................................. 0.0
Individual Toe
Set .................................................................................................................................................. 0.0
Check ............................................................................................................................................. 0.0
Total Toe
Set .................................................................................................................................................. 0.0
Check ............................................................................................................................................. 0.0
Steering Wheel Angle
Set ......................................................................................................................................... ;........ o.o
Check ............................................................................................................................................. 0.0
0.5
1.0
+ 0.7
0.1
0.5
1.0
0.7
0.7
O.l
0.1
O
0.2
0.2
3.5
3.5
REAR
Camber
Set .................................................................................................................................................. O.o 0.6
Check ........................................................................................................~ .................................... 0.0 1.6
Cross Camber
Set ................................................................................. ;................................................................ 0.0 0.6
Check .........................................................................................................................................'.... o.o 0.6
Total Toe
Set .................................................................................................................................................. O.o 0.3
Check ................................................................. '. ........................................................................... 0.0 0.3
Thrust Angle
Set ................................................................................................................................................ 0.0 0.15
Check ........................................................................................................................................... 0.0 0.15"

Steering Linkage Tie Rod Adjust Nut .................................................................................... 47 N.m (35 lb. ft.)
WHEEL ALIGNMENT
3A-7
SPECIAL TOOLS
J 38658
1 CAMBER/CASTER ADJUSTER
01-23-9&
FS0103A
3A-8 WHEEL ALIGNMENT
BLANK
POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE
38-1
SECTION 38
POWER STEERING GEAR AND PUMP

ON-VEHICLE SERVICE
systems.
NOTICE: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When
disconnected, cap or plug all openings of components. Failure to do so could result in contamination or loss of
power steering fluid and damage. to the system.
CONTENTS
General Description ................................................. 3B-1
Power Steering Gear ........................................... 3B-1
Power Steering Pump ......................................... 3B-1
Seal Replacement ................................................3B-4
On-Vehicle Service .................................................. 3B-4
Checking and Adding Power Steering Fluid ..... 3B-4
Power Steering Fluid Replacement .................... 3B-4
Flushing the Power Steering System ............. 3B-4
Bleeding Air from the Power Steering
System ................................................... :.3B-4
Power Steering Pump Belt (Serpentine Belt) .... 3B-4
Power Steering Pump Pulley .............................. 3B-6
Power Steering Gear ......................................... 3B-7

Power Steering Gear Inlet and Outlet
Hoses ............................................................. 3B-8
Hydraulic Pump Flow Control Valve .............. 3B-9
Power Steering Pump ....................................... 3B-10
Power Steering Fluid Reservoir ................... 3B-12
Power Steering Fluid Reservoir Bracket ..... 3B-12
Power Steering Fluid Reservoir Hose .......... 3B-12
Specifications ......................................................... 3B-13
Power Steering Fluid Recommendations ......... 3B-13
Fitting Tightening Specifications ...................... 3B-13
Fastener Tightening Specifications ................... 3B-13
Special Tools ......................................................... 3B-14
GENERAL DESCRIPTION
steel cylinder lines to act on the rack and piston.

When the vehicle is turned right, the steering valve is
opened and routes pressurized fluid to the left side of
the piston, while allowing fluid to escape from the
right side and return to the valve area. The pressure of
the fluid is converted to a mechanical force applied to
the piston and the difference in force across the piston
causes the rack to move to the right. The opposite
occurs when the gear ( 1) is turned to the left.
Whenever the pump (32) provides pressurized fluid to
the gear (1) and the valve is operating correctly, the
effort to steer the vehicle is created by this pressure
difference at the piston. For information on power
steering gear unit repair, refer to SECTION 3B1A.
POWER STEERING GEAR

Figures 1 and 2
The major internal components of the steering
gear (1) are the power steering gear pinion and valve
shaft, steering gear rack and piston and tie rods (inner
and outer tie rods). The steering gear rack and piston
is supported at its ends in the steering gear housing
and sealed to prevent both external and leakage across
the piston. The pinion and valve intersects and meshes
directly with the teeth of the rack and piston. Manual
steering is always available at times when the engine
is not running or in the event of power steering pump
(32) or serpentine belt failure. Steering effort is
increased under such conditions.
The movement of the gear components, when
either parked or moving, is aided by hydraulic
pressure and fluid flow supplied by the power steering
pump (32). Pressurized fluid is directed by the valve
during a steer maneuver and travels through external
POWER STEERING PUMP

Figures 1 and 2
A constant displacement vane-type pump provides
hydraulic pressure and flow for the power steering
system. The pump (32) is located on the engine and is
belt driven by the power steering pulley (31).
38-2
11
33
32
1 GEAR, POWER STEERING

6
7
8
9
10
11
24
30
31
32
33
BOOT, STEERING GEAR

SHAFT, STEERING GEAR COUPLING
KNUCKLE, STEERING
CLAMP, STEERING GEAR CO.UPLING SHIELD
RESERVOIR, POWER STEERING FLUID
HOSE, POWER STEERING FLUID RESERVOIR
CAP, POWER STEERING FLUID RESERVOIR
HOSE, POWER STEERING GEAR INLET
PULLEY, POWER STEERING PUMP
PUMP, POWER STEERING
HOSE, POWER STEERING GEAR OUTLET
Figure 1 - Power Steering System (3800 VIN K)
10-17-94
F80133B
1
6
7
8
9
10
11
24
30
31
32
33
38-3
GEAR, POWER STEERING

BOOT, STEERING GEAR
KNUCKLE, STEERING
CLAMP, STEERING GEAR COUPLING SHIELD
HOSE, POWER STEERING FLUID
RESERVIOR
PULLEY, POWER STEERING PUMP
Ot-:2795
F80023B
Figure 2 Power Steering System (5.7L VIN P)
38-4
POWER STEERING .GEAR AND .PUMP ON-VEHICLE SERVICE
The major components of the pump (32) are the

drive shaft, pump housing, pump fitting, flow control
valve and spring, thrust and pressure plates, pump
ring, rotor and vanes.
The power steering system has a remote
reservoir (10). The reservoir cap (24) has a fluid level
indicator attached to show the fluid level in the
reservoir.
The bore at the front of the housing contains the
flow control fitting, working with the flow control
valve and spring, it limits the maximum flow of the
pump (4). The pressure relief valve, inside the flow
control valve, limits the maximum pump (4) pressure.
The flow control valve, spring and pump fitting
are located in the casting boss that runs across the
housing. For information on power steering pump unit
repair, refer to SECTION 3BlB.
Flushing the Power Steering System

NOTICE: When adding fluid or making a
complete fluid change, always use the proper
fluid. Failure to use the proper fluid will cause
hose and seal damage and fluid leaks. Refer to
"Power Steering Fluid Recommendations" in
this section.
1. Raise and suitably support front of vehicle off
ground until tire and wheels are free to turn.
Refer to SECTION OA.
2. Remove reservoir hose at fluid reservoir inlet
connector and plug fluid inlet connector port on
fluid reservoir.
[I]
Important
SEAL REPLACEMENT
Lip Seals
Lip seals, which seal rotating shafts, require
special treatment. This type of seal is used on the
hydraulic pump shaft of the pump. When leakage
occurs in this area, always replace the seal or seals,
after inspecting and thoroughly cleaning the sealing
surfaces. Replace the shaft if pitting is found. If
corrosion in the lip seal contact zone is slight, clean
the surface of the shaft with crocus cloth. Replace the
shaft only if the leakage cannot be stopped by
smoothing with crocus cloth first.
0-Ring Seals
Whenever a part which forms a sealing surface
for an 0-ring is removed, the 0-ring seal should also
be removed and replaced with a new 0-ring seal.
Lubricate all new 0-ring seals with power steering
fluid to ease.
ON-VEHICLE SERVICE
CHECKING AND ADDING POWER
STEERING FLUID
Fluid level is indicated by marks on a fluid level
indicator on the reservoir cap.
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.
-
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.
POWER STEERING FLUID REPLACEMENT

The fluid replacement procedure is a two-stage
process: first, flushing the old fluid from the system
with new fluid: and second bleeding the system to
remove . trapped air. The following two sequences
outline the steps in each procedure.
Position inlet or reservoir hose toward large

container to catch draining fluid.
3. While an assistant is filling fluid reservoir with
fluid, start and run engine at idle.
NOTICE: Do not hold the steering wheel
against stops while flushing the system. Holding
steering wheel against wheel stops will cause
high system pressure, overheating, and damage
to the pump and/ or steering gear.
4. Turn steering wheel from stop to stop.
5. Continue draining until all old fluid is cleared
from power steering system. Addition bf
approximately 0.94 liters (1 quart) of new fluid
will be required to flush system.
IL!
Inspect
Draining fluid while refilling fluid reservoir.

- If necessary, replace all lines and
disassemble, and clean or replace system
components.
- Do not reuse any drained fluid.
6. Unplug reservoir hose at fluid reservoir inlet
connector.
7. Turn engine off and fill fluid reservoir to "C"
mark on fluid level indicator. Continue with
following procedure "Bleeding the Power Steering
System."
Bleeding Air from Power Steering Systems

Figure 3
Refer to Figure 3 for recommended steering
system bleed procedure.
POWER STEERING PUMP BELT

(SERPENTINE BELT)
The pump is
adjustment of the
remove or install
SECTION 6A3A or
driven by a serpentine belt. No

serpentine belt is required. To
the serpentine belt, refer to
6A8A.
38-5
Bleeding Air from Power Steering Systems

Before bleeding:
Inspect steering system.

Check, and correct as needed:
Hoses must
not touch any
other part of
~........ vehicle.
All hose
connecbons
must be
tight.
Power Steering Fluid
After any component replacement

After d1sconnect1ng flwd line
In case of steenng system noise
Use only clean, n,ew power

steering fluid Fluid must be
Why bleed?
To prevent pump damage
To ensure proper system operation
To stop steering system noise
Loose connections might not

leak but could allow iu,r 1n10
system
Steenng system noise could

be caused by hose touching
frame, body, or engine
When to bleed:
How to bleed:
Special Conditions:
Fluid
~J
ch
0 - ~ S w i tignit,on
off.
Foam or bubbles tn fluid

Fluid must be completely free of bubbles
In step 5, b,e al,ert to penod1c bubbles tha1
could 1nd1cate a loose connection or leak
0-nng seal 1n either the return hose or
pressure hose
A~
V
f t ~ R. atse front
V
wheels off
,t
'
ground.
Al
~1Tumsteer,ng
W
wheel full left.
AED
V
'-
minutes
~3
Fill fluid
reservoir to
"FULL COLD"
level. Leave
cap off
tP.\
W
w,,h assistant chec~ng

fluid level and condtt1on .
turn steering wheel lockto-lock at least 20 times
Engine remains oft
Fill system and repeat bleed procedure for

each possible cause Repeat steps 7-10 to
venfy whether noise has been eliminated
Whtie turning
wheel, check fluid
constantly
apply, procedure 1s
complete
C9
With engme running, recheck

hoses for possible contact with
frame body or engine If no
contact 1s found, follow either
method below to cool down fluid
and repressunze system
Venfy
0 Smooth power assist
0 Noiseless operation
0 Proper fluid level
0 No system leaks
~ Proper fluid condition
G, If all proper cond1t1ons
Keep flrnd level at "FULL COLD "
For any sign of bubbles. rech,eck

connections Repeat step 5
'21 Return hose clamps

'21 Return hose 0-nng
'21 Pressure hose 0-nngs
'21 Gear cylinder line 0-nngs
wheel 1n both
directions
No bubbles, no foam. no
d1scolorat1on
Trapped air may cause fluid to overllow

Thoroughly clean any spilled fluid to allow
for leak check
No bubbles are allowed
I
t:::J
1,,-:_
~ Tum stmng
:::s
(milky, opaque, or light tan color)
Switch 1grnt1on off Wait two minutes Recheck

hose connections Repeat steps 7 -10 If
cond1t1on still exists, replace and check a
possible cause
Pump whine or groan
On systems with long return Imes or fluid

coolers, turn steering wheel lock-to-lock at
least 40 limes
Discolored fluid
Return wheels
to center
Lower front
wheels to
ground.
A
~ Keep
engme
W
1
running for two
I, -:_ I
~
Conventional Climate
GM #1052884 - 16 ounce
#1050017 - 32 ounce
Cold Climate
GM #12345866- 16 ounce
#12345867 - 32 ounce
If any problem remains,

see "Special Cond1t1ons "
Method 1:
Normal Cool Down
Switch engine off
Wait for system
to cool
Install reservou cap
Method 2:
Partial Fluid
Replacement
Switch engine off
Use a suction device to
remove fluid from reservo1
Refill with cool, clean fluid
Install reservoir cap
After either method of cooling, start engine and allow engine to

come up to operating temperature If noise persists. remove anc
replace power steenng pump Repeat bleed procedure follow1n
pump replacement
4-14-94
IJ~B
Figure 3 Bleeding Air from Power Steering Systems
38-6
POWER STEERING PUMP PULLEY

Figure 4
Tools Required:
J 25034-B Pump Pulley Remover
J 25033-B Pump Pulley Installer
f++!
11. Inlet and reservoir hoses from pump 5.7L VIN P

only. Refer to "Power Steering Gear Inlet and
Outlet Hoses" and "Power Steering Fluid
Reservoir" in this section.
12. Pulley (31) from pump (32) using J 25034-B.
!++!
Install or Connect
1. Pulley (31) to pump (32) using J 25033-B
1. Raise and suitably support vehicle on 5.7L VIN P

only. Refer to SECTION OA.
2. Drain engine coolant on 5.7L VIN P only. Refer
to SECTION 6B.
3. Serpentine belt. Refer to SECTION 6A3A or
6A8A.
4. Lower vehicle.
5. Front air intake duct.
6. Generator on 5.7L VIN P only. Refer to
SECTION 6D3.
7. Radiator outlet hose from engine on 5.7L VIN P
only. Refer to SECTION 6B.
8. Heater inlet and outlet hoses from water pump on
5.7L VIN P only. Refer to SECTION IA.
9. Throttle body heater return hose from heater
outlet hose on 5.7L VIN P only. Refer to
SECTION IA.
10. Power steering pump bolts/screws (21) on 5.7L
VIN P only. Refer to "Power Steering Pump" in
this section.
rn
2.
3:
4.
5.
6.
Important
Face of pulley hub must be flush with end of

pump shaft before applying load to pulley hub.
Load required to press pulley hub onto pump
shaft must be greater than 6 672 N (1,500 lbs.)
but less than 31 136 N (7,000 lbs.).
Inlet and reservoir hoses to pump 5.7L VIN P
only. Refer to "Power Steering Gear Inlet and
Outlet Hoses" and "Power Steering Fluid
Power steering pump bolts/screws on 5.7L VIN P
only. Refer to "Refer to Power Steering Pump" in
this section.
Throttle body heater return hose to heater outlet
hose on 5.7L VIN P only. Refer to SECTION IA.
Heater inlet and outlet hoses to water pump on
Radiator outlet hose to engine on 5.7L VIN P
32
32
31 PULLEY, POWER STEERING PUMP

GMt7-t5
fl80o43B
Fi,gure 4 - Power Steering Pump Pulley (Typical)

SECTION 603.
SECTION 6A8A.
11. Lower vehicle.
12. Refill and bleed engine coolant. Refer to
SECTION 6B.
13. Refill and bleed power steering system on 5.7L
VIN P only. Refer to "Bleeding the Power
Steering System" in this section.
Figure 5
!++!
Install or Connect
NOTICE:
Refer to "Notice" on page 3B-1.
1. Position steering gear (1) to crossmember (34).
!~I

SECTION OA.
2. Special security wheel lock nuts, if equipped.
Refer to SECTION 3E.
3. Tire and wheels. Refer to SECTION 3E.
4. Place drain pan under steering gear (1).
5. Inlet and outlet hoses from steering gear. Refer to
"Power Steering Gear Inlet and Outlet Hoses" in
this section.
6. Steering gear outer tie rod from steering knuckle.
Refer to SECTION 3B1A.
1
8
26
27
34
7. Steering gear coupling shaft from steering gear.

Refer to SECTION 3F.
8. Nuts (26) and bolts/screws (27).
9. Steering gear (1).
Adjust
Steering gear (1) so it aligns as straight as

possible with steering gear coupling shaft.
2. Hand start bolts/screws (27) and nuts (26).
3. P~sition back-up wrench to nuts (26).
POWER STEERING GEAR
I++!
38-7
Tighten
Bolts/screws (27) to 85 N.m (63 lb. ft.)

4. Steering gear to steering gear coupling shaft.
5. Steering gear outer tie rods to steering knuckles.
Refer to SECTION 3B1A.
6. Inlet and hoses to steering gear. Refer to "Power
Steering Gear Inlet and Outlet Hoses" in this
section.
7" Tire and wheels. Refer to SECTION 3E.

KNUCKLE, STEERING
NUT, STEERING GEAR
BOLT/SCREW, STEERING GEAR
CROSSMEMBER, FRONT
012795
FS00538
Figure 5 - Power Steering Gear
38-8
9. Lower vehicle.
10. Refill and bleed power steering system. Refer to
"Bleeding the Power Steering System" in this
section.
POWER STEERING GEAR INLET AND

OUTLET HOSES
Figures 6 and 7
E~
1. Place drain pan under steering gear (1) and pump

(32).
SECTION OA.
3. Power steering gear inlet and outlet hoses (30 and
33) from steering gear (1).
to SECTION 6B.
5. Serpentine belt on 5.7L VIN P only. Refer to
SECTION 6A3A.
6. Lower vehicle.
7. Front intake duct on 5.7L VIN P only.
8. Generator on 5. 7L VIN P only. Refer to
SECTION 603.
only. Refer to SECTION IA.
outlet on 5. 7L VIN P only. Refer to
SECTION IA.
12. Power steering pump bolts/screws on 5.7L VIN P
only. Refer to "Power Steering Pump" in this
section.
13. Inlet hose (30) from pump (32).
14. Power steering fluid reservoir bolt/screw and
power steering fluid reservoir retainer on 5.7L
VIN P only. Refer to "Power Steering Fluid
15. Outlet hose (33) from reservoir (10).
I++!
Install or Connect
NOTICE:
Refer .to "Notice" on page 3B-1.
NOTICE: Inlet and outlet hoses must be

installed to clear each other and all surrounding
parts to prevent chafing. Use minimum
clearance of 12 mm (0.47 inch). The outlet hose
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. Outlet hose (33) to reservoir (10). Lubricate with
power steering fluid as required.
11
1
11
30
32
33

11-7-94
F80l83IS
Figure 6 " Power Steering Gear Inlet and Outlet Hoses

(3800 VIN K).

power steering fluid reservoir retainer on 5.7L
VIN P only. Refer to "Power Steering Fluid
3. Inlet hose (30) to pump (32).
I~! Tighten
Inlet hose (30) to 28 N.m (21 lb. ft.).
4. Power steering pump bolts/screws on 5.7L VIN P
section.
5. Throttle body heater return hose to heater outlet
hose on 5.7L VIN P only. Refer to.SECTION lA.
6. Heater inlet and outlet hoses to water pump on
7. Radiator outlet hose to engine on 5.7L VIN P
SECTION 603.
9. _Front air intake duct on 5.7L VIN P only.
38-9
11
30
,t~~
1,-V-IEW_A..,I
30
1
10
11
24
30
32
33
40

HOSE, POWER STEERING FLUID RESERVIOR
CLIP, POWER STEERING GEAR PIPE
012715
FSI0738
Figure 7 Power Steering Gear Inlet and Outlet Hoses (5.7L VIN P)
10. Raise and suitably support vehicle on 5.71 VIN P

11. Serpentine belt on 5.71 VIN P only. Refer to
SECTION 6A3A.
!~I
Tighten
12. Inlet and outlet hoses (30 and 33) to steering gear
(1).
!~I
Tighten
Inlet hose (2 or 30) to 28 N.m (21 lb. ft.).

Outlet hose (5 or 33) to 28 N,m (21 lb. ft.).
13. Outlet hose (33) to pump (32).
!~I
Tighten
Outlet hose (33) to 28 N,m (21 lb. ft.).

14. Lower vehicle.
15. Refill and bleed engine coolant on 5.71 VIN P
"Bleeding the Power Steering System" in this
section.
HYDRAULIC PUMP FLOW CONTROL

VALVE
Figure 8
I++!
1. Place drain pan under pump (32).

2. Inlet hose (30) from fitting (15).
3. Fitting (15) and 0-ring seal (14).
II]
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. Flow control valve (13) and valve spring (12)
from pump (32) using magnet.
rn
Important
Do not disassemble the flow control valve.
!L!
Inspect
Flow control valve (13) for free movement within

housing bore.
-
If sticking occurs check for burrs and clean as

necessary.
- If necessary, replace flow control valve (13).
38-10

POWER STEERING PUMP
Figures 9 and 10
!++!
32
11
12
13
14

SPRING, HYDRAULIC PUMP FLOW CONTROL VALVE
VALVE, HYDRAULIC PUMP FLOW CONTROL
SEAL, HYDRAULIC PUMP FLOW CONTROL VALVE
(0-RING}
15 FITTING, HYDRAULIC PUMP
30 HOSE, POWER STEERING GEAR INLET
32 PUMF:', POWER STEERING
013885
FS0083B
~ure 8 Hydraulic Pump Flow Control Valve (Typical)
I:!]
Install or Connect
NOTICE:
11]
..
1. Place drain pan under pump (32).

only. Refer to SECIJON OA.
to SECTION 6B.
6A8A.
5. Lower vehicle.
SECTION 603.
5.7LVIN P. Refer to SECTION lA.
10, Throttle body heater return from heater outlet
hose on 5.7L VIN P only. Refer to SECTION lA.
11. Bolts/screws (21) on 5.7L VIN P only.
12. Pulley from pump on 3800 VIN K only. Refer to
"Power Steering Pump Pulley" in this section.
13. Inlet and reservoir hoses from pump. Refer to
"Power Steering Gear Inlet and Outlet Hose" in
this section.
14. Nuts (20) on 3800 VIN K only.

15. Pump (32).
Important
The flow control valve (13) should be installed

face out, away from contact with the valve spring
(12).
1. Valve spring (12) and flow control valve (13) to
pump (32).
2. New 0-ring seal (14) to fitting (15).
11]
Important
Lubricate 0-ring seal (14) with power steering

fluid.
3. Hand start fitting (15) and 0-ring seal (14) to
pump (32).
I~!
Tighten
Fitting (15) to 75 N,m (55 lb. ft. ).

4. Inlet hose (30) to fitting (15).
!~I
Tighten
Inlet hose (30) to 28 N.m (21 lb. ft.).

5. Fill reservoir with fluid. Refer to "Checking and
Adding Power Steering Fluid" in this section.
6. Bleed system. Refer to "Bleeding air from the
Power Steering System" in this section.
11
HOSE, POWER STEERING FLUID

RESERVOIR
20 NUT, POWER STEERING PUMP
10-17-M
F80Dl38
Figure 9 - Power Steering Pump (3800 VIN K)
38-11

SECTION 603.
6A8A.
14. Lower vehicle.
15. Refill and bleed engine coolant system on 5.7L
VIN P only. Refer to SECTION 6B.
"Bleeding Air from the Power Steering System"
in this section.
Power Steering Fluid Reservoir

Figures 11 and 12
j++!
4
11
21
36

BOLT/SCREW, POWER STEERING PUMP
BRACKET, GENERATOR AND AIR
CONDITIONER COMPRESSOR AND POWER STEERING
PUMP AND DRIVE BELT TENSIONER
012795
FB0103B
Figure 10 Power Steering Pump (5.7L VIN P)
!H!
Install or Connect
NOTICE:
1. Position pump (32) to mounting studs on 3800

VINK only.
2. Nuts (20) on 3800 VIN K only.
!~!
Tighten

3. Inlet and reservoir hoses to pump. Refer to
"Power Steering Gear Inlet and Outlet Hoses"
and "Power Steering Fluid Reservoir Hose" in
this section.
4. Pulley to pump on 3800 VIN K only. Refer to
"Power Steering Pump Pulley" in this section.
5. Position pump (30) to bracket (36) on 5.7L VIN P
only.
6. Bolts/screws (21) on 5.7L VIN P only.
!~!
Tighten

hose on 5.7L VIN P only. Refer to SECTION lA.
8. Heater inlet and outlet hoses to water pump on
5.7L VIN P only. Refer to SECTION lA.
9. Radiator outlet hose to engine on 5.7L VIN P.
1. Place drain pan under reservoir (10).

2. Cap (24) from reservoir (10).
3. Reservoir (10) from bracket (16) on 3800 VIN K
only.
4. Bolt/screw (22) and retainer (23) on 5.7L VIN P
only.
5. Outlet hose and reservoir hose from reservoir.
Refer to "Power Steering Gear Inlet and Outlet
Hoses" and "Power Steering Fluid Reservoir
Hose" in this section.
6. Reservoir (10).
!++!
Install or Connect
NOTICE:
1. Outlet hose and reservoir hose to reservoir. Refer

to "Power Steering Gear Inlet and Outlet Hoses:
and "Power Steering Fluid Reservoir Hose" in
this section.
2. Position reservoir (10) to right front wheelhouse
on 5.7L VIN P only.
3. Retainer (23) and bolt/screw (22) on 5.7L VIN P
only.
!~!
Tighten
Bolt/screw (22) to 10 N,m (89 lb. in.).

4. Reservoir (10) to bracket (16) on 3800 VIN K
only.
5. Cap (24) to reservoir (10).
in this section.
38-12
16
11
10
11
16
30
32
33
37
38

BRACKET, POWER STEERING FLUID RESERVOIR
BOLT/SCREW, POWER STEERING RESERVOIR BRACKET
NUT, POWER STEERING FLUID RESERVOIR BRACKET
30
10-17-94
FSOl53B
Figure 11 Power Steering Fluid Reservoir and Bracket (3800 VIN K)
Power Steering Fluid Reservoir Bracket

3800 VINK
2.
Figure 11
Remove or Disconnect.
3.
4.
5.
1. Reservoir (10) from bracket (16).
!++!
!++I
Using wire or equivalent, secure reservoir in a

upright position to avoid leakage.
SECTION OA.
Electrical harness from bracket (16).
Bolt/screw (37).
Nuts (38).
Install or Connect
NOTICE: Refer to "Notice" on page 3B-l.

1. Nuts (38).
23
l~J Tighten
Nuts (38) to 12 N.m (107 lb. in.)
2. Bolt/screw (37).
!~! Tighten
3. Electrical harness to bracket (16).
4. Lower vehicle.
5. Reservoir (10) to bracket (16).
A
B
5
10
11
22
23
24
CLAMP, POWER STEERING HOSE

CLAMP, POWER STEERING RESERVOIR HOSE
HOSE. POWER STEERING GEAR OUTLET
BOLT/SCREW, POWER STEERING FLUID RESERVOIR
RETAINER, POWER STEERING FLUID RESERVOIR
0127-SIS
FS01131
Figure 12 - Power Steering Fluid Reservoir (5.7L VIN P)
Power Steering Fluid Reservoir Hose

Figures 7 and 11
!++!
1. Raise and suitably support vehicle on 5.7L VlN P

to SECTION 6B.
3. Serpentine belt on 5.7L VIN P only. Refer to
SECTION 6A3A.
1. Reservoir hose (11) to reservoir (10) using clamp.

Lubricate with power steering fluid as required.
2. Power steering fluid reservoir retainer and power
steering fluid reservoir bolt/screw. Refer to
"Power Steering Fluid Reservoir" in this section.
3. Reservoir hose (11) to pump (32).
4. Power steering pump bolts/screws. Refer to
"Power Steering Pump" in this section.
hose. Refer to SECTION lA.
6. Heater inlet and outlet hoses to water pump. Refer
to SECTION lA.
7. Radiator outlet hose from engine on 5. 7L VIN P
8. Generator. Refer to SECTION 603.
SECTION OA.
11. Serpentine belt. Refer to SECTION 6A3A.
12. Lower vehicle.
13. Refill and bleed engine coolant. Refer to
SECTION 6B.
in this section.
4. Lower vehicle.
5. Front air intake duct on 5.7L VIN P only.
SECTION 603.
7. Radiator outlet hose from engine on 5. 7L VIN P
5.7L VIN P only. Refer to SECTION lA.
outlet on 5. 7L VIN P only. Refer to
SECTION lA.
10. Power steering pump bolts/screws on 5.71 VIN P
section.
11. Reservoir hose (11) from pump (32).
power steering fluid reservoir retainer from
reservoir on 5.7L VIN P only. Refer to "Power
Steering Fluid Reservoir" in this section.
13. Reservoir (10) from bracket (16) on 3800 VIN K
only.
14. Reservoir hose (11) from reservoir (10).
!++!
Install or Connect
NOTICE:
38-13
SPECIFICATIONS
POWER STEERING FLUID RECOMMENDATIONS
Temperate Climate
Power Steering Fluid Requirement
GM Power Steering Fluid PIN 1050017 or 1052884, or equivalent meeting GM Specification 9985010
Cold Climate
Power Steering Fluid RequirementGM Power Steering Fluid PIN 12345867 or 12345866 (System should
be drained and refilled prior to using this fluid.)
FITTING TIGHTENING SPECIFICATIONS

Hydraulic Pump Fitting-to-Power Steering Pump .................................................................. 75 N.m (55 lb. ft.)
Power Steering Gear Inlet Hose Fitting-to-Power Steering Gear ......................................... 28 N.m (21 lb. ft.)
Power Steering Gear Inlet Hose Fitting-to-Power Steering Pump ........................................ 28 N,m (21 lb. ft.)
Power Steering Gear Outlet Hose Fitting-to-Power Steering Gear ...................................... 28 N.m (21 lb. ft.).

Power
Power
Power
Power
Power
Power
Power
Steering
Steering
Steering
Steering
Steering
Steering
Steering
Fluid Reservoir Bolt/Screw (5.7L VIN P) .................................................... 10 N.m (89 lb.in.)

Fluid Reservoir Bracket Bolt/Screw (3800 VIN K) .................................... 50 N.m (37 lb. ft.)
Fluid Reservoir Bracket Nuts(3800 VIN K) .............................................. 12 N.m (107 lb. in.)
Gear Bolt/Screw ............................................................................................ 85 N.m (63 lb. ft.)
Pump Bolt/Screw (5.7L VIN P) .................................................................. 25 N.m (18 lb. ft.).
Pump Nut (3800 VIN K) ............................................................................. 30 N.m (23 lb. ft.)
Pump Rear Bracket Bolt/Screw (5.7L VIN P) ........................................... 50 N.m (37 lb.. ft.)
38-14
SPECIAL TOOLS
,.
J 25034-8
2.
J 25033-B
1. PUMP PULLEY REMOVER

2. PUMP PULLEY INSTALLER
013015
FS01238
POWER STEERING GEAR UNIT REPAIR
381A1
SECTION 381A
POWER STEERING GEAR

UNIT REPAIR
NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part
number for that application. General Motors will call out those fasteners that require a replacement after removal. General
Motors will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED,
do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint
interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage
the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these
instructions can help you avoid damage to parts and systems.
CONTENTS
Power Rack & Pinion Steering Gear Assembly ... 3B lA-2
Outer Tie Rod .................................................. 3B lA-3
Rack Bearing Preload ...................................... 3B1A-4.
Rack & Pinion Boot ......................................... 3B1A-4
Inner Tie Rod ................................................... 3B1A-4
Cylinder Line Assembly and 0-Ring Seals .... 3B1A-5
Pinion Seal, Dust Seal and Bearing

Annulus Assembly ........................................... 3B1A-6
Specifications ....................................................... 3B1A-9
Fluid Capacities ............................................... 3B1A-9
Fastener Tightening Specifications ................. 3B lA-9
Special Tools ........................................................ 3B lA-9
381 A-2
10
2
,,
~. 5a-3
J
9-
~6
Figure 1 Power Rack and Pinion - End Take Off

Key No.
Part Name
Key No.
1 - NUT, HEXAGON SLOTTED

2 - PIN, COTTER
3 - SEAL, TIE ROD
5 - ROD ASM, OUTER TIE
6 - FITTING, LUBE (90 DEG ELBOW)
7 - NUT, METRIC HEX (M14 X 1.5)
8 - CLAMP, TIE ROD END
10 - BOOT, RACK & PINION
11 - CLAMP, SEAL RETAINING
12 - ROD ASM, INNER TIE
13 - RING, SHOCK DAMPENER
15 - NUT, ADJUSTER PLUG LOCK
16 - ADAPTER, SEAL
3B1A-3
Part Name
17- RING, RETAINING

20 - SEAL, STUB SHAFT
21 - BEARING ANNULUS ASM, NEEDLE
23 - SEAL, 0-RING (4.50 I.D.)
25 - LINE ASM, CYLINDER {RT}
26 - LINE ASM, CYLINDER (LT)
30 - GEAR ASM, RACK & PINION (PARTIAL)
32 - NUT, HEX LOCK
33 - COVER, DUST
35 - CLIP, PIPE
36 - BUSHING, STEERING GEAR
37 - SLEEVE, STEERING GEAR BUSHING
Figure 2 Power Rack and Pinion - End Take Off- Legend
OUTER TIE ROD

Figures 1 thru 3
Tool Required:
J 24319-01 Universal Steering Linkage Puller
14- .,.! Remove or Disconnect

1.
2.
3.
4.
l+tl
1.
2.
Cotter pin (2) and hex slotted nut (1) from outer tie
rod assembly (5).
Loosen hex nut (7).
Outer tie rod (5) from steering knuckle with
J 24319-01.
Outer tie rod (5) from inner tie rod (12).
Adjust
Toe by turning inner tie rod (12).
[ [ ) Important
Be sure rack and pinion boot (10) is not

twisted or puckered during toe adjustment.
Tighten
Hex nut (7) against outer tie rod (5) to
68 Nm (50 lb. ft.).
Install or Connect
Outer tie rod assembly (5) to inner tie rod (12). Do
not tighten hex nut (7).
Outer tie rod (5) to steering knuckle, hex slotted
nut (1) to outer tie rod stud.
3.
IZJ
Tighten
Hex slotted nut (1) to 47 Nm (35 lb. ft.).
Tighten nut up to 1/6 additional tum, or 70
Nm (52 lb. ft.) maximum, to align cotter pin
slot.
Do not back off nut for cotter pin
insertion.
Cotter pin (2) into hole in tie rod stud (5).

A-STEERING KNUCKLE
A
,~::/',
1-NUT, HEXAGON SLOTTED
~,;~~fr')
2-PIN COTTER
1
'JJ,,v / - 5-ROD ASM, OUTER TIE
~~/
2
7-NUT, METRIC HEX (M14 X 1.5)
~
12-ROD ASM, INNER TIE
Figure 3 Outer Tie Rod Replacement
3B1A-4
RACK BEARING PRELOAD

(on vehicle adjustment)
1+4-1 Install or Connect
Figure 15
IZJ
1.
2.
3.
1.
Adjust
2.
Make adjustment with front wheels raised and

steering wheel centered. Be sure to check
retumability of the steering wheel to center after
adjustment.
.
Loosen adjuster plug lock nut (15) and tum adjuster
plug clockwise until it bottoms in gear assembly
(30), then back off 50 to 70 (approximately one
flat).
Lock nut (15) to adjuster plug.
3.
New seal retaining clamp (11) onto rack and pinion

boot (10).
Apply grease to inner tie rod ( 12) and gear assembly
(30) prior to boot installation (see Figure 5).
Boot (10) onto inner tie rod assembly (12).

Boot (10) onto gear assembly (30) until seated in
gear assembly groove.
[1J Important
Tighten
Lock nut (15) to 75 Nm (55 lb. ft.) while
holding adjuster plug stationary.
RACK & PINION BOOT

Figures 1 thru 6
Tool Required:
J 22610 Service Boot Clamp Installer
4.
5.
6.
7.
Boot ( 10) must not be twisted, puckered or

out of shape in any way. If the boot is not
shaped properly, adjust by hand before
installing seal retaining clamp (11).
Seal retaining clamp (11) on boot (10) with tool

J 22610 and crimp as shown (see Figure 6).
Tie rod end clamp (8) with pliers on boot (10).
Hex nut (7) to inner tie rod assembly (12).
Do all steps of OUTER TIE ROD "Install or
Connect."
INNER TIE ROD

Figures 1 thru 9
14"..,.I Remove or Disconnect

1.
2.
3.
4.
5.
Do all steps of OUTER TIE ROD "Remove or

Disconnect."
Hex nut (7) from inner tie rod assembly (12).
Tie rod end clamp (8).
Seal retaining clamp (11) with side cutters and
discard.
Rack and pinion boot (10).
14-..,.I
1.
2.
3.
Rack and pinion assembly from vehicle (see

Section 3B).
Do all steps of RACK & PINION BOOT "Remove
or Disconnect."
Shock dampener (13) from inner tie rod assembly
(12) and slide back on rack (see Figure 7).
APPLY GREASE TO
THESE AREAS
10
30
8
~
7-NUT, METRIC HEX (M1i~ 1.5)

~.
8-CLAMP, TIE ROD END
10-BOOT, RACK & PINION
11-CLAMP, SEAL RETAINING
30-GEAR ASM, RACK & PINION (PARTIAL)
Figure 4 Rack and Pinion Boot Replacement
10-BOOT, RACK & PINION

Figure 5 Boot Seal Grease Application

Notice: Steering gear rack must be held stationary during
inner tie rod removal to prevent steering gear damage. Use
an appropriate size wrench at the rack teeth to hold the rack
during inner tie rod removal. For right side inner tie rod
removal, it will be necessary to remove the left side boot to
access the rack teeth.
4.
Inner tie rod assembly (12) from rack assembly as

follows: (See Figure 7.)
Place a wrench on flat of rack assembly.
Place another wrench on flats of inner tie rod

housing.
Rotate inner tie rod housing counterclockwise until inner tie rod (12) separates from
rack.
I+.,! Install or Connect

1.
Remove old Loctite@ from threads of rack and inner

tie rod.
Notice: Steering gear must be held stationary during inner

tie rod installation to prevent steering gear damage.
4.
2.
3.
Threads must be clean prior to Loctite application. Be sure Loctite@ container expiration
date has not passed. Do not use too much
Loctite@. Use only enough to evenly coat
threads.
Apply Loctite 262 to inner tie rod threads

(see Figure 8).
If shock damper was removed, slide it onto steering
gear.
Install inner tie rod assembly onto steering gear

(see Figure 9).
5.
6.
7.
Tighten
Inner tie rod (12) to 100 Nm (74 lb. ft.)
Slide shock dampener up against inner tie rod

assembly.
Do all steps of RACK & PINION BOOT "Install
or Connect."
Rack and pinion assembly to vehicle (see
Section 3B).
CYLINDER LINE ASSEMBLY

and 0-RING SEALS
Figures 1 and 2
Tools Required:
12mm Flare Nut Wrench
16mm Flare Nut Wrench
[ ] ] Important
14" .,.I
1.
2.
3.
4.
Loosen cylinder line fittings (25) or (26) on cylinder
end of gear assembly (30).
Loosen fittings on cylinder line assemblies (25) or
(26) at valve end of gear assembly (30).
Cylinder line assemblies (25) or (26) from rack and
pinion gear assembly (30).
0-ring seals (23) from valve end oflines (25) or (26)
and discard.
13
J22610
10-BOOT, RACK AND PINION
11-CLAMP, SEAL RETAINING
Figure 6 Boot Clamp Installation
381A-5
A-RACK ASM, PISTON AND STEERING

8-HOUSING, INNER TIE ROD
13-RING, SHOCK DAMPENER
Figure 7 Inner Tie Rod Removal
3B1A-6

3.
4.
5.
1+4-1 Install or Connect
ILI
Inspect
6.
Lines for:
Cracks.
Dents.
Damage to threads.
Replace as needed.
1.
2.
7.
Notice: Carefully align threads on all fittings and finger

tighten to avoid stripping and cross-threading.
Notice: Stub shaft must be held to prevent damage to the

pinion teeth.
New 0-ring seals (23) to valve end of lines (25)

or (26).
Cylinder line assemblies (25) or (26) to gear
assembly (30).
Adjuster plug from gear assembly (30).

Adjuster spring and rack bearing.
Retaining ring ( 17) from valve bore of gear
assembly (30).
Dust cover (33) from bottom of gear assembly (30)
(see Figure 11).
Hex lock nut (32) from lower end of pinion and

valve assembly, while holding stub shaft with
14 mm Crowfoot Wrench (see Figure 11).
Notice: DO NOT hammer or pound on pinion and valve

assembly. This will cause damage or loosen the drive
pin.
[II Important
Tighten
Valve end fittings to 16.9 Nm (12.5 lb. ft.).

Cylinder end fittings to 27 .0 Nm (20 lb. ft.).
PINION SEAL, DUST SEAL

and BEARING ANNULUS ASSEMBLY
Figures 1, 2, 10 Thru 15
8.
Tools Required:
J 29810 Stub Shaft Seal Protector
14 mm Crowfoot Wrench
When performing the following procedure,

do not remove pinion and valve assembly
from gear assembly. Press pinion and valve
assembly only far enough to allow removal
pf bearing annulus aud seal. Pinion and valve
assembly removal is not required.
Use an arbor press (see Figure 12). Press on

threaded end of pinion until it is possible to remove
stub shaft seal (20), and stub shaft bearing <lllnulus
assembly (21) (see Figure 13).
I+..,., Remove or Disconnect

1.
2.
Rack and pinion steering assembly from vehicle

(see Section 3B).
Adjuster plug lock nut (15) from adjuster plug (see
Figure 10).
APPLY
LOCTITE

Figure 8 Inner Tie Rod Installation
A-RACK ASM, PISTON AND STEERING

8-HOUSING, INNER TIE ROD
C-TORQUE WRENCH
30-GEAR ASM, RACK&. PINION (PARTIAL)
Figure 9 Inner Tie Rod Tightening
1+4-l install or Connect
9.
1.
2.
3.
4.
5.
6.
7.
8.
Hex lock nut (32) onto pinion, while holding the

valve stub shaft.
Tighten
Hex lock nut (32) to 30 Nm (22 lb. ft.).
Dust cover (33) to gear assembly (30).

Stub shaft bearing annulus assembly (21) onto valve
stub shaft.
Seal protector J 29810 onto valve stub shaft.
Apply a small quantity of grease to seal (20).
Stub shaft seal (20) over protector and into

gear assembly (30).
Retaining ring (17) into groove in gear
assembly (30).
Lubricate stub shaft and dust seal area with grease.
Coat rack bearing, adjuster spring and adjuster plug
with lithium base grease and install in gear
assembly (30) (see Figure 15).
rzJ
Lock nut (15) to adjuster plug.
Notice: If the stub shaft is not held, damage to the

pinion teeth will occur.
10.
3B1A-7
Tighten
Lock nut (15) to 75 Nm (55 lb. ft.) while
holding adjuster plug stationary.
Rack and pinion assembly into vehicle.
II] Important
Flush and bleed power steering system (hoses,

reservoir and cooler lines) with cold climate
power steering fluid - GM Part #12345866
16-oz. or 12345867 32-oz. (see flushing and
bleeding procedures, Section 3B).
Adjust
With rack centered in the gear assembly (30),
tum adjuster plug clockwise until it bottoms
in the gear assembly, then back off 50 to 70
(approximately one flat). Check rotational
torque on pinion. Maximum pinion preload
torque is 1.8 Nm (16 lb. in.)(seeFigure 15).
~"
~'
32
33
A-SHAFT, STUB
32-NUT; HEX LOCK
33-COVER, DUST
Figure 11 Retaining Ring .and Lock Nut Removal
A-ARBOR PRESS
B-THREADED END OF PINION
Figure 1O Rack Bearing Removal
Figure 12 Pressing Pinion
381A-8
21
BACK OFF 50 DEGREES

TO 70 DEGREES
(APPROX. ONE FLAT)
21-BEARING ANNULUS ASM, NEEDLE

Fi,gure 13 Bearing Annulus Installation
17-RING,
18-SEAL,
20-SEAL,
30-GEAR
RETAINING
STUB SHAFT DUST
STUB SHAFT
ASM, RACK & PINION (PARTIAL)
Figure 14 Seal Installation
A-BEARING, RACK
B-SPRING, ADJUSTER
C-PLUG, ADJUSTER
15-NUT, ADJUSTERPLUG LOCK
Figure 15 Rack Bearing Installation and Adustment
381A-9
SPECIFICATIONS
FLUID CAPACITIES
Lubricant.. .................................................................................... Cold Climate Power Steering Fluid 12345866 (16-oz.)
12345867 (32-oz.)
Capacity Complete System .............................................................................................................. 0.75 liter (1-1/2 pints)

(1)
(7)
(12)
(15)
(32)
Hexagon Slotted Nut ...............................................................................................

Hex Nut...................................................................................................................
Inner Tie Rod ..........................................................................................................
Lock Nut .................................................................................................................
Hex Lock Nut ..........................................................................................................
Pinion Preload .........................................................................................................
Valve End Fittings ..................................................................................................
Cylinder End Fittings ..............................................................................................
SPECIAL TOOLS
1. J 22610
1.
2.
3.
SERVICE BOOT CLAMP INSTALLER

UNIVERSAL STEERING LINKAGE PULLER
STUB SHAFT SEAL PROTECTOR
2. J 24319-01
47.0 Nm
68.0 Nm
100.0 Nm
75.0 Nm
30.0 Nm
1.8 Nm
16.9 Nm
27.0 Nm
(35 lb. ft.)

(50 lb. ft.)
(74 lb. ft.)
(55 lb. ft.)
(22 lb. ft.)
(16 lb. in.)
(12.5 lb. ft.)
(20 lb. ft.)
381A-10
BLANK
POWER STEERING PUMP UNIT REPAIR
381 B-1
SECTION 381 B
POWER STEERING PUMP

UNIT REPAIR
NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the exact part
number for that application. General Motors will call out those fasteners that require a replacement after removal. General
Motors will also call out the fasteners that require thread lockers or thread sealant. UNLESS OTHERWISE SPECIFIED,
do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on threaded fasteners or fastener joint
interfaces. Generally, such coatings adversely affect the fastener torque and the joint clamping force, and may damage
the fastener. When you install fasteners, use the correct tightening sequence and specifications. Following these
instructions can help you avoid damage to parts and systems.
CONTENTS
Subsection A: CB Series Power Steering Pump
Power Steering Pump Assembly- CB Series ...... 3B1B-2
Reservoir Assembly ......................................... 3B lB-3
Control Valve .................................................. 3BlB-3
Drive Shaft Seal ............................................... 3B lB-4
Hydraulic Pump Assembly .............................. 3B lB-4
'
Subsection B: Reverse Rotation Power Steering Pump

Reverse Rotation Power Steering
Pump Assembly .................................................... 3B lB-6
Pump Service ........................................................ 3B lB-7
Control Valve Assembly ................................. 3B1B-7
Drive Shaft Seal ............................................... 3B lB-7
Hydraulic Pump Assembly .............................. 3B lB-8
Specifications .................................................... 3B1B-10
Fluid Specifications ....................................... 3B lB-10
Fastener Tightening Specifications ............... 3B lB-10
Special Tools ..................................................... 3B1B-10
3818-2
10
37
36
35
Fi,gure 1 Power Steering Pump - CB Series
Key No.
Part Name
1 - CAPSTICK ASM, RESERVOIR

2 - RESERVOIR ASM, HYO PUMP (TYPICAL)
3 - CLIP, RESERVOIR RETAINING (LH)
5 - CLIP, RESERVOIR RETAINING (RH)
6 - PIN, PUMP RING DOWEL
7 - SHAFT, DRIVE
8 - SEAL, 0-RING
10 - HOUSING ASM, HYO PUMP
11 - SEAL, DRIVE SHAFT
12 - SPRING, FLOW CONTROL
13- VALVE ASM, CONTROL
15 - SEAL, 0-RING
RESERVOIR ASSEMBLY
Figure 1
!+ +l
1.
2.
3.
4.
I++!
1.
2.
3.
4.
Pump assembly from vehicle, if necessary
for access.
Retaining clips (3) and (5) from reservoir assembly
(2) and housing (10).
Reservoir (2) from housing (10).
0-ring seal (8) from reservoir (2).
Install or Connect
Key No.
Part Name
16 - FITTING, 0-RING UNION

25- PLATE, THRUST
26 - RING, PUMP
27-VANE
28 - ROTOR, PUMP
30- RING, SHAFT RETAINING
31-PLATE,PRESSURE
32 - SEAL, 0-RING
33 - SPRING, PRESSURE PLATE
35 - SEAL, 0-RING
36 - COVER, END
37- RING, RETAINING
!+ +!
1.
2.
3.
Install or Connect
Flow control spring (12).
Control valve assembly (13).
Lubricate new 0-ring (15) with power steering
fluid.
0-ring (15) on fitting (16).
4.
Tighten
Fitting (16) to 75 Nm (55 lb. ft.).
Pump assembly to vehicle, if removed.
Lubricate new 0-ring (8) with power steering fluid.

0-ring seal (8) to reservoir (2).
Reservoir assembly (2) to housing (10).

Retaining clips (3) and (5) to reservoir (2) and
housing (10).
CONTROL VALVE
Figure 1
I+ +l
1.
2.
3.
381 B-3
Pump assembly from vehicle, if necessary for access.
Figure 2 Shaft Seal Removal
381 B-4
I++! Install or Connect
DRIVE SHAFT SEAL

(without disassembly of pump)
Figures 2 and 3
1.
Tool Required:
J 7728 Shaft Oil Seal Installer
I+ +I
1.
2.
3.
2.
New drive shaft seal (11), lubricated with power

steering fluid, using tool J 7728 (see Figure 3).
HYDRAULIC PUMP ASSEMBLY

Figures 1, 3 thru 7
Protect drive shaft (7) with shim stock (see
Figure 2).
Seal (11) and discard. (Use smallchiseltocutdrive
shaft seal.)
Tool Required:
I+!+!
1.
Disassemble
Retaining ring (37) using punch in access hole (see
Figure 4).
J 7728
----11
11-SEAL, DRIVE SHAFT

7-SHAFT, DRIVE
25-PLATE, THRUST
28-ROTOR, PUMP
30-RING, SHAFT RETAINING
Figure 5 Retaining Ring Installation (Shaft)
28
THIS SIDE FACING UP

26
A
A
COUNTERBORE
FACING DRIVE
SHAFT END OF
HOUSING
A-ACCESS HOLE
B-PUNCH
37-RING, RETAINING
Figure 4 Retaining Ring Removal
A-DOWEL PIN HOLE (LARGE)

8-CROSS-OVER SLOT
26-RING, PUMP
28-ROTOR, PUMP
Figure 6 Rotor or Pump Ring Installation

2.
3.
4.
5.
6.
7.
8.
9.
Internal components of pump from pump

housing (10) by gently pushing on drive shaft (7).
Components should include pressure plate sub-assembly consisting of:
End cover (36).
0-ring seal (35).
Pressure plate spring (33).
Pressure plate (31).

Drive shaft sub-assembly consisting of:
Pump rotor (28).
Thrust plate (25).
Drive shaft (7).
Shaft retaining ring (30).

Pump ring (26) and vanes (27).
0-ring (32) from pump housing (10).
Dowel pins (6).
Drive shaft seal (11).
End cover (36), pressure plate spring (33) and
0-ring (35) from pressure plate (31).
Pump ring (26) and vanes (27) from drive shaft subassembly.
Shaft retaining ring (30) from drive shaft (7).
Pump rotor (28) and thrust plate (25) from drive
shaft (7).
Ii.ti
!l!
Clean
All parts in power steering fluid.
Dry parts.
Inspect
Pump ring (26).
Rotor (28).
Vanes (27).
Thrust plate (25).
Drive shaft (7).

For scoring, pitting or chatter marks. If noted,
replace appropriate parts.
A-ACCESS HOLE
8-PRESS
C-RETAINING RING OPENING
D-BOLT HOLE
37-RING, RETAINING
Figure 7 Retaining Ring Installation (Housing)
!+!+I
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12;
13.
14.
381 B-5
Assemble
Lubricate new drive shaft seal (11) with power
steering fluid.
Drive shaft seal (11) into pump housing (10)

with tool J 7728 (see Figure 3).
Pump ring dowel pins (6) into pump housing (10).
Thrust plate (25) and pump rotor (28) to drive
shaft (7) (see Figure 5).
New shaft retaining ring (30) onto drive shaft (7).
Drive shaft sub-assembly into pump housing (10).
Vanes (27) into pump rotor (28).
Pump ring (26), with holes positioned correctly onto
dowel pins (6), in pump housing (10) (see Figure.6).
Lubricate new 0-ring (32) with power steenng
fluid.
0-ring (32) into groove in pump housing

(10).
fluid.
0-ring (35) into end cover (36).
Lubricate outer edge of end cover (36) with power

steering fluid.
Press end cover (36) into pump housing (10).
Retaining ring (37) into groove in pump .housing
(10), with ring opening near access hole m pump
housing (see Figure 7).
381 B-6
10
(
33
36
35
32
31
(
Figure 1 Power Steering Pump - Reverse Rotation

Key No.
Key No.
Part Name
6 PIN, PUMP RING DOWEL

7 SHAFT, DRIVE
10 HOUSING ASM, BUSHING &
11 SEAL, DRIVE SHAFT
12 SPRING, FLOW CONTROL
13 VALVE ASM, CONTROL
15 SEAL, 0-RING
16 FITTING, 0-RING UNION
25- PLATE, THRUST
381 B-7
Part Name
26 - RING, PUMP
27-VANE, PUMP
28 - ROTOR, PUMP
30 - RING, SHAFT RETAINING
31-PLATE,PRESSURE
32 - SEAL, 0-RING
33 - SPRING, PRESSURE PLATE
35 - SEAL, 0-RING
36 - COVER, END
37- RING, RETAINING
Figure 2 Power Steering Pump - Reverse Rotation - Legend
CONTROL VALVE
DRIVE SHAFT SEAL
Figure 1
(without disassembly of pump)

Figures 3 and 4
I+ +l
1.
2.
3.
4.
I+ +I
1.
2.
3.
4.
Pump assembly from vehicle, if necessary

for access.
0-ring union fitting (16) and 0-ring (15).
Install or Connect
fluid.
0-ring (15) on fitting (16).

Fitting (16) into hydraulic pump housing
assembly (10).
~
5.
Tool Required:
I+ +I
1.
2.
3.
I+ +I
1.
2.
Protect drive shaft (7) with shim stock (see
Figure 3).
Seal (11) and discard. (Use small chisel to cut drive
shaft seal.)
Install or Connect
New drive shaft seal (11), lubricated with power
steering fluid, using tool J 7728 (see Figure 4).
Tighten
Fitting (16) to 75 Nm (55 lb. ft.).

J 7728
@--11
A-CHISEL
B-SHIM STOCK
7-SHAFT, DRIVE
10-HOUSING ASM, HYO PUMP
Figure 3 Shaft Seal Removal

3B1B8
HYDRAULIC PUMP ASSEMBLY

Figures 1, 4 thru 8
1+:+1
1.
2.
3.
Tool Required:
4.
5.
6.
Disassemble
7.
Retaining ring (37) using punch in access hole (see

Figure 5).
Internal components of pump from pump
housing (10) by gently pushing on drive shaft (7).
Components should include pressure plate
sub-assembly consisting of:
End cover (36) .
0-ring seal (35) .
Pressure
plate spring (33) .
Pressure
plate
(31) .
Drive shaft sub-assembly consisting of:

Pump rotor (28).
Thrust plate (25).
Drive shaft (7) .
Shaft retaining ring (30) .
Pump ring (26) and vanes (27).
0-ring (32) from pump housing (10).
8.
9.
Dowel pins (6).

Drive shaft seal (11).
End cover (36), pressure plate spring (33) and
0-ring (35) from pressure plate (31).
Pump ring (26) and vanes (27) from drive shaft subassembly.
Shaft retaining ring (30) from drive shaft (7).
Pump rotor (28) and thrust plate (25) from drive
shaft (7).
!1-11
IL!
Clean
All parts in power steering fluid.

Dry parts.
Inspect
Pressure plate (31 ).
Pump ring (26) .
Rotor (28) .
Vanes (27).
Thrust plate (25).
Drive shaft (7).

For scoring, pitting or chatter marks. If noted,
replace appropriate parts.
A-ACCESS HOLE
8-PUNCH
37-RING, RETAINING
Figure 5 Retaining Ring Removal
7-SHAFT, DRIVE
25-PLATE, THRUST
28-ROTOR, PUMP
30-RING, SHAFT RETAINING
Fi,gure 6 Retaining Ring Installation (Shaft)
I+!+!
1.
2.
3.
4.
5.
6.
7.
8.
Assemble
Lubricate new drive shaft seal (11) with power
steering fluid.
Drive shaft seal (11) into pump housing (10)

with tool J 7728 (see Figure 4).
Pump ring dowel pins (6) into pump housing (10).
Thrust plate (25) and pump rotor (28) to drive
shaft (7) (see Figure 6).
New shaft retaining ring (30) onto drive shaft (7).
Drive shaft sub-assembly into pump housing (10).
Vanes (27) into pump rotor (28).
Pump ring (26), with holes positioned correctly onto
dowel pins (6), in pump housing ( 10) (see Figure 7).
28
9.
10.
11.
12.
13.
14.
381 e..g

fluid.
0-ring (32) into groove in pump housing
(10).
fluid.
0-ring (35) into end cover (36).

Lubricate outer edge of end cover (36) with power
steering fluid.
Press end cover (36) into pump housing (10).
Retaining ring (37) into groove in pump housing
(10), with ring opening near access hole in pump
housing (see Figure 8).
THIS SIDE FACING UP
COUNTER BORE
FACING DRIVE
SHAFT END OF
HOUSING
ADOWEL PIN HOLE (LARGE)
BCROSS-OVER SLOT
26-RING, PUMP
28-ROTOR, PUMP
Figure 7 Rotor or Pump Ring Installation
A-ACCESS HOLE
B-PRESS
C-RETAINING RING OPENING
D-BOLT HOLE
37-RING, RETAINING
Figure 8 Retaining Ring Installation (Housing)
3818-10
SPECIFICATIONS
FLUID CAPACITIES
Lubricant ...................................................................................................... GM Power Steering Fluid Part No. 1050017
or Equivalent meeting GM Specification 9985010
Capacity Complete System .............................................................................................................. 0.75 liter (1-1/2 pints)
Pump Only ................................................................................................................................................. 0.5 liter (1 pint)
FASTENER TORQUES
P Series Power Steering Pump
(33)
Connector and Fitting Assembly ............................................................................ 75.0 Nm
(36)
Pump Mounting Bolt .............................................................................................. 58.0 Nm
(55 lb. ft.)

(43 lb. ft.)
Reverse Rotation Power Steering Pump

(16)
0-ring Union Fitting ............................................................................................... 75.0 Nm
SPECIAL TOOLS
1. J 22670
2. J 7728
1. SHAFT OIL SEAL INSTALLER (P SERIES PUMP)

2. SHAFT OIL SEAL INSTALLER (REVERSE ROTATION PUMP)
(55 lb. ft.)
FRONT SUSPENSION
3C-1
SECTION 3C
FRONT SUSPENSI N
systems.
CONTENTS
General Description ............................................... 3C-1
Diagnosis ........................................ Refer to Section 3
On-Vehicle Service ................................................ 3C-3
Control Arm Ball Stud Inspection ................... 3C-3
Front Lower Control Arm Ball Stud ........... 3C-3
Front Upper Control Arm Ball Stud............ 3C-4
Control Arm Ball Stud Replacement.. ............. 3C-4
Front Lower Control Arm Ball Stud ........... 3C-4
Front Upper Control Arm Ball Stud............ 3C-4
Front Wheel Hub .............................................. 3C-6
Front Wheel Bolt .............................................. 3C-7
Front Lower Control Arm ................................ 3C-7
Front Lower Control Arm Bushing ................. 3C-8

Shock Absorber and Spring ............................. 3C-9
Stabilizer Shaft.. ................................................ 3C-14
Stabilizer Shaft Link ......................................... 3C-14
Steering Knuckle ............................................... 3C-14
Front Upper Control Arm ................................ 3C-16
Front Upper Control Arm Bushing .................. 3C-17
Front Wheel Bearing ........................................ 3C-18
Specifications ......................................................... 3C-19
Fastener Tightening Specifications ................... 3C-20
Special Tools ......................................................... 3C-21
GENERAL DESCRIPTION
Side roll of the front suspension is controlled by

a stabilizer shaft (11). The stabilizer shaft is mounted
to stabilizer shaft insulators (16) that are held to frame
side rails by stabilizer shaft brackets. The ends of the
stabilizer shaft (11) are connected to the lower control
arms (17) by stabilizer shaft links (12) and are isolated
by complaint bushings.
The inner ends of the lower control arm ( 17)
have pressed-in bushings. Bolts (passing through the
bushings) attach the lower control arm (17) to the
crossmember (20).
The upper control arm (1) is attached to the
steering knuckle (6) with a nut (4) and cotter pin (3)
and is bolted to the shock absorber (24) through an
upper control arm support (46) which attaches to the
body.
The lower ball stud (10) is a press fit in the
lower control arm (17) and is attached to the steering
knuckle (6) with a nut (8) and cotter pin (9).
Rubber seals are provided at ball sockets to keep
dirt and moisture from entering the stud and damaging
bearing surfaces.
The upper ball stud (2) is riveted to the upper
control arm (1) and is attached to the steering knuckle
(6) with a nut (4) and cotter pin (3).
Figures 1 and 2
The short/long arm (SLA) front suspension is
designed to allow each wheel to compensate for
changes in the road surface level without appreciably
affecting the opposite wheel. Each wheel is
independently connected to the frame by a steering
knuckle (6) and wheel hub (44), shock absorber (24)
and spring (23), upper and lower ball studs (2 and 10)
and upper and lower control arms (1 and 17). The
steering knuckle and hubs (6 and 44) move in a
prescribed three-dimensional arc. The front wheels are
held in proper relationship to each other by two front
tie rods. The front tie rods are connected to steering
arms on the knuckles and to the steering gear.
Springs (23) are mounted on the lower control
arms (17). Ride control is provided by direct acting
shock absorbers (24). The upper portion of the shock
absorber is connected to the front upper shock
absorber mount (45). The upper mount (45) extends
through the upper control arm support (46) and the
center wheelhouse and attaches with two shock
absorber upper mount bolts/screws (26) and two shock
absorber upper mount nuts (25).
c:Figure 1 - Front Suspension Components

'
FRONT SUSPENSION
1
ARM, FRONT UPPER CONTROL
16
2 STUD, FRONT UPPER CONTROL ARM BALL

3
4
5
6
7
8
9
10
11
12
13
14
15
PIN, FRONT UPPER CONTROL ARM COTTER

NUT, FRONT UPPER CONTROL ARM
NUT, FRONT STABILIZER SHAFT LINK
KNUCKLE AND HUB, STEEERING
SLEEVE, FRONT STABILIZER SHAFT LINK
NUT, FRONT LOWER CONTROL ARM
PIN, FRONT LOWER CONTROL ARM COTTER
STUD, FRONT LOWER CONTROL ARM BALL
STABILIZER SHAFT, FRONT
LINK, FRONT STABILIZER SHAFT
BOLT /SCREW, FRONT STABILIZER SHAFT
INSULATOR CLAMP
CLAMP, FRONT STABILIZER SHAFT INSULATOR
BOLT /SCREW, FRONT SHOCK ABSORBER
17
18
19
20
21
22
23
24
25
26
27
44
45
46
3C-3
INSULATOR, FRONT STABILIZER SHAFT

BOLT/SCREW, FRONT LOWER CONTROL ARM
CROSSIJEMBER, FRONT
SOLT/SCREW, FRONT LOWER CONTROL ARM
NUT, FRONT SHOCK ABSORBER LOWER BRACKET
SPRING, FRONT
ABSORBER, FRONT SHOCK
NUT, FRONT SHOCK ABSORBER UPPER
SOLT/SCREW, FRONT SHOCK ABSORBER UPPER
MOUNT
HUB, FRONT WHEEL
MOUNT, FRONT UPPER SHOCK ABSORBER
012391
SUPPORT, FRONT UPPER CONTROL ARIJ
FS0023C
Figure 2 Front Suspension Components -Legend
ON-VEHICLE SERVICE
Front Lower Control Arm Ball Stud

Figure 3
CONTROL ARM BALL STUD INSPECTION

Figures 3 and 4
!L!
!L!
Inspect
1. Raise vehicle and position floor stands under both

lower control arms as near as possible to each ball
stud. Refer to SECTION OA.
Inspect
Ball stud seals should be carefully inspected for

cuts and tears. Whenever cuts or tears are found,
ball stud must be replaced.
Ball studs for wear.
[I]
Important
Vehicle must be stable and should not rock on

floor stands.
Wipe the ball joints clean and check the seals
for cut or tears. If the seal is cut or torn, the
ball joint MUST be replaced.
2. Position dial indicator against wheel rim.
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 inch).
If dial indicator reading exceeds 1.19 mm
(0.046875 inch), replace ball stud.
4. Anytime ball stud is disconnected from steering
knuckle, check for looseness or if ball stud can be
twisted in its socket with your fingers. If either of
these conditions exist, replace ball stud.
5. Lower vehicle.
-=--.... 1 SUPPORT FRONT LOWER
CONTROL ARM AS FAR
OUTBOARD AS POSSIBLE
2 POSITION DIAL INDICATOR TO
CHECK MOVEMENT AT THIS
POINT
.............&.~.:....-..............._
,,_......_~
012398
F80033C
Figure 3 - Checking Front Lower Control Arm Ball Stud
3 ROCK WHEEL AND TIRE

IN AND OUT AT TOP
AND BOTTOM
012395
FS0043C
Figure 4 - Checking Front Upper Control Arm Ball Stud
3C-4
FRONT SUSPENSION
Front Upper Control Arm Ball Stud

Figure 4
!LI
1. Raise vehicle and position floor stands under both

lower control arms as near as possible to each ball
stud. Refer to SECTION OA.
Important
Vehicle must be stable and should not rock on

floor stands.
2. Position dial indicator against wheel rim.
3. Grasp wheel and push in on bottom of tire while
pulling out at top. Read gage, then reverse
push-pull procedure. Horizontal deflection on dial
indicator should not exceed 3.18 mm (0.125 inch).
If dial indicator reading exceeds 3 .18 mm

(0.125 inch), replace ball stud.
4. Anytime ball stud is disconnected from steering
knuckle, check for looseness or if ball stud can be
twisted in its socket with your fingers. If either of
these conditions exist, replace ball stud.
5. Lower vehicle.
CONTROL ARM BALL STUD

REPLACEMENT
Front lower Control Arm Ball Stud
Figures 5 through 1O
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 vehicle with floor

stands under frame. Refer to SECTION OA.
2. Special s~curity wheel. lock nut, if equipped. Refer
to SECTION 3E.
3. Tire and wheel. Refer to SECTION 3E.
4. Place floor jack under lower control arm (17).
IT]
Install or Connect
NOTICE: Refer to "Notice" on page 3C-1.
Inspect
IT]
lHI
1. Position ball stud into lower control arm (17) and

press in, using J 9519-9, J 9519-18 and J 9519-23,
until it bottoms on lower control arm (17). Ball
stud must firmly press into lower control arm
(17). If it does not, replace lower control arm
(17).
2. Ball stud to steering knuckle.
3. Hand start lower control arm nut.
[I]
Important
Tighten nut enough to align nut slot with stud

hole. Never loosen nut in order to align slot
with hole.
l~J
Tighten
Nut to 110 N,m (81 lb. ft.).

4. Lower control arm cotter pin.
5. Remove floor jack from under shock absorber
mounting location on lower control arm (17).
7. Special security wheel lock nut, if equipped. Refer
to SECTION 3E.
8. Check wheel alignment. Refer to SECTION 3A.
9. Lower vehicle.
Front Upper Control Arm Ball Stud
!++!
1.
2.
3.
4.
Tool Required:
J 39549 Ball Joint/Tie Rod Separator
SECTION OA.
Special security wheel lock nut, if equipped. Refer
to SECTION 3E.
Tire and wheel. Refer to SECTION 3E.
Place floor jack under shock absorber mounting
location on lower control arm (17).
[I]
Important
Floor jack must remain under shock absorber

mounting location on lower control arm (17)
during removal and installation to hold spring
and lower control arm in position.
5. Separate ball stud from steering knuckle, using
J 39549.
6. Lower control arm cotter pin and loosen lower
control arm nut.
7. Press ball stud out of lower control arm (17),
using J 9519-7, J 9519-18 and J 9519-23.
5.
6.
7.
8.
9.
Important
Floor jack must remain under the shock

absorber mounting location on lower control
arm ( 17) during removal and installation to
hold the spring and lower control arm in
position.
Loosen ball stud (2) from steering knuckle (6).
Cotter pin (3) and nut (4).
Support steering knuckle (6) with floor stands.
Separate ball stud (2) from upper control arm (1),
using J 39549.
With upper control arm ( 1) in raised position, drill
out four rivets approximately 6 mm (0.25 inch)
deep, using 1/8-inch drill bit. Refer to Figure 7.
FRONT SUSPENSION
3C5
J 9519-18
A REMOVING LOWER BALL STUD

B INSTALLING LOWER BALL STUD
ot23N
F88053C
Figure 5 - Removing and Installing Front Lower Control Arm Ball Stud
1 ARM. FRONT UPPER CONTROL

2 STUD, FRONT UPPER CONTROL ARM BALL
6 KNUCKLE, STEERING
012395
2395
F80073C
FS0063C
Figure 6 - Separating Front Upper Control Arm Ball. Stud
10. Drill off rivet heads, using 1/2-inch drill bit. Refer
to Figure 8.
11. Punch out rivets, using small punch, and remove
ball stud (2). Refer to Figure 9.
!++!
Install or Connect
NOTICE:
Refer to "Notice" on page 3C-l.
1. Position new ball stud (2) and install four service

kit bolts/ screws (28) and nuts (29). Use
specifications in ball stud kit.
Figure 7 - Drilling Front Upper Control Arm Ball Stud Rivet
2. Remove temporary support from steering knuckle

(6), then connect ball stud (2) to steering knuckle
(6).
3. Hand start nut (4).
11]
Important
Tighten nut enough to align slot with stud

with hole.
3C:.S
FRONT SUSPENSION
29
Figure 8 - Drilling Front Upper Control Arm Ball Stud Rivet

Heads
1
2
3
4
6
28
29
A PUNCH ..... .
2 stuo;FRONt .UPPER CONTROL ARM BALL

STUD, FRONT UPPER CONTROL BALL
PIN, FRONT UPPER CONTROL ARM COTIER
KNUCKLE, STEERING
BOLT/SCREW, SERVICE KIT
NUT, SERVICE KIT
012395
FS0103C
01-23-15
FSoot3C
Figure 9 - Removing Front Upper Control Arm Ball Stud
!~I
Tighten
Nut (4) to 53 N;m {39 lb. ft.).

Cotter pin (3).
Remove floor jack from under spring seat.
to SECTION 3E.
8. Lower vehicle.
4.
5.
6.
7.
FRONT WHEEL HUB

Figure 11
!++!

SECTION OA.
to SECTION 3E.
.
,
4. Brake caliper. Refer to SECTION 5B 1.
Figure 1o - Front Upper Control Arm Ball Stud Attachment
5. Brake rotor. Refer to SECTION 5Bl.

6. Wheel speed sensor electrical connector and move
aside. Refer to SECTION 5El.
7. Bolts/screws (42) from hub (44).
8. Pull hub (44) from spindle.
!++!
Install or Connect
L Position hub (44) to spindle.

~ Tighten
[I]
Important
Make sure wheel speed sensor electrical

connector is reconnected to wheel speed sensor
wire bracket (43) and wheel speed sensor or
wires could be damaged.
3. Wheel speed sensor electrical connector. Refer to
SECTION 5El.
FRONT SUSPENSION
3C-7
FRONT LOWER CONTROL ARM

Figure 12
!++!
39
6
39
40
41
42
43
44
KNUCKLE, STEERING
ROTOR, FRONT BRAKE
CALIPER, FRONT BRAKE
BOLT/SCREW, FRONT BRAKE CALIPER
BOLT/SCREW, FRONT WHEEL
BRACKET, WHEEL SPEED SENSOR WIRE
HUB, FRONT WHEEL
012385
FS0113C
Figure 11 Front Wheel Hub
4. Brake rotor. Refer to SECTION 5B 1.

5. Brake caliper. Refer to SECTION 5Bl.
to SECTION 3E.
8. Lower vehicle.
FRONT WHEEL BOLT

FRONT WHEEL HUB REMOVED
Tool Required:
J 6627-A Wheel Stud Remover
!++j
NOTICE:
Do not damage wheel mounting

surface on hub flange. Brake disc must be
supported before pressing wheel bolt in or out.
Hub or disc bolts, using J 6627-A.
!++!
Install or Connect
NOTICE:
Refer to "Notice" on page 3C-1.
New serrated bolt into hole in hub. Tap lightly

with hammer to start bolt serration in hole,
making sure that bolt is square with hub flange.

SECTION OA.
to SECTION 3E.
4. Power steering gear from steering knuckle. Refer
to SECTION 3B.
5. Stabilizer shaft link. Refer to "Stabilizer Shaft
Link" in this section.
6. Shock absorber and spring from lower control
arm. Refer to "Shock Absorber and Spring" in
this section.
7. Separate lower control arm ball stud from steering
knuckle. Refer to "Front Control Arm Ball Stud
Replacement" in this section.
8. Lower control arm (17) from steering knuckle (6).
9. Bolts/screws (19 and 21) and nuts (27 and 18).
10. Lower control arm (17).
!++j
Install or Connect
NOTICE:
1. Position lower control arm (17) to crossmember

(20).
2. Hand tighten bolts/screws (19 and 21) and nuts
(18 and 27).
!~!
Tighten
Nuts (18) to 115!,Nim (85 lb. ft.).

Nuts (27) to 100 N,m (74 lb. ft.).
3. Position lower control arm (17) to ~teering
knuckle (6).
[I]
Important
Tighten nut e11ogh to align slot with stud

with hole.
!~!
Tighten
Nut (8) to 110 N,m (81 lb. ft.).

5. Cotter pin (9).
6. Lower control arm to shock absorber and spring.
Refer to "Shock Absorber and Spring" in this
section.
8. Power steering gear to steering knuckle. Refer to
SECTION 3B.
3C-8
FRONT SUSPENSION
23
5
6
7
8
9
10
11
12
15
17
18
19
20
21
22
23
24
27
44

KNUCKLE, STEERING
COTIER PIN, FRONT LOWER CONTROL ARM
BALL STUD, FRONT LOWER CONTROL ARM
BOLT/SCREW, FRONT SHOCK ABSORBER
NUT. FRONT LOWER CONTROL ARM
CROSS MEMBER, FRONT
SPRING, FRONT
HUB, FRONT WHEEL
20
10
15
01-23-85
FS0123C
Figure 12 - Front Lower Control Arm

to SECTION 3E.
11. Lower vehicle.
12. Align wheel. Refer to SECTION 3A.
D. Install J 39875 around outside of bushing to

avoid metal distortion during removal.
E. After making sure all tools are properly lined
up with front bushing and control arm, install
J 21474-4 and tighten until bushing is pushed
all the way out (popping noise may be heard
while removing).
FRONT LOWER CONTROL ARM BUSHING

The lower control arm bushing can be serviced
separately from the lower control arm.
FRONT BUSHING
Figures 12 and 13
Tools Required:
J 21474-3 Lower Control Arm Bushing Screw
J 21474-4 Lower Control Arm Bushing Nut
J 21474-5 Control Arm Bushing Receiver
J 39875 Half Moon Spacer
J 39876 Lower Control Arm Bushing
Receiver
Ill
Disassemble
1. Lower control arm. Refer to "Front Lower

Control Arm" in this section.
2. Remove lower control arm front bushing from
lower control arm (17).
A. Place. J 21474-3 through large end of
J 21474-6.
B. Thread J 21474-3 through front bushing and
push it through open end of J 39876.
C. Place thrust washer onto J 21474-3 with seam
facing toward front bushing.
!#!
Assemble
NOTICE:
1. Lower control arm front bushing.

A. Thread J 21474-3 through J 21474-5.
B. Install J 21474-3 through new front bushing
and into lower control arm.
C. Thread J 21474-3 and accessories into lower
control arm - front.
D. Install J 39876 onto J 21474-3 with open end
of J 39876 facing toward control arm.
E. Install J 39875 around outside bushing to
avoid metal distortion during installation.
F. Place thrust washer onto threaded end of
J 21474-3 with seam facing toward control
arm.
G. After making sure all tools are properly lined
up with control arm and bushing, install
J 21474-4 onto J 21474-3. Tighten J 21474-4
and J 21474-3 until bushing becomes flush
with control arm.
FRONT SUSPENSION
3C-9
J 21474-5
J 21474-4
17
~
I
-1
0
>
A
B
C
17
REMOVING FRONT BUSHING

INSTALLING FRONT BUSHING
WASHER, THRUST
01-23-95
FS0133C
Figure 13 - Removing and Installing Front Lower Control Arm Front Bushing
REAR BUSHING
1. Lower control arm rear bushing.
Figures 12 and 14
A. With lower control arm securely tightened in

vise, place J 21474-3 through small end of
J 39931.
B. Install J 21474-3 through new rear bushing
and then through closed end of lower control
arm - rear.
C. Place small end of J 21474-5 onto J 21474-3.
D. Install thrust washer onto J 21474-3 with seam
of washer facing toward control arm.
E. Making sure all tools are lined up with
bushing and control arm and that window is
facing straight up and visible on J 39931,
install J 21474-4 onto J 21474-3 and tighten
until rubber protrusion on J 39931 side
bottoms out against J 39931.
Tools Required:
J 21474-3 Lower Control Arm Bushing Screw
J 21474-4 Lower Control Arm Bushing Nut
J 3987 4 Lower Control Arm Bushing
Receiver
J 39931 Lower Control Arm Bushing
Receiver
!+t+!
Disassemble

2. Remove lower control arm rear bushing from
A. Install J 39874 onto J 21474-3 with sealed end
of J 3987 4 facing head of screw.
B. Run J 21474-3 through control arm bushing,
control arm, and into small end of J 39931.
C. Install thrust washer onto J 21474-3 with seam
facing toward control arm.
D. Install J 21474-4 onto J 21474-3, making sure
all parts are lined up with control arm bushing.
E. Tighten until control arm bushing is able to be
removed (popping noise may be heard while
removing).
!+;+!
Assemble
NOTICE:
SHOCK ABSORBER AND SPRING

Tools Required:
J 34013-B Strut Spring Compressor
J 34013-114 Modular Shock Compressor
Adapter
J 34013-88 Strut Compressor Adapter
J 39642 Modular Shock Nut Removal Set,
15 mm (0.60 inch)
J 34013-115 Modular Shock Alignment Rod
3C-10
FRONT SUSPENSION
J 21474-4
J 39874
J 39931
(
J 21474-3
J 21474-3
J 21474-4
17
A
B
C
17
REMOVING REAR BUSHING

INSTALLING FRONT BUSHING
VVASHER,THRUST
01-23-85
FS0143C
Figure 14 - Removing and Installing Front Lower Control Arm Rear Bushing
1++1
1. Brake master cylinder nuts (driver-side only).

Refer to SECTION SA.
2. Move brake master cylinder aside (driver-side
only). Refer to SECTION SA.
3. Bolts/screws (26) and nuts (25).
SECTION OA.
to SECTION 3E.
8. Nuts (22).
10. Separate lower baU stud from steering knuckle.
Refer to "Control Arm Ball Stud Replacement"
in this section.
[I]
Important
Be sure to mark with chalk or paint (do not

scribe) the lower mount location relative to the
upper mount location before removing the
shock absorber or the cannot be reinstalled.
11. Shock absorber and spring (24 and 23).
~ Disassemble
1. Install J 34013-114 to J 34013-B. Use wing nuts
to secure tool to mounting holes C-H (lower left
corner) and P (upper right corner) for driver-side
shock absorber and to secure tool to mounting
holes A-X-P (upper left comer) and C-H (lower
right corner) for passenger-side shock absorber.
rn
Important
Be sure J 34013-114 and J 34013-88 are

aligned so they can open and close together. If
the tools are not aligned properly, they will not
open.
2. Install J 34013-114 and J 34013-88.
rn
Important
Be sure the top of the shock absorber is flat

against J 34013-114. The shock absorber will
not be aligned correctly if it does not lay flat
against the tool.
3. Shock absorber to top of J 34013-114.
4. Install shock absorber into J 34013-114 and
J 34013-88.
5. Close J 34013-114 and J 34013-88 and install
locking pin.
FRONT SUSPENSION
3C11
J 34013-B Strut Spring Compressor

Read lmnruction Sh1at J 34013 29/29A
Be~arn Uatng
CHE/K
J-NL
J3Ut!l.&-C
Nova Twin.Cam
01-23-95
FSott3C
Figure 16 - Modular Shock Compressor Mounting Hole
Location
J 34013-B
1
2
3
4
6
B
9
10
15
17
22
23
24
25
26

STUD, FRONT UPPER CONTROL ARM BALL
KNUCKLE, STEERING
PIN, FRONT LOWER CONTROL ARM COTIER
BOLT/SCREW, FRONT SHOCK ABSORBER
SPRING, FRONT
NUT, FRONT SHOCK ABSORBER UPPER MOUNT
BOLT/SCREW, FRONT SHOCK ABSORBER UPPER
MOUNT
44 HUB, FRONT WHEEL
45 MOUNT, FRONT UPPER SHOCK ABSORBER
46 SUPPORT, FRONT UPPER CONTROL ARM
01-23-H
F80153C
Figure 15 - Shock Absorber and Spring
J 34013-114
012395
FS0173C
Figure 17 - Modular Shock Compressor Adapter

-Driver-Side Position
rn
Important
Be sure the mounting ears of the shock

absorber are facing downward, toward the rear
of J 34013-B or the shock absorber will not
align properly.
6. Turn screw on J 34013-B counterclockwise to
raise shock absorber up to J 34013-114. Be sure
studs go through guide holes in J 34013-114 and
the top of the shock absorber is flat against the
tool.
3C12
FRONT SUSPENSION
23
J 34013-B
24
J 34013-B
OMl391
FS0183C
Figure 18 - Modular Shock Compressor Adapter

-Passenger-Side Position
23 SPRING, FRONT
24 ABSORBER, FRONT SHOCK
01-2395
FS0203C
Figure 20 - Installing Shock Absorber to Strut Spring
Compressor
24---........J
012311
FS0113C
Figure 19 - Installing Strut Compressor Adapter to Strut

Spring Compressor
CAUTION: Do not over compress spring.

Severe overloading may cause tool
failure which could result in bodily injury.
7. Compress front spring approximately 13 mm
(0.50 inch) or three or four complete turns of the
screw on J 34013-114.
8. Insert J 39642-1 on shock absorber nut, then
insert J 39642-2 through J 39642-1 to hold shock
absorber rod in place.
9. Remove shock absorber nut with J 39642-1 while
holding shock absorber rod from rotating with
J 39642-2.
1.0. Discard shock absorber nut.
11. Tum J 34013~B clockwise to fully relieve spring
pressure.
A MATCHING ANGLE BElWEEN SHOCK ABSORBER

AND J 34013-114
.
23 SPRING, FRONT
01-2316
FS0213C
Figure 21 - Driver-Side Shock Absorber Installation
!+f+I Assemble
1. Install J 34013-114 to J 34013-B. Use wing nuts
to secure J 34013-114 to J 34013-B mounting

holes C-H (lower left comer) and P (upper right
comer) for driver-side shock absorber and to
secure J 34013-114 to J 34013-B mounting holes
A-X-P (upper left comer) and C-H (lower right
corner) for passenger-side shock absorber
(Figures 17 and 18).
2. Install J 34013-114 and J 34013-88.
3. Install shock absorber to J 34013-114 and
J 34013-88.
FRONT SUSPENSION
3C13
Be sure to mark with chalk or paint (do not

scribe) the lower mount location relative to the
upper mount location before removing the
shock absorber or the shock absorber cannot
be reinstalled.
4. Close J 34013-114 and J 34013-88 and engage
locking pin.
5. Make sure upper and lower spring seats are
positioned correctly.
6. Shock absorber to top of J 34013-114.
J,34013
J 34013-114
[I]
24
A MATCHING ANGLE BETWEEN SHOCK ABSORBER

.
.ANDJ34013114
23 SPRING, FRONT
012315
F80223C
Figure 22 Passenger-Side Shock Absorber Installation
Important
Be sure the top of the shock absorber is flat

against J 34013-114. The shock absorber will
not be aligned properly if it does not lay flat
against the tool.
7. Turn screw on J 34013-B counterclockwise to
raise shock absorber up to J 34013-114 without
compressing spring. Be sure studs on shock
absorber go through guide holes in J 34013-114.
[I]
lmpo,rtant
Only turn the screw until the shock absorber is

held in J 34013-B by itself. Do not load the
spring.
8. Place J 34013-115 down through top of J 34013-B
through top of shock absorber and onto shock
absorber rod.
J 34013-115
J 34013-B
[I]
Important
J 34013-114
Make sure J 34013~115 is straight with the

shock absorber. If J 34013-115 is angled,
repeat steps 1 through 5 until tool is straight.
CAUTION: Do not over compress spring.

Severe overloading may result in tool
failure which could result in bodily injury.
9. Turn operating screw clockwise to compress
spring until threaded portion of the shock absorber
rod is through the top of the shock absorber.
10. Remove J 34013-115.
A ROD, FRONT SHOCK ABSORBER

23 SPRING, FRONT
[I]
Important
012315
FS0233C
Figure 23 - Inserting Modular Shock Alignment Rod
[1]
Important
Be sure the mounting ears of the shock

absorber are facing downward, toward the rear
of J 34013-B or the shock absorber will not
align properly.
When installing front shock absorber nut,

always replace it with a new one. Never install
the same nut that has been removed.
11. Insert new shock absorber nut on shock absorber
rod.
NOTICE: Turning the shock absorber while

tightening the nut could damage the shock
absorber. To prevent damage, keep the shock
absorber in a stationary position when tightening
the nut.
3C-14
FRONT SUSPENSION
12. Place J 39642-1 on shock absorber nut.

13. Insert J 39642-2 through J 39642-1 and tighten
shock absorber nut.
14. Tighten shock absorber nut while holding onto
J 39642-2.
15. Remove shock absorber from J 34013-B.
lHI
Install or Connect
NOTICE:
1. Position shock absorber and spring (24 and 23) to

l~I
3.
4.
5.
6.
7.
8.
Tighten
Bolts/screws (15) and nuts (22) to 65 N.m

(48 lb. ft.).
Lower ball stud to steering knuckle. Refer to
"Control Arm Ball Stud Replacement" in this
section.
Stabilizer shaft link. Refer to "Stabilizer Shaft
to SECTION 3E.
Lower vehicle.
Hand tighten bolts/screws (26) and nuts (25).
l~I
Tighten

Nuts (25) to 43 N.m (32 lb. ft.).
9. Position brake master cylinder (driver-side only).
STABILIZER SHAFT
Figure 24
l++I

SECTION OA.
4. Clamps (14).
5. Stabilizer shaft (11).
6. Insulators (16).
8. Brackets (31).
!++!
Install or Connect
NOTICE:
1. Position brackets (31) to side rail.

2. Hand start bolts/screws (30).
!~I
Tighten
Bolts/screws .(30) to 55 N.m (41 lb. ft.).

3. Place insulators (16) over stabilizer shaft (11).
rn
Important
The slit of the insulator must face the front of

the vehicle.
4. Position clamps (14) over insulators (16) and
stabilizer shaft (11).
!~I Tighten
7. Lower vehicle.
STABILIZER SHAFT LINK

Figure 25
l++I

SECTION OA.
2. Nut (5).
3. Link (12).
4. Sleeve (7).
l++j
Install or Connect
NOTICE:
1. Sleeve (7) between lower control arm (17) and

stabilizer shaft (11).
2. Link (12) through lower control arm (17), sleeve
(7) and stabilizer shaft (11).
3. Nut (5).
l~l
Tighten
Nut (5) to 23 N.m (17 lb. ft.).

4. Lower vehicle.
STEERING KNUCKLE
Figure 26
!++!

SECTION OA.
to SECTION 3E.
4. Brake caliper and move aside. Refer to
SECTION 5B 1.
5. Brake rotor. Refer to SECTION 5.
FRONT SUSPENSION
3C-15
,,
A
5
6
7
11
12
13
14
16
30
31
44
SIDE RAIL
KNUCKLE, STEERING
BOLT/SCREW, FRONT STABILIZER SHAFT INSULATOR
CLAMP
CLAMP, FRONT STABILIZER SHAFT INSULATOR
INSULATOR, FRONT STABILIZER SHAFT
BOLT/SCREW, FRONT STABILIZER SHAFT B~ACKET
BRACKET, FRONT STABILIZER SHAFT
HUB, FRONT WHEEL
44
12
012395
FS0243C
Figure 24 Stabilizer Shaft
6. Wheel speed sensor electrical connector and move

aside. Refer to SECTION 5El.
7. Front wheel hub from steering knuckle. Refer to
"Front Wheel Hub" in this section.
8. Power steering gear from steering knuckle. Refer
to SECTION 3B.
10. Front shock absorber bolts/screws. Refer to
"Shock Absorber and Spring" in this section.
11. Separate lower ball stud from steering knuckle.
in this section.
12. Lower control arm from steering knuckle. Refer
to "Front Lower Control Arm" in this section.
13. Separate upper ball stud from steering knuckle.
in this section.
14. Steering knuckle from upper control arm. Refer to
"Front Upper Control Arm" in this section.
15. Steering knuckle and hubs (6 and 44).
11
44
5
6
7
11
12
17
44

KNUCKLE. STEERING
HUB, FRONT WHEEL
012395
F80213C
Figure 25 - Stabilizer Shaft Link
3C16
FRONT SUSPENSION
8. Front wheel hub to steering knuckle. Refer to
"Front Wheel Hub" in this section.
rn
9.
10.
11.
12.
13.
14.
15.
44
Important
Make sure wheel speed sensor electrical

connector is reconnected to wheel speed sensor
wire bracket and wheel speed sensor or wires
could be damaged.
Wheel speed sensor electrical connector. Refer to
SECTION 5El.
Brake rotor. Refer to SECTION 5.
Brake caliper. Refer to SECTION 5B 1.
to SECTION 3E.
Lower vehicle.
Check wheel toe alignment. Refer to
SECTION 3A.
FRONT UPPER CONTROL ARM

Figure 27
!++!
1
2
3
4
6
8
9
10
17
20
23
24
44
E3

KNUCKLE, STEERING
PIN, FRONT LOWER CONTROL ARM COTTER
CROSSMEMBER, FRONT
SPRING, FRONT
ABSOR.BER, FRONT SHOCK
OMl315
HUB, FRONT WHEEL
FS0283C
Figure 26 - Steering Knuckle
Install or Connect
NOTICE:
1. Position steering knuckle and hubs (6 and 44) to

upper control arm (1).
2. Upper ball stud to steering knuckle. Refer to
"Control Ann Ball Stud Replacement" in this
section.
3. Position steering knuckle to lower control arm.
Refer to "Front Lower Control Ann" in this
section.
4. Lower ball stud to steering knuckle. Refer to
"Control Ann Ball Stud Replacement" in this
section.
7. Power steering gear to steering knuckle. Refer to
SECTION 3B.

2. Move brake master cylinder aside (driver-side
only). Refer to SECTION 5A.
SECTION OA.
to SECTION 3E.
9. Separate upper ball stud from steering knuckle.
Refer to "Control Ann Ball Stud Replacement"
in this section.
10. Steering knuckle (6) from upper control arm (1).
11. Upper control arm (1) and shock absorber (24)
from vehicle.
12. Support steering knuckle (6) with floor stands .
13. Nuts and bolts/screws (37 and 38).
14. Upper control arm (1) from shock absorber (24).
I++!
Install or Connect
NOTICE:
1. Position upper control arm (1) to shock absorber

(24).
2. Bolts/screws and nuts (37 and 38).
!~!
Tighten
Nuts (38) to 98 N,m (72 lb. ft.).
FRONT SUSPENSION
!~I
10.
11.
12.
13.
14.
3C17
Tighten
Nuts (25) to 43 N,m (32 lb. ft.).

to SECTION 3E.
Lower vehicle.
Position brake master cylinder (driver-side only).
Brake master cylinder nuts (driver-side only).
FRONT UPPER CONTROL ARM BUSHING

The upper control arm bushing can be serviced
separately from the upper control arm.
Figures 27 and 28
1
2
3
4
6
22
23
24
25
26
37
38
44
45
46

PIN, FRONT UPPER CONTROL ARM COTTER
KNUCKLE, STEERING
SPRING, FRONT
NUT, FRONT SHOCK ABSORBER UPPER MOUNT
BOLT/SCREW, FRONT SHOCK ABSORBER UPPER
MOUNT
SOLT/SCREW, FRONT UPPER CONTROL ARM
HUB, FRONT WHEEL
MOUNT, FRONT UPPER SHOCK ABSORBER
SUPPORT, FRONT UPPER CONTROL ARM
012a91
F80273C
flgure 27 Front Upper Control Arm
3. Upper control arm (1) and shock absorber (24) to

vehicle.
4. Position steering knuckle (6) to upper control arm
(1).
5. Upper ball stud to steering knuckle. Refer to

"Control Arm Ball Stud Replacement" in this
section.
6. Remove floor stands from steering knuckle (6).
9. Nuts (25) and bolts/screws (26).
NOTICE: Do not turn the shock absorber

when tightening the upper mount nut or the
shock absorber could be damaged. Keep the
shock absorber in a stationary position when
tightening the nut.
Tools Required:
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
Ill
Disassemble
1. Upper control arm. Refer to "Front Upper Control

Arm" in this section.
2. Remove bolts/screws (37) and nuts (38).
3. Separate front upper control arm (1) from front
upper control arm support (46).
4. Remove upper control arm bushing from upper
control arm (1).
A. Thread J 21474-19 through J 39930 (three
tangs on J 39930 should be against head of
screw).
B. Thread J 21474-19 through inside of upper
control arm bushing (it may be necessary to
wiggle J 21474-19 until it slides through
bushing).
C. Run smaller end of J 2147 4-5 onto
J 21474-19. Then, place thrust washer onto
J 21474-19 with seams facing toward
J 21474-5.
D. Install J 39872 around outside of bushing to
E. Make sure both J 39930 and J 21474-5 are
properly lined up and install J 21474-18 onto
J 21474-19. Tighten J 21474-19 and
J 21474-18 until bushing is pushed all the way
out (popping noise may be heard when
bushing breaks loose from control arm).
3C18
FRONT SUSPENSION
J 21474-5
J 39872
A
B
A
B
C
1
REMOVING BUSHING
INSTALLING BUSHING
WASHER, THRUST
01-23-95
FS0283C
Figure 28 - Removing and Installing Front Upper Control Arm Bushing
l+;+I
Assemble
NOTICE:
1. Upper control arm bushings.

A. With control arm securely tightened in vise,
thread J 21474-19 through J 39930 with tangs
facing away from screw head.
B. Install new upper control arm bushing onto
J 21474-19 with three indentations facing
toward three tangs on J 39930.
C. Install threaded end of J 21474-19 into upper
control arm from outer side of control arm.
D. Install J 21474-5 onto J 21474-19 from inside
of control arm.
E. Install thrust washer onto J 21474-19 with
seam facing toward control arm bushing.
F. Install J 39872 around outside of bushing to
G. Install J 21474-18 onto J 21474-19, making

sure that three tanged prongs on J 39930 fit
into indentations of bushing.
H. Tighten until bushing is installed flush with
control arm.
2. Install front upper control arm (1) to front upper
control arm support (46).
I~!
Tighten
Nuts (38) to 98 N.m (72 lb. ft.).

4. Upper control arm. Refer to "Front Upper Control
FRONT WHEEL BEARING

The maintenance-free front wheel bearing does
not need to be serviced separately from the hub. Refer
to "Front Wheel Hub" in this section.
FRONT SUSPENSION
3C.;19
SPECIFICATIONS
Front
Front
Front
Front
Front
Front
Front
Front
Front
Front
Front
Front
Front
Front
Lower Control Arm-to-Front Crossmember Nut (Horizontal) .................................. 100

Lower Control Arm-to-Front Crossmember Nut (Vertical) ....................................... 115
Lower Control Arm-to-Front Lower Control Arm Ball Stud Nut. ........................... 110
Shock Absorber Bolt/Screw .......................................................................................... 65
Shock Absorber Lower Bracket Nut ............................................................................ 65
Shock Absorber Upper Mount Bolt/Screw ................................................................... 50
Shock Absorber Upper Mount Nut .............................................................................. 43
Stabilizer Shaft Bracket Bolt/Screw ............................................................................. 55
Stabilizer Shaft Insulator Clamp Bolt/Screw ............................................................... 55
Stabilizer Shaft Link ..................................................................................................... 23
Stabilizer Shaft Link Nut.. ............................................................................................ 23
Upper Control Arm-to-Front Upper Control Arm Ball Stud Nut. .............................. 53
Upper Control Arm-to-Front Upper Control Arm Support Nut ................................. 98
Wheel Bolt/Screw .......................................................................................................... 86
N.m
N.m
N,m
N.m
N-m
N.m
N.m
N.m
N.m
N.m
N.m
N.m
N.m
N.m
(74
(85
(81
(48
(48
(37
(32
(41
(41
(17
(17
(39
(72
(63
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
3C-20
FRONT SUSPENSION
SPECIAL TOOLS
(
1.
J 24292-B
<)!J
11
J 9519-7
12
(]
J 9519-9
13
J 9519-18
J 34013-88
14
~J:>1013-114
J 34013-115
15
16
(?)
J 39876
Ci])
J 39930
1
2
3
4
5
6
7.
8.
9
f)
J 9519-23
J 6627A
J 39872
J 39549
17
18
J 39642
J 34013-B
10
Cl)
r:::J
J 39874
J 39875
J 39931
BALL JOINT REMOVER

STRUT SPRING COMPRESSOR
STRUT COMPRESSOR ADAPTER
MODULAR SHOCK COMPRESSOR ADAPTER
MODULAR SHOCK ALIGNMENT ROD
BALL JOINT{TIE ROD SEPARATOR
LOWER CONTROL ARM BUSHING RECEIVER
UPPER CONTROL ARM BUSHING RECEIVER/INSTALLER
10
11
12.
13.
14.
15
16
17.
18.
MODULAR SHOCK NUT REMOVAL SET,

15 mm (0.60 INCH}
BALL JOINT REMOVER
BALL JOINT INSTALLER
BALL JOINT PRESSING SCREW
BALL JOINT "C" CLAMP
WHEEL STUD REMOVER
HALF MOON SPACER
HALF MOON SPACER
11-2395
FS0363C
FRONT SUSPENSION 3C-21
19
20
21
19.
20
21.
22.
23
24.
@jjijijijjiiiijijj@M(Oi I
J 21474-3
22
J 21474-4
23
J 21474-5
24
OJ
(
~i@mm@i@o
J 21474-6
J 21474-18
J 21414-19
LOWER CONTROL ARM BUSHING SCREW

LOWER CONTROL ARM BUSHING NUT
CONTROL ARM BUSHING RECEIVER
CONTROL ARM BUSHING RECEIVER
UPPER CONTROL ARM NUT
UPPER CONTROL ARM SCREW
012385
FS0313C
3C22
FRONT SUSPENSION
BLANK
REAR SUSPENSION
3D-1
SECTION 30
REAR SUSPENSION
inhibitors) on threaded fasteners or fastener joint interfaces; Generally, such coatings adversely affect the fastener
systems.
CONTENTS
General Description ................................................ 30-1
Rear Axle Suspension ........................................ 30-1
On-Vehicle Service ................................................. 30-1
Rear Axle Housing ................... Refer to Section 4B
Rear Suspension Jounce Bumper ...................... 30-1
Rear Axle Lower Control Arm Bushing .......... 30-3
Rear Springs ....................................................... 30-4
Rear Spring SeaL ............................................... 30-4
Rear Axle Tie Rod ........................................... ; 30.:5
Rear Axle Lower Control Arm ........................ 30-6

Rear Axle Torque Arm ..................................... 30-6
Rear Axle Torque Arm Vibration Dampener .. 30-8
Rear Stabilizer Shaft ......................................... 30-9
Rear Stabilizer Shaft Bracket and Link ........... 30-10
Rear Shock Absorber ........................................ 30-10
Specifications ......................................................... 30-l 1
Fastener Tightening Specifications ................... 30-11
Special Tools ......................................................... 30-ll
GENERAL DESCRIPTION
ON-VEHICLE SERVICE
REAR AXLE SUSPENSION

Figure 1
The rear axle (13) is attached to the vehicle with
a link suspension system. The rear axle housing is
connected to the floor panel (7) by two lower control
arms (6) and a tie rod (11). A single torque arm (8) is
used in place of an upper control arm. It is rigidly
mounted to the rear axle housing at the rear and
through a torque arm bushing to the transmission at
the front. On some vehicles, the torque arm (8) is also
mounted to the two piece propeller shaft center
support bearing (9) with two bolts/screws. Rear
springs (4) are used to support the weight of the
vehicle, and ride control is provided by rear shock
absorbers (10) mounted to the rear axle housing. A
rear stabilizer shaft (5) is also part of the suspension
system.
The rear shock absorbers (10) are mounted at the
bottom with a nut to brackets welded to the rear of the
rear axle housing, and at the top to the floor panel
with a nut. The only service the rear shock absorbers
reqtire is replacement if they have lost their
resistance, are damaged or are leaking fluid. For rear
shock absorber diagnosis, refer to SECTION 3.
REAR SUSPENSION JOUNCE BUMPER

Figure 2
The rear suspension jounce bumper is located on
top of the rear axle housing.
j++j

SECTION OA.
2. Support rear axle (13).
4. Bumper (1 ).
Remove spacer with bumper (WS6 only).
j++j
Install or Connect
NOTICE:
1. Bumper (1).
Install spacer with bumper (WS6 only).
!~!
Tighten
3D2
REAR SUSPENSION
A
B
1
2
3
4
5
6
7
8
9
10
11
12
13
LONGITUDINAL REINFORCEMENT
WITH REAR DISC BRAKES
BUMPER, REAR SUSPENSION JOUNCE
BOLT/SCREW, REAR AXLE BUMPER
INSULATOR, REAR SPRING UPPER
SPRING, REAR
SHAFT, REAR STABILIZER
ARM, REAR AXLE LOWER CONTROL
PANEL, FLOOR
ARM, REAR AXLE TORQUE
SHAFT, PROPELLER
ABSORBER, REAR SHOCK
ROD, REAR AXLE TIE
BRACE, REAR AXLE TIE ROD BRACKET
AXLE, REAR
fN2495
FS0013D
Figure 1 Rear Axle Suspension (Typical)
REAR SUSPENSION
30-3
J 21474-23
J 21474-5
A PRESS
01-24-H
FS0033D
Figure 3 - Removing Rear Axle Lower Control Arm

Bushing
(\
13
A PRESS
A LONGITUDINAL REINFORCEMENT
B REINFORCEMENT, REAR SUSPENSION JOUNCE
BUMPER
1 BUMPER, REAR SUSPENSION JOUNCE
2 BOLT/SCREW, REAR AXLE BUMPER
13 AXLE, REAR
81-24-95
FS0023D
Figure 2 - Rear Suspension Joun.ce Bumper
3. Remove rear axle support.

4. Lower vehicle.
REAR AXLE LOWER CONTROL ARM

BUSHING
Figures 3 and 4
!YI Important
If both lower control arms are being replaced,
remove and replace one control arm at a time
to prevent the rear axle from rolling or
slipping sideways, making replacement
difficult.
I+-+!
Tools Required:
J 21474-5 Receiver
J 21474-20 Installer
J 21474-23 Remover
SECTION OA.
Figure 4 - Installing Rear Axle Lower Control Arm Bushing
2. Support rear axle.

3. Lower control arm. Refer to "Lower Control
4. Place J 21474-5 over flanged side of bushing.
5. Use arbor press to force bushing out of arm, using
large OD of driver such as J 21474-23 contacting
OD of outer sleeve.
!++!
1.
2.
3.
4.
Install or Connect
Reverse tool. Refer to Figure 4.

Place J 21474-5 over flanged side of bushing.
Bushing into position with J 21474-20.
Lower control arm. Refer to "Lower Control
6. Lower vehicle.
30-4
REAR SUSPENSION
l++I
REAR SPRINGS
Figure 5
E3
1. Rear spring (4) to rear axle (13).
rn
SECTION OA.
[I]
Install or Connect
Important
When raising vehicle, do not use twin post

type hoist.
2. Support rear axle (13) with adjustable lifting
device.
3. Shock absorber nuts from rear axle. Refer to
"Rear Shock Absorber" in this section.
4. Lower rear axle (13).
NOTICE: Do not suspend rear axle by brake

hoses. Damage to hoses could result.
5. Upper insulator (15).
6. Rear spring (4).
2.
3.
4.
5.
6.
Important
Lower end of rear spring should be facing

forward.
It is important not to chip or damage the
corrosion protection coating on the rear spring.
Avoid contact with hard steel. If coating has
been chipped or damaged, do not use rear
spring until it has been replaced.
Upper insulator (15) to rear spring (4).
Raise rear axle (13).
Shock absorber nuts to rear axle. Refer to "Rear
Shock Absorber" in this section.
Remove rear axle support.
Lower vehicle.
REAR SPRING SEAT

Figure 5
. I'"
~~-
IVIEWA
l++I
SECTION OA.
15
[I]
Important

type hoist.
2. Support rear axle (13) with an adjustable lifting
device.
3. Shock absorber nuts from rear axle. Refer to
"Rear Shock Absorber" in this section.
4. Lower rear axle (13).
NOTICE: Do not suspend rear axle by brake

hoses. Damage to hoses could result.
5. Upper insulator and rear spring. Refer to "Rear
Spring" in this section.
6. Spring seat (14).
l++I
4
13
14
15
SPRING, REAR
AXLE , REAR
SEAT, REAR SPfllNG
INSULATOR, REAR
SPRING UPPER
012491
FSOOl3D
Figure 5 Rear Spring and Upper Insulator
Install or Connect
1. Position spring seat (14).

2. Rear spring and upper insulator. Refer to "Rear
Spring" in this section.
3. Raise rear axle (13).
4. Shock absorber nut to rear axle. Refer to "Rear
Shock Absorber" in this section.
5. Remov~ rear axle support.
6. Lower vehicle.
REAR SUSPENSION
3. Position tie rod (11) to right-hand underbody

brace bracket.
4. Hand tighten other bolt/screw (18) and other nut
(19).
5. Bolts/screws (16 and 18) and nuts (19).
REAR AXLE TIE ROD

Figure 6
l++I
Remove or Disco,nnect
l. Raise and suitably support vehicle. Refer to

SECTION OA.
3. Bolt/screw (17) and nut (49).
4. Bolts/screws (16 and 18) and nuts (19).
5. Tie rod (11).
6. Brace (12).
l+~I
Install or Connect
NOTICE:
305
!~I
Tighten

Nuts (19) to 82 N.m (61 lb. ft.).
6. Bolt/screw (17) and nut, (49).
I~!
Tighten
Nut (49) to 82 N.m (61 lb. ft.).

7. Rear axle support.
8. Lower vehicle.
1. Position brace (12) to right-hand underbody brace

bracket.
2. Hand tighten one bolt/screw (18) and one nut
(19).
A
13
12
rr
18
'J>~~U,,
r~/~~.
~
..
A UNDERBODY BRACE BRACKET (LEFT-HAND SIDE)

B UNDERBODY BRACE BRACKET (RIGHT-HAND SIDE)
11 ROD, REAR AXLE TIE
12 BRACE, REAR AXLE TIE ROD BRACKET
13 AXLE, REAR
16 BOLT/SCREW. REAR AXLE TIE ROD BRACKET
17 BOLT/SCREW, REAR AXLE TIE ROD
18 BOLT/SCREW, REAR AXLE TIE ROD BRACKET
19 NUT, REAR AXLE TIE ROD
49 NUT, REAR AXLE TIE ROD
-~--~
12
Figure 6 Rear Axle Tie Rod
,,
11
!VIEWA!
01249$
FS0063D
30-6
REAR SUSPENSION
[I]
REAR AXLE LOWER CONTROL ARM

Figure 7
rn
Important
If both lower control arms are being replaced,

remove and replace one arm at a time to
prevent rear axle from rolling or slipping
sideways, making replacement difficult.
l++I

SECTION OA.
3. Bolts/screws (20), nuts (22) and washers (21)
from rear axle (13).
4. Bolts/screws (20), nuts (22) and washers (21)
from underbody pan.
5. Lower control arm (6).
l++I
Do not tighten bolts/screws (20) and nuts (22)

unless the suspension is at curb height
position.
2. Bolts/screws (20), nuts (22) and washers (21) to
rear axle (13) from inboard side out.
!~I Tighten
Nuts (22) to 82 N.m (60 lb. ft.).
4. Lower vehicle.
REAR AXLE TORQUE ARM

!++!

SECTION OA.
2. Support rear axle (13) with an adjustable lifting

device.
Install or Connect
NOTICE:
Important
(I]
Important
Refer to "Notice" on page 3D-1.
1. Position lower control arm (6) to rear axle (13)

and underbody pan.

type hoist.
3. Torque arm from propeller shaft, if equipped with
two-piece propeller shaft. Refer to SECTION 4A.
~#;-.
=--==r-~;....,....,
6
20-
A FRONT OF LOWER CONTROL ARM

(RIGHT-HAND SHOWN LEFT-HAND OPPOSITE)
B REAR OF LOWER CONTROL ARM
(RIGHT-HAND SHOWN LEFT-HAND OPPOSITE)
C PAN, UNDERBODY
6 ARM, REAR AXLE LOWER CONTROL

13 AXLE, REAR
20 BOLT/SCREW. REAR AXLE LOWER CONTROL ARM
21 WASHER, REAR SUSPENSION CONTROL ARM
22 NUT. REAR AXLE LOWER CONTROL ARM
Figure 7 - Rear Axle Lower Control Arm
01-24-95
FS0073D
REAR SUSPENSION
4. Bolts/screws (23), washers (24) and nuts (25)

from rear axle (13).
5. Bolts/screws (28, 29 and 30) and nuts (27) from
automatic transmission, if equipped.
6. Bolts/screws (29 and 30) and nuts (27) from
manual transmission, if equipped.
7. Outer bracket (31).
8. Inner bracket (32).
9. Torque arm (8).
23
13
l++I
Install or Connect
NOTICE:
1. Position inner bracket (32) through transmission.

2. Position outer bracket (31) to inner bracket (32)
and loosely install nuts (27), and bolts/screws (28,
29 and 30).
3. Insert torque arm (8) into brackets (31 and 32).
4. Nuts (27) and bolts/screws (28, 29 and 30).
B ARM, REAR AXLE TORQUE .

13
23
24
25
307
!~I
AXLE, REAR
BOLT/SCREW, REAR AXLE TORQUE ARM
WASHER, REAR AXLE TORQUE ARM
NUT, REAR AXLE TORQUE ARM
0124915
F80083D
Figure 8 Rear Axle Torque Arm to Rear Axl,e
Tighten
Nuts (27) to 41 N,m (30 lb. ft.).

Bolts/screws (28 and 30)
(37 lb. ft.).
Bolts/screws (29) to 27 N.m (20
5. Position torque arm (8) to rear axle
6. Bolts/screws (23), washers (24) and
to 50 N.m
lb. ft.).
(13).
nuts (25).
A WITH 4L60 E TRANSMISSION

B TRANSMISSION, AUTOMATIC
8 ARM, REAR AXLE TORQUE
26 BRACKET, CATALYTIC CONVERTER HANGER
27 NUT, REAR AXLE TORQUE ARM BRACKET
28
29
30
31
32
SOLT/SCREW, REAR AXLE TORQUE ARM INNER BRACKET

SOLT/SCREW, REAR AXLE TORQUE ARM OUTER BRACKET
BOLT/SCREW, REAR AXLE TORQUE ARM INNER BRACKET
BRACKET, REAR AXLE TORQUE ARM OUTER
BRACKET, REAR AXLE TORQUE ARM INNER
012795
FS0093D
Figure 9 Rear Axle Torque Arm to Automatic Transmission
30-8
REAR SUSPENSION
27
A
B
C
B
26
27
29
30
31
32
26
5-SPEED
6-SPEED
TRANSMISSION, MANUAL
BRACKET, CATALYTIC CONVERTER
HANGER
NUT, REAR AXLE TORQUE ARM BRACKET
BOLT/SCREW, REAR AXLE TORQUE ARM OUTER
BRACKET
BOLT/SCREW, REAR AXLE TORQUE ARM INNER
BRACKET
BRACKET, REAR AXLE TORQUE ARM
OUTER
(
30
01-24-95
FS0103D
!~I
Figure 1O - Rear Axle Torque Arm to Manual Transmission
Tighten

Nuts (25) to 132 N.m (97 lb. ft.).
7. Torque arm to propeller shaft, if equipped with
two-piece propeller shaft. Refer to SECTION 4A.
8. Rear axle support.
9. Lower vehicle.
REAR AXLE TORQUE ARM VIBRATION

DAMPENER
3800 VINK
!++!
1. Rear axle torque arm dampener nut.

2. Rear axle torque arm bolt/screw, washer, and
dampener.
l++I
Install or Connect
NOTICE:
1. Rear axle torque arm dampener, washer, and

bolt/screw.
[I]
Important
Be sure collar of the dampener is positioned

against the torque arm.
2. Rear axle torque arm dampener nut.
I~!
Tighten
Torque arm dampener nut to 50 N.m

(37 lb. ft.).
REAR SUSPENSION
[I]
REAR STABILIZER SHAFT

Figures 11 and 12
j++!
Install or Connect
NOTICE:
Important
The rear stabilizer shaft must be installed with

the bend of the shaft facing down.
1. Place insulator (38) over stabilizer shaft (35).

SECTION OA.
2. Nut (41).
3. Link. Refer to "Rear Stabilizer .Shaft Bracket and
5. Clamp (37).
6. Insulator (38).
7. Bracket (34).
8. Stabilizer shaft (35).
!HI
30-9
[I]
Important
The slit of the shaft insulator must face the

rear of the vehicle.
Position clamp (37) to insulator (38) and stabilizer
shaft (35).
Position bracket (39) to rear axle (13).
Bolts/screws (33) and nuts (36).
Stabilizer shaft link nut. Refer to "Rear Stabilizer
Shaft Bracket and Link" in this section.
2.
3.
4.
5.
!~!
Tighten
Nuts (36) to 24 N.m (18 lb. ft.).

6. Link. Refer to "Rear Stabilizer Shaft Bracket and
7.. Lower vehicle.
~39
~~~
A
40
1VIEWA I
40
35
~
!VIEWA
37
13 AXLE, REAR
.
33 BOLT/SCREW, REAR STABILIZER SHAFT INSULATOR
CLAMP
34 BRACKET, REAR STABILIZER SHAFT ROD
35 SHAFT, REAR STABILIZER
. 36 NUT, REAR STABILIZER SHAFT INSULATOR CLAMP
37 CLAMP, REAR STABILIZER SHAFT INSULATOR
38 INSULATOR, REAR STABILIZER SHAFT
012195
FS0113D
Figure 11 Rear Stabilizer Shaft
A
35
39
40
41
42
PAN, UNDER BODY

SHAFT, REAR STABILIZER
BRACKET, REAR STABILIZER SHAFT
BOLT/SCREW, REAR STABILIZER SHAFT LINK
NUT, REAR STABILIZER SHAFT LINK
LINK, REAR STABILIZER SHAFT
012191
FS0123D
Figure 12 Rear Stabilizer Shaft Bracket and Link
30-10
REAR SUSPENSION
REAR STABILIZER SHAFT BRACKET AND

LINK
Figure 12
I++!

SECTION OA.
2. Nut (41).
3. Link (42).
5. Bracket (39).
l++I
Install or Connect
NOTICE:
1. Position bracket (39) to underbody pan.

l~I
Tighten

3. Position link (42) to bracket (39).
4. Link (42) and nut (41).
I~!
Tighten
Link (42) and nut (41) to 22 N,m (16 lb. ft.).

5. Lower vehicle.
REAR SHOCK ABSORBER

Figure 13
!++I
Figure 13 - Rear Shock Absorber
1.
2.
3.
4.
Fold down seatback frame.

Quarter trim panel. Refer to SECTION 10-6.
Pull folding carpet back.
SECTION OA.
NOTICE: Rear axle must be supported before

removing nut to avoid possible damage to brake
hose lines, tie rod and propeller shaft.
6.
7.
8.
9.
10.
l++I
A TYPICAL REAR SHOCK ABSORBER

INSTALLATION (RIGHT-HAND SHOWN)
B PAN, UNDERBODY
13 AXLE, REAR
43 NUT, REAR SHOCK ABSORBER
44 RETAINER, REAR SHOCK ABSORBER UPPER
INSULATOR
45 INSULATOR, REAR SHOCK ABSORBER UPPER
46 INSULATOR, REAR SHOCK ABSORBER LOWER
47 ABSORBER, REAR SHOCK
48 NUT, REAR SHOCK ABSORBER
01-25-9&
FS0133D
Nut (43).
Retainer (44) and upper insulator (45).
Retainer ( 44) and lower insulator (46).
Nut (48) from rear axle (13).
Shock absorber (47).
Install or Connect
NOTICE:
1. Position shock absorber (47) to rear axle (13).

2. Nut (48).
!~!
Tighten
Nut (48) to 90 N,m (66 lb. ft.).

3. Lower insulator (46) and retainer (44) to shock
absorber (47).
4. Position shock absorber (47) through underbody
pan and seat insulator.
5. Upper insulator (45) and retainer (44) to shock
absorber (47).
NOTICE: Turning the shock absorber while

tightening the nut could damage the shock
absorber. To prevent damage, keep the shock
absorber stationary when tightening the nut.
!~!
Tighten
Nut (43) to 17 N.m (13 lb. ft.).
REAR SUSPENSION
7.
8.
9.
10.
11.
3D11
Remove rear axle support.

Lower vehicle.
Pull folding carpet down into position.
Quarter trim panel. Refer to SECTION 10-6.
Fold seatback frame upright.
SPECIFICATIONS
Rear Axle Bumper Bolt/Screw ............................................................................................... 27
Rear Axle Lower Control Arm Bolt/Screw ......................................................................... 108
Rear Axle Lower Control Arm Nut ....................................................................................... 82
Rear Axle Tie Rod Bracket-to-Left-Hand Brace Bracket Bolt/Screw .................................. 47
Rear Axle Tie Rod-to-Left-Hand Brace Bracket Nut ............................................................ 82
Rear Axle Tie Rod-to-Right-Hand Brace Bracket Nut .......................................................... 82
Rear Axle Torque Arm Bolt/Screw ........................................................................................ 30
Rear Axle Torque Arm Bracket Nut.. .................................................................................... 41
Rear Axle Torque Arm Inner Bracket Bolt/Screw
(Automatic and Manual Transmission) ............................................................................... 50
Rear Axle Torque Arm Inner Bracket Bolt/Screw (Upper)
(Automatic Transmission Only) ........................................................................................... 50
Rear Axle Torque Arm Nut .................................................................................................. 132
Rear Axle Torque Arm Outer Bracket Bolt/Screw ................................................................ 27
Rear Axle Torque Arm Vibration Dampener Nut ................................................................. 50
Rear Shock Absorber Nut (Lower) ......................................................................................... 90
Rear Shock Absorber Nut (Upper) ......................................................................................... 17
Rear Stabilizer Shaft Insulator Clamp Nut ............................................................................ 24
Rear Stabilizer Shaft Link Bolt/Screw ................................................................................... 23
Rear Stabilizer Shaft Link Nut ............................................................................................... 22
N,m
N.m
N.m
N.m
N.m
N.m
N,m
N.m
(20
(80
(60
(35
(61
(61
(96
(30
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
N.m (37 lb. ft.)

N.m
N,m
N.m
N.m
N.m
N.m
N.m
N.m
N.m
(37
(97
(20
(37
(66
(13
(18
(17
(16
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
SPECIAL TQ,QLS
(lb
J 21474-5
J 21474-20
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
J 21474-23
1 BUSHING RECEIVER
2 BUSHING INSTALLER
3 BUSHING REMOVER
OM!G-915
FS0143D
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
30-12
REAR SUSPENSION
BLANK
TIRES AND WHEELS 3E1
SECTION 3E
TIRES AND WHEELS

systems.
CONTENTS
General Description ................................................. 3E-1
Replacement Tires ............................................... 3E-1
Passenger Tire Service Description ................ 3E-2
All Season Tires .................................................. 3E-2
P-Metric Tires ........................... .-......................... 3E-2
Tire Chain Usage ................................................ 3E-3
Tire Placard ......................................................... 3E-3
Wheels ................................................................. 3E-4
On-Vehicle Service .................................................. 3E-4
Wheel Repair ....................................................... 3E-4
Metric Wheel Nuts and Bolts ............................ 3E-4
Wheel Bolt Replacement .................................... 3E-4
Front Wheel Bolt .................. Refer to Section 3C
Rear Wheel Bolt ................... Refer to Section 4B
Tire Inflation ....................................................... 3E-4
Wheel Removal and Installation ........................ 3E-5
Tire and Wheel Rotation ................................ 3E-8
Tire Mounting and Dismounting ...................... 3E-8

Steel Wheel Mounting Surface Check ......... 3E-9
Tire Repair ........................................................ 3E-9
Measuring Wheel Runout ................................. 3E-9
Compact Spare Tire .. '. ....................................... 3E-10
Balancing Tire and Wheel.. .............................. 3E-11
General Balance Precautions ........................ 3E-11
Off-Vehicle Balancing ................................... 3E-12
On-Vehicle Balancing ................................... 3E-12
Wheel Balance Weights ................................ 3E-12
Correcting Non-Uniform Tires ......................... 3E-12
Aluminum Wheels ............................................ 3E-13
Aluminum Wheel Hub Cap .......................... 3E-13
Aluminum Wheel Porosity Repair ............... 3E-13
Aluminum Wheel Refinishing ...................... 3E-13
Specifications ......................................................... 3E-14
Fastener Tightening Specifications ................... 3E-14
Runout Specifications ....................................... 3E-14
Tire Pressures .................................................... 3E-14
GENERAL DESCRIPTION
CAUTION: Do not mix different types of

tires on the same vehicle, such as radial,
bias, and bias-belted tires, except in
emergencies because vehicle handling
may be seriously affected and may result
in loss of control. This caution does not
apply to the compact spare furnished
with the vehicle.
The factory-installed tires and wheels are

designed to operate satisfactorily with loads up to and
including the full load capacity when inflated to the
recommended tire pressures.
Correct tire pressures and driving techniques
have an important influence on tire life. Heavy
cornering, excessively rapid acceleration, and
unnecessarily sharp braking increase tire wear.
REPLACEMENT TIRES
Figure 1
A tire performance criteria (TPC) specification
number is molded in the sidewall near the tire size of
all original equipment tires. This specification number
assures that the tire meets GM's performance
standards for traction, endurance, dimension, noise,
handling, rolling resistance, and others. Usually, a
specific TPC number is assigned to each tire size.
Replacement tires should be the same size, load

range, speed rating, and construction as the original
tires. Replace the original tires with tires of the same
TPC specification number. Use of any other tire size
or type may seriously affect ride, handling,
speedometer/odometer calibration, antilock brake
system, vehicle ground clearance, and tire clearance to
the body and chassis.
It is recommended that new tires be installed in
pairs on the same axle. If it is necessary to replace
only one tire, it should be paired with the tire having
the most tread, to equalize braking traction.
3E-2
TIRES AND WHEELS

Tires should be replaced when:
They are worn to a point where 1.6 mm (1/16
inch) or less tread remains, or cord or fabric is
showing. To help detect this condition, tires
have built-in tread wear indicators that appear
between tread grooves when tread is worn to
1.6 mm (1/16 inch) or less. Replace tire when
indicators appear in two or more adjacent
grooves at three spots around tire.
Tread or sidewall is cracked, cut or snagged
deeply enough to expose cord or fabric.
Tire has a bump, bulge or split. Slight sidewall
indentations are normal and should not affect
ride.
Tire has a puncture, cut or other damage that
cannot be correctly repaired because of size or
location of damage.
Passenger Tire Service Description

Most tires today have a service description
branded on the side wall after the tire size. This
service description consists of two parts: The load
index and the speed symbol. The load index is a
number usually between 75 and 115, which identifies
the tire's load capacity at maximum inflation. Higher
numbers mean greater load capacity. The speed
symbol is a letter usually between P and Z, which
defines the speed capability of the tire. In the past, this
letter might have been part of the tire size; this
continues to be the case with some V and Z rated
tires. The higher the letter, the . greater the speed
capability. Tire companies have charts which define
equivalent loads and speed for all load indexes and
speed symbols that make up the tire service
description.
rn
Important
When replacing tires, never install a tire that is a

smaller size or lesser speed rating than that used
as original equipment. The speed rating only
applies at the tire's full pressure. An
under-inflated tire will not meet its speed rating
capability.
The chart below shows the common speed rating
on tires used by General Motors.
Speed Symbol
Maximum
Speed (km/h)
Maximum
Speed (mph)
160
112
190
118
200
124
210
130
240
149
Over 240
Over 149
ALL SEASON TIRES

Figure 1
Most GM vehicles are now equipped with steel
belted ~11 season radial tires as standard equipment.
These trres qualify as snow tires, with a 37 percent
higher average rating for snow traction than non-all
season radial tires used previously. Other performance
areas,. such as wet traction, rolling resistance, tread life
'.1fld arr retention, were also improved slightly. These
improvements were made by changing both tread
design and tread compounds. These tires are identified
by ~ "M+S" molded in the tire sidewall following
the size. The suffix "MS" is also molded in the
sidewall after the TPC specification number.
P-METRIC TIRES
Figure 2
All GM vehicles now use passenger-metric
(P-metric) sized tires. P-metric tires are available in
two _load ranges: standard load with 210 kPa (30 psi)
maximum pressure and extra load with 240 kPa (35
psi) maximum pressure. Most passenger vehicle tires
are standard load.
Most P-metric tire sizes do not have exact
corresponding. alpha-numeric tire sizes. For example, a
P205n5Rl5 is not exactly equal in size and load
carrying capacity to an FR78-15. For this reason,
replacement tires should be of the same TPC
specification number (same size, load range,
construction) as those originally on the vehicle. If
P-metric tires must be replaced with other sizes, a tire
dealer should be consulted. Tire companies can best
recommend the closest match of alpha-numeric to
P-metric sizes within their own tire lines.
The metric term for tire pressure is the
kilopascal (kPa). Tire pressure may be printed in both
kPa and pounds per square inch (psi). One psi equals
6.9 kPa. Refer to the tire placard or "Specifications"
in this section for tire pressures.
TIRES AND WHEELS
3E-3
p 205 I 70 R 15 958
TIRE TYPE
P-PASSENGER
T-TEMPORARY
LT-LIGHT TRUCK
SECTION
WIDTH
(MIWMETERS)
205
215
ETC.
ASPECT
RATIO
(SECTION HEIGHT)
(SECTION WIDTH)
60
70
ILOAD INDEX I
TYPE UPL"
SPEED SYMBOL
1100 SERIES, SAE CLASS "S"

RIM
DIAMETER
(INCHES)
14
15
16
TYPE"P"
CONSmUCTION
TYPE
1200 SERIES, SAE CLASS "U"
R-RADIAL
8-BIAS-BEL TED
0-DIAGONAL(BIAS)
TYPE"RP"
SECTION
WIDTH
1100 SERIES, LUG-REINFORCED

012595
FS0033E
N40005-3E-CH-EDS
Figure 2 - Metric Tire Size Explanation
TIRE CHAIN USAGE

Figure 3
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 have been
published in the Owner's Manual. When chains are to
be used, most current GM vehicles require SAE Class
"S" tire chains. These may also be designated as 1100
Series, 1ype PL tire chains. These chains are specially
designed to limit the "fly off" effect that occurs when
the tire and wheel rotates.
Manufacturers of tire chains have a specific
chain size for each tire and wheel to ensure proper fit
when installed. Therefore, specific chains should be
obtained for the tires and wheels on which they are to
be used. Rubber adjusters should not be used to take
up slack or clearance in chains which are loose due to
incorrect size. Always follow the chain manufacturer's
installation instructions.
Use of chains may adversely affect vehicle
handling. When tire chains are installed:
Adjust speed to road conditions
Avoid sharp turns
Fi,gure 3 - Examples of Passeng,er Vehicle Tire Chains
In general, to help prevent chain damage to the

vehicle:
Install chains on rear tires and wheels as

tightly as possible, then tighten them again
after driving 0.4 to 0.8 km (1/4 to 1/2 mile).
Use of chains on front tires and wheels is not
recommended; chains may contact and
possibly damage vehicle. If chains are to be
used on front tires and wheels, be sure there is
enough clearance.
Do not exceed 70 km/h (45 mph), or chain
manufacturer's speed limit, if lower.
Drive in restrained manner and avoid large
bumps, potholes, severe turns and other
maneuvers which could cause tires and wheels
to bounce up and down.
Follow any other instructions of chain
manufacturer which do not disagree with
above. Additional specific information is
published in the Owner's Manual.
TIRE PLACARD
Figure 4
The tire placard is permanently located on the
rear face of the driver's door, and should be referred
to for tire information. The placard lists the maximum
vehicle load, tire size (including spare), and cold
inflation pressure (including spare).
3E-4
TIRES AND WHEELS
ON-VEHICLE SERVICE
WHEELS
Wheels must be replaced if they are bent,
dented, have excessive lateral or radial runout, leak air
through welds, have elongated bolt holes, or if the
wheel nuts will not stay tight. Wheels with runout
greater than specified may cause objectionable
vibrations.
Replacement wheels must be equivalent to the
original equipment wheels in load capacity, diameter,
rim width, offset, and mounting configuration. A wheel
of incorrect size or type may affect wheel and bearing
life, brake cooling, speedometer/odometer calibration,
antilock brake system, vehicle ground clearance and
tire clearance to the body and chassis.
Steel wheels can be identified by a two- or
three-letter code stamped into the front side of the rim
near the valve stem. Aluminum wheels have the code,
part number, and manufacturer ID cast into the
inboard side.
WHEEL REPAIR
Wheel repairs that use welding, heating or
peening are not approved. An inner tube is not an
acceptable repair for leaky tires and wheels. Porosity
in aluminum wheels can be repaired. Refer to
"Aluminum Wheel Porosity Repair" in this section.
METRIC WHEEL NUTS AND BOLTS

A metric wheel nut is identified by the word
"Metric" stamped on its face. The wheel bolt has the
letter "M" stamped into its end. The thread size of the
metric wheel nuts and bolts are indicated by a code,
such as M12 x 1.5.
WHEEL BOLT REPLACEMENT

CAUTION: If any wheel bolt is damaged
by a loose-running wheel, all the bolts for
that wheel should be replaced. A
loose-running wheel may break only one
bolt, but the other bolts may be damaged
internally. Replacing only the broken bolt
and remounting the wheel may cause
further damage and personal injury.
MFG liY GENERAL MOTORS CORP

DATE
GVRA
GAWRFR
GAWFtRR
LB
c:::::::u.a c::J!: Fl I
KG
c::=JKG
c::::::JKG
THIS VEHICLE CONFORMS TO ALL APPLICABLE

FEDERAL MOTOR VEHICLE SAFETY AND
BUMPER STANDARDS IN EFFECT ON THE DATE
OF MANUFACTURE SHOWN ABOVE
Front Wheel Bolt

For the front wheel bolt replacement procedure,
refer to SECTION 3C.
Rear Wheel Bolt
For the rear wheel bolt replacement procedure,
TIRE INFLATION
Figure 5
A
B
C
D
E
F
G
H
I
J
K
L
M
N
DATE
GROSS VEHICLE WEIGHT RATING
GROSS AXLE WEIGHT RATING FRONT & REAR
CERTIFICATION STATEMENT
VEHICLE IDENTIFICATION NUMBER
VEHICLE CLASS TYPE: "PASSENGER CARN
MAXIMUM OCCUPANTS
MAXIMUM VEHICLE CAPACITY WEIGHT
MAXIMUM LOADING AT GVWR
TIRE SIZE
SPARE TIRE SIZE
SPEED RATING
TIRE PRESSURE WITH MAXIMUM OCCUPANTS FRONT
&REAR
SPARE TIRE PRESSURE
01-25-95
FS0043E
Figure 4 - Tire Placard
The pressure recommended for all models is

carefully calculated to give a comfortable ride,
responsive steering, and maximum tread wear, tire life
and resistance to bruises. Valve stem caps or
extensions should be installed on the valve stems to
keep out dust and water.
Tire pressure, with tires cold (after vehicle has
sat for three hours or more, or driven less than one
mile), should be checked monthly or before any
extended trip. Set tire pressure to the specifications on
the tire placard located on the rear face of driver's
door or in "Tire Pressures" in this section. Tire
pressure will increase about 6.9 kPa (1 psi) for every
SSC (l0F) temperature increase.
For sustained high-speed driving, tires should be
set at the pressures recommended. Sustained driving at
high speeds, where permitted by law, is not advised
unless vehicle has special high-speed tires.
Tire pressure which is higher than that
recommended can cause:
Hard ride.
Reduced handling.
Tire bruising or carcass damage.
Rapid tread wear at center of tire.
TIRES AND WHEELS

Tire pressure which is lower than that
recommended can cause:
Tire squeal on turns.
Hard steering.
Rapid and uneven wear on edge of tread.
Tire rim bruises and rupture.
Tire cord breakage.
High tire temperatures.
Reduced handling.
High fuel consumption.
Unequal tire pressure on same axle can cause:
POUNDS PER SQUARE INCH (psi)

TO KILOPASCALS (kPal
20
23
24
26
28
29
30
32
35
38
41
45
50
WHEEL REMOVAL AND INSTALLATION

Figures 6, 7 and 8
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 sequence and to the
proper torque specification.
kPa
psi
kPa
psi
40
Uneven braking.
Steering lead.
Reduced handling.
Swerve on acceleration.
3E-5
380
420
450
480
520
550
590
620
55
140
60
160
65
170
70
180
75
190
80
200
85
210.
90
220
95
240
100
260
105
280
110
280
115
310
120
340
CONVERSION: psi x 6.895 .,, kPa
660
690
720
760
790
830
01-25-1115
FSOGS3E
Figure 5 - lnflaUon Pressure Conversion
CAUTION: If penetrating oil gets on the

vertical surfaces between the wheel and
the rotor or brake drum, it could cause
the wheel to work loose as the vehicle is
driven, resulting in a loss of control and
an injury accident.
Penetrating oil has not been found to be

effective in removing tight wheels. However, if it is
used, it should be applied sparingly to the wheel
centerhole area only.
13
10
A WHEEL, 16 X 7.5 STEEL

B WHEEL, 16 X 8 CAST ALUMINUM
9 BOLT, WHEEL
10 WHEEL, TIRE AND
11 NUT, WHEEL
12 NUT, SPECIAL SECURITY WHEEL LOCK
13 COVER, WHEEL TRIM
14 NUT, WHEEL
15 CAP, HUB
B
02-27-95
FT0063E
Figure 6 - Tire and Wheel - (Chevrolet)
3E-6 TIRES AND WHEELS

NOTICE: Never use heat to loosen a tight
wheel. It can shorten the life of the wheel,
studs, or hub and bearing assemblies. Wheel
nuts must be tightened in sequence and to the
proper torque to avoid bending the wheel or
rotor.
Sometimes 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 tire can cause damage and is
not recommended. Slight tapping on the tire sidewall
using a large rubber mallet is acceptable.
The wheel can be removed without damage as
follows:
1. Retighten all wheel nuts on affected wheel. Then
loosen each nut two turns. Rock vehicle from side
to side. If this is not effective, go to step 2.
2. Rock vehicle from "DRIVE" to "REVERSE"
allowing vehicle to move several feet in each
direction. Apply quick, hard jabs on the brake
pedal to loosen wheel. If wheel still does not
loosen, then rock vehicle again from side .to side
as hard as possible using one or more person's
body weight. If wheel is still tight, repeat
procedure.
3. Hub cap (15) or wheel trim cover (13).

4. Special security wheel lock nut (12), if equipped.
Use special security wheel lock key, located in
the front floor console.
5. Wheel nuts (11 or 14).
Mark location of the tires and wheels (10) to
the hub.
6. Tire and wheel (10).
Clean
CAUTION: Before installing wheels,

remove any buildup of corrosion on the
wheel mounting surface and brake drum
or rotor mounting surface by scraping
and wire brushing. Installing wheels
without good metal-to-metal contact at
the mounting surfaces can cause wheel
nuts to loosen, which can later allow the
wheel to come off while causing loss of
control. Wheel nuts must be tightenend
in sequence and to proper torque to
avoid bending wheel or brake drum or
rotor.
CHEVROLET
I+-.!
Wheel nuts (11 or 14), bolts (9), wheel (10)

and brake drum or rotor mounting surfaces.

SECTION OA.
2. Wheel nut caps, if equipped.
!-.+f
Install or Connect
NOTICE: Refer to "Notice" on page 3E-1.
10
17
A
B
9
10
11
12
15
17
WHEEL, 16 x 7.5 ALUMINUM

WHEEL, 16 x 8 STYLED ALUMINUM
BOLT, WHEEL
WHEEL. TIRE AND
NUT, WHEEL
NUT, SPECIAL SECURITY WHEEL LOCK
CAP, HUB
CAP, HUB
Figure 7 Tire and Wheel (Pontiac)
10
11
022795
FT0073E
TIRES AND WHEELS
3E-7
5. Wheel nuts (11).
CAUTION: Never use oil or grease on

bolts or wheel nuts. Tighten the wheel
nuts with your fingers until they are
snug. Then, tighten the wheel nuts in the
proper sequence to the specified torque.
Refer to "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.
Mark location of the tires and wheels (10) to

the hub.
2. Wheel nuts (11 or 14).

Use special security wheel lock key located in
front floor console.
!~!
Tighten
Nuts (11, 12 or 14) in increments of 27 N ,m

(20 lb. ft.) in sequence (Figure 8) up to 140
N.m (100 lb. ft.).
4. Hub cap (15) or wheel trim cover (13), if
equipped.
!~!
CAUTION: Before installing wheels,

remove any buildup of corrosion on the
wheel mounting surface and brake drum
or rotor mounting surface by scraping
and wire brushing. Installing wheels
without good metal-to-metal contact at
the mounting surfaces can cause wheel
nuts to loosen, which can later allow the
wheel to come off while causing loss of
control. Wheel nuts must be tightenend
in sequence and to proper torque to
avoid bending wheel or brake drum or
rotor.
Wheel nuts (11 ), bolts (9), wheel (10) and
brake drum or rotor mounting surfaces.
!++!
Tighten
Cover (13) to 6 N,m (53 lb. in.).
Clean
Install or Connect
NOTICE:
5. Wheel nut ca:ps, if equipped.

6. Lower vehicle.
Refer to "Notice" on page 3E-l.
PONTIAC
j+-+!

SECTION OA.
3. Hub cap (17 or 18).
Use special security wheel lock key, located in
the front floor console.
CAUTION: Never use oil or grease on

bolts or wheel nuts. Tighten the wheel
nuts with your fingers until they are
snug. Then, tighten the wheel nuts (in the
sequence shown) to the specified torque.
Refer to "Specifications" in this 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.
2. Wheel nuts (11).
Use special security wheel lock key located in
!~!
Tighten
Nuts (11 and 12) in increments of 27 N.m (20

lb. ft.) in sequence (Figure 8) up to 140 N.m
(100 lb. ft.).
4. Hub cap (17 or 18).
!~!
01-25-95
FS0083E
Figure 8 - Five-Hole Wheel Nut Tightening Sequence
Tighten
Cap (17 or 18) to 6 N.m (53 lb. in.).

6. Lower vehicle.
3E8
TIRES AND WHEELS
Tire and Wheel Rotation

Figure 9
To equalize wear, rotate tires at intervals
specified in SECTION OB. Whenever uneven tire wear
is noticed, the cause should be investigated. Figure 9
shows the only methods of tire and wheel rotation
recommended.
Due to their design, radial tires tend to wear
faster in the shoulder area, particularly in drive
locations. Radial tires in non-drive locations may
develop an 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 check wheel nut torque and set tire
pressure. Never use oil or grease on wheel bolts or
nuts.
On vehicles with P245/50ZR16 tires, special
rotation provisions must be followed because the tires
are directional. Refer to Figure 9 for the recommended
rotation.
Rotate the tires. If you have directional tires, be
sure the color-coded arrows on the tires point in the
direction the tires roll. Balance the tires arid wheels
using polyester-coated clip-on wheel balancing
weights. Adjust tire pressures and tighten wheel nuts
to the specified torque. Refer to "Wheel Removal and
Installation" in this section.
TIRE MOUNTING AND DISMOUNTING

Figure 10
Use a tire changing machine to mount or
dismount tires. Follow the equipment manufacturer's
instructions. Do not use hand tools or tire irons to
change a tire as they may damage the tire beads,
wheel rim or flanges.
rn
lI Il
.........
a:
u.
B
A NORMAL FOUR-WHEEL ROTATION PATTERN FOR
TIRES DESIGNED TO ROLL IN EITHER DIRECTION
B SPECIAL FOUR-WHEEL ROTATION PATTERN FOR
DIRECTIONAL TIRES DESIGNED TO ROLL ONLY IN
ONE DIRECTION
IMPORTANT: DO NOT INCLUDE COMPACT SPARE TIRE

ASSEMBLY IN ROTATION
012515
FSOOl3E
Figure 9 Tire and Wheel Rotation
Important
Do not lubricate the tire beads or wheel rim with

a lubricant containing silicone. Silicone will allow
the tire to rotate on the wheel rim, throwing the
tire and wheel out of balance.
NOTICE: Do not attempt to break the tire
bead loose before the tire has completely
deflated. It takes about 70 seconds .for the air to
completely exhaust from a large tire. If the
valve stem is removed before this amount of
time, the bead breaker on the tire changing
machine could put enough force on the tire to
bend the wheel at the mounting surface. This
could result in vibration, shimmy and cracking
of the wheel. Completely deflate the tire before
attempting to break the tire bead loose.
Rim bead seats should be cleaned with a wire
brush or 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 PIN 9985555 (50 percent
lubricant and 50 percent water) or equivalent.
TIRE LOCATING RING

012515
FS0103E
Figure 10 Tire Locating Ring
TIRES AND WHEELS

CAUTION: To avoid serious personal
injury, do not stand over the tire when
inflating. Bead may break when bead
snaps over 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 beads,
deflate, relubricate and reinflate. Over
inflation may cause the bead to break
and cause serious personal injury.
MEASURING WHEEL ASSEMBLV RUNOUT
INBOARD SIDE
After mounting, inflate tire so that beads are

completely seated, but never exceed 280 kPa
(40 psi).
(I]
Important
3E-9
RADIAL RUNOUT
OUTBOARD SIDE
RADIAL RUNOUT
* IF WHEEL ASSEMBLV DESIGN MAKES THIS OUTBOARD
-?
When mounting blackwall tires, be sure the TPC

specification number faces the outboard side of
the vehicle.
Install the valve stem and inflate to the pressure
specified on the tire placard. Check the locating rings
of the tire to be sure they show around the rim flanges
on both sides of the wheel.
MEASUREMENT IMPOSSIBLE, THE INBOARD SIDE

ONL V MAY BE USED.
TIRE REMOVED FROM WHEEL ASSEMBL V
RADIAL RUNOUT
INBOARD SIDE
RADIAL RUNOUT
OUTBOARD SIDE
Steel Wheel Mounting Surface Check

0121MNI
FIH133E
Figures 11 and 12
1. Place straight edge (about. eight to nine inches
long) with both hands on inboard mounting
surface of wheel.
2. Try to rock straight edge up and down.
The outer ring of mounting surface is normally
raised above everything else inside it. If
surface has been bent on a tire changer, it will
be raised above outer ring and straight edge
will rock on this position.
3. Repeat steps 1 and 2 at three or four different
positions on inboard mounting surface.

4. If wheel is bent, it must be replaced. Refer to
"Wheel Removal and Installation" in this section.
B
A STRAIGHT EDGE CHECK
B OUTER RING
01-25-95
FS0113E
Figure 11 - Steel Wheel Mounting Surface Check
Figure 12 - Steel Wheel Mounting Surface
TIRE REPAIR
There are many different materials and
techniques on the market to repair tires, but not all
work on some types of tires. Tire manufacturers have
published detailed instructions on how and when to
repair tires. The instructions can be obtained from the
tire manufacturer. Repair of compact spare tire is not
recommended.
MEASURING WHEEL RUNOUT

Figure 13
Wheel runout should be measured with an
accurate dial indicator. Measurements may be taken
with the wheel installed on the vehicle, or off the
vehicle using an accurate mounting surface such as a
wheel balancer. Measurements may be taken with or
without the tire mounted on the wheel.
Radial runout and lateral runout should be
measured on both the inboard and outboard rim
flanges. With the dial indicator firmly in position,
slowly rotate the wheel one revolution and record the
total indicator reading. If any measurement exceeds
specifications, and there is a vibration that wheel
3E;.10
TIRES AND WHEELS

balancing will not correct, the wheel should be
replaced. Disregard any indicator readings caused by
welds, paint runs, or scratches;
MEASURING WHEEL ASSEMBL V RUNOUT
Steel Wheels
INBOARD SIDE
OUTBOARD SIDE
- Radial runout 1.01 mm (0.040 inch)

- Lateral runout L14 mm (0.045 inch)
Aluminum Wheels
- Radial runout 0.76 mm (0.030 inch)
- Lateral runout 0.76 mm (0.030 inch)
dOMPACT SPARE TIRE

RADIAL RUNOUT
Figure 14
IF WHEEL ASSEMBLY DESIGN MAKES THIS OUTBOARD

MEASUREMENT IMPOSSIBLE, THE INBOARD SIDE
ONLY MAY BE USED.
TIRE REMOVED FROM WHEELASSEMBLY

RADIAL RUNOUT
INBOARD SIDE
RADIAL RUNOUT
OUTBOARD SIDE
012595
FSt133E
Figure 13 Wheel Runout
rn
Important
Use of compact spare may result in activating a

wheel sensor fault code. This will result in
"ANTILOCK" warning lamp turning on and
deactivation of .antilock brake system. After
replacing compact spare, recycling ignition switch
will reset system.
NOTICE: If the compact spare is used as a
rear tire, do not drive faster than 80 km/h (50
mph). Damage to the rear axle 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.
1
2
3
4
5
6
7
8
16
NUT. SPARE WHEEL STOWAGE

ADAPTER, SPARE WHEEL STOWAGE
STEM, TIRE VALVE
TIRE. COMPACT SPARE
JACK
COVER, JACK STOWAGE
BOLT/SCREW, JACK STOWAGE
BOLT/SCREW, SPARE WHEEL STOWAGE
NUT, JACK STOWAGE
Figure 14 Compact Spare Tire
16
112595
FS0143E
TIRES AND WHEELS

Some vehicles will be 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.
Inflation pressure of the compact spare must be
periodically checked and maintained at 420 kPa
(60 psi). It can be mounted and dismounted from its
wheel using present tire-changing equipment and
procedures. As with other tires, the beads should
completely seat at 280 kPa (40 psi).

injury, do not stand over the tire when
inflating. Bead may break when bead
snaps over 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 beads,
deflate, relubricate and reinflate. Over
inflation may cause the bead to break
and cause serious personal injury.
3E-11
The compact spare is designed to weigh less

than standard tires and is easier to handle when need
arises. Check inflation pressure as soon as practical
after installing compact spare and adjust to 420 kPa
(60 psi). Replacement of the compact spare should be
made only by an authorized tire dealer.
NOTICE: Do not take the vehicle through an

automatic car wash with the compact spare
installed. The vehicle may get caught, which
could result in property damage.
BALANCING TIRES AND WHEELS

Figures 15 and 16
There are two methods used to balance tires and
wheels; static and dynamic. Static balance is the equal
distribution of weight around the wheel. Wheels that
are statically unbalanced cause a bouncing action
called tramp.
Dynamic balance is the equal distribution of
weight on each side of the centerline so that when the
tire spins there is no tendency for the wheel to move
from side to side. Wheels that are dynamically
unbalanced may cause shimmy.
General Balance Precautions

CAUTION: It is recommended that eye
protection be used to prevent personal
injury .
..--,
--,
CL OF SPINDLE
0
CL
OF SPINDLE
,_-_.,
'HEAVYSPOT
WHEEL ASSEMBLY SHIMMY
HEAVY
SPOT
WHEEL ASSEMBLY TRAMP
ADD WHEEL BALANCE

WEIGHTS HERE
ADD WHEEL BALANCE
WEIGHTS HERE
CORRECTIVE WHEEL BALANCE WEIGHTS
co,RRECTIVE WHEEL BALANCE WEIGHTS

01-25-95
FS0153E
Figure 15 - Static Unbalance Correction
01-25-95
F80163E
Figure 16 - Dynamic Unbalance Correction
3E-12
TIRES AND WHl:ELS
Deposits of foreign material must be cleaned

from the inside of the wheel. Stones should be
removed from the tread in order to avoid operator
injury during spin balancing and to obtain a good
balance. The tire and wheel should be inspected for
any damage, then balanced according to the equipment
manufacturer's recommendations.
OffV~hicle Balancing
When balancing tires and wheels off the vehicle,
use a balancer that pilots the wheel by the centerhole
(not the lug holes) if possible. Always follow the
equipment manufacturer's instructions. Some
electronic off-vehicle balancers are more accurate than
the on-vehicle spin balancers, but do not correct for
rotor unbalance. If the vibration is not corrected by the
off~vehicle balance, an on-vehicle balance may also be
needed.
On-Vehicle Balancing
When needed, on-vehicle balancing will help
correct vibrations due to brake drum, rotor, and wheel
cover imbalance.
When balancing on-vehicle, do not remove the
balance weights from the off-vehicle dynamic balance.
If more than one ounce of additional weight is
required, it should be split between the inboard and
outboard rim flanges.
The driven tires and wheels should be spun
using the engine. Limit speed as stated in the
following caution.
CAUTION: On vehicles equipped with

limited slip rear axles, do not attempt to
balance a tire on a drive wheel with the
other drive wheel o.n the ~round. The
vehicle may drive through this wheel. and
cause the vehicle to move unexpectedly,
resulting in personal injury and property
damage.
Wheel Balance Weights

Figure 17
When static balancing, if more than 28 grams

(1.0 ounce) are needed, the wheel balance weights
should be split as equally as possible between the
inboard and outboard flanges.
Vehicles .with factory aluminum wheels must be
balanced using special polyester-coated clip-on wheel
balance weights. These weights are designed to fit
over the thicker inboard and outboard rim flanges of
the aluminum wheel and should be installed with a
nylon-coated hammer.
Adhesive wheel balance weights are also
available for aluminum wheels. Use the following
procedure to install adhesive wheel balance weights.
ADHESIVE WHEEL BALANCE WEIGHT
INSTALLATION
1. Clean wheel. by. sanding to bare aluminum where

wheel balance weight is to be located.
2. Wipe wheel balance weight attachment area with
mixture of half isopropyl alcohol and half water.
Use clean cloth or paper towel for this operation.
3. Dry attachment area with hot air. Surface of
w,heel should be warm to touch.
4. Warm adhesive backing on wheel balance weights
to room temperature.
5. Remove tape from back of weights. Do not touch
adhesive surface.
6. Apply wheel balance weight and press on with
hand pressure.
7. Secure wheel balance weight with a 70 to 110 N
(16 to 25 pound) force applied with a roller.
CORRECTING NON-UNIFORM TIRES

There are two ways to correct tires which cause
a vibration even though they are properly balanced.
One method uses an automatic machine which loads
the tire and buffs small amounts of rubber from the
stiff spots on the outer two tread rows. Correction by
CAUTION: Do not spin the drive wheels

faster than 55 km/h (35 mph) as indicated
by the speedometer.' This limit is
necessary because the speedometer
indicates only one-half of the actual
wheel speed when one drive wheel is
spinning and the other drive wheel is
stopped. Personal injury and damage
may result from high speed spinning.
To distinguish between standard rear axle and
limited slip, raise rear of vehicle so both tires are clear
of ground. With the transmission in "PARK" (in gear
with a manual transmission) attempt to turn one wheel
by hand. If the wheel can be turned easily, it is a
standard rear axle: if the wheel cannot be turned
easily, it is a limited slip rear axle. Also, check for
limited slip (G80) on the Service Parts Identification
label.
A
B.
C
D
E
F
CENTERLINE
INSIDE FLANGE
CLIP-ON WEIGHT
ADHESIVE WEIGHT - DYNAMIC
ADHESIVE WEIGHT - STATIC ONLY
01-25-95
MOUNTING FACE
FS0173E
Figure 17 - Aluminum Wheel Balance Weight Placement
TIRES AND WHEELS

this method is usually permanent and, if done
properly, does not significantly affect the appearance
or tire tread life. Tire truing for free runout with a
blade-type machine is not recommended as this
reduces the tread life substantially and often does not
pennanently correct the problem.
Another method is to dismount the tire and
rotate it 180 degrees on the rim. It is important that
this be done only on tires and wheels which are
known to be causing a vibration as it is just as likely
to cause good tires and wheels to vibrate. Refer to
SECTION 3 for more details.
ALUMINUM WHEELS .
Aluminum Wheel Hub. Cap
!+-+!
Hubcap.
- Use flat-bladed tool to pry off hub cap by
inserting tool into slot between rim and hub
cap.
!++!
Install or Connect
Hubcap.
- l!se rubber mallet to fully seat hub cap into
nm.
Aluminum Wheel Po,rosity Repair
!+-+!

SECTION OA.
2. Tire and wheel. Refer to "Wheel Removal and

3. Locate leaking areas by inflating tire to 280 kPa
(40 psi) and dipping tire and wheel into water
bath.
4. Mark leak areas.
5. Mark tire at valve stem.
6. Tire from wheel. Refer to "Tire Mounting and
Dismounting" in this section.
7. Scuff inside rim surface at leak area with number
80 grit sandpaper and clean area with general
purpose cleaner such as 3M part number 08984 or
equivalent.
8. Apply 3 mm ( 1/8-inch) thick layer of
adhesive/sealant, GM PIN 1052366 or equivalent,
to leak test area and allow six hours of drying
time.
!++!
Install or Connect
1. Tire .to wheel. Refer to "Tire Mounting and

Dismounting" in this section.
2. Align matchmark on tire with valve stem.
3. Pressurize to 280 kPa (40 psi) and check for
leaks.
4. Adjust tire pressure to meet specifications on tire
placard.
3E-13
5. Balance tires and wheels. Refer to "Balancing

Tire and Wheel" in this section.
6. Tire and wheel. Refer to "Wheel Removal and
7. Lower vehicle.
Aluminum Wheel Refinishing

A protective clearcoat or colorcoat is applied to
the surface of original equipment cast-aluminum
wheels. A surface break-down condition can begin to
develop if frequent, repeated automatic car wash
cleaning scratches or wears off the factory-applied
protective clearcoat. Once the protective clearcoat is
damaged, exposure to caustic. cleaners and/ or road salt
further causes surface break-down. The service
procedures detail how to strip, clean and recoat
aluminum wheels that are affected by the above
condition. Select and follow only those procedures for
the conditions that apply to the wheels you are
refinishing.
REQUIRED MATERIALS
Amchem Alurni Prep number 33, stock number

DX533, or equivalent - cleaning and conditioning
chemical for aluminum.
Amchem Alodine number 1001, stock number
DX501, or equivalent - coating chemical for
aluminum.
Ditzler Declear Acrylic Urethane Clear, stock
number DAU-75, or equivalent.
Ditzler Delthane Ultra-Urethane Additive, stock
number DXR-80, or equivalent.
INITIAL PREPARATION
!++!

SECTION OA.
Matchmark tire for reinstallation of outboard
wheel balance weights after recoating of
wheel.
2. Tire and wheel from vehicle. Refer to "Wheel
Removal and Installation" in this section.
3. Outboard wheel balance weights.
Clean
Wheel inside and out with water base all- purpose

cleaner. Remove grease or oil with solvent
cleaner.
ACCENT COLOR PREPARATION
Sand over painted areas that do not require

recoloring with number 400-grit wet or dry
sandpaper to promote adhesion of clearcoat.
SURFACE DAMAGE

injury, do not use engine power to rotate
wheel while sanding.
3E-14
TIRES AND WHEELS
1. Mount wheel on brake lathe and spin slowly.
NOTICE: Do not use abrasive coarser than

80-grit or wheel may be damaged.
2. Sand wheel with backing block or pad by holding
abrasive flat to surface of wheel and moving
slowly back and forth from center to outer edge to
remove imperfections.
A. First, sand with number 80-grit sandpaper.
B. Follow with number 150-grit sandpaper.
C. Finish with number 24Q-grit sandpaper.
SLIGHT CLEARCOAT DAMAGE ON UNPAINTED
WHEELS
CAUTION: Use of rubber gloves and eye

protection is necessary to prevent
personal injury.
1. Apply chemical stripper.
A. Allow stripper to penetrate coating.
B. Use a small 1/4-inch detail brush dipped in
stripper to apply material around perimeter an.d
spoke-like areas.
2. Remove stripper, following manufacturer's
recommendations.

injury, do not use engine power to rotate
wheel while sanding.
3. Sand wheel with number 240-grit sandpaper while
rotating wheel on slowly spinning brake lathe or
by mounting it on vehicle and spinning by hand.
This restores machined appearance and
promotes adhesion of finish coats.
RECOATING PROCEDURE
CAUTION: Use of rubber gloves and eye

protection is necessary to prevent
personal injury.
1. Clean surface of contaminants by washing with
soap and water.
2. Spray wheel with Amchem number 33 or

equivalent.
A. Let wheel soak for 1 to 3 minutes.
B. Rinse with water and blow dry.
3. Spray wheel with Amchem number 1001 6t
equivalent.
A. Let wheel soak for 1 to 3 minutes.
B. Rinse with water and blow dry.
4. Mask off tire.
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.
5. Finish wheel with Ditzler Declear Acrylic
Urethane Clear and Ditzler Ultra
Urethane-Additive, or equivalents. Refer to labels
for specific directions.
A. First coat - light mist coat, let flash.
B. Second coat - light, let flash.
C. Third coat - heavy duty, wet coat.
6. Let wheel dry for 24 hours or flash for 30
minutes. Force dry at 60C (140F) for 30 minutes
and allow to cool for 30 minutes before mounting.
l++I
Install or Connect
1. Balance tire and wheel. Refer to "Balancing Tire

and Wheel" in this section.
Replace original wheel balance weights with
polyester-coated wheel balance weights to
avoid discoloration of wheel.
2. Trre and wheel. Refer to "Wheel Removal and
3. Lower vehicle.
SPECIFICATIONS
Jack Stowage Bolt/Screw ............................................................................................. ;; ...... ; 6.5 N.m (58 lb. in.)
Wheel Nut - M12 x 1.5 ...........................................................................................................Refer to Procedure
Wheel Nut Cap - 16 x 7.5 Aluminum Wheel (Pontiac) ........................................................ 6 N.m (53 lb. in.)
Wheel Nut Cap - 16 x 8 Aluminum Wheel (Pontiac) ........................................................... 6 N.m (53 lb. in.)
Wheel Trim Cover (Chevrolet) ................................................................................................. 6 N.m (53 lb. in.)
RUNOUT SPECIFICATIONS
Maximum Radial Runout
Steel Wheels ...................................................................................................................... 1.01
Aluminum Wheels ............................................................................................................. 0.76
Maximum Lateral Runout
Steel Wheels ...................................................................................................................... 1.14
Aluminum Wheels .............................................................................................................. 0.76
mm (0.040 in.)
mm (0.030 in.)
mm (0.045 in.)
mm (0.030 in.)
TIRE PRESSURES
Compact Spare ............................................................................................................................. 420 kPa (60 psi)
Front ............................................................................................................................................. 210 kPa (30 psi)
Rear .............................................................................................................................................. 210 kPa (30 psi)
STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE
3F-1
SECTION 3F
STEERING WHEEL AND C LUMN

ON-VEHICLE SERVICE
CAUTION: The procedures in this section must be followed in the order listed to temporarily
disable the Supplemental Inflatable Restraint (SIR) System and prevent false diagnostic codes
from setting. Failure to follow procedures could result in possible air bag deployment, personal
injury, or otherwise unneeded SIR system repairs.
systems.
.CONTENTS
General Description ................................................. 3F-2
Steering Column .................................................. 3F-2
Ignition Lock Systems ........................................ 3F-2
Brake Transmission Shift Interlock (BTSI) ....... 3F-2
Supplemental Inflatable Restraint (SIR) ............. 3F-2
Lubrication ........................................................... 3F-2
Steering Wheel Controls ..................................... 3F-2
Repairs and Inspections Required after
an Accident.. ............................ Refer to Section 9J
Ignition Lock Systems ................. Refer to Section 3
Brake Transmission Shift Interlock
(BTSI) ................................ Refer to Section 3F5B
(SIR) ........................................ Refer to Section 9J
Steering Wheel Controls .... Refer to Section SA-150
OnVehicle Service .................................................. 3F-2
Service Precautions ............................................. 3F-2
Disabling the SIR System .............................. 3F-4
. Enabling the SIR System ............................... 3F-4
Live (Undeployed) Inflatable Restraint
Steering Wheel Module .............................. 3F-4
Deployed Inflatable Restraint Steering
Wheel Module ............................................. 3F-4
Inflatable Restraint Steering Wheel
Module Shipping Procedures ...................... 3F-5
Inflatable Restraint Steering Wheel Module

Scrapping Procedures .................................. 3F-5
Wiring Repairs ..... Refer to Sections 8A-5 and 9J
Park Lock System ................. Refer to Section 7A
Solenoid ............................. Refer to Section 7A
Ignition Switch and Dimmer Switch ................. 3F-5
Turn Signal and Headlamp Dimmer Switch
and Cruise Control Actuator and Windshield
Wiper and Windshield Washer Lever ............ 3F-6
Hazard Warning Switch ...................................... 3F-6
Hazard Warning Switch Knob ........................ 3F-6
Steering Column Tilt Wheel Release
Lever ................................................................ 3F-7
Inflatable Restraint Steering Wheel
Module ............................................................. 3F-7
Steering Wheel Hom Switch .............................. 3F-9
Steering Wheel .................................................. 3F-10
Centering the SIR Coil.. ....... Refer to Section 3F5B
PASS Key Lock Cylinder ..... Refer to Section 3F5B
Radio Control Switch ....................................... 3F-11
Steering Gear Coupling Shaft... ........................ 3F-12
Steering Column Removal... ............................. 3F-12
Checking Steering Column for Accident
Damage ............................... Refer to Section 3F5B
Specifications ......................................................... 3F-15
Fastener Tightening Specifications ................... 3F-15
Special Tools ......................................................... 3F-16
3F-2
GENERAL DESCRIPTION
STEERING COLUMN
Figure 1
The locking, energy-absorbing column (15)
includes three important features in addition to the
steering function.
1. In a front-end collision, the energy-absorbing
column (15) is designed to collapse, minimizing
the possibility of driver injury.
2. The steering column lock and ignition cylinder are
conveniently mounted on the column (15).
3. When locked, the column-mounted lock acts as a
theft deterrent by preventing the operation of both
ignition and steering.
The turn signal, headlamp dimmer switch, cruise
control actuator, windshield wiper and windshield
washer lever (5 or 31) controls the tum signals,
headlamp high beam, windshield washer and wipers,
and, if equipped, cruise control.
To ensure the energy-absorbing action, use only
the specified bolts/screws and nuts and tighten them to
their specified torque. Apply a thin coat of lithium
grease to all friction points during reassembly.
When the column (15) is removed from the
vehicle, handle it with special care. Using a steering
wheel puller other than the one recommended in this
manual, hitting the end of the steering gear coupling
shaft (9) sharply, leaning on the column (15) or
dropping the column (15) could shear or loosen the
plastic fasteners that keep the column (15) rigid.
IGNITION LOCK SYSTEMS,

The automatic transmission uses a park lock
system. This system uses a flexible automatic
transmission park lock cable which is attached at one
end to the automatic transmission control lever and at
the other end to the ignition switch mounted to the
column where it actuates a locking pin. This locking
pin engages an ignition switch sliding contact when
the lever is in "REVERSE" and 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 locking pin engages a cam on
the cable and prevents the lever from being moved
into another position.
A steering column key release lever is used on
vehicles with a manual transmission. A manual
transmission clutch start switch is used so the manual
transmission clutch pedal must be depressed before the
engine will crank.
BRAKE TRANSMISSION SHIFT

INTERLOCK (BTSI)
The brake transmission shift interlock (BTSI)
system prevents the driver from shifting out of
"PARK" 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
BTSI solenoid is de-energized and releases the
automatic transmission control lever.
SUPPLEMENTAL INFLATABLE RESTRAINT

(SIR)
The supplemental inflatable restraint (SIR) helps
supplement the protection offered by the driver's seat
belt by deploying an air bag from the center of the
steering wheel during certain frontal crashes. The air
bag deploys when the vehicle is involved in a frontal
crash of sufficient force up to 30 degrees off the
centerline of the vehicle. The steering column is
collapsible and should be inspected after an accident
whether or not a deployment has occurred.
The SIR system components in the steering
wheel and steering columns are the inflatable restraint
steering wheel module and the SIR coil. To obtain a
detailed description of these components, refer to
SECTION 91.
LUBRICATION
Apply a thin coat of lithium grease to all friction
points when reassembling components.
STEERING WHEEL CONTROLS

PONTIAC
Figure 2
Steering wheel controls enable remote control of
the following sound system functions, if equipped:
PLAY - Starts playing cassette tape player or
compact disc player.
VOL .(Volume) - Adjusts volume of AM/FM
stereo, cassette tape player or compact disc
player.
PRESET - Selects preset stations.
AM/FM - Switches between AM and FM
bands.
SEEK - Seeks the next station, either up or
down.
MUTE - Mutes volume of AM/FM stereo,
cassette tape player or compact disc player.
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
CAUTION: The procedures in this section
must be followed in the order listed to
temporarily disable the Supplemental
Inflatable Restraint (SIR) System and
prevent false diagnostic codes from
setting. Failure to follow procedures
could result in possible air bag
deployment, personal injury, or otherwise
3F-3
A CONNECTOR, RADIO ELECTRICAL

(PONTIAC ONLY)
B CONNECTOR, SIR COIL ELECTRICAL
C LEAD.HORN
D BUTTON, STEERING GEAR COUPLING HEAT SHIELD
1 MODULE, INFLATABLE RESTRAINT
STEERING WHEEL
2 WHEEL, STEERING
3 BOLT/SCREW; STEERING WHEEL
4 NUT, STEERING COLUMN UPPER SUPPORT
5 LEVER, TURN SIGNAL AND HEADLAMP
DIMMER SWITCH AND CRUISE CONTROL ACTUATOR
AND WINDSHIELD WIPER AND WINDSHIELD WASHER
6 LEVER, STEERING COLUMN TILT WHEEL
RELEASE
7 BOLT/SCREW, STEERING COLUMN
8 BOLT/SCREW, INTERMEDIATE STEERING SHAFT
9 SHAFT, STEERING GEAR COUPLING
10 BOLT/SCREW, INTERMEDIATE STEERING SHAFT
11
12
13
14
15
16
17
18
19
20
21
22
23
31

BOOT, STEERING GEAR
SHIELD, STEERING GEAR COUPLING HEAT
COVER, STEERING COLUMN DASH PANEL
COLUMN, STEERING
BOLT/SCREW, STEERING COLUMN GUIDE,
GUIDE, STEERING COLUMN
BOLT/SCREW, HAZARD WARNING SWITCH KNOB
BUTTON, HAZARD WARNING SWITCH
SPRING, HAZARD WARNING SWITCH KNOB
KNOB, HAZARD WARNING SWITCH
NUT, STEERING WHEEL
SEALER, STEERING COLUMN
LEVER, TURN SIGNAL ANO HEADLAMP
DIMMER SWITCH AND WINDSHIELD WIPER AND
WINDSHIELD WASHER
01-1995
FS0013F
Figure 1 Steering Column with SIR
3F4 STEERING Wl1.EEL AND COLUMN ON-VEHICLE SERVICE

Enabling the SIR System
VOLUMN
!++I
Install or Connect
Turn ignition switch to "LOCK" and remove key.
MUTE
AM/FM
PLAY
01-11-95
FS0023F
Figure 2 - Steering Wheel Controls - (Pontiac)
The (SDM) can maintain sufficient voltage

to cause a deployment for up to 10 minutes
after the ignition switch is turned "OFF," the
battery is disconnected or the fuse powering
the SDM is removed. Many of the service
procedures require disconnection of the "AIR BAG"
Fuse and disconnection of the deployment loops to
avoid an accidental deployment. If the inflator
modules are disconnected from the deployment loops
as noted in the "Disabling the SIR System" procedure
that follows, service can begin immediately without
waiting for the 10 minute time period to expire.
Disabling the SIR System
l++I
Turn steering wheel so vehicle's wheels are

pointing straight ahead.
Turn ignition switch to "LOCK" and remove the
key.
1. "AIR BAG" fuse from 1/P fuse block.
2. Instrument panel insulator - LH, refer to
SECTION SC.
3. Connector Position Assurance (CPA) and yellow
2-way connector located near the base of steering
colum1t'.
4. Instrument compartment door, Refer to
SECTION SC.
2-way connector from passenger inflator module.
[I]
Important
With the "AIR BAG" fuse removed and ignition

switch to "RUN," the "AIR BAG" warning lamp
will be "ON." This is normal operation and does
not indicate a SIR malfunction.
1. Yellow 2-way connector and CPA to passenger

inflator module.
2. Instrument panel compartment door, refer to
SECTION SC.
3. Yellow 2-way connector located near the base of
the steering column and the corresponding CPA.
4. Instrument panel insulator - LH, refer to
SECTION SC.
5. "AIR BAG" fuse to IIP fuse block.
Staying well away from the inflator modules, turn
ignition switch to "RUN" and verify that the
"AIR BAG" warning lamp flashes seven times
and then turns "OFF." If it does not operate as
described, perform the "SIR Diagnostic System
Check" in SECTION 9J.
Live (Undeployed} Inflatable Restraint

Steering Wheel Module
Special care is necessary when handling and
storing a live (undeployed) inflator module. The rapid
gas generation produced during deployment of the air
bag could cause the inflatable module, or an object in
front of the inflator module, to be thrown through the
air in the unlikely event of an accidental deployment.
CAUTION: When carrying a live inflator

module, make sure the bag opening is
pointed away from you. In case of an
accidental deployment, the bag will then
deploy with minimal chance of injury.
Never carry the inflator. module by the
wires or connector on the underside of
the module. When placing a live inflator
module on a bench or other surface,
always face the bag up, away from the
surface. This is necessary so that a free
space is provided to allow the air bag to
expand in the unlikely event of accidental
deployment. Never rest a steering column
on the steering wheel with the inflator
module face down and the column
vertical. Otherwise, personal injury may
result.

Wheel Module
After an inflator module has been deployed, the
surface of the air bag may contain a powdery residue.
This powder consists primarily of corn starch (used to
lubricate the bag as it inflates) and by-products of the
chemical reaction. Sodium hydroxide dust (similar to
lye soap) is produced as a by-product of the
deployment reaction. The sodium hydroxide then
quickly reacts _with atmospheric m?istur~ and is
converted to sodmm carbonate and sodmm bicarbonate
(baking soda). Therefore, it is unlikely that sodi~
hydroxide will be present after deployment. As wt.th
many service procedures, you should wear gloves and
safety glasses.

Inflatable Restraint Steering Wheel Module
Shipping Procedures
3F-5
30
Service personnel should refer to the latest

service bulletins for proper SIR inflatable restraint
steering wheel module shipping procedures.
Inflatable Restraint Steering Wheel Modul,e

Scrapping Procedures
During the course of a vehicle's useful life,
certain situations may arise which will necessitate the
disposal of a live (undeployed) inflator module. This
information covers proper procedures for disposing of
a live inflator module.
Before a live inflator module can be disposed of,
it must be deployed. Live inflator modules must not
be disposed of through normal refuse channels.
CAUTION: Failure to follow proper

supplemental inflatable restraint (SIR)
inflatable restraint steering wheel module
disposal procedures can result in air bag
deployment which may cause personal
injury. Undeployed inflator modules must
not be disposed of through normal refuse
channels. The undeployed inflator
module contains substances that can
cause severe illness or personal injury if
the sealed container is damaged during
disposal. Disposal in any manner
inconsistent with proper procedures may
be a violation of federal, state and/or
local laws.
If a vehicle is the subject of a Product Liability
Report related to the SIR system and is subject to a
Preliminary Investigation (GM-1241), DO NOT
DEPLOY the inflator module and DO NOT ALTER
the SIR system in any manner. Refer to the applicable
service bulletin on SIR shipping procedures for details
on handling SIR systems involved with GM-1241. If a
vehicle is the subject of a campaign affecting
inflatable restraint steering wheel modules, DO NOT
DEPLOY the inflator module. Follow instructions in
the campaign service bulletin for proper disposition of
the inflator module.
If an inflator module is replaced under warranty,
DO NOT DEPLOY the Air Bag. The inflator module
may need to be returned, undeployed, to Inland Fisher
Guide. Refer to procedures shown in the appropriate
service bulletin regarding SIR shipping procedures.
In situations which require deployment of a live
(undeployed) inflator module, deployment may be
accomplished inside or outside the vehicle. The
method employed depends upon the final disposition
of the particular vehicle, as noted in "Deployment
Outside Vehicle" and "Deployment Inside Vehicle" in
SECTION 9J.
IGNITION SWITCH AND DIMMER SWITCH

Fi9ures 3 and 4
!+-+!
l, Left-hand instrument panel insulator. Refer to

SECTION 8C.
.
15 COLUMN, STEERING
24 SWITCH, IGNITION
25 SWITCH, DIMMER
25 BOLT/SCREW, IGNITION SWITCH
27 ROD, DIMMER SWITCH ACTUATOR
28 BOLT/SCREW, DIMMER AND IGNITION SWITCH
29 ROD, IGNITION SWITCH ACTUATOR
30 JACKET, STEERING COLUMN
81200
F80033F
Fi,gure 3 Ignition Switch and Dimmer Switch
24
A LOCK POSITION
24 SWITCH, IGNITION
8128-H
FS004SF
Figure 4 Ignition Switch Adjustment
2. Instrument panel driver knee bolster and deflector.

3. Disable SIR system. Refer to "Disabling the SIR
System" in this section.
4. Ensure steering column lock and ignition cylinder
is in "LOCK" position.
5. Steering column upper support nuts from steering
column support. Refer to "Steering Column
Removal" in this section.
6. Lower column (15).
7. Electrical connectors from dimmer switch (25)
and ignition switch (24).
8. Dimmer switch actuator rod (27).
10. Dimmer switch (25).
3F-6
11.
12.
13.
14.
Bolt/screw (26).
Ignition switch actuator rod (29).
Ignition switch (24).
Automatic transmission park lock cable, if
equipped. Refer to SECTION 7A.
1~+1
Install or Connect
NOTICE:
Refer to "Notice" on page 3F-1.
l. Automatic transmission park lock cable, if

2. Ensure ignition switch (24) is in "LOCK"
position.
3.
4.
5.
6.
Move switch slider to extreme right position

and then move slider one detent left.
Ensure steering column lock and ignition cylinder
is in "LOCK" position.
Ignition switch (24) to jacket (30).
Ignition switch actuator rod (29) to ignition switch
(24).
Bolt/screw (26).
l~I
Tighten
Bolt/screw (26) to 2.5 N.m (22 lb. in.).

7. Position dimmer switch (25) to ignition switch
(24).
I~!
Adjust
Dimmer switch (25).

-
I~!
9.
10.
11.
12.
13.
14.
15.
Press switch mechanism slightly to insert

3/32-inch drill bit.
Move dimmer switch (25) to remove lash.
Tighten

Dimmer switch actuator rod (27).
Electrical connectors to dimmer switch (25) and
ignition switch (24).
Raise column (15).
Steering column upper support nuts to steering
column support. Refer to "Steering Column
Removal" in this section.
Enable SIR system. Refer to "Enabling the SIR

Instrument panel driver knee bolster and deflector.
Left-hand instrument panel insulator. Refer to
SECTION 8C.
TURN SIGNAL AND HEADLAMP DIMMER

SWITCH AND CRUISE CONTROL
ACTUATOR AND WINDSHIELD WIPER
AND WINDSHIELD WASHER LEVER
Figure 5
!++!
1. Steering column tilt wheel release lever, if

equipped with cruise control. Refer to "Steering
Column Tilt Wheel Release Lever" in this
section.
2. Access cover, if equipped with cruise control.
3. Electrical connectors, if equipped with cruise
control.
4. Lever (5 or 31) by grasping firmly and pulling
straight out.
!++!
Install. or Connect
1. Position tang on lever (5 or 31) to notch in

column (15).
rn
Important
Be sure the wiper switch is in the "OFF"

position before installing lever (5 or 31).
2. Lever (5 or 31) to column (15).
rn
Important
Be sure the lever (5 or 31) is fully seated.

3. Electrical connectors, if equipped with cruise
control.
4. Access cover, if equipped with cruise control.
5. Steering column tilt wheel release lever, if
equipped with cruise control. Refer to "Steering
Column Tilt Wheel Release Lever" in this
section.
HAZARD WARNING SWITCH

The . hazard warning switch does not require
removal of the steering column for replacement. For
service information, refer to SECTION 3F5B.
Hazard Warning Switch Knob

Figure 6
!++I
1. Bolt/screw (18).
2. Button (19), spring (20) and knob (21).
I++!
Install or Connect
NOTICE: Refer to "Notice" on page 3F-1.

1. Knob (21), spring (20) and button (19).
2. Bolt/screw (18).
l~J Tighten
3F-7
15
31
A
B
C
D
E
F
5
WITHOUT CRUISE CONTROL

WITH CRUISE CONTROL
TANG
NOTCH
CONNECTOR, LEVER ELECTRICAL
CONNECTOR, COLUMN ELECTRICAL
LEVER, TURN SIGNAL AND HEADLAMP
AND WINDSHIELD WIPER AND WINDSHIHD WASHER
15 COLUMN, STEERING
WINDSHIELD WASHER
01-20-15
FSOOS3F
Figure 5 - Turn Signal and Headlamp Dimmer Switch and Cruise Contro,I Actuator and Windshield Wiper and Windshield
Washer Lever
STEERING COLUMN TILT WHEEL

RELEASE LEVER
Figure 7
!++!
Remove or Disco,nnect
Grip tilt wheel release lever (6) firmly and twist

counterclockwise.
E3
Install or Connect
Grip tilt wheel release lever (6) firmly, and twist

clockwise.
18
19
20
21
BOLT/SCREW, HAZARD WARNING SWITCH KNOB

BUTTON, HAZARD WARNING SWITCH
SPRING, HAZARD WARNING SWITCH KNOB
KNOB, HAZARD WARNING SWITCH
01-20-n
FSOOl3F
Figure 6 - Removing Hazard Warning Switch Knob
INFLATABLE RESTRAINT STEERING

WHEEL MODULE
Figures 8 and 9
j++!
l. Disable SIR system. Refer to "Disabling the SIR

3F.;.8
5 LEVER, TURN SIGNAL ANO HEADLAMP

AND WINDSHIELD WIPER AND WINOSHl!ELO WASHER
RELEASE
15 COLUMN, STEERING
DIMMER SWITCH AND WINDSHIELD WIPER ANO
WINDSHIELD WASHER
01-20-1&
FS0073F
Figure 7 - Steering Column Tilt Wheel Release Lever

(Typical)
2. Loosen bolts/screws (3) from back of steering

wheel (2) using number 30 TORX driver
(or equivalent) until inflatable restraint steering
wheel module ( 1) can be released from steering
wheel (2).
.
3. Inflatable restraint steering wheel module
(1 or 46) from steering wheel (2).

Never carry the inflator module by the
on the steering wheel with the inflator
module face down and the column
result.
4. SIR coil electrical connector and retainer (32)

from inflatable restraint steering wheel module
(1).
5. Radio control switch electrical connector from

inflatable restraint steering wheel module ( 1), if
equipped.
6. Hom lead from column (15).
I++!
Install or Connect
1. Hom lead to column (15).
15
A CONNECTOR, SIR COIL ELECTRICAL

STEERING WHEEL
2 WHEEL, STEERING
3 BOLT/SCREW, STEERING WHEEL
15 COLUMN, STEERING
32 RETAINER, INFLATABLE RESTRAINT STEERING WHEEL
MODULE WIRING HARNESS ELECTRICAL CONNECTOR
Figure 8 - Removing Inflatable Restraint Steering Wheel Module - (Chevrolet)
01-20-IS
FS0083F
3F-9
32
J
~-

1 MODULE, INFLATABLE RESTRAINT STEERING WHEEL
2 WHEEL, STEERING
15 COLUMN, STEERING
32 RETAINER, INFLATABLE RESTRAINT STEERING WHEEL MODULE WIRING HARNESS
ELECTRICAL CONNECTOR
Ol-20H
FSOOl3F
Figure 9 - Removing Inflatable Restraint Steering Wheel Module (Pontiac)
2. Radio control switch electrical connector to

inflatable restraint steering wheel module (1), if
equipped.
3. SIR coil electrical connector and retainer (32) to
inflatable restraint steering wheel module (1).
4. Secure SIR coil electrical connector to steering
wheel (2) by inserting thick section of wire into
existing retainers.
5. Position inflatable restraint steering wheel module
(1) to steering wheel (2).
[I)
Important
Ensure wiring is not exposed or trapped

between inflatable restraint steering wheel
module (1) and steering wheel. (2).
!~!
Tighten
Bolts/screws (3) to 2.8 N.m (25 lb. in.).

7. Enable SIR system. Refer to "Enabling the SIR
STEERING WHEEL HORN SWITCH
CHEVROLET
Figure 10
I++!
Install or Connect
1. Inflatable restraint steering wheel module. Refer

to "Inflatable Restraint Steering Wheel Module"
in this section.
2. Bolt/screw (50).
3. Horn switch (52) from inflatable restraint steering
wheel module (1).
A. Lift up on edge of module cover at horn
button to access horn switches.
B. Press lock tang.
C. Remove horn switch.
D. Repeat for remaining horn switch and remove
horn switch (52).
3F-10
!++I
Install or Connect
NOTICE:
1. Position horn switch (52) to steering wheel (2).

!~!
Tighten
Bolts/screws (38) to 1.9 N,m (17 lb. in.).

3. Hom wiring connector to steering column.
in this section.
STEERING WHEEL
Figure 12

STEERING WHEEL
2 WHEEL, STEERING
15 COLUMN, STEERING
22 NUT, STEERING WHEEL
52 SWITCH; STEERING WHEEL HORN
Tools Required:
J 1859-A Steering Wheel Puller
J 38720 Steering Wheel Puller Bolts
(Part of J 1859-A)
I++!
012085
F80103F
Figure 10 Steering Wheel Horn Switch (Chevrolet)
l++I
Install or Connect

in this section.
2. Nut (22).
1. Hom switch (52) to inflatable restraint steering

wheel module (1).
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.
A. Lift up on edge of module cover at horn

button.
B. Install horn switch (52).
C. Repeat for remaining horn switch (52).
2. Bolt/screw (50).
NOTICE: When attaching J 1859-A and

J 38720 to the steering wheel, . use care to
prevent threading J 38720 (bolts) all the way
through the steering wheel hub into the SIR coil
and damaging the SIR coil.
NOTICE:
l~I
Tighten
Bolt/screw (50) to 1.9 N,m (17 lb. in.).

in this section.
PONTIAC
Figure 11
l++I

in this section.
Hom wiring connector from steering column.
4. Hom switch (52) from steering wheel (2).
2:
3. Horn lead.
4. Steering wheel (2), using J 1859-A and J 38720.
5. Steering wheel horn switch.
l++I
Install or Connect
NOTICE:
1. Route SIR coil electrical connector to steering

wheel (2).
2. Steering wheel horn switch.
3. Steering wheel (2).
II]
Important
Align block tooth on steering wheel (2) with

block tooth on steering column shaft within
one female serration;
3F-11
38
A
A
B
C
1
2
3
22
38
39
52
WITH RADIO CONTROL SWITCH

WITHOUT RADIO CONTROL SWITCH
HARNESS, RADIO CONTROL WIRING
MODULE, INFLATABLE RESTRAINT STEERING WHEEL
WHEEL, STEERING
BOLT/SCREW, STEERING WHEEL
NUT, STEERING WHEEL
BOLT/SCREW, HORN SWITCH
SWITCH, RADIO CONTROL
SWITCH, STEERING WHEEL HORN
01-20-H
FS0113F
Figure 11 - Steering Wheel Hom Switch Contact Plate and Radi,o Control Switch (Pontiac)
4. Horn lead.
5. Nut (22).
!..:;"\
~ Tighten
Nut (22) to 43 N.m (32 lb. ft.).

in this section.
RADIO CONTROL SWITCH

PONTIAC
Figure 11
E3

in this section.
2. Radio control wire harness retainer.

3. Radio control switch (39) from steering wheel (2).
Pry out radio control switch at lower edge.

4. Wire harness connector from control(s).
!++!
1.
2.
3.
4.
Install or Connect
Wire harness, connector to control(s).

Radio control switch (39) to steering wheel (2).
Radio control wire harness retainer.
Inflatable restraint steering wheel module. Refer
in this section.
3F-12
I
A CONNECTOR, RADIO ELECTRICAL
(PONTIAC ONLY)
B CONNECTOR, SIR COIL, ELECTRICAL
C LEAD, HORN
2 WHEEL, STEERING
22

RELEASE
15 COLUMN, STEERING
WINDSHIELD WASHER
01-20-11
FS0123F
Figure 12 - Steering Wheel
STEERING GEAR COUPLING SHAFT

Figure 13
l++I
NOTICE: The vehicle's wheels must be in a

straight-ahead position and the key must be in
the "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.
2.
3.
4.
5.
Clamp (11) from boot (12).

Boot (12) from shaft (9).
Bolt/screw (10) from gear (33).
Shaft (9) from gear (33).
Shield (13) from shaft (9) and column (15) on
5.7L VIN P only.
6. Bolt/screw (8) from column (15).
7. Shaft (9) from column (15).
l++I
Install or Connect
NOTICE:
1. Position shaft (9) to column (15).

2. Bolt/screw (8)
l~i Tighten

3. Position shaft (9) to gear (33).
4. Bolt/screw (10).
!~! Tighten
5. Boot (12) to shaft (9) and secure with clamp (11).
6. Position shield (13) to shaft (9) and column (15)
on 5.7L VIN P only.
7. Shield (13) by inserting button into hole in
column (15) on 5.7L VIN P only.
STEERING COLUMN REMOVAL

Figures 14 and 15
NOTICE: The vehicle's wheels must be in a
straight-ahead position and the key must be in
the ''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.
3F-13
11
A
B
8
9
10
11
12
13
14
15
33
34
35
BUTTON, STEERING GEAR COUPLING HEAT SHIELD

CASTING, STEERING GEAR
BOLT/SCREW, INTERMEDIATE STEERING SHAFT
BOLT/SCREW, INTERMEDIATE STEERING SHAFT
BOOT, STEERING GEAR
SHIELD, STEERING GEAR COUPLING HEAT
COLUMN, STEERING
GEAR, STEERING
CROSSMEMBER, FRONT
01-2085
F80133F
Figure 13 Steering Gear Coupl1ing Shaft
3F-14
_____..
A
4
7
14
15
17
36
NUT, WELD
NUT, STEERING COLUMN UPPER SUPPORT
BOLT/SCREW, STEERING COLUMN
COLUMN, STEERING
GUIDE, STEERING COLUMN
WASHER, STEERING COLUMN
012011
FS0143F
Figure 14 - Removing Steering Column
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 rigid.
I++!
1. Left-hand instrument panel insulator. Refer to

SECTION 8C.
4. Steering wheel, if column is to be replaced. Refer
to "Steering Wheel" in this section.
5. Intermediate steering shaft bolt/screw from
steering gear coupling shaft and column. Refer to
"Steering Gear Coupling Shaft" in this section.
6. Bolts/screws (7) attaching cover (14) to dash
panel.
7. Cover (14) from dash panel.
8. Electrical connectors.
9. Nuts (4) from steering column support.
10. Automatic transmission park lock cable from
ignition switch, if equipped. Refer to
SECTION 7A.
ll. Column (15) from vehicle.
!++I
Install or Connect
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.
NOTICE:
1. Position column (15) into vehicle.

2. Automatic transmission park lock cable to ignition
switch, if equipped. Refer to SECTION 7A.
3. Nuts (4) to steering column support.
!~!
Tighten
Nuts (4) to 25 N.m (18 lb. ft.).

4. Intermediate steering shaft bolt/screw to steering
gear coupling shaft. Refer to "Steering Gear
Coupling Shaft" in this section.
[I]
3F-15
Important
14
When installing the cover (14) to the dash

panel, the lower bolt/screw (7) must be
installed first followed in order by the
outboard bolt/screw (7) and inboard bolt/screw
(7). Refer .to Figure 15.
5. Position cover (14) to dash panel.
!~!
Tighten

8. Steering wheel, if column is replaced. Refer to
"Steering Wheel" in this section.
9. Enable SIR system. Refer to "Enabling the SIR
SECTION 8C.
A LOWER
B OUTBOARD
C INBOARD
14 COVER, STEERING COLUMN DASH PANEL
01-20-95
FS0163F
Figure 15 - Steering Column BolVScrew lnstallaUon

Sequence
SPECIFICATIONS
Dimmer and Ignition Switch Bolt/Screw ................................................................................ .4 N.m (35 lb. in.)
Hazard Warning Switch Knob Bolt/Screw .............................................................................. 0.7 N.m (6 lb. in.)
Ignition Switch Bolt/Screw .................................................................................................... 2.5 N.m (22 lb. in.)
Inflatable Restraint Steering Wheel Mounting Plate Bolt/Screw (Pontiac Only) ................ 1.9 N.m (17 lb. in.)
Intermediate Steering Shaft-to-Steering Column Bolt/Screw ................................................. 47 N.m (35 lb. ft.)
Intermediate Steering Shaft-to-Steering Gear Bolt/Screw ...................................................... 47 N.m (35 lb. ft.)
Radio Control Switch Bolt/Screw (Pontiac Only) ................................................................ 1.9 N.m (17 lb. in.)
Steering Column Bolt/Screw ................................................................................................... 18 N.m (14 lb. ft.)
Steering Column Guide Bolt/Screw ........................................................................................ 25 N.m (18 lb. ft.)
Steering Column Upper Support Nut ..................................................................................... 25 N.m (18 lb. ft.)
Steering Wheel Bolt/Screw (Pontiac Only) ........................................................................... 2.8 N.m (25 lb. in.)
Steering Wheel Horn Switch Contact Plate Shoulder Bolt/Screw (Pontiac Only) ............. 2.8 N.m (25 lb. in.)
Steering Wheel Nut ................................................................................................................. 43 N.m (32 lb. ft.)
Steering Wheel-to-Inflatable Restraint Steering Wheel Module Bolt/Screw
(Chevrolet Only) ................................................................................................................. 2.8 N.m (25 lb. in.)
Steering Wheel-to-Steering Wheel Horn Switch Bolt/Screw (Chevrolet Only) .................. 1.9 N.m (17 lb. in.)
3F16
SPECIAL TOOLS
(
ff@01n10o1m111,o
J 1859-A
STEERING WHEEL PULLER
STEERING WHEEL PULLER BOLTS (PART OF J 1859-Al
00HH(llllf HIIIII IHII
J38720
01-2011
F80183F
TILT STAG COL UNIT REPAIR (SIR,FLR SHFT) 3F5B~1
SECTION 3F5B

(SIR) TILT STEERING COLUMN
FLOOR SHIFT
UNIT REPAIR
CAUTION: The procedures in this section must be followed in the order listed to temporarily disable
the Supplemental Inflatable Restraint (SIR) System and prevent false diagnostic codes from setting.
Failure to follow procedures could result in possible air bag deployment, personal injury, or
CAUTION: Before removing or installing any electrical unit or when a tool or equipment could easily
come in contact with 11 1ive 11 exposed electrical terminals, disconnect the negative battery cable to
help prevent personal injury and/or damage to the vehicle or components. Unless instructed
otherwise, the ignition switch must be in the 11 off 11 or 11 lock 11 position.
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If
a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener
is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those
requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners
that 1equire it. If the above conditions are not followed, parts or system damage could result.
CONTENTS
Steering Column, Parts . . . . . . . . . . . . . . . . . 3F5B-2
Sub Section A - Upper Column . . . . . . . . . . . 3F5B-4
Disabling The SIR System
Enabling The SIR System
Infl Restraint Coil Assembly
Shaft Lock
Turn Signal Cancelling Cam Asm
Upper Bearing Spring
Upper Bearing Inner Race Seat
ltliler Race
Turn Signal Switch Assembly
Buzzer Switch Assembly
Strg Col Pass Key Lock Cylinder Set
Centering Infl -Restraint Coil
Sub Section B - Housing Cover . . . . . . . . . . . 3F5B-9
Lock Housing Cover Assembly
Col Hsg Cover End Cap
Pivot & (Pulse) Switch Assembly
Dimmer Switch Rod Actuator
Tilt Spring Assembly
Sub Section C- Mid Column ............

Steering Column Housing Assembly
Steering Wheel Lock Shoe
Switch Actuator Sector
Switch Actuator Rack
Bearing Assembly
Lock Bolt
Strg Column Housing Support Asm
Steering Shaft Assembly
Sub Section D - Lower Column ..........
Dimmer Switch Assembly
Dimmer Switch Adjustment
Ignition Switch Assembly
Ignition Switch Adjustment
Adapter & Bearing Assembly
Accident Damage .....................
Specifications . . . . . . . . . . . . . . . . . . . . . . .
Fastener Torques ..................
Special Tools. . . . . . . . . . . . . . . . . . . . . . . .
3F5B-11
3F5B-15
3F5B-18
3F5B-18
3F5B-18
3F5B-19
'----'
tr
(')
<O
......
::c
U)
a:
...I
LL
a:
a:
~
w
a:
1-
:::>
...I
0
0
CJ
a:
ti
\
\
t8/'\
\
\
TILT STRG COL UNIT REPAIR (SIR,FLR SHFT) 3F5B3
1- NUT, HEX LOCKING (M14x1.5)

2- RING, RETAINING
3- COIL ASM, INFL RESTRAINT
4- WASHER, WAVE
5- RING, RETAINING
6- LOCK, SHAFT
7- CAM ASM, TURN SIG CANCEL
8- SPRING, UPPER BEARING
9- SCREW, BNDG HD CR RECESS
1a-SCREW, RD WASH HD (M4.2x1 .41)
11-ARM ASM, SIGNAL SWITCH
12-SWITCH ASM, TURN SIGNAL
13-SEAT, UPPER BRG INNER RACE
14-RACE, INNER
15-SCREW, PAN HD SOC TAP
16- SWITCH ASM, BUZZER
18-SCREW, LOCK RETAINING
19- COVER ASM, LOCK HOUSING
20- LOCK CYLINDER SET, STRG COL
PASS KEY
21-ACTUATOR, DIMMER SW ROD
22-PIN, SWITCH ACTUATOR PIVOT
23-SWITCH ASM, PIVOT & (PULSE)
24-BASE PLATE, COL HSG CVR END
25-CAP, COL HSG COVER END
26-PROTECTOR, WIRING
2~SHROUD,CONNECTOR
30- HOUSING ASM, STRG COLUMN
31-BEARING ASM
32- BOLT, LOCK
33- SPRING, LOCK BOLT
34- SHOE, STEERING WHEEL LOCK
35- SHOE, STEERING WHEEL LOCK
36- SHIELD, WIRE PROTECTOR
37- SHAFT, DRIVE
38- PIN, DOWEL
39-PIN, PIVOT
40- SPRING, SHOE
41- SPRING, RELEASE LEVER
42-PIN, RELEASE LEVER
43- LEVER, SHOE RELEASE
44- RACK, SWITCH ACTUATOR
45- SPRING, RACK PRELOAD
46- HOUSING, STRG COLUMN
47-SECTOR, SWITCH ACTUATOR
48- SCREW, HEX WASHER HEAD
5051525556575859616271727677787980828386878889-
GUIDE, SPRING
SPRING, WHEEL TILT
RETAINER, SPRING
SHAFT ASM, STEERING COLUMN
SHAFT ASM, RACE & UPPER
SPHERE, CENTERING
SPRING, JOINT PRELOAD
SHAFT ASM, LOWER STEERING
SCREW, SUPPORT
SUPPORT ASM, STRG COL HSG
SHROUD, STRG COLUMN HOUSING
JACKET ASM, STRG COL
ACTUATOR ASM, IGNITION SWITCH
ROD, DIMMER SWITCH
SCREW, WASH HD (#10-24X.25)
SCREW, HEX WASH HD TAP
SWITCH ASM, IGNITION
SCREW, FLT HD (#10-24X.31)
SWITCH ASM, DIMMER
ADAPTER, LOWER BEARING
BEARING ASM
RETAINER, BEARING ADAPTER
CLIP, LOWER BEARING ADAPTER
Service Kits
201- RACK SERV KIT, COL SECTOR &
-INCLUDES: 14,31,33,44,47,48
202- SPRING SERV KIT, TILT COLUMN
-INCLUDES: 13, 14,39,50,51,52
203- COIL SERV KIT, INFL RESTRAINT
-INCLUDES: 3,4,27
204- SPHERE SERV KIT, TILT COLUMN
-INCLUDES: 57,58
205-GREASE SERV KIT, (SYNTHETIC)
Figure 2 - Tilt Steering Column - Legend
3F5B4 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT)

SUB SECTION A UPPER COLUMN
INCLUDES:
DISABLING THE SIR SYSTEM
ENABLING THE SIR SYSTEM
INFL RESTRAINT COIL ASSEMBLY
SHAFT LOCK
TURN SIGNAL CANCELLING CAM ASM
UPPER BEARING SPRING
UPPER BEARING INNER RACE SEAT
INNER RACE
TURN SIGNAL SWITCH ASS EMBLY
BUZZER SWITCH ASS EMBLY
STRG COL PASS KEY LOCK CYL SET
CENTERING INFL RESTRAINT COIL
Tools Required:
J 23653-C Lock Plate Compressor
ENABLING THE SIR SYSTEM
!-++! Install or Connect
1.
2.
3.
4.
5.
SERVICE PRECAUTIONS
CAUTION: When performing service on or
around SIR components or SIR wiring, follow
the procedures listed below to temporarily
disable the SIR system. Failure to follow
procedures could result In possible air bag
deployment, personal Injury or otherwise
rn
DISABLING THE SIR SYSTEM
f+-+! Remove or Disconnect
1.
2.
3.
4.
5.
lI]
Tum the steering wheel so that the vehicle's

wheels are pointing straight ahead.
Turn the ignition switch to "LOCK" and remove
key.
''AIR BAG" fuse from 1/P fuse block.
Lowersondinsulatorpanel-LH. RefertoSECTION
BC.
Connector Position Assurance (CPA) retainer and
yellow 2-way SIR connector at base of steering
column.
I/P compartment door assembly, refer to SECTION BC.
Connector Position Assurance (CPA) retainer and
yellow 2-way SIR connector located near the yellow
24-way DERM harness connector.
Yellow 2-way SIR connector and CPA retainer

located near the yellow 24-way DERM harness
connector.
1/P compartment door assembly, refer to SECTION
BC.
Yellow 2-way SIR connector and CPA retainer at
base of steering column.
Lower sound insulator panel-LH, refer to SECTION
BC.
"AIR BAG" fuse to 1/P fuse block.
Turn ignition switch to "RUN" and verify that
the "AIR BAG" warning lamp flashes 7 times
and then turns "OFF" .If it does not operate as
Check" in SECTION 9J~A.
Important
Before doing any service procedures in this section,
disabling the SIR system and removal of Inflator
Module and Steering Wheel is needed. Columns
equipped with Supplemental Inflatable Restraint
(SIR) and Redundant Steering Wheel Control
(RSWC) will have Inflatable Restraint coils with
two wire leads. (SIR) wire leads are yellow with a
yellow connector shroud. (RSWC) wire leads are
grey with black connectors. (Refer to "Disabling
the SIR System" in this section and service
procedures in section 3F).
The DERM can maintain sufficient voltage to

cause a deployment for up to 2 minutes after the
ignition switch is turned "OFF" or the battery is
disconnected. Many of the service procedures require
disconnection of the "AIR BAG" fuse and the inflator
module circuits from the deployment loops to avoid an
accidental deployment.
j+-+i
Figures 1 through 9 and 13
NOTICE: Place ignition to "LOCK" position to prevent

uncentering coil assembly (3).
1. Disable the SIR system; Refer to "Disabling the
SIR System" in this Section.
2. Negative(-) battery cable.
Important
With the ''AIR BAG" fuse removed and ignition
switch ''ON'', the "AIRBAG" warning lamp will be
"ON". This is normal operation and does not indicate
an SIR system malfunction.
2 RING, RETAINING
3 COIL ASM, INFL RESTRAINT
4 WASHER, WAVE
Figure 3 - Removing Coil Assembly Off Shaft

3.
4.
5.
6.
7.
8.
9.
Coil assembly retaining ring (2).

Inflatable restraint coil assembly (3).
Let switch hang freely ifremoval is not needed.
To remove coil (3), do steps 5 through 17 in this
section.
Wave washer (4).
Shaft lock retaining ring (5) using J 23653-C to push
down shaft lock (6).
Dispose of ring (5).
Shaft lock (6).
Turn signal cancelling cam assembly (7).
Upper bearing spring (8).
10
12
MULTIFUNCTION
LEVER
9 SCREW, BINDING HD CROSS RECESS

10 SCREW, RD WASH HD (M4.2X1 .41)
11 ARM ASM, SIGNAL SWITCH
12 SWITCH ASM, TURN SIGNAL
Figure 6 - Turn Signal Switch Removal Preparation

16.
EXTRA
RETAINING
RINGS
Turn signal switch assembly (12).
Let switch hang freely if removal is not needed.

To remove switch (12):
A. Turn signal switch connector from bulkhead

connector.
B. Wiring protector (26).
C. Gently pull wire harness through column.
J 23653-C
5 RING, RETAINING
El LOCK, SHAFT
Figure 4 - Removing Shaft Lock Retaining Ring
14
131~~
8
6 LOCK, SHAFT
7 CAM ASM, TURN SIG CANCELLING
8 SPRING, UPPER BEARING
13 SEAT, UPPER BEARING INNER RACE
14 RACE, INNER
TURN SIGNAL
SWITCH CONNECTOR
Figure 5 - Removing Components from Upper Shaft

26 PROTECTOR, WIRING
10.
11.
12.
13.
Upper bearing inner race seat (13).

Inner race (14).
Turn signal to "RIGHT TURN" position (up).
Multi-function lever and hazard knob assembly.
(See Section 3F)
14. Screw (10) and signal switch arm (11).
15. Turn signal switch screws (9).
Figure 7 - Removing Turn Signal Switch
NOTICE: Coil assembly (3) will become uncentered if:

1) Steering column is separated from steering gear
and is allowed to rotate, or
2) Centering spring is pushed down, letting hub
rotate while coil (3) is removed from steering
column. (If this occurs, see Figure 13)

21.
22.
Lock retaining screw (18).

Pass key lock cylinder (20) and harness.
To remove lock cylinder (20):
A. Terminal connector from bulkltead

connector.
B. Wiring protector (26).
C. Attach a length of .mechanics wire to
terminal to aid in reassembly.
D. Retaining clip from housing cover (19)
and gently pull wire harness through
column.
26
GREY (RSWC) WIRE LEAD
BLACK(RSWC)CONNECTOR
BLACK TERMINAL CONNECTOR
26 PROTECTOR, WIRING
27SHROUD,CONNECTOR
Figure 8 - Removing CoHAssembly Switch
17.
Inflatablerestraintcoilassembly(3)withwireharness
from column assembly.
A. Wiring protector (26).
B. Attach two lengths of mechanics wire to
coil terminal connectors to aid in
reassembly.
C. Gently pull wires through column.
!-++!
Install or Connect
Figures 1, 1Othrough
15 and 26
NOTICE: See "Notice"<on page 3F5B-1 of this section.

NOTICE: Ensure all fasteners are securely seated before
applying needed torque. Failure to do may result in
component damage or malfunctioning of steering col1mn.
NOTICE: Route wire froni pass key lock cylinder as

shown and snap retaining clip into hole in housing (19).
(See Figures 10 and 11) Failure to do so may result in
component damage of malfunction of pass key lock
cylinder.
20
16 SWITCH ASM, BUZZER

RETAINING
CLIP
Figure 9 - Removing Buzzer Switch
18.
19.
20.
Key from pass key lock cylinder set (20).

Buzzer switch assembly (16).
Reinsert key in pass key lock cylinder (20).
Key in "LOCK" position.
18 SCREW, LOCK RETAINING

20 LOCK CYLINDER SET, STAG COL
(PASS KEY)
WIRE
HARNESS
Figure 10 - Installing Pass Key Lock Cylinder Set
RETAINING
CLIP
WIRE
HARNESS
INFL RESTRAINT COIL ASM AND
TURN SIGNAL SWITCH WIRE HARNESSES
THROUGH HERE. 5 O'CLOCK POSITION.
20 LOCK CYLINDER SET, STRG COL

(PASS KEY)
Figure 11 - Routing Pass Key Wire Harness
Figure 12 - Wire Harnesses through Column
8.
1.
Pass key lock cylinder (20).
A. Wire terminal through column and snap

retaining clip into hole in housing.
B. Lock cylinder (20) connector to vehicle wire
harness.
2.
Turn signal switch assembly (12) and screws (9).
!~! Tighten
9.
Tighten screws (9) to 3.4 Nm (30 lb.in.).
Signal switch arm (11) with screw (10).
!~! Tighten
Lock retaining screw (18).
Tighten screw (10) to 2.3 Nm (20 lb.in.).
!~!Tighten
10.
3.
4.
5.
6.
7.
Key from pass key lock cylinder set (20).

Buzzer switch assembly (16).
Reinstall key in pass key lock cylinder set (20).
Key in "OFF-LOCK" position.
Turn signal switch assembly (12) wire harness

through steering column.
A. Let switch hang freely.
B. Switch connector to bulkhead connector.
Coil assembly (3) wire harness through column.

Let coil hang freely.
Hazard knob assembly and multi-function lever.

(See Section 3F)
11. Inner race (14).
12. Upper bearing inner race seat (13).
13. Upper bearing spring (8).
14. Turn signal cancelling cam assembly (7).
Lubricate with grease, synthetic (service kit).
15.
16.
Shaft lock (6).

New shaft lock retaining ring (5) using J 23653-C to
push down shaft lock (6).
Ring (5) must be firmly seated in groove on
shaft.
NOTICE: Set steering shaft so that block tooth on upper

steering shaft (5 6) is at the 12 o'clock position, wheels on
vehicle should be straight ahead, then set ignition switch
to "LOCK" position, to ensure no damage to coil assembly
(3). (See Figure 26 for steering shaft orientation)
17.
Wave washer (4).

NOTICE: Coil assembly (3) will become uncentered if:
1) Steering column is separated from steering gear

and is allowed to rotate, or
2) Centering spring is pushed down, letting hub
rotate while coil is removed from column. (If
this occurs, see Figure 13)
===::::::
KEEP LOWER WIRES TIGHT WHILE

SEATING SIR COIL ASM HEAD IN
STEERING COLUMN.
3 COILASM, INFL RESTRAINT
6 LOCK, SHAFT
STYLE
LOCKING
TAB
SPRING
LOCK
COIL
HUB
STYLE
B
LOCKING
TAB
SPRING
LOCK
COIL
HUB
PERFORM THE FOLLOWING STEPS TO CENTER COIL ASSEMBLY
A WHEELS STRAIGHT AHEAD.
B REMOVE COIL ASSEMBLY.
C HOLD COIL ASSEMBLY WITH CLEAR BOTTOM UP TO SEE COIL
RIBBON.
D NOTE: THERE ARE TWO DIFFERENT STYLES OF COILS. ONE
ROTATES CLOCKWISE AND THE OTHER ROTATES COUNTER
CLOCKWISE.
E WHILE HOLDING COIL ASSEMBLY, DEPRESS SPRING LOCK TO
ROTATE HUB IN DIRECTION OF ARROW UNTIL IT STOPS.
F THE COIL RIBBON SHOULD BE WOUND UP SNUG AGAINST
CENTER HUB.
G ROTATE COIL HUB IN OPPOSITE DIRECTION APPROXIMATELY
TWO AND A HALF (21/2) TURNS. RELEASE SPRING LOCK
BETWEEN LOCKING TABS IN FRONT OF ARROW.
Figure 14 - Routing Coil Assembly Wires
NOTICE: Sir coil assembly wires must be kept tight with

no slack while installing SIR coil assembly. Failure to do
so may cause wires to be kinked near shaft lock area and
cut when steering wheel is turned.
18. Ensure coil assembly (3) hub is centered.

19. Coil assembly (3).
A. Pull wires tight while positioning SIR coil to
steering shaft.
B. Align opening in coil with horn tower and
"locating bump" between two tabs on housing
cover.
C. Seat coil assembly into steering column.
PROJECTIONS ON
HOUSING COVER
USED FOR ALIGNMENT
OF COIL ASSEMBLY
INSTALL COIL
ASSEMBLY OVER
SHAFT AND
HORN TOWER.
2 RING, RETAINING
3 COIL ASSEMBLY
7 CAM ASM, TURN SIG CANCEL
Figure 15 - Coil Assembly Installed
Figure 13 - Centering Coil Assembly
20. Coil assembly retaining ring (2).

e Ring (2) must be firmly seated in groove on
shaft.
NOTICE: If a new coil assembly (3) is being installed,

assemble pre-centered coil assembly (3) to steering column.
Remove centering tab and dispose. (See Figure 13)
NOTICE: Gently pull lower coil assembly, turn signal,

pass key,and pivot & (pulse) wires to remove any wire
kinks that may be inside steering column assembly.
Failure to do so may cause damage to wire harness.

21. Wiring protector (26).
22. Refer to Section 3F to complete remaining steering
column assembly.
24. If all service operations are completed, enable the
SIR system; refer to "Enabling the SIR System" in
this Section.
MULTl-FUNCTION
LEVER
CRUISE CONTROL
WIRE CONNECTIONS
24 BASE PLATE, COL HSG CVR END
SUB SECTION B HOUSING COVER

Figures 1,2, 16 through 20
INCLUDES:
LOCK HOUSING COVER ASS EMBLY
COL HSG COVER END CAP
PIVOT & (PULSE) SWITCH ASS EMBLY
DIMMER SWITCH ROD ACTUATOR
TILT SPRING ASS EMBLY
Tools Required:
Figure 16 - Cruise Control Equipped

Steering Columns
[I]
Important
Remove cruise control and multi-function lever
connectors from base plate (24) and disconnect.
Remove multi-function lever. (See Section 3F)
15
12 O'CLOCK
j ?! Important

removal of Inflator Module and Steering Wheel is
needed. (Refer to service procedures in Section 3F)
[I] Important
Remove only those components necessary to do

repairs.
15 SCREW, PAN HD SOC TAP
Figure 17 - Lock Housing Cover Screw Positions
:,1
19
,)~
24~
...........
~
!+--+!
1.
2.
Do all steps, "Remove or Disconnect", Sub Section A.

Housing cover end cap (25).
25
19 COVER ASM, LOCK HOUSING
21 ACTUATOR, DIMMER SW ROD
24 BASE PLATE, COL HSG CVR END
25 CAP, COL HSG COVER END
77 ROD, DIMMER SWITCH
CRUISE
CONTROL
PLUG
Figure 18 - Removing Lock Housing Cover

3.
4.
5.
6.
7.
Cover screws (15).

Tilt lever. (See Section 3F)
Lock housing cover assembly (19).
Base plate (24) and dimmer switch rod actuator
(21).
Wire protector shield (36).
!-+~! Install or Co.nnect

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

applying needed torque. Failure to do so may result in
component damage or malfunctioning of steering column.
19
SWITCH
CONNECT~
1.
Spring guide (50) and spring (51).

Lubricate with lithium grease .
2.
Spring retainer (52).

Using a cross recess screwdriver push retainer
down and turn clockwise to lock in place.
3.
Pivot & (pulse) switch assembly (23) to lock housing

cover assembly (19).
Switch actuator pivot pin (22) to switch (23) and
cover (19).
Pivot & (pulse) switch wire harness through steering
column.
Switch connector to bulkhead connector .
Wire protector shield (36) .
c.---- CRUISE
19 COVER ASM, LOCK HOUSING

22 PIN, SWITCH ACTUATOR PIVOT
23 SWITCH ASM, PIVOT & (PULSE)
CONTROL
CONNECTOR
Figure 19 - Removing Pivot & (Pulse) Switch
4.
5.
50 GUIDE, SPRING
51 SPRING, WHEEL TILT
52 RETAINER, SPRING
6.
Dimmer switch rod actuator (21) to base plate(24).

Lubricate with lithium grease .
7.
Base plate (24) to lock housing cover assembly (19).

Bottom edge of dimmer switch rod actuator
(21) must rest on bend in dimmer switch rod
(77).
Figure 20 - Removing Tilt Spring Assembly
8.
9.
Switch actuator pivot pin (22).

Pivot & (pulse) switch assembly (23).
8.
9.
B.
!~!Tighten
bulkhead connector.
Gently pull wire harness through column.
Tighten screws (15) in same order to 9.0 Nm

(80 lb.in.).
Spring retainer (52).
11.
Lock housing cover assembly (19).

Screws (15). Tighten screw in 12 o'clock position
first, screw in 8 o'clock position second, and screw
in 3 o'clock position third.
Let switch hang freely if removal is not needed.

To remove switch (23):
A. Pivot & (pulse) switch connector from
10.
Using a cross recess head screwdriver, push

retainer down and turn counterclockwise to
release.
Spring (51) and spring guide (50).
10.
11.
12.
13.
Install multi-function lever. (See Section 3F)

Plug multi-function lever and cruise control
connectors together and mount on base plate (24).
Housing cover end cap (25).
Do all steps, "Install or Connect", Sub Section A.
TILT STRG COL UNIT REPAIR (SIR,FLR SHFD 3F5B11
!l'B! Inspect
SUB SECTION C MID COLUMN

INCLUDES:
STEERING COLUMN HOUSING ASM
STEERING WHEEL LOCK SHOE
SWITCH ACTUATOR SECTOR
SWITCH ACTUATOR RACK
BEARING ASSEMBLY
LOCK BOLT
STEERING COL HSG SUPPORT ASM
STEERING SHAFT ASS EMBLY
Tools Required:
J 21854-01 Pivot Pin Remover
J 22635 Lock Shoe and Release Lever Pin
Remover and Installer
J 8092 Driver Handle
J 38639 Strg Col Housing Bearing Installer
4.
5.
Steering coiumn for accident damage. (See

Figure 34)
Do steps 3 through 22, "Remove or Disconnect",

Sub Section A.
Do steps 2 through 10, "Remove or Disconnect",
Sub Section B.
39 PIN, PIVOT
Figure 21 - Removing Pivot Pin
11] Important
!+--+!

removal of Inflator Module and Steering Wheel is
needed. (Refer to service procedures in Section 3F)
6.
7.
Pivot pins (39) using J 21854-01.

Reinstall tilt lever. (See Section 3F)
Steering column housing assembly (30).
Pull back on tilt lever and pull steering column
housing assembly (30) down and away from
column.
I?! Important
Figures 1 through 28,30 and 34
1.
2.
3.
Disable the SIR system; refer to "Disabling the

Negative (-) battery cable.
Steering column from vehicle. (See Section 3F)
NOTICE: Oncesteeringcolumnisremovedfromvehicle,
the column is extremely susceptible to damage. Dropping
steering column assembly on its end could collapse
steering shaft or loosen plastic injections which maintain
column rigidity. Leaning on steering column assembly
could cause jacket to bend or deform. Any of the above
damage could impair steering column's collapsible design.
If it is necessary to remove steering wheel, use only the
specified steering wheel puller. Under no conditions
should the end of shaft be hammered on as hammering
could loosen plastic injections which maintain steering
column rigidity.

repairs.
46
J 22635
32 BOLT, LOCK
37 SHAFT, DRIVE
38 PIN, DOWEL
44 RACK, SWITCH ACTUATOR
46 HOUSING, STAG COLUMN
48 SCREW, HEX WASHER HEAD
Figure 22 - Lock Housing Cover Components, Exterior
3F5B12 TILT STAG COL UNIT REPAIR (SIR,FLR SHFT)

Release lever pin (42) using J 22635.
F.
G. Switch actuator sector (47).

H. Drive shaft (37).
I. Rack preload spring (45).
J. Switch actuator rack (44) to actuator sector
(47).
K. Bearing assembly (31) lubricated with
lithium grease to column housing (46)
using J 38639 and J 8092.
L. Lock bolt (32).
M. Lock bolt spring (33). (See Figure 30)
N. Hex head screw (48).
J 22635
34
43
42
36
31 BEARING ASM
34 SHOE, STEERING WHEEL LOCK
35 SHOE, STEERING WHEEL LOCK
36 SHIELD, WIRE PROTECTOR
42 PIN, RELEASE LEVER
43 LEVER, SHOE RELEASE
!~!Tighten
31
Figure 23 - Lock Housing Cover

Components, Interior
!+-!-+! Disassemble
J 8092

J 38639
A. Bearing assembly (31).

B. Hex head screw (48).
C. Lock bolt spring (33).
D. Lock bolt (32).
E. Switch actuator rack (44) and rack preload
spring (45).
F. Drive shaft (37).
G. Switch actuator sector (47).
I. Release lever pin (42) using J 22635.
J. Shoe release lever (43).
K. Release lever spring (41).
L. Dowel pin (38) using J 22635.
M. Lock shoes (34) and (35),
N. Shoe springs (40).
!-+*+-! Assemble
31
46
31 BEARING ASM
46 HOUSING, STAG COLUMN
Figure 24 - Installing Bearings
8. . Lower bearing adapter clip (89).

9. Bearing adapter retainer (88).
10. Lower bearing adapter (86) and bearing assembly
(87).
11. Steering column shaft assembly (55).

A. Shoe springs (40).
B. Lock shoes (34) and (35).
C. Dowel pin (38) using J 22635.
D. Release lever spring (41).
E. Shoe release lever (43).
!l'ii'!
Inspect
Steering column shaft assembly (55) for accident

damage. (See Figure 34)
Important
BLOCK TOOTH
120'CLOCK
POSITION
Mark upper shaft assembly (56) and lower steering

shaft asm (59) to ensure proper assembly. Failure to
assemble properly will cause steering wheel to be
turned 180 degrees. (See Figures 25 and 26)
57~\I("
NOTCHES
56
BOLT
HOLE
120'CLOCK
POSITION
57
5g
ROTATE
SPHERE
AND
LIFT
Figure 26 - Correct Upper to Lower Shaft Orientation
'
ALIGNMENT
MARK
56
56 SHAFT ASM, RACE & UPPER

57 SPHERE, CENTERING
58 SPRING, JOINT PRELOAD
59 SHAFT ASM, LOWER STEERING
Figure 25 - Removing Steering Shaft Components
I?! Important
BOTTOM
END VIEW
56 SHAFT ASM, RACE & UPPER

57 SPHERE, CENTERING
551 SHAFT ASM, LOWER STEERING
so
TILT 90
AND SEPARATE
BOLT
HOLE

repairs.
!-+}! Assemble
Steering Column Shaft Assembly
A. Joint preload spring (58) to two centering
sphere (57).
B. Centering sphere (57).
Lubricate with lithium grease, slip

into upper shaft assembly (56), and
rotate sphere 90 degrees.
C. Upper shaft assembly (56) to lower steering
shaft assembly (59).
Line up marks and tilt assemblies 90

degrees to each other.
!+!-+! Disassemble
Steering Column Shaft Assembly
A. Upper shaft assembly (56), lower steering
shaft assembly (59).
Tilt 90 degrees to each other and

disengage.
B. Centering sphere (57) from upper shaft
assembly (56).
Rotate sphere 90 degrees and slip

out.
C. Joint preload spring (58) from centering
sphere (57).
61 SCREW, SUPPORT
62 SUPPORT ASM, STRG COL HSG
71 SHROUD, STRG COLUMN HSG
77 ROD, DIMMER SWITCH
Figure 27 - Removing Column Housing Support

3.
12.
13.
14.
Support screws (61).

Columnhousingsupportassembly(62)withdimmer
switch rod (77) from steering column jacket assembly
(72).
Rod (77) from support (62).
Steering column housing shroud (71).
Four support screws (61).
~Tighten
4.
5.
Tighten screws (61) to 8.8 Nm (77 lb.in.)
Dimmer switch rod (77) to housing support (62).

Actuator assembly (76) to housing support (62).
34
72 JACKET ASM, STRG COL

78 SCREW, WASH HD (#10-24X.25)
79 SCREW, HEX WASH HD TAP
80 SWITCH ASM, IGNITION
82 SCREW, FLT HD (#10-24X.31)
83 SWITCH ASM, DIMMER
Figure 28 - Removing Ignition and Dimmer Switches
15.
16.
17.
18.
Hex head tapping screw (79).

Washer head screw (78).
Dimmer switch assembly (83).
Dimmer switch (83) from vehicle wire harness.
39
SHOE MUST ENGAGE

WITH DOWEL PINS
34 SHOE, STRG WHEEL LOCK
35 SHOE, STRG WHEEL LOCK
39 PIN, PIVOT
46 HOUSING, STRG COLUMN
62 SUPPORT ASM, STRG COL HSG
76 ACTUATOR ASM, IGN SWITCH
Figure 29 - Installing Column Housing

to Housing Support
Flat head screw (82).

Ignition switch assembly (80) from ignition
switch actuator assembly (76).
6.
Steering shaft assembly (55) to jacket assembly
(72).
!-++!
Install or Connect

1.
2.
Lubricate with lithium grease.
Steering column housing shroud (71 ).

Column housing support (62) to jacket assembly
(72).
7.
8.
Tilt lever. (See Section 3F)

Column housing assembly (30) to column.
Position column housing assembly (30) and
align switch actuator rack (44) with pin on end
of ignition switch actuator assembly (76).
Pull back on tiltlever, pushing column housing
assembly (30) onto column housing support
assembly (62).
Release tilt lever to lock shoes (34) and (35)
onto dowel pins.
Remove tilt lever. (See Section 3F)
TILT.STAG COL UNIT REPAIR (SIR,FLR SHFn 3F5B15

32 BOLT, LOCK
33 SPRING, LOCK BOLT
76
47 SECTOR, SWITCH ACTUATOR
76 ACTUATOR ASM, IGN SWITCH
Figure 30 - Actuator Assembly to Actuator Rack

Installed
NOTICE: Once steering column is removed from vehicle,

the column is extremely susceptible to damage. Dropping
steering column assembly on its end could collapse
steering shaft or loosen plastic injections which maintain
column rigidity. Leaning on steering column assembly
could cause jacket to bend or deform. Any of the above
damage could impair steering column's collapsible design.
If it is necessary to remove steering wheel, use only the
specified steering wheel puller. Under no conditions
should the end of shaft be hammered on as hammering
could loosen plastic injections which maintain steering
column rigidity.
lt'B! Inspect
9.
Pivot pins (39).

Lubricate with lithium grease.
Press pin until firmly seated, two places.
10. Lower bearing adapter (86) and bearing assembly

(87).
Lubricated with lithium grease.
Steering column for accident damage. (See

Figure 34)
Dimmer Switch Assembly
!+--+!
Figures 1,2,28 and 34
11. Bearing adapter retainer (88).

12. Lower bearing adapter clip (89).
13. Do steps 1 through 12, ~'Install or Connect", Sub
Section B.
14. Do steps, 1 through 21 "Install or Connect", Sub
Section A.
15. To install ignition and dimmer switch assemblies,
do all steps Ignition Switch Assembly, "Install or
Connect", Sub Section D.
SUB SECTION D LOWER COLUMN
1.
2.
3.
4.
5.
6.
!-++!

Negative(-) battery cable.
Dimmer switch assembly (83) from rod (77).
e Vehiclewire harness from dimmer switch (83).
Install or Connect
INCLUDES:
DIMMER SWITCH ASS EMBLY
DIMMER SWITCH ADJUSTMENT
IGNITION SWITCH ASS EMBLY
IGNITION SWITCH ADJUSTMENT
ADAPTER & BEARING ASS EMBLY

applying required torque. Failure to do so may result in

1.
2.
Dimmer switch assembly (83).

Hex head tapping screw (79) and washer head screw
(78).
Tighten finger tight.
Ignition Switch Assembly
I+--+!
1.
~-
.
/
3/32"
DRILLBIT

SIR System" in this section.
Dimmer switch assembly (83) from rod (77) .
Ignition switch assembly (80) from ignition switch
actuator assembly (76).
Vehicle wire harness from ignition switch
assembly (80).
2.
3.
4.
5.
6.
7.
8.
83 SWITCH ASM, DIMMER
Figure 31 - Adjusting Dimmer Switch
~Adjust
Dimmer switch (83). (See Figure 31)
I-++-!
Install or Connect
Figures 1,2,28,31 and 32
A. Place 3/32-inch drill bit in hole on.switch

to limit travel.
B. Position switch on column and push against
dimmer switch rod (77) to remove all lash.
C. Remove drill bit.

1.
l<l.J Tighten
Tighten screw (79) to 2.5 Nm (22 lb.in.)
~Tighten
Lock cylinder (20) to "OFF-LOCK" position.
NOTICE: Install ignition switch (80) to jacket (72) with

switch in "OFF-LOCK'' position. (See Figure 32) New
ignition switch will be pinned in "OFF-LOCK" position.
Remove plastic pin after switch is assembled to column.
Failure to do so may cause switch damage.
MOVE SWITCH SLIDER TO EXTREME RIGHT POSITION
AND TH!EN MOVE SLIDER ONE DETENT TO THE LEFT
"OFFLOCK"

80
3.
4.
5.
6.
Vehicle wire harness to dimmer switch (83).

Steering column to vehicle. (See Section 3F)
If all service operations are completed, enable the
this section.
80 SWITCH ASM, IGNITION
Figure 32 - Adjusting Ignition Switch

~Adjust
Adapter & Bearing Assembly
e Ignition switch assembly (80).
!+--+!
A. Move switch slider to extreme right

position.
B. Move switch slider one de tent to left "OFFLOCK" position.
2.
3.
Ignition switch assembly (80) to actuator assembly

(76).
1.

Lower bearing adapter clip (89).
Bearing adapter retainer (88).
Lower bearing adapter (86) and bearing assembly
(87).
2.
3.
4.
5.
6.
~Tighten
4.
5.
Dimmer switch assembly (83) to rod (77).

Hex head tapping screw (79) and washer head screw
(78).
Tighten finger tight.
~Adjust
Dimmer switch (83). (See Figure 31)
A. Place 3/32-inch drill bit in hole on switch

to limit travel.
B. Position switch on column and push against
dimmer switch rod (77) to remove all lash.
C. Remove drill bit.
72 JACKET ASM, STRG COL

BIS ADAPTER, LOWER BEARING
87 BEARING ASM
88 RETAINER, BEARING ADAPTER
89 CLIP, LOWER BEARING ADAPTER
Figure 33 - Removing Lower Bearing Assembly
!-++-!
Install or Connect
Figures 1,2 and 33
~Tighten
Tighten screw (79) to 2.5 Nm (22 lb.in.)
~Tighten

1.
Lower bearing adapter (86) and bearing assembly

(87).
Lubricate inner surface with lithium grease.
2.
3.
4.
5.
6.
Bearing adapter retainer (88).

Lower bearing adapter clip (89).
If all service operations are completed, enable the
this Section.
6.
7.

Vehicle wire harness to dimmer switch assembly
(83).
8. Vehicle wire harness to ignition switch assembly
(80).
10. [f all service operations are completed, enable the
this Section.
3F5818 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT)

CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE
NOTICE: Vehicles Involved In accidents resulting In frame damage,
major body or sheet metal damage, or where the steering column has
been Impacted, or where supplemental Inflatable restraints systems
deployed may also have a damaged or misaligned steering column.
CHECKING PROCEDURE
JACKET ASM, STEERING COLUMN
Check capsules on steering column bracket assembly; all must be

securely seated In bracket slots and cheeked for any loose
conditions when pushed or pulled by hand (View A). lfnot, bracket
should be replaced If bracket Is bolted to the Jacket assembly or the
Jacket assembly should be replaced If bracket Is welded to Jacket
assembly.
Check for Jacket assembly collapse by measuring the distance
from the lower edge of upper jacket to a defined point on the lower
Jacket (View C). If measured dimensions are not within
specifications, a new Jacket must be Installed.
STEERING SHAFT ASM
Visually Inspect steering shaft for sheared Injected plastic (View B).
If steering shaft shows sheared plastic, a new steering shaft must
be Installed.
Any frame damage that could cause a bent steering shaft must
have steering shaft runout checked In the following manner: Using
a dial Indicator at lower end of steering shaft, have steering wheel
rotated. Runout must not exceed 1.59mm.
NOTICE: Inflatable restraint coll assembly must be removed from
steering column and allowed to hang freely before shaft Is rotated. Failure
to do so could damage coll assembly.
I
I
I
I
I
I
I
VIEWA
(CAPSULES)
CHECK FOR ANY LOOSE CONDITION WHEN
PUSHED OR PULLED BY HAND.
t-
CHECK FOR SHEARED INJECTED

PLASTIC AT THESE LOCATIONS.
I
I VIEWS
I
I
I
I
I
I
I
I VIEW c
I
(STEERING SHAFl)
r--n
323.94 MM
+/.50MM
I
(
(METHOD TO DETERMINE COLUMN COLLAPSE)

WITH LOWER BEARING REMOVED
MEASURE DISTANCE BETWEEN ARROWS.
Figure 34 - Checking Steering Column for Accident Damage
SPECIFICATIONS
FASTENER TORQUES
1 Steering Wheel-to-Shaft Nut ............ '. ................................... 41.0 Nm (30 lb.ft.)
9 Turn Signal Switch Connecting Screws ........................................ 3.4 Nm (30 lb.in.)
10 Turn Signal Switch Actuator Assembly Screw ................................... 2.3 Nm (20 lb.in.)
15 Lock Housing Cover Screws ................................................. 9.0 Nm (80 lb.in.)
18 Lock Retaining Screw ...................................................... 2.5 Nm (22 lb.in.)
48 Lock Bolt Spring Screw .................................................... 4.0 Nm (35 lb.in.)
61 Support-to-Jacket Screws ................................................... 8.8 Nm (77 lb.in.)
78 Upper dimmer Switch Mounting Screw ........................... , ............. 4.0 Nm (35 lb.in.)
79 Lower dimmer Switch Mounting Screw ........................................ 2.5 Nm (22 lb.in.)
82 Ignition Switch Mounting Screw .............................................. 3.7 Nm (33 lb.in.)
'
;;,)
&~
J 21854-01
1 PIVOT PIN REMOVER

2 LOCK SHOE AND RELEASE LEVER PIN REMOVER AND INSTALLER
3 DRIVER HANDLE
4 STEERING COLUMN HOUSING BEARING INSTALLER
5 LOCK PLATE COMPRESSOR
Figure 35 - Special Tools
@)
J 38539
3FSB-20 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT)
BLANK
(
PROPELLER SHAFT 4A-1
SECTION 4A
PROPELLER SHAFT
UNLESS OTHER WISE SPECIFIED, do hot use supplemental coatings (paints, greases, or other corrosion
inhibitors) on the threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the
fastener torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the
correct tightening sequence and specifications. Following these instructions can help you avoid damage to parts
and systems.
CONTENTS
General Description ............................... :................ 4A-1
Propeller Shaft .................................................... 4A-1
Center Support Bearing ..................................... 4A-2
Universal Joint. ................................................... 4A-2
Propeller Shaft Joint .......................................... 4A-2
Diagnosis ......... :............. '. ........................................ 4A-2
Road Test. ........................................................... 4A-2
Coast Test ........................................................... 4A-2
Diagnosis of Propeller Shaft and
Universal Joint. ............................................... 4A-5
Propeller Shaft Runout Measurement ............... 4A-5
Differential Drive Pinion Gear Yoke Runout
Measurement ...................................................... 4A-6
Propeller Shaft Balance Check .......................... 4A-7
Propeller Shaft Balancing ................................ .4A-8

Hose Clamp Method ..................................... 4A-8
Strobe Light Method ..................................... 4A-9
One and Two-Piece Propeller Shaft
Replacement .................................................. 4A-10
Unit Repair ............................................................ 4A-12
Two-Piece Propeller Shaft ............................... .4A-12
Center Support Bearing Replacement ............. .4A-12
Universal Joints ................................................ .4A-12
Nylon Injected Ring Type ........................... .4A-12
Snap Ring Type ............................................ 4A-13
General Specifications ....................................... 4A-15
Fastener Tightening Specifications .................. .4A-15
Special Tools ......................................................... 4A-15
GENERAL DESCRIPTION
internal splines which accept the rear propeller shaft

(10). The center support bearing (7) is pressed onto
the outer diameter (OD) of the coupling. On the front
of the rear propeller shaft (10) there is a propeller
shaft joint (9) (sometimes called a constant velocity
(CV) joint) that fits into the spline coupling of the
front propeller shaft (6).
PROPELLER SHAFT
Figure 1
Torque is transmitted from the transmission to
the rear axle through the propeller shaft(s)
(5, 6 and 10) and universal joints (2). The 3800
(VIN K) engine utilizes a two-piece propeller shaft
(6 and 10), while the 5.7L (VIN P) engine utilizes a
one-piece propeller shaft (5).
The propeller shaft(s) (5, 6 and 10) have
universal joints (2) to accommodate angle variations
between the transmission and the rear axle and/or the
rear axle position caused by suspension motion. The
propeller shaft(s) (5, 6 and 10) are connected to the
transmission with a splined slip yoke (1 or 24) and to
the rear axle with a companion flange (fixed yoke).
On the one piece propeller shaft the splined slip yoke
also has a dampener while the two-piece does not. On
the two-piece propeller shaft (6 and 10), the front
propeller shaft (6) contains the center support bearing
(7) and spline coupling. The spline coupling has
II)
Important
If a vehicle is to be undercoated, the propeller

shaft must be kept free of undercoating material.
Undercoating material or any other foreign
material will upset the propeller shaft balance and
produce serious vibrations.
II)
Important
Before propeller shaft removal, reference mark the

propeller shaft to ensure phased installation
alignment. Some propeller shafts have alignment
marks or arrows stamped on the shaft at the time
of production.
4A-2
PROPELLER SHAFT
CENTER SUPPORT BEARING
PROPELLER SHAFT JOINT
Figure 1
Figure 1
The center support bearing (7) supports the

driveline when the two-piece propeller shaft
(6 and 10) is used. The center support bearing (7) is a
ball-type bearing mounted in a rubber cushion that is
mounted to the torque arm. The center support bearing
(7) is pre-lubricated and sealed by the manufacturer.
The propeller shaft joint (9) (sometimes called a

constant velocity (CV) joint) used on the two-piece
propeller shaft (6 and 10) allows the driveline angle to
be adjusted according to the up and down movement
of the vehicle without disturbing the power flow.
UNIVERSAL JOINT
Figure 1
The universal joint connects two Y-shaped yokes
by a crossmember called a spider (2). The spider (2) is
shaped like a cross having arms of equal length called
trunnions. The spider (2) allows the two yoke shafts to
operate at any angle to each other. Universal joints are
lubricated for life.
When torque is transmitted through any ordinary
universal joint, the drive pinion gear yoke fluctuates
slightly in speed. In other words, although the
propeller shaft slip yoke (1 or 24) rotates at a constant
speed, the differential drive pinion gear yoke speeds
up and slows down twice per revolution. This
fluctuation of the pinion gear yoke is in direct
proportion to the angle through which the universal
joint is operating; the greater the angle, the greater the
fluctuation.
Whenever two universal joints are used, this
fluctuation effect can be eliminated by staggering the
joints so that the two yokes are 90. degrees apart,
provided the two joints are transmitting torque through
the same angle.
Therefore, when two universal joints are used,
the angles through which they operate must be very
nearly the same. This allows the alternate acceleration
and deceleration of one joint to be offset by the
alternate deceleration and acceleration of the second
joint. When the two joints do not run at approximately
the same angle, operation is rough and an
objectionable vibration is produced.
Universal joints are designed to handle the
effects of various loads and rear axle windup during
acceleration. Within the designed angle variations the
universal joint will operate efficiently and safely.
When the design angle is change or exceeded, the
operational life of the joint may decrease.
The universal joint spider bearings (3) used are
the needle roller type. The needle roller bearings are
held in place on the trunnions by round bearing caps.
Production universal joint spider bearings (3) are
retained by nylon injected rings instead of
conventional retainer (snap) rings (4). All service
replacement universal joints use retainer (snap) rings
(4).
If it becomes necessary to replace a universal

joint, the entire propeller shaft (5, 6 or 10) must be
removed from the vehicle. Care should be taken to
avoid jamming or bending any parts of the propeller
shaft.
DIAGNOSIS
The following major component groups are
usually the cause of or are related to vibrations:
Engine and mounts.
Transmission.
Tires, wheels and brake drums.
Propeller shaft and universal joints. Before
road testing a vehicle, check the following:
All fasteners for tightness at universal joints,
wheel nuts and engine mounts.
Tire air pressure.
Load conditions.
ROAD TEST
Figure 2
Road test the vehicle to verify the complaint.
Record the speed and RPM at which the greatest
vibration occurs. The vibration is likely to be in the
steering wheel or in the seat bottom. The road test can
be helpful in locating the vibration source.
COAST TEST
Figure 2
NOTICE: When performing a "Coast Test"
on a vehicle equipped with an.. automatic
transmission, caution must be taken when
returning selector lever from "NEUTRAL" to
"DRIVE" to avoid transmission damage.
When shifting from "NEUTRAL" to "DRIVE,"

remember to:
1. Maintain engine speed at 1500 rpm.
2. Brake to 40 km/h (25 mph).
3. Return selector to "DRIVE."
Drive the vehicle past the vibration speed, shift
into "NEUTRAL" and coast back through the
vibration speed. During a coast test, two kinds of
vibrations normally occur: a shaking or a buzzing; A
shaking vibration is usually a problem with the tires or
wheels and brake drum or brake rotor. A buzzing
vibration is usually a driveline problem.
To determine whether a propeller shaft is
causing the problem, drive the vehicle through the
speed range and note at which speed (vehicle and/or
engine) the problem is most pronounced. A tachometer
may be used. Shift the transmission into a lower gear
range ~d drive the vehicle at the same engine speed
as when the problem was most pronounced in direct
drive. Note the effect on the problem.

3
A
B
C
D
E
1
2
3
4
5
6
7
8
9
10
24
SHAFT ASSEMBLY, ONE-PIECE PROPELLER

SHAFT ASSEMBLY. TWO-PIECE PROPELLER
TRUNNIONS
COUPLING, SPLINE
.
DAMPER, PROPELLER SHAFT SLIP YOKE ASSEMBLY
YOKE ASSEMBLV, PROPELLER SHAFT DAMPER ANO
SLIP
SPIDER, PROPELLER SHAFT UNIVERSAL JOINT
BEARING, PROPELLER SHAFT UNIVERSAL JOINT
SPIDER
RING, PROPELLER SHAFT UNIVERSAL JOINT SPIDER
BEARING RETAINER
SHAFT ASSEMBLV, PROPELLER
SHAFT ASSEMBLY. FRONT PROPELLER
BEARING, PROPELLER SHAFT CENTER SUPPORT
SEAL, REAR PROPELLER SHAFT
JOINT, PROPELLER SHAFT
SHAFT ASSEMBLY, REAR PROPELLER
YOKE ASSEMBLY. PROPELLER SHAFT FRONT SLIP
4-20-94
FS0014A
Figure 1 - Propeller Shaft Components
.;l=I,
)>
PROPELLER SHAFT ASSEMBLY DIAGNOSIS
J:.,
DRIVE VEHICLE TO DETERMINE

PROBLEM & SPEED
(ACCELERATION ROAD ENGINE)
'ti
:lJ
'ti
DRIVE AT ROAD SPEED ON

SMOOTH ROAD
al
I\)
"O
en
DAMAGED PROPELLER
SHAFT ASSEMBLY
TIGHT JOINTS
~::s
io"
:!l
IPROBLEM IMPROVED r---1 CHECK AND/OR BALANCE TIRE AND WHEEL ASSEMBLIES I
.....
:::;
UNDERCOATING
'
ON PROPELLER SHAFT
ASSEMBLY
11 MISSING BALANCE
WEIGHT
BURRS OR NICKS ON
SUPPORT YOKE AND/OR PINION YOKE
REPLACE PROPELLER SHAFT 11 CLEAN PROPELLER SHAFT I !BALANCE PROPELLERSHAFTI

ASSEMBLY
ASSEMBLY
ASSEMBLY
IMPACT YOKE WITH
HAMMER OR REPLACE
I REWORK OR REPLACE
11 EXCESSIVE LOOSENESS
AT SLIP YOKE SPLINE
REPLACE NECESSARY
PARTS
EVALUATE ON HOIST
0:::;
PROBLEM NOT IMPROVED
Ill
:c
)>
VISUAL EXAMINATION
40-72 KM/H (25-45 MPH)
~
(D
en
SEE TIRE CHECK
~--------'----~
"'O
CHECK TIRES, SUSPENSION

AND/OR BODY COMPARTMENT
PROBLEM IMPROVED
PLACE VEHICLE ON HOIST,

REMOVE REAR TIRE AND
WHEEL ASSEMBLIES AND
VERIFY PROBLEM SPEED
"Tl
cc
c
r
r
m
:lJ
RIDE AND EVALUATE AT 345 k:Pa (50 PSI) TIRE PRESSURE
PROBLEM NOT IMPROVED
IMPACT BOOM
ROUGH ROAD
ROAD TEST
1-----
'------!PROBLEM IMPROVED
I ROAD TEST
88 KM/H (55 MPH)

ROTATE SHAFT 180 DEGREES AT PINION YOKE
PROBLEM NOT IMPROVED I
WORN UNIVERSAL JOINT
it
>i?
~
REPLACE UNIVERSAL JOINT
I EVALUATE I
I PROBLEM IMPROVED
1-----'r
OUT OF BALANCE DRIVELINE, EXCESSIVE

PINION YOKE OR PROPELLER SHAFT ASSEMBL V RUN OUT
BALANCE PROPELLER SHAFT ASSEMBLY IN VEHICLE
ROAD TEST
.~
PROPELLER SHAFT 4A5

To detennine the engine speed if a tachometer is
not used, divide vehicle speed by the transmission gear
ratio in which the problem occurs.
Example: With the HYDRA-MATIC 4L60-E
automatic transmission in 2 range, divide by 1.63. If
the problem is most pronounced in direct drive at 88
km/h (55 mph) the same engine speed would be
produced in 2 range at 55 km/h (55/1.63 = 34 mph).
If the problem is still present at the same engine

speed whether in direct drive or in the lower gear
range, a propeller shaft cannot be at fault since a
propeller shaft speed varies. If the problem decreases
or is eliminated in a different gear range at the same
engine speed, a propeller shaft may be at fault. Refer
to "Propeller Shaft Runout Measurement," "Diagnosis
of Propeller Shaft and Universal Joint" and Figure 2.
DIAGNOSIS OF PROPELLER SHAFT AND UNIVERSAL JOINT

PROBLEM
Leak at front propeller shaft (An
occasional drop of lubricant leaking
from slip yoke is nonnal and requires
no attention).
POSSIBLE CAUSE
CORRECTION
1. Rough outside surface on propeller

shaft slip yoke.
1. Replace transmission seal if cut by

burrs on slip yoke. Minor burrs can be
smoothed by careful use of crocus cloth
or honing with a fine stone. Replace
slip yoke if outside surface is rough or
burred badly.
2. Fault rear transmission oil seal.
2. Replace the rear transmission oil

seal. Bring transmission fluid up to
proper level after correction.
1. Worn or damaged universal joints.

Knock in driveline; clunking noise
when vehicle is operated under float
condition at 16 km/h (10 mph) in high
gear or "NEU1RAL."
Ping, snap, or clinking noise in

driveline.
Scraping noise.
2. Differential side gears worn.
2. Replace differential side gears as

required.
1. Loose rear axle upper or lower

control arm bolt/screw.
1. Tighten bolt/screw to specified

torque.
2. Worn or damaged universal joints.
2. Replace universal joints.
1. Slinger rubbing on rear axle.
1. Straighten slinger to remove

interference.
2. Brake drum, if equipped contacting

backing plate.
2. Replace brake drum or backing plate.
ON-VEHICLE SERVICE
[J]
1. Replace universal joints.
Important
The driveline components on this vehicle have

been factory system balanced. System
balancing provides a smoother running
driveline operation. However, it is essential
that the positions of all driveline components
relative to the propeller shaft and rear axle be
observed and ACCURATELY REFERENCE
MARKED PRIOR TO DISASSEMBLY.
These components include the propeller shaft,
rear axle, differential drive pinion gear yoke,
output shaft, etc. ALL COMPONENTS
MUST BE REASSEMBLED INTO THE
EXACT RELATIONSHIP TO EACH
OTHER AS THEY WERE WHEN
REMOVED. Additionally, the published

specifications and torque values, as well as any
measurements made prior to disassembly must
be followed to maintain the factory balance.
PROPELLER SHAFT RUNOUT

MEASUREMENT
Figure 3
Tool Required:
J 8001 Dial Indicator Set
Noise or vibrations at high speeds could be
caused by a bent propeller shaft. The propeller shaft
could have been damaged by rough handling or a
collision. Check for propeller shaft straightness.
1. Raise vehicle on a twin post hoist so that the rear
is supported on the rear axle housing and rear
wheels are free to rotate. Refer to SECTION OA.
4A-6
PROPELLER SHAFT
5
(
A
A ONE-PIECE PROPELLER SHAFT ASSEMBLY RUN OUT

CHECK
B ONE-PIECE PROPELLER SHAFT ASSEMBLY FRONT
RUNOUT MEASUREMENT POINT
C ONE-PIECE PROPELLER SHAFT ASSEMBLY CENTER
D ONE-PIECE PROPELLER SHAFT ASSEMBLV REAR
E TWO-PIECE PROPELLER SHAFT ASSEMBLY RUN OUT
CHECK
F TWO-PIECE PROPELLER SHAFT ASSEMBLY CENTER
G TWO-PIECE PROPELLER SHAFT ASSEMBLY FRONT

H TWO-PIECE PROPELLER SHAFT ASSEMBLY REAR
J DAMPER, PROPELLER SHAFT SLIP YOKE ASSEMBLY
1 YOKE ASSEMBLY, PROPELLER SHAFT DAMPER AND
SLIP
5 SHAFT ASSEMBLY, PROPELLER
6 SHAFT ASSEMBLY, FRONT PROPELLER
7 BEARING, PROPELLER SHAFT CENTER SUPPORT
9 JOINT, PROPELLER SHAFT
10 SHAFT ASSEMBLY, REAR PROPELLER
4-20-94
24 YOKE ASSEMBLY, PROPELLER SHAFT FRONT SUP IFSOCl34A
Figure 3 - Checking Propeller Shaft Runout
2. Mount J 8001 on a movable support that is high

enough to permit contact of the indicator button
with the propeller shaft(s) (5, 6 or 10), or mount
J 8001 to a magnetic base and attach to a smooth
place on the vehicle underbody. Readings are to
be taken at points indicated in Figure 3.
3. With transmission in "NEUTRAL," check for
runout by turning a rear wheel to rotate the
propeller shaft(s) ( 5 or 6 and 10).
4. If runout exceeds 1.40 mm (0.055 inch),
disconnect propeller shaft (5 or 10) at differential
drive pinion gear yoke and rotate the propeller
shaft (5 or 10) 180 degrees. Reinstall propeller
shaft (5 or 10). Check runout again.
5. If runout is still over specifications at the
differential drive pinion gear yoke end, differential
drive pinion gear yoke runout should be
measured. Refer to "Differential Drive Pinion
Gear Yoke Runout Measurement" in the
following procedure. If run-out is still over
specifications, replace the propeller shaft
(5, 6 or 10), but only after checking for vibrations
or noise.
6. Lower vehicle.
DIFFERENTIAL DRIVE PINION GEAR

YOKE RUNOUT MEASUREMENT
Figure 4
Tools Required:
J 35819 Runout Gage
J 35819-100 Runout Gage Adapter Sleeves
1. Raise the vehicle on a twin post hoist so the rear
is supported on the rear axle housing and the
wheels can spin. Refer to SECTION OA.
2. Remove propeller shaft. Refer to "One and
Two-Piece Propeller Shaft Replacement" in this
section.
3. Measure pinion gear yoke runout using J 35819,
J 35819-100 and J 8001. Record runout and mark
high and low points of pinion gear yoke.
4. If pinion gear yoke runout is 0.15 mm
(0.006 inch) or less, remove the pinion gear yoke
balance weight, if used. No further action is
required.
5. If pinion gear yoke runout is greater than
0.15 mm (0.006 inch), but less than 0.28 mm
(0.011 inch) and the balance weight is at or near
the low point of pinion gear yoke runout, no
further action is required. If balance weight is not
at or near the low point of pi~on gear yoke
runout, remove the weight.
PROPELLER SHAFT 4A7

3. Install wheel nuts with flat sides against rear
brake drums or rotors.
IL"'I
Inspect
A. Propeller shaft, universal joints, and

attachments for mud, undercoating or loose
fasteners.
~ Clean
Propeller shaft, universal joints, and
attachments.
!~I
J 8001-4
Tighten
Any loose attachments or fasteners to

specifications. Refer to "Specifications'' in
this section.
J 8001-3
MAXIMUN INDICATOR READING
4-20-94
FS0044A
Figure 4 - Differential Drive Gear Yoke Runout
6. If pinion gear runout is over 0.28 mm

(0.011 inch), but no greater than 0.38 mm
(0.015 inch) and the balance weight is at or near
the low point of pinion gear yoke runout no
further action is required.
7. If the balance weight is not at or near the low
point of pinion gear runout, remove the weight
and rotate the pinion gear yoke until runout is
0.25 mm (0.010 inch) or less.
8. If impossible to achieve 0.25 mm (0.010 inch) or
less runout, install a new pinion gear yoke and
recheck for 0.25 mm (0.010 inch) or less runout.
Refer to SECTION 4B for pinion gear yoke
replacement.
Service replacement pinion gear yoke may be
equipped with balance weights. These weights
should not be removed.
9. Install propeller shaft. Refer to "One and
1\vo-Piece Propeller Shaft Replacement" in this
section.
10. Lower vehicle.
PROPELLER SHAFT BALANCE CHECK
!++!
NOTICE:
Refer to "Notice" on page 4A-1.
1. Place vehicle on twim post hoist so that rear of

vehicle is supported on rear axle housing and rear
2. Both rear tires and wheels. Refer to SECTION 3E.
CAUTION: Do not run the vehicle faster

than 88 km/h (55 mph). Stay clear of the
universal joint and balance weight areas
to avoid possible personal injury. Do not
run the vehicle on the hoist for extended
period due to the danger of overheating
the transmission or engine.
NOTICE: Allow the driveline components to
stop rotating with the transmission in
"NEUTRAL" before placing the transmission
in "PARK" or parts may be damaged.
B. Run vehicle in gear at speed where disturbance
peaks. Observe intensity of disturbance.
C. Stop engine.
4. Propeller shaft from pinion gear yoke only. Refer
to "One and Two-Piece Propeller Shaft
Rotate propeller shaft 180 degrees from
original position.
l++I
install or Connect
1. Propeller shaft to pinion gear yoke. Refer to "One

and 1\vo-Piece Propeller Shaft Replacement" in
this section,
2. Remove wheel nuts.
3. Tires and wheels. Refer to SECTION 3E.
4. Determine position that gives best driveline
response by road testing vehicle for final check of
propeller shaft balance.
5. If balance is unacceptable, refer to "Propeller
Shaft Balancing" in this section.
4A-8
PROPELLER SHAFT
PROPELLER SHAFT BALANCING

Hose Clamp Method
Figures 5 through 7
1. Place vehicle on twin post hoist so that rear of
vehicle is supported on rear axle housing and rear
2. Remove both rear tires and wheels. Refer to
SECTION 3E. Install wheel nuts with flat sides
next to rear brake drums or rotors.
3. Mark and number propeller shaft (5) at four
points, 90 degrees apart, at rear of propeller shaft
(5) just forward of balance weight.
4. Install two clamps (11) on rear of propeller shaft
(5) and slide them rearward until clamps (11) stop
at nearest balance weight welded to tube.
Align both clamps (11) at any one of four
marks made on propeller shaft (5) in step 3
and tighten.
A REFERENCE MARKS
4-20-94
F~A
Figure 5 - Propeller Shaft Reference Marks (One-Piece

Propeller Shaft Shown, Two -Piece Propeller Shaft Similar)
A REFERENCE MARK - 180 FROM HOSE CLAMP HEADS
11 CLAMP.HOSE
11

periods due to the danger of overheating
the transmission or engine.
5. Run vehicle through speed range to 81-88 km/h

(50-55 mph). Note amount of imbalance felt at
front of rear axle housing.
6. Loosen clamps ( 11) and rotate clamp heads
90 degrees to next mark on propeller shaft (5).
Tighten clamps (11) and repeat step 5.
7. Repeat step 6 until vehicle has been run with
clamp heads located at all four marks on propeller
shaft (5).
8. Position clamps (11) at point of least imbalance.
Rotate clamp heads away from each other
45 degrees, one on each side of the position.
9.
10.
11.
12.
13.
A. Run vehicle and note if balance has improved.

B. In some cases it may be necessary to use one
clamp (11) or possibly three clamps (11) in
order to obtain good balance.
C. Replace propeller shaft (5) if three clamps (11)
do not improve balance.
Continue to rotate clamps (11) apart in smaller
angular increments until imbalance is at its
minimum.
Remove wheel nuts.
Install tires and wheels. Refer to SECTION 3E.
Lower vehicle.
Road test vehicle to check final balance.
A small vibration felt while vehicle is on hoist
may not be noticed on road test.
A
4-20-94
FS0064A
Figure 6 - Balance Hose Clamps (One-Piece Propeller
Shaft Shown, Two Piece Propeller Shaft Similar)
"'"'------:711
5 SHAFT ASSEMBLY PROPELLER

11
CLAMP, HOSE
4-20-94
FS0074A
Figure 7 - Rotating Balance Hose Clamps (One-Piece

Propeller Shaft Shown, Two -Piece Propeller Shaft Similar)

Strobe Light Method
Figures 5 through 9
If a strobe-light type wheel balancer is used, it
will help in the balancing of the propeller shaft. The
balance pick-up unit should be placed directly under
the nose of the rear axle housing and as far forward as
possible. Make up an extension for the balance
pick-up unit by using 3/8-inch tube and compression
fittings (FIGURE 8).
1. Place vehicle on twin post hoist so rear of vehicle

is supported on rear axle housing and rear wheels
are free to rotate. Lower rear hoist and allow rear
axle to rest on jackstands.
2. Remove both rear tires and wheels. Refer to
SECTION 3E. Install wheel nuts with flat sides
next to rear brake drums or rotors. System is now
released and free to respond to propeller shaft (5).
3. Mark and number propeller shaft (5) at four
points, 90 degrees apart, at rear of propeller shaft
(5) just forward of balance weights.
4. Place strobe light wheel balancer pick-up under
pinion gear yoke in contact with rear axle housing
and as far forward as possible.

periods due to the danger of overheating
the transmission or the engine.
5. Run vehicle in gear at speed where disturbance is
at its peak.
6. Allow driveline to stabilize by holding at steady
speed.
7. Point strobe light up at spinning propeller shaft
(5) and note position of one of the reference
numbers.
\
\
''
LOCALLY
FABRICATED
TOOL
NOTE: LOCALLY FABRICATED EXTENSION FOR BALANCER

PICK-UP CONSISTS OF 3/8" TUBE ANO
COMPRESSION FITIINGS.
4-20-94
FS0084A
Figure 8 Picking-up Differential Drive Pinion Gear Yoke
A DETERMINE POINT OF IMBALANCE

B ADD HOSE CLAMPS 180 FROM POINT OF IMBALANCE
UNTIL THEY BECOME HEAVY SPOT
.
C .ROTATE TWO CLAMPS EQUALLY AWAY FROM EACH
OTHER UNTIL BEST BALANCE IS ACHIEVED
D HEAVYSPOT
11 CLAMP, HOSE
Figure 9 - Positioning Hose clamp to Achieve Best Balance
4-20-94
FS0094A
4A-10
PROPELLER SHAFT
NOTICE: Allow the driveline components to

stop rotating with the transmission in
''NEUTRAL'' before placing the transmission
in "PARK" or parts may be damaged.
8. Shut off engine.

9. Position propeller shaft (5) so reference numbers
will be in same position as was noted while
propeller shaft (5) was rotating.
When strobe light flashed, heaviest point of
propeller shaft (5) was at bottom (6 o'clock).
To balance propeller shaft (5), it would be
necessary to apply balancing weights (hose
clamps) 180 degrees away from heaviest point
or at top of propeller shaft (5) (12 o'clock).
10. Install two screw-type clamps (11) on propeller
shaft (5) as close to rear as possible. Position both
clamp heads 180 degrees from heaviest point of
propeller shaft (5) as indicated by strobe light.
Tighten clamps (11).
11. Run vehicle through speed range 81-88 km/h
(50-55 mph).
A. If disturbance is not gone and strobe light
shows clamp heads at bottom (6 o'clock) of
propeller shaft (5), go to step 12.
B. If strobe light shows two clamp heads at top
of propeller shaft (5), add one more clamp
( 11) and check.
C. If strobe light shows three clamp heads at top
of propeller shaft (5), remove propeller shaft
(5) and rotate 180 degrees on pinion gear yoke
(14). Check again, without clamps (11).
D. Repeat balancing, starting with step 10.
[I]
12.
13.
14.
15.
16.
Important
Do not use more than three clamps ( 11) to

balance propeller shaft (5).
E. If propeller shaft (5) still needs more than
three clamps ( 11) at same clock position,
replace propeller shaft (5).
F. If clamps (11) are also 180 degrees from their
original position after rotating propeller shaft
(5) 180 degrees, pinion gear yoke (14) is out
of balance and must be replaced.
G. If strobe light shows clamps (11) at bottom of
propeller shaft (5), but disturbance still exists,
go to step 12.
Rotate two of the clamps (11) equally away from
each other toward top (one on each side of the
position) in small increments until best balance is
achieved. In some cases it may be necessary to
use one clamp (11) or possibly three clamps (11)
in order to obtain good balance. Replace propeller
shaft (5) if three clamps (11) do not correct
problem.
Remove wheel nuts.
Install tires and wheels. Refer to SECTION 3E.
Remove strobe light and lower vehicle.
Road test vehicle to check final balance.
A small vibration felt while vehicle is on
hoist, may not be noticed on road test.
ONE AND TWO-PIECE PROPELLER

SHAFT REPLACEMENT
FIGURE 10
!++l
NOTICE: Do not strike or drop the propeller

shaft, or allow the universal joints to bend to
extreme angles, as this might fracture a joint
internally.

SECTION OA.
2. Mark relationship of propeller shaft .(5 or 10) to
pinion gear yoke (14).
3. Bolt/screws (16) from center support bearing (7),
if removing two-piece propeller shaft.
4. Center support bearing (7) and washers ( 17) from
torque arm (18), if removing two-piece propeller
shaft.
5. Four bolts/screws (12).
6. Two retainers (13).
7. Propeller shaft(s) (5 or 6 and 10) by withdrawing
slip yoke (1 or 24) from transmission, moving
propeller shaft(s) (5 or 6 and 10) rearward and
passing it under housing (15).
Support propeller shaft(s) (5 or 6 and 10)
during removal.
If bearing caps are loose, tape them together to
prevent dropping and losing needle roller
bearings.
!Ll
Inspect
1. Transmission output shaft splines for burrs.

2. Outer diameter of slip yoke (1 or 24) for burrs.
3. Splines of slip yoke (1 or 24) for damage,
twisting or wear. They should agree in number
and fit with transmission output shaft splines.
4. Pinion gear yoke (14) at universal joint cap
connecting surface for burrs or foreign material.
!++i
Install or Connect
NOTICE:
NOTICE: The propeller shaft must be

supported carefully during handling to avoid
jamming or bending any of the parts.
[I]
Important
To prevent transmission seal damage, do not

place any tool between the propeller shaft slip
yoke and splines.
1. Slip yoke (1 or 24) onto transmission output shaft
after lubricating with chassis lubricant GM
2. Rear of propeller shaft (5 or 10) to pinion gear
yoke (14).
PROPELLER SHAFT 4A11
15
15
A
B
C
1
5
6
7
9
10
12
13
14
15
16
17
18
24
SHAFT, ONE-PIECE PROPELLER

SHAFT, lWO-PIECE PROPELLER
DAMPER, PROPELLER SHAFT SLIP YOKE
YOKE, PROPELLER SHAFT DAMPER AND SLIP
SHAFT, PROPELLER
SHAFT, FRONT PROPELLER
BEARING, PROPELLER SHAFT CENTER SUPPORT
JOINT, PROPELLER SHAFT
SHAFT, REAR PROPELLER
BOLT/SCREW, PROPELLER SHAFT
RETAINER, PROPELLER SHAFT
YOKE, DIFFERENTIAL DRIVE PINION GEAR
HOUSING, REAR AXLE
BOLT/SCREW, PROPELLER SHAFT
WASHER, PROPELLER SHAFT
YOKE, PROPELLER SHAFT FRONT SLIP
01-06-95
FS0104A
Figure 10 - Propeller Shafts
4A-12
[I]
PROPELLER SHAFT
Important
When making the rear propeller shaft

connection, be sure to align the mark on
pinion gear yoke (14) with the mark on
propeller shaft (5 or 10).
3. Rear universal joint to pinion gear yoke (14),
making sure bearing caps are properly seated.
4. Two retainers (13).
!~!
Tighten
Bolts/screws (12) evenly to 22 N.m (16 lb. ft.).

6. Washers (17) and center support bearing (7) to
torque arm (18), if installing two-piece propeller
shaft.
7. Bolts/screws (16) to center support bearing (7), if
installing two-piece propeller shaft.
!~I
Tighten

8. Lower vehicle.
UNIT REPAIR
Nylon Injected Ring Type

Figures 11 Through 13
Tools Required:
J 9522-3 U-Joint Bearing Separator
J 9522-5 U-Joint Bearing Spacer Remover
111
1. Support propeller shaft in a horizontal position in

line with base plate of a press.
2. Place universal joint so that lower ear of shaft
yoke is supported on a 1 1/8-inch socket.
3. Lower bearing cap (19) out of yoke ear by
placing J 9522-3 on open horizontal bearing caps
(19) and pressing lower bearing cap (19) out of
yoke ear. This shears nylon injected ring on lower
bearing cap (19). If bearing cap (19) is .not
completely removed, lift J 9522-3 and insert
J 9522-5 between seal (23) and bearing cap (19).
Complete removal of bearing cap (19) by pressing
it out of yoke.
4. Rotate propeller shaft. Shear opposite nylon
injected ring.
5. Opposite bearing cap (19) out of yoke.
6. Spider (2) from yoke.
There are no bearing retainer grooves in
production bearing caps ( 19), therefore, they
cannot be reused.
If front universal joint is being replaced,
remove pair of bearing caps ( 19) from
propeller shaft slip yoke is same manner.
TWO-PIECE PROPELLER SHAFT
[I]
Important
The two-piece propeller shaft used with the

3800 (VIN K) engine is not serviceable. The
propeller shaft is replaced as a complete unit
only.
Important
The center support bearing used on the

two-piece propeller shaft is not serviceable. It
must be replaced with the two-piece propeller
shaft.
UNIVERSAL JOINTS
When taking apart a propeller shaft, two types of
universal joints may be found: nylon injected ring or
snap ring.
NOTICE:
Never clamp propeller shaft tubing

in a vise. Clamping could dent or deform the
tube causing an Imbalance or unsafe condition.
Always clamp on one of the yokes and support
the shaft horizontally. Avoid damaging the slip
yoke sealing surface. Nicks may damage the
bushing or cut the lip seal.
Clean
Yoke in area locating retainer ring (4) to insure
proper.
All sheared nylon from universal joint cup
bore.
CENTER SUPPORT BEARING

REPLACEMENT
[I]
Disassemble
11]
Important
Production universal joints of this type cannot be

reassembled. Nylon injected ring types are
replaced by external snap ring types.
When reassembling a propeller shaft, always
install a complete universal joint service kit. This
kit includes one pre-greased spider (2), four
service bearing caps with seals (23), needle roller
bearings (21), delrin round washers (20), delrin
flat washers (22), grease and four retainer rings
(4). Make sure that the seals (23) are in place on
the service bearing caps (19) to hold the needle
roller bearings (21) in place during handling.
i+;+l
Assemble
For universal joint re-assembly procedure, refer
to "Snap Ring Type" in the following procedure.

Snap Ring Type
Figure 11 through 16
J 9522-3
Tools Required:
J 9522-3 U-Joint Bearing Separator
J 9522-5 U-Joint Bearing Spacer Remover
[I)
important
Use care not to loosen or damage dust seals. If

dust seals are loose or damaged, replace the
entire universal joint.
These universal joints are designed for
extended life and do not require periodic
inspections or lubrication. When these joints are
taken apart, repack bearings and lubricant reservoir
at the end of the trunnions with chassis lubricant
GM PIN 1052497 or equivalent, or linkage joint
lubricant GM PIN 1052356, or equivalent.
A 11/e SOCKET
TO SUPPORT YOKE
EAR !MUST CLEAR
BEARING CAP)
2 SPIDER, PROPELLER SHAFT---UNIVERSAL JOINT
4-20-94
FSOl14A
Figure 11 - Pressing Out Universal Joint Bearing
~ Disassemble
1. Retainer rings (4). If retainer ring (4) does not
readily snap out of grooves, tap end of bearing
cap (19) lightly to relieve pressure against retainer
ring (4).
2. Support propeller shaft in a horizontal position in
line with base plate of a press.
3. Place universal joint so lower ear of yoke is
supported on a 1 1/8-inch socket.
4. Lower bearing cap (19) out of yoke ear. Place
J 9522-3 on open horizontal bearing cap (19). If
bearing cap (19) is not completely removed, lift
J 9522-3 and insert J 9522-5 between seal (23)
and bearing cap (19) being removed. Complete
removal of bearing cap (19) by pressing it out of
yoke.
5. Rotate propeller shaft and press opposite bearing
cap (19) out of yoke.
6. Spider (2) from yoke.
!!!
Assemble
1. One bearing cap (19) part way into one side of

yoke. Turn this yoke ear to the bottom.
Insert J 9522-3 seating trunnion in bearing cap
(19).
2. Opposite bearing cap (19) part way.
!L"'I
Inspect
Both trunnions to ensure positioning is straight

and true into bearing caps (19).
3. Press against opposite bearing caps (19), working
spider (2) all of the time to ensure free movement
of trunnions in bearings.
!L!
Inspect
Needle roller bearing (21) for binding. If

binding, one or more needle roller bearings
(21) has probably tipped under end of
trunnion.
A TRUNNION
2 SPIDER, PROPELLER SHAFT UNIVERSAL JOINT
19 CAP, BEARING
.
4-20-94
FSOl24A
Figure 12 - Installing Universal Joint Bearing Spacer

Remover
4. Stop pressing when one bearing retainer groove

clears inside of yoke.
5. Retainer ring (4) by pressing into place.
Continue pressing until opposite side can be
snapped into place. If needed, strike yoke
firmly with a hammer to aid in seating the
retainer rings ( 4). This springs yoke ears
slightly.
6. Repeat steps 1 through 5 for other. half of
universal joint.
4A-14
PROPELLER SHAFT
21
22
23
A TRUNNION
4 RING, PROPELLER SHAFT UNIVERSAL JOINT SPIDER
BEARING RETAINER
19 CAP, BEARING
20 WASHER, DELRIN ROUND
21 BEARING, NEEDLE ROLLER
22 WASHER, DELRIN FLAT
23 SEAL
4-20-94
FS0134A
4 RING, PROPELLER SHAFT UNIVERSAL JOINT SPIDER

BEARING RETAINER
4-20-94
FS0154A
Figure 15 - Installing Propeller Shaft Universal Joint Spider

Bearing Retainer Ring
Figure 13 - Service Universal Joint
1',
A STRIKE TUBE YOKE

EAR IN THIS AREA
4-20,.,94
FS0154A
Figure 16 - Seating Propeller shaft Universal Joint Spider

Bearing Retainer Ring
A TRUNNION
19 CAP, BEARING
4-20-94
FS0144A
Figure 14 - Partially Inserted Bearing Cap
PROPELLER SHAFT
4A-15
SPECIFICATIONS
One-Piece Propeller Shaft Runout
Front Propeller Shaft Runout. ............................................................................................... 1.40
Center Propeller Shaft Runout... ........................................................................................... 1.40
Rear Propeller Shaft Runout. ................................................................................................ 1.40
Two-Piece Propeller Shaft Runout ....................................................................................... 1.40
Front Propeller Shaft Center Runout ................................................................................... 1.40
Rear Propeller shaft Front Runout. ...................................................................................... 1.40
Rear Propeller Shaft Rear Runout. ....................................................................................... 1.40
mm
mm
mm
mm
mm
mm
mm
(0.055")
(0.055")
(0.055 11)
(0.055")
(0.055")
(0.055")
(0.055")

Propeller Shaft-to-Center Support Bearing Bolt/Screw .......................................................... 50 N.m (37 lb. ft.)
Propeller Shaft-to-Differential Yoke Bolt/Screw .................................................................... 22 N.m (16 lb. ft.)
SPECIAL TOOLS
3
~
~
J 9522-5
J 95223
4
[)[)
J 35819-100
J8001
1
2
3
4
5
U-JOINT BEARING SEPARATOR

U-JOINT BEARING SPACER REMOVER
RUNOUT GAGE
RUNOUT GAUGE ADAPTER SLEEVES
DIAL INDICATOR SET
01-0SH
FS0174.A
4A-16
PROPELLER SHAFT
BLANK
REAR AXLE
48-1
SECTION 48
REAR AXLE
UNLESS OTHER WISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion
and systems.
CONTENTS
General Description .............................................. .4B-1
Standard Rear Axle .......................................... .4B-1
Operation ...................... ,................................ 4B-3
Limited Slip Rear Axle .................................... 4B-5
Rear Axle Identification .................................... 4B-5
Maintenance and Lubrication ........................... 4B.,.5
Diagnosis ............................................................... 4B-5
Rear Axle Noises .............................................. 4B-6
Gear Noise ..................................................... 4B-6
Bearing Noise ............................................... ;4B-6
Rear Axle Shaft Bearing Noise ................... .4B-6
Knock at Low Speeds ................................... 4B-7
Backlash Clunk ............................................. 4B-7
Limited Slip Rear Axle ................................... .4B-7
Checking Limited Slip Operation ................ .4B-7
Inspection and Diagnosis ................................. .4B-7
Rear Axle Standard and Limited Slip
Diagnosis ..................................................... ,.4B-8
Differential Ring Gear Tooth
Nomenclature ............................................. 4B-8
Tooth Contact Pattern Test ........................... 4B-8
Effects of Increasing Load on Tooth
Contact Pattern .......................................... 4B-9
Adjustments Affecting Tooth Contact.. ....... .4B-9
Effects of Differential Drive Pinion Gear
Position on Tooth Pattern ......................... 4B-9
On Vehicle Service .:............................................. 4B-11
Rear Axle Lubricant Fill and Check. .............. .4B-12
Rear Axle Housing Cover and Gasket ............ 4B-12
Rear Axle Shaft ................................................ 4B-12

Rear Axle Shaft Bearing and/or Bearing
Seal ................................................................ 4B-13
Differential Drive Pinion Gear Yoke and
Seal ................................................................ 4B-14
Rear Axle .......................................................... 4B-15
Rear Wheel Bolt/Screw ................................... .4B-16
Unit Repair ............................................................ 4B-16
Differential. Case ............................................... 4B-17
Vehicle Speed Sensor Reluctor Wheel ........... .4B-20
Differential Ring Gear-to-Differential Drive
Pinion Gear Backlash ................................... 4B-20
Differential Bearing Preload Adjustment.. ...... .4B-20
Differential Drive Pinion Gear ......................... 4B-21
Differential Drive Pinion Gear Outer
Bearing ...................................................... 4B-22
Differential Drive Pinion Gear Inner
Bearing ...................................................... 4B-23
Differential Drive Pinion Gear Depth ............. .4B-23
Differential Case (Limited Slip) .................;..... 4B-25
Rear Axle Housing Replacement .................... .4B-25
Rear Axle Housing with Drum Brakes ....... 4B-25
Rear Axle Housing with Disc Brakes ........ .4B-26
General Specifications ....................................... 4B-28
Limits for Fitting and Adjusting ...................... 4B-28
Rear Axle Usage Chart ........................................ 4B-28
Special Tools ......................................................... 4B-29
GENERAL DESCRIPTION
driveline and coil springs. The rear axle has a hypoid

type ring gear (20) with the centerline of the drive
pinion gear (23) below the centerline of the ring gear
(20).
All parts necessary to transmit power from the
propeller shaft to the rear tires and wheels are
enclosed in the housing (16). A removable steel cover
(43) bolted to the rear of the housing (16) permits
service of the rear axle without removing the entire
axle from the vehicle.
STANDARD REAR AXLE

Figures 1 through 4
The rear axle is a semi-floating hypoid type in
which the vehicle weight is carried on the housing
(16). The rear axle is designed for use with an open
48-2
REAR AXLE
L. ... _______ .____B....,j

4-28-9'1
FS0014B
Figure 1 - Standard Rear Axle
REAR AXLE 48-3
A
B
1
2
3
5
6
7
9
15
16
17
18
19
20
22
23
24
25
26
28
29
32
33
34
35
DIFFERENTIAL
OPTIONAL DISC BRAKE
NUT, DIFFERENTIAL DRIVE PINION GEAR
WASHER, DIFFERENTIAL DRIVE PINION GEAR
DEFLECTOR, DIFFERENTIAL DRIVE PINION GEAR DIRT
SEAL, DIFFERENTIAL DRIVE PINION GEAR
BEARING, DIFFERENTIAL DRIVE PINION
GEAR OUTER
PLUG, REAR AXLE HOUSING DRAIN
SPACER, DIFFERENTIAL DRIVE PINION GEAR BEARING
HOUSING, REAR AXLE
VENT, REAR AXLE
BEARING, DIFFERENTIAL DRIVE PINION
GEAR INNER
SHIM, DIFFERENTIAL DRIVE PINION GEAR
GEAR, DIFFERENTIAL RING
CAP, DIFFERENTIAL CARRIER BEARING
GEAR, DIFFERENTIAL DRIVE PINION
SHIM, DIFFERENTIAL BEARING
SPACER, DIFFERENTIAL BEARING
BOLT/SCREW, DIFFERENTIAL BEARING CAP
BOLT/SCREW, DIFFERENTIAL RING GEAR
BOLT/SCREW, DIFFERENTIAL PINION GEAR SHAFT LOCK
BEARING, DIFFERENTIAL
CASE, DIFFERENTIAL
MAGNET, REAR AXLE HOUSING CHIP COLLECTING
SHAFT, DIFFERENTIAL PINION GEAR
36
37
38
39
40
41
43
44
45
46
48
49
54
58
59
61
63
64
65
66
67
68
69
70
71
72
73
75
GEAR, DIFFERENTIAL PINION

WASHER, DIFFERENTIAL PINION GEAR THRUST
WASHER, DIFFERENTIAL SIDE GEAR THRUST
WHEEL, REAR WHEEL SPEED SENSOR RELUCTOR
GEAR, DIFFERENTIAL SIDE
BOLT/SCREW, REAR AXLE HOUSING
COVER, REAR AXLE HOUSING
BEARING, REAR AXLE SHAFT
GASKET, REAR AXLE HOUSING COVER
PLATE, REAR BRAKE BACKING
BOLT/SCREW, REAR BRAKE BACKING
SEAL, REAR AXLE SHAFT BEARING
LOCK, REAR AXLE SHAFT
DRUM, REAR BRAKE
BRAKE, REAR
BOLT/SCREW, REAR WHEEL
SHAFT REAR AXLE (DRUM BRAKE ASSEMBLIES}
NUT, REAR BRAKE BACKING PLATE
PLATE, REAR BRAKE CALIPER MOUNTING
BOLT/SCREW, CALIPER MOUNTING
SHIM, AXLE TUBE FLANGE
NUT, REAR BRAKE CALIPER MOUNTING PLATE
CALIPER, REAR BRAKE
SHAFT, REAR AXLE {DISC BRAKE ASSEMBLIES}
ROTOR, REAR BRAKE
BOLT/SCREW, REAR BRAKE BACKING PLATE
BOLT/SCREW, SENSOR PLUG MOUNTING
SENSOR, WHEEL SPEED
01-05-95
FS0024B
Figure 2 - Standard Rear Axle - Legend
A universal joint connects the rear end of the

propeller shaft to the yoke (3). The yoke (3) has a
splined end which fits over and drives the drive pinion
gear (23). Two preloaded tapered roller bearings
support the drive pinion gear (23) in the housing (16).
The races of the inner bearing (18) and the outer
bearing (7) are press fit in the housing (16). The inner
bearing (18) is press fit onto the drive pinion gear
(23). The outer bearing (7) combines a light press fit
to a close sliding fit on the yoke end of the pinion
gear stem. The races of the inner and outer bearings
(18 and 7) are pressed against shoulders recessed in
the housing (16).
Located on the rear axle shaft (Figure 3) near
the hub is the rear wheel speed sensor reluctor wheel
used with the antilock brake system (ABS) and
traction control system (TCS) to transmit rear wheel
speed information. The sensor reluctor wheel is press
fit on the shaft (39) and is not serviceable. For more
information refer to SECTION 5E2.
Tightening nut (1) compresses a collapsible
spacer (15) that bears against the outer bearing (7) and
a shoulder on the pinion stem. This spacer (15) is used
to enable automatic bearing preload adjustment and
maintain a preload on both inner and outer bearings
(18 and 7). Adjustment of the fore-and-aft position of
the drive pinion gear (23) is obtained by placing
selective shims (19) between the head of the drive
pinion gear (23) and the inner bearing (18).
The case (33) is one piece and is supported in
the housing (16) by two tapered roller side bearings
(32). These are preloaded by inserting shims (24)
between the bearings (32) and the housing (16). The
case (33) is positioned for proper differential ring

gear-to-differential drive pinion gear backlash by
varying the shim thickness from side to side. The ring,
gear (20) is bolted to the case (33). A speed sen~Qt'
reluctor wheel (39) is press fit to the case (33);PJY/
vehicles equipped with the standard rear axle A wh~e,r . . ...
speed sensor (75) is mounted to the housing (l~)i~J,;)
(Figure 1) or the mounting plate (65) with tractiorr':~\~i
control (Figure 3). This sensor provides wheel speed,
information to the electronic brake control module
(EBCM). For further information, refer to
SECTION 5El.
Two side gears (40) have splined bores for
driving the axle shafts (63 or 70). They are positioned
to turn in counterbored cavities in the case (33). The
pinion gears (36) have smooth bores and are held in
position by a solid pinion gear shaft (35), mounted
and locked in the case (33). All four gears are in mesh
with each other. The pinion gears (36) turn freely on
the pinion gear shaft (35), acting as idler gears when
the rear wheels are turning at different speeds. The
pinion gears (36) and side gears (40) are backed by
steel thrust washers (37 and 38).
OperaUon
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, turning
slower with respect to the outer tire and wheel, slows its
differential side gear (as the axle shaft is splined to the
side gear). The differential pinion gears roll around the
slowed differential side gear, driving the other differential
side gear and tire and wheel faster.
48-4
REAR AXLE
010515
FS0034B
Figure 3 Rear Axle Equipped With Traction Control (Acceleration Slip Regulation)
REAR AXLE
A
B
C
1
2
3
5
6
7
9
15
16
17
18
19
20
22
23
24
25
26
28
29
32
33
34
DIFFERENTIAL
OPTIONAL DISC BRAKE
WHEEL, REAR WHEEL SPEED SENSOR RELUCTOR
NUT, DIFFERENTIAL DRIVE PINION GEAR
WASHER, DIFFERENTIAL DRIVE PINION GEAR
DEFLECTOR, DIFFERENTIAL DRIVE PINION GEAR DIRT
SEAL, DIFFERENTIAL DRIVE PINION GEAR
BEARING, DIFFERENTIAL DRIVE PINION GEAR
OUTER
PLUG, REAR AXLE HOUSING DRAIN
SPACER, DIFFERENTIAL DRIVE PINION GEAR BEARING
HOUSING, REAR AXLE
VENT, REAR AXLE
BEARING, DIFFERENTIAL DRIVE PINION GEAR INNER
SHIM, DIFFERENTIAL DRIVE PINION GEAR
GEAR, DIFFERENTIAL RING
SHIM, DIFFERENTIAL BEARING
SPACER, DIFFERENTIAL BEARING
BOLT/SCREW, DIFFERENTIAL RING GEAR
BOLT/SCREW, DIFFERENTIAL PINION GEAR SHAFT LOCK
BEARING, DIFFERENTIAL
CASE, DIFFERENTIAL
MAGNET, REAR AXLE HOUSING CHIP COLLECTING
35
36
37
38
40
41
43
44
45
46
48
49
54
58
59
61
63
64
65
66
67
68
69
70
71
72
75
48-5
SHAFT, DIFFERENTIAL PINION GEAR

GEAR, DIFFERENTIAL PINION
WASHER, DIFFERENTIAL PINION GEAR THRUST
WASHER, DIFFERENTIAL SIDE GEAR THRUST
GEAR, DIFFERENTIAL SIDE
BOLT/SCREW, REAR AXLE HOUSING
COVER, REAR AXLE HOUSING
GASKET, REAR AXLE HOUSING COVER
BOLT/SCREW, REAR BRAKE BACKING
LOCK, REAR AXLE SHAFT
DRUM, REAR BRAKE
BRAKE, REAR
BOLT/SCREW, REAR WHEEL
SHAFT REAR AXLE (DRUM BRAKE ASSEMBLIES)
BOLT/SCREW, CALIPER MOUNTING
SHIM, AXLE TUBE FLANGE
NUT, REAR BRAK!: CALIPER MOUNTING PLATE
CALIPER', REAR BRAKE
SHAFT, REAR AXLE (DISC BRAKE ASSEMBLIES)
ROTOR', REAR BRAKE
BOLT/SCREW, REAR BRAKE BACKING PLATE
SENSOR, WHEEL SPEED
01-05-95
FS0044B
Figure 4 - Rear Axle Equipped With Traction Control (Acceleration Slip Regulation) - Legend
LIMITED SLIP REAR AXLE

Limited slip rear axles have several definite
operating characteristics. An understanding of these
characteristics is necessary to aid in diagnosis.
The energizing force comes from the thrust side
of the gears. Consequently, a free spinning tire and
wheel may not have enough resistance to driving
torque to apply the clutch packs or cones. If this
occurs, applying the parking brake a few notches will
provide enough resistance to energize the cones.
Energizing the cones is independent of
acceleration; therefore, 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 rear axle parts of vehicles with the limited
slip rear axle are interchangeable with those equipped
with the standard rear axle, except for the differential
case. It is ~imilar 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 and must be
replaced.
REAR AXLE IDENTIFICATION

Figure 5
The rear axle identification code and
manufacturer's code must be known before attempting
to adjust or repair axle shafts or the differential. Rear
axle ratio, differential type, manufacturer, and build
date information is stamped on the right axle tube on

the forward side or on a metal tag on the housing
cover (43) The service parts identification label also
has RPO codes for the rear axle printed on it.

Figures 1 through 4
NOTICE:
Refer to "Notice" on page 4B-l.
To check or add lubricant. Refer to "Rear Axle

Lubricant Fill and Check" in this section.
Limited slip differentials should have lubricant
drained and refilled at the first 12 500 km
(7,500 miles).
If the vehicle is used to pull a trailer, change
lubricant every 12 500 km (7,500 miles) in either type
differential.
DIAGNOSIS
Many noises reported as corning from the rear
axle actually originate from other sources such as tires
and wheels, road surfaces, wheel bearings, engine,
transmission, muffler or body. A thorough and careful
check should be made to determine the source of the
noise before taking apart the rear axle. Noise which
originates in other places cannot be corrected by
adjustment or replacement of parts in the rear axle.
Rear axle differential gears, like any other mechanical
devices, are not absolutely quiet and should be
48-6
A
B
C
D
REAR AXLE
AXLECODE
MANUFACTURER
DAYBUILT
SHIH
5-27-94
FS00548
Figure 5 - Rear Axle Identification
accepted as being commercially quiet unless some

abnormal noise is present.
To make a systematic check for axle noise under
standard conditions, observe the following:
1. Check rear axle lubricant to ensure correct level,
then drive vehicle far enough to thoroughly warm
up rear axle lubricant.
2. Select a level asphalt road to reduce tire noise and
body drumming.
3. Note speed at which noise occurs. Then stop
vehicle and with the transmission control lever in
"NEUTRAL," run engine slowly up and down
through engine speeds, corresponding to vehicle
speed at which noise was most pronounced, to
determine if it is caused by exhaust muffler roar
or other engine conditions.
4. Tire noise changes with different road surfaces,
but rear axle noise does not. Temporarily inflating
all tires to approximately 345 Kpa (50 psi) for test
purposes only, will alter noise caused by the tires,
but will not affect noise caused by the rear axle.
Rear axle noise usually stops when coasting at
speeds under 48 km/h (30 mph). Tire noise
continues, but with a lower tone as vehicle speed
is reduced. Rear axle noise usually changes when
comparing drive and coast, but tire noise remains
about the same.
Distinguish between tire noise and rear axle
noise by noting if noise varies with various
speeds or sudden acceleration and deceleration.
Exhaust and axle noises show variations under
these conditions while tire noise remains
constant and is more noticeable at speeds of
32 to 48 km/h (20 to 30 mph). Check for tire
noise by driving vehicle over smooth
pavements or dirt roads (not gravel) with tires
at normal pressure. If noise is caused by tires,
it will noticeably change or disappear and
appear again with changes in the road surface.
5. Loose or rough front wheel inner or outer

bearings will cause a noise which may be
confused with rear axle noise. Front wheel inner
or outer bearing noise does not change when
comparing drive and coast. Light application of
the brake pedal while holding the vehicle speed
steady will often cause front wheel inner and
outer bearing noise to diminish, as this takes some
weight off the bearing. Front wheel inner and
outer bearings may be easily checked for noise by
jacking up the tires and wheels and spinning them
or by shaking the tires and ,'wheels to determine if
bearings are loose.
6. Rear suspension rubber bushings and spring
insulators dampen out rear axle noise wh.en
correctly installed. Check that no metallic contact
exists between the spring and spring opening in
the underbody or between lower control arm
bushings and underbody or axle housing brackets.
Metal-to-metal contact at these points may result
in telegraphing road noise and normal axle noise
which would not be objectionable if dampened by
bushings.
REAR AXLE NOISES

Gear Noise
After the noise has been determined as being in
the rear axle, the type of noise should be established
to aid in making repairs if necessary.
Gear noise (whine) is audible from 32 to 89
km/h (20 to 55 mph) under four driving conditions:
1. Drive - Acceleration or heavy pull.

2. Road Load - Vehicle driving load or constant
speed.
3. Float - Using enough throttle to keep the vehicle
from driving the engine, the vehicle slows down
gradually but the engine still pulls slightly.
4. Coast - Throttle closed and vehicle in gear. Gear
noise most frequently has periods where noise is
more noticeable, usually 64 to 80 km/h (40 to
50 mph) and 97 to 105 km/h (60 to 65 mph).
Bearing Noise
Bad bearings generally produce more of a rough
growl or grating sound, rather than the whine typical
of gear noise. Bearing noise frequently "wow-wows"
at constant bearing RPM, indicating a faulty
differential drive pinion gear or side bearings. This
noise could easily be confused with rear axle shaft
bearing noise. Inspect and replace as required.
Rear Axle Shaft Bearing Noise

A rough rear axle shaft bearing produces a noise
that continues with the vehicle coasting at low speed
and transmission control lever in "NEUTRAL." Noise
may diminish by gentle braking. With rear tires and
wheels jacked up, spin rear tires and wheels by hand
while listening at hubs for evidence of rough (noisy)
rear axle shaft bearing.
REAR AXLE
Knock at Low Speeds
A low speed knock can be caused by a worn
universal joint or a side gear hub counterbore in the
differential case worn oversize. Inspect and replace
universal joint or the differential case and side gear as
required.
Backlash Clunk
Excessive clunk with acceleration and
deceleration is caused by worn differential drive pinion
gear shaft, worn differential case, excessive clearance
between the rear axle shaft and side gear splines,
excessive clearance between side gear hub and
counterbore in case, worn differential drive pinion gear
and side gear teeth, worn differential pinion gear thrust
washers, and excessive differential ring
gear-to-differential drive pinion gear backlash. Remove
worn parts and replace as required, selecting close
fitting parts when possible. Adjust differential ring
gear-to-differential drive pinion gear backlash. Refer to
"Differential Ring Gear-to-Differential Drive Pinion
Gear Backlash" in this section.
LIMITED SLIP REAR AXLE

Improper operation is generally indicated by
clutch slippage or grabbing. Sometimes this produces a
chatter or whirring sound. These sounds are not
always indicative of failure as they could be produced
from lack of proper lubrication. For example, under
certain conditions where one tire and wheel is on a
very slippery surface and the other on dry pavement,
wheel spin can occur if hard acceleration is attempted.
Continued spinning may ca:use audible noise, such as a
whirring sound, due to the cones lacking sufficient
lubricant. This does not necessarily indicate a failure
of the unit.
During regular operation (straight ahead driving)
when both tires and wheels rotate at equal speeds,
there is an equal driving force delivered to each tire
and wheel. When cornering, the inside tire and wheel
requires extra driving force causing slippage in the
clutch cone. Consequently, the operational life of the
limited slip unit is dependent upon equal rotation of
both tires and wheels during straight ahead operation.
If wheel rotation for both rear tires and wheels is not
equal during straight ahead operation, the limited slip
unit will constantly be functioning as if the vehicle
were cornering. This will impose constant slippage on
the clutch and will eventually lead to abnormal wear
on the clutch cone.
48-7
3. Remove one tire and wheel. Refer to

SECTION 3E.
4. Install J 21579, 1/2 x 13 adapter from J 2619-01
and a torque wrench.
5. Measure torque required to rotate one tire and
wheel. Torque should be between 169 and 305
N.m (125 and 225 lb. ft.).
6. Place transmission control lever in "NEUTRAL"
position and lower one rear tire and wheel to
ground.
7. Measure torque required to rotate raised tire and
wheel. Torque should be between 58 and 91 N.m
(43 and 67 lb. ft.).
8. Install tire and wheel. Refer to SECTION 3E.
The differential case should be replaced if any
of the above checks do not fall within
specifications.
INSPECTION AND DIAGNOSIS

A close examination of the rear axle prior to
taking it apart will often reveal valuable information
as to the extent and type of repairs or adjustments
necessary. This information and the report of the
malfunction provides a basis for determining the
degree of tear down required. Frequent causes of rear
axle noise are improper backlash, differential drive
pinion gear inner or outer bearing preload, differential
side bearing preload, or a combination of these items.
A few simple adjustments may be all that are
necessary to correct the problem.
Before removing the differential case from the
housing, these items should be checked and the results
recorded and analyzed: ( 1) backlash; (2) total
differential preload; and (3) tooth contact pattern.
Use care at all times to keep dirt and other
foreign matter, such as grinder dust, soot, or sand,
away from the rear axle to prevent the possibility of
subsequent failure.
Checking Limited Slip Operation

Figure 6
Tools Required:
J 2619-01 Slide Hammer with 1/2 x 13
Adapter
J 21579 Axle Shaft Remover
1. Place transmission control lever in "PARK"
position, or in gear if manual transmission,
parking brake lever released.
2. Raise both rear tires and wheels off the floor.
A
B
1/2 x 13 ADAPTER FROM J 2619-01

TORQUE WRENCH
4-21-94
FS0064B
Figure 6 - Measuring Limited Slip Rotating Torque
48-8
REAR AXLE
REAR AXLE STANDARD AND LIMITED SLIP DIAGNOSIS
CONDITION
1.
Noise is the same in "DRIVE" or when coasting.
2.
Noise changes on a different type of road.
3.
4.
Noise tone lower as vehicle speed is lowered.

Noise is produced with vehicle standing and driving.
5.
Vibration.
6.
A knock or click approximately every two

revolutions of rear wheel assembly.
Noise most pronounced on turns.
Continuous low pitch whirring or scraping noise
starting at relatively low speed.
Drive noise, coast noise or float noise.
Clunk on acceleration or deceleration.
7.
8.
9.
10.
11. Groan in forward or reverse.

12. Chatter on turns.
13.
Clunk or knock on rough road operation.
CAUSE
a.
b.
c.
d.
a.
b.
a.
a.
b.
a.
b.
c.
d.
e.
f.
Road noise.
Tire noise.
Front wheel bearing noise.
Incorrect driveline angles.
Tire noise.
Road noise.
Tire noise.
Engine noise.
Transmission noise.
Rough rear axle shaft bearing assembly.
Unbalanced or damaged propeller shaft assembly.
Tire unbalance.
Worn universal joint in propeller shaft assembly.
Incorrect driveline angles.
Mis-indexed propeller shaft assembly at drive pinion
gear yoke.
g. Drive pinion gear yoke runout too great.
a. Rear axle shaft bearing assembly.
a.
a.
Differential side gear and pinion gear noise.

Drive pinion gear inner or outer bearing noise.
a.
a.
Ring and drive pinion gear noise.

Worn differential pinion gear shaft in case or side gear
hub counterbore in case worn oversize.
b. Worn universal joint on propeller shaft assembly.
c. Differential drive pinion gear yoke lubrication
insufficient.
a. Wrong lubricant in rear axle assembly.
a. Wrong lubricant in rear axle assembly.
b. Clutch cones worn (limited slip).
a. Excessive end play of rear axle shafts.
T5668
Differential Ring Gear Tooth Nomenclature

Figure 7
The side of the differential ring gear tooth which
curves outward, or is convex, is referred to as the
"drive" side. The concave side is the "coast" side.
The end of the tooth nearest center of the differential
ring gear is referred to as the "toe" end. The end of
the tooth farthest away from the center is the "heel"
end. The toe end of the tooth is smaller than the heel
end.
Tooth Contact Pattern Test

Figures 1 through 4, 7 and 8
Tool Required:
J 39446 ABS Exciter Ring Protector Kit
NOTICE: It is very important that tooth

contact be tested before 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
far away from, or close to, the differential ring
gear. Thus, the tooth contact must be tested and
corrected, if necessary, or the gears may be
noisy.
NOTICE:
Refer to "Notice" on page 4B- l.
Clean
1. All dirt from area of rear axle housing cover (43)

before removing.
2. Remove housing cover. Refer to "Rear Axle
Housing Cover and Gasket" in this section.
3. Wipe oil out of the housing (16) and carefully
clean each tooth of the ring gear (20).
REAR AXLE
48-9
from near toe to near heel on the drive side. The

entire contact also tends to shift toward the heel under
increasingly heavier loads and will become somewhat
broader with respect to tops and bottoms of teeth. The
patterns obtained by this tooth contact pattern test
approximate a light load and, for this reason, they will
extend only about halfway.
The important thing to note is that the contact
pattern is centrally located up and down on the face of
the differential ring gear teeth.
Insufficiently preloaded drive pinion gear and
differential bearings will also cause a change in tooth
contact pattern under load.
Adjustments Affecting Tooth Contact

A
B
C
D
E
Figure 9
TOE
HEEL
CONVEX SIDE !DRIVEi

CONCAVE SIDE ICOASTI
CORRECT PATTERN
4-21-94
FS00748
Figure 7 - Differential Ring Gear Tooth Nomenclature
4. Select correct exciter ring protector from J 39446

and attach to speed sensor reluctor wheel (39) on
vehicles with non-traction control rear axles only.
5. Use gear marking compound GM PIN 1052351 or
equivalent and apply this mixture sparingly to all
ring gear teeth, using a medium stiff brush. When
properly used, the area of differential drive pinion
gear tooth contact will be visible when hand load
is applied.
!~J
Tighten

6. Apply parking brake until a torque of 54 to 70
N.m (40 to 52 lb. ft.) is required to turn drive
pinion gear (23).
II]
Important
A test made without loading the gears will not

give a satisfactory pattern. Turn yoke (3) with
a wrench so that ring gear (20) rotates one full
revolution. Reverse rotation so that ring gear
(20) rotates one revolution in the .opposite
direction.
7i Observe pattern on the ring gear teeth and
compare with Figure 8.
8. If pattern is acceptable, remove J 39446.
9. Install housing cover. Refer to "Rear Axle

Contact Pattern
When the "load" on the differential ring and
drive pinion gears is increased, such as when the
vehicle is accelerated forward from a stand still or
from normal drive, the tooth contact will tend to
spread out and, under very heavy load, will extend
Two adjustments can be made which will affect

the tooth contact pattern: backlash and position of
drive pinion gear (23) in the housing. The effects of
bearing preloads are not readily apparent on
hand-loaded tooth contact pattern tests ..
Backlash is adjusted by means of shims (24).
They move the entire differential closer to or farther
from the drive pinion gear (23). Shims (24) are also
used to set differential bearing preload. If the thickness
of the right shim (24) is increased, along with
decreasing the left shim thickness, backlash will
increase. The backlash will decrease if the left shim
thickness is increased, along with a decrease in right
shim thickness.
The position of the drive pinion gear (23) is
adjusted by increasing or decreasing the shim
thickness between the drive pinion gear head and race
of the differential drive pinion gear inner bearing. The
shim (19) is used in the rear axle to compensate for
manufacturing tolerances. Increasing shim thickness
moves the drive pinion gear (23) closer to the
centerline of the ring gear (20). Decreasing shim
thickness moves the drive pinion gear (23) farther
away from the centerline of the ring gear (20).
Effects of Differential Drive Pinion Gear

Position on Tooth Pattern
Figure 10
When the differential drive pinion gear is too far
away from the centerline of the differential ring gear,
the pattern will be a high heel contact on the drive
side and high toe contact on the coast side. Moving
the differential drive pinion gear closer to the
centerline of the differential ring gear by decreasing
backlash will cause the high heel contact on the drive
side to move down and toward the toe: the high toe
contact on the coast side will move down and toward
the heel.
48-10
REAR AXLE
A LOW FLANK CONTACT: DECREASE DIFFERENTIAL DRIVE PINION GEAR BEARING SHIM THICKNESS - MOVES SMALLER DIAM!ETER OF DIFFERENTIAL DRIVE PINION GEAR OUT TOWARD DIFFERENTIAL RING GEAR CENTER LINE
B HEEL CONTACT: DECREASE BACKLASH - MOVES AREA OF DIFFERENTIAL DRIVE PINION GEAR CONTACT TOWARD TOE
C HIGH FACE CONTACT: INCREASE OIFFERENTIAL DRIVE PINION GEAR BEARING SHIM THICKNESS - MOVES LARGER DIAMETER
OF DIFFERENTIAL DRIVE PINION GEAR IN TOWARD CENTER OF DIFFERENTIAL RING GEAR
D TOE CONTACT: INCREASE BACKLASH - MOVES AREA OF DIFFERENTIAL DRIVE PINION GEAR CONTACT TOWARD HEEL
I: DESIRED PATTERN: IN CENTER OF DIFFERENTIAL RING GEAR TOOTH
.
4-21-94
FS00848
Figure 8 - Differential Ring Gear Tooth Contact Pattern Diagnosis Chart
REAR AXLE
48-11
When the differential drive pinion gear is too

close to the centerline of the differential ring gear, the
pattern will be a low toe contact on the drive side, and
a low heal contact on the coast side. Moving the
differential drive pinion gear farther away from the
differential ring gear by increasing backlash will cause
low toe contact on the drive side to move up and
toward the heel: the low heel contact on the coast side
will move up and toward the toe.
ON-VEHICLE SERVICE
A DIFFERENTIAL DRIVE PINION GEAR DEPTH

ADJUSTMENT
B BACKLASH ADJUSTMENT
19 SHIM, DIFFERENTIAL DRIVE PINION GEAR
20 GEAR, DIFFERENTIAL RING
23 GEAR, DIFFERENTIAL DRIVE PINION
24 SHIM, DIFFERENTIAL BEARING
4-21-94
FS0094B
Figure 9 - Tooth Contact Adjustments
Before attempting any service procedures, the

technician must know what type rear axle is to be
serviced. Refer to "Rear Axle Usage Chart" in this
section to identify codes, differential ring gear size,
and ratios. Also, refer to the service parts
identification label on the vehicle.
Most rear axle service repairs can be made with
the vehicle properly supported ~nd the rear axle
housing lowered to its lowest travel. On some
vehicles, it may be necessary to disconnect the shock
absorbers to obtain additional clearance. When doing
this, do not allow the rear brake hoses to become
kinked or stretched.
Lubricant may be drained by removing all rear
axle housing bolts/screws and breaking the rear axle
housing cover loose at the bottom.
If the rear axle housing is removed for any
reason, rear axle service can be performed on the
bench.
A DIFFERENTIAL DRIVE PINION GEAR TOO FAR AWAY FROM DIFFERENTIAL RING GEAR
(INSUFFICIENT DIFFERENTIAL BEARING SHIM THICKNESSI
B EFFECT ON PATTERN AS DIFFERENTIAL BEARING SHIM THICKNESS IS INCREASED
C DIFFERENTIAL DRIVE PINION GEAR TOO CLOSE TO DIFFERENTIAL RING GEAR
fEXCESSIVE DIFFERENTIAL BEARING SHIM THICKNESS)
D EFFECT ON PATTERN AS DIFFERENTIAL BEARING SHIM THICKNESS IS DECREASED
E TOE
F HEEL, COAST SIDE (CONCAVE)
G HEEL, DRIVE SIDE (CONVEX)
Figure 1O - Differential Bearing Shim Thickness Effect on Tooth Pattern
4-21-94
FS0104B
48-12
REAR AXLE
When a new differential ring gear and

differential drive pinion gear are installed, the owner
should be advised not to accelerate rapidly or exceed
80 km/h (50 mph) for the first 80 km (50 miles) of
driving.
REAR AXLE LUBRICANT FILL AND

CHECK
Figures 1 through 4
NOTICE:
Refer to "Notice" on Page 4B-1.
1. Raise and suitably support vehicle at suspension

contact points. Refer to SECTION OA.
2.
3.
4.
5.
6.
7.
Keep vehicle level.

Clean dirt or foreign material from around plug
opening before removing plug (9).
Remove plug (9).
Maintain axle lubricant level from flush with
bottom of plug opening to no lower than 15 mm
(9/16 inch) below plug opening.
Add or replace axle lubricant using GM
PIN 12345971 axle lubricant or SAE 80W-90
GL-5 gear lubricant or equivalent.
If equipped with a limited slip differential add
59 ml (2 fl. oz.) of GM PIN 1052358 limited slip
differential additive or equivalent.
Install plug (9).
!~!
Tighten
1. New gasket (45) and cover (43).

2. Parking brake cable guides and bolts/screws (41).
!~!
Tighten
Bolts/screws (41) in a crosswise pattern to

30 N.m (22 lb. ft.).
3. Lubricant. Refer to "Rear Axle Lubricant Fill and
Check" in this section.
4. Lower vehicle.
REAR AXLE SHAFT

Figures 1 through 4, and 11
Tool Required.
!++!
1. Rear tire and wheel. Refer to SECTION 3E.

2. Rear brake drum and components, if equipped.
Refer to SECTION 5C2.
3. Rear brake rotor, if equipped. Refer to
SECTION 5B2.
4. Rear axle housing cover. Refer to "Rear Axle
5. Install J 39446 to speed sensor reluctor wheel (39)
on vehicles equipped with non-traction control
rear axles.
6. Bolt/screw (29) from case (33).
7. Pinion gear shaft (35) from case (33).
8. Shaft lock (54).
Plug (9) to 35 N.m (26 lb. ft.).

8. Lower vehicle.
REAR AXLE HOUSING COVER AND

GASKET
Figures 1 through 4
!++!

SECTION OA.
Clean
All dirt from area of rear axle housing cover

(43) before removing.
2. Bolts/screws (41), parking brake cable guides and
pry cover (43) loose.
3. Drain lubricant.
4. Gasket (45).
Clean
Both gasket sealing surfaces.
!++!
Install or Connect
NOTICE:
16
39
16
22
26
29
HOUSING, REAR AXLE

BOLT/SCREW, DIFFERENTIAL PINION GEAR SHAFT
LOCK
39 WHEEL, REAR WHEEL SPEED SENSOR RELUCTOR
54 LOCK, REAR AXLE SHAFT
1-08-95
FS0114B
Figure 11 - Internal View of Rear Axle Housing (Typical)
REAR AXLE
Access by pushing flanged end of axle shaft
(63 or 70) into housing (16).
9. Axle shaft (63 or 70) from housing (16), being
careful not to damage seal (49).
[I]
!++!
REAR AXLE SHAFT BEARING AND/OR

BEARING SEAL
Important
If vehicle is equipped with traction control

(acceleration slip regulation) (ASR), be careful
not to damage rear wheel speed sensor reluctor
wheel located on axle shaft when removing the
axle shaft. If damage has occurred to the rear
wheel speed sensor reluctor wheel, the rear
axle shaft must be replaced.
4813
Tools Required:
J 2619-01 Slide Hammer with 1/2 x 13
Adapter J 8092 Driver Handle
J 22813-01 Axle Bearing Remover
J 23765 Axle Bearing Installer
J 23771 Axle Oil Seal Installer
f++f
1. Rear axle shaft. Refer to "Rear Axle Shaft" m
Install or Connect
NOTICE:
1. Axle shaft (63 or 70) into place, taking care that

splines on end of axle shaft (63 or 70) do not
damage seal (49) and that they engage with
splines of side gear (40).
2. Shaft lock (54).
Push axle shaft (63 or 70) outward so that
shaft lock (54) seats in counterbore of side
gear (40).
3. Pinion gear shaft (35) through case (33), thrust
washers (37) and pinion gears (36), aligning hole
in pinion gear shaft (35) with lock bolt/screw hole
in case (33).
4. Bolt/screw (29).
[I]
this section.
2. Rear brake backing plate, if equipped. Refer to
SECTION 5C2.
3. Rear brake caliper anchor bracket and mounting
plate, if equipped. Refer to SECTION 5B2.
4. Seal (49) from housing (16) with a pry bar behind
steel case of seal (49), being careful not to
damage housing (16).
5. Insert J 22813-01 into bore and position it behind
shaft bearing (44) so tangs on tool engage bearing
outer race.
6. Shaft bearing (44), using J 2619-01.
Important
Coat bolt/screw (29) with Loctite 242 or

equivalent before installing.
l~I
Tighten

5. Remove J 39446 from speed sensor reluctor wheel
(39), if vehicle is equipped with standard rear axle
If new speed sensor reluctor wheel (39) was
installed, remove protective covering and throw
away.
6. Rear axle housing cover. Refer to "Rear Axle
SECTION 5B2.
8. Rear brake drum and components, if equipped.
Refer to SECTION 5C2.
16
44
49
63
70
HOUSING, REAR AXLE

SHAFT, REAR AXLE (DRUM BRAKE ASSEMBLY)
SHAFT, REAR AXLE (DISC BRAKE ASSEMBLY)
1-06-95
FS0124B
Figure 12 - Rear Axle Shaft (Typical)
48-14
REAR AXLE
44
J8092 /
Figure 13 - Removing Rear Axl,e Shaft Bearing
l++I
Install or Connect
1. Lubricate new shaft bearing ( 44) with GM

PIN 12345971 axle lubricant or SAE 80W-90
2. Shaft bearing (44) so that tool bottoms against
shoulder in. housing (16), using J 23765 and
J 8092.
3. Lubricate sealing lips with GM PIN 12345971
axle lubricant or SAE 80W-90 GL-5 gear
lubricant or equivalent.
4. Position seal (49) on J 23771 and direct seal (49)
into housing bore.
5. Seal (49) into place, flush with axle tube.
6. Rear brake backing plate, if equipped. Refer to
SECTION 5C2.
7. Rear brake caliper anchor bracket and mounting
plate, if equipped. Refer to SECTION 5B2.
8. Rear axle shaft. Refer to "Rear Axle Shaft" in
this section.
jL-atl
44 BEARING, REAR AXLE SHAFT
1-06-95
FS01448
Figure 14 - Installing Rear Axle Shaft Bearing
4-21-94
FS0164B
Figure 15 - Installing Rear Axle Shaft Bearing Seal
Inspect
Operation of rear axle.

YOKE AND SEAL
Figures 1 through 4 and 16 through 19
Tools Required:
J 8614-2 Pinion Flange Remover Adapter
J 8614-3 Pinion Flange Remover Screw
J 8614-10 Pinion Flange Remover
J 23911 Pinion Oil Seal Installer
!++I
1. Both tires and wheels. Refer to SECTION 3E.

2. Rear brake drums, if equipped. Refer to
SECTION 5C2.
SECTION 5B2.
4. Propeller shaft from differential drive pinion gear
yoke. Refer to SECTION 4A.
A TORQUE WRENCH
3 YOKE, DIFFERENTIAL DRIVE PINION GEAR
4-21-94
FS0164B
Figure 16 - Checking Differential Drive Pinion Gear Prel,oad
5. Mark position of yoke (3), drive pinion gear (23)

and drive pinion gear nut (1) so proper drive
pinion gear inner and outer bearing preload can be
maintained.
6. If universal joint bearings are not retained by a
retainer strap, use a piece of tape to hold bearings
on their journals.
REAR AXLE
48-15
7. Drive
pinion gear nut (1) and washer (2), using

J 8614-10.
Use a suitable container to hold any fluid that

may drain from rear axle.
8. Yoke (3), using J 8614-2, J 8614-3 and J 8614-10.
9. Seal (6) by driving it out of housing (16) with a
blunt chisel. Do not damage housing (16).
jL'l'I
Inspect
Differential drive pinion gear seal surface of yoke

(3) for tool marks, nicks, or damage, such as a
groove worn by seal (6). If damaged, replace yoke
(3).
\
-
/ -.-
Housing bore and remove any burrs that might

cause leaks around outer diameter (OD) of seal
(6\
!++I
Install or Connect
NOTICE:
A WRENCH
4-21-94
FS0174B

Figure 17 - Removing Differential Drive Pinion Gear Nut
1. New seal (6), using J 23911.
2. Apply chassis lubricant, GM PIN 1052497 or

equivalent, to the OD of yoke (3) and sealing lip
of new seal (6).
3. Yoke (3).
4. Washer (2) and drive pinion gear nut (1) finger
tight. .
5. While holding yoke (3), using J 8614-10, tighten
drive pinion gear nut (1) to the same position
marked, then tighten 1.59 mm (1/16 iflch) beyond
the alignment mark.
6. Propeller shaft to differential drive pinion gear
yoke. Refer to SECTION 4A.
7. Rear brake drums, if equipped. Refer to
SECTION 5C2.
8. Rear brake rotors, if equipped. Refer to
SECTION 5B2.
9. Tire and wheels. Refer to SECTION 3E.
10. Lubricant. Refer to "Rear Axle Lubricant Fill and
11. Lower. vehicle.
!L'I'!
Inspect
6. Shock absorbers from housing. Refer to

SECTION 3D.
7. Rear axle tie rod. Refer to SECTION 3D.
8. Rear brake (center) hose from rear brake (center)
hose junction block.. Refer to SECTION 5.
9. Rear springs. Refer to SECTION 3D.
10. Parking brake cables from housing. Refer to
SECTION SF.
11. Eleetrical connectors from wheel speed sensors if
equipped with traction control (75).
12. Rear axle torque arm from housing. Refer to
SECTION 3D.
13. Rear axle lower control arms from housing. Refer
to SECTION 3D.
14. Housing (16) with aid of helper.
!++!
Install or Connect
1. Housing (16), with aid of helper.

2. Rear axle lower control arms to housing. Refer to
SECTION 3D.
3. Rear axle torque. arm to housing. Refer to
SECTION 3D.
Operation of rear axle.
J 8614-2
REAR AXLE
Figures 1 through 4
!++I
Remove or Disco~nect
1. Rear tires and wheels. Refer to SECTION 3E.

2.. Mark propeller shaft and yoke (3).
3. Propeller shaft. Refer to SECTION 4A.
4. Rear stabilizer shaft. Refer to SECTION 3D.
5. Support housing (16) with adjustable lifting
device.
-----::::::
4-,21-94
FS0184B
Figure 18 - Removing Differential Drive Pinion Gear Yoke
48-16
REAR AXLE
J 23911
6 SEAL, DIFFERENTIAL DRIVE PINION GEAR

4-21-94
FS01948
Figure 19 - Installing Differential Drive Pinion Gear Seal
4. Electrical connectors to wheel speed sensors if

equipped with traction control (75).
5. Parking brake cables to housing. Refer to
SECTION SF.
6. Rear springs. Refer to SECTION 3D.
7. Rear brake (center) hose to rear brake (center)
hose junction block. Refer to SECTION 5.
8. Rear axle tie rod. Refer to SECTION 3D.
9. Shock absorbers to housing. Refer to SECTION
3D.
10. Remove adjustable lifting device from housing.
(16).
11. Rear stabilizer shaft. Refer to SECTION 3D.
13. Bleed hydraulic brake system. Refer to
SECTION 5El.
14. Rear tires and wheels. Refer to SECTION 3E.
REAR WHEEL BOLT/SCREW

Figures 20 and 21
A
B
51
61
REAR AXLE SHAFT FLANGE

WASHER
NUT.REAR WHEEL
SOLT/SCREW, REAR WHEEL
8-18-94
FS0214E
Figure 21 - Installing Rear Wheel Bolt/Screw
Wheel bolt/screw hole elongated - Replace

axle shaft.
!++j

2. Rear brake drum, if equipped. Refer to
SECTION 5C2.
SECTION 5B2.
4. Wheel bolt/screw (61) from axle shaft flange
using J 6627-A.
!-++!
Install or Connect
NOTICE:
1. Wheel bolt/screw (61), four washers and wheel
Tool Required:
J 6627-A Wheel Stud Remover
When replacing wheel bolts (hub studs), use
the following guide:
Stripped bolts/screws - Replace bolts/screws
involved.
One loose bolt/screw - Replace all
bolts/screws.
One broken bolt/screw - Replace all
bolts/screws.
A
nut (51) to axle shaft flange.

2. Wheel nut (51) until wheel bolt/screw (61) is
completely seated against axle shaft flange.
I~! Tighten
Wheel nut (51) to 140 N.m (100 lb. ft.).
3. Remove wheel nut (51) and four washers.
4. Rear brake drum, if equipped. Refer to
SECTION 5C2.
SECTION 5B2.
6. Rear tire and wheel, if equipped. Refer to
SECTION 3E.
UNIT REPAIR
J 6627-A
A REAR AXLE SHAFT FLANGE

61 BOLT/SCREW, REAR WHEEL
4-21-94
FS0204B
Figure 20 - Removing Rear Wheel BolVScrew
[I]
Important
Any time components are removed or replaced

within the rear axle housing on vehicles with
standard rear axles only, use J '39446, ABS
Exciter Ring Protector Kit, to prevent damage
to the rear wheel speed sensor reluctor wheel.
rn
REAR AXLE
Important
The driveline components in this vehicle have

been factory system balanced. System balance
provides a smoother running driveline
operation. However, it is essential that the
positions of all driveline components relative
to the propeller shaft and rear axle be observed
and ACCURATELY REFERENCE
MARKED PRIOR TO DISASSEMBLY.
These components include the propeller shaft,
rear axle, differential drive pinion gear yoke,
output shaft, etc ALL COMPONENTS
MUST BE REASSEMBLED IN THE
EXACT RELATIONSHIP TO EACH
OTHER AS THEY WERE WHEN
REMOVED. Additionally, the published
specifications and torque values, as well as any
measurements made prior to disassembly must
be followed to maintain the factory balance.
When a new differential ring gear and drive
pinion gear are installed, the original differential drive
pinion gear yoke should be replaced with a service
differential drive pinion gear yoke. The owner should
be advised not to accelerate rapidly or exceed 80 km/h
(50 mph) for the first 80 km (50 miles) of driving.
Any time the rear axle is taken apart for service,
the following cleaning and inspecting procedures
should be followed:
Select correct ABS exciter ring protector from
J 39446 and attach to speed sensor reluctor
wheel on vehicles with non-traction control
rear axles only.
Clean
All differential bearings thoroughly in clean

solvent.
!L'i'!
Inspect
Bearings visually and by feel. Bearings should

feel smooth when oiled and rotated while
applying as much hand pressure as possible.
Minute scratches and pits that appear on rollers
and races at low mileage are due to the initial
preload, and bearings having these marks should
not be replaced.
Sealing surface of differential drive pinion gear
yoke for nicks, burrs, or rough tool marks which
would cause damage to the differential drive
pinion gear seal and result in an oil leak. Replace
if damaged.
Housing bore and remove any burrs that might
cause leaks around the OD of the drive pinion
gear seal.
Differential ring gear and drive pinion gear teeth
for excessive wear and scoring. If any of these
conditions exist, replacement of the gears as a set
will be required.
Differential drive pinion gear shaft for unusual
wear. Also, check the differential pinion and side
gears and differential pinion gear thrust washers.
48-17
Press fit of the differential bearing inner race on

the differential case hub by prying against the
shoulder at the puller recess in the case.
Differential bearings must be press fit on the hub.
Rear axle failures such as chipped bearings, loose
(lapped-in) bearings, chipped gears, etc. are
indications that foreign material is present. The
rear axle housing must be cleaned.
Speed sensor reluctor wheel on vehicles with
non-traction control rear axles for chipped or
missing teeth; also check for looseness or wobble.
Replace speed sensor reluctor wheel if damaged.
DIFFERENTIAL CASE
Tools Required:
J 22888'-20 Differential Side Bearing Remover
J 8107-2 Differential Side Bearing Remover
Plug
J 21465-13 Driver Handle Extension
J 25299 Differential Side Bearing Installer
J 25588 Side Bearing Shim Installer
!++l
rn
Important
Before removing the differential case from the

rear axle housing, differential ring
gear-to-differential drive pinion gear backlash
must be checked. Refer to "Differential Ring
Gear-to-Differential Drive Pinion Gear
Backlash" in this section. This will indicate
gear or bearing wear or an error in backlash or
preload setting which will help in determining
the cause of axle noise.
J 39446
A PRY BAR
16 HOUSING, REAR AXLE
33 CASE, DIFFERENTIAL
4-21-94
FS0224B
Figure 22 Removing Differential Case
48-18
REAR AXLE
1. Rear axle shafts. Refer to "Rear Axle Shaft" in

this section.
2. Bolt/screw (73) from wheel speed sensor (75) on
vehicles with standard rear axles only.
3. Wheel speed sensor (75) on vehicles with
non-traction control rear axles.
Carefully place wheel speed sensor (75) along
side of housing (16).
rn
Bolts/screws (28) are left-hand thread type.

Discard bolts/screws (28).
4. Ring gear (20) from case (33).
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 when removed to
prevent the case from falling and being
damaged.
6. Case (33) from housing (16).
rn
- Drive ring gear (20) from case (33) using

brass drift and hammer.
Important
Speed sensor reluctor wheel must be replaced

if removed from vehicles with standard rear
axles.
5. Speed sensor reluctor wheel (39) only if
necessary, using brass hammer.
Discard speed sensor reluctor wheel (39).
I+;+!
Assemble

NOTICE:
rn
Disassemble

1. Differential bearing (32) from case (33), if
replacing, using J 22888-20 and J 81072. If
removing an Auburn type limited slip differential
case, skip step 2.
2. Pinion gears (36), thrust washers (37), side gears
(40) and thrust washers (38) from case (33).
Mark side gears (40) and case (33) so side
gears (40) can be reinstalled in their original
position.
Do not pry between ring gear (20), speed

sensor reluctor wheel (39) and case (33), if
ring gear (20) is on tight.
Important
A. Bearing caps (22) should be marked "R" and

"L" to make sure they will be reassembled in
their original locations.
B. Place right and left bearing outer races of
bearings (32) and shims (24) in sets with
marked bearing caps (22) so that they can be
reinstalled in their original positions.
5. Shims (24).
!+!+!
3. All bolts/screws (28) from case (33), if replacing

ring gear (20) or speed sensor reluctor wheel (39).
Important
Before reassembling the differential, lubricate

all parts with GM PIN 12345971 axle lubricant
or SAE 80W-90 GL-5 gear lubricant or
equivalent.
Clean
Connecting surfaces of ring gear (20) and case

(33), if replacing ring gear (20).
J 22888-20
32
32 BEARING, DIFFERENTIAL
1-06-95
FS02348
Figure 23 Removing Differential Bearing

28 BOLT/SCREW, DIFFERENTIAL RING GEAR (LEFT-HAND
THREAD)
4-21-94
FS0244EI
Figure 24 - Differential Ring Gear-to-Differential Case
REAR AXLE 48-19

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.
1. Speed sensor reluctor wheel (39), if removed from
vehicles with non-traction control rear axles.
Carefully place speed sensor reluctor
wheel (39) over case (33) on ring gear side.
2. Ring gear (20), if removed.
On vehicles with standard rear axles, position
ring gear (20) over speed sensor reluctor wheel
(39).
3. Two bolts/screws (28) into opposite sides of ring
gear (20). If converting to an Auburn type limited
slip differential case, skip to step 4.
Install remaining new bolts/screws (28) until
just snug.
!~!
B.
C.
D.
3.
Tighten
New bolts/screws (28) alternately in

progressive stages to 120 N.m (89 lb. ft.).
4. Thrust washers (38), side gears (40), pinion gears
(36) and thrust washers (37) into case (33).
A. Position thrust ..washers (38) over side gear
hubs and install side gears (40) in case (33). If
same parts are reused, install in original sides.
B. Position one pinion gear (36), without thrust
washer (37), between side gears (40) and
rotate side gears (40) until pinion gear (36) is
directly opposite loading opening in case (33).
Place other pinion gear (36) between side
gears (40) so that pinion gear shaft holes are
in line: then rotate gears, lining up holes in
pinion gears (36) with holes in case (33).
C. Rotate pinion gears (36) back toward loading
opening just enough to permit sliding in thrust
washers (37).
5. Differential bearings (32) to case (33), if removed,
using J 8092, J 25299 and J 21465-13.
!++!
A.
If service shims were previously installed, they

can be reused, but whether using new or old
differential bearings (32), adhere to the
following procedure in all cases. If differential
bearings (32) are used again, they must have
original outer. races in place. Refer to
"Differential Bearing Preload Adjustment" in
this section.
Keep shim packs in their respective position,
right or left side.
Select a shim 0.10 mm (0.004 inch) thicker than
the one removed from the left side, then insert left
side shim pack between the spacer and the left
bearing race.
Loosely install bearing cap (22).
Select a shim 0.10 mm (0.004 inch) thicker than
the one removed from the right side and insert
between the spacer (25) and the right bearing
race.
It will be necessary to drive the right shim into
position using J 25588.
Bolts/screws (26).
J 21465-13
J 25299
1-:06,.,.95
32 BEARING, DIFFERENTIAL
FS0254B .
Figure 25 - Installing Differential Bearing
Install or Connect

NOTICE: Refer to "Notice" on page 4B-1.
1. Case (33) into housing (16). Refer to "Differential
Case" in this section.
2. Shims (24).
[I)
Important
Do not attempt to reinstall the production

shims as they may break when tapped into
place.

22 CAP, DIFFERENTIAL CARRIER BEARING
1-06-95
FS02648
Figure 26 - Installing Differential Bearing Shims
48-20
!~!
REAR AXLE
Tighten

4. Check backlash and correct if necessary. Refer to
"Differential Ring Gear-to-Differential Drive
Pinion Gear Backlash" in this section.
5. Rear axle shafts (63 or 70). Refer to "Rear Axle
Shaft" in this section.
6. Wheel speed sensor (75) and bolt/screw (73), if
removed.
!~!
Tighten
A. Use a small button on indicator stem so that

contact can be made near heel end of tooth.
B. Set J 8001 so that stem is in line with gear
rotation and perpendicular to tooth angle for
accurate backlash reading.
2. Check backlash at three or four points around ring
gear (20).
A. Lash must not vary over 0.05 mm (0.002 inch)
around ring gear (20).
B. Drive pinion gear must be held stationary
when checking backlash.
rn
If variation is over 0.05 mm (0.002 inch),

check for burrs, uneven bolting conditions or
distorted case flange and make corrections as
necessary.
VEHICLE SPEED SENSOR RELUCTOR

WHEEL
Refer to "Differential Case" above, for removal
and installation of the speed sensor reluctor wheel on
vehicles with non-traction control rear axles. On
vehicles with traction control (acceleration slip
regulation), the speed sensor reluctor wheel is not
serviceable. If the speed sensor reluctor wheel is
damaged, the rear axle drive shaft must be replaced.
Refer to "Rear Axle Shaft" in this section.
DIFFERENTIAL RING
GEAR-TO-DIFFERENTIAL DRIVE PINION
GEAR BACKLASH
Figure 27
Tool Required:
I++!
Rear axle housing cover. Refer to "Rear Axle

Measure
1. Rotate case (33) several times to seat bearings.
Mount J 8001.
Important
Adjust
1. Backlash at the point of minimum lash should be

between 0.13 mm and 0.23 mm (0.005 inch and
0.009 inch) for all new gears.
2. Backlash by increasing thickness of one shim and
decreasing thickness of other shim the same
amount.
For each 0.03 mm (0.001 inch) change in
backlash desired, transfer 0.05 mm
(0.002 inch) in shim thickness.
To decrease backlash 0.03 mm (0.001 inch),
decrease th.ickness of right shim 0.05 mm
(0.002 inch) and increase thickness of left
shim 0.05 mm (0.002 inch). To increase
backlash 0.05 mm. (0.002 inch), increase
thickness of right shim 0.10 mm (0.004 inch)
and decrease thickness of left shim 0.10 mm
(0.004 inch).
Refer to "Differential Bearing Preload
Adjustment" in the following procedure for
further information.
lHl
Install or Connect
Rear axle housing cover. Refer to "Rear Axle
DIFFERENTIAL BEARING PRELOAD

ADJUSTMENT

1-06-95
FS02749
Figure 27 - Checking Differential Ring Gear-to-Differential

Drive Pinion Gear Backlash
The differential bearing preload adjustment is to

be made before installing the drive pinion gear (23). If
drive pinion gear (23) is installed, remove ring gear
(20). Refer to "Differential Case" in this section.
Differential bearing preload is adjusted by
changing the thickness of both the right and left shims
(24) by an equal amount.
By changing the thickness of both shims (24)
equally, the original backlash will be maintained.
Production shims (24) are cast iron and vary in
thickness from 5.33 mm to 6.91 mm (0.210 inch to
0.272 inch) in increments of 0.05 mm (0.002 inch).
REAR AXLE
Standard service spacers (25)
(0.170 inch) thick and steel service
available from 1.02 mm to 2.08 mm
0.082 inch) in increments of 0.05 mm
[1J
are 4.32 mm
shims (24) are
(0.040 inch to
(0.002 inch).
Important
Do not attempt to reinstall the production

shims (24) as they may break when tapped
into place.
If service shims (24) were previously installed,
they can be reused, but whether using new or
old differential bearing (32), adhere to the
following procedure in all cases. ff differential
bearing (32) are used again, they must have
original outer races in place.
Adjust
1. Determine the approximate thickness of shims

(24) needed by measuring each production shim
(24) or each service spacer (25) and shim pack.
In addition to the service spacer (25), service
shims (24) will be needed. Select a starting
point in service shim thickness. Refer to
Figure 28.
2. Place case (33) with differential bearing outer
races in position in the housing (16).
3. Slip the service spacer (25) between each
differential bearing race and housing (16) with
chamfered edge against housing (16).
NOTICE: Install the left side differential

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.
4.32 mm (0.170") SERVICE

DIFFERENTIAL BEARING SPACER
TOTAL THICKNESS OF
BOTH PRODUCTION
DIFFERENTIAL BEARING
SHIMS REMOVED
10.57 mm (0.416")
10.92 mm (0.430")
11.18mm (0.440"1
11.43 mm (0.450" l
11.68 mm (0.460")
11.94 mm (0.4 70")
12. 19 mm (0.480")
12.45 mm (0.490")
12.70mm (0.500")
12.95mm (0.510"1
13.21 mm(0.520")
13.46 mm (0.530")
13.97 mm (0.550")
TOTAL THICKNESS OF
SERVICE DIFFERENTIAL
BEARING SHIMS TO BE
USED AS A STARTING POINT
4. Select one or two shims (24) totaling the amount

shown in the right-hand column of Figure 28 and
position between the right side differential bearing
race and service spacer (25).
Be sure left side differential bearing race and
spacer (25) are against left side of housing
(16).
5. Insert progressively larger feeler gage sizes 0.25
mm, 0.30 mm, 0.36 mm, etc. (0.010 inch, 0.012
inch, 0.014 inch, etc.) between the right shim (24)
and service spacer (25) until there is noticeable
increase in drag.
6. Push feeler gage downward until end of gage
makes contact with housing bore to obtain a
correct reading.
The point just before additional drag begins is
the correct feeler gage thickness.
7. Rotate case (33) while using feeler gage to ensure
an even reading.
The original light drag is caused by weight of
case (33) against housing (16) while additional
drag is caused by differential bearing preload.
By starting with a thin feeler gage, a sense of
"feel" is obtained so the beginning of preload
can be recognized to obtain zero clearance.
It will be necessary to work case (33) in and
out and to the left in order to insert feeler
gage.
8. Remove left side differential bearing cap (22) and
shim (24) from housing (16).
9. The total shim pack needed, with no preload on
differential bearings (32), is the feeler gage
reading found in step 7 plus the thickness of
shims (24) installed in step 4.
10. Select two shims (24) of approximately equal size
whose total thickness is equal to the value
obtained in step 9.
These shims (24) will be installed between
each differential bearing race and service
spacer (25) when case (33) is installed in
housing (16).
The preload will not be added until case (33)
is installed.
11. If drive pinion gear is in position, install ring
gear. Refer to "Differential Case" in this section ..

Figures 1 through 4, 16, 19, 29 and 30
1.52 mm (0.060")
Tools Required:
J 22536 Pinion Driver
J 23911 PiniQn Oil Seal Installer
1. 78 mm (0.070")
2.03 mm 10.oao I
2.29 mm (0.090")
2.54 mm (0.100"1
2.79mm (0.110")
3.05 mm (0.120")
3. 30 mm 10.130")
3.56 mm (0.140")
3.81 mm (0.150"1
4.06 mm (0.160")
4.32 mm (0.170")
4.83 mm (0.190")
<4-21-94
FS0284B
Figure 28 - Differential Bearing Shim Thickness
48-21
!.,-+!
1. Differential case. Refer to "Differential Case" in

this section.
2. Check differential drive pinion gear inner and
outer bearing preload. If there is no preload
reading, check for looseness of drive pinion gear
(23) by shaking. Looseness could be caused by
defective inner and outer bearing (18 and 7) or
48-22
REAR AXLE
worn yoke (3). If the rear axle was operated for

an extended period with very loose inner and
outer bearings (18 and 7), ring gear (20) and drive
pinion gear (23) will also require replacement.
3. Differential drive pinion gear yoke. Refer to
"Differential Drive Pinion Gear Yoke and Seal"
in this section.
4. Drive pinion gear (23), using J 22536. Apply
heavy hand pressure on J 22536 toward housing
(16) to keep outer bearing (7) seated to avoid
damage to outer race.
!++!
Install or Connect
1. If installing new ring gear and drive pinion gear,

measure differential drive pinion gear depth. Refer
to "Differential Drive Pinion Gear Depth" in this
section.
2. Drive pinion gear (23) into housing (16).
3. Differential drive pinion gear yoke (3).
A. Install new seal (6) using J 23911.
B. Apply pinion gear seal lubricant GM
PIN 1050169 or equivalent to yoke (3) and
sealing lip of new seal (6).
C. Yoke (3).
D. Washer (2) and nut (1) finger tight.
E. Hold yoke (3).
F. While intermittently rotating drive pinion gear
(23) to seat inner and outer bearings (18 and
7), tighten nut (1) until end play begins to be
taken up.
.[I]
After preload has been checked, final

tightening should be done very carefully.
Additional tightening of nut (1) can add many
additional pound inches of torque.
Nut (1) should be further tightened only
slightly and preload should be checked after
each tightening.
Exceeding preload specifications will compress
the collapsible spacer (15) too far and require
installation of a new collapsible spacer (15).
4. Set preload at 1.7 N,m to 3.4 N,m (15 lb. in. to
30 lb. in.) on new inner and outer bearings
(18 and 7) or LO N,m to 1.7 N,m (10 lb. in. to 15
lb. in.) on used .inner and outer bearings
(18 and 7).
5. Rotate drive pinion gear (23) several times to
ensure that inner and outer bearings ( 18 and 7)
have been seated.
A. Check preload again.

B. If preload has been reduced by rotating drive
pinion gear (23), reset pre load to
specifications.
this section.

Bearing
Tools Required:
J 7817 Front Pinion Bearing Cup Installer
Important
When no further end play is detectable and

when holder will no longer pivot freely as
drive pinion gear (23) is rotated, preload
specifications are being approached.
No further tightening should be attempted until
preload has been checked.
!++!
1. Differential drive pinion gear from rear axle

housing. Refer to "Differential Drive Pinion
Gear" in this section.
2. Differential drive pinion gear seal from rear ax.le
housing. Refer to "Differential Drive Pinion Gear
Yoke and Seal" in this section.
23
A
B
16
23
CHANNEL LOCKING PLIERS

WRENCH
HOUSING, REAR AXLE
01-05-95
FS0294B
Figure 29 - Installing Differential Drive Pinion Gear Driver

1-08-95
FS0304B
Figure 30 - Removing Differential Drive Pinion Gear
REAR AXLE
48-23
3. Outer bearing (7) from housing (16).

4. Outer bearing race from housing (16), if replacing
outer bearing (7).
Drive race from housing (16), using a punch
in slots provided for this purpose.
!++j
Install or Connect
1. Outer bearing race into housing (16), if removed,

using J 8092 and J 7817.
2. Outer bearing (7) into housing (16).
3. Differential drive pinion gear seal. Refer to
"Differential Drive Pinion Gear Yoke and Seal"
in this section.
4. Differential drive pinion gear. Refer to
"Differential Drive Pinion Gear" in this section.
Differential Drive Pinion Gear Inner

Bearing
1.
2.
3.
4.
!++l
Tools Required:
J 22912-01 Rear Pinion Bearing Remover
J 29609 Rear Pinion Bearing Cup Installer
J 5590 Rear Pinion Bearing Cone Installer
Differential drive pinion gear. Refer to
Spacer (15) from drive pinion gear (23).
Discard spacer (15).
Drive pinion gear inner bearing race from housing
(16), if replacing inner bearing (18).
Drive race from housing (16) using a punch in
slots provided for this purpose.
Drive inner bearing (18) from drive pinion gear
(23) using J 22912-01.
using J 5590.
2. Drive inner bearing race into housing (16) using
J 8092 and J 29609, if inner bearing (18) was
replaced.
3. New spacer (15) onto drive pinion gear (23).
4. Differential drive. pinion gear. Refer to
4-21-94
FS03148
Figure 31 Installing Differential Drive Pinion Gear Outer

Bearing Race
FS0324&
Figure 32 Removing Differential Drive Pinion Gear Inner

Bearing
18 BEARING, DIFFERENTIAL DRIVE PINION

GEAR INNER
Install or Connect
1. Inner bearing (18) onto drive pinion gear (23)
4-21-94
A OPENING IN TOOL MUST BE SUPPORTED
1-06-95
FSOG34B
Figure 33 Installing Differential Drive Pinion Gear Inner

Bearing

DEPTH
Tools Required:
J 23597-1 Pinion Setting Gage - Arbor
J 23597-11 Pinion Setting Gage - Gage Plate
J 21777-40 Pinion Setting Gage - Rear Pilot
Washer
J 21777-42 Pinion Setting Gage - Front Pilot
Washer
J 21777-43 Pinion Setting Gage - Stud
Assembly - Bolt
J 21777-45 Pinion Setting Gage - Side
.
Bearing Discs
Differential drive pinion gear depth is
m.easur~d with a pinion setting gage. The gage
provides a "nominal" or "zero" pinion as a
gauging reference.
48-24
REAR AXLE
lHI
Install or Connect
NOTICE: Refer to "Notice" on page 4B-1. .t
1. J 21777-40 through J 21 777-43.

2. J 23597-11.
3. J 777-42 and nut in housing (16).
l~I
A RACE. DIFFERENTIAL DRIVE PINION GEAR INNER
BEARING
1-06-95
FS0344B
Figure 34 - Installing Differential Drive Pinion Gear Inner

Bearing Race
J 8001
Nut to 2.3 N.m (20 lb. in.).

4. Rotate J 23597-11 to seat inner and outer bearings
(18 and 7).
5. Mount J 8001 on J 23597-1 and preload indicator
against plunger about 1.27 mm (0.050 inch).
6. J 21777-45 on J 23597-l and position unit in
housing (16).
7. Bearing caps (22) and bolts/screws (26).
l~I
J 23597-11
J 21777-43
J 21777-42
. 7 BEARING, DIFFERENTIAL DRIVE PINION GEAR OUTER

18 BEARING, DIFFERENTIAL DRIVE PINION GEAR INNER
1-06-95
FS0354B
Figure 35 - .Pinion Gage Plate Installed in Rear Axle
Housing
Disl:l~semble
~Difforential case. Refer to "Differential Case"
in this section.
I++!
Differential drive pinion gear inner bearing.
Refer to "Differential Drive Pinion Gear Inner
Bearing" in this section.
~
1.
2.
3.
4.
Tighten
Bolt/screws (26) to 75 N.m (55 lb. ft.).
!@!
!{+I
Tighten
Clean
All parts of gage.

Differential bearing bore.
Inner and outer bearing cups.
Lubricate inner and outer bearings (18 and 7) with
.GM PIN 12345971 axle lubricant or SAE 80W-90
Measure
Differential drive pinion gear depth.

A. Rotate J 23597-1 slowly back and forth until
J 8001 reads the greatest deflection (the point
where the needled changes direction). At that
point, set J 8001 to zero.
B. Repeat rocking action to verify zero setting.
C. After zero setting is obtained, rotate J 23597-1
just until plunger no longer touches
J 23597-11. This provides the gauging
reference of a "zero" or "nominal" drive
pinion gear (23).
D. Record J 8001 reading at pointer position. This
indicates the proper shim to use. Example: if
pointer moved counterclockwise 1.70 mm
(0.067 inch) to a dial reading of 0;84 mm
(0.033 inch), this indicates a shim thickness
of.84 mm (0.033 inch).
E. Required shim thickness is EQUAL to J 8001
reading.
F. Shims are available in 0.03 mm to 0.94
mm(0.001 inch to 0.037 inch). Shim thickness
is etched on the flat surface for easy
identification.
I++!
Install or Connect
1. Loosen J 21777-43 and remove special tools and

inner and outer bearings (18 and 7) from housing,
(16).
.
2. Correct shim (19) on drive pini<J,Q. gear (23).
'f',.V"
[I]
Important
' ;)
Proper drive pm1on gear depth settui.g is a

two-step procedure.
.. ,~("
a. The set-up dimension arriv~ita.t using
J 8001 is to be considered a ~t~ing poin:t.
REAR AXLE
48-25
22
26
A OFF GAGE BLOCK

B ON GAGE BLOCK
,
22 CAP, DIFFERENTIAL CARRIER BEARING
26 BOLT/SCREW, DIFFERENTIAL BEARING CAP
4-21-94
FS0364B
Figure 36 - Checking Differential Drive Pinion Gear Depth
b. A ring gear tooth pattern check is

necessary to fine tune the drive pinion gear
depth and may indicate additional shim
changes to the drive pinion gear stem.
Refer to "Tooth Contact Pattern Test" in
this section.
Both procedures must be performed to ensure
proper rear axle performance.
3. Differential drive pinion gear inner and outer
bearing. Refer to "Differential Drive Pinion Gear
Inner Bearing" and "Differential Drive Pinion
Gear Outer Bearing" in this section.
!+;+!
Assemble
Differential case. Refer to "Differential Case"

in this section.
!ti!
Measure
Preload of the total at the .drive pinion gear nut

(1). With new inner ,!illd outer bearings (18 and
7), preload is 3.6 N.m to 6.2 N.m (32 lb. in .. to 55
lb. in.) rotating torque with a new seal (6). With
used inner and outer bearing (18 and 7), preload
is 1.8 N.m to 3.1 N.m (16 lb. in. to 28 lb. in.)
rotating torque with a new seal (6).
DIFFERENTIAL CASE (LIMITED SLIP)

Figure 37
The Auburn limited slip differential case (80) is
non-serviceable and must be replaced as a rinit.
Removal and replacement of the differential case and
service on the side bearings and ring gear is the same
as for the standard rear axle.
REAR AXLE HOUSING REPLACEMENT

It is not necessary to remove the rear axle
housing for any nonnal repairs. However, if the rear
axle housing is damaged, it may be removed and
installed using the following procequres:
Rear Axle Housing with Drum Brakes
!++!
1. Rear axle. Refer to "Rear Axle" in this section.

2. Rear brake pipes from rear wheel brake cylinders.
Refer to SECTION 5.
3. Rear brake pipes from rear brake (center) hose
junction block. Refer to SECTION 5.
4. Rear brake (center) hose junction block from
housing. Refer to SECTION 5.
5. Rear brake pipes from housing. Refer to
SECTIONS,
6. Rear axhf.$h~ft bearings and seals. Refer to "Rear
Axle Shaft Bearing and/or ;]learing, Seal" in this
section.
48-26
REAR AXLE
!++!
Rear axle. Refer to "Rear Axle" m this
section.
!+!+!
29 BOLT/SCREW, DIFFERENTIAL PINION GEAR SHAFT

LOCK
80 CASE, AUBURN DIFFERENTIAL (NON-SERVICEABLE)
01-05-95
FS0374B
Figure 37 - Limited Slip Rear Axle -Auburn-Type
7. Rear brake backing plates. Refer to

SECTION 5C2.
this section.
lH!
Install or Connect

this section.
3. Rear brake backing plates. Refer to
SECTION 5C2.
4. Rear axle shaft bearings and seals. Refer to "Rear
Axle Shaft Bearing and/or Bearing Seal" in this
section.
5. Rear brake pipes to housing. Refer to
SECTION 5.
6. Rear brake pipes to rear wheel brake cylinders.
Refer to SECTION 5.
7. Rear brake (center) hose junction block to
8. Rear brake pipes to rear brake (center) hose
9. Rear axle. Refer to "Rear Axle" in this section.
Rear Axle Housing with Disc Brakes

A shim (67) may be installed between the rear
brake caliper mounting plate (65) and the axle shaft
tube flange on the housing (16). This shim (67)
centers the rear brake caliper and pads over the brake
rotor (71), ensuring even brake pad pressure during
braking. This shim (67) may have to be changed when
the housing {16) is replaced.
Disassemble
1. Rear brake pipes from brake hoses. Refer to

SECTION 5.
2. Rear brake pipes from rear brake (center) hose
3. Rear brake (center) hose junction block from
4. Rear brake pipes from housing. Refer to
SECTION 5.
5. Rear brake hose from housing. Refer to
SECTION 5.
6. Rear brake shaft bearings and seals. Refer to
"Rear Axle Shaft Bearing and/or Bearing Seal" in
this section.
7. Rear brake caliper anchor brackets and mounting
plates. Refer to SECTION 5B2.
8. Shim (67), if installed.
this section.
!+++I
Assemble
1. Differential drive pm10n gear. Refer to

this section.
4. Rear axle shaft bearings and seals, but do not
tighten lock bolt/screw at this time. Leave lock
bolt/screw finger tight. Refer to "Rear Axle Shaft
Bearing and/or Bearing Seal" in this section.
!@!
Measure
1. Distance from rear face of rear brake caliper

mounting plate (65) (tube flange mounting
surface) to front face of machined axle shaft tube
flange, using a caliper.
2. Select shim (67). Refer to Figure 38.
!+!+I
Disassemble
1. Rear axle shaft. Refer to "Rear Axle Shaft" in

this section.
!+!+!
Assemble
1. Shim (67), if necessary.

REAR AXLE
48-27
71
DISTANCE "An
SHIM THICKNESS REQUIRED*
68.625-69.79 mm {2.70"-2.74"}
69.800-70.955 mm (2.75"-2.79")
0.60 mm (0.024")
GM PART NUMBER
NO SHIM REQUIRED
26034667
* ORIGINAL SHIM, IF INCLUDED, MAY BE PROPER THICKNESS TO REUSE.

A DIMENSION USED TO DETERMINE SHIM
65 PLATE, REAR BRAKE CALIPER MOUNTING
71 ROTOR, REAR BRAKE
1-06-94
FS03848
Figure 38 - Brake Caliper Mounting Plate Shim Selection
3. Rear brake hoses to housing. Refer to

SECTION 5.
4. Rear brake pipes to housing. Refer to
SECTION 5.
5. Rear brake (center) hose junction block to
6. Rear brake pipes to rear brake (center) brake

7. Rear brake pipes to brake hoses. Refer to
SECTION 5.
!H!
Install or Connect
Rear axle. Refer to "Rear Axle" in this
section.
4828
REAR AXLE
SPECIFICATIONS
Use a reliable torque wrench to tighten the parts listed to make sure the parts are properly tightened without
straining or distorting parts. These specifications are for clean and lightly-lubricated threads only; dry or dirty
threads produce increased friction which prevents measurement of tightness.
Differential Bearing Cap Bolt/Screw ...................................................................................... 75 N.m (55 lb. ft.)
Differential Drive Pinion Gear Setting Gage Nut. ............................................................... 2.3 N.m (20 lb. in.)
Differential Pinion Gear Shaft Lock Bolt/Screw ....................................... ;............................ 36 N.m (27 lb. ft.)
Differential Ring Gear (Left-Hand Thread) Bolt/Screw ...................................................... 120 N.m (89 lb. ft.)
Rear Axle Housing Bolt/Screw ............................................................................................... 30 N.m (22 lb. ft.)
Rear Axle Housing Drain (Fill) Plug .. ;.................................................................................. 35 N.m (26 lb. ft.)
Sensor Plug Mounting Bolt/Screw ......................................................................................... 10 N.m (89 lb. in.)
Wheel Nut .............................................................................................................................. 140 N.m (100 lb.ft.)
Rear Axle Type .................................................................................................................... Semi-Floating Hypoid
Drive and Torque ...................................................................................................:..................... Through 4 Arms
Ring and Drive Pinion Gear Set Type ............................................... ,.................. -..................................... Hypoid
Rear Axle Lubricant Capacity ....................................................................................................... 1.65 L (3.5 pt.)
Rear Axle Lubricant
Standard Differential.. PIN 12345971 Axle Lubricant or SAE 80W-90 GL-5 Gear Lubricant or equivalent
Limited Slip Differential59ml (2 fl.oz.) GM PIN 1052358 Limited Slip Differential Lubricant and GM PIN
12345971 Axle Lubricant or SAE 80W-90 GL-5 Gear Lubricant or equivalent
Chassis Lubricant ........................................................................................... GM PIN 1052497 or equivalent
Ring and Pinion Gear Marking Compound .................................................. GM PIN 1052351 or equivalent
LIMITS FOR FITTING AND ADJUSTING

Differential Drive Pinion Gear Inner and Outer Bearing Preload
(Measured at Drive Pinion Gear Nut)
New Bearings ............................................. 1.7 - 3.4 N.m (15 - 30 lb. in.) Rotating Torque with New Seal
Used Bearings ............................................. 1.0 - 1.7 N.m (10 - 15 lb. in.) Rotating Torque with New Seal
Total Preload
(Measured at Drive Pinion Gear Nut)
New Bearings ........................................ :.... 3.6 - 6.2 N.m (32 - 55 lb. in.) Rotating Torque with New Seal
Used Bearings ............................................. 1.8 - 3.1 N.m (16 - 28 lb. in.) Rotating Torque with New Seal
Differential Ring Gear-to-Differential
Drive Pinion Gear Backlash ......................................................... 0.13 - 0.23 mm (0.005 inch - 0.009 inch)
(
\
REAR AXLE USAGE CHART

ENGINE
{RPO)
TRANSMISSION
REAR AXLE
RATIO
REAR AXLE
RPO
RING GEAR
DIAMETER
REAR
BRAKE
TEETH RING
GEAR:
PINION
5-SPD MANUAL
(M49, MN5)
3.23
GU5
8-1/2"
DRUM
42:13
3.08
GU4
8-1/2"
DRUM
40:13
3.42
GU6
8-1/2"
DRUM
41:12
3.42
GU6
8-112"
DISC
41:12
2.73
GU2
8-1/2"
DISC
41:15
3.23
GU5
8-1/2"
DISC
41:13
3800-V6 (L36) 4-SPD AUTOMATIC

(M30, MXO)
6-SPD MANUAL
(MM6, MN6)
5.7L-V8 (LTl) 4-SPD AUTOMATIC
(M30, MXO)
T5689
REAR AXLE
48-29
SPECIAL TOOLS
J 6627-A
4-21-.94
1 WHEEL STUD REMOVER
FS04048
~=====lllDP;illlll;=====::;::,~
J 8614-10
J 8614-2
J 8614-01 SET
2 <F!IUOUIIO'lll~ J 8614-3
1 PINION FLANGE REMOVER ADAPTER
2 PINION FLANGE REMOVER SCREW
3 PINION FLANGE REMOVER
4-21-94
FS0414B
3.
J 23597-1
1.
4.
2.
J 21777-40
J 21777-42
J23597-11
PWBIOP
s. QOIOIOII
J 21111-43
. 7 1/2" AND 7 5/8" RING GEAR REAR AXLE
1. PINION SETTING GAGE -ARBOR

2.
3:
4.
5.
6.
PINION
PINION
PINION
PINION
PINION
SETTING
SETTING
SETTING
SETTING
SETTING
GAGE GAGE GAGE GAGE GAGE -
GAGE PLATE
REAR PILOT WASHER
FRONT PILOT WASHER
STUD ASM-BOLT
SIDE BEARING DISCS
6.
J 21777-45
4-21-94
FS04248
4830
REAR AXLE
1.
~
J
(dm
12.
2619-01
2.
((0
J 22536
J 23771
gD
13.
8.
J 23911
J 7817
J 22813-01
3.
~,~
J80~Y<
J 25299
9.
(J>
4.
Ql)
14.
J 22888-20
C\
15.
J 8092
J 25588
10.
(9L,
J 22912-01
J 8107-2
~~
16.
J 29609
6.
11.
J 21579
,.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
17.
J 23765
J 5590
7 1/2" AND 7 5/8" RING GEAR REAR AXLE

SLIDE HAMMER WITH 1/2 X 13 ADAPTER
FRONT PINION BEARING CUP INSTALLER
DIAL INDICATOR SET
DRIVER HANDLE
DIFFERENTIAL SIDE BEARING REMOVER PLUG
AXLE SHAFT REMOVER
PINION DRIVER
AXLE BEARING REMOVER
DIFFERENTIAL SIDE BEARING REMOVER
REAR PINION BEARING REMOVER
AXLE BEARING INSTALLER
AXLE OIL SEAL INSTALLER
PINION OIL SEAL INSTALLER
DIFFERENTIAL SIDE BEARING INSTALLER
SIDE BEARING SHIM INSTALLER
REAR PINION BEARING CUP INSTALLER
REAR PINION BEARING CONE INSTALLER
ABS EXCITER RING PROTECTOR KIT
DRIVER HANDLE EXTENSION
{)
18.
J 39446
19.
[JD
(
J 21465-13
4-21-94
FS0434B
BRAKES
51
BRAKES
CONTENTS
Brakes .............................................................. Section 5
Master Cylinder ............................................ Section 5A
Front Disc Brakes ...................................... Section 5Bl
Rear Disc Brakes ....................................... Section 5B2
Duo-Servo Drum Brakes ........................... Section 5C2
Vacuum Booster System ............................ Section 5Dl

Antilock Brake System ............................... Section 5El
Antilock Brake System with Traction
Control System ................................... Section 5E2
Parking Brake ................................................ Section 5F
SECTION 5
BRAKES
CAUTION: Certain components in the Antilock Brake System are not intended to be serviced
individually. Attempting to remove or disconnect certain system components may result in
personal injury and/or improper system operation. Only those components with approved
removal and installation procedures in Sections 5, 5E1, 5E2, or 5E3 should be serviced.
CAUTION: When servicing brake parts, do not create dust by grinding, sanding brake linings, or
by cleaning brake parts with a dry brush or compressed air. Brake parts may contain asbestos
fibers which can become airborne if dust is created during servicing. Breathing dust containing
asbestos fibers may cause serious bodily harm. A water dampened cloth or water based
solution should be used to remove any dust on brake parts. Equipment is commercially
available to perform this washing function. These wet methods will prevent asbestos fibers from
becoming airborne.
CAUTION: Brake fluid may irritate eyes and skin. In case of contact, take the following actions:
Eye contact - rinse thoroughly with water.
Skin contact - wash w.ith soap and water.
If ingested - consult a physician immediately.
NOTICE: The use of rubber hoses or parts other than those specified for the Antilock Brake System (ABS)
may lead to functional problems requiring replacement of the hydraulic parts. Replace all components included
in iepair kits used to service this system. Lubricate rubber parts with clean, fresh, approved brake fluid to ease
assembly. Do not use lubricated shop air on brake parts, as damage to rubber components may result. If any
hydraulic component is removed or brake line disconnected, it may be necessary to bleed all or part of the brake
system. The fastener tightening specifications listed are for dry, unlubricated fasteners.
and systems.
NOTICE: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wrrmg cables or electrical
connectors. Brake fluid will damage paint and electrical connections. If any fluid is spilled on the vehicle,
immediately flush the area with water to minimize the potential for damage.
5-2
BRAKES
CONTENTS
General Description ................................................... 5-2
Brake Fluid and Fluid Handling .......................... 5-2
Substandard or Contaminated Brake Fluid ...... 5-2
Flushing Brake Hydraulic System .................... 5-2
Brake Combination Valve ..................................... 5-2
Brake Pressure Differential Warning Switch ... 5-2
Brake Proportion Valve ..................................... 5-2
Warning/Indicator Lamp Operation ...................... 5-3
Brake .................................................................. 5-3
Antilock ............................................................. 5-3
Diagnosis ................................................................... 5-3
Brake System Testing ........................................... 5-3
External Conditions That Affect Brake
Performance ..................................................... 5-3
Brake System ......................................................... 5-3
Brake Pedal Travel. ............................................... 5-3
Brake Fluid Leaks ................................................. 5-5
Brake Hose and Pipe Inspection ...................... 5-5
Brake Fluid ............................................................ 5-5
Brake Indicator Diagnostic
Charts ................................ Refer to Section 8A-41
On-Vehicle Service .................................................... 5-5
GENERAL DESCRIPTION
BRAKE FLUID AND FLUID HANDLING
CAUTION: Brake fluid may irritate eyes
and skin. In case of contact, take the
following actions:
Eye contact - rinse thoroughly with
water.
Skin contact - wash with soap and
water.
If ingested - consult a physician
immediately.
NOTICE: Avoid spilling brake fluid on any of
the vehicle's painted surfaces, wiring, cables or
electrical connectors. Brake fluid will damage
paint and electrical connections. If any fluid is
spilled on the vehicle, immediately flush the
area with water to minimize the potential for
damage.
[I]
Important
Do not re-use fluid accumulated during brake

hydraulic system bleeding.
Always store brake fluid in a closed container.
Reseal brake fluid containers immediately after
use. Do not use fluid left in an open or
improperly sealed container as it absorbs
moisture or can become contaminated.
Substandard or Contaminated Brake Fluid

Use only SUPREME 11 (GM 1052542) or
equivalent DOT 3 brake fluid from a clean, sealed
container. Do not use fluid from an oper container that
may be contaminated with water. Improper fluid could
result in damage to components.
Filling Brake Master Cylinder

Reservoir ............................... Refer to Section SA
Brake Pedal with Bracket. .................................. 5-5
Brake Pedal ......................................................... 5-9
Stoplamp and Cruise Control Switches ............. 5-9
Adjustment ....................................................... 5-9
Replacement .................................................... 5-10
Brake Pipe ................... ,....................................... 5-10
Double Lap Flare ............................................ 5-10
ISO Flare ......................................................... 5-12
Brake Combination Valve ................................... 5-14
Brake Hoses ........................................................ 5-21
Front Brake Hose ............................................ 5-21
Rear Brake (Center) Hose .............................. 5-22
Rear Brake Hose ............................................. 5-23
Bleeding Brake Hydraulic
System .................................. Refer to Section 5El
Flushing Brake Hydraulic System ...................... 5-24
Specifications ........................................................... 5-24
General Specifications ......................................... 5-24
Special Tools ........................................................... 5-25
Flushing Brake Hydraulic System

The system must be flushed if there is any doubt
about the condition of the fluid in the system or if
fluid has been used which contains the slightest trace
of petroleum or mineral oil based fluids.
Approximately 1.5 liters (1.5 quarts) of hydraulic
brake fluid is required to flush the brake hydraulic
system. Refer to "Flushing Brake Hydraulic System"
under "On-Vehicle Service" in this section for more
information.
BRAKE COMBINATION VALVE

The non-serviceable brake combination valve is
located under the hood, mounted to the ABS
modulator on the left engine compartment side inner
rail. The brake combination valve incorporates the
following functions into a single component:
Brake Pressure Differential Warning Switch

The brake pressure differential warning switch
monitors the front and rear brake systems to measure
any difference in hydraulic pressure between the two
systems. If a sufficient pressure differential exists
between the systems, an electrical ground is made
energizing the red "BRAKE" warning lamp if the
ignition is on. The brake combination valve and brake
pressure differential warning switch are also designed
so the warning switch will latch in the warning
position once a malfunction has occurred. The
"BRAKE" warning lamp will turn off only after the
malfunction is repaired and a pedal .force sufficient to
develop approximately 3 100 kPa (450 psi) hydraulic
brake pressure is applied.
Brake Proport.ion Valve

The brake proportion valve improves
front~to-rear brake balance under severe brake
applications. Severe brake applications transfers part of
the vehicle's rear weight to the front wheels. The
BRAKES 5-3
resulting decrease in weight at the rear wheels can
cause reduced brake efficiency. The brake proportion
valve limits the pressure to the rear brakes to reduce
the tendency for reduced brake efficiency. The
proportion valve also has a by-pass feature which
assures full system pressure to the rear brakes in the
event of a front system brake failure. Full front system
pressure is retained in the event of rear brake system
malfunction.
greasy or covered with loose dirt so that all the tires

do not grip the road equally. Testing will also be
affected if the roadway is crowned, which would
throw the weight of the vehicle toward the wheels on
one side. If the roadway is too rough, the wheels will
tend to bounce.
Test brakes at different vehicle speeds with both
light and heavy brake pedal force.
WARNING/INDICATOR LAMP OPERATION
External Conditions That Affect Brake

Performance
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 come on. It should
go off when the ignition switch returns to the "RUN"
position. The following conditions will activate the
"BRAKE" warning lamp:
1. Parking brake applied. Lamp should be on when
parking brake is applied and ignition switch is
"ON."
2. Brake pressure differential warning switch detects
failure. Refer to SECTION 8A for diagnosis.
3. During engine cranking "BRAKE" warning lamp
should remain on. This notifies driver that
warning circuit is operating properly.
Antilock
The antilock brake system (ABS) uses three
indicator lamps: the red "BRAKE" warning lamp, an
amber "ABS INOP" indicator lamp and an amber
"LOW TRAC" indicator lamp, all located in the
instrument cluster. Under normal conditions, these
lamps should operate as follows:
1. When ignition is turned to "RUN" position, prior
to starting engine, amber "ABS INOP" indicator
lamp should go on and red "BRAKE" warning
lamp should flash.
2. As engine is cranked, both red "BRAKE"
warning lamp and amber "ABS INOP" indicator
lamp should come on and "LOW TRAC"
indicator lamp may come on and off.
3. When engine is started, amber "ABS INOP" and
red "BRAKE" lamps should go out and "LOW
TRAC" indicator lamp may come on and off. The
operation of these three indicator lamps is an
important part of the antilock brake system (ABS)
diagnosis. If the warning/indicator lamps turn on
while driving the vehicle, this indicates a
malfunction. If the warning/indicator lamps do not
tum on under normal conditions as described
above, service the lamps as soon as possible. For
further information regarding warning/indicator
lamp operation for the antilock brake system
(ABS), refer to SECTION 5El.
DIAGNOSIS
BRAKE SYSTEM TESTING
Brakes should be tested on a dry, clean,
reasonably smooth, level roadway. A true test of brake
performance cannot be made if the roadway is wet,
TIRES
Tires having unequal contact and grip on the

road will cause unequal braking. Tires must be equally
inflated, and the tread pattern. of right and left tires
must be approximately equal.
VEHICLE LOADING
A heavily loaded vehicle requires more braking

effort. When a vehicle has unequal loading, the most
heavily loaded wheels require more braking power
than others.
WHEEL ALIGNMENT
Misalignment of the wheels, particularly

excessive camber and caster, will cause the brakes to
pull to one side.
BRAKE SYSTEM
Figure 1
For diagnosis of the brake hydraulic system,
refer to Figure 1.
BRAKE PEDAL TRAVEL

Most low brake pedal problems are caused by
air in the brake system or misadjusted rear drum
brakes. Bleed the system until air is purged and check
rear brake adjustment. Refer to SECTION 5El. Other
less frequent causes of excessive brake pedal travel are
incorrect pushrod length, rear brake shoe adjusters not
operating, linings excessively worn, and brake
hydraulic system leakage.
High brake pedal force problems are usually
caused by low engine vacuum, a vacuum leak, or an
improperly functioning vacuum booster. These
conditions would also result in higher than normal
brake pedal efforts.
l@I
Measure
Tool Required:
J 28662 Brake Pedal Effort Gage
1. Install J 28662 onto brake pedal.
2. Hook end of tape measure over top edge of pedal
and measure the distance to rim of steering wheel.
3. With engine running at idle and the shift lever in
"NEUTRAL"" and the wheels and tires blocked,
apply brake pedal with 445 N (100 lb.) force and
5-4
BRAKES
...e
.;
'C
iii
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L@aking Piston Seal
Leaking Master Cylinder (Internal)

Air in Brake System
Contaminated or Improper Brake Fluid
Leaking Vac. or Booster Sys.
Restricted Passage in Vacuum Booster
Damaged Vacuum Booster
Worn Out Brake Lining
Uneven Brake Lining Wear
Glazed Brake Lining
Incorrect Lining Material
Contaminated Brake Lining
Lining Damaged by Abusive Use
Improper Rotor Surface Finish
Scored Rotor
Improper Thickness Variation in Ro,tor
Excessive Lateral Run-out in Rotor
Brake Asm. Attachm11nts Loose
(Incl, Splash Shield!
Restricted Brake Fluid Pas53ge
Improperly Adj. Stoplamp Switch or Cruise
Control Vacuum Dump
Brake Pedal Linkage Interference or Binding
Incorrect Vacuum Booster Push rod Length
Incorrect Front Wheel Align.
Incorrect Tire Pressure
Loose Front Suspension Perts
Out-of-be lance Wheel Assm.
Operator Riding Brake Pedal
Sticking Caliper or Caliper Pistons
Q)
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x x x
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XX INDICATES MORE PROBABLE CAUSE(S)
5B,5C
5B,5C
SB.SC
5B,5C
5B,5C
58
58
58
5
501
3A
3A
3C
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Grease/Dirt on Rotor
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5
58
Parking Brake Cables Seized
.::u
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x
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x x x
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Poor Drum Surface Finish
ABS Modulator RA Piston Seized
.5
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xx x
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xx
x
Improperly Torqued Wheel Nuts
Rotor Corroded
Q)
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x x xx
xx
x
x
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x x x x
x x
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x
xx
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x xx xx
x
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x
Caliper to Knuckle Clearance
Excessive Vehicle Loading
Q)
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Park. Brake Not Relea,aing
Improper Rear Brake Adj.-
e=
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Low Brake Fluid
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Leaking Brake Line or Conn.
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5F
5
5
5E1
X INDICATES OTHER CAUSE(Sl
5-22-94
FS0015
Figure 1 - Brake System Diagnosis
BRAKES
re-measure. The difference between both readings
is actual brake pedal travel and should be between
51 to 89 mm (2.0 to 3.5 inches).
4. If brake pedal travel is more than specifications,
refer to Figure 1.
BRAKE FLUID L.EAKS

With engine running at idle and the shift lever in
"NEUTRAL," depress the brake pedal and hold with
constant foot pressure. If the pedal gradually falls
away with constant pressure, the brake hydraulic
system may be leaking. Perform visual check to
confirm any suspected leak.
Check the master cylinder fluid level. While a
slight drop in master cylinder reservoir level does
result from normal lining wear, 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 SECTION 5A. Also,
the system may appear to pass this test but still have a
slight leakage.
Check for possible brake fluid leaks at the brake
pipe and brake hose connections. If any signs of
leakage are found, replace the brake pipe or hose.
Also, inspect the connecting brake component to
determine if it is damaged and should be rebuilt or
replaced. Check the brake caliper boots and rear wheel
cylinder boots for leaks. If any brake fluid appears to
be leaking, rebuild or replace the part in question.
Refer to SECTIONS 5Bl, 5B2 or 5C2.
When checking the brake fluid levels, the master
cylinder rear reservoir may be as low as 25.4 mm
(1 inch) from the top if the linings are worn. This is
not abnormal.
Brake Hose and Pipe Inspection

NOTICE: Do not allow brake components to
hang from the flexible 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.
!L"'I
Inspect
1. Flexible hydraulic brake hoses, which transmit

hydraulic pressure from steel brake pipe on body
to steel brake pipes on rear axle and to brake
calipers, at least twice a year when vehicle is on
lift for lubrication.
2. Brake hoses for road hazard damage, cracks, and
chafing of outer cover, and for leaks and blisters.
A light and mirror may be needed for adequate

inspection.
If any of the above conditions are observed on
a brake hose, it will be necessary to replace it.
5-5
BRAKE FLUID
NOTICE: Use only SUPREME 11 (GM
1052542) 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 fluid could result in
damage to components.
If rubber deterioration is evident, disassemble all
hydraulic parts and wash with alcohol. Dry parts with
compressed air before re-assembly to keep alcohol out
of the system. Replace all rubber parts in the system,
including brake hoses, master cylinder rubber parts,
and brake caliper and wheel cylinder boots and seals.
Also replace the combination valve and brake pressure
modulator valve, since they have rubber components
inside which are not serviceable. Check for brake fluid
on the linings. If excessive brake fluid is found,
replace the linings.
as to the condition of brake fluid in the system or if a
fluid has been used which contains the slightest trace
of petroleum or mineral oil based fluids. Refer to
SECTION 5El for complete brake hydraulic system
flush and bleed procedures.
ON-VEHICLE SERVICE
BRAKE PEDAL WITH BRACKET
Figures 2 through 4
!++!
CAUTION: Refer to "CAUTION" under

SECTION 8C.
3. Electronic brake control module. Refer to
SECTION 5El.
4. Release switch, Stoplamp and TCC switch, and
clutch switch or clutch anticipate switch if
equipped, from pedal with bracket. Refer to
"Stoplamp and Cruise Control Switches" in this
section.
5. Clutch start switch (29) from brake pedal with
bracket (5) on vehicle with manual transmission.
6. Accelerator lever pedal. Refer to SECTION 6C.
7. Retainer (16), brake pedal pushrod (15) and
washer (14) from brake pedal pin.
8. Retainer (20) and clutch pushrod (19) from clutch
pedal pin on vehicle with manual transmission.
9. Nuts (3 and 7) and bolts/screws (4 and 8).
10. Nuts (11), on vehicle with manual transmission.
11. Brake pedal with bracket (5 or 6).
5-6
BRAKES
A
A
B
C
1
2
3
4
5
7
8
9
10
11
12
13
14
15
16
17
18
19
20
24
PANEL, DASH
PIN, BRAKE PEDAL
PIN, CLUTCH PEDAL
BOOSTER, POWER BRAKE
VALVE, POWER BRAKE BOOSTER VACUUM CHECK
NUT, BRAKE PEDAL
BOLT/SCREW, BRAKE PEDAL BRACKET
PEDAL, BRAKE AND ACCELERATOR AND
CLUTCH (WITH BRACKET)
NUT, BRAKE PEDAL BRACKET
BOLT/SCREW, BRAKE PEDAL PIVOT
NUT, BRAKE PEDAL PIVOT
NUT. CLUTCH MASTER CYLINDER
BUSHING, BRAKE PEDAL PIVOT
PEDAL, BRAKE
WASHER, BRAKE PEDAL PUSHROD
PUSHROD, BRAKE PEDAL
RETAINER, BRAKE PEDAL PUSHROD PIN
BUSHING, CLUTCH PEDAL PIVOT
PEDAL, CLUTCH
PUSHROD, CLUTCH MASTER CYLINDER
RETAINER, CLUTCH PEDAL LEVER PIN
PEDAL, ACCELERATOR LEVER
010585
F8002!
Figure 2 Brake Pedal (Manual Transmission)
BRAKES
16
A
B
1
2
3
4
6
7
8
12
13
14
15
16
21
22
23
24
PANEL, DASH
PIN, BRAKE PEDAL
NUT, BRAKE PEDAL
PEDAL, BRAKE AND ACCELERATOR
(WITH BRACKET)
NUT, BRAKE PEDAL BRACKET
BUSHING, BRAKE PEDAL PIVOT
PEDAL, BRAKE
WASHER, BRAKE PEDAL PUSHROD
PUSHROD, BRAKE PEDAL
RETAINER, BRAKE PEDAL PUSHROD PIN
BOLT/SCREW, BRAKE PEDAL PIVOT
NUT, BRAKE PEDAL PIVOT
SPACER, BRAKE PEDAL PIVOT
PEDAL, ACCELERATOR LEVER
1-05-96
FS003S
Figure 3 - Brake Pedal (Automatic Transmission)
5-7
58
BRAKES
l++I
Install or Connect
NOTICE:
[I]
Important
When installing brake pedal with bracket,

make sure that dash panel insulator material
does not get pinched between brake pedal with
bracket and dash panel.
1. Brake pedal with bracket (5 or 6).
2. Nuts (11), on vehicle with manual transmission.
3. Nuts (3 and 7) and bolts/screws (4 and 8).
l~I
Tighten
Nuts (11) to 27 N.m (20 lb. ft.) on vehicle

with manual transmission.
Nuts (7) to 20 N.m (15 lb. ft.) in sequence:
inboard upper, outboard lower, outboard upper,
inboard lower.
Nuts (3) to 20 N.m (15 lb. ft.)

Bolts/screws (4 and 8) to 25 N.m (18 lb. ft.).
4. Accelerator lever pedal. Refer to SECTION 6C.
5. Retainer (20) and clutch pushrod (19) to clutch
pedal pin on vehicle with manual transmission.
Lubricate clutch pedal pin with chassis

lubricant, GM PIN 1052497 or equivalent.
washer (14) to brake pedal pin.
Lubricate brake pedal pin with chassis
7. Cruise control release switch, Stoplamp and TCC
switch, and clutch switch or clutch anticipate
switch if equipped, to pedal with bracket Refer to
"Stoplamp and Cruise Control Switches" in this
section.
SECTION 5El.
9. Clutch start switch (29) to brake pedal with
bracket (5), on vehicle with manual transmission.
27
A
B
C
D
E
F
G
H
J
5
6
25
26
27
28
29
MANUAL TRANSMISSION
AUTOMATIC TRANSMISSION
CONNECTOR, ELECTRICAL
WITH 3800 VIN K
WITH 5. 7L VIN P
PEDAL, BRAKE AND ACCELERATOR (WITH
BRACKET)
SWITCH, CRUISE CONTROL CLUTCH
SWITCH, STOPLAMP AND TORQUE
CONVERTER CLUTCH
SWITCH, CRUISE CONTROL RELEASE
ANTICIPATE
SWITCH, CLUTCH START
Figure 4 - Stoplamp and Cruise Control Switches
05-18-915
FT0045
BRAKES
10. Left hand instrument panel insulator. Refer to
SECTION 8C.
Adjust
Cruise control release switch, Stoplamp and TCC

switch, and clutch switch or clutch anticipate
switch on vehicle with manual transmission. Refer
to "Stoplamp and Cruise Control Switches" in
this section.
BRAKE PEDAL
Figures 2 and 3
!+-+!
CAUTION: Refer to "CAUTION" under

SECTION 8C.
SECTION 5El.
washer (14) from brake pedal pin.
5. Nut (10) and bolt/screw (9) on vehicle- with
manual transmission.
6.
7.
8.
9.
&!J
Slide out bolt/screw (9) part way, giving just

enough clearance to remove brake pedal (13).
Nut (22) and bolt/screw (21) on vehicle with
automatic transmission.
Brake pedal (13).
Bushings (12) from brake pedal (13), if necessary.
Spacer (23) from brake pedal (13) on vehicle with
automatic transmission, if necessary.
Clean
All parts with suitable solvent.
!L!
Inspect
All parts for wear. Repair or replace as needed.
!++!
1.
2.
3.
4.
Install or Connect
Spacer (23) to brake pedal (13), if removed.
Bushings (12) to brake pedal (13), if removed.
Brake pedal (13).
Bolt/screw (9) and nut (10) on vehicle with
Lubricate bolt/screw (9) with chassis lubricant,

GM PIN 1052497 or equivalent on vehicle
5. Bolt/screw (21) and nut (22) on vehicle with
automatic transmission.
!~!
5-9
Tighten
Nut (10 or 22) to 54 N,m (40 lb. ft.).

washer (14) to brake pedal pin.
Lubricate brake pedal pin with chassis
SECTION 5El.
SECTION 8C.
Adjust
Cruise control release switch, and Stoplamp and

TCC switch, and clutch switch or clutch anticipate
switch if equipped. Refer to "Stoplamp and
Cruise Control Switches" in the following
procedure.
STOPLAMP AND CRUISE CONTROL

SWITCHES
Figure 4
Adjustment
The cruise control release switch (27) must be
adjusted at the same time the Stoplamp and torque
converter clutch (TCC) switch is adjusted. The clutch
switch (25) or clutch anticipate switch (28) cannot be
adjusted until after the clutch pedal is installed.
NOTICE: Proper Stoplamp switch adjustment
is essential. Improper Stoplamp switch
adjustment may cause brake drag and excessive
brake lining wear.
Adjust
1. To adjust, depress brake pedal or clutch pedal and

insert release switch (27), Stoplamp and TCC
switch (26) and clutch switch (25) or clutch
anticipate. switch (28) into pedal with bracket (5
or 6) until retainer on release switch (27),
Stoplamp and TCC switch (26), or clutch switch
(25) or clutch anticipate switch (28) is fully
seated.
[I]
Important
Make sure to apply the proper amount of force

to the brake pedal during adjustment. Too
much force could damage the vacuum booster.
Too little could cause dragging brakes.
2. Slowly pull brake or clutch pedal rearward with a
force of 222 N (50 pounds) until "click" sounds
can no longer be heard. At this point, release
switch (27), Stoplamp and TCC. switch (26), and
clutch switch (25) or clutch anticipate switch (28)
will have moved retainers to their adjusted .
position.
5-10
l@I
BRAKES
Measure
Release switch and Stoplamp and TCC switch

contacts should be open at 25.4 mm (1 inch) or
less of pedal travel, and occur at the same time or
before the onset of braking. The brake pedal
travel can be up to 25.4 mm (1 inch) before the
cruise control system disengages.
Replacement
I++!

SECTION 8C.
3. Release switch (27), Stoplamp and TCC switch
(26), and .clutch switch (25) or clutch anticipate
switch (28), if equipped, from pedal with bracket
(5 or 6).
l++I
Install or Connect
1. Release switch (27), Stoplamp and TCC switch

(26), and clutch switch (25) or clutch anticipate
switch (28), if equipped, to pedal with bracket
(5 or 6).
SECTION 8C.
~ Adjust
Release switch (27), Stoplamp and TCC switch
(26), and clutch switch (25) or clutch anticipate
switch (28), as outlined above.
BRAKE PIPE
CAUTION: Always use double walled
steel brake pipe when replacing brake
pipes. The use of any other pipe is not
recommended and may cause brake
system failure. Carefully route and retain
replacement brake pipes. Always use the
correct fasteners and the original
location for replacement brake pipes.
Failure to properly route and retain brake
pipes may cause damage to the brake
pipes and cause brake system failure.
Refer to Figures 5 through 14 for brake pipe
routing, tightening specifications and replacement. For
information on the brake pressure modulator valve,
refer to SECTION 5El. For information on the
traction control brake pressure modulator valve, refer
to SECTION 5E~.
[I]
Important
Rear brake front pipes (36, 117 or 118) should

not be locally fabricated. These pipes should
be ordered through your GM Parts Dealer,
Double Lap Flare

[II
Important
Double lap flares are to be used for rear brake

rear pipes. All other brake pipes will use ISO
flares.
Tool Required:
J 23530 Brake Line Flaring Tool (45 Degree
Single and Double)
1. Obtain recommended tubing and steel fitting nuts
of correct size.
Outside diameter of tubing is used to specify
size.
2. Cut tubing to length.
Correct length may be determined by
measuring old brake pipe using string and
adding 3 mm (1/8 inch) for each double flare.
3. Cut end square and chamfer inside and outside
diameter of tubing with de-burring tool.
Remove all traces of lubricant from tubing.
NOTICE: A double lap flaring tool must be

used for steel brake pipes. Single flaring tools
cannot produce a flare strong enough to hold the
pressure in a brake system.
4. Double lap flare tubing ends using J 23530.
A. Make sure fittings are installed before starting
flare.
B. Unscrew compression screw until swivel cone
is at its highest point.
Swing strap to one side.
C. Open lever handle so it is at right angle to rest
of tool and revolve hexagonal tube lights to
accommodate tubing (selection of six sizes).
D. Be sure fitting nut is properly placed on
tubing: Insert end of tube between two blocks
until level with top of gage.
E. Insert proper pin of gage into tubing and
swing strap back in closed position. Tighten
compression screw until gage bottoms on tool,
then unscrew compression screw and swing
strap to one side. Remove gage.
F. Swing strap back in closed position, then
tighten compression screw to flare cone
downward to complete double lap flare.
G. Unscrew compression screw and open smaller
lever handle to remove brake pipe.
H. Inspect flared ends for splits, cracks, pits or
excessive out-of-round which may cause leaks.
I. Blow out brake pipe with dry compressed air
to remove any foreign objects.
5. Bend new brake pipe to match old pipe using a
tubing bender.
[II _Important
Minimum clearance of 19 mm (3/ 4 inch) must
be maintained from all moving components
and 13 mm (1/2 inch) from all vibrating
BRAKES 5-11
31
,f~~
36
J
33
39
44
30
42
/:'~.,.
'
33
31
jv1ewc I
A CROSSMEMBER, FRONT
30 CYLINDER, BRAKE MASTER
31 PIPE, FRONT BRAKE COMBINATION VALVE
32 PIPE, REAR BRAKE COMBINATION VALVE
33 VALVE, BRAKE PRESSURE MODULATOR
3J PIPE, LEFT-HAND FRONT BRAKE
35 PIPE, RIGHT-HAND FRONT BRAKE
36 PIPE. REAR BRAKE FRONT
37
38
39
40
41
42
43
44
CLIP, BRAKE PIPE

CLIP, BRAKE PIPE
CLIP, BRAKE PIPE
CLIP, BRAKE PIPE
CLIP, BRAKE PIPE
SOLT/SCREW, BRAKE PIPE CLIP
BOLT/SCREW, FRONT BRAKE FRONT PIPE CLIP
CLIP, BRAKE PIPE
010585
fS0055
Figure 5 Routing Front Brake Pipe (Without Traction Control System)
512
BRAKES
BRAKE P1PE ASSEMBLIESTO-BRAKE MASTER CYUNDER ASSEMBLY
CALLOUT
NUMBER
CIRCUIT
NUT
SIZE
PIPE ASSEMBLY
DIAMETER
APPROXIMATE BRAKE PIPE

LINEAR LENGTH
NUT TIGHTENING
SPECIFICATION
31
PRIMARY
Mil x 1.5
4.76mm
411.0 mm 116.848"1
32 Norn {24 LB. FT.I
32
SECONDARY
Mil x 1.5
4.76 mm
519.0 mm {20.695"1
32 Norn {24 LB. FT.I
BRAKE PIPE ASSEMBLIES TO-COMBINATION VALVE ASSEMBLY

CALLOUT
NUMBER
CIRCUIT
NUT
SIZE
PIPE ASSEMBLY
DIAMETER
APPROXIMATE BRAKE Pll"i:

LINEAR LENGTH
NUT TIGHTENING
SPECIFICATION
31
PRIMARY
M10xU
4.76mm
411.0 mm 116.848"1
18 N-m {13 LB. FT.)
32
SECONDARY
M10x 1.0
4.76 mm
519.D mm (20.895"1
18 Norn 113 LB. FT.I
BRAKE PIPE ASSEMBUESTDBRAKE PRESSURE MODULATOR VALVE ASSEMBLY

CIRCUIT
NUT
SIZE
PIPE ASSEMBLY
DIAMETER

LINEAR LENGTH
34
LEFT-HANO FRONT
MlOx 1.0
4.76 mm
2321.50 mm 191.379"1
32 N"III (24 LB. FT.I
35
RIGHT-HANO FRONT
MlOx 1.0
4.76mm
1398.84 mm 155.072"1
32 Nom (24 LB. FT.)
36
REAR
M12x 1.5
6.00mm
3736.0 mm (150.155")
32 Norn (24 LB. FT.)
CALLOUT
NUMBER
NUTTIGHTENING
SPECIFICATION
BRAKE PIPEASSEMBUESTOBRAKE HOSE ASSEMBLIES

CALLOUT
NUMBER
CIRCUIT
NUT
SIZE
PIPE ASSEMBLY
DIAMETER

LINEAR LENGTH
NUT TIGHTEN,ING
SPECIFICATION
.34
LEFTHANO FRONT
MlOx 1.0
4.76mm
2321. SO mm 191.379")
15 Norn It !LB. FT.)
35
RIGHT-HAND FRONT
MlOxU
4.76mm
1398.84 mm {55.072"1
15 Nom (I I LB. FT.}
NUT COLOR cooe
SIZE
M1Ux 1.0
Mlt xl.5
M12x1.0
COLOR
OLIVE
ORANGE
OllVE
OLIVE
VIOLET
M12x1.5
31824 UNF
5-22-94
FS0065
Figure 6 Front Brake Pipe Specifications (Without Traction Control System)
components, unless brake pipe is clipped to

the component. For armor wrapped pipe,
contact is permissible if there is no relative
movement between pipe and contact surface.
ISO Flare
[I]
Important
ISO flares are NOT to be used for rear brake

rear pipes.
Tool Required:
J 29803-A ISO Flaring Kit
1. Obtain recommended tubing and steel fitting nuts
of correct size.
Outside diameter of tubing is used to specify
size.
2. Cut tubing to length.
Correct length may be determined by
measuring old brake pipe using string and
adding 3 mm (1/8 inch) for each ISO flare.
3. Cut end square and chamfer inside and outside

diameter of tubing with de-burring tool.
Remove all traces of lubricant from tubing.
4. ISO flare tubing ends using J 29803-A.
A. Make sure fittings are installed on tubing
before starting flare.
B. Clamp flaring tool body in vise.
C. Select correct size collet and forming
mandrel for tube size used.
D. Insert proper forming mandrel into tool
body. While holding mandrel in place with
your finger, thread in forcing screw until it
makes contact and begins to move forming
mandrel. When contact is made, turn
forcing screw back one complete tum.
E. Slide clamping nut over tubing into correct
collet. Leave approximately 19 mm (3/ 4
inch) of tubing extending out collet. Insert
into tool body. Tube end must contact face
of forming .mandrel.
F. Tighten clamping nut into tool body very
tight or tube may push out.
BRAKES 513
36
c
53
IVtEWA
A AXLE, REAR
B CLIP, REAR AXLE RETAINER
C RAIL, REAR COMPARTMENT PANEL
LONGITUDINAL
36 PIPE, REAR BRAKE FRONT
51 BOLT/SCREW, REAR BRAKE HOSE FITIING
52 CLIP, REAR BRAKE PIPE
53 HOSE, REAR BRAKE
54 PIPE, RIGHT-HAND REAR BRAKE
55 PIPE, LEFT-HAND REAR BRAKE
56 RETAINER, REAR BRAKE HOSE
57 BRACKET, REAR BRAKE HOSE
58 BOLT/SCREW, REAR BRAKE HOSE RETAINER
56
IVIEWB I
OMl585
FS0075
Figure 7 - Routing Rear Brake Pipes and Hoses (Without Traction Control System)
5-14
BRAKES
REAR BRAKE Pl,PE ASSEMBLIES- TO REAR BRAKE HOSE ASSEMBLIES
NUT TIGHTENING
SPECIFICATIONS
CALLOUT
NUMBER
CIRCUIT
N'UT SIZE
@CENTER
HOSE
ASSEMBLY
NUT SIZE
@RIGHT AND
LEFT HOSE
ASSEMBLIES
PIPE ASSEMBLY
DIAMETER
APPROXIMATE
PIPE LINEAR
LENGTH
@ CENTER
HOSE
ASSEMBLY
@RlGHT AND
LEFT-HOSE
ASSEMBUES
54
RIGHTHAND
REAR DISC
318-24 UNF
M10x1.0
4,76mm
890.49 mm 135.D&S"I
24 Nm (18 LB FT.)
17 Nm 113 LB. FT.)
55
LEFTHANO
REAR DISC
318-24 UNF
MlOx 1.0
4.76mm
541.91 mm 121.335"1
24 Norn 118 LB. FT.l
17 Nm 113 LB. FT.)
36
REAR
M12x 1.0
6.00mm
3826 mm ll!i0.629")
15 Norn 111 LB. FT.l
REAR BRAKE PIPE ASSEMBLIES TO - REAR WHEEL CYLINDERS

NUT TIGHTENING
SPECIFICATIONS
CALLOUT
NUMBER
CIRCU!IT
NUT SIZE
@CENTER
HOSE
ASSEMBLY
NUT SIZE
@WHEEL
CY1.INOER
PIPE ASSEMBLY
OIAMETER
APPROXIMATE
PIPE LINEAR
LENGTH
@ CENTER HOSE
ASSEMBLY
@RIGHT ANO
LEFT WHEEL
CYLINDERS
67
RIG.HTHANO
REAR ORUM
3/824 UNF
31824 UNF
4.76mm
1170.05 mm<46.064"1
24 Nm 118 LB. FT.)
17 Nm 113 LB. FT.I
68
LEFTHANO
REAR ORUM
3/8-24 UNF
3/824 UNF
4.76mm
864.30 mm (34.027"1
24 Nm (18 Lil. FT.)
17 Nm(13LB.FT.)
NUT COLOR CODE

SIZE
COLOR
M10x 1.0
OLIVE
ORANG,E
YELLOW
BLACK
VIOLET
1.411 x 1.5
M12xl.O
M12x1.S
318-24 UN,F
6-22-94
FS0086
Figure 8 - Rear Brake Pipe and Hose Specifications (Without Traction Control System)
G. Wrench tighten forcing screw in until it

bottoms. Do not tighten forcing screw
further or flare may become over-sized.
H. Back clamping nut out of tool body and
disassemble clamping nut and collet. Flare
is now ready for use.
5. Bend new brake pipe to match old pipe using a
tube bender.
Minimum clearance of 19 mm (3/ 4 inch) must
be maintained from all moving components
and 13 mm (1/2 inch) from all vibrating
components, unless brake pipe is clipped to
the component. For armor wrapped pipe,
contact is permissible if there is no relative
movement between pipe and contact surface.

Figure 22
l++I
1. Brake motor from brake pressure modulator. Refer

to SECTION 5El.
2. Bolts/screws (59) and seals (60).
Discard seals (60).
3. Combination valve (62).
4. Seals (61).
Discard seals (61).
5. Transfer tubes (64 and 65) and seals (63 and 66)
from combination valve (62).
~ Clean
All parts in clean, denatured alcohol.

-
IL!
Dry with unlubricated, compressed air.
Inspect
All parts for wear. Repair or replace as needed.
l++l
Install or Connect
NOTICE: Refer to "Notice" on page 5-1.

1. Transfer tubes (64 and 65) and seals (63 and
66) to combin.ation valve (62).
Lubricate seals (63 and 66) with clean brake
fluid.
2. New seals (61).
Lubricate seals (61) with clean brake fluid.
3. Combination valve (62).
4. New seals (60) and bolts/screws (59).
Lubricate seals (60) with clean brake fluid.
!~l
Tighten

5. Brake motor to brake pressure modulator
valve. Refer to SECTION 5El.
BRAKES
tFRT
48
5-15
36
'ti~~
36
46
jVIEWA!
f~'
46
47
4B
45----
36
!VIEW Bj
36
36
tFRT
49
IVIEW DI
45
IVIEW CI
BRAKE PIPE ASSEMBLY TO BRAKE PRESSURE MODULATOR VALVE ASSEMBLY

CALLOUT
NUMBER
CIRCUIT
NUT
SIZE
PIPE ASSEMBLY
DIAMETER
APPROXIMATE PIPE
LINEAR LEN,GTH
NUT TIGHTENING
SPECIFICATION
36
REAR
M12x 1.5
6.00mm
3813.95 mm (150.155")
32 Norn (24 LB. FT.)
BRAKE PIPE ASSEMBLY TO REAR BRAKE (CENTER) HOSE ASSEMSLY
36
45
46
47
48
49
CALLOUT
NUMBER
CIRCUIT
NUT
SIZE
PIPE ASSEMBLY
DIAMETER
APPROXIMATE PIPE
LINEAR LENGTH
NUT TIGHTENING
SPECIFICATION
36
REAR
M12 x 1.0
6.00mm
3813.95 mm (150.155")
24Nm (18 LB. FT.)
PIPE, REAR BRAKE FRONT,

CLIP, BRAKE PIPE
CLIP, FUEL LINE RETAINER
CLIP. FUEL LINE RETAINER
NUT COLOR
SIZE
M10 x 1.0
M11 x 1.5
M12x 1.0
M12 x 1.5
3/8-24 UNF
COLOR
OLIVE
ORANGE
YELLOW
BLACK
VIOLET
01-05-95
FS0095
Figure 9 - Routing Underbody Rear Brake Front Pipes (Without Traction Control System)
5-16
BRAKES
33
IVIEWA
A
30
31
32
33
34
35
37
38
42
100
101
102
103
104
RAIL, ENGINE COMPARTMENT INNER SIDE

CYLINDER, BRAKE MASTER
PIPE, FRONT BRAKE COMBINATION VALVE
PIPE, REAR BRAKE COMBINATION VALVE
VALVE, BRAKE PRESSURE MODULATOR
PIPE, LEFT-HAND FRONT BRAKE
PIPE', RIGHT-HAND FRONT BRAKE
CLIP, BRAKE PIPE
CLIP, BRAKE PIPE
BOLT/SCREW, BRAKE PIPE CLIP
VALVE, TRACTION CONTROL BRAKE PRESSURE
MODULATOR
PIPE, TRACTION CONTROL BRAKE PRESSURE
MODULATOR VALVE
PIPE, RIGHT-HAND REAR BRAKE
PIPE, LEFT-HAND REAR BRAKE
CLIP, REAR BRAKE PIPE
010595
IFSO'IOS
(
Figure 1O Routing Front Brake Pipes (With Traction Control System)
BRAKES 5-17
BRAKE PIPE ASSEMBLIES TO TRACTION CONTROL MODULATOR VALVE ASSEMBLY

CALLOUT
NUMBER
CIRCUIT
101
REAR
102
RIGHT-HAND
REAR
103
LEFT-HAND
REAR
PIPE ASSEMBLY
DIAMETER
APPROXIMATE BRAKE
LINEAR tENGTH
NUT TIGHTENING
SPECIFICATION
M12x 1.5
6.00mm
403.0 mm (15.86")
32 N"l11 (24 LB. FT.)
,}fM'11 x 1.5
4.76mm
3615.0 mm (142.32")
32 N"111 (24 LB.FT.)
M10x1.0
4.76 mm
3630.0 mm (142.91")
32 N"ftl (24 LB: FT.)
;,:,.
NUT
SIZE
.\
BRAKE PIPE ASSEMBLIES TO BRAKE PRESSURE MODULATOR VALVE ASSEMBLY

CALLOUT
NUMBER
CIRCUIT
NUT
SIZE
PIPE ASSEMBtY
DIAMETER
APPROXIMATE BRAKE
LINEAR LENGTH
NUTTIGHTENING
SPECIFICATION
34
LEFT-HANO
FRONT
MlOx 1.0
4.76mm
2321.50 mm (91.379")
32 Nm (24 LB. FT.I
35
RIGHT-HANO
FRONT
MlOx 1.0
4.76 mm
1398.84 mm (55.072")
32 Nm (24 LB.FT.)
101
REAR
Ml2x 1.5
6.00 mm
403.0 mm (15.86"1
32 Nm (24 LB. FT.)
BRAKE PIPE ASSEMBLIES TO BRAKE HOSE ASSEMBLIES

CALLOUT
NUMBER
CIRCUIT
NUT
SIZE
PIPE ASSEMBlY
DIAMETER
APPROXIMATE BRAKE
LINEAR LENGTH
NUTTIGHTENING
SPECIFICATION
34
LEFT-HANO
FRONT
M10x 1.0
4.76mm
2.321.50 mm (91.379")
15 Nm (11 LB. FT.I
35
RIGHT-HANO
FRONT
MIOx 1.0
4.76mm
1398.84 mm {55.072"1
15 Nm (11 LB.FT.)
NUT COLOR CODE

SIZE
COtOR
M10x 1.0
OLIVE
MIOx 1.5
ORANGE
M12x1.0
OLIVE
M12x 1.5
OLIVE
01-05-95
f80115.
Figure 11 Front Brake Pipe Specifications (With Traction Control Systelll)
5-18
BRAKES
111
~
)
(
,08
\
!
107
106
103
A AXLE, REAR
B RAIL, REAR COMPARTMENT PANEL
LONGITUDINAL
102 PIPE, RIGHTHAND REAR BRAKE
10;3 PIPE, LEFT-HAND REAR BRAKE
108 BOLT/SCREW, REAR BRACKET HOSE
112 BOLT/SCREW, REAR BRAKE HOSE BRACKET
114 HOSE, REAR BRAKE
115 HOSE, REAR BRAKE
112
IVIEWB
01-05-95
FS0125
Figure 12 - Routing Rear Brake Pipes and Hoses (With Traction Control System)
BRAKES 5-19
REAR BRAKE PIPE ASSEMBUES-TO-IIEAR BRAKE HOSE ASSEMBLIES

NUT TIGHTENIN:G
SPECIFICATIONS
CALLOUT
NUMBER
CIRCUIT
NUT SIZE
@CENTER
HOS,E
ASSEMBLY
NUT SIZE
@RIGHT AND
LEFT HOSE
ASSEMBLIES
PIPE ASSEMBLY
DIAMETER
APPROXIMATE
BRAKE PIPE
LINEAR LEN'GTH
CENTER HOSE
ASSEMBLY
@RIGHT ANO
LEFT-HOSE
ASSEMBLIES
54
RIGHT-HANO
REAR DISC
MlOx 1,0
MlOxl.O
4.76m,m
867.0 mm 134.13"!
24D N'ITI (18 LEI. fTJ
17DN<m {13l.EI. FT.)
55
LEFT-HANO
REAROISC
M12x 1.0
MlOx 1.0
4.76mm
51111.m mm (22.28"!
w N'ITI c1a ta m
17D N<m {13 La FT.)
114
RlGHTHANO
REAR
M12x 1.0
4.76mm
3815.0 mm (142.32"!
110 Nom c13 ta
115
LEFT-HANO
REAR
MlOx 1.0
4.76mm
3630.0 mm (14l91"l
170 Noin {13 LB fTJ
5-22-94
FS0136
Figure 13 - Rear Brake Pipe and Hose Specifications (With Traction Control System)
117
48
--'j'-~
116
118
jVIEW
46
47
48
49
116
117
118
CLIP,
CLIP,
CLIP,
CLIP,
CLIP,
PIPE,
PIPE,
cj
FUEL LINE RETAINER

FUEL LINE RETAINER
FUEL LINE RETAINER
FUEL LINE RETAINER
REAR BRAKE FRONT PIPE REAR
RIGHT-HAND REAR BRAKE FRONT
LEFT-HAND REAR BRAKE FRONT
01-05-15
FS0146
Figure 14 - Routing Underbody Rear Brake Front Pipes (With Traction Control System)
5-20
BRAKES
A SINGLE LAP FLARE

B DOUBLE LAP FLARE
4-25-94
FS0155
Figure 15 - Single Lap vs. Double Lap Flares

A FORMING MANDREL
B FLARING TOOL BODY
C FORCING SCREW
A COMPRESSION SCREW
B SWIVEL CONE
03-23-95
FS0191!i
Figure 19 - Forming Mandrel and Forcing Screw
4-25-'-94
FS0186
Figure 16 - Placing Tubing in Tool
A CLAMPING NUT
B COLLET
4-25-94
FS02C6
Figure 20 - Clamping Nut. arid Collet
4-25-94
FS0176
Figure 17 - Preparing for Double Lap Flare
4-25-94
A ISOFLARE
FS0:216
4-25-94
FS0186
Figure 18 - Completing Double Lap Flare
Figure 21 - ISO Flare
BRAKES 521
62
33 VALVE, BRAKE PRESSURE MODULATOR

59
60
61
62
63
. 64
65
66
BOLT/SCREW, BRAKE COMBINATION VALVE

SEAL, BRAKE COMBINATION VALVE
SEAL, BRAKE COMBINATION VALVE
VALVE, BRAKE COMBINATION
SEAL, TRANSFER TUBE
TUBE, TRANSFER
TUBE, TRANSFER
SEAL, TRANSFER TUBE
010695
FS0225
Figure 22 Combination Valve
BRAKE HOSES
Front Brake Hose

Figure 23
!+-+!
.Clean
. Dirt and foreign material from front brake hose

(71) and front brake hose fitting (72).
2. Pipe (34) from hose (71).
.
.
Use a backup wrench on hose fitting.
Be careful not to bend bracket (75) or pipe
.(34).
.
3. Retainer (76) from hose fitting at bracket (75).
4. Hose (71) from bracket (75).
5. Fitting (72), hose (71), and two gaskets (73) from
caliper (70).
Discard two gaskets (73).
!HI
Install or Connect
NOTICE:

.
1. Fitting (72), hose (71), and two new gaskets (73)

to caliper (70)..
.
Lubricate hose fitting threads with brake fluid.
Hose fitting flange must engage calfper
orientation ledge.
!~J Tighten
Fitting (72) to 44 N:m (32 ib. ft.).
2. Hose (71) into bracket (75).
There should be no kinks in hose (71).

3. Retainer (76) at bracket (75). .
.
4. Pipe (34). to hose (71), connect clip (75) and
secure with screw.
Use backup wrench on hose fitting.
Make sure that hose (71) does not inake
contact with any part of suspension .. Check in
extreme right and extreme left turn conditions.
5-22
BRAKES
71
71
34
70
71
72
73
74
75
76
l~I
PIPE, LEFT-HAND FRONT BRAKE

CALIPER, FRONT BRAKE
HOSE, FRONT BRAKE
FITTING, FRONT BRAKE HOSE
GASKET, FRONT BRAKE HOSE FITTING
BOLT/SCREW, FRONT BRAKE HOSE CLIP
BRACKET. FRONT BRAKE HOSE
RETAINER, FRONT BRAKE HOSE
Tighten
Rear Brake (Center) Hose

WITHOUT TRACTION CONTROL SYSTEM
Figures 7, 8 and 9

SECTION OA.
010515
FS0235
Figure 23 Front Brake Hose (Left Side Shown, Right Side Similar)
bolt/screw (74) retaining clip (75) to 15 N.m

(11 lb. ft.).
5. Bleed brake hydraulic system. Refer to
SECTION 5El.
!++!
Clean
Dirt and foreign material from hose and pipe

fittings.

(36).
3. Retainer (56) from bracket (57) and hose (53).
4. Hose (53).
5. Left rear pipe (55 or 68) and right rear pipe
(54 or 67) from. hose (53).
Be careful not to bend left rear pipe (55 or 68)
and right rear pipe (54 or 67).
6. Bolt/screw (51) and hose (53) from rear axle.
Note. position of hose (53) for proper location
!++!
Install or Connect

L lfose-(53) and bolt/screw (51) to rear axle.
I~!
Tighten
BRAKES
2. Left rear pipe (55 or 68) and right rear pipe
(54 or 67) to hose (53).
!~I
Tighten
Left rear pipe (55 or 68) and right rear pipe

(54 or 67) at hose (53) to 24 N.m (18 lb. ft.).
3. Hose (53) into bracket (57).
Be sure hose (53) is seated properly and not
twisted.
4. Retainer (56) to bracket (57) and hose (53).
5. Pipe (36) to hose (53).
Use backup wrench on hose (53).
(36).
!~I
WITH TRACTION CONTROL SYSTEM
l++I

SECTION OA.
Clean
Dirt and foreign material from hose and pipe

fittings.
Use backup wrench on hose fittings.
Be careful not to bend bracket (113) or pipes
(102 and 103).
4. Clip (105) from bracket (113) and hose (114).
Be careful not to bend bracket (107) or pipes
(109 and 110).

10. Hose (114).
lL Hose (115).
j++j
4. Clip (105) to bracket (i07) and hose (114).

Be sure hoses ( 114 and 115) are seated
properly and not twisted.
5. Pipe (110) to hose (114).
6. Pipe (109) to hose (115).
Be -careful not to bend bracket or pipes
(109 and 110).
!~!
7.
8.
Tighten
Pipe (36) to hose (53) to 15 N.m (11 lb. ft.).

SECTION 5El.
7. Lower vehicle.
Install or Connect
NOTICE:
1. Hose (115).
2. Hose (114).
3. Clip (106) to bracket (107) and hose (115).
523
9.
10.
Tighten

Pipe (109) to hose (115) to 17 N,m (13 lb. ft.).
Clip (106) to bracket (113) and hose (115).
Clip (105) to bracket (113) and hose (114).
Be sure hoses (114 and 115) are seated
properly and not twisted.
Pipe (103) to hose (114).
Pipe (102) to hose (115).
Be careful not to bend bracket or pipes ( 102
_and 103).
!~!
Tighten

SECTION 5El.
12. Lower vehicle.
Rear Brake Hose

Figure 24
j++j
1. Wheel and tire. Refer to SECTION 3E.
Clean
Dirt and foreign material from hose (81) and pipe

fitting.
2. Hose (81) from pipe (55).
Be careful not to bend bracket (85) and pipe
(55).
3. Retainer (84) from bracket (85) and hose (81).
4. Fitting (83), two gaskets (82) and hose (81) from
caliper (80).
Discard two gaskets (82).
!++!
Install orConnect
NOTICE:
Refer to "Notice" on page 5~1.
1. Fitting (83), two new gaskets (82) and hose (81)

to caliper (80).
Lubricate hose fitting threads with clean brake
fluid.
Hose fitting flange must engage caliper
orientation ledge.
5-24
BRAKES
I~!
Tighten

4. Bleed hydraulic brake system. Refer to
SECTION 5El.
5. Wheel and tire. Refer to SECTION 3E.
FLUSHING BRAKE HYDRAULIC SYSTEM
NOTICE: Use only SUPR.EME 11

(GM 1052542) 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 fluid could
55
80
81
82
83
84
85
90
PIPE, LEFT-HAND REAR BRAKE

CALIPER, REAR BRAKE
HOSE, LEFT-HAND REAR BRAKE
GASKET, REAR BRAKE HOSE FITTING
FITTING, REAR BRAKE HOSE
RETAINER, REAR BRAKE HOSE
BRACKET, REAR BRAKE HOSE
DAMPENER, REAR BRAKE VIBRATION
01-05-15
. FS0245
Figure 24 - Rear Disc Brake Hose (Typical) (Left Side

Shown, Right Side Similar)
!~!

about the condition of fluid in the system or if fluid
has been used which contains the slightest trace of
petroleum or mineral oil based fluids. Approximately
1.5 liters ( 1.5 quarts) of brake fluid is required to flush
the brake hydraulic system. All rubber parts, including
brake hoses, master cylinder rubber parts, and brake
caliper and wheel cylinder boots and seals that have
been subjected to a contaminated fluid must be
replaced. Also replace the combination valve and
brake pressure modulator, since they have rubber
components inside that are not serviceable. Refer to
SECTION 5El for complete brake hydraulic system
flush and bleed procedures.
Tighten
Fitting (83) to 44 N.m (32 lb. ft.).

2. Retainer (84) to bracket (85) and hose (81).
3. Hose (81) to pipe (55).
Be .careful not to bend bracket (85) and pipe
(55).
SPECIFICATIONS
Brake Pedal Travel ........................................................................................ 5.1 to 89 mm (2.0 inch to 3.5inch)
Brake pedal travel maximum with 445 N (100 lb.) force applied to pedal with engine running at idle.
Hydraulic Brake (Glycol) Fluid'! ...................................................... GM PIN 1052535 or equivalent DOT-3 fluid
Brake Pipe Clearance (Minimum)
Moving Components ..................................................................................................... ~ ....... 19 mm (3/4 inch)
Vibrating Components ........................................................................................................... 13 mm (1/2 inch)
. Armor-Wrapped Pipe Contact is permitted if there is no relative movement between pipe and contact
surface
FASTENER TIGHTENING SPECIFICATIONS.
Brake Combination Valve Bolt/~ci:ew .................................................................................... 16 N.m (12 lb. ft.)
Brake Pedal Bracket Bolt/Screw ............................................................................................. 25 N.m (18 lb. ft.)
Brake Pedal Bracket Nut ......................................................................................................... 20 N.m (15 lb. ft.)
Brake Pedal Nut ....................................... ;.............................................................................. 20 N.m (15 lb. ft.)
Brake :Pedal Pivot Nut................................................................ ;............................................ 54.N.m (40 lb.. ft.)
Brake Pipe Clip Bolt/Screw ..................................................................................................... 5 N.m (44 lb. in.)
Clutch Master Cylinder Nut .................................................................................................... 27 N.m (20 lb. ft.)
Front Brake Combination Valve Pipe-to-Brake Combination Valve ..................................... 18 N.m (13 lb. ft.)
BRAKES 5-25
Front Brake Combination Valve Pipe-to-Brake Master Cylinder .......................................... 32 N,m (24 lb.
Front Brake Hose Fitting ........................................................................................................ 44 N,m (32 lb.
Front Brake Pipe-to-Brake Pressure Modulator Valve ........................................................... 32 N,m (24 lb.
Front Brake Pipe-to-Front Brake Hose ................................................................................... 15 N.m (11 lb.
Front Brake Hose Clip Bolt/Screw ....................................................................................... 13 N.m (115 lb.
Rear Brake (Center) Hose Fitting Bolt/Screw ....................................................................... 21 N,m (15 lb.
Rear Brake Combination Valve Pipe-to-Brake Combination Valve ...................................... 18 N.m (13 lb.
Rear Brake Combination Valve Pipe-to-Brake Master Cylinder ........................................... 32 N.m (24 lb.
Rear Brake Front Pipe-to-Brake Pressure Modulator Valve .................................................. 32 N.m (24 lb.
Rear Brake Front Pipe-to-Rear Brake (Center) Hose ............................................................ 15 N,m (11 lb.
Rear Brake Hose Fitting ......................................................................................................... 44 N,m (32 lb.
Rear Brake Hose Bracket Bolt/Screw ., .................................................................................. 10 N.m (89 lb.
Rear Brake Pipe-to-Rear Brake (Center) Hose ...................................................................... 24 N.m (18 lb.
Rear Brake Pipe-to-Rear Brake Hose ..................................................................................... 17 N,m (13 lb.
Rear Brake Pipe-to-Rear Wheel Cylinder .............................................................................. 17 N.m (13 lb.
Rear Brake Pipe-to-Traction Control Brake Pressure Modulator Valve Pipe ....................... 32 N,m (24 lb.
Traction Control Brake Pressure Modulator Valve Pipe ....................................................... 32 N,m (24 lb.
SPECIAL TOOLS
2.
1.
{&
II~~
~o
J 28662
1. BRAKE PEDAL EFFORT GAGE

2. ISO FLARING KIT
3. BRAKE LINE FLARING TOOL (45 SINGLE AND DOUBLE)
J 29803-A
.fir
J 23530
4-25-94
FS02SS
ft.)
ft.)
ft.)
ft.)
in.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
in.)
ft.)
ft.)
ft.)
ft.)
ft.)
5-26
BRAKES
BLANK
MASTER CYLINDER
5A1
SECTION 5A
MASTER CYLINDER
Skin contact - wash with soap and water.
NOTICE: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wmng cables or electrical
connectors. Brake fluid will. damage paint and electrical connections. If any fluid is spilled on the vehicle,
fastener. torque and the joint clamping force, and may damage the fastener. When you install fasteners, use the
and systems.
CONTENTS
General Description............................. ,.................. 5A-1
Brake Master Cylinder ....................................... 5A-1
Brake Master Cylinder Reservoir ...................... 5A-1
Brake Fluid and Fluid Handling ....................... 5A-1
Substandard or Contaminated Brake Fluid .... 5A-2
Diagnosis ................................................................ 5A-2
Brake Master Cylinder Check .. ,........................ 5A-2
Filling Brake Master Cylinder Reservoir .......... 5A-3
Brake Master Cylinder ....................................... 5A-3
GENERAL DESCRIPTION
BRAKE MASTER CYLINDER
The brake master cylinder is a composite design
(plastic reservoir and aluminum body) incorporating a
conventional front-to-rear brake system split. The
brake master cylinder primary piston provides the fluid
pressure to the front disc brakes, while the brake
master cylinder secondary piston provides the fluid
pressure to the rear drum or disc brakes. If pressure is
lost from either system, the remaining system will
function to stqp the vehicle.
BRAKE MASTER CYLINDER RESERVOIR
Figure 1
'The reservoir (5) has a fluid level indicator mark
located inside the neck of the reservoir fill opening.
The reservoir cap must be removed to view the
indicator mark.
Bleeding Brake Hydraulic

System ...................................... Refer to Section 5E 1
Unit Repair ...................................................... ,....... 5A-4
Brake Master Cylinder........................................ 5A-4
Master Cylinder Bench Bleeding ....................... 5A-4
Brake Master Cylinder Reservoir ....................... 5A-5
Specifications ........................................................... 5A-6
General Specifications ......................................... 5A-6
Fastener Tightening Specifications ..................... 5A-6
BRAKE FLUID AND FLUID HANDLING

following actions:
Eye contact - rinse thoroughly with
water.
Skin contact - wash with soap and
water.
If ingested - consult a physician
immediately.

the vehicle's painted surfaces, wiring cables or
electrical connections. Brake fluid will damage
damage.
5A2
MASTER CYLINDER
Deterioration of the rubber components may

result in costly damage to the brake pressure
modulator valve, disc brake calipers and rear wheel
cylinders.
DIAGNOSIS
BRAKE MASTER CYLINDER CHECK
1. Check for .cracked brake master cylinder body or
brake fluid around brake master cylinder.
A MAXIMUM FILL LEVEL

5 RESERVOIR, BRAKE MASTER CYLINDER
-4-25-94
FS0016A
[I]
Figure 1 - Brake Fluid Level Indicator
Important
Do not re-use brake fluid accumulated during

brake hydraulic system bleeding.
Always store fluid in a closed container.
Reseal containers immediately after use. Do
not use fluid left in an open or improperly
sealed container as it absorbs moisture or may
be contaminated.
Substandard or Contaminated Brake Fluid

Use only SUPREME 11 (GM 1052542) 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 fluid could
Leaks are indicated only if there is at least a

drop of fluid.
A damp condition is not abnormal.
2. Check for binding brake pedal linkage and
incorrect power brake booster power piston
pushrod length.
A. If both of these are satisfactory, disassemble
brake master cylinder and check for swollen
brake master cylinder reservoir diaphragm or
swollen primary or secondary piston seal(s).
B. If swollen primary or secondary seals are
found, substandard or contaminated brake fluid
should be suspected.
C. If contaminated, all components should be
disassembled and cleaned. All rubber
components, including those in the
combination valve, brake pressure modulator
valve, disc brake calipers and rear .wheel
cylinders, should be replaced and all brake
pipes flushed.
BRAKE MASTER CYLINDER CHECKS

CONDITION
Grabby Brakes (Apparent On-Off
Condition)
CORRECTION
POSSIBLE CAUSE
1. Insufficient brake fluid in master
cylinder.
1. Fill master cylinder reservoir with

approved brake fluid and check for
leaks.
2. Faulty master cylinder primary or

secondary piston seals ..
2. Repair or replace as necessary.
3. Cracked master cylinder body.
3. Replace.
These checks will not determine all master cylinder malfunctions. Refer to SECTION 5.
ON-VEHICLE SERVICE
NOTICE: Do not use lubricated compressed
air on brake parts, as damage to rubber
components may result.

(1]
Important
Replace all components included in repair kits

used to .service this brake master cylinder.
Lubricate rubber parts with clean brake fluid
to ease.
If any hydraulic component is removed or
disconnected, it may be necessary to bleed all
or part of the brake hydraulic system.
MASTER CYLINDER
The torque values specified are for dry,
unlubricated fasteners.
Perform service operations on a clean bench,
free from all mineral oil materials.
Add brake fluid GM PIN 1052535 or equivalent

as required to bring fluid level to line located inside
the neck of the reservoir fill opening.
FILLING BRAKE MASTER CYLINDER

RESERVOIR
Figure 2
!++!
The brake master cylinder reservoir must be kept

properly filled to insure adequate reserve and to
prevent air from entering the brake hydraulic system.
However, because of expansion due to heat absorbed
from the brakes and from the engine, the reservoir
must not be overfilled.
A drop in brake fluid level is normal as the pads
and linings wear. Filling the master cylinder reservoir
before installing new pads and linings may result in
brake fluid spillage once the new pads and linings are
in place. Unless there is a leak in the brake hydraulic
system, or if the brake hydraulic system has been
serviced, topping off the master cylinder reservoir
should not be necessary.
Thoroughly clean the master cylinder reservoir
cap before removal to avoid getting dirt in reservoir.
Remove reservoir cap and reservoir diaphragm.
1. Brake fluid from reservoir (5).
Discard old fluid.

2. Brake pipes (1 and 2).
Plug brake pipes (1 and 2) to prevent fluid
loss and contamination.
3. Nuts (18).
4. Brake master cylinder (15).
!++!
Install or Connect
NOTICE:
Refer to "Notice" on page 5A-l.
1. Bench bleed master cylinder. Refer to "Brake

Master Cylinder Bench Bleeding" in this section.
2. Brake master cylinder (15).
3. Nuts (18).
NOTICE: Use only SUPREME 11

contaminated with water. Improper fluid could
I~!
Tighten
Nuts (18) to 29 N.m (21 lb. ft.).
12
18
1
2
3
5
PIPE, FRONT BRAKE COMBINATION VALVE

PIPE, REAR BRAKE COMBINATION VALVE
RESERVOIR, BRAKE MASTER CYLINDER
5A-3
8
12
15
18
BODY, BRAKE MASTER CYLINDER

CAP. BRAKE MASTER, CYLINDER RESERVOIR
NUT, BRAKE MASTER CYLINDER
1-09-95
F$0025A
Figure 2 - Brake Master Cylinder
5A-4
MASTER CYLINDER
4. Fill master cylinder reservoir. Refer to "Filling

Brake Master Cylinder Reservoir" in this section.
5. Brake pipes (1 and 2) to master cylinder (15) one
at a time.
A. Remove locally fabricated plug.

B. Install brake pipe fitting finger tight.
6. Have assistant depress brake pedal to remove air
at loose brake pipe fittings.
!~I
Tighten
Fittings of brake pipes (1 and 2) to 32 N.m

(24 lb. ft.).
7. Have assistant quickly release and pump brake
pedal several times.
8. If brake pedal remains high and firm, start
vehicle. If brake pedal still feels firm, test drive
vehicle. If brake pedal feels soft or spongy, bleed
entire brake hydraulic system. Refer to
SECTION 5El.
UNIT REPAIR
Figure 3
I]]
Important
Reservoir cap (12) and reservoir diaphragm

(13) can be inspected and/or serviced without
removing the master cylinder from the vehicle.
l++I
Brake master cylinder. Refer to "Brake Master

Cylinder" under "On-Vehicle Service" in this
section.
!+!+I
Disassemble
1. Cap (12) and diaphragm (13) from reservoir (5).

Wipe cap (12) and reservoir (5) clean before
removing.
2. Empty brake fluid from reservoir (5).
NOTICE: Use care not to damage the piston

bore or retainer groove during primary piston
retainer ring removal.
3. Ring (14) while depressing primary piston (20).
4. Primary piston (20), secondary piston (21),
retainer (6) and spring (4).
To remove parts, apply clean, low pressure dry
compressed air into outlet port near closed end
of bore with other outlet port plugged.
5. Seals (7 and 10) and retainer (6) from secondary
piston (21).
!L!
Inspect
Cap (12) and diaphragm (13) for cuts, cracks,

nicks and deformation.
Brake master cylinder body bore for scoring or
corrosion. If noted, replace cylinder body (8).
Replace damaged parts.
Clean
All parts in clean denatured alcohol.

Dry with unlubricated compressed air.
Abrasives should not be used in master cylinder
body bore.
!+;+I
Assemble
1. Lubricate rubber parts with clean brake fluid to

ease re-assembly.
2. Seals (7 and 10) and retainer (6) to secondary
piston (21).
3. Lubricated secondary piston (21) and spring (4)
into brake master cylinder body bore.
4. Lubricated primary piston (20) into brake master
cylinder body bore.
5. Ring (14) while depressing primary piston (20).
6. Diaphragm (13) into cap (12).
7. Cap (12) onto reservoir (5).
8. Bench bleed brake master cylinder. Refer to
"Brake Master Cylinder Bleeding" in the
following procedure.
MASTER CYLINDER BENCH BLEEDING

Materials necessary for master cylinder bench
bleeding:
One 11 x 1.5 mm tube fitting nut
One 12 x 1.0 mm tube fitting nut
Two pieces of 4.75 mm (3/16 inch) brake pipe
tube approximately 50 mm (2 inches) long
1. Locally fabricate two plugs for plugging master
cylinder outlet ports.
A. Fashion ISO flares on one end of each tube.
Refer to SECTION 5.
B. Install nuts onto flared tubes.
C. One at a time, place approximately 13 mm
(1/2 inch) of unflared tube in vise.
D. Compress tube end with vise so that tube
collapses completely.
E. With tube still in vise, bend it to a 90 degree
angle.
F. Remove tube from vise and reinstall to fold
tube end against itself to form air-tight seal.
2. Plug master cylinder outlet ports with locally
fabricated plugs.
NOTICE: Do not over-tighten vise or damage

to the brake master cylinder will result.
3. Place shop towels around master cylinder to
absorb bled fluid and mount master cylinder in
vise with front end tilted slightly down.
MASTER CYLINDER
5A5
23
20
4 SPRING, BRAKE MASTER CYLINDER SECONDARY
PISTON
5 RESERVOIR, BRAKE MASTER CYLINDER
6 RETAINER, BRAKE MASTER CYLINDER SECONDARY
PISTON SPRING
7 SEAL, BRAKE MASTER CYLINDER SECONDARY PISTON
PRIMARY
8 BODY, BRAKE MASTER CYLINDER
10 SEAL, BRAKE MASTER CYLINDER SECONDARY PISTON
SECONDARY
12 CAP, BRAKE MASTER CYLINDER RESERVOIR
13 DIAPHRAGM, BRAKE MASTER CYLINDER RESERVOIR
14 RING, BRAKE MASTER CYLINDER PRIMARY PISTON
RETAINER
20 PISTON, BRAKE MASTER CYLINDER PRIMARY
21 PISTON, BRAKE MASTER CYLINDER SECONDARY
22 0-RING
23 PIN, SPRING
14
."-.._
4-25-94
FS0035A
rn
Figure 3 - Brake Master Cylinder Components
4. Fill master cylinder with clean brake fluid.

5. Using tool with smooth rounded end, stroke
primary piston about 25 mm (1 inch) several
times.
[I]
Important
As air is bled from brake master cylinder, with

outlets plugged, resistance to primary piston
travel will not allow full 25 mm ( 1 inch)
stroke.
6. Reposition master cylinder in vise with front end
of master cylinder tilted slightly up. Again, stroke
primary piston about 25 mm (1 inch) several
times.
7. Reposition brake master cylinder in vise to level
position. Loosen two locally fabricated plugs one
at a time and push primary piston into master
cylinder bore to force air out of master cylinder.
Important
To prevent air from being sucked back into

master cylinder, tighten locally fabricated plugs
before allowing primary piston to return to its
original position. Repeat this step until no air
escapes past locally fabricated plugs.
8. Install brake master cylinder into vehicle. Refer to
"Brake Master Cylinder" under "On-Vehicle
Service" in this section.
BRAKE MASTER CYLINDER RESERVOIR

Figures 2 and 3
!+-+!
1. Brake master cylinder. Refer to "Brake Master

section.
5A-6
MASTER CYLINDER
NOTICE: Do not clamp housing area of

master cylinder body in vise or the part may be
damaged.
2. Clamp flange of cylinder body (8) in a vise.
3. Drive out spring pins (23) using 1/8-inch punch.
4. Reservoir (5) by pulling straight up and away
from cylinder body (8).
5. 0-rings (22) from grooves in reservoir (5) and
discard.
ll'l"I
Inspect
Reservoir (5) for cracks or deformation.
Replace reservoir (5), if damaged.
Clean
1. Reservoir (5) with clean denatured alcohol.

2. Dry with unlubricated compressed air.
!++j
Install or Connect
1. Lubricate new 0-rings (22) and grooves in

reservoir (5) with clean brake fluid.
2. 0-rings (22) into grooves in reservoir (5).
Make sure O~rings (22) are properly seated.
3. Reservoir (5) to cylinder body (8) by pressing
straight down by hand into cylinder body (8).
4. Drive in spring pins (23) to retain reservoir (5).
5. Brake master cylinder. Refer to "Brake Master
section.
SPECIFICATIONS
Brake Master Cylinder Body Bore Diameter. ................... "" .................................................. 25.4 mm (1.00 in.)
Supreme 11 Brake Fluid .............................................................. GM PIN 1052542 or equivalent DOT-3 fluid

Brake Master Cylinder Nut. .................................................................................................... 29 N.m (21 lb. ft.)
Brake Pipe Fittings
Front Brake Combination Valve Pipe ................................................................................. 32 N.m (24 lb. ft.)
Rear Brake Combination Valve Pipe ........................ ;......................................................... 32 N.m (24 lb. ft.)
FRONT DISC BRAKES 581-1
SECTION 581
FRONT DISC BRAKES

by cleaning brake parts with a dry brush or compressed air. Brake parts contain asbestos fibers
which can become airborne if dust is created during servicing. Breathing dust containing
becoming airborne.
0 Skin contact - wash with soap and water.
immediately flush the area with water to minimize the potential damage.
and systems.
CONTENTS
General Description ............................................... 5B 1-1
Front Brake Rotor ............................................. 5Bl-1
Front Brake Caliper .......................................... 5B 1-1
Diagnosis ............................................................... 5Bl-2
Front Disc Brake Pad Inspection ..................... 5B 1-2
Front Brake Rotor Inspection ........................... 5Bl-2
Front Brake Rotor Tolerance and
Surface Finish ................................................... 5B 1-2
Thickness Variation Check. ........................... 5Bl-2
Lateral Runout Check ................................... 5Bl-3
Front Brake Caliper Inspection ........................ 5Bl-3
On-Vehicle Service ................................................ 5Bl-3
Front Brake Caliper .......................................... 5Bl-3
Front Disc Brake Pads ...................................... 5Bl-5
GENERAL DESCRIPTION
FRONT BRAKE ROTOR
The rotor is a highly machined, cast iron finned
type. It is mounted on top of an integral hub bearing
unit.
Front Brake Rotor ........................................... 5B 1-7

Unit Repair ......................................................... 5Bl-7
Refinishing Front Brake Rotors .................... 5B 1-7
On-Vehicle Procedure ................................. 5B 1-7
Off-Vehicle Procedure ................................. 5B 1-7 .
Non-Directional Finishing ........................... 5Bl-7
Burnishing Front Brake Rotors .................. 5B 1-7
Front Brake Caliper ........................................ 5B 1-:8
Specifications ....................................................... 5B 1-9
General Specifications ..................................... 5B 1-9
Rotor Refinishing Specifications ................... 5B 1-10
Fastener Tightening Specifications ................. 5B 1:.JO
. Special Tools ....................................................... 5B 1-10
FRONT BRAKE CALIPER

The caliper has a single bore and is mounted to
the steering knuckle with two bolts/screws.
When the brakes are applied, fluid pressure
behind the piston increases. Pressure is exerted equally
against the bottom of the piston and against the
bottom of the caliper housing bore. The pressure
581-2
FRONT DISC BRAKES
applied to the piston is transmitted to the inner pad

forcing the lining against the inner brake rotor swface.
The pressure applied to the bottom of the caliper
housing bore forces the caliper to slide on the caliper
bolts/screws toward the center of the vehicle. This
movement causes the outer section of the caliper to
apply pressure against the back of the outer pad,
forcing the lining against the outer brake rotor surface.
As line pressure builds, the pads are pressed against
the rotor swfaces with increased force, bringing the
vehicle to a stop.
When the brake pedal is released, line pressure
is released and the piston seal and groove cause the
piston to be slightly retracted, resulting in less drag on
the rotor by the pads.
Outward movement of the piston and inward
movement of the caliper automatically compensate for
lining wear. As the linings wear, the increased area
behind the piston is filled with brake fluid from the
brake master cylinder reservoir.
DIAGNOSIS
FRONT DISC BRAKE PAD INSPECTION
A INSPECTION POINTS
Figure 1
IL!
Inspect
Pads at least twice a year when the wheels are

removed (tire rotation, etc.). When inspecting
front disc brakes, check both ends of the outer
pad by looking in at each end of the caliper.
These are the points at which the highest rate of
wear normally occurs. Also, check the lining
thickness of the inner pad to make sure that it has
not worn prematurely. Look through the hole in
the top of the caliper to view the inner pad. Pads
should be replaced when the thickness of any
lining is worn to within 0.76 mm (0.030 inch) of
the shoe. All pads should be replaced in axle sets.
All front disc brakes have a wear indicator that
makes a noise when the linings wear to a degree
where replacement is required. The wear indicator is
an integral part of the outer pad. When the lining is
worn, the clip indicator contacts the rotor and
produces a warning noise~
1@1
Measure
Flatness of inner and outer pads. Place pad

surfaces together and check for gap between
surfaces. If more than 0.13 mm (0.005 inch) gap
is measured midway between attaching lugs, pads
must be replaced.
4-25-94
FS001581
Figure 1 - Front Disc Brake Inner and Outer Pad

Inspection
FRONT BRAKE ROTOR INSPECTION
Front Brake Rotor Tolerance and Surface

Finish
In manufacturing the rotor, tolerances of the
braking swfaces for flatness, thickness variation and
lateral runout are very closely held. The maintenance
of close tolerances on the shape of the braking
swfaces is necessary to prevent brake roughness.
In addition to these tolerances, the surface finish
must be held to a specified range of 60 Ra roughness
or less. A new rotor falls into this swface range, as
will a rotor that is refinished exactly as directed in
"Refinishing Front Brake Rotors " in this section. The
control of the braking swface finish is necessary to
avoid problems of hard pedal-apply, excessive brake
fade, pulls and erratic performance and to extend
lining life.
Light scoring of the rotor surfaces not exceeding
1.5 mm (0.06 inch) in depth, which may result from
normal use, will not affect brake operation.
Thickness Variation Check

Thickness variation can be checked by
measuring the thickness of the front brake rotor at four
or more points around its circumference. All
measurements must be made at the same distance in
from the edge of the rotor. A rotor that varies by more
than 0.013 mm (0;0005 inch) can cause brake pedal
pulsation and/or front end vibration during brake
FRONT DISC BRAKES

applications. A rotor that does not meet these
specifications should be refinished to specifications or
replaced.
Lateral Runout Check
NOTICE:
Whenever the rotor has been

separated from the wheel bearing flange, clean
any rust or foreign material from the mating
surface of the wheel flange and brake rotor.
Failure to do this may result in increased lateral
runout of the rotor and brake pulsation.
Figure 2
A rotor that does not meet the lateral runout

specification should be resurfaced or replaced
as necessary.
Tool Required:
FRONT BRAKE CALIPER INSPECTION
1. Clean surface of rotor (1).

2. Install wheel nuts (13).
!~!
581-3
The front brake caliper must be disassembled for

inspection. Refer to "Front Brake Caliper" under
"Unit Repair" in this section.
Tighten
Wheel nuts (13) in a star pattern to 120 N.m

(89 lb. ft.).
3. Fasten J 800.1 to steering knuckle (18) so that
indicator button contacts rotor surface about
13 mm (0.5 inch) from rotor edge.
4. Set J 8001 to zero.
5. Move rotor ( 1) one complete revolution, and
observe total indicated runout (TIR).
Total indicated runout (TIR) should not be
more than 0.15 mm (0.006 inch).
In some cases, excessive lateral runout of rotor
(1) can be improved by indexing rotor (1) on
hub one or two bolt positions from original
position. Indexing the rotor (1) requires
removal and installation of the front brake
caliper. Refer to "Front Brake Caliper" under
"On-Vehicle Service" in this section. If lateral
runout cannot be corrected by indexing rotor
(1), check hub and front wheel bearing for
excessive lateral runout or looseness. If hub
and bearing lateral runout exceeds 0.040 mm
(0.0015 inch) then replace hub and bearing. If
lateral runout of the hub and bearing is within
specifications then refinish or replace rotor (1)
as necessary.
ON-VEHICLE SERVICE
air on brake parts as damage to rubber
[I]
Important

used to service this front brake caliper.
to ease.
or part of the brake system.
Replace pads in axle sets only.
Perform service operations on a clean bench
FRONT BRAKE CALIPER

Figures 3 through 7
!++l
1. Two-thirds of brake fluid from master cylinder.

SECTION OA.
4. Reinstall wheel nuts to retain rotor (1).
5. Push piston (9) into caliper housing bore to
provide clearance between inner and outer pads (7
and 5) and rotor (1 ).
A. Position C-clamp on housing (12) and against
outer pad (5).
B. Tighten clamp slowly to press piston (9) into
caliper housing bore.
[I]
1 ROTOR, FRONT BRAKE
13 WHEEL NUT
18 KNUCKLE, STEERING
Figure 2 - Lateral Runout Check
1-09-95
FS0025B1
Important
If removing caliper only to access other brake

parts, skip step 6.
If fitting (14) is disconnected, caliper must be
bled during installation.
581-4
FRONT DISC BRAKES
(
2
3
A WEAR SENSOR
2 BOLT/SCREW WITH SLEEVE, FRONT BRAKE
CALIPER
3 BUSHING, FRONT BRAKE CALIPER BOLT
5 PAD, FRONT DISC BRAKE OUTER
7 PAD, FRONT DISC BRAKE INNER
8 BOOT, FRONT BRAKE CALIPER PISTON
9 PISTON, FRONT BRAKE CALIPER
10 SEAL, FRONT BRAKE CALIPER PISTON
11 VALVE, FRONT BRAKE CALIPER BLEEDER
12 HOUSING, FRONT BRAKE CALIPER
20 CAP, FRONT BRAKE CALIPER BLEEDER VALVE
1-09-95
FS003SB1
Figure 3 - Front Brake Caliper
If caliper is not being removed from vehicle

for unit repair, suspend it from front
suspension using a locally fabricated wire
hook.
6. Fitting (14), two copper gaskets, hose (16) from

housing (12), if removing caliper entirely from
vehicle.
A. Plug openings in hose (16) and housing (12) to
prevent brake fluid loss and contamination.
B. Discard copper gaskets.
7. Front brake caliper bolts/screws with sleeves (2).
8. Caliper from rotor (1) and knuckle (18).
Inspect
1. Bolts/screws with sleeves (2) for corrosion and
bushings (3) for cuts and nicks.
If damage is found, use new parts, when
installing caliper.
Do not attempt to polish away corrosion.
16
18
A C-CLAMP
1 ROTOR, FRONT BRAKE
1-09-95
FS00451i11
Figure 4 - ~ompressing Front Brake Caliper Piston
2
12
14
16
18
BOLT/SCREW WITH SLEEVE, FRONT BRAKE CALIPER

HOUSING, FRONT BRAKE CALIPER
FITTING, FRONT BRAKE HOSE
HOSE, FRONT BRAKE
1-09-95
KNUCKLE, STEERING
FS005581
Figure 5 - Front Brake Caliper Attachment
FRONT DISC BRAKES 581 5

A
A
2
12
A ADD SILICONE GREASE TO INNER DIAMETER OF
BUSHING
.
2 BOLT/SCREW WITH SLEEVE, FRONT BRAKE CALIPER
3 BUSHING, FRONT BRAKE CALIPER BOLT
4-25-94
12
FS007581
A WIRE HOOK
18 KNUCKLE, STEERING
1-09-95
FS006581
Figure 6 - Suspending Front Brake Caliper
2. Fitting (14).
If through-hole in fitting (14) is blocked,
remove blockage or replace fitting (14).
!++-I
Install or Connect
NOTICE:
Inspect
A. Bolt/screw with sleeve (2) should slide through

bushing (3) using only hand pressure.
If greater force is required or mechani~al
assistance is needed, remove bolt/screw with
sleeve (2) along with bushing (3).
B. Mounting bore.s for corrosion.
a. If mounting bores show signs of corrosion,
remove corrosion using a 1-inch wheel
cylinder housing brush.
b. Clean mounting bores with clean denatured
alcohol.
C. Replace bushings. Refer to "Front Brake Caliper"
under "Unit Repair" in this section.
!~!
Tighten
Bolts/ screws with sleeves (2) to 51 N.m

(38 lb. ft.).
3. Caliper onto rotor (1) and knuckle (18).
4. Fitting (14), two new copper g~skets, and hose
(16) to housing (12), if removed.
I~!
5. Wheel nuts securing rotor to steering knuckle

flange.
7. Lower vehicle.
8. Fill master cylinder reservoir to proper level.
[[) Important
Refer to "Notice" on page SBl-1.
1. Lubricate inner diameters of bushings (3) with

silicone grease GM PIN 1052863 or equivalent.
2. Bolts/screws with sleeves (2).
JL1'!
Figure 7 - Lubricating Front Brake Caliper Bolt Sleeve and

Bushing
Tighten
Fitting (14) to 44 N.m (32 lb. ft.).
If hose (16) was removed, bleed caliper. Refer
to SECTION 5El.
FRONT DISC BRAKE PADS

Figures 3, 6 and 8 through 12
1. Front brake caliper. Refer to "Front Brake
Caliper" under "On-Vehicle Service" in this
section.
2. Outer pad (5). Use screwdriver to disengage
buttons on shoe from holes in caliper housing.
3. Inner pad (7).
Clean
Wipe outside surface of boot (8).

-
Use denatured alcohol.
[[) Important
1. Bottom piston (9) into caliper housing bore.
A. Use a large C-clamp positioned on housing
(12) and inside piston well.
B. Tighten clamp slowly to press piston (9)
into caliper housing bore:
2. With piston (9) bottomed in caliper ho~sing
bore, lift inner edge of boot (8) next to piston
(9) .and press out any trapped air.
Boot (8) must lay flat.
5816
FRONT DISC BRAKES
8
4-25-94
FS010681
Figure 10 - Lifting Front Brake Caliper Piston Boot

1--09-95
FS0085B1
Figure 8 - Removing Outer Pad
A
7
8
12
1-09-95
FS011681
Figure 11 - Installing Front Disc Brake Inner Pad

12
RETAINER SPRING
PAD, FRONT DISC BRAKE INNER
BOOT, FRONT BRAKE CALIPER PISTON
PAD, FRONT DISC BRAKE INNER

12
1-09-95
FS009SB1
Figure 9 - Front Disc Brake Inner and Outer Pads
!++!
Install or Connect
1. Inner pad (7).
A. Inner pad retainer spring into piston (9) .. The

retainer spring is staked to the inner pad (7).
B. Inner pad (7) must lay flat against piston (9).
C. Check that boot (8) and inner pad (7) are not
touching. If there is contact, remove inner pad
(7) and re-seat or re-position boot (8).
2. Outer pad (5).
Back of outer pad (5) must lay flat against
housing (12).
Wear sensor should be at trailing .lower edge
of outer pad (5) during forward wheel rotation.
If not, outer pad (5) is on wrong side.
3. Front brake caliper. Refer to "Front Brake
Caliper" under "On-Vehicle Service" in this
\~ ...
section. .
4. Apply approximately 778 N (175 pounds) of force
to brake pedal three times to seat pad linings.
'{:\,
A WEAR SENSOR
5 .PAD.FRONT DISC BRAKE OUTER
12 .HOUSING, FRONT BRAKE CALIPER
1-09-95
FS0126B1
Figure 12 - Installing Front Disc Brake Outer Pad
FRONT DISC BRAKES
II]
Important
GM replacement brake lining material is

recommended for all GM vehicles to maintain
the balance between front and rear brake
performance. GM replacement brake parts
have been carefully selected to provide the
proper brake balance for purposes of both
stopping distance and controllability over the
full range of operating conditions. Installation
of front or rear brake lining material with
performance different from that of the GM
replacement parts recommended for this
vehicle can change the intended brake balance
of this vehicle.
FRONT BRAKE ROTOR

The rotor is an integral part of the hub. For
removal procedure, refer to SECTION 3C.
UNIT REPAIR
REFINISHING FRONT BRAKE ROTORS
II]
Important
DO NOT refinish rotors when performing

routine brake maintenance such as replacing
worn front 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
(0.06 inch).
All rotors have a minimum thickness dimension
cast into them. This dimension is the minimum wear
dimension and not a refinish dimension. The minimum
refinish dimension is greater than the discard
dimension. Do not use a rotor that will not meet
specifications. Replace with a new rotor. Refer to
"Specifications" in this section.
Since accurate control of the rotor tolerances is
necessary for proper performance of the front disc
brakes, the rotor should be machined only with
precision equipment. Equipment should be serviced on
a regular basis following the manufacturer's
recommended .maintenance procedure.
When refinishing rotors, the attaching adapters,
tool holders, vibration dampeners and tool bits must
be in good condition. Always use sharp cutting tools
or bits and use only replacement cutting bits
recommended by the equipment manufacturer. Dull or
worn tools leave a poor surface finish which will
affect. braking performance. Vibration dampening
attachments should always be used when refinishing
braking surfaces. These attachments eliminate tool
chatter and will result in better surface finish. Make
sure these adapters are clean and free of nicks.
On-Vehicle Procedure .
Tool Required: On-Vehicle Brake Lathe, such as
Kent-Moore
J 37704 On Disc Brake Lathe
581-7
In the cases where rotors are being refinished

to correct a problem with brake pulsation, it is
recommended that an on-vehicle brake lathe be
used to achieve best results. Follow the equipment
manufacturer's recommended specifications and
procedure.
Off-Vehicle Procedure
II]
Important
Remove rust and scale from rotor and steering

knuckle spindle 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 steering
knuckle spindle.
There are two recommended procedures under
"Rotor Refinishing Specifications" in this section that
achieve adequate results. using two different off-vehicle
drum/disc brake lathes. (If any other lathe is used,
follow that lathe's instructions and recommendations.)
Non-Directional Finishing
It is very important that the rotor surface be
made non-directional by dressing the rotor surfaces
with a sanding disc tool such as Ammoco 8750 Safe
Swirl Disc Rotor Grinder, Accuturn 433179
Non-Directional Swirl Finisher, or equivalent, using
120 grit aluminum oxide sandpaper. Sand each rotor
surface with moderate pressure for a minimum of
60 seconds. If the brake lathe is not equipped with an
adequate non-directional finishing tool, an alternate
method is to use a sanding block with 150 grit
aluminum oxide sandpaper. With the rotor turning at
the equipment manufacturer's highest recommended
cutting speed, sand each rotor surface for a minimum
of 60 seconds .using moderate pressure. After the
rotor has been sanded, clean each surface
with denatured alcohol or a suitable brake
cleaner.
The finished rotor surface should be as close. to
that of a new front brake rotor as possible. Failure to
obtain the best possible finish may affect braking
performance.
[I]
Important
Front brake rotors should always be replaced if

turning will result in a front brake rotor that
does not meet manufacturer specifications for
minimum thickness. When installing new
brake rotors, do not refinish the surfaces of
these parts. New brake rotors have the correct
level of surface finish.
Burnishing Front Brake Rotors

After front brake pads have been replaced, it is
very important that the new braking surface be broken
in, or burnished. In addition, light corrosion on the
rotors can be removed by burnishing the new .braking
surface. This can be accomplished by making 20 stops
581-8
FRONT DISC BRAKES
from 48 km/h (30 mph), using medium to firm brake

pedal pressure. Take care to avoid overheating the
brakes.
FRONT BRAKE CALIPER

Tool Required:
J 26267 Dust Boot Seal Installer
l+!+I
Disassemble
NOTICE: Use clean shop towels to pad

interior of caliper housing during piston
removal. Use just enough air to ease the piston
out of the bore. If the piston is blown out, even
with the padding provided, it may be damaged.
10
1. Remove caliper from vehicle. Refer to "Front

Brake Caliper" under "On-Vehicle Service" in
this section.
2. Bushings (3).
ILI
&,--11 A
..
Inspect
A. Bushings (3) for nicks or cuts. Replace if

damaged.
B. Mounting bores for corrosion.
a. If mounting bores show signs of corrosion,

remove corrosion using a 1-inch wheel
cylinder honing brush.
b. Clean mounting bores with clean denatured
alcohol.
CAUTION: Do not place fingers in front of

the caliper piston(s) in an attempt to
catch or protect it when applying
compressed air. The piston(s) can fly out
with force and result in serious injury.
A
B
3
8
9
10
11
12
20
-20
GROOVE
BEVEL END FIRST
BUSHING, FRONT BRAKE CALIPER BOLT
BOOT, FRONT BRAKE CALIPER PISTON
PISTON, FRONT BRAKE CALIPER
SEAL, FRONT BRAKE CALIPER PISTON
VALVE, FRONT BRAKE CALIPER BLEEDER
CAP, FRONT BRAKE CALIPER BLEEDER VALVE
4-26-94
FS0145B1
Figure 14 - Front Brake Caliper Components
3. Piston (9) from housing (12).

Apply compressed air to housing inlet hple.
Piston (9) for scoring, nicks, corrosion, and
worn or damaged chrome plating.
- Replace piston if any of above are found.

4-25-94
FS016681
Figure 15 - Removing Front Brake Caliper Piston Boot
4. Boot (8) from housing (12).
4-25-94FS013SB1
Figure 13 - Removing Front Brake Caliper Piston
NOTICE: Do not use a metal tool to remove

the piston seal from the caliper housing . bore.
Using a metal tool may damage the caliper bore
or seal groove.
5. Piston seal (10) from housing (12).
FRONT DISC BRAKES
581-9
8
12

4-25-94
FSOl65B1
Figure 16 - Installing Front Brake Caliper Piston Boot
!L!
Inspect
Caliper bore and seal groove for scoring, nicks,

corrosion, and wear.
A. Use crocus cloth to polish out light corrosion.
B. Replace housing (12) if corrosion in andaround seal groove will not clean up with
crocus cloth.
6. Bleeder valve cap (20) and bleeder valve (11)
from housing (12).
!+;+!
Assemble
NOTICE:
Refer to "Notice" on page 5Bl-L
Clean
A. All parts in clean denatured alcohol.

B. Dry with unlubricated compressed air.
C. Blow out all passages in housing (12) and bleeder
valve (11).
1. Lubricate all rubber parts with clean brake fluid.
2. Bleeder valve (11) into housing (12).
!~!
4-25-94
FS0176B1
Figure 17 - Seating Front Brake Caliper Piston Boot
3. Replace bleeder valve cap (20).

4. Piston seal (10) into bore groove of housing (12).
_. Make sure piston seal (10) is not twisted.
5. Boot (8) onto piston (9).
6. Piston (9) with assembled boot (8) into bore of
housing (12).
Push piston (9) to bottom of housing bore.
7. Seat boot (8) into counterbore of housing (12)
using J 26267.
8. Bushings (3).
A. Lubricate beveled end of bushing (3) with GM
B. Pinch bushing (3) and install bevel end first.
C. Push bushing (3) through housing mounting
bore.
9. Install caliper. Refer to "Front Brake Caliper"
under "On-Vehicle Service" in this section.
Tighten
Bleeder valve (11) to 13 N.m (115 lb. in.).
SPECIFICATIONS
Front Brake Caliper
Front Brake Caliper Housing Bore Diameter ............................................................. 63.50 mm (2.500 inch)
Front Brake Rotor
Rotor Diameter (Nominal) ........................................................................................ 278.00 mm (10.945 inch)
Lateral Runout ................................................................................................................ 0.13 mm (0.005 inch)
Thickness Variation .................................................................. :.................................. 0.013 mm (0.0005 inch)
Rotor Thickness (Maximum) ....................................................................................... 32.00 mm ( 1.260 inch)
Minimum Thickness After Refinish ............................................................................ 31.74 mm (1.250 inch)
Discard Thickness ........................................................................................................ 30.70 mm (1.209 inch)
All front brake rotors have a discard dimension cast into them. This is a wear dimension and not a
refinish dimension. Any front brake rotor which does not meet the specifications should be replaced.
581-10
FRONT DISC BRAKES
ROTOR REFINISHING SPECIFICATIONS

Ammco Brake Lathe
Rough Cut
Spindle Speed ........................................................................ ;........................................................... 150 rpm
Depth of Cut (Per Side)-................................................ 0.15 mm to 0.64 mm (0.006 inch to 0.025 inch)
Tool Cross Feed (Per Revolution) ............................................................................ 0.25 mm (0.010 inch)
Vibration Dampener ................................................................................. ,................................................ Yes
Sand Front Brake Rotor (Swirl Pattern) ........................................................... :....................................... No
Finish Cut
Spindle 'Speed .. .: .......................................... 150 rpm

Depth of Cut (Per Side) ................................................ 0.10 mm to 0.15 mm (0.004 inch to 0.006 inch)
Vibration Dampener ............................................................................................................_. ..................... Yes
Sand Front Brake Rotor (Swirl Pattern) ........................................................................................ :......... Yes
Accuturn Brake Lathe
Finish Cut
Spindle Speed ................................. :; ................................................................................................. 105 rpm
Depth of Cut ............................................................................................................................. As necessary
Vibration Dampener .................................................................................................................................. Yes
Front Brake Caliper Bleeder Valve .......................................... .';.......................... :................ 13 N.ni (115 lb. in.)
Front Brake Caliper Bolt/Screw With Sleeve ........................................................................ 51 N.m (38 lb. ft.)
Front Brake Hose Fitting ................................. :...................................................................... 44 N.m (32 lb. ft.)
Wheel Nut ...... :..................................................................................................................... 120 N.m (89 lb. ft.)
SPECIAL TOOLS
(
,.
~
2.
J26267
J 37704
1. DUST BOOT SEAL INSTALLER

2. ON DISC BRAKE LATHE
3. DIAL INDICATOR SET
4-25-94
FS0185B1
REAR DISC BRAKES 582-1
SECTION 582
REAR DISC BRAKES

becoming airborne.
.
Eye contact rinse thoroughly with water. ,
Skin contact wash with soap and water.
If ingested consult" a physician immediately.
NOTICE: Av~id spilling brake fluid on any of the vehicle's painted surfaces, wiring cables or electrical
connectors. Brake fluid will damage paint and electrical connections: If any fluid is spilled on the vehicle,
immediately flush the area with water to minimize the potential damage.
NOTICE: Always use the correct fastener in the correct location. When you replace a fastener, use O;NLY the
fastener torque and the. joint clamping force, and may damage the fastener. When you install fasteners, use the
and systems.
CONTENTS
General Description ........... ;...................... ;............ 5B2-1
Diagnosis ............................................................... 5B2-2
Rear Disc Brake Pad Inspection ...................... 5B2-2
Rear Brake Rotor Inspection ............................ 5B2~2
Rear Brake Rotor Tolerance and Surface
Finish ........ '. ................ ;............................... 5B2-2
Thickness Variation Check ........................... 5B2-2
Lateral Runout Check ................................... 5B2-2
Rear Brake Caliper Inspection ......................... 5B2-3
On-Vehicle Service ................................................ 5B2-3
Rear Brake Caliper ........................................... 5B2-3
Rear Disc Brake Pads ....................................... 5B2-7
Rear Brake Caliper Anchor Bracket and
Mounting Plate .............................................. 5B2-8
Rear Brake Rotor ............................................ 5B2-8

Parking Brake Free-Travel Adjustment .......... 5B2-9
Unit Repair .......................................................... 5B2-9
Refinishing Rear Brake Rotors ...................... 5B2-9
On-Vehicle ................................................... 5B2-10
Off-Vehicle ................... ;.............................. 5B2-10
Non-Directional Finishing .................... ,...... 5B2-10
Burnishing Rear Brake Rotors ......... ;......... 5B2-11
Rear Brake Caliper ......................................... 5B2-11
Specifications ....................................................... 5B2-14
General Specifications.............................. ;;,.... 5B2-14
Rotor Refinishing Specifications .................... 5B2-14
Fastener Tightening Specifications ................. 5B2-14
Special Tools ............................... ;............... ;....... 5B2-15
GENERAL DESCRIPTION
the rotor creating friction to stop the vehicle. When

the parking brake is applied, the lever on the caliper
causes the pushrod, the actuating collar and the clamp
rod to be moved outward and the caliper to slide
inward, mechanically forcing the pads against the
rotor. Parking orake application is completely
independent of the hydraulic braking system.
. . The rear disc brake rotor. is a composite cast iron
vented rotor. It has a stamped sheet metal flarige
which is insert .cast.
The rear disc brake caliper has a single piston in

an aluminum housing which is suspended in the
anchor bracket on two guide pins. Hydraulic pressure,
created by applying force to the brake pedal, acts
equally against the piston and the bottom of the
caliper .bore to move the piston outward and to slide
the caliper inward resulting in a clamping action on
the rotor. This clamping action forces the pads against
5822
REAR DISC BRAKES
DIAGNOSIS
REAR DISC BRAKE PAD INSPECTION
Figure 1
!L!
Inspect
Pads at least twice a year when the wheels are

removed (tire rotation, etc.). When inspecting rear
disc brakes, check both ends of the outer pad by
looking in at each end of the caliper. These are
the points at which the highest rate of wear
normally occurs. Also, check the lining thickness
of the inner pad to make sure that it has not worn
prematurely. Look through the hole in the top of
the caliper to view the inner pad. Pads should be
replaced when the thickness of any lining is worn
to within 0.76 mm (0.030 inch) of the shoe. All
pads should be replaced in axle sets.
All rear disc brakes have a wear indicator that
makes a noise when the linings wear to a degree
where replacement is required. The wear indicator. is
an integral part of the inner pad. When the pad lining
is worn, the clip indicator contacts the rotor and
produces a warning noise.
!@I
Measure
Flatness of inner and outer pads. Place pacl

surfaces together .and check for gap between
surfaces. If more than 0.13 mm (0.005 inch) gap
is measured midway between attaching lugs, pads
must be replaced.
applications. A rotor that does not meet these

replaced.
Thickness Variation Check

measuring the thickness of the rear brake rotor at four
from the ~ge of the rotor. A rotor that varies by more
than 0.013 mm (0.0005 inch) can cause brake pedal
pulsation and/or rear end vibration during bra~e
applications. A rotor that dose not meet these
replaced.
Lateral Runout Check

Figure 2
.Tool Required:
1. Fasten J 8001 to rear brake caliper housing so that
indicator button contacts the rotor surface about
13 mm (0.5 inch) from rotor edge.
2. Set J 8001 to zero.
Push in rear axle while setting J 8001 to
eliminate endplay.
3. Turn rofor (39) one complete revolution, and
observe total indicated runout (TIR).
Push in .rear axle while turning rotor to
eliminate endplay.
Total indicated runout (TIR) .should not be
REAR BRAKE ROTOR INSPECTION

Rear Brake Rotor Tolerance and Surface
Finish
In manufacturing the rotor, tolerances of the
braking surfaces for flatness, thickness variation and
lateral runout are held very close. The maintenance of
close tolerances on the shape of the braking surfaces is
necessary to prevent brake roughness.
In addition to these tolerances, the surface finish
must be held to a specified range of 60 Ra roughness
or less. A new rotor falls into this surface range,, as
will a rotor that is refinished exactly as directed in
"Refinishing Rear Brake Rotors" in this section. The
control of the braking surface finish is necessary to
avoid problems of hard pedal-apply, excessive brake
fade, pulls and erratic performance and to extend
lining life.
Light scoring of the rotor surfaces not exceediJJ.g
1.5 mm (0.06 inch) in depth, which may result from
normal use, will not affect .brake operation.
measuring the thickness of the rear brake rotor at four
from the edge of the rotor. A rotor that varies by more
than 0.013 mm (0.0005 inch) can cause brake pedal
pulsation and/or rear end vibration during brake
A INSPECTION POINTS
4-25-94
FS0016B2
Figure 1 - Rear Disc Brake Pad Inspection
REAR DISC BRAKES

4. In some cases, excessive lateral runout of rotor
(39) can be improved by indexing rotor (39).
A. Remove tire and wheel. Refer to SECTION 3E.
B. Remove rear brake caliper. Refer to "Rear
Brake Caliper" under "On-Vehicle Service" in
this section.
C. Index rotor (39) on hub one or two bolt
positions from original position.
5. Check lateral runout of rotor (39).
6. If lateral runout of rotor (39) still exceeds
0.15 mm (0.006 inch), check rear axle shaft
flange for excessive lateral runout or looseness.
A. Reposition J 8001 so button contacts surface
of axle shaft flange.
B. Push axle shaft flange inward while turning
the axle shaft flange one full revolution.
C. Continue pushing in axle shaft flange while
setting J 8001 to zero ..
D. While maintaining inward pressure, rotate axle
shaft flange and note lateral runout.
E. If axle shaft flange lateral runout exceeds
0.05 mm (0.002 inch), replace rear axle shaft.
F. If axle shaft flange lateral runout is within
specifications, refinish or replace rotor (39) as
necessary. Refer to "Refinishing Rear Brake
Rotors" under "Unit Repair" in this section.
NOTICE: Whenever the rotor has been
separated from the wheel bearing flange, clean
any rust or foreign material from the mating
surface of the wheel flange and brake rotor.
Failure to do this may result in increased lateral
runout of the rotor and brake pulsation.
G. A rotor that does not meet the lateral runout
specification should be resurfaced or replaced
as necessary.
REAR BRAKE CALIPER INSPECTION

The rear brake caliper must be disassembled for
inspection. Refer to "Rear Brake Caliper" under
"Unit Repair" in this section.
582-3
ONmVEHICLE SERVICE
IT]
Important

used to service this caliper.
to ease.
Replace pads in axle sets only.
REAR BRAKE CALIPER

Figures 3 through 6
!++I
SECTION OA.
2. Parking brake cable at equalizer. Refer to
SECTION SF.
Install wheel nuts to retain rotor (39).
4. Brake hose fitting bolt/screw (32), brake hose
fitting (33) and two gaskets (34) only if caliper is
being removed for overhaul.
A. Discard old gaskets (34).
B. Plug hole in caliper housing (14) and brake
hose fitting (33).
5. Actuator lever return spring (4) only if defective.
Discard actuator lever return spring (4) if coils
are opened.
6. Parking brake cable (35) from parking brake
actuator lever (5) and parking brake cable bracket
O
(8).
7. Vibration dampener nut (41) and vibration

dampener (40) from parking brake cable bracket
(8), if necessary.
8. Upper caliper guide pin bolt/screw (13) and
discard.
9. Lower caliper guide pin bolt/screw (9) and
discard, only if removing caliper from vehicle.
10. Caliper housing (14) from rotor (39) and anchor
bracket (17).
A JOUNCE PAD
39 ROTOR. REAR BRAKE
1-09-95
FS002582
Figure 2 - Checking Lateral Runout
If caliper overhaul or replacement is not

required, hang caliper housing (14) from
suspension to avoid damage to brake hose.
582-4
REAR DISC BRAKES
13
41~
20
(
22
30
1 SEAL, REAR PARKING BRAKE LEVER PIVOT PIN

2 CLIP, REAR PARKING BRAKE LEVER SPRAG
3 PIN, REAR PARKING BRAKE LEVER PIVOT
4 SPRING, REAR CALIPER PARKING BRAKE ACTUATOR
LEVER RETURN
5 LEVER, REAR PARKING BRAKE ACTUATOR
6 VALVE, REAR BRAKE CALIPER BLEEDER,
7 CAP, REAR BRAKE CALIPER BLEEDER VALVE
8 BRACKET, PARKING BRAKE CABLE
9 BOLT/SCfl.EW. LOWER CALIPER GUIDE PIN,
10 SHIM
11 SCREW, PARKING BRAKE LEVER ADJUSTER
12 NUT, REAR PARKING BRAKE LEVER PIVOT PIN,
13 BOLT/SCREW, UPPER CALIPER GUIDE PIN,
14 HOUSING, REAR BRAKE CALIPER
15 PIN. REAR BRAKE CALIPER GUIDE
16 BOOT, REAR BRAKE CALIPER GUIDE PIN

17 BRACKET, REAR BRAKE CALIPER l>.NCHOR
18 SEAL. REAR BRAKE CALIPER PISTON
19 PISTON, REAR BRAKE CALIPER
20 BOOT.ACTUATING COLLAR
21 RETAINER, ACTUATING COLLAR BOOT
22 PUSHROD
23 SPRING, PRELOAD
24 COLLAR. ACTUATING
25 BOOT.ACTUATING COLLAR
28 SPRING, REAR CALIPER PARKING BRAKE COLLAR
RETURN
27 BUSHING
28 ROD, CLAMP
29 PAD. REAR DISC BRAKE INNER
30 PAD, REAR D1SC BRAKE OUTER
40 DAMPENER, REAR BRAKE VIBRATION
41 NUT, REAR BRAKE VIBRATION DAMPENER,
1-09-95
FS003582
(
Figure 3 - Rear Brake Caliper Components

39
8
4 $.PRING, REAR CALIPER PARKING BRAKE ACTUATOR
LEVER RETURN
35 CABLE, PARKING BRAKE REAR
40 DAMPENER, REAR BRAKE VIBRATION
40
14
32
33
34
39
40
HOUSING, REAR BRAKE CALIPER

BOLT/SCREW, REAR BRAKE HOSE FITIING
FITIING, REAR BRAKE HOSE
GASKET, REAR BRAKE HOSE FITIING
ROTOR, REAR BRAKE
DAMPENER. REAR BRAKE VIBRATION
1-09-95
1-09-95
FS004582
FS0055B2
Figure 4 - Removing Rear Brake Hose Fitting
11. Inner and outer pads (29 and 30) only if they are
being replaced or if anchor bracket (17) is being
removed.
12. Shim (10), if inner and outer pads (29 and 30)
were removed.
!L'I'!
Inspect
l. Guide pins (15) for free movement in anchor
bracket ( 17). Rear brake caliper guide pin boot

( 16) for proper seating in retaining groove of
guide pin (15) and rear anchor bracket (17).
Replace guide pins (15) or guide pin boots (16) if
corroded, worn or damaged.
2. Inner and outer pads (29 and 30) for wear and
maximum taper of 0.15 mm (0.006 inch).
Replace with new pads (29 and 30) if they are
tapered beyond specification.
- Replace inner and outer pads (29 and 30)
in sets of four.
3. Brake hose fitting bolt/screw (32).
If through-hole in brake hose fitting bolt/screw
(32) is blocked, remove blockage or replace
brake hose fitting bolt/screw (32).
!-++!
Install or Connect
NOTICE:
Refer to "Notice" on page 5B2-l.
l. New shim (10), if removed.

2. Inner and outer pads (29 and 30), if removed.
Figure 5 - Parking Brake Cable Attachment
[II
Important
Whenever rear disc brake pads are replaced,

immediately check the parking brake
free-travel. Adjust as necessary. Refer to
"Parking Brake Free-Travel Adjustment" in
this section.
A. Outer pad (30) with insulator is installed
toward caliper housing (14). Inner pad (29)
with wear sensor is installed nearest to
piston (19).
B. Wear sensor must be in leading position
with forward wheel rotation. If not, use
other inner pad (29) in replacement kit.
3. Caliper housing (14) over rotor (39) and into
anchor bracket (17).
4. New upper caliper guide pin bolt/screw (13).
I~!
Tighten
Upper caliper guide pin bolt/screw (13) to

37 N.m (27 lb. ft.).
5. New lower caliper guide pin bolt/screw (9), if
removed.
I~!
Tighten
Lower caliper guide pin bolt/screw (9) to

37 N.m (27 lb. ft.).
6. Brake hose fitting (33), two new gaskets (34) and
brake hose fitting bolt/screw (32), if removed.
582-6
REAR DISC BRAKES
A C-CLAMP
17 BRACKET. REAR BRAKE CALIPER ANCHOR
30
4-25-94
FS0075B2
Figure 7 - Compressing Rear Brake Caliper Piston
A
8
9
10
13
14
15
16
17
29
30
40
41
WEAR SENSOR
BRACKET. PARKING BRAKE CABLE
BOLT/SCREW, LOWER CALIPER GUIDE PIN
SHIM
SOLT/SCREW, UPPER CALIPER GUIDE PIN
PIN, REAR BRAKE CALIPER GUIDE
BOOT, REAR BRAKE CALIPER GUIDE PIN
BRACKET, REAR BRAKE CALIPER ANCHOR
PAO. REAR DISC BRAKE INNER
PAD. REAR DISC BRAKE OUTER
NUT, REAR BRAKE VIBRATION DAMPENER
1-09-95
FS006582
l~I
Figure 6 Rear Brake Caliper
Brake hose fitting bolt/screw (32) to 30 N.m

(22 lb. ft.).
7. Vibration dampener (40) and vibration dampener
nut (41) to parking brake cable bracket (8), if
removed.
!~I
30
Tighten
Tighten
Vibration dampener nut (41) to 50 N.m (37 lb. ft.).

8. Parking brake cable (35) to parking brake cable
bracket (8) and parking brake actuator lever (5),
and parking brake cable equalizer.
9. Actuator lever return spring (4), if removed.
10. Bleed brake hydraulic system, if brake hose fitting
was removed. Refer to SECTION 5El.
11. Lower vehicle.
12. Cycle parking brake.
13. Raise arid suitably support vehicle. Refer to
SECTION OA.
13
14
15
17
29
30
39
BOLT/SCREW, UPPER CALIPER GUIDE PIN.

PIN, REAR BRAKE CALIPER GUIDE
BRACKET. REAR BRAKE CALIPER ANCHOR
PAD, REAR DISC BRAKE INNER
PAO, REAR DISC BRAKE OUTER
ROTOR. REAR BRAKE
1-09-95
FS008582
Figure 8 - Rear Disc Brake Inner and Outer Pad

Replacement

REAR DISC BRAKE PADS
38
Figures 3, 7 and 8
[++I
1. Two-thirds of brake fluid from master cylinder

reservoir.
SECTION OA.
Install wheel nuts to retain rotor.

4. Position a C-clamp and tighten until piston (19)
bottoms in base of caliper housing (14).
A
Make sure one end of C-clamp rests on brake

hose fitting bolt/screw (32) and other end
against outer pad (30).
rn
Important
It is not necessary to remove the artuator lever
return spring (4) to replace the inner and outer

pads (29 and 30).
5. Upper caliper guide pin bolt/screw (13).
Discard upper caliper guide pin bolt/screw
(13).
6. Inner and outer pads (29 and 30).
A
B
17
36
38
39
CALIPER REMOVED FROM ANCHOR BRACKET

CALIPER AND ANCHOR BRACKET ASSEMBLED
BRACKET, REAR BRAKE CALIPER ANCHOR
BOLT/SCREW, REAR BRAKE CALIPER MOUNTING PLATE.
ROTOR, REAR BRAKE
1-09-95
FS009582
Figure 9 - Rear Brake Rotor, Caliper Anchor Bracket, and

Mounting Plate
!l!
Inspect
Parking brake actuator levers to make sure

they are against stops on caliper housing (14).
If parking brake actuator levers are not on
their stops, make sure actuator lever return
spring (4) is correctly installed, then refer to
SECTION 5F for parking brake linkage
repairs.
Remove wheel nuts securing rotor (39).
15. Lower vehicle.
16. With engine running, pump brake pedal slowly
and firmly three times to seat inner and outer
pads (29 and 30).
17. Check brake hydraulic system for leaks.
A. Rotate caliper housing (14) about _lowe~ caliper

guide pin bolt/screw (9) and gmde pm (15).
Be careful not to strain hose or cable conduit.
B. Lift out inner and outer pads (29 and 30).
7. Shim (10).
Discard shim (10).
Clean
All residue from shoe guide surfaces on anchor

bracket (17) and caliper housing (14).
llI
Inspect
Guide pins ( 15) for free movement in anchor

bracket (17).
Rear brake caliper guide pin boo~ ( 16)_ for proper
seating in retaining groove of gmde pm (15) and
rear anchor bracket (17).
- Replace guide pins (15) or guide pin boots
(16) if corroded or damaged. Refer to "Rear
Brake Caliper " in this section.
!++I
Install or Connect
NOTICE:
Refer to "Notice" on page 5B2-1.
1. New shim (10).

2. New inner and outer pads (29 and 30).
582-8
REAR DISC BRAKES
[I]
Important
Whenever rear disc brake pads are replaced,

immediately check the parking brake
free-travel. Adjust as necessary. Refer to
"Parking Brake Free-Travel Adjustment" in
this section.
A. Outer pad (30) with insulator is installed
toward caliper housing (14). Inner pad (29)
with wear sensor is installed nearest the
piston (19).
B. Wear sensor must be on leading edge of
inner pad (29) with forward wheel rotation.
If not, use other inner pad (29) in
replacement kit.
C. Replace inner and outer pads (29 and 30)
in axle sets only.
3. Rotate caliper housing (14) into its operating
position.
Springs on outer pad (30) must not stick
through inspection hole in caliper housing
(14). If springs are sticking through inspection
hole in caliper housing (14), lift caliper
housing (14) and reposition outer pad (30).
4. New upper caliper guide pin bolt/screw (13).
!~!
Tighten
REAR BRAKE CALIPER ANCHOR

BRACKET AND MOUNTING PLATE
Figure 9
!++l
Inspect
Rear brake caliper guide pin boot ( 16) for proper

seating in retaining groove of guide pin (15) and
rear anchor bracket (17).
5. With engine running, pump brake pedal slowly
and firmly to seat inner and outer pads
(29 and 30).
!LI
Inspect
Parking brake actuator levers (5) to ensure

they are against stops on caliper housing (14).
-
If parking brake actuator levers are not on

their stops, refer to SECTION 5F for
parking brake linkage repairs.
Remove wheel nuts securing rotor (39).

7. Lower vehicle.
8. Fill master cylinder reservoir to proper level.
1. Caliper. Refer to "Rear Brake Caliper" under

"On-Vehicle Service" in this section.
[I)
Important
Remove anchor bracket (17) only if it is

damaged or if rotor (39) is being removed for
refinishing or other service operations.
2. Two mounting plate bolts/screws (36).
Discard mounting plate bolts/screws (36).
3. Anchor bracket (17) from mounting plate (38).
!++I
Install or Connect
NOTICE:
1. Anchor bracket (17) to mounting plate (38).

2. Two new mounting plate bolts/screws (36).
!~!
Upper caliper guide pin bolt/screw (13) to

37 N.m (27 lb. ft.).
!L!
Tighten
Mounting plate bolts/screws (36) to 100 N.m

(74 lb. ft.).
- Check torque on both mounting plate

bolts/screws (36) immediately.
3. Caliper. Refer to "Rear Brake Caliper" under
REAR BRAKE ROTOR

Figure 9
The rear brake rotor can be removed without
removal of caliper from anchor bracket.
!++!

SECTION OA.
3. Two mounting plate bolts/screws (36).
Discard mounting plate bolts/screws (36).
4. Anchor bracket (17) with assembled caliper from
mounting plate (38) and suspend them from rear
suspension out of the way using locally fabricated
wire hook.
5. Rotor (39).
REAR DISC BRAKES
!++!
Install or Connect
NOTICE:
Refer to "Notice" on page 5B2-l.
1. Rotor (39).
2. Anchor bracket (17) with assembled caliper to
mounting plate (38).
3. Two new mounting plate bolts/screws (36).
!~!
Tighten
Mounting plate bolts/screws (36) to 100 N.m

(74 lb. ft.).
-
Check torque on both mounting plate

bolts/screws (39) immediately.
5. Lower vehicle.
PARKING BRAKE FREE-TRAVEL

ADJUSTMENT
The adjustment process requires a second person

to apply a light brake pedal load. Parking brake lever
free-travel is set by the position of the adjuster screw
(11). Turning the adjuster screw (11) clockwise
increases the free-travel; turning the adjuster screw
(11) counterclockwise decreases the free-travel.
NOTICE: Pads must be new or parallel to
within 0.15 mm (0.006 inch). Parking brake
adjustment is not valid with tapered pads and
may cause caliper/parking brake binding.
[I]
Important
Inspect old pads and replace with new ones if

they are tapered.
Parking brake free-travel should only be
changed if the caliper has been taken apart, or
when the pads are replaced.
This adjustment will not correct a condition
where parking brake actuator levers will not
return to their stops.
1. Disconnect parking brake cable and remove
actuator lever return spring (4).
2. Have an assistant apply light brake pedal load,
enough to stop rotor from turning by hand.
This takes up all clearances and ensures that
components are correctly aligned.
3. Apply light pressure to parking brake actuator
lever (5).
!@I
Measure
Free-travel between parking brake actuator

lever (5) and caliper housing (14) at point B.
-
4. If free-travel is incorrect, do the following:

A.
B.
C.
D.
Remove adjuster screw (11).

Clean thread adhesive residue from threads.
Coat threads with adhesive.
Screw in adjuster screw (11) far enough to
obtain 0.61 mm to 0.71 mm (0.024 inch to
0.028 inch) free-travel between parking brake
actuator lever (5) and caliper housing (14) at
point B.
5. Have assistant release brake pedal, then apply
brake pedal finnly three times.
6. Recheck free-travel as described in steps 2 and 3
and adjust as necessary.
7. Install actuator lever return spring (4) and parking
brake cable.
UNIT REPAIR
REFINISHING REAR BRAKE ROTORS
[I]
Figure 10
Free-travel must be 0.61 mm to 0.71 mm

(0.024 inch to 0.028 inch).
582-9
Important
DO NOT refinish rotors when performing

routine brake maintenance such as replacing
worn rear 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
(0.06 inch).
All rotors have a minimum thickness dimension
cast into them. This dimension is the minimum wear
dimension and not a refinish dimension. The minimum
refinish dimension is greater than the discard
dimension. Do not use a rotor that will not meet
specifications. A rotor that has been refinished too thin
will not have proper heat transfer capabilities. Replace
with a new rotor. Refer to "Specifications" in this
section.
Since accurate control of the rotor tolerances is
necessary for proper performance of the rear disc
brakes, the rotor should be machined only with
precision equipment. Equipment should be serviced on
a regular basis following the manufacturer's
recommended maintenance procedure.
When refinishing rotors, the attaching adapters,
tool holders, vibration dampeners and tool bits must
be in good condition. Always use sharp cutting tools
or bits and use only replacement cutting bits
recommended by the equipment manufacturer. Dull or
worn tools leave a poor surface finish which will
affect braking performance. Vibration dampening
attachments should always be used when refinishing
braking surfaces. These attachments eliminate tool
chatter and will result in better surface finish. Make
sure these adapters are clean and free of nicks.
582-10
REAR DISC BRAKES
14
A APPLY PRESSURE HERE

B MEASURE HERE
LEVER RETURN
5 LEVER. REAR PARKING BRAKE ACTUATOR
(
4-25-94
FS010682
Figure 10 - Parking Brake Free-Travel Adjustment
On-Vehicle
Tool Required: On-Vehicle Brake Lathe, such as
Kent-Moore
J 37704 On Disc Brake Lathe
J 37160-A Brake Rotor Mounting Adapter
In the cases where rotors are being refinished
to correct a problem with brake pulsation, it is
recommended that an on-vehicle brake lathe be
used to achieve best results. Follow the equipment
manufacturer's recommended specifications and
procedure.
Off-Vehicle
Tool Required:
J 37160-A Brake Rotor Mounting Adapter
[I] .Important
Remove rust and scale from rotor and rear
axle shaft flange 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 rear axle
shaft flange.
There are two recommended procedures under

"Rotor Refinishing Specifications" in this section
that achieve adequate results using two different
off-vehicle drum/disc brake lathes. (If any other
lathe is used, follow that lathe's instructions and
recommendations.)
Non-Directional Finishing
It is very important that the rotor surface be
made non-directional by dressing the rotor surfaces
with a sanding disc tool such as Ammco 8750 Safe
Swirl Disc Rotor Grinder, Accuturn 433179
Non-Directional Swirl Finisher, or equivalent, using
120 grit aluminum oxide sandpaper. Sand each rotor
surface with moderate pressure for a minimum of 60
seconds. If the brake lathe is not equipped with an
adequate non-directional finishing tool, an alternate
method is to use a sanding block with 150 grit
aluminum oxide sandpaper. With the rotor turning at
the equipment manufacturer's highest recommended
cutting speed, sand each rotor surface for a minimum
of 60 seconds using moderate pressure. After the
rotor has been sanded, clean each surface
REAR DISC BRAKES
582-11
4. Clamp rod (28) and bushing (27) from actuating

collar (24).
Discard bushing (27).
5. Actuating collar boot retainers (21 and 31),
actuating collar boots (20 and 25) and pushrod
(22) from actuating collar (24).
A. Bend back actuating collar boot retainer tabs
and take apart.
B. Remove preload spring (23) from actuating
collar boot retainer (21).
C. Remove pushrod (22) from actuating collar
boot retainer (21).
D. Remove and discard actuating collar boot
retainers (21 and 31) and actuating collar boots
(20 and 25).
A SHOPTOWEL
4-25-94
FS0115B2
Figure 11 - Removing Rear Brake Caliper Piston
with denatured alcohol or a. suitable brake

cleaner.
The finished rotor surface should be as close to
that of a new rear brake rotor as possible. Failure to
obtain the best possible finish may affect braking
performance.
[I]
Important
Rear brake rotors should always be replaced if

turning will result in a rear brake rotor that
does not meet manufacturer specifications for
minimum thickness. When installing new
brake rotors, do not refinish the surfaces of
these parts. New brake rotors have the correct
level of surface finish.
Burnishing Rear Brake Rotors

After rear brake pads have been replaced, it is
very important that the new braking surface be broken
in, or burnished. In addition, light corrosion on the
rotors can be removed by burnishing the new parking
brake surface. This can be accomplished by making 20
stops from 48 kni/h (30 mph), using medium to firm
brake pedal pressure. Allow 0.8 km (0.5 mile) to
1.6 km (1.0 mile) between stops to avoid overheating
the brakes.
REAR BRAKE CALIPER

!+!+!
Disassemble
1. Remove caliper. Refer to "Rear Brake Caliper"

2. Two collar return springs (26) from actuating
3. Actuating collar (24) with assembled parts.
Firmly but gently pull actuating collar (24)
with assembled parts out of caliper housing
(14) by pulling on both ends of actuating
CAUTION: Do not place fingers in front of

the caliper piston(s) in an attempt to
catch or protect it when applying
compressed air. The piston can fly out
with force and could result in serious
injury.
[I]
Important
Use clean shop towels to pad the inside of the

caliper housing (14) during rear brake caliper
piston removal.
NOTICE: To prevent damage, be careful when

handling rear brake caliper piston.
6. Piston (19) by directing dry, filtered compressed
air into brake hose port of caliper housing (14).
!LI
Inspect
Piston (19) for scoring, nicks, corrosion and

wear.
- Replace piston (19) if necessary.
NOTICE: Do not use a metal tool to remove

the piston seal from the caliper housing. Using a
metal tool may damage the caliper housing bore
or the piston seal groove.
7. Piston seal (18).
Use small wood or plastic tool.
8. Bleeder valve cap (7) and bleeder valve (6).
Discard bleeder valve cap (7).
9. Parking brake lever pivot pin seal (1), sprag clip
(2), actuator lever return spring (4) and parking
brake actuator lever (5) from parking brake lever
pivot pin (3).
Discard sprag clip (2).
!L!
~
Inspect
Contact points on parking brake actuator lever

(5) and parking brake lever pivot pin (3) for
wear and corrosion.
- Replace if necessary.
10. Parking brake lever pivot pin (3) and pivot pin
nut (12), if worn.
11. Adjuster screw (11) from caliper housing (14).
Discard if damaged or worn.
582-12
REAR DISC BRAKES

14
17
A WEAR SENSOR
3 PIN, REAR PARKING BRAKE LEVER PIVOT
LEVER RETURN
6 VALVE, REAR BRAKE CALIPER BLEEDER,
7 CAP, REAR BRAKE CALIPER BLEEDER VALVE
9 BOLT/SCREW, LOWER CALIPER GUIDE PIN
10 SHIM
13 BOLT/SCREW, UPPER CALIPER GUIDE PIN
15 PIN, REAR BRAKE CALIPER GUIDE
17 . BRACKET, REAR BRAKE CALIPER ANCHOR
18 SEAL, REAR 8RAKE CALIPER PISTON
19 PISTON, REAR BRAKE CALIPER
20 BOOT, ACTUATING COLLAR
22 PUSHROD
23 SPRING, PRELOAO
24 COLLAR, ACTUATING
25 BOOT, ACTUATING COLLAR
26 SPRING, REAR CALIPER PARKING BRAKE
COLLAR RETURN
27 BUSHING
28 ROD, CLAMP
29 PAD, REAR DISC BRAKE INNER
30 PAD, REAR DISC BRAKE OUTER
(
28
1-09-95
FS012582
Figure 12 - Rear Brake Caliper - Cutaway View
REAR DISC BRAKES
!L!
Inspect
Caliper anchor bracket (17) for wear and

damage.
- Replace if necessary. Refer to "Rear Brake
Caliper Anchor Bracket and Mounting
Plate" in this section.
Clean
Pad contact area on anchor bracket (17).

12. Two guide pins (15) and guide pin boots (16)
from anchor bracket (17).
~ Clean
1. All parts not included in repair kit in denatured
alcohol.
2. Use dry, filtered compressed air to dry parts.
3. Blow out all passages in caliper housing (14) and
bleeder valve (6).
!L!
Inspect
Caliper housing bore for scoring and corrosion.

Replace caliper housing (14) if badly scored or
corroded around seal area.
!;~I
Assemble
NOTICE:
1. Lubricate new piston seal (18) and caliper housing

bore seal groove with silicone grease or clean
brake fluid.
2. New piston seal (18) into caliper housing seal
groove.
Make sure piston seal (18) is not twisted.
3. Lubricate bore of caliper housing (14) and piston
(19) with clean brake fluid.
4. Piston (19) into bore of caliper housing (14).
Push down by hand to bottom of bore.
!L!
Inspect
Actuating collar (24) and clamp rod (28) for

corrosion and excessive wear on working
faces.
- If corrosion or excessive wear is present,
replace actuating collar.
5. Pushrod (22), new inner and outer actuating collar
boots (20 and 25) and new actuating collar boot
retainers (21 and 31) to actuating collar (24).
A. Lightly coat actuating collar (24) with liquid
lubricant provided in repair kit. Do not use
any other fluid or grease.
B. Install preload spring (23) into new actuating
C. Install new inner and outer actuating collar
boots (20 and 25) into new actuating collar
boot retainers (21 and 31).
D. Install pushrod (22) to new actuating collar
boot retainer (21).
582-13
E. Clamp new actuating collar boot retainers

(21 and 31) firmly against actuating collar
(24).
F. Bend tabs on new actuating collar boot
retainer (21) to hold actuating collar assembly
together.
6. Clamp rod (28) to actuating collar (24) and
actuating collar boot (25).
A. Lightly coat clamp rod (28) with liquid
lubricant provided in repair kit.
B. Slide clamp rod (28) through hole.s in
actuating collar boot (25) and actuating collar
(24).
C. Actuating collar boot (25) must be against
reaction plate on clamp rod (28).
7. New bushing (27) to clamp rod (28).
Lubricate outside of bushing (27) with
provided lubricant.
8. Clamp rod (28) with assembled parts into
connecting hole in piston (19).
A. Lubricate grooved bead of actuating collar
boot (20) and boot groove in caliper housing
(14) with provided lubricant. Use remaining
liquid lubricant to coat actuating collar (24),
especially around center hole.
B. Push clamp rod (28) firmly to bottom of
connecting hole in piston (19).
C. Pull on actuating collar (24) and seat actuating
collar boot (20) into boot groove in caliper
housing (14).
D. Make sure that pushrod (22) enters hole in
caliper housing (14).
9. Two collar return springs (26) to actuating collar
boot retainer (31).
Actuating collar boot retainer (31) must enter
collar return springs (26) at end of second
spring coil.
10. New bleeder valve cap (7) and bleeder valve (6)
into caliper housing (14).
!~!
Tighten

11. Parking brake lever pivot pin (3) and new pivot
pin nut (12) to caliper housing (14), if removed.
!~!
Tighten
Pivot pin nut (12) to 22 N.m (16 lb. ft.).

12. Lubricate parking brake actuator lever (5) and
parking brake lever pivot pin (3) with grease
provided in repair kit.
13. Pivot pin seal (1), parking brake actuator lever
(5), new sprag clip (2) and actuator lever return
spring (4), in that order.
A. Teeth of sprag clip (2) must face away from
parking brake actuator lever (5).
B. Snap pivot pin seal cap over parking brake
lever pivot pin (3).
14. Adjuster screw (11) into caliper housing (14) until
actuating collar (24) is about parallel to piston
bore face of caliper housing (14).
58214
REAR DISC BRAKES
15. New guide pin boots (16) and guide pins (15).
A. Lubricate two guide pins (15) with grease
provided in repair kit.
B. Slide guide pin boots (16) on guide pins (15).
C. Fill guide pin boots (16) with provided grease.
D. Assemble to anchor bracket (17).

E. Make sure guide pin boots ( 16) fit into
grooves of guide pins (15) and anchor bracket
(17).
16. Install caliper. Refer to "Rear Brake Caliper"
SPECIFICATIONS
Rear Brake Caliper
Rear Brake Caliper Housing Bore Diameter (Nominal) ............................................ 40.50 mm (1.595 inch)
Rear Brake Rotor
Rotor Diameter.(Nominal) ........................................................................................ 293.00 mm (11.535 inch)
Lateral Runout
Rear Brake Rotor (On-Vehicle Condition) .................................................:.............. 0.15 mm (0.006 inch)
Rear Axle Shaft Flange ............................................................................................. 0.05 mm (0.002 inch)
Thickness Variation .................................................................................................... 0.013 mm (0.0005 inch)
Rotor Thickness (Maximum) .................... :.................................................................. 20.00 mm (0.787 inch)
Minimum Thickness After Refinish ......................................... :.................... ,............. 18.63 mm (0.733 inch)
Discard Thickness .................... :.........................................................................~ .......... 18.40 mm (0.724 inch)
All rear brake rotors have a discard dimension cast into them. This is a wear dimension and not a
refinish dimension. Any rear brake rotor which does not meet the sp~ifications should be replaced .
.'{,ROTOR REFINISHING SPECIFICATIONS

.ff . Amnico Brake Lathe.,
,
Rough Cut
.. ;
. .. . . ..
, .
Spindle Speed.:.'::':: .......... ,............................................. ,................;-..-..................:........................ :.... :150 tpIIi
Depth of Cut (Per Side) "\'.""""""'"""'""""""""'""'"0.15 mm to 0.64 mm (0.006 inch to 0;025 inch)
Tool Crossfeed (Per Revolution) ............................................................................... 0.25 mm (0.010 inch)
Vibration Dampener ............... '. ................................................................................................................... Yes
Sand Front Brake Rotor (Swirl Pattern) ....................................................................... ,........................... No
Finish Cut
Spindle Speed .................................................................................................................................... 150 rpm
Depth of Cut (Per Side) ................................................ 0.10 mm to 0.15 mm (0.004 inch to 0.006. inch)
Vibration Dampener ................................................................................................................................ :. Yes
Sand Front Brake Rotor (Swirl Pattern) ............................................................................................... ,.. Yes
Accutum Brake Lathe
Finish Cut
Spindle Speed .................................................................................................................................... 105 rpm
Depth of Cut ............................................................................................................................. As necessary
Vibration Dampener .................................................................................................................................. Yes

Lower Caliper Guide Pin Bolt/Screw ..................................................................................... 37 N.m (27 lb. ft.)
Rear Brake Caliper Bleeder Valve .......................................................................................... 11 N.m.(97 lb. in.)
Rear Brake Caliper Mounting Plate Bolt/Screw .................................................................. 100 N,m. (74 lb. ft.)
Rear Brake Hose Fitting Bolt/Screw ...................................................................................... 44 N.m (33 lb. ft.)
Rear Brake Vibration Dampener Nut ..................................................................................... 50 N'.m (37 lb. ft.)
Rear Parking Brake Lever Pivot Pin Nut ......................................................................... ;.... 22 N,m {16 lb. ft.)
Upper Caliper Guide Pin Bolt/Screw ........................................ ,..................................... :....... 37;N,m
(27. :lb. ft.)
,,:;::'
,'
SPECIAL TOOLS
2
~ J 37160-A
.A
o~~
1 BRAKE ROTOR MOUNTING ADAPTER

2 ON DISC BRAKE LATHE
3 DIAL INDICATOR SET
J 37704
J 8001
07-10-95
FSO'l35B2
582-16
REAR DISC BRAKES
BLANK
DUO-SERVO DRUM BRAKES
5C2-1
SECTION 5C2

CAUTION: When servicing brake parts, do not create dust by grinding, sanding brake linings or
becoming airborne.
e Eye contact - rinse thoroughly with water.
If ingested~ contact a physician immediately.
and systems.
CONTENTS
General Description ............................................... 5C2-1
Diagnosis ............................................................... 5C2-1
Rear Brake Shoe Inspection ............................. 5C2-1
Rear Brake Drum Inspection ............................ 5C2-1
Surface Finish ................................................ 5C2-2
Inside Diameter Check ................................. 5C2-2
Out-of-Round or Taper Check ...................... 5C2-2
Runout Check ......... , ...................................... 5C2-2
Balance .......................................................... 5C2-2
On-Vehicle Service ................................................ 5C2-2
Rear Brake Drum ..............................................5C2-2
Rear Brake Shoes .............................................. 5C2-3
Rear Wheel Cylinder ........................................ 5C2-5
Rear Brake Backing Plate ................................ 5C2-6
Rear Brake Drum Adjustment .......................... 5C2-6

Unit Repair ............................................................ 5C2-7
Rear Brake Drum .............................................. 5C2-7
Cracked, Scored or Grooved ........................ 5C2-7
Out-of-Round or Tapered ............. ,............... 5C2-7
Refinishing ..................................................... 5C2-7
Replacing Drums ........................................... 5C2-8
Balance .......................................................... 5C2-8
Rear Wheel Cylinder ............................ .- ........... 5C2-8
Specifications ......................................................... 5C2-9
General Specifications ....................................... 5C2-9
Drum Refinishing Specifications ...................... 5C2-9
Fastener Tightening Specifications ................... 5C2-9
Special Tools ......... ;............................................... 5C2-9
GENERAL DESCRIPTION
DIAGNOSIS
The rear drum brake is a duo-servo design. In

the duo-servo brake, the force which the rear wheel
cylinder applies to the primary shoe is multiplied by
the primary lining friction to provide a very large
force applied to the secondary shoe. Adjustment for
both the shoes is automatic during reverse brake
applications.
The rear brake drum has a honed friction surface
that reduces shoe slap, increases lining life, and
reduces the break-in time.
REAR BRAKE SHOE INSPECTION

When the thickness of any lining is worn within
0.76 mm (0.030 inch) of the shoes, the shoes must be
replaced. Replace shoes in axle sets only.
REAR BRAKE DRUM INSPECTION

Pulsation in the brake pedal is usually corrected
by servicing the front brakes. Service the rear brakes
only if the problem persists.
5C2-2
To determine if the front or rear brakes are at

fault, drive the vehicle in an area away from people
and moving traffic (such as a large parking lot), and at
a slow speed. Lightly apply the parking brake, and
feel for the pulsation. Be careful not to lock the brakes
and flat-spot the rear tires. If the pulsation is not
noticed, the fault is probably in the front brakes.
When drums are removed, thoroughly clean and
inspect them for cracks, scores, deep grooves,
out-of-round and taper.
Surface Finish
Normal light scoring of the drum surfaces not
exceeding 0.51 mm (0.020 inch) in depth will not
affect brake operation.
Inside Diameter Check
Replace shoes in axle sets only.

REAR BRAKE DRUM

Figu~ 1
!++I

SECTION OA.
2. Tire and wheel. Refer to SECTION 3E...
The nominal inside diameter of the drum 1s

241.30 mm (9.500 inches).
Out-of-Round or Taper Check

An out-of-round or tapered drum makes accurate
primary or secondary shoe adjustment impossible and
is likely to cause excessive wear of other parts of
brake mechanism due to its eccentric action. An
out-of-round drum can also cause severe and irregular
tire tread wear as well as a pulsating brake pedal.
When the drum exceeds the specification limits in
taper and/or out-of-round, refinish drum to true up the
braking surface. Out-of-round as well as taper and
wear can be accurately measured with an inside
micrometer fitted with proper extension rods.
When measuring a drum for out-of-round, taper,
and wear, take measurements at the open and closed
edges of machined surface and at right angles
(90 degrees) to each other.
Mark relationship of wheel to axle flange.

NOTICE: Be careful not to drop the brake
drum during handling. An out-of-round
condition can occur from even the smallest fall,
resulting in brake pulsation.
(
A
Runout Check
Runout for drums is not to exceed 0.15 mm
(0.006 inch).
Balance
, During manufacture, weights are used to balance
drums. These weights must not be removed. After
drums have been refinished or if difficulty is
experienced in maintaining proper wheel balance,
drums should be checked for balance. Drums may be
checked for balance on most off-the-vehicle wheel
balancers.
ON-VEHICLE SERVICE
(I]
Important

used to service this drum brake.
Lubricate parts as specified.
or part of the brake system.
A SCREWDRIVER USED ONLY WHEN BACKING OFF

ADJUSTMENT
B BRAKE ADJUSTING TOOL
C ST AR WHEEL ROTATION TO RETRACT REAR BRAKE
SHOES
D STAR WHEEL ROTATION TO EXPAND
REAR BRAKE SHOES
7 ACTUATOR, REAR BRAKE SHOE ADJUST
29 PLATE, REAR BRAKE BACKING
4-25-94
FS0015C2
Figure 1 - Backing Off Rear Brake Shoe Adjustment

NOTICE: Do not pry against the splash shield
or backing plate in an attempt to free the drum.
This will bend the splash shield or backing
plate. A bent backing plate may cause brake
chatter and/or pulsation.
3. Drum.
A. Mark relationship of drum to axle flange.
B. If you have trouble removing rear brake drum,
try the .following:
a. Make sure parking brake is released.
b. Disconnect parking brake cables from
equalizer. Refer to SECTION 5F.
c. Remove adjusting hole cover or knockout
plate from backing plate (29) and back off
adjusting screw, using screwdriver and
brake adjusting tool.
d. Use rubber mallet to tap gently on outer
rim of drum and/or around inner drum
diameter by axle flange and/or axle pilot,
while pulling outward on drum. Take care
not to deform drum by excessive use of
force.
!++!
Install or Connect
~ Adjust
Rear drum brakes. Refer to "Rear Drum Brake
Adjustment" in this section.
1. Drum.
Align locating marks on drum and axle flange.
Align locating marks on wheel and axle
flange.
If knockout plate was removed, an adjusting
hole cover, GM PIN 5464803 must be
installed.
If parking brake cables were disconnected
from equalizer, install to equalizer.
3. Lower vehicle.
4. Cycle parking brake lever three times.
REAR BRAKE SHOES

Figures 2 through 4
Tools Required:
J 8049 Brake Spring Remover and Installer
J 8057 Brake Spring Pliers
!+-+!
1. Drum. Refer to "Rear Brake Drum" under

CAUTION: Keep fingers away from rear

brake shoe return springs to prevent
fingers from being pinched between
spring and shoe web or spring and
backing plate.
2. Return springs (1 and 2) using J 8049.
5C2-3
3. Hold-down springs (3) and pins (5) using suitable

pliers.
4. Actuator pivot (4).
5. Actuator link (6) while lifting up on actuator (7).
6. Actuator (7) and actuator return spring (8).
7. Shoe guide (32), strut (9) and strut spring (10).
8. Primary shoe (13) and secondary shoe (14) from
backing plate (29) and parking brake rear cable.
9. Adjuster (31) and spring (15).
10. Parking brake cable from parking brake lever (12)
by pushing parking brake lever (12) into parking
brake cable return spring (30). Disengage cable
end from parking brake lever (12).
11. Primary shoe (13) with parking brake lever (12)
and parking brake cable return spring (30).
12. Parking brake lever (12).
A. Pry open retainer ring (17), remove and
discard.
B. Push out pivot pin (11 ).
~ Clean
1. Adjuster (31).
A. Clean adjusting screw threads with wire brush.
B. Wash all components in clean denatured
alcohol.
C. Lubricate shoe pads and adjuster screw threads
with a film of GM 9985907 lubricant or
equivalent, inside diameter of adjust socket
(16) and adjust socket face.
Adequate lubrication is achieved when a
continuous bead of lubricant is at open end
of adjust nut (18) and adjust socket (16)
when threads are fully engaged.
2. Backing plate (29) and lubricate contact surfaces
with brake lubricant, GM PIN 9985907 or
equivalent.
O
!L"'!
Inspect
1. Threads of adjuster (19) for smooth rotation over

full length.
2. All parts.
If any parts are of doubtful strength or quality
due to discoloration from heat, overstress, or
wear, the parts should be replaced.
!++I
Install or Connect
NOTICE:
Refer to "Notice" on page 5C2-1.
1. Parking brake lever (12).

A. Insert pivot pin (11) through holes in primary
shoe (13) and parking brake lever (12).
B. Install and crimp new retainer ring ( 17).
2. Parking brake cable to parking brake lever (12) by
pulling back parking brake cable return spring
(30). Engage cable end into parking brake lever
(12).
3. Adjuster (31) and spring (15).
5C24
(
B
12
17
29
6
A
22
(
30
\'B
3
A
B
C
1.
2
3
4
5
6
7
B
9
10
11
12
13
14
15
16
SHOE PAD
ANCHORPIN
REAR AXLE FLANGE
SPRING, REAR BRAKE SHOE RETURN
SPRING, REAR BRAKE SHOE RETURN
SPRING, REAR BRAKE SHOE HOLD-DOWN
PIVOT, REAR BRAKE SHOE ADJUST ACTUATOR
PIN, REAR BRAKE SHOE .
LINK. REAR BRAKE SHOE ADJUST ACTUATOR
ACTUATOR. REAR BRAKE SHOE ADJUST
SPRING, REAR BRAKE SHOE ADJUST
ACTUATOR RETURN
STRUT, REAR PARKING BRAKE LEVER
SPRING, REAR PARKING BRAKE LEVER STRUT
PIN, REAR PARKING BRAKE LEVER PIVOT
LEVER, REAR PARKING BRAKE
SHOE, REAR BRAKE PRIMARY
SHOE, REAR BRAKE SECONDARY
SOCKET, REAR BRAKE SHOE ADJUST
17
18
19
20
21
22
23
24
25
26
28
29
30
31
32
34
35
36
RING, REAR PARKING BRAKE LEVER RETAINER

NUT, REAR BRAKE SHOE ADJUST
ADJUSTER. REAR BRAKE SHOE
VALVE, REAR BRAKE BLEEDER
BOLT/SCR~W, REAR WHEEL CYLINDER,
BOOT, REAR WHEEL CYLINDER PISTON
PISTON, REAR WHEEL CYLINDER
SEAL, REAR WHEEL CYLINDER PISTON
SPRING, REAR WHEEL CYLINDER PISTON
BODY, REAR WHEEL CYLINDER
CYLINDER, REAR WHEEL
SPRING, PARKING BRAKE CABLE RETURN
ADJUSTER, REAR BRAKE SHOE
GUIDE, REAR BRAKE SHOE
CAP, BLEEDER VALVE
BOLT/SCREW, REAR BRAKE BACKING PLATE _ _
1 09 85
FS0025C2
Figure 2 Rear Brake Components
5C2-5
5. Strut (9) and strut spring (10) by spreading

primary shoe (13) and secondary shoe (14) apart.
For proper positioning:
29
6.
7.
8.
9.
10.
11.
12.
A
B
12
13
29
30
A. Strut end without strut spring (10) engages

parking brake lever (12) and primary shoe (13)
or secondary shoe (14).
B. Strut end with strut spring ( 10) engages
opposite primary shoe ( 13) or secondary shoe
(14).
Shoe guide (32).
Actuator (7) and actuator return spring (8).
Pins (5), actuator pivot ( 4) and hold-down springs
(3).
Actuator link (6) on anchor pin.
Actuator link (6) into actuator (7) while holding
up on actuator (7).
Return springs (1 and 2) using J 8057.
Drum. Refer to "Rear Brake Drum" under
REAR WHEEL CYLINDER
REAR PARKING BRAKE LEVER NOTCH

REAR PARKING BRAKE CABLE END
LEVER, REAR PARKING BRAKE
SPRING, PARKING BRAKE CABLE RETURN
Figure 5
I++!
4-25-94
FS003SC2
Figure 3 - Removing Parking Brake Cable
4. Primary shoe (13) and secondary shoe (14) to

backing plate (29) and parking brake rear cable.
A. Start the shoe spring tang into the piston near
the I.D. of the shoe.
B. Pull up on the shoe, compress the shoe spring
tang, and rotate the shoe towards the piston
face until the opposite shoe spring tang snaps
into the piston. Shoe should lay flat against
piston.
C. After installing shoe and lining, check that the
boot is not touching the shoe. If it is, remove
the shoe and lining and re-seat or reposition
the boot.

SECTION OA.
Clean
Dirt and foreign material around wheel

cylinder (28) and rear brake rear pipe.
2. Primary and secondary shoes. Refer to "Rear
Brake Shoes" in this section.
3. Brake pipe fitting and rear brake rear pipe.
Plug opening in rear brake rear pipe to prevent
brake fluid loss and contamination.
5. Wheel cylinder (28).
B
A
B
13
14
15
16
18
19
31
STARWHEEL
PROPER SPRING INSTALLATION
SOCKET, REAR BRAKE SHOE ADJUST
NUT, REAR BRAKE SHOE ADJUST
1-09-95
FS0045C2
Figure 4 - Rear Brake Shoe Adjuster
5C2-6

3. Rear axle shaft. Refer to SECTION 4B.
4. Parking brake cable from rear brake backing
plate. Refer to SECTION 5F.
5. Brake pipe from wheel cylinder (28).
6. Wheel cylinder. Refer to "Wheel Cylinder" under
7. Backing plate bolts/screws (36) and nuts (35).
8. Backing plate (29) from axle flange.
I++!
Install or Connect
NOTICE:
Refer to "Notice" on page 5C2-l.
1. Backing plate (29) to axle flange.

2. Backing plate bolts/screws (36) and nuts (35).
!~I Tighten
21
28
I++!
BOLT/SCREW, REAR WHEEL CYLINDER

CYLINDER, REAR WHEEL
Backing plate nuts (35) to 58 N.m (43 lb. ft.).

3. Wheel cylinder. Refer to "Wheel Cylinder" under
4. Rear brake rear pipe to wheel cylinder (28).
4-25-94
FS0065C2
Figure 5 - Rear Wheel Cylinder
Install or Connect
NOTICE:
Refer to "Notice" on page 5C2-1.
1. Wheel cylinder (28).

Hold in place with wooden block between
wheel cylinder (28) and axle flange.
!~!
Tighten

3. Rear brake rear pipe.
I~!
Tighten
Brake pipe fitting to 17 N.m (13 lb. ft.).

5. Lower vehicle.
SECTION 5El.
REAR BRAKE BACKING PLATE

Figure 2
l++I

SECTION OA.
!~I Tighten
Brake pipe fitting to 17 N,m (13 lb. ft.).
5. Parking brake cable to brake backing plate. Refer
to SECTION 5F.
6. Rear axle shaft. Refer to SECTION 4B.
SECTION 5El.
Adjust
Rear drum brakes. Refer to "Rear Drum Brake

9. Lower vehicle.
REAR BRAKE DRUM ADJUSTMENT

Figures 4, 6 and 7
Tool Required:
J 21177-A Drum-to-Brake Shoe Clearance
Gage
!++!

SECTION OA.
3. Drums. Refer to "Rear Brake Drum" under
33 DRUM. REAR BRAKE
1-09-95
FS0065C2
19
Figure 6 - Setting Tool to Rear Brake Drum
IL'I'!
Inspect
Rear brakes.
A. Set J 21177-A so that it contacts inside
diameter of drum (33).
B. Position J 21177-A over primary and
secondary shoes (13 and 14).
C. Turn star wheel on adjuster (19) until primary
and secondary shoes (13 and 14) contact
J 21177~A.
Outside diameter of primary shoe (13) and
secondary shoe (14) will be approximately
1.27 mm (0.050 inch) less than inside
diameter of drum (33) on each wheel.
lH!
5C2-7
Install or Connect
1. Drums. Refer to "Rear Brake Drum" under

3. Lower vehicle.
4. Make several stops, applying firm force to brake
pedal.
Repeat until ample pedal reserve is built up.
UNIT REPAIR
REAR BRAKE DRUM
Cracked, Scored or Grooved
A cracked drum is unsafe for further service and
must be replaced. Do not attempt to weld a cracked
drum.
Smooth up any slight scores. Heavy or extensive
scoring will cause excessive brake lining wear, and it
may be necessary to refinish the drum braking surface.
If the brake linings are slightly worn, but still
reusable, and the drum is grooved, polish the drum
with fine emery cloth but do not refinish. Eliminating
all grooves in the drum and smoothing the ridges on
the shoe linings would require removing too much
metal and lining, while if left alone, the grooves and
ridges match and satisfactory service can be obtained.
A
13
14
19
STARWHEEL
4-25-94
FS0075C2
Figure 7 - Setting Rear Brake Primary and Secondary

Shoes to Tool
If brake linings are to be replaced, refinish a

grooved drum. A grooved drum, if used with new
lining, will not only wear the lining, but will make it
difficult, if not impossible, to obtain proper brake
performance.
Out-of-Round or Tapered
An out-of-round or tapered drum prevents
accurate rear brake shoe adjustment and is likely to
cause excessive wear of other brake parts due to its
eccentric action. An out-of-round drum can also cause
severe and irregular tire tread wear as well as a
pulsating brake pedal. When the drum exceeds the
specification limits in taper and/or out-of-round,
refinish drum to true up the braking surface.
Out-of-round as well as taper and wear can be
accurately measured with an inside micrometer and
extension rods.
When measuring a drum for out-of-round, taper,
and wear, take measurements at the open and closed
edges of the machined surface and at right angles
(90 degrees) to each other.
Refinishing
All drums have a maximum diameter cast into
them. This diameter is the maximum wear diameter
and not a refinish diameter. Do not refinish a drum
that will not meet the specifications. Refer to
"Specifications" at the end of this section.
Any drum that does not meet specifications
shown should be replaced.
5C2-8
When refinishing a drum, resurface the drum to

no more than a dimension of 0.76 mm (0.030 inch)
less than the discard diameter; The refinish diameter is
the maximum diameter the drum should be refinished
to, and still allow safe braking action. If this
dimension is exceeded, the drum will wear beyond the
discard diameter during normal brake wear.
If a drum must be refinished, remove only
.enough metal to obtain a true, smooth braking surface.
If a drum does not clean-up when refinished to a
maximum rebore diameter as shown at the end of this
section, replace it. Removal of more metal will affect
heat dissipation and may cause rear brake drum
distortion.
When refinishing drums, always use sharp
cutting tools or bits. Dull or worn tools leave a poor
surface finish which will affect initial braking
performance. Vibration dampening attachments should
always be used when refinishing braking surfaces.
These attachments eliminate tool chatter and will
result in better surface finish.
After making the finish cuts, sand the brake
drum friction surface for at least 60 seconds. Use 150
grit aluminum oxide sandpaper on a curved sanding
block. Make smooth in-and-out motions with the block
while sanding. This procedure will simulate the
original factory surface finish.
26
Balance
During manufacture, weights are used to balance
drums. Do not remove these weights.
After drums have been refinished, or when
maintaining proper wheel balance is difficult, check
the drum for balance. They can be checked on most
off-the-vehicle balancers. If found to be out of
balance, replace drum.
NOTICE: Be careful not to drop the brake
drum during handling. An out-of-round
condition can occur from even the smallest fall,
resulting in brake pulsation.
REAR WHEEL CYLINDER

Figure 8
i!I
Disassemble
1. Wheel cylinder completely from vehicle. Refer to

"Wheel Cylinder" under "On-Vehicle Service" in
this section.
2. Boots (22).
3. Pistons (23) and seals (24).
4. Piston spring (25).
5. Bleeder valve cap (34).
6. Bleeder valve (20) from wheel cylinder body (26).
34~'
"A
20 VALVE, REAR BRAKE BLEEDER.

22
23
24
25
26
34
Replacing Drums
When installing new drums, do not refinish the
braking surface. New drums have the correct level of
surface finish.
22
BOOT, REAR WHEEL CYLINDER PISTON

PISTON, REAR WHEEL CYLINDER
SEAL, REAR WHEEL CYLINDER 'PISTON
SPRING, REAR WHEEL CYLINDER PISTON
BODY, REAR WHEEL CYLINDER
CAP, BLEEDER VALVE
4-25-94
FS0085C2
Figure 8 - Rear Wheel Cylinder Components
!LI
Inspect
Wheel cylinder bore for scoring, nicks, corrosion

and wear.
Clean
1. All parts in clean denatured alcohol.

3. Lubricate new seals (24) with clean brake fluid.
!+!+!
Assemble
NOTICE:
Refer to "Notice" on page 5C2-l.
1. Bleeder valve (20).
!~!
2.
3.
4.
5.
Tighten

Bleeder valve cap (34).
Piston spring (25).
Seals (24), pistons (23) and boots (22).
Wheel cylinder. Refer to "Wheel Cylinder" under
DUO-SERVO DRUM BRAKES 5C29
SPECIFICATIONS
Rear Wheel Cylinder Bore Diameter .................................................................................. 20.6 mm (0.81 inch)
Brake Lubricant ......................................................................................................................... GM PIN 9985907
Rear Brake Drum Inside Diameter (Nominal) .............................................................. 241.30 mm (9.500 inch)
Runout ............................................................................................................................. 0.15 mm (0.006 inch)
Maximum Refinish Diameter ...................................................................................... 242.82 mm (9.560 inch)
Discard Diameter ......................................................................................................... 243.59 mm (9.590 inch)
All rear brake drums have a discard dimension cast into them. This is a wear dimension and not a refinish
dimension. Any rear brake drum which does not meet the specification should be replaced.
DRUM REFINISHING SPECIFICATIONS

Rough Cut
Spindle Speed ...................................................................................................................................... 200 RPM
Tool Crossfeed .................................................................... 0.15 mm to 0;25 mm (0.006 inch to 0.010 inch)
Vibration Dampener ...................................................................................................................................... Yes
Sand Rear Brake Drum ................................................................................................................................. No
Finish Cut
Spindle Speed ...................................................................................................................................... 200 RPM
Tool Crossfeed ................................................................................................................ 0.05 mm (0.002 inch)
Vibration Dampener ...................................................................................................................................... Yes
Sand Rear Brake Drum ................................................................................................................................ Yes

Rear
Rear
Rear
Rear
Brake Backing Plate Nut ............................................................................................... 58 N.m (43 lb.

Brake Bleeder Valve .........................................................................................................6 N,m (53 lb.
Brake Rear Pipe Fitting ................................................................................................. 17 N.m (13 lb.
Wheel Cylinder Bolt/Screw ............................................................................................ 18 N,m (13 lb.
SPECIAL TOOLS
1.
2.
~
~
J8049
J8057
3.
J 21177-A
1. BRAKE SPRING REMOVER AND INSTALLER

2. BRAKE SPRING PLIERS
3. DRUMTOBRAKE SHOE CLEARANCE GAGE
4-25-94
FS0096C2
ft.)
in.)
ft.)
ft.)
5C2-10
BLANK
VACUUM BOOSTER SYSTEM
5011
SECTION 501
VACUUM BOOSTER SYSTE

UNLESS OTHER WISE SPECIFIED, do not .. use supplemental coatings (paints, greases, or other corrosion
and systems.
CONTENTS
General Description., ............................................ 501-1
Power Brake Booster ....................................... 501-1
On-Vehicle Service ............................................... 501-1
Power Brake Booster ....................................... 5D 1-1
GENERAL DESCRIPTION
POWER BRAKE BOOSTER
The power brake booster is a tandem vacuum
suspended unit. In a normal operating mode, with the
brakes in the released position, the tandem vacuum
suspended booster operates with vacuum on both sides
of its diaphragms. When the brakes are applied, air at
atmospheric pressure is admitted to one side of each
diaphragm. The air is then drawn from the booster
through the vacuum check valve to the vacuum
source.
NOTICE: Internal components of this booster
are not serviceable. The housing must not be
unstaked and separated. Separating the housing
will cause permanent deformation, preventing
the booster from holding proper volume.
ON-VEHICLE SERVICE
[I]
Important

. used to service the booster.
Lubricate rubber parts with silicone grease to
ease.
Power Brake Booster Vacuum Hose

and Routing ....................................................... 501-4
Power Brake Booster Vacuum Check Valve ... 5Dl-4
Specifications ................. ,... ,................................... 501-4
POWER BRAKE BOOSTER

Figures 1 through 3
1. Secondary air injection system (AIR) pipe from
fitting on exhaust manifold, if necessary.
Move AIR pipe out of the way.
2. Clamp (31) and vacuum hose (30) from check
valve (4).
3. Nuts (1) attaching master cylinder (2) to booster
(3).
4. Master cylinder (2).
Move master cylinder (2) forward and toward
driver's side to provide clearance for booster
(3). This will flex brake pipes slightly. Take
care not to bend or distort brake pipes.
5. Lower instrument panel insulator: Refer to
SECTION 8C.
.
6. Nuts (5) attaching booster (3) to brake pedal (20).
7. Loosen nut (40).
8. On vehicle with manual transmission, loosen nuts
(41).
9. Pull back on brake pedal (20) to access nuts (35).
10. Nuts (35) attaching booster (3) to dash panel.
5012 VACUUM BOOSTER SYSTEM
A
32
A
B
2
3
30
31
32
33
34
-a
FITTING, ENGINE
FITTING, POWER BRAKE BOOSTER
CYLINDER, BRA.KE MASTER
2
HOSE, POWER BRAKE BOOSTER VACUUM
CLAMP, POWER BRAKE BOOSTER VACUUM HOSE
BODY, MASTER CYLINDER
34
33
01-30-95
FT0076D1
Figure 1 - Vacuum Booster Hose Routing (3800 VIN K)
---
c--~L-A
B
C
D
2
3
4
30
31
32
33
34
PIPE, AIR INJECTION REACTION

MANIFOLD, EXHAUST
FITTING, EXHAUST MANIFOLD
FITTING, ENGINE
HOSE, POWER BRAKE BOOSTER VACUUM
Cl.AMP, POWER BRAKE BOOSTER VACUUM HOSE
BODY, BRAKE MASTER CYLINDER
Figure 2 - Vacuum Booster Hose Routing (5.7L VIN P)
01-13-95
FS0015D1

B
40
501-3
~ _J_
<"-..
'
-~ \~
i~
~'2.
16
-~~
A POWER BRAKE BOOSTER PUSHROD INSTALLED TO

BRAKE PEDAL LEVER PIN
B PANEL, DASH
C PIN, BRAKE PEDAL LEVER
1 NUT, BRAKE MASTER CYLINDER
2 CYLINDER, BRAKE MASTER
3 BOOSTER, POWER BRAKE
4 VAL VE, POWER BRAKE BOOSTER VACUUM CHECK
5 NUT, BRAKE PEDAL BRACKET
6 PUSHROD, POWER BRAKE BOOSTER
7 OUTPUT ROD, POWER BRAKE BOOSTER
10 BOLT/SCREW, POWER BRAKE BOOSTER MOUNTING
15 WASHER, BRAKE PEDAL PUSHROD

16 RETAINER, BRAKE PEDAL PUSHROD
20 PEDAL, BRAKE AND ACCELERATOR ANO
30 HOSE, POWER BRAKE BOOSTER VACUUM
31 CLAMP, POWER BRAKE BOOSTER VACUUM HOSE
33 BODY, BRAKE MASTER CYLINDER
34 RESERVOIR, BRAKE MASTER CYLINDER (PUSH-ON)
35 NUT, POWER BRAKE BOOSTER
40 NUT, BRAKE PEDAL
1-05-95
41 NUT, CLUTCH MASTER CYLINDER
FS003SD1
Figure 3 - Removing and Installing Power Brake Booster (Manual Transmission Shown - Automatic Transmission Similar)
Discard nuts (35) needed for production

purposes only.
11. Pushrod (6) from brake pedal pin.
A. From inside vehicle, remove retainer (16) and
washer (15).
B. Tilt entire booster (3) slightly to work pushrod
(6) off brake pedal pin without putting undue
side pressure on pushrod (6).
12. Booster (3) from vehicle.
!++-!
Install or Connect
NOTICE:
Refer to "Notice" on page 5Dl-1.
1. Booster (3) onto vehicle.

2. Pushrod (6) to brake pedal pin.
A. Tilt entire booster (3) slightly to work pushrod
(6) off brake pedal pin without putting undue
side pressure on pushrod (6).
B. From inside vehicle, install washer (15) and
retainer (16).
3. Nuts (5).
!~!
Tighten
Nuts (5) to 20 N.m (15 lb. ft.) in sequence:

inboard upper, outboard lower, outboard upper,
inboard lower.
Nuts (40) to 20 N.m (15 lb. ft.).
Nuts (41) to 27 N.m (20 lb. ft.) on vehicle
4. Master cylinder (2) to booster (3) and nuts (1).
!~!
Tighten
Nuts (1) to 29 N.m (31 lb. ft.).

5. Vacuum hose (30) and clamp (31) to check valve
(4).
6. Lower instrument panel insulator. Refer to
SECTION 8C.
7. AIR pipe to fitting on exhaust manifold, if
removed.
501-4
l~I

Tighten
AIR pipe-to-exhaust manifold fitting to

55 N,m (41 lb. ft.).
POWER BRAKE BOOSTER VACUUM

HOSE AND ROUTING
Figures 1 and 2
Refer to Figures 1 and 2 for routing of the
vacuum hose (30).
POWER BRAKE BOOSTER VACUUM

CHECK VALVE
Figure 4
Vacuum check valve and grommet can be
inspected and/or serviced without removing booster
from vehicle.
l++I
1. Clamp (31) and vacuum hose (30) from check

valve (4).
2. Check valve (4) and grommet (9).
!L"'i
Inspect
Grommet (9) and vacuum hose (30) for cuts,

nicks and excessive wear.
- Replace grommet (9) or .vacuum hose (30) if
damaged.
3
4
6
9

PUSHROD, POWER BRAKE BOOSTER
GROMMET, POWER BRAKE BOOSTER VACUUM CHECK
VALVE
.
30 HOSE, POWER BRAKE BOOSTER VACUUM .
31 CLAMP, POWER BRAKE BOOSTERVACUUM HOSE
Clean
01-131$
FB004501
1. All parts in denatured alcohol.

l++I
Figure 4 - Vacuum Valve and Grommet
Install or Connect
1. Lubricate inner and outer diameters of grommet

(9) with thin layer of silicone grease GM
2. Grommet (9) and check valve (4).
3. Vacuum hose (30) and clamp (31) to vacuum
check valve (4).
SPECIFICATIONS
Brake Master Cylinder Nut. .................................................................................. ,................. 29
Brake Pedal Bracket Nut. ........................................................................................................ 20
Brake Pedal Nut ...................................................................................................................... 20
Clutch Master Cylinder Nut .................................................................................................... 27
Secondary Air Injection System (AIR) Pipe-to-Exhaust Manifold Fitting ........................... 55
N.m
N.m
N,m
N,m
N.m
(21
(15
(15
(20
(41
lb.
lb.
lb.
lb.
lb.
ft.)
ft.)
ft.)
ft.)
ft.)
ANTI LOCK BRAKE SYSTEM
5E1 1
SECTION 5E1
ANTILOCK BRAKE SYSTEM

CAUTIONS in Section 9J under ON-VEHICLE SERVICE and the SIR component and wiring
location view in Section 9J before performing service on or around SIR components or wiring.
CAUTION: Certain components in the ABS are not intended to be serviced individually.
Attempting to remove or disconnect certain system components may result in personal injury
and/or improper system operation. Only those components with approved removal and
installation procedures should be serviced.
CAUTION: To help avoid personal injury due to poor braking, DO NOT tap into the vehicle's
brake system to operate a trailer brake system.
NOTICE: Do not use a quick charger for. engine starting or for battery charging if the battery is still connected
to the vehicles electrical system. Failure to do so may cause the air bag fuse to open or cause serious damage to
other electrical components. Always disconnect the negative battery cable when charging battery.
NOTICE: Always use the correctfastener in the correct location. When you replace a fastener, use ONLY the
exact part number for that application. General Motors will call out those. fasteners that require a replacement
after removal. General. :M:otors .will al.so call out the fasteners that require thread lockers or thread sealant.
tightening sequence and specifications. Following these instructions can help avoid damage to parts and systems.
in repair kits used to service this system. Lubricate rubber parts with clean, fresh brake fluid to ease assembly.
Do not use lubricated shop air on brake parts as damage to rubber components may result. If any hydraulic
component is removed or brake line disconnected, it may be necessary to bleed all or part of the brake system.
The fastener tightening specifications specified are for dry, unlubricated fasteners.
NOTICE: Use only Supreme 11 (GM 1052542) or equivalent DOT 3 brake fluid. The use of DOT 5 (silicone)
brake fluid is not re:!commended. Reduced braking performance or durability may result.
NOTICE: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring, cables or electrical
connectors. Brake fluid. will damage paint and electrical connections. If any fluid is spilled on the vehicle,
CONTENTS
General Description ............................................... 5E 1-2
Abbreviations/Definitions .................................. 5E 1-2
Basic Knowledge Required ............................... 5El-2
System Operation .............................................. 5E 1-3
Base Braking Mode .......................:................ 5El-3
Antilock Braking Mode ................................ 5El-3
.ESB Operation .................................... :...... :.. 5El-4
System - Self Test (Initialization) ................ 5El-4
Warning Lamp Operation ............................. 5El-5
Normal Lamp Operation ........................... 5El-5
Tires and ABS ............................................... 5El-6
Spare Tire .................................................. 5El-6
Replacement Tires ................................. ;... 5El-6

System Components ...................... ,....................... 5El -6
ABS Hydraulic Modulator/Motor Pack
Assembly ....................................................... 5E 1-6
Electronic Brake Control Module
(EBCM) ......................................................... 5El-7
Front Wheel Speed Sensors ............................. 5El-7
Front Wheel Speed Sensor Rings .................... 5El-7
Rear Wheel Speed Sensor and Ring ............... 5E 1-7
ABS Relay ........................................................ 5El-7
Brake Combination Valve ................................. 5El-7
Wiring Harness .................................................. 5E 1-7
5E1-2
Wheel Speed Sensor Jumper Harness ...... 5El-7

Warning Lamps ............................................. 5El-7
Fuses and Fusible Links ............................... 5El-8
Diagnosis-Electrical ........................................... 5E 1-8
Diagnostic Process ......................................... 5E 1-8
Self-Diagnostics ............................................. 5E 1-8
Displaying Diagnostic Trouble Codes
(DTCs) ....................................................... 5El-8
Clearing Diagnostic Trouble Codes
(DTCs) ....................................................... 5El-8
Tech 1 Method .......................................... 5E 1-9
Ignition Cycle Default .............................. 5E 1-9
Intermittents and Poor Connections ............. 5E 1-9
Tech 1 Diagnostics ........................................ 5E 1-9
Enhanced Diagnostics ............................... 5E 1-9
Diagnostic Process ( 1 of 3) .......................... 5E 1-11
Diagnostic System Check (1 of 4) ............... 5El-16
Diagnostic Trouble Code and Symptom
Table ........................................................... 5El-22
Wiring Diagram (1 of 2) .............................. 5El-24
EBCM Connector End View (1 of 2) ......... 5El-26
Diagnosis/Misc. Test (F4) ................................. 5El-162
Manual Control (FO) ..................................... 5El-162
Motor Test (Apply/Release) ...................... 5El-162
Solenoid Test ("ON/OFF") ...................... 5E1-162
Hydraulic Control Test (F2) ......................... 5El-162
Motor Test (F4) ............................................. 5El-163
No Gear Movement ...................................... 5El-163
Gear Tension Relief (F5) .............................. 5El-163
Relay Test (F6) ............................................. 5El-163
Voltage Load Test (F7) ................................. 5El-163
Lamp Test (F8) ............................................. 5El-163
System ID (F9) ............................................. 5El-163
Motor Rehome (F5) ...................................... 5El-163
On-Vehicle Service ............................................ 5El-164
Service Precautions ....................................... 5E 1-164
Checking and Adding Fluid ......................... 5El-164
Flushing Procedure ........................................ 5E 1-164
Flushing Preparation .................................. 5El-164
Pressure Flush ........................................... 5El-165
Manual Flush ............................................. 5El-165
GENERAL DESCRIPTION
ABBREVIATIONS/DEFINITIONS
Several abbreviations are commonly used
throughout this section. They are presented here for
reference.
ABS .............................................. Antilock Brake System
B+ .............................................................. Battery Voltage
CKT ......................................................................... Circuit
CPA .................................... Connector Position Assurance
DLC .................................................. Data Link Connector
DTC ......................................... Diagnostic Trouble Codes
DVM ..................................................... Digital Multimeter
EBCM .......................... Electronic Brake Control Module
ESB ............................................. Expansion Spring Brake
Infinite ....... Open Circuit/Unmeasurable High Resistance
MSC. ............................................. Mass Storage Cartridge
Bleeding System ............................................ 5E 1-167

With Tech 1 (Preferred Method) .............. 5El-167
Without Tech 1 ......................................... 5El-168
Rehome Procedure ........................................ 5E 1-168
Pressure Bleeding ...................................... 5E 1-168
Hydraulic Modulator .. ,.......................... 5El-168
Brake Pipe Connections ........................ 5El -169
Wheel Brakes ........................................ 5El -169
Manual Bleeding ....................................... 5El-170
Hydraulic Modulator,............................ 5El-170
ABS Hydraulic Modulator Bleeder
Valves ......................................................... 5El-171
ABS Hydraulic Modulator Solenoid ............ 5El-171
Assembly ................................................... 5E 1-172
(EBCM) ....................... :.............................. 5El-173
Front Wheel Bearing and Speed Sensor
Assembly ................................................... 5El-174
Front Wheel Speed Sensor Jumper
Harness ...................................................... 5El-174
Rear Wheel Speed Sensor ............................ 5El-174
Rear Wheel Speed Sensor Toothed
Ring ........................................................... 5El-174
Rear Wheel Speed Sensor Jumper
Harness ...................................................... 5El~l 74
ABS Relay .................................................... ;5El-l75
Brake Combination Valve ............................. 5El-l75
Warning/Indicator Lamps .............................. 5E 1-l75
Electrical Conne~tors .................................... 5E 1-l76
Fuse and Fusible Links ................................. 5El-l76
Unit Repair ........................................................ 5El-l76
Gear Cover ........... ;........................................ 5El-l76
Motor Pack .................................................... 5El-177
Gear Replacement ......................................... 5E 1-178
Hydraulic Modulator ..................................... 5E 1-179
Master Cylinder............................................. .SEl-180
Specifications ..................................................... 5E 1-180
Fastener Tightening Specifications ............... 5E 1-180
Special Tools ..................................................... 5E 1-181
BASIC KNOWLEDGE REQUIRED

Before using this section, it is important that you
have a basic knowledge of the following items.
Without this basic knowledge, it will be difficult to
use the diagnostic procedures contained in this section.
If you need a review of basic electrical
troubleshooting knowledge, SECTION 8A contains
helpful information in the introduction. Basic use of
circuit testing tools is also covered in SECTION 8A.
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 vpltage, current (amps) and resistance (ohms). You
should understand what happens in a circuit with an
open or shorted wire. You should be able to read and
understand a wiring diagram.
Use of Circuit Testing Tools - You should be
familiar with the High Impedance Multimeter (DVM)
J 39200. You should be able to measure voltage,
resistance and current and be familiar with the meter
controls and how to use them correctly.
5E1-3
wheel: (1) through the modulator, around the check

valve, and out to the wheel, (2) through the modulator,
past the normally open solenoid, and out to the wheel.
The solenoid in the front circuits provides an alternate
brake pressure path to the wheel.. With this
arrangement, if the ABS were to lose power or
malfunction with the piston not in its home position, a
redundant brake fluid path is available. See Figure 1.
The rear channels operate in a similar manner
except no solenoid exists.
Antilock Braking Mode
1 CHECK VALVE OPEN

2 BRAKE PRESSURE FROM COMBINATION VALVE
3 OPEN SOLENOID
4 PISTON
5 BALL SCREW NUT
8 BALL SCREW SPINDLE
7 ABS MOTOR PACK
EXPANSION SPRING BRAKE (ESB)
9 BRAK! PRl!SSURI! TO P:RONT BRAK!
rn
IS-18-95
FSO()IIIE
Figure 1 - Front Base Braking Mode
Important
When measuring the resistance to ground of a

circuit or component, make sure to use a solid,
unpainted chassis ground or the negative battery
temil.nal.
SYSTEM OPERATION
Base Braking Mode
Under normal operating conditions, the brake
systems will . operate using conventional braking by
means of brake pedal force, the vacuum booster, and
the compact master cylinder. Each front channel
consists of a motor, solenoid, ESB, ball screw, piston,
and. check valve'. As illustrated in Figure 1, under
nonnal operating conditions (base brakes), the piston
is held in the upmost (or "home") position and the
solenoid is open (not energized). This is accomplished
by turning the ball screw via .the motor to drive the
nut upwards. Once at the upmost position, the piston
is held by an Expansion Spring Brake (ESB). Two
paths are available to transfer braking pressure to the
ABS .VI has been designed to improve the

controllabiHty and steerability of a vehicle during
braking. ABS VI accomplishes this objective by
controlling the hydraulic pressure applied to each
wheel brake. Antilock braking occurs only when the
brake switch is closed and a microprocessor, located in
the EBCM, determines one or more wheels is about to
lose traction during braking. The EBCM will then
allow the ABS hydraulic modulator to change the
brake pressures several times each second to keep the
wheel(s) from locking and provide. the driver with
maximum vehicle controllability; . ABS VI CANNOT
INCREASE THE BRAKE PRESSURE ABOVE THE
MASTER CYLINDER PRESSURE APPLIED BY
THE DRIVER, AND CANNOT APPLY THE
BRAKES BY ITSELF.
The result is greatly improved braking, enabling
the driver to more easily maintain steerability and to
bring the vehicle to a controlled stop. ABS VI
provides effective braking and directional control over
a wide range .of road surfaces and driving conditions.
If any wheel(s) begins to approach lock-up, the
EBCM will control the three (3) motors and two (2)
solenoids, appropriately, to control brake pressure to
the affected wheel(s). During front wheel ABS
operation, the solenoids are turned "ON" to isolate
that brake pressure path to the wheel (see Figure 3).
The EBCM then provides controlled current to the
motors to regulate the speed and amount of
movement. As the motors move backwards, the piston
follows the nut downward, allowing the check valve to
seat. The brake pressure to the wheel is now a
function of the controlled volume within the piston
chamber. To reduce brake pressure, the motor drives
the nut further downward. To reapply or increase
brake pressure, the motor drives the nut and piston
upward. If ABS was entered during low brake
pressure, such as on ice, and dry pavement is then
encountered during reapply, the piston is driven all the
way to the top. This results in the unseating of the
check valve, and a return to .base brakes until
sufficient brake pressure exists to cause the wheel to
approach lock-up again. At this point, the ABS cycle
would start again. This process can occur in less than
one second if the driver is pressing firmly on the
brake pedal.
Total brake pressure during. ABS is limited to
the brake pressure present when ABS was entered.
Also, any time wheel brake pressure exceeds the brake
pressure at the master cylinder (caused by reduced
force on the brake pedal), the check valve unseats and
a small volume of brake fluid is returned to the master
5E1-4

MOTOR DRIVES
CLOCKWISE
1 MOTOR DRIVE. DOG REL.EASES
MOTOR DRIVES
COUNTI!RCLOCKWISII'!
SPRING BRAKE AND DRIVES PINION

2 CIRCUP
3 MOTOR PINION
4 PINION DRIVE. DOG
15 EXPANISON .SPRING BRAKE (ESB)

8 MOTOR DRIVE DOG
7 MOTOR SHAFT
8 STEEL SLEEVE
9 MOTOR DRIVE DOG RELEASES SPRING BRAKE
(SPRING LEO BENEATH PINION DOG)
AND DRIVl!S PINION.
PINION STOPPED l'ROIM TURNING

COUNTERCLOCKWISE
10
10 PINION DOG EXPANDS SPRING AND

LOCKS AGAINST SLEEVE
519-M
FS004151!
Figure 2 - Expansion Spring Brake
cylinder. hi this manner, ABS VI CANNOT

INCREASE BRAKE PRESSURE ABOVE MASTER
CYLINDER PRESSURE APPLIED BY THE
DRIVER AND CANNOT APPLY THE BRAKES BY
ITSELF. When ABS is no longer required, the pistons
are returned to their upmost (or "home") position and
are held by the ESBs (refer to "ESB Operation,"
found in this section). The solenoids on the front
channels are simultaneously opened to again provide a
redundant base braking path.
The rear channel operates in a similar manner
except no solenoid is used (refer to Figure 4). Both
rear brake pressures are controlled by the same motor
and both rear brake pressures are controlled together.
If either rear wheel begins to lock, brake pressure to
both rear wheels is reduced to maximize vehicle
stability.
There is no rear solenoid due to the nature of the
braking system. The vast majority of braking is
accomplished with the front ):,rakes. If an ABS failure
were to occur that affected the operation of the rear
base brakes, a diagnostic trouble code would be stored
and the EBCM would turn "ON" both the amber ABS
and the red "BRAKE" warning lamps.
ESB Operation
The Expansion Spring Brake (ESB) is used to
hold the piston in the upmost (or "home") position.
An ESB is a spring that is retained in a housing at a
close tolerance. One end of the spring is in contact
with the motor drive dog and the other end is in
contact with the pinion drive dog (see Figure 2). In
normal braking, brake pressure is present on the top of
the piston, applying a downward force. The force

applies a counterclockwise torque to the motor pinion
which tries to rotate the spring counterclockwise. The
counterclockwise torque expands the spring outward
within the housing and prevents gear rotation.
When the motor is turned "ON" and tries to
drive the ball screw nut, the end of the ESB in contact
with the motor drive dog rotates inward causing the
spring to contract in its housing allowing the motor to
rotate the modulator gear (see Figure 2). The most
common application of this principle is in window
crank mechanisms, where a small amount of force on
the crank handle allows the window to be lowered or
raised, but the weight of the window or force on the
window will not allow the window to move
downward. For the ESB, brake pressure on the top of
the pistons corresponds to the weight of the window
and the motor corresponds to the window crank
handle.
System Self Test (Initialization)

During initialization, the EBCM will not only
perform self-diagnostics, but will also verify motor,
modulator, solenoid, relay, and lamp operation to
ensure all components are functioning properly. The
EBCM also checks the wheel speed sensor circuitry
for open circuits and shorts to ground or voltage at
this time. If the EBCM detects a malfunction in either
itself or other ABS VI components, it will store a
Diagnostic Trouble Code (DTC) and turn "ON" the
amber ABS warning lamp if applicable.
The amber ABS warning lamp will be "ON" for
about 3 seconds with the key in the "RUN" position.
5E1-5
IM'Lll:T FROM COMBO VALVE
RHR
1 CHECK VALVE CLOSED

2 ~P6~:8'D VALVE
3 BRAKE PRESSURE FROM
COMBO VALVE
4 MODULATION
CHAMBER
BALL SCREW NUT IN

6 "MODULATION" POSITION
7 ~~:~~,~~~)SPRING
8 ABS MOTOR PACK
g BRAKE PRESSURE
TO FRONT BRAKE
?~I,~il'l
TION
POSITION
5-22-94
FS005SE
Figure 3 - Front ABS Braking Mode
During cranking the amber ABS warning lamp will be

"ON" and then remain "ON" for about 3 seconds
after the engine starts. A slight mechanical noise may
be heard during the system initialization, which is
normal. The entire initialization is run about 2-3
seconds after the engine starts. If your foot is on the
brake pedal when the engine is started, the system will
not initialize until your foot is removed or 5 km/h
(3 mph) is reached. If foot pressure on the pedal
interrupts the system initialization, a slight movement
in the pedal may be felt.
Warning Lamp Operation

Normal Lamp Operation
The standard brake system uses a single red

"BRAKE" warning lamp located in the instrument
panel cluster. The antilock brake system uses the same
red "BRAKE" warning lamp, an amber ABS warning
lamp and a amber ABS active lamp ("LOW TRAC").
1. When the ignition is turned to the "RUN"
position, the "ABS INOP", "LOW TRAC", and
"BRAKE" lamps all turn "ON" for
approximately three seconds, then turn "OFF."
LHR
1 CHECK VALVES CLOSED

2 MODULATED PRESSURE TO REAR BRAKES
3 PISTON LOWERED
4 EXPANSION SPRING BRAKE (ESB) LOCATION
5 MOTOR PINION
G YOKE ON BALL SCREW DRIVES BOTH REAR
CIRCUIT PISTONS
7 MODULATION CHAMBER
06-01-96
FS0085E
Figure 4 - Rear ABS Braking Mode
2. As the engine is cranked, both the "ABS INOP"

lamp and the "BRAKE" lamp will turn "ON"
and remain "ON."
3. After the engine is started, the "ABS INOP",
"LOW TRAC", and "BRAKE" lamps will be
"ON" for approximately three seconds then turn
"OFF."
4. Anytime the EBCM determines that the vehicle
has entered a braking event where ABS is
required, the "LOW TRAC" lamp will turn
"ON" to indicate that ABS is active. The "LOW
TRAC" lamp will remain "ON" for
approximately 3 to 4 seconds after the ABS event
is completed. For further information regarding
"ABS INOP", "LOW TRAC", and '~BRAKE"
lamp operation, refer to "Warning Lamps" in this
section.
5E1-6

SYSTEM COMPONENTS
Tires and ABS
The ABS VI Antilock Braking System (ABS)

consists of a conventional hydraulic brake system plus
antilock components. The conventional brake srstem
includes a vacuum power booster, master cylmder,
front disc brakes, rear disc or drum brakes,
interconnecting hydraulic brake lines, brake fluid level
switch and a red "BRAKE" warning lamp.
The ABS . components include a hydradic
modulator/motor pack assembly, an Electronic Brake
Control Module (EBCM), a system enable relay, three
wheel speed sensors, interconnecting wiring, ~n amber
ABS warning lamp, and an amber ABS active lamp
(refer to Figure 5).
Spare Tire
Using the compact spare supplied with the

vehicle will not affect the operation of ABS.
The EBCM software can compensate for this
smaller tire. However, increased stopping distances
may occur due to reduced tire tread depth on compact
spare tires.
Replacement Tires
Tire size is important for proper performance. of

the ABS. Replacement tires should be the same size
load range and construction as the original tires.
Replace tires in axle sets and only 'Yith tire~ of ~e
same TPC (Tire Performance Cntena) specification
number. Use of any other tire size or type may
seriously affect the ABS operation. For more
information on original equipment and replacement
tires, refer to SECTION 3E.
MODULATOR ASSEMBLY
(REMOTE MOUNTED AT LEFT
FRONT UNDERHOOD)

Assembly
The ABS hydraulic modulator/motor pack
assembly controls hydraulic pre~sure to the front ~d
rear calipers or rear wheel cylmders by modulatmg
hydraulic pressure to prevent wheel lock-up.
EBCM
~ (ABOVE DRIVER'S SIOE KICK PANEL)
LAMP DRIVER MODULE

(INTEGRATED INTO I. P. CLUSTER)
ABS RELAY IN UNDERHOOD

ELECTRICAL CENTER MOUNTED
TO THE LEFT FRONT INNER FENDER
-~
INTEGRAL F R O N T ~
SPEED SENSORS
(ONE AT EACH FRONT WHEEL)
0501-85
FT007&E1
Figure 5 - ABS-VI Component Location View

The basic ABS hydraulic modulator
configuration consists of gear subassemblies, ball
screws, nuts, pistons, and hydraulic check valves. The
ABS motor pack consists of three motors, three drive
gears, and three ESBs. For more information, refer to
"Base Braking Mode" and "Antilock Braking Mode"
in this section.
Electronic Brake Control Module (EBCM)

The controlling element of ABS VI is a
microprocessor based Electronic Brake Control
Module, or EBCM. Inputs to the system include four
wheel speed sensors, the brake switch, ignition switch,
and unswitched battery voltage. Outputs include three
bi-directional motor controls, three lamp controls, two
solenoid controls, and the system enable relay. A serial
data line, located in terminal "9" of the Data Link
Connector (DLC), is provided for service diagnostic
tools and assembly plant testing.
The EBCM monitors the speed of each wheel. If
any wheel begins to approach lock-up and the brake
switch is "ON," the EBCM controls the motors and
solenoids to reduce brake pressure to the wheel
approaching lock-up. Once the wheel regains traction,
brake pressure is increased until the wheel again
begins to approach lock-up. This cycle repeats until
either the vehicle comes to a stop, the brake is
released, or no wheels approach lock-up. Additionally,
the EBCM monitors itself, each input (except the
serial data line) and each output for proper operation.
If any system malfunction is detected, the EBCM will
store a DTC in nonvolatile memory (DTCs will not
disappear if the battery is disconnected). Refer to
"Self-Diagnostics" in this section for more detailed
information.
NOTICE: There is no serviceable or

removable PROM. The EBCM must be replaced
as an assembly.
Front Wheel Speed Sensors

The front wheel speed sensors consist of a
variable reluctance sensor. The sensor and toothed ring
are part of the hub and bearing assembly. As teeth
pass by the sensor, an AC voltage with a frequency
proportional to the speed of the wheel is generated.
The magnitude of the voltage increases with increasing
speed. The sensor is not repairable, nor is the air gap
adjustable. The entire front bearing assembly must be
replaced.
Front Wheel Speed Sensor Rings

The front wheel speed sensor toothed rings are
an integral part of the hub and bearing assembly. Like
the front wheel speed sensors themselves, they are not
serviceable. If a malfunction is detected in either the
sensor or the toothed ring, the entire hub and bearing
assembly must be replaced.
Rear Wheel Speed Sensor and Ring

A single rear wheel speed sensor is used for this
ABS application and is located on the rear differential.
It operates in the same manner as the front wheel
5E1-7
speed sensors; refer to "Front Wheel Speed Sensors."

However, the toothed ring is located within the rear
differential and contains 106 equally spaced teeth. The
sensors and toothed rings are not repairable and no
provision for afrgap adjustment exists.
ABS Relay
The ABS relay is a normally-open contact type
relay, and has special contact material to handle the
high currents required for ABS VI operation. The
relay allows battery voltage and current to be supplied
to the EBCM, which supplies power to the ABS
motors and solenoids.
Brake Combination Valve

Refer to "ijrake Combination Valve" in
SECTION 5A.
Wiring Harness
The wiring harness is the mechanism by which
the EBCM is electrically connected to power and
ground, wheel speed sensors, motors, solenoids, fuses,
switches, lamps, the enable relay and the serial
communications port. The components, considered part
of the wiring harness, are the wires that provide
electrical interconnection and connectors/terminals that
provide an electrical/mechanical interface from the
wire to a system component.
Wheel Speed Sensor Jumper Harness

Between each wheel speed sensor and the main
wiring harness is a jumper harness made up of highly
flexible twisted pair wiring. This wiring exists because
the main harness must connect to the suspension of
the vehicle, thus the wiring in this area is subjected to
the same motion as a spring or shock absorber.
Consequently, any repair to this section of wiring will
result in stiffening and therefore, eventual failure due
to wire fatigue. For this reason, THE WHEEL SPEED
SENSOR JUMPER HARNESSES ARE NOT
REPAIRABLE AND MUST BE REPLACED. DO
NOT ATTEMPT TO SOLDER, SPLICE, OR CRIMP
THESE HARNESSES AS EVENTUAL FAILURE
WILL LIKELY RESULT. Refer to "On-Vehicle
Warning Lamps
The Electronic Brake Control Module (EBCM)
continuously monitors itself and the other ABS VI
components. If the EBCM detects a malfunction with
the system, the amber ABS warning lamp will either
flash or light continuously (solid lamp) to alert the
driver of the malfunction. The amber ABS. warning
lamp will flash if the EBCM attempts to tum "ON"
the red "BRAKE" warning lamp in conjunction with
the amber ABS warning lamp and is unable to do so.
The lamp is flashed to warn the driver that an ABS
malfunction exists which may have degraded base
brake performance. No antilock braking will be
available. The vehicle must be serviced immediately to
regain full base and ABS braking ability.
5E1-8
CAUTION: The braking system may not

be working properly if the amber ABS
warning lamp is flashing. Driving with a
flashinQ ABS warning lamp can lead to
an accident. If the amber ABS warning
lamp is flashing, pull safely off the road
and have the vehicle towed for service.
A solid amber ABS warning lamp indicates that
a malfunction has been detected that affects the
ope!ation of ABS. No antilock braking will be
a".ailable.. Normal, non-antilock brake performance
will remam. In order to regain ABS braking ability,
the ABS must be serviced
.
_The red "BRAKE" warning lamp will be
illummated when a low brake fluid level in the master
cylinder is sensed, the parking brake switch is closed,
or under control of the EBCM when certain ABS
DTCs are set. This lamp indicates to the driver a base
brake problem may exist.
The ABS active "LOW TRAC" amber indicator
lamp is used to alert the driver when ABS is active.
Anytime the EBCM determines that the vehicle has
~ntered an event where ABS is required, the amber
LOW TRAC" lamp will tum "ON" to indicate that
ABS is active. The amber "LOW TRAC" lamp will
remain "ON" for approximately 3 to 4 seconds after
the ABS event is completed,
Fuses and Fusible Links

The vehicle's power distribution system consists
of fuses, fu~ible I.inks, circuit breakers, and the ignition
s~itch. Fusible links are short pieces of wire several
sizes smaller than the circuit wire to which they
supply power. .They ~e covered with special high
~emperatur~ insulation. When conducting an
improperly high current flow, they will melt and stop
curre~t flow. They are designed to protect the vehicle's
electncal system from electrical shorts in circuits that
are not protected by circuit breakers or fuses. For fuse
and fusible link locations, refer to SECTIONS 8A-10
and 8A-11.
DIAGNOSIS-ELECTRICAL
DIAGNOSTIC PROCESS
When servicing_ the ABS V~, the following steps
should be followed m order. Failure to follow these
steps may result in .the loss of important diagnostic
data and may lead to difficult and time-consuming
diagnosis procedures:
1. Perform a vehicle preliminary diagnosis
inspection. This should include:
Inspection of the master cylinder fluid
reservoir for proper brake fluid level and signs
of contamination.
Inspection of the hydraulic modulator for any
leaks or wiring damage.
Inspection of brake components at all four
wheels. Verify no drag exists. Also, verify
proper brake apply operation.
Inspection for worn or damaged wheel
bearings that may allow a wheel to "wobble."
Inspection of the wheel speed sensors and their

wirin.g. Verify _Proper undamaged wiring,
especially at vehicle attachment points.
Ver!fY tires meet legal tread depth
requirements.
2. Perform "Diagnostic System Check" found in this
section. If any DTCs are displayed, select "Fl:
DTC History" to note the last malfunction that
occurred. Diagnose and repair this malfunction
first.
3. If no DTCs are present, or no mechanical
component malfunctions are present, or if the
failure is intermittent and not reproducible, test
drive the vehicle while using the auto trigger
feature of the Tech 1. Perform normal
ac_celeration, stopping, .and turning maneuvers. If
this does not reproduce the malfunction, perform
an ABS stop, on a low coefficient surface such. as
gravel, from approximately 48-80 km/h (30-50
mph) while triggering the snapshot mode on any
DTC. If the failure is still not reproducible, use
the enhanced diagnostic information found in
DTC HISTORY to determine whether or not this
malfunction should be diagnosed further based on
frequency of failure. Refer to "Enhanced
Diagnostics" found in this section.
4. Once all system malfunctions have been
corrected, clear the ABS DTCs.
SELF-DIAGNOSTICS
The EBCM contains sophisticated on-board
diagnostics that, when accessed with a Tech 1 (this
service manual is written for the use of Tech 1) are
designe~ to identify the source of any . sy~tem
malfunction as specifically as possible, including
whether or not the malfunction is intermittent. There
are 80 diagnostic trouble codes to assist with
diagnosis.
When using the Tech 1 with ABS VI, the last
dia~~stic trouble code is specifically identified, and
specific ABS data is stored at the time of this
malfunction. Also, in addition to the last DTC set
there is information about the first five DTCs set'.
Usin.g the Tech l, .each input and output can be
monitored, thus enabling malfunction confirmation and
repair verificatioi:i, Manual control of components and
automated functional tests are also available when
using the Tech 1. Details of many of these functions
are contained in the following sections.
DISPLAYING DIAGNOSTIC TROUBLE

CODES (DTCs)
Diagnostic trouble codes can be read through the
use of the Tech 1 scan tool. There are no provisions
for "Flash Code" diagnostics.
CLEARING DIAGNOSTIC TROUBLE

CODES (DTCs)
The DTCs in EBCM memory are erased in one
of two ways:
1. Tech 1.
2. Ignition cycle default.

These two methods are detailed below. Be sure
to verify proper system operation and absence of
DTCs when the clearing procedure is completed.
The Tech 1 will not permit DTC clearing until
all DTCs have been displayed. Also, DTCs cannot be
cleared by unplugging the EBCM, disconnecting the
battery cables, or turning the ignition "OFF" (except
on an ignition cycle default).
Tech 1 Method
The Tech 1 method is the only method to be
used when servicing a vehicle. Select "F2: DTC(s)"
for diagnostic trouble codes. After DTCs have been
viewed completely; Tech 1 will ask, "CLEAR
DTCs"?; answer "YES." Tech 1 will then read,
"HISTORY DATA WILL BE LOST. CLEAR DTCs"?
Answer "YES" and DTCs will be cleared.
Ignition Cycle Default

If no diagnostic trouble codes occur for 100
drive cycles [a drive cycle occurs when the ignition is
turned to "RUN" and the vehicle is driven faster than
16 km/h (10 mph)], any existing DTCs are
automatically cleared from the EBCM memory.
INTERMITTENTS AND POOR

CONNECTIONS
As with most electronic systems, intermittent
malfunctions may be difficult to accurately diagnose.
The following is a method to try to isolate an
intermittent malfunction, especially wheel speed
circuitry.
If an ABS malfunction occurs, the amber ABS
warning lamp will be "ON" during the ignition cycle
in which the malfunction was detected. If it is an
intermittent problem which seems to have corrected
itself (ABS warning lamp "OFF"), a diagnostic
trouble code will be stored. Also stored will be the
history data of the DTC at the time the malfunction
occurred. The Tech 1 must be used to read DTC
hislory data.
Most intermittent malfunctions are caused by
faulty electrical connections or wiring. Refer to
"Intermittent and Poor Connections" in SECTION
8A-4 for a very detailed explanation of how to locate
and repair intermittent conditions.
TECH 1 DIAGNOSTICS
The Tech 1, when plugged into the DLC,
becomes part of the vehicles electronic system. The
Tech 1 can perform the following functions:
Display ABS data.
, Display and clear ABS diagnostic trouble codes.
Control ABS components.
Perform extensive ABS diagnosis.
Provide diagnostic testing for intermittent ABS
conditions.
Each test mode has specific diagnosis
capabilities which depend upon various keystrokes. In
general, five keys control sequencing: "YES," "NO,"
"EXIT," "UP ARROW" and "DOWN ARROW."
The FO through F9 keys select operating modes,
5E1-9
perform functions within an operating mode, or enter

DTC or model year designations.
In general, the Tech 1 has six test modes for
diagnosing the ABS. The six test modes are as
follows:
MODE FO: DATA LIST - In this test mode, the
Tech 1 continuously monitors wheel speed data,
brake switch status and other inputs and outputs.
MODE F1: DTC HISTORY - In this mode, DTC
history data is displayed. This data includes. how
many ignition cycles since the DTC occurred,
along with other information for the last DTC set.
The first five and last DTC set are included in the
DTC history data.
MODE F2: DIAGNOSTIC TROUBLE CODES
- In this test mode, diagnostic trouble codes stored
by the EBCM, both current ignition cycle and
history, may be displayed or cleared.
MODE F3: SNAPSHOT - In this test mode, the
Tech 1 captures data before and after a system
malfunction (auto trigger) from a forced manual
key press, or from a DTC setting.
MODE F4: MISC. TESTS - In this test mode,
the Tech 1 performs various ABS functional tests
to assist in problem isolation during
troubleshooting.
MODE F5: MOTOR REHOME - In this mode,
the Tech 1 commands the EBCM to rehome the
motors on the hydraulic modulator/master cylinder
assembly. This mode should always be used prior
to bleeding the brake system.
Enhanced Diagnostics
Enhanced diagnostic information, found in the
DTC HISTORY function of the Tech 1, is designed to
provide the service technician with specific
malfunction occurrence information. For each of the
first five and the very last diagnostic trouble code set,
data is stored to identify the specific DTC, the number
of occurrences, and the number of drive cycles since
the malfunction first and last occurred [a drive cycle
occurs when the ignition is turned to "RUN" and the
vehicle is driven faster than 16 km/h (10 mph)].
However, if a malfunction is present, the drive cycle
counter will increment by turning the ignition to
"RUN" and "OFF." These first five diagnostic
trouble codes are also stored in the order of
occurrence. The order in which the first five DTCs
occurred can be useful in determining if a previous
malfunction is linked to the most recent malfunction,
such as an intermittent wheel speed sensor which later
becomes completely open.
During difficult diagnosis situations, this
information can be used to identify malfunction
occurrence trends. Did the malfunction only
occurrence over a large number of drive cycles,
indicating an unusual condition present when it
occurred? Does the malfunction occur infrequently
over a large number of drive cycles, indicating that
special diagnosis techniques may be required to
identify the source of the malfunction?
5E1-10
If, for example, a malfunction occurred 1 out of

50 drive cycles, the malfunction is intermittent and has
not recurred for 49 drive cycles. This malfunction may
be difficult or impossible to duplicate and may have
been caused by a severe vehicle impact (large pot
hole, speed bump at high speed, etc.) that momentarily
opened an electrical connection or caused unusual
vehicle suspension movement. Problem resolution is
unlikely, and the problem may never recur (check
diagnostic aids provided for that OTC). If, for
example, the malfunction occurred 3 out of 15 drive
cycles, the odds of finding the cause are still not good,
but you know how often it occurs. If the malfunction
occurred 10 out of 20 drive cycles, the odds of finding
the cause are very good, as the .malfunction may be
easily reproduced. By using the additional malfunction

data, you can also determine if a malfunction is
randomly intermittent or if it has not recurred for long
periods of time due to weather changes or a repair
prior to this visit.
Say a OTC occurred 10 of 20 drive cycles but
has not recurred for 10 drive cycles. This means the
malfunction occurred 10 of 10 drive cycles but has not
reoccurred since. A significant environmental change
or a repair may have occurred 10 drive cycles ago. A
repair may not be necessary if customer information
can confirm a recent repair. If no repair was made, the
service technician can focus on diagnosis techniques
used to locate difficult-to-recreate problems, such as
those suggested in "Diagnostic Aids" for the OTC in
question.
5E1-11
DIAGNOSTIC PROCESS
(Page 1 of 3)
TECH 1 SCREEN DISPLAY

MODEL YEAR: 19??
"FO: PASSENGER CAR"
MSC CHASSIS APPLICATION SELECTION

STEP 1 SELECT VEHICLE MODEL YEAR
STEP 2 SELECT VEHICLE TYPE
STEP 3 SELECT BODY TYPE
STEP 4 SELECT MODE (FIRST SCREEN)
I
FRONT WHL SPEEDS

REAR WHL SPEEDS
VEHICLE SPEED
ABS WARNING LAMP
LF ABS MOTOR CMD
LF ABS MTR FDBK
RF ABS MOTOR CMD
RF ABS MTR FDBK
REAR ABS MTR CMD
REAR ABS MTR FDBK
LF SOLENOID CMD
RF SOLENOID CMD
BRAKE SWITCH
ABS RELAY CMD
BRK WARN LP CMD
BRAKE WARN LAMP
EBCM BAT VOLTAGE
EBCM IGN VOLTAGE
FO: DATA LIST
F1: DTC HISTORY
INFORMATION ABOUT PREVIOUS

OTCs STORED
F2: DTC(s)
DTCs STORED AND CLEAR DTCs
F3: SNAPSHOT
SNAPSHOT OPTIONS
FO: REPLAY DATA
F1: MANUAL TRIG.
F2: AUTO TRIG.
F3: ANY OTC
F4: SINGLE OTC
F9: TRIG. POINT
F4: MISC. TESTS
FS: MOTOR REHOME
FO: BEGINNING
F1: CENTER
F2: END OF DATA
~,,,,,,,,,.,,u,,,,,,,,,,,,u,,,,,,,,,,,,,,,,,,.,,u,,,,,,,,,,-,,.,.,,,,,,,,,,
.J
CONTINUED ON FOLLOWING
CHART
.,,JPAGE_2 OF 3l.................
L,,,...........
j
l
.J
REHOMES MOTORS PRIOR TO

BLEEDING THE BRAKE SYSTEM
C7393
5E112
DIAGNOSTIC PROCESS
(Page 2 of 3)
1 CONTINUED FROM PREVIOUS CHART l

j
(PAGE 1 OF 3)
""""f'"'""""'""'""""""'"'""""""'""""""""""'
MISC. TESTS
I
FO: MANUAL CNTRL
'. CONTINUED ON FOLLOWING CHART (PAGE 3 OF 3).
F2: HYDRL. CNTRL
,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,;,;;,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,.,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,
F4: MOTOR TEST
MANUAL TEST OF MODULATOR HYDRAULICS APPLY/HOLD/RELEASE FUNCTIONS
AUTOMATED ABS MOTOR PACK DIAGNOSIS
PREPARE ABS HYDRAULIC MODULATOR FOR OFF

VEHICLE SERVICE.
F5: GEAR TEN REL
I
I
F6: RELAY TEST
I TEST OF ABS RELAY
I TEST FOR ADEQUATE BATTERY CAPACITY FOR ABS
F7: VOLTAGE LOAD
OPERATION.
F8: LAMP TEST
I ACTIVE AND RED "BRAKE" WARNING LAMPS
F9: SYSTEM ID
I SYSTEM NUMBER
MANUAL CONTROL OF THE ABS WARNING, ABS
C7014
5E1-13
DIAGNOSTIC PROCESS
(Page 3 of 3)
CONTINUED FROM
l
PREVIOUS CHART
!:
(PAGE 2 OF 3)
,.
'"'f_,,,,,,,,,,,,,,,,.,,,,,,,,,,,,.,,,,,,,,.,,,,,,,,,,,,,.,,,,,,,,,
!:
MANUAL CONTROL OF
SOLENOIDS AND MOTORS.
I
= TURN ON
.J, =TURNOFF
YES TO CONTINUE
I
SELECT FUNCTION
FO: LF APPLY
F1: LF RELEASE
F2: LF SOLENOID
F4: RF APPLY
FS: RF RELEASE
F6: RF S.OLENOID
F8: REAR APPLY
F9: REAR RELEASE
I
MOTOR APPLY
COMMAND: XX AMPS
FEEDBACK: XX AMPS
ABS RELAY: ON/OFF
I
MOTOR RELEASE
COMMAND: XX AMPS
FEEDBACK: XX AMPS
ABS RELAY: ON/OFF
I
SOLENOID
COMMAND: ON/OFF
ABS RELAY: ON/OFF
C7395
5E1 14 ANTI LOCK BRAKE SYSTEM

REFER TO
SECTIONSA-50
DATA LINK CONNECTOR

(DLC)
t . -,
I"' .,
._&_,--BOO TAN
B+
REFER TO
SECTION
8A10
5225
r-------------.
UNDERHOOD ELECTRICAL CENTER
FUSIBLE
Ll'NKUK"
; ,.i
EBCM
C1
SERIAL DATA LINE
L A12 .I
. 800 TAN
C200A 8270
C200D
ABS BAT
FUSEt
L.,I
502 R E D - - . - - - - - t r v - - - -......- - - - - ; - - - 4 4 0 ORN
IGNITION
I
5 AMP
REFER TO
SECTION IA-10
I ABS IGN
I FUSE1
300 ORN---flr U l - - - - - - - - - - , , - - - - - - + - - 6 4 1 BRN
BATTERY FEED
__
302RED--- 1
_,
RED
-......-~-....-.....-----1633
.____"+ 1633 RED
302RED
ABS VALVE
FUSE I
SWITCHED
IGNITI.QN
SWITCHED
BATTERY INPUT
REFER TO
r - - - - - .I SECTION 8A141
t :
20 AMP
~------~
TO ABS BRAKE PRESSURE

VALVE SOLENOIDS
_.tl
...-1
....--M.,...,-&51 BLK/WHT
51 11
-
G101
~00
=
GROUND
C2
04-18-85
FT1011E
DIAGNOSTIC SYSTEM CHECK

(Page 1 of 4)
System Description:
The diagnostic system check is an organized
approach to identifying a problem created by an
Antilock Brake Control System (ABS VI) malfunction.
It must be the starting point for any ABS VI
complaint diagnosis because it directs the service
technician to the next logical step in diagnosing the
complaint.
Serial data is transmitted by the EBCM through
terminal "Al". The EBCM is supplied switched
ignition voltage through terminal "A9", battery
voltage through terminal "Bl2" and switched battery
voltage through terminal "C". The EBCM ground is
provided through terminal "D".
Chart Test Description:

Number(s) below refer to circled number(s) on
the diagnostic chart.
1. Indicates if EBCM is transmitting data.
2. Checks for a serial data line malfunction.
3.
4.
5.
6.
Checks
Checks
Checks
Checks
circuit..
7. Checks
8. Checks
9. Checks
for
for
for
for
proper Tech 1 connection to DLC.

open ABS BAT 5 amp Fuse 6.
open ABS IGN 5 amp Fuse 1.
high resistance in the EBCM ground
for current DTCs.

for proper ABS warning lamp operation.
for history DTCs.
Diagnostic Aids:
Excessive resistance in the ground or power
supply circuits will not allow communication with the
EBCM. If communication with the EBCM is not
possible, ensure the ABS VI ground connection is
good and that there is no excessive resistance in any
of the power supply circuits.
5E1-15
DIAGNOSTIC
SYSTEM CHECK
VERIFY ALL EBCM CONNECTORS ARE CONNECTED PROPERLY.

INSTALL TECH 1.
IGNITION TO "RUN".
WITHIN ABS PORTION OF MASS STORAGE CARTRIDGE
CHASSIS APPLICATION, SELECT "FO: DATA LIST."
IS DATA BEING RECEIVED FROM THE EBCM?
(Page 1 of 4)
NO
DOES TECH 1
DISPLAY "NO
COMMUNICATION
WITH VEHICLE.
CHECK DLC
CONNECTOR"?
YES
01.
\:_J
SELECT "F2: DTC(s)."

ARE ANY CURRENT DTCs DISPLAYED?
NOTICE: ENSURE MASS STORAGE CARTRIDGE

IS UPDATED TO INCLUDE THE LATEST AVAILABLE
VERSION OF THE CHASSIS APPLICATION.
NOTICE: J 39200 TEST LEADS MUST BE "ZEROED"

PRIOR TO MAKING ANY RESISTANCE MEASUREMENTS.
REFER TO J 39200 USER'S MANUAL.
NO
IGNITION "OFF" FOR 10 SECONDS.

TURN IGNITION TO "RUN" AND OBSERVE ABS WARNING LAMP.
DID LAMP ILLUMINATE FOR 3 SECONDS AND THEN GO "OFF"?
.
NO
"'"'
ENSURE TECH 1
DLC CONNECTOR IS
CONNECTED
PROPERLY TO DLC.
IS CONNECTION
GOOD?
,......... .. !
YES
YES
! REFER TO
! SECTION !
!_ SA-50..........J
NO
IGNITION "OFF."
REMOVE AND INSPECT
ABS BAT 5 AMP FUSE 6.
IS FUSE OPEN?
NO
I
RECONNECT TECH 1 DLC CONNECTOR.

RETURN TO FIRST STEP IN THIS CHART.
YES
,""".
! GO TO CHART B
""""""'"
IS ABS
WARNING
LAMP "O,FF"
CONSTANTLY?
l
FOR ABS
WARNING LAMP
~ "ON"
INTERMITIENTLY,
NO DTCs STORED. )!
,...............................................................................
',!.l
!
YES
NO
_..... l ...................... ,
l GO TO CHART ! ('G;TO .CHART
l ~!~~.:is l !!
l
l!
!
',l'':;
:
',!.
!---~~~~=-~:... """'"'
...... 1 ................................................. ,
INSTALL ABS BAT 5 AMP FUSE 6.

REMOVE AND INSPECT ABS IGN, 5 AMP FUSE 1.
IS FUSE OPEN?
! GO TO PAGE 2 OF 4 OF THIS !
SYSTEM CHECK. !
!, DIAGNOSTIC
.................................................................................................................
~
I
NO
I
YES
""'"'"''"'"""""'"""""'""""'""""''
INSTALL ABS IGN, 5 AMP FUSE 1.

DISCONNECT NEGATIVE BATIERY CABLE.
DISCONNECT 8-WAY EBCM CONNECTOR "C2".
USING J 39200, MEASURE RESISTANCE BETWEEN THE NEGATIVE BATIERY
TERMINAL AND 8-WAY EBCM HARNESS CONNECTOR "C2" TERMINAL "D".
IS RESISTANCE 2 OHMS OR LESS?
!GO TO PAGE 3 OF 4 OF THIS !
(~~~~-~.?.:~!.:..~~-~~-=~--~-~ECK., j
YES
NO
!!
A FOR ABS
WARNING
' LAMP "OFF"
' !.' LAMP "ON"
CONSTANTLY,
, CONSTANTLY,
, NO DTCs
,
NO DTCs
!...............................
STORED.
,...............................)
YES
REVIEW
"ENHANCED
DIAGNOSTICS"
INFORMATION
IN THIS
SECTION.
TO FURTHER
DIAGNOSE
CUSTOMER
COMPLAINT,
REFER TO
"DIAGNOSTIC
PROCESS,"
STEP 3, IN
THIS SECTION.
NO
I
NO
YES
YES
NO
I
C9809
5E1-16
REFER TO
SE.CTION BA-SO ; ] _
DATA LINK CONNECTOR

(DLC)
EBCM
I"9"1--800 TAN----t...____,,rLA12 ,.I

800 TAN
L .I
.
S
S
225
C200A 270
C200D
UNDERHOO,D ELECTRICAL CENTER
B+
REFER TO
SECTION
8A10
SERIAL DATA LINE
.. ------------ ..
FUSIBLE
LINKUK"
ABS BAT
FUSES
LJ
502RED~---.,....----~~.....,~---.-~----.----4400RN
IGNITION
I
5 AMP
REFER TO
SECTION 8A-10
I ABS IGN
I FUSE1
300 O,RN----1,,_,.
BRN
BATTERY FEED
u...--------_,..,r------;---541
SWITCHED
IGNITION
ABS RELAY
CONTROL
h-------1.....--1632 PNK11.----,.1633 RED
302RED
SWITCHED
BATTERY INPUT
--r-:::-""H---1111
' - - - + 1633 RED
302 RED
ABS VALVE
FUSE IS
20 AMP
REFER TO
r - - - - """ .I SECTION 8A141

I
~------~
TO ABS l!IRAKE PRESSURE

VALVE SOLENOIDS
t :
_.*J--511-1 --.,..-,-551 BLK/WHT

G101
~00
=
GROUND
C2
04-1895
FT1015E
(Page 2 of 4)
System Description:

complaint.
terminal "A 1". The EBCM is supplied switched
Number(s) .below refer to circled number(s) on

10. Checks for possible short to ground in the battery
feed circuitry.
11. Checks for possible short to ground in the
EBCM.
12. Ensures short to ground is not due to physical
damage of the circuitry.
Diagnostic Aids:
ANTILOCK BRAKE SYSTEM 5E1-17

(Page 2 of 4)
,.................................................................................................
, .....,.......................,..............................................
.
~
j
j
,...........
,
j
j
~
'
CONTINUED FROM DIAGONSTIC SYSTEM

CHECK (PAGE 1 OF 4).
..........................................................................................................................................................
REPLACE ABS BAT 5 AMP FUSE 6.

WAIT 10 SECONDS.
.REMOVE AND INSPECT FUSE.
IS FUSE OPEN?
I
YES
I
NO
INSTALL FUSE.
REFER TO SECTION SA TO DIAGNOSE
FOR A POSSIBLE SHORT TO GROUND IN
BATTERY FEED CIRCUITRY. RETURN TO
FIRST STEP IN THIS CHART.
DISCONNECT 24WAY EBCM CONNECTOR "C1 ".

REPLACE ABS BAT 5 AMP FUSE 6.
WAIT 10 SECONDS.
REMOVE AND INSPECT FUSE.
IS FUSE OPEN?
I
I
YES
NO
,...... l ,..,........................................... ,
I~;;[!~~~
!
l'
8
0
~~~T~~H tR~ To
GROUND IN THE BATTERY
!
FEED CIRCUITRY.
I
,......................................,.... .................................................................., ................... I

,.
INSPECT CKT 440 AND 24WAY EBCM

HARNESS CONNECTOR "C1" FOR
PHYSICAL DAMAGE WHICH MAY RESULT
IN A SHORT TO GROUND WITH THE
24WAY EBCM HARNESS CONNECTOR
"C1" CONNECTED TO THE EBCM.
CORRECT DAMAGE IF EVIDENT.
RECONNECT ALL CONNECTORS.
WAIT 10 SECONDS.
REMOVE AND INSPECT ABS BAT 5 AMP
FUSE 6.
IS FUSE OPEN?
I
I
YES
I
REPLACE EBCM.
REPLACE ABS BAT 5
AMP FUSE 6.
RETURN TO FIRST
STEP IN THIS CHART.
NO
MALFUNCTION IS
INTERMITTENT.
C9810
5E1-18

. REFERTO
SECTION SA-50
DATA LINK CON1NECTOR

(DLC)
r'9"1--800TAN
REFER TO
SECTION
8A10
L A12 .I
800 TAN
C200A S270
C200D
5225
r------------.,
FUSIBLE
LINKUKN
EBCM
1 r-,
.....
B+
;:i
ABS BAT
FUSES
U
502RED~~.~---_,~.._----------.c--~4400RN
5AMP
IGNITION
i
REFER TO
SECTION IA-10
I ABS IGN
I FUSE1
30,0 ORN---jl-4/r .Jt----------,-----,----541 BRN
BATTERY FEED
SWITCHED
IGNITION
- - - - - - - 1 6 3 2 PNK- A11
11,----., 1633 RED
302RED
,.__,--:;-:-""H---il
1
I
I
REFERTO
ABS RELAY
CONTROL
SWITCHED
BATTERY INPUT
302 RED
SERIAL DATA UNE
1633RED
.I SECTION 8A141
1.---~--..
I

VALVE SOLENOIDS
t r,:
_jj111
G101
GROUND
651 BLKIWHT
'100
C2
04-18-95
FT1015E
{Page 3 of 4)
System Description:

complaint.
terminal "A 1". The EBCM is supplied switched

switched ignition circuitry.
14. Isolates the short to ground to either the circuitry
or the EBCM.
Diagnostic Aids:
5E1-19

{Page 3 of 4)
,,m,m,mumu,mmmmum,m,mmumm,m j
j CONTINUED FROM
j
! DIAGNOSTIC SYSTEM CHECK !
j (PAGE 1 OF 4)
j
,,,,u,, ,,,,,,,..,,.,,,,,,.,,,,,,,,,,.,,,,,,.,,,,,,,,,.,,,,,.,.,,,,.,,.,,,,.,,,,.,,,
REPLACE ABS IGN 5 AMP FUSE 1.

IGNITION TO "RUN."
WAIT 10 SECONDS THEN TURN IGNITION "OFF."
IS FUSE OPEN?
DISCONNECT 24WAY EBCM CONNECTOR "C1".

REPLACE ABS IGN 5 AMP FUSE 1.
IGNITION TO "RUN."
IS FUSE OPEN?
INSTALL FUSE. REFER TO

SECTION BA TO DIAGNOSE FOR
A POSSIBLE SHORT TO GROUND
IN THE SWITCHED IGNITION
CIRCUITRY. RETURN TO FIRST
STEP IN THIS CHART.
...'"""' ........................................................ ......................................................................
INSPECT CKT 641 AND 24-WAY EBCM HARNESS

CONNECTOR "C1" FOR PHYSICAL DAMAGE WHICH MAY
RESULT IN A SHORT TO GROUND WITH THE 24WAY EBCM
HARNESS CONNECTOR "C1" CONNECTED TO THE EBCM.
CORRECT DAMAGE IF EVIDENT.
IGNITION TO "RUN."
REMOVE AND INSPECT ABS IGN 5 AMP FUSE 1,
IS FUSE OPEN?
j
!
j
REFER TO SECTION BA TO
j
REPAIR A SHORT TO GROUND !
IN ONE OF THE CKT 641
j
j BRANCHES EXITING THE ABS !
! IGN 5 AMP FUSE 1. REPLACE !
! FUSE. RETURN TO THE FIRST !
!}. .........................
STEP IN THIS CHART.
,....,,..................................... .........................,...................., .................~
REPLACE EBCM. REPLACE ABS IGN

5 AMP FUSE 1. RETURN TO FIRST
STEP IN THIS CHART.
C9B11
5E1-20

REFER TO
DATA LINK CONNECTOR
(DLC)
SECTION 8A-50
... .,
1"9"1--800TAN
B+
REFER TO
SECTION
8A10
;,J__
r - .,
I.A12 .I
5225
ABS BAT
FUSE8
502 RED---..-------1
IGNITION
REFER TO
SECTION 8A10
.rv
I
I ABS IGN
I FUSE 1
C1
800 TAN
SERIAL DATA LINE
4400RN
BATTERY FEED
641 BRN
SWITCHED
IGNITION
C200A S270
C200D
r-------------.
EBCM
SAMP
300 ORN---1--flr"II.
1632PNK- A11
1633 RED
302 RED
ABS RELAY
CONTROL
SWITCHED
BATTERY INPUT
302RED
REFER TO
r .. -- -- - -- .I SECTION 8A141
I
L------~

VALVE SOLENOIDS
1 r,:
_jj111
G101
GROUND
651 BLK/WHT
~00
C2
041895
FT1015E

{Page 4 of 4)
System Description:
complaint.
terminal "Al". The EBCM is supplied switched
voltage through terminal "B12" and switched battery

16. Checks for proper battery voltage at the EBCM.
17. Checks for high resistance in the battery feed
circuitry.
18. Checks for high resistance in the switched
ignition feed circuitry.
19. Ensures malfunction is not due to poor terminal
contact.
20. Checks for high .resistance in the switched
ignition circuit between the fuse block and the
EBCM.
Diagnostic Aids:

(Page 4 of 4)
! CONTINUED FROM
! DIAGNOSTIC SYSTEM CHECK !

ltu.,;.;,,
(PAGE 1 OF 4)
l
,,,,,,,,,.,,,,,,..,.,,,.,,,.,.,,,.,,,.,.,.,.,,.,.,,,,,.,,,,,,.,.,,,.,,,,.,,,,.,,,,,,.,,,.,,,.,,.,,,.,,.,,,~
NOTICE: J 39200 TEST LEADS MUST
RECONNECT NEGATIVE BATTERY CABLE.

DISCONNECT 24-WAY EBCM CONNECTOR "C1 ".
USING J 39200, MEASURE VOLTAGE BETWEEN GROUND AND
24-WAY EBCM HARNESS CONNECTOR "C1", TERMINAL "812".
IS VOLTAGE GREATER THAN 10 VOLTS?
BE "ZEROED" PRIOR TO MAKING ANY

RESISTANCE MEASUREMENTS. REFER
TO J 39200 USER'S MANUAL.
DISCONNECT NEGATIVE BATTERY CABLE.

DISCONNECT POSITIVE BATTERY CABLE.
USING J 39200, MEASURE RESISTANCE BETWEEN POSITIVE
BATTERY CABLE TERMINAL AND 24-WAY EBCM HARNESS
CONNECTOR "C1", TERMINAL "812".
REPAIR OPEN IN CKT 440.

RETURN TO FIRST STEP IN
THIS CHART.
IGNITION TO "RUN" (THIS IS DONE TO PROVIDE CIRCUIT

CONTINUITY.)
USING J 39200, MEASURE RESISTANCE BETWEEN POSITIVE
BATTERY CABLE TERMINAL AND 24-WAY EBCM
CONNECTOR "C1", TERMINAL "A9".
REPAIR HIGH RESISTANCE

IN CKT 440. RETURN TO
IGNITION "OFF."
REMOVE ABS IGN 5 AMP FUSE 1.
USING J 39200, MEASURE RESISTANCE BETWEEN EACH FUSE
TERMINAL AND 24-WAY EBCM HARNESS CONNECTOR "C1",
TERMINAL "A9".
IS RESISTANCE 2 OHMS OR LESS FOR EITHER MEASUREMENT?
INSPECT EBCM AND EBCM

CONNECTOR TERMINALS FOR
POOR TERMINAL CONTACT.
INSPECT BATTERY TERMINALS
AND BATTERY CABLE TERMINALS
FOR A POOR CONNECTION.
REFER TO SECTION SA,
"CHECKING TERMINAL CONTACT."
IS POOR TERMINAL CONTACT OR
A POOR CONNECTION EVIDENT?
,...,,, ,,,,,.,,,,.,,,.,,,.,,,,,,,,,,,.,.,,,,.,,,.,,,,.,.,,,,.,,,.,.,,,.,,,,,,,.,,,,.,,.,.,,,,,,,,,,,,,.,,.,.,,,,,,,,,,,,,,
! REFER TO SECTION SA .TO REPAIR
! OPEN OR HIGH RESISTANCE BETWEEN !

! POSITIVE BATTERY CABLE TERMINAL !
j AND ABS IGN 5 AMP FUSE 1 BLOCK
j
! TERMINAL. RETURN TO THE FIRST
!
!/.,,,,.,,.,,.,,,.,,,,,,,,,,,,,,,,.,,u.,,,,,,.,,,.u.u11,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,.,,,,,,.,,,,,,,J
STEP IN THIS CHART.
!
REPAIR OPEN OR HIGH

RESISTANCE IN CKT 641.
INSTALL ABS IGN 5 AMP
FUSE 1. RE.TURN TO FIRST
STEP IN THIS CHART.
I'''''' ,.,,,,,,,.,.,.,.,.,.,,,,,u,u,,,,,,,,,,,,,,,,,.,,,,.,,,,,.u1,u11111111u11
I:~go
8NA~i1-i~~~L~~~NECTORS
! PROCEED TO SECTION SA-50.
I
!
f,,,,,,u,,,,,,,,,,,,.,.,,,.,,,,,,,.,,.,.,.,,.,,.,,,,,,,,,,,,,,,,,,,uu1uu1.,;,,,;,,,,!
REPLACE TERMINALS OR REPAIR POOR

CONNECTION. RETURN TO FIRST STEP
IN THIS CHART.
C9S12
5E1-22

DIAGNOSTIC TROUBLE CODE AND SYMPTOM TABLE
CHART
A
B
c
D
DTC
11
13
14
15
16
17
18
21
22
24
25
26
28
32
33
35
36
37
38
41
42
44
45
46
47
48
51
52
53
54
55
56
57
58
61
62
63
64
65
SYMPTOM
ABS (Amber) Warning Lamp "ON" or "OFF" Constantly, No DTCs Stored
ABS (Amber) Warning Lamp "ON" Intermittently, No DTCs Stored
ABS/TCS Active Indicator Lamp "ON" with Ignition "OFF," No DTCs Stored
Tech 1 Displays Undefined DTCs
DESCRIPTION
ABS Warning Lamp Circuit Malfunction
ABS Active or Low Trac Lamp CKT Malfunction
ABS Relay Contact Circuit Open (1 of 3)
ABS Rly Contact CKT Short to Bat or Always Closed
ABS Relay Coil Circuit Open
ABS Relay Coil Circuit Shorted to Gnd
ABS Relay Coil Circuit Shorted to Batt
Left Front Wheel Speed = 0
Right Front Wheel Speed - 0
Rear Wheel Speed = 0
Left Front Excessive Wheel Speed Variation
Right Front Excessive Wheel Speed Variation
Rear Excessive Wheel Speed Variation
LF Wheel Speed Snr CKT Open or Short to Gnd/Bat (1 of 3)
RF Wheel Speed Snr CKT Open or Short to Gnd/Bat (1 of 3)
Rear Wheel Speed Snr CKT Open or Short to Gnd/Bat (1 of 3)
Low System Voltage (1 of 2)
High System Voltage
Left Front ESB Will Not Hold Motor
Right Front ESB Will Not Hold Motor
Rear ESB Will Not Hold Motor
Left Front ABS Channel Will Not Move
Right Front ABS Channel Will Not Move
Rear ABS Channel Will Not Move
..
Left Front ABS Motor Free Spins (1 of 2)
Right Front ABS Motor Free Spins (1 of 2)
Rear ABS Motor Free Spins (1 of 2)
Left Front ABS Channel in Release Too Long
Right Front ABS Channel in Release Too Long
Rear ABS Channel in Release Too Long
EBCM Malfunction
Left Front ABS Motor Circuit Open
Left Front ABS Motor Circuit Shorted to Gnd
Left Front ABS Motor Circuit Shorted to Batt
Right Front ABS Motor Circuit Open
Right Front ABS Motor Circuit Shorted to Gnd
Right Front ABS Motor Circuit Shorted to Batt
Rear ABS Motor Circuit Open
Rear ABS Motor Circuit Shorted to Ground
PAGE
5El-28
5El-29
5El-30
5El-31
5El-32
5El-34
5El-36
5El-42
5El-44
5El-46
5El-48
5El-50
5El-52
5El-54
5El-56
5El-58
5El-60
5El-62
5El-68
5El-74
5El-80
5El-84
5El-86
5El-88
5El-90
5El-92
5El-94
5El-96
5El-98
5El-102
5El-106
5El-110
5El-112
5El-114
5El-116
5El-118
5El-120
5El-122
5El-124
5El-126
5El-128
5El-130
5El-132
(
T5737
5E1-23

66
76
77
78
81
82
86
87
91
92
93
94
95
Rear ABS Motor Circuit Shorted to Battery

Left Front Sol Circuit Open or Shorted to Gnd
Left Front Solenoid Circuit Shorted to Batt
Right Front Sol Circuit Open or Shorted to Gnd
Right Front Solenoid Circuit Shorted to Batt
.
Calibration Malfunction
EBCM Turned "ON" the Red ''BRAKE" Warning Lamp
Red "BRAKE" Warn Lamp Circuit Open or Shorted to Batt (1 of 2)
Open Brake Switch During Deceleration
Open Brake Switch When ABS Was Required
DTC 91 or 92 Set in Current or Prev. Ign Cycle
Brake Switch Contacts Always Closed
Brake Switch Circuit Open
5El-134
5El-136
5El-138
5El-140
5El-142
5El-144
5El-146
5El-148
5El-152
5El-154
5El-156
5El-158
5El-160
T5737(Cont'd)
5E1-24
EBCM
REFER TO
SECTION 8A50 ..,._._ _ _.....,
DATA LINK
IGNITION
REFER TO
SECTION
8A10
.1
CONN;'C!~ (DLC)
I" - i
1 9 r-----800TAN----1-1t---- A12 , - - - - - - - - SOOTAN
S270
--
5225
I. .. .I
C200A
2
INSTRUMENT
C 00D
BRAKE
CLUSTER
BRAKE WARNING
COMBO
~-
REFER TO
SWITCH
!<> '9l<>
REFER TO
SECTION
8A11
I
I
I
GAGES
39PNK
10 AMP 5206
"BRAKE"
RED
~
:c10 c~~;TION 8A41

r. - '.:'I
IA10PONT 33TAN,WHT
AS
33TAN,WHT
.
5228.
15273
AMBER
f~J
& DICHEV
L - ...I
C200D
C200A
"AH !'NOP"
817 PONT
t---~~1!.E!I___ ]
1/P FUSE BLOCK
ci"l
STOP HAZARD
FUSE 1
1002 ~1400RN
L: :..!! RED 20 AMP

C200A
C200D
BRAKE WARNING
LAMP CONTROL
ABS ACTIVE LAMP

CONTROL
ABS WARNING
LAMP CONTROL
TO
CHMSL
TO CRUISE
BULBS
CONTROL
RE~ER TO
MODULE
SECTION
REFER TO
8A110 SECTION 8A34
B+
LFIUNSKl~,LFt
1---e
867LTGRN~867LTGRN
(REFER TO
SECTION
SA-10)
SERIAL DATA LINE
IS278 .
1!~~=~~~11~M~
1537DKBLU0'9.1537DKBLU
"LOW TRAC"
I
I
Q\
!11
-I
-EE"'--::E]-'"
A
kJ
B 20LTBLU
A4
20LTBLU
.........
5243 L :..J 5271
STOPLAMP SWITCH (C1)
C200D
C200A
BRAKE SWITCH
INPUT
-------------.
..
ABS BAT
FUSE 6
L.J
502RED~.......... . . - ~ ~ ~ ~ ~ ~ - - -........---+---~4400RN
IGNITION
1
5 AMP
I
REFER TO
SECTION 8A10
I ABS IGN
I FUSE1
3000RN~--a~~~t--~~~~---~...--~-+--~~541sRN
302 RED
1633 RED
302 Rl!D
1633 RED
.a
SWITCHED
IGNITION
SWITCHED
BATTERY l:NPUT
I
I
I
I
REFERT01
SECTION I
8A14 I
s1111

VALVE SOLENOIDS
BATTERY FEED
I-
0101
GROUND
651 BU<JWHT
P100
060195
,___ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
FTI_o2_s_E~
Figure 6 Wiring Diagram (1 of 2)
5E1-25
EBCM
ABS MOTORPACK
~
LF ABS MOTOR HIGH
1280 BLK
LFABS
MOTOR
LF ABS MOTOR LOW
1281 PNK-
1284DICGRN
REAR ABS MOTOR

HIGH
1285 ORN
REAR ABS MOTOR

LOW
REAR ABS
MOTOR
RF ABS
MOTOR
r,
1282 PPL
RF ABS MOTOR HIGH
1283 BLK
RF ABS MOTOR
LOW
C2
ABS JUMPER HARNESS
P100
1J""
1----
!
E:I-"------+----
873 BLK ----1E]B.

830WHT
873 VEL
LI' WHEEL SPEED

SIGNAL LOW
830 LT BLU
LF WHEEL SPEED
SIGNAL HIGH
C120
LFWHEEL SPEED SENSOR
ABS JUMPER HARNESS
RF WHEEL SPEED
SIGNAL LOW
RF WHEEL SPEED
SIGNAL HIGH
1-----::::~:----t~:==========r,:1======-8-72:;:::
C130
RF WHEEL SPEED SENSOR
ABS JUMPER HARNESS
II""" -
...,.
i - - - - - w H T ~ 884BU<
BU< _-1..fcil_L 886 RED
..__ .....
REAR WHEEL SPEED SENSOR
C405B
C405C
-a
-}-8+.iJ;.i;l...l_
,-i.:::.:.::.r.-
---
884BU<
REAR WHEEL SPEED

SIGNAL HIGH
886 RED
REAR WHEEL SPEED

SIGNAL LOW
C200A
C200D
FROM ABS RELAY
ABS VALVE
FUSES
20AMP
8550RN
. _ _ - - - - - 8 5 5 ORN
...__ __.._ _ _ 1288 DK GRN
LF ABS SOLENOID
CONTROL
a----..--- 1289 LT BLU
RF ABS SOLENOID
CONTROL
C:1
05-13915
FT1031SE
5E1-26
12110088
24WAV F MICROPACK 100 SERIES
LTGRV
ELECTRONIC BRAKE CONTROL MODULE
(EBCM) CONNECTOR c1"
WIRE ENTRY VIEW
11994
WVOOUE
Figure 8 EBCM Connector End View (1 of 2)
CIRCUIT NO.
COLOR
12
800
TAN
SERIAL DATA LINE

REAR WHEEL SIGNAL HIGH
CONNECTOR
TERMINAL*
Al
CIRCUIT DESCRIPTION
NOT USED
A2
11
PLUGGED
A3
10
884
BLK
A4
872
DKGRN
RF WHEEL SIGNAL HIGH
830
1537
LTBLU
DK BLU
LF WHEEL SIGNAL HIGH

ABS ACTIVE LAMP CONTROL
867
LTGRN
AS
9
8
A6
A7
7
6
AB
PLUGGED
A9
AlO
4
3
641
1288
DKGRN
PNK
BRN
ABS WARNING LAMP CONTROL

NOT USED
SWITCHED IGNITION
LF ABS SOLENOID CONTROL
All
1632
A12
PLUGGED
ABS ENABLE RELAY CONTROL

NOT USED
Bl
24
PLUGGED
NOT USED
B2
23
885
RED
REAR WHEEL SIGNAL LOW
B3
22
833
TAN
RF WHEEL SIGNAL LOW
B4
873
YEL
LF WHEEL SIGNAL LOW
BS
21
20
33
TAN/WHT
B6
19
1289
LT BLU
B7
18
PLUGGED
BB
17
PLUGGED
B9
16
20
BIO
15
PLUGGED
BRAKE WARNING LAMP CONTROL

RF ABS SOLENOID CONTROL
NOT USED
NOT USED
LT BLU
BRAKE SWITCH INPUT

NOT USED
NOT USED
PLUGGED
Bll
14
BATTERY FEED
440
ORN
B12
13
*CONNECTOR SHELL MAY BE LABELED WITH EITHER OR BOTH INDEX SEQUENCES.
T5738
5E1-27
12110826
r;'9 ~:ll;5:11:z:1
8-WAYF
METAi-PACK 280 SERIES
ORY CONNECTOR "C2"
WIRE ENTRY VIEW
1:2:n:2:n:211:~
05-11-95
AT0085E
Figure 9 - EBCM Connector End View (2 of 2)
PIN
A
B
c
D
E
F
G
H
CIRCUIT NO.
1282
1283
1633
651
1285
1284
1280
1281
COLOR
PPL
BLK
RED
BLK/WHT
ORN
DKGRN
BLK
PNK
CIRCUIT
RF ABS MOTOR HIGH
RF ABS MOTOR LOW
SWITCHED BATTERY INPUT
GROUND
REAR ABS MOTOR LOW
REAR ABS MOTOR HIGH
LF ABS MOTOR HIGH
LF ABS MOTOR LOW
T5739
5E1-28
CHART A
ABS (AMBER) WARNING
LAMP "ON" CONSTANTLY,
NO DTCs STORED
NOTICE: DIAGNOSTIC SYSTEM

CHECK MUST BE COMPLETED
BEFORE USING THIS CHART.
IGNITION "OFF."
INSTALL TECH 1.
IGNITION TO "RUN."
USING TECH 1, SELECT "F4: MISC. TESTS."
SELECT "F8: LAMP TEST" AND ATTEMPT TO
"FLASH" THE ABS WARNING LAMP.
DID THE ABS WARNING LAMP "FLASH"?
I
YES
I
MALFUNCTION IS NOT PRESENT AT THIS TIME. INTEMITTENTS
COULD BE CAUSED BY INCORRECT WIRING HARNESS
ROUTING OR LOOSE CONNECTIONS. INSPECT ALL
CONNECTORS AND TERMINALS FOR POOR TERMINAL
CONTACT AND EVIDENCE OF CORROSION. REPLACE ALL
TERMINALS THAT EXHIBIT SIGNS OF POOR TERMINAL
CONTACT OR CORROSION.
I
NO
I
REPAIR SHORT TO GROUND IN CKT 867.
REFER TO SECTION SA-81 FOR FURTHER
DIAGNOSIS OF INSTRUMENT CLUSTER.
C7020

5E1-29
CHART B
ABS (AMBER) WARNING LAMP "ON"
INTERMITIENTLY, NO DTCs STORED

IGNITION "OFF."
DISCONNECT 8WAY EBCM CONNECTOR.
DISCONNECT NEGATIVE BATTERY TERMINAL.
DISCONNECT POSITIVE BATTERY TERMINAL.
USING J 39200, MEASURE THE RESISTANCE BETWEEN THE NEGATIVE BATTERY CABLE
TERMINAL AND TERMINAL "D" OF THE 8-WAY EBCM HARNESS CONNECTOR.
OBSERVE MEASURED RESISTANCE WHILE "WIGGLING" WIRE HARNESS AND CONNECTORS.
IS RESISTANCE ALWAYS 2 OHMS OR LESS?

USING J 39200, MEASURE THE RESISTANCE BETWEEN POSITIVE BATTERY CABL.E
TERMINAL AND TERMINAL "812" OF THE 24-WAY EBCM HARNESS CONNECTOR.
OBSERVE MEASURED RESISTANCE WHILE "WIGGLING" WIRE HARNESS AND
CONNECTORS.
REPAIR INTERMITTENT OPEN OR

HIGH RESISTANCE IN CKT 651.
REFER TO SECTION 8A4,
"INTERMITTENTS AND POOR
CONNECTIONS."
TURN IGNITION SWITCH TO "RUN" (THIS IS DONE TO COMPLETE THE IGNITION

CIRCUIT).
USING J 39200, MEASURE THE RESISTANCE BETWEEN POSITIVE BATTERY CABLE
TERMINAL AND TERMINAL "A9" OF THE 24-WAY EBCM HARNESS CONNECTOR.
OBSERVE MEASURED RESISTANCE WHILE "WIGGLING" WIRE HARNESS AND
CONNECTORS.

HIGH RESISTANCE IN CKT 440 OR
502. REFER TO SECTION 8A4,
CONNECTIONS."
CHECK POSITIVE BATTERY TERMINAL AND POSITIVE BATTERY CABLE

TERMINAL FOR A POOR CONNECTION.
INSPECT TERMINALS "A9" AND "812" OF THE 24WAY EBCM CONNECTOR "C1"
AND TERMINAL "C" OF THE 8-WAY EBCM CONNECTOR FOR POOR TERMINAL
CONTACT AND EVIDENCE OF CORROSION. REFER TO SECTION 8A4,
IS THERE EVIDENCE OF POOR TERMINAL CONTACT OR CORROSION?

HIGH RESISTANCE IN CKTs 641, 300
OR 142. REFER TO SECTION 8A4,
CONNECTIONS."
IGNITION "OFF."
IGNITION TO "RUN."
IS ABS WARNING LAMP "ON" INTERMITTENTLY WITH NO DTCs SET?
REPLACE TERMINALS THAT EXHIBIT

POOR TERMINAL CONTACT OR
SIGNS OR CORROSION. REPAIR
CONNECTION IF POOR CONTACT
EXISTS AT BATTERY.
MALFUNCTION IS NOT PRESENT AT THIS TIME. INTERMITTENTS

MAY BE CAUSED BY INCORRECT WIRING HARNESS ROUTING
OR LOOSE GROUND CONNECTIONS. REFER TO SECTION 8A4,
"INTERMITTENTS AND POOR CONNECTIONS."
C9813
5E1-30
CHART C
ABSfTCS ACTIVE. INDICATOR LAMP "ON"
WITH IGNITION "OFF," NO DTCs STORED

IGNITION "OFF."
OBSERVE THE ABS/TCS ACTIVE WARNING LAMP.
IS THE ABS!TCS ACTIVE LAMP "ON"?
I
I
I
NO
I
MALFUNCTION IS NOT PRESENT AT THIS TIME.
INTERMITTENTS COULD BE CAUSED BY INCORRECT WIRING
HARNESS ROUTING OR LOOSE CONNECTIONS. INSPECT ALL
TERMINALS THAT.EXHIBIT SIGNS OF POOR TERMINAL
YES
REPAIR SHORT TO
VOLTAGE ON CKT 1537.
C7978
5E1-31
CHART D
TECH 1 DISPLAYS UNDEFINED DTCs
rn
IMPORTANT
USE THIS CHART IF ANY OF THE FOLLOWING UNDEFINED DTCs

ARE SET 12, 27, 31, 35, 43, 67, 68, 71, 72, 73, 75, 83, 84, 85, 88,
96, 97, OR 98.
IGNITION TO "RUN."
USING TECH 1 , CLEAR DTCs.
DOES UNDEFINED DTC. RESET?
C9814
5E1-32
INSTRUMENT
CLUSTER
REFER TO
SECTION
8A11
FUS!I
GAGES
BRAKE
WARNING
33TAN/
ii~(;~C10 CHEV
"BRAKE"
A10 PONT
1
D13 CHEYu_JD11 CHEV
A5 PONTI "LOW TRAC" IA11 PONT
I
AMBER
I
!/Q\
:C,/
t ~hl:33TAN/
WHT ~ 1 8 2 7 3 WHT
I
I
I
~D~l!"!!C!'!"!H~EV'!'I
~~-....._-...:IB17 PONT
817 LT GRN
I "ABS INOP"
I
AMBER
I
----------
I
I
I
BRAKE WARN,ING
LAMP CONTROL
I
I
I
1537 DK BLU ~ 1537 DK BLU
EBCM
BRAKE
COMBO
SWITCH
ABS ACTIVE
LAMP CONTROL
I
I
I
fil
---
117 LT GAN
ABS WARNING
LAMP CONTROL
C200D
C200A
0428115
FT1045E
DTC 11
ABS WARNING LAMP CIRCUIT MALFUNCTION
Circuit Description:
This DTC checks the state of the amber ABS
warning lamp to identify a situation in which the
driver could not be alerted to a system malfunction.
Due to an integral lamp driver module within the
instrument panel cluster, the EBCM must provide a
ground to turn the amber ABS warning lamp "OFF."
DTC Will Set When:

DTC 11 can only be set during the three second
bulb check or when the lamp is commanded "ON." If
the EBCM cannot control the amber ABS warning
lamp for two seconds, a malfunction exists.
Action Taken:
A malfunction DTC is stored; however, ABS is
not disabled.
DTC Chart Test Description:

1. Determines if the ABS warning lamp can be
properly controlled.
2. Determines if the ABS warning lamp is "ON"
constantly.
3. Checks for other DTCs which could turn "ON"
the ABS warning lamp.
turned "OFF" manually.
5. Checks the integrity of the ABS warning lamp
circuitry.
6. Checks for a short to voltage on the ABS warning

lamp circuitry.
7. Determines if a malfunctioning EBCM is the
cause of DTC 11.
8. Verifies that the other J/P indicator lamps function
properly.
turned "ON" manually.
10. Checks for a short to ground in the ABS warning
lamp circuitry.
11. Verifies condition of the 10 amp "GAGES" Fuse
9.
12. Determines if DTC 11 was set due to an EBCM
malfunction.
Diagnostic Aids:
An intermittent malfunction may be caused by a
poor connection, rubbed through wire insulation, or a
wire that is broken inside the insulation.
The lamp test function of the Tech 1 may be
used to command the lamp on" while looking for an
intermittent malfunction in the ABS warning lamp
circuitry.
The frequency of the malfunction can be
checked by using the enhanced diagnostic function of
the Tech 1, as described in "Tech 1 Diagnostics" in
this section.
Any circuitry that is suspected of causing the
intermittent complaint should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
ANTILOCK BRAKE SYSTEM 5E1 33
DTC 11
INSTALL TECH 1.
IGNITION TO "RUN."
SELECT "F8: LAMP TEST" AND ATTEMPT TO TURN "ON,"
THEN "FLASH" THE ABS WARNING LAMP.
CAN THE ABS WARNING LAMP BE BOTH TURNED "ON"
AND FLASHED USING THE TECH 1?
ABS WARNING LAMP

CIRCUIT MALFUNCTION
MALFUNCTION IS NOT PRESENT AT

THIS TIME. REFER TO "DIAGNOSTIC
AIDS" ON FACING PAGE.
IGNITION "OFF."
REMOVE TECH 1.
IGNITION TO "RUN."
DOES THE ABS WARNING LAMP TURN "ON" AND STAY "ON"?

t;;"\
DO REMAINING 1/P WARNING LAMPS WORK PROPERLY?
\V--,:;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;-~~~---1
IGNITION "OFF."
DISCONNECT 24WAY EBCM
CONNECTOR "C1 ",
IGNITION TO "RUN."
CONNECT A FUSED JUMPER
WIRE, SUCH AS J 36169, WITH
A 3 AMP FUSE BETWEEN
GROUND AND TERMINAL "A7"
OF THE 24-WAY EBCM
HARNESS CONNECTOR "C1 ".
DOES ABS WARNING LAMP
REMAIN "ON"?
r--~E;~;;~---------i
i THAT OTC
i
ii,,,,,,.,,,,,,,.,.,,,,,,,,,,,,,,.,,,,,,,,,$
CHART FIRST. !
INSPECT TERMINAL
'.'A7" OF THE 24WAY
EBCM CONNECTOR
"C1" FOR POOR
TERMINAL CONTACT.
IGNITION "OFF."
RECONNECT ALL
CONNECTORS.
IGNITION TO "RUN."
DOES OTC 11 RESET?
IGNITION "OFF."
REMOVE JUMPER.
DISCONNECT 1/P
CLUSTER CONNECTOR.
USING J 39200, MEASURE
THE RESISTANCE
BETWEEN TERMINAL
"A7" OF THE 24WAY
EBCM CONNECTOR "C1"
AND TERMINAL "06"
(CHEV) "817" (PONT) OF
THE 1/P CLUSTER
HARNESS CONNECTOR.
IS RESISTANCE .2 OHMS
OR LESS?
IGNITION "RUN."
THE VOLTAGE BETWEEN
GROUND AND TERMINAL
"A7" OF THE 24-WAY
EBCM CONNECTOR "C1",
IS VOLTAGE 2 VOLTS OR
LESS?
REPAIR
OPEN OR
HIGH
RESISTANCE
IN CKT 867.
fg'
\:!..,)
\!V
MALFUNCTION
IS NOT
PRESENT AT
THIS TIME.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE.
IGNITION "OFF."
DISCONNECT
24-WAY EBCM
CONNECTOR "C1 ",
IGNITION TO
"RUN."
DOES ABS
WARNING LAMP
TURN "ON"?
REPAIR
OPEN IN
CKT 39.
IGNITION "OFF."
DISCONNECT IP
CONNECTOR.
USING J 39200,
MEASURE THE
RESISTANCE BETWEEN
GROUND AND
TERMINAL "A7" OF
24-WAY EBCM
CONNECTOR "C1".
DOES J 39200 DISPLAY
RESISTANCE AS "OL"
(INFINITE)?
.-------.
REPAIR
SHORT TO
GROUND IN
CKT 867.
..______.
, ,,,,
IGNITION "OFF."
INSPECT TERMINAL "A7"
OF THE 24WAY EBCM
CONNECTOR "C1" FOR
BENT TERMINALS OR
FOREIGN DEBRIS.
CORRECT AS
NECESSARY.
RECONNECT ALL
CONNECTORS.
IGNITION TO "RUN."
DOES OTC 11 RESET?
,,,,,,,,,.,,,.,.,,,,,,,,,,,
REFER TO
SECTION
! 8A81 FOR
il FURTHER
DIAGNOSIS
l OF CLUSTER,
CHECK FOR
SHORT TO
GROUND ON
CKT 39 AND ALL
OTHER
CIRCUITS FROM
SPLICE S206.
REPAIR ANY
SHORTS TO
GROUND AND
REPLACE FUSE.
IF NO SHORTS
ARE FOUND,
REPLACE FUSE.
j
j
!
l!
,,,,,,,,.,,,.,,,,,,.,,.,.,,,,,,,,,.,,.,,,,.,,,,,~!
MALFUNCTION
IS NOT
PRESENT AT
THIS TIME.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE.
,,,,, ,,.,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,.uu,,,.,,,.,.,,.,,,,,,.,,,,,,u,,,,,,,u,,1,,1,5,
REFER TO SECTION 8A81 FOR
LFURTHER_ DIAGNOSIS_OF_CLUSTER. J
C9815
5E1-34
INSTRUMENT
CLUSTER
REFER TO
SECTION
8A11
BRAKE
WARNING
EBCM
BRAKE
COMBO
SWITCH
;@l~@>~C10 CHEV
"BRAK!"
A10 PONT
1
33 TAN/
rr~-11-b33TAN/
WHT 82281
1 8273 WHT
D13CHEY~D1'1CHEV
AS PONTI .. LOW TRAC" I A18 PONT
I
AMBER
I
11537 DK BLU !.r;:;l!.11537 DK BLU
I
I
I
I
I
"ABS INOP"
AMBER
B17PONT
----------
I
I
I
BRAKE WARNING
LAMP CONTROL
I
I
I
!~\
Fl.........,...,..
.
~
,:..=.;..'J,-...__~
1 DG CHEV
I
I
I
.!r.::'1L 867 LT GRN

867 LT GRN 11..::..J.
---
ABS ACTIVE
LAMP CONTROL
ABS WARNING
LAMP CONTROL
C200D
C200A
04~2815
fT1,Q4&E
DTC 13
ABS ACTIVE OR LOW TRAC LAMP CKT MALFUNCTION
This DTC checks the state of the amber ABS
active lamp, "LOW TRAC" to identify a situation in
which the driver could not be alerted to a possible
slippery driving condition. The amber ABS active
lamp circuit is such that the EBCM provides a ground
to tum "ON". the amber ABS active lamp.
DTC Will Set When:

DTC 13 c.an only be set during the three second
bulb check or when the lamp is commanded "ON." If
the EBCM cannot control the amber ABS active lamp
for two seconds, a malfunction exists.
Action Taken:
A malfunction DTC is stored; however, ABS is
not disabled.

1. Determines if the ABS active lamp can be
2. Determines if the ABS active lamp is "ON"
constantly.
3. Checks for a short to ground in the ABS active
lamp circuitry.
4. Determines if DTC 13 was set due to a EBCM
malfunction.
5. Determines if DTC 13 was set due to a EBCM

malfunction.
6. Determines if the ABS active lamp can be
controlled manually.
7. Verifies the integrity of the ABS active lamp
circuitry.
8. Determines if there is a short to voltage in the
ABS active lamp circuitry.
9. Determines if DTC 13 was set due to an EBCM
malfunction.
Diagnostic Aids:
The lamp test function of the Tech 1 may be
used to command the lamp "ON" while looking for
an intermittent malfunction in the ABS active lamp
circuitry.
this section.
for backed out terminals, improper .mating, broken
the wiring harness.
5E1-35
DTC 13
INSTALL TECH 1.
IGNITION TO "RUN."
USING TECH 1, SELECT l'F4: MISC. TESTS."
SELECT "F8: LAMP TEST" ATTEMPT TO TURN "ON," THEN
"OFF" THE "LOW TRAC" LAMP.
CAN THE "LOW TRAC" LAMP BE TURNED BOTH "ON" AND
"OFF" USING THE TECH .1?
ABS ACTIVE OR LOW TRAC LAMP

CKT MALFUNCTION.

IGNITION "OFF."
INSPECT ALL CONNECTORS FOR
IGNITION TO "RUN."
DOES OTC 13 RESET?
IGNITION "OFF."
REMOVE TECH 1.
IGNITION TO "RUN."
DOES THE "LOW TRAC" LAMP
TURN "ON" AND STAY "ON"?

AIDS'' ON FACING PAGE.
IGNITION "OFF."
IGNITION TO "RUN."
DOES THE "LOW TRAC" LAMP TURN "ON"?
IGNITION "OFF."
OF THE 24WAY EBCM
CONNECTOR FOR BENT
TERMINALS OR FOREIGN
DEBRIS. CORRECT AS
NECESSARY.
RECONNECT ALL
CONNECTORS.
iGNITION TO "RUN."
DOES OTC 13 RESET?
REPAIR SHORT
TO GROUND
ON CKT 1537.
MALFUNCTION
ISNOT
PRESENT AT
THIS TIME.
REFER TO.
"DIAGNOSTIC
AIDS" ON
FACING PAGE.
IGNITION "OFF."
IGNITION TO "RUN."
CONNECT A FUSED JUMPER WIRE, SUCH AS J 36169, WITH
A 3 AMP FUSE BETWEEN GROUND AND TERMINAL "A6"
OF THE 24WAY EBCM HARNESS CONNECTOR.
DOES THE "LOW TRAC" LAMP TURN "ON"?
IGNITION "OFF."
DISCONNECT 1/P CLUSTER
CONNECTOR.
USING J 39200, MEASURE THE
RESISTANCE BETWEEN
TERMINAL "A6" OF THE 24WAY
EBCM HARNESS CONNECTOR AND
TERMINAL "016" (CHEV) OR "A16"
(PONT) OF THE 1/P CLUSTER
HARNESS CONNECTOR.
IGNITION TO "RUN."
THE VOLTAGE FROM
GROUND TO TERMINAL
"A6" OF THE 24WAY
EBCM HARNESS
CONNECTOR.
LESS?
! REFER TO SECTION
MALFUNCTION
IS NOT
PRESENT AT
THIS TIME.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE.
.
FOR FURTHER
!
!~1,,,,,111,u1,,,.,,,,.,,,.,,.,,.,.,,,.,,.,,..,,,,,,,,,,,11111,ul
DIAGNOSIS OF CLUSTER. (
j .8A81
REPAIR
OPEN OR
HIGH
RESISTANCE
IN CKT 1537.
IGNITION "OFF."
OF THE 24WAY EBCM
CONNECTOR FOR POOR
TERMINAL CONTACT.
RECONNECT ALL
CONNECTORS.
IGNITION TO "RUN."
DOES OTC 13 RESET?
C9816
5E1-36

EBCM EBTCM
IGNITION
REFER TO SECTION
8A10
r- -
P100
SWITCHED IGNITION
1----1132 PNK--1111i--1133 RED
ABS/TCS RELAY
ENABLE CONTROL
ABS/TCS SWITCHED
BATTERY INPUT
----.J
UNDERHOOD ELECTRICAL
CENTER
041tt5
FT0185E
DTC 14
(Page 1 of 3)
ABS RELAY CONTACT CIRCUIT OPEN

Ignition voltage is supplied through terminal
"C2" of the ABS relay. The EBCM then is able to
energize the pull-in coil by completing the ground
circuit at connector "C 1", terminal "A 11 " of the
EBCM. The magnetic field created closes the ABS
relay contacts and allows battery voltage and current
to .be supplied to the EBCM, which supplies power to
the motors and solenoids.
DTC Will Set When:

DTC 14 can be set anytime after the EBCM
commands the ABS relay "ON" (the relay is first
commanded . "ON" during the three second bulb
check). This test monitors the availability of current
and voltage to the motors and solenoids. This
malfunction indicates voltage is not available and
would therefore not allow ABS operation if required.
4. Checks for high resistance in the switched battery

circuit from the ABS relay to the EBCM.
circuit from the battery to the ABS relay.
6. Checks for high resistance in the ABS relay
contacts.
7. Checks for poor terminal contact or corrosion at
the connectors.
8. Determines if the EBCM is the cause of the.
malfunction.
Diagnostic Aids:
A malfunction DTC is stored, ABS is disabled

and the amber ABS warning lamp is turned "ON."
The red "BRAKE" warning lamp is turned "ON" if
the hydraulic modulator rear piston is not in the
"HOME" position.

checked by using .the enhanced diagnostic function of
the Tech l, as described in "Tech 1 Diagnostics" in
this section.
Any circuitry .that is suspected of causing the
the wiring harness.
VIBRATION, TEMPERATURE EFFECTS:

1. Checks to see if DTC 16 is also set as current or
history. If DTC 16 is also set, proceed to that
chart first.
2. Verifies that the malfunction is currently present.
3. Verifies that the relay can be turned "ON" and
provide voltage to the EBCM.
Check for vibration effects by performing the

relay test function of the Tech 1. With the relay test
commanded "ON," lightly tap the top and sides of the
relay while monitoring relay voltage. If the relay
voltage changes significantly, replace the relay.
If OTC 14 only sets when the vehicle is initially
started in cold ambient conditions (temperature less
than 0 C - 32 F), replace the relay.
Action Taken:
IS OTC 16 ALSO PRESENT OR IN HISTORY?
DTC 14
,,,,,,, ,,,,,,,,,.,,,,,,,,,,,,.,,,,,,1
IGNITION TO "RUN," ENGINE "OFF."

USING TECH 1, SELECT DATA LIST AND
OBSERVE EBCM BATTERY VOLTAGE.
DOES TECH 1 INDICATE THAT EBCM BATTERY
VOLTAGE IS GREATER THAN 10 VOLTS?
! PROCEED TO !
! OTC 16 CHART!
!$,,,,,,,,,,,,,.,,.,,,,,,,,,,,,,,.,,,,$
FIRST.
I
(Page 1 of 3)
ABS RELAY CONTACT
CIRCUIT OPEN
NOTICE: J 39200 TEST LEADS
MUST BE "ZEROED" PRIOR TO
MAKING ANY RESISTANCE
MEASUREMENTS. REFER TO
J 39200 USER'S MANUAL.
IGNITION "OFF."
DISCONNECT 24-WAY AND 8-WAY EBCM CONNECTORS.
CONNECT A FUSED JUMPER SUCH AS J 36169 WITH A 3 AMP FUSE BETWEEN
GROUND AND TERMINAL "A11" OF THE 24-WAY EBCM HARNESS CONNECTOR.
IGNITION TO "RUN."
USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND AND TERMINAL "C"
OF THE 8-WAY EBCM HARNESS CONNECTOR.
IS VOLTAGE 10 VOLTS OR GREATER?
MALFUNCTION IS NOT
PRESENT AT THIS
TIME. REFER TO
"DIAGNOSTIC AIDS"
. ON FACING PAGE.
,.,,, ,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,
IGNITION "OFF."
DISCONNECT JUMPER USED IN STEP 3.
DISCONNECT ABS RELAY.
USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "C4" OF THE ABS RELAY
HARNESS CONNECTOR AND TERMINAL "C" OF THE BWAY EBCM HARNESS CONNECTOR.
! DIAGNOSIS
!
j CONTINUED ON i
LNEXT_PAGE._,,,.,,J

TERMINAL AND TERMINAL "C1" OF THE ABS RELAY HARNESS CONNECTOR.
REPAIR HIGH
RESISTANCE
IN CKT 1633.
USING A JUMPER WIRE, CONNECT TERMINAL "86" ON THE ABS RELAY TO GROUND.
USING A FUSED JUMPER WIRE, SUCH AS J 36169, WITH A 3 AMP FUSE, CONNECT TERMINAL "85"
ON THE ABS RELAY TO B+.
USING J'39200, MEASURE THE RESISTANCE BETWEEN TERMINALS "30" AND "87" ON THE ABS
RELAY,
REPAIR HIGH
RESISTANCE IN
CKT 302. REFER
TO SECTION BA.
INSPECT ABS RELAY AND ABS RELAY HARNESS CONNECTOR FOR A POOR CONNECTION OR POOR
TERMINAL CONTACT.
INSPECT EBCM AND EBCM CONNECTOR TERMINALS "A11" AND "C" FOR POOR TERMINAL CONTACT.
INSPECT POSITIVE BATTERY TERMINAL AND POSITIVE BATTERY CABLE TERMINAL FOR A POOR
CONNECTION. REFER TO SECTION BA-4, "CHECKING TERMINAL CONTACT."
IS POOR TERMINAL CONTACT OR A POOR CONNECTION EVIDENT?
MALFUNCTION IS INTERMITTENT. REFER

TO "DIAGNOSTIC AIDS" ON FACING PAGE.
C9817
5E1-38

EBCM EBTCM
IGNITION
Rl!Pl!R TO SECTION
8A10
...
- - -
--
, - - - - - - - - - - - - - - - - 6 4 1 BRN
i.;;...--illl"'\_AI'--- 641 l!IRN

B+ L
.SAMP
~302RED-,
FUSIBLE
LINK B
a,..;..--1832PNK
1833 RED
SWITCHED IGNITION
ABS/TCS RELAY
ENABLE CONTROL
ABS/TCS SWITCHED
BATTERY INPUT
302 RED
S17fl
---
---
---
---
CENTER
.J
041ttS
FT0165E
DTC 14
(Page 2 of 3)
circuit at connector "Cl", terminal "All" of the
to be supplied to the EBCM, which supplies power to
DTC Will .Set When:

commanded "ON" during the three second bulb
Action Taken:
"HOME" position.

9. Checks for high resistance in the entire ABS
relay coil circuit.
10. Verifies proper battery condition.
11. Verifies proper voltage .is available at the ABS

relay.
12. Checks for an open in the switched battery
circuit from the relay to the EBCM.
13. Verifies the condition of the ABS relay.
Diagnostic Aids:
the Tech 1, as described in "Tech l Diagnostics" in
this section.
for backed out terminals, improper. mating, broken
the wiring harness.

If DTC 14 only sets when the vehicle is initially
than o C - 32" F), replace the relay.
5E1 ..;39
OTC 14
NOTICE: J 39200 TEST LEADS MUST BE "ZEROED" PRIOR TO

MAKING ANY RESISTANCE MEASUREMENTS. REFER TO
(Page 2 of 3)
ABS RELAY .CONTACT
CIRCUIT OPEN
,,,,,,,,,.,,,,,,.,.,,,,,,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,.,,.,
l DIAGNOSIS CONTINUED i
!,.,,.,,,,,,
FROM PREVIOUS PAGE. !
,,,,,,,,,,,,,,,,,,,,,,,,,,..
,,,,,,,.,,,,,,,,,,..,.,/
IGNITION "OFF."
REMOVE JUMPER WIRE INSTALLED IN STEP #3, IF NOT ALREADY REMOVED.
WITH BATTERY STILL DISCONNECTED, TURN IGNITION SWITCH TO "RUN."
THIS COMPLETES THE IGNITION CIRCUIT TO THE ABS RELAY.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "A11'' OF
THE 24-WAY EBCM HARNESS CONNECTOR AND THE POSITIVE BATTERY
CABLE TERMINAL.
IS RESISTANCE 95 OHMS OR LESS WHEN MEASURED AT APPROXIMATELY
20'C (68'F)?
USING J 39200, MEASURE THE VOLTAGE BETWEEN THE

NEGATIVE AND POSITIVE BATTERY TERMINALS.
r!
j
DIAGNOSIS
CONTINUED ON
NEXT PAGE.
l
!
!
--------------------------------'-
I'""' ,,,,.,,,.,,.,.,,,u11,,u,,,,,,,,,,,,,,,,,,,,,,,,;,;;.,
IGNITION "OFF."
RECONNECT POSITIVE BATTERY CABLE.
MEASURE THE VOLTAGE BETWEEN TERMINAL "C1" OF THE
ABS RELAY HARNESS CONNECTOR AND GROUND.
! REFER TO SECTION 603
! TO CORRECT LOW
j
VOLTAGE CONDITION.
!!
j
~,,,.,.,,.,,,,.,,.,.,,.,,,,,,,,,,,,,,,,,.,,,,,.,,,,,,,,,,,,,,,,,~
USING J 39200, MEASURE THE RESISTANCE BETWEEN

TERMINAL "C4" OF THE ABS RELAY HARNESS
CONNECTOR AND TERMINAL "C" OF THE 8-WAY EBCM
HARNESS CONNECTOR.
USING A JUMPER WIRE, CONNECT TERMINAL "86" ON THE ABS RELAY

TO GROUND.
USING A FUSED JUMPER WIRE, SUCH AS J 36169, WITH A 3 AMP FUSE,
CONNECT TERMINAL "85" ON THE ABS RELAY TO B+.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINALS "30"
AND "87" ON THE ABS RELAY.
MALFUNCTION WAS MOST LIKELY DUE TO A POOR

COl'IINECTION. INSPECT ALL CONNECTORS AND TERMINALS
FOR POOR TERMINAL CONTACT AND EVIDENCE OF
CORROSION. REFER TO SECTION 8A4, "CHECKING TERMINAL
CONTACT." REPLACE ALL TERMINALS THAT EXHIBIT
EVIDENCE OF POOR TERMINAL CONTACT OR CORROSION.
C9818
5E1-40

EBCM EBTCM
IGNITION
REIFER TO SECTION
8A10
r -
PICO
,-----------------841 BFIN--IIU.---1
-- -
----841 EIFIN
B+ L
--1632 PNK--11111----1
SAMP
1833 RED
~302RED"'II
FUSIBLE
SWITCHED IGNITION
ABS/TCS RELAY
ENABLE CONTROL
ABS/TCS SWITCHED
BATTERY INPUT
302 .RED
LINK 8
8171!1
----..I
UNDEFIHOOD ELECTRICAL
CENTER
041SH15
FT0165E
DTC 14
(Page 3 of 3)
DTC
wm
Set When:

commanded "ON" during the three second bulb
Action Taken:
"HOME" position.

14. Checks for proper resistance of the ABS relay

coil.

control circuit between the ABS relay and the
EBCM.
control circuit between the battery and the ABS
relay.
Diagnostic Aids:
this section.
the wiring harness.

relay .while monitoring relay voltage. If the relay
than o C - 32 F), replace the relay.
DTC 14
(Page 3 of 3)
ABS RELAY CONTACT
CIRCUIT OPEN
NOTICE: J 39200 Tl::ST LEADS MUST BE "ZEROED" PRIOR TO MAKING

ANY RESISTANCE MEASUREMENTS. REFER TO J 39200 USER'S MANUAL.
,,.,,,,,11,,,1111n,,,;,1,,;;,u;,;,1,u;;.;,;,;,,,.,,uf
! DIAGNOSIS CONTINUED !
j
FROM PREVIOUS PAGE.
,,,,,,, ,,,,,,u,,,.1,,,,,,,,,,,,,,,,.,,,;,,;;;,,,,.,,,.,,,;/

USING .J 39200, MEASURE THE RESISTANCE BETWEEN
TERMINALS "85" AND "86" ON THE ABS RELAY.
IS RESISTANCE 95 OHMS OR LESS WHEN MEASURED AT
APPROXIMATELY 20'C (68'F)?
MEASURE THE RESISTANCE BETWEEN TERMINAL "CS" OF THE

ABS RELAY HARNESS CONNECTOR AND TERMINAL "A11'' OF
THE 24-WAY EBCM HARNESS CONNECTOR.
MEASURE THE RESISTANCE BETWEEN TERMINAL "C2" OF THE

ABS Rl;:LAY HARNESS CONNECTOR AND THE POSITIVE BATTERY
CABLE TERMINAL.
,MALFUNCTION WAS MOST LIKELY DUE TO A POOR

CONNECTJON. INSPECT ALL CONNECTORS AND TERMINALS
CORl;IOSION. REFER TO SECTION BA4, "CHECKING TERMINAL
CONTACT." Rj:PLACE Al,.L TERMINALS THAT EXHIBIT
REPAIR OPEN OR HIGH

RESISTANCE IN CKT 641,
CKT 300, IGNITiON SWITCH,
OR BATTERY FEED CIRCUIT
TO IGNIT.ION SWITCH.
REFl::R TO SECTION BA FOR
FURTHER INFORMATION.
C9819
5E1-42

EBCM EBTCM
IGNITION
REfER TO SECTION
IA10
r- -
, . . . . . . . . . - - - - - - - - - - - - - - 8 4 1 BAN
AEIS/TCS RELAY
ENABLE CONTROL
i.;..--r\._JfF--- 841 BAN

B+ L
5AMP
~302RED-,
FUSIBLE
LINKB
ABS/TCS SWITCHED
BATTERY INPUT
302 RED I
6175
SWITCHED IGNITION
----..I
CENTER
041995
FT0165E
DTC 15
ABS RLY CONTACT CKT SHORT TO BAT OR ALWAYS
CLOSED


1. Determines if any other DTCs are present.
2. Indicates that the EBCM is capable of controlling
the ABS relay as commanded.
3. Checks for a possible short to voltage in CKT
1633.
4. Determines whether the short to voltage is in
CKT 1633 or as a result of a malfunctioning ABS
relay.
5. Checks for a possible intermittent malfunction in
wiring or connectors.
DTC Will Set When:

DTC 15 can be set orily before the EBCM
commands the ABS relay "ON." This test determines
if the ABS relay is energized when it should not be.
This malfunction would not allow the ABS relay to
remove power to the EBCM. If a second malfunction
were to occur that requires the ABS relay to be turned
"OFF," that malfunction cannot be removed if the
relay cannot be controlled. The malfunction must be
present for three consecutive drive cycles before the
DTC is set.
Action Taken:
A malfunction DTC is stored. ABS is not
disabled.
Diagnostic Aids:
this section.
Any circuitry, that is suspected of causing the
intermittent complaint, should be thoroughly checked
the wiring harness.
5E143
OTC 15
ABS ALY CONTACT CKT SHORT
TO BAT OR ALWAYS CLOSED
G)
ARE ANY OTHER DTCs PRESENT?
~,,,, ,,,,,,,,,,,,, 0,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,

USING THE RELAY TEST FUNCTION OF THE TECH 1,
COMMAND ABS RELAY "OFF."
DOES TECH 1 INDICATE THAT ABS RELAY IS "O,FF," AND
BATTERY VOLTAGE IS LESS THAN 5 VOLTS?
!t.,,,,,,,,,,,,,,,,.,,,,..,,,,,,..,,,.,,,;,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,n
PROCEED TO THAT DTC CHART FIRST. !
J.
IGNITION "OFF."
DISCONNECT 24-WAY AND 8-WAY EBCM HARNESS
CONNECTORS.
IGNITION TO "RUN."
USING J 39200, MEASURE THE VOLTAGE BETWEEN
GROUND AND TERMINAL "C" OF THE EBCM BWAY
CONNECTOR.
IS VOLTAGE 2 VOLTS OR LESS?

IGNITION "OFF."
INSPECT CKT 1633 AND 8-WAY EBCM HARNESS
CONNECTOR FOR DAMAGE WHICH MAY RESULT
IN A SHORT TO VOLTAGE WHEN ALL
CONNECTORS ARE CONNECTED. REPAIR
DAMAGE IF EVIDENT.
RECONNECT 8-WAY AND 24-WAY EBCM
CONNECTORS.
IGNITION TO "RUN."
USING RELAY TEST FUNCTION OF TECH 1,
COMMAND. ABS RELAY "OFF."
DOES TECH 1 INDICATE THAT ABS RELAY IS
"OFF," AND BATTERY VOLTAGE IS LESS THAN 5
VOLTS?
IGNITION "OFF."
IGNITION TO "RUN."
MEASURE THE VOLTAGE BETWEEN GROUND AND
TERMINAL "C" OF THE 8-WAY EBCM HARNESS
CONNECTOR.
REPAIR SHORT
TO VOLTAGE IN
CKT 1633.
MALFUNCTION MOST
LIKELY CAUSED BY A
POOR CONNECTION.
REFER TO "DIAGNOSTIC
AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs, AND TEST DRIVE VEHICLE FOR 3 DRIVE CYCLES TO VERIFY THAT DTC DOES NOT
RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING ABOVE 16 km/h (10 mph), AND THEN IGNITION TO "OFF."
C7329
5E1-44

EBCM EBTCM
IGNITION
REFER TO SECTION
8A10
C1
SWITCHED IGNITION
r--641 BAN
5AMP
~302RED,
1,;..._
---1832PNK
_.""\,._--
B+ L
FUSIBLE
LINK 8
1833 RED
302 RED I
8175
ABS/TCS RELAY
ENABLE CONTROL
ABS/TCS SWITCHED
BATTERY INPUT
----.J
CENTER
041995
FT0185E
DTC 16
ABS RELAY COIL CIRCUIT OPEN
DTC Will Set When:

DTC 16 can be set only after DTC 14 has been
set. This test detects an open in the ABS relay coil
circuit. An open in this circuit will not allow the ABS
relay to be energized thus preventing voltage and
current to the motors and solenoids. If this
malfunction is present and the ignition is turned
"OFF" before 5 km/h (3 mph) is reached, DTC 14 is
set alone.
Action Taken:
"HOME" position.
2. Checks to ensure that voltage is available to the

pull-in coil of the ABS relay.
3. Ensures that there is continuity through the pull-in
coil of the ABS relay.
4. Verifies the integrity of the ABS relay control
circuit.
5. Ensures malfunction was not due to poor terminal
contact.
Diagnostic Aids:
this section.
If the frequency of the malfunction is high, but
is currently intermittent, check for high coil resistance
by measuring between relay terminals "85" and "86"
using a J 39200. If resistance shows greater than 100
ohms, replace the relay.
the wiring harness.

1. Indicates the EBCM is capable of controlling the
ABS relay as commanded.
5E1-45
DTC 16
ABS RELAY COIL
CIRCUIT OPEN
USING THE RELAY TEST FUNCTION OF. THE TECH 1,
COMMAND THE ABS RELAY "ON."
DOES TECH 1 INDICATE ABS RELAY "ON,,,AND IS VOLTAGE
10 VOLTS OR GREATER?

GROUND AND TERMINAL "C2" OF THE ABS RELAY
CONNECTOR.

AIDS'' ON FACING PAGE.

COMMAND THE ABS RELAY "OFF."
MEASURE THE VOLTAGE BETWEEN GROUND AND
TERMINAL "CS" OF THE ABS RELAY CONNECTOR.
REPAIR OPEN OR HIGH

RESISTANCE IN CKT 641
OR
ABS IGN FUSE 1.
CHECK FOR INTERMITTENT

CONNECTIONS AT ABS
RELAY. IF OK, REPLACE
ABS RELAY.
IGNITION "OFF."
IGNITION TO "RUN."
MEASURE THE VOLTAGE BETWEEN GROUND AND TERMINAL "A11"
IGNITION "OFF."
INSPECT 24-WAY EBCM CONNECTOR TERMINAL "A11" FOR
POOR TERMINAL CONTACT OR EVIDENCE OF CORROSION.
REFER TO SECTION 8A4 "CHECKING TERMINAL CONTACT."
REPLACE ALL TERMINALS THAT EXHIBIT SIGNS. OF POOR
TERMINAL CONTACT OR CORROSION.
IGNITION TO "RUN."
DOES OTC 16 SET AS A CURRECT OTC?
MALFUNCTION WAS MOST

LIKELY CAUSED BY A
POOR CONNECTION.
AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY
THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING ABOVE 16 km/h (10mph),
AND THEN IGNITION TO "OFF."
C9820
5E1-46

EBCM EBTCM
IGNITION
REFER TO SECTION
P100
IA10
r -
SWITCHED IGNITION
- -1---1632 PNK-11-1633 RED
ABS/TCS RELAY
ENABLE CONTROL
ABS/TCS SWITCHED
BATTERY INPUT
_ _ _ _ .J
CENTER
041tt5
FT0165E
DTC 17
ABS RELAY COIL CIRCUIT SHORTED TO GND
circuit at connector "Cl", .terminal "All" of the
DTC Will Set When:
DTC 17 can be set. before the EBCM commands
the ABS relay "ON." This test determines if the ABS
relay is energized when it should not be. This
malfunction would not allow the ABS relay to remove
power to the EBCM. If a second malfunction were to
occur that requires the ABS relay to be turned "OFF,"
that malfunction cannot be removed if the relay cannot
be controlled.
Action Taken:
disabled.

Number(s) below refer to circled nutnber(s) on

the ABS relay as commanded;
2. Checks. to ensure that the ABS relay or control
CKT 1632 are not shorted to ground.
3. Checks to see if the EBCM is internally shorted
to ground. A grounded terminal "A 11 " would
cause the ABS relay to be energized any time the
ignition is in the "RUN" position.
4. Checks for a short to ground in control CKT 1632
or a defective relay.
Diagnostic Aids:
An intermittent malfunction. may be caused by a
this section.
the wiring harness.
5E1-47
DTC 17
ABS RELAY COIL CIRCUIT
SHORTED TO GND

USING THE RELAY TEST FUNCnON OF THE TECH 1,
COMMAND THE ABS RELAY "OFF."
DOES TECH 1 INDICATE THAT ABS RELAY IS "OFF" AND
BATTERY VOLTAGE IS LESS THAN 5 VOLTS?
IGNITION "OFF."
DISCONNECT 24-WAV EBCM CONNECTOR.
IGNITION TO "RUN."
USING J 39200, MEASURE THE VOLTAGE
BETWEEN TERMINAL "A11" OF THE 24-WAY
EBCM HARNESS CONNECTOR AND B+.
IGNITION "OFF."
INSPECT CKT 1632 AND TERMINAL "A11" OF
THE 24-WAY EBCM CONNECTOR FOR DAMAGE
WHICH MAY RESULT IN A SHORT TO GROUND
WITH ALL CONNECTORS CONNECTED. REPAIR
ALL DAMAGE IF EVIDENT.
IGNITION TO "RUN."

LIKELY CAUSED BY A
POOR CONNECTION.

IGNITION "OFF."
MEASURE VOLTAGE BETWEEN
TERMINAL "CS" OF THE ABS RELAY
CONNECTOR AND B+.
REPAIR SHORT
TO GROUND IN
CKT 1632.
THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHl,CLE, DRIVING OVER 16 km/h (10 mph),
C9821
5E1-48

EBCM EBTCM
IGNITION
REfER TO SECTION
8A10
.
r -
- - - - - - - - - - - - - - - 6 4 1 BRN
....... -
'----411"~.1--- 641 BRN

B+ L
SAMP
~302RED,
FUSIBLE
LINK B
1---1632 PNK
1833 RED
SWITCHED IGNITION
ABSITCS RELAY
ENABLE CONTROL
ABSITCS SWITCHED
BATTERY INPUT
302 RED
8175
L
CENTER
0411MfS
FT0185E
DTC 18
ABS RELAY COIL CIRCUIT SHORTED TO BATT
DTC Chart. Test Description:


the ABS relay as commanded.
2. Checks for a short to voltage on the ABS relay
control circuit.
3. Verifies that the ABS relay coil has the
appropriate resistance.
4. Checks for ABS relay contacts that are failed
closed.
5. Checks for possible pqor terminal contact at the
EBCM.
DTC Will Set When:

DTC 18 can be set after the EBCM commands
the ABS relay "ON." A malfunction of this type will
not allow voltage to be available to the motors and
solenoids; therefore, ABS operation would not be
allowed if required.
Action Taken:
"HOME" position.
Diagnostic Aids:
this section.
for, backed out terminals, improper mating, broken
the wiring harness.
5E1-49
DTC 18
SHORTED TO BATT
USING THE RELAY TEST FUNCTION OF TECH 1, COMMAND
ABS RELAY "ON."
DOES TECH 1 INDICATE ABS RELAY "ON" AND BATTERY
VOLTAGE ABOVE 10 VOLTS?
IGNITION "OFF."
DISCONNECT 24-WAY EBCM CONNECTOR.
IGNITION TO "RUN."
GROUND AND TERMINAL "A11" OF THE 24-WAY
EBCM HARNESS CONNECTOR.
MALFUNCTION.IS NOT PRESENT AT

IGNITION "OFF."
USING J 39200, MEASURE THE RESISTANCE
BETWEEN TERMINAL "86" AND TERMINAL "BS"
OF THE ABS RELAY.
IS RESISTANCE 40 OHMS OR GREATER?

TERMINALS "30" AND "87" OF THE ABS RELAY.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?
INSPECT CKT 1632 AND TERMINAL "A11" OF THE 24-WAY

EBCM CONNECTOR FOR DAMAGE WHICH MAY RESULT IN
A SHORT TO VOLTAGE WITH ALL CONNECTORS
CONNECTED. REPAIR ALL DAMAGE IF EVIDENT.
IGNITION TO "RUN."
DOES DTC 18 SET AS A CURRENT DTC?
MALFUNCTION IS MOST LIKELY DUE TO

A POOR CONNECTION. PIEFER TO
"DIAGNOSTIC AIDS" ON FACING PAGE.
THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 mph),
C7033
5E1-50
EBCM/EBTCM
(
ABS JUMPER HARNESS
: ::~:----.ffit----=:
::~,.....L-U-~111---11
C120
LF WHEEL SPEED SIGNAL

HIGH
LOW
LF WHHL SPEED SENSOR
04-19-95
FT0175E
DTC 21
LEFT FRONT WHEEL SPEED
=0
Diagnostic Ai.ds:
As a toothed ring passes by the wheel speed

sensor, changes in the electromagnetic field cause the
wheel speed sensor to produce a sinusoidal (AC)
voltage signal whose frequency is proportional to
wheel speed. The magnitude of this signal is directly
related to wheel speed and the proximity of the wheel
speed sensor to the toothed ring, often referred to as
the air gap.

this section.
If the customer's comments reflect that the ABS
warning lamps are "ON" only during moist
environmental changes (rain, snow, vehicle wash), all
wheel speed sensor circuitry should be thoroughly
inspected for signs of water intrusion. If DTC is not
current, clear DTCs and simulate the effects of water
intrusion .. Use the following procedure. Spray the
suspected area with a 5% salt water solution (two
teaspoons of salt to 12 oz. of water). Test drive
vehicle over various road surfaces (bumps, turns, etc.)
above 24 km/h (15 mph) for at least 30 seconds. If
DTC returns, replace suspected harness.
the wiring harness.
Resistance of the wheel speed sensor will
increase with an increase in sensor temperature.
When replacing a wheel speed sensor, inspect
the sensor terminals and harness connector for
corrosion and/or water intrusion. If evidence of
corrosion or water intrusion exists,. replace wheel
speed sensor jumper harness. Likewise, if replacing a
wheel speed sensor jumper harness, inspect sensor
terminals. If evidence of corrosion or water intrusion
exists, replace wheel speed sensor. Refer to
DTC Will Set When:

DTC 21 can be set when the vehicle is not in an
ABS event. If the left front wheel speed = 0 and the
vehicle's reference speed is greater than 8 km/h (5
mph), a malfunction exists.
Action Taken:
and the amber ABS warning lamps are turned "ON."

1. This step identifies a wheel speed sensor or
circuitry that is damaged and visibly apparent.
2. Checks to see that the wheel speed sensor coil is
within proper resistance values.
3. Verifies that the wheel speed sensor can generate
an appropriate output signal.
4. This ensures that the wheel speed circuitry is not
shorted together.
5. Ensures that the malfunction was not due to
physical damage.
rn
DTC 21
IMPORTANT:
WHEEL SPEED SENSOR INTERMITTENT MALFUNCTIONS MAY BE DIFFICULT TO LOCATE.

CARE SHOULD BE TAKEN NOT TO DISTURB ANY ELECTFIICAL CONNECTIONS PRIOR TO AN
INDICATED STEP OF THIS CHART. THIS Wl'LL ENSURE THAT AN INTERMITTENT CONNECTION
WILL NOT BE CORRECTED BEFORE THE SOURCE OF THE MALFUNCTION IS FOUND.
LEFT FRONT
WHEEL SPEED = 0
IGNITION "QFF."
PHYSICALLY INSPECT THE LEFT FRONT WHEEL SPEED SENSOR, .LEFT FRONT
WHEEL SPEED SENSOR JUMPER HARNESS, AND CONNECTORS FOR DAMAGE.
IS PHYSICAL DAMAGE INDICATED?
I
. I
NO
YES
DISCONNECT LEFT FRONT WHEEL SPEED SENSOR DIRECTLY AT SENSOR.

USING J 39200, MEASURE THE RESISTANCE BETWEEN SENSOR TERMINALS
"A" AND 0 8 11
IS RESISTANCE BETWEEN 1020 AND 1137 OHMS WHEN SENSOR IS 20'C
(68'F)?
(IF TEMPERATURE OF THE SENSOR IS SUSPECTED TO BE OTHER THAN
20'C (68'F), REFER TO THE TABLE BELOW FOR APPLICABLE SENSOR
RESISTANCE VALUES; THE VALUES IN THE TABLE ARE FOR TEMPERATURE
OF THE SENSOR, NOT AIR TEMPERATURE.)
REPLACE WHEEL SPEED SENSOR AND/OR

JUMPER HARNESS IF DAMAGED.
DRIVE :VEHICLE ABOVE 24 km/h (15 MPH) TO
ENSURE OTC 21 DOES NOT SET.
I
I
YES
. I
NO
WITH J 39200 STILL CONNECTED; SELECT A/C VOLTAGE SCALE.

SPIN WHEEL BY HAND WHILE OBSERVING VOLTAGE.
IS VOLTAGE AT LEAST 100 mV (VOLTAGE WILL INCREASE AS
WHEEL SPEED INCREASES)?
REPLACE WHEEL SPEED SENSOR.
I
I
YES
NO
IGNITION "OFF."
DISCONNECT 24WAY EBCM/EBTCM CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN. TERMINAL "AS"
AND "84" OF THE 24WAY EBCM/EBTCM HARNESS CONNECTOR.
YES
. I
NO
INSPECT CKTs 830 AND 873 AND 24~WAY EBCM/EBTCM CONNECTOR FOP!
DAMAGE WHICH MAY RESULT IN A SHORT BETWEEN CKTs 830 AND 873
WITH ALL CONNECTORS CONNECTED. REPAIR ALL DAMAGE IF EVIDENT.
RECONNECT ALL. CONNECTORS.
TEST DRIVE .VEHICL,E ABOVE 24 km/h (15 MPH) FOR AT LEAST 30 SECONDS.
DOES OTC 21 SET AS A CURRENT OTC?
YES
REPAIR SHORT BETWEEN CKTs 830 AND 873.
REPLACE
EBCM/EBTCM.
NO
FRONT WHEEL SPEED SENSOR

TO "DIAGNOSTIC AIDS" ON FACIN.G PAGE .
TEMPERATURE OF SENSOR
VS. SENSOR RESISTANCE
(APPROXIMATE)
TEMP.
TEMP.
RESISTANCE
("F)
(OHMS)
('C)
34 TO 4
30 TO 40
804 TO 1066
5 TO 43
41 TO 110
956 TO 1240
44 TO 93
111 TO 200
.1112 TO 1463
C7991
5E1-52
EBCM/EBTCM
(
ABS JUMPER HARNESS
872
eliO
BU<-----110B..
a----872 DK ORN
[!)a-.- - - - 8 3 3 TAN
RF WHEEL SPEED SIGNAL
HIGH
LOW
C130
04-20-91!
FT0186E
DTC 22
RIGHT FRONT WHEEL SPEED =0
Diagnostic Aids:

the air gap.

this section.
If .the customer's comments reflect that the ABS
warning lamps are "ON'' only during moist
env.ironmental changes (rain, snow, vehicle .wash), all
wheel speed sensor circuitry should be thorougltly
intrusion. .Use the following .procedure. Spray the
suspected area .with a 5% salt water solution (two
teaspoons of salt to 12 oz. of. water). Test drive
locks, improperly formed or damaged terminals, ,poor
terminal to wiring connections or physical . damage to
the wiring harness,
corrosion or water intrusion exists, replace wheel
speed sensor jumper harness'. Likewise, if replacing a
OTC Will Set When:

ABS event. If the right front wheel speed = 0 and the
mph), a malfunction exists:
Action Taken:
OTC Chart Test Description:

shorted together.
physical damage.
II]
DTC 22
IMPORTANT:

CARE SHOULD BE TAKEN NOT TO DISTURB ANY ELECTRICAL CONNECTIONS PRIOR TO AN
INDICATED STEP OF THIS CHART. THIS WILL ENSURE THAT AN INTERMITTENT CONNECT!,ON
5E1-53
RIGHT FRONT
WHEEL SPEED = 0
IGNITION "OFF."
PHYSICALLY INSPECT THE RIGHT FRONT WHEEL SPEED SENSOR, RIGHT FRONT
. I
NO
YES
DISCONNECT RIGHT FRONT WHEEL SPEED SENSOR DIRECTLY AT SENSOR.

"A" AND 11 8."
IS RESISTANCE BETWEEN 1020 AND 1137 OHMS WHEN SENSOR IS 2oc
(68'F)?
20'C (68'F), REFER TO THE TABLE BELOW FOR APPLICABLE SENSOR

DRIVE VEHICLE ABOVE 24 km/h (15 MPH) TO
I
I
YES
NO
I
WITH J 39200 STILL CONNECTED, SELECT A/C VOLTAGE SCALE.

I
I
YES
NO
I
IGNITION "OFF."
O DISCONNECT 24-WAY EBCMIEBTCM CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "83"
AND "A4" OF THE 24-WAY EBCMIEBTCM HARNESS CONNECTOR.
I '.
'
YES
NO
I
INSPECT CKTs 833 AND 872 AND 24-WAY EBCM/EBTCM CONNECTOR FOR
WITH .ALL CONNECTORS CONNECTED. REPAIR ALL DAMAGE IF EVIDENT.
TEST DRIVE VEHICLE ABOVE 24 km/h (15 MPH) FOR AT LEAST 30 SECONDS.
I
I
YES
REPLACE
.,
EBCM/EBTCM.
NO
I

TO ''DIAGNOSTIC AIDS" ON FACING PAGE.
(APPROXIMATE)
TEMP.
TEMP.
RESISTANCE
('F)
(OHMS)
('C)
34 TO 4
30 TO 40
5 TO 43
41 TO 110
804 TO 1066
956 TO 1240
44 TO 93
111 TO 200
1112 TO 1463
C7992
EBCM
r- - ,
r--,
ABS JUMPER HARNESS

B
884WHT
~ 884BLK ~ 884BLK
l __ J
+Bf
L __ J
C40SB
C405C
C200A
C200D
SfiSBLK--i-GT SfiSRED
885RED
REAR WHEEL SPEED

SIGNAL HIGH
REAR WHEEL SPEED
SIGNAL LOW
05-13-95
FTIOUE
OTC 24
REAR WHEEL SPEED
=0
Diagnostic Aids:

the air gap.

this section.
current, clear DTCs and simulate the effects .of water
intrusion. Use the following procedure. Spray the
the wiring harness.
DTC
wm
Set When:

ABS event. If the rear wheel speed = 0 and the
Action Taken:

4. Verifies that the wheel speed circuitry is not
shorted together.
physical damage.
[I]
DTC 24
IMPORTANT:
REAR WHEEL
SPEED= 0

INDICATED STEP OF THIS CHART. THIS WILL ENSURE THAT AN INTERMITTENT CONNECTION
WILL NOT BE CORRECTED BEFORE THE SOURCE DF THE MALFUNCTION IS FOUND.
IGNITION "OFF."
PHYSICALLY INSPECT THE REAR WHEEL SPEED SENSOR, WHEEL SPEED
SENSOR JUMPER HARNESS, AND CONNECTORS FOR DAMAGE.
. I
NO
YES
YES
YES
NO
INSPECT CKTs 884 AND 885 AND 24WAY EBCM CONNECTOR FOR DAMAGE
WHICH MAY RESULT IN A SHORT BETWEEN CKTs 884 AND 885 WITH ALL
CONNECTORS CONNECTED. REPAIR ALL DAMAGE IF EVIDENT.
TEST DRIVE VEHICLE ABOVE 24 km/h (15 mph) FOR AT LEAST 30 SECONDS.
NO
USING TECH 1, SELECT "FO: DATA LIST."

MONITOR WHEEL SPEEDS WHILE SLOWLY ACCELERATING TO 65 km/h
(40 mph) AND THEN SLOWLY DECELERATING TOO km/h (0 mph);
IS THE REAR WHEEL SPEED CONSTANTLY HIGHER THAN THE TWO
REMAINING WHEEL SPEEDS?
YES
NO
REPLACE INCORRECT OR MALFUNCTIONING REAR WHEEL SPEED

SENSOR ASSEMBLY WITH THE PROPER ASSEMBLY. REFER TO PARTS
CATALOG FOR PROPER PART NUMBER.
MALFUNCTION WAS MOST LIKELY

CAUSED BY A POOR CONNECTION.
REFER TO "DIAGNOSTIC AIDS" ON
FACING PAGE.
REPAIR SHORT BETWEEN

CKTs 884 AND 885.
. I
YES
NO

AND "A3" OF THE 24-WAY EBCM HARNESS CONNECTOR.
REPLACE WHEEL SPEED SENSOR

AND/OR WHEEL SPEED SENSOR
DRIVE VEHICLE ABOVE 24 km/h
(15 mph) TO ENSURE DTC 24
DOES NOT SET.
NO

IS VOLTAGE AT LEAST 100 mV (VOLTAGE WILL INCREASE AS WHEEL SPEED
INCREASES)?
.
YES
DISCONNECT REAR WHEEL SPEED SENSOR DIRECTLY AT SENSOR.

USING J 39200, MEASURE THE RESISTANCE BETWEEN SENSOR TERMINALS "A"
AND "B."
IS RESISTANCE BETWEEN 969 AND 1185 OHMS WHEN SENSOR IS 20'C (68'F)?
(IF TEMPERATURE OF THE SENSOR IS SUSPECTED TO BE OTHER THAN 20'C
(68'F), REFER TO THE TABLE BELOW FOR APPLICABLE SENSOR RESISTANCE
VALUES; THE VALUES IN THE TABLE ARE FOR TEMPERATURE OF THE SENSOR,
NOT AIR TEMPERATURE.)
.
.
5E1-55
REPLACE EBCM.

TEMPERATURE OF SENSOR VS. SENSOR RESISTANCE (APPROXIMATE)
TEMP.
TEMP.
RESISTANCE
("C)
('F)
(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
C9822
5E156
EBCM/EBTCM
(
ABS JUMPER HARNESS
::::~:----1ffi1----=:::_L_U-1111-(120

HIGH

LOW
LF WHEEL SPEED SENSOR
04-19-95
FT0175E
DTC 25
LEFT FRONT EXCESSIVE WHEEL SPEED VARIATION
Diagnostic Aids:

the air gap.

wire that is broken inside the insulation:
this section.
If thecustomer's comments reflect that the ABS
locks, improperly formed or. damaged terminals, poor
the wiring harness.
DTC Will Set When:

DTC 25 can be set when the brake is "OFF."
The purpose of this test is to detect a situation in
which the left front wheel acceleration or deceleration
is beyond specified limits.
Action Taken:
A malfunction DTC is stored, ABS are disabled

shorted together.
5. ,Ensures that the malfunction was not due to
physical damage.
[I] IMPORTANT:
OTC 25
WHEEL SPEED SENSOR INTERMITTENT MALFUNCTIONS MAY BE DIFFICULT TO LO,CATE. CARE

SHOULD BE TAKEN NOT TO DISTURB ANY ELECTRICAL CONNECTIONS PRIOR TO AN INDl,CATED
STEP OF THIS CHART. THIS WILL ENSURE THAT AN INTERMITTENT CONNECTION WILL NOT BE
CORRECTED BEFORE THE SOURCE OF THE MALFUNCTION IS FOUND.
5E1-57
LEFT FRONT
EXCESSIVE
WHEEL SPEED
VARIATION
IGNITION "OFF."
PHYSICALLY INSPECT THE LEFT FRONT WHEEL SPEED SENSOR, LEFT FRONT
NO
I
YES

AND "B."
IS RESISTANCE BETWEEN 1020 AND 1137 OHMS WHEN SENSOR IS 2oc (68F)?
(IF TEMPERATURE OF THE SENSOR IS SUSPECTED TO BE OTHER THAN 2oc
(68F}, REFER TO THE TABLE BELOW FOR APPLICABLE SENSOR RESISTANCE
NOT AIR TEMPERATURE.I
YES

AND/OR JUMPER HARNESS DRIVE
VEHICLE ABOVE 24 km/h (15 MPH) TO
. I
NO

IS VOLTAGE AT LEAST 100 mV (VOLTAGE WILL 1.NCREASE AS WHEEL SPEED
INCREASES)?
I
I
YES
NO
IGNITION .''OFF."
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "AS"
AND "84" OF THE 24-WAY EBCM/EBTCM HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESI.STANCE AS "OL" (INFINITE)?
a
I
YES
NO
I
I
YES

CKTs 830 AND 873.
NO

REPLACE
EBCM/EBTCM .

(APPROXIMATE)
RESISTANCE
TEMP.
TEMP.
(OHMS)
(C)
(F)
804 TO 1066
34 TO 4
30 TO 40
5 TO 43
41 TO 110
956 TO 1240
44 TO 93
111 TO 200
1112 TO 1463
C7995
5E1 58
ANTILOCK B.RAKE SYSTEM
EBCM/EBTCM
(
ABS JUMPER HARNESS
872
BLI<----ffi. .
e:mQ
---87-2: : : : :
C130

HIGH
LOW
04-20-95
FT0185E
OTC 26
RIGHT FRONT EXCESSIVE WHEEL SPEED VARIATION
Diagnostic Aids:

the air gap.

checked by using tlle enhanced diagnostic function of
this section;
,
above. 24 km/h (15 mph) for at least 30 seconds. If
the wiring harness.
DTC Will Set When:

The purpose of .this test is to detect a situation in
which the right front wheel acceleration or
deceleration is beyond specified limits.
Action Taken:
and the ABS warning lamps are turned "ON."

shorted together.
physical damage.
rn
DTC 26
IMPORTANT:
WHEEL SPEED SENSOR INTERMITIENT MALFUNCTIONS MAY BE DIFFICULT TO LOCATE. CARE

SHOULD BE TAKEN NOT TO DISTURB ANY ELECTRICAL CONNECTIONS PRIOR TO AN INDICATED
CORRECTED BEFORE THE SOURCE OF THE MALFUNCnON IS FOUND.
I
I
RIGHT FRONT
EXCESSIVE
WHEEL SPEED
VARIATION
IGNITION "OFF."
NO
-.
YES

AND "B."
(68F), REFER TO THE TABLE BELOW FOR APPLICABLE SENSOR RESISTANCE
NOT AIR TEMPERATURE.}
5E1-59

ENSURE DTC 26 DOES NOT SET.
YES
NO
I

INCREASES)?
. I
11
NO
YES
IGNITION "OFF."
DISCONNECT 24-WAY EBCM/EBTCM CONNECTOR.
AND "A4" OF THE 24-WAY EBCM/EBTCM HARNESS CONNECTOR.
I
B
YES
NO

CKTs 833 AND 872.
I
I
I
YES
REPLACE
EBCM/EBTCM.
NO


(APPROXIMATE)
RESISTANCE
TEMP.
TEMP.
(OHMS)
('F)
('C)
804 TO 1066
34 TO 4
-30 TO 40
.5 TO 43
41 TO 110
956 TO 1240
44 TO 93
111 TO 200
1112 TO 1463
C7996
EBCM
r--,
~ 'o1 :
r- - ,
ABS JUMPER HARNESS
884WHT.
884BLK
g;
C1
884BLK
REAR WHEEL SPEED

SIGNAL HIGH
885 Fll!D
REAR WHEEL SPEED

SIGNAL LOW
~~
885 IIW<
L __ J
+B-f
L __ J
C405B
C405C
C200A
C200D
~ 885 Rl!D
06-13-95
FT1085E
DTC 28
REAR EXCESSIVE WHEEL SPEED VARIATION
the air gap.
DTC Will Set When:

which the rear wheel acceleration or deceleration is
beyond specified limits.
Action Taken:

shorted together.
physical damage.
6. Checks rear sensor toothed ring for physical
damage or a possible build-up of metal chips on
speed sensor magnetic pole piece.
Diagnostic Aids:
An intennittent malfunction may be caused by a
this section.
teaspoons of salt to 12 oz. of water).Test drive vehicle
over various road surfaces (bumps, turns, etc.) above
24 km/h (15 mph) for at least 30 seconds. If DTC
returns, replace suspected harness.
locks, improperly fonned or damaged terminals, poor
the wiring harness.
rn
5E1-61
OTC 28
IMPORTANT:
REAR
EXCESSIVE
WHEEL SPEED
VARIATION
WHEEL SPEED SENSOR INTERMITTENT MALFUNCTIONS MAY BE DIFFICULT TO LOCATE. CARE

STEP OF THIS CHART. THIS WILL ENSURE THAT AN INTERMIITENT CONNECTION WILL NOT BE
IGNITION "OFF.''
PHYSICALLY INSPECT THE REAR WHEEL SPEED SENSOR, REAR WHEEL SPEED
I
ffl
NO
I
YES

AND "B.''
IS RESISTANCE BETWEEN 969 AND 1185 OHMS WHEN SENSOR IS 2oc (68'F)?
(68FJ, REFER TO THE TABLE BELOW FOR APPLICABLE SENSOR RESISTANCE
VALUES: THE VALUES IN THE TABLE ARE FOR TEMPERATURE OF THE SENSOR,
YES
I
NO
I

IS VOLTAGE AT LEAST 100 mV (VOLTAGE WILL INCREASE AS WHEEL
SPEED INCREASES)?
111
NO
INSPECT CKTs 884 AND 885 AND 24;WAY EBCM CONNECTOR FOR DAMAGE
WHICH MAY. RESULT IN .A SHORT BETWEEN CKTs 884 AND 885 WITH ALL
CONNECTORS CONNECTED. REPAIR .ALL DAMAGE IF EVIDENT.
TEST DRIVE VEHICLE ABOVE 24 km/h (15 mph) FOR AT LEAST 30 SECONDS.
. REPLACE WHEEL SPEED SENSOR.
NO
DISCONNECT 24-WAY EBCM CONNECTOR.

USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "B2"
. AND "A3" OF THE 24-WAY EBCM HARNESS CONNECTOR.
YES
11
YES

JUMPER HARNESS IF DAMAGED. DRIVE
VEHICLE ABOVE 24 km/h (15 mph) TO

CKTs 884 AND 885.
I
YES
NO
INSPECT REAR SENSOR TOOTHED RING IN REAR AXLE DIFFERENTIAL FOR

MISSING TEETH, A BUILD-UP OF METAL CHIPS ON SPEED SENSOR MAGNETIC
POLE PIECE OR OTHER PHYSICAL DAMAGE. REFER TO SECTION 4B.
IS ANY PHYSICAL DAMAGE INDICATED?
MALFUNCTION IS INTERMIITENT.
REFER TO "DIAGNOSTIC AIDS"
ON FACING PAGE.
I
NO
REPLACE EBCM.

TEMPERATURE OF .SENSOR VS. SENSOR
RESISTA.NCE (APPROXIMATE)
RESISTANCE
TEMP.
TEMP.
(OHMS)
( 'F )
(C)
34TO 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
YES
REPLACE TOOTHED RING.

REFER TO SECTION 4B.
I
C9823
5E1-62
ANTIL()CK BRAKE SYSTEM
EBCM/EBTCM
(
ABS JUMPER HARNESS
830 BLK---G]...._ _ _ 830 LT B-L-U-~ni-8

873 WHT-----10873 VEI:.
C120

HIGH

LOW
04-19-95
FT0175E
OTC 32
{Page 1 of 3)
LF WHEEL SPEED SNR CKT OPEN OR SHORT TO GND/BAT
Diagnostic Aids:

speed sensor to the toothed ring often referred to as
the air gap.

this section.
wheel speed sensor circuitry sho~ld be thoroughly
intermittent complaint should be thoroughly .checked
for backed out terminals, improper .mating; .. broken
the wiring harness.
DTC Will Set When:

DTC 32 can be set anytime after initialization. If
either of the left front wheel speed circuits are open or
shorted to voltage or ground, a malfunction exists.
Action Taken:

1. Checks for proper resistance of the wheel speed
sensor coil.
2. Checks for a short to ground in the wheel speed
sensor wiring.
3. Checks for a short to voltage in the wheel speed
sensor wiring.
4. Checks for a short to voltage in CKT 873.
physical damage of the circuitry.
rn
DTC 32
IMPORTANT:
WHEEL SPEED SENSOR INTERMITTENT MALFUNCTIONS MAY BE

DIFFICULT TO LOCATE. CARE SHOULD BE TAKEN NOT TO DISTURB ANY
ELECTRICAL CONNECTIONS PRIOR TO AN INDICATED STEP OF THIS
CHART. THIS WILL ENSURE THAT AN INTERMITTENT CONNECTION WILL
NOT BE CORRECTED BEFORE THE SOURCE OF THE MALFUNCTION IS
FOUND.
G)
5E1-63
(Page 1 of 3)
LF WHEEL SPEED SNR
CKT OPEN OR SHORT TO
GND/BAT
IGNITION "OFF."
USING A 5% SALT WATER SOLUTION (TWO TEASPOONS OF SALT TO 12 OZ. WATER), THOROUGHLY SPRAY
THE LEFT FRONT WHEEL SPEED SENSOR JUMPER HARNESS.
DISCONNECT 24WAY EBCM/EBTCM HARNESS CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINALS "AS" AND "B4" OF THE 24WAY
EBCM/EBTCM HARNESS CONNECTOR.
IS RESISTANCE BETWEEN 1020 AND 1137 0 WHEN SENSOR IS 20'C (68'F)? (IF TEMPERATURE OF SENSOR
IS SUSPECTED TO OTHER THAN 2oc (68F), REFER TO THE TABLE ON PAGE 2 OF 3 OF THIS DTC CHART
FOR APPLICABLE SENSOR RESISTANCE VALUES; THE VALUES IN THE TABLE ARE FOR TEMPERATURE OF
THE SENSOR, NOT AIR TEMPERATURE.)
YES
I
,..., .............................................
NO
USING J 39200, MEASURE THE RESISTANCE BETWEEN GROUND AND

TERMINAL "B4" OF THE 24WAY EBCM/EBTCM HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" {INFINITE)?
i DIAGNOSIS CONTINUED j
l ON PAGE 2 OF 3 OF THIS l
!,,,,,.,,.,,.,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,
DTC CHART.
!
YES
G)
NO
I

VOLTAGE BETWEEN GROUND AND
TERMINAL "AS" OF THE 24WAY
IS VOLTAGE 1 VOLT OR LESS?
NO
I
REPAIR SHORT TO
VOLTAGE IN CKT 873.
YES
MALFUNCTION IS INTERMITTENT.
INSPECT ALL CONNECTORS AND
HARNESSES FOR DAMAGE WHICH
MAY RESULT IN A SHORT TO VOLTAGE
WHEN ALL COMPONENTS ARE
CONNECTED. REPAIR ALL DAMAGE IF
FOUND. REFER TO "DIAGNOSIS AIDS"
ON FACING PAGE FOR MORE
INFORMATION.
NO
I
IGNITION "OFF."
INSPECT TERMINALS "AS;' AND "B4" OF THE
24-WAY EBCM/EBTCM HARNESS CONNECTOR
FOR POOR TERMINAL CONTACT AND
CONTAMINATION. ALSO INSPECT CKTs 830
AND 873 FOR DAMAGE WHICH MAY RESULT
IN AN OPEN CIRCUIT, SHORT TO GROUND,
OR SHORT TO VOLTAGE. REPAIR ALL
DAMAGE IF EVIDENT.
IGNITION TO "RUN."
YES
REPLACE
EBCM/EBTCM.
l ON PAGE 3 OF 3 OF THIS j
l~~,,,,,,,,.,..,,,,,,,,.,,u,,u,,,,,,,.,,,u,,,,,,,,,,,,,,,,.h~
DTC CHART.
l
YES
IGNITION "OFF."
DISCONNECT LEFT FRONT WHEEL SPEED SENSOR DIRECTLY AT
SENSOR.
IGNITION TO "RUN."
USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND
AND TERMINAL "B4" OF THE 24-WAY EBCM/EBTCM HARNESS
CONNECTOR.
YES
, .... 1 ................................,...........
IGNITION TO "RUN."
USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND AND
TERMINAL "B4" OF THE 24-WAY EBCM/EBTCM HARNESS CONNECTOR.
NO
NO
MALFUNCTION IS
INTERMITTENT. REFER TO
"DIAGNOSTIC AIDS" ON
FACING PAGE.
REPAIR SHORT
TO VOLTAGE IN
CKT 830.
C7999
5E1 64
EBCM/EBTCM
ABS JUMPER HARNESS
830 BLK----1G]B..__ _ _ 830 LT B-L-U-~ni--1

873 WHT'-----1@
873 VIL:
C120

HIGH
LOW
04-19-85
FT0175E
DTC 32
(Page 2 of 3)
the air gap.
DTC Will Set When:
Action Taken:
7. Checks for high resistance in CKT 873.
9. Verifies proper resistance of the wheel speed
sensor coil.
Diagnostic Aids:

this section.
teaspoons of salt to 12 oz; of water).Test drive vehicle
the wiring harness.
DTC 32
(Page 2 of 3)
LF WHEEL SPEED SNR CKT
OPEN OR SHORT TO GND/BAT
, .........,,,,,,,,.,,,,,,,,..,,,,,,,.,.,,,,,,,,,.,.,.,,,,.,,,,.;,.,,.....,,. ,,..,,,,..,,....,,.,
j DIAGNOSIS CONTINUED FROM j
! PAGE 1 OF 3 OF THIS
j CHART.
OTC
j
j
'"""'"f"'""""'"""""""""'"""""'"""""

USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "84" OF
THE 24WAY EBCM/EBTCM HARNESS CONNECTOR AND TERMINAL "B" OF
THE LEFT FRONT WHEEL SPEED SENSOR HARNESS CONNECTOR.
IS RESISTANCE 2 0 OR LESS?
I
I
YES
NO
I
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "AS" OF

THE 24WAY EBCM/EBTCM HARNESS CONNECTOR AND TERMINAL "A" OF
REPAIR HIGH RESISTANCE IN

CKT 873 (WHEEL SPEED
SENSOR JUMPER MUST EIE
REPLACED IF DAMAGED).
I
YES
I
NO
I
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL

"A" AND TERMINAL "B" OF THE LEFT FRONT WHEEL SPEED
SENSOR CONNECTOR.
IS RESISTANCE BETWEEN 1020 AND 1137 0 WHEN SENSOR IS
2oc (68F)? (IF TEMPERATURE OF SENSOR IS SUSPECTED TO
OTHER THAN 20'0 (68'F), REFER TO THE TABLE BELOW FOR
APPLICABLE SENSOR RESISTANCE VALUES; THE VALUES IN THE
TABLE ARE FOR TEMPERATURE OF THE SENSOR, NOT AIR
... TEMPERATURE.)

SENSOR JUMPER MUST BE
YES
I
NO
I
MALFUNCTION IS INTERMITTENT. INSPECT ALL CONNECTORS AND

HARNESSES FOR DAMAGE WHICH MAY RESULT IN HIGH
RESISTANCE WHEN ALL COMPONENTS ARE CONNECTED. REFER
TO "DIAGNOSTIC AIDS" ON FACING PAGE FOR MORE INFORMATION.
REPAIR ALL DAMAGE IF FOUND.

(APPROXIMATE)
TEMP.
TEMP.
RESISTANCE
('C)
('F)
(OHMS)
804 TO 1066
34 TO 4
30 TO 40
5 TO 43
41 TO 110
956 TO 1240
44 TO 93
111 TO 200
1112 TO 1463
C8000
5E1-66
EBCM/EBTCM
(
ABS JUMPER HARNESS
830 BLK----tG]B1----830 LT I-L-U-" - 11

873 WHT---l!I
873 YEL:
C120

HIGH
LOW
04-19-95
FT0175E
DTC 32
(Page 3 of 3)
wheel speed sensor to produce a sinusoidal .(AC)
the air gap.
OTC Will Set When:

Action Taken:

10. Checks for a short to ground in CKT 873.
sensor jumper harness.
13. Verifies that the wheel speed sensor is not
internally shorted to ground.
Diagnostic Aids:

this section.
warning lamps are "ON" only .during moist
intrusion. Use .the . following procedure. Spray the
the. wiring harness.
5E1-67
DTC 32
(Page 3 of 3)
""""f""'"''"'"'"""'"'""""""'""'"'"""'
DISCONNECT CONNECTOR C120 (LOCATED LH INNER FRAME RAIL).

TERMINAL "84" OF THE 24-WAY EBCM/EBTCM HARNESS CONNECTOR.
I
I
YES.

TERMINAL "AS" OF THE 24-WAY EBCM/EBTCM HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE "OL" (INFINITE)?
NO
REPAIR SHORT TO GROUND

IN CKT 873.
YES
I
THOROUGHLY RESPRAY THE LEFT FRONT WHEEL SPEED SENSOR

JUMPER HARNESS WITH THE SALT WATER SOLUTION.
NO

IN CKT 830.
IMPORTANT: DO NOT ALLOW WATER TO ENTER ANY WHEEL SPEED

SENSOR CONNECTOR.
SENSOR.
USNG J 39200, MEASURE THE RESISTANCE BETWEEN GROUND AND
TERMINAL "A," THEN "B" OF THE LEFT FRONT WHEEL SPEED
SENSOR HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE) FOR BOTH
MEASUREMENTS?
..
.I
YES
I
'

TERMINAL "A" OF THE LEFT FRONT WHEEL SPEED.SENSOR CONNECTOR.
NO
REPLACE LEFT FRONT WHEEL

SPEED SENSOR JUMPER HARNESS.
YES
I
HARNESSES FOR DAMAGE WHICH MAY RESULT IN A SHORT TO
GROUND WHEN ALL COMPONENTS ARE CONNECTED. PAY PARTICULAR
ATTENTION TO THE JUMPER HARNESS, SMALL NICKS OR CUTS CAN
CAUSE A MALFUNCTION. REPAIR ANY DAMAGE IF FOUND. JUMPER
HARNESS MUST BE REPLACED IF DAMAGED. REFER TO "DIAGNOSTIC
AIDS" ON FACING PAGE FOR MORE INFORMATION.
I
I
NO
C8001
5E1 ..;59
EBCM/EBTCM
(
e1H
ABS JUMPER HARNESS
872 BLI<-----1ffi1----87-2: :::

C130

HIGH
LOW
04-20-lfi
FT018SE
OTC 33
(Page 1 of 3)
RF WHEEL SPEED SNR CKT OPEN OR SHORT TO GND/BAT
the air gap.
DTC Will Set When:
either of the right front wheel speed circuits are open
or shorted to voltage or ground, a malfunction exists.
Action Taken:
and the amber ABS warning lamps. are turned "ON."
sensor coil.
sensor wiring.
sensor wiring.
Diagnostic Aids:
The frequency of the .malfunction can be

this section.
the wiring harness.
speed sensor jumper harness. Likewise, if replacin.g a
[I]
5E1-69
DTC 33
IMPORTANT:

DIFFICULT TO LOCATE. CARE SHOULD BE TAKEN NOT TO DISTURB
ANY ELECTRICAL CONNECTIONS PRIOR TO AN INDICATED STEP OF
THIS CHART. THIS WILL ENSURE THAT AN INTERMITTENT
CONNECTION WILL NOT BE CORRECTED BEFORE THE SOURCE OF
THE MALFUNCTION IS FOUND.
(Page 1 of 3)
RF WHEEL SPEED SNR CKT
OPEN OR SHORT TO
GND/BAT
IGNITION "OFF. 11
USING A 5% SALT WATER SOLUTION (TWO TEASPOONS OF SALT TO 12 OZ. WATER), THOROUGHLY SPRAY THE RIGHT
FRONT WHEEL SPEED SENSOR JUMPER HARNESS.
DISCONNECT 24-WAY EBTCM HARNESS CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINALS "83" AND "A4" OF THE 24-WAY EBTCM HARNESS
CONNECTOR.
IS RESISTANCE BETWEEN 1020 AND 1137 Q WHEN SENSOR IS 20'C (68'F)? (IF TEMPERATURE OF SENSOR IS SUSPECTED
TO OTHER THAN 2oc (68'F), REFER TO THE TABLE ON PAGE 2 OF 3 OF THE DTC CHART FOR APPLICABLE SENSOR
RESISTANCE VALUES; THE VALUES IN THE TABLE ARE FOR TEMPERATURE OF THE SENSOR, NOT AIR TEMPERATURE.)
YES
NO
! DIAGNOSIS CONTINUED ON
1
I PAGE 2 OF 3 OF THIS OTC l
j~,,.,,.,,.,.,,,,,.,,,.,,,_.,,,_.,,.,.,,,,
CHART.
l
..,,.,,,,.,;.,.,,,,.,.,.,,,,,.,,uni

I
I
YES
"..1 .............................................,,,
NO
i .... J...............................................;
i DIAGNOSIS CONTINUED ON j
IGNITION TO "RUN."
j PAGE 3 OF 3 OF THIS OTC
CHART.
1,,.,.,,,.,.,,,,,,,,.,.,,,_,,,,,,,.,.,.,,,,,.,,,,,,.,.,.,.,,.,,,,,,,1,,u
I
I
NO
I
YES
I
IGNITION "OFF."
DISCONNECT RIGHT FRONT WHEEL SPEED SENSOR DIRECTLY AT
SENSOR.
IGNITION TO "RUN."
I
I
YES
I

BETWEEN GROUND AND TERMINAL "A4"
OF THE 24-WAY EBCM/EBTCM HARNESS
CONNECTOR.
NO
REPAIR SHORT TO
VOLTAGE IN CKT 833.
NO
NO
I
.I
REPLACE
EBCM/EBTCM.
MALFUNCTION IS INTERMITTENT.. INSPECT

ALL CONNECTORS AND HARNESSES FOR
DAMAGE WHICH MAY RESULT IN A SHORT
TO VOLTAGE WHEN ALL COMPONENTS ARE
FOUND. REFER TO "DIAGNOSTIC AIDS" ON
FACING PAGE FOR MORE INFORMATION.
IGNITION "OFF."
INSPECT TERMINALS "83" AND "A4" OF THE
24-WAY EBCM/EBTCM HARNESS
CONNECTOR FOR POOR TERMINAL
CONTACT AND CONTAMINATION. ALSO
INSPECT CKTs 833 AND 872 FOR DAMAGE
WHICH MAY RESULT IN AN OPEN CIRCUIT,
SHORT TO GROUND, OR SHORT TO
VOLTAGE. REPAIR ALL DAMAGE IF EVIDENT.
IGNITl'ON TO "RUN."
DOES OTC 33 SET AS A CURRENT DTC?
YES
YES
G)
MALFUNCTION IS
INTERMITTENT. REFER
TO "DIAGNOSTIC AIDS"
ON FACING PAGE.
REPAIR SHORT TO
VOLTAGE IN CKT 872.
C8002
5E1-70
EBCM/EBTCM
(
ABS JUMPER HARNESS
f1ao
~::~~~~--t~:=====-7-2~:::
C130
AF WHEEL SPl!ED SIGNAL

HIGH
AF WHEEL SPEED SIGNAL
LOW
04-20-91!
FT0185E
DTC 33
(Page 2 of 3)
As a toothed ririg passes by the wheel speed
the air gap.
DTC Will Set When:

Action Taken:

Number(s) below refer to
7. Checks for high resistance
9. Verifies proper resistance
sensor coil.
circled number(s) on
in CKT 833.
in CKT 872.
of the wheel speed
Diagnostic Aids:
The frequency .of the malfunction can be

this section.
the wiring harness.
OTC 33
{Page 2 of 3)
RF WHEEL SPEED SNR
GND/BAT
!
!
DIAGNOSIS CONTINUED
FROM PAGE 1 OF 3 OF
THIS DTC CHART.
!
!
'
-'
"'""J'""'"'""""""""""'""""""'

USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "83" OF THE
24-WAY EBCM/EBTCM HARNESS CONNECTOR AND TERMINAL "B" OF THE RIGHT
FRONT WHEEL SPEED SENSOR HARNESS CONNECTOR.
YES
I
NO
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "A4"

OF THE 24-WAY EBCM/EBTCM HARNESS CONNECTOR AND TERMINAL "A"
OF THE RIGHT FRONT WHEEL SPEED SENSOR HARNESS CONNECTOR.
REPAIR HIGH RESISTANCE IN CKT 833

(WHEEL SPEED SENSOR JUMPER MUST
BE REPLACED IF DAMAGED).
I
I
YES
I
NO
I
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "A''

AND TERMINAL "B" OF THE RIGHT FRONT WHEEL SPEED SENSOR
CONNECTOR.
IS RESISTANCE BETWEEN 1020 AND 1137 0 WHEN SEt,ISOR IS 20'C
(68F)? (IF TEMPERATURE OF SENSOR IS SUSPECTED TO OTHER THAN
2oc (68'FJ, REFER TO THE TABLE BELOW FOR APPLICABLE SENSOFI
RESISTANCE VALUES; THE VALUES IN THE TABLE FOR TEMPERATURE

I
YES
I
NO
MALFUNCTION IS INTERMITIENT. INSPECT ALL CONNECTORS

AND HARNESSES FOR DAMAGE WHICH MAY RESULT IN HIGH
RESISTANCE WHEN ALL COMPONENTS ARE CONNECTED.
REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE FOR MORE
INFORMATION. REPAIR ALL DAMAGE IF FOUND.

(APPROXIMATE)
TEMP.
RESISTANCE
TEMP.
('C)
('F)
(OHMS)
34 TO 4
-30 TO 40
5 TO 43
41 TO 110
804 TO 1055
956 TO 1240
44 TO 93
111 TO 20,0
1112 TO 1463
C8003
5E1-72
EBCM/EBTCM
(
ABS JUMPER HARNESS
872
IBU(-----i[;]B
(!]1--
e:IJm
11----872 DK ORN
- - - - 8 3 3 TAN
C130
AF WHl!!l!!L SPl!!l!!D SIGNAL

HIGH
FIF WHEEL SPEED SIGNAL
LOW
04-20-95
FT0185E
DTC 33
{Page 3 of 3)
the air gap.
DTC Will Set When:

Action Taken:


11. Checks for a short to ground in. CKT 872.
Diagnostic Aids:

this section.
24 km/h (15 mph) for at least. 30 seconds. If DTC
the wiring harness.
5E1-73
DTC 33
'"'""(""'""""""'"'"""""'"'"'""'
(Page 3 of 3)
RF WHEEL SPEED SNR
GND/BAT
DISCONNECT CONNECTOR C130 (LOCATED RH INNER OF FRAME RAIL).

TERMINAL "B3" OF THE 24-WAY EBCM/EBTCM HARNESS CONNECTOR.
I
I
YES

TERMINAL "A4" OF THE 24-WAY EBCM/EBTCM HARNESS CONNECTOR.
NO
REPAIR SHORT TO GROUND IN

CKT 833.
YES
THOROUGHLY RESPRAY THE RIGHT FRONT WHEEL SPEED SENSOR

NO

CKT 872.

SENSOR CONNECTOR.
SENSOR.
USING. J 39200, MEASURE THE RESISTANCE BETWEEN GROUND AND
TERll('IINAL "A," THEN "B" OF THE RIGHT FRONT WHEEL SPEED
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE} FOR BOTH
.
MEASUREMENTS?
I
I
YES
USING J 39200, MEASURE THE RESISTANCE B.ETWEEN GROUND AND

TERMINAL "A" .OF THE RIGHT FRONT WHEEL SPEED SENSOR
CONNECTOR.
B
II
YES
I
NO
REPLACE RIGHT FRONT WHEEL

MALFUNCTION IS INTERMITTENT. INSPECT ALL CONNECTORS

AND HARNESSES FOR DAMAGE WHICH MAY RESULT IN A
SHORT TO GROUND WHEN ALL COMPONENTS ARE
CONNECTED. PAY PARTICULAR ATTENTION TO THE JUMPER
HARNESS, SMALL NICKS OR cuts CAN CAUSE A
MALFUNCTION. REPAIR ANY DAMAGE IF FOUND. JUMPER
HARNESS MUST BE REPLACED IF DAMAGED. REFER TO
"DIAGNOSTIC AIDS" ON FACING PAGE FOR MORE
INFORMATION.
I I
I
NO
C8004
5E1-74
EBCM
r- - ,
r--,
ABS JUMPER HARNESS

B
-+GJ-+
I
I
BU<-+B+
L __ J
C1
884 WHT
884 B U < ~ . 884 BU<
886
886 RED
+EH-.
L __ J
I
C40SB
C40SC
. I
885 Rl!!D
REAR WHEEL SPEED

SIGNAL HIGH
REAR WHEEL.SPEED
SIGNAL LOW
C200A
C200D
05-13-96
FT1086E
OTC 35
(Page 1 of 3)
REAR WHEEL SPEED SNR CKT OPEN OR SHORT OT
GND/BAT
Diagnostic Aids:

the air gap.

the. Tech 1, as described in "Tech 1 Diagnostics" in
this section.
intermittent .complaint should be thoroughly checked
the wiring harness.
DTC Will Set When:

the rear wheel speed circuits are open or shorted to
voltage or ground, a malfunction exists.
Action Taken:

sensor coil.
sensor wiring.
sensor wiring.
4. Checks for a short to voltage in wheel speed
sensor low side wiring.
5. Checks for a short to voltage in wheel speed
sensor high side wiring.
rn
OTC
35
(Page 1 of 3)
REAR WHEEL SPEED SNR
GND/BAT
IMPORTANT:
WHEEL SPEED SENSOR INTERMITTENT MALFUNCTIONS MAY BE DIFFICULT

TO LOCATE. CARE SHOULD BE TAKEN NOT TO DISTURB ANY ELECTRICAL
CONNECTIONS PRIOR TO AN INDICATED STEP OF THIS CHART. THIS WILL
ENSURE THAT AN INTERMITTENT CONNECTION WILL NOT BE CORRECTED
BEFORE THE SOURCE OF THE MALFUNCTION IS FOUND.
5E1-75
IGNITION "OFF."
USING A 5% SALT WATER SOLUTION (TWO TEASPOONS OF SALT TO 12 OZ. WATER), THOROUGHLY SPRAY THE REAR WHEEL
DISCONNECT 24-WAY EBCM HARNESS CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINALS "82" AND "A3" OF THE 24-WAY .EBCM HARNESS
CONNECTOR.
IS RESISTANCE BETWEEN 969 AND 1185 OHMS (METAUPLASTIC), 1030 AND 1180 OHMS (PLASTIC) WHEN SENSOR IS 2oc
(68'F)? (IF TEMPERATURE OF SENSOR IS SUSPECTED TO OTHER THAN 2oc (68F), RliFER TO THE TABLE ON PAGE 2 OF 3 OF
THIS DTC CHART FOR APPLICABLE SENSOR RESISTANCE VALUES; THE VALUES IN THE TABLE ARE FOR TEMPERATURE OF
I
I
YES
NO
f""'"'""'"'""""""""""""""i
i DIAGNOSIS CONTINUED i
i ON PAGE 2 OF 3 OF THIS i
i1,,1;,u;,u,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,;
DTC CHART.
i
MEASURE THE RESISTANCE BETWEEN GROUND AND TERMINAL "82"

YES
NO
j DIAGNOSIS CONTINUED j
i~,,,,,,,,,,,,,.,.,,,,,,,.,,,,,,,,,,,,..,.,,,,,,,,,,,,,,,,,
DTC CHART.
i
/
NO
YES
IGNITION "OFF."
DISCONNECT REAR WHEEL SPEED SENSOR DIRECTLY AT
SENSOR.
IGNITION TO "RUN."
TERMINAL "B2" OF THE 24WAY EBCM HARNESS CONNECTOR.
YES

TERMINAL "A3" OF THE 24-WAY
EBCM HARNESS CONNECTOR.
.
NO
G)
REPAIR SHORT TO
VOLTAGE IN CKT 885.
REPLACE EBCM. ,
I
IGNITION "OFF."
INSPECT TERMINALS "82" AND "A3" OF
THE 24.WAY EBCM HARNESS CONNECTOR
AND 885 FOR DAMAGE WHICH MAY
RESULT IN AN OPEN CIRCUIT, SHORT TO
GROUND, OR SHORT TO VOLTAGE. REPAIR
ALL DAMAGE IF EVIDENT
IGNITION TO "RUN."
YES
YES
,.,,,,J.,,.,,,,,,,,,.,,,.,,,,.,,,,.,,,,,,,.,,,,,
IGNITION TO "RUN."
TERMINAL "B2" OF THE 24-WAY EBCM HARNESS CONNECTOR
MALFUNCTION IS INTERMITTENT. INSPECT

TO VOLTAGE WHEN ALL COMPONENTS
ARE CONNECTED. REPAIR ALL DAMAGE IF
FOUND. REFER TO "DIAGNOSTIC AIDS"
INFORMATION.
NO
NO
I
MALFUNCTION IS
FACING PAGE.
REPAIR SHORT TO
VOLTAGE IN CKT 884.
C9824
5E1-76 ANTILOCK.BRAKE SYSTEM
EBCM
ABS JUMPER HARNErS- _
B
884WHT
. r-
~ 884SU< ~ 884BU<
I
lr:::-,l
885SU<~885RED . : ~ : 885RED
L __ J
C40SB
C40SC
L __ J
REAR WHEEL SPEED

SIGNAL HIGH
.
REAR WHEEL SPEED
SIGNAL LOW
C200A
C200D
015-13-95
FTIO&SE
DTC 35
{Page 2 of 3)
REAR WHEEL SPEED SNR CKT OPEN OR SHORT TO
GND/BAT
sensor changes in the electromagnetic field cause the
wheel' speed sensor to produce ~ sinusoid~! (AC)
voltage signal whose frequency _is propo!tioi:ial to
wheel speed. The magnitude of this signal 1s drrectly
related to wheel speed and the proxinlity of the wheel
the air gap.
DTC Will Set When:

either of the right rear wheel speed circuits are open
Action Taken:
A malfunction OTC is stored, ABS are disabled

7. Checks for high resistance in wheel speed sensor
low side wiring.
8. Checks for high resistance in wheel speed sensor
high side wiring.
sensor coil.
Diagnostic Aids:
poor connection, ru~be.d throu~h wir~ insulation, or a
wire that is broken ms1de the msulat1on.
The frequency of the. malfunction can be

this section.
If the customer's comments. reflect.that the ABS
wheel speed sensor . circuit!): sho_uld be thoro.ughly
inspected for signs of water mtrus1on. If OTC 1s not
current clear DTCs and simulate the effects of water
intrusi~n. Use the following procedure. Spray the
.
Any circuitry that is suspected of causmg the
locks, improperly formed or damaged !erminals, poor
the wiring harness.
.
5E1 -77
DTC 35
(Page 2 of 3)
REAR WHEEL SPEED SNR
GND/BAT
!!
!
DIAGNOSIS .CONTINUED
FROM PAGE 1 OF 3 OF !
THIS DTC CHART.
j
'"""('"'""'"."""'"'.'"'""'"'"'"'

USING J 39200, MEAS.URE THE RESISTANCE BETWEEN TERMINAL "82" OF THE
24WAY EBCM HARNESS CONNECTOR AND TERMINAL "A" OF THE RIGHT REAR
WHEEL SPEED SENSOR HARNESS CONNECTOR.
I
I
YES
NO

OF THE 24-WAY EBCM HARNESS CONNECTOR AND TERMINAL "B" OF
THE REAR WHEEL SPEED SENSOR HARNESS CONNECTOR.
I
I
YES
I

NO
I

"A" AND TERMINAL "B" OF THE REAR WHEEL SPEED SENSOR
CONNECTOR .
IS RESISTANCE BETWEEN 969 AND 1185 OHMS WHEN SENSOR IS
2oc (68F)? (IF TEMPERATURE OF SENSOR IS SUSPECTED TO
OTHER THAN 20'C (68'FJ, REFER TO THE TABLE BELOW FOR
APPLICABLE SENSOR RESISTANCE VALUES; THE VALUES IN THE
TABLE FOR TEMPERATURE OF THE SENSOR, NOT AIR
TEMPERATURE.)

I
I
YES
I
NO

INFORMATION . REPAIR ALL DAMAGE IF FOUND.

(APPROXIMATE)
TEMP.
("C)
TEMP.
("F)
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
C9825
5E178
EBCM
r __ l
r--,
ABS JUMPER HARNESS
884 WHT
4GJ+
I
I
L __ J
REAR WHl:EL S.Pl:ED SENSOR
C405B
C405C
C1
884 I L K ~ 884 ILK
885BU<-t0+ 885RED
~
L __ J
885RED
REAR WHEEL SPEED

SIGNAL HIGH
REAR WHEEL SPEED
SIGNAL LOW
C200A
C200D
05-13-95
FT1085E
OTC 35
(Page 3 of 3)
REAR WHEEL SPEED SNR CKT OPEN OR SHORT TO
GND/BAT
Circuit D~scription:
the air gap.
DTC Will Set When:

the rear wheel speed circuits are open or shorted to
voltage or ground, a malfunction exists.
Action Taken:

10. Checks for a short to ground in wheel speed
sensor low side wiring.
11. Checks for a short to ground m wheel speed
sensor high side wiring.
Diagnostic Aids:

checked by using the enhanced .diagnostic .function of
the Tech 1, as described in "Tech 1. Diagnostics" in
this section.

environmental changes (rain, snow, vehicle wash), all.
~heel speed s.ensor circuitry should. be thoroughly.
mspected for signs of water intrusion. If DTC is not
current, clear DTCs and simulate the effects. of water
intrusion. Use th.e following procedure. Spray the
vehicle over various road. surfaces (bumps, turns, etc.)

for ba?ked out terminals, improper mating, broken
lock~, improp~~ly formed or damaged terminals, poor
termmal to wmng connections or physical damage to
the wiring harness.
increase with an i~crease in sensor temperature.
When repla~mg a wheel speed sensor, inspect
the . sensor termmals and harness connector for
speed sensor jumper harness. Likewise, if replacing a.
5E1 -79
DTC 35
(Page 3 of 3)
REAR WHEEL SPEED SNR CKT
,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,.,,,.,,.,,,,u,,;u,,,,,,,,.,
!DIAGNOSIS CONTINUED
l FROM
PAGE 1 OF 3 OF THIS
OTC CHART.
l
j
""'""('"""'""""'"""'"'""'""'""'""'''
DISCONNECT CONNECTOR C4058, C405C (LOCATED ON THE LH

SIDE REAR UNDER BODY, BEHIND REAR SEAT).
USING J 39200, MEASURE THE RESISTANCE BETWEEN GROUND
AND TERMINAL "82" OF THE 24-WAY EBCM HARNESS CONNECTOR.
I
I
YES
I

TERMINAL "A3" OF THE 24-WAY EBCM HARNESS CONNECTOR.
NO

IN CKT 885.
I
I
YES
I
THOROUGHLY RESPRAY THE REAR WHEEL SPEED SENSOR

NO

IN CKT 884.
IMPORTANT: DO NOT ALLOW WATER TO ENTER ANY WHEEL

SPEED SENSOR CONNECTOR.
DISCONNECT REAR WHEEL SPEED SENSOR DIRECTLY AT
SENSOR.
AND TERMINAL "A," THEN "B" OF THE RIGHT REAR WHEEL
SPEED SENSOR HARNESS CONNECTOR.
MEASUREMENTS?
I
I
YES
I

AND TERMINAL "A" OF THE REAR WHEEL SPEED SENSOR
CONNECTOR.
NO
I
REPLACE REAR WHEEL SPEED

SENSOR JUMPER HARNESS.
YES
I

ATTENTION TO THE JUMPER HARNESS. SMALL NICKS OR CUTS CAN
CAUSE A MALFUNCTION. REPAIR ANY DAMAGE l'F FOUND. JUMPER
I
I
NO

.
C9826
5E1-80

EBCM EBTCM
IGNITION
REFER TO SECTION
8A10
,----
..---------------641
~--11132 PNK'......j111-----1
i.;...--dllr'\_~-- 641 BRN
B+ L
ISAMP
1133 RED
~302RED-,
FUSIBLE
UNKB
SWITCHED IGNITION
BRN
ABSITCS RELAY
ENABLE CONTROL
ABS/TCS SWITCHED
BATTERY INPUT
302 RED
8175
--------.J
5272
CENTER
041HIS
FT01e&E
OTC 36
{Page 1 of 2)
LOW SYSTEM VOLTAGE
This DTC is used to monitor the voltage level
available to the EBCM. If the voltage drops below
10.25 volts, full performance of the ABS system
cannot be guaranteed. During ABS operation, there are
several current requirements that will cause battery
voltage to drop. Because of this, voltage is monitored
prior to ABS to indicate good charging system
condition and also during ABS when voltage may
drop significantly.
DTC Will Set When:

DTC 36 can only be set if the vehicle's speed is
greater than 5 km/h (3 mph). If the switched battery
voltage is less than 10.25 volts non-ABS or less than
8.32 volts ABS, a malfunction exists. Because of
tolerances within the the EBCM sensing software DTC
36 may set as high as 10.95 volts non-ABS or as high
as 8.6 volts ABS.
Action Taken:
2. Isolates the condition to high circuit resistance, or

improper charging system operation.
Diagnostic Aids:
this section.
.
the wiring harness.
While performing a voltage load test, if it is
noted that only ignition voltage drops below
acceptable voltage levels, CKT 641 should be checked
for high resistance or an open condition.

1. Checks to see what voltage is readily available at
terminal "C" of the EBCM. If voltage is
representative of good charging system condition,
a malfunction is not present.
5E1-81
OTC 36
(Page 1 of 2)
LOW SYSTEM VOLTAGE
START ENGINE.
USING TECH 1, SELECT "F3: SNAPSHOT."
SELECT "F4: SINGLE OTC"; THEN ENTER "36".
DRIVE VEHICLE ABOVE 5 km/h (3 mph).
DID TECH 1 TRIGGER?
NOTICE: J 39200 TEST LE.ADS MUST BE "ZEROED" PRIOR TO MAKING

YES
NO
I
WITH ENGINE RUNNING, USE TECH 1 AND SELECT "F4: MISC. TESTS."
PERFORM "VOLTAGE LOAD" TEST.
ARE IGNITION AND BATTERY VOLTAGES GREATER THAN 10 VOLTS?
NO
_J
-...-
REFER TO SECTION 603 TO DIAGNOSE CHARGING SYSTEM.

IS CHARGING SYSTEM OK?
YES

YES
I
NO
,,,..
l ..,,,....,,,,,,,,,,,.,,,,,,.,,,.,,,....i
! REFER TO SECTION 603 !

! TO CORRECT LOW
!
!t,,,.,.,,,.,,.,.,.,,,,,,,,,,.,.,.,.,,.,.,,,.,,,,,,,,,,,,.,,,,,,,,I
VOLTAGE CONDITION.
!
IGNITION "OFF."
DISCONNECT 8WAY AND 24WAY EBCM CONNECTORS.
USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "C4" OF
THE ABS RELAY HARNESS CONNECTOR AND TERMINAL "C" OF THE
8WAY EBCM HARNESS CONNECTOR.
YES
NO

IN CKT 1633.

USING J 39200, MEASURE RESISTANCE BETWEEN THE POSITIVE
BATTERY CABLE TERMINAL AND TERMINAL "C1" OF THE ABS RELAY
HARNESS CONNECTOR.
I
I
YES
NO
, REPAIR HIGH RESISTANCE

IN CKT 302.
~
,,,.,,.,,,, ,,,,,,,,,,,,,,,,.,,u.,,,,,,,,,,,,,,,,,,,,,,,,,,,.,
'
_J
"""'
DIAGNOSIS CONTINUED
, ON PAGE 2 OF 2 OF
!
!,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,,..,1
THIS OTC CHART.
!
C9827
5E1-82

EBCM EBTCM
IGNmON
REFER TO SECTION
8A10
...
C1
- - -
SWITCHED IGNITION
ABSITCS RELAY
ENABLE CONTROL
.,;,.-,--fll"'\._~--841 BRN
B+ L
5AMP
~302RED"'I
FUSIBLE
LINKB
ABSITCS SWITCHED
BATTERY INPUT
302 RED
8175
--------..1
CENTER
041995
FT0165E
DTC 36
(Page 2 of 2)
LOW SYSTEM VOLTAGE

available to the EBCM. If the voltage drops .below
10.25 volts, full performance of the ABS system
cannot be guaranteed. During ABS operation, there are
several current requirements that will cause battery
voltage to drop. Because of this, voltage is monitored
prior to ABS to indicate good charging system
condition and also during ABS when voltage may
drop significantly.

the diagnostic .chart.
6. Checks for high resistance in the ignition fused
feed circuit.
7. Checks for malfunctioning EBCM.
DTC Will Set When:

voltage is less than 10.25 volts non-ABS or less than
8.32 volts ABS, a malfunction exists. Because of
tolerances within the the EBCM sensing software DTC
36 may set as high as 10.95 volts non-ABS or as high
as 8.6 volts ABS.
Action Taken:
Diagnostic Aids:
this section.
the wiring harness.
5E1-83
DTC 36.
(Page 2 of 2)
LOW SYSTEM VOLTAGE
NOTICE: J 39200 TEST LEADS MUST BE "ZEROED" PRIOR TO MAKING

u,u,,.,,u,,,,,,.,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,.,,.,;;u,,,,,,,,,,,,,,,,,,.,,,,.,.,.,;;,,,,,,,,,,,,,,,,;,,,.,.,,,,,,,,,,,u,,,u,;1
!',,.,,,,..,DIAGNOSIS
CONTINUED FROM PAGE 1 OF 2 OF THIS OTC CHART. !
,,,.,,,.,,,,,,,.,,,,,,u,,,,,,,,,,,u,11,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,.,,,,,,u,,,,.,,,,,,,,,,,,,,,,u,111,,,,,,,,,,1,,,,,,,u,,1,,u1,11a~
REMOVE ABS IGN 5 AMP FUSE 1.
USING J 39200, MEASURE RESISTANCE BETWEEN EACH ABS IGN FUSE BLOCK
TERMINAL AND TERMINAL "A9" OF THE 24WAY EBCM HARNESS CONNECTOR.
IS EITHER MEASUREMENT 2 OHMS OR LESS?
NO
WITH BATTERY CABLES DISCONNECTED, TURN IGNITION TO "RUN."

(THIS PROVIDES IGNITION CIRCUIT CONTINUITY).
.
USING J 39200, MEASURE RESISTANCE BETWEEN POSITIVE BATTERY
CABLE TERMINAL AND EACH ABS IGN 5 AMP FUSE 1 BLOCK
TERMINAL.
IS EITHER MEASUREMENT 2 OHMS OR LESS?
REPAIR HIGH RESISTANCE IN CKT 641.
I"''
IGNITION "OFF."
INSPECT ABS RELAY AND ABS RELAY HARNESS CONNECTOR FOR
POOR TERMINAL CONTACT. INSPECT BWAY AND 24WAY EBCM
HARNESS CONNECTORS FOR A POOR CONNECTION TO THE
EBCM. INSPECT POSITIVE BATTERY CABLE TERMINAL FOR POOR
CONTACT TO THE BATTERY. REFER TO SECTION BA4, "CHECKING
TERMINAL CONTACT." REPLACE TERMINALS IF POOR CONTACT IS
EVIDENT.
DRIVE VEHICLE ABOVE 5 kmih (3 mph).
REPLACE EBCM.
,,,,,,,,,,,,,,,,,,,,,,,,,,.,.,,,,.,.,,,,,,,u,,,,,,,,,,,,,,,,,,,,..,,,,,.,,,,, 1
! REFER TO SECTION. BA TO REPAIR !
! HIGH RESISTANCE IN THE "IGNITION !

!t,,,,,,,,,,.,,.,,,,,,,,.,,,,,,,,,,,,,,,,,,.,,,.,,,,.,.,,,.,,,,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,;
SWITCH 'RUN' FUSE FEED" CIRCUIT. !
MALFUNCTION IS MOST LIKELY DUE

TO A POOR CONNECTION. REFER
TO "DIAGNOSTIC AIDS" ON FACING
PAGE.
C9828
5E1-84

EBCM EBTCM
IGNITION
REFER TO SECTION
8A10
SWITCHED IGNITION
r---
AEISITCS RELAY
ENABLE CONTROL
i.:....--r'\._.1111--- 641 BRN

SAMP
B+ L
~302REDil
FUSIBLE
LINK 8
ABSITCS SWITCHED
BATTERY INPUT
302 RED
6175
---
---
---
CENTER
.J
04-19-85
FT016SE
DTC 37
HIGH SYSTEM VOLTAGE
This DTC is designed to detect high vehicle
voltage levels prior to any required motor movement
(initializa~ion. or ABS). If excessive voltage exists,
de~agnet1zat10n of the motor magnets may occur,
which would eventually affect or eliminate ABS
performance.
DTC Will Set When:

greater ~han 5 km/h (3 mph). If the switched battery
voltage 1s greater than 17 volts, a malfunction exists.
Action Taken:
,DTC Chart Test Description:

1. Checks the voltage level being received by the

EBCM.
2. Checks to see if high voltage condition is due to

charging system malfunction. .
3. Checks for poor terminal contact which may
cause an intermittent malfunction or a
malfunctioning EBCM.
'
Diagnostic Aids:
An inte.rmittent malfunction may be caused by a

wire that is broken inside the insulation: .
this section.
for ba~ked out terminals, improper mating, broken
lock~, 1mprop~~ly formed ?r damaged t~rminals, poor
termn~a.l to wmng connections or physical damage to
the wmng harness.
5E1-85
OTC 37
HIGH SYSTEM VOLTAGE
TURN ALL ACCESSORIES "OFF."

START ENGINE.
USING TECH 1, SELECT "FO: DATA
LIST" AND MONITOR BATIERY
VOLTAGE WHILE RUNNING ENGINE
AT APPROXIMATELY 2000 RPM.
IS VOLTAGE LESS THAN 16 VOLTS?
IGNITION "OFF."
START ENGINE.
USING J 39200, MEASURE VOLTAGE
BETWEEN GROUND AND ABS RELAY
HARNESS CONNECTOR TERMINAL "C1"
WHILE RUNNING ENGINE AT APPROXIMATELY
2000 RPM.
MALFUNCTION NOT PRESENT THIS

TIME. REFER TO "DIAGNOSTIC AIDS"
ON FACING PAGE.
''"'""" ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,,,,.,,,,u,;;;;;,.,,,,;,;;;;1;;,,,,,,,.,
1 REFER TO SECTION 603 TO CHECK 1

j
CHARGING SYSTEM OPERATION.
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,..,,,,.,,,,,.,,,,,,,,,u,,,,.
IGNITION "OFF."
RECONNECT ABS RELAY.
DRIVE VEHICLE ABOVE 5 km/h (3 mph).
REPLACE EBCM.
MALFUNCTION IS INTERMITIENT.
FACING PAGE.
C9829
...
- ... ... - - -
EBCM/EBTCM
"'I
Hi0
P100
1280BLK
LF Al!IS MOTOR CONTROL HIGH
1281 PNK
LF ABS MOTOR CONTROL LOW
MOTOR
t.BJ
ABS MOTOR PACK

6 WAY CONNECTOR C1
--
... -
.J
HYDRAULIC
MODULATOR ASSEMBLY
04-20-95
FT0215E
OTC 38
LEFT FRONT ESB WILL NOT HOLD MOTOR
This DTC is designed to detect a slipping left
front ESB. During initialization and braking, the left
front motor is re-homed. If the ESB slips, the
motor/piston will move. During the next key to
"RUN" initialization, a re~home of the motor verifies
the motor/piston remained at the home position. If
motor movement is detected, the ESB must be
slipping.
2. Checks for high resistance in the

"HIGH" circuitry.
3. This step checks for high resistance
motor "LOW" circuitry.
4. Checks for proper resistance of the
windings.
5. Checks for poor terminal contact or
the connectors.
6. Checks for a malfunctioning EBCM.
ABS motor
in the ABS
ABS motor
DTC Will Set When:
Diagnostic Aids:
DTC 38 can be set during initialization. If the

EBCM detects that the ESB could not hold the piston
in the home position, a malfunction exists. DTC 86 is
always set with DTC 38.
An intermittent malfunction in this DTC may

result from a mechanical part of the system that sticks,
binds, or slips.
this section.
The hydraulic control modulator test function of
the Tech 1 may be used to locate an intermittent
malfunction associated with the ESB.
Action Taken:
If an ESB cannot hold a piston in the home
position, the piston may be back driven when the
brake pedal is applied, causing the brake pedal to
drop. A malfunction DTC is stored, ABS is disabled.
The amber ABS and the red "BRAKE" warning
lamps are turned "ON."
corrosion in

1. Checks the left front ESB. A broken or defective
ESB would result in the left front piston being
back driven by hydraulic pressure and pedal
movement would result.
5E1-87
OTC 38

PUMP BRAKE PEDAL UNTIL FIRM TO DEPLETE VACUUM RESERVE.
USING TECH 1 MISC. TESTS, SELECT MANUAL CONTROL FUNCTION.
SELECT ABS MOTOR APPLY FUNCTION OF THE LEFT FRONT
CHANNEL AND APPLY THE MOTOR.
WAIT 5 SECONDS.
APPLY FIRM PRESSURE ON BRAKE PEDAL.
DID BRAKE PEDAL FALL?
..
NO
I
LEFT FRONT ESB WI LL

NOT HOLD MOTOR
TO J 39200 USER'S MANUAL
YES
EXIT TECH 1 MANUAL CONTROL FUNCTION.

IGNITION "OFF."
DISCONNECT 6WAY ABS MOTOR PACK CONNECTOR AND GRAY 8WAY
EBCM/EBTCM CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "A" OF
THE 6WAY ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL
"G" OF THE GRAY 8-WAY EBCM/EBTCM HARNESS CONNECTOR.
IS RESISTANCE 1.5 0 OR LESS?
REPLACE ABS
MOTOR PACK.
YES
NO
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL ''B" OF

THE 6WAY ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL "H"
OF THE GRAY 8-WAY EBCM/EBTCM HARNESS CONNECTOR.
REPAIR HIGH
I
I
YES
NO
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "A"

AND TERMINAL "B" OF THE MOTOR PACK CONNECTOR.
IS RESISTANCE BETWEEN 0.2 O AND 1.5 O?
REPAIR HIGH
YES
I
NO
I
INSPECT THE 6-WAY ABS MOTOR PACK CONNECTOR AND GRAY 8WAY
EBCM/EBTCM CONNECTOR FOR POOR TERMINAL CONTACT OR CORROSION.
REFER TO SECTION 8A4, "CHECKING TERMINAL CONTACT."
DO ANY TERMINALS EXHIBIT POOR CONTACT OR EVIDENCE OF CORROSION?
NO
I
YES
I
REPLACE ABS
MOTOR PACK.
YES
IGNITION "OFF."
START ENGINE AND TEST DRIVE VEHICLE, ACHIEVING AT LEAST
16 km/h (10 MPH).
REPEAT ABOVE DRIVE CYCLE SEQUENCE TWO MORE TIMES.
DID OTC 38 SET IN THE LAST THREE DRIVE CYCLES?

EVIDENCE OF CORROSION.
NO
I
REPLACE EBCM/EBTCM.
MALFUNCTION IS
FACING PAGE.
AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3)
DRIVE CYCLES TO VERIFY THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF
STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN TURNING KEY "OFF."
C8014
5E1-88
EBCM/EBTCM
,,--------.
" E " " - - 1 - - - - - - - - - 1282 PPL - - - - - - I I H - - - 1 A
I
I
:..~:/(:)
/;, .,--1--------I.F
1283 BU<
ABS MOTOR PACK

6WAYCONNECTOR C1
.....
RF ABS MOTOR CONTROL HIGH
RF ABS MOTOR CONTROL LOW
C2
HYDRAULIC
MODULATOR ASSl!MBLY
0420115
FT0225E
OTC 41
RIGHT FRONT ESB WILL NOT HOLD MOTOR
This DTC is designed to detect a slipping right
front ESB. During initialization and braking, the right
motor/piston will move. During the next key to
"RUN" initialization, a re-home of the motor verifies
slipping.
DTC
wm
Set When:

Action Taken:

1. Checks the right front ESB. A broken or defective
ESB would result in the right front piston being
back driven by hydraulic pressure, and pedal

"HIGH" circuitry.
3. This step checks for high resistance
windings.

the connectors.
ABS motor
in the ABS
ABS motor
corrosion in
Diagnostic Aids:
binds, or slips.
this section.
the Tech 1 may be used tO locate an intermittent
malfunction associated with the.ESB.
5E1-89
OTC 41

SELECT ABS MOTOR APPLY FUNCTION OF THE RIGHT FRONT
WAIT 5 SECONDS.
..
NO
RIGHT FRONT ESB Will

NOT HOLD MOTOR
TO J 39200 USER'S MANUAL .
YES

IGNITION "OFF."
DISCONNECT 6-WAY ABS MOTOR PACK CONNECTOR AND GRAY 8-WAY
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "E" OF
THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL "A"
IS RESISTANCE 1.5 n OR LESS?
REPLACE ABS
MOTOR PACK.
YES
NO
I
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "F" OF

THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL "B"
REPAIR HIGH
YES
NO
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "E"

AND TERMINAL "F" OF THE ABS MOTOR PACK CONNECTOR.
IS RESISTANCE BETWEEN 0.2 n AND 1.5 n?
REPAIR HIGH
..
'
YES
NO
INSPECT THE 6-WAY MOTOR PACK CONNECTOR AND GRAY 8-WAY EBCM/EBTCM
CONNECTOR FOR POOR TERMINAL CONTACT OR CORROSION. REFER TO
SECTION 8A4, "CHECKING TERMINAL CONTACT."
NO
I
YES
REPLACE ABS
MOTOR PACK.
YES
IGNITION "OFF."
16 km/h (10 MPH).

NO
I
REPLACE EBCM/EBTCM.
I
I..
FACING PAGE.
STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH) AND THEN TURNING KEY "OFF."
C8015
5E1-90

EBCM/EBTCM
r- -
- -- -
.,
" c " - - - - i - - - - - - - - 1 2 8 4 DKGRN----111
REARABS
MOTOR
REAR ABS MOTOR

CONTROL HIGH
,,D.,---,i---------1281 ORN
REAR ABS MOTOR

CONTROL LOW
ABS MOTOR PACK
I 6 WAY CONNECTOR
C1
L-----
HYDRAULIC
MODULATOR ASSEMBLY
06-01-95
FT0235E
OTC 42
REAR ESB WILL NOT HOLD MOTOR
This DTC is designed to detect a slipping rear
axle ESB. During initialization and braking, the rear
motor is re-homed. If the ESB slips, the motor/piston
will move. During the next key to "RUN"
initialization, a re-home of the motor verifies the
motor/piston remained at the home position. If motor
movement is detected, the ESB must be slipping.
DTC Will Set When:

Action Taken:
If an ESB can hold a piston in the home
brake pedal is .applied, causing the brake pedal to
2. Checks for high resistance m the

"HIGH" circuitry.
"LOW" circuitry.
windings.
the connectors.
ABS motor
ABS motor
ABS motor
corrosion in
Diagnostic Aids:
binds, or slips.
this section.

1. Checks the rear axle ESB. A broken or defective
ESB would result in the rear axle pistons being
back driven by hydraulic pressure and wheel
5E1-91
OTC 42
RAISE THE VEHICLE SUCH THAT THE REAR WHEELS ARE

APPROXIMATELY SIX INCHES OFF THE FLOOR.
APPLY FIRM PRESSURE ON BRAKE PEDAL AND RELEASE.
REAPPLY VERY FIRM PRESSURE ON BRAKE PEDAL AND HAVE AN
ASSISTANT TRY TO SPIN THE REAR WHEELS BY HAND.
COULD ASSISTANT SPIN THE REAR WHEELS?
REAR ESB WILL NOT

HOLD MOTOR
NO
YES
IGNITION "OFF."
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "C" OF
THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL "F"
IS RESISTANCE 1.5 Q OR LESS?
REPLACE ABS
MOTOR PACK.
I
YES
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "D" OF

THE 6WAY ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL "E"
OF THE GRAY BWAY EBCM/EBTCM HARNESS CONNECTOR.
REPAIR HIGH
. I
NO
YES
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "C"

AND TERMINAL "D" OF THE ABS MOTOR PACK CONNECTOR.
IS RESISTANCE BETWEEN 0.2 Q AND 1.5 Q?
REPAIR HIGH
I
YES
NO
NO
INSPECT THE 6-WAY ABS MOTOR. PACK CONNECTOR AND GRAY 8-WAY
REPLACE ABS
MOTOR PACK.
I
NO
YES
IGNITION "OFF."
16 .km/h (10 MPH).
YES
I

REPLACE EBCM/EBTCM.
NO

FACING PAGE.
DRIVE CYCLES TO VERIFY OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING
THE VEHICLE, DRIVING OVER 16 km/h (10 MPH) AND THEN TURNING KEY "OFF."
C8016
5E1 92
r"'
------
Hi0
EBCM/EBTCM
.,
P100
1280 BLK
LF AIS MOTOR CONTROL HIGH
LF ABB MOTOR CONTROL LOW
MOTOR
1281 PNK
._BJ
C2
ABS MOTOR PACK

6 WAY CONNECTOR C1
...
- ... - - -
.J
HYDRAULIC
MODULATOR ASSEMBLY
042095
FT021&E
DTC 44
LEFT FRONT ABS CHANNEL WILL NOT MOVE
This DTC is designed to detect bound-up ESB, a
stuck ABS motor, or a seized ABS hydraulic
modulator. When the release. is commanded during
initialization, the ESB should release the ABS motor,
resulting in sensed current being less than commanded
current (motor is spinning freely). If the ABS motor is
not moving, sensed current will be equal to stall
current.
OTC Will Set When:

DTC 44 can be set during normal operation. If
the EBCM detects a condition in which it cannot
move the motor in either direction, a malfunction
exists.
Action Taken:
This malfunction indicates the channel cannot be
moved properly. A malfunction DTC is stored, ABS is
disabled. The amber ABS warning lamp are turned
"ON."

1. Checks for proper ABS motor movement during
apply and release commands from the Tech 1.
2. Compares EBCM command current to motor
feedback current.
3. Checks for a shorted circuit between the ABS

motor "HIGH" and ABS motor "LOW" circuits.
4. Checks for an ABS .motor that is internally
shorted;
5. Determines if the malfunction is caused by a
defective EBCM or poor terminal contact.
6. Verifies that the ABS motor can actually apply
when commanded.
7. Checks for proper hydraulic modulator gear and
piston movement.
Diagnostic Aids:
binds, or slips.
this section. DTC 44 may set after modulator
disassembly if the modulator pistons are positioned at
the bottom of their bore.
the wiring harness.

5E1-93
DTC 44
LEFT FRONT ABS
CHANNEL Will NOT MOVE
1,GNITION TO "RUN," ENGINE "OFF."

SELECT LEFT FRONT ABS MOTOR APPLY FUNCTION AND APPLY THE MOTOR.
SELECT LEFT FRONT ABS MOTOR RELEASE FUNCTION AND RELEASE MOTOR.
MAINTAIN FIRM PRESSURE ON BRAKE PEDAL.

SELECT LEFT FRONT MOTOR APPLY FUNCTION AND APPLY THE MOTOR.
DID BRAKE PEDAL RISE?
ON FACING PAGE.
REMOVE FOOT FROM BRAKE PEDAL.

SELECT LEFT FRONT ABS MOTOR APPLY FUNCTION AND APPLY THE MOTOR
WHILE CAREFULLY OBSERVING THE COMMANDED CURRENT AND THE
FEEDBACK CURRENT ON THE TECH 1.
WAS THE FEEDBACK CURRENT HIGHER THAN THE COMMANDED CURRENT?
EXIT TECH 1 MANUAL CONTROL.

IGNITION "OFF."
DISCONNECT THE GRAY 8-WAY EBCM/EBTCM CONNECTOR AND THE 6-WAY
ABS MOTOR PACK CONNECTOR.
.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "G" AND
TERMINAL "H" OF THE GRAY 8WAY EBCM/EBTCM HARNESS CONNECTOR.

TERMINAL "A" AND TERMINAL "B" OF THE ABS MOTOR
PACK CONNECTOR.
IGNITION "OFF."
START ENGINE AND TEST DRIVE VEHICLE, ACHIEVING AT
LEAST 16 kni/h (10 MPH).
REPEAT ABOVE DRIVE CYCLE SEQUENCE TWO MORE
TIMES.
. .
.
t::;'\
\.:..)
REPAIR SHORT
BETWEEN CKT 1280
AND CKT 1281.
USING TECH 1 MISC. TESTS, PERFORM

GEAR TENSION RELIEF FUNCTION.
IGNITION "OFF."
REMOVE HYDRAULIC
MODULATOR/MASTER CYI.INDER
ASSEMBLY FROM .VEHICLE. REFER TO
"ON VEHICLE SERVICE" IN THIS
SECTION.
SEPARATE ABS MOTOR PACK FROM
HYDRAULIC MODULATOR.
GRASP THE GEAR ON THE HYDRAULIC
MODULATOR (THE HYDRAULIC
MODULATOR IS THE UNIT WITH THE
THREE LARGE GEARS) FURTHEST
FORWARD WHEN THE UNIT IS
INSTALLED IN THE VEHICLE AND
ATIEMPT TO MOVE THE GEAR.
CAN THE GEAR BE ROTATED AT
LEAST 10 FULL TURNS LOCK TO
LOCK?
REPLACE
ABS MOTOR
PACK.
REPLACE
HYDRAULIC
MODULATOR.
MALFUNCTION IS INTERMITIENT. INSPECT ALL CONNECTORS FOR CONTAMINATION

AND POOR CONTACT. REPLACE ANY TERMINALS THAT EXHIBIT POOR TERMINAL
CONTACT OR EVIDENCE OF CORROSION.
AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT
OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND
THEN IGNITION "OFF."
C8017
5E1-94 ANTILOCK .BRAKE SYSTEM
EBCM/EBTCM
.---v----.,
"E"ll:...---11---------1282 PPL - - - - - 1 1 1
I
I
L
~:/0
~
._FJ - - - - - l l - - - - - - - - - 1283 BU<
.....
RF ABS MOTOR CONTROL LOY/
C2
ABS MOTOR PACK

6WAYCONNECTOR C1
HYDRAULIC
MODULATOR ASSEMBLY
042095
FT022SE
DTC 45
RIGHT FRONT ABS CHANNEL WILL NOT MOVE
modulator. When the release is commanded during
current.
DTC Will Set When:

move the ABS motor in either direction, a malfunction
exists.
Action taken:
moved properly. A malfunction DTC is stored, ABS is
disabled. The amber ABS warning lamp is turned
"ON."

Numb<;r(s) below refer to.circled number(s) on
1. Checks for proper motor movement during apply
and release commands from the Tech 1.

feedback current.
3. Checks for shorted circuit between the ABS motor
"HIGH" and ABS motor "LOW" circuits.
4. Checks for an ABS motor that is internally
shorted.
5. Checks to see if malfunction is due to poor
terminal contact or the EBCM.
6. Verifies that the motor can actually apply when
commanded.

piston movement.
Diagnostic Aids:
binds, or slips.
the wiring harness.
DTC 45

5E1-95
RIGHT FRONT
ABS CHANNEL
Will NOT MOVE

USING TECH 1 MISC. TESTS, SELECT MANUAL CONTROL FUNCnON.
SELECT RIGHT FRONT ABS MOTOR APPLY FUNCTION AND APPLY THE MOTOR.
SELECT RIGHT FRONT ABS MOTOR RELEASE FUNCTION AND RELEASE MOTOR.
MAINTAION FIRM PRESSURE ON BRAKE PEDAL.


SELECT RIGHT FRONT ABS MOTOR APPLY FUNCTION AND APPLY THE
MOTOR WHILE CAREFULLY OBSERVING THE COMMANDED CURRENT AND
.
THE FEEDBACK CURRENT ON THE TECH 1.

IGNITION "OFF."
DISCONNECT THE GRAV 8-WAV EBCM/EBTCM CONNECTOR AND THE 6WAY
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "A" AND
TERMINAL "B" OF THE GRAY 8-WAY EBCM/EBTCM HARNESS CONNECTOR.

TERMINAL "E" AND TERMINAL "F" OF THE ABS MOTOR
PACK CONNECTOR.
IS RESISTANCE BETWEEN 0.2 Q AND 1.5 O?
ON FACING PAGE.
REPAIR SHORT
BETWEEN CKT 1282
AND CKT 1283.

IGNITION "OFF."
REMOVE HYDRAULIC
MODULATOR/MASTER CYLINDER
ASSEMBLY FROM VEHICLE. REFER TO
SECTION.
REARWARD WHEN THE UNIT IS
ATTEMPT TO MOVE THE GEAR.
LOCK?
IGNITION "OFF."
LEAST 16 km/h (10 MPH).
TIMES.
DOES OTC 45 SET IN THE LAST THREE DRIVE CYCLES?
MALFUNCTION IS INTERMITTENT. INSPECT ALL CONNECTORS FOR CONTAMINATION

AND POOR TERMINAL CONTACT. REPLACE ANY TERMINALS THAT EXHIBIT POOR
TERMINAL CONTACT OR EVIDENCE OF CORROSION.
DTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND
C8018
5E1-96

EBCM/EBTCM
I"'
----
--- -
..
P100
re..
REAR ABS
MOTOR
0
,A,
I
L
(
1284DKGRN
REAR ABS MOTOR

CONTROL HIGH
12860RN
REAR ABS MOTOR

CONTROL LOW
ABS MOTOR PACK

8WAYCONNECTOR C1
- --- - - -
C2
.J
HYDRAULIC
MODULATOR ASSEMBLY
06-01-95
FT023!E
OTC 46
REAR ABS CHANNEL WILL NOT MOVE
stuck ABS motor, or a seized hydraulic modulator.
When the release is commanded during initialization,
the ESB should release the ABS motor, resulting in
sensed current being less than commanded current
(motor is spinning freely). If the ABS motor is not
moving, sensed current will be equal to stall current.
DTC Will Set When:

exists.
Action Taken:
moved properly. A malfunction DTC is stored, ABS .is
"ON."

feedback current.

shorted.
terminal contact or the EBCM.
commanded.
piston movement.
Diagnostic Aids:
result from a mechanical part of the system that sticks
or binds.
The frequency of the malfunction .can be
the bottom of their bore. Depending on the frequency
of the malfunction, a physical inspection of the
mechanical parts suspected may be necessary.
locks, improperly. formed or damaged terminals, poor
the wiring harness.
5E1-97
DTC 46
REAR ABS CHANNEL
Will NOT MOVE
RAISE AND SUPPORT THE VEHICLE SUCH THAT THE REAR WHEELS ARE
SELECT REAR AXLE ABS MOTOR APPLY FUNCTION AND APPLY THE MOTOR.
HAVE AN ASSISTANT TRY TO SPIN THE REAR WHEELS BY HAND.

SELECT REAR AXLE ABS MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR.
ON FACING PAGE.

SELECT REAR AXLE ABS MOTOR APPLY FUNCTION AND APPLY THE MOTOR
FEEDBACK CURRENT ON THE TECH 1,

IGNITION "OFF."
DISCONNECT THE GRAY 8WAY EBCM/EBTCM CONNECTOR AND THE
6WAY ABS MOTOR PACK CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL ~'E" AND
TERMINAL "F" OF THE GRAY 8WAY EBCM/EBTCM HARNESS CONNECTOR.

TERMINAL "C" AND TERMINAL "D" OF THE ABS MOTOR
PACK CONNECTOR.
USING TECH 1 MISC. TESTS,

PERFORM GEAR TENSION RELIEF
FUNCTION.
IGNITION "OFF."
REMOVE HYDRAULIC
ASSEMBLY FROM VEHICLE.
REFER TO "ON VEHICLE
SERVICE" IN THIS SECTION.
SEPARATE ABS MOTOR PACK
FROM HYDRAULIC MODULATOR.
GRASP THE MIDDLE GEAR ON
THE HYDRAULIC MODULATO.R
(THE HYDRAULIC MODULATOR IS
THE UNIT WITH THE THREE
LARGE GEARS) AND ATTEMPT TO
MOVE THE GEAR.
LOCK?

IGNITION "OFF."
TIMES.
DID DTC 46 SET IN THE LAST THREE DRIVE CYCLES?

AFTER DIAGNOSIS IS COMP'LETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT
C8019
THEN IGNITION TO "OFF."
5E1-98
I"'
--
- - - - .,
~-i0
EBCM/EBTCM
1280BLI<
LF ABS MOTOR CONTROL HIGH
1281 PNK
MOTOR
ABS MOTOR PACK

6 WAY CONNECTOR C1
'-a"
- - - - -
g
.J
HYDRAULIC
MODULATOR ASSEMBLY
04-20-96
FT0211E
OTC 47
(Page 1 of 2)
LEFT FRONT ABS MOTOR FREE SPINS
This DTC is designed to detect a stripped nut or
gear assembly during initialization. During the homing
sequence, the piston should reach the top of the bore
resulting in a stalled ABS motor. If this does riot
occur, the ABS motor must be spinning with little or
no resistance, indicating a nut/screw or gear
malfunction.
DTC Will Set. When:

DTC 47 can only be set during initialization. If .
the feedback current is less than the command current
for a specified period of time, a malfunction exists.
Action Taken:
A malfunction DTC is stored, ABS is disabled.
The amber ABS warning lamp is turned "ON."

1. Checks to see if the corresponding open motor
DTC is also set.
2. Verifies that the ABS motor was actually applied
as command by observing feedback current.
3. Verifies that the ABS motor can release.

4. Verifies that the ABS motor can be applied by
observing pedal movement.
5. Checks. for high resistance m. the ABS motor
"HIGH" circuitry.
6. Checks for high resistance m the ABS motor
"LOW" circuitry.
shorted.
Diagnostic Aid~:
binds, or slips.
this section. If the DTC only occurs once and DTC 56
also occurs, refer to DTC 56. If intermittent and
enhanced diagnostics shows this DTC occurs dwing
ABS, refer to DTC 56.
Depending on the frequency of the malfunction,
a physical inspection of the mechanical parts suspected
may be necessary.
5E1 99
DTC 47
NOTICE: J 39200 TEST LEADS MUST BE "ZEROED" PRIOR TO MAKING ANY
RESISTANCE MEASUREMENTS. REFER TO J 39200 USER'S MANUAL.
'0
IS OTC 56
ALSO CURRENTLY
SET?
~......,,._
_
_____.
(Page 1 of 2)
LEFT FRONT ABS
MOTOR FREE SPINS
~,.,,,., ,,,,,,,,,,,,,,.,,.,,.,,,,,,,,,,.,,,,,,,,,,,,,,,,.,

SELECT LEFT FRONT ABS MOTOR APPLY FUNCTION AND APPLY
THE MOTOR WHILE CAREFULLY OBSERVING THE COMMAND
CURRENT AND FEEDBACK CURRENT ON THE TECH 1.
WERE BOTH COMMAND AND FEEDBACK CURRENT APPROXIMATELY
10 AMPS?
')
j PROCEED TO OTC 56 !
j CHART FIRST.
!
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,,.,,.,,.)
APPLY FIRM PRESSURE ON BRAKE PEDAL,

SELECT LEFT FRONT ABS MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR.
DID THE BRAKE PEDAL FALL AND WERE BOTH COMMAND AND FEEDBACK
CURRENT APPROXIMATELY 6 AMPS?

SELECT LEFT ABS MOTOR APPLY FUNCTION AND APPLY THE MOTOR
(THIS MOVES THE PISTON TO THE TOP OF ITS BORE)
. DID BRAKE PEDAL RISE?
USING TECH 1 MISC. TESTS, PERFORM GEAR TENSION RELIEF FUNCTION .

IGNITION "OFF."
DISCONNECT 6-WAY ABS MOTOR PACK CONNECTOR AND GRAY 8WAY EBCM/EBTCM
CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "A" OF THE 6-WAY
ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL "G" OF THE GRAY 8-WAY
IS RESISTANCE 1.5 !i OR'LESS?
MALFUNCTION IS
INTERMITTENT. REFER
ON FACING PAGE.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "Iii" OF

THE &WAY ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL "H"
IS RESISTANCE 1.5 n OR LESS? .
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "A'' AND

TERMINAL "B" OF THE ABS MOTOR PACK CONNECTOR.
If,,,,,.,,,,.,,.,,,.,,,,u,,11.;11,,,,,,,1111111,,,,,,,,.,,,,,,.,,,,,.,,,u1u1,,1,111u111111u11,,.,,,,J
DIAGNOSIS CONTINUED ON NEXT PAGE. !
C8020
5E1-100
---
...
I
I
EBCM/EBTCM .
.,
P100
~-t0
1280BLK
1281 PNK
MOTOR
..B"
ABS MOTOR PACK

6 WAY CONNECTOR C1
...
--- --- ---
.J
HYDRAULIC
MODULATOR ASSEMBLY
04-20-ta
FT021!E
DTC 47
(Page 2 of 2)
-:,
This DTC is designed to detect a stripped nut. or
gear assembly during initialization. During the horrung
resulting in a stalled motor. If this does not occur, the
motor must be spinning with little or no resistance,
indicating a nut/screw or gear malfunction.
OTC Will Set When:

DTC 47 can only be set during initialization. If
the feedback current is less than the command .current
Action Taken:
The ABS warning lamp is turned "ON."

.
8. Checks for a stripped gear on the ABS motor
pack (unit with three small gears).
9. Checks for a stripped gear on the hydraulic

modulator (unit with three large gears).
10. Checks to see if the ABS motor pack has an
internal malfunction.
11. Checks for a malfunctioning hydraulic modulator.
12. Ensures malfunction was not due to poor
terminal contact.
Diagnostic Aids:
binds, or slips.
this section.. If the DTC only occurs once and DTC 56
enhanced diagnostics shows this DTC occurs during
may be necessary.
5E1-101
r ,,,,,,,,,,,,,,.,,.,.,.,,,;;,,,,,,,,,.,.,,,,,,,,,,,,,,,,,,,,,,,,,u,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,,,,,,,
! DIAGNOSIS CONTINUED FROM PREv1,ous PAGE.

f,,,
,,,,,,,,,,,,,u,,,,,,,u,,,,,,,,,,,,,,,.,.,,.,;;.;;,u,u.;,;;,,;1u,,u,11,,,,,,,,,,,..,,,,.,.,1,11,1unl'
REMOVE HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY FROM

VEHICLE (REFER TO "ON-VEHICLE SERVICE" IN THIS SECTION).
REMOVE GEAR COVER.
CHECK FOR STRIPPED GEAR ON ABS MOTOR PACK; ABS MOTOR
PACK IS THE UNIT WITH THE THREE SMALL GEARS. THE LEFT FRONT
GEAR IS THE GEAR FURTHEST FORWARD WHEN THE ASSEMBLY IS
INSTALLED IN THE VEHICLE.
IS THE ABS MOTOR PACK GEAR STRIPPED?
DTC 47
(Page 2 of 2)
LEFT FRONT ABS
MOTOR FREE SPINS
CHECK FOR A STRIPPED GEAR ON HYDRAULIC MODULATOR; MODULATOR IS THE

UNIT WITH THE THREE LARGE GEARS. THE LEFT FRONT GEAR IS THE GEAR
FURTHEST FORWARD WHEN THE UNIT IS INSTALLED IN THE VEHICLE.
IS THE MODULATOR GEAR STRIPPED?
RECONNECT ELECTRICAL CONNECTORS.

SECURELY POSITION HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY IN VEHICLE
WITH GEAR COVER REMOVED SUCH THAT THE GEAR SET CAN BE OBSERVED. BE
CAREFUL NOT TO DAMAGE GEAR SET OR ALLOW THE HYDRAULIC MODULATOR TO
MOVE WHILE TESTING.
IGNITION TO "RUN."
USING TECH 1 MISC. TESTS SELECT MANUAL CONTROL FUNCTION.
SELECT LEFT FRONT ABS MOTOR APPLY AND APPLY THE MOTOR WHILE OBSERVING
THE GEAR SET FURTHEST FORWARD WHEN THE UNIT IS INSTALLED IN THE VEHICLE.
SELECT LEFT. FRONT ABS MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR
WHILE STILL OBSERVING THE GEAR SET.
DID GEAR SET MOVE IN BOTH DIRECTIONS FOR AT LEAST ONE REVOLUTION?
USING TECH 1 MISC. TESTS, PERFORM GEAR TENSION RELIEF FUNCTION.

IGNITION "OFF."
SEPARATE THE ABS MOTOR PACK FROM THE. HYDRAULIC MODULATOR.
GRASP THE GEAR ON THE HYDRAULIC MODULATOR (THE HYDRAULIC MODULATOR
IS THE UNIT WITH THE THREE LARGE GEARS) FURTHEST FORWARD WHEN THE
UNIT IS INSTALLED IN THE VEHICLE AND ATTEMPT TO MOVE THE GEAR.
CAN THE GEAR BE ROTATED MORE THAN}3 FULL TURNS LOCK TO LOCK?
INSPECT ALL CONNECTORS AND TERMINALS FOR POOR TERMINAL CONTACT AND
EVIDENCE OF CORROSION. REFER TO SECTION 8A-4 "CHECKING TERMINAL
CONTACT." REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF POOR TERMINAL
REINSTALL HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY IN VEHICLE.
START ENGINE WITH FOOT OFF BRAKE.
ALLOW ENGINE TO RUN FOR AT LEAST 10 SECONDS.
REPEAT ABOVE IGNITION CYCLE SEQUENCE TWO MORE TIMES.
DID DTC 47 SET IN THE LAST THREE IGNITION CYCLES?
MALFUNCTION IS MOST
LIKELY CAUSED BY A POOR
CONNECTION. REFER TO
FACING PAGE.
THEN TURNING KEY "OFF."
C8021
5E1-102
...
I
I
I
I
EBCM/EBTCM
- -:.- - - .,
rE" l : . . . , _ - - 1 1 - - - - - - - - - 1212 PPL -----1111---1 A
:"~10
/;
._FJ - - - 1 1 - - - - - - - - - 1283 BU<
C2
ABS MOTOR PACK

6WAYCONNECTOR C1
L---
HYDRAULIC
MODULATOR ASSEMBLY
04-20-95
FT02211E
OTC 48
(Page 1 of 2)
RIGHT FRONT ABS MOTOR FREE SPINS
resultirtg in a stalled ABS motor. If this does not
malfunction.
DTC Will Set When:

Action Taken:

DTC is also set.

"HIGH" circuitry.
6. Checks for high resistance in the ABS motor
"LOW" circuitry.
7. Checks for proper resistance of the ABS motor
windings.
Diagnostic Aids:
result from a mech~ical part of the system that sticks,
binds, or slips.
may be necessary.
DTC 48
NOTICE: J 39200 TEST LEADS MUST BE "ZEROED" PRl,OR TO MAKING ANY

IS OTC 61 ALSO CURRENTLY SET?
NO
(Page 1 of 2)
O IGNITION TO "RUN," ENGINE "OFF."

USING TECH 1 MISC. TESTS, SELECT MANUAL CONTROL
FUNCTION.
SELECT RIGHT FRONT ABS MOTOR APPLY FUNCTION AND APPLY
WERE BOTH COMMAND AND FEEDBACK CURRENT
APPROXIMATELY 10 AMPS?
.
YES
5E1-103
YES
RIGHT FRONT ABS

MOTOR FREE SPIN s
Y""'""'"'"""'"'"'"''""'-''"""""'"""'"'"'"'"',
j PROCEED TO OTC 61
CHART FIRST.
1,,,.,,,,,,,.,,,,,,.,,.,,,;,,,,,,,,,.,,,.,,,,,,,,,1,,,,,.,,.,,,,,,.,.,,,,u1111,,,.,,,.,.,.,,,,1
',

SELECT RIGHT FRONT ABS MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR.
.
I
YES
NO
I
IGO TO STEP 5. I

THE MOTOR (THIS MOVES THE PISTON TO THE TOP OF ITS BORE;)
I
I
. I
. I
NO
YES

IGNITION "OFF."
DISCONNECT 6WAY ABS MOTOR PACK CONNECTOR AND GRAY 8-WAY EBCM/EBTCM CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "E" OF THE 6WAY ABS MOTOR
PACK HARNESS CONNECTOR AND TERMINAL "A" OF THE GRAY 8-WAY EBCM/EBTCM HARNESS
CONNECTOR.
MALFUNCTION IS
INTERMITTENT.
REFER TO
"DIAGNOSTIC
AIDS" ON FACING
PAGE.
I
YES
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "F" o,F

THE 6WAY ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL ''B''
OF THE GRAY 8WAY EBCM/EBTCM HARNESS CONNECTOR.

IS RESISTANCE BETWEEN 0.2 AND 1.5 O?
YES

IN CKT 1282.
I
YES
NO
NO
I

IN CKT 1283.
,,,,...., IJI,..,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,
l DIAGNOSIS CONTINUED ON NEXT PAGE.
f,,u,,,,,.,,,,,,.,,.,,,,,,,,,,,u,,.,,,,.,,.,,,,.,,.,,,.,,.,,..,,,,.,,,,,,,,,,,,,.,,,.,,,..,,,,,,,,,,,,i
I
I
NO
REPLACE ABS MOTOR PACK.
AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHl,CLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT
CB0
22
5E1-104
EBCM/EBTCM
..---------,
r
I
I
I
"'!--11--------- 1282 PPL -----1111---1
:'~10
~ ..
FJ ' - - - l i - - - - - - - - - 128311:'iLK
HYDRAULIC
MODULATOR ASSEMBLY
El
C2
ABS MOTOR PACK

6WAYCONNECTOR C1
L---
..I
042095
FT0226E
DTC 48
(Page 2 of 2)
gear assembly during initialization. During the hommg
sequence, the piston should reach the top .of. the bore
resulting in a stalled ABS motor. If this does not
malfunction.
DTC
wm
Set When:

Action Taken:


terminal contact.
Diagnostic Aids:
binds, or slips.
checked by using the enh~ced diagnost.ic func_tio~ ?f
the Tech 1, as described m "Tech 1 Diagnostics m
also occurs refer to DTC 61. If intermittent and
.
may be necessary.
5E1-105
y,1,1,,,,,,,,,,u,,,,,,,,,,,,1,,,,,,,,,,u,,,,,,,,,u,,,,,,,,,,,,,,,,,,,,,,,,,,1,1;1,,111,,11111111,
!,,,.,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
DIAGNOSIS CONTINUED FROM PREVIOUS PAGE. l
..,,,.,,,,,,,,,,,,,,,,,,,,,..,,...............
'
DTC 48
/.
REMOVE HYDRAULIC MODULATOR/MASTER CYLINDER ASSEMBLY FROM VEHl,CLE.

(REFER TO "ON-VEHICLE SERVICE" IN THIS SECTl'ON.)
REMOVE GEAR COVER.
CHECK FOR STRIPPED GEAR ON ABS MOTOR PACK; ABS MOTOR PACK IS THE
UNIT WITH THE THREE SMALL GEARS. THE RIGHT FRONT GEAR IS THE GEAR
FURTHEST REARWARD WHEN THE ASSEMBLY IS INSTALLED IN THE VEHICLE.
(Page 2 of 2)
RIGHT FRONT ABS
MOTOR FREE SPINS
I
I
NO
I
YES
I
CHECK FOR A STRIPPED GEAR ON HYDRAULIC MODULATOR; MODULATOR IS

THE UNIT WITH THE THREE LARGE GEARS. THE RIGHT FRONT GEAR IS THE
GEAR FURTHEST REARWARD WHEN THE UNIT IS INSTALLED IN THE VEHICLE.
NO
I
YES

SECURELY POSITION HYDRAULIC MODULATOR/MASTER CYLINDER ASSEMBLY
IN VEHICLE WITH GEAR COVER REMOVED SUCH THAT THE GEAR SET CAN BE
OBSERVED. BE CAREFUL NOT TO DAMAGE GEAR SET OR ALLOW THE
HYDRAULIC MODULATOR TO MOVE WHILE TESTING.
IGNITION TO "RUN."
SELECT RIGHT FRONT ABS MOTOR APPLY AND APPLY THE MOTOR WHILE
OBSERVING THE GEAR SET FURTHEST REARWARD WHEN THE UNIT IS
SELECT RIGHT FRONT ABS MOTOR RELEASE.FUNCTION AND RELEASE THE
MOTOR WHILE STILL OBSERVING THE GEAR SET.
YES
REPLACE HYDRAULIC
MODULATOR GEAR.
NO

IGNITION "OFF."
SEPARATE THE ABS MOTOR PACK FROM THE HYDRAULIC MODULATOR.
GRASP THE GEAR ON THE HYDRAULIC MODULATOR (THE HYDRAULIC
MODULATOR IS THE UNIT WITH THE THREE LARGE GEARS) FURTHEST
REARWARD WHEN THE UNIT IS INSTALLED IN THE VEHICLE AND ATTEMPT TO
MOVE THE GEAR.
CAN THE GEAR BE ROTATED MORE THAN 13 FULL TURNS LOCK TO LOCK?
NO
I
I
YES
I
EVIDENCE OF CORROSION. REFER TO SECTION 8A4 "CHECKING TERMINAL
REINSTALL HYDRAULIC MODULATOR/MASTER CYLINDER ASSEMBLY IN VEHICLE.
START ENGINE AND TEST DRIVE VEHICLE, ACHIEVING AT LEAST 16 km/h (10 MPH).
REPLACE THE HYDRAULIC

MODULATOR.
I
I
YES
REPLACE EBCM/EBTCM.
NO
AFT ER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3)

FACING PAGE.
C8023
5E1-106

EBCM/EBTCM
,. -- - -
--
.,
re,
REAR ABS
MOTOR
0
D
I, .,
(
1284DKORN
REAR ABS MOTOR

CONTROL HIGH
12850RN
REAR ABS MOTOR

CONTROL LOW
ABS MOTOR PACK
I 8WAYCONNECTOR
L
C1
- - - - -
...
HYDRAULIC
MODULATOR ASSEMBLY
060195
FT023$E
OTC 51
{Page 1 of 2)
REAR ABS MOTOR FREE SPINS
malfunction.
DTC Will Set When:

feedback current is less than the command current for
a specified period of time, a malfunction exists.
Action Taken:

1. Checks to see if the corresponding open ABS
motor DTC is also set.

"HIGH" circuitry.
"LOW" circuitry.
windings.
Diagnostic Aids:
binds, or slips.
this section. If .the DTC only occurs once and DTC 64
enhanced diagnostics show this DTC occurs during
may be necessary.

IS DTC 64 ALSO CURRENTLY SET?

NO
YES
I
DTC 51
(1 of 2)
REAR ABS MOTOR
FREE SPINS
IGNITION TO "RUN." ENGINE "OFF."

SELECT REAR AXLE ABS MOTOR APPLY FUNCTION AND APPLY THE
MOTOR WHILE CAREFULLY OBSERVING THE COMMAND CURRENT
AND FEEDBACK CURRENT ON THE TECH 1.
WERE BOTH COMMAND AND' FEEDBACK CURRENT APPROXIMATELY
10 AMPS?

SELECT REAR AXLE ABS MOTOR RELEASE FUNCTION AND RELEASE THE
MOTOR.
5E1-107
YES
i"'"'
ammm,,,.,,,.,,.,,.,,,,,,,,,,,,,,,,.,,.,.,,,,,.,,.,,,,,,.,.
j PROCEED TO DTC 64 CHART FIRST.
',,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,u,,,,,,,.,,,,,,,,,,,,,,u,,,,.,,.,,,,,~
'
"
YES
MAINTAIN FIRM PRESSURE ON BRAKE PEDAL,

(THIS MOVES THE PISTON TO THE TOP OF ITS BORE).
GOTO
STEP 5.
NO
I
USING TECH 1, MISC. TESTS, PERFORM GEAR TENSION RELIEF FUNCTION.

IGNITION "OFF."
DISCONNECT &WAY ABS MOTOR PACK CONNECTOR AND GRAY 8WAY
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "C" OF THE
&WAY ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL "F" OF THE
GRAY 8-WAY EBCM/EBTCM HARNESS CONNECTOR.
IS RESISTANCE 1.5f.l OR LESS?
NO
YES
MALFUNCTION IS
FACING PAGE.
I
I
YES
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "D" OF THE

6WAY ABS MOTOR PARK HARNESS CONNECTOR AND TERMINAL "E" OF THE
GRAY 8WAY EBCM/EBTCM HARNESS CONNECTOR.
IS RESISTANCE 1.Sf.l OR LESS?
YES
. I
NO

IN CKT 1284.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "C" AND

TERMINAL "D" OF THE ABS MOTOR PACK CONNECTOR.
IS RESISTANCE BETWEEN 0.2 AND 1.5fl?
NO

IN CKT 1285,
YES
, ..,,,, IL..,,,,,,.,,,,,,,,,,.,.,,,,,,,.,.,..,.,..,,.........,,.,.....,,....,,.,,,
i DIAGNOSIS CONTINUED ON NEXT PAGE. l

t,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,h,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,A
. I
NO
AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT DTC DOES
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN IGNITION "OFF."
C8024
5E1-108 ANTILOCK BRAKE SYSTEM

EBCM/EBTCM
.-------,
(
P100
1214DKORN
REAR ABS MOTOR

CONTROL HIGH
REAR ABS
MOTOR
I
ABS MOTOR PACK
I 6 WAY CONNECTOR
REAR ABS MOTOR

CONTROL LOW
12860R,N
C2
C1
L-----
HYDRAULIC
MODULATOR ASSEMBLY
.J
06-01-85
FT0235E
DTC 51
(Page 2 of 2)
gear assembly during initialization ... During the homing
resulting in a stalled motor. If this .does not occur, the
ABS motor must be spinning with little or. no
resistance, indicating a nut/screw or gear malfunct10n.
DTC
wm
Set When:

Action Taken:
A malfunction DTC is stored, ABS are disabled.
The amber ABS warning lamps are turned "ON."


terminal contact.
Diagnostic Aids:
binds, or slips.
The frequency .of the malfunction can be
'
.
enhanced diagnostics
show this DTC occurs durmg
.
Depending on the frequency ?f the malfunction,
may be necessary.
5E1109
y,u;;;,u;,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,..,,.,.,,,.,,,.,,.,,,,.,,,,,,,,,.,,,.,,,.,,,,,,,,,,,,,.,,,,,,,.,,.,,,,,,
.............,,.....,,,.................,,,....,,,..,,,.............................. l
DTC 51
; DIAGNOSIS CONTINUED FROM PREVIOUS PAGE.
,,,,,
,,,,,/.
REMOVE HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY FROM VEHICLE

(REFER TO "ON-VEHICLE SERVICE" IN THIS SECTION).
REMOVE GEAR COVER.
UNIT WITH THE THREE SMALL GEARS. THE REAR AXLE GEAR IS THE MIDDLE
GEAR OF THE THREE.
(Page 2 of 2)
REAR ABS
MOTOR FREE SPIN s
I
NO
I
YES
I

THE UNIT WITH THE THREE LARGE GEARS. THE REAR AXLE GEAR IS THE
MIDDLE GEAR OF THE THREE.
NO
I
YES

SECURELY POSITION HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY IN
VEHICLE WITH GEAR COVER REMOVED SUCH THAT THE GEAR SET CAN BE
IGNITION TO "RUN".
USING TECH 1, TESTS, SELECT MANUAL CONTROL FUNCTION.
SELECT REAR AXLE.ABS MOTOR APP!,.Y AND APPLY Tl:IE MOTOR WHILE
OBSERVING THE MIDDLE GEAR SET.
MOTOR WHILE. OBSERVING THE GEAR SET.
REPLACE HYDRAULIC
MODULATOR GEAR.
I
YES
I
I
NO
I
USING TECH 1, PERFORM GEAR TENSION RELIEF FUNCTION.

IGNITION "OFF."
GRASP THE MIDDLE GEAR ON THE HYDRAULIC MODULATOR (THE
HYDRAULIC MODULATOR IS THE UNIT WITH THE THREE LARGE GEARS) AND
ATTEMF>T TO MOVE THE GEAR.
NO
YES
INSPECT ALL CONNECTORS AND TERMINALS FOR flOOR TERMINAL CONTACT

AND EVIDENCE OF CORROSION. REFER TO SECTION 8A4 "CHECKING
TERMINAL CONTACT." REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF POOR
ALLOW ENGINE TO RUN FOl't AT LEAST 10 SECONDS.
DID OTC 51 SET IN THE LAST THREE IGNITION CYCLES?
.I
YES
I
REPLACE EBCM/EBTCM.

MODULATOR.
NO

FACING PAGE.
AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT OTC DOES
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN TURNING KEY OFF.
C8025
5E1-110
...
- - - ,-,- -
EBCM/EBTCM
.,
L---
HYDRAULIC
MODULATOR ASSEMBLY
04-20-15
FT0215E
OTC 52
LEFT FRONT ABS CHANNEL IN RELEASE TOO LONG
This DTC will diagnose an ABS motor that is
energized longer than expected. This. could occur if .a
wheel speed sensor is malfunctioning, the ABS motor
does not turn, the left front solenoid mechanically fails
open, or the ABS motor wires are crossed.
DTC Will Set When:

DTC 52 can be set only during an ABS stop. If
the EBCM commands the left front ABS channel in
release for three seconds, a malfunction exists.
Action Taken:

1. Identifies a malfunction in a wheel speed sensor
that may cause the system to be in release too
long.
2. Identifies an ABS motor as being failed or wired
incorrectly.
3. Checks for a solenoid that may have mechanically
failed open.
4. Verifies proper soienoid operation:.

5. If Step 3 has failed, this serves to isolate the
cause of the hydraulic malfunction, to either the
solenoid or the ABS hydraulic modulator
assembly.
6. Determines whether a malfunctioning motor pack
or. hydraulic modulator is the reason for DTC 52
being set.
Diagnostic Aids:
An intermitte.nt malfunction may be. caused by a
mechanical part of the system that sticks or binds.
checked by using the enhanced diagnostic .function of
this section. DTC 52 may occur if on ice and steering
wheel. is turned to lock during braking; Using the Tech
1, perform hydraulic test to ensure total brake system
is functional.
Any circuitry that is suspected of. causing the

the wiring harness.
rn
DTC 52
IMPORTANT:
LEFT FRONT ABS

CHANNEL IN
RELEASE TOO LONG
EXCESSIVE DRAG OR HIGH RESISTANCE IN THE BASE BRAKE OR

SUSPENSION SYSTEM MUST BE INSPECTED AND CORRECTED BEFORE
PROCEEDING WITH DTC D,IAGNOSIS.
ARE ANY WHEEL SPEED DTCs CURRENTLY SET?
NO
YES
!i PROCEED
TO THAT DTC !
CHART FIRST.
i
$ .,,.,,,,,,,,.,,,,,,,,,,,1 ,,,,,,,.,,.,,.,,.,,,_,.,,.,,,,,,,,,u,,,u,,,,,,,/
YES
I
.
NO
NO
m J,,.,.,,,,.,.,.,.,.,.,,,,.,.,.,.,.,.,.,.,.,.,,.,,,,,.mmm
PROCEED TO WHEEL SPEED
l DTC FOR AFFECTED WHEEL.
FIRM PRESSURE STILL APPLIED

TO BRAKE PEDAL.
USING TECH 1, COMMAND LEFT
FRONT SOLENOID "OFF."
YES
NO
I
PROCEED TO STEP 51
OF THIS CHART.

IGNITION "OFF."
PHYSICALLY SWITCH THE LEFT FRONT
SOLENOID WITH THE RIGHT FRONT SOLENOID.
IGNITION TO "RUN",
USING TECH 1 MANUAL CONTROL FUNCTION,
SELECT LEFT FRONT SOLENOID AND COMMAND
THE SOLENOID "ON."
APPLY FIRM PRESSURE TO BRAKE PEDAL.
I
I
BRAKE .PEDAL ROSE.
REPAIR CROSSED WIRES

(CKTs 1280 AND 1281) TO
LEFT FRONT ABS MOTOR
(0
I -. l
=0
,,,_,.,,.,,,.,,.,,,,,.,,.,,..,,.,,.,,..,,.,.,,.,,.,,.,,,..,,..,,..,,.,.,.,,...,,,.,,,,,,,,,.,,.,.,,..,,..,,..,,.,,.,,.,,.,,,,,.,,.,,,.,,.,,I
BRAKE PEDAL DID. NOT MOVE.
YES

USING TECH 1 MANUAL CONTROL FUNCTION, SELECT
LEFT FRONT SOLENOID AND COMMAND THE
SOLENOID "ON."
IGNITION TO "RUN".
USING TECH 1 MANUAL CONTRO,L FUNCTION, SELECT LEFT FRONT ABS MOTOR
APPLY AND APPLY MOTOR.
SELECT LEFT FRONT ABS MOTOR RELEASE AND COMMAND RELEASE OF MOTOR.
,m ' mummmmmmmmm,m,m,
USING TECH 1, SELECT "FO: DATA LIST" AND TEST VEHICLE DURING A
STEADY DECEL CONDITION FROM 35 MPH TO O MPH WHILE MONITORING ALL
WHEEL SPEEDS.
DO ANY OF THE WHEEL SPEEDS INDICATE ERRATIC OR INTERMITTENT
OPERATION?
NO
5E1-111
YES
USING TECH 1 PERFORM GEAR TENSION RELIEF FUNCTION.

IGNITION "OFF."
SEPARATE ABS MOTOR PACK FROM HYDRAULIC
MODULATOR.
GRASP THE GEAR ON THE HYDRAULIC MODULATOR
(HYDRAULIC MODULATOR IS THE UNIT WITH THE THREE
LARGE GEARS) FURTHEST FORWARD WHEN THE UNIT IS
INSTALLED IN THE VEHICLE AND ATTEMPT TO ROTATE THE
GEAR IN EITHER DIRECnON.
CAN THE GEAR BE MOVED BY HAND?
I
I
YES
I
REPLACE ABS
MOTOR PACK.
NO
REPLACE ABS HYDRAULIC

MODULATOR;

REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE.
I
I
YES
REPLACE ABS HYDRAULIC MODULATOR.
NO
DRIVE CYCLES TO VERIFY THAT DTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF
STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN TURNING KEY OFF.
REPLACE THE SOLENOID WHICH

WAS ORIGINALLY IN THE LEFT
FRONT CHANNEL.
C8026
5E1-112
EBCM/EBTCM
r------.,
I
I
I
I
I
0
:~g: 8
l l " E ' l - - - - - 1 1 - - - - - - - - 1282 PPL - - - - - I I I I - - - ' A
AF ABS MOTOR CONTROL HIGH
.. F.,---11--------- 1283 BU<
AF ABS MOTOR CONTROL LOW
-----llll---1
ABS MOTOR PACK

6 WAY CONNECTOR C1
B
C2
-
.. - - -
HYDRAULIC
MODULATOR ASSEMBLY
042095
FT0225E
DTC.53
RIGHT FRONT ABS CHANNEL IN RELEASE TOO LONG
energized longer than expected. This could occur if a
does not turn, the right front solenoid mechanically
fails open, or the ABS motor wires are crossed.
DTC Will Set When:

DTC 53 can be set only during an ABS stop; If
the EBCM commands the right front channel in
release for three seconds, a malfunction exists. .
Action Taken:

.
long.
2. Identifies a ABS motor as being failed or wired
incorrectly.
failed open.
4. Verifies proper solenoid operation.

assembly.
6. Determines whether a malfunction motor pack or
hydraulic modulator is the reason for DTC 53
being set.
Diagnostic Aids:
this section. DTC 53 may occur on ice if steering
wheel is turned to lock during braking. Using the Tech
1 perform hydraulic test to ensure total brake system
is functional.

intermittent complaint should be. thoroughly checked
the wiring harness.
rn
DTC 53
IMPORTANT
RIGHT FRONT ABS

CHANNEL IN RELEASE
TOO LONG
EXCESSIVE DRAG OR HIGH RESISTANCE IN THE BASE BRAKE

OR SUSPENSION SYSTEM MUST BE INSPECTED AND
CORRECTED BEFORE PROCEEDING WITH DTC DIAGNOSIS.
NO
5E1-113
YES
JI
Ii PROCEED
TO THAT !
DTC CHART FIRST. l
,m,
USING TECH 1, SELECT "FO: DATA LIST" AND TEST VEHICLE DURING A STEADY
DECEL CONDITION FROM 35 MPH TO O MPH WHILE MONITORING ALL WHEEL SPEEDS.
DO ANY OF THE WHEEL SPEEDS INDICATE ERRATIC OR INTERMITTENT OPERATION?
,mummmummmmm,,
,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,,,,.,,,,,,,,.,,u,f
NO
I
("'
!
!
IGNITION TO "RUN."
USING TECH 1 MANUAL CONTROL FUNCTION, SELECT RIGHT FRONT ABS MOTOR
SELECT RIGHT FRONT ABS MOTOR RELEASE AND COMMAND RELEASE OF MOTOR.
YES
. I
NO
I
PR~CEED TO STEP
5 OF THIS CHART.

MODULATOR.
MALFUNCTION NOT
PRESENT AT THIS
TIME. REFER TO
"DIAGNOSTIC AIDS"
ON FACING PAGE.
BRAKE PEDAL DID NOT MOVE.
NO
BRAKE PEDAL ROSE.
REPAIR CROSSED
WIRES (CKTs 1282
AND 1283) TO RIGHT
FRONT ABS MOTOR.
USING TECH 1 PERFORM GEAR TENSION RELIEF

FUNCTION.
IGNITION "OFF."
SEPARATE ABS MOTOR PACK FROM HYDRAUUC
MODULATOR.
(HYDRAULIC MODULATOR IS THE UNIT WITH THE
THREE LARGE GEARS) FURTHEST REARWARD WHEN
THE UNIT IS INSTALLED IN THE VEHICLE AND ATTEMPT
TO ROTATE THE GEAR IN EITHER DIRECTION.
YES
I
REPLACE ABS
MOTOR PACK.
I0
YES
REMOVE FOOT FROM BRAKE

PEDAL.
IGNITION "OFF."
PHYSICALLY SWITCH THE RIGHT
FRONT SOLENOID WITH THE LEFT
FRONT SOLENOID.
IGNITION TO "RUN."
USING TECH 1 MANUAL CONTROL
FUNCTION, SELECT RIGHT FRONT
SOLENOID AND COMMAND THE
SOLENOID "ON,"
APPLY FIRM PRESSURE TO
BRAKE PEDAL.
YES
YES
FIRM PRESSURE STILL

APPLIED TO BRAKE PEDAL.
USING TECH 1, COMMAND
RIGHT FRONT SOLENOID "OFF."
..........,,,,,,,,,,,,,,,,,,.. ;
i
,,,.,,
PROCEED TO WHEEL l
SPEED = 0 DTC FOR
i,,,,,,,,,,,,.,.,,,,,,,,,,,,,,,,,,.,.,.,,,,,,.,,,,,,,,"
AFFECTED WHEEL.
i
.I
NO

USING TECH 1 MANUAL CONTROL FUNCTION, SELECT RIGHT
FRONT SOLENOID AND COMMAND THE SOLENOID "ON."
NO
YES
NO
I
REPLACE ABS
HYDRAULIC
MODULATOR.
REPLACE THE SOLENOID WHICH WAS

ORIGINALLY IN THE RIGHT FRONT CHANNEL.
AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY DTC DOES NOT
RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH) AND THEN TURNING KEY OFF.
C8027
5E1-114

EBCM/EBTCM
I"'
- - - --- -- --- ,
P100
"c,
1284DKGRN
REAR ABS MOTOR

CONTROL HIGH
..,
1281SORN
REAR ABS MOTOR

CONTROL LOW
REAR ABS
MOTOR
11
ABS MOTOR PACK
I 6 WAY CONNECTOR
L
---
--
C2
C1
--- ---
..I
HYDRAULIC
MODULATOR ASSEMBLY
06-0195
FT02355
DTC 54
REAR ABS CHANNEL IN RELEASE TOO LONG
does not turn, or the ABS motor wires are crossed.
DTC Will Set When:

the EBCM commands the rear axle channel in release
for three seconds, a malfunction exists.
Action Taken:

long.
2. Checks for a wheel that may stick or bind because
of a mechanical malfunction.
3. Checks to see if the ABS motor is capable of

moving and applying the hydraulic piston for the
rear wheels.
4. Ensures that the ABS motor wiring is not crossed.
5. Isolates the fault of a "no-apply" situation to
either the ABS motor pack or ABS hydraulic
modulator assembly.
Diagnostic Aids:
this section. Using the Tech 1, perform hydraulic test
to ensure total brake system is functional.
terminal to wiring. connections or physical damage to
the wiring harness.
[I]
OTC 54
IMPORTANT
EXCESSIVE DRAG OR HIGH RESISTANCE IN THE BASE: BRAKE

OR SUSPENSION SYSTEM MUST BE l!NSPECTl:D AND
CORRECTED BEFORE PROCEEDING WITH OTC DIAGNOSIS.
NO
I
REAR ABS CHANNEL IN

RELEASE TOO LONG
I'
.
YES
>'"''.
mmummummumuu,
l PROCEED TO THAT l
l,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
OTC CHART FIRST. l
NO
I
Yl:S
RAISE REAR OF VEHICLE AND SUPPORT AS INDICATED IN SECTION OA.

SPIN BOTH REAR WHEELS AND CONFIRM PHYSICAL CONDITION OF
BASE BRAKE SYSTEM.
COULD BOTH REAR WHEELS BE SPUN FREELY BY HAND?
PROCEED TO WHEEL
. I
NO
IGNITION. TO "RUN".
USING MANUAL CONTROL FUNCTION OF TECH 1, SELECT REAR AXLE: ABS MOTOR .APPLY.
.
COMMAND APPLY OF REAR ABS MOTOR AND TRY TO SPIN REAR WHEELS BY HAND.
COULD REAR WHEELS BE SPUN BY HAND?
.
.
YES
I
I
MALFUNCTION IS NOT
PRESENT AT THIS TIME.
NO

SEPARATE ABS MOTOR PACK FROM HYDRAULIC MODULATOR.
CONNECT ABS MOTOR PACK WIRING.
IGNITION TO "RUN."
USING TECH 1, PERFORM MOTOR TEST.
DO ALL THREE ABS MOTOR PACK GEARS (SMALL GEARS} SPIN FREELY?
NO
REPAIR SOURCE OF
RESISTANCE IN BASE
BRAKE SYSTEM.
NO
WITH FIRM PRESSURE ON BRAKE PEDAL STILL APPLIED,

COMMAND A RELEASE OF THE REAR AXLE ABS MOTOR.
CAN WHEELS BE MOVED?
YES
i SPEED = 0 OTC FOR l

l,,,,,,,,,,,,,,,,,,,,,.,,,,.,.,,,,,,,,,,,,,,,.,,.,,,,,.,,,!
AFFECTED WHEEL.
l
I
YES
l"''uuum,mmmummmm,,
REPAIR CROSSED
WIRES AT REAR ABS
MOTOR {CKTs 1284
AND 1285).
YES
REPLACE ABS
AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) o,RIVE CYCLES TO VERIFY OTC DOES NOT
RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH} AND THEN TURNING KEY OFF.
C8028
5E1-116
10-8-94
WV020R
OTC 55
EBCM MALFUNCTION
This DTC identifies an internal malfunction

detected by the EBCM ABS motor driver interface,
(MDI) custom integrated circuit (IC). It also ensures
the cause of the malfunction is not the result of a
problem with the ABS relay under a DTC
malfunction.
. Number(s) below refer to circled number(s) on

1. Checks to see if the malfunction is still present.
2. Checks to see if the malfunction is intermittent.
Action Taken:
The ambe:t; ABS warning lamp is turned "ON." The
red "BRAKE" warning lamp is turned "ON" if the
rear piston in the ABS motor pack is not in the home
position.
5E1-117
DTC 55
EBCM MALFUNCTION
IGNITION TO "RUN," ENG,INE "OFF."

USING TECH 1, READ DTCs.
IS OTC 55 CURRENTLY SET?
USING TECH 1, CLEAR DTCs.

TEST DRIVE VEHICLE FOR THREE (3) DRIVE
CYCLES. A DRIVE CYCLE CONSISTS OF STARTING
THE VEHICLE, DRIVING OVER 16km/h (10 MPH),
DOES DTC 55 RESET?
MALFUNCTION IS
INTERMITTENT.
REPLACE EBCM.
MALFUNCTION IS
INTERMITTENT.
C7371
5E1 118 ANTILOCK BRAKE SYSTEM
~~
i0----1...--------12lio
EBCM/EBTCM
r-------.,
BU< - - - - - - i n i - -
/;, ..BJ - - - - - - - - - - 1 2 8 1 PNK - - - - - i u

ABS MOTOR PACK
6 WAY CONNECTOR C1
C2
-
L---
HYDRAULIC
MODULATOR ASSEMBLY
04-20-95
FT0215E
DTC 56
LEFT FRONT ABS MOTOR CIRCUIT OPEN
Diagnostic Aids:
This DTC identifies an ABS motor that cannot

be energized due to an open in its circuitry. This
malfunction will not allow proper ABS operation.
Using Tech 1, select manual control function,

and exercise ABS motor movement of affected
channel in both directions while applying light
pressure on the brake pedal.
If erratic or "jumpy" brake pedal movement is
detected while performing an "apply" or "release"
function of the ABS motor, an intermittent
malfunction may be indicated.
If the malfunction is not current, wiggle the
wires of the affected channel and check if the DTC
resets. This will help to pinpoint an intermittent
malfunction in the motor circuitry or connections.
this section.
Any .circuitry that is suspected of causing the
the wiring harness.
DTC Will Set When:

DTC 56 can be set only when the ABS motor is
commanded "OFF." If the EBCM detects an out of
range voltage on either of the left front ABS motor
circuits indicating an open circuit, a malfunction
exists.
Action Taken:
An open ABS motor will not activate when
requested. A malfunction DTC is stored, ABS is
"ON."

1. Checks for proper resistance of the ABS motor.
2. Checks for an open in the ABS motor "HIGH"
circuitry.
3. Checks for an open in the ABS motor "LOW"
circuitry.
contact.
5E1-119
OTC 56
DOES OTC 56 OCCUR INTERMITIENTLY?

CIRCUIT OPEN
IGNITION "OFF."
DISCONNECT 6WAY CONNECTOR AT ABS MOTOR PACK
CONNECTOR.
USING J 39200, MEASURE RESISTANCE ACROSS ABS
MOTOR PACK TERMINALS "A" AND "B".
IS RESISTANCE BETWEEN 0.2'1 AND 1.5Q?
DISCONNECT GRAY 8WAY CONNECTOR AT EBCM/EBTCM.

USING J 39200, MEASURE RESISTANCE BETWEEN
TERMINAL "G" OF THE GRAY 8WAY EBCM/EBTCM
HARNESS CONNECTOR AND TERMINAL "A" OF THE 6WAY
ABS MOTOR PACK HARNESS CONNECTOR.
IS RESISTANCE 2Q OR LESS?

TERMINAL "H" OF THE GRAY 8WAY EBCM/EBTCM
HARNESS CONNECTOR AND TERMINAL "B" OF THE
6WAY ABS MOTOR PACK HARNESS CONNECTOR.
IS RESISTANCE 2Q OR LESS?
REPAIR OPEN OR HIGH

INSPECT THE 6WAY ABS 'MOTOR PACK AND GRAY SWAY

EBCM/EBTCM CONNECTORS FOR POOR TERMINAL CONTACT AND
EVIDENCE OF CORROSION. REFER TO SECTION 8A4, "CHECKING
TERMINAL CONTACT." REPLACE ALL TERMINALS THAT EXHIBIT
SIGNS OF POOR TERMINAL CONTACT OR CORROSION.
IGNITION "OFF".
16 km/h (10 MPH).
REPAIR OPEN OR HIGH

REPLACE
EBCM/EBTCM.

CAUSED BY A POOR CONNECTION. REFER
TO "DIAGNOSTIC AIDS'' ON FACING PAGE .
AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE
CYCLES TO VERIFY THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS O,F STARTING THE VEHl,CLE,
DRIVING OVER 16 km/h (10 MPHh), AND THEN IGNITION ''0,ff,"
Cll030
...
I
I
- - - - - .,
EBCM/EBTCM
r A"'4,._____,a---------1280 BU< - - - - - ! D l - - 1 1
U: ABS MOTOR CONTROL HIGH
----11--
H
C2
u: ABS MOTOR CONTROL LOW
1:~10
'j;, . .
I
I
ABS MOTOR PACK
I e WAY CONNECTOR c1
- - - - - - - - - - 1 2 8 1 PNK
L---
HYDRAULIC
MODULATOR ASSEMBLY
04-20-95
FT02151E
DTC 57
LEFT FRONT ABS MOTOR CIRCUIT.SHORTED TO GND
Diagnostic Aids:
This DTC identifies an ABS motor. circuit that is

shorted to ground. This malfunction will not allow the
ABS motor to be controlled at the commanded current
rate or will cause the ABS motor driver circuit to
allow current directly to ground.

channel in both directions .while applying light
this section.
the wiring harness.
OTC Will Set When:

DTC 57 can be set anytime. If the EBCM
detects an out of range voltage on either of the left
front ABS motor circuits indicating a circuit shorted to
ground, a malfunction exists.
Action Taken:

1. Checks for a short to ground in the ABS motor
"HIGH" circuitry.
"LOW" circuitry.
shorted to ground.
4. Ensures malfunction was not due to physical
ANTILOCK BRAKE SYSTEM 5E1121
DTC 57
CIRCUIT SHORTED TO GND
DOES DTC 57 OCCUR INTERMITIENTLY?
NO
YES
IGNITION "OFF."
DISCONNECT SWAY CONNECTOR ABS MOTOR PACK CONNECTOR
AND THE GRAY 8WAY EBCM/EBTCM CONNECTOR.
USING J 39200, MEASURE RESISTANCE BETWEEN GROUND AND
TERMINAL "A" OF THE 6-WAY ABS MOTOR PACK HARNESS
CONNECTOR.
REFER TO "DIAG,NOSTIC

BETWEEN GROUND AND TERMINAL "B" OF THE
SWAY ABS MOTOR PACK HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL"
(INFINITE)?

IN CKT 1280.

GROUND AND TERMINAL "A" OF THE ABS MOTOR PACK.
INSPECT CKTs 1280 AND 1281 AND RELATED CONNECTORS

FOR DAMAGE WHICH MAY RESULT IN A SHORT TO GROUND
WITH ALL CONNECTORS CONNECTED. REPAIR ALL DAMAGE IF
EVIDENT.
REPAIR SHORT TO
GROUND IN CKT 1281.
REPLACE ABS MOTOR

PACK.
YES
REPLACE
EBCM/EBTCM.

CYCLES TO VERIFY THAT DTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE,
DRIVING OVER 16 km/h (10 MPH), AND THEN IGNITION "OFF."
C8031
5E1-122
r A"'
~~-~--11----------------~
..""..-
1280 BLK
----11
1281 PNK
----11
HYDRAULIC
MODULATOR ASSEMBLY
C2
ABS MOTOR PACK

6 WAY CONNECTOR C1
L-----
EBCM/EBTCM
.-------.,
.I
042095
FT02115E
OTC 58
LEFT FRONT ABS MOTOR CIRCUIT SHORTED TO BATT
Diagnostic Aids:
This DTC identifies an ABS motor circuit that is

shorted to battery or an ABS motor that has low or no
resistance. This malfunction will not allow the ABS
motor to be controlled at the commanded current rate
or will cause the ABS motor to tum in the opposite
direction, or not at all.

this section.
the wiring harness.
DTC Will Set When:

circuits indicating a circuit shorted to battery or an
ABS motor shorted, a malfunction exists.
Action Taken:

1. Checks for a short to voltage in the ABS motor
"HIGH" circuitry.
2. Checks . for a short to voltage in the ABS motor
"LOW" circuitry.
3. Checks for a short between the "HIGH" and
"LOW" motor circuits.
shorted.
5E1-123
DTC 58


CIRCUIT SHORTED TO BATT
DOES DTC 58 OCCUR INTERMITTENTLY?
NO
YES
IGNITION "OFF."
DISCONNECT THE 6WAY ABS MOTOR PACK CONNECTOR
IGNITION TO "RUN."
GROUND AND TERMINAL "A" OF THE 6WAY ABS MOTOR
PACK HARNESS CONNECTOR.
YES
NO

TERMINAL "B" OF THE 6-WAY ABS MOTOR PACK HARNESS
CONNECTOR.
REPAIR SHORT TO VOLTAGE IN CKT 1280.
..
I
YES
NO
IGNl:TION "OFF."
TERMINAL !'A" AND TERMINAL "B" OF THE 6WAY ABS
MOTOR PACK HARNESS CONNECTOR.
YES
NO

TERMINAL "A" AND TERMINAL "B" OF THE ABS MOTOR PACK.
IS RESISTANCE BETWEEN 0.2n AND 1.5n?
YES
NO
'
.INSPECT CKTs 1280 AND 1281.. AND RELATED CONNECTORS FOR

DAMAGE WHICH MAY RESULT IN A SHORT TO VOLTAGE WITH
ALL CONNECTORS CONNECTED, REPAIR ALL DAMAGE IF
1
EVIDENT.
STAR.T ENGINE AND TEST DRIVE VEHICLE, ACHIEVING AT LEAST
16 km/h (10 MPH).
..
I
I
YES
i'
"-
.,
'
I
REPLACE
EBCM/EBTCM.
NO

DRIVING OVER 16 km/h (10 MPH), AND THEN TURNING KEY OFF.
C8032
5E1124 ANTILOCK BRAKE SYSTEM
.-
EBCM/EBTCM
- - - - - - .,
10------------1212 PPL-----tn
I
~ ._FJ ; . _ _ - - 1 1 - - - - - - - - - 1283 BU<-----111
ABS MOTOR PACK
I 6 WAY CONNECTOR C1
L
HYDRAULIC
MODULATOR ASSEMBLY
C2
...
04-20-95
FT0221E
DTC 61
RIGHT FRONT ABS MOTOR CIRCUIT OPEN
Diagnostic Aids:

/
DTC Will Set When:

detected while performing an, "apply" or "release"
range voltage on either of the right front ABS motor
poor connection, rubbed through wire insulation, .or a
exists.
Action Taken:
reqested. A malfunction DTC is stored, ABS is
malfunction
in the motor circuitry or connections.
disah led. The amber ABS warning lamp is turned
"ON.:'1
checked by using the enhanced diagnostic fnction of
.
the
Tech 1, as described in "Tech 1 Diagnostics" in
this
section.

the diagnostic chart
circuitry.
the wiring harness.
circuitry.
contact.
5E1125
DTC 61
RIGHT FRONT ABS
MOTOR CIRCUIT OPEN
DOES OTC 61 OCCUR INTERMITTENTLY?
0
)
IGNITION "OFF."
DISCONNECT 6-WAY CONNECTOR AT ABS MOTOR PACK CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE ACROSS ABS MOTOR
PACK TERMINALS "E" AND "F".
IS RESISTANCE BETWEEN 0.20 AND 1.50?
DISCONNECT GRAY 8-WAY CONNECTOR AT EBCM/EBTCM.

USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "A" OF
THE GRAY 8-WAY EBCM/EBTCM HARNESS CONNECTOR AND
TERMINAL "E" OF THE 6-WAY ABS MOTOR PACK HARNESS
CONNECTOR.
IS RESISTANCE 20 OR LESS?

TERMINAL "B" OF THE GRAY 8-WAY EBCM/EBTCM
HARNESS CONNECTOR AND TERMINAL "F" OF THE
REPAIR OPEN OR HIGH

RESISTAI\ICE IN CKT 1282.
INSPECT THE 6WAY ABS MOTOR PACK AND GRAY 8WAY

EBCM/EBTCM CONNECTORS FOR POOR TERMINAL CONTACT
AND EVIDENCE OF CORROSION. REFER TO SECTION 8A4,
"CHECKING TERMINAL CONTACT.'' REPLACE ALL TERMINALS
THAT EXHIBIT SIGNS OF POOR TERMINAL CONTACT OR
CORROSION.
.REPLACE
EBCM/EBTCM.
REPAIR OPEN OR HIGH


CYCLES TO VERIFY THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE,
C8033
5E1-126 ANTILOCK. BRAKE SYSTEM
...
!BCM/!BTCM
------.,
"E"-----11--------- 1282 P P L - - - -
=~-=10
I
I
~ ._F" - - - - - - - - - - 1283 BLI<-----10
ABS MOTOR PACK
I 6 WAY CONNECTOR C1
L----_, ....
RF ABS MOTOR .CONTROL LOW
C2
.J
HYDRAULIC
MODULATOR ASSEMBLY
0420H
FT0221E
DTC 62
RIGHT FRONT ABS MOTOR; CIRCUIT SHORTED TO GND
Diagnostic Aids:


channel in bo.th directions . while. applying light
pressure on. the brake pedal.
If erratic or "jumpy" brake. pedal movement is
poor connection, rubbed through wire insulation, .or a
If the malfunction is .not current, wiggle the
this section.
Any circuitry, that is suspected as causing the
the wiring harness.
DTC Will Set When:

detects an out of range voltage on either of the right
Action Taken:
The amber A~S warning lamp is turned "ON."

"HIGH" circuitry.
"LOW" circuitry.
shorted to ground.
ANTILOCK BRAKE SYSTEM 5E1127
DTC 62
RIGHT FRONT ABS

MOTOR CIRCUIT
SHORTED TO GND
I
I
NO
YES
I
IGNITION "OFF."
DISCONNECT 6WAY ABS MOTOR PACK CONNECTOR AND
THE GRAY BWAY EBCM/EBTCM CONNECTOR.
GROUND AND TERMINAL "E" OF THE 6WAY ABS MOTOR
I
YES
I
NO

AND TERMINAL "F" OF THE 6WAY ABS MOTOR PACK HARNESS
CONNECTOR.
.
I
YES
I
NO
USING J 39200; MEASURE THE RESISTANCE BETWEEN GROUND

AND TERMINAL "E" OF THE ABS MOTOR PACK.
NO

EVIDENT.
LEAST 16 km/h (10 MPH),
I
I
REPLACE
EBCM/EBTCM.
NO
YES
REPAIR SHORT TO GROUND IN CKT 1283.1
I
YES

C8034
5E1-128
EBCM/!BTCM
,-------,
I
I
I
/0'-----,1---------12&2 PPL-----1n
~ ._F.,----11---------1283 BU<-----iu
C2
ABS MOTOR PACK

6WAYCONNECTOR C1
L---
1111
.J
HYDRAUUC
MODULATOR ASSEI\IJIIIILV
04-20-98
FT022&E
DTC 63
RIGHT FRONT ABS MOTOR CIRCUIT SHORTED TO BATT
or will cause the ABS motor to turn in the opposite
DTC Will Set When:

Action Taken:

"HIGH" circuitry.
"LOW" circuitry.
3. Checks for short circuit between ABS motor
"HIGH" and motor "LOW".

shorted.
Diagnostic Aids:
this section.
the wiring harness.
5E1-129
DTC 63
PRIOR TO MAKING ANY RESISTANCE
MEASUREMENTS. REFER TO J 39200 USER'S MANUAL.
NO
IGNITION "OFF."
DISCONNECT THE 6WAY ABS MOTOR PACK CONNECTOR AND THE
GRAY 8-WAY EBCM/EBTCM CONNECTOR.
IGNITION TO "RUN".
TERMINAL "E" OF THE 6-WAV ABS MOTOR PACK HARNESS
CONNECTOR.
YES
YES
YES
NO
NO

CKTs 1282 AND 1283.
NO
T
NO
I
REPLACE EBCM/EBTCM.
--.
REPAIR SHORT TO VOLTAGE

IN CKT 1283.
-.
INSPECT CKTs 1282 AND 128~ AND RELATED CONNECTORS

FOR DAMAGE WHICH MAY RESULT IN A SHORT TO VOLTAGE
EVIDENT.
LEAST 16 km/h (10 mph).
YES
--.
YES

IN CKT 1282.
NO

TERMINAL "E" AND TERMINAL "F" OF THE ABS MOTOR PACK.
IS RESISTANCE BETWEEN 0.2 AND 1.5 n?
I
-.
IGNITION "OFF."
TERMINAL "E" AND TERMINAL "F" OF THE 6WAY ABS MOTOR
PACK HARNESS CONNECTO'R.
I
I

CONNECTOR.
.
.
YES
RIGHT FRONT ABS

MOTOR SHORTED TO BATT.

REFER TO "DIAGNOSTIC .AIDS" ON
FACING PAGE.
DTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 mph), AND
THEN TURNING KEV OFF.
C8035

EBCM/EBTCM
.--------.
REAR ABS MOTOR

CONTROL HIGH
r C " ' ' - - - - - - - - - - - - 1 2 8 4 DK OPIN-----11111---1
REARABS
MOTOR
~DJ~"--11--~~~~~~~12850PIN~~~~~11~--11 E
ABS MOTOR PACK
I iWAVCONNECTOR
REAR ABS MOTOR

CONTROL LOW
C2
C1
L-----
HVDRAUI.IC
MODULATOR ASSEMBLY
06-01-95
FT0235E
DTC 64
REAR ABS MOTOR CIRCUIT OPEN
Diagnostic Aids:


and exercise ABS motor .movement of affected
this section.
the wiring harness.
DTC Will Set When:

range voltage on either of the rear axle ABS motor
exists.
Action Taken:
requested. A malfunction DTC is stored, ABS is
"ON."

1. This checks for proper resistance of the ABS
motor.
circuitry.
circuitry.
contact.
NOTICE:
J 39200 TEST LEADS MUST BE "ZEROED" PRIOR
TO MAKING ANY RESISTANCE MEASUREMENTS. REFER TO

5E1131
OTC 64
IGNITION "OFF."
DISCONNECT &WAY ABS MOTOR PACK CONNECTOR.
MOTOR PACK TERMINALS "C" AND "D".
IS RESISTANCE BETWEEN 0.20 AND 1.5n?
DISCONNECT GRAY 8WAY CONNECTOR AT EBCM/EBTCM.

USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "F" OF THE
GRAY 8WAY EBCM/EBTCM HARNESS CONNECTOR AND TERMINAL "C" OF
THE &WAY ABS MOTOR PACK HARNESS CONNECTOR.
USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "E" OF THE GRAY

8-WAY EBCM/EBTCM HARNESS CONNECTOR AND TERMINAL "D" OF THE &WAY
IS RESISTANCE 20 .OR.LESS?
INSPECT THE 6,WAY ABS MOTOR PACK AND GRAY 8WAY

RECONNECT ALL CONNECTORS,
.,
16 km/h (1 O mph).

CAUSED BY A POOR CON.NECTION .
FACING PAGE.
THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND
THEN TURNING KEY OFF.
C8036

EBCM/EIBTCM
.-------.,
REARABS
MOTOR
,.C,:.....--11--------1294 DK QRN----4HI---I F
REAR ABS MOTOR

CONTROL HIGH
,_c,.~--11---------1285 ORN-----1!111---1 E
REAR ABS MOTOR

CONTROi.LOW
C2
ABS MOTOR PACK
I 6 WAY CONNECTOR
C1
L-----
HYDRAULIC
MODULATOR ASSEMBLY
06-01-915
FT0235E
OTC 65
REAR ABS MOTOR CIRCUIT SHORTED TO GROUND
Diagnostic Aids:

Using Tech 1, select manual control function;

wires of the .affected channel .and check if the DTC
this section.
the wiring harness.
DTC
wm
Set When:

detects an out of range voltage on either of the rear
axle ABS motor circuits indicating a circuit shorted to
Action Taken:
A malfunction DTC is stored, ABS are disabled.
The amber ABS warning lamps are turned "ON."

.
"HIGH" circuitry.
"LOW" circuitry.
shorted to ground.
5E1133
DTC 65
REAR ABS MOTOR CIRCUIT
SHORTED TO GROUND
IGNITION "OFF."
DISCONNECT 6WAY ABS MOTOR PACK CONNECTOR AND
THE GRAY 8WAY EBCM/EBTCM CONNECTOR.
USING A J 39200, MEASURE THE RESISTANCE BETWEEN
GROUND AND TERMINAL "C" OF THE 6WAY ABS MOTOR

TERMINAL "D" OF THE 6WAY ABS MOTOR PACK HARNESS
CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS '!OL" (INFINITE)?

TERMINAL "C" OF THE ABS MOTOR PACK.

WITH ALL CONNECTORS CONNECTED. REPAIR ALL DAMAGE
IF EVIDENT.
LEAST 16 km/h (10 mph). .
.
MALFUNCTION WAS MOST LIKELY CAUSED

BY A POOR CONNECTION. REFER TO
AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR OT.Cs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY
THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE.VEHICLE, DRIVING OVER 16 km/h (10 mph),
AND THEN TURNING KEY OFF.
C8037

EBCM/EBTCM
r-------.-,
REARABS
MOTOR
,.C-.........-e---------1284 DK O,RN-----111...._-.1 F
REAR ABS IIJIOTOR

CONTROi. HIOH
~DJ~~1--~~~~~~~12asORN
REAR ABS MOTOR

CONTROL LOW
ABS MOTOR PACK
I 6WAYCONN:ECTOR
Ct
L------
..J
HYDRAULIC
MODULATOR ASSEMBLY
08-01-85
FT0235E
DTC 66
REAR ABS MOTOR CIRCUIT SHORTED TO BATTERY
Diagnostic Aids:

direction, or not tum at all.

.

this section.
the wiring harness.
DTC
wm
Set When:

range voltage on either of the rear ABS axle motor
Action Taken:

"HIGH" circuitry.
"LOW" circuitry.
3. Checks for a short circuit between motor "HIGH"
and motor "LOW".
shorted.
5E1-135
DTC 66
NOTICE: J 39200 TEST LEADS MUST BE "ZEROED" PRIOR

SHORTED TO BATTERY
IGNITION "OFF."
DISCONNECT THE 6-WAY ABS MOTOR PACK CONNECTOR AND
THE GRAY 8-WAY EBCM/EBTCM CONNECTOR.
IGNITION TO "RUN".
USING A J 39200, MEASURE THE VOLTAGE BETWEEN GROUND
AND TERMINAL "C" OF THE 6-WAY ABS MOTOR PACK HARNESS
CONNECTOR.

TERMINAL "D" OF THE 6-WAY ABS MOTOR PACK HARNESS
CONNECTOR.
IGNITION "OFF."
"C" AND TERMINAL "D" OF THE 6-WAY ABS MOTOR PACK
HARNESS CONNECTOR.

TERMINAL "C" AND TERMINAL "D" OF THE ABS MOTOR PACK.

IF EVIDENT.
.

FACING PAGE.
C8038
5E1136
EBCM/EBTCM
TO ABS RELAY
REFER TO
SECTION 8.A-44
,...ABS VALVE~
FUSE IS
~QS
,.,.,. ~ S O L E N O I D [ ! ]
,-------- .....,
"
.
1288
ORN
B - - - - - D K GRN
r:,
"'
LF ABS SOLENOID
CONTROL
I
I
lJ
RFQS
~!~LEN~ID~
' - - - - - 855 --,,,,,----. A --Q-Q Q Q - B . - 1 - - - - - - - 1289
ORN
LTBLU
RF ABS SOLENOID
CONTROL
P100
04-20-85
FT028liE
DTC 76
LEFT FRONT SOL CIRCUIT OPEN OR SHORTED TO GND
This DTC identifies a solenoid that cannot be

energized due to an open in its circuitry, or a solenoid
that is always energized due to a short to ground in its
circuitry between the driver and the solenoid. An open
will not allow proper ABS operation, but the short to
ground simply turns "ON" the solenoid; A path for
base brakes is still allowed once the motor re-homes
and the check ball is lifted off its seat during ignition
to "RUN" initialization.

1. Checks for a short to ground in the control
circuitry of the solenoid.
2. Checks for an open in the control circuit of the
solenoid.
3. Checks the solenoid coil for proper resistance.
4. Checks for an open in the solenoid voltage supply
circuit.
the solenoid circuitry due to poor terminal
contact.
DTC
wm
Set When:
DTC 76 can be set only when the solenoid is

commanded "OFF" while the ABS relay is enabled. If
the EBCM detects the left front solenoid control
circuit voltage is out of specification, a malfunction
exists.
Action Taken:
Diagnostic Aids:
this section.
the wiring harness.
5E1-137
DTC 76
LEFT FRONT SOL CIRCUIT
OPEN OR SHORTED TO GND
IGNITION "OFF."
DISCONNECT 24-WAY EBCM/EBTCM CONNECTOR AND LEFT
FRONT SOLENOID CONNECTOR.
IGNITION TO "RUN", ENGINE "OFF."
AND TERMINAL "AtO" OF THE 24-WAY EBCM/EBTCM HARNESS
CONNECTOR.
I
I
YES
. I
NO
IGNITION "OFF."
TERMINAL "A10" OF THE 24-WAY EBCM/EBTCM HARNESS
CONNECTOR AND TERMINAL "B" OF THE LEFT FRONT
SOLENOID HARNESS CONNECTOR.
YES
REPAIR SHORT TO
GROUND IN CKT 1288.
NO
MEASURE THE RESISTANCE BETWEEN TERMINAL "A" AND

TERMIINAL "B" OF THE LEFT FRONT SOLENOID.
IS RESISTANCE BETWEEN 2.5 AND 5 OHMS?
. I
REPAIR OPEN OR HIGH

NO
YES
MEASURE THE RESISTANCE BETWEEN ABS RELAY TERMINAL "C4"

AND TERMINAL "A" OF THE LEFT FRONT SOLENOID HARNESS
CONNECTOR.
REPLACE LEFT
1
FRONT SOLENOID.
YES
. I
NO
INSPECT LEFT FRONT SOLENOID AND 24-WAY EBCM/EBTCM

HARNESS CONNECTORS FOR POOR TERMINAL CONTACT AND
EVIDENCE OF CORROSION. REFER TO SECTION BA-4, "CHECKING
TERMINAL CONTACT". REPLACE ALL TERMINALS THAT EXHIBIT
INSPECT CKT 1288 FOR DAMAGE WHICH MAY RESULT IN A SHORT
TO, GROUND WITH ALL CONNECTORS CONNECTED. REPAIR
DAMAGE IF EVIDENT.
IGNITION TO "RUN."
DOES OTC 76 SET AS A CURRENT DTC?
REPAIR OPEN OR HIGH RESISTANCE

IN CKT 855/1633.CHECK FOR OPEN
ABS VALVE FUSE IN UNDERHOOD
ELECTRICAL CENTER.
I
YES
REPLACE EBCM/EBTCM.
NO
I

A POOR CONNECTION. REFER TO
C9793
5E1-138
EBCM/EBTCM
TO ABS RELAY
REFER TO
SECTION 8A44
LFABS
~r:,
_ _ _ _ 8155
ORN~
0 00 0
1288
- L . ! . J - - - - - D K GRN
LF ABS SOLENOID
CONTROL
I
I
855
'----ORN
LJ
RF ABS
r:, .s<:LENOI~ r:,
-n----1~ QQQQ' 1 . ! J - - - - - - L T1289

BLU
RF ABS SOLENO,ID
CONTROL
P'IOO
04-20-115
FT0285E
DTC T1
LEFT FRONT SOLENOID CIRCUIT SHORTED TO BATT
energized due to an short to voltage in its driver
circuitry. These malfunctions can affect ABS operation
since the flow of brake fluid to the wheel cylinder
cannot be stopped, making ABS operation for that
channel impossible.
DTC
wm
Set When:

commanded "ON." If the EBCM detects the left front
solenoid control circuit voltage is out of specification,
a malfunction exists.
Action Taken:

1. Checks for a solenoid that is internally shorted to
voltage.
2. Checks for a solenoid that is not within proper

resistance values.
3. Indicates if a short to voltage exists in the
solenoid control circuitry.
contact.
Diagnostic Aids:
this section.
the wiring harness.
5E1139
DTC 77
LEFT FRONT SOLENOID CIRCUIT
SHORTED TO BATT
IGNITION "OFF."
DISCONNECT LEFT FRONT SOLENOID CONNECTOR.
AND TERMINAL "B" OF THE LEFT FRONT SOLENOID
CONNECTOR.
I
I
YES
I

TERMINAL "A" AND TERMINAL "B" OF THE LEFT
FRONT SOLENOID.
IS RESISTANCE BETWEEN 2.5 AND 5.0 OHMS?
I
I
YES
NO
I
REPLACE LEFT FRONT SOLENOID.

USING J 39200 MEASURE THE VOLTAGE BETWEEN GROUND AND
NO
I
I
YES
INSPECT CKT 1288, THE LEFT FRONT SOLENOID AND 24-WAY

EBCM/EBTCM HARNESS CONNECTORS FOR DAMAGE WHICH
MAY RESULT IN A SHORT TO VOLTAGE WITH ALL CONNECTORS
CONNECTED. REPAIR DAMAGE IF EVIDENT.
I
I
YES
I
NO
--.
REPAIR SHORT TO VOLTAGE IN

CKT 1288.
,I
REPLACE EBCM/EBTCM.
NO
--.
FACING PAGE.
C9794
l!BCM/l!BTCM
(
TO ABS RELAY
REFER TO
SECTION 8A44
~ABS
,.,.,. ~SOLENOID[!].
..1288
----ORN rJ
A
B 1 - - - - - - D K GAN
LF ABS SOLENOl1D
CONTROL
I
I
855
'----ORN
LJ
RF ABS
r:, "SOLiNOI~ r:,
_n.....,,..._-~ QOQQ
1289
, ! J I - - - - - - - L T BLU
RF ABS SOLENOl1D
CONTROL
P'IOO
042095
FT0285E
DTC 78
RIGHT FRONT SOL CIRCUIT OPEN OR SHORTED TO GND
ground simply turns "ON" the solenoid. A path for
to "RUN" initialization..
DTC Will Set When:

commanded "OFF" while the ABS relay is enabled. If
the EBCM detects the right front solenoid control
circuit voltage is out of specification, a malfunction
exists.
Action Taken:

solenoid.
circuit.
5. Checks for a possible. intermittent malfunction in
contact.
Diagnostic Aids:
this section.
the wiring harness.

5E1141
DTC 78
RIGHT FRONT SOL CIRCUIT
IGNITION "OFF."
DISCONNECT 24-WAY EBCM/EBTCM CONNECTOR AND
RIGHT FRONT SOLENOID CONNECTOR.
GROUND AND TERMINAL "B6" OF THE 24-WAY
IGNITION "OFF."
OF THE 24-WAY EBCM/EBTCM HARNESS CONNECTOR AND TERMINAL
"A" OF THE RIGHT FRONT SOLENOID HARNESS CONNECTOR.
MEASURE THE RESISTANCE BETWEEN TERMINAL "A"

AND TERMINAL "B" OF THE RIGHT FRONT SOLENOID.
MEASURE THE RESISTANCE BETWEEN ABS RELAY

TERMINAL "C4" AND TERMINAL "A" OF THE RIGHT
FRONT SOLENOID HARNESS CONNECTOR.
INSPECT RIGHT FRONT SOLENOID AND 24WAY EBCM/EBTCM

TERMINAL CONTACT." REPLACE ALL TERMINALS. THAT EXHIBIT
TO GROUND WITH ALL CONNECTORS CONNECTED. REPAIR
DAMAGE IF EVIDENT.
IGNITION TO "RUN."
IS OTC 78 SET AS A CURRENT OTC?
REPAIR OPEN OR HIGH

RESISTANCE IN CKT 855/1633.
CHECK FOR OPEN ABS VALVE
FUSE IN UNDERHOOD
ELECTRICAL CENTER.
MALFUNCnON IS MOST LIKELY

DUE TO A POOR CONNECTION.
ON FACING PAGE.
C9795
5E1-142
EBCM/EBTCM
TO ABS RELAY
REFER TO
SECTION 8A44
LFABS
~r
:,
1288
0 0 0 0 -L.!.J--------DK GRN
855
---ORN~
LF ABS S0 LENOID
CONTROL
1
I
I
'-----855
ORN
RF ABS
_LJn__r;:,
_!~LENOI~ l'i'1
1289
L:.J""Ql) QQ""'L.:.1.....-----LT ILU
RF ABS SOLENOID
.CONTROL
P100
04-20-96
FT028SE
DTC 81
RIGHT FRONT SOLENOID CIRCUIT SHORTED TO BATT
channel impossible.

resistance values.
contact.
DTC Will Set When:
Diagnostic Aids:

commanded "ON." If the EBCM detects the right
front solenoid control circuit voltage is out of
specification, a malfunction exists.

this section.
the wiring harness.
Action Taken:

voltage.
5E1-143
DTC 81
RIGHT FRONT SOLENOID
IGNITION "OFF."
DISCONNECT RIGHT FRONT SOLENOID CONNECTOR.
AND TERMINAL "A" OF THE RIGHT FRONT SOLENOID;

BETWEEN TERMINAL "A" AND TERMINAL "B"
OF THE RIGHT FRONT SOLENOID,

GROUND AND TERMINAL "BS" OF THE 24WAY
.
IS VOLTAGE 1. VOLT OR LESS?
INSPECT CKT 1289, THE RIGHT FRONT SOLENOID AND 24WAY

EBCM/EBTCM. HARNESS CONNECTORS FOR DAMAGE WHICH MAY
RESULT IN A SHORT TO VOLTAGE WITH ALL CONNECTORS
START ENGINE WiTH FOOT OFF BRAKE.
ON FACING PAGE.
C9796
5E1144
10-1-94
WV020SE
DTC 82
CALIBRATION MALFUNCTION
This DTC allows the EBCM to check for a
calibration malfunction by comparing the calibration
value to a known value stored in the EEPROM.
This DTC is also used as a security measure to
prevent improper use of calibrations or changes to
these calibrations that may alter the designed function
of ABS.
DTC Will Set When:
DTC 82 can be set at key-up. If the program
identifier is incorrect or the memory checksum is
incorrect, a malfunction exists.
Action Taken:
Dl;C Chart Test Description:

Number(s) below .refer to circled number(s) on
. . ..
1. Checks to see if the malfunction is present during
diagnosis. If present, the EBCM is not functioning
correctly and must be replaced.
Diagnostic Aids:
An intermittent DTC 82 may be caused by a bad
cell in the .EEPROM that is sensitive to temperature
changes. If DTC 82 failed more than once, but is
intermittent, replace EBCM.
this section.
5E1-145
DTC 82
G)
IGNITION TO "RUN".
MALFUNCTION IS NOT
THIS CHART ASSUMES THAT A CURRENT OTC IS STORED INDICATING THAT THIS MALFUNCTION IS PRESENT.
C8044
INSTRUMENT
CLUSTER
BRAKE
WARNING
i((D)~')~CtO
REFER TO
SECTION
8A11
CHEV
A10 PONT
"BRAKE"
013 CHEYL_U,..D1-IS_C_H-EV.,.
AS PONTI .. LOW TRAC"
I
AMBER
!Q\
~I
I
"AIIS INOP"
AMBER
I A18 PONT
33TAN/
rr;.-~33TAN/
WHT 82281
18273 WHT
I
I
I
~
I
I
I
- -EVI--
DISC
117PONT
I
----------
887 LT GRN
BRAKE WARNING
LAMP CONTROL
I
I
I
1537 DK BLU ~ 1137 DK IILU
EBCM
BRAKE
COMBO
SWITCH
ABS ACTIVE
LAMP CONTROL
I
I
I
---
887 LT ORN
ABS WARNING
LAMP CONTROL
C200D
C200A
042895
FTI045E
DTC 86
EBCM TURNED ON THE RED BRAKE WARNING LAMP
Diagnostic Aids:
This DTC is provided as an information only

DTC, and reflects the status of the command issued by
the ABS EBCM to illuminate the red "BRAKE"
warning lamp. If another DTC issues a command to
illuminate the red "BRAKE" warning lamp, DTC 86
will be stored in EEPROM as a history DTC at the
conclusion of the ignition cycle.
Any ABS mechanical DTC that issues a

command to illuminate the red "BRAKE" warning
lamp will also result in DTC 86 being stored in
EEPROM during shut down. These DTCs are: 38, 41,
42, 46, and 51. If the motor car not in their home
position, certain electrical DTCs will also command
the red "BRAKE" warning lamp "ON." These DTCs
are: 14, 16, 18, 55, 56, 57, 58, 61, 62, 63, 64, 65, and
66.
If any of these DTCs are indicated along with
DTC 86, they must be corrected prior to addressing a
DTC 86 malfunction.

1. Serves to identify if a DTC other than DTC 86
commanded the red "BRAKE" warning lamp
"ON."
5E1-147
DTC 86
EBCM TURNED ON THE RED
BRAKE WARNING LAMP
ARE ANY DTCs CURRENTLY

SET WITH OTC 86?
CLEAR OTC. PERFORM

DIAGNOSTIC SYSTEM
CHECK.
PROCEED TO "DIAGNOSTIC
AIDS" ON FACING PAGE OF
THIS CHART.
C7404
5E1-t48 ANTILOCK BRAKE SYSTEM
INSTRUMENT
CLUSTER
;---~---~C10 CHEV
REFER TO
SECTION
8A11
FUSE9
GAGES
BRAKE
WARNING
33TAN/
A10 PONT
"BRAKE"
BRAKE
COMBO
SWITCH
rr;l5-,~33TAN/
WHT S228u
I
I
I
ID13CHEY~D11SCHEV
11537 DK l!!ILU
AS PONTI "LOW TRAC" BA18 PONT
I
AMBER
I
!~\
~u....................
:i-~;..;;;;..;..'f/.,r.......__...:I
DIS CHEV
887 LT GRN
B17PONT
I "ABS IINOP"
I
AMBER
I
BS273 WHT
IBRAKE WARNING
LAIIIIP CONTROL
I
S
I
0,
11537 DK BLU
8
8
B
I
ABS ACTIVE
LAMP CONTROL
B
I
fil
-----------
EBCM
---
887 LT GRN
ASS WARNING
LAl\ll,P CONTROL
C200D
C200A
04-28-ts
FTI04!E
DTC 87
(Page 1 of 2)
RED BRAKE WARN LAMP CKT OPEN OR SHORTED TO
BATT
This OTC identifies a open or short to voltage
between the EBCM and the red "BRAKE" warning
lamp, or an open driver that does not allow the red
"BRAKE" warning lamp to be illuminated by the
EBCM. This will only occur if an ABS malfunction is
detected that may degrade base brake operation.
Because ABS is not the only device controlling the
red "BRAKE" warning lamp (parking brake and
brake fluid level switch or may also tum "ON" the
red "BRAKE" warning lamp) a short to ground in
this circuit cannot be detected.
DTC Will Set When:

OTC 87 can be set during the three second bulb
check and after initialization is completed. If the red
"BRAKE" warning lamp circuit voltage is out of
specification indicating an open circuit or a short to
voltage, a malfunction exists.
Action Taken:
A malfunction OTC is stored ABS is not
disabled, however, if the EBCM co~ands the red
"BRAKE" warning lamp on due to a ABS
malfunction that may degrade base brake operation
and cannot do so the ABS warning lamp will flash to
indicate the serious nature of the problem.

1. C;hec~s ~hether the "BRAKE" warning lamp
crrcuitry is open or shorted to battery.
2. C;hec_ks the comple~e "BRAKE" warning lamp

circuitry by attemptmg to manually tum "ON"
the "BRAKE" warning lamp.
3. Checks for high resistance in park brake circuitry.

contact at the brake fluid level switch which may
result in an intermittent.
6. Checks the integrity of the "BRAKE" warning
lamp.
7. Checks for high resistance in the "BRAKE"
warning lamp control circuitry.
Diagnostic Aids:
An inte_rmittent malfunction may be caused by a
th~ Tee~ 1, as described _in "Tech 1 Diagnostics" in
this section. If a Tech 1 is not available, the parking
brake handle may be lifted to verify proper lamp
operation and continuity of CKTs 3 and 39.
for ba?ked out terminals, improper mating, broken
lock~, improp~~ly formed or damaged terminals, poor
termi~a! to wmng connections or physical damage to
the wmng harness.
5E1-149
DTC 87
IGNITION "OFF.''
DISCONNECT INSTRUMENT CLUSTER HARNESS CONNECTOR.
TURN IGNITION TO "RUN.''
USING J 39200, MEASURE VOLTAGE FROM GROUND TO TERMINAL
"BS" OF THE 24WAY EBCM/EBTCM HARNESS CONNECTOR.
IS VOLTAGE GREATER THAN 1 VOLT?
NO
(Page 1 of 2)
RED BRAKE WARN LAMP
CKT OPEN OR SHORTED TO
BATI
,.
IGNITION "OFF.''
CONNECT INSTRUMENT CLUSTER HARNESS CONNECTOR.
USING A FUSED JUMPER SUCH AS J 36169 WITH A 3 AMP FUSE, CONNECT 24-WAY
EBCM/EBTCM HARNESS CONNECTOR TERMINAL "BS" TO GROUND.
IGNITION TO "RUN.''
IS RED BRAKE WARNING LAMP "ON"?
I
I
YES
NO
I
I
RELEASE PARK BRAKE.

IGNITION "OFF.''
DISCONNECT BRAKE FLUID LEVEL SWITCH.
INSPECT 24WAY EBCM/EBTCM HARNESS
CONNECTOR TERMINAL "BS" FOR POOR
TERMINAL CONTACT OR CORROSION. REFER
TO SECTION BA4, "CHECKING TERMINAL
CONTACT." REPLACE TERMINALS THAT
EXHIBIT POOR CONTACT OR CORROSION.
RECONNECT 24-WAY EBCM/EBTCM
CONNECTOR.
START ENGINE.
WAIT 10 SECONDS.
NO
NO
I
NO

RESISTANCE BETWEEN VP
CLUSTER HARNESS
CONNECTOR TERMINAL "C10"
(CHEV), "A10" (PONT) AND
24-WAY EBCM/EBTCM
HARNESS CONNECTOR
TERMINAL "BS".
IS RESISTANCE LESS THAN 2
OHMS?
RESISTANCE i
! IN PARK !
i BRAKE
l
!,,,,,,,,,,,,u,,,,,,,,,,,,,,,
CIRCUITRY. j
YES
REPLACE
BULB.
NO
r,. ,.lu,,,. . . . . .,. . . . . . .,. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..,. . . . . !
! REFER TO SECTION BA TO
i
I
i
f,,,1,u111,,,,,,,,u1;,;,-,1;;1111,,,,,,,,,,,,,,,,,,,,,,u1,,,,,.,J
DIAGNOSE CLUSTER AND/OR

l CIRCUITRY TO CLUSTER.
REPAIR OPEN OR
HIGH RESISTANCE
IN CKT 33.
.
YES
REPLACE
EBCM/EBTCM.
. I
NO
YES
'"'"'"""""'"'"'"'"'"'""'""'"'"'"'"'"'"'"'"'"'"'"'"'""'"''"''"'"'"'""'"""''"''
I CHECK BRAKE FLUID LEVEL AND REFER TO SECTION BA TO

REPAIR HIGH RESISTANCE IN FLUID LEVEL SWITCH CIRCUITRY.
YES
I
I
IGNITION "OFF.''
INSPECT BRAKE FLUID LEVEL SWITCH HARNESS CONNECTOR FOR POOR TERMINAL CONTACT
AND EVIDENCE OF CORROSION. REFER TO SECTION BA4, "CHECKING TERMINAL CONTACT."
REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF TERMINAL CONTACT OR CORROSION.
RECONNECT BRAKE FLUID LEVEL SWITCH CONNECTOR.
START ENGINE.
WAIT 10 SECONDS.
...,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.;
..
.......
.. I
i
'''"'"'""'""'"'""
GO TO DTC 87
PAGE 2 OF 2.
IGNITION "OFF.''
REMOVE 1/P CLUSTER.
REMOVE AND INSPECT RED BRAKE WARNING LAMP.
IS BULB OPEN?
i"" l,,,......,,,,,,,l
l REFER TO l
l SECTION BA l
i TO REPAIR i
l HIGH
l
li
ENSURE BRAKE FLUID IS AT THE PROPER LEVEL.

IGNITION "OFF.''
REMOVE JUMPER USED IN STEP 2.
APPLY PARK BRAKE.
IGNITION TO "RUN.''
USING J 39200, MEASURE VOLTAGE BETWEEN
GROUND AND 24-WAY EBCM/EBTCM HARNESS
CONNECTOR TERMINAL "BS",
YES
, I
YES
1,,,,,,,,,,,,.,,u.,1,,,,,,,,,,,,,,,,u,u,,,,,,,,.,,,,,,,.,,,,,.,,,,,,,,.,,,,,,,,,,,,,,u,,,11,,uu,,,,,,,,,,u,u,,u.,,,,,,,,,.,,,,,.,,,,,,,,,,A

C9797
INSTRUMENT
CLUSTER
REFER TO
SECTION
8A11
FUSEI
GAGES
BRAKE
WARNING
;@l~@>~C10
1
"llFIAKI!"
CHEV
A10 PONT
EBCM
BRAKE
COMBO
SWITCH
1rr;-11133
33 TAN/
WHT 82281
I
8
I
I 8273
I
TAN/
WHT
013 CHEYL.i._jl""D1-8-C-H-EV-.
1537 DK l!tLU
1537 DK IBLU
A5 PONTI .. LOW TFIAC" I A18 PONT
~
!f"i."i"1!
AMBER
!Q\
~I
I
I
"ABSINOP"
AMBER
......................
I DICHEV
817PONT
I
----------
I
I
I
BRAKE WARNING
LAMP CONTROL
AB8ACTIVE
LAMP CONTROL
I
I
I
---
887 LT G F I N f i l 867 LT ORN
ABS WARNING
LAMP CONTROL
C200D
C200A
04-28-95
FT1045E
DTC 87
(Page 2 of 2)
RED BRAKE WARN LAMP CKT OPEN OR SHORTED TO
BATT
This DTC identifies a open or short to voltage

between the EBCM and the red "BRAKE" warning
"BRAKE" warning lamp to be illuminated by the
EBCM. This will only occur if an ABS malfunction is
detected that may degrade base brake operation.
Because ABS is not the only device controlling the
red "BRAKE" warning lamp (parking brake and
brake. fluid level switch or may also turn "ON" the
red "BRAKE" warning lamp) a short to ground in
this circuit cannot be detected.

8. Identifies if a malfunction is currently present.
9. With the Tech 1 connected, attempts to turn
"ON" the "BRAKE" warning lamp.
12. Checks for DTC 86 also being set.
DTC Will Set When:

.
DTC 87 can be set during the three second bulb
"BRAKE" warning lamp circuit voltage is out of
Action Taken:
A malfunction DTC is stored, ABS is not
disabled, however, if the EBCM commands the red
"BRAKE" warning lamp on due to a ABS
Diagnostic Aids:
the Tech 1, as described in "Tech 1 Diagnostics" in.
this section.
the wiring harness.
5E1 151
DTC 87
{Page 2 of 2)
RED BRAKE WARN LAMP CKT.
OPEN OR SHORTED TO BATT
~u,,,,.u,,,,,,,,,,,,,.,,,,,,,,u111111111,,,,,.,..,,,,,,,,.,,,,,,,,,
CONTINUED FROM OTC 87
! PAGE 1 OF 2.
.,,,,....r......,,,,,,..,,,,,..,,....,,..,,,,,,......,,,.A!
~
IGNITION "OFF."
IGNITION TO "RUN."
OBSERVE RED "BRAKE" WARNING LAMP.
IS LAMP "OFF"?
I
I
YES
NO
USING TECH 1 MISC. TESTS, SELECT LAMP TEST

FUNCTION, COMMAND RED "BRAKE" LAMP "ON."
IS LAMP ILLUMINATED?
IS OTC 86 ALSO SET?
I
I
NO
I
YES
I
IGNITION "OFF."
REMOVE 10 AMP GAGES FUSE 9.
DISCONNECT 24WAY
IGNITION TO "RUN."
VOLTAGE BETWEEN GROUND
AND TERMINAL "BS" OF THE
24WAY EBCM/EBTCM HARNESS
CONNECTOR.
MALFUNCTION IS
NOT PRESENT AT
THIS TIME. REFER
TO "DIAGNOSTIC
AIDS" ON FACING
PAGE.
NO
I
CHECK FOR LOW FLUID LEVEL

OR
PARKING BRAKE SWITCH
CLOSED AND CORRECT AS
NECESSARY.
YES
I
PROCEED
TO OTC 86
DIAGNOSTIC
CHART.
I
I
NO
I
REPAIR SHORT TO
VOLTAGE IN CKT 33.'
YES
IGNITION "OFF."
INSPECT CKT 33 AND 24-WAY EBCM/EBTCM HARNESS
CONNECTOR FOR DAMAGE WHICH MAY RESULT IN A
SHORT TO VOLTAGE WITH ALL CONNECTORS
IGNITION TO ''RUN."
I
. I
YES
REPLACE
EBCM/EBTCM.
I
NO
I
MALFUNCTION IS MOST
LIKELY DUE TO A POOR
FACING PAGE.
C9798
5E1-152
EBCM/EBTCM
B+
FUSIBLE
STOP/HAZARD
LINK"F"
~!}-C200A
C200D
~:: ~
FUSE1
140 OFH'II
20 AMP
cr-
C'I
C'I
~ A~~
1
B
1
., .,
C200D
C200AS271
O LT BL
OLT BLU
8243
IBRAKIE SWITCH INPUT
BRAKIE SWITCH
ASSEMBLY
CRUISE CONTROL
MODULE
06-01-95
FT027&E
DTC 91
OPEN BRAKE SWITCH DURING DECELERATION
This DTC is used to detect an open brake switch
in the non-ABS mode. The EBCM looks for
deceleration rates that would indicate braking action
and verifies this assumption by requiring several
repeats of this detection method. In each case, ABS
will not be available since a brake switch signal is not
seen.
DTC
wm
Set When:
DTC 91 can be set if three deceleration cycles

occur with the brake switch "OFF."
Action Taken:

1. Indicates if the brake switch signal is being
received by the EBCM.
2. Indicates if an open circuit exists in the brake
switch or brake lamp circuitry.
3. Isolates the open circuit to either the brake switch

input circuitry or the EBCM.
contact.
5. Verifies that voltage is available at the brake
switch.
6. Verifies that the brake switch is functioning
properly.
Diagnostic Aids:
this section.
itltermittent complaint should be thoroughly checked
the wiring harness.
OTC 91
OPEN BRAKE SWITCH
DURING DECELERATION
IS DTC 95 CURRENTLY SET?
I " ' ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,.,,,,,,,,,,.,,,,,,,,.,.,,.,,,.,,,,,,,,,,.,,~
IGNITION TO "RUN."
APPLY LIGHT PRESSURE TO BRAKE PEDAL,
WHILE MONITORING BRAKE SWITCH STATUS
ON TECH 1.
DOES TECH 1 INDICATE BRAKE SWITCH "ON"
WITHIN 1 INCH OF TRAVEL?
j~,,,,,,,,,,,,,,,.,,.,,,,,,,,.,u,,,,,,,,,.,,.,.,.,.,,,,,,,,,,,,,,,,,,,,.,,,.,,.,,,,,,,,,,,.,,,,,,,,,,,,.
PROCEED TO OTC 95 DIAGNOSTIC CHART. j
,I
WITH PRESSURE STILL APPLIED TO BRAKE

PEDAL, OBSERVE REAR BRAKE LAMPS.
ARE BRAKE LAMPS "ON"?
IGNITION "OFF."
IGNITION TO "RUN."
USING J 39200, MEAS.URE THE VOLTAGE BETWEEN
GROUND AND TERMINAL "89" OF THE 24WAY
EBCM/EBTCM HARNESS CONNECTOR WHILE
APPLYING FIRM PRESSURE ON BRAKE PEDAL.
INSPECT 24-WAY EBCM/EBTCM

HARNESS CONNECTOR TERMINAL "89"
EVIDENCE OF CORROSION. REFER TO
SECTION 8A4, "CHECKING TERMINAL
CONTACT." REPLACE ALL TERMINALS
THAT EXHIBIT SIGNS OF TERMINAL
DRIVE VEHICLE AND PERFORM A
MODERATELY HARD ABS STOP.
DOES DTC 91 OR 92 SET AS A
CURRENT DTC?
REPAIR
SHORTED
OR OPEN
CKT 820.

BETWEEN GROUND AND TERMINAL "A" OF
THE BRAKE SWITCH.
USING J 39200, MEASURE THE '

AND TERMINAL "B" OF THE
BRAKE SWITCH WHILE
APPLYING FIRM PRESSURE ON
BRAKE PEDAL.
GREATER?
REPAIR OPEN OR
SHORTED CKT 140
AND REPLACE
STOP HAZARD
FUSE 1.
MISADJUSTED OR FAULTY BRAKE

SWITCH. ADJUST OR REPLACE
SWITCH AS NECESSARY.

TO A POOR CONNECTION. REFER TO
C8048
EBCM/EBTCM
B+
FUSIBLE
L1N1K "F"
STOP/HAZARD
r..., ::: -.rvFuse1 1400RN

--=.:~C200A
C200D
20 AMP
G Er
C1
C1
_ _
A~...-:a
1
BRAKE SWITCH INPUT
GLTB
BRAKE SWITCH
ASSEMEILY
CRUISE CONTROL
MODULE
080115
FT027fiE
OTC 92
OPEN BRAKE SWITCH WHEN ABS WAS REQUIRED
This DTC is run to determine the proper
operation of the brake switch. This is important
because ABS is activated when the brake switch is
"ON." If the brake switch is "OFF," ABS will never
be activated. Since this malfunction is difficult to
detect under normal braking conditions, this
malfunction is only detected when ABS is required.
DTC Will Set When:

DTC 92 can be set if the vehicle's speed is
greater than 8 km/h (5 mph). If the brake was not
"ON" and a release was required on two channels for
0.5 seconds, a malfunction exists.
Action Taken:


contact.
5. Verifies the voltage is available at the brake
switch.
properly.
Diagnostic Aids:
this section.
the wiring harness.
5E1-155
DTC 92
OPEN BRAKE SWITCH WHEN
ABS WAS REQUIRED
,,,,, ,.,,,,,,,,,,,,,,.,,,,,,,,.,u,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,;,,.,.,,,,,,,,,,,,,,,,,,,,.,,,,,.,.,,,,,,,,,,,,,,,,,,,
1, PROCEED TO, OTC 95, DIAGNOSTIC,CHART.j
IGNITION TO "RUN."
APPLY LIGHT PRESSURE ON BRAKE PEDAL,
ON TECH 1.
IGNITION "OFF."
IGNITION TO "RUN."
GROUND AND TERMINAL "89" OF THE 24-WAY
APPLY'ING FIRM PRESSURE ON BRAKE PEDAL.

HARNESS CONNECTOR TERMINAL
"89" FOR POOR TERMINAL CONTACT
AND EVIDENCE OF CORROSION.
REPLACE ALL TERMINALS THAT
EXHIBIT SIGNS OF TERMINAL
DOES OTC 91 OR 92 SET AS A
CURRENT OTC?
REPAIR
SHORTED
OR OPEN
CKT 820.

THE BRAKE SWITCH.

TERMINAL "B" OF THE BRAKE
SWITCH WHILE APPLYING FIRM
PRESSURE ON BRAKE PEDAL.
GREATER?
REPAIR OPEN OR
SHORTED CKT 140
AND REPLACE STOP
HAZARD FUSE 1.


C8049
5E1-156
EBCM/EBTCM
B+
FUSIBLE
LINK "F"
ST0,111/HAZARD
r...,
e-:L.cz....1-
~o:~ ~
C200A
C200D
FUSE1
20 AMiii
1400RN
C1
C
- .....:!
A~~B
1
OLTBL
C20CD
CZOCA
243
s211
OLTBLU
BRAKE SWITCH l'NPUT
.. . . .
BRAKE SWITCH
ASSEM,BLY
CRUISE CONTROL
MODULE
OfH>195
FT027&E
DTC 93
DTC 91 OR 92 SET IN CURRENT OR PREV. IGN CYCLE
Diagnostic Aids:
This DTC is the second portion of DTCs 91 and

92. If DTCs 91 or 92 failed during the last ignition
cycle, DTC 93 becomes a current failure during the
next ignition cycle, keeping ABS disabled until a
brake switch "ON" state is seen. When a change is
seen during an ignition cycle in which DTC 93 is a
current malfunction, DTC 91 or 92 will clear itself at
the end of the current ignition cycle, and ABS and
will be enabled at the start of the next ignition cycle.
DTC 93 alone indicates 91 or 92 failed previously, but
is intermittent, or has been corrected.

this section.
the wiring harness.
Also, verify proper brake switch operation using
the data list of the Tech 1. As the brake is applied, the
data list should display the brake switch "ON" within
1 inch of travel.

1. Indicates which DTC (either 91 or 92) caused
DTC 93 to set.
5E1-157
DTC 93
DTC 91 OR 92 SET IN CURRENT
OR PREV. IGN CYCLE
IGNITION TO "RUN."
IS OTC 91 OR 92 SET AS A HISTORY OR CURRENT OTC?
USING TECH 1, SELECT "F1:

OTC HISTORY," VERIFY
MALFUNCTION FREQUENCY
WAS LOW AND CLEAR DTCs.
C7405
5E1-158
EBCM/EBTCM
B+
CRUISE CONTROL
MODULE
Ol01H
FT027&E
DTC 94
BRAKE SWITCH CONTACTS ALWAYS CLOSED
"ON" and deactivated when the brake switch is
"OFF." If the brake switch is always "ON," ABS
operation will always be requested resulting in
potential modulator cycling on rough roads.
OTC Will Set When:
DTC 94 can be set when the vehicle reaches at
least 40 km/h (25 mph). If the brake was never
"OFF" during two consecutive drive cycles, a
malfunction exists.
Action Taken:
disabled.

1. Checks if the malfunction is currently present.
2. Isolates the cause of the malfunction to either a
malfunctioning or misadjusted brake switch, or a
short to voltage in the brake switch circuitry.
3. Checks for unwanted voltage on the brake switch
input circuit.
4. Checks for a possible intermittent malfunction.
Diagnostic Aids:
this section.
the wiring harness.
5E1-159
DTC 94
BRAKE SWITCH CONTACTS
ALWAYS CLOSED
IGNITION "OFF."
OBSERVE REAR CENTER HIGH MOUNTED
STOP LAMP (CHMSL).
ARE THE CHMSL LAMPS "OFF"?
UNPLUG BRAKE LAMP SWITCH

CONNECTOR.
REPAIR
SHORT TO
VOLTAGE
ON CKT 820.
MISADJUSTED OR
MALFUNCTIONING
BRAKE SWITCH;
ADJUST OR REPLACE
SWITCH AS
NECESSARY.
DISCONNECT 24-WAY EBCM/EBTCM HARNESS CONNECTOR.

IGNITION TO "RUN."
USING J 39200, MEASURE VOLTAGE BETWEEN TERMINAL
"B9" OF 24-WAY EBCM/EBTCM HARNESS CONNECTOR AND
GROUND.
IGl'jlTION "OFF."
INSPECT 24~WAY EBCM/EBTCM
HARNESS CONNECTOR
TERMINAL "B9" FOR POOR
.
CONTACT.
START ENGINE AND TEST DRIVE
VEHICLE, ACHIEVING AT LEAST
40 km/h (25 MPH).
REPEAT ABOVE DRIVE CYCLE
SEQUENCE TWO MORE TIMES.
DID DTC 94 SET IN THE LAST
THREE DRIVE CYCLES?
REPAIR SHORT
TO VOLTAGE
IN CKT 820.
MALFUNCTION IS NOT
PRESENT AT 'THIS TIME,
C8050
5E1-160
EBCM/EBTCM
B+
FUSl,BLE
LIN!K "F"
STOP/HAZARD
FUSE 1
1400RN
20 AMP
e{c~ i:~ ~.
C200A
C20ID
G Er
C1
C1
- -
A~~B
I
I

BRAKE SWITCH
ASSEMBLY
OLTBL
C20ID
c2ooA
243
8271
OLTBLU
BRAKE SWITCH IN,PUT
CRUISE CONTROL
MODULE
0801-95
FT0275E
DTC 95
BRAKE SWITCH CIRCUIT OPEN
This DTC is used to identify open. brake switch

circuitry that prevents the brake switch input to the
EBCM from changing states when the brake is
applied. This DTC is used in conjunction with DTCs
91 and 92 to determine the cause of an open brake
switch malfunction.

1. Is used to confirm that an open in the brake
switch circuitry currently exists.
DTC Will Set When:

DTC 95 can be set after initialization is
completed. If the brake switch input voltage is out of
specification for one second indicating an open circuit,
Action Taken:
Diagnostic Aids:
this section.
the wiring harness.
5E1-161
DTC 95
ARE ANY OTHER BRAKE SWITCH DTCs CURRENTLY SET?
I'"'
IGNITION TO "RUN."
USING TECH 1, SELECT "FO: DATA LIST" AND MONITOR
BRAKE SWITCH STATUS.
DOES TECH 1 INDICATE THAT BRAKE SWITCH IS OPEN?
APPLY LIGHT PRESSURE ON BRAKE PEDAL WHILE

MONITORING BRAKE SWITCH STATUS ON TECH 1.
,,,,,,,,,,,,,,,,,,,,,u,u,,,,,,,,,,1,,,,,,,,,,,,,1,,,,,,,,,,,,,,,,,,,,,,,,,,,,,u,,1,,,,,,1
j PROCEED TO THAT OTC DIAGNOSTIC CHART. l

l;1,;;;;11,,,,,,,,,u,ui1ii,;11111,,,,.,,.,,.,,,.,.,,,.,,.,,,,,,.,.,,,.,,.,,,,..,,,,,.,,,,1111,,,,,,;.;;;11111,,,,,,,,I

REPAIR OPEN CHMSL LAMP CIRCUIT

AS DIRECTED IN SECTION SA-110.
IGNITION "OFF."
IGNITION TO "RUN."
CHECK FOR POOR TERMINAL CONTACT

AT EBTCM.
IF OK, REPLACE EBCM/EBTCM.
C8051
5E1-162
DIAGNOSIS/MISC. TEST (F4)

MANUAL CONTROL (FO)
This function can be used to manually control
the ABS VI motors and solenoids.
Motor Test (Apply/Release)

Each motor can be manually turned "ON" for
up to 5 seconds, at a current of 10 amps applied
(forward) or 6 amps released (reverse). After runn~g
the motors, the command and feedback currents will
be stored in a snapshot buffer. This information can .be
reviewed when instructed to do so by the service
manual, 'to determine if the motors are operating
properly.
The test below describes how the front motors
will normally operate, the rear mo~or can be teste~ in
a similar manner, except there will be only a shght
pedal drop (bump) and rise during the test.
1. Ignition "OFF."
2. Install Tech 1 with MSC.
3. Ignition to "RUN," engine "OFF."
4. Pump brake pedal until firm to deplete vacuum
from power booster.
5. Select manual control.
6. Depress and hold brake pedal.
7. Using the Tech 1, "Release" one of the ABS
motors. The brake pedal should move smoothly
toward the floor. As the pedal drops, the feedback
current should momentarily drop to only a few
amps (indicating motor movement) and then
become equal to co~and current (6. amp.s): This
indicates the motor is no longer movmg smce the
piston has reached the bottom of the bore.
8. With the brake pedal .still depressed and at the
floor, "Apply" the same A~S motor. The brake
pedal should now smoothly nse back to the top of
its travel. The feedback current should
momentarily drop to a few amps, then quic~y
increase to the command current (10 amps). This
indicates the motor is no longer moving since the
piston has reached the top of the bore. ("home"
position).
Solenoid Test ("ON/OFF")

you
1.
2.
3.
4.
5.
6.
7.
8.
Only use this test when no DTCs are stored and

suspect a leaky ABS solenoid or check valve.
Ignition "OFF."
Install Tech 1 with MSC.
Ignition to "RUN," engine "OFF."
Pump brake pedal and deplete vacuum from
power booster.
Select manual control (FO).
Select left front or right front motor release.
"Release" the motor for the channel being tested.
Review the motor command and feedback
currents to be sure the motor released properly.
Refer to "Motor (Apply/Release)" in this section.
Select the solenoid for the same channel as that
being tested.
9. With no brake pedal pressure applied, turn the

solenoid "ON."
10. Depress the brake pedal. It should be very high
and firm.
If the pedal goes nearly to the floor, the
solenoid is leaking or not closing and/or the
check valve is leaking, proceed to Step 12.
I 1. With brake pressure still applied, tum the solenoid
"OFF." The brake pedal should move toward the
floor. This verifies normal solenoid operation.
END OF TEST.
If the pedal does not move toward the floor,
the solenoid is stuck "ON," proceed to Step
12.
12. Verify that the solenoid connectors are connected
to the proper solenoids, (the right front solenoid is
the one on the rear of the ABS hydraulic
modulator, closest to the brake booster). If the
wiring is incorrect, move th~ co~nectors to ~e
proper solenoid and repeat this entire test startmg
with Step 1.
.
.
A. Physically switch the two solenoids.
B. Repeat the entire test starting at Step 1 for the
channel in question.
If the test. now works properly, test the other

channel. If the test fails for this channel,
replace the solenoid currently installed in this
channel. Refer to "ABS Hydraulic Modulator
Solenoid" under "On-Vehicle Service" in this
section.
If the test fails for the same channel, the check
valve is leaking, Replace ABS hydraulic
modulator. Refer to "ABS Hydraulic
Modulator" under "Unit Repair" in this
section.
(]] Important
After performing Step 12; it is necessary to bleed
the brake system. Refer to "Bleeding Procedure"
in this section.
HYDRAULIC CONTROL TEST (F2)

This test is used to verify base brake apply and
ABS release, hold, and apply function.
1. Ignition "OFF."
2. Raise the vehicle such that all wheels to be tested
are off the ground.
.
"OFF," vehi'cle
4. Igmt10n
to "RUN , " engme
transmission in neutral.
5. Select a channel to test; left front, right front, or
rear. When testing the rear brakes, both rear
wheels should rotate or not rotate simultaneously
at various points in the test; this is true because
both rear brake pressures are controlled together..
6. Firmly depress brake pedal. Pedal should remain
high and firm.
7. Have an assistant attempt to rotate the wheel
being tested. If the wheel does not rotate, base
brake apply is working properly.

8. With the brake pedal still depressed, press the =
key on the Tech 1 to start the test. The Tech 1
will display "Release" on the screen. Your
assistant should be able to rotate the wheel being
tested during the release portion of the test
(approximately 2 seconds long). This verifies ABS
pressure release. The brake pedal should remain
high and firm. (If the brake pedal moves toward
the floor, verify the solenoid electrical connectors
are connected to the correct solenoids.)
9. The Tech 1 will switch to the "Hold" mode and
display the word "Hold" on the screen along with
an 18 second decrement counter. With the brake
pedal still depressed, have your assistant attempt
to rotate the wheel. The wheel should rotate for
the full 18 seconds of the test. If the wheel does
not rotate for the full 18 seconds it could indicate
that either the check valve or the solenoid may be
leaking. This verifies ABS pressure hold.
10. When the hold portion of the test is complete,
brake pressure will be applied and a slight bump
may be felt in the pedal. This is normal. The
assistant should not be able to rotate the wheel at
this point. This verifies ABS apply.
MOTOR TEST (F4)

Once the motor pack has been separated from
the hydraulic modulator, this test will help determine
if the motor pack is operating properly.
The Tech 1 will rotate the motors in one
direction; then the other.
If any motor does not turn in both directions, the
motor pack is malfunctioning and must be
replaced. The motor pack is not serviceable and
must be replaced as an assembly. Refer to "Motor
Pack" under "Unit Repair" in this section.
If all three ABS motors and both TCS motors
rotate, try to rotate each gear on the hydraulic
modulator, refer to "No Gear Movement" in this
section.
NO GEAR MOVEMENT
After the ABS motor pack has been removed,
rotate each gear by hand on the ABS hydraulic
modulator (unit with large gears). The front gears
(non-center gears) should be able to be rotated
approximately 12.25 full turns lock to lock. If the gear
does not turn freely or at least 12 turns are not
possible, replace the ABS hydraulic modulator.
The rear gear (center gear) should rotate
approximately 7 .25 turns. If the gear does not turn
freely or at least 7 turns are not possible, replace the
ABS hydraulic modulator.
Refer to "ABS Hydraulic Modulator" under

"Unit Repair" in this section if replacement of the
ABS hydraulic modulator is indicated above.
GEAR TENSION RELIEF (FS)
When the displacement cylinder pistons are in
the "home" position, each motor has prevailing
torque. This torque results in "gear tension," or force
5E1-163
on each gear that .makes motor pack separation

difficult. To avoid injury, or damage to the gears, the
"Gear Tension Relief Function" briefly reverses each
motor to eliminate the prevailing torque.
Always perform the "Gear Tension Relief
Function" prior to removing the ABS hydraulic
modulator/motor pack assembly from the vehicle.
RELAY TEST (F6)

This test allows the user to turn the relay "ON"
and "OFF" using the "UP ARROW" and the
"DOWN ARROW" keys on the Tech 1. The battery
voltage supplied to the EBCM through the relay
contacts is displayed on the screen during the test.
When the relay is commanded "ON,'' the
voltage should be equal to the battery voltage. When
the relay is "OFF," the voltage should drop below 2
volts.
NOTICE: Voltage will not drop to zero when
the relay contacts are open due to capacitors in
the EBCM. If voltage drops below 2 volts, the
relay is operating properly.
VOLTAGE LOAD TEST (F7)

The ABS VI system can draw significant
amounts of current when operating. This test turns
"ON" many of the system components to load-test the
vehicle's electrical system.
If low voltage malfunctions or intermittent ABS
operations are occurring, this test will allow you to
monitor the ignition and switched battery inputs to the
EBCM. If only one of these two inputs drops .below
10 volts during testing, a high resistance may be
present in that power feed circuit. If both inputs drop
below 10 volts the vehicle's electrical system needs to
be diagnosed. In either case, the Tech 1 will display
that the "Voltage Load Test'' failed.
LAMP TEST (F8)
This test allows the user to control the
warning/indicator lamps associated with ABS VI. It
can be used to check. the lamp circuits. The amber
ABS lamp can be turried "ON" or flashed. The red
"BRAKE" warning lamp and the amber "LOW
TRAC" lamp can be turned "ON" and "OFF."
SYSTEM ID (F9)
This feature is used to determine the ABS VI
version and to provide manufacturing information on
the EBCM.
MOTOR REHOME (FS)
The motor rehome function is initiated by
pressing the F5 key from the Tech 1 "Select Mode"
menu. The motor rehome function must ALWAYS be
used prior to bleeding the brake system. This function
will return all of the hydraulic modulator pistons to
their upmost or "home" position. This allows all fluid
paths within the modulator to be open so that the
modulator can be properly bled.
5E1-164
ON-VEHICLE SERVICE
CHECKING AND ADDING FLUID

SERVICE PRECAUTIONS
following actions:

due to poor braking, DO NOT tap into the
vehicle's brake system to operate a
trailer brake system.
NOTICE: Always use the correct fastener in
fasteners that require thread lockers or thread
fasteners o.r fastener joint interfaces. Generally,
such coatmgs adversely affect the fastener
torque and joint clamping force, and may
damage the fastener. When you install fasteners,
help avoid damage to parts and systems.
NOTICE: The use of rubber hoses or parts
other than those specified for the Antilock
Brake System (ABS) may lead to functional
problems requiring replacement of the hydraulic
p~rts. Replace all c?mpon~nts included in repair
kits used to service this system. Lubricate
rubber parts with clean, fresh brake fluid to ease
assembly. Do not use lubricated shop air on
brake parts as damage to rnbber components
may result. If any hydraulic component is
removed or brake line disconnected, it is
necessary to bleed all or part of the brake
system. The fastener tightening specifications
listed are for dry, unlubricated fasteners.
NOTICE: Use only Supreme 11
(GM 1052542) or equivalent DOT 3 brake fluid.
The use of DOT 5 (silicone) brake fluid is not
recommended. Reduced braking performance or
durability may result.
el~ctrical connectors. Brake fluid will damage
pamt and electrical connections. If any fluid is
damage.
FLUSHING PROCEDURE
[I]
Important
If evidence of contamination is present in the

vehicle's brake fluid, the entire brake system must
be flushed following one of the procedures
outlined below.
After flushing the entire brake system, all rubber
components must be replaced. Components which
must be replaced include: brake hose assemblies
master C)'.linder rubber parts, brake caliper and
wheel cylmder boots and seals, combination valve
assembly, ABS hydraulic modulator, TCS
hydraulic modulator and ABS solenoids. Refer to
the proper "On-Vehicle Service" for replacement
procedures.
After all rubber components have been replaced
the entire brake system must be re-flushed
following one of the procedures outlined below.
Once the second flushing procedure has been
performed, a complete system bleed must be
performed, refer to "Bleeding Procedure" in this
section.

from a clean, sealed container. Do not use any
fluid from a container which is wet with water.
Do not use DOT 5 silicone brake fluid.
Improper brake fluid, mineral oil (from such
things as engine oil, transmission fluid, etc.), or
water in the brake fluid may cause the brake
fluid. to boil or the rubber components to
deteriorate. Keep all fluid containers capped to
prevent contamination.
ab?ut the condition of fluid in the system or if
flmd has been used which contains the slightest
trace of mineral oil (from such things as engine
oil, transmissi~n fluid, etc.).
Flushing Preparation
NOTICE: The flushing prep procedure must
be performed prior to using "Pressure Flush"
or "Manual Flush" procedures.
[I]
Important
Do not place your foot on the brake pedal through

this entire procedure unless specifically directed to
do so.
1. Remove foot from brake pedal.
2. Start engine and allow it to run for at least
10 seconds while observing the amber ABS
warning lamp.

3. If the amber ABS warning lamps turned "ON"
and stayed "ON" after about 10 seconds, the
flushing procedure must be stopped and a Tech 1
must be used to diagnose the ABS malfunction.
4. If the amber ABS warning lamps turned "ON"
for approximately 3 seconds, then turned "OFF"
and stayed "OFF," turn the ignition "OFF."
5. Repeat Steps 1 through 4 one more time.
6. The entire brake system should now be flushed
following' either "Pressure Flush" or "Manual
Flush" outlined below.
Pressure Flush
D. Repeat above procedure for the forward

bleeder valve until clean brake fluid flows or
until at least 118 ml (4 ounces) of fluid is
accumulated.
!~!
rn
11.
Clean
1. Fluid reservoir cover and surrounding area.
!+-+!
2. Fluid reservoir cover.

3. Any remaining brake fluid in reservoir.
!L!
Inspect
4. Refill reservoir with clean DOT 3 brake fluid to

proper level.
!H!
Install or Connect
5. Bleeder adapter J 35589 to brake fluid reservoir.

6. Bleeder adapter to pressure bleeding equipment.
tll
Adjust
7. Pressure bleeding equipment to 35-70 kPa

(5-10 psi) and wait for approximately 30 seconds
to insure there is no leakage.
8. Pressure bleed equipment to 205-240. kPa
(30-35 psi).
9. Proceed as follows with pressure bleeding

equipment connected and pressurized:
A. 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
to collect draining brake fluid. Do not
submerge hose end into fluid.
B. Slowly open bleeder valve and allow fluid to
flow until clean brake fluid flows or until at
least 118 ml ( 4 ounces) of fluid is
accumulated.
C. Close valve.
Tighten
ABS hydraulic modulator bleeder valve to

9 N.m (80 lb. in.).
10. Raise vehicle and suitably support.
Tool Required: J 35589, Bleeding Adapter
NOTICE: Pressure bleeding equipment can be

used to perform the flush procedure. The
pressure bleeding equipment used for flushing
must be of the diaphragm type. It must have a
rubber diaphragm between the air supply and
the brake fluid to prevent air, moisture, and
other contaminants from entering the hydraulic
system.
5E1-165
12.
13.
14.
15.
16.
17.
18.
!L!
Important
Flush sequence:
- Right rear.
- Left rear.
- Right front.
- Left front.
Flush wheel brakes in sequence shown above.
A. Attach bleeder hose to bleeder .valve at each
wheel and place the other end into a container
submerge hose end in fluid.
flow.
C. Close valve when clean brake fluid begins to
flow or at least 235 ml (8 ounces) of fluid is
accumulated.
Repeat Step 11 on left rear wheel brake.
Repeat Step 11 on right front wheel brake.
Repeat Step 11 on left front wheel brake.
Lower vehkle.
Remove bleeder adapter.
Replace all rubber components listed under
"Flushing Procedure," refer to the appropriate
"On-Vehicle Service" section.
Repeat flushing preparation and flushing
procedure Steps 4-16 one more time.
Inspect
19. Fluid level in reservoir and fill to correct level if

necessary.
!++!
Install or Connect
20. Fluid reservoir cap.

21. Bleed the entire brake hydraulic system; refer to
"Bleeding Procedure" in .this section.
Manual Flush
[1J
Important
In the following steps, use a suitable container

and/or shop rags to catch fluid and prevent it from
contacting any painted surfaces.
Clean
5E1-166
!++!

D. Close valve and release brake pedal. Repeat
above steps until clean brake fluid flows or at
least 118 ml (4 ounces) of fluid is
accumulated.
E. Repeat above procedure for the forward
at least 118 ml (4 ounces) of brake fluid is
accumulated.

!L!
Inspect

proper level.
!++!
I~!
Install or Connect

6. Flush ABS hydraulic modulator as follows:
A. Attach a clear plastic bleeder hose to rearward
bleeder valve on the ABS hydraulic modulator
and place the other end of hose in a container
B. Slowly open rearward bleeder valve one half
to one full turn.
C. Depress brake pedal until fluid begins to flow.
Tighten
ABS hydraulic modulator bleeder valves to

9 N.m (80 lb. in.).
j++j
IL!
Inspect

necessary.
1 HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY
3 UNDl!RHOOD l!Ll!CTFIICAL Cl!NTl!R
2 LEFT HAND WHEELHOUSE
0811-91
FS034Si
Figure 10 ABS Hydraulic Modulator/Motor Pack Assembly
5E1-167
12.
13.
14.
15.
16.
Repeat Step 11 on left rear brake.

Repeat Step 11 on right front brake.
Repeat Step 11 on left front brake.
Lower vehicle.
Replace all rubber components listed under
17. Repeat flushing preparation and flushing
!l"'!
Inspect
18. Fluid level in reservoir. and fill to correct level if

necessary.
15-1894
FS0355E
!H!
Install or Connect

"Bleeding Procedure" in this section.
Figure 11 Gear Removal (Typical)
BLEEDING SYSTEM
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.
5-18-94
FS0385E
Figure 12 - Gear Positioning (Typical)
!H!
Install or Connect

[I]
Important
Flush sequence:
- Right rear.
- Left rear.
- Right front.
- Left front.
11. Flush wheel brakes in sequence shown above.
A. Attach bleeder hose to bleeder valve at each
B. Open bleeder valve.
C. Slowly depress brake pedal.
D. Close valve and slowly release brake pedal.
E. Repeat above procedure until clean brake fluid
flows or at least 235 ml (8 ounces) of fluid is
accumulated.
NOTICE: Use. only Supreme 11

fluid to boil or the . rubber components to
damage.
NOTICE: Prior to bleeding the brakes, the
front and rear displacement cylinder pistons
must be returned to the topmost position. The
preferred method uses a Tech 1 to perform the
rehoming procedure. If a Tech 1 is not
available, the second procedure may be used,
but it is extremely important that the procedure
be followed exactly as outlined.
With Tech 1 {Preferred Method)

1. Using a Tech 1, select "F5: Motor Rehome." The
motor rehome function cannot be performed if
current DTCs are present. If DTCs are present,
the vehicle must be repaired and DTCs cleared
before performing the motor rehome function.

2. The entire brake system should now be bled
following either "Pressure Bleeding" or "Manual
Bleeding" outlined below.
Without Tech 1
NOTICE: This method can only be used if the
amber ABS warning lamp is not illuminated and
no DTCs are present.
rn
Important
Do not place your foot on the brake pedal through

do so.
2. Start engine and allow it to run for at least 10
seconds while observing the amber ABS warning
lamp.
3. If the amber ABS warning lamp turned "ON"
bleeding procedure must be stopped and a Tech 1
must be used to diagnose the ABS malfunction.
4. If the amber ABS warning lamp turned "ON" for
approximately 3 seconds, then turned "OFF" and
stayed "OFF," turn the ignition "OFF."
6. The entire brake system should now be bled
Pressure Bleeding

fluid to boil or the rubber components to
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.
Clean
l+-+I
IL"'I
Inspect
3. Fluid to be at proper level. Refer to

SECTION SA. Add clean brake fluid as required.
lHI
Install or Connect

Adjust
6. Pressure bleed equipment to 35-70 kPa (5-10 psi)

and wait for approximately 30 seconds to insure
there is no leakage.
7. Pressure bleed equipment to 205-240 kPa (30-35
psi).
A. Attach a clear plastic bleeder hose to the
rearward bleeder valve on the ABS hydraulic
modulator. Submerge opposite hose end in a
clean container partially filled with clean brake
fluid.
flow until no airis seen in fluid.
C. Close valve when fluid flows without any air
bubbles.
D. Repeat Steps 9B and 9C until no air bubbles
are present.
E. Relocate the bleeder hose on the forward ABS
hydraulic modulator bleeder valve and repeat
Steps 9A through 9D.
I~!
Tighten
ABS hydraulic modulator bleeder valves to 9

N.m (80 lb. in.).
[I]
Important
Use a shop cloth to catch escaping brake fluid.

Take care to prevent fluid from running down
motor pack and entering the motor pack base
or into the electrical connector. Also, do not
allow brake fluid to contact any painted
surfaces as surface damage will occur. If brake
fluid does contact any surface, flush surface
with water to lessen damage.
9. Proceed to bleed the master cylinder brake
connections as follows with pressure bleeding
A. Slowly loosen the forward brake pipe tube nut
on the master cylinder and check for air in
escaping fluid.
B. When air flow ceases, immediately tighten
tube nut.
!~I
Tighten
Master cylinder tube nut to 32 N.m (24 lb. ft.).

C. Repeat Steps 1OA and 1OB for the rearward
master cylinder brake pipe connection.

10. Proceed to bleed the brake combination valve
on the brake combination valve and check for
air in escaping fluid.
tube nut.
!~!
Tighten
Brake combination. valve tube nut to 18 N.m

(13 lb. ft.).
C. Repeat Steps llA and llB for the rearward
brake combination valve pipe connection.
11. Proceed to bleed the ABS hydraulic modulator
brake connections as follows with pressure
bleeding equipment connected and pressurized:
A. Slowly loosen the forward. brake pipe tube nut
on the ABS hydraulic modulator and check for
tube nut.
l~!
Tighten
ABS hydraulic modulator tube nut to 32 N,m

(24 lb. ft.).
C. Repeat Steps 12A and l2B for the remaining
ABS hydraulic modulator brake pipe
connections, moving from front to rear.
13. Proceed as follows to bleed the rear wheel brakes:
A. Attach a clear plastic bleeder hose to the right
rear wheel bleeder valve and submerge
opposite hose end in a clean container partially
filled with clean brake fluid.
flow.
C. Close valve when fluid begins to flow without
any air bubbles. Tap lightly on the caliper or
backing plate to dislodge any trapped air
bubbles.
D. Relocate bleeder hose to the left rear wheel
bleeder valve and repeat Steps 13A through
16C.
14. Remove pressure to the pressure bleeding
equipment.
15. Attach a clear plastic bleeder hose to the right
front wheel bleeder valve and submerge opposite
hose end in a clean container partially filled with
clean brake fluid.
16. Tum the ignition to "RUN," engine "OFF."
17. Open the bleeder valve and apply the brake until
the red "BRAKE" warning lamp turns "ON."
This. shuttles the. brake pressure differential
warning valve.
18. Close bleeder valve.
19. Reapply pressure to pressure bleeding equipment.
5E1169
20. Tum the ignition "OFF."
II]
21.
22.
23.
24.
25.
Important
Do not reapply the brakes after closing the

bleeder valve.
Lower vehicle.
Repeat the entire Step 8.
Raise vehicle and suitably support.
Proceed as follows to bleed the front wheel
brakes:


front wheel bleeder valve and submerge
flow.
any air bubbles. Tap lightly on the caliper to
dislodge any trapped air bubbles.
D. Relocate bleeder hose to the left front wheel
25C.
26. Lower vehicle.
27. Remove pressure bleeding equipment, including
bleeder adapter J 35589.
ll!
Inspect
.28. Fluid level in reservoir and fill to proper level if

necessary.
!H!
Install or Connect
!L!
Inspect
30. With ignition to "RUN" apply brake pedal with

moderate force and hold. Note pedal travel and
feel.
If pedal feels firm and constant and pedal
travel is not excessive, start the engine. With
the engine running, recheck the pedal travel. If
it's still firm and constant and pedal travel is
not excessive, go to Step 31.
If pedal feels soft or has excessive travel either
initially or after the engine is started, the
following procedure may be used. With the
Tech 1, "Release" then "Apply" each ABS
motor 2 to 3 times and cycle each ABS
solenoid 5 to 10 times. This procedure will
ensure all trapped air has been removed from
the ABS hydraulic modulator bores. Now
repeat bleeding procedure starting at Step 1.
31. Road test the vehicle.
Make several normal (non ABS) stops from a
moderate speed to ensure proper brake system
function. Allow adequate cooling time between
stops.
5E1-170
Manual Bleeding
fluid to boil or the rubber components to
rn
Important
l++j
ll'I'!
I++!
[I]
Clean
10.
IL!
Inspect
3. Fluid level in reservoir and fill to the correct level

if necessary.
j++!
Install or Connect

5. Prime ABS hydraulic modulator as follows:
A. Attach clear plastic bleeder hose to the
fluid.
to one full turn.
C. Depress brake pedal and hold until fluid
begins to flow.
D. Close valve and release brake pedal.
E. Repeat Steps 5B and 5D until no air bubbles
are present.
F. Relocate the bleeder hose on the forward ABS
Steps 5A through 5E.
rn
Important
Once fluid is seen to flow from both ABS

hydraulic modulator bleeder valves, the ABS
hydraulic modulator is sufficiently full of fluid.
However, it may not be completely purged of
air. At this point move to the wheel brakes and
bleed them. This ensures that the lowest points
in the system are completely free of air and
then the ABS hydraulic modulator can be
purged of any remaining air.
Install or Connect

9. Raise vehicle and suitable support.
j++j
Inspect

if necessary.

and/or shop cloths to catch fluid and prevent it
from contacting any painted surfaces.
11.
12.
13.
14.
f++!
Important
Bleed sequence:
- Right rear.
-Left rear.
- Right front.
- Left front.
Bleed wheel brakes in sequence shown above.
bleeder valve at each wheel and submerge
E. Wait 5 seconds.
F. Repeat Steps 1OB through 1OE until the brake
pedal feels firm and no air bubbles are
observed in the bleeder hose.
To assist in freeing entrapped air, tap
lightly on caliper or backing plate with a
rubber mallet.
Repeat Step 10 on left rear wheel brake.
Repeat Step 10 on right front wheel brake.
Repeat Step 10 on left front wheel brake.
Lower vehicle.
!L!
Inspect

if necessary.
l++l
Install or Connect

18. Bleed the ABS hydraulic modulator.
fluid.
B. Depress brake pedal with moderate force.
C. Slowly open rearward bleeder valve one half
to one full turns and allow fluid to flow.
5E1
_.t't"f
E. Wait 5 seconds.
F. Repeat Steps 18B through 18E until the no air
bubbles are observed in the bleeder hose.
G. Relocate the bleeder hose on the forward ABS
Steps 18A through 18F.
j~!
Tighten

9 N.m (80 lb. in.).
!++!
!L'l'l
Inspect

if necessary.
!++!
Install or Connect
!L"'!
2 FORWARD BI.IEIEDIER VALVE

feel.
solenoid 5 to 10 times. When finished, be sure
to "Apply" the front and rear motors on the
ABS hydraulic modulator. This procedure will
ensure all trapped air has been removed from
the ABS hydraulic modulator bores. Now
repeat bleeding procedure starting at Step 1.
Make several normal (non-ABS) stops from a
moderate speed to en$ure proper brake system
stops.
ABS HYDRAULIC MODULATOR BLEEDER

VALVES
Figure 13
!++l
Damaged bleeder valve or valves.
!-++!
1 REARWARD IBI.EIEDIER VALVE
Inspect
Install or Connect
New bleeder valve or valves.
15-19-94
f803751E
Figure 13 - ABS Hydraulic Modulator Bleeder Valve

Locations
!~!
Tighten
Bleeder valve to 9 N.m (80 lb. in.).
ABS HYDRAULIC MODULATQR SOLENOID

flgure 14
i++!
1. Solenoid electrical connector.

2. Torx head bolts.
3. Solenoid.
[I]
Important
Be sure the seal is still attached to the solenoid

when it is removed. If not, check solenoid bore in
modulator.
Do not attempt to disassemble solenoid, it is
serviceable only as an assembly.
Lubricate seal on new solenoid with clean brake
fluid.
!++I
Install or Connect
1. New solenoid.
Verify that the solenoid lip seal is properly
positioned before solenoid is installed in ABS
hydraulic modulator (refer to Figure 14).
5E1172
(
1 SOLENOID UP SEAi.
2 SOLENOID
3 TORX HEAD BOLT

4 HYDRAULIC I\IODULATOR/MOTOR
PACK ASSEMBLY
IM984
F803aaE
Figure 14 - Hydraulic Modulator Solenoid Removal
Position solenoid so that its electrical

connector will face the same direction as the
solenoid that was removed.
By hand, press down firmly on solenoid until
its flange seats on ABS hydraulic modulator.
2. Torx head bolts.
I~!
Tighten
Bolts to 4.5 N.m (40 lb. in.).

3. Solenoid electrical connector to solenoid.
[I]
Important
Make sure the solenoid connectors are installed on

correct solenoids.
It is necessary to bleed the entire system. Refer to
"Bleeding System" in this section.
ABS HYDRAULIC MODULATOR/MOTOR

PACK ASSEMBLY
Figure 10
CAUTION: To help avoid personal injury,

due to a retained load on the ABS
hydraulic modulator, the gear tension
relief function of the Tech 1 must be
performed prior to the removal of the
j+-+!
1. Using Tech 1, perform "Gear Tension Relief

Sequence," as outlined in this section.
2. Air cleaner duct assembly.
3. Two solenoid electrical connectors.
4. Brake pressure differential warning switch
electrical connector.
5. 6-pin motor pack electrical connector.
5E1-173
6. Five brake pipes (two to master cylinder, three to

wheel brakes).
Place shop cloth on top of motor pack to catch
any dripping fluid. Take care not to allow any
brake fluid to enter the bottom of the motor
pack or the electrical connectors. Plug open
brake pipes to prevent fluid loss and
contamination.
7. Bolt attaching front of ABS hydraulic
modulator/motor pack assembly to frame rail.
8. ABS hydraulic modulator/motor pack assembly
from vehicle.
!H!
Install or Connect
rJ
1. ABS hydraulic modulator/motor pack assembly in

vehicle.
2. Bolt attaching ABS hydraulic modulator/motor
pack assembly to frame rail.
!~!
Tighten
1 EBTCM AND IFIACK!T
Bolt to 9.0 N.m (80 lb. in.).

Five brake pipes to ABS hydraulic
modulator/motor pack assembly.
6-pin motor pack electrical connector.
Brake pressure differential warning switch
Two solenoid electrical connectors.
Air cleaner duct assembly.
3.
4.
5.
6.
7.
11]
Important
Bleed entire brake system as outlines in

I~!
Tighten
Two brake combination valve tube nuts to 18 N,m

(13 lb. ft.).
Three hydraulic modulator tube nuts to 32 N,m
(24 lb. ft.).
2
3
4
S
p\cAUTION
Replace with
Recommended
Port Number
Only
Control modules that appear

similar may not operate the
some under all conditions. To
help ovoid personal injury due
to improper broke operation,
replace this module only with
port specified for this vehicle.
LEFT HAND KICK PANEL

PUSH-IN Fl!TAINEFI
MOUNTING STUD AND NUT
IM994
1'$039511!
!++!
Figure 15 - EBCM Location
1. Fasteners on lower sound insulator panel under

steering column.
2. Lower sound insulator panel from vehicle.
3. Manual transmission only: left side kick panel.
4. Nut attaching EBCM bracket to upper I/P.
5. Push in retainer ("Christmas Tree") attaching
EBCM bracket to side wall.
11]
ELECTRONIC BRAKE CONTROL MODULE

(EBCM)
Figure 15
HTCM HAFINl!SS
6.
7.
8.
9.
Important
It will be necessary to cut. the push-in retainer

head off to remove EBCM bracket. Do not
attempt to pry fastener out as damage to the
EBCM bracket may result.
EBCM and EBCM bracket from mounting place.
EBCM electrical connectors.
EBCM from vehicle.
Remaining portion of push-in retainer.
11]
Important
It is necessary to remove the destroyed retainer

to insure proper retaining force when installing
the new push-in retainer.
!++I
Install or Connect
10-215-94
ATHtl5E
1. EBCM electrical connectors.
5E1-174
2. EBCM and EBCM bracket into mounting

location.
3. New push-in retainer ("Christmas Tree")
attaching EBCM bracket to side wall.
4. Nut attaching EBCM bracket to upper 1/P.
!~I
Tighten
Nut to 25.0 N.m (18.5 lb. ft.).

6. Lower sound insulator panel and fasteners.
FRONT WHEEL BEARING AND SPEED

SENSOR ASSEMBLY
Figure 16
[I]
Important
l++I
1.
2.
3.
4.
Connector from wheel speed sensor.
Harness from retaining clips.
Harness grommets from retainers.
Upper jumper harness connector attached to inside
of frame rail.
!++j
Install or Connect
1. Upper jumper harness connector attached to inside

of frame rail.
2. Harness to retaining clips.
3. Harness rubber grommets into retainers.
4. Connector to wheel speed sensor.
The front wheel speed sensors and rings are

integral with the hub and bearing assemblies.
Should a speed sensor or ring require
replacement, the entire hub and bearing assembly
must be replaced. Refer to SECTION 3C.
FRONT WHEEL SPEED SENSOR JUMPER

HARNESS
Figure 17
Raise and support vehicle on a suitable hoist as
indicated in SECTION OA.
Figure 18
!++!
1. Connector from wheel speed sensor.

2. Bolt attaching sensor to backing plate.
3. Sensor from backing plate.
!++!
Install or Connect
1. Sensor into backing plate.

!~!
Tighten
Bolt to 10 N.m (89 lb. in.).

REAR WHEEL SPEED SENSOR TOOTHED

RINGS
[I]
Important
The rear wheel speed sensor toothed rings are an

integral part of the rear axle shafts. If it has been
determined that the toothed rings must be
replaced, refer to SECTION 4B for removal and
installation procedures.
l.l!!FT SIDI!! SHOWN

RIGHT SIDE SIMII.AR
REAR WHEEL SPEED SENSOR JUMPER

HARNESS
1 FRONT WHEEi. SPEED SENSOR
!++I
2 FRONT WHEEi. SPEED SENSOR

JUMPER HARNESS
3 LOWER CONTROi. ARM
15-19-94
FSC405E
Figure 16 - Front Wheel Bearing and Speed Sensor

Assembly
1. Connector from wheel speed sensors.

2. Jumper harness grommet from retainer.
3. Upper jumper harness connector from rear body
pass-thru connector.
LH SHOWN
RH SIMILAR
4 BRAKE LINE
5 WHEEL
6 CRADLE
1 FRONT WHEEL SPEED SENSOR JUMPER HARNESS

2 HARNESS ROSEBUD RETAINER (PUSH INTO CRADLE HOLE)
3 HARNESS GROMMET (PUSH INTO GROMMET RETAINER)
5E1-175
511MM
11"804151!
Figure 17 - Front Wheel Speed Sensor Jumper Harness
!H!
Install or Connect
1. Upper jumper harness connector to rear body

2. Connector to wheel speed sensors.
3. Jumper harness grommet into retainer.
ABS RELAY
Figure 19
!++!
1. ABS relay cover.

2. ABS relay from connector.
!++!
Install or Connect
1. ABS relay to connector.

2. ABS relay cover.

REAR WHEEL SPEED SENSOR JUMPER HARNESS
REAR AXLE HOUSING
REAR WHEEL SPEED SENSOR MOUNTING BOLT

5-5-94
WARNING/INDICATOR LAMPS
Refer to SECTION 8C for replacement
procedures and detailed information.
FS1005E
Figure 18 - Rear Wheel Speed Sensor
5E1-176
1 UNDERHOOD ELECTRICAL CENTER

ABS/TCS RELAY LOCATED INSIDE
04-20-95
FT0435E
Figure 19 - ABS Relay Location
UNIT REPAIR
ELECTRICAL CONNECTORS
Figure 20
Some ABS VI components are equipped with
electrical connectors using a Connector Position
Assurance (CPA) lock. This feature insures that when
the connectors are installed they are aligned properly
and connected securely.
[I]
Important
.Remove the lock before separating the electrical

connectors.
Take care not to damage the locking pin during
removal.
Make sure that the rubber connector seal is in
place on the connector before and after
connection.
Always install the lock after the connection is
made.

hydraulic modulator/motor pack
assembly, the gear tension relief function
of the Tech 1 must be performed prior to
removal of the ABS hydraulic
NOTICE: The following service procedures
shall be performed only after the ABS hydraulic
modulator/motor pack assemblies have been
removed from the vehicle. Do not perform these
procedures with the unit installed on the vehicle.
Complete overhaul of the ABS hydraulic
modulator/motor pack assemblies are not
authorized - only the following steps. These
steps will break the unit down into major
components for replacement purposes.
GEAR COVER
FUSE AND FUSIBLE LINKS
Refer to SECTION 8A-ll for repair or
replacement information.
Figure 21
!+!+I
Disassemble
1. Torx head screws attaching gear cover.

2. Remove gear cover.
5E1-177
LOCKING PIN
CONNECTOR
""
CONNl!CTOR
LOCKING PIN,
LOCKING PIN
l""~'"f"' ~
SEAL;"
CONNECTOR
CONN!CTOR
CONNECTOR
1 CONNECTOR POSITION ASSURANCI! (CPA) TYPICAL
* IIIAKI! SURI! SEAL IS IN PLACI! ON CONNll!CTOR

FS0445E
Figure 20 - ABS VI Electrical Connectors (Typical)
!+++I
Assemble
1. Gear cover to hydraulic modulator/motor pack

assembly.
2. Tone head screws.
!~!
Tighten
Tone bolts to 4 N.m (35 lb. in.).
MOTOR PACK
Figure 21
l+!+I
Disassemble

2. Torx head screws attaching motor pack.
[I]
Important
Use care when handling motor pack to ensure

motor pack connector is not damaged, or
accidental intrusion of brake fluid into the
motor pack does not occur. This may result in
a premature failure of the motor pack.
Take care in handling the motor pack. If
dropped or damaged during handling, the
motor pack must be replaced.
3. Remove motor pack.
[I]
Important
If disassembly of the hydraulic modulator/motor

pack assembly was due to a ABS hydraulic
functional test that did not pass, the "Automated
Motor Pack Diagnosis Test" described in this
section should be performed at this time to isolate
the motor pack or hydraulic modulator.
No repair of the motor pack is authorized.
Replace as an assembly.
f+!+I
Assemble
1. With the hydraulic modulator upside down, and

the gears facing you, rotate each hydraulic
modulator gear counterclockwise until movement
stops. This procedure will position the pistons
very close to their "home" position of the
modulator bore, simplifying the brake bleeding
procedure (refer to Figure 14).
2. Motor pack to hydraulic modulator.
[I)
Important

dropped or damaged during handling the motor
pack must be replaced.
Align each of the three ABS motor pack
pinions with the hydraulic modulator gears.
3. Torx head screws.
5E1178
I
I
15-18-94
FS'04155E
!~!
Figure 21 - ABS Hydraulic Modulator Components
Tighten
Torx head screws to 4.5 N.m (40 lb. in.).

assembly.
GEAR REPLACEMENT (Typical)

Figures 11 and 12
[I)
Important
Do not attempt to repair damaged motor packs or

hydraulic modulators. Other than modulator drive
gear replacement, repair of these assemblies is not
authorized. Do not lubricate or oil gears on motor
pack.
CAUTION: The modulator drive gears are

under spring load and will turn during
disassembly. After removing hydraulic
modulator drive gear cover, exercise
extreme care not to place fingers into.the
gear set, since fingers can be pinched by
rotating gears.
l+!+l
Disassemble
1. Hydraulic modulator. Refer to "Hydraulic
Modulator" in this section.

3. Motor pack to hydraulic modulator Torx head
screws.
[I)
Important

dropped or damaged in the handling, the motor
4. Separate motor pack from hydraulic modulator.

5. Tirree ABS modulator drive gears to modulator
drive shaft retaining nuts.
6. Gears from modulator (refer to Figure 11).
NOTICE: Do not allow gear to turn while
removing the retaining nut, since the modulator
piston can hit the top of the modulator bore,
damaging the piston. Turn the modulator gear to
position the piston in the center of its travel.
Place a screwdriver through the holes in the
gears (not between the gears) into the recessed
hole in the modulator base. This will prevent the
gear from turning, aiding in gear removal.
tightening the retaining nut, since the modulator
piston can bottom out in the modulator bore
gear from turning, aiding in gear installation
l+;+I
Assemble
1. Position hydraulic modulator drive gears onto

hydraulic modulator drive shaft.
2. Tirree ABS gear retaining nuts.
l~I
Tighten
Nuts to 8.5 N.m (76 lb. in.).

hydraulic modulator bore, simplifying the brake
bleeding procedure (refer to Figure 14).
4. Position motor pack onto hydraulic modulator,
aligning the three ABS motor pack gears with the
modulator gears.
[I]
Important

5. Motor pack to hydraulic modulator Tone head
screws.
l~I
Tighten
Torx head screws 4.5 N.m (40 lb. in.).

6. Gear cover onto hydraulic modulator with Torx
head screws.
1~1
Tighten
Torx head screws to 4 N.m (35 lb. in.).

5E1-179
HYDRAULIC MODULATOR
Figure 21
l+t!
Disassemble
1. Remove gear cover. Refer to "Gear Cover" in

this section.
2. Remove motor pack. Refer to "Motor Pack" in
this section.
3. Two hydraulic modulator to brake combo valve
banjo bolts; separate hydraulic modulator from
brake combo valve.
4. Two transfer tubes with 0-rings from brake
combo valve or hydraulic modulator.
5. Banjo bolt 0-rings from brake combo valve and
hydraulic modulator.
[I]
Important
If hydraulic modulator is to be replaced, install

the three gears in the same location on
replacement hydraulic modulator. Refer to "Gear
No repair of the hydraulic modulator is
authorized. Replace as an assembly.
Refer to SECTION 5A for repair of brake combo
valve.
Use new transfer tube assemblies when
assembling the hydraulic modulator/brake combo
valve assembly. Make sure two 0-rings are
properly installed on each transfer tube.
l+;+I
Assemble
1. Two transfer assemblies.

Lubricate transfer tube assembly 0-rings with
clean brake fluid.
Install transfer tube assemblies in ports in
hydraulic modulator and push-in by hand to
bottom.
2. Lubricate new banjo bolt 0-ring with clean brake
fluid and install into the brake combo valve and
3. Hydraulic modulator to brake combo valve.
Hold brake combo value and rock into position
on hydraulic modulator inserting transfer tube
assemblies into brake combo valve ports.
banjo bolts.
!~!
Tighten
Banjo bolts to 16 N.m (12 lb. ft.).

modulator bore simplifying the brake bleeding
5E1-180

assembly.
MASTER CYLINDER
Refer to SECTION SA for repair of master
cylinder.
SPECIFICATIONS
ABS Hydraulic Modulator Bleeder Valves ................................................................................................. 9.0 N.m (80 lb. ia.)
ABS Hydraulic Modulator Solenoid Tone Head Bolt ............................................................................ 4.5 N.m (40 lb. ia.)
Electronic Brake Control Module (EBCM) Nut ....................................................................................... 25 N.m (18.5 lb. ft.)
ABS Hydraulic Modulator Mounting Bolt ................................................................................................. 9.0 N.m (80 lb. in.)
Three Hydraulic Modulator Brake Pipe Tube Nuts ..................................................................................... 32 N.m (24 lb. ft.)
Two Brake Combination Valve Brake Pipe Tube Nuts ............................................................................... 18 N.m (13 lb. ft.)
1\vo Master Cylinder Brake Pipe Tube Nuts ............................................................................................... 32 N.m (24 lb. ft.)
Modulator Drive Gear Nuts ......................................................................................................................... 8.5 N.m (75 lb. in.)
Torx Head Screws Attaching Gear Cover ............................................................................................... 4.0 N,m (35 lb. in.)
Torx Head Screws Attaching Motor Pack ............................................................................................... 4.5 N,m (40 lb. in.}
1\vo Banjo Bolts Attaching Brake Combination Valve to ABS Hydraulic Modulator ............................. 16 N.m (12 lb. ft.)
5E1181
SPECIAL TOOLS
Figure 22
The J 39200 High Impedance Multimeter is the
only DVM authorized for use in diagnosing and
servicing the ABS VI system.
J 35589
7000001
1 BRAKE BLEIEDINO ADAPTER
3 TECH 1 SCAN TOOL
2 MASS STORAGE CARTRIDGE
J 39200 DIGITAL IMULTIMIETEFI
15-1994
FS041SE
Figure 22 - ABS VI Special Tools
5E1-182
BLANK
ANTILOCK BRAKE SYSTEM WITH TRACTION CONTROL 5E2-1
SECTION 5E2
ANTILOCK BRAKE SYSTEM WITH TRACTION

CONTROL
CAUTIONS in Section 9J under ON-VEHICLE SERVICE and the SIR component and wiring
Failure to follow .CAUTIONS could result in possible air bag deployment, personal injury, or
CAUTION: Certain components in the ABS are not intended to be serviced individually.
Attempting to remove or disconnect certain system components may result in personal injury
and/or improper system operation. Only those components with approved removal and
installation procedures should be serviced.
CAUTION: To help avoid personal injury due to poor braking, DO NOT tap into the vehicle's
brake system to operate a trailer brake system.
NOTICE: Do not use a quick charger for engine starting or for battery charging if the battery is still connected
to the vehicle" s electrical system. Failure to do so may cause the air bag fuse to open or cause serious damage
to other electrical components. Always disconnect the negative battery cable when charging battery.
NOTICE: Always use the correct Fastener in the correct location. When you replace a fastener, use ONLY the
tightening sequence and specifications. Following these instructions can help avoid damage to parts and systems.
in repair kits used to service this system. Lubricate rubber parts with clean, fresh brake fluid. to ease assembly.
Do not use lubricated shop air on brake past as damage to rubber components may result If any hydraulic
component is removed or brake line disconnected, it may be necessary to bleed all or part of the brake system.
The fastener tightening specifications specified are for dry, unlubricated fasteners.
NOTICE: Use only Supreme 11 (GM 1052542) or equivalent DOT 3 brake fluid. The use of DOT 5 (silicone)
brake fluid is not recommended. Reduced braking performance or durability may result.
NOTICE: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring, cables or electrical
CONTENTS
General Description ............................................... 5E2-3
Abbreviations/Definitions .................................. 5E2-3
Basic Knowledge Required ............................... 5E2-3
System Operation .............................................. 5E2-3
Base Braking Mode ...................................... 5E2-3
Antilock Braking Mode ................................ 5E2-4
Traction Control Mode ................................. 5E2-5
ESB Operation .................................................. 5E2-6
System - Self Test (Initialization) .................... 5E2-6
Warning Lamp Operation ................................. 5E2-6
Normal Lamp Operation ............................... 5E2-6

Warning Lamps ............................................. 5E2-6
Tires and ABS/TCS ...................................... 5E2-8
Spare Tire .......................................................... 5E2-8
Replacement Tires ......................................... 5E2-8
System Components .......................................... 5E2-8
Assembly ............................................... 5E2-8
TCS Hydraulic Modulator/Motor Pack
Assembly ............................................... 5E2-8
5E2-2
ANTILOCK BRAKE SYSTEM WITH TRACTION CONTROL
Electronic Brake Traction Control

Module(EBTCM) .......................................... 5E2-8
Adjuster Assembly .................................... 5E2-9
Front Wheel Speed Sensors ...................... 5E2-9
Front Wheel Speed Sensor Rings ............ 5E2-10
Rear Wheel Speed Sensors and Rings ..... 5E2-10
ABS/TCS Relay (Enable) ......................... 5E2-10
Brake Combination Valve ......................... 5E2-10
Wiring Harness .......................................... 5E2-10
Wheel Speed Sensor Jumper Harness ...... 5E2-10
Fuses and Fusible Links ........................... 5E2-10
Diagnosis-Electrical ........................................... 5E2-10
Diagnostic Process ......................................... 5E2-10
Self-Diagnostics ............................................. 5E2-11
(DTCs) ....................................................... 5E2-11
Clearing Diagnostic Trouble Codes
(DTCs) ....................................................... 5E2-11
Tech 1 Method .......................................... 5E2-l 1
Ignition Cycle Default. .............................. 5E2-11
Intermittent and Poor Connections ............... 5E2-l 1
Tech 1 Diagnostics ........................................ 5E2-11
Enhanced Diagnostics ................................ 5E2-11
Diagnostic Process (1 of 5) .......................... 5E2~ 13
Diagnostic System Check (1 of 4) ............... 5E2-18
Table ..............................................0. ........... 5E2-26
Wiring Diagram (1 of 3) .............................. 5E2-28
EBTCM Connector End View (1 of 3) ....... 5E2-31
Diagnosis/Misc. Test (F4) ................................. 5E2-222
Manual Control (PO) ..................................... 5E2-222
ABS Motor Test (Apply/Release) ............. 5E2-222
TCS Motor Test (Apply/Release) ............. 5E2-222
Solenoid Test ("ON/OFF") ...................... 5E2-222
Hydraulic Control Test (F2) ......................... 5E2-223
ABS Motor Test (F4) .................................... 5E2-223
ABS No Gear Movement.. ........................... 5E2-223
Gear Tension Relief (F5) .............................. 5E2-223
ABS/TCS Relay Test (F6) ............................ 5E2-223
Voltage Load Test (F7) ................................. 5E2-224
Lamp Test (F8) ............................................. 5E2-224
System ID (F9) ............................................. 5E2-224
Bleed Prep (F6) ............................................. 5E2-224
On-Vehicle Service ....................................... .-.... 5E2-224
Service Precautions ....................................... 5E2-224
Checking and Adding Fluid ............................. 5E2-224
Flushing Procedure ........................................ 5E2-224
Pressure Flush ........................................... 5E2-226
ABS Hydraulic Modulator .............0. ... 5E2-226
Manual Flush ............................................. 5E2-227
ABS Hydraulic Modulator .................... 5E2-227
Bleeding Procedure ....................................... 5E2-227

With Tech 1 .............................................. 5E2-227
Bleed Procedure ........................................ 5E2-228
Pressure Bleeding ...................................... 5E2-228
Brake Pipe Connections ........................ 5E2-229
Wheel Brakes ........................................ 5E2-229
Manual Bleeding ....................................... 5E2-230
Wheel Brakes ........................................ 5E2-230
Valves ......................................................... 5E2-232
ABS Hydraulic Modulator Solenoid ............ 5E2-232
Assembly ................................................... 5E2-233
TCS .Hydraulic Modulator/Motor Pack
Assembly ................................................... 5E2-234
Electronic Brake Traction Control Module
(EBTCM) ..... ,............................................. 5E2-234
Adjuster Assembly ........................................ 5E2-235
Adjustment Procedure - Throttle Body and
Cruise Control Cables ............................... 5E2-236
Throttle Cable Replacement ......................... 5E2-239
Accelerator Pedal Cable and Cruise Cable
Replacement .............................................. 5E2-240
Accelerator Pedal Replacement .................... 5E2-240
Front Wheel Bearing and Speed Sensor
Assembly ......................................... :......... 5E2-241
Harness ...................................................... 5E2-241
Rear Wheel Speed Sensor ............................ 5E2-242
Rings .......................................................... 5E2...242
Harness ...................................................... 5E2-242
ABS/TCS Relay (Enable) ............................. 5E2-242
Brake Combination Valve ............................. 5E2-242
Warning/Indicator Lamps .............................. 5E2-242
Electrical Connectors ................................... 5E2-242
Fuse and Fusible Links ................................. 5E2-244
Unit Repair ................................................... :... 5E2-244
Gear Cover (ABS) ........................................ 5E2-244
Motor Pack (ABS) ........................................ 5E2-244
Gear Replacement ......................................... 5E2-244
ABS Hydraulic Modulator ............................ 5E2-246
.TCS Hydraulic Modulator ............................ 5E2-246
Master Cylinder ............................................. 5E2-246
Specifications ..................................................... 5E2-247
Fastener Tightening Specifications ............... 5;E2-247
Special Tools ..................................................... 5E2-247
GENERAL DESCRIPTION
Several abbreviations are commonly used
reference.
ABS .............................................. Antilock Brake System
B+ .............................................................. Battery Voltage
BATT ....................................................................... Battery
CKT .......................................................................... Circuit
CPA ................................... Connector Position Assurance
DLC .................................................. Data Link Connector
DTC .......................................... Diagnostic Trouble Codes
DVM ..................................................... Digital Multimeter
EBTCM ........ Electronic Brake Traction Control Module
ESB ..................... ,....................... Expansion Spring Brake
GND ....................................................................... Ground
IGN ................... Battery Voltage with Ignition to"RUN"
Infinite ....... Open Circuit/Unmeasurable High Resistance
MSC ............................................. Mass Storage Cartridge
PCM ...................................... Powertrain Control Module
SNR .......................................................................... Sensor
SOL .............................................................. ,....... Solenoid
TCS ............................................. Traction Control System
BASIC KNOWLEDGE REQUIRED

Before using this section, it is important that you
have a basic knowledge of the following items.
Without this basic knowledge, it will be difficult to
use the diagnostic procedures contained in this section.
If you need a review of basic electrical
troubleshooting knowledge, SECTION SA contains
helpful information in the introduction. Basic use of
circuit testing tools is also covered in SECTION SA.
Additionally, electrical/electronic courses are
offered through General Motors Service Training.
Basic Electrical Circuits - You should understand
the basic theory of electricity and know the
meaning of voltage, current (amps) and resistance
(ohms). You should understand what happens in a
circuit with an open or shorted wire. You should
be able to read and understand a wiring diagram.
Use of Circuit Testing Tools - You should be
familiar with the High Impedance Multimeter
(DVM) J 39200. You should be able to measure
voltage, resistance and current and be familiar
with the meter controls and how to use them
correctly.
[I]
Important
5E2-3
SYSTEM OPERATION
The Antilock Brake System and the Traction
Control System (ABS VI/TCS) are both part of the
same hydraulic and electric system. Both systems use
many of the same components and a problem in either
system may disable the other system until it is
repaired. Antilock braking controls wheel slip when
braking; traction control controls wheel slip when
accelerating.
Base Braking Mode

Under normal operating conditions, the brake
system will operate using conventional braking by
means of brake pedal force, the vacuum booster, and
the compact master cylinder. For the front wheels, the
brake fluid flows from the master cylinder, through the
ABS hydraulic modulator, and then out to the front
wheels. The fluid flow to the rear wheels flows first
through the master cylinder, through the ABS
hydraulic modulator, through the TCS hydraulic
modulator, and then out to the rear wheels.
ABS Hydraulic Modulator Fluid Flow

Each front ABS channel consists of a motor,
solenoid, ESB, ball screw, piston, and check valve.
Under normal operating conditions (base brakes),the
piston is held in the up most (or "home") position and
the solenoid is open (not energized), (refer to
Figure 1). This is accomplished by turning the ball
screw via the motor to drive the nut upwards. Once at
the up most position, the piston is held by an
Expansion Spring Brake (ESB). Two paths are
available to transfer braking pressure to the front
wheels: (1) through the ABS modulator, around the
check valve, and out to the front wheels, (2) through
the ABS modulator, past the normally open solenoid,
and out to the front wheels. The solenoids in the front
circuits provide an alternate brake pressure path to the
front wheels. With this arrangement, if ABS were to
lose power or malfunction with the piston not in its
home position, a redundant brake fluid path is
available, (see Figure 1). The rear ABS channels
operate in a similar manner except no solenoid exists.
The fluid flows from the master cylinder, through the
ABS modulator, through the TCS modulator, and then
out to the rear wheel brakes.
TCS Hydraulic Modulator Fluid Flow

Each TCS channel consists of. a motor, piston,
ball screw, spring, and poppet valve. Under normal
operating conditions (base brakes) .the piston is located
in the downward (or "home") position and the poppet
valve is unseated, (refer to Figure 2). This is
accomplished by turning the ball screw via the motor
to drive the nut downward. The brake fluid enters the
inlet port of the TCS modulator, flows past the
unseated poppet valve to the outlet port of the TCS
modulator, and then out to the rear calipers. There are
no solenoid valves or ESBs within the TCS modulator.
When measuring the resistance to ground of a

circuit or component, make .sure to use a solid,
unpainted chassis ground or the negative battery
terminal.
/,
I
5E24

2
1 CHECK VALVE OPEN

2 BRAKE PRESSURE FROM coa.,IHNATION VALVE
3 OPEN SOLENOID
1 INLET PORT FROM ABS MODULATOR

2 OUTL!T PORT (NOT SHOWN) TO R!AR
BRAKE CALIPER
4 PISTON
3 POPPET VALVE (UNSEATED)
5 BALL SCREW NUT
4 SPRING
6 BALL SCREW SPINDLE
I BALLSCREW
8 EXPANSION SPRING BRAKE (ESB)
7 BALL SCREW NUT
9 BRAK! PFl!SSUR! TO FRONT BRAK!
5 PISTON
7 ABS MOTOR PACK
11-18-95
FSOOtlSE
Figure 1 - ABS Front Base Braking Mode
Antilock Braking Mode

AB~ . VI has been ~~signed to improve the
conn:ollab1hty and steerab1hty of a vehicle during
brakmg: ABS VI acc~mplishes this objective by
controllmg the hydraulic pressure applied to each
wheel br~e .. Antilock brakin~ occurs only when the
brake switch 1s closed and a microprocessor, located in
the EBTCM, determines one or more wheels is about
to lose traction during braking. The EBTCM will then
allow the hydraulic modulator to change the brake
pressures several . times each second to keep the
wheel(s) from locking and provide the driver with
maximum vehicle controllability. ABS VI CANNOT
INCREASE THE BRAKE PRESSURE ABOVE THE
MASTER CYLINDER PRESSURE APPLIED BY
THE DRIVER, AND CANNOT APPLY THE
BRAKES BY ITSELF.
!he result is greatly improved braking, enabling
the dnver to more easily maintain steerability and to
brin~ the ve~icle to. a controlled stop. ABS VI
provides effective braking and directional control over
a wide range of road surfaces and driving conditions.
5-19-94
FS0025E
Figure 2 - Modulator Base Braking Mode
If any wheel(s) begins to approach lock-up the

EBTCM will control the t):rree (3) motors and tw~ (2)
solenoids, appropriately, to control brake pressure to
the affected wheel(s). During front wheel ABS
operation, the solenoids are turned "ON" to isolate
that brake pressure path to the wheel (see Figure 5).
The EBTCM then provides controlled current to the
motors to regulate the speed and amount of
movement. As the motors move. backwards, the piston
follows the nut downward, allowing the check valve to
seat. The brake pressure to the wheel is now a
function of the controlled volume within the piston
chamber. To reduce brake pressure, the motor drives
the nut further downward. To reapply or increase
brake pressure, the motor drives the nut and piston
upward. If ABS was entered during low brake
pressure, such as on ice, and dry pavement is then
encountered during reapply, the piston is driven all the
way to the top. This results in the unseating of the
check valve, and a return to base brakes until
sufficient brake pressure exists to cause the wheel to
approach lock-up again. At this point, the ABS cycle
would start again. This process can occur in less than

one second if the driver is pressing firmly on the
brake pedal.
Total brake pressure during ABS is limited to
the brake pressure present when ABS was entered.
Also, anytime wheel brake pressure exceeds the brake
pressure at the master cylinder (caused by reduced
force on the brake pedal), the check valve unseats and
a small volume of brake fluid is returned to the master
cylinder. In this manner, ABS VI CANNOT
INCREASE BRAKE PRESSURE ABOVE MASTER
CYLINDER PRESSURE APPLIED BY THE
DRIVER AND CANNOT APPLY THE BRAKES BY
ITSELF. When ABS is no longer required, the pistons
are returned to their up most (or "home") position and
are held by the ESBs (refer to "ESB Operation,"
found in this section). The solenoids on the front
channels are simultaneously opened to again provide a
redundant base braking path.
The rear channel operates in a similar manner
except no solenoid is used (refer to Figure 6). Both
rear brake pressures are controlled by the same motor
and both rear brake pressures are controlled together.
If either rear wheel begins to lock, brake pressure to
1 INLET PORT FROM ABS MOLULATOR

2 OUTLET PORT (NOT SHOWN) TO REAR
BRAKE CALIPERS
3 POPPET VALVE (SEATED)
4 SPRING
5 PISTON
6 BALL SCREW NUT
7 BALLSCREW
15-18-94
FS0035E
Figure 3 - Traction Control Mode
5E25
both rear wheels is reduced to maximize vehicle

stability.
There is no rear solenoid due to the nature of the
braking system. The vast majority of braking is
accomplished with the front brakes. If an ABS failure
were to occur that affected the operation of the rear
base brakes, a diagnostic trouble code would be stored
and the EBTCM would turn "ON" both the "ABS
INOP" lamp and the "BRAKE" warning lamp.
Traction Control Mode

The Traction Control System (TCS) is an add on
to the ABS VI Antilock brake system. The TCS
provides the capability to control wheel spin at each
driven wheel. This improves the ability to maintain
vehicle stability and acceleration (drive traction) under
changing road and vehicle load conditions.
Traction Control occurs when the EBTCM
determines one or more of the drive wheels are
accelerating . too rapidly and the brake switch is
"OFF." The EBTCM processes wheel speed sensor
data and can control wheel slip by utilizing up to three
different methods: 1. By commanding the PCM to
retard ignition timing, thereby reducing engine torque;
2. by utilizing the throttle adjuster motor to reduce the
throttle angle, thereby reducing engine torque and 3.
by brake intervention through the use of the TCS
The EBTCM can control one or both of the TCS
motors simultaneously. The TCS motors are
bi-directional and are used with the gear assemblies to
drive the ball screws and pistons in the TCS
modulator: The bi-directional motors allow pressure to
be applied, held, or released from the wheels. During
TCS operation, the ball screws and pistons are driven
upward from their home position. This process seats
the poppet valve (thus isolating the master cylinder).
The brake pressure to the wheel is now a function of
the controlled volume within the piston chamber (refer
to Figure 3). As drive wheel speed is reduced, the
pistons are driven downward to their home position.
This unseats the poppet valve and releases fluid
pressure from the rear brake calipers. This process of
apply, hold, and release can repeat itself several times
a second, until drive wheel speed is reduced a
prescribed amount.
The EBTCM also controls the throttle adjuster
motor and sends commands via a PWM signal to the
PCM to retard ignition timing, thereby reducing engine
torque and wheel slip.
TCS cannot be entered if the brake switch is
"ON." Base brakes and ABS take precedence over
TCS in all conditions. If TCS is being utilized and the
brake switch is depressed, the EBTCM will
immediately command the TCS motors to re-home the
TCS ball screws and pistons. The applied brake
pressure from the master cylinder can overcome the
poppet valve spring to apply brake pressure
immediately to the wheels during the re-home
operation.
5E26
TCS THERMAL SHUTDOWN MODE

During prolonged TCS operation, brake lining
temperatures may rise to a higher than desired level
and the lining wear rate may increase. For this reason
the TCS system incorporates a brake thermal modei
which esti~ates brake temperatures during braking and
TCS operation. The program calculates potential brake
temperature based on time vs. amount of and duration
of TCS brake applications. If the brakes or TCS
modulator reach a potential over-temperature condition
the TCS modulator is disabled but the PCM will still
co~trol the adjuster assembly and spark control. If the
adJus.t~r assembly reaches a potential over-temperature
condit10n the TCS system will disable. The amber
TCS warning lamp will tum "ON" and TCS will
remain disabled until the brake linings are cooled to
the proper temperature. The TCS system will
automatically re-enable at this time. No DTC's will be
stored.
Norm~lly TCS w.ill not disable during a traction
event, but if the maximum temperature threshold is
reached, it will disable.
A'TION
ESB OPER'"'
The Expansion Spring Brake (ESB) is used to

hol~. the ABS piston in the upmost (or "home")
posit10n. ~SBs are used only in the ABS modulator.
An ESB 1s a spring that is retained in a housing at a
cl?se tolerance. O:e end of the spring is in contact
with the motor drive dog and the other end is in
contact with the pinion drive dog (refer to Figure 4).
In normal braking, brake pressure is present on the top
of the ABS piston, applying a downward force. The

fo.rc~ applies ~ count~rclockwise torque to the motor
pinion which tnes to rotate the spring
counterclockwi~e. The coun.te~clockwise torque
expands the spnng outward withm the housing and
prevents gear rotation.
When the motor is turned "ON" and tries to
drive the ball screw nut; the end of the ESB in contact
wi~ the motor dr!v': dog r~tates inward causing the
spnng to contract m its housmg allowing the motor to
rotate the modulator gear (refer to Figure 4). The most
common application of this principle is in window
crank mechanisms, where a small amount of force on
the crank handle allows the window to be lowered or
raised, but the weight of the window or force on the
window will not allow the window to move
down~ard. For the ESB, brake pressure on the top of
the pistons corresponds to the weight of the window
and the motor corresponds to the window crank
handle.
SYSTEM SELF TEST (INITIALIZATION)

During i~itializ~tion, the ~BTCM will not only
perform self-diagn?stlcs, but will also verify motor,
modulator, solenoid, relay; and lamp operation to
ensure all ABS and TCS components are functioning
properly. The EBTCM also checks the wheel speed
sensor circuitry for open circuits and shorts to ground
or voltage at this time. If the EBTCM detects a
malfunction in either itself or other ABS VI/TCS
components, it will store a Diagnostic Trouble Code
(DTC) and turn "ON" the ABS warning lamp the
TCS warning lamp, or the red "BRAKE" wa:.ning
MOTOR DRIVES
CLOCKWISE
MOTOR DRIVES
COUNTERCLOCKWISI!!
1 MOTOR DRIVE DOG RELEASES

SPRING BRAKE AND DRIVES PINIO'N
2 CIRCUP
3 MOTOR PINION
4 PINION DRIVI!! DOO
Ii EXPANISON SPRING BRAKE (ESB)
6 MOTOR DRIVE DOG

7 MOTOR SHAFT
PIN!ION STOPPl!!D l"ROM TURNING
COUNTHCLOCKWISE
B STEEL SLEEVE
9 MOTOR DRIVE DOG RELEASES SPRING BRAKE
(SPRING LEG BENEATH PINION DOG)
AN'D DRIVl!!S PINION
10 PINION DOG EXPANDS SPRING AND
LOCKS AGAINST SLEEVE
61994
FS0045E
Figure 4 Expansion Spring Brake

lamp if applicable. See "Warning Lamp Operation" in
this section for normal lamp operation during
initialization (Steps 1- 3). A slight mechanical noise
may be heard during the system initialization, which .is
normal. The entire initialization is run about 2-3
seconds after the engine starts. If your foot is on the
brake. pedal when the engine is started, the system will
not initialize until your foot is removed or 5 km/h (3
mph) is reached. If foot pressure on the pedal
interrupts the Lsystem initialization, a slight movement
in the pedal may be felt.
Warning Lamp Operation

Normal Lamp Operation
The Standard brake system uses a single red

"BRAKE" warning lamp located in the instrument
panel cluster. The antilock brake system uses the red
"BRAKE" warning lamp and an amber ABS warning
lamp (" ABS INOP"). The traction control system uses
the red "BRAKE" warning lamp and an amber TCS
warning lamp ("TCS OFF" PONT) ("ASR"
CHEVY). A amber ABS/TCS active lamp
("LOWTRAC") is illuminated during an ABS or TCS
event and for several seconds after the event is
complete. Throughout this manual, the lamps will be
referred to by their function, not by what is indicated
on the instrument panel cluster.
1. When the ignition is turned to the "RUN"
position, the BRAKE, ABS warning, TCS
warning, and ABS/TCS active lamps are turned
"ON" for approximately three seconds, then turn
"OFF."
2. As the engine is cranked, the BRAKE, ABS
warning, TCS warning, and the ABS/TCS active
lamps will turn "ON" and remain "ON."
3. After the engine is started, the BRAKE, ABS
warning, TCS warning, and the ABS/TCS active
lamps will remain "ON" for approximately three
seconds, then turn "OFF."
A solid ABS warning lamp indicates that a

malfunction has been detected that affects the
operation of ABS. No antilock braking will be
available. Normal, non-antilock brake performance
will remain. In order to regain ABS braking ability,
the ABS must be serviced. If the EBTCM detects a
problem with the TCS, the amber TCS warning lamp
will illuminate to alert the driver of the problem. A
solid TCS warning lamp indicates that a problem has
been detected that affects the operation of the TCS.
No traction control will be available, however base
braking and ABS will be unaffected.
The amber ABS warning lamp will be turned
"ON" along with the amber TCS warning lamp
anytime the EBTCM suspects the ABS operation has
been degraded due to a system malfunction.
The red BRAKE warning lamp will be
illuminated when a low brake fluid level in the master
cylinder is sensed, the parking brake switch is closed,
or under control of the EBTCM when certain ABS or
TCS DTCs are set. This lamp indicates to the driver a
base brake problem may exist.
Warning Lamps
The Electronic Brake Traction Control Module
(EBTCM) continuously monitors itself and the other
ABS VI/TCS components. If the EBTCM detects a
malfunction with the system, the ABS warning lamp
or TCS warning lamp will light continuously (solid
lamp) to alert the driver of the malfunction. The ABS
warning lamp will flash if the EBTCM attempts to
turn "ON" the red "BRAKE" warning lamp in
conjunction with the ABS warning lamp and is unable
to do so. The ABS warning lamp is flashed to warn
the driver that an ABS malfunction exists which may
have degraded base brake performance. No antilock
braking will be available. The vehicle must be
serviced immediately to regain full base and ABS
braking ability.
CAUTION: The braking system may not

be working properly if the ABS warning
lamp is flashing. Driving with a flashing
"ABS INOP" lamp can lead to an
accident. If the ABS warning lamp is
flashing, pull safely off the road and have
the vehicle towed for service.
1 CHECK VALVE CLOSED

SOLENOID VALVE
2 CLOSED
3 BRAKE PRESSURE FROM
COMBO VALVE
4 MODULATION
CHAMBER
S
6 BALL SCREW NUT IN

"MODULATION" POSITION
7 ~~:~~t~~~)SPRING
8 ABS MOTOR PACK
g BTROAKE PRTESSURKEE
FR 0 N BRA
!~I,%~L~TION.
POSITION
Figure 5 - Front ABS Braking Mode
5-22-94
FSOOSSE
5E2-8

Replacement Tires
INLET FROM COMBO VALVE
RHR
Tire size is important for proper performance of

the ABS VI/TCS. Replacement tires should be the
same size load range and construction as the original
tires. Replace tires in axle sets and only with tires of
the same TPC (Tire Performance Criteria) specification
number. Use of any other tire size or type may
seriously affect the ABS VI/TCS operation. For more
information on original equipment and replacement
tires, refer to SECTION 3E.
LHR
SYSTEM COMPONENTS
1 CHECK VALVES CLOSED

MODULATED PRESSURE TO REAR BRAKES
PISTON LOWERED
.
EXPANSION SPRING BRAKE (ESB) LOCATION
MOTOR PINION
YOKE ON BALL SCREW DRIVES BOTH REAR
CIRCUIT PISTONS
7 MODULATION CHAMBER
2
3
4
5
8
06-01-95
FSOOHE
Figure 6 - Rear ABS Braking Mode
The ABS/TCS active "LOW TRAC" indicator

lamp is used to alert the driver when ABS or TCS is
active. Anytime the EBTCM determines that the
vehicle has entered an event where ABS or TCS is
required, the "LOW TRAC" lamp will tum "ON" to
indicate that ABS or TCS is active. The "LOW
TRAC" lamp will remain "ON" for approximately 3
to 4 seconds after the ABS or TCS event is
completed.
Tires and ABS!TCS

Spare Tire
Using the compact spare tire supplied with the

vehicle will not affect the operation of the ABS
system. The EBTCM software can compensate for this
smaller tire. However, increased stopping distances
may occur due to reduced tire tread depth and width
of the compact spare tire. When using the compact
spare tire on the rear axle the Traction Control System
will cycle and limit acceleration for about the first 15
seconds of driving after each engine start. After that
time the smaller tire will not affect the operation of
TCS.
The ABS VI/TCS Antilock Braking Traction

Control System consists of a conventional hydraulic
brake system plus antilock and traction control
components. The conventional brake system includes a
vacuum power booster, master cylinder, front disc
brakes, rear disc brakes, interconnecting hydraulic
brake lines, low fluid sensor, and a red "BRAKE"
warning lamp.
The ABS VI/TCS components include separate
hydraulic modulator/motorpack assemblies, an
integrated Electronic Brake Traction Control Module
(EBTCM), an adjuster assembly, four wheel speed
sensors, an ABS/TCS relay, a TCS enable switch, an
amber ABS warning lamp, an amber TCS warning
lamp, a common ABS/TCS active lamp, and
interconnecting wiring.

Assembly
The ABS hydraulic modulator/motor pack
assembly controls hydraulic pressure to the front and
rear calipers by modulating hydraulic pressure to
prevent wheel lock-up. The basic hydraulic modulator
configuration consists of gear subassemblies, ball
screws, nuts, pistons, and hydraulic check valves. The
motor pack consists of three motors,, three drive gears,
and three ESBs. For more information, refer to "Base
Braking Mode" and "Antilock Braking Mode" in this
section.

Assembly
The TCS hydraulic modulator/motor pack
assembly controls drive wheel slip during acceleration
by modulating brake pressure to the drive wheel brake
calipers to prevent slip. The basic hydraulic modulator
configuration consists of. gear subassemblies, ball
screws, nuts, pistons, and hydraulic poppet valves. The
motor pack consists of two motors and two drive
gears. For more information refer to "Base Braking
Mode" or "Traction Control Mode" in this section.
Electronic Brake Traction Control Module

(EBTCM)
The controlling element of ABS VI/TCS is a
microprocessor based Electronic Brake Traction
Control Module, or EBTCM. Inputs to the system
include four wheel speed sensors, the brake switch,
switched ignition voltage, unswitched ignition voltage,
and serial data communications with the PCM.
The EBTCM monitors itself, each input and

each output for proper operation. If any system
malfunction is detected, the EBTCM will store a DTC
in nonvolatile memory (DTCs will not disappear if the
battery is disconnected). Refer to "Self-Diagnostics"
in this section for more detailed information.
Outputs include five bi-directional motor. controls, four

lamp controls, two solenoid controls (ABS), and the
ABS/TCS relay. A serial data link, located in terminal
"9" of the Data Link Connector (DLC), is provided
for service diagnostic tools and assembly plant testing.
The EBTCM monitors the speed of each wheel.
If any wheel begins to approach lock-up and the brake
switch is "ON," the EBTCM controls the ABS motors
and solenoids to reduce brake pressure to the wheel
approaching lock-up. Once the wheel regains traction,
brake pressure is increased until the wheel again
begins to approach lock-up. Thi.s cycle repeats until
either the vehicle comes to a stop, the brake is
released, or no wheels approach lock-up. Additionally,
if one or more of the drive wheels are accelerating too
rapidly, the EBTCM sends commands to the adjuster
assembly motor, to the PCM to reduce engine torque
and to the TCS motors to apply and release the brakes
several times each se.cond to reduce driven wheel
speed to a prescribed amount over the non-driven
wheel speed. Once the wheel regains traction, brake
pressure is decreased and engine torque reduction is
no longer requested. This cycle repeats until tr.action
control is no longer necessary.
BRAKE PRESSURE MODULATOR

VALVE (REMOTE MOUNTED AT
LEFT FRONT UNDERHOOD)
5E2-9
NOTICE: There is no serviceable or

removable PROM. The EBTCM must be
replaced as an assembly.
Adjuster Assembly
The adjuster assembly is mounted in the engine
compartment, and is used as a cable extender. It
allows the throttle lever cam on the throttle body to
reduce the throttle angle when the TCS system
requests it. This reduces engine power to control
wheel spin. The EBTCM provides the control logic.
Front Wheel Speed Sensors

The front wheel speed sensors consist of a
variable reluctance sensor. The sensor and toothed ring
are part of the hub and bearing assembly. As .teeth
EBTCM
~ (ABOVE DRIVER'S SIDE KICK PANEL)
LAMP DRIVER MODULE

(INTEGRATED \'INTO I. P: CLUSTER)
ABS/TCS RELAY IN UNDERHOOD

ELECTRICAL CENTER MOUNTED TO
THE LEFT FRONT INNER FENDER
-~
INTEGRAL F R O N T ~
SPEED SENSORS
(ONE AT EACH FRONT WHEEL)
041995
FT0075E
Figure 7 - ABS VlfTCS Component Location View
5E210
pass by the sensor, an AC voltage with a frequency

proportional to the speed of the wheel is generated.
The magnitude of the voltage increases with increasing
speed. The sensor is not repairable, nor is the air gap
adjustable. The entire front bearing assembly must be
replaced.
Front Wheel Speed Sensor Rings

The front wheel speed sensor toothed rings are
an integral part of the hub and bearing assembly. Like
the front wheel speed sensors themselves, they are not
serviceable. If a malfunction is detected in either the
sensor or the toothed ring, the entire hub and bearing
assembly must be replaced.
Rear Wheel Speed Sensors and Rings

The rear wheel speed sensors operate in the
same manner as the front wheel speed sensors; refer to
"Front Wheel Speed Sensors." However, the rear
wheel speed sensors are mounted at each end of the
rear axle housing. The toothed rings are an integral
part of the rear axle shafts. The sensors and toothed
rings are not repairable and no provision for air gap
adjustment exists.
ABS/TCS Relay
The ABS/TCS relay is a normally-open contact
type relay, and has a special contact material to handle
the high currents required for ABS VI/TCS operation.
The relay allows battery voltage and current to be
supplied to the EBTCM, which supplies power to the
ABS motors and solenoids and to the TCS motors.
Wheel Speed Sensor Jumper Harness

Between each wheel speed sensor and the main
wiring harness is a jumper harness made up of highly
flexible twisted pair wiring. This wiring exists because
the main harness must connect to the suspension of
the vehicle, thus the wiring in this area is subjected to
the same motion as a spring or shock absorber.
Consequently, any repair to. this section of wiring will
result in stiffening and therefore, eventual failure due
to wire fatigue. For this reason, THE WHEEL SPEED
SENSOR JUMPER HARNESSES ARE NOT
REPAIRABLE AND MUST BE REPLACED. DO
NOT ATTEMPT TO SOLDER, SPLICE, OR CRIMP
THESE HARNESSES AS EVENTUAL FAILURE
WILL LIKELY RESULT. Refer to "On-Vehicle
Fuses and Fusible links

The vehicle's power distribution system consists
of fuses, fusible links, circuit breakers, and the ignition
switch. Fusible links are short pieces of wire several
sizes smaller than the circuit wire to .which they
supply power. They are covered with special high
temperature insulation. When conducting an
improperly high current flow, they will melt and stop
current flow. They are designed to protect the vehicle's,
electrical system from electrical shorts in circuits that
are not protected by circuit breakers or fuses. For fuse
and fusible link locations, refer to SECTIONS 8A-10
.
and 8A-11.
DIAGNOSIS-ELECTRICAL
TCS Enable Switch

The TCS enable switch is a momentary contact
switch used to enable or disable the Traction Control
System. The switch assembly consists of a momentary
contact press button switch and an indicator lamp. The
Traction Control System can be enabled and disabled
during an ignition cycle by pressing the switch. Each
Ignition to "RUN" resets the TCS to enable. This
insures a consistent state at startup for the driver. The
indicator lamp within the switch assembly will
illuminate when TCS is enabled.
When the TCS enable switch is depressed, the
TCS will be disabled. The indicator lamp in the switch
assembly will turn "OFF"and the TCS warning lamp
in the instument cluster will tum "ON."
Brake Combination Valve

Refer to "Brake Combination Valve" in
SECTION 5A.
Wiring Harness
The wiring harness is the mechanism by which
the EBTCM is electrically connected to power and
ground, wheel speed sensors, motors, solenoids, fuses,
switches, lamps, the enable relay and the serial
communications port. The components, considered part
of the wiring harness, are the wires that provide
electrical interconnection and connectors/terminals that
provide an electrical/mechanical interface from the
wire to a system component.
DIAGNOSTIC PROCESS
When servicing the ABS VI/TCS, the following
steps should be followed in order. Failure to follow
these steps may result in the loss of important
diagnostic data and may lead to difficult and
time-consuming diagnosis procedures:
1. Perform a vehicle preliminary diagnosis
inspection. This should include:
Inspection of the master cylinder fluid
reservoir for proper brake fluid level and signs
of contamination.
Inspection of the hydraulic modulator for any
leaks or wiring damage.
Inspection of brake components at all four
wheels. Verify no drag exists. Also, verify
proper brake apply operation.
Inspection for worn or damaged wheel
bearings that may allow a wheel to "wobble."
Inspection of the wheel speed sensors and their
wiring. Verify proper undamaged wiring,
especially at vehicle attachment points.
Verify tires meet legal tread depth
requirements.
2. Perform "Diagnostic System Check" found in this
section. If any DTCs are displayed, select "Fl:
DTC History" to note the last malfunction that
occurred. Diagnose and repair this malfunction
first.

3. If no DTCs are present; or no mechanical
component malfunctions are present, .or if the
.. failure is .intermittent and no.t reproducible, test
drive the yehicle while using the auto trigger
feature of the Tech 1. Perform normal
acceleration, stopping; and turning maneuvers. If
this does not reproduce the malfunction, perform
an ABS stop, on a low coefficient surface such as
gravel, from approximately 48-80 km/h (30-50
mph) while triggering the snapshot mode on any
DTC. Still using the Tech 1 auto trigger feature,
perform a TCS .event on a low coefficient surface,
such as gravel, from a stop. If the failure is still
not reproducible, .use the enhanced diagnostic
information found in DTC HISTORY to
determine whether or not this malfunction should
b~ diagnosed further based on frequency of
failure. Refer to "Enhanced Diagnostics" found in
this section.
4. Once all system .malfunctions have been
corrected, clear the ABS and' TCS DTCs:
SELF-DIAGNOSTICS
The EBTCM contains sophisticated on-board
diagnostics that, when accessed with a Tech 1, are
designed to identify the source of any system
malfunction as specifically as possible, including
whether or not the malfunction is intermittent. There
are 7 4 diagnostic trouble codes to assist with
diagnosis.
When using the Tech 1 with ABS/TCS VI th~

last dia~ostic trouble code is specifically identified,
and specific ABS or TCS data is stored at the tiine of
this malfunction. Also, in addition to the last DTC set
there is information about the first five DTCs set'.
Using the Tech 1, each input and output can be
monitored, thus enabling malfunction confirmation and
repair. verification. Manual .control of components and
automated functional tests are also available when
using the Tech 1. Details of many of these functions
are contained in the following sections.
DISPLAYING DIAGNOSTIC TROUBLE

CODES (DTCs)
Diagnostic trouble codes can be read through the
use of the Tech 1 scan tool. There are no provisions
for "Flash Code" diagnostics.
CLEARING DIAGNOSTIC TROUBLE

CODES (DTCs)
The DTCs in EBTCM memory are erased in one
of two ways:
1. Tech 1.
2. Ignition cycle default.
These two methods are detailed below. Be sure
to verify proper system operation and absence of
DTCs when the clearing procedure is completed.
The Tech 1 will not permit DTC clearing until
all DTCs have been displayed. Also, DTCs cannot be
cleared by' unplugging the EBTCM, disconnecting the
battery cables, or turning the ignition "OFF" (except
on an ignition cycle default).
5E211
Tech 1 Method
The Tech 1 method is the only method to be
used .when ~ervicing a vehicle. Select "F2: DTC(s)"
for diagnostic trouble codes. After DTCs have been
viewed completely, Tech 1 wHI ask, "CLEAR
DTCs"?; answer "YES." Tech 1 will then read
"HISTORY DATA WILL BE LOST. CLEAR DTCs"?
Answer "YES" and DTCs will be cleared.
Ignition Cycle Default

If no diagnostic trouble codes occur for 100
drive cycles [a drive cycle occurs when the ignition is
turned to "RUN" and the vehicle is driven faster than
16 km/h (10 mph)], any existing DTCs are
automatically cleared from the EBTCM memory.
INTERMITTENTS AND POOR

CONNECTIONS
As wJ.th most electronic systems, intermittent
malfunctions. ma~ be difficult to accurately diagnose.
The followmg is a method to try to isolate an
i1;1ter~ittent malfunction, especially wheel speed
crrcmtry.
If an ABS or TCS malfunction occurs, the ABS
warning lamp or TCS warning lamp will be "ON"
during the ignition cycle in which the malfunction was
detected. If it is an intermittent problem which seems
to have corrected itself (ABS warning lamp or TCS
warning lamp "OFF"), a diagnostic trouble code will
be stored. Also stored will be the history data of the
DTC at the time the malfunction occurred. The Tech 1
must be used to read DTC history data.
Most intermittent malfunctions are caused by
faulty electrical connections or wiring. Refer to
"Intermittent and Poor Connections" in SECTION
8A-4 for a very detailed explanation of how to locate
and repair intermittent conditions.
TECH 1 DIAGNOSTICS
The Tech 1, when plugged into the DLC,
becomes part of the vehicles electronic system. The
Tech 1 can perform the following functions:
Display ABS and TCS data.
.
Display and clear ABS and TCS diagnostic
trouble codes.
Control ABS and TCS components.
Perform extensive ABS and TCS diagnosis.
Provide diagnostic testing for intermittent ABS
and TCS conditions.
Each test mode has specific diagnosis
capabilities which depend upon various keystrokes. In
general, five keys control sequencing: "YES," "NO,"
"EXIT," "UP ARROW" and "DOWN ARROW."
The FO through F9 keys select operating modes,
perform functions within an operating mode, or enter
DTC or model year designations.
In general, the Tech 1 has six test modes for
diagnosing the ABS and TCS. The six test modes are
as follows:
MODE FO: DATA LIST - In this test mode, the
Tech 1 continuously monitors wheel speed data,
brake switch status and other inputs and outputs.
5E2-12
MODE F1: DTC HISTORY - In this mode, DTC

history data is displayed. This data includes how
many ignition' cycles since the DTC occurred,
along with other information for the last DTC set.
The first, five and last DTC set are included in the
DTC history data.
MODE F2: DIAGNOSTIC TROUBLE CODES
- In this, test mode, diagnostic trouble codes stored
by the EBTCM, both current ignition cycle and
history, may be displayed or cleared.
MODE F3: SNAPSHOT - In this test mode, the
Tech 1 captures data before and after a system
malfunction (auto trigger) from a forced manual
key press, or from a DTC setting.
MODE F4: MISC. TESTS - In this test mode,
the Tech 1 performs various ABS functional tests
to assist in problem isolation during
troubleshooting.
MODE F6: BLEED PREP - In the first part of
this mode, the Tech 1 commands the EBTCM to
re-home the motors on the ABS hydraulic
modulator and the TCS hydraulic modulator. In
the second part of bleed prep, the Tech 1 cycles
the TCS modulator to move any trapped air that
may be remaining to the top of the TCS
modulator so that , it may be removed when
bleeding is continued. This mode must ALWAYS
be used prior to bleeding the brake system.
Enhanced Diagnostics
Enhanced diagnostic information,, found in the
DTC HISTORY function ,of the Tech 1, is designed to
provide the service technician with specific
malfunction occurrence information. For each of the
first five and the very last diagnostic trouble code set,
data is stored to identify the specific DTC, the number
of occurrences, and the number of drive cycles since
the malfunction first and last occurred [a drive cycle
occurs when the ignition is turned to "RUN" and the
vehicle is driven faster than 16 km/h (10 mph)].
However, if a malfunction is present, the drive cycle
counter will increment by turning the ignition to
"RUN" and "OFF." These first five diagnostic
trouble codes are also stored in the order of
occurrence. The order in which the first five DTCs

occurred can be useful in determining if a previous
malfunction is linked to the most recent malfunction,
such as an intermittent wheel speed sensor which later
becomes completely open.
During difficult diagnosis situations, this
information can be used to identify malfunction
occurrence trends. Did the malfunction only
occurrence over a large number of drive cycles,
indicating an unusual condition present when it
occurred? Does the malfunction occur infrequently
over a large number ,of drive cycles, indicating that
special diagnosis techniques may be required to
identify the source of the malfunction?
If, for example, a malfunction occurred 1 out of
50 drive cycles, the malfunction is intermittent and has
not recurred for 49 drive cycles. This malfunction may
be difficult or impossible to duplicate and may have
been caused by a severe vehicle impact (large pot
hole, speed bump at high speed, etc.) that momentarily
opened an electrical connection or caused unusual
vehicle suspension movement. Problem resolution is
unlikely, and the problem may never recur (check
diagnostic aids provided for that DTC). If, for
example, the malfunction occurred 3 out of 15 drive
cycles, the odds of finding the cause are still not good,
but you know how often it occurs. If the malfunction
occurred 10 out of 20 drive cycles, the odds of finding
the cause are very good, as the malfunction may be
easily reproduced. By using the additional malfunction
data, you can also, determine if a malfunction is
randomly intermittent or, if it has not recurred for long
periods of time due to weather changes or a, repair
prior to this visit. Say a DTC occurred 10 of 20 drive
cycles but has not recurred for 10 drive cycles. This
means the malfunction occurred l O of 10 drive cycles
but has not reoccurred since. A significant
environmental change or a repair may have occurred
10 drive cycles ago. A repair may not be necessary if
customer information can confinn a recent repair. If
no repair was made, the ,service technician can focus
on diagnosis techniques used to locate
difficult-to-recreate problems, such as those suggested
in "Diagnostic Aids" for the DTC in question.
DIAGNOSTIC PROCESS
(Page 1 of 5)
MSC CHASSIS APPLICATION SELECTION
TECH 1 SCREEN DISPLAY
STEP 1 SELECT VEHICLE MODEL YEAR
MODEL YEAR: 19??
STEP 2 SELECT VEHICLE TYPE
"FO: PASSENGER CAR"
STEP 3 SELECT BODY TYPE

STEP 4 SELECT MODE (FIRST SCREEN)
I
FO:
DATA LIST
F1:
OTC HISTORY
F2:
DTC(s)
F3:
SNAPSHOT
F4:
MISC. TESTS
F6:
BLEED PREP
i,..............................,i
INFORMATION ABOUT
PREVIOUS DTCs STORED
DTCs STORED AND CLEAR DTCs
....,_....,-II
I
L~::============~""'1
SELECT SYSTEM
FO: ABS
F1: TCS
i"'
FRONT WHL SPEEDS

REAR WHL SPEEDS
VEHICLE SPEED
LR TCS MOTOR CMD
LR TCS MTR FDBK
RR TCS MOTOR CMD
RR TCS MTR FDBK
BRAKE SWITCH
EBTCM BAT VOLT
EBTCM IGN VOLT
TRACTION CONTROL ENABLED/DISABLED
TRACTION CONTROL ACTIVE/NOT ACTIVE
ADJUSTER ASM CMD
ADJUSTER ASM FDBK
THROTTLE ANGLE
THERMAL MODEL
DEL TORQUE FREQ
LF ROTOR TEMP
RF ROTOR TEMP
RR ROTOR TEMP
LR ROTOR TEMP
TCS SYSTEM TEMP
ROTOR TEMPS
ADJ. ASS TEMP
TCS MODEL TEMP
..........~ SELECT SNAPSHOT
FRONT WHL SPEEDS

REAR WHL SPEEDS
VEHICLE SPEED
ABS WARNING LAMP
LF ABS MOTOR CMD
LF ABS MTR FDBK
RF ABS MOTOR CMD
RF ABS MTR FDBK
REAR ABS MTR CMD
REAR ABS MTR FBK
LF SOLENOID CMD
RF SOLENOID CMD
BRAKE SWITCH
ABS RELAY CMD
BRK WARN LP CMD
BRAKE WARN LAMP
EBCM BAT VOLTAGE
EBCM IGN VOLTAGE
FO: ABS
F1: TCS
1 t : = = = J - - - - - - 1 SNAP SHOT OPTIONS

I,,
FO: REPLAY DATA
F1: MANUAL TRIG.
F2: AUTO TRIG.
SELECT SYSTEM
CONTINUED ON FOLLOWING
F3: ANY OTC
FO: ABS
L-._
........"'l,
CHART
!
F4: SINGLE OTC
F1: TCS
r-{PAGE 2 OF 5)
/
F9: TRIG. POINT
!
!
1,,,,.;;,;1;;;,,u,u;,,,,,,,,,,,,,,,.u,,,,,,,,,,,;,,,,,,,,,,;;,I
,,,,,,,,,,,.,,,,,,,,,,,.,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,9
i CONTINUED ON FOLLOWING
.........,
CHART
L,,,,,...,,,,,<PAGE_4_0F
THIS FUNCTION IS USED TO
1,,,,...,.....,....,...........j PREPARE THE SYSTEM FOR
BLEEDING AND TO PURGE
AIR DURING BLEEDING.
/
/
5l,,,,,,,,,,,,,,,l
FO:
F1:
F2:
BEGINNING
CENTER
END OF DATA
C10009
5E2-14
DIAGNOSTIC PROCESS
(Page 2 of 5)
(
f CONTINUED FROM PREVIOUS CHART I
j
."""I
'"' "'"'"'"'""'""""'"'""''"'"'"""''"' "'"'"!
(PAGE 1 OF 5)
MISC. TESTS
,.,,,.,,,,.,.,,.,,,,,,,,,,,.,.,,,.,,,.,,,.,,,,.,,,.,,,,,.,,,,,,.,,,.,,.,.,,,,.,,,,,.,,.,,,,,.,.,,.,,,,,.,.,,.,.,,,,.,.,,,.,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,.,,,,.,,
FO:
MANUAL CNTRL
: CONTINUED ON FOLLOWING CHART (PAGE 3 OF 5).
F2:
HYDRL.CNTRL
I APPLY/HOLD/RELEASE FUNCTIONS.
F4:
MOTOR TEST
l AUTOMATED ABS MOTOR PACK DIAGNOSIS.
F5:
GEAR TEN REL
I VEHICLE SERVICE.
F6:
RELAY TEST
I TEST OF ABS ENABLE RELAY.
F7:
VOLTAGE LOAD
I ABS
F8:
LAMP TEST
I MANUAL CONTROL OF THE "ABS WARNING", "ABS

I ACTIVE" AND RED "BRAKE" WARNING LAMPS.
F9:
SYSTEM ID
I ID, DATE, CODE,
,,,.,,,,,.,.,.,,,,,.,,,,.,,.,.,.,,,.,,,,.,.,.,.,.,.,.,.,.,.,,.,,.,.,,.,,,,,,.,.,,,.,.,.,.,.,.,.,,,,.,.,.,.,.,.,,,.,.,.,.,.,,,,,.,,,,.,.,.,.,.,.,.,.,.,,.,.,.,,.,.,.,.,.,,,,.,,.,.,,,
I MANUAL TEST OF MODULATOR HYDRAULICS -
I PREPARE
ABS HYDRAULIC MODULATOR FOR OFF
TEST FOR ADEQUATE BATIERY CAPACITY FOR

OPERATION.
INFORMATION ON SYSTEM CONFIGURATION, PROM

ETC.
c10,010
DIAGNOSTIC PROCESS
(Page 3 of 5)
r
:
!
CONTINUED FROM
PREVIOUS CHART
(PAGE 2 OF 5)
!
!
"'"l"'""'"'"'"""'""'""'"""'"'"'
MANUAL CONTROL
OF SOLENOIDS
AND MOTORS.
I
t = TURN ON
=TURNOFF
YES TO CONTINUE
I
SELECT ABS FUNCTION
FO: LF APPLY
F1: LF RELEASE
F2: LF SOLENOID
F4: RF APPLY
FS: RF RELEASE
F6: RF SOI.ENOID
FB: REAR APPLY
F9: REAR RELEASE
I
ABS MTR APPLY
COMMAND: XX AMPS
FEEDBACK: XX AMPS
ABS RELAY: ON/OFF
I
ABS MTR REL
COMMAND: XX AMPS
FEEDBACK: XX AMPS
ABS RELAY: ON/OFF
I
SOLENOID
COMMAND: ON/OFF
ABS RELAY: ON/OFF
C7969
5E2-16
DIAGNOSTIC PROCESS
(Page 4 of 5)
f CONTINUED FROM PREVl,OUS CHART !
(PAGE 1 OF 5)
""""l"""'"""'""""'""""""'""""'""""'""'"""'
MISC. TESTS
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,1,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
FO:
MANUAL CNTRL
; CONTINUED ON FOLLOWING CHART (PAGE 5 OF 5). \
F4:
MOTOR TEST
: AUTOMATED TCS MOTOR PACK DIAGNOSIS.
FS:
LAMP TEST
MANUAL CONTROL OF TCS WARNING LAMP, "LOW

I TRAC" AND RED "BRAKE" LAMPS.
F9:
SYSTEM ID
I INFORMATION ON SYSTEM
I ID, DATE, CODE, ETC.
t,,,,.,.,,,,Uiil,Ulllllll,11,,uuiiiiiilll',1,,,,,,,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,u,,,,,,.,,,,,,,,,,,/.
CONFIGURATION, PROM
I
I
ANTILOCK BRAKE SYSTEM WITH TRACTION CONTROL 5E217
DIAGNOSTIC PROCESS
(Page 5 of 5)
i,'.i:
CONTINUED FROM
PREVIOUS CHART
(PAGE 4 OF 5)
ii,
'"""'[""'""""'"'""""""""'"""'
MANUAL CONTROL
OF TCS MOTORS.
I
t = TURN ON
J =TURNOFF
YES TO CONTINUE.
I
SELECT ABS FUNCTION
FO: LT APPLY
F1: LT RELEASE
F4: RT APPLY
'F5: RT RELEASE
F6: ADJUSTER ASM
I
TCS MTR APPLY
COMMAND: XX AMPS
FEEDBACK: XX AMPS
TCS RELAY: ON/OFF.
I
TCS MTR REL.
COMMAND: XX AMPS
FEEDBACK: XX AMPS
TCS RELAY: ON/OFF.
I
ADJUSTER ASM.
COMMAND: XX AMPS
FEEDBACK: XX AMPS
TCS RELAY: OFF.
C7971
5E2-18
REFER TO SECTION 8A10
B+
IGNITION
DATALINK CoNNE CTO R

(DLC}
r--,
! ..
B+
REFER TO
5ECTIONBASO
;;-J
EBTCM
--800TAN----4e11----~A12 ~
SOOTAN
5225 C200 S270
UNDERHOOD l!LECTRICAL CENTER
t
~Dr---------------,
I
L
FUSIBLE
LINKB
!502
AF~S~A8T
SERIAL DATA LINE
'100
....-11-I-'11"'V------------1,-.----'1fL440 ORN
641 BRN
I
I
I
EIATTERYINIPUT
~
I
5AMP
ABS IGN
FUSE 1
'
,1r---------------------r-------111
SWITCHED
IGNITION
641 BRiii
SAMP
AEIS/TCS
RELAY ENABLE
302 RED
CONTROL
I
5272
AEIS/TCS
SWITCHED
BATTERY INPUT
GROUND
C2
0604!16
FT0085E

(Page 1 of 4)
System Description:
Antilock Brake Traction Control System (ABS
VI/TCS) malfunction. It must be the starting point for
any ABS VI/TCS complaint diagnosis because it
directs the service technician to the next logical step in
diagnosing the complaint.
Serial data is transmitted by the EBTCM through
connector "Cl", terminal "Al". The EBTCM is
supplied switched ignition voltage through connector
"Cl", terminal "A9", battery voltage through
connector "Cl," terminal "B12" and switched battery
voltage through connector "C2", terminal "C." The
EBTCM ground is provided through connector "C2",
terminal "D."

1. Indicates if EBTCM is transmitting data.
2. Checks for a serial data line malfunction.
3.
4.
5.
6.
Checks for
Checks for
Checks for
Checks for
circuit.
7. Checks for
8. Checks for
operation.
9. Checks for
proper Tech 1 connection to DLC.

open ABS BAT 5 amp Fuse 6.
open ABS IGN 5 amp Fuse 1.
high resistance in the EBTCM ground
current DTCs.
proper ABS and TCS warning lamp
history DTCs.
Diagnostic Aids:
EBTCM. If communication with the EBTCM is not
possible, ensure the ABS VI/TCS ground connection is
0
\
5E2-19
DIAGNOSTIC SYSTE M
CHECK
VERIFY ALL EBTCM CONNECTORS ARE CONNECTED PROPERLY.

INSTALL TECH 1.
IGNITION TO "RUN."
WITHIN ABS OR TCS PORTION OF MASS STORAGE CARTRIDGE
CHASSIS APPLICATION, SELECT "FO: DATA LIST."
IS DATA BEING RECEIVED FROM THE EBTCM?
(Page 1 of 4)
. I
I . I
YES
NO
DOES TECH 1
DISPLAY "NO
COMMUNICATION
WITH VEHICLE.
CHECK DLC
CONNECTOR"?
NOTICE: ENSURE MASS STORAGE

CARTRIDGE IS UPDATED TO INCLUDE
THE LATEST AVAILABLE VERSION OF
THE CHASSIS APPLICATION.
01
SELECT "F2: DTC(s)."

ARE ANY CURRENT DTCs DISPLAYED?
YES
NO
, ... (.,,,..,,,,,,,,,,,, i
REFER TO
i APPLICABLE i
G)
8
!,,,,,,,,,,,,,,,,,,,,,.,,,.,.,,..,..
DTC CHART. !
IGNITION "OFF" FOR 10 SECONDS.

TURN IGNITION TO "RUN" AND OBSERVE ABS WARNING LAMP
AND TCS WARNING LAMP.
DID LAMPS ILLUMINATE FOR 3 SECONDS AND THEN GO "OFF"?
.
. I
.
. I
YES
G)
. I
NO
ENSURE TECH 1
DLC CONNECTOR
IS CONNECTED
PROPERLY TO
DLC.
IS CONNECTION
GOOD?
.I
YES
YES
SELECT "F1: DTC HISTORY."

ARE ANY HISTORY DTCs PRESENT?
NO
, ... IL,.,,.,,..,,,,,
i REFER TO!
! SECTION j
if,.,.,.,,,..,,,,,,,.,,,.,,,,,,,,,,
8A50.
j
NO
DOES ABS WARNING LAMP OR TCS

WARNING LAMP ILLUMINATE
INTERMITTENTLY?
I
. I
YES
TO FURTHER
DIAGNOSE
CUSTOMER
COMPLAINT, REFER
TO "DIAGNOSTIC
PROCESS," STEP 3,
IN THIS SECTION.
NO
,,,,.,.,mumm,mmhum,,
REVIEW
GO TO CHART A
"ENHANCED
FOR ABS
DIAGNOSTICS" ! WARNING LAMP
INFORMATION j OR CHART E FOR
IN THIS
! TCS WARNING
SECTION.
j LAMP "ON" OR
i uoFF"
! CONSTANTLY, NO
! DTCs STORED.
..
NO
IGNITION "OFF."
REMOVE AND INSPECT ABS/BAT FUSE 6,5 AMP.
IS FUSE OPEN?
YES
,,,.R,mmummmu
! !GO TO CHART
! ! FOR ABS
!
J
!
!
f
!
!
,,,,,,,,,,,.,,,,,,,,,,,,,.,.,,,,,.,,,,,,,;
b':'bNJ:~/:
i TCS WARNING
! LAMP "ON"
! INTERMITTEN
! NO DTCs
!,STORED .,,,,,,,,
RECONNECT TECH 1 DLC CONNECTOR.

NO
I
u , J. . , m m , m h m h m , m , m m m m m m m " j
! GO TQ
PAGE 2 OF 4 OF THIS. !
!_DIAGNOSTIC, SYSTEM, CHECK.
.
YES
puu Jhmuummmmmhm,mmhmmm,-. ,

INSTALL ABS/IGN FUSE 1, 5 AMP.
DISCONNECT GREY 8-WAY EBTCM CONNECTOR.
USING J 39200, MEASURE FIESISTANCE BETWEEN THE
NEGATIVE BATTERY TERMINAL AND GREY 8~WAY EBTCM
HARNESS CONNECTOR TERMINAL "D".
IS ::IESISTANCE 2 OHMS OR LESS?
R
YES
YES
i
INSTALL ABS/BAT FUSE 6, 5 AMP.

REMOVE AND INSPECT ABS/IGN FUSE 1, 5 AMP.
IS FUSE OPEN?
NO
(' J. """"""'"'""'"'"'"'""""""""'"'"""'""""""'"'"'""'"""'"'"""""""" !
!GO TO PAGE 4 OF 4 OF THIS DIAGNOSTIC SYSTEM CHECK. !

1;;,u,;.,.,,,.,.,,,,,,,,,,u,,,,,,,,,,,,,,,,.,,.,,,.,,,,.,,,.,,,.,.,,.,,.,,.,,,,,,,,,,.,,,,,,,,,,,,,,,,,.,,,,,,,,,,.,,,.,.,.,.,,,.,,,,,,,,,,.,,,I
!LGO
TO PAGE 3 OF 4 OF THIS !
DIAGNOSTIC SYSTEM _CHECK. J
.
NO
I
REPAIR OPEN OR HIGH RESISTANCE IN CKT 651.

C7972
5E2-20 ANTILOCK BRAKE SYSTEM WITH TRACTION CONTROL

B+
IGNITION
FUSIBLE
UNKB
REFER TO
SECTION8A50 ~
DATALINKCONNECTOR
(DLC)
~ ! ~--800 TAN----ti1....---rA12 ~
B+
5225 C200
502
Ri.I --A~lAr- .. -
EBTCM
800 TAN
8270
SERIAL DATA LINE
P100
...... - .. - .. - ,
'-------fll"""V-------------11-----r1f'L440 ORN
I SAMP
V641 BRN
I
I
ABSIGN
FUSE 1
BATTERY INPUT
:
SWITCHED
IGNITION
641 BRN
' - - - - - - 3 0 2 RED-"-----,
ABS/TCS
RELAY ENABLE
CONTROL
ABS/TCS
SWITCHED
BATTERY INPUT
1633
RED
1833
RED
s11s---1
' - - - - - - - 3 0 2 RED-+-----'
1633
RED
:
I
I
I TO ADJUSTER
I ASSEMBLY :
5111
I
~651
01-!L ______ j _______ ~_ BLK/WHT
VALVE SOLENOIDS
-
L .... -
............... _
............... .,.J
GROUND
C2
05-04-95
FT0085E
(Page 2 of 4)
System Description:

connector "Cl," terminal "Bl2" and switched battery
terminal "D."

10. Checks for possible short to ground in the battery
feed circuitry.
EBTCM.
Diagnostic Aids:
supply circuits will no_t allow communication with the
EBTCM; If communication with the EBTCM is not
DIAGNOSTIC SYSTEM
CHECK
{Page 2 of 4)
CONTINUED FROM DIAGNOSTIC

LSYSTEM_CHECK_ (PAGE 1_0F_4).J
YES
REPLACE ABS/BAT FUSE 6, 5 AMP.

WAIT 10 SECONDS.
REMOVE AND INSPECT ABS/BAT FUSE 6, 5 AMP.
IS FUSE OPEN?
DISCONNECT 32WAY EBTCM CONNECTOR.

REPLACE ABS/BAT FUSE 6, 5 AMP.
WAIT 10 SECONDS.
IS FUSE OPEN?
INSTALL FUSE.
REFER TO SECTION SA TO DIAGNOSE FOR A
POSSIBLE SHORT TO GROUND IN BATTERY FEED
CIRCUITRY. RETURN TO FIRST STEP IN THIS CHART.
yu,,, .u,,,,,,,,,,u;,,u,,,,u,uu,,,,,,,,,,,;,u;;,;,,,,.,,,,,,,,,,,,,,,,,,,
! REFER TO SECTION SA TO DIAGNOSE !

! FOR A SHORT TO GROUND IN THE j
!I,,,,,,,,,,,,,,,,,.,.,,.,.,,,.,,,,,,,,,,,,,.,,,,.,,.,.,,,,.,,.,.,.,,,.,.,,,,..,,,,,,,,,.,,,,,,,.,,,,,,$
BATTERY FEED CIRCUIT.
!
INSPECT CKT 440 AND 32-WAY EBTCM HARNESS

CONNECTOR FOR PHYSICAL DAMAGE WHICH MAY
RESULT IN A SHORT TO GROUND WITH THE 32-WAY
EBTCM HARNESS CONNECTOR CONNECTED TO THE
EBTCM. CORRECT DAMAGE IF EVIDENT.
WAIT 10 SECONDS.
IS FUSE OPEN?
REPLACE EBTCM.
REPLACE ABS/BAT FUSE, 6,
5 AMP. RETURN TO FIRST
STEP IN'THIS CHART.
MALFUNCTION IS
INTERMITTENT.
C7973
5E2-22
ANTI LOCK BRAKE SYSTEM WITH TRACTION CONTROL

B+
IGNITION
r '; 1
502
REID
EBTCM
sEfM:f"CJf.5o ;:;)_
DATAUNKCONNECTOR
(DLC)
B+
L - ..--BOO TAN
_ _ __.:_ _ _rLA-12,...
5225 C200
800 TAN
SERIAL DATA LINE
-ABS BAT-- - ----- ---.,
P100
FUSE &
.
I
'-----il......_fl'"'-.Ja-------~--~--1.-------,r1tt._4400RN
I SAMP
~
I
I ABS IGN
I
I FUSE 1
~t-------------,r--------t
641 BRN
641 BRN
SAMP
302 RED
S270
..
BATTERY INPUT
SWITCHED
IGNITION
1633
s11s----11
- - - RED
'---------302 RED-+---__,
5272
1833
RED
1833
I
I
1
I
I TO ADJUSTER
I ASSEMBLY :
.. ___________
RED
ABS/TCS
RELAY ENABLE
CONTROL
ABS/TCS
SWITCHED
BATTERY INPUT
- - - ~ 851
..
I
I
I
GROUND
TO ABS BRAKE PRESSURE G 1
- ~
VALVE SOLENOIDS
_____ TO
-''-------~BLKJWHT
REFER
SECTION 8A14
..
C2
05-0495
FT0081iE
{Page 3 of 4)
System Description:

directs the service technician to the riext logical step in
"C 1 ", terminal "A9", battery voltage through
terminal "D."

switched ignition circuitry.
14. Isolates the short to ground to either the circuitry
or the EBTCM.
Diagnostic Aids:
5E2..;23
DIAGNOSTIC SYSTEM
CHECK
(Page 3 of 4)
rmmm,muumuum,mmuuumummummu
! CONTINUED FROM DIAGNOSTIC !

!~,,,,,,,,,
SYSTEM CHECK (PAGE 1 OF 4) !
,,.,,,,,,,,,,,,,,,,,,,n.,,,,,,,,,,,,,,,..,,,,,.,,,,,,,,,,,,,,.,,,,../
REPLACE 5 AMP ABS IGN FUSE 1.

IGNITION "ON."
WAIT 10 SECONDS THEN TURN IGNITION "OFF.''
REMOVE AND INSPECT 5 AMP ABS IGN FUSE 1.
IS FUSE OPEN?
DISCONNECT 24-WAY EBTCM CONNECTOR.

REPLACE 5 AMP ABS IGN FUSE 1.
IS FUSE OPEN?
INSPECT CKT 641 AND 24-WAY EBTCM HARNESS

CONNECTOR FOR PHYSICAL DAMAGE WHICH MAY
RESULT IN A SHORT TO GROUND WITH THE 24-WAY
EBTCM HARNESS CONNECTOR CONNECTED TO THE
EBTCM. CORRECT DAMAGE IF EVIDENT.
IGNITION TO "RUN.''
IS FUSE OPEN?
REPLACE EBTCM.
REPLACE 5 AMP ABS IGN FUSE 1. RETURN TO
INSTALL FUSE. REFER TO SECTION SA TO DIAGNOSE

FOR A POSSIBLE SHORT TO GROUND IN THE
SWITCHED IGNITION CIRCUITRY. RETURN TO FIRST
STEP IN THIS CHART.
.
f REFER TO SECTION 8A TO REPAIR A
! SHORT TO GROUND IN ONE OF THE !

! CKT 641 BRANCHES EXITING THE 5 !
! AMP ABS IGN FUSE 5. REPLACE 5 !
! AMP ABS IGN FUSE 5. RETURN TO l
!,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,u,,,,,,,,,.,,,,,,,,,,,.,,
THE FIRST STEP IN THIS CHART.
!
MALFUNCTION IS
INTERMITTENT.
C7974
5E2-24

B+
IGNITION
r-,
! ..
B+
502
RED
I
641 BRN
REFER TO
SECTION 8A50
DATA LINK CONNECTOR

(DLC)
L
--BOO TAN
5225 C200
EBTCM
~A12~
SOOTAN
S270
r---------------,
SERIAL DATA LINE
I
I
I
I
I
ABS BAT
FUSE 6
I
I
5AMP
ABS IGN
FUSE 1
I
I
I
fl"'V
P'IOO
BATTERY INPUT
@-4400RN
I
I
SWITCHED
IGNITION
641 BRN
5AMP
302 RED
ABS/TCS
RELAY ENABLE
CONTROL
ABStrCS
SWITCHED
BATTERY INPUT
1833
RED
S175
302RED
1833
RED
1833
RED
I
I
I
I
I TO ADJUSTER
I ASSEMBLY :
.. ___________
- - - ~ 851
f _______
01~
_____
'ff)_ ~LK/WHT
TO ABS BRAKE PR&SSURIE
REFER TO SECTION .8A14
VALVE SOLENOIDS
GROUND
C2
050495
FT0085E
(Page 4 of 4)
System Description:

terminal "D."

16. Checks, for an open in CKT 440 or 502.
17. Checks for high resistance in CKT 440 or 502.
ignition feed circuitry.
contact.
ignition circuit between the fuse block and the
EBTCM.
Diagnostic Aids:
DIAGNOSTIC SYSTEM
CHECK
,,,,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,,,,.,,,,,,,,,,,,,,,,,;
(Page 4 of 4)
! CONTINUED FROM DIAGNOSTIC !

l SYSTEM
CHECK (PAGE 1 OF 4)
l
).
~
""""f"'""'"'uuumuummuuummmum,.u.

24-WAY EBTCM HARNESS CONNECTOR TERMINAL "B12."
. I
I
YES
I
NO
REPAIR OPEN IN CKT 440

OR 502. RETURN TO FIRST
STEP IN THIS CHART.

POSITIVE BATTERY CABLE TERMINAL AND 24-WAY
EBTCM HARNESS CONNECTOR TERMINAL "B12".
I
I
YES
I
NO
IGNITION TO "RUN." (THIS IS DONE TO PROVIDE

CIRCUIT CONTINUITY).
POSITIVE BATTERY CABLE TERMINAL AND 24-WAY
EBTCM HARNESS CONNECTOR TERMINAL "A9".

CKT 440 OR 502. RETURN TO
I
YES
INSPECT EBTCM AND EBTCM CONNECTOR

TERMINALS FOR POOR TERMINAL CONTACT.
INSPECT BATTERY TERMINALS AND BATTERY
CABLE TERMINALS FOR A POOR CONNECTION.
REFER TO SECTION SA-4, "CHECKING TERMINAL
CONTACT."
IS POOR TERMINAL CONTACT OR A POOR
CONNECTION EVIDENT?
NO
IGNITION "OFF."
REMOVE 5 AMP ABS IGN FUSE 1.
USING J 39200, MEASURE RESISTANCE BETWEEN EACH 5
AMP ABS IGN FUSE 1. BLOCK TERMINAL AND 24-WAY EBTCM
HARNESS CONNECTOR TERMINAL "A9".
IS RESISTANCE 2 OHMS OR LESS FOR EITHER
MEASUREMENT?
I
YES
,
NO
mu ,m,mm,mmuuuum,mumumm.,
l REFER TO SECTION SA TO l
l REPAIR OPEN OR HIGH
! RESISTANCE BETWEEN
! POSITIVE BATTERY CABLE
l TERMINAL AND 5 AMP ABS
! IGN FUSE 1 BLOCK
j TERMINAL. RETURN TO THE
! FIRST STEP IN THIS CHART.
l
l
l
l
!
j
l
I
REPAIR OPEN OR
HIGH RESISTANCE IN
CKT 641. INSTALL 5
AMP ABS IGN FUSE 1.
RETURN TO FIRST
S.TEP IN THIS CHART.
i,,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,.i
I
NO
,,,.J.,,,,,,,,.,,,,,,,..,,.,,,.,,,.,,,mmmmuuuuummmmmm-,
l RECONNECT EBTCM CONNECTORS AND l
!
j
!
l;;,,,,,,u,1,uu,u,,,,,,,,,,,,,,,,,,,,,,u,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,u,,,,.,,..,/
BATTERY CABLES.
PROCEED TO SECTION SA-50.
YES
REPLACE TERMINALS OR REPAIR POOR

CONNECTION INTEGRITY. RETURN TO
C7975
5E226

CHART
A
B
c
D
E
F
DTC
14
15
16
17
18
21
22
23
24
25
26
27
28
32
33
34
35
36
37
38
41
42
44
45
46
47
48
51
52
53
54
55
56
57
58
61
62
SYMPTOM
"Al3S .!NOP" Lamp "ON" or "OFF" Constantly, No DTCs Stored
"ABS INOP" Lamp "ON" Intermittently, No DTCs Stored
ABS/TCS Active Indicator Lamp "ON" With Ignition "OFF", No DTCs Stored
Tech 1 Displays Undefined DTCs
TCS (Amber) Warning Lamp "ON" or "OFF" Constantly, No DTCs Stored
TCS (Amber) Warning Lamp "ON" Intermittently, No DTCs Stored
DESCRIPTION
ABS Relay Contact Circuit or Fuse Open (1 of 3)
ABS Rly. Contact CKT Short to Bat or Always Closed
ABS Relay Coil Circuit Open
ABS Relay Coil Circuit Shorted to Gnd.
ABS Relay Coil Circuit Shorted to Batt.
Left Front Wheel Speed = 0
Right Front Wheel Speed = 0
Left Rear Wheel Speed = 0
Right Rear Wheel Speed - 0
Left Front Excessive Wheel Speed Variation
Right Front Excessive Wheel Speed Variation
Left Rear Excessive Wheel Speed Variation
Right Rear Excessive Wheel Speed Variation
LF Wheel Speed SNR CKT Open or Short to Gnd/Bat (1
RF Wheel Speed SNR CKT Open or Short to Gnd/Bat (1
LR Wheel Speed SNR CKT Open or Short to Gnd/Bat (1
RR Wheel Speed SNR CKT Open or Short to Gnd/Bat (1
Low System Voltage (1 of 2)
High System Voltage
Left Front ESB Will Not Hold Motor
Right Front ESB Will Not Hold Motor
Rear ESB Will Not Hold Motor
Left Front ABS Channel Will Not Move
Right Front ABS Channel Will Not Move
Rear ABS Channel Will Not Move
Left Ftont ABS Motor Free Spins (1 of 2)
Right Front ABS Motor Free Spins (1 of 2)
Rear ABS Motor Free Spins (1 of 2)
Left Front ABS Channel in Release Too Long
Right Front ABS Channel in Release Too Long
Rear ABS Channel in Release Too Long
EBTCM Malfunction (ABS)
Left Front ABS Motor Circuit Open
Left Front ABS Motor Circuit Shorted to Gnd
Left Front ABS Motor Circuit Shorted to Batt
Right Front ABS Motor Circuit Open
Right Front ABS Motor Circuit Shorted to Gnd
PAGE
5E2-34
5E2-35
5E2-36
5E2-37
5E2-38
5E2~39
5E2-40
5E2-46
5E2-48
5E2-50
5E2-52
5E2-54
5E2-56
5E2-58
5E2.:.60
of 3)
of 3)
of 3)
of 3)
5E2-62
5E2-64
5E2-66
5E2-68
5E2-70
5E2-76
5E2-82
5E2-88
5E2-94
5E2-98
5E2-100
5E2-102
5E2-104
5E2-106
5E2-108
5E2-110
5E2-112
5E2-116
5E2-120
5E2-124
5E2-126
5E2-128
5E2-130
5E2-132
5E2-134
5E2-136
5E2-138
5E2-140
(
T5731

Right Front ABS Motor Circuit Shorted to Batt
63
64
Rear ABS Motor Circuit Open
5E2-144
65
Rear ABS Motor Circuit Shorted to Ground
5E2-146
66
Rear ABS Motor Circuit Shorted to Battery
5E2-148
75
76
PCM to EBTCM Serial Data Malfunction

Left Front Sol Circuit Open or Shorted to Gnd.
5E2-150
5E2-152
77
Left Front Solenoid Circuit Shorted to Batt.
5E2-154
78
Right Front Sol Circuit Open or shorted to Gnd.
5E2-156
81
5E2-158
82
Right Front Solenoid Circuit Shorted to Batt.

Calibration Malfunction
5E2-160
86
EBTCM Turned ON the Red BRAKE Warning Lamp
5E2-162
87
Red BRAKE Warn Lamp Ckt. Open or Short to Batt. (1 of 2)
5E2-164
5E2-142
91
Open Brake Switch During Deceleration
92
Open Brake Switch When ABS Was Required
5E2-168
5E2-170
93
DTC 91 or 92 Set in Current or Prev. Ign. Cycle
5E2-172
94
Brake Switch Contacts Always Closed
5E2-174
95
111
Brake Switch Circuit Open

TCS Warning Lamp or Active Ckt. Malfunction (1 of 3)
5E2-176
5E2-178
115
Adjuster Assembly Thermal Model Temp Exceeded
5E2-184
123
PCM to EBTCM TP Sensor Circuit Malfunction
125
EBTCM to PCM .TCS Active Ckt Malfunction
5E2-186
5E2-188
126
144
EBTCM to PCM Spark Retarted Ckt Malfunction

Left TCS Channel Will Not Move
145
Right TCS Channel Will Not Move
5E2-190
5E2-192
5E2-194
146
Adjuster Assembly Will Not Move
147
Left TCS Motor Free Spins

Right TCS Motor Free Spins
5E2-200
148
5E2-196
5E2-198
154
Adjuster Assembly Malfunction
5E2-202
155
EBTCM Malfunction (TCS)
5E2-204.
156
Left TCS Motor Circuit Open
5E2-206
157
Left TCS Motor Circuit Shorted to Ground
5E2-208
158
Left TCS Motor Circuit Shorted to Battery
5E2-210
161
Right TCS Motor Circuit Open
5E2-212
162
163
Right TCS Motor Shorted to Ground
5E2-214
Right TCS Motor Shorted to Battery
5E2-216
Adjusted Assembly Motor Circuit Shorted to Gnd. or Open
5E2-218
Adjuster Assembly Motor Circuit Shorted to Batt.
5E2-220
165
166
T5731 (Cont'd)
5E2-28
1 ...,-----.1.,.
REFER TO
SECTION BASO
DATA LINK CONNECTOR

(DLC}
r-,
!
C1
SERIAL DATA UNE
J ~ - - - - - - - 8 0 0 T A N - - - - - - [ ~2Jo--S--1 - - 8 0 0 TAN
70
522 5
EBTCM
C200
INSTRUMENT
CLUSTER
IGNITION
REFER TO
SECTION BA-10
REFER TO SECTION BA-41
~R~---~
I
I
I
<<I<C!>l C10 CHEV

.. BRAKEU
A 1Op 0 NT
p-~-J-l-l
~~6&PCOHNEVT
"LOW TRAC"
~~:::
AMBER
IQ\
\0/
52061
REFERTO
5228
I
I
I
S~~~~N I
06 CHEV
B17PONT
"ABSINOP"
AMBER
AC18CPOHENVT
(CHEV)" ASR"
(PONT) "TCS OFF" I
~-----~
rr AS- :;'1
I
B+
ABS/TCS ACTIVE
LAMP CONTRO,L
II
II TO CRUISE CONTROL
I
I
I
I
TERMINAL "D".
REFER TO
SECTION SA-34
867LTGRN
ABS WARNING
LAMP CONTROL
l~I
1---1
1572PP~L
C4/ W
I T1572PPL/WHT
867LTGRN
TCSWARNING
LAMP CONTROL
:J
C200A
~~
(PONT ONLY)
TO TRACTION CONTROL SWITCH

REFER TO PAGE 3 OF 3
REFER TO SECTION
8A10
BRAKE WARNING
LAMP CONTROL
33TAN/WHT
. 5273
1537DKBLU~~537DKBLU
: .....__.:
I
I
10AMP
33 TAN/WHT
AMBER
3
..D-A\-
39 PNK
TO CRUISE CONTROL
TERMINAL "G".
TO CHMSL BULBS
REFER TO SECTION BA-110
1/P FUSE BLOCK

FUSIBLE
STOP/HAZARD
STOPLAMP SWITCH (C1)
FUS! 1
LINKF
11002 ~
20LT
A4,
20L1
14ooRNJ A ~ - ? a
L - J RED 20 AMP
BLU S243L - J 5271 BLU
C200A
C200A
C200D
C2000
[:__".:::] !
BRAKE SWITCH
INPUT
P100
BATTERY INPUT
---4400RN
SWITCHED
IGNITION
ABS/TCS
RELAY CONTROL
...._----302 RED------
ABS/TCS
SWITCHED
BATTERY INPUT
- - - - - - 3 0 2 RED-+---_,
r---------J
I. -
TO ABS
BRAKE
PRESSURE
VALVE
SOLENOIDS
REFER TO
PAGE 2 OF 3
I
I
I
TO ADJUSTER
ASSEMBLY I
REFER TO I
PAO! 3 OF 3 :
6111
1
1
--------1
G101 ~ REFER TO SECTION 8A14
Figure 8 - Wiring Diagram (1 of 3)
651
BLK/WHT
GROUN'D
'3
C
0101115
FT00911E

EBTCM
r------------------------.,
HYDRAULIC
ABS MOTOR PACK
MODULATOR
I
P100
ASSEMBLY
1.,.1
1 1 + - - - - - - 1 - - - - - - - 1 2 8 0 BLK
C2
LF ABS MOTOR HIGH
LFABS
MOTOR
LF ABS MOTOR LOW
11+------i---------1284 DK GRN
REAR ABS MOTOR

HIGH
1-r------,---------12850RN
REAR ABS MOTOR

LOW
- - - - - - - - - - - - - 1 2 8 2 PPL
RF ABS MOTOR HIGH
REAR ABS
MOTOR
RF ABS
MOTOR
Rf ABS MOTOR LOW
-----------------,I
FROM ABS VALVE

FUSE 5 REFER TO
PAGE 1 OF 3
I''
LF ABS SOLENOID
CONTROL
9 - - . - - - - - - 1 2 8 8 DK ORN
855
t.._____
orN
'-- - - - - 8 5 5 0 R N
I....
I
RF ABS SOLENOID
CONTROL
LT BLU
______________ _t-'-..._------1289
n
ABS JUMPER HARNESS
Lf WHEEL SPEED
SIGNAL HIGH
830 BLK--@aso LT BL 1.,.1

------873WHT---&873YEL-.--------1
I
I
C120
LF WHEEL SPEED
SIGNAL LOW
I
I
, I
I
I
I
ABS JUMPER HARNESS
I
I
RF WHEEL SPEED
SIGNAL HIGH
872 BLK - - 0 8 7 2 DK GRN
RF WHEEL SPEED
SIGNAL LOW
i - - - - - - - 8 3 3 W H T - - 0 - - 833 TAN-::::1::-------t
C130
P100
ABS JUMPER HARNESS
. - .. .,
884 BLK ---t[Jt-se4 BLK
.....
-...,
~ 884BLK
LR WHEEL SPEED
SIGNAL HIGH
LR WHEEL SPEED
SIGNAL LOW
885RED ~ 8 8 5 R E D ~ 8 8 5 R E D
LR WHEEL SPEED SENSOR

ABS JUMPER HARNESS
I
I
I
I
I
I
I
I
I
I
:
I
:
I
RR WHEEL SPEED
SIGNAL HIGH
8 8 2 B R N ~ 2 882BRN~882BRN
I
883WHT
D1
883WHT ~ 8 8 3 W H T
.. __ .,
L.-....1
C405
C200
RR WHEEL SPEED SENSOR
RR WHEEL SPEED
SIGNAL LOW
C1
051695
FT0105E
5E2-30
EBTCM
PtOO
TCS MOTORPACK
A
564 LT BLU
LRTCSMOTOR
HIGH
565DKBLU
LR TCS MOTOR
LOW
566LTGRN
RR TCS MOTO,R
HIGH
567DKGRN
RRTCSMOTOR
LOW
LRTCS
MOTOR
RRTCS
MOTOR
ADJUSTER ASSEMBLY
TO S180
REFER TO
PAGE1 OF3
1633RED
TCS ADJUSTER
ASSEMBLY MOlOR
LOW
561 GRY
POWERTRAIN CONTROL
C3
MODULE {PCM)
C1
, - TCS ACTWEID 832 LT BLU
I
I
I
TCS SPARK
I RETARD REQUEST
I
EBTCMTP
I._ SENSOR SIGNAL
lE]I
_____ ....fil
463
ORN/BU<
I
484
TAN/SU<
C1
TRACTION CONTRO
ACTIVE SIGNAL
832LTBLU
I
I
I
I
101
I
1.----..1
I
I
4630RN/BLK
SPARK RETARD
REQUEST
464TAN/BLK
RECEIVED THROTTL
POSITION
C3
C1,05
-----------------------------------
TCS ENABLE
SWITCH SIGNAL
----------------------------------- -----l,NTERIOR LIGHTS

REFER T O - - - - 8 GRY
SECTION BA-117
TRACTION CONTROL SWITCH

A
1571
BRN/WHT
.J A13"'I_
L-
C200D
C200A
1571
BRN/WHT
TCS ENABLE
SWITCH SIGNAL
I
C1
- --- - - - -- - -- --- - ----- -- - -- -- ------ --- -- -- -CHEV
051595
FT0116E
ANTI LOCK BRAKE SYSTEM WITH TRACTION CONTROL 5E2-31
12110088
24-WAY F MICRO-PACK 100 SERIES
LTGRY
ELECTRONIC BRAKE CONTROL MODULE (EBCM)/
ELECTRONIC BRAKE TRACTION CONTROL
MODULE (EBTCM) CONNETOR "Ci"
WIRE ENTRY VIEW

04119S
FT01251!
Figure 11 EBTCM Connector End View (1 of 3)
CONNECTOR
TERMINAL*
COLOR
800
TAN
BRN
RR WHEEL SIGNAL HIGH
BLK
LR WHEEL SIGNAL HIGH
DKGRN
RF WHEEL SIGNAL HIGH
Al
12
A2
11
A3
10
884
A4
872
A5 ..
A6
CIRCUIT NO.
8
7 ..
...
882
..
CIRCUIT DESCRIPTION
SERIAL DATA LINE
830
LT BLU
LF WHEEL SIGNAL HIGH
1537
DK BLU
ABS/TCS ACTIVE LAMP CONTROL
867
LTGRN
ABS WARNING LAMP CONTROL
A7
A8
PLUGGED
A9
5
4
641
BRN
AlO
All
3
2
1288
1632
DKGRN
PNK
A12
Bl
1
24
PLUGGED
883
WHT
RR WHEEL SIGNAL LOW
B2
B3
23
885
RED
LR WHEEL SIGNAL LOW
22
833
TAN
RF WHEEL SIGNAL LOW
B4
21
20
873
YEL
LF WHEEL SIGNAL LOW
B5
33
TAN/WHT
B6
19
1289
LT BLU
B7
18
1572
PPL/WHT
NOT USED
SWITCHED IGNITION
LF ABS SOLENOID CONTROL

ABS RELAY ENABLE CONTROL
NOT USED
B8
17
832
LT BLU
B9
16
820
YEL
BlO
15
PLUGGED
BRN/WHT
Bll
14
1571
ORN
13
440
B12
* connector shell may have one or both mdex sequence markmg.
BRAKE WARNING LAMP CONTROL

RF ABS SOLENOID CONTROL
TCS WARNING LAMP CONTROL
TRACTION CONTROL ACTIVE SIGNAL
BRAKE SWITCH INPUT
NOT USED
TCS CONTROL SWITCH SIGNAL
BATTERY FEED
T5732
5E2;..32
ELECTRONIC BRAKE/TRACTION
CONTROL MODULE (EBTCM) .
C2
8-WAY F METAi- PACK 280 SERIES

LRGRY
WIRE ENTRY VIEW
04-19-li
FT0135E
Figure 12 - EBTCM Connector End View (2 of 3)
TERMINAL
A
B
c
D
E
F
G
..
CIRCUIT NO.
1282
1283
1633
651
1285
1284
1280
1281
CIRCUIT
COLOR
PPL
RF ABS MOTOR HIGH
BLK
RF ABS MOTOR LOW
RED
SWITCHED BATI'ERY INPUT
BLKIWHT
GROUND
oRN/BLK
REAR ABS MOTOR LOW
DKGRN
REAR ABS MOTOR HIGH
ORN
LF ABS MOTOR HIGH
PNK
LF ABS MOTOR LOW

T5733
ELECTRONIC BRAKE/TRACTION
CONTROL MODULE (EBTCM)
C3
8-WAY F METRI- PACK 280 SERIES

BU<
WIRE ENTRY VIEW
04-18-fl
FT0141E
Figure 13 - EBTCM Connector End View (3 of 3)
PIN
A
B
c
D
E
F
G
H
CIRCUIT NO.
464
463
561
COLOR
TAN/BLK
RECEIVED THROTILE POSITION
ORN/BLK
GRY
TCS ADJUSTER ASSEMBLY MOTOR LOW
SPARK RETARD REQUEST

NOT USED
PLUGGED
567
566
565
564
CIRCUIT
DKGRN
RR TCS MOTOR LOW
LTGRN
RR TCS MOTOR HIGH
DK BLU
LR TCS MOTOR LOW
LT BLU
LR TCS MOTOR HIGH

T5734
5E234 ANTILOCK BRAKE SYSTEM WITH TRACTION CONTROL
CHART A
ABS (AMBER) ,WARNING LAMP "ON" OR
"OFF" CONSTANTLY, NO DTCs STORED

IGNITION "OFF."
INSTALL TECH 1.
IGNITION TO "RUN."
USING TECH 1, SELECT F4: MISC. TESTS.
SELECT FB: LAMP TEST AND ATTEMPT TO
TURN "ON" THE ABS WARNING LAMP.
DID THE ABS WARNING LAMP TURN "ON"?
I
I
YES
USING A TECH 1 LAMP TEST, ATTEMPT

TO "FLASH" THE ABS WARNING LAMP.
DID THE ABS WARNING LAMP "FLASH"?
I
YES

COULD BE CAUSED BY INCORRECT WIRING HARNESS ROUTING OR
LOOSE CONNECTIONS. INSPECT ALL CONNECTORS AND
TERMINALS FOR POOR TERMINAL CONTACT AND EVIDENCE OF
CORROSION. REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF
POOR TERMINAL CONTACT OR CORROSION.
NO
INSPECT THE ABS WARNING BULB TO

VERIFY BULB IS GOOD. REPLACE AND
BLOWN BULBS. IF BULB IS GOOD, REFER
TO SECTION 8A81 FOR FURTHER
DIAGNOSIS OF INSTRUMENT CLUSTER.
C7976
CHART B
ABS (AMBER) .WARNING LAMP "ON"
INTERMITTENTLY, NO DTCs STORED
5E2-35

IGNITION "OFF."
TERMINAL AND TERMINAL "D" OF THE GREY BWAY EBTCM HARNESS CONNECTOR.
NOTICE:
J 39200 TEST
LEADS MUST BE "ZEROE D"
PRIOR TO MAKING ANY
RESISTANCE
MEASUREMENTS.REFER TO
YES
NO
B

POSITIVE BATTERY CABLE TERMINAL AND TERMINAL "812"
OF THE 24-WAY EBTCM HARNESS CONNECTOR.
OBSERVE MEASURED RESISTANCE WHILE "WIGGLING" WIRE
HARNESS AND CONNECTORS.
REPAIR INTERMITTENT OPEN OR HIGH

RESISTANCE IN CKT 651. REFER TO
SECTION BA4, "INTERMITTENT$ AND
POOR CONNECTIONS."
I
II
YES
, NO
'
TURN IGNITION SWITCH TO "RUN" {THIS IS DONE TO

COMPLETE THE IGNITION CIRCUIT).
POSITIVE BATTERY CABLE TERMINAL AND TERMINAL "A9"
OF THE 24WAY EBTCM HARNESS CONNECTOR.

RESISTANCE IN CKTs 502 OR 440. REFER
TO SECTION BA-4, "INTERMITTENT$ AND
POOR CONNECTIONS."
I
YES
NO
R
INSPECT TERMINALS "A9" AND "812" OF THE 24-WAY EBTCM
CONNECTOR AND TERMINAL "D" OF THE GREY 8-WAY EBTCM
CONNECTOR FOR POOR TERMINAL CONTACT AND EVIDENCE OF
CORROCION. REFER TO SECTION 8A4, "CHECKING TERMINAL
CONTACT."

SECTION BA-4, "INTERMITTENTS AND
POOR CONNECTIONS."
I
l
I
NO
IGNITION "OFF."
IGNITION TO "RUN."
IS ABS WARNING LAMP "ON" INTERMITTENTLY WITH NO DTCs SET?
I
I

SIGNS OF CORROSION. REPAIR
CONNECTION INTEGRITY IF POOR
CONTACT EXISTS AT BATTERY.
--.
I
NO
-, I
YES
MALFUNCTION IS NOT PRESENT AT THIS TIME. INTERMITTENT$

OR LOOSE GROUND CONNECTIONS. REFER TO SECTION BA-4,
"INTERMITTENT$ AND POOR CONNECTIONS."
YES
REPLACE EBTCM.
l
C7977
5E2-36
CHART C
ABS/TCS ACTIVE INDICATOR LAMP "ON"
WITH IGNITION "OFF," NO DTCs STORED

IGNITION "OFF."
OBSERVE THE ABS/TCS ACTIVE WARNING LAMP.
IS THE ABS/TCS ACTIVE LAMP "ON"?
I
I
NO
I
INTERMITIENTS COULD BE CAUSED BY INCORRECT WIRING
HARNESS ROUTING OR LOOSE CONNECTIONS. INSPECT ALL
TERMINALS THAT EXHIBIT SIGNS OF POOR TERMINAL
I
YES
REPAIR SHORT TO
VOLTAGE ON CKT 1537.
C7978
.._~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~--'
CHART.D
TECH 1 DISPLAYS UNDEFINED DTCs
NOTICE: USE THIS CHART IF ANY OF THE FO,LLOWING UNDEFINED

DTCs ARE SET: 11, 12, 13, 31, 43, 67, 68, 71, 72, 73, 74, 83, 84, 85, 88, 96,'
97, 98, 112, 113, 116, 117, 118, 121, 122, 124, 125, 126, 127, 128, 131, 132,
133, 134, 135, 136, 137, 138, 141, 142, 143, 151, 152, 153, 164, 167, OR
168.
IGNITION TO "RUN."
DOES UNDEFINED DTC RESET?
REPLACE EBTCM.
MALFUNCTION IS NOT
C7979
5E2-38
CHART.E
TCS (AMBER) WARNING LAMP "ON" OR
"OFF" CONSTANTLY, NO DTCs STORED

IGNITION "OFF."
INSTALL TECH 1.
IGNITION TO "RUN."
USING TECH 1, SELECT F4: MISC. TESTS.
SELECT F8: LAMP TEST AND ATTEMPT TO TURN "ON" THE
TCS WARNING LAMP.
DID THE TCS WARNING LAMP TURN "ON"?
I
I
YES
I
USING TECH 1 LAMP TEST, ATTEMPT TO
"FLASH" THE TCS WARNING LAMP.
DID THE TCS WARNING LAMP "FLASH"?
1
I
YES
I
COULD BNE CAUSED BY INCORRECT WIRING HARNESS ROUTING
OR LOOSE CONNECTIONS. INSPECT ALL CONNECTORS AND
TERMINALS FOR POOR TERMINAL CONTACT AND EVIDENCE OF
CORROSION. REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF
I
NO
I
(
INSPECT THE TCS WARNING BULB TO VERIFY

BULB IS GOOD. REPLACE ANY OPEN BULBS. IF
BULB IS GOOD, REFER TO SECTION BA-81 FOR
FURTHER DIAGNOSIS OF INSTRUMENT CLUSTER.
C7980
CHART F
TCS (AMBER) WARNING LAMP "ON"
INTERMITTENTLY, NO DTCs STORED

IGNITION "OFF."
TERMINAL AND TERMINAL "D" OF THE GREY 8-WAY EBTCM HARNESS CONNECTOR.
NOTICE : J 39200 TEST L EADS

MUST BE "ZEROED" PRIO R TO
MAKING ANY RESISTANCE
MEASUREMENTS. REFER T0
YES
I

POSITIVE BATTERY CABLE TERMINAL AND TERMINAL "812"
NO
I

SECTION 8A-4, "INTERMITTENTS AND
POOR CONNECTIONS."
I
I
YES
TURN IGNITION SWITCH TO "RUN" (THIS IS DONE TO

COMPLETE THE IGNITION CIRCUIT).
POSITIVE BATTERY CABLE TERMINAL AND TERMINAL "A9"
NO

RESISTANCE IN CKTs 502 OR 440. REFER
TO SECTION 8A-4, "INTERMITTENTS AND
POOR CONNECTIONS."
I
I
YES

INSPECT TERMINALS "A9" AND "812" OF THE 24-WAY EBTCM
CONNECTOR AND TERMINAL "D" OF THE GREY 8-WAY EBTCM
CONNECTOR FOR POOR TERMINAL CONTACT AND EVIDENCE OF
CORROCION. REFER TO SECTION 8A4, "CHECKING TERMINAL
CONTACT."
I
I
NO
I
I

SECTION 8A4, "INTERMITTENTS AND
POOR CONNECTIONS."
IGNITION "OFF."
IGNITION TO "RUN."
IS TCS WARNING LAMP "ON" INTERMITTENTLY WITH NO DTCs SET?
NO
NO
YES

SIGNS OF CORROSION. REPAIR
CONNECTION INTEGRITY IF POOR
CONTACT EXISTS AT BATTERY.
MALFUNCTION IS NOT PRESENT AT THIS TIME. INTERMITIENTS

OR LOOSE GROUND CONNECTIONS. REFER TO SECTION 8A4,
"INTERMITTENTS AND POOR CONNECTIONS."
YES
REPLACE EBTCM.
I
C7981
5E2-40
ANTI LOCK BRAKE. SYSTEM WITH TRACTION CONTROL

EBCM EBTCM
IGNITION
REFER TO SECTION
C1
8A10
...
---
SWITCHED IGNITION
.,;,...--#11"\.__JIIF--- 841 BAN
B+ L
'-'---1632 PNK--111r----1
&AMP
1633RED
~302RED~
FUSIBLE
ABS/TCS RELAY
ENABLE CONTROL
ABS/TCS SWITCH!D
BATTERY INPUT
302 RED
LINKB
8171
----..I
CENTER
041115
FT01UE
DTC 14
(Page 1 of 3)
ABS RELAY CONTACT CIRCUIT OR FUSE OPEN
"C2" of the ABS/TCS relay. The EBTCM then is able
to energize the pull-in coil by completing the ground
EBTCM. The magnetic field created closes the
ABS/TCS relay contact and allows battery voltage and
current to be supplied to the EBTCM, which supplies
power to the motors and solenoids.

circuit from the battery to the relay.
6. Checks for high resistance in the relay contacts.
7. Checks for poor terminal coritact or corrosion at
the connectors.
8. Determines if the EBTCM is the cause of the
malfunction.
Diagnostic Aids:

and the ABS warning lamp is turned "ON."

this section.
the wiring harness.

1. Checks to see if DTC 16 is also set as current or
history. If DTC 16 is also set, proceed to that
chart first.
2. Verifies that the malfunction is currently present.
3. Verifies that the relay can be turned "ON" and
provide voltage to the EBTCM.
circuit from the relay to the EBTCM.

voltage changes significantly,. replace the relay. ,
than 32 F- o C), replace the relay.
DTC Will Set When:

DTC 14 can be set anytime after the EBTCM
commands the ABS/TCS relay "ON" (the relay is
first commanded "ON" during the three second bulb
Action Taken:
0 .
IS DTC 16 ALSO PRESENT OR IN HISTORY?
DTC 14
(Page 1 of 3)
ABS RELAY CONTACT
CIRCUIT OR FUSE OPEN
~""'"'"'""')
IGNITION TO "RUN," ENGINE "OFF.''

USING TECH 1, SELECT DATA LIST AND
OBSERVE EBTCM BATTERY VOLTAGE.
DOES TECH 1 INDICATE THAT EBTCM BATTERY
VOLTAGE IS GREATER THAN 10 VOLTS?
l
l
PROCEED TO l
DTC 16 CHART l
L_FIRST.,,,.,.,,,,,,,,.,..
NOTICE: J 39200 TEST LEADS MUST BE ''ZEROED"

8
G)
8
MALFUNCTION IS
NOT PRESENT AT
THIS TIME. REFER
TO "DIAGNOSTIC
AIDS" ON FACING
PAGE.
IGNITION "OFF.''
DISCONNECT 24-WAY AND GRAY 8-WAY EBTCM CONNECTORS.
CONNECT A FUSED JUMPER SUCH AS J 36169 WITH A 3 AMP FUSE BETWEEN
GROUND AND TERMINAL "A11" OF THE 24-WAY EBTCM HARNESS CONNECTOR.
IGNITION TO "RUN.''
USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND AND TERMINAL "C"
OF THE GRAY 8WAY EBTCM HARNESS CONNECTOR.
5E2-41
~.
IGNITION "OFF.''
DISCONNECT JUMPER USED IN STEP 3.
DISCONNECT ABSfTCS RELAY.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "C4" OF THE ABS!TCS RELAY
HARNESS CONNECTOR AND TERMINAL "C" OF THE GRAY 8-WAY EBTCM HARNESS CONNECTOR.
s
0
,,,,,,,.,,,,,,,,,,.,,,,,,,,,
j
j
DIAGNOSIS
CONTINUED
j
II,,,,;,,,,,,,,,,,,;,,,,,,,,,,,,.,.,,,,,/
PAGE 2 OF 3.
I
REPAIR HIGH
RESISTANCE
IN CKT 1633.

TERMINAL AND TERMINAL "C1" OF THE ABS!TCS RELAY HARNESS CONNECTOR.
s
0
USING A JUMPER WIRE, CONNECT TERMINAL "85" ON THE ABSfTCS RELAY TO GROUND.
USING A FUSED JUMPER WIRE, SUCH AS J 36169, WITH A 3 AMP FUSE, CONNECT TERMINAL ''86"
ON THE ABS!TCS RELAY TO B+.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINALS "30" AND "87" ON THE
ABS!TCS RELAY.
.
~
INSPECT ABS!TCS RELAY AND ABS!TCS RELAY HARNESS CONNECTOR FOR A POOR CONNECTION OR
INSPECT EBTCM AND EBTCM CONNECTOR TERMINALS "A11" AND "C" FOR POOR TERMINAL CONTACT.
INSPECT POSITIVE BATTERY TERMINAL AND POSITIVE BATTERY CABLE TERMINAL FOR A POOR
CONNECTION. REFER TO SECTION 8A4, "CHECKING TERMINAL CONTACT.''
IS POOR TERMINAL CONTACT OR A POOR CONNECTION EVIDENT?
s
0
.
s

IGNITION TO "RUN.''
DOES DTC 14 RESET?
REPLACE EBTCM,
REPAIR HIGH
RESISTANCE IN
CKT 302. REFER
TO SECTION SA.
s
s
REPLACE
ABS!TCS RELAY.


C7984
5E2-42

EBCM EBTCM
IGNITION
REFER TO SECTION
8A10
.----
. . . . . - - - - - - - - - - - - - - - 6 4 1 BAN
SWITCHED IGNilTION
ABS/TCS RELAY
ENABLE CONTROL
ABS/TCS SWITCHED
BATTERY INPUT
5272
CENTER
041995
FT0165E
DTC 14
{Page 2 of 3)
ABS/TCS relay contact and allows battery _voltage a!1d
DTC
wm
Set When:

commands the ABS/TCS relay "ON" (the relay. is
Action Taken:

Number(s) below refer to circled number(s) .on
.
9. Checks for high resistance in the entire relay cod
circuit.
10. Verifies proper battery condition.
11. Verifies proper voltage is available at the

ABS/TCS relay.
12. Checks for an open in the switched battery
circuit from the relay to the EBTCM.
13. Verifies the condition of the ABS/TCS relay.
Diagnostic Aids:
poor connection, ru~be_d throuh wir~ insulation, or a
wire that is broken mside the msulation.
The frequency of the ID:alfunc_tion c~n be
this section.
locks, improperly formed ?r damaged !erminals, poor
terminal to wiring. connections or physical damage to
the wiring harness.

voltage changes significantly, replace th~ rel~y.. . .
If DTC 14 only sets when the vehicle ts mitially
than 32 F- o C), replace the relay.
DTC 14
,,,,,,,.,,,,,,,,,,,,.,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
DIAGNOSIS CONTINUED
1
FROM PREVIOUS PAGE. 1
I,,.,,, ,,,,.,,,,,,,,,,,.,,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,nl
(Page 2 of 3)
ABS RELAY CONTACT
IGNITION "OFF."
REMOVE JUMPER WIRE INSTALLED IN STEP #3, IF NOT ALREADY REMOVED.
WITH BATTERY STILL DISCONNECTED, TURN IGNITION SWITCH TO "RUN."
THIS COMPLETES THE IGNITION CIRCUIT TO THE ABSfTCS RELAY.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "A11" OF
THE 24-WAY EBTCM HARNESS CONNECTOR AND THE POSITIVE BATTERY
CABLE TERMINAL.
IS RESISTANCE 95 OHMS OR LESS WHEN MEASURED AT APPROXIMATELY
20'C (68'F)?
,,,,, ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
USING J 39200, MEASURE THE VOLTAGE BETWEEN THE

NEGATIVE AND POSITIVE BATTERY TERMINALS.
! DIAGNOSIS
!
CONTINUED ON
NEXT PAGE.
!
!
!t,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.;!
,,,,,, ;,u,,;,,11,,,,,,,.,.,.,,,,,,,,,.,.,,,,,,,,,.,,,,,,,,,.
IGNITION "OFF."
RECONNECT POSITIVE BATTERY CABLE.
DISCONNECT ABSfTCS RELAY.
USING J 39200, MEASURE THE VOLTAGE BETWEEN TERMINAL "C1"
OF THE ABSfTCS RELAY HARNESS CONNECTOR AND GROUND.
! TO CORRECT LOW
1
j VOLTAGE CONDITION. l
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,f

TERMINAL "C4" OF THE ABSfTCS RELAY HARNESS
CONNECTOR AND TERMINAL "C" OF THE 8-WAY EBCM
HARNESS CONNECTOR.
USING A JUMPER WIRE, CONNECT TERMINAL "86" ON THE ABSfTCS

RELAY TO GROUND.
USING A FUSED JUMPER WIRE, SUCH AS J 36169, WITH A 3 AMP FUSE,
CONNECT TERMINAL "85" ON THE ABSfTCS RELAY TO B+.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINALS "30"
AND "87" ON THE ABSfTCS RELAY.

CONNECTION. INSPECT ALL CONNECTORS AND TERMINALS
CORROSION. REFER TO SECTION 8A4, "CHECKING TERMINAL
C7985
5E2-44

EBCM EBTCM
IGNITION
REFER TO SECTION
IA10
,----
SWITCHED IGNITION
i.;...._--.1'"-..JJJ'--- 141 BRN
1----1832 PNK--1111---
B+ L
SAMP
~302RED-,
FUSIBLE
1833 RED
AEIS/TCS RELAY
ENABLE CONTROL
ABS/TCS SWITCHED
BATTERY INPUT
302 RED
LINK B
8175
L
CENTER
0411t-95
FT0165E
DTC 14
(Page 3 of 3)
circuit at connector "C 1", terminal "A 11" of the
DTC Will Set When:
commands the ABS/TCS relay "ON" (the relay is
Action Taken:
14. Checks for proper resistance of the relay coil.
control circuit between the relay and the
EBTCM.
control circuit between the battery and the relay.
Diagnostic Aids:
this section.
Any circuitry that is .suspected of causing the
the wiring harness.

than 32 F- 0 C), replace the relay.
DTC 14
(Page 3 of 3)
ABS RELAY CONTACT
,,,.,,,,u,.,,,,.,,,,.,,,,,,,,,u,;;,,,,,,,,u,;,,,,.,,,,,.,I
I DIAGNOSIS CONTINUED i
!''"""""
FROM PREVIOUS PAGE. !
,,,.,,.,,,,,,,,,,,,,,,,,,.,.,,,,,.u..,,,,,,,,.........
DISCONNECT ABS/TCS RELAY.
TERMINALS "85" AND "86" ON THE ABSfTCS RELAY.
IS RESISTANCE 95 OHMS OR LESS WHEN MEASURED AT
APPROXIMATELY 24"C {75"F)?
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "C5"

OF THE ABSfTCS RELAY HARNESS CONNECTOR AND TERMINAL "A11"
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "C2"

OF THE ABSfTCS RELAY HARNESS CONNECTOR AND THE POSITIVE
.
BATTERY CABLE TERMINAL.

CONNECTION. INSPECT ALL CONNECTORS AND TERMINALS
CORROSiON. REFER TO SECTION BA-4, "CHECKING TERMINAL
REPAIR OPEN OR HIGH

RESISTANCE IN CKT 641,
CKT 300; IGNITI.ON SWITCH,
OR .BATTERY FEED CIRCUIT
TO IGNITION SWITCH.
REFER TO SECTION SA FOR
FURTHER INFORMATION,
C7986
5E2-46

EBCM EBTCM
IGNITION
REFER TO SECTION
8A10
r---
. . - - - - - - - - - - - - - - - - 6 4 1 BRN
ABS/TCS RELAY
ENABLE CONTROL
i.;...--flf'--..1~-- 641 BAN

B+ L
SAMP
~302AED,
FUSIBLE
LINKS
ABS/TCS SWITCHED
BATTERY INPUT
302 RED I
8175
SWITCHED IGNITION
----.I
UN,DERHOOD ELECTRICAL
CENTER
041995
FT0165E
DTC 15
ABS RLY CONTACT CKT SHORT TO BAT OR ALWAYS
CLOSED
DTC Will Set When:
DTC 15 can be set only before the EBTCM
commands the relay "ON." This test determines if the
ABS/TCS relay is energized when it should not be.
This malfunction would not allow the ABS/TCS relay
to remove power to the EBTCM. If a second
malfunction were to occur that requires the ABS/TCS
relay to be turned "OFF," that malfunction cannot be
removed if the relay cannot be controlled. The
malfunction must be present for three consecutive
drive cycles before the DTC is set.
Action Taken:
disabled.

1. Determines if any other DTCs are present.
2. Indicates that the EBTCM is capable of
controlling the ABS relay as commanded.
3. Checks for a possible short to battery voltage in
CKT 1633.
4. Determines whether the short to voltage is in
CKT 1633 or as a result of a malfunctioning
relay.
wiring or connectors.
Diagnostic Aids:
this section.
the wiring harness.
DTC 15
ABS RLV CONTACT CKT SHORT
TO BAT OR ALWAYS CLOSED
ARE ANY OTHER DTCs SET?
( m

COMMAND ABS/TCS .RELAY "OFF."
DOES TECH 1 INDICATE THAT ABS/TCS RELAY IS "OFF,"
AND BATTERY VOLTAGE IS LESS THAN 5 VOLTS?
!
~
"'"""''"'"'""'"'"'"mmm,mmmm,mm"""'"'""'
PROCEED TO THAT DTC CHART FIRST.
f~
,,,u,u,1,1111,;111,11111,,,,,,,,,,,,.,,,u,;11111,,,,,.,,,,,11111,,,,.,,..,,,,,11111111,,I
IGNITION "OFF."
DISCONNECT 24-WAY AND 8-WAY EBTCM HARNESS
CONNECTORS.
IGNITION TO "RUN."
USING J 39200, MEASURE THE VOLTAGE BETWEEN.
GROUND AND TERMINAL "C" OF THE 8-WAY EBTCM
CONNECTOR.

IGNITION "OFF."
INSPECT CKT 1633 AND GRAY 8-WAY EBTCM
HARNESS CONNECTOR FOR DAMAGE WHICH
MAY RESULT IN A SHORT TO VOLTAGE WHEN
ALL CONNECTORS ARE CONNECTED. REPAIR
DAMAGE IF EVIDENT.
RECONNECT GRAY 8-WAY AND 32-WAY EBTCM
CONNECTORS.
IGNITION TO "RUN."
USING RELAY TEST FUNCTION OF TECH 1,
COMMAND ABS/TCS RELAY "OFF." .
DOES TECH 1 1NDICATE THAT ABS/TCS RELAY IS
"OFF," AND BATTERY VOLTAGE IS LESS THAN 5
VOLTS?
IGNITION "OFF."
IGNITION TO "RUN."
GROUND AND TERMINAL "C" OF THE GRAY 8-WAY
EBTCM HARNESS CONNECTOR.
REPAIR SHORT
TO VOLTAGE IN
CKT 1633.
MALFUNCTION IS
INTERMITTENT. REFER
ON FACING PAGE.
AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs, AND TEST DRIVE VEHICLE FOR 3 DRIVE CYCLES TO VERIFY THAT DTC DOES NOT
RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING ABOVE 16 km/h (10 MPH), AND THEN TURNING KEY "OFF."
C7987
5E2;.49

EBCM EBTCM
IGNITION
REFER TO SECTION
8A10
r- -
~
SWITCHED IGNITION
ABS/TCS RELAY
ENABLE CONTROL
'----41"'\..IF--- 641 BRN

5AMP
~302AED-,
B+ L
FUSIBLE
1833 RED
302 RED I
LINKB
8175
ABS/TCS SWITCHED
BATTERY INPUT
----..I
CENTER
041995
fT0165E
DTC 16
ABS RELAY COIL C,IRCUIT OPEN
ABS/TCS; relay contact and allows battery voltage and
DTC Will Set When:

DTC 16 can be set only after DTC 14 has been
set. This test detects an open in the ABS/TCS relay
coil circuit. An open in this circuit Will not allow the
ABS/TCS relay to be energized thus preventing
voltage and current to the motors and solenoids. If this
malfunction is present and the ignition is turned
"OFF" before 5 km/h (3 mph) is reached, DTC 14 is
set alone.
Action Taken:

1. Indicates the EBTCM is capable of controlling the
ABS/TCS relay as commanded.
2. Checks to ensure that voltage is available to the
pull-in coil of the ABS/TCS relay.
3. Ensures that there is continuity through the pull-in

coil of the ABS/TCS relay.
4. Verifies the integrity of the ABS/TCS relay
control circuit.
5. Ensures malfunction was not.due to poor terminal
contact.
Diagnostic Aids:
this section.
If the frequency of the malfunction is high, but
is currently intermittent, check for high coil resistance
by measuring between relay terminals "85" and "86"
using a J 39200. If resistance shows greater than 100
ohms, replace the relay.
the wiring harness.
DTC 16
ABS RELAY COIL
CIRCUIT OPEN
COMMAND THE ABS/TCS RELAY "ON."
DOES TECH 1 INDICATE ABS/TCS RELAY "ON," AND
BATTERY VOLTAGE ABOVE 10 VOLTS?
USING J 39200, MEASURE THE VOLTAGE BY

BACKPROBING BETWEEN GROUND AND TERMINAL "C2"
OF THE ABS/TCS RELAY CONNECTOR.

USING THE RELAY TEST FUNCTION OF THE TECH 1, COMMAND THE

ABS/TCS RELAY "OFF."
USING J 39200, MEASURE THE VOLTAGE BY BACKPROBING BETWEEN
GROUND AND TERMINAL "CS" OF THE ABS/TCS RELAY CONNECTOR.
REPAIR OPEN OR HIGH

RESISTANCE IN CKT 641
OR
ABS IGN FUSE 1.
CHECK FOR INTERMITTENT

CONNECTIONS AT ABS/TCS
RELAY. IF OK, REPLACE
ABS RELAY.
IGNITION "OFF."
IGNITION TO "RUN."
TERMINAL "A11" OF THE 24-WAY EBTCM HARNESS CONNECTOR.
IGNITION "OFF."
INSPECT 24-WAY EBTCM CONNECTOR TERMINAL "A11" FOR
POOR TERMINAL CONTACT OR EVIDENCE OF CORROSION.
REFER TO SECTION SA-4 "CHECKING TERMINAL CONTACT."
REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF POOR
IGNITION TO "RUN."
DOES DTC 16 SET AS A CURRECT DTC?

LIKELY CAUSED BY A
POOR CONNECTION.
THAT DTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING ABOVE 16 km/h (10MPH),
AND THEN TURNING KEY "OFF."
C7988
5E2-50

EBCM EBTCM
IGNITION
REFER TO SECTION
8A10
SWITCHED IGNITION
,---~ - - # I T \ . A ~ - - 641 BFIN

B+ I..
SAMP
~302RED-,
FUSIBLE
LINKB
1----1832 IPNK
1833 RED
302 FIED I
ABS/TCS RELAY
ENABLE CONTROL
Al!IS/TCS SWITCHED
BATTERY INPUT
8175
L
CENTER
04-11-15
FT0165E
DTC 17
ABS RELAY COIL CIRCUIT SHORTED TO GROUND


.
controlling the ABS/TCS relay as commanded.
2. Checks to ensure that the ABS/TCS relay or
control CKT 1632 are not shorted to ground.
3. Checks to see if the EBTCM is internally shorled
to ground.
4. Checks for a short to ground in control CKT 1632
or a defective ABS/TCS relay.
DTC
wm
Set When:
DTC 1 7 can be set before the EBTCM

commands the ABS/TCS relay "ON." This test
determines if the ABS/TCS relay is energized when it
should not be. This malfunction would not allow the
ABS/TCS relay to remove power to the EBTCM. If a
second malfunction were to occur that requires the
ABS/TCS relay to be turned "OFF," that malfunction
cannot be removed if the relay cannot be controlled. A
grounded terminal "A 11" would cause the ABS/TCS
relay to be energized any time the ignition was in the
"ON" position.
Action Taken:
disabled.
Diagnostic Aids:
this section.
the wiring harness.
OTC 17
SHORTED TO GROUND

COMMAND THE ABS/TCS RELAY "OFF."
DOES TECH 1 INDICATE THAT ABS/TCS RELAY IS "OFF"
AND BATTERY VOLTAGE IS LESS THAN 5 VOLTS?
IGNITION "OFF."
IGNITION TO "RUN."
BETWEEN TERMINAL "A11'' OF THE 24-WAY
EBTCM HARNESS CONNECTOR AND B+.
IGNITION "OFF."
INSPECT CKT 1632 AND TERMINAL<'A11" OF
THE 24WAY EBTCM CONNECTOR FOR DAMAGE
WHICH MAY RESULT IN A SHORT TO GROUND
WITH ALL CONNECTORS CONNECTED. REPAIR
IGNITION TO "RUN."
MALFUNCTION IS
FACING PAGE.

IGNITION "OFF."
BETWEEN TERMINAL "CS" OF THE
ABS/TCS RELAY CONNECTOR AND B+.
REPAIR SHORT
TO GROUND IN
CKT 1632.
THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH),
C7989

EBCM EBTCM
IGNITION
REFER TO SECTION
8A10
P100
SWITCHED IGNITION
,----
ABSITCS RELAY
ENABLE CONTROL
~--ti/I'"'\....*--- 641 BAN

B+ L
5AMP
~302RED"'I
FUSIBLE
LINKB
AISSITCS SWITCHED
BATTERY INPUT
302 RED I
8175
5272
-----'
CENTER
04-1998
FT0165E
DTC 18
ABS RELAY COIL CIRCUIT SHORTED TO BATT
Ignition voltage is supplied through . terminal
"C2" of the ABS/TCS relay. The EBTCM .then is able
OTC Will Set When:

DTC 18 can be set after the EBTCM commands
the ABS/TCS relay "ON." This test monitors the
availability of current and voltage to the motors and
solenoids. A malfunction of this type will not allow
voltage to be available to the motors and solenoids;
therefore, ABS operation would not be allowed if
required.
Action Taken:

controlling the ABS/TCS relay as commanded.
2. Checks for a short to voltage on the ABS/TCS

relay control circuit.
3. Verifies that the ABS/TCS relay coil has the
appropriate resistance.
4. Checks for ABS/TCS relay contacts that are failed
closed.
5. Checks for possible poor terminal contact at the
EBTCM.
Diagnostic Aids:
this section.
the wiring harness.
OTC 18
SHORTED TO BATT
IGNITION TO "RUN," .ENGINE "OFF."
USING RELAY TEST FUNCTION OF TECH 1, COMMAND
ABS/TCS RELAY "ON."
DOES TECH 1 INDICATE ABS/TCS RELAY "ON" AND
BATTERY VOLTAGE ABOVE 10 VOLTS?
IGNITION "OFF."
IGNITION TO "RUN."
GROUND AND TERMINAL "A11" OF THE 24WAY

IGNITION "OFF."
BETWEEN TERMINAL "85" AND TERMINAL "86"
OF THE ABS/TCS RELAY.
IS RESISTANCE 40 OHMS OR GREATER?

TERMINALS ''30" AND "87" OF THE ABS/TCS RELAY.
DOES J 39200 D.ISPLAY RESISTANCE AS "OL" (INFINITE)?
INSPECT CKT 1632 AND TERMINAL "A11" OF THE 24WAY

EBTCM CONNECTOR FOR DAMAGE WHICH MAY RESULT
IN A SHORT TO VOLTAGE WITH ALL CONNECTORS
CONNECTED .REPAIR ALL DAMAGE IF EVIDENT.
IGNITION TO "RUN."
MALFUNCTION IS INTERMITTNET.
FACING PAGE.
AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) l>RIVE CYCLES TO VERIFY
C7990
5E2:-54
EBCM/EBTCM
(
ABS JUMPER HARNESS
::::::---~-1:1----= ~::_L_U-~lll----1
C120

HIGH

LOW
LP: WHEEL SPEED SENSOR
04-19-95
FT0175E
DTC 21
LEFT FRONT WHEEL SPEED
wheel speed sensor to produce a sinusoida.l(AC)
the air gap.
DTC Will Set When:
ABS or TCS event. If the left front wheel speed=O
and the vehicle's reference speed is greater than 8
km/h (5 mph), a malfunction exists.
Action Taken:
A malfunction DTC is stored, ABS and TCS are
disabled and the ABS and TCS warning lamps are
turned "ON."
shorted together.
physical damage.
=0
Diagnostic Aids:
wire that is broken inside the insulation. Any circuitry
that is suspected of causing the intermittent complaint
should be thoroughly checked for backed out
terminals, improper mating, broken locks, improperly
formed or damaged terminals, poor terminal to wiring
connections or physical damage to the wiring harness.
this section.
or TCS warning lamps are "ON" only during moist
current, clear DTCs and simulate the effects of waler
intrusion. Use the following procedure. Spray down
the suspected area with a 5% salt water solution (two
increase with an increase in sensor temperature. When
replacing a wheel speed sensor, inspect the sensor
terminals and harness connector for corrosion and/or
water intrusion. If evidence of corrosion or water
intrusion exists, replace wheel speed sensor jumper
harness. Likewise, if replacing a .wheel speed sensor
jumper harness, inspect sensor terminals. If evidence
of corrosion or water intrusion exists, replace wheel
speed sensor. Refer to "On-Vehicle Service" in this
section.
rn
DTC 21
IMPORTANT:

SE2.;55
LEFT FRONT
WHEEL SPEED = 0
IGNITION "OFF."
PHYSICALLY INSPECT THE LEFT FRONT WHEEL SPEED SENSOR, LEFT FRONT
I
I
. I
NO
YES

"A" AND 11 8".
IS RESISTANCE BETWEEN 1020 AND 1137 OHMS WHEN SENSOR IS 20'C
(68'F)?
2oc (68FJ, REFER TO THE TABLE BELOW FOR APPLICABLE SENSOR

I
I
YES
. I
NO

IS VOLTAGE AT LEAST 100 mV (VOLTAGE WILL IN.CREASE AS
YES
NO
IGNITION "OFF."
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "AS"
AND "84" OF THE 24-WAY EBCM/EBTCM HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS ".OL" (INFINITE)?
YES
. I
NO
INSPECT CKTs 830 AND 873 AND 24WAY EBCM/EBTCM CONNECTOR FOR
YES
REPLACE
EBCM/EBTCM.
NO

(APPROXIMATE)
TEMP.
TEMP.
RESISTANCE
(C)
(F)
(OHMS)
34 TO 4
30 TO 40
5 TO 43
41 TO 110
804 TO 1066
956 TO 1240
44 TO 93
111 TO 200
1112 TO 1463
C7991
5E2-56
EBCM/EBTCM
(
fmO
ABS JUMPER HARNESS
872 9U(:-----1ffi. .___1_2: :::

C130

HIGH
LOW
04-20-95
FT0185E
DTC 22
RIGHT FRONT WHEEL SPEED
=0
Diagnostic Aids:

wheel speed sensor to produce a sinusoidal(AC)
the air gap.

formed or damaged terminals, .poor terminal to wiring
this section.
environmental changes (rain, snow,. vehicle wash), all
harness. Likewise, if replacing a wheel speed sensor
section.
DTC Will Set When:

ABS or TCS event. If the right front wheel speed=O
Action Taken:
turned "ON."

shorted together.
physical damage.
rn
OTC 22
IMPORTANT:

WILL NOT BE CORRECTED BEFORE THE SOURCE OF THE MALFUNCTION IS FO.UND.
RIGHT FRONT
WHEEL SPEED = 0
IGNITION "OFF."
NO
YES

"A" AND "B."
IS RESISTANCE BETWEEN 1020 AND 1137 OHMS WHEN SENSOR IS 2oc
(68'F)?
20'C {68'F), REFER TO THE TABLE BELOW FOR APPLICABLE SENSOR
I
I
YES
D

NO

I
I
I
I
YES
NO
I
IGNITION "OFF."
YES
NO
I
I
I
YES
REPLACE
EBCMIEBTCM.
NO
I

(APPROXIMATE)
TEMP.
RESISTANCE
TEMP.
("F)
(OHMS)
('C)
-34 TO 4
-30 TO 40
5 TO 43
41 TO 110
804 TO 1066
956 TO 1240
44 TO 93
111 TO 200
1112 TO 1463
C7992
5E2-58
EBTCM
(
.--------, ABS JUMPER HARNESS
r--,
r--,
8 8 4 B L K ~ 8 8 4 BLK~884BLK
885 RED---+B?- 885 RED
L __ J
C405
.l.r:::1..!.
~~ ~
885 RED
L __ J
LR WHEEL SPEED SIGNAL

HIGH
LOW
C200
051595
FT0195E
OTC 23
LEFT REAR WHEEL SPEED
the air gap.
DTC Will Set When:
OTC 23 can be set when the vehicle is not in an
ABS or TCS event. If the left rear wheel speed=O and
the vehicle's reference speed is greater than 8 km/h (5
Action Taken:
A malfunction OTC is stored, ABS and TCS are
turned "ON."
shorted together.
physical damage.
=0
Diagnostic Aids:
this section.
inspected for. signs of water intrusion. If OTC is not
OTC returns, replace suspected harness.
section.
DTC 23
[ ] ] IMPORTANT:
WHEEL SPEED SENSOR INTERMITTENT MALFUNCTl,QNS MAY BE DIFFICULT TO LOCATE.
LEFT REAR
WHEEL SPEED
=0
IGNITION "OFF."
PHYSICALLY INSPECT THE LEFT REAR WHEEL SPEED SENSOR, WHEEL
SPEED SENSOR JUMPER HARNESS, AND CONNECTORS FOR DAMAGE.
I
I
NO
YES
DISCONNECT LEFT REAR WHEEL SPEED SENSOR DIRECTLY AT SENSOR.

AND "B."
(68'FJ, REFER TO THE TABLE BELOW FOR APPLICABLE SENSOR RESISTANCE
NOT AIR TEMPERATURE./
I
YES
I
NO

VEHICLE TRANSMISSION IN NEUTRAL.
INCREASES)?
I
YES

(15 MPH) TO ENSURE OTC 23
DOES NOT SET.
NO
.
IGNITION "OFF."
AND "A3" OF THE 24-WAY EBTCM HARNESS CONNECTOR.
'
"
I
YES
NO
I
INSPECT CKTs 884 AND 885 AND 24-WAY EBTCM CONNECTOR FOR DAMAGE

CKTs 884 AND 885.
I
I
YES
I
REPLACE EBTCM.
NO
I
FACING PAGE.

TEMP.
TEMP.
RESISTANCE
('C)
('F)
(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
C7993
EBTCM
r--, . ~
r--,
ABS JUMPER HARNESS
882 BRN --+8!-882 BRN
883 WHT--+G+ 883 WHT
.!.r:::i!
!~ ~
C405
(200
t __ J
L __ J
RR WHEEL SPEED
SIGNAL HIGH
882 BRN
883 WHT
C1
RRWHEELSPEED
SIGNAL LOW
05-1ri-95
FT0206E
DTC 24
RIGHT REAR WHEEL SPEED
=0
Diagnostic Aids:

the air gap.

should be thoroughly ehecked for backed out
this section.
wheel speed sensor circuitry should. be thoroughly
replacing a wheel . speed sensor, inspect the sensor
section.
DTC Will Set When:

ABS or TCS event. If the right rear wheel speed=O
Action Taken:
turned "ON."

shorted together.
physical damage.
rn
DTC 24
IMPORTANT:

G)
RIGHT REAR
WHEEL
SPEED 0
IGNITION "OFF."
PHYSICALLY INSPECT THE RIGHT REAR WHEEL SPEl:D SENSOR, WHEEL
. I
NO
YES
DISCONNECT RIGHT REAR WHEEL SPEED SENSOR DIRECTLY AT SENSOR.

AND "B,"
.
.
YES

(15 MPH) TO ENSURE OTC 24
DOES NOT SET.
.
N,O
WITH J 39200 STILL CONNECTED, SELECT A/C VOLTAGE SCALE,

VEHICLE TRANSMISSION IN NUETRAL.
IS VOLTAGE AT LEAST 100 mv (VOLTAGE WILL INCREASE AS WHEEL SPEED
INCREASES)?
YES
NO
IGNITION "OFF."
AND "A2" OF THE 24-WAY EBTCM HARNESS CONNECTOR.
YES
NO
INSPECT CKTs 882 AND 883 AND 24-WAY EBTCM CONNECTOR FOR DAMAGE
CONNECTORS CONNECTED, REPAIR ALL DAMAGE IF EVIDENT.
..
YES

CKTs 882 AND 883.
NO
FACING PAGE.
REPLACE EBTCM,I

TEMP.
TEMP.
RESISTANCE
('F)
(OHMS)
('C)
2032 TO 3107
-34 TO 4
30 TO 40
5 TO 43
41 TO 110
2417 TO 3615
44 TO 93
111 TO 200
2812 TO 4266
C7994
5E2-62
EBCM/EBTCM
(
ABS JUMPER HARNESS
::::~:.___ffi.____ : :::_L_U-~111----1
C120

HIGH
LOW
04-19-95
FT0175E
DTC 25
LEFT FRONT EXCESSIVE WHEEL SPEED VARIATION
Diagnostic Aids:

wheel -speed sensor to produce a sinusoidal(AC)
the air gap.

this section.
section.
DTC Will Set When:

which the left front wheel acceleration or deceleration
Action Taken:
turned "ON."

shorted together.
physical damage.
OTC 25
[ [ ) IMPORTANT:
5E2-63
LEFT FRONT
EXCESSIVE
WHEEL SPEED
VARIATION
IGNITION "OFF."
PHYSICALLY INSPECT THE LEFT FRONT WHEEL SPEED ~ENSOR, LEFT FRONT
IS PHYSICAL DAMAGE INDICATED?. .
NO
I
YES

AND "B."
{IF TEMPERATURE OF THE SENSOR IS SUSPECTED TO BE OTHER THAN 2oc
YES

. I
NO

INCREASES)?
I
I
YES
NO
I
IGNITION "OFF."
USING J 39200, MEASURE THE RESISTANCE. BETWEEN TERMINAL "AS"
AND "B4" OF THE 24WAY EBCM/EBTCM HARNESS CONNECTOR.
DOES J 39200 DISPLAY.RESISTANCE AS "OL" (INFINITE)?
REPLACE WHEEL SPEED .SENSOR.
YES
NO
I

CKTs 830 AND 873.
I
I
I
YES
NO
I

REPLACE
.,
EBCM/EBTCM.

(APPROXIMATE)
RESISTANCE
TEMP.
TEMP.
(C)
(OHMS)
CF)
.34 TO 4
30 TO 40
5 TO 43
41 TO 110
804 TO 1066
956 TO 1240
44 TO 93
111 TO 200
1112 TO 1463
C7995
EBCM/EBTCM.
(
ABS JUMPER HARNESS
e:tlO
872 IBU<----~======-7_2::::
C130
FIF WHl!l!L SPl!l!D SIGNAL

HIGH
LOW
04-20-96
FT0186E
DTC 26
RIGHT FRONT EXCESSIVE WHEEL SPEED VARIATION
Diagnostic Aids:

the air gap.
.. An intermittent malfunction may be caused by a

terminal's, improper mating, broken locks, improperly
this section.
environmental changes (rain, snow, vehicle wash), alL
current, clear DTCs .and simulate the effects of water
section.
DTC Will Set When:

which the right front wheel acceleration or
deceleration is beyond specified limits.
Action Taken:
turned "ON."

.
shorted together.
physical damage.
rn
DTC 26
IMPORTANT:

G)
RIGHT FRONT
EXCESSIVE
WHEEL SPEED
VARIATION
IGNITION "OFF."
PHYSICALLY INSPECT THE RIGHT FRONT WHEEL SPEED. SENSOR, RIGHT FRONT
NO
5E2-65
YES

AND "B."
(IF TEMPERATURE OF THE SENSOR JS SUSPECTED TO BE OTHER THAN 20'C
(6B'F), REFER TO THE TABLE BELOW FOR APPLICABLE SENSOR RESISTANCE

YES
"
NO
I

IS VOLTAGE AT LEAST .100 mV (VOLTAGE WILL INCREASE AS WHEEL SPEED
INCREASES)?
I
YES
NO
I
IGNITION "OFF."
I
I
I
I
YES
NO
WITH AL!,. CONNECTORS CONNECTED. REPAIR ALL DAMAGE IF EVIDENT.
REPLACE
EBCM/EBTCM.

CKTs 833 AND 872.
I
YES
NO


(APPROXIMATE)
TEMP.
RESISTANCE
TEMP.
(OHMS)
('F)
('C)
804 TO 1066
-34 TO 4
-30 TO 40
5 TO 43
41 TO 110
956 TO 1240
44TO 93
111 TO 200
1112 TO 1463
C7996
EBTCM
r--,
-+6TJ
r--, .
. - - - - - - ABS JUMPER HARNESS
884BLK~884BLK~884BLK
885 RED
1.. __
C405
885 RED
...!.r::l_!_
~~!
L__ J
885 RED

HIGH
LOW
C200
05-115-95
FT0196E
OTC 27
LEFT REAR EXCESSIVE WHEEL SPEED VARIATION
the air gap.
DTC Will Set When:

which the left rear wheel acceleration or deceleration
Action Taken:
turned HON."

shorted together.
physical damage.
damage.
Diagnostic Aids:
poor. connection, rubbed through wire insulation, .or .~
should be thoroughly checked for .backed out
formed or. damaged terminals, poor terminal to wiring
this section.
Ifthe customer's comments reflect that the ABS
or TCS warning lamps are "ON" . only during moist
DTC retl.lll1S, replace suspected harness.
. harness. Likewise, if replacing a wheel speed sensor
section.
rn
DTC 27
IMPORTANT:

G)
IGNITION "OFF."
PHYSICALLY INSPECT THE LEFT REAR WHEEL SPEED Sl;:NSOR, WHEEL SPEED
LEFT REAR
EXCESSIVE
WHEEL SPEED
VARIATION
I
NO
I
YES

AND "B."
IS RESISTANCE BETWEEN 2579 AND 3315 n WHEN SENSOR IS 20'C (68'F)?
(68'F), REFER TO THE TABLE BELOW FOR APPLICABLE SENSOR RESISTANCE
YES
I
I
YES
1.

CKTs 884 AND 885.
NO
I
REPLACE EBTCM.

NO
NO
INSPECT LEFT REAR SENSOR TOOTHED RING FOR MISSING

TEETH OR OTHER PHYSICAL DAMAGE. REFER TO SECTION 48.
INSPECT CKTs 884 AND 885 AND 24;WAY EBTCM CONNECTOR FOR DAMAGE
..
YES
NO
.
I
IGNITION "OFF."
.DISCONNECT 24WAY EBTCM CONNECTOR.
AND "82" OF THE 24WAY EBTCM HARNESS CONNECTOR.
YES

NO

SPEED INCREASES)?
(APPROXIMATE)
TEMP.
TEMP.
('C)
('F)
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
YES
I

REFER TO SECTION 48.
I
C7997
5E2~68
EBTCM
. r--,
ABS JUMPER HARNESS
r--,
882 BRN ~ 8 8 2 BRN - + 8 + 8 8 2 BRN
8B3WHT
-f0+
I
~ B83WHT
L __ J
L__ J
C405
883WHT
RR WHEEL SPEED
SIGNAL HIGH
RR WHEEL SPEED
SIGNAL LOW
C200
05-15-95
FT020EE
DTC 28
RIGHT REAR EXCESSIVE WHEEL SPEED VARIATION
Diagnostic Aids:

speed sensor to the toothed ring, often referred .to as
the air gap.

this section.
th!'!. suspected area with a 5% salt water solution (two
above 24 km/h (15 mph) for at least 30 seconds. ff

section.
DTC Will Set When:

DTC 28 can be set when the brake is "OFF,"
which the right rear wheel acceleration or deceleration
Action Taken:
turned "ON."

shorted together.
physical damage.
damage.
rn
DTC 28
IMPORTANT:

IGNITION "OFF."
PHYSICALLY INSPECT THE RIGHT REAR WHEEL SPEED SENSOR, WHEEL
.
NO
.
.
YES .

AND "B."
IS RESISTANCE BETWEEN 2579 AND 3315 n WHEN SENSOR IS 20'C (68'F)?
(68FJ, REFER TO THE TABLE BELOW FOR APPLICABLE SENSOR RESISTANCE
NOT AIR TEMPERATURE,)
..
YES
..
YES
I
I
YES
YES
NO
I

CKTs 882 AND 883.
.
. I
NO
REPLACE EBTCM.
REPLACE. WHEEL SPEED SENSOR.
NO
INSPECT RIGHT REAR SENSOR TOOTHED RING FOR MISSING

TEETH OR OTHER PHYSICAL DAMAGE. REFER TO SECTION 48.
.I
.
I
INSPECT CKTs 882 AND 883 AND 24WAY EBTCM CONNECTOR FOR DAMAGE
TEST DRIVE VEHICLE ABOVE 24 km/h (15 MPH) FOR AT LEAST 30 SECONDS;
NO
IGNITION "OFF."
AND "81" OF THE 24-WAY EBTCM HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESI.STANCE AS. "OL" (INFINITE)?

NO

VEHICLE TRANSMISSION IN NEUTRAL.
SPEED INCREASES)?
RIGHT REAR
EXCESSIVE
WHEEL SPEED
VARIATION
MALFUNCTION IS
FACING PAGE.
YES
(APPROXIMATE)
TEMP.
RESISTANCE
TEMP.
('C)
('F)
(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

REFER TO SECTION 48.
.C7998
5E2~70 ANTllOCK BRAKE SYSTEM WITH,TRACTION CONTROL
EBCM/EBTCM
ABS JUMPER HARNESS
830 auc:----l~B1----830 LT B,....L_u_-111

873 W H T - - ~ l ! l
873 Yl!!I:
C120

HIGH
LOW
04-19-95
FT0175E
DTC 32
(Page 1 of 3)
Diagnostic Aids:

speed sensor to the toothed ring often referred to as
the air gap.

wire that is broken inside the insulation.: Any circuitry
this section.
current, clear DTCs and simulate the effects: of water
jumper harness, inspect sensor terminals. If evidence of
corrosion or water intrusion exists, replace wheel speed
sensor. Refer to "On-Vehicle Service" in this section.
DTC
wm
Set When:

Action Taken:
disabled and the ~ABS and TCS warning lamps are
turned "ON."

sensor coil.
sensor wiring.
sensor wiring.
rn
DTC 32
IMPORTANT:
WHEEL SPEED SENSOR INTERMITIENT MALFUNCTIONS MAY BE

CHART. THIS WILL ENSURE THAT AN INTERMITIENT CONNECTION WILL
NOT BE CORRECTED BEFORE THE SOURCE O,F THE MALFUNCTION IS
FOUND.
(Page 1 of 3)
LF WHEEL SPEED SNR
GND/BAT
IGNITION "OFF."
USING A So/o SALT WATER SOLUTION (TWO TEASPOONS OF SALT TO 12 OZ. WATER), THOROUGHLY SPRAY
THE LEFT FRONT WHEEL SPEED SENSOR JUMPER HARNESS.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINALS "AS" AND "84" OF THE 24-WAY
IS RESISTANCE BETWEEN 1020 AND 1137 n WHEN SENSOR IS 2oc (68'F)? (IF TEMPERATURE OF SENSOR
IS SUSPECTED TO OTHER THAN 2oc (68F), REFER TO THE TABLE ON PAGE 2 OF 3 OF THIS OTC CHART
FOR APPLICABLE SENSOR RESISTANCE VALUES; THE VALUES IN THE TABLE ARE FOR TEMPERATURE OF
I
I
YES
NO

TERMINAL "84" OF THE 24WAY EBCM/EBTCM HARNESS CONNECTOR.

TERMINAL "AS" OF THE 24WAY
I
I
YES
INSPECT ALL CONNECTORS.AND
HARNESSES FOR DAMAGE WHICH
MAY RESULT IN A SHORT TO VOLTAGE
WHEN ALL COMPONENTS ARE
FOUND. REFER TO "DIAGNOSIS AIDS"
INFORMATION.
NO
I
REPAIR SHORT TO
VOLTAGE IN CKT 873.
i~,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
OTC CHART.
. ,,,,,,,,,,;i
NO
I
IGNITION "OFF."
INSPECT TERMINALS "AS" AND "84" OF THE
24-WAY EBCM/EBTCM HARNESS CONNECTOR
DAMAGE IF EVIDENT.
IGNITION TO "RUN."
YES
................................................,.,
! DIAGNOSIS CONTINUED l
YES
IGNITION "OFF."
SENSOR.
IGNITION TO "RUN."
AND TERMINAL "84" OF THE 24-WAY EBCM/EBTCM HARNESS
CONNECTOR.
YES
i ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,;
OTC CHART.
i
NO
IGNITION TO "RUN."
NO
YES
, .... P ............................................,
REPLACE
EBCM/EBTCM.
NO
MALFUNCnON IS
INTERMITIENT. REFER TO
FACING PAGE.
REPAIR SHORT
TO VOLTAGE IN
CKT 830.
C7999
5E2-72
EBCM/EBTCM
ABS JUMPER HARNESS
: ::~:---1ffi1----=
C120

HIGH
~::,....L....U-UI
C1

LOW
04-19-95
FT0175E
DTC 32
{Page 2 of 3)
the air gap.
OTC Will Set When:
Action Taken:
turned "ON."
sensor coil.
Diagnostic Aids:

The frequency of the malfunction . can be
this section.
section.
DTC 32
(Page 2 of 3)
,.,,.,,,,.,,,,,,,,,,,,.,,,,,,,,,,,,,,,.,;,,,,.,,,,,,,,,,,.,,,,,,,,,.,,.,,,,,,,,,,,...,,,,,,.,, .,
l DIAGNOSIS CONTINUED FROM I

! PAGE
1 OF 3 OF THIS OTC
! CHART.
""'"'"'[""""'"'"'""""""'""'"""""""'"'"

THE 24WAY EBCM/EBTCM HARNESS CONNECTOR AND TERMINAL "B" OF
IS RESISTANCE 2 n OR LESS?
I
I
YES
I
NO
I
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "AS" OF

THE 24WAY EBCM/EBTCM HARNESS CONNECTOR AND TERMINAL "A" OF
IS\RESISTANCE 2 n OR LESS?

~.J<
."' /
r \.
...
NO
I
/USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL

"A" AND TERMINAL "B" OF THE LEFT FRONT WHEEL SPEED
(
SENSOR CONNECTOR.
IS RESISTANCE BETWEEN 1020 AND 1137 n WHEN SENSOR IS
2oc (68'F)? (IF TEMPERATURE OF SENSOR IS SUSPECTED TO
OTHER THAN 20'C (68'F), REFER TO THE TABLE BELOW FOR
APPLICABLE.SENSOR RESISTANCE VALUES; THE VALUES IN THE
TABLE ARE FOR TEMPERATURE OF THE SENSOR, NOT AIR
TEMPERATURE.)
YES
I

NO
I

HARNESSES FOR DAMAGE WHICH MAY RESULT IN HIGH
RESISTANCE WHEN ALL COMPONENTS ARE CONNECTED. REFER
TO "DIAGNOSTIC AIDS" ON FACING PAGE FOR MORE INFORMATION.
REPAIR ALL DAMAGE IFFOUND.

1
(APPROXIMATE)
TEMP.
TEMP.
RESISTANCE
('C)
('F)
(OHMS)
34 TO 4
30 TO 40
804 TO 1066
5 TO 43
41 TO 110
956 TO 1240
44 TO 93
111 TO 200
1112 TO 1463
C8000
EBCM/EBTCM
ABS JUMPER HARNESS
P100
::::::__--1ffi11----= :::,.....L_U-111
C120

HIGH
LOW
041995
FT0175E
OTC 32
{Page 3 of 3)
the air gap.
DTC Will Set When:

Action Taken:
turned "ON."

10. Checks for a short to ground in CKT 873.'
Diagnostic Aids:
that is suspected of causing the intermittent copiplaint

should be thoroughly checked for backec;l out
this section.
intrusio],'l. Use the following procedure. Spray down
section.
OTC 32
(Page 3 of 3)
\)
l""""'"'"'""'"'"""'"'""'""""''"'""'""'l
j DIAGNOSIS CONTINUED FROM !

! PAGE 1 OF 3 OF THIS OTC
j
! CHART.
!
. . . . r. , . . , . . , , . ., , , , , , , , ,. ., ,. ., , ,
DISCONNECT CONNECTOR C120 (LOCATED LH INNER FRAME RAIL).

I
YES
I

DOES J 39200 DISPLAY RESISTANCE "OL" (INFINITE)?
NO

IN CKT 873.
I
I
YES
I
THOROUGHLY RESPRAY THE LEFT FRONT WHEEL SPEED SENSOR

NO

IN CKT 830.

SENSOR CONNECTOR.

SENSOR.
TERMINAL "A," THEN "B" OF THE LEFT FRONT WHEEL SPEED
MEASUREMENTS?
.I
YES
I

TERMINAL "A" OF THE LEFT FRONT WHEEL SPEED SENSOR CONNECTOR.
YES
I
MALFUNCTION IS INTERMITIENT. INSPECT ALL CONNECTORS AND
ATIENTION TO THE JUMPER HARNESS, SMALL NICKS OR CUTS CAN
REPLACE LEFT FRONT WHEEL

NO
I
I
.
NO
C8001
5E276
EBCM/EBTCM
(
ABS JUMPER HARNESS
eltil
~::~~~~---1~======8-7-2~:::
C130

HIGH
LOW
04-20-95
FT0185E
OTC 33
(Page 1 of 3)
Diagnostic Aids:

the air gap.

wire that is. broken inside the insulation. Any circuitry
this section.
intrusion. Use the following .procedure. Spray down
DTC Will Set When:

Action Taken:
turned "ON."

sensor coil.
sensor wiring.
sensor wiring.
DTC 33
[ ] ] IMPORTANT:
DIFFICULT TO LOCATE. CARE SHOULD BE TAKEN NOT TO DISTURB
ANY ELECTRICAL CONNECTIONS PRIOR TO AN INDICATED STEP OF
THIS CHART. THIS WILL ENSURE THAT AN INTERMITTENT
CONNECTION WILL NOT BE CORRECTED BEFORE THE SOURCE OF
THE MALFUNCTION IS FOUND.
(Page 1 of 3)
RF WHEEL SPEED SNR CKT
OPEN OR SHORT TO
GND/BATT
IGNITION "OFF."
USING A 5% SALT WATER SOLUTION (TWO TEASPOONS OF SALT TO 12 OZ. WATER), THOROUGHLY SPRAY THE RIGHT
FRONT WHEEL SPEED SENSOR JUMPER HARNESS.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINALS "83" AND "A4" OF THE 24-WAY EBCM/EBTCM HARNESS
CONNECTOR.
IS RESISTANCE BETWEEN 1020 AND 1137 0 WHEN SENSOR IS 20'C (68'F)? {IF TEMPERATURE OF SENSOR IS SUSPECTED
TO OTHER THAN 2oc (68F}, REFER TO THE TABLE ON PAGE 2 OF 3 OF THE OTC CHART FOR APPLICABLE SENSOR
RESISTANCE VALUES; THE VALUES IN THE TABLE ARE FOR TEMPERATURE OF THE SENSOR, NOT AIR TEMPERATURE.)
I
I
YES
NO
! DIAGNOSIS CONTINUED ON j

i
i
PAGE 2 OF 3 OF THIS OTC

CHART.
i
i
[.,,.,,.,,,,,,,,,,,,,,,.,,.,.,,,,,,,.,,,.,,,,,,,,,,,,,.,, ,,.,,,,,,,,,,,,,,,,,,,)
I
YES
; m l,,,,,,,,m,mmu,,,,,,,,.,,.,,,,,.,,,,,.,,,,
NO
1....,,....................,,....,,,.....,,.....,
l DIAGNOSIS CONTINUED ON I
! ....
IGNITION TO "RUN."
j PAGE 3 OF 3 OF THIS OTC j

i~,,,,,,,u,,,,,,,,.,,,,,,,.,,,,,.,,.,,,,,,.,,,,,,.,,,,,,,,,,,,,,,,,,uu~
CHART.
l
I
I
NO
'
YES
I
IGNITION "OFF."
DISCONNECT RIGHT.FRONT WHEEL SPEED SENSOR DIRECTLY AT
SENSOR.
IGNITION TO "RUN."
TERMINAL "83'.' OF THE 24-WAY EBCM/EBTCM HARNESS CONNECTOR.
I
I
YES
I

BETWEEN GROUND AND TERMINAL "A4"
OF THE 24'WAY EBCM/EBTCM HARNESS
CONNECTOR.
I
I
NO
REPAIR SHORT TO
VOLTAGE IN CKT 833.

TO VOLTAGE WHEN ALL COMPONENTS ARE
FOUND. REFER TO "DIAGNOSTIC AIDS" ON
FACING PAGE FOR MORE INFORMATION.
I
I
NO
NO
.I
REPLACE
EBCM/EBTCM.
IGNITION "OFF."
CONNECTOR FOR POOR TERMINAL
CONTACT AND CONTAMINATION. ALSO
INSPECT CKTs 833 AND 872 FOR DAMAGE
WHICH MAY RESULT IN AN OPEN CIRCUIT,
SHORT TO GROUND, OR SHORT TO
VOLTAGE. REPAIR ALL DAMAGE IF EVIDENT.
IGNITION TO "RUN."
YES
I
I
YES
MALFUNCTION IS
INTERMITTENT. REFER
ON FACING PAGE.
REPAIR SHORT TO
VOLTAGE IN CKT 872.
C8002
5E2-78
EBCM/EBTCM
(
ABS JUMPER HARNESS
fUHl
872 BU<-----iG]Bl----'--872 DK ORN
(!]1--- - - - 8 3 3 TAN
C130

HIGH
LOW
04-20-96
FT0185E
DTC 33
(Page 2 of 3)
the air gap.
OTC Will Set When:

Action Taken:
turned "ON."

sensor coil.
in CKT 833.
in CKT 872.
of the wheel speed
Diagnostic Aids:

this section.
increase with an increase in sensor. temperature. When
section.
DTC 33
(Page 2 of 3)
RF WHEEL SPEED SNR
GND/BATT
s .....,,...,,.,,.,,.,,.,,.,,.,,.,,.,,.,,,.,,... ;
!
!
FROM PAGE 1 OF 3 OF
THIS OTC CHART.
.,,....r.........,,.........,,....................!
.I.

24WAY EBCM/EBTCM HARNESS CONNECTOR AND TERMINAL "B" OF THE RIGHT
FRONT WHEEL SPEED SENSOR HARNESS CONNECTOR.
YES
I
NO

OF THE 24-WAY EBCM/EBTCM HARNESS CONNECTOR AND TERMINAL "A"
OF THE RIGHT FRONT WHEEL SPEED SENSOR HARNESS CONNECTOR.

I
I
YES
I
NO
I
USING J 39200; MEASURE THE RESISTANCE BETWEEN TERMINAL "A"

AND TERMINAL "B" OF THE RIGHT FRONT WHEEL SPEED SENSOR
CONNECTOR.
IS RESISTANCE BETWEEN 1020 AND 1137 0 WHEN SENSOR IS 2oc
(68F)? (IF TEMPERATURE OF SENSOR IS SUSPECTED TO OTHER THAN
2oc (68FJ, REFER .TO THE TABLE BELOW FOR APPLICABLE SENSOR
RESISTANCE VALUES; THE.VALUES IN THE TABLE FOR TEMPERATURE

I
I
YES
I
NO
MALFUNCTION IS INTERMITIENT. INSPECT ALL CONNECTORS

.
FRONT WHEEL ~PEED SENSOR

(APPROXIMATE)
TEMP.
TEMP.
RESISTANCE
('F)
(OHMS)
('C)
.34 TO 4
30 TO 40
5 TO 43
41 TO 110
804 TO 1055
956 TO 1240
44 TO 93
111 TO 200
1112 TO 1463
C8003
EBCM/EBTCM
(
ABS JUMPER HARNESS
e:Hl!l
a12 auc____ffi:=====-e1_2: :::

C130

HIGH
LOW
04-20-95
FT0185E
DTC 33
(Page 3 of 3)
As a toothed ring passes by. the wheel speed
speed sensor to the toothed ring, often referred to a:s
the air gap.
DTC Will Set When:

Action Taken:
turned "ON."

Diagnostic Aids:

this section.
.environmental changes (rain, snow, vehicle wash), all
current, clear. DTCs and simulate the effects of water
intrusion exists, replace wheel speed sensor jumper.
section.
DTC 33
j
DIAGNOSIS CONTINUED
! FROM PAGE 1 OF 3 OF !
j THIS OTC CHART.
j
'""'" .......,,.,,.,,,..,,,..,,,.,,,.,,.,,.,,...<
(Page 3 of 3)
RF WHEEL SPEED SNR
GND/BAT
DISCONNECT CONNECTOR C130 (LOCATED RH INNER OF FRAME RAIL).



CKT 833.
NO
THOROUGHLY RESPRAY THE RIGHT FRONT WHEEL SPEED SENSOR


CKT 872.

SENSOR CONNECTOR.
SENSOR.
TERMINAL "A," THEN "B" OF THE RIGHT FRONT WHEEL SPEED
MEASUREMENTS?

TERMINAL "A" OF THE RIGHT FRONT WHEEL SPEED SENSOR
CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE.AS "OL" (INFINITE)?

AND HARNESSES FOR DAMAGE WHICH MAY RESULT IN A
SHORT TO GROUND WHEN ALL COMPONENTS ARE
CONNECTED. PAY PARTICULAR ATTENTION TO THE JUMPER
. HARNESS, SMALL NICKS OR CUTS CAN CAUSE A
MALFUNCTION. REPAIR ANY DAMAGE IF FOUND. JUMPER
HARNESS MUST BE REPLACED IF DAMAGED. REFER TO
"DIAGNOSTIC AIDS" ON FACING PAGE FOR MORE
INFORMATION.
REPLACE RIGHT FRONT WHEEL

C8004
5E2~82
EBTCM
r--,
r--,
- - - - . ABS JUMPER HARNESS

884 BLK
~ 884 BLK-+B+ 884 BLK

I
I
...!..r::-L!_
BBS R E D ~ 885 RED
L __ J
C405
!~ !
L __ J
BBS RED
I.R WHEEi. SPEED SIGNAi.

HIGH

LOW
C200
05-15-95
FT0195E
DTC 34
(Page 1 of 3)
LR WHEEL SPEED SNR CKT OPEN OR SHORT TO GND/BAT
Diagnostic Aids:

the air gap.

checked by using .the enhanced diagnostic function of
this section.
DTC
wm
Set When:

either of the left rear wheel speed circuits are open or
Action Taken:
turned "ON."

sensor coil.
sensor wiring.
sensor wiring.
rn
DTC
IMPORTANT:

FOUND.
34
(Page 1 of 3)
LR WHEEL SPEED SNR CKT

OPEN OR SHORT TO
GND/BAT
IGNITION "OFF."
USING A 5% SALT WATER SOLUTION (TWO TEASPOONS OF SALT TO 12 OZ. WATER), THOROUGHLY SPRAY THE LEFT REAR
WHEEL SPEED SENSOR JUMPER HARNESS.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINALS "A3" AND "82" OF THE 24-WAY EBCM/EBTCM HARNESS
CONNECTOR.
IS RESISTANCE BETWEEN 2579 AND 3315 0 WHEN SENSOR IS 2oc (68F)? (IF TEMPERATURE OF SENSOR IS SUSPECTED TO
OTHER THAN 2oc (68F), REFER TO THE TABLE ON PAGE 2 OF 3 OF THIS DTC CHART FOR APPLICABLE SENSOR RESISTANCE
VALUES; THE VALUES IN THE TABLE ARE FOR TEMPERATURE OF THE SENSOR, NOT AIR TEMPERATURE.)
YES
I
G)
NO

TERMINAL "82" OF THE 24-WAY EBTCM HARNESS CONNECTOR.
I
G)
l DIAGNOSIS CONTINUED l
! ON
PAGE 2 OF 3 OF THIS
! OTC CHART...,,,,,,,,,,,,,,,,..,,,..J
I
YES
,,,,,,_J.,,,,,,,,,,,,,,,,....,,,,,,,,,,,,,,,,,,,,
NO
,..,.. J.,,,.,,,,,,..,,,,,,.,,.,,,,,,,,,,,..,,,.,
! DIAGNOSIS CONT.INUED I
IGNITION TO "RUN."
TERMINAL "82" OF THE 24-WAY EBTCM HARNESS CONNECTOR.
! ON PAGE 3 OF 3 OF THIS !
!~,,,,,,,.,,,,,.,,,.,,,,,,,,,.,,.,.,.,,,,.,,u,u;;,u,,,,,,,,,,,,,,,.,,,.I
OTC CHART.
!
I
NO
YES
IGNITION "OFF."
DISCONNECT LEFT REAR WHEEL SPEED SENSOR DIRECTLY AT
SENSOR.
IGNITION TO "RUN."
TERMINAL "82" OF THE 24WAY EBTCM HARNESS CONNECTOR.
YES
G)

TERMINAL "A3" OF THE 24-WAY
.
NO
G)
REPAIR SHORT TO
VOLTAGE IN CKT 885.

ARE CONNECTED. REPAIR ALL DAMAGE IF
INFORMATION.
NO
REPLACE
EBTCM.
YES
IGNITION "OFF."
24-WAY EBTCM HARNESS CONNECTOR FOR
POOR TERMINAL CONTACT AND
DAMAGE IF EVIDENT
IGNITION TO "RUN."
YES
NO
MALFUNCTION IS
FACING PAGE.
REPAIR SHORT TO
VOLTAGE IN CKT 884.
C8005
5E2-84
EBTCM
r--,
r--,
....----, ABS JUMPER HARNESS
8 8 4 B L K ~ 8 8 4 BLK~884BLK
885 R E D - i G T 885 RED
l_ ... J
C405
...!s::"l!_
~~ ~
l __ J
885 RED
I.R WHEEi. SPEED SlGNAL

HIGH
I.R WHEEL SPEED SIGNAL
LOW
C200
0511M5
FT0195E
DTC 34
{Page 2 of 3)
related to wheel speed and the. proximity of the wheel
the air gap.
DTC Will Set When:

Action Taken:
turned "ON."

sensor coil.
in CKT 885.
in CKT 884.
of the wheel speed
Diagnostic Aids:

formed or da111.aged terminals, poor terminal to wiring
this section.
section.
DTC 34
(Page 2 of 3)

OPEN OR SHORT TO
GND/BAT
j DIAGNOSIS CONTINUED !
I FROM PAGE 1 OF 3 OF I
I THIS OTC CHART.
I
I'''''"'''''''''"''''''''"''""''"''''''"'''''''''~
'""""1'"""""'""""""""'""'""''

THE 24-WAY EBTCM HARNESS CONNECTOR AND TERMINAL "A" OF THE
LEFT REAR WHEEL SPEED SENSOR HARNESS CONNECTOR.
I
YES
I
NO

TERMINAL "A3" OF THE 24-WAY EBTCM HARNESS
CONNECTOR AND TERMINAL "B" OF THE LEFT REAR WHEEL
SPEED SENSOR HARNESS CONNECTOR.

(WHEEL SPEED SENSOR JUMPER
MUST BE REPLACED IF DAMAGED).
I
I
YES
NO

TERMINAL "A" AND TERMINAL "8" OF THE LEFT REAR
WHEEL SPEED SENSOR CONNECTOR.
IS RESISTANCE BETWEEN 2579 AND 3315 0 WHEN SENSOR
IS 2oc (68F)? (IF TEMPERATURE OF SENSOR IS
SUSPECTED TO OTHER THAN 2oc (68F), REFER TO THE
TABLE BELOW FOR APPLICABLE SENSOR RESISTANCE
VALUES; THE VALUES IN THE TABLE ARE FOR
TEMPERATURE OF THE SENSOR, NOT AIR TEMPERATURE.)
..

(WHEEL SPEED SENSOR JUMPER
MUST BE REPLACED IF DAMAGED).
I
YES
NO
REPLACE WHEEL SPEED SENSOR:

.

(APPROXIMATE)
TEMP.
TEMP.
RESISTANCE
~HM~
rq
r~
-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
C8006
5E286
EBTCM
r--,
r--,
.....----. ABS JUMPER HARNESS
884BLK~884BLK~BB4BLK
...!J::1.!_
885 R E D ~ 885 RED
L ... _J
C405
!~ !
L __ J
885 RED

HIGH
.
.
LOW
C200
051595
FT0198E
DTC 34
(Page 3 of 3)
the air gap.
DTC Will Set When:

Action Taken:
turned "ON."

Diagnostic Aids:
that is suspected of causing the intennittent complaint

terminals, improper inating, broken locks, improperly
formed or damaged terminals, poor tenninal to wirlng
connections or physical damage to the wiring harness;
this section.
or TCS warning lamps are ''ON" only during moist
section.
DTC 34
(Page 3 of 3)
,,,,,,,,,,,,,,,,,,,,,,,u,,,,,,,,,,,.,,,,,,,,,,,_,,,,

OPEN OR SHORT TO
GND/BAT
1DIAGNOSIS CONTINUED l
1FROM
! THIS
PAGE 1 OF 3 OF
OTC CHART.
"'"""l'"'""'""""'""'""'"""'"'
DISCONNECT CONNECTOR C405B, C405C (LOCATED BEHIND LH SIDE REAR UNDER BODY, BEHIND REAR SEAT).
USING J 39200, MEASURE THE RESISTANCE BETWEEN GROUND AND TERMINAL "82" OF THE 24-WAY EBTCM
HARNESS CONNECTOR.
I
I
YES

TERMINAL "A3" OF THE 24-WAY EBTCM HARNESS CONNECTOR.
NO
REPAIR SHORT TO
GROUND IN CKT 885.
I
I
YES
THOROUGHLY RESPRAY THE LEFT REAR WHEEL SPEED

SENSOR JUMPER HARNESS WITH THE SALT WATER
SOLUTION.
NO
REPAIR SHORT TO
GROUND IN CKT 884.
IMPORTANT: DO NOT ALLOW WATER TO ENTER ANY WHEEL

DISCONNECT LEFT REAR WHEEL SPEED SENSOR DIRECTLY
AT SENSOR.
USING J 39200, MEASURE THE RESI.STANCE BETWEEN
GROUND AND TERMINAL "A", THEN "B" OF THE LEFT REAR
DOES J 39200 DISPLAY RESISTANCE AS "OL" {INFINITE) FOR
BOTH MEASUREMENTS?
I
I
I
YES

GROUND AND TERMINAL "A" OF THE LEFT REAR WHEEL
NO
REPLACE LEFT REAR WHEEL

I
I
YES

GROUND WHEN ALL COMPONENTS ARE CONNECTED. PAY
PARTICULAR ATTENTION TO THE JUMPER HARNESS. SMALL
NICKS OR CUTS CAN CAUSE A MALFUNCTION. REPAIR ANY
DAMAGE IF FOUND. JUMPER HARNESS MUST BE REPLACED IF
DAMAGED. REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE FOR
MORE INFORMATION.
NO
IREPLACE WHEEL SPEED SENSOR. I
C8007
5E2-88
EBTCM
r--,
ABS JUMPER HARNESS
. r--,
882 BRN --+EJ+a82 BRN
883WHT--+G+ 883WHT
L __ J
HL__ J
C405
C200
~ 882 BRN
RR WHEEL SPEED
SIGNAL HIGH
883WHT
C1
RR WHEEL SPEED
SIGNAL LOW
06-15-96
FT0206E
DTC 35
(Page 1 of 3)
RR WHEEL SPEED SNR CKT OPEN OR SHORT TO GND/BAT
Diagnostic Aids:

the air gap.

this section.
DTC Will Set When:

Action Taken:
turned "ON."

sensor coil.
sensor wiring.
sensor wiring.
rn
OTC 35
IMPORTANT:
(Page 1 of 3)

FOUND.
RR WHEEL SPEED SNR CKT

OPEN OR SHORT TO
GND/BAT
.
IGNITION "OFF."
USING A 5% SALT WATER SOLUTION {TWO TEASPOONS OF SALT TO 12 OZ. WATER), THOROUGHLY SPRAY THE RIGHT REAR
WHEEL SPEED SENSOR JUMPER HARNESS.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINALS "A2" AND "B1" OF THE 24-WAY EBTCM HARNESS
CONNECTOR.
IS RESISTANCE BETWEEN 2579 AND 3315 n WHEN SENSOR IS 2oc {68'F)? (IF TEMPERATURE OF SENSOR IS SUSPECTED TO
OTHER THAN 2oc (68FJ, REFER TO THE TABLE ON PAGE 2 OF 3 OF THIS DTC CHART FOR APPLICABLE SENSOR RESISTANCE
VALUES; THE VALUES IN THE TABLE ARE FOR TEMPERATURE OF THE SENSOR, NOT AIR TEMPERATURE.)
I
YES
NO
Ii
USING J 39200 MEASURE THE RESISTANCE BETWEEN GROUND AND

TERMINAL "B1" OF THE 24-WAY EBTCM HARNESS CONNECTOR.
G)
1
g~~:~: ~ g~~TbNFui~1s
DTC CHART.,,,,,,,,,,,,,,,,,,,,,,,,J
YES
,,,,,,J,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
NO
, .... J"'"'"'."'"'"""'""'""""'"''
i DIAGNOSIS CONTINUED i
IGNITION TO "RUN."
TERMINAL "B1" OF THE 24-WAY EBTCM HARNESS CONNECTOR.
! ON PAGE 3 OF 3 OF THIS !
!',,,,,.,,,,,.,,,,,,,,,,,,,,,,,,,,..,,,,,,,,,,.,u,;11,,,,,,,,,,,,,,I
DTC CHART.
!
I
NO
YES
I
IGNITION "OFF."
DISCONNECT RIGHT REAR WHEEL SPEED SENSOR DIRECTLY AT
SENSOR.
IGNITION TO "RUN."
TERMINAL "B1" OF THE 24WAY EBTCM HARNESS CONNECTOR.
.
YES

TERMINAL "A2" OF THE 24WAY
IS VOLTAGE 1.VOLT OR LESS?
NO
G)
REPAIR SHORT TO
.VOLTAGE IN CKT 883.

ARE CONNECTED. REPAIR ALI. DAMAGE IF
INFORMATION.
NO
REPLACE
EBTCM.
I
I
IGNITION "OFF."
INSPECT TERMINALS "A2" AND "B1" OF THE
24WAY EBTCM HARNESS.CONNECTOR FOR
IN AN OPEN CIRCUIT, SHORT TO. GROUND,
. DAMAGE IF EVIDENT
IGNITION TO "RUN."
YES
YES
REPAIR SHORT TO
VOLTAGE IN CKT 882.
NO
I
MALFUNCTION IS
FACING PAGE.
I
C8008
5E2-90
EBTCM
(
ABS JUMPER HARNESS
r--,
. r--,
882 BRN ~ 8 8 2 BRN --+8+882 BRN
883 WHT
+B+
I
~ 883 WHT
883 WHT
L __ J
L __ J
C405
RRWHEELSPEED
SIGNAL HIGH
RR WHEEL SPEED
SIGNAL LOW
C200
01i-11i-91i
FT0206E
DTC 35
{Page 2 of 3)
the air gap.
DTC Will Set When:
Action Taken:
turned "ON."
sensor coil.
Diagnostic Aids:

formed or damaged terminals,. poor terminal Jo wiring
this section.
Resistance of the. wheel speed sensor will
section.
DTC 35
(Page 2 of 3)
,.,,,,,,,.,,,,,,,.,,.,,,.,.,,,,.,,,,,.,,,,,.,,,.,,,,.,..,,.,,.,,,,,,,.
I! FROM
DIAGNOSIS CONTINUED I
PAGE 1 OF 3 OF !
I. . THIS
. .r........OTC,,,....CHART.
,,,,,,. . . . . ,,,,,,,,,,!

24-WAY EBTCM HARNESS CONNECTOR AND TERMINAL "A" OF THE RIGHT REAR
I
I
YES
NO

OF THE 24-WAY EBTCM HARNESS CONNECTOR AND TERMINAL "B" OF
THE RIGHT REAR WHEEL SPEED SENSOR HARNESS CONNECTOR.

I
I
YES
I
NO
I

"A" AND TERMINAL "B" OF THE RIGHT REAR WHEEL SPEED
.
SENSOR CONNECTOR.
IS RESISTANCE BETWEEN 2579 AND 3315 0 WHEN SENSOR IS 2oc
(68F)? (IF TEMPERATURE OF SENSOR IS SUSPECTED TO OTHER
THAN 2oc (68FJ, REFER TO THE TABLE BELOW FOR APPLICABLE
SENSOR RESISTANCE VALUES; THE VALUES IN THE TABLE FOR
TEMPERATURE OF THE SENSOR, NOT AIR TEMPERATURE.)

BE REPLACED IF DAMAGED),
YES
I
NO
MALFUNCTION IS INTERMITTENT. INSPECT ALL .CONNECTORS


(APPROXIMATE)
TEMP.
TEMP.
RESISTANCE
CC)
CF)
(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
C8009
5E2-92
ANTI LOCK BRAKE .SYSTEM .WITH TRACTION CONTROL
EBTCM
r--,
ABS JUMPER HARNESS
r--,
RR WHEEL SPEED
SIGNAL HIGH
882 BRN ~ 8 8 2 BRN --+8-!-882 BRN
883 WHT
HI
~ 883 WHT
L __ J
L__ J
C405
883 WHT
C1
RR WHEEL SPEED
SIGNAL LOW
C200
05-11595
FT020l5E
oTC 35
(Page 3 of 3)
the air gap.
DTC Will Set When:

Action Taken:
turned "ON."

Diagnostic Aids:

should be. thoroughly checked for backed out
. connections or physical damage to the wiring harness.
this section.
wheel speed sensor circuitry should be . thoroughly
section.
DTC 35
(Page 3 of 3)
,.,.,,,,,,,,,..,.,.,,.,,,,,,.,,,.,.,,,,,,,,,,,,.,,.,,,,.,..,,,,,,.,.,.,.,.,,,.,.,,,,.,u,.,,
!! FROM
DIAGNOSIS CONTINUED
. !
PAGE 1 OF 3 OF THIS !
I OTC CHART.
"'"'"'['"''""""""""'"""'""""""!"'"'
DISCONNECT CONNECTOR C405B, C405C (LOCATED ON THE LH SIDE

REAR UNDER BODY, BEHIND REAR SEAT).
TERMINAL "81" OF THE 24-WAV EBTCM HARNESS CONNECTOR.
I
I
YES

TERMINAL "A2" OF THE 24-WAV EBTCM HARNESS CONNECTOR.
NO
'
THOROUGHLY RESPRAY THE RIGHT REAR WHEEL SPEED SENSOR


IN CKT 883.
I
YES
NO

IN CKT 882.
.

SENSOR CONNECTOR.
DISCONNECT RIGHT REAR WHEEL SPEED SENSOR DIRECTLY AT
SENSOR.
TERMINAL "A," THEN "B" OF THE RIGHT REAR WHEEL SPEED
MEASUREMENTS?
I
YES

TERMINAL "A" OF THE RIGHT REAR WHEEL SPEED SENSOR
CONNECTOR.
DOES J 39200 DISPLAY RESiSTANCE AS "OL" (INFINITE)?
NO
I
REPLACE RIGHT REAR WHEEL

SPEED SENSOR JUMPER HARNESS;
I
YES
I
MALFUNCTION IS INTERMITTENT. INSPECT ALL CONNECTORS .AND

GROUND WHEN. ALL COMPONENTS ARE CONNECTED. PAV PARTICULAR
ATTENTION TO THE JUMPER HARNESS. SMALL NICKS OR CUTS CAN
I
I
NO
C8010
5E2-94

EBCM EBTCM
IGNITION
REFER TO SECTION
8A10
. _ _...
C1
. . . - - - - - - - - - - - - - - - - 6 4 1 BAN
i..;,..._
_ . . , " ' " - ~ - - 641 BAN
B+ L
&AMP
~302RED"'I
FUSIBLE
LINK B
---1632PNK
1633 RED
SWITCHED IGNITION
ABS/TCS RELAY
ENABLE CONTROL
ABS/TCS SWITCHED
BATTERY INPUT
302 RED
8176
----.J
CENTER
041995
FT0165E
DTC 36
(Page 1 of 2)
LOW SYSTEM VOLTAGE


available to the EBTCM. If the voltage drops below
10.25 volts, full performance of the ABS/TCS system
cannot be guaranteed. During ABS/TCS operation,
there are several current requirements that will cause
battery voltage to drop. Because of this, voltage is
monitored prior to ABS/TCS to indicate good charging
system condition and also during ABS/TCS when
voltage may drop significantly.

1. Checks to see what voltage is readily available at

terminal "C" of the EBTCM. If voltage is
representative of good charging system condition,
a malfunction is. not present.
2. Isolates the condition to high circuit resistance, or
improper charging system operation.
DTC Will Set When:

voltage is less than 10.25 volts non- ABS/TCS or less
than 8.32 volts ABS/TCS, a malfunction exists.
Because of tolerances within the the EBTCM sensing
software DTC 36 may set as high as 10.95 volts nonABS/TCS or as high as 8.6 volts ABS/TCS.
Action Taken:
A malfunction DTC is stored, ABS/TCS is
turned "ON." The red brake warning lamp is also
turned "ON" if either of the TCS motors are not in
the home position at the time of the malfunction.
Diagnostic Aids:
this section.
for backed out terminals, improper . mating, broken
the wiring harness.
ANTILOCK BRAKE SYSTEM WITH. TRACTION CONTROL 5E2-95
DTC 36
(Page 1 of 2)
LOW SYSTEM VOLTAGE
START ENGINE.
USING TECH 1, SELECT "F3: SNAPSHOT."
SELECT "F4: SINGLE OTC"; THEN ENTER "38".
DRIVE VEHICLE ABOVE 5 km/h (3 MPH).
DID TECH 1 TRIGGER?
YES
NO
I
WITH ENGINE RUNNING, USE TECH 1 AND SELECT "F4: MISC. TESTS."
PERFORM "VOLTAGE LOAD" TEST.
ARE IGNITION AND BATTERY VOLTAGES GREATER THAN 10 VOLTS?
NO
_,#
"""
REFER TO SECTION 803 TO DIAGNOSE CHARGING SYSTEM.
IS CHARGING SYSTEM OK?
YES

YES
NO
,
I
mmmmuuumummuumu
TO CORRECT LOW
l
l
~""""'"""""""""'l'I""""""""""""'""'"""""""''"'""""""'
NO
NO

IN CKT 1833.

USING J 39200, MEASURE RESISTANCE BETWEEN THE POSITIVE
BATTERY CABLE TERMINAL AND TERMINAL "C1" OF THE ABS/TCS
RELAY HARNESS CONNECTOR.
IS RESISTANCE 2 O OR LESS?
YES
! VOLTAGE CONDITION.
IGNITION "OFF."
DISCONNECT GRAY SWAY AND 24-WAY EBTCM CONNECTORS.
USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "C4" OF
THE ABS/TCS RELAY HARNESS CONNECTOR AND TERMINAL "C" OF
THE GRAY SWAY EBTCM HARNESS CONNECTOR.
YES

IN CKT 302.
,,,.,,,,,,,. 1,;,,,.,,,,,.,,.,.,,,u111111,,1,11,;1,,;,,.,;,;
"'
'
DIAGNOSIS CONTINUED
I ON PAGE 2 OF 2 OF
I
I,.,.,,,.,,.,,,,,,,.,,,,,,,,,u,;,t;;;;.,,,,,,,,,,.,,,,u,,,,,~I
THIS OTC CHART.
I
C8011
5E2..96

EBCM EBTCM
IGNITION
REFER TO SECTION
P100
8A10
r---
i.;;..._-td"'-~-- 641 BRN

B+ L
---1832 PNK_n _ _
5AMP
1833 RED
~302RED,
FUSIBLE
. . . . - - - - - - - - - - - - - - - 8 4 1 BRN---t1111---1 A9
SWITCHED IGNITION
ABS/TCS RELAY
ENABLE CONTROL
ABSITCS SWITCHED
BATTERY INPUT
302 RED
LINK B
8175
----.J
CENTER
0419-t5
FT0161E
DTC 36
(Page 2 of 2)
LOW SYSTEM VOLTAGE

available to the EBTCM. If the voltage drops below
10.25 volts, full performance of the ABS/TCS system
cannot be guaranteed. During ABS/TCS operation,
there are several current requirements that will cause
battery voltage to drop. Because of this, voltage is
monitored prior to ABS/TCS to indicate good charging
system condition and also during ABS/TCS when
voltage may drop significantly.

.
6. Checks for high resistance in the ignition fused
feed circuit.
7. Checks for malfunctioning EBTCM.
DTC Will Set When:

voltage is less than 10.25 volts non- ABS/TCS or less
than 8.32 volts ABS/TCS, a malfunction exists.
Because of tolerances within the the EBTCM sensing
software DTC 36 may set as high as 10.95 volts nonABS/TCS or as high as 8.6 volts ABS/TCS.
Action Taken:
the home position at the time of the malfunction.
Diagnostic Aids:
this section.
the wiring harness.
DTC 36
(Page 2 of 2)
LOW SYSTEM VOLTAGE
,.,.,,.,.,,,.,,.,,,,,,,,,,,.,,,,,,,,,,,,,,.,,,,,,,,,,n,,n,,,,,,,,,,,,,,,,,,,,,.,,,,.,,,,,,,,,,,.,,,,,,,,,,,,.,,,,,,,,,,,,,.,,,,,,,,,,,.,,,,,,,.,,,.,,.,
i
i
j DIAGNOSIS CONTINUED FROM PAGE 1 OF 2 OF THIS DTC CHART. j
""'"f"""'"'""""""""'"""""""""""'""""'"'"""'"""'""'"'"""'"""""""'"'""'""'""'
REMOVE ABS IGN FUSE 1.

USING J 39200, MEASURE RESISTANCE BETWEEN EACH ABS IGN FUSE 1 BLOCK
TERMINAL AND TERMINAL "A9" OF THE 24-WAV EBTCM HARNESS CONNECTOR.
IS EITHER MEASUREMENT 2 0 OR LESS?
YES
NO
I
WITH BATTERY CABLES DISCONNECTED, TURN IGNITION TO "RUN."

USING J 39200, MEASURE RESISTANCE BETWEEN POSITIVE BATTERY
CABLE TERMINAL AND EACH ABS IGN FUSE 1 BLOCK TERMINAL.
IS EITHER MEASUREMENT 2 0 OR LESS?
YES
I
NO
I
I
,.J .......,,,,..,,...................................................
IGNITION "OFF."
INSPECT ABSfTCS RELAY AND ABSfTCS RELAY HARNESS
CONNECTOR FOR POOR TERMINAL CONTACT. INSPECT GRAY
BWAY AND 24WAY EBTCM HARNESS CONNECTORS FOR A POOR
CONNEC'l:ION TO THE EBTCM. INSPECT POSITIVE BATTERY CABLE
TERMINAL FOR POOR CONTACT TO THE BATTERY. REFER TO
SECTION BA4, "CHECKING TERMINAL CONTACT." REPLACE
TERMINALS IF POOR CONTACT IS EVIDENT.
YES
REPAIR HIGH RESISTANCE IN CKT 641.
I REFER TO SECTION BA TO REPAIR I

! HIGH RESISTANCE IN THE "IGNITION l
!l.,.,..,,,,.,,,,.,.,.,,.,.,,.,,.,.,;,,.,,,,,..,,.,,,.,,,u,,,,.,,,.,.,,,,,,,.,.,,,,,,u,1.u1,,,,.,,.,.,,,,',
SWITCH 'RUN' FUSE FEED" CIRCUIT. j
REPLACE EBTCM.
NO
I

TO A POOR CONNECTION. REFER
TO "DIAGNOSTIC AIDS" ON FACING
PAGE.
C8012
5E2-98

EBCM EBTCM
IGNITION
Rl!Fl!R TO SECTION
IIA10
...
..----------------841 BRN
-- ABS ION
FUSE 1
1.:---d"\_.IJII=--- 641 BRN

B+
I..
1---1632PNK
SAMII'
1633 RED
~302RED""I
FUSIBLE
302 RED I
LINKB
SWITCHED IGNITION
AEISITCS RELAY
ENABLE CONTROL
ABSITCS SWITCHED
BATTERY INPUT
S175
---
---
---
UN;DERHOOD ELECTRICAL
CENTER
.J
041995
FT0185E
OTC 37
HIGH SYSTEM VOLTAGE
This DTC is designed to detect high vehicle

voltage levels prior to any required motor movement
(initialization or ABS/TCS). If excessive voltage
exists, demagnetization of the motor magnets may
occur, which would eventually affect or eliminate
ABS/TCS performance.

1. Checks the voltage level being received by the
EBTCM.
2. Checks to see if high voltage condition is due to
charging system malfunction.
3. Checks for poor terminal contact which may
cause an intermittent malfunction, or a
malfunctioning EBTCM.
DTC Will Set When:

voltage is greater than 17 volts, a malfunction exists.
Action Taken:
the home position at the time of the fault.
Diagnostic Aids:
this section.
the wiring harness.
DTC 37
HIGH SYSTEM VOLTAGE
TURN ALL ACCESSORIES "OFF."

START ENGINE.
USING TECH 1, SELECT "FO: DATA LIST" AND
MONITOR EBTCM BATTERY VOLTAGE WHILE RUNNING
ENGINE AT APPROXIMATELY 2000 RPM.
IS EBTCM BATTERY VOLTAGE LESS THAN 16 VOLTS?
IGNITION "OFF."
START ENGINE.
BETWEEN ABS/TCS RELAY HARNESS
CONNECTOR TERMINAL "C1" AND GROUND
WHILE RUNNING ENGINE AT APPROXIMATELY
2000 RPM.
MALFUNCTION NOT PRESENT THIS

TIME. REFER TO "DIAGNOSTIC AIDS"
ON FACING PAGE.
~,,,,, ,,,,.,,,,.,,.,,,u,,,,,,,,,,,,,,,..,,,,.,,,,,,,,,,,,,,,,,..,,.,,,,,,,,u,,,,,,,,.,
I REFER TO SECTION 603 TO CHECK
! ...,,,,,,'
CHARGING SYSTEM OPERATION.
!
,,,1;11,,,,,,,,,,,,,,..,,.,,.....,,,,,,,,,,,,.,..,,,,..,,.,,,,,,,,.,,,,,,,,~
~
IGNITION "OFF."
RECONNECT ABS/TCS RELAY.
DID DTC 37 SET AS A CURRENT OTC?
REPLACE EBTCM.
FACING PAGE.
C8013
r-------,
I
:f"~O: / G ) - - - - - 1 i - - - - - - - - - 1 2 e o ILK - - - - - i n
I
I
EBCM/EBTCM
; ; ._I J----11---------1281 PNK

ABS MOTOR PACK
I WAY CONNECTOR C1
.. - - -
------IIRl--1 H
C2
-
HYDRAULIC
MODULATOR ASSEMBLY
04-21-811
FT021SE
DTC 38
LEFT FRONT ESB WILL NOT HOLD MOTOR
This DTC is designed to detect a slipping left

front ESB. During initialization and braking, the left
motor/piston will move. During the next ignition to
"RUN" initialization, a re-home of the motor verifies
slipping.

1. Checks the left front ESB. A broken or defective
ESB would result in the left front piston being
back driven by hydraulic pressure and pedal
"HIGH" circuitry.
3. This step checks for high resistance in the ABS
windings.
5. Checks for poor terminal contact or corrosion in
the connectors.
6. Checks for a malfunctioning EBTCM.
DTC Will Set When:

EBTCM detects that the ESB could not hold the
piston in the home position, a malfunction exists. DTC
86 is always set with DTC 38.
Action Taken:
drop. A malfunction DTC is stored, ABS and TCS are
disabled. The amber ABS and TCS warning lamps and
the red BRAKE warning lamp are turned "ON."
Diagnostic Aids:
binds, or slips.
this section.
DTC 38
IGN.ITION TO "RUN," ENGINE "OFF."

SELECT ABS MOTOR APPLY FUNCTION OF THE LEFT FRONT
WAIT 5 SECONDS.
..
NO
I
YES
YES
NO
--.-
I
I
.
I
REPAIR HIGH
NO
INSPECT THE 6-WAY ABS MOTOR PACK CONNECTOR AND GRAY 8-WAY
REFER TO SECTION 8A-4, "CHECKING TERMINAL CONTACT."
NO
REPAIR HIGH
NO
.
I
REPLACE ABS
MOTOR PACK.
USING J. 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "A"

AND TERMINAL "B" OF THE MOTOR PACK CONNECTOR.
IS RESISTANCE BETWEEN 0.2 0 AND 1.5 O?
YES
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "B" OF

THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR AND TERMiNAL "H"
OF THE, GRAY 8WAY EBCM/EBTCM HARNESS CONNECTO.R.

TO J 39200 USER'S MANUAL .
YES

IGNITION "OFF."
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "A" OF
THE 6WAY ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL
"G" OF THE GRAY 8-WAY EBCM/EBTCM HARNESS CONNECTOR.
LEFT FRONT ESB Wlll

NOT HOLD MOTOR
REPLACE ABS
MOTOR PACK.
YES
IGNITION "OFF."
16 km/h (10 MPH).
DID DTC 38 SET IN THE LAST THREE DRIVE. CYCLES?

..
YES
NO
---.
REPLACE EBCM/EBTCM.
MALFUNCTION IS
FACING PAGE.
C8014
5E2-102
EBCM/EBTCM
.-------.,
~=
~-----1--------- 1282 PPL-----1111--
1
~ ._F~ - - - 1 , - - - - - - - - - 1283 BLI<-----1111---t
ABS MOTOR PACK
I 6 WAY CONNECTOR Q:!
L
C2
...I
HYDRAULIC
MODULATOR ASSEMBLY
04-2095
FT0225E
DTC 41
RIGHT FRONT ESB WILL NOT HOLD MOTOR
This DTC is designed to detect a slipping right

front ESB. During initialization and braking, the right
motor/piston will move. During the next ignition
to"RUN" initialization, a re-home of the motor
verifies the motor/piston remained at the home
position. If motor movement is detected, the ESB must
be slipping.

1. Checks the right front ESB. A broken or defective
ESB would result in the right front piston being
back driven by hydraulic pressure, and pedal
"HIGH" circuitry.
3. This step checks for high resistance in the ABS
windings.
the connectors.
DTC Will Set When:

Action Taken:
Diagnostic Aids:
binds, or slips.
this section.
DTC 41

SELECT ABS MOTOR APPLY FUNCTION OF THE RIGHT FRONT
WAIT 5 SECONDS.
RIGHT FRONT ESB WILL

NOT HOLD MOTOR
.
NO

.
.
YES
..

IGNITION "OFF."
DISCONNECT 6-WAY ABS MOTOR PACK CONNECTOR AND GRAY 8WAY
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "E" OF
THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL "A"
REPLACE ABS
MOTOR PACK.
YES
NO
I

OF THE GRAY 8-WAY .EBCM/EBTCM HARNESS CONNECTOR.
REPAIR HIGH
YES
NO

AND TERMINAL ''F" OF THE ABS MOTOR PACK CONNECTOR.
IS RESISTANCE BETWEEN 0.2 n AND 1,5 !l?
YES
NO
INSPECT THE 6-WAY MOTOR PACK CONNECTOR AND GRAY 8-WAY EBCM/EBTCM
CONNECTOR FOR POOR TERMINAL CONTACT OR CORROSION. REFER TO
SECTION 8A4, "CHECKING TERMINAL CONTACT."
I
YES
REPLACE ABS
MOTOR PACK.

REPLACE EBCM/EBTCM.
YES
IGNITION "OFF."
16 km/h (10 MPH).
. I
NO
REPAIR HIGH
NO
I
FACING PAGE.
STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH) AND THEN TURNING KEY "OFF."
C8015
5E2-104

EBCM/EBTCM
- --- --- - - - .,
...
"c"
1284DKORN
REAR ABS MOTOR

CONTROL HIGH
,,D.,
12850RN
REAR ABS MOTOR

CONTROL LOW
REAR ABS
MOTOR
ABS MOTOR PACK
I 8 WAY CONNECTOR
I..
C2
C1
--- - - ..... -
..I
HYDRAULIC
MODULATOR ASSEMBLY
060195
FT023SE
DTC 42
REAR ESB WILL NOT HOLD MOTOR
This DTC is designed to detect a slipping rear

axle ESB. During initialization and braking, the rear
motor is re-homed. If the ESB slips, the motor/piston
will move. During the next ignition to "RUN"
initialization, a re-home of the motor verifies the
motor/piston remained at the home position. If motor
movement is detected, the ESB must be slipping.

1. Checks the rear axle ESB. A broken or defective

ESB would. result in the rear axle pistons being
back driven by. hydraulic pressure and wheel
"HIGH" circuitry.
"LOW" circuitry.
4, Checks for proper resistance of the ABS motor
windings.
the connectors.
6. Checks for a malfunctioning EBTCM .
DTC
wm
Set When:

Action Taken:
. If an ESB can hold a piston in the home
Diagnostic Aids:
binds, or slips.
this section.
5E2-105
OTC 42
REAREs B WILL NOT

HOLD MOTOR
RAISE THE VEHICLE SUCH THAT THE REAR WHEELS ARE

APPLY FIRM PRESSURE ON BRAKE PEDAL AND RELEASE.
REAPPLY VERY FIRM PRESSURE ON BRAKE PEDAL AND HAVE AN
ASSISTANT TRY TO SPIN THE REAR WHEELS BY HANO.
NOTICE:
J 39200 TEST LEADS MUST

NO
I
YES
IGNITION "OFF."
DISCONNECT 6WAY ABS MOTOR PACK CONNECTOR AND GRAY 8-WAY
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "C" OF
THE 6WAY ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL "F"
OF THE GRAY 8WAY EBCM/EBTCM HARNESS CONNECTOR.
REPLACE ABS
MOTOR PACK.
I
YES
NO
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "D" OF

THE 6WAY ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL "E"
OF THE GRAY 8WAY EBCM/EBTCM HARNESS CONNECTOR. .
.
YES
I
I
I
NO

AND TERMINAL "D" OF THE ABS MOTOR PACK CONNECTOR.
YES
REPAIR HIGH
"C."
REPAIR HIGH
RESISTANCE INCKT 1285.
NO
INSPECT THE 6WAY ABS MOTOR PACK CONNECTOR AND GRAY 8WAY
.
REPLACE ABS
MOTOR PACK.
..
I
NO
I
YES
IGNITION "OFF."
: :~~f~~giN~L,~NcDo~::-::1~~:E VEHICLE, ACHIEVING AT LEAST
16 km/h (10 MPH),

POOR .TERMINAL CONTACT OR
EVIDENCE.OF CORROSION.
I
I
YES
I
REPLACE EBCM/EBTCM.
'
NO
'

FACING PAGE.
DRIVE CYCLES TO VERIFY OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING
THE VEHICLE, DRIVING OVER 16 km/h (10 MPH) AND THEN TURNING KEY "OFF."
C8016
5E2-106
r-
---- - -
EBCM/EBTCM
.,
~i8
1280BLK
1281 PNK
MOTOR
..B.,
CZ
ABS MOTOR PACK

6 WAY CONNECTOR C1
.....
- - -
.I
HYDRAULIC
MODULATOR ASSEMBLY
04-20-95
FT021!E
DTC44
LEFT FRONT ABS CHANNEL WILL NOT MOVE
modulator. When the release is commanded during
current.
DTC Will Set When:

the EBTCM detects a condition in which it cannot
exists.
Action Taken:
moved properly. A malfunction DTC is stored, ABS
and TCS are disabled; The amber ABS and TCS
warning lamps are turned "ON."

1. Checks for proper ABS motor movement during
2. Compares EBTCM command current to motor
feedback current.
3. Checks for a shorted circuit between the ABS

motor "HIGH" and ABS motor "LOW" circuits.
shorted.
5. Determine,s if the malfunction is caused by a
defective EBTCM or poor terminal contact.
6. Verifies that the ABS motor can actually apply
when commanded.
piston movement.
Diagnostic Aids:
binds, or slips.
1
the wiring harness.

DTC 44
LEFT FRONT ABS
CHANNEL WILL NOT MOVE

SELECT LEFT FRONT ABS MOTOR RELEASE FUNCTION AND RELEASE MOTOR.

SELECT LEFT FRONT MOTOR APPLY FUNCTION AND APPLY THE MOTOR.
ON FACING PAGE.

SELECT LEFT FRONT ABS MOTOR APPLY FUNCTION AND APPLY THE MOTOR
FEEDBACK CURRENT ON THE TECH 1;

IGNITION "OFF."
DISCONNECT THE GRAY 8-WAY EBCM/EBTCM CONNECTOR AND THE 6-WAY
.
USING J. 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "G" AND
TERMINAL "H" OF THE GRAY 8-WAY EBCM/EBTCM HARNESS CONNECTOR.
U.SING.J 39200, MEASURE THE RESISTANCE BETWEEN

TERMINAL "A" AND TERMINAL "B" OF THE ABS MOTOR
PACK CONNECTOR.
IGNITION "OFF."
.
TIMES.
r.;'i
\.!J
REPAIR SHORT
BETWEEN CKT 1280
AND CKT 1281.

IGNITION "OFF."
REMOVE HYDRAULIC
SECTION.
FORWARD WHEN THE UNIT IS
LOCK?
REPLACE
ABS MOTOR
PACK.
REPLACE
HYDRAULIC
MODULATOR.

AND POOR CONTACT. REPLACE ANY TERMINALS THAT EXHIBIT POOR TERMINAL
CONTACT OR EVIDENCE OF CORROSION.
C8017
5E2-108
EBCM/EBTCM
.--------.
r E " - - - - - - - - - - - - 1 2 8 2 PPL------11 A
I
I
I
L
:,::/0
~
-
I .
._F~ - - - - - - - - - - 1 2 8 3 BU<-----1111---t B
ABS MOTOR PACK

6WAYCONNECTOR C1
RF ABS MOTOR CC)NTROL LOW
HYDRAULIC
MODULATOR ASSEMBLY
042095
FT0225E
OTC 45
RIGHT FRONT ABS CHANNEL WILL NOT MOVE
modulator'. When the release is commanded during
current.
DTC Will Set When:
DTC 45 .can be set during normal operation. If
move the ABS motor in either direction, a malfunction
exists.
Action Taken:
and TCS are disabled. The amber ABS and TCS
feedback current.

shorted.
terminal contact or the EBTCM.
commanded.

piston movement.
Diagnostic Aids:
binds, or slips.
the wiring harness.


SELECT RIGHT FRONT ABS MOTOR APPLY FUNCTION AN.D APPLY THE MOTOR.
SELECT RIGHT FRONT ABS MOTOR RELEASE FUNCTION AND RELEASE MOTOR.
DTC 45
RIGHT FRONT
ABS CHANNEL
WILL NOT MOVE
MAINTAION FIRM PRESSURE ON BRAKE PEDAL.


SELECT RIGHT FRONT ABS MOTOR APPLY FUNCTION AND APPLY THE
MOTOR WHILE CAREFULLY OBSERVING THE COMMANDED CURRENT AND
THE FEEDBACK CURRENT ON THE TECH 1.
.
ON FACING PAGE.

IGNITION "OFF."
DISCONNECT THE GRAY 8-WAY EBCM/EBTCM CONNECTOR AND THE 6WAY
TERMINAL "B" OF THE GRAY 8WAY EBCMiEBTCM HARNESS CONNECTOR.

IGNITION "OFF."
REMOVE HYDRAULIC
"ON VEHICLE SERVICE" IN THIS.
SECTION.
SEPARATE ABS MOTOR PACK FROM ,
REARWARD WHEN THE UNIT IS
ATTEMPT TO MOVE THE GEAR,
LOCK?

TERMINAL "E" AND TERMINAL "F" OF THE ABS MOTOR
PACK CONNECTOR.
IS RESISTANCE BETWEEN 0.2.Q AND 1.5 Q?
IGNITION "OFF."
.LEAST 16 km/h (10 MPH).
TIMES.
.
DOES DTC 45 SET IN THE LAST THREE DRIVE CYCLES?

AND POOR TERMINAL CONTACT. REPLACE ANY TERMINALS THAT EXl:IIBIT POOR
C8018
5E2-110
EBCM/EBTCM
------
.,
re"
REAR ABS
MOTOR
I
L
ABS MOTOR PACK

6WAYCONNECTOR C1
D
~
"
- - - - -
(
1284DKORN
REAR ABS MOTOR

CONTROL HIOH
12810RN
REAR ABS MOTOR

CONTROL LOW
C2
..I
HYDRAULIC
MODULATOR ASSEMBLY
06-01-95
FT023SE
DTC 46
REAR ABS CHANNEL WILL NOT MOVE
stuck ABS motor, or a seized hydraulic modulator.
When the release is commanded during initialization,
the ESB should release the ABS motor, resulting in
sensed current being less than commanded current
(motor is spinning freely): If the ABS motor is not
moving, sensed. current will be equal to stall current.
DTC Will Set When:
exists.
Action Taken:
and TCS are disabled. The amber ABS and TCS
2. Compares EBTCM command current to ABS
motor feedback current.
3. Checks for a short circuit between the ABS motor

shorted.
terminal contact or the EBTCM.
6. Verifies that the motor can actually release when
commanded.
piston movement.
Diagnostic Aids:
or binds.
the bottom of their bore. Depending on the frequency
of the malfunction, a physical inspection of the
mechanical parts suspected may be necessary.
the wiring harness.
OTC 46
REAR ABS CHANNEL

WILL NOT MOVE

RAISE AND SUPPORT THE VEHICLE SUCH THAT THE REAR WHEELS ARE
.

SELECT REAR AXLE ABS MOTOR RELEASE FUNCnON AND RELEASE THE MOTOR.
ON FACING PAGE.

.
FEEDBACK CURRENT ON THE TECH 1.

IGNITION "OFF."
DISCONNECT THE GRAV BWAY EBCM/EBTCM CONNECTOR AND THE
6-WAV ABS MOTOR PACK CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "E" AND
TERMINAL "F" OF THE GRAV BWAV EBCM/EBTCM HARNESS CONNECTOR.

TERMINAL "C" AND TERMINAL "D" OF THE ABS MOTOR
PACK CONNECTOR.
t;'\
\.!..)
REPAIR SHORT
BETWEEN CKT 1284
AND CKT 1285.
USING TECH 1 MISC. TESTS,

PERFORM GEAR TENSION RELIEF
FUNCTION.
IGNITION "OFF."
REMOVE HYDRAULIC
ASSEMBLY FROM VEHICLE.
REFER TO "ON VEHICLE
SERVICE" IN THIS SECTION.
SEPARATE ABS MOTOR PACK
FROM HYDRAULIC MODULATOR.
GRASP THE MIDDLE GEAR ON
THE HYDRAULIC MODULATOR
{THE HYDRAULIC MODULATOR IS
THE UNIT WITH THE THREE
LARGE GEARS) AND ATTEMPT TO
MOVE THE GEAR.
LOCK?

IGNITION "OFF."
TIMES.

C8019
5E2112
I"'
-----
EBCM/EBTCM
..,
~ot0
P100
1280 BLK
1281 PNK
MOTOR
I.BJ
C2
ABS MOTOR PACK

6 WAY CONNECTOR C1
---
...I
HYDRAULIC
MODULATOR ASSEMBLY
04-20-95
FT0215E
DTC 47
{Page 1 of 2)
malfunction.
DTC Will Set When:

Action Taken:
disabled. The amber ABS and TCS warning lamps are
turned "ON."

DTC is also set.

"HIGH" circuitry.
"LOW" circuitry.
shorted.
Diagnostic Aids:
binds, or slips.
the Tech 1, as described in "Tech 1 Diagn.ostics" in
may be necessary.
5E2-113
OTC 47
RESISTANCE MEASUREMENTS. REFER TO J 39WO USER'S MANUAL.
(Page 1 of 2)
LEFT FRONT ABS
MOTOR FREE SPINS
\.}J--,1==::::::::::::::::::::::::::::........................................_.......................................:::-:-:-:-:-:::;~~~~~~~~---1
..
~,,,

SELECT LEFT FRONT ABS MOTOR APPLY FUNCTION AND APPLY
WERE BOTH COMMAND AND FEEDBACK CURRENT APPROXIMATELY
10 AMPS?
,,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
! PROCEED TO OTC 56 !
!t,,CHART
FIRST.
!
..,,.,,.,,.,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,....,,,..,

SELECT LEFT FRONT ABS MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR.

SELECT LEFT ABS MOTOR APPLY FUNCTION AND APPLY THE MOTOR

IGNITION "OFF."
DISCONNECT 6-WAY ABS MOTOR PACK CONNECTOR AND GRAY 8-WAY EBCM/EBTCM
CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "A" OF THE 6WAY
ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL "G" OF THE GRAY BWAY
MALFUNCTION IS
INTERMITTENT. REFER
ON FACING PAGE.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "B" OF

THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL "H"

TERMINAL "B" OF THE ABS MOTOR PACK CONNECTOR.
,,,,, ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,u,,,,,,,..,,,u,,,,,,,,
Il,,,,,,,,,.,,.,,,,,,,,.,.,,;;;;1,,,,,,..,,
DIAGNOSIS CONTINUED ON NEXT PAGE. I
..,,.,,,.,.,,,,,,,,,,,,,.,.u;,,,,,,,,,,,;1u,,,,,1u;;,,uj
C8020
5E2;.114 ANTILOCK BRAKE SYSTEM WITH TRACTION CONTROL
....
- - .... - - - .,
MOTOR
...,
H~
ABS MOTOR PACK

6 WAY CONNECTOR C1
......
- -- - -
EBCM/EBTCM
1280 BLK
1281 PNK
C2
.J
HYDRAULIC
MODULATOR ASSEMBLY
04-20-95
FT021SE
DTC 47
(Page 2 of 2)
gear assembly during initialization. During the hommg
sequence, the piston should reac~ the top of the bore
resulting in a stalled motor. If this does not oc~ur, the
motor must be spinning with little or. IJ.O resistance,
indicating a nut/screw or gear malfunct10n.
DTC Will Set When:

Action Taken:
disabled. The ABS and TCS warning lamps are turned
"ON."

8. Checks for a. stripped gear on the ABS motor

terminal contact.
Diagnostic Aids:
binds, or slips.
The frequency of the ~alfunc.tion c~n be
checked by using the enhanced diagnostic funct10n of
.
may be necessary.
5E2-115
('"'''"""'"'"'''"'"''"'u,u,,,,,,,,,,,uu,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
! DIAGNOSIS CONTINUED FROM PREVIOUS PAGE.
~,,,,. ,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,.,.,,.,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,.,,,,,,,,,.,,u,,,u,,,,,,,,,I
REMOVE HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY FROM

VEHICLE (REFER TO "ON-VEHICLE SERVICE" IN THIS SECTION).
REMOVE GEAR COVER.
CHECK FOR STRIPPED GEAR ON ABS MOTOR PACK; ABS MOTOR
PACK IS THE UNIT WITH THE THREE SMALL GEARS. THE LEFT FRONT
GEAR IS THE GEAR FURTHEST FORWARD WHEN THE .ASSEMBLY IS
OTC 47
(Page 2 of 2)
LEFT FRONT ABS
MOTOR FREE SPINS
CHECK FOR A STRIPPED GEAR ON HYDRAULIC MODULATOR; MODULATOR IS THE

UNIT WITH THE THREE LARGE GEARS. THE LEFT FRONT GEAR IS THE GEAR
FURTHEST FORWARD WHEN THE UNIT IS INSTALLED IN THE VEHICLE.

SECURELY POSITION HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY IN VEHICLE
WITH GEAR COVER REMOVED SUCH THAT THE GEAR SET CAN BE OBSERVED. BE
CAREFUL NOT TO DAMAGE GEAR SET OR ALLOW THE HYDRAULIC MODULATOR TO
MOVE WHILE TESTING.
.
IGNITION TO "RUN."
USING TECH 1 MISC. TESTS SELECT MANUAL CONTROL FUNCTION.
SELECT LEFT FRONT ABS MOTOR APPLY AND APPLY THE MOTOR WHILE OBSERVING
THE GEAR SET FURTHEST FORWARD WHEN THE UNIT IS INSTALLED IN THE VEHICLE.
SELECT LEFT FRONT ABS MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR
WHILE STILL OBSERVING THE GEAR SET.

IGNITION "OFF."
GRASP THE GEAR ON THE HYDRAULIC MODULATOR (THE HYDRAULIC MODULATOR
IS THE UNIT WITH THE THREE LARGE GEARS) FURTHEST FORWARD WHEN THE
UNIT IS INSTALLED IN THE VEHICLE AND ATTEMPT TO MOVE THE GEAR.
MALFUNCTION IS MOST
FACING PAGE.
C8021
5E2-116
EBCM/EBTCM
r-------,
=~= 10------------
I
I
I
L
J;-
1282 PPL
-----rn
._F. - - - 1 - - - - - - - - 1 2 8 3 BU<-----lll
C2
ABS MOTOR PACK

6WAYCONNECTOR C1
.J
HYDRAULIC
MODULATOR ASSEMBLY
04-20-9!
FT0225E
DTC 48
(Page 1 of 2)
malfunction.
DTC Will Set When:

Action Taken:
turned "ON."

DTC is also set.

"HIGH" circuitry.
"LOW" circuitry.
windings.
Diagnostic Aids:
binds, or slips.
this section. If the DTC only occurs. once and DTC 61
may be necessary.
5E2-117
DTC 48

(Page 1 of 2)
I
NO
RIGHT FRONT ABS

MOTOR FREE SPIN

USING TECH 1 MISC. TESTS, SELECT MANUAL CONTROL
FUNCTION.
WERE BOTH COMMAND AND FEEDBACK CURRENT
APPROXIMATELY 10 AMPS?
YES
I PROCEED TO DTC 61 CHART FIRST. I
YES

SELECT RIGHT FRONT ABS MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR.
.
I
YES
NO
I
IGO TO STEP 5. I

THE MOTOR (THIS MOVES THE PISTON TO THE TOP OF ITS BORE.)
I
I
. I
'
NO

IGNITION "OFF."
DISCONNECT 6-WAY ABS MOTOR PACK CONNECTOR AND GRAY 8-WAY EB.CM/EBTCM CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "E" OF THE 6-WAY ABS MOTOR
PACK HARNESS CONNECTOR AND TERMINAL "A" OF THE GRAY 8-WAY EBCM/EBTCM HARNESS
CONNECTOR.
YES

IS RESISTANCE 1.5 O OR LESS?
I
YES

MALFUNCTION IS
INTERMITTENT.
REFER TO
"DIAGNOSTIC
AIDS" ON FACING
PAGE.
NO
I

IN CKT 1282.
NO
B

IN CKT 1283.
YES
,-,m
YES
,mm,,,m,ummmmummumm,mmm,mummmu',
j DIAGNOSIS CONTINUED ON NEXT PAGE. j
f,,,,.,,,,,,,,,,,,,.,,,,.,n,,.,,,,,,,,,,,,,,,.,,,,.,,,,,,,,,,,,,,,,,,,.,.,,,,,,,,,,,,,.,,,,,,,,,,,J
I
I
NO
C8022
5E2-118
EBCM/EBTCM
.--------.
"-----11--------- 1282 f:IPL
"E
I
I
I
L
8
0
:~~g=
P100
---~111---1 A
"_----t-------- 1283 BU< -----1111---1
._F
ABS MOTOR PACK

6 WAY CONNECTOR C1
C2
HYDRAULIC
MODULATOR ASSEMBLY
042095
FT0225E
DTC 48
{Page 2 of 2)
seque~ce, .the piston should reach the top of the bore
resultmg m a stalled ABS motor. If this does not
malfunction.
DTC Will Set When:

for a specified period of time., a malfunction exists.
Action Taken:
turned "0N."

9. Checks for a .stripped gear on the hydraulic

terminal contact.
Diagnostic Aids:
An intermittent. malfunction in this DTC may
'
binds, or slips.
Depending on the frequency of the malfunction
may be necessary.

V''"'''u,,,,,,,,,,u,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,;;,;,u;,,,,,,,,,uu,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
i,'.............
DIAGNOSIS CONTINUED FROM PREVIOUS PAGE. j
,,,...., ....,,,,,,,,,........,,,....................,,,....,,,.........,,,....,,,.
DTC 48
/.
REMOVE HYDRAULIC MODULATOR/MASTER CYLINDER ASSEMBLY FROM VEHICLE.

(REFER TO "ON-VEHICLE SERVICE" IN THIS SECTION.)
REMOVE GEAR COVER.
UNIT WITH THE THREE SMALL GEARS. THE RIGHT FRONT GEAR IS THE GEAR
FURTHEST REARWARD WHEN THE ASSEMBLY IS INSJ'ALLED IN THE VEHICLE.
(Page 2 of 2)
RIGHT FRONT ABS
MOTOR FREE SPIN
NO
I
YES

THE UNIT WITH THE THREE LARGE GEARS. THE RIGHT FRONT GEAR IS THE
GEAR FURTHEST REARWARD WHEN THE UNIT IS INSTALLED IN THE VEHICLE.
NO
I
NO
I

IGNITION "OFF."
SEPARATE THE ABS MOTOR. PACK FROM THE HYDRAULIC MODULATOR.
GRASP THE GEAR ON THE HYDRAULIC MODULATOR (THE HYDRAULIC
MODULATOR IS THE UNIT WITH THE THREE LARGE GEARS) FURTHEST
REARWARD WHEN THE UNIT IS INSTALLED IN THE VEHICLE AND ATTEMPT TO
MOVE THE GEAR.
REPLACE HYDRAULIC
MODULATOR GEAR.
YES

SECURELY POSITION HYDRAULIC MODULATOR/MASTER CYLINDER ASSEMBLY
IN VEHICLE WITH GEAR COVER REMOVED SUCH THAT THE GEAR SET CAN BE
IGNITION TO "RUN."
SELECT RIGHT FRONT ABS MOTOR APPLY AND APPLY THE MOTOR WHILE
OBSERVING THE GEAR SET FURTHEST REARWARD WHEN THE UNIT IS
SELECT RIGHT FRONT ABS MOTOR RELEASE FUNCTION AND RELEASE THE
MOTOR WHILE STILL OBSERVING THE GEAR SET.
YES
NO
YES
REINSTALL HYDRAULIC MODULATOR/MASTER CYLINDER ASSEMBLY IN VEHICLE.
RECONNECT ALL .CONNECTORS.

MODULATOR.
.
I
YES
REPLACE EBCM/EBTCM.
NO
I
STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN TURNING KEV "OFF."

FACING PAGE.
C8023
5E2-120

EBCM/EBTCM
I"'
- - - - - - .,
"c"'
1284DKORN
.,o~
12850RN
REAR ABS
MOTOR
ABS MOTOR PACK
I 8WAYCONNECTOR
L
- -
(
REAR ABS MOTOR
CONTROL HIGH
REAR ABS MOTOR

CONTROL LOW
C2
C1
--
.J
HYDRAULIC
MODULATOR ASSEMBLY
08-01-95
FT0235E
DTC 51
{Page 1 of 2)
sequence, the piston should reach the top of. the bore
resulting in a stalled .ABS motor. If this does not
malfunction.
DTC Will Set When:

Action Taken:
turned "ON."

1. Checks to see if the corresponding open ABS
motor DTC is also set. .

"IDGH" circuitry.
"LOW" circuitry.
7. Checks for proper resistance nf the ABS motor
windings.
Diagnostic Aids:
binds, or. slips.
enhanced diagnostics show this DTC occurs during
may be necessary.

G)
NO
I
YES
DTC 51
(1 of 2)
REAR ABS MOTOR
FREE SPINS

SELECT REAR AXLE ABS MOTOR APPLY FUNCTION AND APPLY THE
MOTOR WHILE CAREFULLY OBSERVING THE COMMAND CURRENT
AND FEEDBACK CURRENT ON THE TECH.1.
WERE. BOTH COMMAND AND FEEDBACK CURRENT APPROXIMATELY
10 AMPS?
5E2-121
YES'
mm, .l ,m,.m,umomomou..,.,..,..,,..,.,...,..,,..,,.,...,,
PROCEED TO OTC 64 CHART FIRST. (
,,,,,,,,,,,,,,,,,,,,,,,,,,,..,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,.,,,.,,,,,,,,,,,,,,,,.,,,,.,;,
,f

MOTOR.
I
YES
NO

GOTO
STEP 5.
NO
, I
YES
USING TECH 1, MISC. TESTS, PERFORM GEAR TENSION RELIEF FUNCTION. :

IGNITION "OFF."
DISCONNECT 6-WAY ABS MOTOR PACK CONNECTOR AND GRAY 8WAY
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "C" OF THE.
6WAY ABS MOTOR PACK HARNESS CONNECTOR AND TERMINAL "F" OF THE
GRAY 8-WAY EBCM/EBTCM HARNESS CONNECTOR.
IS RESISTANCE 1.50 OR LESS?
I
I
YES
. I
NO
I
I

IN CKT 1285.
NO
,,,.,,lll,,,,,,,,,,,,.,,,,,.;;;,11,;1,,,,n,,;,,.,,,;,,;,,;,n,;u,_,u,,.,,1u;;;;1;,,,1u7,
YES

IN CKT 1284.
NO
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL ''C" AND

TERMINAL "D" OF THE ABS MOTOR PACK CONNECTOR.
MALFUNCTION IS
fACING PAGE.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "D" OF THE

6-WAY ABS MOTOR PARK HARNESS CONNECTOR AND TERMINAL "E" OF THE
GRAY 8-WAY E.BCM/EBTCM HARNESS CONNECTOR.
YES
..
DIAGNOSIS CONTINUED ON NEXT PAGE.

,................................................................................. J
C8024
5E2-122

EBCM/EBTCM
,-------.,
(
P100
1284DKORN
REAR ABS MOTOR

CONTROL HIGH
12850RN
REAR ABS MOTOR

CONTROL LOW
REAR ABS
MOTOR
I
I
ABS MOTOR PACK

8 WAY CONNECTOR C1
L - -HYDRAULIC
---
C2
.I
MODULATOR ASSEMBLY
08-01-95
FT0235E
DTC 51
(Pag(i! 2 of 2)
gear assembly during initialization. During the horrung
sequence, the piston should reac~ the top of the bore
resulting in a stalled motor.. If _this d~es n~t occur, the
ABS motor must be spuinmg with little or no
resistance, indicating a nut/screw or gear malfunction.
OTC Will Set When:

Action Taken:
turned "ON."


terminal contact.
Diagnostic Aids:
binds, or slips.
The frequency of the ~alfunc.tion c~n be
also occurs, refer to DTC 64. If intermittent ~nd
enhanced diagnostics show this DTC occurs durmg
.
may be necessary.

y,,,,,.,,,,,.,,,,,,,,,,,,,,u;1;;;;1uu,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,.,,,,,,.,,,,,,,,,,,,,,,,uu;,;1
i DIAGNOSIS CONTINUED FROM....,,,,,.,,,,,,,,,,,,.,,,,.,,,,,,,,.,.

PREVIOUS PAGE. !
,.
OTC 51
,,,,,,,,,,.,,.,,,,,,,,,,,,,,,,,.,,,,.,,,,,,,,,,,,,,,,,.,,
'
REMOVE HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY FROM VEHICLE

(REFER TO "ON-VEHICLE SERVICE" IN THIS SECTION).
REMOVE GEAR COVER.
UNIT WITH THE THREE SMALL GEARS. THE REAR AXLE GEAR IS THE MIDDLE
GEAR OF THE THREE.
IS THE ABS MOTOR PACK, GEAR STRIPPED?
NO
I
YES

THE UNIT WITH THE THREE LARGE GEARS. THE REAR AXLE GEAR IS THE
MIDDLE GEAR OF THE THREE.
NO
NO
I

IGNITION "OFF."
GRASP THE MIDDLE GEAR ON THE HYDRAULIC MODULATOR (THE
HYDRAULIC MODULATOR IS THE UNIT WITH THE THREE LARGE GEARS) AND
REPLACE HYDRAULIC
MODULATOR GEAR.
YES
YES

SECURELY POSITION HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY IN
VEHICLE WITH GEAR COVER REMOVED SUCH THAT THE GEAR SET CAN BE
IGNITION TO "RUN".
USING TECH 1, TESTS, SELECT MANUAL CONTROL FUNCTION.
SELECT REAR AXLE ABS MOTOR APPLY AND APPLY THE MOTOR WHILE
OBSERVING THE MIDDLE GEAR SET.
MOTOR WHILE OBSERVING THE GEAR SET.
(Page 2 of 2)
REAR ABS
MOTOR FREE SPINS
a
NO
YES
INSPECT ALL CONNECTORS AND TERMINALS FOR POOR TERMINAL CONTACT

AND EVIDENCE OF CORROSION. REFER TO SECTION 8A4 "CHECKING
TERMINAL CONTACT." REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF POOR
REINSTALL.HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY IN VEHICLE.
.I
YES
I
REPLACE EBCM/EBTCM.

MODULATOR.
NO

FACING PAGE.
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN TURNING KEY OFF.
C8025
I"'
- - - -
--- .,
Hi0
EBCM/EBTCM
.1
1280 BLK
LF ABS MOTOR CONTROL HIOH
MOTOR
ABS MOTOR PACK .

6 WAY CONNECTOR C1
- - --- - -
1281 PNK
..B~
..I
HYDRAULIC
MODULATOR ASSEMBLY
04-20-95
FT0215E
DTC 52
LEFT FRONT ABS CHANNEL IN RELEASE TOO LONG
does not turn, the left front solenoid mechanically fails
DTC Will Set When:

the EBTCM commands the left front ABS channel in
Action Taken:
turned "ON."

long.
2. Identifies an ABS motor as being failed or wired
incorrectly.

failed open.
assembly.
6. Determines whether a malfunctioning motor pack
or hydraulic modulator is the reason for DTC 52
being set.
Diagnostic Aids:
The frequency of the malfunction .can be
the .Tech 1, as described in "Tech l Diagnostics" in
this section. DTC 52 may occur if on ice and steering
1, perform hydraulic test to ensure total brake system
is functional.
the wiring harness.
rn
DTC 52
IMPORTANT:
LEFT FRONT ABS

CHANNEL IN
RELEASE TOO LONG
EXCESSIVE DRAG OR HIGH RESISTANCE IN THE BASE BRAKE OR

SUSPENSION SYSTEM MUST BE INSPECTED AND CORRECTED BEFORE
PROCEEDING WITH OTC DIAGNOSIS.
NO
I
l PROCEED TO THAT OTC l
35
NO
l CHART FIRST.
l
',,,,,,,,,,,,,,,,,,,.,,,,,,,,,u,,,,.,,.,,,,,,,,,11,n1,,,,,,,.,,,,,/
I, ,...............................................
I
....
YES
.,,
i PROCEED TO WHEEL SPEED =0
YES
I
NO
I
I
I

USING TECH 1 MANUAL CONTROL FUNCTION, SELECT
LEFT FRONT SOLENOID AND COMMAND THE
1 SOLENOID "ON."
NO
FIRM PRESSURE STILL APPLIED

TO BRAKE PEDAL.
USING TECH 1, COMMAND LEFT
FRONT SOLENOID "OFF."
DID BRAKE PEDAL FALi.?
YES

IGNITION "OFF."
PHYSICALLY SWITCH THE LEFT FRONT
SOLENOID WITH THE RIGHT FRONT SOLENOID.
IGNITION TO "RUN".
~ USING TECH 1 MANUAL CONTROL FUNCTION,
SELECT LEFT FRONT SOLENOID AND COMMAND
THE SOLENOID "ON."
USING TECH 1 PERFORM GEAR TENSION RELIEF FUNCTION.

IGNITION "OFF."
MODULATOR.
(HYDRAULIC MODULATOR IS THE UNIT WITH THE THREE
LARGE GEARS) FURTHEST FORWARD WHEN THE UNIT IS
INSTALLED IN THE VEHICLE AND ATTEMPT TO ROTATE THE
GEAR IN EITHER DIRECTION.
51
YES
YES
I
REPLACE ABS
MOTOR PACK.
NO
II

MODULATOR.

REPLACE ABS HYDRAULIC MODULATOR.
BRAKE PEDAL ROSE.
REPAIR CROSSED WIRES

(CKTs 1280 A.ND 1281) TO
YES
PROCEED TO STEP
OF THIS CHART.
I
NO
..,
1
lt.,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,;
OTC FOR AFFECTED WHEEL.
l
IGNITION TO "RUN".
USING TECH 1 MANUAL CONTROL FUNCTION, SELECT LEFT FRONT ABS MOTOR
SELECT LEFT FRONT ABS MOTOR RELEASE AND COMMAND RELEASE OF MOTOR.
'
..
,,,,..,,,mmmmummmmmmmm,
USING TECH 1, SELECT "FO: DATA LIST" AND TEST VEHICLE DURING A
STEADY DECEL CONDITION FROM
MPH TO O MPH WHILE MONITORING ALL
WHEEL SPEEDS.
DO ANY OF THE WHEEL SPEEDS INDICATE ERRATIC OR INTERMITTENT
OPERATION?
YES
NO
STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN TURNING KEY OFF.
REPLACE THE SOLENOID WHICH

WAS ORIGINALLY IN THE LEFT
FRONT CHANNEL.
C8026
5E2-126
...
I
I
I
------
EBCM/EBTCM
...
"------11--------- 1282 PPL -----1111---1
rE
._F" - - - ' - - I I - - - - - - - ' - - - - 1283 BU( - - - - 1 1 1 1 - - - 1 B
8
0
:~~~=
ABS MOTOR PACK

6WAYCONNECTOR C1
C2
-
L-----..1
HYDRAULIC
MODULATOR ASSEMBLY
042095
FT0225E
OTC 53
RIGHT FRONT ABS CHANNEL IN RELEASE TOO LONG
This DTC will diagnose a motor that is
wheel speed sensor is malfunctioning, the motor does
not turn, the right front solenoid mechanically fails
DTC Will Set When:

the EBTCM commands the right front channel in
Action Taken:
turned "ON."

long.
2. Identifies a motor as being failed or wired
incorrectly.

failed open.
assembly.
6. Determines whether a malfunction motor pack or
hydraulic modulator is the reason for DTC 53
being set.
Diagnostic Aids:
this section. DTC 53 may occur on ice if steering
1 perform hydraulic test to ensure total brake system
is functional.
intermittent complaint should be thoroughly. checked
the wiring harness.
rn
DTC 53
IMPORTANT

CORRECTED BEFORE PROCEEDING WITH OTC DIAGNOSIS.
NO
I
RIGHT FRONT ABS

CHANNEL IN RELEASE
TOO LONG
NO
I
YES
NO
YES
! PROCEED TO WHEEL !
! SPEED = 0 OTC FOR I
!~,,AFFECTED
WHEEL.
. ,,,,,,,,,,,.,,,,,,,,,,,,,.,,.,,,,
......,,,,,,,,,,,,,,.,!
. I
NO
I
YES
PROCEED TO STEP
5 OF THIS CHART.
I0
YES
I
MALFUNCTION NOT
PRESENT AT THIS
TIME. REFER TO
"DIAGNOSTIC AIDS"
ON FACING PAGE.
BRAKEPEDAL ROSE.
a
REPAIR CROSSED
WIRES (CKTs 1282
AND 1283) TO RIGHT.
FRONT ABS MOTOR.
REMOVE FOOT FROM BRAKE

PEDAL.
IGNITION "OFF."
PHYSICALLY SWITCH THE.RIGHT
FRONT SOLENOID WITH THE LEFT
FRONT SOLENOID.
IGNITION TO "RUN."
USING TECH 1 MANUAL CONTROL
FUNCTION, SELECT RIGHT FRONT
SOLENOID AND COMMAND THE
SOLENOID "ON."
APPLY FIRM PRESSURE TO
BRAKE PEDAL.
YES
FIRM PRESSURE STILL

APPLIED TO BRAKE PEDAL.
USING TECH 1, COMMAND
RIGHT FRONT SOLENOID "OFF."
..
,... .11 .................,,,.,,,,,,.,,,,,,... ,
PROCEED TO THAT

USING TECH 1 MANUAL CONTROL FUNCTION, SELECT RIGHT
FRONT SOLENOID AND COMMAND THE SOLENOID "ON."
APPLY FIRM PRl:SSURE TO BRAKE PEDAL.
NO
"mmnmmmn,n,mm.,
!.. .....OTC
CHART FIRST. !
,.,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,.,,,,,,,..,,,,,,,!
IGNITION TO "RUN."
USING TECH 1 MANUAL CONTROL FUNCTION, SELECT RIGHT FRONT ABS MOTOR
SELECT RIGHT FRONT ABS MOTOR RELEASE AND COMMAND RELEASE OF MOTOR.
YES
i""'
USING TECH 1 PERFORM GEAR TENSION RELIEF

FUNCTION.
IGNITION "OFF."
MODULATOR .
(HYDRAULIC MODULATOR IS THE UNIT WITH THE
THREE LARGE GEARS) FURTHEST REARWARD WHEN
THE UNIT IS INSTALLED IN THE VEHICLE AND ATTEMPT
TO ROTATE THE GEAR IN EITHER DIRECTION.
YES
I
REPLACE ABS
MOTOR PACK.
NO
I
I
.
REPLACE ABS
HYDRAULIC
MODULATOR.

MODULATOR.
NO
REPLACE THE SOLENOID WHICH WAS

ORIGINALLY IN THE RIGHT FRONT CHANNEL.
AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY OTC DOES NOT
C8027
5E2-128

EBCM/EBTCM
,-------.,
REARABS
MOTOR
r c , - - - - - - - - - - - 1 2 8 4 DK OFIN----m
REAR ABS MOTOR

CONTROL HIGH
&. D.,---11---------1286
REAR ABS MOTOR

CONTROL LOW
ORN-----m
ABS MOTOR PACK
I 8 WAY CONN,ECTOR
C1
L-----
HYDRAULIC
MODULATOR ASSEMBLY
.J
06-01-911
FT0236E
DTC 54
REAR ABS CHANNEL IN RELEASE TOO LONG
does not turn, or the ABS motor wires are crossed.
DTC Will Set When:

DTC 54 can be set only during an ABS. stop. If
the EBTCM commands the .rear axle channel in
Action Taken:
turned "ON."
.

long.
2. Checks for a wheel that may stick or bind because
of a mechanical malfunction.
3. Checks to see if the ABS motor is capable of

moving and applying the hydraulic piston for the
rear wheels.
4. Ensures that the ABS motor wiring is not crossed.
5. Isolates the fault of a "no-apply" situation to
either the ABS motor pack or ABS hydraulic
modulator assembly.
Diagnostic Aids:
this section. Using the Tech 1, perform hydraulic test
to ensure total brake system is functional.
intermittent. complaint s:hould be thoroughly checked
the wiring harness.
rn
OTC 54
IMPORTANT

CORRECTED BEFORE PROCEEDING WITH DTC DIAGNOSIS.
NO
REAR ABS CHANNEL IN

RELEASE TOO LONG
YES
PROCEED TO THAT
'm,m.,mmmm.,mm,
!~,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,~
DTC CHART FIRST. !
NO
I
YES
RAISE REAR OF VEHICLE AND SUPPORT AS INDICATED IN SECTION OA.

SPIN BOTH REAR WHEELS AND CONFIRM PHYSICAL CONDITION OF
BASE BRAKE SYSTEM.
COULD BOTH REAR WHEELS BE SPUN FREELY BY HAND?
.. YES
..J
REPAIR SOURCE OF
RESISTANCE IN BASE
BRAKE SYSTEM.
!.
NO
. I
WITH FIRM PRESSURE ON BRAKE PEDAL STILL APPLIED,

COMMAND A RELEASE OF THE REAR AXLE ABS MOTOR.
CAN WHEELS BE MOVED?
YES
j
j
PROCEED TO WHEEL
SPEED 0 DTC FOR
AFFECTED. WHEEL...
YES
j
j
NO
IGNITION TO "RUN".
USING MANUAL CONTROL FUNCTION OF TECH 1, SELECT REAR AXLE ABS MOTOR APPLY.
COMMAND APPLY OF REAR ABS MOTOR AND TRY TO SPIN REAR WHEELS BY HAND.
COULD REAR WHEELS BE SPUN BY HAND?
.
.
,,,,,1',u,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
MALFUNCTION IS NOT
NO
I

SEPARATE ABS MOTOR PACK FROM HYDRAULIC MODULATOR.
CONNECT ABS MOTOR PACK WIRING.
IGNITION TO "RUN."
USING TECH 1, PERFORM MOTOR TEST.
DO ALL THREE ABS MOTOR PACK GEARS (SMALL GEARS) SPIN FREELY?
REPAIR CROSSED
WIRES AT REAR ABS
MOTOR (CKTs 1284
AND 1285).
I
NO
I
YES
REPLACE ABS
AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY DTC DOES NOT
C8028
5E2-130
04-20-911
FT0245E
DTC 55
EBTCM MALFUNCTION (ABS)
This DTC identifies an malfunction detected by
the EBTCM internal integrated circuitry.
Action Taken:
turned "ON." The red BRAKE warning lamp is
turned "ON" if the rear ABS motor is not in the
home position and if either of the TCS motors were

not in the home position at the time of the
malfunction. This will warn the driver of a possible
base brake degradation.

OTC 55
EBTCM MALFUNCTION (ABS)


TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES.
A DRIVE CYCLE CONSISTS OF STARTING THE
VEHICLE, DRIVING VEHICLE OVER 16km/h (10 MPH),
THEN KEV "OFF."
DOES OTC 55 RESET?
MALFUNCTION IS
INTERMITIENT.
REPLACE EBTCM.
MALFUNCTION IS
INTERMITIENT.
C9800
...
-- - - --
EBCM/EBTCM
.,
~t0
1280 BLK
1281 PNK
MOTOR
..a.,
ABS MOTOR PACK

I WAY CONNECTOR C1
L.
- -- - - -
.J
HYDRAULIC
MODULATOR ASSEMBLY
04-20-95
FT0215E
DTC 56
LEFT FRONT ABS MOTOR CIRCUIT OPEN
Diagnostic Aids:


and exercise ABS motor movement of affected.
If the malfunction is not current, wiggle tile
this section.
the wiring harness.
DTC Will Set When:

commanded "OFF." If the EBTCM detects an out of
exists.
Action Taken:
requested. A malfunction DTC is stored, ABS and
TCS are disabled. The amber ABS and TCS warning

circuitry.
circuitry.
contact.
5E2-133
DTC 56
CIRCUIT OPEN
IGNITION "OFF."
DISCONNECT 6WAY CONNECTOR AT ABS MOTOR PACK
CONNECTOR.

TERMINAL "G" OF THE GRAY 8WAY EBCM/EBTCM
HARNESS CONNECTOR AND TERMINAL "A" OF THE 6WAY

TERMINAL "H" OF THE GRAY 8WAY EBCM/EBTCM
HARNESS CONNECTOR AND TERMINAL "B" OF THE
6-WAY ABS MOTOR PACK HARNESS CONNECTOR.
REPAIR OPEN OR HIGH

INSPECT THE 6-WAY ABS MOTOR PACK AND GRAY 8WAY

IGNITION "OFF".
16 km/h (10 MPH),
REPAIR OPEN OR HIGH

REPLACE
EBCM/EBTCM.

DRIVING OVER 16 km/h (10 MPHh), AND THEN IGNITION "OFF."
C8030
5E2-134
...
- - - - - - .,
EBCM/EBTCM
P100
~tG>
1280 BLK
1281 PNK
MOTOR
._B.a
C2
ABS MOTOR PACK

6 WAY CONNECTOR C1
- - - - -
.J
HYDRAULIC
MODULATOR ASSEMBLY
04-20-95
FT0215E
DTC 57
LEFT FRONT ABS MOTOR CIRCUIT SHORTED TO GND
Diagnostic Aids:

shorted to ground. This malful}.ction will not allow the
ABS motor to be controlled. at the commanded current

and exercise ABS . motor movement of affected
pressure on the brake pedal. .
this section.
the wiring harness.
DTC Will Set When:

DTC 57 can be set anytime. If the EBTCM
Action Taken:
turned "ON."

"HIGH" circuitry.
"LOW" circuitry.
shorted to ground.
DTC 57
CIRCUIT SHORTED TO GND
YES
IGNITION "OFF."
DISCONNECT 6-WAY CONNECTOR ABS MOTOR PACK CONNECTOR
AND THE GRAY 8-WAY EBCMIEBTCM CONNECTOR.
TERMINAL "A" OF THE 6-WAY ABS MOTOR PACK HARNESS
CONNECTOR.

BETWEEN GROUND AND TERMINAL "B" OF THE
DOES J 39200 DISPLAY RESISTANCE AS "OL"
(INFINITE)?

IN CKT 1280.

GROUND AND TERMINAL "A" OF THE ABS MOTOR PACK.
INSPECT CKTs 1280 AND 128.1 AND RELATED CONNECTORS

EVIDENT.
LEAST 16 kmlh (10 MPH).
REPAIR SHORT TO
GROUND IN CKT 1281.
REPLACE ABS MOTOR

PACK.
.
YES
REPLACE
EBCMIEBTCM.

DRIVING OVER 16 kmlh (10 MPH), AND THEN IGNITION "OFF."
C8031
5E213f>
IEBCM/EBTCM
r-------.,
I
~ti,
"j;,
I
I
10-----------1280BLK
. _ a J - - - - - - - - - - 1 2 1 1 PNK
-----111
ABS MOTOR PACK

I WAY CONNECTOR C1
L.........
HYDRAULIC
..II
MODULATOR ASSEMBLY
04-20-95
FT0215E
DTC 58
LEFT FRONT ABS MOTOR CIRCUIT SHORTED TO BATT
DTC Will Set When:

Action Taken:
turned "ON."

"HIGH" circuitry.
"LOW" circuitry.

shorted.
Diagnostic Aids:
this section.
the wiring harness.
ANTILOCK BRAKE SYSTEM WITH TRACTION CONTROL 5E2~137
DTC 58

NO

I
YES
IGNITION "OFF."
DISCONNECT THE 6WAY ABS MOTOR PACK CONNECTOR
IGNITION TO "RUN."
GROUND AND TERMINAL "A" OF THE 6-WAY ABS MOTOR
I
I
YES
NO
I

TERMINAL "B" OF THE 6-WAY ABS MOTOR PACK HARNESS
CONNECTOR.
..
YES
NO
IGNITION "OFF."
TERMINAL "A" AND TERMINAL "B" OF THE 6-WAY ABS
MOTOR PACK HARNESS CONNECTOR.
REPAl,R SHORT TO VOLTAGE IN CKT 1281.
I
I
YES
I
NO
I

TERMINAL "A" AND TERMINAL "B" OF THE ABS MOTOR PACK.
IS RESISTANCE BETWEEN o.2n AND 1.5n?
I
I
YES
I
NO
I
INSPECT CKTs 1280 AND 1281 AND RELATED CONNECTORS FOR

DAMAGE WHICH MAY RESULT IN A SHORT TO VOLTAGE WITH
ALL CONNECTORS CONNECTED. REPAIR ALL DAMAGE IF
EVIDENT.
16 km/h (10 MPH).
I
I
YES
REPLACE
EBCM/EBTCM.
NO

C8032
5E2-138
EBCM/EBTCM
,--------,
"E" - - - - - - - - - - - - 1282 PPL - - - - - 4 l ' l l - - f A
I
I
L
:,::/0
~
._F~ - - - - - - - - - - 1283 BU< - - - - l l t - - - 1 1 B
ABS MOTOR PACK

6WAYCONNECTOR C1
........
C2
.J
HYDRAULIC
MODULATOR ASSEMBLY
042095
FT02211E
DTC 61
RIGHT FRONT ABS MOTOR CIRCUIT OPEN
Diagnostic Aids:


channel in both dire.ctions while applying light
this section.
for backed out. terminals, improper mating, broken
the wiring harness.
DTC Will Set When:

exists.
Action Taken:

circuitry.
circuitry.
contact.
5E2139
DTC 61
RIGHT FRONT ABS
MOTOR CIRCUIT OPEN
\
IGNITION "OFF."
DISCONNECT 6-WAY CONNECTOR AT ABS MOTOR PACK CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE ACROSS ABS MOTOR
PACK TERMINALS "E" AND "F".

USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "A" OF
THE GRAY 6-WAY EBCM/EBTCM HARNESS CONNECTOR AND
TERMINAL "E" OF THE 6-WAY ABS MOTOR PACK HARNESS
CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE Bf:TWEEN

TERMINAL "B" OF THE GRAY 6-WAY EBCM/EBTCM
HARNESS CONNECTOR AND TERMINAL "F" OF THE
6-WAY ABS MOTOR PACK HARNESS CONNECTOR.
REPAIR OPEN OR HIGH

INSPECT THE 6-WAY ABS MOTOR PACK AND GRAY 6-WAY

EBCM/EBTCM CONNECTORS FOR POOR TERMINAL CONTACT
AND EVIDENCE OF CORROSION. REFER TO SECTION 8A4,
"CHECKING TERMINAL CONTACT." REPLACE ALL TERMINALS
THAT EXHIBIT SIGNS OF POOR TERMINAL CONTACT OR
CORROSION.
REPLACE
EBCM/EBTCM.
REPAIR OPEN OR HIGH

MALFUNCTIONWAS MOST LIKELY

C8033
5E2-140. ANTILOCK BRAKE SYSTEM WITH TRACTION CONTROL
EBCM/EBTCM
...
'!-
:~~~
I
I
L
0----11--------
08
~
FJ -
1282 PPL -----1111----1 A
--t,-------- 1283 BU<
ABS MOTOR PACK

6WAYCONNECTOR C1
.,
B.
C2
HYDRAULIC
MODULATOR ASSEMBLY
04-20-95
FT0225E
DTC 62
RIGHT FRONT ABS MOTOR CIRCUIT SHORTED TO G.ND
Diagnostic Aids:

shorted to ground. This malfurictfon will' not allow the

channel iri both directions while applying light
If erratic or "jumpy" .brake pedal movement is
wire. that is broken inside the insulation.
wires of the affected channel and check if the DTC.
resets. This will help to pinpoint .an intermittent
malfunction in the motor circuitry .or. connections.
checked by using the eriharice4 diagnostic. function of
this section.
Any circuitry, that is suspected as causing the
intermittent complaint, should be thoroughly checked.
the wiring harness.
OTC Will Set When:

Action Taken:
turned "ON."

"HIGH" circuitry.
"LOW''. circuitry.
shorted to ground.
OTC 62
RIGHT FRONT ABS

MOTOR CIRCUIT
SHORTED TO GND
I
I
NO
I
YES
IGNITION "OFF."
DISCONNECT 6-WAY ABS MOTOR PACK CONNECTOR AND
GROUND AND TERMINAL "E" OF THE 6-WAY ABS MOTOR
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE}?
I
I
YES
I
NO

AND TERMINAL "F" OF THE 6-WAY ABS MOTOR PACK HARNESS
CONNECTOR.
.
I
YES
NO
I

AND TERMINAL "E" OF THE ABS MOTOR PACK.
,,,
I
I
YES
I
NO

EVIDENT.
DID OTC 62 SET 11',! THE LAST THREE DRIVE CYCLES?
I
I
YES
I
REPLACE
EBCM/EBTCM.
NO

C8034
5E2142
EBCM/EBTCM
.-------.,
~= i0=---11---------12e2
,
I
I
L
._FJ - - 1 1 - - - - - - - -
1283
PPL -----1111---1 A
BU<-----111
ABS MOTOR PACK

6WAYCONNECTOR ~
....
-.
HYDRAULIC
MODULATOR ASSEMBLY
04,20-95
FT0225E
DTC 63
RIGHT FRONT ABS MOTOR CIRCUIT SHORTED TO BATT
DTC Will Set When:

Action Taken:
turned "ON."

"HIGH" circuitry.
"LOW" circuitry.
3. Checks for short circuit between ABS motor

shorted.
Diagnostic Aids:
wire that is broken inside the insulation:
this section.
the wiring harness.
DTC 63
PRIOR TO MAKING ANY RESISTANCE
MEASUREMENTS. REFER TO J 39200 USER'S MANUAL.
NO
I
YES
YES

IN CKT 1282.
NO
I
I
I
IGNITION "OFF."
TERMINAL "E" AND TERMINAL "F" OF THE 6WAY ABS MOTOR
YES
NO

CONNECTOR.
.
YES
IGNITION "OFF."
DISCONNECT THE 6WAY ABS MOTOR PACK CONNECTOR AND THE
GRAY 8WAY EBCM/EBTCM CONNECTOR.
IGNITION TO "RUN".
TERMINAL "E" OF THE 6WAY ABS MOTOR PACK HARNESS
CONNECTOR.
RIGHT FRONT ABS

MOTOR SHORTED TO BATI.

IN CKT 1283-.
NO
I

TERMINAL "E" AND TERMINAL "F" OF THE ABS MOTOR PACK.
IS RESISTANCE BETWEEN 0.2 AND 1.5 n?

CKTs 1282 AND 1283.
YES
NO

EVIDENT.
YES
REPLACE EBCM/EBTCM.
NO

FACING PAGE.
OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 mph), AND
C8035
5E2-144

EBCM/EBTCM
r-------,
rc"----11--------1284 DK ORN----111---1 F
REAR ABS MOTOR

CONTROL HIGH
REAR ABS MOTOR

CONTROL LOW
REARABS
MOTOR
~DJ'---a---------12860RN~---~ll~--i
ABS MOTOR PACK
I 6 WAY CONNECTOR
L
---
C2
C1
--- --- --- --HYDRAULIC

MODULATOR ASSEMBLY
06-01-96
FT0235E
DTC 64
Diagnostic Aids:
This DTC identifies an ABS' motor that cannot


this section.
the wiring harness.
DTC Will Set When:

range voltage on either of the rear axle ABS motor
exists.
Action Taken:

1. This checks for proper resistance of the ABS
motor.
circuitry.
circuitry.
contact.
NOTICE: J
39200 TEST LEADS MUST BE "ZEROED" PRIOR

5E2-145
DTC 64
IGNITION "OFF."
DISCONNECT 6-WAY ABS MOTOR PACK CONNECTOR.

USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "F" OF THE
GRAY BWAY EBCM/EBTCM HARNESS CONNECTOR.AND TERMINAL "C" OF
THE 6-WAY ABS MOTOR PACK HARNESS CONNECTOR.
USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "E" OF THE GRAY

8-WAY EBCM/EBTCM HARNESS CONNECTOR AND 'TERMINAL "D'' OF THE 6-WAY
INSPECT THE 6-WAY ABS MOTOR PACK AND GRAY 8-WAY

EVIDENCE OF CORROSION. REFER TO SECTION BA-4, "CHECKING
16 km/h (10 mph).

FACING PAGE.
THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND
C8036
5E2-146

EBCM/EBTCM
I"'
---
- --- --- --- .,
(
P100
"c"
1284 DKOFIN
FIEAR ABS MOTOR

CONTROL HIGH
"D.,
12860RN
REAR ABS MOTOR

CONTROL LOW
REAR ABS
MOTOR
ABS MOTOR PACK
I 8 WAY CONNECTOR
L.
---
C2
Ct
--- ---
.J
HYDRAULIC
MODULATOR ASSEMBLY
06-01-95
FT023SE
DTC 65
REAR ABS MOTOR CIRCUIT SHORTED TO GROUND
Diagnostic Aids:


this section.
the wiring harness.
DTC Will Set When:

detects an out of range voltage on either of the rear
axle ABS motor circuits indicating a circuit shorted to
Action Taken:
turned "ON."

"HIGH" circuitry.
.
"LOW" circuitry.
shorted to ground.
OTC 65
SHORTED TO GROUND
IGNITION "OFF."
DISCONNECT 6-WAY ABS MOTOR PACK CONNECTOR AND
USING A J 39200, MEASURE THE ~ESISTANCE BETWEEN
GROUND AND TERMINAL "C" OF THE 6-WAY ABS MOTOR
USING j 39200, MEASURE THE RESISTANCE BETWEEN G.ROUND AND

TERMINAL "D" OF THE 6-WAY ABS MOTOR PACK HARNESS
CONNECTOR.

TERMINAL "C" OF THE ABS MOTOR PACK.
DOES J 39200 DISPLAY RESISTANCE AS '.'OL" (INFINITE)?

IF EVIDENT.
.
MALFUNCTION WAS MOST LIKELY CAUSED

BY A POOR CONNECTION. REFER TO
THAT DTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 mph),
C8037
5E2-148

EBCM/EBTCM
...
--
- - - -
-,
P100
re"'
REAR ABS
MOTOR
,A,
1284 DKGRN
REAR ABS MOTOR

CONTROL HIGH
12850RN
REAR ABS MOTOR

CONTROL LOW
ABS MOTOR PACK
I a WAY CONNECTOR
L
C2
c1
- - - - -
..I
HYDRAULIC
MODULATOR ASSEMBLY
06-01-95
FT0235E
DTC 66
REAR ABS MOTOR CIRCUIT SHORTED TO BATTERY
direction, or not turn at all.
DTC Will Set When:

range voltage on either of the rear ABS axle motor
Action Taken:
turned "0N."

"HIGH" circuitry.
"LOW" circuitry.
3. Checks for a short circuit between motor "HIGH"
and motor "LOW".

shorted.
Diagnostic Aids:
this section.
the wiring harness.
DTC 66
TO MAKING ANY RESISTANCE MEASUREMENTS. REFER.TO

SHORTED TO BATTERY
IGNITION "OFF."
DISCONNECT THE 6-WAV ABS MOTOR PACK CONNECTOR AND
THE GRAV 8WAV EBCM/EBTCM CONNECTOR.
IGNITION TO "RUN",
USING A J 39200, MEASURE THE VOLTAGE BETWEEN GROUND
AND TERMINAL "C" OF THE 6-WAV ABS MOTOR PACK HARNESS
CONNECTOR
. IS VOLTAGE 1 VOLT OR LESS?

TERMINAL "D" OF THE 6-WAV ABS MOTOR PACK HARNESS
CONNECTOR.
IGNITION "OFF."
USING J 39200, MEASURE THE RESISTANCE B.ETWEEN TERMINAL
"C" AND TERMINAL "D" OF THE 6-WAV ABS MOTOR PACK
HARNESS CONNECTOR .

TERMINAL "C" AND TERMINAL "D" OF THE ABS MOTOR PACK.
IS RESISTANCE BETWEEN o.2n AND 1.SQ?

- IF EVIDENT.
,.
,

FACING PAGE.
AND THEN TURNING KEV OFF.
C8038
5E2-150
DIAGNOSTIC ENERGY
RESERVE MODULE (DERM)
C2
.J,~,. ....,. . --r

PIOO
POWERTRAIN CONTROL
MODULE (PCM)
VI
SERIAL DATA LINE
V8
.I
EBTCM
DATA LINK CONNECTOR

(DLC)
C1
, - 9 - , : - - - - - - - 800TAN---...l~---' -;2,1-----SOOTAN
I. .I
5225
LA- J
SERIALDATAUNE
C200A
C200D
04-20-95
FT0255E
DTC 75
PCM TO EBTCM SERIAL DATA MALFUNCTION
The serial data communications circuit is used to
transmit messages from one electronic control unit to
another when interface is necessary between systems.
The ABS VI/TCS systems depends on information
from the PCM for proper operation.
OTC Will Set When:
DTC 75 will set when the vehicle speed is
greater than 3 mph and there is a malfunction on the
serial data circuit, or if the PCM has not broadcasted a
serial message for at least 10 seconds.
Action Taken:
A malfunction DTC is stored, TCS is disabled.
The amber TCS warning lamp is turned "ON."
1. This step tests the test equipment.
2. Checks other systems on the circuit.
3. Checks for short to ground on serial data line.
4. Checks for short to voltage on serial data line.

5. Checks for poor terminal contact or corrosion
which can cause malfunction.
6. Attempts to establish communication with
modules.
Diagnostic Aids:
When DTC 75 is current (malfunction in
CKT 800), no communication can be established with
the Tech 1 scan tool. When the malfunction is
removed, DTC 75 will be stored in system memory.
this section.
the wiring harness.
DTC 75
PCM TO EBTCM SERIAL
DATA MALFUNCTION
ATTEMPT TO ESTABLISH COMMUNICATION WITH THE SAME

SYSTEM ON A DIFFERENT VEHICLE.
CAN COMMUNICATION BE ESTABLISHED?
IGNITION SWITCH "OFF."

CHECK FOR PROPER CONNECTION OF SCAN TOOL TO DATA
LINK CONNECTOR.
IS CONNECTION GOOD?
................................................................................................................... .
! SCAN TOOL MAY BE

! MALFUNCTIONING,
!
!
! REFER TO SCAN TOOL !

INSTRUCTION MANUAL. !
,! ...........................................................................................................
\
IGNITION SWITCH TO "RUN."

ATTEMPT TO ESTABLISH COMMUNICATION WITH THE OTHER TWO
MODULES (PCM AND DERM) CONNECTED TO SERIAL DATA LINE.
CAN COMMUNICATION BE ESTABLISHED WITH THE PCM AND
DERM?
REPAIR DATA LINK CONNECTOR

TERMINAL "9" OR RECONNECT SCAN
TOOL, AS NECESSARY.

DISCONNECT ALL MODULES CONNECTED TO CKT 800 AND
DATA. LINK CONNECTOR TERMINAL "9".
USING J 39200, MEASURE THE RESISTANCE ON DATA LINK
CONNECTOR FROM TERMINAL "9" TO TERMINAL "5"
(GROUND).
.
DOES J 39200 DISPLAY "OL" (INFINITE)?

DISCONNECT 24-WAY EBTCM HARNESS
CONNECTOR AND CHECK FOR POOR
TERMINAL CONTACT AND EVIDENCE OF
CORROSION. REFER TO SECTION 8A4
"CHECKING TERMINAL CONTACT". REPLACE
ALL TERMINALS THAT EXHIBIT SIGNS OF
POOR TERMINAL C.ONTACT OR.CORROSION.
IF OK, THEN MEASURE RESISTANCE FROM
DATA LINK CONNECTOR TERMINAL "9" TO
24-WAY EBTCM HARNESS CONNECTOR
TERMINAL "A1",

ON DATA LINK CONNECTOR FROM
TERMINAL "9" TO TERMINAL "5"
(GROUND).
IS VOLTAGE MEASURED?
REPAIR SHORT
TO GROUND IN
CKT 800.
CHECK FOR POWER

AND GROUND TO THE
EBTCM.
IF OK, THEN
REPLACE EBTCM.
IGNITION SWITCH "OFF".

RECONNECT ONE OF THE MODULES WHICH IS
DISCONNECTED.
IGNITION SWITCH TO "RUN." ATTEMPT TO ESTABLISH
COMMUNICATION; WHEN COMMUNI.CATION CANNOT BE
ESTABLISHED REPLACE THE MOST RECENTLY CONNECTED
MODULE.
REPEAT THIS PROCESS UNTIL THE MALFUNCTIONING
MODULE IS ISOLATED.
REPAIR OPEN IN
CKT 800 FROM
S225 TO EBTCM.

CKT 800.
C8039
5E2-152
EBCM/EBTCM
TOABSRELAV
REFER TO
SECTION 8A44
I
I
I
RF ABS
lJ r:, _!~LENOI~ r:,

1289
---onN -n--~ OlJo o. . ! J - - - - - - L T a L u
855
RF ABS SOLENOID
CONTROL
P100
04-20-95
FT028SE
OTC 76
LEFT FRONT SOL CIRCUIT OPEN OR SHORTED TO GND

circuitry between the driver and the. solenoid. An open

solenoid.
circuit.
contact.
OTC Will Set When:

commanded "OFF" while the ABS/TCS relay is
enabled. If the EBTCM detects the left front solenoid
control circuit voltage is out of specification, a
malfunction exists.
Action Taken:
turned "ON."
Diagnostic Aids:
this section.
the wiring harness.
5E2-153
DTC 76
LEFT FRONT SOL CIRCUIT
IGNITION "OFF."
DISCONNECT 24WAY EBCM/EBTCM CONNECTOR AND LEFT
FRONT SOLENOID CONNECTOR.
IGNITION TO "RUN", ENGINE "OFF."
AND TERMINAL "A10" OF THE 24-WAY EBCM/EBTCM HARNESS
CONNECTOR.
DOES 'J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?
I
YES
. I
NO
IGNITION "OFF."
TERMINAL "A10" OF THE 24-WAY EBCM/EBTCM HARNESS
CONNECTOR AND TERMINAL "B" OF THE LEFT FRONT
SOLENOID HARNESS CONNECTOR.
YES
REPAIR SHORT TO
GROUND IN CKT 1288.
NO
...
MEASURE THE RESISTANCE BETWEEN TERMINAL "A" AND

TERMIINAL "B" OF THE LEFT FRONT SOLENOID.
NO
MEASURE THE RESISTANCE BETWEEN ABS RELAY TERMINAL "C4"

AND TERMINAL "A" OF THE LEFT FRONT SOLENOID HARNESS
CONNECTOR.
REPAIR OPEN OR HIGH

YES
. I
REPLACE LEFT
FRONT SOLENOID.
YES
. I
NO
INSPECT LEFT FRONT SOLENOID AND 24WAY EBCM/EBTCM

TERMINAL CONTACT". REPLACE ALL TERMINALS THAT EXHIBIT
DAMAGE IF EVIDENT.
IGNITION TO "RUN."
REPAIR OPEN OR HIGH RESISTANCE

IN CKT 855/1633.CHECK FOR OPEN
ABS VALVE FUSE IN UNDERHOOD
ELECTRICAL CENTER.
I
YES
I
REPLACE EBCM/EBTCM.
NO
I

C9793
5E2-154
EBCM/EBTCM
TO ABS RELAY
REFER TO
SECTION 8A44
..ABS VALVE.,
FUSEI
855
ORN
[J
r.i
I
I
I
855
ORN
lJ
n
LFABS
~~L:.NOID
AQl)OO-
[!]
a .
RF ABS
~SO~NOI~.
A
O QQQ
B
1288
DK GAN
1281
LTBLU
LF ABS SOLENOID
CONTROL
I
I
I
'1
I
RF ABS SOLENOID
CONTROL'
P100
04-20-95
FT0215E
DTCn
LEFT FRONT SOLENOID CIRCUIT SHORTED TO BATT
channel impossible.

resistance values.
.
contact.
OTC Will Set When:

commanded "ON." If the EBTCM detects the left
Diagnostic Aids:
this section.
for backed out terminals, improper mating, .. broken
the wiring harness.
Action Taken:
disabled. The amber ABS and TCS warning lamp is
turned "ON."

voltage.
OTC 77
LEFT FRONT SOLENOID CIRCUIT
SHORTED TO BATT
IGNITION "OFF."
DISCONNECT LEFT FRONT SOLENOID CONNECTOR.
AND TERMINAL "B" OF THE LEFT FRONT SOLENOID
CONNECTOR.
I
YES
I
NO
I

TERMINAL "A" AND TERMINAL "B" OF THE LEFT
FRONT SOLENOID.
YES
'
NO
I

USING J 39200 MEASURE THE VOLTAGE BETWEEN GROUND AND
TERMINAL "A10" OF THE 24WAY EBCM/EBTCM HARNESS CONNECTOR.
I
YES
NO
I
INSPECT CKT 1288, THE LEFT FRONT SOLENOID AND 24WAY

EBCM/EBTCM HARNESS CONNECTORS FOR DAMAGE WHICH
MAY RESULT IN A SHORT TO VOLTAGE WITH ALL CONNECTORS
. CONNECTED. REPAIR DAMAGE IF EVIDENT.

CKT 1288.
I
YES
I
REPLACE EBCM/EBTCM.
NO
I
FACING PAGE.
C9794
5E2-156
EBCM/EBTCM
TO ABS REI.AV
REFER TO
SECTION 8A44
_ _ _ _ _ _ 1289
LTBLU
RF ABS SOLENOID
CONTROL
04-20-95
FT0286E
DTC 78
RIGHT FRONT SOL CIRCUIT OPEN OR SHORTED TO GND
will not allow proper ABS operation, but .the shortJo
DTC Will Set When:
commanded "OFF" while the ABS/TCS relay is
enabled. If the EBTCM detects the left front solenoid
control circuit voltage is out of specification, a
malfunction exists.
Action Taken:
A malfunction .DTC is stored,. ABS and TCS are
disabled. The. amber ABS and TCS warning lamps are
turned "ON."

solenoid.
circuit.
contact.
Diagnostic Aids:
wire that is broken inside the insulation;
this section.
the wiring harness.

DTC 78
RIGHT FRONT SOL CIRCUIT
IGNITION "OFF/'
DISCONNECT 24-WAY EBCM/EBTCM CONNECTOR AND
RIGHT FRONT SOLENOID CONNECTOR.
IGNITION "OFF."
OF THE 24-WAY EBCM/EBTCM HARNESS CONNECTOR AND TERMINAL
"A" OF THE RIGHT FRONT SOLENOID HARNESS CONNECTOR.
MEASURE THE RESISTANCE BETWEEN TERMINAL "A"

AND TERMINAL "B" OF THE RIGHT FRONT SOLENOID:
MEASURE THE RESISTANCE BETWEEN ABS RELAY

TERMINAL "C4" AND TERMINAL "A" OF THE RIGHT
FRONT SOLENOID HARNESS CONNECTOR.
INSPECT RIGHT FRONT SOLENOID AND 24-WAY EBCM/EBTCM

. TERMINAL CONTACT." REPLACE ALL TERMINALS THAT EXHIBIT
DAMAGE IF EVIDENT.
IGNITION TO "RUN."
REPAIR OPEN OR HIGH

RESISTANCE IN CKT 855/1633.
CHECK FOR OPEN ABS VALVE
FUSE IN UNDERHOOD
ELECTRICAL CENTER.
MALFUNCTION IS MOST LIKELY

DUE TO A POOR CONNECTION.
ON FACING PAGE.
C9795
5E2-158
EBCM/EBTCM
TOABSRELAV
REFER TO
SECTION 8A44
(
855
ORN
u
r,l
I
I
I
855
ORN
lJ
LFABS
[!]
~~'=NOID
8
AO
000,..
1288
DKGRN
RF ABS
~~LENOI~
AOlJOO
B
1289
LTBLU
LF ABS SOLENOID
CO~TROL
RF ABS SOLENOID
CONTROL
P100
04-20-95
FT0215E
DTC 81
RIGHT FRONT SOLENOID CIRCUIT SHORTED TO BATT
channel impossible.

resistance values.
the . solenoid circuitry due to poor terminal
contact.
DTC Will Set When:
Diagnostic Aids:

commanded "ON." If the EBTCM detects the right

this section.
the wiring harness.
Action Taken:
turned "ON."

voltage.
DTC 81
RIGHT FRONT SOLENOID
IGNITION "OFF."
DISCONNECT RIGHT FRONT SOLENOID CONNECTOR.
AND TERMINAL "A" OF THE RIGHT FRONT SOLENOID.

BETWEEN TERMINAL "A" AND TERMINAL "B"
OF THE RIGHT FRONT SOLENOID.

GROUND AND TERMINAL "BS" OF THE 24-WAY
INSPECT CKT 1289, THE RIGHT FRONT SOLENOID AND 24WAY

EBCM/EBTCM HARNESS CONNECTORS FOR DAMAGE WHICH MAY
RESULT IN A SHORT TO VOLTAGE WITH ALL CONNECTORS
ON FACING PAGE.
C9796
5E2~160 ANTILOCK BRAKE SYSTEM WITH TRACTION CONTROL
04-20-95
FT0245E
DTC 82
This DTC allows the EBTCM to check for a

calibration malfunction by comparing the calibration
value to a known value stored in the EEPROM.
This DTC is also used as a security measure to
prevent improper use of calibrations or changes to
these calibrations that may alter the designed function
of ABS and TCS.

1. Checks to see if the malfunction is present during
diagnosis. If present, the EBTCM is not
functioning correctly and must be replaced.
DTC Will Set When:

DTC 82 can be set at key-up. If the program
identifier is incorrect or the memory checksum is
incorrect, a malfunction exists.
Action Taken:
turned "ON."
Diagnostic Aids:
An intermittent DTC 82 may be caused by a bad
cell in the EEPROM that is sensitive to temperature
changes. If DTC 82 failed more than once, but is
intermittent, replace EBTCM.
this section.
DTC 82
IGNITl:ON TO "RUN".
MALFUNCTION IS NOT
THIS CHART ASSUMES THAT A CURRENT OTC IS STORED INDICATING THAT THIS MALFUNCTION IS PRESENT.
C8044
5E2-162
...
REFER TO
SECTION 8A11
GAGES
FUSEII
ION
INSTRUMENT
CLUSTER
- ---
RED
C200A
C200D
(IC)-,
.. -
@)
"ABSINOP
AMBER
--- ---
'"I
BRAKE WARNING
LAMP CONTROL
D18CHEV
A18PONT
1 6 3 7 ~ 1537
I All I
DK BLU
DK BLU
AEIS/TCS ACTIVE
LAMP CONTROL
DGCHEV
B17PONT
887
I
I
887
LTGR~LTGRN
ABS WARNING
LAMP CONTROL
...
I 8273
-- ...
C1 CHEV
A8PONT
(CHEV)"ASR"
(PONT)"TCS OFF"
33 TAN/
WHT
C10 CHEV 33 TAN/

Ai
A10 PONT WHY 8228 I
D13CHEV
All PONT
EBTCM
REFER TO
SECTION
8A41
TCSWARNING
LAMP CONTROL
C1
..I
(PONT ONLY) TO
04201111
FT0155E
DTC 86
EBTCM TURNED ON THE RED BRAKE WARNING LAMP
Diagnostic Aids:
This DTC is provided as an information only

DTC, and reflects the status of the command issued by
the ABS EBTCM to illuminate the red BRAKE
warning lamp. If another DTC issues a command to
illuminate the red BRAKE warning lamp, DTC 86
will be stored in EEPROM as a history DTC at the
conclusion of the ignition cycle.
Any ABS mechanical DTC that issues a

command to illuminate the red BRAKE warning lamp
will also result in DTC 86 being stored in EEPROM
during shut down. These DTCs are: 38, 41, 42, 46,
and 51. If the motor car not in their home position,
certain electrical DTCs will also command the red
BRAKE warning lamp "ON." These DTCs are: 14,
16, 18, 55, 56, 57, 58, 61, 62, 63, 64, 65, 66, 144, and
145.
.
If any of these DTCs are indicated along with
DTC 86, they must be corrected prior to addressing a
DTC 86 malfunction.

1. Serves to identify if a DTC other than DTC 86
commanded the red BRAKE warning lamp
"ON."
DTC 86
EBTCM TURNED ON THE RED
BRAKE WARNING LAMP
ARE ANY DTCs CURRENTLY

SET WITH OTC 86?
CLEAR OTC, PERFORM

DIAGNOSTIC SYSTEM
CHECK;
PROCEED TO "DIAGNOSTIC
AIDS" ON FACING PAGE OF
THIS CHART.
C8045
5E2~164 ANTILOCK BRAKE SYSTEM WITH TRACTION CONTROL
.----~
REFER TO
SECTION 8A11
GAGES
FUSE9
IGN
. - - . - - - REFERTO
SECTION
C200A
8A41
~2.,!!!)~
INSTRUMENT
CLUSTER
RED
((l)l(l
.----4"-ii---1C10 CHEV 33 TAN/

AS
33 TAN/
"BRAKE"
A10 PONT WHT 8228 I
I 8273 WHT
BLUE
D18 CHEV
1537
lr==il
1537
"LOW TRAC"
A18 PONT DK B L U ~ DK BLU
AMBER
l---'i'-t1-----1 D8 CHEV
887
887
"ABS INOP
817 PONT LT G R ~ LT GRN
AMBER
1, ..
D13CHEV
AS PONT
' - - - - 4 " - t - - - l C1 CHEV

(CHEV)"ASR"
A8 PONT
(PONT)"TCS OFF"
L
..I
(PONT ONLY) TO
EBTCM
(
BRAKE WARNING
I.AMP CONTROL
ABS/TCS ACTIVE
LAMP CONTROL
ABS WARNING
LAMP CONTROL
TCSWARNING
LAMP CONTROL
0420911
FT0155E
OTC 87
(Page 1 of 2)
RED BRAKE WARNING LAMP CIRCUIT OPEN OR SHORTED
TO BATT
between the EBTCM and the red BRAKE warning
BRAKE warning lamp to be illuminated by the
EBTCM. This will only occur if an ABS/TCS
malfunction is detected that may degrade base brake
operation. Because ABS/TCS is not the only device
controlling the red BRAKE warning lamp (parking
brake and brake fluid level switch may also tum
"ON" the red BRAKE warning lamp) a short to
ground in this circuit cannot be detected.
DTC Will Set When:

BRAKE warning lamp circuit voltage is out of
Action Taken:
A malfunction DTC is stored, ABS/TCS is not
disabled, however, if the EBTCM commands the red
BRAKE warning lamp on due to a ABS/TCS


1. Checks whether the "BRAKE" warning lamp
circuitry is open or shorted to battery.
2. Checks the complete "BRAKE" warning lamp

circuitry by attempting to manually tum "ON"
the "BRAKE" warning lamp.
3. Checks for high resistance in park brake circuitry.
contact at the brake fluid level switch which may
result in an intermittent.
6. Checks the integrity of the "BRAKE" warning
lamp.
7. Checks for high resistance in the "BRAKE"
warning lamp control circuitry.
Diagnostic Aids:
this section. If a Tech 1 is not available, the parking
brake handle may be lifted to verify proper lamp
operation and continuity of CKTs 3 and 39.
the wiring harness.
DTC 87
0
(Page 1 of 2)
IGNITION "OFF."
DISCONNECT INSTRUMENT CLUSTER HARNESS CONNECTOR.
TURN IGNITION TO "RUN."
USING J 39200, MEASURE VOLTAGE FROM GROUND TO TERMINAL
"BS" OF THE 24-WAY EBCM/EBTCM HARNESS CONNECTOR.
IS VOLTAGE GREATER THAN 1 VOLT?
RED BRAKE WARNING LAMP

CKT OPEN OR SHORTED TO
BATT
..
. I
.
YES
NO
!!
IGNITION "OFF."
USING A FUSED JUMPER SUCH AS J 36169 WITH A 3 AMP FUSE, CONNECT 24WAY
EBCM/EBTCM HARNESS CONNECTOR TERMINAL "BS" TO GROUND.
IGNITION TO "RUN."
IS RED BRAKE WARNING LAMP "ON"?
I
YES
NO
I
I
RELEASE PARK BRAKE.

IGNITION "OFF."
DISCONNECT BRAKE FLUID LEVEL SWITCH.
INSPECT 24WAY EBCM/EBTCM HARNESS
CONNECTOR TERMINAL "BS" FOR POOR
TERMINAL CONTACT OR CORROSION. REFER
TO. SECTION 8A4, "CHECKING TERMINAL
CONTACT." REPLACE TERMINALS THAT
EXHIBIT POOR CONTACT OR CORROSION.
RECONNECT 24WAY EBCM/EBTCM
CONNECTOR.
START ENGINE.
WAIT 10 SECONDS.
IGNITION "OFF."
REMOVE IIP CLUSTER.
REMOVE AND INSPECT RED BRAKE WARNING LAMP.
IS BULB OPEN?
NO
I
~E~t::NCE
BRAKE
CIRCUITRY.
YES
I

RESISTANCE BETWEEN 1/P
CLUSTER HARNESS
CONNECTOR TERMINAL "C10"
(CHEV), "A10" (PONT) AND
24WAY EBCM/EBTCM
HARNESS CONNECTOR
TERMINAi. "BS".
IS RESISTANCE LESS THAN 2
OHMS?
i"''' l ................ l
l REFER TO i
! SECTION BA i
i TO REPAIR I
i HIGH
i
j
I!
,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,,,.
YES
NO
...... 1 ................................. -........... ......
!i
REFER TO SECTION BA TO
DIAGNOSE CLUSTER AND/OR
CIRCUITRY TO CLUSTER.
1
l
j,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,.,,,,,,.,.,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,j
YES
.... ....................................................................................................................,
,..
! CHECK BRAKE FLUID LEVEL AND REFER TO SECTION BA TO .i

! REPAIR HIGH RESISTANCE IN.... FLUID LEVEL SWITCH CIRCUITRY. j
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, ..,,,,,,,,,,,.,,,,,,,,,,,,,,,,,.,.,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,,/
REPAIR OPEN OR
HIGH RESISTANCE
IN CKT 33.
YES
IGNITION "OFF."
INSPECT BRAKE FLUID LEVEL SWITCH HARNESS CONNECTOR FOR POOR TERMINAL CONTACT
AND EVIDENCE OF CORROSION. REFER TO SE_CTION 8A4, "CHECKING TERMINAL CONTACT."
REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF TERMINAL CONTACT OR CORROSION.
RECONNECT BRAKE FLUID LEVEL SWITCH CONNECTOR.
START ENGINE.
WAIT 10 SECONDS.
DO.ES OTC 87 SET AS A CURRENT OTC?
REPLACE
BULB.
NO
NO
Ii
GO TO OTC 87
PAGE 2 OF 2. i
f,,,.;,,u,,.,,,,,,,,,,,,,,,,,,,,,,,
ENSURE BRAKE FLUID IS AT THE PROPER LEVEL.

IGNITION "OFF."
REMOVE JUMPER USED IN STEP 2.
APPLY PARK BRAKE.
IGNITION TO "RUN."
USING J 39200, MEASURE VOLTAGE BETWEEN
GROUND AND 24-WAY EBCM/EBTCM HARNESS
CONNECTOR TERMINAL "BS".
IS VOLTAGE LESS THAN 2 VOLTS?,
YES
....,,, ..........................
REPLACE
EBCM/EBTCM.
.
. l
NO

A POOR C.ONNECTION. REFER TO
C9797
5E2-166
EBTCM
REFER TO
SECTION 8A11
GAGES
FUSE9
ION
BRAKE WARNING
LAMP CONTROL
D13CHEV
A5PONT
ABS/TCS ACTIVE
LAMP CONTROL
ABS WARNING
LAMP CONTROL
,____,_---1 C1 CHEV
AB PONT
(CHEV)"ASR"
(PONT)"TCS OFF"
---
---
TCSWARNING
LAMP CONTROL
..I
(PONT ONLY) TO
042095
FT0155E
OTC 87
{Page 2 of 2)
RED BRAKE WARNING LAMP CIRCUIT OPEN OR SHORTED
TO BATT

between the EBTCM and the red BRAKE warning
BRAKE warning lamp to be illuminated by. the
EBTCM. This will only occur if an ABS/TCS
malfunction is detected that may degrade base brake
operation. Because ABS/TCS is not the only device
controlling the red BRAKE warning lamp (parking
brake and brake fluid level switch may also turn
"ON'' the red BRAKE warning lamp) a short to
ground in this circuit cannot be detected.

8. Identifies if a malfunction is currently present.
9. With the Tech 1 connected, attempts to tum
"ON" the "BRAKE" warning lamp.
11; Ensures malfunction was not due to physical
12. Checks for DTC 86 also being set.
OTC Will Set When:

BRAKE warning lamp circuit voltage is out of
Action Taken:
A malfunction DTC is stored, ABS/TCS is not
disabled, however, if the EBTCM commands the red
BRAKE warning lamp on due to a ABS/TCS
malfunction that may degrade .base brake operation
Diagnostic Aids:
this section.
the wiring harness.
5E2-167
DTC 87
(Page 2 of 2)
RED BRAKE WARNING LAMP CKT.
OPEN OR SHORTED TO BATT
,,.,,.,,,.,.,,,.,.,,,;;;;;;;,un,,,,;nun,,,,,.,,,,,.,,,,.,,u.,,,,.,.<,
CONTINUED FROM DTC 87
i PAGE 1 OF 2.
'""'"'f"'"""""'"""""""""""'"''""/.
IGNITION "OFF."
IGNITION TO "RUN."
OBSERVE RED "BRAKE" WARNING LAMP.
IS LAMP "OFF"?
I
I
YES
NO
USING TECH 1 MISC. TESTS, SELECT LAMP TEST

FUNCTION, COMMAND RED "BRAKE" LAMP "ON."
IS LAMP ILLUMINATED?
IS OTC 86 ALSO SET?
I
I
NO
I
YES
I
IGNITION "OFF."
REMOVE 10 AMP GAGES FUSE 9.
DISCONNECT 24-WAY
IGNITION TO "RUN."
AND TERMINAL "85" OF THE
CONNECTOR.
I
I
NO
I
MALFUNCTION IS
NOT PRESENT AT
THIS TIME. REFER
TO "DIAGNOSTIC
AIDS" ON FACING
PAGE.
NO
I
CHECK FOR LOW FLUID LEVEL

OR
PARKING BRAKE SWITCH
CLOSED AND CORRECT AS
NECESSARY.
YES
I
PROCEED
TO OTC 86
DIAGNOSTIC
CHART.
REPAIR SHORT TO
VOLTAGE IN CKT 33.
YES
I e
IGNITION "OFF."
INSPECT CKT 33 AND 24-WAY EBCM/EBTCM HARNESS
CONNECTOR FOR DAMAGE WHICH MAY RESULT IN A
SHORT TO VOLTAGE WITH ALL CONNECTORS
IGNITION TO "RUN."
I
I
YES
REPLACE
EBCM/EBTCM.
NO
I
MALFUNCTION IS MOST
LIKELY DUE TO A POOR
FACING PAGE.
C9798
5E2-168
EBCM/EBTCM
B+
FUSIBLE
LINK "F"
STOP/HAZARD
FUSE1
0
:~ ~ 140 ORN
20 AMP
e-[c~ ~
C200A
C200D
-i------E}-
C1
C1
A~....,: B

BRAKE SWITCH
ASSEMBLY
C200D
C200AS271
O LT BLS243
0 LT BLU
BRAKE SWITCH INPUT
CRUISE CONTROL
MODULE
080195
FT0275E
DTC 91
OPEN BRAKE SWITCH DURING DECELERATION
This DTC is used. to detect an open brake switch
in the non-ABS mode. The EBTCM looks for
deceleration rates that would indicate braking action
and verifies this assumption by requiring several
repeats of this detection method. In each case, ABS
will not be available since no brake switch input is
seen by the EBTCM.

input circuitry or the EBTCM.
contact.
5. Verifies that voltage is available at the brake
switch.
properly.
DTC Will Set When:
Diagnostic Aids:
DTC 91 can be set if three deceleration cycles

occur with the brake switch "OFF."

this section.
Any circuitry that is suspected of causing tie
the wiring harness.
Action Taken:
turned "ON."

received by the EBTCM.
DTC 91
OPEN BRAKE SWITCH
DURING DECELERATION
I''" ,,,,,,,,,,,,,,,,,,,,,,,,,,.,,.,,,,.,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.~
IGNITION TO "RUN."
APPLY LIGHT PRESSURE TO BRAKE PEDAL,
ON TECH 1.
! PROCEED TO DTC 95 DIAGNOSTIC CHART.
(,,,.,,,,,,,,,,.,,,.,.,.,.,,,,,,,,,,,,,,,.,.,,,,,.,.,.,,,.,,,,,.,.,,,,,,,.,,,,,.,,.,,,u,,,,,,,,,,,,,,,,,,,,.,/

IGNITION "OFF."
IGNITION TO "RUN."
EBCM/EBTCM HARNESS CONNECTOR WHILE .

FOR POOR TERMINAL CONTACT'AND
EVIDENCE OF CORROSION. REFER TO
SECTION 8A4, "CHECKING TERMINAL
CONTACT." REPLACE ALL TERMINALS
THAT EXHIBIT SIGNS OF TERMINAL
CURRENT DTC?
REPAIR
SHORTED OR
OPEN CKT 820.

THE BRAKE SWITCH.

AND TERMINAL "B" OF THE
BRAKE SWITCH WHILE
APPLYING FIRM PRESSURE ON
BRAKE PEDAL.
GREATER?
REPAIR OPEN OR
SHORTED CKT 140
AND REPLACE
STOP HAZARD
FUSE 1.


C8048
5E2-170
EBCM/EBTCM
B+
FUSIBLE
STOP/HAZARD
e{c~ ~o:: -f!l"V- 140 ORN
LINK "F"
FUSE1
C200A
C200D
20 AMP
f i" uC1
C1
A:-----------: B
1
C200D
C200A 8271
O LT BL
O LT BLU
BRAKE SWITCH INPUT
43
BRAKE SWITCH
ASSEMBLY
CRUISE CONTROL
MODULI!
0801-95
FT0275E
DTC 92
OPEN BRAKE SWITCH WHEN ABS WAS REQUIRED
"ON." If the brake switch is "OFF," ABS will never
be activated. Since this malfunction is difficult to
detect under normal braking conditions, this
malfunction is only detected when ABS is required.
DTC Will Set When:
DTC 92 can be set if the vehicle's speed is
greater than 8 km/h (5 mph). If the brake was not
"ON" and a release was required on two channels for
0.5 seconds, a malfunction ex.ists.
Action Taken:
turned "ON."

contact.
5. Verifies the voltage is available at the brake
switch.
properly.
Diagnostic Aids:
this section.
the wiring harness.
5E2171
DTC 92
OPEN BRAKE SWITCH WHEN
ABS WAS REQUIRED
f,
IGNITION TO "RUN."
USING TECH 1, SELECT "FD: DATA LIST."
APPLY LIGHT PRESSURE ON BRAKE PEDAL,
ON TECH 1.
PROCEED TO, DTC 95, DIAGN,OSTIC ,CHART.J

IGNITION "OFF."
IGNITION TO "RUN."
GROUND AND TERMINAL "89" OF THE 24WAY
IS'.VOLTAGE 10 VOLTS OR GREATER?
INSPECT 24WAY EBCM/EBTCM

"89" FOR POOR TERMINAL CONTACT
AND EVIDENCE OF CORROSION.
REPLACE ALL TERMINALS THAT
EXHIBIT SIGNS OF TERMINAL
RECONNECT ALL CONNECTORS;
CURRENT DTC?
REPAIR
SHORTED
OR OPEN
CKT 820.

THE BRAKE SWITCH.

TERMINAL "B" OF THE BRAKE
SWITCH WHILE APPLYING FIRM
PRESSURE ON BRAKE PEDAL.
GREATER?
REPAIR OPEN OR
SHORTED CKT 140
AND REPLACE STOP
HAZARD FUSE 1.


TO A POOR CONNECnON. REFER TO
CB049
5E2-172
EBCM/EBTCM
B+
FUSIBLE
LINK "F" r"
e-:L..c~
STOP/HAZARD
FUSE 1
~ 1400RN
20AMP
~o::
C200A
C200D
a.-
C1
C1
A~~B
1
r:r1
BRAKE SWITCH
ASSEMBLY
OLTBL
C200D
C200A 8271
OLTBL
8243
BRAKE SWITCH INPUT
CRUISE CONTROL
MODULE
' 08-01-15
FT027&E
DTC 93
DTC 91 OR 92 SET IN CURRENT OR PREV. IGN CYCLE
.Diagnostic Aids:
This DTC is the second portion ofDTCs 91 and

92. If DTCs 91 or 92 failed during the last ignition
cycle, DTC 93 becomes a current failure during the
next ignition cycle, keeping ABS and TCS disabled
until a brake switch "ON" state is seen. When a
change is seen during an ignition cycle in which DTC
93 is a current malfunction, DTC 91 or 92 will clear
itself at the end of the current ignition cycle, and ABS
and will be enabled at the start of the next ignition
cycle. DTC 93 alone indicates 91 or 92 failed
previously, but is intermittent, or has been corrected.
An intermittent malfunction may .be caused by a

this section.
terminal to wiring connections .or physical damage to
the wiring harness.
Also, verify proper brake switch operation using
the data list of the Tech 1'. As the brake is applied, the
data list should display the brake switch "ON" within
1 inch of travel.

1. Indicates which DTC (either 91 or 92) caused
DTC 93 to set.
5E2-173
DTC 93
DTC 91 OR 92 SET IN CURRENT
OR PREV. IGN CYCLE
G)
IGNITION TO "RUN."
IS OTC 91 OR 92 SET AS A HISTORY OR CURRENT OTC?
USING TECH 1, SELECT "F1:

OTC HISTORY," VERIFY
MALFUNCTION FREQUENCY
WAS LOW AND CLEAR DTCs.
C7405
5E2-174
ANTILOCK BRAKE SYSTEM WITH TRACTION .CONTROL
EBCM/EBTCM
B+
FUSIBLE
STOP/HAZARD
--re;,. ~o:: -1//1""\.>-
LINK....
FUSE 1
... -
C200A
C200D
20 AMP
140 ORN
C1
r---aC1
A~~ B
1

BRAKE SWITCH
ASSEMBLY
C200D
C200A 9271
O LT BL
O LT BLU
8243
BRAKE SWITCH INPUT
CRUISE CONTROL
MODULE
080195
FT0276E
DTC 94
BRAKE SWITCH CONTACTS ALWAYS CLOSED

"ON" and turned "OFF" when the brake is "OFF."
If the brake switch is always "ON," ABS operation
will always be requested resulting in potential
modulator cycling on rough roads.

1. Checks if the malfunction is currently present.
2. Isolates the cause of the malfunction to either a
malfunctioning or misadjusted brake switch, or a
short to voltage in the brake switch circuitry.
3. Checks for unwanted voltage on the brake switch
input circuit.
4. Checks for a possible intermittent malfunction.
DTC Will Set When:

DTC 94 can be set when the vehicle reaches at
least 40 km/h (25 mph). If the brake was never
"OFF" during two consecutive drive cycles, a
malfunction exists.
Action Taken:
disabled; however, TCS is disabled and the TCS
warning lamp is turned "ON."
Diagnostic Aids:
this section.
the wiring harness.
5E2-175
OTC 94
BRAKE SWITCH CONTACTS
ALWAYS CLOSED
IGNITION ''OFF."
OBSERVE REAR CENTER HIGH MOUNTED
STOP LAMP (CHMSL).
ARE THE CHMSL LAMPS ''OFF"?
UNPLUG BRAKE LAMP SWITCH

CONNECTOR.
REPAIR
SHORT TO
VOLTAGE
ON CKT 820.
MISADJUSTED OR
MALFUNCTIONING
BRAKE SWITCH.
ADJUST OR REPLACE
SWITCH AS
NECESSARY.

IGNITION TO "RUN."
USING J 39200, MEASURE VOLTAGE BETWEEN TERMINAL
"89" OF 24-WAY EBCM/EBTCM HARNESS CONNECTOR AND
GROUND.
IGNITION "OFF."
HARNESS CONNECTOR
TERMINAL "89" FOR POOR
CONTACT.
START ENGINE AND TEST DRIVE
VEHICLE, ACHIEVING AT LEAST
40 km/h (25 MPH).
REPEAT ABOVE DRIVE CYCLE
SEQUENCE TWO MORE TIMES.
DID DTC 94 SET IN THE LAST
THREE DRIVE CYCLES?
REPAIR SHORT
TO VOLTAGE
IN CKT 820.
MALFUNCTION IS NOT
PRESENT AT THIS TIME,
caoso
5E2-176
EBCM/EBTCM
B+
BRAKE SWITCH INPUT
CRUISE CONTROL
MODULE
080M15
FT0275E
DTC.95
This DTC is used to identify open brake switch
circuitry that prevents the brake switch input to the
EBTCM from changing states when the brake is
applied. This DTC is used in conjunction with DTCs
91 and 92 to determine the cause .of an open brake

switch malfunction.
DTC Will Set When:
DTC 95 can be set. after initialization is
completed. If the brake switch input voltage is out of
specification for one second indicating an open circuit,
Action Taken:
disabled. The. amber ABS and TCS warning lamps are
turned "ON."
1. Is used to confirm that an open in the brake
switch circuitry currently exists.
2. Indicates if the . brake switch signal is being

switch. or .brake lamp circuitry.
Diagnostic Aids:
this section.
for backed out terminals, improper mating, broken.
the wiring harness.
DTC 95
ARE ANY OTHER BRAKE SWITCH DTCs CURRENTLY SET?
,,.,, ,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.,.,,,,,,,,,,,,,,,,,,,.,,,,,,,.,,,,,,,,,,.,,.,,,,,,,,,,,,11,,,,,4.
IGNITION TO "RUN."
USING TECH 1, SELECT "FO: DATA LIST" AND MONITOR
BRAKE SWITCH STATUS.
DOES TECH 1 INDICATE THAT BRAKE SWITCH IS OPEN?
APPLY LIGHT PRESSURE ON BRAKE PEDAL WHILE

MONITORING BRAKE SWITCH STATUS ON TECH 1.
j.,,,,,,,,,.,,,,u.,,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,,,,,,,..,,,,,,,,,u,,,,,,,,.,,,,,,,.,,.,,,,,,,,,,,,,,,
PROCEED TO THAT OTC DIAGNOSTIC CHART. j

APPLY FIRM PRESSURE TO BRAKE PEDAL AND

OBSERVE CHMSL LAMPS.
ARE ALL CHMSL LAMPS "ON"?
IGNITION "OFF."
IGNITION TO "RUN."
CHECK FOR POOR TERMINAL CONTACT

AT EBCM/EBTCM.
IF OK, REPLACE EBCM/EBTCM.
C8051
5E2-178
I
EBTCM
TCSWARNING
I.AMP CONTROL
06-01-95
FT0285E
DTC 111
{Page 1 of 3)
TCS WARNING LAMP OR ACTIVE CKT MALFUNCTION
This DTC checks the state of both the TCS

warning lamp and the TCS active circuit to identify a
situation in which the driver could not be alerted to a
system malfunction or the availability of traction
control. The EBTCM turns the amber TCS warning
lamp "ON" by providing a ground. The TCS active
circuit is such that the EBTCM provides a ground to
signal the PCM that TCS is active.
DTC 111 can be set anytime. The TCS warning
lamp will set DTC 111 if open or shorted to ground
during the 3 second bulb check. In addition, a
malfunction exists if the TCS warning lamp is opened
anytime after the bulb check for more than 2 seconds.
Shorts to voltage on the TCS warning lamp are
detected anytime after the bulb check is complete and
the EBTCM is commanding the lamp "OFF."
Shorts to voltage on the TCS active circuit when
the EBTCM is commanding it "ON" and the
malfunction exists for 2 seconds will set DTC 111. An
open on the TCS active circuit will set DTC 111 if the
malfunction exists for 2 seconds. An open on the
spark retard line while the TCS is not active will set
DTC 111 if the malfunction is present in excess of 2
seconds. A short to ground malfunction exists if the
TCS active circuit is commanded "OFF" by the
EBTCM and the short is present for 2 seconds.

1. Determines if the TCS warning lamp can be
2. Determines if the lamp is "ON'; constantly.
3. Checks for other DTCs which could turn "ON"
the TCS warning lamp.
turned "OFF" manually.
5. Checks the integrity of the TCS warning lamp
circuitry.
6. Checks for a short to voltage on the TCS warning
lamp circuitry.
7. Determines if a malfunctioning EBTCM is the
cause of DTC 111.
8. Verifies that the other 1/P indicator lamps function
properly.
turned "ON" manually.
10. Checks for a short to ground in the TCS warning
lamp circuitry.
11. Checks for a open between the "Gages" fuse and
the 1/P cluster.
12. Verifies condition of the "Gages" fuse.
13. Determines if DTC 111 was set due to a EBTCM
malfunction.
Action Taken:
Diagnostic Aids:
A malfunction DTC is stored, however ABS and

TCS are not disabled.
aids.
DTC Will Set When:
Refer to Page 3 of 3 of this chart for diagnostic
..
NO
. I
YES
YES
IGNITION "OFF."
DISCONNECT 24WAY EBTCM
CONNECTOR.
IGNITION TO "RUN."
CONNECT A FUSED JUMPER
WIRE, SUCH AS J 36169, WITH A
3 AMP FUSE BETWEEN
GROUND AND TERMINAL "87"
OF THE 24WAY EBTCM
HARNESS CONNECTOR.
DOES TCS WARNING LAMP
REMAIN "ON"?
IGNITION "OFF."
REMOVE JUMPER.
DISCONNECT BLACK 1/P
CONNECTOR.
THE RESISTANCE
BETWEEN TERMINAL "87"
OF THE 24WAY EBTCM
HARNESS CONNECTOR
AND TERMINAL "C1"
CHEVY AND "AS" PONT. OF
THE BLACK 1/P
CONNECTOR.
IS RESISTANCE 20 OR
LESS?
.
NO
REFER TO THAT
DTC CHART FIRST.
YES
G)
NO
I
MALFUNCTION
IS NOT
PRESENT AT
THIS TIME.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE.
. I
IGNITION TO "RUN.''
.
USING J 39200, MEASURE.THE VOLTAGE
BETWI..EN GROUND AND TERMINAL "87"
OF THE 24-WAY EBTCM HARNESS
CONNECTOR.
NO
. REPAIR SHORT TO VOLTAGE ON CKT 1572.
C8053
NO.
REPAIR OPEN
OR HIGH
RESISTANCE IN
CKT 1572.
@1
IGNITION "OFF."
DISCONNECT
24WAY EBTCM
CONNECTOR.
IGNITION TO "RUN."
DOES TCS
WARNING LAMP
TURN "ON"?
NO
INSPECT "GAGES" FUSE 9.

IS FUSE OPEN?
NO
YES
I I
I
I YES I
I I
NO
G)
REPLACE EBTCM.
DO REMAINING WARNING LAMPS WORK PROPERLY?
YES
G)
'.
YES
..
. I
NO
YES
.
NO
. I
. I
YES
IGNITION"OFF."
INSPECT TERMINAL "87" OF THE
24WAY EBTCM CONNECTOR .FOR
BENT TERMINALS OR FOREIGN
DEBRIS. CORRECT AS
NECESSARY.
IGNITION TO "RUN.''
DOES DTC 111 RESET?
REPAIR
SHORT TO
GROUND IN
CKT 1572.
YES
IGNITION '.'OFF."
DISCONNECT BLACK
LDM CONNECTOR.
USING J 39200,
MEASURE THE
RESISTANCE BETWEEN
GROUND AND
TERMINAL "87" OF
24WAY EBTCM
HARNESS CONNECTOR.
RESISTANCE AS "OL"
(INFINITE)?
CHECK FOR SHORT

TO GROUND ON
CKT 39 AND ALL
OTHER CIRCUITS
FROM SPLICE S206
REPAIR ANY
SHORTS TO
GROUND AND
REPLACE FUSE. IF
NO SHORTS ARE
FOUND,REPLACE
FUSE.
REPAIR
OPEN
IN
CKT 39.
REPLACE
EBTCM.
G)
INSPECT TERMINAL
"B7" OF THE 24'#AY
EBTCM CONNECTOR
FOR POOR TERMINAL
CONTACT.
IGNITIOlll 0 0FF."
.RECONNECT ALL
CONNECTORS.
o IGNITION TO "RUN.''
DOES DTC 111 RESET?
YES
{Page 1 of 3)
TCS WARNING LAMP OR
ACTIVE CKT. MALFUNCTION
m J,m,mummm,m,mu,-mm, ..,
NO
ARE THERE ANY OTHER DTCs PRESENT?
111
! DIAGNOSIS CONTINUED ON i
j FOLLOWING PAGE.
l
4,,,,,,,,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,,,.,,,,,,,,,nJ
IGNITION "OFF."
REMOVE TECH 1.
IGNITION TO "RUN."
DOES THE TCS WARNING LAMP TURN "ON" AND STAY
"ON" FOR GREATER THAN 3 SECONDS?
NO
.
'
..
YES I
.
G)
.
DTC
INSTALL TECH 1.
IGNITION TO "RUN."
SELECT F8: LAMP TEST AND ATTEMPT TO TURN "ON," THEN "FLASH"
THE TCS WARNING LAMP.
CAN THE TCS WARNING LAMP BE BOTH TURNED "ON".AND FLASHED
USING THE TECH 1?
REPLACE
EBTCM.
IGNITION TO "RUN.''
USING J 39200,
MEASURE THE VOLTAGE
BETWEEN GROUND AND
TERMINAL "D13" CHEVY
AND "AS" PONT. OF THE
BLACK 1/P CLUSTER
HARNESS CONNECTOR.
IS VOLTAGE 10 VOLTS
OR MORE?
. MALFUNCTION
IS NOT
PRESENT AT
THIS TIME.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE.
I
R
YES
I REPLACE EBTCM. I
NO
REPAIR OPEN IN
CKT 39 BETWEEN
"GAGES" FUSE 9
AND 1/P CLUSTER.
5E2180
EBTCM
TCSWARNING
LAMP CONTROL
TRACTION CONTROL
ACTIVE SIGNAL
TCSSPARK
RETARD REQUEST
EBTCMTP
Sl!!'AL
.... s~s~
SPARK RETARD
REQUEST
RECEIVED THROTTLE
POSITION
06-01-95
FT0285E
OTC 111
{Page 2 of 3)
TCS WARNING LAMP OR ACTIVE CKT MALFUNCTION.
lamp "ON,,. by providing a ground. The TCS active
DTC Will Set When:
spark retard line while the TCS is not active will set
Action Taken:
14. Determines if the switch lamp can be properly
controlled. (Pont Only)
15. Determines if the switch lamp is "ON"
constantly.
.
16. Checks for a short to ground in the switch lamp
circuitry (Pont Only)
17. Determines if DTC 111 was set due to an
EBTCM malfunction.
EBTCM malfunction.
19. Determines if there is an open in CKT 141 or
ABS fuse.
20. Determines if the switch lamp can be controlled
manually.
21. Verifies the integrity of the switch lamp circuitry.
22. Determines if there is a .short to voltage in the
switch lamp circuitry.
EBTCM. malfunction.
Diagnostic Aids:
Refer to page 3 of 3 of this chart for diagnostic
aids.
OTC
\ DIAGNOSIS CONTINUED
TCS WARNING OR ACTIVE CKT. MALFUNCTION
! FROM PREVIOUS
PAGE. !
,,,,,.,,,.,,,.,,,,,,,,,,,,
...,,,,,,.,,,,,,.,,.,,,,,
EXIT LAMP TEST UNTIL "SELECT TEST" MAIN MENU IS DISPLAYED ON TECH 1.
SELECT F8: LAMP TEST.
OBSERVE ENABLE SWITCH LAMP WHILE TURNll':IG "ON" THE TCS WARNING LAMP.
DOES THE ENABLE SWITCH LAMP TURN "ON" WHEN THE TCS WARNING LAMP IS TURNED "ON"?
NO
111
(Page 2 of 3)
y,u,,,.,,u,,,,,,,u1,,,,,,,,,..,,,,,,,.,,,uu,,,.,,,,,,,
YES
IGNITION "OFF."
REMOVE TECH 1.
IGNITION TO "RUN."
DOES THE TCS ENABLE SWITCH
LAMP TURN "ON" ANO STAY "ON"
WHEN THE MOMENTARY CONTACT
SWITCH IS DEPRESSED?
IGNITION "OFF."
INSPECT ALL CONNECTORS FOR POOR TERMINAL CONTACT.
IGNITION TO "RUN."
DOES OTC 111 RESET?
YES
NO
,,,, ,,,,,,,,,,.,,,,,,,,,.,,.,,,,,,,,,,;;1,,u,,,.,.,,,,,,,,,,u,11,u,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,.,,,,,,.
REPLACE EBTCM.
YES
. I
YES
,.,,,.,,,.,.,.,.,.,.,,,,,,,,,.,.,,,,,.,,,.,.,,,,.,,,,,,,,.,.,,,,,,,,.,,.,,,.,,,,,.,.,,,.,.,.,,,,,,,.,,,,,,,,,,.,,,,,.,,,~
. I
REPLACE EBTCM.
NO
IGNITION "OFF."
DISCONNECT TCS ENABLE SWITCH HARNESS CONNECTOR.
IGNITION TO "RUN."
WITH J 39200, MEASURE VOLTAGE FROM GROUND TO TERMINAL "G" (PONT),
"A" (CHEV) OF THE TCS ENABLE SWITCH HARNESS CONNECTOR.
IS VOLTAGE 10 VOLTS OR MORE?
.
. I
NO
IGNITION ."OFF."
RECONNECT TCS ENABLE SWITCH HARNESS CONNECTOR.
IGNITION TO "RUN."
CONNECT A FUSED JUMPER WIRE, SUCH AS J 36169, WITH A
3 AMP FUSE BETWEEN GROUND AND TERMINAL "87" OF THE
24WAY EBTCM HARNESS CONNECTOR.
DOES THE TCS ENABLE SWITCH LAMP TURN "ON"? (PONT.)
NO
I
YES
"OFF."
@ IGNITION
DISCONNECT TCS ENABLE SWITCH
CONNECTOR.
BETWEEN TERMINAL "87" OF THE
24WAYEBTCM HARNESS CONNECTOR AND
TERMINAL "E" OF THE TCS ENABLE SWITCH
HARNESS CONNECTOR (PONT).
MALFUNCTION IS
NOT PRESENT AT
THIS TIME.
REFER TO
"DIAGNOSTIC
AIDS" ON FACING
PAGE;
YES
IGNITION "OFF."
24WAY EBTCM CONNECTOR FOR
BENT TERMINALS OR FOREIGN
DEBRIS. CORRECT AS NECESSARY.
IGNITION TO "RUN."
DOES OTC 111 RESET?
YES
REPAIR SHORT
TO GROUND
ON CKT 1572.
NO
IGNITION "OFF."
DISCONNECT 24WAY EBTCM
CONNECTOR.
IGNITION TO "RUN."
DOES THE TCS ENABLE
SWITCH LAMP TURN "ON"?
NO
I i DIAGNOSIS CONTINUE ON FOLLOWING PAGE. j
. I
YES .,
IGNITION TO "RUN."
VOLTAGE FROM GROUND TO
TERMINAL "87" OF THE 24WAY
.I
. I
YES

IGNITION "OFF."
INSPECT TERMINAL "87"
OF THE 24-WAY EBTCM
CONNECTOR FOR POOR
TERMINAL CONTACT.
RECONNECT ALL
CONNECTORS.
IGNITION TO "RUN."
DOES OTC 111 RESET?
NO
REPAIR
OPEN OR
HIGH
RESISTANCE
IN CKT 1572,
.
NO
REPAIR OPEN
IN CKT 141
BETWEEN
TURN BU
FUSE (PONT),
CKT8 VP
DIMMER
FUSE (CHEV)
AND TCS
ENABLE
SWITCH.
YES
REPLACE
EBTCM.
11 REPAIR SHORT TO
VOLTAGE IN CKT 1572
. I
NO
MALFUNCTION
IS NOT
PRESENT AT
THIS TIME.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE.
I
C8054
5E2-182
I
EBTCM
~ G1572 PPL./WHT
TCSWARNING
LAMP CONTROL
C200A
C200D
TO TRACTION
CONTROL SWITCH
(PONT ONLY}
TRACTION CONTROL
ACTIVE SIGNAL
- - - - - - - - 8 3 2 LT BLU
TCSSPARK
FIETARD REQUEST
EBTCMTP
... s~s~ Sl!!"AL
- - - - - - - 4 8 3 ORN/BLK
-------464 TAN/BLK
SPARK RETARD
REQUEST
Rl!CEIVED THROTTLE
POSITION
080195
FT0285E
OTC 111
(Page 3 of 3)
TCS WARNING LAMP OR ACTIVE CKT MALFUNCTION
lamp "ON," by providing a ground. The TCS active
DTC Will Set When:
spark retard line while the TCS is .not active will set
Action Taken:

24. Checks for or high resistance in spark retard
request line (CKT 463) between PCM and
EBTCM.
25. Check for short to voltage in spark retard request
line (CKT 463) between PCM and EBTCM.
26. Checks for short to ground in spark retard
request line (CKT 463) between PCM and
EBTCM.
the connectors in CKT 463.
Diagnostic Aids:
this section.
the wiring harness.
5E2183
DTC 111
,,,,,,,,.,.,,,,,,;;,,,,,,,u,,,,,,,1,,,,,,,,n,,,,,,,,.,,,,,;u,,u,,,,,.,,,,,,,,,,,,,,,,,,.,,,,,u,;1,,,,u,,
!.,,,,,,r,,,
DIAGNOISS CONTINUED FROM PREVIOUS PAGE. j
............................,,,......................,,,..,,,,,,,,,,,,,,,............,.
'
/.
(Page 3 of 3)
TCS WARNING LAMP OR
ACTIVE CKT. MALFUNCTION
IGNITION "OFF."
DISCONNECT PCM CONNECTOR "C1" AND 24-WAY EBTCM CONNECTOR.
THE PCM HARNESS CONNECTOR "C1" AND TERMINAL "B" OF THE BWAY
EBTCM HARNESS CONNECTOR "C3."
. I
NO
YES
USING J 39200 MEASURE VOLTAGE BETWEEN TERMINAL "B" OF

THE 8-WAY EBTCM CONNECTOR "C3" AND GROUND.
YES
I
REPAIR OPEN OR HIGH

NO
USING J 39200 MEASURE THE RESISTANCE BETWEEN GROUND

AND TERMINAL "B" OF THE BWAY EBTCM HARNESS
CONNECTOR "C3."
. I
NO
INSPECT TERMINAL "C4" OF CONNECTOR C200 AID, PCM

CONNECTOR "C1" AND BWAY EBTCM CONNECTOR "C3" FOR POOR
TERMINAL CONTACT OR CORROSION. REFER TO SECTION. BA4,
"CHECKING TERMINAL CONTACT.''
DO ANY TERMINALS EXHIBIT POOR CONTACT OR EVIDENCE OF
CORROSION?
REPLACE EBTCM.
NO
REPLACE TERMINALS
THAT EXHIBIT POOR
TERMINAL CONTACT OR
EVIDENCE OF
CORROSION
REPAIR SHORT TO
GROUND IN CKT 463.
YES
IGNITION "OFF.''
START ENGINE.
YES
I
NO
REPAIR SHORT TO
VOLTAGE IN CKT 463.
.
YES

LIKELY CAUSED BY A
POOR CONNECTION. REFER
TO "DIAGNOSTIC AIDS" ON
FACING PAGE.
C8055
5E2-184

EBTCM
REFER TO
SECTION 8A44
:------~
1'100
rc;t-1633 R E D - - e - - - - ~ -----'1f'L__
,
H1 GRY--'c'"
~
8180
~
--....:..
:
I
:AiSJTCi!
RELAY
~M---- B
TCS ADJUSTER
ASSEMBLY
MOTOR LOW
C3
ADJUSTER
ASSEMBLY
04-20-95
FT0335E
DTC 115
ADJUSTER ASSEMBLY THERMAL MODEL TEMP EXCEEDED
This DTC identifies an condition in which the
EBTCM uses a Brake Thermal Model (BTM) to
determine if the adjuster assembly has exceeded its
specified thermal limit. Usually the adjuster assembly
will reach its thermal limit after the rotors are past
their thermal limit. In this way, the adjuster assembly
motor can still react even though the rotors are over
thier specified thermal temperature for shutdown.
DTC Will Set When:
commands the ASR/TCS relay "ON." The DTC will
set when the thermal limit temperature is reached for
the adjuster assemby motor.
Action Taken:
A malfunction DTC is stored, TCS is disabled
and the amber TCS warning lamp is turned "ON."
When the adjuster assembly motor cools below its
re-entry limit temperature the amber TCS warning
lamp will tum "OFF" and TCS will be available.
(Note that even though the TCS system is available
DTC 115 will still be current for the rest of the
current drive cycle for service reasons.)

1. Checks to see if any other DTCs are set.
2. Checks to see if DTC 115 is set as a current
DTC.
3. Checks adjuster assembly temperature to see if it
is over limit.
4. Lets adjuster assembly cool for 20 minutes and
then rechecks to see if adjuster assembly
temperature remains over temperature limit.
Diagnostic Aids:
The temperature of each rotor can be read in the
TCS data list on the Tech .1. In addition, the TCS data
list will display if the rotors, modulators, or adjuster
assembly motor are over their specified temperature
limits independently.
5E2-185
DTC 115
ADJUSTER ASSEMBLY THERMAL
MODEL TEMP EXCEEDED
IGNITION TO "RUN."
ARE ANY OTHER DTCs CURRENTLY SET?
I
NO
I
YES
IS DTC 115 SET AS A CURRENT CODE?
NO
I
USING TECH 1 ENTER DATA LIST FOR TCS

AND READ "ADJ. ASM. TEMP."
IS ADJUSTER ASSEMBLY OVER LIMIT?
I
I
PROCEED TO DTC CHART THAT SET.
YES
...
CLEAR DTCs
ADJUSTER ASSEMBLY TEMPERATURE
LIMIT EXCEEDED TEMPORARILY.
I
I
YES
I
NO
I
IGNITION "OFF."
RAISE VEHICLE HOOD
LET VEHICLE COOL FOR 20 MINUTES
IGNITION TO "RUN."
USING TECH 1 ENTER DATA LIST FOR TCS
AND READ "ADJ. ASM. TEMP."
IS ADJUSTER ASSEMBLY OVER LIMIT?
YES.
REPLACE EBTCM.
NO
..
REPLACE EBTCM.
CLEAR DTCs
ADJUSTER ASSEMBLY TEMPERATURE
LIMIT EXCEEDED TEMPORARILY.
C9799
5E2-186
IGNITION
REFER TO
D13 CHEV
SECTION 8A10
A5 PONT
GAGES
\.
FUSE9
82
'
3PNK~39PNK
10AMP
INSTRUMENT
CLUSTER
r-----, /
EBTCM
~~
"ASR" (CHEV)
f1::S_2F!'
POWERTRAIN CONTROL
MODULE (PCM)
C3
I" -
C1 CHEV
AB PONT
~0!1'?J
TCSWARNING
LAMP CONTROL
1572 PPL./WHT
C200A
C200D
TO TRACTION
CONTROL SWITCH
(PONT ONLY)
TCS ACTIVE
TRACTION CONTROL
ACTIVE SIGNAL
I TCSSPARK
RETARD REQUEST
I EBTCMTP
L. S~S<?! Sl~AL
SPARK RETARD
REQUEST
RECEIVED THROTTLI
POSITION
06-01-115
FT0285E
DTC 123
PCM TO EBTCM TP SENSOR .CIRCUIT MALFUNCTION
The traction control system uses the antilock
brake system in conjunction with the Powertrain
Control Module (PCM) fuel and ignition controls to
limit drive wheel slippage during acceleration. The
PCM controlled portion of the traction control system
reduces engine torque by altering spark timing and
controlling throttle position. The EBTCM sends a TCS
active signal (CKT 832) to the PCM and a spark
retard request to the PCM via a Pulse Width
Modulated (PWM) signal requesting the desired spark
level for proper traction control system operation
(CKT 463). The PCM then provides a throttle position
(TP) PWM signal (CKT 464) informing the EBTCM
what the actual throttle position of the engine is.
DTC
wm
Set When:
DTC 123 will set when there is a malfunction in

the throttle position circuit (CKT 464) or if the signal
is out of range.
Action Taken:
A malfunction DTC is stored, TCS is disabled at
the end of the current TCS cycle and the amber TCS
warning lamp is turned "ON."

the diagnostic chart,
1. Checks to determine if "Delivered Torque
Frequency" and "Throttle Angle" are within
specified ranges using the Tech 1.
2. Checks to determine if "Delivered Torque
Frequency" and "Throttle Angle" indicate a ..
possible malfunctioning PCM.
3. Checks for proper voltage at the PCM terminal.

4. Checks for short to voltage in CKT 464.
damage of circuitry.
6. Checks for open in CKT 464.
7. Checks for short to ground in CKT 464.
EBTCM.
Diagnostic Aids:
Note that the Tech 1 TCS data list will display
the frequency of this signal to isolate a frequency
slightly out of range. Usually when the PWM line is
open or shorted to ground/voltage the throttle position
will read 100% and the PWM frequency will read
64Hz.
this section.
intermittent complaints should be thoroughly checked
the wiring harness.
Before beginning diagnostics perform a
Powertrain "OBD" system check. (Refer to Section
6E3). If OK, begin chart.
DTC 123
NOTICE: PERFORM A POWERTRAIN

OBD SYSTEM CHECK, REFER TO
SECTION 6E3 BEFORE BEGINNING
CHART. IF OK; BEGIN CHART.
PCM TO EBTCM TP SENSOR

CIRCUIT MALFUNCTION
START ENGINE.
USING TECH 1 "FO", DATA LIST READ "DEL TORQUE FREQ" AND "THROTTLE ANGLE".
IS "DEL TORQUE FREQ" BETWEEN 119 AND 137 HERTZ AND "THROTTLE ANGLE" .BETWEEN 5 AND 95%?
..
. I
.
. I
YES
NO
IS "DEL TORQUE FREQ" 64 HERTZ AND

"THROTTLE ANGLE" 100%?
MALFUNCTION IS INTERMITTENT. REFER TO

I
B
. I
NO
YES
I
I
NO
IGNITION "OFF."
DISCONNECT BLACK 8-WAY EBTCM HARNESS CONNECTOR.
IGNITION TO "RUN."
BLACK SWAY EBTCM CONNECTOR TERMINAL "A."
IS VOLTAGE ZERO VOLTS?
YES
IGNITION "OFF."
INSPECT CKT 464 AND PCM
CONNECTOR ~C1", TERMINAL "12"
AND BLACK SWAY. EBTCM
"A" FOR DAMAGE WHICH MAY
RESULT IN AN INTERMITTENT
OPEN, SHORT TO GROUND, OR
SHORT TO B + WITH ALL
CONNECTORS CONNECTED.
REPAIR DAMAGE IF EVIDENT.
START ENGINE.
WAIT 10 SECONDS.
DOES DTC 123 SET AS A
CURRENT DTC?
YES
I
REPLACE PCM. REFER TO

SECTION 6E3 FOR REPLACEMENT
PROCEDURES.
IGNITION "OFF."
DISCONNECT PCM CONNECTOR "C1."
IGNITION TO "RUN."
TERMINAL "12" OF THE PCM CONNECTOR "C1".
IS VOLTAGE APPROXIMATELY 12 VOLTS?
YES
REPLACE f>CM. REFER TO

PROCEDURES.
NO
IGNITION "OFF."
DISCONNECT BLACK 8-WAY EBTCM HARNESS
CONNECTOR.
PCM CONNECTOR "C1" TERMINAL "12" AND
BLACK SWAY EBTCM CONNECTOR TERMINAL "A."
YES
YES
MALFUNCTION IS
MOST.LIKELY
DUE TO A POOR
CONNECTION.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE.
YES
REPAIR OPEN OR
HIGH RESISTANCE
IN CKT 464.
NO
REPAIR SHORT
TO GROUND IN
CKT 464
REPLACE EBTCM.
'
IGNITION "OFF."
INSPECT TERMINAL "12" OF
THE PCM CONNECTOR "C1"
AND TERMINAL "A" OF THE
BLACK 8-WAY EBTCM
CONNECTOR FOR POOR
TERMINAL CONTACT AND
CONTAMINATION. REPAIR
RECONNECT ALL
CONNECTORS.
START ENGINE.
CURRENT DTC?
NO

RESISTANCE BETWEEN
GROUND AND BLACK
SWAY EBTCM CONNECTOR
TERMINAL "A."
RESISTANCE AS "OL"
(INFINITE)?
NO
REPAIR SHORT TO
. VOLTAGE. IN CKT 464.
NO
I
C9790
MALFUNCTION IS
FACING PAGE.
5E2-188
EBTCM
~~
"ASR" (CHEV)
I.,~S!F!'.'
POWERTRAIN CONTROL
MODULE (PCM)
C3
...
- --
!!:0!11J
11172 PPL/WHT
C200A
C200D
TO TRACTION
CONTROL SWITCH
(PONT ONLY)
TRACTION CONTROL
ACTIVE SIGNAL
TCSACTIVE
i - - - - - - - - - 8 3 2 LT BLU
I TCSSPARK
RETARD REQUEST
I EBTCMTP
1 - - - - - - - - 4 6 3 ORN/BLK
13
i - - - - - - - - 4 6 4 TAN/BLK
L.
s~s~ Sl~AL
TCSWARNING
LAMP CONTROL
SPARK RETARD
REQUEST
Rl!Cl!!IVl!D THROTTU
POSITION
06-01-96
FT0285E
DTC 125
EBTCM TO PCM TCS ACTIVE CKT MALFUNCTION

I;>CM controlled portion of the traction control system

I. Checks for proper voltage at the PCM terminal.
4. Checks for open in CKT 832;
EBTCM.
DTC Will Set When:

the TCS Active circuit.
Action Taken:
Diagnostic Aids:
the Tech I, as described in "Tech I Diagnostics" in
this section.
locks, improperly fonned or damaged terminals, poor
the wiring harness.
6E3). If OK begin chart.
DTC 125
EBTCM TO PCM TCS ACTIVE CKT
MALFUNCTION
NOTE:
PERFORM A POWERTRAIN 080

SYSTEM CHECK, REFER TO SECTION 6E3
BEFORE BEGINNING CHART. IF OK, BEGIN
CHART.
IGNITION "OFF."
DISCONNECT PCM CONNECTOR "C3".
IGNITION TO "RUN."
..
. I
NO
YES
IGNITION "OFF."
IGNITION TO "RUN."
USING J 39200, MEASURE VOLTAGE BETWEEN GROUND
AND 24WAY EBTCM CONNECTOR TERMINAL "88".
..
YES
0
\I
IGNITION "OFF."
CONNECTOR "C3", TERMINAL "11"
AND 24-WAY EBTCM HARNESS
CONNECTOR "88" FOR [)AMAGE
WHICH MAY RESULT IN AN
INTERMITTENT OPEN, SHORT TO
GROUND, OR SHORT TO B+ WITH
ALL CONNECTORS CONNECTED.
REPAIR DAMAGE IF EVIDENT,
START ENGINE.
WAIT 10 SECONDS.
DOES OTC 125 SET AS A
CURRENT OTC?
YES

PROCEDURES.
.
NO
IGNITION "OFF."
DISCONNECT 24WAY EBTCM HARNESS
CONNECTOR.
USING J 39200, MEASURE RESISTANCE
BETWEEN PCM CONNECTOR "C3"
TERMINAL "11" AND 24-WAY EBTCM
CONNECTOR TERMINAL "BB"
YES
YES
0
I
MALFUNCTION IS
MOST LIKELY DUE
TO A POOR
CONNECTION.
REFER TO
"DIAGNOSTIC AIDS"
ON FACING PAGE.
NO
USING J 39200 MEASURE

RESISTANCE BETWEEN GROUND
AND 24-WAY EBTCM CONNECTOR
TERMINAL "BB",
RESISTANCE AS "OL" (INFINITE)?
I
I
NO
REPAIR
SHORT TO
VOLTAGE IN
CKT 832.
REPAIR OPEN
OR HIGH
RESISTANCE
IN CKT 832.
. I
NO

PCM CONNECTOR "C3" AND
TERMINAL "88" OF THE 24-WAY
EBTCM CONNECTOR FOR POOR
TERMINAL CONTACT AND
CONTAMINATION. REPAIR ALL
DAMAGE IF EVIDENT.
START ENGINE.
DOES OTC 125 SET AS A
CURRENT OTC?
REPAIR SHORT
TO GROUND IN
CKT 832
I
I
YES
REPLACE
EBTCM.
NO
MALFUNCTION IS
INTERMITTENT.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE.
C9791
EBTCM
TCSWARNING
LAMP CONTROL
1572 PPI./WHT
- - - - - - - - 8 3 2 LT BLU
TCSSPARK
RETARD REQUEST
EBTCMTP
IL S~S~Sl~AL
t - - - - - - - - 4 6 3 ORN/BLK
-------464 TAN/BLK
TRACTION CONTROL
ACTIVE SIGNAL
SPARK RETARD
REQUEST
RECEIVED THROTTLE
POSITION
06-01-95
FT0286E
DTC 126
EBTCM TO PCM SPARK RETARD CKT MALFUNCTION

PCM controlled portion of the traction control system

1. Checks for proper voltage at the PCM terminal.
4. Checks for open in CKT 463.
6. Checks for possible poor' terminal contact at the
EBTCM.
DTC Will Set When:

the spark retard request circuit (CKT 463).
Action Taken:
Diagnostic Aids:
this section.
the wiring harness.
6E3). If OK begin chart.
OTC 126
EBTCM TO PCM SPARK RETARD
CKT MALFUNCTION
NOTE:
PERFORM A POWERTRAIN OBD

SYSTEM CHECK, REFER TO SECnON 6E3
BEFORE BEGINNING CHART. IF OK, BEGIN
CHART.
IGNITION "OFF."
DISCONNECT PCM CONNECTOR "C1".
IGNITION TO "RUN."
I
. I
NO
YES
IGNITION "OFF."
DISCONNECT BLACK BWAY EBTCM HARNESS CONNECTOR.
IGNITION TO "RUN."
USING J 39200, MEASURE VOLTAGE BETWEEN GROUND
AND BLACK BWAY EBTCM CONNECTOR TERMINAL "B".
YES
IGNITION "OFF."
CONNECTOR "C1", TERMINAL "23"
AND BLACK 8-WAY EBTCM HARNESS
CONNECTOR TERMINAL "B" FOR
DAMAGE WHICH MAY RESULT IN AN
INTERMITTENT OPEN, SHORT TO
GROUND, OR SHORT TO B+ WITH ALL
CONNECTORS CONNECTED. REPA.IR
DAMAGE IF EVIDENT.
START ENGINE.
WAIT 10 SECONDS.
DOES DTC 126 SET AS A CURRENT
DTC?
YES

PROCEDURES.
NO
IGNITION "OFF."
DISCONNECT BLACK BWAY EBTCM
HARNESS CONNECTOR.
USING J 39200, MEASURE RESISTANCE
BETWEEN PCM CONNECTOR "C1"
TERMINAL "23" AND BLACK BWAY
EBTCM CONNECTOR TERMINAL "B"
YES
REPAIR
SHORT TO
VOLTAGE IN
CKT 463.
NO
USING J 39200 MEASURE

RESISTANCE BETWEEN GROUND
AND BLACK 8-WAY EBTCM
CONNECTOR TERMINAL "B".
RESISTANCE AS "OL" (INFINITE)?
REPAIR OPEN
OR HIGH
RESISTANCE
IN CKT 463.
YES
NO
MALFUNCTION IS
MOST LIKELY DUE
TO A POOR
CONNECTION.
REFER TO
"DIAGNOSTIC AIDS"
ON FACING PAGE.
NO
IGNITION "OFF."
PCM CONNECTOR "C1" AND
TERMINAL "B" OF THE BLACK
8WAY EBTCM CONNECTOR FOR
CONTAMINATION. REPAIR ALL
DAMAGE IF EVIDENT.
START ENGINE.
CURRENT DTC?
I
YES
REPLACE
EBTCM.
REPAIR SHORT
TO GROUND IN
CKT 463
NO
MALFUNCTION IS
INTERMITTENT.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE.
C9792
5E2-192
EBTCM
~M~t~------~1---------585
TCS MOTOR PACK

4 WAY CONNECTOR
LEFT REAR TCS

MOTOR HIGH
584LTl!ILU
DKBLU
C3
LEFT REAR TCS

MOTOR LOW
042091
FT0315E
DTC 144
LEFT TCS CHANNEL WILL NOT MOVE
This DTC is designed to detect a stuck TCS
motor or a seized hydraulic modulator. During
initialization or after a TCS cycle, the EBTCM
commands the TCS motor in the reverse direction and
the forward direction to ensure that the motor moves
properly. If the TCS motor does not move, improper
current feedback will be detected by the EBTCM, and
a DTC will set.
2. V~rifies that the TCS motor can actually apply

when commanded.
feedback current.
4. Checks for a short circuit between the TCS motor
"HIGH" and TCS motor "LOW" circuits.
5. Checks for a TCS motor that is internally shorted.
6. Determines if the. malfunction is caused by a
defective EBTCM or poor terminal contact.
DTC Will Set When:
Diagnostic Aids:
DTC 144 can be set during initialization or after

a TCS cycle. If the EBTCM detects a condition in
which it cannot move the motor in either direction, a
malfunction exists.

binds, or slips.
checked by using the enhanced diagnostic .function of
this section.
Any. circuitry that is suspected of causing the
the wiring harness.
Action Taken:
The amber TCS warning and the red BRAKE warning

1. Checks for proper TCS motor movement during

OTC 144
RAISE VEHICLE.
1,GNlnON TO "RUN." ENGINE ''OFF."
USING TECH 1 MISC. TEST, SELECT MANUAL CONTROL FUNCTION.
FOOT OFF BRAKE PEDAL.
SELECT LEFT REAR TCS MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR.
DOES THE LEFT REAR WHEEL ROTATE?
NO
YES
LEFT TCS CHANNEL

Will NOT MOVE

SELECT LEFT REAR TCS MOTOR APPLY FUNCTION AND APP.LY THE MOTOR;
DOES THE LEFT REAR WHEEL ROTATE?
YES
NO
FACING PAGE.

SELECT LEFT REAR TCS MOTOR RELEASE FUNCTION AND RELEASE THE TCS MOTOR WHILE
CAREFULLY OBSERVING THE COMMANDED CURRENT AND THE FEEDBACK CURRENT ON THE TECH 1.
WAS FEEDBACK CURRENT HIGHER THAN THE COMMANDED CURRENT?
I
I
YES
NO

IGNITION "OFF."
DISCONNECT THE BLACK BWAY EBTCM CONNECTOR
AND THE 4-WAY TCS MOTOR PACK CONNECTOR.
TERMINAL "H" AND TERMINAL "G" OF THE BLACK BWAY
..
YES
NO.
REPAIR SHORT
BETWEEN CKT 564
AND CKT 565.
.
. I
. I
NO
YES

16 km/h (10 MPH).
REPLACE TCS HYDRAULIC MODULATOR/MOTOR

PACK ASSEMBLY.
YES
REPLACE EBTCM.
. I
REPLACE TCS HYDRAULIC MODULATOR/MOTOR

PACK ASSEMBLY.

RESISTANCE BETWEEN TERMINAL "A"
AND TERMINAL "B" OF THE TCS MOTOR
PACK CONNECTOR.
. I
NO
MALFUNCTION IS INTERMITTENT. INSPECT ALL CONNECTORS FOR

CONTAMINATION AND POOR CONTACT. REPLACE ANY TERMINALS THAT
EXHIBIT POOR TERMINAL CONTACT OR EVIDENCE OF CORROSION.
C7955
EBTCM
RIGHT Al!AA TCS

MOTOR HIGH
04-20-95
FT03215E
OTC 145
RIGHT TCS CHANNEL WILL NOT MOVE
This DTC is designed to detect a stuck TCS
motor or a seized hydraulic modulator. During
initialization or after a TCS event, the EBTCM
commands the TCS motor in the reverse direction and
the forward direction to ensure that the motor moves
properly. If the TCS motor does not move, improper
a DTC will set.
OTC
wm
Set When:
DTC 145 can be set during initialization or after

a TCS cycle. If the EBTCM detects a condition in
which it cannot move the motor in either direction, a
malfunction exists.
Action Taken:
The amber TCS warning and the red BRAKE warning

1. Checks for proper TCS motor movement during
2. Verifies that the TCS motor can actually apply

when commanded.
feedback current.
4. Checks for short circuit between TCS motor
"HIGH" and TCS motor "LOW" circuits.
6. Determines if the malfunction is caused by a
defective EBTCMor poor terminal contact..
Diagnostic Aids:
binds, or slips.
this section.
the wiring harness.

DTC 145
RIGHT TCS CHANN El
Will NOT MOVE
RAISE VEHICLE.
SELECT RIGHT REAR TCS MOTOR RELEASE FUNCTION AND
RELEASE THE MOTOR.
DOES THE RIGHT REAR WHEEL ROTATE?
..
NO
YES
5E2-195

SELECT RIGHT REAR TCS MOTOR APPLY FUNCTION AND APPLY THE MOTOR.
DOES THE RIGHT REAR WHEEL ROTATE?
YES
NO
REFER TO "DIAGNOSISTIC AIDS" ON FACING PAGE.

SELECT RIGHT REAR TCS MOTOR RELEASE FUNCTION AND RELEASE THE TCS MOTOR WHILE
CAREFULLY OBSERVING THE COMMANDED CURRENT AND THE FEEDBACK CURRENT ON THE TECH 1.
WAS FEEDBACK CURRENT HIGHER THAN THE COMMANDED CURRENT?
. I
NO
YES

IGNITION "OFF."
DISCONNECT THE BLACK 8-WAY EBTCM CONNECTOR AND THE 4-WAY
TCS MOTOR PACK CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "F" AND
TERMINAL "E" OF THE BLACK 8-WAY EBTCM HARNESS CONNECTOR.
REPLACE TCS HYDRAULIC

MODULATOR/MOTOR PACK
ASSEMBLY.
I
I
YES
NO

"C" AND TERMINAL "D" OF THE TCS MOTOR PACK CONNECTOR.
IS RESISTANCE BETWEEN 0.2 AND 1.5 fl?
YES
NO
YES
REPLACE EBTCM.

ASSEMBLY.


CKT 566 AND 567.
NO
MALFUNCTION IS INTERMITTENT. INSPECT ALL

CONNECTORS FOR CONTAMINATION AND
POOR CONTACT. REPLACE ANY TERMINALS
THAT EXHIBIT POOR TERMINAL CONTACT OR
C7956
5E2-196

EBTCM
REFER TO
SECTION 8A44
:i------~
P100
..----@--m GR
s---1933 R E D - - s : - o - - - - ~ . . . .
------
I
ABS/TCS
RELAY
TCS ADJUSTER
ASSEMBLY
MOTOR LOW
A +--M---.- B
-
ADJUSTER
ASSEMBLY
042095
FT0335E
DTC 146
ADJUSTER ASSEMBLY WILL NOT MOVE
This DTC is designed to detect a stalled or

frozen TCS adjuster assembly motor. During
initialization, the adjuster assembly motor is
commanded through a test sequence to determine if it
can be moved for proper TCS operation. If the
adjuster assembly motor cannot be moved, improper
a DTC will set.

the .diagnostic chart.
1. Checks to see if DTC's 154, 165 .or 166 are set.
2. Checks for any mechanical binding of the adjuster
assembly, attached cables, and cpmponents to
which the cables are attached, which could cause
excessive load on the adjuster assembly.
3. Checks for initialization with throttle position
between 10% to 60%.
DTC
wm
Set When:
DTC 146 can be set during and after

initialization of the adjuster assembly. If the EBTCM
detects a condition in which it cannot move the
adjuster assembly motor, a malfunction exists. DTC
146 will not set during a TCS event.
Action Taken:
A malfunction DTC is stored, TCS modulator
motors are commanded "HOME", TCS is disabled
Diagnostic Aids:
It may be helpful to disconnect all cables from.
the adjuster assembly and move them manually
throughout their entire operating range. Also check the
components to which the cables are attached for
binding.
[I]
lmportt;tnt
After cables are reconnected to the adjuster

assembly, perform "Adjustment Procedure
Adjuster Assembly-Accelerator and Cruise
Control Cables" in this section.
DTC 146
ADJUSTER ASSEMBLY
WILL NOT MOVE
BEFORE BEGINNING 'TESTING, INSPECT ALL ADJUSTER

ASSEMBLY CABLES AND LINKAGES TO WHICH THEY
ATTACH TO ENSURE NO OBVIOUS PROBLEMS THAT
COULD CAUSE BINDING OR STICKING EXIST.
IS OTC 154, 165, OR 166 SET?
IGNITION "OFF."
HAVE ASSISTANT DEPRESS ACCELERATOR PEDAL SMOOTHLY AND
FULLY TO WIDE OPEN THROTTLE (WOT), THEN SLOWLY RETURN TO
IDLE POSITION WHILE INSPECTING CABLES AND LINKAGES TO
WHICH THEY ARE ATTACHED FOR SMOOTH OPERATION.
DO ALL CABLES AND LINKAGES MOVE SMOOTHLY AND EVENLY
WITH NO BINDING?
REPAIR OTC 154, 165 OR 166.
REPAIR LINKAGES AND/OR REPLACE

CABLES, AND/OR REPAIR OR
REPLACE COMPONENTS AS NEEDED
TO RESTORE SMOOTH OPERATION.
CLEAR DTC(s), WAIT 15 SECONDS, IGNITION "OFF."

CONNECT TECH 1 WITH MASS STORAGE CARTRIDGE.
START ENGINE.
SELECT TECH 1 DATA LIST AND MONITOR THROTTLE POSITION.
APPLY BRAKES.
DEPRESS AND HOLD ACCELERATOR PEDAL AT A THROTTLE ANGLE
BETWEEN 10% AND 60% FOR NO LESS THAN FOUR SECONDS, THEN
RELEASE.
DOES OTC 146 RESET?
IMPORTANT: AFTER CABLES ARE

REATTACHED TO THE ADJUSTER
ASSEMBLY OR COMPONENTS, OR
AFTER CABLES ARE REPLACED,
PERFORM "ADJUSTMENT
PROCEDURE ADJUSTER ASSEMBLY
THROTTLE AND CRUISE CONTROL
CABLES," IN THIS SECTION.
YES
REPLACE ADJUSTER ASSEMBLY.
NO TROUBLE FOUND, SEE

FACING PAGE.
C8064
EBTCM
. :
0
TCS I\IJOTO
LEFT REAR
M.
TCS MOTOR PACK

4 WAY CONNECTOR
-------,
LEFT REAR TCS

MOTOR HIGH
SMLTILU
t-------- 565 DK
BLU
C3
LEFT REAR TCS

MOTOR LOW
04-20-15
FT0315E
DTC 147
LEFT TCS MOTOR FREE SPINS
sequence, the piston should reach the bottom of the
bore resulting in a. stalled TCS motor. If this does not
occur, the TCS motor must be spinning with little or
malfunction.
DTC Will Set When:

Action Taken:
The amber TCS warning and red BRAKE warning
lainps are turned "ON."

DTC is also set.
2. Verifies that the TCS motor was released as
commanded by observing feedback current.
3. Verifies that the TCS motor can be applied as

4. Verifies that the TCS motor can be released by
observing wheel movement.
5. Checks for an open in the TCS motor "HIGH"
circuitry.
6. Checks for an open in the TCS motor "LOW"
circuitry.
7. Checks for a TCS. motor that is internally shorted.
contact.
Diagnostic Aids:
binds, or slips.
enhanced diagnostics shows this DTC occurs dwing
ABS, refer to DTC 56. DTC 86 is always set with
DTC 147.
may be necessary.

0 ..
NO
OTC 147
LEFT TCS MOTOR
FREE SPINS
YES

SELECT LEFT REAR TCS MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR WHILE
CAREFULLY OBSERVING THE COMMAND CURRENT AND FEEDBACK CURRENT ON THE TECH 1.
WERE BOTH COMMAND AND FEEDBACK CURRENT APPROXIMATELY 10 AMPS?
..
YES
PROCEED TO
DTC 156
CHART FIRST.
RAISE DRIVE WHEELS AND SUPPORT VEHICLE.

SELECT LEFT REAR TCS MOTOR, APPLY FUNCTION AND APPLY THE MOTOR.
DOES THE LEFT REAR WHEEL LOCK, AND WERE BOTH COMMAND
AND FEEDBACK CURRENTS APPROXIMATELY 8 AMPS?
YES
..
YES
..
.
. I
MALFUNCTION IS
INTERMITTENT.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE.
REPAIR OPEN OR
HIGH RESISTANCE
IN CKT 564
.
. I
NO
REPAIR OPEN OR
HIGH RESISTANCE
IN CKT 565.
.
. I
NO
INSPECT ALL CONNECTORS AND TERMINALS FOR POOR TERMINAL CONTACT AND EVIDENCE
OF CORROSIQN. REFER TO SECTION 8A4 "CHECKING TERMINAL CONTACT." REPLACE ALL
TERMINALS THAT EXHIBIT SIGNS OF POOR TERMINAL CONTACT OR CORROSION.
DOE$ OTC 147 SET IN THE LAST THREE DRIVE CYCLES?
YES
REPLACE EBTCM.
NO
.
. I
GO TO STEP 5.
.
. I

TERMINAL "B" OF THE TCS MOTOR PACK CONNECTOR.
IS RESISTANCE LESS THAN 1.5 OHMS?
YES
YES
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "B" OF THE 4-WAY TCS MOTOR PACK
HARNESS CONNECTOR AND TERMINAL "G" OF THE BLACK 8-WAY EBTCM HARNESS CONNECTOR.
YES
IGNITION "OFF."
DISCONNECT 4-WAY TCS MOTOR PACK CONNECTOR AND BLACK 8-WAY EBTCM CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "A" OF THE 4-WAY TCS MOTOR PACK
HARNESS CONNECTOR AND TERMINAL "H" OF THE BLACK 8-WAY EBTCM HARNESS CONNECTOR.
.I
NO
SELECT LEFT REAR TCS MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR.
CAN THE LEFT REAR WHEEL SPIN FREELY?
NO
NO
REPLACE TCS
HYDRAULIC
MODULATOR/
MOTOR PACK
ASSEMBLY.
MALFUNCTION WAS MOST LIKELY CAUSED BY A POOR

CONNECTION. REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE.
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN IGNITION "OFF". C
7957
5E2-200
EBTCM
RIGHT REAR TCS

MOTOR HIGH
042095
FT0325E
DTC 148
RIGHT TCS MOTOR FREE SPINS
sequence, the piston should reach the bottom of the
bore resulting in a stalled TCS motor. If this does not
occur, the TCS motor must be spinning with little or
malfunction.
DTC Will Set When:

Action Taken:
The amber TCS warning and red BRAKE warning

DTC is also set.
2. Verifies that the TCS motor was released as
3. Verifies that the TCS motor can be applied as

4. Verifies that the TCS motor .can be released by
observing wheel movement.
circuitry.
circuitry.
contact.
Diagnostic Aids:
binds, or slips.
ABS, refer to DTC 61. DTC 86 is always set with
OTC 148.
may be necessary.
DTC 148

RIGHT TCS MOTOR

FREE SPINS
NO
YES

SELECT RIGHT REAR TCS MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR WHILE
CAREFULLY OBSERVING THE COMMAND CURRENT AND FEEDBACK CURRENT ON THE TECH 1.
WERE BOTH COMMAND AND FEEDBACK CURRENT APPROXIMATELY 10 AMPS?
..
YES
5E2-201
PROCEED TO
OTC 161
CHART FIRST.
RAISE DRIVE WHEELS AND SUPPORT VEHICLE.

SELECT RIGHT REAR TCS MOTOR, APPLY FUNCTION AND APPLY THE MOTOR.
DOES THE RIGHT REAR WHEEL LOCK, AND WERE BOTH COMMAND
AND FEEDBACK CURRENTS APPROXIMATELY 8 AMPS?
YES
SELECT RIGHT REAR TCS MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR.
CAN THE RIGHT REAR WHEEL SPIN FREELY?
..
. I
NO
YES
GO TO STEP 5.
.
. I
YES
IGNITION "OFF."
DISCONNECT 4-WAY TCS MOTOR PACK CONNECTOR AND BLACK 8-WAY EBTCM CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "C" OF THE 4-WAY TCS MOTOR PACK
HARNESS CONNECTOR AND TERMINAL "F" OF THE BLACK 8-WAY EBTCM HARNESS CONNECTOR.
I.
NO
MALFUNCTION IS
INTERMITIENT.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE.
NO
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "D" OF THE 4-WAY TCS MOTOR PACK
HARNESS CONNECTOR AND TERMINAL "E" OF THE BLACK 8-WAY EBTCM HARNESS CONNECTOR.
REPAIR OPEN OR
HIGH RESISTANCE
IN CKT 566
..
YES
NO

TERMINAL "D" OF THE TCS MOTOR PACK CONNECTOR.
..
YES
. I
REPLACE TCS
HYDRAULIC
MODULATOR/
MOTOR PACK
ASSEMBLY.
I . I
NO
YES
REPLACE EBTCM.
REPAIR OPEN OR
HIGH RESISTANCE
IN CKT 567
NO
INSPECT ALL CONNECTORS AND TERMINALS FOR POOR TERMINAL CONTACT AND EVIDENCE
OF CORROSIO.N. REFER TO SECTION BA-4 "CHECKING TERMINAL CONTACT." REPLACE ALL
TERMINALS THAT EXHIBIT SIGNS OF POOR TERMINAL CONTACT OR CORROSION.
MALFUNCTION WAS MOST LIKELY CAUSED BY A POOR

CONNECTION. REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE.
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN IGNITION "OFF". C
7959
5E2-202

EBTCM
REFER TO
SECTION 8A44
~------~
(
P100
s - 1 8 3 3 RED--e,----------,
.ABS/TCS.
S180.
- - - - 0 0 - - - 5 8 1 GRY
TCS ADJUSTER
ASSEMBLY
MOTOR LOW
A+-----.- B
RELAY
..
ADJUSTER
ASSEMBLY
0420S5
FT0335E
DTC 154
ADJUSTER ASSEMBLY MALFUNCTION
This DTC is designed to detect malfunctions of
th~ adjuster assembly that can not be detected by the
adJuster assembly electrical tests or the initialization
movement test, it is necessary to monitor the
performance of the adjuster assembly during a TCS
event. The TPS monitors the a~tual position of the
adjuster assembly while the EBTCM commands a
target position. A malfunction exists is the difference
between the two positions becomes larger then a
calibration value indicative of a non-responding
adjuster assembly.
DTC Will Set When:

An adjuster assembly malfunction DTC sets
(during a TCS event and initialization) if the adjuster
assembly motor position error becomes larger than a
calibration value indicating a non-responding adjuster
assembly motor. The adjuster assembly malfunction
DTC also sets if there is excessive motor load present.
Action Taken:

1. Checks to see if DTC 146 set.
2. Checks for any mechanical binding. of the adjuster

assembly, attached cables, and components to
which the cables are attached, which could cause
excessive load on the adjuster assembly.
3. Since DTC 154 only sets during an TCS event,
this check raises the vehicle on a hoist such that
the rear wheels will spin while the fronts do not,
inducing the system into. attempting TCS control.
This step ensures the throttle angle must be
greater than 10% and less than 60%, and the
system must attempt TCS control for greater than
3 sec~n~s to ensure that the DTC setting throttle
and tlllllllg parameters are met when checking for
a DTC 154.
Diagnostic Aids:
It may be helpful to disconnect all cables from
the adjuster assembly and move them manually
throughout their entire operating range. Also check the
components to which the cables are attached for
binding.
rn
Important
After cables are reconnected to the adjuster

assembly, perform "Adjustment
Procedure-Adjuster Assembly-Accelerator and
Cruise Control Cables" in this section.
DTC 154
ADJUSTER ASSEMBLY
MALFUNCTION
BEFORE BEGINNING TESTING, INSPECT ALL ADJUSTER

ASSEMBLY CABLES AND LINKAGES TO WHICH THEY
ATTACH TO ENSURE NO OBVIOUS PROBLEMS THAT
COULD CAUSE BINDING OR STICKING EXIST.
IS DTC 146 SET?
I
I
NO
YES
IGNITION "OFF."
HAVE ASSISTANT DEPRESS ACCELERATOR PEDAL SMOOTHLY AND
FULLY TO WIDE OPEN THROTTLE (WOT), THEN SLOWLY RETURN TO
IDLE POSITION WHILE INSPECTING CABLES AND LINKAGES TO
WHICH THEY ARE ATTACHED FOR SMOOTH OPERATION.
DO ALL CABLES AND LINKAGES MOVE SMOOTHLY AND EVENLY
WITH NO BINDING?
I
I
YES
I
PRO,CEED TO DTC 146 DIAGNOSTIC CHART.
NO
I
CLEAR DTC(s), WAIT 15 SECONDS, IGNITION "OFF."

CONNECT TECH 1 WITH MASS STORAGE CARTRIDGE.
START ENGINE.
SELECT TECH 1 DATA LIST AND MONITOR THROTTLE POSITION.
APPLY BRAKES.
PUT VEHICLE IN GEAR.
RELEASE BRAKES (AND CLUTCH, IF MANUAL TRANS).
DEPRESS AND HOLD ACCELERATOR PEDAL AT A THROTTLE ANGLE
BETWEEN 15% AND 45% FOR NO LESS THAN FOUR SECONDS, THEN
RELEASE.
DOES DTC 154 RESET?
REPAIR LINKAGES AND/OR REPLACE

CABLES, AND/OR REPAIR OR REPLACE
COMPONENTS AS NEEDED TO RESTORE
SMOOTH OPERATION.
IMPORTANT: AFTER CAB.LES ARE

REATTACHED TO THE ADJUSTER
ASSEMBLY OR COMPONENTS, OR AFTER
CABLES ARE REPLACED, PERFORM
"ADJUSTMENT PROCEDURE ADJUSTER
ASSEMBLY THROTTLE AND CRUISE
CONTROL CABLES," IN THIS SECTION.
IF A NEW TP SENSOR OR THROTTLE
BODY IS INSTALLED, BE SURE TO
PERFORM "TP SENSOR LEARN
PROCEDURE" IN THIS SECTION.
YES
NO
REPLACE ADJUSTER ASSEMBLY.
NO TROUBLE FOUND, SEE

FACING PAGE.
C8065
5E2204
04-20-915
FT0245E
DTC 155
EBTCM MALFUNCTION (TCS)
This DTC identifies an internal malfunction
detected by the EBTCM TCS interface custom
integrated circuit.
Action Taken:
turned "ON." The red BRAKE warning lamp is
turned "ON" if the TCS was active at the time of the
malfunction.

5E2-205
OTC 155
EBTCM MALFUNCTION

IS OTC 155 SET AS A CURRENT CODE?

TEST DRIVE VEHICLE FOR THREE (3)
DRIVE CYCLES. A DRIVE CYCLE
CONSISTS OF STARTING THE
VEHICLE, DRIVING VEHICLE OVER 16
km/h (10 MPH), THEN KEY "OFF."
DOES OTC 155 RESET?
MALFUNCTION IS
INTERMITTENT.
REPLACE EBTCM.
MALFUNCTION IS
INTERMITTENT.
THEN IGNITION OFF.
C8066
5E2-206
EBTCM
~M~~~~~~~--a:1---~~~~~~-~::~
LEFT REAR TCS

MOTOR HIGH
TCS MOTOR PACK

4 WAY CONNECTOR
C3
Ll!FT Rl!AFI TCS

MOTOR LOW
042095
FT0315E
DTC 156
LEFT TCS MOTOR CIRCUIT OPEN
This DTC identifies a TCS motor that cannot be
energized due to an open in its circuitry. This
malfunction will not allow proper TCS operation.
DTC Will Set When:
DTC 156 can be set only when the TCS motor
is commanded "OFF." If the EBTCM detects an out
of range voltage on either of the left TCS motor
exists.
Action Taken:
An open motor will not activate when requested.
A malfunction DTC is stored, TCS is disabled and the
amber TCS warning lamp is turned "ON." The other
TCS motor is commanded to its home position. The
red "Brake" warning lamp will be turned "ON" if the
malfunctioning TCS motor was not rehomed at the
end of the last drive cycle.
1. Checks for proper resistance of the TCS motor.

circuitry.
circuitry.
,
contact.
Diagnostic Aids:
this section.
the wiring harness.
5E2-207
DTC 156
LEFT TCS MOTOR CIRCUIT OPEN
NO
I
YES
I
IGNITION "OFF."
DISCONNECT 4-WAY TCS MOTOR PACK CONNECTOR.
USING J 39200, MEASURE RESISTANCE ACROSS TCS
I
I
YES
I

ON FACING PAGE.
NO
I
DISCONNECT BLACK BWAY CONNECTOR AT EBTCM.

USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "H" OF
THE BLACK BWAY EBTCM HARNESS CONNECTOR AND TERMINAL "A"
OF THE 4-WAY TCS MOTOR PACK HARNESS CONNECTOR.

ASSEMBLY.
YES
I
NO
I
USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "G" OF

THE BLACK 8-WAY EBTCM HARNESS CONNECTOR AND TERMINAL "B"
OF THE 4WAY TCS MOTOR PACK HARNESS CONNECTOR
. IS RESISTANCE 2 OHMS OR LESS?
I
I
YES
I
REPAIR OPEN OR HIGH

NO
I
INSPECT THE 4WAY TCS MOTOR PACK AND BLACK BWAV EBTCM
CONNECTORS FOR POOR TERMINAL CONTACT AND EVIDENCE OF
CORROSION. REFER TO SECTION BA-4, "CHECKING TERMINAL
CONTACT." REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF
16 km/h (10 MPH).
REPAIR OPEN OR HIGH

I
I
YES
I
REPLACE EBTCM.
NO

FACING PAGE.
C7961
5E2-208
EBTCM
t~
TCS MOTO
LEFT REAR
TCS MOTOR PACK
4 WAY CONNECTOR
---------
LEFT REAR TCS

MOTOR HIGH
584LTBLU
t-------- 585 DK BLU

C3
LEFT REAR TCS

MOTOR LOW
042095
FT0315E
DTC 157
LEFT TCS MOTOR CIRCUIT SHORTED TO GROUND
This DTC identifies an TCS motor circuit that is
TCS motor to be controlled at the commanded current
rate or will cause the driver circuit to allow current
directly to ground.
DTC
wm
Set When:

TCS motor circuits indicating a circuit shorted to
Action Taken:
The amber TCS warning lamp is turned "ON." The
red "Brake" warning lamp will be turned "ON" ifthe
the TCS motors were not at "Home" at the time of
the malfunction.

1. Checks for a short to ground in the TCS motor
"HIGH" circuitry.

"LOW" circuitry.
3. Checks for an TCS motor that is internally
shorted to ground.
damage of .the circuitry.
Diagnostic .Aids:
wires of the. affected channel and check if the DTC
malfunction .in the motor circuitry or connections.
this section.
, Any circuitry that is suspected of causing the
the wiring harness.
DTC 157
LEFT TCS MOTOR CIRCUIT
SHORTED TO GROUND

I
NO
I
YES
I
IGNITION "OFF."
DISCONNECT THE 4WAY TCS MOTOR PACK CONNECTOR
AND THE BLACK B~WAY EBTCM CONNECTOR.
GROUND AND TERMINAL "A" OF THE 4-WAV TCS MOTOR

ON FACING PAGE.
YES
NO
I

GROUND AND TERMINAL "B" OF THE 4-WAV TCS MOTOR
REPAIR SHORT TO
GROUND IN CKT 564.
I
I
YES
NO

TERMINAL "A" OF THE TCS MOTOR PACK CONNECTOR.
YES
REPAIR SHORT TO
GROUND IN CKT 565.
..
NO

DAMAGE WHICH MAY RESULT IN A SHORT TO GROUND WITH ALL
16 km/h (1 O MPH).

ASSEMBLY.
I
I
YES
I
REPLACE EBTCM.
NO

FACING PAGE.
C7962
5E2210
EBTCM
LEFT REAR TCS

MOTOR HIGH
564LTBLU
~ M ~ - - - - - - - , ~ - - - - - - - - - - - 5 6 5 DK BLU
TCS MOTOR PACK
4 WAY CONNECTOR
C3
LEFT REAR TCS

MOTOR LOW
042095
FT031&E
OTC 158
LEFT TCS MOTOR CIRCUIT SHORTED TO BAlTERY
This DTC identifies a TCS motor circuit that is
shorted to battery or a TCS motor that has low or no
resistance. This malfunction will not allow the TCS
or will cause the TCS motor to turn in the opposite
DTC
wm
Set When:

of range voltage on either of the left TCS motor
circuits indicating a circuit shorted to battery or a TCS
motor shorted, a malfunction exists.
Action Taken:
the malfunction.

1. Checks for a short to voltage in the TCS motor
"HIGH" circuitry.

"LOW" circuitry.
Diagnostic Aids:
this section.
the wiring harness.
DTC 158
NOTICE: J 39200 TEST LEADS MUST BE

"ZEROED" PRIOR TO MAKING ANY
I
LEFT TCS MOTOR CIRCUIT

SHORTED TO BATTERY
I
a
NO
I
YES
R
IGNITION "OFF."
DISCONNECT THE 4-WAY TCS MOTOR PACK CONNECTOR AND THE
BLACK 8WAY EBTCM CONNECTOR.
IGNITION TO "RUN."
TERMINAL "A" OF THE 4-WAY TCS MOTOR PACK HARNESS CONNECTOR.
I
B
YES
I
NO
I

DAMAGE WHICH MAY RESULT IN A SHORT TO VOLTAGE WITH ALL
16 km/h (10 MPH).
I
B

CKTs 564 AND 565.
YES
REPAIR SHORT TO
VOLTAGE IN CKT 565.
NO
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "A"

AND TERMINAL "B" OF THE TCS MOTOR PACK CONNECTOR.
YES
B
g
REPAIR SHORT TO
VOLTAGE IN CKT 564.
NO
IGNITION "OFF."
TERMINAL "B" OF THE 4-WAY TCS MOTOR PACK HARNESS CONNECTOR.
YES
B
I

ON FACING PAGE.
NO

TERMINAL "B" OF THE 4-WAY TCS MOTOR PACK HARNESS CONNECTOR.
YES
5E2211

ASSEMBLY.
REPLACE EBTCM.
NO

FACING PAGE.
C7963
5E2212
EBTCM
~~s"~~:~R~----------I. ______ ::::::: __~ :=~:

D
C3
MOTOR LOW
TCS MOTOR PACK

4 WAY CONNECTOR
04-20-95
FT0325E
RIGHT
res
DTC 161
MOTOR CIRCUIT OPEN
This DTC identifies a TCS motor that cannot be
energized due to an open in its circuitry. This
malfunction will not allow proper TCS operation.
DTC Will Set When:

of range voltage on either of the right TCS motor
exists.
Action Taken:
An open motor will not activate when requested.
A malfunction DTC is stored, TCS is disabled and the
amber TCS warning lamp is turned "ON." The other
TCS motor is commanded to its home position. The
malfunctioning TCS motor was not rehomed at the
end of the last drive cycle

1. Checks for proper resistance of the TCS motor.

circuitry.
circuitry.
Diagnostic Aids:
this section.
the wiring harness.
DTC 161
RIGHT TCS MOTOR CIRCUIT OPEN
IGNITION "OFF."
DISCONNECT 4WAY TCS MOTOR PACK CONNECTOR.
USING J 39200, MEASURE RESISTANCE ACROSS TCS
REFER TO "DIAGNOSTIC AIDS''

ON FACING PAGE.
DISCONNECT BLACK BWAY CONNECTOR AT EBTCM.

USING J 39200, MEASURE RESIS.TANC:E BETWEEN TERMINAL "F" OF
THE BLACK BWAY EBTCM HARNESS CONNECTOR AND TERMINAL "C"
OF THE 4WAY TCS MOTOR PACK HARNESS CONNECTOR.

ASSEMBLY.
USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "E" OF

THE BLACK BWAY EBTCM HARNESS CONNECTOR AND TERMINAL "D"
OF THE 4WAY TCS MOTOR PACK HARNESS CONNECTOR.
REPAIR OPEN OR HIGH

INSPECT THE 4WAY TCS MOTOR PACK AND BLACK BWAY EBTCM
CONNECTORS FOR POOR TERMINAL CONTACT AND EVIDENCE OF
CORROSION. REFER TO SECTION BA4, uCHECKING TERMINAL
CONTACT." REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF
16 km/h (10 MPH).
.
.
~ REPEAT ABOVE DRIVE CYCLE SEQUENCE TWO MORE TIMES.
REPAIR OPEN OR HIGH

REPLACE EBTCM.
MALFUNCTION WAS. MOST

FACING PAGE.
THAT DTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH),
C7964
5E2-214
EBTCM
~~SH~~~R~
P1:00
:
66 T G
_ _ _ _ _ ___,: ~ - - - - - - S
D-
_ __. F
RN
RIGHT REAR TCS

MOTOR HIGH
567 DK GRN - - E
C3
RIGHT REAR TCS

MOTOR LOW
TCS MOTOR PACK

4 WAY CONNECTOR
04-20-95
FT0325E
DTC 162
RIGHT TCS MOTOR CIRCUIT SHORTED TO GROUND
This OTC identifies a TCS motor circuit that is
TCS motor to be controlled at the commanded current
rate or will cause the TCS motor driver circuit to
.allow current directly to ground.

"LOW" circuitry.
3. Checks for a TCS motor that is internally shorted
to ground.
OTC Will Set When:
Diagnostic Aids:
OTC 162 can be set anytime. If the EBTCM

TCS motor circuits indicating a circuit shorted to

this section.
the wiring harness.
Action Taken:
A malfunction OTC is stored, TCS is disabled.
the malfunction.

"HIGH" circuitry.
DTC 162
RIGHT TCS MOTOR CIRCUIT
SHORTED TO GROUND


I
NO
I
YES
I
IGNITION "OFF."
DISCONNECT 4WAY TCS MOTOR PACK CONNECTOR AND THE BLACK
BWAY EBTCM CONNECTOR.
TERMINAL "C" OF THE 4-WAY TCS MOTOR PACK HARNESS CONNECTOR.

ON FACING PAGE.
YES
NO
USING J 39200, MEASURE RESISTANCE BETWEEN GROUND

AND TERMINAL "D" OF THE 4-WAY TCS MOTOR PACK
HARNESS CONNECTOR.
REPAIR SHORT TO
GROUND IN CKT 566,
YES
NO

GROUND AND TERMINAL "C" OF THE TCS MOTOR PACK.
REPAIR SHORT TO
GROUND IN CKT 567.
I
I
YES
NO

16 .km/h (10 MPH).

ASSEMBLY.
YES
I
REPLACE EBT,CM.
NO

CONNECTION. REFER .TO
FACING PAGE.
C7965
5E2216
EBTCM
RIGHT REAR TCS

MOTOR HIGH
04-20-9&
FT032&E
DTC 163
RIGHT TCS MOTOR CIRCUIT SHORTED TO BATTERY
This DTC identifies a TCS motor circuit that is
shorted to battery or a TCS motor that has low or no
resistance. This malfunction will not allow the TCS
or will cause the TCS motor to tum in the opposite
direction or not at all.

"LOW" circuitry.
3. Checks for short circuit between TCS motor
4. Checks for proper resistance of the 'I'CS motor.
DTC Will Set When:

of range voltage on either of the right TCS motor
circuits indicating a circuit shorted to battery or a TCS
motor shorted, a malfunction exists.
Diagnostic Aids:
the Tech 1,. as described in "Tech 1 Diagnostics" in
this section.
the wiring harness.
Action Taken:
the malfunction.

"HIGH" circuitry.
DTC 163
NOTICE: J
39200 TEST LEADS MUST BE

"ZEROED" PRIOR TO MAKING ANY

I
RIGHT TCS MOTOR CIRCUIT

SHORTED TO BATTERY
NO
I
YES
I
IGNITION "OFF."
DISCONNECT THE 4-WAY TCS MOTOR PACK CONNECTOR AND THE
BLACK 8-WAY EBTCM CONNECTOR.
IGNITION TO "RUN."
TERMINAL "C" OF THE 4-WAY- TCS MOTOR PACK HARNESS CONNECTOR.
I

ON FACING PAGE.
'
YES
5E2;.217
NO
I

TERMINAL "D" OF THE 4-WAY TCS MOTOR PACK HARNESS CONNECTOR.
REPAIR SHORT TO
VOLTAGE IN CKT 566.
.YES
I
NO
I
IGNITION "OFF."
TERMINAL "D" OF THE 4-WAY TCS MOTOR PACK HARNESS CONNECTOR.
REPAIR SHORT TO
VOLTAGE IN CKT 567.
I
I
YES
I
NO
I
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "C"

AND TERMINAL "D" OF THE TCS MOTOR PACK CONNECTOR.

CKTs 566 AND. 567.
YES
I
NO
I

DAMAGE WHICH MAY RESULT IN A SHORT TO VOLTAGE WITH ALL
16 km/h (10 MPH).

ASSEMBLY.
I
I
YES
I
REPLACE EBTCM.
NO
I

FACING PAGE.
C7966
5E2-218
:------~
L.....
EBTCM
REFER TO
SECTION 8A44
(
P100
~ W R E D - - s : - o - - -+__~
M
____
-A
B..-------H'IGRY~
TCS ADJUSTER
ASSEMBLY
MOTOR LOW
ABS/TCS
RELAY
ADJUSTER
042095
FT0335E
ASSEMBLY
DTC 165
ADJUSTER ASSEMBLY MOTOR CIRCUIT SHORTED TO GND
OR OPEN
This DTC identifies a TCS adjuster assembly
motor circuit that is shorted to ground. This
malfunction will not allow the adjuster assembly
or will cause the driver circuit to allow current directly .
to ground.
DTC Will Set When:

detects an out of range voltage on either of the
adjuster assembly circuits indicating a circuit shorted
to ground, a malfunction exists.
Action Taken:
turned "ON."

1. Checks for a short to ground in the adjuster
assembly motor "HIGH" circuitry.
2. Checks for a short to ground in the adjuster

assembly motor "LOW" circuitry.
3. Checks for an adjuster assembly motor that is
internally shorted to .ground.
Diagnostic Aids:
this section.
the wiring harness.
DTC 165
ADJUSTER ASSEMBLY MOTOR
CIRCUIT SHORTED TO GND OR OPEN
IGNITION "OFF."
DISCONNECT THE ADJUSTER ASSEMBLY MOTOR CONNECTOR AND THE
BLACK 8-WAY EBTCM CONNECTOR,
TERMINAL "A" OF THE ADJUSTER ASSEMBLY HARNESS CONNECTOR.
I
I
YES
NO

GROUND AND TERMINAL "B" OF THE ADJUSTER
ASSEMBLY HARNESS CONNECTOR.
REPAIR SHORT TO
GROUND IN CKT 1633.
I
YES
NO
USING J 39200, MEASURE RESISTANCE BETWEEN GROUND

AND TERMINAL "A" OF THE ADJUSTER ASSEMBLY.
REPAIR SHORT TO
GROUND IN CKT 561.
I
YES
I
NO
I

IGNITION "OFF."
16 km/h (10 MPH).
O REPEAT ABOVE.DRIVE CYCLE SEQUENCE TWO MORE TIMES.
REPLACE ADJUSTER
ASSEMBLY MOTOR.
I
I
YES
REPLACE EBTCM.
NO

FACING PAGE.
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN TURNING KEY "OFF."
C8068
------~
EBTCM
REFER TO
SECTION 8A44
(
P100
s-1633 RED--41------.
------
8180
~~
RELAY
.--------5151 GRY
~
----A
B
+
.
TCS ADJUSTER
ASSEMBLY
MOTOR LOW
ADJUSTER
ASSEMBLY
04-2096
FT0335E
DTC 166
ADJUSTER ASSEMBLY MOTOR CIRCUIT SHORTED TO BATT
This DTC identifies an adjuster assembly motor
circuit that is shorted to battery or an adjuster
assembly motor that has low or no resistance. This
malfunction will not allow the adjuster assembly
or will cause the adjuster assembly motor to turn in
the opposite direction, or not at all.
.DTC Will Set When:

DTC 166 cah be set
detects an out of range
adjuster assembly circuits
to battery or an adjuster
malfunction exists.
2. Checks for a short to voltage in the adjuster

assembly motor "LOW" circuitry.
"LOW" motor circuits ..
4. Checks for an adjuster assembly motor that is
internally shorted.
Diagnostic Aids:
at any time. If the EBTCM
voltage on either of the
indicating a circuit shorted
assembly motor shorted, a
Action Taken:

1. Checks for a short to voltage in the adjuster
assembly motor "HIGH" circuitry.

the Tech 1, as described in "Tech ] Diagnostics" in
this section.
the wiring harness.
OTC 166
ADJUSTER ASSEMBLY MOTOR

IGNITION "OFF."
DISCONNECT THE ADJUSTER ASSEMBLY MOTOR CONNECTOR AND THE
BLACK 8-WAY EBTCM CONNECTOR.
IGNITION TO "RUN."
TERMINAL "A" OF THE ADJUSTER ASSEMBLY HARNESS CONNECTOR.

TERMINAL "B" OF THE ADJUSTER ASSEMBLY HARNESS CONNECTOR.
REPAIR SHORT TO
VOLTAGE IN CKT 1633.
IGNITION "OFF."
TERMINAL "A" AND TERMINAL "B" OF THE ADJUSTER
ASSEMBLY HARNESS CONNECTOR.
REPAIR SHORT TO
VOLTAGE IN CKT 561.

TERMINAL "A" AND TERMINAL "B" OF THE ADJUSTER
ASSEMBLY MOTOR.
IS RESISTANCE GREATER THAN 0.50?

CKTs 1633 AND 561.

DAMAGE WHICH MAY RESULT IN A SHORT TO VOLTAGE WITH Al.L
IGNITION "OFF."
16 km/h (10 MPH).
REPLACE ADJUSTER
ASSEMBLY MOTOR.
REPLACE EBTCM.

FACING PAGE.
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN TURNING KEY "OFF."
C8069
5E2-222 .ANTILOCK BRAKE SYSTEM WITH TRACTION CONTROL
DIAGNOSIS/MISC. TEST (F4)

MANUAL CONTROL (FO)
This function can be used to manually control
the ABS VI/TCS motors and solenoids.
ABS Motor Test (Apply/Release)

(forward) or 6 amps released (reverse). After running
be stored in a snapshot buffer. This information can be
reviewed, when instructed to do so by the service
manual, to determine if the motors are operating
properly.
The test below describes how the front motors
will normally operate, the rear motor can be tested in
a similar manner, except there will be only a slight
pedal drop (bump) and rise during the test.
1. Ignition "OFF."
4. Pump brake pedal until firm to deplete vacuum
from power booster.
5. Select manual control.
6. Depress and hold brake pedal.
7. Using the Tech l, "Release" one of the ABS
motors. The brake pedal should move smoothly
toward the floor. As the pedal drops, the feedback
current should momentarily drop to only a few
amps (indicating motor movement) and then
become equal to command current (6 amps). This
piston has reached the bottom of the bore.
8. With the brake pedal still depressed and at the
floor, "Apply" the same ABS motor. The brake
pedal should now smoothly rise back to the top of
its travel. The feedback current should
momentarily drop to a few amps, then quickly
increase to the command current (10 amps). This
piston has reached the top of the bore ("home"
position).
TCS Motor Test (Apply/Release)

(forward) or 10 amps released (reverse). After running
be stored in a snapshot buffer. This information can be
reviewed, when instructed. to do so by the service
manual, to determine if the motors are operating
properly.
1. Ignition "OFF."
3. Ignition to. "RUN," engine "OFF."
are off the ground.
5. Select manual control (FO).
6. Using the Tech 1, "Apply" one of the motors.

The feedback current should momentarily drop to
only a few amps (indicating motor movement),
and then become equal to command current (8
amps). This indicates the motor is no longer
moving since the piston has reached the top of the
bore.
7. With the. specific. motor still applied, have an
assistant try to spin the wheel that has been
applied. The wheel should not move indicating
the motor is applied.
8. With the Tech 1, now "Release" one of the

motors. The feedback current should momentarily
drop to only a few amps (indicating motor
movement) and then become equal to command
current (10 amps). This indicates the motor is no
longer moving since the piston has reached the
bottom of the bore or ("home" position). Now
the wheel should spin freely.
Solenoid Test ("ON/OFF")
Only use this test when no DTCs are stored and

you suspect a leaky ABS solenoid or check valve.
1. Ignition "OFF."
4. Pump brake pedal and deplete vacuum from
power booster.
5. Select manual control (FO).
6. Select left front or right front motor release.
7. "Release" the motor for the channel being tested.
Review the motor command and feedback
currents to be sure .the motor released properly.
Refer to "Motor (Apply/Release)" in this section.
8. Select the solenoid for the same channel as that
being tested.
9. With no brake pedal pressure applied, turn the
solenoid "ON."
10. Depress the brake pedal. It should be very high
and firm.
If the pedal goes nearly to the floor, the
solenoid is leaking or not closing and/ or the
check valve is leaking, proceed to Step 12.
11. With brake pressure still applied, turn the solenoid
"OFF." The brake pedal should move toward the
floor. This verifies normal solenoid. operation.
END OF TEST.
If the pedal does not move toward the floor,
the solenoid is stuck "ON," proceed to
Step 12.
12. Verify that the solenoid connectors are connected
to the proper solenoids, (the right front solenoid is
the one on the rear of the ABS hydraulic
modulator, closest to the brake booster). If the
wiring is incorrect, move the connectors to the
proper solenoid and .repeat this entire test starting
with Step 1.
A. Physically switch the two solenoids.

B. Repeat the entire test starting at Step 1 for the
channel in question.
If the test now works properly, test the other
channel. If the test fails for this channel,
replace the solenoid currently installed in this
channel. Refer to "ABS Hydraulic Modulator
Solenoid" under "On-Vehicle Service" in this
section.
If the test fails for the same channel, the check
valve is leaking. Replace ABS hydraulic
modulator. Refer to "ABS Hydraulic
Modulator" under "Unit Repair" in this
section.
[I]
Important
After performing Step 12, it is necessary to

bleed the brake system. Refer to "Bleeding
Procedure" in this section.
HYDRAULIC CONTROL TEST (F2)
This test is used to verify base brake apply and

ABS release, hold, and apply function.
1. Ignition "OFF."
are off the ground.
4. Ignition to "RUN," engine "OFF," vehicle
transmission in neutral.
5. Select a channel to test; left front, right front, or
rear. When testing the rear brakes, both rear
wheels should rotate or not rotate simultaneously
at various points in the test; this is true because
both rear brake pressures are controlled together.
6. Firmly depress brake pedal. Pedal should remain
high and firm.
7. Have an assistant attempt to rotate the wheel
being tested. If the wheel does not rotate, base
brake apply is working properly.
8. With the brake pedal still depressed, press the =
key ort the Tech 1 to start the test. The Tech 1
will display "Release" on the screen. Your
assistant should be able to rotate the wheel being
tested during the release portion of the test
(approximately 2 seconds long). This verifies ABS
. pressure release. The brake pedal should remain
high and firm. (If the brake pedal moves toward
the floor, verify the solenoid electrical connectors
are connected to the correct solenoids.)
9. The Tech 1 will switch to the "Hold" mode and
display the word "Hold" on the screen along with
an 18 second decrement counter. With the brake
pedal still depressed, have your assistant attempt
to rotate the wheel. The wheel should rotate for
the full 18 seconds of the test. If the wheel does
not rotate for the full 18 seconds it could indicate
that either the check valve or the solenoid may be
leaking. This verifies ABS pressure hold.
10. When the hold portion of the test is complete,
brake pressure will be applied and a slight bump
may be felt in the pedal. This is normal. The
assistant should not be able to rotate the wheel at
this point. This verifies ABS apply.
5E2-223
ABS MOTOR TEST (F4)

Once the motor pack has been separated from
the hydraulic modulator, this test will help determine
if the motor pack is operating properly.
The Tech 1 will rotate the motors in one
direction, then the other.
If any motor does not turn in both directions, the
motor pack is malfunctioning and must be
replaced. The motor pack is not serviceable and
must be replaced as an assembly. Refer to "Motor
Pack" under "Unit Repair" in this section.
If all three ABS motors rotate, try to rotate each
gear on the hydraulic modulator, refer to "No
Gear Movement" in this section.
ABS NO GEAR MOVEMENT

After the ABS motor pack has been removed,
rotate each gear by hand on the ABS hydraulic
modulator (unit with large gears). The front gears
(non-center gears) should be able to be rotated
approximately 12.25 full turns lock to lock. If the gear
does not turn freely or at least 12 turns are not
possible, replace the ABS hydraulic modulator.
The rear gear (center gear) should rotate
approximately 7 .25 turns. If the gear does not turn
freely or at least 7 turns are not possible replace the
'
Refer to "ABS Hydraulic Modulator" under
"Unit Repair" in this section if replacement of the
ABS hydraulic modulator is indicated above.
GEAR TENSION RELIEF (F5)

When the displacement cylinder pistons are in
the "home" position, each motor has prevailing
torque. This torque results in "gear tension," or force
on each gear that makes motor pack separation
difficult. To avoid injury, or damage to the gears, the
"Gear Tension Relief Function" briefly reverses each
motor to eliminate the prevailing torque.
Always, perform the "Gear Tension Relief
Function" prior to removing the ABS hydraulic
modulator/motor pack assembly from the vehicle.
ABS/TCS RELAY TEST (F6)

This test allows the user to turn the relay "ON"
and "OFF" using the "UP" and "DOWN" arrow
keys on the Tech 1. The battery voltage supplied to
the EBTCM through the relay contacts is displayed on
the screen during the test.
When the relay is commanded "ON," the
voltage should be equal to the battery voltage. When
the relay is "OFF," the voltage should drop below
2 volts.
NOTICE: Voltage will not drop to zero when

the relay contacts are open due to capacitors in
the E~TCM. If voltage drops below 2 volts, the
relay 1s operating properly.
5E2-224
VOLTAGE LOAD TEST (F7)

The ABS VI/TCS system can draw significant
amounts of current when operating. This test turns
"ON" many of the system components to load-test the
vehicle's electrical system.
If low voltage malfunctions or intermittent
ABS/TCS operations are occurring, this test will allow
you to monitor the ignition and switched battery inputs
to the EBTCM. If only one of these two inputs drops
below 10 volts during testing, a high resistance may
be present in that power feed circuit. If both inputs
dJ;op below 10 volts the vehicle's electrical system
needs to be diagnosed. In either case, the Tech 1 will
display that the "Voltage Load Test" failed.
LAMP TEST (F8)

This test allows the user to control the
warning/indicator lamps associated with ABS VI/TCS.
It can be used to check the lamp circuits. The amber
"ABS INOP" lamp and the amber TCS warning lamp
can be turned "ON" or flashed. The red "BRAKE"
warning lamp and the amber "LOW TRAC' lamp can
be turned "ON" and "OFF."
SYSTEM ID (F9)
This feature is used to determine the ABS VI
version and whether the system includes Traction
Control (TCS) system configuration, and to provide
manufacturing information on the EBTCM.
BLEED PREP (F6)

The bleed prep function is initiated by pressing
the (F6) key froni the Tech 1 "Select Mode!' menu.
The bleed prep function must ALWAYS be used prior
to bleeding the brake system. This is a two part
function. The first part of this function will return all
of the hydraulic modulator pistons to their "home"
position. This allows all fluid paths within the
modulators to be open so that the modulators can be
properly bled. The second part of bleed prep cycles
the TCS modulator to move any trapped air that may
be remaining to the top of the TCS modulator so that
it may be removed when bleeding the system is
continued.
[I]
Important
The bleed prep function cannot be performed if

certain current DTCs are present. If current DTCs
are present, the vehicle must be repaired and
DTCs cleared before performing the bleed prep
function.

due to poor braking, DO NOT tap into the
vehicle's .brake system to operate a
trailer brake system.
NOTICE: Always use the correct Fastener in

fasteners that require thread lockers or thread .
fasteners or fastener joint interfaces. Generally,
such coatings adversely affect the fastener
torque and joint clamping force, and may
damage the fastener; When you install fasteners,
help avoid damage to parts and systems.
NOTICE: The use of rubber hoses or parts
other than those specified for the Antilock
Brake System (ABS) may lead to functional
problems requiring replacement of the hydraulic
parts. Replace all components included in repair
kits used to service this system. Lubricate
rubber parts with clean, fresh brake fluid to ease
assembly. Do not use lubricated shop air on
brake parts as damage to rubber components
may result. If any hydraulic component is
removed or brake line disconnected, it is
necessary to bleed all or part of the brake
system. The fastener tightening specifications
listed are for dry, unlubricated fasteners.

(GM 1052542) or equivalent DOT 3 brake fluid.
The use of DOT 5 (silicone) brake fluid is not
recommended. Reduced braking performance or
durability may result.
NOTICE: A void spilling brake fluid on any of
damage.
CHECKING AND ADDING FLUID
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
following actions:
FLUSHING PROCEDURE
[I]
Important
If evidence of contamination is present in the

vehicle's brake fluid, the entire brake system must
be flushed following one of the procedures
outlined below.
ANTllOCK BRAKE SYSTEM WITH TRACTION CONTROL 5E2-225
)
1 HYDRAULIC MODULATOFI/MOTOFI PACK ASSEMBLY
3 UNDERHOOD ELECTRICAL CENTER
2 LEFT HAND WHEELHOUSE
060195
FS03415E
Figure 14 ABS Hydraulic Modulator/Motor Pack Assembly
After flushing the entire brake system, all rubber

components must be replaced. Components which
must be replaced include: brake hose assemblies,
master cylinder rubber parts, brake caliper and
wheel cylinder boots and seals, combination valve
assembly, ABS hydraulic modulator, TCS
hydraulic modulator and ABS solenoids. Refer to
the proper "On-Vehicle Service" for replacement
procedures.
After all rubber components have been replaced,
the entire brake system must be re-flushed
following one of the procedures outlined below.
Once the second flushing procedure has been
performed, a complete system bleed must be
performed, refer to "Bleeding Procedure" in this
section.
NOTICE: Use only DOT 3 brake fluid from a

clean, sealed container. Do not use any fluid
from a container which is wet with water. Do
not use DOT 5 silicone brake fluid. Improper
brake fluid, mineral oil (from such things as
engine oil, transmission fluid, etc.), or water in
the fluid may cause the brake fluid to boil or
the rubber components to deteriorate. Keep all
fluid containers capped to prevent
contamination.

about the condition of fluid in the system or if
fluid has been used which contains the slightest
trace of mineral oil (from such things as engine
oil, transmission fluid, etc.).
Flushing Preparation
NOTICE: The flushing prep procedure must
be performed prior to using ''Pressure Flush''
or "Manual Flush" procedures.
5E2-226

Pressure Flush
(
NOTICE:
Pressure bleeding equipment can be

used to perform the flush procedure. The
pressure bleeding equipment used for flushing
must be of the diaphragm type. It must have a
rubber diaphragm between the air supply and
the brake fluid to prevent air, moisture, and
other contaminants from entering the hydraulic
system.
~
li-18-94
FS035!1E
!++I
Figure 15 - Gear Removal (Typical)
Clean

!L"'!
Inspect

proper level.
j++j
Install or Connect

~
5-18-94
FS0365E
Figure 16 - Gear Positioning (Typical)
[[] Important
Do Not place your foot on the brake pedal
through this entire procedure unless specifically
directed to do so.
2. Start engine and allow it to run for at least 10
seconds while observing the ABS and TCS
warning lamp.
3. If the ABS or TCS warning lamps turned "ON"
flushing procedure must be stopped and a Tech 1
must be used to diagnose the ABS or TCS
malfunction.
4. If the ABS or TCS warning lamps turned "ON"
for approximately 3 seconds, then turned "OFF"
and stayed "OFF," tum the ignition "OFF."
6. The entire brake system should now be flushed
following either "Pressure Flush" or "Manual
Flush" outlined below.
Adjust
7. Pressure bleeding equipment to 35-70 kPa

(5-10 psi) and wait for approximately 30 seconds
to insure there is no leakage.
8. Pressure bleed equipment to 205-240 kPa
(30-35 psi).
A. 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
flow until clean brake fluid flows or until at
accumulated.
C. Close valve.
D. Repeat above. procedure for the forward
until at least 118 ml (4 ounces) of fluid is
accumulated.
I~!
Tighten
ABS hydraulic modulator bleeder valve to

9 N.m (80 lb. in.).
[I]
Important
Flush sequence:
11. Flush
Right rear.
Left rear.
Right front.
Left front.
wheel brakes in sequence shown above.

flow.
C. Close valve when clean brake fluid begins to
flow or at least 235 ml (8 ounces) of fluid is
accumulated.
12. Repeat Step 11 on left rear wheel brake.
13. Repeat Step 11 on right front wheel brake.
14. Repeat Step 11 on left front wheel brake.
15. Lower vehicle.
16. Remove bleeder adapter.
17. Replace all rubber components listed under
!Ll
Inspect

necessary.
j-t+!
Install or Connect

Manual Flush
rn
Important

and/or shop rags to catch fluid and prevent it from
contacting any painted surfaces.
lHI
A. Attach a clear plastic bleeder hose to rearward

bleeder valve on the ABS hydraulic modulator
and place the other end of hose in a container
to one full tum.
C. Depress brake pedal until fluid begins to flow.
D. Close valve and release brake pedal. Repeat
above steps until clean brake fluid flows or at
accumulated.
E. Repeat above procedure for the forward
at least 118 ml (4 ounces) of brake fluid is
accumulated.
l~i
O
I++!
!L'l'j
!++j
proper level.
Inspect
Install or Connect

[TI
Important
Flush sequence:
- Right rear.
- Left rear.
- Right front.
- Left front.
11. Flush wheel brakes in sequence shown above.

9 N.m (80 lb. in.).

necessary.
Clean
Inspect
Tighten

!L1'1
Install or Connect

6. Flush ABS hydraulic modulator as follows:
l++j
5E2-227
12.
13.
14.
15.

E. Repeat above procedure until clean brake fluid
flows or at least 235 ml (8 ounces) of fluid is
accumulated.
Repeat Step 11 on left rear brake.
Repeat Step 11 on right front brake.
Repeat Step 11 on left front brake.
Lower vehicle.
5E2-228
16. Replace all rubber components listed under

!L!
Inspect

necessary.
!HI
turned "ON" and stay "ON" after about 10

seconds, the bleeding procedure must be stopped
and a Tech 1 must be used to diagnose the ABS
or TCS malfunction.
Do not place your foot on the brake pedal thro1gh
do so.
Pressure Bleeding
Install or Connect

BLEEDING PROCEDURE
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 SUPREME 11
contaminated with water. DOT 5 (silicone)
brake fluid should never be used in the
ABS/TCS bra:ke system. Reduced braking
performance or durability may result.
damage.
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.
[I]
If the amber ABS or TCS warning lamps are
Important
Using a Tech 1, select "F6: Bleed Prep." The

bleed prep function cannot be performed if certain
current DTCs are present. If DTCs are present,
the vehicle must be repaired and DTCs cleared
before performing the bleed prep function.
The entire brake system should now be bled

clean, sealed container. Do not use fluid from
an open container that may be contaminated
with water. Do not use DOT 5 brake fluid.
NOTICE: Pressure bleeding equipment must
be of the diaphragm type. It must have a rubber
diaphragm between the air supply and the brake
fluid to prevent air, moisture and other
contaminants from entering the hydraulic
system.
Clean
l+-+i
!L"'I
Inspect
3. Fluid to be at proper level. Refer to

SECTION 5A. Add clean brake fluid as required.
j++j
Install or Connect

Adjust
6. Pressure bleed equipment to 35-70 kPa (5-10 psi)

and wait for approximately 30 seconds to insure
there is no leakage.
7. Pressure bleed equipment to 205-240 kPa
(30-35 psi).
8. Using Tech 1 select "F6: Bleed Prep" function
and follow the Tech 1 as instructed. After
completion of the bleed prep function, proceed
with Step 9.
fluid.
flow until no air is seen in fluid.

C. Close valve when fluid flows without any air
bubbles.
D. Repeat Steps 9B and 9C until no air bubbles
are present.
E. Relocate the bleeder hose on the forward ABS
Steps 9A through 90.
!.!
Tighten
!~!

on the brake combination valve and check for
.air in escaping fluid.
tube nut.
!.!
Tighten
Brake combination valve tube nut to 18

N.m (13 lb. ft.).
C. Repeat Steps llA and llB for the rearward
brake combination valve pipe connection.
12. Proceed to bleed the ABS hydraulic modulator
on the ABS hydraulic modulator and check for
tube nut.
Tighten
ABS hydraulic modulator tube nut to

32 N.m (24 lb. ft.).
C. Repeat Steps 12A and 12B for the remaining
ABS hydraulic modulator brake pipe
connections, moving from front to rear.
13. Proceed to bleed the TCS hydraulic modulator
on the TCS hydraulic modulator and check for
tube nut.
!~!
Master cylinder tube nut to 32 N.m

(24 lb. ft.).
C. Repeat Steps 1OA and lOB for the rearward
master cylinder brake pipe connection.
11. Proceed to bleed the brake combination valve
5E2-229
Tighten
TCS hydraulic modulator tube nut to

32 N.m (24 lb. ft.).
C. Repeat Steps 13A and 13B for the remaining
TCS hydraulic modulator brake pipe
connections.
15. Proceed as follows to bleed the rear wheel brakes:
B. Slowly. open bleeder valve and allow fluid to
flow.
bubbles.
15C.
16. Remove pressure to the pressure bleeding
equipment.
17. Attach a clear plastic .bleeder hose to the right
front wheel bleeder valve and submerge opposite
hose end in a clean container partially filled with
clean brake fluid .
18. Turn the ignition to "RUN," engine "OFF."
19. Open the bleeder valve and apply the brake until
the red BRAKE warning lamp turns "ON." This
shuttles the brake pressure differential warning
valve.
20. Close bleeder valve.
21. Reapply pressure to pressure bleeding equipment.
22. Turn the ignition "OFF."
[I]
23.
24.
25.
26.
Important
Do not reapply the brakes after closing the

bleeder valve.
Lower vehicle.
Raise vehicle and suitably support.
Repeat the entire Step 1.5.
5E2-230
27. Proceed as follows to bleed the front wheel

brakes:
front wheel bleeder valve and submerge
flow.
any air bubbles. Tap lightly on the caliper to
dislodge any trapped air bubbles.
D. Relocate bleeder hose to the left front wheel
27C.
28. Continuing with the Tech l, press "ENTER" to
initialize the TCS modulator for bleeding. Follow
the Tech 1 as directed.
29. Proceed as follows to bleed the rear wheel brakes
only:
flow.
C. Close valve. when fluid begins to flow without
bubbles.
29C.
rn
Important
This procedure must be followed to insure

all air has been removed from the TCS
30. Lower vehicle.
31. Remove pressure bleeding equipment, including
blee.der adapter J 35589.
!L"'!
Inspect
32. Fluid level in reservoir and fill to proper level if

necessary.
!++!
Install or Connect
lL"'!
Inspect

feel.


ABS hydraulic modulator. "Apply" and
"Release" each TCS motor 2 to 3 times.
When finished be sure to "Release" each
motor on the TCS hydraulic modulator. This
procedure will ensure all trapped air has been
removed from the ABS and TCS hydraulic
modulator bores. Now repeat bleeding
procedure starting at Step 1.
Make several normal (non ABS) stops from a
moderate speed to ensure proper brake syslem
stops.
Manual Bleeding
clean, sealed container. Do not use brake fluid
contaminated with water. Do not use DOT 5
brake fluid.
11]
Important
and/or shop cloths to catch fluid and prevent it

from contacting any painted surfaces.
Clean
!++!
IL'l'I
Inspect

if necessary.
l++i
Install or Connect

5. Using Tech 1, select "F6: Bleed Prep" function
and follow the Tech 1 as instructed. After
completion of the bleed prep function proceed
with Step 6.
6; Prime ABS hydraulic modulator as follows:
A. Attach clear plastic bleeder hose to the
fluid.
to one full turn.

C. Depress brake pedal and hold until fluid
begins to flow.
D. Close valve and release brake pedal.
E. Repeat Steps 6B and 6D until no air bubbles
are present.
F. Relocate the bleeder hose on the forward ABS
Steps 6A through 6E.
[I]
Important
Once fluid is seen to flow from both ABS

hydraulic modulator bleeder valves, the ABS
hydraulic modulator is sufficiently full of fluid.
However, it may not be completely purged of
air. At.this point move to the wheel brakes and
bleed them. This ensures that the lowest points
in the system are completely free of air and
then the ABS hydraulic modulator can be
purged of any remaining air.
!+-+!
!L!
Inspect

if necessary.
j++j
Install or Connect

10. Raise vehicle and suitable support.
rn
Important
Bleed sequence:
- Right rear.
- Left rear.
- Right front.
- Left front
11. Bleed wheel brakes in sequence shown above.
bleeder valve at each wheel and submerge
E. Wait 5 seconds.
F. Repeat Steps llB through 1lE until the brake
pedal feels firm and no air bubbles are
observed in the bleeder hose.
To assist in freeing entrapped air, tap
lightly on caliper or backing plate with a
rubber mallet.
12. Repeat Step 11 on left rear wheel brake.
13. Repeat Step 11 on right front wheel brake.
14. Repeat Step 11 on left front wheel brake.
15. Continuing with the Tech l, press "ENTER" to
initialize the TCS modulator for bleeding. Follow
the Tech 1 as directed.
16. Proceed as follows to bleed the rear wheel brakes

only:
B. Slowly open bleeder valve.
D. Close valve when fluid begins to flow without
bubbles.
E. Relocate bleeder hose to the left rear wheel
16D.
rn
Important
This procedure must be followed to insure all

air has been removed from the TCS hydraulic
modulator.
!++!
!L"'!
Inspect

if necessary.
!++!
Install or Connect

20. Bleed the ABS hydraulic modulator.
fluid.
B. Depress brake pedal with moderate force.
C. Slowly open rearward bleeder valve one half
to one full turn and allow fluid to flow;
E. Wait 5 seconds.
F. Repeat Steps 20B through 20E until the no air
bubbles are observed in the bleeder hose.
G. Relocate the bleeder hose on the forward ABS
Steps 20A through 20F.
!~!' Tighten
9 N.m (80 lb. in.).
!++!
!L"'!
Inspect

if necessary.
5E2-232
!++!
Install or Connect
!L"'!
Inspect
24. With ignition to "RUN" apply brake pedal. with

feel.
initially or after the engine is. started, the
ABS hydraulic modulator. "Apply" and
"Release" each TCS motor 2 to 3 times.
When finished be sure to "Release" each
motor on the TCS hydraulic modulator. This
procedure will ensure all trapped air has been
removed from the ABS and TCS hydraulic
modulator bores. Now repeat bleeding
procedure starting at Step 1.
I]]
Important
Be sure the seal is still attached to the solenoid

when it is removed. If not, check solenoid bore in
modulator.
Do not attempt to disassemble solenoid, it is
serviceable only as an assembly.
Lubricate seal on new solenoid with clean brake
fluid.
!++!
Install or Connect
1. New solenoid.
Verify that the solenoid lip seal is properly
positioned before solenoid is installed in ABS
hydraulic modulator (refer to Figure 16).
Position solenoid so that its electrical
connector will face the same direction as the
solenoid that was removed.
By hand, press down firmly on solenoid until
its flange seats on ABS hydraulic modulator.
2. Torx head bolts.
I~!
Tighten
Bolts to 4.5 N.m (40 lb. in.).
Make several normal (non-ABS) stops from a

moderate speed to ensure proper brake system
stops.
ABS HYDRAULIC MODULATOR BLEEDER

VALVES
Figure 17
!++j
Damaged bleeder valve or valves.
!++!
Install or Connect
New bleeder valve or valves.
!~!
Tighten
Bleeder valve to 9 N.m (80 lb. in.).
ABS HYDRAULIC MODULATOR SOLENOID

Figure 18
j++!
1. Solenoid electrical connector.

2. Torx head bolts.
3. Solenoid.
1 REARWARD BLEEDER VALVE

2 FORWARD BLEEDER VALVE
(
S-1994
F8037SE
Fi,gure 17 - ABS Hydraulic Modulator Bleeder Locations
1 SOLENOID UP SEAL
2 SOLENOID
5E2-233
3 TORX HEAD BOLT

4 HYDRAULIC MODULATOR/MOTOR
PACK ASSEMBLY
511MM
FS0385E
Figure 18 Hydraulic Modulator Solenoid Removal
3. Solenoid electrical connector to solenoid.
[I)
Important
Make sure the solenoid connectors are installed on

correct solenoids.
It is necessary to bleed the entire system. Refer to
ABS HYDRAULIC MODULATOR/MOTOR

PACK ASSEMBLY
Figure 14

hydraulic modulator, the gear tension
relief function of the Tech 1 must be
performed prior to the removal of the
j++!
1. Using Tech 1, perform "Gear Tension Relief

Sequence," as outlined in this section.
6. Five brake pipes (two to )llaster cylinder, two to
wheel brakes, one to TCS modulator).
contamination.
7. Bolt attaching front of ABS hydraulic
modulator/motor pack assembly to frame rail.
8. ABS hydraulic modulator/motor pack assembly
from vehicle.
5E2-234
!HI
1. ABS hydraulic modulator/motor pack assembly in

vehicle.
2. Bolt attaching ABS hydraulic modulator/motor
pack assembly to frame rail.
!~!
Tighten

3. Five brake pipes to ABS hydraulic
rn
Install or Connect
[I]
Bleed entire brake system as outlined in

Figure 19
Control modules that appear
j1\cAUTION similar may not operate the

same under all conditions. To
Replace with
Recommended
Port Number
Only
Important
TCS HYDRAULIC MODULATOR/MOTOR

PACK ASSEMBLY
j++!

2. Three brake pipes (one to ABS hydraulic
modulator, two to wheel brakes).
contamination.
3. Bolt attaching front of the TCS hydraulic
modulator/motor pack assembly to mounting
bracket.
4. TCS hydraulic modulator/motor pack assembly
from vehicle.
!++!
help avoid personal injury due

to improper brake operation,
replace this module only with
part specified for this vehicle.
10-25-IM
Tighten
Two brake combination valve tube nuts to 18 N.m

(13 lb. ft.).
Three hydraulic modulator tube nuts to 32 N.m
(24 lb. ft.).
ATl8815E
!++!
!~J
Tighten

3. Three brake pipes to hydra u 1i c
1. Fasteners on lower sound insulator panel under

steering column.
2. Lower sound insulator panel from vehicle.
4. Nut attaching EBTCM bracket to upper I/P.
5. Push in retainer ("Christmas Tree") attaching
EBTCM bracket to sidewall.
[I]
6.
7.
8.
9.
Important
It will be necessary to cut the push in retainer

head off to remove EBTCM bracket. Do not
attempt to pry fastener out as damage to the
EBTCM bracket may result.
EBTCM and EBTCM bracket from mounting
place.
EBTCM electrical connectors.
EBTCM from vehicle.
Remaining portion of push in retainer.
[I]
Install or Connect
1. TCS hydraulic modulator/motor. pack assembly
in vehicle.
2. Bolt attaching the TCS hydraulic
modulator/motor pack assembly to mounting
bracket.
ELECTRONIC BRAKE TRACTION

CONTROL MODULE {EBTCM)
Bleed entire brake system as outlines in

!~!
Important
Important
It is necessary to remove the destroyed retainer

to insure proper retaining force when installing
the new push in retainer.
!++!
Install or Connect
1. EBTCM electrical connectors.

2. EBTCM and EBTCM bracket into mounting
location.
3. New push in retainer ("Christmas Tree")
attaching EBTCM bracket to sidewall.
4. Nut attaching EBTCM bracket to upper I/P.

NOTICE: The adjuster assembly wiring
harness must be routed between the adjuster
assembly motor and the mounting stud and nut.
The cable must not be placed under the motor
in a position that creates stress on the cover
hinge. Make certain the wiring harness is
contained inside the cover and also that it is not
pinched by the flap when closed.
ADJUSTER ASSEMBLY CABLE

ADJUSTMENT PROCEDURE
Adjuster Assembly Replacement
Figures 22, 23, 24
[I]
3
The adjuster assembly cable must always be

adjusted each time the adjuster assembly is
removed and/or replaced to ensure optimum
system performance. See this section for
adjustment procedure.
1 EBTCM AND BRACKET

2 EBTCM HARNESS
3 LEFT HAND KICK PANEL
!++I
4 PUSHIN RETAINER
IS MOUNTING STUD AND NUT
151994
FS0395E
!~!
Figure 19 EBTCM Location
"fighten
Nut to 25.0 N.m (18.5 lb. ft.).

6. Lower sound insulator panel and fasteners.
ADJUSTER ASSEMBLY
Figures 22, 23, 24
!+-+!
1.
2.
3.
4.
5.
6.
1. Adjuster assembly splash cover.

2. Cable cam cover.
3. Throttle body lever shield attaching screw and
shield.
4. Throttle body cable from throttle body lever.
5. Adjuster assembly electrical connector.
6. Nuts attaching adjuster assembly to bracket (2).
7. Cables from adjuster assembly.
8. Adjuster assembly.
l++!
Install or Connect
1. Position adjuster assembly near mounting bracket.
2. Cables on adjuster assembly.
1. Two piece cover from adjuster assembly.

2. Cover from throttle body.
3. Accelerator cable from throttle body.
4. Cables from adjuster assembly (3).
6. Nuts attaching adjuster assembly to bracket (2).
!++!
Important
Install or Connect
Nuts attaching adjuster assembly to bracket (2).
Adjuster assembly electrical connector.
Cables to the adjuster assembly.
Accelerator cable to throttle body.
All covers on throttle body and adjuster assembly.
Perform adjuster assembly procedure.
3. Adjuster assembly to mounting bracket.

4. Adjuster assembly attaching nuts.
!~!
Tighten
Adjuster assembly attaching nuts to 25 N.m

(18 lb. ft.).
6. Throttle body cable to throttle body lever.
Adjust
Adjuster assembly cables. Refer to the

adjustment procedure in this section.
7. Cable cam cover.
9. Throttle body lever shield and attaching screw.
5E2-236
!~I
Tighten
Throttle body lever shield and attaching screw

to 2 N.m (18 lb. in.).
11]
Important
Adjuster assembly cable locations (Figure 24):

-
Throttle body to adjuster assembly cable on

cam closest to adjuster assembly DC motor.
Accelerator pedal to adjuster assembly
cable on middle cam.
Cruise module to adjuster assembly cable
on cam farthest from adjuster assembly DC
motor.
ADJUSTMENT PROCEDURE - THROTTLE

BODY AND CRUISE CONTROL CABLES
L!FT SID! SHOWN
Figures 25, 26, 27
FIIGHT SID! SIMILAR
Throttle body, accelerator pedal control, and

cruise control cables must be fully installed before
making adjustments.
1 FRONT WHEEL SPEED SENSOR

2 FRONT WHE!L SPEED SENSOR
JUMPER HARNESS
Adjust
3 LOWER CONTROL ARNI
Throttle body cable.

1. Remove throttle body lever cover.
2. Unlock throttle body cable and cruise control
cable adjusters by pulling up locking tabs
(Figure 26).
51994
FS0405E
Figure 20 Front Wheel Bearing and Speed Sensor

Assembly
LHSHOWN
RH SIMILAR
1 FRONT WHEEL SPEED SENSOR JUMPER HARNESS

2 HARNESS ROSEBUD RETAINER (PUSH INTO CRADLE HOLE)
3 HARNESS GROMMET (PUSH INTO GROMMET RETAINER)
4 BRAKE LINE
6 WHEEL
IS CRADLE
Figure 21 - Front Wheel Speed Sensor Jumper Harness
(
51994
fS04151
5E2237
SPLASH COYER
THROTTLE CABLE
ACCELERATOR
CABLE
5-28-114
FS0475E
Figure 22 - Adjuster Assembly Splash Cover
BRACKET (ENGINE)
ADJUSTER ASSEMBLY
ADJUSTER BRACKET
BRACE
SCRl!W
NUT
5-30-94
FS048SE
Figure 23 - Adjuster Assembly - Accelerator and Cruise Control
5E2-238
ANTILOCK BRAKE. SYSTEM WITH TRACTION CONTROL
TO CRUISE CONTROL
OJ
ADJUSTER ASSEMBLY ACCELERATOR AND

CRUISE CONTROL CABLES
TO ACCELERATOR PEDAL
ADJUSTER ASSEMBLY GEAR
II]
TO THROTTLI! BODY
m
m
CAMS
5-30-94
F80495E
DC MOTOR
Figure 24 - Adjuster Assembly Cable Locations
3. Hold thro~tle body lever firmly at stop/idle

position.
4. Pull throttle body cable assembly just rearward
of the adjuster lock to remove slack. from
cable.
[TI
Important
Do not disturb cable after removing slack.

5. Lock throttle body cable adjuster by pushing
tab down.
[TI
Important
The clip that is part of the cruise control

cable assembly that gets attached to the
brake booster should not be installed until
after the adjustment is made.
6. Hold throttle body lever firmly at stop/idle
position.
7. Pull cruise control cable assembly just
rearward of the adjuster lock (between lock
assembly and cruise control module) to
remove slack from cable.
[TI
Important
8. Lock cruise control cable adjuster by pushing

tab down.
9. Check that throttle body lever returns fully to
stop/idle position. If throttle body lever does
not return to stop/idle position repeat
procedure.
10. Install throttle body lever cover and screw.
11. Attach cruise control cable clip to brake
booster.
[I]
Important
Cables should never be adjusted so tight

that tension from cable will not allow
throttle to close solidly. If cable is adjusted
too tight, the cable will prevent engine
from returning to idle and will cause
unstable idle quality.
Using a Tech J with a mass storage
cartridge, check throttle angle. percentage
by depressing the accelerator pedal. When
accelerator pedal is fully depressed, throttle
opening should be 100%. When the
accelerator pedal is released, throttle
opening should return to 0%. If proper
results are not obtained, check cables for
kinks or damage and repeat procedure.

THROTTLE BODY CABLE REPLACEMENT
Figures 25, 26
[II
Install or Connect
1. Throttle body cable to adjuster assembly.

2. Accelerator cable routing clips.
3. Cable to throttle body.
Important
The adjuster assembly adjustment procedure

outlined in this section must be followed each
time the throttle body cable is removed and
replaced to ensure optimum system performance.
!+.,.!
!.,.+!
5E2-239
1. Throttle body cable routing clips.

2. Throttle body lever shield attaching screw and
shield.
3. Cable from throttle body.

5. Adjuster assembly cable cam cover.
6. Cable from adjuster assembly.
Adjust
Accelerator and cruise control cables. Refer to

"Adjustment Procedure - Adjuster Assembly
-Accelerator and Cruise Control Cables" in
this section.
4. Adjuster assembly cable cam cover.
6. Throttle body lever shield and attaching screw at
throttle body.
!~!
Tighten
Throttle body lever shield attaching screw to

2.0 N.m (18 lb. in.).
~FRT
OJ
W
ADJUSTER ASSEMBLY
THROTTLE BODY CABLE ADJUSTER
l}J
[!]
[I]
MASTER CYLINER
ACCELERATOR PEDAL AND CRUISE CONTROL CABLE ASSEMBLY
([I
TO ACCELERATOR PEDAL
DASH PANEL
CRUISE CONTROL CABLE
5-30-94
FSOSOSE
Figure 25 - Adjuster Assembly Cable Routing
5E2-240
ANTl~OCK BRAKE'SYSTEM WITH TRACTION CONTROL

RESET TAB
READJUST
,.POSmON
00
a~
THROTl'I.E BODY AND ACCELERATOR PEDAL CABLE ADJUSTER
ALWAYS MAKE SURE CABLE SHEATH IS AT FULLY EXTENDED POSITION

BEFORE PERFORMING ADJUSTMENT PROCEDURE
. RELEASED
POSfflON
LOCK TAB
READJUST
/.POBmON
CRUISE CONTROL CABL! ADJUSTER

5-28-94
F8051SE
Figure 26 - .Cable Adjustment Mechanisms
ACCELERATOR PEDAL CABLE AND

REPLACEMENT
Figures 25, 26
[I]
Important
The adjuster assembly adjustment procedure

outlined in this section must be followed each
time the accelerator and cruise control cables are
removed and/or replaced to ensure optimum
system performance.
f+-.!
1.
2.
3.
4.
5.
6.
Lower instrument panel trim.

Sound insulator.
Accelerator cable from accelerator pedal assembly.
Adjuster assembly splash cover.
Adjuster assembly cam cover.
Cruise control and accelerator pedal cables from
adjuster assembly.
7. Accelerator cable from dash panel by using a
small flat blade screwdriver. Depress each tang
with the tip of the screwdriver to release.
8. Cruise control cable from cruise control module.
!H!
Install or Connect
1. Accelerator and cruise' control cables to adjuster

assembly.
2. Push accelerator cable tangs into dash panel.
3. Accelerator cable to accelerator pedal.
4. Cruise control cable to cruise control module.
5.
6.
7.
8.
Adjust
Accelerator and cruise control cables. Refer to

"Adjustment Procedure - Adjuster Assembly
Accelerator and Cruise Control Cables" in this
section. ,
Cable cam cover to adjuster assembly.
Adjuster assembly splash cover.
Sound insulator.
Lower instrument panel trim.
ACCELERATOR PEDAL REPLACEMENT

Figure 27
I+-+!
1. Lower instrument panel trim.
2. Sound insulator.
3. Accelerator cable from accelerator pedal.
4. Accelerator pedal attaching nut.
. 5. Accelerator pedal stop attaching bolt and
accelerator pedal stop.
5E2-241
PLATE ACCEL CABLE MTG
RETAINER
CABLE
MOUNTING SURFACE BETWEEN

ACCELERATOR PEDAL SUPPORT &
DASH PANEL MUST BE FREE OF
INSULATION.
CAUTION: CARE MUST BE UTILIZED
IN PRESSING THE RETAINER INTO
HOLE IN LEVER TO ASSURE THE
CABLE IS NOT KINKED OR DAMAGED
IN ANYWAY.
SUPPORT STRG
COLUMN LOWER MTG.
NUT
15-30-IM
F8CIIS38I!
Figure 27 - Accelerator Control - Passenger Compartment
6. Accelyrator pedal.
!++!
rn
Install or Connect
Important
The mounting surface between support and dash

panel must be free of insulation. The carpet and
padding in the pedal and tunnel area must be
positioned to lay flat and be free of wrinkles and
bunches.
1. Accelerator pedal and attaching nut.
2. Accelerator pedal stop and attaching bolt.
!~!
Tighten
Accelerator pedal stoi{\md attaching nut and

bolt to 25 N.m (18 lb. ft.).
3. Accelerator cable on accelerator pedal.
!LI
Inspect
Check for complete throttle opening and

closing positions by operating accelerator
pedal. Also check for poor carpet fit under the
accelerator pedal.
Throttle should operate freely without bind
between full closed and wide open throttle.
4. Sound insulator.
5. Lower instrument panel trim.
FRONT WHEEL BEARING AND SPEED

SENSOR ASSEMBLY
Figure 20
[I]
Important
The front wheel speed sensors and rings are

integral with the hub and bearing assemblies.
Should a speed sensor or ring require
replacement, the entire hub and bearing assembly
must be replaced. Refer to SECTION 3C.
FRONT WHEEL SPEED SENSOR JUMPER

HARNESS
Figure 21
I++!
1.
2.
3.
4.
!++I
Connector from wheel speed sensor.
Harness from retaining clips.
Harness grommets from retainers.
Upper jumper harness connector attached to inside
of frame rail.
Install or Connect
1. Upper jumper harness connector attached to inside

of frame rail.
5E2-242
2. Harness fo retaining clips.

3. Harness rubber grommets into retainers.
WHEEL SPEED
SENSOR, RIGHT REAR
Figure 28
j++!
1. Connector from wheel speed sensor.

3. Sensor from backing plate.
!H!
Install or Connect
RIGHT REAR WHEEL
SPEED SENSOR
CONNECTOR
1. Sensor into backing plate.

!~I
Tighten

5-27-94
REAR WHEEL SPEED SENSOR TOOTHED

RINGS
rn
Important
The rear wheel speed sensor toothed rings are an
integral part of the rear axle shafts. If it has been

determined that the toothed rings must be
replaced, refer to SECTION 4B for removal and
REAR WHEEL SPEED SENSOR JUMPER

HARNESS
!++I
1. Connector. from wheel speed sensors.

2. Jumper harness grommet from retainer.
3. Upper jumper harness connector from rear body
!++j
Install or Connect
1. Upper jumper harness connector to rear body

2. Connector to wheel speed sensors.
3. Jumper harness grommet into retainer.
ABS/TCS RELAY
Figure 29
I++!
1. ABS/TCS relay cover.

2. ABS/TCS relay from connector.
FS04251:
j++I
Figure 28 - Rear Wheel Speed Sensors
Install or Connect
1. ABS/TCS relay to connector.

2. ABS/TCS relay cover.

WARNING/INDICATOR LAMPS
Refer to SECTION 8C for replacement
procedures and detailed information.
ELECTRICAL CONNECTORS
Figure 30
Some ABS VI/TCS components are equipped
with electrical connectors using a Com;i.~s:tor Position
Assurance (CPA) lock. This feature insur~s that when
the connectors are installed they are aligned properly
and connected securely.
[I]
Important
Remove the lock before separating the electrical

connectors.
Take care not to damage the locking pin during
removal.
Make sure that the rubber connector seal is in
place on the connector before and after
connection.
Always install the lock after the connection is
made.
1 UNDEFIHOOD EI..ECTFIICAI.. CENTI:FI

(AIIIS ENABLE !RELAY LOCATED INSIDE)
519-94
FS043SE
Figure 29 - ABSfTCS Relay Location
I..OCKINO PIN
CONNECTOR
CONN!CTOR
LOCKING PIN
sru.~
~
I..OCKINO PIN
~~
CONNECTOR
~
I
CONNECTOR
CONNECTOR
1 CONN!CTOR POSITION ASSURANCE (CPA) TYPICAi.
*NAKI! SURI! SDI.. IS IN PI.ACII! ON CONNl!CTOFI

FS0445E
Figure 30 - ABS VI/TCS Electrical Connectors (Typical)
5E2-244
FUSE AND FUSIBLE LINKS

Refer to SECTION 8A-11 for repair or
replacement information.
UNIT REPAIR
hydraulic modulator/motor pack
assembly, the gear tension relief function
of the Tech 1 must be performed prior to
removal of the ABS hydraulic
NOTICE: The following service procedures

shall be performed only after the ABS hydraulic.
modulator/motor pack assembly has been
removed from the vehicle. Do not perform these
procedures with the unit installed on the vehicle.
Complete overhaul of the ABS hydraulic
modulator/motor pack assembly are not
authorized - only the following steps. These
steps will break the unit down into major
components for replacement purposes.
GEAR COVER (ABS)

Figure 31
fJ
Disassemble

2. Remove gear cover;
I+++!
Assemble

assembly.
l~I
Tighten
Torx bolts to 4 N.m (35 lb. in.).
MOTOR PACK (ABS)

Figure 31
!+!+I
Disassemble

2. Torx head screws attaching motor pack.
[I]
Important
Use care when handling motor pack to ensure

motor pack connector is not damaged, or
accidental intrusion of brake fluid into the
motor pack does not occur. This may result in
a premature failure of the motor pack.
3. Remove motor pack.
[I]
Important
If disassembly of the hydraulic modulator/motor

pack assembly was due to a ABS hydraulic
functional test that did not pass, the "Automated
Motor Pack Diagnosis Test" described in this
section should be performed at this time to isolate
.the. motor pack or hydraulic modulator.
No repair of the motor pack is authorized.
Replace as an assembly.
l+f+!
Assemble
l. With the hydraulic modulator upside down, .and

modulator bore, simplifying the brake bleeding
procedure (refer to Figure 14)'.
[I]
Important

dropped or damaged during handling the motor
Align each of the three ABS motor pack
pinions with the hydraulic modulator gears.
!~!
Tighten
Torx head screws to 4.5 N.m (40 lb. in.).

assembly.
GEAR REPLACEMENT (Typical)

Figures 15 and 16
[I]
Important
Do not attempt to repair damaged motor packs or

hydraulic modulators. Other than modulator drive
gear replacement, repair of these assemblies is not
authorized. Do not lubricate or oil gears on motor
pack.
CAUTION: The modulator drive gears are

under spring load and will turn during
disassembly. After removing hydraulic
modulator drive gear cover, exercise
extreme care not to place fingers into the
gear set, since fingers can be pinched by
rotating gears.
!+!+!
Disassemble

15-11194
FS0455E
Figure 31 ABS Hydraulic Modulator Components

screws.
rn
Important

dropped or damaged in the handling, the motor
4. Separate motor pack from hydraulic modulator.
5. Three ABS modulator drive gears to modulator
drive shaft retaining nuts.
6. Gears from modulator (refer to Figure 13).
removing the retaining nut, since the modulator
piston can hit the top of the modulator bore,
gear from turning, aiding in gear removal.
NOTICE: Do not allow gear to tum while

tightening the retaining nut, since the modulator
piston can bottom out in the modulator bore
gear from turning, aiding in gear installation
l+!+I
Assemble
1. Position hydraulic modulator drive gears onto
hydraulic modulator drive shaft.

2. Three ABS gear retaining nuts.
l~I
Tighten
Nuts to 8.5 N,m (76 lb. in.).
5E2-246

hydraulic modulator bore, simplifying the brake
bleeding procedure (refer to Figure 14).
4. Position motor pack onto hydraulic modulator,
aligning the three ABS motor pack gears with the
modulator gears.
rn
Important

screws.
!~!
Tighten
Torx head screws 4.5 N.m (40 lb. in.).

6. Gear cover onto hydraulic modulator with Torx
head screws.
I~!
Tighten
Torx head screws to 4 N.m (35 lb. in.).

ABS HYDRAUlJC MODULATOR

Figure 32
l+t+I
Disassemble
1. Remove gear cover. Refer to "Gear Cover" m

this section.
2. Remove motor pack. Refer to "Motor .Pack" m
this section.
banjo bolts; separate hydraulic modulator from
brake combo valve.
4. Two transfer tubes with 0-rings from brake
combo valve or hydraulic modulator.
5. Banjo bolt 0-rings from brake combo valve and
rn
!+;+!
Assemble
1. Two transfer assemblies.

Lubricate transfer tube assembly 0-rings with
clean brake fluid.
Install transfer tube assemblies in ports in
hydraulic modulator and push in by hand to
bottom.
2. Lubricate new banjo bolt 0-ring with clean brake
fluid and install into the brake combo valve and
3. Hydraulic modulator to brake combo valve.
Hold brake combo value and rock into position

on hydraulic modulator inserting transfer tube
assemblies into brake combo valve ports.
banjo bolts.
!~!
Tighten
Banjo bolts to 16 N.m (12 lb. ft.).

modulator bore simplifying the brake bleeding
assembly.
TCS HYDRAULIC MODULATOR

The TCS Hydraulic Modulator/Motor Pack
Assembly is a sealed unit and cannot be serviced. The
TCS Hydraulic Modulator/Motor Pack Assembly ,must
be replaced as a assembly.
MASTER CYLINDER
Refer to SECTION SA for repair of master
cylinder.
Important
If hydraulic modulator is to be replaced, install

the three gears in the same location on
replacement hydraulic modulator. Refer to "Gear
No repair of the hydraulic modulator is
authorized. Replace as an assembly.
Refer to SECTION SA for repair of brake combo
valve.
Use new transfer tube assemblies when
assembling the hydraulic modulator/brake combo
valve assembly. Make sure two 0-rings are
properly installed on each transfer tube.
5E2-247
SPECIFICATIONS
ABS Hydraulic Modulator Bleeder Valves ................................................................................................. 9.0 N.m (80
ABS Hydraulic Modulator Solenoid Torx Head Bolt ............................................................................ 4.5 N.m (40
Electronic Brake Traction Control Module (EBTCM) Nut.. .................................................................... 25 N.m (18.5
ABS Hydraulic Modulator Mounting Bolt ................................................................................................. 9.0 N.m (80
res Hydraulic Modulator Mounting Bolt. ................................................................................................. 9.0 N.m (80
lb.
lb.
lb.
lb.
lb.
in.)
in.)
ft.)
in.)
in.)
Three Hydraulic Modulator Brake Pipe Tube Nuts ..................................................................................... 32 N.m (24 lb.
l\vo Brake Combination Valve Brake Pipe Tube Nuts ............................................................................... 18 N.m (13 lb.
l\vo Master Cylinder Brake Pipe Tube Nuts ............................................................................................... 32 N.m (24 lb.
Modulator Drive Gear Nuts ......................................................................................................................... 8.5 N.m (75 lb.
ft.)
ft.)
ft.)
in.)
Torx Head Screws Attaching Gear Cover ....... :....................................................................................... 4.0 N.m (35 lb. in.)
Torx Head Screws Attaching Motor Pack ............................................................................................... 4.5 N,m (40 lb. in.)
l\vo Banjo Bolts Attaching Brake Combination Valve to ABS Hydraulic Modulator............................. 16 N,m (12 lb. ft.)
SPECIAL TOOLS
Figure 32
The J 39200 High Impedance Multimeter is the
only DVM authorized for use in diagnosing and
servicing the ABS VI/TCS system.
J 35589
7000001
1 BRAKE BLEEDING ADAPTER
3 TECH 1 SCAN TOOL
2 MASS STORAGE CARTRIDGE
4 J 39200 - DIGITAL MULTIMETER
15-1994
FS046SE
Figure 32 - ABS Vl!TCS Special Tools
5E2-248
BLANK
(
PARKING BRAKE
SF-1
SECTION SF
PARKING BRAKE
becoming airborne.
NOTICE: Always use the correct fastener iri the correct location. When you replace a fastener, use ONLY the
exact part number for that application, General Motors will call out those fasteners that require a replacement
after removal. General Motors will also call out the fasteners. that require thread lockers or thread sealant.
and systems.
CONTENTS
Parking Brake System ......................................... 5F-1
Parking Brake Lever ........................................... 5F-1
Parking Brake Cables; ......................................... 5F-1
"BRAKE" Warning Lamp ................................. 5F-2
On-Vehicle Service .................................................. 5F-2
Lubrication ........................................................... 5F-2
Parking Brake Lever ........................................... 5F-2
Parking Brake Cables ......................................... 5F-2
Front Cable ...................................................... 5F-2
Rear Cable (Drum Brakes) ............................. 5F-5

Rear Cable (Disc Brakes) ............................... 5F-6
Parking Brake Adjustment .................................. 5F-7
"BRAKE" Warning Lamp ........ Refer to Section 8C
Unit Repair .............................................................. 5F-7
Rotor Refinishing ..................... Refer to Section 5B2
Drum Refinishing ..................... Refer to Section 5C2
Specifications ........................................................... 5F~8
Fastener Tightening Specifications ..................... 5F-8
Special Tools ........................................................... 5F-8
GENERAL DESCRIPTION
When operating correctly, the rear parking brake

actuator levers on the rear disc brake calipers or the
rear drum brakes will fully return to their mechanical
stops when the parking brake lever is fully released.
PARKING BRAKE SYSTEM

The parking brake system allows the rear brakes
to be mechanically applied by lifting the parking brake
lever. On vehicles with rear drum brakes, this system
mechanically forces the rear brake shoes outward,
forcing the rear shoes against the brake drums. On
vehicles with rear disc brakes, this system
mechanically forces the rear brake pads against the
brake rotor.
PARKING BRAKE LEVER

This vehicle is equipped with a self-adjusting
parking brake lever. This mechanism automatically
takes up any slack in the cables and provides the
correct amount of tension in the cables when the
system is engaged. The parking brake cables cannot be
manually adjusted.
PARKING BRAKE CABLES

Three separate cables are used in the parking
brake system. The left and right rear cables are joined
to'the front cable at the equalizer, with the rear cables
running to the rear of the vehicle.
This vehicle is equipped with coated parking
brake cables. The wire strand is coated with a plastic
material which slides over plastic seals inside the
conduit end fittings. This is for corrosion protection
and reduced parking brake effort.
5F-2
PARKING BRAKE
"BRAKE" WARNING LAMP

The red "BRAKE" warning lamp will illuminate
when the ignition switch is in "START" and the
parking brake lever is applied or not fully released.
The parking brake warning switch, located in the
parking brake lever, will ground the "BRAKE"
warning lamp circuit and cause the "BRAKE"
warning lamp to illuminate.
ON-VEHICLE SERVICE
LUBRICATION
Figure 1
!++!
Install or Connect
1. Front cable (15) and casing to parking brake lever

(1) and bracket.
2. 1\vo bolts/screws (12) and parking brake lever (1)
to floor pan.
!~I
Tighten

3. Bolt/screw (5) and parking brake indicator switch
(4).
NOTICE: Do not lubricate the parking brake

cables. Lubrication destroys the plastic coating
on the parking brake cables.
If the parking brake lever (1) does not fully
return, lubricate the following parts using GM PIN
1052497:
Adjust pawl pin.
Handle ratchet.
Adjusting ratchet.
PARKING BRAKE LEVER

Figures 1 and 2
Tool Required:
J 37043 i:iarking Brake Cable Release Tool
!++!

2. Light switch and wiring from parking brake
indicator switch (4).
3. Bolt/screw (5) and parking brake indicator switch
(4) from parking brake lever (1).
4. With parking brake lever (1) in up position,
remove pretension spring (16).
5. With parking brake lever (1) in down position,
rotate adjuster arm toward front of vehicle until a
3 mm metal pin can be inserted into hole.
A. Remove and discard remaining piece of plastic
shear pin.
B. Insert 3 mm metal pin into hole, locking out
self adjuster.
6. If there is sufficient parking brake cable slack,
skip to step 10.
7. Raise and. suitably support vehicle. Refer to
SECTION OA.
8. Rear cables (17 and 18) from equalizer (8).
9. Lower vehicle.
10. Bend back cable retainer tab on pulley.
11. Barrel-shaped front cable end fitting from adjuster
track on pulley.
12. 1\vo bolts/screws (12) and parking brake lever (1)
from floor pan.
13. Front cable (15) and casing from parking brake
lever (1) and bracket, using J 37043.
I~!
Tighten

4. Light switch and wiring to parking brake indicator
switch (4).
5. Barrel-shaped front cable end fitting to adjuster
track on pulley.
6. Bend cable retainer tab to original position on
pulley.
7. If rear cables (17 and 18) were not disconnected
from equalizer, skip to step 11.
SECTION OA.
9. Rear cables (17 and 18) to equalizer (8).
10. Lower vehicle.
11. Rotate adjuster arm toward rear of vehicle and
fully raise parking brake lever (1).
12. Pretension spring (16).
13. Remove 3 mm metal pin from hole.
14. Cycle parking brake lever (1) three times.
PARKING BRAKE CABLES

NOTICE: Handling these cables while
servicing the parking brake . system requires
extra care. Damage to the plastic coating will
reduce corrosion protection and if the damaged
area passes through the seal, increased parking
brake effort could result. Contacting the coating
with sharp-edged tools, or with sharp surfaces of
the vehicle underbody, should be avoided.
Front Cable
Figures 1 and 2
Tool Required:
J 37043 Parking Brake Cable Release Tool
!++I

2. With parking brake lever (1) in up position,
remove pretension spring (16).
PARKING BRAKE
5F3
!VIEWAI
A
B
C
D
E
F
1
4
5
8
9
12
15
16
ARM, ADJUSTER
GRIP, PARKING BRAKE LEVER
BUTION, PARKING BRAKE LEVER RELEASE
PAWL, ADJUST
PIN, ADJUST PAWL
PULLEY, PARKING BRAKE LEVER
LEVER, PARKING BRAKE .
SWITCH, PARKING BRAKE INDICATOR
BOLT/SCREW, PARKING BRAKE INDICATOR
SWITCH
EQUALIZER, PARKING BRAKE CABLE
GROMMET, PARKING BRAKE CABLE
BOLT/SCREW, PARKING BRAKE LEVER,
CABLE, PARKING BRAKE FRONT
SPRING, PRETENSION
01-1395
FS00115F
Figure 1 Parking Brake Lever
SF-4
PARKING BRAKE
18
10
19
17
A WITH DISC BRAKE ASSEMBLIES

B WITH DRUM BRAKE ASSEMBLIES
C
D
8
10
11
13
BRACKET, UNDERBODY
FITIING, PARKING BRAKE REAR CABLE END

CALIPER, REAR BRAKE
DRUM, REAR BRAKE
GUIDE, PARKING BRAKE REAR CABLE
17 CABLE, LEFT PARKING BRAKE REAR

18 CABLE, RIGHT PARKING BRAKE REAR
23 GUIDE, PARKING BRAKE REAR CABLE (DRUM BRAKE
ASSEMBLIES ONLY)
25 ANTI-RATTLE BUMPERS, FOAM
26 STRAP, TIE
27 SOUND DEADENER, FLOOR PANEL
01-13-95
FS0025F
\
Figure 2 - Parking Brake Cable Routing
PARKING BRAKE
3. With parking brake lever (1) in down position,
rotate adjuster arm toward front of vehicle until a
3 mm metal pin can be inserted into hole.
A. Remove remaining piece of plastic shear pin
from hole.
B. Insert 3 mm metal pin into hole, locking out
self adjuster.
4. Pull parking brake lever (1) all the way back.
SECTION OA.
6. Left and right rear cables (17 and 18) from
equalizer (8).
7. Fitting of front cable (15) from bracket, using
J 37043.
8. Grommet (9) from slot in underbody.
9. Lower vehicle.
10. Bend back cable retainer tab on pulley.
11. Barrel-shaped front cable end fitting from adjuster
track on pulley.
12. Front cable (15) and casing from parking brake
lever (1), using J 37043.
13. Front cable (15) from floor pan.
Rear Cable (Drum Brakes)
l+.-1
Figures 2, 3 and 4
5F-5
D. Be sure grommet (9) is properly seated in slot

in floor pan.
2. Front parking. brake cable casing to parking brake
lever (1).
3. Barrel-shaped front cable end fitting into adjuster
track on pulley.
4. Bend cable retainer tab to original position on
pulley.
5. Make sure parking brake lever (1) is in down
position.
.
SECTION OA.
7. Rear cable (17 and 18) to equalizer (8).
8. Lower vehicle.
9. With parking brake lever ( 1) in up position, install
pretension spring (16).
10. Remove 3 mm metal pin from hole.
11. Cycle parking brake lever (1) three times.
Install or Connect
1. Front cable (15) and grommet (9) into slot in

floor pan.
A. Soapy water can be used as lubricant.
B. Feed forward end of grommet (9) into slot.
C. Use a small, curved, flat-ended pry bar to
gently press rearward end into slot.
Tool Required:
This vehicle is equipped with a blind cable
system at the brake drum. The rear parking brake
cable can be installed to the brake drum without
disassembling the brake drum.
18
It-~-102 mm (4.0') ----1
~~.~5~
Ill
III 5 mm (0.2')
5 mm (0.2")
1-'4
d~
'~"{'"
~113 mm
I0.5"1
A
B
~
B
A
B
C
8
17
18
SURFACE OF NOTCHES MUST BE SMOOTH

SPACER, PARKING BRAKE CABLE EQUALIZER
BRACKET,UNDERBODY
CABLE, LEFT PARKING BRAKE REAR
CABLE, RIGHT PARKING BRAKE REAR
Ol-13H
FS0035F
Figure 3 - Parking Brake Cable Equalizer Spacer (Locally Fabricated)
SF-6
!++!
PARKING BRAKE
11
1. Fully disengage parking brake lever. Be sure

handle is down and brake indicator lamp is not lit.
If parking brake lever is partially engaged, it will
not be possible to pull equalizer (8) rearward in
step 3.
SECTION OA.
3. Left or right rear cable (17 or 18) from equalizer
(8).
A. Pull equalizer (8) rearward to gain necessary
cable slack.
B. Insert locally fabricated spacer to hold
equalizer (8) in place as shown in Figure. 3.
C. Remove left or right rear cable (17 or 18)
from equalizer (8).
4. Left or right rear cable ( 17 or 18) and casing
from underbody bracket and retainer.
Use J 37043 to compress retainer fingers on
casing and pull left or right rear cable
(17 or 18) from underbody bracket.
5. Pull rear cables (17 and 18) through guides
(13 and 23) installed on rear axle housing (19).
7. Drum (11).
8. Left or right rear cable (17 or 18) from backing
plate.
Use J 37043 to compress retainer fingers and
pull out left or right rear cable (17 or 18).
9. Cable end fitting from parking brake lever. Refer
to SECTION 5C2.
!++I
11
.c
A SPRING, GUIDE
B LEFT PARKING BRAKE REAR CABLE PRIOR
TO INSTALLATION
C LEFT PARKING BRAKE REAR CABLE INSTALLED
11 DRUM, REAR BRAKE
17 CABLE, LEFT PARKING BRAKE REAR
Install or Connect
01-1315
FS004SF
1. Drum (11).
[I)
2.
3.
4.
5.
6.
Important
When reassembling drum brake, make sure

guide spring projects through hole in backing
plate so that cable insertion can be performed.
Feed left rear cable (17) through guide (13) or
right rear cable (18) through guides (13 and 23)
on rear axle housing (19).
Cable end fitting into parking brake lever. This
can be done by inserting tear-drop shaped end
fitting into guide spring until a click. is heard.
After click is heard, pull on cable to ensure
connection has been made.
Left or right rear cable (17 or 18) to backing
plate.
Ensure that retainer fingers are seated.
Align previous marks on axle flange and
wheel.
Left or right rear cable (17 or 18) into underbody
bracket.
If it was necessary to remove the tie strap
from the brake cables, then a new tie strap
must be installed in its original position.
Figure 4 - Installing Rear Parking Brake Cable to Rear

Brake Drum
7.
8.
9.
10.
Left or right rear cable (17 or 18) to equalizer (8).

Remove locally fabricated spacer.
Lower vehicle.
Cycle parking brake lever three times.
Rear Cable (Disc Brakes)

Figures 2, 3 and 5
Tool Required:
!++!
1. Fully disengage parking brake lever. Be sure

handle is down and brake indicator lamp is not lit.
If parking brake lever is partially engaged, it will
not be possible to pull equalizer (8) rearward in
step 3.
SECTION OA.
3. Left or right rear cable (17 or 18) from
equalizer (8).
PARKING BRAKE
10
17
21
22
24
5F-7
CALIPER, REAR BRAKE

CABLE, LEFT PARKING BRAKE REAR
LEVER, REAR PARKING BRAKE ACTUATOR
BRACKET, PARKING BRAKE CABLE
01-1795
FSOOSIF
Figure 5 Installing Rear Parking Brake Cable to Rear Disc Brake Caliper
4.
5.
6.
7.
I++-!
A. Pull equalizer (8) rearward to gain necessary

parking brake cable slack.
B. Insert locally fabricated spacer to hold
equalizer (8) in place as shown in Figure 3.
C. Remove left or right rear cable (17 or 18)
from equalizer (8).
Left or right rear cable (17 or 18) and casing
from underbody bracket.
Compress retainer fingers on casing using
J 37043 and pull left or right rear cable (17 or
18) from underbody bracket.
Pull left or right rear cable (17 or 18) through
guide (13) installed on rear axle housing (19).
Left or right rear cable ( 17 or 18) from actuator
lever (21) and cable bracket (22).
A. Pull all parking brake cable slack to caliper
end of parking brake cable.
B. Remove left or right rear cable (17 or 18)
from tang on actuator lever (21).
C. Using J 37043, compress retainer fingers on
cable casing and pull from cable bracket (22).
Install or Connect
1. Left or right rear cable (17 or 18) to actuator

lever (21) and cable bracket (22).
Seat retainer fingers into cable bracket (22).
3. Feed left or right rear cable (17 or 18) through

guide (13) on rear axle housing (19).
4. Left or right rear cable (17 or 18) into underbody
bracket.
If it was necessary to remove the tie strap
from the brake cables, then a new tie strap
must be installed in its original position.
5. Left or right rear cable(17 or 18) to equalizer (8).
6. Remove locally fabricated spacer.
7. Lower vehicle.
PARKING BRAKE ADJUSTMENT

Adjustments are not normally necessary after
replacing the parking brake cables or the parking
brake lever. Refer to SECTION 5B2 for parking brake
free-travel adjustment procedures and to
SECTION 5C2 for rear drum brake adjustment.
UNIT REPAIR
ROTOR REFINISHING
For rear brake rotor refinishing, refer to
SECTION 5B2.
DRUM REFINISHING
For rear brake drum refinishing, refer to
SECTION 5C2.
5F-8
PARKING BRAKE ,
SPECIFICATIONS
(

Parking Brake Indicator Switch Bolt/Screw ......................................................................... 2.8 N.m (25 lb. in.)
Parking Brake Lever Bolt/Screw .................................................... ;..................................... 12 N.m (106 lb. in.)
SPECIAL TOOLS
1. J 37043
1. PARKING BRAKE CABLE RELEASE TOOL

01-1795
FS006SF
ENGINE GENERAL INFORMATION AND MECHANICAL DIAGNOSIS
6-1
SECTION 6
ENGINE
CONTENTS
Engine General Information and Mechanical
Diagnosis ..................................................... Section 6
5.7 Liter V8 Engine On-Vehicle
Service ................................................. Section 6A3A
5.7 Liter V8 Engine Unit Repair ............ Section 6A3B
3800 V6 Engine On-Vehicle Service ..... Section 6A8A
3800 V6 Engine Unit Repair .................. Section 6A8B
Cooling and Radiator ................................... Section 6B
Engine Fuel .................................................. Section 6C
Engine Electrical .......................................... Section 6D
Battery ........................................................ Section 6Dl
Cranking System ........................................ Section 6D2

Charging System ........................................ Section 6D3
Ignition System .......................................... Section 6D4
Engine Wiring ........................................... Section 6D5
Driveability and Emissions - General
Information ...............:i~ ............................... Section 6E
Driveability and Emissions - Fuel Injection
(SFI) (3800) ............................................ Section 6E3
Driveability and Emissions - Fuel Injection
(SFI) (5.7L) ..... ~.. ;: .................................... Section 6E3
Exhaust System.:: .......................................... Section 6F
SECTION 6
EN INE GENERAL INFORM ION AND

ECHANICAL DIAGNOSIS
Failure to follow CAUTIONS could result in possible air bag deployment, personal injur.y, or
CONTENTS
Description of Section 6 ..... .'..................................... 6-2
Section 6A - Engine Mechanical ......................... 6-2
Section 6B - Cooling and Radiator ..................... 6-2
Section 6C - Engine Fuel.. ................................... 6-2
Section 6D - Engine Electrical ............................ 6-2
Section 6E - Driveability and Emissions General Information ........ ;................................. 6-2
Section 6F - Exhaust System ............................... 6-2
General Information .................................................. 6-2
Cleanliness and Care ............................................. 6-2
General Information on Engine Service .............. 6-3
Engine Performance Diagnosis ................................. 6-3
On.:Board Diagnostics II (OBD II) .......................... 6-3
Heated Oxygen Sensor (H02S) Monitoring ........ 6-3
Catalyst Monitoring ............................................... 6-3
Misfire Monitoring ................................................ 6-4
Fuel Trim System Monitoring .............................. 6-4
Exhaust Gas Recirculation (EGR)
System Monitoring ...................... '. ..................... 6-4
Secondary Air Injection (AIR) System

Monitoring ....................................................... 6-4
Evaporative Emission Canister Purge Valve
Monitoring ........ :.............................................. 6-5
Engine Coolant Temperature (ECT) Sensor
Monitoring ....................................................... 6-5
Engine Misfire Mechanical Diagnosis ................... 6-5
Engine Mechanical Diagnosis ................................ 6-5
Excessive Oil Loss ............................................. 6-5
Oil Leak Diagnosis ........ ;.................................... 6-5
Finding the Leak ............................................. 6-5
Repairing the Leak ......................................... 6-7
Low or No Oil Pressure ..................................... 6-8
Engine Noise Diagnosis .......................................... 6-8
Main Bearing Noise ............................................ 6-9
Connecting Rod Bearing Noise .......................... 6-9
Timing Gear or Chain and Sprocket Noise ....... 6-9
Piston Noises ....................................................... 6-9
Valve Mechanism or Valve Train Noises .......... 6-9
Rattle (Balance Shaft) ......................................... 6-10
6-2
Accessory Drive Belt Noise ............................... 6-10

Flywheel Noises (Automatic Transmission) ....... 6-10
Engine Knock Diagnosis ......................................... 6-10
Knocks Cold and Continue for Two to Three
Minutes and Increases with Torque ............... 6-10
Heavy Knock Hot with Torque Applied ............ 6-10
Light Knock Hot. ................................................ 6-10

Knocks on Initial Start-Up but Only Lasts a
Few Seconds ................................................... 6-11
Knocks at Idle Hot ............................................. 6-11
Engine Compression Test ................................... 6-11
Cylinder Leak Test.. ............................................ 6-11
All NEW GENERAL MOTORS VEHICLES ARE CERTIFIED BY THE UNITED STATES
ENVIRONMENTAL PROTECTION AGENCY AS CONFORMING TO THE REQUIREMENTS OF THE
REGULATIONS FOR THE CONTROL OF AIR POLLUTION FROM NEW MOTOR VEHICLES. THIS
CERTIFICATION IS CONTINGENT ON CERTAIN ADJUSTMENT POINTS BEING SET TO FACTORY
STANDARDS. IN MOST CASES, THESE ADJUSTMENT POINTS EITHER HAVE BEEN
PERMANENTLY SEALED AND/OR MADE INACCESSIBLE TO PREVENT INDISCRIMINATE OR
ROUTINE ADJUSTMENT IN THE FIELD. FOR THIS REASON, THE FACTORY PROCEDURE FOR
TEMPORARILY REMOVING PLUGS, CAPS, ETC., FOR PURPOSES OF SERVICING THE PRODUCT
MUST BE STRICTLY FOLLOWED AND, WHEREVER PRACTICABLE, RETURNED TO THE
ORIGINAL INTENT OF THE DESIGN.
DESCRIPTION OF SECTION 6
SECTION 6A - ENGINE MECHANICAL
This section contains information of the
mechanical parts of the engine, such as the block,
crankshaft, pistons, valve train, and camshaft.
Overhaul procedures, removal and replacement
procedures, and specifications are also covered. The
specific subsections are:
6A3A - 5.7 Liter V8 Engine On-Vehicle Service
RPO LTl - VIN P
6A3B - 5.7 Liter V8 Engine Unit Repair
RPO LTl - VIN P
6A8A - 3800 V6 Engine On-Vehicle Service L36
(VINK)
6A8B - 3800 V6 Engine Unit Repair L36
(VINK)
SECTION 68 - COOLING AND RADIATOR

Engine cooling system components such as the
radiator, water pump, hoses, thermostat, and cooling
fan, are covered in this section.
SECTION 6E - DRIVEABILITY AND

EMISSIONS - GENERAL INFORMATION
This section covers emission control systems,
general information, and diagnostic procedures which
will lead to repairing performance and driveability
related problems. Emission components are covered,
as well as removal and replacement procedures.
Instructions on use of special tools are also given.
Specific subsections are:
6E - Driveability and Emissions - General
Information
6E3 - Driveability and Emissions - Sequential
Multiport Fuel Injection (SFI) (3800) (VIN K)
6E3 - Driveability and Emissions - Sequential
Multiport Fuel Injection (SFI) (5.7L) (VIN P)
SECTION 6F - EXHAUST SYSTEM

This section has information on all exhaust
system parts, such as tailpipes, mufflers, and the
catalytic converter.
GENERAL INFORMATION
SECTION 6C - ENGINE FUEL

This section contains information on all the parts
of the fuel system except the Sequential Multiport
Fuel Injection (SFI) components. Items covered are:
fuel tank, fuel pump, fuel filter, and fuel lines.
SECTION 6D - ENGINE ELECTRICAL

Items covered in this section are the battery,
generator, starter, distributor, engine wire harness,
spark plugs and wires. Ignition system diagnosis can
be found in the appropriate 6E Section as a "C-4"
chart. Specific subsections are:
6D - Engine Electrical
6Dl - Battery
6D2 - Cranking System
6D3 - Charging System
6D4 - Ignition System
6D5 - Engine Wiring
CLEANLINESS AND CARE

An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with
tolerances that are measured in .the ten-thousandths of
an inch. When any internal engine parts are serviced,
care and cleanliness are important. A liberal coating of
engine oil should be applied to friction areas during
assembly to protect and lubricate the surfaces on
initial operation. Throughout this section, it should be
understood that proper cleaning and protection of
machined surfaces and friction areas is part of the
repair procedure. This is considered standard shop
practice even if not specifically stated.
Whenever valve train components are removed
for service, they should be kept in order. They should
be installed in the same locations, and with the same
mating surfaces, as when removed. Battery cables
should be disconnected before any major work is

performed on the engine. Failme to disconnect cables
may result in damage to wiring harness or other
electrical parts.
GENERAL INFORMATION ON ENGINE

SERVICE
CAUTION: Before removing or installing
any electrical unit, or when a tool or
equipment could easily .come in contact
with "live" or "hot at all times" exposed
electrical terminals, disconnect the
negative battery cable to help prevent
personal injury and/or damage to the
vehicle or components. Unless instructed
otherwise, the ignition switch must be in
the "off" or "lock" position.
NOTICE: THE FOLLOWING
INFORMATION ON ENGINE SHOULD BE
NOTEDCAREFULLY,ASITISIMPORTANT
lN PREVENTING DAMAGE AND IN
CONTRIBUTING TO RELIABLE
PERFORMANCE.
When raising or supporting the engine for any
reason, DO NOT use a jack under the oil pan,
crankshaft balancer, or any sheet metal. Due to small
clearances between the oil pan and the oil pump
screen, jacking against the oil pan may cause it to be
bent against the pump screen, resulting in a damaged
oil pickup unit. Jacking against the crankshaft balancer
may also .cause oil seal and/or crankshaft bearing
damage. Always use J 28467-A (Universal Support
Fixtme) along with J 41044 (Engine Support Adapters)
when raising or supporting the engine.
Any time the air cleaner is removed; the intake
opening should be co.vered. This will protect against
accidental entrance of foreign material which could
follow that intake passage into the cylinder and cause
extensive damage when the engine is started.
IN THE MECHANICAL PROCEDURES
DESCRIBED IN THIS SECTION, REFERENCES
WlLL BE MADE TO THE REMOVAL OF
EQUIPMENT SUCH AS POWER STEERING PUMP,
AIR CONDITIONING COMPRESSOR, ETC.
SHOULD IT BECOME NECESSARY TO
REMOVE ANY SUCH ITEM TO PERFORM
OTHER SERVICES, REFER TO THE
APPROPRIATE SECTION OF THIS SERVICE
MANUAL FOR SPECIFIC INFORMATION.
ENGINE PERFORMANCE DIAGNOSIS

Engine performance diagnosis procedures are
covered in Section 6E and should be consulted for
diagnosis of any driveability, emissions, or "Service
Engine Soon" light complaint. Refer to:
SECTION 6E - Driveability and Emissions General Information
SECTION 6E3 - Driveability and Emissions Fuel Injection (SFI) (3800)
SECTION 6E3 - Driveability and Emissions Fuel Injection (SFI) (5.7L)
6-3
ON-BOARD DIAGNOSTICS II (OBD II)

OBD II requires not only that emission
components be monitored and tested, but that entire
systems be tested as well. This diagnostic system now
includes both active and passive tests. Operation of
some of these systems, such as ignition control
circuits, were already being monitored to provide
better powertrain control. Additional system
monitoring, such as catalyst efficiency, is being
introduced with OBD II. The following is how OBD II
monitoring and diagnostic testing is accomplished. For
further information on OBD II diagnostics, refer to
SECTION 6E.
HEATED OXYGEN SENSOR (H02S)

MONITORING
The exhaust Heated Oxygen Sensor (H02S)
monitoring diagnostic is designed to meet the
following requirements:
Monitor voltage and response rate of the primary
(pre-catalyst) sensors.
Monitor output voltage or response rate of any
. secondary sensors.
Monitor the heating system for appropriate
performance.
The heater circuit will be considered
malfunctioning when its performance drops outside the
manufacturer's specification. For fmther diagnostic
information, refer to SECTION 6E.
CATALYST MONITORING
The OBD II catalyst monitor diagnostic
measmes oxygen storage capacity. To do this, oxygen
sensors are installed before and after the Three-Way
Catalytic Converter (TWC). Voltage variations
between the sensors allow the PCM to measme the
catalyst emission performance. When the TWC is
operating properly, the post-catalyst oxygen sensor will
have significantly less activity than the pre-catalyst
oxygen sensor. This is because the TWC stores and
releases oxygen as needed during its normal reduction
and oxidation processes.
To help aid in these processes, most modem
TWC's also contain a base metal known as cerium.
Cerium has the ability to attract and release excess
oxygen in the exhaust stream. This stabilizes the
operation of the catalyst and enhances the
effectiveness of the precious metals in converting
undesirable by-products of combustion to harmless
gasses. As a catalyst becomes less effective in
promoting chemical reactions, its capacity to store and
release oxygen generally degrades as well. The OBD
II catalyst monitor diagnostic is based on an observed
correlation between conversion efficiency and oxygen
storage capacity.
A good catalyst (e.g. 95% hydrocarbon
conversion efficiency) will show a relatively flat
output voltage on the post-catalyst Heated Oxygen
Sensor (H02S). A poor catalyst (65% hydrocarbon
conversion) will show peaks and valleys in output
voltage. This indicates that the catalyst has lost some
of its ability to process the exhaust gasses properly.
64
The post-catalyst H02S is used to measure the oxygen

storage/release capacity of the catalyst. From this we
can infer the catalyst efficiency and the oxygen storage
capacity of the catalyst. A high oxygen storage
capacity indicates a good catalyst; low oxygen storage
capacity indicates a catalyst that is failing. For further
diagnostic information, refer to SECTION 6E.
MISFIRE MONITORING
Failure criteria for the misfire diagnostic
includes the following:
A level of misfire sufficient to result in emission
levels exceeding 1.5 times the Federal Test
Procedure (FTP) standard.
A level of misfire sufficient to result in catalyst
damage at the current operating condition (engine
speed, engine load, and coolant temperature).
A level of misfire sufficient to cause the vehicle
to fail the California Inspection Maintenance
(1/M) test.
Regulations require misfire monitoring under all
positive speed and load conditions (defined as cruises,
accelerations, and idle). The diagnostic must
discriminate between single versus multiple cylinder
misfiring. If a single cylinder misfires, the diagnostic
must identify the specific cylinder and the conditions
under which the misfire occurs. The misfire monitor
diagnostic is based on the principle that crankshaft
rotational velocity fluctuates as each cylinder
contributes a pov.:er input. When the engine misfires,
the crankshaft slows down momentarily. For
non-catalyst damage misfire, the diagnostic will
require between 1000 and 3200 engine revolutions to
respond to the onset of a misfire, and up to 200
engine revolutions to respond to a catalyst damage
misfire. The PCM monitors crankshaft rotational
velocity using both the crankshaft and camshaft
position sensors.
The Malfunction Indicator Lamp (MIL) will turn
on when misfire is detected for two consecutive trips,
or there is a malfunction in two non-consecutive trips
(not more than 80 trips apart) under similar engine
speed, load and coolant temperature conditions.
Flashing the .MIL is intended to discourage the driver
from operating the vehicle in this condition (to ease
off the throttle) before catalyst damage results.
Rough roads may cause false misfire detections.
A rough road will cause torque to be applied to the
drive wheels and drivetrain. These torque spikes can
temporarily and intermittently decrease the engine
speed, and this may be detected as a false misfire; .The
solution to rough road misfire problems is to utilize
the Anti-Lock Brake System (ABS) and/or PCM
software to detect patterns characteristic of rough
roads, and disable the diagnostic when rough roads are
present.
A feature that is incorporated into the OBD II
system for diagnosing misfire problems is called
"misfire accumulators." These "misfire accumulators"
are basically a file on each engine cylinder. Anytime a
cylinder misfires, the misfire diagnostic counts the
misfire and notes in which cylinder it occurred. A

misfire accumulator is maintained for each cylinder,
and misfire accumulator data can be accessed by using
a TECH L This will enable you to determine which
cylinders misfired, even when dealing with a random
misfire DTC. Misfire accumulator information will be
found in the MISFIRE DATA sub-menu of the
SPECIFIC ENG. MENU of the data list. For further
diagnostic information, refer to SECTION 6E.
FUEL TRIM SYSTEM MONITORING

The operational theory for fuel trim includes
monitoring the averages of long-term and short-term
fuel trim. If these fuel trim values reach ancl stay at
their limits for a period of time, a malfunction is
indicated. The fuel trim diagnostic compares an
average of long-term trim value and short-term-trim
value to rich and lean thresholds. If either value is
within the thresholds, a pass is recorded. (The closed
loop system still has control authority). If both values
are outside of their thresholds, then a failure condition
exists. This will cause a DTC to be stored, and the
rich or lean condition to be recorded. The fuel trim
diagnostic also conducts an intrusive test to determine
if a rich condition is ,being caused by excessive vapor
from the EVAP canister.
OBD II fuel trim monitoring system will be
considered malfunctioning when it causes the emission
levels to exceed the 1.5 times the Federal Test
Procedure (FTP) standards. The operating conditions at
the instant of fault detection must be stored in Freeze
Frame data for the service technician.
Like a misfire diagnostic, fuel .trim faults do not
have to occur on consecutive trips to store a DTC.
The enabling criteria for system operation includes:
coolant temperature, throttle position, vehicle speed,
intake air temperature, long-term fuel trim learning
(updating), engine speed/load values, and barometric
pressure. For further diagnostic information, refer to
SECTION 6E.
EXHAUST GAS RECIRCULATION (EGR)

SYSTEM MONITORING
The OBD II requirement states that the Exhaust
Gas Recirculation (EGR) system must be monitored
for abnormally low and high flow rate malfunctions.
The diagnostic will consider the EGR malfunctioning
when an EGR system component fails, or a change in
the EGR flow rate results in the vehicle exceeding 1.5
times the Federal Test Procedure (FTP) emission
standard: The Diagnostic Trouble Code (DTC) must
set within two vehicle trips once the malfunction has
been detected.
SECONDARY AIR INJECTION (AIR)

SYSTEM MONITORING
OBD II diagnostics require monitoring for the
presence of airflow in the exhaust stream, as well as
functional monitoring of the secondary AIR pump, and
any switching valves. For further diagnostic
information, refer to SECTION 6E.

EVAPORATIVE EMISSION CANISTER
PURGE VALVE MONITORING
)
OBD II diagnostics utilize an evaporative

(EVAP) emission canister purge valve monitor which
uses an EVAP diagnostic switch in the hose between
the EVAP canister and purge valve to determine
proper function of the EVAP purge valve. When the
EVAP purge valve is closed (no purge), the switch
should not indicate a vacuum. An EVAP purge valve
stuck open will result in the switch consistently
indicating the presence of vacuum at the switch. An
EVAP purge valve stuck closed will result in the
switch constantly indicating atmospheric pressure. A
vacuum switch in the evaporative emission canister
purge hose is the only additional piece of hardware
required for this diagnostic.
ENGINE COOLANT TEMPERATURE (ECT)

SENSOR MONITORING
There are two separate Engine Coolant

Temperature (ECT) sensor diagnostics; ECT out of
range (high or low) and ECT input failed to enable
closed loop within the proper time frame.
The ECT out of range diagnostic monitors the
temperature readings from the ECT sensor at
approximately 100 millisecond intervals. For a fixed
interval of time, the diagnostic counts the number of
ECT readings outside of the sensor's expected output
range. If the number of ECT readings in. the high or
low ranges exceeds a certain calibrated threshold, the
sensor is. indicated to be failed high or low
accordingly.
If a relatively small number of samples fall in
either the high or low ranges, the sensor is diagnosed
as intermittently out of range high. or low. The
intermittent diagnostic is not required by OBD II
regulations, so no DTC is set. For further diagnostic
information, see SECTION 6E.
ENGINE MISFIRE MECHANICAL

DIAGNOSIS
.This diagnostic chart will isolate any engine
misfire due to a mechanical problem such as a faulty
camshaft, leaking headgasket, etc. However, this chart
will not isolate a crossed injector wire, faulty injector
or any other electrical failure that may cause a misfire.
Therefore, the "On-Board Diagnostic System Check"
must be performed first to insure the correct chart is
followed for diagnosis of a misfire. Refer to
SECTION 6E3-A first, then, if necessary, refer to
Chart A.
ENGINE MECHANICAL DIAGNOSIS

The following diagnostic information covers
common problems and possible causes. When the
proper diagnosis is made, the problem should be
corrected by adjustment, repair or part replacement as
required. Refer to the appropriate section of the
manual for these procedures.
65
EXCESSIVE OIL LOSS

Excessive oil consumption, not due to leaks, is
the use of 1 quarts (0.9L) or more of engine oil within
2,000 miles or 3 200 kilometers.
External oil leaks. Tighten bolt and/or replace
gaskets and seals as necessary.
Improper reading of oil level indicator (dipstick).
Check oil with vehicle on a level surface and
allow adequate drain-down time.
Improper oil viscosity. Use recommended SAE
viscosity for prevailing temperatures. Refer to
SECTION OB for engine oil specifications.
Continuous high speed driving, and/or severe
usage such as trailer hauling, will normally cause
decreased oil mileage.
Crankcase ventilation system malfunctioning.
Valve guides and/or valve stem seals worn, or
seals omitted. Ream guides and install oversize
service valves and/or new valve stem seals.
Piston rings broken, improperly installed, worn, or
not seated. Allow adequate time for rings to seat.
Replace broken or worn rings as necessary.
Piston improperly installed or misfitted.
Oil LEAK DIAGNOSIS

Most oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions a fluid leak may
be difficult to locate or repair. The following
procedure may help in locating and repairing most
leaks.
Finding the Leak

1. Identify the fluid, determine whether it is engine
oil, automatic transmission fluid, power steering
fluid, etc.
2. At what point is the fluid leaking from? After
running the vehicle at normal operating
temperature, park the vehicle over a large sheet of
paper. After a few minutes, the approximate
location of the leak should be found by the
drippings on the paper.
3. Visually check around the suspected component.
Check around all gasket mating. surfaces for leaks.
A mirror is useful for finding leaks in areas that
are hard to reach.
4. If the leak still cannot be found, it may be
necessary to clean the suspected area with a
degreaser, steam or spray solvent. Clean the area
well, then dry the area. Operate the vehicle for
several miles at normal operating temperature and
varying speeds. After operating the vehicle,
visually check the suspected component. If leak
still cannot be located, try using the powder or
black light and dye method.
POWDER METHOD
1. Clean the suspected area.

2. Apply an aerosol-type powder (such as foot
powder) to the suspected area.
6-6
CHART A
DIAGNOSIS
1. ARE THERE ANY OBVIOUS MECHANICAL NOISES?
ill IMPORTANT
OBD II SYSTEM CHECK MUST BE
PERFORMED FIRST.
REFER TO SECTION 6E3-A.
1. PERFORM VISUAL INSPECTION. CHECK SPARK

PLUGS, WIRES, AND HOSES FOR PROPER HOOK
UP AND DAMAGE.
2. IS THERE ANY APPARENT DAMAGE OR
IMPROPERLY CONNECTED HOSES OR WIRES?
REFER TO CHART B.
1. REMOVE AND INSPECT SPARK PLUGS.

2, ARE ANY SPARK PLUGS CONTAMINATED WITH
ENGINE COOLANT (THIS MAY SHOW UP AS A
SPARK PLUG WHICH LOOKS EXCEPTIONALLY
CLEAN)?
REPAIR OR REPLACE PARTS AS NECESSARY.
1. ARE SPARK PLUG(S) CONTAMINATED WITH ENGINE

OIL?
REMOVE CYLINDER HEAD AND GASKET.

INSPECT AND REPAIR/REPLACE PARTS AS
NECESSARY,
(
1. PERFORM CYLINDER LEAK TEST. REFER TO
"CYLINDER LEAK TEST" IN THIS SECTION.
2. DOES ENGINE PASS CYLINDER LEAK TEST?
REMOVE INTAKE MANIFOLD. INSPECT

MANIFOLD AND GASKET, IF O.K. REMOVE
CYLINDER HEAD AND INSPECT VALVE
GUIDES AND SEALS, IF O.K. REMOVE PISTON
AND INSPECT PISTON, RINGS, AND CYLINDER
FOR WEAR.
1. INSTALL SPARK PLUG(S). CHECK FOR CARBON

TRACKING OF PLUG WIRES.
2, INSTALL A VACUUM GAUGE TO THE INTAKE
MANIFOLD AND MEASURE MANIFOLD VACUUM
WITH ENGINE AT IDLE AND RECORD.
3. DISCONNECT ALL VACUUM LINES FROM MANIFOLD
AND PLUG ALL OPENINGS.
4, CHECK MANIFOLD VACUUM AGAIN WITH ENGINE
AT IDLE.
5, ARE BOTH VACUUM READINGS THE SAME?
REPAIR AS DESCRIBED UNDER "CYLINDER

LEAK TEST"
(CONTINUE ON NEXT PAGE)
(CONTINUE ON NEXT PAGE)
C7479
(CONTINUE FROM PREVIOUS PAGE)
67
(CONTINUE FROM PREVIOUS PAGE)
CHECK EACH VACUUM OPERATED ACCESSORY/

VACUUM LINE AND REPAIR ANY OPEN OR LEAKING
COMPONENT.
1. USING A SPRAY BOTTLE, LIGHTLY SPRAY THE

SPARK PLUG WIRES AND DISTRIBUTOR/IGNITION
MODULE WHILE LISTENING TO ENGINE.
2. DID THE ENGINE STUMBLE OR STALL?
1. REMOVE INTAKE MANIFOLD AND CAREFULLY

INSPECT INTAKE MANIFOLD GASKET AND TBI
GASKET.
2. IS THERE ANY APPARENT DAMAGE OR PROBLEM
WITH THE GASKETS OR SEALING SURFACE?
REPLACE SPARK PLUG WIRES AND/OR

DISTRIBUTOR CAP AND ROTOR/IGNITION MODULE.
1. WITH THE INTAKE MANIFOLD REMOVED, ROTATE

THE ENGINE AND MEASURE CAMSHAFT LOBE LIFT
(LIFTER MOVEMENT IN BORE).
2. IS CAMSHAFT WITHIN SPECIFICATIONS?
REPAIR OR REPLACE AS NECESSARY.
1. IF PROBLEM IS STILL SUSPECTED TO BE

MECHANICAL, REMOVE ENGINE AND PERFORM A
COMPLETE DISASSEMBLY AND INSPECTION.
REPLACE CAMSHAFT.
C7480
3. Operate the vehicle under normal operating

conditions.
4. Visually inspect the suspected component. The
leak path to the source should be found by tracing
the white powder surface.
gasket is replaced, but the sealing flange is bent, the

new gasket will not repair the leak. The bent flange
must be repaired also. Before attempting to. repair a
leak, check to be sure that the following conditions are
correct as they may cause a leak.
BLACK LIGHT AND DYE METHOD
GASKETS
A dye and light kit is available for finding leaks.

Refer to the manufacturer's directions when using the
kit.
1. Pour specified amount of dye into leaking
component.
2. Operate the vehicle under normal operating
conditions as directed in the kit.
3. Direct the light toward the suspected area. The
dyed fluid will appear as a yellow path leading to
the source.
iL!
Repairing the Leak

Once the origin of the leak .has pinpointed and
traced back to its source, the cause of the leak must be
determined in order for it to be repaired properly. If a
Inspect
Fluid level/pressure is too high.

Improperly tightened fasteners or dirty/damaged
threads.
Warped flanges or sealing surface.
Scratches, burrs or other damage to the sealing
surface.
Damaged or worn gasket.
Cracking or porosity of the component.
Improper sealant used (where applicable).
68
CHART B
DIAGNOSIS
1. WITH THE ENGINE RUNNING, TRY TO DETERMINE

IF THE NOISE IS TIMED TO CRANKSHAFT SPEED
OR CAMSHAFT SPEED (USE TIMING LIGHT, TWO
KNOCKS PER FLASH IS CRANKSHAFT, ONE
KNOCK PER FLASH IS CAMSHAFT).
2. IS NOISE TIMED TO CRANKSHAFT SPEED.?
1. IS NOISE TIMED TO CAMSHAFT SPEED?
REMOVE ROD BEARINGS AND INSPECT BEARINGS

AND JOURNALS FOR WEAR. IF O.K. REMOVE
CRANKSHAFT AND INSPECT MAIN BEARINGS AND
JOURNALS FOR WEAR. REPLACE PARTS AS
NECESSARY. OTHER AREAS TO LOOK MAY BE THE
BALANCE SHAFT, PISTON PINS, PISTON SIZES OR
NORMAL OPERATING CONDITION.
1. REMOVE INTAKE MANIFOLD, ROTATE ENGINE AND MEASURE

CAMSHAFT LOBE LIFT (LIFTER MOVEMENT IN BORE) AND
COMPARE WITH "SPECIFICATIONS" IN ENGINE SECTION.
2. IS CAMSHAFT WITHIN SPECIFICATIONS?
CHECK FOR LOOSE ACCESSORY

ATTACHMENTS, FLYWHEEL, OR TORQUE
CONVERTER.
(
1. REMOVE ROCKER ARMS, PUSHRODS AND
LIFTERS. CAREFULLY INSPECT FOR EXCESSIVE
WEAR OR DAMAGE, REPLACE PARTS AS
NECESSARY.
REPLACE CAMSHAFT.
C7481
SEALS
Fluid level/pressure is too high.

Damaged seal bore (scratched, burred or nicked).
Damaged or' worn seal.
Improper installation.
Cracks in components.
Shaft surface scratched, nicked or damaged..
Loose or worn bearing causing excess seal wear.
LOW OR NO OIL PRESSURE

Low oil level. Fill to full mark on oil level
indicator.
Slow idle speed.
Incorrect or malfunctioning oil pressure switch.
Improper oil viscosity or diluted oil. Install oil of
proper viscosity for expected temperature, or
install new oil if diluted with moisture or
unburned mixtures.
Oil pump worn or dirty.
Plugged oil filter.
Oil pickup screen loose or plugged.

Hole in oil pickup tube.
Excessive bearing clearance. Replace if necessary.
Cracked, porous .or plugged oil galleries. Repair
or replace block.
Gallery plugs missing or misinstalled. Install
plugs or repair as necessary.
Camshaft worn, or poorly machined. Replace
camshaft.
ENGINE NOISE DIAGNOSIS

There are four steps to diagnosing engine noise.
You must determine:
1. Type of noise.
2. Under which operating conditions it exists.
3. At what rate, and at what location in the engine.
4. Compare sounds in other engines to make sure the
condition is not normal.
Identify the type of noise, for example, a light
rattle or a low rumble. Determine the exact operating
conditions under which the noise appears.

Remember, engine noises are generally
synchronized to either speed (caused by the c~ankshaft,
connecting rods or pistons) or one-half engme speed
(valve train noises). Try to determine the rate at which
the noise is occurring.
MAIN BEARING NOISE

Damaged or worn main bearing noise is revealed
by dull thuds or knocks which happen on every engine
revolution, and this noise is loudest when the engine is
under heavy load.
Excessive crankshaft end play is indicated by an
intermittent rap or knock sharper than a worn main
bearing. Causes of main bearing noises include:.
Low oil pump pressure.
Thin, diluted or dirty oil and/or filter.
Excessive main bearing clearance.
Excessive crankshaft end play.
Out-or-round crankshaft journals.
Excessive belt tension.
Loose crankshaft pulley.
Loose flywheel or torque converter.
Loose main bearing cap.
Belt pilling.
CONNECTING ROD BEARING NOISE

A damaged or worn connecting rod bearing will
produce knock under all speeds. During the early
stages of wear, connecting rod noise may be confused
with piston slap or loose wrist pins. Connecting rod
knock noise increases in volume with engine speed
and is at its loudest on deceleration.. Causes of
connecting rod bearing noise include:
Excessive bearing clearance.

Worn crankshaft connecting rod journal.
Thin, diluted or dirty oil and/or filter.
Low oil pressure.
Crankshaft connecting rod journals our-of-round.
Misaligned connecting rod.
Connecting rod bolts not properly torqued.
Wrong bearing inserts or misaligned bearing half.
TIMING GEAR OR CHAIN AND SPROCKET

NOISE
Engines designed with timing gears, to those
equipped with timing chain and sprocket~, C3.? prod1;1ce
different noises. The most common noise 1s a high
frequency, light knocking sound. this sound will
generally be the same in intensity whether the engine
is idling, operating at high speeds, or under load,
causes of timing gear or chain and sprocket noises
include:
Worn timing chain and/or gears.

Misaligl).ed gears.
Excessive backlash.
Damaged tooth.
Gear or sprocket loose on shaft.
Too much end play in the camshaft or crankshaft.
6-9
PISTON NOISES
Piston pin, piston, and connecting rod noises are
hard to separate. A loose piston pin, for example,
causes a. sharp double knock usually heard when the
engine is idling, or during sudden acceleration then
deceleration of the engine. A piston pin that has been
improperly fitted will. emit a light ticking noise that is
more noticeable with no load on the engine.
Excessive piston-to-cylinder bore clearance will
cause piston slap noise. The noise is similar to a
metallic knock, as if the piston were "slapping" the
cylinder wall during its stroke. As with most engine
noises, understanding the cause of the noise will help
you imagine what the noise sounds like. An indication
of piston slap is a decrease in noise .as the engine
warms up. When the engine is cold, the piston-to-bore
clearance is greater and piston slap will be louder.
Causes of piston noises include:
Worn of loose piston pin or bushing.
Improper fit of pin.
Excessive piston-to-cylinder bore clearance
(piston slap).
Lack of lubrication.
Carbon deposits on top of piston. striking cylinder
head..
Worn or broken piston ring land.
Broken or cracked piston.
e Misaligned connecting rods.
Worn or damaged rings.
Worn or out-of-round cylinder waj.ls.
Excessive ring land clearance.
Insufficient ring-end gap clearance.
Piston 180 degrees out of position.
Incorrect piston cam grind.
VALVE MECHANISM OR VALVE TRAIN

NOISES
A light tapping at one-half engine speed, or any
varying frequency, can indicate a valve train problem.
These tapping noises increase with engine speed.
Before attempting to judge valve train noises,
thoroughly warm up the engine. This will bring all
engine components to a normal state of expansion.
Also, run the engine at various speeds and listen for
engine noise with the hood closed while sitting in the
driver's seat.
NOTICE: This procedure is not recommended

on engines with stainless steel exhaust
manifolds because manifold temperature will
exceed the flash point of the oil causing a fire
with possible personal injury.
If the valve mechanism is abnormally. noisy,
remove the rocker arm covers and use an engine
stethoscope to determine which values or valve train
parts are causirig the noise. Causes of valve
mechanism noises include:
Broken or weak valve spring(s).
Sticking or warped valves.
610
Bent pushrods.
Dirty, stuck, worn or faulty valve lifters.
Damaged or improperly machined camshaft lobes.
Insufficient or poor oil supply to valve train (low
oil pressure).
Worn valve seats.
Excessive valve stem-to-guide clearance.
Worn valve guides.
Worn rocker arms or pushrods.
Broken rocker arm studs.
- Loose or worn rocker arm attachments.
Missing or mispositioned lifter guides.
Loose torque converter-to-flywheel or

flywheel-to-crankshaft bolts will sound similar to
bearing knock. This condition produces several raps
during quick acceleration on a free running engine.
Depending on the idle smoothness, when the
transmission is in gear, the noise may or may not
appear. Check the torque converter-to-flywheel and
flywheel-to-crankshaft bolts before attempting to
investigate any bearing-related .knock.
NOTICE: Be sure the converter-to-flywheel

bolts are not too long. Converter bolts that are
too long may dimple the torque converter clutch
surface causing a shudder condition.
RATTLE {BALANCE SHAFT)

Complaint of an engine noise that sounds like a
tinny, chatter rattle or a knocking noise that seems to
come from the top rear of the engine. This noise is
most pronounced when the engine is hot, and is not
affected by engine load. An example would be dirt
lodged in the root between two gear teeth. Each time
the root between two balance shaft gear teeth meshes
with a cam gear tooth, the balance shaft would be
momentarily forced upward. This pivots the shaft
through the front bearing, .causing a downward force
on the rear bushing that eventually wears the rear
bushing, causing a rattle. Other factors that contribute
to balance shaft bearing rattle include:
A tight link on the timing chain.
Damaged, broken, dirty teeth on the balance shaft
gear.
A worn timing chain.
Misaligned rear balance shaft bushing.
ACCESSORY DRIVE BELT NOISE

If a "thump" noise is heard at or just above idle
speed, the noise could be an indication of accessory
drive belt noise. A thump or knocking noise at or near
idle could be caused by "belt pilling." Belt pilling
occurs in a single belt accessory drive belt when small
particles of belt material separate from the belt
grooves to form small balls or "pills" in the belt
grooves. While some belt pilling is normal, excessive
pilling can cause a thump or knocking noise when the
pills pass over the various pulleys. This causes the belt
to jump off the pulley and then slap back onto the
pulley. The thump or knocking noise can easily be
misdiagnosed as an engine noise.
To diagnose belt pilling, remove the drive belt
and run the engine for no more than 30 to 40 seconds
to confirm that the noise has disappeared. Inspect the
power steering pulley for proper alignment. Then,
inspect all other pulleys for excess paint, debris, or
pills in the grooves. Clean .the pulleys as necessary
with a wire brush.
FLYWHEEL NOISES (AUTOMATIC

TRANSMISSION)
A loose or cracked flywheel will produce an
irregular thud or click. To test for a loose or cracked
flywheel, operate the vehicle at approximately 20 mph
(32 km/h) and shut off the engine. If a thud is heard,
the flywheel may be loose or damaged. This type of
thud is loudest on deceleration.
ENGINE KNOCK DIAGNOSIS

Noises in engines are sometimes characteristic of
the design. Compare the sounds in other engines to
make sure the condition is not normal.
KNOCKS COLD AND CONTINUES FOR

TWO TO THREE MINUTES AND
INCREASES WITH TORQUE
Flywheel contacting splash shield. Reposition
splash shield.
Loose or broken balancer or drive pulleys.
Tighten or replace as necessary.
Excessive piston-to-bore clearance. Replace
piston.
Bent connecting rod.
Cold engine piston knock usually disappears when
the cylinder is grounded out. Cold engine piston
knock which disappears in 1.5 minutes should be
considered acceptable.
HEAVY KNOCK HOT WITH TORQUE

APPLIED
Broken balancer or pulley hub. Replace. parts
necessary.
Loose torque converter bolts.
Exhaust. system grounded. Reposition
necessary.
Flywheel cracked.
Excessive main bearing clearance. Replace
necessary.
Excessive rod bearing clearance. Replace
necessary.
as
as
as
as
LIGHT KNOCK HOT

Detonation or spark knock. Check operation of
Knock Sensor (KS) system. Refer to
SECTION 6E3. Check engine timing and fuel
quality.
Loose torque converter bolts. Tighten bolts.
Exhaust leak at manifold. Tighten bolts and/or
replace manifold.
Excessive rod bearing clearance. Replace bearings
as necessary.

KNOCKS ON INITIAL START-UP BUT
ONLY LASTS A FEW SECONDS
Improper oil viscosity. Install proper oil viscosity
for expected temperatures. Refer to SECTION OB
for engine oil specifications.
Hydraulic lifter bleed down. Clean, test and
replace as necessary.
- When the engine is stopped, some valves
will be open. Spring pressure against lifters
will tend to .bleed lifter down. Attempts to
repair should be made. only if the problem
is consistent.
- An engine that is operated for only short
periods between start-ups may have lifter
noise that last for a few minutes. This is a
normal condition.
Excessive crankshaft end clearance. Replace
crankshaft thrust bearing.
Excessive front main bearing clearance. Replace
worn parts.
KNOCKS AT IDLE HOT
5. Air duct from throttle body.

Block throttle plate in open position.
!@I
!Ll
1. Run engine until it reaches normal operating

temperature. Battery must be at or near full
charge.
2. Tum engine off.
3. Disable fuel and ignition systems.
[I]
Important
Ignition "IGNITION" and BOTH fuel injector

"INJECTOR" fuses must be removed from
underhood electrical center. Refer to
SECTION 8A-1 l.
4. Spark plugs from all cylinders.
Inspect
Record compression readings from all cylinders.

The lowest reading should not be less than 70
percent of the highest and no cylinder reading
should be less than 689 kPa (100 psi).
Problem areas can be identified as follows:
-
Normal - Compression builds up quick and

evenly to specified compression on each
cylinder.
- Piston Rings - Compression is low on first
stroke and tends to build up on following
strokes, but does not reach normal.
Compression improves considerably with
the addition of oil. Use approximately three
squirts from a plunger type oiler.
- Valves - Compression is low on first stroke
and it does not tend to build up in
following strokes. Compression does not
improve much with the addition of oil. Use
approximately three squirts from a plunger
type oiler.
- Head Gaskets - Leaking head gaskets give
nearly the same test results as valve
problems but may be recognized by engine
coolant in the crankcase. Head gasket
leakage between two cylinders will give
low readings on both cylinders.
ENGINE COMPRESSION TEST
!++!
Measure
Engine compression.
A. Install compression gage firmly to cylinder
spark plug hole.
B. Have a helper crank the engine through at
least four compression .strokes in the cylinder
being tested and check the readings on the
gage at each stroke. Record the results.
C. Disconnect gage.
D. Repeat compression test for each cylinder.
A/C compressor or generator bearing. Replace as

necessary.
Valve train. Replace parts as necessary.
Improper oil viscosity. Install proper viscosity oil
for expected temperature. Refer to SECTION OB
for engine oil specifications.
Excessive piston pin clearance. Replace piston and
pin.
Connecting rod alignment. Check and replace rods
as necessary.
Loose crankshaft balancer. Torque and/or replace
worn parts.
Piston pin offset to wrong side. Install correct
piston.
Dirt or foreign material lodged in balance shaft
gear or camshaft gear.
A compression pressure test is performed on the

engine cylinders to determine the condition of the
rings, valves and head gasket.
611
i++I
1.
2.
3.
4.
Install or Connect
Remove block from throttle plate.
Air duct to throttle body.
Spark plugs.
Ignition and fuel injector fuses to underhood
electrical center. Refer to SECTION 8A-ll.
CYLINDER LEAK TEST

Tool Required:
J 35687 Cylinder Leakage Tester
With the use of air pressure, a cylinder leak
test will help to diagnose leakage from the
cylinders. If necessary, it may be used in
conjunction with the engine compression test to
help isolate the cause of leaking cylinders.
6-12
I++!

(IJ Important
Note any cylinder with more leakage than the
others. Normal leakage is 12 to 18 percent.
Any cylinder with 30 percent leakage or more
has a problem.

2. Spark plug.
!@!
Measure
A. Cylinder on compression .stroke (both valves

closed).
B. Apply air pressure using J 35687
It may be necessary to hold crankshaft

balancer bolt/screw to prevent the piston from
moving.
C. Repeat leak test for each cylinder. Record leakage
readings for all cylinders.
!L!
Inspect
There are four primary areas to listen and feel to

diagnose a leaking cylinder.
- Intake system for faulty intake valves.
- Tail pipe for faulty exhaust valves.
- Oil filler tube for piston ring leakage.
-:- Radiator (bubbles in coolant).
!++I
Install or Connect
1. Spark plug.
5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 VIN P
6A3A1
SECTION 6A3A
\)
5.7 LITER VS ENGINE ON-VEHICLE SERVICE

RPO LT1 - VIN P
CAUTIONS in SECTION .9J under "On-Vehicle Service" and the SIR Components and Wiring
Location view in SECTION 9J before performing service on or around SIR components or wiring.
CAUTION: Before removing or installing any electrical unit, or when a tool or equipment could
easily come in contact with ."live" or II.hot at all times" exposed electrical terminals, disconnect
the battery negative cable to help prevent personal injury and/or damage to the vehicle or
components. Unless instructed otherwise, the ignition switch must be in the "OFF" or "LOCK"
position.
NOTICE: Always use the correct fastener in the correct location. When you replace .a fastener, use ONLY the
inhibitors) on the threaded fasteners or fastener. joint interfaces. Generally,. such coatings adversely affect the
and systems.
CONTENTS
General Description ................... Refer to Section 6A3B
On-Vehicle Service ........................................... 6A3A-2
Fuel System Pressure Relief........................ 6A3A-2
Serpentine Drive Belt and Drive Belt
Tensioner .................................................. 6A3A-2
Engine Mounts and Engine
. Mount Brackets ........................................ 6A3A-3
Oil Level Indicator and Oil Level
Indicator Tube .......................................... 6A3A-5
Intake Manifold ............................................ 6A3A-5
EGR Valve Pipe ........................................... 6A3A-7
Exhaust Manifold ......................................... 6A3A-8
Valve Rocker Arm Covers ........................... 6A3A-10
Valve Rocker Arms and Pushrods .............. 6A3A-ll
Valve Rocker Arm Studs ...................~ ......... 6A3A-12
Valve Lifters ................................................. 6A3A-12
Water Pump ................................................... 6A3A-13
Crankshaft Balancer and Hub...................... 6A3A-13
Distributor ..................................................... 6A3A-13
E;ngine Front Cover ...................................... 6A3A-13
-Camshaft Timing Chain, Crankshaft
and Camshaft Sprockets, and Water
Pump Driveshaft ....................................... 6A3A-14
Camshaft ....................................................... 6A3A-16

Valve Spring and Valve Stem Oil Seal.. .... 6A3A-17
Cylinder Heads and Cylinder Head
Gaskets ..................................................... 6A3A-18
Oil Pan ......................................................... 6A3A-21
Oil Pump ...................................................... 6A3A-22
Connecting Rod Bearings ............................ 6A3A-22
Piston and Connecting Rod ......................... 6A3A-24
Crankshaft Bearings.: ................................... 6A3A-25
Engine Flywheel .......................................... 6A3A-27
Crankshaft Rear Oil Seal ............................. 6A3A-28
Crankshaft Rear Oil Seal Housing and
Gasket ....................................................... 6A3A-28
Engine .................... ;...... ;............................... 6A3A-29
Thread Repair ............................................... 6A3A-31
Specifications .................................................... 6A3A-32
Fastener Tightening Specifications .............. 6A3A-32
Engine Specifications ................................... 6A3A-33
Special Tools .................................................... 6A3A-36
6A3A-2
5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P
ON-VEHICLE SERVICE
FUEL SYSTEM PRESSURE RELIEF
CAUTION:
To reduce the risk of fire and
personal injury, it is necessary to
relieve the fuel system pressure
before servicing fuel system
components.
After relieving system pressure, a
small amount of fuel may be released
when servicing fuel lines or
connections. In order to reduce the
chance of personal injury, cover fuel
pipe fittings with a shop towel before
disconnecting, to catch any .fuel that
may leak out. Place the towel in an
approved container when disconnect
is completed.
Tool Required:
J 34730-1 Fuel Pressure Gage
1. Disconnect battery negative cable terminal to
avoid possible fuel discharge if an additional
attempt is made to start the engine.
2. Loosen fuel filler cap to relieve tank vapor
pressure.
3. Connect gage J 34730-1 to fuel press~re
connection. Wrap a shop towel around fittmg
while connecting gage to avoid spilling.
A
B
C
D
E
42
145
146
147
148
149
150
4. Install bleed hose into an approved container and

open valve to bleed system pressure. Fuel
connections are now safe for servicing.
5. Drain any fuel remaining in gage into an
approved container.
SERPENTINE DRIVE BELT AND DRIVE

BELT TENSIONER
Figures 1 and 2
NOTICE: Routine inspection of the dri.ve belt

may reveal cracks in the belt ribs. These cracks
will not impair belt performance and therefore
should not be considered a problem requiring
belt replacement. However, .the belt shoul~ be
replaced if belt slipping occurs or if sections of
the belt ribs are rnissirig.
A single serpentine drive belt is used to drive all

engine accessories. All belt driven accessories are
rigidly mounted with belt tension maintained by a
spring loaded tensioner.
'
The indicator on the movable portion of the
tensioner must be within the limits of the tolerance
marks of the .stationary portion of the tensioner. Any
reading outside of these marks indicates either a
defective belt or tensioner.
INDICATOR MARK
READING FOR REPLACING BELT IN SERVICE
DEFECTIVE PARTS CHECK RANGE
MAXIMUM TOLERANCE BELT READING
MINIMUM TOLERANCE BELT READING
BALANCER, CRANKSHAFT
TENSIONER, DRIVE BELT
GENERATOR
BELT, SERPENTINE DRIVE
PULLEY, DRIVE BELT IDLER
Figure 1 Serpentine Drive Belt
01-1895
F80016A3A
5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A-3

SERPENTINE DRIVE BELT
DRIVE BELT TENSIONER
ILI
!++I
Inspect
Belt length scale on the drive belt tensioner for

the proper installed length. If the belt length scale
does not indicate the proper installed length,
install a new drive belt.
l++I
1. Serpentine drive belt (148).

2. Drive belt tensioner bolts/screws (152).
3. Drive belt tensioner (145).
!++!
Install or Connect
NOTICE:
Refer to "Notice" on page
6A3A-1.
CAUTION: Refer to "Caution" on page

6A3A1.
2. Lift drive belt tensioner (145) downward
(clockwise) off serpentine drive belt (148) using a
socket and handle on tensioner pulley bolt/screw.
l++-l

!~I
Tighten
Drive belt tensioner bolts/screws (152) to

25 N.m (18 lb. ft.).
DRIVE BELT IDLER PULLEY
Install or Connect
1. Serpentine drive belt (148) over tensioner pulley

by pushing down on serpentine drive belt
tensioner (145).
-
Be sure serpentine drive belt (148) is aligned

into proper grooves of accessory drive pulleys.
. The drive belt idler pulley is used in place of the

A/C compressor when the vehicle is not equipped with
air conditioning.
!++!

2. Idler pulley bolts/screws (151).
3. Drive belt idler pulley (150).
l++i
Install or Connect
NOTICE:
6A3A-1.
1. Drive belt idler pulley (150).

2. Idler pulley bolts/screws (151).
!~I
Tighten
Idler pulley bolts/screws (151) to 50 N.m

(37 lb. ft.).
3. Drive belt (148).
ENGINE MOUNTS AND ENGINE MOUNT

BRACKETS
152
Figure 3
145
150
151
152

PULLEY, DRIVE BELT IDLER
BOLT/SCREW, DRIVE BELT IDLER PULLEY
BOLT/SCREW, DRIVE BELTTENSIONER
01-18-15
F80028A3A
Figure 2 - Drive Belt Tensioner and Idler Pulley
NOTICE: When ra1smg or supporting the

engine for any reason, do not use a jack under
the oil pan, crankshaft pulley, or any sheet
metal. Due to a small clearance between the oil
pan and the oil pump screen, jacking against the
oil pan may cause it to be bent against the
pump screen resulting in a damaged oil pickup
unit.
6A3A4
5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P
131
RH SIDE
124
125
126
127
128
129
130
131
132
BRACKET, ENGINE MOUNT

NUT, ENGINE MOUNT
MOUNT, ENGINE
SOLT/SCREW, ENGINE MOUNT
STUD, ENGINE MOUNT
SOLT/SCREW, ENGINE MOUNT
BOLT/SCREW, ENGINE MOUNT BRACKET
INDICATES SEQUENCE
FOR INSTALLING SCREWS
Figure 3 Engine Mounts and Brackets
0301fl
FS0038A3A
5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A5
!L! Inspect
Engine mounts for damage to the rubber portions
of the mount.
- Rubber surface covered with heat check
cracks.
- Rubber cushion separated from the plate of the
mount.
- Rubber cushion split through the center.
!++!

SECTION OA.
2. Engine mount through-bolts/screws (130) and nuts
(125).
3. Raise engine with a jacking fixture.
4. Engine mount bolts/screws (128) and engine
mounts (127).
5. Engine bracket bolts/screws (126) and engine
brackets (124).
I++-!
Install or Connect
NOTICE:
6A3A-1.
1. Engine brackets (124) and engine bracket

bolts/screws (126).
2. Engine mounts (127) and engine mount
bolts/screws (128).
!~I
Tighten
Engine mount and bracket bolts/screws (126

and 128) to 58 N.m (43 lb. ft.).
3. Lower engine.
4. Engine mount through-bolts/screws (130) and nuts
(125).
l~I
Tighten
Engine mount through-bolt/screw nuts (125) to

80 N.m (59 lb. ft.).
-or Engine mount through-bolts/screws (130) to
95 N.m (70 lb. ft.).
OIL LEVEL INDICATOR AND OIL LEVEL

INDICATOR TUBE
!++!
1. Bolt/screw securing oil level indicator tube

bracket to engine block.
2. Level indicator and tube from engine block.
I++!
Install or Connect
NOTICE:
6A3A-1.
1. Clean tube and apply sealant, GM PIN 12345493

or equivalent, around tube 12.7 mm (0.50 inch)
below bead.
2. Tube into engine block and rotate into position.
3. Bolt/screw securing tube bracket to engine block.
I~!
Tighten
Oil level indicator tube bolt/screw to 12 N.m

(106 lb. ft.).
4. Oil level indicator.
INTAKE MANIFOLD
Figures 4 through 6
I++!

6A3A-1.
1.
2.
3.
4.
5.
6.

Drain coolant. Refer to SECTION 6B.
Throttle body air duct.
Wiring harness connectors from fuel injectors.
Left and right wiring harnesses and lay aside.
Accelerator cable bracket bolts/screws, bracket
and cables from throttle body (3).
7. Accelerator control/cruise control servo cable
adjuster, if equipped. Refer to SECTION 5E2.
8. Relieve fuel system pressure. Refer to "Fuel
System Pressure Relief" in this section.
9. Secondary air injection diverter valve hoses.
10. Fuel pipe connectors from fuel rail (2).
11. Fuel rail bolts/screws (1).
12. Fuel pressure regulator vacuum tube (7).
13. Fuel rail (2) from intake manifold (6) and lay
aside.
14. Vacuum and crankcase vent hoses.
15. Exhaust gas recirculation (EGR) control valve
relay nut and control valve relay.
16. Emission canister purge solenoid bracket nut and
solenoid.
17. EGR valve nuts and valve.
18. EGR valve pipe nuts and studs.
19. Secondary air injection pipe fitting, nuts and pipe
from intake and right exhaust manifold.
20. Generator rear brace. Refer to SECTION 6D3.
21. Coolant hoses from throttle body (3).
22. Throttle body bolts/screws (4), throttle body (3)
and gasket (5).
23. Intake manifold bolts/screws (8) and studs (9).
24. Intake manifold (6) and gaskets (10).
Discard gaskets (10).
Clean
Intake manifold bolts/screws (8) and studs (9).

Cylinder head, engine block and intake manifold
sealing surfaces.
6A3A-6
1
2
3
4
5
6
7
BOLT/SCREW, FUEL INJECTION FUEL RAIL

RAIL, MULTIPORT FUEL INJECTION FUEL
BODY, THROTILE
BOLT/SCREW, THROTILE BODY
GASKET, THROTILE BODY
MANIFOLD, INTAKE
TUBE, FUEL PRESSURE REGULATOR VACUUM
01-18-95
FS0048A3A
Figure 4 - Fuel Rail and Throttle Body
!H!
Install or Connect
l~i
NOTICE:
6A3A-l.
1. Apply a 5 mm (.189 inch) bead of RTV sealer,

GM PIN 12345336 or equivalent, to the front and
rear of the engine block. Extend the bead 13 mm
(0.5 inch) up each cylinder head to seal and retain
the gaskets.
2. Intake manifold (6) with new gaskets (10).
3. Intake manifold bolts/screws (8) and studs (9).
l~I
Tighten
Intake manifold bolts/screws (8) and studs (9)

in a first pass to 8 N.m (71 lb. in.) in sequence
as shown in Figure 6. Tighten in sequence in a
second pass to final specifications of 48 N,m
(35 lb. ft.).
4. Throttle body (3), gasket (5) and throttle body
bolts/screws (4).
l~I
5.
6.
7.
8.
9. Secondary air injection pipe and nuts.
j~I
Secondary air injection pipe exhaust manifold

fitting to 55 N.m (41 lb. ft.).
10. EGR valve pipe studs and nuts.
11. EGR valve and nuts.
12. EGR control valve relay and nut.
!~!
Tighten
Accelerator cable bracket bolts/screws to

10 N.m (90 lb. in.).
Tighten
EGR valve pipe studs to 6 N.m (53 lb. in.).

EGR valve pipe nuts to 25 N,m (18 lb. ft.).
EGR valve nuts to 25 N,m (18 lb. ft.).
EGR control valve relay nut to 25 N.m
(18 lb. ft.).
13. Emission canister purge solenoid and bracket
bolt/screw.
I~!
Tighten
Emission canister purge solenoid bracket

bolt/screw to 6 N.m (53 lb. in:).
14 Vacuum and crankcase vent hoses.
Tighten
Throttle body bolts/screws (4) to 26 N.m

(18 lb. ft.).
Coolant hoses to throttle body (3).
Generator rear brace. Refer to SECTION 6D3.
Accelerator control/ cruise control servo cable
Accelerator cable bracket, bolts/screws and cables.
Tighten
1. Fuel rail (2) to intake manifold (6).

2. Fuel pressure regulator vacuum tube (7).
3. Fuel rail bolts/screws (1).
!~I
4.
5.
6.
7.
Tighten
Fuel rail bolts/screws (1) to 20 N,m

(15 lb. ft.).
Fuel pipe connectors to fuel rail (2).
Secondary air injection diverter valve hoses.
Left and right wiring harnesses.
Wiring harness connectors to fuel injectors.
5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 VIN P 6A3A-7
.FRT
02-0195
FSOOSIA3A
Figure 6 - Intake Manito.id Tightening Sequence
8. Throttle body air duct.

10. Refill with coolant. Refer to SECTION 6B.
EGR VALVE PIPE

Figure 7

6A3A-1.
1. Transmission fluid level indicator.
SECTION OA.
3. Catalytic converter hanger. Refer to SECTION 6F.
4. Support exhaust system.
5. Catalytic converter. Refer to SECTION 6F.
6. Transmission fluid filler tube. Refer to
SECTION 7A.
7. EGR pipe (12) to exhaust manifold mounting
bolt/screw (229).
8. Lower vehicle.
9. EGR pipe nuts (14) and gasket (22) from intake
manifold.
10. EGR pipe (12) from vehicle.
Discard Gasket (22).
Clean
Intake manifold sealing surface.

A
6
8
9
10
!++!
SEALER
MANIFOLD ASSEMBLY, INTAKE
BOLT/SCREW, INTAKE MANIFOLD
STUD, INTAKE MANIFOLD
GASKET, INTAKE MANIFOLD
NOTICE:
6A3A-1.
FS9096A38
Figure 5 - Intake Manifold
Install or Connect
1. EGR pipe gasket (22), pipe (12) and nuts (14) to

intake manifold finger tight.
2. Raise and suitable support vehicle. Refer to
SECTION OA.
3. EGR pipe (12) and EGR pipe bolt/screw (229) to
exhaust manifold.
6A3A8 5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 >VIN P
::/
13
11
12
13
14
15
22
229
14
12
1~1
4.
5.
6.
7.
8.
9.
Figure 7 - Secondary Air Injection and EGR Valve Pipe
Tighten
EGR pipe bolt/screw (229) to 25 N.m

(18 lb. ft.).
Transmission fluid filler tube. Refer to
SECTION 7A.
Catalytic converter. Refer to SECTION 6F.
Remove exhaust system support.
Catalytic converter hanger. Refer to SECTION 6F.
Lower vehicle.
Tighten EGR pipe nuts (14) at intake manifold.
!~!
VALVE, SECONDARY AIR INJECTION CHECK

PIPE, EGR VALVE
STUD, EGR VALVE PIPE
NUT, EGR VALVE PIPE
PIPE, SECONDARY AIR INJECTION
GASKET, EGR VALVE PIPE
BOLT/SCREW, EGR VALVE PIPE
02-1-95
FSOOIIA3A
Tighten
EGRpipe nuts (14) to 25 N.m (18 lb. ft.).

10. Transmission. fluid level indicator.
EXHAUST MANIFOLD
Figures 7 and B
RIGHT EXHAUST MANIFOLD
!++!

6A3A-1.
SECTION OA.
4. Serpentine drive belt. Refer to "Serpentine Drive
Belt and Tensioner" in this section.
16
17
18
19
20
21
26
MANIFOLD, EXHAUST
GASKET, EXHAUST MANIFOLD
MANIFOLD, EXHAUST
STUD, EXHAUST MANIFOLD
BOLT/SCREW, EXHAUST MANIFOLD
SPACER, EXHAUST MANIFOLD BOLT
21
20
19
OS04H
FS0071A3A
Figure 8 Exhaust Manifolds
5. Oil level indicator and tube. Refer to "Oil Level

Indicator and Tube" in this section.
6. Oxygen sensor electrical connector.
7. Three rear exhaust manifold bolts/screws (21).
8. Lower vehicle.
9. Secondary air injection pipe fitting from exhaust
manifold. Refer to SECTION 6E3.
10. EGR 'valve pipe. Refer to "EGR Valve Pipe" in
this section.
11. Generator and rear lower brace. Refer to
.SECTION 603.
12. Remaining exhaust manifold studs (20) and
bolt/screw (21).
13. Exhaust manifold (19) and exhaust manifold
gasket (18).
Install or. Connect
NOTICE:
Tighten
Exhaust manifold studs (20) and bolts/screws

(21) to 40 N.m (30 lb. ft.).
Indicator and Oil Level Indicator Tube" in this
section.
10. Lower vehicle.
11. EGR valve pipe. Refer to "EGR Valve Pipe" in
this section.
12. Secondary air injection pipe fitting to exhaust
1~1 Tighten
Clean
Exhaust manifold and cylinder head sealing

surfaces.
l++-1
!~I
Secondary air iqj~~Jion pipe fitting to 55 N.m

(41 lb. ft.).
13. Battery negative
LEFT EXHAUST MA
l+-+i
Remove or Di .
6A3A-1.
1. Exhaust manifold gasket (18) and exhaust
manifold (19).
2. Front three exhaust manifold studs (20) and
bolt/screw (21).
3. Generator and rear lower brace. Refer to
SECTION 603.
SECTION OA.
5. Remaining exhaust manifold bolts/screws (21).

6A3A-1.
SECTION OA.
4. Lower vehicle.
5. Brake booster vacuum hose.
6A3A-10

9. Exhaust manifold bolts/screws (21).
10. Exhaust manifold ( 16) and exhaust manifold
gasket (17).
Clean
Exhaust manifold and cylinder head sealing

surfaces.
I++!
Install or Connect
NOTICE:
6A3A-1.

manifold (16).
2. Exhaust manifold bolts/screws (21).
l~l
Tighten
Exhaust manifold bolts/screws (21) to 40 N.m

(30 lb. ft.).
l~I
6.
7.
8.
9.
10.
Tighten
5. Lower vehicle.
6. Crankcase vent hose.
7. Generator and rear generator brace. Refer to
SECTION 603.
manifold. Refer to SECTION 603.
9. Valve rocker arm cover bolts/screws (24).
10~ Valve rocker arm cover (23) and gasket (25).
Clean
Valve rocker arm cover and cylinder head gasket

surfaces.
l++l
Install or Connect
NOTICE:
6A3A-1.
1. Gasket (25) and valve rocker arm cover (23).

!~!
Tighten
Valve rocker arm cover bolts/screws (24) to

.
12 N.m (106 lb. in.).
3. Secondary air injection pipe fitting to exhaust
4. Generator and rear generator brace. Refer to
SECTION 603.
Secondary air injection pipe fitting to. 55 N.m

(41 lb. ft.).
Brake booster vacuum hose.
SECTION OA.
Lower vehicle.
VALVE ROCKER ARM COVERS

Figure 9
RIGHT COVER
I++!

6A3A1.
SECTION OA.
4. Automatic transmission fluid level indicator tube
bracket from transmission housing, if equipped.
23 COVER, VALVE ROCKER ARM

24 BOLT/SCREW, VALVE ROCKER ARM COVER
25 GASKET, VALVE ROCKER ARM COVER
01-1895
FS008WA
Figure 9 Valve Rocker Arm Cover

SECTION OA.
7. Transmission fluid level indicator tube to
transmission housing, if equipped.
8. Serpentine drive belt. Refer. to "Serpentine Drive
9. Lower vehicle.
27
28
29
30
31
PUSHROD,VALVE
STUD, VALVE ROCKER ARM BALL
ARM, VALVE ROCKER
BALL, VALVE ROCKER ARM
NUT, VALVE ROCKER ARM
LEFT.COVER
!++!

2. Secondary air injection hose from pump to check
valve.
5. Valve rocker arm cover .bolts/screws (24).
6. Valve rocker arm cover (23) and gasket (25).
.Clean
Install or Connect
NOTICE:
6A3A-1.
!~J Tighten
4.
5.
6.

12 N.m (106 lb. in.).
Accelerator control/cruise control servo cable
Secondary .air injection pipe fitting to exhaust
Secondary air injection hose to pump .and check
valve.
VALVE ROCKER ARMS AND. PUSHRODS

Figure 10
I+-.!
Refer to SECTION 6A3B for inspection of the

valve rocker arms, studs and pushrods.
!++!
Install or Connect

3.
Figure 10 - Valve Rocker Arms and Pushrods
Important

surfaces.
!++!
01-18-95
FSOONA3A
NOTICE:
6A3A-1.
Important
When installing valve rocker arms (29) and

valve rocker arm. balls (30), coat their bearing
surfaces with pre. lube, GM PIN 1052365 or
equivalent. Install these components. and the
pushrods (27) in the locations from which they
were removed.
1. Pushrods (27). Make sure pushrods (27) seat in
lifter sockets.
2. Valve rocker arms (29).
3. Valve rocker
balls (30) and valve rocker arm
nuts (31).
arm
l~.J
Tighten
Valve rocker arm nuts (31) until all lash is

eliminated.
1. Valve rocker arm covers. Refer to "Valve Rocker

Arm Covers" in this section.\
2. Valve rocker arm nuts (31) .and valve rocker arm
balls (30).
3. Valve rocker arms (29) and pushrods '(27).
Place the valve rocker arms (29), valve rocker
arm balls (30) and pushrods (27) in a rack so
that they can be reinstalled in the same
locations from which they were removed.
Refer to ''Notice" .on page
(ll
Adjust
1. Turn crankshaft until cast arrow on crankshaft hub

is in 12 o'clock position and number 1 cylinder is
in firing position (top dead center).
Watch number 1 cylinder valves as crankshaft
hub arrow approaches 12 o'clock position. If a
valve moves as the arrow moves to position,
the engine is in number 6 cylinder firing

SECTION OA.
7. Transmission fluid level indicator tube to
transmission housing, if equipped.
9. Lower vehicle.
27
28
29
30
31
PUSHROD,VALVE
STUD, VALVE ROCKER ARM BALL
ARM, VALVE ROCKER
LEFT.COVER
!++I

2. Secondary air injection hose from pump to check
valve.
6. Valve rocker arm cover (23) and gasket (25).
011895
FS0096A3A
Figure 1O Valve Rocker Arms and Pushrods
[I]
Clean
surfaces.
1-++i
install or Connect
NOTICE:
6A3A-l.
3.
4.
5.
6.
Tighten
Valve rocker arm cover bolts/screws. (24) to

12 N;m (106 lb. in.).
Accelerator control/cruise control servo cable
Secondary . air injection pipe fitting to exhaust
Secondary air injection hose to pump and check
valve.
VALVE ROCKER ARMS AND. PUSHRODS

Figure 10
!+-+!

valve rocker arms, studs and pushrods.
!-++!
Install or Connect

!~I
Important
NOTICE:
6A3A-1.
[I]
Important

valve rocker arm. balls (30), coat their bearing
surfaces with. pre. lube, GM PIN 1052365 or
equivalent. Install these components and .the
pushrods (27) in the locations from which they
were removed.
1. Pushrods (27). Make sure pushrods (27) seat in
lifter sockets.
3. Valve rocker arm balls (30) and valve rocker arm
nuts (31).
I~!
Tighten
Valve rocker arm nuts (31) until all lash is

eliminated.

Arm Covers" in this section.
2. Valve rocker arm nuts (31) and valve rocker arm
balls (30).
3. Valve rocker arms (29) and pushrods (27).
Place the valve rocker arms (29), valve rocker
arm balls (30) and pushrods (27) in a rack so
that they can be reinstalled in the .. same
locations from which they were removed.
Refer 'to "Notice" on page
Adjust
1. Turn crankshaft until cast arrow on crankshaft hub

is in 12 o'clock position and number 1 cylinder is
in firing position (top dead center).
Watch number 1 cylinder valves as crankshaft
hub arrow approaches 12 o'clock position. If a
valve moves as the arrow moves to position,
the engine is in number 6 cylinder firing

NOTICE:
6A3A-1.
1. Coat valve lifter rollers with pre lube, GM
2. Valve lifters (36) in the same location from which
they were removed.
3. Valve lifter guides (35), valve lifter guide retainer
(33) and bolts/screws (32).
!~!
Tighten

4. Valve rocker arms and pushrods. Refer to "Valve
Rocker Arms and Pushrods" in this section.
5. Valve rocker arm cover. Refer to "Valve Rocker

6. Intake manifold. Refer to "Intake Manifold" in
this section:
WATER PUMP
The water pump is directly .driven by the water
pump shaft which is coupled to a bearing, gear and
shaft driven by the camshaft sprocket. Refer to
SECTION 6B for water pump service procedures.
Do not crank engine over after match-marking

crankshaft hub and engine front cover.
Rotating crankshaft will misalign installation
of balancer to crankshaft possibly resulting in
engine imbalance.
5. Crankshaft hub bolt/screw and washer.
6. Crankshaft hub (45) using J 39046.
The crankshaft hub ( 45) can be installed by a
different procedure if the engine should
accidentally be cranked over after match marking
the hub and engine front cover.
A. Set number 1 piston to top dead center.
B. Install crankshaft hub (45) with cast arrow on
hub in the 12 o'clock position.
!++!
NOTICE:
1. Crankshaft hub ( 45) using J 39046.

2. Crankshaft hub washer and bolt/screw.
3. Crankshaft balancer (42) and bolts/screws (46).
rn

SECTION OA.
3. Balancer bolts/screws (46) and balancer (42).
4. Match-mark crankshaft hub (45) to engine front
cover.
Important
If balancer is replaced, new balance weights of

the same size must be installed on the new
balancer in the same hole locations as the old
balancer.
Figure 12
!++!
6A3A-1.
CRANKSHAFT BALANCER AND HUB
Tool .Required:
.
J 39046 Crankshaft Hub Remover/Installer
Install or Connect
I~!
Tighten
Crankshaft balancer hub bolt/screw to 100 N.m

(74 lb. ft.).
Crankshaft balancer bolts/screws (46) to
85 N.m (63 lb. ft.).
5. Lower vehicle.
DISTRIBUTOR
The distributor is mounted to the engine front
cover and driven by a pin connected to the camshaft
sprocket. Refer to SECTION 6D4 for the distributor
service procedures.
ENGINE FRONT COVER

42
Figure 13
Tool Required:
J 39087 Water Pump Driveshaft Assembly
Front Cover Oil Seal Protector
!++!
42
45
46
77
BALANCER.CRANKSHAFT
HUB, CRANKSHAFT BALANCER
BOLT/SCREW, CRANKSHAFT BALANCER
WEIGHT, CRANKSHAFT BALANCER
01-18-95
F80118A3A
Figure 12 - Crankshaft Balancer and Hub

3. Water pump. Refer to SECTION 6B.
4. Crankshaft balancer and hub. Refer to
"Crankshaft Balancer and Hub" in this section.
6A3A14
5.
6.
7.
8.

Distributor. Refer to SECTION 6D4.

Oil pan. Refer to "Oil Pan" in this section.
Engine front cover bolts/screws (52).
Engine front cover (50) and gasket (51).
CAMSHAFT TIMING CHAIN, CRANKSHAFT

AND CAMSHAFT SPROCKETS, AND
WATER PUMP DRIVESHAFT
Clean
Engine front cover and engine block gasket

surfaces.
IL!
Figures 14 and 15
Inspect
Tools Required:
J 5825-A Crankshaft Sprocket Remover
J 5590 Crankshaft Sprocket Installer
J 39243 Water PumpDriveshaft Assembly
Remover
Installer
J 39087 Water Pump Driveshaft Front. Cover
Oil Seal Protector
J 39089 Water Pump Driveshaft 0-Ring Seal
Installer
Engine front cover (50) for damage to the oil

seals or gasket surface. Refer to SECTION 6A3B
to replace front cover oil seals if necessary.
!++!
Install or Connect
NOTICE:
6A3A-l.
[II
Important
!++!
Be careful not to damage the oil seal when

installing the engine front cover over the water
pump driveshaft.
1. Gasket (51) and engine front cover (50) using
J 39087 on water pump driveshaft.
2. Engine front cover bolts/screws (52).
!~!
1. Engine front cover. Refer to "Engine Front

Cover" in this section.
2. Rotate crankshaft until sprocket alignment marks
on the crankshaft sprocket (62) and camshaft
sprocket (57) are aligned as shown in Figure 14.
3. Camshaft sprocket bolts/screws (56).
4. Camshaft sprocket (57) and camshaft timing chain
(61).
Tightel'!
Engine front cover bolts/screws (52) to 12

N.m (106 lb. in.).
3. Oil pan. Refer to "Oil Pan" in this section.
4. Distributor. Refer to SECTION 6D4.
5. Crankshaft balancer and hub. Refer to
"Crankshaft Balancer and Hub" in this section.
11]
Important
Do not turn the crankshaft after the timing

chain has been removed to prevent damage to
pistons or valves.
50
74
50
51
52
74
COVER , ENGINE FRONT

GASKET, ENGINE FRONT COVER
BOLT/SCREW, ENGINE FRONT COVER
PIN, ENGINE FRONT COVER LOCATING
Figure 13 Engine Front Cover
041895
FT0258A3A

5. Water pump driveshaft bolts/screws (64) and
water pump driveshaft (63) using J 39243.
Remove and discard 0-ring seal from water

pump driveshaft (63).
6. Crankshaft sprocket (62) using J 5825-A.
7. Key, if necessary.
!L!
Inspect
Refer to SECTION 6A3B for component

inspection.
!++!
Install or Connect
NOTICE:
6A3A-1.
1. Key, if previously removed.

2. Crankshaft sprocket (62) using J 5590.
3. Water pump driveshaft (63) using J 41546.
4. Water pump driveshaft bolts/screws (64).
l~I
6A3A-15
Tighten
Water pump driveshaft bolts/screws (64) to

12 N.m (105 lb. in.).
5. Camshaft sprocket (57) and timing chain (61).
Camshaft sprocket and water pump driveshaft
gears must mesh, or damage to camshaft
retainer (59) could occur.
6. Camshaft sprocket bolts/screws (56).
Make sure that camshaft and crankshaft
sprocket alignment marks align as shown in
Figure 14.
!~!
Tighten
Camshaft sprocket bolts/screws (56) to 25 N.m

(18 lb. ft.).
7. New 0-ring seal to water pump driveshaft using
J 39089.
68
A
B
C
56
57
58
59
TIMIMG MARKS
KEYWAY
PIN
BOLT/SCREW, CAMSHAFT .SPROCKET
SPROCKET, CAMSHAFT
BOLT/SCREW, CAMSHAFT RETAINER
RETAINER. CAMSHAFT
60 CAMSHAFT
61 CHAIN, TIMING
62 SPROCKET, CRANKSHAFT
63 DRIVESHAFT, WATER PUMP
64 BOLT/SCREW, WATER PUMP DRIVESHAFT
68 RING, CRANKSHAFT POSITION SENSOR RELUCTOR
Figure 14 - Camshaft, Sprockets and Water Pump Driveshaft
05-04-95
FT029GA3A
6A3A-16
65 DRIVESHAFT, OIL PUMP

66 BOLT/SCREW, OIL PUMP DRIVESHAFT
01-18-95
FS0136A3A
Figure 16 - Oil Pump Driveshaft
60 CAMSHAFT
01-18-95
FS0126A3A
Figure 15 - Crankshaft Sprocket Replacement
CAMSHAFT
l+-+I

this section.
3. Bolt/screw (66) and oil pump driveshaft (65).
5. Camshaft sprocket. Refer to "Camshaft Timing
Chain, Crankshaft and Camshaft Sprockets, and
Water Pump Driveshaft" in this section.
6. Valve lifters. Refer to "Valve Lifters" in this
section.
7. Discharge air conditioning system. Refer to
SECTION lB.
8. Air conditioning compressor and condenser hose
from condenser.
9. Air conditioning receiver and dehydrator hose

from. condenser.
l 0. Radiator with air conditioning condenser. Refer to
SECTION 6B.
11. Air conditioning condenser support.
12. Camshaft retainer bolts/screws (58) and camshaft
retainer:(59).
[I]
Important
All camshaft journals are the same diameter so

care must be used fo removing the camshaft to
avoid damage to the bearings.
13. Camshaft (60).
A. Install three 7.9375 mm - 18 x 101.6 mm
(0.3125 - 18 x 4.0 inch) bolts/screws in
camshaft bolt holes.
B. Carefully rotate and pull camshaft out of
bearings.
rn
important
Refer to "Cleaning, Inspection and Repair" in

SECTION 6A3B for inspection and
measurement procedures for the camshaft.
Refer to "Valve Rocker Arms and Pushrods"
in SECTION 6A3B to measure camshaft lobe
lift.

9. Air conditioning compressor and condenser hose
to condenser.
10. Charge air conditioning system. Refer to
SECTION lB.
section.
12. Camshaft sprocket. Refer to "Timing Chain,
Crankshaft and Camshaft Sprockets, and Water
Pump Driveshaft" in this section.
14. Oil pump driveshaft (65) and bolt/screw (66).
!~I
Tighten

this section.
VALVE SPRING AND VALVE STEM OIL

SEAL
A 0.3125 - 18 x 4.0 INCH BOLT
60 CAMSHAFT
Figure 17 Removing Camshaft
IL'l'I
Inspect
Camshaft bearings for scratches, pits, or loose fit

in their bores. Replace the camshaft bearings, if
necessary. Refer to SECTION 6A3B.
Install or Connect
NOTICE:
6A3A-J.
1. When installing a new camshaft (60), coat

camshaft lobes with "Molykote" or its equivalent.
2. When installing a new camshaft (60), replace all
valve lifters to ensure durability of the. camshaft
lobes and lifter rollers.
3. Lubricate all camshaft journals with engine oil.
4. Camshaft (60).
5. Camshaft retainer (59) and camshaft retainer
bolts/screws (58).
!~I
Tools Required:
J 22794 Spark Plug Port Adapter
J 5892-C Valve Spring Compressor (Head-On)
050416
FS0148A3A
Tighten .
Camshaft retainer bolts/screws (58) to 12 N.m

(105 lb. in.).
6. Air conditioning condenser support.
7. Radiator with air conditioning condenser. Refer to
SECTION 6B.
B. Air conditioning receiver and dehydrator hose to
condenser.
!++I
1. Valve rocker arms and pushrods at cylinder to be

serviced. Refer to "Valve Rocker Arms and
Pushrods" in this section.
2. Spark plug at cylinder to be serviced.
3. Install J 22794 to spark plug hole and apply
compressed air to hold valves in place.
4. Compress valve spring (69) using J 5892-C
(Figure 18).
5. Valve stem keys (72).
6. Valve spring cap (70).
7. Valve spring (69).
8. Valve stem oil seal (73).
!++!
Install or Connect
1. Valve stem oil seal (73) and seat seal against

valve spring shim (76).
3. Valve spring cap (70).
4. Compress valve spring (69) using J 5892-C.
A. Use grease to hold keys in place while
disconnecting J 5892-C.
B. Remove J 22794.
C. Make sure keys seat properly in upper groove
of valve stem.
D. Tap end of stem with plastic-faced hammer to
seat keys, if necessary.
6. Spark plug.
6A3A-18
5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO' LT1 VIN P
!~I
J 22794
Tighten
Spark plug to 20 N,m (15 lb. ft.).

7. Valve rocker arms ~d pushrods. Refer to "Valve
CYLINDER HEADS AND CYLINDER HEAD

GASKETS
Figure20
LEFT CYLINDER HEAD
31 NUT, VALVE ROCKER ARM

69 SPRING, VALVE
01-1895
FS0158A3A
Figure 18 Compressing Valve Spring
71

SECTION OA.
2. Drain coolant. Refer to SECTION .6B.
3. Catalytic converter. Refer to SECTION 6E
4. Lower vehicle.
this section.
6. Secondary air injection hose from check valve.

7. Engine coolant bleed pipe bolt/screw from left
cylinder head using a backup wrench on pipe
fitting.
8. Ignition coil bolts/screws and coil. Refer to
SECTION 604.
9~ Left exhaust manifold. Refer to "Exhaust
Manifolds" in this section.
10. Spark plug wire harness from clips.
11. Spark plug wire harness from spark plugs.
12. Spark plugs .
.13. Coolant temperature sensor electrical connector.
14. Valve rocker arm cover bolts/screws and cover.
Refer to ".Valve Rocker Arm Cover" in this
section.
15. Valve rocker arm nuts, rocker arms, and pushrods.
Refer to "Valve Rocker Arms and Pushrods" in
this section.
16. Cylinder head bolts/screws (81).
17. Cylinder head (34) and cylinder head gasket(82).
Discard cylinder head gasket (82).
rn.
Important
R~fer to SECTION 6A3B for cylinder head
cleaning, inspection and repair.
!++!
Install 'or Connect
NOTICE:
6A3A-1.
69
70
71
72
73
76
SPRING, VALVE
CAP, VALVE SPRIN.G
VALVE, INTAKE
KEV, VALVE STEM
SEAL, VALVE STEM OIL
SHIM, VALVE SPRING
01-1895
F8018GA3A
Figure 19 Valve (Intake Shown, Exhaust Similar)
1. New cylinder head gasket (82) with yellow tab

facing up;
2. Cylinder head (34) over locator pins and cylinder
head gasket (82).
3. Coat threads of cylinder head bolts/screws, (81)
with sealing compound, GM P/N 1052080 or
equivalent.
4. Cylinder head bolts/screws (81) finger tight.
5.7 LITER VS ENGINE ON~VEHICLE SERVICE RPO LT1 VIN P
[I]
Important
When installing cylinder head bolts/screws, be

sure to mark the short bolts/screws for
identification after installation to insure that
correct torque specifications are met.
l~J Tighten
13. Engine coolant air bleed pipe and bolt/screw to

le~ cylinder head using a backup wrench on pipe
fitting.
!~!
14.
Cylinder head bolts/screws (81) in sequence to
30 N.m (22 lb. ft.) (Figure 20).
15.
Long and medium length bolts/screw +

additional 80 degrees ( 3 degrees).
Short length bolts/screws + additional
67 degrees ( 3 degrees).
5. Pushrods and valve rocker arms. Refer to "Valve
6. Right valve rocker arm cover and bolts/screws.
16.
!~I
Tighten
Valve rocker arm cover bolts/screws to 12 N.m

(106 lb. in.).
7. Coolant temperature sensor electrical connector.
8. Spark plugs.
!~I
Tighten
Spark plugs to 20 N,m (15 lb. ft.).

9. Spark plug wire harness to spark plugs.
10. Spark plug wire harness to clips.
11. Left exhaust manifold. Refer to "Exhaust
12. Ignition coil bolts/screws and coil.
!~I
Tighten
Ignition coil studs to 40 N.m (30 lb. ft.).
17.
18.
19.
Tighten
Engine coolant bleed pipe bolt/screw to

40 N.m (30 lb. ft.).
Secondary air injection hose to check valve.
Intake manifold. Refer to "Intake Manifold" in
this section.
SECTION OA.
Lower vehicle.
Refill with coolant. Refer to SECTION 6B.
RIGHT CYLINDER HEAD
l++I

SECTION OA.
2. Drain coolant. Refer to SECTION 6B.
3. Serpentine drive belt and belt tensioner. Refer to
"Serpentine Drive Belt and Tensioner" in this
section.
bracket from transmission housing, if equipped.
5. Air conditioning compressor rear brace bolt/screw
from engine block.
6. Air conditioning compressor electrical connector.
7. Air conditioning compressor front mounting
bolts/screws and lay air conditioning compressor
aside.
8. Right exhaust manifold. Refer to "Exhaust
9. Lower vehicle.
B
16 12
6A3A19
34
7 11 15
A GASKET TAB (YELLOW SIDE UP)
B
34
67
81
82
BOLT TIGHTENING SEQUENCE

HEAD, CYLINDER
BLOCK, ENGINE
BOLT/SCREW, CYLINDER HEAD
GASKET, CYLINDER HEAD
01-1895
F8017GA3A
Figure 20 Cylinder Head
6A3A20

11. Right valve rocker arm cover. Refer to "Valve
Rocker Arm Covers" in this section.
this section.
13. Engine coolant air bleed pipe bolt/screw from left
cylinder head using a backup wrench on pipe
fitting.
14. Lower radiator hose from water pump and
reposition.
15. Heater hose from water pump and reposition.
16. Engine coolant air bleed pipe hose from radiator.
18. Generator bracket bolts/screws and generator and
air conditioning compressor and power steering
pump bracket.
20. Spark plugs.
23. Cylinder head (34) and gasket (82).
Discard gasket (82).
24. Engine cool.ant air bleed pipe bolt/screw using a
backup wrench on pipe fitting, nut and pipe from
cylinder head.
rn
Important
Refer to SECTION 6A3B for cylinder head

lH!
Install or Connect
NOTICE:
6A3A-1.
1. Engine coolant air bleed pipe, nut and bolt/screw

using a backup wrench on pipe fitting to cylinder
head finger tight.
2. New cylinder head gasket (82) with yellow tab
facing up.
3. Cylinder head (34) over dowe.l pins and gasket
(82).
4. Coat threads of cylinder head bolts/screws (81)
with sealing compound, GM PIN 1052080 or
equivalent.
5. Cylinder head bolts/screws (81) finger tight.
rn
important
When installing cylinder head bolts/screws be

sure to mark the short bolts/screws for
identification after installation to insure that
correct torque specifications are met.
l~I
Tighten
Cylinder head bolts/screws (81) in sequence to

30 N,m (22 lb. ft.) (Figure 20).
Long and medium length bolts/screws +

additional 80 degrees ( 3 degrees).
Short length bolts/screws + additional
67 degrees ( 3 degrees).
!~!
Tighten
Engine coolant air bleed pipe bolt/screw to

40 N.m (30 lb. ft.).
Engine coolant air bleed pipe nut to 17 N.m
(13 lb. ft.).
6. Pushrods and valve rocker arms. Refer to "Valve
7. Spark plugs.
!~!
Tighten
Spark plugs to 20 N.m (15 lb. ft.).

9. Generator and air conditioning compressor and
power steering pump bracket and generator
bracket bolts/screws.
!~!
Tighten
Generator bracket bolts/screws to 40 N,m

(30 lb. ft.).
10. Right valve rocker arm cover. Refer to ''Valve
Rocker Arm Covers" in this section.
13. Engine coolant air bleed pipe hose to radiator.
14. Heater hose to water pump and reposition.
15. Lower radiator hose to water pump.
16. Engine coolant air bleed pipe bolt/screw to left
cylinder head using a backup wrench.
!~I
17.
18.
19.
20.
21.
22.
Tighten
Engine coolant air bleed pipe bolt/screw to

40 N.m (30 lb. ft.).
Intake manifold. Refer to "Intake Manifold" in
this section.
SECTION OA.
Right exhaust manifold. Refer to "Exhaust
Air conditioning compressor front mounting
bolts/screws.
Air conditioning compressor electrical connector.
Air conditioning compressor rear brace bolt/screw
to engine block.
!~I
Tighten
Air conditioning compressor rear brace

bolt/screw to 33 N,m (24 lb. ft.).
bracket to transmission housing, if equipped.
24. Serpentine drive belt and belt tensioner. Refer to
section.

25. Lower vehicle.
26. Refill with coolant. Refer to SECTION 6B.
Clean
1. Oil pan and engine block gasket surfaces.

2. Apply a small amount of silcone sealer, GM
PIN 1052914 or equivalent, to the front cover and
engine block junction and to the rear oil seal
housing and engine block junction. Apply sealer
25 mm (1 inch) in either direction of the radius
cavity of these junctions. See Figure 22.
OIL PAN
Figures 21 and 22
!++!

6A3A1.
!++!
Install or Connect
NOTICE:
2. Air intake duct.
SECTION OA.
4. Drain engine oil.
6. Oil level sensor electrical connector.
7. Oil level sensor (178) from oil pan (54).
9. Exhaust pipe hanger bolt/screw and reposition
pipe.
10. Transmission fluid cooler lines from clip at oil
pan (automatic transmission).
11. Starter motor. Refer to SECTION 602.
12. Converter cover bolts/screws and cover (automatic
transmission).
13. Engine mount through-bolts/screws.
14. Raise engine with jacking fixture.
15. Oil pan bolts/screws (84), studs (83) and nuts
(85).
16. Oil pan (54), reinforcements (53) and gasket (55).
Rotate crankshaft to reposition counterweights

if necessary.
6A3A-1.
1. Oil pan gasket (55), oil pan (54) and

reinforcements (53).
2. Oil pan nuts (85), bolts/screws (84) and studs
(83).
I~!
Tighten
Comer oil pan bolts/screws (84) or stud (83),

and nuts (85) to 20 N:m (15 lb. ft.).
Remainder of oil pan bolts/screws (84) and
studs (83) to 12 N.m (106 lb. in.).
3. Lower engine.
5. Oil level sensor (178) to oil pan (54).
!~!
Tighten
Engine mount through-bolts/screws to 95 N,m

(70 lb. ft.).
.
Engine oil level sensor (178) to 22 N.irt'2~":"
(16 lb. ft.).
6. Converter cover and bolts/screws (autom(\tic
transmission).
53
A
A SEALER
53 REINFORCEMENT, OIL PAN
54 PAN, OIL
55 GASKET, OIL PAN.
01-18-15
FS9178A3B
Figure 21 - Oil Pan Sealer
6A3A22
i~I
7.
8.
9.
10.
11.
12.
13.
14.
15.
5.7 LITER V8. ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P
Tighten
Converter cover bolts/screws to 10 N.m

(89 in. lb.).
Starter motor. Refer to SECTION 602.
Exhaust pipe hanger bolt/screw.
Oil level sensor electrical connector.
Lower vehicle.
Air intake duct.
Refill engine with oil.
Refill with coolant. Refer to SECTION 6B.
OIL PUMP
Figure 23
j++!

2. Crankshaft oil deflector nuts.
3. Bolt/screw (120) attaching oil pump (118) to rear
crankshaft bearing cap.
4. Crankshaft oil deflector (119), oil pump (118) and
driveshaft (89) and retainer (95).
[I]
Important
53
Refer to SECTION 6A3B for oil pump

!H!
Install or Connect
NOTICE:
6A3A-l.
1. Oil pump (118), and driveshaft (89) with retainer
(95).
Align slot on end of driveshaft (89) with drive
tang on oil pump (118).
2. Crankshaft oil deflector (119).
3. Bolt/screw (120) attaching oil pump (118) to rear
crankshaft bearing cap.
l~I
Tighten

Crankshaft oil deflector nuts to 40 N.m (30 lb.
ft.).
CONNECTING ROD BEARINGS
53
54
55
83
84
85
178
190
REINFORCEMENT, OIL PAN

PAN, OIL
GASKET, OIL PAN
STUD, OIL PAN
BOLT/SCREW, OIL PAN
NUT, OIL PAN
SENSOR, ENGINE OIL LEVEL SWITCH
BRACKET, ENGINE WIRING HARNESS
Figure 24
Connecting rod bearings are the precision insert
type and do not use shims for adjustment. Do not file
connecting rods or rod caps. If clearances are found to
be excessive, a new bearing will be required. Service
01-30-95
FS0198A3A
Figure 22 - Oil Pan

Keep bearings (101) with their original
connecting rod (104) and connecting rod cap
(99) for re-assembly.
Wipe oil from bearings (101) and crankpins.
120
!L'l'I
inspect
Bearings (101) for excessive wear or damage.
!@!
Measure
NOTICE:
6A3A-l.
1. Crankpin for out-of-round and taper with a

micrometer. Refer measurements to
If not within specifications, replace or
recondition crankshaft (98).
If installing new bearings (101), determine
new bearing size from maximum crankpin
diameter.
2. Bearing clearances, using gauging plastic.
A. Place piece of gauging plastic the full width of

bearing (101), (parallel to crankshaft) onto
crankpin.
89 DRIVESHAFT, OIL PUMP
95 RETAINER, OIL PUMP DRIVESHAFT
118 PUMP, OIL
119 DEFLECTOR, CRANKSHAFT OIL
120 SOLT /SCREW, OIL PUMP
05.04.915
FT0186A3A
Figure 23 Oil Pump
bearings are available in standard size and 0.025 mm

(0.001 inch) and 0.05 mm (0.002 inch) undersize for
use with new and used standard size crankshafts, and
in 0.025 mm (0.010 inch).and 0.5 mm (0.020 inch)
undersize for use with reconditioned crankshafts.
When removing a connecting rod cap, you may
find a 0.025 mm (0.010 inch) undersize bearing. These
are used in manufacturing for selective fitting.
f++I

2. Oil pump. Refer to "Oil Pump" in this section.
[I]
Important
Place match marks or numbers on connecting

rods (104) and connecting rod caps (99).
Connecting rod caps (99) must be assembled
to their original connecting rods (104).
3. Connecting rod nuts (100).
4. Connecting rod cap (99) and bearings (101).
Plastic gage should be positioned in middle

of bearing (101). Bearing (101) is thickest
in center and bearing clearance must be
measured at this location.
B. Install connecting rod cap (99) with bearing
(101) onto connecting rod (104).
C. Install connecting rod nuts (100).
!~!
Tighten
Connecting rod nuts (100), evenly, to 27 N,m

(20 lb .. ft.), +additional 55 degrees.
NOTICE: Do not turn the crankshaft with the

gauging plastic installed or the accuracy of the
measurement will be affected.
D. Remove connecting rod nuts ( 100) and
connecting rod cap (99). The gauging plastic
will be found adhering to either the connecting
rod cap (99) or crankshaft journal. Leave the
gauging plastic in place to measure it.
E. Measure gauging plastic at its widest, using
scale provided with gauging plastic. Refer
measurements to "Specifications" in this
section.
If clearance is greater than specified, select
an undersize bearing (101) and re-measure
clearance.
If clearance cannot be brought to
specifications, regrind crankpin. If crankpin
is already at maximum undersize, replace
crankshaft (98).
F. Remove gauging plastic.
6A3A-24
NOTICE: Refer to "Notice" on page

6A3A-1.
1. Coat inside surface of bearings (101) with engine
oil.
I~!
98
Tighten
Connecting rod nuts (100), evenly, to 27 N,m

(20 lb. ft.) +additional 55 degrees.
I@!
Measure
Connecting rod side clearance.

A. When all connecting rod bearings (101)
have been installed, tap each connecting
rod (104) lightly parallel to crankpin to
make sure they have clearance.
B. Measure side clearance between connecting
rod caps (99) using a feeler gage, or dial
indicator.
C. Rod side clearance should be 0.16 to
0.35 mm (0.006 to 0.014 inch).
98
PISTON AND CONNECTING ROD

Figure 24
1.
2.
3.
4.
Tools Required:
J 8037 Piston Ring Compressor
J 5239 Connecting Rod Bolt Guide Set
Oil pump. Refer to "Oil Pump" in this section.
Cylinder head. Refer to "Cylinder Heads and
Gaskets" in this section.
Ring ridge.
A. Turn crankshaft (98) until piston (103) is at
bottom of its stroke.
B. Place a cloth on top of piston (103).
C. Use a ridge reamer to remove ring ridge.
D. Turn crankshaft (98) so piston (103) is at top
of its stroke.
E. Remove cloth and cutting debris.
[I)
Important

to their original connecting rods (104).
5. Connecting rod nuts (100) and connecting rod cap
(99).
6. Connecting rod (104) and piston (103) out of top
of engine block using J 5239.
[I)
103
tFRT
A FLANGES OF CONNECTING RODS MUST FACE TO

THE FRONT IN THE LEFT' BANK AND TO THE
REAR IN THE RIGHT BANK
B ARROW TO BE ORIENTED TO FRONT OF ENGINE
98 CRANKSHAFT
99 CAP, CONNECTING ROD
100 NUT, CONNECTING ROD
101 BEARING, CONNECTING ROD
102 BOLT/SCREW, CONNECTING ROD
103 PISTON
104 ROD, CONNECTING
01-18911
FS9141A3B
Important
Refer to SECTION 6A3B for cleaning,

inspection and repair of the piston and
connecting rod.
Figure 24 - Piston and Connecting Rod
II]
Clean
1. Cylinder bores with hot water and detergent or

with a light honing.
2. Swab bores with engine oil and a clean, dry cloth.
!++!
If replacing the rear crankshaft .bearing, check

for the correct part numbet. Some rear
crankshaft bearings are 0.20 mm (0.008 inch)
wider than standard. The crankshaft will be
identified by "0.008 "stamped on the rear
counterweight.
Install or Connect
NOTICE:
Refer to "Notice" .on page
6A3A-1.
1. Coat piston (103), piston rings, cylinder bore, and

bearing surfaces with engine oil.
2. Piston (103) into its original bore using J 5239
and J 8037 and lightly tapping top of piston (103)
with a wooden hammer handle.
A. When installing piston (103) and connecting
rod (104), stamped arrow on piston (103) must
point to front of engine while flange on
connecting rod (104) must face toward front of
piston on left-hand and face toward rear of
piston on right-hand. Refer to Figure 25.
B. Hold J 8037 firmly against engine block until
all piston rings have entered cylinder bore;
3. Connecting rod ~aps (99) onto their original
connecting rods (104).
Align match marks or numbers which were

placed on connecting rod (104) and connecting
rod cap (99) during removal.
!~I
Tighten
!++!
1.
2.
3.
4.

Oil pump. Refer to "Oil Pump" in this section.
Spark plugs.
Cap (107 or 109) and lower bearing of crankshaft
bearing (110 or 111) requiring replacement.
5. Insert J 8080 into oil hole in crankshaft journal.
6. Rotate crankshaft (98) allowing J 8080 to push
against insert's straight (unnotched) side. This will
roll upper bearing out of block.
7. Remove J 8080 from crankshaft (98).
!L"'!
Inspect
In general, the lower half of the crankshaft

bearing insert (except # 1 bearing) shows a
greater wear and the most distress from fatigue. If
upon inspection the lower half is suitable for use,
it can be assumed that the upper half is also
satisfactory. If the lower half shows evidence of
wear or damage, both upper and lower halves
should be replaced. Never replace one half
without replacing the other half.
[I]
Connecting rod nuts (100), evenly, to 27 N.m

(20 lb. ft.) +additional 55 degrees.
5. Cylinder head. Refer to "Cylinder Heads and
Gaskets" in this section.
Important
To obtain the most accurate results when

checking crankshaft bearing clearances, use
gauging plastic.
If the engine is out of the vehicle and upside
down, the crankshaft will rest on the upper
bearings and the total clearance can be
measured between the lower bearing and
journal. If the engine is to remain in the
vehicle, the crankshaft must be supported
upward to remove any clearance from the
upper bearing. The total clearance can then be
measured between the lower bearing and
journal.
To assure the proper seating of the crankshaft,
all bearing cap bolts/screws should be at their
specified torque. In addition, prior to checking
fit of bearings, the surface of the crankshaft
journal and. bearing should be wiped clean of
oil.
CRANKSHAFT BEARINGS
Figures 25 and 26
Tool Required:
J 8080 Main Bearing Shell Remover and
Installer
Crankshaft bearings are of the precision insert
type. If clearances are found to be excessive, a new
bearing, both upper and lower halves, will be
required. Service bearings are available in both
standard size and undersize.
Selective fitting of both connecting rod and
crankshaft bearing inserts is necessary in production
in order to obtain close tolerances. For example, on
a rear crankshaft bearing you may find one half of
a standard insert with one half of a 0.0254 mm
(0.001 inch) undersize insert which will decrease
the clearance 0.0127 mm (0.0005 inch) from using
a full standard bearing.
Important
!@!
Measure
1. With oil pan and oil pump removed, and starting

with rear crankshaft bearing, remove bearing cap
and wipe oil from journal and bearing cap. Note
location of stud bolts/screws.
6A3A26
5.7 LITER V8 ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P
115
67
98
107
108
109
110
111
112
113
114
115
116
139
BLOCK, ENGINE
CRANKSHAFT
CAP, CRANKSHAFT BEARING
BOLT/SCREW, CRANKSHAFT BEARING CAP
BEARING, CRANKSHAFT
BEARING, CRANKSHAFT
STUD, CRANKSHAFT REAR OIL SEAL RETAINER
GASKET, CRANKSHAFT REAR OIL SEAL HOUSING
HOUSING, CRANKSHAFT REAR OIL SEAL
NUT, CRANKSHAFT REAR OIL SEAL HOUSING
BOLT/SCREW, CRANKSHAFT REAR OIL SEAL HOUSING
PIN, CRANKSHAFT REAR OIL SEAL HOUSING LOCATOR
139
(
01-1815
FS020IA3A
Figure 25 Crankshaft Removal
2. Place a piece of gauging plastic the full width of

bearing (parallel to the crankshaft) on journal.
II]
.---------------------.
Important
Do not rotate the crankshaft while the gauging

plastic is between the bearing and journal.
3. Install bearing cap and evenly tighten retaining
bolts/screws to specifications. Bearing cap must
be tightened to specification in order to assure
proper reading. Variations in torque affect the
compression of the gauging plastic.
I~!
Tighten
Crankshaft bearing cap bolts/screws (108) and

studs to 105 N.m (77 lb. ft.).
4. Remove bearing caps. The flattened gauging
plastic will be found adhering to either the
bearing shell or journal.
5. Without removing gauging plastic, measure its
compressed width (at the widest point) with
graduations on gauging plastic envelope. Normally
crankshaft bearing journals wear evenly and are
01-188S
F80218A3A
Figure 26 Removing Crankshaft Bearing

not out-of-round. However, if a bearing is being
fitted to an out-of-round journal 0.025 mm (0.001
inch) maximum, be sure to fit to maximum
diameter of journal: If bearing is fitted to
minimum diameter, and journal is out-of-round
0.025 mm (0.001 inch), interference between
bearing and journal will result in rapid bearing
failure. If flattened gauging plastic tapers toward
middle or ends, there is a difference in clearance
indicating taper, low spot or other irregularity of
bearing or journal. Be sure to measure journal
with a micrometer if flattened. gauging plastic
indicates more than 0.025 mm (0.001 inch)
difference.
6. If bearing clearance is within specifications,
bearing insert is satisfactory. If clearance is not
within specifications, replace insert Always
replace both upper and lower inserts as a unit.
When beating cap is installed and clearance is
less than 0.025 mm (0.001 inch), inspect for burrs
or nicks.
7. A standard, 0.025 mm (0.001 inch) or 0.05 mm
(0.002 inch) uhdersize bearing may produce
proper clearance. If not, it. will be necessary to
regrind crankshaft journal for use with next
undersize bearing. After selecting new bearing,
recheck. clearance.
8. Proceed to next bearing. When checking #1
cranJ(:shaft bearing, loosen accessory drive belt so
as to prevent tapered reading with gauging plastic.
After all bearings have been checked, rotate
crank~haft to see that there is no excessive drag.
E3
Install or Connect
NOTICE:
6A3A-1.
1. Crankshaft bearings (110 and 111) into engine

block (67) and crankshaft bearing caps (107) and
rear crankshaft bearing cap (109).
A. Coat crankshaft bearings (110 and 111) with

oil.
B. Insert plain (unnotched) end between
crankshaft and indented or notched side of
block. Rotate bearing into place using J 8080
as previously described, and remove J 8080
from oil hole in. crankshaft joqrnal.
2. Crankshaft bearing caps (l 07) and rear crankshaft
bearing cap (109} with assembled crankshaft
bearings (110 and 111) with arrows pointing
toward front of engine.
3. Crankshaft bearing cap ho.Its/screws (108) and
studs.
With crankshaft (98), crankshaft bearings (110

and 111) and crankshaft bearing caps (107)
and rear crankshaft bearing cap (109) installed
and bolts/screws (108) and studs started, thrust
crankshaft (98) rearward to set and align
bearing caps (107 and 109). Then thrust
crankshaft forward to align rear faces of rear
crankshaft bearings (111).
I~!
Tighten
Crankshaft bearing cap bolts/screws (108) and

studs to 105 N,m (77 lb. ft.).
!@I
Measure
Crankshaft end play, using a dial indicator or

feeler gage. Refer to "Specifications" in this
section.
If using a feeler gage, measure between the
front of the rear crankshaft bearing cap (109)
and the crankshaft thrust surface.
ENGINE FLYWHEEL
Figure 27
ENGINE FLYWHEEL REPLACEMENT
I++!
L Transmission. Refer to SECTION 7 A for an

automatic transmission, SECTION 7B for a
manual transmission and SECTION 7C for the
clutch.
2. Engine flywheel bolts/screws (136 or 138) and
engine flywheel (135 or 137}.
!++I
Install or Connect
NOTICE:
6A3A-1.
1. Engine flywheel (135 or 137) and engine flywheel

bolts/screws (136 or 138).
!~!
Tighten
Bolts/screws (136 or 138) to 100 N.m

(74 lb. ft.).
2. Transmission. Refer to SECTION 7A for an
automatic transmission, SECTION 7B for a
manual transmission and SECTION 7C for the
clutch.
ENGINE FLYWHEEL BALANCING
Figure 27
!LI
Inspect
Engine flywheel (135 or 137) for missing or loose

converter-to-flywheel bolts/screws. Tighten or
Converter for damage, or missing balance
weights. If converter is damaged or balance
weights are missing, replace converter. Refer to
SECTION 7A.
If engine flywheel is replaced, new balance
weights (134) of the same size must be installed
on new flywheel in same hole locations as old
flywheel.
6A3A-28
5.7 LITER V8 ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P
CRANKSHAFT REAR OIL SEAL

Figures 25, 28 and. 29
Tool Required:
J 35621 Rear Main Seal Installer
L Engine flywheel. Refer to "Engine Flywheel
Replacement" under "Engine Flywheel" in this
section.
Care should be taken not to nick crankshaft
sealing surface when removing seal.
2. Crankshaft rear oil seal.
Using notches provided in: crankshaft rear oil
seal housing ( 114), pry out seal with a
screwdriver.
I++!
Install or Connect
1. Coat new seal entirely with engine oil.

2. Seal onto J 35621.
3. J 35621 onto rear of crankshaft (98). Tighten
screws snugly to ensure seal will be installed
squarely .over crankshaft (98).
4. Crankshaft rear oil seal to crankshaft (98) and

crankshaft rear oil seal housing (114).
5. Tighten wing nut on J 35621 until it bottoms.
6. Remove J 35621 from crankshaft rear oil seal
.
housing (114).
7. Engine flywheel. Refer to ''Engine Flywheel
section.
CRANKSHAFT REAR OIL SEAL HOUSING

AND GASKET
Figures 25 and 28
l++I
1. Engine flywheel. Refer to "Engine Flywheel

section.
133
(
A
114
A SEAL REMOVAL NOTCHES .

114 HOUSING, CRANKSHAFT REAR OIL SEAL
01-181&
F8023IAaA
Figure 28 - Removing Crankshaft Rear Oil Seal
B
A
... B
. 'C
<98
133
134
135
136
137
138
FOR MANUAL TRANSMISSION

FOR AUTOMATIC TRANSMISSION
LOCATOR HOLE
CRANKSHAFT
PIN, FLYWHEEL LOCATOR
WEIGHT, FLYWHEEL
FLYWHEEL
BOLT/SCREW, FLYWHEEL
FLYWHEEL
01-1895
FS0228A3A
Figure 27 - Engine Flywheel
Figure 29 - Installing Crankshaft Rear Oil Seal

3. Crankshaft rear oil seal housing nuts (115) and
bolts/screws (116).
4. Crankshaft rear oil seal housing (114) with the
assembled seal, and gasket (113).
5. Crankshaft rear oil seal from crankshaft rear oil
seal housing (114).
Clean
Gasket surfaces.
!++!
Install or Connect
NOTICE:
6A3A-l.
[I]
Important
Always Ue a new crankshaft rear oil seal and

a new oil seal housing gasket (113) during the
installation of the crankshaft rear oil seal
hoqsing (114).
1. Ne:w oil seal housing gasket (113) and
crankshaft rear oil seal housing (114) on
. studs (112).
It is not necessary to use any type of sealant to
hold oil seal housing gasket (113) in place.
2. Crankshaft rear oil seal housing nuts (115)
and bolts/screws (116).
!~!
Tighten
Crankshaft rear oil seal housing nuts (115) and

bolts/screws (116) to 15 N,m (11 lb. ft.)'.
3. New oil pan gasket.
5. New crankshaft rear oil seal. Refer to
"Crankshaft Rear Oil Seal" in this section.
6. Engine flywheel. Refer to. "Engine
Flywheel Replacement" under "Engine
Flywheel" in this section.
ENGINE
CAUTION: See "Caution" on page 6A2A-1
of this section.
1. Discharge air conditioning system. Refer to
2.
3.
4.
5.
6.
7.
8.
9.
SECTION lB.
Battery positive cable.
SECTION OA.
Front wheels and tires. Refer to. SECTION 3E.
Drain engine oil.
Converter bolts/screws (automatic transmission).
6A3A29
10. Front fascia lower deflectors. Refer to

SECTION 10-5.
11. Stabilizer bar bolts/screws. Refer to
SECTION 3C.
13. Air conditioning hose from condenser and
compressor; Refer to SECTION lB.
14. Transmission fluid cooler lines from radiator
(automatic transmission). Refer to SECTION 6B.
15. Lower radiator hose from radiator. Refer to
SECTION 6B.
16. Lower heater hose from water pump. Refer to
SECTION 6B.
17. Electrical ground straps frqm right side of engine
block.
18. Shift linkage from transmission. Refer to
SECTION 7A or SECTION 7B.
19. Propeller shaft after match marking. Refer to
SECTION 4A.
20. Torque arm from transmission. Refer to
.
SECTION 3D.
21. Intermediate steering shaft from rack and pinion.
Refer to SECTION 3F4..
22. Electrical ground straps from left side of frame
rail.
23. Electrical connectors from wheel speed sensors.
24. Lower vehicle.
. 25. Air intake duct.
26. Fuel lines from fuel rail. Refer to SECTION 6C.
adjuster, if equipped. Refer to SECTION5E2.
28. Cruise and accelerator control cables from throttle
body.
29. Upper and lower radiator hoses from water pump.
31. Upper heater hose from water pump. Refer to
SECTION 6B.
32. Engine coolant air bleed pipe hose from,~ridiator.
33. Air conditioning receiver and dehydrator hose
from condenser. Refer to SECTION lB.
34. Air conditioning hose from expansion tube. Refer
to SECTION lB.
35. Brake. lines from antilock brake system (ABS)
brake combination valve. Refer to SECTION. 5.
36. Power steering reservoir and reposition.1,:R~fer to
SECTION lB.
37. Brake lines and clips from ABS hydraulic
modulator. Refer to SECTION 5.
38. Right-hand body hinge pillar trim panel. Refer to
SECTION 10-5.
39. Three engine wiring harness connectors (blue,
black and white connectors) and evaporator
temperature sensor connector.
40. Forward lamp wiring harness connectors ..
41. Powertrain control module (PCM) and harness.
Place PCM and harness on top of engine.
6A3A-30
42. Engine wire harness through front of dash.

Place harness on top of engine.
43. Positive lead at generator.
44. Positive lead at junction block.
45. Negative lead at mounting stud (located next to
the junction block).
46. Lower shock attachment bolts/screws and nuts
from lower control arm.
47. Upper control arm ball. stud from steering
knuckle. Refer to SECTION 3C.
SECTION OA.
49. Position lift table under engine and front
crossmember. Kent-Moore tool number J 39580 or
equivalent may be used.
50. Front crossmember and transmission support
.
bolts/screws. Refer to SECTION 10-3.
51. Raise vehicle from front crossmember engine, and
transmission.
52. Secure struts to front crossmember.
53. Transmission. Refer to SECTION 7A or
SECTION 7B.
54. Clutch housing and clutch (manual transmission).
55. Power steering lines from power steering pump.
56. Hoses from air conditioning compressor. Refer to
SECTION lB.
57. Air conditioning compressor bolts/screws a.nd
compressor. Refer to SECTION lB.
58. Engine mount through-bolts/screws. Refer to
"Engine Mounts and Brackets" in this section.
59. Engine from front crossmember.
rn
Important
Refer to SECTION 6A3B for engine block

!++I
Install or Connect
NOTICE:
Refer to "Notice" on page 6A2A-1.
1. Engine to front crossmember.

2. Engine mount through-bolts/screws. Refer to
"Engine Mounts and Brackets" in this section.
3. Power steering lines to power steering pump.
4. Air conditioning compressor and bolts/screws.
5. Hoses to air conditioning compressor. Refer to
SECTION lB.
6. Clutch housing and clutch. Ref er to
SECTION 7C.
7. Transmission. Refer to SECTION 7A or
SECTION 7B.
8. Position engine lift table and install engine,
transmission and engine frame by lowering
vehicle to front crossmember.
9. Front crossmember and transmission support

10. Engine lift table.
11. Lower vehicle.
12. Upper control arm ba.11 stud to steering knuckle.
13. Lower shock attachment bolts/screws and nuts to
lower control arm.
14. Negative lead at mounting stud (located next to
junction block).
16. Engine wire harness though front of dash.
rn
Important
When reinstalling engine wiring harness back

through front of dash, the rubber grommet
MUST BE INSTALLED PROPERLY to
ensure correct sea.ling. If grommet is torn or
damaged for any reason, it must be replaced.
17. PCM and harness.
18. Forward lamp wiring harness connectors.
19. Wiring harness connectors.
20. Right-hand body hinge pillar trim panel. Refer to
SECTION 10-5.
21. Bra.ke lines and clips to ABS hydraulic modulator.
Refer to SECTION 5.
22. Bra.ke lines to ABS bra.ke combination valve.
Refer to SECTION 5.
23. Air conditioning hose to expansion tube. Refer to
SECTION lB.
24. Air conditioning receiver and dehydrator hose to
condenser. Refer to SECTION lB.
25. Engine coolant air bleed pipe hose to radiator.
26. Bra.ke booster vacuum hose.
27. Upper and lower radiator hose to water pump.
29. Cruise and accelerator control cables to throttle
body
30. Fuel lines to fuel rail. Refer to SECTION 6B.
SECTION OA.
32. Electrical connectors to wheel speed sensor.
33. Electrical ground straps to left side of frame rail.
34. Intermediate steering shaft to rack and pinion.
Refer to SECTION 3F4.
35. Torque arm to transmission. Refer to
SECTION 3D.
37. Shift linkage to transmission. Refer to
SECTION 7A or SECTION 7B.
38. Electrical ground straps to right side of engine
block.
39. Lower heater hose to water pump. Refer to
SECTION 6B.

40. Lower radiator hose to radiator. Refer to
SECTION 6B.
41. Transmission fluid cooler lines to radiator
Belt and Tensioner" in the section.
43. Air conditioning hose to condenser and
compressor. Refer to SECTION lB.
44. Stabilizer bar bo Its/sere w s. Refer to
SECTION 3C.
SECTION 10-5.
46. Converter bolts/screws (automatic transmission).
48. Lower vehicle.
49. Refill with engine oil. Refer to SECTION OA.
50. Refill with engine coolant. Refer to
SECTION 6B.
51. Front wheels and tires. Refer to SECTION 3E.
52. Battery positive cable.
54. Bleed brake system. Refer to SECTION 5El.
SECTION 3B.
56. Charge air conditioning system. Refer to
SECTION lB.
57. Air intake duct.
58. Align wheels. Refer to SECTION 3A.
THREAD REPAIR
Figure 30
Damaged threads may be reconditioned by
drilling out, re-threading and installing :1- s~itable
thread insert. General purpose thread reparr kits are
available commercially.
CAUTION: Wear safety glasses to avoid

eye damage.
1. Determine size, pitch and depth of damaged
thread. If necessary, adjust stop collars on cutting
tool and tap to required depth.
[I]
Important
Refer to kit manufacturer's instructions

regarding size of drill arid tap to be used.
2. Drill out damaged thread. Clean out chips.
3. Tap hole.
A. Lubricate tap with light engine oil.
B. Clean thread.
[I]
Important
Avoid build-up of chips. Back out tap every

few turns and remove chips.
4. Thread the thread insert onto mandrel of installer.
Engage tang of insert onto end of mandrel.
5. Lubricate insert with light engine oil (except when
installing in aluminum) and install.
[I]
Important
When correctly installed, insert should be flush

to one turn below surface.
6. If tang of insert does not break off when backing
out installer, break tang off with drift pin.
STEP 2
STEP 3
STEP 4
STEP 5
01-18-95
F80268A3A
Figure 30 - Repairing Threaded Holes
6A3A-32
SPECIFICATIONS
FASTENER TIGHTEI\IING SPECIFICATIONS
Accelerator Control Cable Bracket Bolt/Screw ., ............ :.................................................... .12 N.m (106 lb. in.)
Air Conditioning Cpmpressor .Rear Brace-to-Engine Block Bolt/Screw............................... 33 N.m (24 lb. ft.)
Camshaft Retainer Bolt/Screw .............................................................................................. 12.N;m (105 lb. in.)
Camshaft Sprocket Bolt/Screw ................................................................................................ 25 N.m (l8 lb. ft.)
Catalytic Converter-to-Exhaust Manifold Nut ........................................................................ 21 N.m (15 lb .. ft.)
Connecting Rod Nut.. ................................................ ,..................... 27 N,m (20 lb. ft.) + additional 55 degrees
Crankshaft Balancer Bolt/Screw ............................................................................................... 85 N.m (63 lb. ft.)
Crankshaft Balancer Hub Bolt/Screw .......... ,........................................................................ 100 N.m (74 lb. ft.)
Crankshaft Bearing Cap Bolt/Screw .............. ,...................................................................... 105 N.m (77 lb. ft.)
Crankshaft Rear Oil Seal Housing Nut and Bolt/Screw ....................................................... 15 N.m (H lb. ft.)
Cylinder Head Bolts/Screws .................................................................................................... 30 N.m (22 lb. ft.)
Long and Medium Length Bolts/Screws + Additional 80 Degrees ( 3 Degrees)
Short Length Bolts/Screw + Additional 67 Degrees ( 3 Degrees)
Distributor _Bolt/Screw .......................... '. ........................................................................ 12 N.m (106 lb. in.)
Drive Belt Idler Pulley Bolt/Screw .......................................... :......................................... 50 N,m (37 lb. ft.)
Drive Belt Tensioner Bolt/Screw ........................................................................................ 25 N.m (18 lb. ft.)
EGR Control Valve Relay Nut.. .......... :.......................................... ;................................... 25 N.m (18 lb. ft.)
EGR Valve Nut .................................................................................................................... 25 N.m (18 lb. ft.)
Engine Block Oil Gallery Plug .......................................................................................... 20 N.m (15 lb. ft.)
Engine Bracket Bolt/Screw ................................................................................................. 58 N.m (43 lb. ft.)
Engine Coolant Air Bleed Pipe Bolt/Screw ....................................................................... 40 N.m (30 lb. ft.)
Engine Coolant Air Bleed Pipe Nut ........ ,......................................................................... 17 N.m (13 1b. ft.)
Engine Front Cover Bolt/Screw ...................................................................... ;................. 12 N.m (106 lb. in.)
Engine Mount Through-Bolt Nut .................................................,.., .................................. 80 N.m (59 lb. ft.)
Engine Mount Through-Bolt/Screw .................................................................................... 95 N.m (70 lb. ft.)
Engine Mount-to-Frame or Engine Bolt/Screw ................................................................. 58. N.m (43 lb. ft.)
Engine Oil Level Sensor ..................................................................................................... 35 N.m (26 lb. ft.)
Evaporatiye Emission Canister Purge Solenoid Valve Bracket Bolt/Screw ...................... 6 N.m (53 lb. in.)
Exhaust Manifold Bolt/Screw and Stud ............................................................................. 40 N.m (30 lb. ft.)
Flywheel Bolt/Screw ......................................................................................................... 100 N.m (74 lb. ft.)
Fuel Injection Fuel Rail Bolt/Screw .................................................................................. 10 N.m (90 lb. in.)
Fuel Pump Switch and Engine Oil Pressure Gage Sensor ............................................. 12 N.m (105 lb. in.)
Generator Bracket Bolt/Screw............................................................................................. 40 N.m (30 lb. ft.)
Ignition Coil Bolt/Screw ..................................................................................................... 40 N.m (30 lb. ft.)
Intake Manifold Bolt/Screw and Stud
First Pass ............................................................................................................................... 8 N.m (71 lb. in.)
Final Pass ............................................................................................................................. 48 N.m (35 lb. ft.)
Knock Sensor ....................................................................................................................... 20 N.m (15 lb. ft.)
Oil Filter Adapter Bolt/Screw ............................................................................................. 25 N.m (18 lb. ft.)
Oil Level Indicator Tube Nut.. ......................................................................................... 12 N.m (106 lb. in.)
Oil Pan
Corner Bolt/Screw and Nut ................................................................................................ 20 N,m (15 lb. ft.)
Side Rail Bolt/Screw ......................................................................................................... 12 N.m (106 lb. in.)
Oil Pan Deflector Nut ......................................................................................................... 40 N.m (30 lb. ft.)
Oil Pan Drain Plug ............................................................................................................. 20 N.m (16 lb. ft.)
Oil Pump Cover Bolt/Screw ............................................................................ :................... 9 N.m (80 lb. in.)
Oil Pump Driveshaft Bolt/Screw .................................................................. ;..................... 18 N.m (13 lb. ft.)
Oil Pump-to-Rear Crankshaft Bearing Cap Bolt/Screw, ................................................... 90 N.m (66 lb. ft.)
Oil Temperature Sensor........................................................ '. ............................................ 12 N.m (108 lb. in.)
Secondary Air Injection Pump Bracket Bolt/Screw .......................................................... 40 N.m (30 lb. ft.)
Secondary Air Injection Pipe Fitting-to-Exhaust Manifold ............................................... 55 N.m (41 lb. ft.)
Spark Plug ........................................................................................................................... 20 N.m (15 lb. ft.)
Starter Motor Bolt/Screw ......................................................................................... ;.......... 47 N.m (35 lb. ft.)
Throttle Body Bolt/Screw ................................................................................................... 25 N,m (18 lb. ft.)
Transmission Converter Cover Bolts/screws ..................................................................... 10 N.m (89 lb. in.)
Valve Lifter Guide Retainer Bolt/Screw ............................................................................ 25 N.m (18 lb. ft.)
Valve Rocker Arm Cover Bolt/Screw .............................................................................. 12 N,m (106 lb. in.)
Valve Rocker Arm Stud ...................................................................................................... 68 N,m (50 lb. ft.)
Water Pump Driveshaft Bearing Retainer Bolt/Screw ..................................................... 12 N.m (105 lb. in.)
Water Pump Bolt/Screw ...................................................................................................... 45 N.m (33 lb. ft.)

ENGINE SPECIFICATIONS 5.7l (LT1)
GENERAL
TypeV8 Displacement .................................................................................................................... 5;7L (350 CID)

Bore ........................................................................................................................................ ;101.60 mm (4.0001)
Stroke ........................................................................................................................................ 88.39 mm (3.4801)
Compression Ratio ......................................................................................................................................... l 0.4: 1
Firing Order .................................................................................................................................... 1-8-4-3-6-5-7-2
Spark Plugs
Type .................................................................................................................................................... AC41-943
Gap ......................................................................................................................................... 1.24 mm (0.0501)
Torque .................................................................................................................................. 20 N.m (15 lb. ft.)
Oil Pressure (Minimum) .................................................................. 41.4 kPa (6.0 psig) at 1,000 engine rpm
...................................................................................................... 124.1 kPa (18.0 psig) at 2,000 engine rpm
...................................................................................................... 165.5 kPa (24.0 psig) at 4,000 engine rpm
Oil Filter Torque ................................................................................................................. 21 N.m (15 lb. ft.)
CYLINDER BORE
Diameter ...............................................................:...................... 101.618- 101.643 mm (4.0007 - 4.0017 inch)

Out-of-Round
Production ............................................................................................................ 0.02 mm (0.001 inch) MAX.
Service Limit ....................................................................................................... 0.05 mm (0.002 inch) MAX.
Taper
Production
Thrust Side ...................................................................................................... 0.012 mm (0.0005 inch) MAX.
Relief Side ....................................................................................................... 0.025 mm (0.0010 inch) MAX.
Service Limit ................................................................................................... 0.025 mm (0.0010 inch) MAX.
PISTON
Piston Bore Clearance

Production ....................................................................................... 0.025 - 0.068 mm (0.0010 - 0.0027 inch)
Service Limit ................................................................................................... 0.068 mm (0.0027 .inch) MAX.
PISTON RINGS
Piston Compression Ring

Groove Clearance
Production Top ........................................................................... 0.050 - 0.090 mm (0.0019 - 0.0035 inch)
Production 2nd ........................................................................... 0.050 - 0.090 mm (0.0019 - 0.0035 inch)
Service Limit. .............................................................................................. 0.107 mm (0.0042 inch) MAX.
Gap
Production Upper .................................................................................... 0.25 - 0.40 mm (0.010 - 0.016 inch)
Production Lower ....................................................................... 0.46 - 0.66 mm (0.018 - 0.026 inch) MAX.
Service Limit ....................................................................................................... 0.88 mm (0.035 inch) MAX.
Piston Oil Ring
Groove Clearance
Production ......................................................................................... 0.051 - 0.17 mm (0.002 - 0.007 inch)
Service Limit. .................................................................................................. 0.20 mm (0.008 inch) MAX.
Gap
Production ........................................................................................... 0.25 - 0.76 mm (0.010 - 0.030 inch)
Service Limit ................................................................................................... 1.65 mm (0.065 inch) MAX.
PISTON PIN
Diameter .......................................................................................... 23.545 - 23.548 mm (0.9270 - 0.9271 inch)

Clearance in Piston
Production ................................................................................... 0.0120 - 0.0210 mm (0.0004 - 0.0008 inch)
Service Limit ..................................................................................................... 0.025 mm (0.001 inch) MAX.
Fit In Connecting Rod .............................................. 0.021 - 0.040 mm (0.0008 - 0.0016 inch) Interference
6A3A34
CRANKSHAFT
Main Journal
Diameter #1 ................................................................................ 62.189 - 62.212 mm (2.4484 - 2.4493 inch)
Diameter #2, #3, #4 ............................................ ;...................... 62.182 - 62.205 mm (2.4481 - 2.4490 inch)
Diameter #5 ................................................................................ 62.177 - 62.199 mm (2.4479 - 2.4488 inch)
Taper
Production .................................................................................................... 0.005 mm (0.0002 inch) MAX.
Service Limit ............................................................................................... 0.025 mm (0.0010 inch) MAX.
Out-of-Round
Service Limit. .............................................................................................. 0.025 mm (0.0010 inch) MAX.
Crankshaft Bearing Clearance
Production #1 .................................................................................. 0.017 - 0.053 mm (0.0007 - 0.0021 inch)
Production #2; #3, #4..................................................................... 0.022 - 0.061 mm (0.0009 - 0.0024 inch)
Production #5 .................................................................................. 0.025 - 0.069 mm (0.0010 - 0.0027 inch)
Service Limit #1 ............................................................................. 0.025 - 0.051 mm (0.0010 - 0.0020 inch)
Service Limit #2, #3, #4 ................................................................ 0.025 - 0.064 mm (0.0010 - 0.0025 inch)
Service Limit #5 ............................................................................. 0.038 - 0.076 mm (0.0015 - 0.0030 inch)
Crankshaft End Play .............................................................................. 0.05 - 0.20 mm (0.002 - 0.008 inch)
Crankshaft Runout (At Rear Flange) ........................ ;.. ;....... ;; ................................... 0.038 mm (0.0015 inch)
CONNECTING ROD
Connecting Rod Journal

Diameter ...................................................................................... 53.284 - 53.334 mm (2.0978 - 2.0998 inch)
Taper
Production ..................................................................................................... 0.007 mm (0.0003 inch) MAX.
Out-of-Round
Rod B~aring Clearance
Production ........................... :..................................................;........ 0.033 - 0.088 mm (0.0013 - 0.0035 inch)
Service Limit ...................................................................... 0.025 - 0.076 mm (0.0010. - 0.0030 inch) MAX.
Rod Side Clearance ............................................................................... 0.16 - 0.35 mm (0.006 - 0.014 inch)
CAMSHAFT
Journal Diamet~r .... '. ........................................................................ 47.440 - 47.490 mm (1.8677 - 1.8697

End Play ................: ........................................................ :;........................... 0.11 - 0.30 mm (0.004 - 0.012
(0.002 inch)
Lobe Lift. 0.050
lntake .................................................................. ;.. ;.......................................................;.. 7.57. mm (0.298
Exhaust ............................................................................................................................ 7.77 mm (0.306
mm
inch)
inch)
inch)
inch)
VALVE SYSTEM
Valve Lifter .............................................................................................................................................. Hydraulic

Valve Rocker Arm Ratio ..................................................................................................... , ......................... 1.50: 1
Valve Lash................... ;................................................................................... 1 1/4 turn down from zero lash
Face Angle .......................................................................................................................................................... 45
Seat Angle .......................................................................................................................................................... 46
Seat Runout ....... ;..................................................................................................... 0.05 mm (0.002 inch) MAX.
Seat Width
Intake ...................................................................................................... 0.76 - 1.27 mm (0.030 - 0.050 inch)
Exhaust ................................................................................................... 1.52 - 2.03 mm (0.060 - 0.080 inch)
Stem Clearance
Production
Intake .......................................................................................... 0.025 - 0.069 mm (0.0010 - 0.0027 inch)
Exhaust ... ;................................................................................... 0.025 - 0.069 mm (0.0010 - 0.0027 inch)
Service
Intake ........................................................................................................... 0.093" mm (0.0037 inch) MAX.
Exhaust ........................................................................................................ 0.119 mm (0.0047 inch) MAX.
Valve Spring Free Length ............................................................................................ 51.3 mm (2.02 inch)
Pressure
5.7 UTER VS ENGINE ON-VEHICLE SERVICE RPO LT1 VIN P 6A3A-35

Closed ............................................................................ 360 ~ 396 N at 45.2 mm (81 - 89 lb. at 1.78
Open ........................................................................ 1090 - 1179 N at 33.8 mm (245 - 265 lb. at 1.33
Installed Height
Intake ................................................................................................................................ 45.2 mm (1.78
Exhaust. ............................................................................................................................. 45.2 mm (1.78
Valve Lift
Intake ............................................................................................................................. 11.36 mm (0.447
Exhaust. .......................................................................................................................... 11.66 mm (0.459
inch)
inch)
inch)
inch)
inch)
inch)
6A3A36 5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 VIN P
SPECIAL TOOLS
1
J 39087
((])
J 5590
J 5825-A
J 5892-D
CCD
J 39089
~(i~Eiii
~
e
J 6098-01
~
J 39088
~
J 8037
'Q)
J 9666 OR J 8056
11
J 8062
12
83@
J 39937
J 24270
1
2
3
4
5
6
7
8
9
10
11
12
13
CRANKSHAFT GEAR INSTALLER

DRIVEN GEAR SHAFT FRONT COVER SEAL PROTECTOR
CRANKSHAFT GEAR REMOVER
VALVE SPRING COMPRESSOR (HEAD-ON)
DRIVEN GEAR/WATER PUMP SHAFT SEAL INSTALLER
CAMSHAFT BEARING REMOVER AND INSTALLER
DRIVEN GEAR SHAFT FRONT COVER SEAL INSTALLER
PISTON RING COMPRESSOR
VAL VE SPRING TESTER
VAL VE SPRING COMPRESSOR (HEAD-OFF)
RIDGE REAMER
FRONT COVER DISTRIBUTOR SEAL INSTALLER
CONNECTING ROD GUIDE SET
13
J 5239
01-1881
FS0211A3A
6A3A37
J 8358
J 8520
-tffiBiliRMMWIIMI-
J 21882
ammmmmm>
J 39046
l ~,. ts
J 23738-A
J 23590
J 35468
J 35621
11
12
41546
1
2
3
4
5
6
7
8
9
10
11
12
CARBON REMOVING BRUSH (ALUMINUM)

CAM LOBE LIFT INDICATOR
OIL SUCTION PIPE INSTALLER
CRANKSHAFT HUB REMOVER AND INSTALLER
SPARK PLUG PORT ADAPTOR
(14mm TAPERED SEAT)
VALVE STEM SEAL TESTER (MllY-VAC)
PISTON PIN REMOVER AND INSTALLER SET
FRONT COVER OIL SEAL INSTALLER
REAR MAIN SEAL INSTALLER
VALVE GUIDE CLEANER
DRIVEN GEAR ASSEMBLY INSTALLER
DISTRIBUTOR DRIVESHAFT FRONT COVER SEAL INSTALLER
@=r
J 39090
05.04.95
FS0278A3A
6A3A-38

2
11
J 3049-A
J 7872
J 34730-1
)
J 8080
mm
w;
oe=D
J 5239
' 7
~
J 9290-01
J 39243
@nmmrnm@>
J 36660
J 39046
1 HYDRAULIC VAL VE LIFTER REMOVER (PLIER TYPE)

2 MAGNETIC BASE INDICATOR SET
.3 DIAL INDICATOR SET
4 FUEL PRESSURE GAGE
5 MAIN BEARING SHELL REMOVER & INSTALLER
6 CONNECTING ROD BOLT GUIDE SET
7 HYDRAULIC VAL VE LIFTER REMOVER (SLIDE HAMMER TYPE)
8 DRIVEN GEAR REMOVER
9 TORQUE ANGLE METER
10
CRANKSHAFT HUB REMOVER/INSTALLER
05-04-95
FS0286A3A
\.
5.7L ENGINE UNIT REPAIR VIN CODE P 6A3B-1
SECTION 6A3B
5.7 LITER VS EN INE
UNIT REPAIR
RPO LT1 - VIN P
NOTICE: Always use the correct fastener in the proper location. When you replace a fastener, use ONLY the
exact part number for that application. General Motors will call out those fasteners that require replacement after
removal. General Motors also will call out the fasteners that require thread lockers or thread. sealant. UNLESS
OTHERWISE SPECIFIED, do not use supplement coatings (paints, greases, or other corrosion inhibitors) on
threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and
the joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening
systems.
CONTENTS
General Description .......................................... 6A3B-2
Construction .................................................. 6A3B-'2
Engine Block ............................................ 6A3B-2
Cylinder Heads ......................................... 6A3B-2
Crankshaft ................................................. 6A3B-2
Piston and Connecting Rod
Assemblies ...... ,..................................... 6A3B-2
Cams)1aft ....................................... ;; .......... 6A3B-2
Valve Train ............................................... 6A3B~2
Intake Manifold ........................................ 6A3B-2
Exhaust Manifolds .................................... 6A3B-2
Lubrication .................................................... 6A3B-3
Disassembly ...................................................... 6A3B-3
Engine Flywheel... ........................................ 6A3B-3
Draining the Engine ..................................... 6A3B-3
Intake Manifold ............................................ 6A3B-3
Exhaust Manifolds ........................................ 6A3B-3
Right Exhaust Manifold ........................... 6A3B-3
Left Exhaust Manifold ............................. 6A3B-11
Valve Rocker Arm Covers ........................... 6A3B-11
Right Valve Rocker Arm Cover .............. 6A3B-11
Left Valve Rocker Arm Cover ................ 6A3B-11
Valve Rocker Arms and Valve
Pushrods .................................................... 6A3B-12
Valve Lifters ................................................. 6A3B-12
Water Pump .................................................. 6A3B-12
Crankshaft Balancer and Hub ...................... 6A3B-13
Distributor ..................................................... 6A3B-13
Oil Pan ......................................................... 6A3B-14
Crankshaft Position Sensor .......................... 6A3B-14
Engine Front Cover ...................................... 6A3B-14
Crankshaft Position Sensor
Reluctor Ring ........................................... 6A3B-17
Camshaft Timing Chain, Crankshaft
and Camshaft Sprockets, and
Water Pump Driveshaft Assembly .......... 6A3B-17
Camshaft ....................................................... 6A3B-18
Cylinder Head .............................................. 6A3B-18
Oil Pump ...................................................... 6A3B-19
Piston and Connecting Rod Assembly ........ 6A3B-19
Crankshaft Rear Oil Seal Housing

and Crankshaft ......................................... 6A3B-21
Camshaft Bearings ....................................... 6A3B-21
Cleaning, Inspection and Repair ..................... 6A3B-22
Engine Block ................................................ 6A3B-22
Boring ....................................................... 6A3B-23
Honing ...................................................... 6A3B-23
Crankshaft Bearing Fit ................................. 6A3B-23
Crankshaft. ..............................;....................... 6A3B-24
Piston and Connecting Rod Assembly ....... 6A3B-24
Connecting Rod Bearings ............................ 6A3B-27
Oil Pump ...................................................... 6A3B-28
Cylinder Head .............................................. 6A3B-29
Recondition ............................................... 6A3B-31
Camshaft. ...................................................... 6A3B-31
Reluctor Ring ........................................... 6A3B-31
EngL11e Front Cover ..................................... 6A3B-32
Engine Front Cover Oil Seals ..................... 6A3B-32
Oil Pan ......................................................... 6A3B-32
Water Pump ................................... ,.............. 6A3B-32
Valve Lifters ................................................. 6A3B-32
Pushrods ................................................... 6A3B-32
Valve Rocker Arm Covers .......................... 6A3B-33
Assembly ......................................... :................ 6A3B-33
Engine Block ................................................ 6A3B-33
Crankshaft ..................................................... 6A3B-34
Crankshaft Rear Oil Seal Housing .............. 6A3B-35
Crankshaft Rear Oil Seal ............................. 6A3B-35
Piston and Connecting Rod Assembly ....... 6A3B-36
Connecting Rod Bearings ............................ 6A3B-36
Oil Pump ...................................................... 6A3B-37
Cylinder Head: 6A3B-37
Camshaft ....................................................... 6A3B-38
6A3B-2
5.7L ENGINE UNIT REPAIR VIN CODE P

Reluctor Ring ........................................... 6A3B-40
Engine Front Cover .......................... ;........... 6A3B-40
Crankshaft Position Sensor .......................... 6A3B-41
Distributor ..................................................... 6A3B-41
Oil Pan .......................................................... 6A3B-42
Crankshaft Balancer and Hub ...................... 6A3B-43
Water Pump .................................................. 6A3B-44
Valve Lifters ................................................. 6A3B-44
Valve Rocker Arm Ball Studs ..................... 6A3B-45
Pushrods .................................................... 6A3B-45
GENERAL DESCRIPTION
CONSTRUCTION
Figures 1 through 4
Engine Block
The engine block is made of cast iron and has

eight cylinders arranged in a "V" shape with four
cylinders in each bank. It is a one piece casting with
the cylinders encircled by coolant jackets.
Cylinder Heads
The cylinder heads are cast aluminum and have

powdered metal valve guides and valve seats pressed
into the intake and exhaust ports. The spark plugs are
located between the intake and exhaust ports.
Valve Rocker Arm Covers .......................... 6A3B-47

Right Valve Rocker Arm Cover .............. 6A3B-47
LefLValve Rocker Arm Cover ................ 6A3B-47
Exhaust Manifolds ........................................ 6A3B-48
Right Exhaust Manifold ........................... 6A3B-48
Left Exhaust Manifold ............................. 6A3B-49
Engine Flywheel... ........................................ 6A3B-49
Specifications .................................................... 6A3B-51
Fastener Tightening Specifications
5.7L (LT1) ................................................ 6A3B-51
Engine Assembly Specifications
5.7L (LT1) ................................................ 6A3B-52
Special Tools ................................................ 6A3B-55
The connecting rods are .made out of forged
powdered metal. They are machined with the rod cap
installed for proper. clearances and alignment.
Camshaft
A steel camshaft is supported by five bearings

pressed into the engine block. The camshaft sprocket,
mounted to the front of the camshaft is driven by the
crankshaft sprocket through a camshaft. timing chain.
The camshaft .sprocket also has spur gear. teeth
which drive a geared shaft assembly to operate the
water pump.
A spiral gear machined into the camshaft near
the rear journal drives a shaft assembly which operates
the oil pump driveshaft assembly.
A pin on the camshaft mates with the distributor
driveshaft. This provides net build timing, meaning the
ignition timing does not have to be adjusted.
Valve Train
Crankshaft
The crankshaft is made of cast nodular iron. It is

supported by five crankshaft bearings that are retained
by bearing caps which are machined with the block
for proper alignment and clearances. The bearing caps
are retained by two bolts each. The number five
bearing at the rear of the engine assembly is the end
thrust bearing. Four connecting rod journals (two rods
per journal) are spaced 90 degrees apart. Pushed onto
the front of the crankshaft is the crankshaft position
sensor reluctor ring. The reluctor ring has four lugs
used for crankshaft timing and is constructed of
powdered metal. The reluctor ring has a slight
interference fit onto the crankshaft and an internal
keyway for correct positioning.
Piston and Connecting Rod Assemblies
The valve train is a ball pivot type. Motion is

transmitted from the camshaft through hydraulic roller
valve lifters and tubular valve pushrods to the valve
rocker arms. The valve rocker arm pivots on a ball to
open the valve. The hydraulic valve lifters keep all
parts of the valve train in constant contact.
The valve rocker arm ball is retained on the
valve rocker arm stud with a locking nut. The valve
rocker arm stud is threaded into the cylinder head.
Intake Manifold
The intake manifold is a one-piece cast

aluminum unit. The intake manifold has exhaust gas
recirculation and crankcase vent passages cast into it.
Coolant crossover passages have been eliminated.
Exhaust Manifolds
The pistons are cast aluminum that use two

compression rings and one oil control ring assembly.
The piston is a low-friction, lightweight design with a
flat top and barrel-shaped skirt. The piston pins are
chromium steel. They have a floating fit in the piston
and are retained by a press fit in the connecting rod
assembly.
The two cast-iron exhaust manifolds direct

exhaust gases from the combustion chambers to the
exhaust system. The exhaust manifolds each have a
port for air injection system pipe fittings.

LUBRICATION
DRAINING THE ENGINE
Figures 5 through 7
!++!
Engine lubrication is supplied by a gear-type oil

pump. The oil pump is driven by an intermediate
shaft. The intermediate shaft is connected to a
driveshaft assembly which is driven by the camshaft.
The oil pump gears rotate and draw oil from the oil
pan. sump through an oil pump screen and pipe. The
oil is pressurized as it passes through the oil pump and
sent through engine block oil galleries.
Contained within the oil pump is a pressure
relief valve that maintains oil pressure within a
specified range.
Pressurized oil is directed to the oil filter where
harmful contaminants are removed. A bypass valve is
also incorporated into the oil filter. The bypass allows
oil to bypass the filter and flow to the engine
assembly if the filter becomes clogged.
The oil is then pumped to the main oil gallery
which is drilled through the length of the engine block
just above the camshaft. At the rear of the engine
block, oil also flows into the right and left valve lifter
oil galleries. From the main oil gallery, oil is pumped
downward to the camshaft bearings, then to the
crankshaft bearings. The crankshaft bearing upper
inserts are grooved to align with oil passages drilled
from the crankshaft bearing journal to the connecting
rod journal. After lubricating the connecting rod
bearings, the cylinder walls, rings and piston pins are
lubricated by oil which is "slung" from the
connecting rod bearing journals due to the rotation of
the crankshaft. This oil then returns to the oil pan
sump. Oil that has entered the left and right valve
lifter oil galleries pressurizes the hydraulic valve lifters
and is then pumped up through the valve pushrods to
lubricate the valve rocker arms and valve stems.
Oil returning to the oil pan from the cylinder
heads and the front camshaft bearing, lubricates the
camshaft timing chain and crankshaft and camshaft
sprockets.
DISASSEMBLY
When beginning the engine assembly unit repair,
the belt tensioner, power steering pump and bracket,
generator, NC compressor, and generator and NC
compressor brackets should already be removed. For
removal procedures, refer to the specific section in the
service manual for each component.
ENGINE FLYWHEEL
Figure B
l++I
1. Engine flywheel bolts.

2. Engine flywheel.
1. Oil pan drain plug and allow oil to drain.

2. Oil filter.
3. Knock sensor and block drain plug and allow
coolant to drain.
INTAKE MANIFOLD
Figures 9 and 10
!++I
1. Fuel pressure regulator vacuum tube.

2. Fuel rail bolts.
3. Evaporative emission canister purge valve vacuum
hose.
4. Fuel injectors and fuel rail. from intake manifold.
5. Exhaust gas recirculation (EGR) vacuum harness
and crankcase vent hoses.
6. EGR vacuum control solenoid and bracket.
7. Evaporative emission canister purge valve and
bracket.
8. Move wiring harnesses out of area.
9. Disconnect distributor wiring harness, if necessary.
10. EGR valve nuts, valve and gasket.
11. EGR valve pipe bolt (229), nut (14), pipe (12),
and gasket (22).
12. Accelerator cable bracket bolt and bracket.
13. Engine coolant air bleed pipe bolts and pipe.
Use a backup wrench on pipe fitting when
removing bolts.
14. Intake manifold absolute pressure (MAP) sensor
bolts and MAP sensor.
15. Throttle body bolts, throttle body, and gasket.
16. Intake manifold bolts and studs.
17. Intake manifold and gaskets.
EXHAUST MANIFOLDS
Figures 10 and 11
Right Exhaust Manifold
l++I
1. Right cylinder bank spark plug wire harness from
spark plugs and supports.

2. Oil level indicator tube bolt.
3. Oil level indicator and tube.
4. Right exhaust manifold air injection pipe (15) and
check valve (11).
5. Right exhaust manifold studs (20), bolts (21), and
spacers (245).
6. Right heat shields, exhaust manifold (19) and
gasket (18).
5. 7L ENGINE UNIT REPAIR. VIN CODE P
6A38-4
195~
210
48
18
227
16
82
17
Figure 1 Upper Engine Assembly
2
3
5
6
8
9
10
11
12
15
16
17
18
19
21
23
24
25
27
28
29
30
31
33
34
35
36
48
69
70
71
RAIL, MUL TIPORT FUEL INJECTION

BODY, THROTILE
GASKET, THROTILE BODY
MANIFOLD, INTAKE
BOLT/SCREW, INTAKE MANIFOLD
STUD, INTAKE MANIFOLD
GASKET, INTAKE MANIFOLD
VALVE, SECONDARY AIR INJECTION CHECK
PIPE, EGR
PIPE, SECONDARY AIR INJECTION
MANIFOLD, LEFT EXHAUST
MANIFOLD, RIGHT EXHAUST
BOLT /SCREW, EXHAUST MANIFOLD
COVER, VALVE ROCKER ARM
BOLT/SCREW, VALVE ROCKER ARM COVER
GASKET, VALVE ROCKER ARM COVER
PUSHROD, VAL VE
STUO, VALVE ROCKER ARM
ARM, VALVE ROCKER
RETAINER, VALVE LIFTER GUIDE
HEAD, CYLINDER
GUIDE. VALVE LIFTER
LIFTER, VALVE
HARNESS, DISTRIBUTOR VACUUM
SPRING, VAL VE
CAP, VALVE SPRING
VALVE, INTAKE
72 KEY, VALVE
73
79
81
82
193
194
195
196
197
199
200
201
202
203
204
205
206
207
209
210
211
212
213
217
218
222
226
227
235

VALVE, EXHAUST
BOLT/SCREW, CYLINDER HEAD
SOLENOID, EGR CONTROL VALVE RELAY
NUT, EGR CONTROL VALVE RELAY
FITTINGS, INTAKE MANIFOLD VACUUM
VAL VE, EVAPORATIVE EMISSION CANISTER
PURGE SOLENOID
HOSE, EVAPORATIVE EMISSION CANISTER PURGE
SOLENOID VAL VE
PIPE, EVAPORATIVE EMISSION CANISTER PURGE
SOLENOID VAL VE
HOSE, CRANKCASE VENT VAL VE
GROMMET, CRANKCASE VENT HOSE CONNECTOR
FITTING, POWER BRAKE BOOSTER VACUUM TUBE
GASKET, EGR VALVE
VALVE, EGR
BOLT/SCREW, EGR VALVE
GROMMET, CRANKCASE VENT VALVE
VALVE, CRANKCASE VENT
HOSE, CRANKCASE VENT
PIPE. ENGINE COOLANT AIR BLEED
HARNESS, EGR VAL VE VACUUM
BOLT/SCREW, ACCELERATOR CONTROL CABLE BRACKET
BRACKET, ACCELERATOR CONTROL CABLE
SHIELD, EXHAUST MANIFOLD HEAT OUTER
SHIELD, EXHAUST MANIFOLD HEAT INNER
COIL, IGNITION
PLUG, SPARK
SUPPORT, SPARK PLUG WIRE
HARNESS, IGNITION DISTRIBUTOR WIRING
Figure 2 - Upper Engine. Assembly - Legend
6A38-6

37
~63
1~7)4
154
58
59
(
45
.l
~
121
137
145
178
54
189
.,.__190
Figure 3 - Lower Engine Assembly
FS903IA38
5.7L ENGINE UNIT REPAIR VIN CODE P 6A3B~7
37
38
39
40
41
42
43
44
45
46
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
74
77
\)
84
89
95
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
PUMP, WATER
GASKET, WATER PUMP
COUPLING, WATER PUMP DRIVESHAFT
BOLT/SCREW. WATER PUMP
BOLT/SCREW, WATER PUMP
BALANCER. CRANKSHAFT
BOLT/SCREW. CRANKSHAFT BALANCER HUB
WASHER, CRANKSHAFT BALANCER HUB
HUB. CRANKSHAFT BALANCER
BOLT/SCREW, CRANKSHAFT BALANCER
DISTRIBUTOR
COVER, ENGINE FRONT
BOLT/SCREW, ENGINE FRONT COVER
REINFORCEMENT, OIL PAN
PAN, OIL
GASKET, OIL PAN
SOLT/SCREW, CAMSHAFT SPROCKET
SPROCKET, CAMSHAFT
RETAINER, CAMSHAFT
CAMSHAFT
CHAIN, TIMING
SPROCKET, CRANKSHAFT
DRIVESHAFT ASSEMBLY, WATER PUMP
BOLT/SCREW, WATER PUMP DRIVESHAFT
BEARING RETAINER
DRIVESHAFT, OIL PUMP
BOLT/SCREW, OIL PUMP DRIVESHAFT
BLOCK, ENGINE
PLUG, CAMSHAFT REAR BEARING HOLE
PIN, ENGINE FRONT COVER LOCATOR
WEIGHT, CRANKSHAFT BALANCER
BOLT/SCREW, OIL PAN
DRIVESHAFT, OIL PUMP
RETAINER, OIL .PUMP DRIVESHAFT
CRANKSHAFT
CAP, CONNECTING ROD
NUT, CONNECTING ROD
BEARING, CONNECTING ROD
SOLT /SCREW, CONNECTING ROD
PISTON
ROD, CONNECTING
PIN, PISTON
RING, PISTON
BEARING, CRANKSHAFT
BEARING, CRANKSHAFT
STUD, CRANKSHAFT REAR OIL SEAL HOUSING
GASKET, CRANKSHAFT REAR OIL SEAL HOUSING
NUT, CRANKSHAFT REAR OIL SEAL HOUSING
116
117
118
119
120
121
135
136
137
138
139
142
143
144
145
154
155
156
157
158
159
160
161
162
165
167
168
170
171
172
174
175
176
177
178
179
180
181
183
184
185
186
187
188
189
190
191
223
250
251
252

STUD, CRANKSHAFT BEARING CAP
PUMP, OIL
DEFLECTOR, OIL
BOLT/SCREW, OIL PUMP
BRACKET, GENERATOR, AIR CONDITIONING
COMPRESSOR, AND POWER STEERING PUMP
ENGINE FLYWHEEL. MANUAL TRANSMISSION
BOLT/SCREW, ENGINE FLYWHEEL
ENGINE FLYWHEEL, AUTOMATIC TRANSMISSION
BOLT/SCREW, ENGINE FLYWHEEL
PIN, CRANKSHAFT REAR OIL SEAL HOUSING LOCATOR
ADAPTER., OIL FILTER
BOLT/SCREW, OIL FILTER ADAPTER
FILTER, OIL
HARNESS, SPARK PLUG WIRE
SENSOR, ENGINE COOLANT TEMPERATURE
OIL SEAL, WATER PUMP DRIVESHAFT
OIL SEAL, WATER PUMP DRIVESHAFT
OIL SEAL, ENGINE FRONT COVER DISTRIBUTOR
OIL SEAL, ENGINE FRONT COVER CRANKSHAFT HUB
INDICATOR, OIL LEVEL
TUBE, OIL LEVEL INDICATOR
NUT, OIL. LEVEL INDICATOR TUBE
SENSOR, FUEL PUMP AND ENGINE OIL PRESSURE
INDICATOR SWITCH
PLUG, ENGINE BLOCK OIL GALLERY
PIN TRANSMISSION HOUSING LOCATOR
PLUG, ENGINE BLOCK CORE HOLE
SENSOR, KNOCK
PLUG, OIL FILTER ADAPTER HOLE
BEARING, CAMSHAFT
BEARING, CLUTCH PILOT
STUD, CRANKSHAFT REAR OIL SEAL HOUSING
SEAL, CRANKSHAFT REAR OIL
SENSOR, ENGINE OIL LEVEL SWITCH
PIN, OIL PUMP LOCATOR
KEY, CRANKSHAFT
CLIP, TRANSMISSION OIL COOLER PIPE
NUT, OIL DEFLECTOR
SHIM, STARTER MOTOR
MOTOR, STARTER
BOLT/SCREW, STARTER MOTOR
STUD, STARTER MOTOR
GASKET, OIL PAN DRAIN PLUG
PLUG, OIL PAN DRAIN
PLUG, ENGINE BLOCK OIL GALLERY
HARNESS, IGNITION COIL WIRE
RING, CRANKSHAFT POSITION SENSOR RELUCTOR
SENSOR, CRANKSHAFT POSITION
BOLT /SCREW, CRANKSHAFT POSITION SENSOR
Figure 4 - Lower Engine Assembly - Legend
6A3J38
(
Figure 5 - Engine Assembly Lubrication Left Side View
5.7l ENGINE UNIT REPAIR VIN CODE P 6A3B-9
I SECTION A-A I
FSICINA38
Figure 6 Engine Assembly Lubrication Front View
6A3B10
SECTIONIB-B
SECTIONC.C
c
BS9078MB
(
Figure .7 - Engine Assembly Lubrication - Rear Views

2. Left cylinder bank spark plug wire harness from
spark plugs and supports.
3. Left exhaust manifold bolts (21), studs (20), and
spacers (245).
4. Left heat shields, exhaust manifold (19), and
gasket (17).

Figure 12
Right Valve Rocker Arm Cover
l+-+l
Figure 8 Engine Flywheel

2. Right valve rocker arm cover bolts.
3. Right valve rocker arm cover and gasket.
Left Valve Rocker Arm Cover
Left Exhaust Manifold
I++!
1. Left exhaust manifold secondary air injection pipe

(15) and check valve (11).
l++!
1. Left valve rocker arm cover bolts"

2. Left valve rocker arm cover and gasket.
Figure 9 Intake Manifold, Fuel Rail, and Throttle Body
6A3B-12

11
!VIEW Ai
11 VALVE, SECONDARY AIR INJECTION

CHECK
12 PIPE, EGR VALVE
13 STIJD, EGA VALVE PIPE
14 NUT, EGRVALVE PIPE
16 PIPE, SECONDARVAIR INJECTION
22 GASKET, EGR VALVE PIPE
229 BOLT/SCREW, EGR VALVE PIPE
JJ-.
(
12
040788
BSfflGA48
Figure 10 Secondary AIR Injection and EGR Pipe
VALVE ROCKER ARMS AND VALVE

PUSH RODS
Figures 13 and 14
l++I
!++!
1. Valve lifter guide retainer bolts and retainer.

2. Valve lifter guides and valve lifters.
Some valve lifters may be stuck in their bores
because of gum. or varnish deposits. These
valve lifters can be removed using J 3049 or
J 9290-01.
.
1. Valve rocker arm nuts (2) and balls (1).

2. Valve rocker arms (3) and valve pushrods (4).
Place valve rocker arms (3), valve rocker arm
balls (1), and valve pushrods (4) in a rack so
that they can be reinstalled in same locations
from which they were removed.
3. Valve rocker arm ball studs (5).
VALVE LIFTERS
Tool Required:
J 3049-A Valve Lifter Removal (Plier Type)
J 9290-01 Valve Lifter Removal
(Slide Hammer Type)
WATER PUMP
Figure 18
l++I
1. Air injection pump bracket bolt and bracket.

2. Water pump bolts (40 and 41).
I]]
Important
A. Keep ignition wires connected to distributor

until water pump is removed.
17
19
20
21
245

MANIFOLD, EXHAUST
SPACER, EXHAUST MANIFOLD
21
040NH5
BS9128A419
Figure 11 - Exhaust Manifolds
1
2
3
4
5
Figure 12 - Valve Rocker Arm Covers
B. Make sure coolant is drained.

3. Water pump (37), coupling (39), and gaskets (38).

Rgures 19 and 20
Tool Required:
J 39046 Crankshaft Hub Removal and
Installation
l++I
1. Crankshaft balancer bolts and balancer.

2. Crankshaft balancer hub bolt and washer.
3. Crankshaft balancer hub using J 39046.

NUT, VAL VE ROCKER ARM
ROCKER ARM
PUSHROD
STUD, VALVE ROCKER ARM
Figure 13 - Valve Rocker Arm, Ball, and Nut
DISTRIBUTOR
Figure 21
!++!
1. Spark plug and ignition harnesses from ignition

coil and spark plugs.
Do not remove wires from distributor unless
necessary.
2. Distributor vacuum harness.
[I]
Important
Do not allow foreign material to enter open

vacuum lines.
Cap ends as necessary.
3. Distributor bolts (47) and distributor (49).
6A38-14 5.7L ENGINE UNIT REPAIR VIN CODE P
.~
J 3049-A /
(_
~
Figure 14 - Valve Pushrods
Figure 16 - Removing Valve Lifters
Figure 17 - Removing Valve Lifters
Figure 15 - Valve Lifters, Guides, and Retainers
OIL PAN
CRANKSHAFT POSITION SENSOR
Figures 22 and 23
Figure 24
l++I
!+-+!
1. Oil level sensor.
2.
3.
4.
5.
Oil level sensor must be removed to prevent it

from being damaged as the oil pan is removed.
Oil pan bolts, nuts, and studs.
Oil pan, reinforcements, and gasket.
Oil filter adapter bolts.
Oil filter adapter and seal.
1. Bolt from engine front cover.

2. Sensor from engine front cover.
ENGINE FRONT COVER

Figure 25
!++I
I
1. Engine front cover bolts (5).

2. Engine front cover (4) and gasket (1).
5.7L ENGINE UNIT REPAIR VIN CODE P 6A3B15
A. SHAFT, WATERPUMP
B. TAB ON GASKET
37. PUMP, WATER
38. GASKET, WATERPUMP
39. COUPLING, WATERPUMP DRIVESHAFT
40. BOLT/SCREW, WATERPUMP
63. DRIVESHAFT ASSEMBLY, WATERPUMP
156. SEAL, WATERPUMP DRIVESHAFT
View A
Figure 18 Water Pump
Figure 20 Crankshaft Balancer Hub, Bolt, and Washer
View A
Figure 19 Crankshaft Balancer and Hub
6A3B-16
c
8
jVIEWAI
A
B
C
24
47
49
jVIEW Bj
CAMSHAFT PIN
CAMSHAFT PIN SLOT
DISTRIBUTOR BASE TIMING MARK
DISTRIBUTOR VACUUM HARNESS
BOLT /SCREW DISTRIBUTOR
DISTRIBUTOR
04-0Ml6
ISS918&A4B
Figure 21 - Distributor
Figure 23 - Oil Filter, Adapter and Seals
(
DT9016A4B
Figure 22 - Oil Pan, Reinforcements, and Gasket
Figure 24 - Crankshaft Position Sensor
2
3
4
5
Figure 25 - Engine Front Cover

RELUCTOR RING
Figure 26
I++!

WATER PUMP DRIVESHAFT ASSEMBLY
Tools Required:
J 39243-1 Water Pump Driveshaft
Assembly Removal
J 39243-2 Water Pump Driveshaft
Assembly Removal
J 5825-A Crankshaft Sprocket Removal
1. Reluctor ring from crankshaft.

2. Key if necessary.
I+-.!
1. Camshaft sprocket bolts (56).

NOTICE: To prevent damage to pistons or
valves, do not turn the crankshaft after the
camshaft timing chain has been removed.
(61).
3. Water pump driveshaft bolts (64) and driveshaft
assembly (63) using J 39243-1 and J 39243-2.
4. Crankshaft sprocket (62) using J 5825-A.
Figure 26 - Crankshaft Position Sensor Reluctor Ring
6A3B-18
62
A
B
C
56
57
58
59
60
61
62
63
64
SPROCKET ALIGNMENT MARKS

KEYWAY
PIN, CAMSHAFT
BOLT/SCREW, CAMSHAFT SPROCKET
SPROCKET, CAMSHAFT
RETAINER, CAMSHAFT
CAMSHAFT '
CHAIN, CAMSHAFT TIMING
?PROCKET, CRANKSHAFT
DRIVESHAFT, WATER PUMP
BOLT /SCREW, WATER PUMP DRIVESHAFT
(
01-18t5
YS9208A18
Figure 27 - Camshaft, Sprockets, and Water Pump Driveshaft Assembly
CAMSHAFT
CYLINDER HEAD
Figures 30 and 31
Figures 32 and 33
l++I
!++!
1. Oil pump driveshaft assembly bolt and oil pump

driveshaft assembly.
2. Camshaft retainer bolts and retainer.
NOTICE: All camshaft journals are the same

diameter so care must be used in removing the
camshaft to avoid damage to the bearings.
3. Camshaft.
A. Install three 5/16 - 18 x 4.0 in. bolts in
camshaft front bolt holes.
B. Carefully rotate and pull camshaft out of
bearings.
1. Engine coolant air bleed pipe bolts and pipe.

Use a backup wrench on pipe fitting when
removing bolts.
2. Generator bracket bolts, spark plug wire support,
and bracket from right cylinder head.
3. Cylinder head bolts.
NOTICE: After removal, place the cylinder

head on two wood blocks to prevent damage.
I
4. Cylinder head and gasket

5. Ignition coil studs, coil and bracket from left
cylinder head.
5.7L ENGINE UNIT REPAIR VIN CODE P 6A3B~19
J 39243-1
J39243-2
Figure 30 - Oil Pump Driveshaft Assembly
Figure 28 - Water Pump Driveshaft Assembly Removal
Figure 29 - Crankshaft Sprocket Removal
Oil PUMP
Figure 34
i++I

2. Bolt attaching oil pump to rear crankshaft bearing
cap.
Figure 31 - Removing the Camshaft
3. Crankshaft oil deflector, oil pump, driveshaft, and

retainer.

ASSEMBLY
Figures 35 and 36
Tool Required:
6A3B20 5.7L ENGINE UNIT REPAIR VIN CODE P
~-
Figure 32 Engine Coolant Air Bleed Pipe
Figure 34 Oil Pump, Crankshaft Oil Deflector, Driveshaft,

and Retainer
I++!
Figure 33 Cylinder Head and Gasket

Figure 35 Piston and Connecting Rod Assembly
1. Ring ridge.
A. Tum crankshaft until piston is at bottom of its
stroke.
B. Place a cloth on top of piston.
C. Use a ridge reamer to remove cylinder ring
ridge.
D. Tum crankshaft so piston is at top of its
stroke.
E. Remove cloth and cutting debris.
[I)
Important
Place matchmarks or numbers on connecting rods

and connecting rod caps. Connecting rod caps
must be assembled to their original connecting
rods.
2. Connecting rod nuts.
Figure 37 - Crankshaft Rear Oil Seal Housing, Housing

Gasket, and Rear Oil Seal
Figure 36 - Connecting Rod Guide Tool
3. Connecting rod cap and bearings.

If re-using, keep bearings . with their original
connecting rod and connecting rod cap.
Wipe oil from bearings and crankpins.
4. Connecting rod and piston out of top of engine
block using J 5239.
AND. CRANKSHAFT.
Figure 38 - Crankshaft Rear Oil Seal Removal
CAMSHAFT BEARINGS
l++I
1. Crankshaft rear oil seal housing nuts and bolts.

2. Crankshaft rear oil seal housing, crankshaft rear
oil seal, and crankshaft rear oil seal housing
gasket.
seal housing.
4. Crankshaft bearing cap bolts and. studs.
5. Crankshaft bearing caps.
6. Crankshaft.
7. Crankshaft bearings from engine block.
8. Crankshaft bearings from crankshaft bearing caps.
Figures 40 and 41
Tool Required:
J 6098-01 Camshaft Bearing .Removal and
Installation
!++!
1. Camshaft rear. bearing hole plug.

2. Inner camshaft bearings using J 6098-01.
A. With nut and thrust washer installed to end of
puller screw threads, index pilot in camshaft
front bearing and install puller screw through
pilot and bearing to be removed.
B . .Install bearing tool with shoulder toward
bearing. Make sure that enough threads are
engaged.
6A3B22
C. Using two wrenches, hold puller screw while

turning nut to draw bearing out of bore.
When bearing has been pulled from bore,
remove bearing tool and bearing from
puller screw.
D. Repeat above steps for remaining inner

camshaft bearings.
Index pilot in rear camshaft bearing to
remove rear inner bearing.
3. Front and rear camshaft bearings using J 6098-01.
A. Assemble bearing tool to driver handle.
B. Drive front and rear bearings out, toward
center of engine block.
CLEANING, INSPECTION AND

REPAIR
ENGINE BLOCK
Figures 42 and 43
!++I
1. Front and rear oil gallery plugs.

2. Fuel pump oil pressure switch and fitting.
Figure 39 - Crankshaft, Crankshaft Bearings, and

Crankshaft Bearing Caps
Figure 41 - Camshaft OuterBearing Removal
A BEARING TOOL
B PILOT
C PULLER SCREW
D WASHER
E NUT
67 BLOCK, ENGINE
67
(
\
FS91MA39
Figure 40 - Camshaft Inner Bearing Removal
Figure 42 - Checking Block Surface for Flatness
Follow instructions provided by manufacturer

of boring equipment being used.
Clean
Engine block in solvent.

Gasket swfaces.
Coolant passages.
Oil passages.
Oil filter by-pass valve and spring.
!L'I'!
Inspect
For cracks in cylinder walls, coolant jacket, valve

lifter bores and crankshaft bearing webs.
Oil filter by-pass valve for operation.
!@!
6A3B23
Measure
Cylinder bores for taper, out-of-round, or

excessive ring ridge at top of ring travel. Use a
dial indicator. Compare measurements to
- Cylinders with less than 0.025 mm
(0.0010 in.) of wear or taper may be
reconditioned with a hone.
"--- Cylinders with more than 0.025 mm
(0.0010 in.) of wear or taper must be bored
and honed to smallest oversize piston that will
permit complete reswfacing of all cylinders.
Boring
1. Draw a flat file across top of engine block several

times. to remove any burrs or gasket material. If
engine block surface is not completely smooth
and flat, boring bar may be tilted which would
result in cylinder having an incorrect angle to
crankshaft.
2. Me!lsure piston to be installed 11.5 mm (0.45 in.)
from bottom of piston skirt and at right angles to
piston pin.
3. Bore cylinder to same diameter as piston.
4. Hone cylinder as outlined below to provide
specified clearance.
NOTICE: Handle pistons with care. Do not

attempt to force them into the cylinder. The
pistons may be easily distorted.
Honing
1. Follow instructions provided by manufacturer of

honing equipment being used.
2. Occasionally during honing operation:
A. Clean cylinder bore.
B. Measure cylinder bore for proper piston fit.
3. Finish operation with a 45 to 65 degree
cross-hatch pattern on cylinder walls.
Finish marks should be clean but not sharp,
free from imbedded particles and tom or faded
metal.
4. Place a permanent mark on each piston to match
it to its proper cylinder.
Clean
Cylinder bores and block with hot water and

detergent using a stiff bristle brush. Rinse
thoroughly and dry with a clean cloth'.
- Any abrasive material left in cylinder bores
will cause rapid wear of piston rings, bearings,
and other engine assembly parts.
- Do not use kerosene or gasoline for cleaning.
- After cleaning, swab cylinder bores with light
engine oil and a clean cloth. Then wipe them
out with a clean dry cloth.
CRANKSHAFT BEARING FIT

Figure 44
If replacing rear crankshaft bearing, check for
correct part number. Some rear crankshaft bearings
are 0.20 mm (0.008 in.) wider than standard.
Crankshaft will beidentified by "0.008"stamped on
rear counterweight.
-------~------ ------
Figure 43 - Measuring the Piston
Figure 44 - Plastic-gage
6A3B-24. 5.7L ENGINE UNIT REPAIR VIN CODE P

It is necessary to measure clearance of each
crankshaft bearing to determine proper sizes.
Factory installed crankshaft bearings may not be
same size for each journal.
!lI
If clearance is greater than specified, select

an undersize bearing and re-measure
clearance. Always replace both upper and
lower crankshaft bearings as a unit.
specifications using a standard undersize
bearing, regrind crankshaft for use with
next undersize bearing.
Inspect
Lower half of crankshaft bearing.

- If lower half is worn or damaged, both upper
and lower half should be replaced.
- If lower half is suitable for use, upper half will
also be suitable for use.
CRANKSHAFT
Figures 45 and 46
!@! Measure
Crankshaft bearing clearance using gaging plastic.

A. Place a piece of gaging plastic full width of
crankshaft bearing onto journal.
B. Measure all five bearing clearances at same
time.
[I]
!@I
Tighten
If gaging plastic shows an irregularity in

journal exceeding 0.025 mm (0.0010 in.),
measure journal with a micrometer.
Measure
Crankpins for out-of-round, taper, or undersize

with a micrometer. Refer to "Specifications" in
this section.
Crankshaft run-out at front and rear intermediate
journals with a dial indicator. Support crankshaft
front and . rear journals on V-blocks. Refer to
Replace or recondition crankshaft if measurements
are not within specifications.
Important
Bolts and studs to 105 N,m (77 lb. ft.).

E. Remove crankshaft bearing cap bolts, studs,
crankshaft bearing caps.
F. Measure gaging plastic at its widest using
scale provided with gaging plastic. Refer
section.
Clean
Crankshaft in solvent and dry it with compressed

air.
Do not rotate crankshaft while gaging

plastic is between journal and crankshaft
bearing.
C. Install crankshaft bearing caps with arrows
pointing toward front of engine block.
D. Install bearing cap bolts and studs.
l~I

ASSEMBLY
Tool Required:
J 24086-C Piston Pin Removal and
Installation
Ill
Disassemble
1. Piston rings from piston.
J 7872
Figure 45 - Measuring Crankshaft Runout
Figure 48 Removing the Piston Pin
Figure 46 Measuring Crankshaft Journals
Figure 49 - Measuring Piston Ring Side Clearance
2. Piston pin from piston and connecting rod using

J 24086-C.
~ Clean
I
I
I
tNI .
M
~
I
Figure 47 - Piston and Connecting Rod Components
1. Connecting rod in cleaning solvent.

2. Dry connecting rod with compressed air. Do not
wire brush any part of piston.
3. Varnish from piston skirts and pins with cleaning
solvent.
4. Piston ring grooves with groove cleaner.
5. Piston oil ring holes and slots.
!L!
Inspect
Connecting rod for twisting, nicks and cracks.

Replace any damaged connecting rods.
Piston for:
- Cracked ring lands, skirts, or pin bosses.
- Grooves for nicks or burrs that may cause
binding.
6A3B26
5. 7L ENGINE UNIT REPAIR VIN CODE P
- ------------ -~
Figure 51 - . Measuring Piston Diameter
Figure 50 Measuring Piston Ring End Gap
- Warped or worn ring lands.

- Scuffed or damaged skirts.
- Eroded areas at top of piston.
- Worn piston bores and piston pins.
- Replace pistons that are damaged or show
signs of excessive wear.
l@I
Measure
1. Piston pin bore-to-piston pin clearance.

A. Piston pin bores and piston pins must be free
of varnish or scuffing when being measured.
B. Use a micrometer to measure piston pin and
an inside micrometer to measure piston pin
bore.
C. If clearance is in excess of 0.025 mm
(0.0010 in.), piston and piston pin should be
replaced. Piston and piston pin are matched
and are not. serviced separately.
2. Piston compression ring end gap.
11]
Important
Fit each compression ring to cylinder in. which it

will be used.
A. Place compression ring into cylinder bore.
B. Push compression ring into cylinder bore to
approximately 6.5 mm (0.25 in.) above ring
travel. Ring must be square to cylinder wall.
C. Measure end gap with a feeler gage. Refer to
"Specifications" in this section for acceptable
end gaps.
D. If end gap exceeds specifications, select
another size ring set.
3. Piston ring side clearance.
A. Roll piston ring entirely around its ring groove

on piston.
B. If any binding is caused by ring groove, dress
groove with a. fine cut file.
C. If any binding is caused by a distorted piston
ring, replace piston ring.
D. Measure side clearance of piston ring and

groove with a feeler gage. For acceptable side
clearances, .refer to "Specifications" in this
section.
E. If side clearance is too small, try another
piston ring.
4. Piston-to-cylinder bore clearance to determine
suitability of a used piston. Measure
piston-to-cylinder bore clearance as follows:
A. Measure cylinder bore diameter at a point
64 mm (25 in.) from top of cylinder bore
using a bore gage.
B. Measure piston 11.5 mm (0.45 in.) from
bottom of skirt at. right angles to piston pin
using a caliper or micrometer.
C. Subtract piston diameter from cylinder bore
diameter. This will indicate piston-to-bore
clearance.
D. Compare measurements to "Specifications" in
this section.
E. If clearance exceeds specifications, subtract
size of new piston from cylinder bore diameter
previously measured.
F. If clearance with new piston is within
specifications, mark that piston to the cylinder
to which it is to be installed.
G. If clearance is within specifications, used
piston may be reinstalled.
!+#+I
Assemble
Tool Required:
J 24086-C Piston Pin Removal and
Installation
[I]
Important
When assembling piston and connecting rod,

stamped arrow on piston must point to front of
engine block. The flange on connecting rod
must face toward front of piston on left hand
assembly and face toward rear of piston on
right hand assembly.
ENGINE LEFT
ENGINE FRONT
c-
ENGINE RIGHT
-A.D
A OIL RING SPACER GAP

(TANG IN HOLE OR SLOT WITHIN ARC)
B OIL RING RAIL GAPS
C 2ND COMPRESSION RING GAP
D TOP COMPRESSION RING GAP
Figure 52 - Installing the Piston Pin
NOTICE: After J 24086-C installer bottoms

on support assembly, do not exceed 34 475 kPa
(5000 psi) or the tool may be damaged.
1. Piston and connecting rod.
A. Lubricate piston pin holes in both piston and
connecting rod assembly.
B. Press piston pin into piston and connecting rod
using J 24086-C.
!L!
Figure 53 - Piston Ring Gap Locations
When removing a connecting rod cap, you

may find a 0.25 mm (0.010 in.) undersize bearing.
These are used in manufacturing for selective
fitting.
!L!
Inspect
Bearings for excessive wear or damage.
inspect
For freedom of movement of piston on piston

pin.
2. Piston rings onto piston.
Marked side of piston rings must face toward
top of piston. Locate piston ring gaps as
shown (Figure 53).
A. Install oil ring spacer in groove.
B. Hold spacer ends together and instalUower
oil ring rail with gap properly located.
C. Install upper oil ring rail with gap properly
located.
D. Flex oil ring assembly to make sure rings
are free.
E. Install lower compression ring with gap
properly located.
F. Install upper compression ring with gap
properly located.

Connecting rod bearings are the precision
insert type and do not use shims for adjustment. Do
not file connecting rods or rod caps. If clearances
are found to be excessive, a new bearing will be
required. Service bearings are available in standard
size and 0.025 mm (0.001 in.) and 0.05 mm
(0.002 in.) undersize for use with new and used
standard size crankshaft, and in 0.25 mm (0.010 in.)
and 0.5 mm (0.020 in.) undersize for use with
reconditioned crankshaft.
!@l
Measure

micrometer. Refer measurements to
recondition crankshaft.
If installing new bearings, determine new
bearing size from maximum crankpin diameter.
2. Bearing clearances using gaging plastic.
A. Place a piece of gaging plastic full width of
bearing; (parallel to crankshaft) onto crankpin.
Plastic gage material should be positioned
in middle of bearing. Bearing is thickest in
center and bearing clearance must be
measured at this location.
B. Install connecting rod cap with bearing onto
connecting rod.
C. Install connecting rod nuts.
l%l
Tighten
Connecting rod nuts, evenly, to 27 N .m

(20 lb. ft.) plus an additional
55 degrees.
(}] Important
Do not turn crankshaft with gaging
plastic installed or accuracy of
6A3B28
. D. Remove connecting rod nuts and cap.

E. Measure gaging plastic at its widest using
scale provided with gaging plastic. Refer
section.
F. If clearance is greater than specified, select an
undersize bearing and re-measure clearance.
G. If clearance cannot be brought to
specifications, regrind crankpin. If crankpin is
already at. maximum undersize, replace
crankshaft.
J 21882
OIL PUMP
Figures 54 and 55
Tool Required:
J 21882 Oil Pump Screen Installation
Ill
Disassemble
1. Oil pump cover bolts (5) and oil pump cover (4).
Matchmark gear teeth for assembly.
2. Driven gear (7), drive gear (7), driveshaft (9), and
retainer (8), from oil pump housing (10).
3. Oil pressure relief valve pin (1), relief valve (3),
and spring (2).
4. Oil pump screen (6) from oil pump housing (10),
if replacement is necessary.
Mount oil pump housing (10) in a soft-jaw
vise and extract oil pump screen (6).
Oil pump screen (6) is serviced as a unit. Do
not distur~ pipe on screen.
Figure 55 Installing the Oil Pump Screen
Clean
1. All parts in cleaning solvent.

2. Dry parts with compressed air.
!L!
ln~pect
Oil pump housing (10) and cover (4) for cracks,

scoring, casting imperfections, and damaged
threads.
Drive gear shaft. If loose in oil pump housing
(10), replace oil pump.
Pressure relief valve (3) for scoring and sticking.
- Burrs may be removed with a fine oil stone.
Relief valve spring (2) for loss of tension.
Oil pump screen . (6) for broken wire mesh or
looseness.
- If pipe is loose or has been removed from
screen, oil pump screen (6) must be replaced.
Gears for chipping, galling, and wear.
Drive gear (7) and driveshaft {9) for looseness
and wear.
II]
Important
- If wear is noted, replace entire oil pump.
!+!+!
8
9
Figure 54 Oil Pump Components
Assemble
1. A new oil pump screen (6), if previously

disassembled, to oil pump housing (10).
II]
Important
Be careful not to twist, shear, or collapse oil

pump screen (6) .while installing it to oil pump
housing.
A. Mount oil pump housing (10) in a soft-jaw
vise.
B. Apply sealer to end of pipe.
C. Tap oil pump screen into place using J 21882
and a plastic-faced hammer.
rn
2.
3.
4.
5.
6.

lmpo,rtant
Replace the pressure relief valve spring when

reusing the oil pump.
Relief valve (3), spring (2), and pin (1).
Drive gear (7), driveshaft (9), and retainer (8) to
oil pump housing (10).
Driven gear (7) to oil pump housing (10) with
smooth side of gear toward oil pump cover (4).
Oil pump cover (4).
Oil pump cover bolts (5).
!~!
Tighten
Oil pump cover bolts (5) to 9 N.m (80 lb. in.).
!L"'!
Inspect
For smoothness of operation by turning oil pump

driveshaft (9) by hand.
CYLINDER HEAD
Tools Required:
J 9666 Valve Spring Tester
J 8062 Valve Spring Compressor
J 8358 Carbon Removing Brush
III
Disassemble
Figure 57 - Valve and Components
1. Spark plugs from cylinder head.

2.
3.
4.
5.
6.
7.
Compress valve springs using J 8062.

Valve stem keys (72).
Cap (70) from valve (71).
Valve spring (69).
Valve seal (73).
Valve (71).
Place valves in rack in proper sequence. so
they can be assembled in their original order.
8. Shim (76).
69
70
71
72
73
76
34
HEAD ASSEMBLY, CYLINDER

Figure 56 - Compressing the Valve Spring
SPRING, VALVE
CAP, VALVE SPRING
VALVE. INTAKE
KEY, VALVE STEM
SHIM, VALVE SPRING
04-28-H
BSl44SMB
Figure 58 - Valve and Components
6A3B-30 5.7l.ENGINE UNIT REPAIR VIN CODE P

A
04-28-96
BS9408A4B
Figure 59 - Cleaning the Combustion Chamber
A STEM, VAL VE
B GUIDE, VALVE
Figure 61 - Measuring Valve Stem Clearance
A TORQUE WRENCH
DT9296A4B
Figure 60 - Checking Valve Spring Tension
A SCALE
15 SPRING, VAL VE
15
Clean
BU0276A1B
Figure 62 - Measuring Valve Spring Installed Height
1. Carbon from combustion chambers and valve

parts using J 8358.
Be careful not to scuff chamber
2. Carbon and sludge from valve pushrods and valve
rocker arms.
3. Valve stems and heads on buffing wheel.
4. Cylinder head and engine block gasket surfaces.
5. Bolt hole threads in cylinder head and engine
block.
!l"'!
Inspect
1. Cylinder head for cracks in exhaust ports,

combustion chambers, or external cracks to water
chamber.
2. Valves for burned heads, cracked faces, or
damaged stems.
3. Valve springs for squareness.
I@!
Measure
1. Valve spring tension using J 9666.

If spring tension is less than 360 N (81 lb.) at
45.2 mm (1.78 in.), replace spring.
2. Valve stem-to-bore clearance.
A. Excessive valve stem-to-bore clearance will
cause excessive oil consumption and may
cause a valve to break. Insufficient clearance
will result in noisy and sticky functioning of
valve and disturb engine assembly smoothness.
B. Clamp J 8001 on exhaust port side of cylinder
head.
C. Locate indicator so movement of valve stem
from side to side (crosswise to cylinder head)
will cause a direct movement of indicator
stem. Indicator stem must contact side of valve
stem just above valve guide.

D. Drop valve head about 1.6 mm (0.0064 in.) off
valve seat.
E. Move stem of valve from side to side using
light pressure to obtain a clearance reading. If
clearance exceeds specifications, it will be
necessary to ream valve guides for oversize
valves. Refer to "Specifications" in this
section.
F. Service valves are available in standard
0.076 mm (0.003 in.) and 0.038 mm
(0.015 in.), 0.76 mm (0.030 in.) oversize.
Recondition
1. Valves with oversize stems are available as

outlined above. Ream valve guide bores for
oversize valves as necessary.
2. Reconditioning valve seats is very important.
Valve seat reconditioning must be done after
reaming valve guide bores or installing new valve
guides.
Seating of valves must be perfect for engine
assembly to deliver optimum power and
performance.
Another important factor is cooling of valve
heads. Good contact between each valve and
its seat in cylinder head is necessary to insure
that heat in valve head will be properly carried
away.
Several different types of equipment are
available for reconditioning valve seats.
Recommendations of manufacturer of
equipment being used should be carefully
followed to attain proper results.
Regardless of what type of equipment is used,
it is essential that valve guide bores be free
from carbon or dirt to ensure proper centering
of pilot in guide. Valve seats should be
concentric to within 0.05 mm (0.002 in.) total
indicator reading~
3. Valves that are pitted can be refaced to proper
angle, insuring correct relation between head and
stem, on a valve refacing mechanism. Valve stems
which show excessive wear, or valves that are
warped excessively should be replaced. If edge of
valve head is less than 0.79 mm (0.031 in.) thick
after grinding, replace valve.
Several different types of equipment are
available for refacing. valves. Recommendation
of manufacturer of equipment being used
should be carefully followed to attain proper
results.
l;+I
A. Use grease to hold keys (72) in place while

disconnecting J 8062.
B. Make sure keys (72) seat properly in upper
groove of valve stem.
C. Tap end of stem with a plastic-faced hammer
to seat keys (72), if necessary.
8. Remaining valves.
!@I
Measure
Valve spring installed height from valve spring

seat to locating surface on cap.
- If installed height exceeds 46.2 mm (1.82 in.),
install valve spring seat shim approximately
1.6 mm (0.0625 in.) thick.
- Do not shim valve spring to obtain a less than
specified installed height.
CAMSHAFT
Figures 63 and 64
Tool Required:
J 7872 Magnetic Base Indicator Set
!@I
Measure
1. Camshaft journals with micrometer.

If journals are more than 0.025 mm
(0.0010 in.) out..aof-round, replace camshaft.
2. Camshaft runout using J 7872.
Mount camshaft in V-blocks or between
centers. Using J 7872, check intermediate
camshaft journal. If runout exceeds 0.065 mm
(0.0026 in.), camshaft is excessively bent and
should be replaced.

RELUCTOR RING
!LI
Inspect
Crankshaft position sensor reluctor ring for

knicks, scratches, or damage to the lugs.
Assemble
1. Shim (76) to cylinder head.

2. Valve into proper port.
3. Valve seal (73), lightly seat seal against cylinder
head and shim (76).
5. Cap (70) on valve stem.
6. Compress valve spring (69) using J 8062.
2906T901S
Figure 63 - Measuring Camshaft Journals
l++I
Engine front cover oil seals for crankshaft,

distributor shaft, and water pump driveshaft
assembly.
l++I
Install or Connect
1. Crankshaft seal using J 3546K

2. Distributor driveshaft oil seal using J 39937.
3. Water pump driveshaft oil seal using J 39088.
Oil PAN
Clean
Oil pan in solvent. Remove an sludge and

varnish.
.. Gasket surfaces.
Figure 64 - Measuring Camshaft Runout
Crankshaft position sensor reluctor ring for worn

keyway.

IL'l'I
IL'l'i
.. Gasket flanges for bending or damage.

" Oil pan for rock damage or cracks.
Crankshaft oil deflector for lack of fit.
Oil pan drain plug opening for stripped threads.
WATER PUMP
Tool Required:
Shaft 0-Ring Seal Installation
Inspect
Camshaft and crankshaft sprockets and water

pump driveshaft assembly for wear.
One edge of teeth worn or teeth no longer
concentric.
Valley between teeth worn.
Key and crankshaft keyway for wear.
Camshaft timing chain for binding.
ENGINE FRONT COVER
Inspect
Clean
Water pump and engine block gasket surfaces.
IL'l'I
Inspect
0-ring seals on water pump driveshaft assembly

and water pump shaft. Replace seals, if necessary,
using J 39089.
VALVE LIFTERS
Clean
Engine front cover for damage to seals, gasket
surfaces, and crankshaft position sensor bore.
IL'l'I
Inspect
Engine front cover for damage to seals or gasket

surface.
ENGINE FRONT COVER OIL SEALS

Tools Required:
J 35468 Engine Front Cover Alignment and
Oil Seal Installation
J 3993 7 Engine Front Cover Distributor
Shaft Oil Seal Installation
J 39088 Engine Front Cover Water Pump
Driveshaft Assembly Oil Seal
Installation
IL'l'I
Inspect
Valve lifter body for wear and scuffing. Also

inspect bore in engine block for scuffing.
Valve lifter roller for:
- Binding or roughness.
- Excessive looseness in roller bearings.
- Flat spots.
- Pitting.
Valve lifter valve pushrod seat and valve pushrod
end for wear or scoring.

PUSH RODS
!L'l'I
Inspect
Valve rocker arms and balls at their mating

surfaces. These surfaces should be smooth and
free of scoring or other damage.

Valve rocker arm valve pushrod sockets and valve
stem mating surfaces. These surfaces should be
smooth with no scoring or exceptional wear.
Valve pushrods for scored ends or bends.
CAMSHAFT BEARINGS
Clean

surfaces.
!l!
Inspect
Gasket flanges for damage.

Rubber grommets for deterioration.
INTAKE MANIFOLD
Fuel pump and oil pressure switch to

12 N.m (106 lb. in.).
Oil Pressure Fitting and Switch to 20 N.m
(15 lb. ft.).
Oil filter to 21 N.m (15 lb. ft.).

Tool Required:
J 6098-01 Camshaft Bearing Removal and
Installation
Outer front and rear camshaft bearings must
be installed first. These bearings serve as guides for
tool pilot, and help center inner bearings during
installation process.
Clean
Intake manifold bolts and studs.

All intake manifold sealing surfaces.
Remove old RTV from intake.
ASSEMBLY
ENGINE BLOCK
!Hi
.Install or Connect
1. Engi~e block core plugs.
2. Front and rear oil gallery plugs.
l~i
Tighten
Rear engine block oil gallery plugs to 20 N.m

(15 lb. ft.).
!Li
Inspect
Figure 65 - Installing Camshaft Outer Bearings
Oil filter adapter bypass valve and spring for

operation.
For cracked or broken bypass valve.
- Oil filter adapter and bypass valve
assembly must be replaced as a unit.
3. Oil filter adapter, with new adapter seal.
4. Oil filter adapter bolts and washers.
I~!
5.
6.
7.
8.
Oil filter adapter bolts to 25 N.m (18 lb. ft.).

Oil filter.
Fuel pump and oil pressure switch.
Knock sensor.
Oil pressure fitting and switch.
l~i
\
Tighten
Tighten
Knock sensors to 20 N.m (15 lb. ft.).
Fuel pump and oil pressure fitting to
12 N.m (106 lb. in.) plus necessary
alignment.
A BEARING TOOL
B PILOT
C PULLER SCREW
D WASHER
E NUT
67 BLOCK, ENGINE
67
Figure 66 - Installing Camshaft Inner Bearings
6A3B34

D. Using two wrenches, hold puller screw while
turning nut to draw bearing into bore.
When bearing has been pulled into bore,
remove bearing tool and puller screw and
check alignment of bearing oil hole to bore
oil hole.
E. Repeat above steps for remaining inner
camshaft bearings.
Index pilot in rear camshaft bearing to

install rear inner bearing.
3. New camshaft rear bearing hole plug (68).
A. Coat plug outside diameter with GM
PIN 1052080 sealant, or equivalent.
B. Install camshaft rear bearing hole plug (68) as
shown (Figure 67).
CRANKSHAFT
Figures 68 and 69
l++I
87 BLOCK, ENGINE
1. Crankshaft bearings into engine block and

crankshaft bearing caps.
SECTION AA
88 PLUG, CAMSHAFT REAR BEARING HOLE

BS9488A4B
Figure 67 - Camshaft Rear Bearing Hole Plug
[I]
Install or Connect
Important
Coat crankshaft bearings with oil.

2. Crankshaft.
3. Crankshaft bearing caps with installed crankshaft
bearings. Cap directional arrows must point
toward front of engine block.
Align camshaft bearing oil holes properly during

installation.
- Number one (front) camshaft bearing oil holes
must be positioned so that they are at
1 o'clock and 5 o'clock positions.
- Number two through number four inner
camshaft bearing oil holes must be positioned
at 5 o'clock toward left side of engine block
and even with bottom of cylinder bore.
- Number five (rear) camshaft bearing oil hole
must be positioned at 12 o'clock.
!++I
Install or Connect
1. Front and rear camshaft bearings using J 6098-01.

A. Assemble bearing tool to driver handle.
B. Align oil holes as outlined above.
C. Drive front and rear bearings in, toward center
of engine block.
2. Inner camshaft bearings using J 6098-01.
A. With nut and thrust washer assembled to end
of puller screw threads, index pilot in camshaft
front bearing and install puller screw through
pilot.
B. Index camshaft bearing in bore, aligning oil
hole as outlined above.
C. Install puller screw through bearing bore and
bearing to be installed and assemble bearing
tool to puller screw with shoulder toward
bearing. Make sure that enough threads are
engaged.
\
Figure 68 - Crankshaft, Bearings, and Main Cap

4. Crankshaft bearing cap bolts and studs.
With crankshaft, crankshaft bearings,
crankshaft bearing caps installed, and bolts and
studs started, thrust crankshaft rearward to set
and align bearing caps. Then thrust crankshaft
forward to align rear faces of rear crankshaft
bearings.
!~J
Tighten
Bolts and studs to 105 N,m (77 lb. ft.).
!@!
Measure
Crankshaft end play using a dial indicator or

feeler gage. Refer to "Specifications" in this
section.
- If using a feeler gage, measure between
front of rear crankshaft bearing cap and
crankshaft thrust surface.

Figure 70
Clean
Gasket surfaces.
E3
Install or Connect
1. New crankshaft rear oil seal housing gasket and
Figure 69 Checking Crankshaft End Play
crankshaft rear oil seal housing on studs.
rn
Important
Always use new crankshaft rear oil seal and

new crankshaft rear oil seal housing gasket
during installation of crankshaft rear oil seal
housing.
hold gasket in place.
2. Crankshaft rear oil seal housing nuts and bolts.
!~!
Tighten
Crankshaft rear oil seal housing nuts and bolts

to 15 N.m (11 lb. ft.).

Figure 71
Tool Required:
J 35621 Crankshaft Rear Oil Seal
Installation
!++!
Install or Connect

2. Oil seal onto J 35621.
NOTICE: Crankshaft sealing surface and

chamfer must be free of nicks and burrs to
prevent damage to the lip of the seal.
Figure 70 Crankshaft Rear Oil Seal Housing
3. J 35621 onto rear of crankshaft. Tighten screws

snugly to ensure seal will be installed squarely
over crankshaft.
4. Crankshaft rear oil seal to crankshaft and
crankshaft rear oil seal housing.
Tighten wing nut on J 35621 until it bottoms.
5. Remove J 35621 from crankshaft rear oil seal
housing.
6A3B36
{)
J 35621
Figure 72 - Installing the Piston
Figure 71 - Crankshaft Rear Oil Seal Installation Tool

ASSEMBLY
Tools Required:
l++I
Install or Connect
1. Coat piston, piston rings, cylinder bore, and

bearing surfaces with engine oil.
2. Piston with stamped arrow facing forward and
connecting rod assembly into its matched bore.
Use J 8037 and J 5239 and lightly tap top of
piston with wooden hammer handle.
Hold J 8037 firmly against engine block until
all piston rings have entered cylinder bore.
Guide connecting rod using J 5239.
3. Remove J 5239.

Figure 75
l++I
Install or Connect
Figure 73 - Connecting Rod Guide Tool
1. Coat inside surface of bearings with engine oil.
[I]
Important
When assembled, flanges on connecting rod

and cap should face to front in left bank and
to rear in right bank.
2. Connecting rod cap and bearings.

3. Connecting rod nuts.
l~I
Tighten
I
Connecting rod nuts, evenly, to 27 N.m

(20 lb. ft.) plus an additional 55 degrees.
Figure 74 - Installing the Piston and Connecting Rod

Assembly
!t!i!!
Figure 75 - Measuring Connecting Rod Side Clearance
Measure
1. When all connecting rod bearings have been

installed, tap each connecting rod lightly parallel
to crankpin to make sure they have clearance.
2. Side clearance between connecting rod caps using
a feeler gage or dial indicator.
Rod side clearance should be 0.16 to 0.35 mm
(0.006 to 0.014 in.).
OIL PUMP
Figure 76
!++!
Install or Connect
1. Oil pump, driveshaft, and retainer.

Align slot on end of driveshaft with drive tang
on oil pump shaft.
2. Crankshaft oil deflector.
3. Bolt attaching oil pump to rear crankshaft bearing
cap.
!~I
Tighten
Oil pump bolt to 90 N.m (66 lb. ft.).

Crankshaft oil deflector nuts to 40 N .m
(30 lb. ft.).
CYLINDER HEAD
Figures 77 and 78
Tools Required:
J 36660 Torque Angle Meter
!++I
Install or Connect
1. New cylinder head gasket.

2. Gasket over locating pins, with yellow side of tab
on outboard side facing up.
Figure 76 - Oil Pump, Crankshaft Oil .Deflector, Driveshaft,

and Retainer
3. Cylinder head over locating pins and gasket.

Coat threads of cylinder head bolts with
sealing compound GM PIN 1052080 or
equivalent.
4. Cylinder head bolts finger tight.
6A3B-38
13
17
,.
12
0
3
10
14
,,
,,
Figure 78 - Cylinder Head Tightening Sequence
Figure 77 - Cylinder Head and Gasket
!~I
Tighten
Cylinder head bolts in sequence first pass to

30 N.m (22 lb. ft.) (Figure 78).
Cylinder head bolts in sequence second pass
using J 36660 to:
- Short bolts (3, 4, 7, 8, 11, 12, 15, 16)
67 degrees.
- Medium bolts (14,17) 80 degrees.
-Long bolts (1, 2, 5, 6, 9, 10, 13)
80 degrees.
5. Spark plugs.
6. Engine coolant air bleed pipe and bolts.
!~!
Tighten
Spark plugs to 20 N.m (15.lb. ft.).

Engine coolant air bleed pipe bolts to 40 N.m
(30 lb. ft.).
- Use backup wrench on pipe fittings when
installing bolts.
CAMSHAFT
Figures 79 and 80
When installing new camshaft, coat .camshaft
lobes and journals with engine oil.
When installing a new camshaft, inspect all
valve lifters and replace as necessary to ensure
durability of camshaft lobes and valve lifter rollers.
Figure 79 - Installing the Camshaft
!++l
Install or Connect
1. Install three 5/16 - 18 x 4.0 in. bolts in camshaft

front bolt holes.
2. Camshaft.
3. Remove the three bolts from front of camshaft.
4. Camshaft retainer and camshaft retainer bolts.
!~l
Tighten
Camshaft retainer bolts to 12 N.m

(106 lb. in.).
5. Oil pump driveshaft assembly and bolt.
Bolt hole ''ear" must be seated on boss before
tightening bolt.
Figure 82 - Installing the Crankshaft Sprocket
Figure 80 - Oil Pump Driveshaft Assembly
!~I
!H!
Tighten
Oil pump driveshaft bolt to 18 N.m

(13 lb. ft.).

Tools Required:
J 5590 Crankshaft Sprocket Installation
Shaft 0-Ring Seal Installation
J 41546 Water Pump. Driveshaft Assembly
Installation
6A3B-39
Install or Connect
1. Align key with keyway, if previously removed.

2. Crankshaft sprocket (62) using J 5590.
3. Water pump driveshaft assembly (63) using
J 41546.
4. Water pump driveshaft bearing retainer bolts (64).
I~!
Tighten
Water pump driveshaft bearing retainer bolts

(64) to 12 N,m (106 lb. in.).
(61).
Gears must mesh, or damage to camshaft
retainer could occur.
6. Camshaft sprocket bolts (56).
Make sure that camshaft and crankshaft
sprocket alignment marks align (Figure 83).
Figure 81 - Installing the Water Pump Driveshaft Assembly
6A3B-40
62
A
8
C
56
57
58
59
60
61
62
63
64
SPROCKET ALIGNMENT MARKS

KEYWAY
PIN, CAMSHAFT
SPROCKET, CAMSHAFT
RETAINER, CAMSHAFT
CAMSHAFT
CHAIN, CAMSHAFT TIMING
DRIVESHAFT, WATER PUMP
SOLT/SCREW, WATER PUMP DRIVESHAFT
I~!
01-1896
YS920IA1B
Figure 83 Camshaft Timing Chain, Sprockets, and Water Pump Driveshaft Assembly
Tighten
Camshaft sprocket bolts (56) to 25 N.m

(18 lb. ft.).
7. New 0-ring seal to water pump driveshaft
assembly (63) using J 39089.

RELUCTOR RING
Figure 84
l++I
Install or Connect
Reluctor ring onto crankshaft.
Important
Align the keyway on the reluctor ring with the

key in the crankshaft and install the reluctor ring
onto the crankshaft until the ring is completely
seated against the crankshaft sprocket.
ENGINE FRONT COVER

Figure 85
Tool Required:
Engine Front Cover Oil Seal Protector
!++I
Install or Connect
1. Gasket (1) and engine front cover ( 4) using

J 39087 on water pump driveshaft assembly.
NOTICE: Be careful not to damage oil seal

when installing engine front cover over water
pump driveshaft assembly.
2. Engine front cover bolts (5).
!~!
Tighten
Engine front cover bolts (5) to 12 N.m

(106 lb. in.).
5.7l ENGINE UNIT REPAIR VIN CODE P 6A3B-41
!HI
Install or Connect
1. Lubricate the 0-ring seal of the sensor with clean

engine oil.
2. Crankshaft position sensor into engine front cover.
[I]
Important
When installing the crankshaft position sensor

be sure the sensor is fully seated and held
stationary in the engine front cover bore.
Torque the hold down bolt to the specification
shown below. A sensor that is not fully seated
will cock in the engine front cover and may
result in erratic engine operation.
3. Bolt into cover.
!~!
Figure 84 - Crankshaft Position Sensor Reluctor Ring
Tighten
Bolt to 12 N,m (106 lb. in.).
DISTRIBUTOR
Figure 87
Figure 86
rn
[I]
Important
Do not re-use the 0-ring seal on the crankshaft

position sensor. Install a new 0-ring seal onto the
sensor.
Important
Distributor (49) is driven by a camshaft pin that

mates to one slot in distributor driveshaft.
Align distributor driveshaft slot with distributor
base timing mark.
2
\
3
4
5
Figure 85 - Engine Front Cover
6A3B-42

Rotate engine crankshaft until number one piston
is at top dead center (intake and exhaust valves
closed). Camshaft pin will be at 9 o'clock
position.
l++I
Install or Connect
1. Distributor (49).
Before inserting distributor bolts (47), make
sure distributor (49) is fully seated to engine
front cover. If it is difficult to seat, check
alignment of distributor driveshaft slot, timing
mark and camshaft pin.
2. Distributor bolts (47).
!~!
Tighten
Distributor bolts (47) to 12 N.m (106 lb. in.).

3. Ignition coil and bracket and studs.
!~!
Tighten
Ignition coil studs to 40 N,m (30 lb. ft.).

4. Spark plug and ignition harnesses to distributor
(49), if removed, and ignition coil.
5. Distributor vacuum harness.
OT9016A4B
OIL PAN
Figure 86 - Crankshaft Position Sensor
!++I
(
Install or Connect
1. Apply a small amount of sealer, GM PIN 1052914

or equivalent, to engine front cover and engine
block junction and to crankshaft rear oil seal
housing and engine block junction. Apply sealer
25 mm (1.0 in.) in either direction of radius
cavity of junctions.
2. Oil pan gasket, oil pan, and reinforcements.
3. Oil pan nuts, bolts and studs.
c
8
jVIEWA!
A
B
C
24
47
49
!VIEW B!
CAMSHAFT PIN
CAMSHAFT PIN SLOT
DISTRIBUTOR BASE TIMING MARK
DISTRIBUTOR VACUUM HARNESS
BOLT/SCREW DISTRIBUTOR
DISTRIBUTOR
Figure 87 - Distributor
l~I
Tighten
Corner bolts or stud, and nuts to 20 N.m

(15 lb. ft.).
Remainder of bolts and studs to 12 N,m
(106 lb. in.).
!~I
Tighten
Oil level sensor to 35 N.m (26 lb. ft.).

5. Starter motor and bolts.
6. Oil pan drain plug and gasket.
04-07-915
BSt188A4B
!~!
Tighten
Starter motor bolts to 47 N.m (35 lb. ft.).

Oil pan drain plug to 20 N,m (15 lb. ft.).
10mm
(0.393 IN.)
Figure 89 - Applying Sealer to Front of Engine Oil Pan

Surface
Figure 88 - Oil Pan, Reinforcements, and Gasket

Figures 92 and 93
Tool Required:
J 39046 Crankshaft Hub Removal and
Installation
!++!
25.4 mm
(1.00 IN.)
Install or Connect
1. Crankshaft balancer hub must be installed by

following procedure:
Figure 90 - Applying Sealer to Rear of Engine Oil Pan

Surface
B. Drive weights in old balancer to bottom of

hole then measure depth of hole. Record
measurement.
C. Subtract measurement of hole with weight
from measurement of empty hole.
Difference will be the length of balancer
weight that must be installed in new
balancer in the same location.
A. Set number 1 piston assembly to top dead

center.
B. Install crankshaft balancer hub with cast arrow
on hub in 12 o'clock position.
2. Crankshaft balancer hub, until completely seated
against the crankshaft position sensor reluctor ring
using J 39046.
3. Crankshaft balancer hub washer and bolt.
4. Crankshaft balancer and bolts.
[II
Important
If crankshaft balancer is replaced, new

balancer weights of same size must be
installed on new balancer in same location as
old balancer.
A. Measure depth of empty balancer weight
hole. Record measurement.
!~I
Tighten
Crankshaft balancer hub bolt to 100 N .m

(75 lb. ft.).
Crankshaft balancer bolts to 85 N.m (63 lb. ft.).
6A3B-44
SF.!t
Figure 92 - Crankshaft Balancer Hub, Bolt, and Washer
Figure 91 - Oil Filter, Adapter, and Seals
WATER PUMP
Figure 94
I++!
Install or Connect
1. Coupling (39) to water pump shaft with groove on
coupling toward engine block.

Apply a light coat of grease to 0-ring seals
(156) and grease to coupling (39).
2. Position water pump (37) and gaskets (38), with
tabs straight up, to engine block. Rotate coupling
(39), if necessary, to align it to water pump
driveshaft splines and then seat water pump (37).
3. Water pump bolts (40 and 41) ..
l~I
Tighten
View A
Water pump bolts (40 and 41) 45 N.m

(33 lb. ft.).
VALVE LIFTERS
Figure 95
l++I
Install or Connect
1. Coat valve lifter rollers with prelube, GM

2. Valve lifters in same location from which they
were removed.
Figure 93 - Crankshaft Balancer and Hub
3. Valve lifter guides, retainer and valve lifter guide

retainer bolts.
!~!
Tighten
Valve lifter guide retainer bolts to 25 N.m

(18 lb. ft.).
A. SHAFT, WATERPUMP
B. TAB ON GASKET
37. PUMP, WATER
38. GASKET, WATERPUMP
39. COUPLING, WATERPUMP DRIVESHAFT
63. DRIVESHAFT ASSEMBLY, WATERPUMP
156. SEAL, WATERPUMP DRIVESHAFT
6A3B-45
View A
Figure 94 Water Pump
VALVE ROCKER ARM BALL STUDS
!HI
Install or Connect
1. Apply sealer, GM PIN 1052080 or equivalent, to

threads of new valve rocker arm ball stud.
2. Valve rocker arm ball stud.
!~i
Tighten
Valve rocker arm ball stud to 68 N.m

(50 lb. ft.).

PUSH RODS
Tool Required:
J 8520 Cam Lobe Lift Indicator
l~I
Install or Connect
1. Coat valve rocker arm (3) and valve rocker arm

ball bearing surfaces with prelube, GM
PIN 1052365 or equivalent, when installing. Keep
these components and valve pushtods (4) in same
sequence to ensure their return to the original
positions from which they were removed.
2. Valve pushrods ( 4). Make sure valve pushrods
seat in valve lifter sockets.
Figure 95 - Valve Lifters, Guides, and Retainer
!@I
Measure
Camshaft lobe lift.

A. Position J 8520 with ball socket adapter on
valve pushrod ( 4). Make sure valve
pushtod is in valve lifter socket.
B. Rotate crankshaft slowly in direction of
rotation until valve lifter roller is on heel of
cam lobe. At this point, valve .pushtod will
be in its lowest position.
6A3B-46
1 BALL, VALVE ROCKER ARM

2 NUT, VALVE ROCKER ARM
3 ROCKER ARM
4 PUSHROD
5 STUD, VAL VE ROCKER ARM
Figure 98 Valve Rocker Arm, Ball, and Nut
Figure 96 - Valve Pushrods
nn
"
BS9646A48
Figure 97 Measuring Camshaft Lobe Lift
C. Set J 8520 on zero.
D. Rotate crankshaft slowly until valve

pushrod is in fully raised position.
E. Compare total lift shown on J 8520 with
specifications. Refer to "Specification" in
this section.
F. Remove J 8520.
4. Valve rocker arm balls (1) and nuts (2).
llJ
Adjust
Valve rocker arm nuts until all lash is eliminated.

1. Turn crankshaft until cast arrow on crankshaft
balancer hub is in 12 o'clock position and
number 1 cylinder is in firing position (top
dead center).
Watch number 1 cylinder valves as
crankshaft balancer hub arrow approaches
12 o'clock position. If a valve moves as
arrow moves to position, engine assembly
is in number 6 cylinder firing position.
Figure 99 Adjusting Valve Lash
Crankshaft must then be turned one more

revolution to reach number 1 cylinder
firing position.
2. With engine assembly in number. I cylinder
firing position, following valves can be
adjusted:
Exhaust 1, 3, 4, 8
Intake 1, 2, 5, 7
3. Back off valve rocker arm nut (2) until lash is
felt in valve pushrod (4). Then tighten valve
rocker arm nut until all lash is removed. Zero
lash can be felt by moving valve pushrod up
and down between thumb and forefmger until
there is no more movement.
4. When all free play has been removed, tighten
valve rocker arm nut (2) one additional turn
(360 degrees).

5. Turn crankshaft one revolution until hub arrow
is again at 12 o'clock position. This is number
6 cylinder firing position. Following valves
can now be adjusted:
Exhaust 2, 5, 6, 7
Intake 3, 4, 6, 8

Figure 100
Right Valve Rocker Arm Cover
!++-!
install or Connect
1. Gasket and valve rocker arm cover.

2. Valve rocker arm cover bolts.
I~!
Tighten
Valve rocker arm cover bolts to 12 N,m

(106 lb. in.).
Left Valve Rocker Arm Cover
I++-!
Install or Connect
1. Gasket and valve rocker arm cover.

2. Valve rocker arm cover bolts.
!~!
Tighten
Valve rocker arm cover bolts to 12 N,m

(106 lb. in.).
6A3B-47
INTAKE MANIFOLD
iHI
Install or Connect
1. Apply a 5 mm (0.197 in.) bead of RTV sealer,

GM PIN 12346141 or equivalent, to front and rear
of engine block. Extend bead 13 mm (0.5 in.) up
each cylinder head to seal and retain gaskets.
2. Intake manifold with new gaskets.
3. Intake manifold bolts and studs.
l~I
Tighten
Intake manifold bolts and studs in a first pass

(Figure 104) to. 8 N,m (71 lb. in.) in sequence.
Tighten bolts in sequence a second pass to
48 N.m (35 lb. ft.).
4. Throttle body, gasket and bolts.
!~!
Tighten
Throttle body bolts to 25 N.m (18 lb. ft.).
5. Accelerator cable bracket and bolts.

6. Engine coolant air bleed pipe bolts.
7. EGR valve and bolts.
8. EGR vacuum control solenoid, bracket and nut.
l~I
Tighten
EGR valve bolts to 25 N,m (18 lb. ft.).

EGR vacuum control solenoid nut to 25 N.m
(18 lb. ft.).
Engine coolant air bleed pipe bolts to 40 N.m
(30 lb. ft.).
Accelerator control cable bracket bolts to
12 N,m (106 lb. in.).
9. Evaporative emission canister purge valve vacuum
hose and nut.
i~I
10.
11.
12.
13.
14.
Tighten
Evaporative emission canister purge valve

bracket nut to 20 N.m (15 lb. ft.).
EGR vacuum harness and crankcase vent hoses.
Evaporative emission canister purge valve vacuum
hose.
Fuel injectors with fuel rail to intake manifold.
Fuel pressure regulator vacuum tube.
Fuel rail bolts.
I~!
Tighten
Fuel rail bolts to 20 N.m (15 lb. ft.).

15. Wiring harness if moved or disconnected.
16. MAP sensor and bolts.
I~!
Figure 100 - Valve Rocker Arm Cover
Tighten
MAP sensor bolts to 6 N.m (53 lb. in.).
6A3B-48
Figure 101 Intake Manifold, Fuel Rail, and Throttle Body
Figure 102 Applying Sealer to the Rear of the Block
EXHAUST MANIFOLDS
Right Exhaust Manifold
lHi
Install or Connect
1. Exhaust manifold gasket (18), exhaust manifold

(19), and heat shields.
2. Exhaust manifold studs (20) and bolts (21).
Figure 103 Applying Sealer to the Rear of the Block
l~i
Tighten
Exhaust manifold studs (20) and bolts (21) to

40 N.m (30 lb. ft.).
3. Air injection pipe (15) and check valve (11).
!~!
Tighten
Air injection pipe fitting-to-exhaust manifold

to 55 N.m (41 lb. ft.).
Figure 105 - Engine Coolant Air Bleed Pipe
Figure 104 - Intake Manifold Tightening Sequence
4. Apply sealer, GM PIN 1052080 or equivalent

around level indicator tube (0.5 in.) below bead.
5. Oil level indicator and tube to engine block.
!~i
Tighten
Oil level indicator tube bolt to 12 N .m

(106 lb. in.).
6. Spark plug wire harness.
7. EGR valve pipe gasket (22), pipe (12), nut (14),
and bolt (229).
!~!
Tighten
EGR valve pipe nuts (14) and bolts (229) to

25 N.m (18 lb. ft.).
Left Exhaust Manifold
iH!
Install or Connect
1. Exhaust manifold gasket (17), exhaust manifold

and heat shields.
2. Exhaust manifold studs (20) and bolts (21).
!~I
Tighten
Exhaust manifold studs (20) and bolts (21) to

40 N.m (30 lb. ft.).
4. Air injection pipe (15) and check valve (11).
!~I
Tighten
Air injection pipe fitting at exhaust manifold

to 55 N.m (41 lb. ft.).
Figure 106 - Checking the Exhaust Manifold for Flatness
ENGINE FLYWHEEL
Figure 109
1++1
Install or Connect
1. Engine flywheel to crankshaft.

Align locator hole to pin.
2. Engine flywheel bolts.
i~!
Tighten
Engine flywheel bolts to 100 N.m (74 lb. ft.).
6A3B-50
17 GASKET, EXHAUST MANIFOLD

19 MANIFOLD, EXHAUST
20 STUD, EXHAUST MANIFOLD
21 BOLT/SCREW, EXHAUST MANIFOLD
240 SPACER, EXHAUST MANIFOLD
21
04-07-95
1Ut12GMD

11
_Jj.
11 VALVE, SECONDARY AIR INJECTION
CHECK
12 PIPE, EGR VAJ.VE
13 STIJD. EGR VALVE PIPE
14 NUT, EGRVALVE PIPE

15 PIPE, SECONDAAVAIR INJECTION
22 GASKET. EGA VALVE PIPE
229 BOLT/SCREW, EGR VALVE PIPE
12
Figure 108 - Secondary AIR Injection and EGR Valve Pipes
Figure 109 Engine Flywheel
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS 5.7L (LT1)
Accelerator Control Cable Bracket Bolt............................................................................... 12 N,m (106 lb. in.)
. Camshaft Retainer Bolt ......................................................................................................... 12 N.m (106 lb. in.)
Camshaft Sprocket Bolt........................................................................................................... 25 N.m (18 lb. ft.)
Connecting Rod Nut .............................................................. 27 N.m (20 lb. ft.) plus an additional 55 degrees
Crankshaft Balancer Bolt ........................................................................................................ 85 N.m (63 lb. ft.)
Crankshaft Balancer Hub Bolt .............................................................................................. 100 N,m (74 lb. ft.)
Crankshaft Bearing Cap ........................................................................................................ 105 N.m (77 lb. ft.)
Crankshaft Position Sensor Bolt ........................................................................................... 12 N.m (106 lb. in.)
CrankshaftRear Oil Seal Housing Nut and Bolt .................................................................. 15 N.m (11 lb. ft.)
Cylinder Head Bolt
First Pass all Bolt in Sequence ............................................................................................. 30 N.m (22 lb. ft.)
Second Pass all Bolt in Sequence:
Short Bolt. ...................................................................................................................................... 67 degrees
Medium Bolt .................................................................................................................................. 80 degrees
Long Bolt ....................................................................................................................................... 80 degrees
Distributor Bolt ...................................................................................................................... 12 N,m (106 lb. in.)
EGR Solenoid Valve Bracket Nut .......................................................................................... 25 N,m (18 lb. ft.)
EGR Valve Bolt ....................................................................................................................... 25 N.m (18 lb. ft.)
EGR Valve Pipe Bolt and Nut ................................................................................................ 25 N.m (18 lb. ft.)
Engine Block Coolant Drain Plug ............................................................................ ;............. 20 N.m (15 lb. ft.)
Engine Block Oil Gallery Plug ............................................................................................... 20 N.m (15 lb. ft.)
Engine Coolant Air Bleed Pipe Bolt ...................................................................................... 40 N.m (30 lb. ft.)
Engine Front Cover Bolt ....................................................................................................... 12 N.m (106 lb. in.)
Engine Oit Level Sensor ......................................................................................................... 35 N.m (26 lb. ft.)
Evaporative Emission Canister Purge Valve Bracket Bolt. ..................................................... 6 N.m (53 lb. in.)
Exhaust Manifold Stud and Bolt ............................................................................................ 40 N.m (30 lb. ft.)
Engine Flywheel Bolt ............................................................................................................ 100 N.m (74 lb. ft.)
Fuel Injection Fuel Rail Bolt .................................................................................................. 10 N,m (89 lb. in.)
Generator Bracket Bolt ........ ,................................................................................................... 40 N.m (30 lb. ft.)
Ignition Coil Studs .................................................................................................................. 40 N.m (30 lb. ft.)
Intake Manifold Bolt and Stud
First Pass ................................................................................................................................ 8 N,m (71 lb. in.)
Final Pass ............................................................................................................................. 48 N.m (35 lb. ft.)
Knock Sensor ........................................................................................................................... 20 N.m (15 lb. ft.)
MAP Sensor Bolt ...................................................................................................................... 6 N.m (53 lb. in.)
Oil Filter Adapter Bolt. ........................................................................................................... 25 N.m (18 lb. ft.)
Oil Filter .................................................................................................................................. 21 N,m (15 lb. ft.)
Oil Level Indicator Tube Bolt .............................................................................................. 12 N.m (106 lb. in.)
6A3B-52
Oil Pan
Corner Bolt and Nut or Stud .............................................................................................. 20 N.m (15 lb. ft.)
Side Rail Bolt or Stud ...................................................................................................... 12 N.m (106 lb. ill.)
Crankshaft Oil Deflector Nut. ................................................................................................. 40 N.m (30 lb. ft.)
Oil Pan Drain Plug ...................................................................................... :......................... ,. 20 N.m (15 lb. ft.)
Oil Pressure Fittings (plus necessary alignment) ........................................ ,oo, 12 N.m (106 lb. ill.)
Oil Pressure Gage Sensor.........................................................................., .......................... .12 N.m (106 lb. ill.)
Oil Pressure Sensor and Switch ............................................................................................ 12 N.m (106 lb. ill.)
Oil Pump Bolt-to-Rear Crankshaft Bearing Cap .................................................................... 90 N.m (66 lb. ft.)
Oil Pump Cover Bolt ............................................................................................................... 9 N.m (80. lb. ill.)
Oil Pump Driveshaft Bolt ................................................................................................ ,...... 18 N.m (13 lb. ft.)
Oil Temperature Sensor ........................................................................... ,............................. 12 N.m (106 lb. in.)
Secondary Air Injection Pipe Fitting-to-Exhaust Manifold ................................................... 55 N.m (41 lb. ft.)
Secondary Air Injection Pump Bracket Bolt. ............................................ ,......... :.................. 40 N.m (30 lb. ft.)
Spark Plugs .............................................................................................................................. 20 N.m (15 lb. ft.)
Starter Motor Bolt ................................................................................................................... 47 N.m (35 lb. ft.)
Throttle Body Bolt. ................................................................................................................ .. 25 N.m (18 lb. ft.)
Valve Lifter Guide Retainer Bolt. ........................................................................................... 25 N.m (18 lb. ft.)
Valve Rocker Arm Ball Stud .................................................................................................. 68 N.m (50 lb. ft.)
Valve Rocker Arm Cover Bolt .......................................................... ,.................................. 12 N.m (106 lb. ill.)
Water Pump Bolt and Stud ..................................................................................................... 45 N.m (33 lb. ft.)
Water Pump Driveshaft Bearing Retainer Bolt.. .................................................................. 12 N.m (106 lb. in.)
ENGINE ASSEMBLY SPECIFICATIONS 5.7L (LT1)

GENERAL
Type ....................................................................................................... ,............................................................. V8
Displacement .................................................................................................................................. 5.7L (350 CID)
Bore .................................................................................................................................... 101.60 mm (4.000 in.)
Stroke ................................................................................................................................... 88.39 mm (3.480 in.)
Compression Ratio ......................................................................................................................................... 10.4: 1
:~:: ~~~r .................................................................................................................................... 1-8-4-3-6-5-7-2
Type ..................................................................................................................................................... AC41-943
Gap ............................................................................................................................................ 1.24 mm (0.050)
Torque ................................................................................................................................... 20 N.m (15 lb. ft.)
Oil Pressure (Minimum) ...................................................................... .41.4 kPa (6.0 psig) at 1,000 engine rpm
124.1 kPa (18.0 psig) at 2,000 engine rpm
165.5 kPa (24.0 psig) at 4,000 engine rpm
Oil Filter Torque ...................................................................................................................... 21 N.m (15 lb. ft.)
CYLINDER BORE
Diameter ......... ,.................................................................. ,............ 101.618. - 101.643 mm (4.0007 - 4.0017 in.)
Out-of-Round
Production ........................................................................................................... 0.02 mm (0.001 in.) MAX.
Service Limit. ..................................................................................................... 0.05 mm (0.002 in.) MAX.
Taper
Production
Thrust Side ..................................................................................................... 0.012 mm (0.0005 in.) MAX.
Relief Side...................................................................................................... 0.025 mm (0.0010 in.) MAX.
Service Lillllit. .................................................................. ;............. ;........................ 0.025 .mm (0.0010 in.) MAX.
PISTON
Piston Bore Clearance
Production .............................................. :.......................................... 0.025 - 0.068 mm (0.0010 - 0.0027 in.)
Service Limit. ..................................................................................................... 0.068 mm (0.0027 in.) MAX.
PISTON RINGS
Groove Clearance
Production Top .............................................................................. 0.050 - 0.090 mm (0.0019 - 0.0035 in.)
Production 2nd .............................................................................. 0.050 - 0.090 mm (0.0019 - 0.0035 in.)
Service Limit. ................................................................................................. 0.107 mm (0.0042 in.) MAX.
6A3B-53
Gap
Production Upper .................................................................................. 0.25 - 0.40 mm (0.010 - 0.016 in.)
Production Lower ...................................................................... 0.46 - 0.66 mm (0.018 - 0.026 in.) MAX.
Service Limit ..................................................................................................... 0.88 mm (0.035 in.) MAX.
Piston Oil Ring
Groove Clearance
Production ........................................................................................... 0.051 - 0.17 mm (0.002 - 0.007 in.)
Gap
Production ............................................................................................. 0.25 - 0.76 mm (0.010 - 0.030 in.)
PISTON PIN
Diameter ............................................................................................. 23.545 - 23.548 mm (0.9270 - 0.9271 in.)
Clearance in Piston
Production ...................................................................................... 0.0120 - 0.0210 mm (0.0004 - 0.0008 in.)
Fit In Connecting Rod ...................................................... 0.021 - 0.040 mm (0.0008 - 0.0016 in.) Interference
CRANKSHAFT
Crankshaft Journal
Diameter #1 ................................................................................... 62.189 - 62.212 mm (2.4484 - 2.4493 in.)
Diameter #2, #3, #4 ...................................................................... 62.182 - 62.205 mm (2.4481 - 2.4490 in.)
Diameter #5 ................................................................................... 62.177 - 62.199 mm (2.4479 - 2.4488 in.)
Taper
Production ....................................................................................................... 0.005 mm (0.0002 in.) MAX.
Out-of-Round
Service Limit ................................................................................................. 0.025 mm (0.0010 in.) MAX.
Crankshaft Bearing Clearance
Production #1 .................................................................................... 0.017 - 0.053 mm (0.0007 - 0.0021 in.)
Production #2, #3, #4 ....................................................................... 0.022 - 0.061 mm (0.0009 - 0.0024 in.)
Production #5 .................................................................................... 0.025 - 0.069 mm (0.0010 - 0.0027 in.)
Service Limit #1 ............................................................................... 0.025 - 0.051 mm (0.0010 - 0.0020 in.)
Service Limit #2, #3, #4 .................................................................. 0.025 - 0.064 mm (0.0010 - 0.0025 in.)
Service Limit #5 ............................................................................... 0.038 - 0.076 mm (0.0015 - 0.0030 in.)
Crankshaft End Play ..................................................................................... 0.05 - 0.20 mm (0.002 - 0.008 in.)
Crankshaft Runout (At Rear Flange) ................................................................................ 0.038 mm (0.0015 in.)
CONNECTING ROD
Diameter ......................................................................................... 53.284 - 53.334 mm (2.0978 - 2.0998 in.)
Taper
Out-of-Round
Rod Bearing Clearance
Production .......................................................................................... 0.033 - 0.088 mm (0.0013 - 0.0035 in.)
Service Limit .................................................................................... 0.025 - 0.076 mm (0.0010 - 0.0030 in.)
Rod Side Clearance ...................................................................................... 0.16 - 0.35 mm (0.006 - 0.014 in.)
CAMSHAFT
Journal Diameter ............................................................................... .47.440 - 47.490 mm (1.8677 - 1.8697
End Play ........................................................................................................ 0.11 - 0.30 mm (0.004 - 0.012
Lobe Lift ......................................................................................................................... 0.050 mm (0.002
Intake .................................................................................................................................. 7.57 mm (0.298
Exhaust ............................................................................................................................... 7.77 mm (0.306
in.)
in.)
in.)
in.)
in.)
VALVE SYSTEM
Valve Lifter .............................................................................................................................................. Hydraulic
Valve Rocker Arm Ratio ............................................................................................................................... 1.50: 1
Valve Lash ...................................................................................................... 1 1/4 turn down from zero lash
Face Angle ............................................................................................................................................. 45 degrees
Seat Angle .............................................................................................................................................. 46 degrees
6A3B54
Seat Runout. ............................................................................................................... 0.05 mm (0.002 in.) MAX.

Seat Width
Intake ......................................................................................................... 0.76 - 1.27 mm (0.030 - 0.050 in.)

st!xh~r:~~~~ 1.52 - 2.03 mm (0.060 - 0.080 in.)
Production
Intake ............................................................................................. 0.025 - 0.069 mm (0.0010 - 0.0027 in.)
Exhaust.. ........................................................................................ 0.025 - 0.069 mm.(0.0010 - 0.0027 in.)
Service
Intake ............................................................................. '" .............................. 0.093 mm (0.0037 in.) MAX.
Exhaust ............................................................................................................ 0.119 mm (0.0047 in.) MAX.
Valve Spring
Free Length .......................................................................................................................... 51.3 mm (2.02 in.)
Pressure
Closed ............................................................................ 360 - 396 N at 45.2 mm (81 - 89 lb. at 1.78 in.)
Open .................. ,................................................... 1090 - 1179 Nat 33.8 mm (245 - 265 lb. at 1.33 in.)
Installed Height Intake ........................................................................................................ 45.2 mm (1.78 in.)
Exhaust ............................................................................................................................. 45.2 mm (l.78 in.)
Valve Lift Intake .................................................................................................................. 11.36 mm (0.447 in.)
Exhaust ............................................................................................................................. 11.66 mm (0.459 in.)
SPECIAL TOOLS
1
C:::@
J5590
J3049
J5239
~~~~
J5825-A
to_
J6098-01
J7872
J8037
J8062
J8001
12
11
10
J8087
13
J8358
J8520
15
14
('---_ __.r
J9290-01
J 21882
J 9666 OR J 8056
1. VALVE LIFTER REMOVAL
2.
3.
4.
5.
6.
7.
8.
(PLIER TYPE)
CONNECTING ROD GUIDE SET
CRANKSHAFT SPROCKET INSTALLATION
CRANKSHAFT SPROCKET REMOVAL
CAMSHAFT BEARING INSTALLATION/REMOVAL
MAGNETIC BASE DIAL INDICATOR SET
DIAL INDICATOR SET
9. VALVE SPRING COMPRESSOR
(HEAD-OFF)
10. CYLINDER BORE CHECKING GAGE
11. CARBON REMOVAL BRUSH

12. CAM LOBE LIFTER INDICATOR
13. VALVE LIFTER REMOVAL
(SLIDE HAMMER TYPE)
14. VALVE SPRING TESTER
15; OIL PIPE INSTALLATION
6A3B-56

2
~~
J 5715 OR J 6036
'
J 5802-01
\\~~~
J6880
Q~
J35468
J24270
J24086-C
\\\II!
,\\
@\
@MUWiHUih
QIIIIIOOIOOIOi>
J 35621
J 36660
10
((])
J 39087
13~
~
J39088
14
J39046
12
((])
J39089
15
~
J 39937
g{ey
J41546
J39243
1. ROCKER STUD REAMER (0.003 IN. OVERSIZE 0.013 IN. OVERSIZE) (IRON CYLINDER HEAD)
2. ROCKER STUD REMOVAL (IRON CYLINDER HEAD)
3. ROCKER STUD INSTALLATION (IRON CYLINDER HEAD)
4. PISTON PIN REMOVAL/INSTALLATION
5. RIDGE REAMER
6. ENGINE FRONT COVER ALIGNMENT
7. CRANKSHAFT REAR Oil SEAL INSTALLATION
8. TORQUE ANGLE METER
9. CRANKSHAFT HUB REMOVAL/INSTALLATION
10. WATER PUMP DRIVESH.AFTASSEMBLY ENGINE FRONT COVER Oil SEAL PROTECTOR (l99/lT1/lT4)
11. WATER PUMP DRIVESHAFT ASSEMBLY ENGINE FRONT COVER Oil SEAL INSTALLATION (L.99/lT1/lT4)
12. WATER PUMP DRIVESHAFT ASSEMBLY ENGINE FRONT COVER OIL SEAL INSTALLATION (l99/lT1/lT4)
13. WATER PUMP DRIVESHAFT ASSEMBLY REMOVAL (l99/LT1/LT4)
.
14. ENGINE FRONT COVER DISTRIBUTOR Oil SEAL INSTALLATION (L99/lT1/lT4)
15. WATER PUMP DRIVESHAFT ASSEMBLY INSTALLATION (l99/LT1/LT4)
3800 ENGINE ON-VEHICLE SERVICE L36 (VIN K)
6A8A-1
SECTION 6A8A
3800 ENGINE ON .. VEHICLE SERVICE

L36 {VIN K)
CAUTION: This vehicle is equipped with Supplemental. Inflatable Restraint (SIR). Refer to
systems.
CONTENTS
General Description ................... Refer to Section 6A8B
On-Vehicle Service ........................................... 6A8A-2
Fuel System Pressure Relief........................ 6A8A-2
Serpentine Drive Belt and Tensioner .......... 6A8A-2
Engine Mounts and Brackets ....................... 6A8A-4
Oil Level Indicator and Tube ...................... 6A8A-6
Upper Intake Manifold ................................ 6A8A-6
Valve Rocker Arm Covers ........................... 6A8A-8
Valve Rocker Arms and Pushrods .............. 6A8A-9
Lower Intake Manifold ................................ 6A8A-10
Valve Lifters ................................................. 6A8A-l 1
EGR Valve Outlet Pipe ................................ 6A8A-12
EGR Valve Adapter ...................................... 6A8A-12
Exhaust Manifolds ........................................ 6A8A-12
Crankshaft Balancer ...................................... 6A8A-16
Crankshaft Front Oil Seal.. .......................... 6A8A-17
Engine Front Cover ...................................... 6A8A-17
Timing Chain, Crankshaft and Camshaft
Sprockets ...................................................... 6A8A-19
Balance Shaft ............................................... 6A8A-20
Camshaft ....................................................... 6A8A-22
Valve Springs and Stem Seals .................... 6A8A-23

Cylinder Head and Gasket .......................... 6A8A-24
Oil Filter Adapter and Pressure Relief
Valve ............................................................. 6A8A-26
Oil Pan ......................................................... 6A8A-26
Oil Pump Screen .......................................... 6A8A-27
Oil Pump Gear Set. ..................................... 6A8A-28
Connecting Rod Bearings ............................ 6A8A-28
Pistons and Connecting Rods ...................... 6A8A-30
Crankshaft Bearings ..................................... 6A8A-30
Flywheel ....................................................... 6A8A-32
Crankshaft Rear Oil Seal... .......................... 6A8A-33
Crankshaft Rear Oil Seal Housing and
Gasket. .......................................................... 6A8A-33
Engine ........................................................... 6A8A-34
Thread Repair ................................................. 6A8A-36
Specifications .................................. ;................. 6A8A-37
Fastener Tightening Specifications .............. 6A8A-37
Engine Specificatons .................................... 6A8A-38
Special Tools ................................................ 6A8A-40
6A8A2
ON-VEHICLE SERVICE
1. Disconnect battery negative cable terminal to
FUEL SYSTEM PRESSURE RELIEF
2.
CAUTION:
To reduce the risk of fire and
personal injury, it is necessary to
relieve the fuel system pressure
before servicing fuel system
components.
After relieving system pressure, a
small amount of fuel may .be released
when servicing fuel lines or
connections. In order to reduce the
chance of personal injury, cover fuel
pipe fittings with a shop towel before
disconnecting, to catch any fuel that
may leak out. Place the towel in and
approved container when disconnect
is completed.
3.
4.
5.
avoid possible fuel discharge if and additiotal

attempt is made to start the engine.
Loosen fuel filler cap to relieve tank vapor
pressure.
Connect J 34730-lA to fuel pressure connection.
Wrap a shop towel around fitting while
connecting J 34730-lA to avoid spilling.
Install bleed hose into an approved container and
connections are now safe from servicing.
Drain any fuel remaining in J 34730:'lA into an
approved container.
SERPENTINE DRIVE BELT AND

TENSIONER
Figures 1 and 2
[I]
Important
Routine inspection of the belt may reveal cracks

in the belt ribs. These cracks will not impair belt
performance and therefore should not be
Tool Required:
J 34730-lA Fuel Pressure Gage
8
A INDICATOR MARK
B MINIMUM TOLERANCE BELT READING
c MAXIMUM TOLERANCE BELT READING
1 PULLEY, GENERATOR
2 PULLEY, DRIVE BELT IDLER
3 PULLEY, AIR CONDITINING COMPRESSOR
4 TENSIONER, DRIVE BELT
5 PULLEY, CRANKSHAFT
6 PULLEY, POWER STEERING PUMP
7 PULLEY, WATER PUMP
8 BELT, SERPENTINE DRIVE
2
5
WITHOUT AIR CONDITIONING

7
c
WITH AIR CONDITIONING
Figure 1 Serpentine Drive Belt
06080
FT001WA
3800 ENGINE ON-VEHICLE. SERVICE L36 (VIN K)
4 TENSIONER, DRIVE BELT

10 BOLT /SCREW, DRIVE BELT TENSIONER
59 COVER, ENGINE FRONT
6A8A-3
11-11-94
59
FS0028A8A
Figure 2 Drive Belt Tensioner
considered a problem requiring belt replacement.

However, the belt should be replaced if belt slip
occurs or if sections of the belt ribs are missing.
A single serpentine drive belt is used to drive all
engine accessories. All belt driven accessories are
rigidly mounted with belt tension maintained by a
spring loaded tensioner. The indicator on the movable
portion of the tensioner must be within the limits of
the marks of the stationary portion of the tensioner.
Any reading outside of these limits indicates either a
defective belt or tensioner.
l++I
Install or Connect
1. Drive belt (8) over tensioner pulley by pushing

downward (clockwise) on drive belt tensioner (4).
[II
Important
Be sure drive belt (8) is aligned into proper

grooves of accessory drive pulleys.
DRIVE BELT
DRIVE BELT TENSIONER
IL"'!
l++!
Inspect
Belt length scale on drive belt tensioner for proper

installed length. If belt length scale does not
indicate proper installed length, install a new drive
belt.
l++I


2. Push drive belt tensioner (4) downward
(clockwise) off drive belt using a socket and
handle on tensioner pulley bolt/screw.
3. Drive belt (8).
L Drain engine coolant. Refer to SECTION 6B.

2. Drive belt (8). Refer to "Drive Belt" in the
procedure above.
3. Oil filler neck from rocker arm cover.
4. Transmission oil dipstick from filler tube.
5. Manifold Absolute Pressure (MAP) sensor from
generator bracket.
7. Heater hoses from drive belt tensioner. Refer to
SECTION lB.
6A8A~4
l++I
Install or Connect
NOTICE:
6A8A-l.

!~!
3.
4.
5.
6.
7.
8.
9.
Tighten

Heater hoses to drive belt tensioner. Refer to
SECTION lB.
Generator. Refer to SECTION 603.
Manifold Absolute Pressure (MAP) sensor to
generator bracket.
Transmission oil dipstick to filler tube.
Oil filler neck to rocker arm cover.
Drive belt (8). Refer to "Drive Belt" in the
procedure above.
Refill engine coolant. Refer to SECTION 6B.
ENGINE MOUNTS AND BRACKETS

Figure 3
Tools Required
J 28467-A Universal Support Fixture
J 41044 Engine Support Adapters
NOTICE: When raising or supporting the

engine for any reason, DO NOT use a jack
under the oil pan, crankshaft balancer, or any
sheet metal. Due to small clearances between
the oil pan and the oil pump screen, jacking
against the oil pan may cause it to be bent
against the pump screen, resulting in a damaged
oil pifl,cup unit. Jacking against the crankshaft
balancer may also cause oil seal and/or
crankshaft bearing damage. Always use
J 28467-A (Universal Support Fixture) along
with J 41044 (Engine Support Adapters) when
raising or supporting the engine.
I@!
Measure
Engine movement al engine mounts to check for

damage to the rubber portions of the mount.
A. Apply parking brake.
B. Start engine,
C. Firmly apply primary .brakes.
D. Slightly load engine in "Reverse" and
"Drive" while assistant observes engine
movement. If engine moves more than 24 mm
(0.945 inch) from the "at rest" position in
either direction, check engine mount
attachment. If engine mount attachment is
within specifications, replace engine mount.
!++I
2. Ignition control module. Refer to SECTION 6D4.

SECTION OA.
4. Exhaust catalytic converter pipe. Refer to
SECTION 6F.
5. Engine mount nuts (17).
6. Transmission oil cooler lines from engine mount
brac~et, if necessary. Refer to SECTION 7A.
7. A/C compressor, if necessary. Refer to
SECTION lB.
Compressor can be positioned forward to

.allow removal of engine mount
through-bolt/screw (16) without refrigerant
recovery.
8. Install J 28467 and J 41044.
Support engine to allow removal of
through-bolts/screws (16).
9. Raise engine.
10, Engine mount bolts/screws (18) and mounts (19
or 20) from engine cradle, if necessary.
11. Engine bracket bolts/screws (13 and 14), studs
(11) and brackets (12), if necessary.
IL!
Inspect
Engine mounts for damage to rubber portions of

mount.
- Rubber surfaces covered with heat check
cracks.
_:_ Rubber cushions separated from plate of
niount.
- Rubber cushion split through center.
I++! Install or Connect

NOTICE:
6A8A-L
1. Engine brackets (12) and engine bracket

bolts/screws (13 and 14) and studs (11), if
necessary.
I~!
Tighten

Studs (11) to 100 N,m (74 lb. ft.).
2. Engine mounts (19 and 20) and engine mount
. bolts/screws (18), if necessary.
I~!
Tighten
Engine mount bolts/screws (18) to 58 N.m

(43 lb. ft.).
3. Lower engine.
4. Engine mount through-bolts (16).
5. Engine mount nuts (17).
6A8A-5
13
12
14
B
18
16
A
B
11
12
13
14
15
16
17
18
19
20
LEFT SIDE
RIGHT SIDE
STUD, ENGINE MOUNT
BOLT /SCREW, ENGINE/TRANSMISSION BRACE MOUNT BRACKET
BRACE, TRANSMISSION
BOLT/SCREW, ENGINE MOUNT THROUGH
NUT, ENGINE MOUNT
BOLT/SCREW, ENGINE MOUNT
MOUNT, LEFT SIDE ENGINE
MOUNT, RIGHT SIDE ENGINE
Figure 3 Engine Mounts and Brackets
0508H
FT0031A8A
6A8A-6
l~I
3800 ENGINE. ON-VEHICLE SERVICE L36 (VIN K)
I~!
Tighten
Engine mount through-bolt/screw nuts to

80 N~m (59 lb. ft.). OR
Engine mount through-bolts/screws to 95 N.m
(70 lb. ft.).
6. A/C compressor, if necessary. Refer to
SECTION lB.
7. Transmission oil cooler lines to engine mount
bracket, if necessary. Refer to SECTION 7A.
SECTION 6F.
9. Lower vehicle.
11. Ignition control module. Refer to SECTION 604.
OIL LEVEL INDICATOR AND TUBE
l++I
1. Oil level indicator tube bolt/screw.

. 2. Oil level indicator and tube from engine.
l++I
Install or Connect
L Oil)evel indicator tube to engine.

Replace 0-ring seal, if necessary.
2. Oil level indicator tube bolt/screw.
21
22
23
Tighten
Bolt/screw mounting indicator tube to EGR

valve adapter to 10 N,m (89 lb. in.).
3. Level indicator.
UPPER INTAKE MANIFOLD

Figures 4 and 5
!++!

2. Drain engine coolant. Refer to SECTION 6B.
4. Transmission level indicator, if necessary. RefeI to
SECTION 7A.
6. Serpentine drive belt tensioner. Refer to
section.
7. Manifold absol.ute pressure sensor (MAP) and
vacuum source from upper intake manifold.
8. Evaporative emissions canister purge solenoid
valve
NUT, FUEL RAIL MOUNTING

RAIL, FUEL
INJECTOR, FUEL
102194
FS0048AIA
Figure 4 - Fuel Rail
6A8A-7
9. Fuel pressure regulator and canister purge harness.

10. Idle air control (IAC) valve from upper intake
manifold.
11. Relieve fuel pressure. Refer to "Fuel System
Pressure Relief" in this section.
12. Fuel lines from fuel rail (22).
13. Accelerator control cable bracket bolts/screws,
bracket and accelerator control cables from
throttle body.
14. Ignition control module. Refer to SECTION 6D4.
15. Brake booster hose from upper intake manifold
(25).
16. Generator brace from upper intake manifold (25).
17. Electrical connectors from the following:
27
18.
19.
20.
21.
22.
Idle air control

Throttle position sensor
Mass airflow sensor
Intake air temperature sensor
Wiring harness from rosebud clips at fuel rail
(22).
Air cleaner, air cleaner outlet rear duct, and
resonator duct.
Throttle body from upper intake manifold (25), if
necessary.
EGR valve outlet pipe. Refer to "EGR Valve
Outlet Pipe" in this section.
Thermostat and thermostat housing. Refer to
SECTION 6B.
[I]
Important
The thermostat housing must be removed in

order to access the "hidden" bolt/screw
located under the housing. The "hidden"
bolt/screw secures the upper and lower intake
manifolds together.
23. Electrical connectors from fuel injectors (23).
[I]
A TWO HIDDEN INTAKE MANIFOLD BOLT/SCREWS

8 APPLY GM P/N 9985675 TO BOTH
ENDS OF SEAL
C SEAL, LOWER INTAKE MANIFOLD AND GASKET
24 BOLT/SCREW, UPPER INTAKE MANIFOLD
25 MANIFOLD, UPPER INTAKE
26 GASKET, UPPER INTAKE MAINFOLD
27 MANIFOLD. LOWER INTAKE
33 SOLT/SCREW, LOWER INTAKE MANIFOLD
35 GASKET, LOWER INTAKE MANIFOLD GASKET
36 SEAL. INTAKE MANIFOLD
O NUMBER IN BOX IDENTIFY
0508915
24.
25.
26.
27.
Important
Clean dirt out of injector bores with

compressed air.
Fuel rail nuts (21).
Fuel rail (22).
Upper intake manifold bolts/screws (24).
Upper intake manifold (25) and gasket (26).
Clean
Upper intake manifold bolts/screws.

Upper intake manifold gasket surfaces.
!++I
Install or Connect
NOTICE:
6A8A-1.
Figure 5 Intake Manifolds and Gaskets
1. Upper intake manifold gasket (26) and manifold

(25).
6A8A8
2. Upper intake manifold bolts/screws (24).
!~I
Tighten
A. Ten vertical intake manifold bolts/screws

(1-10) to 15 N.m (11 lb. ft.) using sequence
shown in Figure 5.
B. Two coolant outlet bolts/screws (11) to 27 N.m
(20 lb. ft.).
C. Side bolt/screw (12) to 30 N.m (22 lb. ft.).
D. Side bolt/screw (13) to 30 N.m (22 lb. ft.).
3. Fuel rail (22).
A. Lightly lubricate fuel injector 0-rings using
clean engine oil.
B. Install injectors (23) of rail (22) into bores of
manifold.
C. Carefully press fuel rail (22) with palms of
both hands until injectors (23) are fully seated.
4. Fuel rail nuts (21).
l~I
Tighten
Fuel rail nuts (21) to 10 N.m (89 lb. in.).

5. Electrical connectors to fuel injectors (23).
6. Thermostat and thermostat housing. Refer to
SECTION 6B.
7. EGR valve outlet pipe. Refer to "EGR Valve
8. Throttle body to upper intake manifold (25), if
necessary.
9. Air cleaner, air cleaner outlet duct, and resonator
duct.
10. Wiring harness to rosebud clips at fuel rail.
11. Electrical connectors to the following:
Idle air control
Throttle position sensor
Mass airflow sensor
Intake air temperature sensor
12. Generator brace to upper intake manifold (25).
13. Brake booster hose to upper intake manifold (25).
14. Ignition control module. Refer to SECTION 604.
15. Accelerator cable bracket, bolts/screws, and
accelerator control cables to throttle body.
l~i
16.
17.
18.
19.
20.
21.
22.
23. Serpentine drive belt tensioner. Refer to

section.
25. Transmission level indicator, if necessary. Refer to
SECTION 7A.
27. Refill engine coolant. Refer to SECTION 6B.

Figure 6
RIGHT SIDE
l++i

2. Generator. Refer to S.ECTION 603.
3. Oil fill tube and cap.
4. Transmission level indicator tube mounting nut
and reposition tube, if necessary.
5. Spark plug wiring harness from clip and
reposition.
6. Evaporative emissions canister purge solenoid
valve.
7. Loosen right rear engine lift bracket.
28
Tighten
Accelerator cable bracket bolts/screws to 10

N.m (89 lb. in.).
Fuel lines to fuel rail (22).
Idle air control (IAC) valve to upper intake
manifold (25).
Fuel pressure regulator and canister purge harness.
Evaporative emissions canister purge solenoid
valve.
Manifold absolute pressure sensor (MAP) and
vacuum source to upper intake manifold (25).
Serpentine drive belt tensioner. Refer to
section.
Manifold absolute pressure (MAP) and vacuum
source to upper intake manifold.
9 BOLT/SCREW, VALVE ROCKER COVER

28 COVER, VALVE ROCKER
Figure 6 Valve Rocker Arm Cover
1M5M
FSOOGeMA

9. Valve rocker arm cover (28) and gasket.
Ill
Install or Connect
NOTICE:
6A8A-1.
Refer to "Notice'' on page
1. Valve rocker arm cover gasket, rocker arm cover

(28) and bolts/screws (9).
Apply thread lock compound or equivalent to

bolt/screw threads.
l~J
Tighten

10 N,m (89 lb. in.).
2. Right rear engine lift bracket.
I~!
!~!
NOTICE:
6A8A-1.
Tighten

bolt/screw threads.
I~!
VALVE ROCKER ARMS AND PUSHRODS

Figure 7
Tool Required:
!++!

2. Valve rocker arm bolts/screws (30).
3. Valve rocker arms (31), retainer (32), and
pushrods (29).
[I]
Important
Place valve rocker arms (31) and pushrods

(29) in a rack so they can be reinstalled in
same the locations from which they were
removed.
rocker arms and pushrods.
l++I
Install or Connect
1. Ignition coil module and bracket. Refer to

SECTION 6D4.
2. EGR valve and adapter. Refer to "EGR Valve
Adapter" in this section.
3. Left front engine lift bracket.
5. Rocker arm cover (28) and gasket.
Tighten

10 N.m (89 lb. in.).
2. Left front engine lift bracket.
3. EGR valve and adapter. Refer to "EGR Valve
Adapter" in this section.
4. Ignition coil module and bracket. Refer to
SECTION 6D4.
Transmission fluid fill tube nut to 50 N.m

(37 lb. ft.).
6. Oil fill tube. and cap.
LEFT SIDE
1. Valve rocker arm cover gasket, rocker arm cover

(28), and bolts/screws (9).
Tighten
Engine lift bracket studs to 50 N .m

(37 lb. in.).
3. Evaporative emission canister purge solenoid
valve.
4. Spark plug wiring harness to clip.
5. Transmission level indicator tube and mounting
nut, if necessary.
!++!
Install or Connect
Clean
Rocker cover and cylinder head gasket surfaces.

Bolts/screws (9) of any debris.
!++!
!++!
6A8A9
Clean
Rocker cover and cylinder head gasket surfaces.

Bolts/Screws (9) of any debris.
NOTICE:
6A8A-l.
[I]
Important

pushrods (29), coat bearing surfaces with
prelube, GM PIN 12345501 or equivalent.
Install these components in the locations from
which they were removed.
1. Pushrods. Make sure pushrods (29) seat in lifter
sockets.
2. Valve rocker arms (31) and retainer (32).
6A8A-10
3800 .ENGINE ON-VEHICLE SERVICE L36 (VIN K)
(
29
31
29 PUSHROD, VALVE
30 BOLT/SCREW, VALVE ROCKER ARM
31 ARM, VALVE ROCKER
32 RETAINER, VAL VE ROCKER ARM
102114
FS0078A8A
Figure 7 Valve Rocker Arm and Pushrod
3. Valve rocker arm bolts/screws (30).
11]

bolt threads before installing.
NOTICE: This bolt is designed to permanently

stretch when tightened. The correct part number
fastener must be used to replace this type of
.fastener. Do not use a bolt that .is stronger in
this application. If the correct bolt is not used,
the parts will not be tightened correctly. Part or
system damage may occur.
I~!
Tighten
Valve rocker arm bolts/screws to 15 N,m

(11 lb. ft.) + 90 using J 36660.
ILI
Inspect
For valve train noise.
2.
3.
4.
5.
!++!
Important
There are two bolts/screws which are hidden

beneath the upper intake manifold. These
bolts/screws are located in the front and left
rear comers of the lower intake manifold. It is
necessary to remove the upper intake manifold
to service the lower intake manifold.
Valve rocker arm covers. Refer to "Valve Rocker
Engine coolant temperature (ECT) sensor. Refer to
SECTION 6E3.
.
.
Lower intake manifold bolts/screws (33).
Lower intake manifold (27), gaskets (35), and
seals (36).
Install or Connect
NOTICE:
6A8A-l.
.LOWER INTAKE. MANIFOLD
1. Intake manifold gaskets (35) and seals (36).
Figure .5
Apply GM PIN 12345336 or equivalent to

both front and rear intake manifold seals.
2. Lower intake manifold (27).
3. Lower intake manifold bolts/screws (33).
l++I
1. Upper intake manifold. Refer to "Upper Intake

Manifold" in this section.
[I]
Important
Two lower intake manifold bolts/screws (33)

are located under the upper intake manifold
(right front and left rear comers) and must be
installed prior to the upper intake manifold
installation.
Apply GM PIN 12345493 or equivalent thread
lock compound to bolt threads before
installing.
l~I
Tighten
Manifold bolts/screws (33) to 15 N.m

(11 lb. ft.) using sequence shown in Figure 5.
4. Engine coolant temperature (ECT) sensor. Refei: to
.
SECTION 6E3.
VALVE LIFTERS
Figures 8 and 9
No service parts are available for valve lifters.
They are replaced as a unit when worn and when a
new camshaft is installed. Valve lifters should be kept
in order so they may be installed in their original
position. If the lifters are removed, they must be
installed in their. original location. If replacement is
6A8A-11
necessary, use lifters with a narrow flat ground along

the lower 3/4 of lifters. These flats provide additional
oil to the cam lobe and lifter surfaces.
(++I

3. Lower intake manifold. Refer to "Lower Intake
4. Valve lifter guide bolts/screws (37) and guide
~~-
5. Valve lifters (39).
[I]
Important
Refer to SECTION 6A8B for cleaning and

inspection of valve lifters.
!++I
Install or Connect
1. Coat lifters with prelube, GM PIN 12345501 or

equivalent.
2. Valve lifters (39).
3. Valve lifter guide (38) and bolts/screws (37).
l~I
Tighten
Valve lifter guide bolts/screws (37) to 30 N,m

(22 lb. ft.).
29
A
B
C
D
E
F
29
39
37 BOLT /SCREW, VAL VE LIFTER GUIDE

38 GUIDE, VAL VE LIFTER
39 LIFTER, VAL VE
PLUNGER
LIFTER BODY
CHECK BALL SPRING
PLUNGER RETURN SPRING
CHECK BALL (CLOSED)
CHECK BALL (OPEN)
PUSHROD ASSEMBLY VALVE
LIFTER ASSEMBLY, VALVE
102414
FS010GA2A
102414
FSOOHA8A
Figure 8 - Valve Lifter Guide
Figure 9 Valve Lifter Operation
6A8A-12
3800 ENGINE ON-VEHICLE SERVICE l36 (VIN K)

EGR VALVE OUTLET PIPE

Figure 10
!++l
1. Bolt/ screw (116).

2. Nut (118).
3. EGR valve outlet pipe (117).
!++!
Install or Connect
!~!
Tighten
Nuts (120) to 50 N.m (37 lb. ft.).

4. EGR valve gasket and valve. Refer to
SECTION 6E3.
Outlet Pipe'' in this section.
!L!
Inspect
EGR valve adapter tube for leaks.

-
If exhaust leaks are present, replace EGR

valve adapter.
EXHAUST MANIFOLDS
Figures 11 and 12
LEFT SIDE
NOTICE:
6A8A-l.
1. EGR valve outlet pipe(ll 7).
2. Nut (118).
!~!
Tighten

I~!
Tighten
EGR VALVE ADAPTER

Figure 10
I++!

2. EGR valve and gasket. Refer to SECTION 6E3.
3. Nuts (120).
5. EGR valve adapter (119).
l++I
Install or Connect
NOTICE:
6A8A-l.
1. EGR valve adapter (119).
1~1
Tighten
Bolt/Screw to 25 N.m (18 lb. ft.).

3. Nuts (120).
!++!

2. EGR valve adapter from exhaust manifold (46).
3. Nuts (44).
4. Exhaust manifold heat shields (42, 43 and 45).
SECTION OA.
SECTION 6F.
8. Spark plug wires from spark plugs.
9. Lower vehicle.
11. Studs (53).
12. Exhaust manifold (46) and gasket (51).
Clean
Exhaust manifold and cylinder head gasket

surfaces.
I++!
Install or Connect
NOTICE:
6A8A-1.
manifold (46).
2. Studs (53).
!~! Tighten
Studs (53) to 12 N.m (106 lb. in.).
3. Bolt/screw (52).
6A8A-13
25
120
122
25
46
116
117
118
119
120
121
122
123
MANIFOLD, UPPER INTAKE

BOLT/SCREW, EGR VALVE OUTLET PIPE
PIPE, EGR VAL VE OUTLET
NUT, EGR VALVE OUTLET PIPE
ADAPTER, EGR VAL VE
NUT, EGR VAL VE ADAPTER
STUD, EGR VALVE ADAPTER
BOLT/SCREW, EGR VALVE ADAPTER
BRACKET, ENGINE LIFT
Figure 10 - Valve Adapter and Outlet Pipe
05-08-96
FT02HA8A
6A8A-14
46
50
42
43
44
45
46
47
48
49
50
SHIELD, LEFT HAND OUTER UPPER

SHIELD, LEFT HAND UPPER
NUT, SHIELD
SHIELD, LEFT HAND OUTER LOWER
SHIELD, RIGHT HAND UPPER
SHIELD, RIGHT HAND OUTER UPPER
SHIELD, RIGHT HAND OUTER LOWER
01-27-95
FS0118A8A
Figure 11 - Exhaust Manifold Heat Shield
3800 ENGINE ON-VEHICLE SERVICE L36 (VIN K.)
6A8A15
51
52
-~
53
)
51
A
. 46
50
51
52
53
CYLINDER HEAD
53
10-24-14
F80128A8A
6A8A-16
!~!
Tighten

SECTION OA.
SECTION 6F.
7. Spark plug wires to spark plugs.
8. Lower vehicle.
9. Exhaust manifold heat shields (42, 43 and 45).
10. Nuts (44).
!~I
EGR valve adapter bolt/screw to 25 N,m

(18 lb. ft.).
IL'I'!
Inspect
EGR valve adapter tube for leaks.
If exhaust leaks are present, replace EGR

valve adapter.
RIGHT SIDE
I++!
5.
6.
7.
8.
9.
10.

Nuts (44).
Exhaust manifold heat shields (47, 48 and 49).
SECTION OA.
Exhaust catalytic converter pipe. Refer to
SECTION 6F.
Oxygen sensor electrical connector.
Spark plug wires from spark plugs.
Lower vehicle.
Studs and bolts/screws (53).
Exhaust manifold (50) and gasket (51).
Clean
Exhaust manifold and cylinder head gasket

surfaces.
L Exhaust
manifold gasket (51) and exhaust

manifold (50).
2. Studs and bolts/screws (53).
l~l
4.
5.
6.
7.
8.
9.
Tighten
Studs and bolts/screws (53) to 12 N.m

(106 lb. in.).
SECTION OA.
Spark plug wires to spark plugs.
Oxygen sensor electrical connector.
Exhaust catalytic converter pipe. Refer to
SECTION 6F.
Lower vehicle.
Exhaust manifold heat shields (47, 48 and 49).
Nuts (44).
!~l
Tighten
Nuts (44) to 9 N,m (80 lb. in.).

CRANKSHAFT BALANCER
Figure 13
Tools Required:
J 38197 Crankshaft Balancer Puller
J 37096 Flywheel Holding Tool

1.
2.
3.
4.
NOTICE:
3.
Tighten
Install or Connect
6A8A-1.
Tighten
Nuts (44) to 9 N,m (80 lb. in.).

Indicator and Tube" in this section.
12. EGR valve adapter to exhaust manifold (46).
!~!
l++!
l++l

SECTION OA.
5. Transmission braces. Refer to SECTION 7A.
6. Transmission cover pan. Refer to SECTION 7A.
7. Hold flywheel using J 37096.
8. Crankshaft balancer bolt/screw (54).
9. Crankshaft balancer (56) using J 38197. Use
1/4 inch bolts to attach to pulley and screw in
1/4 inch.
.3800 ENGINE ON-VEHICLE SERVICE L36 (VIN K)
6A8A-17
J 38197
56
54 SOLT/SCREW, CRANKSHAFT BALANCER

56 BALANCER, CRANKSHAFT
57 KEY, CRANKSHAFT BALANCER
110 CRANKSHAFT
57
050891
FT0136AIA
Figure 13 Crankshaft Balancer
[I]
Important
The crankshaft balancer is serviced as an

assembly. Do not attempt to separate pulley
from balancer hub.
!-++I
Install or Connect
NOTICE:
6A8A-1.
1. Crankshaft balancer (56).
2. Crankshaft balancer bolt/screw (54).
l~I
Tighten
Crankshaft balancer bolt/screw to 150 N.m

(111 lb. ft.) + 76 using J 36660.
3. Transmission cover pan. Refer to SECTION 7A.
4. Transmission braces. Refer to SECTION 7A.
6. Lower vehicle
CRANKSHAFT FRONT OIL SEAL

Figure 14
Tool Required:
J 35354 Seal Installer
l++I
1. Crankshaft balancer. Refer to "Crankshaft

Balancer" in this section.
2. Pry out crankshaft front oil seal using screwdriver.
Use care to avoid damage to seal bore or seal
contact surfaces.
!++!
Install or Connect
1. Crankshaft front oil seal using J 35354 and soft

faced hammer.
2. Remove J 35354.
3. Coat outside seal surface of crankshaft balancer
with GM PIN 1052497 or equivalent.
ENGINE FRONT COVER

Figure 14
Tool Required:
!++I
1. Drain engine coolant. Refer to SECTION 6B.

2. Air cleaner, air cleaner outlet rear duct, and
resonator duct. .
3. Radiator inlet hose from front cover (59).
SECTION OA.
6A8A-18
(
c
A
B
C
40
54
58
59
60
61
LOCATOR PINS
STUDS
SOL TS/SCREWS
SEAL, CRANKSHAFT FRONT OIL
SOLT/SCREW, CRANKSHAFT BALANCER
GASKET, FRONT COVER
COVER, FRONT
STUD, FRONT COVER
BOLT/SCREW, FRONT COVER
54
Figure 14 Engine Front Cover

6. Oil pan to front cover bolts/screws.
7. Lower vehicle.
8. Electrical connections.
9. Crankshaft sensor shield.
11. Engine front cover studs (60) and bolts/screws
(61).
It)
Disassemble
If replacing front cover:

A. Oil filter adapter and pressure relief valve.
Refer to "Oil Filter Adapter and Pressure
,
Relief Valve" in this section.
B. Camshaft sensor. Refer to SECTION 6D4.
Ill
Clean
Engine front cover and engine block gasket

surfaces.
ll'l"I
Assemble
If front cover has been replaced:

A. Oil filter adapter and pressure relief valve.
Refer to "Oil Filter Adapter and Pressure
Relief Valve" in this section.
B. Camshaft sensor. Refer to SECTION 6D4.
l..+I
Install or Connect .
NOTICE:
6A8A-1.
1. Crankshaft front oil seal. Refer to "Crankshaft

Front Oil Seal" in this section.
Oil pan bolts/screws can be loosened and oil
pan can be dropped slightly to add clearance
for front cover.
3. Engine front cover studs (60) and bolts/screws
(61).
Apply sealant GM PIN 12346004 or equivalent
to threads of bolts/screws and studs.
Crankshaft sensor requires no adjustment.
l~I
\
6. Electrical connections.
SECTION OA.
8. Oil pan to front cover bolts/screws.
!~!
Tighten
Oil pan to front cover bolts/screws to 14 N.m

(125 lb. in.).
10. Lower vehicle.
11. Radiator inlet hose to front cover (59).
12, Serpentine drive belt and tensioner. Refer to
section.
13. Air cleaner, air cleaner outlet rear duct, and
resonator duct.
14. Refill engine coolant. Refer to SECTION .6B.
TIMING CHAIN, CRANKSHAFT AND

CAMSHAFT SPROCKETS
Figure 15
Inspect
Engine. front cover (59) for damage to the seals or

gasket surface. Refer to "Crankshaft Front Oil
Seal" in this section.
l+!+I
6A8A19
Tighten
Bolts/screws and studs (60 and 61) to 15 N.m

(11 lb. ft.) + 40 using J 36660.
5. Crankshaft sensor shield.
Tool Required:
l++I

2. Align timing marks on sprockets so that they are
as close together as possible. Refer to Figure 15.
3. Timing chain dampener (67).
4. Camshaft sprocket bolt/screw (63).
6. Crankshaft sprocket (66).
rn
Important
If crankshaft sprocket does not come off
easily, a light blow on the edge of the sprocket

(with a plastic mallet) should dislodge the
sprocket.
Ill
Clean
Timing chain.
Sprockets.
ll"'I
Inspect
All components for wear and/or damage.
rn
Important
If the balance shaft timing has been disturbed,
refer to "Balance Shaft" in this section.

If the pistons have been moved in the engine,
do the following:
6A8A20

62
64
67
62
63
64
65
66
67
68
69
CHAIN, TIMING
SPROCKET, CAMSHAFT
GEAR, BALANCE SHAFT DRIVEN
DAMPENER, TIMING CHAIN
BOLT/SCREW, BALANCE SHAFT GEAR
GEAR, BALANCE SHAFT
65
ASSEMBLED VIEW- GEARS

11-1594
FS0158A8A
Figure 15 Timing Chain and Sprockets
A. Turn crankshaft so that the number one

piston is at top dead center.
B. Turn camshaft so that, with sprocket
temporarily installed, timing mark is
straight down.
!++I
Install or Connect
NOTICE:
6A8A-1.
Tighten
Camshaft sprocket bolt/screw (63) to 100 N.m

(74 lb. ft.) + 90 using J 36660.
4. Timing chain dampener (67).
!~!
Tighten
Timing chain dampener (67) bolt/screw to 22

N.m (16 lb. ft.).
rn
BALANCE SHAFT
Figures 14 and 16
Tools Required:
J 8001 Dial Indicator
J 36995 and J 36995-UPD Balance Shaft Rear
Bushing Installer
J 36996 Balance Shaft Installer
J 6125-B Slide Hammer
1. Assembly timing chain (62) on sprockets (64 and

66) with timing marks in their closest together
position. Refer to Figure 15.
2. Timing chain and sprockets.
3. Camshaft sprocket bolt/screw (63).
!~I

Important
Rotate engine two revolutions and check

timing marks. Make sure marks are aligned.
!++!
1. R~cover refrigerant, if necessary. Refer to

"Refrigerant Recovery and Recycling, Adding Oil
Evacuating and Recharging Procedure" in
SECTION lB.
2. Radiator with A/C condenser, if necessary. Refer
to SECTION 6B and SECTION lB.
3. Rear oil seal housing. Refer to "Crankshaft Rear
Oil Seal Housing and Gasket" in this section.
5. Lower intake manifold.. Refer to "Lower Intake
6. Lifter guide retainer bolt and retainer. Refer to
"Valve Lifters" in this section.
6A8A-21
73
68 SOLT /SCREW, BALANCE SHAFT GEAR

69 GEAR, BALANCE SHAFT
70 SOLT /SCREW, BALANCE SHAFT RETAINER
71 RETAINER, BALANCE SHAFT
72 BUSHING, BALANCE SHAFT REAR
73 SHAFT, BALANCE
11-2294
FS0188AIA
Figure 16 - Balance Shaft

8. Balance shaft gear bolt/screw (68).
Refer to "Timing Chain, Camshaft and Crankshaft
Sprockets" in this section.
10. Balance shaft driven gear (65).
11. Balance shaft retainer bolts/screws (70).
12. Balance shaft retainer (71) and gear (69).
13. Balance shaft (73) using J 6125-B.
14. Balance shaft rear bushing (72) using J 36995-5,
J 36995-3A and J 36995-2A.
[I]
Important
Balance shaft, front bearing, and rear bushing

are serviced as a complete package.
Use only the correct tools for bearing, bushing,
and shaft installation.
IL"I
Inspect
Balance shaft gear and camshaft gear for nicks

and burrs.
1-++I
Install or Connect
NOTICE:
6A8A-l.
1. Balance shaft rear bushing (72) using J 36995-2A,

J 36995-3A, J 36995-1 and J 36995-8.
Dip bushing in clean engine oil before
installation.
Install bushing with the lubrication hole facing
the flywheel side.
- J 36995-8 assures that the rear bushing is
installed in the engine block to the correct
depth. The bushing will be installed
properly when J 36995-1 and J 36995-8
fully contacts the balance shaft bore or the
cylinder block transaxle mounting flange.
2. Remove J 36995 assembly.
3. Balance shaft (73) using J 36996 and J 21465-13.
Apply clean engine oil to balance shaft inner
race and front balance shaft bearing before
installation.
4. Temporarily install balance shaft retainer (71) and
bolts/screws (70).
5. Balance shaft gear (69) and balance shaft gear
bolt/screw (68).
Apply thread lock compound GM
PIN 12345493 or equivalent to bolt threads.
l~I
Tighten
Balance shaft gear bolt/screw to 22 N.m

(16 lb. ft.) + 70 using J 36660.
I@!
Measure .
Balance shaft end play.
6A8A-22
Front and rear balance shaft radial play.

- Refer to "Engine Specifications" in this
section.
6. Turn camshaft so, with camshaft sprocket (64)
temporarily installed, timing mark is straight
down.
7. With camshaft sprocket (64) and balance shaft
driven gear (65) removed, turn the balance shaft
(72) so that the timing mark on balance shaft gear
(69) points straight down.
8. Balance shaft driven gear (65).
Align marks on balance shaft gear (69) and
balance shaft driven gear (65) by turning the
balance shaft.
9. Turn crankshaft so the number one piston is at top
dead center.
I@!
Figure 17 - Measuring Camshaft Lobe
Measure
Balance shaft gear lash at four places, every

1/4 turn.
- Lash should be 0.050 to 0.127 mm
(0.002 to 0.005 in.).
11. Balance shaft retainer (71) and retainer
bolts/screws (70).
l~I
12.
13.
14.
15.
16.
17..
18.
Tighten
Balance shaft retainer bolts/screws (70) to

30 N.m (22 lb. ft.).
Engine front cover. Refer to "Engine Front
Lifter guide retainer bolt and retainer. Refer to
"Valve Lifters" in this section.
Lower intake manifold. Refer to "Lower Intake
Upper intake manifold. Refer to "Upper Intake
Rear oil seal housing. Refer to "Crankshaft Rear
Oil Seal Housing and Gasket" in this section.
Radiator with NC condenser, if necessary. Refer
Charge A/C system, if necessary. Refer to
"Refrigerant Recovering and Recycling, Adding
Oil, Evacuating and Recharging Procedures" in
SECTION lB.
CAMSHAFT
Figures 17 and 18
MEASURING CAMSHAFT LOBE LIFT
Tool Required:
J 8520 Cam Lobe Lift Indicator
Measuring lobe lift procedure is similar to
that used for checking valve timing. If improper
valve operation is indicated, measure lift of each
pushrod in consecutive order and record readings.
A BOLTS
74 CAMSHAFT
10-25-94
FS0226A2i'
Figure 18. - Removing and Installing Camshaft
1. Remove valve rocker arm. Refer to "Valve

2. Position J 8520 with ball socket adapter on
pushrod. Make sure pushrod is in lifter socket.
3. Rotate crankshaft slowly in direction of rotation
until lifter is on heel of camshaft lobe. At this
point, pushrod is in its lowest position.
4. Set dial indicator on zero, then rotate crankshaft
slowly until pushrod is in fully raised position.
(Figure 17).

5. Compare total lift recorded from dial indicator
with specifications. Refer to "Engine
Specifications" in this section.
6. If camshaft readings for all lobes are within
specifications, remove dial indicator.
7. Install rocker arms. Refer to "Valve Rocker Arms
and Pushrods" in this section.
!++!
1. Recover refrigerant, if necessary. Refer to

''Refrigerant Recovery and Recycling, Adding Oil
SECTION lB.
2. Radiator with A/C condenser, if necessary. Refer
section.
NOTICE:
All camshaft journals are in the

same diameter so care must be used in
removing the camshaft to avoid damage to the
bearings.
I-++!
Install or Connect
1. Coat camshaft (74) with prelube GM PIN

12345501 or equivalent before installation.
2. Camshaft (74).
3. Camshaft thrust plate and thrust plate
bolts/screws.
!~I
4.
5.
6.
7.
!L"'!
Inspect
Sprocket.
Keyway and threads.
Bearing surfaces and lobes for:
-Wear.
-Galling.
-Gouge.
- Overheating (Discoloration).
[I]
Important
Do not attempt to repair the camshaft, replace

it if damaged.
If a new camshaft is installed, all valve lifters
must be replaced.
Replace camshaft bearings, if necessary. Refer
to SECTION 6A8B.
!@I
Measure
Bearing journals.
- Using a micrometer, measure diameter and
run-out. If out of specification replace the
camshaft.
Tighten
Camshaft thrust plate bolts/screws to 15 N.m

(11 lb. ft.).
Engine front cover. Refer to "Engine Front
Valve lifters. Refer to "Valve Lifters" in this
section.
Radiator with A/C condenser, if necessary. Refer
Charge A/C system, if necessary. Refer to
Oil, . Evacuating and Recharging Procedures" in
SECTION lB.
VALVE SPRINGS AND STEM SEALS

Figure 19
Tools Required:
J 22794 Spark Plug Port Adapter
J 38606 Valve Spring Compressor (Head-on)
J 23738-A Valve Stem Seal Tester
J 41512 Valve Guide Seal Installer
6. Camshaft thrust plate bolts/screws and thrust

plate.
7. Camshaft (74).
A. Install three 5/16-18 x 4-inch bolts/screws in

camshaft bolt/screw holes.
B. Carefully rotate and pull camshaft (74) out of
bearings.
6A8A23
!+-+!

2. Spark plug at cylinder to be serviced.
[I]
Important
Rotate engine so that piston in cylinder being

serviced is at TDC before removing valve
keys. This will eliminate the possibility of the
valve accidentally falling inside cylinder.
3. Install J 22794 to spark plug hole and apply
compressed air to hold valve (75 or 82) in place.
NOTICE: When using the valve spring

compressor, be careful not to scratch or gouge
the valve stem.
4. Compress valve spring (78 or 84) using J 38606.
5. Valve stem key (81 or 88).
6. Valve spring cap (80 or 87) and oil shield (86) on
exhaust valves.
7. Valve spring (78 or 84) and dampener (77 or 83).
8. Intake valve stem oil seal (76).
9. Valve stem 0-ring seal (79 or 85).
6A8A-24
rn
Important
Refer to SECTION 6A8B for valve spring

inspection and repair.
i++i
Install or Connect
NOTICE:
D. Tap end of stem with a plastic - faced hammer

to seat key, if necessary.
7. Spark plug.
1~1
1. Intake valve stem oil seal (76).
iL"'!
Use hand pressure only when

installing valve stem seal using J 41512. Using
too much force may cause damage to the seal
and possibly lead to excessive oil consumption.
5.
6.
A. Place oil seal over valve stem so seal begins to

contact valve guide.
B. Push valve stem oil over valve guide using
J 41512.
Valve stem 0-ring seal (79 or 85).
Valve spring dampener (77 or 83) and spring (78
or 84).
Valve spring oil shield (86) on exhaust valve and
valve cap (80 or 87).
Compress valve spring (78 or 84) using J 38606.
Valve stem key (81 or 88).
A. Use grease to hold key in place while
disconnecting J 38606.
B. Remove J 22794.
C. Make sure key seats properly in upper groove
of valve stem.
81
82
83
84
85
86
87
88
!@I
Place J 23738-A in position over end of

valve stem and against valve spring cap (80
- or 87). Operate J 23738-A and make sure
no air leaks past valve stem 0-ring seals
(79 or 85).
Measure
Valve spring installed height.

-
Use a narrow, thin scale and measure from

bottom of valve spring (78 or 84) on
dampener lip to bottom inside of oil shield
(86) for exhaust valve (82) and to top of
valve spring cap (80) for intake valve (75).
If measurement exceeds specified height,
install valve seat shims as necessary. Do
not shim so height is less than specified.
Refer to "Engine Specifications" in this
section.
81~&
~~88
80~
~87
CYLINDER HEAD AND GASKET
79~
--86
Figure 20
78~
~85
75--J ,77 t--~ 82

J1 ,-- J1
76 '
75
76
77
78
79
80
Inspect
Valve stem 0-ring seal (79 or 85) for leaks.
NOTICE:
4.
Spark plug to 27 N.m (20 lb. ft.).

Refer to ''Notice'' on page
6A8A-1.
2.
3.
Tighten
VALVE, INTAKE
83
DAMPENER, VAL VE SPRING
SPRING, VALVE
SEAL, VALVE STEM 0-RING
CAP, VALVE SPRING
KEY, VALVE STEM
VALVE. EXHAUST
DAMPENER, VAL VE SPRING
SPRING, VAL VE
SEAL, VAL VE STEM 0-RING
SHIELD, VALVE STEM OIL
CAP, VALVE SPRING
KEY, VAL VE STEM
Figure 19 - Valve Assemblies
10-25-94
FS0246A2A
Tool Required:
LEFT CYLINDER HEAD

2. Fuel lines at fuel rail.
6. Spark plugs.
7. Left exhaust manifold. Refer to "Exhaust
Manifolds" in this section
3800 ENGINE ON-VEHICLE SERVICE l36 (VIN K) 6A8A-25

89
.FRT
A
89
90
91
92
TIGHTENING SEQUENCE
SOLT/SCREW, CYLINDER HEAD
HEAD, CYLINDER
LOCATOR PINS
10-24-94
FS0176A8A
Figure 20 - Cylinder Head and Gasket
[I]
Important

3. NEW cylinder head bolts/screws (89).
!~I
Clean
Engine block threads using 7/16-14 tap.
1++-1 Install or Connect

4.
NOTICE:
6A8A-1.
5.
6.
1. New cylinder head gasket (91).
[I]
Important
Arrow on gasket must point to front of engine.

Failure to install gasket properly will cause
gasket failure and possible engine failure.
2. Cylinder head (90).
7.
Tighten
A. Cylinder head bolts/screws to 50 N .m

(37 lb. ft.) in sequence. Refer to Figure 20.
B. Rotate bolts/screws 130 in sequence using
J 36660.
C. Rotate the center four bolts/screws an
additional 30 in sequence using J 36660.
Valve rocker arms and pushrods. Refer to "Valve
Valve rocker arm cover. Refer to "Valve Rocker
Arms Covers" in this section.
Left exhaust manifold. Refer to "Exhaust
Spark plugs.
l~I
Tighten
Spark plugs to 27 N,m (20 lb. ft.).

6A8A26
9>Upper intake manifold. Refer fo "Upper Intake

10. Refill engine coolant. Refer to SECTION 6B.
RIGHT CYLINDER HEAD
!++I
Remove
:r
'oi~~onnect
1. Relieve fuel , press1.1re. Refer to "Fuel System

2. Fuel linesi;t"~fJuel rail.
3. Drain coolant: Refer to SECTION 6B.
,, ,,4. Upper intake manifold. Refer to "Upper Intake
5.Lower intake manifold. Refer to "Lower Intake
6. Spark plugs.
Manifolds" in this section
10. Drive belt tensioner. Refer to "Serpentine Drive
11. Rear generator brace.
12. Cylinder .head bolts/screws (89).
[I]
Important

Clean
Engine block threads using 7/16-14 tap.
l++I
Install or Connect
NOTICE:
6A8A-1.
New cylinder head gasket (91).
[I]
Important
Arrow on gasket must point to front of engine.

Failure to install gasket properly will cause
gasket failure and possible engine failure.
2. Cylinder head (90).
3. NEW cylinder head bolts/screws (89).
l~I
Tighten
A. Cylinder head bolts/screws to 50 N,m (37 lb.
ft.) in sequence. Refer to Figure 20.

B. Rotate bolts/screws 130 in sequence using
J 36660..
C. Rotate the center four bolts/screws an

additional 30 in sequence using J 36660.
4. Rear generator brace.

5. Drive belt tensioner. Refer to "Serpentine Drive
6. Valve rocker anns and pushrods. Refer to "Valve
7. Valve rocker ann cover. Refer to "Valve Roder
Arms Covers" in this section.
9. Spark plugs.
!~l
Tighten
Spark plugs to 27 N,m (20

10. Lower intake manifold. Refer
11. Upper intake manifold. Refer
12. Refill engine coolant. Refer to
lb. ft.).
to "Lower Intclce
to "Upper Intclce
SECTION 6B.
Oil FILTER ADAPTER AND PRESSURE

RELIEF VALVE
I++!

SECTION OA.
3. Oil filter
4. Oil filter adapter bolts/screws.
5. Oil filter adapter and gasket.
6. Oil pressure relief valve and spring.
Clean
Oil filter adapter gasket surfaces
!++!
Install or Connect
1. Oil pressure relief valve and spring.

2. Oil filter adapter gasket and oil filter adapter.
3. Oil filter adapter bolts/screws.
!~!
Tighten
Oil filter adapter bolts/screws to 30 :N,m

(22 lb. ft.).
4. Oil filter.
5. Lower vehicle.
6. Refill engine oil. Refer to Section OB.
Oil PAN
Figure 21
Tools Required
J 28467-A Universal Support Fixture
J 41044 Engine Support Adapters
6A8A-27
Clean
Oil pan gasket surfaces.
!HI
.Install or Connect
NOTICE:
6A8A-l.
1. Oil pan gasket (95) and oil pan (93).
NOTICE: The oil level switch, located in the

oil pan, must be installed after the oil pan has
been installed. If the oil level switch is installed
first, damage to the switch may occur.
2. Oil pan bolts/screws (94).
1~1
Tighten
Oil pan bolts/screws to 14 N.m (125 lb. in.).

Oil level indicator switch.
Oil level indicator switch electrical connector.
Lower engine.
Engine mount through-bolts/screws and nuts.
Refer to "Engine Mounts and Brackets" in this
section.
7. Automatic transmission converter cover, if
.equipped. Refer to SECTION 7A.
SECTION 6F.
9. Lower vehicle.
10. Ignition coil. Refer to SECTION 604.
12. Refill engine oil. Refer to SECTION OB.
3.
4.
5.
6.
59 COVER, FRONT
93 PAN, OIL
94 BOLT/SCREW, OIL PAN
95 GASKET, OIL PAN
10-2594
FS0188A8A
Figure 21 - Oil Pan and Gasket
!++!

SECTION OA.
2. Automatic transmission converter cover, if
3. Engine mount through-bolts/screws and nuts.
Refer to "Engine Mounts and Brackets" in
this section.
4. Raise engine using J 28467 and J 41044.
5. Oil level indicator switch electrical connector.
6. Oil level indicator switch.
'
NOTICE: The oil level switch, located in the

oil pan, must be removed prior to removal of
the pan. If the oil pan is removed. first, damage
to the switch may occur.
7. Oil pan bolts/screws (94).
8. Oil pan (93) and gasket (95).
Lower rear of oil pan while rotating outward.
OIL PUMP SCREEN
!++!

2. Oil pump screen attaching bolts/screws.
3. Oil pump screen.
Clean
Screen and housing with solvent and blow dry.

Gasket mating surfaces on pipe flange and
cylinder block.
l++I
Install or Connect
NOTICE:
6A8A-1.
1. Oil pump screen with new gasket.

2. Oil pump screen attaching bolts/screws.
6A8A28
I~!
Tighten
Oil pump screen bolts/screws to 15 N,m

(11 lb. ft.).
Figure 22
1. Front cover. Refer to "Engine Front Cover" m

this section.
2. Oil filter adapter, pressure valve and spring. Refer
to "Oil Filter Adapter and Pressure Valve" in this
section.
3. Oil pump cover attaching bolts/screws (96) and
cover (97).
4. Oil pump gear set (98).
[I]
Important
Refer to SECTION 6A8B for cleaning and

inspection of gear set, front cover and oil
pressure relief valve.
iHI
OIL PUMP GEAR SET
i++I
3. Pack gear cavity with petroleum jelly after gear

set has been installed.
4. Oil pump cover (97) and bolts/screws (96).
Install or Connect
1. Lubricate gear set with petroleum jelly.

2. Oil pump gear set (98) into front cover (59).
Tool Required:
Connecting rod bearings are a precision insert
type and do not use shims for adjustment. Do not
file connecting rods or rod caps. If clearances are
found to be excessive, a new bearing will be
required. service bearings are available in standard
size and 0.013 and 0.026 mm undersize for use
with new and used standard size crankshafts.
j++!

2. Oil pump screen. Refer to "Oil Pump Screen" in
this section.
[I)
Important ,

to their original connecting rod (102).
106
103
102
96
59
96
97
98
COVER, FRONT
SOLT/SCREW, OIL PUMP COVER
COVER, OIL PUMP
GEAR SET, OIL PUMP
Figure 22 - Oil Pump Gear Set
10-25-94
FS0196A8A
~ T , CONNECTING ROD
1; ;
CONNECTING ROD
' 101 BEARING, CONNECTING ROD
102 ROD, CONNECTING
103 BOLT, CONNECTING ROD
104 PIN, PISTON
105 PISTON
106 RING, PISTON
10-27-94
FS0286A2A
~1p.
Figure 23 - Piston and Connecting Rod
6A8A29
B. Install connecting rod cap (100) with bearing

(101) onto connecting rod (102).
C. Install connecting rod nuts (99).
!~!
Tighten
Connecting rod nuts (99), evenly, to 27 N.m

(20 lb. ft.) + 50 using J 36660.
NOTICE: Do not turn crankshaft with the

gauging plastic installed or the accuracy of the
D. Remove connecting rod nuts . (99) and cap
(100). Gauging plastic will be found adhering
to either connecting rod cap (100) or
crankshaft journal and is measured without
removing it.
E. Measure gauging plastic at its widest, using
scale provided with gauging plastic. Refer
measurements to "Engine Specifications" in
this section.
Figure 24 - Measuring Bearing Clearance
5-13-94
FS0306A2A
rn
If clearance is greater than specified, select an

under size bearing ( 101) and re-measure
clearance.
specifications, regrind crankpin. If crankpin is
already at maximum undersize, replace
crankshaft.
F. Remove all gauging plastic material after
measuring.
!H!
Install or Connect
Important
Keep bearings (101) with their original

connecting rod (102) and cap (100) for
reassembly.
Wipe oil from bearings (101) and crankpins.
!L1'!
Inspect
Bearings (101) for excessive wear or damage.
1,1 Measure
micrometer. Refer to "Engine Specifications" in
this section.
recondition crankshaft.
If installing new bearings (101), determine
new bearing size from the maximum crankpin
diameter.
2. Bearing clearances, using gauging plastic.
A. Place piece of gauging plastic the full width of
bearing (101), (parallel to crankshaft) onto
crankpin.
Gauging plastic should be positioned in
middle of bearing (101). Bearing (101) is
thickest. in center and bearing clearance
must be measured at this location.
NOTICE:
6A8A-l.
1. Coat inside surface of bearings (101) with engine

oil.
!~! Tighten
Connecting rod nuts (99), evenly to 27 N,m
(20 lb. ft.) + 50 using J 36660.
.l~U
Measure

A. When all connecting rod bearings (101)
have .been installed, tap connecting rod
(102) lightly to crankpin to make sure they
have clearance.
B. Measure side clearance between connecting
rod caps (100) using a feeler gage, or dial
indicator.
C. Rod side clearance should be 0.033 to
0.079 mm (0.0013 to 0.0031 in.);
this section.
6A8A-30
PISTONS AND CONNECTING RODS
l~l
Figure 23
Tools Required:
J 41507 Connecting Rod Guide
l++I
A. J 41507 to connecting rod (102).

B. Tum crankshaft until piston is at bottom of its
stroke.
C. Place a cloth on top of piston (105).
D. Use a ridge reamer to remove ring ridge.
E. Tum crankshaft so piston (105) is at top of its
stroke.
F. Remove cloth and cutting debris.
5. Piston (105) and connecting rod (102).
[I)
Important
Refer to SECTION 6A8B for cleaning,

inspection and repair of piston and connecting
rod.
Clean
1. Cylinder bores with hot water and detergent or

with a light honing.
2. Swab bores with engine oil and a clean, dry cloth.
l++I
Connecting rod nuts (99) to 27 N.m (20 lb. ft.)

+ 50 using J 36660.
!L!
Inspect
Connecting rod (102) for binding by prying

back and forth with suitable tool. If necessary,
loosen and re-tighten connecting rod cap (100).

this section.
3. Cylinder head. Refer .to "Cylinder Head and
Gasket" in this section.
4. Ring ridge.
Tighten
!@!
Measure
Connecting rod side clearance. Refer to

"Engine Specifications" in this section.
5. Cylinder head. Refer to "Cylinder Head and
Gasket" in this section.

this section.
CRANKSHAFT BEARINGS
Figures 26 and 27
Tools Required:
J 41348 Main Bearing Cap Puller
J 8080 Main Bearing Shell Remover
and Installer
Crankshaft bearings are of the precision insert
type. If clearances are found to be excessive, a new
bearing, both upper and lower halves, will be
required. Service bearings are available in both
standard size and undersize. Replace both bearing
shells as a set.
!++I
Install or Connect
NOTICE:
6A8A-l.
1. Coat piston (105), piston rings(106) cylinder bore,

and bearing surfaces with engine oil.
2. Piston (105) into its original bore using J 8037
and J 41507 and lightly tapping top of piston
(105) with a wooden hammer handle.
A. When installing piston (105) and connecting
rod (102), stamped arrow on piston (105) must
point to front of engine.
B. Hold J 8037 firmly against engine block until
all piston rings have entered cylinder bore.
3. Connecting rod bearings (101) and caps (100)
onto their original connecting rod (102).
Align match marks or numbers which were
placed on connecting rod (102) and connecting
rod cap (100) during removal.

this section.
3. Spark plugs.
4. Cap (108) using J 41348 and lower crankshaft
bearing (109).
5. Insert J 8080 into oil hole in crankshaft journal.
6. Rotate crankshaft (110) allowing J 8080 to push
against insert's straight (un-notched) side. This
will role upper bearing (109) out of block.
7. Remove J 8080 from crankshaft (110).
!LI
Inspect
In general, lower half of crankshaft bearing insert

(except number 1 bearing) shows a greater wear
and most distress from fatigue. If upon inspection
lower half is suitable for use, it can be assumed
that upper half is also satisfactory. If lower half
shows evidence of wear or damage, both upper
and lower halves should be replaced. Never
replace. one half without replacing other half.
[I]
6A8A31
Important
To obta.in most accurate results when checking

crankshaft bearing clearances, use gauging
plastic.
When engine is in vehicle, crankshaft (110)
must be supported upward to remove any
clearance from upper bearing (109). Total
clearance can then be measured between lower
bearing journal.
To assure proper seating of crankshaft (110),
all bearing cap bolts/screws (107 and 111)
should be at their specified torque. In addition,
prior to checking fit of bearings, surface of
crankshaft journal and bearing (109) should be
wiped clean of oil.
!@!
Measure
1. With oil pan and pump screen removed, and

starting with rear crankshaft bearing, remove
bearing cap (108) using J 41348 and wipe oil
from journal and bearing cap (108).
2: Place a piece of gauging plastic full width of
bearing (parallel to crankshaft) on journal.
[I]
107

Cf.P. CRANKSHAFT BEARING
109 BEARING, CRANKSHAFT
110 CRANKSHAFT
111 BOLT/SCREW, CRANKSHAFT BEARING CAP
1025114
108
FS0206A8A
Figure 26 Crankshaft, Bearings, and Bearing Caps
Important
Do not rotate crankshaft while gauging plastic

is between bearing and journal.
3. Install bearing cap (108) and evenly tighten
retaining bolts/screws (107 and U 1) to
specifications in order to assure proper reading.
Variations in torque affect compression of gauging
plastic.
[I]
Important
Start bearing cap bolts/screws (107 and 111)

by hand.
Tighten all bearing caps in equal increments.
Do not tighten one cap completely at a time.
!~I
Tighten
A. Tighten bearing cap bolts/screws (107) to 70

N,m (52 lb. ft.) to fully seat caps.
B. Loosen bearing cap bolts/screws (107) 360
ccw.
5-13-94
FS0326A2A
Figure 27 Removing Crankshaft Bearing
C. Crankshaft bearing cap bolts/screws (107) to

20 N,m (15 lb. ft.), then to 40 N,m (30 lb. ft.),
then 35 + 35 + 40 for a total of 110 using
J 36660.
D. Crankshaft bearing cap side bolts/screws (111)
to 15 N,m (11 lb.. ft.) + 45 using J 36660.
4. Remove bearing caps (108).
5. Without removing gauging plastic, measure its
compressed width (at lowest point) with
graduations on gauging plastic envelope. Normally
crankshaft bearing journals wear evenly and are
not out-of-round. However, if a bearing is being
fitted to an out-of-round journal 0.005 mm
(0.0002 inch maximum), be sure to fit to
6A8A32
maximum diameter of journal. If bearing is fitted

to minimum diameter, and journal is out-of-round
0.005 mm (0.0002 inch) or more, interference
between bearing and journal will result in rapid
bearing failure. If flattened gauging plastic tapers
toward middle or ends, there is a difference in
clearance indicating taper, low spot or other
irregular of bearing of journal. Be sure to measure
journal with micrometer if flattened gauging
plastic indicates this difference.
6. If bearing clearance is within specifications,
bearing insert is satisfactory. If clearance is not
within specifications, replace insert. Always
replace both upper and lower inserts as a unit.
When bearing cap is installed and clearance is
less than 0.032 mm (0.0012 inch), inspect for
burrs or nicks.
7. An undersize bearing may produce proper
clearance. If not, it will be necessary to regrind
crankshaft journal for use. with .next undersize
bearing. After selecting new bearing, recheck
clearance.
8. Proceed to next bearing. When checking number
1 crankshaft bearing, remove serpentine drive belt
so as to prevent tapered reading .with gauging
plastic. After all bearings have been checked,
rotate crankshaft to see that there is no excessive
drag.
l++I
!~!
Crankshaft bearing cap bolts/screws (107) to

40 N.m (30 lb. ft.) + 35 + 35 + 40 for a
total of 11 o using J 36660.
Crankshaft bearing cap side bolts/screws (111)
to 15 N.m (11 lb. ft.) + 45 using J 36660.
!@!
1. Crankshaft bearings (109) into engine block and

crankshaft bearing caps (108).
A. Coat crankshaft bearings (109) with oil.
B. Insert plain (un-notched) end between
crankshaft (110) and indented or notched side
of block. Rotate bearing (109) into place using
J 8080 as previously described, and remove
J 8080 from oil hole in crankshaft journal.
2. Crankshaft bearing caps (108) with assembled
crankshaft bearing (109) with arrows pointing to
front of engine.
Use sealer GM PIN 1052942 or equivalent at
#4 bearing cap (108) to engine block surface.
Measure
If using a feeler gage, measure between

front of bearing cap (108) and crankshaft
thrust surface.
this section.
6. Spark plugs.
FLYWHEEL
Figure 28
Tool Required:
!++i
1. Transmission. Refer to SECTION 7 A for

automatic transmission, SECTION 7B for manual
transmission and SECTION 7C for the clutch.
2. Flywheel housing bolts/screws (manual
transmission).
3. Flywheel housing (manual transmission).
4. Flywheel bolts/screws (113) and flywheel (112).
Use J 37096 to prevent crankshaft rotation.
NOTICE: The #4 (rear) main bearing cap

must be installed flush with torque converter
bolt/screw heads or 0.25 mm (0.010 inch)
forward of the rear face of cylinder block to
avoid interference with flywheel.
3. Crankshaft bearing cap bolts/screws (107 and
111).
With crankshaft (110), crankshaft bearings
(109) and bearing caps (108) installed and
bolts/screws (107 and 111) started, thrust
crankshaft ( 110) rearward to set and align
bearing caps (108). Then force crankshaft
( 110) forward to align crankshaft thrust
bearing.
Crankshaft end play, using a dial indicator or

feeler gage. Refer to "Engine Specifications"
in this section.
Install or Connect
NOTICE:
6A8A-1.
Tighten
11 0 CRANKSHAFT
110
112 FLYWHEEL
113 BOLT /SCREW. FLYWHEEL
Figure 28 - Flywheel
!++!
Install or Connect
NOTICE:
6A8A-1.
1. Flywheel (112) and flywheel bolts/screws (113).

Use J 37096 to prevent crankshaft rotation.
!~!
Tighten
Flywheel bolts/screws to 15 N.m (11 lb. ft.) +

50 using J 36660.
2. Flywheel housing (manual transmission).
3. Flywheel housing bolts/screws (manual
transmission).
!~!
Tighten
Flywheel housing bolts/screws to 95 N.m

(70 lb. ft.).
4. Transmission. Refer to SECTION 7A for
automatic transmission, SECTION 7B for manual
transmission and SECTION 7C for the clutch.
FLYWHEEL BALANCING
!L"!
Inspect
Flywheel for missing or loose

converter-to-flywheel bolts/screws. Tighten or
Converter for damage or missing balance weights.
If converter is damaged or balance weights are
missing, replace converter. Refer to
SECTION 7A.
If flywheel is replaced, new balance weights of
the same size must be installed on new flywheel
in same hole locations as old flywheel.
Figure 30
Tools Required:
J 38196 Rear Main Oil Seal Installer
!++!
1. Flywheel. Refer to "Flywheel" in this section.

2. Crankshaft rear oil seal.
Insert a screwdriver or similar tool through
dust lip at an angle. Pry seal out by moving
handle of tool towards end of crankshaft.
Repeat as necessary around seal.
[I]
Important
Care should be taken not to nick crankshaft

sealing surface when removing seal.
l~I
Install or Connect

2. Seal onto J 38196.
6A8A-33
3. J 38196 onto rear of crankshaft.

4. Tighten screws snugly to ensure seal will be
installed squarely over crankshaft.
5. Tighten wing nut on J 38196 until it bottoms.
6. Remove J 38196 from crankshaft.

AND GASKET
Figure 29
Tool Required:
J 41349 Crankshaft Rear Oil Seal Housing
Aligning Tool
I++!

3. Crankshaft rear oil seal housing bolts/screws
(115).
4. Crankshaft rear oil seal housing (114) and gasket.
seal housing (114).
Clean
Gasket surfaces.
!++!
Install or Connect
NOTICE:
6A8A-l.
[I]
Important
Always use a new crankshaft rear oil seal and

a new oil seal housing gasket during the
installation of the crankshaft rear oil seal
housing.
1. New crankshaft rear oil seal housing (114) and
gasket.
hold oil seal housing gasket in place. Gasket

can be positioned over oil seal housing
bolts/screws to aid in gasket alignment. 2. Finger tighten crankshaft rear oil seal housing
bolts/screws (115).
3. Install J 41349 over crankshaft.
Coat J 41349 with engine oil and twist or turn
to aid in sliding the tool completely over
crankshaft.
!@I
Measure
A. Place straight edge on oil pan flange and rear

oil seal housing flange.
B. Using a feeler gage, measure the clearance on
both sides.
6A8A34
114
114
115

Figure 29 - Crankshaft Rear Oil Seal Housing Alignment
116
(
110 CRANKSHAFT
114 HOUSING, CRANKSHAFT REAR OIL SEAL
116 SEAL, CRANKSHAFT REAR OIL
110
11-15-94
FS0238ABA
Figure 30 - Crankshaft Rear Oil Seal Installation
C. Rotate the housing (114) until clearance is no

more than 0.004 inch step (high or low) on
each side. If the housing can not be rotated to
get the step within specifications, replace with
a new housing.
4. Tighten all crankshaft rear oil seal housing
bolts/screws (115) to specifications.
l~I
5.
6.
7.
8.
9.
ENGINE
l+-+I

.
Tighten
Crankshaft rear oil seal housing bolts/screws

(115) to 30 N,m (22 lb. ft.).
Remove J 41349.
Recheck step height to make sure it within
specifications. If step height is beyond
specifications, repeat steps 2-4 and measure again.
Crankshaft rear main oil seal. Refer to
"Crankshaft Rear Oil Seal" in this section.
Flywheel. Refer to "Flywheel" in this section.
1. Battery negative cable;

3. Recover refrigerant, if necessary. Refer to
"Refrigerant Recovery and Recycling, Adding Oil
SECTION lB.
5. A/C compressor and condenser hose from

accumulator, if necessary. Refer to SECTION lB.
SECTION OA.

8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30:
31.
32.
33;
34.
35.
36.
37.
38.
39.
40.
41.

Drain engine oil.
3-Way catalytic converter. Refer to SECTION 6F.
Transmission converter bolts/screws (automatic
transmission). Refer to SECTION 7A.
Front fascia lower deflectors. Refer to
SECTION 10-5.
Stabilizer bar bushing bolts/screws. Refer to
SECTION 3C.
Transmission fluid oil cooler lines from radiator
Radiator inlet hose from radiator. Refer to
SECTION 6B.
Shift linkage from transmission. Refer to
SECTION 7 A or SECTION 7B.
Propeller shaft. Refer to SECTION 4A.
Torque arm from transmission. Refer to
SECTION 3D.
Power steering gear. inlet and outlet hoses from
power steering gear. Refer to SECTION 38.
Steering gear coupling shaft from rack and pinion.
Electrical ground strap from engine block.
Starter motor. Refer to SECTION 602.
A/C compressor and condenser hose from
compressor and condenser, if necessary. Refer to
SECTION lB.
Battery negative cable from rear compressor
bracket mounting stud. Refer to SECTION 601.
Engine coolant heater cord from block, if
equipped.
Lower vehicle.
A/C compressor and condenser hose from vehicle,
if necessary.
Serpentine drive belt. Refer to "Serpentine Drive
Heater hoses from serpentine drive belt tensioner.
Air cleaner outlet rear duct and. resonator duct.
Fuel lines at fuel rail. Refer to SECTION 6E3.
Cruise and accelerator control cables from throttle
body. Refer to SECTION 6E3.
Radiator outlet hose from thermostat housing.
Brake lines from antilockbrake system (ABS)
brake combination valve. Refer to SECTION 5.
Brake lines and clips from ABS hydraulic
modulator. Refer to SECTION 5E 1 or
SECTION 5E2.
Right-hand body hinge pillar trim panel. Refer to
SECTION 10-5.
Three engine wiring harness connectors (blue,
black and white connectors).
Forward lamp wiring harness connectors.
Powertrain control module (PCM) and harness.
Place PCM and harness on top of engine.
Engine wiring harness through front of dash.
Place harness on top of engine.
SASA-35

43. Lower shock attachment bolts/screws and nuts
from lower control arm. Refer to SECTION 3C.
44. Upper control arm ball stud from steering
45. Secure struts to outboard using upper control arm.
46. Electrical connectors to wheel speed sensors at
engine frame.
47. Position lift table under engine and frame. Use
Kent-Moore tool number J 39580 or equivalent.
48. Engine frame and transmission support
49. Raise vehicle from engine, transmission and
engine frame.
50. Transmission. Refer to SECTION 7 A or
SECTION 7B.
53. Engine from engine frame.
!++!
Install or Connect
NOTICE:
6A8A-1.
1. Engine .to engine frame.

2. Engine mount through-bolts/screws
!~!
Tighten
Engine mount through-bolts/screws to 95 N.m

(70 lb. ft.). OR
Engine mount through-bolt/screw nuts to
80 N.m (59 lb. ft.).
4. Transmission. Refer to SECTION 7 A or
SECTION 7B.
5. Position engine lift table and install engine,
transmission and engine frame by lowering
vehicle to crossmember.
6. Engine frame and transmission support
7. Engine lift table.
8. Electrical connectors to wheel speed sensors.
9. Upper control arm ball stud from steering
10. Lower shock attachment bolts/screws and nuts to
lower control arm. Refer to SECTION 3C.
12. Engine wiring harness through front of dash.
[I]
Important
When reinstalling engine wiring harness back

through front of dash, the rubber grommet
MUST BE INSTALLED PROPERLY to
ensure correct sealing. If grommet is tom or
damaged for any reason, it must be replaced.
6A8A36
13. Powertrain control module (PCM) and harness.

14. Forward lamp wiring harness connectors.
15. Three engine wiring harness connectors (blue,
black and white connectors).

16. Right-hand body hinge trim panel. Refer to
SECTION 10-5.
17. Brake lines and clips to ABS hydraulic modulator.
Refer to SECTION 5El or SECTION 5E2.
18. Brake lines to antilock brake system (ABS) brake
combination valve. Refer to SECTION 5.
20. Radiator outlet hose to thermostat housing. Refer
to SECTION 6B.
21. Cruise and accelerator control cables to throttle
body. Refer to SECTION 6E3.
22. Fuel lines to fuel rail.
23. Air cleaner outlet rear duct and resonator duct.
24. Heater hoses to serpentine belt tensioner. Refer to
SECTION lB.
26. A/C compressor and condenser hose to
accumulator, if necessary. Refer to SECTION lB.
SECTION OA.
28. Engine coolant heater cord to block, if equipped.
29. Battery negative cable to rear compressor bracket
mounting stud. Refer to SECTION 6Dl.
30. A/C compressor and condenser hose to
compressor and condenser, if necessary. Refer to
SECTION lB.
31. Starter motor. Refer to SECTION 6D2.
32. Electrical ground strap to engine block.
33. Steering gear coupling shaft to rack and pinion.
34. Power steering gear inlet and outlet hoses to
steering gear. Refer to SECTION 3R
35. Torque arm to transmission. Refer to
SECTION 3D.
37. Shift linkage to transmission. Refer to
SECTION 7A or 7B.
38. Radiator inlet hose to radiator. Refer to
SECTION 6B.
STEP 2
STEP 3
39. Transmission fluid oil cooler lines to radiator

40. Stabilizer bar bushing bolts/screws. Refer .to
SECTION 3C.
SECTION 10-5.
42. Transmission converter bolts/screws (automatic
transmission). Refer to SECTION. 7A.
43. 3-Way catalytic converter. Refer to SECTION 6F.
45. Lower vehicle.
46. Refill with engine oil. Refer to SECTION OA.
47. Refill with engine coolant. Refer to
SECTION 6B;
50. Bleed brake system. Refer to SECTION 5E1 or
SECTION 5E2.
SECTION 3B.
52. Charge A/C system, if necessary. Refer to
Oil,. Evacuating and Recharging Procedures" in
SECTION lB.
53. Align wheels. Refer to SECTION 3A.
THREAD REPAIR
Figure 31
Damaged threads may be reconditioned by
drilling out, re-threading and installing a suitable
thread insert. General purpose thread repair kits . are
available commercially.
CAUTION:. Wear safety glasses to avoid

eye damage.
1. Determine size, pitch and depth of damaged
tool and tap to required depth.
IT]
Important
Refer to kit manufacturer's instructions

regarding size of drill and tap to be used.
STEP 4
Figure 31 - Repairing Threaded Bolts
STEP 5
5-13-94
FS0366A2A

2. Drill out damaged thread. Clean out chips.
3. Tap hole.
A. Lubricate tap with light engine oil.
B. Clean thread.
III
Important
Avoid build-up of chips. Back out tap every

few turns and remove chips.
4. Thread the thread insert onto mandrel of installer.
Engage tang of insert onto end on mandrel.
6A8A-37
5. Lubricate insert. with light engine oil (except when

installing in aluminum) and install.
III
Important
When correctly installed, insert should be flush

to one turn below surface.
6. If tang of insert does not break off when backing
out installer, break tang off with a drift pin.
SPECIFICATIONS
Accelerator Control Cable Bracket Bolt/Screw ...................................................................... 10 N .m (89 lb. in.)
Accessory Drive Belt Tensioner Bolts/Screw ......................................................................... 50 N.m (37 lb. ft.)
Balance Shaft Gear Bolt/Screw ..................................................................................... 22 N.m (16 lb. ft.) + 70
Balance Shaft Retainer Bolt/Screw ......................................................................................... 30 N.m (22 lb. ft.)
Camshaft Position Sensor Bolt/Screw .................................................................................... 10 N.m (89 lb. in.)
Camshaft Sprocket Bolt/Screw .............................................................................................. 100 N.m (74 lb. ft.)
Camshaft Thrust Plate Bolt/Screw .......................................................................................... 15 N.m (11 lb. ft.)
Connecting Rod Cap Bolt/Screw ............................................................................................ 27 N.m (20 lb. ft.)
Coolant Outlet Bolt/Screw ................................................................................................... ,.. 27 N.m (20 lb. ft.)
Crankshaft Balancer Bolt/Screw ................................................................................ 150 N.m (111 lb. ft.) + 76
Crankshaft Main Bearing Cap Bolt/Screw .............................................................................. Refer to procedure
Crankshaft Main Side Bearing Cap Bolt/Screw ........................................................... 15 N.m (11 lb. ft.) + 45
Crankshaft Position Sensor Stud ............................................................................................. 30 N.m (22 lb. ft.)
Crankshaft Rear Oil Seal Housing Bolt/Screw ............................................................ 15 N.m (11 lb. ft.) + 50
Cylinder Block Drain Plug ..................................................................................................... 20 N.m (15 lb. ft.)
Cylinder Head ''NEW" Bolt/Screw ........................................................................................ Refer to procedure
Drive Belt Tensioner Bolt/Screw ............................................................................................ 50 N.m (37 lb. ft.)
EGR Valve Adapter Bolt/Screw .............................................................................................. 25 N.m (18 lb. ft.)
EGR Valve Adapter Nut. ......................................................................................................... 50 N:m (37 lb. ft.)
EGR Valve Nut ........................................................................................................................ 29 N.m (21 lb. ft.)
EGR Valve Outlet Pipe Bolt/Screw ........................................................................................ 29 N.m (21 lb. ft.)
EGR Valve Outlet Pipe Nut. ................................................................................................... 29 N.m (21 lb. ft.)
Engine Coolant Temperature Sensor ..................................................................................... 13 N.m (116 lb. in.)
Engine Front Cover Bolt/Stud ...................................................................................... 15 N.m (11 lb. ft.) + 40
Engine Front Lift Bracket Bolt/Screw .................................................................................... 25 N.m (18 lb. ft.)
Engine Oil Pressure Gage Sensor ......................................................................................... 13 N.m (116 lb. in.)
Engine Rear Lift Bracket Bolt/Stud ....................................................................................... 50 N.m (37 lb. ft.)
Engine Rear Lift Bracket to ICM .......................................................................................... 25 N.m (18 lb. ft.)
ESC Knock Sensor .................................................................................................................. 18 N.m (13 lb. ft.)
Exhaust Manifold Bolt/Stud .................................................................................................. 12 N.m (106 lb. in.)
Exhaust Manifold Heat Shield Nut .......................................................................................... 9 N.m (80 lb. in.)
Flywheel "NEW" Bolt/Screw ...................................................................................... 15 N.m (11 lb. ft.) + 50
Fuel Injector Rail Nut ............................................................................................................. 10 N.m (89 lb. in.)
Generator Brace Bracket Bolt/Screw ...................................................................................... 50 N.m (37 lb. ft.)
ICM Bracket Bolt/Screw ......................................................................................................... 50 N.m (37 lb. ft.)
ICM Nut/ldr ............................................................................................................................. 30 N.m (22 lb. ft.)
Lower Intake Manifold Bolt/Screw ........................................................................................ 15 N.m (11 lb. ft.)
Oil Filter .................................................................................................................................. 16 N.m (12 lb. ft.)
Oil Filter Adapter Bolt/Screw ................................................................................................. 30 N.m (22 lb. ft.)
Oil Level Indicator Bolt/Screw ............................................................................................... 10 N.m (89 lb. in.)
Oil Level Indicator Switch .................... ,................................................................................. 22 N.m (16 lb. ft.)
Oil Pan Bolt/Screw ...................................................................................... ,.......................... 14 N.m (125 lb. in.)
Oil Pan Drain Plug ........................................ ,......................................................................... 44 N.m (33 lb. ft.)
Oil Pump Cover Bolt/Screw ................................................................................................... 11 N.m (98 lb. in.)
Oil Pump Screen Bolt/Screw .................................................................................................. 15 N.m (11 lb. ft.)
Oxygen Sensor ......................................................................................................................... 42 N.m (31 lb. ft.)
Side Bearing Cap Bolt/Screw ....................................................................................... 15 N.m (11 lb. ft.) + 45
6A8A-38
Spark Plug Wire Retainer Bracket Bolt/Screw ............................................................... LH 50 N.m (37 lb. ft.)
Spark Plug Wire Retainer Bracket Bolt/Screw ............................................................... RH 30 N.m (22 lb. ft.)
Throttle Body Bolt/Screw ....................................................................................................... 10 N.m (89 lb. in.)
Throttle Body Nut .................................................................................................................. 10 N.m (89 lb. in.)
Timing Chain Dampener Bolt/Screw ...................................................................................... 22 N.m (16 lb. ft.)
Upper Intake Manifold Bolt/Screw ......................................................................................... 15 N.m (11 lb. ft.)
Vacuum Source Manifold Bolt/Screw .................................................................................... 10 N.m (89 lb. in.)
Valve Lifter Guide Retainer Bolt/Screw ................................................................................. 30 N.m (22 lb. ft.)
Valve Rocker Arm Bolt/Screw .............................................................................................. ;. 15 N.m (11 lb. ft.)
Valve Rocker Arm Cover Bolt/Screw ........................... ,....................................................... 10 N.m (89Jb. in.)
Water Pump Bolt/Screw ................................................................................................ 15 N.m (lllb. ft.)+ 80
Water Pump Pulley Bolt/Screw ............................................................................................. 13 N.m (116 lb. in.)
ENGINE SPECIFICATIONS (3800 VIN K)

General
Type .......................................................................................................... ,................................................... 90 V6
Displacement ................................................................................... ;.................................................... 231 Cu. In.
Liters ................................................................................................................................................................... .3.8
Bore ........................................................................ ,........................................ :.......................... 96.52 mm(3.8 in.)
Stroke ....................................................................................................................................... 86.36 mm (3.4 in.)
Compression Ratio ........................................................................................................................................ ;... 9.4:1
Firing Order ................................................................... , ...................................................................... 1-6.:.5-4-3-2
Oil Pressure (Minimum at operating temperature) ............................... 414kPa (60 psig) at 1850 engine RPM
Cylinder Bore
Diameter ..................................................................................................................................... 96.5 mm (3.8 in.)
Out~of-Round Max ........................................................................................ ,.................... 0.010 mm (0.0004 in.)
Taper ...................................................................................... ,............................................ 0.013 mm (0.0005 in.)
Piston
Clearance (39 mm from top of piston) ...................................................... 0.010-0.051 mm (0.0004-0.0020 in.)
Piston Rings
Ring Groove Depth
Top .......................................................................................................... 4.019-40146 mm (0.158-0.163 in.)
Second ................................................................................................... 4.214-4.341 mm (0.0166-0.171 in.)
End Gap
Top ............................................................................................................. 0.305-0.559 mm (0.012-0,022 in)
Second ............................................................ :; ...................... :................ 0.762-l.016 mm (0.030-0.040 in.)
Side Clearance
Top ....................................................................................................... 0.033-0.079 mm (0.0013-0.0031 in.)
Second ........................................ :........................................................ 0.033-0.079 mm (0.0013-0.0031 in.)
Ring Width
Top ........................................................................................................... 1.176-1.197 mm (0.0463.:.0.0471 in.)
Second ............................................................................................................ 1.476-1.497 mm (0.0581-0.0589)
Piston Oil Ring
Ring Groove Depth ...................................................................................... 3.814-3.941 mm (0.150-0.155 in)
End Gap ....................................................................................................... 0.254-0.762 mm (0.010-0.030 in.)
Side Clearance ......................................................................................... 0.023-0.201 mm (0.0009-0.0079 in.)
Ring Width .................................................................................................. 1.854-2.007 mm (0.073-0.079 in.)
Piston Pin
Diameter ........................................................................... ,................... 21.9950-22.0000 mm (0.8659-0.8661 in.)
Clearance in Piston ........ ,...................................................................... 0.0020-0.0130 .mm. (0.00008-0.00051 in)
Fit in Connecting Rod ............................................................................. 0.0066-0.0217 mm (0.0003-0.0009 in.)
Crankshaft
Main Journal
Diameter - All ....... ;............................................................................. 63.470-63.495 mm (2.4988-2.4998
Taper - Max............................... :.................................................................. ;.............. 0.0008 mm (0.0003
Out-of-Round ............................................................................................................... 0~0008 mm (0.0003
Crankshaft Bearing Clearance ................................................................. 0.020-0.055 nun (0.0008-0.0022
Crankshaft End Play ............................................................................ 0.076 mm-0.279 mm (0;003-0.011
in.)
in.)
in.)
in.)
in.)
6A8A-39
Connecting Rod
Diameter ............................................................................................... 57 .117-57 .147 mm (2.2487-2.2499
Taper - Max ................................................................................................................... 0.008 mm (0.0003
Out~of-Round ................................................................................................................. 0.008 mm (0.0003
Rod Bearing Clearance ........................................................................... 0.020-0.055 mm (0.0008-0.0022
Rod Side Clearance ....................................................... ,............................. 0.076-0.381 mm (0.003-0.015
in.)
in.)
in.)
in.)
in.)
Camshaft
Journal Diameter ...................................................................................... 45.339-45.364 mm (1.7865-1.7885
Bearing Inside Diameter .......................................................................... 45.377-45.428 mm (1.7865-1.7885
Journal Clearance ......................................................................................... 0.013-0.089 mm (0.0005-0.0035
Lobe Lift
Intake ..................................................................................................................... .-........... 6.43 mm (0.250
Exhaust ............................................................................................................................... 6.48 mm (0.255
in.)
in.)
in.)
in.)
in.)
Balance Shaft
End Play ................................................................................................................... 0.0-0.203 mm (0.0-0.008
Radial Play - Front. ............................................................................................... 0.0-0.028 mm (0.0-0.0011
Radial Play - Rear ..................................................................................... 0.0127-0.119 mm (0.0005-0.0047
Drive Gear Lash .............................................................................................. 0.050-0.127 mm (0.002-0.005
Bearing Bore Diameter - Front. .............................................................. 51.973-51.999 mm (2.0462-2.0472
Bearing Bore Diameter - Rear ...................................................................... 49.53-49.580 mm (1.950-1.952
in.)
in.)
in.)
in.)
in.)
in.)
Valve System
Lifter ......................................................................................................................................................... Hydraulic
Rocker Arm Ratio ........................................................................................................................................... 1.6: 1
Face Angle ....................................................................................... .'. .... '. ........................................................... 45
Seat Angle .......................................................................................................................................................... 45
Seat Runout - Max.............................................................................................................. 0.050 mm (0.002 in.)
Seat Width
Intake ............................................................................................................... 1.53-2.03 mm (0.060-0.080 in.)
Exhaust. ........................................................................................................... 2.29-2.79 mm (0.090-.0.080 in.)
Stem Height - All ............................................................................................ .49.15-50.17 mm (1.935-1.975)
Stem Clearance - All .............................................................................. 0.038-0.089 mm (0.0015-0.0032 in.)
Valve Spring Free Length ............................................................................................... 50.32 mm (1.981 in.)
Pressure
Closed .............................................................................................. 356 N at 43.69 mm (80 lbs. at 1.75 in.)
Open ................................................................................................ 935 N at 33.4 mm (210 lbs. at 1.315 in.)
Installed Height ............................................................................................. 42.93-4.45 mm (1.690-1.720 in.)
Approximate # of coils ........................................ ,............................................................................................ 4
Flywheel
Runout - Max ........................................................................................................................ 0.38 mm (0.015 in.)
Oil Pump
Gear Pocket
Depth .......................................................................................................... 11.71-11.75 mm (0.461-0.4625
Diameter....................................................................................................... 89.10-89.20 mm (3.508-3.512
Inner Gear
Tip Clearance .................................................................................................................... 0152 mm (0.006
Outer Gear
Diameter Clearance ..................................................................................... 0.203-0.381 mm (0.008-0.015
End Clearance ............................................................................................ 0.025-0.089 mm (0.001-0.0035
Valve to Bore Clearance ........................................................................... 0.038-0.076 mm (0.0015-0.003
in.)
in.)
in.)
in.)
in.)
in.)
6A8A-40
SPECIAL TOOLS
(
1
J 34730-1
5
J 8520
4
~J8037
'
6
J 8080
~~
=>::,
7
J 23738-A
8
J 22794
~
9
J 35354
u;::1
10
J 36660
c fj
11
J 36995 AND
J 36995-UPD
1
2
3
4
5
6
7
8
9
10
11
12
FUEL PRESSURE GAGE

SLIDE HAMMER
DIAL INDICATOR
CAM LIFT LOBE INDICATOR
MAIN BEARING SHELL REMOVER
VALVE STEM SEAL TESTER
SPARK PLUG PORT ADAPTER
TORQUE ANGLE METER
BALANCE SHAFT REAR BUSHING INSTALLER
BALANCE SHAFT INSTALLER
12
J 36996
05-08-95
FT0248A8A
6A8A-41
3
J 38197
J 37096
2
J 38196
4
J 38606
5
J
1
2
3
4
5
6
FLYWHEEL HOLDING TOOL

REAR MAIN OIL SEAL INSTALLER
CRANKSHAFT BALANCER PULLER
VAL VE SPRING COMPRESSOR
MAIN BEARING CAP PULLER
CRANKSHAFT REAR MAIN OIL SEAL
HOUSING ALIGNING TOOL
7 CONNECTING ROD ASSEMBLY GUIDE
8 VALVE GUIDE SEAL INSTALLER
41348
J 41512
02-10-H
WT91HA8B
6A8A42 3800 ENGINE ON-VEHICLE SERVICE L36 (VIN K)
BLANK
3800 ENGINE UNIT REPAIR L36 (VIN K)
6A88-1.
SECTION 6A8B
3800 ENGINE UNIT REPAIR
(VIN K)
exact part number for that location. General Motors will call out those fasteners that require a replacement after
removal. General Motors will also call out the fasteners that require thread lockers or thread sealant. UNLESS
OTHERWISE SPECIFIED, do not use supplemental coatings (paints, greases, or other corrosion inhibitors) on
sequence and specifications. Following these instructions can help you avoid damage to parts or systems.
CONTENTS
General Description ............................................ 6A8B-2
Engine Construction ....................................... 6A8B-2
Engine Lubrication ......................................... 6A8B-2
Disassembly ........................................................ 6A8B-3
Tools and Shop Equipment.. .......................... 6A8B-3
Engine Accessories ......................................... 6A8B-3
Cleaning .......................................................... 6A8B-3
EGR Valve Outlet Pipe .................................. 6A8B-3
EGR Valve ...................................................... 6A8B-3
EGR Valve Adapter ........................................ 6A8B-8
Coolant Outlet Housing and Thermostat. ..... 6A8B-8
Throttle Body ................................................. 6A.gB-.8
Upper Intake Manifold .................................. 6A8B-9
Lower Intake Manifold ................................ 6A8B-10
Accessory Drive Belt Tensioner Assembly.6A8B-10
Oil Level Indicator. ...................................... 6A8B-11
Exhaust Manifold ......................................... 6A8B-11
Rocker Arm Covers And/Or Gaskets .......... 6A8B-12
Rocker Arm and Pushrod ............................ 6A8B-12
Valve Lifters ................................................. 6A8B-13
Cylinder Head .............................................. 6A8B-13
Coolant Pump ............................................... 6A8B-13
Oil Filter Adapter and Pressure Relief
Valve ......................................................... 6A8B-13
Crankshaft Balancer ..................................... 6A8B-13
Front Cover .................................................. 6A8B-14
Front Cover Oil Seal ................................... 6A8B-14
Timing Chain and Sprockets ....................... 6A8B-15
Oil Pan ......................................................... 6A8B-15
Oil Pump Screen .......................................... 6A8B-15
Oil Pump Gear Set. ..................................... 6A8B-16
Flywheel ....................................................... 6A8B-16
Crankshaft Rear Main Oil Seal Housing .... 6A8B-16
Crankshaft Rear Main Oil Seal ................... 6A8B-16
Piston and Connecting Rod ......................... 6A8B-16
Balance Shaft ............................................... 6A8B-17
Camshaft ....................................................... 6A8B-17
Crankshaft ..................................................... 6A8B-19
Cleaning, Inspection and Repair...................... 6A8B-20
Cylinder Block ............................................. 6A8B-20
Crankshaft ..................................................... 6A8B-22
Piston Fitting ................................................ 6A8B-24
Piston Ring Fitting ....................................... 6A8B-24
Connecting Rod and Piston ......................... 6A8B-25

Main and Rod Bearings .............................. 6A8B-25
Measuring Bearing Clearance...................... 6A8B-26
Bearing Installation ...................................... 6A8B-27
Flywheel ....................................................... 6A8B-28
Balance Shaft ............................................... 6A8B-28
Cylinder Head .............................................. 6A8B-28
Valve Stem Height.. ..................................... 6A8B-32
Valve Spring Installed Height ..................... 6A8B-32
Valve Lifter Diagnosis ................................. 6A8B-32
Oil Pump Unit Repair ................................. 6A8B-33
Thread Repair ............................................... 6A8B-34
Assembly .......................................................... 6A8B-34
Prior to Assembly ........................................ 6A8B-34
Crankshaft ..................................................... 6A8B-34
Balance Shaft ............................................... 6A8B-35
Camshaft ....................................................... 6A8B-37
Crankshaft Rear Main Oil Seal Housing .... 6A8B-39
Crankshaft Rear Main Oil Seal... ................ 6A8B-40
Flywheel ....................................................... 6A8B-40
Oil Pump Screen .......................................... 6A8B-40
Oil Pan ......................................................... 6A8B-40
Oil Pump Gear Set ...................................... 6A8B-41
Front Cover .................................................. 6A8B-41
Front Cover Oil Seal ................................... 6A8B-41
Crankshaft Balancer ..................................... 6A8B-42
Oil Filter Adapter and Pressure. Relief
Valve ......................................................... 6A8B-42
Coolant Pump ............................................... 6A8B-42
Cylinder Head .......................... ,................... 6A8B-42
Valve Lifters ................................................. 6A8B-43
Rocker Arm and Pushrod ............................ 6A8B-43
Rocker Arm Covers And/Or Gaskets ......... 6A8B-44
Exhaust Manifold ......................................... 6A8B-44
Oil Level Indicator ...................................... 6A8B-44
Accessory Drive Belt Tensioner .................. 6A8B-44
Lower Intake Manifold ................................ 6A8B-45
Upper Intake Manifold ................................ 6A8B-45
Throttle Body ............................................... 6A8B-45
Coolant Outlet Housing and Thermostat .... 6A8B-45
EGR Valve Adapter ..................................... 6A8B-45
6A8B-2
3800 ENGINE UNIT REPAIR l36 (VIN K)
EGR Valve .................................................... 6A8B-45

EGR Valve Outlet Pipe ................................ 6A8B-45
Specifications .................................................... 6A8B-46
Fastener Tightening ...................................... 6A8B-46
Efl:gme
. ........................................................... 6A8B-47
Special Tools .................................................... 6A8B-49
GENERAL DESCRIPTION
ENGINE CONSTRUCTION
Figures 1 through 5
.
Starting from the front of the engine, cylinders
m the left bank are 1, 3, 5 and cylinders in the right
bank are 2, 4, 6.
The. crankshaft is supported in the crankcase by
four bearmgs. The crankshaft is counterbalanced by
~e flywheel, crankshaft balancer, and weights cast
mto . the crankshaft. Additional counterbalancing is
obtamed from the balance shaft which rides in the
block above the camshaft and is driven by the
camshaft.
The 3800 engine is even-firing, in that the
cylinders fire _at equal int~rvals (120 degree) of
crankshaft rotation. The location of the crankpins has
been offset by 30 de~ee in order to fire the cylinders
at equal 120 degree mtervals of crankshaft rotation.
The camshaft lobes and timing also reflect 120
degree spacing.
!hus, the even-firing crankshaft provides an
equal mte:Yal of 120 degrees between ignition of each
of the cylmders throughout the firing order.
The firing order is 1,6,5,4,3,2.
The aluminum alloy pistons have slipper skirts
and are cam turned. Four drilled holes or casted slots
in the oil ring grooves permit drain back of oil
collected by the oil ring.
The camshaft is supported in the block by four
bearings. It is driven from the crankshaft by sprockets
and chain.
.
The cylinder heads are cast iron and incorporate
mtegral valve stem guides. Right and left cylinder
hea~s ai:e ~dentical and interchangeable, although in
service it is good practice to reinstall the cylinder
heads on the side from which they are removed.
The intake manifold is bolted to the inner faces
of both cylinder heads so that it connects with all inlet
ports.
NOTICE: There are two bolts which fasten
the lower intake manifold to the cylinder head
that are accessible only after the upper intake is
removed. These bolts are located in the right
front and left rear corners of the lower intake
~anifold. It_ is necessary to remove the upper
mtake manifold to service the lower intake.
Refer to "Upper Intake Manifold" procedure in
this section.
Each exh~ust ~d intake ".~ve has a valve spring
of ample ~apacity to msure positive seating throughout
the operatmg speed range.
The valve rocker arms for each bank of
cylinders pivot on pedestals which bolt to the cylinder
head.
Hydraulic roller valve lifters and tubtilar

pushrods are used to operate overhead rocker arms and
valves of b<,>th banks of .cylinders from a single
':amshaft. This syste1? requrres no lash adjustment at
time of assembly or m service. Operation of hydraulic
valve lifters is described below.
In addition to its normal function of a cam
follower, each hydraulic valve lifter also serves as an
automatic adjuster which maintains zero lash in the
v~lv~ t~ain under al_l operating conditions. By
ehmmatmg all lash m the valve train and also
providing a ':ushion of ~il to absorb operating shocks,
the hydraulic valve: l.1fter promotes quiet valve
operation. It also ehmmates the need for periodic
valve a?jl!stment !o compensate for wear of parts.
.
011 is supplied to the lifter through a hole in the
side of t~e lifter body which indexes with a groove
and h?le m the lifter plunger. Oil is then metered past
the 011 metering valve in the lifter, through the
pushrods to the rocker arms.
When the lifter begins to move up the cam lobe,
the check ball is held against its seat in the plunger by
the check ball spring which traps the oil in the base of
~e lifter body below the plunger. The plunger and
lifter body then raise as a unit, pushing up the pushrod
!o open the valve. The force of the valve spring which
is exerted on the plunger through the rocker arm and
pushrod causes a slight amount of leakage between the
plunger and lifter body. This "leak-down" allows a
slow escape of trapped oil in the base of the lifter
body. As the lifter rolls down the other side of the
cam lobe and reaches the base circle or "valve
closed" position, the plunger spring quickly moves the
plunger back (up) to its original position. This
movem~nt causes. the chec~ ~all to open against the
?all sprmg and 011 fro!Il within the plunger is drawn
mto the base of the lifter. This restores the lifter to
zero lash.
ENGINE LUBRICATION
Figure 6
The engine lubrication system is of the
force-feed type in which oil is supplied under full
pressure to the crankshaft, connecting rods, camshaft
and rear balance shaft bearing, valve lifters and a
controlled volume is supplied to the rocker ~s and
push;ods. All other moving parts are lubricated by
gravity flow or splash.
The supply of oil is carried in the lower
cra~casc: oil pan which is filled through a filler
opening m the rocker arm cover. A removable oil
level indicator located on the left side of the crankcase
is provided to check oil level.
. The oil pump is located in the front cover and is
dri~en ~y the cr~nks?aft. It is a "gerotor" style pump
which is a combmation of gear and rotor pumps. It is
connected by a passage in the cylinder crankcase to an
oil screen housing and pipe assembly. The screen is
submerged in the oil supply and has ample volume for

all operating conditions. If the screen should become
clogged for any reason, oil may be drawn into the
system through the relief valve in the screen.
Oil is drawn into the pump through the screen
and pipe asse,ii.bly and a passage in the crankcase
which connects Jo passages in the front cover. All oil
is discharged from the pump to the oil pump filter
adapter assembly which consists of an oil filter bypass
valve and nipple for installation of an oil filter. The
spring loaded oil pressure relief valve located in the
timing chain cover, limits the oil pressure. The oil
filter by-pass valve opens when the filter has become
restricted, to the extent that approximately 68.95 kPa
(10 psi) pressure difference exists between the filter
inlet and discharge, to by-pass the oil filter and
channel unfiltered oil directly to the main oil galleries
of the engine.
A full flow oil filter is externally mounted to the
oil filter adapter on the lower right front side of the
engine. Normally; all engine oil passes through the
filter element, however, if the element becomes
restricted, a spring loaded by-pass valve opens as
mentioned above.
The main oil galleries run the full length of the
crankcase and cut into the valve lifter guide holes to
supply oil at full pressure to the lifters. Holes drilled
from the crankshaft bearings to the main gallery
intersect the cam bearing bores to supply oil to the
cam bearings.
Holes drilled in the crankshaft carry oil from the
cral!lkshaft bearings to the connecting rod bearings.
Pistons and cylinder walls are lubricated by oil thrown
off the crankshaft and by connecting rod splash. Piston
pins are lubricated by splash.
Each rocker arm and valve is supplied with oil
through the tubular pushrod. This oil comes from the
inside of the lifter, passing around the metering valve
and through a hole in the lifter pushrod seat. Oil from
the pushrod passes through a hole in the rocker arm
pushrod seat, and emerges on top of the pushrod seat
boss.
DISASSEMBLY
TOOLS AND SHOP EQUIPMENT
A clean, well lit work area should be available.
Other necessary aides include: a suitable parts cleaning
tank, compressed air supply, trays to keep parts and
fasteners organized, and an adequate set of hand tools.
An approved engine repair stand will help
prevent personal injury or damage to the engine
components.
Special tools are illustrated throughout this
section, and listed at its end. These tools (or their
equivalents) are specially designed to quickly and
6A8B.;.3
safely accomplish the operations for which they are

intended. The use of these tools will also minimize
possible damage to engine components.
Some precision measuring tools are required for
inspection of certain critical components. Torque
wrenches are necessary for the correct assembly of
various parts.
ENGINE ACCESSORIES
This section assumes that the engine accessories
have been removed. These accessories may include
one or more of the following:
Power steering pump.
Generator.
AJC compressor.
It is beyond the scope of this section to detail
the many different accessory installations. Refer to the
appropriate service manual section for this
information.
Diagrams of emission and vacuum hose routings,
wiring harness routings, accessory drive belt layout,
etc., should be made before removing accessories.
CLEANING
Remove the engine accessories before cleaning
to provide better access to engine exterior surfaces.
Cover the openings with tape to prevent the entry of
coolant, solvent and dirt. Methods used to clean the
engine will depend on the equipment available. Steam
cleaning, pressure washing or solvent cleaning are
some acceptable methods. Allow the engine to dry
before beginning to work.
It is important that the engine be as clean as
, possible to prevent dirt from entering critical areas
during disassembly.

Figure 7
j+-+I
1. Outlet pipe bolt from adapter.

2. Outlet pipe bolt from upper intake manifold.
3. Outlet pipe.
[I]
Important
Whenever the EGR tube is removed from the left

hand exhaust manifold, the outlet' tube should be
inspected for leaks during installation. If leaks are
present, replace the EGR adapter. assembly.
EGR VALVE
Figure 8
!+-+I
1. EGR valve nuts.

2. EGR valve.
6A884 3800 ENGINE UNIT REPAIR L36 (VIN K)
45
65 34
39
j
37
49
Figure 1 - Disassembled Lower Engine
1 CAMSHAFT
2 SOLT/SCREW, BALANCE SHAFT GEAR
4 SHAFT, BALANCE
5 PIN, BALANCE SHAFT GEAR

5 SOLT /SCREW, BALANCE SHAF.T RETAINER
9 BUSHING, BALANCE SHAFT
10
11
12
13
15
16
17
18
19
20
21
22
23
24
32
33
34
35
36
37
39
40
41
43
44
45
46
47
48
49
50
51
RINGS, PISTON
PISTON
ROD, CONNECTING
BEARING KIT, CONNECTING ROD CAP
BEARINGS, CAMSHAFT
GASKET, UPPER INTAKE MANIFOLD
SENSOR, ESC KNOCK
PLUG, CYL. BLOCK OIL GALLERY
PIN, ENGINE FRONT COVER
BLOCK, ENGINE CYLINDER
NUT, ERG VAL VE
BOLT/SCREW, CONNECTING ROD CAP
CAP, CONNECTING ROD
PIN, CYLINDER HEAD LOCATION HOLE
GASKET, OIL PUMP SCREEN
SCREEN, OIL PUMP
80.L T/SCREW, OIL PUMP SCREEN
CRANKSHAFT, ENGINE
FLYWHEEL
SENSOR, OIL LEVEL
CLIP, PISTON PIN RETAINER
SOLT/SCREW, CRANKSHAFT MAIN BEARING CAP
GASKET, OIL PAN (INCLUDES BAFFLE)
INDICATOR, OIL LEVEL
TUBE, OIL LEVEL INDICATOR
PAN ASSEMBLY, ENGINE OIL
BOLT/SCREW, OIL LEVEL INDICATOR TUBE
BOLT/SCREW, OIL PAN
GASKET, OIL PAN DRAIN
PLUG, OIL PAN DRAIN
52 SHIELD, CRANKSHAFT SENSOR
53 BALANCER, CRANKSHAFT
54 WASHER, CRANKSHAFT BALANCER
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
97
130
132
133
6A8B5
SOLT /SCREW, CRANKSHAFT BALANCER

BOLT, SENSOR CAMSHAFT POSITION
SENSOR, CAMSHAFT POSITION
GEAR SET, OIL PUMP
COVER, OIL PUMP
CAP, CRANKSHAFT MAIN BEARING
BEARING, CRANKSHAFT LOWER
KEY, CRANKSHAFT BALANCER
SOLT/SCREW, OIL PUMP COVER
BEARING, CRANKSHAFT UPPER
SEAL, ENGINE FRONT COVER OIL
BOLT/SCREW, COOLANT PUMP PULLEY
PULLEY, COOLANT PUMP
BOLT/SCREW, COOLANT PUMP
PUMP, COOLANT
GASKET, COOLANT PUMP
COVER, ENGINE FRONT
SPRING, OIL PRESSURE RELIEF VAL VE
VAL VE, OIL PRESSURE RELIEF
GASKET, OIL FILTER ADAPTER
ADAPTER, OIL FILTER
DAMPER, TIMING CHAIN
SOLT/SCREW, CRANKSHAFT REAR OIL
SEAL HOUSING
SOLT/SCREW, OIL FILTER ADAPTER
FILTER, OIL
CHAIN, TIMING
MAGNET, CAMSHAFT POSITION SENSOR
SPROCKET, CAMSHAFT
GEAR, BALANCE SHAFT DRIVE
BOLT/SCRl:.W, CAMSHAFT THRUST PLATE
PLATE, CAMSHAFT THRUST
BOLT/SCREW, SIDE MAIN
GASKET, CRANKSHAFT REAR OIL
SEAL HOUSING
KEY, CAMSHAFT
PLUG, ENGINE BLOCK CORE HOLE
'-\_
02-16-95
FT9266A8B
Figure 2 - Disassembled Lower Engine -Legend
6A8B-6 3800 ENGINE UNIT REPAIR L36 (VIN K)

166
106
171
105
_Jb.J (:-;,...
122
/
205
2.~-
')(~/
203
152
138
167
116
128
141
31
Figure 3 - Disassembled Upper Engine
02-18-85
FT8288A8B
16
21
25
26
27
28
29
30
31
38
100
102
103
105
106
109
110
111
112
113
114
115
116
117
118
119
121
122
123
124
128
129
134
135
GASKET, UPPER INTAKE

NUT, EGR VALVE
VALVE, EGR
GASKET, EGR VALVE
ADAPTER, EGR VALVE
BOLT/SCREW, EGR VAL VE OUTLET PIPE
PIPE, EGR VALVE OUTLET
NUT, EGR VALVE OUTLET PIPE
BOLT/SCREW, EGR VAL VE ADAPTER
NUT, EGR VALVE ADAPTER
MANIFOLD, VACUUM SOURCE
BOLT/SCREW, UPPER INTAKE MANIFOLD
GASKET, THROTTLE BODY
SENSOR, COOLANT TEMPERTURE
BODY, THROTTLE
BOLT/SCREW, COOLANT OUTLET
OUTLET, COOLANT
GASKET, COOLANT OUTLET
THERMOSTAT
GASKET, LOWER INTAKE MANIFOLD
BOLT/SCREW, LOWER INTAKE MANIFOLD
BRACKET, ENGINE LIFT REAR
SOLT/STUD, EXHAUST MANIFOLD
NUT, FUEL INJECTOR RAIL
GASKET, EXHAUST MANIFOLD (LEFT)
GASKET, EXHAUST MANIFOLD (RIGHT)
SOLT/SCREW, VALVE ROCKER ARM COVER
CAP, OIL FILL
COVER, VAL VE ROCKER ARM
SEAL, INTAKE MANIFOLD
MANIFOLD, EXHAUST (LEFT)
SOLT/SCREW, CYLINDER HEAD
KEY, VALVE STEM
CAP, VALVE STEM
136
137
138
139
141
142
143
144
145
146
149
150
151
152
153
154
155
159
163
164
165
166
167
168
170
171
173
201
202
203
204
205
6A8B7
SPRING, VAL VE STEM

SEAL, VALVE
PLUG, SPARK
VALVE, INTAKE
BOLT/SCREW, DRIVE BELT TENSIONER
HEAD, CYLINDER
BRACKET, GENERATOR BRACE
BOLT/SCREW, GENERATOR BRACE
LIFTER, HYDRAULIC VALVE
RETAINER, VALVE ROCKER ARM PIVOT
ARM, VALVE ROCKER
BOLT/SCREW, VALVE ROCKER ARM
GASKET, VALVE ROCKER ARM COVER
PUSH ROD
GUIDE, VAL VE LIFTER
BOLT/STUD, EXHAUST MANIFOLD
MANIFOLD, LOWER INTAKE
MANIFOLD, UPPER INTAKE
SEAL, LOWER INTAKE MANIFOLD AND GASKET
RAIL, FUEL INJECTION
MANIFOLD, EXHAUST (RIGHT)
SENSOR, HEATED OXYGEN
BOLT/SCREW, ICM BRACKET
BRACKET, ICM
BRACKET, ENGINE LIFT FRONT
SHIELD, EXHAUST MANIFOLD HEAT
NUT, EXHAUST MANIFOLD HEAT SHIELD
TUBE, OIL FILL
SEAL, OIL FILL TUBE
SEAL, OIL FILL CAP
02-18-95
FT9278A8B
Figure 4 Disassembled Upper Engine -Legend
6A8B-8

154
149
LIFTER BODY
177 ROLLER
154 PUSH ROD
178 CHECK BALL (OPEN)
174
PLUNGER
179
175
CHECK BALL SPRING
176
PLUNGER RETURN SPRING
CHECK BALL (CLOSED)
N40003-6A8-H-EDS
Figure 5 - Valve .Lifter Operation
8-19-94
WM0026A1
Figure 6 - Engine Lubrication
EGR VALVE ADAPTER
Figure 9
!+-+i
1.
2.
3.
4.
5.
Oil level indicator bolt.
EGR valve.
Outlet pipe.
Adapter bolts from cylinder head.
Adapter.
COOLANT OUTLET HOUSING AND

THEAMOSTAT
Figure 10
!+-+!
1. Housing bolts.
2. Housing.
THROTTLE BODY
Figures 1 through 4
!+-+!
27 ADAPTER ASSEMBLY, EGR VALVE

28 BOLT/SCREW, EGR VALVE OUTLET
PIPE ASSEMBLY
29 PIPE ASSEMBLY, EGR VALVE OUTLET
30 NUT, EGR VAL VE OUTLET PIPE ASSEMBLY
1. Control bracket from upper intake manifold.

2. Throttle body nuts and bolt.
3. Throttle body.
(
Figure 7 - EGR Valve Outlet Pipe
6A889
31
21
25
26
27
NUT, EGR VALVE ASSEMBLY

VAL VE ASSEMBLY, EGR
GASKET, EGR VALVE
ADAPTER ASSEMBLY, EGR VALVE
Figure 8 - EGR Valve
27 ADAPTER ASSEMBLY, EGR VAL VE

31 BOLT/SCREW, EGR VALVE ADAPTER ASSEMBLY
38 NUT, EGR VAL VE ADAPTER ASSEMBLY
Figure 9 - EGR Valve Adapter

Figure 11
!++!
1. Spark plug. wires on right side of engine and set

aside.
2. Manifold vacuum source.
3. EGR outlet pipe from intake manifold.
NOTICE: The coolant outlet housing must be
removed in order to access the "hidden"' bolt
located under the housing. The "hidden" bolt
secures the upper and lower intake manifolds
together.
4. Coolant outlet housing and thermostat.

manifold. It is necessary to remove the upper
intake manifold to service the lower intake.
Refer to ''Upper Intake Manifold'' procedure in
this section.
109 BOLT/SCREW, COOLANT OUTLET ASSEMBLY

110 OUTLET ASSEMBLY, COOLANT
111 GASKET, COOLANT OUTLET ASSEMBLY
112 THERMOSTAT ASSEMBLY
FS0081..36
Figure 10 - Coolant Outlet Housing and Thermostat
5. Throttle body.
6. Fuel rail.
7. Upper intake manifold bolts and upper manifold.
6A8B-10

LOWER INTAKE MANIFOLD
Figure 11
j++!
(

manifold. It is necessary to remove the upper
intake manifold to service the lower intake.
Refer to "Upper Intake Manifold" procedure in
this section.
1. Upper intake. manifold. Refer to "Upper Intake
2. Intake manifold bolts and manifold.
ACCESSORY DRIVE BELT TENSIONER

Figure 12
!++!
1. Tensioner assembly bolts.

2. Tensioner assembly.
A TWO HIDDEN INTAKE MANIFOLD BOLT/SCREWS

8 APPLY GM P/N 9985675 TO BOTH
ENOS OF SEAL
16 GASKET, UPPER INTAKE MANJFOLLD
102 SOLT/SCREW, UPPER INTAKE MANIFOLD
113 GASKET, LOWER INTAKE MANIFOLD GASKET
114 BOLT/SCREW, LOWER INTAKE MANIFOLD
124 SEAL, INTAKE MANIFOLD
163 MANIFOLD, LOWER INTAKE
164 MANIFOLD, UPPER INTAKE
165 SEAL, LOWER INTAKE MANIFOLD AND GASKET
O NUMBER IN BOX IDENTIFY
022715
TIGHTENING SEQUENCE
FTt2NA8B
Figure 11 Intake Manifold and Gaskets
141 BOLT/SCREW, DRIVE BELT TENSIONER ASSEMBLY

142 TENSIONER ASSEMBLY, DRIVE BELT
FSOOSL38
Figure 12 Drive Belt Tensioner Assembly

45
6A8B-11
OIL LEVEL INDICATOR

Figure 13
I++!
1. Oil level indicator bolt.

EXHAUST MANIFOLD
Figures 14 and 15
Left Side
!++!
1. Heated oxygen sensor electrical connector from

wire support bracket.
2. Exhaust manifold heat shield nuts and shield.
3. EGR outlet pipe from exhaust manifold.
4. Manifold studs and bolts.
5. Manifold.
Right Side
45 INDICATOR ASSEMBLY, OIL LEVEL

46 TUBE ASSEMBLY, OIL LEVEL
48 SOLT /SCREW, OIL LEVEL INDICATOR
TUBE ASSEMBLY
l++I
l'SOl31.31
Figure 13 Oil Level Indicator
1. Heated oxygen sensor electrical connector from

lift bracket.
2. Exhaust manifold heat shield nuts and shields.
3. Manifold studs and bolts.
4. Manifold.
116
-~
128
116 BOLT/STUD, EXHAUST MANIFOLD

118 GASKET ASSEMBLY, EXHAUST MANIFOLD
128 MANIFOLD ASSEMBLY, EXHAUST (LEFT)
159
119 GASKET ASSEMBLY, EXHAUST MANIFOLD
159 BOLT/STUD, EXHAUST MANIFOLD
167 MANIFOLD ASSEMBLY, EXHAUST (RIGHT)
Figure 14 Left Exhaust Manifold
FS012LH
Figure 15 Right Exhaust Manifold
6A8B12
3800 ENGINE UNIT REPAIR L36 (VINK)

ROCKER ARM COVERS AND/OR
GASKETS
123
Left Side
Figure 16
i++I
1. Engine lift bracket.

2. ICM bracket.
3. Rocker arm cover bolts and cover.
Right Side
!++!

2. Spark plug wires harness from clip.
121
BOLT/SCREW, VAL VE ROCKER ARM

COVER ASSEMBLY
123 COVER ASSEMBLY, VAL VE ROCKER ARM
Figure 16 Rocker Arm Cover and Gasket
ROCKER ARM AND PUSHROD

Figures 16 and 17
l++j
1. Rocker arm cover. refer to "Rocker Arm Covers

and/or Gaskets" in this section.
2. Rocker arm bolts.
3. Rocker arm assembly.
202
201
155
.,,.
24
143
149
150
151
154
155
201
202
203
DOWEL PIN
HEAD GASKET
VALVE LIFTER
PIVOT RETAINER
ROCKER ARM
PUSH ROD
LIFTER GUIDE
BOLT
BOLT
HEAD BOLT
G502~6A8
Figure 17 Cylinder Head and Valve Train Components

VALVE LIFTERS
COOLANT PUMP
Figure 17
Figure 18
!+-+!
!+-+!
1. Rocker arm covers.

2. Lower intake manifold.
3. Rocker arm assemblies.
Be sure to keep all valve train parts in order
so they may be reinstalled in their original
locations and with the same mating surfaces as
when removed.
4. Pushrods.
5. Guide retainer bolts and retainer.
6. Lifter guides.
7. Valve lifters.
CYLINDER HEAD
1. Coolant pump pulley bolts and pulley.

2. Coolant pump bolts and coolant pump.
OIL FILTER ADAPTER AND PRESSURE

RELIEF VALVE
Figure 19
l+-+l
1. Oil filter adapter bolts from front cover.

2. Oil filter adapter, gasket, oil pressure valve and
spring.
Figure 17
CRANKSHAFT BALANCER
!+-+!
Figures 20 and 21
1.
2.
3.
4.
5.
6.
7.
6A8B-13
Tools Required:
Exhaust manifold.
Rocker arm cover.
Lower intake manifold.
Rocker arm and pushrods.
Cylinder head bolts and discard.
Cylinder head.
Belt tensioner assembly.
!+-+!
1. Hold flywheel using J 37096.

2. Balancer bolt.
72
67
68
69
70
71
72
SOLT/SCREW, COOLANT PUMP PULLEY

PULLEY ASSEMSL Y, COOLANT PUMP
SOLT/SCREW, COOLANT PUMP
PUMP ASSEMSL Y, COOLANT
GASKET, COOLANT PUMP
COVER ASSEMSL Y, ENGINE FRONT
Figure 18 - Coolant Pump and Pulley
72
74
COVER ASSEMBLY, ENGINE FRONT

SPRING ASSEMBLY, OIL PRESSURE
RELIEF VALVE
75 VALVE ASSEMSL Y, OIL PRESSURE RELIEF
76 GASKET, OIL FILTER ADAPTER
77 ADAPTER ASSEMBLY, OIL FILTER
82 BOLT/SCREW, OIL FILTER ADAPTER
fS017Ue
Figure 19 - Oil Filter Adapter and Oil Pressure Relief Valve
6A8B-14
3800 ENGINE UNIT REPAIR L36. (VIN K)

FRONT COVER
52
53
55
SHIELD ASSEMBLY
CRANKSHAFT BALANCER
ATTACHING BOLTS
Figure 22
(
Tools Required:
!++!
1.
2.
3.
4.
5.
6.
J 38197
Drive belt tensioner.
Crankshaft balancer using J 38197.
Sensor shield.
Crankshaft position sensor.
Oil pan to front cover bolts.
Front cover bolts and cover.
FRONT COVER OIL SEAL

Figure 22
52
I++!
GS0266A8
Figure 20 - Crankshaft Balancer
1. Crankshaft balancer.
2. Pry out old seal using screwdriver.
Use care to avoid damage to seal bore or seal
contact surfaces.
J 37096
37
FLYWHEEL
N40023-6AB-H-EDS
Figure 21 - Holding Flywheel using J 37096
3. Balancer using J 38197, using 1/4 inch bolts to

attach to pulley. Screw in 114 inch.
rn
Important
The balancer is serviced as an assembly. Do

not attempt to separate pulley from balancer
hub.
66 SEAL ASSEMBLY, ENGINE FRONT COVER OIL

SEAL
72 COVER ASSEMBLY, ENGINE FRONT
94 BOLT/STUD, ENGINE FRONT COVER ASSEMBLY
FS011L.38
Figure 22 - Front Cover and Oil Seal
3800 ENGINE UNIT REPAIR L36 {VIN K)
SASB-15
TIMING
MARKS
TIMING
MARKS
BALANCE SHAFT
GEAR TO
BALANCE SHAFT
DRIVE GEAR
CAMSHAFT
SPROCKET
TO CRANKSHAFT
SPROCKET
GS0306A8
Figure 24 - Balance Shaft and Camshaft Timing Marks
63 KEY, CRANKSHAFT BALANCER

78 DAMPER, TIMING CHAIN
84 SOLT, CAMSHAFT SPROCKET
85 CHAIN, TIMING
87 SPROCKET, CAMSHAFT
88 GEAR, BALANCE SHAFT DRIVE
132 KEY, CAMSHAFT
47
02-10-95
WT90NA8B
Figure 23 - Timing Chain and Sprockets
TIMING CHAIN AND SPROCKETS

Figures 23 and 24
!+-+!
1. Front cover. Refer to "Front Cover" in this

section.
2. Align timing marks on sprockets so that they are
as close together as possible.
3. Timing chain damper.
4. Camshaft sprocket bolt.
5. Camshaft sprocket and chain.
6. Crankshaft sprocket.
OIL PAN
44
47
49
GASKET, OIL PAN

PAN ASSEMBLY, OIL
SOLT /SCREW, OIL PAN ASSEMBLY
Figure 25
!++!
Figure 25 - Oil Pan
NOTICE: The oil level sensor, located in the

the oil pan. If the oil pan is removed first,
damage to the sensor may occur.
1.
2.
3.
4.
Oil
Oil
Oil
Oil
level sensor.
pan bolts.
pan.
pan gasket.
OIL PUMP SCREEN

Figure 26
!++!

the oil pan. If the oil pan is removed first,
damage to the sensor may occur.
6A8B16
33
37
'"0~
-~
"'ll).
32
33
34
GASKET, OIL PUMP SCREEN

SCREEN ASSEMBLY, OIL PUMP
BOLT /SCREW, OIL PUMP SCREEN ASSEMBLY
39
37
39
FLYWHEEL ASSEMBLY
BOLT/SCREW, FLYWHEEL ASSEMBLY
FS023L.38
Figure 28 - Flywheel
Figure 26 - Oil Pump Screen Assembly
FLYWHEEL
Figure 28
!++!
1. Flywheel bolts and discard.

2. Flywheel.

HOUSING
59
60
64
72
GEAR SET, OIL PUMP

COVER ASSEMBLY, OIL PUMP
BOLT/SCREW, OIL PUMP COVER
COVER ASSEMBLY, ENGINE FRONT
Figure 29
!++!
FS024L.38
Figure 27 - Oil Pump Gear Set
2. Oil pan and gasket.

3. Oil pump pipe screen assembly bolts.
Clean
Screen and housing with solvent and blow dry.

Gasket mating swfaces.
OIL PUMP GEAR SET

Figure 27
j++I
1. Flywheel.
2. Oil pan.
3. Rear main oil seal housing bolts. Bolts may stay
in housing bolt holes.
4. Rear main oil seal housing.

Figure 29
!++!
1. Flywheel.
2. Pry out oil seal using screwdriver.


section.
2. Oil filter adapter, pressure relief valve and spring.
3. Oil pump cover screws and cover.
4. Gears.
Figure 30
Tool Required:
J 41507 Connecting Rod Assembly Guide
l++I
1. Cylinder head.
2. Oil pump screen.
81
36

HOUSING ASSEMBLY, CRANKSHAFT REAR
OIL SEAL
BOLT/SCREW, CRANKSHAFT REAR
OIL SEAL HOUSING
36
80
81
11 PISTON ASSEMBLY
13 BEARING ASSEMBLY, CONNECTING ROD CAP
22 BOLT/SCREW, CONNECTING ROD CAP
23 CAP, CONNECTING ROD
Figure 29 - Crankshaft Rear Main Oil Seal Housing
3. Mark the connecting rod cap and rod for proper

reassembly.
4. Connecting rod bolts.
5. Connecting rod cap.
6. Install J 41507 to connecting rod.
J 41507 must be hand tightened securely to
connecting rod.
7. Using hand pressure on J 41507, push the
connecting rod assembly towards the top of the
cylinder.
rn
Figure 30 - Piston and Connecting Rod Assembly
2.
3.
4.
5.
6.
7.
8.
9.
10.
Important
Rear main oil seal housing.

Lifter guide retainer.
Front cover.
Balance shaft drive gear bolt.
Camshaft sprocket and timing chain.
Balance shaft retainer bolts, retainer and gear.
Balance shaft using J 6125-B.
Balance shaft rear bushing using J 36995-5,
J 36995-3A and J 36995-2A.
O
To avoid damage to piston ring lands be sure

to remove any carbon or ridge at the top of
the cylinder bore.
8. Piston and connecting rod assembly from top of
cylinder. Refer to "Cleaning, Inspection And
Repair" in this section for proper measurement
and replacement procedures.
BALANCE SHAFT
Figure 31
Tools Required:
J 36995 and J 36995-UPD Balance
Shaft Remover
!++!
1. Flywheel.
6A8B-17
It may take a considerable amount. of force to

loosen the bushing from the block bore.
CAMSHAFT
Figure 32
l++i
1.
2.
3.
4.
Valve lifters.
Timing chain and sprockets.
Camshaft thrust plate screws and thrust plate.
Camshaft.
6A8B-18
(
215
REMOVING REAR BUSHING
2 BOLT/SCREW, BALANCE SHAFT GEAR

4
SHAFT, BALANCE
5 PIN, BALANCE SHAFT GEAR

6 BOLT/SCREW BALANCER SHAFT GEAR
RETAINER
214 WASHER
215 NUT
REMOVING BALANCE SHAFT
Figure 31 - Removing Balance Shaft
6A8B19
CAMSHAFT BEARINGS
Figure 32
Tool Required:
J 33049 Camshaft Bearing Remover
!++!
1. Camshaft. refer to "Camshaft" in this section.

2. Rear main oil seal housing.
3. Assemble J 33049 according to manufacturer's
recommendations.
4. Camshaft bearings using J 33049.
CRANKSHAFT
Figures 33 and 34
180
Tools Required:
J 6125 - B Slide Hammer
J 41348 Main Bearing Cap Puller
!++I
1. Timing chain.
2. Oil pump screen assembly.
3. Connecting rod caps and push piston and
connecting rod assemblies to top of cylinder
bores.
NOTICE: This engine uses side bolts on all
main caps except rear cap. These bolts must be
removed to service the caps.
20 BLOCK, ENGINE
35 CRANKSHAFT
61 CAP, MAIN
179 SOLT, MAIN CAP
180 SOLT, MAIN CAP SIDE
10-27-94
C380038A8
Figure 33 - Crankshaft and Bearings
J 6125-8
J 41348
4. Side bolts and main cap bolts.
"/:'/:/]-.
1
CAMSHAFT ASSEMBLY
89 SOLT /SCREW, CAMSHAFT THRUST PLATE

90 PLATE, CAMSHAFT THRUST
132 KEY, CAMSHAFT
FS021L.31
Figure 32 - Camshaft and Bearings
04-06-96
WT9218A8B
Figure 34 - Removing Main Caps using J 41348
6A8B-20
NOTICE: Main bearing caps are press fit and

special care is required when removing the caps
for service. J 41348 has been designed to work
with J 6125-B in order to prevent damage to the
bearing and/or cap. J 41348 [MUST] be
installed properly into the bolt holes of the caps
and J 6125-B attached to it in order to properly
remove the main cap without damaging the
bearing or cap. Any deviation from this
procedure may cause damage to the cap and/or
bearing possibly resulting in future engine
damage.
5.
6.
7.
8.
Install J 41348 into main cap bolt holes.

Tighten J 41348 bolts to 100 lb. in.
Install J 6125-B to J 41348.
Using the slide hammer motion of J 6125-B,
remove main bearing cap.
NOTICE: To avoid damaging crankshaft

journals, rod or main bearing inserts, or
connecting rods, use extreme care when
removing crankshaft.
9. Crankshaft.
CLEANING, INSPECTION AND

REPAIR
A solvent tank large enough to hold the larger
engine parts will be needed, as well as various bristle
brushes and gasket scrapers. A source of compressed
air will also be helpful in the cleaning operations.
Special tools are illustrated throughout this
section, and listed at its end. These tools (or their
equivalents) are specially designed to quickly and
safely accomplish the operations for which they are
intended. These special tools, when they are properly
used, will also minimize possible damage to engine
components.
Some precision measuring tools are required for
inspection of certain critical components. These
include micrometers, torque wrenches, feeler gages,
dial indicator set, etc ..The inspection work, when
performed with the proper methods and tools., is most
important.
The rebuilt engine cannot be expected to
perform properly if part are sworn beyond acceptable
limits are reused.
CYLINDER BLOCK
!+++i
Disassemble
Cooling jacket plugs.

- Obtain a suitable self-threading screw.
- Drill a hole into the plug.
- Install the self-threading screw.
- Pry out plug.
Oil gallery screw plugs.
Camshaft bearings. Refer to "Camshaft Bearings"
in this section.
NOTICE: Caustic cleaning solution destroys

the bearing material. All bearings must be
replaced after cleaning with a caustic solution.
Do not clean bearing material or aluminum parts
with caustic solutions.
Clean
Sealing material from mating surfaces.

Boil in caustic solution.
- Flush with clean water or steam.
Oil passages.
All blind holes.
Spray or wipe cylinder bores and machined
surfaces with engine oil.
!L!
Inspect
Deck surface for flatness. Use a straight edge and

a feeler gage. Minor irregularities may be
carefully machined. If more than 0.254 mm
(0.010 inch) inust be removed, replace the block.
Oil pan rail and front cover attaching area for
nicks. Minor irregularities may be cleaned up with
a flat mill file.
Transmission case mating surface.
NOTICE: If this surface is not flat, a broken

flywheel may result.
Temporarily install the crankshaft. Measure
crankshaft flange runout (refer to "Crankshaft" in
. this section).
IL!
Inspect
Cylinder block flange surface runout at six

mounting hole bosses.
1. Hold gage plate flat against the crankshaft
flange.
2. Place dial indicator stern on the
transmission mounting bolt hole boss and
set indicator to 0.
3. Record the readings obtained on the
remaining transmission mounting bolt hole
bosses. Measurements should not vary
4. If the readings vary more than 0.254 mm

(0.010 inch), recheck crankshaft flange
runout. If the runout is excessive, replace
the crankshaft.
Threaded holes. If necessary, clean with a tap or
drill out and install thread inserts (refer to
"Thread Repair" in this section).
[I]
Important
The following
reconditioning, if
out with the main
bolts installed and
inspections as well as
necessary, must be carried
bearing caps and main side
tightened to specification.
6A8B-21
230
!VIEWA!
19
18
19
24
27
229
230
PLUG, ENGINE OIL GALLERY

PIN, ENGINE FRONT COVER
PIN, CYLINDER HEAD LOCATION HOLE
ESC
PIN, FLYWHEEL HOUSING LOCATOR
PLUG, RH ENGINE OIL GALLERY HOLE
040695
WT9106A8B
Figure 35 Cylinder Block Plugs and Pins
227
231
FEELER GAGE
STRAIGHT EDGE
N40042-6A8-H-EDS
Figure 36 - Checking Cylinder Block Flatness
M40143-6AB-C-EDS
Figure 37 Measuring Cylinder Block. Flange Surface

Runout
6A8B-22

61
MAIN BEARING CAP
8087
61
N40043-6A8-H-EDS
Figure 38 - Measuring Bearing Bore
Make sure main bearing caps are installed

correctly, with the arrows pointing toward the
front of the engine.
Bearing bores, with a bore gage, measure
concentricity and alignment
-Camshaft.
- Crankshaft.
- I f outside specification (refer to
"Specifications"), replace the block.
- If an examination of the outside of the bearing
inserts indicates minor high spots, they may be
carefully removed.
Cylinder bore for wear, taper, runout and ridging
using J 8087.
If the bore is worn beyond limits, it may be
rebored, honed and fitted with oversize pistons.
The smallest available oversize should be selected
(refer to "Piston Fitting" in this section).
rn
J 8087
Important
Leave sufficient material to allow finish

honing in conjunction with fitting the piston.
If the bore is glazed but otherwise serviceable,
break the glaze lightly with a hone and replace
the piston rings.
Make sure the honing stones are clean, sharp
and straight. Move the hone slowly up and
down to produce a cross-hatch pattern. Clean
bore thoroughly with soap and water. Dry and
rub in clean engine oil, remeasure.
!+;+I
Assemble
\\".
WMOMIA7
Figure 39 - Measuring Cylinder Bore For Taper and

Out-of-Round
Cooling jacket plugs. Apply GM approved sealer

or equivalent.
Oil gallery s~rew plug.
Camshaft bearings (refer to "Camshaft Bearings"
in this section).
!~!
Tighten
Cylinder block drain plug to 44 N.m

(32 lb. ft.).
Engine oil gallery plug to 30 N,m (22 lb. ft.).
CRANKSHAFT
Figure 33
lil
A-B=AMOUNT OF CYLINDER TAPER
WMHHA7
Figure 40 - Cylinder Wear Pattern
Clean
Oil sludge and carbon.

Probe oil passages for obstructions.
!LI
Inspect
Keyway.
Threads.

Bearing journals and thrust surfaces for:
rn
-Cracks.
-Chips.
-Gouges.
- Roughness.
-Grooves.
- Overheating (discoloration).
Important
Measure
Crankshaft journals wi.th a micrometer. Measure

for both taper and runout. If the readings are
within specifications, note the results for later
selection of bearing inserts (refer to "Connecting
Rod and Main Bearings" in this section). If the
crankshaft journals are not within the specified
tolerances the crankshaft must be replaced.
Crankshaft flange run-out. With the crankshaft
installed, place dial indicator stem just outside the
flywheel mounting bolt holes. Set indicator to 0.
Rotate crankshaft and record readings. If the
readings are not within limits, refer to "Engine
Specifications" at the end of this section, the
crankshaft must be replaced.

Figure 41
!+}!
Disassemble
1. Piston and connecting rod assembly.
1
2
3
4
5
RETAINER
PISTON
CONNECTING ROD
PIN
RETAINER GROOVE
Figure 41 - Piston Pin
CAUTION: Use care when handling the

piston. Worn piston rings are sharp and
may cause bodily injury.
2. Piston rings. Use a suitable tool to expand the
rings. Piston rings must not be reused.
3. Piston pin retaining clips.
Inspect the corresponding bearing inserts for

imbedded foreign material and determine its
source.
If cracks, severe gouges or burned spots are
found, the crankshaft must be replaced. Slight
roughness may be removed with a fine polishing
cloth soaked in clean engine oil. Burrs may be
removed with a fine oil stone.
!@!
6A8B-23
M40302-6A8-C-EDS
The piston pins used are held in place by two

(2) retainers. No special tools are required to
remove or install the retainers or piston pin.
The retainers may be reused if they are not
damaged. Make sure that the piston pin hole is
not damaged.
4. Piston pin.
Clean
CAUTION: Avoid inhaling fumes or

exposure of the skin to carburetor
cleaning fluid, as bodily injury may
result.
Piston, piston pin and connecting rod.
-Sludge.
-Carbon.
- It is essential that the piston ring grooves are
cleaned of carbon to the bare metal.
Use proper ring cleaning tools to avoid damage to
the piston ring lands.
- Varnish from the piston pin by soaking in
c~buretor cleaning solution.
- Do not scrape the piston skirt.
!L"'!
Inspect ',
1. Connecting rod for:

Bending.
1\visting.
- Install the connecting rod cap and tighten
to specifications.
- Place the connecting rod assembly on a
checking fixture and check for bending or
twisting.
- If the connecting rod is bent more than
0.127 mm (0.005 inch) measured over the
entire length of the connecting rod, it must
be replaced.
- If the connecting rod is twisted more than
0.254 mm (.010 inch) measured over the
entire length of the connecting rod, it must
be replaced.
Do not attempt to straighten any connecting
rod. Always check new connecting rods before
using them.
Outside of the connecting rod bearing and the
inside diameter of the connecting rod lower
end for wear indicating high spots in the
connecting rod lower end.
Connecting rod bolts for stretching by
comparing them with a new bolt.
Upper end for scoring.
6A8B-24
2. Piston pin for:

Scoring.
Galling caused by improper installation.
Fit in connecting rod and piston.
3. Piston for:
Scoring of the skirt.
Cracks.
Broken ring groove lands.
Wear.
PISTON FITTING
Figure 42
(II
Important
When fitting pistons, both piston and cylinder

bore condition must be considered together.
Production and service pistons. have the same
nominal weight and can be intermixed without
affecting engine balance. If necessary, used
pistons may be fitted selectively to any cylinder
of the engine, providing they are in good
condition.
!t!ll!
C. Subtract piston diameter from cylinder bore
diameter to determine piston-to-bore clearance.

D. Compare piston-to-bore clearance obtained
with specifications.
E. Determine if piston-to-bore clearance is in
acceptable range.
If a used piston is not acceptable, check service
piston sizes and determine if a new piston can be
selected. Service pistons are available in standard
and 0.508 mm (0.020 inch) oversize.
. If cylinder bore must be reconditioned, .measure
new piston diameter then hone cylinder bore to
obtain preferable clearance.
Select new piston and mark piston to identify the

cylinder for which. it was fitted. (On some engines
oversize piston& may be found. These pistons will
be 0.020 inch. oversize.).
Clean
Scrub the cylinder bore and the piston with soap

and water and remove all foreign material. Dry
and rub in clean engine oil.
PISTON RING FITIING

Figures 43 and 44
Measure
1. Piston. If worn or damaged, replace with a

standard or oversize piston.
2. Cylinder bore, refer to "Cylinder Block". If worn
beyond specifications (refer to "Specifications" at
the end of this section), rebore and hone to size.
A. Select a piston.
B. Hone the cylinder bore to obtain the
recommended clearance.
C. Scrub the cylinder bore and the piston with
soap and water and remove all foreign
material. Dry and rub in clean engine oil.
3. Check piston to cylinder bore clearance as
follows:
A. Measure the cylinder bore diameter with a
telescope gage.
B. Measure the piston diameter.
Select a set of new piston rings.

Piston ring end gap.
--'-- Place piston into the cylinder at the bottom
of the ring travel.
- Place a piston ring on top of the piston.
- Back off the piston.
- Measure the ring gap. If the gap is below
specification increase the gap by carefully
filing off excess material.
Piston ring side clearance (compression rings).
NOTICE: Do not attempt to cut the ring

groove with a file or other rough edged tool.
Ring groove straightness and smoothness is very
important to maintain good performance and
durability.
-MEASURE PISTON
44 MM FROM
TOP OF PISTON
10 RING
227 FEELER GAGE

M40050-6A7-W-EDS
Figure 42 - Measuring Piston
N40038-6A6-H-ED~
Figure 43 - Measuring Piston Ring Gap
6A8B25
!u! Install or Connect

INSERT FEELER GAGE AT TOP
OF RING GROOVE TO MEASURE
RING SIDE CLEARANCE.
NOTICE: Use a piston ring expander to install

the rings. Avoid expanding the rings more than
necessary, which may cause ring damage.
1. Oil control ring assembly.
-Expander.
- Lower oil control ring.
- Upper oil control ring.
2. Upper and lower compression ring. Manufacturers
mark facing up.
MAIN AND ROD BEARINGS

M40053-6A7-W-EOS
Figure 44 - Measuring Piston Ring Side Clearance
- Roll the piston ring around the groove in

which it is to be installed and measure the
side clearance. If the ring is too tight,
check for nicks or burrs in groove or on
ring. Burrs may be removed using emery
paper. If no cause can be found, determine
if the ring is within specification and
replace the ring or the piston as necessary.
CONNECTING ROD AND PISTON

Figure 30
!+;+!
Assemble
Connecting rod and piston .
rn
Important
The piston may be installed on the connecting

rod in either direction.
Piston Pin and Retainer
!+4-1
Install or Connect
1. Coat the piston pin with oil.

2. One piston pin retainer by starting one side of
retainer in retaining groove and rotating retainer
until it is fully seated in groove.
NOTICE: Ensure that piston pin retainers are

properly installed in the retaining groove during
assembly. Failure to do so may cause engine
damage.
3. Connecting rod and piston pin. Push piston pin
until it bottoms on previously installed retainer.
4. Second piston pin retainer.
!L!
Inspect
Piston for freedom of movement.
Figure 45
11]
Important
Engine bearings are of the precision insert type.

They are available for service use in standard and
0.001 inch undersize.
NOTICE: Bearing inserts must not be

shimmed, scraped or filed. Do not touch the
bearing surface of the insert with the bare
fingers. Skin oil and acids will etch the bearing
surface.
!L!
Inspect
1. Bearing surfaces for:

Wear.
Gouges.
Embedded foreign material. If foreign material
is found, determine its nature and source.
Inspect oil pan sludge and residue.
Uneven side to side wear. If uneven wear is
found, check for a bent crankshaft or tapered
bearing journals.
.............
AMOUNT
UNDERSIZE
STAMPED AT
THIS END
(.0005,etc.)
OR ON TANG
WITH A
LETIER
STAMP,
A=.0005,
B=.0010,
C=.0015.
M40056-SA7-W-EDS
Fi,gure 45 - Bearing Inserts
6A8B-26
2. Outer surfaces for:

Wear. Surface wear indicates either movement
of the insert or high spots in the surrounding
material (spot wear).
Overheating (discoloration).
Looseness or rotation (flattened tangs and wear
grooves).
3. Thrust surfaces (main thrust bearing) for:
Wear
Grooving. Grooves are caused by irregularities
of the crankshaft thrust surface. Refer to
"Crankshaft" in this section.
4. Connecting rods or main bearing bores for:
rn
Important
Bearing failure, other than normal wear, must

be investigated carefully. Inspect the crankshaft
or connecting rod and the bearing bores.
Measure the bore for taper and out of round.
Neither condition should exist.
To inspect connecting rods or main bearing
bores:
Tighten the bearing cap to specifications
using the following sequence:
fastener. Do not use a bolt that is stronger in
!~I
Tighten
Start main bolts by hand. Make sure bottom of

cap is parallel to bottom of channel. Tighten
all caps in equal increments. Do not tighten
one cap completely at a time. Tighten bolts to
70 N.m to fully seat caps. Loosen bolts 360
CCW, Then: tighten bolts to 20 N.m ,then 40
N.m . Using J 36660, tighten bolts in steps:
35 + 35 + 40 for a total of 110.
5. Side main bolts.
!~I
Tighten
Side main bolts to 15 N.m (11 lb. ft.) + 45

using J 36660
Measure the bore for taper and out of round.
No taper or out of round should exist.
6. Inspect bearing cap bolts. If bolts are stretched,
replace them.
" To determine if a bolt is stretched, compare it
to a new bolt.
MEASURING BEARING CLEARANCE
rn
Important
To determine the correct replacement insert size,

the bearing clearance must be measured
accurately. Either of the following two methods
may be used: however, Method "A" gives more
reliable results and is .preferred.
Method "A" yields measurements from which
the bearing clearance can be computed.
Method "B" yields the bearing clearance
directly. Method "B" does not give any
indication of bearing or journal runout.
Method "A"
1. Measure the crankshaft journal diameter with a

micrometer in. several places, approximately 90
apart, and average the measurements.
2. With the bearing inserts installed in the correct

bore (cylinder block or connecting rod) and
tightened to specification, measure the bearing
insert ID with an inside micrometer. Measure
using new inserts if the inserts are being replaced.
3. If the readings are within limits, select a suitable
set of inserts. Bearing sets are available in
standard and undersize in order td keep clearances
within limits. If clearances cannot be brought into
specifications with selectively fitting bearings, the
crankshaft should be replaced.
Method "B"
1. Install all bearing inserts and crankshaft into

block.
2. Place a piece of gaging plastic across the entire
bearing width.
[I]
Important
Do not rotate the crankshaft.

NOTICE: In order to prevent the possibility of
cylinder block and/or main bearing cap damage,
the main bearing caps are not to be tapped into
their cylinder block cavity using a brass, lead or
leather mallet. Use the two attaching bolts to
pull main bearing caps into their seats by using
an alternating installation sequence that will
help to install them evenly. Failure to observe
this information may damage a. cylinder block
or bearing cap.
3. Tighten bearing cap bolts to specification using

the following sequence:
!~I
6A8B-27
Tighten

35 + 35 + 40 for a total of 110.
4. Side main bolts.
!~i
42
Tighten
Side main bolts to 15 N,m (11 lb. ft.) + 45

using J 36660
5. Remove the bearing cap, leaving the gaging
plastic in place. It does not matter whether the
gaging plastic adheres to the journal or to the
bearing cap.
6. Measure the flattened gaging plastic at its widest
point with the scale printed on the gaging plastic
package.
7. Remove all traces of the gaging plastic after
measuring.
I!!]
Install or Connect
42 THRUST BEARING
227 FEELER GAGE
N40039-6A8-H-EDS
Figure 47 - Measuring Crankshaft End Play
[I]
Make sure the bearing cap bolt holes and the cap
mating surfaces are clean and dry.
1. Dip bearing cap bolts in clean engine oil.
2. Place inserts into the bearing cap and into the
engine block or connecting rod.
The inserts will project slightly when put into
place. Make sure they project an equal
distance on both sides. Make sure the insert
tangs are engaged.
BEARING INSTALLATION
Tool Required:
J 41507 Connecting Rod Assembly Guide
l++i
Important
rn
Install or Connect
3.
NOTICE:
Bearing inserts must not be

shimmed, scraped or filed. Do not touch the
bearing surface of the insert with the bare
fingers. Skin oil and acids will etch the bearing
surface.
4.
5.
6.
7.
8.
9.
10.
M40057-6A7-W-EDS
Figure 46 - Seating the Crankshaft Thrust Bearing
Important
Upper and lower inserts may be different. Do

not obstruct any oil passages.
In case of a thrust bearing type main bearing
insert, coat the thrust surface with lubricant GM
Lubricate the bearing surface with clean engine
oil.
Position crankshaft to the location of the
connecting rod being installed. This will aid in
installation of connecting rod assembly.
Install J 41507 to connecting rod and J 8037 to
piston.
J 41507 must be hand tightened securely to
connecting rod.
Install assembly through top of cylinder by
tapping lightly on top of piston using a hammer
handle. Make sure that J 41507 is properly
positioned over crankshaft.
Pull the connecting rod assembly into place using
J 41507.
.
Remove J 41507.
Bearing cap.
6A8B-28

BALANCE SHAFT
IL"'!
Inspect
The balance shaft, front bearing and reaf bushing

are serviced as an assembly.
Inspect the balance shaft drive gear and the
camshaft drive gear for nicks and burrs.
IL"'!
12
227
CONNECTING ROD
FEELER GAGE
N40040-6A8-H-EDS

pull main bearing caps into their seats by using
an alternating installation sequence that will
help to install them evenly. Failure to observe
this information may damage a cylinder block
or bearing cap.
Inspect
All components for wear and/or damage.

- Timing chain for overall "in and out"
movement. Should not exceed 25 inm (one
inch).
- Sprockets .for wear.
CYLINDER. HEAD
[I]
Important
During disassembly, be sure that the valve train

components are kept together and identified so
that they can be reinstalled in their original
locations and with the same mating surfaces as
when removed.
Valve Stem Oil Seal
11. Bearing cap bolts.
l~I
Tighten
Bolts to 27 N.m (22 lb. ft.) + 50 using

J 36660.
12. Seat the crankshaft thrust bearing by tapping
crankshaft in both directions with a wooden
mallet.
!L!
Inspect
Pry the connecting rods back and forth and check

for binding. If necessary, loosen and retighten the
bearing cap.
!~i
Measure
Crankshaft end play.

FLYWHEEL
IL"'I
Inspect
Flywheel, if cracked, badly worn or broken teeth,

replace flywheel.
Crankshaft and flywheel mating surfaces for burrs.
Remove as required.
Figure 49
!{+!
1.
2.
3.
4.
5.
ll"'!
Disassemble
Tool Required:
J 38606 Valve Spring Compressor
Cylinder head. Refer to "Cylinder Head" in this
section.
Compress valve spring using J 38606.
Valve keys.
Valve cap and spring.
Valve stem oil seal by prying up on bottom of
seal using a suitable tool.
Inspect
Cylinder head gasket and mating surfaces for

leaks, corrosion and blow by. If the gasket has
failed, determine the cause:
- Improper installation.
- Loose or warped cylinder head.
- Missing dowel pins.
Clean
Cylinder head. Remove all varnish, soot and

carbon to the bare metal. [DO NOT] use a
motorized wire brush on any gasket sealing
surface.
Threaded holes.
Remains of sealer from plug holes.
6A8B-29
J 41512
139
144
137
021195
WTl128A88
134
135
136
137
139
144
KEY, VALVE STEM

CAP, VAL VE SPRING
SPRING, VAL VE STEM
VALVE
HEAD, CYLINDER
Figure 51 Checking Cylinder Head Resurfacing

Dimension
ll"'l
040895
HTl138A8B
1. Cylinder head for cracks, especially between valve

seats, and in the exhaust ports.
2. Cylinder head deck for corrosion.
Figure 49 Cylinder Head Disassembled
3.
4.
5.
021095
WTt118A88
Figure 50 - Checking Cylinder Head Flatness
Inspect
6.
7.
Do not attempt to weld the cylinder head,
replace it.
Cylinder head deck, intake and exhaust manifold
mating surfaces for flatness;
These surfaces may be reconditioned by parallel
grinding. if more than. 0.254 mm (0.010 inch)
must be removed, replace the head.
To determine if the cylinder head has sufficient
deck . surface thickness for resurfacing, measure
the height from the deck surface to the cast pads.
New cylinder heads will measure from 1.372 1.676 min (0.054 - 0.066 inch). The minimum
dimension allowed after resurfacing is 1.118 mm
(0.044 inch). If the cylinder head does not meet
the minimum thickness after resurfacing, replace
the cylinder head.
All threaded holes for damage. Repair as needed.
Seating surfaces.
Cooling jacket plugs.

8. Clean and inspect valve guides for wear.
6A8B-30
(
205
206
207
208
M40026-6A7-W-EDS
Figure 54 - Reaming Valve Guide
NEW VALVE
204 VALVE TIP
WORN VALVE
207 STEM-MOST WORN
SECTION
FACE
205 KEY GROOVE
208
206 STEM-LEAST WORN
209 MARGIN
SECTION
NOT MORE THAN

1/16" VARIANCE
WHILE ROTATING
SPRING
HN0211A8
Figure 52 - Valve Wear
Figure 55 - Checking Valve Springs
J 8001
1
VALVEMOVE STEM IN GUIDE AND NOTE

CLEARANCE WITH VALVE OFF OF
VALVE SEAT
M40026-6A7-W-EOS
02-10-es
WTl1HA8B
Figure 53 Measuring Valve Guide Clearance
Figure 56 - Checking Valve Spring Load
3800 ENGINE UNIT REPAIR 1t'.36 {VIN K)
6A8B-31
9. Valve seats for excessive wear and burned spots.

Valve seats may be reconditioned by grinding.
An oscillating type valve seat grinder is
preferred. Follow the grinder manufacturer's
instructions. If, after grinding, the new seat is
too wide, it may be narrowed by using a 20
or 70 stone. The 20 stone will lower the seat
and the 70 stone will raise the seat. If the
seats are reconditioned, the valves also must
be reconditioned or replaced. Refer to "Valve
Springs and Caps" in this section.
!+!+I
Assemble
1. Cooling jacket plugs, if removed. Coat plugs with
GM approved sealer or equivalent.

2. Valve and spring mechanism.
Valves, Springs and Caps
Tool Required:
J 5830-2 Valve Guide Reamer Set
NOTICE: Avoid breaking the valve guide. If

the valve stem has mushroomed due to rocker
arm wear or there are burrs at the key groove,
remove burrs by chamfering the valve stem with
an oil stone or file. Do not remove the valve
from the guide using a hammer and drift punch.
CAUTION: Safety glasses must be wom
when using a power wire brush. Avoid
inhaling of fumes and exposure of skin to
carburetor cleaning fluid, as bodily injury
may result.
1. Clean valves of carbon, oil and varnish. Carbon
can be removed with a wire brush, varnish by
soaking in carburetor cleaning fluid.
Do not scratch the valve stem with the wire
brush.
2. Clean valve guides using suitable tools.
iL"!
Inspect
Valve stem tip for wear. The valve stem tip may
be reconditioned by grinding.
Follow the grinder manufacturer's instructions.
Make sure the new surface is perpendicular to the
valve stem.
Valve (key) for chipped or worn lands. Replace
the valve if chipped or worn or severely burned at
the key groove.
Valve face for burning or cracking. If pieces are
broken off, inspect the corresponding piston and
cylinder head area for damage.
Valve stem for burrs and scratches. Burrs and
minor scratches may be removed with an oil
stone.
Valve stem for straightness and valve head for
bending or distortion. Use "V" blocks. Bent or
distorted valves must be replaced.
GS0316AS
Figure 57 Measuring Valve Spring Installed Height
Valve face for grooving. If the groove is so deep

that refacing would result in a knife edge
(destroying the margin), the valve must be
replaced.
Measure valve margin after grinding valves. If the
margin is less than the minimum recommended
margin, replace the valve.
!@I
Measure
Insert the valve into its guide. Lift it 2 mm (1/8

inch) off the seat and move it side to side
(towards intake and exhaust manifold flanges),
measuring the amount of movement with a dial
indicator.
rn
Important
Clean the valve guide before reaming. To avoid

breaking reamer flutes do not push down on the
reamer. Clean and lubricate the reamer often
during use.
IL'I'!
Inspect
Valve springs.
- Expanded height.
- Spring ends. If they are not parallel, the spring
is bent and must be replaced.
- Spring load. If below specification (refer to
"Specifications" at the end of this section),
replace.
Valve spring seating surface of the spring retainers
for wear or gouging. Replace as required.
6A8B-32
j+!+j
Assemble
1. Valves. Valves are available for service in two

sizes, standard and 0.010 inch oversize.
Valve run out. Place valve in guide, lift the
valve off its seat and apply a dab of Prussian
blue on the valve face. Seat the valve and
carefully rotate it. The Prussian blue traces
transferred to the valve seat are an indication
of concentricity of the .valve seat. Clean all
traces of Prussian blue. Apply a dab of
Prussian blue on the valve seat and repeat the
check. The traces of Prussian blue transferred
to the valve face indicates valve run out.
Recondition valve seat/face or replace valves
as required. Be sure to measure valve margin
after refacing any valve. Replace any valve
that is less than the specified minimum.
2. Place oil seal over stem just so seal begins to
contact the valve guide.
NOTICE: Use hand pressure only when

installing valve stem seal using J 41512. Using
too much force may cause dai;nage to the oil
seal and possibly lead to excessive oil
consumption.
3. Push the valve stem seal over the valve guide
using J 41512.
4. Valve spring and cap using J 38606.
5. Valve keys.
6. Cylinder head. Refer to "Cylinder Head" in this
section.
VALVE STEM HEIGHT

1. Place the valve in its guide and hold it in the
closed position.
2. With a steel machinists rule, measure from the
machined spring seat to the valve tip.
3. The measurement should be 49 - 50 mm
(1.93 - 1.97 inch).
VALVE SPRING INSTALLED HEIGHT

Figure 57
i@!
Measure
Valve spring installed height. Excessive valve

spring installed height is caused by the lowering
of the valve seat by wear and grinding and valve
face grinding during reconditioning. To correct the
valve spring installed height, add shims under the
valve spring.
1. Place the valve in the guide.
2. Install valve spring cap pulley and key.
3. Pull up on the valve spring retainer to seat it.
4. With a steel machinists rule or other suitable
measuring device, measure the distance from the
machined spring seat to the spring side of the cap.
5. The measurement should be 42 - 44 mm
(1.69 - 1.75 inch). If not within specifications, add
shims under the valve spring as required.
VALVE LIFTER DIAGNOSIS
1. [Momentarily Noisy When Vehicle is Siarted:]

This condition is normal. Oil drains from the
lifters which are holding the valves open when the
engine is not running. It will take a few/ seconds
for the lifter to fill after the engine is started.
2. [Intermittently Noisy On Idle Only, Dis.~ppearing
When Engine Speed is Increased:] I#termittent
clicking may be an indication of a pitted check
valve ball, or it may be caused1 by dirt.
Correction: Replace faulty lifter.
3. [Noisy At Slow Idle Or With Hot Oil, 1 Quiet With
Cold Oil Or As Engine Speed Is Increased:] High
leak down rate. Replace suspect lifter,
4. [Noisy At High Vehicle Speeds And Quiet At
Low Speeds:]
High oil level - Oil level above the Full mark
allows crankshaft counterweights to churn the
oil into foam. When foam is pumped into the
lifters, they will become noisy since a solid
column of oil is required for proper operation.
Correction: Drain oil until proper level is
obtained. Refer to MAINTENANCE AND
LUBRICATION (SECTION OB).
Low oil level - Oil level below the operating
range allows the pump to pump air at high
speeds which results in noisy lifters.
Correction: Fill until proper oil level is
obtained. Refer to MAINTENANCE AND
LUBRICATION (SECTION OB).
Oil pan bent on bottom or pump screen cocked
or loose. Correction.: Repair or replace parts as
necessary.
5. [Noisy At Idle Becoming Louder As Engine
Speed Is Increased To 1500 rpm:] This noise is
not connected with lifter malfunction. It becomes
most noticeable in the vehicle at 10 to 15 mph
"1" (Low) range, or 30 to 35 mph "D" (Drive)
range and is best described as a hashy sound. At
slow idle, it may be entirely gone or appear as a
light ticking noise in one or more valves. It is
caused by one or more of the following:
Badly worn or scuffed valve tip and rocker
arm pad.
Excessive valve stem to guide clearance.
Excessive valve seat runout.
Off square valve spring.
Excessive valve face runout.
Valve spring damper clicking on rotator. To
check valve spring and guide clearance,
remove the rocker arm covers.
- Occasionally this noise can be eliminated
by rotating the valve spring and valve.
Crank engine until noisy valve is off its
seat. Rotate spring. This will also rotate
valve. Repeat until valve becomes quiet. If
correction is obtained, check for an off
square valve spring. If spring is off square
more than 1/ 16 inch in free position,
replace spring.
- Check for excessive valve stem to guide
clearance. Correct as required.

6. Valves Noisy Regardless Of Engine Speed:. This
condition can be caused by foreign particles or
excessive valve lash. Check for valve lash by
turning engine so the piston in that cylinder is on
top dead center of firing stroke. If valve lash is
present, the pushrod can be freely moved up and
down a certain amount with rocker arm held
against valve. If lash exists, replace suspected
valve lifters. Valve lash indicates one of the
following:
Worn pushrod.
Worn rocker arm.
Lifter plunger stuck in down position due to
dirt or carbon.
Faulty lifter.
Checking of the above four items:
1. Look at the upper end of pushrod. Excessive wear
of the spherical surface indicates one of the
following conditions.
Improper hardness of the pushrod ball. The
pushrod and rocker arm must be replaced.
Improper lubrication of the pushrod. The
pushrod and rocker arm must be replaced.
The oiling system to the pushrod should be
checked.
2. If pushrod appears in good condition and has been
properly lubricated, replace rocker arm and
recheck valve lash.
3. If valve lash exists and pushrod and rocker arm
are OK, trouble is in the lifter. Lifter should be
replaced.
O
!@!
SASB-33
Measure
Oil pump gears for:

- Inner gear tip clearance.
- Outer gear diameter clearance.
- Gear end clearance (gear drop in housing).
Pressure regulator valve for:
-
jHI
1.
2.
3.
4.
Valve to bore clearance.
Install or Connect
Lubricate gears with petroleum jelly.
Assemble gears in housing.
Pack gear cavity with petroleum jelly.
Oil pump cover and screws.
l~I
Tighten
e Screws to 11 N.m (98 lb. in.).

5. Pressure regulator spring and valve.
OIL PUMP UNIT REPAIR

Clean
All parts in a suitable solvent. Remove all
varnish, sludge and dirt.
Remove all traces of old gasket from front cover
and engine block.
!L"'I
GS0326!\6
Inspect
Pump cover and front cover for:

-Cracks.
- Scoring.
- Porous or damaged casting.
- Damaged threads.
- Excessive wear.
Pressure regulator valve for:
- Scoring.
- Sticking in bore.
- Burrs.
- Foreign material.
Pressure regulator spring for:
- Loss of tension.
- Bent condition. -if in doubt, replace the spring.
Oil pump gears for:
- Chipping.
- Galling.
- Scoring.
- Excessive wear.
Figure 58 - Measuring Gear Tip Clearance
GS03J6AB
Figure 59 - Measuring Outer Gear Diameter Clearance
6A8B-34
ASSEMBLY
PRIOR TO ASSEMBLY
The importance of cleanliness during assembly
procedures cannot be overstressed. Dirt will cause
1
premature wear of the rebuilt engine.
Lubricate all moving parts lightly with engine oil
or engine assembly lubricant (unless specified
otherwise) during assembly. This will provide initial
lubrication when the engine is started.
CRANKSHAFT
Figure 33
Tool Required:
GSOJ46A8
Figure 60 - Measuring Gear End Clearance

(Gear Drop in Housing)
6. Oil filter adapter with a new gasket.
l~I
Tighten
Bolts to 30 N.m (22 lb. ft.).

7. Front cover.
O
THREAD REPAIR
!Hi
Install or Connect
NOTICE: Number 4 main bearing cap must

be installed flush with torque converter bolt
heads or 0.254 mm (0.010 in.) forward of rear
face of cylinder block to avoid interference with
flywheel.
1. Crankshaft.
Figure 61
CAUTION: Wear safety glasses to avoid
eye damage.
Damaged threads may be reconditioned by drilling
out, rethreading and installing a suitable thread
insert. General purpose thread repair kits are
available commercially. J 33425 is recommended
for spark plug threads.
Determine size, pitch and depth of damaged
tool and tap to the required depth.
Refer to the kit manufacturer's instructions
regarding the size of drill and tap to be used.

pull each main bearing caps into their seats by
using an alternating installation sequence that
will help to install them evenly. Failure to
observe this information may damage a cylinder
block or bearing cap.
2. Main bearing caps. Use GM approved sealer at
Number 4 main bearing cap to block surface.
A
DRILL HOLE TO
PROPER SIZE
TAP HOLE TO
PROPER SIZE
D
INSTALL INSERT
ON MANDREL
INSTALL INSERT
INTO NEWLY
THREADED HOLE
td40066-6A7.,-w-EDS
Figure 61 Repairing Threaded Holes

3. Main bearing cap bolts.
!~!
Tighten

35 + 35 + 40 for a total of 110.
4. Side main bolts.
!~!
!~l
4. Remove J 36995 assembly.

5. Dip the front balance shaft bearing into clean
engine oil before installation.
6. Balance shaft into block using J 36996 and
J 21465-13.
7. Temporarily install balance shaft bearing retainer
and bolts.
8. Balance shaft drive gear and bolt.

!~i
Tighten
Side main bolts to 15 N.m (11 lb. ft.) + 45

using J 36660.
5. Connecting rod bearing inserts.
6. Connecting rod cap bolts.
9.
10.
11.
Tighten

J 36660.
7. Oil pump screen.
8. Timing chain.
12.
13.
BALANCE SHAFT
Figures 62 and 63
Tools Required:
J 8001 Dial Indicator
.J 21465-13 Drive Handle Extension
J 36995 and J 36995 UPD Balance Shaft
Bushing Installer
J 36996 Balance Shaft Installer
!H!
Install ~r Connect
1. Make sure rear main oil seal housing gasket is

removed and no debris remains.
2. Dip bushing in clean engine oil before installation.
3. Balance shaft rear bushing using J 36995-2A,
J 36995-3A, J 36995-1, and J 36995-8.
J 36995-8 assures that the rear bushing is
installed in the engine block to the correct

depth. The bushing will be installed properly
when J 36995-8 and J 36995-1 fully contact
the balance shaft bore or the cylinder
block/transaxle mounting flange.
6A8B-35
14.
15.
16.
17.
18.
Bolt to 22 N.m (16 lb. ft.) + 70 using

J 36660.
Rear main oil seal housing. Refer to "Crankshaft
Rear Main Oil Seal Housing" in this section.
Measure balance shaft end play. Refer to
"Specifications" at .the end of this section.
Measure balance shaft radial play at both the front
and rear. Refer to "Specifications" at the end of
this section.
Turn the camshaft so that with the camshaft
sprocket temporarily installed, timing mark is
straight down;
With the camshaft sprocket and the camshaft gear
removed, turn the balance shaft so that the timing
mark on the gear points are straight down.
Camshaft gear.
Align the marks on the balance shaft gear and
the camshaft gear by turning the balance shaft.
Tum the crankshaft so that number one piston is
at top dead center (TDC).
Timing chain and camshaft sprocket.
Measure gear lash at four places, every 1/4 turn.
Refer to "Specifications" at the end of this
section.
Balance shaft front bearing retainer and bolts.
l~I
19.
20.
21.
22.
Tighten
Tighten
Bolt to 30 N.m (22 lb. ft.).

Front cover.
Lifter guide retainer.
Flywheel.
6A8B36
J 36995-2A
J 36995-3A
J 36995-8
J 36995-1
INSTALLING REAR BUSHING
J .36996
2
3
4
5
6
BOLT/SCREW, BALANCE SHAFT GEAR

GEAR, BALANCE SHAFT
SHAFT, BALANCE
PIN, BALANCE SHAFT GEAR
BOLT/SCREW BALANCER SHAFT GEAR
RETAINER
INSTALLING BALANCE SHAFT
Figure 62 - Balance Shaft Installation
FIOl3L38
c:::;($
6A8B-37
MEASURING REAR RADIAL PLAY
MEASURING END PLAY
MEASURING GEAR LASH
MEASURING FRONT RADIAL PLAY
M40043-6A7-W-EDS
Figure 63 - Measuring Balance Shaft Clearances
CAMSHAFT BEARINGS
CAMSHAFT
Figure 32
Figure 32
Tool Required:
J 33049 Camshaft Bearing Installer
!-++I
!++I
Install or Connect
1; Camshaft.
Install or Connect
1. Select and install front, rear and intermediate

camshaft bearings.
A. Assemble J 33049 according to manufacturer's
recommendations.
B. Place bearing on tool.
C. Index bearing oil holes with cylinder block oil
passages.
2. Rear main oil seal housing. Refer to "Crankshaft
Rear Main Oil Seal Housing" in this section.
3. Camshaft.
Coat the camshaft with prelube GM

PIN 12345507 or equivalent before installation.
2. Camshaft .thrust plate and screws.
!~I
Tighten
Screws to 15 N,m (11 lb. ft.).

3. Timing chain and sprockets. .
4. Valve lifters.
Dip the valve lifters in prelube GM
6A8B38
11
PISTON ASSEMBLY
FS018L38
Figure 64 - Piston Installation Direction

Tools Required:
!++!
11
PISTON
03-31-85
HT9146A88
Install or Connect
Figure 65 - Connecting Rod Guide Assembly Tool J 41507
1. Piston rings to piston.
2.
3.
4.
5.
In order to provide an effective compression

seal, the ring gaps must be staggered.
Turn crankshaft to bottom dead center.
Lubricate cylinder with oil.
Connecting rod bearing.
Piston and connecting rod assembly using J 8037.
Ridge(s) toward front of engine.
NOTICE: Guide the lower connecting rod end

carefully to avoid damaging the crankshaft
journal.
6. Connecting rod cap and bolts.
!~I Tighten
Connecting rod bolts to 27 N.m (20 lb. ft.) +
50 using J 36660.
7. Oil pump screen assembly.
8. Cylinder head.
226 RING COMPRESSOR

N40037-6A8-H-EOS
Figure 66 - Installing Piston Using J 8037
6A8B-39
231
80
81
HOUSING ASSEMBLY, CRANKSHAFT REAR

OIL SEAL
BOLT/SCREW, CRANKSHAFT REAR OIL
SEAL HOUSING ASSEMBLY
80
FS030L38
Figure 67 - Crankshaft Rear Main Oil Seal Housing

HOUSING
Figures 67 and 68
Tools Required:
J 41349 Crankshaft Rear Main Oil Seal
Housing Aligning Tool
l++!
Install or Connect
1. Make sure oil seal is removed from housing.

2. Clean gasket from housing.
3. Gasket over housing bolts to aid in proper
alignment of gasket.
NOTICE: Correct alignment of housing is

crucial to sealability of rear main and oil pan.
Take care when installing housing to assure
alignment to crankshaft centerline during
installation of the housing. Failure to follow
these procedures may result in oil leaks.
4. Housing and finger tighten all bolts (loose enough
to adjust housing) to hold housing in place. Make
sure gasket is not higher than the housing.
Plastic inserts in housing assembly are used as
an assembly aid only and are not required for
service.
227
231
HOUSING ASSEMBLY, CRANKSHAFT

REAR MAIN OIL SEAL
FEELER GAGE
STRAIGHT EDGE
Figure 68 - Crankshaft Rear Main Oil Seal Aligning Tool
5. Wipe a thin film of oil on both sides of J 41439

to aid in installation and removal from crankshaft.
Install J 41349 over crankshaft. Twisting or
turning J 41349 aids in sliding it completely over
the crankshaft.
6. Place a straight edge on the cylinder block oil pan
flange and the housing flange. Use a feeler gage
to make sure there is no more than 0.004 inch
step (high or low) on each side. Rotate the
housing to get the step equal on each side, if
necessary. If the housing can not be rotated to get
step within specification, replace with a new
housing.
7. Tighten all housing bolts to specification.
!~!
8.
9.
10.
11.
12.
Tighten

J 36660.
Remove J 41349.
Recheck step height on each side to make sure
housing did not move while tightening bolts. If
step height is beyond specification, repeat steps
4-8 and measure again. If excessive clearance is
still present replace housing.
Install rear main oil seal. Refer to "Crankshaft
Rear Main Oil Seal" in this section.
Oil pan and bolts.
Flywheel.
6ASB-40 3800 ENGINE UNIT REPAIR l36 (VIN K)
SPRING SIDE
SEAL BORE TO SEAL SURFACE

TO BE LUBRICATED WITH ENGINE
OIL BEFORE ASSEMBLY
SEAL BORE TO SEAL SURFACE

TO BE LUBRICATED WITH ENGINE
OIL BEFORE ASSEMBLY
P40007-6A8-E-EDS
Figure 69 - Rear Main Oil Seal Installing Tool
Figure 70 - Installing Rear Main Oil Seal
CRANKSHAFT REAR MAIN Oil SEAL
OIL PUMP SCREEN
Figures 69 and 70
Figure 26
Tool Required:
lHI
Install or Connect
1. Apply engine oil to ID and OD of new oil seal.

Slide new seal over mandrel until back of seal
bottoms squarely against collar of J 38196.
2. Seal.
A. Attach J 38196 to crankshaft by hand, or
tighten attaching screws to 5 N.m (54 lb. in.).
B. Turn T-handle of J 38196 so that collar pushes
seal into bore, turn the handle until the collar
is tight against the case. This .will ensure the
seal is seated properly.
C. Loosen the T-handle of J 38196 until it comes
to a stop. This will ensure that the collar will
be in the proper position for installing another
new seal.
D. Remove attaching screws.
3. Flywheel.
FLYWHEEL
Figure 28
Tool Required:
!H!
Install or Connect
1. Flywheel.
2. "NEW" bolts.
!~I
Tighten
"NEW" bolts to 15 N.m (11 lb. ft.) + 50

using J 36660.
iH!
Install or Connect
1. Oil pump screen with new gasket.
l~I
Tighten

2. Oil pan.

been installed. If the oil level sensor is installed
first, damage to the sensor may occur.
3. Oil level sensor
Oil PAN
Figure 25
l++I
Install or Connect
1. Oil pan gasket to oil pan flange.

2. Oil pan.
l~I
Tighten
Bolts to 14 N.m (125 lb. in.).

been installed. If the oil level sensor is installed
first, damage to the sensor may occur.

FRONT COVER
Figures 23 and 24
Figure 22
Tool Required:
Tool Required:
!H!
1.
2.
3.
4.
5.
Install or Connect
If the pistons have not been moved in the
engine, go to Step 3, otherwise Step 1.
If the balance shaft timing has been disturbed,
refer to "Balance Shaft" in this section.
Turn crankshaft so that number one piston is at
top dead center.
Turn camshaft so that with sprocket temporarily
installed, timing mark is straight down.
Assemble timing chain on sprockets with timing
marks in their closest together position.
Timing chain and sprocket.
Camshaft sprocket bolt.

!~!
Tighten
Bolt to 100 N,m (74 lb. ft.) + 90 using

J 36660.
6. Timing chain damper.
!~!
Tighten
Bolt to 22 N,m (16 lb. ft.).

7. Front cover.
Oil PUMP GEAR SET

Figure 27
!++-!
!++!
Install or Connect
1. Front cover and bolts.

Align the cogs on the crankshaft sprocket with
the cogs on the oil .pump in the front .cover.
Apply sealant GM PIN 12346004 or equivalent
to bolt threads.
l~.J
Tighten
Bolts to 15 N,m (11 lb. ft.) + 40 using

J 36660.
2. Oil pan to front cover bolts.
!~I
Tighten

3. Crankshaft position sensor.
Crankshaft position sensor requires no
adjustment.
4. Sensor shield.

5. Balancer and bolt.
!~I
Tighten
Balancer bolt to 150 N.m (111 lb. ft.) + 76

using J 36660.
6. Drive belt tensioner.
FRONT COVER OIL SEAL

Install or Connect
Figure 71
1. Gears.
2. Oil pump cover and screws.
!~!
\
6A8B-41
Tighten
Screws to 11 N.m (98 lb. in.).

3. Spring, valve and oil filter adapter:
section.
Tools Required:
J 35354 Seal Installer
I++!
Install or Connect
1. Coat outside seal surface of crankshaft balancer

with lubricant GM PIN 10522497 or equivalent.
2. Oil seal using J 35354 and a soft faced hammer.
3. Remove J 35354.
6A8B-42

I~!
Tighten

using J 36660.
OIL FILTER ADAPTER AND PRESSURE

RELIEF VALVE
Figure 19
!++!
1.
2.
3.
4.
Install or Connect
Spring into front cover.
Oil pressure valve into front cover.
Oil filter adapter and a new gasket.
Bolts.
!~I
CRANKSHAFT BALANCER
Tighten
Figures 20 and 21
COOLANT PUMP
Tools Required:
l++I
Figure 18
Tool Required:
Install or Connect listO
!++I
Install or Connect
Lubricate seal surface with engine oil.

1. Coolant pump and bolts.

2. Balancer bolt.
!~I

J 36660.
2. Coolant pump pulley and bolts.
l~I Tighten
Hold flywheel using J 37096.
!~!
Tighten
CYLINDER HEAD
Tighten

using J 36660.
Figures 17 and 72
Tools Required:
7/16-14 Tap
I++!
J
66
1. Clean threads in the block using a 7/16.:.14 tap.

2. Install head gasket with arrow pointing towards
front of engine. Left hand gasket has the letter
"L" stamped next to the arrow. The right hand
gasket has no marking other than the arrow.
35354
SEAL, ENGINE FRONT COVER OIL
Install or Connect
021095
WT9148A8B
Figure 71 - Installing Front Cover Oil Seal Using J 35354
NOTICE: Head gaskets are not

interchangeable. Failure to install with arrow
pointing to front will cause gasket failure and
possible engine failure.
3. NEW cylinder head bolts.
6A8B-43
VALVE LIFTERS
Figure 17
Tool Required:
j++I
Install or Connect
1. Lifters.
@
8
5
04-08-96
WT9208A8B
Figure 72 - Cylinder Head Bolt Tightening Sequence
Dip the valve lifters in prelube GM

2. Lifter guides.
3. Guide retainer.
!~!
Tighten
Bolts to 30 N,m (22 lb. ft.).

4. Pushrods.
NOTICE:
This bolt is designed to permanently

!~l

Tighten
5. Rocker arms and bolts.
A. Cylinder head bolts to 50 N.m (37 lb. ft.) in

the sequence shown in Figure 72.
B. Rotate each bolt 130 in sequence using
J 36660.
C. Rotate the center four bolts an additional 30
in sequence using J 36660.

4. Pushrods, guide plate and rocker arm assemblies
Apply GM approved thread lock compound or
equivalent to rocker arm bolts before assembly.
!~!
5.
6.
7.
8.
Tighten
Rocker arm bolts to 15 N,m (11 lb. ft.) + 90

using J 36660.
Rocker arm cover.
Exhaust manifold.
Belt tensioner assembly.

bolt threads before assembly.
!~!
Tighten
Bolts to 15 N,m (11 lb. ft.) + 90 using

J 36660.
6. Lower intake manifold and gaskets.
7. Rocker arm covers and gaskets.
ROCKER ARM AND PUSHROD

Figures 16 and 17
Tool Required:
!++!
Install or Connect
1. Rocker arm assembly.

2. Rocker arm bolts.
Apply thread lock compound or equivalent to bolt
threads before assembly.

6A8B-44
!~I
Tighten
Bolts to 15 N.m (11 lb. ft.) + 90 using J 36660.

3. Rocker arm cover. Refer to "Rocker Arm Covers
and/ or Gaskets" in this section.
ROCKER ARM COVERS AND/OR

GASKETS
Figure 16
Left Side
j++!
Install or Connect
Clean
Bolt threads of any debris.

bolt threads.
I~!
Tighten

2. ICM bracket.
Right Side
!++I
Install or Connect
Clean
Bolt threads of any debris.

bolt threads.
!~!
Tighten

2. Spark plug wire.
EXHAUST MANIFOLD
[I]
Important
Whenever the EGR tube is removed from the

left hand exhaust manifold, the outlet tube
should be inspected for leaks during
installation. If leaks are present, replace the
EGR adapter assembly.
4. Exhaust manifold heat shield and nuts.
I~!
Tighten
Nut to 9 N.m (80 lb. in.).

5. Heated oxygen sensor electrical connector to wire
support bracket.
Right Side
l++j
Install or Connect
1. Exhaust manifold gasket and manifold to cylinder

head.
2. Mamfold bolts and studs.
!~l
Tighten
Bolt and stud to 12 N.m (107 lb. in.).

3. Exhaust manifold heat shields and nuts.
I~!
Tighten
Nut to 9 N.m (80 lb. in.).

4. Heated oxygen sensor electrical connector to lift
bracket.
Figure 13
!++!
Install or Connect

Make sure 0-ring is in place.
Make sure assembly is fully seated in engine.
I~!
Tighten
Left Side
ACCESSORY DRIVE BELT TENSIONER
!++I
Figure 12
1. Exhaust manifold gasket and manifold to cylinder

head.
2. Manifold bolts and studs.
!~!
Tighten
Bolt and studs to 12 N.m (107 lb. in.).

3. EGR outlet pipe to exhaust manifold.
OIL LEVEL INDICATOR
Figures 14 and 15
Install or Connect
E3
Install or Connect
1. Tensioner assembly.
2. Tensioner assembly bolts.
I~!
Tighten

LOWER INTAKE MANIFOLD
Figure 11
!++-!
Install or Connect
Apply thread locking compound to the intake

manifold bolt threads before assembly.
I~!

Figure 11
Install or Connect
l. Upper intake manifold.

Make sure to install the two "Hidden" bolts in
the lower intake manifold.
I~!
3.
4.
5.
6.
1.
!H!
Tighten
A. Ten vertical bolts (1-10) to 15 N.m (11 lb. ft.)

using sequence shown in Figure 11.
B. 1\vo coolant outlet bolts (11 and 12) to 27
N.m (20 lb. ft.).
C. Side bolt (13) to 30 N.m (22 lb. ft.).
D. Side bolt (14) to 30 N.m (22 lb. ft.).
Fuel rail.
Throttle body.
Coolant outlet and thermostat assembly.
EGR outlet pipe to intake manifold.
Manifold vacuum source.
Spark plug wires on right side of engine.
Install or Connect
1. Housing.
2. Bolts.
!~!
Tighten
Bolts to 15 N.m (11 lb. ft.) using sequence

shown in Figure 11.
2.
COOLANT OUTLET HOUSING AND

THERMOSTAT
Figure 10
1. Intake manifold bolts and manifold.
!++-!
Tighten
EGR VALVE ADAPTER

Figure 9
!++!
Install or Connect
1. Adapter to cylinder head.

2. Adapter bolts.
!~I
Tighten

3. Outlet pipe.
4. EGR valve.
!~!
Tighten
EGR VALVE
Figure 8
I++!
Install or Connect
1. EGR valve.
2. EGR nuts.
!~I
Tighten
Nuts to 29 N.m (21 lb. ft.).
THROTTLE BODY
Figures 1 through 4
Figure 7
!++-!
6A88-45
Install or Connect
!++I
Install or Connect
1. Outlet pipe.
l. Throttle body.
2. Throttle body nuts and bolt.
l~I
Tighten
Nuts/bolt to 10 N.m (89 lb. in.).

3. Cable bracket to upper intake manifold.
rn
Important
Whenever the EGR tube is removed from the

left hand exhaust manifold, the outlet tube
should be inspected for leaks during
installation. If leaks are present, replace the
EGR adapter assembly.
2. Outlet pipe to upper intake manifold.
6A8B-46
l~I
Tighten

3. Outlet pipe to adapter.
!~! Tighten
SPECIFICATIONS
FASTENER TIGHTENING
Accelerator Control Cable Bracket Bolt ...........'. .................................................................... 10 N,m (89 lb. ia.)
Accessory Drive Belt Tensioner Assembly Bolt .................................................................... 50 N.m (37 lb. ft.)
Balance Shaft Gear Bolt............................................................................................... 22 N,m (16 lb. ft.) + 70
Balance Shaft Retainer Bolt .................................................................................................... 30 N.m (22 lb. ft.)
Camshaft Position Sensor Bolt ............................................................................................... 10 N,m (89.lb. ia.)
Camshaft Sprocket Bolt ............................................................................. ~ ................ 100 N,m (74 lb. ft.) + 90
Camshaft Thrust Plate Screw .................................................................................................. 15 N,m (11 lb. ft.)
Connecting Rod Cap Bolt ............................................................................................ 27 N,m (20 lb. ft.) + S0
Coolant Outlet Assembly Bolt ................................................................................................ 27 N,m (20 lb. ft.)
Coolant Pump Bolt ........................................................................................................ 15 N,m (11 lb. ft.) + 80
Coolant Pump Pulley Bolt .................................................................................................... 13 N.m (116 lb. ia.)
Crankshaft Balancer Bolt.. ......................................................................................... 150 N.m (111 lb. ft.) + 76
Crankshaft Main Bearing Cap Bolt ........................................................................................ Refer to Procedure
Crankshaft Position Sensor Stud ............................................................................................. 30 N,m (22 lb. ft.)
Crankshaft Rear Main Oil Seal Housing Bolt ............................................................. 15 N.m (11 lb. ft.) + S0
Cylinder Head "NEW" Bolt .................................................................................................. Refer to Procedure
Drive Belt Tensioner Bolt ....................................................................................................... 50 N.m (37 lb. ft.)
EGR Valve Adapter Nut .......................................................................................................... 50 N,m (37 lb. ft.)
EGR Valve Nut ...................................... ' ................................................................................ 29 N,m (21 lb. ft.)
EGR Valve Outlet Pipe Bolt/Nut (Except Upper Intake Manifold) ...................................... 29 N,m (21 lb. ft.)
EGR Valve Outlet Pipe Bolt to Upper Intake Manifold ....................................................... 25 N,m (18 lb. ft.)
EGR Valve Wiring Harness Heat Shield Bolt/Nut................................................................ 10 N,m (89 lb. ia.)
Engine Block Coolant Drain Plug .......................................................................................... 18 N.m (13 lb. ft.)
Engine Coolant Temperature Sensor ..................................................................................... 13 N,m (116 lb. ia.)
Engine Front Cover Bolt/Stud....................................................................................... 15 N,m (11 lb. ft.) + 40
Engine Front Lift Bracket Bolt .............................................. ;................................................ 25 N,m (18 lb. ft.)
Engine Rear Lift Bracket Bolt/Stud........................................................................................ 50 N,m (37 lb. ft.)
Exhaust Manifold Bolt/Stud ............................................................................................ ;..... 12 N,m (107 lb. ia.)
Exhaust Manifold Heat Shield Nut .......................................................................................... 9 N,m (80 lb. ia.)
Flywheel "NEW" Bolt ................................................................................................. 15 N,m (11 lb. ft.) + S0
Fuel Injector Rail Assembly Nut ........................................................................................... 10 N,m (89 lb. ia.)
Fuel Pump and Engine Oil Pressure Gage Sensor .............................................................. 13 N .m ( 116 .lb. ia.)
Generator Brace Bracket Bolt ................................................................................................. 50 N.m (37 lb. ft.)
Heated Oxygen Sensor ............................................................................................................ 42 N,m (31 lb. ft.)
ICM Bracket Bolt ................................... ;................................................................................ 50 N.m (37 lb. ft.)
ICM Assembly Nut ................................................................................................................. 30 N.m (22 lb. ft.)
Lower Intake Manifold Bolt ................................................................................................... Refer to Procedure
Oil Filter Adapter Bolt ............................................................................................................ 30 N.m (22 lb. ft.)
Oil Level Indicator Bolt ......................................................................................................... 10 N.m (89 lb. ia.)
Oil Level Switch...................................................................................................................... 22 N.m (16 lb. ft.)
Oil Pan Bolt. .......................................................................................................................... 14 N.m (125 lb. in.)
Oil Pan Drain Plug .................................................................................................................. 44 N.m (32 lb. ft.)
Oil Pump Cover Screw ........................................................................................................... 11 N,m (98 lb. in.)
Oil Pump Screen Bolt ............................................................................................................. 15 N,m (11 lb. ft.)
Side Main Cap Bolt ....................................................................................................... 15 N.m (11.lb ft.) + 45
Spark Plug Wire Retainer Bracket Bolt ................................................................................. 30 N.m (22 lb. ft.)
Throttle Body Bolt/Nut........................................................................................................... 10 N.m (89 lb. ia.)
Timing Chain Dampener Bolt ................................................................................................. 22 N.m (16 lb. ft.)
Upper Intake Manifold Bolts ...................................................................................................Refer to Procedure
Vacuum Source Manifold Screw ............................................................................................ 10 N,m (89 lb. ia.)
Valve Lifter Guide Retaine:r Bolt............................................................................................ 30 N.m (22 lb. ft.)
Valve Rocker Arm Bolt................................................................................................. 15 N,m (11 lb. ft.) + 90
Valve Rocker Arm Cover Bolt .............................................................................................. 10 N.m (89 lb. in.)
6A8B-47
ENGINE
GENERAL
Type ................................................................................................................................................................ 90V6
Displacement ........................................................................................................................................... 231 cu.in.
Liter(VIN) ..................................................................................................................................................... 3.8(K)
RPO ................................................................................................................................................................... L36
Bore .......................................................................................................................................... 96.52 mm (3.8 in.)
Stroke ....................................................................................................................................... 86.36 mm (3.4 in.)
Compression Ratio ........................................................................................................................................... 9.4: 1
Firing Order .......................................................................................................................................... 1-6-5-4-3-2
Lubrication System
Oil Capacity Without Filter Change ............................................................................................. 4Liters (4 Qts.)

Oil Pressure.@ Operating Temperature ............................... 414kPa (60 psi).@ 1850 RPM using lOW-30 oil*
Oil Filter Type .................................................................................... Throw-Away Element and Can Oil Pump
Gear Pocket Depth ........................................................................... 11.71 mm-11.75 mm (0.461 in.-0.4625 in.)
Gear Pocket Diameter ....................................................................... 89.10 mm-89.20 mm (3.508 in.-3.512 in.)
Inner Gear Tip Clearance .................................................................................................... 0.152 mm (0.006 in.)
Outer Gear Diameter Clearance ........................................................ 0.203 mm-0.381 mm (0.008 in.-0.015 in.)
End Clearance .................................................................................. 0.025 mm-0.089 mm (0.001 in.-0.0035 in.)
Valve to Bore Clearance ................................................................. 0.038 mm-0.076 mm (0.0015 in.-0.003 in.)
* When changing oil filter, additional engine oil may be required to bring oil level to the full mark.
Type of Lubrication
Main Bearings ............................................................................................................................................ Pressure

Connecting Rods ........................................................................................................................................ Pressure
Piston Pins .................................................................................................................................................... Splash
Camshaft Bearings ..................................................................................................................................... Pressure
Timing Chain .................................................................................................. ;............................................. Splash
Cylinder Walls .............................................................................................................................................. Splash
Oil Pump Type ........................................................................................................................................... Gerotor
Oil Pressure Sending Unit. ....................................................................................................................... Electrical
Oil Intake ................................................................................................................................................ Stationary
Oil Filter System ..................................................................................................................................... Full Flow
Cylinder Bore
Diameter ..................................................................................................................................... 96.5 mm (3.8 in.)

Out-of-Round-Max.......................................................................................................... 0.010 mm (0.0004 in.)
Taper ................................................................................................................................... 0.013 mm (0.0005 in.)
Piston
Clearance (39 mm from top of piston) ........................................ 0.010 mm-0.051 mm (0.0004 in.!0.0020 in.)
Piston Ring Groove Depth
Top Compression ............................................................................... 4.019 mm-4.146 mm (0.158 in.-0.163 in.)

2nd Compression ............................................................................. 4.214 mm-4.341 mm (0.0166 in.-0.171 in.)
Oil Control ......................................................................................... 3.814 mm-3.941 mm (0.150 in.-0.155 in.)
Piston Ring End Gap
Top Compression ............................................................................... 0.305 mm-0.559 mm (0.012 in.-0.022 in.)

2nd Compression ............................................................................... 0.762 mm-1.016 mm (0.030 in.-0.040 in.)
Oil Control ............................... ;......................................................... 0.254 mm-0.762 mm (0.010 in.-0,030 in.)
\
6A8B-48
Piston Ring Side Clearance
Top Compression ........................................................................... 0.033 mm-0.079 mm (0.0013 in.-0.0031 in.)

2nd Compression ........................................................................... 0.033 mm-0.079 mm (0.0013 in.-0.0031 in.)
Oil Control ..................................................................................... 0.023 mm-0.201 mm (0.0009 in.-0.0079 in.)
Piston Ring Width
Top Compression ........................................................................... 1.176 mm-1.197 mm (0.0463 in.-0.0471 in.)

2nd Compression ........................................................................... 1.476 mm-1.497 mm (0.0581 in.-0.0589 in.)
Oil Control.'. 1.854 mm-2.007 mm (0.073 in.-0.079 in.)
Piston Pin
Diameter .................................................................................. 21.9950 mm-22.0000 mm (0.8659 in.-0.8661 in.)
Fit in Piston ........................................................................... 0.0020 mm-0.0130 mm (0.00008 in.-0.00051 in.)
Fit in Rod (Clearance) ............................................................... 0.0066 mm-0.0217 mm (0~0003 in.-0.0009 in.)
Crankshaft - Main Bearings
Journal Diameter-All ............................................................... 63.470 mm-63.495 mm (2.4988 in.-2.4998

Taper Max ........................................................................................................................ 0.0008 mm (0.0003
Runout-Max ..................................................................................................... :............. 0.0008 mm (0.0003
Bearing to Journal Clearance ........................................................ 0.020 mm-0.055 mm (0.0008 in.-0.0022
in.)
in.)
in.)
in.)
Connecting Rod
Rod Side Clearance ........................................................................... 0.076 mm-0.381mm (0.003 in.-0.015 in.)

Connecting Rod Large End Bore ID ...................................... 60.295 mm-60.312 mm (2.37378 in.-2.3745 in.)
Camshaft Lobe lift
Intake ...................................................................................................................................... 6.43 mm (0.250

Exhaust ................................................................................................... '. ............................... 6.48 mm (0.255
Journal Diameter ........................................................................ 45.339 mm-45.364 mm (1.7865 in.-1.7885
Bearing Inside Diameter ... :........................................................ 45.377 mm-45.428 mm (1.7865 in.-1.7885
Bearing to Journal Clearance ................................................................ 0.013 mm-0.089 (0.0005 in.-0.0035
in.)
in.)
in.)
in.)
in.)
Balance Shaft
End Play ....................................................................................................... 0.0 mm-0.203mm (0.0 in.-0.008

Radial Play-Front .................................................................................. 0.0 mm-0.028 mm (0.0 in.-0.0011
Radial Play Rear ........................................................................... 0.0127 mm-0.119 mm (0.0005 in.-0.0047
Drive Gear Lash ................................................................................ 0.050 mm-0.127 mm (0.002 in.-0.005
Bearing Bore Diameter -Front .................................................. 51.973 mm-51.999 mm (2.0462 in.-2.0472
Bearing Bore Diameter-Rear ...................................................... 49.530 mm-49.580 mm (1.950 in.-1.952
Valve System
in.)
in.)
in.)
in.)
in.)
in.)
Lifter ......................................................................................................................................................... Hydraulic

Rocker Arm Ratio ........................................................................................................................................... 1.6: 1
Face Angle ............................................................................................................................................ 45 Degrees
Seat Angle ............................................................................................................................................. 45 Degrees
Minimum Margin ................................................................................................................. 0.635 mm (0.025 in.)
Seat Runout-Maximum ..................................................................................................... 0.050 mm (0.002 in.)
Seat Width-Intake ................................................................................ 1.53 mm-2.03 mm (0.060 in.-0.080 in.)
Seat Width Exhaust ............................................................................... 2.29 mm-2.79 mm (0.090 in.-0.110 in.)
Stem Height All ................................................................................. 49.15 mm-50.17 mm (1.935 in.-1.975 in.)
Stem Clearance All ........................................................................ 0.038 mm-0.089 mm (0.0015 in.-0.0032 in.)
Valve Spring
Free Length .......................................................................................................................... 50.32 mm (1.981 in.)
Load---,-Closed ....................................................................................... 356 N.@ 43.69 mm (80 lbs ..@ 1.75 in.)
Load Open............................................................................................ 935N.@ 33.4 mm (210 lbs ..@ 1.315 in.)
Installed Height. ................................................................................. 42.93 mm-44.45 mm (1.690 in.-1.720 in.)
Approximate number of Coils .............................................................................................................................. 4
Flywheel
Runout-Max ......................................................................................................................... 0.38 mm (0.015 in.)
6A8B49
SPECIAL TOOLS
~~~
~~
2
1
J 5830-4
1=0
J 8001
5
J 8520
4
~J8037
J 8087
7
J 9666
8
J 33049
9
J 35354
1
2
3
4
5
6
7
8
9
10
11
12
VAL VE GUIDE REAMER

SLIDE HAMMER
DIAL INDICATOR
CAM LIFT LOBE INDICATOR
CYLINDER BORE CHECKING GAGE
VAL VE SPRING TESTER
CAMSHAFT BUSHING REMOVER AND INSTALLER
TORQUE ANGLE METER
BALANCE SHAFT REAR BUSHING INSTALLER
BALANCE SHAFT INSTALLER
11
J 36995 AND
J 36995-UPD
10
J 36660
12
J 36996
02-10-95
WT9186A8B
6A8B50
3800 ENGINE UNIT REPAIR L36 {VIN K)
SPECIAL TOOLS {CONTINUED)

(
3
J 38197
1
J 37096
2
J 38196
4
J
38606
5
J
1 FLYWHEEL HOLDING TOOL

2 REAR MAIN OIL SEAL INSTALLER
3 CRANKSHAFT BALANCER PULLER
4 VAL VE SPRING COMPRESSOR
5 MAIN BEARING CAP PULLER
6 CRANKSHAFT REAR MAIN OIL SEAL
HOUSING ALIGNING TOOL
7 CONNECTING ROD ASSEMBLY GUIDE
8 VALVE GUIDE SEAL INSTALLER
41348
41512
02-10-96
WT91HA8B
COOLING. AND RADIATOR 681
SECTION 68
COOLING AND RADIATOR

exact part number for that application. General Motors will call out those fasteners that require replacement after
removal. General Motors will also call out the fasteners that require thread lockers or thread sealant. .UNLESS
sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
NOTICE: When adding coolant, it is important that you use DEX - COOL (orange-colored, silicate-free)
coolant meeting GM Specification 6277M. If silicate coolant is added to the system, premature engine, heater
core or radiator corrosion may result, the engine will require change sooner-at 50 000 km (30 000 miles) or 24
months.
CONTENTS
General Description ............................... ;................. 6B-2
Coolant Radiator ..................................... :........... 6B-2
Cross-Flow Radiator Core and Inlet and
Outlet Tanks ................................................ 6B-2
Transmission Oil Cooler ................................. 6B-2
Radiator Drain Cock .................. '. .................... 6B-2
Heater Core ............................... Refer to Section 1A
Radiator Fill Cap ..... ,.......................................... 6B-2
Electric Engine Coolant Fan ............................... 6B-3
Engine Coolant Temperature Gage Sensor ........ 6B-3
Engine Coolant Temperature (ECT) Sensor ...... 6B-3
Engine Coolant Thermostat ................................ 6B-3
Coolant Recovery. System................................... 6B-3
Radiator Air Lower Baffles and Deflectors ....... 6B-3
Serpentine Drive Belt ......................................... 6B-3
Engine Block Coolant Drain Hole Plug ............ 6B-3
Maintenance Recommendations .............................. 6B-3
Long Life Engine Coolant.. ................................ 6B-3
Checking Engine Coolant ................................... 6B-4
Engine Coolant Concentration ..................... ,...... 6B-4
Hose and Clamp Inspection................................ 6B-4
Water Pump Coolant Seepage ............................ 6B-4
Pressure Testing ................................................... 6B-4
Exterior Radiator Cleaning ................................. 6B-4
Diagnosis ................................................................ 6B-4
Cooling System Overheating .............................. 68-4
Engine Coolant Thermostat Test ........................ 6B-5
Radiator Fill Cap ............................. ~ .......... 6B-6
Pressure Test. ................................................... 6B-6
Serpentine Drive Belt ......................................... 6B-6
Cooling System Diagnosis Chart ....................... 6B-6
On-Vehicle Service ............................ ;.................... ;6B-8
Draining and Refilling Cooling System ............. 6B-8
Engine Coolant Flushing and Recycling ......... 6B-8

Aluminum Radiator Service ............................. 6B-10
Precautions ..................................................... 6B-10
Diagnosis ....................................................... 6B-10
Repairable Leaks ........................................... 6B-11
Repair Methods ............................................. 6B-12
Cooling Fin Removal ................................... 6B-1,2
Tube Blocking ............................................... 6B-12
Header Repair .... ,... ,...................................... 6B-12
General Core Repair .................................... 6B-12
Radiator Side Tank Gasket Leak Repair ..... 6B- l4
Transmission Oil Cooler Gasket .................. 6B-15
Transmission Oil Cooler ............................... 6B-15
Recore ............................................................ 6B-16
Radiator Drain Cock ..................................... 6B- i 6
Engine Coolant Thermostat .......................... ,... 6B-16
Electric Engine Coolant Fan ............................ 6B-17
Water Pump ....................................................... 6B-18
Battery Tray and Coolant Recovery
Reservoir ........................................................ 6B-20
Coolant Level Indicator Module ...................... 6B-20
Radiator .............................................................. 6B-20
Radiator Air Baffles and Deflectors ................ 6B-22
Radiator Upper Mounting Panel .................. 6B-22
Radiator Air Lower Baffle and Deflector ... 6B-22
Radiator Air Upper Baffle ............................ 6B-23
Engine Coolant Hoses ...................................... 6B-23
Engine Coolant Air Bleed Pipe ....................... 6B-23
Testing the Coolant Concentration ................... 6B-23
Calibrating Testers ......................................... 6B-25
General Specifications ....................................... 6B-25
Fastener Tightening Specifications ................. ;.6B-25
Special Tools ......................................................... 6B-26
682 COOLING AND RADIATOR

GENERAL DESCRIPTION
The cooling system, which consists of a radiator
and coolant recovery subsystem, electric engine
coolant fan, engine coolant thermostat, water pump
and serpentine drive belt, works to maintain engine
temperature at an efficient level during all engine
operating conditions.
On the 5.7L (VIN P) engine, coolant is drawn
from the radiator by the water pump and circulated
through coolant jackets in the cylinder heads, then
through coolant jackets in the engine block It is then
directed back to the radiator.
On the 3800 (VIN K) engine, coolant is drawn
from the radiator by the water pump and circulated
through coolant jackets in the cylinder block, and then
through coolant jackets in the cylinder heads. It is then
directed back to the radiator.
The system directs some engine coolant through
hoses to the heater core to provide defrost and
passenger compartment heat. A coolant recovery
reservoir is connected to the radiator to recover engine
coolant displaced by expansion. As the engine cools,
the engine coolant is drawn back into the radiator by
vacuum.
COOLANT RADIATOR
Cross-Flow Radiator Core and Inlet and
Outlet Tanks
A cross-flow radiator core is used on all models.
Inlet and Outlet tanks are located to the right and left
of the cross-flow radiator core. All radiators used with
automatic transmissions have transmission oil cooler
inlet and outlet fittings for transmission fluid
circulation. Vehicles with manual transmissions use
radiators without transmission oil coolers.
An aluminum-plastic radiator can be identified
by a note on the outlet tank 127 mm (5 inches) below
the filler neck which reads: "Important - for repair see
Harrison Service Manual." Service procedures for the
aluminum-plastic radiator are described in that manual
and in this section.
Transmission Oil Cooler

If equipped, the transmission . oil cooler is
located in the outlet tank on the right side of the
radiator. For information on servidng the transmission
oil cooler See "Transmission Oil Cooler " in this
section. For service of the transmission oil cooler hose
and pipes. Refer to SECTION 7A.
Radiator Drain Cock

The radiator drain cock includes the radiator
drain cock and the radiator drain cock seal, it is
located on the inner right side of the radiator, near the
bottom.
RADIATOR FILL CAP

Figure 1
A pressure-type radiator fill cap is used with the
cross-flow radiator to allow a buildup of 124 kPa (18
psi) in the cooling system. This pressure raises the
boiling point of engine coolant to approximately
128C (262F) at sea level.
VACUUM RELIEF
PRESSURE REL.IEF
01-17-95
FS00188
Figure 1 - Pressure-Type Radiator Fill Cap (Typical)
CAUTION: Do not remove radiator fill cap

to check engine coolant level; check
engine coolant at the coolant recovery
reservoir. Engine coolant should be
added only to the coolant recovery
reservoir, when the system co.ols.
CAUTION: As long as there is pressure in
the cooling system, the temperature can
be considerably higher than the boiling
temperature of the solution. Removal of
the radiator fill cap while engine is hot
and pressure .is high will cause the:,
solution to boil instantaneously and
possibly with explosive force, spewing
the solution over engine, fenders and
person removing cap. If the solution
contains flammable antifreeze, such as
alcohol (not recommended for use at any
time), there is also the possibility of
causing a serious fire.
The pressure-type radiator fill cap contains a
blow-off (pressure) valve and a vacuum (atmospheric)
valve. The pressure valve is held against its seat by a
heavy spring; This spring protects the radiator by
relieving pressure exceeding 124 kPa (18 psi).
To prevent radiator collapse caused by vacuum
as the engine cools, the vacuum valve prevents
excessive pressure differences from occurring between
the cooling system and the atmosphere.
The radiator fill cap has been designed without
finger grips to discourage inadvertent removal. To
safely remove the radiator fill cap, rotate the cap
slowly counter-clockwise (do not press down) to
detent. Allow any pressure to be relieved. Next, press
down on the cap and continue to rotate cap
counterclockwise and lift off the cap. Embossed on the
cap is a caution against opening it and arrows
indicating the proper closed position.
68-3
ELECTRIC ENGINE COOLANT FAN
COOLANT RECOVERY SYSTEM
Dual electric engine coolant fans aid in air flow

through the radiator. The engine coolant fans are
attached to the radiator.
The engine coolant fan blades are driven by
motors attached to the fan shroud. The fan motors are
activated by PCM controlled fan relays. If the vehicle
is equipped with air conditioning, the fan motors also
operate when the compressor is operating.
A plastic .coolant recovery reservoir is connected

to the radiator by a hose. As the vehicle is driven, the
engine coolant is heated and expands. The portion of
the engine coolant displaced by this expansion flows
from the radiator into the reservoir. When the engine
is stopped and the engine coolant cools and contracts,
the displaced engine coolant is drawn back into the
radiator by vacuum. Thus, the radiator is kept filled
with engine coolant to the desired level at all times,
resulting in increased cooling efficiency.
CAUTION: If a fan blade is bent or

damaged in any way, no attempt should
be made to repair or reuse the damaged
part. A bent or damaged fan blade should
always be replaced. It is essential that
fan blades remain in proper balance and
proper balance cannot be assured once a
fan blade has been bent or damaged. A
fan blade that is not in proper balance
could fail and fly apart during
subsequent use, creating an extremely
dangerous condition.
The fan blade is designed to aid air flow through
the radiator and air conditioning condenser.
RADIATOR AIR LOWER BAFFLES AND

DEFLECTORS
Radiator air lower baffles and deflectors are
located at the top and bottom of the radiator to
increase .air flow through the radiator.

The serpentine drive belt drives the water pump
(V6 only) and engine accessories. To check the
condition .of the serpentine drive belt and tensioner,
refer to SECTIONS 6A3A or 6A8A.
ENGINE BLOCK COOLANT DRAIN HOLE

PLUG
ENGINE COOLANT TEMPERATURE GAGE

SENSOR
3800 VINK
This sensor controls a temperature gage in the

instrument cluster. The temperature gage indicates the
operating temperature of the engine. Refer to
SECTION 8A for engine coolant temperature gage
sensor diagnosis and location.
The engine block coolant drain hole plugs are

located on either .side of the engine block just above
the oil pan. Knock sensors are installed in both drain
holes. They must be removed to completely drain the
coolant system.
ENGINE COOLANT TEMPERATURE (ECT)

SENSOR
5.7L VIN P
This sensor sends a signal to the powertrain

control module (PCM) which completes the ground for
the electric engine coolant fan relays, which operates
the fan when the engine coolant temperature exceeds
1l0C (230F). Refer to SECTION 6E3 for engine
coolant temperature (ECT) sensor diagnosis and
location.
ENGINE COOLANT THERMOSTAT

A pellet-type engine coolant thermostat is used
in the engine coolant outlet passage to control the flow
of engine coolant to provide fast engine warm-up and
to regulate engine temperatures. The wax pellet
element in the thermostat expands when heated and
contracts when cooled. The pellet element is connected
through a piston to a valve. The valve remains closed
while the engine coolant is cold, preventing circulation
of engine coolant through the radiator and allowing
the circulation of engine coolant only through the
engine.
As the engine warms, the pellet element expands
aid the thermostat valve opens, permitting engine
coolant to flow through the radiator.
The engine block coolant drain hole plug is on

the left side of the engine block. It must be removed
to completely drain the coolant system. The knock
sensor, on the right side of the engine block must also
be removed.
MAINTENANCE RECOMMENDATIONS
Regular maintenance of the cooling system will
help keep it operating properly. Use the following
procedures to check the cooling system at least once a
year or 25 000 km (15,000 miles).
LONG LIFE ENGINE COOLANT

Starting with the 1996 model year, the
Camaro/Firebird will be using DEX - COOL engine
coolant. Which meets GM Specification 6277M.
DEX - COOL engine coolant is a long life
engine coolant and is ethylene glycol based,
silicate-free and orange in color. DEX - COOL
coolant provides longer lasting protection against rust
and corrosion, and also increases water pump seal life.
It also gives freezing protection down to -34F (-37C)
and gives boiling protection up to 265F (129C).
68-4
CHECKING ENGINE COOLANT

Check the engine coolant level in the reservoir
b~ r~movi~g the re~ervoir cap and checking the
dipstick while the engme is cold. The level should be
at or above the ."FU~L COLD" mark on the dipstick
when the engme is cold. At normal operating
temperatures the engine coolant level should be at or
above the "FULL HOT" mark on the dipstick.
E~gine c.oolant should be added only to the
reservoir to raise the level to the appropriate mark.
Use a 50/50 mixture of DEX - COOL engine
coolant and water (preferably distilled) for engine
coolant additions.
. Every. five years or 160 000 kilometers (100,000
miles), whic~ever comes first, the cooling system
shoul~ be dramed and refilled. Refer to "Draining and
Refillmg the Cooling System" in this section.
ENGINE COOLANT CONCENTRATION

The percentage of ethylene glycol in the engine
coolant should be checked periodically, when the
engine coolant level is adjusted or the system drained
and refilled.
This test is done by using a refractometer engine
coolant tester. Refractometers test for the amount of
ethylene g.lycol i: a coolant mixture by ~easuring the
speed of hght as it passes through the fluid and are is
affected by the specific gravity of the glycol. Refer to
"Engine Coolant Testing" in this section for the test
procedures.
CAUTION: To avoid the danger of being

burned, do not remove the cap while the
en~ine and radiator are still hot. Scalding
fluid and steam can be blown out under
pressure.
[I]
Important
Do not add pellets into non-pressurized coolant

recovery bottles.
The two pellets should be installed into the
radiator. Care should be exercised to avoid
contamination of the pressure/radiator cap and mating
sealing surfaces with pellet debris. The use of sealant
pellets may cause a film to appear around the sides of
non-pressurized coolant recovery bottles. The presence
of this film is considered to be normal.
Following installation of the pellets, run the
engine for approximately 15 minutes, then check for
coolant leaks and proper cooling system operation.
[I]
Important
If pellets have been installed to correct an

excessive water pump seal seepage condition, one
to two weeks of normal vehicle operation may be
required to lap in the mating seal surfaces. Some
staining due to minor seepage may continue to
occur. This is considered normal.
HOSE AND CLAMP INSPECTION
PRESSURE TESTING
Inspect the condition of all hoses and clamps.

Hoses should be flexible and show no signs of
bulging, cracks, cuts, kinks or other signs of possible
leaks. Inspect the brackets, supports, ties and clamps.
Adjust and tighten as necessary.
Test the radiator fill cap for the proper pressure

holding capacity. Refer to "Pressure Test" in this
section.
WATER PUMP COOLANT SEEPAGE
Clearing away bugs, leaves and other debris

from the small air passageways of the radiator will
improve the operation of the cooling system.
Use compressed air to blow through the radiator
from the rear towards the front of the vehicle.
A very slight amount of seepage may occur at the

water pump vent hole during vehicle operation. Traces of
residue may occur from the lower vent hole. The water
pump should be replaced only if coolant is dripping from
the vent hole while the engine is in operation or while the
coolin~ system. is pres~uriz.ed. Minor water pump seepage
and mmor engme cooling system leaks may be corrected
by adding two sealant pellets to the cooling system. The
pellets are available from GMSPO in packages of six
under GM PIN 3634621.
Two engine coolant supplement pellets should be
added to the coolant system under the following
conditions:
Vehicles encountering water pump seepage or
minor coolant leak/loss that cannot be
corrected through normal service procedures.
When cooling system is drained and coolant is
replaced with new coolant due to engine repair
~ork or at recommended coolant change
mtervals (five years or 100,000 miles).
Whenever engine water pump is replaced. The
addition of pellets provides a mild lapping of
the new water pump seal that improves
conformability of the mating surfaces. Water
pump seal seepage is minimized by the
addition of pellets.
EXTERIOR RADIATOR CLEANING
.rn
Important
The radiat~r fms are necessary for good heat

transfer and should not be brushed. Brushing
may damage the fms, reducing heat transfer.
DIAGNOSIS
COOLING SYSTEM OVERHEATING
Figure 2
1. If ov~rheating occurs due to prolonged idling in
gear, mstruct operator on driving techniques which
would reduce possibility of engine overheating:
Id~e in "~UTRAL'.' as much as possible and

raise engme rpm usmg accelerator pedal.
Turn air conditioning "OFF" during extended
idling.
2. If above does not apply, refer to diagnosis .chart.

ENGINE COOLANT THERMOSTAT TEST
Figure 2
The thermostat controls coolant flow into the
engine (inlet side). As the thermostat opens, cold
coolant from the radiator passes through the thermostat
causing it to close until the thermostat again reaches
normal operating temperature. This slow bleeding of
685
cold coolant into a hot engine helps prevent thermal

shock due to the sudden rush of cold coolant. The
thermostat will remain open after the entire cooling
system has reached normal operating temperature.
!LI
Inspect
Engine coolant thermostat opening temperature

(Figure 2).
ENGINE OVERHEAT BOILING POOR ENGINE COOLING

1.
2.
3.
4.
ALLOW ENGINE TO COOL.

CHECK FOR PROPER COOLANT LEVEL.
START ENGINE.
MONITOR ENGINE COOLANT TEMPERATURE USING A TECH1 SCAN
TOOL (REFER TO SECTION 6E3).
5. SQUEEZE RADIATOR OUTLET HOSE BY HAND TO DETECT COOLANT
FLOW WHILE MONITORING ENGINE COOLANT TEMPERATURE. IS
COOLANT FLOW THROUGH RADIATOR PRESENT AT OR BEFORE
100'C (212'F)?
INSTALL NEW ENGINE

COOLANT THERMOSTAT.
NO
[I] IMPORTANT:
COOLANT FLOW MAY BE INTERRUPTED AT TIMES DUE TO
THERMOSTAT CLOSING DURING WARMUP.
RECHECK
TO BE SURE
SYSTEM OK
PROBLEM CAUSED BY OTHER THAN

BAD ENGINE COOLANT THERMOSTAT.
COLD ENGINE SLOW WARMUP NOT ENOUGH HEAT

1. ALLOW ENGINE TO COOL.
2. START ENGINE.
3. MONITOR ENGINE COOLANT. TEMPERATURE USING A TECH1 SCAN
TOOL (REFER TO SECTION 6E3).
4. CHECK RADIATOR INLET HOSE TEMPERATURE BY FEEL WHILE
MONITORING ENGINE COOLANT TEMPERATURE. IS RADIATOR INLET
HOSE COOL TO THE TOUCH UNTIL ENGINE COOLANT TEMPERATURE
REACHES AT LEAST 63'C (181'F)?
NO
INSTALL NEW ENGINE

COOLANT THERMOSTAT.
RECHECK
TO BE SURE
SYSTEM OK
PROBLEM CAUSED BY OTHER THAN

BAD ENGINE COOLANT THERMOSTAT.
C10177
Figure 2 Thermostat Diagnosis
68-6
RADIATOR FILL CAP
ILI
Inspect
Cap for weak spring washer or damage to gasket.

If spring washer is weak, replace cap.
Relief valve gasket in cap and inner sealing
surface of neck for damage or debris.
Hose fitting .on neck for cracks. If fitting is loose
or cracked, replace radiator end tank.
Pressure Test
Tool Required:
J 24460-01 Cooling System Tester
1. Clean cap.
2. Install cap on J 24460-01.

3. Pump pressure tester slowly to obtain minimum
holding pressure.
A. If cap fails to hold 83 kPa (12 psi), replace
cap.
B. If installing new cap, coat both gaskets with
engine coolant

Routine inspection of the serpentine drive belt
may reveal cracks in the belt ribs. These cracks will
not impair belt performance and are not a basis for
belt replacement. For belt tensioning and replacement
procedures, refer to SECTIONS 6A3A or 6A8A.
COOLING SYSTEM DIAGNOSIS CHART

CONDITION
Engine overheats.
POSSIBLE CAUSE
A. Loss of engine coolant
B. Loss of system pressure.
C. Weak engine coolant solution.
D. Loose serpentine drive belt.
E. Advanced/Retarded ignition timing.
F. Obstructed radiator fins.
G. Cooling system passages blocked

by rust or scale.
H. Kinked reservoir hose.
I. Inoperative electric engine coolant
fan.
J. Loose, damaged, and/or missing
radiator upper and lower shrouds, air
deflectors or baffles.
K. Thermostat stuck in the closed
position.
L. Faulty water pump.
M. Incorrect radiator.
CORRECTION
A. Refer to next condition - "Loss of
engine coolant."
B. Perform radiator fill cap pressure
test.
C. Test engine coolant for proper 50-50
mixture.
D. Check serpentine drive belt tension.
Refer to SECTIONS 6A3A or 6A8A.
E. Refer to SECTION 6E.
F. Remove or relocate added-on parts
that block air to radiator. Clean away
bugs, leaves, and other debris.
G. Flush cooling system or flow check

radiator. Remove cylinder head and
inspect, if required.
H. Re-route reservoir hose.
I. Refer to SECTION 8A.
J. Repair or replace as required.
K. Replace thermostat.
L. Replace water pump.
M. Determine proper radiator for

vehicle and replace if necessary.
N. Incorrect or damaged fan blade.
N. Check for correct part number,

replace fan blade if required.
0. Faulty emission system components. 0. Refer to SECTION 6E or 6F.
- PCV valve.
- Catalytic converter plugged.
P. Engine oil overfill.
P. Check engine oil level. Drain and
refill if necessary.

POSSIBLE CAUSE
CONDITION
Q. Water pump drive shaft broken or

splines slipping.
R. Electric engine coolant fan operating
in reverse, forcing hot air from engine
through radiator.
S. Exhaust system restriction.
- Catalytic converter plugged.
Loss of engine coolant.
68~7
CORRECTION
Q. Replace drive shaft and/or water
pump.
R. Reverse polarity at electric engine
coolant fan motor connector terminals.
S. Refer to SECTION 6F.
A. Leaking radiator.
A. Inspect radiator. Repair as necessary.
B. Radiator fill cap faulty.
B. Perform cap pressure test.
C. Distorted neck.
C. If radiator neck upper sealing area is

distorted, use wood block and mallet to
reform neck to fit cap.
D. Leaking reservoir or hose.
D. Replace reservoir or hose.
E. Loose or damaged radiator or heater E. Re-se.at hoses. Replace hoses or

hoses or connections.
clamps.
F. Water pump seal leaking.

G. Water pump gasket leaking.
H. Improper cylinder head bolt/screw
torque.
F. Replace water pump.
I. Leaking
I. Make repairs or replace components

as necessary to correct leak.
G. Replace water pump gasket.

H. Re-tighten cylinder head bolts/screws
to specifications. Replace cylinder head
gasket if required.
intake manifold (3800 VIN K)

cylinder head gasket.
engine block coolant drain hole
plug or knock sensor.
heater core.
A. Engine coolant thermostat stuck

open or wrong type installed.
A. Install new thermostat of correct

type and heat range.
B. Coolant below the "FULL COLD"

mark.
B. Add engine coolant.
C. Blockage in coolant circuit.
C. Flush cooling system or flow check

radiator.
Incorrect coolant temperature gage

reading.
Faulty engine coolant temperature

sensor or circuit.
Low coolant light "ON" (reservoir

level correct) (5.7L Only)
Faulty coolant level indicator module

or circuit.
Engine fails to reach normal operating

temperature. Cool air from the heater.
68-8
ON'."VEHICLE SERVICE
in the cooling system. Removing used coolant (from

the vehicle) can be accomplished by several methods:
Utilize waterless coolant evacuation system
available in the GM Dealer Equipment
program (or equivalent) which removes the
used coolant and replaces it with approved
new or recycled coolant.
Utilize a GM approved coolant recycling
system available in the GM Dealer Equipment
program (or equivalent) which recycles the
coolant on the vehicle thereby eliminating the
need for evacuation.
Recover used coolant and store in a used
coolant .holding tank and submit the used
coolant for recycling on a regular basis.
DRAINING AND REFILLING COOLING

SYSTEM
CAUTION: To avoid the danger of being
burned, do not remove the radiator fill
cap while the engine and radiator are still
hot. Scalding fluid and steam may be
blown out under pressure.
NOTICE:
[I]
See "Notice" on page 6B-l.
Important
Dispose of used coolant in a proper fashion,

i.e., in a used .coolant holding tank. NEVER
POUR USED COOLANT DOWN THE
DRAIN! Ethylene glycol based engine coolant
is a very toxic chemical; disposing of it into
the sewer system or ground water is both
illegal and ecologically unsound!
[I]
3800 (VIN K) ENGINE
1. Park vehicle on a level surface.

2. Remove coolant recovery reservoir fill cap.
3. Remove radiator pressure cap
Important
When adding coolant, it is important that you

use DEX -COOL (orange-colored,
silicate-free) coolant meeting GM Specification
6277M. If silicate coolant is added to the
system, premature engine, heater core or
radiator corrosion may result. In addition, the
engine coolant will require change sooner-at
30 000 miles (50 000 km) or 24 months.
ENGINE COOLANT FLUSHING AND

RECYCLING
ENGINE COOLANT FU.ISHING
Tool Required:
Non-Aqueous Coolant Exchanger such as
Pro-Fill J 75010-KM (Available in the GM Dealer
Equipment program)
If your state/local environmental enforcement
group does not allow the discharge of coolant or if
you do not desire to put used coolant into the
environment there are various methods and equipment
that can be used to flush the coolant system. If using
special equipment such as a back flusher, follow the
manufacturer's instructions. However, the thermostat
should be removed before flushing the system.
4.
5.
6.
7.
A. Slowly rotate cap counterclockwise until it

reaches the "stop." Do not press down while
turning pressure cap.
B. Wait until any remaining pressure (indicated
by hissing sound) is relieved.
C. After all hissing ceases, press down on
pressure cap and continue to rotate pressure
cap counterclockwise.
Open radiator drain cock.
Open air bleed vent located on the top of the
water outlet. Air bleed vent should be open two
or three turns.
Remove knock sensors, located on either side of
engine block.
Allow system to drain completely.
rn
Important
Store used coolant in a proper fashion, i.e., in

a used coolant holding tank. NEVER POUR
USED COOLANT DOWN THE DRAIN!
Ethylene gylcol based engine coolant is a very
toxic chemical; disposing of it into the sewer
system or ground water is both illegal and
ecologically unsound!
8. Close radiator drain cock.
9. Install knock sensors.
!~!
Tighten
ENGINE COOLANT RECYCLING
Tool Required:
GM approved Recycling System such as Pro
Clean (Available in the GM Dealer Equipment
program)
As the need arises to conduct cooling system
maintenance or repairs, all of the used coolant must be
removed and replaced with qualified new or recycled
coolant. If only the radiator is drained, up to 50
percent of the used, contaminated coolant can remain
10.
11.
12.
13.
Knock sensor to 20 N.m (15 lb. ft.).

Radiator drain cock to 1.5 N.m (13 lb. in.).
Add enough water to fill cooling system.
Run engine until thermostat opens.
Stop engine. Repeat steps 2 through 10, until
drained fluid is nearly colorless.
Remove, clean and reinstall coolant recovery
reservoir. Refer to "Battery Tray and Coolant
Recovery Reservoir" in this section.
[I]
Important
Use ONLY DEX - COOL engine coolant

meeting GM specification 6277M to provide
required freezing and corrosion protection.
14. Add enough water and DEX - COOL engine
coolant (meeting GM specification 6277M) to
provide a solution that is at least 50 percent
antifreeze, but no more than 70 percent antifreeze.
A. Close air bleed vent when bubbles disappear
and only coolant is visible.
B. Fill radiator to below neck.
C. Fill reservoir to "FULL HOT" mark.
D. Add two cooling system sealer pellets (GM
PIN 3634621).
E. Install reservoir cap.
15. Run engine, with radiator pressure cap removed,
until normal operating temperature is reached
(radiator inlet hose becomes hot).
CAUTION: Under some conditions,

ethylene glycol based in engine coolant
is flammable. To avoid being burned
when adding engine coolant, do not spill
it on the exhaust system or on hot
engine parts.
16. With engine idling, add engine coolant to radiator
until level reaches bottom of neck.
17. Install pressure cap.
Arrows on cap must line up with vent tube.
!L"'!
Inspect
For leaks, after running engine until normal

operating temperature is reached.
5.7L (VIN P) ENGINE
l. Park vehicle on level surface.

2. Remove coolant recovery reservoir fill cap.
3. Remove radiator pressure cap.
A. Slowly rotate cap counterclockwise until it
reaches the "stop". Do not press down while
turning pressure cap.
B. Wait until any remaining pressure (indicated
by hissing sound) is relieved.
C. After all hissing ceases, press down on
pressure cap and continue to rotate pressure
cap counterclockwise.
4. Open radiator drain cock.
5. Open heater air bleed vents located just above
water pump on the thermostat housing and heater
outlet hose pipe. Air bleed vents should be open
two or three turns.
Place a shop towel under the bleed valve to
prevent coolant from splashing onto distributor.
6. Remove coolant drain hole plug and knock sensor,
located on either side of engine block.
7. Allow system to drain completely.
[I]
68-9
Important
Store used coolant in a proper fashion, i.e., in

a used coolant holding tank. NEVER POUR
USED COOLANT DOWN THE DRAIN!
Ethylene glycol based engine coolant is a very
toxic chemical; disposing of it into the sewer
system or ground water is both illegal and
ecologically unsound!
9. Install knock sensor and coolant drain hole plug.
!~!
10.
11.
12.
13.
Tighten
Radiator drain cock to 1.5 N.m (15 lb. in.)

Knock sensor to 20 N.m (15 lb. ft.)
Coolant drain hole plug to 18 N.m (13 lb. ft.)
Add enough water to fill cooling system.
Run engine until thermostat opens.
Stop engine. Repeat steps 2 through 10, until
drained fluid is nearly colorless.
Remove, clean and reinstall coolant recovery
reservoir. Refer to "Battery Tray and Coolant
Recovery Reservoir" in this section.
[I]
Important
Use ONLY DEX - COOL engine coolant

meeting GM specification 6277M to provide
required freezing and corrosion protection.
14. Add enough water and DEX - COOL engine
coolant, (meeting GM specification 6277M) to
provide a solution that is at least 50 percent
antifreeze, but no more than 70 percent antifreeze.
A. Close air bleed vent when bubbles disappear
and only coolant is visible.
B. Fill radiator to below neck.
C. Fill reservoir to "FULL HOT" mark.
D. Add two cooling system sealer pellets (GM
PIN 3634621).
E. Install reservoir cap.
15. Run engine, with radiator pressure cap removed,
until normal operating temperature is reached
(radiator inlet hose becomes hot).
[I]
Important
All 5.7L (VIN P) engines are equipped with a

coolant level "latching" circuit. Read circuit
description under SECTION 8A-81 (Low
Coolant Indicator) and cycle ignition from
"OFF" to "RUN" before completing this
procedure.
CAUTION: Under some conditions,

ethylene glycol in engine coolant is
flammable. To avoid being burned when
adding engine coolant, do not spill it cm
the exhaust system or on hot engine
parts.
613-10
16. With engine idling, add engine coolant to radiator

until level reaches bottom of neck.
17. Install radiator pressure cap.
Arrows on cap must line up with vent tube.
ILI
~
Inspect
NOTICE: "LOW COOLANT"

warning/indicator lamp may come on after this
procedure. After operating vehicle so engine
heats up and cools down three times, if "LOW
COOLANT'' warning/indicator lamp does not
go out, or fails to come on at ignition check,
and coolant is above "FULL COLD" mark in
reservoir, refer to SECTION 8A. If at any time
the ''TEMP'' warning/indicator lamp comes on,
immediate action is required. Turn off engine
and allow vehicle to cool. Do not remove
radiator pressure cap at this time.
ALUMINUM RADIATOR SERVICE

Figures 3 and 4
This radiator uses an aluminum core with plastic
side tanks. The core and side tanks can be replaced
separately. Core repair is easily made with the hot
melt adhesive method. A transmission oil cooler may
be located in one of the side tanks. The radiator drain
cock is located on the lower part of one of the tanks.
3
The following components are serviceable:

Radiator core.
Tanks and gaskets. (Tanks cannot be repaired
if broken or cracked).
- Oil cooler and gaskets.
- Radiator drain cock and gasket.
-
Precautions
CAUTION: Failure to follow any one of
these procedures could result in personal
injury or component damage.
Do not remove radiator cap while engine is at
normal operating temperature. Cooling system
will release scalding fluid and steam if cap is
removed while engine and radiator are still
hot.
Do not use boil-out tanks or any tank that has
been used for copper or brass radiators.
Do not open hood if steam or coolant can be
seen escaping from engine compartment.
Do not remove cap on coolant recovery
reservoir if an engine over heat condition is
suspected.
Diagnosis
LEAK TESTING
Some core leaks can be detected by adding

water to the radiator. Clean the core so the damaged
area is easier to find.
4
2
~/' a~-r
ij,
l
I
i[
1
2
3
4
5
6
7
8
CORE, CROSS-FLOW RADIATOR

TANK, RADIATOR OUTLET
TANK, RADIATOR INLET
GASKET, RADIATOR SIDE TANK
COOLER, TRANSMISSION OIL
GASKET, TRANSMISSION OIL COOLER
NUT, TRANSMISSION OIL COOLER RETAINING
COCK, RADIATOR DRAIN
Figure 3 - Aluminum Radiator
'Ii.-~,--l.
-
.
-L~
----- 0
!,;,-,..,_
68-11
3. Remove radiator fill cap.

4. Fill cooling system to base of radiator neck.
5. Attach J 24460-01 to radiator neck.
Follow instructions supplied with J 24460-01.
6. Build up pressure to no more than 138 kPa
(20 psi).
7. System should hold pressure for about two
minutes.
A. If a measurable amount of pressure drops in
less than two minutes, check for leaks.
B. Mark leaking area and remove radiator for
repair; Refer to "Radiator" in this section.
OFF-VEHICLE LEAK TESTING
NOTICE: Do not use boil-out tanks or any

tank that has been used for copper or brass
radiators. The remaining solutions or chemicals
in these tanks could cause radiator failure.
Figures 6 and 7
\
I
8 COCK, RADIATOR DRAIN

9 SEALER, RADIATOR DRAIN COCK THREAD
10 ELBOW, RADIATOR DRAIN COCK
01-1795
FS00481:1
Figure 4 Aluminum Radiator Drain Cock
ON-VEHICLE PRESSURE TESTING
Figure 5
Tool Required:
1. Ensure that radiator and heater hose clamps are

properly positioned and secured.
2. Inspect connections for leaks. Repair as required.
CAUTION: To avoid being burned, do not

remove radiator cap while engine is at
normal operating temperature. The
cooling system will release scalding fluid
and steam under pressure if radiator fill
cap is removed while engine and radiator
are still hot.
Tool Required:
1. Plug radiator inlet and outlet tubes. Make sure
drain cock is closed.
2. Attach J 24460-01 to radiator.
3. Build up pressure to 138 kPa (20 psi).
4. Observe gage for any pressure loss.
5. Run water over repair area and look for any
bubbles.
If a large tank is available, radiator can be
submerged to check for air bubbles.
Repairable Leaks
Core leaks and gasket leaks are the two types of
leaks that can be repaired on the radiator. Core leaks
can occur in a tube or in the joints between the tubes
and headers. Gasket leaks can occur between the oil
cooler fittings and the tank. Some leaks can be
repaired while the radiator is on the vehicle; however,
it is more practical to remove the radiator from the
vehicle.
\
01-1Nl5
FSOOHl:1
Figure 5 Pressure Testing the Radiator
Figure 6 Aluminum Radiator and Oil Cooler Plugs
68-12
------Figure 9 - Fins Removed from Damaged Area

E
D
A
B
C
D
E
F
GASKET, RADIATOR INLET TANK

TUBE ASSEMBLIES, RADIATOR CORE
GASKET, RADIATOR OUTLET TANK
GASKET, RADIATOR DRAIN COCK
GASKETS, OIL COOLER
JOINT BE1WEEN TUBE AND HEADER
CUT
TUBE
01-17-15
FS0078B
Figure 1O - Tube Blocking
Figure 7 - Possible Leak Areas
Repair Methods
Tube Blocking
off.
The hot melt adhesive is the most effective

method of repairing the radiator core. The hot melt
adhesive kit contains adhesive sticks, cotton swabs,
wire brush and primer. The adhesive kit is reusable,
has an indefinite shelf life and is waste free. The
sticks must be stored in a sealed container to keep
them dry.
Cooling Fin Removal

For damaged areas that are between the cooling
fins, it may be necessary to remove some of the fins.
Do not remove more fins than necessary. Usually
removal of fins 6 mm ( 1/4 inch) beyond the leak or
damage area is enough to make an accurate repair.
If a tube is severely damaged, it can be blocked
II]
Important
Do not block off more than two tubes in a

radiator. Blocking off more than two tubes will
reduce the cooling capability of the system.
The tube should be cut off 6 mm (114 inch)
from the header and pinched shut before it is cleaned
and sealed.
Header Repair
NOTICE: To prevent damage to the tank or
gasket, the following procedures must be used
when repairs are made on or near the header. If
the header or the tube near the header requires a
repair, the side tank does not have to be
removed. A damp cloth can be placed against
the side tank where the repair has to be made.
The side tank can also be submerged in a tank
of water up to the header.
General Core Repair

If the leak area surface is not clean, the repair
material will not stick to the surface.
Figure 8 - Hot Melt Adhesive Repair Kit
1. Position core so repair area is accessible.
01-1795
FS0118B
Figure 11 Using a Wet Cloth on the Side Tank
68-13
OM795
F80146B
Figure 14 Scrubbing the Area with Primer
SUBMERGE
TANKKEEP
HEADER
ABOVE
WATER LINE
011795
F80128B
Figure 12 - Submerging the Side Tank
Figure 15 Heating the Repair Area
Figure 13 Cleaning the Area with a Steel Brush
Figure 16 Applying Hot Melt Adhesive
2. Apply wet cloth between core pipes and headers

if working near plastic tanks or joints or submerge
tank in water.
3. Heat repair area slightly with small torch or heat
gun to be sure it is dry.
Do not use a blow torch.
4. Brush area to be repaired with small steel brush

that is supplied in kit and remove dust away from
repair area.
6814

when using the primer (which contains
trichloroethane) the following
precautions and steps should be
followed:
If primer is swallowed, seek
medical attention.
If primer contacts the eyes, do not
rub eyes. Splash the affected area
with large quantities of cold water
and seek medical attention.
If primer contacts the body, wash
thoroughly with soap and water.
Do not mix the primer with water.
5. Open tube of primer using spurred cap or pin and
apply primer to repair area only. Use of primer
produces stronger repair.
6. Scrub repair area with cotton swab until fresh
swab stays clean.
Clear, yellow-brown coating does not have to
be removed.
7. Heat repair area with heat gun or by moving
small torch in circular pattern using soft, blue
flame.
8. Withdraw small torch or heat gun and rub
adhesive stick on repair area. Adhesive will flow
at temperature of approximately 260C (500F).
If stick doesn't start to melt, remove it and
reapply heat. Do not heat stick directly with
flame. High heat will bum and char adhesive.
9. Continue heating until adhesive flows and wets
entire repair area and fills joint. If a hole is in
center of tube, heat tube and let hot surface melt
and pull in adhesive. Force of flame or heat gun
will also tend to guide adhesive toward hole. For
leaks between tube and header, flow adhesive
completely around tube and header joint with tank
installed.
10. Heat repair area until adhesive is bubble free,
smooth and has light yellow color. Curing is not
required.
11. Test radiator for leaks when cool. Refer to
"Off-Vehicle Testing" in this section. If repair
area still leaks, heat it gently to dry it. Heat and
flow adhesive or apply more as necessary to
repair leak.
NOTICE: Do not over bend tabs. Over

bending tabs could result in breaking tab. If
more than three tabs are broken on one side of
header or more than two adjacent tabs are
broken, the core must be replaced.
2. Lift tank and slide it out from under remaining
clinched tab.
Tapping tank with your hand may be required
to dislodge gasket.
3. Lift remaining tab(s) with pliers.
4. Remove and discard gasket.
Clean
Header gasket groove of dirt and old rubber.

Sealing edge of plastic tank.
IL!
5.
6.
7.
8.
Inspect
Header gasket surface and tank flange for

evidence of leaks.
Surfaces and remove dirt, burrs and bumps.
Remove transmission oil cooler, if equipped, and
install it into new tank.
Dip or coat new gasket in engine coolant and
position it on header surface.
Position tank and gasket to header. Clamp it in
place and secure it by bending four clinch tabs.
Clamp remaining clinch tabs around header using
J 33419-A or pliers.
Start at center and work towards end.

9. Replace core if there are more than three tabs
broken on one side or if two adjacent tabs are
broken.
10. Install radiator drain cock, if removed.
lL Test radiator for leaks. Refer to "Off-Vehicle Leak
Testing" in this section.
Radiator Side Tank Gasket Leak Repair

Tool Required:
J 33419-A Radiator Core Remover/Installer
Radiator side tank gasket leaks cari easily be
mistaken for tank or header leaks. If a plastic tank
leaks from the header joint gasket, tighten the
clinch tabs with J 33419-A or locking-type pliers. If
the tank still leaks, remove and repair it.
1. Pry open clinch tabs except those under inlet,
outlet and radiator neck, using J 33419-A or
screwdriver.
Lift tabs only enough to allow removal.
01-1715
FS0118B
Figure 17 Tightening the Clinch Tabs
68-15
SLIP J 33419-A
UNDER TAB
AND PUSH BACK
01-1795
01-1795
FS0188B
FS0218B
Figure 21 - Removing the Transmission Oil Cooler Gasket
Figure 18 - Opening the Clinch Tabs
3. Press transmission oil cooler into hole and remove

gasket using small .hook.
4. Blow dry all surfaces on outlet tank and
transmission oil cooler.
5. Install new transmission oil cooler gasket without
lubrication.
BEND FOUR
CLINCH TABS
01-1796
Be sure gasket is properly seated inside lip of

fitting.
6. Reach into inlet or outlet opening and push
transmission oil cooler into position against outlet
tank.
FS0198B
Figure 19 Seating the Tank to the Core
NOTICE:
See "Notice" on page 6B-1.
7. Install transmission oil cooler pipe loosely.

To replace other gasket, follow previous steps
in order.
!~!
Tighten
Transmission oil cooler pipe connections to

27 N.m (20 lb. ft.).
011796
FS0208B
Figure 20 - Clinching Sequence
Transmission Oil Cooler Gasket

Figure 21
\I
The outlet tank must be removed to replace the

transmission oil cooler but the transmission oil cooler
gasket can be replaced without removing the outlet
tank.
1. Remove radiator. Refer to "Radiator" in this
section.
Lay radiator on flat surface.
2. Remove bottom transmission oil cooler pipe and
loosen top pipe connection.
- Do not overtighten.
8. Leak test radiator. Refer to "Off-Vehicle Leak
Testing" in this section.
9. Install radiator. Refer to. "Radiator" in this
section.
Transmission Oil Cooler

Figure 3
!+-+I
1.
2.
3.
4.
5.
Radiator. Refer to "Radiator" in this section.
Outlet tank.
Transmission oil cooler retaining nuts.
Transmission oil cooler gaskets.
Transmission oil cooler.
68-16
Clean
Sealing surfaces.
lHi
Install or Connect
NOTICE:
1. New transmission .oil cooler gaskets without

lubrication.
2. Transmission oil cooler into outlet tank.
3. Transmission oil cooler retaining nuts:
4. Outlet tank.
Be careful not to loosen or misalign gaskets.
5. Radiator. Refer to "Radiator" in this section.
11
12
13
16
Recore
If the radiator core is damaged beyond repair
and the other parts are serviceable, install the original
inlet and outlet tanks, transmission oil cooler, radiator
filler cap and radiator drain cock onto a new core and
install new gaskets.
OUTLET, WATER
SOLT/SCREW, WATER OUTLET
THERMOSTAT, ENGINE COOLANT
GASKET, WATER OUTLET
9-13-&i
FS0396B
Figure 22 - Engine Coolant Thermostat (3800 VIN K)
Radiator Drain Cock

Figure 4
If the radiator drain cock does not seal when
tightened snugly, remove the radiator drain cock, clean
the drain hole and replace the radiator drain cock. If
the body of the radiator drain cock is broken, remove
the body from the tank by squeezing the sides together
with needle nose pliers.
11
ENGINE COOLANT THERMOSTAT

Figures 22 and 23
3800 VINK
!++!
NOTICE:
3.
4.
5.
6.
7.
8.
9.
OUTLET, WATER
BOLT/SCREW, WATER OUTLET
THERMOSTAT, ENGINE COOLANT
GASKET, WATER OUTLET
01-17115
FS0236B
Figure 23 Engine Coolant Thermostat (5.7L VIN P)
1. Open radiator drain cock and drain engine coolant

from radiator to below level of engine coolant
thermostat.
!~I
11
12
13
16
Clean
Gasket surfaces of water outlet and upper intake

manifold.
l++I
Install or Connect
Tighten

EGR valve outlet pipe bolts/screws from upper
intake and EGR valve adapter.
EGR valve outlet pipe.
Loosen hose clamp and remove inlet hose (11)
from water outlet.
Water outlet bolts/screws (12).
Water outlet (11).
Water outlet gasket (16).
Engine coolant thermostat (13).
NOTICE:
1. Engine coolant thermostat (13) into upper intake

manifold.
2. New water outlet gasket (16).
3. Water outlet (11).
4. Water outlet bolts/screws (12).
l~J
Tighten
Water outlet bolts/screws (12) to 27 N.m

(20 lb. ft.).

5. Inlet hose (11) to water outlet and tighten hose
clamp.
6. EGR valve outlet pipe.
7. EGR valve outlet pipe bolt/screw to upper intake
and EGR valve adapter.
!~!
Tighten
EGR valve outlet pipe bolt/screw to upper

intake to 25 N.m (18 lb. ft.).
EGR valve outlet pipe nut to EGR valve
adapter to 29 N,m (21 lb. ft.).
!L!
Inspect
For leaks, after running engine to normal

5.7L VIN P
E3
NOTICE:
1. Open radiator drain cock and drain engine coolant

from radiator to below level of engine coolant
thermostat.
l~I
Tighten

3. Air intake duct and air cleaner.
4. Inlet hose and clamp from water outlet.
5. Water outlet bolt/screw (12).
7. Water outlet gasket (16), if equipped.
8. Engine coolant thermostat ( 13).
68-17
5. Inlet hose and clamp to water outlet.

6. Air cleaner and air intake duct.
7. Add engine coolant. Refer to "Draining and
Refilling the Cooling System" in this section.
IL!
Inspect

ELECTRIC ENGINE COOLANT FAN

Figure 24
CAU.TION: Keep hands, tools, and
clothing away from electric engine
coolant fans to help prevent personal
injury. These fans are electric and can
come on whether or not the engine is
running. The fans can start automatically
in response to a heat sensor with the
ignition in the "ON" position.
!+-+!
1.
2.
3.
4.
Air intake duct and air cleaner.

Electrical connector and clips.
Radiator upper mounting panel.
Electric engine coolant fan (19).
Electric engine coolant fan (19) will slide off
of radiator (18).
5. Fan blade nut.
6. Fan blade.
IL!
Inspect
For bent or cracked fan blades.

Mating surfaces for smoothness. Remove burrs or
other imperfections as necessary.
Clean
Gasket surfaces of water outlet and intake

manifold or water pump.
!++!
Install or Connect
NOTICE:
1. Engine coolant thermostat into intake manifold or

water pump.
2. New water outlet gasket (16), if equipped.
4. Water outlet bolt/screw (12).
l~I
Tighten
Water outlet bolt/screw (12) to 28 N,m

(21 lb. ft.).
18
18
19
RADIATOR
FAN, ENGINE COOLANT
Figure 24 - Engine Coolant Fan
03-27-95
FT02481!1
68-18
CAUTION: If a fan blade is bent or

damaged in any way, no attempt should
be made to repair and/or reuse the
damaged part. A bent or damaged fan
blade should always be replaced with a
new fan blade.
CAUTION: It is essential that the fan

blade remain in proper balance. Balance
cannot be assured once a fan blade has
been bent or damaged. A fan blade that
is not in proper balance could fail and fly
apart during subsequent use, creating an
extremely dangerous condition.
I++!
Install or Connect
NOTICE:
Tighten
Radiator upper panel mounting bolts/screws to

12 N.m (106 lb. in.).
5. Electrical connector and clips.
3800 VINK
!++!
1. Drain radiator. Refer to "Draining and Refil1ing

Cooling System" in this section.
3. Radiator inlet hose from pump.
4. Water pump pulley bolts/screws (27).
5. Water pump pulley (28).
6. Water pump bolts/screws (29).
7. Water pump (32) and water pump gasket (33).
Clean
All gasket surfaces.

Water pump bolts/screws.
!++!
Electric engine coolant fan (19) will slide into

place.
4. Radiator upper mounting panel.
A
27
28
29
32
33
34
Figures 25 and 26
1. Fan blade.
2. Fan blade nut.
3. Electric engine coolant fan (19).
l~I
WATER PUMP
Install or Connect
NOTICE:
1. New water pump gasket (33).

2. Water pump (32).
3. Water pump bolts/screws (29).
l~l
Tighten
Water pump bolts/screws (29) to 15 N.m

(11 lb. ft.) plus 80.
4. Water pump pulley and bolts/screws {27).
LOCATING PINS
BOLT/SCREW, WATER PUMP PULLEY
PULLEY, WATER PUMP
PUMP. WATER
GASKET, WATER PUMP
COVER, ENGINE FRONT
34
9-13-94
FS04068
Figure 25 Water Pump (3800 VIN K)
156
6819
63
37
A
B
37
38
39
40
41
63
156
40
41
SHAFT, WATER PUMP

TAB ON GASKET
PUMP, WATER
GASKET, WATER PUMP
COUPLING, WATER PUMP DRIVESHAFT
BOLT/SCREW, WATER PUMP.
ORIVESHAFT, WATER PUMP
SEAL, WATER PUMP DRIVESHAFT
01-17-95
FS0286B
Figure 26 - Water Pump (5.7L VIN P)
!~I
Tighten
Water pump pulley bolts/screws (27) to

13 N.m (115 lb. in.).
6. Radiator inlet hose to water pump.
Refilling the Cooling System " in this section.
IL!
Inspect

5.7l. VIN P
Tool Required:
0-Ring Seal Installer
I+-+!
1. Electrical connectors from electric engine coolant

fans.
2. Electric engine coolant fans. Refer to "Electric
Engine Coolant Fan" in this section.
3. Engine block coolant drain hole plug and knock
sensor.
4. Drain engine coolant. Refer to "Draining and
5. Install drain plug and knock sensor.

7. Upper and lower radiator hose from water pump.
8. Heater hoses from water pump and throttle body.
Refer to SECTION lA.
9. Electrical connector from coolant sensor.
10. Reposition coil and bracket.
11. Air pump and bracket. Refer to SECTION 6E3.
12. Water pump bolts/screws (40 and 41).
13. Water pump (37).
14. Water pump gaskets (38).
15. Shaft coupling (39), and water pump driveshaft
seals (156).
Clean
Water pump gasket surfaces.

Water pump bolts/screws (40 and 41).
I++!
Install or Connect
1. Shaft coupling (39), and water pump driveshaft

seals using J 39089 (156).
2. Water pump gaskets (38).
3. Water pump (37).
4. Water pump bolts/screws (40 and 41).
!~!
Tighten
Water pump bolts/screws (40 and 41) to

41 N.m (30 lb. ft.).
6820
5.
6.
7.
8.
9.
10.
11.
12.
Air pump and bracket. Refer to SECTION 6E3.

Position coil and bracket.
Electrical connector to coolant sensor.
Heater hoses to water pump and throttle body.
Refer to SECTION lA.
Upper and lower radiator hose to water pump.
Air cleaner and air intake duct.
Refill cooling system. Refer to "Draining and
Electrical connectors to electric engine coolant
fans.
IL!
Clean
Battery tray and reservoir (39) with soap aid

water. Rinse thoroughly.
I++!
NOTICE:

BATTERY TRAY AND COOLANT

RECOVERY RESERVOIR
1. Battery tray and coolant recovery reservoir (39).

2. Bolt/screw (40).
!~!
Inspect
Tighten

3. Coolant recovery hose.
4. Battery. Refer to SECTION 601.
5. Add engine coolant to "FULL COLD" mark on
reservoir.
Figure 27
COOLANT LEVEL INDICATOR MODULE
!++!
5.7L VIN P
1.
2.
3.
4.
Battery. Refer to SECTION 601.
Coolant recovery hose.
Bolt/screw (40).
Battery tray and coolant recovery reservoir (39).
!++!

SECTION OA.
2. Open radiator drain cock, and drain engine
coolant from radiator to below level of engine
coolant level indicator module.
3. Lower vehicle.
5. Electrical connector at module.
6. Module from radiator.
!++!
Install or Connect
1. Module to radiator.
A. Apply lubricant to 0-ring.
B. Align coolant module to module port in
radiator.
C. Press module probe into radiator module port
housing until retainer spring snaps onto port
flange.
2. Electrical connector to sensor.
RADIATOR
Figures 28 and 29
39 RESERVOIR, BATIERYTRAY AND COOLANT
RECOVERY
40 BOLT/SCREW, COOLANT RECOVERY RESERVOIR
01-1715
FS02HB
Figure 27 Battery Tray and Coolant Recovery Reservoir
Install or Connect
f++!
1. Hold down bolts/screws and air box cover

(WS6 Only).
2. Air Filter (WS6 Only).
68-21
43
45
~:
18 RADIATOR ASSEMBLY
42 INSULATOR, RADIATOR LOWER (LEFT HAND)
43 INSULATOR, RADIATOR LOWER (RIGHT HAND)
44 SEAL ASSEMBLY, RADIATOR AIR LOWER
01-17-95
FS030fSB
Figure 28 - Radiator Insulators and Seal
4. Electrical connector from air temperature sensor

(WS6 Only).
5. Vent hose clamp and vent hose from lower air
box (WS6 Only).
6. Clamp attaching rubber shoulder from lower air
box to mass air flow sensor (WS6 Only).
7. Bolt/screw attaching lower air box to radiator
support (WS6 Only).
8. Lower air box from vehicle (WS6 Only).
SECTION OA.
10. Drain engine coolant. Refer to "Draining and
11. Electrical connectors at electric engine coolant
fans.
12. Radiator upper mounting panel (48).
14. Transmission oil cooler lines. Refer to
SECTION 7A.
15. Coolant level indicator module, if equipped. Refer
to "Coolant Level Indicator Module" in this
section.
16. Lower vehicle.
17. Loosen receiver dehydrator bracket.
18. Lower radiator hose at water pump.
19. Upper radiator hose.
20. Overflow tube.
21. Radiator from condenser.
22. Radiator (18).
!!
Install or Connect
NOTICE:
1. Radiator (18).
A
B
C
D
E
45
46
47
48
PANEL, UPPER
RADIATOR
INSULATOR, RADIATOR UPPER
INSULATOR, RADIATOR UPPER MOUNTING PANEL
FAN, ENGINE COOLING
BAR, FRONT BUMPER IMPACT
BAR, FRONT END UPPER TIE
BOLT/SCREW, RADIATOR UPPER MOUNTING PANEL
PANEL, RADIATOR UPPER MOUNTING
01-17-95
FS0318B
Figure 29 - Radiator Upper Mounting Panel
Make sure radiator is seated on radiator

insulators (42 and 43).
2. Radiator to condenser.
3. Overflow tube.
4. Upper radiator hose.
5. Lower radiator hose to water pump.
6. Tighten receiver dehydrator bracket.
SECTION OA.
8. Coolant level indicator module, if equipped. Refer
to "Coolant Level Indicator Module" in this
section.
9. Transmission oil cooler lines. Refer to
SECTION 7A.
11. Radiator upper mounting panel (48).
!~!
Tighten
Radiator upper panel mounting ( 48)

bolts/screws to 12 N.m (106 lb. in.).
12. Electrical connectors to electric engine coolant
fans.
Refilling the Cooling System'' in this section.
14. Lower vehicle.
15. Lower air box to vehicle (WS6 Only).
16. Bolt/screw attaching lower air box to vehicle
(WS6 Only).
68-22
17. Clamp attaching rubber shoulder from lower air

box to mass air flow sensor (WS6 Only).
18. Vent hose and vent hose clamp to lower air box
(WS6 Only).
19. Electrical connector to air temperature sensor
(WS6 Only).
20. Air cleaner. and air intake duct.
21. Air Filter (WS6 Only).
22. Air box cover and h.old down bolts/screws
(WS6 Only).
!LI
Inspect

I~!
Radiator Upper Mounting Panel
Radiator Air Lower Baffle and Deflector

Figure 30
!++I
1. Radiator air lower deflector bolt/screw (52).

2. Radiator air lower baffle retainers (500).
3. Radiator air lower baffle (49).
!L!
RADIATOR AIR BAFFLES AND

DEFLECTORS
Tighten
Inspect
NOTICE:
Figure 29
!++I
1. Radiator air lower baffle (49).

2. Radiator air lower baffle retainers (50).
3. Radiator air lower deflector bolt/screw (52).
2. Upper mounting panel (48).
!++!
I~!
Install or Connect
Tighten
1. Upper mounting panel (48).
18
49
50
51
52
RADIATOR
BAFFLE, RADIATOR AIR LOWER
RETAINER, RADIATOR AIR LOWER BAFFLE
DEFLECTOR, RADIATOR AIR LOWER
BOLT/SCREW, RADIATOR AIR LOWER DEFLECTOR
Figure 30 Radiator Air Lower Baffle
01-1795
FS0326B
68-23
ENGINE COOLANT AIR BLEED PIPE

5.7L VIN P
Figure 32
!+-+!
18
45
46
53
54
RADIATOR
BAR, FRONT END UPPER TIE
BAFFLE, RADIATOR AIR UPPER
RETAINER, RADIATOR AIR UPPER BAFFLE
01-17-SIS
FS033tB
Figure 31 - Radiator Air Upper Baffle
1. Drain coolant. Refer to "Draining and Refilling

Cooling System" in this section.
2. Coolant air blee.d pipe bolts/screws (59) from
cylinder heads.
Use a backup wrench.
3. Lower vehicle.
4. Upper alternator bracket. Refer to SECTION 6D3.
5. Electrical connectors and vacuum hoses, as
necessary, to gain access to bleed pipe.
6. Coolant air bleed pipe mounting nut (56) at intake
manifold.
7. Coolant hose at air bleed pipe (55).
8. Coolant air bleed pipe (55).
!-++I
Install or Connect
Radiator Air Upper Baffle

NOTICE:
Figure 31
l++I
1. Radiator air upper baffle retainers (54).

2. Radiator air upper baffle (53) from radiator (18).
!.+!
Install or Connect
NOTICE:
1. Radiator air upper baffle (53) to radiator (18).

2. Radiator air upper baffle retainers (54).
ENGINE COOLANT HOSES
I++!
1. Drain radiator so level of engine coolant is below
hose being removed.

3. Inlet hose from radiator and engine coolant
thermostat.
4. Outlet hose from radiator and water pump.
!.+!
Install or Connect
NOTICE:
See "Notice" on page 6B.:.1.
1. Outlet hose and clamps to radiator and water

pump.
2. Inlet hose to radiator and engine coolant
thermostat.
l Add engine coolant. Refer to "Draining and
Refilling Cooling System" in this section.
1. Coolant air bleed pipe (55).

2. Coolant hose at air bleed pipe (55).
3. Air bleed pipe mounting nut (56) at intake
manifold.
!~!
Tighten
Mounting nut (56) to 21 N.m (15 lb. ft.).

4. Electrical connectors and vacuum hoses, as
necessary.
5. Upper alternator bracket. Refer to SECTION 6D3.
SECTION OA.
7. Coolant air bleed pipe bolts/screws (59) to
cylinder heads.
Use a backup wrench.
!~!
Tighten
Mounting bolts (59) to 42 N.m (31 lb. ft.).

8. Refill cooling system. Refer to "Draining and
Refilling Cooling System" in this section.
TESTING THE COOLANT

CONCENTRATION
Tools Required:
J 23688-A or J 26568-A Coolant Tester
[I)
Important
Both J 23688-A and J 26568-A automatically

compensate for temperature.
68-24
55
PIPE, COOLANT AIR BLEED
56 NUT, COOLANT AIR BLEED PIPE MOUNTING

57
STUD, COOLANT AIR BLEED PIPE
58 WASHER, COOLANT AIR BLEED PIPE

59
OMNJS
BOLT/SCREW, COOLANT AIR BLEED PIPE
FS0348B
Figure 32 - Engine Coolant Air Bleed Pipe (5.7L VIN P)
Make sure eyepiece of J 23688-A or

J 26568-A is totally free of solution before
looking through it. Refer to Figure 33.
Before each use, swing plastic cover at slanted
end of J 26568-A or J 23688-A exposing
measuring window and bottom of plastic
cover.
Wipe dry both prism and bottom of sample
cover with tissue or clean soft cloth. Refer to
Figure 33.
Close plastic cover.
1. Release tip of pump from J 23688-A or
J 26568-A housing.
Do not remove clear plastic pump from
J 23688-A or J 26568-A.
CAUTION: To avoid being burned, DO

NOT remove coolant recovery reservoir
cap while engine is at normal operating
temperature. The cooling system will
release scalding fluid and steam under
pressure if cap is removed while engine
and radiator are still hot. This could
result in a. large coolant loss and
possible personal injury.
2. Remove coolant recovery reservoir cap.
3. Insert. tube into coolant recovery reservoir.
Make sure tube is below level of coolant.
4. Press and release bulb to get sample of coolant.
5. Bend tube around J 23688-A or J 23568-A so that
tip can be inserted in cover plate opening.
01-17-85
FS03688
Figure 33 - Cleaning the Coolant Tester
01-17-115
FS0366B
Figure 34 - Collecting the Coolant
68-25
Temperature scale is reversed from a standard

thermometer scale. Below zero readings are on
upper half of scale.
If readings are not clear, the measuring prism
was not cleaned and dried or there was not
enough fluid on measuring prism.
J 23688-A OR
J 26568-A
Calibrating Testers
01-1795
FS0378B
Figure 35 - Reading the Coolant Tester
6. Press bulb and allow a few drops to fall onto

measuring surface.
Do not open plastic cover when taking
readings because water evaporation can change
readings.
7. Point J 23688-A or J 26568-A toward any light
source and look into eyepiece.
Coolant protection reading is at point where
dividing line between light and dark crosses
scale on right.
J 23688-A and J 26568-A are factory calibrated

and sealed and should not require adjustment. If
adjustment is required, follow instructions below.
1. Make sure J 23688-A and J 26568-A is between
21 and 29C (70 and 85F).
2. Using distilled water, take a reading. If reading
departs from a 0C (32F) reading on scale, a
correction can be made by adjusting screw on
bottom of J 23688-A and J 26568-A.
3. Remove sealant covering screw.
[I]
Important
Do not remove screw from J 23688-A and

J 26568-A.
4. Turn screw in direction necessary to adjust
reading to 0C (32F) line.
5. Reseal the screw using a silicone sealant.
SPECIFICATIONS
Cooling System Approximate Fluid Capacities
3800 VINK
With Manual Transmission ............................................................................................ 11.8
With Automatic Transmission ....................................................................................... 11.6
5.7L VIN P
With Manual Transmission ........................................................................................... 14.5
With Automatic Transmission .. .... .. .. .. .. .. .. .... .. .. .. .. .... .. .. .. .. ... .. ... .. .. .... .. .. .. .. .. .. .. .. .. . .. ... .. .. 14.3
liters (12.5 qt.)

liters (12.3 qt.)
liters (15.3 qt.)
liters (15 .1 qt.)

Battery Tray and Coolant Recovery Reservoir Bolt/Screw ................................................. 12 N .m (106 lb. in.)
Engine Coolant Air Bleed Pipe Mounting Bolts/Screws ....................................................... 40 N.m (30 lb. ft.)
Engine Coolant Air Bleed Pipe Mounting Nut ..................................................................... 17 N,m (13 lb. ft.)
Engine Block Coolant Drain Hole Plug ................................................................................... 18 N,m (3 lb. ft.)
Engine Front Cover Bolt/Screw .............................................................................................. 11 N .m (97 lb. in.)
Knock Sensor ........................................................................................................................... 20 N.m (15 lb. ft.)
Power Steering Bracket Bolt/Screw ........................................................................................ 40 N.m (30 lb. ft.)
Radiator Air Lower Deflector Bolt/Screw ............................................................................. 1.5 N.m (13 lb. in.)
Radiator Drain Cock ............................................................................................................... 1.5 N,m (13 lb. in.)
Radiator Upper Mounting Panel Bolt/Screw ........................................................................ 12 N,m (106 lb. in.)
Water Outlet Bolt/Screw (3800 VIN K) ................................................................................ 27 N.m (20 lb. ft.)
Water Outlet Bolt/Screw (5.7L VIN P) .................................................................................. 28 N,m (21 lb. ft.)
Water Pump Bolt/Screw (3800 VIN K) ......................................... 15 N.m (11 lb. ft.) + additional 80 degrees
Water Pump Bolt/Screw (5.7L VIN P) ................................................................................... 41 N.m (30 lb. ft.)
Water Pump Cover Bolt/Screw ............................................................................................... 41 N,m (30 lb. ft.)
Water Pump Pulley Bolt/Screw (3800 VIN K) ................................................................... 13 N,m (115 lb. in.)
68-26
SPECIAL TOOLS
(
2
J 33419-A
1 COOLING SYSTEM TESTER

2 RADIATOR CORE REMOVER/INSTALLER
3 COLLANT TESTER
J 23688-A OR J 26568-A
0501811
FT0388B
Engine Fuel 6C-1
Section 6C
Engine Fuel
CAUTION: This vehicle is equipped with
Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "ON-VEHICLE
SERVICE" and the SIR Component and Wiring
Location view in Section 9J before performing
service on or around SIR components or wiring.
Failure to follow CAUTIONS could result in possible
air bag deployment, personal injury, or otherwise
Notice: Always use the correct fastener in the correct

location. When you replace a fastener, use ONLY the
exact part number for that application. General Motors
will call out those fasteners that require a replacement
after removal. General Motors will also call out the
fasteners that require thread lockers or thread sealant.
UNLESS OTHERWISE SPECIFIED, Do Not use
supplemental coatings (paints, greases,or other
corrosion inhibitors) on threaded fasteners or fastener
joint interfaces. Generally, such coatings adversely
affect the fastener torque and the joint clamping force,
and may damage the fastener. When you install
fasteners, use the correct tightening sequence and
specifications. Following these instructions can help you
avoid damage to parts and systems.
Contents
General Description . . . . . . . . . . . . . . . . . . . 6C-2
Fuel Tank Vent Valve (Remote Mounted) . . . . . 6C-2
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-2
Fuel Tank Filler Pipe . . . . . . . . . . . . . . . . . . . . . 6C-2
Fuel Filler Cap . . . . .. . . . .. . . . . . . . . . . .. .. . 6C-2
Fuel Sender Assembly . . . . . . . . . . . . . . . . . . . . . 6C-3
Fuel Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-3
Fuel Pump and Reservoir Assembly . . . . . . . 6C-4
Fuel Pump Strainer . . . . . . . . . . . . . . . . . . . . . . 6C-5
In-Line Fuel Filter ................. , . . . . . . . 6C-5
Fuel Feed and Return Pipes ................ 6C-5
Nylon Fuel Pipes . . . . . . . . . . . . . . . . . . . . . . . . 6C-5
Quick-Connect Fittings . . . . . . . . . . . . . . . . . . . 6C-6
Fuel Pipe 0-Rings . .. . . . . . . .. .. . . . . . .. . .. 6C-6
EVAP Pipes and Hoses . . . . . . . . . . . . . . . . . . . . 6C-6
Accelerator Controls ............ Go to Section 6E3
Diagnosis . . . . . . . . . . . . 6C-6
Alcohol-in-Fuel .. . . . . .. .. . .. . . . . . . . . . . .. . .. 6C-6
Testing Procedure . . . . . . . . . . . . . . . . . . . . . . . 6C-6
Fuel Tank Leak Check . . . . . . . . . . . . . . . . . . . . . 6C-6
Fuel Tank Vent Valve Check ................ 6C-7
Fuel System Pressure
Test . . . . . . . . . . . . . . Go to Section 6E3, Table A-7
Fuel Sender Assembly Diagnosis ... Go to Section BA
Fuel Pump Electrical
Diagnosis . . . . Go to Section 6E3 and Section BA
On-Vehicle Service .................... 6C-7

Fuel System Pressure Relief . . . . . . . . . . . . . . . . 6C-7
Servicing Quick-Connect Fittings . . . . . . . . . . . . 6C-B
In-Line Fuel Filter Replacement . . . . . . . . . . . . . 6C-9
Draining Fuel Tank ....................... 6C-10
Fuel Tank Replacement ................... 6C-10
Fuel Tank Vent Valve ...................... 6C-11
Fuel Sender Assembly Replacement ....... 6C-12
Fuel Sender Assembly Service ............. 6C-13
Fuel System Cleaning .................... 6C-14
Fuel Tank ............................. 6C-14
Fuel Feed, Return, and EVAP Pipes ........ 6C-15
Rear Fuel Feed, Return, and EVAP
Pipe Replacement (Fuel Tank) ......... 6C-15
Chassis Fuel Feed, Return,
and EVAP Pipe Repair/Replacement ... 6C-16
Engine Compartment Connecting
Fuel Feed, Return, and EVAP
Pipe Replacement (Chassis to Engine) . 6C-1B
Accelerator Controls ............ Go to Section 6E3
Specifications ........................... 6C-19
Torque Specifications ..................... 6C-19
Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . 6C-19
Special Tools ........................ 6C-19
6C-2 Engine Fuel
General Description
The fuel supply is stored in the fuel tank. An electric fuel
pump, attached to the fuel sender assembly (inside the
fuel tank) pumps fuel through an in-line filter to the fuel
rail assembly. The pump is designed to provide fuel at a
pressure above the regulated pressure needed by the
injectors. A pressure regulator, an integral part of the
fuel rail assembly, keeps fuel available to the injectors at
a regulated pressure. Unused fuel is returned to the fuel
tank by a separate pipe. For further information on the
fuel injection system, go to Fuel Metering System
located in Section 6E3-C2.
Unleaded fuel must be used with all gasoline engines for
proper emission control system operation. Using
unleaded fuel will also decrease spark plug fouling and
extend engine oil life. Leaded fuel can damage the
emission control system, and its use can result in loss of
emission warranty coverage.
All vehicles with gasoline engines are equipped with an
evaporative emission system that minimizes the escape
of fuel vapors to the atmosphere. Information on this
system is located in Section 6E3-C3.
Figure 1
The fuel tank vent valve, located in the rear of the

vehicle by the fuel tank, is a pressure/vacuum relief
valve. When fuel tank pressure exceeds a specified
pressure the valve will open allowing tank pressure to
bleed off. When the fuel tank is in a vacuum condition,
the vent valve will open when the vacuum is within a
specified range allowing fresh air to be pulled in.
Fuel Tank
The fuel tank is used to store fuel for the vehicle. The
tank is located in the rear of the vehicle and is held in
place by two metal straps that are attached to the frame.
The fuel tank is made of steel and is coated internally
with a special corrosion inhibitor.
Fuel Tank Filler Pipe
Figure2
To prevent refueling with leaded fuel, the fuel filler pipe

has a built-in restrictor and deflector.
Fuel Filler Cap
Fuel Tank Vent Valve
Figure 2 - Fuel Filler Cap
(Remote Mounted)
Figure 1 - Fuel Tank Vent Valve
FUEL FILLER CAP
FUEL TANK FILLER PIPE
FUEL FILLER DOOR
MS90716C
Figure2
The fuel tank filler pipe is equipped with a non-vented

threaded-type cap. The threaded part of the cap
requires several turns counterclockwise to remove. A
built-in torque-limiting device prevents over tightening.
To install, turn the cap clockwise until a clicking noise is
heard. This signals that the correct torque has been
reached and the cap is fully seated.
1
2
3
Notice: If a fuel filler cap requires replacement, use only

a cap with the same features. Failure to use the correct
cap can result in a serious malfunction of the system.
FUEL TANK
FUEL TANK VENT VALVE
REAR BRAKE HOSE BRACKET
3-31-94
NS15941
Engine Fuel 6C-3

Fuel Sender Assembly
Figure 3 - Fuel Sender Assembly
10
QUICK- CONNECT FITTING

{FUEL PUMP FLEX PIPE)
LOCKING TABS
ROLL-OVER VALVE
FUEL PUMP STRAINER
VENT HOSE RETAINER
10
FUEL SENDER ASSEMBLY
VENT HOSE
11
FLOAT
SENSOR
12
FUEL SENDER
13
FLOAT ARM
FUEL PUMP&
RESERVOIR ASSEMBLY
BUMPER
14
FUEL RETURN HOSE
Figure 3
Fuel Sender
The fuel sender assembly is located inside the fuel tank

and is attached to the top of the fuel tank. The fuel
'
sender assembly consists of the following major
components: a fuel sender, fuel pump and reservoir
assembly, and a fuel pump strainer.
Figure 3
3-17-94
NA5094-AS
The fuel sender consists of the float, wire float arm,

sensor and roll-over valve. Fuel level is sensed by the
position of the float arm, and a signal is sent to the
display in the vehicle instrument cluster.
The roll-over valve is pressed into the EVAP pipe of the
fuel sender and is not serviced separately. The roll-over
valve prevents fuel spilling from the fuel sender EVAP
pipe if the vehicle rolls over.
6C-4 Engine Fuel

Fuel Pump and Reservoir Assembly
Figure 4 - Fuel Pump and Reservoir Fuel Flow
AS INSTALLED IN FUEL TANK
....
:a,
=:i!
-~)I FUEL FEED

~ FUEL RETURN
VAPORVENT
NA 5054 SY
Engine Fuel 6C-5

Figures 3 and 4
Figure 5
An electric high pressure roller vane fuel pump is

mounted inside the fuel reservoir, which is located in the
fuel tank. The fuel is pumped to the fuel rail assembly at
a specified flow and pressure by the fuel pump. Excess
fuel is returned to the fuel tank by the return pipe. The
fuel pump delivers a constant flow of fuel to the engine
even during low fuel conditions and aggressive vehicle
maneuvers. As part of the fuel pump, and reservoir
assembly, three hoses are permanently attached. The
fuel pump flex pipe has a quick-connect fitting, the fuel
return hose has a square end and the fuel vapor hose is
cut on an angle. The fuel pump flex pipe also acts to
dampen fuel pulses and noise generated by the
fuel pump.
A steel in-line fuel filter is used in the fuel feed pipe

ahead of the fuel injection system. The filter element is
made of paper, and is designed to trap particles in the
fuel that may damage the injection system. The filter
housing is constructed to withstand maximum fuel
system pressure, exposure to fuel additives, and
changes in temperature. The filter has a quick-connect
inlet and a threaded outlet fitting. The threaded fitting is
sealed with an 0-ring. There is no service interval for
fuel filter replacement. Only replace the fuel filter if it
is restricted.
The electric fuel pump operation is controlled by the

Powertrain Control Module (PCM) through a fuel pump
relay. Go to Section 6E3-C2 and Section BA of this
manual for further description and a wiring diagram of
the fuel pump relay.
Fuel Pump Strainer
Fuel Feed and Return Pipes

The fuel feed pipe carries fuel from the fuel tank to the
fuel rail assembly. The fuel return pipe carries fuel from
the fuel rail assembly back to the fuel tank. The fuel feed
and return pipes consist of three sections:
Figures 3 and 4
The rear fuel pipe assemblies are located from the

top of the fuel tank to the chassis fuel pipes. The
rear fuel pipes are constructed of nylon.
The chassis fuel pipes are located under the vehicle
and connect the rear fuel pipes to the engine
compartment connecting fuel pipes. These pipes are
constructed of steel.
The engine compartment connecting fuel pipes
connect the chassis pipes to the engine fuel rail.
These fuel pipes are routed from the chassis fuel
pipes under the vehicle and behind the front driver
side wheel house liner to the engine compartment.
These fuel pipes are constructed of nylon.
A woven plastic fuel pump strainer is attached to the

lower end of the fueLpump and reservoir assembly in the
fuel tank. The functions of the fuel pump strainer are to
filter contaminants and to wick fuel.
The life of the fuel pump strainer is generally considered

to be that of the fuel pump. The fuel pump strainer is
self-cleaning and normally requires no maintenance.
Fuel stoppage at this point indicates that the fuel tank
contains an abnormal amount of sediment or water. In
this case, the tank should be thoroughly cleaned. Go to
Fuel System Cleaning in this section. If the fuel pump
strainer is plugged, replace it with a new one.
Nylon Fuel Pipes
In-Line Fuel Filter

Figure 5 - In-Line Fuel Filter (Typical)
The fuel feed and return pipes are assembled as a

harness. Retaining clips hold the pipes together and
provide a means for attaching the pipes to the vehicle,
Sections of the pipes that are exposed to chafing, high
temperature or vibration are protected with heat
resistant rubber hose and/or corrugated plastic conduit.
~------~
..... OUT
,....
IN:~::]
I
I
I
I
I
I
I
'-------------------~
SHELL
2
PAPER ELEMENT
INNER END PLATE
Nylon fuel pipes are designed to perform the same job

as the steel or flexible fuel pipes or hoses they replace.
Nylon pipes are constructed to withstand maximum fuel
system pressure, exposure to fuel additives, and
changes in temperature. There are two sizes used:
3/8" ID for the fuel feed, and 5/16" ID for the fuel return.
MA 5050-SY
Nylon fuel pipes are somewhat flexible and can be

formed around gradual turns under the vehicle.
However, if forced into sharp bends, nylon pipes will kink
and restrict fuel flow. Also, once exposed to fuel, nylon
pipes may become stiffer and are more likely to kink if
bent too far. Special care should be taken when working
on a vehicle with nylon fuel pipes:
6C-6 Engine Fuel

CAUTION: To Reduce the Risk of Fire and Personal
Injury:
Always cover nylon fuel pipes with a wet towel
before using a torch near them. Also, never
expose the vehicle to temperatures higher than
115 C (239 F) for more than one hour, or more
than 90 C (194 F) for any extended period.
Take care not to nick or scratch the nylon fuel

pipes. If damaged, they must be replaced.
Fuel Pipe 0-Rings

The fuel feed pipe threaded connection at the fuel filter
is sealed with an 0-ring seal. Fuel system 0-ring seals
are made of special material, and should only be
serviced with the correct service part.
EVAP Pipes and Hoses

The EVAP pipe and hoses extend from the fuel sender
assembly to the evaporative emission canister.
Quick-Connect Fittings
Quick-connect type fittings provide a simplified means of
installing and connecting fuel system components.
Depending on the vehicle model, there are two types of
quick-connect fittings, each used at different locations in the
fuel system. Each type consists of a unique female
connector and a compatible male pipe end. 0-rings, located
inside the female connector, provide the fuel seal. Integral
locking tabs or fingers hold the fittings together.
Diagnosis
Alcohol-in-Fuel
5.
Alcohol-in-fuel can be detrimental to fuel system

components and may cause driveability problems such
as hesitation, lack of power, stall, no start, etc.
6.
The problems may be due to fuel system corrosion and

subsequent fuel filter plugging, deterioration of rubber
components and/or air-fuel mixture leaning.
If alcohol is present in the fuel, the volume of the lower

layer (which would now contain both alcohol and water) will
be greater than 1O ml. For example, if the volume of the
lower layer is increased to 15 ml, it will indicate at least
5 percent alcohol in fuel. The actual amount of alcohol may
be somewhat greater because this procedure does.not
extract all of the alcohol from the fuel.
Various types and concentrations of alcohols are used in

commercial fuel. Some alcohols are more detrimental to
fuel system components than others. If an excessive
amount of alcohol in the fuel is suspected as the cause
of a driveability condition, the following procedure may
be used to detect the presence of alcohol in the fuel.
Testing Procedure
The fuel sample should be drawn from the bottom of the
tank so that any water present in the tank will be detected.
The sample should be bright and clear. If the sample
appears cloudy, or contaminated with water (as indicated by
a water layer at the bottom of the sample), this procedure
should not be used, and the fuel system should be cleaned.
Go to Fuel System Cleaning in this section.
1.
2.
3.
4.
Using a 100 ml cylinder with 1 ml graduation marks,

fill with fuel to the 90 ml mark.
Add 1o ml of water to bring the total fluid volume to
100 ml and install a stopper.
Shake vigorously for 1O to 15 seconds.
Carefully loosen the stopper to release pressure.
Close the stopper and shake vigorously again for

1O to 15 seconds.
Put the graduated cylinder on a level surface for
approximately 5 minutes to allow adequate
liquid separation.
Fuel Tank leak Check

Important:
Before attempting "Fuel Tank Leak Check'' place a dry

chemical (Class B) fire extinguisher near work area.
Before removing the fuel tank for a suspected leak,

make sure fuel pipes are not leaking onto the tank.
Once removed, make sure fuel is not leaking around
fuel sender assembly seal.
This check requires a fuel sender assembly, fuel
filler cap, and a fuel sender seal to be installed in the
fuel tank.
1. Disconnect negative battery cable.
2. Relieve fuel system pressure. Refer to Fuel System
Pressure Relief.
3.
Drain fuel tank. Refer to Draining Fuel Tank.
Engine Fuel 6C-7

4. Remove fuel tank. Refer to Fuel Tank Replacement.
5. Cap fuel feed pipe, fuel return pipe, and EVAP pipe
on fuel sender assembly.
6. Connect a piece of hose to the vent pipe.
7. Submerge tank in water or apply soap solution to
outside of tank.
8. Apply 31 to 38 kPa (4.5 to 5.5 psi) air pressure to
the piece of hose on the fuel tank vent pipe.
Air bubbles appearing from fuel tank indicate a
leak. Replace fuel tank if it is leaking. Refer to
Fuel Tank Replacement.
Fuel Tank Vent Valve Check

The fuel tank vent valve, located in the rear of the vehicle
by the fuel tank, is a pressure/vacuum relief valve, If the
valve is not functioning properly it could cause excessive
pressure or vacuum to build up in the tank. The result may
be possible fuel discharge when removing cap or possible
damage to the tank or fuel sender.
Checking procedure:
1.
2.
3.
4.
, 5.
6.
7.
8.
Loosen fuel filler cap to relieve tank pressure.

Remove tank vent valve from vehicle.
Wrap vent valve in shop towel and shake out any
remaining fuel.
Using the appropriate adapters, connect vent valve
to a radiator pressure check device.
Slowly apply pressure to vent valve. The valve
should open at approximately 1 psi. If not, replace
vent valve.
Disconnect vent valve from pressure tester.
Using the appropriate adapters, connect vent valve
to a hand operated vacuum pump.
Slowly apply vacuum to the vent valve. The valve
should open at approximately 1-2" Hg. If not,
replace vent valve.
On-Vehicle Service
Important: Before attempting any "On-Vehicle Service"
place a dry chemical (Class B) fire extinguisher near
work area.
Fuel System Pressure Relief

Tool Required:
J 34730-1A, Fuel Pressure Gauge

CAUTION:
To reduce the risk of fire and personal injury, it

is necessary to relieve the fuel system pressure
before servicing fuel system components.
After relieving system pressure, a small amount of
fuel may be released when servicing fuel pipes or
connections. In order to reduce the chance of
personal injury, cover fuel pipe fittings with a
shop towel before disconnecting, to catch any fuel
that may leak out. Place the towel in an approved
container when disconnect is completed.
1. Ignition "OFF."
2. Disconnect negative battery cable to avoid possible
fuel discharge if an accidental attempt is made to
start the engine.
3. Loosen fuel filler cap to relieve tank pressure. (Do
. not tighten until service has been completed.)
4. Connect J 34730-1A to fuel pressure connection.
Wrap a shop towel around fitting while connecting
gauge to avoid spillage.
5. Install bleed hose into an approved container and
connections are now safe for servicing.
6. Drain any fuel remaining in gauge into an approved
container.
6C-8 Engine Fuel

Servicing Quick-Connect Fittings
Figure 6 - Quick-Connect Fittings
, :: nl). . . . . . . ._ . . ,.
(
Plastic Collar Quick-connect Fitting
Metal Collar Quick-connect Fitting
Removal
IF EQUIPPED, SLIDE DUST COVER
CAUTION: TO REDUCE THE RISK OF FIRE

AND PERSONAL INJURY, RELIEVE FUEL
SYSTEM PRESSURE BEFORE DISCONNECTING
FUEL PIPE FITTINGS.
BACK TO ACCESS FITTING
(
OR
Installation
~+--
c::: 1@~
@
c : : !@..__ _,
........
........ ~-
~--
C: : 1@:l:::=J
IF EQUIPPED, REPOSITION
DUST COVER AFTER SERVICE
c::--;-,ii--..
(
5294
NA5089AS
Engine Fuel 6C-9

Figure 6
In-Line Fuel Filter Replacement
Tools Required:
Figure 7 - In-Line Fuel Filter Replacement
J 37088-A, tool set, Fuel Line Quick-Connect

Separator
Important:
Relieve fuel system pressure before servicing any

fuel system connection. Refer to Fuel System
Pressure Relief.
Slide dust covers from quick-connect fittings,
if equipped.
1. Grasp both sides of fitting. Twist female connector
1/4 turn in each direction to loosen any dirt within fitting.
'
CAUTION: Safety glasses must be worn when using

compressed air, as flying dirt particles may cause
eye injury.
2. Using compressed air, blow dirt out of fitting.
- For plastic (Hand Releasable) Fitting3.
4.
Squeeze plastic retainer release tabs.

Pull connection apart.
-OR-
THREADED FITTING
- For Metal Fitting -
IN-LINE FUEL FILTER
3. Choose correct tool from J 37088-A tool set for size

of fitting. Insert tool into female connector, then push
inward to release locking tabs.
4. Pull connection apart.
QUICK-CONNECT FITTING
IN-LINE FUEL FILTER BRACKET
Clean and Inspect
NS 15923
Figure 7
Notice: If it is necessary to remove rust or burrs from

fuel pipe: use emery cloth in a radial motion with the
pipe end to prevent damage to 0-ring sealing surface.
Using a clean shop towel, wipe off male pipe end.
Inspect both ends of fitting for dirt and burrs. Clean
or replace components/assemblies as required.
Important:
Install or Connect
CAUTION: To Reduce the Risk of Fire and Personal

Injury:
Before connecting fitting, always apply a few drops
of clean engine oil to the male pipe end. This will
ensure proper reconnection and prevent a possible
fuel leak. (During normal operation, the 0-rings
located in the female connector will swell and may
prevent proper reconnection if not lubricated.)
1.
2.
1. Apply a few drops of clean engine oil to the male

pipe end.
2. Push both sides of fitting together to cause the
retaining tabs/fingers to snap into place.
3. Once installed, pull on both sides of fitting to make
sure connection is secure.
4. Reposition dust cover over quick-connect fitting,
if equipped.
3.
There is no service interval for fuel filter

replacement. Only replace fuel filter if it is restricted.
If the in-line fuel filter is restricted, the fuel tank should
be inspected internally and cleaned if necessary.
Negative battery cable.

Relieve fuel system pressure. Refer to Fuel System
Pressure Relief.
Raise vehicle.
Clean
4.
5.
6.
Clean all in-line fuel filter connections and

surrounding areas before disconnecting to avoid
possible contamination of the fuel system.
Quick-connect fitting at fuel filter inlet. Refer to
Servicing Quick-Connect Fittings.
Threaded fitting from fuel filter outlet.
Slide fuel filter from bracket.
6C-10 Engine Fuel

Inspect
Fuel Tank Replacement
Figure 8
Fuel pipe 0-ring for cuts, nicks, swelling or

distortion. Replace if necessary.
Install or Connect
1.
2.
3.
Slide fuel filter into bracket.

Threaded fitting to fuel filter outlet.
Tighten
In-line fuel filter fitting to 30 Nm (22 lb. ft.).

Quick-connect fitting to fuel filter inlet. Refer to
Servicing QuickConnect Fittings.

4.
5.
6.
Lower vehicle.
Tighten fuel filler cap.
Inspect
Turn ignition switch to "ON" position for two

seconds, then turn to "OFF" for ten seconds. Again
turn to "ON" position and check for fuel leaks.
Draining Fuel Tank
CAUTION:
Never drain or store fuel in an open
container due to the possibility of fire
or explosion.
When draining fuel tank, slowly insert and

do not force hand operated pump device in
fuel tank. Forcing pump device can cause
fuel pump to be dislocated from fuel
sender assembly.
Use a hand operated pump device to drain fuel
through the fuel filler pipe. Remove fuel and install
fuel filler cap.
CAUTION: To help avoid personal injury when a

vehicle is on a hoist, provide additional support for
the vehicle on the opposite end from which
components are being removed. This will reduce the
possibility of the vehicle falling off the hoist.
1.
2.

3.
4.
5.
6.
Drain fuel tank. Refer to Draining Fuel Tank.

Raise vehicle.
Fuel filler pipe shield.
Exhaust system (pipe and muffler). Refer to
7.
8.
Exhaust system heat shields.

Rear axle assembly. Refer to Section 48.
Pressure Relief.
Section 6F.
Clean
9.
Clean all fuel pipe and hose connections and

Fuel feed pipe, fuel return pipe, EVAP pipe and vent
hose at fuel sender assembly. Refer to Servicing
Quick-Connect Fittings.
1o. Electrical connector.
Notice: Do Not bend fuel tank straps, as this may
damage straps.
11 . With aid of an assistant, support fuel tank, and
remove fuel tank strap front attaching bolts, fuel 1ank
straps and fuel tank.
Place fuel tank in a suitable work area.
Disassemble
1 . Fuel tank insulator pads and tank strap insulator pads.
2. Fuel sender assembly from fuel tank. Refer to Fuel
Sender Assembly Replacement.
Engine Fuel 6C-11

Figure 8 - Fuel Tank Insulators and Fuel Tank Mounting
Assemble
1. Fuel sender assembly to fuel tank. Refer to Fuel
Sender Assembly Replacement.
2. Tank strap insulator pads and fuel tank insulator
pads.
UNDERBODV
INSULATOR
QUARTER PANEL
INSULATOR
FUEL TANK STRAP
BOLT
FUEL TANK ASSEMBLY

9S53516E
9. Lower vehicle.
10. Add fuel and install fuel filler cap.
11 . Negative battery cable.
Inspect
Install or Connect
1. Hook rear end of fuel tank straps into underbody
bracket.
2. With the aid of an assistant, position and support
fuel tank. Position fuel tank straps and loosely install
front fuel tank strap attaching bolts.
Tighten
Front fuel tank strap attaching bolts to 33 Nm
(24 lb. ft.).
3. Electrical connector.
4. Fuel return pipe, fuel feed pipe, EVAP pipe, and vent
hose and clamps at fuel sender assembly. Refer to
5. Rear axle assembly. Refer to Section 48.
6. Exhaust system heat shields and attaching screws.
7. Exhaust system (pipe and muffler). Refer to
Section 6F.
8. Fuel filler pipe shield.

Fuel Tank Vent Valve


Fuel filler cap.
3. Raise vehicle.
4. Fuel tank vent valve hose.
5. Fuel tank vent valve from rear brake hose bracket.
1.
2.
Install or Connect
1.
2.
3.
4.
5.
Fuel tank vent valve to fuel tank vent valve hose.

Fuel tank vent valve to rear brake hose bracket.
Lower vehicle.
Fuel filler cap.
6C-12 Engine Fuel

Fuel Sender Assembly Replacement
Figure 9 - Fuel Sender Assembly Replacement
RETAINING NUT
FUEL SENDER RETAINING

RING
FUEL SENDER ASSEMBLY
FUEL SENDER SEAL
FUEL TANK
(
NS15922
Figure 9
Important: Always replace fuel sender assembly seal
when reinstalling fuel sender assembly.
Notice: Do N_ot handle Jhe fuel sender assembly by the

fuel sender pipes. Due to the length of the pipes, the
amount of leverage generated by handling the pipes
could damage the solder joints.
1.
2.
3.
4.
5.

Relieve fuel system pressure. Refer to. Fuel System
Pressure Relief.
Drain fuel ta.nk. Refer to Draining Fuel Tank.
Fuel tank. Refer to Fuel Tank Replacement.
Fuel sender retaining nuts, retaining ring, fuel
sender assembly and seal from fuel tank.
Discard seal.
CAlfTION: To reduce risk of fire and personal injury,

dram fuel from fuel sender assembly into an
approved container.
Clean
Fuel sender assembly sealing surfaces.
Install or Connect
1.
Position new fuel sender assembly seal on fuel tank.
Important: Fuel pump strainer must be in a horizontal

position. When installing the fuel sender assembly,
assure that the fuel pump strainer does not block full
travel of float arm.
2. Gently fold fuel strainer over itself.

3. Slowly position fuel sender assembly in fuel tank so
4.
that fuel strainer is not damaged or trapped by

sump walls.
Fuel sender assembly into fuel tank.
Tighten
Fuel sender assembly retaining nuts to 6.5 Nm
(58 lb. in.).
Fuel tank. Refer to Fuel Tank Replacement.
Add fuel and install fuel filler cap.
5.
6.
7.
Inspect

Engine Fuel 6C-13

Fuel Sender Assembly Service
\
Figure 1O Fuel ~ender Assembly Disassembly
SENDER - FUEL
FUEL PUMP AND RESERVOIR

ASSEMBLY
A
VAPOR VENT HOSE
B
FUEL PUMP FLEX PIPE AND
QUICK-CONNECT FITTING
FUEL RETURN HOSE
STRAINER-FUEL PUMP
3-24-94
NA5017-XV
Figure 10
Inspect
1. Negative battery cable.

Pressure Relief.
3. Drain fuel tank. Refer to Draining Fuel Tank.
4. Fuel tank. Refer to Fuel Tank Replacement.
5. Fuel sender assembly. Refer to Fuel Sender
Assembly Replacement.
Disassemble
1. Note position of fuel strainer on fuel pump.

2. Support fuel sender assembly with one hand and
grasp strainer with other hand.
Rotate strainer in one direction and pull off of
pump. Discard strainer after inspection.
Fuel pump strainer. If strainer is contaminated, the

fuel tank should be cleaned.
Fuel pump inlet for dirt and debris. If found, fuel
pump and reservoir should be replaced.
- If fuel pump and reservoir is being replaced, proceed to
step 3. 3. Vent hose and fuel return hose from under cover.
4. Quick-connect fitting on fuel pump flex pipe. Refer to
5. Electrical connector from fuel pump.
6. Pry locking tabs on bottom of fuel reservoir, lift
reservoir to clear locking tabs and pull reservoir
downward to clear guides on fuel sender.
6C-14 Engine Fuel

Assemble
Fuel Tank
1. Align tabs on reservoir with guide on fuel sender,

push upward to stop on top of reservoir and snap
locking tabs over ramps on bottom of reservoir.
2. Fuel vent and return hose.
3. Quick-connect fitting on fuel pump flex pipe. Refer to
4. Electrical connector on fuel pump.
Important: Always install a new pump strainer when

replacing fuel pump.
5. New pump strainer in same position as noted during

disassembly.
Push on outer edge of strainer ferrule until
fully seated.
Install or Connect

Inspect

Fuel System Cleaning

Important:
Only use oil free compressed air to blow out fuel pipes.
If the in-line fuel filter is plugged, the fuel tank should
be inspected internally and cleaned if necessary.

Pressure Relief.
3. Drain fuel tank. Refer to Draining Fuel Tank.
Inspect
Fuel pump strainer. If contaminated, it must be

replaced and the fuel pump must be inspected.
Fuel pump inlet for dirt and debris. If found, fuel
pump and reservoir should be replaced.
6. Flush fuel tank with hot water.
Important: When flushing fuel tank, the fuel and water
mixture needs to be treated as a hazardous material.
The material needs to be handled in accordance with all
applicable local, state,'and federal laws and regulations.
7. Pour water out of fuel sender assembly opening.

Rock tank to be sure that removal of water from
tank is complete.
Install or Connect

Inspect

turn to "ON"position and,check for fuel leaks.
Engine Fuel 6C-15

Fuel Feed, Return, and EVAP Pipes \
Rear Fuel Feed, Return, and EVAP Pipe Replacement {Fuel Tank)
Figure 11 Fuel and EVAP Pipe Replacement (Rear Pipes)
VIEWA
3
4
S
6
7
8
9
10
FUEL SENDER
FUEL TANK
FUEL FILLER PIPE
EVAPORATIVE EMISSION CANISTER
FUEL TANK VENT VALVE
FUEL FEED PIP'E QUICK-CONNECT FITTING
FUEL FILTl:R
FUl:L RETURN PIPE QUICK-CONNECT FITTING
FUEL TANK VENT HOSE
EVAP PIPE
4-13-94
NS15919
Figure 11
Notice: Do Not attempt to repair rear fuel feed, return,
6. EVAP hoses from EVAP pressure control valve and

EVAP canister.
and EVAP pipes. If damaged, replace.
Install or Connect
1. EVAP hoses to EVAP pressure control valve and

EVAP canister.
2. Rear fuel feed and return pipes to chassis fuel pipe
and fuel filter.
4. Lower vehicle.
6. Tighten fuel filler cap.

Pressure Relief.
3. Raise vehicle.
Clean
Clean all fuel and EVAP pipe and hose connections

and surrounding areas before disconnecting to avoid
5. Rear fuel feed and return pipes from chassis fuel pipe
and fuel filter. Refer to Servicing Quick-Connect
Fittings.
Inspect

6C-16 Engine Fuel

Chassis Fuel Feed, Return, and EVAP Pipe
Repair/Replacement
Figure 12 - Fuel and EVAP Pipe Replacement (Chassis Fuel Pipes)
RETAINING CLAMP
IN-LINE FUEL FILTER
EVAPORATIVE EMISSION Pl.PE
QUICK-CONNECT FITTINGS
(
NS 15920
Figure 12
Notice:
When r~pla~i~g fuel o: EVAP pipes, always replace
them with ong1nal equipment or parts that meet the GM
specifications for those parts. The replacement pipes
~ust have the same type of fittings as the original
pipes to ensure the integrity of the connection.
Do not use copper or aluminum tubing to replace steel
tubing. Only tubing meeting the 124-M specification or
its equivalent is capable of meeting all pressure,
corrosion and vibration characteristics necessary to
ensure the durability standard required.
When repairing fuel or EVAP pipes with hoses, always
replace t~~m ~ith original equipment or parts meeting
GM spec1f1cat1ons. Use only reinforced fuel-resistant
hose which is identified with the word
"Fluoroelastomer'' or "GM 6163-M" on the hose. Inside
hose diameter must match outside pipe diameter.
Do not use rubber hose within 100 mm (4") of any

part of the exhaust system or within 254 mm (1 O")
of the catalytic converter.
A minimum of 13 mm (1/2") clearance must be
~aintained around sharp edges such as flanges,
pinch welds, etc., to prevent contact and chaffing. A
minimum of 19 mm (3/4") clearance must be
maintained around all moving parts.
If more than a 6 inch length of pipe is removed, use
a combination of steel pipe and hose so that the
total hose lengths, including the 100 mm (4".)
additional length will not be more than 254 mm (10")
long. Follow the same routing as the original pipe.
Cut ends of pipe remaining on car square with a
tube cutter. Using the first step of a double flaring
tool, form a bead on the end of both pipe sections. If
pipe is too corroded to withstand the beading
operation without damage, the pipe should be
replaced. If a new section of pipe is used, form a
bead on both ends of it also.
Use screw type hose clamps. Slide clamps onto
pipe and push hose 51 mm (2") onto each portion of
fuel pipe.
Engine Fuel 6C-17
Install or Connect

Pressure Relief.
1. Position new or repaired fuel pipe or pipes in body

clips as noted during removal and install with
attaching hardware.
2. Position new 0-ring on fuel feed pipe and connect to
outlet side of in-line fuel filter.
Tighten
Fuel feed pipe fitting to 30 Nm (22 lb. ft.).
3. Fuel return and EVAP pipes to rear fuel pipes. Refer
to Servicing Quick-Connect Fittings.
4. Chassis fuel pipes to engine compartment
connecting fuel pipes. Refer to Servicing
Quick-Connect Fittings.
5. Lower vehicle.
2.
Clean
3.
4.
5.
6.
7.
Clean all fuel and EVAP pipe/hose connections and

Raise vehicle.
Engine compartment connecting fuel feed, return,
and EVAP pipe assemblies from chassis fuel pipes.
Refer to Servicing Quick-Connect Fittings.
Fuel feed pipe from outlet side of in-line fuel filter.
Discard 0-ring.
Fuel return and EVAP pipes from rear fuel pipes.
Refer to Servicing Quick-Connect Fittings.
Fuel pipes and attaching hardware from under body.
Note position of fuel pipes for installation.
Inspect
Pipes for bends, kinks and cracks. Repair or replace

pipes as required.
Inspect

6C-18 Engine Fuel

Engine Compartment Connecting Fuel Feed, Return,
and EVAP Pipe Replacement (Chassis to Engine)
Figure 13 - Fuel and EVAP Pipe Replacement (Engine Compartment

Connecting Fuel Pipes)
ENGINE COMPARTMENT CONNECTING PIPES
GROMMET (WHEELHOUSE OPENING)
EVAPORATIVE EMISSION PIPE
TO CHASSIS FUEL PIPES
RETAINING CLAMP
Figure 13
Notice: Do Not attempt to repair sections of engine
compartment connecting fuel and EVAP pipes. If
damaged, replace.
1.
2.

Pressure Relief.
Clean
Clean all engine compartment connecting fuel pipe

connections and surrounding areas before
disconnecting to avoid possible contamination of the
fuel system.
3. Fuel feed, return and EVAP pipes at engine. Refer to
4. Fuel and EVAP pipes from routing clip.
5. Reposition grommet in wheelhouse.
6. Raise vehicle.
7. Reposition left front wheelhouse panel liner.
8. Fuel feed, return, and EVAP pipe protector.
9. Fuel and EVAP pipes at chassis fuel and EVAP
pipes. Refer to Servicing Quick-Connect Fittings.
10. Fuel feed, return, and EVAP pipes from underbody
retainer.
4-13-94
NS15921
Install or Connect
1.
2.
Fuel and EVAP pipes through wheelhouse opening.

Fuel and EVAP pipes at chassis fuel and EVAP
pipes.
3. Fuel feed, return, and EVAP pipes into underbody
retainer.
4. Fuel and EVAP pipe protector.
5. Left front wheelhouse panel liner.
6. Lower vehicle.
7. Fuel and EVAP pipes to routing clip.
8. Grommet in wheelhouse.
9. Fuel feed, return, and EVAP pipes at engine.
11 . Negative battery cable.
Inspect

Engine Fuel 6C-19
Specifications
Torque Specifications
Application
In-line Fuel Filter Fitting
Fuel Sender Assembly Retaining Nuts
Fuel Tank Strap Attaching Bolts
Nm
30
Lb Ft
22
Lbln
6.5
58
33
24
FUEL SPECIFICATIONS
Methyl Tertiary-Butyl Ether (MTBE)
The fuel must meet ASTM Standard: 04814 (U.S.),

CGSB 3.5-92 (Canada).
Fuel containing Methyl Tertiary-Butyl Ether (MTBE) may

be used, providing there is no more than 15 percent
MTBE by volume.
Octane Requirements
Ethanol
3.8L (VINK)
Min. Octane Recommended: 87[(R+M)/2] (pump) octane

where R= research octane number, and M= motor
octane number.
5.7L (VIN P)
Min. Octane Recommended: 91 [(R+M)/2] (pump} octane

where R= research octane number, and M= motor
octane number.
Gasoline With Alcohol

Notice: Do Not spill fuel containing alcohol on the vehicle.
Alcohol can cause damage to the paint finish and trim.
Fuel containing ethanol (ethyl) or grain alcohol may be

used, providing that there is no more than 1O percent
ethanol alcohol by volume.
Methanol
Fuel containing methanol (methyl) or wood alcohol may
be used, providing that there is no more than 5 percent
methanol by volume.
Notice: Do Not use fuel that contains more than 5 percent
methanol. Use of a fuel (gasohol) that contains more than
5 percent of methanol can corrode metal fuel system
components and damage plastic and rubber parts.
Special Tools
Figure 14 - Special Tools
J 34730-1A
1
2
FUEL LINE QUICK-CONNECT SEPARATOR

FUEL PRESSURE GAGE AND HOSE
6-10-95
MS11890
6C-20 Engine Fuel
BLANK
ENGINE ELECTRICAL 60-1
SECTION 60
ENGINE ELECTRICAL
CAUTIONS in SECTION 9J under ''ON-VEHICLE SERVICE" and the SIR Component and Wiring
CONTENTS
General Description ................................................ 6D-1
Battery ........................................................ Section 6D 1
Cranking System ........................................ Section 602
Charging System ........................................ Section 603

Ignition System .......................................... Section 604
Engine Wiring ............................................ Section 605
GENERAL DESCRIPTION
To diagnose and troubleshoot system faults, refer to

SECTION 8A for wiring diagrams, component
locations and system checks.
When a fault is traced to a particular component,
refer to that component's section of the service
manual.
The engine electrical system includes the battery,

ignition (primary and secondary), starter motor (and
related wiring) and the generator (and related wiring).
6D-2
ENGINE ELECTRICAL
BLANK
BATTERY 601-1
SECTION 601
BATTERY
easily come in contact with "live" exposed electrical terminals, disconnect the battery negative
cable to help prevent personal injury and/or damage to the vehicle or components. Unless
instructed otherwise, the ignition switch must be in the "OFF" or "LOCK" position.
systems.
CONTENTS
General Description .............................................. 601-2
Battery .............................................................. 601-2
Battery Ratings ................................................. 601-2
Reserve Capacity .......................................... 6D 1-2
Cold Cranking Amps ................................... 601-2
Common Causes of Failure ............................. 601-2
Electrolyte Freezing ......................................... 601-2
Battery Tray and Hold-Down Retainer ........... 6D 1-3
Battery Protection During Vehicle Storage ..... 601-3
Built-In Hydrometer ......................................... 601-3
Diagnosis .............................................................. 601-3
Battery Testing ................................................. 601-3
Battery Electrical Drain ................................... 6D 1-4
Parasitic Load Test. ...................................... 6D 1-4
Alternate Parasitic Load Test ...................... 601-5
Battery Charging .............................................. 601-6
Charging Procedure ..................................... 6D 1-6

Charging Time Required ............................ 6D 1-7
Charging a Very Low or Completely
Discharged Battery ...................................... 6D 1-7
Jump Starting in Case of Emergency with
Auxiliary (Booster) Battery ............................ 601-7
Battery Tray Replacement .............................. 601-8
Battery Replacement ....................................... 601-8
Battery Cable Replacement and Routing ....... 601-8
Negative Cable ............................................ 6.Dl-9
Positive Cable ............................................. 601-10
Ground Straps ................................................. 601-12
Charging Equipment ....................................... 601-12
Specifications ....................................................... 6D 1-15
Battery Usage ................................................... 601-15
Fastener Tightening Specifications ................. 601-15
Special Tools ....................................................... 6D 1-15
CAUTION: All battery assemblies generate hydrogen gas which is extremely flammable. If i~nited
by a spark or flame, the gas may explode violently, causing spraying of acid, fragmentation of
1he battery and possible severe personal injuries. Wear approved eye protection. Battery fluid is
corrosive acid. Flush any contacted area with water immediately and thoroughly.
601-2
BATIERY
GENERAL DESCRIPTION
BATIE RY
Figures 1 and 2
The maintenance-free battery is standard on all
vehicles. Refer to "Specifications" in this section for
battery usage applications. There are no vent plugs in
the cover. The battery is completely sealed except for
two small vent holes in the sides. These vent holes
allow the. small amount of gas produced in the battery
to escape.
The battery has three major functions in the
electrical system: first, it provides a source of energy
for cranking the engine; second, it acts as a voltage
stabilizer for the electrical system, and third, it
provides energy for a limited time when the electrical
load .exceeds the output of the generator.
The battery specifications label contains
important information for servicing the battery. This
information includes test rating and both original
equipment and recommended replacement part
numbers. Refer to "Specifications" at the end of this
section.
BATIERY RATINGS
A battery has two ratings: (1) a reserve capacity
rating and (2) a cold cranking amperage rating at
-l8C (0F). When replacing the battery, use these two
ratings as a guide in selecting a replacement. For the
catalog number of a replacement battery with ratings
similar to the original battery, refer to "Specifications"
at the end of this section.
01-20-96
FS001flD1
Figure 1 - Maintenance-Free Battery
Delco Remy
CAT. NO.
514
CCA
LOAD
TEST
l'IEPLACEMENT
MODEL
525
260
75-60
1-2
For warranty 11'a111&ction, l'IIIICIYllt mnlll 11t11ch to WBITlllty clelm.

012015
FS002flD1
Figure 2 - Battery Label
Reserve Capacity
The "Reserve Capacity" is an estimate of the
maximum length of time it is possible to travel at
night with minimum electrical load and no generator
output.
Expressed in minutes, it is the approximate time
the fully-charged battery can support a 25-amp load
without the battery terminal voltage dropping below
10.5 volts at 27C (80F).
Cold Cranking Amps

The cold cranking amperage (CCA) test is
expressed at a battery temperature of -l8C (0F). The
current rating is the minimum amperage which must
be maintained by the battery for 30 seconds, at the
specified temperature, while meeting a minimum
voltage requirement of 7 .2 volts. This rating is .a
measure of cold cranking capacity.
COMMON CAUSES OF FAILURE

The battery is not designed to last indefinitely;
however, with proper care, it will provide many years
of service.
If the battery tests "good," but fails to perfonn
satisfactorily in service for no apparent reason, the
following are some of the more important factors that
may point to the cause of trouble:
1. Vehicle accessories are left on overnight.
2. Slow average driving speeds for short periods.
3. The vehicle's electrical load being more than the
generator output, particularly with the addition of
aftermarket equipment.
4. Conditions in the charging system such as
electrical shorts, slipping serpentine belt, faulty
generator, or generator voltage regulator, .
5. Battery abuse, including failure to keep the battery
terminals clean and tight or loose battery
hold-down. Refer to "Battery Replacement" in this
section for torque specifications.
6. Mechanical conditions in the. electrical system,
such as shorted or pinched wires.
7. Extended storage of vehicles.
8. Extended cranking periods due to plug fouling.
9. Incorrect interpretation of the hydrometer.
10. Insufficient ampere-hour charge rate for a
discharged battery.
11. Continuous current draw on the battery through
excessive parasitic drain.
ELECTROLYTE FREEZING
The freezing point of electrolyte depends on a
specific gravity. Since freezing may ruin a battery, it
should be protected against freezing by keeping it in a
charged condition.
As long as the green dot is visible in tb.e
hydrometer, the freezing point of the battery will be
somewhere below -32C (-25F).
The higher the state of charge, the lower the
freezing point. A fully charged battery will not freeze
until the temperature gets below -65C (-85F).
BATTERY
BATTERY TRAY AND HOLD-DOWN
RETAINER
The battery tray and hold-down retainer should
be clean and free from corrosion before installing the
battery.
The battery tray should be in a sound condition
so that it will hold the battery securely and keep it
level. Make certain there are no parts in the battery
tray before installing battery.
To prevent the battery from shaking in its battery
tray, the hold-down retainers should be tight, but not
over-tightened.
BATTERY PROTECTION DURING VEHICLE
STORAGE
Today's vehicles. have many high technology
electronic devices which result in very small but
continuous current drains on the battery, commonly
referred to as "parasitic loads." Vehicles that are not
used for an extended period of time may develop an
extremely discharged and/or permanently damaged
battery resulting from .parasitic loads. Any battery
discharged by parasitic loading and then allowed to
stand in this condition for a period of time may not
accept recharge. However, if properly recharged, most
battery will return to a good usable condition.
An extremely dischatged battery can freeze at
temperatures as high as -7C (20F), causing
permanent damage. Permanent damage to a discharged
battery can also be accelerated by high temperatures.
To prevent this condition, the battery negative
cable should be disconnected on vehicles which are
not going to be in service within a 30-day period,
beginning from the time the vehicle is shipped. If this
is not possible, battery should be recharged
periodically (every 20-45 days) until the green dot of
the built-in hydrometer is visible.
BUILT-IN HYDROMETER
Figure 3
The maintenance-free battery has a built-in
temperature compensated hydrometer in the top of the
battery. This hydrometer is used with the following
diagnostic procedure.
When observing the hydrometer, make sure that
the battery has a clean top. A light may be required in
some poorly-lit areas. Tap the hydrometer lightly on
STORAG~
BATTERY
STORAGE
BATTERY
601-3
top to dislodge any air bubbles that might cause a

false indication.
Under normal operation, two indications can be
observed.
1. GREEN DOT VISIBLE
- Any green appearance is interpreted as a
"green dot" and the battery is ready for testing.
2. DARK; GREEN DOT NOT VISIBLE
- If there is cranking complaint, the battery
should be tested as described in "Diagnosis" in
this section. The charging and electrical
systems should also be checked at this time.
- Occasionally, a third condition may appear:
3. CLEAR OR LIGHT YELLOW
- This means the fluid level is below the bottom

of the hydrometer. This may have been caused
by excessive or prolonged charging, a broken
case, or excessive tipping. When finding a
battery in this condition it may indicate high
chargmg voltages caused by a faulty charging
system, therefore, the charging and electrical
systems may need to be checked. If a cranking
complaint exists and is caused by the battery,
the battery should be replaced.
DIAGNOSIS
BATTERY TESTING
Figures 3, 4 and 5
The following procedure should be used for
testing battery:
1. VISUAL INSPECTION
Check for obvious damage, such as a cracked
or broken case or cover that could permit loss
of electrolyte. If obvious damage is noted,
replace the battery. Determine the cause of
damage and correct as needed. If not, proceed
to step 2.
STORAGE
BATTERY
[jj00[00
DARKENED
INDICATOR
(WITH GREEN
DOT)
DARKENED
INDICATOR
(NO GREEN
DOT)
LIGHT
YELLOW OR
BRIGHT
INDICATOR
01~2095
FS0038D1
Figure 3 Built-In Hydrometer
012095
FS0041D1
Figure 4 Battery Side Terminal Adapters
601 4 BAlTERY
ESTIMATED
TEMPERATURE
MINIMUM
VOLTAGE
21 C (70FI
10C(50FI
0C (32FI
-10Cl14F)
-18C (0F)
BELOW: - 18C (0FI
9.6
9.4
9.1
8.8
8.5
8.0
01-2095
FS0056D1
Figure 5 - Battery Voltage Drop Temperature
2. HYDROMETER CHECK (Figure 3).

GREEN DOT VISIBLE - Go to step 3.
DARK; GREEN DOT NOT VISIBLE.
- Charge the battery as outlined under
"Charging Procedure" in this section and
proceed to step 3.
3. LOAD TEST
Load testing requires using battery side
terminal adapters to ensure good connection
(Figure 4). Do not load test a frozen battery.
A. Connect a voltmeter and a battery load
tester across the battery terminals.
B. Apply a 300-amp load for 15 seconds to
remove surface charge from the battery.
C. Wait 15 seconds to let the battery recover.
Apply load specified on the battery label or
in "Specifications" at the end of this
section. Read voltage after 15 seconds, then
remove load.
D. If voltage does not drop below the
minimum listed in Figure 5, the battery is
good and should be returned to service.
The battery temperature must be estimated
by feel and by the temperature the battery
has been exposed to for the past few hours.
E. If voltage drops below the minimum listed,
replace the battery.
BAlTERY ELECTRICAL DRAIN

Battery electrical drain is a small amount of
current required by specific control modules that is
needed to retain system memory and system
monitoring. Too much el.ectrical drain, however, can
cause an extremely discharged and/or permanently
damaged battery. To test the battery electrical drain,
refer to "Parasitic Load Test" in this section.
Parasitic Load Test

Figures 6 and 7
Tool Required:
J 38758 Parasitic Draw Test Switch
If the battery discharges while the vehicle sits
for a few hours or days, the vehicle should be
diagnosed for parasitic loads. Simple connection of
an ammeter in series with the battery may not find
the cause as the condition may not show up when
power is restored unless that particular component
is repeatedly cycled. Parasitic loads can be
D
-+
(
A AMMETER, HIGH CAPACITY (10A)
2 CABLE, BATIERV NEGATIVE
3 BATTERV,STORAGE
0120-95
FSOOHDI
Figure 6 Use of Parasitic Draw Test Switch
diagnosed using either of the procedures below, but

use of the special tool as described in the first
procedure is recommended.
NOTICE: Parasitic draw test switch should

never be turned to "OFF" position with engine
running or damage could occur to attached
ammeter or vehicle electrical system.
1. Turn test switch knob to "OFF" position.

Cable" in Section OA.
2. Remove battery negative cable.
3. Install parasitic draw test switch male (cable) end
to negative battery terminal.
4. Install battery negative cable to female end of test
switch tool.
5. Turn test switch tool knob to "ON" position.
6. Road test vehicle while activating all accessories
(radio, A/C, etc.).
7. Turn ignition switch to "LOCK" position and
remove ignition key.
BATTERY 601-5
8. Set ammeter to 10-amp scale and connect to
terminals on test switch tool with alligator clips.
Use of 10-amp scale may prevent damage to
meter.
9. Turn test switch tool knob to "OFF" position to
allow current to flow through ammeter.
10. Check current reading. Allow time for reading to
stabilize. Verify that retained accessory power
(RAP) is off. If current reading is at or below two
amps, turn test tool knob to "ON" position (to
maintain continuity in electrical system) and
switch to a lower scale for a more accurate
reading, or install a more accurate meter, if
necessary. Tum test tool knob to "OFF. 11 If current
reading is above 25 milliamps, refer to
components parasitic load chart (Figure 7) for
specific current loads and micro-processor
"time-outs" for modules in "awake" and "asleep"
states. Total reading below 20 milliamps is
normal, and a reading below 25 milliamps is
acceptable. A zero reading indicates a problem
with meter, scale being used, or connection.
11. If current draw is above specifications listed in
component parasitic load chart, remove system
maxi-fuses and circuit breakers one at a time until
current draw returns to a value less than or equal
to specifications listed. This should be done while
monitoring ammeter so that a disruption of drain
will be evident. Perform steps 9 and 10 each time
a fuse is removed. Refer to SECTION 8A for
specific circuit schematics. Total readings in the
hundreds of milliamps may suggest grounded
wires, sticking relays, or small lamps remaining
lit.
II]
Important
Always tum test switch tool knob to "ON"

position before removing each fuse to maintain
continuity in electrical system and to avoid
damaging ammeter due to accidental
overloading (i.e., opening door). Do not turn
switch to "OFF" while engine is running.
12. When cause of excessive current draw has been
located and repaired, repeat steps 9 and 10 to
verify the repair. Then tum test tool to "OFF,"
Component
remove tool, and reconnect battery negative cable

to battery negative terminal.
!~I
Tighten
Negative cable to 15 N.m (11 lb. ft.).

Alternate Parasitic Load Test
Figures 4, 7, and 8
The following alternate procedure may be used
when testing for parasitic load if J 38758 is not
available.

Cable " in SECTION OA.
1. Disconnect battery negative cable.
2. Install a battery side terminal adapter, AC Delco
PIN ST-1201 or GM PIN 12303040 or equivalent,
in negative terminal of battery (Refer to Figure 4).
3. Install other battery side terminal adapter or a
318-inch nut with standard threads (16 UNC) on
battery negative cable to assure a good electrical
contact with metal face on cable for testing (add a
washer behind nut if nut does not contact firmly).
Yellow or black finish nuts are generally
non-conductive and should not be used.
4. With all lights, accessories, retained accessory
power (RAP), and ignition switch off, connect a
high capacity ammeter (at least 10 amps) from
battery negative cable to side terminal adapter.
This high capacity ammeter is connected to verify
whether or not a high current draw is occurring at
a constant rate. It is this type of high current draw
which will blow the fuse in lower capacity
ammeters.
NOTICE: If a high capacity ammeter is not

available, install a section of heavy wire
(preferably battery cable section) between
existing battery negative cable and side terminal
adapter. Allow time for initial draw to occur or
check for reduced current with and inductive
ammeter (current clamp) and proceed to step 5.
Approximate Parasitic Draw
*Body Control Module (BCM)

Without Universal Theft Deterrent
With Universal Theft Deterrent
PASS-Key II
Powertrain Control Module (PCM)
Radio Control Head
Voltage Regulator in Generator
*After specified timeout period elapses, component
switches from "AWAKE" to "ASLEEP" mode.
Figure 7 - Component Parasitic Loads
1.7
2.4
2
5-10
5
1
601"6
BATTERY
c
ST-1201 or
GM P/N 12303040
ST-1201or
GM P/N 12303040
c
ST-1201 or
GM P/N 12303040
A AMMETER, HIGH CAPACITY (10A)

B NUT, 3/8-INC,H
C MULTl METER
1 CABLE, BATIERY POSITIVE
2 CABLE, BATIERY NEGATIVE

3 BATIERY,STORAGE
01-20-95
FS0088D1
Figure 8 - Alternate Parasitic Load Diagnosis Procedure
5. With high capacity ammeter or battery cable

section still connected, connect digital multimeter,
set on 2000 mA de range, in parallel with high
reading ammeter.
6. Disconnect high capacity ammeter and take
reading with digital multimeter.
If current draw is above specifications listed in
component parasitic load chart, remove system
fuses and mini-breakers one at a time until
current draw returns to a value less than or
equal to specifications listed. This should be
done while monitoring ammeter so that a
disruption of drain will be evident. Refer to
Figure 7 for approximate parasitic loads for
various vehicle components. Set ammeter on
maximum scale when pulling fuses to avoid
damage. Refer to SECTION 8A for specific
circuit schematics.
7. When cause of excessive draw has been located
and repaired, repeat step 6 to verify the repair.
Reconnect battery negative cable to battery
negative terminal.
1~1
Tighten
Negative cable to 15 N.m (11 lb. ft.).
ON-VEHICLE SERVICE
BATTERY CHARGING
NOTICE: Always disconnect the negative
cable when charging a battery or electronic
components may be damaged.
When it is necessary to charge the battery follow
these basic rules:
.
1. Do not charge battery if hydrometer is clear or
light yellow. Replace battery.
2. If the battery feels hot [52C (125F) or higher],
or if electrolyte violently gasses or spews through
the vent holes, discontinue charging or reduce
charging rate.
3. Do not charge a battery if it seems to be frozen.
Charging Procedure
Tool Required:
AIC Delco PIN ST-1201 or GM
PIN 12303040 Battery Side TeJ,"minal Adapters
(Pair)
1. Battery with green hydrometer dot showing do not
require charging unless they have just been
discharged (such as in cranking vehicle).
2. When charging battery with side terminals, install
adapter kit (AC Delco PIN ST-1201 or GM
PIN 12303040 or equivalent). Refer to Figure 4.
The adapter should be snugged up against the
battery terminals to keep resistance between
BATTERY
3.
4.
5.
6.
the adapter and the battery terminal to a

minimum. Recommended battery side terminal
adapter torque is 15 N.m (11 lb. ft.).
Make sure all battery charger connections are
clean and tight.
For best results, battery should be charged while
electrolyte and plates are at room temperature. A
battery that is extremely cold may not accept
current for several hours after starting battery
charger.
Charge battery until green dot of built-in
hydrometer appears. Refer to "Charging Time
Required" in this section. Battery should be
checked every half-hour while charging. Tap the
hydrometer lightly on top to dislodge any air
bubbles that might cause a false indication.
After charging, battery should be tested. Refer to
"Diagnosis" in this section.
Charging Time Required
3. Some chargers feature polarity protection circuitry

which prevents charging unless the battery charger
leads are connected to the battery terminals
correctly. A completely discharged battery may
not have enough voltage to activate this circuitry
even though battery charger leads are connected
properly, making it appear that the battery will not
accept charging current. Therefore, follow the
specific charger manufacturer's instructions telling
how to bypass or override the circuitry so that the
charger will turn on and charge a low-voltage
battery.
4. Battery chargers vary in the amount of voltage
and current they provide. The time required for
the battery to accept measurable charger current at
various voltages may be as follows:
CHARGING VOLTAGE
16.0 or more
14.0 - 15.9
13.0 or less
The time required to charge a battery will vary

depending on the following factors:
Size of Battery - A completely discharged

large heavy-duty battery requires more than
twice the recharging as a completely
discharged small passenger vehicle battery.
Temperature - A longer time will be needed
to charge any battery at -l8C (0F) than at
27C (80F). When a fast battery charger is
connected to a cold battery the current
accepted by the battery will be very low at
first, then in time, the battery will accept a
higher rate as the battery warms.
Battery Charger Capacity - A battery
charger which can supply only five amps will
require a much longer period of charging than
a battery charger that an supply 30 amps or
more.
State-of-Charge - A completely discharged
battery requires more than twice as much
charge as a half-charged battery. Because the
electrolyte is nearly pure water and a poor
conductor in a completely discharged battery,
the current accepted by the battery is very low
at first. Later, as the charging current causes
the electrolyte acid content to increase, the
charging current will also increase.
CHARGING A VERY LOW OR

COMPLETELY DISCHARGED BATTERY
The following procedure should be use.d to
recharge a very low or completely discharged battery.
Unless the procedure is properly followed, a perfectly
good battery may be needlessly. replaced.
1. Measure voltage at battery terminals with an
accurate voltmeter. If below 11 volts, the charge
current will be very low and it could take some
time before it accepts a current in excess of a few
milliamps. Such low current may be detectable on
ammeter available in the field.
2. Set battery charger on high setting.
601-7
HOURS
Up to 4 Hours
Up to 8 Hours
Up to 16 Hours
If the charge current is still not measurable at
the end of the above charging times, the

battery should be replaced.
If the charge current is measurable during the
charging time, the battery is considered good
and charging should be completed in the
normal manner.
5. It is important to remember that a completely
discharged battery must be recharged for a
sufficient number of ampere hours (AH) to restore
it to a. usable state. As a general rule of thumb,
using the reserve capacity (RC) rating of the
battery as the number of ampere hours of charge
will usually bring the green dot into view. For
reserve capacity refer to "Specifications" in this
section. If battery is rated at 75 RC minutes, it
would usually be completely recharged as follows:
10 ampere charge 7 1/2 hours = 75 AH
or
25 ampere charge 3 hours = 75 AH, etc.
6. It is recommended that any battery recharged by
this procedure by LOAD TESTED to establish
serviceability. Refer to "Battery Testing in this
section.
JUMP STARTING IN CASE OF

EMERGENCY WITH AUXILIARY
(BOOSTER) BATTERY
NOTICE: Do not push or tow the vehicle to
start. Damage to the emission system and/or to
other parts of the vehicle may result.
Both auxiliary battery and discharged battery

should be treated carefully when using jumper cables.
601 8
BATIERY
CAUTION: Departure from these

conditions or the procedure below could
result in: (1) serious personal injury
(particularly to eyes) or property damage
from such causes as battery explosion,
battery acid or electrical burns; and/or (2)
damage to electronic components of
either vehicle.
Never expose battery to open flame or
electric spark -battery generate a gas
which is flammable and explosive.
Remove rings, watches, and other
jewelry. Wear approved eye protection.
Do not allow battery fluid to contact
eyes, skin, fabrics, or painted surfaces
battery fluid is a corrosive acid. Flush
any contacted area with water
immediately and thoroughly. Be careful
that metal tools or jumper cables do not
contact the battery positive terminal (or
metal in contact with it) and any other
metal on the vehicle, because a short
circuit could occur.
1. Set parking brake lever and place automatic
transmission in "PARK." Tum off the ignition,
lamps and all other electrical loads.
2. Check the built-in hydrometer. If it is clear or
light yellow, replace the battery.
NOTICE: Do not jump start a vehicle with

charging equipment unless the. equipment is
specifically designed for jump starting. Using
improper equipment can cause serious damage
.to the electrical system or electronic parts.
3. Attach the end of one jumper cable to the
auxiliary battery positive terminal and the other
end of the same cable to the positive terminal of
the junction block.
Do not permit vehicles to touch each other as
this could cause a ground connection and
counteract the benefits of this procedure.
CAUTION: To prevent sparking and

possibly explosion of battery gases, do
not connect jumper cable directly to the,
battery negative terminal of the dead
battery.
4. Attach one end of the remaining negative cable to
the auxiliary battery negative terminal, and the
other end to a solid engine ground (such as the
compressor bracket or power steering pulllp
bracket) at least 46 cm (18 inches from the
battery of the vehicle being started.
5. Start the engine of the vehicle that is providing
the jump start and tum off electrical accessories.
Then start the engine of. the vehicle with the
discharged battery.
6. Reverse these directions exactly when removing
the jumper cables. The negative cable must first
be disconnected from the engine that was jump
started.
BATIERY TRAY REPLACEMENT

The battery tray is part of the coolant recovezy
reservoir. Refer to Section 6B for replacement.
BATIERY REPLACEMENT
Figure 9
!++I

Cable " in Section OA.
1. Negative cable (2) from battery negative terminal.
2. Positive cable (1) from battery positive terminal.
3. Battery hold-down retainer bolt/screw (5) and
bat~ry hold-down retainer (9).
4. Battery (3).
1++1
Install or Connect
NOTICE: Refer to "Notice" on page 6Dl-1.

1. Battery (3).
2. Battery hold-down retainer (9) and battery
hold-down retainer bolt/screw (5).
I~!
Tighten
Battery hold-down retainer bolt/screw (5) to 18

N.m (13 lb. ft.).
3. Positive cable (1) to battery positive terminal.
I~!
Tighten
Positive cable (1) to 15 N.m (11 lb. ft.).

4. Negative cable (2) to battery negative terminal.
I~!
Tighten
Negative cable (2) to 15 N,m (11 lb. ft.);
BATTERY CABLE REPLACEMENT AND

ROUTING
Whenever battery cables are replaced, always be
certain to use a replacement battery cable that is the
same type and length. Some positive cables have
additional feed wires attached to them and some
negative cable have additional ground straps attached.
Always be certain when replacing a battery cable to
route it the same as the one being replaced.
BATTERY 601-9
1
2
3
5
9
23
!VIEWAI
CABLE, BATTERY POSITIVE

CABLE, BATTERY NEGATIVE
BATTERY, STORAGE
BOLT/SCREW, BATTERY HOLD-DOWN RETAINER
RETAINER, BATTERY HOLD-DOWN
TRAY, BATTERY
012095
FS0098D1
Figure 9 - Battery
Negative Cable
3800 (VIN K)
Figure 10
!++!
3. Negative battery cable (2) to clip on accumulator

bracket.
4. Negative battery cable (2) and nut (8) to stud on
wheelhouse.
!~I
Tighten
Nut (8) to 6 N.m (53 lb. in.).

5. Battery. Refer to "Battery Replacement" in this
section.

5.7L (VIN P)
L. Battery. Refer to "Battery Replacement" in. this
Figures 11 and 12
2.
3.
4.
5.
!++I
section.
Nut (8) and negative cable (2) from stud on
wheelhouse.
Negative battery cable (2) from clip on
accumulator bracket.
Nut (13) from engine block stud.
Negative battery cable (2).
Install or Connect
NOTICE:
1. Negative battery cable (2) to engine block stud.

2. Nut (13).
l~!
Tighten
Nut (13) to 22 N,m (16 lb. ft.).
!+-+!

''Disconnecting the Battery Negative
section.
2. Nut (8) and negative cable (2) from stud (7) on
wheelhouse.
SECTION OA.
4. Using a standard screwdriver, pop open cable clip
(16) and remove negative cable (2).
5. Negative cable (2) from engine block.
The negative cable (2) is connected to the
601-10
BATIERY
engine block by either a stud (13) or nut (10)

just behind the air conditioning compressor.
Remove stud (13) or nut (10) and negative
cable (2).
l++i
Install or Connect
NOTICE:
Connect negative cable (2) and either stud (13)

or nut (10) to engine block just behind air
conditioning .compressor.
NOTICE: Before installing positive cable to

starter solenoid switch, be sure solenoid terminal
is secure in cap by and push nut next to cap is
tight. If terminal is not tight in solenoid cap, the
cap may be damaged during installation of the
positive cable and cause starter failure later.
Tighten
Nut (10) to 35 N.m (26 lb. ft.).

or
Stud (13) to 33 N.m (24 lb. ft.).
2. Place negative cable (2) back into cable clip (16)
and snap clip closed.
3. Lower vehicle.
4. Negative cable (2) and nut (8) to stud (7) on
wheelhouse.
l~i Tighten
Nut (8) to 6 N.m (53 lb. in.).
section.
Positive Cable
!++!
Figure 10
Hemove or Disconnect

Cable" in SECTION Ott
section.
2. Positive cable (1) from junction block.
A.
Open junction block cover (4).

B. Remove nut (6) from stud (14).
C. Positive cable (1) from stud (14).
3. Positive cable (1) from generator (21).
A. Move boot covering connection and slide out
of way.
B. Remove nut (18) from generator {21).
C. Positive cable (1) from generator (21).
4. Usillg stan,dard screwdriver, remove positive cable
(1) from clips (16) at engine lift bracket and
engine cooling fans.
SECTION OA.
Install or Connect
NOTICE: Refer to "Notice" on page 6Dl-1.

1. Positive cable (1) to starter solenoid switch and

nut (12).
l~I
Tighten
Nut (12) to 10 N.m (89 lb. in.).

2. Clip and nut (11) securing positive cable (1) to
engine mount.
I~!
3800 (VIN K)
j++I
Refer to "Notice" on page 6Dl-1
1. Negative cable (2) to engine block.
l~I
6. Positive cable (1) from clip (16) at power steering

reservoir bracket.
7. Nut (11) and clip securing positive cable (1) to
engine mount.
8. Nut (12) and positive cable from starter solenoid
switch.
9. Positive cable (1).
3.
4.
5.
6.
Tighten
Nut (11) to 25 N.m (18 lb. ft.).

Positive cable (1) to clip (16) at power steering
reservoir bracket.
Lower vehicle.
Positive cable (1) to clips (16) at engine cooling
fans and engine lift bracket.
Positive cable (1) and nut (18) to generator (21).
l~I
Tighten
Nut (18) to 22 N.m (16 lb. ft.).

7. Carefuliy slide boot over positive cable (1) and
.
generator (21) connection.
8. Positive cable (1) to junction block.
A. Positive cable (1) and nut (6).
!~I
Tighten
Nut (6) to 6 N.m (53 lb. in.).

B. Close junction block cover (4).
section.
BATTERY 601-11
21
18
16
16
I CABLE, BATTERY POSITIVE

2 CABLE, BATTERY NEGATIVE
4 COVER, JUNCTION BLOCK
6 NUT, BATIERY POSITIVE CABLE-TO-JUNCTION
BLOCK
7 STUD, GROUND
B NUT, BATTERY NEGATIVE-TO-GROUND
10 RF GROUND, BATTERY POSITIVE CABLE
11 NUT, BATTERY-POSITIVE AND NEGATIVE
CABLE CLIP
12 NUT, BATTERY POSITIVE CABLE
13 NUT, BATTERY NEGATIVE CABLE-TO-ENGINE
BLOCK GROUND
14 STUD, JUNCTION BLOCK POSITIVE TERMINAL
15 MOTOR, STARTER
16 CLIP, CABLE
17 CLIP, CABLE
18 NUT, BATTERY POSITIVE CABLE-TO-GENERATOR
STUD
20 WASHER, BATTERY POSITIVE RF GROUND
21 GENERATOR
Figure 10 - Battery Cable Routing (3800 VIN K)
11-1794
FS0148D1
601-12
BATTERY
l~I Tighten
5.7L (VIN P)
Figures 11 and 12
l++I

section.
2. Positive cable (1) from junction block.
A. Open junction block cover (4).
B. Remove nut (6) from stud (14).
C. Remove positive cable (1) from stud (14).
3. Positive cable (1) from generator (21).
A. Move boot covering connection and slide out
of way.
B. Remove positive cable (1).
The positive cable (1) is connected to
generator (21) with bolt/screw (20). Remove
bolt/screw (20) and positive cable (1).
SECTION OA.
5. Using a standard screwdriver, pop open cable clip
(16) and remove positive cable (1).
6. Bolt/screw (11) securing positive cable (1) and
clip ( 17) to engine mount bracket.
7. Nut (12) and positive cable (1) from starter
solenoid switch (19).
NOTICE:
Before installing positive cable to

starter solenoid switch, be sure solenoid terminal
is secure in cap by tightening terminal nut next
to cap. If terminal is not tight in solenoid cap,
the cap may be damaged during installation of
positive cable and cause starter to fail later.
!++I
Install or Connect
NOTICE:
Refer to "Notice" on page 6Dl-1.
1. Positive cable (1) and nut (12) to starter solenoid

switch ( 19).
1~1
Tighten
Nut (12) to 10 N.m (89 lb. ft.).

2. Bolt/screw (11) and Clip (17) securing positive
cable to engine mount bracket.

3. Place positive cable (1) back into cable clip (16)
and snap clip ( 16) closed.

4. Lower vehicle.
5. Positive cable (1) to generator (21).
!~!
Tighten

6. Carefully slide boot over positive cable (1) and
generator (21) connection.
7. Positive cable (1) to junction block.
A. Place positive cable (1) and nut (6) on stud
(14).
I~!
Tighten
Nut (6) to 2.0 N.m (18 lb. in.).

B. Close junction block cover (4).
section.
Route positive cable between heater hoses as
shown in Figure 12.
GROUND STRAPS
Additional ground straps are used to connect the
body and frame to the engine and transmission.
Always connect all ground straps to ensure a good
ground path to the battery from all electrical
components.
CHARGING EQUIPMENT
A battery charger that is considered sufficient is
usually capable of a 16-volt output. When choosing a
charger, the following items should be considered
essential:
1. A 16-volt minimum output.
2. To prevent overcharging, the unit should have a
timer (1 to 2 hours) or a voltage regulator that
would regulate a maximum of 18 volts, or have
an automatic shut-off feature at full charge.
3. Ammeter or charging rate meter..
4. An automatic pblarity protector.
Some equipment that is available includes the
AC Delco MP2101-07, Associated No. 6001, the Sun
720, or equivalent. Very few chargers have sensitive
low-voltage meters, therefore, separate voltmeters may
be necessary.
A suitable load tester such as the Sun VAT-40 (or
equivalent) is available and is a very useful tool to
properly diagnose battery problems.
BATTERY
601-13
15
A
1
2
3
4
6
7
8
10
11
12
13
14
15
17
19
BLOCK, ENGINE
CABLE, BATTERY POSITIVE
CABLE, BATTERY NEGATIVE
BATTERV,STORAGE
COVER, JUNCTION BLOCK
NUT, BATTERY POSITIVE CABLE-TO-JUNCTION
BLOCK
STUD, GROUND
NUT, BATTERY NEGATIVE CABLE GROUND
NUT, BATTERY NEGATIVE CABLE-TO-ENGINE BLOCK
GROUND
BOLT/SCREW, BATTERY POSITIVE AND NEGATIVE
CA8LE CLIP
NUT, BATTERY POSITIVE CABLE
STUD, BATTERY NEGATIVE CABLE-TO-ENGINE BLOCK
GROUND
STUD, JUNCTION BLOCK POSITIVE TERMINAL
MOTOR, STARTEA
CLIP, CABLE
SWITCH, STARTER SOLENOID
!VIEW B!
012095
FS0108D1
Figure 11 Battery Cable Routing (5.7L VIN P) (1 of 2)
601-14
BATTERY
1 CABLE, BATIERY POSITIVE

BATIERY, STORAGE
16 CLIP, CABLE
18 NUT, ENGINE WIRING HARNESS GENERATOR LEAD
21 GENERATOR
22 HOSE, HEATER INLET/OUTLET
16
01-19-96
FS0118D1
(
Figure 12 - Battery Cable Routing (5.7L VIN P) (2 of 2)
BATIERY
601-15
SPECIFICATIONS
BATIERY USAGE
STORAGE BATTERY ASSEMBLY USAGE CHART
CATALOG NUMBER
TEST
LOAD
AMPS
COLD
CRANKING
AMPS*
RESERVE
CAPACITY
MINUTES**
REPLACEMENT
NUMBER
484 (Std. L36)
345
690
90
75Z-72
514 (Std. LTl)
260
525
90
75-60
*Cold Cranking= Amperage available for 30 seconds of engine cranking at -18C (OF).
**Reserve Capacity = The approximate time in minutes a storage battery assembly can support a 25 amp load
without the terminal voltage dropping below 10.5 volts at 27C (80F) in the event of a charging system failure.
T5524

Battery
Battery
Battery
Battery
Battery
Battery
Battery
Battery
Battery
Battery
Battery
Battery
Battery
Hold-Down Retainer Bolt/Screw ............................................................................... 18 N.m (13 lb. ft.)

Negative Cable-to-Battery .......................................................................................... 15 N.m (11 lb. ft.)
Negative Cable Ground Body-to-Nut .......................................................................... 6 N.m (53 lb. in.)
Negative Cable-to-Engine Block Nut (3800 Engine with C41) ............................... 27 N.m (20 lb. ft.)
Negative Cable-to-Engine Block Nut (3800 Engine with C60) ............................... 22 N.m (16 lb. ft.)
Negative Cable-to-Engine Block Stud ....................................................................... 33 N.m (24 lb. ft.)
Positive Cable Clip-to-Engine Mount Nut (3800 Engine) ....................................... 22 N.m (16 lb. ft.)
Positive Cable RF Ground-to-Engine Mount Nut (3800 Engine) ............................ 25 N.m (18 lb. ft.)
Positive Cable Clip/RF Ground-to-Engine Mount (5.7L Engine) ............................ 35 N.m (26 lb. ft.)
Positive Cable-to-Battery ............................................................................................ 15 N.m (11 lb. ft.)
Positive Cable-to-Generator Nut.. .............. '. ............................................................... 22 N.m (16 lb. ft.)
Positive Cable-to-Junction Block Nut ...................................................................... 6.0 N.m (53 lb. in.)
Positive Cable-to-Starter Solenoid Switch Nut.. ....................................................... 10 N.m (89 lb. in.)
SPECIAL TOOLS
1.
J 38758
2.
ST-1201
1. PARASITIC DRAW TEST SWITCH

2. BATTERY SIDE TERMINAL ADAPTERS (PAIR)
01-2CM)5
FS0136D1
601-16
BATTERY
BLANK
CRANKING SYSTEM
6021
SECTION 602
CRANKING SYSTEM
CAUTIONS in SECTION 9J. under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
and systems.
CONTENTS
Cranking Circuit ............................................... 602-:-1
Starter Motor ............................................. ;...... 602-1
Diagnosis ............................................................... 602-1
Lubrication ........................................................ 602-2
Starter Shield .................................................... 602-2
Starter Motor Replacement. ............................. 602-5
Unit Repair ............................................................ 602-7

PG-260 Starter Motor ....................................... 602-7
No-Load Test. .................................................... 602-7
Specifications ......................................................... 602-9
Starter Motor Usage Chart ............................... 602-9
General Specifications ....................................... 602-9
GENERAL DESCRIPTION
the starter solenoid switch. The starter solenoid switch

will move the starter shift lever, causing the starter
drive pinion to engage the flywheel ring gear. After
engagement, the starter solenoid switch will close the
main contacts, which results in cranking of the engine.
When the engine starts, pinion overrun protects the
armature from excessive speed until the switch is
opened, at which time the solenoid switch plunger
spring causes the pinion to disengage. To prevent
excessive overrun, the ignition switch should be
opened immediately when the engine starts.
CRANKING CIRCUIT
The cranking circuit consists of the battery,
starter motor, ignition switch, control circuits, starter
enable relay and related electrical wiring; these
components are connected electrically. Refer to
SECTION 8A for a complete electromechanical
schematic.
STARTER MOTOR
Figure 1
When the ignition switch is turned to the start
position, battery voltage is applied to the PASS-Key
II decoder module and resistance is read at this time.
If proper resistance is recognized and vehicle is in
"PARK" or "NEUTRAL," then the PASS-KEY II
decoder module will energize the starter enable relay.
The starter enable relay will send battery voltage to
DIAGNOSIS
Before removing any unit in a cranking circuit
repair, perform the diagnostic procedures
recommended in Figures 2, 3 and 4, and in
SECTION 8A. Then check the following items:
Battery: Determine condition of battery. Follow
testing procedure outlined in SECTION 601.
602-2
CRANKING SYSTEM
(
1
2
3
4
5
6
7
8
9
10
11
12
CONTACT, STARTER SOLENOID SWITCH

PLUNGER, STARTER SOLENOID SWITCH
SWITCH, STARTER SOLENOID
SPRING, STARTER SOLENOID SWITCH PLUNGER
LEVER, STARTER SHIFT
BUSHING, STARTER DRIVE
COLLAR, STARTER DRIVE STOP
DRIVE. STARTER
COIL, STARTER FIELD
ARMATURE, STARTER
BRUSH, STARTER
TERMINAL, STARTER SOLENOID
10
5-9-94
FS001802
Figure 1- Starter Motor (Typical)
Wiring: Inspect wiring for damage. Inspect all

connections to starter motor, solenoid switch, ignition
switch, and battery, including all ground connections.
Clean and tighten all connections as required.
Ignition Switch and Control Circuits:
Inspect all switches and relays to determine condition.
Non-Cranking or Slow Cranking: If engine
does not crank, or cranks slowly, follow diagnostic
procedure in Figures 2, 3 and 4, and in SECTION 8A.
If faulty starter motor is diagnosed, replace starter
motor.
Starter Motor Noise: Correct starter motor
noise using the following procedure:
1. Refer to Figure 4 to determine problem.
2. Shims are not installed during vehicle
assembly. However if complaint is similar to
problem 1 or 2 in Figure 4, correct
"shimming" as follows:
For starter motor noise during cranking, add
one 0.38 mm (0.015 inch) single shim (13 or
18) to outer bolt/screw only. Refer to Figure 5.
For high-pitched whining after engine fires,
add 0.38 mm (0.015 inch) double shims (14 or
19) until noise disappears. Number of shims
should not exceed 1.14 mm (0.045 inch).
Starter Motor: If battery, wiring and switches
are in satisfactory condition, engine is functioning
properly, and problem has been traced to starter motor,
remove starter motor (Refer to "Starter Motor
Replacement" in this section) and replace as stated.
NOTICE: Never operate the starter motor for

more than 30 seconds at a time without pausing
to allow it to cool for at least two minutes.
Overheating, caused by excessive cranking, will
seriously damage the starter motor.
ON-VEHICLE SERVICE
LUBRICATION
The PG-260 starter motors do not require
lubrication.
STARTER SHIELD
3800 VINK
Figure 5
CAUTION: Refer to "Caution" on
page 6D21.
!++!

SECTION OA.
3. Bolts/screws (17 and 20) and nut (19) attaching
shield (18) to engine.
4. Starter shield (18) from vehicle.
!++!
Install or Connect
NOTICE:
1. Starter shield (18) to vehicle.

2. Bolts/screws (17 and 20) and nut (19) attaching
shield (18) to engine.
!~! Tighten
Bolt/screw (17) attaching shield to engine to
30 N.m (22 lb. ft.).
Bolt/screw (20) attaching shield to engine to
10 N.m (89 lb. in.).
Nut (19) attaching shield to engine to 10 N,m
(89 lb. in.).
3. Lower vehicle.
!~I Tighten
Battery negative cable to 15 N.m (11 lb. ft.).
CRANKING SYSTEM
602-3
NO CRANKING, NO SOUND FROM SOLENOID
CHECK TO SEE IF SECURITY LIGHT IS ON,

IF SO REFER TO SECTION SA-133.
I
TURN HEADLAMPS AND DOME LAMP ON.
TURN KEY TO "START".
'
I
I
I LAMPS DIM OR GO OUT I
LAMPS STAY BRIGHT
I CHECK BATTERY STATE-OF-CHARGE. I

GREEN EYE SHOWING
LESS THAN 9.6 VOLTS
LESS THAN 7 VOLTS
CHECK VOLTAGE FROM

ENGINE BLOCK TO BATTERY
NEGATIVE POST KEY IN
"START" POSITION (POSITIVE
LEAD ON ENGINE BLOCK).
.I
7 VOLTS OR MORE
CLEAN AND TIGHTEN

GROUND CABLE
CONNECTION AND/OR
REPLACE CABLE
I
CLEAN AND TIGHTEN
BATTERY POSITIVE
CABLE TERMINALS
AND/OR REPLACE
CABLE.
CHECK CRANKING
VOLTAGE AT STARTER
"B" TERMINAL.
9 VOLTS OR MORE
I
I 7 VOLTS OR MORE I
I
REPLACE.STARTER MOTOR.
WITH KEY IN "START", CHECK VOLTAGE AT

IGNITION SWITCH SOLENOID TERMINAL.
LESS THAN 0.5 VOLT
CHECK BULKHEAD
CONNECTOR, FUSIBLE
LINK AND IGNITION
SWITCH CONNECTIONS
0.5 VOLT OR MORE
9.6 VOLTS OR MORE
TEST BATTERY IF
OK,REPLACE
STARTER MOTOR.
LESS THAN 9 VOLTS
IDON'T OPERATE I
CHECK CONNECTIONS
AND VOLTAGE AT
SOLENOID "S" TERM.
CHECK CRANKING
VOLTAGE AT
BATTERY POSTS.
IOPERATE OK I
CHARGE BATTERY.
CHECK FOR DRAIN
AND CHECK
GENERATOR.
TURN ON RADIO AND HEATER.
I EYE DARK I
REPAIR WIRE FROM

IGNITION SWITCH.
ILESS THAN 7 VOLTS I
I I
I
REPLACE IGNITION
SWITCH.
CHECK FUSIBLE LINK

AND BULKHEAD
CONNECTOR.
C8543
Figure 2 - Electrical System General Diagnosis (1 of 2)
602-4 CRANKING SYSTEM

SLOW CRANKING SOLENOID CLICKS OR CHATTERS
(
CHECK:
BATTERY FOR GREEN INDICATOR.
VISUAL CONDITION OF BATTERY CABLE AND CONNECTIONS.
IF BATTERY NEEDS CHARGING, MAKE GENERATOR AND BATTERY
DRAIN CHECK, CHARGE BATTERY AND CHECK CRANKING IF
PROBLEM HAS NOT BEEN FOUND, DO THE FOLLOWING:
REMOVE BATTERY LEAD FROM DISTRIBUTOR OR IGNITION MODULE.

MAKE ALL VOLTMETER READINGS WITH KEY IN "START" POSITION.
MEASURE CRANKING VOLTAGE AT BATTERY TERMINAL POSTS.
LESS THAN 9.6 VOLTS
9.6 VOLTS OR MORE
MEASURE VOLTAGE FROM BATTERY

NEGATIVE TERMINAL TO ENGINE BLOCK
(POSITIVE LEAD ON ENGINE BLOCK).
0.5 VOLT OR MORE
REPAIR GROUND CABLE

AND CONNECTIONS.
9 VOLTS OR MORE
REPLACE STARTER MOTOR.
LESS THAN 0.5 VOLT
CHARGE AND LOAD TEST

BATTERY.
REPLACE
STARTER MOTOR.
REPLACE
BATTERY.
MEASURE VOLTAGE AT
SOLENOID "B" TERMINAL,
CLEAN AND TIGHTEN
CONNECTIONS AT
STARTER MOTOR.
LESS THAN 9 VOLTS
CLEAN AND TIGHTEN POSITIVE CABLE CONNECTIONS.

IF OK, REPLACE CABLE.
THIS PROCEDURE IS DESIGNED FOR USE ON ENGINES AND

BATTERIES AT ROOM OR NORMAL OPERATING
TEMPERATURES. IT ALSO ASSUMES THERE ARE NOT ENGINE
DEFECTS WHICH WOULD CAUSE CRANKING PROBLEMS TO
USE IT UNDER OTHER CONDITIONS MIGHT RESULT IN AN
IMPROPER DIAGNOSIS.
C8544
Figure 3 - Electrical System General Diagnosis (2 of 2)
CRANKING SYSTEM
6025
CAUSE
PROBLEM
HIGH PITCHED WHINE DURING CRANKING
(BEFORE ENGINE FIRESI BUT ENGINE CRANKS
AND FIRES OK
DISTANCE TOO GREAT BETWEEN STARTER DRIVE

PINION AND FLYWHEEL ASSEMBLY
HIGH PITCHED "WHINE" AFTER ENGINE

FIRES, AS IGNITION KEY IS BEING
RELEASED ENGINE CRANKS AND FIRES OK
THIS INTERMITTENT COMPLAINT IS OFTEN
DIAGNOSED AS "STARTER HANG-tN" OR
"SOLENOID WEAK "
DISTANCE TOO SMALL BETWEEN STARTER DRIVE

PINION AND FLYWHEEL ASSEMBLY FLYWHEEL
ASSEMBLY RUNOUT CONTRIBUTES TO THE
INTERMITTENT NATURE
A LOUD "WHOOP" AFTER THE ENGINE

FIRES BUT WHILE THE STARTER DRIVE
PINION IS STILL HELD ENGAGED SOUNDS
LIKE A SIREN IF THE ENGINE IS REVVED
WHILE STARTER DRIVE PINION tS
ENGAGED
A NEW STARTER DRIVE ASSEMBLY WILL OFTEN

CORRECT THIS PROBLEM
A "RUMBLE," "GROWL" OR (IN SEVERE

CASES) A "KNOCK" AS THE STARTER
MOTOR ASS EMBLY IS COASTING DOWN TO
A STOP AFTER STARTING THE ENGINE
MOST PROBABLE CAUSE 1$ A BENT OR

UNBALANCED STARTER ARMATURE A NEW
ST ARTER ARMATURE WILL OFTEN CORRECT THIS
PROBLEM
5-9-94
FS004602
Figure 4 - Starter Motor Noise Diagnosis
STARTER MOTOR REPLACEMENT
!H!
Install or Connect
Figures 6 and 7
NOTICE:
3800 VINK
!+-t!
[I)
Important
This vehicle was designed for starter mounting

without shims. However if single shims (13) or
double shims (14) have been added to correct a
noise or engagement condition, they should be
reinstalled in their original location to ensure
proper pinion-to-flywheel engagement. Refer to
figure 7.

6021.
SECTION OA.
3. 3-way catalytic converter. Refer to SECTION 6F.
4. Starter shield. Refer to "Starter Shield" in this
section.
5. Starter motor mounting bolt/screw (16) and stud
(21), and lower starter motor (15).
6. Electrical leads from starter motor (15).
Note position of wires before disconnecting.
7. Starter motor (15) from vehicle.
1. Electrical leads to starter motor (15).
!~!
Tighten
Starter solenoid 'BAT" terminal nut to 10 N.m

(89 lb. in.).
Starter solenoid "S" terminal nut to 3 N,m
(27 lb. in.).
2. Bolt/screw (16) and stud (21) attaching starter
motor (15) to engine.
l~!
Tighten
Bolt/screw (16) attaching starter motor (15) to

engine to 47 N,m (35 lb. ft.).
Stud (21) attaching starter motor (15) to
engine to 45 N,m (33 lb. ft.).
!tll!
Measure
Pinion-to-flywheel clearance (see Figure 7).

Add shims (13 or 14) if necessary.
3. 3-way catalytic converter. Refer to SECTION 6F.
4. Lower vehicle.
!~!
Tighten
602-6
CRANKING SYSTEM
17
18
19
20
BOLT/SCREW, STARTER MOTOR SHIELD

SHIELD, STARTER MOTOR
NUT, STARTER MOTOR SHIELD
BOLT/SCREW, STARTER MOTOR SHIELD
10-4-94
F80118D2
Figure 5 Starter Shield (3800 VIN K)
5.7L VIN P
l++I
[I]
Important
This vehicle was designed for starter mounting

without shims. However if single shims (13)
or double shims (14) have been added to
correct a noise or engagement condition, they
should be reinstalled in their original location
to ensure proper pinion-to-flywheel
engagement. Refer to figure 7.

602-1.
j++!
Install or Connect

1. Electrical leads to starter motor (15).
!~! Tighten
Starter solenoid switch "BAT" terminal outer
nut to 10 N.m (89 lb. in.).
Starter solenoid switch "S" terminal nut to
3 N.m (27 lb. in.).
2. Starter motor (15) to engine.
I~!
Tighten

SECTION OA.
3. Oxidation catalytic converter. Refer to
SECTION 6F.
4. T\vo starter mounting bolts/screws (16) and lower
starter motor (15).
5. Electrical leads from starter motor (15).
Note position of wires before disconnecting.
6. Starter motor (15).
!@!
Measure
Pinion;.to-flywheel clearance (see Figure 7).

Add shims (13 or 14) if necessary.
4. Oxidation catalytic converter. Refer to
SECTION 6F.
5. Lower vehicle.
!~!
Tighten
CRANKING SYSTEM
6D27
16
A
8
13
14
15
16
21
5.7L VIN P
3800 VIN K
SHIM, STARTER MOTOR SINGLE
SHIM, STARTER MOTOR DOUBLE
MOTOR, STARTER
BOLT/SCREW, STARTER MOTOR
STUD. STARTER MOTOR
03-09-95
FTOOHD2
Figure 6 - Mounting Starter Motor
UNIT REPAIR
PG-260 STARTER MOTOR
[I]
Important
The PG-260 starter motor used with 3800 VIN K

and 5. 7L VIN P engines are not serviceable and
should be replaced as complete units only.
NO-LOAD TEST
Figure B
With carbon pile "OFF", make connection as
shown in Figure 8. Close the switch, adjust carbon
pile to obtain 10 volts, and compare the RPM, current
and voltage readings with "Specifications" listed at
the end of this section.
Make disconnection's only with the switch open.

Use the test results as follows:
1. Rated current draw and no-load speed indicates
normal starter motor condition.
2. Low free speed and high current draw indicates:
Too much friction. This can be caused by
tight, dirty or worn bearings, or bent armature
shaft allowing armature to drag.
Shorted armature.
Grounded armature or fields.
3. Failure to operate with high current draw
indicates:
Direct ground in terminal or fields.
"Frozen" bearings (this should have been
determined by hand turning armature).
602-8 CRANKING SYSTEM

4. Failure to operate with no current draw indicates:
Open field circuit.
Open armature coils.
Broken brush springs, worn brushes, high
insulation between commutator bars or other
causes which would prevent good contact
between brushes and commutator.
5. Low no-load speed and low current draw
indicates:
High internal resistance due to poor
connections, defective leads, dirty commutator
and causes listed above under number 4.
6. High free speed and high current draw usually
indicate shorted fields.
If above conditions exist, then the starter motor
needs to be replaced.
A INSERT O 5 mm (0 20") WIRE

GAGE HERE TO CHECK
84 FLYWHEEL ASSEMBLY
85 PINION, STARTER DRIVE
5-5-94
FS006602
Figure 7 - Flywheel-to-Pinion Clearance
(
22
A---1-...J
E ---;;....---1
A CARBON PILE
B AMMETER
C VOLTMETER
D SWITCH
E RPM INDICATOR
15 MOTOR ASSEMBLY, STARTER
22 BATIERY ASSEMBLY, STORAGE
23 SWITCH, STARTER SOLENOID
5-5-94
FS008602
Figure 8 - No-Load Test
CRANKING SYSTEM
602-9
SPECIFICATIONS
STARTER MOTOR USAGE CHART
3800 (VIN K) AND 5.7L (VIN P)
Starter type ............................................................................................................................................. PG-260

No-Load Test at 11.5 Volts
Amps-Minimum .......................................................................................................................................... 60
Amps-Maximum ........................................................................................................................................ 125
RPM at Drive Pinion
Minimum ................................................................................................................................................ 2,900
Maximum ............................................................................................................................................... 3,400
Starter Solenoid Switch
Hold-in Windings at 11.5 Volts .................................................................................................. 5-15 Amps
Both Windings at 11.5 Volts ..................................................................................................... 30-50 Amps

Battery Negative Cable ........................................................................................................... 15 N,m (11 lb. ft.)
Starter Motor Heat Shield Nut ............................................................................................. 12 N.m (106 lb. in.)
Starter Motor Bolt.Screw ........................................................................................................ 47 N.m (35 lb. ft.)
Starter Solenoid Switch "BAT" Terminal Inner Nut .............................................................. 9 N.m (80 lb. in.)
Starter Solenoid Switch Clamp Bolt/Screw ............................................................................ 11 N.m (97 lb. in.)
Starter Solenoid Switch "S" Terminal Nut .......................................................................... 2.5 N.m (22 lb. in.)
Pinion Clearance ..................................................................... 0.25 mm to 4.06 mm (0.010 inch to 0.160 inch)
60210 CRANKING SYSTEM
BLANK
CHARGING SYSTEM
6031
SECTION 603
CHARGING SYSTEM
CAUTIONS in SECTION 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
and systems.
CONTENTS
Charging Circuit ........................ Refer to Section 8A
CS-130D and CS-144 Generators .................... 603-1
Diagnosis .............................................................. 603-2
CS Generator On-Vehicle Check ..................... 603-2
CS Generator Bench Check............................. 603-2
Generator Replacement .................................... 603-3
CS-130D Generator ...................................... 603-3
CS-144 Generator ......................................... 603-4
Generator Rear Brace ..................................... 603-6

Generator Brace Bracket................................. 603-6
Unit Repair .......................................................... 603-6
CS-130D Generator ......................................... 603-6
CS-144 Generator Disassembly, Test and
Re-assembly ................................................. 603-6
Specifications ............................. ;......................... 603-12
Generator Usage Chart .................................... 603-12
Fastener Tightening Specifications ................. 603-12
Special Tools ....................................................... 603-12
GENERAL DESCRIPTION
addition to the ground path through the generator

bracket. Use of "P," "I" and "S" terminals is
optional. The "P" terminal is connected to the stator
and may be connected externally to a tachometer or
other device. The "I" terminal can be connected
directly to battery voltage to power the generators
instead of, or in addition to, the "L" terminal which
must be stepped down. The "S" terminal may be
connected to an external voltage source, such as
voltage near the battery, for voltage control. If the "S"
terminal is not used, internal generator voltage is used
for control.
The voltmeter reads battery voltage when the
engine is not running and reads charging system
voltage when the engine is running. The normal
indication is between 11 volts and 16 volts.
CS-1300 AND CS-144 GENERATORS

The charging system generators use a built-in
voltage regulator with fault detection, a stator, rectifier
bridge, and rntor with slip rings and brushes. The
CS-130D generator used on the 3800 (VIN K) engine
uses a conventional pulley and dual internal cooling
fans to cool the slip ring end frame, rectifier bridge
and voltage regulator. The CS-144 generator used on
the 5.7L (VIN P) engine U:ses a conventional pulley
and fan to cool the slip ring end frame, rectifier bridge
and voltage regulator. These generators use only two
connections - battery positive and "L" terminal, in
6032
CHARGING SYSTEM
The regulator voltage setting varies w.ith

temperature and limits system voltage by controlling
rotor field current. While the field current is "on,"
this regulator actually switches rotor field current on
and off at a fixed frequency of about 400 cy~les per
second to help control radio noise. By varymg the
overall on-off time, correct average field current for
proper system voltage control can be obtained. At high
speeds the on-time may be 10 percent and the
off-ti~e 90 percent. At low speeds, with high
electrical loads, on-off time may be 90 percent and 10
percent respectively.
DIAGNOSIS
CS GENERATOR ON-VEHICLE CHECK
Tool Required:
J 39200 Digital Multimeter
When the CS charging system is operating
normally the voltmeter will read between 11 volts
and 16 ~olts when the engine is running. If the
voltmeter operates abnormally, or if an
undercharged or overcharged battery condition
occurs, the following procedure may be used to
diagnose the charging system. Remember that .an
undercharged battery is often caused by ~ccessones
being left on overnight, or by a hood or mstrument
panel compartment lamp that stays on.
Noise from a generator may be caused by a
loose drive pulley, loose mounting bolts/screws,
worn or dirty bearings, faulty diode or faulty stator.
A magnetic whining noise may be heard fro'?
vehicles equipped with the CS-130D generator. This
is a normal condition.
.
To avoid damage to the electrical equipment,
always observe the following precautions:
Do not reverse connections to generator.
Do not short across or ground any of the
terminals in charging circuit, except as directed
by instructions.
NEVER disconnect generator "BAT" terminal
with generator operating.
When connecting a battery charger, or
connecting battery to battery, refer to
SECTION 6Dl.
In some vehicles, a voltmeter may be used
instead of the indicator lamp. In this case,
steps 1 through 4 pertaining to faulty indicator
lamp operation, should be omitted from
troubleshooting procedure.
Do not attempt to disassemble CS-130D
generator. Damage to generator could result.
Trouble in the charging system will show up
as one or more of the following conditions:
Faulty voltmeter operation.
Undercharged battery, as evidenced by slow
cranking or dark hydrometer.
Overcharged battery, as evidenced by spewing
of electrolyte from vents or a yellow
hydrometer.
To diagnose the CS-130D or CS-144 charging
system, use the following procedure:
rn
Important
Only the CS-144 generator may be repaired.

1. Visually check serpentine drive belt and wiring.
2. Battery undercharged or overcharged (voltage

lower than 11 volts or higher than 16 volts).
A. Detach wiring harness connector from
generator.
.
B. With ignition switch "ON" and engme not
running, connect J 39200 as voltmeter from
ground to "L" terminal in wiring harness
connector. Connect to "F" or "I" terminal for
gage equipped vehicles. At least one terminal
should have battery voltage.
C. Zero volts indicates open circuit between

terminal and battery. Correct as required.
D. Reconnect harness connector to generator.
CAUTION: Disconnect battery negative

cable before installing or removing a
series-type ammeter at generator battery
terminal.
603-1.
E. Install ammeter at generator output .terminal.
With load off, install carbon pile load test
across battery terminals. Start engine and run
at 2500 rpm. Make sure this is done at
ambient temperature.
F. Measure voltage across battery, using J 392~.
If voltage is above 16 volts, replace or reparr
generator.
.
G. Tum on accessories and load battery with
carbon pile to obtain maximum generator
output. Maintain voltage at 13 volts or above.
Use ammeter to check amperage. Compare
output to ampere rating in "Specifications" at
the end of this section.
If within 15 amps of rated output,
generator is OK.
If not within 15 amps of rated output,
repair or replace generator.
CS GENERATOR BENCH CHECK

Figure 1
Tool Required:
J 39200 Digital Multimeter
The following bench check may be used to
simulate operation on a vehicle. Use the bench
check to verify operation of a CS-144 generator that
has been repaired.
1. Mount generator in suitable test stand according
to test stand manufacturer's instructions. Test
stand must be capable of driving generator at
6,500 rpm.
2. Make connections as shown in Figure 1. Be sure
carbon pile is turned off. Ground polarity of
generator and battery must be same. Battery must
be fully charged. Use a 30-500 ohm resistor
between battery and "L" terminal of generator.
CHARGING SYSTEM
3. Slowly increase generator speed and observe
voltage using J 39200.
(I]
GENERATOR REPLACEMENT
CSm 1300 Generator
Important
3800 VINK
The battery must be fully charged when

making this test.
The engine must be run at 2500 rpm and at
ambient temperature.
4. If voltage is uncontrolled and increases above
16 volts, repair or replace generator.
5. If voltage is below 16 volts, increase speed and
connect and adjust carbon pile to obtain maximum
amperage output. Maintain voltage above 13 volts.
6. Use ammeter to check amperage. If output is
within 15 amps of rated output, generator is good.
7. If output is not within 15 amps of rated output,
repair or replace generator.
[I]
603-3
Figure 2
j++I

6D3-1.
1.
2.
3.
4.
5.
Important
Only the CS-144 generator may be repaired.
6.
ON-VEHICLE SERVICE
7.
The CS generator does not require periodic

lubrication. The rotor shaft is mounted on permanently
lubricated bearings. At periodic intervals, check
mounting bolts/screws for tightness and check
serpentine drive belt tension. Refer to
8.
j++!
Battery negative cable from battery terminal.

Serpentine drive belt. Refer to SECTION 6A8A
Electrical connector from generator.
Battery positive cable nut from generator "BAT"
terminal.
Charcoal canister solenoid from generator brace
(13).
Bolt/screw ( 4) attaching generator (5) to rear
brace (13).
Bolts/screws (8 and 11) attaching generator (5) to
drive belt tensioner.
Generator (5) from drive belt tensioner.
Install or Connect
NOTICE:
1. Generator (5) to drive belt tensioner.

2. Bolts/screws (8 and 11) attaching generator (5) to
drive belt tensioner.
!~!
Tighten

3. Charcoal canister solenoid to generator rear brace
(13).
4. Bolt/screw (4) attaching generator (5) to rear
brace(l3).
l~I
Tighten
Bolt/screw (4) attaching generator to rear brace

to 30 N.m (22 lb. ft.).
5. Battery positive cable nut to generator "BAT"
terminal.
l~i
Tighten
D
A CARBON PILE
B VOLTMETER
C RESISTOR (305000)
D AMMETER
E CONNECTOR RESISTOR TO "L" TERMINAL
5 GENERATOR
6 BATTERY, STORAGE
01-17-95
F80018D3
Figure 1 - Generator Bench Check
Battery positive cable nut to 10 N.m

(89 lb. in.).
6. Electrical connector to generator.
8. Battery negative cable to battery terminal.
Tighten.
Battery negative cable bolt/screw to 15 N.m
(11 lb. ft.).
603'."4 CHARGING SYSTEM
3 BOLT/SCREW, GENERATOR BRACE TO BRACKET

4 SOLT /SCREW, GENERATOR BRACE
5 GENERATOR
8 SOLT /SCREW, GENERATOR
11 BOLT/SCREW, GENERATOR
13 BRACE, GENERATOR REAR
0523-15
FT0136D3
Figure 2 CS-1300 Generator Mounting (3800 VIN K)
CS-144 Generator
5.7L VIN P

603-1.
1.
2.
3.
4.
5.
6.
7.
8.
9.
!++I
Battery negative .cable from battery terminal.

Serpentine drive belt. Refer to SECTION 6A3A.
Lower vehicle.
Battery positive cable from generator "BAT"
terminal.
Electrical connector from generator (5).
Bolts/screws (9, 17 and 21) and nut (61) at
generator (5).
Nut (12) at generator rear inner brace (10).
Generator rear inner brace (10).
Generator (5) from accessory mounting
bracket (7).
Install or Connect
NOTICE:
!~! Tighten
Figure 3
!++I
2. Generator rear inner brace (10).

3. Nut (12) at generator rear inner brace (10).
1. Generator (5) to accessory mounting bracket (7).
Nut (12) to 33 N.m (24 lb. ft.).

4. Bolts/screws (9, 17 and 21) and nut (61) at
generator (5).
!~!
Tighten

5. Electrical connector to generator (5).
6. Battery positive cable to generator "BAT"
tenninal.
!~!
Tighten
Battery positive cable nut to 20 N,m

(15 lb. ft.).
SECTION OA.
.
9. Battery negative cable to battery terminal.
!~!
Tighten
Battery negative cable bolt/screw to 15 N,m

(11 lb. ft.).
CHARGING SYSTEM
..
10
10
~~~~~~~~:CCESESNOrR:T~~u~:i BRACE
BOLT/SCREW, G R REAR OUTER
1 BRACE, GENETROA!OREAR BRACE
T GENERA
R
12 NU
EW GENERATO
17 BOLT/SCREW' GENERATOR
21 BOLT/s~~RATo
R
61
62
NUT C~E GENERATOR REA\~~~~ MOUNTING

BRA
' NERATOR OUTER
N
63
-UT-------Fl!
GE
----:-:-:-;;:~~~~-~
alor Moun11ng ( 7L VIN P)
5
Figure 3 - CS- 144 Gener
603-5
6036 CHARGING SYSTEM

GENERATOR REAR BRACE
GENERATOR BRACE BRACKET
3800 VINK
3800 VINK
Figures 2 and 4
Figure 4
l+-+I
l+-+I

603-1.
1. Generator (5) from drive belt tensioner. Refer to
"CS-1300 Generator" in this section.
2. Generator brace bolt/screws (3) attaching brace
(4) to generator brace bracket.
3. Generator brace (13) from vehicle.
1-++I
Install or Connect
NOTICE:
1. Generator brace (13) to vehicle.

2. Generator brace bolts/screws (3) attaching brace
(13) to generator brace bracket.
!~I
Tighten

3. Generator (5) to drive belt tensioner. Refer to

603-1.
1. Generator from drive belt tensioner.. Refer to
2. Generator rear brace. Refer to "Generator Rear
Brace" in this section.
3. Fuel rail from upper intake manifold. Refer to
"Fuel Rail" in SECTION 6A8A.
4. Bolts/screws (14) attaching generator brace
bracket to cylinder head.
5. Generator brace bracket (15) from vehicle.
I-++!
Install or Connect
NOTICE:
1. Generator brace bracket (15) to vehicle.

2. Bolts/screws (14) attaching generator brace
bracket to cylinder head.
!~l Tighten
Bolts/screws to 50 N.m (37 lb. ft.).
3. Fuel rail to upper intake manifold. Refer to "Fuel
Rail" in SECTION 6A8A.
4. Generator rear brace. Refer to "Generator Rear
Brace" in this section.
5. Generator to drive belt tensioner. Refer to
CS-1300 Generator" in this section.
UNIT REPAIR
CS-1300 GENERATOR
3800 VINK
[I]
Important
Do not attempt to disassemble a CS-1300

generator. Damage to the generator could
result. The CS-1300 generator is replaced as a
complete unit only.
CS-144 GENERATOR DISASSEMBLY, TEST

AND RE-ASSEMBLY
5.7L VIN P
A CYLINDER HEAD
14- BOLT/SCREW, GENERATOR BRACE BRACKET
15 BRACKET, GENERATOR BRACE
8-11-14
FSOl48D3
Figure 4 - Generator Brace Bracket (3800 VIN K)
l+t+l
Disassemble
1. Make scribe marks on slip ring end frame (43)

and drive end frame (59) to ease re-assembly.
CHARGING SYSTEM
6D37
2. Through-bolts/screws (26) and separate slip ring

end frame (43) and drive end frame (59).
3. End frame bearing (28) from rotor shaft.
!~!
Measure
Rotor (31) for grounds, opens and shorts

(Figure 5).
[I]
Important
Test should be performed at approximately

21 C (70F). A different temperature may
result in inaccurate ohmmeter readings.
A. Connect ohmmeter to slip ring and clean
metal grounding surface on frame of rotor
(31) to check for grounds.
Ohmmeter should read infinity (open).
If not, replace rotor (31).
B. Connect ohmmeter to both slip rings to
check for shorts and. opens.
Ohmmeter should read 1.7 to 2.1 ohms.
If not, replace rotor (31).
4. Nuts (35).
5. Stator (36) from slip ring end frame (43).
!@!
A
B
C
D
31
011785
FS0056D3
Measure
Figure 6 Testing Generator Rotor
Stator (36) for grounds (Figure 7).

A. Connect ohmmeter to stator terminal and to
clean metal ground on laminations.
32
33
34
35
36
57
OHMMETER CHECK FOR GROUNDS

OHMMETER CHECK FOR SHORTS ANO OPENS
RING, SLIP
RING, SLIP
ROTOR.GENERATOR
A "P" "L" "!" "S" TERMINALS

26 THROUGH-BOLT/SCREW, GENERATOR
27 TERMINAL, GENERATOR BATTERY
011795
FS0041D3
Figure 5 Generator Through-Bolt/Screw Location
BOLT/SCREW, REGULATOR ATTACHING

REGULATOR, GENERATOR VOLTAGE
HOLDER, GENERATOR BRUSH
NUT, STATOR LEAD ATTACHING
STATOR. GENERATOR
BOLT/SCREW, GENERATOR BRUSH HOLDER
011785
FS0088D3
Figure 7 Generator Slip Ring End Frame View
603~8
CHARGING SYSTEM
6.
7.
8.
B
9.
B. If ohmmeter reading is low, replace stator (36).

Stator (36) cannot be checked for opens and
shorts with ohmmeter.
Unsolder connections at connector strap (38) and
brush holder (34) to voltage regulator (33).
Bolt/screw (32) and bolt/screw (57).
Voltage regulator (33) and brush holder (34) with
dust shield (60) from slip ring end frame (43).
Tap plastic retaining pin from dust shield
retaining clip. Be sure to keep pin for
re-assembly.
Brushes (41) and dust shield (60) from brush

holder (34).
Clean
Brushes (41) with soft, dry cloth.
I@!
A
B
C
36
OHMMETER CHECK FOR GROUNDS

TERMINAL, GENERATOR STATOR
. .
LAMINATIONS
STATOR.GENERATOR
01-17-95
FS0076D3
Figure 8 - Testing Generator Stator
Measure
Rectifier bridge (53) for continuity (Figure 9).

A. Connect ohmmeter to grounded heat sink and
flat metal clip at rectifier bridge (53).
B. Reverse leads. One reading should be high
(open) and one low (continuity). If both
readings are the same, replace rectifier bridge
(53).
C. Repeat test between grounded heat sink and
clips at two other bridge terminals.
D. Repeat test between insulated heat sink and at
bridge terminals.
10. Capacitor (39) and rectifier bridge (53).
D
38
A
B
C
32
33
34
38
CONNECTION. SOLDERED
CONNECTION. SOLDERED
STRAP, REGULATORATIACHING
BOLT/SCREW, REGULATORATIACHING
REGULATOR, GENERATOR VOLTAGE
STRAP, REGULATOR CONNECTOR
01-17-95
FSOOHD3
Figure 9 - Removing Generator Voltage Regulator and

Generator Brush Holder
A
B
C
D
39
53
OHMMETER
SINK, GROUNDED HEAT
SINK, INSULATED HEAT
STRAP, GENERA TOR CAPACITOR
CAPACITOR, GENERATOR
BRIDGE, GENERATOR RECTIFIER
01-17-85
FSOOHD3
Figure 1O - Testing Generator Rectifier Bridge
CHARGING SYSTEM
11. Washers (55) and bolts/screws (56 and 58).
12. Bearing (28) from slip ring end frame (43) by
pushing through to inside.
13. Nut (49), using hex wrench to hold rotor shaft.
14. Washer (47), pulley (48), fan collar (46), fan (45)
and outside collar (50).
15. Rotor (31) from drive end frame (59).
16. Inside collar (52) from rotor (31).
I#!
Assemble
NOTICE:
Tighten
Nut (49) to 100 N.m (75 lb. ft.).

5. Bearing (28) into slip ring end frame (43) from
outside, until flush with outside shoulder of slip
ring end frame (43).
6. Slip ring end frame electrical components.
45
46
47
48
49
FAN, GENERATOR
COLLAR, GENERATOR ROTOR DRIVE END FAN
WASHER, GENERATOR ROTOR SHAFT DRIVE END
PULLEY. GENERATOR
NUT, GENERATOR ROTOR SHAFT DRIVE END,
A.
B.
C.
D.
Important
Installation of the slip ring end frame electrical

components must be .done in the following
order to insure proper operation of the unit.
Re-assembly in any other manner will result in
either no output from generator (5) or a direct
internal ground in the generator (5).
Rectifier bridge (53).
Capacitor (39).
Washers (55).
Bolts/screws (56 and 58).
[I]
Refer to "Notice!' on page 603-1.
1. Inside collar (52) onto rotor (31).

2. Rotor (31) to drive end frame (59).
3. Outside collar (50), fan (45), fan collar (46),
pulley (48) and washer (47) onto rotor shaft.
4. Nut (49).
!~!
[I]
603-9
Important
The capacitor (39) has an insulator material on

one side which must rest against the drive end
frame (59) (ground).
The capacitor/rectifier bridge insulated
attaching bolt/screw (58) must be installed in
the proper hole, attaching the capacitor strap
and rectifier bridge (53) to the slip ring end
frame (43).
E. Brushes (41) into brush holder (34) with retaining
pin (40).
F. Dust shield (60) onto brush holder (34).
G. Voltage regulator (33), and brush holder (34) with
dust shield (60), brushes (41) and retaining pin
(40) installed into slip ring end frame (43).
50 COLLAR, GENERATOR ROTOR DRIVE END BEARING OUTSIDE

52 COLLAR. GENERATOR ROTOR DRIVE END BEARING INSIDE
59 FRAME, GENERATOR ROTOR DRIVE END BEARING
\
01-17815
FS0108D3
Figure 11 Generator Rotor Drive End Bearing
603-10
CHARGING SYSTEM
43
(
28
-0-
A CLIPS, SOLDER
B STRAP, GENERATOR CAPACITOR
C METALSIDE
O INSULATEDSIDE
E PIN. PLASTIC RETAINING
F CLIP, DUST SHIELD RETAINING
28 BEARING, GENERATOR ROTOR SLIP RING END FRAME
32 BOLT/SCREW, REGULATOR ATTACHING
33 REGULATOR. GENERATOR VOLTAGE
34 HOLDER, GENERATOR BRUSH
35 NUT, STATOR LEAD ATTACHING
38 STRAP, REGULATOR CONNECTOR
39 CAPACITOR, GENERATOR
40 PIN, BRUSH RETAINING
41 BRUSH.GENERATOR
43 FRAME, GENERATOR SLIP RING END
53 BRIDGE, GENERATOR RECTIFIER
54 NUT, GENERATOR BATTERY TERMINAL
55 WASHER, GENERATOR RECTIFIER BRIDGE
56 BOLT/SCREW, GENERATOR RECTIFIER BRIDGE
57 BOLT/SCREW, GENERATOR BRUSH HOLDER
58 BOLT/SCREW, GENERATOR CAPACITOR/RECTIFIER
BRIDGE INSULATEDATTACHING
60 SHIELD, OUST
01-11-95
FS0118D3
(
Figure 12 - Generator Slip Ring End Frame Components
CHARGING SYSTEM 603-11
34
34
40
41
60
rn

PIN, BRUSH RETAINING
BRUSH.GENERATOR
SHIELD, DUST
Figure 13 - Generator Brushes Retained in Generator Brush Holder
Important
The metal side of the capacitor strap must be

against the regulator connection.
H. Tap plastic retaining pin on dust shield (60) into
retaining clip.
Be sure brush retaining pin (40) goes through
access hole to outside of slip ring end frame
( 43) for removal after generator is
reassembled.
I. Bolt/screw (32) and bolt/screw (57).
J. Connector strap (38) to voltage regulator solder
clip, and brush holder connection to other voltage
regulator solder clip.
Crimp ~d solder voltage regulator solder clip
connections.
01-18-15
FS0128D3
NOTICE: Avoid excessive heat when

soldering connections, as this can cause voltage
regulator damage.
K. Stator (36), placing stator terminals over rectifier
bridge terminals.
L. Nuts (35).
M. Slip ring end frame ( 43) and drive end frame
(59), noting scribe marks.
N. Slip ring end bearing outer race into bearing well
in slip ring end frame casting.
0. Through-bolts/screws (26).
P. Remove retaining pin (40) to release brushes (41)
against slip rings.
60312
CHARGING SYSTEM
SPECIFICATIONS
(
GENERATOR USAGE CHART

ENGINE
3800 VINK
5.7L VIN P
EQUIPMENT
ALL
ALL
MODEL
CS-1300
CS-144
RATED AMPERES
105
140
FASTENER TIGHTENING. SPECIFICATIONS

CS-130D Generator (3800 VIN K)
Battery Negative Cable~to-Battery Terminal ........................................................................ 5 N.m (11 lb. ft.)
Battery Positive Cable-to-Generator Nut. ........................................................................... 20 N.m (15 lb. ft.)
Generator Brace Bracket-to-Cylinder Head Bolt/Screw .................................................... 50 N.m (37 lb. ft.)
Generator-to-Drive Belt TeJis.ioner Bolt/Screw (Upper) ..................................................... 27 N.m (20 lb. ft.)
Generator-to-Drive Belt Tensioner Bolt/Screw (Lower) .................................................... 52 N.m (38 lb. ft.)
Rear Brace-to-Generator Bolt/Screw .................................................................................. 27 N.m (20 lb. ft.)
Rear Brace-to-Rear Brace Bracket Bolt/Screw .................................................................. 27 N.m (20 lb. ft.)
Rear Brace Bracket to Cylinder Head ............................................................................... 50 N.m (37 lb. ft.)
CS-144 Generator (5.7L VIN P)
Battery Negative Cable-to-Battery Terminal ...................................................................... 15 N.m (11 lb. ft.)
Battery Positive Cable-to-Generator Bolt/Screw ............................................................... 10 Nm (89 lb. in.)
Battery Positive Cable-to-Generator Nut.. .......................................................................... 20 N.m (15 lb. ft.)
Generator Inner Brace Mounting Nut ................................................................................ 33 N.m (24 lb. ft.)
Generator Outer Brace Mounting Nut. ............................................................................... 33 N.m (24 lb. ft.)
Generator Rotor Shaft Drive End Nut.. ........................................................................... 100 N.m (75 lb. ft.)
Generator-to-Accessory Mounting Bracket Bolt/Screw (Lower) ....................................... 50 N.m (37 lb. ft.)
Generator-to-Accessory Mounting Bracket Bolt/Screw (Upper) ....................................... 50 N.m (37 lb. ft.)
Generator-to-Generator Lower Brace Bolt/Screw .............................................................. 25 N.m (18 lb. ft.)
Generator-to-Generator Upper Brace Bolt/Screw ............................................................... 50 N.m (37 lb. ft.)
SPECIAL TOOLS
(
1 DIGITAL MULTIMETER
05-2395
FT01&eD3
IGNITION SYSTEM
604-1
SECTION 604
IGNITION SYSTEM
CAUTION: Before removing or installing any electrical unit or when a tool or equipment could
easily come in contact with "live" exposed electrical terminals, disconnect the negative battery
inhibitors) on threaded fasteners or fasteners joint interfaces. Generally, such coatings adversely affect the
correct tightening sequence and specifications. Following these instructions can help you avoid damage to the
parts and systems.
CONTENTS
Ignition System................................................. 604-1
Camshaft Position Sensor ............................ 604-2
Crankshaft Position Sensor .......................... 604-2
Spark Plug Wire Harness ............. '. .................. 604-2
Spark Plugs ....................................................... 604-2
Ignition Switch ................................................. 604-3
Knock Sensor System ...................................... 604-3
Ignition Timing ................................................. 604-3
Diagnosis .............................................................. 604-3
Ignition System ........................ Refer to Section 6E3
Spark Plugs ....................................................... 604-3
Spark Plug Wire Harness ................................ 604-4
Service Precautions .......................................... 604-4
Spark Plug Wire Harness Replacement .......... 604-4
Spark Plugs ..................................................... 604-7

Distributor Ventilation System........................ 604-7
Distributor ........................................................ 604-7
Distributor Cap, Cover, Rotor and Base........ 604-9
Electronic Ignition Control Module ............... 604-10
Electronic Ignition Control Module Bracket .604-10
Ignition Coil .................................................... 604-11
Camshaft Position Sensor ............................... 604-12
Crankshaft Position Sensor ............................. 604-13
Crankshaft Position Sensor Reluctor Ring .... 604-14
Unit Repair .......................................................... 604-15
Electronic Ignition Control Module
and Coils ..................................................... 604-15
Ignition Control Module and Coil ................. 604-15
Specifications ....................................................... 604-16
GENERAL DESCRIPTION
On the 3800 ignition system the spark timing is

controlled electronically. The ICM controls the spark
timing during engine start-up, and provides a back-up
timing system that will allow the engine to run in the
event of an open or ground in the ignition control
circuit. Once the engine starts and is running above
400 rpm, the PCM takes over the spark timing and
sends signals to the ICM for ignition coil switching.
The electronic ignition system used on this
engine uses a "waste spark" method of spark
distribution. Each cylinder is paired with its opposing
cylinder in the firing order, so that one cylinder on
compression fires simultaneously with the opposing
cylinder on exhaust. The spark that occurs in the
cylinder that is on the exhaust stroke is referred to as
the waste spark.
The sparks plugs in the two opposing cylinders
are connected to the two secondary terminals of the
same ignition coil. The spark voltage appears at the
center electrode of one of the spark plugs and jumps
the side electrode, then passes through the cylinder
The ignition system controls fuel combustion by

providing a spark to ignite the compressed air/fuel
mixture at the correct time. To provide improved
engine performance, fuel economy, and control of
exhaust emissions, the powertrain control module
(PCM) controls distributor spark advance (timing) with
an ignition control system.
IGNITION SYSTEM
3800 VINK
The electronic ignition system on the 3800 VIN

K engine uses a coil pack with one ignition coil for
each two cylinders in the engine. Mounted under the
ignition coils is the ignition control module (ICM) that
performs ignition coil switching functions and interacts
with the powertrain control module (PCM) to optimize
ignition system operation.
604-2
IGNITION SYSTEM
head to the other spark plug. At the second spark plug,

the spark jumps from the side electrode to the center
electrode and completes the series circuit back to the
ignition coiL The high level of energy available from
the ignition coil is more than sufficient to fire both
plugs simultaneously. Since the waste spark requires
very little of the available voltage to fire, most of the
coil output voltage is available to fire the cylinder that
is on compression stroke.
5.7LVIN P
The 5. 7L VIN P engine ignition system consists

of a crankshaft position sensor, crankshaft position
sensor reluctor ring, distributor, control circuits for
ignition timing in the powertrain control module
(PCM), a separate ignition coil/ignition control
module, vacuum harness, primary and secondary
wiring, and spark plugs. All ignition timing is
controlled by the PCM; there is no "bypass" mode
built into the ignition control module as in other
ignition systems.
The distributor is mounted directly to the engine
front cover behind the water pump. It directs the spark
from the ignition coil to the proper spark plug
secondary wire through a rotor. Spark plug secondary
wire connectors in the distributor cap are arranged for
convenience in routing spark plug wire harnesses. The
corresponding cylinder number is molded into the
distributor cap next to each spark plug secondary wire
connector.
The distributor also contains a signal disk and
two optical camshaft position (CMP) sensors that
provide signals to the PCM for timing control. One
CMP sensor senses 360 equally-spaced slots in the
signal disk to provide 720 signals per camshaft
revolution for high-resolution timing control. The other
CMP sensor senses 8 disk slots of variable length,
providing a low-resolution signal that tells the PCM
which spark plug is being fired. Power for the optical
CMP sensors, a system ground, and the two CMP
sensor signals are transferred between the PCM and
the distributor through a shielded harness connected to
the four-terminal connector on the distributor.
The ignition system supplies two timing inputs
to the PCM, a high resolution signal (360 pulses per
one camshaft revolution) and a low resolution signal
(8 pulses per one camshaft revolution). The PCM can
determine if one of the timing inputs is not being
received by comparing the two inputs. If the PCM
detects one timing pulse without detecting the other
timing pulse, diagnostic trouble code 16 or 36 will set.
The reference signals toggle between O and
5 volts as the camshaft turns. Therefore, an open, a
short to voltage, a short to ground, or a defective
sensor inside the distributor can prevent the voltage
from pulsing at the PCM.
The ignition coil/ignition control module
provides spark to the distributor, timed by signals from
the PCM. Power (B+) for the ignition coil primary
circuit and the ignition control module is supplied by
the ignition switch. The PCM combines the camshaft
position information supplied by the distributor with
other system parameters and calculates the required
spark advance and coil dwell. The PCM signals the
ignition control module, which turns on the primary
current to the ignition coil by grounding the primary

circuit,. and then turns it off by removing the ground.
When .the primary current flow stops, high voltage
induced in the ignition coil secondary winding
becomes .the spark voltage for the spark plug. The
spark voltage is delivered to the distributor through the
coil output (secondary) wire, and then directed to the
proper spark plug connector by the distributor rotor.
Camshaft Position Sensor

3800 VINK
The 3800 VIN K engine uses a camshaft

position (CMP) sensor, whose circuitry is integral with
the ignition system, and is mounted on the engine
front cover below the water pump cover. The signal
from. this sensor passes through the ICM to the PCM,
and is used for fuel synchronization.

3800 VINK
The 3800 VIN K engine uses a dual crankshaft

position (CKP) sensor to monitor engine speed and
stroke. sequence. It is mounted on the engine front
cover below the crankshaft balancer and covered with
a shield. The sensor has dual hall-effect switches .that
sense interrupter rings on the crankshaft balancer.
Gaps in the interrupter rings cause signals to be
generated by the sensor to indicate crankshaft speed
(RPM) and position (CKP). These signals are sent to
the ICM for use during start-up, then on the to the
PCM for use in timing as the engine runs. The PCM
also uses other inputs separate from the ignition
system itself, to determine optimum timing. Refer to
SECTION 6E.
5.7L VIN P
The 5.7L VIN P engine crankshaft .position

sensor is an electronic device used to sense four lugs
on the crankshaft position sensor reluctor ring. The
sensor provides a signal directly to the Powertrain
Control Module (PCM) for processing of the misfire
diagnostics. The crankshaft position sensor has an
0-ring seal to seal against external oil leakage and to
position the sensor in the center of the engine front
cover bore.
SPARK PLUG WIRE HARNESS

The spark plug wire harnesses used with both
ignition systems use carbon impregnated cord
conductors, encased in 8 mm (5/16-inch) diameter
silicone jackets. The silicone jackets withstand very
high temperatures and also provide excellent insulation
for the high voltage of the system. Silicone spark plug
boots form a tight seal to the spark plugs.
SPARK PLUGS
Figure 1
Resistor type, tapered seat spark plugs are used
on all engines. No gasket is used on these tapered-seat
spark plugs. Refer to SECTION OB for spark plug
IGNITION SYSTEM
type and gap size. When replacing spark plugs, use
only the type specified.
Normal operation is assumed to be a mixture of
idling, slow speed, and high speed driving. Occasional
or intermittent high-speed driving is needed for good
spark plug performance. It gives increased combustion
heat, burning away carbon or oxides that have built up
from frequent idling, or continual stop-and-go driving.
IGNITION SWITCH
The mechanical key and lock cylinder ignition
switch is located in the steering column on the
right-hand side, just below the steering wheel. The
electrical switching portion of the ignition switch is
separate from the key and lock cylinder. However,
both are synchronized and work in conjunction
through the action of the actuator rod.
For a complete explanation of the key and lock
cylinder, and the actuator rod, refer to SECTION 3F
or SECTION 3F5B. For electrical switching
information, refer to SECTION 8A.
KNOCK SENSOR SYSTEM
The knock sensor system retards the spark
advance when detonation occurs. Further information
is found in SECTION 6E3.
IGNITION TIMING
The base timing is preset when the engine is
manufactured, no adjustment is possible. Timing
advance and retard are accomplished through the PCM
with ignition control and knock sensor systems.
DIAGNOSIS
SPARK PLUGS
Worn or dirty spark plugs may give satisfactory
operation at idling speed, but frequently fail at higher
rpm. Faulty spark plugs may cause poor fuel economy,
power loss, loss of speed, hard starting and generally
poor engine performance. Follow the scheduled
maintenance services recommendations given in
SECTION OB, to assure satisfactory spark plug
performance.
A TYPICAL IDENTIFICATION NUMBER
Figure 1 - Spark Plug Identification
5-13-94
FS001804
6043
Normal spark plug operation will result in brown

to grayish-tan deposits and slight electrode wear
indicated correct spark plug heat range and mixed
periods of high and low speed driving. A small
amount of red-brown, yellow, and white powdery
material may also be present on the insulator tip
around the center electrode. These deposits are normal
combustion by-products of fuels and lubricating oils
with additives.
Engines which are not running properly are often
referred to as "misfiring." This means the ignition
spark is not igniting the air/fuel mixture at the proper
time. While other ignition and fuel system causes must
also be considered, possible causes include ignition
system conditions which allow the spark voltage to
reach ground in some other manner than by jumping
across the air gap at the tip of the spark plug, leaving
the air/fuel mixture unburned. Refer to SECTION 6E3.
Misfiring may also occur when the tip of the
spark plug becomes overheated and ignites the mixture
before the spark jumps. This is referred to as
"pre-ignition." Pre-ignition causes burned or blistered
insulator tips and badly eroded electroded. Spark plugs
which are the wrong (too hot) heat range, or not
properly installed are also a possible cause. Sustained
high speed, heavy load service can produce high
temperatures which will cause pre-ingition.
Spark plug misfiring may be indicated in a
number of ways: poor fuel economy, power loss, loss
of speed, hard starting, and/or generally poor engine
performance. Worn or dirty plugs may give
satisfactory operation at idling speed, but will misfire
under other operating conditions. Spark plugs may also
misfire due to fouling, excessive gap, or a cracked or
broken insulator. Should misfiring occur before the
recommended replacement interval, locate and correct
the cause.
Carbon fouling of the spark plug is indicated by
dry, fluffy black carbon (soot) deposits on the portion
of the spark plug in the cylinder. Excessive idling and
slow speeds under light engine loads can keep the
spark plug temperatures so low that these deposits are
not burned off. Over-rich fuel mixtures or poor
ignition system output may also be the cause. Refer to
SECTION 6E for diagnosis.
Oil fouling of the spark plug is indicated by wet
oily deposits with minor electrode wear. This may be
caused by oil getting past worn piston rings.
"Break-in" of a new or recently overhauled engine
before rings are fully seated may also result in this
condition.
Deposit fouling of the spark plug occurs when
the normal red-brown, yellow or white deposits of
combustion by-products become sufficient to cause
misfiring. In some cases, these deposits may melt and
form a shiny glaze on the insulator which, when hot,
acts as a good electrical conductor. This allows the
current to follow the deposits instead of jumping the
gap, thus shorting out the spark plug. If the fouling is
found in only one or two cylinders, valve stem
clearances or intake valve seals may be allowing
excess lubricating oil to enter the cylinder, particularly
if the deposits are heavier on the side of the spark
plug that was facing the intake valve.
604-4 IGNITION SYSTEM

Excessive gap means that the air space between
the center and side electrodes at the bottom .of the
spark plug is too wide for consistent firing. This may
be due to improper gap adjustment or to excessive
wear of the electrodes during use. A check of the gap
size and comparison to the gap specified for. the
vehicle in SECTION OB, will tell if the gap is too
wide. Too small of a spark plug gap may cause an
unstable idle condition. Excessive gap wear can be an
indication of continuous operation at high speeds or
with high engine loads, causing the spark plug to run
too hot. Another possible cause is an excessively lean
fuel mixture.
Low or high spark plug installation torque or
improper seating can result in the spark plug running
too hot and cause excessive gap wear. The plug and
cylinder head seats must be in good contact for proper
heat transfer and spark plug cooling. Dirty or damaged
threads in the head or on the spark plug can keep it
from seating even though the proper torque is applied.
Once spark plugs are properly seated, tighten to torque
shown under "Specifications" in this section. Low
torque may result in poor contact of seats due to a
loose spark plug. Over-tightening may cause spark
plug shell to be stretched and also result in poor
contact between seats. In extreme cases, exhaust
blow-by and damage beyond simple gap wear may
occur.
Cracked or broken insulators may be the result
of improper installation, damage during spark plug
regapping, or heat shock to the insulator material.
Upper insulators can be broken when a poorly fitting
tool is used during installation or removal, or when
the spark plug is hit from the outside. Cracks in the
upper insulator may be inside the shell and not visible.
Also, the breakage may not cause problems until oil or
moisture penetrates the crack later.
A broken or cracked lower insulator tip (around
the center electrode) may result from damage during
regapping or from "heat shock" (spark plug suddenly
operating too hot).
Damage during regapping can happen if the
gapping tool is pushed against the center electrode or
the insulator around it, causing the insulator to crack.
When regapping a spark plug, make the adjustment by
only bending the ground side terminal, keeping the
tool clear of other parts.
"Heat shock" breakage in the lower insulator tip
generally occurs during severe engine operating
conditions (high speeds or heavy loading) and may be
caused by over-advanced timing or low grade fuels.
Heat shock refers to a rapid increase .in the tip
temperature that causes the insulator material to crack.
Spark plugs with le.ss than the recommended
amount of service can sometimes be cleaned and
re-gapped, then returned to service. However, if there
is any doubt about the serviceability of a spark plug,
replace it. Spark plugs with cracked or broken
insulators should always be replaced.

Inspect spark plug wires visually first for any
cuts, burns, or damage. While engine is running,
inspect for any arcing to ground or other components.
Use a spray bottle to lightly coat the spark plug wiles

with water while observing idle quality, if idle quality
diminishes or engine stalls, spark plug wires should be
replaced.
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
Allow engine to cool before removing spark
plugs. Attempting to remove spark plugs from a
hot engine may cause spark plugs to seize,
causing damage to cylinder head threads.
Clean spark plug. recess area before removing
spark. plug. Failure to do so can result in engine
damage due. to dirt or foreign material entering
cylinder h~ad, . or in contamination of cylinder
head threads. Contaminated threads may preyent
proper seating of new spark plug.
Spark plug gap must be checked using a ''wire
type" gage (as opposed to a flat feeler type gage)
before installing into engine. Refer to
SECTION OB, for spark plug usage information.
Today's technology requires a specific spark plug
heat range for each engine type. Installing spark
plugs of any other heat range can severely
damage the engine.
The material used to construct spark plug wires is

very soft. This wire will withstand more heat and
carry a higher voltage, but chaffing and cutting
become easier. The spark plug wires must be
routed correctly to prevent chaffing or cutting. See
"Spark Plug Wire Harness Replacement" in the
following procedure, for routing. When removing
a spark plug wire from a spark .plug, twist the
boot on the spark plug one-half turn while pulling
on the boot.

REPLACEMENT
Figures 2 and 3
3800 VINK
NOTICE: The boots should be twisted

one-half turn while removing. Do not pull on
the wires to remove them from the spark plugs.
Pull on the boots, or use a tool designed for this
purpose.
!+ +!
1. Be sure ignition switch is in "OFF" or "LOCK"

position.
2. Spark plug wire harness from wire harness
retainers.
3. Spark plug wire. harness from ignition control
module.
Note position of wires before removing them
from vehicle.
IGNITION SYSTEM 6045
CYL 3
CYL 6
CYL 2
~~~--CYL 4
CYL 1
A CONNECTOR, IGNITION CONTROL MODULE ELECTRICAL
2 MODULE, IGNITION CONTROL
102894
FS01HD4
Figure 2 Spark Plug Wire Harness Routing (3800 VIN P)
CYL 8
CYL 6
CYL 4
CYL 2
(
1 DISTRIBUTOR, IGNITION
;++I
01-27-915
FS0028D4
Figure 3 - Spark Plug Wire Harness Routing (5.7L VIN P)
Install or Connect
NOTICE:
Refer to ''Notice" on page 6D4-1.
rn
important
To complete installation of heat shield and

boot to spark plug, lower tabs of heat shield
must extend over hex on spark plug.
2. Spark plug wire harness to ignition control
module.
3. Spark plug wire harness to wire harness retainers.
5.7l VIN P
NOTICE: The boots should be twisted
one-half turn while removing. Do not pull on
the wires to remove them from the spark plugs.
Pull on the boots, or use a tool designed for this
purpose.
When replacing spark plug wire harnesses

(secondary wiring), route the wires correctly and
through the proper retainers. Failure to route the wires
properly can lead to radio ignition noise and
cross-firing of the spark plugs, or shorting of the leads
to ground.
!+-+!

position.
SECTION OA.
4. Catalytic converter from exhaust manifolds.
5. Lower radiator hose from water pump.
6. Spark plug wire harness from wire harness clips.
7. Spark plug wire harness from distributor.
Note position of wires before removing them
from vehicle.
IGNITION SYSTEM
lH!
Install or Connect
604-7
DISTRIBUTOR VENTILATION SYSTEM

5.7L VIN P
NOTICE:
Figure 4
1.
2.
3.
4.
5.
Spark plug wire harness to spark plugs.

Spark plug wire harness to distributor.
Spark plug wire harness to wire harness clips.
Lower radiator hose to water pump.
Catalytic converter to exhaust manifolds.
!~I
Tighten
Catalytic converter to exhaust manifold nuts to

35 N.m (26 lb. ft.).
7. Lower vehicle.
SPARK PLUGS
Figures 2 and 3
CAUTION: If you smoke while handling
coated spark plugs, wear gloves to
prevent transfer of the coating to
cigarettes and subsequent burn_ing of ~he
coating. Wash hands after mstalhng
spark plugs.
l++I

position.
Note positions of wires before removing.
[I]
[I]
Install or Connect
Important
Failure to connect all hoses of the
ventilation system will eventually result in
distributor failure.
Important
Clean dirt and debris from spark plug recess

areas.
3. Spark plugs from cylinder heads.
lH!
The ventilation system vacuum harness (29),

connected to the air intake duct (30), the distributor
(1) and the air intake manifold (31), provides
ventilation to the distributor (1 ), thus preventing
moisture build-up and possible ignition system failure.
A check valve at the air intake duct connection insures
one-way flow through the distributor (1) to the air
intake manifold (31), refer to Figure 4 for correct
orientation.
The ventilation system vacuum harness (29)
connects to the air intake duct (30) and the air intake
manifold (31) with vacuum fittings. It attaches to the
distributor (1) at two places with separately sized
connectors.
In the case of ignition system failure, check
vacuum harness (29) for proper hook-up and/or kinks.
If OK, check the ventilation system for a possible
restriction before removing the distributor (1 ).
Disconnect the vacuum harness (29) at the air intake
duct (30) and check for vacuum using a vacuum gage.
The gage needle should slowly move towards
manifold vacuum. If no vacuum is present, replace the
vacuum harness (29). Once is has been determined
that the ventilation system vacuum harness is
functioning properly, disconnect the vacuum gage and
reconnect the vacuum hose to the air intake duct.
Running the engine with manifold vacuum present in
the distributor may lead to engine misfire.
DISTRIBUTOR
5.7L VIN P
Figure 5
NOTICE: Be sure spark plugs thread smoothly
into cylinder heads and are fully seated.
Cross-threading or failing to fully seat spark
plugs can cause overheating of spark plugs,
exhaust blow-by, or thread damage. Follow
recommended torque specifications carefully.
Over or under-tightening can also cause severe
damage to cylinder heads or spark plugs.
1. Spark plugs to cylinder heads.
l~I
Tighten
Spark plugs to 20 N.m (15 lb. ft.).

2. Spark plug wire harnesses, routed properly as note
during removal.
i++j
1. Check the distributor ventilation system for proper

operation. Refer to "Distributor Ventilation
position.
[I]
Important

vacuum lines, cap ends as necessary.
4. Crankshaft balancer. Refer to SECTION 6A3A.
31
jv1EWAI
A
B
1
29
30
31
ORIFICE AND FILTER {BLUE SIDE TO AIR INTAKE MANIFOLD)

VACUUM CHECK VALVE ("VAC" SIDE TO AIR INTAKE MANIFOLD)
DISTRIBUTOR, IGNITION
VACUUM HARNESS, DISTRIBUTOR VENTILATION SYSTEM
DUCT, AIR INTAKE
MANIFOLD, AIR INTAKE
(
012785
FS0046D4
rn
5.
6.
7.
8.
9.
I++!
Figure 4 Distributor Ventilation System (5.7L VIN P)
Important
Make sure all coolant has been wiped off

distributor and surrounding area before
disconnecting any electrical connectors or
spark plug wire harnesses.
Spark plug wire harnesses from distributor (1).
Refer to "Spark Plug Wire Harness Replacement"
in this section.
Four-terminal PCM connector from distributor (1).
Vacuum harness (29) from distributor (1 ). Refer to
"Distributor Ventilation System" in this section.
Distributor bolts/screws (3).
Distributor (1).
Pull distributor forward until driveshaft (4)
disengages from end of camshaft.
Install or Connect

1. Distributor (1) into position with driveshaft (4) in
end of camshaft.
A. Rotat~ distributor coupling until camshaft

sprocket pin slot aligns with camshaft sprocket
pin.
B. Slide distributor (1) onto end of camshaft u1ttil
fully seated on engine front cover.
[I]
Important
Do not attempt to fully seat distributor (1)

using bolts/screws (3); If distributor (1) will
not seat by hand, it is not properly aligned
with camshaft. Rotate crankshaft until engine
is at number 1 cylinder TDC (camshaft
sprocket pin at the 9 o'clock position). Rotate
the distributor coupling (4) until the camshaft
sprocket pin slot aligns with the distributor
base timing mark. Install distributor (1) using
hand pressure to fully seat.
2. Distributor bolts/screws (3).
!~I
Tighten
Bolts/screws (3) to 12 N,m (106 lb. in.).
IGNITION SYSTEM
604-9
A CAMSHAFT SPROCKET PIN SLOT

B DISTRIBUTOR BASE TIMING MARK, CYLINDER
NUMBER 1 TDC
C CAMSHAFT SPROCKET PIN
1 DISTRIBUTOR
3 SOLT/SCREW, DISTRIBUTOR
4 COUPLING, DISTRIBUTOR
01-27-915
FSOOHD4
Figure 5 - Distributor (5.7L VIN P)
3. Four-terminal PCM connector to distributor (1).

4. Vacuum harness (29) to distributor (1). Refer to
"Distributor Ventilation System" in this section.
5. Spark plug wire harnesses to distributor (1).
6. Crankshaft balancer. Refer to SECTION 6A3A.
DISTRIBUTOR CAP, COVER, ROTOR AND

BASE
5.7L VIN P
Figure 6
Tools Required:
J 39997 Ignition Distributor Cap Socket
J 39998 Ignition Distributor Rotor
NOTICE:
The distributor and timing disk

must be kept clean and free of oil, dirt and
engine coolant. Any contamination may lead to
engine misfire and distributor damage. Do not
disassemble the distributor until all coolant. has
been cleaned from the distributor and
surrounding area.
!++!
1. Remove the water pump and crankshaft balancer.

Refer to SECTION 6A3A.
2. Spark plug wire harnesses from distributor.
3. Four-terminal PCM connector from distributor.

4. Vacuum harness from distributor.
[II
5.
6.
7.
8.
9.
Important

vacuum lines, cap ends as necessary.
Distributor cap bolts/screws (29) using J 39997 or
equivalent.
Distributor cap (30).
Rotor bolts/screws (31) using J 39998 or
equivalent.
Rotor (32).
Distributor cover (33) and shield (34).
[II
Important
Do not touch timing disk sensor or distributor

base.
!L"'!
Inspect
Distributor base and timing disk for damage,

corrosion or plastic particles. If any are present,
replace entire distributor.
iHI
Install or Connect
1. Shield (34) and distributor cover (33).

2. Rotor (32).
3. Rotor bolts/screws (31) using J 39998 or
equivalent.
604-10
IGNITION SYSTEM
3
29
30
31
32
33
34
35
i~I
BOLT/SCREW, DISTRIBUTOR
BOLT/SCREW, DISTRIBUTOR CAP
CAP, DISTRIBUTOR
BOLT/SCREW, DISTRIBUTOR ROTOR
ROTOR, DISTRIBUTOR
COVER, DISTRIBUTOR
SHIELD. DISTRIBUTOR
BASE, DISTRIBUTOR
Figure 6 - Distributor Cap, Cover, Rotor and Base (5.7L VIN P)
Tighten
Rotor bolts/screws (31) to 0.7 N.m (6 lb. in.).

4. Distributor cap (30).
5. Distributor cap bolts/screws (29) using J 39997 or
equivalent.
!~I
6.
7.
8.
9.
Tighten
Distributor cap bolts/screws (29) to 2.8 N,m

(25 lb. in.).
Vacuum harness to distributor.
Connect four-terminal PCM connector to
distributor.
Spark plug wire harnesses to distributor.
Crankshaft balancer and water pump. Refer to
SECTION 6A3A.
ELECTRONIC IGNITION CONTROL

MODULE
3800 VINK
Figure 7
I++!
01-27-95
FSOOHD4

position.
2. Spark plug wire harness from ignition control
module (2).
4. Nuts (16).
5. Ignition coil (2).
!H!
Install or Connect

2. Nuts (16).
!~!
Tighten
Nuts (16) to 10 N,m (89 lb. in.).


MODULE BRACKET
3800 VIN K
Figure B
!++!
1. Ignition control module. Refer to "Electronic

Ignition Control Module" in this section.
2. Bolts/ screws ( 47) attaching bracket ( 46) to
cylinder head.
3. Bracket (46) from cylinder head.
IGNITION SYSTEM
604-11
46 BRACKET, IGNITION CONTROL MODULE

47 BOLT /SCREW, IGNITION CONTROL
MODULE BRACKET
2 MODULE, IGNITION CONTROL

16 NUT, IGNITION CONTROL MODULE
46 BRACKET, IGNITION CONTROL MODULE
1021MM
F8014604
Figure 8 Electronic Ignition Control Module Bracket

(3800 VINK)
IGNITION COIL
5.7L VIN P
112394
FS0136D4
Figure 7 - Electronic Ignition Control Module (3800 VIN K)
I;++-!
Install or Connect
NOTICE:
1. Bracket (46) to cylinder head.

2. Bolts/screw (47) attaching bracket (46) to cylinder
head.
l~J Tighten
3. Ignition control modt1le. Refer to "Electronic
Ignition Control Module" in this section.
Figure 9
!+-+!

position.
2. Four-terminal PCM connector at ignition coil
module.
3. Ignition coil wiring connectors.
4. Ignition coil harness.
5. Bolt/screw (6).
6. Stud (5).
Do not wipe silicone grease from bottom of
ignition coil (8) if it is to be reinstalled.
!++-!
Install or Connect
NOTICE:
NOTICE: If a new ignition coil is to be

installed, a package of silicone grease will .be
included in the box. This grease is necessary for
ignition coil cooling.
604-12
IGNITION SYSTEM

27 SENSOR, CAMSHAFT POSITION
28 BOLT/SCREW, CAMSHAFT POSITION SENSOR
5 STUD, IGNITION COIL

7 RETAINER, FUEL CANISTER PURGE TUBE
8 IGNITION COIL
01-27-95
FS0078D4
Figure 9 - Ignition. Coil (5.7L VIN P)
1. Spread silicone grease on metal mounting face of

ignition coil bracket ( 14) if necessary, and
position ignition coil (8) to cylinder head.
2. Stud (5).
l~I
Tighten

4. Ignition coil harness.
5. Ignition coil wiring connectors.
6. Four-terminal PCM connector to ignition coil
module.
CAMSHAFT POSITION SENSOR

3800 VINK
Figure 10
!++!
Figure 10 - Camshaft Position Sensor (3800 VIN K)
3. Bolt/screw (28) mounting camshaft position

sensor (27) to engine front cover (6).
NOTICE: Be careful not to damage sensor
when prying at its base during removal.
Tighten
Stud (5) to 25 N.m (18 lb. ft.).

3. Bolt/screw (6).
!~!
10-28-94
FS0176D4

position.
2. Electrical connector from camshaft position
sensor (27).
4. Sensor (27) using a small-bladed screwdriver to

gently pry between sensor and engine front cover.
Pry from alternate sides to loosen sensor in its
mounting boss.
(I]
Important
Sensor 0-ring seal for wear, cracks or leakage.

Replace if necessary.
l++I
Install or Connect
NOTICE:
1. Lubricate sensor 0-ring seal with engine oil.

2. Camshaft position sensor (27) to engine front
cover (6).
3. Bolt/screw (26) mounting camshaft position
sensor (27) to engine front cover (6).
l~I
Tighten
Bolt/screw (28) sensor (27) to engine front

cover (6) to 10 N.m (89 lb. in.).
IGNITION SYSTEM
!++!
604-13
Install or Connect

NOTICE:
Refer to "Notice" on page 6D4-1.
3800 VINK
I++!

position.
3. Crankshaft balancer hub bolt, balancer and key
from crankshaft.
4. Fuel pump/engine oil pressure sensor wire harness
retainer clip from shield.
5. Electrical connector from crankshaft position
sensor (43).
6. Crankshaft position sensor shield (45) from engine
front cover (6).
7. Studs (44) mounting crankshaft position sensor
(43) to engine front cover (6).
8. Crankshaft position sensor (43) from engine front
cover (6).
[I]
Important
Sensor 0-ring seal for wear, cracks or leakage.

Replace if necessary.
A
6
43
44
CYLINDER BLOCK
COVER, ENGINE FRONT
STUD, CRANKSHAFT. POSITION SENSOR
1. Lubricate sensor 0-ring seal with engine oil.

2. Crankshaft position sensor (43) to engine front
cover (6).
3. Stu?s (44) and crankshaft position sensor (43) to
engme front cover (6).
!~I
Tighten
Studs (44) to 30 N.m (22 lb. ft.).

4. Crankshaft position sensor shield (45) to engine
front cover (6).
5. Electrical connector to crankshaft position sensor
(43).
6. Fuel pump/engine oil pressure sensor wire harness
retainer clip to shield.
7. Crankshaft balancer key, balancer, and crankshaft
balancer hub bolt/screw to crankshaft.
!~!
Tighten
Crankshaft balancer hub bolt/screw to 150 N.m

(111 lb. ft.) 4 degrees.
44
45
STUD, CRANKSHAFT POSITION SENSOR

SHIELD. CRANKSHAFT POSITION SENSOR
10-28-94
10-28-94
FS018804
F8015804
Figure 11 - Crankshaft Position Sensor (3800 VIN K)
Figure 12 - Crankshaft Position Sensor Shield

(3800 VINK)
604-14
IGNITION SYSTEM
!H!
5.7L VIN P
!+-+I
Install or Connect
NOTICE: Refer to "Notice" on page 6D4-l.

position.
SECTION OA.
3. Electrical connector from crankshaft position
sensor (48).
4. Bolt/screw ( 49) from crankshaft position
sensor (48).
5. Crankshaft position sensor (48) from engine front
cover (6).
II]
1. Lubricate new sensor 0-ring seal with engine oil.

2. Crankshaft position sensor (48) to engine front
cover (6).
3. Bolt/screw (49) to crankshaft position sensor (48).
[I]
Important
When installing the crankshaft position sensor

be sure the sensor is fully seated and held
stationary in the engine front cover bore.
Torque the hold down bolt/screw to the
specification shown below. A sensor that is not
fully seated will cock in the engine front cover
and may result in erratic engine operation.
Important
Do not re-use the 0-ring seal on the crankshaft

position sensor. Install a new 0-ring seal onto
the sensor.
I~!
Tighten

4. Electrical connector to crankshaft position
sensor (6).
5. Lower vehicle.

RELUCTOR RING
5.7L VIN P
I+-+!
1. Engine front cover. Refer to SECTION 6A3A.

2. Reluctor ring from crankshaft.
l-++l
Install or Connect
1. Key, if removed.
[I]
Align the keyway on the reluctor ring with the

key in the crankshaft and install the reluctor
ring onto the crankshaft until the ring is
completely seated against the crankshaft
sprocket.
2. Reluctor ring to crankshaft.
3. Engine front cover. Refer to SECTION 6A3A.
49

48
49
Important

BOLT/SCREW, CRANKSHAFT POSITION SENSOR
041095
FT0188D4
Figure 13 Crankshaft Position Sensor (5.7L VIN P)
IGNITION SYSTEM
UNIT REPAIR
604-15
IGNITION CONTROL MODULE AND COIL

5.7L VIN P

MODULE AND COILS
!+t+!
3800 VINK
1. Bolts/screws attaching ignition coils to ignition

control module.
2. Ignition coils and seal from ignition control
module.
3. Ignition control module from ignition control
module bracket.
!++!
Install or Connect
NOTICE:
1. Ignition control module to bracket.

2. Seals and ignition coils to ignition control
module.
3. Bolts/screws attaching ignition coils to ignition
control module.
!~!
Disassemble
1. Coil (10) from brackets (13 and 14) by drilling
Figure 14
!++!
Figure 15
out rivets (9).

3. Ignition coil module (11).
!+;+!
Assemble
NOTICE:
NOTICE: A package of silicone grease is

included with a new ignition control module.
This grease is necessary for ignition control
module cooling.
1. Spread silicone grease on metal face of ignition

control module (11) and on bracket (13) where it
seats, and position ignition control module (11) to
bracket (13).
I~!
Bolts/screws attaching coils to control module

to 45 N.m (40 lb. ft.).
Tighten

3. Coil (10) to brackets (13 and 14) using
bolts/screws provided with replacement coil (10).
I~!
Tighten
Tighten
Bolts/screws to 2.8 N,m (25 lb. in.).
18
21
18
19
20
21
22
COIL, IGNITION
SEAL, IGNITION COIL
MODULE, ELECTRONIC IGNITION CONTROL
BRACKET, ELECTRONIC IGNITION CONTROL MODULE
BOLT/SCREW, IGNITION COIL
22
18
Figure 14. Electronic Ignition Control Module and Coils (3800 VIN K)
0417H
FT0116D4
604-16
IGNITION SYSTEM
9 RIVET, BRACKET ATIACHMENT

10 COIL, IGNITION
11 MODULE. IGNITION CONTROL
12 BOLT /SCREW, IGNITION CONTROL MODULE
13 BRACKET, IGNITION CONTROL
14 BRACKET, IGNITION COIL
01-27-H
FS0108D4
Figure 15 - Ignition Control Module and Coil (5. 7L VIN P)
SPECIFICATIONS

Camshaft Position Sensor Bolt/Screw (3800 VIN K) ......................................................... 1.9 N.m (17 lb. in.)
Crankshaft Position Sensor Bolt/screw (5.7L VIN P) ........................................................ .12 N.m (106 lb. in.)
Crankshaft Position Sensor Studs (3800 VIN K) .................................................................. 30 N.m (22 lb. ft.)
Distributor Bolt/Screw (5.7L VIN P) ....................................................... ,., .......................... 12 N.m (106 lb. in.)
Distributor Cap Bolt/Screw ................................................................................................... 2.8 N.m (25 lb. in.)
Distributor Rotor Bolt/Screw ................................................................................................... 0.7 N.m (6 lb. in.)
Ignition Coil Bolt/Screw (3800 VIN K) .............................................................................. .4.5 N.m (40 lb. in.)
Ignition Coil Bolt/Screw (5.7L VIN P) ............. ,................................ ,................................... 25 N.m (18 lb. ft.)
Ignition Coil Nut (3800 VIN K) .......................................................... o'................................ 10 N.m (89 lb. in.)
Ignition Coil Stud (5.7L VIN P) ..................... ,'. ..................................................................... 40 N.m (30 lb. ft.)
Ignition Coil Bolt/Screw (5.7L VIN P) ................................................................................ 2.8 N.m (25 lb. in.)
Ignition Coil Module Bolt/Screw (5.7L VIN P) .................................................................. 1.7 N.m (15 lb. in.)
Spark Plugs .............................................................................................................................. 20 N,m (15 lb. ft.)
ENGINE WIRING
6051
SECTION 605
ENGINE WIRING
NOTICE: This vehicle uses a sequential multi-port fuel injected engine. Fuel injector connectors must be
positioned onto their appropriate fuel injectors or engine performance and exhaust emissions may be seriously
affected. Fuel injector connectors are numbered to match their correct fuel injector for that cylinder. If fuel
injector connector numbers can not be identified, refer to SECTION 8A-20 for correct fuel injector connector
wire color-to-fuel injector for each cylinder.
CONTENTS
Right-Hand Side Engine Wiring Harness
(3800 VIN K) .................................................. 605-2
Left-Hand Side Engine Wiring Harness
(3800 VIN K) .................................................. 605-4
Front Engine Wiring Harness (3800 VIN K) ..... 605-5
(5.7L VIN P) .................................................... 605-6

(5.7L VIN P) ....................................................... 605-7
Transmission Engine Wiring Harness
(3800 VIN K) ................................................... 605-8
(5.7L VIN P) ..................................................... 605-9
The following figures illustrate engine wiring harness routing and the. various electrical/electronic components that
have terminal connectors attached to them. In the illustration legends, the connectors are identified with the
component name that completes their connection. Refer to SECTION 8A for detailed diagnostics.
605-2
ENGINE .WIRING
A
B
C
D
E
F
G
1
CONNECTOR, FUEL INJECTOR

CONNECTOR, CHARCOAL CANNISTER
CONNECTOR, CANISTER PURGE SOLENOID
CONNECTOR, MANIFOLD ABSOLUTE PRESSURE
CONNECTOR, OXYGEN SENSOR
TUBE, VACUUM
CONNECTOR, RIGHT SIDE KNOCK SENSOR
CLIPS, ENGINE WIRING HARNESS
2 BOLTS/SCREW, TRANSMISSION
3 PORT, VACUUM
4 BRACKET, RIGHT SIDE ENGINE MOUNT
8-29-94
F8007to&
(
Figure 1 - Right-Hand Side Engine Wiring Harness (3800 VIN K) (Part 1 of 2)
ENGINE WIRING
6053
A
B
C
D
E
F
1
5
6
CONNECTOR, GENERATOR
CONNECTOR, IDLE AIR CONTROL
CONNECTOR, MASS AIR FLOW
CONNECTOR, ENGINE TEMPERATURE SENSOR
CONNECTOR, THROTILE POSITION SENSOR
CONNECTOR, A/C COMPRESSOR
CLIP, ENGINE WIRING HARNESS
BOLT/SCREW, ENGINE WIRING HARNESS CLIP
BRACKET, ENGINE
11-1804
FS0088D5
Figure 2 Right-Hand Side Engine Wiring Harness (3800 VIN K) (Part 2 of 2)
605-4
ENGINE WIRING
10
11
(
8
A
B
C
D
E
F
1
7
8
9
10
11
12
CONNECTOR, FUEL INJECTOR

CONNECTOR, EGR SOLENOID
CONNECTOR, ELECTRONIC ENGINE CONTROL MODULE
CONNECTOR, LOW OIL .SENSOR
CONNECTOR, LEFT SIDE KNOCK SENSOR
MODULE, ELECTRONIC ENGINE CONTROL
BOLT /SCREW, ENGINE WIRING HARNESS GROUND
NUT, ENGINE WIRING HARNESS STARTER LEAD
TERMINAL, WIRING HARNESS STARTER
WASHER, ENGINE WIRING HARNESS STARTER LEAD
MOTOR, STARTER
Figure 3 - Left-Hand Side Engine Wiring Harness (3800 VIN K)
8-18-94
FIOOl8DS
ENGINE WIRING
605-5
!VIEWAI
A
8
C
D
1
8
13
CONNECTOR, CAMSHAFT SENSOR

CONNECTOR, OIL PRESSURE SWITCH
CONNECTOR, CRANKSHAFT SENSOR
CONNECTOR, A/C COMPRESSOR
BOLT/SCREW, ENGINE WIRING HARNESS GROUND
TERMINAL, ENGINE GROUND
10'."'12-14
FS010805
Figure 4 - Front Engine Wiring Harness (3800 VIN K)
605,;6
ENGINE WIRING
(
E
11
14
12
A CONNECTOR, IGNITION DISTRIBUTOR ELECTRICAL

B CONNECTOR, CANISTER PURGE SOLENOID VALVE
ELECTRICAL
C CONNECTOR, INJECTOR ELECTRICAL
D CONNECTOR, MANIFOLD ABSOLUTE PRESSURE
SENSOR ELECTRICAL
E CONNECTOR, GENERATOR ELECTRICAL
F CONNECTOR, A/C COMPRESSOR CLUTCH ELECTRICAL
G TUBE, VACUUM
H CONNECTOR, KNOCK SENSOR ELECTRICAL
J TERMINAL, ENGINE GROUND
K CONNECTOR, IDLE AIR CONTROL STEPPER MOTOR
ELECTRICAL
L CONNECTOR, THROTTLE POSITION SENSOR

ELECTRICAL
M CONNECTOR, OXYGEN SENSOR ELECTRICAL
9 BOLT/SCREW, ENGINE WIRING HARNESS CLAMP
10 HARNESS, ENGINE WIRING
11 NUT, ENGINE WIRING HARNESS GROUND
12 NUT, ENGINE WIRING HARNESS START LEAD
13 WASHER, ENGINE WIRING HARNESS START LEAD
14 LEAD, ENGINE WIRING HARNESS START
15 SENSOR, MANIFOLD ABSOLUTE PRESSURE
Figure 5 - Right,Hand Side Engine Wiring Harness (5.7L VIN P)
ENGINE WIRING
6057
A CONNECTOR, IGNITION COIL DRIVER ELECTRICAL

B CONNECTOR, INJECTOR ELECTRICAL
C CONNECTOR, EXHAUST GAS RECIRCULATION
SOLENOID VALVE ELECTRICAL
D CONNECTOR, OXYGEN SENSOR ELECTRICAL
E CONNECTOR, OIL PRESSURE SENSOR ELECTRICAL
F CONNECTOR, OIL LEVEL SENSOR ELECTRICAL
G CONNECTOR, ENGINE COOLANT TEMPERATURE GAGE
SENSOR ELECTRICAL
H STRAP, RIGHT FRONT GROUND
J CONNECTOR, IGNITION COIL ELECTRICAL
K CONNECTOR, ENGINE COOLANT TEMPERATURE
SENSOR ELECTRICAL
L TERMINAL, GROUND
16 NUT, ENGINE WIRING HARNESS CLAMP
17 NUT, ENGINE WIRING HARNESS GROUND
!VIEWA!
Figure 6 - Left-Hand Side Engine Wiring Harness (5.7L VIN P)
17
01-27-915
FS006605
605-8
ENGINE WIRING
f:Flrj
jVIEWA!
20
A
B
C
D
E
F
G
H
J
TRANSMISSION, AUTOMATIC (M30)

TRANSMISSION, MANUAL (5-:SPEED .M49)
CONNECTOR, VEHICLE SPEED SENSOR
CONNECTOR, ELECTRONIC CONNECTOR
CONNECTOR, SKIP SHIFT SOLENOID
CONNECTOR, VEHICLE SPEED SENSOR
SHIELD, OXYGEN SENSOR WIRING HEAT
18 CLIP, ENGINE WIRING HARNESS
19 SOLT/SCREW, ENGINE WIRING HARNESS CLIP
20 SENSOR, OXYGEN
05-215-95
FT0118D5
Figure 7 - Transmission Engine Wiring Harness (3800 VIN K)
ENGINE WIRING 605-9
19
A
B
C
D
E
F
G
H
J
TRANSMISSION, AUTOMATIC (M30)

TRANSMISSION, MANUAL (5-SPEED M49l
TRANSMISSION, MANUAL (6-SPEED MM6l
CONNECTOR, ELECTRONIC SWITCH
CONNECTOR, VEHICLE SPEED SENSOR ELECTRICAL
CONNECTOR, BACKUP SWITCH ELECTRICAL
CONNECTOR, BACKUP SWITCH ELECTRICAL
CONNECTOR, REVERSE LOCKOUT SOLENOID ELECTRICAL
CONNECTOR, SKIP SHIFT SOLENOID
K
L
M CONNECTOR, EXHAUST TEMPERATURE ALARM (EXPORT)
N CONNECTOR, OXYGEN SENSOR
18 CLIP, ENGINE WIRING HARNESS
19 BOLT/SCREW, ENGINE WIRING HARNESS CLIP
051895
FT0088D5
Figure 8 - Transmission Engine Wiring Harness (5.7L VIN P)
605-10
ENGINE WIRING
BLANK
EXHAUST SYSTEM
6F-1
SECTION 6F
EXHAUST SYSTEM
NOTICE: All new GM vehicles are certified by the United States Environmental Protection Agency as
conforming to the requirements of the regulations for the control of air pollution from new motor vehicles. This
certification is contingent on certain adjustments being set to factory standards, thus, these adjustment points
either have been permanently sealed and/or made inaccessible to prevent indiscriminate adjustment in the field.
For this reason, the factory procedure for temporarily removing plugs, caps, etc., for the purpose of servicing the
product must be strictly followed and, where practical, returned to the original intent of the design.
NOTICE: Exhaust system components must have enough clearance from the underbody to prevent overheating
of the floor panel and possible damage to the passenger compartment, insulation and trim materials.
NOTICE: Always use the correct fasteners in the correct location. When you replace a fastener, use ONLY the
exact part number for that application. General Motors will call. out those fasteners that require a replacement
systems.
CONTENTS
)

Catalytic Converter .............................................. 6F-1
Exhaust Muffler................................................... 6F-2
Hangers ................................................................ 6F-2
Clamps and Welded Connections ....................... 6F-2
Diagnosis ....................;............................................ 6F-2
Testing for Restricted
Exhaust ................................. Refer to Section 6E2
On-Vehicle Service .................................................. 6F-3
Component Replacement. .................................... 6F-3
3-Way Catalytic Converter ................................. 6F-3,
Oxidation Catalytic Converter ............................ 6F-4
Exhaust Pipe ........................................................ 6F-5
Exhaust Muffler ................................................ 6F-6

Exhaust Tailpipe Extensions ............................. 6F-7
Catalytic Converter Hanger .............................. 6F-8
Exhaust Muffler Hangers .................................. 6F-9
Exhaust Muffler Interior Hanger Bracket ........ 6F-10
Catalytic Converter Heat Shield..... :................. 6F-l 1
Exhaust Heat Shield.......................................... 6F-12
Exhaust Pipe Heat Shield and Exhaust
Muffler Heat Shield.................................... 6F-12
Exhaust Pipe Dampener.................................... 6F-13
Exhaust System Clearance Dimensions ........... 6F-13
Specifications ......................................................... 6F-20
Fastener Tightening Specifications ................... 6F-20
GENERAL DESCRIPTION
compartment or passenger compartment. Dust or water

in the rear compartment may indicate a problem in
one of these areas. Any faulty areas should be
corrected immediately.
NOTICE: When inspecting or replacing

exhaust system components, make sure there is
adequate clearance from all points on the
underbody to prevent overheating of the floor
panel and possible damage to the passenger
compartment, insulation and trim materials.
Periodic maintenance of the exhaust system is
1ot required. If the vehicle is raised for other service,
it is advisable to check the condition of the complete
exhaust system.
Check the complete exhaust system, nearby body
areas and rear compartment lid for broken, damaged,
missing or mis-positioned parts, open seams, holes,
loose connections or other deterioration that could
permit exhaust fumes to seep into the rear
CATALYTIC CONVERTER
CAUTION: Prolonged operation with a
misfiring or flooded engine may cause
the catalytic converter to overheat. This
could cause damage either to the catalyst
itself or the operating vehicle and
possible personal injury.
NOTICE: When jacking or lifting the vehicle
from the frame side rails, be certain lift pads do
not contact catalytic converter or damage to the
catalytic converter may result.
6F2
EXHAUST SYSTEM
The catalytic converter is an enuss1on control

devise added to the exhaust system to reduce
pollutants from the exhaust gas stream.
NOTICE:
The catalytic converter requires the

use of unleaded fuel only, or damage to the
catalyst may result.
A single bed ceramic monolith style "brick"
catalytic converter is used in combination with two
different types of catalyst. These are oxidation catalyst,
and three-way (reduction/oxidation) catalyst.
The catalysts have coatings that contain platinum
and palladium. The oxidation catalyst lowers the level
of hydrocarbons (HC) and carbon monoxide (CO). The
three-way catalyst lowers the levels of oxides of
nitrogen (NOx) as well as HC and CO.
EXHAUST MUFFLER
The muffler is a tri-flow design; The muffler has
a slot in the inlet pipe. The slot indexes to a key (tab)
welded on the exhaust pipe to help maintain
alignment.
HANGERS
II]
Important
The installation of exhaust system hangers is

very important, as improperly installed hangers
can cause annoying vibrations that can be
difficult to diagnose.
Two types of hangers are used to support the
exhaust system. One type is a conventional rubber
strap. The second type is a "rubber block". The
rubber block type provides a rigid hanger along with a
feature that continues to support the exhaust system if
a rubber insulator block is broken,
CLAMPS AND WELDED CONNECTIONS

CAUTION: Coat slip joints with .exhaust
system sealer before re-assembly to
prevent exhaust fumes from entering the
vehicle and causing personal injury.
1\vo methods are used for connecting exhaust
system slip joints: clamps and welds. When servicing
a welded connection it should be cut and the new
connection clamped when installing replacement parts.
Three types of clamps are used for connecting exhaust
system slip joints: guillotine, saddle/U-bolt and single
nut compression.
DIAGNOSIS
CONDITION
POSSIBLE CAUSE
CORRECTION
Leaking Exhaust Gases
Leaks at pipe joints
Tighten nuts/bolts at leaking joints to

specifications.
Exhaust Noises
1. Exhaust pipes contacting heat

shields, or loose shields. Inspect cold
and after wann-up.
1. Tighten heat shield bolts/screws to

specifications. Align exhaust system if
necessary. Refer to "Exhaust System ,
clearance Dimensions" in this section.
2. Tighten clamps at leaking
connections to specifications.
3. Replace muffler.
4. Replace exhaust pipe.
5. Tighten exhaust crossover pipe nuts
to specifications.
6. Replace manifold.
7. Tighten manifold-to-cylinder head
stud nuts or bolts/screws to
specifications. Refer to
2. Leaks at manifold or pipe

connections.
3. Burned or blown out muffler.
4. Burned or rusted out exhaust pipe.
5. Leaking exhaust crossover pipe at
manifold flange.
6.. Cracked or broken manifold.
7. Leak between manifold and
cylinder head.
EXHAUST SYSTEM
CONDITION
Exhaust Vibrations
Loss of Engine Power and/or Internal

Rattles in Muffler
6F3
POSSIBLE CAUSE
1. Transmission shims are between
catalytic converter and transmission
support
2. Inadequate clearance, less than
3 mm (1/8 inch), between
transmission support and floor panel.
3. Inadequate clearance, less than
3 mm (1/8 inch), between catalytic
converter hanger and transmission
support.
CORRECTION
1. Reposition shims so they are
between transmission and catalytic
converter bracket.
2. Replace transmission support. Refer
to SECTION 11.
Dislodged turning tubes and/or

baffles in muffler, catalytic
converter or exhaust pipe.
Replace muffler, catalytic converter or

exhaust pipe.
ON-VEHICLE SERVICE
COMPONENT REPLACEMENT
Exhaust system service includes replacement of
the following items:
Exhaust pipe
Exhaust muffler (with tailpipe(s))
Complete exhaust system
Catalytic converter and exhaust muffler hangers
Catalytic converter heat shield
Exhaust heat shield
Exhaust pipe heat shield
3. Loosen catalytic converter hanger

bolts/screws and reposition catalytic
converter hanger.
Exhaust muffler heat shield.
3-WAY CATALYTIC CONVERTER

3800 VINK
Figures 1, 3 and 9
!++I

SECTION OA.
2. Heated oxygen sensors electrical connectors.
3. Heated oxygen sensors from catalytic converter
(7).
3 SEAL, EXHAUST MANIFOLD PIPE

6 BOLT/SCREW, CATALYTIC CONVERTER
7 CONVERTER, THREE WAY CATALYTIC
03-01-H
FS0146F
Figure 1 - 3-Way Catalytic Converter (3800 VIN K)
6F-4
EXltAUST SYSTEM
4. Catalytic converter bolts/screws (6) at exhaust

manifolds.
5. Exhaust pipe clamp (9) bolt/screw at catalytic
converter.
6. Catalytic converter (7) from exhaust pipe (12).
7. Catalytic converter hanger bolts/screw (31).
8. Catalytic converter hanger (30) from catalytic
converter (7).
!++!
Install or Connect

1. Catalytic converter (7) to catalytic converter
hanger (30).
2. Catalytic converter hanger bolts/screws (31).
l~i
Tighten
Catalytic converter hanger bolts/screws (31) to

41 N.m (30 lb. ft.).
3. Catalytic converter (7) to exhaust pipe (12).
4. Exhaust pipe clamp (9) bolt/screw at catalytic
converter.
!~!
Tighten
Clamp (9) bolt/screw to 68 N.m (50 lb. ft.).

5. Catalytic converter pipe bolts/screws (6) at
exhaust manifolds.
!~!
Tighten
3-way catalytic converter pipe bolts/screws (6)

to 30 N.m (22 lb. ft.).
6. Heated oxygen sensors to catalytic converters.
!~!
Tighten
Heated oxygen sensor to 42 N.m (31 lb. ft.).

7. Heated oxygen sensors electrical connectors.
8. Lower vehicle.
OXIDATION CATALYTIC CONVERTER

5.7L VIN P
Figures 2, 4 and 11
LEFT SIDE
I++!

SECTION OA.
2. Heated oxygen sensor electrical connector and
disconnect rosebud clip from bracket above starter
motor.
3. Heated oxygen sensor from left side catalytic
converter (1).
4. Nuts (5) attaching catalytic converter (1) to
exhaust manifold.
5. Bolts/screws (8) attaching left side catalytic
converter (1) to right side catalytic converter (2).
6. Left side catalytic converter (1) from vehicle.
i++!
Install or Connect
NOTICE:
(
1. Left side catalytic converter (1) to vehicle.

converter (1) to right side catalytic converter (2).
I~! .Tighten
Catalytic converter bolts/screws (8) to 25 N.m
(18 lb. ft.).
3. Nuts (5) attaching left side catalytic converter (1)
to exhaust manifold.
l~I
Tighten
Exhaust crossover pipe nuts (5) to 35 N,m

(26 lb. ft.).
4. Heated oxygen sensor to catalytic converter.
!~!
Tighten
Heated Oxygen sensor to 42 N.m (31 lb. ft.).

5. Electrical connector and attach rosebud clip to
bracket above starter motor.
6. Lower vehicle.
RIGHT SIDE
l++I

SECTION OA.
2. Heated oxygen sensor electrical connector and
disconnect ros,ebud clip from catalytic converter
hanger bracket.
3. Heated oxygen sensor from right side catalytic
converter (2).
4. Bolts/screws (8) attaching to left side catalytic
converter (2).
5. Nuts (11) attaching left side catalytic converter (2)
to exhaust manifold.
6. Loosen clamp (9) attaching left side catalytic
converter (2) to exhaust pipe (12) and reposition.
7. Bolts/screws (31) attaching catalytic converter
hanger (30) to left side catalytic converter (2).
8. Right side catalytic converter by sliding converter
out of exhaust pipe.
!++!
Install or Connect
NOTICE:
1. Right side catalytic converter by sliding converter

into exhaust pipe.
converter (2) to catalytic converter hanger (30).
EXHAUST SYSTEM
6F-5
1
2
4
5
8
10
)
8
!VIEW Bj
!~!
lVIEWCj
Tighten
Tighten
Exhaust crossover pipe nuts (5) to 35 N.m

(26 lb. ft.).
4. Position clamp (9) and tighten.
!~I
Tighten
Clamp (9) bolt/screw to 68 N,m (50 lb. ft.).

5. Bolts/screws (8) attaching right side catalytic
converter (2) to left side catalytic converter (1).
I~!
018195
FTG1HF
Figure 2 Oxidation Catalytic Converter (5.7L VIN P)
Catalytic converter bolts/screws (31) to

41 N.m (30 lb. ft.).
3. Exhaust crossover pipe nuts (5) attaching left side
catalytic converter (2) to exhaust pipe.
I~!
CONVERTER, LEFT HANO OXIDATION CATALYTIC

CONVERTER, RIGHT HANO OXIDATION CATALYTIC
GASKET, EXHAUST MANIFOLD PIPE
NUT, EXHAUST CROSSOVER PIPE
SOLT/SCREW, CATALYTIC CONVERTER
NUT, CATALYTIC CONVERTER
Tighten
Catalytic converter bolts/screws to 25 N.m

(18 lb. ft.).
6. Heated oxygen sensor to right side catalytic

converter.
!~!
Tighten
Heated oxygen sensor to 42 N.m (31 lb. ft.).

7. Electrical connector and attach rosebud clip to
catalytic converter hanger bracket.
8. Lower vehicle.
EXHAUST PIPE
Figures 3 through 6
I++!
1. Raise and suitably support vehicle. Refer

SECTION OA.
2. Exhaust muffler. Refer to "Exhaust Muffler"
this section.
3. Rear axle tie rod brace bracket. Refer
SECTION 3D. Under "Rear Axle Tie Rod."
4. Loosen clamp (9) from exhaust pipe (12)
catalytic converter (7).
to
in
to
to
6F-6
EXHAUST SYSTEM
12

9 CLAMP, EXHAUST PIPE
12 PIPE. EXHAUST
(
030196
FS01HF
2 CONVERTER, RIGHT HAND OXIDATION CATALYTIC

9 CLAMP, EXHAUST PIPE
12 PIPE, EXHAUST
022895
FT0208F
Figure 3 Exhaust Pipe (3800 VIN K)
5. Slide exhaust pipe (12) from catalytic converter

(7).
6. Exhaust pipe (12) from vehicle.
l++I
Install or Connect

1. Exhaust pipe to vehicle.
2. Slide exhaust pipe (12) onto catalytic converter
(7).
3. Tighten clamp (9) from exhaust pipe (12) to
catalytic converter (7).
l~I
Tighten
Clamp (9) to 68 N.m (50 lb. ft.).

4. Rear axle tie rod. Refer to SECTION 3D. Under
"Rear Axle Tie Rod."
5. Exhaust muffler. Refer to "Exhaust Muffler" in
this section.
6. Lower vehicle.
Figure 4 Exhaust Pipe (5.7L VIN P)
EXHAUST MUFFLER
Figures 5 and 6
l++I

SECTION OA.
2. Exhaust pipe hanger nut (19).
3. Loosen muffler clamp (17).
4. Slide exhaust pipe (12) out of exhaust muffler
(15).
5. Slide exhaust muffler (15) from exhaust muffler
bracket.
6. Exhaust muffler (15) from vehicle.
!++!
Install or Connect
NOTICE:
1. Exhaust muffler (15) to vehicle.

2. Slide exhaust muffler (15) onto exhaust muffler
bracket.
EXHAUST SYSTEM
3. Slide exhaust pipe (12) into exhaust muffler (15).
4. Tighten muffler clamp (17).
!~!
Tighten
Tighten
Exhaust pipe hanger nut (19) to 20 N.m

(15 lb. ft.).
[I]
EXHAUST TAILPIPE EXTENSIONS

5.7L VIN P
Figures 7 and 8
Muffler clamp (17) to 68 N.m (50 lb. ft.)

(3800 VIN K).
Muffler clamp (17) to 78 N.m (58 lb. ft.)
(5.7L VIN P and 3800 VIN K with RPO Y87).
I~!
6F7
!+-+!
1. Loosen exhaust tailpipe extension clamp

bolt/ screw.
2. Exhaust tailpipe extension (20, 21 or 23) from
exhaust muffler tailpipe.
I++!
Install or Connect
NOTICE:
Important
To ensure proper tailpipe extension to rear

fascia alignment, when reinstalling exhaust
mufflers be sure to follow specifications.
(Figures 5, 6 and 8).
6. Lower vehicle.
Refer to "Notice" on page 6F- l.
1. Exhaust tailpipe extension (20, 21 or 23) to

exhaust muffler tailpipe until stop position is
reached.
2. Align exhaust tailpipe extensions to rear fascia
(Figure 8) and tighten exhaust tailpipe extension
clamp.
12
9
73.6mm (2.90")
A
9
12
15
16
17
18
19
TAILPIPE
CLAMP. EXHAUST PIPE
PIPE, EXHAUST
MUFFLER, EXHAUST
HANGER, EXHAUST MUFFLER
CLAMP, MUFFLER
BRACKET, EXHAUST PIPE HANGER
NUT, EXHAUST PIPE HANGER
19
lv1ewcl
jv1ewel
12
Figure 5 Exhaust Muffler (3800 VIN K w/o RPO Y87)
022895
FTOOIS8f
6F-8
EXHAUST SYSTEM
19
16
A
12
13
15
16
17
18
19
TAILPIPE
PIPE, EXHAUST
NUT, EXHAUST MUFFLER HANGER
MUFFLER, EXHAUST
CLAMP, MUFFLER
BRACKET, EXHAUST PIPE HANGER
NUT, EXHAUST PIPE HANGER
!~I
93.3 mm (3.67") (PONT)

107.0 mm (4.21") (CHEV)
022815
FT0216F
Figure 6 - Exhaust Muffler (5.7L VIN P) and (3800 VIN Kw/ RPO Y87)
Tighten
Tailpipe extension clamp bolt/screw to 68 N.m

(50 lb. ft.).
rn
Important
The WS6 (Pontiac Only) exhaust tailpipe

extension to rear fascia alignment
specifications are the same as the . Pontiac
Formula, or Pontiac Trans Am depending on
model.
CATALYTIC CONVERTER HANGER

!++!
Install or Connect

1. Catalytic converter hanger (30) to catalytic
converter hanger bracket (22 or 33).
2. Catalytic converter hanger bracket (22 or 33) with
catalytic converter hanger (30) to rear axle torque
arm inner bracket (27).
3. Rear axle torque ar,.n bracket nuts (29) to rear
axle torque arm inner bracket bolts/screws (28).
I~!
Tighten
Rear axle torque arm bracket nuts (29) to

41 N.m (20 lb. ft.).
EXHAUST SYSTEM
4. Rear axle torque arm outer bracket bolt/screw
(34). (3800 VIN K Automatic only).
!~I
!HI
Install or Connect
NOTICE:
Tighten
Rear axle torque arm outer bracket bolt/screw

(34) to 27 N.m (20 lb. ft.).
5. Catalytic converter hanger bolts/screws (31).
!~i .Tighten
Catalytic converter hanger bolts/screws (31) to
41 N.m (30 lb. ft.).
6. Remove support from catalytic converter (7).
7. Lower vehicle.
6F-9
1. Exhaust muffler hanger (16) to underbody.

2. Exhaust muffler hanger bracket bolts/screws (42).
I~!
Tighten
Exhaust muffler hanger bracket bolts/screws

(42) to 9.5 N.tn (84 lb. in.).
!~I
Tighten
Exhaust pipe hanger nut (19) to 20 N.m

(15 lb. ft.).
4. Remove support from exhaust muffler (15).
5. Lower vehicle.
EXHAUST MUFFLER HANGERS

3800 VIN K WITHOUT RPO Y87
Figures 5, 6 and 12
5.7l VIN P
!++I Remove or Disconnect
3800 VIN K WITH RPO Y87
l. Raise and suitably support vehicle. Refer to

SECTION OA.
2. Support exhaust muffler (15).
5. Exhaust muffler hanger (16).
!++!

SECTION OA.
2. Support exhaust muffler (15).
3. Exhaust muffler hanger nut (13).
23
20
15 MUFFLER, EXHAUST
20 EXTENSION, EXHAUST TAILPIPE (CHEVROLET)

21 EXTENSION, EXHAUST TAILPIPE (PONTIAC)
23 EXTENSION, EXHAUST TAILPIPE (PONTIAC WITH RPO WS6)
21
Figure 7 Exhaust Tailpipe Extensions (5.7L VIN P Only)
050Ml15
FT022GF
6F".10
EXHAUST SYSTEM
FASCIA LINE
(
.....
41.0mm (1.61")
FASCIA TO -----1......_1
TAILPIPE
.,.....-===~
jVIEWA!
TAILPIPE
EXTENSION
LINE
CHEV
FASCIA LINE
25.0mm (.98")
FORMULA
34.0mm (1.34") TRANS AM
FASCIA TO TAILPIPE
PONT
IVIEW BI
TAILPIPE
EXTENSION
LINE
02-28-95
FT0238F
Figure 8 - Exhaust Tailpipe Extension Alignment Specifications

. 6. Exhaust muffler hanger (43).
EXHAUST MUFFLER INTERIOR HANGER

BRACKET
!HI
Figures 5, 6 and 12
Install or Connect
NOTICE:
Refer to "Notice" on page 6F-l.
1. Exhaust muffler hanger (43) to underbody.

2. Exhaust muffler hanger bracket bolts/screws {44).
!~!
Tighten
Exhaust muffler hanger bracket bolts/screws

(44) to 9.5 N.m (84 lb. in.).
4. Exhaust muffler hanger nut (13).
l~i
Tighten
Exhaust muffler hanger nut (13) to 20 N.m

(15 lb. ft.).
5. Remove support from exhaust muffler (15).
6. Lower vehicle.
!++!

SECTION OA.
2. Support exhaust muffler (15) and exhaust pipe
(12).

4. Exhaust pipe hanger bracket (18).
5. Exhaust muffler interior hanger bolts/screws (44).
6. Exhaust muffler interior bracket (43).
!++!
Install or Connect

1. Exhaust muffler interior bracket (43).
2. Exhaust muffler interior hanger bolts/screws (44).
I~!
Tighten
Exhaust muffler interior hanger bolts/screws

(44) to 9.5 N.m (84 lb. in.).
EXHAUST SYSTEM
6F-11
25
34
33
7
25
27
28
29
30
31
33
34
CONVERTER, THREE WAY CATALYTIC

TRANSMISSION, AUTOMATIC
HANGE~. CATALYTIC CONV~RTER
BOLT/SCREW, CATALYTIC CONVERTER HANGER
BRACKET, CATALYTIC CONVERTER HANGER
SOLT/SCREW, REAR AXLE TORQUE ARM OUTER BRACKET
jVIEWA!
0228915
FT0188F
Figure 9 Catalytic Converter Hanger to Automatic Transmission (3800 VIN K)
3. Exhaust pipe hanger bracket (18).

!~!
Tighten
Exhaust pipe hanger nut (19) to 20 N,m

(15 lb. in.).
5. Remove support from exhaust muffler (15) and
exhaust pipe (12).
6. Lower vehicle.
CATALYTIC CONVERTER HEAT SHIELD
2. Catalytic converter heat shield bolts/screws (46).

3. Catalytic converter heat shield (45).
I++!
Install or Connect
NOTICE:
1. Catalytic converter heat shield (45).

2. Catalytic converter heat shield bolts/screws (46).
I~!
Tighten
Figure 13
!++!
1. Catalytic converter. Refer to "Catalytic

Converter" under "On-Vehicle Service" in this
section.
Catalytic converter heat shield bolts/screws

(46) to 2.0 N.m (18 lb. in.).
3. Catalytic converter. Refer to "Catalytic
Converter" under "On-Vehicle Service" in this
section.
6F12
EXHAUST SYSTEM
22
27
22

14 TRANSMISSION, MANUAL
22 BRACKET, CATALYTIC CONVERTER FRONT HANGER
27 BRACKET, REAR AXLE TORQUE ARM INNER
28 BOLT /SCREW, REAR AXLE TORQUE ARM INNER BRACKET
29 NUT, REAR AXLE TORQUE ARM BRACKET
30 HANGER, CATALYTIC CONVERTER
31 BOLT/SCREW, CATALYTIC CONVERTER HANGER
(
7
022895
FT0246F
Figure 1O - Catalytic Converter Hanger to Manual Transmissio.n (3800 VIN K)
EXHAUST HEAT SHIELD

Figure 13
l++i
1. 3-way catalytic converter (3800 VIN K). Refer to

"3-Way Catalytic Converter" under "On-Vehicle
2. Oxidation catalytic converter (5.7L VIN P). Refer
to "Oxidation Catalytic Converter" under
3. Exhaust heat shield bolt/screw (48).
4. Exhaust heat shield (47).
!++!
Install or Connect
NOTICE:
Refer to "Notice" on page 6F-L
1. Exhaust heat shield (47).

2. Exhaust heat shield bolt/screw (48) ..
!~!
Tighten
Exhaust heat shield bolt/screw (48) to 2.0 N.m

(18 lb. in.).
3. Oxidation catalytic converter (5.7L VIN P). Refer
to "Oxidation Catalytic Converter" under
4. 3-way catalytic converter (3800 VIN K). Refer to
"3-Way Catalytic Converter" under "On-Vehicle
EXHAUST PIPE HEAT SHIELD AND

EXHAUST MUFFLER HEAT SHIELD
Figure 14
!++!

under "On-Vehicle Service" in this section'.
2. Exhaust pipe. Refer to "Exhaust Pipe" in this
section.
EXHAUST SYSTEM
6F-13
25
29
33
7
25
27
28
29
30
31
33
CONVERTER, THREE WAY CATALYTIC

HANGER, CATALYTIC CONVERTER
BOLT /SCREW, CATALYTIC CONVERTER
BRACKET, CATALYTIC CONVERTER
IVIEWAI
27
022895
FT0258F
Figure 11 Catalytic Converter Hanger to Transmission (5.7L VIN P)
3. Exhaust pipe heat shield bolts/screws (50).

4. Exhaust pipe heat shield (49).
5. Exhaust muffler heat shield bolts/screws (51).
6. Exhaust muffler heat shield (52).
!H!
Install or Connect
NOTICE:
1. Exhaust muffler heat shield (52).
2. Exhaust muffler heat shield bolts/screws (51).
!~I
Tighten
Exhaust muffler heat shield bolts/screws (51)

to 2.0 N.m (18 lb. in.).
3. Exhaust pipe heat shield (49).
4. Exhaust pipe heat shield bolts/screws (50).
1~1 Tighten
Exhaust pipe heat shield bolts/screws (50) to
2.0 N.m (18 lb. in.).
5. Exhaust pipe. Refer to "Exhaust Pipe" in this
section.
EXHAUST PIPE DAMPENER

3800 VIN K WITHOUT RPO Y87
Figure 15
!++!
1. Bolt/screw (32), washer (26), and dampener (24)

from exhaust bracket.
!++!
Install or Connect
NOTICE: Refer to "Notice" on page 6F- l.

1. Dampener (24), washer (26), and bolt/screw (32)
to exhaust bracket.
!~I
Tighten
EXHAUST SYSTEM CLEARANCE

DIMENSIONS
Figures 16 and 17
All checking dimensions are to be made on a
cold exhaust system.
If dimensions cannot be met, it indicates a
quality deficiency in a component part that must be
corrected.
6F-14
EXHAUST SYSTEM
(
16
!VIEWA!
L36 W/0 RPO Y87
A
43
44
A
15
16
20
42
43
44
!VIEWA!
UNOERBOOY
MUFFLER, EXHAUST
LT1
L36 W/ RPO
MUFFLER, EXHAUST
BOLT/SCREW, EXHAUST MUFFLER HANGER BRACKET
BRACKET, EXHAUST MUFFLER INTERIOR
BOLT/SCREW, EXHAUST MUFFLER INTERIOR HANGER
Y87
!VIEW B!
02-2815
FT0178F
Figure 12 Installing Exhaust Muffler Hangers to Underbody
EXHAUST SYSTEM
6F-15
47
45
!VIEWA!
45
46
47
48
SHIELD, CATALYTIC CONVERTER HEAT

BOLT/SCREW, CATALYTIC CONVERTER HEAT SHIELD
SHIELD, EXHAUST HEAT
BOLT/SCREW, EXHAUST HEAT SHIELD
46
022795
FT0106F
Figure 13 Catalytic Converter and Exhaust Heat Shield
6F16
EXHAUST SYSTEM
A
::;,
~~~EE:i~~D;AIL COMPARTMENT
~1~~,:;, \
C
49
50
51
BRACKET
HEAT
~51
SHIELD, EXHAUST PIPE PIPE HEAT SHIELD
SOLT/SCREW, EXH:~~; MUFFLER HEAT SHIELD
SOLT/SCREW, EXH
FLER HEAT
52
SHIELD, EXHAUST MUF
(
02-28-95
FT0116F
Muffler Heat Shield
Figure 14 - Exhaust Pi Pe Heat Shield and Exhaust
EXHAUST SYSTEM 6F-17
A BRACKET, EXHAUST PIPE

24 DAMPENER, EXHAUST PIPE
26 WASHER, EXHAUST PIPE DAMPENER
32 BOLT/SCREW, EXHAUST PIPE DAMPENER
052395
FT0188F
Figure 15 Exhaust Pipe Dampener (3800 w/o RPO Y87)
6F-18
EXHAUST SYSTEM
18mm(071LL
)j 9:::
57
ro____,2
16 mm (0 63")
jVIEWG!
(0 67") ma,
I_VIEWA_I 12 mm (0 47") min
27 mm (1.06") max
22 mm (0 87") mm
!VIEW oj
55~A
--~\~~
25 mm (0.98") mm
!VIEW
22 mm (0 87'') max.
18.5 mm (0 73") mm
18 mm (071") max
13 mm (0 51") mm
Bj
I VIEW JI
56
.....:'6--""L"==_=-
18 mm (0 71"li1...
19 mm (0 75") m"
t4mm(055")mm
jv1Ewcj
A
8
C
D
E
F
12
15
53
54
55
56
57
UNDERBODY
FRAME BRACKET AND SCREW
PANEL, DASH FRONT
FRAME
TAILPIPE
EXTENSION, EXHAUST HEAT SHIELD
PIPE, EXHAUST
MUFFLER, EXHAUST
PIPE, EXHAUST CROSSOVER
CONVERTER, CATALYTIC
CLAMP, CATALYTIC CONVERTER
PAN, OIL
29.5 mm (1 16") max

24 5 mm (0 96") mm
15
jv1ew L!
Figure 16 Exhaust System Clearance Dimensions (3800 VIN K)
02-28-95
FT0128F
EXHAUST SYSTEM
A~~
6F-19
19 mm (0.75") max
14 mm (0 55") mm
!VIEWHI
12 5 mm (0.50") max
7 5 mm (0.30") min
-:,._
H
"~"(,.
57
57
~8 mm (0.71") max.
-.,.....,,_1...,.3 mm (0.51") mm
J:'.
~~_
__ j
--r
29 5 mm (1 16") max
- - ~ 2 4 5 mm (0 96") mm
IVIEW DI
1/]'-fj
56
27 mm (1 07")
I. VIEW K I.
21mm(082")max
6 mm (0.63") min
4ff\\
.
\
SECTION L-L
12~
54
!VIEW
El
30 5 mm (1 20") max
25 5 mm (1 O") mm
SECTION N-N
D
58
21 5 mm (0 85") m a x ) : : ;
16 5 mm (0 65") mm
29 5 mm (1.16") max
24.5 mm (0.96") mm
29 5 mm (1 16") max
24 5 mm (0 96") mm
24 mm (0 95") max
19 mm (0.75"1 mm
26 5 mm (1.04") max.
26 5 mm (1 04") max
'( 21 5 mm (O 55 ") mm
21.5 mm (0 85") mm. -~,~;...----- 8
!VIEWCI
A
12
~7")
0
!VIEW
A
8
C
D
E
12
15
54
56
57
58
59
60
61
Pl
UNDERBOOY
CROSSMEMBER
TAILPIPE
SPARE TIRE WHEEL WELL PINCH PINCH
PIPE, EXHAUST CROSSOVER
PIPE, EXHAUST
MUFFLER, EXHAUST
CONVERTER, CATALYTIC
PAN, OIL
SHIELD, EXHAUST PIPE HEAT
PIPE, TRANSMISSION OIL COOLER
TRANSMISSION
SOLENOID, EXHAUST PRESSURE REGULATOR VALVE
022895
FT0138F
Figure 17 Exhaust System Clearance Dimensions (5.7L VIN P)
6F20
EXHAUST SYSTEM
SPECIFICATIONS
3-Way Catalytic Converter Pipe Bolt/Screw .......................................................................... 30 N.m (22 lb. ft.)
Catalytic Converter Hanger Bolt/Screw ...................... '. ........................................................... 41 N.m (30 lb. ft.)
Catalytic Converter Heat Shield Bolt/Screw ........................................................................ 2.0 N,m (18 lb. in.)
Exhaust Crossover Pipe Nut .................................................................................................... 35 N,m (26 lb. ft)
Exhaust Heat Shield Bolt/Screw ........................................................................................... 2.0 N.m (18 lb. in.)
Exhaust Muffler Clamp (3800 VIN K) .................................................................................. 68 N.m (50 lb. ft.)
Exhaust Muffler Clamp (5.7L VIN P and 3800 VIN K with RPO Y87) ........................... 78 N.m (58 lb. ft.)
Exhaust Muffler Hanger Bracket Bolt/Screw ....................................................................... 9.5 N,m (84 lb. in.)
Exhaust Muffler Heat Shield Bolt/Screw ............................................................................. 2.0 N,m (18 lb. ill.)
Exhaust Muffler Interior Hanger Bolt/Screw ....................................................................... 9.5 N,m (84 lb. in.)
Exhaust Pipe Clamp Bolt/Screw .......................................... ;.................................................. 68 N.m (50 lb. ft.)
Exhaust Pipe Dampener Bolt/Screw ....................................................................................... 50 N.m (37 lb. ft.)
Exhaust Pipe Hanger Nut ........................................................................................................ 20 N.m (15 lb. ft.)
Exhaust Pipe Heat Shield Bolt/Screw .................................................................................. 2.0 N.m (18 lb. ill.)
Exhaust Tailpipe Extension Clamp Bolt/Screw ...................................................................... 68 N,m (50 lb. ft.)
Heated Oxygen Sensor ............................................................................................................ 42 N.m (31 lb. ft.)
Oxidation Catalytic Converter Bolt/Screw .............................................................................. 25 N.m (18 lb. ft.)
Rear Axle Torque Arm Bracket Nut ...................................................................................... 41 N,m (20 lb. ft.)
Rear Axle Torque Arm Bracket Outer Bracket Bolt/Screw .................................................... 27 N,m (20 lb.ft.)
AUTOMATIC AND MANUAL TRANSMISSION
7-1
SECTION 7

inhibitors) on threaded fasteners or fasteners joint interfaces. Generally, such coatings adversely affect the
fastener torque and joint clamping force, and may damage the fastener. When you install fasteners, use the
and systems.
CONTENTS
General Description ................................................... 7-1
Description of Section 7 ........................................... 7-1
Section 7A - Automatic Transmission
On-Vehicle Service ............................................ 7-1
Section 7B - Manual Transmission On-Vehicle
Service (RPO M49 and MM6) ............................ 7-1
GENERAL DESCRIPTION
Section 7 contains both on-vehicle service
unit repair, as well as diagnosis procedures for
HYDRA-MATIC 4L60-E automatic transmission,
Borg-Warner 5-speed manual transmission and
Borg-Warner 6-speed manual transmission.
Section 7C - Clutch .............................................. 7-1

Automatic Transmission Diagnosis .......................... 7-1
Automatic and Manual Transmission
Unit Repair ........................................................... 7-1
SECTION 7C - CLUTCH
and
the
the
the
DESCRIPTION OF SECTION 7
SECTION 7A - AUTOMATIC
TRANSMISSION ON-VEHICLE SERVICE
This section contains information for automatic
transmission identification, automatic transmission
fluid level checking procedures and specific
information for servicing some components while the
automatic transmission is in the vehicle. This section
also contains procedures for removing and installing
the automatic transmission.
SECTION 78 - MANUAL TRANSMISSION
ON-VEHICLE SERVICE (RPO M49 AND
MM6)
This section contains information on the
Borg-Warner 5-speed (RPO M49) manual transmission
and Borg-Warner 6-speed (RPO MM6) manual
transmission. It includes information on transmission
identification, fluid level checking procedures and
specifics on servicing some components while the
transmission is in the vehicle. This section also
contains procedures for the removal and installation of
the transmission from the vehicle.
This section contains clutch diagnosis, on-vehicle

service of the hydraulic system, pressure plate/clutch
disc removal and installation procedures, torque
specifications and special tools required.
AUTOMATIC TRANSMISSION DIAGNOSIS

Refer to BOOK 2 for Automatic Transmission
Diagnosis. This section contains information to assist
diagnosing transmission operating conditions when the
unit is in the vehicle. The diagnosis covers: road test
procedures, shift speed charts, pressure check
procedures, diagnosis charts, electrical wiring
diagrams, automatic transmission oil passage
identification and torque converter clutch diagnosis.
For fluid flow diagrams and circuit descriptions, refer
to the TRANSMISSION/TRANSAXLE/IRANSFER CASE
UNIT REPAIR MANUAL.
AUTOMATIC AND MANUAL

TRANSMISSION UNIT REPAIR
Refer to the Transmission/Transaxle/Transfer
Case Unit Repair Manual. This manual contains the
disassembly, inspection, overhaul and assembly
procedures for the mechanical components in the
transmission. Also included is information on the
gaging of certain components, proper use of special
tools, and torque specifications required for assembly.
72
BLANK
AUTOMATIC TRANSMISSION ON-VEHICLE. SERVICE
7A-1
SECTION 7A
ON-VEHICLE SERVICE
torque and the joint clamping force, and may damage the fastener. when you install fasteners, use the correct
systems.
NOTICE: The re-assembly of some components will require the use of an assembly lube. It is recommended
that Transjelt TM or petroleum jelly be used during re-assembly. Grease other than the recommended assembly
lube will change transmission fluid characteristics and cause undesirable shift conditions and/or filter clogging.
CONTENTS
General Information ............................................. 7A-2
Transmission Identification Information .......... 7A-2
Transmission Definitions .................................. 7A-2
Throttle Positions ......................................... 7A-2
Shift Conditions ............................................ 7A-2
Noise Conditions .......................................... 7A-3
Preliminary Checking Procedure ..................... 7A-3
Line Pressure Check ..... Refer to Section 7A-14A
Noise and Vibration Analysis .......................... 7A-3
Transmission Fluid Checking and Filling
Procedures ......................................................... 7A-3
General Service Procedures ................................. 7A-4
No Air Tool Recommendation ........................ 7A-4
Parts Cleaning, Inspection and Replacement .. 7A-4
Flywheel/Torque Converter Clutch Vibration
Test Procedure .................................................. 7A-6
Fluid Leak Diagnosis ............................... ,....... 7A-6
Methods for Locating Leak ......................... 7A-6
Repairing the Leak ....................................... 7A-8
Possible Points of Fluid .Leaks .................... 7A-8
Transmission Case Porosity Repair ............. 7A-8
Torque Converter Clutch Electrical Controls .. 7A-9
Torque Converter Clutch Diagnosis ................ 7A-9
On-Vehicle Service ............................................... 7A-9
Automatic Transmission Range Selector Lever
Cable ................................................................. 7A-9
Automatic Transmission Control.. ................... 7A-10
Automatic Transmission Park Lock Cable ..... 7A-10
System Diagnosis ............... Refer to Section 8A-138
Automatic Transmission Control
Lever Solenoid ................................................. 7A-12
Park/Neutral Position Switch ............................ 7A-12

Park/Neutral Position Switch
Adjustment Using Old Switch ..................... 7A-12
Park/Neutral Position Switch
Adjustment Using New Switch .................... 7A-13
Changing Transmission
Fluid and Filter ................................................. 7A-13
Automatic Transmission Oil Cooler
Upper Hose ................................................... 7A-14
Automatic Transmission Oil Cooler Upper and
Lower Pipes ...................................................... 7A-16
Oil Cooler Flushing Procedure ......................... 7A-17
Serviceable Components ....................................... 7A-18
Transmission Fluid Fill Tube ........................... 7A-18
Transmission Ventilation Hose ......................... 7A-19
Vehicle Speed Sensor (VSS) ............................ 7A-19
Automatic Transmission Case Extension ......... 7A-20
Accumulators ..................................................... 7A-21
2-4 Band Servo ................................................. 7A-21
Transmission Converter Cover ......................... 7A-24
Pressure Regulator Valve .................................. 7A-25
Control Valve Body and Pressure Switch ....... 7A-26
Control and Shift Solenoids ............................. 7A-27
Torque Converter Clutch Solenoid and
Wiring Harness Replacement ........................... 7A-28
Electrical Connector and Seal.. ........................ 7A-28
Case Extension Oil Seal ................................... 7A-28
Automatic Transmission .................................... 7A-29
Fastener Tightening Specifications ................... 7A-33
Special .Tools ......................................................... 7A-34
7A-2
AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE

JULIAN DATE
OR DAY or THE YEAR
TRANSMISSION 1.0.
03-09-95 .
FT0017A
IDENTIFICATION INFORMATION
Figure 1 - Automatic Transmission Identification Information
GENERAL INFORMATION
TRANSMISSION IDENTIFICATION
INFORMATION
Figures 1 and 2
The HYDRA~MATIC 4L60-E transmission has
the identification information stamped into the case
pan rail. The location of this information is shown in
Figure 1. This information will. assist in the servicing
and determination of replacement parts when ordering
through a GM parts catalog.
Additional transmission identification is provided
on the "Service Parts Identification" label shown in
Figure 2. This label contains information on the
Regular Production Options (RPO) as well as standard
and mandatory options. This label is affixed to the
inside of each vehicle at the assembly plant. Refer to
SECTION OA for additional information.
TRANSMISSION DEFINITIONS
The following definitions are provided to
establish a common language and assist the user in
describing transmission related conditions. Some of
these terms or conditions are used in the transmission
diagnosis section of this service manual.
Shift Conditions
Bump - sudden and forceful application .of
clutch or band.
Chuggle - bucking or jerking condition that
may be engine related. May be most noticeable when
the torque converter clutch is engaged. Similar to the
feel of towing a trailer.
Delayed - condition where shift is expected but
does not occur for a period of time. Examples of this
condition could be described as clutch or band
engagement that does not occur as quickly as expected
during part throttle or wide open throttle application of
accelerator, or when manually downshifting to lower
range. Also defined as "late" or "extended."
Double Bump - two sudden and forceful
applications of clutch or band. Also defined as
"double feel."
Early - condition where shift occurs before
vehicle has reached proper speed and tends to labor
engine after upshift.
End Bump - firmer feel at end of shift as
compared to feel at start of shift. Also defined as "end
feel" or "slip l,ump."
Firm - noticeable quick application of clutch or
band that is considered normal with medium to heavy
throttle shift. Should not be confused with "harsh" or
"rough."
Throttle Positions
Minimum Throttle - least amount of throttle
opening required for an upshift.
Light Throttle - approximately 1/4 of
accelerator pedal travel.
Medium Throttle - approximately 1/2 of
Heavy Throttle - approximately 3/4 of
.
Wide Open Throttle (WOT) - full travel of
accelerator pedal.
Full Throttle Detent Downshift - quick
application of accelerator pedal to its full travel,
forcing a downshift.
Zero Throttle Coastdown - full release of
accelerator pedal while vehicle is in motion in drive
range.
Engine Braking - condition where engine is
used to slow vehicle by manually downshifting during
zero throttle coastdown.
M INDICATES TRANSMISSION
TYPE IN OPTION LIST (SPECIFIC
MODEL CODE IS FOUND ON THE
TRANSMISSION NAMEPLATE)
M30- DESIGNATES HYDRAMATI C4L60E
SERVICE PARTS IDENTIFICATION
MX - DESIGNATES
ASSEMBLY
MXO - DESIGNATES 4 SPEED
DO NOT REMOVE .
o:f
1 G3 AR4 7 Y X E5 1
O1
C90 C95 OFJ 03C 033 0 8 E Z E O FFL F40 661 GW9 660 GUZ 689
JA1 JA4 KOS K22 K99 LT1 I M30IMXOINA5 NB! NK1 NK2 N33 N67 GJW
T87 UJ3 U23 U35 YOB V10 WC3 WG2 YT9 Y56 OIL SSC 428 421 420
42T 409 7SB BWT 9WT 11A 90A
PRINTED IN U.S.A.
PART NO. 14065987
01-31-95
FS0027A
Figure 2 - Service Parts Identification Label

Flare - quick increase in engine RPM
accompanied with momentary loss of torque. This
most generally occurs during a shift. Also defined as
"slipping."
Harsh - more noticeable application of clutch or
band as compared to "firm." This condition is
considered undesirable at any throttle position. Also
defined as "rough."
Hunting - repeating quick series of upshifts and
downshifts causing noticeable change in engine RPM.
An example could be described as a 4-3-4 shift
pattern. Also defined as "busyness."
Initial Feel - distinct firmer feel at start of shift
as compared to finish of shift.
Late - shift that occurs when engine is at higher
than normal RPM for given amount of throttle.
Shudder - repeating jerking sensation similar to
"chuggle" but more severe and rapid in nature. This
condition may be most noticeable during certain
ranges of vehicle speed. May also be used to define
the condition after torque converter clutch engagement.
Slipping - noticeable increase in engine RPM
without vehicle speed increase. Slip .usually occurs
during or after initial clutch or band engagement.
Soft - slow, almost unnoticeable clutch
application with very little shift feel.
Surge - repeating engine related feeling of
acceleration and deceleration that is less intense than
"chuggle."
Tie-Up - condition where two opposing clutches
are attempting to apply at the same time .causing the
engine to labor with noticeable loss of engine RPM.
Noise Conditions
Gear Noise - whine, most noticeable in first
gear and reverse that is related to vehicle speed. A
gear noise condition may become less noticeable or go
away after an upshift.
Pump Noise - high-pitched whine increasing in
intensity with engine RPM. This condition may also
be noticeable in "PARK" and "NEUTRAL" operating
ranges with the vehicle stationary.
PRELIMINARY CHECKING PROCEDURE

Transmission performance may be influenced by
one or more of the following items. These items
should be checked and corrected if necessary, before
attempting transmission diagnosis.
High or low fluid level.
Engine performance. Refer to SECTION 6 and
SECTION 6E.
Manual linkage adjustment.
Electrical system. Refer to SECTION 8A.
Transmission or other mechanical component.
Perform "Functional Test Procedure." Rrefer to
SECTION 7A-14A.
NOISE AND VIBRATION ANALYSIS
A noise or vibration noticeable when the vehicle
is in motion, may not be caused by the transmission.
If a noise or vibration is noticeable in "PARK" and
"NEUTRAL" with engine at idle, but is less
noticeable as RPM increases, the cause may be poor
engine performance.
!L!
7A-3
Inspect
Tire and wheels for:

- Uneven wear.
- Imbalance.
- Mixed sizes.
- Mixed radial and bias ply. Refer to SECTION
3E.
!L!
Inspect
Suspension components for:

- Alignment and wear.
- Loose fasteners. Refer to SECTION 3C.
Engine and transmission mounts for:
-Damage.
- Loose bolts/screws.
Transmission case mounting holes for:
- Missing bolts/screws, nuts, studs.
- Stripped threads.
-Cracks.
Flywheel for:
- Missing or loose bolts/screws.
-Cracks.
- Imbalance. Refer to SECTIONS 6A3A or
6A8A.
Torque converter clutch for:
- Missing or loose bolts/screws or lugs.
- Missing or loose balance weights.
- Imbalance.
TRANSMISSION FLUID CHECKING AND

FILLING PROCEDURES
Figures 3 and 4
Checking fluid level, color and condition at

regular intervals will provide early diagnosis
information about the transmission. This information
may then be used to correct a condition that, if not
detected early, could result in major transmission
repair.
Refer to SECTION OB for maintenance
information and servicing intervals.
[I]
Important
When new, automatic transmission fluid should

be red. The red dye is added so the assembly
plant can identify it as transmission fluid and
distinguish it from engine oil or antifreeze.
The red dye, which is not an indicator of fluid
quality, is not permanent. As the vehicle is
driven the transmission fluid will begin to look
darker. The color may eventually appear light
brown.
Wait at least 30 minutes before checking the
transmission fluid level if you have been driving:
- When outside temperatures are above 32C
(90F).
- At high speeds for greater than 15 minutes.
- In heavy traffic during hot weather.
- While pulling a trailer.
7A-4
AUTOMATIC TRANSMISSION ON-VEHICLE $ERVICE

4L60- E TRANSMISSION FLUID CHECKING PROCEDURE
1.
2.
3.
4.
*It
Worm the transmission to operating temperature by driving the vehicle about 15 miles (24km). Operating
temperature is 180-200 F(82-94C).
Pork vehicle on a level surface, place shift lever in "P" park .and apply the parking brake.
Check fluid level on the dipstick (read the lower level).
If fluid level is low, DEXRONe-111 Automatic Transmission Fluid is preferred, if unavailable DEXRONe-nE is
acceptable, add only enough to bring the fluid level into the hot area.
is important to check fluid level when the transmission hos reached operating temperature. The hot range is calibrated
to correspond to the correct fluid level range for fluid between 180 and 200F(82-94 C).
! ----t--"~~-___,)
( _____j c_oLD___
062095
FT0037A
Figure 3 4L60-E Transmission Fluid Checking Procedure
To get the right reading, the fluid should be at

normal operating temperature, which is 82 to
94C (180 to 200F).
Hot check:
- Get the vehicle warmed up by driving about
24 km (15 miles), when outside temperatures
are above l0C (50F). If it's colder than l0C
(50F), you may have to drive longer.
Cold check:
- A cold check can be made when the
transmission temperature is between 24 to
29C (75 to 85F). Let the engine run at slow
idle for 5 minutes if the outside temperature is
l0C (50F) or more. If it's colder than 10C
(50F), you may have to idle the engine
longer.
Fluid check procedure hot or cold:
A. Park the vehicle on a level surface.
B. Place the shift lever in "PARK" with the
parking brake applied.
C. With your foot on the brake pedal, move the
shift lever through each gear range, pausing
for about 3 seconds in each range. Then,
position the shift lever in "PARK."
D. Let the engine idle for 3 minutes or more.
E. Then follow these steps to check the fluid
level:
a. Pull out the dipstick and wipe it with a
clean rag or paper towel.
b. Push it back in all the way, wait 3 seconds
and then pull it back out again.
F. Check both sides of the dipstick, and read the
lower level. The fluid level must be in the
"COLD" area for a cold check or in the
"HOT" area or cross-hatched area for a hot
check.
G. If the fluid level is where it should be, push
the dipstick back in all the way.
NOTICE: Do not overfill. Overfilling will
cause foaming, loss of fluid and possible
damage to the transmission.
H. If the fluid level is low, add only. enough

DEXRO.N-III or if unavaible,
DEXTRON-IIE is acceptable to bring the
fluid level up to the "COLD" area for a cold
check or the "HOT" area for a hot check It
doesn't take much fluid, generally less than a
pint. DO NOT OVERFILL.
I. After adding fluid, recheck the fluid level as
described above. When the correct fluid level
is obtained, push the dipstick back in all the
way.
Fluid color.
- Should be red when new.
GENERAL SERVICE PROCEDURES

NO AIR TOOL RECOMMENDATION
NOTICE: It is not recommended to use air
powered tools to disassemble or re-assemble
transmissions. Improper bolt torque can
contribute to transmission repair problems, and
this information, vital to diagnosis can only be
detected when using hand tools.
PARTS CLEANING, INSPECTION AND

REPLACEMENT
Use appropriate safety equipment such as:
- Safety glasses.
- Safety shoes.
-Gloves.
Keep work areas and tools clean.
Clean transmission exterior before removing parts.
Do not use wipe cloths or rags.
Do not use solvents on:
- Rubber seals.
- Plastic/Teflon thrust washers or spacers.
Blow out all passages with compressed air.
Clean out small passages with fine wire.
Handle parts carefully to prevent damage.
7A-5
CHECKING AUTOMATIC TRANSMISSION FLUID COLOR AND CONDITION

I
$
CHECK FLUID LEVEL.
HIGH
REMOVE
EXCESS FLUID.
CHECK FLUID COLOR
I
I
LOW
ADD FLUID TO
OBTAIN PROPER
LEVEL.
REPL,ACE
COOLER.
FOAM
FLUID LEVEL
HIGH.
.
CONTAMINANTS
IN FLUID.
REMOVE
EXCESS FLUID.
DRAIN FLUID TO
DETERMINE IF
THERE IS
CONTAMINATION.
NOTICE: A VERY
SMALL AMOUNT
OF MATERIAL IN
THE BOTTOM
PAN IS A
NORMAL
CONDITION.
...
CHANGE FLUID
AND FILTER
I
ADD NEW FLUID
CHECK FLUID
LEVEL.
I
LARGE PIECES
OF METAL OR
OTHER
MATERIAL IN
THE BOTTOM
PAN.
I
FLUSH COOLER
NOTICE:
TRANSMISSION
FLUID MAY TURN
DARK WITH
NORMAL USE AND
DOES NOT ALWAYS
INDICATE
CONTAMINATION
OR OXIDATION.
I
TRANSMISSION
OVERHAUL(OR
SRTA)
REQUIRED
(REFER TO
"UNIT REPAIR
SECTl'ON").
LT. BROWN
I
DRAIN FLUID TO
DETERMINE
SOURCE OF
CONTAMINATION.
CHECK FOR EXTERNAL

LEAKS (REFER TO
"FLUID LEAK
DIAGNOSIS").
CORRECT LEAK
CONDITION.
NON-TRANSPARENT
PINK
TRANSMISSION
OVERHAUL(OR
SRTA)
REQUIRED.
(REFER TO
"UNIT REPAIR
SECTION").
I
FLUSH COOLER
I
PERFORM OBD
SYSTEM CHECK IF
NOT ALREADY
PERFORMED,
I
I
ADD NEW
FLUID.
I
I
CHECK FLUID
LEVEL.
REFER TO 4L60E
TRANSMISSION
FUNCTIONAL TEST
PROCEDURE.
C10393
Figure 4 Checking Automatic Transmission Fluid Color and Condition
7A6
NOTICE: The re-assembly of some

components will require use of an assembly
lube. It is recommended that J 36850
Transjelt TM or equivalent, be used during
re-assembly. Do not use any type of grease to
retain parts during re-assembly of this unit.
Lubricants other than the recommended
assembly lube will change fluid characteristics
and cause undesirable shift conditions and/or oil
filter clogging.
When installing bolts/screws or studs into
aluminum, always dip the threads in Transjelt, TM
or equivalent.
Recondition damaged or stripped aluminum
threads with thread inserts.
Replace all gaskets and 0-rirtg seals.
- Do not use gasket cement or sealers.
Replace Teflon and rubber lip seals only when
necessary and install using the appropriate seal
installer.
IL!
Inspect
Manual linkage for:

- Bent or broken links and rods.
All seals, gaskets, 0-ring seals and mating
surfaces for:
-Nicks.
-Cuts.
-Damage.
Snap rings for:
- Expansion or compression.
- Distortion.
-Nicks.
- Proper ring-to-groove fit.
Bearings and thrust surfaces for:
-Wear.
- Scoring.
- Pitting.
FLYWHEEUTORQUE CONVERTER
CLUTCH VIBRATION TEST PROCEDURE
NOTICE: Some engine/transmission
combinations cannot be balanced in this manner
due to limited clearances between the. torque
converter clutch bolts/screws and the engine. Be
sure bolts/screws do not bottom out in lug nuts
or the transmission converter cover could be
dented and cause internal damage.
l++j
1. Start engine.
2. With engine at idle speed and transmission in
"PARK" or "NEUTRAL," observe vibration.
3. Shut off engine.
SECTION OA.
5. Transmission converter cover bolts/screws.
6. Flywheel bolts/screws.
Discard flywheel bolts/screws.
7. Rotate torque converter clutch 120 degrees (1/3
turn).
I++!
lnst~II or Connect
NOTICE:
1. Flywheel bolts/screws.
Hand start flywheel bolts/screws.
- Use new flywheel bolts/screws with
retaining compound removed from first
three threads.
!~I
Tighten
Flywheel bolts/screws to 63 N.m (46 lb. ft.).

2. Transmission converter cover bolts/screws.
l~!
Tighten
Transmission converter cover bolts/screws to

10 N.m (89 lb. in.).
3. Lower vehicle.
4. Start engine and check for vibration.
If vibration still exists repeat this procedure
until best possible balance is obtained.
FLUID LEAK DIAGNOSIS

Figure 5
The cause of most external leaks generally can

be located and repaired with the transmission in the
vehicle.
Methods for Locating leak

GENERAL METHOD
1. Verify leak is transmission fluid.

2. Thoroughly clean suspected leak area.
3. Operate vehicle for about 24 km (15 miles) or
until normal operating temperatures are reached.
4. Park vehicle over clean paper or cardboard.
5. Shut off engine and look for fluid spots on paper.
6. Make necessary repairs.
POWDER METHOD
1. Thoroughly clean suspected leak area with

solvent.
2. Apply aerosol type powder (foot powder) to
suspected leak area.
3. Operate vehicle for about 24 km (15 miles) or
until normal operating temperatures are reached.
4. Shut off engine.
5. Inspect suspected leak area and trace leak path
through powder to find source.
7A-7
A
B
C
D
E
BOTTOM PAN GASKET

CASE
COOLER CONNECTORS
SERVO COVER SEAL
OIL FILL TUBE SEAL
F OIL PUMP SEAL

G OIL PUMP TO CASE SEAL
H CONVERTER
I VENT
J ELECTRICAL CONNECTOR SEAL
K
L
M
N
O
MANUAL SHAFT SEAL

SPEED SENSOR SEAL
EXTENSION TO CASE SEAL
EXTENSION OIL SEAL
LINE PRESSURE PLUG
04-03-95
FS0047A
Figure 5 - Automatic Transmission Fluid Leak Points
7A-8
AUTOMATI.C TRANSMISSION ON-VEHICLE SERVICE
DYE AND BLACK LIGHT METHOD
A fluid dye and black light kit is available from

various tool manufacturers.
1. Follow manufacturer's recommendations for
amount of dye to use.
2. Detect leak with black light.
Repairing the Leak

Once the leak has been pinpointed and traced
back to its source, the cause of the leak must be
determined for it to be properly repaired. For example,
if a gasket is replaced, but the sealing flange is bent,
the new gasket will not repair the leak. The bent
flange also must be repaired.
The following conditions may cause a leak.
Before attempting to repair a leak, these conditions
should be checked and corrected if necessary.
GASKETS
iL"'!
Inspect
Fluid level/pressure too high.

Plugged vent or drain-back holes.
Improper torque on fasteners, dirty or damaged
threads.
Warped flanges or sealing surface.
Scratches, burrs or other damage to sealing
surface.
Damaged or worn gasket.
Cracking or porosity of component.
Improper sealant used, where applicable.
Incorrect gasket.
SEALS
IL"'!
Inspect
Fluid level/pressure too high.

Plugged vent or drain-back holes.
Damaged seal bore.
Damaged or worn seal.
Improper installation.
Cracks in component.
Scratched, nicked or damaged, manual or output
shaft surface.
Loose or worn bearing causing excess seal wear.
Possible Points of Fluid Leaks

OIL PAN
!L"'I
Inspect
Incorrectly tightened oil pan bolts/screws.
Improperly installed or damaged oil pan gasket.
Damaged oil pan.
Incorrect oil pan gasket
OIL CASE LEAK
!L!
Inspect
Damaged or missing transmission filler tube seal.

Mislocated filler tube bracket.
Damaged vehicle speed sensor seal.
Damaged manual shaft seal.
Loose or damaged oil cooler connector fittings.
Worn or damaged propeller shaft oil seal.
Loose parking pawl shaft cup plug, if equipped.
Loose line pressure pipe plug.
Porous casting.
LEAK AT TORQUE CONVERTER END
Torque converter seal damaged.

- Torque converter seal lip cut. Check torque
converter hub for damage.
- Bushing moved forward and damaged.
- Garter spring missing from seal.
Torque converter leak in weld area.
Porous casting of transmission case or oil pump.
LEAK AT VENT PIPE OF FLUID FILL TUBE
!L!
Inspect
Over-filled system.
Water or coolant in fluid. Fluid will appear milky.
Transmission case porous.
Incorrect fluid level indicator.
Plugged vent.
Plugged drain-back holes.
Mispositioned oil pump-to-case gasket, if
equipped.
Transmission Case Porosity Repair

CAUTION: Epoxy cement may cause skin
irritations and eye damage. Read and
follow all information on container label
as provided by manufacturer.
1. Clean leak area with solvent and air dry.
2. Mix sufficient amount of epoxy cement, GM PIN
1052533, or equivalent, following manufacturers'
recommendations.
3. While transmission case is hot, apply epoxy
cement with clean, dry soldering acid brush.
4. Allow epoxy cement to cure for three hours
before starting engine.
5. Repeat fluid leak diagnosis procedures to
determine if leak is fixed.
A
B
812
813
814
815
816
SPRING, AUTOMATIC TRANSMISSION PARK LOCK CABLE

BRACKET, AUTOMATIC TRANSMISSION PARK LOCK CABLE
CABLE, AUTOMATIC TRANSMISSION PARK LOCK
CLIP, AUTOMATIC TRANSMISSION PARK LOCK CABLE
NUT, AUTOMATIC TRANSMISSION PARK LOCK CABLE
BUTTON, AUTOMATIC TRANSMISSION PARK LOCK CABLE LOCK
COLUMN, STEERING
7 A-11
01-31-95
FS0077A
Figure 8 - Automatic Transmission Park Lock Cable (Typical)
5. Left-hand instrument panel insulator, instrument

panel driver knee bolster, and instrument panel
driver knee bolster deflector. Refer to
SECTION 8C.
7. Nut (814).
8. Clip (813).
9. Cable (812) from bracket.
10. Move button (815) to "UP" position.
11. Unsnap cable terminal from park lock lever pin.
12. Lower steering column. Refer to SECTION 3F.
13. Unsnap cable (812) from steering column (816).
!HI
Install or Connect
1. Make sure ignition key is in "RUN" position and

automatic transmission control is in "PARK."
Do not proceed to next step with ignition key
in any other position.
2. Snap cable terminal to park lock lever pin.
3. Push cable connector forward to remove slack.
4. With no load applied to connector, press button
(815) down.
5. Cable (812) to bracket.
A. Push bracket housing against adjusting spring.
B. Drop cable (812) through slot in bracket and
seat housing to automatic transmission control.
6. Push button (815) down.
7. Snap cable (812) into steering column (816).
8. Raise steering column. Refer to SECTION 3F.

9. Clip (813).
10. Nut (814).
12. Left-hand instrument panel insulator, instrument
panel driver knee. bolster, and instrument panel
driver knee bolster deflector. Refer to SECTION
8C.
13. Turn ignition key to "OFF" position.
15. Enable the SIR system. Refer to SECTION 9J.
IL!
Inspect
Functional operation.
A. With automatic transmission control in
"PARK" and the ignition key in "LOCK"
position, make sure automatic transmission
control cannot be moved to different position.
Ignition key should be removable from
steering column.
B. With ignition key in "RUN" and automatic
transmission control in "NEU1RAL," make
sure key cannot be turned to "LOCK."
C. If above conditions are met, system is properly
adjusted. Proceed to step E.
D. If above conditions are not met, put button
(815) back to "UP" position, and readjust as
above. Then push button (815) down and
recheck operation.
7A-12
AUTOMATIC TRANSMISSION .ON-VEHICLE SERVICE
E. If key cannot be removed in "PARK"

position, move button (815) to "UP" position
and move cable connector nose rearward until
ignition key can be removed.
F. Snap button (815) down.
.
G. Reinstall cable (812) into clip (813) to ensure
correct routing.
AUTOMATIC TRANSMISSION CONTROL

LEVER SOLENOID
[I]
Important
The automatic transm1ss10n control lever

solenoid is part of the brake transmission shift
interlock system (BTSI). The solenoid prevents
the operator from shifting the automatic
transmission control out of "PARK" unless the
brake pedal is depressed.
Figure 9
!++I

!VIEWA

2. Front floor console trim plate. Refer to
SECTION 8C.
3. Wiring harness electrical connector from
automatic transmission control lever solenoid
(804).
4. Automatic transmission control lever solef).oid
(804) by unsnapping retainers.
I++!
Install or Connect
1. Automatic transmission control lever solenoid

(804) by snapping retainers mto place.
2. Wiring harness electrical connector to automatic
transmission control lever solenoid (804).
3. Front floor console trim plate. Refer to SECTION
8C.
PARK/NEUTRAL POSITION SWITCH
[I]
Important
The park/neutral position switch prevents

starter motor operation when the automatic
transmission control is in any gear by breaking
the starter motor circuit. When the automatic
transmission control is in reverse (engine
running), the park/neutral position switch
completes the backup lamp circuit, lighting the
backup lamps.
A
B
C
804
RETAINER, PLASTIC
STUD
SOLENOID, AUTOMATIC TRANSMISSION CONTROL
LEVER
.
805 CONTROL, AUTOMATIC TRANSMISSION
01-31-96
FS0087A
Figure 9 - Automatic Transmission Control Lever Solenoid

(Typical)
Figure 10
!++!

L
2.
3.
4.

Front floor console. Refer to SECTION 8C.
Bolts/screws (819).
Switch (817).
Park/Neutral Position Switch Adjustment

Using Old Switch
!++l
NOTICE: Refer to "Notice'; on page 7A-1.

1. Place automatic transmission control (805) in
"NEUTRAL."
!~!
7A-13
Tighten
rn
Important
If park/neutral position switch bolt/screw holes
will not align with automatic transmission

control, verify automatic transmission control
is in "NEUTRAL" position. Do not rotate
park/neutral position switch. If switch has been
rotated and the pin is broken, the switch can
be adjusted using the procedure under
"Park/Neutral Position Switch Adjustment
Using Old Switch" in this section.
818
A
B
C
D
805
817
818
819
825
NEUTRAL NOTCH
PARK NOTCH
TANG SLOT
PIN.GAGE
CONTROL, AUTOMATIC TRANSMISSION
SWITCH, PARK/NEUTRAL POSITION
TANG, PARK/NEUTRAL POSITION SWITCH CARRIER
BOLT/SCREW, PARK/NEUTRAL POSITION SWITCH
DETENT PLATE, PARK/NEUTRAL POSITION SWITCH
013195
FS0097A
Figure 1O Park/Neutral Position Switch
2. Tang (818) on switch (817) into slot on automatic

transmission control (805).
3. Bolts/screws (819) to automatic transmission case,
loosely.
4. Insert 2.34 mm (3/32-inch) gage pin into service
adjustment hole, and rotate switch (817) until
gage pin drops to 15 mm (19/32-inch) depth.
!~l
Tighten

CHANGING TRANSMISSION FLUID AND

FILTER
!++!

SECTION OA.
2. Place drain pan under transmission oil pan (73).
3. Bolts/screws (74) from front and sides of pan
only.
4. Loosen rear bolts/screws (74) approximately four
turns.
NOTICE: When removing automatic

transmission oil pan bolts/screws, use caution in
order not to damage the automatic transmission
case or automatic transmission oil pan sealing
surfaces.
rn
Important
After park/neutral position switch adjustment,

verify engine will only start with ignition key
in "PARK" or "NEUTRAL." If engine will
start with ignition key in any other position,
re-adjust park/neutral position switch.

Using New Switch
!++!
1. Place automatic transmission control (805) in

"NEUTRAL."
2. Tang (818) on switch (817) into slot on automatic
transmission control (805).
3. Bolts/screws (819) to automatic transmission case.
5. Lightly tap oil pan (73) with rubber mallet or pry

to allow fluid to drain.
!L!
Inspect
Fluid color and condition. Refer to Figures 3

and 4:
Filter. Open filter by prying the metal
crimping away from the top of the filter
(black) and pulling apart. The filter may
contain evidence for root cause diagnosis.
- Clutch material.
- Bronze slivers indicating bushing wear.
- Steel particles.
6. Remaining bolts/screws (74), oil pan (73) and
gasket (72).
7. Filter (71) and seal (70).
Seal (70) may be stuck in automatic
transmission case.
7A-14
(
A AUTOMATIC TRANSMISSION OIL PAN BOLT/SCREW
AND CONICAL WASHER IS REUSABLE
B AUTOMATIC TRANSMISSION OIL PAN BOLT/SCREW
AND CONICAL WASHER IS NOT REUSABLE
01-31-95
FS0117A
Figure 12 - Automatic Transmission Oil Pan Bolt/Screw

and Conical Washer
!~!
Tighten

6. Lower vehicle.

10
70
71
72
73
74
CASE, TRANSMISSION
SEAL, FILTER
FILTER, TRANSMISSION OIL
GASKET, TRANSMISSION OIL PAN
PAN, TRANSMISSION OIL
BOLT/SCREW, TRANSMISSION OIL PAN
7. Fill automatic transmission fluid to proper level.

8. Check "COLD" fluid level reading for initial fill
only. Refer to "Transmission Fluid Checking
Procedures" in this section.
!L!
Inspect
Gasket (72) for leaks.
01-31-95
FS0107A
Figure 11 - Automatic Transmission Oil Pan and Oil Filter
Clean
Automatic transmission case .and gasket surfaces

with solvent, and air dry. All traces of gasket
material must be removed.
!H!
Install or Connect
NOTICE:
1.
2.
3.
4.
5.
Filter seal (70) into the pump.

Oil filter (71).
Oil pan gasket (72).
Chip magnet onto oil pan (73).
New gasket (72), oil pan (73) and bolts/screws
(74).
NOTICE: Automatic transm1ss10n oil pan

bolt/screws and washers must not be reused if
conical washers are reversed. Failure to replace
the bolt/screws and washers may result in
improper fastening of system components.
AUTOMATIC TRANSMISSION OIL COOLER

UPPER HOSE
Figures 13 and 14
!+-+!
1. Fitting (4) on radiator end of upper oil cooler

hose (860).
SECTION OA.
3. Transmission oil cooler upper hose clamp (862).
4. Transmission oil cooler upper hose (860) from
upper pipe (856).
!-++!
Install or Connect
NOTICE: Refer to "Notice" on page 7A-1.

1. Transmission oil cooler upper hose (860) to upper
pipe (856).
2. Transmission oil cooler upper hose clamp (862).
3. Lower vehicle.
4. Fitting on radiator end of upper oil cooler hose
(860).
!~!
Tighten
Fitting on radiator end of upper oil cooler hose

(860) to 27 N.m (20 lb. ft.).
7A-15
861
859
860
856
856~
jVIEWA!
8~40mmMAX.
856
862
ef
!VIEW
2
3
4
5
6
838
856
857
859
860
861
862
oj
BOLT/SCREW, TRANSMISSION OIL COOLER PIPE BRACKET

BRACKET, TRANSMISSION OIL COOLER PIPE
FITTING, TRANSMISSION OIL COOLER UPPER PIPE
FITTING, TRANSMISSION OIL COOLER LOWER PIPE
PIPE, TRANSMISSION OIL COOLER UPPER
PIPE, TRANSMISSION OIL COOLER LOWER
HOSE, TRANSMISSION OIL COOLER UPPER
RADIATOR
CLAMP, TRANSMISSION OIL COOLER UPPER HOSE
03-23-95
FT0387A
Figure 13 - Transmission ml Cooler Pipes and Hose (3800 VIN K)
7A-16
AUTOMATICTRANSMISSION ON-VEHICLE SERVICE
AUTOMATIC TRANSMISSION OIL COOLER

UPPER AND LOWER PIPES
Figures 13 and 14
If replacement of automatic transmission oil
cooler pipes and hoses is required, use only
double-wrapped and brazed steel tubing meeting
GM specification 123 M or equivalent. Tubing should
be double flared.
NOTICE: Allow sufficient clearance to

transmission oil cooler pipe and hoses to
prevent damage or wear which may cause fluid
loss.
!++!

SECTION OA.
2. Fitting on radiator end of oil cooler lower hose
(857).
3. Transmission oil cooler upper hose clamp (862)
from upper hose (860) and pipe (856).
5. Rear axle torque arm. Refer to SECTION 30.
7. Support automatic transmission with a
transmission stand.
8. Transmission support member. Refer to
SECTION 10-3.
9. Lower the transmission stand slightly, to allow
access to oil cooler fittings at transmission.
l 0. Fitting on transmission end of upper pipe (856).
11. Fitting on transmission end of lower pipe (857).

12. Upper pipe (856) and lower pipe (857) from
engine clip (858) and pipe clip (859) (5.7L VIN P
Only).
13. Upper and lower pipe from transmission oil cooler
pipe bracket (3) (3800 VIN K Only).
!++j
Install or Connect
1. Upper and lower pipe to transmission oil cooler

pipe bracket (3) (3800 VIN K Only).
2. Upper pipe (856) and lower hose (857) to engine
clip (858) and pipe clip (859) (5.7L VIN P Only).
3. Fitting on transmission end of lower hose (857).
I~!
Tighten
Fitting on transmission end of lower hose

(857) to 27 N.m (20 lb. ft.).
4. Fitting on transmission end of upper pipe (856).
!~!
Tighten
Fitting on transm1ss1on end of upper pipe

(856) to 27 N.m (20 lb. ft.).
5. Raise the transmission.
SECTION 10-3.
856
856
856
857
858
859
860
861
862
PIPE, TRANSMISSION OIL COOLER UPPER

HOSE, TRANSMISSION OIL COOLER LOWER
CLIP, ENGINE
HOSE, TRANSMISSION OIL COOLER UPPER
RADIATOR
CLAMP, TRANSMISSION OIL COOLER UPPER HOSE
..
857
Figure 14 - Transmission Oil Cooler Pipes and Hose (5.7L VIN P)
__~
!VIEWA!
01-31-98
FS0127A

7.
8.
9.
10.
11.
Remove transmission stand.

Rear axle torque arm. Refer to SECTION 3D.
Transmission oil cooler upper hose clamp (862) to
upper hose (860) and pipe (856).
12. Fitting on radiator end of oil cooler lower hose
(857).
!~!
Tighten
Fitting on radiator end of oil cooler lower hose

(857) to 27 N.m (20 lb. ft.).
13. Lower vehicle.
OIL COOLER FLUSHING PROCEDURE

Figures 13 and 14
Tools Required:
J 35944 "Transmission" Oil Cooler and
Line Flusher
J 35944-20 Cooler Flushing Fluid
NOTICE: The automatic transmission oil

cooler flushing procedure must be performed
whenever a transmission is removed for service
to remove existing oil which may. be
contaminated and to prevent contamination of
new oil. The flushing procedure must be
performed before installation of the overhauled
or replacement transmission.
NOTICE: Flushing tool is designed for use
with only J 35944-20 flushing fluid. Use of any
other fluid can result in damage to the tool,
automatic transmission oil cooler components or
improper flushing of the cooler.
1. Remove fill cap on J 35944 and fill with 0.6 liters
(20 to 21 ounces) of J 35944-20.
Do not overfill tool.
Follow manufacturer's suggested procedures
for handling fluid.
2. Replace cap on J 35944 and pressurize to 550 to
700 kPa (80 to 100 psi).
NOTICE: Shop air supply must be equipped

with a water/oil filter and pressure should not
exceed 825 kPa (120 psi). Failure to use a
water/oil filter can allow residual moisture to
cause corrosion of components. Excessive air
pressure can cause damage to components.
3. Install J 35944 to undercarriage of vehicle with
hook provided, and attach hose from flushing tool
to upper pipe (856) attaching to top fitting at
transmission end of oil cooler.
4. Install discharge hose to lower hose (857)
attaching to bottom fitting at transmission end of
oil cooler. Clip opposite end of discharge hose to
oil drain container.
7A-17
5. With water valve on tool in "OFF" position,

attach water supply to J 35944.
6. Turn water supply on at faucet.
7. Flush transmission fluid by opening water valve
on tool to "ON" position for about 10 seconds.
If water does not flow through cooler (system
is completely plugged), do not complete
flushing procedure. Turn water off immediately
and inspect oil cooler and pipes for restriction.
Replace cooler and/or pipes as required.
8. Turn water valve on tool to "OFF" position and
clip discharge hose to 5-gallon pail. Cover pail
with shop cloth to prevent splash.
9. Turn water valve on tool to "ON" position and
depress trigger to mix flushing fluid into water
flow.
Use bale clip to hold trigger down.
10. Flush oil cooler with water and fluid for two
minutes.
Every 15 to 20 seconds during flushing
procedure, attach air supply to air valve on
J 35944 and leave in place for 3 to 5 seconds
to create surging action for complete cleaning.
11. Release trigger and turn water valve on tool to
"OFF" position.
12. Disconnect discharge hose from lower hose (857).
13. Install hose from J 35944 to lower hose (857)
attaching to bottom fitting of oil cooler.
14. Connect discharge hose to upper pipe (856)
attaching to top fitting of oil cooler.
Reversing hoses creates back-flush.
15. Repeat steps 9 and 10.
16. Release trigger and allow water only to rinse the
oil cooler for one minute.
17. Turn water valve on tool to "OFF" position and
turn water supply off at faucet.
18. Attach air supply to air valve on J 35944 and dry
system out with dry compressed air for at least
two minutes. Be sure no moisture can be seen
leaving hose.
19. Remove J 35944 and discharge hose from oil
cooler/hoses.
20. Connect oil cooler feed hose to automatic
transmission.
Feed hose is lower hose (857) attached to
bottom connection at transmission end of
system.
21. Attach discharge hose to oil cooler return pipe.
Return pipe is upper pipe (856) attached to top
connection at transmission end of system.
22. Attach opposite end of discharge hose to oil drain
container.
23. Fill automatic transmission with fluid.
24. Start engine and run for 30 seconds to remove
any residual moisture from cooler.
!L!
Inspect
A. Fluid flow through cooler feed lines during 30

second running period. Minimum of 1.8 liters
(2 quarts) of fluid should flow during this
time.
7A18
AUTOMATIC TRANSMISSION ONNEHICLE SERVICE
B. If fluid flow is insufficient, check flow by

disconnecting feed line at cooler and observe
flow with engine running at idle.
Insufficient . Flow: Inspect transmission for
causes.
Sufficient Flow: Inspect cooler pipes, hoses
and fittings and repeat cooler flushing
procedure. If the flow through cooler is still
insufficient after. second flushing procedure,
replace cooler.
25. Disconnect discharge. hose.
26. Connect oil cooler return pipe to fitting.
[lJ
Adjust
Transmission fluid level.
SERVICEABLE COMPONENTS
TRANSMISSION FLUID FILL TUBE
Figures 15 and 16
!+-+I
5.
6.
7.
8.
!-++!
Loosen tube (836) from transmission (838).

Place drain pan under transmission (838).
Lower vehicle.
Tube (836) and seal (901) from vehicle by pulling
out from top.
Install or Connect

1. Seal (901) and tube (836) through top of vehicle.
SECTION OA.
3. Insert seal (901) into automatic transmission case
hole.
4. Tube (836) to transmission (838).

5. Bolt/screw (835) attaching tube (836) to
transmission (838) (5.7L VIN P Only).
I~!
1. Indicator (837).
SECTION OA.
3. Bolt/screw (835) retaining tube (836) to
transmission (838) (5.7L VIN P Only).
4. Nut (7) retaining tube (836) to transmission (838)
(3800 VIN K Only).
Tighten

6. Nut (7) attching tube (836) to transmission (838)
(3800 VIN K Only).
I~!
Tighten
Nut (7) to 25 N;m (18 lb. ft.).

7. Lower vehicle.
8. Indicator (837).
"'
----.......-----~,.,....~
,.
7 NUT, TRANSMISSION FLUID FILLER TUBE
8 STUD, TRANSMISSION FLUID FILLER TUBE

836 TUBE, TRANSMISSION FLUID FILLER
901
SEAL, TRANSMISSION FLUID FILLER TUBE
836
!VIEW Bj
9-14-94
FS0317A
Figure 15 - Transmission Fluid Fill Tube (3800 VIN K)
835
836
837
838
901
BOLT/SCREW, TRANSMISSION
TUBE, TRANSMISSION FLUID FILLER
INDICATOR, TRANSMISSION FLUID LEVEL
SEAL, TRANSMISSION FLUID FILLER TUBE
835
7A-19
I....V-IE_W_B-,1
03.09.915
FT0137A
Figure 16 - Transmission Fluid Fill Tube (5.7L VIN P)
TRANSMISSION VENTILATION HOSE

Figure 17
!++!

SECTION OA.
2. Support transmission using transmission jack.

SECTION 10-3.
4. Lower transmission.
5. Ventilation hose (18) from transmission ventilation
tube (20) at transmission (838).
6. Ventilation hose clip (19) from transmission
support (850).
Squeeze clip tabs to remove from holes in

transmission support (850).
!++!
Install or Connect

SECTION 10-3.
6. Support from transmission.
7. Lower vehicle.
VEHICLE SPEED SENSOR (VSS)

Figure 18
i++I

SECTION OA.
2. Speed sensor electrical connector.
3. Speed sensor bolt/screw (100).
4. Speed sensor (99) and 0-ring seal (42).
Use suitable container to catch transmission
fluid.
l++I
Install or Connect
NOTICE:
NOTICE Refer to "Notice" on page 7A-1.
l. New ventilation hose clip (19) around ventilation

hose (18) 37 mm from end of hose.
2. Ventilation hose clip (19) into holes at rear side of
transmission support (850).
3. Ventilation hose (18) to transmission ventilation
tube (20) at transmission (838).
4. Raise transmission.
1. Speed sensor (99) with new 0-ring seal (42).

2. Speed sensor bolt/screw (100).
!~i
Tighten
Speed sensor bolt/screw (100) to 11 N,m

(97 lb. in.).
3. Speed sensor electrical connector.
4. Lower vehicle.
7A-20
20
(
18
IVIEWA r
18
18 HOSE, TRANSMISSION VENTILATION

19 CLIP, TRANSMISSION VENTILATION HOSE
20 TUBE, TRANSMISSION VENTILATION
838 TRANSMISSION, AUTOMATIC
850 SUPPORT, TRANSMISSION
jv1ewel
8-14-94
FS0327A
Figure 17 Transmission Ventilation Hose (Typical)

....--------,------,.------,
Refill with transmission fluid as required.
AUTOMATIC TRANSMISSION CASE

EXTENSION
Figure 19
I++!
99

SECTION OA.
3. Rear axle torque arm. Refer to SECTION 3D.
6. Extension (36), with seal (35).
42
SEAL, 0-RING (ITSS TO CASE

EXTENSION
99 SPEED SENSOR, INTERNAL
TRANSMISSION
100 BOLT/SCREW, SPEED
SENSOR RETAINING
!~!
Discard seal (35),.

7. Sleeve (690) and seal (691), if necessary.
!++!
Install or Connect
NOTICE:
1. Sleeve (690) and seal (691), if removed.

2. New seal (35) and extension (36).
4.
5.
6.
7.
0530815
FT0147A
Figure 18 - Vehicle Speed Sensor
Tighten

Lower vehicle.
2. Control valve, if removed. Refer to "Control

Valve Body and Pressure Switch" in this section.
3. 1-2 accumulator springs (59 and 59A), ring (60),
and piston (61).
.---------.
I
I
SOME MODELS
II 6916 9 0 ~ II
:
I
I..
_______
7A-21
If spring (59) is conical in shape, larger end is

installed in piston (61).
4. 1-2 accumulator cover and pin (62).
5. Bolts/screws (57 and 58) attaching 1-2
accumulator cover and pin (62) to transmission
case.
I
I
..I
!~I
Tighten
Bolts/sctews (57 and 58) to 11 N .m

(97 lb. in;).
6. Transmission oil pan and filter. Refer to
"Changing Transmission Fluid and Filter" in this
section.
37
2-4 BAND SERVO

35 SEAL, CASE EXTENSION TO CASE
36 EXTENSION, CASE
37 BOLT, CASE EXTENSION TO CASE
690 SLEEVE, OUTPUT SHAFT
691 SEAL, OUTPUT SHAFT
Figures 22 and 23
l++I
05-30-95
FT0157A
Figure 19 - Automatic Transmission Case Extension
ACCUMULATORS
Figures 20 and 21
I++!
2.
3.
4.
5.
6.
IL_.!

section.
Bolts/screws (57 and 58) attaching 1-2
accumulator cover and pin (62) to transmission
case.
1-2 accumulator cover and pin (62).
1-2 accumulator piston (61), ring (60), and springs
(59 and 59A).
Piston (61) and ring (60) may remain inside
cover and pin (62).
Control valve, if replacing 3-4 accumulator. Refer
to "Control Valve Body and Pressure Switch" in
this section.
3-4 accumulator piston (52), ring (53) and pin
(87).
Inspect
Accumulators. Refer to SECTION 7A-14B for

disassembly and inspection procedures.
!++!
Install or Connect
1. 3-4 accumulator piston (52), ring (53) and pin

(87).
Tool Required:
J 29714-A Servo Cover Depressor
SECTION OA.
2. 3-way (3800 VIN K) or oxidation (5.7L VIN P)
catalytic converter and catalytic converter hanger.
5. Support automatic transmission with transmission
stand.
6. Transmission support. Refer to SECTION 10-3.
7. Catalytic converter heat shield. Refer to
SECTION 6F.
8. Lower automatic transmission.
9. Two automatic transmission oil pan bolts/screws
from below servo cover (15).
10. Install J 29714-A on automatic transmission oil
pan rail.
11. Reinstall automatic transmission oil pan
bolts/screws.
12. Depress servo cover (15) and remove retaining
ring (13).
13. J 29714-A.
14. Servo cover (15).
If unable to remove by hand, use slip joint
pliers.
0-ring seal may remain in automatic
transmission case.
15. 2-4 band servo (16).
!l"'I
Inspect
2-4 band servo. Refer to SECTION 7A-14B for

disassembly and inspection procedures.
7A-22

100
10
~
~
32
57
33
29
3070
~68
.
80
71~
31
72
74
Figure 20 - Wiring Harness, Pressure Switch, Control Valve and Accumulators
10
21
22
23
24
25
26
27
28
29
30
31
32
33
35
36
37
38
39
42
43
52
53
54
56
57
58
59
59A
60
61
62
63
64
65
67
68
70
71
72
73
74
80
87
88
89
93
99
100
7 A-23
CASE, TRANSMISSION
RETAINER AND BALL, 3RD ACCUMULATOR
PIN, BAND ANCHOR
RETAINER AND BALL (DOUBLE ORIFICE)
NUMBER 10 CHECKBALL
SCREEN, SHIFT SOLENOID
SCREEN, PRESSURE CONTROL SOLENOID
CHECK BALL
SEAL, WIRING HARNESS PASS-THRU CONNECTOR 0-RING
SEAL, 0-RING (SOLENOID)
SOLT/SCREW, HEX WASHER HEAD (SOLENOID)
MAGNET, CHIP COLLECTOR
PLATE, SPACER PLATE SUPPORT
BOLT/SCREW, SPACER PLATE SUPPORT
SEAL, CASE EXTENSION TO CASE
EXTENSION CASE
SOLT/SCREW, CASE EXTENSION TO CASE
PLUG, TRANSMISSION CASE (ACCUMULATOR BLEED)
SEAL, CASE EXTENSION OIL
SEAL, 0-RING (ITSS TO CASE EXTENSION)
SOLT/SCREW, VALVE BODY
PISTON, 3-4 ACCUMULATOR
RING, OIL SEAL (3-4 ACCUMULATOR PISTON)
SPRING, 3-4 ACCUMULATOR
PLATE, VALVE BODY SPACER
SOLT/SCREW, ACCUMULATOR COVER
BOLT/SCREW, ACCUMULATOR COVER
SPRING, 1-2 ACCUMULATOR
SPRING, 1-2 ACCUMULATOR (INNER)
RING, OIL SEAL (1-2 ACCUMULATOR)
PISTON, 1-2 ACCUMULATOR
COVER AND PIN, 1-2 ACCUMULATOR
SPRING, MANUAL DETENT
BOLT/SCREW, MANUAL DETENT SPRING
SEAL, WIRING HARNESS PASS-THRU CONNECTOR 0-RING
VALVE, CONTROL BODY
SWITCH, TRANSMISSION PRESSURE
SEAL, FILTER
FILTER, TRANSMISSION OIL
GASKET, TRANSMISSION OIL PAN
PAN, TRANSMISSION OIL
BOLT/SCREW, TRANSMISSION OIL PAN
BOLT/SCREW, PRESSURE SWITCH
PIN, ACCUMULATOR PIN
GASKET, SPACER PLATE TO CASE
GASKET, SPACER TO PLATE VALVE BODY
BRACKET, DIPSTICK STOP
SENSOR, VEHICLE SPEED
BOLT/SCREW, VEHICLE SPEED SENSOR
06-02-16
FT0407A
Figure 21 - Wiring Harness, Pressure Switch, Control Valve and Accumulators - Legend
7A24
!H!
Install or Connect
NOTICE:
Refer to "Notice" on page 7A-L
1. 2-4 band servo (16).

2. Servo cover (15).
Replace 0-ring seal on servo cover (15).
3. Install J 29714-A on automatic transmission oil
pan rail.
4. Depress servo cover (15).
5. Retaining ring (13).
6. Remove J 29714-A.
!~!
Tighten
Automatic transmission oil pan bolts/screws to

12 N.m (9 lb. ft.).
7. Raise automatic transmission.
8. Catalytic converter heat shield. Refer to

SECTION 6F.
9. Transmission support. Refer to SECTION 10-3.
10. Remove tool supporting automatic transmission.
13. 3-way (3800 VIN K) or oxidation (5.7L VIN P)
catalytic converter and catalytic converter hanger.
14. Lower vehicle.
TRANSMISSION CONVERTER COVER

Figures 24 and 25 .
l+-+I

SECTION OA.
2. Starter motor shield and starter motor
(3800 VINK). Refer to SECTION 602.
3. Converter cover bolts/screws (840).
4. Converter cover (839) from automatic
trasmission (838).
!-++!
Install or Connect
NOTICE: Refer to "Notice" on page 7A-l.

1. Converter cover (839) to automatic transmission
(838).
2. Converter cover bolts/screws (840).
J 29714-A
13 RING, 2-4 BAND SERVO COVER RETAINING

15 COVER, 2-4 BAND SERVO
020115
F80177A
Figure 22 2-4 Band Servo Cover
840
15 COVER, 2-4 BAND SERVO

16 SERVO, 2-4 BAND

839 COVER, TRANSMISSION CONVERTER
840 SOLT/SCREW, TRANSMISSION CONVERTER COVER
02-0185
F80187A
Figure 23 - 2-4 Band Servo
02-01-95
F80117A
Figure 24 - Transmission Converter Cover (5. 7L VIN P)
219
7A-25
217
220
221
838
839
COVER, TRANSMISSION CONVERTER
BOLT/SCREW, TRANSMISSION CONVERTER COVER
840
9-14-94
FS0337A
Figure 25 - Transmission Converter Cover (3800 VIN K)
I~!
Tighten
Transmission converter cover bolts/screws

(840) to 10 N.m (89 lb. in.).
3. Starter motor and starter motor shield
(3800 VIN K). Refer to SECTION 6D2.
4. Lower vehicle.
PRESSURE REGULATOR VALVE

Figure 26
!++!
1. Automatic transmission oil pan. Refer to

section.
2. Compress TV (throttle valve) boost valve bushing
and related components (223 through 218) with
small screwdriver.
3. Retainer ring (224).
4. Slowly release spring pressure.
5. Regulator valve (218).
6. Spring (219).
7. Reverse boost valve (220) and bushing (221).
8. TV boost valve (222) and bushing (223).
217 PUMP, AUTOMATIC TRANSMISSION OIL

218 VALVE, PRESSURE REGULATOR
219 SPRING, PRESSURE REGULATOR VALVE
220 VAL VE, REVERSE BOOST
221 BUSHING, REVERSE BOOST VAL VE
222 VAL VE, TV BOOST
223 BUSHING, TV BOOST VAL VE
224 RING, TV BOOST VAL VE BUSHING
RETAINER
!L"'I
020Ml15
FS0207A
Figure 26 - Pressure Regulator Valve
Inspect
Pressure regulator valve. Refer to

SECTION 7A-14B for disassembly and inspection
procedures.
I++!
Install or Connect
1. Regulator valve (218) into pump cover bore.

2. Spring (219).
3. Reverse boost valve (220) into bushing (221).
Small end first. Retain with Transjel, TM or

equivalent.
4. Bushing (221) with reverse boost valve (220) into
pump cover bore.
5. TV boost valve (222) into bushing (223).
6.
7.
8.
9.
Insert long land of TV boost valve (222) into

largest hole of bushing (223). Retain with
Transjel, or equivalent.
Bushing (223) with TV boost valve (222) into
pump cover bore.
Compress TV boost valve bushing and related
components (223 through 218).
Retainer ring (224).
Automatic transmission oil pan. Refer to "Changing
Transmission Fluid and Filter" in this section.
7A26
CONTROL VALVE BODY AND PRESSURE

SWITCH
Figures 20, 21, 27 through 30
!+-+I
!L!
Control valve body (67). Refer to

SECTION 7A-14B for cleaning, inspection and
repair of the control valve body.
!++!

section.
2. Electrical connectors from control valve body
components.
3. Torque converter clutch (TCC) solenoid
bolts/screws and solenoid with 0-ring seal.
4. Wiring harness bolts/screws and lay wiring
harness aside.
5. Bolts/screws (80) and pressure switch (68).
6. Bolt/screw (64) arid manual detent spring (63).
7. Remaining control valve body bolts/screws.
8. Manual valve link.
9. Control valve body (67).
Inspect
Install or Connect
NOTICE: Install all valve body bolts/screws

then torque in a spiral pattern starting from the
center (see Figure 28). If bolts/screws are
torqued at random, valve bores may be distorted
and inhibit valve operation.
1. Control valve body (67) and manual valve link to
transmission case (10).
2. Control valve body bolts/screws (43).
3. Manual detent spring (63) and bolt/screw (64).
4. Pressure switch (68) and bolts/screws (80).
5. Wiring harness and wiring harness bolts/screws.
6. TCC solenoid, 0-ring seal and bolts/screws.
84
86
81
82
83
84
85
86
SOLENOID, SHIFT
~5
RETAINER, PRESSURE CONTROL SOLENOID
~
SOLENOID, PRESSURE CONTROL
BOLT/SCREW, PRESSURE CONTROL SOLENOID RETAINER
RETAINER, SOLENOID
SOLENOID, 3-2 CONTROL
Figure 27 Control and Shift Solenoids
052091
FT0217A
7A-27
A MG X 1.0 X 65.0
B MG X 1 0 X 54.4
C M6X1.0X475
D MG X 1.0 X 18 0
E MG X 1.0 X 35.0
F M8 X 1.25 X 20.0
G MG X 1.0 X 12 0
62
68
93
364
379
396
935
939
942
BOLT/SCREW, VALVE BODY

SOLT/SCREW, HEX WASHER HEAD (SOLENOID)
BRACKET, DIPSTICK STOP
SOLT/SCREW, FORWARD ACCUMULATOR COVER
RETAINER, SOLENOID
TCC PWM SOLENOID
SOLT/SCREW, ACCUMULATOR COVER
SOLT /SCREW, MANUAL DETENT SPRING
SOLT/SCREW, PRESSURE SWITCH
032396
FT0377A
!~I
Figure 28 Valve Body Bolt Locations
Tighten
All bolts/screws in the pattern shown in

Figure 28 to 11 N,m (97 lb. in.).
section.
020196
FS0227A
Figure 29 Valve Body Bolt/Screw Tightening Pattern
6. TCC Solenoid bolts and solenoid with 0-ring seal

and wiring harness.
7. Pressure control solenoid retainer bolt/screw,
retainer and solenoid.
8. Solenoid retainers (82) and shift solenoids (83).
9. Control solenoid retainer (85) and 3-2 control
solenoid (86).
10. Dipstick stop bracket (93).
I++!
1.
2.
3.
4.
CONTROL AND SHIFT SOLENOIDS

5.
l++I
6.
2.
3.
4.
5.

section.
Accumulator cover bolts/screws (57 and 58).
1-2 accumulator cover (62), piston (61) and
springs (59 and 59A).
Component electrical connectors.
TCC PWM Solenoid Retainer Clip (379) and
Solenoid (396).
7.
8.
9.
10.
Install or Connect
Dipstick stop bracket (93).
3-2 control solenoid (86) and retainer (85).
Shift solenoids (81) and retainers (85).
Pressure control solenoid (83), retainer (82) and
retainer bolt/screw (84).
Position pressure control solenoid with the
electrical tabs facing outboard.
TCC Solenoid bolts and solenoid with 0-ring seal
and wiring harness.
TCC PWM Solenoid Retainer Clip (379) and
Solenoid (396).
Component electrical connectors.
1-2 accumulator piston (61) to the accumulator
cover (62).
Piston legs must face toward the case when
installed.
1-2 accumulator springs (59 and 59A) onto piston
(61).
1-2 accumulator cover (62) and accumulator cover
bolts/screws (57 and 58).
7A-28
!~!

Tighten
Bolts/screws (57 and 58) to 11 N.m

(97 lb. in.).
section.
TORQUE CONVERTER CLUTCH

SOLENOID AND WIRING HARNESS
REPLACEMENT
Tool Required:
J 8458 Power Piston Seal Protector and
Diaphragm Retainer Installer
!++!
1. Exhaust system. Refer to SECTION 6F.

section.
3. External wiring harness connector from
transmission pass-through connector.
Squeeze fore and aft flats on connector to
release locking tabs and pull connector.
4. 1-2 accumulator cover bolts/screws (57 and 58).
5. 1-2 accumulator cover (62), piston (61) and
springs (59 and 59A).
6. Component electrical connectors.
7. Pressure control solenoid retainer bolt/screw (84),
retainer (82) and solenoid (83).
8. TCC solenoid bolts/screws.
9. Pass-through electrical connector from
transmission case.
Use small end of J 28458 over top of
connector and twist to release four tabs while
at the same time pulling harness connector
from the transmission case.
10. TCC solenoid with wiring harness from
transmission case.
!++!
Install or Connect
1. TCC solenoid with wiring harness to transmission

case.
2. Pass-through electrical connector to transmission
case.
3. TCC solenoid bolts/screws.
4. Pressure control solenoid (83), retainer (82) and
bolt/screw (84).
!~!
6. 1-2 accumulator piston (61) to 1-2 accumulator

cover (62).
Piston legs must face toward the case when
installed.
7. 1-2 accumulator springs (59 and 59A) onto piston
(61).
8. 1-2 accumulator cover (62) and accumulator cover
bolts/screws (57 and 58).
!~!
Tighten
Bolts/screws (57 and 58) to 11 N,m

(97 lb. in.).
9. Wiring harness connector to transmission
pass-through connector.
section.
11. Exhaust system. Refer to SECTION 6F.
ELECTRICAL CONNECTOR AND SEAL
!++!

section.
2. Internal and external electrical wires from
electrical connections.
3. Electrical connector and seal from automatic
transmission.
4. Seal from electrical connector.
Discard old seal.
!L!
Inspect
Automatic transmission sealing surface for

damage or corrosion.
j++!
Install or Connect
1. New seal to electrical connector.

2. Electrical connector and new seal to automatic
transmission.
3. Internal and external electrical wires to electrical
connectors.
section.
CASE EXTENSION OIL SEAL

Figu~s 20 and 21
Tools Required:
J 21426 Extension Housing Seal Installer
J 8092 Universal Driver Handle
Tighten
TCC solenoid bolts/screws to 11 N.m

(97 lb. in.).
Pressure control solenoid bolt/screw (84) to
11 N,m (97 lb. in.).
5. Component electrical connectors.
!++I

2. Oil seal (39) with screwdriver.
lH!
Install or Connect
1. Oil seal (39). Tap into place with J 21426 and

J 8092.

lL1'!
Inspect
Automatic transmission fluid level.
Figures 24, 25 and 32 through 36
A pressure test should be performed before
automatic transmission removal to aid in diagnosis.
NOTICE: Transmission oil cooler flushing

must be performed when an automatic
transmission is removed for service. The
flushing procedure should be performed after
the installation of the overhauled or replacement
transmission. Failure to flush the system may
cause damage to the system and its components.
!++!
)
Tools Required:
J 21426 Output Shaft Sleeve and Case
Extension Oil Seal Installer
J 8092 Universal Driver Handle

Cable' in SECTION OA.
SECTION OA.
3. Mark position of propeller shaft to pinion yoke.
5. Support transmission (838).
6. Washer (853) and nut (852) from support (850)
and transmission (838).
7. Bolts/screws (854) from support (850) and rail
(846).
8. Support (850) from transmission (838) and rail
(846).
9. Support rear axle.
11. Starter motor shield and starter (3800 VIN K).
Refer to SECTION 6D2.
12. Loosen right side rear engine mount bracket
bolt/screw (17). (3800 VIN K).
13. Bolts/screws (9 and 11) from left and right
transmission support braces and braces from
vehicle. (3800 VIN K).
7 A-29

15. Bolts/screws (840) from cover (839).
16. Cover (839) from transmission (838).
17. Bolts/screws (842) from converter (1 ).
18. Flywheel (841) from converter (1).
19. Move catalytic converter heat shield as necessary.
20. Automatic transmission range selector lever cable.
Refer to "Automatic Transmission Range Selector
Lever Cable" in this section.
21. Transmission oil cooler pipes from transmission
oil cooler pipe clips.
22. Electrical connectors at transmission (838).
23. Bolts/screws (843 or 845).
24. Transmission fluid level indicator.
25. Separate transmission (838) from engine (844).
26. Transmission oil cooler lines.
27. Lower transmission (838) from vehide.
!H!
Install or Connect
NOTICE:
1.
2.
3.
4.
5.
Raise transmission (838) into vehicle.

Transmission oil cooler lines.
Align transmission (838) to engine (844).
Transmission fluid level indicator.
Bolts/screws (843 or 845).
!~!
6.
7.
8.
9.
10.
11.
Tighten

Electrical connectors to. transmission (838).
Transmission oil cooler pipe and hoses to
transmission oil cooler pipe clips.
Automatic transmission range selector lever cable.
Reposition catalytic converter heat shield. Refer to
SECTION 6F.
Flywheel (841) to converter (1).
Bolts/screws (842) to converter (1).
!~!
Tighten

12. Converter cover (839) to transmission (838).
13. Bolts/screws (840) to cover (839).
I~!
Tighten

14. Bolts/screws (9 and 11) to left and right
transmission support braces. (3800 VIN K).
7A-30
(
PRESSURE CONTROL SOLENOID
OUTPUT SPEED SENSOR
(OR VEHICLE SPEED SENSOR)
TORQUE
CONVERTER CLUTCH
SOLENOID
TORQUE
CONVERTER CLUTCH PWM
SOLENOID
1-2 AND 2-3
SHIFT SOLENOID
3-2 CONTROL SOLENOID
TRANSMISSION FLUID
PRESSURE SWITCH
052085
FT0237A
Figure 30 Electronic Component Location Views
7A-31
703
709
340
340
703
705
709
VAL VE. MANUAL

LEVER, MANUAL SHIFT DETENT
LINK, MANUAL VALVE
DETENT, MANUAL SHIFT
~ ...
02018S
FS0247A
Figure 31 Manual Shift Detent
838
846
850
852
853
854
SUPPORT, TRANSMISSION
NUT, TRANSMISSION MOUNT
WASHER, TRANSMISSION MOUNT
BOLT/SCREW, TRANSMISSION SUPPORT
020195
FS0217A
Figure 33 Automatic Transmission Mounting
20. Bolts/screws (854) to support (850) and rail (846).

21. Support from rear axle.
22. Washer (853) and nut (852) to support (850) and
transmission (838).
1 CONVERTER.TORQUE
841 FLYWHEEL
842 BOLT/SCREW, TRANSMISSION TORQUE CONVERTER
020195
FS0257A
!~!
Figure 32 Torque Converter-to-Flywheel
Tighten

15. Tighten right side rear engine mount bracket
bolt/screw (17). (3800 VIN K).
!~!
16.
17.
18.
19.
Tighten
Tighten right side rear engine mount bracket

bolt/screw (17) to 50 N,m (37 lb. ft.).
Starter motor and starter motor shield
(3800 VIN K). Refer to SECTION 602.
Support (850) to transmission (838) and rail
(846).
!~I
Tighten
Nut (852) to 47 N.m (35 lb. ft.).

23. Remove support from transmission (838).
24. Propeller shaft, using marks made during removal.
25. Lower vehicle.
Clean
NOTICE: Transmission oil cooler flushing

must be performed when a transmission is
removed for service. The flushing procedure
should be performed after the installation of the
overhauled or replacement. Failure to flush the
system may cause damage to the system and its
components.
Transmission oil cooler and oil cooler pipe and
hoses. Refer to "Oil Cooler Flushing Procedure"
in this section.
7A-32
(
9
12
11
A
B
6
9
LEFT SIDE
RIGHT SIDE
BOLT/SCREW, TRANSMISSION BRACE
11
12
14
17
17
BOLT/SCREW, TRANSMISSION BRACE

BRACE, TRANSMISSION LEFT SIDE
BRACE, TRANSMISSION RIGHT SIDE
9-14-IM
FS0347A
Figure 34 Transmission Support Braces (3800 VIN K)
(
843
18 HARNESS, WIRING
19 NUT, TRANSMISSION
20. BOLT/SCREW, TRANSMISSION
843 BOLT/SCREW. TRANSMISSION
041885
FS0397A
Figure 35 Automatic Transmission-to-Engine

(3800 VIN K)
[lJ

843 BOLT/SCREW, TRANSMISSION
844 ENGINE
Adjust
Automatic transmission shift control lever cable.

0201-95
FS0277A
Figure 36 Automatic Transmission-to-Engine (5.7L VIN P)

Transmission fluid level.
7 A-33
SPECIFICATIONS
Accumulator Cover Bolt/Screw ............................................................................................... 11 N.m (97 lb. in.)
Control Valve Body Bolt/Screw .............................................................................................. 11 N.m (97 lb. in.)
Engine Mount Bracket Bolt/Screw ............................................................... ;......................... 50 N.m (37 lb. ft.)
Manual Shift Detent Bolt/Screw ............................................................................................. 22 N.m (16 lb. ft.)
Park/Neutral Position Switch Bolt/Screw .............................................................................. 2.2 N.m (19 lb. in.)
Pressure Control Solenoid Retainer Bolt/Screw ...................................................... ;.............. 11 N.m (97 lb. in.)
Spacer Plate Support Bolt/Screw ............................................................................................ 11 N.m (97 lb. in.)
Special Hex Washer Head Bolt (M6X1X16) ......................................................................... 11 N.m (97 lb. in.)
TCC Solenoid Valve Bolt/Screw ............................................................................................. 11 N.m (97 lb. in.)
Transmission Bolt/Screw (3800 VIN K) ................................................................................ 95 N.m (70 lb. ft.)
Transmission Bolt/Screw (5.7L VIN P) .................................................................................. 47 N.m (35 lb. ft.)
Transmission Case Extension Bolt/Screw ............................................................................... 35 N.m (26 lb. ft.)
Transmission Control Bolt/Screw ........................................................................................... 4.5 N.m (40 lb. in.)
Transmission Converter Cover Bolt/Screw ............................................................................. 10 N.m (89 lb. in.)
Transmission Fluid Fill Tube Nut (3800 VIN K) ................................................................. 25 N.m (18 lb. ft.)
Transmission Mount Nut. ........................................................................................................ 47 N.m (35 lb. ft.)
Transmission Oil Cooler Pipe and Hose Fittings .................................................................. 27 N.m (20 lb. ft.)
Transmission Oil Pan Bolt/Screw ............................................................................................. 12 N,m (9 lb. ft.)
Transmission Range Selector Lever Cable Bracket Bolt/Screw ............................................ 24 N.m (18 lb. ft.)
Transmission Range Selector Lever Nut. ............................................................................... 20 N.m (15 lb. ft.)
Transmission Support Brace-to-Engine Bolt/Screw ................................................................ 28 N.m (21 lb. ft.)
Transmission Support Brace-to-Transmission Bolt/Screw ...................................................... 50 N.m (37 lb. ft.)
Transmission Torque Converter Bolt/Screw ........................................................................... 63 N.m (46 lb. ft.)
Vehicle Speed Sensor Bolt/Screw ............................................................................................ ]J N.m (97 lb. in.)
Vehicle Speed Sensor Retaining Bolt/Screw .......................................................................... 10 N.m (89 lb. in.)
7A-34
SPECIAL TOOLS
(
J 21366
J 36850
J 35944-20
J 29714-A
6
CID
J 28458
@)=n
J 21426
CONVERTER HOLDING STRAP

2
TRANSMISSION LUBRICANT (TRANSJEL l
SERVO COVER DEPRESSOR
OIL COOLER AND LINE FLUSHER
COOLER FLUSHING FLUID (1 GALLON)
POWER PISTON SEAL PROTECTOR AND DIAPHRAGM

RETAINER INSTALLER
CASE EXTENSION OIL SEAL INSTALLER
02-01-85
FS0287A
MANUAL TRANSMISSION ON-VEHICLE SERVICE RPO MM6 AND M49
78-1
SECTION 78
MANUAL TRANSMISSION
ON~VEHICLE SERVICE
RPO MM6 AND. M49
exact part number for that application. General Motors will call out those fasteners that. require a replacement
after removal. General Motors will . also call out the fasteners that require thread lockers or thread sealant.
tightening sequence and specifications. Following these instructions can help you avoid damage to parts ~d
systems.
CONTENTS

5-Speed Manual Transmission (RPO M49) ....... 7B-1
6-Speed Manual Transmission (RPO MM6) ..... 7B-1
Diagnosis .................................................................. 7B-2
Checking Manual Transmission Fluid Level.. ... 7B-4
Transmission Support and Transmission
Mount. .............................................................. 7B-4
Manual Transmission Control Lever Boot. ........ 7B-4
Manual Transmission Control (5-Speed) ............ 7B-6
Manual Transmission Control Lever Handle
(6-Speed) .......................................................... 7B-7
Manual Transmission Control (6-Speed) ............ 7B-8
.Output Shaft Seal ................................................ 7B-8
Backup Lamp Switch ....................................... 7B-9

Speed Sensor (5-Speed) .................................... 7B-11
Electronic Speed Sensor (6-Speed) .................. 7B-11
Reverse Lockout Solenoid (6-Speed) ............... 7B-11
Reverse Lockout (6-Speed) ............................... 7B-14
Skip Shift Solenoid (6-Speed) .......................... 7B-14
5-Speed Manual Transmission
(RPO M49) .................................................... 7B-14

(RPO MM6) .................................................. 7B-16
Special Tools ......................................................... 7B-18
GENERAL DESCRIPTION
with friction material. The fifth gear blocker ring is

brass.
The 5-speed manual transmission (RPO M49) is

the only manual transmission available for the 3800
VIN K V6 engine. The 6-speed manual transmission
(RPO MM6) is available for the 5.7L VIN P VS
engine. Manual transmissions are identified by the
number of forward gears and the measured distance
between the centerline of the output shaft and the
counter gear.
NOTICE: No lubricant other than

DEXRON-III GM PIN 12346143 should be
used in this manual transmission. Other
lubricants or additives may damage the blocker
ring friction material or its adhesive.
5-SPEED MANUAL TRANSMISSION

(RPO M49)
The 5-speed 77 mm manual transmission is a
fully synchronized unit with blocker ring synchronizers
and a sliding mesh reverse gear. First and second gears
have three-piece synchronizer rings, consisting of steel
inner and outer cones and a tapered metal ring that is
lined on both sides with friction material similar to
automatic transmission friction plates. The cones are
independent of the gears and can be replaced
separately. Third and fourth gear blocker rings are
more conventional in appearance, but are also lined
The mainshaft and countershaft are supported on

tapered roller bearings and must be shimmed for
proper end. play. First through fourth speed mainshaft
gears ride on caged roller bearings. An aluminum
transmission case houses the various gears and
bearings. The manual transmission control is mounted
on top of the extension housing. The manual
transmission control cannot be adjusted and can be
serviced independently of the manual transmission.
6-SPEED MANUAL TRANSMISSION (RPO

MM6)
The 6-speed 85 mm manual transmission is a
fully synchronized unit with blocker ring synchronizers
and sliding mesh reverse gears.
78-2
NOTICE: No lubricant other than

DEXRON-III GM PIN 12346143 should be
The 6-speed manual transmission has a reverse
lockout solenoid, which operates a reverse lockout to
prevent the operator from accidentally shifting into
reverse when the vehicle is moving forward at a speed
of 5 km/h (3 mph) or more.
The 6-speed manual transmission is equipped
with a skip shift solenoid. This is to ensure good fuel
economy and compliance with federal fuel economy
standards. When shifting out of first gear, second and
third gears are inhibited by the use of an electric
solenoid. The following conditions must be present for
this to occur:
Coolant temperature is above 77C (162F).
Vehicle speed is between 24 and 29 km/h (15 and
21 mph).
Throttle is opened 35 percent or less.
The 6-speed manual transmission also utilizes an

electronic speed sensor.
Each forward gear synchronizer is made up of a
splined hub with three synchronizer keys, a sleeve,
and two synchronizer springs. The reverse
synchronizer has a splined hub with three synchronizer
keys, a sleeve, two synchronizer springs, and a reverse
synchronizer retainer.
The mainshaft and countershaft are supported on
tapered roller bearings. All speed gears ride on caged
roller bearings; An aluminum transmission case houses
the various gears and bearings.
Like the 5-speed manual transmission, the
6-speed manual transmission control is mounted on
top of the extension housing, and can be serviced
independently of the manual transmission. The manual
transmission control cannot be adjusted. Unlike the
5-speed manual transmission, the manual transmission
control lev.er handle on the 6-speed manual
transmission can be removed from the manual
transmission control. This allows for removal of the
6-speed manual transmission with the manual
transmission control intact.
DIAGNOSIS
For diagnosis of the 5-speed 77 mm manual transmission or the 6~speed 85 mm. manual transmission refer to
the following diagnosis chart.
CONDITION
Transmission Shifts Hard
POSSIBLE CAUSE
1. Incorrect clutch travel.
2. Misaligned clutch housing bore to
crankshaft .pilot.
3. Binding shift rail.
CORRECTION
1. Refer to SECTION 7C.
2. Check alignment as necessary.
1. No power to reverse lockout

solenoid.
1. Turn ignition switch to "RUN"

position and check for voltage (12
volts) at the reverse lockout.
3. 5-Speed Manual Transmission Remove transmission cover and check

for mispositioned selector arm roll pin,
loose cover bolts, worn shift rail bores,
worn shift rail, distorted oil seal, or
extension housing not aligned with
case. Replace worn. or damaged
components as necessary.
6-Speed Manual Transmission Remove, disassemble and inspect
transmission. Check for worn. shift
bores; worn shift rail or worn shift rail
bushings. Replace worn or damaged
components as necessary.
4. Internal bind in transmission caused 4. Remove, disassemble and inspect
by shift forks, selector plates, or
manual transmission. Replace worn or
damaged components as necessary.
synchronizers.
5. Incorrect lubricant.
5. Drain and refill manual
transmission.
Manual Transmission Shifts Hard

Into Reverse or Does Not Shift
Into Reverse (6-Speed Manual
Transmission)
MANUAL TRANSMISSION ON-VEHICLE SERVICE RPO MM6 AND M49 783

CONDITION
Gear Clash When Shifting From

One Gear to Another
Noisy Transmission
POSSIBLE CAUSE
2. Remove and check function of

reverse lockout. Replace worn or
damaged parts as necessary.
3. Worn or broken shift linkage

components. Worn or damaged
synchronizer sleeve or hub.
3. Remove, disassemble, and inspect

1. Incorrect clutch travel.
1. Refer to SECTION 7C.
2. Low lubricant level or incorrect

lubricant.

transmission. If lubricant level was
low, check for leaks and repair as
necessary.
3. Worn or damaged control or

synchronizers.
3. Remove, disassemble and inspect

1. Low lubricant level or incorrect

lubricant.

transmission. If lubricant level was
low, check for leaks and repair as
necessary.
2. Loose clutch housing-to-engine, or

transmission-to-clutch, housing bolts.
2. Check for correct bolt torque and

torque as necessary.
3. Check alignment.
3. Misaligned clutch housing bore to

crankshaft pilot.
4. Worn or damaged control,
transmission gears, or bearing
components.
)
Jumps Out of Gear
Will Not Shift Into One Gear
Locked In One Gear, Cannot Be

Shifted Out
CORRECTION
2. Damaged reverse lockout solenoid.

Worn or broken reverse lockout
mechanism.

1. Worn offset lever plastic insert or

loose lever.
1. Remove control and check for loose

offset lever or worn insert. Replace
worn or damaged components as
necessary..
2. Worn or damaged control, shift

forks, selector plates, interlock plate,
selector arm, shift rail, springs or
shift cover.

manual trans.mission. Replace worn or
3. Worn or tapered gear teeth, worn

or damaged synchronizers, excessive
end play caused by worn thrust
washers or output shaft gears.

1. Worn, damaged, or incorrectly

assembled control, selector plates,
interlock plate, or selector arm.

2. Damaged or worn synchronizer

sleeves or hubs.
2'. Remove, disassemble, and inspect

1. Worn or broken shift rail(s). Bent

or damaged shift fork.

2. Worn control. Incorrectly assembled 2. Remove, disassemble, and inspect

or broken shift mechanism. Worn or
damaged gear train components.
damaged parts or assemble correctly.
78-4
ON-VEHICLE SERVICE
CHECKING MANUAL TRANSMISSION
FLUID LEVEL
l++j

Figure 1
!++I

SECTION OA.
~ Clean
All dirt and oil from around fill plug
(10 or 11).
Fill plug (11) is located on right side of

5-speed manual transmission.
- Fill plug (10) is located on left side of
2. Fill plug (10 or 11).
3. Fluid level should be even with bottom of fill
plug hole.
l++I
Install or Connect
NOTICE:
No lubricant other than

DEXRON-III GM PIN 12346143, should be
NOTICE:
1. Lubricant, if required.
2. Fill plug (10 or 11).
l~J
Tighten
Fill plug (11) on 5-speed manual transmission

to 27 N.m (20 lb. ft.).
Fill plug (10) on 6-speed manual transmission
to 27 N.m (20 lb. ft.).
3. Lower vehicle.

SECTION OA.
3. Support manual transmission O or 2) with
transmission stand.
4. Transmission mount nut (16) and washer (17)
from transmission mount (13).
5. Transmission support bolts/screws (15) from rail.
6. Transmission support (14).
7. Transmission mount bolts/screws (18) from
manual transmission (1 or 2).
8. Transmission mount (13).
!++!
Install or Connect
NOTICE:
1. Transmission mount (13) to manual transmission

(1 or 2).
2. Transmission mount bolts/screws (18).
I~!
Tighten
Transmission mount bolts/screws (18) to

48 N.m (36 lb. ft.).
3. Transmission support (14) to rails.
4. Transmission support bolts/screws (15).
I~!
Tighten
Transmission support bolts/screws (15) to

57 N.m (43 lb. ft.).
5. Transmission mount washer (17) and nut (16).
l~I
Tighten
Transmission mount nut (16) to 57 N.m

(43 lb. ft.).
6. Remove transmission stand supporting manual
transmission (1 or 2).
7. Lower vehicle.
TRANSMISSION SUPPORT AND

TRANSMISSION .MOUNT
MANUAL TRANSMISSION CONTROL

LEVER BOOT
Figure 2
Figures 3 and 4
The transmission mount for the 5-speed manual

transmission is similar to the transmission mount for
the 6-speed manual transmission. The difference
between the two mounts is the shape. The removal
and installation procedure for the two different mounts
will be the same.
!++!

SECTION 8C.
2. Handle bolts/screws (27), for 6-speed manual
transmission.
MANUAL TRANSMISSION ON-VEHICLE SERVICE RPO MM6 AND M49 78-5
\)
12
10
55
A 6-SPEED MANUAL TRANSMISSION COMPONENT

LOCATIONS
B 5-SPEED MANUAL TRANSMISSION COMPONENT
LOCATIONS
1 TRANSMISSION, 6-SPEED MANUAL
2 TRANSMISSION, 5-SPEED MANUAL
3 SWITCH, BACKUP LAMP (6-SPEED)
4 SWITCH, BACKUP LAMP (5-SPEED)
5 PLUG, TRANSMISSION OIL DRAIN (6-SPEED)
6 PLUG, TRANSMISSION OIL DRAIN (5-SPEED)
7 SOLENOID, REVERSE LOCKOUT (6-SPEED)
8 LOCKOUT, REVERSE (6-SPEEDl
9 SENSOR, ELECTRONIC SPEED (6-SPEED)
10 PLUG, TRANSMISSION OIL FILL (6-SPEED)
11 PLUG, TRANSMISSION OIL FILL (5-SPEED)
12 SENSOR, SPEED (5-SPEED)
55 SOLENOID, SKIP SHIFT (6-SPEED)
01-21-95
FS0017B
Figure 1 - Manual Transmission Component Locations
78-6
MANUAL TRANSMISSION ON-VEHICLE. SERVICE RPO MM6 AND M49
1
2
13
14
15
16
17
18
TRANSMISSION, 6-SPEED MANUAL

TRANSMISSION, 5-SPEEO MANUAL
MOUNT, TRANSMISSION
SUPPORT, TRANSMISSION
SOLT/SCREW, TRANSMISSION SUPPORT
NUT, TRANSMISSION MOUNT
WASHER, TRANS.MISSION MOUNT
BOLT/SCREW, TRANSMISSION MOUNT
17--?
14
16
~15
(
02-08-95
F80027B
Figure 2 - Transmission Support and Transmission Mount (Typical)
3. Handle (26), for 6-speed manual transmission.

4. Boot bolts/screws (22 or 23).
5. Boot (24 or 25) from front compartment floor pan
(44 or 51).
!++I
Install or Connect

1. Boot (24 or 25) to front compartment floor pan
(44 or 51).
2. Boot bolts/screws (22 or 23).
!~!
Tighten
Boot bolts/screws (22 or 23) to 1.7 N-m

(15 lb. in.).
3. Handle (26) to control (20).
4. Handle bolts/screws (27).
!~I
Tighten
Handle bolts/screws (27) to 25 N .m

(18 lb. ft.).
SECTION 8C.

(5-SPEED)
Figure 3
l++j
Remove or .Disconnect

SECTION 8C.
2. Boot bolts/screws (23).
3. Boot (24).
4. Transmission control bolts/screws (19).
5. Control (21).
24
19
21
2
19
21
23

BOLT/SCREW, TRANSMISSION CONTROL
CONTROL, MANUAL TRANSMISSION
BOLT/SCREW, MANUAL TRANSMISSION CONTROL
LEVER BOOT
24 BOOT, MANUAL TRANSMISSION
CONTROL LEVER
51 PAN, FRONT COMPARTMENT FLOOR
012895
FS0037B
Figure 3 Manual Transmission Control Lever Boot (5-Speed)
NOTICE: The upper and lower transmission

control levers are bonded together. Separation of
the levers will cause damage, requiring
replacement of the transmission control.
!++I
Install or Connect
!~I
Transmission control bolts/screws (19) to

17 N.m (13 lb. ft.).
4. Boot (24).
I~!
NOTICE:
Ill Clean
Sealant from manual transmission extension
housing.
Sealant from control (21), if reinstalling.
1. Apply a continuous 3 mm (1/S-inch) bead of RTV
Sealant GM PIN 12345739, or equivalent to
manual transmission extension housing-to-control
sealing surface.
2. Control (21).
Tighten
Tighten
Boot bolts/screws (23) to 1.7 N.m (15 lb. in.).

SECTION SC.

LEVER HANDLE (6-SPEED)
Figure 4
!++I

SECTION SC.
788
2. Control lever handle bolts/screws (27).

3. Control lever handle (26).
l++I
Install or Connect
NOTICE:
1. Control lever handle (26).

2. Control lever handle bolts/screws (27).
I~!
Tighten
Control lever handle bolts/screws (27) to

25 N,m (18 lb. ft.).
SECTION 8C.

(6-SPEED)
Figure 4
l++I

SECTION 8C.
3. Handle (26).
5. Boot (25).
7. Control (20).
I++!
Install or Connect
NOTICE:
Clean

housing.
1. Apply a continuous 3 mm (1/8-inch) bead of RTV
sealing surface.
2. Control (20).
l~I
Tighten

18 N,m (13 lb. ft.).
4. Boot (25).
A REMOVAL OF 6-SPEED MANUAL TRANSMISSION

CONTROL LEVER BOOT
8 REMOVAL OF 6-SPEED MANUAL TRANSMISSION
CONTROL LEVER HANDLE
20 CONTROL, MANUAL TRANSMISSION (6-SPEED)
22 SOLT/SCREW, MANUAL TRANMISSION CONTROL
LEVER BOOT
25 BOOT, MANUAL TRANSMISSION CONTROL LEVER
26 HANDLE, MANUAL TRANSMISSION CONTROL LEVER
27 BOLT/SCREW, MANUAL TRANSMISSION CONTROL
LEVER HANDLE
44 PAN, FRONT COMPARTMENT FLOOR
52 SOLT/SCREW, TRANSMISSION CONTROL
02-06-95
FS0047B
Figure 4 - Manual Transmission Control, Handle, and Boot

(6-Speed)
!~! Tighten
Boot bolts/screws (22) to 1.7 N,m (15 lb. in.).
6. Handle (26) to control (20).
!~! Tighten
Handle bolts/screws (27) to 25 N,m (18 lb. ft.).
SECTION 8C.
OUTPUT SHAFT SEAL

The output shaft seal for the 5-speed manual
transmission is similar to the output shaft seal for the
6-speed manual transmission. While there are
differences in the design, the removal and installation
procedures for the two different output shaft seals is
essentially the same. The only difference is the
installation tool used to install the different seals.

Figures 5 and 6
BACKUP LAMP SWITCH
Tools Required:
J 23907 Slide Hammer
J 26941 Extension Housing Seal Remover
J 21426 Extension Housing Seal Installer,
J 39440 Extension Housing Seal Installer,
!++!
Install or Connect
NOTICE:
1. Output shaft seal (28 or 29), using J 21426 for

5-speed manual transmission, or J 39440 for

2. Lubricate inside diameter of output shaft seal
(28 or 29) with transmission fluid.
!L"!
The backup lamp switch is located on the

left-hand side of the 5-speed manual transmission,
while the backup lamp switch on the 6-speed manual
transmission is located on the right-hand side.
Figures 7 and 8
l++l

2. Output shaft seal (28 or 29) using J 26941 with
J 23907.
!++!
78-9

SECTION OA.
3. Electrical connector from backup lamp switch
(3 or 4).
4. Backup lamp switch (3 or 4) from manual
i++I
Install or Connect
NOTICE:
Inspect
Manual transmission fluid level. Refer to

"Checking Manual Transmission Fluid Level" in
this section.
1. Apply thin coating of Teflon sealant, GM
PIN 1052080 or equivalent to threads of backup

lamp switch (3 or 4).
J 39440
A
28
B
A
B
C
1
28
REMOVAL OF OUTPUT SHAFT SEAL

INSTALLATION OF OUTPUT SHAFT SEAL
RUBBER MALLET
SEAL, OUTPUT SHAFT
01-28-95
FS0057B
Figure 5 - Manual Transmission Output Shaft Seal (6-Speed)
78-10
J 21426
!VIEWA!
B
A
B
C
2
29
.A
29
REMOVAL OF OUTPUT SHAFT SEAL

INSTALLATION OF OUTPUT SHAFT SEAL
RUBBER MALLET
TRANSMISSION. 5-SPEED MANUAL
SEAL, OUTPUT SHAFT
01-28-95
FS0087B
Figure 6 - Manual Transmission Output Shaft Seal (5-Speed)
2
4
12
30
31

SWITCH, BACKUP LAMP
SENSOR. SPEED
BOLT/SCREW, SPEED SENSOR RETAINING
DRIVEN GEAR, SPEEDOMETER
01-28-95
FSOOnB
Figure 7 - Manual Transmission Backup Lamp Switch and Speed Sensor (5-Speed)

2. Backup lamp switch (3 or 4) to manual
!~!
Tighten
Backup lamp switch (4) 38 N,m (28 lb. ft.) for

Backup lamp switch (3) to 20 N.m (15 lb. ft.)
for 6-speed manual transmission.
3. Electrical connector to backup lamp switch
(3 or 4).
4. Lower vehicle.
SPEED SENSOR (5-SPEED)

Figure 7
!++-!
Install or Connect

L. Battery negative cable.
SECTION OA.
3. Electrical connector from speed sensor (12).
4. Speed sensor retaining bolt/screw (30) from
5-speed manual transmission (2).
5. Speed sensor (12) and speedometer driven gear
(31) from 5-speed manual transmission (2).
!++!
Install or Connect

SECTION OA.
3. Electrical connector from electronic speed sensor
(9).
4. Electronic speed sensor retaining bolt/screw (32)
from 6-speed manual transmission (1).
5. Electronic speed sensor (9) from 6-speed manual
transmission ( 1).
l++!
Install or Connect
NOTICE:
1. Electronic speed sensor (9) to 6-speed manual

transmission (1).
2. Electronic speed sensor retaining bolt/screw (32)
to 6-speed manual transmission (1).
l~i
Tighten
Electronic speed sensor retaining bolt/screw

(32) to 10 N.m (89 lb. in.).
3. Electrical connector to electronic speed sensor (9).
4. Lower vehicle.
REVERSE LOCKOUT SOLENOID

(6-SPEED)
Figures 8 and 9
l++I
.r
NOTICE:
1. Speedometer driven gear (31) and speed sensor

(12) to 5-speed manual transmission (2).
2. Speed sensor retaining bolt/screw (30) to 5-speed
manual transmission (2).
!~I
Tighten
Speed sensor retaining bolt/screw (30) to

10 N,m (89 lb. in.).
3. Electrical connector to speed sensor (12).
4. Lower vehicle.
ELECTRONIC SPEED SENSOR (6-SPEED)

Figure 8
1++1

Cable" in SECTION. OA.

SECTION OA.
3. Electrical connector from reverse lockout solenoid
(7).
4. Reverse lockout bolt/screw (40).
5. Reverse lockout (8).
6. Reverse lockout solenoid (7) from reverse lockout
(8).
!++I
Install or Connect
NOTICE:
Refer to ''Notice" on page 7B-1.
1. Reverse lockout solenoid (7) to reverse

lockout (8).
l~I
Tighten
Reverse lockout solenoid (7) to 40 N .m

(30 lb. ft.).
78-12
39
A
B
1
3
7
8
9
32
33
34
35
36
37
38
39
40
LEFT-HAND SIDE
RIGHT-HAND SIDE
SWITCH, BACKUP LAMP
SOLENOID, REVERSE LOCKOUT
LOCKOUT,REVERSE
SENSOR, ELECTRONIC SPEED
BOLT/SCREW, ELECTRONIC SPEED SENSOR
RETAINING
RING, REVERSE LOCKOUT SNAP
PLUNGER, REVERSE LOCKOUT
SPRING, REVERSE LOCKOUT OUTER
SEAT, REVERSE LOCKOUT
RETAINING RING, REVERSE LOCKOUT
SPRING, REVERSE LOCKOUT INNER
BODY, REVERSE LOCKOUT
BOLT/SCREW, REVERSE LOCKOUT
0128-95
FS0087B
Figure 8 - Manual Transmission Backup Lamp Switch, Electronic Speed Sensor, Reverse Lockout Solenoid, and Reverse
Lockout (6-Speed)
APPLY 12 VOLTS TO REVERSE LOCKOUT SOLENOID.

REMOVE REVERSE
LOCKOUT SOLENOID.
SOLENOID PLUNGER
EXTENDED.
CHECK REVERSE LOCKOUT. REFER TO

SECTION 7B10B (EXTENSION HOUSING).
SOLENOID PLUNGER
RETRACTED.
REPLACE REVERSE
LOCKOUT SOLENOID.
REVERSE LOCKOUT PLUNGER CAN

BE DEPRESSED EASILY WITH THUMB.
REVERSE LOCKOUT PLUNGER CANNOT

REVERSE LOCKOUT SOLENOID

AND REVERSE LOCKOUT OK.
REMOVE REVERSE LOCKOUT

SOLENOID FROM REVERSE LOCKOUT.
CHECK REVERSE LOCKOUT SOLENOID

CIRCUIT. REFER TO SECTION BA.
REVERSE LOCKOUT PLUNGER CAN BE

DEPRESSED EASILY WITH THUMB.
REVERSE LOCKOUT PLUNGER CANNOT

REPLACE REVERSE
LOCKOUT SOLENOID,
CHECK REVERSE LOCKOUT. REFER TO

SECTION.7B10EI (EXTENSION HOUSING).
C8886
Figure 9 Reverse Lockout Bench Check
78-14
2. Reverse lockout (8) to 6-speed manual

transmission (1).
3. Reverse lockout bolt/screw (40).
!~!
Tighten
Reverse lockout bolt/screw (40) to 18 N.m

(13 lb. ft.).
4. Electrical connector to reverse lockout solenoid
(7).
5. Lower vehicle.
REVERSE LOCKOUT (6-SPEED)

Figures 8 and 9
!++!

SECTION OA.
3. Electrical connector from reverse lockout solenoid
(7).
4. Reverse lockout bolt/screw (40) from 6-speed
5. Reverse lockout (8) from 6-speed manual
transmission (1).
IL'I'!
Inspect
Reverse lockout. Refer to SECTION 7B-10B

for inspection and disassembly procedures.
!++I
Install or Connect
NOTICE:

2. Raise . and suitably support vehicle. Refer to
SECTION OA.
3. Electrical connector from skip shift solenoid (55).
4. Skip shift solenoid (55) from transmission (1).
!++I
Install or Connect
1. Skip shift solenoid (55) to transmission (1).
I~!
Tighten
Skip shift solenoid (55) to 40 N.m (30 lb. ft.).

2. Electrical connector to skip shift solenoid (55).
3. Lower vehicle.
5-SPEED MANUAL TRANSMISSION (RPO

M49)
Tools Required:
J 36842 Transmission Holding Fixture
J 3289-20 Bench Mount Holding Fixture Base
!++I

SECTION 8C.
SECTION OA.
4. Clutch actuator cylinder line from actuator. Refer
to "Clutch Actuator Cylinder" in SECTION 7C.
5. Drain fluid from 5-speed manual transmission (2).
1. Reverse lockout (8) to 6-speed manual

transmission (1).
2. Reverse lockout bolt/screw ( 40) to 6-speed
!~!
Tighten
Reverse lockout bolt/screw (40) to 18 N.m

(13 lb. ft.).
3. Electrical connector to reverse lockout solenoid
(7).
4. Lower vehicle.
SKIP SHIFT SOLENOID (6-SPEED)

Figure 10
I++!

1 TRANSMISSION
55 SOLENOID, SKIP SHIFT
01-2tMl5
FS0107B
Figure 10 - Skip Shift Solenoid (6-Speed)

6.
7.
8.
9.
10.

Support rear axle with jack stand.
Wiring harness connector from backup lamp
switch (4).
11. Wiring harness connector from speed sensor (12).
12. Support engine with a jack stand.
13. Support 5-speed manual transmission (2) with
jack stand.
14. Transmission support and transmission mount.
Refer to "Transmission Support and Transmission
Mount" in this section.
15. Lower 5-speed manual transmission (2), enough
to reach transmission control bolts/screws (19),
with aid of helper.
NOTICE: Manual transmission control must
be held when lowering manual transmission, as
control is not retained in vehicle. If control is
not held it could drop causing damage to the
component.
6. Raise 5-speed manual transmission (2) up

engaging manual transmission control (21).
!~!
Tighten

20 N.m (15 lb. ft.).
8. Raise 5-speed manual transmission (2) to installed
position.
9. Transmission support and transmission mount.
10. Remove jack stands from transmission and
engine.
11. Wiring harness connector to speed sensor (12).
12. Wiring harness connector to backup lamp switch
(4).
15. Remove support from rear axle.
17.
18.
19.
20.
Lower 5-speed manual transmission (2).

Manual transmission control (21).
Transmission bolts/screws (41).
5-speed manual transmission (2) to flywheel
housing (45) with aid of helper.
21. Place 5-speed manual transmission (2) in J 36842.
!HI
Install or Connect
NOTICE:
Clean

housing.
1. Control (21) to installed position on vehicle.
2. 5-speed manual transmission (2) to flywheel
housing (45), with aid of helper.
Pilot splined input shaft (53) into clutch disc
hub and pilot bearing.
jack stand.
4. Transmission bolts/screws (41).
!~!
Tighten
Transmission bolts/screws (41) to 75 N.m

(55 lb. ft.).
5. Apply a continuous 3 mm (1/8-inch) bead of RTV
sealing surface.
A
2
41
45
53
ACTUATOR CYLINDER, CLUTCH

TRANSMISSION, 5-SPEEO MANUAL
SOLT/SCREW, TRANSMISSION
HOUSING, FLYWHEEL
SHAFT, INPUT
051696
FT0117B
Figure 11 - Manual Transmission to Engine (5-Speed)
78-16
17. Clutch actuator cylinder line to actuator.
11]
18.
19.
.20.
21.
Important
Make sure the braded actuator line is not

twisted or kinked. Line must be maintained
away from other components to avoid damage
to the line.
Quick connect fitting must be pushed on, then
pulled back to verify engagement. Do not rely
on audible click or visual verification.
Bleed clutch hydraulic system. Refer to "Bleeding
Hydraulic System" in SECTION 7C.
Check and fill manual transmission with fluid.
Refer to "Checking Manual Transmission Fluid
Level" in this section.
Lower vehicle.
Front floor console trim plate. Refer to
SECTION 8C.

(RPO MM6)
15.
16.
17.
18.
19.
20.
.
21.
Important
Do not let the actuator cylinder hang by

hydraulic .line.
Clutch actuator cylinder and retain with
mechanic's wire.
Actuator spacer (46).
Pull clutch fork (47) down to disengage from
release bearing.
Wiring harness connector from electronic speed
sensor (9).
Support engine with jack stand.
Support 6-speed manual transmission (1) with
jack stand.
Transmission support and transmission mount.
Tool Required:
J 39430 Transmission Holding Fixture
j++l

SECTION 8C.
3. Manual transmission control lever handle
bolts/screws (27).
4. Handle (26).
SECTION OA.
6. Drain fluid from 6-speed manual transmission (1 ).
7. Support rear axle with jack stand.
8. Propeller shaft. Refer. to SECTION 4A.
11. Wiring harness connector from reverse lockout
solenoid (7).
12. Wiring harness connector from skip shift solenoid
(55).
13. Wiring harness connector from backup lamp
switch (3).
14. Actuator cylinder nuts (50).
NOTICE: Disconnect the clutch master

cylinder pushrod before removing the actuator
cylinder. If not disconnected, permanent damage
to the actuator cylinder will occur if the clutch
pedal is depressed while the actuator is
disconnected.
NOTICE: The clutch fork (47) must be

disengaged .from the release bearing to. prevent
damage to. the clutch system.
23. Six-speed manual transmission (1) with aid of
helper.
24. Place 6-speed manual transmission (1) in J 39430.
!++!
rn
Install or Connect

1. Six-speed manual transmission (1) with aid of
helper.
Pilot transmission input shaft through .the
release bearing, the clutch driven plate splines
and into the clutch pilot bearing.
jack stand.
!~!
4.
5.
6.
7.
8.
9.
Tighten
Transmission b.olts/screws (43) to 35 N.m

(26 lb. ft.).
Transmission support and transmission mount.
Remove jack stands from transmission and
engine.
Push clutch fork ( 47) up to engage release
bearing.
Actuator spacer (46).
Actuator cylinder.
Actuator cylinder nuts (50).
!~!
Tighten
Actuator cylinder nuts (50) to 20 N.m

(15 lb. ft.).
10. Wiring harness connector. to electronic speed
sensor (9).
MANUAL TRANSMISSION ONNEHICLE SERVICE RPO MM6 AND M49 78-17
A
1
43
46
47
48
49
50
54
(:YLINDER, CLUTCH ACTUATOR

SPACER, CLUTCH ACTUATOR
FORK, CLUTCH
HOUSING, FLYWHEEL
ENGINE
NUT, CLUTCH ACTUATOR CYLINDER
SHAFT, INPUT
43
012695
FS0127B
Figure 12 - Manual Transmission to Engine (6-Speed)
11. Wiring harness connector to backup lamp switch

(3).
12. Wiring harness connector to skip shift solenoid
(55).
13. Wiring harness connector to reverse lockout
solenoid (7).
17. Remove support from rear axle.
18. Fill transmission with fluid. Refer to "Checking
Manual Transmission Fluid Level" in this section.
19. Lower vehicle.
20. Clutch master cylinder pushrod. Refer to

SECTION 7C.
21. Manual transmission control lever handle (26).
22. Manual transmission control lever handle
bolts/screws (27).
~
~ Tighten
Manual transmission control lever handle

bolts/screws (27) to 25 N,m (18 lb. ft.).
SECTION 8C.
78-18
SPECIFICATIONS
(

Backup Lamp Switch (5-Speed) ............................................................................................. 27 N.m (20 lb. ft.)
Backup Lamp Switch (6-Speed) ..........................................................................., ................. 27 N.m (20 lb. ft.)
Clutch Actuator Cylinder Nut ................................................................................................. 20 N.m (15 lb. ft.)
Electronic Speed Sensor Retaining Bolt/Screw ..................................................................... 10 N.m (89 lb. in.)
Manual Transmission Control .Lever Boot Bolt/Screw (5-Speed) ....................................... 1.7 N.m (15 lb. in.)
Manual Transmission Control Lever Boot Bolt/Screw (6-Speed) ....................................... 1.7 N.m (15 lb. in.)
Manual Transmission Control Lever Handle Bolt/Screw .............................. :....................... 25 N.m (18 lb. ft.)
Reverse Lockout Bolt/Screw ................................................................................................... 18 N,m (13 lb. ft.)
Reverse Lockout Solenoid....................................................................................................... 40 N,m (30 lb. ft.)
Skip Shift Solenoid (6-Speed) ................................................................................................. 40 N.m (30 lb. ft.)
Speed Sensor Retaining Bolt/Screw ........................................................................................ 10 N.m (89 lb. in.)
Transmission Bolt/Screw (5-Speed) ........................................................................................ 75 N,m (55 lb. ft.)
Transmission Bolt/Screw (6-Speed) ........................................................................................ 35 N.m (26 lb. ft.)
Transmission Control Bolt/Screw (5-Speed) ...... ;.............................................. ,..................... 20 N.m (15 lb. ft.)
Transmission Control Bolt/Screw (6-Speed) ........................................................................... 20 N.m (15 lb. ft.)
Transmission Mount Bolt/Screw ............................................................................................. 48 N.m (36 lb. ft.)
Transmission Mount Nut .......................................................................................................... 57 N.m (43 lb. ft.)
Transmission Oil Fill Plug (5-Speed) ............................................................... :..................... 27 N.m (20 lb. ft.)
Transmission Oil Fill Plug (6-Speed) ..................................................................................... 27 N.m (20 lb. ft.)
Transmission Support Bolt/Screw ........................................................................................... 57 N.m (43 lb. ft.)
SPECIAL TOOLS
(
J 39430
2.
4.
&-SPEED MANUAL TRANSMISSION

1.
2.
3.
4.
5.
BENCH MOUNT HOLDING FIXTURE BASE

TRANSMISSION HOLDING FIXTURE
SLIDE HAMMER
EXTENSION HOUSING SEAL INSTALLER
EXTENSION HOUSING SEAL REMOVER
01H95
FS01378
78-19
4.
J 21426
J 23907
E.3
u,,o=-:z
2.
J 36842
- - . ->"l'i
( c:at--=- )
1.
2.
3.
4.
5.
BENCH MOUNT HOLDING FIXTURE BASE

TRANSMISSION HOLDING FIXTURE
SLIDE HAMMER
EXTENSION HOUSING SEAL INSTALLER
EXTENSION HOUSING SEAL REMOVER
01-21-95
F801478
78-20
MANUAL TRANSMISSION ONNEHICLE SERVICE RPO MM6 AND M49
BLANK
(
CLUTCH
7C-1
SECTION 7C
CLUTCH
CAUTION: When servicing the clutch system, do not create dust by cleaning components with
compressed air. While not containing asbestos fibers, the clutch disc does contain fiberglass
fibers which could cause bodily harm if inhaled. Any residue should also be washed from the
skin as it could cause irritation.
systems.
CONTENTS
General Description ................................................. 7C-1

Principle Components ......................................... 7C-l
Driving Members ............................................ 7C-l
Driven Member ............................................... 7C-1
Hydraulic Clutch ............................................. 7C-1
Hydraulic Clutch Fluid ............... ;................... 7C-2
Clutch Pilot Bearing ....................................... 7C-2
Diagnosis ................................................................. 7C-2
Preliminary Checks ............................................. 7C-2
Clutch System Diagnosis .................................... 7C-3
On-Vehicle Service .................................................. 7C-4
Bleeding Hydraulic System ................................ 7C-4
Clutch Master Cylinder (5-Speed) ...................... 7C-6
Clutch Actuator Cylinder (5-Speed) ................... 7C-8
Clutch Master and Actuator Cylinder
(6-Speed) ........................................................ 7C-8
GENERAL DESCRIPTION
PRINCIPLE COMPONENTS
The principal components of the clutch system
are the driving members, attached to the engine and
turning with the engine; the driven member, attached
to the transmission and turning with the transmission;
and the operating members. The operating members
include the clutch master cylinder and actuator, the
clutch release bearing, the clutch pedal, and the clutch
pilot bearing.
Driving Members
The driving members of the clutch consist of
two flat surfaced iron plates machined to a smooth
finish. One of these surfaces is the rear face of the
engine flywheel and the other is the clutch pressure
plate (with cover). The 3800 VIN K engine uses a
push-type clutch release system, while the 5.7L VIN P
engine utilizes a pull-type clutch release system.
Clutch Pedal ...................................................... 7C-9

Clutch Anticipate Switch .................................. 7C-9
Clutch Pedal Position Switch
(Clutch Start Switch) .................................... 7C-9
Clutch Driven Plate (5-Speed) ......................... 7C-9
Clutch Driven Plate (6-Speed) ......................... 7C-11
Clutch Fork and Clutch Release Bearing
(6-Speed) ....................................................... 7C-13
Engine Flywheel
(5.7L VIN P) .................... Refer to Section 6A3A
Engihe Flywheel
(3800 VIN K) ................... Refer to Section 6A8A
Clutch Pilot Bearing ......................................... 7C-14
Special Tools ......................................................... 7C-15
Driven Member
The driven member is the clutch driven plate.
This clutch driven plate has a splined hub which
meshes with the splines of the input shaft and drives
the input shaft.
The driving and driven members are held in
contact by spring pressure. This pressure is exerted by
a diaphragm spring in the clutch pressure plate (with
cover).
Hydraulic Clutch
A hydraulic clutch operating mechanism is used
to engage and disengage the clutch system. The
mechanism consists of a remote master cylinder
reservoir, a clutch master cylinder and a clutch
actuator cylinder. The remote master cylinder reservoir
is mounted to the left-hand hood strut bracket using a
push-on retainer. The clutch master cylinder is
mounted on the front of dash with a U-bolt fastener.
The clutch actuator cylinder is mounted inside the
7C-2
CLUTCH
flywheel housing with the 3800 VIN K engine and to

the clutch actuator cylinder spacer on the flywheel
housing with the 5.7L VIN P engine. The clutch
master cylinder is operated directly by the clutch
pedal.
When the clutch pedal is pressed down,
hydraulic fluid under pressure is pushed from the
clutch master cylinder into the clutch actuator. On the
3800 VIN K engine the actuator piston moves the
release bearing forward, pressing the diaphragm spring
fingers to disengage the clutch. On the 5. 7L VIN P
engine .the actuator piston engages the clutch fork,
which moves the release bearing, pulling the
diaphragm spring fingers to disengage the clutch.
The hydraulic clutch system sets the clutch pedal
height and provides automatic clutch adjustment. No
adjustment of clutch or clutch pedal position is
required.
Hydraulic Clutch Fluid

When adding fluid to or refilling the system
after service operations, the use of hydraulic clutch
fluid G/M PIN 12345347 or equivalent is preferred
over standard DOT 3 brake fluid.
NOTICE: Do not use silicon, mineral or

paraffin based oil in the clutch hydraulic system.
These fluids will damage the rubber parts in the
cylinders.
Clutch Pilot Bearing

The clutch pilot bearing is an oil-impregnated
bearing pressed into the crankshaft. The clutch pilot
bearing should be cleaned and inspected for .excessive
wear or damage and replaced if necessary.
DIAGNOSIS
PRELIMINARY CHECKS
Before attempting to repair the clutch, manual
transmission or related hydraulic components for any
reason other than an obvious failure, the problem and
probable cause should be identified. A large
percentage of clutch and manual transmission
problems show up as shifting difficulties, such as high
shift effort, gear clash and grinding, or transmission
blockout. When any of these conditions occur, a

careful analysis of these difficulties should be
performed before removing the clutch or manual
transmission for repairs. Refer to "Clutch System
Diagnosis" in this section for conditions, causes and
corrections.
Before removal of the clutch hydraulic system,
verify the malfunction by removing the flywheel
housing cover and measure the travel of the clutch
actuator pushrod (6~sp~d ori.ly). With the clutch pedal
pushed fully to the floor, the clutch actuator pusluod
should extend a minimum of 11 mm (0.43 inch). Do
not replace the hydraulic system if pushrod travel
exceeds this distance.
If the clutch actuator pushrod does not meet the
travel requirements, check the clutch master cylinder
reservoir fluid level.
The clutch actuator cylinder must be in place
when checking the fluid level.
. The proper level is indicated by a step on the
clutch master cylinder reservoir. Fill to specified
level with hydraulic clutch fluid G/M PIN
12345347 or equivalent.
Do not overfill. The upper portion of the clutch
master cylinder reservoir must accept fluid that is
displaced from the clutch actuator cylinder as the
clutch wears.
NOTICE: Carefully clean the top and sides of

the clutch master cylinder reservoir before
opening to prevent contamination of the system
with dirt, water or other foreign material.
Remove the clutch master cylinder reservoir
diaphragm before adding fluid. Carefully replace
the diaphragm, cover gasket and cover after
filling.
If the clutch master cylinder reservoir requires

any fluid, check the clutch hydraulic system
components for leakage. Remove the rubber boots
from the clutch master cylinder and check for leakage
past the pistons. A slight wetting of the surfaces is
acceptable. Replace the clutch hydraulic system if
excessive leakage is evident.
CLUTCH
7C-3
CLUTCH SYSTEM DIAGNOSIS

For diagnosis of either the 5-speed manual transmission clutch system or the 6-speed manual transmissions
clutch system refer to. the following chart:
CONDITION
Fails to Release (Pedal pressed to
floor, shift lever does not move freely
in and out of reverse gear)
POSSIBLE CAUSE
1. Faulty clutch pilot bearing.
1. Replace clutch pilot bearing.
2. Faulty driven plate.

3. Fork off of clutch fork T-stud
loose on 6-speed.
2. Replace clutch driven plate.

3. Install properly and lightly lubricate
fingers at clutch release bearing and
clutch fork ball stud.
4. Repair or replace input shaft and/or
driven plate. Runout should not exceed
0.5 mm (0.020 inch).
5. Bleed clutch hydraulic system.
6. Loosen pedal mounting bolts/screws
and realign pedal.
7. Repair leak.
4. Driven plate hub binding on input

shaft splines.
5. Air in clutch hydraulic system.
6. Pedal misaligned to the cowl.
7. Leak in clutch hydraulic system.
Slipping
CORRECTION
1. Oil-soaked driven plate.

2. Worn facing or facing tom from
driven plate.
3. Warp~d pressure plate or flywheel.
4. Weak diaphragm spring.
5. Clutch driven plate not seated in.
1. Install new clutch driven plate and

correct leak at source.
2. Replace clutch driven plate.
6. Clutch driven plate overheated.
3. Replace pressure plate or flywheel.

4. Replace pressure plate.
5. Make 30 to 40 normal start. Do not
overheat.
6. Allow to cool.
Grabbing (Chattering)
1. Oil on clutch pressure plate facing

or burned
2. Worn splines on input shaft.
3. Warped pressure plate or flywheel.
' .
4. Burned or smeared resin on
flywheel or pressure plate.
1. Install new clutch driven plate and

correct leak at source.
2. Replace input shaft.
3. Replace pressure plate or flywheel.
4. Sand off if superficial. Replace
burned or heat checked parts.
Release Bearing Noise with Clutch

Fully Engaged
1. Release bearing binding on

transmission bearing retainer.
2. Fork improperly installed on
6-speed.
1. Clean, lubricate, check for burrs,

nicks, and other wear.
2. Install properly.
Noisy
1. Worn release bearing.

2. Fork off T-stud on 6-speed (heavy
clicking).
L Replace bearing.
Clutch Pedal Stays on Floor when

Disengaged
1. Birid in release bearing.
2. Master cylinder pushrod foil off

pedal.
3. Leak in clutch hydraulic system.
2. Install properly and lubricate fork

fingers and bearing.
1. Lubricate and free-up release
bearing.
2. Install correctly.
3. Repair leak.
7C-4
CLUTCH
POSSIBLE CAUSE
CONDITION
Excessive Pedal Pressure
Rapid Clutch Driven Plate Wear
1. Linkage needs lubrication.

2. Pressure plate release fingers
binding.
3. Linkage misaligned.
4. Release bearing sleeve binding on
transmission bearing retainer.
5. Sticking linkage, master cylinder
or actuator cylinder.
6. Worn pressure plate.
1. Lubricate linkage.
2. Free and lubricate.
1. Scored flywheel or pressure plate.

2. Driver rides the clutch (rests left
foot on clutch while driving).
3. Driver races engine and slips clutch
excessively during hard starting.
4. Driver holds vehicle on hill by
slipping clutch.
5. Weak pressure plate springs.
1. Grind or replace.
2. Instruct diver.
ON-VEHICLE SERVICE
BLEEDING HYDRAULIC SYSTEM
Figures 1, 2, and 3
Bleeding is necessary whenever the level of fluid
in the reservoir has been allowed to fall so low that air
has been drawn into the master cylinder.
5-SPEED
NOTICE: Never, under any circumstances, use

fluid which has been bled from a system to fill
the clutch master cylinder reservoir as it may be
aerated, have too much moisture content and
possibly be contaminated.
NOTICE:

SECTION OA.
2. Attach a hose to the bleeder ( 11) on the clutch
actuator and submerge the other end of the hose
in a container of hydraulic clutch fluid GIM
3. Depress the clutch pedal slowly and hold.
4. Loosen the bleeder ( 11) to purge air.
5. Tighten bleeder (11).
6. Repeat steps 2 through 4 until air is completely
purged.
!L!
CORRECTION
Inspect
Fill clutch master cylinder reservoir with fluid.

Use of hydraulic clutch fluid GIM
PIN 12345347 or equivalent is preferred over
standard DOT 3 brake fluid.
3. Align linkage.
4. Free and lubricate:
5. Clean or replace as needed.
6. Replace pressure plate.
3. Instruct driver.
4. Instruct driver.
5. Rebuild or replace pressure plate.
6-SPEED
NOTICE: Never, under any circumstances, use

fluid which has been bled from a system to fill
the clutch master cylinder reservoir as it may be
aerated, have too much moisture content and
possibly be contaminated.
NOTICE:
1. Loosen clutch master cylinder nuts (23 and 24) to

end of threads on U-bolt (25).
2. Clean dirt and grease from the reservoir cap to
ensure no foreign substances will enter the
system.
3. Remove the reservoir cap and diaphragm.
4. Wrap a piece of mechanics wire around left-hand
hood strut bracket (2 or 8) making sure wire is
accessible from underside of vehicle.
SECTION OA.
6. Remove actuator cylinder nuts (5 or 10).
7. Remove actuator cylinder.
Retain actuator cylinder in engine
compartment using mechanics wire previously
installed.
8. Lower vehicle.
9. Grasp actuator cylinder and depress hydraulic
actuator cylinder pushrod approximately 20.0 mm
(0.0787 inch) into actuator cylinder bore and hold.
10. Install diaphragm and reservoir cap while holding
in actuator cylinder pushrod.
11. Release actuator cylinder pushrod.
12. Hold actuator cylinder vertically with the pushrod
end facing down.
CLUTCH
7C-5
10
A
B
C
7
8
9
10
11
12
RESERVOIR, CLUTCH MASTER CYLINDER

MASTER CYLINDER, CLUTCH
RETAINER, CLUTCH MASTER CYLINDER
BRACKET, HOOD STRUT LEFT-HAND
LINE, ACTUATOR CYLINDER
SOLT/SCREW, CLUTCH ACTUATOR CYLINDER
BLEEDER, HYDRAULIC CLUTCH SYSTEM
COVER, FLYWHEEL HOUSING
rn
05-06-95
FT0027C
Figure 1 Clutch Hydraulic System (5-Speed)
Important
Actuator cylinder should be lower than the

master cylinder.
13. Press pushrod into actuator cylinder bore with
short 10.0 mm (0.0390 inch) strokes.
iL'l'i
12
Inspect
Master cylinder reservoir for air bubbles.

14. Continue until air bubbles are no longer entering
reservoir.
SECTION OA.
16. Remove actuator cylinder from mechanics wire.
17. Install actuator cylinder.
18. Install actuator cylinder nuts (5 or 10).
!~I
Tighten
Clutch actuator cylinder nuts (5 or 10) to

20 N.m (15 lb. ft.).
19. Lower vehicle.
20. Remove mechanics wire from left-hand hood strut
bracket (2 or 8).
21. Install clutch master cylinder nuts (23 and 24).
!~I
Tighten
Clutch master cylinder nuts (23) to 27 N.m

(20 lb. ft.).
!L"'I
Inspect
Fill clutch master cylinder reservoir with fluid.

Use of hydraulic clutch fluid G/M
PIN 12345347 or equivalent is preferred over
standard DOT 3 brake fluid.
7C-6
CLUTCH
A
A
B
C
1
2
3
4
5
RESERVOIR, CLUTCH MASTER CYLINDER

MASTER CYLINDER, CLUTCH
CYLINDER, CLUTCH MASTER AND
ACTUATOR
BRACKET, HOOD STRUT LEFT-HAND
RETAINER, CLUTCH MASTER CYLINDER RESERVOIR
HOSE CLIP, CLUTCH MASTER CYLINDER AND
ACTUATOR
NUT, CLUTCH ACTUATOR CYLINDER
(
!VIEW B!
"
Figure 2 Clutch Hydraulic System (6-Speed)
CLUTCH MASTER CYLINDER (5-SPEED)

Figures 1 and 3
Tool Required:
J 36221 Hydraulic Clutch Line Seperator
El

2. Instrument panel driver knee bolster. Refer to
SECTION 8C.
3. Clutch master cylinder pushrod from clutch pedal
(19).
012595
FS0017C
4. Clutch master cylinder nuts (23 and 24) from dash

panel.
5. Clutch master cylinder U-bolt (25) from dash
panel.
6. Clutch master cylinder from dash panel.
7. Clutch master cylinder reservoir retainer (3 or 7).
8. Clutch master cylinder ,reservoir from left-hand
hood strut bracket (2 or 8).
SECTION OA.
10. Actuator cylinder line (9) from actuator using
J 36221.
11. Clutch master cylinder (6) from vehicle.
!++!
Install or Connect

1. Clutch master cylinder (6) to vehicle.
CLUTCH
JB
19
7C-7
..
,/~'
17
15~
<
21
16
24
A PUSHROD, CLUTCH MASTER CYLINDER

B MASTER CYLINDER. CLUTCH
c CONNECTOR, CLUTCH ANTICIPATE SWITCH HARNESS
ELECTRICAL
D CONNECTOR, CLUTCH ANTICIPATE SWITCH HARNESS
ELECTRICAL
E CONNECTOR, CLUTCH PEDAL POSITION SWITCH
HARNESS ELECTRICAL
15 NUT, BRAKE PEDAL
16 PEDAL, BRAKE AND ACCELERATOR AND
17 NUT, BRAKE PEDAL PIVOT
18 BUSHING, CLUTCH PEDAL PIVOT
19 PEDAL. CLUTCH
20 RETAINER, CLUTCH PEDAL LEVER PIN
21 BOLT/SCREW, BRAKE PEDAL PIVOT
22 BUMPER, CLUTCH PEDAL
23 NUT, CLUTCH MASTER CYLINDER
24 NUT, CLUTCH MASTER CYLINDER (PUSH-ON)
25 U-BOL T, CLUTCH MASTER CYLINDER
26 SWITCH, CLUTCH ANTICIPATE (WITH 3800
L36 ENGINE)
27 SWITCH, CLUTCH ANTICIPATE (WITH 5.7L
L 1 ENGINE)
28 SWITCH, CLUTCH PEDAL POSITION (SWITCH,
CLUTCH START)
0121596
FS0037C
Figure 3 Clutch Pedal and Switches
7C-8
CLUTCH
2. Actuator cylinder line (9) to actuator.
[II
3.
4.
5.
6.

to the line.
Lower vehicle.
Clutch master cylinder to dash panel.
Clutch master cylinder U-bolt (25) to dash panel.
Clutch master cylinder nuts (23 and 24).
I~!
7.
8.
9.
10.
11.
12.
Important
Tighten

(20 lb. ft.).
Clutch master cylinder reservoir to left-hand hood
strut bracket (2 or 8).
Clutch master cylinder reservoir retainer (3 or 7).
Clutch master cylinder pushrod to clutch
pedal (19).
Instrument panel driver knee bolster. Refer to
SECTION 8C.
Bleed hydraulic system. Refer to. "Bleeding
Hydraulic System" in this section.
CLUTCH ACTUATOR CYLINDER (5-SPEED)

Figures 1 and 3
Tool Required:
J 36221 Hydraulic Clutch Line Seperator
!++!

2. Actuator cylinder line (9) from actuator using
J 36221.
3. 5-speed manual transmission. Refer to
SECTION 7B.
4. Actuator cylinder bolts/screws (10).
5. Clutch actuator cylinder from transmission.
!++!
Install or Connect
NOTICE:
1. Clutch actuator cylinder to transmission.

2. Actuator cylinder bolts/screws (10).
!~!
Tighten
Clutch actuator cylinder bolts/screws (10) to

8 N,m (71 lb. in.).
SECTION 7B.
4. Actuator cylinder line (9) to actuator.
lI]
Important

to the line.
6. Bleed hydraulic system. Refer to "Bleeding
Hydraulic System" in this section.
CLUTCH MASTER AND ACTUATOR

CYLINDER (6-SPEED)
Figures 2 and 3
!++!

Cable" in SECTION .OA.

SECTION 8C.
(19).
4. Clutch master cylinder nuts (23 and 24) from dash
panel.
5. Clutch master cylinder U-bolt (25) from dash
panel.
6. Clutch master cylinder from dash panel.
7. Clutch master cylinder reservoir retainer (3 or 7).
8. Clutch master cylinder reservoir from left-hand
hood strut bracket (2 or 8).
SECTION OA.
10. Clutch actuator cylinder nuts (5 or 10).
11. Clutch actuator cylinder from clutch housing.
12. Clutch master and actuator cylinder (1 or 6) from
vehicle.
!++!
Install or Connect

1. Clutch actuator cylinder.
2. Clutch actuator cylinder nuts (5 or 10).
CLUTCH
!~I
3.
4.
5.
6.
Clutch actuator cylinder nuts (5 or 10) to

20 N.m (15 lb. ft.).
Lower vehicle.
Clutch master cylinder to dash panel.
Clutch master cylinder U-bolt (25) to dash panel.
Clutch master cylinder nuts (23 and 24).
!~!
7.
8.
9.
10.
11.
Tighten
Tighten

(20 lb. ft.).
Clutch master cylinder reservoir to left-hand hood
strut bracket (2 or 8).
Clutch master cylinder reservoir retainer (3 or 7).
Clutch master cylinder pushrod to clutch pedal
(19).
SECTION 8C.
CLUTCH PEDAL
Figure 3
!++!
1. Brake and accelerator and clutch pedal

(with bracket). Refer to SECTION 5.
2. Brake pedal pivot nut (17) and bolt/screw (21).
3. Clutch pedal (19) with pivot bushings (18).
!++-!
Install or Connect
NOTICE:
1. Clutch pedal (19) with pivot bushings (18).

2. Brake pedal pivot bolt/screw (21) and nut (17).
!~!
Tighten
Brake pedal pivot nut (17) to 54 N .m

(40 lb. ft.).
3. Brake and accelerator and clutch pedal
(with bracket). Refer to SECTION 5.
CLUTCH ANTICIPATE SWITCH
7C-9
3. Clutch anticipate switch harness electrical

connector from clutch anticipate switch
(26 or 27).
4. Clutch anticipate switch (26 or 27) from brake
and accelerator and clutch pedal (with bracket)
(16).
I++!
Install or Connect
1. Clutch-anticipate switch (26 or 27). to brake and

accelerator and clutch pedal (with bracket) (16).
2. Clutch anticipate switch harness electrical
connector to clutch anticipate switch (26 or 27).
SECTION 8C.
CLUTCH PEDAL POSITION SWITCH

(CLUTCH START SWITCH)
Figure 3
!++!

SECTION 8C.
3. Clutch pedal position switch harness electrical
connector from clutch pedal position switch {28).
4. Clutch pedal position switch (28) from brake and
accelerator and clutch pedal (with bracket) (16).
l++l
Install or Connect
1. Clutch pedal position switch (28) to brake and
accelerator and clutch pedal (with bracket)
(16).
2. Clutch pedal position switch harness electrical
connector to clutch pedal position switch (28).
SECTION 8C.
CLUTCH DRIVEN PLATE (5-SPEED)

Figures 1, 3, and 4
Figure 3
!++!

SECTION 8C.
Tools Required:
J 33169 Clutch Alignment Arbor
!++! Remove or Disconnect

.
7C10
CLUTCH
54
34
10
12
29
30
34
37
38
50
51
53
54
65
SOLT/SCREW, CLUTCH ACTUATOR CYLINDER

FLYWHEEL, ENGINE
PLATE, CLUTCH PRESSURE (WITH COVER)
HOUSING, FLYWHEEL
PLATE, CLUTCH DRIVEN
BOLT/SCREW, CLUTCH PRESSURE PLATE AND COVER
BOLT/SCREW, FLYWHEEL HOUSING COVER
TRANSMISSION, MANUAL (5-SPEED)
BOLT/SCREW, FLYWHEEL HOUSING
042115
FTOOIS7C
Figure 4 Clutch System (5-Speed)
CLUTCH
SECTION OA.
SECTION 7B.
4. Flywheel housing cover bolts/screws (53).
5. Flywheel housing cover (12).
6. Flywheel housing bolts/screws (65).
7. Flywheel housing (34).
8. Clutch pressure plate and cover bolts/screws (51).
9. Clutch pressure plate (with cover) (30) and clutch
driven plate (37).
!L'I'!
Inspect
Clutch pressure plate (with cover) (30) for wear

or damage. Repair or replace as necessary.
Clutch driven plate (37) for wear or damage.
Replace as necessary.
Engine flywheel. Refer to SECTION 6A8A.
lH-1
Install or Connect
NOTICE:
Refer to "Notice" on page 7C-l.
1. Clutch driven plate (37) to engine flywheel (29).

2. Clutch pressure plate (with cover) (30).
!~!
Tighten
CLUTCH DRIVEN PLATE (6-SPEED)

Figures 2, 3, and 5
!++!
Tighten
Clutch pressure plate and cover bolts/screws

(51) to 20 N.m (15 lb. ft.) plus 45 using
J 36660 in star pattern.
!~!
Tighten
Flywheel housing bolts/screws (65) to 95 N.m

(70 lb. ft.).
!~!
Tighten
Flywheel housing cover bolts/screws (53) to

8.5 N.m (75 lb. in.).
SECTION 7B.
10. Lower vehicle.
Tool Required:
SECTION 8C.
(19).

SECTION OA.
SECTION 7B.
NOTICE: Do not allow clutch actuator

cylinder to hang by hydraulic lines as this cold
cause damage to clutch hydraulic lines.
5.
6.
7.
8.
9.
10.
!L!
Flywheel housing cover bolts/screws (61).

Flywheel housing cover (56).
Flywheel housing bolts/screws (62).
Flywheel housing (44).
Clutch pressure plate and cover bolts/screws (57).
Clutch pressure plate (with cover) (39) and clutch
driven plate (47):
Inspect
Clutch pressure plate (with cover) (39) for
wear or damage. Repair or replace as
necessary.
Clutch driven plate (47) for wear or damage.
Replace as necessary.
Engine flywheel. Refer to SECTION 6A3A.

(51) finger tight.
4. Align clutch driven plate (37) with pilot bearing
(38) and clutch pressure plate (with cover) (30)
using J 33169.
!~!
7C-11
!++!
Install or Connect
NOTICE:
1. Clutch driven plate (47) to engine flywheel (46).

2. Clutch pressure plate (with cover) (39).
!~I
Tighten

(57) finger tight.
4. Align clutch driven plate ( 47) with clutch pilot
bearing (48) and clutch pressure plate (with cover)
(39) using J 38836.
!~!
Tighten

(57) to 30 N.m (22 lb. ft.) in star pattern.
7C12
CLUTCH
(
56
48
45
39
40
41
42
43
44
45
46
47
48
1
43
PLATE, CLUTCH PRESSURE (WITH COVER)

BEARING, CLUTCH RELEASE
T-STUD, CLUTCH FORK
TRANSMISSION, MANUAL (6-SPEED)
SPACER, CLUTCH _ACTUATOR CYLINDER
HOUSING, FLYWHEEL
FORK, CLUTCH
FLYWHEEL, ENGINE
PLATE, CLUTCH DRIVEN
55
56
57
58
59
60
61
62
63
64
PIN, FLYWHEEL HOUSING LOCATOR

BOLT/SCREW, CLUTCH PRESSURE PLATE ANO COVER
RETAINER, CLUTCH RELEASE BEARING
BOLT /SCREW, FLYWHEEL
PIN, FLYWHEEL GROOVE
BOLT/SCREW, FLYWHEEL HOUSING COVER
BOLT/SCREW, FLYWHEEL HOUSING
BOLT/SCREW, CLUTCH FORK T-STUO
0121M15
FS0077C
(
Figure 5 Clutch System (6-Speed)
CLUTCH
!~!
Tighten
Flywheel housing bolts/screws (62) to 47 N,m

(35 lb. ft.).
!~!
9.
10.
11.
12.
Tighten
Flywheel housing cover bolts. Screws (61) to

8.5 N,m (75 lb. in.).
6-speed manual transmission. Refer to
SECTION 7B.
Lower vehicle.
Clutch master cylinder pushrod to clutch pedal
(19).
SECTION 8C.
CLUTCH FORK AND CLUTCH RELEASE

BEARING .,6-SPEED)
Figures 2, 3, and 5
Tool Required:
!++!
)

SECTION 8C.
(19).
SECTION OA.
SECTION 7B.
10. Clutch pressure plate (with cover) (39) and clutch
driven plate (47).
11. Clutch release bearing retainer (58).
12. Clutch release bearing (40).
13. Clutch fork (54) from 6-speed manual
transmission (42).
14. Bolt/screw (63) and clutch fork T-stud (41) from
6-speed manual transmission (42).
!L1'!
Inspect
!++-!
Install or Connect
NOTICE:
1. Clutch fork T-stud (41) and bolt/screw (63).
!~!
2.
3.
4.
5.
6.
7.
8.
Tighten
Clutch fork T-stud bolt/screw (63) to 24 N,m

(18 lb. ft.).
Lubricate clutch fork T-stud (41) using wheel
bearing lubricant GM PIN 1051344, or equivalent.
Clutch fork (45) on clutch fork T-stud (41) at first
detent position.
Do not fully seat clutch fork (45) ort clutch
fork T-stud ( 41) until after installation of
6-speed manual transmission (42). It will fully
seat itself when transmission (42) is installed.
Clutch release bearing (40) to clutch pressure
plate (with cover) (39).
Clutch release bearing retainer (58).
Clutch driven plate (47) to engine flywheel (46).
Clutch pressure plate (with cover) (39).
Clutch pressure plate and cover bolts/screws (57).
I~!
Tighten

(57) finger tight.
9. Align clutch driven plate (47) with clutch pilot
bearing (48) and clutch pressure plate (with cover)
(39) using J 38836.
!~I
Tighten

(57) to 30 N,m (22 lb. ft.) in star pattern.
11. Flywheel housing bolts/screw (62).
!~!
Tighten
Flywheel housing bolts/screws (62) to 47 N.m

(35 lb. ft.).
!~!
14.
15.
16.
17.
Clutch release bearing (40), clutch fork (45),

and clutch fork T-stud (41) for wear or
damage. Replace as necessary.
7C-13
Tighten
Flywheel housing cover bolts/screws (61) to

8.5 N,m (75 lb. in.).
6-speed manual transmission. Refer to
SECTION 7B.
Lower vehicle.
Clutch master cylinder pushrod to clutch
pedal (19).
SECTION 8C.
7C14
CLUTCH
3. Clutch pilot bearing (38 or 48) using J 23907.
CLUTCH PILOT BEARING
!HI
Figures 4 and 5
Tool Required:
J 23907 Clutch Pilot Bearing Remover
E3
1. Clutch driven plate. Refer to "Clutch Driven Plate

(5-Speed)" or "Clutch Driven Plate (6-Speed)" in
this section.
2. Engine flywheel. Refer to SECTION 6A3A or
6A8A.
Install or Connect
1. Clutch pilot bearing (38 or 48).
2. Engine flywheel. Refer to SECTION 6A3A or
6A8A.
3. Clutch driven plate. Refer to "Clutch Driven
Plate 5-Speed)" or "Clutch Driven Plate
(6-Speed)" in this section.
SPECIFICATIONS
Brake Pedal Nut .............................................. :....................................................................... 20 N.m (15 lb. ft.)
Brake Pedal Pivot Nut. .........................................................................................................;... 54 N.m (40 lb. ft.)
Clutch Actuator Cylinder Bolt/Screw (5-Speed) ..................................................................... 8 N.m (71 lb. in.)
Clutch Actuator Cylinder Nut (6-Speed) ................................................................................ 20 N.m (15 lb. ft.) .
Clutch Fork T-Stud Bolt/Screw (6-Speed) .............................................................................. 24 N.m (18 lb. ft.)
Clutch Master Cylinder Nut. ................................................................................................... 27 N.m (20 lb. ft.)
Clutch Pressure Plate and Cover Bolt/Screw (5-Speed) ............... 20 N.m (15 lb. ft.) Plus 45 in Star Pattern
Clutch Pressure Plate and Cover Bolt/Screw (6-Speed) ............................... 30 N.m (22 lb. ft.) in Star Pattern
Flywheel Bolt/Screw (5-Speed) ..................................................................................... 15 N.m (11 lb. ft.)+ 50
Flywheel Bolt/Screw (6-Speed) ............................................................................................. 100 N.m (74 lb. ft.)
Flywheel Housing Bolt/Screw (5:..Speed) ................................................................................ 95 N.m (70 lb. ft.)
Flywheel Housing Bolt/Screw (6-Speed) ................................................................................ 47 N.m (35 lb. ft.)
Flywheel Housing Cover Bolt/Screw (All) .......................................................................... 8.5 N.m (75 lb. in.)
Transmission Bolt/Screw (5-Speed) ........................................................................................ 75 N.m (55 lb. ft.)
Transmission Bolt/Screw (6-speed) ......................................................................................... 35 N.m (26 lb. ft.)
Transmission Brace Bolt/Screw (5-Speed) ............................................................................. 50 N.m (37 lb. ft.)
CLUTCH 7C-15
SPECIAL TOOLS
J 33169
J 38836
((-.
--
J 23907
J 36221
1
2
3
4
CLUTCH ALIGNMENT ARBOR (5-SPEED)

CLUTCH ALIGNMENT ARBOR (6-SPEED)
CLUTCH PILOT BEARING REMOVER
HYDRAULIC CLUTCH LINE SEPARATOR (5-SPEED)
06-18-96
FT0087C
7C-16
CLUTCH
BLANK
ELECTRICAL BODY AND CHASSIS 81
SECTION 8

CONTENTS
Electrical Diagnosis ........................................................................................................................................ Section
Lighting Systems and Horns .......................................................................................................................... Section
Instrument Panel, Gages and Console ........................................................................................................... Section
Body Control Module .................................................................................................................................... Section
Windshield Wiper/Washer System .................................................................................................................. Section
8A
8B
8C
8D
8E
8-2 ELECTRICAL BODY AND CHASSIS
BLANK
LIGHTING SYSTEMS AND HORNS 88-1
SECTION 88
LIGHTING SYSTEMS AND H RNS

inhibitors) on threaded fasteners orfastener joint interfaces. Generally, such coatings adversely affect the fastener
systems.
CONTENTS
Halogen Bulbs ................................................. ,... 8B-2
Exterior Lighting ................................................. 8B-2
Backup Lamps ................................................. 8B-2
Daytime Running Lamps
(Canadian Only) .................................................. 8B-2
Front Fog Lamps ............................................ 8B-2
Front Sidemarker Lamps ................................ 8B-2
Hazard Lamp Flasher ...................................... 8B-2
Headlamp Capsules and Headlamps .............. 8B-2
High-Mount Stoplamp ..................................... 8B-3
Parking and Turn Signal Lamps .................... 8B-3
Rear License Lamp ......... ,............................... 8B-3
Rear Sidemarker Lamps ................................. 8B-3
Taillamps .......................................................... 8B-3
Turn Signal Lamp Flasher .............................. 8B-3
- Interior Lighting .................................................. 8B-3
Ashtray Lamp .................................................. 8B-3
Automatic Transmission Range Selector
Indicator Lamp .................................................... 8B-3
Console Lamp ...................... ,.......................... 8B-3
Dome and Reading Lamps ............................. 8B-3
Front Side Door Courtesy Lamps .................. 8B-3
Heater and Air Conditioning Control
Lamp ........... ,....................................................... 8B-4
Instrument Panel Compartment Lamp ............ 8B-4
Rear Quarter Courtesy Lamps ........................ 8B-4
Rear Compartment Lamp ... ,........................... 8B-4
Horns ................................................................... 8B-4
Diagnosis ................................................................. 8B-4
Lighting System Troubleshooting ....................... 8B-4
Horns ................................................................... 8B-4
Horn Tone Poor............................................... 8B-4
Exterior Lighting ................................................. 8B-4
Backup Lamps ........... ;............................... ;..... 8B-4
Daytime. Running Lamps
(Canadian Only) ........................ Refer to Section 8C
Front Fog Lamps .......................................... 8B-4

Front Fog Lamp Aiming Procedure ............. 8B-5
Front Sidemarker Lamp ................................ 8B-5
Hazard Lamp Flasher ................................... 8B-5
Headlamp Capsules ....................... ,............... 8B.-5
Headlamps ......................................._. ............. 8B-6
Headlamp Opening Housing and Door
Replacement ......................... ,............ ,............... 8B-7
Headlamp Opening Door Actuator Control
Module .............................................................. 8B-8
Headlamp Aiming by Screen Method ......... 8B-9
Headlamp Aiming Alternate Procedure ....... 8B-10
Headlamp Aiming After a Collision ............ 8B-11
High-Mount Stoplamp ................................... 8B-11
Parking and Turn Signal Lamps .................. 8B-12
Rear License Lamp ....................................... 8B-12
Rear Sidemarker Lamps ............................... 8B-13
Taillamps ....................................................... 8B-13
Turn Signal Lamp Flasher ............................ 8B-14
Interior Lighting ................................................ 8B-15
Ashtray Lamp ................................................ 8B-15
Indicator Lamp ................................................. 8B-15
Front Floor Console Lamp ........................... 8B-16
Dome Lamp .................................................. 8B-16
Front Reading Lamps ................................... 8B-16
Front Side Door Courtesy Lamps ................ 8B-16
Lamp ................................................................. 8B-17
Instrument Panel Compartment Lamp ......... 8B-17
Horns ................................................................. 8B-17
Current Adjustment. ...................................... 8B-17
Horns ............................................................. 8B:-17
Hom Relay ..................................................... 8B-18
Specifications .......................... ,.............................. 8B-18
Bulb Usage Chart ............................................. 8B-19
Special Tools ................................ .- ........................ 8B-19
88-2
LIGHTING SYSTEMS AND HORNS
GENERAL DESCRIPTION
HALOGEN BULBS
Some bulbs in this vehicle may contain halogen
gas.
CAUTION: Halogen bulbs contain a gas

under pressure. Handling a bulb
improperly could cause it to shatter into
flying glass fragments. To help avoid
personal injury:
Turn off lamp and allow bulb to
cool before changing bulbs. Leave
switch off until bulb change is
complete.
Always wear eye protection when
changing a halogen bulb.
Handle bulb only by its base.
Avoid touching glass.
Do not drop or scratch bulb. Keep
moisture away.
Place used bulb in new bulb's
carton and dispose of it properly.
Keep halogen bulbs out of the
reach of children.
EXTERIOR LIGHTING
Backup Lamps
The backup lamps are part of the taillamps.
They are located on the innermost side of the taillamp
next to the taillamp filler. They will come on when the
transmission is shifted into "REVERSE." On vehicles
with an automatic transmission, the backup lamps are
activated by the park/neutral position switch. On
vehicles with a manual, they are activated by a backup
lamp switch which is part of the transmission. For
more information, refer to SECTION 7A or 7B.
Daytime Running Lamps (Canadian Only)

All Canadian vehicles are equipped with daytime
running lamps. The daytime running lamp system
includes a solid state module, and headlamp automatic
control ambient light sensor. The system lights
low-beam headlamps at reduced intensity when the
ignition switch is in the "RUN" position during
daylight. The daytime running lamp system is
designed to light the low-beam headlamps at full
intensity, and the parking and taillamps when low light
conditions are present.
Front Fog Lamps

If equipped, the fog lamp switch will be next to
the headlamp and instrument panel lamp dimmer
switch to the left of the steering column on Chevrolet
and below the headlamp and instrument panel dimmer
switch to the left of the steering column on Pontiac.
To use the front fog lamps, first turn on the headlamps
or parking lamps. Then push the right side of the fog
lamp switch to tum on the front fog lamps. Push the
left side of the switch to tum off the front fog lamps.
The front fog lamps should not be used as a

substitute for the headlamps.
Switching to high-beam headlamps will turn off
the front fog lamps. Switching back to low-beam
headlamps will turn the front fog lamps on again.
The front fog lamps must be aimed for proper
illumination of the road. Fog lamp aim should be
checked when a new bulb is installed or if service or
repairs in the front end area may have disturbed the
fog lamp mountings.
Front Sidemarker Lamps

The front sidemarker lamps are housed within
the parking and turn signal lamp. They will come on
when the headlamps or parking lamps are on. The
front sidymarker lamps also have reflectors that will
shine when struck by light whether or notthe vehicle's
lamps are on.
If the headlamps or parking lamps are off when
a turn is signaled, the appropriate front sidemarker
lamps will flash in unison with the front turn signal
lamp on the same side. If the headlamps or parking
lamps are on when a tum is signaled, the front
.sidemarker lamp and front turn signal lamp will flash
alternately.
Hazard Lamp Flasher

The hazard warning flashers ate part of the turn
signal circuit. The hazard warning switch is on the
right side of the steering column. Pressing in on the
hazard warning switch button causes the front and rear
turn signal lamps and front sidemarker lamps to .flash.
Pulling on the hazard warning switch knob will turn
off the hazard warning flashers.
The hazard warning flashers will work with the
ignition switch in any position. When the hazard
warning flashers are "ON," the turn signals do not
work. The hazard lamp flasher is in the convenience
center behind the instrument panel on the knee bolster
bracket. For more information on the hazard warning
switch, refer to SECTION 3F.
Headlamp Capsules and Headlamps

The headlamp capsules (Chevrolet) and
headlamps (Pontiac) are controlled by the headlamp
switch located on the headlamp and instrument panel
lamp dimmer switch to the left of the steering column.
They will come on with the ignition switch in any
position. Turning the headlamp switch all the way to
the right turns on the headlamps. Turning the
headlamp switch all the way to the left turns off the
headlamps.
Headlamp low beam and high beam are
controlled by the headlamp dimmer switch lever on
the left side of the steering column. When the
headlamps are on, pulling the lever toward the driver
until the switch clicks changes the lamp from low
beam to high beam, or from high beam to low beam.
An indicator lamp on the instrument cluster will come
on when the high-beam headlamps are on.
LIGHTING SYSTEMS AND HORNS 883

The headlamps must be aimed for proper
illumination of the road. Headlamp aim should be
checked whenever a new headlamp is installed or
service repairs to the front end area may have
disturbed the headlamp or its mountings.
[I]
Important
Some state and local laws specify requirements

for headlamp aim. These laws must be
followed.
High-Mount Stoplamp
The high-mount stoplamp is in the center of the
rear end spoiler. It will illuminate whenever the brake
pedal is pushed down. The lamp is powered separately
from the taillamps through a circuit in the stoplamp
switch.
Parking and Turn Signal Lamps

The parking lamps can be turned on by turning
the headlamp switch to the first position on the right.
The parking lamps can be turned off by turning the
headlamp switch to the left. If the parking lamps are
on and the ignition switch is off, a warning tone will
sound as a reminder to turn the lamps off.
When the turn signals are activated, the
appropriate front parking lamps flash to signal a tum.
The turn signal works only when the ignition switch is
on and the hazard lamp flashers are turned off.
The turn signals are controlled by the tum signal
lever on the left side of the steering column. Moving
the lever all the way up or down (past the detent) will
turn on the turn signals. When the turn is completed,
the lever will return to horizontal and the turn signals
will stop flashing.
For changing lanes or shallow turns where the
steering wheel does not turn far enough to cancel the
signal, move the signal only to the first detent and
hold it there. When the lever is released, it will return
to horizontal and the turn signal will cancel. For more
Rear License Lamp

The rear license lamp will come on when the
headlamps or parking lamps are on .. The rear license
lamp is mounted on the rear bumper fascia above the
license plate.
Rear Sidemarker Lamps

The rear sidemarker lamps are mounted on the
rear bumper fascia.
The rear sidemarker lamps will come on when
the headlamps or parking lamps are on. The rear
sidemarker lamps also have reflectors that will shine
when struck by light whether or not the vehicle's
lamps are on.
Taillamps
The taillamps, backup lamps and turn signal
lamps are all part of the taillamp.
Turning on either the headlamps or parking
lamps will turn on the taillamps. When the brake
pedal is pushed down, the taillamps glow brighter to
serve as stoplamps.
The tum signals are controlled by the turn signal

lever on the left side of the steering column. Moving
the lever all the way up or down (past the detent) will
tum on the tum signals. When the turn is completed,
the lever will return to neutral and the turn signals will
stop flashing. If the brake pedal is held down when a
tum is signaled, one side will flash and the other will
stay on brightly.
For changing lanes or shallow turns where the
steering wheel does not tum far enough to cancel the
signal, move the lever only to the first detent. When
the lever is released, it will return to neutral and the
tum signals will cancel.
Turn Signal Lamp Flasher

The tum signal lamp flasher is mounted behind
the instrument panel on the driver knee bolster
bracket.
INTERIOR LIGHTING
For information on the warning/indicator lamps,
cluster lamps, etc. Refer to SECTION 8C. For circuit
Ashtray Lamp
An ashtray lamp is available on vehicles with a
manual transmission. It is mounted beneath the ashtray
and it will come on when the parking lamps or
headlamps are turned on.

Indicator Lamp
The automatic transmission indicator lamp will
illuminate the transmission control indicator located on
the front floor console on vehicles equipped with an
automatic transmission. It will come on when the
parking lamps or headlamps are turned on.
Console Lamp
The console lamp is mounted on the front floor
console. It lights when the console compartment door
is opened.
Dome and Reading Lamps

The dome lamp (not available on convertible
models) is located on the roof above the rear seat. It
will come on when a door is opened or when the
inside lamp is turned on. To turn on the interior lamps,
rotate the interior lights thumbwheel switch, located to
the left of the headlamp switch, full up.
The front reading lamps are part of the inside
rearview mirror. Use the switch to turn a reading lamp
on or off when the doors are closed. With the doors
open, the reading lamps are always on. For more
information on the dome and reading lamps, refer to
SECTION 10-9 and SECTION 10-2.
Front Side Door Courtesy lamps

The front side door courtesy lamps are mounted
behind the front side door inside handle bezels. They
come on when the parking lamps or headlamps are
turned on to illuminate the door handles and controls.
8B-4
Heater and Air Conditioning Control lamp

The heater and air conditioning control lamp is
mounted on the back of the heater and air conditioning
control. It will come on when the parking lamps or
headlamps are turned on to illuminate the heater and
air conditioning controls.
Instrument Panel Compartment lamp

The instrument panel compartment lamp lights
when the instrument panel compartment door is
opened.
Rear Quarter Courtesy lamps

The rear quarter courtesy lamps are mounted in
the right and left quarter inner rear trim finishing
panels. They will come on when a door is opened or
when the interior lamps are turned on. For more
information on the rear quarter courtesy lamps, refer
to SECTION 10-7.
Rear Compartment lamp

The rear compartment lamp is located in the rear
compartment below the rear compartment lid latch. It
will come on when the rear compartment lid is
opened. For more information on the rear
compartment lamp, refer to SECTION 10-8.
HORNS
Pushing the pads on the left-hand or right-hand
center of the steering wheel sounds the horns by
closing the horn relay. For wiring and circuit
DIAGNOSIS
For wiring diagrams and other diagnosis
information on properly repairing wiring harnesses,
connectors, etc. Refer to SECTION 8A.
LIGHTING SYSTEM TROUBLESHOOTING

Most lighting problems are caused by loose
connectors, open or shorted wiring, burned-out bulbs,
bad switches, an inadequate ground or blown fuses.
Check these items first and then refer to
SECTION 8A.
HORNS
If the horns do not blow, or blow constantly,
follow the diagnostic procedures in SECTION 8A.
Horn Tone Poor

1. Horn tone poor - tighten horn bolts/screws in
mounting area, or correct poor connections or
ground.
2. Low-pitched moan - sounds like "mooing".
Caused by current too high. Adjust current. Refer
to "Horns" under "On-Vehicle Service" in this
section.
3. Weak tone - current too low. Correct poor
connections or ground, or adjust current. Refer to
"Horns" under "On-Vehicle Service" in this
section.
4. Weak, strained tone - remove foreign object in

horn.
5. Harsh vibration - bend bracket so horn is not
touching sheet metal.
ON-VEHICLE SERVICE
When replacing a part that requires a special
procedure (such as a lens and housing sealed together),
follow the instructions normally included in the
replacement parts package.
When removing a part that requires special
sealing items (such as sealing washers), be sure to
reinstall those items when replacing the part. Also, if
any body sealing items (grommets, etc.) are disturbed,
be sure to repair them so the passenger compartment
remains properly sealed.
Take care to prevent waterleaks if sealing
surfaces are disturbed. Damaged gaskets must be
replaced. If necessary, use sealer (body caulking
compound or equivalent) in critical areas or any ruea
where the gasket doesn't seal properly.

EXTERIOR LIGHTING
Backup lamps
To replace a backup lamp bulb, refer to
'!Taillamps" under "On-Vehicle Service" in this
section.
Front Fog lamps

Figure 1
!++!

SECTION OA.
2. Front bumper fascia lower deflector. Refer to
SECTION 10-4.
3. Bolts/screws (3) attaching front fog lamp (1) to
front bumper impact bar (4).
4. Front fog lamp (1) from front bumper impact bar
(4).
5. Nuts (2) from front bumper impact bar (4), if

necessary.
!++!
Install or Connect
NOTICE:
1. Nuts (2) to front bumper impact bar ( 4), if

removed.
!~!
Tighten
Nuts (2) to 10 N.m (89 lb. in.).
1
2
3
4
LAMP, FRONT FOG

NUT, FRONT FOG LAMP
SOLT/SCREW, FRONT FOG LAMP
OMl7-91S
FS0018B
Figure 1 - Front Fog Lamps (Typical)
2. Front fog lamp (1) to front bumper impact bar

(4).
3. Bolts/screws (3) attaching front fog lamp (1) to
front bumper impact bar (4).
!~i
Tighten

SECTION 10-4.
5. Lower vehicle.
Front Fog lamp Aiming Procedure

Horizontal aim is not adjustable oh this vehicle.
Vertical aim is done by an adjusting screw located at
the top .center of the front fog lamp.
Prepare vehicle:
A. Make sure all components are in place, if
other service has been performed on vehicle.
B. Make sure vehicle has 1/2 tank of fuel or less.
C. Move vehicle to level area and park 7.6 m
(25 feet) away from target screen.
D. Measure from center of front fog lamp to
ground line.
E. Turn front fog lamps on. Top edge of high
intensity zone to be 102 mm (4 inches) below
centerline of front fog lamp.
F. Adjust front fog lamp as required, using
adjusting screw at top center of front fog lamp.
I++!
Install or Connect
1. Hazard lamp flasher (6) to convenience center.
2. drivers knee bolster. refer to SECTION 8C.
Headlamp Capsules
CHEVROLET
Figure 3
!++I
1.
2.
3.
4.
5.
Open hood.
Bolts/screws (7).
Headlamp mounting ring (8).
Electrical connector.
Headlamp capsule (9).
------
Front Sidemarker Lamp

For replacement of front sidemarker lamp bulb,
refer to "Parking and Turn Signal Lamps" under
Hazard Lamp Flasher

Figure 2
!++!
1. Drivers knee bolster. Refer to SECTION 8C.

2. Hazard lamp flasher (6) by pulling from
convenience center.
A CONVENIENCE CENTER ..----5 RELAY, HORN

6 FLASHER. HAZARD LAMP
Figure 2 - Horn Relay and Hazard Lamp Flasher
88-6
(
B
A
B
C
D
E
F
7
8
9
HORIZONTAL ADJUSTMENT SCREW

HORIZONTAL uoH (ZERO) INDICATOR
VERTICAL LEVEL INDICATOR
VERTICAL ADJUSTMENT SCREW
VEHICLE WITH 1/2 TANK OF FUEL OR MORE
VEHICLE WITH 1/4 TANK OF FUEL OR LESS
BOLT/SCREW, HEADLAMP
RING, HEADLAMP MOUNTING
CAPSULE.HEADLAMP
(
!VIEW B ! -
012795
FS0038B
!++!
Figure 3 - Headlamp Capsules (Chevrolet)
Install or Connect
Headlamps
PONTIAC
NOTICE:
1. Headlamp capsule (9).

3. Headlamp mounting ring (8).
If replacing headlamp mounting ring (8),
transfer undamaged vertical level indicator to
new headlamp mounting ring (8).
Tighten securely.
5. Close hood.
Figure 4
l++I
1.
2.
3.
4.
Open hood.
Bolts/screws (44).
Headlamp bezel (43).
Headlamp bolts/screws attaching mounting ring to
headlamp opening housing (49).
5. Headlamp mounting ring.
7. Sealed-beam headlamp.
41
42
43
44
45
46
47
48
49
53
56
57
88-7
BOLT/SCREW, HEADLAMP OPENING DOOR

DOOR, HEADLAMP OPENING
BEZEL, HEADLAMP
BOLT/SCREW, HEADLAMP BEZEL
BRACKET, HEADLAMP OPENl~G HOUSING
BOLT/SCREW, HEADLAMP OPENING DOOR BRACKET
BRACKET, HEADLAMP OPENING DOOR
BRACKET, HEADLAMP INTERMEDIATE
HOUSING, HEADLAMP OPENING
ACTUATOR, HEADLAMP
NUT, HEADLAMP OPENING HOUSING
BOLT/SCREW, HEADLAMP OPENING HOUSING
01-2796
FS0048B
Figure 4 - Headlamps - (Pontiac)
!-++!
Install or Connect
NOTICE: Refer to "Notice" on page 8B-l.

1.
2.
3.
4.
Sealed-beam headlamp.
Electrical connector;
Headlamp mounting ring.
Headlamp bolts/screws attaching mounting ring to
headlamp opening housing (49).
Tighten securely.
5. Headlamp bezel (43).
Top of headlamp bezel (43) must be flush to
inner surface of headlamp opening door (42).
l~I
Tighten

7. Close hood.
Headlamp Opening Housing and Door

Replacement
PONTIAC
Figure 4
!++!
1. Raise headlamp manually by turning knob on

headlamp actuator (53).
5. Headlamp opening door (42).
6. Nuts (56) and bolts/screws (57) attaching
headlamp opening housing ( 49) to headlamp
opening housing bracket (45).
7. Headlamp opening housing (49) from headlamp
9. Opening door bracket (47).
8B8
10. Intermediate bracket (48).

11. Headlamp actuator cap.
12. Cable up stop bolt/screw.
13. Actuator (53) from headlamp opening housing
bracket (45), if necessary, by removing attaching
nut and bolts/screws.
lHI
Install or Connect
NOTICE:
1. Actuator (53) to headlamp opening housing

bracket (45), if removed, by installing attaching
nut and bolts/screws.
2. Cable up stop bolt/screw.
l~I
3.
4.
5.
6.
Tighten
Cable up stop bolt/screw to 1.7 N.m

(15 lb. in.).
Headlamp actuator cap.
Intermediate bracket (48) to headlamp opening
housing (49).
Opening door bracket (47) on top of intermediate
bracket (48).
Bolts/screws (46).
ll'l'I
Inspect
Headlamp Opening Door Actuator Control

Module
PONTIAC
Figure 5
!+-+I
1. Front air intake duct (without RPO WS6). Refer

to SECTION 6E3.
2. Electrical conectors.
4. Actuator module .from cover plate.
5. Door actuator module (50) from air intake duct
(52) (without RPO WS6).
!-++!
Install or Connect
1. Door actuator module (50) to air intake duct (52)

(without RPO WS6).
2. Acutator module to cover plate.
5. Front air intake duct. Refer to SECTION 6E3
(without RPO WS6).
Gaps and flushness of headlamp opening door

(42) to surrounding area using bolts/ screws
(46).
Tighten securely.
7. Headlamp opening housing (49) to headlamp
!LI
Inspect
Gaps on headlamp opening housing (49) to

surrounding area using the forward and
rearward adjustment bolts/screws (60), or
side-to-side adjustment bolts/screws (59).
Tighten securely.
8. Bolts/screws (57) and nuts (56) attaching
headlamp opening housing ( 49) to headlamp
Tighten securely.
9. Headlamp opening door (42).
1~1 Tighten
l~I
Tighten

13. Lower headlamp.
A CONNECTOR, ELECTRICAL
50 MODULE, HEADLAMP OPENING DOOR ACTUATOR
CONTROL
51 BOLT/SCREW, HEADLAMP AUTOMATIC CONTROL
MODULE
012785
52 DUCT, FRONT AIR INTAKE
FS00511B
Figure 5 Headlamp Opening Door Actuator Control
Module (Pontiac)

Headlamp Aiming by Screen Method
Figures 6, 7 and 8
Horizontal aim is corrected by an adjusting
screw on the outer side of the headlamp capsule
(Chevrolet) or headlamp (Pontiac). Vertical aim is
corrected by an adjusting screw in the top center of
the.
It is desirable to have a specific aiming area in a
darkened location. This area should be large enough to
accommodate the vehicle, plus an additional 25 feet
measured from the face of the headlamp capsule to the
front of the visual screen.
The floor on which the vehicle rests must be
flat with the bottom of the screen. If the floor
is not level, then compensation must be made.
The aiming screen should be 5 feet high by
12 feet wide with a matte white surface, well
shaded from outside light, and properly
adjusted to the floor on which the vehicle
stands. The screen must be provided with a
vertical center line, two laterally adjustable
vertical tapes, and a vertically adjustable
horizontal tape.
[I)
Important
For each vehicle checked, the horizontal lines

or tape on the screen must be adjusted.
Vehicles of the same model and year will have
different standing height for the headlamp
capsules.
889
Provisions should be made for moving the screen,

so that it can be aligned parallel with the rear
axle. This will allow for a horizontal line drawn
perpendicular from the center line of the screen to
pass through the center point between the two
capsules.
Once the screen has been set up in a permanent
location, a reference line is to be painted on the
floor to identify the proper location of the
headlamp capsules (Chevrolet) or headlamps
(Pontiac) when they are being aimed (Figure 6).
-
If a regular commercial aiming screen is not

available, the screen may consist of a vertical
wall having a clear uninterrupted area
approximately 6 feet high by 12 feet wide,
finished with a washable non-gloss white
paint.
1. Prepare vehicle for checking beam aim as follows:
A. Completely assemble all components on
vehicle.
B. Fuel load to be 1/2 tank or less.
Only other load in vehicle is the driver.
C. Position vehicle so it is square with aiming
screen, and with the headlamp capsules
(Chevrolet) or headlamps (Pontiac) directly
over reference line which has been painted on
floor.
D. Locate vertical line on aiming screen so that it
is in line with center of rear window and over
hood (Figure 6).
3.66 m (12') MINIMUM
DISTANCE BETWEEN
HEADLAMPS
ADJUSTABLE
VERTICAL TAPES
ADJUSTABLE
HORIZONTAL TAPE
DIAGRAM OF LIGHT SCREEN
A CENTERLINE OF LAMPS, TRANSFER MEASUREMENT

FROM VEHICLE TO WALL/SCREEN
Figure 6 Visual Headlamp Aiming Preparation
012795
FS0068B
8810
VERTICAL CENTERLINE
STRAIGHT AHEAD OF
LAMPCENTllR
-------I
VERTICAL AIMHIGH
INTENSITY ZONE
CENTERED ON (HI
LIMITS.
HORIZONTAL CENTERLINE
LOCATEO-AT LEVEL OF
LAMP CENTER
E. Mark center of front and rear windows with

narrow tape. Use these "sights" to locate
center of vehicle.
Move the vehicle or the screen until the
center line of the screen comes into
alignment with the two points.
F. Close doors.
G. Rock vehicle sideways to stabilize suspension.
2. With headlamps on high beam, observe center of
high intensity zone on screen.
IL!
LATERAL AIM-HIGH
INTENSITY ZONE
CENTERED ON M
LIMITS
AIM INSPECTION FOR HIGHBEAM HEADLAMP
VERTICAL CENTERLINE
STRAIGHT AHEAD OF
LAMP C E N T E R - - - - - - ~
012Ml5
FS0078B
AIM INSPECTION FOR LOWBEAM-HEAOLAMP
Figure 7 Visual Headlamp Aim Limits (Pontiac)
VERTICAL CENTERLINE
STRAIGHT AHEAD OF
LAMP CENTER
--------1
VERTICAL AIM HIGH

INTENSITY ZONE
CENTERED ON (Hl
LIMITS.
_ _ _ _ ___.,....._
__.____.....__--t_
--CENTERHIOH--_
- .....__--tH
- ~NTENSITY ZONE- - - - - -
LATERAL AIM HIGH

INTENSITY ZONE
CENTERED ON (V)
LIMITS
AIM INSPECTION FOR HIGHBEAM HEADLAMP
VERTICAL CENTERLINE
STRAIGHT AHEAD OF
LAMP C E N T E R - - - - - - ~
Inspect
Horizontal aim using horizontal adjusting

screw if center is more than:
- 102 mm (4 inches) RIGHT of straight
ahead ..
- 102 mm (4 inches) LEFT of straight ahead.
Vertical aim using vertical adjusting screw if
center is more than:
- 51 mm (2 inches) ABOVE the horizontal
line.
- 51 mm (2 inches) BELOW the horizontal
line (Chevrolet).
- 64 mm (2.5 inches) BELOW the horizontal
line (Pontiac).
3. Switch headlamps on to .low beam, and observe
left and top edges of high intensity zone on
screen.
!L!
HORIZONTAL CENTERLINE
LOCATED AT LEVEL OF
LAMP CENTER
Inspect
Horizontal aim using horizontal adjusting

screw if left edge is more than:
- 102 mm (4 inches) RIGHT of straight
ahead.
- 102 mm (4 inches) LEFT of straight ahead.
Vertical aim using vertical adjusting screw if
top edge is more than:
- 51 mm (2 inches) ABOVE the horizontal
line.
- 51 mm (2 inches) BELOW the horizontal
line (Chevrolet).
-'- 64 mm (2.5 inches) BELOW the horizontal
line (Pontiac).
Headlamp_ Aiming Alternate Procedure

CHEVROLET
Figure 3
LATERAL AIM LEFT EDGE

OF HIGH INTENSITY ZONE
ATIVI
LIMITS.-----;.._-...i...-+--'
-A-IM-IN-S-PE-C-TIO_N_F_O_RL-0-W--B-EA_M_H-EA-D-LA-Mr...P------
r~:
Figure 8 Visual Headlamp Aim Limits -(Chevrolet)
vehicle.
B. Place vehicle on level surface.
Vehicle must be level. If necessary, pads
may be used on uneven floors.
C. Stop all other work on vehicle.
D. Close doors.
E. Rock vehicle sideways to stabilize suspension.
LIGHTING SYSTEMS AND HORNS 8811

NOTICE: Horizontal aim of headlamp capsule
must be done first. Adjusting vertical aim first
will result in incorrect headlamp aim.
[I]
Aim-adjusting tools should be carefully

selected since one full turn of an adjusting
screw will move the aim approximately
89 mm (3.5 inches) when measured at 25 feet.
2. Assure horizontal adjuster is set to "O" (zero)

mark:
A. If vehicle has been damaged, refer to

"Headlamp Aiming After a Collision" in the
following procedure.
B. If horizontal pointer is not set at "O" (zero),
turn horizontal aiming adjustment screw until
pointer is lined up with "O" (zero).
3. Adjust vertical aim by turning vertical aiming
screw until bubble in level is centered at
"O" (zero).
If fuel tank is near empty to 1/4 full, adjust

aim to center bubble at -0.4 degrees. This will
reduce the chance of raising the headlamp
capsules into oncoming driver's eyes when the
fuel tank is filled.
PONTIAC
If a headlamp testing machine is used, it should

give results equivalent to those obtained using the
screen method. It should be in good repair and
adjustment, and should be used in accordance with the
manufacturer's instructions. The machine using a
photoelectric cell or cells to determine aim should also
have a visual screen upon which the beam pattern is
projected proportional to its appearance and aim on a
screen at 25 feet. Such visual screen should be plainly
visible to the operator and should have horizontal and
vertical reference lines to permit visual appraisal of
the lamp beam.
Tool Required:
J 25300-E Headlamp Aimer

vehicle.
D. Close doors.
2. Install headlamp aimer J 25300-E to headlamp.
3. Calibrate mechanical aimers (conforming to
SAE J1602):
Important
Headlamp Aiming After a Collision

vehicle.
D. Close doors.
NOTICE: Horizontal aim of headlamp capsule

(Chevrolet) or headlamp (Pontiac) must be done
first. Adjusting vertical aim first will result in
incorrect headlamp aim.
2. Headlamp aim may be accomplished using a wall
and visual aiming. Refer to "Headlamp Aiming
by Screen Method" in this section.
3. It may be necessary to re-calibrate horizontal
adjuster after a collision. This is done after
completion of the screen aiming procedure. Use a
T-15 TORX screwdriver to reset horizontal
indicator to "O" (zero) (Chevrolet only).
High-Mount Stoplamp
Figure 9
I++!
1. Bolts/screws (11) from stoplamp (10).

2. Stoplamp (10) from rear end spoiler (13).
3. Nut (12), if necessary.
5. Bulbs and sockets from stoplamp (10).
6. Bulbs from sockets.
!++!
Install or Connect
NOTICE:
A. Set master fixture to "O" U/D and "O" R/L.

B. Calibrate aimers on master fixture to read "O"
and "O" R/L.
!LI
Inspect
Horizontal aim using horizontal adjusting screw.

- 102 mm (4 inches) left to 102 mm (4 inches)
right.
Vertical aim using vertical adjusting screw. -51 mm (2 inches) up to 64 mm (2.5 inches)
down.
1.
2.
3.
4.
5.
6.
Bulbs to sockets.
Bulbs and sockets to stoplamp (10).
Nut (12), if removed.
Stoplamp (10) to rear end spoiler (13).
Bolts/screws (11) to stoplamp (10).
!~I
Tighten
8B12

4. Parking and tum signal lamp (14) from shelf on
front bumper fascia.
5. Front sidemarker lamp bulb (17), parking and tum
signal lamp bulb (16) and sockets from front
parking and tum signal lamp (14).
6. Front sidemarker lamp bulb (17) and parking and
tum signal lamp bulb (16) from sockets.
13
!++!
13
Install or Connect
1 Front sidemarker lamp bulb ( 17) and parking attd

tum signal lamp bulb ( 16) to sockets.
2. Front sidemarker lamp bulb (17), parking and tum
.signal lamp bulb ( 16) and sockets to parking and
tum signal lamp (14).
3. Parking and tum signal lamp (14) to shelf on
front bumper fascia.
4. Bolts/screws (15) to parking and tum signal lamp
(14).
o
10
A
8
10
11
12
13
TAPE
STOPLAMP, HIGH-MOUNT
BOLT/SCREW, HIGH-MOUNT STOPLAMP
NUT, HIGH-MOUNT STOPLAMP
SPOILER, REAR END
I~!
012795
FS0098B
Figure 9 - High-Mount Stoplamp (Typical)
Parking and Turn Signal lamps

Figure 10
l++I
Tighten

SECTION 10-4.
6. Lower vehicle.
Rear License lamp

Figure 11
I++!

SECTION OA.
SECTION 10-4.
3. Bolts/screws (15) from parking and tum signal
lamp (14).
1. Bolts/screws (18) from rear license lamp (20).

2. Rear license lamp (20) from rear bumper fascia
(25).
3. Bulb (19) and socket from rear license lamp (2D).
4. Bulb (19) from socket.
A SOCKET
14
15 BOLT/SCREW, PARKING LAMP
16 BULB, PARKING AND TURN SIGNAL LAMP
17 BULB. FRONT SIDEMARKER LAMP
5-5-94
FS0108B
Figure 10 - Parking and Tum Signal Lamps (Typical)
----
22
A
22
23
24
25
A
18
19
20
21
SOCKET
BOLT/SCREW, REAR LICENSE LAMP
BULB, REAR LICENSE LAMP
LAMP, REAR LICENSE
HARNESS, REAR LICENSE AND REAR SIDEMARKER
LAMP WIRING
013195
25 FASCIA, REAR BUMPER
FS01181S
Figure 11 Rear License Lamp (Typical)
lHI
Install or Connect
NOTICE:
I++!
88-13
SOCKET
BOLT /SCREW, REAR SIDEMARKER LAMP
LAMP, REAR SIDEMARKER
BULB, REAR SIDEMARKER LAMP
FASCIA, REAR BUMPER
093195
FS0128B
Figure 12 Rear Sidemarker Lamps
Install or Connect
NOTICE:
1. Bulb (24) to socket.
2. Bulb (24) and socket to rear sidemarker lamp

(23).
3. Rear sidemarker lamp (23) to rear bumper fascia
(25).
4. Bolts/screws (22) to rear sidemarker lamp (23).
!~!
Tighten

1.
2.
3.
4.
Bulb (19) to socket.

Bulb (19) and socket to rear license lamp (20).
Rear license lamp (20) to rear bumper fascia (25).
Bolts/screws (18) to rear license lamp (20).
!~!
Tighten
Rear Sidemarker lamps

Figure 12
!++j
1. Bolts/screws (22) from rear sidemarker lamp (23).

2. Rear sidemarker lamp (23) from rear bumper
fascia (25).
3. Bulb (24) and socket from rear sidemarker lamp
(23).
4. Bulb (24) from socket.
Taillamps
CHEVROLET
Figure 13
!++!
1. Reposition rear compartment trim.

2. Nuts (131) attaching taillamp (126) to rear end
finishing panel.
3. Taillamp (126) from rear end finishing panel.
4. Taillamp, tum signal and backup lamp bulbs
(127, 128, 129 and 130) and sockets from
taillamp (126).
5. Taillamp, tum signal and backup lamp bulbs
(127, 128, 129 and 130) from sockets.
!++!
Install or Connect
NOTICE:
1. Taillamp, tum signal and backup lamp bulbs (127,
128, 129 and 130) to sockets.
88-14
126
A BACKUP LAMP OPENING

B TURN SIGNAL LAMP OPENING
C TAILLAMP OPENING
128
D TAILLAMP OPENING 129
126 TAILLAMP
130
127 BULB, TAILLAMP
131
BULB, TURN SIGNAL

BULB, TAILLAMP
BULB, PACKUP LAMP
013195
NUT, TAILLAMP
FS01381!1
Figure 13 Taillamps (Chevrolet)
2. Taillamp, turn signal and backup lamp bulbs (127,

128, 129 and 130) and sockets to taillamp (126).
Rotate socket 90 degrees in taillamp (126) to
lock and secure.
3. Taillamp ( 126) to rear end finishing panel.
finishing panel.
I~!
Tighten
Nuts (131) to 3 N.m (27 lb. in.).

5. Position rear compartment trim.
PONTIAC
Figure 14
I++!
1. Reposition rear compartment trim.

panel.
3. Taillamp (26) from rear end panel.
4. Taillamp filler (40), if necessary.
Both taillamps (26) must be removed to
replace taillamp filler (40).
28 and 30) and sockets from taillamp (26).
28 and 30) from sockets.
lH!
Install or Connect

1. Taillamp, tum
(27, 28 and 30)
2. Taillamp, turn
(27, 28 and 30)
signal and backup lamp bulbs

to sockets.
signal and backup lamp bulbs
and sockets to taillamp (26).
Rotate socket 90 degrees in taillamp (26) to

lock and secure.
3. Taillamp filler (40), if removed.
4. Taillamp (26) to rear end panel.
panel.
l~I
Tighten
Nuts (31) to 3 N.m (27 lb. in.).

6. Position rear compartment trim.
Turn Signal lamp Flasher

Figure 15
i++!
1. Clip (33) from driver knee bolster bracket.

3. Flasher (32) from clip (33), if necessary.
SB-15
26
A
B
C
26
BACKUP LAMP OPENING

TURN SIGNAL LAMP OPENING
TAILLAMP OPENING
TAILLAMP
27
28
30
31
40
BULB, TAILLAMP
BULB, TURN SIGNAL
BULB, BACKUP LAMP
NUT, TAILLAMP
FILLER, TAILLAMP
Figure 14 Taillamps (Pontiac)
!-.+!
Install or Connect
1. Flasher (32) to clip (33), if removed.

3. Clip (33) to driver knee bolster bracket.
INTERIOR LIGHTING
For information on warning/indicator lamps,
instrument cluster lamps, etc. Refer to SECTION 8C.
For circuit information, refer to SECTION 8A.
\.---,,r,----33
CONNECTOR,
ELECTRICAL
32 FLASHER, TURN
SIGNAL LAMP
33 CLIP, TURN SIGNAL
LAMP FLASHER
0131915
f8011S81B
Ashtray Lamp
BULB REPLACEMENT
i~. .~I
1. Open ashtray opening cover.

2. Ashtray.
3. Pull bulb, socket and shield through opening in
4. Bulb and socket from shield.
!++!
Install or Connect
1. Bulb to socket.
2. Shield to bulb and socket.
3. Bulb, socket and shield to opening in front floor
console.
4. Ashtray.
5. Close ashtray opening cover.
Figure 15 - Turn Signal Lamp Flasher

Indicator lamp
BULB REPLACEMENT
!+-+!
1. Front floor console transmission opening trim

plate.
2. Bulb and socket from front floor console
transmission opening trim plate.
SB-16
!++I
Install or Connect
1. Bulb to socket.
2. Bulb and socket to front floor console
transmission opening trim plate.
3. Front floor console transmission opening trim
plate.
Snap in place to secure.
Front Floor Console Lamp

BULB REPLACEMENT
l++I
1. Open front floor console compartment door.

2. Console lamp and retainer from front floor
console transmission shift opening trim plate.
4. Retainer from console lamp, if necessary.
!++!
35-r--*'~
!VIEWAI
A CONNECTOR,ELECTRICAL
B PIN, LOCATING
34 HOUSING, DOME LAMP
35 BOLT/SCREW, DOME LAMP
36 BULB, DOME LAMP
Install or Connect
1. Retainer to console lamp, if removed.

2. Bulb to socket.
3. Lamp and retainer to opening in front floor
console transmission shift opening trim plate until
retainer is seated.
4. Close front floor console compartment door.
Dome lamp
BULB REPLACEMENT
Figure 16
l++i
36
013195
F80168B
Figure 16 Dome Lamp Housing (Typical)
Front Reading lamps

BULB REPLACEMENT
!++!
1. Lamp lens from inside rearview mirror, using a

flat-bladed tool.
2. Bulb from socket, using a flat-bladed tool.
!++I
Install or Connect
1. Bulb into socket.

2. Lens to inside rearview mirror by snapping into
place.
Loosen enough to pull dome lamp housing
(34) from headlining trim finish panel.
2. Dome lamp housing (34) by pulling from
headlining trim finish panel.
4. Bulb (36) from dome lamp housing (34).
I++!
Install or Connect
NOTICE:
1. Bulb (36) to dome lamp housing (34).

3. Dome lamp housing (34).
Use locating pins to position dome lamp
housing (34) to headlining trim finish panel.
l~I
O
Tighten
Front Side Door Courtesy lamps

BULB REPLACEMENT
i++!
1. Front side door inside handle bezel bolt/screw.

2. Front side door inside handle bezel.
3. Bulb and socket from front side door inside
handle bezel.
I++!
Install or Connect

1. Bulb to socket.
2. Bulb and socket to front side door inside handle
bezel.
3. Front side door inside handle bezel.
4. Front side door inside handle bezel bolt/screw.
!~!
Tighten
Front side door inside handle bezel bolt/screw

to 1.4 N.m (12 lb. in.).
Heater and Air Conditioning Control lamp

BULB REPLACEMENT
!++I
1. Instrument panel cluster trim plate bezel. Refer to

SECTION 8C.
2. Heater and air conditioning control bolts/screws.
3. Heater and air conditioning control.
5. Bulbs and sockets from heater and air
conditioning control.
6. Bulbs from sockets.
!H!
Install or Connect
NOTICE:
88-17
HORNS
CURRENT ADJUSTMENT
Figure 17
Current draw for a horn while operating should
be 4.5 to 5.5 amperes at 11.5 to 12.5 volts. High
current (more than 20 amperes) indicates an
overheated winding or shorted horn: replace the horn.
A current reading of about 18 amperes means
contacting points are not open: adjust horn current. No
current reading indicates a broken connection or an
open circuit due to a broken lead or overheated horn.
An overheated horn must be replaced. No current
reading may also mean contact points are open: adjust
horn.
!L'I"!
Inspect
1. Increase current - tum adjustment screw (55)

clockwise.
2. Decrease current - tum adjustment screw (55)
counterclockwise.
3. Current adjustments should be made 1/ 4 tum
(90 degrees) at a time.
Homs
1. Bulbs to sockets.
2. Bulbs and sockets to heater and air conditioning
control.
4. Heater and air conditioning control.
5. Heater and air conditioning control bolts/screws.
bolts/screws to 1.9 N.m (17 lb. in.).
6. Instrument panel cluster trim plate bezel. Refer to
SECTION 8C.
e
Instrument Panel Compartment lamp

BULB REPLACEMENT
!++!
l++I

SECTION OA.
SECTION 10-4.
4. Bolt/screw (39) from horn (37 or 38).
1. Open instrument panel compartment door.

2. Instrument panel compartment lamp and retainer
from instrument panel.
4. Retainer from instrument panel compartment
lamp, if necessary.
I++!
Figure 18
55 SCREW, HORN ADJUSTMENT
Install or Connect
1. Retainer to instrument panel compartment lamp, if

removed.
2. Bulb to socket.
3. Lamp and retainer to opening in instrument panel
until retainer is seated.
4. Close instrument panel compartment door.
0131-H
FS01789
Figure 17 - Hom Adjustment
88-18

2. Horn (37 or 38) to right-hand engine compartment
side outer rail.
Use "F" and "A" designations on inboard
side of horn (37 or 38).
3. Bolt/screw (39) to horn (37 or 38).
I~!
Tighten

SECTION 10-4.
5. Lower vehicle.
A
37
38
39
HORN, F NOTE
HORN, A NOTE
BOLT/SCREW, HORN
Horn Relay
Figure 2
013195
FS0188B
Figure 18 Horns
5. Horn (37 or 38) from right-hand engine

compartment side outer rail.
I++!
The horn relay (5) is in the convenience center,

behind the instrument panel on the driver knee bolster
bracket.
!+-+I
Horn relay (5) from convenience center.
Install or Connect
!-++I
NOTICE:
Install or Connect
Hom relay (5) to convenience center.
SPECIFICATIONS
Dome Lamp Bolt/Screw ........................................................................................................ 1.7 N.m (15 lb. in.)
Front Fog Lamp Bolt/Screw ................................................................................................... 15 N,m (11 lb. ft.)
Front Fog Lamp Nut .............................................................................................................. 10 N.m (89 lb. in.)
Front Side Door Inside Handle Bezel Bolt/Screw ............................................................... 1.4 N.m (12 lb. in.)
Headlamp Bezel Bolt/Screw (Pontiac Only) ........................................................................ 1.7 N.m (15 lb'. in.)
Headlamp Opening Door Bolt/Screw (Pontiac Only) .......................................................... 1.7 N.m (15 lb. in.)
Heater and Air Conditioning Control Bolt/Screw ................................................................ .1.9 N.m (17 lb. in.)
High-Mount Stoplamp Bolt/Screw ........................................................................................ 1.7 N.m (15 lb. in.)
Hom Bolt/Screw ............................................................................................................... ;...... 27 N.m (20 lb. ft.)
Parking Lamp Bolt/Screw ..................................................................................................... 2.5 N.m (22 lb. in.)
Rear License Lamp Bolt/Screw ............................................................................................ 1.9 N.m (17 lb. in.)
Rear Sidemarker Lamp Bolt/Screw ...................................................................................... 1.4 N.m (12 lb. in.)
Taillamp Nut ...................................................................... ;...................................................... 3 N.m (27 lb. in.)
BULB USAGE CHART

EXTERIOR LAMPS
TRADE NO.
Backup (Chevrolet)
1141
Ashtray*
194
Backup (Pontiac)
1156
Automatic Transmission Indicator (PRNDL)
73
INTERIOR LAMPS
TRADE NO.
Front Fog (Chevrolet)
885
Cluster Illumination
161
Front Fog (Pontiac)
880
Console
194
Front Sldemarker
194
Dome
906
Headlamp (Chevrolet)
Low Beam
H-4351
Front Reading
212-2
Front Side Door Courtesy
74
High Beam
H-4352
37
Headlamp (Pontiac)
H6545
Instrument Panel Compartment
194
High-Mount Stoplamp
921
Rear Compartment (Convertible Only)
562
Parking and Turn Signal
3057
Rear Courtesy (Convertible Only)
562
Rear License
194
Turn Signal Indicator
161
Rear Sldemarker
194
Warning/Indicator (Chevrolet)
161
Talllamp (Stop, Turn Signal)
2057
PC74
Talllamp (Fill In)
194
Warning/Indicator (excluding Turn Slgnal Indicator)

(Pontiac)
Turn Signal (Rear)
3057
C8751
SPECIAL TOOLS
J 25300-E
HEADLAMP AIMER
01-31-96
FS02088
88-20
BLANK
INSTRUMENT PANEL, GAGES AND CONSOLE
8C-1
SECTION SC

otherwise unneeded SIR system repair.
NOTICE:Always use the correct fastener in. the correct location. When you replace a fastener, use ONLY the
exact part number for that application. General Motors will call out those fasteners tht require a replacement
inhibitors) on threaded fasteners or fastener joint interfaces. Generally such coatings adversely affect the fastener
torque and the joint clamping force, and may damage the fastener. When you intstall fasteners, use the correct
systems.
CONTENTS
General. Description ................................................. 8C-2

Instrument Panel Fuse Block.............................. 8C-2
AM/FM Stereo and
Clock Radio ........................... Refer to Section 9A
Data Link Connector (DLC) ...... Refer to Section 6E
Heater and Air Conditioning
Control.. ............................... Refer to Section. 1B 1
Convenience Center ............................................ 8C-2
Powertrain Control
Module (PCM) ................... Refer to. Section. 6E
Daytime Running Lamps (DRL)

(Canadian Only) .............................................. 8C-2
Power Window Control Module ......................... 8C-2
Retained Accessory Power ............................ ,.... 8C-2
Front Floor Console ............................................ 8C-2
Instrument Cluster ............................................... 8C~3
Gages ................................................................... 8C-3
Instrument Panel. ................................................. 8C-4
Instrument Panel Switches .................................. 8C-4
Headlamp and Instrument Panel
Lamp Dimmer Switch................................. 8C-4
Front Fog Lamp Switch ................................. 8C-4
Rear Compartment Lid Release Switch ....... ,.8C-5
Rear Defogger Switch..................................... 8C-5
Sensors ................................................................. 8C-5
Daytime Running Lamp (DRL)
Ambient Light Sensor
(Canadian Only) .......................................... 8C-5
Cluster Warning/Indicator Lamps ....................... 8C-5
Warning/Reminder Chimes ................................. 8C-7
Diagnosis ................................................................. 8C-7
On-Vehicle Service .................................................. 8C-7
Service Precautions .... :........................................ 8C-7
Disabling the SIR System .............................. 8C-7
Enabling the SIR System ............................... 8C-7
Handling Electrostatic Discharge (ESD)
Sensitive Parts ................................................. 8C-8
Controls ................................................................ 8C-8
AM/FM Stereo and Clock Radio ................. 8C-8

Heater and Air Conditioning Control.. ........ 8C-10
Data Link Connector (DLC) ............................ 8C-11
Components (Canadian Only) ....................... 8C-12
Daytime Running Lamp Ambient
Light Sensor .............................................. 8C-12
Light Sensor Module ................................ 8C-12
Instrument Panel Driver Knee Bolster
and Deflector ................................................. 8C-12
Engine Oil Level Indicator Control
and Low Engine Coolant
Indicator Modules .................. Refer to Section 6B
Front Floor Console .......................................... 8C-14
Front Floor Console Tape Storage Tray ...... 8C-15
Cigarette Lighter ........................................... 8C-15
Convertible Top Switch ................................ 8C-16
Compartment Lamp Switch .......................... 8C-16
Second Gear Start Switch (V6 Automatic) .8C-16
Traction Control Switches ............................ 8C-19
Front Floor Console Transmission
Shift Opening Trim Plate ......................... 8C-19
Heat, Ventilation and Air
Conditioning Ducts ....................................... 8C-19
Windshield Defroster Nozzle and
Air Distributor ........................................... 8C-19
Instrument Panel Center Air Outlet Ducts .. 8C-21
Side Window Defogger Outlet Duct... ......... 8C-21
Floor Air Outlet Duct. .................................. 8C-22
Instrument Panel Outer Air Outlet Ducts .... 8C-22
Instrument Cluster ............................................. 8C-22
Instrument Panel Carrier ................................... 8C-23
Instrument Panel Switches ................................ 8C-25
Headlamp and Instrument Panel
Lamp Dimmer. Switch .............................. 8C-25
Rear Compartment Lid Release Switch ....... 8C-25
Instrument Panel Wiring Harness ..................... 8C-26
SC-2
Instrument Panel Fuse Block ........................ 8C-27

Convenience Center ....................................... 8C-27
Power Window Control Module ....................... 8C-28
Odometer Repair Notice Label... ...................... 8C-29
Instrument Panel Insulator ................................ 8C-29
Instrument Panel Cluster Trim. Plate Bezel,
Instrument Panel Compartment and
Instrument Panel Upper Trim Panel... .......... 8C-30
Instrument Panel Cluster Trim
Plate Bezel ................................................. 8C-30
Instrument Panel Compartment .................... 8C-30
GENERAL DESCRIPTION
INSTRUMENT PANEL FUSE BLOCK
The instrument panel fuse block is a part of the
body wiring harness. It is attached by a bracket on the
left front hinge pillar and is accessed through a
removable panel on the instrument panel carrier.
For diagnosis, refer to SECTION 8A.
CONVENIENCE CENTER
The convenience center is part of the body
wiring harness. It is attached to a bracket located on
the cowl below the instrument panel carrier to the left
of the steering column.
The vehicle speed sensor (VSS) buffer, and
hazard lamp flasher are attached to the convenience
center. The tum signal lamp flasher is opposite the
convenience center to the right of the steering column
and the instrument panel driver knee bolster bracket.
For diagnosis of the convenience center and
components, refer to SECTION 8A.
DAYTIME RUNNING LAMPS (DRL)

(CANADIAN ONLY)
All Canadian vehicles are equipped with daytime
running lamps. The daytime running lamp system
includes a solid state module and a headlamp
automatic control ambient light sensor. The system
lights the park lamps when the ignition switch is in
the "RUN" position during daylight. The daytime
running lamp system is designed to light the low-beam
headlamps at full intensity, and the parking and
taillamps when low light conditions are present.
POWER WINDOW CONTROL MODULE

The power window control module fully lowers
the driver's front side door window when the side
window switch is pressed quickly and released.
RETAINED ACCESSORY POWER (RAP)

If the vehicle is equipped with power door locks,
the vehicles Body Control Module (BCM) has a
feature called Retained Accessory Power (RAP). With
RAP the power door locks, electric mirrors, power
windows, audio system and remote hatch release will
continue to work up to 10 minutes after the ignition
key is turned to "OFF" and neither door is opened.
If a door is opened, the audio system and power
windows will shut off. The power door locks, electric
mirrors and remote hatch release will work until you
Instrument Panel Compartment Door ........... 8C-30

Lamp Switch ............................................. 8C-32
Instrument Panel Fuse Block
Access Door .............................................. 8C-33
Instrument Panel Upper Trim Panel ............ 8C-33
Instrument Panel Inflatable
Restraint Module ........................................... 8C-33
shut the door. Once you have shut the door, these
accessories will continue to work for approximately
35 seconds. After this time you will not be able to use
these accessories until the next time you open a door
or tum on the ignition.
FRONT FLOOR CONSOLE

The console fits over the tunnel in the floor of
the vehicle and extends from under the center of the
instrument panel to the rear seat area. The front floor
console is a one piece design.
CHEVROLET
The front floor console for Chevrolet houses a
cassette/compact disc holder, cigarette lighter and any
of the following switches: convertible top switch,
traction control switch, or second gear start switch in
the front portion of the console beneath the instrument
panel. The portion of the console between the driver
and passenger seats house the transmission shift lever,
ashtray, cup holder with mat, parking brake lever and
storage compartment. The parking brake lever is in a
recess on the right side of the console. The. storage
compartment is located at the rear of the console. The
storage compartment also contains a tray for cassette
tapes or compact discs. The.. storage compartment has
a padded door that serves as a front seat center
armrest.
PONTIAC
The front floor console for Pontiac houses the
ashtray, cigarette lighter, transmission shift lever, cup
holder with mat, and any of the following switches:
convertible top switch, traction control switch, second
gear start switch. The convertible top switch is located
in the recess on the left side of the console. On a
manual transmission equipped vehicle the traction
control switch is located above and to the right of the
shift lever. '"_fhere is also a storage holder with mat
located behind the ashtray on manual equipped
vehicles. On automatic transmission equipped vehicles
the traction control switch or second gear start switch
is located behind the transmission shift lever. The
parking brake lever is in a recess on the right side of
the console. The storage compartment is located at the
rear of the console. The storage compartment contains
a tray for cassette tapes or compact discs. The storage
compartment has a padded door that serves as a front
seat center armrest.
INSTRUMENT CLUSTER
The instrument cluster is centered above the
steering column in the instrument panel and is
removable from the rear of the panel (toward the
steering wheel). The instrument cluster contains gages
and indicator lamps that provide the driver with
vehicle performance information.
Gages in the instrument cluster include a fuel
gage, engine coolant temperature gage, and a
voltmeter. A speedometer, odometer, trip odometer and
tachometer are also included.
The instrument cluster has indicator lamps for
the headlamp high beam symbol, fasten seat belt, turn
signal directional arrows and five lamps for
illumination.
The cluster also contains warning indicator
lamps for "ABS INOP," "AIR BAG," "ASR"
(Acceleration Slip Regulation - Chevrolet VS only),
"BRAKE," "CHECK GAGES," "LOW COOLANT"
(V8 only), ''LOW OIL," "LOW TRAC" (with ASR
or TCS systems), "SECURITY," "SERVICE ENGINE
SOON," "SKIP SHIFT" (V8 manual only) and "TCS
OFF" (Traction Control System - Pontiac V8 only).
Electric power is directed to the appropriate
lamps and gages of the instrument cluster by a flexible
printed circuit attached to the back of the instrument
cluster case. Two multiple connectors and the snap-in
bulb sockets help to hold the printed circuit to the
back of the instrument cluster.
The instrument cluster is non-serviceable, except
as noted in this section, and must be replaced as a
unit.
When an instrument cluster is replaced, the law
requires the odometer reading of the replacement unit
to be set to register the same mileage as the prior
odometer. If the same mileage cannot be set, the law
requires the replacement odometer to be set at zero
and a label be installed on the driver's door frame to
show the previous odometer reading and the date of
replacement. Refer to "Odometer Repair Notice
Label" in this section.
GAGES
ENGINE COOLANT TEMPERATURE GAGE
The coolant temperature sending unit is mounted

to the engine at a point where it is exposed to the
coolant being circulated through the engine coolant
passages. The sending unit contains a
temperature-sensitive variable resistor that senses and
reacts to coolant temperature. Resistance decreases as
temperature increases.
When electric power is supplied to the engine
coolant temperature gage, a current flows through the
gage to the variable resistor and then to a ground at
the engine. The position of the gage pointer is
determined by the strength of the current flowing
through the gage. When the engine coolant is cold,
resistance is high, the current flow is low, and the
pointer indicates a cold reading. As coolant
temperature increases, the resistance of the sending
unit resistor decreases and the pointer moves toward
the center of the gage. Prolonged driving or idling in
8C-3
very hot weather may cause the pointer to move

beyond this point. An overheat condition exists if the
pointer goes into the red zone at the upper limit of the
scale.
Dial calibrations go far above the normal boiling
point of water - 100C (212F) - because the cooling
system is pressurized. The increase in pressure also
increases the boiling temperature of the coolant,
permitting it to reach temperatures above those
possible with a non-:-pressurized system without
boiling. The higher operating temperature of the
cooling system that results gives greater cooling
efficiency and other benefits.
FUEL GAGE
The fuel gage sending unit is mounted on the

top surface of the fuel tank. The fuel level sender
itself consists of a float that rides on the surface of the
fuel in the tank, and a variable resistor controlled by
the float arm. When electric power is supplied to the
fuel gage, current flows through the gage to the
variable resistor and then to ground. The position of
the gage pointer is determined by the strength of the
current flowing through the gage.
If the tank is full, the resistance of the variable
resistor is high (90 ohms) and the current flow through
the gage is at a minimum. This causes the pointer to
indicate the "F" mark on the gage dial.
If the fuel level is low, the resistance of the
variable resistor is also low and current flow through
the gage is high. This causes the pointer to show a
low fuel level reading. Intermediate fuel levels cause
the pointer to indicate the corresponding position
between "F" and "E".
OIL PRESSURE GAGE
The oil pressure gage indicates the pressure of

the lubricating oil flow provided. by the engine oil
pump. The oil pressure gage sending unit is a variable
resistor mounted to the engine block so it will sense
the oil pressure in a main oil passage just downstream
from the engine oil pump. When electric power is
supplied to the gage, current flows through the gage to
the resistor in the sending unit and then to ground at
the engine block. The positio.n of the oil pressure gage
pointer is determined by the strength of the current
flowing through the gage.
When oil pressure is low, the resistance of the
sending unit also is low and current flow through the
gage is high. This causes the gage indicator needle to
show a low pressure reading. As oil pressure
increases, the resistance of the sending unit resistor
also increases and current flow through the gage is
reduced. Under normal conditions, the oil pressure
reading should be between 138 and 414 kPa (20 and
60 psi). Engine oil pressure never should fall below a
reading of 28 kPa (4 psi), even at idle.
SPEEDOMETER
The electric speedometer does not have a

speedometer cable. The source of speed information is
a small permanent magnet alternating current generator
SC-4
called a vehicle speed sensor (VSS), mounted on the

transmission. The shaft of the VSS fits into rotor teeth
on the transmission output shaft in the same manner as
the speedometer cable of a mechanical speedometer
system. The transmission output shaft rotates and turns
the rotor teeth near a magnetic pick-up within the
vehicle speed sensor. This generates an alternating
current in the coil with a frequency that is proportional
to the speed of the vehicle.
The alternating current from the VSS is sent to
the Powertrain Control Module (PCM).
The PCM modifies the current to a series of
direct current pulses at a frequency proportional to the
speed of the vehicle. These pulses form. a vehicle
speed signal that is transmitted to the speedometer.
At the speedometer, a solid state circuit uses the
speed signal to regulate the distribution of current
from the fuse block to two electromagnetic coils at
right angles to each other near the base of the
speedometer pointer pivot. At the base of the
speedometer pointer pivot is a magnet that is acted
upon by the magnetic fields of the two coils. The
relative strength of the two magnetic fields determines
the position of the magnet and accordingly, the
position of .the speedometer pointer.
Pulses from the solid state circuit also are used
to drive a small electric stepper motor. The stepper
motor turns the numbered wheels of the odometer. and
the trip odometer. The numbered wheels are geared so
when any one wheel completes a revolution, the next
wheel to the left is turned one-tenth of a revolution.
Every tenth of a revolution advances the displayed
number by one unit: The trip odometer can be reset to
zero at any time so the driver can record the distance
traveled from any selected starting point.
TACHOMETER
The tachometer signal comes from the PCM.

VOLTMETER
The voltmeter is an instrument that shows the

voltage of the vehicle electrical system and indicates
the ability of the charging system to keep the storage
battery charged. The voltmeter is wired in parallel
with other circuits in the vehicle.
When the engine is running, the. voltmeter
indicates charging system voltage. If the engine is not
running and the ignition switch is in the ''RUN" or
"START" position, the voltmeter will show battery
voltage. The voltmeter can be used as a first step in
diagnosing many electrical problems. Battery voltage
drop can be seen while the. engine is cranking. After
the engine is running, generator output voltage is
indicated.
It is normal for the voltmeter to read between
11 and 13 volts during extended idle or just after
starting. As the electrical load is increased, or in
stop-and-go driving, the pointer may rotate temporarily
to the bottom of the scale. A voltmeter reading
continuously below 11 volts or above 16 volts
indicates an electrical system problem.
INSTRUMENT PANEL
The instrument panel and related parts form a
rigid structure that encloses and supports many
components on or near the passenger compartment
side of the cowl. The top of the instrument panel is
attached to the cowl next to the base of the windshield
near both outboard ends by bolts/screws, and at the
center by a support bracket. The bottom of the
instrument panel is attached to a stamped metal tie bar
that adds to the rigidity of the structure. A sound
insulator panel is attached to the support bracket and
the cowl on the passenger side of the panel to conceal
the components under the instrument panel and
provide a finished appearance.
The steering column is clamped in place at the
left side of the instrument panel. Below and to both
sides of the steering column is an instrument panel
driver knee bolster. An impact-:absorbing pad covers
the top of the instrument panel. Trim covers and trim
plates accent the appearance of the exposed rear face
of the instrument. panel.
The air conditioning module case is attached to
the cowl. Air ducts connect the case outlets to floor
outlets, windshield defroster outlets, side window
defogger outlets and a high level outlet in the center
of the instrument panel. A high level air outlet is
provided at each end of the instrument panel. The air
conditioning module and ducts are concealed wi.thin
the instrument panel structure.
Canadian vehicles equipped with daytime
running lamps .have a. headlamp automatic control
ambient light sensor installed flush with the top
surface of the instrument. panel upper trim panel under
the windshield defroster nozzle grille.
Vehicles equipped with the theft .deterrent system
have a security LE.D. installed flush with the top
surface of the instrument panel upper trim panel under
the windshield defroster nozzle grille.
Canadian vehicles may have both the headlamp
automatic control ambient light sensor and security
L.E.D. If equipped.
The instrument panel wiring harness is installed
within the instrument panel area.
INSTRUMENT PANEL SWITCHES

Headlamp and Instrument Panel Lamp
Dimmer Switch
The headlamp and instrument panel hi.mp
dimmer switch with thumbwheel dimmer control is
mounted in the instrument panel to the left of the
instrument cluster on both Chevrolet, and Pontiac.
The headlamp switch controls headlamps,
parking and sidemarker lamps, taillamps, interior
lamps and instrument panel lamps. The dimmer
control regulates the intensity of the instrument panel
illumination.
Front Fog Lamp Switch

If equipped, the front fog lamp switch will be
next to the headlamp and instrument panel lamp
dimmer switch for Chevrolet, and below the headlamp
and instrument panel lamp dimmer switch for Pontiac.

To use the front fog lamps, first turn on the
headlamps or parking lamps. Then push the right side
of the front fog lamp switch to turn on the front fog
lamps. Push the left side of the switch to tum off the
front fog lamps. The front fog lamps should not be
used as a substitute for the headlamps. Switching to
high-beam headlamps will turn off the front.fog lamps.
Switching back to low-beam headlamps will turn the
front fog lamps on again.
Rear Compartment Lid Release Switch

The rear compartment lid release switch releases
the rear deck lid of the vehicle automatically.
The rear compartment lid release switch is
located in the glove box for Chevrolet and on the
left-hand side of the instrument panel below the
headlamp and instrument panel lamp dimmer switch,
and foglamp switch for Pontiac.
Rear Defogger Switch

The rear defogger switch, when activated slowly
heats the rear window to remove interior fog or
outside snow and ice. The switch has an integral lamp
and will operate for five .or ten minutes d~pend~g on
such conditions as vehicle speed, outside wmdow
temperature, atmospheric pressure and number of
passengers. The switch will automatically turn off
through the use of a timer or may be turned off by
either the instrument panel switch or by turning the
ignition switch to "OFF."
The rear defogger switch on Chevrolet is located
to the right of the steering column on the instrument
panel driver knee bolster.
On Pontiac the rear defogger switch is located
with the HVAC controls.
SENSORS
Daytime Running Lamp (DRL) Ambient
Light Sensor (Canadian Only)
The headlamp automatic control ambient light
(daylight) sensor is located to the right of th~ heat and
air conditioning duct in the center of the mstrument
panel.
As the intensity of light reaching the sensor
increases, the electrical resistance of the sensor
decreases. When the DRL control module senses a
low resistance in the sensor, the module allows voltage
to be applied to the DRL diode and then to the
headlamps. Due to the voltage drop across the diode,
the headlamps are on a reduced intensity.
As the intensity of light reaching the sensor
decreases the electrical resistance of the sensor
increases.' When the DRL module senses a high
resistance in the sensor, the module closes an internal
relay and allows the headlamps to come to full
intensity.
CLUSTER WARNING/INDICATOR LAMPS

"FASTEN SEAT BELTS" INDICATOR LAMP
The "FASTEN SEAT BELTS" indicator lamp

will always go on whenever the ignition switch is in
"RUN," "BULB TEST," or "START," if the driver's
SC-5
seat belt is unbuckled. It will remain on until the

driver's seat belt is buckled.
For more information, refer to
"Warning/Reminder Chimes" in this section or
SECTION 10-11.
"TURN SIGNAL" INDICATOR LAMPS
The left or right turn signal indicator lamp will

illuminate when the multi-function lever on the left
side of the steering column is moved to signal a tum.
The tum/hazard switch in the steering column receives
an on-and-off flashing current from the fuse block and
the turn signal flasher unit in the convenience center
when the ignition switch is in the "RUN," "START"
or "BULB TEST" position. The tum/hazard switch
routes the current to circuits that feed the left or right
front turn signal lamp, left or right rear tail/stop/tum
signal lamps when the multi-function lever is moved.
The circuit to the left or right front turn signal lamp,
and cornering and sidemarker lamps has a branch that
feeds the appropriate turn indicator lamp in the
instrument cluster, causing it to flash when the exterior
lamps are indicating a turn.
When the hazard warning button on the right
side of the steering column is pressed in, the left and
right front turn signal lamps, cornering and sidemarker
lamps, and rear tail/stop/tum signal lamps all flash,
and both turn signal indicator lamps in the instrument
cluster flash. Power for the hazard warning system
reaches the tum/hazard switch from the fuse block and
the hazard flasher in the convenience center. Power is
supplied with the ignition switch in any position.
When the hazard warning system is flashing, the turn
signal circuits are inoperative.
"AIR BAG" INDICATOR LAMP
The "AIR BAG" indicator lamp will light to

warn the driver of a potential supplemental inflatable
restraint (SIR) system problem that could prevent the
proper deployment of the air bags in an accident.
When the ignition switch is first turned on, the lamp
will flash seven times to verify proper operation of the
lamp circuit and the Sensing and Discriminating
Module (SDM). A Scan Tool can be used to read
diagnostic trouble codes (DTCs) in the SDM and to
clear all DTCs after repair. For additional information,
including service precautions, refer to SECTION 9J.
"SERVICE ENGINE SOON" INDICATOR LAMP
The "SERVICE ENGINE SOON" indicator

lamp in the instrument cluster will come on when
turning the ignition "ON" or "OFF" to serve as a
bulb and system check. It should go off after the
engine starts unless a problem has been detected by
the system.
For diagnosis, refer to SECTION. 6E.
"LOW COOLANT" INDICATOR LAMP (V8 ONLY)
With a low coolant level, the circuit made by the

low coolant probe has very high resistance (over
50,000 ohms). The low engine coolant indicator
module senses the voltage change at the low coolant
level input and provides ground to the "LOW
COOLANT" indicator and the indicator lights up. The
8C-6
"LOW COOLANT" indicator is grounded for

1.5 seconds when the ignition switch is initially turned
"ON," causing the "LOW COOLANT" indicator to
light.
"LOW OIL" INDICATOR LAMP
The "LOW OIL" indicator ground is controlied

by the engine oil level indicator control module. To
check for a low oil condition, the low oil module
looks for a ground through the oil level switch after
the ignition switch has been turned to "OFF" or
"LOCK".
The low oil module checks for a low oil
condition 32 minutes after the ignition switch is turned
to "OFF" or "LOCK," if the previous ignition cycle
was less than 12 minutes. If the previous ignition
cycle was longer than 12 minutes, the low oil module
checks for a low oil condition 3 minutes after the
ignition switch is turned to "OFF" or "LOCK."
When the low oil module loses the ground
through the oil level switch (oil level switch open
indicating low oil level), the low oil module grounds
the "LOW OIL" indicator for the duration of the next
ignition cycle.
When the low oil module is grounded through
the oil level switch, the low oil module grounds the
"LOW OIL" indicator for a bulb test when the
ignition switch is turned to "RUN" during the next
ignition cycle. The bulb test takes four to five seconds;
"BRAKE" WARNING LAMP
When the ignition switch is turned to "RUN,"

the "BRAKE" warning lamp will come on for
approximately 3 seconds. If the parking brake is set,
the lamp will remain on. The lamp may also be
illuminated by information from the Electronic Brake
Control Module (EBCM) or Electronic Brake/Traction
Control Module (EBTCM).
Additionally, with the ignition switch turned to
"RUN," "BULB TEST," or "START," the lamp may
be activated by the brake combo valve. For more
information, refer to SECTION 8A-41 and
SECTION 5El.
"ABS INOP" INDICATOR LAMP
The "ABS INOP" indicator lamp is part of the

antilock brake system. When the ignition switch is
turned to the "RUN" position, the "ABS INOP" lamp
will turn on for approximately 3 seconds and then turn
off if no ABS malfunction is detected. If a
malfunction is detected, the lamp will remain on.
If the "ABS INOP' indicator lamp comes on
while driving, there is a malfunction in the antilock
brake system. For more information, refer to
SECTION 5El.
"ASR" INDICATOR LAMP
Chevrolet V8 Only
The Accelerated Slip Regulation (ASR) system

limits wheel spin if it senses that one or both of the
rear wheels are beginning to lose traction. When this
happens, the ASR system works the rear brakes and
reduces engine power to limit wheel spin.
The "ASR" indicator lamp will come on if there

is a system failure, if the system has been turned .off
by the driver, or momentarily when starting the
engine.
When the ignition switch is turned to the crank
position, the "ABS INOP," "ASR," and "TCS OFF"
lamps will come on. They will remain on if the switch
is held in the crank position.
"CHECK GAUGES" INDICATOR LAMP
The "CHECK GAUGES" indicator lamp alerts

the driver to check instrument cluster gages when any
of the following abnormalities are detected: coolant
temperature too high, generator voltage too high or too
low, oil pressure too low.
The indicator lamp also comes on for about .one
second after ignition "ON" as a bulb test.
"LOW TRAC" INDICATOR LAMP
(With ASR or TCS Systems)
On vehicles equipped with Accelerated Slip

Regulation (ASR) or Traction Control Systems (TCS),
the "LOW TRAC" indicator lamp comes on to
indicate that the system is active and is limiting wheel
spin.
The "LOW TRAC" lamp will turn on during
ABS initialization; an ABS stop or a TCS event. It
will remain on for approximately 3 seconds and then
turn off.
The "LOW TRAC" indicator lamp also comes
on when the Antilock Brake System (ABS) is
adjusting brake pressure to help avoid a skid.
"SECURITY" INDICATOR LAMP
The "SECURITY" indicator lamp is part of the

theft deterrent system. It will come on when the Body
Control Module (BCM) is preventing the engine from
starting, or if the Body Control Module (BCM) is not
properly programmed. It also comes ori for about
five seconds during "BULB TEST."
"SKIP SHIFT" INDICATOR LAMP
{V8 Manual Only)
When the "SKIP SHIFT" indicator lamp is on,

the manual transmission can only be shifted from first
to fourth gear. For more information on skip shift,
refer to SECTION 6E3-C8.
"TCS OFF" INDICATOR LAMP
Pontiac V8 Only
The Traction Control System (TCS), if equipped,

limits wheel spin if it senses that one or both of the
rear wheels are beginning to lose traction. When this
happens, the TCS works the rear brakes and reduces
engine power to limit wheel spin.
The "TCS OFF" indicator lamp will come on if
there is a system failure, if the system has been turned
off by the driver, or momentarily when starting the
engine.
When the ignition switch is turned to the crank

position, the "ABS INOP," "ASR," and "TCS OFF"
lamps will come on. They will remain on if the switch
is held in the crank position.
WARNING/REMINDER CHIMES
The body control module sounds a chime to
bring attention to one or more of several conditions.
These conditions are:
l. The lights are on and the ignition switch is not in
"RUN," "BULB TEST," or "START."
2. The ignition key is in the ignition switch when
the driver's door is open.
3. The seatbelt is unbuckled when the ignition
switch is in "RUN," "BULB TEST," or
"START."
4. The turn signal has been on for more than a
half mile. Voltage is applied at all times through
the fuse block to power the solid state body
control module.
IGNITION KEY WARNING
Whenever the key is in the ignition switch and

the driver's door is open, it provides a ground to the
body control module, which sounds the chime.
FASTEN SEAT BELT WARNING
With the ignition switch in "RUN," "BULB

TEST," or "START," voltage is applied through the
fuse block to the body control module. With the
chiver's seat belt unbuckled, the module is grounded
through the seat belt switch and the alarm sounds.
When the driver's seat belt is buckled, the alarm shuts
off. If the driver's seat belt remains unbuckled, the
alarm times out after 4 to 8 seconds.
LIGHTS-ON WARNING
When the headlamp switch is in "HEAD" or

"PARK," voltage is applied to the audio alarm
module. When the ignition switch is in "RUN,"
"BULB TEST," or "START," voltage is applied
through the fuse block to the module. These two
voltages are sensed and the alarm is not sounded.
When the ignition switch is not in "RUN,"
"BULB TEST" or "START," the module loses
voltage. The audio alarm module senses change. If
voltage is still available, it is applied to sound the
alarm. The alarm can be turned off by turning the
headlamp switch to "OFF". The module no longer
senses voltage from the headlamp switch, so the alarm
does not sound.
DIAGNOSIS
For diagnosis of the instrument panel cluster
electrical system (including individual wire color
information and applicable precautions for testing solid
state electronic devices and systems), refer to
SECTION 8A.
SC-7
ON-VEHICLE SERVICE
It may be necessary to color coat some
replacement components before installing them in the
vehicle. For information regarding this procedure, refer
to SECTION 10-1.
SERVICE PRECAUTIONS
CAUTION: When performing service on
or around SIR components or SIR wiring,
follow the procedures listed below to
temporarily disable the SIR system.
Failure to follow procedures could result
in possible Air Bag deployment, personal
injury, or otherwise unneeded SIR system
repairs.
The SDM can maintain sufficient voltage
procedures require removal of the "AIR BAG" fuse
and disconnection of the deployment loops to avoid an
accidental deployment. If the inflator modules are
disconnected from the deployment loops as noted in
the "Disabling the SIR System" procedure that
follows, service can begin immediately without
!++I
Turn the steering wheel so that the vehicle's

1. "AIR BAG" fuse from I/P fuse block.
2. Instrument panel insulator - left side, refer to
"Instrument Panel Insulator" in this section.
2-way connector for both connectors located near
the base of the steering column.
[II
Important
With the "AIR BAG" fuse removed and

ignition switch "RUN," the "AIR BAG"
warning lamp will be "ON." This is normal
operation and does not indicate a SIR system
malfunction.
!HI
Install or Connect
Tum ignition switch to "LOCK" and remove key.

1. Both yellow 2-way connectors located near the
base of steering column and corresponding CPA.
2. Instrument panel insulator - left side, refer to
"Instrument Panel Sound Insulator" in this
section.
8C-8
3. "AIR BAG" fuse to I/P fuse block.

Check" in SECTION 91.
HANDLING ELECTROSTATIC DISCHARGE

(ESD) SENSITIVE PARTS
NOTICE: When handling an electronic part
that has an BSD-sensitive sticker, refer to
SECTION OA. Follow these guidelines to reduce
any possible build-up of electrostatic charge:
Do not open the package until time to install part.

Avoid touching electrical terminals of the part.
Before removing part from its package, ground
package to known good ground on vehicle.
Always touch known good ground before
handling part. This should be repeated while
handling part. Do it more often after sliding
across seat, sitting down from standing position,
or walking a distance. Not all parts that can be
damaged by BSD have an BSD label. Components
that can be damaged by BSD are:
AM/FM stereo radio /radio control
Antilock brake system EBCM
Automatic day/night mirror
Body Control Module (BCM)
CalPak
Cruise control module
Electronic spark control module
MEM-CAL (memory and calibration unit)
PROM (programmable read only memory)
Sensing and Discriminating Module (SDM)
CONTROLS
AM/FM Stereo and Clock Radio
CHEVROLET
Figures 1 and 2
l++I
1. Driver knee bolster. Refer to "Instrument Panel

Driver Knee Bolster and Deflector" in this
section.
2. Trim plate (15) and bolts/screws (16) from
instrument panel.
3. Bolts/screws (67) attaching brackets (68) to
instrument panel carrier.
4. Brackets (68) and attached radio (66) from
5. Instrument panel wiring harness electrical
connectors from radio (66).
6. Bolts/screws (65) and nuts (64) attaching radio
(66) to brackets (68), if necessary.
7. Radio (66) from brackets (68), if necessary.
16
15 PLATE ASSEMBLY, INSTRUMENT PANEL ACCESSORY
TRIM
16 BOLT/SCREW, INSTRUMENT PANEL ACCESSORY TRIM
PLATE
D INDICATES SEQUENCE
FOR INSTALLING SCREWS
9-20-94
FS0018C
Figure 1 - Instrument Panel Accessory Trim Plate (Chevrolet)
!++!
NOTICE:
1. Brackets (68) and nut (64) to left side of radio

(66), if removed.
I~!
Tighten
Nut (64) attaching bracket (68). to radio (66) to

2.8 N.m (25 lb. in.).
connectors to radio (66).
3. Radio stud (65) and nut (64) to right side of
radion (66), if removed.
I~!
Tighten
Nut (64) attaching stud (65) to instrument

panel to 2.8 N,m (25 lb. in.).
4. Bolts/screws (67) through bracket (68) to
instrument panel.
!~i
Tighten

5. Align trim plate to instrument panel using the
locator pins on the trim plate to the holes in the
instrument panel.
6. Bolt/screw (16) to the lower left comer and torque
to specifications.
7. Push trim plate to the left, then install upper left
bolt/screw (16) and torque to specifications.
8. Bolt/screw (16) to lower left and torque to
specifications.
9. Push trim plate to the left, then install center right
bolt/screw (16) and torque to specifications.
8C9
A CONNECTOR, INSTRUMENT PANEL WIRING HARNESS

ELECTRICAL
64 NUT, RADIO .BRACKET
65 BOLT/SCREW, RADIO
66 RADIO ASSEMBLY, AM/FM STEREO AND CLOCK
67 BOLT/SCREW, RADIO BRACKET
... 68 BRACKET, RADIO
5-06-94
FS0028C
Figure 2 - AM/FM Stereo and Clock Radio - (Chevrolet)
10. Push upper right comer to the left, and install

upper right bolt/screw (16) and torque to
specifications.
l~.J Tighten
Bolts/screws (16) attaching trim plate to
1.9 N.m (17 lb. in.).
section.
8. Instrument panel wmng harness electrical

connectors from radio (66).
9. Bolts/screws (65) and nuts (64) attaching radio
(66) to brackets (68), if necessary.
10. Radio (66) from brackets (68), if necessary.
!H!
Install or Connect
NOTICE:
PONTIAC
Figures 3 and 4
!++!

section.
2. Trim plate (15) from instrument panel (40).
3. Bolt/screw (63) from instrument panel tie bar, if
necessary.
4. Retainer (62) and bolt/screw (65) from bracket
(27).
5. Radio (66).

7. Brackets (68) and attached radio_ (66) from
Figure 3 Instrument Panel Accessory Trim Plate (Pontiac)
8C10
40
(
68
67
68
40
27 BRACKET, REAR RADIO
40
62
63
64
65
66
67
68
PANEL, INSTRUMENT
RETAINER, RADIO (PUSH-ON)
BOLT/SCREW, REAR RADIO BRACKET
NUT, RADIO BRACKET
BOLT/SCREW, RADIO
RADIO, AM/FM STEREO AND CLOCK
BOLT/SCREW, RADIO BRACKET
BRACKET, RADIO
jvtEWA
I
020185
FS0048C
Figure 4 AM/FM Stereo and Clock Radio (Pontiac)
1. Brackets (68) to radio (66), if removed.

.
2. Bolts/screws (65) and nuts (64) attaching brackets
(68) to radio (66), if removed.
!~!
Tighten
Nuts (64) to 2.8 N,m (25 lb. in.).

connectors to radio (66).
4. Brackets (68) and attached radio (66) to
l~I
Tighten

6. Radio (66) to instrument panel (40).
7. Retainer (62) and bolt/screw (65) to bracket (27).
8. Bolt/screw (63) to instrument panel tie bar, if
removed.
I~!
Tighten

9. Trim plate (15) to instrument panel (40).
section.

Figure 5
l++I
1. Bezel (Chevrolet). Refer to "Instrument Panel

Cluster Trim Plate Bezel" in this section.
2. Instrument Panel accessory trim plate (Pontiac).
3. Temperature control cable electrical connector and
vacuum wiring harness electrical connector
through hole in panel and from over
reinforcement (85).
8C11
40
25
85
A CONNECTOR, TEMPERATURE CONTROL CABLE

ELECTRICAL
B CONNECTOR, VACUUM WIRING HARNESS ELECTRICAL
40 PANEL, INSTRUMENT
CONTROL
82 CONTROL, HEATER AND AIR CONDITIONING 02.01.915
85 REINFORCEMENT, INSTRUMENT PANEL
FS0058C

ENGINE CONTROL MODULE DATA LINK ELECTRICAL
B CONNECTOR, INSTRUMENT CLUSTER TURN SIGNAL
FLASHER ELECTRICAL
25 BAR, INSTRUMENT PANEL TIE
60 BRACKET, INSTRUMENT PANEL KNEE BOLSTER
61 BOLT/SCREW, INSTRUMENT PANEL WIRING HARNESS
ENGINE CONTROL MODULE DATA LINK CONNECTOR
Figure 5 Heater and Air Conditioning Control (Typical)
Figure 6 - Data Link Connector (DLC}
4. Bolts/ screws (81) attaching heater and air

conditioning control (82) to instrument panel (40).
5. Heater and air conditioning control (82) from
instrument panel (40).
!HI
Install or Connect
NOTICE:
1. Heater and air conditioning control (82) to

instrument panel (40).
2. Bolts/ screws (81) attaching heater and air
condtioning control (82) to instrument panel (40).
l~J
Tighten

3. Temperature control cable electrical connector and
vacuum wiring harness electrical connector
through hole in panel (40) and over reinforcement
(85).
4. Instrument panel accessory trim plate (Pontiac).
5. Bezel (Chevrolet). Refer to "Instrument Panel
Cluster Trim Plate Bezel" in this section.
DATA LINK CONNECTOR (DLC)
020195
IFSOOOSC
l++I
1. Two bolts/screws (61) attaching DLC to bracket

(60).
2. Three instrument panel bolts/screws attaching
bracket (60) to instrument panel carrier, if
necessary.
!++!
Install or Connect
NOTICE:
1. Three instrument panel bolts/screws attaching

bracket (60) to instrument panel carrier, if
removed.
l~I
Tighten
Instrqment panl',ll bolts/screws to 1.9 N.m

(17 lb. in.).
2. Two bolts/screws (61) attaching DLC to bracket
(60).
Tighten
Figure 6
The data link connector (DLC) is part of the
instrument panel wiring harness. Refer to
SECTION SA.
SC-12
DAYTIME RUNNING LAMP (DRL)

COMPONENTS (CANADIAN ONLY)
Daytime Running lamp Ambient light
Sensor
Figure 7
j++I
1. Grille (70) from instrument panel upper trim

panel.
Gently unsnap grille (70).
2. Sensor (88) from grille (70).
Twist counterclockwise.
3. Sensor (88) from instrument panel wiring harness
grille electrical connector.
INSTRUMENT PANEL DRIVER KNEE

BOLSTER AND DEFLECTOR
CHEVROLET
Figure 8
i++!
1. Bolts/screws (4) attaching bolster (3) to deflector

(49) and instrument panel tie bar.
2. Nuts (48) attaching deflector to instrument panel
studs (74).
3. Deflector (49) from instrument panel studs (74).
j++I
Install or Connect
Install or Connect
1. Sensor (88) to instrument panel wiring harness
grille electrical connector.
2. Sensor (88) to grille (70).
Twist clockwise.
3. Grille (70). to instrument panel upper trim panel.
Snap into place.
Daytime Running lamp Ambient light

Sensor Module
Figure 7
l++i
1. Module (71) from heat and air conditioning duct.

connectors from module (71) by depressing lock
retainers on daytime running lamp ambient light
sensor module electrical connectors.
3. Instrument panel wiring harness from under and
behind tie bar (25).
l++I
NOTICE:
1. Deflector (49) to instrument panel studs (74).

2. Nuts (48) attaching deflector to instrument panel
studs (74).
l~j Tighten
Nuts (48) to studs (74) to 1.9 N.m (17 lb. in.).
!~!
Tighten

PONTIAC
Figure 9
l++I

2. Bolster (3) from dual lock retainers on instrument
panel carrier.
3. Nuts (48) instrument panel studs (74).
4. Deflector (49) from instrument panel studs (74).
j++I
Install or Connect
Install or Connect
1. Route instrument panel wiring harness under tie

bar (25).
2. Daytime running lamp ambient light sensor
module electrical connectors to module (71).
When connecting, push, click, then tug on
daytime running lamp ambient light sensor
electrical connector, not wire.
3. Slide module (71) onto heat and air conditioning
duct.
NOTICE:
1. Deflector (49) to instrument panel studs (74).

2. Nuts (48) to instrument panel studs (74).
l~I
Tighten
Nuts (48) to studs (74) to 1.9 N.m (17 lb. in.).

3. Bolster (3) to dual lock retainers on instrument
panel carrier.
Position bolster (3) for best fit and apply
pressure on retainers to secure.
SC-13
75
25
IVIEW A I
70
---,
flr.:11.,.
~--./I
A HARNESS, INSTRUMENT PANEL WIRING

B DUCT, HEAT AND AIR CONDITIONING
C CONNECTOR, DAYTIME RUNNING LAMP AMBIENT
LIGHT SENSOR GRILLE ELECTRICAL
D CONNECTOR, DAYTIME RUNNING LAMP AMBIENT
LIGHT SENSOR MODULE ELECTRICAL
70 GRILLE, DAYTIME RUNNING LAMP AMBIENT LIGHT
SENSOR
71 MODULE, DAYTIME RUNNING LAMP AMBIENT
LIGHT SENSOR
88 SENSOR, DAYTIME RUNNING LAMP AMBIENT
LIGHT
~~:8
Figure 7 - Daytime Running Lamp Ambient Light Sensor Module
8C-14

40
!VIEWA!
3 BOLSTER, INSTRUMENT PANEL DRIVER KNEE
4 SOLT/SCREW, INSTRUMENT PANEL DRIVER
KNEE BOLSTER
48 NUT, INSTRUMENT PANEL DRIVER KNEE
BOLSTER DEFLECTOR
49 DEFLECTOR, INSTRUMENT PANEL DRIVER
KNEE BOLSTER
74 STUD, INSTRUMENT PANEL DRIVER KNEE
BOLSTER DEFLECTOR
1i~!
Figure 8 - Instrument Panel Driver Knee Bolster and

Deflector - (Chevrolet)

!~I
Tighten
FRONT FLOOR CONSOLE

Figure 10
i++I
1. Bolts/screws (34) attaching console (33) to

instrument panel center support bracket and
manual floor console bracket.
2. Bolt/screw (35) attaching console (33) to
instrument panel.
bracket (37).
4. Console (33).
A RETAINER. DEFLECTOR
4 BOLT/SCREW, INSTRUMENT PANEL DRIVER
KNEE BOLSTER
48 NUT, INSTRUMENT PANEL DRIVER KNEE
BOLSTER DEFLECTOR
49 DEFLECTOR, INSTRUMENT PANEL DRIVER
KNEE BOLSTER
74 STUD, INSTRUMENT PANEL DRIVER KNEE 02D1ts
BOLSTER DEFLECTOR
FS0098C
Figure 9 - Instrument Panel Driver Knee Bolster and

Deflector (Pontiac)
!++i
Install or Connect
NOTICE:
1. Console (33).
A. Route wiring connectors through appropriate
openings.
B. Insert parking brake through appropriate
opening.
C. Locating pin on console (33) into hole in
shifter bracket drive.
D. Position console (33) to floor of .vehicle.
bracket (37).
,~, Tighten
3. Bolt/screw (35) attaching console (33) to
instrument panel.
INSTRUMENT PANEL, GAGES AND CONSOLE SC-15
--
---
35
33
34
35
36
37
CONSOLE, FRONT FLOOR

SOLT /SCREW, FRONT FLOOR CONSOLE
SOLT /SCREW, INSTRUMENT PANEL, LOWER
SOLT/SCREW, FRONT FLOOR CONSOLE BRACKET
BRACKET, FRONT FLOOR CONSOLE
I~!
Figure 10 Front Floor Console (Typical)
Tighten

instrument panel center support bracket and
manual floor console bracket.
I~!
020185
FS0108C
Tighten
Bolts/screws (34) to .8 N.m (71 lb. in.).
Front Floor Console Tape Storage Tray
Cigarette Lighter
CHEVROLET
Figure 11
!++!
1. Cigarette lighter from console (33).

2. Bezel (32) from cigarette lighter bezel wiring
harness electrical connector.
I++!
Install or Connect
Figure 11
I++!
1. Bezel (32) to cigarette lighter bezel wiring harness
2: Cigarette lighter to appropriate opening in console

(33).
Tray (30) from console storage area.

Depress dual lock fasteners on either side of
tray (30).
I++!
Install or Connect
Tray (30) into console storage area.

Apply pressure to secure dual lock fasteners.
Snap into place.
PONTIAC
!++!
1. Front floor console. Refer to "Front Floor

Console" under "On-Vehicle Service" in this
section.
2. Cigarette lighter electrical connector from
cigarette lighter.
3. Cigarette lighter from front floor console.
SC-16

cigarette lighter, if equipped.
4. Cigarette lighter, if equipped, to folding top
switch.
33
!++!
Install or Connect
1. Cigarette lighter, if equipped, to folding top

switch.
2. Cigarette lighter electrical connector to cigarette
lighter, if equipped.
3. Convertible top switch connector to folding top
switch.
4. Folding top switch to console.
33
PONTIAC
Figure 13
E3
1. Folding top switch from console.

2. Convertible. top switch connector from folding top
switch..
32
!++!
A CIGARETTE LIGHTER ELECTRICAL CONNECTOR

30 TRAY, FRONT FLOOR CONSOLE TAPE/DISC
STORAGE
32 BEZEL, CIGARETTE LIGHTER
33 CONSOLE, FRONT FLOOR
03-11-11
FT0118C
Figure 11 - Cigarette Lighter Bezel and Front Floor

Console Tape Storage Tray - (Chevrolet)
!++I
Install or Connect
1. Cigarette lighter to front floor console.

2. Cigarette lighter electrical connector to cigarette
lighter.
3. Front floor console. Refer to "Front Floor
Console" under "On-Vehicle Service" in this
section.
Install or Connect
1. Convertible top switch connector to folding top

switch.
2. Folding top switch to console.
Compartment Lamp Switch
Figure 14
E3
1. Switch (93) and retainer (94) from opening in

console (33).
2. Retainer (94) from switch (93).
!++!
Install or Connect
1. Retainer (94) to switch (93).

2. Switch (93) and retainer (94) down through
opening in console (33).
Be sure retainer (94) is seated in console (33).
Convert.ible Top Switch
Second Gear Start Switch {V6 Automatic)
CHEVROLET
E3
Figure 12
E3
1. Folding top switch from console.

2. Convertible top switch connector from folding top
switch.
1. Second gear start switch from console.

2. Electrical connector from second gear start switch.
E3
Install or Connect
1. Second gear start switch electrical connector.

2. Second gear start switch to console.
00000
2HD GEAR
UP
ZND GEAR
9 GB 8 GB
VB-Convertible Top V8 Coupe with

Power Switch
Traction Control
VB-Convertible Top
Power Switch with
Traction Control
VG-Coupe with
V6-Convertlble Top
Automatic Trana. Power Switch with
2nd Gear Start
Automatic Trana.2nd Gear Start
031191
FT0418C
Figure 12 - Convertible Top, Traction Control and 2nd Gear Start Switches (Chevrolet)
SC-18
(
V6Auto. Only 2nd
Gear Start
V8Autometlo
Traction Control
TRANSMISSION
2ND GEAR
START
Convertible
031891
FT0428C
(
Figure 13 Convertible Top, Traction Control and 2nd Gear Start Switches (Pontiac)

29
8C-19
28
B
B
A

93 SWITCH, INSTRUMENT PANEL COMPARTMENT LAMP
94 RETAINER, INSTRUMENT PANEL COMPARTMENT
LAMP SWITCH
020295
FS0138C
Figure 14 Compartment Lamp Switch
Traction Control Switches

ASR SWITCH CHEVROLET (VS)
TCS SWITCH - PONTIAC (VS)
!++!
1. Electronic traction control switch from console.

2. Traction control switch electrical connector from
electronic traction control switch.
cigarette lighter, if equipped (Chevrolet only).
4. Cigarette lighter, if equipped, from traction control
switch (Chevrolet only).
!++!
Install or Connect
Figure 15 Front Floor Console Transmission Shift

Opening Trim Plate
i++!
Install or Connect
l, Plate (28 or 29) to console (33).

Position plate (28 or 29) over shifter stem,
initially inserting forward end of plate (28 or
29) into console (33).
2. Retainers attaching plate (28 or 29) to console
(33).
Apply pressure, snap into place and secure.
HEAT, VENTILATION AND AIR

CONDITIONING DUCTS
Windshield Defroster Nozzle and Air
Distributor
Figures 16 and 17
1. Cigarette lighter, if equipped, to traction control

switch (98) (Chevrolet only).
2. Cigarette lighter electrical connectof to cigarette
lighter, if equipped (Chevrolet only).
3. Traction control switch electrical connector to
electronic traction control switch (98 or 99).
4. Electronic traction control switch (98 or 99) to
console (33).
Front Floor Console Transmission Shift

Opening Trim Plate
Figure 15
!++I
A STEM, SHIFTER
B RETAINER
28 PLATE, FRONT FLOOR CONSOLE TRANSMISSION
(MANUAL)
29 PLATE, FRONT FLOOR CONSOLE TRANSMISSION
(AUTOMATIC)
1. Retainers attaching plate (28 or 29) to console
(33).
2. Plate (28 or 29).
1. Instrument panel carrier. Refer to "Instrument

Panel Carrier" in this section.
2. Bolts/screws (55) attaching distributor (54) to
carrier (75).
3. Distributor (54) from carrier (75).
!++I
Install or Connect

1. Distributor (54) to carrier (75).
2. Route heater control cable and vacuum wiring
harness over reinforcement in carrier (75).
Align cable and wires with depression in
distributor (54).
3. Bolts/screws (55) attaching distributor (54) to
carrier (75).
SC-20
75
A
52
53
54
55
56
57
58
59
75
PIN, LOCATOR
DUCT, INSTRUMENT PANEL OUTER AIR OUTLET
SOLT/SCREW, INSTRUMENT PANEL OUTER AIR OUTLET
DISTRIBUTOR, WINDSHIELD DEFROSTER NOZZLE AND AIR
53
BOLT/SCREW, AIR DISTRIBUTOR DUCT
DUCT, SIDE WINDOW DEFOGGER OUTLET
SOLT/SCREW, INSTRUMENT PANEL CENTER AIR OUTLET DUCT
52
Figure 16 - Heat, Ventilation and Air Conditioning Ducts - (Chevrolet)
02-o2-H
F80168C
!~I
2. Bolts/screws (57) attaching duct (58 or 59) to

carrier (75).
Tighten

4. Instrument panel carrier (75). Refer to
"Instrument Panel Carrier" in this section.
Instrument Panel Center Air Outlet Ducts

CHEVROLET ONLY
Side Window Defogger Outlet Duct
!++!
1. Bolts/screws (57) attaching duct (58 or 59) to

carrier (75).
2. Duct (58 or 59).
!+.-!
Tighten
Figures 16 and 17
Figure 16
!++!
l~I
1. Duct (56) from distributor (54).

2. Duct (56) from carrier (75).
!++!
Install or Connect
Install or Connect
NOTICE:

1. Duct (58 or 59) to carrier (75).
52 DUCT, INSTRUMENT PANEL OUTER AIR OUTLET

53 BOLT/SCREW, INSTRUMENT PANEL OUTER AIR OUTLET
54 DISTRIBUTOR, WINDSHIELD DEFROSTER NOZZLE AND AIR
55 BOLT/SCREW, AIR DISTRIBUTOR DUCT
56 DUCT, SIDE WINDOW DEFOGGER OUTLET
1. Duct (56) to carrier (75).

2. Duct (56) to distributor (54).
IVIEW A I
Figure 17 - Heat, Ventilation and Air Conditioning Ducts - (Pontiac)
02-02-n
Fsote&C
SC-22 INSTRUMENT PANEL, GAGES AND CONSOLE

75
A
B
52
53
75
LEFT SIDE
RIGHT SIDE
DUCT, INSTRUMENT PANEL OUTER AIR OUTLET
BOLT/SCREW, INSTRUMENT PANEL OUTER AIR OUTLET
020285
F80188C
Figure 18 Instrument Panel Outer Air Outlet Ducts (Chevrolet)
Floor Air Outlet Duct
INSTRUMENT CLUSTER
!++I
Figure 19
1. Bolts/screws attaching duct to module.

2. Duct.
!++I
Install or Connect
NOTICE:
Refer to "Notice" on page 8C-J.
1. Duct to module.
2. Bolts/screws attaching duct to module.
I~!
Tighten
Bolts/screws 1.9 N.m (17 lb. in.).
!++!
1. Instrument panel upper trim panel. Refer lo

"Instrument Panel Upper Trim Panel" in this
section.
2. Bolts/screws (79) attaching cluster (78) to carrier
(75).
3. Cluster (78) from carrier (75).
4. Instrument cluster wiring harness electrical
connector from cluster (78).
I++!
Install or Connect
lnstrumet Panel Outer Air Outlet Ducts

Figures 17 and 18
l++I
1. Bolts/screws (53) attaching duct (52) to carrier

(75).
2. Duct (52).
l++I
Install or Connect
NOTICE:
1. Duct (52) to carrier (75).

2. Bolts/screws (53) attaching duct (52) to carrier
(75).
l~I
Tighten

1. Instrument cluster wiring harness electrical
connector to cluster (78).
When connecting, push, click, then tug on
electrical connector, not wire.
2. Cluster (78) to carrier (75).
3. Bolts/screws (79) attaching cluster (78) to carrier
(75).
!~I
Tighten
Bolts/screws (79) to 2.2 N.m (20 lb: in.).

4. Instrument panel upper trim panel. Refer to
"Instrument Panel Upper Trim Panel" in this
section.
SC-23
78
A
75
78
79
CONNECTOR, INSTRUMENT CLUSTER WIRING HARNESS ELECTRICAL

CLUSTER, INSTRUMENT
BOLT/SCREW, INSTRUMENT CLUSTER
Figure 19 - Instrument Cluster (Typical)
INSTRUMENT PANEL CARRIER

Figure 20
I++!

page 8C-1.
1. Instrument panel insulator from both sides of
vehicle. Refer to "Instrument Panel Insulator" in
this section.
2. Removable top, if equipped. Refer to
SECTION 10-9.
3. Window rail trim panel. Refer to SECTION 10-6.
4. Knee bolster and deflector. Refer to "Instrument
Panel Driver Knee Bolster and Deflector" in this
section.
5. Disable SIR. Refer to "Disabling the SIR
NOTICE: Remove stoplamp switch before

fully lowering the steering column. Failure to do
so may cause the stoplamp switch to become
damaged or thrown out of adjustment resulting
in a malfunctioning stoplamp switch or
premature brake wear.
6. Stoplamp switch. Refer to SECTION 5.
7. Steering column. Refer to SECTION 3F.
8.
9.
10.
11.
Gently lower steering column.

Trim panel. Refer to "Instrument Panel Upper
Trim Panel" in this section.
Trim plate. Refer to "AM/FM Stereo and Clock
Radio" under "On-Vehicle Service" in this
section.
Bezel. Refer to "Instrument Panel Cluster Trim
Plate Bezel" in this section.
Instrument cluster. Refer to "Instrument Cluster"
12. Radio. Refer to "AM/FM Stereo and Clock

section.
13. Temperature control. Refer to "Heater and Air
Conditioning Control" under "On-Vehicle
14. Left side ducts. Refer to "Heat, Ventilation, and
Air Conditioning Ducts" in this section.
15. Transmission gear shift knob, cover and console.
Refer to "Front Floor Console" under
16. Fuse block. Refer to "Auxiliary Fuse Block"
under "Instrument Panel Wiring Harness" in this
section.
17. Data link connector. Refer to "Instrument Panel
Wiring Harness" in this section.
18. Hazard and chime. Refer to "Warning/Reminder
Chimes" under "On-Vehicle Service" in this
section.
19. Upper bolts/screws (9).
20. Lower nuts (8).
21. Reposition carrier (75).
22. Air duct. Refer to "Heat, Ventilation and Air
Conditioning Ducts" in this section.
23. Audio alarm. Refer to "Alarm" in this section.
24. Wiring harness from carrier (75). Refer to
"Instrument Panel Wiring Harness" in this
section.
25. Carrier (75).
!++I
Install or Connect
NOTICE:
L Carrier (75).
2. Wiring harness to carrier (75). Refer to
"Instrument Panel Wiring Harness" in this
section.
3. Audio alarm. Refer to "Alarm" in this section.
8C24
A
B
C
D
WIRE,
WIRE,
WIRE,
WIRE,
CROSS CAR WIRING

INSTRUMENT PANEL
INSTRUMENT PANEL
INSTRUMENT PANEL
HARNESS GROUND
WIRING HARNESS GROUND
WIRING HARNESS GROUND
WIRING. HARNESS GROUND
8
9
40
75
NUT, INSTRUMENT PANEL

SOLT /SCREW, INSTRUMENT PANEL
PANEL, INSTRUMENT
02-o2-95
FS0208C
Figure 20 - Instrument Panel Mounting (Typical)
4. Air duct. Refer to "Heat, Ventilation and Air

Conditioning Ducts" in this section.
5. Position carrier (75).
6. Lower nuts (8).
l~I
Tighten
Lower nuts (8) to 25 N,m (18 lb. ft.).

7. Upper bolts/screws (9).
!~I
8.
9.
10.
11.
12.
13.
Tighten
Upper bolts/screws (9) to 1.9 N,m (17 lb. in.).

Hazard and chime. Refer to "Warning/Reminder
Chimes" under "On-Vehicle Service" in this
section.
Data link connector. Refer to "Instrument Panel
Wiring Harness" in this section.
Fuse block. Refer to "Auxiliary Fuse Block"
under "Instrument Panel Wrring Harness" in this
section.
Transmission gear shift knob, cover and console.
Refer to "Front Floor Console" under
Left side ducts. Refer to "Heat, Ventilation and
Air Conditioning Ducts" in this section.
Temperature control. Refer to "Heater and Air
Conditioning Control" under "On-Vehicle
14. Radio. Refer to "AM/FM Stereo and Clock

section.
15. Instrument cluster. Refer to "Instrument Cluster"
16. Bezel. Refer to "Instrument Panel Cluster Trim
Plate Bezel" in this section.
17. Trim plate. Refer to "AM/FM Stereo and Clock
section.
18. Trim panel. Refer to "Instrument Panel Upper
Trim Panel" in this section.
19. Steering column.' Refer to SECTION 3F.
Gently raise steering column into place.

20. Stoplamp switch. Refer to SECTION .5.

page 8C-1.
21. Enable SIR. Refer to "Enabling the SIR System"
in this section.
22. Knee bolster and deflector. Refer to "Instrument
Panel Driver Knee Bolster and Deflector" in this
section.
23. Window rail trim panel. Refer to SECTION 10-6.
24. Removable top, if equipped. Refer to
SECTION 10-9.
25. Instrument panel insulator. Refer to "Instrument
Panel Insulator" in this section.
A CONNECTOR. INSTRUMENT PANEL WIRING HARNESS

FOG LAMP ELECTRICAL
8 CONNECTOR. INSTRUMENT PANEL WIRING HARNESS
ELECTRICAL
C CONNECTOR, INSTRUMENT PANEL WIRING HARNESS
DIMMER SWITCH ELECTRICAL
5 BEZEL. INSTRUMENT PANEL CLUSTER TRIM PLATE
83 SWITCH. HEADLAMP AND INSTRUMENT PANEL LAMP DIMMER
SC-25
tFRT
02-02-95
FT0228C
Figure 21 - Headlamp and Instrument Panel Lamp Dimmer Switch - (Chevrolet)
INSTRUMENT PANEL SWITCHES

Dimmer Switch
Figures 21 and 22
CHEVROLET
1. Switch (83) from bezel (5).
2. Instmment panel wiring harness electrical
connectors from switch (83).
!++!
Install or Connect
NOTICE: When installing switch, do not put

pressure on switch knob or dimmer thumbwheel.
Failure to follow these instructions may result in
damage to the switch.
1. Switch (83) to instrument panel wiring harness
electrical connectors.
2. Switch (83) to bezel (5).
PONTIAC
!+-.!
1. Switch (83) from carrier (75).

connectors from switch (83).
l++I
Install or Connect
r-.JOTICE: When installing switch, do not put

pressure on switch knob or dimmer thumbwheel.
Failure to follow these instructions may result in
damage to the switch.
electrical connectors.
2. Switch (83) to carrier (75).
75

ELECTRICAL
8 CONNECTOR, INSTRUMENT PANEL WIRING HARNESS
ELECTRICAL
83 SWITCH, HEADLAMP AND INSTRUMENT PANEL
LAMP DIMMER
~t::i.f~
Figure 22 - Headlamp and Instrument Panel Lamp Dimmer

Switch - (Pontiac)
Rear Compartment lid Release Switch

Figures 23 and 24
CHEVROLET
!++!
1. Switch (31) from instrument panel carrier (75)

inside instrument panel compartment door.
SC-26
~31

31 SWITCH, REAR COMPARTMENT LID RELEASE
~lo'fJ~
Figure 23 - Rear Compartment Lid Release Switch (Chevrolet)

connector from switch (31).
l++I
Install or Connect

connector to switch (31).
2. Switch (31) to instrument panel carrier (75) inside
instrument panel compartment door.
PONTIAC
I+-+!

ELECTRICAL
31 SWITCH, REAR COMPARTMENT LID RELEASE
~,~
Figure 24 - Rear Compartment Lid Release Switch (Pontiac)
2. Switch (31) from instrument panel wiring harness

3. Switch (31) from bolster (3).
I++!
Install or Connect
1. Switch (31) to bolster (3).

section.
INSTRUMENT PANEL WIRING HARNESS

section.
Refer to Figures 25 and 26 for instrument panel

wiring harness routing.
02-02-95
F802MC
Figure 25 - Instrument Panel Wiring Harness Routing - (Chevrolet)
8C27
020285
FS0278C
Figure 26 Instrument Panel Wiring Harness Routing (Pontiac)
Instrument Panel Fuse Block
lHI
Install or Connect
Figure 27
!+-+!
1. Bolt/screw (86) connecting fuse block to carrier

(75).
2. Instrument panel fuse block.
!++!
NOTICE:
Refer .to "Notice" on page 8C-1.
1. Convenience center to tie bar (25).

Install or Connect
NOTICE:
1. Instrument panel fuse block to carrier (75).

2. Bolt/screw (86).
!~I
Tighten
Bolt/screw (86) to 1.5 N.m (13 lb. in.) ..
Convenience Center
Figure 28
!+-+!
1. Bolts/screws (87) attaching convenience center to

tie bar (25).
2. Convenience center.
A FUSE BLOCK, INSTRUMENT PANEL WIRING HARNESS

AUXILIARY
75 CARRIER, INSTRUMl:NT PANEL
FUSE BLOCK
020285
FS0288C
Figure 27 Instrument Panel Fuse Block
SC-28

Figure 29
I++!

page 8C-1.
87
25
A CONVENIENCE CENTER, INSTRUMENT PANEL WIRING

HARNESS
CONVENIENCE CENTER
020215
FS0218C
Figure 28 Convenience Center
l~I
Tighten
1. Left side sound insulator panel. Refer to

section.
2. Power window control module.
3. Wiring harness electrical connector from power
window control module.
!++I
Install or Connect
1. Wiring harness electrical connector to power

window control module.
2. Power window control module.
3. Left side sound insulator panel Refer to
section.
(
A
103
A RAISED AREA OF DASH MAT

B FRONT OF DASH (DASH MAT)
103 MODULE, RETAINED ACCESSORY POWER
Figure 29 Power Window Control Module
042&15
FT0308C

ODOMETER REPAIR NOTICE LABEL
INSTRUMENT PANEL INSULATOR
Figure 30
Figure 31
[TI
LEFT SIDE
Important
When repairing an instrument cluster, the law

requires the odometer reading of the
replacement unit to be set to register the same
mileage as the prior . odometer. If the same
mileage cannot be set, the law requires that the
replacement odometer be set to zero and a
label be installed on the driver's door frame to
show the previous reading and the date of
replacement.
A copy of the label must be. retained in
compliance with the retention requirements
specified in the "Guidelines for General
Motors Odometer Policy "
!++I
Install or Connect
1. Clean area around left B-pillar where odometer

repair notice label is to be attached. .
Label area is to be clean and free from

plastisol or any foreign materfal that could
affect adhesion of odometer repair notice label.
2. Properly fill out all necessary information on
odometer repair notice label.
Sign and date odometer repair notice label.
3. Remove backing and attach odometer repair
notice label to left B-pillar.
i++!
1. Retainer,(13) from instrument panel carrier.

2. Insulator (14) from instrument panel carrier.
A. Unhook flange on insulator (14) from side

kick panel.
B. Detach tab on insulator (14) from retainer on
j++I
Install. or Connect
1. Insulator (14) to instrument panel carrier.
A. Attach tab on insulator (14) to retainer on

B. Hook flange on insulator (14) to side kick
panel.
2. Retainer (13) to instrument panel carrier.
RIGHT SIDE
i++I
1. Retainer ( 11) from boss on heater and air

conditioning module.
2. Retainer (12) from insulator (10).
3. Insulator (10) from instrument panel carrier.
____.......
""'OOOflltTl011r..,...,t-cu:t ..
.....oMO~UCllfOfllOOII
.., ..,ucu,.,. ..,.GOOllll,usa,

"' IPG. -..AG&,.. ro ...... ,..
. _____
"-"'IIIIIUIITW&I
_ _ _ _ , ..01,nattt
ou, ..,....,IIUUClo _ _
JtN61.1,AW . . . . . rlP1IIIOll'ac.
........-...
OA-.f&MfOIIGIIYWt-..&
!VIEWA!
A LABEL. ODOMETER REPAIR NOTICE
Figure 30 Odometer Repair Notice Label
020295
FS0318C
8C30
c
A
8
C
D
10
11
12
13
14
LEFT SIDE
RIGHT SIDE
FLANGE
TAB
INSULATOR, INSTRUMENT PANEL
RETAINER, INSTRUMENT PANEL INSULATOR
INSULATOR, INSTRUMENT PANEL
11
.B
12
0508-85
FT0328C
Figure 31 - Instrument Panel Insulator (Typical)
A. Detach forward flange on insulator (10) from

boss on heater and air conditioning module.
B. Unhook flange on insulator (10) from under
side kick panel.
!H!
Install or Connect
1. Insulator (10) to instrument panel carrier.

A. Hook flange on insulator (10) over side kick
panel.
B. Attach forward flange on insulator (10) to boss
on heater and air conditioning module.
2. Retainer (12) to insulator (10).
3. Retainer (11) to boss on heater and air
conditioning module.
INSTRUMENT PANEL CLUSTER TRIM

PLATE BEZEL, INSTRUMENT PANEL
COMPARTMENT AND INSTRUMENT
PANEL UPPER TRIM PANEL
Instrument Panel Cluster Trim Plate Bezel
Figures 32 and 33
1. Five bolts/screws (6) attaching bezel (5) to carrier

(75).
2. Bezel (5) from carrier (75).
l++I
Install or Connect
NOTICE:
!~!
Tighten
PONTIAC
I++!
1. Locator pins attaching bezel (5) to carrier (75).

2. Bezel (5) from carrier (75).
j++I
Install or Connect
1. Bezel (5) onto carrier (75).

2. Locator pins attaching bezel (5) to carrier (75).
CHEVROLET
l++I
A. Position bezel (5) over instrument cluster.

B. Insert locating pins on trim plate into
appropriate holes in instrument panel.
C. Align holes on bezel (5) with holes on carrier
(75).
2. Five bolts/screws (6) attaching bezel (5) to carrier
(75), following torque sequence indicated if
Figure 32.
1. Bezel (5) onto carrier (75).
The instrument panel compartment is part of the

instrument panel carrier. The door, lock and lamp are
serviceable. The lamp switch is part of the body
wiring harness. For further information, refer to
SECTION 8B.
Instrument Panel Compartment Door

Figure 34
!++I
1. Bolts/screws (20 and 90) attaching hinge to

A PIN, LOCATOR
5 BEZEL ASSEMBLY, INSTRUMENT PANEL CLUSTER
TRIM PLATE
0210-95
FS0348C
Figure 33 - Instrument Panel Cluster Trim Plate Bezel

(Pontiac)
I SECTION A-A I
INSTRUMENT PANEL COMPARTMENT DOOR

LOCK
A LOCATING PIN
5 BEZEL, INSTRUMENT PANEL CLUSTER
TRIM PLATE
6 BOLT/SCREW, INSTRUMENT PANEL CLUSTER
TRIM PLATE
D INDICATES SEQUENCE FOR

INSTALLING SCREWS
03-15-95
FT0338C
Figure 32 - Instrument Panel Cluster Trim Plate Bezel (Chevrolet)
2. Open door (89).

3. Door (89) from instrument panel carrier.
!++-!
Install or Connect
NOTICE:
1. Door (89) onto instrument panel carrier.

2. Close door (89).
3. Bolts/screws (20 and 90) attaching hinge to
Align hinge.
l~I
Tighten
Bolts/screws (20 and 90) to 2.8 N.m

(25 lb. in.).
Figure 34
!++!
1. Open door (89).

2. Three bolts/screws (92) attaching lock (91) to
door (89).
3. Lock (91) from door (89).
!++!
Install or Connect
1. Lock (91) to door (89).

2. Three bolts/screws (92) attaching lock (91) to
door (89).
Align and tighten bolts/screws (92).
3. Close door (89).
INSTRUMENT PANEL COMPARTMENT DOOR
LOCK CYLINDER
Figure 34
!++!
1. Door lock. Refer to "Instrument Panel

Compartment Door Lock" in this section.
2. Insert key in lock cylinder (101) and rotate to
locked position.
3. Remove key from lock cylinder (101).
4. Depress silver key tumbler using small bladed
screwdriver.
5. Reinsert key into lock cylinder (101) while
depressing key tumbler.
SC-32
2 0 - -.....,
'
'"""
jVIEWAj
~20
. . .-::::1
. 91
89
~~
18 MODULE, INFLATABLE RESTRAINT INSTRUMENT PANEL

20 BOLT/SCREW, INFLATABLE RESTRAINT CONTROL MODULE BRACKET
89 DOOR, INSTRUMENT PANEL COMPARTMENT
90 BOLT/SCREW, INSTRUMENT PANEL COMPARTMENT DOOR
91 LOCK, INSTRUMENT PANEL COMPAR.TMENT DOOR
92 BOLT/SCREW, INSTRUMENT PANEL COMPARTMENT DOOR LOCK
101 LOCK, CYLINDER INSTRUMENT PANEL DOOR LOCK
!VIEW
el
02-02-etl
FS0358C
Figure 34 - Instrument Panel Compartment Door and Lock
6. Rotate the cylinder clockwise and remove lock

cylinder (101) and key.
!++I
Install or Connect
1. Depress silver key tumbler and insert key into the

lock cylinder (101).
2. Lock cylinder (101) and key into the lock.
ro,
LLI
Important
The lock handle must be opened to allow for

installation.
3. Relock the lock (rotor) and rotate the key to the
unlock position.
4. Remove key from the lock cylinder (101).
5. Door lock. Refer to "Instrument Panel
Compartment Door Lock" in this section.
Instrument Panel Compartment Lamp

Switch
Figure 35
!++!
1. Switch (96) and retainer (95) from carrier (75).

2. Retainer (95) from switch (96).
!++!
95 RETAINER, INSTRUMENT PANEL COMPARTMENT
LAMP SWITCH
96 SWITCH, INSTRUMENT PANEL COMPARTMENT LAMP
020215
F80388C
Figure 35 Instrument Panel Compartment Lamp Switch

(Typical)
Install or Connect
1. Retainer (95) to switch (96).

2. Switch (96) and retainer (95) down through
opening in carrier (75).
Be sure retainer (95) is seated into carrier (75).

Instrument Panel Fuse Block Access Door
8C33
3. Windshield side upper garnish moldings (right and

left).
Figure 36
!++j
INSTRUMENT PANEL INFLATABLE

RESTRAINT MODULE
Figures 34 and 38
Door (2) from carrier (75).
!++!

page 8C-1.
Install or Connect
Door (2) to carrier (75).

A. Align tabs on door (2) with front edge of
carrier (75).
B. Align locator pins on door (2) with holes on
carrier (75) and apply pressure.
Instrument Panel Upper Trim Panel

Figure 37
!++!
!++I

2. Bolts/screws (20) attaching bracket (19) to
3. Bracket (19) from instrument panel carrier.
I. Windshield side upper garnish moldings (right and

left).
2. Security indicator lamp retainer, and/or daytime
running lamp ambient light sensor grille from
upper trim panel.
3. Panel (1) from carrier (75), carefully pulling up at
dual lock fasteners.
4. Panel ( 1) from vehicle.
!++!
Install or Connect
75
I. Panel ( 1) to vehicle.
A. Align panel (1), using locator pins.

B. Apply pressure to rear of panel (1), engaging
dual lock fasteners with mating surface.
C. Apply pressure to front of panel (1), engaging
dual lock fasteners with mating surface.
2. Security indiactor lamp retainer, and/or daytime
running lamp ambient light sensor grille to upper
trim panel.
A
B
C
1
75
PIN, LOCATOR
FASTENER, DUAL LOCK
SUPPORT, LOWER WINDSHIELD
PANEL. INSTRUMENT PANEL UPPER TRIM
020295
FS0388C
Figure 37 Instrument Panel Upper Trim Panel (Typical}
18
17
A LOCK, DUAL
2 DOOR, INSTRUMENT PANEL FUSE BLOCK ACCESS
020295
FS0378C
Figure 36 Instrument Panel Fuse Block Access Door

(Typical)
18
19
19
SOLT/SCREW, INFLATABLE RESTRAINT INSTRUMENT

PANEL MODULE
MODULE. INFLATABLE RESTRAINT INSTRUMENT
PANEL
BRACKET, INFLATABLE RESTRAINT INSTRUMENT
PANEL MODULE
,~~~
Figure 38 Instrument Panel Inflatable Restraint Module
SC-34 INSTRUMENT PANEL, GAGES AND CONSOLE

4. Bolts/screws (17) attaching module (18) to bracket
(19).
5. Module (18).
lH!
Install or Connect
NOTICE:
1. Module (18) into bracket (19).

2. Bolts/screws (17) attaching module (18) to bracket
(19).
I~!
Tighten

3. Bracket (19) to instrument panel carrier.
4. Bolts/screws (20) attaching bracket ( 19) to
!~!
Tighten

5. Enable the SIR system. Refer to "Enabling the
SPECIFICATIONS
Air Distributor Duct Bolt/Screw ........... ;............................................................................... 1.9 N.m (17 lb. in.)
Data Link Connector Bolt/Screw ........................................................................................... 1.5 N.m (13 lb. in.)
Floor Air Outlet Duct Bolt/Screw ........................................................................................ 1.9 N.m (17 lb. in.)
Front Floor Console Bolt/Screw .............................................................................................. 8 N.m (71 lb. in.)
Front Floor Console Bracket Bolt/Screw ................................................................................ 8 N.m (71 lb. in.)
Heater and Air Conditioning Control Bolt/Screw ................................................................. 1.9 N,m (17 lb. in.)
Heater and Air Conditioning Evaporator and Blower Module Bolt/Screw ......................... 10 N.m (89 lb. in.)
Instrument Cluster Bolt/Screw ........................................................................ ,..................... 2.2 N.m (20 lb. in.)
Instrument Panel Accessory Trim Plate Bolt/Screw ............................................................ 1.9 N.m (17 lb. in.)
Instrument Panel Bolt/Screw (Upper) ................................................................................... 1.9 N.m (17 lb. in.)
Instrument Panel Bolt/Screw (Lower) ................................................................................... 5.5 N.m (49 lb. in.)
Instrument Panel Center Air Outlet Duct Bolt/Screw ......................................................... 1.9 N.m (17 lb. in.)
Instrument Panel Cluster Trim Plate Bolt/Screw .................................................... :............ 2.8 N.m (25 lb. in.)
Instrument Panel Compartment Door Bolt/Screw ................................................................ 2.8 N,m (25 lb. in.)
Instrument Panel Driver Knee Bolster Deflector Nut.. ........................................................ 1.9 N.m (17 lb. in.)
Instrument Panel Driver Knee Bolster Bolt/Screw .......................... :: .................................. 1.9 N.m (17 lb. in.)
Instrument Panel Inflatable Restraint Module Bolt/Screw ................................................... 3.2 N.m (28 lb. in.)
Instrument Panel Inflatable Restraint Control Module Bracket Bolt/Screw ....................... 3.2 N.m (28 lb. in.)
Instrument Panel Nut. .............................................................................................................. 25 N.m (18 lb. ft.)
Instrument Panel Outer Air Outlet Bolt/Screw .................................................................... 1.9 N.m (17 lb. in.)
Instrument Panel Wiring Harness Convenience Center Bolt/Screw .................................... 1.9 N,m (17 lb. in.)
Instrument Panel Wiring Harness Fuse Block Bolt/Screw .................................................. 1.5 N.m (13 lb. in.)
Radio Bracket Bolt/Screw ..................................................................................................... 1.8 N.m (16 lb. in.)
Radio Bracket Nut. ................................................................................................................ 2.8 N.m (25 lb. in.)
Rear Radio Bracket Bolt/Screw ............................................................................................ 1.9 N.m (17 lb. in.)
BODY CONTROL MODULE
801
SECTION SD
BODY CONTROL MODULE

CAUTIONS in Section 9J under "ON VEHICLE SERVICE" and the SIR Component and Wiring
CONTENTS
General Description .............................................. 8D-1 ,
System Functions ............................................. 8D-1
Wake-Up/Asleep States .................................... 8D-1
Power Requirements ......................................... 8D-2
Abbreviations/Definitions ................................. 8D-2
On-Vehicle Service ............................................... 8D-2
BCM Replacement ........................................... 8D-2
Component Locations/Removal Procedures .... 8D-2
Diagnostics ............................................... ;............ 8D-2
Entry Into Diagnostics ..................................... 8D-2
Intermittent/History DTCs ................................ 8D-3
Replacement/Removal Procedures ................... 8D-3
Clearing BCM DTCs ....................................... 8D-3
BCM Wiring Diagrams ........................................ 8D-4
DTC Display Order................................ ;............. 8D-6
BCM DTCs .............................................. ;........... 8D-6
DTC 12-Begin Diagnostic Display ......... ;:: ......... 8D-6
DTC 21/31-Courtesy Lamps Feed (Circuit
Shorted to Ground) .......................................... 8D-10
DTC 22/32-Courtesy Lamps Return

(Circuit Shorted to B+) ......................... ,.......... 80-14
DTC 23/33-Retained Accessory Power (RAP)
(Circuit Shorted to Ground or B+) ................. 80-16
DTC 24/34-"Fasten Seatbelt" Indicator Lamp
(Circuit Shorted to Ground or B+) ................. 80-18
DTC 25/35-Security L.E.D. Present
(With UA6 only) .............................................. 80-20
"REMOTE CONTROL DOOR LOCK
TRANSMITTER DTCs" .................................. 80-21
DTC 41- Last Transmitter Message Received
Valid (With AUO only) .................................... 80-21
DTC 42- Last Transmitter Message Received had
Invalid ID (With AUO only) ............................ 80-21
Sumcheck Error (With AUO only) .................. 80-22
Encryption Error (With AUO only) ................. 80-22
DTC 45-, Receiver Processing Currently in
20 Second Lockout (With AUO only) ............. 80-23
DTC 55-Begin Configuration Display ................. 80-23
GENERAL DESCRIPTION
control or monitoring and has become idle again. The

signals that will cause the BCM to wake-up are as
follows:
SYSTEM FUNCTIONS
The Body Control Module (BCM) performs the
following functions:
Remote keyless entry.
Universal theft deterrent system.
PASS-Key II.
Chime.
"Fasten Seatbelt" Indicator.
"Low Coolant" Indicator latching.
Retained Accessory Power (RAP).
Power Door Locks. ,
Hatch Release.
Courtesy lamp control.
Illuminated entry.
Delayed interior lamps.
WAKE-UP/ASLEEP STATES
"Wake-ups" are signals that will tum the BCM
"ON" and cause it to begin active control and/or
monitoring. The BCM is "asleep" when it has stopped
Courtesy lamp system.

Remote keyless entry system.
Ignition "ON" (IGN 1).
Park Lamps.
Headlamps.
Door Jamb Switches.
Hatch Switch.
Key in Ignition Switch.
Shock Sensor Inputs.
After the BCM is awake and the wake-up input
is removed (i.e., a door is opened, then closed) the
BCM will "go to sleep" again in 10 minutes.
If the BCM sees a door ajar wake-up, and that
wake-up remains active (i.e., the door remains open
with ignition "OFF") for 10 minutes, the BCM will
tum courtesy lamps "OFF," if they were "ON." This
is done to prevent battery drain if a door is
inadvertently left open for an extended period of time.
802
BODY CONTROL MODULE
POWER REQUIREMENTS
Operating current at the BCMs battery terminals
should not exceed 75 milliamps while the BCM is
awake with ignition "OFF"; 250 milliamps -is an
approximate "normal" value with ignition in "RUN".
The RAP system allows operation of the Power Door
Locks, convertible top and radio until a door is opened
or 10 minutes has elapsed. When the BCM is asleep,
the current should not exceed 3 milliamps (w/UA6), or
2 milliamps (without UA6). The BCM goes asleep
after the ignition is shut "OFF" and 10 minutes has
elapsed. Operating current drawn by the IGN 1 and
IGN 3 terminals of the BCM should not exceed 15
milliamps. Refer to SECTION 601 for more details
on BCM current drain in various awake and asleep
conditions. For most BCM functions, the BCM will
operate properly with a system voltage of 9-16 volts.
COMPONENT LOCATIONS/REMOVAL
PROCEDURES
Below is a list of each component that a BCM
diagnostic chart may direct you to replace. Use the list
to determine which section in the manual contains the
removal and replacement procedures for the
component in question. Refer to Page 80-3 for actual
BCM replacement/removal procedures.
BCM .................................................................. 80
PCM ................................................................ 6E3
Instrument Cluster ............................................ 8C
PASS-Key II Ignition Key .... ,....................... 90
Theft Deterrent Shock Sensor ...... ,.................... 90
Theft Deterrent L.E.D ...................................... 90
DIAGNOSTICS
ENTRY INTO DIAGNOSTICS
Several abbr_eviations are commonly used

easy reference.
BCM .................................. Body Control Module
CKT ................................................. ,.......... Circuit
DLC ..................................... Data Link Connector
DTC .............................. Diagnostic Trouble Code
DVM.......................................... Digital Voltmeter
PCM .......................... Powertrain Control Module
PASS-Key II .................... Personal Automotive
Security System
RAP ................. ~ .......... Retained Accessory Power.
UTD ............................. Universal Theft Deterrent
The BCM can display a series of DTCs, when it

is placed in the diagnostic mode. These DTCs are
displayed as flash codes through the "Security"
indicator lamp on the Instrument Cluster. During
normal operation, if the. BCM detects a fault on a
monitored circuit, there will be no flashing .or any
indication to the customer that an fault has occurred,
though he/she might detect a system malfunction. The
system faults will be recorded as "Current," or
"History". A "Current" DTC means that the
condition was present when the Diagnostic mode was
entered. A "History" DTC means the condition has
occurred sometime since. the BCM was installed in the
vehicle, but may not be present currently. If a
"Current" DTC is present, the associated "History"
DTC will always be present. When working on
systems controlled by the BCM, the technician should
always .refer to this section and check for DTCs.
Diagnostics is entered by performing the
following steps:
Put the key into the Ignition Switch and turn it
to the "RUN" position (to disarm the theft
deterrent system, if equipped).
Turn the Ignition Switch to the "OFF"
position.
Remove the RADIO fuse 17. from the 1/P fuse
block.
Turn the Ignition Switch to the "ACC"
position (enters "Program" mode for feature
customization, 1 or 2 "Chimes" for mode
verification).
Within 5 seconds, turn the Ignition Switch to
"OFF" then back to "ACC" position (enters
diagnostic mode, 3 "Chimes" for mode
verification).
The BCM will begin to flash DTCs 4 seconds
after entering the diagnostic mode, from the
programming mode. Each flash of the "Security"
indicator lamp on the 1/P represents a number. For
example, one flash followed by two quick flashes
represents a code 12. Each code is displayed 3 times
before the next code is displayed. Any DTCs present
are displayed in numerical order. Once the last code is
ON-VEHICLE SERVICE
CAUTION: This vehicle is equipped with
Supplemental Inflatable Restraint (SIR).
Refer to CAUTIONS in Seetion 9J under
"ON-VEHICLE SERVICE" and the SIR
Component and Wiring location view in
Section 9J before performing service on
Failure to follow CAUTIONS could result
injury, or otherwise unneeded SIR system
repairs.
BCM REPLACEMENT
The BCM should only be replaced if diagnostics
in this section, or 8A direct you specifically to do so.
Most system concerns are traceable to faulty wiring,
connectors, or components; the BCM itself is very
reliable, and is not likely the cause of a fault. BCM
replacement before complete diagnosis is performed
will likely lead to a recurrence of the fault.
The .BCM electrical connectors are designed
with indexing tabs and slots such that they only fit one
way. They do not require excessive force if they are
being installed correctly. Installing the connectors in
the wrong mating half or upside down can cause
damage to the. connector, the BCM, or other vehicle
components or systems. BCM replacement procedures
can be found on Page 80-3.
BODY CONTROL MODULE

displayed, the list begins over again with the first
code. The display continues until the Diagnostic Mode
is exited.
INTERMITTENT/HISTORY DTCs
History DTCs are those indicating that the BCM
previously detected a fault which later disappeared.
Any DTC that has a 3 as its first digit is a "History"
DTC. Examples are: 31, 32, 33 etc. The reason could
be either that the fault is a true intermittent only
happening occasionally, or that the system which the
DTC monitors is not currently being operated.
If a visual (physical) check does not find the
cause. of the concern, the vehicle can be driven with a
DVM connected to the suspected circuit. An abnormal
voltage or resistance reading when the concern occurs
indicates the concern may be in that circuit.
BODY CONTROL MODULE (BCM)
REPLACEMENT/REMOVAL PROCEDURES
NOTICE:
If BCM C2 connector is removed first and
reinstalled last, no BCM DTCs will set.
If BCM is being replaced (as opposed to being
removed for access to other components), refer to
"BCM Replacement" in SECTION 9D after new
BCM is installed in vehicle. This will enable the
PASS-Key II system portion of the BCM, to
properly code the new BCM to the present
ignition key being used.
The electrical connectors are designed to fit in
only one way; there are indexing tabs and slots on
both halves of the connector. Forcing the
connector into place is not necessary if it being
installed with the proper orientation.
80-3
Failure to take care to match the indexing tabs

and slots to ensure the connector is being installed
correctly can cause damage to the connector, the
module or other vehicle components or systems.
!++!
1. Lower instrument panel insulator.

2. Unsnap BCM from HVAC duct bracket.
Lower BCM.
3. Electrical connectors and remove BCM from
vehicle.
!++!
Install or Co,nnect
1. Electrical connectors to BCM.

2. Snap BCM to HVAC duct bracket.
3. Lower instrument panel insulator.
[I]
Important
G200 ground is the primary ground for the
BCM and other electrical components. This
ground must be tight at all times, or failure of
the BCM could occur.
CLEARING BCM DTCs

"Current" DTCs (21-25) will remain stored and
display as long as the BCM detects the fault criteria.
"History" DTC (31-35) can be cleared by depressing
the door unlock switch for a period of 4 seconds while
the BCM is in the Diagnostic Mode. The Chime will
sound 3 times at the end of the 4 second period as a
confirmation that the DTC(s) have cleared.
A DUCT, HEATER, VENTILATION AND

AIR CONDITIONING
8 HARNESS, INSTRUMENT PANEL WIRING
MODULE, BODY CONTROL
05-13-95
FT0018D
Figure 1 - Body Control Module
80-4
BODY CONTROL MODULE
HOT AT ALL TIMES
MM
3 RED
HOT IN RUN, BULB 1EST OR START
1 BU<
SEE POWER
CMSTRIBUTION
PAGE SA-10-3 G3
SEE POWER
DISTRIBUTION .
PAGE 8A-10-2
I
I
I
I
I
LINKE
91lllllllllllllmlllll
102
102
\
COURTESY
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10 AMP
______ .,. I
MU
20 AMP
A2
.8 PNK
AaQQ
SE POWER
DISTRIBUTION
PAGE SA-10-1
---------------- -------
3 RED
.s2QQ
1GN
(NOT USED)
~
FUSE 7
15 AMP
. ____ _
3 RED
Cl
------ .,
102
39
1 ORN
C2Q.QP
.8 ORN
640
ll!J
,{
.8 ORN
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3 RED
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8 ORN
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640
.8 ORN
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640
.5 ORN
640
--~~~,i~_J
624
TO EXTERIOR LIGHTS
I
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a.
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l"Q ...... -
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-
TO HATCH RELEASE
PAGE 8A-134-0
'f-. " I .
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-- -- -- __Cl
HATCH
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ORN
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253
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PAGE SA-11-5 ~
1111'9
650
BATTERY
I
I
:5
PARK LAMP
RELAY
CONTROL
SHOCK SENSOR
"SHOCK" INPUT
REAR COMPARTMENT
LID RELEASE
SEAT BELT
SWITCH
SHOCK SENSOR
"TAMPER" INPUT
HATCH
AJAR
HATCH RELEASE
RELAY CONTROL
.
HORN
RELAY
IGN KEY
RESISTOR
IGNITION BATTERY
I
\
IGN KEY
RESISTOR
~~~~------~-~~--~~----~~--.:?H~-~--~~~---~-~-J
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13
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ICHEV I
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JS[!
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TERMINALS
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COMPARTMENT
650
I
A
_... SEE GROUND
650
PAGE BA-14-789
#IJIIIIIIIIIIIIIIIIIIIIIIIIII
.... ~
INDICATOR
SEE GROUND
AI
DISTRIBUTION
PAGE BA-14-12
.35
PPL/
WHT
1074
,35
GRY/
BU<
- --.,
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rz['os~
,35
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3 BLK
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1073
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(OPEN WITH
LH FRONT
SEATBELT
650
,35
T.o HORN
RELAY
PAGE
BA- 4o-o
"'111111111111111111111111111111111111111111~3i[i!5!1iBLiK1111111111111BIII
PASSENGER
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28
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.mr
650
.
3BLK
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~~~7-0
SEAT
EILK
.35
BU<
.5
.35 BLK/1238
WHT
TO INFLATABLE
RESTRAINT
DIAGNOSTIC
A
ENERGY
650
RESERVE
MODULE (SOM)
~
.35
737
.35 ORN/
DRIVER
:~:o
DOOR JAMB
I
WITH=I
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L-~
DOOR JAMB
SWITCH, RH
(CLOSED
WITH DOOR
OPEN)
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A
I _ _, ~
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REAR
COMPT LID IS
UNLATCHED)
.s BLK
1550
111111111111111111111111111111111111~
G400
..:I_
015-1895
FT0008A051
(
BCM Wiring Diagram (1 of 2)
BODY CONTROL MODULE
.----------.~
g
;-------
-------.!Lf!
SEE POWER
I !.!g
I !ILOCK
''
______ .
'
-------\
DISTRIBUTION
PAGE SA-10-2
B5
RADIO
I
I
I
I
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C6
43
SEE FUSE
BLOCK DETAILS
PAGE ISA-11-9
illl! -
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BSWITCH
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.5 YEL
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I
I
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15 AMP
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ORN
75
43
.5
YEL
(CHEV) C14
(PONT) A13
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229
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3 BRN
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(CHEV) C13
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1
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BLK
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1376
.35
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BLK
625
781
1
GRY/
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780
295
1
GRY
1663
694
.8
TAN
,-------------------------------------------~~
C12
f
\
SEE POWER
OISTRIBUTION
PAGE 8A-10-2
SEE POWER DOOR LOCKS

TO THEFT
PAGE SA-130-0
TO ~ DETERRENT
PAGE
RELAY PAGE
BA-51-0 BA-133-0 ,,.,.,,..,_....,"""'""'"""'""""""""'..,,.....,,'-
SEE POWERTRAIN
CONTROL MODULE
PAGE(S) SA-21-2
8A-22-2
640
SD-5
06
- - - - - - ~ ' \~
C16
__C1.1
!.J
I CONTROL
MQQ!,!JJ;
I (BCM)
\
CONTROL
INTERIOR LAMPS
''FASTEN SEATBELT''
"LOW COOLANT''
CONTROL PARK
KEY
INTERIOR INTERIOR I
J
COMMAND
INDICATOR LAMP
LATCHING
LAMPS
IGNITION LAMPS
LAMPS fl
t i - - - - ...... ~Pl!_- ........... --~~I;_ ......... .?!;!~T2,f!~NJ!!O!;_ _ - ma._._!~._ -~N!:, _R.:!,U!!! _F~O- J
"SECURITY''
INDICATOR
LAMP
PROGRAM
INPUT
FUEL
ENABLE
C7
,5 GRY
RETAINED ACCESSORY ACCY

POWER (RAP)
C4
.35
PPL/WHT
157
SECURITY
LEO
CONTROL
C15l g
.35 YEL/BLK
66
gJ.21
237
,35 YEL/BLK
(a.OSED I
AT FULL
BRIGHTNESS) I. -
-1
.5 BLI<
SEE GROUND
DISTRIBUTION
PAGE SA-14-7,8,9
. __
011
A6
INTERIOR
-~~S-~:!i~
I II
-B
..... - .I I
llili..-
"FASTEN @"LOW
SEATBELT
COOLANT''
INDICATOR"
(PONT) 83
(CHEV) C4
IQJEB
,,:!l
I
I
I
I
111e1111111111111111111111111111111111111111111111111111111111111111111ll!IIIIIIIIIII
3 SLK
650
650
c14,,
01
_g
35
WHT
156
.35
YEL/
BLK
.35
LT GRN
68
80
.8
DK
BLU/
WHT
149
..I
39
1 SLI<
.8
BRN
"ll INTR!,!M~T
CID
t ____J_____l
650
015'
68
=::uer1----, ,----1----f
(CHEV) C6
(PONT) A12
THEFT
DETERRENT
RELAY
TO~
PAGE
8A-5 1-0
,,
SEE
INSTRUMENT
CLUSTER
PAGE
SA-81-3
,.
SEE
EXTERIOR
LIGHTS
PAGE
BA-110-0
SEE
AUDlSLE
WARNINGS:
CHIME
PAGE
SA-76-0
SEE
INTERIOR
LIGHTS
PAGE
SA-114-0
.::..__~
061896
FT0018A061
BCM Wiring Diagram (2 of 2)
SD-6
BODY CONTROL MODULE
DTC DISPLAY ORDER

DTC DISPLAY ORDER
Upon entering the Diagnostic Mode, the BCM will display DTCs in numerical order. The first DTC displayed is always
DTC 12, followed by any "Current" DTCs (21-25) or any "History" DTCs (31-35). "Remote Control Door Lock
Transmitter Diagnostic DTCs " (41-45) will then be displayed if evoked while in the Diagnostic Mode. The last DTC
displayed is "Begin Configuration Display" (55). The first number following DTC 55 is the hardware configuration,
and the second number is the software configuration. DTC 55 and the two configuration numbers are always displayed.
After the configuration numbers are displayed, the entire list is repeated beginning with DTC 12. The system faults will
be recorded as "Current," or "History" DTCs. A "Current" DTC means that the condition was present when the
Diagnostic mode was entered. A "History" DTC means the condition has occurred sometime since the BCM was
installed in the vehicle, but may not be present currently. If a "Current" DTC is present, the associated "History" DTC
will always be present. When working on systems controlled by the BCM, the technician should always refer to this
section and check for DTCs.
BCM DTCs
DTC
12
21/31
22/32
23/33
24/34
25/35
41
DESCRIPTION
Begin Diagnostic Display
Courtesy Lamps Feed (Circuit Shorted to Ground)
Courtesy Lamps Return (Circuit Shorted to B+)
Retained Accessory Power (Circuit Shorted to Ground or B+)
"Fasten Seatbelt" Indicator Lamp (Circuit Shorted to Ground or B+)
Security L.E.D. Present (With UA6 only)
Last Transmitter Message Received Valid (With AUO only)
42
43
Last Transmitter Message Received had Invalid ID (With AUO only)

Last Transmitter Message Received had Sumcheck Error (With AUO only)
44
Last Transmitter Message Received had Encryption Error (With AUO only)
Receiver Processing Currently in 20 Second Lockout (With AUO only)
Begin Configuration Display
-## Hardware Configuration
-## Software Configuration
45
55
DTC 12
BEGIN DIAGNOSTIC DISPLAY
Condition:
This DTC is always displayed. It indicates that
the diagnostic display is in progress.
BODY CONTROL MODULE
NK
SD-7
SD-8
BODY CONTROL MODULE
BCM
- - - - - - 1 i 7 G R V - - - - - - - - - - - - - - C3C7
~OR
COMMAND
INPUT
i.HOOOR
AJAR
INPUT
a
A 1 - - - - - 746 -----<i~.~~--o---746
lilU</WHT
BU</WHT
RH OOOR JAMB SWITCH
(CLOSED WHEN DOOR OPEN)
158
WHT
l (( I
S247
156
WHT
821 7
- - - ~ - - - - - - - - -- - A
158
< ~ - + - ) . - - - s 2....
41WHT_
~ .
@P.
OPEN
IS
c1.0SED
CONSOLE COMP.AlmAENT I.AMP
_r-1'::-+~~--11-REAR COMPMmllfflf I.ID
AJAR INDICATION SWITCH

1118 (DIP)
El+ ~ R E D - - - " - - - - - - - ORN
~ 1002
""V"'
40
20AMP
COUPE
---------11 ~-B
BATTERY
05-26-95
IF'l'0028D
BODY CONTROL MODULE
8D-9
BCM
_
INTERIOR
......,... LAMPS
c . . _ - - - - - 1 6 7 0 R V - - - - - - - - - - - - - - - 1 1 C3C7 COMMAND
"'"""-ml INPUT
1/P DIMMER SWITCH

(ON AT FUU. IISRIGHTNESS) ---..........
I(':J---aRi:LK---~-~-:-
r
..J!IL
~ .. ~~D
C3D1i LH DOOR
a.;;;;;......,-4 AJAR
INPUT
1.H DOOR JAMB SWITCH

(CLOSIED WHEN DOOR OPEN)
ES
I
----1--~((,-...il,___
BLK/WHT
I
880
BU<
---1RHDOOR
~-D12 AJAR
INPUT
..........
A a - - - - - 748
RH DOOR JAMB SWITCH

1158
WHT
.-----t B
----c@,----1
COURTESY I.AMP,
149
WHY
LT REAR
156
WHT
19
----c@----11
,....._,.. COURTESY
~-D1 LAMPS
RETURN
COURTESY I.AMP,
,----t-~~
C200C
RT REAR
C200D
41
~;..._];...._-
-11-1-<(@)>---1-1-)..1111---1
COURTESY
LAMPS
= - S24i:;..7_ ---~~~
FEED
REAR COMPARTMENT LAMP
156
WHT
l a--
'----~--------821-7--,a A
@>5"7
OPEN
19
CLOSED
149
BW/WHT
1/P COMPARTMENT LAMP
A
A
CONSOLE COMPARTMENT LAMP

REARVIEW MIRROR
REAR COMPARTMENT UD
----------11 .QaIII
CONVERTIBLE
BATTERY
015-1996
FT0038D
80-10
BODY CONTROL MODULE
DTC 21/31
COURTESY LAMPS FEED
(CIRCUIT SHORTED TO GROUND)
The BCM provides 12 volt input to the courtesy
lamps on CKT 149 to S241 when commanded by the
1/P dimmer switch input, or the RH or LH door jamb
switch, or Hatch Switch inputs. S241 distributes power
to the following on coupe and convertible models:
Coupe
Dome Lamp.
1/P Compartment Lamp (Glove Box).
Console Compartment Lamp (Center Console).
Courtesy/Reading lamps.
Convertible
S317 (RH/LH Rear Courtesy Lamps, Rear

Compartment Lamp).
1/P Compartment Lamp (Glove Box).
Console Compartment Lamp (Center Console).
~ Courtesy/Reading Lamps.
DTC Will Set When:

CKT 40 is open due to either Courtesy Fuse 8,
harness or connector failure; CKT 149 (Courtesy
Lamps Feed) is shorted to ground for greater than
50 milliseconds, while the BCM is attempting to
Power this circuit; or BCM is defective.
Action Taken:
DTC Will Clear When:

Fault is corrected and DTC memory is cleared.

1. This check is made to make sure tltat
COURTESY fuse 8 is good.
2. If COURTESY fuse 8 is open, this test checks for
a short to ground on CKT 40 as the possible
cause.
3. If COURTESY fuse 8 is OK, this test checks for
an open in CKT 40 as the possible cause.
4. If CKT 40 is not shorted, this test bypasses the
BCM and checks for a short to ground in
CKT 149.
5. If CKT 40 is not open, this test bypasses the
BCM and checks for a short to ground in
CKT 149.
Diagnostic Aids:
If the only DTC that flashes is a "History" code
(DTC 31), the problem may be intermittent. Try
performing the test shown while "wiggling" wiring
and connectors; this can often cause the fault to
appear. Check for poor connections at the BCM
connector. these could cause an open or an intermittent
fault. Refer to "Intermittent/History" DTCs near the
beginning of this section.
DTC 21 will set. No Courtesy lighting in the

vehicle; Interior Lamp Switch next to Headlamp
Switch inoperative. Center console and Glove Box
Lamps inoperative. BCM will read out a series of
flash DTCs upon entering Diagnostic Mode.
BODY CONTROL MODULE 80-11
DTC 21/31
III
COURTESY
LAMPS CIRCUIT
IMPORTANT:
CHECK FOR PROPER INSTALLATION OF AFTERMARKET

ELECTRONIC EQUIPMENT WHICH MAY AFFECT THE INTEGRITY
OF THIS SYSTEM.
CHECK COURTESY FUSE 8 FOR OPEN.

IS FUSE 8 OPEN?
DISCONNECT BODY CONTROL MODULE (BCM)

CONNECTOR C2.
CONNECT A TEST LIGHT BETWEEN BCM
CONN C2 TERM B AND GROUND.
IS TEST LIGHT "ON"?
CONNECT TEST
LIGHT BETWEEN
TERMINALS B
AND EON CONN
C2.
IS TEST LIGHT
UON"?
REPAIR OPEN
IN CKT 40.
DISCONNECT BODY CONTROL MODULE

(BCM) CONNECTOR C2.
TEST FOR A SHORT TO GROUND ON
CONN C2 TERM B.
IS THERE A SHORT?
REPLACE FUSE 8.
CONNECT TEST
LIGHT BETWEEN
TERMINALS B
AND EON CONN
C2.
IS TEST LIGHT
"ON"?
REPAIR SHORT TO
GROUND IN CKT 40.
YES
REPAIR SHORT
TO GROUND IN
CKT 149.
REPLACE
BCM.
C10556
8012
BODY CONTROL MODULE
~BC_M
_____
A
....__...C"1-------157 GRY
ON
1/P DIMMER SWITCH

(ON AT FULL BRIGHTNESS)
I
..JL
650
BU<
---------------11
ILl.:J11----0Ri1:uc----,,.-~s:~----II
~
C200C
r- - -
.a
C200D
"I
E4
.---,
I E1o I
C200C C200D
WHT
((
~~
LH DOOR JAMB SWITCH

(CLOSED WHEN COOR OPEN)
IGl--1--B~HT-------::____~-. . ..
WHT l (( I<@>---1-;.---WHT
RH DOOR JAMB SWITCH

(CLOSED WHEN COOR OPEN)
158
,.......... RHDOOR
~-D12 AJAR
INPUT
,....,.._,at COURTESY
~D1 LAMPS
Rl!lVRN
COURTESY
158
LAMPS
.S247
FEED
DOME LAMP
158
~OR
COMMAND
INPUT
LH DOOR
~-Dn
...
650
BLK
C3-C7
Q)J{ OPEN
650 _ _ _ _ _ _ _ _821
_ 7_
....__ _ BLK
149
CLOSED B
BLU/WHT
B l--+--111
A
A
c,,.
--1
r ~,L::*'"'- : ~
REAFMEWMIRROR
_J
B ~-
,-.--1 HATCH
~-D1 3 AJAR INPUT
REAR COMPARTMENT UD
~ RED
B + ~ 1002
!I'S (1/P)
--~ff\.J,-------
ORN
40
---------11 ~-8
BATTERY
20AMP
COUPE
052595
FT0028D
BODY CONTROL MODULE 80-13
BCM
INTERIOR
11"'!"''""'!!'"-ILAMPS
c t - - - - - - - 1 5 7 GRY - - - - - - - - - - - - - " " " " " ' C3C7 COMMAND
---1INPUT
A
1/P DIMMER SWITCH

(ON AT FULL BRIGHTNESS)
850
..JL
C200C
INJ. .
D" -
C200D
..., -
"I
C3D11
--o-Ri,:uc------c((i~-:--
IBLK
r-------...
loiiiii.....-1
I
I
LH DOOR JAMB SWITCH

ES
I
--.....a.-c((i~...Jla...-_
BLKJWHT
I
--""RHDOOR
~-D12 AJAR
INPUT
A t - - - - 748
850
ILK
..............
RH DOOR JAMB SWITCH

15&
WHT
.----11 B
WHT
B
_S..
24i:;.7_
~-D1
COURTESY
LAMPS
RETURN
A
149
WHT
A
----4~r~~--111--<(@))..--+1-).~>----'
C2E COURTESY
---1LAMPS
FEED
REAR COMPARTMENT LAMP
158
WHT
---@~---'
---1
COURTESY LAMP,
RT REAR
C200C C200D
, ---[-:c(~(~:-::. . - ~
---@:----1
COURTESY LAMP,
LT REAR
156
LH DOOR
AJAR
INPUT
...._--::--------921-7--1
@ri
OPEN
El
CLOSED
B _ __.
149
BW/WHT

REARVIEW MIRROR
C3-D1a HATCH AJAR
----1 INPUT
REAR COMPARTMENT LID
----------1 ~-B
CONVERTIBLE
BATTERY
051995
FT0038D
80-14
BODY CONTROL MODULE
DTC 22/32
COURTESY LAMPS RETURN
(CIRCUIT SHORTED TO B+)
The BCM provides a ground path to the courtesy
lamps on CKT 156 to S247 when commanded by the
1/P dimmer switch input, or the RH or LH door jamb
switch or Hatch Switch inputs. S247 distributes the
ground to the following on coupe and convertible
models:
Coupe
Dome Lamp.
Courtesy/Reading lamps.
Convertible
RH/LH Rear Courtesy Lamps.

Rear Compartment Lamp.
Courtesy/Reading Lamps.

Fault is corrected and DTC memory is cleared.

1. This test will determine if the short to B+ still
exists with the BCM disconnected.
2. This test will determine if the short to B+ is in
CKT 156 or the BCM.
3. Knowing that the Short to B+ is in CKT 156, this
test will further isolate the fault to one side of
connector C200 or the other.
4. Knowing that the fault lies in the C200C side of
CKT 156, this test will further isolate it to either
the harness, or the Rearview Mirror/Courtesy
Reading Lamps.
DTC Will Set When:
Diagnostic Aids:
CKT 156 (Courtesy Lamps Return) is shorted to

B+ for greater than 50 milliseconds, while the BCM is
attempting to ground this circuit. The BCM grounds
CKT 156 if either door or hatch is opened, or
Courtesy Lamps command input is received from the
1/P Dimmer Switch.

connector. these could cause an open .or an intermittent
fault. Refer to "Intermittent/History DTCs" near the
Action Taken:
DTC 22 will set. No Courtesy lighting in the

vehicle; Interior Lamp Switch next to Headlamp
Switch Inoperative. Center console and Glove Box
Lamps operate normally. BCM will read out a series
of flash codes upon entering Diagnostic Mode.
BODY CONTROL MODULE
80-15
DTC 22/32
COURTESY
LAMPS CIRCUIT
DISCONNECT BODY CONTROL MODULE CONNECTORS C2 AND C3.

CONNECT TEST LIGHT BETWEEN CONN C3 TERM 01 AND GROUND.
IS TEST LIGHT "ON"?
TEST LIGHT STILL CONNECTED.

DISCONNECT HARNESS CONNECTOR
C200C FROM C200D.
IS TEST LIGHT "ON"?
TEST FOR A SHORT BETWEEN CONN

C2 TERM E AND CONN C3 TERM 01.
IS THERE A SHORT?
DISCONNECT LAMPS BETWEEN

COURTESY LAMPS FE.ED (CKT 149)
AND COURTESY LAMPS RETURN
(CKT 156) ONE AT A TIME AND
RECHECK FOR THE SHORT. REPAIR
HARNESS AS NECESSARY, OR
REPLACE LAMP SOCKETS AS
NECESSARY.
.
TEST LIGHT STILL CONNECTED.

CONNECT C200C TO C200D.
DISCONNECT HARNESS CONNECTOR FROM
REARVIEW MIRROR/COURTESY READING LAMPS.
IS TES.T LIGHT "ON"?
REPLACE
BCM.
REPAIR SHORT TO B+ IN CKT 156

BETWEEN C200D AND BCM CONN C3.
NO
REPLACE REARVIEW MIRROR/COURTESY

READING. LAMPS.
REPAIR SHORT TO B+ IN HARNESS

BETWEEN C200C AND REARVIEW
MIRROR/COURTESY LIGHTS.
C10557
80-16
BODY CONTROL MODULE

BCM
RETAINED
75
DK aw
: C2C
ACCESSORY
POWER (RAP)
FEED
WINDOWS
'"
I
C200ti I
C200C
BRN
BRN
341
341
POWER
L.
-,
E11 I
_.,I
WIR6oW
SWITCH
(RH)
B+ ~FUSEFUNK
A4
RADI0
FOm17
15.AMp
..._.....,____._..__
BRN
341
BRN- 8253
341
-
POWER
WIR6oW
SWITCH
85
CIRCUIT
iiiiEAKER 15
30AMP
AS
CONVERTIBLE
: C3D8 PROGRAM
43
YEL
INPUT
A12
C1-9
RADIO
AMPLIFIER
TOP SWITCH
r--,
__
---~:----1""---....--<!E--..
._ ..,. :-----~:
8200
1-!
I
I
C2F
BATTERY
C200B C200D
052595
FT00481>
DTC 23/33
RETAINED ACCESSORY POWER (RAP)
(CIRCUIT SHORTED TO GROUND OR B+)
RAP is enabled anytime IGN 1 is turned to

"RUN." RAP will continue operation of power
windows, radio or convertible top for up to 10 minutes
after an ignition cycle from "RUN" to "OFF" or will
shut "OFF" immediately if any door is opened. The
BCM provides the RAP function through CKT 75 to
WINDOWS Circuit Breaker 15 and RADIO fuse 17 in
the I/P fuse block
Fault is corrected and DTC memory clearing

procedure is completed.
DTC Will Set When:

The BCM detects that the RAP output on
CKT 75 is either shorted to ground (while RAP is
enabled), or shorted to B+ (while RAP is disabled) for
more than 50 milliseconds.
Action Taken:
DTC 23 will set. RAP feature will not function
(if shorted to ground), or RAP feature will not
deactivate when door is opened (if shorted to B+).
BCM will read out a series of flash codes upon
entering Diagnostic Mode.

1. This test checks for an open in CKT 102.
2. If CKT 102 is OK, this test checks for a short to
B+ in CKT 75.
3. If CKT 75 is not shorted to B+, this test checks for a
short to ground in CKT 75 or a defective BCM.
Diagnostic Aids:
BODY CONTROL MODULE 80~17
OTC 23/33
RETAINED
ACCESSORY
POWER (RAP)
DISCONNECT HARNESS CONNECTOR C2 FROM BODY CONTROL

MODULE (BCM).
CONNECT A TEST LIGHT BETWEEN CONN C2 TERM F AND GROUND.
IS TEST LIGHT "ON"?
CONNECT A TEST LIGHT BETWEEN

CONN C2 TERM C AND GROUND.
IS TEST LIGHT "ON"?
TEST FOR A SHORT TO

GROUND ON CONN C2 TERM C.
IS THERE A SHORT?
REPAIR SHORT
TO B+ IN CKT 75
NO
REPLACE BCM.
REPAIR SHORT TO
GROUND IN CKT 75.
C10558
80-18
BODY CONTROL MODULE
BCM
C4
8211
T
l- -850
BU<
850
(CHEV)
BU<
Ct
(CHEV)
237
PPL/WHT
C3-C4
A12
83
"FASTEN SEATBELT"
(PONT)
(PONT)
INDICATOR
FASTEN
SEATBELT
INDICATOR
LAMP
CONTROL
INSTRUMENT CWSTER
0200
05-18-95
FT00581
DTC 24/34
"FASTEN SEATBELT" INDICATOR LAMP
(CIRCUIT SHORTED TO 'GROUND OR B+)
The BCM provides a 12 volt output to the
"Fasten Seatbelt" Indicator Lamp on the Instrument
Cluster while the drivers seatbelt is unfastened.
DTC Will Set When:
The "Fasten Seatbelt" output has been detected
by the BCM to be shorted to ground, or shorted to B+
for greater than 50 milliseconds.
Action Taken:
DTC 24 will set. The "Fasten Seatbelt"
indicator lamp will not illuminate when ignition is
"ON" and the drivers' seatbelt is not fastened, or
"Fasten Seatbelt" indicator is always on.
Fault is corrected and DTC memory clearing
procedure is completed.

Number(s) below. refer to circled number(s) on
the diagnostic chart
1. This test checks for a short to B+ in CKT 237.
2. This test checks for a short to ground in
CKT 237.
3. This test will bypass around the BCM directly to
CKT 237, which will reveal if CKT 237 is open
or BCM is defective.
Diagnostic Aids:
appear. Check for poor connections at the BCM .
BODY CONTROL MODULE
80-19
DTC 24/34
FASTEN
SEATBELT
INDICATOR
CIRCUIT
DISCONNECT CONNECTOR C3 FROM BODY CONTROL MODULE (BCM).

CONNECT A TEST LIGHT BETWEEN CONN C3 TERM1INAL C4 AND
GROUND.
IS TEST LIGHT "ON"?
TEST FOR A SHORT TO GROUND ON

CONN C3 TERM C4,
IS THERE A SHORT?
REPAIR SHORT TO B+
IN CKT 237.
DISCONNECT CONNECTOR C2 FROM BODY

CONTROL MODULE (BCM).
CONNECT A JUMPER BETWEEN CONN C2
TERM B CONN C3 TERM C4.
DOES SEATBELT INDICATOR COME ON ?
REPAIR SHORT TO
GROUND IN CKT 237
REPLACE BODY CONTROL MODULE

(BCM).
REPAIR OPEN IN
CKT 237.
C10559
SD-20
BODY CONTROL MODULE
BCM
8218
850
BLK
850
BLK
j_
H H
~
(
1378
DKGRN
SECURITY
:C3-C18 INDICATOR
LED
CONTROL
SECURITY INDICATOR LED
0200
051995
FT0088D
DTC 25/35
SECURITY L.E.D. PRESENT
(With UA6 only)
The BCM provides an output on CKT 1376 to
the Security L.E.D. (if installed).
DTC Will Set When:

Battery is applied to the BCM through connector
C2 and the BCM "sees" an L.E.D circuit through
connector C3 terminal "C16". The presence of the
L.E.D. connected through conn C3 at the time of
battery (conn C2) connection is required for proper
UTD operation. If the L.E.D. is present on the vehicle
and DTCs 25/35 are not indicated, verify continuity of
CKTs 1376 and 650 and check for proper connections
at BCM conn C3 and at L.E.D., then disconnect and
reconnect conn C2 to the BCM.
rn
Important
Do not use battery or test light to test Theft

Deterrenj Security L.E.D. Failure to follow proper
testing procedures will damage L.E.D.
If DTCs . 25/35 appear in a vehicle not equipped
with (UA6) Universal Theft Deterrent System,
disregard them.
BODY CONTROL MODULE
8D21
REMOTE CONTROL DOOR LOCK TRANSMITTER DTCs
II]
Important
DTCs 41 through 45 will set only while the BCM

is in the Diagnostic Mode, and a button on the
face of the Remote Control Door Lock
Transmitter has been pressed. These DTCs are
used to determine the RF performance of the
Remote Control Door Lock Transmitter, and the
receiver in the BCM.
DTC 41
Last Transmitter Message Received Valid
(With AUO only)
Malfunction/Condition:
Potential Causes:
The digital RF message received from the

Remote Control Door Lock Transmitter was valid, all
security checks passed. No Malfunction.
If Remote Control Door Lock Transmitter digital

RF message is sent, but a DTC 41 is not set (or any
other DTC 42-45), then Remote Control Door Lock
Transmitter may be defective. If Remote Control Door
Lock Transmitter digital RF message is sent and
DTC 41 is set, but the corresponding function does not
take place, the BCM or harness may be defective.
Operational Effects:
Correct Remote Control Door Lock Transmitter
functionality should be observed (i.e. Lock, Unlock,
etc.).
Comments:
None.
OTC 42
Last Transmitter Message Received had Invalid ID
(With AUO only)
Comments:
The digital RF message received was from a

Remote Control Door Lock Transmitter not assigned
to the BCM.
The BCM should be put into the Remote Control

Door Lock Transmitter programming mode. Both
Remote Control Door Lock Transmitters must be
reassigned to the BCM at the same time. Refer to
Section 9K.
No remote function capability (i.e. Lock,
Unlock, etc.).
Potential Causes:
A Remote Control Door Lock Transmitter was
used without programming it to the BCM. If the
Remote Control Door Lock Transmitter was already
programmed, it may be defective.
80-22
BODY. CONTROL MODULE
DTC 43
Last Transmitter Message Received had Sumcheck Error
(With AUO only}
Remote Control Door Lock Transmitter that is
programmed to the BCM, but the message did not
pass the sumcheck security test.
Unlock, etc.).
Potential Causes:
The Remote Control Door Lock Transmitter is
out of sync with the BCM. This can be caused by the
Remote Control Door Lock Transmitter buttons being
pressed more than 256 times out of range of the BCM.
It can also be caused by changing the Remote Control
Door Lo.ck T[ansmitter's battery and pushing the

tramsm1tter s buttons more than 10 times
out of range of the BCM. This Malfunction could also
be encountered if the digital RF message has an error
due to noise from the surrounding environment or if
the Remote Control Door Lock Transmitter itself is
defective.
Comments:
The most likely cause is the Remote Control
Door Lock Transmitter is out of sync. To resync the
transmitter, press "Lock" and "Unlock" buttons on
the Remote Control Door Lock Transmitter at the
same time for 5 seconds. This will resync the Remote
Control Door Lock Transmitter to the BCM.
DTC 44
Last Transmitter Message Received had Encryption Error
(With AUO only)
Remote Control Door Lock Transmitter that is
programmed to the BCM, but the message did not
pass the encryption security test.
Unlock, etc.).
Potential Causes:
The Remote Control Door Lock Transmitter has
been in the program or resync mode out of range of
the BCM. This Malfunction could also be encountered
if the digital RF message has an error due to noise

from the surrounding environment or if the Remote
Control Door Lock Transmitter itself is defective.
Comments:
The .most likely cause is the Remote Control
Door Lock Transmitter has resynced out of the range
of the BCM. To resync the Remote Control Door Lock
Transmitter, press "Lock" and "Unlock" buttons on
the Transmitter at the same time for 5 seconds. This
will resync the Remote Control Door Lock Transmitter
to the BCM.
BODY CONTROL MODULE
SD23
DTC 45
Receiver Processing Currently in 20 Second Lockout
(With AUO only)
Comments:
At least 50 consecutive digital RF messages

were received from a Remote Control Door Lock
Transmitter that is programmed to the BCM, but the
messages did not pass the encryption security test. The
BCM will cease processing any Remote Control Door
Lock Transmitter digital RF messages (good or bad)
for 20 seconds.
The most likely cause is the Remote Control

Door Lock Transmitter has resynced out of the range
of the BCM. To resync the Remote Control Door Lock
Transmitter, press "Lock" and "Unlock" buttons on
the Transmitter at the same time for 5 seconds. This
will resync the Remote Control Door Lock Transmitter
to the BCM. This Malfunction Could be induced prior
to the BCM entering the Diagnostic Mode.
Unlock, etc.).
Potential Causes:
The Remote Control Door Lock Transmitter has
been in the resync or program mode out of range of
the BCM. This Malfunction could also be encountered
if the Remote Control Door Lock Transmitter itself is
defective.
DTC 55
Begin Configuration Display
Condition:
Comments:
Code 55 is displayed to indicate the next two

numbers displayed are BCM hardware and software
configurations. The first number following 55 is the
hardware configuration, the second number is the
software configuration. Code 55 and the two
configuration numbers are always displayed.
After the configuration code numbers are

displayed, the entire DTC list is repeated beginning
with DTC 12.
80-24
BODY CONTROL MODULE
BLANK
WINDSHIELD WIPER/WASHER SYSTEM 8E-1
SECTION SE
WINDSHIELD WIPER
ASHER SYSTEM
NOTICE: Refer to battery disconnect caution in Section OA.

exact part number for that application. General Motors will call out those fasteners that require a replacement after
removal. General Motors will also call out the fasteners that require thread lockers or thread sealant. UNLESS
OTHERWISE SPECIFIED, do not use supplemental coatings (paint, grease, or other corrosion inhibitors) on
threaded fasteners or fastener joint interfaces. Generally, such coatings adversely affect the fastener torque and the
joint clamping force, and may damage the fastener. When you install fasteners, use the correct tightening sequence
and specifications. Following these instructions can help you avoid damage to parts and systems.
CONTENTS
General Description ............................................ 8E-1
Circuit Operation ............................................. 8E-1
Diagnosis ............................................................. 8E-3
Component Locations ..................................... 8E-3
Troubleshooting Hints .................................... 8E-3
System Diagnosis ............................................ 8E-3
On-Vehicle Service ............................................ 8E-10
Washer Pump Replacement ............................ SE-10
Washer Reservoir Replacement ..................... SE-10
Wiper Arm Replacement ................................ SE-10
Wiper Blade Assembly Replacement ............. SE-11
Wiper Blade Element Replacement ............... SE-13
Windshield Washer ......................................... SE-13
GENERAL DESCRIPTION
Figure 1
The windshield wiper/washer system consists of
a permanent magnet depressed park wiper motor assembly, wiper linkage assemblies, wiper arm and blade
assemblies, a washer pump mounted on a washer fluid
reservoir and a wiper/washer switch assembly (Figure 1).
Pulse and timing functions, along with the demand wash function, are controlled by a printed circuit
board in the wiper motor cover assembly. The wiper
motor also is equipped with RFI (radio frequency interference) suppression.
Figure 1 - Wiper/Washer Switch Assembly
Wiper Motor Assembly Replacement ............ SE-13

Wiper Linkage Assembly Replacement ......... SE-14
Off-Vehicle Service ............................................ SE-15
Wiper Motor Cover Assembly Replacement . SE-15
Wiper Chatter Repair ......................................... SE-16
Windshield Glass Cleaning ............................. SE-16
Blade Element Cleaning ................................. SE-16
Wiper Arm Tip Pressure Check ..................... SE-16
Blade Element Set Check ................................ SE-17
Specifications ...................................................... SE-18
Fastener Tightening Specifications ................ SE-18
Special Tools ...................................................... SE-18
Depressed park positioning is accomplished
by an external drive mechanism on the wiper motor
assembly.
CIRCUIT OPERATION
Figure 2
Wiper Operation
In addition to the features of a conventional
(non-pulse) wiper system (mist, low and high
speeds), the pulse type windshield wiper/washer
system includes an operating mode in which the
wipers make single sweeps with an adjustable time
interval between sweeps. The time interval is controlled by a solid state timer in the wiper motor
cover assembly. The duration of the delay interval
is determined by the delay resistor in the wiper/
washer switch assembly.
When the wiper switch is turned OFF, the
wiper motor returns the wipers to end of sweep
(inner wipe) position, the wiper motor reverses and
activates its external depressed park mechanism to
lower the wipers to park position.
8E-2 WINDSHIELD WIPER/WASHER SYSTEM
--------"'IIIIP
I
FUSE
BLOCK
II
I
ACCY
(NOTUSEDI
'---------
..a
1 YEL
1 YEL
143
WIPER/WASHER
SWITCH ASSEMBLY
WASHER
SWITCH
HI
MIST
MIST
, c,
OFF
OFF
0 c,
0
PULSE
"
LO
3600
.8 PNK
94
WIPER/
WASHER
REQUEST
INPUT
WIPERS
DELAY
INPl/f
WIPER
INTERLOCK
INPUT
WIPERS
ENABLE
ISOLAf
TION
DIODE
WIPERS
SOLID
STATE
PARK
POSITION
11-----------~
ENO OF
SWEEP
SWITCH
(OPEN AT
ENO OF
"SWEEP"
AND
"PARK"
POSITION)
----------------
PARK
SWITCH
(CLOSED
UNTIL WIPERS
IN "PARK")
PARK
WIPERS
CONTROL
------"'"LOW
SPEED
RELAY
r l
L,T2
T1
II--'-----'--+-----.
228
GROUND
(PTCI
11----~>---...
INPUT
.8 RED
11------------.
I
I
PARK
RELAY
tt----WIPER MOTOR
.8 BLI(
150
Figure 2 -
Wiper/Washer System Electrical Schematic
SEE GROUND
DISTRIBUTION
SECTION 8A
W.INDSHIELD WIPER/WASHER SYSTEM SE-3
Pulse Operation
Mist Operation
With the wiper switch in DELAY (pulse), battery

voltage is applied to the wiper motor connector at
terminal "B" through CKT.143. Voltage also is applied
to terminal "D" through CKT 113 and terminal "E"
through CKT 112.
The length of delay time between sweeps is controlled by the variable pulse delay resistor. The delay
is adjustable from 1 to 22 seconds, nominally.
When the wiper switch is turned to "MIST;' and

released, the wipers make one sweep at low speed and
return to park position. If the wiper switch is held in
"MIST", the wipers will continue to operate until the
switch is released. The circuit operation is the same as
that of "LO."
low Speed Operation
COMPONENT LOCATIONS
In the "LO" position of the wiper switch, battery

voltage is applied to the wiper motor connector at
terminal "B" through CKT 143 and terminal ''E" through
CKT 112, with voltage applied to terminal "D" through
CKT 113.
"
High Speed Operation

In the "HI" position of the wiper switch, battery
voltage is applied at terminals "B", "C" and "E" of the
wiper motor assembly through CKTs 143, 92 and 112.
Voltage also is applied to terminal "D" through
CKT 113.
DIAGNOSIS
TROUBLESHOOTING HINTS
Figure 2
"
1.
2.
3.
Park Position Operation

When turned "OFF" from any position, the wipers complete the last sweep and park. When the wiper
switch is in "OFF", the wiper motor assembly has
battery voltage applied to terminal "B" only, from
CKT 143. When the end of sweep switch opens, the
control circuit reverses the wiper motor which activates the external depressed park mechanism. The
wiper motor continues to run until the park switch
opens.
Washer Operation
When the switch is turned to "ON", battery voltage is applied to terminal "D" of the wiper motor
assembly through CKT 113. The washer switch also
applies voltage to terminal "A" which turns "ON" the
washer pump through CKTs 94 and 228. The wiper
motor has voltage applied through the low speed relay
and operates at low speed for 2 to 4 wipes.
When the washer switch is held "ON", the wiper
motor circuit board will keep the washer pump "ON"
only as long as the washer switch is held "ON".
If the wipers had been in "DELAY", "LO" or
"HI", they would return to that operation after the wash
cycle. If in "OFF", they then return to park position
after2 to 4 wipes.
Refer to Figure 4 for a list of component locations.
4.
0 .
Make the following checks before beginning System Diagnosis.

Check wiper fuse 14. If open, check for short to
ground through CKT 143 and replace fuse.
Check that all system electrical connectors are
mated correctly.
If washer does not operate, check that:
-Washer reservoir is filled.
-Hoses are correctly attached.
-Hoses are not cut, pinched or kinked.
-Nozzles are not clogged.
-Connector seal at washer pump is not damaged
or missing.
Check for binding or broken wiper arm linkage.
Refer to system Diagnosis.
SYSTEM DIAGNOSIS
Perform the System check (Figure 5), then refer to

the Symptom Table (Figure 6) for the appropriate
diagnostic procedures.
A BLK
B YEL
C PPL
D DKGRN
E
GAY
Figure 3 - Wiper Motor Wiring Harness Connector

COMPONENT
LOCATION
1/P Fuse Block ............................................................................... LH side of 1/P carrier, on the side
Isolation Diode (Wipers) ................................................................ Approx. 20 cm (8 in.) from C215
Washer Pump ................................................................................ Front of vehicle, below engine hood latch
Wiper Motor Assembly .................................................................. Rear of LH shock tower, mounted to dash
panel below LH wiper mount
Wiper/Washer Switch
Assembly ............................................................................,........ In left side of steering column, actuated by
multi-function lever
C200B (18 cavities) ....................................................................... Part of forward lamp harness, between LH
kick panel and steering column
C200D (48 cavities) ...................................................................... Part of lip harness, between LH kick panel
and steering column
C215 (11 cavities) ......................................................................... Near base of steering column
G 106 .............................................................................................. Near top LH side of radiator, in top of T-bar
P100 .............................................................................................. Left side in dash panel, engine to passenger
compartment
S113 .............................................................................................. Forward lamp harness, approx. 13 cm (5 in.)
from electrical center breakout
Figure 4 - Component locations
NORMAL OPERATION
ACTION
[1]
Turn ignition switch to RUN.
Press washer switch to ON.
Wipers operate at LO speed. Washer sprays windshield as long as washer switch is held in ON position. After releasing switch, washer stops and wipers
return to park position after 2 to 4 sweeps.
[2]
Turn wiper switch to DELAY (pulse mode).
[3]
Wiper switch in DELAY.
Press washer switch ON.
Wipers make one complete sweep, then pause for 1

to 22 seconds before making next sweep. The pause
time is adjusted by turning the wiper switch through
the delay range.
Washer sprays windshield as long as washer switch
is held ON. Wipers run at low speed while spraying
and continue for 2 to 4 sweeps after washer switch is
released: Wipers then return to pulse operation.
[4]
Turn wiper switch to LO.
Wipers run continuously at low speed.
[5]
Turn wiper switch to HI.
Wipers run continuously at faster speed.
[6]
Turn wiper switch to OFF.
Wipers return to park position at low speed.
[7]
Turn wiper switch to MIST, then release.
Wipers make one complete sweep, then return to park

position.
Figure 5 - Wiper/Washer System Check
.WINDSHIELD WIPER/WASHER SYSTEM BE-5

SYMPTOM
PROCEDURE
PAGE
Wipers do not operate in any mode.
Chart 1
8E-5
Wipers run when switch is "OFF."
Chart 2
8E-6
No low speed mode.
Replace wiper/washer switch

assembly.
No high speed mode.
Chart 3
Wipers operate orily when switch is in HI position,

but run atlow speed.
Check for open or poor connection in

CKT 143 between wiper/washer
switch CONN C215 TERM "D" and
wiper motor CONN TERM "B". If OK,
replace wiper motor assembly.
8E-7
Low speed, pulse delay and mi.st modes inoperative

(high speed mode OK).
Chart 4
8E-7
Pulse delay operates incorrectly or not at all.
Chart 5
8E-8
Wipers stop randomly and do not park when switch is

moved to "OFF."
Chart 6
8E-8
Wipers do not operate when washer switch is activated.
Chart 7
8E-9
Washer does not operate.
Chart 8
8E-9
Figure 6 - Symptom Table
CHART 1
WIPERS DO NOT OPERATE IN ANY MODE
BACKPROBE WITH A TEST LIGHT FROM WIPER/WASHER SWITCH
CONN C215 TERM "D" TO GROUND.
IS TEST LIGHT ON?
WIPER.SWITCH JO "HI".
CONNECT TEST LIGHT FROM CONN C215 TERM "G" TO GROUND.
IS TEST LIGHT ON?
REPAl'R OPEN OR POOR CONNECTION IN CKT 143 TO

WIPER/WASHER SWITCH ASSEMBLY. IF FUSE 14 IS OPEN,
CHECK FOR SHORT TO GROUND IN RELATED CKTS .
RELATED CKTS WILL DEPEND ON WHETHER FUSE BLOWS
BEFORE OR AFTER SYSTEM OPERATION.
DISCONNECT WIPER MOTOR CONNECTOR.

CONNECT TEST LIGHT FROM WIPER MOTOR CONN TERM "C" TO
GROUND.
IS TEST LIGHT ON?
CHECK FOR POOR CONNECTION AT CONN C215 TERM "D"

OR OPEN IN PIGTAIL (CKT 143) TO WIPER/WASHER SWITCH
ASSEMBLY.
IF OK, REPLACE WIPER/WASHER SWITCH ASSEMBLY.
(CONTINUED ON NEXT PAGE)
BE-6 WINDSHIELD WIPER/WASHER SYSTEM

(CONTINUED FROM PREVIOUS PAGE)
(
CONNECT TEST LIGHT FROM WIPER MOTOR CONN TERM "C" TO
TERM"A".
IS TEST LIGHT ON?
REPAIR OPEN OR POOR CONNECTION IN CKT 92 BETWEEN

CONN C215 AND WIPER .MOTOR ASSEMBLY.
THEN, CONTINUE DIAGNOSIS IN OPPOSITE BOX OF CHART.
CHECK FOR POOR CONNECTION TO WIPER MOTOR ASSEMBLY.

IF OK, REPLACE WIPER MOTOR ASS EMBLY.
REPAIR OPEN OR POOR CONNECTION IN GROUND CKT 150.
CHART2
WIPERS RUN WHEN SWITCH IS "OFF"
WIPER SWITCH "OFF."
DISCONNECT WIPER/WASHER SWITCH CONN C215.
WIPER MOTOR KEEPS RUNNING
USING A DVM, MEASURE VOLTAGE FROM CONN C215

(VEHICLE SIDE) TERM "E" TO GROUND.
CHECK FOR SHORTED WIRES IN PIGTAIL TO WIPER/

WASHER SWITCH ASSEMBLY.
MORE THAN 1 VOLT
RECONNECT WIPER/WASHER SWITCH CONN C215.

USING THE DVM, MEASURE VOLTAGE FROM WIPER MOTOR
CONN TERM "D" TO GROUND.
MORE THAN 1 VOLT
LESS THAN 1 VOLT
REPAIR B+ CONNECTION
TO CKT 113.
REPLACE WIPER MOTOR

COVER ASSEMBLY.

USING THE DVM, MEASURE VOLTAGE FROM WIPER
MOTOR CONN TERM "C" TO GROUND.
REPLACE WIPER MOTOR

COVER ASSEMBLY.
CHART3
NO HIGH SPEED MODE
DO WIPERS OPERATE AT ALL WITH WIPER SWITCH IN "HI"?
IGNITION SWITCH TO "RUN".

WIPER SWITCH TO "HI".
CONNECT A TEST LIGHT BETWEEN WIPER/WASHER SWITCH
CONN C215 TERM "G" AND GROUND.
IS TEST LIGHT ON?
REPLACE WIPER/WASHERSWITCH ASSEMBLY.

CONNECT TEST LIGHT BETWEEN HARNESS TERM "C" AND
GROUND.
IS TEST LIGHT ON?
CHECK FOR POOR CONNECTION AT CONN C215 OR FOR

OPEN IN PIGTAIL TO WIPER/WASHER SWITCH ASSEMBLY.
CHECK FOR POOR CONNECTION TO WIPER MOTOR

ASSEMBLY.
IF OK, REPLACE WIPER MOTOR ASSEMBLY.
CHART4
LOW SPEED, PULSE DELAY AND MIST MODES INOPERATIVE
(HIGH SPEED MODE OK)
WIPER SWITCH TO "LO."
USING A DVM, MEASURE VOLTAGE FROM WIPER/WASHER
SWITCH CONN C215 TERM "E" TO GROUND.
II
MORE THAN 1 VOLT

USING THE DVM, MEASURE VOLTAGE FROM WIPER MOTOR
CONN TERM "D" TO GROUND
..
LESS THAN 1 VOLT (APPROX. 0 VOLT)
CHECK FOR POOR CONNECTION AT CONN C215 OR FOR

OPEN IN PIGTAIL TO WIPER/WASHER SWITCH ASSEMBLY.
MORE THAN 1 VOLT
I
REPLACE WIPER MOTOR COVER ASSEMBLY.
I
I
CHART 5
PULSE DELAY OPERATES INCORRECTLY OR NOT AT ALL
IGNITION SWITCH TO "OFF".

WIPER SWITCH TO "DELAY".
WITH A DIGITAL MULTIMETER SET TO OHMS SCALE, MEASURE
RESISTANCE THROUGH WIPER/WASHER SWITCH ASSEMBLY
FROM CONN C215 TERM "D" TO TERM "F".
MOVE WIPER SWITCH THROUGH ENTIRE DELAY RANGE, ONE
NOTCH AT A TIME.
DOES RESISTANCE VARY FROM APPROXIMATELY 39 ldl TO
680 nl? (SEE FIGURE 2.)

USING A DVM, MEASURE VOLTAGE FROM WIPER
MOTOR CONN TERM "E" TO GROUND.
CHECK CKT 112 FOR OPEN OR POOR CONNECTION.

IF OK, REPLACE WIPER MOTOR COVER ASSEMBLY.
CHART6
WIPERS STOP RANDOMLY AND DO NOT PARK WHEN SWITCH IS MOVED TO "OFF"

WIPER SWITCH "OFF."
DO WIPERS PARK?
USING A DVM, MEASURE VOLTAGE FROM CONN C215

(VEHICLE SIDE) TERM "E" TO GROUND.

USING THE DVM, MEASURE VOLTAGE FROM CONN TERM "D"
TO GROUND.
REPAIR SHORT TO B+ IN CKT 113.
WINDSHIELD WIPERJW ASHER SYSTEM 8E9
CHART7
WIPERS DO NOT OPERATE WHEN WASHER SWITCH IS ACTIVATED
CONNECT A TEST LIGHT BETWEEN WIPER/WASHER SWITCH
CONN C215 TERM "E" AND GROUND.
ACTIVATE WASHER SWITCH AND OBSERVE TEST LIGHT.
IS TEST LIGHT ON?
CHECK FOR OPEN IN CKT 113 OR FOR POOR CONNECTION AT

CONN C215 OR AT WIPER MOTOR ASSEMBLY.
IF OK, REPLACE WIPER MOTOR COVER ASSEMBLY.
CHECK FOR OPEN IN WIPER/WASHER SWITCH ASSEMBLY

PIGTAIL AND CONNECTION.
CHART 8
WASHER DOES NOT OPERATE
DISCONNECT WASHER PUMP CONNECTOR.
CONNECT A TEST LIGHT BETWEEN TERMINALS "A" AND "B"
OF PUMP CONNECTOR.
ACTIVATE WASHER SWITCH.
IS TEST LIGHT ON?
CONNECT THE TEST LIGHT BETWEEN WASHER PUMP CONN

TERM "A" AND GROUND.
ACTIVATE WASHER SWITCH.
IS TEST LIGHT ON?
CHECK FOR POOR CONNECTION TO WASHER PUMP.

IF OK, REPLACE WASHER PUMP.
CONNECT THE TEST LIGHT BETWEEN WIPER/WASHER

SWITCH CONN C215 TERM "H" AND GROUND.
IS TEST LIGHT ON?
CHECK FOR POOR CONNECTION AT CONN C215 TERM "H".

CHECK FOR OPEN IN CKT 94, CKT 228 OR ISOLATION DIODE.
ON-VEHICLE SERVICE
WASHER PUMP REPLACEMENT
Figure 8
1.
2.
3.
4.

Electrical connector (3).
Place drain pan under vehicle.
Washer pump (4) from reservoir (2) using suitable
pliers.
5. Washer hose assembly (5) from pump.
!+ +I Install or Connect
SCRIVET (4)
RESERVOIR, WASHER
Figure 7 - Washer Reservoir {Top Front View)
1. Washer hose assembly (5).

2. Washer pump (4) in washer reservoir (2) using
pliers.
[I) Important
Make sure washer pump is pushed all the way
into washer reservoir seal.
3. Electrical connector (3).
4. Refill washer reservoir.
WASHER RESERVOIR REPLACEMENT

Figures 7 and B
1. Washedluid.
2. Two scrivets (1, Figure 7) from top of washer
reservoir (2).
3. Drive vehicle onto rack.
5. Raise vehicle on rack.
6. Splash guard and mounting screws.
7. Two scrivets (1) from bottom of washer reservoir.
8. Washer reservoir and pump (4, Figure 8).
9. Electrical connector (3) and washer hose assembly (5).
10. Washer pump from reservoir.
I+ +I Install or Connect
NOTICE: See "Notice" on page 8E-1 of this section.
1. Washer pump (4, Figure 8) in washer reservoir (2).
[I) Important
Make sure washer pump is pushed all the way
into washer reservoir seal.
A GUARD, SPLASH
2 RESERVOIR, WASHER
3 CONNECTOR, ELECTRICAL
4 PUMP, WASHER
5 HOSE ASSEMBLY, WASHER
Figure 8 - Washer Reservoir Removal
2. Washer hose assembly (5) and electrical connector (3).

3. Washer reservoir with 2 scrivets (1, Figure 7) at
bottom of reservoir.
4. Splash guard with mounting screws.
5. Lower vehicle on rack.
6. Negative battery cable, then drive vehicle off rack.
7. Two scrivets (1) at top of washer reservoir.
8. Washer fluid.
WIPER ARM REPLACEMENT

Tool Required:
J 39637 Wiper Arm Puller
1. Operate wipers at lowest DELAY setting, then shut
off wipers at inner wipe (end of sweep) position.
At tip of blade assembly, mark windshield to aid at
installation. See Figure 11 for wipe pattern and
inner wipe positions.
2. Raise hood (chev only).
3. Lift wiper arm nut cover and remove nut (7, Figure 9).
rn
WINDSHIELDWIPER/WASHERSYSTEM SE-11
Important
Do not grasp plastic spoiler of wiper arm.

4. Wiper arm (6, Figure 10) from linkage drive shaft
using J 39637.
5. Wiper blade assembly, if required. See "Wiper
Blade Assembly Replacement."
NOTICE:: See "Notice" on page 8E-1 of this
section.
1. Wiper blade assembly, if removed. See "Wiper
2. Wiper arm (6) on linkage drive shaft, with tip of
blade assembly aligned with mark made at removal.
rn
Important
If wipers could not be stopped at inner wipe

position for wiper arm removal, position blade
tip(s) according to dimensions given in Figure 11.
3. Nut (7, Figure 9) on linkage drive shaft.
rn
Important
It may be necessary to allow for some movement of a wiper arm when its nut is being
tightened. If wiper arm moves away from desired alignment mark, loosen nut (7) and reposition wiper arm.
~ Tighten
Nut (7) to 32 Nm (24 lb. ft.) while holding
wiper arm.
4. Close nut cover.
5. Close hood.
A COVER, NUT
6 ARM, WIPER
7 NUT, 32 Nm (24 LB. FT.)
Figure 9 - Wiper Arm Nut Removal
le.I Inspect
Run wipers and check for proper wipe pattern
(Figure 11).
Shut off wipers and check for correct park position.
WIPER BLADE ASSEMBLY

REPLACEMENT
Figures 12 and 13
rn
Important
Do not grasp plastic spoiler of wiper arm.
1. If wiper arms have not been removed, lift wiper

arm (6, Figure 12) until it locks into service-up
position.
rn
Important
Use care when removing or installing a blade

assembly (8). Inadvertent bumping can cause
the wiper arm to toggle back and strike the
windshield.
2. Press down on locking tab of blade pivot, then pull
blade assembly downward to disengage it from
hook of wiper arm.
1. Position pivot of blade assembly (8, Figure 13) in
hook of wiper arm (6), then pull blade assembly
upward until locking tab of blade pivot engages
slot in arm hook.
2. Carefully lower wiper arm and blade assembly
onto windshield.
ARM, WIPER
Figure 1O - Wiper Arm Removal
SE-12 WINDSHIELD WIPER/WASHER SYSTEM
(
A
B
C
D
PAINT LINE
LH BLADE INNER WIPE POSITION
95-125mm(3-3/4-51N.)
TOP EDGE OF MOLDING
E BLADETIP
F RH BLADE INNER WIPE POSITION
G 87-117 mm (3-1/2 -4-1/2 IN.)
Figure 11 -Wipe Pattern and Inner Wipe Positions

A
B
C
D
6
8
HOOK.ARM
TAB, LOCKING
PIVOT, BLADE
SPOILER, PLASTIC
ARM, WIPER
BLADE
ASSEMBLY,
WIPER
SLOT, HOOK
TAB, LOCKING
PIVOT, BLADE
D SPOILER, PLASTIC
6 ARM, WIPER
8 BLADE
ASSEMBLY,
WIPER
A
B
(
Figure 12 - Wiper Blade Assembly Removal
Figure 13 - Wiper Blade Assembly Installation
WINDSHIELD WIPERJWASHER SYSTEM 8E-13
WIPER BLADE ELEMENT REPLACEMENT

Figures 14 and 15
PULL
!+ +I Remove or Disconnect
1. Wiper blade assembly from wiper arm. See "Wiper
2. Blade element (9, Figure 14) has two notches at
one end which are engaged by the bottom claw set
of blade assembly. At notched end, pull blade
element from blade assembly.
I +I
A
B
C
9
HEEL END OF BLADE ASSEMBLY

NOTCH (2)
CLAW SET
ELEMENT, BLADE
Install or Connect
NOTICE:: The heel end of the wiper blade assembly is the end nearest to the base of the wiper arm.
rn
Figure 14-Wiper Blade Element Removal
Important
Replacement blade elements have three plastic

caps which retain the two metal flexor strips.
Do not remove these caps before the element is
installed.
1. At heel end of blade assembly, slide blade element
(9, Figure 15), notched end last, into blade claw
sets. The plastic retainer caps will be forced off as
element is fully inserted.
2. Be certain that the two element .notches are engaged by last claw set and that all other claws are
properly engaged in slots of element on both sides.
3. Wiper blade assembly on wiper arm. See "Wiper
A
9
CAP, RETAINING (3)

ELEMENT, BLADE
WINDSHIELD WASHER
Figures 11 and 16
A correctly operating windshield wiper/washer
system has a spray pattern that cleans 75% of the wipe
pattern (Figure 11) within ten wiper cycles.
If a washer nozzle (10, Figure 16) becomes
plugged, apply air pressure. If a nozzle remains plugged,
the nozzle must be replaced.
CLAW ENGAGED IN NOTCH

WRONG
RIGHT
WIPER MOTOR ASSEMBLY

REPLACEMENT
Tool Required:
J 39232 Wiper Linkage Separator
1. Wiper arm and blade assemblies. See "Wiper Arm
Replacement."
3. LH cowl panel and hood seal.
C SLOT
D CLAW IN ELEMENT SLOT
E CLAW AGAINST METAL FLEXOR
Figure 15 - Wiper Blade Element Installation
4. Washer hose assembly (11, Figure 16) from LH

cowl panel.
5. Electrical connector from wiper motor assembly
(17, Figure 17).
6. Screw (14) and nut (20).
7. Socket of RH linkage assembly (13) from ball of
LH linkage assembly (15) using J 39232 (see Figure 18).
8. LH linkage assembly.
9. Screw (19, Figure 17).
10. Pull wiper motor assembly free from slots of
bracket (16).
11. Socket of RH linkage assembly from crank arm
ball of wiper motor assembly using J 39232 (see
Figure 18).
Tool Required:
J 39529 Wiper Linkage Installer
NOTICE:: See "Notice" on page 8E-1 of this
section.
A
B
C
10
11
[I] Important
When installing wiper motor assembly, make
certain that the crank arm is in inner wipe position as shown in Figure 17. The crank arm drive
pin must be engaged in the cam pocket.
L Press socket of RH linkage assembly (13) into
engagement with crank arm ball of wiper motor
assembly (17) using J 39529 (see Figure 19).
2. Wiper motor assembly (17, Figure 17) with two
locator pads (18) pressed fully into slots of
bracket ( 16).
3. Screw (19).
~ Tighten
Screw (19) to 10 Nm (7 .5 lb. ft.).
4. LH linkage assembly (15) without attaching parts.
5. Press socket of RH linkage assembly into engagement with ball of LH linkage assembly using J
39529 (see Figure 19).
6. Attach LH linkage assembly with screw (14, Figure 17) and nut (20).
~ Tighten
7.
8.
9.
10.
11.
Screw (14) and nut (20) to 10 Nm (7.5 lb. ft.).

Electrical connector to wiper motor assembly.
Washer hose assembly (11, Figure 16) to LH cowl
panel and washer nozzle (10).
LH cowl panel and hood seal.
Wiper arm and blade assemblies. See "Wiper Arm
Replacement."
SCRIVET (8)
PANEL, RH COWL
PANEL, LH COWL
NOZZLE, WASHER (2)
HOSE ASSESMBLY, WASHER
Figure 16 - Cowl Panels and Washer Components
WIPER LINKAGE ASSEMBLY

REPLACEMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
Tool Required:
J 39232 Wiper Linkage Separator
Wiper arm and blade assemblies. See "Wiper Arm
Replacement."
LH cowl panel and hood seal.
Washer hose assembly (11, Figure 16) from LH
cowl paneL
Screw (14, Figure 17) and nut (20).
Socket of RH linkage assembly (13) from ball of
LH linkage assembly (15) using J 39232 (see Figure 18).
LH linkage assembly.
Three screws (12, Figure 17).
Socket of RH linkage assembly from crank arm
ball of wiper motor assembly (17) using J 39232
(see Figure 18).
RH linkage assembly from slotted plenum access
hole.
E3
Install or Connect
Tool Required:
J 39529 Wiper Linkage installer
NOTICE: See "Notice" on page 8E-1 of this
section.

1. RH linkage assembly (13, Figure 17) through slotted plenum access hole.
2. Three screws (12) finger tight.
3. Align RH linkage assembly.
4. Press socket of RH linkage assembly into engagement with crank arm ball of wiper motor assembly (17) using J 39529 (see Figure 19).
5. LH linkage assembly (15, Figure 17) without attaching parts.
6. Press socket of RH linkage assembly into engagement with ball of LH linkage assembly using
J 39529 (see Figure 19).
7. Screw (14, Figure 17) and nut (20).
~ Tighten
Screw (14), nut (20) and three screws (12) to
10 Nm (7.5 lb. ft.).
8. Washer hose assembly to LH cowl panel and washer
nozzle (10).
9. LH cowl panel and hood seal.
10. Wiper arm and blade assemblies. See "Wiper Arm
Replacement."
OFF-VEHICLE SERVICE
WIPER MOTOR COVER ASSEMBLY
REPLACEMENT
Figures 20 and 21
1. Three screws (21, Figure 20) using Torx screwdriver.
2. Cover assembly (22).
NOTICE:: See "Notice" on page 8E-l of this
section.
1. Cover assembly (22, Figure 20).
rn
Important
Before installing the cover assembly, make certain that the inner wipe cam is positioned as
shown in Figure 21.
2. Three screws (21, Figure 20).
14
16
)
/
18
19
A
12
13
14
15
CRANK ARM DRIVE PIN IN CAM POCKET

SCREW (3), 10 Nm (7.5 LB. FT.)
LINKAGE ASSEMBLY, RH
SCREW, 10 Nm (7.5 LB. FT.)
LINKAGE ASSEMBLY, LH
Figure 17 -
16
17
18
19
20
BRACKET, WIPER MOTOR

MOTOR ASSEMBLY, WIPER
PAD, LOCATOR (2)
SCREW, 10 Nm (7.5 LB. FT.)
NUT, 10 Nm (7.5 LB. FT.)
Linkage and Wiper Motor Assemblies
Figure 18 - J 39232 Wiper Linkage Separator {Typical

Usage)
Figure 19 - J 39529 Wiper Linkage Installer (Typical

Usage)
~ Tighten
Screws (21) to 2 Nm (18 lb. in.).
WIPER CHATTER REPAIR
Some vehicles may exhibit a condition where the

windshield wipers chatter and/or wipe unevenly. Several items may contribute to this condition. To completely repair this condition ALL items listed should be
checked and repaired as necessary.
WINDSHIELD GLASS CLEANING

Clean windshield with windshield cleaner, GM
PN 1050011 or equivalent. The cleaner used should be
one which will not harm paint finish or scratch glass.
The glass is clean when water no longer "beads", but
"sheets" across entire glass surface.
BLADE ELEMENT CLEANING

Lift each blade assembly off windshield and clean
element with a cloth saturated in full strength washer
solution. Rinse blade assemblies with water.
CAUTION: Avoid prolonged skin contact with
washer solution.
WIPER ARM TIP PRESSURE CHECK

1. Run wipers at lowest DELAY setting, then shut
wipers off at inner wiper (end of sweep) position.
21
22
23
SCREW (3), 2 Nm (18 LB. IN.)

COVER ASSEMBLY
MOTOR, WIPER
Figure 20 - Wiper Motor Cover Assembly Replacement
2. Remove blade assemblies from wiper arms, providing protection for windshield surface.
3. Attach a scale to wiper arm hook and measure the
force required to lift wiper arm perpendicular to
windshield to normal working height (height with
blade assembly attached).
4. If the force required is not within the specifications
given below, the wiper arm should be replaced.
Tip Pressure RH Wiper Arm - 9-11 N
(32.5-39.5 oz.)
LH Wiper Arm-10-12 N
(36.0-43.0 oz.)
A CAM, INNER WIPE
BLADE ELEMENT SET CHECK

Figure 22
Remove wiper blade assemblies from wiper arms.
Look down the length of the blade element. The rubber
element which contacts the glass must be on the center
line of the blade assembly 15 degrees. Replace the
element if necessary.
Figure 21 - Inner Wipe Cam Position for Cover

Assembly Installation
A BLADE ELEMENT SHOULD NOT BE BENT

MORE THAN 15 IN EITHER DIRECTION
FROM CENTER LINE
9 ELEMENT, BLADE
Figure 22 -
Blade Element Set Check
SE-18 WINDSHIELD WIPERIWASHER SYSTEM
SPECIFICATIONS
Linkage Assembly Nut (20) ...................................................................
Linkage Assembly Screws (12 and 14) .................................................
Wiper Arm Nuts (7) ................................................................................
Wiper Motor Assembly Screw (19) .......................................................
Wiper Motor Cover Assembly Screws (21) ..........................................
10 Nm (7.5 lb. ft.)

10 Nm (7.5 lb. ft.)
32 Nm (24 lb. ft.)
10 Nm (7 .5 lb. ft.)
2 Nm (18 lb. in.)
SPECIAL TOOLS
1.
2.
3.
J 39637
J 39232
J 39529
1.
2.
3.
WIPER ARM PULLER

WIPER LINKAGE SEPARATOR
WIPER LINKAGE INSTALLER
ACCESSORIES 9-1
SECTION 9
ACCESSORIES
CONTENTS
Audio Systems ............................................................................................................................................... Section 9A
Cruise Control ................................................................................................................................................. Section 9B
Theft Deterrent Systems ................................................................................................................................ Section 9D
Engine Coolant Heater .................................................................................................................................... Section 9E
Supplemental Inflatable Restraint (SIR) System ............................................................................................ Section 9J
Remote Keyless Entry ................................................................................................................................... Section 9K
9-2 ACCESSORIES
BLANK
AUDIO SYSTEMS 9A-1
SECTION 9A
AUDIO SYSTEMS
CAUTION: This vehicle is equipped. with Supplemental Inflatable Restraint (SIR). Refer to
systems.
CONTENTS
General Description ................................................ 9A-2
Speaker Systems ................................................. 9A-2
Base Audio System (UQO) ............................ 9A-2
Delco-GM/Bose Music Systems .............. 9A-2
Optional Audio System .................................. 9A-2
Radio Fixed Antenna ......................................... 9A-2
Radio Power Antenna ........................................ 9A-2
Radios ................................................................. 9A-2
FM Stereo ....................................................... 9A-3
AMAX Stereo Certification ........................... 9A-3
Radio Controls ................................................... 9A-4
ETR AM/FM Stereo/Cassette (Chevrolet) ........ 9A-4
Radio Operation ............................................. 9A-4
Cassette Tape Player ...................................... 9A-4
Delco-GM/Bose Music System/Cassette
(Chevrolet) .................................................. ,....... 9A-5
Delco-GM/Bose Music System/Compact
Disc (Chevrolet) ............................................. 9A-6
Compact Disc Player ..................................... 9A-6
ETR AM/FM Stereo/Compact Disc
(Chevrolet) ...................................................... 9A-7
Compact Disc Player ..................................... 9A-7
ETR AM/FM Stereo/Cassette Tape
(Pontiac) ......................................................... 9A-8
Diagnostic Tape Error Indicator .. ,. .............. :. 9A-9
ETR AM/FM Stereo/Cassette Tape with
Graphic Equalizer (Pontiac) .......................... 9A-9
Cassette Tape Player ..................................... 9A-10

Diagnostic Tape Error Indicator ................... 9A-10
ETR AM/FM Stereo/Compact Disc with
Graphic Equalizer (Pontiac) ......................... 9A-11
Radio Operation ............................................ 9A-11
AMAX Stereo Certification .......................... 9A-11
Compact Disc Player .................................... 9A-11
Setting Radio Anti-Theft Feature ..................... 9A-12
Unlocking Secured Radio ................................. 9A-13
Unlocking Secured Radio after Power Loss ... 9A-13
Determining Factory Backup Unlocking
Code for Secured Radio ............................... 9A-13
Diagnosis ............................................................... 9A-13
Audio System Diagnosis .......... Refer to Section 8A
Radio Fixed Antenna Diagnosis ....................... 9A-13
Radio Power Antenna
Diagnosis ............................... Refer to Section 8A
Radio Power Antenna Mounting
and Connections ............................................ 9A-13
Radio Power Antenna Lead-In Cable Check .. 9A-14
Radio Power Antenna Check ........................... 9A-14
Radio Speaker Diagnosis (Cassette Only) ....... 9A-14
On-Vehicle Service................................................ 9A-15
Tape Player and Cassette Care ......................... 9A-15
Radio Power Antenna Care .............................. 9A-16
Compact Disc Care ........................................... 9A-16
Radio ................................................................. 9A-16
Speakers ............................................................. 9A-16
Radio Suppression Equipment .......................... 9A-16
Radio Fixed Antenna ........................................ 9A-16
Radio Power Antenna ....................................... 9A-17
Radio Power Antenna Mast ............................. 9A-17
Special Tools ......................................................... 9A-19
9A-2
AUDIO SYSTEMS
GENERAL DESCRIPTION
All radios have electronic memory for
pre-selected station function.
SPEAKER SYSTEMS
Base Audio System (UQO)
There are two front speakers, one in each front
side door, and two rear speakers mounted in the rear
panel. These speaker locations allow for a full, high
fidelity sound.
Standard radio front side door speakers are
6 inches round and 4 ohms. Radio rear speakers are
6 inches round and 10 ohms.
High performance extended range speakers are
standard with full electronically tuned receiver (ETR)
system.
Chevrolet convertibles are equipped with (U62)
sound systems which include two door coax speakers
and two "B" pillar coax speakers.
RADIOS
All 2000 (Chevrolet), CDM (Chevrolet), and
2001 (Pontiac) series radios feature ETR tuning,
vacuum fluorescent display, AM-FM stereo, seek
tuning, and digital clock display. Seven radios are
available.
CHEVROLET
Figures 1 through 4
AM/FM Stereo/Cassette with dynamic noise
reduction and Automatic Program Search:
Delco-GM/Bose Music System with Cassette
Tape, dynamic noise reduction and Automatic
Program Search.
Delco@-GM/Bose Music Systems
CHEVROLET
The speaker system for the Delco-GM/Bose
Music Systems includes five speakers. There are two
front speakers, one in each front side door, two "B"
pillar subwoofer speakers, and one rear speaker,
mounted in the left rear cargo compartment trim.
Amplifiers for all rear speakers are housed in the rear
Bose speaker.
012595
FS01tA
Figure 1 ETR AM/FM Stereo Cassette (Chevrolet)
Optional Audio System
PONTIAC
The premium speaker system is available on the
(W54 and W55) radio systems. It consists of four
front speakers, two in each front side door, and six
rear speakers, two mounted in the rear sail panel, and
four mounted in the rear compartment trim panels.
The amplifier is located under the right rear armrest.
Pontiac convertibles are equipped with (W57 and
W58) sound systems which includes two door coax
speakers and two "B" pillar coax speakers. Pontiac
convertibles also can be equipped with (W59 and
W73), sound systems which include two door
high-sensitivity speakers, two door dome tweeters and
two "B" pillar coax speakers.
11111.UMI
11111
~~
AIIHI
18:B.B ::.':-
~~@ ~==========;;.AM.fM.a.
012595
FS002tA
Figure 2 Delco-GM/Bose Music System/Cassette

(Chevrolet)
RADIO FIXED ANTENNA

The fixed antenna is designed to provide good
radio omni-directional reception in moderate fringe
areas.
RADIO POWER ANTENNA

The electrically operated, rear-mounted,
telescoping rod-type antenna extends fully whenever
the radio is in use and retracts whenever the radio or
ignition switch is turned to "OFF" and retained
accessory power is not active.
The antenna mast is attached to a plastic cable
that is driven up and down by an electric motor. The
motor is automatically shut off by limit switches when
the antenna reaches the full-up or full-down position.
012591
FS003tA
Figure 3 Delco-GM/Bose Music System/Compact Disc

(Chevrolet)
AUDIO SYSTEMS
9A3
AMAX Stereo Certification
AM-FM.c.
Figure 4 - ETR AM/FM Stereo/Compact Disc -(Chevrolet)
Delco-GM/Bose Music System with Compact

Disc and Delco-Loc II.
AM/FM Stereo/Compact Disc with scan and
directional seek and Delco-Loc II (convertible).
All Chevrolet radios are equipped with scan and
dual directional seek.
All optional radios are AMAX certified. These

receivers can reproduce the fidelity sound now
transmitted by all AM stations but not received on all
AM radios.
Some improvements are high fidelity, adjustable
receiver band width (wide for high fidelity or narrow
to cut out any interference), noise cancellation, full
stereo sound, new frequencies received and external
antenna capability.
The range of most AM stations is greater than
FM, especially at night. The longer range, however,
can cause stations to interfere with each other. AM is
also subject to noise pick-up from storms, power lines,
etc. AMAX certification reduces many of these
problems.
PONTIAC
Figures 5 through 7
AM/FM Stereo/Cassette with Theftlock.
AM/FM Stereo/Cassette Equalizer with Steering
Wheel Radio Controls with Theftlock.
AM/FM Stereo/Compact Disc/Equalizer with
Steering Wheel Radio Controls.
All Pontiac radios are equipped with dual
directional seek. Cassette radios are equipped with
Dolby.
Pontiac Firebird models have a new family of
radios (2001 series) available featuring new styling
(flush front design) and steering wheel controls on
up-level radios. Some are available with or without a
graphic equalizer.
The Pontiac optional audio system (W54 and
W55) uses ten speakers and an amplifier: four
speakers mounted in the front side doors, two speakers
in the rear sail panel and four speakers in the rear
compartment trim panels. The amplifier is under the
right rear armrest.
BAL
FADE
~(!)) Cle
Figure 5 - ETR AM/FM Stereo/Cassette Tape - (Pontiac)
Figure 6 - ETR AM/FM Stereo/Cassette Tape with Graphic

Equalizer - (Pontiac)
FM Stereo
All factory-equipped sound systems with an FM
stereo radio will switch to stereo operation whenever
an FM stereo broadcast is being received, and an
indicator in the dial will light. Stereo operation means
the radio is separating a stereo broadcast back into the
original two channels, called "left" and "right."
Stereo sound is noticeably more realistic to the ear.
Although FM is normally static-free, reception
can be limited by terrain, atmospheric conditions,
station strength and distance from the transmitter.
Buildings or other obstructions can cause momentary
static, flutter or station swapping. If reception is poor,
tuning to a stronger station will bring improvement.
Figure 7 - ETR AM/FM Stereo/Compact Disc with Graphic

Equalizer - (Pontiac)
9A-4
AUDIO SYSTEMS
RADIO CONTROLS
Clock
When the radio is first turned on, the frequency

will appear on the display for five seconds, and then
the display will return to the time display. To recall
the frequency, simply push in the upper knob
(Chevrolet) or the "Recall" button (Pontiac) while the
radio is turned on. The frequency will appear on the
display for five seconds. When the ignition lock
cylinder is in the "LOCK" or "OFF" position, the
radio display is blank. To display the time when the
ignition lock cylinder is in the "OFF" or "LOCK"
position, simply push the upper knob or the "Recall"
button. The time will display for five seconds. Then
the display will turn blank.
To set the clock display on a 2000 series radio,

the ignition lock cylinder must be in the
"ACCESSORY" or "RUN" position and the radio
must be off. To set the clock:
1. Push "SET."
2. Within five seconds, push and hold "SEEK 'f""
until the correct hour appears.
3. Then press and hold "SEEK A" until the correct
minute appears.
Seek and Scan Feature
ETR AM/FM STEREO/CASSETTE

(CHEVROLET)
Radio Operation
Figure 1
Upper Knob
This knob turns the radio on and off. Rotate

knob to control volume. The control ring behind the
knob is the balance control.
Turn the ring clockwise to move speaker balance
to the right and counterclockwise to move speaker
balance to the left. Press the knob to select the other
side of the tape when playing a cassette.
Lower Knob
Turn the knob to manually select radio stations.
When the radio is on and the tape player is off, press
the knob to choose either the AM or the FM band.
The control ring behind the lower knob fades the
sound between the front and rear speaker.
Bass and Treble Controls
Slide the "TREB" lever up to increase treble
and down to decrease treble. Slide the "BASS" lever
up to increase bass and down to decrease bass.
If a station is weak and noisy, move the
"TREB" lever down to reduce the noise.
Push Buttons
To preset four AM stations and four FM

stations:
1. Tune in desired station.
2. Press "SET." Within five seconds, press a station
button.
To preset three additional AM stations and three
additional FM stations:
2. Press "SET." Within five seconds, press any two
adjacent buttons simultaneously.
The radio will tune to the pre-selected station
when the push button or button pair is pressed.
Button pairing allows for seven AM and seven
FM stations to be preset for a total of fourteen preset
stations.
If electrical power is interrupted by a blown fuse
or a discharged battery, the stations must be reset.
The 2000 series radios have "SEEK" and

"SCAN" features for electronic station tuning up and
down the band.
Push the "SEEK A or V" and the radio will
tune to next higher or lower station with enough signal
strength to be heard clearly, and stay there.
"SCAN" is a two-button sequence. To "SCAN"
to the next higher station, press "SEEK A" and hold
it there while you press "SEEK V." To "SCAN" to
the next lower station, press "SEEK V" and hold it
there while you press "SEEK A." The radio will
move to the next strong station. It will pause there a
few seconds, then move to the next strong station.
When the radio reaches the end of the band, it will
return to the other end of the band and continue to
"SCAN." This will continue until the "SCAN" mode
is terminated. To terminate the "SCAN" mode, press
either seek up, seek down, both buttons again, or press
the upper knob.
Cassette Tape Player

To play a tape, the ignition lock cylinder must
be in the "ACCESSORY" or "RUN" position and the
receiver/tape player must be turned on. Insert the
cassette squarely through the door, exposed tape side
of the cassette first. When the tape is fully inserted,
the radio will turn off and the tape will begin playing.
To advance the tape, press the ..,.. (forward)
button. To reverse the tape, press the <ll l1 (reverse)
button. To resume tape play from fast forward or
reverse, press the "STOP-EJECT" button lightly.
When the tape reaches the end of a side, it will
automatically reverse and play the other side of the
tape. To resume listening to the radio or to eject the
tape, push the "STOP-EJECT" button.
The cassette player is turned off by ejecting the
tape, turning the power knob (upper knob) or rotating
the ignition lock cylinder to "LOCK," "OFF" or
"START." When this occurs, the tape player will
either eject the cassette automatically or the internal
tape drive and roller will retract automatically. This is
to protect the tape player and cassette tape.
For the best operation of the cassette player do
not use cassette tapes longer than 60 minutes per side.
Tape Direction Indicators
The direction the tape is being played is
indicated by indicator arrows. When the indicator
arrow on the left side is on, the tape direction is to the
left. When the indicator arrow on the right side is on,
the tape direction is to the right.
AUDIO SYSTEMS
Reversing Sides
Press the upper knob to play the other side of

the tape. When the end of tape is reached, it
automatically reverses direction and plays the other
side.
"APS'' (Automatic Program Search)
9A5
The radio will tune to the pre-selected station

when the push button or button pair is pressed.
Button pairing allows for seven AM and seven
FM stations to be preset for a total of fourteen preset
stations.
If electrical power is interrupted by a blown fuse
or a discharged battery, the stations must be reset.
Clock
Push "APS" to go to the beginning of a new

selection.
To go forward to the beginning of the next
selection, push ~ To go back to the beginning of the
current selection, push Push ~ again to go to the
beginning of the previous selection.
Tape Eject Button
Press "STOP-EJECT" to eject tape or stop tape

and switch to radio.
DELCOGMIBOSE MUSIC
SYSTEM/CASSETTE(CHEVROLET)
Radio Operation
Figure 2
Upper Knob

kn.ob to control volume. Press the knob to select the
other side of the tape when playing a cassette.
Lower Knob
Turn the knob to manually select radio stations.

Wheri the radio is on and the tape player is off, press
the knob to choose either the AM or the FM band.
The control ring behind the lower knob fades the
sound between the front and rear speakers.
Slide the "TREB" lever up to increase treble

and down to decrease treble. Slide the "BASS" lever
up to increase bass and down to decrease bass.
If a 1?tation is weak and noisy, move the
"TREB" lever down to reduce the noise.
Balance
The speakers are electronically balanced on the

Delco-GM/Bose Music System.
Push Buttons
To preset four AM stations and four FM

stations:
2. Press "SET." Within five seconds, press a station
button.
To preset three additional AM stations and three
additional FM stations:
2. Press "SET." Within five seconds, press any two
adjacent buttons simultaneously.
To set the clock display on a 2000 series radio,

the ignition lock cylinder must be in the
"ACCESSORY" or "RUN" position and the radio
must be off. To set the clock:
1. Push "SET."
2. Within five seconds, push and hold "SEEK V"
3. Then press and hold "SEEK A" until the correct
minute appears.
Seek and Scan Feature-
The 2000 series radios have "SEEK" and

"SCAN" features for electronic station tuning up and
down the band.
Push the "SEEK A or V" and the radio will
tune to next higher or lower station with enough signal
"SCAN" is a two-button sequence. To "SCAN"
to the next higher station, press "SEEK A" and hold
it there while you press "SEEK V." To "SCAN" to
the next lower station, press "SEEK V" and hold it
there while you press "SEEK A." The radio will
move to the next strong station. It will pause there a
few seconds, then move to the next strong station.
When the radio reaches the end of the band, it will
return to the other end of the band and continue to
"SCAN." This will continue until the "SCAN" mode
is terminated. To terminate the "SCAN" mode, press
either seek up, seek down, both buttons again, or press
the upper knob.

of the cassette first. When the tape is fully inserted,
the radio will turn off and the tape will begin playing.
To advance the tape, press the IJlr,,- (forward)
button. To reverse the tape, press the 411 (reverse)
button. To resume tape play from fast forward or
reverse, press the "STOP-EJECT" button lightly.
When the tape reaches the end of a side, it will
automatically reverse and play the other side of the
tape. To resume listening to the radio or to eject the
tape, push the "STOP-EJECT" button.
The cassette player is turned off by ejecting the
tape, turning the power knob (upper knob) or rotating
the ignition lock cylinder to "LOCK," "OFF" or
"START." When this occurs, the tape player will
either eject the cassette automatically or the internal
tape drive and roller will retract automatically. This is
to protect the tape player and cassette tape.
9A-6
AUDIO SYSTEMS
For the best operation of the cassette player do

not use cassette tapes longer than 60 minutes per side.
Tape Direction Indicators
The direction the tape is being played is
indicated by indicator arrows. When the indicator
arrow on the left side is on, the tape direction is to the
left. When the indicator arrow on the right side is on,
the tape direction is to the right.
Reversing Sides
Press the upper knob to play the other side of
the tape. When the end of tape is reached, it
automatically reverses direction and plays the other
side.
"APS" (Automatic Program Search)
Push "APS" to go to the beginning of a new
selection.
To go forward to the beginning of the next
selection, push ~ To go back to the beginning of the
current selection, push Push <111111 again to go to the
beginning of the previous selection.
Tape Eject Button
Press "STOP-EJECT" to eject tape or stop tape
and switch to radio.
Tape Equalization Button
Select the 70 usec (chrome or metal) tape by
pressing "Cr02" button in, or 120 usec (standard) by
leaving "Cr02" button out.
DELCOGM/BOSE MUSIC
SYSTEM/COMPACT DISC (CHEVROLET)
Radio Operation
Figure 3
Push Buttons
To preset five AM stations; five FMl stations

and five FM2 stations, use the following procedure:
2. Push "SET." Within five seconds, push one of the
five push buttons.
3. Repeat these steps for each push button.
Clock
To set the clock display, the ignition lock

cylinder must be in the "ACCESSORY" or "RUN"
position and the radio must be off. To set the clock:
1. Press the lower knob to select AM, FMl, or FM2.
2. Push "SET."
3. Within five seconds, push and hold "SCAN" until
the correct hour appears.
4. Then push and hold "SEEK .... or <111111" until the
correct Iriinute appears.
"SEEK"
Press "SEEK .... or <11111" and the radio will tune to

the next higher or lower station with enough signal
"SCAN"
Push "SCAN" to hear each station for a few

seconds. To stop scanning, push "SCAN" again or the
upper knob.
Compact Disc Player

With the radio on, insert disc into slot, label side
up (player pulls it in). "CD" will appear on the
display and track 1 will begin to play. If disc comes
back out and "ERR" appears on display, check to s~e
if:
Disc is upside down.
Disc is dirty, scratched or wet.
Too much moisture is in the air.
Temperature is too hot or too cold.
Upper Knob

knob to control volume. Press knob to silence the
sound. The control ring behind the knob is the balance
control. Tum the ring clockwise to move speaker
balance to .the right and counterclockwise to move
speaker balance to the left.
Lower Knob
.
Rotate knob to tune radio stations manually.
Press knob to alternately select AM or FM (FMl or
FM2) band. Rotate control behind lower. knob to
adjust the sound between front and rear speakers.
Push "BASS &.." to hear more bass and "BASS
'f'" to hear less bass.
Push "TREB &.." to hear more treble and
"TREB 'f"" to hear less treble. For the clearest sound,
keep both of these adjusted all the way up. If a station
is weak and noisy, push "TREB 'f"" to reduce the
noise.
"RCL" {Recall)
Press "RCL" to see current track number. Press

"RCL" again within five seconds to see time elapsed
in current track on the display.
"PREV" (Previous)
Press "PREY" to play track again.. If held or

pressed more than once, the disc will return to
previous track. If "PREY" is pressed within eight
seconds from start of track, the disc will go to the
beginning of the previous track and begin. to play. If
"PREY" button is pressed after eight seconds into the
track, the disc will go to the beginning of the current
track and begin to play.
"NEXT"
Press "NEXT" when you want to hear the next

track now (before the present track is finished) .. If
"NEXT" is held or pressed more than once, .the disc
will advance farther.
AUDIO SYSTEMS
9A-7
"FWD'' (Forward)
Press and hold "FWD" to quickly advance

within a track. Release it to resume playing.
Push "BASS .It." to hear more bass and "BASS

'Y" to hear less bass. Push "TREB .It." to hear more
treble and "TREB '\"" to hear less treble. For the
clearest sound, keep both of these adjusted all the way
up. If a station is weak and noisy, push "TREB V" to
reduce the noise.
''REV'' (Reverse)
Press and hold "REV" to return quickly to a

favorite passage on the disc. Release it to resume
playing.
"SCAN"
Press "SCAN" to listen to each track for about

10 seconds. To stop scanning, push "RDM" or
"SCAN."
"RDM" (Random)
Press this button and the player chooses a

random order of tracks to play. When the, final random
track has been played, the disc will play the same
random selection again. Press "RDM" again for a
different selection of tracks.
Push Buttons
To preset five AM stations, five FMl stations

and five FM2 stations, use the following procedure:
1. Press the lower knob to select AM, FMl, or FM2.
3. Push "SET." Within five seconds, push one of the
five push buttons.
4. Repeat these steps for each push button.
Clock
Push "COMP" to make loud and soft passages

more nearly equal in volume.
To set the clock display, the ignition lock

cylinder must be in the "ACCESSORY" or "RUN"
position and the radio must be off. To set the clock:
1. Push "SET."
2. Within five seconds, push and hold "SCAN <111111"
3. Then push and hold "SEEK ~ or <111111" until the
correct minute appears.
"ST-PL" (Stop/Play)
"SEEK"
Press "ST-PL" to stop disc from playing. The

radio will resume playing. "ST-PL" will also restart
the disc. The disc will resume playing. at the point
where it stopped.
Press "SEEK ~ or <111111" and the radio will tune to

the next higher or lower station with enough signal
"COMP" (Compression)
''EJCT" (Ej,ect)
Push "EJCT" to eject disc and resume radio

play.
ETR AM/FM STEREO/COMPACT DISC

(CHEVROLET)
Radio Operation
Figure 4
Upper Knob

knob to control volume. Press knob to silence the
sound. The control ring behind the knob is the balance
control. Turn the ring clockwise to move speaker
balance to the right and counterclockwise to move
speaker balance to the left.
"SCAN"
Push "SCAN" to hear each station for a few

seconds. To stop scanning, push "SCAN" again or the
upper knob.
Compact Disc Player

With the radio on, insert disc into slot, label side
up (player pulls it in). "CD" will appear on the
display and track 1 will begin to play. If disc comes
back out and "ERR" appears on display, check to see
if:
"RCL'' (Recall)
Press "RCL" to see current track number. Press

"RCL" again within five seconds to see time elapsed
in current track on the display.
Lower Knob
"PREV" (Previous)
Rotate knob to tune radio stations manually.

Press knob to alternately select AM or FM (FMl or
FM2) band. Rotate control behind lower knob to
adjust the sound between front and rear speakers.
Press the "PREY" to play track again. If held or

previous track. If "PREY" is pressed within eight
9A-8
AUDIO SYSTEMS
beginning of the previous track and begin to play. If

"PREY" button is pressed after eight seconds into the
Tune Knob
Press the "TUNE" knob to release the knob.

Turn the knob to choose desired radio stations. Push
"NEXT"
the "TUNE" knob back in to store it when not in use.

"RECALL"
Press "NEXT" when you want to hear the next

track now (before the present track is finished). If
"NEXT" is held or pressed more than once, the disc
will advance farther.
Press "RECALL" to recall the station being

played or the clock display. Press "RECALL" also to
display the time when the ignition is off.
"FWD" (Forward)
"SEEK"
Press and hold "FWD" to quickly advance

within a track. Release it to resume playing.
Press "SEEK T or .A" and the radio will tune

to the next lower or higher station and stay there.
"REV" (Reverse)
Press and hold "REV" to return quickly to a

playing.
"SCAN"
Press "SCAN" to listen to each track for about

10 seconds. To stop scanning, push "RDM" or
"SCAN."
"ROM" (Random)
Press this button and Jhe player chooses a

random order to tracks to play. When the final random
"COMP" (Compression)
Push "COMP" to make loud and soft passages

more equal in volume.
"ST-PL" (Stop/Play)
Press "ST-PL" to stop disc from playing. The

radio will resume playing. "ST-PL" will also restart
the disc. The disc will resume playing at the point
where it stopped.
"EJCT" (Eject)
Push "EJCT" to eject disc and resume radio

play.
ETA AM/FM STEREO/CASSETTE TAPE

(PONTIAC)
Radio Operation
Figure 5
Volume Knob
Push the "VOLUME" knob to turn the radio on

or off. Rotate the knob to adjust sound.
"AM/FM"
Press "AM/FM" to receive either AM/FMl or

FM2. The lighted display shows the selection.
Slide the "TREBLE" lever to the right to

increase treble and to the left to decrease treble. Slide
the "BASS" lever to the right to increase bass and to
the left to decrease bass.
If a station is weak and noisy, move the
"TREBLE" lever to the left to reduce the noise. .

With an AMAX-certified receiver, the radio can
produce quality AM sound comparable to FM stereo.
AMAX reduces noise without reducing .the high
frequencies needed for the best sound. In addition to
improved sound quality, AMAX includes more stations
on the AM band. You don't have to do anything to a
Delco GM radio because AMAX is automatic.
Clock
To set the clock display on the radio; the ignition

may be off. To set the clock:
1. Press and hold "HR" (hour) until the correct hour
appears.
2. Press and hold "MIN" (minute) until the correct
minute appears.
There will be a two-second delay before the
clock goes into the time-set mode.
Push Buttons
To preset six AM stations and six FMl stations
or six FM2 stations:
1. Press the AM/FM button to select AM, FMl, or
FM2.
3. Press and hold one of the six push buttons until
the display show~ "SET." Whenever that button
is pressed, the preset station will return.
Repeat these steps for each push button.
Speaker Adjustment
Balance Knob: Press "BAL" knob to release

knob. Turn the knob to move the sound between the
right and left speakers. Push "BAL" knob back in to
store it when not adjusting.
Fade Knob: Press "FADE" knob to release the
front and rear speakers. Push "FADE" knob back in
to store it. when not adjusting.
AUDIO SYSTEMS 9A-9

If "Cln" (Clean) appears on the display when
you insert your cassette tape, your cassette player

needs to be cleaned. It will still play cassette tapes,
but it should be cleaned to prevent damage to your
cassette tape and player. Refer to "Tape Player and
Cassette Care" later in this section.
After you have cleaned the cassette tape player,
press and hold "EJECT" for five seconds to reset the
"C1n" indicator. The radio will display "- - -" to
show that the clean feature has been reset.
The tape player is built to work best with tapes
that are 30 minutes long on each side. Tapes longer
than that are so thin they may not work well in this
player.
receiver/tape player must be turned on. Insert !he
of the cassette first. If you hear nothing or hear just
garbled sound, it may not be in squarely. Press
"EJECT" to remove the tape and start over. A cassette
symbol will appear in the. u~per left hand comer of t~e
display whenever a tape 1s mserted. When the tape .1s
fully inserted,. the radio will turn off and the tape will
begin playing.
.
Once the tape is playing, use "VOLUME,"
"BAL," "FADE," "TREBLE" and "BASS" just as
for the radio. The arrow shows which side of the tape
is playing.
To rapidly advance the tape, press "FWD"
(forward). Press "PROG" (program) . or '_'REV"
(reverse) to stop this process. The radio will play
during this operation. To rapidly reverse the tape, press
"REV" (reverse). Press "PR<?G" (program) ?r
"REV" (reverse) again to stop this process. The radio
will play during this operation.
To play the next selection, press "NEXT" or
"SEEK A\." (instead of waiting until the current
selection is finished). For "NEXT" to work properly,
your tape must have at least three seconds of sile~ce
between each selection. The radio will not play durmg
this operation.
To replay the current selection, press "PREV"
or "SEEK V." For "PREV" to work properly, your
tape must have at least thre~ se~onds of sile~ce
between each selection. The radio will not play durmg
this operation.
To switch from one side of the tape to the other
or to stop the tape from searching, press the "PROG"
(program) knob.
To reduce tape noise, press [Dolby] symbol.
This symbol will appear in the. display. To stop the
tape player do any of the followmg:
Turn the power off or turn the ignition key off.
The cassette stays in the player and will resume
playing at the point where it stopped.
Press AM/FM to stop playing the cassette and
switch to radio. Press "TAPE/PLAY" to restart
the cassette at the point where it stopped.
Press "EJECT" to remove the cassette or stop the
cassette and switch to radio. "EJECT" will work
with the ignition on or off.
Diagnostic Tape Error Indicator

When the cassette player detects a problem with
the tape either just after it is loaded or while it is
playing, it will attempt to work around the error. If the
cassette player cannot continue to play the tape, it will
. .
eject it and switch ~o the radio mode. .
If a problem 1s detected, the radio will display:
the error message, the radio frequency that is playing,
and the time. Each message will appear for five
seconds. These error messages and their meanings are
as follows: E 10 -cassette too tight; E 11 - cassette
broken; E13 -communication problem.
This error indicator feature may not work with
certain types of adapters for add-on CD players. If
there is not tension on the reels of the cassette player,
it will interpret the adapter as a broken tape and eject
it.
ETR AM/FM STEREO/CASSETTE TAPE

WITH GRAPHIC EQUALIZER (PONTIAC)
Radio Operation
Figure 6
Volume Knob

"AM/FM"

Tune Knob

Turn the knob to choose desired radio stations. Push
"RECALL''

played or the clock display: P~~ss ''.RECALL" also to
display the time when the 1gn1t1on 1s off.
"SEEK"
Press "SEEK T or A\." and the radio will tune


AMAX reduces noise without reducing the high
frequencies needed ~or the best .sound. In additio~ to
improved sound quality, AMAX mcludes more. stations
Clock
To set the clock display on the radio, the ignition

appears.
9A10
AUDIO SYSTEMS

minute appears.
Push Buttons

FM2.
the display shows "SET." Whenever pressing that
button, the preset station will return.
Speaker Adjustment

the knob. Turn the knob to move the sound between
the right and left speakers. Push "BAL" knob back in
to store it when not adjusting.
Steering Wheel Controls
Vehicles equipped with this radio have steering

wheel controls for the audio system. With steering
wheel controls, use the buttons on the steering wheel
to:
1. Play the cassette tape player.
2. Adjust the volume.
3. Choose AM, FMl or FM2.
4. Use the "SEEK" and "MUTE" functions.
5. Cqoose one of the preset stations.
Setting the Graphic Equalizer

of the cassette first. If you hear nothing or hear just
garbled sound, it may not be in squarely. Press
"EJECT" to remove t4e tape and start over. A cassette
symbol will appear in the upper left hand comer of the
display whenever a tape is inserted. When the tape is
fully inserted, the radio will turn off and the tape will
begin playing.
Once the tape is playing, use "VOLUME,"
"BAL," "FADE," "TREBLE" and "BASS" just as
for the radio .. The arrow shows which side of the tape
is playing.
To rapidly advance the tape, press "FWD"
(forward) ...Press ~'PROG" (program) or "REV"
(reverse) to stop this process. The radio will play
during thi~ operation. To rapidly reverse the tape, press
"REV" {reverse). Press "PROG" (program) or
"REV" (reverse) again to stop this process. The radio
To play the next selection, press "NEXT" or
"SEEK .A" (instead of waiting until the current
selection is finished). For ''NEXT" to work properly,
your tape must have at least three seconds of silence
between each selection. The radio will not play during
this operation.
To replay the current selection, press "PREV"
or "SEEK T." For "PREY" to work properly, your
tape must. have at least three seconds of silence
between each selection. The radio will not play during
this operation.
To switch from one side of the tape to the other
or to stop the tape from searching press the "PROG"
(program) knob.
To reduce tape noise, press [Dolby] symbol.
This symbol .will appear in the display. To stop the
tape player do any of the following:
Turn the power off or turn the ignition key off.

Use the levers to set the bass, midrange and
treble until you get the sound you want. The 40, 100,
250 and 625 levers adjust the bass; 1.6K is midrange,
and 4K and 12K control the treble. The l.6K lever
may be set in the middle position and then the other
levers may be moved up or down until a satisfactory
amount of bass and treble is achieved.

If "Cln" (Clean) appears on the display when
you insert your cassette tape, your cassette player
needs to be cleaned. It will still play cassette tapes,
but it should be cleaned to prevent damage to your
cassette tape and player.. Refer to "Tape Player and
Cassette Care" later in this section.
After you have cleaned the cassette tape player,
press and hold "EJECT" for five seconds to reset the
"Cln" indicator. The radio will display "- - -" to
show that the clean feature has been reset.
The tape player is built to work best with tapes
that are 30 to 45 minutes long on each side. Tapes
longer than that are so thin they may not work well in
this player.
The cassette stays in the player and will resume

playing at the. point where it stopped.
Press AM/FM to stop playing the cassette and
switch to radio. Press "TAPE/PLAY" to restart
the cassette at the point where it stopped.
Press "EJECT" to remove the cassette or stop the
cassette and switch to radio. "EJECT" will work
with the ignition or radio off.
Diagnostic Tape Error Indicator

When the cassette player detects a problem with
the tape either just after it is loaded or while it is
playing, it will attempt to work around the error. If the
cassette player cannot continue to play the tape, it will
eject it and switch to the radio mode.
If a problem is detected, the radio will display:
the error message, the radio frequency that is playing,
and the time. Each message will appear for five
seconds. These error messages and their meanings are
as follows: ElO ~cassette too tight; Ell - cassette
broken; E13 -communication problem.
AUDIO SYSTEMS
This error indicator feature may not work with
certain types of adapters for add-on CD players. If
there is not tension on the reels of the cassette player,
it will interpret the adapter as a broken tape and eject
it.
ETR AM/FM STEREO/COMPACT DISC

WITH GRAPHIC EQUALIZER (PONTIAC)
Radio Operation
Figure 7
Volume Knob

9A-11

display shows "SET." Whenever pressing that
button, the preset station will return.
Speaker Adjustment

the knob. Turn the knob to move the sound between
the right and left speakers. Push "BAL" knob back in
Steering Wheel Controls

Tum the knob to choose desired radio stations. Push
Vehicles equipped with this radio have steering

wheel controls for the audio system. With steering
wheel controls, use the buttons on the steering wheel
to:
1. Play the compact disc player.
2. Adjust the volume.
3. Choose AM, FMl or FM2.
4. Use the "SEEK" and "MUTE" functions.
5. Choose one of the preset stations.
"RECALL"
Setting the Graphic Equalizer

played or the clock display. Press "RECALL" also to
display the time when the ignition is off.
Use the levers to set the bass, midrange and

treble until you get the sound you want. The 40, 100,
250 and 625 levers adjust the bass; 1.6K is midrange,
and 4K and 12K control the treble. The 1.6K lever
may be set in the middle position and then the other
levers may be moved up or down until a satisfactory
amount of bass and treble is achieved.
"AM/FM"

Tune Knob
"SEEK"
Press "SEEK T or A" and the radio will tune


AMAX reduces noise without reducing the high
frequencies needed for the best sound. In addition to
improved sound quality, AMAX includes more stations
Clock
To set the clock display on the radio, the ignition

appears.
minute appears.
Push Buttons

FM2.
Compact Disc Player

With the radio on, insert the disc into the slot,
label side up (player pulls it in). "CD" will appear on
the display and track 1 will begin to play. If the disc
comes back out and "ERR" appears on display, check
to see if:
"RECALL"
Press "RECALL" to see current track number.

Press "RECALL" again within five seconds to see
time elapsed in current track on the display. The track
number also appears when the disc is inserted.
"PREV'' (Previous)
Press "PREV" to play track again. If held or

previous track. If "PREV" is pressed within eight
beginning of the previous track and begin to play. If
"PREV" button is pressed after eight seconds into the
9.A-12
AUDIO SYSTEMS
To Play Next Selection
Press "NEXT" or "SEEK .A." when you want

to hear the next track now (before the present track is
finished). If "NEXT" or "SEEK .A." is held or
pressed more than once, the disc will advance farther.
To Replay Current Selection
Press "PREV" or "SEEK V" to play a track

again. If you press and hold these buttons or press
more than once, the disc will return to previous tracks.
"FWD" (Forward)
Press and hold "FWD" to advance quickly

within a track. Release it to resume playing. The radio
"REV" (Reverse)
Push "REV" and hold it to return quickly to a

playing.
"RDM" (Random)
Press this button and the player chooses a

random order of tracks to play. When the final random
To Stop Disc Player
Any of the following steps will stop the disc

player:
Tum the power off or tum the ignition key off.
The disc stays in the player and will resume
playing at the point where it stopped.
Press "AM/FM" to stop playing the disc and
switch to the radio. Press "CD/PLAY" to restart
the disc at the point where it stopped.
Press "EJECT" to eject the disc or stop the disc
and switch to radio. "EJECT" will work with the
ignition or radio off. Press "EJECT" to load a
disc when the radio is off.
O
SETTING RADIO ANTI-THEFT FEATURE

Delco-Loc II and Theftlock is a security
feature which can be used or ignored. If ignored, the
radio will play normally. If used, the radio will be
useless if stolen because it won't tum on.
This is how to enter a secret code into the radio.
If battery power is lost for any reason, the secret code
must be entered again before the radio will tum on.
DELCO@-LOC II
Chevrolet
1. Write down any 6-digit number and keep in safe

place.
2. Tum ignition to "ACCESSORY" or "RUN"
position.
3. Turn the volume control knob to the left to turn
radio off.
4. Press buttons "1 " and "4" together and hold until
" - - -" shows on display.
5. Do not wait more than 15 seconds between each
step.
6. Press "SET" and "000" appears on the display.
7. Press "SCAN" and hold until first digit of code
appears.
8. Press "SEEK ~ or ~" to make second and third
digits appear.
9. Press the lower knob (tune knob) ("000"
appears).
10. Press "SCAN" and hold until fourth digit of code
appears.
11. Press "SEEK ~or~" to make last two digits of
code appear.
12. Press the lower knob (tune knob) ("REP" appears
for 5 seconds, then "000" appears).
13. For verification, repeat steps 7 through 11. Next,
press the lower knob (tune knob). "SEC" will
then be seen on display, meaning radio is secured.
If the display shows " - - -", the verification steps
were not successful and the entire sequence must
be repeated from step 6.
THEFTLOCK
Pontiac
The instructions below explain how to enter a

security code into the system. If the vehicle loses
battery power for any reason, the security code must
be entered again before the system will tum on.
1. Write down any number from 000 to 1999 and

keep it in a safe place.
2. Turn ignition switch to the "ACCESSORY" or
"RUN" position.
3. Turn radio system off.
4. Press and hold buttons " 1" and "4" together for
about 6 seconds until " - - -" shows on the
display.
You are now ready to enter the security code,
pausing no more than 15 seconds between steps.
1. Press "MIN" and "000" will appear on the

display.
2. Press "MIN" again and hold until the last two
digits of the code appear. Release button.
3. Press "HR" until the first one or two digits of the
code appear.
4. Press "AM/FM," "REP" will appear on the
display.
5. Repeat steps 1 through 3.
6. Press "AM/FM," "SEC" will appear on the
display. This means that the audio system is
secured.
The indicator light will also flash when the
ignition is off. If the display shows " - - -, " the
verification steps were not successful and the entire
sequence must be done over.
AUDIO SYSTEMS
9A-13
UNLOCKING SECURED RADIO
THEFTLOCK
THEFTLOCK
Pontiac
Pontiac
If power is disrupted to the audio system while

in the "SEC" mode, the unit will not work and
"LOC" will show on the display whenever the
ignition is on. To unlock the unit (with the ignition in
"ACC" or "RUN" position and radio oft):
display.
2. Press "MIN" again and hold until last two digits
of the code appear. Release the button.
3. Press "HR" until the first one or two digits
appear.
4. Press "AM/FM" and "SEC" will appear and the
unit will work. If "LOC" shows, the numbers did
not match and the unit is still locked.
If the radio system is secured ("SEC" shows on

the display) and you wish to disable it, enter the
security code as follows, pausing no more than
15 seconds between steps:
1. Tum ignition on. Make sure radio system is off.

The time will show on the display.
2. Press pushbuttons "1" and "4" together until
"SEC" shows on the display.
display.
4. Press "MIN" again and hold until the last two
digits of the code appear. Release the button.
5. Press "HR" until the first one or two digits
appear.
6. Press "AM/FM." If " - - -" shows, you have shut
off the theft-deterrent feature. If "SEC" shows,
the audio system is still secured.
rn
important
If the security code is lost or forgotten, contact

the dealer for assistance.
UNLOCKING SECURED RADIO AFTER

POWER LOSS
DETERMINING FACTORY BACKUP

UNLOCKING CODE FOR SECURED RADIO
If the security is activated and the radio is
disconnected from battery power, the radio will display
"LOC." The radio will not turn on until the correct
unlocking code is entered. If the customer code is lost
or unavailable, refer to Dealer Communications
System bulletin of unlock procedure or call Technical
Assistance.
DIAGNOSIS
AUDIO SYSTEM DIAGNOSIS
When battery power is reapplied to a secured

radio, the radio won't turn on and "LOC" appears on
the display. Enter the secret customer or factory
backup code as follows (do not pause more than
15 seconds between steps):
For information on audio system diagnosis, refer

to SECTION 8A.
Check for proper torque at antenna base to ensure
proper ground.
DELCO-LOC II
Unplug antenna lead-in at back of radio and plug

a test antenna into the radio. Make sure test antenna
base is grounded to the vehicle chassis and keep hands
off of antenna. Check radio reception in an area away
from electrical interference. These include tall
buildings, metal structures, power lines, fluorescent
lighting and power tools. Tune to high and low ends
of the dial on both AM and FM, checking weak and
strong station reception. If reception is OK, problem
exists with antenna and/or its lead-in cable. If
reception is still poor, refer to SECTION 8A.
Chevrolet
1. Tum ignition to "ACCESSORY" or "RUN"

position.
2. Press "SET" and "000" appears on display.
3. Press "SCAN" and hold until first digit of secret
code appears.
4. Press "SEEK ~ or ~,, to make second and third
digits of code appear.
5. Press the lower knob (tune knob) and "000"
appears on display.
6. Press "SCAN" and hold until fourth digit of
secret code appears.
7. Press "SEEK ~ or r,;,." to make fifth and sixth
digits of code appear.
8. Press the lower knob (tune knob). If the unlock
sequence was successful, the display will show
the "Time of Day (CLOCK)," indicating the
radio is operational and in the SECURED mode.
If "LOC" shows, the numbers did not match and
the unit is still locked. Repeat steps 2 through 8.
RADIO FIXED ANTENNA DIAGNOSIS
RADIO POWER ANTENNA MOUNTING

AND CONNECTIONS
Poor grounding of the radio power antenna,
either at the antenna mounting or at any other
connection in the antenna/lead-in system, can result in
seriously reduced radio performance. A poor ground
can cause excess ignition noise in AM reception and
erratic audio.
To check for a poor ground of the radio power
antenna mast, perform the following:
1. Fully lower antenna.
2. Disconnect antenna motor electrical connector.
9A-14
AUDIO SYSTEMS
3. Remove escutcheon from fender.

4. Attach alligator clips to upper end of mast to act
as antenna. Leave other end of clip unattached.
5. Tune radio for weak AM station or signal which
is dependent on clip, i.e., clip attached, station is
present; clip removed, no station.
6. Remove clip.
7. Ground upper end of mast to body.
8. If radio station is not received, then antenna
grounds are good. If station is still present or
stronger, a poor ground or no ground connection
is preset in system.
Possible ground loss points are:
"Antenna upper mounting (bolts/screws loose,
paint overspray).
Coaxial connector at antenna (if applicable)
loose or corroded .. Remove to inspect inside
connector for corrosion.
Coaxial connector at extension cable (if
applicable) loose.
Coaxial connector at radio loose or corroded.
Antenna harness connector corroded.
RADIO POWER ANTENNA LEAD-IN

CABLE CHECK
been traced to moisture in the tube, the antenna must

be removed, disassembled, and thoroughly cleaned. All
moisture can be removed by blowing out with
compressed air, then pushing a clean dry cloth through
the support tube as far as possible Before assembling
antenna, check drain holes in motor housing to be sure
they are not obstructed.
RADIO SPEAKER DIAGNOSIS (CASSETTE

ONLY)
Tools required:
J 39916 Speaker Diagnostic Test Tape Kit
[I]
Important
Always compare the front speakers to front, and

rear speakers to rear. Do not compare front
speaker to rear speaker because they could be
different speakers or their mounting environment
could cause them to sound different.
Tones are used to test and evaluate coaxial
speakers or other complex speaker systems. There
are three basic tones used, 50 Hz tone, 500 Hz
warble tone, and 9k Hz spectral tone. The
combination tone is a blend of the above three
tones.
Figure 8
BASS/SUB-WOOFER TEST (50 Hz SINE TONE)
Usually, symptoms of a broken center conductor

of the lead-in cable will result in no AM and weak
FM. In case of continued reception or noise
complaints, always check the lead-in with a
multimeter. The chart and diagram in Figure 8 show
accurate readings. When checking resistance,
cautiously wiggle the lead-in tip and cable. If the
readings shown in Figure 8 are not obtained, some
portion of the lead-in is intermittent and the lead-in
should be replaced.
The 50 Hz tone is used to evaluate the bass

response of an audio system. This tone is also helpful
in evaluating audio systems which have separate
subwoofer amplifiers and speakers.
RADIO POWER ANTENNA CHECK

Figure 9
Improperly grounded antennas are usually the
cause of poor reception or noise complaints. To assure
a good ground, a braided ground strap should be
connected from the housing case to chassis ground.
After checking and repairing the antenna, always
make sure lead-in connector(s) are dirt and corrosion
free, and are tightly fastened.
The antenna can be checked by using a
multimeter. With the probes fastened to each point as
shown in Figure 9, wiggle the separate antenna
sections and antenna housing case. With a properly
grounded antenna, the readings shown should always
be obtained. If not, replace the antenna. Refer to
"Radio Power Antenna" under "On-Vehicle Service"
in this section.
~p
A-TIP
OHMMETER PROBES
AT POINTS:
D-METAL
CASE
C-METAL
B-ANTENNA
ASSEMBLY
RECEPTACLE
RESISTANCE MEASURED
IN OHMS
AANDB
LESS THAN 0.5
CANDD
LESS THAN 0.5
AANDD
INFINITE
CANDB
INFINITE
AANDC
INFINITE
BANDD
INFINITE
*ON SOME LONG LENGTHS OF LEAD-INS, SUCH AS RADIO

POWER ANTENNA ASSEMBLIES, CAPACITANCE IS ADDED
IN THE TIP. THISRESULTS IN A RESISTANCE READING OF
APPROXIMATELY 100,0000HMS.
MOISTURE IN RADIO POWER ANTENNA TUBE
Weak reception or fading may be caused by

moisture in the support tube, due to condensation or
leakage through the insulation bushings. If trouble has
012685
FSCICHA
Figure 8 - Lead-In Cable Diagnosis
AUDIO SYSTEMS 9A15
A}
balance controls are in the detent position. With these

voltage measurements, a determination can be made in
the diagnosis of speaker or amplifier.
MAST
SECTIONS
SPEAKER/GRILL RATTLE TEST (50 Hz TO Bk Hz

SWEPT SINE)
D - CENTER PIN
(INSIDE CONNECTOR)
The next portion of the tape can be used to

diagnose speaker and grill rattles. The first test is two
tones played back to back. The second test is a
variable frequency tone, but frequency change is at a
much slower rate. Both tests can be used to repair a
speaker rattle or buzz. If the problem has already been
isolated, the fade and balance controls can be set to
the proper location and the test tones can be played in
the specific problem area.
.,,.-
OHMMETER PROBES
AT POINTS:
C - BODY GROUND
RESISTANCE MEASURED
IN OHMS*
AANDD
LESS THAN 0.5
BANDC
LESS THAN 1 ;0
A ANO.C
INFINITE
FOR BEST RESULTS, USE A DIGITAL OHMMETER.

01-26-96
FS0109A
Figure 9 - Antenna Diagnosis (Typical)
MIDRANGE SPEAKER TEST (500 Hz WARBLE

TONE)
The 500 Hz warble tone is used for the

evaluation of midrange speaker response. This tone is
qualified as a warble tone because it has different
audio characteristics than a sine tone. This tone
produces a warble sound. At these tone midrange
frequencies, it is better to use a warble tone. than a
sine wave because the location of a warble tone
source, such as a speaker, is easier to identify. A
nonnal sine tone can set up a standing wave within a
vehicle which can make it difficult to determine its
source location.
TWEETER TEST (9k Hz SPECTRAL TONE)
The 9k Hz spectral tone is used for tweeter or

high frequency evaluation; This tone is a section of
frequencies of equal amplitudes ranging from 8.5k Hz
- 9.5k Hz. This sounds like a group of crickets
chirping. This type of tone is used for two reasons.
One, much like a warble tone, it is easy to locate its
source, and two, this type of tone is easier to identify
for those people with high end hearing loss problems.
ALL SPEAKER TEST
The combination tone can be used for numerous

audio problems such as distorted or no sound from
speaker(s). When using the combination tone,
comparative AC voltage measurements can be made
on the speaker terminals, provided the fade and
MOTOR SPEED TEST
There is a two minute time period marked in

this section of tape for the purpose of checking the
cassette tape motor speed. This portion of the
diagnostic tape can be used to verify complaints of
abnormal sound from the cassette tape player. In some
cases, improper tape motor speed can cause audio
abnormalities. If the time taken for this is between one
minute and fifty-six seconds to two minutes and one
second, the tape motor speed is within tolerance.
TAPE CLEANING PROCEDURES
The recommended time for cleaning is every

fifteen hours for best performance .and every fifty
hours to prevent damage to the tape head. The
preferred tape cleaner is available as a part of the
Audio System Kit PIN J 39916.
NOISE DIAGNOSIS (DEAD SPACE)
This portion can be used for noise diagnosis

such as alternator whine, switch pops, etc. which can
be more easily detected during dead space (blank
space in between songs). This portion of the diagnostic
tape may be used in conjunction with noise diagnosis
in Section SA.
ON-VEHICLE SERVICE
TAPE PLAYER AND CASSETTE CARE
TAPE HEAD AND CAPSTAN CLEANING
Figure 10
Two parts should be cleaned on the tape player,
the head and the capstan. Since they can be reached
through the tape door, leave the tape player in the
vehicle. This service should be performed every
50 hours of cassette .operation.
To clean the head and capstan, use a cotton swab
dipped in rubbing alcohol.
A cassette cleaning kit may also be used to clean
the head and capstan. Follow instructions on the kit to
clean the tape player.
9A-16
AUDIO SYSTEMS
RADIO
Refer to SECTION 8C for removal and
SPEAKERS
For removal and installation of radio front side

door speakers, refer to SECTION 10-6. For removal
and installation of rear speakers (including the Bose
amplifier), refer to SECTION 10-7.
[I]
01-26-915
fS0119A
Figure 10 - Cleaning Cassette Player
Do not contact the tape head with magnetized

tools. If the head becomes magnetized, it. will degrade
every cassette played in the player.
The Pontiac tape deck has an added function that
helps prevent damage if the cassette tape would break
or become jammed. This tape deck may eject the
scrubbing-type cleaning cartridge after about five
seconds. Therefore, it may be necessary to insert the
scrubbing-type cleaner at least three times to
thoroughly clean the deck.
A non-scrubbing, wet type tape cleaner could be
used in replace of the scrubbing-type. This type uses a
fabric belt in place of the tape and will not eject after
five seconds. However, it may not provide as thorough
a cleaning as the scrubbing-type cleaner.
No service is performed on the cassettes. The
cassette manufacturer handles warranties of cassettes.
The test cassette used by the dealer should be stored
in its container to. keep the tape clean. Store cassette
away from extreme heat and direct sunlight.
Important
All Delco sound systems have ungrounded

speakers. Installing add-on tape players, CBs or
other units which use the vehicle speakers may
damage your Delco sound system, and is not
recommended.
RADIO SUPPRESSION EQUIPMENT

When installing a new radio, or when noise is a
problem, ensure that radio suppression equipment is
present and properly installed. Refer to "Noise
Diagnostic Charts" in SECTION 8A for determining
locations.
RADIO FIXED ANTENNA

Figure 11
Tool Required:
J 38536-A Antenna Bezel Socket
I+-+!
1. Using J 38536-A loosen nut (2).

2.
3.
4.
5.
Antenna base (3) from spare tire bracket.

Nut (2) and bezel (1).
Top of antenna base (3) from rear quarter panel
Cable (4) from antenna base (3).
RADIO POWER ANTENNA CARE

Periodic cleaning may be necessary to assure
proper radio power antenna operation.
CLEANING THE RADIO POWER ANTENNA:
1. Actuate antenna to full extension.

2. Dampen clean cloth with mineral spirits.
3. Wipe cloth over antenna sections removing any
dirt.
4. Actuate antenna through one complete cycle
(retract and extend).
5. Repeat steps 1 through 4 at least two more times.
COMPACT Disc CARE

Handle discs carefully. Store in protective case
away from sun, heat and dust. If surface is soiled,
dampen a clean, soft cloth in a solution of mild
neutral detergent and wipe clean. Mini discs called
"singles" (about 3 inches in diameter) will not eject
and should not be used.
A
B
1
2
3
4
PANEL, REAR QUARTER

BRACKET, SPARE TIRE
BEZEL, FIXED MAST ANTENNA
NUT, FIXED MAST ANTENNA
BASE, ANTENNA
CABLE, INSTRUMENT PANEL HARNESS
01-21595
FS0129A
Figure 11 Radio Fixed Antenna Mounting
AUDIO SYSTEMS 9A-17
E3
j++I
Install or Connect
CAUTION; If substituting an antenna or

cable, be sure to use a barbless-type
connector. Incorrect connectors may
cause poor reception or damage to
connectors.
NOTICE:
1. Cable (4) into antenna base (3).

2. Top of antenna. base (3) into hole in rear
quarter panel.
3. Bezel (1) to antenna base (3) and secure with
nut (2) (finger tighten only).
4. Bottom of antenna base (3) into spare tire
bracket.
!~I .Tighten
Nut (2) to 3 N.m (34 lb. in.) using J 38536-A.
RADIO POWER ANTENNA
1. Quarter inner rear trim finishing panel. Refer to

SECTION 10-7.
2. Jack and spare tire. Refer to SECTION 3E.
3. Cable (4) from antenna cable connector.
4. Electrical connector from power antenna (6).
5. Nut (2) from power antenna (6) using J 38536.
6. Bezel (1) from power antenna (6).
7. Drain tube and grommet (7) from rear quarter
panel.
8. Bolt/screw (5) from power antenna (6) and spare
tire bracket.
9. Power antenna (6).
l++l
Install or Connect
NOTICE:
1. Power antenna (6).

2. Bolt/screw (5) to power antenna (6) and spare tire
bracket.
I~!
Tighten
Bolt/screw (5) to 5 N.m (44 lb. in.)

3. Drain tube and grommet (7) to rear quarter panel.
4. Bezel (1) to power antenna (6).
5. Nut (2) to power antenna (6) using J 38536.
Figure 12
Tool Required:
J 38536 Antenna Bezel Socket
l~I
6.
7.
8.
9.
Tighten
Nut (3) to 3 N.m (34 lb. in.).

Electrical connector to power antenna (6).
Cable (4) to antenna cable connector.
Jack and spare tire. Refer to SECTION 3E.
Quarter inner rear trim finishing panel. Refer to
SECTION 10-7.
RADIO POWER ANTENNA MAST

7
Figures 13 and 14
Tool Required:
J 38536 Antenna Bezel Socket
!++!
~8
1. Antenna nut (2) using J 38536,
rn
5
A
1
2
4
5
6
7
PANEL REAR QUARTER

BEZEL, POWER ANTENNA
NUT, POWER ANTENNA
CABLE, INSTRUMENT PANEL HARNESS
BOLT/SCREW, ANTENNA BRACKET
ANTENNA, POWER RADIO
TUBE, ANTENNA DRAIN
Important
Do not pull antenna mast (10) by hand to

remove it.
2. Antenna mast (10).
01-26-95
FS0139A
Figure 12 - Radio Power Antenna Mounting (Chevrolet

Shown - Pontiac Similar)
A. Tum on ignition switch and radio.

B. Remove antenna mast (10) and contact spring
(9).
Note orientation of serrated side of plastic

cable for proper placement during installation.
9A-18
AUDIO SYSTEMS
Clean
Contact spring (9) with contact cleaner.
!++I
Install or Connect
NOTICE:
NOTICE: Serrated side of plastic cable must

face antenna motor. Plastic cable could be
damaged if not properly oriented.
1. New antenna mast (10) into antenna housing.
A. Insert plastic cable into housing oriented as
noted during removal, and stop when
resistance is felt (approximately 30 cm
[12 inches]).
B. Turn ignition switch to "OFF" position so that
plastic cable retracts into housing and catches
onto gear mechanism of drum housing.
C. If plastic cable does not retract into housing,
rotate cable clockwise and/or counterclockwise
until cable retracts into housing with motor
operating.
2. Contact spring (9) onto antenna mast (10).
2 NUT, RADIO POWER ANTENNA

9 SPRING, ANTENNA MAST CONTACT
10 ANTENNA MAST, RADIO
01-25-fl
FS0141A
Figure 13 - Radio Power Antenna Mast
Make certain flanged end of contact spring (9)

faces upward.
3. Antenna nut (3) using J 38536.
l~I
Tighten
Antenna nut (2) to 3 N.m (34 lb. in.).
!L"'I
Inspect
Antenna operation.
-
Cycle antenna several times. Antenna mast

(10) may only extend or retract halfway.
Continue to operate antenna until antenna mast
(10) will fully extend and retract.
10 ANTENNA MAST, RADIO
01-21-15
FS0111A
Figure 14 - lnstall.ing Radio Power Antenna Mast ,
S.PECIFICATIONS
Radio Antenna Nut. .................................................................................................................. 3 N.m (34 lb. in.)
Radio Antenna Bracket Bolt/Screw ......................................................................................... 5 N.m (44 lb. in.)
AUDIO SYSTEMS 9A-19
SPECIAL TOOLS
2
J 39916
1 ANTENNA BEZEL SOCKET

2 DIAGNOSTIC TEST TAPE KIT
012586
FS0189A
9A20
AUDIO SYSTEMS
BLANK
CRUISE CONTROL
981
SECTION 98
\
CRUISE CO
ROL
torque and the joint clamping force, and may damage the fastener ..When you install fasteners, use the correct
systems.
CONTENTS
General Description................................................. 9B-1
Cruise Control Module ....................................... 9B-1
Cruise Control Switches ..................................... 9B-2
Speed Sensor ....................................................... 9B-2
Vehicle Speed Sensor (VSS) .......................... 9B-2
Functional Control Switches ............................... 9B-2
Off-On-Resume/Accelerate Switch ................. 9B-2
Set/Coast Button Switch ................................. 9B-2
Diagnosis .................................. Refer to SECTION 8A
On-Vehicle Service ................, .. ;.............................. 9B-3
Accelerator Control/Cruise Control Servo
Cable Adjuster (Throttle
Relaxer) ............................ Refer to SECTION 5E2
Cruise Control Switches ..................................... 9B-3

Engagement Switch ............................................. 98-3
Cruise Control Module ....................................... 9B-4
Cruise Control Cable .......................................... 9B-6
Cable Replacement (Standard) ....................... 9B-6
Cable Replacement (Optional) ........................ 98-6
Cable Adjustment (Standard) ......................... 9B-7
Cable Adjustment (Optional) .......................... 9B-7
Specifications ........................................................... 9B-9
Fastener Tightening Specifications ..................... 9B-9
Special Tools ........................................................... 9B-9
GENERAL DESCRIPTION
speed limit which will prevent system engagement

below a minimum speed of 40 km/h (25 mph). The
operation of the controller is controlled by functional
control switches located on the turn signal and
headlamp dimmer switch and cruise control actuator
and windshield wiper and windshield washer lever.
Cruise control release switch, stoplamp and TCC
switch, and clutch or clutch anticipate switches are
provided to disengage the cruise system. The switches
are mounted on the brake and accelerator and clutch
pedal bracket. When the brake pedal or clutch pedal is
depressed, the cruise control system is electrically
disengaged and the throttle is returned to the idle
position.
Cruise control is a speed control system that

maintains a desired vehicle speed under normal
driving conditions. However, steep grades up or down
may cause variations in the selected speeds. The
electronic cruise control system has the capability to
cruise, coast, resume speed, accelerate, and raise
"tap-up" or lower "tap-down" set speed in increments
of 1.6 km/h (1 mph) when tapping-up or
tapping-down.
The main parts of the cruise control system are
the functional control switches, cruise control module,
vehicle speed sensor, cruise control release switch,
stoplamp and torque converter clutch (TCC) switch,
and clutch (5.7L VIN P) or clutch anticipate (3800
VIN K) switches and wiring harnesses that connect
them.
The cruise control system uses a cruise control
module to obtain the desired vehicle cruise operation.
1\vo important components in the module help to do
this. One is an electronic controller and the second is
an electric stepper motor. The controller monitors
vehicle speed and operates the electric stepper motor.
The motor moves a ribbon and throttle linkage, in
response to the controller, to maintain the desired
cruise speed. The cruise control module contains a low
NOTICE: If vehicle is equipped with traction

control (acceleration slip regulation), in a low
traction situation the cruise control will
disengage.
CRUISE CONTROL MODULE

The cruise control module is mounted on the left
engine compartment inner side rail. The module has
an electronic controller and an electric stepper motor
to vary the throttle with each different cruise control
mode. The module is not serviceable.
982
CRUISE CONTROL
CRUISE CONTROL SWITCHES

The cruise control release switch, stoplamp and
TCC switch, and clutch or clutch anticipate switches
are used to disengage the cruise control system. A
release switch, a stoplamp and TCC switch, and a
clutch or clutch anticipate switch mounted on the
brake pedal bracket disengage the system electrically
when the brake pedal or clutch pedal is depressed.
This is done by activating the brake cut-out input to
the cruise control module. The set speed will be
retained in memory when the brakes are activated. The
stoplamp and TCC switch has a three-wire stoplamp
connector and a two-wire TCC connector on automatic
transmission only. The cruise control release switch
has a two-wire cruise control disable connector. The
clutch switch (5.7L VIN P) has a two-wire cruise
control disable connector and the clutch anticipate
switch (3800 VIN K) has a four-wire cruise control
disable connector.
SPEED SENSOR
Vehicle Speed Sensor (VSS)
The vehicle speed sensor (VSS) is mounted to
the automatic or manual transmission and produces an
alternating current (ac) signal. The frequency of this
signal is proportional to the speed at which the
automatic transmission output shaft rotates, which in
turn, is proportional to the speed of the vehicle.
The ac signal produced by the VSS is supplied
to the powertrain control module (PCM).
The PCM internally converts the ac signal to a
4,000 pulses per mile signal. It then delivers that
signal to the cruise control module and speedometer.
For removal procedure, refer to SECTION 7A or
to SECTION SA for diagnostic information.
FUNCTIONAL CONTROL SWITCHES

Off-On-Resume/Accelerate Switch
Figure 1
[TI
Important
Vehicle IS equipped with a "Set To Get Cruise"

feature requiring Operator to use the
"SET/COAST" button before
"RESUME/ACCEL" slider switch will activate.
The "OFF-ON-RI A" switch (2) has three
positions. This switch turns the cruise control system
"ON" and "OFF" and also returns cruise control
operation to the last speed setting when momentarily
moved toward the "RIA" (RESUME/ACCELERATE)
position after braking. If the "OFF-ON-RIA" switch
(2) is held in the "RI A" position for more than one
second, the system goes into the acceleration mode to
accelerate the vehicle. Move the switch (2) to the
"RI A" position and hold it there until the vehicle
reaches the desired speed. When the "OFF-ON-RIA"
switch (2) is released, the system will cruise the
vehicle at the speed it was going when the switch was
released. In order to use the acceleration mode, the
"OFF-ON-RI A" switch (2) must be in the "ON"
position and the vehicle must be above the low speed

limit of 40 km/h (25 mph), with a set speed already in
memory.
The "OFF-ON-RIA" switch (2) can also be used
to raise "tap-up" vehicle speed. In order to do this the
cruise control system must be engaged and operating.
"Tapping-up" is done by quickly pressing the
"OFF-ON-RI A" switch (2) toward the "RI A" position
and quickly releasing it, or "tapping" the
"OFF-ON-RIA" switch (2). Do not hold the
"OFF-ON-RIA" switch (2) in the "RIA" position, or
the system will go into the acceleration mode.
"Tap-up" is a function in which cruise speed can be
increased by 1.6 km/h (1 mph) increments (one tap =
1.6 km/h (1 mph) increase).
Set/Coast Button Switch

Figure 1
The cruise control "SET/COAST" button switch
(3) (located in the end of the turn signal and headlamp
dimmer switch and cruise control actuator and
windshield wiper and windshield washer lever ) has
two positions -"NORMAL" and "DEPRESSED."
The Set Position - With the "SET/COAST"
button switch depressed and then released (vehicle
speed must exceed the low speed limit point, and
the "OFF-ON-RIA" switch (2) must be in the
"ON" position), the cruise speed will be set at
the speed the vehicle was going when the
"SET/COAST" button switch (3) was released.
Vehicle cruise speed will be within " 1.6 km/h (1
mph) of the actual speed at engaged speed. The
system will cruise until either the "OFF-ON-RI A"
switch (2) is moved to "OFF," the ignition switch
is turned "OFF," and/or the "SET/COAST"
button switch (3) is pushed in fully and held.
Pushing the brake pedal releases the
"SET/COAST" button switch (3) but not the
resume capability.
The Coast Position - With the "SET/COAST"
button switch (3) fully depressed, the driver can
lower vehicle speed. To decrease cruise speed, the

2 SWITCH, OFF-ON-RESUME/ACCELERATE
3 SWITCH, SET/COAST BUTTON
012495
U:800198
Figure 1 Cruise Control Actuator Lever (Typical)
CRUISE CONTROL
"SET/COAST" button switch (3) is held in,

disengaging the cruise system, which allows the
throttle to return to the idle position. When the
vehicle has slowed to the desired cruise speed,
releasing the "SET/COAST" button switch (3)
will re-engage the system at the new selected
speed.
The "Tap Down" Position - To lower "tap down"
the cruise must be engaged and operating.
"Tapping-down" is done by quickly pressing and
releasing the "SET/COAST" button switch (3), or
"tapping" the "SET/COAST" button switch (3).
Do not hold the "SET/COAST" button switch (3)
in the depressed position or the system will go
into the coast mode. "Tap-down" is a function in
which cruise speed can be decreased by 1.6 km/h
(1 mph) increments (one tap = 1.6 km/h (1 mph)
decrease). The accelerator pedal may be depressed
at any time to override the cruise system. Release
of the accelerator pedal will return the vehicle to
the previously set cruise speed.
CAUTION: To keep the vehicle under

control, and to prevent possible personal
injury and vehicle damage, the cruise
control should not be used on slippery or
winding roads or in traffic of heavy or
varying volume. When traveling down a
steeply graded hill, the cruise control
should be disengaged by depressing the
brake pedal lightly. The automatic
transmission can then be shifted into a
lower gear range to help control vehicle
speed.
ON-VEHICLE SERVICE
CRUISE CONTROL SWITCHES
Figure 2
ADJUSTMENT
The release switch (6) must be adjusted at the

same time the stoplamp and torque converter clutch
(TCC) switch is adjusted. The clutch switch (5) or
clutch anticipate switch (4) cannot be adjusted until
after clutch pedal (20) is installed.
NOTICE:
Proper stoplamp switch adjustment

is essential. Improper stoplamp switch
adjustment will cause brake drag and excessive
brake lining wear.
Ill
Adjust
1. To adjust, depress brake pedal or clutch pedal and

insert release switch (6), stoplamp and TCC
switch (7), and clutch switch (5) or clutch
anticipate switch (4) into pedal with bracket (20
or 21) until retainer on release switch (6),
stoplamp and TCC switch (7), or clutch switch (5)
or clutch anticipate (4) is fully seated.
98-3
NOTICE: Make sure to apply the proper

amount of force to the brake pedal during
adjustment. Too much force could damage the
vacuum booster. Too little could cause dragging
brakes.
2. Slowly pull brake or clutch pedal rearward with a
force of 222 N (50 pounds) until "click" sounds
can no longer be heard. At this point, release
switch (6), stoplamp and TCC switch (7), and
clutch switch (5) or clutch anticipate (4) will have
moved retainers to their original position.
!@!
Measure
The release switch and stoplamp and TCC switch

contacts should be open at 25.4 mm (1 inch) or
less of pedal travel, and occur at the same time or
before the onset of braking. The brake pedal
travel can be up to 25.4 mm (1 inch) before the
cruise control system disengages.
REPLACEMENT
I++!
1. Left-hand instrument panel sound insulator.

3. Release switch (6), stoplamp and TCC switch (7),
and clutch switch (5) or clutch anticipate switch
(4), if equipped, from pedal with bracket (20 or
21).
I++!
Install or Connect
1. Release switch (6), stoplamp and TCC switch (7),

(4), if equipped, to pedal with bracket (20 or 21).
3. Left-hand instrument panel sound insulator.
~ Adjust
Release switch (6), stoplamp and TCC switch (7),
(4) as outlined above.
ENGAGEMENT SWITCH
Figure 3
The Turn signal and headlamp dimmer switch
and cruise control actuator and windshield wiper and
windshield washer lever (multi-function lever) cannot
be serviced. The complete lever must be replaced.
!++!

Cable " in SECTION OA.
2. Steering column access cover.
Make sure windshield wiper switch is in the
"OFF" position.
98-4
CRUISE CONTROL
20
21
19
A
B
C
D
E
F
G
H
J
4
5
6
7
19
20
21
MANUAL TRANSMISSION
WITH 3800 L36 ENGINE
WITH 5.7L LT1 ENGINE
ANTICIPATE
SWITCH, CRUISE CONTROL RELEASE
SWITCH, STOPLAMP AND TORQUE
CONVERTER CLUTCH
SWITCH, CLUTCH START
CLUTCH (WITH BRACKET!
PEDAL. BRAKE ANO ACCELERATOR (WITH
BRACKET)
(
012481
F80029B
Figure 2 - Cruise Control Switches
4. Lever (1) by pulling it straight out
lHI
Install or Connect
L Lever (1).
Align tang on lever (1) to notch on column (8)
and push in until fully seated.
3. Steering column access cover.
CRUISE CONTROL MODULE

Figure 4
The cruise control module (11) is mounted on
the left engine compartment inner side rail using two
cruise control module bracket bolts/screws (16).
!++j
2. Accelerator control cable splash shield from

throttle body, if equipped.
3. Left-hand front bumper fascia lower deflector.
Refer to SECTION 10-4.
4. Cruise -control cover (13) to access connectors.
5. Electrical connector from cruise control module
(11).
6. Cruise control cable from cruise control module.
Refer to "Cable Replacement" in this section.
8. Cruise control module (11) with bracket (12) from
left engine compartment inner side rail.
9. Bolts/screws (10) attaching cruise control module
(11) to bracket (12).
10. Cruise control module (11) from bracket (12).
I++!
Install or Connect
NOTICE:
1. Accelerator control cable splash shield

bolts/screws from throttle body, if equipped.
1. Cruise control module (11) to bracket (12).
CRUISE CONTROL 985

3. Cruise control module (11) with bracket (12) to
left engine compartment inner side rail.
!~J

5. Cable to module. Refer to "Cable Replacement"
in this section.
6. Electrical connector to cruise control module (11).
7. Cruise control cover (13) over connectors.
8. Left-hand front bumper fascia lower deflector.
9. Accelerator control cable splash shield to throttle
body, if equipped.
10. Accelerator control cable splash shield
bolts/screws to throttle body, if equipped.
A
B
C
1
COVER.ACCESS
TANG
LEVER, TURN SIGNAL AND HEADLAMP
AND WINDSHIELD WIPER AND WINDSHIELD WASHER.
8 COLUMN, STEERING
012485
!~! Tighten
FS0039B
Figure 3 Engagement Switch
2. Bolts/screws (10) attaching cruise control module

(11) to bracket (12).
I~!
Tighten
Accelerator control cable splash shield

bolts/screws to. 1.9 N.m (17 lb. in.).
Adjust
Cable, if necessary. Refer to "Cable Adjustment"

in this section.
Tighten
A
10
11
12
13
BOLT/SCREW, CRUISE CONTROL
MODULE, CRUISE CONTROL
BRACKET, CRUISE CONTROL MODULE
COVER, CRUISE CONTROL
14
-15
16
17
CABLE, CRUISE CONTROL

HARNESS. FORWARD LAMP WIRIN.G
BOLT/SCREW, CRUISE CONTROL MODULE BRACKET
012491
FS004tB
Figure 4 - Cruise Control Module
98-6
CRUISE .CONTROL
A. Attach cable bead to cruise motor ribbon end
fitting on cruise control module (11).
B. Pull engine end of cable (14) until it is taut.
C. Turn engine end of cable until ribbon is flat.

Figures 5 through 7
The cable (14) is connected between: the cruise
control module ( 11) and the throttle body lever, or
accelerator control/cruise control servo .cable adjuster,
if equipped.
[II
Cable Replacement (Standard)
E3
2.
1. Cable (14) and conduit from engine bracket.

2. Cable end fitting from throttle body lever stud.
3. Cruise control retainer (18) at cruise control
module.
4. Cable (14) from cruise control module (11).
A. Compress conduit tangs and pull out of cruise
control module housing. (11).
B. Disconnect cable bead from cruise motor band
end fitting on cruise control module (11).
C. Note routing and remove cable (14) from
vehicle.
l++I
3.
4.
5.
Important
Ribbon must not be twisted.

- Slide cable conduit fitting over ribbon and
snap into module housing assuring that
both tangs are engaged.
Cruise control .retainer (18) at cruise control
module ( 11 ).
Cable (14) to vehicle.
Use routing noted during removal.
Cable end fitting to throttle body lever stud.
Cable (14) and conduit to engine bracket.
~ Adjust
Cable. Refer to "Cable Adjustment (Standard)" in
this section.
Cable Replacement (Optional)

Figures 5 through 8
Install or Connect
1. Cable (14) to cruise control module (11).
[I]
Important
If vehicle is equipped with accelerator
control/cruise control servo cable adjuster (throttle

relaxer), follow these procedures to replace cable.
I+-+!
A RIBBON
B BEAD
11 MODULE, CRUISE CONTROL
14 CABLE, CRUISE CONTROL
012495
F80059B
1. Cover (19).
2. Cable (14) and conduit from engine bracket.
3. Cable end fitting from accelerator control/cruise
coritrol servo cable adjuster (20).
module.
Figure 5 - Cable Bead to Cruise Control Module .
A RIBBON
B RIBBON MUST NOT BE TWISTED .
C MARKINGS IN YELLOW FOR LTl ENGINE,
PINK FOR L36 ENGINE
D BEAD
E LOCKING TAB
Figure 6 Pulling Cruise Control Cable
08129S
FT0081B
CRUISE CONTROL 987

5. Cable (14) and conduit to engine bracket.
NOTICE: The adjuster assembly wiring

harness must be routed between the adjuster
assembly motor and the mounting stud and nut.
The cable must not be placed under the motor
in a position that ~reates str~s~ on the cov~r
hinge. Make certam the wmng har~e.ss 1s
contained inside the. cover and also that 1t 1s not
pinched by the flap when closed.
6. Cover (19).
Cable.Refer to "Cable Adjustment (Optional)" in

this section.
If replacing accelerator pedal/cruise control
cable, refer to SECTION 5E2 for replacement and
adjustment procedures.
D
A CONDUIT
B TANG
HOUSING
D END FITIING
E LOCKING TAB
18 RETAINER, CABLE CONTROL
Cable Adjustment (Standard)
081595
FT0079B
Figure 7 Installing Cruise Control Cable to Cruise Control

Module
5. Cable (14) from cruise control module (11). . .

A. Compress conduit tangs and pull out of cruise
control module housing.
B. Disconnect cable bead from cruise motor band
end fitting on cruise control module (11).
C. Note routing and remove cable (14) from
vehicle.
Install or Connect
1. Cable (14) to cruise control module (11).

A. Attach cable bead to cruise motor ribbon end
fitting on cruise control module ~11) ..
B. Pull engine end of cable (14) .un~l 1t 1s_ taught.
C. Turn engine end of cable until nbbon 1s flat.
rn
Adjust
Important
Ribbon must not be twisted.

- Slide cable conduit fitting over ribbon and
snap into module housing assuring that
both tangs are engaged.
module (11).
3. Cable (14) to vehicle.
Use routing noted during removal.
4. Cable end fitting to accelerator control/cruise
control servo cable adjuster (20).
Install slug of cable into cam of throttle
relaxer before installing cable end fitting to
adjuster.
With throttle closed, lock cable conduit by

pressing down on lock button.
A. Pull cruise cable adjust slider rearward. out of
adjuster to remove cable slack without moving
throttle lever from its idle stop. Push down cruise
cable adjust lock button until it snaps and locks
.
.
into place.
B. A gap O - 2 mm (0.07 inch) between termmal end
of cable to the plastic connector that snaps on to
throttle body 1ower is allowed when checking for
this condition. Pull on terminal end making sure
connector to throttle body is hard against its
fitting. If more than 2 mm (0.07 inch) exist,
readjust cable.
Cable Adjustment (Optional)

To manually adjust the cable (14):
A. Place fmger on throttle making sure throttle arm
is hard against stop.
B. Pull cable ( 14) to remove slack from cable.
rn
Important

C. Press locking tab down to retain cable.
rn
Important
Cable should never be adjusted so tight that

tension from cable will not allow throttle to
close solidly. If cable is adjusted too tight, the
cable will prevent engine from returning to
idle and will cause unstable idle quality.
98-8
CRUISE CONTROL
3800 L36 ENGINE
5. 7L LTl ENGINE
A
B
14
19
CABLE ENO FITIING

CABLE LOCKING TAB
CABLE, CRUISE CONTROL
COVER, ACCELERATOR CONTROL/CRUISE CONTROL
SERVO CABLE ADJUSTER
20 ADJUSTER, ACCELERATOR CONTROL/
CRUISE CONTROL SERVO CABLE
21 CABLE, ACCELERATOR PEDAL/CRUISE CONTROL
19
012418
F800898
Figure 8 Cable Replacement
CRUISE CONTROL
98-9
SPECIFICATIONS
Accelerator Control Cable Splash Shield Bolt/Screw ........................................................... 1.9 N.m (17 lb. in.)
Cruise Control Bolt/Screw ........................................................................................................ 6 N.m (53 lb. in.)
Cruise Control Module Bracket Bolt/Screw ........................................................................... 10 N.m (89 lb. in.)
SPECIAL TOOLS
1.
1. FLUKE 87 KIT
J 39200
OM!4-95
FSOOHllil
98-10
CRUISE CONTROL
BLANK
THEFT DETERRENT SYSTEMS 90-1
SECTION 90
THEFT DETERRENT SYSTEMS

systems.
CONTENTS
PASS-Key II SYSTEM ....................................... 9D-2
General Description ................................................ 9D-2
System Operation ............................................ ,,.. 9D-2
System Components ........................................... 9D-2
Ignition Key ................................................... 9D-2
Steering Column Lock and Ignition
Cylinder ...................................................... 9D-2
Body Control Module (BCM) ....................... 9D-3
Ignition Input .................................................. 9D-3
Key Resistor Inputs ........................................ 9D-3
Starter Enable Output .................................... 9D-3
Fuel Enable Output. ....................................... 9D-4
Security Indicator Lamp Output .................... 9D-4
Theft Deterrent Relay .................................... 9D-4
Powertrain Control Module (PCM) ............... 9D-4
Diagnosis ....................................... Refer to Section 8A
On-Vehicle Service ................................................. 9D-4
Ignition Key ....................................................... 9D-4
Duplicating Ignition Keys .............................. 9D-4
Replacing Lost Ignition Keys ........................ 9D-4
Programming a New Body Control
Module (BCM) ............................................... 9D-4
Cylinder ................................. Refer to Section 3F5B
Theft Deterrent Relay ........................................ 9D-5
Powertrain Control Module
(PCM) ..................................... Refer to Section 6E
UNIVERSAL THEFT DETERRENT
SYSTEM..................................................... 9D-5

System Operation .............................................. 90-5
Arming the System ..... :................................. 90-5
Locking without Arming .............................. 90-6
Disarming the System................................... 90-6
Deactivating the Alarm ................................. 90-6
System Components .......................................... 90-6
Body Control Module (BCM) ...... ,............... 90-6
Remote Control Door Lock Transmitter ...... 90-6
Shock Sensor ................................................. 90-6
Starter Enable Output ................................... 9D-7
Fuel Enable Output. ...................................... 90-7
Security Indicator L.E.D. Output ................. 90-7
Door Jamb and Rear Lid Release
Switches ..................................................... 90-7
Horn and Parking Lamp Relays ................... 90-7
Diagnosis ....................................... Refer to Section 8A
On-Vehicle Service................................................ 90-7
Feature Customization....................................... 90-7
Programming Mode ...................................... 90-7
Customization Charts .................................... 90-7
Body Control Module ............... Refer to Section 80
Remote Control Door Lock
Transmitter ............................. Refer to Section 9K
Security Indicator L.E.D ................................... 90-9
Shock Sensor ..................................................... 90-10
Horn and Parking Lamp
Relays ..................................... Refer to Section 8B
Special Tools ......................................................... 90-11
902 THEFT DETERRENT SYSTEMS
PASS-Key II SYSTEM
GENERAL DESCRIPTION
The personal automotive security system
(PASS-Key II) is standard equipment on this vehicle.
The system is designed to prevent vehicle theft by
disabling the engine unless an ignition key with a
specific electrical resistance is used in the ignition
cylinder. The PASS-Key JI system and the universal
theft deterrent (optional) operate completely separate.
The components of the system are the ignition key, the
ignition cylinder, the body control module (BCM), the
theft deterrent relay, and the powertrain control
module (PCM).
SYSTEM OPERATION
The PASS-Key II system is designed to
prevent the engine from starting if the proper
resistance is not sensed from the ignition key. Of the
15 key codes (resistance values) available, only one
will work with each BCM. Once the key code is
programmed into the BCM, the resistance value is
stored in a non-volatile memory.
The PASS-Key II system prevents the engine
from starting by controlling the theft deterrent relay
and the PCM fuel enable input. If the PCM does not
sense the proper frequency signal on the fuel enable
input, it will not provide fuel to the engine.
If the wrong resistance value is sensed when the
ignition switch is in the "RUN" position, the BCM
will not ground the starter enable circuit and will not
output the fuel enable signal for approximately three
minutes. This prevents the engine from starting and
discourages the thief from trying key codes (resistance
values) at random.
If the correct resistance value is sensed when the
ignition switch is in the "RUN" position, the BCM
will ground the starter enable circuit and output the
fuel enable signal. This will allow the engine to start
normally.
If the PASS-KEY II system detects an open or

short to ground when the ignition switch is in "RUN"
position, the BCM will default to fail enable. Fail
enable occurs when the proper key resistance has been
sensed before the open or short to ground occurs. Fail
enable will illuminate the security indicator lamp and
allow the operator to stop and start the vehicle until
the problem is corrected.
SYSTEM COMPONENTS
Figure 1
Ignition Key
The ignition key for vehicles equipped with .the
PASS-Key II system is an assembly of a typical
square ignition key blank and resistor. The ignition
key blank and resistor are not serviceable separately.
There are 15 different different resistance values. The
ignition key also has mechanical cuts similar to
non-PASS-Key II ignition keys.
II]
Important
When servicing the PASS-Key II system, obtain

all ignition keys, if possible, and verify proper
values with tool J 35628-A, VATS/PASS
Interrogator. Refer to "Duplicating Ignition Keys"
in this section.
Steering Column lock and Ignition

Cylinder
Figure 2
The ignition cylinder in vehicles equipped with
the PASS-Key II system contains a set of electrical
contacts used to measure the resistor in the ignition
key. When servicing the ignition cylinder, be certain to
maintain proper wire routing. A two pin connector at
the base of the steering column connects the contacts
~
2
1 MODULE, BODY CONTROL

2 KEY, THEFT DETERRENT IGNITION
3 CYLINDER, STEERING COLUMN LOCK
AND IGNITION
4 RELAY, THEFT DETERRENT
5 MODULE, POWERTRAIN CONTROL
Figure .1 PASS-Key II System Components (Typical)
(
05011115
FT0019D

to the vehicle wiring. The connector is also used for
diagnostic purposes. The ignition cylinder also
performs all functions of ignition cylinders on
non-PASS-Key II vehicles. When replacing an
ignition cylinder, it will be necessary to make new
ignition keys which match the PASS-Key II key
code of the BCM and the mechanical cut of the new
ignition cylinder.
rn
Important
The wire routing for the contacts inside the

steering column is critical.

The BCM contains the logic of the PASS-Key
II system. The. BCM has inputs from the battery,
ignition circuits, key resistor, shock sensor, and door
lock, door jamb and hatch switches. The BCM has
outputs to the starter enable circuit, the fuel enable
circuit, the security lamp circuit, and the remote hatch
release. The BCM also controls power locks, interior
lights, horn chirps and parking light flashes for locking
and arming functions.
The BCM has some diagnostic features,
including diagnostic trouble codes. For details, refer to
SECTION 8D.
Ignition Input
The ignition input is used to tum the BCM on.
When the BCM is turned on, it will read the resistor
and control the outputs accordingly. When the BCM is
turned off the resistor is not read, and the theft
deterrent relay and fuel enable output will not allow
the engine to start. When the ignition switch is in the
"OFF" position, the battery input to the BCM will
draw about 75 milli-amps for the first 10 minutes and
about 2.4 milli-amps after 10 minutes of ignition off.
Key Resistor Inputs

The key resistor inputs are used to determine if
the correct ignition key is being used to start the
vehicle. The key resistor inputs are read when the
ignition.is ~~ed on. If the key code (resistance value)
of the 1gmt1on key matches the value stored in the
B~M, the theft de!errent relay and fuel enable output
will allow the vehicle to start. If the resistance value
of the ignition key does not match the value stored in
the BCM, the relay and fuel enable output .will not
allow the vehicle to start.
Starter Enable Output

The starter enable circuit controls the theft
deterrent relay. When the BCM sees the proper
resistance at the . ignition key, it grounds the starter
enable circuit which allows the engine to be cranked.
If the BCM does not sense the proper resistance at the
ignition key, it will not ground the starter enable
circuit.
A PROPER WIRE ROUTING FROM STEERING COLUMN

LOCK AND IGNITION CYLINDER ASSEMBLY
(DO NOT TWIST WIRES)
B CUTOFF WIRE RETAINER LEG
ON ORIGINAL CONNECTION WHEN REPLACING
STEERING COLUMN LOCK AND IGNITION
CYLINDER ASSEMBLY
2 KEY ASSEMBLY, THEFT DETERRENT IGNITION
3 CYLINDER ASSEMBLY, STEERING COLUMN LOCK
AND IGNITION
Figure 2 - Ignition Cylinder Wire Routing
05-18-95
F800290
90-4 THEFT DETERRENT SYSTEMS

Fuel Enable Output
The fuel enable circuit is an output from the BCM
and an input to the PCM. When the BCM senses the
proper resistance at the ignition key, it will output a signal to
the PCM. If the BCM does not see the proper resistance at
the ignition key, it will not output the signal to the PCM.
Security Indicator Lamp Output

The "SECURITY" lamp circuit is an indicator
lamp output. The lamp output will be grounded during
a five second "bulb test" at key on, at any time that
the BCM is preventing the engine from starting,
during an open or short to ground, or if the BCM is
not properly programmed.
Theft Deterrent Relay

The relay is used to stop the engine from
cranking if the correct resistance is not sensed at the
ignition key. It prevents the engine from cranking by
opening the circuit to the starter solenoid switch.
Powertrain Control Module (PCM)

The PCM reads the fuel enable circuit to
determine if fuel injection should be allowed. If the
fuel enable signal is not present, the PCM will not
allow fuel injection. If the signal is present, the PCM
will allow fuel injection and normal engine operation.
The PCM has some diagnostic features
associated with the fuel enable input, including
diagnostic trouble codes. For details, refer to
SECTION 6E.
ON-VEHICLE SERVICE
IGNITION KEY
Duplicating Ignition Keys
Tool Required:
J 35628-A VATS/PASS Interrogator
To copy an ignition key, it is necessary to first
determine which PASS-Key II@ key code
(resistance value) is needed. The ignition key being
copied must be tested to determine the key code.
The ignition key may be tested using J 35628-A.
1. Insert the customer's spare Ignition Key into the
Key Code Reader on the J 35628-A Interrogator.
2. Press the On-Off rocker switch to the "ON"
position.
3. A number from 1 to 15 will appear in the window
designating the electrical cooe of the key.
4. Cut a new key having the electrical code
determined from the J 35628-A Interrogator.
5. Start the engine using the new key to insure that
the key is correct both mechanically and
electrically.
Replacing Lost Ignition Keys

Tool Required:
J 35628-A VATS/PASS Interrogator
To replace lost ignition keys it is necessary to
determine the mechanical cut and the electrical key
code.
The mechanical .and electrical key codes are
recorded on the vehicle invoice. If these codes are
available, use them to create a new ignition key. If

they are not, follow the procedure below.
The mechanical cut must be determined first.
The mechanical cut can be. determined from the key
code on the ignition cylinder or by calling
Divisional Roadside Assistance. If the mechanical
cut canriot be determined, the ignition cylinder
should be replaced. Make an ignition key blank
with the correct mechanical cut to use while
determining the proper electrical key code.
To determine the proper electrical key code,
use J 35628-A and the following procedure:
[I]
Important
Do not disconnect yellow two-way SIR

connector.
1. Connect J 35628-A wiring to PASS-Key II dash
connector at base of steering column. Do not
connect to steering column wiring.
2. Turn J 35628-A on and place key code switch to
"l" and attempt to start engine with proper
mechanically cut key. If engine starts, key code is
"l."
3; If engine does not start, turn ignition "OFF" arid
press 4-minute timer on J 35628-A.
4. When timer light goes out, place key code switch
to "2" and attempt to start engine; If engine
starts, key code is "2."
5. Continue trying different key codes until proper
key code is found.
6. Make new ignition key with proper key code and
mechanical cut.
PROGRAMMING A NEW BODY CONTROL

MODULE (BCM)
[I]
Important
Any new body control module (BCM) will

automatically program to the resistance of the key
(or interrogator setting) being used at the first
ignition "ON" cycle, This can only be done once
for the life of the module.

.A new BCM is unprogrammed. Before the
system will function properly it must be programmed
to the code that matches the customer's keys:
1. Install new unprogrammed BCM.
2. Insert one of the customer's keys into the ignition
lock cylinder and turn it to the "ON" position.
It is good to start the engine at this time to
verify system operation.
3. Observe the ''SECURITY" indicator lamp.
The indicator lamp lights for about five
seconds and then goes out
- Indicates that the BCM is programmed
properly.
The indicator lamp flashes at a rate of one
flash per second until ignition is "OFF."
- Indicates that the BCM did not program
and the system components, wiring and
contacts should be checked for a fault.
THEFT DETERRENT. SYSTEMS
905
THEFT DETERRENT RELAY

Figure 3
If the relay is determined to be inoperative, it
should be replaced.
f+-+!

SECTION 8C.
3. Relay (8) from inflatable restrait bracket (7).
4. Electrical connector from relay (8).
!++!
Install or Connect
1. Electrical connector to relay (8).

2. Relay (8) to inflatable restraint brack~t (7).
SECTION 8C .
. 4. Battery negative. cable.
7 BRACKET ASSEMBLY, INFLATABLE RESTRAINT
INSTRUMENT PANEL MODULE
8 RELAY ASSEMBLY, THEFT DETERRENT
OIM89S
FS0049D
Figure 3 Theft Deterrent Relay
UNIVERSAL THEFT DETERRENT SYSTEM

GENERAL DESCRIPTION
The universal theft deterrent (UTD) option
(UA6), combined with the remote control door lock
option (AUO), is available on this vehicle. The
universal theft deterrent system operates separately
from the personal automotive security system
(PASS-Key II), which is standard on this vehl,cle.
The universal theft deterrent system is comprised of
the remote transmitters, the red light emitting diode
(L.E.D.) on the top of the I/P upper trim panel, a
shock sensor, a controller with fuel and starter disable
and horn and parking light outputs, and door jamb and
rear lid release switches. Once armed, the system will
sound the horn and flash the parking lights for 2
minutes if the vehicle is broken into. Two levels of
alanns are available through the shock sensor: Two
horn blasts and light flashes for non-threatening blows
to the vehicle, and a full 2 minute alarm for harder
blows to the vehicle. The red L.E.D. is used to
provide status of the system and to warn off potential
thieves. Many features of the system, including horn
chirps, how the system arms and delay times can be
set to customer's preferences. The alarm system can
also be turned off. Refer to "Feature Customization"
in this section.
SYSTEM OPERATION
Arming the System
The normal arming procedure when locking the
vehicle is:
1. Close all windows and place shift lever in
"PARK."
2. Turn ignition switch to the "LOCK" position and
remove ignition key.
3. Open any door.
4. Lock doors with power door lock switch or
remote transmitter.
5. Close doors.
This will arm the system to sound if door
switches, the rear compartment lid. release switch, or
the shock sensor is activate.d or "tripped." The system
will also sound if the wrong key resistance (PASS-key
II) is detected. The armed system will flash the red
L.E.D. briefly every 2 seconds. The system can also
be armed with the windows open. The system will be
disarmed only when the unlock button on the remote
transmitter is pushed or the ignition .key is turned
"ON."
When any door is opened during the arming
procedure, the system goes into an armed wait mode.
Once the doors are closed, if the remote transmitter
was used to arm the system, it will arm, chirp the

horns twice and flash the parking lights. If the door
switch was used to arm the system, only the parking
lights will flash. If the rear compartment lift window
panel is open or ajar during arming procedure, the
horn will only chirp once.
[I]
Important
Locking the doors with the lock control side knob

will not arm the system.
PASSIVE ARMING
If the ignition is turned off and a door was

opened, the system will automatically. arm 6 seconds
after all doors are closed, whether or not they are
locked. In all other cases, the system will wait 30
seconds after all doors are closed before automatically
arming. The parking lights will flash when the system
arms. The vehicle has been set to active arming mode
from the factory, but passive arming can be enabled, if
preferred. Refer to "Feature Customization" in this
section.
locking without Arming

To lock the vehicle without arming the system,
simply lock the doors manually with the inside lock
knobs or front door lock key and close them.
Disarming the System

When the system is disarmed, the red L.E.D. is
off. The rear compartment lift window panel button on
the remote transmitter will disarm the rear
compartment lift window panel and the shock sensor,
to allow access to the rear compartment, but the doors
will remain armed. Five seconds after the it is closed,
the rear compartment lift window panel will again be
armed. There are two ways to disarm the entire
system:
Pressing the "UNLOCK" button on the remote
transmitter.
Turning the ignition "ON" with the proper key.
DRIVER'S DOOR DELAY
Unlocking the door or rear compartment lift

window panel with the use of a key will not disarm
the system. The BCM has been factory set with
driver's door delay that allows 8 seconds to turn the
ignition key "ON" after the. driver's door has been
unlocked with a key. If active disarming. with the
transmitter is used more often, the driver's door delay
can be set to. 0 seconds, making any entry without the
transmitter activate the alarm. Refer to "Feature
Customization" in this section.
Deactivating the Alarm

To deactivate the alarm once it has been tripped,
that is, actually sounding, refer to the following:
If activated by pressing the panic mode button on
the remote. transmitter, the panic mode button

MUST be pressed again to deactivate.
If activated by the shock sensor, door or rear lid
release switch, it can be turned off by turning the

ignition "ON" using the proper key, or by
pressing any button on the remote transmitter:
- Pressing "UNLOCK" will silence the alarm,

unlock the driver's door and disarm the
system.
- Pressing "LOCK" will silence the alarm,
keeping the doors locked and the system
armed.
--:- Pressing the rear compartment lift window
panel button will silence the alarm, unlocking
and disarming the lift window panel.
- Pressing the panic button will silence the
alarm, keeping the doors locked and the
system armed.
The alarm will deactivate by itself after
2 minutes.
If activated by an improper ignition key, press any
button on the remote transmitter to. deactivate.
SYSTEM COMPONENTS
While the theft deterrent system is armed, the
BCM monitors the shock sensor and door and rear
compartment lift window panel switches for activity. If
an alarm is required, the BCM sounds the horns,
flashes the parking lights for 2 minutes and disables
the starter, the fuel system and the remote lift window
release switch. It also controls horn chirps and parking
light flashes for locking and arming functions. For
further information on the BCM, refer to SECTION
80.
Remote Control Door lock Transmitter

The remote transmitter is the primary device to
disarm the theft system. If the vehicle has universal
theft deterrent, the remote transmitter has a panic
button on it. Press this button to sound the car alarm;
press it again to turn the alarm off. As with the other
functions, operation of this feature is subject to the
range of the remote transmitter. For further
information, refer to SECTION 9K.
Shock Sensor
The shock sensor is located near the spare tire in
the hatch area (Figure 5). Its sensitivity has been set to
comply with various. local regulations requiring vehicle
contact to set off the alarm. It can be adjusted if more
or less sensitivity is desired. If sensitivity is increased
too much, it may give false alarms caused be gusts of
wind or other natural events that may shake the
vehicle. To adjust, remove the label covering the
adjustment knob and adjust as desired. Tum clockwise
to increase sensitivity. Turn counterclockwise to
decrease sensitivity. The red light on the shock sensor
illuminates at shock levels that would cause the full
(2 minute) alarm to sound. Different levels of shock
are required on the various body panels and windows

to activate the sensor, depending on the material
(plastic, steel or glass) and distance from the shock
sensor. Two levels of alarms are available through the
shock sensor.:
2 horn blasts and light flashes for non-threatening
blows to the vehicle.
A full 2 minute alarm for harder blows to .the
.
vehicle.
The shock sensor is ignored by the system
during ignition "ON," when the rear compartment lift
window panel is open, when the alarm is disarmed, 5
seconds after the horn sounds, or when customized to
be ignored. Refer to "Feature Customization" in this
section.
Starter Enable Output

The starter enable circuit controls the theft
deterrent relay. When the BCM sees the proper
resistance at the ignition key, it grounds the starter
enabl.e circuit which allows the engine to be cranked,
If the BCM does not sense the proper resistance at the
ignition key, it will not ground the starter enable
circuit.
Fuel Enable Output

The fuel enable circuit is an output from the
BCM and an input to the PCM. When the BCM
senses the proper resistance at the ignition key, it will
output a signal to the PCM. If the BCM does not see
the proper resistance at the ignition key, it will not
output the signal to the PCM.
Security Indicator l.E.D. Output

The security indicator light on the top of the
upper trim panel provides the status of the alarm
system and acts as a theft deterrent to potential
thieves, warning them that the vehicle has a alarm
system. The status of the alarm system can be
determined by the output of the security indicator light
as described below:
Light blinking once a second - Door is open,
alarm system is not armed.
Light on steady Alarm system is waiting for
the doors Jo close before arming; Three .second
bulb test at ignition on, alarm will sound once the
driver's door 8 second delay finishes.
Light flashes briefly every 2 seconds Alarm system is armed.
Light flashes twice every 2 seconds - Alarm
system is armed and the shock sensor triggered a
two minute alarm .
Light flashes three times every 2 seconds Alarm system is armed and there was an intrusion
that. sounded the .alarm.
Light off - Alarm system is off, disarmed, or a
door is opened for more than 10 minutes.
Door Jamb and Rear lid Release Switches

The front side door jamb switches and rear
compartment lid release switch are used by the BCM
to monitor any activity of the doors and rear
compartment lift window panel. For diagnosis, refer to
SECTION 8A.
Horn and Parking Lamp Relays

The relays are controlled by the BCM to provide
power for the horn and parking lamps when the
system is activated. For further information and
diagnosis, refer to SECTION 8A.
ON-VEHICLE SERVICE
FEATURE CUSTOMIZATION
Many features of the universal theft deterrent
system, including horn chirps, how the system arms
and delay times, may be set to the customer's
preference. The alarm system can also be turned off.
To customize features, after the system is in
programming mode, refer to the appropriate chart
below.
Programming Mode
Programming mode is necessary to cu~t:gmize

features of the system. To set BCM in program.ming
mode, refer to the following procedure.
Entering Programming Mode
1. Turn ignition "ON".

This will disarm theft system, if necessary.
2. Turn ignition "OFF".
3. Remove "RADIO" fuse.
4. Turn ignition to "ACC" position.
Chime will sound to verify the system is in
programming mode.
- If the chime sounds once; exit lighting,
delayed illumination, last door closed
locking and lockout prevention can be
customized.
- If the chime sounds twice and the vehicle
is equipped with universal theft deterrent;
remote lock control verification, arming
method, arming verification, driver's door
delay and shock sensor enable/disable can
be customized.
5. Program features desired using the appropriate
chart(s) below;
Exiting Programming Mode
1. When programming is done, turn ignition switch

"OFF".
2. Install "RADIO" fuse.
Customization Charts
EXIT LIGHTING AND DELAYED ILLUMINATION
Exit lighting illuminates interior lights when the

key is removed from the ignition switch to help in
exiting the vehicle. Delayed illumination illuminates
interior lights for 25 seconds after the doors are
closed. The 25 seconds is shortened if the ignition is
turned on or if the power locks are activated. Both
exit lighting and delayed illumination are enabled from
the factory, and can be disabled if desired.
1. Turn courtesy lamp switch ON then OFF (1/P
dimmer switch, not parking lights).
Listen to number of chimes to determine
current setting (Factory setting).

2. Turn the courtesy lamp. switch from ON and OFF
to increment desired setting below:
REMOTE LOCK CONTROL VERIFICATION (HORN

CHIRP AND PARKING LIGHTS FLASH)
Number of
Chimes
Exit Lighting
Feature
Delayed
Illumination
Feature
Disabled
Disabled
Available on vehicles equipped with universal

theft deterrent (UTD) system, this feature provides
horn chirps and/or parking light illumination to
indicate that the remote transmitter "LOCK" or
"UNLOCK" command was received.
2
3
Disabled
Enabled
1. Press the unlock switch on the remote transmitter.
Enabled
Disabled
(4)
Enabled
Enabled
3. Continue custom1zmg other features or exit

programming mode. Refer to "Programming
Mode" in this section.
LAST DOOR CLOSED LOCKING AND LOCKOUT
PREVENTION
Last door closed locking is available on cars

with power locks, this feature provides for delayed
locking of the doors (3 seconds after the last door is
closed). This allows the driver or passengers to exit
the vehicle after the driver's power door lock switch is
pressed and still have the doors remain locked after
exiting. When the locked switch is pressed, the chime
will sound 3 times, indicating a last door closed
locking is pending. Pressing the lock switch again will
lock the doors immediately. Pressing the unlock switch
will cancel a pending last door closed locking. Last
door closed locking is disabled from the factory, and
.can be enabled if desired.
Lockout prevention protects the driver from
locking the keys in the vehicle, this feature disables
the power locks from locking when the keys are in the
ignition and a door is open. If the power lock button
is pressed when a door is open, the chime will sound
5 times as a reminder to take the keys before locking
the door. Lockout prevention is enabled from the
factory, and can be disabled if desired.
2. Press the lock switch on the door to increment
desired setting below:
Number of
Chimes

2. Press the unlock switch on the remote transmitter
to increment desired setting below:
Transmitter Transmitter
Number of Lock 1st Lock 2nd Transmitter
Chimes
Push
Push
Unlock
1
Verification
Off
Verification
Off
Verification
Off
Homs and
Lights
Homs and
Lights
Lights
Homs and
Lights
Homs and
Lights
Homs and
Lights
4
(5)
Lights
Lights
Lights
Lights
Homs and
Lights
Lights
(
3. Continue custom1zmg other features or e,dt
THEFT DETERRENT ARMING METHOD
Available on vehicles equipped with Universal

Theft Deterrent (UTD) system, this feature provides
different methods of arming the UTD system.
1. Press the unlock switch on the door.
1. Press the lock switch on the door.
Last Door
Closed
Locking
Lockout
Prevention

2. Press the unlock switch on the door to increment
Number of Chimes
Theft Deterrent
Arming Method
Alarm System Off

Remote Transmitter Anns
Disabled
Disabled
(2)
Disabled
Enabled
(3)
Enabled
Disabled
Remote Transmitter or Door

Lock Switch Arms
Enabled
Enabled
Passive (Automatic)
3. Continue customizing other features or-.exit

programming mode. Refer to "ProgrammHig


THEFT DETERRENT ARMING VERIFICATION
{HORN CHIRP AND PARKING LIGHTS FLASH)
90-9
SECURITY INDICATOR L.E.D.

Figure 4
Available on vehicles equipped with universal

theft deterrent (UTD) system, this feature provides
horn chirps and/or parking light illumination to
indicate when the UTD system has armed. It is
programmed separately from the remote lock control
verification listed above.
1. Press the lock switch on the remote transmitter.
2. Press the lock switch on the remote transmitter to
increment desired setting below:
Arming
Arming
with
with Door
Lock
Number of Remote
Chimes Transmitter Switch
Verification
Off
Homs and
Lights
Borns and
Lights
Lights
2
(3)
Passive
Arming
Verification
Off
Homs and
Lights
Lights
Verification
Off
Horns and
Lights
Lights
Lights
Lights

!++!

2. Carefully pry indicator L.E.D. (11) from I/P upper
trim panel.
4. Ambient light sensor, if equipped.
5. Indicator L.E.D. (11).
II]
Important
Do not test the L.E.D. using 12 volts or a test

light. Use only a digital voltmeter on the diode
scale, or damage to the L.E.D. will occur.
l++!
1.
2.
3.
4.
Install or Connect
Ambient light sensor, if necessary.
Indicator L.E.D. (11).
THEFT DETERRENT OPERATION (DRIVER'S

DOOR DELAY AND SHOCK SENSOR ENABLE)
11
Available on vehicles equipped with Universal

Theft Deterrent (UTD) system, this feature provides a
driver's door delay that can be set at zero or 8 seconds
from the time the driver's door is opened until the
alarm sounds. The shock sensor feature, that detects
sharp blows to the vehicle, can also be enabled or
disabled using this chart. Refer to "System
Components" for a description of the two sensitivity
levels and adjustment procedure.
l. Tum the parking lights ON and OFF.
2. Tum the parking lights ON and OFF to increment
Number of
Chimes
1
2
3
(4)
11
Driver's. Door Shock Sensor

Delay
Enable
Zero
8 Seconds
Zero
8 Seconds
Disabled
Disabled
Enabled
Enabled

c
A
8
C
11
12
U.S. VEHICLES
CANADIAN VEHICLES
CONNECTOR,_ ELECTRICAL
L.E.D., SECURITY INDICATOR
SENSOR, DAYTIME RUNNING
LAMP AMBIENT LIGHT
Figure 4 Security Indicator L.E.D.
9P10
SHOCK SENSOR
Figure 5
!+-+!

.
10

2. Right quarter inner rear trim finishing panel
(Coupe). Refer to SECTION 10-7.
3. Right side trim finish panel (Convertible). Refer
to SECTION 10-8.
5. Shock sensor (9).
Clean
Shock sensor attaching surfaces.
rn
Important
Shock sensor sensitivity has been preset and

should require no adjustment. Remove label
covering and adjust only . if more or less
sensitivity is desired. Refer to "System
Components" in this section for a description of
the two sensitivity levels and adjustment
procedure.
!-++!
Install or Connect
1. Shock sensor (9).
2.
3.
4.
5.
A
B
C
9
10
CONVERTIBLE
SENSOR, THEFT DETERRENT SHOCK
PANEL, REAR WHEELHOUSE INNER
06-01-95
FT0039D
Figure 5 - Theft Deterrent Shock Sensor
Remove adhesive backing and install in

original position.
Right side trim finish panel (Convertible). Refer
to SECTION 10-8.
Right quarter inner rear trim finishing panel
(Coupe). Refer to SECTION 10-7.
SPECIAL TOOLS
J 35628-A
1 VATS/PASS INTERROGATOR
051895
FS0059D
9012 THEFT DETERRENT SYSTEMS
BLANK
(
ENGINE COOLANT HEATER
9E1
SECTION 9E

systems.
CONTENTS
General Description ................................................. 9E-1
On-Vehicle Service .................................................. 9E-1
Engine Coolant Heater ........................................ 9E-1
GENERAL DESCRIPTION
The engine coolant heater is used to heat engine
coolant making it easier to start the engine in cold
climates. It is installed into the engine block at a water
jacket plug location. An engine coolant heater cord is
routed inside the engine compartment. The heater is
rated at 600 watts and uses a 110-volt ac power
supply. For electrical diagram of engine coolant heater,
refer to Electrical Diagnosis 8A-32.
ON-VEHICLE SERVICE
Figures 1 and 2
!+--+!
CAUTION: Perform this operation when

the engine is cool or personal injury may
result.
SECTION OA.
2. Drain engine coolant from engine block into an
approved container. Refer to SECTION 6B.
3. Cord from heater (1).
4. Loosen bolt/screw (2).
NOTICE: When removing the engine coolant

heater from the engine block, be careful not to
score the machined surface of the plug hole.
5. Heater. (1) carefully from plug hole.
If removing heater (1) permanently, install
water jacket plug into plug hole and replace
engine coolant. For engine coolant replacement
procedures, refer to SECTION 6B.
Engine Coolant Heater Cord .............................. 9E-2

Specifications ........................................................... 9E-3
Fastener Tightening Specifications ..................... 9E-3
~
O
!-++!
Clean
Plug hole.
- Remove burrs, sealer, paint and other rough
spots.
Install or Connect
NOTICE: The element must not touch the

engine block inner wall in the installed position
or damage to the engine block and heater could
result.
NOTICE:
Refer to "Notice" on page 9E-1.
1. Apply coat of engine coolant heater lubricant, GM

PIN 9985164 or equivalent, to 0-ring and walls of
plug holes.
2. Engine coolant heater (1) into plug hole.
A. Insert heating element end of heater ( 1) into
plug hole.
B. Line up heater (1) with plug hole and push it
straight into place.
C. Rotate heater ( 1) so that center electrical
contact and bolt/screw (2) are in line
horizontally.
D. Turn bolt/screw (2) so that yoke presses
against engine block inner wall.
l~l
Tighten
CAUTION: Engine coolant heater cord

must not touch the engine, hot pipes,
manifold or any moving parts or damage
to the vehicle and possible personal
injury may result.
9E-2
3. Cord to heater (1).

4. Lower vehicle.
5. Replace engine coolant. Refer to SECTION 6B.
Install or Connect
CAUTION: Engine coolant heater cord

must not touch the engine, hot pipes,
manifold or any moving parts, or damage
to the vehicle and possible personal
injury may result.
ENGINE COOLANT HEATER CORD

Figures 3 and 4
!++!
!++!
1. Note position and routing of cord (3) for proper

placement during installation.
2. Cord (3) from heater (1).
3. Cord straps (4).
4. Cord (3) from vehicle.
NOTICE: Refer to "Notice" on page 9E-1.

1. Cord (3) to vehicle routing as noted during
removal.
2. Cord (3) to heater (1).
3. Cord straps (4).
D
D
A
8
C
O
1
2
0-RING
WALL, ENGINE BLOCK
PLUG, HOLE
ELEMENT, HEATING
HEATER, ENGINE COOLANT
BOLT /SCREW, ENGINE COOLANT HEATER
10-11-94
F80029E
Figure 1 - Engine Coolant Heater (3800 VIN K)
!VIEWAI
A
B
C
1
2
!VIEW B!
0-RING
WALL, ENGINE BLOCK
PLUG, HOLE
HEATER, ENGINE COOLANT
BOLT/SCREW, ENGINE COOLANT HEATER
01-20-95
IFS0019E
Fi,gure 2 - Engine Coolant Heater (5.7L VIN P)
9E3
1 HEATER, ENGINE COOLANT

3 CORD, ENGINE COOLANT HEATER
4 STRAP, ENGINE COOLANT HEATER CORD
1 HEATER, ENGINE COOLANT

3 CORD, ENGINE COOLANT HEATER
4 STRAP, ENGINE COOLANT HEATER CORD
040895
FT0039E
040895
FT0049E
Figure 3 Engine Coolant Heater Cord (3800 VIN K)
Fi,gure 4 Engine Coolant Heater Cord (5.7L VIN P)
SPECIFICATIONS
Engine Coolant Heater Bolt/Screw ........................................................................................ 1.9 N.m (17 lb. in.)
9E-4
BLANK
SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM
9J-1
SECTION 9J

{SIR) SYSTEM
CAUTIONS in this section under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location view in this section before performing service on or around SIR components or wiring.
systems.
CONTENTS
General Description ........... ,.................................... 9J-2
Restraint Devices ................................................ 9J-2
System Des.cription ...... ~ ................ '. .................... 9J-:2.
Component Description ...................................... 9J-3
SDM ................................................................ 9J-3
"AIR BAG" Warning Lamp ......................... 9J-3
SIR Coil Assembly ........................................ 9J-3
SIR Component and Wiring Location
View ............................................................ 9J-4
Inflator Modules ............................................. 9J-5
Steering Column ............................................. 9J-6
Knee Bolsters ................................................. 9J-6
Definitions .......................................................... 9J-6
Diagnosis ................................................................. 9J-7
Diagnostic Trouble Codes .................................. 9J-7
Scan Tool Diagnostics ................................... 9J-7
Use of Special Tools .......................................... 9J-7
SIR Connector Body Face Views ......................... 9J-8
SIR Diagnostic System Check .............................. 9J-10
Circuit Description ............................................. 9J-10
Notes on System Check Chart .......................... 91-10
Diagnostic Aids .................................................. 91-10
Chart A-SDM Integrity Check............................ 91-12
Chart B-"AIR BAG" Warning Lamp Comes
"ON" Steady ..................................................... 91-14
Chart C-"AIR BAG" Warning Lamp Does Not
Come "ON" ............................... :....................... 91-18
DTC 15 ................................................................... 91-22
DTC 16 ................................................................... 9J-24
DTC 17 ................................................................... 91-26
DTC 18 ................................................................... 9J-28
DTC 19 ................................................................... 91-30
DTC 21 ................................................................... 9J-32
DTC 22 ................................................................... 91-34
DTC 24 ................................................................... 9J-36
DTC 25 .................................................................... 91-38
DTC 26 .................................................................. 91-40

DTC 51 .................................................................. 91-42
DTC 53 .................................................................. 9J-44
DTC 61 ............................................... :................... 91-46
DTC 71 .................................................................. 91-48
On-Vehicle Service................................................. 91-50
Service Precautions ............................................ 9J-50
Disabling the SIR System ............ '. ................ 91-50
Enabling the SIR System .............................. 91-50
Handling/Installation/Diagnosis ...................... 91-51
Repairs and Inspections Required After an
Accident .................. ,....................................... 9J-51
Accident. With Deployment - Component
Replacement and Inspections .................... 91-51
Accident With or Without Deployment Component Inspections .............................. 9J-51
Sensing and Diagnostic Module (SDM) ........... 91-52
Passenger Inflator Module ................................. 91-53
Live (Undeployed) Inflator Module .............. 91-53
Deployed Inflator Module ............................. 9J-53
"AIR BAG" Warning Lamp .................... Section 8C
Driver Inflator Module ............................. Section 3F
SIR Coil Assembly ................................. Section 3F5
Inflator Module Handling/Shipping/
Scrapping ........................................................ 91-54
Live (Undeployed) Inflator Module .............. 91-54
Shipping Procedures for Live (Undeployed)
Inflator Modules .......................................... 91-54
Inflator Module Scrapping Procedure ........... 9J-54
Deployment Outside Vehicle (Driver
Inflator Module) ......................................... 91-55
Deployment Outside Vehicle (Passenger
Inflator Module) .......... ,.............................. 9J-61
Deployment Inside Vehicle (Vehicle
Scrapping Procedure) ................................. 91-61
Deployed Inflator Mo.dule Handling ............. 91-65
9J-2
SUPPLEMENTAL INFLATABLE RESTRAINT (SIR} SYSTEM
Wiring Repair ................................................. 91-66

Terminal Repair Kit 1 38125-A ..................... 91-66
SIR Connector (Plastic Body and Terminal
Metal Pin) Repair ....................................... 91-66
SIR Wire Pigtail Repair ................................. 91-66
SIR Wire Repair ............................................. 91-66
SIR System Wire Splice Repair ........... ;........ 91-67
Alternative Repair Methods ........................... 91-67
Connector Position Assurance (CPA) ............ 91-67
Terminal Position Assurance (TPA) .............. 91-67
GENERAL DESCRIPTION
RESTRAINT DEVICES
Figures 1 and 2
The Supplemental Inflatable Restraint (SIR)
system helps supplement the protection offered by the
driver and front passenger seat belts by deploying an
air bag from the center of the steering wheel and from
the top of the right side of the instrument panel
(Figure 1).
The air bag deploys when the vehicle is involved
in a frontal crash of sufficient force up to 30 degrees
off the centerline of the vehicle (Figure 2). To further
absorb the crash energy there is a knee bolster located
beneath the instrument panel for both the driver and
passenger and the steering column is collapsible.
SYSTEM DESCRIPTION
Special Tools .......................................................... 91-68

SIR Driver/Passenger Load Tool... .................... 91-68
1 39200 DVM .................................................... 91-68
Scan Tool. ........................................................... 91-68
1 35616-A Connector Test Adapter Kit. ........... 91-68
Specifications .......................................................... 91-68
Fastener Tightening Specifications .................... 91-68
Service Parts Information ...................................... 91-68
SIR Special Tools .................................................. 91-69
inflator module, passenger inflator module and

connector wires make up the deployment loops. The
function of the deployment loops is to supply current
through the inflator modules, which will cause
deployment of the air bags in the event of a frontal
crash of sufficient force, up to 30 degrees off the
centerline of the vehicle. The inflator modules are only
supplied enough current to deploy when the SDM
detects vehicle velocity changes severe enough to
warrant deployment.
The SDM contains a sensing device which
converts vehicle velocity changes to an electrical
signal. The electrical signal generated is processed by
the SDM and then compared to a value stored in
memory. When the generated signal exceeds the stored
value, additional signal processing is performed and
the generated signals are compared to signals stored in
memory. When two of the generated signals exceed
the stored values, the SDM will cause current to flow
through the inflator modules deploying the air bags.
Figure 3
The SIR system consists of the Module, INFL

RST DIAGN ENGY RESV (W/SEN) (SDM), the
Module, INFL RST STRG WHL ( driver inflator
module), the Coil, INFL RST STRG WHL MDL (SIR
coil assembly), the Module, INFL RST I/P (passenger
inflator module) and the Lamp, INST CLSTR ("AIR
BAG" warning lamp) in the instrument cluster. The
SDM, SIR coil assembly (driver side only), driver
1 DEPLOYED AIR BAG
2 KNEE BOLSTER
3 SEAT BELT
Figure 1 - Restraint Devices
9-1-94
CHS0019J
Figure 2 - SIR System "Deployment Window"
SUPPLEMENTAL INFLATABLE RESTRAINT {SIR) SYSTEM

SOM
18A
TO IGNITION--.., , ,-4---1110
SWITCH
AIRBAG FUSE
IGNITION 1
SIR COIL
ASSEMBLY
DRIVER SIDE HIGH
DRIVER SIDE LOW
PASS. SIDI! HIGH
PASS. SIDE LOW
GROUND
06-13-95
9J-3
3. Air Bag Deployment - When a frontal crash of

sufficient force is detected, the SDM will cause
enough current to flow through the inflator
modules to deploy the air bags.
4. Frontal Crash Recording - The SDM records
information regarding the SIR system status
during a frontal crash.
5. Malfunction Detection - The SDM performs
diagnostic monitoring of the SIR system electrical
components and sets a diagnostic trouble code
when a malfunction is detected.
6. Malfunction Diagnosis - The SDM displays SIR
diagnostic trouble codes and system status
information through the use of a .scan tool.
7. Driver Notification - The SDM warns the vehicle
driver of SIR system malfunctions by controlling
the "AIR BAG" warning lamp.
The SDM is connected to the SIR wiring harness
by a 12-way connector. This harness connector uses a
shorting bar across certain terminals in the contact
area. This shorting bar connects the "AIR BAG"
warning lamp to ground when the SDM Connector
Position Assurance (CPA) is removed.
This will cause the "AIR BAG" warning lamp
to come "ON" steady whenever the ignition switch is
at the RUN, BULB TEST or START positions with
the SDM CPA removed.
FT0018J
"AIR BAG" Warning Lamp

Figure 3 - Deployment Loops
COMPONENT DESCRIPTION
Figure 4
SDM
CAUTION: During service procedures, be
very careful when handling a Sensing
and Diagnostic Module (SOM). Never
strike or jar the SOM. Never power up the
SIR system when the SOM 1s not rigidly
attached to the vehicle. All SOM and
mounting bracket fasteners must be
carefully torqued and the arrow must be
pointed toward the front of the vehicle to
ensure proper operation of the SIR
system. The SOM could be activated
when powered while not rigidly attached
to the vehicle which could cause
deployment and result in personal injury.
The Sensing and Diagnostic Module (SDM) is
designed to petform the following functions in the SIR
system.
1. Energy Reserve - The SDM maintains a 23 Volt

Loop Reserve (23 VLR) energy supply to provide
deployment energy when ignition voltage is lost
in a frontal crash.
2. Frontal Crash Detection - The SDM monitors
vehicle velocity changes to detect frontal crashes
which are severe enough to warrant deployment.
Ignition voltage is applied to the "AIR BAG"

warning lamp when the ignition switch is at the RUN,
BULB TEST or START position. The SDM controls
the lamp by providing ground with a lamp driver. The
"AIR BAG" warning lamp is used in the SIR system
to do the following:
1. Verify lamp and SDM operation by flashing seven
times when the ignition switch is first turned to
"RUN."
2. Warn the vehicle driver of SIR electrical system
malfunctions which could potentially affect the
operation of the SIR system. These malfunctions
could result in non-deployment in case of a
frontal crash or deployment for conditions less
severe than intended.
The "AIR BAG" warning lamp is the key to
~- driver notification of SIR system malfunctions.. For
proper lamp operation, refer to the "SIR Diagnostic
System Check" in this section.
SIR Coil Assembly

Figure 5
The SIR coil assembly consists of two or more
current-carrying coils. They are attached to the
steering column and two of the current-carrying coils
allow rotation of the steering wheel while maintaining
continuous contact of the driver deployment loop to
the driver. inflator module.
9J-4
1 SIR COIL
2 DRIVER INFLATOR MODULE
3 DRIVER INFLATOR MODULE
HARNESS CONNECTOR
4 PASSENGER INFLATOR MODULE
5 1/P COMPARTMENT DOOR
6
7
8
9
SIR WIRING HARNESS

SOM
PARK BRAKE
SOM HARNESS CONNECTOR
10 FLOOR TUNNEL
O.M0-15
FT0029J
Figure 4 - SIR Component and Wiring Location View
9J-5
1 SIR COIL ASSEMBLY

2 INFLATOR MODULE CONNECTOR
3 STEERING COLUMN CONNECTOR
SIR COIL ASSEMBLY
INFLATOR MODULE
CONNECTOR POSITION ASSURANCE (CPA}
INFLATORIIIIODULE HARNESS CONNECTOR
10-12-84
.STS5919J
5-24-84
F80049J
Figure 5 - SIR Coil Assembly
Figure 6A - Driver lnflator Module (Camaro)
There is .a shorting bar on the yellow 2-way

connector near the base of the steering column which
connects the SIR coil to the SIR wiring harness. The
shorting bar shorts the circuits to the SIR coil and
driver inflator module when the yellow 2-way
connector is disconnected. The circuit to the driver
inflator module is shorted in this way to help prevent
unwanted deployment of the air bag when. servicing
the steering column or other SIR system components.
Inflater Modules
Figures 6 and 7
The inflator modules consist of an inflatable bag

and an inflator (a canister of gas-generating material
and . an initiating device). When the vehicle is in a
frontal crash of sufficient force, the SOM causes
current to flow through the deployment loops. Current
passing through the initiator ignites the material in the
inflator module. The gas produced from this reaction
rapidly inflates the air bag.
There is a shorting bar on the driver inflator
module side of the upper steering column connector
which connects the SIR coil assembly to the driver
inflator module. The shorting bar shorts across the
driver inflator module circuits when the upper steering
column connector is disconnected. The circuit to the
driver inflator module is shorted in this way to help
prevent unwanted deployment of the air bag when
servicing the driver inflator module, the steering
column or other SIR system components.
5
1
2
3
4
5
SIR COIL ASSEMBLY

INFLATOR MODULE HARNESS CONNECTOR
CONNECTOR POSITION ASSURANCE (CPA)
DRIVER INFLATOR MODDULE
REDUNDANT STEERING WHEEL
CONTROLS CONNECTOR
(FIREBIRD WITH UK3)
04-0SM
FT0039J
Figure 68 - Driver lnflator Module (Firebird)
9J-6
There is a shorting bar on the passenger inflator

module connector which connects to the SIR wiring
harness. The shorting bar shorts across the passenger
inflator module circuits when the passenger inflator
module connector is disconnected. The circuit to the
passenger inflator module is shorted in this way to
help prevent unwanted deployment of the air bag
when servicing the passenger inflator module, the
instrument panel or other SIR system components.
Steering Column
The steering column is energy absorbing and is
designed to compress in a frontal crash to decrease the
chance of injury to the driver. A steering column
reinforcement is also used for additional support.
Knee Bolsters
The knee bolsters are used to absorb energy and
control the forward movement of the vehicle's front
seat occupants during a frontal crash, by limiting leg
movement.
DEFINITIONS:
AIR BAG - An inflatable cloth cushion designed
to deploy in certain frontal crashes. It supplements the
protection offered by the seat belts by distributing the
impact load more evenly over the vehicle occupant's
head and torso.
ASYNCHRONOUS - Performed in a
non-periodic fashion, i.e. no defined time or interval.
B+ - Battery voltage, the voltage available at the
battery at the time of the indicated measurement. With
the key to "RUN" and the engine not running, the
2
CHEV SHOWN
PONT SIMILAR
1 PASSENGER INFLATOR MODULE

2 PASSENGER INFLATOR MODULE BRACKET
3 FASTENERS
040895
FT0048J
Figure 7 - Passenger Inflater Module
system voltage will likely be between 12 and 12.5

volts. At idle the voltage may be 14 to 16 volts. The
voltage could be as low as 10 volts during engine
cranking.
BULB TEST - The SDM will cause the "AIR
BAG" warning lamp to flash seven times and then go
"OFF" whenever the ignition switch transitions from
the OFF position to the RUN position and no
malfunctions are detected.
CONTINUOUS MONITORING - Tests
performed by the SDM on the SIR system every 100
milliseconds while "Ignition 1" voltage is in the
normal operating voltage range at the SDM.
DATA LINK CONNECTOR (DLC) - Formerly
"ALDL," a connector which is connected by wires to
multiple on-board computers allowing communication
with an off-board computer, such as a scan tool.
DATUM LINE - A base line parallel to the
plane of the underbody or frame from which all
vertical measurements originate.
DEPLOY - To inflate the air bag.
DEPLOYMENT LOOP CONTINUITY - Test is
performed by the SDM after "Ignition 1" and 23 VLR
are measured within their respective normal voltage
ranges. This test checks voltage differences between
"Driver Side High/Low" and "Passenger Side
High/Low" circuits.
DEPLOYMENT LOOPS - The circuits which
supply current to the inflator modules to deploy the air
bags.
DIAGNOSTIC TROUBLE CODE (DTC) Formerly "Code," a numerical designator used by the
SDM to indicate specific SIR system malfunctions.
DRIVER CURRENT SINK - An output of the
SDM which supplies a low. resistance path to ground
for the driver inflator module circuit.
DRIVER CURRENT SOURCE - An output of
the SDM which supplies current into the .driver
inflator module circuit.
DRIVER INFLATOR MODULE - An assembly
located in the steering wheel hub consisting of an
inflatable bag, an inflator and an initiator.
EEPROM - Electrically Erasable Programmable
Read Only Memory. Memory which retains its
contents when power is removed from the SDM.
HIGHER PRIORITY FAULT - Each diagnostic
trouble code is assigned a priority based on the
detectability with other DTCs present. The priority
corresponds to the detectability of the malfunction
ONLY, and does NOT relate to .the criticality of the
malfunction with respect to deployment or
non-deployment under any given condition.
IGNITION CYCLE - The voltage at the SDM
"Ignition 1" input, with ignition switch to "RUN," is
greater than 8.2 volts for at least ten seconds before
turning ignition switch "OFF."
IGNITION 1 - A battery voltage (B+) circuit
which is only powered with the ignition switch in the
RUN, BULB TEST, or START positions.
INITIATOR - The electrical component inside
the inflator module which, when sufficient current
flows, sets off the chemical reaction that inflates the
air bag.

NORMAL OPERATING VOLTAGE RANGE The voltage measured between the SDM "Ignition 1"
terminal and "Ground" terminal is between 8.2 and
17 .2 volts.
PASSENGER CURRENT SINK _ An output
of the SDM which supplies a low resistance path to
ground for the passenger inflator module circuit.
PASSENGER CURRENT SOURCE - An
output of the SDM which supplies current into the
passenger inflator module circuit.
PASSENGER INFLATOR MODULE _ An
assembly located in the right side of the 1/P consisting
of an inflatable bag, an inflator and an initiator.
RESISTANCE MEASUREMENT TEST _ Is
performed by the SDM after "Ignition l," 23 VLR,
and deployment loop voltages are all measured within
their respective normal voltage ranges. This test
checks for proper. resistance .of the deployment loops
and for proper operation of the driver and passenger
current sources. If an open is detected this test is
aborted before resistances are calculated, however,
should the open clear the test will be completed
meaning resistances will be checked.
SCAN TOOL - An off-board computer used to
read diagnostic information from on-board computers
via the data link connector.
SDM - Sensing and Diagnostic Module which
provides reserve energy to. the deployment loops,
deploys the air bags when required and performs
diagnostic monitoring of all SIR system components.
SERIAL DATA - Information representing the
status of the SIR system.
SIR - Supplemental Inflatable Restraint.
SIR COIL ASSEMBLY - An assembly of two
current-carrying coils in the driver deployment loop
that allows the rotation of the steering wheel while
maintaining the continuous contact of the driver
deployment loop to the driver inflator module.
SIR WIRING HARNESS - The wires and
connectors that electrically connect the components in
the SIR system.
TURN-ON - Test which the SDM performs on
the SIR system once during each ignition cycle
immediately after "Ignition 1" voltage is applied to
the SDM and before "Continuous Monitoring."
23 VLR - The 23 volt loop reserve energy
supply from the SDM which provides deployment
power when vehicle voltage is lost in a frontal crash.
DIAGNOSIS
CAUTION: To avoid deployment when
troubleshooting the SIR system, do not
use electrical test equipment such as a
battery powered or ac powered voltmeter,
ohmmeter, etc., or any type of electrical
equipment other than that specified in
this manual. Do not use a non-powered
probe type tester. Instructions in this
manual must be followed carefully,
otherwise personal injury may result.
9J-7
DIAGNOSTIC TROUBLE CODES (DTC)

The "SIR Diagnostic System Check" must
always be the starting point of any SIR system
diagnosis. The "SIR Diagnostic System Check"
checks for proper "AIR BAG" warning lamp
operation and checks for SIR diagnostic trouble codes
using the scan tool.
1. Current diagnostic trouble codes - Malfunctions
that are presently being detected. Current
diagnostic trouble codes are stored in RAM
(Random Access Memory).
2. History diagnostic trouble codes - All
malfunctions detected since the last time the
history memory was cleared. History diagnostic
trouble codes are stored in EEPROM.
Scan Tool Diagnostics

A scan tool is used to read data lists, current and
history diagnostic trouble codes and to clear all
diagnostic trouble codes after a repair is completed.
The scan tool must be updated to communicate with
the SIR system through a replaceable cartridge before
it can be used for SIR diagnostics. To use the scan
tool, connect it to the data link connector and turn the
ignition switch to "RUN." The scan tool reads "Serial
Data" from the SDM "Serial Data" output terminal
"5" to the DLC terminal "9."
USE OF SPECIAL TOOLS

equipment other than that specified in
this manual. Do not use a non-powered
probe type tester. Instructions in this
You should be familiar with the tools listed in
this section under the heading "SIR SPECIAL
TOOLS." You should be able to measure voltage and
resistance. You should be familiar with proper use of a
scan tool such as the Tech 1 Diagnostic Computer
TK-0, SIR Driver/Passenger Load Tool J 38715,
Connector Test Adapter Kit J 35616-A, and the DVM
(Digital Multimeter) J 39200.
9J-8
PASSENGER JUMPER HARNESS AND

INFLATOR CONNECTORS (FEMALE)
SOM HARNESS CONNECTOR
PASSENGER JUMPER HARNESS AND

INFLATOR CONNECTORS (MALE)
STEERING COLUMN HARNESS CONNECTOR
040895
FTOOS9J
Figure 8 SIR Connector Body Face Views
BLANK
9J9
9J10
SIR DIAGNOSTIC SYSTEM CHECK

CAUTION: To avoid deployment when troubleshooting the SIR system, do not use electrical
test equipment such as a battery powered or ac powered voltmeter, ohmmeter, etc., or any
type of electrical equipment other than that specified in this manual. Do not use a
non-powered probe type tester. Instructions in this manual must be followed carefully,
NOTICE: If the vehicle interior has been exposed to extensive water intrusion, such as water leaks,
window left open, driving through high water and so forth, the Sensing and Diagnostic Module (SDM) and
the SDM connector may need to be replaced. With the ignition "OFF," inspect the floor tunnel and the
area around the SDM, including the carpet. If any significant soaking or evidence of significant soaking is
detected, the water must be removed, water damage repaired and the SDM and SDM harness connector
MUST be replaced. Before attempting any of these repairs, the SIR system must be disabled. Refer to
"ON-VEHICLE SERVICE" for instructions on how to disable the SIR system and replace the SDM and
SDM connector.
The diagnostic procedures used in this section
are designed to find and repair SIR system
malfunctions. To get the best results, it is important to
use the diagnostic charts and follow the sequence
listed below.
A. PERFORM THE "SIR DIAGNOSTIC SYSTEM
CHECK." The "SIR Diagnostic System Check"
must be the starting point of any SIR diagnostics.
The "SIR Diagnostic System Check" checks for
proper "AIR BAG" warning lamp operation, the
ability of the SDM to communicate through the
"Serial Data" line and whether SIR diagnostic
trouble codes exist.
B. REFER TO THE PROPER DIAGNOSTIC
CHART AS DIRECTED BY THE "SIR
DIAGNOSTIC SYSTEM CHECK." The "SIR
Diagnostic System Check" will lead you to the
correct chart to diagnose any SIR system
malfunctions. Bypassing these procedures
may result in extended diagnostic time,
incorrect diagnosis and incorrect parts
replacement.
C. REPEAT THE "SIR DIAGNOSTIC SYSTEM
CHECK" AFTER ANY REPAIR OR
DIAGNOSTIC PROCEDURES HAVE BEEN
PERFORMED. Performing the "SIR Diagnostic
System Check" after all repair or diagnostic
procedures will ensure that the repair has been
made correctly and that no other malfunctions
exist.
CIRCUIT DESCRIPTION
When the ignition switch is first turned to
"RUN," "Ignition 1" voltage is applied from "AIR
BAG" fuse to the SDM at the "Ignition 1" input
terminal "10." The SDM responds by flashing the
"AIR BAG" warning lamp seven times then turning it
"OFF" while performing tests on the SIR system.
NOTES ON SYSTEM CHECK CHART:

1. The "AIR BAG" warning lamp should flash
seven times after the ignition is first turned to
"RUN."
2. After the "AIR BAG" warning lamp flashes
seven times it should turn "OFF."
3. This test checks for the proper operation of the
"Serial Data" line. This test will also determine
whether history diagnostic trouble codes are
stored and, if so, identify them.
4. Improper operation of the "AIR BAG" warning
lamp is indicated. This test differentiates a
warning lamp stays "ON" condition from a
warning lamp does not come "ON" condition.
5. This test checks for proper operation of the
"Serial Data" line. This test will also identify the
stored diagnostic trouble codes and whether they
are current or history.
DIAGNOSTIC AIDS:
The order in which diagnostic trouble codes are
diagnosed is very important. Failure to diagnose the
DTCs in the order specified may result in extended
diagnostic time, incorrect diagnosis and incorrect parts
replacement.
9J-11
SIR DIAGNOSTIC SYSTEM CHECK
NOTE "AIR BAG" WARNING LAMP AS IGNITION SWITCH IS TURNED TO "RUN."

DOES WARNING LAMP FLASH 7 TIMES?
DOES THE "AIR BAG" WARNING

LAMP COME "ON" STEADY?
NOTE "AIR BAG" WARNING LAMP AFTER

IT FLASHED 7 TIMES.
DOES WARNING LAMP GO "OFF"?
,.,,,,.,,,,.,,.,, ,,,,,,..,,,,,,,,,,,,,,,,,,.,,.,,,,,,,,,,.,,,.,,,,
l GO TO CHART 8. l
I,,,,,,..,,,,,,,.,,,,,,,,.,,,,,,,,..,,.,,u,,,,,,,,.,,,,.,,.,,.,,.... ,tI
.,...
c..J
'"" """""""""""""""""""""""""""""
l_Go TO,CHART
YES
IGNITION SWITCH "OFF.''
CONNECT SCAN TOOL TO DATA LINK CONNECTOR.
FOLLOW DIRECTIONS AS GIVEN IN THE SCAN TOOL
INSTRUCTION MANUAL.
IGNITION SWITCH TO "RUN.''
REQUEST SIR OTC DISPLAY, RECORD ALL
DISPLAYED DTCs, SPECIFYING AS CURRENT OR
HISTORY ON REPAIR ORDER,

CONNECT SCAN TOOL TO DATA LINK CONNECTOR.
FOLLOW DIRECTIONS AS GIVEN IN THE SCAN TOOL
INSTRUCTION MANUAL.
IGNITION SWITCH TO "RUN.''
REQUEST SIR OTC DISPLAY, RECORD ALL HISTORY
DTCs, SPECIFY AS SUCH, ON REPAIR ORDER.
SCAN TOOL INDICATES "NO

DATA RECEIVED FROM SIR"
NO SIR DTCs
ARE DISPLAYED
HISTORY SIR DTCs

ARE DISPLAYED
SIR SYSTEM IS
FUNCTIONAL AND FREE
OF MALFUNCTIONS. NO
FURTHER DIAGNOSIS IS
REQUIRED.
IGNITION SWITCH "OFF.''

WHEN DTC 71 IS SET, GO TO
DTC 71 CHART.
FOR ALL OTHER HISTORY DTCs
REFER TO "DIAGNOSTICS AIDS"
FOR THAT SPECIFIC OTC. A
HISTORY OTC INDICATES THE
MALFUNCTION HAS BEEN
REPAIRED OR IS INTERMITTENT.
,,.,,,,.,,.,.,, ,,.,,,,.,,.,,,,,,,,,,,,,,,.,,,u.,,,,,,I
l REFER TO
l#u,,,,,,,.,.,.,,..,,,.,,,,,.,.,,,,.,,u.,,,,.,,,.,,,.,..,,,,.,,,,.f
SECTION 8A-50. l

OTC 51 CHART.
OTC 18 CHART.
OTC 24 CHART.
DIAGNOSE REMAINING
CURRENT DTCs FROM
LOWEST TO HIGHEST.
WHEN ONLY HISTORY DTCs
EXIST, REFER TO
"DIAGNOSTIC AIDS" FOR
THAT SPECIFIC OTC. A
HISTORY OTC INDICATES THE
MALFUNCTION HAS BEEN
REPAIRED OR IS
INTERMITTENT.
C9496
9J-12

SDM
TOIONfflON
. SWITCH 4
IONfflON1
SEE FUSE BLOCK DETAILS SECTION SA-11
AIR BAO FUSE
REFER TO SECTION 8A50 - - DRIVER INFLATOR

MODULE
SIR COIL
ASSEMBLY
[] I fi]
REFER TO
SECTION 8A76 - - -238BLK/WH
ffi----J
I
SERIAi.DATA
DRIVER SEAT BELT
2 DRIVER SIDE HIGH

3
DRIVER SIDE LOW
~sHoRTINo BARS
PASSENGER
l:~J&R PASSENGER INFLATOR MODULE JUMPER
~1403BWHTIBLKJ"0
M03AWHT/BLK
~ 1 4 0 4 8 DK ORN/WHT~....,_----------1404A DK ORN/WHT
1 PASS. SIDE HIGH

4 PASS. SIDE LOW
SHORTINO BARS
C18 (CHEV)
TO IONfflON
10A
8206
(CHEV) D13
SWITCH ~ 39APNK
388 PNK ............,t-1....c::::,,i11--1--,t----OAOES
(PONT) Al
A7 (PONT)
LAMP
SEI!! FUSE BLOCK DETAILS INS~IWMENT CL.u'sTER
SECTION SA-11
GROUND
051995
FT011fJ
CHART A
SDM Integrity Check

When the SDM recognizes "Ignition 1" voltage,

applied to terminal "10," is greater than 8.2 volts, the
"AIR BAG" warning lamp is flashed seven times to
verify operation. At this time the SDM performs
"Turn-ON" tests followed by "Resistance
Measurement Test" and "Continuous Monitoring"
tests. When a malfunction is detected the SDM sets a
current diagnostic trouble code and illuminates the
"AIR BAG" warning lamp. The SOM will clear
current diagnostic trouble codes and move them to a
history file when the malfunction is no longer detected
and/or the ignition switch is cycled, except for DTCs
18, 24, 51, 53 and 71. DTCs 18, 24, 51, and 53 are
latched faults which cannot be cleared. DTC 71 may
not clear after a "Clear Codes" command is issued.
The SOM must be replaced only after the
malfunction that set the DTC has been
repaired.

1. This test confirms a current malfunction. If no
current malfunction is occurring (History DTC
set) the "Diagnostic Aids" for the appropriate
diagnostic trouble code should be referenced. The
SDM should not be replaced for a History DTC.
2. This test checks for a malfunction introduced into
the SIR system during the diagnostic process. It is
extremely unlikely that a malfunctioning SDM
would cause a new malfunction to occur during
the diagnostic process.
3. When all circuitry outside the SDM has been
found to operate properly, as indicated by the
appropriate diagnostic chart, then and only then
should the SOM be replaced.
9J-13
CHART A
SDM INTEGRITY CHE,!CK
CAUTION: DURING SERVICE PROCEDURES, BE VERY CAREFUL WHEN HANDUNG A SENSING AND
DIAGNOSTIC MODULE (SOM). NEVER STRIKE OR JAR THE SOM. NEVER POWER UP THE SIR SYSTEM
WHEN THE SOM IS NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SOM AND MOUNTING BRACKET
FASTENERS MUST BE CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE
FRONT OF THE VEHICLE TO ENSURE PROPER OPERATION OF THE SIR SYSTEM. THE SOM COULD BE
ACTIVATED WHEN POWERED WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE
DEPLOYMENT AND RESULTIN PERSONAL INJURY.
THIS CHART ASSUMES THAT THE "SIR DIAGNOSTIC SYSTEM CHECK" AND EITHER A
SYMPTOM CHART OR A DIAGNOSTIC TROUBLE CODE CHART DIAGNOSIS HAVE BEEN
PERFORMED. WHEN ALL CIRCUITRY OUTSIDE THE SOM HAS BEEN FOUND TO OPERATE
PROPERLY, AS INDICATED BY THE APPROPRIATE DIAGNOSTIC CHART, AND THE
SYMPTOM OR OTC REMAINS CURRENT, THE FOLLOWING DIAGNOSTIC PROCEDURES
MUST BE PERFORMED TO VERIFY THE NEED FOR SOM REPLACEMENT.
I
RECONNECT ALL SIR SYSTEM COMPONENTS, ENSURE ALL COMPONENTS ARE
PROPERLY MOUNTED.
ENSURE THE IGNITION SWITCH HAS BEEN "OFF" FOR AT LEAST THIRTY SECONDS.
NOTE "AIR BAG" WARNING LAMP AS IGNITION SWITCH IS TURNED TO "RUN."
DOES WARNING LAMP FLASH 7 TIMES THEN GO "OFF."
I
I
NO
YES
USING A SCAN TOOL REQUEST DIAGNOSTIC TROUBLE

CODE DISPLAY.
IS THE SAME SYMPTOM OR OTC OCCURING AS WAS WHEN
THE "SIR DIAGNOSTIC SYSTEM CHECK" WAS FIRST
PERFORMED?
THE SYMPTOM OR OTC IS NO LONGER

OCCURING.
CLEAR SIR DIAGNOSTIC TROUBLE CODES .,
REPEAT "SIR DIAGNOSTIC SYSTEM CHECK.
I
YES
CLEAR "SIR DIAGNOSTIC TROUBLE CODES."

IGNITION SWITCH "OFF" FOR AT LEAST THIRTY SECONDS.
NOTE "AIR BAG" WARNING LAMP AS IGNITION SWITCH IS
TURNED TO "RUN."
DOES WARNING LAMP FLASH 7 TIMES THEN GO "OFF"?
NO

GO 10 THE APPROPRIATE CHART
FORTHE INDICATED MALFUNCTION.
I
I
YES
SIR SYSTEM IS FUNCTIONAL AND FREE OF

MALFUNCTIONS. NO FURTHER DIAGNOSIS
IS REQUIRED.
NO
--.
IGNlriON SWITCH "OFF."

.
REPLACE SOM.
RECONNECT ALL SIR SYSTEM COMPONENTS.
ENS~RE ALL COMPONENTS ARE PROPERLY
"
MOUNTED.
REPEAT "SIR DIAGNOSTIC SYSTEM CHECK.
C9497
9J-14

SDM
TOIONfflON
SWITCH ~
1139YEL
SEE FUSE BLOCK DETAILS SECTION SA-11
AIRBAG FUSE
REFER TO SECTION 8A50 - - - 800TAN
DRw:.i~St:TOR
REFER TO
SECTION 8A76
SIRCOIL
ASSEMBLY
SERIAL DATA
DRIVER SEAT BELT

2
3
DRIVER SIDE HIGH
348DKORN
1403A WHT/BLK
PASS. SIDE HIGH
DRIVER SIDE LOW
tSHORTINO BARSJ
PASSENGER
:~J&R
238BLK/WHT
rHfil ffi----I
10NfflON1
PASSENGER INFLATOR MODULE JUMPER
~14038WHT/BLK.0
H!J--14048 DK ORN/WHTii!J1----..----..-----1404A DKORN/WHT
4 PASS. SIDE LOW
~SHORTINO BARS~
TO IGNfflON
10A
8208
(CHEV) D13
C18 (CHEV)
SWITCH +--fl"\Ji;- SIA PNK
39B PNK _...,_-HIHPol~l-............i - - - - - 3 5 8 BRN
GAGES
(PONT) A5
A7 (PONT)
LAMP
GROUND
SEE FUSE BLOCK DETAILS INS~RUMENT nu'sTER

SECTION IA-11
....L
051996
FT0119J
CHART B
(Page 1 of 2)
"AIR BAG" Warning Lamp Comes "ON" Steady

"RUN," "Ignition 1" voltage is applied from
"GAGES" Fuse to the "AIR BAG" warning lamp
which is connected to "SIR Indicator," terminal "7."
The "AIR BAG" fuse applies system voltage to the
"Ignition 1" input, terminal "10." The SDM responds
by flashing the "AIR BAG" warning lamp seven
times. If "Ignition 1" is outside of the normal
operating voltage range, the "AIR BAG" warning
lamp will come "ON" solid with no DTCs set.

1. This test determines if "Serial Data"
communication can be established with the SDM.
Successful communication indicates that the SDM
is properly connected.
2. This test checks for sufficient "Ignition 1"
voltage applied to the SDM.
3. This test checks for a correctly installed CPA.
4. This test determines whether the malfunction is a
short to ground in CKT 358.
5. This test checks for a disconnected SDM.
\
\
9J-15
CHART 8
(Page 1 of 2)
"AIR BAG" WARNING LAMP
COMES "ON" STEADY
)
WHEN MEASUREMENTS ARE REQUESTED IN THIS CHART USE
J 39200 DVM WITH CORRECT TERMINAL ADAPTER FROM J 35616-A.

WHEN A CHECK FOR PRO,PER CONNECTION IS REQUESTED, REFER
TO "INTERMITTENTS AND POOR CONNECTIONS" IN SECTION 8A4.
WHEN A WIRE, CONNECTOR OR TERMINAL REPAIR IS REQUESTED,
USE J 38125-A TERMINAL REPAIR KIT AND REFER TO "WIRING
REPAIR" IN THIS SECTION.
I

CONNECT SCAN TOOL TO DATA LINK CONNECTOR. FOLLOW DIRECTIONS
AS GIVEN IN THE SCAN TOOL INSTRUCTION MANUAL.
REQUEST SIR DATA LIST DISPLAY.
DOES SCAN TOOL INDICATE "NO DATA RECEIVED FROM SIR"?
I
I
NO
'
YES
USING SCAN TOOL, REQUEST SIR DATA LIST.

IS "IGNITION" > 8.2 VOLTS?

INSPECT SDM HARNESS CONNECTOR
CONNECTION TO SDM.
IS IT SECURELY CONNECTED TO THE SDM?
I
YES

INSPECT SDM HARNESS CONNECTOR CPA.
IS CPA INSTALLED CORRECTLY?
YES
I
GO TO CHART B
(PAGE 2 OF 2).
YES
NO
NO
DISCONNECT DRIVER AND

PASSENGER INFLATOR MODULES,
YELLOW 2WAY CONNECTORS
LOCATED NEAR THE BASE OF THE
STEERING COLUMN AND BEHIND THE
1/P COMPARTMENT DOOR ASSEMBLY.
DISCONNECT SDM.
DISCONNECT CKT 1751 GROUND RING
TERMINAL FROM FLOOR SHEETMETAL,
REFER TO SECTION 8A-47.
DISCONNECT INSTRUMENT CLUSTER.
MEASURE RESISTANCE FROM SDM
TO GROUND.
DOES J 39200 DISPLAY "OL"
(INFINITE)?
NO
CONNECT SDM SECURELY AND

INSTALL CPA TO DE-ACTIVATE
SHORTING BAR IN SDM
HARNESS CONNECTOR.
REPEAT "SIR DIAGNOSTIC
SYSTEM CHECK."
INSTALL CPA CORRECTLY TO

DE-ACTIVATE SHORTING BAR
IN SDM HARNESS
CONNECTOR.
SYSTEM CHECK. "
,I
NO
I
REPAIR SHORT FROM

CKT 358 TO GROUND.
YES
,,,,,.1,,.......,,.................,
li,,GO
TO CHART A. !
.............................................................................f
I
RECONNECT ALL SIR SYSTEM COMPONENTS, ENSURE ALL COMPONENTS ARE PROPERLY MOUNTED.
REPEAT "SIR DIAGNOSTIC SYSTEM CHECK."
I
C9498
9J16. SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM
SOM
TOIONmON
SWITCH 4
""-.15A
. . . , . _SEE
_FUSE
- -BLOCK
--------------DETAILS SECTION IA-11
1139YEL
IONmON1
AIR BAO FUSE
REFER TO SECTION 8A50 - - - BOO TAN

DRIVER INFLATOR
MODULE
REFER TO
SECTION 8A76
SIR COIL
ASSEMBLY
238BLKJWH
[gJtl~ li11------
SERIAL DATA
DRIVER SEAT BELT
2 DRIVER SIDE HIGH

3 DRIVER SIDE LOW
~sHoRT1No BARSJ
PASSENGER
1:~&R PASSENGER INFLATOR MODULE JUMPER
1403A WHT/BLK
1 PASS. SIDE HIGH
~ 1 4 0 4 8 DKGRN/WHTy[!]l-.----------1404ADKGRN/WHT
4 PASS. SIDE LOW
~14038WHTIBLKJ""0
L _ SHORTINO BARS
TO IONmON
10A
8208
(CHEV) D13
C18 (CH!V)
SWITCH +-----fl\.>- 39A PNK
398 PNK-1--o1-tMPc~t--t--olf----- 358 BRN
GAGES
(PONT) M
A7 (PONT)
LAMP
...~ : . ~.... ...~RUMENTCui'sTER
17St
ILK/WIIT
_._0101
GROUND
05199&
FT0119J
CHART 8
(Page 2 of 2)
"AIR BAG" Warning Lamp Comes "ON" Steady


6. An open "AIR BAG" fuse would cause the
"AIR BAG" warning lamp to come "ON"
steady.
7. This test checks for an open in the "Ignition 1"
circuit.
8. This checks whether a short to ground caused the
"AIR BAG" fuse to open.
9. This test determines whether the short to ground
is due to a short in the wiring or internal to the
SDM.
9J-17
CHART B
(Page 2 of 2)
COMES "ON" STEADY
WERE YOU SENT HERE FROM CHART B (PAGE 1 OF 2)?
I"''' ,,,,,,,,,,,,,,,,,,,,11,,,,,,,,,,,,,,,,,,,..,,,,,,,,,,,,,,,,,,1;
! GO TO CHART B (PAGE 1 OF 2). !

REMOVE AND INSPECT AIR BAG FUSE.
IS FUSE GOOD?
DISCONNECT DRIVER AND PASSENGER INFLATOR

MODULES, YELLOW 2-WAY CONNECTORS LOCATED
NEAR THE BASE OF THE STEERING COLUMN AND
BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY.
MEASURE RESISTANCE FROM SDM HARNESS
CONNECTOR TERMINAL "10" TO EACH TERMINAL
OF THE AIR BAG FUSE FUSEHOLDER.
IS EITHER MEASUREMENT 5.0 0 OR LESS?
V''''"'' ,,,,,,,,,,,,,,,,,,,,,,,,,,,$
I GO TO CHART A.
f,,,,,.,,,.,,u,,,,,,.,,.,.,,.,,,,,,,,,,,,,,,.,J
RECONNECT ALL SIR SYSTEM COMPONENTS;

ENSURE ALL COMPONENTS ARE PROPERLY
MOUNTED.
REPEAT "SIR.DIAGNOSTIC SYSTEM CHECK."
f,,,,..,,,,,,,,,,,,,,..,,,,,,,,,,,,,,,,u,,,,,,,,,,,,,,,,,,,..,,,.,,,,,,.,,,,,,f
REPLACE AIR BAG FUSE.

IGNITION SWITCH "ON," WAIT 10 SECONDS,
THEN IGNITION SWITCH "OFF."
REMOVE AND INSPECT AIR BAG FUSE.
IS FUSE GOOD?
DISCONNECT SDM.
REPLACE AIR BAG
FUSE.
IGNITION SWITCH TO
"RUN," WAIT 10
SECONDS,THEN
REMOVE AND INSPECT
AIR BAG FUSE.
IS FUSE GOOD?
REPAIR SHORT TO
GROUND IN CKT 1139.
RECONNECT SDM.
REPLACE AIR BAG
FUSE.
REPEAT "SIR
DIAGNOSTIC SYSTEM
CHECK."
INSTALL AIR BAG FUSE.

REPEAT "SIR
DIAGNOSTIC SYSTEM
CHECK."
REPLACE SDM.
INSTALL AIR BAG
FUSE.
REPEAT "SIR
DIAGNOSTIC
SYSTEM CHECK."
C9499
9J-18
,:t"-----SE_E_FU_SE_BL_OC_K_D_ET_AI_LS_SE_CTI_O_N_8A___11_ _ _ __
TO IGNmON
swrrcH 4
SOM
11
39
VEL
IGNmON1
AIRBAG FUSE
REFER TO SECTION 8A-50 ..,_--800 TAN
DRIVER INFLATOR
MODULE
PASSENGER
SERIAi. DATA
REFER TO
SECTION BA-76 - - - 2 3 8 BLK/WHT
SIR COIL
ASSEMBLY
[}r::ffi J(ffi----------
2 DRIVER SIDE HIGH

348DKGRN
DRIVER SIDE LOW
SHORTING BARS
1:~J&R PASSENGER INFLATOR MODULE JUMPER
,-0
1403A WHT/BLK
1 PASS, SIDE HIGH
+[!)-14049 DKGRNIWHTyl!J~----------1404ADKGRNIWHT
4 PASS; SIDI! LOW
~ 1 4 0 3 8 WHT/BU<
TO IGNmON
swrrcH
SHORTING BARS
10A
+--fl'\.JI-- 39A PNK

GAGES
8206
(CHEV)
D13
(PONT)
C18
(CHEV)
na PNK +-oi-4...,c::::i,i11--1--+----- 358 BRN

A7
(PONT)
LAMP
SEE FUSE BLOCK DETAILS INS~RUMENT nu'sTER
SECTION 8A-11
GROUND
..JL
051995
FT0111J
CHART C
(Page 1 of 2)
"AIR BAG" Warning Lamp Does Not Come "ON"


1. This test determines whether the malfunction is in
the SDM circuitry or in the instrument cluster
power feed circuitry.
2. This test determines whether voltage is present in
the warning lamp circuit.
3. This test determines if the malfunction is in the
instrument cluster.
4. This test isolates an open in the warning lamp
circuitry.
5. This test isolates CKT 358 and checks for a short
in CKT 358 to B+.
9J-19
CHART C
(Page 1 0 f 2)
"AIR BAG" WARNIN G LAMP
DOES NOT COME "ON"
WHEN MEASUREMENTS ARE REQUESTED IN THIS CHART USE J 39200

DVM WITH CORRECT TERMINAL ADAPTER FROM J 35616A. WHEN A
CHECK FOR PROPER CONNECTION IS REQUESTED, REFER TO
"INTERMITTENTS AND POOR CONNECTIONS" IN SECTION 8A4. WHEN
A WIRE, CONNECTOR OR TERMINAL REPAIR IS REQUESTED, USE
J 38125A TERMINAL REPAIR KIT AND REFER TO "WIRING REPAIR" IN
THIS SECTION.
I
SET PARK BRAKE.

NOTE INSTRUMENT CLUSTER AS IGNITION IS TURNED TO "RUN."
DOES THE "BRAKE" INDICATOR COME "ON"?
I
I
YES
NO
.... J.,.,,,.,,.,,,.,,.,,.,,.,,,,.,.,,.,,,,,,,,,,,,,,,,,,.,,,,,,,,,,
If GO TO CHART c (PAGE 2 OF 2). l

DISCONNECT DRIVER AND PASSENGER INFLATOR MODULES, YELLOW 2WAY
CONNECTORS LOCATED NEAR THE BASE OF THE STEERING COLUMN AND
DISCONNECT SOM.
DISCONNECT CKT f751 GROUND RING TERMINAL FROM FLOOR SHEETMETAL,
REFER TO SECTION 8A47.
MEASURE VOLTAGE ON SOM HARNESS CONNECTOR FROM TERMINAL "7" TO
GROUND.
IS SYSTEM VOLTAGE PRESENT ON TERMINAL "7"?
,,,,,,,,,,,,,,,,,,,,,,,.,!
11111,,1111,1111,1111,,,,,,111111111;11111111,u
I
I
NO
I
YES

REMOVE INSTRUMENT CLUSTER.
CHECK FOR PROPER CONNECTION TO INSTRUMENT
CLUSTER AT TERMINAL "C16" (CAMARO), TERMINAL "A7"
(FIREBIRD).
IF OK, THEN REMOVE AND INSPECT "AIR BAG" BULB.
IS BULB GOOD?
I
I
YES
I
INSTALL BUI.B.
MEASURE RESISTANCE FROM
INSTRUMENT CLUSTER
HARNESS CONNECTOR
TERMINAL "C16" (CAMARO),
TERMINAL "A7" (FIREBIRD)
TO SOM HARNESS
CONNECTOR TERMINAL "7".
IS RESISTANCE 5.0 '2 OR
LESS?
NO
I

DISCONNECT INSTRUMENT
CLUSTER.
MEASURE VOLTAGE ON SOM
HARNESS CONNECTOR FROM
TERMINAL "7" TO GROUND.
I
REPLACE BULB.
INSTALL INSTRUMENT
CLUSTER.
I
NO
REPAIR SHORT FROM

CKT 358 TO B+.
INSTALL INSTRUMENT
CLUSTER.
YES
i''"
'""'""CHART A.
j GOTO
~,,,,,,,,,.,,.,,,,,,,,,,,_,,,,,,,,,,,,,,,,,,,,,
I
I
NO
I

INSTALL INSTRUMENT
CLUSTER.
YES
I
SERVICE INSTRUMENT CLUSTER.

INSTALL INSTRUMENT CLUSTER.
I
I
C9500
9J-20

SDM
TOIGNmON
SWITCH
IGNmON1
SEE FUSE BLOCK DETAILS SECTION 8A-11
AIR BAG FUSE
REFER TO SECTION BA-50 - - - 8 0 0 TAN
DRIVER INFLATOR
MODULE
[Jit:ffi
SERIAi. DATA
REFER TO
SECTION 8A76 ---238 BLK/WHT
SIR COIL
ASSEMBLY
J ffi. .------------348==
DRIVER SIDE HIGH
DRIVER SIDE LOW
1403A WHTJBLK
PASS. SIDE HIGH
~ 1 4 0 4 9 DKGRN/WHTyl!l1------------1404ADKGRN/WHT
PASS. SIDI! LOW
PASSENGER
SHORTING BARS
:~J&R PASSENGER INFLATOR MODULE JUMPER
~ 14038 WHT/BLK ,0
L _ SHORTING BARS
TO IGNmON
SWITCH
10A
+--ff'\>-- DA PNK
GAGES
8206
C16 (CHEV)
(CHEV) 013
39B PNK ..........+-4HP,~D--t--+----- 358 BRN
(PONT) AS
A.7 (PONT)
LAMP
SEii! l'USE BLOCK DETAILS INS~RUMENT au8sTER
GROUND
SECTION 8A-11
061996
FT0119J
CHART C
(Page 2 of 2)
"AIR BAG" Warning Lamp Does Not Come "ON"

times. If "Ignition l" is outside of the normal
Numbei(s) below refer to circled number(s) on

6. This test checks whether power is available to
the instrument cluster power feed circuit.
7. This test checks for a short from the instrument
cluster power feed circuit to ground.
8. This test determines whether the short to ground
is due to a short in the wiring or internal to the
instrument cluster.
9. This test determines whether the malfunction is
due to an open power feed circuit from the
"GAGES" fuse.
9J-21
CHART C
(Page 2 of 2)
DOES NOT COME "ON"
WERE YOU SENT HERE FROM CHART C (PAGE 1 OF 2)?
YES
NO
,me
j GO TO

REMOVE AND INSPECT GAGES FUSE.
IS FUSE GOOD?
~,m,m,mmumummuummmmm,mu-.1
CHART C (PAGE 1 OF 2).
i,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,j
NO
I
YES
REPLACE GAGES FUSE.

IGNITION SWITCH TO "RUN," WAIT 10
SECONDS, THEN IGNITION SWITCH "OFF."
IS FUSE GOOD?
NO
I
DISCONNECT DRIVER AND

PASSENGER INFLATOR MODULES,
YELLOW 2WAY CONNECTORS
LOCATED NEAR THE BASE OF THE
STEERING COLUMN AND BEHIND THE
REPLACE GAGES FUSE.
IGNITION SWITCH TO "RUN," WAIT 10
SECONDS.
IS FUSE GOOD?
INSTALL GAGES
FUSE.

CHECK FOR PROPER CONNECTION AT INSTRUMENT
.CLUSTER HARNESS CONNECTOR TERMINAL "013"
(CAMARO), TERMINAL "AS" (FIREBIRD).
IF OK, THEN MEASURE RESISTANCE FROM THE
INSTRUMENT CLUSTER HARNESS CONNECTOR
TERMINAL "013" (CAMARO), TERMINAL "AS"
(FIREBIRD) TO EACH TERMINAL OF THE GAGES
FUSE FUSEHOLDER.
IS EITHER MEASUREMENT 5.0 0 OR LESS?
YES
REPAIR OPEN IN
POWER FEED TO
GAGES FUSE, REFER
TO SECTION 8A10.
INSTALL GAGES FUSE.
NO
I
REPAIR OPEN IN
CKT 39.
INSTALL GAGES
FUSE.
I
NO
YES

IN CKT 39.
REPLACE GAGES FUSE.
YES
SERVICE INSTRUMENT
CLUSTER.
INSTALL INSTRUMENT
CLUSTER.
INSTALL GAGES FUSE.
I
C9501
9J-22

SDM
TO IGNITION
DRIVER INFLATOR
MODULE
16A
[]tffi ,ffi
PASSENGER
:~J3:'
r:SHORTING BARS
...: :
IGNITION1
SWITCH + - - ' \ > - - - 1 1 3 9 YEL

AIR BAG FUSE
SIR COIL
ASSEMBLY
DRIVER SIDE HIGH
DRIVER SIDI!! LOW
~1403BWHT/BLK
70
~ 1 4 0 4 8 DKGRN/WHT
i - 0 - - - - - - - - 1 4 0 4 , \ D K GRN/WHT
~SHORTING BARS~
i - - 1 7 5 1 BLK/WHT
J__ 010101
060795
FT0109J
DTC 15
Passenger Deployment Loop Resistance High
the SDM will perform tests to diagnose critical
malfunctions within itself. Upon passing these tests
"Ignition l," 23 VLR, and deployment loop voltages
are measured to ensure they are within their respective
normal voltage ranges. The SDM then proceeds with
the "Resistance Measurement Test." "Passenger Side
Low" terminal "4" is grounded through a current sink
and the passenger current source connected to
"Passenger Side High" terminal "1" allows a known
amount of current to flow. By monitoring the voltage
difference between "Passenger Side High" and
"Passenger Side Low" the SDM calculates the
combined resistance of the passenger inflator module,
harness wiring CKTs 1403 and 1404 and connector
terminal contacts.
DTC Will Set When:
The combined resistance of the passenger
inflator module, harness wiring CKTs 1403 and 1404,
and connector terminal contact is above 3.0 Q. This
test is run once each ignition cycle during the
"Resistance Measurement Test" test when: 1) No
"higher priority faults" are detected during
"Turn-ON," 2) "Ignition 1" voltage is above a
specified value.
Action Taken:
SDM turns "ON" the "AIR BAG" warning
lamp and sets a diagnostic trouble code.
The resistance of the passenger deployment loop
is less than the specified value and the ignition switch
has been cycled.

Number(s) below refer to circled number(s). on
1. This test determines the deployment loop
resistance measured by the SDM.
2. This test verifies proper connection of the yellow
2-way connector.
3. This test checks for proper contact and/or
corrosion of the yellow 2-way connector.
4. This test isolates the malfunction to one side of
the passenger inflator module jumper yellow
2-way connector located behind the I/P
compartment door assembly.
5. This test checks whether the malfunction is due to
increased resistance in CKT 1403A, CKT 1404A,
or the SDM harness connector terminals "1" and
"4".
due to the passenger inflator module or the
passenger .inflator module jumper.
Diagnostic Aids:
An intermittent condition is likely to be caused
by a poor connection at the passenger inflator module
or passenger inflator module jumper harness connector
terminals "A" and "B," SDM terminals "4" and "l,"
or a poor wire to terminal connection in CKT 1403 or
CKT 1404. The test for this diagnostic trouble code is
only run while the "AIR BAG" warning lamp is
performing the BULB TEST, unless "higher priority
faults" are detected. When a scan tool "Clear Codes"
command is issued and the malfunction is still present,
the DTC will not reappear until the next ignition
cycle.
SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM 9J-23

WAS THE "SIR DIAGNOSTIC SYSTEM CHECK" PERFORMED?
.
. I
YES
PASSENGER
I
DEPLOYMENT
j G;TO THE j
LOOP
i "SIR
i
RESISTANCE
! DIAGNOSTIC!
I SYSTEM
I
HIGH
LCHECK." .,.,,J
NO
WHEN MEASUREMENTS ARE REQUESTED IN THIS CHART USE J 39200 DVM WITH
CORRECT TERMINAL ADAPTER FROM J 35616-A. WHEN A CHECK FOR PROPER
CONNECTION IS REQUESTED, REFER TO "INTERMITTENTS AND POOR
CONNECTIONS" IN SECTION BA-4. WHEN A WIRE, CONNECTOR OR TERMINAL
REPAIR IS REQUESTED, USE J 38125-A TERMINAL REPAIR KIT AND REFER TO
"WIRING REPAIR" IN THIS SECTION.
DTC 15

CONNECT TECH 1 DATA LINK CONNECTOR. FOLLOW DIRECTIONS IN THE TECH 1 OPERATORS MANUAL.
USING TECH 1 DATA LIST FUNCTION, READ AND RECORD THE PASSENGER DEPLOYMENT LOOP RESISTANCE "PASS.
RESIST."

MAKE SURE THE PASSENGER INFLATOR MODULE YELLOW 2WAY CONNECTOR
LOCATED BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY IS SEATED PROPERLY.
IS THE YELLOW 2-WAY CONNECTOR CONNECTED PROPERLY?
YES
NO
. I
DISCONNECT AND INSPECT FOR PROPER CONNECTION TERMINALS "A" AND

"B" OF THE PASSENGER INFLATOR MODULE YELLOW 2WAY CONNECTOR
LOCATED BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY.
IF OK, RECONNECT THE PASSENGER INFLATOR MODULE YELLOW 2-WAY
CONNECTOR.
IS OTC 15 CURRENT?
..
YES
..
YES
NO

THERE HAS BEEN A SMALL INCREASE IN,
THE TOTAL CIRCUIT RESISTANCE OF THE
PASSENGER INFLATOR DEPLOYMENT
LOOP. USE THE HIGH RESOLUTION
OHMMETER MODE OF THE J 39200 WHILE
CHECKING CKTS 1403A AND 1404A, AND
SOM CONNECTOR TERMINALS "1" AND "4"
TO. LOCATE THE SOURCE OF INCREASED
RESISTANCE.
WAS A MALFUNCTION FOUND AND
REPAIRED?
.
NO
I''' JI,,,,,,,,,,,,,,,,,)
j GOTO
j
It,u,,,,,,,,.,.,,,,,,,,,,,,
CHART A. I
C95 02
SEAT PASSENGER INFLATOR

MODULE YELLOW 2-WAY
CONNECTOR PROPERLY.
NO

DISCONNECT DRIVER AND PASSENGER INFLATOR MODULES, YELLOW 2-WAY
BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY,
CONNECT J 38715-A SIR DRIVER/PASSENGER LOAD TOOL TO DRIVER AND
PASSENGER INFLATOR MODULE HARNESS CONNECTORS.
IS OTC 15 CURRENT?
.
YES
I
RECONNECT ALL SIR

SYSTEM COMPONENTS,
ENSURE ALL
COMPONENTS ARE
.PROPERLY MOUNTED.
CLEAR SIR DIAGNOSTIC
TROUBLE CODES.
REPEAT "SIR
DIAGNOSTIC SYSTEM
CHECK."

REPLACE THE PASSENGER
INFLATOR MODULE JUMPER
2-WAY CONNECTOR ONLY.

DISCONNECT PASSENGER INFLATOR MODULE PIGTAIL CONNECTOR
FROM PASSENGER INFLATOR MODULE JUMPER.
.CHECK FOR PROPER CONNECTION TO PASSENGER INFLATOR
MODULE AT TERMINALS "A" AND "B".
IF OK THEN DISCONNECT PASSENGER INFLATOR JUMPER HARNESS
CONNECTOR FROM SIR DRIVER/PASSENGER LOAD TOOL AND
RECONNECT TO SIR WIRING HARNESS.
CONNECT SIR DRIVER/PASSENGER LOAD TOOL TO INFLATOR
MODULE SIDE OF PASSENGER INFLATOR MODULE JUMPER (NO
ADAPTER NEEDED).
IS OTC 15 CURRENT?
YES

PASSENGER INFLATOR MODULE
JUMPER.
NO
IGNITION SWITCH
"OFF."
REPLACE PASSENGER
INFLATOR MODULE.
RECONNECT ALL SIR SYSTEM COMPONENTS, ENSURE

ALL COMPONENTS ARE PROPERLY MOUNTED.
CLEAR SIR DIAGNOSTIC TROUBLE CODES.
9J24
SUPPLEMENTAL INFLATABLE RESTRAINT {SIR} SYSTEM

SOM
DRIVER INFLATOR
MODULI!
SIR COIL
ASSEMBLY
TO IGNITION
15A
SWITCH ~ 1 1 3 9 YEL
AIR BAG FUSE
['.H~ 1f!I
PASSENGER
:~J~
...:::
J
70
IGNITION1
2
DRIVER SIDE HIGH
.3
DRIVER SIDI! LOW
eSHOFITING BARS
~1403BWHT/BLK
~ 1 4 0 4 8 DKGRN/WHT
L__SHOFITING BARS
fl!]-------
____J
1404ADKGRN/WHT
r-----1751 BLKJWHT
..l._
01
Ci10IOI
080795
FT0109J
OTC 16
Passenger Deployment Loop Resistance Low


the "Resistance Measurement Test." "Passenger Side
and the passenger current source connected to
"Passenger Side High" terminal "1" allows a known
amount of current to flow. By monitoring the voltage
difference between "Passenger Side High" and
"Passenger Side Low" the SDM calculates the
combined resistance of the passenger inflator module,
harness wiring CKTs 1403 and 1404 and connector
terminal contact.

2. This >test verifies proper connection. of the yellow
2-way connector.
2-way connector located behind the 1/P
4. This test checks for a short from the "Passenger
Side High" circuit to the "Passenger Side Low"
circuit.
5. This test checks for a short from the ''Passenger
Side High" circuit to the "Driver Side Low"
circuit.
passenger inflator module jumper.
OTC Will Set When:

The combined resistance of the passenger
inflator module, harness wiring CKTs 1403 and 1404
and connector terminal contact is below 1.4 n. This
test is run once each ignition cycle during the
"Resistance Measurement Test" test when: 1) No
"higher priority faults" are detected during
"Turn-ON," 2) "Ignition 1" voltage is above a
specified value.
Action Taken:
OTC Will Clear When:

The resistance of the passenger deployment loop
is more than the specified value and the ignition
switch has been cycled.
Diagnostic Aids:
by a short between CKT 1403 and CKT 347, CKT
348 or CKT 1404, or a malfunctioning shorting bar on
the passenger inflator module or passenger inflator
module jumper harness. The test for this diagnostic
trouble code is only run while the "AIR BAG"
warning lamp is performing the BULB TEST, unless
"higher priority faults" are detected. When a scan tool
"Clear Codes" commarid is issued and the
malfunction is still present, the DTC will not reappear
until the next ignition cycle.
OTC 16
.
YES
CONNECTIONS" IN SECTION SA-4. WHEN A WIRE, CONNECTOR OR TERMINAL
"WIRING REPAIR" IN THIS SECTION.
PASSENGER
DEPLOYMENT
LOOP
RESISTANCE
LOW
NO
f ~f.jo THE j
! DIAGNOSTIC\
l SYSTEM
l
!t.,CHECK."
l
..,,.., .., ..............,,.., ............J,

CONNECT TECH 1 DATA LINK CONNECTOR. FOLLOW DIRECTIONS AS GIVEN IN THE TECH 1 OPERATORS MANUAL.
USING TECH 1 DATA LIST FUNCTION, READ AND RECORD THE PASSENGER DEPLOYMENT LOOP RESISTANCE "PASS. RESIST."
IS OTC 22 ALSO CURRENT?
NO
YES
. I

MAKE SURE THE PASSENGER INFLATOR MODULE
YELLOW 2-WAY CONNECTOR LOCATED BEHIND THE 1/P
COMPARTMENT DOOR ASSEMBLY IS SEATED PROPERLY.
IS THE YELLOW 2-WAY CONNECTOR CONNECTED
PROPERLY?
YES

MODULE YELLOW 2WAY CONNECTORS LOCATED NEAR
THE BASE OF THE STEERING COLUMN AND BEHIND
THE 1/P COMPARTMENT DOOR ASSEMBLY.
REPAIR SHORT FROM CKT 347 TO CKT 1403A OR 14038.
9J-25
NO

IS OTC 16 CURRENT?

MODULE YELLOW 2-WAY
CONNECTOR PROPERLY.
. I
NO
YES

THERE HAS BEEN A DECREASE IN THE TOTAL
CIRCUIT RESISTANCE OF THE PASSENGER
INFLATOR DEPLOYMENT LOOP.
DISCONNECT THE LOAD TOOL FROM THE
PASSENGER INFLATOR MODULE YELLOW "2~WAY
CONNECTOR LOCATED BEHIND THE 1/P
COMPARTMENT DOOR ASSEMBLY.
DISCONNECT THE SOM.
MEASURE THE RESISTANCE FROM SOM HARNES.S
TERMINAL "1" TO TERMINAL "4."
DOES J 39200 DISPLAY '!OL''. (INFINITE)?
.I
. I
.
. I
MEASURE THE RESISTANCE FROM

SOM HARNESS TERMINAL "1" TO
TERMINAL "3."
(INFINITE)?
YES
CHART A.
YES
IGNITION
SWITCH "OFF.''
REPAIR SHORT
FROM CKT
1403A TO CKT
1404A.
IGNITION SWITCH
"OFF.''
REPAIR SHORT FROM
CKT 14038 TO CKT
14048.
NO
IGNITION SWITCH
HOFF."
REPLACE PASSENGER
INFLATOR MODULE.
NO
: ,,.,I, ..........................................., ............., ~
! GO TO
.
. I

DISCONNECT PASSENGER INFLATOR MODULE PIGTAIL
CONNECTOR FROM PASSENGER INFLATOR MODULE
JUMPER,
DISCONNECT PASSENGER INFLATOR JUMPER
HARNESS CONNECTOR FROM SIR DRIVER/PASSENGER
LOAD TOOL AND RECONNECT TO SIR WIRING
HARNESS.
CONNECT SIR DRIVER/PASSENGER LOAD TOOL TO
INFLATOR MODULE SIDE OF PASSENGER INFLATOR
MODULE JUMPER (NO ADAPTER NEEDED).
IGNITION SWITCH "ON."
IS OTC 16 CURRENT?
I
NO
YES
;,,,,,,,,,,,,,.,.,,,.,u,,,,,,,,,;;;1,u1,)

REPAIR SHORT FROM
CKT 1403A TO CKT 348.
.....

CLEAR SIR DIAGNOSTIC TROUBLE CODES
REPEAT "SIR DIAGNOSTIC SYSTEM CHECK.''
C9503
9J-26 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM

SDM
DFIIVEFI !NFL.ATOR
MODULE
SIR COIL
ASSEMBLY
[fil ,ffi
PASSENGER
:~JP:
t:SHORTING BARS
TO IGNITION
15A
SWITCH ~ 1 1 3 9 V E L
AIR BAG FUSE
,ffi
J
. .:::
IONITION1
DFIIVER SIDE HIGH
DFIIVER SIDE LOW
~140313WHT/13LK
70
~ 1 4 0 4 8 DKGRN/WHT
f[!]-------1404ADKOFIN/WHT
L__ SHORTING BARS ___J
r----1761 BLK/WHT
_i_
0101
-
06-07-1115
Fr0109J
DTC 17
Passenger Deployment Loop Open

normal voltage ranges. During "Deployment Loop
Continuity" and "Continuous Monitoring" diagnostics,
a fixed amount of current is flowing in the deployment
loop. This produces proportional voltage drops in the
loop. By monitoring the voltage difference between
"Passenger Side High" and "Passenger Side Low" the
SDM calculates the combined resistance of the
passenger inflator module, harness wiring CKTs 1403
and 1404 and connector terminal contact.

2-way connector.
2-way connector located behind the If P
4. This test checks whether the malfunction is due to
increased resistance in CKT 1403A, CKT 1404A,
or the SDM harness connector terminals "1" and
"4".
DTC Will Set When:

The voltage difference between "Passenger Side
High" terminal "1" and "Passenger Side Low"
terminal "4" is above or equal to a specified value for
500 milliseconds during "Deployment Loop
Continuity" test or "Continuous Monitoring."
Action Taken:
Diagnostic Aids:
by a poor connection at the passenger inflator module
harness connector terminals "A" and "B," SDM
terminals "4" and " 1," or an open in CKT 1403 or
CKT 1404.

The voltage difference between "Passenger Side
High" terminal "1" and "Passenger Side Low"
terminal "4" is below a specified value for 500
milliseconds during "Continuous Monitoring."

..
YES
DTC 17
NO
,,..,,,,.JIJ,,,,,.,,,,,.,,,,.,,,,,.,
CONNECTION IS REQUESTED, REFER TO "INTERMITIENTS AND POOR
CONNECTIONS" IN SECTION BA-4. WHEN A WIRE, CONNECTOR OR TERMINAL
"WIRING REPAIR" IN THIS SECTION
9J-27
! GO TO THE j
i "SIR
i
! DIAGNOSTIC!
L~~~1~~I
mm
PASSENGER
DEPLOYMENT
LOOP OPEN

MAKE SURE THE PASSENGER INFLATOR MODULE YELLOW 2WAY CONNECTOR
LOCATED BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY IS SEATED PROPERLY.
IS THE YELLOW 2WAY CONNECTOR CONNECTED PROPERLY?
YES
NO
DISCONNECT AND INSPECT FOR PROPER CONNECTION TERMINALS "A" AND "B"
OF THE PASSENGER INFLATOR MODULE YELLOW 2-WAY CONNECTOR LOCATED
IF OK, RECONNECT THE PASSENGER INFLATOR MODULE YELLOW 2WAY
CONNECTOR.
IS OTC 17 CURRENT?
I
I
YES
YES
NO
. I
, . , , ,..
~.,mmm,,
! GOTO
!
!:' ,,.,,,,,,.,,,,,,,,,,,,.,,,,!
CHART A. !
C9!04

REPLACE THE PASSENGER
INFLATOR MODULE JUMPER 2-WAY
HARNESS SIDE CONNECTOR ONLY.
NO
. I
NO

THERE HAS BEEN A LARGE INCREASE
IN THE TOTAL CIRCUIT RESISTANCE OF
THE PASSENGER INFLATOR
DEPLOYMENT LOOP. USE THE J 39200
WHILE CHECKING CKTS 1403A, 1404A,
AND SOM CONNECTOR TERMINALS "1"
AND "4" TO LOCATE THE SOURCE OF
INCREASED RESISTANCE.
REPAIRED?

MODULE 2WAY CONNECTOR
PROPERLY.

BEHIND THE 1/P COMPARTMENT D.OOR ASSEMBLY.
CONNECT J 38715A SIR DRIVER/PASSENGER LOAD TOOL TO DRIVER AND
IS OTC 17 CURRENT?
YES
RECONNECT ALL SIR

SYSTEM COMPONENTS,
ENSURE ALL
COMPONENTS ARE
PROPERLY MOUNTED.
TROUBLE CODES.
REPEAT "SIR
DIAGNOSTIC SYSTEM
CHECK."

DISCONNECT PASSENGER INFLATOR MODULE PIGTAIL CONNECTOR
FROM PASSENGER INFLATOR MODULE JUMPER.
CHECK FOR PROPER CONNECTION TO PASSENGER INFLATOR
MODULE AT TERMINALS "A" AND "B."
IF OK THEN DISCONNECT PASSENGER INFLATOR JUMPER HARNESS
CONNECTOR FROM SIR DRIVER/PASSENGER LOAD TOOL AND
RECONNECT TO SIR WIRING HARNESS.
CONNECT SIR DRIVER/PASSENGER LOAD TOOL TO INFLATOR
MODULE SIDE OF PASSENGER INFLATOR MODULE JUMPER (NO
ADAPTER NEEDED).
IS OTC 17 CURRENT?
I
I
NO

REPLACE PASSENGER
INFLATOR MODULE.
RECONNECT ALL SIR
SYSTEM COMPONENTS,
ENSURE ALL COMPONENTS
ARE PROPERLY MOUNTED.
TROUBLE CODES.
SYSTEM CHECK."
YES

REPAIR OPEN IN
PASSENGERINFLATOR
MODULE JUMPER.
RECONNECT ALL SIR
SYSTEM COMPONENTS,
ENSURE ALL COMPONENTS
ARE PROPERLY MOUNTED.
TROUBLE CODES.
SYSTEM CHECK."
9J-28
SOM
SiRCOII.
ASSEMBLY
.--1--11 A
TO IGNITION~...___
SWITCH ....----.. ~1139VEI.
AIR_
BAG
FUSE
_ _ _....._
_
_ _ _ 347WKf
11--,j..-.e,..----
B 11-'~,,_-"""::""II
1 1 - - - - - - - - - 3 4 8 DKGRN
~1403BWHT/BI.K
J
70
+{!]-14049 DKGRN/WHT
ft!]-------1404ADKGRN/WHT
PASSENGER
1
:~J~
IGNITION1
2
DRIVER SIDE HIGH
DRIVER SIDE I.OW
U:SHOMING IIIIARS
PASSENGER INFI.ATOR MODULE ..II.IMPER
L _ SHORTING IIIIARS ___J
i - - - 1 7 6 1 BU(JWHT
__.__ G1
G10IOI
080795
FT0109..I
DTC 18
Passenger Deployment Loop Short to Ground

"Ignition l," 23 VLR and deployment loop voltages
normal voltage ranges. The SDM monitors the
voltages at "Driver Side Low" terminal "3" and
"Passenger Side Low" terminal "4" to detect shorts
to ground in the inflator module circuits. The service
Number(s) below refer. to circled number(s) on

1. This test determines the pass. side low voltage
measured by the SDM.
2-way connector located behind the 1/P
CKT 1403A.
CKT 1404A.
wait time is 1O minutes. Refer to "On-Vehicle

Service" for enable/disable procedures.
DTC
wm
Set When:
Neither of the two inflator module circuits is

open. "Ignition 1" is within the normal operating
voltage range. The voltages of both "Drivers Side
Low" and "Passenger Side Low" are NOT below a
specified value. Once these conditions are met and the
voltage at "Passenger Side Low" is below a specified
value, DTC 18 will set. This test is run during
"Turn-ON" tests and every 100 milliseconds during
"Continuous Monitoring.;,
Action Taken:
lamp, sets DTC 18 and also DTC 71.

The malfunction is no longer occurring (has
been repaired) and the SDM has been replaced. DTC
18 is a latched code and cannot be cleared.
Diagnostic Aids:
by a short to ground in. the passenger inflator module
circuit. Inspect CKTs 1403 and 1404 carefully for
cutting or chafing. If the wiring pigtail of the
passenger inflator module is damaged the component
must be replaced. A careful inspection of the
circuits and components indicated on the OTC

18 chart is essential to ensure that the
replacement SDM will not be damaged.
DTC 18
NOTICE: WHEN OTC 18 HAS BEEN SET IT IS NECESSARY TO REPLACE THE SOM. SETIING OTC 18
WILL ALSO CAUSE OTC 71 TO SET. WHEN A SCAN TOOL "CLEAR CODES" COMMAND IS ISSUED
AND THE MALFUNCTION IS NO LONGER PRESENT, DTCs 18 AND 71 WILL REMAIN CURRENT.
ENSURE THAT THE SHORT TO GROUND CONDITION IS REPAIRED PRIOR TO INSTALLING A
REPLACEMENT SOM TO AVOID DAMAGING THE SOM.
.
. I
9J-29
PASSENGER
DEPLOYMENT
LOOP SHORT
TO GROUND
YES
NO
, ... w ..,,,,,,,,,,,,,,,,.,,,,,,,,,,,,
WHEN MEASUREMENTS ARE REQUESTED IN THIS CHART USE J 39200 DVM WITH CORRECT TERMINAL
ADAPTER FROM J 35616-A. WHEN A CHECK FOR PROPER CONNECTION IS REQUESTED, REFER TO
"INTERMITIENTS AND POOR CONNECTIONS" IN SECTION 8A4. WHEN A WIRE, CONNECTOR OR
TERMINAL REPAIR IS REQUESTED, USE J 38125-A TERMINAL REPAIR KIT AND REFER TO "WIRING
REPAIR" IN THIS SECTION
i
i
GO TO THE "SIR i
DIAGNOSTIC
i
SYSTEM CHECK."
tu,,,,,.,,.,,,,,,,.,,.,,,,,.,,,,,,,.,,,,,,,,.,1

CONNECT TECH 1 DATA LINK CONNECTOR. FOLLOW DIRECTIONS AS GIVEN IN THE TECH 1 OPERATOR'S MANUAL.
USING TECH 1 DATA LIST FUNCTION, READ AND RECORD THE PASS. SIDE LOW VOLTAGE "PASS. SENSELO."

DISCONNECT DRIVER AND PASSENGER INFLATOR MODULES, YELLOW 2WAY CONNECTORS LOCATED NEAR
THE BASE OF THE STEERING COLUMN AND BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY.
CONNECT SIR DRIVER/PASSENGER LOAD TOOL J 38715-A TO DRIVER AND PASSENGER INFLATOR MODULE
HARNESS CONNECTORS.
IS "PASS. SENSELO" LESS THAN 3.3 VOLTS?
YES
IGNITION SWITCH
"OFF.''
DISCONNECT SOM.
DISCONNECT SIR
DRIVER/PASSENGER
LOAD TOOL.
MEASURE RESISTANCE
ON SOM HARNESS
CONNECTOR FROM
TERMINAL "1" TO
TERMINAL "6"
(GROUND).
"OL" (INFINITE)?
NO
~ IGNITION SWITCH "OFF."

DISCONNECT PASSENGER INFLATOR MODULE PIGTAIL CONNECTOR FROM PASSENGER
INFLATOR MODULE JUMPER.
DISCONNECT PASSENGER INFLATOR JUMPER HARNESS CONNECTOR FROM SIR
DRIVER/PASSENGER LOAD TOOL AND RECONNECT TO SIR WIRING HARNESS.
CONNECT SIR DRIVER/PASSENGER LOAD TOOL TO INFLATOR MODULE SIDE OF
PASSENGER INFLATOR MODULE JUMPER (NO ADAPTER NEEDED).
IS "PASS. SENSELO" LESS THAN 3.3 VOLTS?
..
NO
YES

INSPECT PASSENGER INFLATOR MODULE PIGTAIL
FOR DAMAGE AND ENSURE PIGTAIL IS ROUTED
CORRECTLY.
REPLACE PASSENGER INFLATOR MODULE.
I
YES
YES

JUMPER.
ENSURE JUMPER IS ROUTED
CORRECTLY.
I
.
. I
NO
MEASURE RESISTANCE ON SOM HARNESS CONNECTOR FROM

TERMINAL "4" TO TERMINAL "6" (GROUND).
,..,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,'
I, GO TO CHART A. II
i.,,,,,,,,,.,,.,,,,,,.,,.,,,.,,,,,,,,,,,,,,,,,,,,.,.,
REPAIR SHORT FROM

CKT 1403A TO GROUND.
. I
NO
REPAIR SHORT FROM CKT 1404A TO GROUND.
I
I

ENSURE "PASS. SENSELO" IS MORE THAN 3.3 VOLTS.
REPLACE SOM.
REPEAT "SIR DIAGNOSTIC SYSTEM CHECK,"
C950 5
9J-30

SDM
DFII\IEFI INFI.ATOR
MODULE
:~Jsr
PASSENGEFI
SIR COIL
ASSEMBLY
[Jt rn
rSHOIRTING BARS
TO IGNfflON
15A
AIR IBAG FUSE
. .:=
rn
J
I
IONfflON1
DRIVEFI SIDE HIGH
DRIVER SIDE LOW
PASSENGER !NFL.ATOR MODULE JUMPER
~1403BWHT/BLK
~ 1 4 0 4 8 DKGRN/WHT
70
. t{!]-------1404ADKOFIN,'WHT
L__SHORTINO BARS _ _ J
~ 1751 BLK/WHT
_j__ 01
010IOI
060795
FT0109J
DTC 19
Passenger Deployment Loop Short to Voltage

to B+ in the inflator module circuits.

1. This test determines the pass. side low voltage
2-way connector located behind the I/P
CKT 1403A.
CKT 1404A.
DTC Will Set When:

"Ignition 1" is within the normal operating
Low" and "Passenger Side Low" are NOT above a
voltage at "Passenger Side Low" is above a specified
"Continuous Monitoring."
Action Taken:
OTC
wm
Diagnostic Aids:
by a short to B+ in the passenger inflator module
circuit. Inspect CKTs 1403 and 1404 carefully for
cutting or chafing. If the wire pigtail of the passenger
inflator module is damaged the component must be
replaced.
Clear When:
The voltage measured at "Passenger Side Low"

is below a specified value for 500 milliseconds.
9J-31
DTC 19
..
. I
PASSENGER DEPLOYMENT
LOOP SHORT TO VOLTAGE
I, ... , I
NO
YES
WHEN MEASUREMENTS ARE REQUESTED IN THIS CHART USE J 39200 DVM WITH CORRECT TERMINAL
ADAPTER FROM J 35616-A. WHEN A CHECK FOR PROPER CONNECTION IS REQUESTED, REFER TO
"INTERMITTENTS AND POOR CONNECTIONS" IN SECTION 8A4. WHEN A WIRE, CONNECTOR OR
TERMINAL REPAIR IS REQUESTED, USE J 38125-A TERMINAL REPAIR KIT AND REFER TO "WIRING
REPAIR" IN THIS SECTION
~~~~cisHT~~s1R
! SYSTEM CHECK."
I!
;,,,,,,,,.,.,,,.,.,,,,,,,,,,,,,,,,.,.,,,.,,,,,.,,.,.,.,,J

CONNECT TECH 1 TO DATA LINK CONNECTOR. FOLLOW DIRECTIONS AS GIVEN IN THE TECH 1 OPERATOR'S MANUAL.
USING TECH 1 DATA LIST FUNCTION, READ AND RECORD PASS. SIDE LOW VOLTAGE "PASS. SENSELO."

DISCONNECT DRIVER AND PASSENGER INFLATOR MODULES, YELLOW 2-WAY CONNECTORS LOCATED NEAR THE BASE
OF THE STEERING COLUMN AND BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY.
CONNECT SIR DRIVER/PASSENGER LOAD TOOL J 38715-A TO DRIVER AND PASSENGER INFLATOR MODULE HARNESS
CONNECTORS.
IS "PASS. SENSELO" MORE THAN 4.8 VOLTS?
YES
NO
IGNITION SWITCH
"OFF."
DISCONNECT SOM.
DISCONNECT SIR
DRIVER/PASSENGER
LOAD TOOL.
IGNITION SWITCH TO
"RUN."
MEASURE VOLTAGE
ON SDM HARNESS
CONNECTOR FROM
TERMINAL "1" TO
TERMINAL "6"
(GROUND).
DOES J 39200
DISPLAY 1 VOI.T OR
LESS?

DISCONNECT PASSENGER INFLATOR MODULE PIGTAIL CONNECTOR FROM PASSENGER
INFLATOR MODULE JUMPER.
DISCONNECT PASSENGER INFLATOR JUMPER HARNESS CONNECTOR FROM SIR
DRIVER/PASSENGER LOAD TOOL AND RECONNECT TO SIR WIRING HARNESS.
CONNECT SIR DRIVER/PASSENGER LOAD TOOL TO INFLATOR MODULE SIDE OF
PASSENGER INFLATOR MODULE JUMPER (NO ADAPTER NEEDED).
IS "PASS. SENSELO" MORE THAN 4.8 VOLTS?
. I
YES

INSPECT PASSENGER INFLATOR
MODULE JUMPER FOR DAMAGE AND
ENSURE JUMPER IS ROUTED
CORRECTLY.
REPAIR SHORT FROM CKT 14038 OR
CKT 14048 TO B+.
YES
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
, '"'" JI
.
. I
I
CHART A.

REPAIR SHORT FROM CKT 1403A TO B+.
. I
NO
mmmmmmmmn",
! GO TO

INSPECT PASSENGER INFLATOR
MODULE PIGTAIL FOR DAMAGE AND
ENSURE PIGTAIL AND NEARBY WIRING
ARE ROUTED CORRECTLY.
REPLACE PASSENGER INFLATOR
MODULE.
NO
MEASURE VOLTAGE ON SDM HARNESS CONNECTOR

FROM TERMINAL "4" TO TERMINAL "6" (GROUND).
DOES J 39200 DISPLAY 1 VOLT OR LESS?
YES
NO
{,,,,,,,,,,..,,,,,,,.,.,.,,,,.,,.,,,,,.,,,,,,.,,.,.,,, J

REPAIR SHORT FROM CKT 1404A TO B+.
I
I
ENSURE "PASS. SENSELO" IS LESS THAN 4.8 VOLTS.
C9506
9J-32

SOM
DRIVERINFLATOR
MODULI!
0
[] f Iii
PASSENGER
:~JP:
TO IGNmON
15A
SIRCOIL
eSHORTING BARS
0
(
Iii
J
AIIBAGFUSE
348: : :
IGNmON1
DRIVER SIDE HIGH
DRIVER SIDI! LOW
PASSENGER !NFL.ATOR MODULE JUMPER
~1403BWHTJBLK
-;G
~ 1 4 0 4 8 DKGRN/WHT
tl!J--------1404ADKGRN/WHT
L__SHORTING BARS _ _ J
r-----1751 BLKJWHT
..l._
G1
010101
080795
FT0109J
DTC 21
Driver Deployment Loop Resistance High

the "Resistance Measurement Test." "Driver Side
and the driver current source connected to "Driver
Side High" terminal "2" allows a known amount of
current to flow. By monitoring the voltage difference
between "Driver Side High" and "Driver Side Low,"
the SDM calculates the combined resistance of the
driver inflator module, SIR coil assembly, harness
wiring CKTs 347 and 348 and connector terminal
contact.

2-way connector.
the driver inflator module yellow 2-way connector
located near the base of the steering column.
due to high resistance in the wiring.
the SIR coil assembly or the driver inflator
module.
DTC Will Set When:

The combined resistance of the driver inflator
module, SIR coil assembly, harness wiring CKTs 347
and 348 and connector terminal contact is above
3.8 n. This test is run during the "Resistance
Measurement Test" when: 1) No "higher priority
faults" are detected during "Turn-ON," 2) "Ignition
1" voltage is above a specified value.
Action Taken:

The resistance of the driver deployment loop is
less than the specified value and the ignition switch
has been cycled.
Diagnostic Aids:
An intermittent c.ondition is likely to be caused
by a poor connection at terminals "A" and "B" of the
SIR coil connector at the base of the steering column,
terminals "A" and "B" of the driver inflator module
connector at the top of the steering column, SDM
terminals "2" and "3" or a poor wire to terminal
connection in CKT 347 or CKT 348. The test for this
diagnostic trouble code is only run while the "AIR
BAG" warning lamp is performing the BULB TEST,
unless DTC 17 or DTC 26 is detected. When a scan
tool "Clear Codes" command is issued and the
YES
NO
0
0
"SIR
j CHECK."
~,.,,,,,,,,.,,,,,,,,,,,,,.,,,,,,,,,,,.,
NO
DISCONNECT AND INSPEC.T FOR PROPER CONNECTION TERMINALS "A" AND

"B" OF THE DRIVER INFLATOR MODULE YELLOW 2WAY CONNECTOR
LOCATED NEAR THE BASE OF THE STEERING COLUMN.
IF OK, RECONNECT THE DRIVER INFLATOR MODULE 2WAY CONNECTOR.
IS OTC 21 CURRENT?
.
YES
NO

THERE HAS BEEN A SMALL INCREASE
IN THE TOTAL CIRCUIT RESISTANCE OF
THE DRIVER INFLATOR DEPLOYMENT
LOOP. USE THE HIGH RESOLUTION
OHMMETER MODE OF THE J 39200
WHILE CHECKING CKTS 347 AND 348,
AND SOM CONNECTOR TERMINALS "2"
AND "3" TO LOCATE THE SOURCE OF
INCREASED RESISTANCE.
REPAIRED?
NO
, m,
.
I
YES
~"""''"'<
! GOTO
SEAT DRIVER INFLATOR

MODULE 2WAY CONNECTOR
PROPERLY.
I
NO

CONNECT J 38715A SIR DRIVER/PASSENGER LOAD TOOL TO DRIVER AND
IS OTC 21 CURRENT?
YES
I~~~~~~STICI
IGNITION SWITCH ,;OFF."

MAKE SURE THE DRIVER INFLATOR MODULE YELLOW 2WAY CONNECTOR
LOCATED IIIEAR THE BASE OF THE STEERING COLUMN IS SEATED PROPERLY.
IS THE 2WAY CONNECTOR CONNECTED PROPERLY?
! GO TO THE i
DRIVER
DEPLOYMENT
LOOP
RESISTANCE
HIGH

CONNECT TECH 1 DATA LINK CONNECTOR. FOLLOW DIRECTIONS AS GIVEN IN THE TECH 1 OPERATOR'S MANUAL.
USING THE TECH 1 DATA LIST FUNCTION, READ AND RECORD THE DRIVER DEPLOYMENT LOOP RESISTANCE "DRIV. RESIST."
YES
Vi'" Jll,.,,,,,,,,.,,,.,.,.,.,,.,,,,,1
CONNECTIONS" IN SECTION 8A4. WHEN A WIRE, CONNECTOR OR TERMINAL
REPAIR IS REQUESTED, USE J 38125A TERMINAL REPAIR KIT AND REFER TO
"WIRING REPAIR" IN THIS SECTION
DTC 21
9J33
~ .CHART A., j
';

REPLACE THE DRIVER
INFLATOR MODULE 2~WAY
HARNESS SIDE CONNECTOR
ONLY.

DISCONNECT SIR DRIVER/PASSENGER LOAD TOOL FROM DRIVER
INFLATOR MODULE HARNESS CONNECTOR.
REMOVE INFLATOR MODULE FROM STEERING WHEEL, REFER TO
SECTION 3F.
CONNECT SIR DRIVER/PASSENGER LOAD TOOL WITH APPROPRIATE
ADAPTER TO INFLATOR MODULE CONNECTOR ON STEERING COLUMN.
RECONNECT DRIVER INFLATOR MODULE HARNESS CONNECTOR AT THE
BASE OF THE STEERING COLUMN.
IS OTC 21 CURRENT?
. I
YES

REPLACE SIR COIL
ASSEMBLY, REFER TO
SECTION 3FS.
I
. I
NO

REPLACE DRIVER INFLATOR
MODULE, REFER TO SECTION 3F.

C9507

SDM
DRIVER INFLATOR
MODULE
[]t ffi
r:SHOFITING BMS
PASSENGER
l:~J~
TO IGNITION
15A
AIR BAG FUSE
SIR COIL
ASSEMBLY
:=
ffi
..
IGNITION1
2
DRIVER SIDE HIGH
DRIVER SIDI! LOW
PASSENGER INFI.ATOA MODULE JUMPER
~1403BWHT/BL.K
-;-E]
~ 1 4 0 4 8 DKGAN/WHT
i { ! ) . . . - - - - - - - 1 4 0 4 A DKGAN/WHT
L__ SHORTING BAAS __J
r----17151 BIJ(JWHT
_i__
G1
G10IOI
GROUND
060795
.FT0109J
DTC 22
Driver Deployment Loop Resistance Low

the "Resistance Measurement Test." "Driver Side
and the driver current source connected to "Driver
Side High" terminal "2" allows a known amount of
current to flow. By monitoring the voltage difference
between "Driver Side High" and "Driver Side Low,"
the SDM calculates the combined resistance of the
driver inflator module, SIR coil assembly, harness
wiring CKTs 347 and 348 and connector terminal
contact.

2-way connector.
4. This test checks for a short from the "Driver Side
High" circuit to the "Driver Side Low" circuit.
5. This test checks for a short from the "Driver Side
High" circuit to the "Passenger Side Low"
circuit.
6; This test determines whether the malfunction is in
module.
DTC Will Set When:

The combined resistance of the driver inflator
module, SIR coil assembly, harness wiring CKTs 347
and 348 and connector terminal contact is below
1. 7 n. This test is run during the "Resistance
Measurement Test" when: 1) No "higher priority
faults" are detected during "Turn-ON," 2) "Ignition
1" voltage is above a specified value.
Action Taken:

The resist,mce of the driver deployment loop is
more than the specified value and the ignition switch
has been cycled.
Diagnostic Aids:
by a short between CKT 347 and CKT 348 or CKT
1404, or a malfunctioning shorting bar on the driver
inflator module or SIR coil assembly which would
require replacement of the component. The test for
this diagnostic trouble code is only run while the
"AIR BAG" warning lamp is performing the BULB
TEST, unless DTC 17 or DTC 26 is detected. When a
scan tool "Clear Codes" command is issued and the
DTC 22
..
. I
YES
NO
,,.,..11,.,,,,,.,,.,,.,,,,,,,~
CORRECT TERMINAL ADAPTER FROM J 35616A. WHEN A CHECK FOR PROPER
CONNECTIONS" IN SECTION 8A4, WHEN A WIRE, CONNECTOR OR TERMINAL
"WIRING REPAIR" IN THIS SECTION .
9J35
! GO TO THE !
l "SIR
! DIAGNOSTIC J
I SYSTEM
j
! CHECK.",,,,,,,)
DRIVER
DEPLOYMENT
LOOP
RESISTANC E
LOW

CONNECT TECH 1 DATA LINK CONNECTOR. FOLLOW DIRECTIONS AS GIVEN IN THE TECH 1 OPERATORS MANUAL.
USING TECH 1 DATA LIST FUNCTION, READ AND RECORD THE DRIVER DEPLOYMENT LOOP RESISTANCE "DRIV. RESIST."
I
IS OTC 16 ALSO CURRENT?
. I
NO
YES

MAKE SURE THE DRIVER INFLATOR MODULE YELLOW
2WAY CONNECTOR LOCATED NEAR THE BASE OF THE
STEERING COLUMN IS SEATED PROPERLY.
IS THE YELLOW 2WAY CONNECTOR CONNECTED
PROPERLY?

MODULES YELLOW 2WAY CONNECTORS LOCATED NEAR
THE BASE OF THE STEERING COLUMN AND BEHIND THE
REPAIR SHORT FROM CKT 347 TO CKT 1403A OR 14038.
.I
. I
YES
NO

CONNECT J. 38715-A SIR DRIVER/PASSENGER LOAD TOOL TO DRIVER AND
IS OTC 22 CURRENT?

MODULE YELLOW 2WAY
CONNECTOR PROPERLY.
I
YES
NO

THERE HAS BEEN A DECREASE IN THE TOTAL
CIRCUIT RESISTANCE OF THE DRIVER INFLATOR
DEPLOYMENT LOOP.
DISCONNECT THE LOAD TOOL FROM THE DRIVER
INFLATOR MODULE YELLOW 2WAY .CONNECTOR
LOCATED NEAR THE BASE OF THE STEERING
COLUMN.
DISCONNECT THE SOM.
MEASURE THE RESISTANCE FROM SOM HARNESS
TERMINAL "2" TO TERMINAL "3."
.I
. I
NO
MEASURE THE RESISTANCE FROM

SOM HARNESS TERMINAL "2" TO
TERMINAL. "4,"
(INFINITE)?
.
I
YES
""""" )f,.,,,,.,.,,,,,,,,,.,,.,..,,.,.,,,,,,_,,,
I
'I
j GO TO CHART A. j
,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,.
NO
YES
IGNITION
SWITCH "OFF."
REPAIR SHORT
FROM CKT 347
TO CKT 348.
1 IGNITION SWITCH "OFF."
REPAIR SHORT FROM CKT 347

TO CKT 1404A OR 14048.

DISCONNECT SIR DRIVER/PASSENGER LOAD TOOL
FROM DRIVER INFLATOR MODULE HARNESS
CONNECTOR.
REMOVE INFLATOR MODULE FROM STEERING WHEEL,
REFER TO SECTION 3F.
CONNECT SIR DRIVER/PASSENGER LOAD TOOL WITH
APPROPRIATE ADAPTER TO INFLATOR MODULE
CONNECTOR ON STEERING COLUMN.
RECONNECT DRIVER INFLATOR MODULE HARNESS
CONNECTOR AT THE BASE OF THE STEERING COLUMN.
IS OTC 22 CURRENT?
.
. I
YES
IGNITION SWITCH
UOFF."
REPLACE SIR COIL
ASSEMBLY, REFER TO
SECTION 3F5.
I
NO
REPLACE DRIVER
INFLATOR MODULE.

C9508
9J-36
SOM
TO IGNITION
DFIM!FI !NFL.ATOR
MODULE
SIR COIL
ASSEMl!ILV
['.Ji!~
PASSENGER
:~JP:
eSHOMING BARS
15A
rn
J
AIR BAO FUSE
. .:::
IONITION1
SWITCH +--41'\>-1139 YEL

2
DRM!R SIDE HIGH
DRIVER SIDE LOW
PASSENGER INFLATOFI MODULE JUMPER
~1403BWHT/BI.K
-70
~ 1 4 0 4 8 DKORN/WHT
i { ! ] e " - - - - - - - - 1 4 0 4 A DK GFIN/WHT
L__ SHORTING BARS __J
r-----1761 BI.K/WHT
...l_
01
010101
0607&5
FT01otJ
DTC 24
Driver Deployment Loop Short to Ground


to ground in the inflator module circuits. The service
wait time is 10 minutes. Refer to "On-Vehicle
Service" for enable/disable procedures.
The malfunction is no longer occurring (has

been repaired) and the SDM has been replaced. DTC
24 i.s a latched code and cannot be cleared.
DTC Will Set When:

Neither of the two inflator module circuits is
open. "Ignition 1" is within the normal operating
voltage range. The voltages of both "Driver Side
Low" and "Passenger Side Low" are NOT below a
voltage measured at "Driver Side Low" is below a
specified value for 500 milliseconds, DTC 24 will set.
This test is run during "Turn~ON" tests and every 100
milliseconds during "Continuous Monitoring."
Action Taken:
lamp, sets DTC 24 and also DTC 71.

1. This test determines the driver side low voltage
CKT 347.
CKT 348.
the coil assembly or the driver inflator module.
Diagnostic Aids:
by a short to ground in the driver inflator module
circuit. A DTC 24 would be accompanied by DTC 71.
Inspect CKTs 347 and 348 carefully for cutting or
chafing. A careful inspection of the circuits and
components indicated on the DTC 24 chart is
essential to ensure that the replacement SDM
will not be damaged.
DTC 24
NOTICE: WHEN OTC 24 HAS BEEN SET IT IS NECESSARY TO REPLACE THE SOM. SETTING OTC 24
WILL ALSO CAUSE OTC 71 TO SET. WHEN A SCAN TOOL "CLEAR CODES" COMMAND IS ISSUED AND
THE MALFUNCTION .IS NO LONGER PRESENT, DTCs 24 AND 71 WILL REMAIN CURRENT. ENSURE THAT
THE SHORT TO GROUND CONDITION IS REPAIRED PRIOR TO INSTALLING A REPLACEMENT SOM TO
AVOID DAMAGING THE SOM.
9J37
DRIVER
DEPLOYMENT
LOOP SHORT
TO GROUND
I,.,..
NO
YES
CONNECTION IS REQUESTED, REFER TO "INTERMITTENTS AND POOR CONNECTIONS" IN
SECTION 8A4. WHEN A WIRE, CONNECTOR OR TERMINAL REPAIR IS REQUESTED, USE
J 38125-A TERMINAL REPAIR KIT AND REFER TO "WIRING REPAIR" IN THIS SECTION.
...........................,,,
! GO TO THE "SIR
l DIAGNOSTIC
l
! SYSTEM CHECK." !
lu,,,,,u,11111,1,11111111,,,,,,,,,,,,,~

USING TECH 1 DATA LIST FUNCTION, READ AND RECORD THE DRIVER SIDE LOW VOLTAGE "DRIV. SENSELO."
I

DISCONNECT DRIVER AND PASSENGER INFLATOR MODULES, YELLOW 2WAY CONNECTORS LOCATED NEAR THE
BASE OF THE STEERING COLUMN AND BEHIND 1/P COMPARTMENT DOOR ASSEMBLY.
CONNECT SIR DRIVER/PASSENGER LOAD TOOL J 38715A TO DRIVER AND PASSENGER INFLATOR MODULE HARNESS
CONNECTORS.
IGNITION SWITCl:I '1'0 "RUN."
IS "DRIV. SENSELO" LESS THAN 3.3 VOLTS?
I
YES
NO

DISCONNECT SOM.
DISCONNECT SIR DRIVER/PASSENGER LOAD.TOOL.
MEASURE RESISTANCE ON SOM HARNESS CONNECTOR
FROM TERMINAL "2" TO TERMINAL "6" (GRQUND),
..DOES J 39200 DISPLAY "OL" (INFINITE)?
I
YES
NO
MEASURE RESISTANCE ON SOM HARNESS

CONNECTOR FROM TERMINAL "3" TO
TERMINAL "6" (GROUND).
DOES J 392.00 DISPLAY "OL" (INFINITE)?
I
I
REPAIR
SHORT FROM
CKT 347 TO
GROUND.
YES
,.., ................ ...........,

,,
Ii ..,,,,,,,,,,,,,,,,,,,.,,,,,,,,,,,.,,,,.,,I
GO TO CHART A. I
~
NO
REPAIR SHORT FROM

CKT 348 TO GROUND.

CONNECTOR AT THE BASE OF THE STEERING COLUMN.
IS "DRIV. SENSELO" LESS THAN 3.3 VOLTS?
I
YES

REMOVE AND INSPECT SIR COIL
ASSEMBLY AND CONNECTING
WIRES FOR DAMAGE.
DETERMINE AND REPAIR THE
CAUSE OF DAMAGE AND
REPLACE SIR COIL ASSEMBLY,
REFER TO SECTION 3F5.
NO
I
IGNITION
SWITCH "OFF."
REPLACE
DRIVER
INFLATOR
MODULE, REFER
TO SECTION 3F.
ENSURE "DRIV. SENSELO" IS MORE THAN 3.3 VOLTS.
REPLACE SOM.
C9509
9J38 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM

SOM
DRIVER INFI.ATOR
MODULE
SIR COIL
ASS!MEILY
[} ffi
PASSENGER
:~m:
r:SHORTING BARS
TO IGNmON
15A
SWITCH + - - ' \ J t - - 1 1 3 9 YEL
AIR BAO FUSE
ffi
J
...::
IGNmON1
2
DRIVER SIDE HIGH

DRIVER SID! LOW
PASSENGER INFI.ATOR MODULE JUMPER
~1403BWHTJBU<
70
~ 1 4 0 4 8 DK GRN/WHT
i{!]i---------1404ADKGRN/WHT
C'"'IIU(/WIIT
L__SHORTINGBARS__J
0607115
FT0108J
DTC 25
Driver Deployment Loop Short to Voltage


"Ignition 1," 23 VLR and deployment loop voltages
to B+ in the inflator module circuits.
The voltage measured at "Driver Side Low" is

below a specified value for 500 milliseconds.
DTC
wm
Set When:
"Ignition 1" is within the normal operating

Low" and "Passenger Side Low" are NOT above a
voltage at "Driver Side Low" is above a specified
Action Taken:

.
1. This test determines the driver side low voltage
CKT 347.
CKT 348.
the coil assembly or the driver inflator module.
Diagnostic Aids:
by a short to B+ in the driver inflator module circuit.
Inspect CKT 347 and CKT 348 carefully for cutting or
chafing.
9J-39
DTC 25
DRIVER
DEPLOYMENT
LOOP SHORT
TO VOLTAGE
I, .. 1..,,,,...I,,,,,,......,,,..........,,,,
NO
YES
I
CONNECTION IS REQUESTED, REFER TO "INTERMITTENTS AND POOR CONNECTIONS" IN
SECTION 8A4. WHEN A WIRE, CONNECTOR OR TERMINAL REPAIR IS REQUESTED, USE
J 38125-A TERMINAL REPAIR KIT AND REFER TO "WIRING REPAIR" IN THIS SECTION.
! GO TO THE "SIR
l DIAGNOSTIC SYSTEM l
l&..,,,,,,,,_
CHECK."
l
.._ _,,.,,.........,.,.,...........,....,,,,,,,,..,.~

USING TECH 1 DATA LIST FUNCTION, READ AND RECORD DRIVER SIDE LOW VOLTAGE "DRIV. SENSELO."
I

DISCONNECT DRIVER AND PASSENGER INFLATOR MODULES, YELLOW 2WAY CONNECTORS LOCATED NEAR THE BASE OF
THE STEERING COLUMN AND BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY.
CONNECT SIR DRIVER/PASSENGER LOAD TOOL J 38715A TO DRIVER AND PASSENGER INFLATOR MODULE HARNESS
CONNECTORS.
IGNITION SWITCH TO "RUN,."
IS "DRIV. SENSELO" MORE THAN 4.8 VOLTS?
YES
NO

DISCONNECT SOM.
DISCONNECT SIR DRIVER/PASSENGER LOAD TOOL.
MEASURE VOLTAGE ON SOM HARNESS CONNECTOR
FROM TERMINAL "2" TO TERMINAL "6" (GROUND).
I
YES
NO
MEASURE VOLTAGE ON SOM HARNESS

CONNECTOR FROM TERMINAL "3" TO
TERMINAL "6" (GROUND),
I
I
YES
NO
,....1 ............................,
j ,,,,,,,,,,,,,
GO TO CHART A. !
..........,,,,,,,,,,,,,,.,,.,,,,,.. J
~
IGNITION SWITCH
"OFF."
REPAIR SHORT FROM
CKT 348 TO B+
IGNITION
SWITCH "OFF."
REPAIR SHORT
FROM CKT 347
TO B+.

CONNECTOR AT THE. BASE OF THE STEERING COLUMN.
IS "DRIV. SENSELO" MORE THAN 4.8 VOLTS?
I
I
YES

REMOVE AND INSPECT SIR COIL
ASSEMBLY AND CONNECTING
WIRES FOR DAMAGE.
DETERMINE AND REPAIR THE
CAUSE OF DAMAGE AND
NO
I
IGNITION
SWITCH "OFF."
REPLACE
DRIVER
INFLATOR
MODULE, REFER
TO SECTION 3F
ENSURE "DRIV. SENSELO" IS LESS THAN 4.8 VOLTS.
C9510
9J40

SOM
DRIVERINFI.ATOR
MODULE
SIRCOIL
ASSEMBLY
[] ,ffi
PASSENGER
:~J~
eSHORTING BARS
TO IGNITION
16A
AIR BAG FUSE
,ffi
J
. .:::
IGNITION1
DRIVER SIDE HIGH
DRIVER SIDE LOW
PASSENGER INFI.ATOR MODULE JUMPER
~1403BWHT/BLK
ll::lf[!)-14049 DK GRN/WHT
1 { ! ] - - - - - - - - 1 4 0 4 A DK GRN/WHT
L__SHORTING BARS ___J
i-----1751 81.K/WHT
j__ 01010101
08~0795
FT0109J
DTC 26
Driver Deployment Loop Open

"Ignition 1," 23 VLR, and deployment loop voltages
normal voltage ranges. During "Deployment Loop
Continuity" and "Continuous Monitoring" diagnostics,
a fixed amount of current is. flowing in the deployment
loop. This produces proportional voltage drops in the
loop. By monitoring the voltage difference between
"Driver Side High" and " Driver Side Low," the
SDM calculates the combined resistance of the driver
inflator module, SIR coil assembly, harness wiring
CKTs 347 and 348 and connector terminal contact.

2-way connector.
due to an open in the wiring.
module.
DTC Will Set When:

The voltage difference between "Driver Side
High" terminal "2" and "Driver Side Low" terminal
"3" is above or equal to a specified value for 500
milliseconds during "Deployment Loop Continuity" or
Action Taken:

The voltage difference between "Driver Side
High" terminal "2" and "Driver Side Low" terminal
"3" is below a specified value for 500 milliseconds
during "Continuous Monitoring."
Diagnostic Aids:
by a poor connection at the driver inflator module
terminals "A" or "B," SIR coil assembly terminals
"A" or "B," SDM terminals "2" or "3," or an open
in CKT 347 or CKT 348. An intermittent open in the
SIR coil assembly could also set this DTC. To test for
a bad SIR coil assembly, clear DTCs, then turn the
steering wheel back and forth with the ignition switch
in "RUN." If the "AIR BAG" warning lamp comes
"ON" and DTC 26 has set again, it is likely the SIR
coil is malfunctioning.
9J-41
DTC 26
YES
DRIVER DEPLOYMENT
LOOP OPEN
NO
; ml u m m m m m m u u u u m m m m m m m , ,
j GO TO THE "SIR DIAGNOSTIC
!~,,,,,,,,,,,,1,,111111;,,u,,.,,,.,,,u,,;,,,,,,,,,,,,,.,,.,,,,,,,u,,,.,'
SYSTEM CHECK."
!
WHEN MEASUREMENTS ARE REQUESTED IN THIS CHART USE J 39200

DVM WITH CORRECT TERMINAL ADAPTER FROM J 35616-A. WHEN A
CHECK FOR PROPER CONNECTION IS REQUESTED, REFER TO
"INTERMITTENTS AND POOR CONNECTIONS" IN SECTION 8A4. WHEN A
WIRE, CONNECTOR OR TERMINAL REPAIR IS REQUESTED, USE
J 38125-A TERMINAL REPAIR KIT AND REFER TO "WIRING REPAIR" IN
THIS SECTION.
I

MAKE SURE THE DRIVER INFLATOR MODULE YELLOW 2WAY CONNECTOR LOCATED NEAR THE
BASE OF THE STEERING COLUMN IS SEATED PROPERLY.
IS THE YELLOW 2WAY CONNECTOR CONNECTED PROPERLY?
.
YES I
.
NO

MODULE YELLOW 2-WAY
CONNECTOR PROPERLY.
DISCONNECT AND INSPECT FOR PROPER CONNECTION

TERMINALS "A" AND "B" OF THE DRIVER INFLATOR MODULE
YELLOW 2-WAY CONNECTOR LOCATED NEAR THE BASE OF
THE STEERING COLUMN.
IF OK, RECONNECT THE DRIVER INFLATOR MODULE YELLOW
2-WAY CONNECTOR.
IS OTC 26 CURRENT?
.
YES I
.
I
NO
I

IS OTC 26 CURRENT?

REPLACE THE DRIVER
INFLATOR MODULE YELLOW
2WAY HARNESS SIDE
CONNECTOR ONLY.
YES
NO
. I

THERE HAS BEEN A LARGE INCREASE IN THE TOTAL
CIRCUIT RESISTANCE OF THE DRIVER INFLATOR
DEPLOYMENT LOOP. USE THE J 39200 WHILE CHECKING
CKTs 347, 348, AND SOM CONNECTOR TERMINALS "2" AND
"3" TO LOCATE THE SOURCE OF INCREASED RESISTANCE.
WAS A MALFUNCTION FOUND AND REPAIRED?
NO
IG~TO_CHART A._J
YES

DISCONNECT SIR DRIVER/PASSENGER LOAD
TOOL FROM DRIVER INFLATOR MODULE
HARNESS CONNECTOR.
REMOVE INFLATOR MODULE FROM STEERING
WHEEL, REFER TO SECTION 3F.
CONNECT SIR DRIVER/PASSENGER LOAD TOOL
WITH APPROPRIATE ADAPTER TO INFLATOR
MODULE CONNECTOR ON STEERING COLUMN
RECONNECT DRIVER INFLATOR MODULE
HARNESS CONNECTOR AT THE BASE OF THE
STEERING COLUMN.
IS OTC 26 CURRENT?
YES
NO

REPLACE DRIVER INFLATOR
MODULE, REFER TO SECTION 3F.
I

C9511
9J42

SOM
DRIVER INFLATOR
MODULE
SIR COIL
ASSEMBLY
[] I ffi
PASSENGER
l:~J~
r:SHOATINO BAAS
TO IGNfflON
15A
SWITCH + - 4 / ' \ > - 1 1 3 9 YEL
AIR BAO FUSE
...:=
ffi
J
I
IONfflON1
2
DRIVER SIDE HIGH
DRIVER SIDE LOW
~1403BWHTIBLI<
~1404BDKGRN/WHT
L___SHOATING BAAS
70
fl!Ji--------
__J
r - 1 7 5 1 BLKJWHT
_i_
GROUND
0101
-
080795
FT0109J
DTC 51
Deployment Commanded
value, additional signal processing is perforrned and
the generated signals. are compared to signals stored in
through the inflator modules, deploying the air bags
and causing DTC 51 to set.
DTC Will Set When:
The SDM detects a frontal crash, up to 30
degrees off the centerline of the vehicle, of sufficient
force to warrant deployment of the air bags.
Action Taken:
lamp, records "Crash Data," and sets a diagnostic
trouble code.
DTC 51 cannot be cleared and therefore requires
replacement of the SDM.

1. If inflator module(s) has not deployed, DTC 51
may have set falsely.
2. If DTC 51 has set with no signs of frontal impact,
the diagnostic trouble code has set falsely.
9J-43
DTC 51
DEPLOYMENT COMMANDED
CAUTION: DURING SERVICE PROCEDURES, BE CAREFUL WHEN HANDLING A SENSING AND DIAGNOSTIC
MODULE (SOM). NEVER STRIKE OR JAR THE SOM. NEVER POWER UP THE SIR SYSTEM WHEN THE SOM IS
NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SOM AND MOUNTING BRACKET FASTENERS MUST BE
CAREFULLY TORQUED AND THE ARROW MUST BE POINTING TOWARD THE FRONT OF THE VEHICLE TO
ENSURE PROPER OPERATION OF THE SIR SYSTEM. THE SOM COULD BE ACTIVATED WHEN POWERED
WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN
PERSONAL INJURY,
NO
HAS INFLATOR MODULE(S) DEPLOYED?
r GO TO THE "SIR DIAGNOSTIC j

!l',,,,,_,,,_,,,,,,,,,,,,_,,,,,,,,u,,,,,,,,,,,,,,,,,,,,,u,111111.!'
SYSTEM CHECK."
l
INSPECT FRONT OF VEHICLE AND

UNDERCARRIAGE FOR SIGNS OF IMPACT.
NO SIGNS OF IMPACT
SIGNS OF IMPACT

REPLACE SOM.
RECONNECT ALL SIR SYSTEM COMPONENTS, ,ENSURE
REPLACE COMPONENTS AND PERFORM

INSPECTIONS AS DIRECTED IN "REPAIRS
AND INSPECTIONS REQUIRED AFTER AN
ACCIDENT" IN THIS SECTION.
C8891
9J44

SDM
DRIVERINFLATOR
MODULE
SIRCOIL
ASSEMBLY
[}ffi
PASSENGER
l:~J~
eSHORTINO BARS
TO IGNfflON
1SA
AIR BAO FUSE
ffi
J
. .::
IONfflON1
2
DRIVER SIDE HIGH
DRIVER SIDE LOW
.m
~1403BWHTJBLK
~ 1 4 0 4 8 DKORN/WHT
f[!]-------1404ADKORN/WHT
L___ SHORTING BARS ___J
,----17151 BU(JWHT
_1__
0101
01
080795
FT0109J
DTC 53
Deployment Commanded with Loop Faults Present
Action Taken:

value, additional signal processing is performed and
the generated signals are compared to signals stored in
through the inflator modules, deploying the air bags.
DTC 53 is set instead of DTC 51 when a deployment
occurs while an inflator circuit fault is present that
could possibly result in a non-deployment situation in
one or both inflator modules.

lamp, records "Crash Data," and sets a diagnostic
trouble code.
DTC Will Set When:

The SDM detects a frontal crash, up to 30
degrees off the centerline of the vehicle, of sufficient
force to warrant deployment of the air bags and .an
inflator circuit fault is present.
DTC
Wm Clear When:
DTC 53 cannot be cleared and therefore requires

replacement of the SDM. If DTC 53 is set, one or
more DTC's will be set in addition to DTC 53.
Malfunction(s) setting DTC(s) (other than DTC 71)
must be repaired so that DTC(s) will not be set when
a new SOM is installed.

1. If inflator module(s) has not deployed, DTC 53
may have set falsely.
2. If DTC 53 has set with no signs of frontal impact,
the diagnostic trouble code has set falsely.
9J-45
DTC 53
DEPLOYMENT
COMMANDED WITH LOOP
FAULT PRESENT
MODULE (SDM); NEVER STRIKE OR JAR THE SDM. NEVER POWER UP THE SIR SYSTEM WHEN THE SDM IS
NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SDM AND MOUNTING BRACKET FASTENERS MUST BE
WHILE NOT RIGIDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN
PERSONAL INJURY.
NO
~

HAS INFLATOR MODULE(S) DEPLOYED?
.,,,., .,.,.,.,,.,,,,,,u,,,.,,.,,,.,.,,,.,.,.,,.,.,.,.,,,,.,,,,,.,.,,.,,,.,.,,,.,,,.,
! GO TO THE "SIR DIAGNOSTIC !

!' ,.,,,.,,,,.,,,,.,.,.,,.,,,_,.,,,,.,,,,.,,.,,,,.,.,,,.,,,,,,.,.,.,,.,,.,.,,,.,..,,,.,,.,.,
SYSTEM CHECK."
!
INSPECT FRONT OF VEHICLE AND

UNDERCARRIAGE FOR SIGNS OF IMPACT.
NO SIGNS OF IMPACT
SIGNS OF IMPACT

REPLACE SDM.
REPLACE COMPONENTS AND PERFORM

INSPECTIONS AS DIRECTED IN "ACCIDENT
WITH DEPLOYMENT-COMPONENT
REPLACEMENT AND INSPECTIONS" IN THIS
SECTION.
C8892

SOM
TO~NfflON 4
SWITCH
~ - - - - - - - - - - - - - - - - - - - - - ~ 1139VEL
'"' V""
SEE RISE BLOCK DETAILS SECTION 8A-11
AIRBAG RISE
REFER TO SECTION 8ASO - - - - - BOO TAN
DRIVER INFLATOR
MODULE
REFER TO
SECTION 8A76
SIR COIL
ASSEMBLY
[Ji!~
r:
238BLKIWHT
ffi...__ _____,.._
348DKGRN
IGNITIOH1
SEFIIM. DATA
DRIVER SEAT BEI.T
2 DRIVER SIDE HIGH

3 DRIVER SIDE LOW
SHORTING BARS
PASSENGER
:~J&R PASSENGER INFLATOR MODULE JUMPER
~1403BWHT/BLK
.0
1403A WHT/BLK
~ 1 4 0 4 8 DKGFIN/WHTyl!J.._----------1404ADKGRN/WHT
SHORTING BARS
C1& (CHEV)
TO ~NfflON
tOA
S20f
(CHEV) 013
SWITCH ~ 39A PNK
399 PNK ......_al---4....~ l l t - - t - - o l - - - - - 358 BRN
GAGES
(PONT) A5
A7 (PONT)
LAMP
SEE RISI! BLOCK DETAILS INS~RUMENT nu'sTER
SECTION IA-11
GROUND
015-1995
FT0119J
OTC 61
Lamp Circuit Failure
Action Taken:

"RUN" battery voltage is applied to the "AIR BAG"
warning lamp and to the "Ignition l" input terminal
"10." The SDM responds by flashing the "AIR
BAG" warning lamp seven times. The SDM monitors
the lamp driver output by comparing the output state
at "SIR Indicator" terminal "7" to the microprocessor
commanded state. When "Ignition 1" is above a
specified value and the output state does not match the
commanded state of the lamp driver for 400
milliseconds, DTC 61 is set.
SDM attempts to turn "ON" the "AIR BAG"

warning lamp and sets a diagnostic trouble code.
DTC Will Set When:

"Ignition l" voltage is above a specified value
and the output state at the "SIR Indicator" terminal
"7" does not match the commanded state of the lamp
driver for 400 milliseconds. This test is run every 100
milliseconds during "Continuous Monitoring" tests.

The output state at the "SIR Indicator" terminal
"7" matches the commanded state of the lamp driver
for 400 milliseconds

1. When the SDM is configured for a serial data
controlled warning lamp (smart cluster), DTC 61
will set.
Diagnostic Aids:
Refer to CHARTS B and C to diagnose warning
lamp circuit malfunctions.
9J-47
DTC 61
LAMP CIRCUIT FAILURE
('"""" 11,u11,,,.,.,.,.,,.,,,,,.,,,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,.,,,.,.,.,.,,.,.,.,.,.,.,.,.,.,
1
MALFUNCTIONS WITHIN THE "AIR BAG" WARNING LAMP

CIRCUITRY WILL SET THIS DIAGNOSTIC TROUBLE CODE.
THESE MALFUNCTIONS ARE ADDRESSED IN THE "SIR
DIAGNOSTIC SYSTEM CHECK" VIA CHART B AND CHART C.
FAILURE TO PROPERLY PERFORM THE "SIR DIAGNOSTIC
SYSTEM CHECK" MAY RESULT IN MISDIAGNOSIS.
IS OTC 61 SET?
l GO TO THE "SIR DIAGNOSTIC l

SYSTEM CHECK."
l
lt,_,.,,.,_.,.,,.,.,.,.,,,.,.,.,..,,..,.,.,.,.,,.,.,.,.,,.,.,,,,.,.,.,.,.,.,,.,,,.,.,.,,.,,,,.,,.,.,
,..,.,.,.,., ,,..,.,.,,,..,.,.,.,,.,,,.,,,,.,.,.,.,.,,..,,,,..,.,.,.,.,.,,,..,.,.,,,..,.,.,,,.,.,,u,,,
I IGNITION SWITCH "OFF." I

!t.,,.,.,.,,,,,,.,.,,_,.,,_.,,,,,,,.,.,.,,,,..,.,,,,.,,,_.,,,1'1111111,,,.,,_.,
GO TO CHART A.
!

SYSTEM CHECK."
C9512
9J48 SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEM

SDM
TO IGNfflON
SWITCH~
16A
,l'\J>-------S-EE_FU
__S_E_BL_OC
__K_D_ET_AI_LS
__S_ECTIO---N-SA----11--------~
AIR BAO FUSE
1139VEI.
SERIAi. DATA
238BLKIWHT
DRIVER SEAT BELT
348DKOFIN
REFER TO SECTION BA-50 - - - - - BOO TAN

REFER TO
SECTION BA-76
IGNITION1
2 DRIVER SIDE HIGH

DRIVER SIDE LOW
1 PASS, SIDE HIGH

4 PASS. SID! LOW
GROUND
05-19-95
FT011tJ
DTC 71
Internal SDM Failure
DTC Will Set When:
OTC 71 is an indication of a potential internal

SOM malfunction and will set if any of the following
conditions are detected: 1) 23 VLR voltage out of
normal operating range, 2) Crash data recording
reserve voltage discharge time failure for three
consecutive ignition cycles, 3) The calculated
checksum for internal memory does not match the
stored value, 4) The voltage measured at "Driver Side
Low" and "Passenger Side Low" are too high, 5) The
sensing device inside the SOM which converts vehicle
velocity changes to an electrical signal is
malfunctioning, 6) The driver current source and/or
passenger current source is malfunctioning, 7) The
temporary memory storage area is malfunctioning, 8)
SOM is unable to read from or write to EEPROM, 9)
The arming sensor inside the SDM is not closed
during a deployment event, 10) The voltage measured
at "Driver Side Low" and "Passenger Side Low" are
too low, 11) The device inside the SOM that arms the
system for deployment is malfunctioning, 12) The
permanent memory storage area is malfunctioning.
Any of the indicated malfunctions are detected

by the SOM. The malfunctions are tested at different
times: 1) "Tum-ON" and "Continuous Monitoring,"
2) "Turn-ON," 3) "Turn-ON," 4) "Continuous
Monitoring," 5) "Turn-ON" and "Continuous
Monitoring," 6) "Resistance Measurement Test," 7)
"Tum-ON," 8) "Tum-ON," 9) Asynchronously, 10)
"Tum-ON" and "Continuous Monitoring," ll)"Turn
ON" and "Continuous Monitoring," 12) "Tum ON."
Action Taken:
SOM turns "ON" the "AIR BAG" warning

A scan tool "Clear Codes" command is received
by the SOM. Some of the indicated malfunctions will
only allow the "AIR BAG" warning lamp to go out
briefly then come back "ON."
9J-49
DTC 71
INTERNAL SDM FAILURE
MODULE (SOM). NEVER STRIKE OR JAR THE SOM. NEVER POWER UP THE SIR SYSTEM WHEN THE SOM IS
NOT RIGIDLY ATTACHED TO THE VEHICLE. ALL SOM AND MOUNTING BRACKET FASTENERS MUST BE
WHILE NOT Rl~IDLY ATTACHED TO THE VEHICLE WHICH COULD CAUSE DEPLOYMENT AND RESULT IN
PERSONAL INJURY.
NOTICE: WHEN OTC 18 OR 24 HAS BEEN SET IT IS NECESSARY TO REPLACE THE SOM. SETTING OTC 18
OR 24 WILL ALSO CAUSE OTC 71 TO SET. WHEN A SCAN TOOL "CLEAR CODES" COMMAND IS ISSUED AND
THE MALFUNCTION IS NO LONGER PRESENT, OTC 18 OR 24 AND OTC 71 WILL REMAIN CURRENT. ENSURE
THAT THE SHORT TO GROUND CONDITION IS REPAIRED PRIOR TO INSTALLING A REPLACEMENT SOM TO
AVOID DAMAGING THE SOM.
E'"'''" ..,,,,,,,,,,,,,,,,,,,.,,,,,.,,,,,,,,,,,,,,,,,,.,,_,,,,,,,,,,.1
IS OTC 18 OR 24 ALSO SET (CURRENT OR

HISTORY)? (REFER TO NOTICE ABOVE.)

REPLACE SOM.
l GO TO THE "SIR DIAGNOSTIC

SYSTEM CHECK." u m m u m m m m , l
GO TO OTC 18 IF A OTC 18 IS SET,

GO TO OTC 24 IF A OTC 24 IS SET.
C8893
9J-50
ON-VEHICLE SERVICE
Turn the ignition switch to "LOCK" and remove
SERVICE PRECAUTIONS
CAUTION: When performing service on
or around SIR components or SIR wiring,
follow the procedures listed below to
temporarily disable the SIR system.
injury or otherwise unneeded SIR system
repairs.
The SOM can maintain sufficient voltage
procedures require removal of "AIR BAG" fuse and
disconnection of the deployment loops to avoid an
accidental deployment. If the inflator modules are
disconnected from the deployment loops as noted in
the "Disabling the SIR System" procedure that
follows, service can begin immediately without

Figures 9 and 10
!++!
Tum the steering wheel so that the vehicle's

key.
1. '' AIR BAG" fuse from I/P fuse block.
2. Sound insulator panel - LH, refer to
SECTION 8C.
2-way connector located near the base of the
steering column.
4. I/P compartment door assembly, refer to
SECTION 8C.
5. CPA and yellow 2-way connector from passenger
inflator module jumper in the I/P compartment.
I]]
Important
With "AIR BAG" fuse removed and ignition

switch to "RUN," the "AIR BAG" warning lamp
will be "ON." This is normal operation and does
not indicate a SIR system malfunction.

Figures 9 and 10
i++!
Install or Connect

1. Yellow 2-way connector and CPA to passenger
inflator module jumper in the I/P compartment.
2. I/P compartment door assembly, refer to
SECTION 8C.
3
1 STEERING COLUMN
2 DRIVER YELLOW 2-WAY SIR CONNECTOR
3 CPA
4 KNEE BOLSTER BRACKET
050815
FT0089J
Figure 9 Driver Yel'low 2-Way SIR Connector
1
2
3
4
BODY CONTROL MODULE

INSTRUMENT PANEL
PASSENGER YELLOW 2-WAY SIR CONNECTOR
CPA
OSOlII
FT0071J
Figure 10 Passenger Yellow 2-Way SIR Connector

3. Yellow 2-way connector and CPA located near the
base of the steering column.
4. Sound insulator panel - LH, refer to
SECTION SC.
5. "AIR BAG" fuse to 1/P fuse block.
Handling/Installation/Diagnosis
1. Inflator modules should not be subjected to
temperatures above 65C (150"F).
2. lnflator modules or SDMs should not be used if
they have been dropped from a height of 91.4
centimeters (3 feet) or greater.
3. When a SDM is replaced, it MUST be oriented
with the arrow on the sensor pointing toward the
front of the vehicle. It is very important for the
SDM to be located flat on the mounting surface,
parallel to the vehicle datum line. It is important
that the mounting surface is free of any dirt or
other foreign material.

4. Do not apply power to the SIR system unless all
components are connected or a diagnostic chart
requests it, as this will set a diagnostic trouble
code.
5. The "SIR Diagnostic System Check" must be the
starting point of any SIR diagnostics. The "SIR
Diagnostic System Check" will verify proper
"AIR BAG" warning lamp operation and will
lead you to the correct chart to. diagnose any SIR
malfunctions. Bypassing these procedures
may result in extended diagnostic time,
incorrect diagnosis, and incorrect parts
replacements.
REPAIRS AND INSPECTIONS REQUIRED
AFTER AN ACCIDENT
rn
Important
If any SIR system components are damaged, they

must be replaced. If SIR component mounting
points are damaged, they must be repaired or
replaced.
Never use. SIR parts from another vehicle. This
does not include remanufactured parts purchased
from an authorized GM dealer; they may be used
for SIR repairs.
Do not attempt to service the SDM, the SIR coil
assembly, or the inflator modules. Service of these
items is by replacement only.
9J51
Verify the part number of replacement inflator

modules. Some GM inflator modules look
identical but contain different internal
components.
CAUTION: Proper operation of. the

sensors and Supplemental Inflatable
Restraint (SIR) system requires that anY.
repairs to the vehicle structure return 1t
to the original production confi~uration.
Deployment requires, at a minimum,
replacement of the SOM, inflator
modules, and dimensional inspection of
the steering column. Any visible damage
to the SOM mounting bracket(s) requires
replacement and the steering column
must be dimensionally inspected,
whether deployment occurred or not.
Accident With Deployment Component
Replacement and Inspections
Certain SIR components must be replaced or
inspected for damage after a frontal crash involving air
bag deployment.
Replace the following SIR components:
SDM,
lnflator modules.
Inspect and replace if necessary the following
SIR components:
SIR coil assembly - Inspect wiring and
connector for any signs of scorching, melting,
or damage due to excessive heat. Replace if
damaged. Refer to SECTION 3F5.
Accident With or Without Deployment Component Inspections
Certain SIR and restraint system components
must be inspected after any crash, whether the air bag
deployed or not. Those components are:
Steering column - Dimensionally inspect per
"Checking Steering Column for Accident
Damage" in SECTION 3F5.
Knee bolsters and mounting points - Inspect for
any distortion, bending, cracking, or other
damage.
1/P steering column reinforcement plate - Inspect
for any distortion, bending, cracking, or other
damage.
1/P braces '" Inspect for any distortion, bending, .
cracking, or other damage.
Seat belts and mounting points - Refer to "Seat
Belts" in SECTION 10-11.
9J-52
SENSING AND DIAGNOSTIC MODULE

(SDM)
Figure 11
CAUTION: During service procedures, be

very careful when handling a Sensing
and Dia~nostic Module (SOM). Never
strike or Jar the SOM. Never power up the
SIR system when the SOM is not rigidly
attached to the vehicle. All SOM and
mounting bracket fasteners must be
carefully torqued and the arrow must be
pointing toward the front of the vehicle to
ensure proper operation of the SIR
system. The SOM could be activated
when powered while not rigidly attached
to the vehicle which could cause
deployment and result in personal injury.
NOTICE: If the vehicle interior has been
exposed to extensive water intrusion, such as
water leaks, window left open, driving through
high water and so forth, the Sensing and
Diagnostic Module (SDM) and the SDM
connector may need to be replaced. With the
ignition "OFF," inspect the floor tunnel and the
area around the SDM, including the carpet. If
any significant soaking or evidence of
significant soaking is detected, the water must
be removed, water damage repaired and the
SDM and SDM connector MUST be replaced.
Before attempting any of these repairs, the SIR
system must be disabled. Refer to
"ON-VEHICLE SERVICE" for instructions on
how to disable the SIR system and replace the
SDM and SDM connector.
l++I
CAUTION: Proper operation of the

Sensing and Diagnostic Module (SOM)
requires the SOM be rigidly attached to
the vehicle structure and that the arrow
on the SOM be pointing toward the front
of the vehicle.
Important
The following procedures should be utilized in the

event that SDM mounting holes or fasteners are
damaged to the extent that the SDM can no
longer be properly mounted.
040885
FT008tJ
Figure 11 Sensing and Diagnostic Module (SOM)
First Repair:
1. Remove stripped fastener and discard.
2. Attach S DM with new M8 fastener
(part # 11504031).
I~!
Disable SIR system, Refer to "Disabling the SIR

1. Front floor console assembly, refer to
SECTION 8C.
2. Connector Position Assurance (CPA) and
3. Fasteners from SDM.
4. SDM from vehicle.
[I]
1 SOM
2 FASTENER
3 SDM BRACKET
Tighten
Fasteners to 14.0 N.m (124 lb. in.).
Second Repair:
1. Remove stripped fastener and discard.
2. Attach SDM with new M6 fastener
(part # 11515926) through star washer
(part # 11501045) into nut (part # 11503746).
I~!
Tighten
Fasteners to 10.0 N,m (89 lb. in.).
NOTICE: To avoid repair strippage, it is

recommended that only hand tools be used to
achieve fastener torque.
!++!
Install or Connect
1. SDM to vehicle, ensure arrow is pointing toward

the front of the vehicle.
2. SDM fasteners.
!~!
Tighten
Fasteners to 10.0 N,m (89 lb.in.).

3. Electrical connector and CPA.
4. Front floor console assembly, refer to
SECTION 8C.
Eriable SIR system, refer to "Enabling the SIR
Syst~m" in this section.
quickly reacts with atmospheric . moisture and is

converted to sodium carbonate and sodium bicarbonate
(baking soda). Therefore, it is unlikely that sodium
hydroxide will be present after deployment. As with
safety glasses.
!++I
Figure 12
CAUTION: The following procedures

must be followed in the order listed to
temporarily disable the Supplemental
Inflatable Restraint (SIR) system and
prevent false diagnostic trouble codes
from setting. Failure to follow procedures
could result in possible air bag
deployment, personal injury or otherwise
live (Undeployed) lnflator Module

Refer 'to ''Inflator Module
Handling/Shipping/Scrapping" in this section.
Deployed lnflator Module

After the inflator module has been deployed, the
This powder consists primarily of cornstarch (used to
lubricate the bag as it inflates) and byproducts of the
lye soap) is produced as a byproduct of the
PONT SHOWN
CHEV SIMILAR
Disable SIR system, refer to "Disabling the SIR

1. IIP carrier, refer to SECTION 8C.
2. Connector Position Assurance (CPA) and
electrical connectpr.
3. Fasteners from passenger inflator module bracket.
4. Passenger inflator module bracket assembly from
1/P carrier.
5. Fasteners from passenger inflator module ..
6. Passenger inflator module from bracket.
CAUTION: When carrying a live inflater

module, make sure the bag opening .is
pointed away from you. Never carry the
inflater module by the wires or connector
on the side of the module. In case of an
When placing a live inflator module on a
bench or other surface, always face the
bag up, away from the surface. This is
necessary so that a free space is
provided to allow the air bag to expand
in the unlikely event of accidental
deployment. Otherwise personal injury
may result.
!HI
Install or Connect
1. Passenger inflator module to bracket.

2. Fasteners to passenger inflator module.
3. Passenger inflator module bracket assembly to 1/P
carrier.
4. Fasteners to passenger inflator module bracket.
l~!
Tighten
Fasteners to 10.0 N.m (89 lb.in.).

5. Electrical connector and CPA.
6. IIP carrier, refer to SECTION 8C.
Enable SIR system, refer to "Enabling the SIR
.
.

1
2
3
4
.5
9J-53
1/P TRIM PAO

SIR BRACKET
1/P COMPARTMENT DOOR
FASTENER
Figure 12 Passenger Inflater Module
DRIVER INFLATOR. MODULE

041015
FTOOHJ
SIR COIL ASSEMBLY

Refer to SECTION 3F5.
9J-54
INFLATOR MODULE
HANDLING/SHIPPING/SCRAPPING
ALWAYS CARRY
INFLATOR MODULE
WITH TRIM COVER
AWAY FROM BODY
Figure 13
Live (Undeployed) lnflator Module
Special care is necessary when handling and
storing a live (undeployed) inflator module. The rapid
gas generation produced during deployment of the air
bag could cause the inflator module, or an object in
front of the inflator module, to be thrown through the
air in the unlikely event of an accidental deployment.

Never carry the inflator module by the
assembly on the steering wheel with the
inflator module face down and column
result.
ALWAYS PLACE
INFLATOR MODULE
ON WORKBENCH
WITH TRIM COVER
UP, AWAY FROM
LOOSE OBJECTS
Shipping Procedures For Live

(Undeployed) lnflator Modules
Service personnel should refer to the latest
Service Bulletins for proper SIR inflator module
shipping procedures.
lnflator Module Scrapping Procedure

During the course of a vehicle's useful life,
certain situations may arise which will necessitate the
disposal of a live (undeployed) inflator module. This
information covers proper procedures for disposing of
a live inflator module.
Before a live inflator module can be disposed of,
it must be deployed. Live inflator modules must not
be disposed of through normal refuse channels.
CAUTION: Failure to follow proper

inflator module disposal procedures can
result in air bag deployment which may
cause personal injury. Undeployed
inflator modules must not be disposed of
through normal refuse channels. The
undeployed inflator module contains
substances that can cause severe illness
or personal injury if the sealed container
is damaged during disposal. Disposal in
any manner inconsistent with proper
procedures may be a violation of federal,
state, and/or local laws.
9-1-84
ST88009J
Figure 13 - Proper Live lnflator Module Handling
If a vehicle is the subject of a Product Liability

Report related to the SIR system and is subject to a
Preliminary Investigation (GM-1241), DO NOT
DEPLOY the inflator module and DO NOT ALTER
the SIR system in any manner. Refer to the applicable
service bulletin on SIR shipping procedures for details
on handling SIR systems involved with GM-1241. If a
vehicle is .the subject of a campaign affecting inflator
modules, DO NOT DEPLOY the inflator module.
Follow instructions in the Campaign Service Bulletin
for proper disposition of the inflator module.
If an inflator module is replaced under warranty,
DO NOT DEPLOY the air bag. The inflator module
may need to be returned, undeployed; to Inland Fisher
Guide. Refer to procedures shown in the appropriate
service bulletin regarding SIR shipping procedures.
In situations which require deployment of a live
inflator module, deployment may be accomplished
inside or outside the .vehicle. The method employed
depends upon the final disposition of the particular
vehicle, as noted in "Deployment Outside Vehicle"
and "Deployment Inside Vehicle" in this section.
SUPPLEMENTAL, INFLATABLE RESTRAINT {SIR) SYSTEM

Deployment Outside Vehicle
(Driver lnflator Module)
Deployment outside .the vehicle is proper when
the vehicle is to be returned to service. This includes,
for example, situations in which the vehicle will be
returned to useful service after a functionally or
cosmetically deficient inflator module is replaced.
Deployment and disposal of a malfunctioning ,inflator
module is, of course, subject to any required retention
period.
For deployment of a live (undeployed) inflator

module outside the vehicle, the deployment procedure
must be followed exactly. Always wear safety glasses
during this deployment procedure until a deployed
inflator module is scrapped or until an undeployed
inflator module is shipped. Before performing the
procedures you should be familiar with servicing the
SIR system and with. proper handling of the inflator
module. Procedures should be read fully before they
are performed.
The following procedure requires use of J 38826

SIR deployment ha,mess with appropriate pigtail
adapter. Do not attempt procedure without J 38826
adapter.
9J-55
CAUTION: Failure to follow procedures in

the order listed may result in personal
injury. Never connect deployment
harness to any power source before
connecting deployment harness to the
driver inflator module. Deployment
harness shall remain shorted and not be
connected to a power source until the air
bag is to be deployed. The inflator
module will immediately deploy the air
ba~ when a power source is connected
to 1t. Wear safety glasses throughout this
entire deployment and disposal
procedure.
1 YI
Important
This information applies only to driver inflator

modules. Refer to "Deployment Outside Vehicle
(Passenger Inflator Module)" in this section for
information on passenger inflator module
scrapping.
1. Tum ignition switch to "LOCK," remove key and
put on safety glasses.
2. Inspect J 38826 SIR Deployment Harness and
appropriate pigtail adapter for damage. If harness
or pigtail adapter is damaged, discard and obtain a
replacement.
CAUTION: SIR DEPLOYMENT HARNESS SHALL REMAIN SHORTED

AND NOT BE CONNECTED TO A POWER SOURCE UNTIL THE AIR
BAG IS TO BE DEPLOYED.
SIR
DEPLOYMENT
HARNESS
Figure 14 - Shorting the SIR Deployment Harness Wires
9J56
SUPPLEMENTAL INFLATABLE:.RESTRAINT (SIR) SYSTEM
(
VINYL TRIM CO\IER MUST FACE UP
Figure 15 - Proper Storage of lnflator Module
...
185 cm (6 FEET) OF CLEARANCE.
------1. . .
(
Figure 16 - Provide Adequate Clearance for Air Bag to Deploy

3. Short the two SIR deployment harness leads
together by fully seating one banana plug into the
other. SIR deployment harness shall remain
shorted and not be connected to a power source
until the air bag is to be deployed (Figure 14).
4. Connect the appropriate pigtail adapter to the SIR
deployment harness (Figure 14).
5. Remove driver inflator module from vehicle.
6. Remove horn lead from the back of the driver
inflator module.
7. Remove all horn buttons and steering wheel
control buttons from driver inflator module, if
applicable.
CAUTION: When storing a live inflater

module or when leaving a live inflater
module unattended on a bench or other
surface, always face the bag and trim
cover up and away from the surface. This
is necessary so that a free space is
deployment. Failure to follow procedures
may result in personal injury.
8. Place the driver inflator module on a work bench
or other surface away from all loose or flammable
objects with its vinyl trim cover facing up, away
from the surface (Figure 15).
9. Clear a space on the ground about 185 cm (six
feet) in diameter where the driver inflator module
is to be deployed. A paved, outdoor location
9J57
where there is no activity is preferred. If an

outdoor location is not available, a space on the
shop floor where there is no activity and sufficient
ventilation is recommended. Ensure no loose or
flammable objects are within the deployment area
(Figure 16).
10. Place the driver inflator module, with its vinyl
trim cover facing up, on the ground in the space
just cleared (Figure 16).
11. Stretch the SIR deployment harness and pigtail
adapter from the driver inflator module to its full
length (Figure 17).

12. Place a power source. near the shorted end of the
SIR deployment harness. Recommended
application: 12 volts minimum, 2 amps minimum.
A vehicle battery is suggested.
13. Connect the driver 'mflator module to the pigtail
adapter on the SIR deployme..nt harness.
Deployment harness shall remain shorted and. not
be connected to a power source until the air bag
is to be deployed. The driver inflator module will
immediately deploy the air bag when a power
source is connected to it (Figure 18).
[I]
Important
Ensure that the pigtail adapter is firmly seated

into the driver inflator module connector. Failure
to fully. seat the connectors may lea".e the shorting
bar loc.ated in the driver inflator module connector
functioning (shorted) and may result in
non-deployment of the driver inflator module.
CAUTION: SIR DEPLOYMENT HARNESS SHALL

REMAIN SHORTED AND NOT BE CONNECTED TO
A POWER SOURCE UNTIL THE AIR BAG IS TO
BE DEPLOYED.
STRETCH SIR DEPLOYMENT HARNESS

& PIGTAIL ADAPTER TO FULL LENGTH
Figure 17 - Stretching the SIR Deployment Harness and Pigtail Adapter
9J58
CAUTION: SIR DEPLOYMENT HARNESS SHALL

REMAIN SHORTED AND NOT BE CONNECTED TO
A POWER SOURCE UNTIL THE AIR BAG IS TO
BE DEPLOYED.
PIGTAIL
ADAPTER
SIR
DEPLOYMENT
HARNESS
INFLATOR
MODULE
Figure 18 - Connecting the SIR Deployment Harness to the lnflator Module
14. Verify that the area around the driver inflator

module is clear of all people and loose or
flammable objects.
15. Verify that the driver inflator module is resting
with its vinyl trim cover facing up.
16. Notify all people in the immediate area that you
intend to deploy the driver inflator module. The
deployment will be accompanied by a substantial
report which may startle the uninformed.
17. Separate the two banana plugs on the SIR
. deployment harness (Figure 19).
CAUTION: Deployment harness shall

remain shorted and not be connected to
a power source until the air bag is to be
deployed. The driver inflator module will
immediately deploy the air bag when a
power source is connected to it.
Connecting the deployment harness to
the power source should always be the
last step prior to deployment in the
inflator module deployment procedure.
Failure to follow procedures in the order
listed may result in personal injury.
N~Tl(?E: When the air bag deploys, the

driver mflator module may jump about 30 cm
(one foot) vertically. This is a normal reaction
of the driver inflator module to the force of the
rapid gas expansion inside the air bag.
18. Connect the SIR deployment harness wires to the

power source to immediately deploy the driver
inflator module. Recommended application: 12
volts minimum, 2 amps minimum. A vehicle
battery is suggested (Figure 20).
19. Disconnect the SIR deployment harness from the
power source.
20. Short the two SIR deployment harness leads
together by fully seating one banana plug into the
other (Figure 14).
21. In the unlikely event that the driver inflator
module did not deploy after following these
procedures, proceed immediately with Steps 26
through 29. If the driver inflator module did
deploy, proceed with Steps 22 through 25.
NOTICE: When the air bag deploys, the rapid

gas expansion will create a substantial report.
Notify all people in the immediate area that you
intend to deploy the driver inflator module.
(.
.

22. Put on a pair of shop gloves to protect your hands
from possible irritation and heat when handling
the deployed driver inflator module.
After the driver inflator module has been
deployed, the surface of the air bag may contain a
powdery residue. This powder consists primarily
of cornstarch (used to lubricate the bag as it
inflates) and byproducts of the chemical reaction.
Sodium hydroxide dust (similar to lye soap) is
produced as a byproduct of the deployment
reaction. The sodium hydroxide then quickly
reacts with the atmospheric moisture and is
converted to sodium carbonate and sodium
bicarbonate (baking soda). Therefore, it is unlikely
that sodium hydroxide will be present after
deployment. As a precaution, however, gloves and
safety glasses are recommended to prevent any
possible irritation of the skin or eyes.
CAUTION: Safety precautions must be

observed when handling a deployed
inflator module. After deployment, the
metal surfaces of the inflator module will
be very hot. Allow the inflator module to
cool before handling any metal portion of
it. Do not place the deployed inflator
module near any flammable objects.
Failure to follow procedures may result
in fire or personal injury.
After a driver inflator module has been
deployed, the metal canister and surrounding areas
of the driver inflator module will be very hot. Do
not touch the metal areas of the driver inflator

module for about ten minutes after deployment. If
the deployed driver inflator module must be.
moved before it is cool, wear gloves and handle
by the air bag or vinyl trim (Figure 21).
23. Disconnect the pigtail adapter from the driver
inflator module as soon after deployment as
possible. This will prevent damage to the pigtail
adapter or SIR deployment harness due to.
possible contact with the hot driver inflator
module canister. The pigtail adapter and SIR
deployment harness are designed to be reused.
They should, however, be inspected for damage
after each deployment and replaced if necessary.
24. Dispose of the deployed driver inflator module
through normal refuse channels after it has cooled
for at least 10 minutes.
25. Wash your hands with mild soap and water
afterward.
NOTICE: The remaining steps are to be

followed in the unlikely event that the driver
inflator module did not deploy after following
these procedures.
26. Ensure that the SIR deployment harness has been
disconnected from the power source and that its
two banana plugs have been shorted together by
fully seating one banana plug into the other
(Figure 14).
27. Disconnect the pigtail adapter from the driver
inflator module.
.t===.=======::::::::JoJ-~-}
j
J'
.............
.,.
9J-59
~-}
>
...........
>
.'
w-}
~f============================================"~---}
'
~-}
....
>
>
t-30-94
STS80ltJ
Figure 19 Separating the Two Shorted Banana Plugs
9J-60
CAUTION: THE INFLATOR MODULE WILL IMMEDIATELY DEPLOY

THE AIR BAG WHEN A POWER SOURCE IS CONNECTED TO .IT.
+
BATTERY
BATTERY
Figure 20 - Connecting to a Power Source
(
Figure 21 - Handling a Hot, Deployed lnflator Module

CAUTION: When storing a live inflater
module or when leaving a live inflater
surface, always face the bag and trim
cover up and away from the surface. This
is necessary so that a free space is
deployment. Failure to follow procedures
may result in personal injury.
28. Temporarily store the driver inflator module with
its vinyl trim cover facing up, away froi:n the
surface upon which it rests.
29. Call the Technical Assistance group for further
assistance.

lnflator Module)
CAUTION: Failure to follow proper SIR
undeployed inflator module contains
state and/or local laws.
General Motors dealers should refer to the latest
General Motors Service Bulletins for proper live
(undeployed) passenger inflator module scrapping and
disposal procedures. All others should contact a local
General Motors dealership for proper live passenger
inflator module scrapping and disposal procedures.
Deployed passenger inflator modules may be disposed
of through normal refuse channels.
Deployment Inside Vehicle (Vehicle

Scrapping Procedure)
9J-61
vehicle. This is done to ensure SIR system

integrity since only new SIR system
components, with the exception of
remanufactured parts as noted below, may be
used in servicing an SIR equipped vehicle.
Remanufactured parts purchased from an
authorized General Motors dealer may be used
for SIR repairs.
CAUTION: Failure to follow proper SIR

undeployed inflater module contains
state and/or local laws.
~ - ,- - y -- , /
MINIMUM 16 cm (SIX INCHES)
~~
STRIP 13 mm (1/2 INCH) OF INSULATION

9-1-94
STSICl98J
Figure 22 - Cutting the Harness Connector Wires (Driver)
Deployment inside the vehicle is proper when
the vehicle is to be destroyed or salvaged for
component parts. This includes, but is not limited to,
the following situations:
The vehicle has completed its useful life.
The vehicle has been damaged beyond repair
in a non-deployment type accident.
The vehicle has been stripped or damaged
beyond repair in a theft.
The vehicle will be salvaged for component
parts to be used on a vehicle with a different
Vehicle Identification Number (VIN) as
opposed to being rebuilt as the same VIN.
Never use SIR components from another
CAUTION: Deployment wires shall

remain shorted and not be connected
to o power source until the air bag
is to be deployed.
_,. . . . . . . . . ~~:. . . . . . . . . . . . . . . . .~>-
'-.
,../
"'V'
MINIMUM 460 cm (15 FEET) FOR DRIVER SIDE

MINIMUM 610 cm (20 FEET) FOR PASSENGER SIDE
SHORT THE TWO DEPLOYMENT WIRES TOGETHER
9-1-94
STIIGIOIJ
Figure 23 - Shorting the Deployment Wires
9J62
1. Turn ignition switch to "LOCK," remove key and

put on safety glasses.
2. Remove all loose objects from front seats.
3. Disconnect driver in:flator module, yellow 2-way
connector located near the base of the steering
column.
4. Cut the driver inflator module yellow 2-way
harness connector from the vehicle leaving at least
16 cm (six inches) of wire at the connector
(Figure 22).
5. Strip 13 mm (112 inch) of insulation from each
wire lead of the connector (Figure 22).
6. Cut two 460 cm (15 feet) deployment wires from
0.8mm2 (18 gauge) or thicker multi-strand wire.
These wires will be used to fabricate the driver
deployment harness.
7. Strip 13 mm (1/2 inch) of insulation from both
ends of the wires cut in the previous step.
8. Short the wires by twisting together one end from
each (Figure 23). Deployment wires shall remain
shorted and not be connected to a power source
until the air bag is to be deployed.

the order listed could result in personal
injury. Never connect deployment wires
to any power source before connecting
deployment wires to the inflator module
leads. Deployment wires shall remain
shorted and not be connected to a power
source until the air bag is to be
deployed. The inflator module will
power source is connected to it. Wear
safety glasses throughout this entire
deployment and disposal procedure.
9. Twist together one connector wire lead to one
deployment wire. The connection should be
mechanically secure (Figure 24-A).
10. Bend twisted connection made in the previous
step flat and wrap tightly with electrical tape to
insulate and secure (Figure 24-B).
11. Twist together, bend and tape the remaining
connector wire lead to the remaining deployment
wire (Figure 24-C).
12. Connect the deployment harness to the driver
inflator module, yellow 2-way connector near the
base of the steering column. Route deployment
harness out the driver side of the vehicle
(Figure 25).
CAUTION: Deployment wires shall remain

Connecting the deployment wires to the
power source should always be the final
step in the inflater module deployment
procedure. Failure to follow procedures
in the order listed could result in
personal injury.
13. Disconnect passenger inflator module, yellow

2-way connector located behind the If P
14. Cut the passenger inflator module harness
connector from the vehicle leaving at least 16 cm
(six inches) of wire at the connector (Figure 26).
15. Strip 13 mm (112 inch) of insulation from each
wire lead of the connector (Figure 26).
16. Cut two 610 cm (20 feet) deployment wires from
0.8mm2 (18 gauge) or thicker multi-strand wire.
These wires will be used to fabricate the
passenger deployment harness.
17. Strip 13 mm (1/2 inch) of insulation from both
ends of the wires cut in the previous step.
18. Short the wires by twisting together one end from
each (Figure 23). Deployment wires shall remain
shorted .and not be connected to a power source
until the air bag is to be deployed.
CAUTION: DEPLOYMENT WIRES SHALL

REMAIN SHORTED AND NOT BE
CONNECTED TO A POWER SOURCE UNTIL
THE AIR BAG IS TO BE DEPLOYED.
TWIST TOGETHER SECURELY
-,:::>-,:::>-
BEND FLAT
-,:::>WRAP WITH TAPE
REPEAT PROCEDURE
OIM9-95
STS&119J
Figure 24 - Fabricating the Deployment Harness (Driver)
9J-63
Figure 25 - Prepare the Deployment Harness for In-Vehicle Deployment (Driver)

the order listed could result in personal
injury. Never connect deployment wires
to any power source before connecting
deployment wires to the inflator module
leads. Deployment wires shall remain
power source is connected to it. Wear
safety glasses throughout this entire
deployment and disposal procedure.
19. Twist together one connector wire lead to one
deployment wire. The connection should be
mechanically secure (Figure 27-A).
20. Bend twisted connection made in the previous
step flat and wrap tightly with electrical tape to
insulate and secure (Figure 27-B).
21. Twist together, bend and tape the remaining
connector wire lead to the remaining deployment
wire (Figure 27-C).
22. Connect the deployment harness to the passenger

inflator module, yellow 2-way connector located
behind the 1/P compartment door assembly. Route
deployment harness out the passenger side of the
vehicle (Figure 28).
CAUTION: Deployment wires shall

remain shorted and not be connected
to a power source until the air bag
is to be deployed.
0-
'
TWIST TOGETHER SECURELY
:)
J
~---MINIMUM 16 cm (SIX INCHES)
0-
':::>--
BEND FLAT
0'
WRAP WITH TAPE
::::Z~:Z~:2:~---,'!l'O-
STRIP 13 mm ( 1/2 INCH)

OF INSULATION
REPEAT PROCEDURE
9-1-94
CHS0219J
Figure 26 - Cutting the Harness Connector Wires

(Passenger)
CHS0229J
Figure 27 - Fabricating the Deployment Harness

(Passenger)
9J-64

deployed. The inflater module will
step in the inflator module deployment
personal injury.

deployed. The inflater module will
step in the inflater module deployment
personal injury.
23. Verify that the inside of the vehicle and the area
surrounding the vehicle are clear of all people and
loose or flammable objects.
24. Stretch the driver and passenger deployment
harnesses to their full length (Figures 25 and 28).
25. Completely cover windshield area and front door
window openings with a drop cloth, blanket or
similar item. This reduces the possibility of injury
due to possible fragmentation of the vehicle's
glass or interior.
26. Notify all people in the immediate area that you
intend to deploy the air bags. The deployment
will be accompanied by a substantial report which
may startle the uninformed.
27. Separate the two ends of the driver deployment
harness wires (Figure 29).
NOTICE: When the air bag deploys, the rapid

gas expansion will create a substantial report.
Notify all people in the immediate area that you
intend to deploy the air bags.
28. Connect the driver deployment harness wires to a

power source to immediately deploy the driver
inflator module. Recommended application: 12
volts minimum, 2 amps minimum. A vehicle
battery is suggested (Figure 29).
29. Separate the two ends of the passenger
deployment harness wires (Figure 30).
Figure 28 - Prepare Deployment Harness for In-Vehicle Deployment (Passenger)

SEPARATE SHORTED ENDS OF DEPLOYMENT
WIRES AND CONNECT TO POWER SOURCE
BATTERY
(
Figure 29 - Separate Shorted End of Deployment Harness and Connect to Power Source (Driver)
9J".65
SEPARATE SHORTED ENDS OF DEPLOYMENT

WIRES AND CONNECT TO POWER SOURCE
Figure 30 - Separate Shorted End of Deployment Harness and Connect to Power Source (Passenger)

depl~yed. The inflator module will
step in the inflator module deployment
personal injury.
30. Connect the passenger deployment harness wires
to a power source to immediately deploy the
passenger inflator module. Recommended
application: 12 volts minimum, 2 amps minimum.
A vehicle battery is suggested (Figure 30).
smface of the air bag may contain a powdery residue.
q1ickly reacts with atmospheric moisture and is
hydroxide will be present after deployment. As a
precaution, however, gloves and safety glasses are
recommended to prevent any possible irritation of the
skin or eyes.
CAUTION: Safety precautions must be

observed when handling a deployed
inflator module. After deployment, the
metal surfaces of the inflator module will
be very hot. Allow the inflator module to
cool before handling any metal portion of
it. Do not place the hot deployed inflator
module near any flammable objects.
in fire or personal injury.
metal canister and surrounding areas of the inflator
module will be very hot. Do not touch the metal areas
of the inflator module for about 10 minutes after
deployment. If the deployed inflator module must be

moved before it is cool, wear gloves and handle by the
air bag or vinyl trim.
31. Short the driver deployment harness wires by
twisting together one end from each. Repeat this
procedure for the passenger deployment harness.
32. Carefully remove drop cloth from vehicle and
clean off any fragments or discard drop cloth
entirely.
33. Disconnect driver deployment harness and
passenger deployment harness from vehicle and
discard.
34. In the unlikely event that either or both of the
inflator modules did not deploy after following
these procedures, proceed immediately with Steps
36 through 38.
35. With both air bags deployed the vehicle may be
scrapped in the same manner as a non-SIR
equipped vehicle.
36. Remove the undeployed inflator module(s) from
the vehicle. For driver inflator module refer to
SECTION '.3F, for passenger inflator module refer
to "On-Vehicle Service" in this section.
CAUTION: When storing a live inflator

module or when leaving a live inflator
surface, always face the bag up, away
from the surface. This is necessary so
that a free space is provided to allow the
air bag to expand in the unlikely event of
accidental deployment. Failure to follow
procedures could result in personal
injury.
37. Temporarily store the inflator module with the air
bag opening facing up, away from the surface
upon which it rests.
38. Call the Technical Assistance group for further
assistance.
Deployed Inflater Module Handling

After the inflator module has been deployed, the
9J-66

quickly reacts with atmospheric moisture and is
hydroxide will be present after deployment. As with
safety glasses.
WIRING REPAIR
Special wiring repair procedures have been
developed for use on the Supplemental Inflatable
Restraint. (SIR) system due to the sensitive nature of
the circuitry. These specific procedures and
instructions must be followed when working with SIR
system wiring, and wiring components (such as
connectors and terminals).
TERMINAL REPAIR KIT J 38125-A

Essential tool kit J 38125-A contains special
"sealed splices" for use in repairing SIR system
wiring. A special . crimping tool, heat torch, and
instruction manual for these splices are also included.
1\vo critical features of the sealed splices are a
special heat shrink sleeve with sealing adhesive to
produce an environmentally sealed splice and a cross
hatched (knurled) core crimp to provide necessary
contact integrity for the sensitive, low energy circuits.
Terminal Repair Kit J 38125-A also serves as a
generic terminal repair kit. The kit contains a large
sampling of common GM electrical terminals and the
correct tools to attach them to wires and remove them
from connectors. The terminals in the kit are not
to be used to replace damaged SIR system

terminals unless specifically indicated by the
terminal. package.
SIR CONNECTOR (PLASTIC BODY AND

TERMINAL METAL PIN) REPAIR
If any connector or terminal in the SIR wire
harness (except pigtails) is damaged, it should be
repaired using one of the connector repair assembly
packs. These kits include an instruction sheet and the
sealed splices which will be used to splice the new
wires, connector, and terminals to the harness. The
splice crimping tool, which is color keyed to match
the splices from Terminal Repair Kit J 38125-A, must
be used to apply these splices.
The terminals in the SIR system are made of a
special metal to provide necessary contact integrity for
the sensitive, low energy circuits. These terminals are
only available in the connector repair assembly packs,
do not substitute any other terminals for those in the
assembly packs.
If individual terminals are damaged on the SDM
connector, the SDM connector must be replaced with a
SDM connector\pigtail assembly (part #12167134). If
individual terminals are damaged on any other SIR
connection, the entire connection should be replaced
using the appropriate connector repair assembly pack.
It may be necessary to replace the entire SIR wiring
harness.
SIR WIRE PIGTAIL REPAIR

If the wiring pigtail (a wire or wires attached
directly to the device, not by a connector) is damaged,
the entire component (with pigtail) must be replaced.
Examples of "pigtail" components are the driver
inflator module, the passenger inflator module and the
SIR coil assembly. Absolutely no wire, connector, or
terminal repairs are to be attempted on the driver
inflator module, passenger inflator module or the SIR
coil assembly.
SIR WIRE REPAIR

If any wire except the pigtail is damaged, the
wire should be repaired by splicing in a new section
of wire of the same gauge size (.5, .8, 1.0, etc.). The
sealed splices and splice crimping tool from Terminal
Repair Kit J 38125-A must be used for these repairs.
The following wiring repair procedures must be used
to ensure the integrity of the sealed splice application.
Step One: Open the Harness
If the harness. is taped, remove the tape. To

avoid wire insulation damage use a sewing "seam
ripper" (available from sewing supply stores) to cut
open the harness. The crimp and sealed splice sleeves
may be used on all types of insulation except tefzel
and coaxial and may only be used to form a
one-to-one splice.
Step Two: Cut the Wire
Begin by cutting as little wire off the harness as

possible. You may need the extra length of wire later
if you decide to cut more wire to change the location
of a splice. You may have to adjust splice locations to
make certain that each splice is at least 40 mm (1.5
in.) away from other splices, harness branches, or
connectors.
Step Three: Strip the Insulation
NOTICE: The following procedures must be

followed in the order listed. If wire strands are
damaged, the procedure must be repeated until a
clean strip with all wire strands intact is
obtained.
If it is necessary to add a length of wire to the
existing harness, be certain to use the same size as the
original wire. To find the correct wire size either fmd
the wire on the schematic and convert the metric size
to the equivalent AWG size or use an AWG wire
gage.
If unsure about the wire. size, begin with the
largest opening in the wire stripper and work down
until achieving a clean strip of the insulation. Strip
approximately 7.5 mm (5/16 in.) of insulation from
each wire to be spliced. Be careful to avoid nicking or
cutting any of the strands. Check the stripped wire for
nicks or cut strands. If the wire is damaged, repeat this
procedure after removing the damaged section.
9J-67
Step Four: Select and Position the Splice Sleeve
Select the proper sealed splice sleeve according

to wire size. The splice sleeves and tool nests are
color coded (see following chart).
Color Splice
Sleeve
Crimp Tool
Nest Color
Wire Gage
AWG/(Metric)
Salmon
(yellow-pink)
Red
20, 18/(0.5, 0.8)
Blue
Blue
Yellow
Yellow
16, 14/(1.0, 2.0)

12; 10/(3.0, 5.0)
7.5mm (5/16 INCH)
WIRE:::,. ~ A R E L
STOP
SPLICE BEFORE CRIMPING
~
SPLICE AFTER CRIMPING
[SEALAd
Crimp and Seal Splice Chart
Using the J 38125-A Splice Crimp Tool (Figure

31), position the splice sleeve in the proper color nest
of the hand crimp tool. Place the splice sleeve in the
nest so that the crimp falls midway between the end of
the barrel and the stop.
The sleeve has a stop in the middle ofthe barrel
to prevent the wire from going further (Figure 32).
Close the hand crimper handles slightly to hold the
splice. sleeve firmly in the proper nest.
Step Five: Insert Wires Into Splice Sleeve and
Crimp
Insert the wire into the splice sleeve until it hits

the barrel stop and close the handles of the crimp tool
tightly until the crimper handles open when released
(Figure 32). The crimper handles will not open until
the ,proper amount of pressure is applied to the splice
sleeve. Repeat Steps 4 and 5 for opposite end of the
splice.
Step Six: Shrink the Insulation Around the Splice
Using the heat torch apply heat where the barrel

is crimped. Gradually move the heat barrel to the open
end of the tubing, shrinking the tubing completely as
the heat is moved along the insulation. A small
amount of sealant will come out of the end of the
tubing when sufficient shrinking is achieved
(Figure 32).
IZI_
SPLICE AFTER HEATING

5-23-14
STS81UJ
Figure 32 - Seal Splice Sequence
SIR SYSTEM WIRE SPLICE REPAIR

If any of the original equipment splices (three
wires or more) in the SIR system wiring are damaged
they should be repaired by applying a new splice (not
sealed) from the Terminal Repair Kit J 38125-A.
Carefully follow the instructions included in the kit for
proper splice clip application. Cloth duct tape may be
substituted for splice tape if necessary.
ALTERNATIVE REPAIR METHODS---No alternative repair methods are
available for the SIR system wiring ~nd
components.
CONNECTOR POSITION ASSURANCE
(CPA)
The Connector Position Assurance (CPA) is a
small plastic insert that is inserted through the locking
tabs of all of the SIR system connectors. The purpose
of the CPA is to assure the connector halves are
securely connected and they cannot vibrate apart. The
CPA must be in place to ensure good contact between
the SIR mating terminals. Removing the SDM harness
connector CPA will activate the shorting bar in this
connector turning the "AIR BAG" warning lamp
"ON" when the ignition switch is in the "RUN" or
"START" position.
TERMINAL POSITION ASSURANCE (TPA)
The Terminal Position Assurance (TPA) insert is
similar to the plastic "combs" used in ECM
connectors. The function of the TPA is to keep the
terminal securely seated in the connector body. The
TPA is not to be removed from the connector body
unless a terminal must be removed for replacement.
5-23-M
81'86149.1
Figure 31 - Splice Crimp Tool J 38125-A
9J-68
SUPF>LEMENTAL INFL.ATAaLE RESTRAINT (SIR} SYSTEM
SPECIAL TOOLS
equipment >other than that specified in
this manual. Do not use a rion-powered
probe type' t~ster. Instructions in this
otherwise person~!,1 injury may result.
a.
:,
SIR DRIVER/PASSENGER LOAD TOOL

The SIR Driver/Passenger. Load Tool J 38715 is
used only when called for in this section. It is used as
a diagnostic aid and 'safety device to prevent
inadvertent inflator module deployment.
The load tool has four yellow connectors
attached to its case. The three small connectors are
electrically functional and serve as re.sistive load
substitutions. The large dummy connector does not
serve as a load substitution and is not used.
.
No more than two connectors are. used at any
time. One of the small connectors with adapter
J 38715-5 is used to substitute the load of the driver
inflator module when it ci~, .cqnnected at the top of the
column to the SIR coil\ .assembly. Another small
connector is used to substitute the load of the driver
inflator module and. the SIR coil assembly when it is
connected.at the basex>f the.column to the SIR wiring
harness. The third small connector is used to substitute
for the load of the passenger inflator module when
connected to the passenger inflator module harness
connector.
By substituting the resistance of the load tool

when called for, a determination can be made as to
whether an inflator circuit component is causing
system malfunction and which component is causing
the malfunction. The load tool should be used only
when specifically called for in the diagnostic
procedures.
J 39200 DVM
. The J 39200 DVM is the preferred DVM for use
in SIR diagnosis and repair. However, J 34029-A may
be used if J 39200 is not available. No other DVMs
are approved for SIR diagnosis .and repair.
SCAN TOOL
The Tech 1 is used to read and clear SIR system
Diagnostic Trouble Codes (DTCs). The Tech 1 will
also provide SIR system circuit values using the "Data
List" function. Refer to the Tech 1 Operator's Manual
for specific information on how to use the Tech 1.
Scan tools from other manufacturers IQ.ay be
used. Refer to the Operator's Manual for the tool for
specific instructions.
J 35616-A CONNECTOR TEST ADAPTER

KIT
The J 35616-A Connector Test Adapter Kit must
be used whenever .a diagnostic procedure requests
checking or probing a terminal. Using the appropriate
adapter will ensure that no damage to the terminal will
occur from the DVM probe, such as spreading or
bending. The adapter will also give an idea of whether
contact tension is sufficient, helping to find an open or
intermittent open due to poor terminal contact.
SPECIFICATIONS
.-!\"
Passenger Inflator Module Fasteners .....:.... :.. :.:X: ...............................................................................;............. 10.0 N.m (89 lb.in.)
Sensing and Diagnostic Mqdu]e Fasteners:-,;,; ............................................................................ :................... 10.0 N,m (89 lb.in.)
SERVICE PARTS INFORMATION

. PART NAME
COMPONENTS
Driver Inflator Module
Passenger Inflator Module
SIR Coil Assembly
SDM
Warning Lamp "AIR BAG"
SERVICE PARTS CATALOG

REFERENCE NAME
MODULE, INFL RST STRG WHL
MODULE, INFL RST I/P
COIL KIT, INFL RST STRG WHL
MDL
MODULE, INFL RST DIAGN ENGY
RESV (W/SEN)
LAMP, INST CLSTR
SERVICE PARTS CATALOG

GROUP
14.865
14.865
14.865
14.865
9.744 .
'
SUPPLEMENTAL INFLATABLE RESTRAINT (SIR) SYSTEI\II
9J-69
J38826
J38125-A
J39200
J38715
J35616-A
1 TERMINAL REPAIR KIT

2 SIR DEPLOYMENT HARNESS
3 SIR DRIVER/PASSENGER
LOAD TOOL (J38715-5)
4 DIGITAL MULTIMETER
5 CONNECTOR TEST ADAPTER KIT
6 SCAN TOOL
9-8-94
8181219.1
Figure 33 - SIR Special Tools
9J-70
BLANK
(
REMOTE KEYLESS ENTRY
9K1
SECTION 9K

systems.
CONTENTS
General Description ................................................ 9K-1
Functional Operation .......................................... 9K-1
Remote Control Door Lock Transmitter ........... 9K-2
Body Control Module ........................................ 9K-2
Diagnosis .............. Refer to Section 8A or Section 8D
On-Vehicle Service ................................................. 9K-2
Battery Replacement ........................................... 9K-2

Programming Body Control Module .... '. ............. 9K-2
Re-Synchronizing Transmitter and Body
Control Module ................................................... 9K-3
Specifications ........................................................... 9K-3
Battery Recommendation .................................... 9K-3
GENERAL DESCRIPTION
Close proximity to a radio transmitter, such as a

radio station tower, airport transmitter, and some
mobile or CB radios.
The remote control door lock transmitter is a
hand-held item that is attached to a key ring. It has
three or four buttons that control the functions of the
system; This device complies with Part 15 of the FCC
Rules. Operation is subject to the following two
conditions: ( 1) This device may not cause harmful
interference, and (2) This device must accept any
interference received, including interference that may
cause undesired operation.
The remote keyless entry system (remote control

door lock system) locks and unlocks front side doors,
turns on interior lamps, releases the rear compartment
lift window panel, and arms and disarms the universal
theft-deterrent system, if equipped. Vehicles with the
universal theft-deterrent system are also equipped with
a panic button that activates the horn and parking
lights when depressed. The signal is received by the
body control module (BCM) located above the right
hand instrument panel insulator on the HVAC module.
[I]
Important
The Remote Keyless Entry System is intended to

be used as a supplementary vehicle entry device.
It is not intended to replace, but rather should be
used in conjunction with a door lock key. The
system could be disabled due to radio frequency
interference or low transmitter battery power
level. It is therefore. necessary to always maintain
access to a door lock key.
The remote control door lock system operates on
a 315 MHz radio frequency at a low energy level. If
the system fails to operate from a normal distance,
check for the following conditions:
Weak batteries in the remote transmitter (expected
battery life is two years).
Transmitter and BCM not synchronized.
Items such as trees, bushes, or other objects that
may be blocking the signal.
FUNCTIONAL OPERATION
Figure 1
TO UNLOCK DOORS
Press "UNLOCK" button once and release to

unlock driver's front side door, turn on
illuminated entry, and disarm the universal
theft-deterrent system.
Press "UNLOCK" a second time within 5
seconds to unlock passenger's door.
TO RELEASE REAR COMPARTMENT LIFT
WINDOW PANEL
Press button marked with vehicle symbol on top

cover to release rear compartment lift window
panel and activate illuminated entry. Vehicle must
be in "P" (Park) or "N" (Neutral) with automatic
the ignition must be "OFF" or parking brake set
9K-2
TO LOCK DOORS
Press "LOCK" button to lock doors, deactivate

illuminated entry, and arm the universal
theft-deterrent system.
PANIC MODE
Press button marked with horn symbol on top

cover to activate the emergency panic mode. This
mode will activate the horn and parking lights
intermittently until the panic mode button on
transmitter is pressed again.
REMOTE CONTROL DOOR LOCK

TRANSMITTER
The transmitter transmits a radio signal to the
body control module, which will control functions of
the transmitter. The range is approximately 9 m
(30 feet).
. The transmitter data is encrypted and changes
.with each use. If the transmitter buttons are pressed
too many times out of range from the vehicle
(256 times is the limit), the transmitter and BCM will
get out of sync, and the transmitter will appear not to
work at all. This may also occur if the transmitter
battery has been replaced and the buttons were pushed
a few. times out of range. If this happens, the
transmitter and BCM need to be re-synchronized.
Refer to "Re-synchronizing Transmitter and Body
Control Module" in this section.
BODY CONTROL MODULE

The body control module (BCM) is battery fed
and is always monitoring the transmitter signal. When
the correct transmitter signal is received to lock the
doors, a transistor driver will energize the correct lock
control relay coil and arm the universal theft deterrent
if equipped. The BCM also regulates which lock
control relays will be energized to unlock the doors,
r~lease the re~ compartment lift window panel and
disarm the umversal theft deterrent, if equipped. For
on-vehicle service or diagnosis to the BCM, refer to
SECTION 8D.
ON-VEHICLE SERVICE
1. Battery.
Use battery type CR2032, or equivalent.
2. Top cover by snapping into bottom cover.
3. Press any button near the vehicle to synchronize
the transmitter and BCM.
!L"'!
Inspect
Transmitter operation.
PROGRAMMING BODY CONTROL

MOD~LE
1. Tum ignition switch to "OFF" position.
2. ''.RADIO" .fuse from 1/P fuse block..
3. Cycle ignition switch from "OFF" to "RUN':
three times within five seconds until the door
locks and hatch release cycle indicating the BCM
is in programming mode.
Leave ignition switch in "RUN" position.
4. Press and hold BOTH "LOCK" and "UNLOCK"
buttons on transmitter for 16 seconds.
A. Door locks wilJ cycle once confirming that
transmitter ..code is programmed.
The aoor locks must cycle completely to
unlock before proceeding.
B. Any transmitter code that was previously

progranuned has been erased.
C. Body control module (BCM) is now
programmed to transmitter.
5. When progranurnng BCM to match transmitters,
first transmitter code matched will be stored in
BCM memories unless second transmitter is
matched at the same time. If programming BCM
to match a second transmitter, repeat step 4. This
must be done before "RADIO" fuse is installed.
6. Ignition switch to "OFF".
7. "RAD.IO" fuse to 1/P fuse block.
BATTERY REPLACEMENT
Figure 1
l++I
Remove or Discon~ect
1. Top cover from bottom cover.

Insert a coin into the slotted end of the
transmitter and turn clockwise, if necessary.
2. Battery.
!++I
Install or Connect
A LOCK/UNLOCK
8 PANIC MODE (WITH UNIVERSAL
.THEFT DETERRENT)
C REAR COMPARTMENT LIFT
WINDOW PANEL
040811
FT0019K
NOTICE: Use of wrong type of battery will

cause damage to the transmitter.
Figure 1 Remote Control Door Lock Transmitter (Typical)
ILI
9K3
Inspect
Operation of each transmitter.
RE-SYNCHRONIZING TRANSMITTER AND

BODY CONTROL MODULE
Press both "LOCK" and "UNLOCK" on the
transmitter and hold both buttons for at least 8
seconds.
- This will attempt to match security codes.
IL'l'I
Inspect
Transmitter operation.
SPECIFICATIONS
BATTERY RECOMMENDATION
Remote Control Door Lock Transmitter Battery .............................................................. CR2032 or Equivalent
9K-4
BLANK
(
BODY SERVICE
101
SECTION 10
BODY SERVICE
CONTENTS
General Body Service ................................ Section
Stationary Windows ................................... Section
Body Dimensions and Underbody ............. Section
Bumpers ...................................................... Section
Body Front End ......................................... Section
Doors .......................................................... Section
10-1
10-2
10-3
10-4
10-5
10-6
Rear Quarters ............................................. Section 10-7

Body Rear End .......................................... Section 10-8
Roof and Folding Top ............................... Section 10-9
Seats and Carpet.. .................................... Section 10-10
Seat Belts ................................................. Section 10-11
102 BODY SERVICE
BLANK
GENERAL BODY SERVICE
10-11
SECTION 10-1

Location View i.n SECTION 9J before performing service on or around SIR components or wiring.
NOTICE: The theft .deterrent label found on some major sheet metal must be masked prior to painting,
rustproofing, undercoating, etc. The mask must be removed following the above operations. Failure to keep the
label clean and readable may result in liability for violation of the Federal Vehicle Theft Prevention Standard,
and subject the vehicle owner to possible suspicion that the part was stolen.
CONTENTS
General Description .............................................. 10-1-1
On-Vehicle Service ............................................... 10-1-1
Fasteners ........................................................... 10-1-1
Weld Stud Replacement ............................... 10-1-1
Lubrication ........................................................ 10-1-2
Federal Vehicle Theft Prevention
Standard ................................. Refer to Section OA
Stripes and Decals ......... ,.................................. 10-l-2
Adhesive Nameplates/Emblems ....................... 10-1-3
Adhesive Moldings .......................................... 10..,1-3:
Secure Loose Moldings ............................... 10-1-3
Molding Completely Removed
(Method l) ................................................ 10-l-3
(Method 2) ................................................ 10-1-3
Molding Replacement .................................. 10-1-4
Waterleak Diagnosis and Repair ..................... 10-1-4
Generalized Testing ...................................... 10-1-4
Localized Testing (Spot Test) ...................... 10-1-5
Water Hose Test ........................................... 10-l-5
Air Hose Test ............................................... 10-l-5
Waterleak Repair .......................................... 10-l-5
Windnoise Diagnosis and Repair .................... 10-1-6
Squeak and Rattle Diagnosis and Repair ....... 10-1-7
Anti-Corrosion Treatment ................................ 10-1-7
Corrosion Repair .............................................. 10-1-8
GENERAL DESCRIPTION
The information in this section provides body
service procedures that apply to the entire vehicle.
ON-VEHICLE SERVICE
FASTENERS
NOTICE: Many aluminum components are
used in present models. Aluminum in contact
with steel may corrode rapidly if not protected
by special finishes or isolators.
Metal Part Refinishing - Basecoat/

Clearcoat ..................................................... 10-1-8
Clearcoat Repair without Repainting ........ 10-1-9
Basecoat/Clearcoat Preparation ........... ,...... 10-1-9
Basecoat Application ................................. 10-1-10
Clearcoat Application ................................. 10-1-1 O
Industrial Fallout (Acid Rain) ........................... 10-1-10
Surface Level Contamination Repair ............ 10-1-10
Slight Clearcoat Damage - Wet Sanding,
Finesse Polishing ........................................ 10-1-10
Clearcoat Thickness ....................................... 10-1-11
Paint Gages ......... "'. ........................................ 10-1-11
Plastic Part Identification ................................... 10-1-11
How to Identify Plastic Parts ........................ 10-1-11
Flexible Plastic Part Repair and
Refinishing ...................................................... 10-1-11

Repair Materials ............................................. 10-1-11
Fabricating a Patch Panel.. ............................ 10-1-11
Flexible Plastic Part Repair ........................... 10-1-15
Flexible Plastic Part Refinishing ................... 10.:.1-16
Rigid Plastic Part Repair and
Refinishing ...................................................... 10-1-16
Repair Materials ............................................. 10-1-17
Rigid Plastic Part Repair ............................... 10-1-17
Rigid Plastic Part Refinishing ....................... 10-1-19
Carpet Insert Reattachment ................................ 10-1-19
Body Panel Adjustment and Alignment.. ......... 10-1-19
Weld Stud Replacement

If during a repair procedure, a weld stud
becomes damaged, the following procedure may be
used to replace the weld stud.
1. Drill a hole into same location as damaged weld
stud.
2. Drive a screw into drilled hole.
3. Use screws to retain clips, moldings, etc. in same
manner used with weld studs.
4. If surface becomes marred, repair and/or paint to
provide a smooth surface. Refer to "Metal Part
Refinishing - Basecoat/Clearcoat" in this section.
10-1-2 GENERAL BODY SERVICE

LUBRICATION
Mechanical parts having contacting surfaces in
relative motion with any other body parts are
lubricated during re-assembly. To maintain ease of
operation, it is recommended that .these parts be
lubricated at the basic service intervals shown in
SECTION OB, using the following lubricants:
Door hinges - oil (30 weight preferred). Apply
lubricant to roller and hinge pin bushings.
[I)
Important
Do not apply lubrication to hold-open link and

roller contacting surfaces as this could cause
improper roller operation.
Compartment lid hinges and torque rod-to-hinge
surfaces -Lithium Lubricant (3M P/N 8915) or
equivalent.
Chrome key lock cylinders should be lubricated
with Multi-Purpose Lubricant (GM PIN 12345120
or equivalent) and black key lock cylinders with
Synthetic SAE 5W-30 engine oil.
Seat mechanism and door hardware are covered in
their specific body sections in this manual.
All weatherstrips should be periodically lubricated
with a silicone grease (GM PIN 12345579 or
equivalent). A thin film of lubricant should be
applied using a clean cloth.
STRIPES AND DECALS

Stripes and decals adhere to a painted surface
using pressure sensitive adhesive. The use of a wetting
solution aids the technician in lifting and positioning
the stripe or decal during installation. A wetting
solution also ensures a. better b.ond between stripe or
decal and panel.
Stripe or decal replacement involving collision
damage, or damage to underlying painted surface,
requires that metal repair and/ or refinish operations be
completed before stripe or decal is installed.
NOTICE: Freshly painted surfaces must be
allowed to dry thoroughly before installing
stripe or decal. Residual solvents in fresh
painted surfaces can lead to subsequent
blistering problems if stripe or decal is applied
before complete release of solvents. The striping
material highlights vehicle surface imperfection.
All dings, rough metal, paint defects and uneven
two-tone paint breaklines must be eliminated
before stripe/decal application can take place.
Body surfaces and decals must be maintained

between 21 to 38C (70 to 100F) during installation.
Auxiliary heat sources to warm the body surfaces and
decals are required if the temperature is below 21 C
(70F), or the body surface must be allowed to cool if
above 38C (100F).
[I]
Stripes and decals may be applied "dry." If this

does not result in a consistent bubble free application,
the "wet" method must be used as in the case of large
graphics packages.
II]
Important
Stripes or decals that are applied on flexible

surfaces (fascias, etc.) must be applied
using the "wet" method. This will reduce
the formation of bubbles under the decal due
to the outgassing potential of the flexible
materials.
The following equipment and materials are
necessary when making a quality stripe or decal
installation. Equivalent products may be used.
Wetting solution - a foaming type window cleaner,
that does not contain ammonia.
A silicone, wax and grease remover.
Isopropyl alcohol.
Squeegee - 75 to 100 mm (3 to 4 inches) wide,
plastic or hard rubber. Deburr any sharp or rough
edges to prevent scratching of the stripe or decal.
Water bucket and sponge or spray bottle.
Sandpaper - 600 grit or finer, wet-or-dry type.
Heat gun or infrared heat lamp.
Clean, lint-free wiping rags.
Sharp knife or razor blade.
Scissors.
Fine pin or needle.
Marking pencil.
I+-.!
Remove or Dis.connect
1. Necessary moldings or trim panels.

2. Wash and clean repair surfaces, adjacent panels
and openings as required.
3. Molding attaching clips, handles, sidemarker
reflectors and/or other stripe or decal overlapping
parts.
NOTICE: To avoid damaging underlying paint

finish, do not use pointed or sharp instruments
for removal of stripe or decal from panel.
4. Stripe or decal by starting at one edge and peeling

stripe or decal from panel surface.
Application of heat to stripe or decal at point
of removal aids removal operation.
5. All traces of adhesive residue from painted
surfaces with a silicone, wax and grease remover.
!-.+!
Install or Connect
1. Prepare surface.
Important
Never apply decals when body surface and

decal temperatures are below 21 C (70F).
NOTICE: To prevent possible vehicle, stripe

or decal damage, always refer to manufacture's
packaged instructions.
[I]
Important
If area where stripe or decal is to be applied

has been refinished, remove any imperfections
that would show through stripe or decal.
Clean
A. Painted surface with a silicone, wax and grease

remover.
B. Area where stripe or decal will be applied with
a 50-50 mixture of isopropyl alcohol and
water.
C. Wipe panel surface with a clean cloth while
solvent is still wet and allow to dry.
2. Apply wetting solution to area where stripe or
decal is to be installed.
3. Put wetting solution on adhesive side of stripe or
decal.
Remove backing material of stripe or decal as
necessary.
4. Stripe or decal to panel. Wetting solution will
allow movement of stripe or decal for proper
positioning.
A. Working from center where possible, squeegee
stripe or decal into position. Application of
additional wetting solution may be necessary
to ease installation of stripe or decal.
Application of soapy wetting solution on top
side of stripe or decal will ease pull of
squeegee on stripe or decal and help to
eliminate damage to it.
B. Apply heat to stripe or decal at recessed areas.
Press stripe or decal into recess to obtain firm
bond.
ILI
Inspect
Stripe or decal from critical angle using

adequate light reflection to detect any
irregularities that may have developed during
installation.
C. Remove all air bubbles by piercing with a
safety pin, needle or tool with same size
piercing tip. Never use razor blade or knife
edge.
Pierce bubble on its outer edge and force air
out from opposite edge with blade of
squeegee.
5. Previously removed parts and clean as required.
ADHESIVE NAMEPLATES/EMBLEMS
For information on adhesive nameplates and
emblems, refer to the specific body sections in which
the nameplate and emblems are located.
ADHESIVE MOLDINGS
The moldings are attached to the body panels
with adhesive tape. To ensure a good replacement of
new or old moldings, the panel surface should be
warm, 21 to 32C (70 to 90F), clean and free of any
wax or oily film. Methods are listed to attach loose
molding ends, completely removed moldings, and
replacement moldings.
10-1-3
Secure Loose Moldings

1. Wash affected area with soap and water and wipe
dry. Wipe panel and adhesive side of molding
with clean rag using oil-free naphtha or alcohol.
If molding has been pulled loose from
adhesive backing (tape remains on body
panel), do not remove tape from body panel.
Clean back of molding and tape on body panel
with oil-free naphtha or alcohol and proceed
with step 3.
2. If needed, apply length of masking tape as
molding guide. Straight edge may also be used.
3. Apply adhesive to back of molding and press in
place. If adhesive (GM PIN 1052621 or
equivalent), is used, apply constant pressure to
molding for 30 seconds or until firm bond has
been made.
Molding Completely Removed (Method 1)
Figure 1
[I]
Important
Do not use this procedure if molding is dented

or was pried from body panel.
1. Wash affected area with soap and water and wipe
dry.
2. Remove all traces of adhesive from body panel

and back of molding using oil-free naphtha or
isopropyl alcohol.
3. Mark proper position of molding with length of
masking tape (Figure 1). Use adjacent moldings
as guide.
4. Warm body panel with heat lamp or heat gun to
21C (70F).
5. Apply double-coated foam tape (3M PIN 06380 or
equivalent) to the molding.
6. Line up molding to tape guideline on body panel
or use straight edge to align molding to front or
rear moldings already on vehicle.
Adhesive tape on molding to be flush 0.010.5
to edge of part when viewed perpendicular to
surface.
7. Peel backing from end of molding.
8. Press firmly into place while continuing to
remove backing.
9. Hand roll molding to body panel to ensure proper
adhesion.
Molding Completely Removed (Method 2)

Scotch-Brite Molding Adhesive and Stripe
Removal Discs (3M PINs 07501 and 07502) and the
Roloc + Holder (3M PIN 07500) can be used for
quick removal of adhesives from moldings and panels.
CAUTION: Standard shop practices,
particularly eye protection, should be
followed during these operations to avoid
personal injury.
10-1-4
1. Tighten holder in collet or chuck of any standard

tool.
2. Twist disc securely into holder.
3. With tool running, bring outer edges of disc into
contact with material to be removed. Light contact
is all that is needed.
4. Guide tool so it works against the rotation of the
disc.
Molding Replacement
Figure 1
l++I
Inspect
WATERLEAK DIAGNOSIS AND REPAIR
Install or Connect
Molding.
A. Mark proper position of molding with length
of masking tape or straight edge, aligning to
front or rear moldings already on vehicle.
IL"'I
Molding ends for bonding.

Hand roll loose ends.
Molding.
A. Hold hot air gun 152 mm (6 inches) from
surface of molding to be removed.
B. Apply heat, using circular motion for about
30 seconds.
C. Place catgut or fishing line between molding
and body panel. Using sawing motion, remove
molding from panel surface.
D. Discard molding.
l++I
D. Press molding to body panel while continuing

to remove backing.
E. Hand roll molding to body panel to ensure
proper adhesion.
F. Molding ends should not overlap door edge,
door edge guard, lock cylinder or body
openings.
Clean
Area with soap and water and wipe dry.

Body panel using oil-free naphtha or isopropyl
alcohol.
B. If needed, warm body panel with heat lamp or
heat gun to 21 C (70F).
C. Peel backing from front end of molding.
Do not touch adhesive backing.
Adhesive tape on molding to be flush 0.0/0.5
to edge of part when viewed perpendicular to
surface.
GM .vehicles are designed to operate under

normal environmental conditions. The design criteria
for sealing materials and components takes into
consideration the sealing forces required to withstand
the natural elements. These specifications do not, and
cannot, take into consideration all artificial conditions
such as may be encountered in some high pressure car
washes.
The water test procedure has been correlated to
the natural elements and will determine the ability of a
vehicle to perform under normal operating conditions.
Repairing body waterleaks is a problem of
proper testing, diagnosis and repair through adjustment
of mis-aligned components and/or application of
proven repair materials. The first step in waterleak
diagnosis is finding the condition under which the leak
occurs. For example, the leak is noticed only when
parked on an inclined drive, or when water is in the
jack and spare tire stowage.
If the general leak area can be found, the exact
entry point can be quickly isolated by use of a
localized test such as a water hose or air hose; If the
leak source is not obvious, a testing method using
water test equipment should be used. It may be
necessary to remove some interior trim panels or
components to locate areas needing repairs.
Generalized Testing
The water test stand must be constructed.
Water test stand specifications:
\.. ,t.
A TAPE GUIDELINE OR STRAIGHT EDGE
Figure 1 Adhesive Molding Repair
012495
FS001101
- Volume of flow should be 14 liters

(3.7 gallons) per minute.
- Water pressure, measured at nozzle - 155 kPa
(22 psi). .
- Windshield and front body pillar
approximately 30 degrees down, 45 degrees
toward rear and aimed at comer of windshield.
- Doors - approximately 30 degrees down, 45
degrees toward rear and aimed at center of
rear door or rear quarter panel.
- Rear window and rear compartment lid or end
gate -approximately 30 degrees down, 30
degrees toward front and aimed about 600 mm
(24 inches) from corner of rear window.
If specified water pressure of 155 kPa (22 psi)
cannot be obtained because of local situation, both
test stands may be moved toward body until water
spray overlap can be obtained.
101 5
Localized Testing (Spot Test)

Localized testing may be made with. either water
or air. Begin the test at the base of the suspected area
and continue up slowly until the leak is located.
(I]
Important
Pinpoint the leak area before any. reparr 1s

made. Random repair may only temporarily
restrict water entry and make future diagnosis
and repair more difficult.
Continue localized testing in the same general
area to confrrm that all leaks have been located.
012495
FS003101
Figure 3 - Water Hose Test of Wheelhouse Assembly
Water Hose Test

Figures 2 and 3
1. Have helper inside vehicle to detect actual leak
point.
2. Use unrestricted water flow (no nozzle).
3. Begin at base of suspected leak area and move
upward slowly.
Air Hose Test

Figures 4 and 5
01-2495
FS004101
1. Apply bubble solution (liquid soap) to suspected

leak area.
2. Apply air pressure with an air hose from inside
vehicle. Do not exceed 205 kPa (30 psi).
3. Observe for bubbles on outsid.e at suspected leak
area.
Figure 4 - Air Hose and Bubble Solution Test of Windshield

Glass Sealant
Waterleak Repair
Figure 6
To locate the exact leak point or to repair the
leak, it may be necessary to remove some interior trim
panels or components. Waterleak repair is covered in
the section covering the component. For ex.ample, for
the repair procedure on stationary windows, refer to
SECTION 10-2.
After completion of any waterleak, repair, the
general area should be re-tested using the water test
stand. Do not use high-pressure air hose.
01-24-95
FS002101
Figure 2 - Water Hose Test of Windshield Pillar
Figure 5 - Air Hose and Bubble Solution Test of Panel

Joints
Materials recommended for specific leak areas

include:
Urethane adhesive caulking kit (GM
PIN 12345633 or equivalent) for windshield,
rear window, and stationary window repair.
Brushable seam sealer which can be painted
on metal joints.
Bedding and glazing compound for ventilation
ducts and drip moldings.
Drip-check sealer for small cracks and pin holes.
All-Around Autobody Sealant (3M PIN 08500
or equivalent) for large holes.
Weatherstrip adhesive (3M PIN 08011 or
equivalent) for weatherstrips.
Strip caulk for bolts, studs and screws.
10-1-.6 GENERAL BODY SERVICE
A
1
2
3
4
SEALER
PILLAR, WINDSHIELD
PANEL, DASH
REINFORCEMENT, WINDSHIELD LOWER FRAME
PILLAR INNER, BODY HINGE
0Mt495
FS006101
Figure 6 Sealing Front End to Prevent Water Leaks
WINDNOISE DIAGNOSIS AND REPAIR

Figures 4, 5 and 7
Many of the waterleak diagnosis tests are also
used for windnoise diagnosis.
Visual inspection.
- Mis-aligned components
- Loose fasteners
- Tom weatherstrips
- Broken weld joints
- Sealer and/or adhesive skips
Tracing powder or chalk test.
A. Clean weatherstrips and contact surfaces with
solvent.
B. Apply powder or chalk in an unbroken line to
contact surface of weatherstrip around
perimeter of rear compartment lid, door, side
door window or hood. Surrounding areas must
be free of chalk or powder.
C. Close panel completely. Do not slam. This
presses weatherstrip firmly against mating
surfaces.
!LI
Air pressure test.

A. Mask off pressure relief valves.
B. Turn on vehicle's ventilation fan.
C. Close all openings - windows, doors, etc. An
abnormal amount of high pressure will build
up in vehicle and will escape through poor
seals.
D. With stethoscope or length of heater hose,
listen for escaping air along door and window
seals.
Smoke or dusting powder test can be used in

same manner. Exact leak location can be seen
as smoke or powder travels through poor seal.
Soap suds or bubble test.
A. Pressurize interior of vehicle as outlined in air
pressure test above.
B. Apply soapy solution to potential leak areas.
Escaping air pinpoints leak area. Air pressure
from air hose inside vehicle can be used
instead of pressurizing vehicle's interior. Do
not exceed 205 kPa (30 psi) when using air
hose. (Figures 4 and 5).
External windnoise.
A. Road-test vehicle to determine source of noise.
Wind roar is caused by outside air passing
over an opening.
Wind whistle is caused by inside air
seeping through a bad seal, or by outside
air passage over a protruding edge.
Wind rush is outside air passing over the
vehicle's body.
B. Tape various moldings and gaps until noise is
eliminated (Figure 7).
[I]
Important
If masking the grille and headlamp capsule

areas, care must be taken not to restrict airflow
and cause vehicle overheating.

Windnoise leak repairs are very similar to
waterleak repairs. The actual procedure depends on the
type of seal being repaired.
Inspect
Applied chalk line on weatherstrip will be

marred where contact is good. A
corresponding imprint will be on mating
surfaces.
Gaps or irregularities in powder or chalk line
on mating surfaces indicate areas with poor
seal.
012415
FS007101
Figure 7 - Masking Tape Application to Identify Windnoise

Leaks around door opening weatherstrips do not
always indicate a faulty weatherstrip. A door or
window adjustment may resolve the condition. Refer
to SECTION 10-6.
SQUEAK AND RATTLE DIAGNOSIS AND

REPAIR
Basically, squeaks and rattles are caused by
improperly controlled relative motion between
components. There are three ways to prevent the
squeak or rattle.
1. Attach component securely so there is no relative
motiori during operation.
2. Separate components so there is no contact under
operating conditions.
3. Insulate components so that no squeaks or rattles
occur with relative motion between components.
Low uniform friction surfaces can be provided to
eliminate "stick-slip" motion.
ANTI-CORROSION TREATMENT.
Figures 8 and 9
CAUTION: When applying sound

deadeners, or anti-corrosion materials
due care and preventive measures must
be exercised to prevent any material from
being sprayed i.nto door and quarter
panel mechanisms such as door lock,
window run channels, window regulators
and seat belt retractors, as well as any
moving or rotating mechanical or
suspension parts on the underbody,
particularly the parking brake cable. After
material application, be sure all body
drain holes are open. Improper
application may increase chance of
corrosion damage or limit the operation
of moving parts, resulting in personal
injury.
Anti-corrosion materials are used on interior and
exterior surfaces of metal panels to provide rust
resistance. These materials include metals such as
one-sided and two-sided galvanized zipcrqmetal and
zinc-iron alloy steels. These treated metals are used on
components such as quarter panels, wheelhousings and
other critical parts. These materials have multiple
production and field usage's.
Metal conditioners and primers are used on
interior and exterior surfaces along with protective
waxes on interior surfaces in areas where moisture
might accumulate. Sealers are applied along exposed
joints and moisture-repelling asphaltic sound deadeners
are applied inside the wheel wells and on some
underbody components.
Any procedure that disturbs these special
treatments, such as panel replacement or collision
damage repair operations, may leave the metal
unprotected and result in corrosion. Proper re-coating
of these surfaces with service-type anti-corrosion
material is essential.
10-1-7
Metal conditioners and primer coatings are

applied to all metal panels at the time of vehicle
manufacture. After repair and/or replacement parts are
installed, all accessible bare metal surfaces must be
treated with metal conditioner and reprimed using a
zinc chromate primer. This operation is to be
performed prior to the application of sealers, waxes,
deadeners and anti-rust compounds.
Sealers are applied to specific joints during
manufacture. These sealers are intended to prevent
water and dust from entering the vehicle and also are
anti-corrosion barriers. Sealers are applied to such
areas as lid hem flanges, wheelhouse panel, quarter
outer panel, floor panel, cowl, roof module and
various other panel-to-panel attaching points. The
originally sealed joints are obvious and any damage to
these sealed locations should be corrected by resealing.
Attaching points of new replacement panels should be
resealed. Replacement lids will also require sealing in
the hem flange areas.
Flanged joints, overlap joints and seams should
be sealed using a quality sealer of medium-bodied
consistency. The sealer used must retain its flexible
characteristics after curing and be paintable.
Open joints which require bridging of the sealer
to close a gap should be sealed using a heavy-bodied
caulking material. Follow the label directions for the
material selected.
Color application may be required to restore
repaired areas such as the hood, quarter outer panels,
roof module, engine compartment, underbody and
inner panels to original appearance. When this is
necessary, conventional refinishing preparation,
undercoat build-up and color application techniques
should be followed.
Deadener materials (spray-on type) are used on
various metal panels to provide corrosion resistance
and joint sealing. They control the general noise level
inside the passenger area of the vehicle. When
deadeners are disturbed because of damage, removed
A SEALER
012495
FS008101.
Figure 8 - Typical Joint Sealing, Rear End Area
10-1-8
during repair operations, or a new replacement panel is

installed, the deadener material must be replaced by a
service equivalent material. The application pattern
and location of deadener materials can be determined
by observing the original production installation.
Anti-corrosion compounds are light-bodied
materials designed to penetrate between metal-to-metal
surfaces, such as pinch-weld joints, hem flanges, and
integral panel attaching points where metal surfaces
are difficult to coat with conventional undercoating
materials, and are inaccessible for painting. Material
suited for this type application is a wax-type coating
(GM PIN 12345489 or equivalent).
Conventional undercoating is recommended to
coat large areas such as quarter outer panels, floor
panels, lids, hoods, etc.
The sequence of steps for application of
anti-corrosion materials is as follows:
1.
2.
3.
4.
Clean and prepare metal.

Apply primer (zinc chromate).
Apply sealers at all previously sealed joints.
Apply color in areas where color is required, such
as hem flanges, exposed joints and underbody
components.
5. Apply deadeners as indicated by original
application pattern.
6. Apply anti-corrosion compounds.
7. Apply underbody rustproofing material.
Cleaning of the interior and underbody panel
surfaces is necessary when original galvanized or other
anti-corrosion materials have been burned off during
welding or heating operations. Removal of the residue
from burning will require additional care in such areas
as interior surfaces of box-type construction and when
configurations of the metal panels limit access to
interior surfaces. One or more of the following
methods will remove the residue.
CAUTION: Approved safety glasses

should be worn when performing this
procedure to reduce the chance of
personal injury.
Where access is possible, scraping can be used. If

a standard putty knife or scraper will not fit into
the affected area, fabricate a small, flexible
scraper from a narrow piece of sheet metal.
A jet of compressed air will remove most residue
and could be effective in limited-access areas. Eye
protection is absolutely necessary in an operation
of this type.
Sandblasting is most effective and should be used
when the equipment is available and access to the
area is good. Sandblasting is an exceUent method
for cleanup and preparation of open joints,
underbody components and hem flange areas.
Wire brushing (power and by hand).
When access is good, sandpaper and steel wool
can be used.
CORROSION REPAIR
Prior to replacing exterior body parts, check
condition of paint on all covered or hidden interior
surfaces. If corrosion is found in these areas, proceed
as follows:
1. Remove corrosion with suitable wire brush and
abrasive or liquid corrosion-removing agent.

Follow label directions.
2. If necessary, wash with detergent, rinse and dry.
3. Apply a heavy coating of anti-corrosion
compound to all cleaned hidden surfaces before
installing exterior body parts. Also, apply
anti-corrosion compound to all inner surfaces of
exterior body parts being installed.
METAL PART REFINISHING BASECOAT/CLEARCOAT
7'=
A
I SECTION A-A I
A SEALER
012495
FS009101
Figure 9 Typical Anti-corrosion Treatment Around

Perimeter of Hood Outer-to-Inner Panel Flanges
CAUTION: Many paint repair systems

require additives containing isocyanates.
It is essential that all recommendations
and warnings listed on the container .
label for materials selected be followed. It
is mandatory that adequate respiratory
protection such as air line respirators
with a full hood be worn during the entire
painting process. Persons with
respiratory problems or those allergic to
isocyanates must not be exposed to
isocyanate vapors or spray mist.
Basecoat/clearcoat is factory applied in four
layers: a cathodic immersion primer, a primer-surfacer,
base color of high-solids acrylic enamel (basecoat),
and a clear acrylic top coat (clearcoat) to give the
finish a high-gloss look.
GENERAL BODY SERVICE .10-1-9
rn
Clearcoat Repair without Repainting

Figure 10
Frequently wipe or squeegee repair to

determine when defect has been removed.
Sand only enough clearcoat to remove defect.
Sanding below clearcoat requires repainting.
8. Using clean cloth, wipe repair area clean of water
and clearcoat residue.
9. Polish as necessary. Often, hand compounding and
polishing of a small repa:ir area is all that is
necessary to restore. appearance.
lf the damage or imperfection can be s~ded or

J:>Olished without reaching the basecoat, you .do not
have to repaint.
1. Thoroughly wash repair .area with mild detergent
and water.
2. Apply small amount of medium to fine machine
rubbing compound to repair area and smear
evenly with compounding pad.
3. With polisher running at approximately 1,700
rpm, polish repair area. Keep pad flat against
panel while applying light pressure. Feature lines
and panel edges should be done with care.
4. If sanding is not required, proceed to step 9.
5. If repair is near adjacent panels, mask adjacent
panels to protect against sand scratches and
bum-through of panel edges.
6. Saturate piece of micro-fine sandpaper of 1,500 to
2,000 grit in container of water and attach to
sanding pad. Adding small amount of liquid
detergent to water will improve wet-out and
sanding performance.
7. Keep repair area wet while sanding. Sand lightly
and evenly in one direction only, using straight
strokes.
Important
Keep pad flat to panel and allow weight of

polisher to do the work.
Use polish sparingly to achieve original shine.
Machine or hand polish repair area first, then
. 1:,lend. in with rest of panel.
Basecoat/Clearcoat Preparation
1. Wash repair area with detergent and water.
2. Clean repair area with a silicone, wax and grease
remover.
3. Repair and feather-edge damaged areas.
4. Treat metal surface with metal conditioner and
conversion coating. Allow to dry.
5. Apply primer-surfacer. Dry 20 to 30 minutes.
6. Sand basecoat paint area with 400 grit or finer
paper. (For clearcoat only, wet sand with 600 grit
or finer paper or hand compound.)
7. Clean with a silicone, wax and grease remover
and tack wipe.
CHEMICAL SPOTTING
..............
.. ..---:--
SAG
. .--
CLEARCOAT
BASECOAT ~..;...,
-
PRIMER
.....;.
""
CLEARCOAT
BASECOAT~/' :-.
PRIMER
PRIMER
PRIMER
METAL
METAL
ORANGE PEEL
-
CLEARCOAT
:~~;- BASECOAT
!,;::::;;:
PRIMER
PRIMER
METAL
rv
SCRATCH
CLEARCQAT
!-_" _ , BA SEC OA T -
DIRT
CLEARCOAT
.._:-
-;--:.__:~-- BASECOAT ::.., .,:
PRIMER
PRIMER
PRIMER
PRIMER
METAL
METAL
012415
FS010101
Figure 1O - Minor Paint Defects That Can Be Repaired Without Repainting
10-1-10
rn

Important
Do not do step 8 if the basecoat enamel used

for repair does not require it. Always refer to
manufacturer label directions.
8. Apply one or two coats of adhesion promoter:
A. Within moldings or breaklines.
B. Onto adjacent panel 100 to 150 mm (4 to
6 inches) if repair is not confined and beyond
area to be covered by clearcoat.
C. Allow to flash at least 30 minutes before
applying clearcoat.
Basecoat Application
CAUTION: See "Caution'' under "Metal
Part Refinishing -Basecoat/Clearcoat."
Since the severity of the condition varies from

area to area, proper diagnosis of the damage extent is
critical to the success of repairs. Diagnosis should be
performed under high-intensity fluorescent lighting, on
horizontal surfaces (hood, roof panel, rear
compartment .lid) after they have been properly
cleaned. There are three basic types of acid rain
damage:
Surface level contamination - may be repaired by
simply washing the vehicle, cleaning the surface
with a silicone, wax and grease remover,
neutralizing acidic residue and finesse polishing.
Clearcoat etching - slight etching still noticeable
after the above washing and finesse polishing
procedure.
..
Basecoat etching - severe etching beyond the
clearcoat into the basecoat
Surface. Level Contamination Repair

1. Activate enamel material per manufacturer
instructions.
2. Mix thoroughly.
3. Reduce basecoat per manufacturer instructions.
4. Check viscosity with a Zahn number 2 viscosity
cup or equivalent.
5. Spray two or more medium-wet coats, 15 to 20
minutes apart, to achieve full-hiding and color
match.
6. Cure per manufacturer instructions.
Clearcoat Application
CAUTION: See "Caution" under "Metal
Part Refinishing -Baseco.at/Clearcoat."
1.
2.
3.
4.
Activate materials per manufacturer instructions.

Mix thoroughly.
Reduce clearcoat per manufacturer instructions.
Check viscosity with a Zahn number 2 viscosity
cup or equivalent.
5. Spray at 50 psi gun pressure. Apply two
medium-wet coats, 15 to 20 minutes apart.
Cover entire panel wherever possible.
When there are no breaklines, blend spray
within area prepared.
rn
Important
Clean spray equipment iriuriediately after use

with lacquer thinner.
INDUSTRIAL FALLOUT (ACID RAIN)
rn
Important
The following information regards the use of

finesse-type repairs to industrial fallout
damage to basecoat/clearcoat paint finishes.
1. Wash vehicle with standard car detergent and

water, and dry thoroughly.
2. Clean affected area with a . silicone, wax and
grease remover.
3. Neutralize leftover acidic residue by cleaning
. damaged areas with mixture of baking soda and
water (one tablespoon per one quart of water),
rinse thoroughly and dry panels completely.
4. Apply finesse-type polish with foam pad.
If damage has been repaired, remove any swirl
marks with dual-action orbital polisher and
foam pad.
If some damage remains, proceed to "Slight
Clearcoat Damage - Wet Sanding, Finesse
Polishing" in following procedure.

Finesse Polishing
1. Select small test area on damaged panel.
2. Wet sand damaged area with an American grade
ultra-fine sandpaper of 1;500 to 2,000 grit and
rubber sponge sanding block. During wet sand
process:
A. Use ample amounts of water.
B. Go sfow to prevent removing too much
clearcoat.
[I]
Important
Be sure to use American sandpaper. European

sandpaper has a P before the grit number and
European grits do not align with American
grits the majority of the time.
3. Remove excess water with rubber squeegee and
inspect area.
If wet sanding has repaired the damage,
continue the sanding procedure on the entire
panel. Apply a finesse-type polish with a foam
pad and remove any swirl marks with a
dual-action orbital polisher and foam pad.

If (during the repair) it is suspected or
observed that etching has penetrated into the
basecoat, too much clearcoat has been
removed during sanding or base color is
transferred to pad during polishing, the
affected areas may require clearcoat/basecoat
application or refinishing. Refer to "Metal Part
Refinishing - Basecoat/Clearcoat," "Flexible
Plastic Part Refinishing" and/or "Rigid Plastic
Part Refinishing" in this section.
4. Polish entire vehicle after all damage has been
repaired.
Clearcoat Thickness
The clearcoat on the vehicle is typically 0.059 to
0.078 mm (1.5 to 2 mils; 0.0015 to 0.0020 inch) thick.
Paint Gages
10-1-11
_l_
3mm
HEIGHT
OF LETTERS
PREFERRED
SAE PVC
ACCEPTABLE
SAE
t
i
3mrn
HEIGHT
OF LETTERS.
t
_j_
The best way to accurately measure how much

clearcoat has been removed is to use a paint gage
before, during and after the sanding process. Paint
gages measure the total thickness of the finish and
when used, can determine how much clearcoat has
been removed during the repair process. Paint gages
range from magnetic pull types to sophisticated
electronic types and are available from a variety of
sources. The older magnetic type gages, at best have a
5 percent accuracy range and are not sensitive
enough to detect removal of 0.020 mm (0.5 mil;
0.0005 inch) clearcoat. The newer type magnetic gages
have improved accuracy ranges. Most gages are
confined to checking either ferrous metal (steel) or
non-ferrous metal (aluminum) panels. At this time,
there are .no viable gages for reading film thickness on
non-metallic panels.
The more sophisticated digital type gages are
able to read film thickness on both ferrous and
non-ferrous metal panels. Digital gages can have an
accuracy range of 1 percent and include thickness
standards for re-calibration.
FLEXIBLE PLASTIC PART REPAIR AND

REFINISHING
PLASTIC PART IDENTIFICATION
Repair Materials
How to Identify Plastic Parts

CAUTION: General Motors does NOT

recommend using a plastic "Burn Test"
to distinguish different types of plastics.
This test produces vapors that can be
harmful to your health.
Specific plastics used on this vehicle are shown
in Figures 12 and 13. The procedures provided in this
section classify the plastics into two groups; flexible
and rigid. Refer to Figures 12 and 13 to identify the
parts and the repair/refinish procedure to use.
The following information can be used to
specifically identify plastic parts when necessary.
1. Look on the back of the part for the International
Organization for Standardization (ISO) code
marking as shown in Figure 11.
[El
3mm
HEIGHT
OF LETTERS
t
Ol-24-95
FSOl110I
Figure 11 Typical Plastic Parts Marking Symbol
2. Refer to Figures 12 and 13. Match the ISO code

found on the parts with those on the charts.
3. Use the chart in Figure 14 chart to identify special
handling procedures and the repair/refinish
classification (rigid or flexible).
rn
Important
Use supplies and repair . materials from the

same manufacturer for the best results. Do not
mix systems.
These flexible plastic panel repair procedures
require the use of GM Goodwrench Compoxy Repair
Material (GM PIN 12345744) or equivalent.
Fabricating a Patch Panel

Panels requiring slicing or sustaining major
damage may need a reinforcement panel or patch
panel. If possible, obtain this part by cutting a piece
from the original damaged panel. It should be 76 to
102 mm (3 to 4 inches) in width if the damage is a
split or break. If a part of the damaged panel is
missing, the reinforcement panel or patch should
extend 38 to 50 mm (1 1/2 to 2 inches) beyond the
edges of the damaged area.

An adequate part may be manufactured as
follows:
I. Lay out a piece .. of wax paper larger than the
damaged area on the panel.
Apply a layer of repair material.
3. Cut a piece of reinforcement mat material to
desired size and shape and place over repair
material. Extend mat 38 to 50 mm (1 1/2 to
2 inches) beyond repair area.
2:
4. Apply a .coat of repair material as necessary.

5. Place a piece of wax pa.per over the mat material
and roll with the saturation roller to ensure
saturation of. mat.
6. Remove wax paper from panel.
7. Apply patch to inner side of the damaged area, if
ac.cessible. Work out .any air pockets.
8. Allow to cure.
CHART OF PLASTIC PARTS IDENTIFICATION AND REFINISHING SYSTEMS

Identifying Symbol
Old Symbol in ( )
Chemical
Composition or
Plastic ~Family"
Name
Typical Area(s)
Where Part Used
Examples of
Common and/or
Trade Names
Typical Paint
Repair System
UP
Polyester/Thermoset
Fender extensions
Hoods
Roofs
Deck lids
Instrument housings
Ventilation grids
Air scoops
Air spoilers
SMC, Premi-glas,
Selectron, Vibrinmat,
"Fiberglass"
PE
Polyethylene
Inner Fender Panels

Valances, Spoilers,
Interior Trim Panels,
Safety Belt Covers,
Gas Tank Shields
Dylan, Fortiflex,
Marlex, Alathon,
Hi-fax, Hosalen,
Paxon
#7
PS
Polystyrene
Dash Panels
Door Panels
Lustrex, Dylan
Styron, Durathon,
Polystyrol
#7
Polyphenylene Ether
Chromed Plastic parts;

Headlamp Doors
Ornaments, Bezels
Noryl, Oleflo, Prevex
pp
Polypropylene
Door Panels, Load

Floors, Kick Panels,
Deflector Panels,
Cowl Panels,
Wheel Covers,
Interior Moldings,
Radiator Shrouds,
Inner Fenders,
Bumper Fascia
Profax, Oleflo,
Marlex, Azdel,
Novolen, Tenite,
Daplen, Escorene
#2, #3, #5 and #7
TPU (TPUR)
Polyurethane,
Thermoplastic
Bumper Fascia,
Soft Filler Panels,
Glass Moldings,
Gravel Deflectors
Pellethane, Estane,
Roylar, Toxin
#2, #3, #5 and #7
PUR
Polyurethane,
Thermoset
(Unsaturated}
Bumper Fascia
Front and Rear Body
Panels,
Filler Panels
Castethane, Bayflex,
(Commonly referred
to as RIM .AND
RRIM)
ABS
Acrylonitrile,
But~diene/Styrene
Instrument Clusters.
ABS, Cycolac,. Abson,
Trim. Moldings
Kralastic, Lustran,
Consoles
Absafil, Dyel
Armrest Supports
Steering .Column
Brackets
Steering. Column Jackets
PPE (PPO)
#1 and #4
NIA
#2 and #5
#1, #4 .lllld #6
(
T5428
10-1-13
CHART OF PLASTIC PARTS IDENTIFICATION AND REFINISHING SYSTEMS (cont'd)

Chemical
Examples of
Identifying Symbol Composition or
Typical Area(s)
Typical Paint
Common and/or
Old Symbol in ( ) Plastic "Family"
Where Part Used
Repair System
Trade Names
Name
ABS+ PC
Aery lonitrile/B utadien

e Styrene +
Polycarbonate
Instrument Panels,
Instrument Clusters
Baybland, Proloy,
Cycoloy, KHA
ABS/PVC
ABS/Vinyl -(Soft)
Head Restraint Covers

Instrument Panel Pads
Trim Moldings
Trim Panels
ABS Vinyl
#7 and #8
IBO
(EP, EPM, TPO)
Ethylene/Propylene
(Rubber)
Bumper Fascia
Valance Panels
Air Dams
TPO, TPR,
(Thermoplastic
Rubber)
EPI, EPII
#3 and #5
EPDM
Ethylene Propylene
Diene Monomer
Bumper Impact Strips

Body Panels
EPDM, Nordel
#2, #3 and #5
Ethy lene/Viny1
Acetate
Head Restraint Cover

Elvax, Microthane
Miscellaneous Soft Trim
Components
Fenders,
GTX
Exterior Trim
EVA (EVAC)
PA+ PPE
Polyamide +
Polyphenylene Ether
#1, #4 and #6
#7 and #8
#2, #3 and #5
IMPORTANT: Follow selected paint manufacturer's product label directions. Observe all warnings on material container
labels.
T5428(Cont'd)
Figure 12 Plastics Identification Chart (1 of 2)
CHART OF PLASTIC PARTS IDENTIFICATION AND REFINISHING SYSTEMS

Chemical
Examples of
Identifying Symbol Composition or
Typical Area(s)
Typical Paint
Common and/or
Old Symbol in ( )
Plastic
Where Part Used
Repair System
Trade Names
"Family" Name
Geon, Vinylite,
Pliovic, "Viny1",
Vinoflex, Unichem
Lustran, Tyril,
Foracryl
PVC
Polyvinyl chloride
(Vinyl)
Interior Soft Trim,

Instrument Panel
Skins, Roof Covers
SAN
(SA)
Styrene-Aerylonitrite
Center Consoles
Glove Box Doors
Interior Trim Panels
Polycarbonate +
Polybutylene
Terephthalate
Bumper Covers
Xenoy, Valox,
Macroblend
Poly amide
Headlamp bezels
Quarter panel exits
Exterior Finish
Trim Panels
Nylon, Capron, Zytel

Rilsan, Minion,
Vydyne, Wellamid
#1 and #4
Polybutylene
Terephthalate + Ether
Ester Block
Copolymer
Rocker Cover Mldgs.

Fascias
Bexloy "M"
#1 and #4
PC
Polycarbonate
Interior Hard (Rigid)

Trim Panels
Valance Panels
Lexan, Merion,
Calibre
PF
Phenol Formaldehyde
Ash Trays
Phenolic, Bakelite,
Durez, Genal,
Resinox, Amberol,
Plyophen
PC+ PETP
PA
PAG
PAGG
PBT + 1EEE
(PBTP + EEBC)
#8
#6 and #7
#1, #2, #4 and #5
#1, #4 and #6
#6
T5429
10-1-14
CHART OF PLASTIC PARTS IDENTIFICATION AND REFINISHING SYSTEMS (cont'd)

Identifying Symbol
Old Symbol in ( )
Chemical
Composition or
Plastic
"Family" Name
Examples of
Common and/or
Trade Names
Typical Area(s)
Where Part Used
Typical Paint
Repair System
FOR SYMBOLS NOT LISTED IN THIS CHART, CONTACT THE SOCIETY OF AUTOMOTIVE ENGINEERS,
'
400 COMMONWEALTH DRIVE, WARRENDALE, PA. 15096-0001 FOR A COPY OF SAE J1344.
( )
= OLD IDENTIFYING SYMBOLS IN ABOVE CHARTS.
= TYPICAL ISO MARKING SYMBOL FOUND ON PLASTIC PARTS.
I I=
SAE PVC
TYPICAL NEW SAE MARKING SYMBOL FOUND ON PLASTIC PARTS.
SUGGESTED PLASTIC PARTS PAINT REPAIR SYSTEMS

SYSTEM #1 (Exterior)
Conventional Lacquer/Enamel *Acrylic Urethane
*Flexible/Lacquer/Enamel/* Acrylic Urethane
Polypropylene Primer and *Special Topcoat
Base Color Coat with Acrylic Lacquer or *Acrylic Urethane Clear Coat
Base Color Coat with *Flexible Urethane Clear Coat
SYSTEM #6 (Interior)
Conventional (Standard) Interior Acrylic Lacquer
Polypropylene Primer and Standard Interior Topcoat
Vinyl Interior Color
*Contains Isocyanates - Use recommended respiratory protection.

T5429(Cont'd)
Figure 13 - Plastics Identification Chart (2 of 2)
HANDLING PRECAUTIONS FOR PLASTICS

Abbreviation
Material Name
Heat Resisting
Temperature
c (F
0
Resistance to
Gasoline and
Solvents
Other Cautions
PE
Polyethylene
80 (176)
Gasoline and most

solvents are harmless.
Flammable
PVC
Polyvinyl chloride
90 (194)
Gasoline and most

solvents are harmless
if applied for a very
short time (wipe up
quickly).
Poison gas is emitted

when burned.
pp
Polypropylene
90 (194)
Gasoline and most

Flammable
ABS
Acrylonitrile butadiene 90 (194)

styrene resin
Avoid gasoline and

solvents.
Avoid brake fluid.
AES
Acrylonitrile ethylene
styrene
90 (194)
Avoid gasoline and

solvents.
Avoid brake fluid.
PMMA
Polymethyl
methacrylate
90 (194)
Avoid gasoline and

solvents.
Avoid brake fluid.
PUR
Polyurethane
90 (194)
Avoid brake fluid.
AAS
Acrylonitrile acrylic
rubber styrene
95 (203)
Gasoline and most

Avoid gasoline and
solvents.
Avoid brake fluid.

T5430
10-1-15
HANDLING PRECAUTIONS FOR PLASTICS (cont'd)

Material Name
Abbreviation
Heat Resisting
Temperature
c (F
0
PPE
Polyphenylene, ether
110 (230)
POM
Polyacetal
120 (248)
PC
Polycarbonate
120 (24B)
PA, PAG, PAGG
Polyamide (Nylon)
150 (302)
FRP
Fiber reinforced
plastics
Polypropylene
composite
Polybutylene
terephthalate
Thermoplastic rubber
170 (338)
PPC
PBT
TPR
TPE
Thermoplastic
elastomer
115 (239)
140 (284)
80 (176)
80 (176)
Resistance to
Gasoline and
Solvents
Avoid gasoline and
solvents.
Gasoline and most
Avoid gasoline and
solvents.
Gasoline and most
Gasoline and most
Gasoline and most
Gasoline and most
Avoid gasoline and
solvents.
Avoid gasoline and
solvents.
Other Cautions
Avoid battery acid.
Avoid immersing in
water.
Flammable
1. When repairing and painting a portion of the body adjacent to plastic parts, consider their characteristics (influence
of heat and solvent) and remove them if necessary or take suitable mearsures to protect them.
2. Plastic parts should be repaired and painted using methods suiting the materials.
T5430(Cont'd)
Figure 14 - Plastics Handling Precautions
[[) Important
Save leftover pieces of repair material. They

can be used later for reinforcing the back of
small damaged areas and puncture repairs.
When using mat reinforcement to repair inner
or outer surfaces of a panel, be sure there are
no strands of the mat left uncovered or
unsaturated by repair material. If exposed, the
mat may act as a wick and draw moisture into
the repaired area, affecting the integrity and
finish.
Flexible Plastic Part Repair

1. Clean and inspect damaged area as required
(Figure 15).
2. Support and line up parts as necessary using tape
and a clamp for minor damage (Figure 16).
Fabricate a patch panel if necessary.
3. Abrade back side of damage by scuffing the area
with a 36 grit disc on a Roloc sander.
Important
Use only compressed air or a clean dry cloth

to remove residue.
4. If necessary, cut piece of reinforcement mat

(porous or uni-directional) to desired shape.
Extend mat 38 to 50 mm (1 1/2 to 2 inches)
beyond repair area (Figure 17).
5. Mix and apply thin coat of GM Goodwrench
Compoxy Repair Material (GM PIN 12345744) or
equivalent to back side of damaged area.
6. Lay pre-cut piece of reinforcement mat into thin
coat of repair material using applicator to press
mat so it becomes saturated. Make sure all
trapped air is forced out.
7. If mat is not screen type, use saturation roller to
ensure mat is completely saturated and there are
no exposed fibers or trapped air.
8. Apply second coat of flexible repair material,
making sure mat is completely saturated and there
are no exposed fibers or trapped air (Figure 18).
9. Allow to cure per manufacturer instructions.
10. Remove tape or clamps used for maintaining
alignment and contours.
11. At outer surface of panel, bevel damaged area
with a 50 grit Roloc disc. This step extends
contact between repair material and substrate
(Figure 19).
10-1-16

B
-~
012495
FS015101
Figure 15 Inspect Damaged Area
12. Using a 180 grit disc on a dual-action orbital

sander, feather out several inches beyond damaged
area to remove any paint or primer from substrate.
This provides proper surface for adhesion
(Figure 20).
13. Apply light coat of repair material to front side of
damaged area, taking care to apply it smoothly.
Repair material should be level and slightly above
surrounding contour.
14. Allow to cure per manufacturer recommendations.
15. Rough out surface with an 80 grit disc on a
dual-action orbital sander.
16. Finish contour sanding with 220 to 320 grit (wet
or dry) sandpaper on a sanding block (Figure 21).
For further detailed information, refer to the
STG Composite Plastic Repair Book
(PIN 22005.35-10).
A TAPE
B CLAMP
012495
FS018101
Figure 16 Aligning Damage with Tape and Clamp
Flexible Plastic Part Refinishing

Figures 12 and 13
To refinish repaired flexible parts, it is very
important to follow the paint manufacturer's system
regarding preparation, priming, and refinishing.
Because these parts are flexible, they may require
special additives in the primers and topcoat to prevent
cracking and poor adhesion. Always use
manufacturer's recommended materials and never mix
with other systems.
012495
FS017101
Figure 17 Cutting Fiberglass Cloth to Size
RIGID PLASTIC PART REPAIR AND

REFINISHING
CAUTION: Many paint repair systems
require additives containing isocyanates.
It is essential that all recommendations
and warnings listed on the container
label for materials selected be followed. It
is mandatory that adequate respiratory
protection such as air line respirators
with a full hood be worn. Such protection
should be worn during the entire painting
process. Persons with respiratory
problems or those allergic to isocyanates
must not be exposed to isocyanate
vapors or spray mist.
01249S
FS018101
Figure 18 Applying Repair Material
[I]
01-24-95
FS019101
Figure 19 - Panel Beveling
01-24-95
Figure 20 - Panel Feathering
Repair Materials
rn
Important
Use supplies and repair materials from the

same manufacturer for the best results. Do not
mix systems. These rigid plastic panel
assembly repair procedures require the use of
GM Goodwrench Structural Bonding Epoxy
(GM PIN 12345726) or equivalent.
Important
Use only compressed air or a clean dry cloth

to remove residue.
3. Apply skim coat of GM Goodwrench Structural
Bonding Epoxy (GM PIN 12345726) or
equivalent (Figure 23) to bonding strip.
4. Position bonding strip in place and secure with
clamp (Figure 24).
5. For best results, bonding epoxy should be force
dried.
A. After applying epoxy to panel, allow epoxy to
air dry at room temperature for twenty
minutes.
B. Apply heat with uniform heat source to force
dry at surface temperature of 70 to 82C
(160 to 180F) for 45 minutes. Use surface
temperature gage to obtain proper surface
temperature.
[1J
FS020101
10-1-17
Important
Exceeding 82C (180F) may cause damage to

interior components, weatherstrips or related
trim in the heated area.
C. Allow panel to return to room temperature
before sanding.
6. Remove tape or clamps used for maintaining
alignment and contours.
7. At outer surface of panel, bevel damaged area
with 50 grit disc on a Roloc sander or equivalent.
This step extends contact between bonding epoxy
and substrate (Figure 19).
8. Using a 180 grit disc on a dual-action orbital
sander, feather out several inches beyond damaged
area to remove any paint or primer from substrate.
This provides proper surface for bonding
(Figure 20).
9. Apply light coat of GM Goodwrench Structural
Bonding Epoxy (GM PIN 12345726) or
equivalent (Figure 23).
10. Smooth out bonding epoxy. Bonding epoxy should
be level and slightly above surrounding area
(Figure 25).
11. Lay pre-cut piece of reinforcement cloth into
bonding epoxy. Use applicator to saturate and
remove all trapped air.
Rigid Plastic Part Repair

Figures 15, 19, 20 and 22 through 25
1. Clean and inspect damaged area as required

(Figure 15).
2. Begin reinforcement repair to inner surface of
panel by scuffing back side of area with an 80
grit disc on a dual-action orbital sander or by
hand if access is limited. Do not heavily rough
out surface of panel.
01-24-95
FS021101
Figure 21 - Block Sanding for Accurate Contour
10-1-18
..
z~--~
01-24-95
FS022101
01-24-95
FS023101
Figure 22 - Reinforcement Mat
Figure 23 - Bonding Epoxy
12. Apply second coat of bonding epoxy, making sure

reinforcement mat is fully enclosed and no air is
trapped. Smooth surface with applicator.
13. Place second layer of reinforcement cloth over
second coat of bonding epoxy, working it smooth
and removing all trapped air.
14. Apply final coat of bonding epoxy, and place
sheet of wax paper over it. Use saturation roller to
ensure full penetration of bonding epoxy into mat.
15. For best results, bonding epoxy should be force
dried.
A. After applying epoxy to panel, allow epoxy to
air dry at room temperature for 20 minutes.
B. Apply heat with uniform heat source to force
dry at surface temperature of 70C to 82C
(160F to 180F) for 45 minutes. Use surface
temperature gage to obtain proper surface
temperature.
rn
A CLAMP
B BACKING PANEL
01-24-95
FS024101
Figure 24 - Secure Bonding Strip
Important
Exceeding 82C (180F) may cause damage to

interior components, weatherstrips or related
trim in the heated area.
C. Allow panel to return to room temperature
before sanding.
16. Rough out surface with an 80 grit disc on a
dual-action orbital sander.
17. Finish contour sanding with 220 to 320 grit (wet
or dry) sandpaper on a sanding block.
For further detailed information, refer to the
STG Composite Plastic Repair Book
(PIN 22005.35-10).
A ROUND CORNERS
B MATIING
C BONDING MATERIAL
O EXISTING PANEL
E BONDING STRIP
Figure 25 - Cross Section of Splice
01-24-95
FS025101
Rigid Plastic Part Refinishing

To refinish repaired rigid parts, it is very
important to follow the paint manufacturer's directions
regarding preparation, priming and refinishing. Some
TEO (EP, EPM, TPO) rigid parts require special
polypropylene primers for adhesion. Always use
manufacturer's recommended materials and never mix
with other systems.
CARPET INSERT REATTACHMENT

Carpet inserts attached to body sides, doors and
quarter trim panels which have become loose may be
reattached with general trim adhesive (3M PIN 08080
or equivalent).
Use the following procedure:
1. Remove trim panel when necessary and place
on clean work surface. Mask off trim panel to
prevent glue overspray.
10-1-19
2. Sand areas of trim panel where carpet is to be

re-glued using a coarse grit sandpaper.
Polypropylene panels should have a rough
surface for best adhesion. Remove all sanding
debris.
3. Spray general trim adhesive (3M PIN 08080 or
equivalent) on sanded surface and back side of
carpet following manufacturer instructions.
4. When both sprayed surfaces become tacky to
the touch, press carpet in place and smooth out
any irregularities.
5. Remove masking materials and reinstall panel.
BODY PANEL ADJUSTMENT AND

ALIGNMENT
Use Figures 26 through 29 as a maximum and
minimum gap reference.
CLEARANCE GAP*
(MILLIMETERS)
LOCATION
FLUSHNESS*
(MILLIMETERS)
4.0 ( 1.5}
B. HOOD TO
FRONT FENDER
4.0 ( 1.5} (PARALLEL WITHIN 1.5}
0,5
C. FRONT FENDER
TO FRONT FASCIA
0.0 (+ 0.5/- 0.0}
0,5
D. FRONT FENDER
TO FRONT FASCIA
0.0 (+0.5/- 0.0}
0,5
E. FRONT SIDE DOOR

TO FRONT
FENDER
5.0 ( 1.51 (PARALLEL WITHIN 1.5)
2.01 2.0)
F. FRONT FENDER
TO OUTER ROCKER PANEL
2.0 (+ 3.0/- 2.0}
+ 1.5/- 0.0
G. FRONT TURN SIGNAL LAMP

TO FRONT FASCIA
1.5 ( 0.5) (PARALLEL WITHIN 0.5)
N/A
H. HOOD AIR
EXTRACTOR TO HOOD
OUTER PANEL
1.0 ( 1.5)
0.51 0.5)
+ 1.0/ 0.5 (PARALLEL
A. HOOD TO
FRONT FASCIA
WITHIN 1.5}
OPENINGS MUST BE PARALLEL WITHIN 1.0
mm
UNLESS OTHERWISE NOTED.
0124-95
FS028101
Figure 26 - Body Panel Fit Requirements (1 of 2) - (Chevrolet)
CLEARANCE GAP*
(MIUIMETERS)
LOCATION
J. REAR HATCH TO
ROOF OUTER SAIL
K. REAR HATCH TO
QUARTER PANEL
L. REAR HATCH TO
ROOF
M.ROOFOUTERPANELTO
QUARTER OUTER PANEL
"

10-1-21
FLUSHNESS*
(MILLIMETERS)
+ 3.0 (OUTBOARD)
- 1.0 (INBOARD)
1.5
4.0 ( 1.5) {PARALLEL WITHIN 1.5)
+ 3.0 (OUTBOARD)
- 1.0 (INBOARD)
N/A
N. REAR COMPARTMENT LIFT

WINDOW OUTER PANEL TO
OUTER LENS
1.0.5 I 2.0) (PARALLEL WITHIN 3.0)
N/A
N. OUTER LENS TO REAR FASCIA
2.0 ( 2.0) {PARALLEL WITHIN 3.0)
1.0
0. ROCKER QUARTER OUTER
N/A
+ 0.0/- 1.0
P. ROCKER QUARTER OUTER

PANEL TO FUEL FILLER
DOOR
3.0 ! 1.0)
1.5/- 0.0
Q. REAR END FINISHING PANEL

TO OUTER LENS
2.0 I 2.0) {PARALLEL WITHIN 3.0)
1.0
R. QUARTER OUTER PANEL

TO REAR FASCIA
2.0
S. QUARTER OUTER PANEL TO

OUTER LENS
2.0 ! 1.5) {PARALLEL WITHIN 1.5)
2.0
T. REAR COMPARTMENT LID

OUTER PANEL TO REAR END
FINISHING PANEL
2,0
T. REAR END FINISHING

PANEL TO REAR BUMPER
FASCIA
7.0 I 2.0) (PARALLEL WITHIN 3.0)
N/A
U. FRONT DOOR OUTER PANEL

TO QUARTER OUTER PANEL
2.0 ( 2.0)
V. REAR FINISHING PANEL TO

REAR QUARTER PANEL
2.0 ( 1.0)
+ 1.0/- 3.0
PANEL TO ROCKER OUTER

PANEL
* OPENINGS MUST BE PARALLEL WITHIN 1.0 mm UNLESS OTHERWISE NOTED.

01-24-95
FS027101
Figure 27 - Body Panel Fit Requirements (2 of 2) - (Chevrolet)
LOCATION
CLEARANCE GAP
(MIWMETERSI
FLUSHNESS
(MILLIMETERS)
A. HOOD TO
FRONT FASCIA
4.0 ( 1.5)
+ 1.0/-0.5 (PARALLEL
WITHIN 1.5)
B. HOOD TO
FRONT FENDER
4.0 ( 1.5) (PARALLEL WITHIN 1.51
0,5
C. FRONT FENDER
TO FRONT FASCIA
0,5
D. FRONT FENDER
TO FRONT FASCIA
2.0 (0.5) (PARALLEL WITHIN 0.5)
0,5
E. FRONT SIDE DOOR

TO FRONT
FENDER
2.0 (2.0)
F. F.RONT SIDE DOOR

TO FRONT
FENDER
7.5 to 4.0
+ 0.0 (OUTBOARD)
-1.5 (INBOARD)
G. FRONT FENDER
TO OUTER ROCKER PANEL
2.0 (+ 3.0/-2.0)
+ 1.5/ 0.0
H. FRONT TURN SIGNAL LAMP

TO FRONT FASCIA
1.5 (0,5) (PARALLEL WITHIN 0.5)
NIA
J. HOOD TO
4.0 ( 1.5)
+ 0.5/- 1.0
4.0 ( 1.5)
0,5
L. FRONT FASCIA TO
HEADLAMP DOOR
4.0 ( 1.5)
+ 0.5/ 1.0
M.HOOD AIR
EXTRACTOR TO HOOD
OUTER PANEL
1.01 0.5)
0.5 (0.5)
HEADLAMP DOOR
I<. FRONT FENDER

TO HEADLAMP DOOR
OPENINGS MUST BE PARALLEL WITHIN 1.0 mm UNLESS OTHERWISE NOTED.

012495
FS028101
(
Figure 28 Body Panel Fit Requirements (1 of 2) (Pontiac)
CLEARANCE GAP*
(MILLIMETERS)
LOCATION
FLUSHNESS*
(MILLIMETERS)
N. REAR HATCH TO
ROOF OUTER SAIL
8.0 (.:1: 1.5) (PARALLEL WITHIN 2.01
+ 3.0 (OUTBOARD)
1.0 (INBOARD)
0. REAR HATCH TO
QUARTER PANEL
1.5
P. REAR HATCH TO
ROOF
8.0
0. ROOF OUTER PANEL TO

QUARTER OUTER PANEL
N/A
R. REAR COMPARTMENT LIFT

WINDOW OUTER PANEL TO
OUTER LENS
N/A
R. OUTER LENS TO REAR FASCIA
4.0 ( 2.0) (PARALLEL WITHIN 1.51
1.0
S. ROCKER QUARTER OUTER

PANEL TO ROCKER OUTER
PANEL
N/A
+ 0.0/ 1.0
T. ROCKER QUARTER OUTER

PANEL TO FUEL FILLER
DOOR
3.0 ! 1.0)
+ 1.5/ 0.0
V. QUARTER OUTER PANEL

TO REAR FASCIA
2.0
W. QUARTER OUTER PANEL

TO OUTER LENS
2,0
X. SPOILER TO TAIL LAMP
5.0 1 2.0) (PARALLEL WITHIN 3.0)
N/A
X, CENTER FILLER PANEL

TO REAR BUMPER FASCIA
4.0 (.:1: 2.0) (PARALLEL WITHIN 3.01
1.0
Y. FRONT DOOR OUTER PANEL

TO QUARTER OUTER PANEL
5.0 (.:1: 1.5) (PARALLEL WITHIN 1.5)
2.0 (.:1: 2.0)
Z. REAR FASCIA TO REAR

QUARTER PANEL
N/A
N/A
! 1.5) (PARALLEL WITHIN 1.5)
10-1-23
+ 3.0 (OUTBOARD)
1.0 {INBOARD)
OPENINGS MUST BE PARALLEL WITHIN 1.0 mm UNLESS OTHERWISE NOTED.
Figure 29 - Body Panel Fit Requirements (2 of 2) - (Pontiac)
012495
FS029101
BLANK
STATIONARY WINDOWS
10-2-1
SECTION 10-2
IN DOWS
STATIONARY
CAUTIONS in .SECTION 9J under "ONNEHICLE SERVICE" and the SIR Compom:mt and Wiring
Location view in SECTION 9J before performing service on or around SIR components. or wiring.
Failure .to follow CAUTIONS could result in possible air bag deployment, personal injury, or
CAUTION: When replacing stationary windows, urethane kit GM P/N 12346284 or equivalent must
be used to maintain original installation integrity. Failure to use the urethane kit will result in
poor retention of the windshield which may allow unrestrained occupants to be ejected from the
vehicle resulting in personal injury.
NOTICE: Always use the correct fastener in the correct locat.ion. When you replace a fastener, use ONLY the
after removal, General Motors will also call out the fasteners that require thread lockers or thread sealant.
systems.
CONTENTS
General Description ........................... ;.................. 10-2-1
Stationary Windows .......................................... 10-2-1
Adhesive Caulking Kit ..................................... J 0-2-1
Windshield Reveal Molding ............. ;.............. 10-2-1
Windshield Reveal Molding ............................ 10-2-1
Windshield ........................................................ 10-2-2
Short Method ................................................ 10-2-2
Extended Method ......................................... 10-2-4
GENERAL DESCRIPTION
Waterleak Correction ...................................... 10~2-5

Inside Rearview Mirror ................................. 10-2-6
Inside Rearview Mirror Support ............... 10-2-6
Rear Window Defogger ................................. 10-2-7
Testing Grid Lines ..................................... 10-2-7
Grid Line Repair ........................................ 10-2-8
Braided Lead Wire Repair......................... 10-2-9
Special Tools ...................................................... 10-2-10
WINDSHIELD REVEAL MOLDING

Figure 1
STATIONARY WINDOWS
Figure 1
The windshield (1) is installed from outside the
body, using self-curing urethane. Replacement of the
windshield (1) requires removal of ~omponents and
cutting it away from the adhesive.
The one-piece windshield reveal molding (2) is

vinyl and is hand-pressed into place. The reveal
molding (2) is retained. in place by the urethane
adhesive.
ON-VEHICLE SERVICE
ADHESIVE CAULKING KIT
WINDSHIELD REVEAL MOLDING
The urethane adhesive kit (GM PIN 12346284)

is used for windshield adhes1ve service operations and
leak repair. This kit includes urethane adhesive and
primers. Failure to use this kit, or an equivalent, when
indicated, will result in poor retention of the
windshield.
Figure 1
1~-..1
1. Roof drip scalp moldings, if equipped. Refer to

SECTION.10-9.
10-2-2
STATIONARY WINDOWS
2. Carefully pry end of reveal molding (2) out about

76 mm (3 inches), using screwdriver.
3. Grasp with pliers and slowly pull reveal molding
(2) away from body.
!L!
Inspect
Reveal molding (2).

- If original reveal molding (2) cannot be reused
(due to damage, cut short, etc.), discard .it and
replace it with a new. ,reveal molding (2). Be
sure to pre-fit the new reveal molding (2) by
locating. it .on the body prior to installation.
Clean
Windshield ( 1) of all traces of urethane, using

alcohol-dampened cloth.
!++!
WINDSHIELD
All windshields are installed from outside the
vehi~le b~ing .self-curing. urethane adhesive. Replacing
a. wmdshi~ld installed with urethane adhesive requires
either partial or complete replacement of the adhesive.
Partial replacement of the adhesive is known as the
"Short Method." Complete replacement of the
adhesive is known as the "Extended Method."
Windshield removal is the same for both the
short and extended installation methods with one
exception. Use more care with the short method
during cutout to make certain that an even

bead of. adhesive remains on the windshield
opening to serve as a base for the new
windshield.
Short Method
Figures 1 and 2
Install or Connect
1. Clear primer #1 from urethane adhesive kit (GM

PIN 12346284 or equivalent) in glass edge
channel of reveal molding (2).
2. Black primer #2 from urethane adhesive kit (GM
PIN 12346284 or equivalent) over clear primer.
3. Urethane adhesive from kit (GM PIN 12346284 or
equivalent) evenly in glass edge channel of reveal
molding (2) over black primer.
4. Reveal molding (2).
A. Start from center and hand press reveal

molding (2) in place over edge of windshield
(1).
B. Tape can be applied to keep reveal molding
(2) flush with body.
C. Flood reveal molding (2) with warm water to
speed setup of adhesive.
5.. Roof drip scalp moldings, if equipped. Refer to
SECTION 10-9.
Tool Required:
J 24402-A Window Sealant Remover
(Cold Knife) or
J 24709-01 or J 24899-01 Urethane Window
Sealant Remover (Hot Knife) or
J 39032 Stationary Glass Removal Tool
CAUTION: When working with any type of

glass, use approved safety glasses and
f;il!)ves to reduce the chance of personal
mJury.
!++I
1. Place masking tape around area where windshield

(1) is being removed.
2. Inside rearview mirror. Refer to "Inside Rearview
Mirror" in this section.
) - ~~=-=-----?
/7
A APPLY CLEAR AND BLACK PRIMER, THEN URETHANE ADHESIVE

TO REVEAL MOLDING GLASS EDGE CHANNEL BEFORE
1 WINDSHIELD
2 MOLDING, WINDSHIELD REVEAL
3 STRIP, WINDSHIELD SEALING
4 SUPPORT, INSIDE REARVIEW MIRROR
5 MIRROR, INSIDE REARVIEW
6 ROOF
I SECTION A-A I
(
01-18-96
FS001102
Figure 1 - Windshield and Reveal Molding
STATIONARY WINDOWS
3. Windshield side garnish moldings. Refer to

SECTION 10-9.
4. Wiper arm and wiper blades. Refer to
SECTION 8E.
5. Top rear front fender bolts/screws to provide
clearance for tools (Chevrolet only). Refer to
SECTION 10-5.
6. Air inlet screens. Refer to SECTION 10-5.
SECTION 10-9. ,
8. Wind.shield reveal molding. Refer to "Windshield
Reveal Molding" in this section.
9. Mask area around windshield opening to protect
painted surfaces and to aid in cleanup after
installation.
Tape must not , touch windshield sealant
surface.
10. Using J 39032, make preliminary cut into
urethane adhesive around entire perimeter of
windshield (1), staying as close to edge of
windshield (1) as possible.
11. Pull away portion of reveal molding (2) between
windshield ( 1) and body.
12. Cut out windshield (1), using J 24402-A,
J 24709-01 or J 24899-01, or J.39032.
Keep blade as close to edge of windshield (1)
as possible.
Use care during cutout to make certain that
even bead of adhesive remains on windshield
opening to serve as base for new
windshield (1).
13. Windshield (1).
14. Windshield sealing strip (3) from windshield (1).
111 Clean
Windshield opening of any loose material. If old
windshield (1) is to be reinstalled, all old urethane
adhesive must be removed from it, using a
!-++I
Install .or Connect
1. Windshield reveal molding. Refer to ''Windshield

2. Windshield ( 1) in opening for fit.
A. With aid of helper, properly position
windshield (1) in opening and apply piece of
masking tape over each edge of windshield (1)
and adjacent body pillars.
B. Slit tape vertically at edge of windshield (1).
C. During installation, tape on windshield (1) can
be aligned with tape on body to guide
windshield (1) into desired position.
3. Remove windshield (1).
Clean
A. Surface of windshield (1) to which adhesive

will be applied (around edge of inside surface)
by wiping with clean, alcohol-dampened cloth.
B. Allow to air dry.
102-3
ISECTION A-A I
8-9.5mm
j_
B
. (0.31-0.37")
14-15.Smm
~ !
(0.55-0.61"1..!.it=~
6~~s~o~~-) I SECTION e-ej
<
A WINDSHIELD ADHESIVE PRIMER LOCATION

(CLEAR AND BLACK)
B URETHANE ADHESIVE MATERIAL
1 WINDSHIELD
2 MOLDING, WINDSHIELD REVEAL
4 SUPPORT, INSIDE REARVIEW MIRROR
01-18-H
FS002102
Figure 2 - Windshield Primer and Adhesive Locations
4. Windshield sealing strip (3).

Remove paper backing from new windshield
sealing strip (3) and position adjacent to lower
blackout line.
5. Primers from urethane adhesive kit (GM
PIN 12346284 .or equivalent) to entire perimeter
of windshield inner surface as shown in Figure 2.
A. Apply pinchweld primer #3 to any exposed
paint surfaces on windshield flange.
B. Apply clear #1, immediately followed by black
primer #2 to windshield (1).
C. Allow black primer #2 to dry five minutes
prior to application of urethane adhesive.
Application of primers is important because
primers cause urethane adhesive to bond to
window (1) and windshield flange.
[I)
Important
Maximum surface temperature must not

exceed 49C (120F) at time of primer
application.
1024 STATIONARY WINDOWS

6.. Urethane adhesive from kit (GMP/N 12346284or
equivalent).
With household cartridge-type caulking gun
and nozzle, apply smooth continuous bead of
urethane adhesive, 7.0 to 8.5 mm (0.28 to 0.33
inch) wide and 14.0 to 15.5 mm (0.55 to 0.61
inch) high, around edge of windshield where
primed in previous step .
. 7. Windshield (1) into windshield opening with aid
of helper.
Carry ~indshield (1) with one hand on inside
and one hand on outside. Guide windshield (1)
along rear edge of front fender to avoid
smearing fresh adhesive on instrument panel.
At windshield opening, put windshield (1) in
horizontal position. While one person holds
windshield (1) in this position, second person
can reach one
around body pillar and
support
it
while
first
person assumes same
I

pos1t10n.
8. Windshield (1).
arm

SECTION 8E.
SECTION 10-9.
17. Inside rearview mirror. Refer to ''Inside Rearview
11]
Extended Method
Figures 1 and 2
The extended method requires that all old

urethane adhesive be completely removed from
windshield opening. This method. is used only for
extreme cases such as:.
When the old urethane adhesive cart no longer

serve as a good base.
When there is damage to the windshield
opening.
When there is a need for the windshield
opening to be repainted in a body shop.
If necessary, paddle additional material .to fill
voids.in seal.
11. Water test vehicle at once, using soft spray.

~
Use warm water. .

.
Do not direct hard stream of water at fresh
. adhesive material.
Water applied on, top of urethane adhesive,
either during water test or as separate
operation, will speed up cure of urethane
adhesive.
11]
Important
For leaks. Paddle in extra adhesive at leak

point, using small disposable brush or flat, soft
fiberglass tool.
SECTION 10-9.
14; Top rear front fender bolts/screws (Chevrolet
only). Refer to SECTION 10-5.
Clean
Windshield opening.
-
Using sharp scraper or chisel, remove old

adhesive material from windshield opening
mounting surfaces.
- All traces of material need not be removed,
but there should not be any mounds or loose
pieces left.
NOTICE: Until the new urethane has cured,

air pressure from a. closing door. may cause the
windshield to move. To prevent this, lower a
window several inches before closing the door.
10. Using small disposable brush or flat, soft

fiberglass tool, paddle material around edge of
windshield (1) to ensure watertight seal.
Important
On windshield installations, the vehicle must

remain at normal room temperature .for six
hours or the adhesive wm not cure properly.
Center in opening.
Use tape guides previously applied to place
. windshield (1) in proper position.
9. Press windshield (1) firmly to wet-out and set
adhesive.
Use care to avoid squeezing out excessive
amounts of adhesive that would cause
appearance problem.
!++I
Install or Connect

gloves to reduce the chance of personal
injury.
1. Windshield reveal molding. Refer to "Windshield

2. Windshield (1) in opening for fit.
A. With aid of helper, properly position
windshield ( 1) in opening.
B. Check relationship of new windshield (1) to
urethane adhesive of windshield opening
mounting surfaces. Excessive gaps must be
corrected by locating spacers or by applying
more adhesive than specified.
C. Apply piece of masking tape over each edge
of windshield (1) and adjacent body pillars.
D. Slit tape vertically .at edge of windshield (1).
E. During installation, tape on windshield (1) can
be aligned with tape on body to guide
windshield (1) into desired position.
STATIONARY WINDOWS
3. Remove windshield (1).
Clean
A. Surface of windshield (1) to which adhesive

will be applied (around edge of inside surface)
by wiping with clean, alcohol-dampened cloth.
B. Allow to air dry.
4. Windshield sealing strip (3).
Remove paper backing from new windshield
sealing strip (3) and position adjacent to lower
blackout line.
5. Primers from urethane adhesive kit (GM
PIN 12346284 or equivalent) to entire perimeter
of windshield inner surface as shown in Figure 2.
A. Apply pinchweld primer #3 to any exposed
paint surfaces on the windshield flange.
B. Apply clear primer #1; immediately followed
by black primer #2 to windshield.
C. Allow black primer to dry five minutes prior
to application of urethane adhesive.
window (1) and window flange.
[I]
Important
Maximum surface temperature must not

exceed 49c (120F) at time of primer
application.
6. Urethane adhesive from adhesive kit (GM
PIN 12346284 or equivalent).
and nozzle, apply smooth continuous bead of
urethane adhesive, 7.0 to 8.5 mm (0.28 to
0.33 inch) wide and 14.0 to 15.5 mm (0.55 to
0.61 inch) high, around edge of windshield (1)
where primed in previous step.
7. Windshield (1) into windshield opening with aid
of helper.
Carry windshield (1) with one hand on inside
and one hand on outside. Guide windshield (1)
along rear edge of front fender to avoid
smearing fresh adhesive on instrument panel.
At windshield opening, put windshield (1) in
horizontal position. While one person holds
windshield (1) in this position, second person
can reach one arm around body pillar and
support it while first person assumes same
position.
8. Windshield (1 ).
Center in opening.
Use tape guides previously applied to place
windshield (1) in proper position.
9. Press windshield (1) firmly to wet-out and set
adhesive.
Use care to avoid squeezing out excessive
amounts of urethane adhesive that would cause
appearance problem.
NOTICE: Until the new urethane has cured,
air pressure from a closing door may cause the
windshield to move. To prevent this, lower a
window several inches before closing the door.
1025
10. Using small disposable brush or flat, soft

fiberglass tool, paddle material around edge of
windshield ( 1) to ensure watertight seal.
If necessary, paddle additional material to fill
voids in seal.
11. Water test vehicle at once, using soft spray.
Use warm water.
Do not direct hard stream of water at fresh
adhesive material.
Water applied on top of urethane adhesive,
either during water test or as separate
operation, will speed up cure of urethane
adhesive.
!L'I'!
Inspect
For leaks. Paddle in extra adhesive at leak

point, using small disposable brush or flat, soft
fiberglass tool.
SECTION 10-9.
14. Top rear front fender bolts/screws (Chevrolet
only). Refer to SECTION 10-5.
SECTION 8E.
SECTION 10-9.
17. Inside rearview mirror. Refer to "Inside Rearview
rn
Important
On windshield installations, the vehicle must

remain at normal room temperature for six
hours or the adhesive will not cure properly.
WATERLEAK CORRECTION
Where accessible, waterleaks can be corrected
without removing and reinstalling the windshield. This
method applies only to urethane-installed windshields
and use of windshield urethane adhesive furnished in
urethane adhesive kit (GM PIN 12346284 or
equivalent).
1. Remove reveal molding in area of leak.
In some cases, it may become necessary to
remove interior moldings to locate source of
leak.
2. Mark location of leak.
A. Carefully push outward on windshield in area
of leak to determine extent of leak.
Operation should be performed while water
is being applied to leak area.
B. Mark extent of leak area.
3. Using sharp knife, trim off uneven edge of
adhesive at leak point and 76 mm to 102 mm
(3 inches to 4 inches) on both sides of leak point
or beyond limits of leak area.
4. Clean dirt or foreign material from leak area with
water (outside body). Dry area with air hose.
5. Prime affected area with black primer #2 supplied
in adhesive kit (GM PIN 12346284 or equivalent).
Allow primer to dry five minutes.
1026 STATIONARY WINDOWS

6. Apply urethane adhesive from urethane adhesive
kit (GM PIN 12346284 or equivalent) at leak
point and 76 mm to 102 mm (3 inches to
4 inches) on both sides of leak point or beyond
limits of leak area.
7. Right after performing previous step, use flat stick
or other suitable flat, soft fiberglass tool to work
adhesive material well. into leak point and into
joint of original material and body. This will
ensure watertight seal along entire length of
material application.
8. Using warm water, spray test to ensure leak has
been corrected.
Do not run heavy stream of water directly on
freshly applied urethane adhesive.
9. If leak stiU exists, use flat, soft fiberglass tool and
paddle additional adhesive material into leak
point.
10. Replace all previously removed parts.
10
1
4
5
8
WINDSHIELD
SUPPORT, INSIDE REARVIEW MIRROR
MIRROR, INSIDE REARVIEW
CONNECTOR, INSIDE REARVIEW MIRROR
COURTESY LAMP ELECTRICAL
10 LENS. COURTESY LAMP
01-189&
INSIDE REARVIEW MIRROR
FS003102
Figure 3
Figure 3 - Inside Rearview Mirror
The inside rearview mirror is fastened to an

inside rearview mirror support that is secured to the
windshield.
The rearview mirror offered on these vehicles
are a "breakaway" type. Breakaway rearview mirrors
are designed to detach from the windshield in the
event of an inflatable restraint deployment. The
mirrors attach to the support on the windshield, but
break away in different manners. Be sure to follow the
appropriate procedure when servicing the rearview
mirror..
!++!
Inside Rearview Mirror Support
Figure 4
The inside rearview mirror is attached to an
inside rearview mirror support (4) that is secured to
the windshield (1). The rearview mirror support (4) is
installed by the window supplier, using a
plastic-polyvinyl butyral adhesive.
Service replacement windshields have the
rearview mirror support (4) bonded to the windshield
(1). To install a detached rearview mirror support (4)
or install a new part, the following items are needed:
GM PIN 1052369, Loctite 312 Adhesive kit,
two-component pack or equivalent.
Mirror support (4).
Wax marking pencil or crayon.
Window cleaning solution or window polishing
compound.
Rubbing alcohol.
Clean paper towels.
Fine grit emery cloth or sandpaper, number
320 or number 360.
Clean toothpick.

2. Rearview mirror (5) from rearview mirror
support (4).
A. Use one hand to support one end of rearview

mirror (5) against windshield (1).
B. Use other hand to pull rearview mirror (5)
away from mirror support ( 4).
I++!
Install or Connect
NOTICE:
Refer to "Notice'' on page 10-2-1.
1. Rearview mirror (5) to rearview mirror

support (4).
A. Center bottom of rearview mirror (5) to top of

mirror support (4).
B. Slide rearview mirror (5) onto mirror support
(4), keeping rearview mirror (5) parallel to
windshield (1).
C. Apply at least 90 N (20 pounds) of force to
fully seat rearview mirror (5) onto mirror
support (4). Audible click will be heard when
rearview mirror (5) is fully seated.
!~!
Measure
Distance from bottom of windshield ( 1) to

determine location of rearview mirror support (4).
A. Rearview mirror support (4) should be located
at center of windshield (1), 689 mm
(27 1/8 inches) from base of windshield (1) to
base of rearview mirror support (4).
B. Mark location on outside of windshield (1)
with wax pencil or crayon.
C. Make larger diameter circle around marked
location on outside windshield surface.
STATIONARY WINDOWS
Ill
Cl,ean
1. Area of large circle on inside windshield surface

with paper towel and window cleaning solution or
window polishing compound.
A. Rub area until completely clean and dry.
B. When dry, clean area with alcohol-saturated
paper towel to remove any traces of cleaning
solution or polishing compound.
1. Sand bonding surface of new or detached
original rearview mirror support (4) with
piece of fine grit emery cloth or sandpaper,
number 320 or number 360.
If original rearview mirror support (4) is to be
reused, all traces of old adhesive must be
removed prior to installation.
2. Wipe sanded rearview mirror support (4)
with clean paper towel saturated with
alcohol and allow to dry.
!++!
Install or Connect
Rearview mirror support (4) to windshield (1).
1027
A. Follow directions on adhesive kit (GM

PIN 1052369 or equivalent) to prepare
rearview mirror support (4) prior to installation
on windshield (1).
B. Lightly apply adhesive accelerator to bonding
surfaces of rearview mirror support (4) and
windshield (1) and allow to dry completely.
[I]
Important
Due to rapid bonding of adhesive, the

following steps must be performed without
hesitation.
C. Apply two drops of adhesive to rearview
mirror support (4).
D. Use toothpick to evenly distribute adhesive
over entire bonding surface of rearview mirror
support (4).
E. Properly position rearview mirror support (4)
to pre-marked location with rounded end
pointed upward.
F. Press rearview mirror support ( 4) against
windshield (1) for 30 to 60 seconds, exerting
steady pressure against windshield (1 ).
G. After five minutes, remove excess adhesive
with alcohol-moistened paper towel or window
cleaning solution.
REAR WINDOW DEFOGGER
I\
A
B
C
D
E
1
4
LOCATING CIRCLE
CLEANING AREA CIRCLE
BASE OF SUPPORT LINE
OUTSIDE GLASS
CENTERLINE
WINDSHIELD
SUPPORT, INSIDE REARVIEW MIRROR
The optional rear window defogger system

consists of tinted windows with a number of
horizontal ceramic silver compound element lines and
two vertical bus bars baked into the inside surface
during the glass forming operation. The feed wire or
terminal is soldered to the feed bus bar on the left
side. The ground wire or terminal is soldered to the
ground bus bar on the right side.
The system operates on 12 volts. Under some
conditions, heat from the window may not be detected
by finger touch. The length of time required to remove
interior fog from the rear window will vary with such
conditions as vehicle speed, outside window
temperature, atmospheric pressure and number of
passengers.
The system uses an instrument panel mounted
switch with an integral indicator lamp and will operate
for five or ten minutes, automatically turning off
through the use of a timer. The system can be turned
off during this operation period by turning either the
instrument panel mounted switch or ignition switch to
"OFF".
Testing Grid Lines
Figures 5 and 6
01-24-115
FS004102
Figure 4 - Inside Rearview Mirror Support Placement
To locate inoperative grid lines, start the engine

and turn on the rear window defogger system. Ground
one test lamp lead and lightly touch other probe to
each grid line. Figure 5 illustrates pattern of test lamp
brilliance to be expected with a properly functioning
grid.
10-2-8
STATIONARY WINDOWS
Grid Line Repair

Figures 7 and 8
l++I
_ _ _,.,_'
NO BULB BRILLIANCE
''',i&
,(
ONE-QUARTER BULB BRILLIANCE

C
ONE-HALF BULB BRILLIANCE
THREE-QUARTER BULB BRILLIANCE
FULL BULB BRILLIANCE
01-24-95
FS005102
Figure 5 - Normal Test Lamp Bulb Brilliance Zones
If test lamp bulb shows full brilliance at both

ends of grid lines, check for loose ground wire contact
to body metal.
Range of zones of bulb brilliance may vary
slightly from one window to another. Bulb brilliance
will decrease proportionately to increased resistance in
grid line as probe is moved from feed bus bar to
ground bus bar.
All grid lines must be tested in at least two
places to eliminate the possibility of bridging a break.
For best results, contact each grid line a few
centimeters (inches) either side of window centerline.
If an abnormal lamp reading is apparent on a specific
grid line, place test lamp probe on that grid at the feed
bus bar and move probe toward ground bus bar until
lamp goes out. This will indicate a break in continuity
of grid line (Figure 6).
If no break in continuity is found and braided
lead wire repairs are not needed but system is still
inoperative, refer to SECTION 8A for electrical
diagnosis.

CAUTION: To Avoid Personal Injury
Do not allow the repair material to
come in contact with skin or eyes
and avoid breathing vapor.
Do not use near sparks or open
flame.
1. Battery negative cable. Refer to SECTION 601.
!L"'!
Inspect
Rear window defogger grid lines.
A REPAIR MATERIAL
B TWO STRIPS OF TAPE
C WOOD SPATULA
01-24-95
FS007102
Figure 7 - Applying Repair Material to Broken Grid Line
A
B
C
D
NO BULB BRILLIANCE
BROKEN GRID LINE
FULL BULB BRILLIANCE
INSIDE OF GLASS
E FEED BUS BAR
F GROUND BUS BAR
A REPAIR AREA
8 HEAT GUN
01-24-95
FS006102
Figure 6 - Test Lamp Bulb Brilliance with Broken Grid

Lines
C 25 mm ( 1") BETWEEN REPAIR

AREA AND HEAT GUN NOZZLE
01-24-05
FS008102
Figure 8 - Applying Heat to Grid Line Repair
STATIONARY WINDOWS
2. Mark grid line breaks on outside of window with
grease pencil.
Clean
Grid line area to be repaired.

3. Buff with fine steel wool and wipe clean, using
4. Buff and clean about 6 mm (1/4 inch) beyond
each side of break in grid line.
!H!
Install or Connect

injury.
1. Grid line repair decal or two strips of tape
positioned above and below repair area.
Repair decal or tape must be used to control
width of repair area.
If decal is used, be sure die-cut metering slot
is same width as grid line.
2. Mix grid repair material according to
manufacturer instructions.
3. Grid repair material, at room temperature, to
repair area, using small wood stick or spatula.
4. Carefully remove decal or tape.
NOTICE: The grid line repair material must

be cured with heat. To avoid heat damage to
interior trim, protect trim near repair area where
heat is to be applied.
5. Apply heat to repair area for one to two minutes
with heat gun capable of reaching 260C (500F).
Hold heat gun nozzle 25 mm (1 inch) from
surface.
Minimum temperature of 149C (300F) is
required.
!l"'!
10-2-9
Braided Lead Wire Repair

Figures 8 and 9
injury.
The rear defogger bus bar lead wire or terminal
can be reattached by resoldering, using a solder
containing 3 percent silver and a rosin flux paste.
!++!

Battery negative cable. Refer to SECTION 6Dl.
Clean
Buff repair area with fine steel wool to remove

oxide coating formed during window
manufacturing.
11]
Important
To prevent burning bus bar, soldering iron tip

temperature should be just enough to melt
solder and allow it to run freely. Iron should
be in contact with bus bar as short a time as
possible.
!++!
Install or Connect
1. Paste-type rosin flux in small quantities to wire

lead and bus bar repair, using brush.
Soldering iron tip should be coated with solder
beforehand.
2. Solder to feed bus bar or ground bus bar.
Draw soldering iron tip across fluxed area,
thinly coating bus bar with solder.
Inspect
Grid line repair area.

A. If repair appears discolored, apply coating
of tincture of iodine to repair area, using
pipe cleaner or fine brush.
B. Allow iodine to dry for about 30 seconds
and carefully wipe off excess with lint-free
cloth.
7. Test rear window defogger operation to verify
grid line repair. Refer to "Testing Grid Lines" in
this section.
NOTICE: At least 24 hours are required for

complete curing of repair materials. The repair
area should not be physically disturbed until
after that time.
A SOLDERING IRON
B FLUX
C FEED BUS BAR
Figure 9 - Bus Bar Repair
01-24-95
FS009102
10-2-10
STATIONARY WINDOWS
3. Small amount of flux to underside of lead wire

braid.
Align spots with fluxed and tinned spots on
feed bus bar or ground bus bar.
4. Coat tip of soldering iron with solder.
5. Solder to underside of lead wire braid.
Draw iron across fluxed spot, thinly coating
spot with solder.
6. Solder spot on braid against spot on feed bus bar

or ground bus bar.
A. Apply heat to top of lead wire braid, causing
solder spots to melt and fuse together.
B. Holding force should not be removed until
solder has solidified.
7. Wipe off excess flux with solvent.
SPECIAL TOOLS
1.
2.
J24402-A
J 24709-01
OR
J 24899-01
1. URETHANE GLASS SEALANT REMOVER (HOT KNIFE)
2. GLASS SEALANT REMOVER (COLD KNIFE)
3. STATIONARY GLASS REMOVAL TOOL
01-24-96
FS010102
BODY DIMENSIONS AND UNDERBODY
10-3-1
SECTION 10-3

Failure to follow CAUTIONS could result in possible air bag deployment, injury, or otherwise
CAUTION: To help avoid personal injury when a vehicle is on a hoist, provide additional support
for the vehicle at the opposite end from which components are being removed. This will reduce
the possibility of the vehicle falling off the hoist.
NOTICE: The theft deterrent label found on some major sheet metal, must be masked prior to pamtmg,
label clean and readable may result in liability for violation of Federal Vehicle Theft Prevention Standard and
subject the vehicle owner to possible suspicion that the part was stolen.
systems.
CONTENTS
General Description .............................................. 10-3-l
General Body Construction .............................. 10-3-1
Alignment Checking ......................................... 10-3-2
Frame and Underbody .............. ,.................. 10-3-2
Underbody Dimensions ..... Refer to SECTION 11
Frame Dimensions ............. Refer to SECTION 11
Underhood Dimensions ..... Refer to SECTION 11
Upper Body Dimensions ... Refer to SECTION 11
Body Side Dimensions ...... Refer to SECTION 11
Cradle-to-Body Fastener Repair ...................... 10-3-2
Floor Panel Reinforcement .............................. 10-3-2

Front Crossmember .......................................... 10-3-2
Front Crossmember Braces .............................. 10-3-3
Underbody Flush .............................................. 10-3-3
Steering Unit Rack and Pinion Support
Mount Plates .................................................... 10-3-4
Steering Unit Mounting ................................... 10-3-4
Floor Pan Insulator .......... Refer to SECTION 10-10
Front Side Door Sill Trim Plate ..................... 10-3-4
Specifications ................. ,...................................... 10-3-4
Fastener Tightening Specifications .................. 10-3-4
GENERAL DESCRIPTION
The suspension strut towers must be dimensionally

correct in relation to the remainder of the underbody
in order to maintain specified suspension strut and
caster/camber angles.
Since the individual underbody components
contribute directly to the overall strength of the body,
proper welding techniques must be observed during
service repair operations. The underbody components
should be properly sealed and rustproofed whenever
body repair operations destroy or damage the original
sealing and rustproofing. When rustproofing critical
underbody components, use a good quality air dry
primer such as corrosion-resistant chromate or
equivalent material. Combination type primer-surfaces
are not recommended.
GENERAL BODY CONSTRUCTION

Information in this section pertains to unitized
body construction which incorporates integral front
and rear frame side rails.
The front suspension lower control arms are
supported by the front crossmember. The front
crossmember is bolted to the body at six locations three on each side of the engine front compartment
lower rails. Mounting provisions for the front
suspension system are shared by chassis components
(suspension lower control arms and crossmember) and
body components (engine compartment side panels).
10-3-2
ON-VEHICLE SERVICE
ALIGNMENT CHECKING
Frame and Underbody
Use a tram gage to accurately measure
underbody alignment. Make sure the tram gage has a
vertical pointer that can reach 914 mm (36 inches).
Two types of measurements can be made with a
tram gage: direct point-to-point measurements and
measurements calculated on a horizontal plane, or
datum line, parallel to the underbody. To calculate
measurements on a horizontal plane, the vertical
pointers must be set as specified for each point to be
measured.
Point-to-point measurements are generally taken
only on engine compartment components and simply
require the vertical pointers to be equally set.
Dimensions-to-gage holes are measured to dead center
of the holes and flush to the adjacent surface metal
unless otherwise specified.
CRADLE-TO-BODY FASTENER REPAIR

1. Drill out center of drive train and front suspension
nut in rear mount.
2. Insert drive train and front suspension nut.
3. Insert front crossmember bolt/screw through drive
train and front suspension nut.
l~!
Tighten
Front crossmember bolt/screw to 125 N.m

(92 lb. ft.).
FLOOR PANEL REINFORCEMENT
j++!
Figure 1
!++!

SECTION OA.
3. Front tires and wheels. Refer to SECTION 3E.
4. Stabilizer shaft links. Refer to SECTION 3C.
5. Front shock absorber bolt/screws. Refer to
SECTION 3C.
6. Separate lower control arm ball studs from
steering knuckles. Refer to SECTION 3C.
7. Front lower control arm bolts/screws and nuts.
.
8. Lower control arms from crossmember. Refer to
SECTION 3C.
9. Steering gear bolts/screws from crossmember.
Refer to SECTION 3B
10. Engine mount nuts and bolts/screws. Refer to
SECTION 6A3A or SECTION 6A8A.
11. Front brake pipes. Refer to SECTION 5.
12. Wheel speed sensor electrical connector. Refer to
SECTION 5El.
13. Drivetrain and front suspension frame nut plug.
14. Nuts (34).
16. Crossmember (20) and reposition power steering
gear.
lHI
Install or Connect
NOTICE:
Refer to "Notice" on page 10-3-1.

SECTION OA.
2. Bolts/screws attaching floor panel reinforcement
to underbody.
3. Floor panel reinforcement from vehicle.
!H!
FRONT CROSSMEMBER
1. Position crossmember (20) to side rails.

2. Crossmember to power steering gear. Refer to
SECTION 3B.
l~l
Install or Connect
NOTICE:
1. Floor panel reinforcement to vehicle.

2. Bolts/screws attaching floor panel reinforcement
to underbody.
!~!
4.
5.
6.
7.
8.
9.
Tighten
Bolts/screws to 27 N.m (20 lb. ft.).

3. Lower vehicle.
10.
11.
Tighten

Nuts (34).
Drivetrain and front suspension frame nut plug.
Wheel speed sensor electrical connector. Refer to
SECTION 5El.
Front brake pipes. Refer to SECTION 5.
Engine mount bolts/screws and nuts. Refer to
Power steering gear bolts/screws. Refer to
SECTION 3B.
Position lower control arms (17) to crossmember
(20).
Front lower control arm bolts/screws and nuts.
A
17
18
19
20
21
27
32
33
34
SIDE RAIL
SOLT /SCREW, FRONT LOWER CONTROL ARM
CROSSMEMBER, FRONT
BOLT /SCREW, FRONT CROSSMEMBER
BOLT/SCREW, FRONT CROSSMEMBER
NUT, FRONT CROSSMEMBER
10-3-3
03-08-95
FS0293C
Figure 1 - Front Crossmember
12. Lower control arm ball studs to steering knuckles.

SECTION 3C.
14. Stabilizer shaft links. Refer to SECTION 3C.
15. Front tires and wheels. Refer to SECTION 3E.
17. Lower vehicle.
18. Align front wheels. Refer to SECTION 3A.
FRONT CROSSMEMBER BRACES

Figure 2
!++I

SECTION OA.
2. Bolts/screws (5) attaching brace to front
crossmember (20).
3. Brace from front crossmember (20).
!++!
Install or Connect
NOTICE:
1. Brace to front crossmember (20).

2. Bolts/screws (5) attaching brace to front
crossmember (20).
!~I
Tighten

3. Lower vehicle.
UNDERBODY FLUSH
Due to buildup of road salts and corrosives on
the vehicle underbody, the underbody, (including
suspension, exhaust and fuel line areas) should be
flushed with clean water annually, preferably each
spring. This will increase the life and strength of the
underbody components.
10-3-4
5~
1
2
3
4
5
20
BRACE, LEFT FRONT CROSSMEMBER

BRACE, RIGHT FRONT CROSSMEMBER
BRACE, RIGHT REAR FRONT CROSSMEMBER
BRACE, LEFT REAR FRONT CROSSMEMBER
BOLT/SCREW, FRONT CROSSMEMBER BRACE
CROSSMEMBER, FRONT
(
031895
FT001103
Figure 2 Front Crossmember Braces (Convertible)
STEERING UNIT RACK AND PINION

SUPPORT MOUNT PLATES
The fore and aft and side-to-side dimension
reference points for the rack and pinion steering mount
plates are measured point to point. The vertical
dimensions for the reference points are measured on a
vertical plane from the datum line to the center of the
steering unit attaching holes.
STEERING UNIT MOUNTING

Vehicles involved in accidents resulting in frame
damage, major body or sheet metal damage, or where
the steering column has been impacted, may also have
a mis-aligned steering column.
For the procedure to check capsules on the
steering column bracket, refer to SECTION 3F.
FRONT SIDE DOOR SILL TRIM PLATE

To remove, pull up on front side door sill trim
plate. Snap into place to install.
SPECIFICATIONS
Floor Panel Reinforcement Bolt/Screw .................................................................................. 27 N.m (20 lb. ft.)
Front Crossmember Bolt/Screw ........................................................................................... 125 N.m (92 lb. ft.)
Front Crossmember Brace Bolt/Screw ................................................................................... 29 N.m (21 lb. ft.)
BUMPERS 10-41
SECTION 10-4
BUMPERS
CAUTIONS in SECTION 9J "ON-VEHICLE SERVICE" and the SIR Component and Wiring Location
view in SECTION 9J before performing service on or around SIR components or wiring. Failure
to follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise
unneeded SIR system repair.
torque and the joint clamping force, and may damage the fastener. Wheri you install fasteners, use the correct
systems.
NOTICE: The theft deterrent label found on some major sheet metal must be masked prior to painting,
label clean and readable may result in liability for violation of the Federal Vehicle Theft Prevention Standard,
and subject the vehicle owner to possible suspicion that the part was stolen.
CONTENTS
Bumpers ............................................................ 10-4-1
Fascia Energy Absorber ................................... 10-4-2
Front Bumper ................................................... 10-4-2
Front Bumper Fascia.................................... 10-4-2
Front License Plate Bracket ........................ 10-4-5
Front Bumper Energy Absorber .................. 10-4-6
Front Bumper Impact Bar ........................... 10-4-6
Front Bumper Fascia Emblems ................... 10-4-6
GENERAL DESCRIPTION
BUMPERS
CHEVROLET
The front and rear bumper design is a full-width
honeycomb energy absorber of guide flex (or
equivalent) material backed up by rigidly mounted
impact bars. The front bumper fascia is polyurea
painted body color. The rear bumper fascia is
polyurethane painted body color.
For repair of the front and/or rear bumper fascia,
refer to SECTION 10-1.
Front Fog Lamp Opening Cover .............. 10-4-7

Front Bumper Fascia Lower Deflectors.... 10-4-8
Rear Bumper .................................................. 10-4-8
Rear Bumper Fascia .................................. 10-4-8
Rear Bumper Energy Absorber ................. 10-4-9
Rear Bumper Impact Bar .......................... 10-4-11
Rear Bumper Fascia Decal.. ...................... 10-4-11
Specifications ...................................................... 10-4-12
Fastener Tightening Specifications ................ 10-4-12
PONTIAC
The front bumper design includes a full-width

energy absorber of a Styrofoam material. The rear
bumper design is a full-width honeycomb energy
absorber of guide flex (or equivalent) material. Both
bumpers are backed up by rigidly mounted impact
bars. The front bumper fascia is polyurea painted body
color. The rear bumper fascia is polyurethane painted
body color.
For repair of the front and/or rear bumper fascia,
refer to SECTION 10-1.
1042
BUMPERS
FASCIA ENERGY ABSORBER

CAUTION: Failure to observe the
following procedure when handling
energy absorbing device or personal
injury may result.
Do not apply heat to a unit.
Do not weld in the area of a unit.
Do not attempt to repair a
damaged unit. Always replace with
a new unit.
If a unit is bound-up as a result of
a collision such that it cannot
extend, take precautions to avoid
spring-back when bending sheet
metal. Provide a positive restraint,
such as a chain or cable to hold
the bumper in the position it is in.
Wear approved safety glasses and
using a 1/8 inch drill bit, drill a
small hole in the piston tube near
the bumper bracket to relieve gas
pressure. Remove the energy
absorbers after gas pressure has
been relieved.
If unit is to be scrapped, relieve
the gas pressure prior to disposal
of a unit. Make an indentation with
a center punch in the small
cylinder section of the energy
absorber.
General Motors passenger car bumper systems
are designed to take a collision into a fixed barrier at
8 km/h (5 mph) without damage. After absorbing the
energy of a collision, these bumper systems restore
themselves to their original position.
ON-VEHICLE SERVICE
9. Front bumper fascia (1).
10. Electrical connectors from front bumper
fascia (1).
!++!
Install or Connect
NOTICE:
1. Electrical connectors to front bumper fascia (1).

!~! Tighten
4. Retainers (4).
SECTION OA.
6. Bolts/screws (11) attaching front bumper
fascia (1) to headlamp mounting panel.
!~!
Tighten

7. Lower supports (6), nuts (5) and bolts/screws
(75).
!~!
Tighten
Nuts (5) to 10 N.m (89 lb. in.).

8. Retainers under fascia (4).
9. Front bumper fascia lower deflectors. Refer to
"Front Bumper Fascia Lower Deflectors" in this
section.
10. Lower vehicle.
PONTIAC
FRONT BUMPER
Figures 2 and 3
Front Bumper Fascia
!++!
CHEVROLET
Figure 1
I++!

SECTION OA.
section.
3. Retainers (4).
4. Nuts (5), bolts/screws (75) and lower supports (6).
5. Bolts/screws (11) attaching front bumper fascia
( 1) to headlamp mounting panel.
6. Lower vehicle.
7. Retainers under fascia (4).

SECTION OA.
section.
3. Retainers (4).
4. Nuts (5), bolts/screws (75) and lower supports (6).
5. Lower vehicle.
7. Manually raise headlamps.
8. Retainers (4).
BUMPERS 10-4-3
20
6
75
19
22
22
29
28
A COLLAR, RAIL
B BRACKET, OUTER SUPPORT
c PANEL, HEADLAMP SUPPORT
D STUD, FRONT BUMPER PLATE
1 FASCIA, FRONT BUMPER
2 BOLT/SCREW, FRONT FENDER
4 RETAINER. FRONT BUMPER FASCIA (PUSH-IN)
5 NUT, FRONT BUMPER FASCIA LOWER SUPPORT
6 SUPPORT, FRONT BUMPER FASCIA LOWER
7 RIVET, FRONT BUMPER FASCIA ENERGY ABSORBER
8 ABSORBER, FRONT BUMPER FASCIA ENERGY
9 BAR, FRONT BUMPER IMPACT
10
11
14
19
20
22
28
29
40
75
NUT, FRONT BUMPER IMPACT BAR

BOLT/SCREW, HEADLAMP HOUSING PANEL
PLATE, FRONT BUMPER IMPACT
RETAINER, FRONT BUMPER FASCIA LOWER
DEFLECTOR
DEFLECTOR, FRONT BUMPER FASCIA LOWER
BOLT/SCREW, FRONT BUMPER FASCIA LOWER
DEFLECTOR
COVER, FRONT FOG LAMP OPENING
SOLT /SCREW, FRONT FOG LAMP OPENING COVER
RETAINER, FRONT BUMPER IMPACT BAR STUD
SOLT/SCREW, FRONT BUMPER FASCIA LOWER SUPPORT
03-14-91
FT001104
Figure 1 - Front Bumper - (Chevrolet)
1044 BUM PERS
82
6
5.
75
20
21
E
Figure 2 - Front Bu
mper - (Pon;tia~c))_ _ _ _ _ _ _ I
BUMPERS
A
B
C
D
E
1
2
4
5
6
9
10
14
COLLAR, RAIL
BRACKET, OUTER SUPPORT
STUD, FRONT BUMPER PLATE
BASE FIREBIRD AND FORMULA
TRANS AM
FASCIA, FRONT BUMPER
BOLT/SCREW, FRONT BUMPER FASCIA BRACE
RETAINER, FRONT BUMPER FASCIA (PUSH-IN)
NUT, FRONT BUMPER FASCIA LOWER SUPPORT
SUPPORT, FRONT BUMPER FASCIA LOWER
NUT, FRONT BUMPER IMPACT BAR
PLATE, FRONT BUMPER IMPACT
19
20
22
28
29
40
75
82
89
97
10-45
RETAINER, FRONT BUMPER FASCIA LOWER

BOLT/SCREW, FRONT BUMPER FASCIA LOWER DEFLECTOR
BOLT/SCREW, FRONT FOG LAMP OPENING COVER
RETAINER, FRONT BU,MPER IMPACT BAR STUD
BOLT /SCREW, FRONT BUMPER FASCIA LOWER SUPPORT
ABSORBER, FRONT BUMPER FASCIA ENERGY
RETAINER, FRONT BUMPER FASCIA ENERGY
NUT, FRONT FOG LAMP OPENING COVER
012411
FS003104
Figure 3 Front Bumper Legend (Pontiac)
11. Electrical connectors from front bumper
fascia (1).
l++I
Install or Connect
NOTICE:
1. Electrical connectors to front bumper fascia (1).

l~l
Tighten

Retainers (4).
Manually retract headlamps.
SECTION OA.
8. Lower supports (6), nuts (5) and bolts/
screws (75).
4.
5.
6.
7.
l~I
Tighten
Nuts (5) to 10 N,m (89 lb. in.).

9. Retainers (4).
section.
11. Lower vehicle.
Front License Plate Bracket
l++l
1. Bolts/screws attaching front license plate bracket

to front bumper fascia.
2. License plate bracket from front bumper fascia.
l++I
Install or Connect
License plate bracket to front bumper fascia.

A. Align holes in license plate bracket with holes
in front bumper fascia.
B. Install bolts/screws attaching license plate
bracket to front bumper fascia.
10-4-6
BUMPERS
,Front Bumper Energy Absorber
CHEVROLET
Figure 1
injury may. result.
Do not atte.mpt to repair a
a new unit.
spring-back when bending sheet
small hole in the piston tube .near
abs.orbers .after gas pressure has
been relieved.
the gas pressure .prior to disposal
absorber.
!++I
1. Front bumper fascia. Refer to "Front Bumper

Fascia" in this section.
2. Rivets (7) using 1/4-inch drill bit.
3..Front bumper energy absorber (8).
!++I
Install or Connect
1. Front bumper energy absorber (8).

2. Rivets (7).
Install rivets (7) starting at. center of front
bumper energy absorber (8) and working
outboard.
PONTIAC
Figures 2 and 3
!++!

2. Retainers (89).
!++!
Install or Connect

2. Retainers (89).
Install retainers (89) starting at center of front
bumper energy absorber (82) and working
outboard.
Front Bumper Impact Bar
Figures 1, 2 and 3
!++!
1. Front bumper energy absorber. Refer to "Front

Bumper Energy Absorber" in this section.
2. Nuts (10) from plate studs.
3. Front bumper impact bar (9).
!++!
Install or Connect
NOTICE: Refer to "Notice" on page 10-4-1.

1. Front bumper impact bar (9).
2. Nuts (10) to plate studs.
I~!
Tighten
Nuts (10) to 25 N,m (18 lb. ft.).

3. Front bumper energy absorber. Refer to "Front
Front Bumper Fascia Emblems
Figures 4 and 5
!++!
Emblem (45 or 104).

A. Apply heat using heat gun, making sure heat
gun is moved in circular motion and is, held at
least 152 mm (6 inches) frorrt emblem (45, or
104) for about 30 seconds. . .
.
B. Gently peel emblem (45 or 104) from front
bumper fascia (1) with flat-bladed tool,
making sure not to damage paint.
Clean
Area with suitable solvent of isopropyl alcohol

50-50 mixture by volume with water or high-flash
naphtha.
!++I
Install or Connect
Emblem (45 or 104).

A. Body and part temperature must be 26C
(80F) minimum or 6C ( 10F) above ambient
air temperature, whichever is higher, but not to
exceed 40C (105F) during installation.
BUMPERS
155 mm (6.1")
10-47
104
45 EMBLEM, FRONT BUMPER FASCIA

104 EMBLEM, RADIATOR GRILLE
ISECTION A-A I
45 EMBLEM, FRONT BUMPER FASCIA
01-24-ff
F800&104
Figure 5 - Front Bumper Fascia Emblems -(Chevrol,et)

0124915
FS004104
Figure 4 - Front Bumper Fascia Emblem (Pontiac)
B. Peel protective paper from emblem adhesive.
rn
Important
Position emblem (45, or 104) carefully on

front bumper fascia (1). Emblem (45, or 104)
cannot be easily removed after contact with
vehicle.
C. Press emblem (45, or 104) into place and
apply constant pressure for 30 seconds.
D. Remove pre-mask from emblem (45, Pontiac
only).
Front Fog Lamp Opening Cover
CHEVROLET
Install or Connect
NOTICE:
1. Front fog lamp opening cover (28).

2. Bolts/screws (29) to front bumper fascia (1).
l~I
Figure 6 - Front Fog Lamp Opening Cover (Left Side

Shown, Right Side Similar) (Chevrolet)
Figure 7
1. Bolts/screws (29) from front bumper fascia (1).

1-++I
FSCOl104
PONTIAC
Figure 6
!++I

28 COVER, FRONT FOG LAMP OPENING
29 BOLT/SCREW, FRONT FOG LAMP OPENING COVER
01-2415
Tighten
I++!

SECTION OA.
2. Retainers (4).
Remove enough retainers (4) so that lower
portion of front bumper fascia ( 1) can be
pulled down to gain access to nuts (97) or
bolts/screws (29).
3. Nuts (97) from front fog lamp opening cover (28)
or bolts/screws (29) from front fog lamp opening
cover (28).
l++I
install or Connect
NOTICE:
1048
BUMPERS
I
~4
28
B
A
8
1
4
BASE FIREBIRD AND FORMULA

TRANS AM
RETAINER, FRONT BUMPER FASCIA (PUSH-IN)
28
97
29

NUT, FRONT FOG LAMP OPENING COVER
BOLT/SCREW, FRONT FOG LAMP OPENING COVER
012495
FS007104
Figure 7 Front Fog Lamp Opening Covers (Left Side Shown, Right Side Sirnilar) - (Pontiac)

2. Nuts (97) to front fog lamp opening cover (28) or
bolts/screws (29) to front fog lamp opening cover
(28).
!~J
Tighten
Nuts (97) to 2.3 N.m (20 lb. in.).

3. Retainers (4).
4. Lower vehicle.
2. Retainer (4) to radiator air lower baffle (48) and

front lower deflector (20).
3. Bolts/screws (22) to radiator air lower deflector
(49) and front lower deflector (20).
l~I Tighten
4. Bolts/screws (20) to wheelhouse panel liner (51)
and front lower deflector (20).
5. Retainers (19).
Front Bumper Fascia Lower Deflectors
REAR BUMPER
Figure 8
Rear Bumper Fascia
I++!
Remove
or Disconnect
1.
2.
3.
Retainers (19).
Bolts/screws (22) from front lower deflector (20)
and wheelhouse panel liner (51).
Bolts/screws (22) from front lower deflector (20)
and radiator air lower deflector (49).
4. Retainers (4) from front lower deflector (20) and
radiator air lower baffle (48).
5. Front lower deflector (20).
Slide front lower deflector (20) outward from
radiator air lower deflector (49) and wheelhouse
panel liner (51).
I++!
Install or Connect
NOTICE:
1. Front lower deflector (20).

Slide front lower deflector (20) inward and
over radiator air lower deflector (49) and
wheelhouse panel liner (51).
Figure 9
!++!

SECTION OA.
2. Retainers (67).
4. Nuts (53).
5. Lower vehicle.
6. Rear end finish panel. Refer to SECTION 10-8.
7. Compact spare tire and jack.
8. Retainers (67).
9. Nuts (54).
10. Rear bumper fascia (68).
11. Rear body wiring harness connector from rear
fascia wiring harness connector.
!++!
Install or Connect
NOTICE:
BUMPERS 10-4-9
20
20
51
22
v
22
. jVIEWAj
!VIEW Bj
4 RETAINER, FRONT BUMPER FASCIA LOWER
DEFLECTOR
/
19 RETAINER. FRONT BUMPER FASCIA LOWER
DEFLECTOR
20 DEFLECTOR, FRONT BUMPER FASCIA LOWER
22
BOLT/SCREW, FRONT BUMPER FASCIA LOWER

DEFLECTOR
48 BAFFLE, RADIATOR AIR LOWER
49 DEFLECTOR, RADIATOR AIR LOWER
51 LINER, FRONT WHEELHOUSE PANEL
012495
FS008104
Figure 8 Front Bumper Fascia Lower Deflector (Left Side Shown, Right Side Similar)
1. Rear body wiring harness connector to rear fascia

wiring harness connector.
2. Rear bumper fascia (68).
3. Nuts (54).
!~I
Tighten
Nuts (54) to 10 N.m (89 lb. in.).

Retainers (67).
Compact spare tire and jack.
Rear end finish panel. Refer to SECTION 10-8.
SECTION OA.
8. Nuts (53).
4.
5.
6.
7.
!~I
Tighten
Nuts (53) to 10 N.m (89 lb. in.).

!~I
Tighten

10. Retainers (67).
11. Lower vehicle.
Rear Bumper Energy Absorber

Figure 9
injury may result.
Do not attempt to repair a
a new unit.
spring-back when bending .sheet
small hole in the piston tube near
absorbers after gas pressure has
been relieved.
the gas pressure prior to disposal
absorber.
10~4-10 BUMPERS
61
65
67
A
53
54
56
57.
58
61
62
64
65
66
67
68
71
67
BOSS, LOCATING
NUT, REAR BUMPER FASCIA
NUT, REAR BUMPER FASCIA
NUT, REAR BUMPER IMPACT BAR
SHIM, REAR BUMPER IMPACT BAR
RETAINER, REAR BUMPER IMPACT BAR BOLT (PUSH-ON)
BAR, REAR BUMPER IMPACT
PLATE, REAR BUMPER IMPACT BAR STUD
RIVET, REAR-END FASCIA ENERGY ABSORBER (PONTIAC ONLY)
ABSORBER, REAR BUMPER FASCIA ENERGY
BOLT/SCREW, REAR END FASCIA ENERGY ABSORBER
RETAINER, REAR BUMPER FASCIA (PUSH-IN)
FASCIA, REAR BUMPER
BOLT/SCREW, REAR BUMPER FASCIA
OMM-96
FS009104
Figure 9 - Rear Bumper (Pontiac Shown, Chevrolet Similar)
BUMPERS
!++!
2. Nuts (56 and 72) from plate studs.

3. Rear bumper impact bar (61).
Note number and placement of shims (57).
1. Rear bumper fascia. Refer to "Rear Bumper

2. Rivets (64) using 1/4-inch drill bit (Pontiac only).
4. Rear bumper energy absorber (65).
I++-!
!++!
1. Rear bumper impact bar (61) and shims (57).

Place shims (57) in location from which they
were removed.
2. Nuts (56) to plate studs.
1. Rear bumper energy absorber (65).

Position hole at center of rear bumper energy
absorber (65) over locating boss at center of rear
bumper impact bar (61).
Install bolts/screws (66) starting at center of
rear bumper energy absorber (65) and working
outboard.
1. Rivets (64) (Pontiac only).
2. Rear bumper fascia. Refer to "Rear
Bumper Fascia" in this section.
I~!
Tighten
Nuts (56) to 15 N.m (11 lb. ft.).

3. Rear bumper energy absorber. Refer to "Rear
REAR BUMPER FASCIA DECAL
Pontiac
Figure 10
Rear Bumper Impact Bar
For information and procedures on replacing

decals refer to SECTION 10-1. Refer to Figure 10 for
correct placement of the decal (98).
Figure 9
!++I
Install or Connect
NOTICE:
Install or Connect
NOTICE:
10-4-11
1. Rear bumper energy absorber. Refer to "Rear
'--
----:;~
-
30~
~~~/
jv1Ew Al
98
98
DECAL, REAR BUMPER FASCIA
03-14-H
FT010184
Figure 10 - Rear Bumper Fascia Decal (Pontiac)
10-4-12
BUMPERS
SPECIFICATIONS
Front Bumper Fascia Brace Bolt/Screw (Pontiac Only) ....................................................... 10 N.m (89 lb. in.)
Front Bumper Fascia Lower Support Bolt/Screw ................................................................. 10 N.m (89 lb. in.)
Front Bumper Fascia Lower Supp01t Nut ............................................................................. 10 N.m (89 lb. in.)
Front Bumper Impact Bar Nut. ............................................................................................... 25 N.m (18 lb. ft.)
Front Fender Bolt/Screw ....................................................................................................... 1.7 N.m (15 lb. in.)
Front Fog Lamp Opening Cover Bolt/Screw ....................................................................... 1.7 N.m (15 lb. in.)
Front Fog Lamp Opening Cover Nut (Pontiac Only) ......................................................... 2.3 N.m (20 lb. in.)
Headlamp Housing Panel Bolt/Screw ................................................................................... 1.7 N.m (15 lb. in.)
Radiator Air Lower Deflector Bolt/Screw ............................................................................. 10 N.m (89 lb. in.)
Rear Bumper Fascia Bolt/Screw .............................................................................................. 2 N.m (18 lb. in.)
Rear Bumper Fascia Nut. ......................................................................................................... 6 N.m (53 lb. in.)
Rear Bumper Impact Bar Nut. ................................................................................................ 15 N.m (11 lb. ft.)
Rear End Fascia Energy Absorber Bolt/Screw .................................................................... 5.5 N.m (49 lb. in.)
BODY FRONT END
10-5-1
SECTION 10-5
BODY FRONT END

location view in SECTION 9J before performing service on or around SIR components or wiring.
after removal. General Motors will also call out the fasteners that require thread locker or thread sealant.
systems.
CONTENTS
General Description ............................................ 10-5-1
Body Front End ............................................. 10-5-1
Lubrication ...................................................... 10-5-3
Fasteners ......................................................... 10-5-3
Anti-Corrosion Protection .............................. 10-5-3
On-Vehicle Service ............................................. 10-5-3
Front End Panels ............................................ 10-5-3
Radiator Air Lower Baffles and
Deflectors ......................... Refer to Section 6B
Radiator Air Lower Deflector ................... 10-5-3
Radiator Support .................... Refer to Section 11
Headlamp Housing Panel and Brackets .... 10-5-3
Battery Tray and Coolant Recovery
Reservoir ............................ Refer to Section 6B
SIR Forward Discriminating
Sensor .................................. Refer to Section 9J
Front Fender ..............;.................................... 10-5-5
Front Wheelhouse Panel Liner .................. 10-5-5
Front Fender and Brackets ........................ 10-5-6
Front Fender Emblem ................................ 10-5-7
Hood ............................................................... 10-5-8
Hood Insulator ............................................ 10-5-11
Hood Close-Out Filler................................ 10-5-12
Hood Hinge Cover ..................................... 10-5-12
Hood Hinge ................................................ 10-5-12
Hood Primary Latch .................................. 10-5-15
Hood Secondary Latch .............................. 10-5-16

Hood Primary Latch Release Cable .......... 10-5-17
Hood Open Assist Rod .............................. 10-5-18
Hood Open Assist Rod Bracket ................ 10-5-18
Hood Rear Seal. ......................................... 10-5-19
Hood Adjust Front Bumper....................... 10-5-19
Hood Air Extractors .................................. 10-5-19
Plenum Chamber ............................................ 10-5-21
Front End Sealing .......................................... 10-5-21
Air Inlet Screens ............................................ 10-5-21
Body Hinge Pillar Trim Panel ...................... 10-5-22
Dash Sound Barrier ....................................... 10-5-22
Body Hinge Pillar Inner Panel Sound
Barriers ....................................................... 10-5-22
Door Jamb Switches ...................................... 10-5-22
Exterior Moldings and Decal ........................ 10-5-24
Rocker Panel Molding ............................... 10-5-24
Front Fender Center Rear Molding .......... 10-5-24
Headlamp Opening Door Decal ................ 10-5-24
Hood Decals ............................................... 10-5-25
Roof Side Rail Weatherstrip Retainer ........... 10-5-25
Body Panel Adjustment and Alignment ....... 10-5-26
Hood Adjustment ....................................... 10-5-26
Specifications:..................................................... 10-5-30
Special Tools ...................................................... 10-5-30
GENERAL DESCRIPTION
braces and brackets located so as not to interfere with

adjustments or service repair. The hood primary latch
(27) is attached to the hood primary latch support (26).
Front fenders (13) are composed of reinforced
reaction injection molded (RRIM) urethane. The front
fenders (13) attach to the front wheelhouse panel
liner (15).
BODY FRONT END

Figures 1 through 4
The hood (1) is composed of galvanized metal.
Further rigidity is obtained by the use of reinforcement
10-5-2 BODY FRONT END
(
3
20
18
24
15
16
17
(
Figure 1 _ Body Front End Components - (Pontiac)
BODY FRONT END

1
2
3
4
5
6
7
8
9
11
12
13
14
15
16
17
18
19
20
21
PANEL, HOOD
BRACKET, HOOD HINGE
HINGE, HOOD
MOLDING, HOOD REAR (PONTIAC)
PLATE, HOOD HINGE MOUNT
SHIM, HOOD
BRACKET, HOOD OPEN ASSIST ROD
ROD. HOOD OPEN ASSIST
STUD, HOOD STRUT BALL
BRACKET, FRONT FENDER REAR UPPER
BRACKET, FRONT FENDER REAR CENTER
FENDER, FRONT
MOLDING, FRONT FENDER CENTER REAR
LINER, FRONT WHEELHOUSE PANEL
BRACKET, FRONT BUMPER FASCIA OUTER
FILLER, HOOD CLOSEOUT (PONTIAC)
CABLE, HOOD PRIMARY LATCH RELEASE
BRACKET, HEADLAMP HOUSING PANEL UPPER
22
23
24
25
26
27
30
31
32
33
34
35
36
37
38
204
210
223
105-3
SUPPORT, HEADLAMP HOUSING PANEL

BRACKET, HEADLAMP HOUSING PANEL (PONTIAC)
PANEL. HEADLAMP HOUSING
CUP, HOOD PRIMARY LATCH RELEASE CABLE
SUPPORT, HOOD PRIMARY LATCH
LATCH, HOOD PRIMARY
BUMPER, HOOD ASJUST FRONT
CAP, HOOD ADJUST FRONT BUMPER
LATCH, HOOD SECONDARY
STRIKER. HOOD PRIMARY LATCH
INSULATOR, HOOD
SEAL, HOOD REAR
DOOR. HEADLAMP OPENING (PONTIAC)
EXTRACTOR, HOOD AIR
SCREEN, HOOD AIR EXTRACTOR
COVER, HOOD HINGE (CHEVROLET)
RETAINER, HOOD HINGE COVER (CHEVROLET)
EMBLEM. FRONT FENDER (CHEVROLET)
012495
FSCI02105
Figure 2 - Body Front End Components - Legend
LUBRICATION
For lubrication of hood hinges, hood latch
release pawl, hood latch and pivots, headlamp door,
etc., refer to SECTION OB.
FASTENERS
NOTICE: When replacing fasteners avoid
substituting otherwise similar fasteners in
locations which require the use of special
fasteners meeting GM specifications 61 lM,
6047, 6174M for aluminum components. Failing
to follow this precaution may result in
premature corrosion of the sheet metal in the
areas mentioned above.
ANTI-CORROSION PROTECTION
Anti-corrosion materials are part of the coating
on most metal panels to provide rust resistance. When
servicing these panels, use only GM replacement parts
and re-coat with specified service primers and paints.
ON-VEHICLE SERVICE
FRONT END PANELS
Radiator Air Lower Deflector

Figure 4
E3
1. Bolts/screws (40) attaching radiator air lower

deflector (17) to front bumper fascia lower
deflectors (16).
2. Radiator air lower deflector (17).
lHI
Install or Connect
NOTICE:
1. Radiator air lower deflector ( 17).

l~I
Tighten
Headlamp Housing Panel and Brackets

Figures 5 and 6
!++i
1. Front bumper fascia. Refer to SECTION 10-4.

2. Bolts/screws (48) from pivot support brackets and
panel brackets (23) (Pontiac only).
3. Bolts/screws (44) from headlamp housing panel
(24).
Slide headlamp housing panel (24) slightly out
to gain access to headlamp electrical
connectors.
5. Headlamp housing panel (24).
6. Panel support bolts/screws (49) and panel supports
(22), if necessary.
7. Panel bracket bolts/screws (47) and panel brackets
(23), if necessary (Pontiac only).
8. Upper bracket bolts/screws (50) and upper bracket
(21), if necessary.
l++I
Install or Connect
NOTICE:
10-5-4
BODY FRONT END

38
~37
33
32
~
(
26
25
20
14
18
24
16
17
012495
FS003105
F,gure 3 Body Front End Components (Chevrolet)
BODY FRONT END
A
16
17
. 40
SUPPORT, RADIATOR
BOLT/SCREW, RADIATOR AIR LOWER DEFLE~TOR
1055
~03-18-15
FT004105
Figure 4 Radiator Air Lower Deflector
1. Panel supports (22) and panel support bolts/screws

(49), if removed.
!~I
Front Wheelhouse Panel Liner

Tighten
Panel support bolts/screws (49) to 10 N.m (89 lb.

in.).
2. Panel bracket (23) and panel bracket bolts/screws
(47), if removed (Pontiac only).
I~!
Tighten
Panel bracket bolts/screws (47) to 5.5 N.m

(49 lb. in.).
3. Upper brackets (21) and upper bracket
bolts/screws (50), if removed.
!~I
Tighten
Upper bracket bolts/screws (50) to 10 N.m

(89 lb. in.).
4. Headlamp housing panel (24).
6. Bolts/screws (44) to headlamp housing panel (24).
l~I
Tighten

7. Panel bracket bolts/screws (48) to panel brackets
(23) and pivot support brackets (Pontiac only).
l~I
FRONT FENDER
Tighten
Panel bracket bolts/screws (48) to 1.7 N.m

(15 lb. in.).
8. Front bumper fascia. Refer to SECTION 10-4.
Figure 7
l++j
1. Front wheelhouse bolt/screw caps (53).

SECTION OA.
3. Front tire and wheel. Refer to SECTION 3E.
4. Bolts/screws (54) from wheelhouse panel liner
(15) and lower deflector (16).
5. Bolts/screws (55) from wheelhouse panel liner
(15).
6. Retainers (56).
7. Wheelhouse panel liner (15).
l++I
Install or Connect
NOTICE:
1. Wheelhouse panel liner (15).

2. Retainers (56).
3. Bolts/screws (55) to wheelhouse panel liner (15).
!~I
Tighten

4. Bolts/screws (54) to wheelhouse panel liner (15)
and lower deflector (16).
!~!
Tighten

5. Front tire and wheel. Refer to SECTION 3E.
6. Lower vehicle.
24
A BRACKET, PIVOT SUPPORT
21 BRACKET, HEADLAMP HOUSING PANEL UPPER
22 SUPPORT, HEADLAMP HOUSING PANEL
23 BRACKET, HEADLAMP HOUSING PANEL
24 PANEL, HEADLAMP HOUSING
28 NUT, HOOD PRIMARY LATCH BRACKET
44
47
48
49
50
BOLT/SCREW,
SOLT/SCREW,
SOLT/SCREW,
BOLT/SCREW,
BOLT/SCREW,
HEADLAMP
HEADLAMP
HEADLAMP
HEADLAMP
HEADLAMP
HOUSING
HOUSING
HOUSING
HOUSING
HOUSING
PANEL
PANEL
PANEL
PANEL
PANEL
BRACKET
BRACKET
SUPPORT
UPPER BRACKET
03-18-95
FT005105
Figure 5 - Headlamp Housing Panel and Brackets - (Pontiac)
Front Fender and Brackets

Figures 8 and 9
NOTICE: When removing body panels, apply

tape to corners of panel and adjacent surfaces to
help prevent paint damage.
!++I
8. Rear center bracket bolts/screws (66) and rear

center bracket (12), if necessary.
!H!
Install or Connect

1. Rear center bracket (12) and rear center bracket
1. Front fender bolts/screws (60).

SECTION OA.
3. Front wheelhouse panel liner enough to gain
access to front fender bolt/screw (63). Refer to
"Front Wheelhouse Panel Liner" in this section.
4. Front fender bolts/screws (62 and 63).
5. Front fender (13).
6. Outer bracket bolts/screws (64) and fascia outer
bracket (18), if necessary.
7. Rear upper bracket bolts/screws (65) and rear
upper bracket (11), if necessary.
!~! Tighten
Rear center bracket bolts/screws (66) to
5.5 N,m (49 lb. in.).
2. Rear upper bracket (11) and rear upper bracket
bolts/screws (65).
!~I
Tighten
Rear upper bracket bolts/screws (65) to

5.5 N,m (49 lb. in.).
3. Outer bracket (18) and outer bracket bolts/
screws (64), if removed.
BODY FRONT END
1057
21
13 FENDER, FRONT
21 BRACKET, HEADLAMP HOUSING PANEL UPPER
22 SUPPORT, HEADLAMP HOUSING PANEL
28 NUT, HOOD PRIMARY LATCH BRACKET
44 BOLT/SCREW, HEADLAMP HOUSING PANEL
49 BOLT/SCREW, HEADLAMP HOUSING PANEL SUPPORT
50 BOLT/SCREW, HEADLAMP HOUSING PANEL UPPER BRACKET
l~I
Tighten
Tighten
Front fender bolts/screws (62 and 63) to

5.5 N,m (49 lb. in.).
6. Front wheelhouse panel liner. Refer to "Front
Wheelhouse Panel Liner" in this section.
7. Lower vehicle.
8. Front fender bolts/screws (60).
l~I
031895
FTOoe105
Figure 6 Headlamp Housing Panel and Brackets (Chevrolet)
Outer bracket bolts/screws (64) to 5.5 N.m

(49 lb. in.).
4. Front fender (13).
5. Front fender bolts/screws (62 and 63).
1~1
49
Tighten
Front fender bolts/screws (60) to 5.5 N.m

(49 lb. in.).
Front Fender Emblem
CHEVROLET
Figure 10
Tool Required:
. J 25070 Heat Gun
!++!
Emblem (223).
A. Hold J 25070 at least 152 mm (6 inches) from
emblem (223).
B. Pull emblem (223) from front fender (13) with
flat-bladed tool, making sure not to damage
paint
Clean
1. Area with suitable solution of isopropyl alcohol

50/50 mixture by volume with water or high-flash
naphtha.
1058
BODY FRONT. END
16
15
13 FENDER, FRONT
15 LINER, FRONT WHEELHOUSE PANEL
16 DEFLECTOR, FRONT BUMPER FASCIA LOWER
53 CAP, FRONT WHEELHOUSE PANEL LINER
.
BOLT/SCREW
54 BOLT/SCREW, FRONT WHEELHOUSE PANEL LINER
55 BOLT/SCREW, FRONT WHEELHOUSE PANEL LINER
56 RETAINER, FRONT WHEELHOUSE PANEL LINER
54
0124-H
FS007105
Figure 7 - Front Wheelhouse Panel Liner (Typical)
2. Area with clean dry cloth.
j++!
Install or Connect
New emblem (223).

A. Heat fender surface and adhesive side of new
emblem (223). Temperature must be 26C
(80F) or 6C (l0F) above air temperature in
area, whichever is higher, but not exceeding
40C (105F).
B. Remove liner from adhesive strip.
rn
Important
Position emblem (223) carefully. Emblem

(223) cannot be removed without reapplying
adhesive after contact with vehicle.
C. Press emblem (223) into place and apply
pressure.
HOOD
Figures 1, 3, 11, 12 and 13

tape to comers of panel and adjacent surfaces to
!++I
1. With aid of a helper, support hood (1).

2. Rod (8) from strut stud (71).
3. Hood hinge bolts/screws (72) and nuts (73), from
hood hinges (3).
4. Hood (1).
j++I
Install or Connect

1. Hood (1), with aid of a helper.
2. Hood hinge bolts/screws (72) and nuts (73).
BODY FRONT END 1059
13
62
11
12
13
18
60
62
63
64
BRACKET. FRONT FENDER REAR UPPER

BRACKET, FRONT FENDER REAR CENTER
FENDER, FRONT
BRACKET.FRONT BUMPER FASCIA OUTER
BOLT/SCREW, FRONT FENDER
BOLT/SCREW, FRONT BUMPER FASCIA OUTER
BRACKET
65 BOLT/SCREW, FRONT FENDER REAR UPPER BRACKET
66 BOLT/SCREW, FRONT FENDER REAR CENTER
BRACKET
!VIEWB
I
01-24-ts
FS00810&
Figure 8 - Front Fender and Brackets (Pontiac)
1o~s-10 BODY FRONT .END
62
13
13
63
13
..
,_
ff
IVIEWB j
11
12
13
18
60
62
63
64
65
66
BRACKET, FRONT FENDER REAR UPPER

BRACKET, FRONT FENDER REAR C~NTER
FENDER, FRONT
BRACKET, FRONT B.UMPER FASCIA OUTER
BOLT/SCREW, FRONT BUMPER FASCIA OUTER BRACKET
BOLT/SCREW, FRONT FENDER REAR UPPER BRACKET
BOLT/SCREW, FRONT FENDER REAR CENTER BRACKET
jv1ewcj
IVIEWD I
01-24-15
P8009105
(
Figure 9 - Front Fender and Brackets - (Chevrolet)
BODY FRONT END
!LI
10-5-11
Inspect
1. Close hood (1) slowly, checking clearance
~f...-51.Smm
..--vi I
(2.03")
/,',~~ f;_~~
13
between hood (1) and front fenders (13) and

headlamp opening doors.
2. With hood ( 1) closed, check alignment of hood
(1). For hood alignment specifications, refer to
"Body Panel Adjustment and Alignment" in this
section.
12]
Adjust
Hood, if necessary. Refer to "Hood Adjustment"

in this section.
223
Hood Insulator
!++I
13 FENDER, FRONT
14 MOLDING, FRONT FENDER CENTER REAR

223 EMBLEM, FRONT FENDER
031895
FT010105
Figure 1O Front Fender Emblem (Chevrolet)
l~I
Tighten
Hood hinge bolts/screws (72) or nuts (73) to

27 N.m (20 lb. ft.).
3. Rod (8) to strut stud (71).
1. Raise hood (1) to full-open position.

2. Retainers (74) from hood (1) and hood insulator
(34).
3. Hood insulator (34).
j++!
Install or Connect
NOTICE:
1. Hood insulator (34).
A BRACKET, WHEELHOUSE
B CLIP
7 BRACKET, HOOD OPEN ASSIST ROD
8 ROD ASSEMBLY, HOOD OPEN ASSIST
9 STUD, HOOD STRUT BALL
69 NUT, HOOD STRUT
71 STUD, HOOD STRUT
Figure 11 Hood Open Assist Rod (Typical)
012595
FS011105
10-5-12
BODY FRONT END
(
3
1 PANEL, HOOD
3 HINGE, HOOD
72 BOLT/SCREW, HOOD BODY SIDE HINGE
73 NUT, HOOD HINGE BRACKET
012595
FS012105
Figure 12 Hood (Typical)
2. Retainers ( 7 4) to hood (1 ) and hood

insulator (34).
Start installing retainers (74) at front of hood
insulator (34) and work rearward.
3. Close hood (1).
I++!
Install or Connect
1. Hood hinge cover (204).

2. Hood hinge cover retainer (210).
Hood Close-Out Filler
Hood Hinge
PONTIAC
Figures 12 and 17
Figure 15
!+-+!
1. Retainers (79).
2. Hood close-out filler (19).
!-++I
Install or Connect
NOTICE:
1. Hood close-out filler (19).

2. Retainers (79).
Hood Hinge Cover
CHEVROLET
Figure 16
!+-+I
1. Hood hinge cover retainer (210).

2. Hood hinge cover (204).

tape to corners of panel and adjacent surfaces to
!+-+!
1.
2.
3,
4.
Safely support hood (1) in full open position.

Hood hinge bolt/screw (76) and shim (6).
Hood hinge bolts/screws (72) and nuts (73).
Hood hinge nuts (77) from lower attachment of
hood hinge (3).
5. Hood hinge (3).
6. Hood hinge mount plate (5), if necessary.
A. Remove front wheelhouse panel liner. Refer to
"Front Wheelhouse Panel Liner" in this
section.
B. Remove retainers (78).
Use a flat-bladed tool to pry off retainers

(78) from plate studs.
C. Remove hood hinge mount plate (5).
BODY FRONT END
10-5-13
10
'
PANEL. HOOD
8 ROD, HOOD OPEN ASSIST
10 DECAL, HOOD
32 LATCH, HOOD SECONDARY
33 STRIKER, HOOD PRIMARY LATCH
38 SCREEN, HOOD AIR EXTRACTOR
1
OSotts
FT038108
Figure 13 - Hood (Pontiac with WS6 Performance Package Only)
10514 BODY FRONT END
34
74
INSULATOR, HOOD
RETAINER, HOOD INSULATOR
01-26-t&
FS013105
Figure 14 - Hood Insulator - (Typical)
I++!
!~!
Install or Connect
NOTICE:
1. Hood hinge mount plate (5), if removed.

A. Install retainers (78).
Hold hood hinge plate (5) in position and
press retainers (78) over plate studs.
B. Install front wheelhouse panel liner. Refer to
"Front Wheelhouse Panel Liner" in .this
section.
2. Hood hinge (3).
3. Hood hinge nuts (77) to lower attachment of hood
hinge (3).
Tighten
Nuts (77) to 25 N,m (18 lb. ft.).

4. Hood body side hinge bolts/screws (72) and
nuts (73).
I~! Tighten

Nuts (73) to 25 N,m (18 lb. ft.).
5. Shim (6) and bolt/screw (76) to lower attachment
of hood hinge (3).
,~~-\
19 FILLER, HOOD CLOSEOUT
79 RETAINER, HOOD CLOSEOUT FILLER
Figure 15 - Hood Close-out Filler - (Pontiac)
01-25-91
F801410S
BODY FRONT END
IL'i'I
10-5-15
Inspect
Hood (1) for alignment. Refer to "Hood

Hood Primary latch

Figures 18 and 19
l++j
3 HINGE, HOOD
204 COVER, HOOD HINGE
.210 RETAINER, HOOD HINGE COVER
01-25-H
FS01510!ii
Figure 16 - Hood Hinge Cover - {Chevrolet)
l~I
1. Mark position of hood primary latch bolts/screws

(82) on latch support (26).
2. Hood primary latch bolts/screws (82).
3. Hood latch release cable (20) from hood primary
latch (27).
Insert screwdriver into latch clip and lift hood
latch release cable (20) from hood primary
latch (27).
4. Latch support (26), if necessary.
A. Mark location of hood primary latch (27) on
upper radiator support.
B. Remove headlamp housing panel and
headlamp housing panel upper bracket. Refer
to "Headlamp Housing Panel and Brackets" in
this section .
C. Remove windshield washer solvent reservoir.
D. Latch support bolts/screws (83) and latch
support (26).
I++!
Tighten

6. Hood support from hood (1).
Install or Connect
NOTICE:
1. Latch support (26), if removed.

A. Position latch support (26) with marks made
during removal.
A
3
5
6
76
77
78
STUD, HOOD HINGE MOUNT PLATE

HINGE, HOOD
PLATE, HOOD HINGE MOUNT
SHIM, HOOD HINGE
BOLT/SCREW, HOOD HINGE
NUT, HOOD HINGE
RETAINER, HOOD HINGE MOUNT PLATE
A
0125-91
FT011105
Figure 17 - Hood Hinge
10-5-16
BODY FRONT END
26
26
27
82
83
SUPPORT, HOOD PRIMARY LATCH

LATCH, HOOD PRIMARY
BOLT/SCREW, HOOD PRIMARY LATCH
BOLT/SCREW, HOOD PRIMARY LATCH SUPPORT
012595
FS017105
Figure 18 Hood Primary Latch
B. Install latch support (26) and latch support

!~I
Tighten
Latch support bolts/screws (83) to 18 N,m

(13 lb. ft.).
C. Install windshield washer solvent reservoir.
D. Install headlamp housing panel and headlamp
housing panel upper bracket. Refer to
"Headlamp Housing Panel and Brackets" in
this section.
2. Hood latch release cable (20) to hood primary
latch (27).
A. Connect hood latch release cable (20) by
inserting end of hood latch release cable (20)
to hood primary latch (27).
B. Connect latch clip to hood primary latch (27).
3. Hood primary latch (27) to latch support (26).
4. Hood primary latch bolts/screws (82).
Position hood primary latch (27) so that hood
primary latch bolts/screws (82) line up with
marks on latch support (26).
!~I
Tighten
Hood primary latch bolts/screws (82) to 18

N.m (13 lb. ft.).
iL"'I
Inspect
Hood alignment. Refer to "Hood Adjustment" in

this section.
Adjust
Hood primary latch (27), if necessary.

A. Loosen hood primary latch bolts/screws (82).
B. Adjust hood primary latch (27) up or down to
specifications noted during inspection.
Hood Secondary Latch

Figure 20
l++i
1. Hood secondary latch bolts/screws (81).

2. Hood secondary latch (32) from hood (1).
l++l
Install or Connect

1. Hood secondary latch (32) to hood (1).
2. Hood secondary latch bolts/screws (81).
!~!
Tighten
Hood secondary latch bolts/screws (81) to

12 N.m (106 lb. in.).
BODY FRONT END
10-5-17
A
25
L&
A
20
25
29
HANDLE, HOOD PRIMARY LATCH RELEASE CABLE

CABLE, HOOD PRIMARY LATCH RELEASE
CLIP, HOOD PRIMARY LATCH RELEASE CABLE
BOLT/SCREW, HOOD PRIMARY LATCH RELEASE
CABLE
01-25-115
FS018105
Figure 19 - Hood Primary Latch Release Cable
Hood Primary latch Release Cable

Figures 18 and 19
l++I
1. Hood primary latch release cable (20) from

primary latch (27) and radiator support.
A. Disconnect cable (20) by inserting a
screwdriver into latch clip and
lifting cable
1
(20) from primary latch (27).
B. Pry cable grommet from primary latch (27).
C. Pull primary latch release cable (20) out
through hole in radiator support.
2. Driver side body hinge pillar trim panel. Refer to
"Body Hinge Pillar Trim Panel" in this section.
3. Hood primary latch release cable bolts/screws (29)
and hood primary latch release cable handle.
4. Cowl grommet by prying with a screwdriver.
[I]
Important
When removing the hood primary release

cable from the front of dash through hole, be
careful not to damage the hood cable patch
sealing pad surrounding the through hole, or
possible water intrusion may develop.
5. Hood primary latch release cable (20).
Note where hood primary latch release cable
(20) is routed before removing so it can be
installed correctly.
1 PANEL, HOOD
32 LATCH, HOOD SECONDARY
81 BOLT/SCREW, HOOD SECONDARY LATCH
01-25-95
FS019105
Figure 20 - Hood Secondary Latch
10518
!++!
BODY FRONT END
!++!
Install or Connect
NOTICE:
1. Hood primary latch release cable (20) through

cowl.
Route hood primary latch release cable (20)
where previously noted.
2. Cowl grommet.
3. Hood primary latch release cable handle and hood
primary latch release cable bolts/screws (29).
I~!
Tighten
Hood primary latch release cable bolts/screws

(29) to 7 N.m (62 lb. in.).
4. Driver side body hinge pillar trim panel. Refer to
"Body Hinge Pillar Trim Panel" in this section.
5. Hood primary latch release cable (20) to primary
latch (27).
A. Connect hood primary latch release cable (20)
to cable clip.
B. Route hood primary latch release cable (20)
through hole in radiator support.
C. Insert end of hood primary latch release cable
(20) into latch clip and attach cable grommet.
Hood Open Assist Rod

Figure 11
If both rods are being replaced, replace only one
at a time.
1. Safely support hood (1) in the full open position.

2. Hood open assist rod (8) from hood strut
stud (71).
Use a small flat-bladed tool to pry clip out
while pulling assist rod (8) from hood strut
stud (71).
3. Hood open assist rod (8) from hood strut ball
stud (9).
Use a small flat-bladed tool to pry clip out
while pulling assist rod (8) away from hood
strut ball stud (9).
!++!
Install or Connect
NOTICE:
1. Hood open assist rod (8) to hood strut ball stud

(9).
Snap rod (8) to ball stud (9).
2. Hood open assist rod (8) to hood strut stud (71).
Snap rod (8) onto strut stud (71).
3. Remove hood support.
Hood Open Assist Rod Bracket

Figure 21
!++!
CAUTION: When a hood hold open

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

devise is being removed or installed,
provide alternate support to avoid the
possibility of damage to the vehicle or
personal injury.
1.
2.
3.
4.
1 PANEL, HOOD
86 BOLT/SCREW, HOOD OPEN ASSIST ROD
.J
Safely support hood (1) in full open position.

Upper hood open assist rod attachment.
Hood open assist rod bracket bolts/screws (86).
Hood open assist rod bracket (84) .
86
Figure 21 - Hood Open Assist Rod Bracket (Typical)
01-25-H
F8020105
BODY FRONT END 10519
lH!
Install or Connect
Hood Adjust Front Bumper

Figure 23

1. Hood open assist rod bracket (84).
2. Hood open assist rod bracket bolts/screws (86).
I~!
Tighten
Hood open assist rod bracket bolts/screws (86)

to 23 N.m (17 lb. ft.).
3. Upper hood open assist rod attachment.
4. Remove hood support.
Hood Rear Seal

Figure.22
l++I
1. Hood rear seal fasteners.

2. Hood rear seal (35).
l++I
Install or Connect
1. Hood rear seal (35).

2. Hood rear seal fasteners.
To aid in adjustment, measure hood adjust front

bumper height and record before removing.
l+-+I
Hood adjust front bumper (30).

- Rotate counterclockwise.
l-++!
Install or Connect
1. Hood adjust front bumper (30).

Rotate clockwise until hood adjust front
bumper (30) is at the same height as measured
before removal.
2. Check hood alignment. Refer to "Hood
Hood Air Extractors

l+-+I
1.
2.
3.
4.
5.
Hood insulator front attachments.
Hood air extractor push-on nuts (92).
Hood air extractor nuts (91).
Hood air extractor (37).
Hood air extractor screen bolts/screws (98)
(Pontiac only).
35
!VIEWA!
A FASTENER, HOOD REAR SEAL

35 SEAL, HOOD REAR
Ol2511
FI02110I
Figure 22 - Hood Rear Seal
10520
BODY FRONT END
30
31~
30

30 BUMPER, HOOD ADJUST FRONT
31 CAP, HOOD ADJUST FRONT BUMPER
01-25-95
FS022101
Figure 23 - Hood Adjust Front Bumpers (Typical)
37
1
37
38
91
92
98
PANEL, HOOD
EXTRACTOR, HOOD AIR
NUT, HOOD AIR EXTRACTOR
NUT, HOOD AIR EXTRACTOR iPUSH-ONl
BOLT/SCREW, HOOD AIR EXTRACTOR SCREEN
01-2195
FS023105
Figure 24 - Hood Air Extractor - (Pontiac)
6. Hood air extractor screen (38).

7. Unsnap hood air extractor screen from hood (WS6
Only).
!++!
Install or Connect
NOTICE:
1
37
38
91
92
PANEL, HOOD
EXTRACTOR, HOOD AIR
NUT, HOOD AIR EXTRACTOR
NUT, HOOD AIR EXTRACTOR (PUSH-ON)
01-21-11
FS02410&
Figure 25 - Hood Air Extractor - (Chevrolet)
1. Snap hood air extractor screen to hood

(WS6 Only).
2. Hood air extractor screen (38) to hood air
extractor (37).
3. Hood air extractor screen bolts/screws (98)
(Pontiac only).
BODY FRONT END
!~l
10-5-21
Tighten
Hood air extractor screen bolts/screws (98) to

1.7 N.m (15 lb. in.),
4. Hood air extractor (37) to hood.
5. Hood air extractor nuts (91).
O
l~I
Tighten
Hood air extractor nuts (91) to 3 N .m

(27 lb. in.).
6. Hood air extractor push-on nut (92).
7. Hood insulator front attachments.
PLENUM CHAMBER
Air enters the front plenum chamber through air
inlet screens. The air is drawn through the plenum
chamber to the heater and air conditioning evaporator
module by the blower motor. Air is distributed in the
vehicle through the air distribution system. For air
distribution information, refer to SECTION lA or
1B 1. Water entering the plenum chamber is drained
tluough openings provided for that purpose.
FRONT END SEALING

All potential waterleak locations are sealed in
production with high quality durable sealers. To reseal
specific areas, a high quality medium-bodied sealer
that will remain flexible after curing and can be
painted should be used. Refer to SECTION 10-1.
AIR INLET SCREENS

Figure 26
I++!
93 SCREEN, AIR INLET !PASSENGER SIDE)

94 SCREEN, AIR INLET (DRIVER SIDE)
95 RETAINER, AIR INLET SCREEN
Figure 26 - Air Inlet Screens
3. Retainers (95) to passenger side screen (93).

4. Windshield washer nozzle hose clips to driver side
screen (94).
5. Driver side screen (94).
6. Retainers (95) to driver side screen (94).
7. Windshield wiper arms. Refer to SECTION 8E.
1. Hood rear seal. Refer to "Hood Rear Seal" in this

section.
2. Retainers (95) from driver side screen.
3. Windshield wiper arms. Refer to SECTION 8E.
4. Drivers side screen (94).
5. Windshield washer nozzle hose clips to driver side
screen (94).
6. Retainers (95) from passenger side screens (93).
7. Passenger side screens (93).
8. Windshield washer nozzle hose clips from
passenger side screen (93).
1-++1
Install or Connect
NOTICE:
[I]
Important
Install air inlet screens prior to water testing or

the windshield wiper motor could be damaged.
1. Route windshield washer nozzle hose clips to
passenger side screen (93).
2. Passenger side screen (93).
96 PANEL. BODY HINGE PILLAR TRIM

97 BOLT/SCREW, BODY HINGE PILLAR TRIM PANEL
08-26-96
IFS02G105
Figure 27 - Body Hinge Pillar Trim Panel

(Right Side Shown, Left Side Similar) (Typical)
10-5-22
BODY FRONT END

100
100 BARRIER, DASH SOUND

101 PAN.EL, INSTRUMENT
012111
F802710&
Figure 28 - Dash Sound Barrier (Typical)
8. Check for proper operation of windshield wiper

and washer system.
9. Hood rear seal. Refer to "Hood Rear Seal" in this
section.
BODY HINGE PILLAR TRIM PANEL

Figure 27
!++I
2. Body hinge pillar trim panel (96).
Slide upward and rearward.
I++!
Install or Connect
1. Body hinge pillar trim panel (96).

Slide forward and downward into position.
I~!
Tighten
DASH SOUND BARRIER

Figure 28
I++!

SECTION 8C.
2. Dash sound barrier (100).
E3
Install or Connect
1. Dash sound barrier (100).

SECTION 8C.
BODY HINGE PILLAR INNER PANEL

SOUND BARRIERS
Figure 29
!++!
1. Body hinge pillar trim panel. Refer to "Body

Hinge Pillar Trim Panel" in this section.
2. Body hinge pillar inner panel sound barriers ( 102,
103 and 104 or 105, 106 and 107).
!++!
Install or Connect
1. Paper backing from body hinge pillar inner panel

sound barrier (102, 103 and 104 or 105, 106 and
107).
2. Body hinge pillar inner panel sound barriers ( 102,
103 and 104 or 105, 106 and 107).
3. Body hinge pillar trim panel. Refer to "Body
Hinge Pillar Trim Panel" in this section.
DOOR JAMB SWITCHES

Figure 30
Door jamb switches (108) consist of a plunger,

plunger collar, threaded retainer and terminals. They
are installed in the door hinge pillars. When the door
of the vehicle is closed, the plunger is depressed,
which creates an open in the ground circuit. When the
door is opened, the plunger is released and completes
the circuit to ground.
When a new door jamb switch (108) is installed
and the door is closed the first time, the plunger is
forced into the sleeve and automatically adjusts the
door jamb switch (108) for that particular door. If a
door jamb switch ( 108) fails, it should not be
readjusted by hand. A new door jamb switch (108)
should be installed.
BODY FRONT END
!++!

2. Double or single terminal door jamb switch (108).

4. Seal (109).
!++!
Install or Connect
NOTICE:
10523
A
A DRIVER SIDE
B PASSENGER SIDE
102 BARRIER, BODY HINGE PILLAR INNER PANEL
SOUND (LEFT)
SOUND (LEFT)
.
SOUND (LEFT)

SOUND {RIGHT)
SOUND (RIGHT)
SOUND {RIGHT)
01-25-ts
FS028105
Figure 29 - Body Hinge Pillar Inner Panel Sound Barriers
~..J
~
B
A
A
B
C
108
109
DRIVER SIDE
PASSENGER SIDE
CONNECTOR. ELECTRICAL
SWITCH, DRIVER SIDE DOOR JAMB
SEAL, DOOR JAMB SWITCH
01-25-96
FS0291015
Figure 30 - Door Jamb Switches

1. Seal (109) to door jamb switch (108) until fully
seated.
3. Double or single terminal door jamb switch (108).
!~I
Tighten
Door jamb switch (108) to 6 N.m (53 lb. in.).

EXTERIOR MOLDINGS AND DECAL
PONTIAC
Tighten
Rocker panel molding bolts/screws (117) to

1.5 N,m (13 lb. in.).
3. Rocker panel molding retainers (115 and 119).
4. Rocker panel molding retainer nuts (116).
!~I
Tighten
Front Fender Center Rear Molding
Figure 31
Figures 32 and 33
1. Rear wheelhouse panel liner attachments. Pull rear

portion of liner away from fender.
2. Rocker panel molding retainer nuts (116).
3. Rocker panel molding retainers (115 and 119).
4. Rocker panel molding bolts/screws (117).
5. Rocker panel molding (118).
!++!
l~I
Nuts (116) to 6 N.m (53 lb. in.).

5. Rear wheelhouse panel liner attachments.
Rocker Panel Molding
!++!
1. Rocker panel molding (118).

2. Rocker panel molding bolts/screws (117).
Headlamp Opening Door Decal

PONTIAC
Figure 34
Install or Connect
NOTICE:

adhesive moldings, refer to SECTION 10-1. Refer to
Figures 31 and 32 for correct placement of the
molding (14).

decals, refer to SECTION 10-1. Refer to Figure 35 for
correct placement of the decal (68).
116
13
115
116
117
118
119
120
FENDER, FRONT
RETAINER, ROCKER MOLDING
NUT, ROCKER PANEL MOLDING RETAINER
BOLT/SCREW, ROCKER PANEL MOLDING
MOLDING, ROCKER PANEL
117
119~
Figure 31 - Rocker Panel Molding - (Pontiac)
lvrewej
0121H
FS03010&
BODY FRONT END
10-5-25
14
! SECTION B-8 !
14
7.5mm(0.30")....,...
iFRT
I...-
14
I SECTION A-A I
13 FENDER, FRONT
52 DOOR, FRONT SIDE
031111
FT03110I
Figure 32 Installing Front Fender Center Rear Molding (Pontiac)
Hood Decals
WS6 Package Only (Pontiac)

decals, refer to SECTION 10-1. For correct placement
of the "RAM AIR" decals, refer to Figure 13.
ROOF SIDE RAIL WEATHERSTRIP

RETAINER
Figure 35
l+--+I
1. Lower the upper front portion of front side door

weatherstrip. Refer to SECTION 10-6.
2. Roof side rail weatherstrip retainer bolts/screws

(121).
3. Roof side rail weatherstrip retainer (122).
E3
Install or Connect
NOTICE:

(121).
l~I Tighten
3. Front side door weatherstrip. Refer to
SECTION 10-6.
10-5-26
BODY FRONT END
14
52
ISECTION A-A I
13
14
3.5mm(0.13")
5.0mm(0.20")
14
7.5mm(0.30")....,.
ISECTION B-B I
13 FENDER, FRONT
52 DOOR, FRONT SIDE
(
0323H
FT032105
Figure 33 - Installing Front Fender Center Rear Molding - (Chevrolet)
B. Determine amount of adjustment needed. Refer

to Figures 36 or 37 for hood alignment
specifications.
C. Open hood.
D. Change height by turp.ing the hood bumpers up
or down.
E. Repeat. above steps until hood is properly
aligned.
BODY PANEL ADJUSTMENT AND

ALIGNMENT
Hood Adjustment
The hood, front fenders and hood hinges are
"net build," therefore minimum adjustment can be
made. If the door panel can not be brought into
specifications shown in Figures 36 or 37 by loosening
hood hinge bolts/screws and/or adjusting the hood
adjust front bumpers, the structural body should be
checked for damage or misalignment.
RAISING OR LOWERING REAR CORNERS OF
HOOD
FORE AND AFT ADJUSTMENT
A minimum adjustment can be obtained by

loosening the hood hinge bolts/screws (76) and nuts
(77), then sliding forward or rearward. For best
appearance, adjust one side at a time.
Adjust
Adjust
NOTICE:
e. Hood adjust front bumper.
A. Close
hood firmly.
Hood.
A. Loosen hood hinge to body bolts/screws (76)
and nuts (77).
BODY FRONT END 10527

B. Move hood forward or rearward. Refer to
Figures 36 and 37 for hood alignment
specifications.
A
!~I
Tighten
Hood hinge nuts (77) to 25 N,m (18 lb. ft.).

Hood hinge bolts/screws (76) to 10 N,m
(89 lb. in.).
68
A ALIGN INBOARD EDGE OF DECAL WITH INBOARD
EDGE OF HEADLAMP OPENING DOOR AND ALIGN
LOWER EDGE OF DECAL WITH FORWARD EDGE OF
HEADLAMP OPENING DOOR
36 DOOR, HEADLAMP OPENING
68 DECAL, HEADLAMP OPENING DOOR (FORMULA)
012St5
FI033105
Figure 34 Headlamp Opening Door Decal (Pontiac)
B
A
A STANDARD ROOF
B T-TOPROOF
121 BOLT/SCREW, ROOF SIDE RAIL WEATHERSTRIP
RETAINER
122 RETAINER, ROOF SIDE RAIL WEATHERSTRIP
Figure 35 - Roof Side Rail Weatherstrip Retainer
81HU
P8034105
10-5-28
BODY FRONT END

GAP 4.0 mm 1.5 m ~ m
(0.16 0.06")
GAP PARALLEL WITHIN 1.5 mm 10.06")
.
(
FLUSH UP TO 0.5 mm + 1.0 mm - 0m.:m%
_::c;;;;;,
5
{0.02" + 0.04" ~
~r
51
51
. .---lf---
-l'
( / ~_::"
GAP
0.5 mm 0.5 mm
(0.02" 0.02")
GAP 4.0 mm 1.5 mm

(0.16":t.04")
~ PARALLEL WITHIN 1,5 mm {0.06"1
0"'
\___
~
SECTION A-A
FLU~:H 0.5 mm (0.02")
~.Omm0.05mm
(0.08" 0.02")
PARALLEL WITHIN 0.5 mm (0.02")
SECTIONC-C
13
52
13
---
SECTION B-B
v13
GAP 5.0
GAP2.0mm:t0.5mmf
(0.08" + 0.02") L
PARALLEL WITHIN 0.5 mm-(0.02") T
FLUSH + 0.5 mm 10.02")
mm 1.5 mm 10.20 ! o.~
DOOR FLUSH
TO FENDER 25.4 mm (1.0") FROM
BOTTOM OF DOOR 2.0 mm 2.0 mm
(0.08" + 0.08")
SECTION E-E
52
57
SECTION D-0
GAP 4.0 mm to 7.5 mm ~ (0.16" to 0.30")

DOOR FLUSH TO
FENDER
OUTBOARD 0.0 mm (O.OO"J
INBOARD 1.5 mm (0.06")
13
~
.
___::g
2.0 mm (0.08")
PARALLEL WITHIN 1.0 mm (0.04")
FENDER FLUSH TO
ROCKER PANEL
+1.5 mm (0.06") 0.0 mm 10.00")
SECTION G-G
13
52
SECTIONF-F
FLUSH +0.5 mm (0.02")
,,.,-----
.'L---/
36
1r
mm {0.04'1
j\
SECTION K-K
GAP 4.0 mm 1.5 mm
4
(O. l B" + 0.0 ")
GAP 1.0 mm 0.5 mm (0.04" 0.02")
PARALLEL WITHIN 1.0 mm {0.04"1
FRONT BUMPER FASCIA

0.5 mm (0.02")
DOWN FROM HEADLAMP OPENING
DOOR +0.5 mm (0.02")- 1.0 mm (0.04")
PANEL, HOOD
FENDER, FRONT
DOOR, HEADLAMP OPENING
EXTRACTOR, HOOD AIR
DOOR, FRONT SIDE
PANEL. ROCKER
HEADLAMP
GAP 4.0 mm+ 1.5 mm

(0. 16" 0.06")WITHIN 1.0
13
36
SECTION J-J
1
13
36
37
51
52
57
58
TrjrKLLEL
~-
GAP 4.0 mm 1.5 mm_....\\-:"~

(0.16" + 0.06")
PARALLEL WITHIN
1.0 mm (0.04")
-JI-- GAP
2.0 mm (0.08")
3.0 mm (0.12")
51
---j/::
- , -
37
SECTION M-M
SECTION L-L
Figure 36 - Front End Body Panel Alignment Specifications - (Pontiac)
01-21-95
FS035105
BODY FRONT END
10-5-29
SECTION AA
13
51
GAP 4.0 mm 1.5 mm
(0.16"+ 0.04")
PARALLEL WITHIN 1.5
mm (0.06'.'l
\\ ~ FLUSH+ 0.5
13
mm (0.02")
--,...\\..... GAP 2.0 mm ::: 0.5 mm

(0.08" 0.02")
PARALLEL WITHIN 0.5
mm (0.02")
SECTION CC
SECTION BB
GAP 0.5 mm ::: 0.5

(0.02" :t 0.02")
mm
13
52
13
GAP 5.0 mm 1.5 mm

(0.20" :t 0.06")
DOOR FLUSH
TO FENDER
25.4 mm (1.0") FROM
BOTIOM OF DOOR
2.0 mm 2.0 mm
(0.08" 0.08")
1=:0N~O [
SECTION E-E
--to--1\.- GAP 2.0 mm (0.08") + 3.0 mm (0.12")

2.0
mm (0.08")
SECTION FF
52
DOOR ASSEMBLY 2.0 mm (0.08")
INBOARD TO ROCKER PANEL
=======P~li"".. 1.5 mm (0.06")
1.5 mm
GAP 6.0 mm
(0.24" 0.06")
T
SECTION GG
59
37
1
13
37
51
52
59
SECTION H-H
PANEL, HOOD
FENDER, FRONT
EXTRACTOR, HOOD AIR
DOOR, FRONT SIDE
PANEL, ROCKER OUTER
031815
FT038105
Figure 37 Front End Body Panel Alignment Specifications (Chevrolet)
10-5-30
BODY FRONT END
SPECIFICATIONS
Battery Negative Cable .............................................................................. ;............................. 15 N.m (11 lb. ft)

Body Hinge Pillar Trim Panel Bolt/Screw ........................................................................... 1.3 N.m (12 lb. in.)
Driver Side Door Jamb Switch ............................................... ;................................................ 6 N;m (53 lb. in.)
Front Bumper Fascia Outer Bracket Bolt/Screw................................................................... 10 N.m (89 lb. in.)
Front Fender Bolt/Screw ....................................................................................................... 5.5 N,m (49 lb. in.)
Front Fender Rear Center Bracket Bolt/Screw ....................................................... :............ 5.5 N.m (49 lb. in.)
Front Fender Rear Upper Bracket Bolt/Screw ..................................................................... 5.5 N.m (49 lb. in.)
Front Wheelhouse Panel Liner Bolt/Screw ........................................................................ ,. 1.3 N.m (12 lb. in.)
Front Wheelhouse Panel Liner Bolt/Screw (Lower) ............................................................. 10 N,m (89 lb. in.)
Headlamp Housing Panel Bracket and Pivot Support Bracket Bolt/Screw ........................ 1.7 N.m (15 lb. in.)
Headlamp Housing Panel Bolt/Screw ...................................................................................... 8 N.m (71 lb. in.)
Headlamp Housing Panel Bracket Bolt/Screw ..................................................................... 5.5 N.m (49 lb. in.)
Headlamp Housing Panel Support Bolt/Screw ...................................................................... 10 N.m (89 lb. in.)
Headlamp Housing Panel Upper Bracket Bolt/Screw ........................................ ,.................. 10 N.m (89 lb. in.)
Hood Air Extractor Nut ........................................................................................................... 3 N.m (27 lb. in.)
Hood Air Extractor Screen Bolt/Screw ................................................................................ 1.7 N,m (15 lb. in.)
Hood Body Side Hinge Bolt/Screw ........................................................................................ 27 N.m (20 lb. ft.)
Hood Hinge Bolt/Screw ......................................................................................................... 10 N.m (89 lb. in.)
Hood Hinge Nut ...................................................................................................................... 25 N.m (18 lb. ft.)
Hood Open Assist Rod Bolt/Screw ....................................................................................... 10 N.m (89 lb. in.)
Hood Primary Latch Bolt/Screw ............................................................................................. 18 N.m (13 lb. ft.)
Hood Primary Latch Bracket Nut. ..................................................................................... ~ ... 10 N.m (89 lb. in.)
Hood Primary Latch Release Cable Bolt/Screw ..................................................................... 7 N.m (62 lb. in.)
Hood Primary Latch Support Bolt/Screw .............................................................................. 10 N,m (89 lb. in.)
Hood Secondary Latch Bolt/Screw ....................................................................................... 12 N.m (106 lb. in.)
Passenger Side Door Jamb Switch .......................................................................................... 6 N.m (53 lb. in.)
Radiator Air Lower Deflector Bolt/Screw ............................................................................. 10 N.m (89 lb. in.)
Rocker Panel Molding Bolt/Screw ........................................................................................ 1.5 N.m (13 lb. in.)
Rocker Panel Molding Nut ...................................................................................................... 6 N.m (53 lb. in.)
Roof Side Rail Weatherstrip Retainer Bolt/Screw ................................................................ 1.3 N,m (12 lb. in.)
SPECIAL TOOLS
(
1. HEATGUN
01-26-H
FS03710S
DOORS
10-6-1
SECTION 10-6
DOORS
CAUTION: This vehicle is equipped with Supplemental
CAUTIONS in SECTION 9J under "ON-VEHICLE SERVICE"
Location view in SECTION 9J before performing service on
Failure to follow CAUTIONS could result in possible air
otherwise unneeded SIR system repair.
Inflatable Restraint (SIR). Refer to

and the SIR Components and Wiring
bag deployment, personal injury, or
CAUTION: Make sure to disconnect the power window switch when working inside the driver's
door. When operated, the Express Down feature allows the door window to drop very quickly
which could cause personal injury.
after removal. General Motors will also call the fasteners that require thread locker or thread sealant. UNLESS
sequence and specifications. Following these instructions can help you avoid damage to parts and systems.
CONTENTS
Theft Deterrent Labels ............ Refer to Section OA
Hardware Lubrication .............. Refer to Section OB
Thread Locking Fasteners .............................. 10-6-2
Front Side Door Water Deflectors ................ 10-6-2
Front Side Door Lock Strikers ...................... 10-6-2
Front Side Door Locks .................................. 10-6-2
Front Side Door Outside Handles ................. 10-6-2
Front Side Door Upper and Lower Hinges .. 10-6-2
Outside Rearview Mirrors ............................. 10-6-2
Power Window Control Module .................... 10-6-2
Front Side Door Interior Trim ...................... 10-6-2
Front Side Door Trim Panels .................... 10-6-2
Front Side Door Armrest, Map Pocket
and Radio Front Side Door Speaker
Grilles ..................................................... 10-6-3
Front Side Door Armrest and Radio
Front Side Door Speaker Grille ............ 10-6-3
Accessory Switch Panel and Accessory
Switch Opening Cover ........................... 10-6-7
Front Side Door Inside Handle Bezel ...... 10-6-9
Front Side Door Locking Rod Knob ........ 10-6-10
Front Side Door Exterior Trim ..................... 10-6-11
Front Side Door Center Molding .............. 10-6-11
Front Side Door Emblem .......................... 10-6-12
Door Edge Protector .................................. 10-6-13
Front Side Door Hardware and Front Side
Door Window ............................................. 10-6-14
Front Side Door Weatherstrip ................... 10-'6-14

Front Side Door Window Outer Sealing
Strip ........................................................ 10-6-14
Front Side Door Window Inner Sealing
Strip ........................................................ 10-6-15
Front Side Door Front and Rear Belt
Seals ........................................................ 10-6-15
Front Side Door Bottom Auxiliary Sealing
Strip ........................................................ 10-6-16
Front Side Door Trim Panel Retainer
Seals ........................................................ 10-6-17
Front Side Door Inside Handle Seal ........ 10-6-17
Front Side Door Window Regulator
Counterbalance Arm Channel ....................... 10-6-17
Front Side Door Window Channel and
Front Side Door Window Rear Guide
Channel ................................................... 10-6-18
Side Window, Outside Remote Control
Rearview Mirror Selector and Door
Lock Switches ........................................ 10-6-19
Front Side Door Water Deflector .............. 10-6-19
Outside Rearview Mirror. .......................... 10-6-20
Outside Rearview Mirror Reflective
Glass ....................................................... 10-6-21
Outside Rearview Mirror Applique ........... 10-6-22
Radio Front Side Door Speaker ................ 10-6-23
Radio Front Side Door (Tweeter)
Speaker ................................................... 10-6-23
Front Side Door Outside Handle .............. 10-6-24
106-2
DOORS
Front Side Door Inside Handle ................. 10-6-24

Handle . ., .................................................. 10-6-25
Front Side Door Lock .... ., .......................... 10-6-26
Front Side Door Outside Handle Rod ...... 10-6-27
Front Side Door Inside Handle Rod ......... 10-6-28
Front Side Door Locking Rod .................. 10-6-28
Front Side Door Lock Cylinder Rod ........ 10-6-29
Front Side Door Lock Striker ................... 10-6-29
Front Side Door Lock Striker
Adjustment .............................................. 10-6-30
Front Side Door Lock Striker Anchor
Plate ........................................................ 10-6-30
Frnnt Side Door Interlock Striker ............. 10-6-31
Front Side Door Bumper ........................... 10-6-31
Front Side Door Lock Actuator ................ 10-6-31
Front Side Door Lock Cylinder ................ 10-6-32
GENERAL DESCRIPTION
This section contains the service operations
necessary for removal, installation, adjustment and
sealing of doors, hardware and trim (Figures 1
through 6).
THREAD LOCKING FASTENERS
Front Side Door Upper Hinge .................. 10-6-33

Front Side Door Lower Hinge .................. 10-6-34
Front Side Door ......................................... 10-6-35
Front Side Door Window .......................... 10-6-36
Front Side Door Window Adjustment ...... 10-6-37
Front Side Door Window Front Up
Stop Support ........................................... 10-6-39
Front Side Door Window Stabilizer ......... 10-6-40
Front Side Door Window Front and Rear
Bumpers .................................................. 10-6-40
Front Side Door Window Regulator ......... 10-6-41
Motor ...................................................... 10-6-42
Specifications ...................................................... 10-6-43
Special Tools ...................................................... 10-6-44
FRONT SIDE DOOR UPPER AND LOWER

HINGES
The hinges are steel and are fastened with
bolts/screws and nuts. The hinges are directly
accessible.
OUTSIDE REARVIEW MIRRORS
All factory installed door hardware attaching

bolts/screws contain an epoxy thread-locking
compound to ensure that torque will be maintained.
Service replacement bolts/screws may not
contain a thread-locking compound. Such bolts/screws
may be treated with GM PIN 1052279, Loctite 75,
or equivalent. The adhesive is placed on the fastener
prior to installation. After the fastener is installed and
tightened, the adhesive will cure, preventing the
fastener from becoming loose.
The left-hand mirror is remote control and the

right-hand mirror is direct control. Electric control is
optional.
FRONT SIDE DOOR WATER DEFLECTORS
ON-VEHICLE SERVICE

The power window control module (express
down) fully lowers the driver's front side door window
when the side window switch is pressed quickly and
released.
Front side door water deflectors are used to seal

the door inner panels, preventing water entry.
FRONT SIDE DOOR INTERIOR TRIM
FRONT SIDE DOOR LOCK STRIKERS
Front Side Door Trim Panels
Each lock striker is a dual-pin type that attaches

to an anchor plate in the body lock pillar. The door is
held in the closed position when the lock snaps over
and engages the striker.
An interlock striker is also installed to the body
lock pillar. It engages into a slot in the door.
Figures 6 and 7
FRONT SIDE DOOR LOCKS

The door locks use the fork bolt lock design
which includes a safety interlock feature. The door is
secured in the dosed position when the fork bolt
engages the striker. Doors can be locked from the
inside by moving the knob rearward and from the
outside using the oval-headed key.
FRONT SIDE DOOR OUTSIDE HANDLES

The outside handles actuate the locks through
rods.
l+-+I
1. Accessory switch panel or accessory switch

opening cover, as equipped. Refer to "Accessory
Switch Panel and Accessory Switch Opening
Cover" in this section (Pontiac only).
2. Front side door inside handle bezel. Refer to
"Front Side Door Inside Handle Bezel" in this
section.
3. Front side door window regulator handle and front
side door window regulator handle spacer. Refer
to "Front Side Door Window Regulator Handle"
in this section.
4. Outside rearview mirror bezel. Refer to "Outside
Rearview Mirror" in this section.
DOORS
10-6-3
NOTICE: Do not try to pull trim panel

straight off door, or hooks in trim panel will
break. To disengage hooks, trim panel must be
lifted up and then pulled away from door.
Front Side Door Armrest, Map Pocket and

Radio Front Side Door Speaker Grilles
6. Trim panel (89).
Figures 3 and 4
A. Pull slightly on rear of trim (89) to release tab.

B. Lift up on trim (89).
C. Pull trim (89) away from door (152), making
sure that hooks release from holes in door
inner panel.
D. Disconnect radio front side door (tweeter)
speaker electrical connector, if equipped
(Pontiac only).
E. Remove courtesy lamp socket from trim (89).
[I]
Important
PONTIAC
These components of the trim panel (89) are

held in position with heat stakes. These components
are included with the replacement part trim panel, but
they can also be serviced separately.
!++I
1. Front side door trim panel. Refer to "Front Side

Door Right and Left Trim Panels" in this section.
2. Armrest (95), pocket (110) and grille (98 and 99).
If trim panel is being replaced, radio front side
A. Peel back the sound deadener.

B. Using a soldering iron, melt heat stakes
retaining armrest (95), pocket (110) or grille
(98 or 99).
C. Pull armrest (95), pocket (110) and grille
(98 and 99) from trim (89).
door (tweeter) speaker, if equipped, must be

removed from trim panel and transferred to
new trim panel. Refer to "Radio Front Side
Door (Tweeter) Speaker" in this section
(Pontiac only).
!-++!
Install or Connect
NOTICE:
1. Trim (89) to door inner panel.

A. Insert hooks along bottom of trim (89) part
way into holes in door inner panel.
B. Route electrical connectors through opening in
trim panel (89), if equipped.
C. Install courtesy lamp socket to trim panel (89).
D. Connect radio front side door (tweeter) speaker
electrical connector (Pontiac only).
E. Align upper edge of trim panel (89) over door
inner panel flange and insert remaining hooks
into holes.
F. Push downward to engage hooks.
G. Push rear of trim panel (89) into door (152) to
engage tab.
!~!
Tighten

3. Outside rearview mirror bezel. Refer to "Outside
4. Front side door window regulator handle and front
side door window regulator handle spacer. Refer
to "Front Side Door Window Regulator Handle"
in this section.
section.
opening cover, as equipped. Refer to "Accessory
Switch Panel and Accessory Switch Opening
Cover" in this section (Pontiac only).
!++I
Install or Connect
1. Armrest (95), pocket (110) and grille (98 and 99).

A. Insert heat stakes through holes in trim (89).
B. Melt heat stakes using a soldering iron.
C. Press melted heat stakes flat using suitable
surface.
D. Apply adhesive to sound deadener.
E. Reposition sound deadener.
Front Side Door Armrest and Radio Front

Side Door Speaker Grille
CHEVROLET
Figures 4 and 5
These components of the trim panel (89) are
held in position with heat stakes. These components
are included with the replacement part trim panel, but
they can also be serviced separately.
i++!

2. Armrest (89) or grille (98).
A. Peel back sound deadener.
B. Using soldering iron, melt heat stakes retaining
armrest (95) or grille (98).
C. Pull armrest (95) or grille (98) from trim panel
(89).
1064 D=O=O=R=-s_ __
10
,.;,alp
~.~
20
A
2s
23
26
81-26-05
FS00110fl
.
Door (Typical)
Figure 1 - Front Side
DOORS
A WITH ELECTRIC-OPERATED SIDE WINDOW

B WITHOUT ELECTRIC-OPERATED SIDE WINDOW
1 WINDOW, FRONT SIDE DOOR
2 RETAINER, FRONT SIDE DOOR WINDOW BUSHING
3 PIN, FRONT SIDE DOOR WINDOW STABILIZER
4 BOLT/SCREW, FRONT SIDE DOOR WINDOW STABILIZER
PIN
5 RETAINER, FRONT SIDE DOOR FRONT BELT SEAL
6 SEAL, FRONT SIDE DOOR REAR BELT
7 BOLT/SCREW, FRONT SIDE DOOR LOCK ACTUATOR
8 ACTUATOR, FRONT SIDE DOOR LOCK
9 LOCK, FRONT SIDE DOOR
10 BOLT/SCREW, FRONT SIDE DOOR LOCK
11 CLIP, FRONT SIDE DOOR LOCKING ROD
12 RETAINER, FRONT SIDE DOOR OUTSIDE HANDLE ROD
13 ROD, FRONT SIDE DOOR OUTSIDE HANDLE
14 ROD, FRONT SIDE DOOR LOCK CYLINDER
16 BUMPER, FRONT SIDE DOOR
.18 CHANNEL, FRONT SIDE DOOR WINDOW
19 RIVET, FRONT SIDE DOOR WINDOW
20 REGULATOR, FRONT SIDE DOOR WINDOW
21 CHANNEL, FRONT SIDE DOOR WINDOW
REGULATOR COUNTERBALANCE ARM
22 NUT, FRONT SIDE DOOR WINDOW REGULATOR
COUNTERBALANCE ARM CHANNEL
23 RIVET, FRONT SIDE DOOR WINDOW REGULATOR
24 SPACER, FRONT SIDE DOOR WINDOW REGULATOR
HANDLE
25 SPRING, DOOR WINDOW REGULATOR HANDLE
26 HANDLE, FRONT SIDE DOOR WINDOW
REGULATOR
27 NUT, FRONT SIDE DOOR WINDOW REAR GUIDE
CHANNEL,
REAR GUIDE
CHANNEL
30 SEALING STRIP, FRONT SIDE DOOR BOTIOM
AUXILIARY
31 BUMPER, FRONT SIDE DOOR WINDOW REAR
32 KNOB, FRONT SIDE DOOR LOCKING ROD
33 BUMPER. FRONT SIDE DOOR WINDOW FRONT
34 RIVET, FRONT SIDE DOOR INSIDE HANDLE
35 HANDLE, FRONT SIDE DOOR INSIDE
36 BOLT/SCREW, OUTSIDE REARVIEW MIRROR APPLIQUE
37 NUT, OUTSIDE REARVIEW MIRROR OPENING
APPLIOUE
38 HINGE, FRONT SIDE DOOR LOWER
39 NUT, FRONT SIDE DOOR LOWER HINGE
40 GROMMET, DOOR WIRING HARNESS
41 NUT, FRONT"SIDE DOOR UPPER HINGE
1065
42 HINGE, FRONT SIDE DOOR UPPER

43 WASHER, OUTSIDE REARVIEW MIRROR APPLIQUE
44 SUPPORT. FRONT SIDE DOOR WINDOW
FRONT UP STOP
45 NUT, FRONT SIDE DOOR WINDOW FRONT UP STOP

46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
116
136
152
SUPPORT
CLIP, FRONT SIDE DOOR INSIDE HANDLE ROD
ROD, FRONT SIDE DOOR INSIDE HANDLE
CLIP, FRONT SIDE DOOR LOCKING ROD
ROD, FRONT SIDE DOOR LOCKING
SEAL, FRONT SIDE DOOR INSDE HANDLE
STABILIZER, FRONT SIDE DOOR WINDOW
BOLT/SCREW, FRONT SIDE DOOR WINDOW STABILIZER
BOLT/SCREW, FRONT SIDE DOOR WINDOW FRONT UP
STOP
STOP, FRONT SIDE DOOR WINDOW FRONT UP
APPLIQUE, OUTSIDE REARVIEW MIRROR
SEAL, FRONT SIDE DOOR FRONT BELT
NUT, FRONT SIDE DOOR WINDOW FRONT UP STOP
WASHER, FRONT SIDE DOOR WINDOW FRONT UP
STOP
BUSHING, FRONT SIDE DOOR WINDOW
WEDGE, FRONT SIDE DOOR WINDOW
NUT, FRONT SIDE DOOR WINDOW STABILIZER PIN
SEALING STRIP, FRONT SIDE DOOR
WINDOW OUTER
STRIKER, FRONT SIDE DOOR INTERLOCK
SPACER, FRONT SIDE DOOR INTERLOCK STRIKER
PLATE, FRONT SIDE DOOR LOCK STRIKER ANCHOR
WASHER, FRONT SIDE DOOR LOCK STRIKER
SPACER, FRONT SIDE DOOR LOCK STRIKER
STRIKER, FRONT SIDE DOOR LOCK
BOLT/SCREW, FRONT SIDE DOOR LOCK STRIKER
NUT, FRONT SIDE DOOR OUTSIDE HANDLE
CLIP, FRONT SIDE DOOR LOCK CYLINDER PAWL
RETAINER, FRONT SIDE DOOR LOCK CYLINDER
GASKET, FRONT SIDE DOOR LOCK CYLINDER
CYLINDER UNIT, LOCK
CLIP, FRONT SIDE DOOR OUTSIDE HANDLE
HANDLE, FRONT SIDE DOOR OUTSIDE
FILLER, FRONT SIDE DOOR OUTSIDE HANDLE
PROTECTOR, DOOR EDGE
BOLT/SCREW, FRONT SIDE DOOR UPPER HINGE
BOLT/SCREW, FRONT SIDE DOOR LOWER HINGE
WASHER, FRONT SIDE DOOR INTERLOCK STRIKER
REGULATOR, FRONT SIDE DOOR WINDOW
MOTOR, FRONT SIDE DOOR WINDOW
REGULATOR
DOOR, FRONT SIDE
ROD, FRONT SIDE DOOR LOCK CYLINDER
DOOR, FRONT SIDE
01-25-15
FS002108
Figure 2 - Front Side Door - Legend (Typical)
10-6-6 DOORS
(
84
87
89
5
85~-i:,'\i_~
4
I.
,A
--~
jv1EwA[~,
01-2595
FS003108
Figure 3 Front Side Door (Pontiac)
DOORS
A WITH QUAD FRONT DOOR-MOUNTED SPEAKERS
8 WITH DUAL FRONT DOOR-MOUNTED SPEAKERS
c DRIVER'S SIDE MANUAL REMOTE CONTROL

D DRIVER'S SIDE ELECTRIC CONTROL
E JACK SCREW
F TRUNNION, OUTSIDE REARVIEW MIRROR
55 APPLIQUE, OUTSIDE REARVIEW MIRROR
84 BEZEL, OUTSIDE REARVIEW MIRROR
85 BOLT /SCREW, OUTSIDE REARVIEW MIRROR BEZEL
86 DEFLECTOR, FRONT SIDE DOOR WATER
87 NUT, FRONT SIDE DOOR ARMREST
88 SEALING STRIP, FRONT SIDE DOOR WINDOW INNER
89 TRIM, FRONT SIDE DOOR
90 BOLT/SCREW, FRONT SIDE DOOR ARMREST
91 BEZEL, FRONT SIDE DOOR INSIDE HANDLE
92 PANEL, ACCESSORY SWITCH
93 SWITCH, DOOR LOCK
94 SWITCH, SIDE WINDOW
95 ARMREST. FRONT SIDE DOOR
96 SOLT/SCREW, FRONT SIDE DOOR ARMREST
97 BOLT/SCREW, FRONT SIDE DOOR INSIDE HANDLE
BEZEL
98 GRILLE, RADIO FRONT SIDE DOOR SPEAKER
99 GRILLE, RADIO FRONT SIDE DOOR TWEETER
101 NUT, OUTSIDE REARVIEW MIRROR
103 GLASS, OUTSIDE REARVIEW MIRROR REFLECTIVE
104 MIRROR, OUTSIDE REARVIEW
109 MIRROR, OUTSIDE REARVIEW
110 POCKET, FRONT SIDE DOOR MAP
152 DOOR, FRONT SIDE
(CHEVROLET)
0121595
FS004108
Figure 4 - Front Side Door - Legend
!++!
Install or Connect
1. Armrest (95) or grille (98).
A. Insert heat stakes through holes in trim

assembly (89).
B. Melt heat stakes using soldering iron.
surface.
D. Apply adhesive to sound deadener.
E. Reposition sound deadener.

Switch Opening Cover
Figures B and 9
If the vehicle is equipped with side window,
mirror selector or door lock switches (92, 93 and 114
or 94, 218), it will have a accessory switch panel (92).
If the vehicle is not equipped with any of these
switches, then it will have a cover. Both parts are
removed in the same way.
10-6-7
NOTICE: When removing the accessory

switch panel, the ignition switch must be in the
''OFF'' position and retained accessory power
(RAP) must not be present. This will eliminate
the possibility of shorting out the switch if a
screwdriver, awl or metal object is used.
PONTIAC
!++I
Accessory switch panel (92) or accessory switch

cover.
A. Pry at front and rear of accessory switch panel
(92) or accessory switch cover with a
flat-bladed tool to release metal clips.
B. Disconnect electrical connectors, if equipped.
C. Remove switches, if equipped and accessory
switch panel is being replaced. Refer to "Side
Window, Outside Remote Control Rearview
Mirror Selector and Door Lock Switches" m
this section.
!++!
Install or Connect
Accessory switch panel (92) or accessory switch

cover.
A. Install switches if removed. Refer to "Side
Mirror Selector and Door Lock Switches" in
this section.
B. Connect electrical connectors, if equipped.
C. Position accessory switch panel (92) or
accessory switch cover and press to secure
clips.
CHEVROLET
!++!

section.
2. Accessory switch panel (92) or accessory switch
cover.
A. Squeeze metal clips to release from handle
bezel.
!L"'l
Inspect
Clips for proper position.

B. Remove switches, if equipped and accessory
switch panel is being replaced. Refer to "Side
this section.
88
89
93 9 ~
~Q~
~94
~.
98
10~~
IVIEW A I
109
55
103
6
c
(
Figure 5 Front
side
Door (Chevrolet)
DOORS
A CONNECTOR, RADIO FRONT.,SIDE DOOR SPEAKER

(TWEETER) ELECTRICAL
90 SOLT/SCREW, FRONT SIDE DOOR ARMREST
1069
90
012516
FS006108
Figure 6 - Front Side Door Trim (Right Shown, Left Similar) - (Pontiac)
52
89
\

90 BOLT/SCREW, FRONT SIDE DOOR ARMREST
90
012595
FS007106
Figure 7 - Front Side Door Trim (Right Shown, Left Similar) - (Chevrolet)
!++!
Install or Connect
1. Accessory switch panel (92) or accessory switch

cover.
,
A. Install switches if removed. Refer to "Side
this section.
B. Position accessory switch panel (92) or
accessory switch cover and press to secure
clips.
section.
Front Side Door Inside Handle Bezel

Figures 10 and 11
!++!

opening cover. Refer to, "Accessory Switch Panel
and Accessory Switch Opening Cover" in this
section (Pontiac only).
2. Front side door locking rod knob. Refer to "Front
Side Door Locking Rod Knob" in the following
procedure.
3. Bolt/screw (97).
10-6-10
DOORS
4. Bezel (91 or 203).

A. Slide bezel (91) forward to release from trim
panel (Pontiac only).
B. Unsnap bezel (203) from trim panel (Chevrolet
only).
C. Disconnect electrical connectors, if equipped
(Chevrolet only).
D. Squeeze metal clips on accessory switch panel
or accessory switch cover to release from
bezel (203), if replacing bezel (203) (Chevrolet
only).
IL!
Inspect
Clips for proper position (Chevrolet only).
5. Switch illumination lamp socket by turning socket

and removing from bezel (91 or 203).
!H!
D. Position accessory switch panel or accessory

switch cover to bezel (203) and press to secure
clips, if removed (Chevrolet only).
E. Snap bezel (203) into trim panel (Chevrolet
only).
3. Bolt/screw (97).
!~!
Tighten
4. Front side door locking rod knob. Refer to "Front

Side Door Locking Rod Knob" in the followin.g
procedure.
opening cover. Refer to "Accessory Switch Panel
and Accessory Switch Opening Cover" in this
Install or Connect
Front Side Door Locking Rod Knob

NOTICE:
1. Switch illumination lamp socket.

2. Bezel (91 or 203).
A. Route inside handle (35) and locking rod
through appropriate openings in bezel (91 or
203).
B. Position bezel (91) and slide rearward (Pontiac
only).
C. Connect electrical connectors, if equipped
(Chevrolet only).
Figure 12
l++I
Knob (32).
A. Slide knob (32) forward.
B. Insert a small flat-bladed tool behind end of
knob (32) and pry it away from locking rod
(49).
~-r--B
f'A <:~~.:---i----
94
c
A CONNECTOR, DOOR LOCK SWITCH ELECTRICAL
8 CONNECTOR, OUTSIDE REMOTE CONTROL
c
92
93
94
114
115
REARVIEW MIRROR SELECTOR SWITCH ELECTRICAL

CONNECTOR, SIDE WINDOW SWITCH ELECTRICAL
PANEL ACCESSORY SWITCH
SWITCH, DOOR LOCK
SWITCH, SIDE WINDOW
SWITCH, OUTSIDE REMOTE CONTROL
REARVIEW MIRROR SELECTOR
HARNESS, CROSSBODY AND FRONT SIDE
0126t5
DOOR WIRING
FSOCl8106
Figure 8 Accessory Switch Panel (Pontiac)
A PIGTAIL, OUTSIDE REMOTE CONTROL REARVIEW

MIRROR SELECTOR SWITCH
8 CONNECTOR, OUTSIDE REMOTE CONTROL REARVIEVI
MIRROR SELECTOR SWITCH ELECTRICAL
CONNECTOR, DOOR LOCK SWITCH ELECTRICAL

D CONNECTOR, SIDE WINDOW SWITCH ELECTRICAL
115 HARNESS, CROSSBODY AND FRONT SIDE
DOOR WIRING
218 SWITCH, OUTSIDE REMOTE CONTROL REARVIEW
012695
MIRROR SELECTOR
FS009108
Figure 9 Accessory Switch Panel (Chevrolet)
DOORS

97 BOLT/SCREW, FRONT SIDE DOOR INSIDE HANDLE
BEZEL
115 HARNESS, CROSSBODY AND FRONT SID.E
DOOR WIRING

49 ROD, FRONT SIDE DOOR LOCKING
01-l!&-95
01-28-95
FS010105
Figure 10 - Front Side Door Inside Handle Bezel

(Right Shown, Left Similar) - (Pontiac)
10-611
FS012105
Figure 12 - Installing Front Side Door Locking Rod Knob

(Typical)
!++I
Install or Connect
Knob (32).
A. Position knob (32) over locking rod (49) and
insert end of knob (32) through hole in handle
bezel.
B. Slide knob (32) rearward over locking rod (49)
until end of locking rod ( 49) fits into
depression in knob (32).
C. Snap knob (32) over locking rod (49).
FRONT SIDE DOOR EXTERIOR TRIM
Front Side Door Center Molding

Figures 13 and 14
35
97
HANDLE, FRONT SIDE DOOR INSIDE

BOLT /SCREW, FRONT SIDE DOOR INSIDE HANDLE
BEZEL
115 HARNESS, CROSSBODY ANO FRONT SIDE DOOR
WIRING
01-28-95
FS011108
Figure 11 - Front Side Door Inside Handle Bezel

(Right Shown, Left Similar) - (Chevrolet)

adhesive moldings, refer to SECTION 10-1. Refer to
Figures 14 and 15 for correct placement of the
molding (117).
10-6-12
DOORS
116
I SECTION A-A I
152
152
117
5.0 m m ( 0 . 2 0 " ~ ~ 3 . 5 mm (0.14")

117
117
152
MOLDING, FRONT SIDE DOOR CENTER

DOOR, FRONT SIDE
.FRT I SECTION B-8 I

01-28-85
FS013101
Figure 13 - Installing Front Side Door Center Molding - (Pontiac)
117
152
I SECTION A-A I
152
~~~
117
5.0 mm (0.20")
FRT
11 7 MOLDING, FRONT SIDE DOOR CENTER

3.5 mm (0. 14")
ISECTION B-B I
91-21-85
FSG1410I
Figure 14 - Installing Front Side Door Center Molding - (Chevrolet)
Front Side Door Emblem
B. Gently pull emblem (118) from door (152)

with flat-bladed tool, making sure not to
damage paint.
PONTIAC
Figure 15
l++I
Tool Required:
J 25070 Heat Gun
Emblem (118).
emblem (118). Apply heat in an even and
circular motion.
Clean

naphtha.
2. Area with clean, dry cloth.
!++!
Install or Connect
New emblem (118).
DOORS
A. Heat door surface and adhesive side of new

(80F) or 6C (10F) above air temperature in
40c (105F).
14.0 mm (0.55")
[
5{.-:c=/-8
2-=t:o
-it
10-6-13
\
'
[I]
mm (1.6")
152
Important

C. Press emblem ( 118) into place and apply
pressure.
Door Edge Protector

Figure 16
118
!++!
Tool Required:
J 25070 Heat Gun
Door edge protector (78).
door edge protector (78). Apply heat in an
even and circular motion.
B. Peel door edge protector (78) from door (116)
with flat-bladed tool, making sure not to
damage paint.
20.0 m~ (0.79")
Uc::::::~
-(?
w-\...58.0 mm (2.3")
152
Clean

naphtha.
~-<
78
/\i~
A~\
118
A LINER, PROTECTIVE
8 LOWER EDGE OF FRONT SIDE DOOR CENTER
MOLDING
118 EMBLEM, FRONT SIDE DOOR
01-2695
FS015108
Figure 15 Installing Front Side Door Emblem (Pontiac)
78
I SECTION A-A I
A LINER, TAPE
78 PROTECTOR, DOOR EDGE
01-2195
FS011108
Figure 16 Installing Door Edge Protector
10-6-14
!HI
DOORS
install or Connect
Door edge protector (78).

A. Remove liner from door edge protector (78).
B. Line up top of door edge protector (78) to
bottom of handle at outer edge of door (116).
[I]
Important
Be sure that inside corner of door edge

protector is against edge of door.
C. Press entire length of tape area to secure.
FRONT SIDE DOOR HARDWARE AND

FRONT SIDE DOOR WINDOW
Front Side Door Weatherstrip
Figures 17 and 18
l++I
1.
2.
3.
4.
5.
6.
!HI
Tool Required:
J 21104-B Universal Weatherstrip Remover
Body hinge pillar trim panel. Refer to
SECTION 10-5.
Windshield pillar trim panel. Refer to
SECTION 10-5.
Rear quarter trim panel. Refer to SECTION 10-7.
Bolts/screws (124), if equipped.
Retainers (121) using J 21104-B.
Weatherstrip (122).
A. Pull weatherstrip (122) from flange and
weatherstrip retainers.
B. Break adhesive bond at front belt with a
flat-bladed tool.
121 RETAINER, FRONT SIDE DOOR WEATHERSTRIP

122 WEATHERSTRIP, FRONT SIDE DOOR
123 SOLT/SCREW, FRONT SIDE DOOR WEATHERSTRIP
03-24-95
fT017106
Install or Connect
NOTICE:
1. Remove protective liner from adhesive strip on

weatherstip (122).
2. Position weatherstrip (122) at front belt.
3. Retainer (121) at front belt.
4. Weatherstrip (122).
A. Insert weatherstrip (122) into retainer up hinge
pillar.
B. Install retainer (121) at lock pillar belt.
C. Insert weatherstrip (122) into retainers up lock
pillar and across roof.
D. Roll weatherstrip (122) into retainer.
a. Starting at lock pillar belt, roll up to comer
and back down to belt.
b. Starting at lock pillar top corner, roll
forward to front belt and back to lock pillar
top comer.
E. Insert weatherstrip (122) into flange below belt
at front, bottom and back.
F. Roll entire length to seat.
5. Bolts/screws (124), if equipped.
6. Rear quarter trim panel. Refer to SECTION 10-7.
Figure 17 - Front Side Door Weatherstrip
7. Windshield pillar trim panel. Refer to

SECTION 10-5.
8. Body hinge pillar trim panel. Refer to
SECTION 10-5.

Strip
Figure 19
I+ +j
1. Lower window.
2. Sealing strip (62) by pulling to release the spring
clips.
I++!
Install or Connect
Sealing strip (62).

A. Align spring clips to slots in door outer panel
reinforcement and insert clips.
B. Tap to secure clips.
C. Ensure that sealing strip (62) is seated flush to
the door outer panel.
DOORS
RETAINER, FRONT SIDE

DOOR WEATHERSTRIP
122 WEATHERSTRIP, FRONT
SIDE DOOR
123 BOLT/SCREW. FRONT SIDE
DOOR WEATHERSTRIP
124 BOLT/SCREW, ROOF LIFT-OFF
WINDOW BODY SIDE WEATHERSTRIP
10-6-15
121
jv1Ewcl
03-24-95
FTG1810I
Figure 18 - Front Side Door Weatherstrip (With Roof Lift-Off Panels) (Typical)

Strip
Figures 3 through 5
!++!
l. Front side door trim panel. Refer to "Front Side

2. Inner sealing strip (88) by removing staples.
lH!
1. Inner sealing strip (88) to trim panel (89).

2. Staples to secure inner sealing strip (88) to trim
panel (89).
Front Side Door Front and Rear Belt Seals

Figure 20
!+-+!
62
Install or Connect
152

2. Retainers (5) by prying out with a flat-bladed
tool.
Discard retainers (5).
3. Seal (6 or 56).
!-++!
A DOOR INNER PANEL
62 SEALING STRIP, FRONT SIDE DOOR
WINDOW OUTER
152 DOOR. FRONT SIDE
01-28-95
FB019108
Figure 19 - Front Side Door Window Outer Sealing Strip
Install or Connect
1. Seal (6 or 56).
2. New retainers (5).
10616 DOORS

Strip
Figure 21
!++!
Tool Required:
J 25070 Heat Gun
Sealing strip (30).

sealing strip (30). Apply heat in an even and
circular motion.
B. Pull sealing strip (30) from door (152) with
flat-bladed tool, making sure not to damage
paint.
~
152
5
6
56
152
RETAINER, FRONT SIDE DOOR FRONT BELT SEAL

SEAL, FRONT SIDE DOOR REAR BELT
SEAL, FRONT SIDE DOOR FRONT BELT
DOOR, FRONT SIDE
01-26-15
FS020106
Figure 20 - Front Side Door Front and Rear Belt Seals

(Typical)
Clean

naphtha.
!++I
Install or Connect
New sealing strip (30).

A. Heat door surface and adhesive side of new
sealing strip (30). Temperature must be 35C
3c (95F 5F)~
B. Remove protective liner from adhesive strip.
152
30
A LOCATING FEATURE
30 SEALING STRIP, FRONT SIDE DOOR BOTIOM
AUXILIARY
I SECTION A-A I
01-28-95
FS021108
Figure 21 - Installing Front Side Door Bottom Auxiliary Sealing Strip (Typical)
rn
DOORS,. 10-617
Important
Position sealing strip carefully. Sealing strip

cannot be removed witho.ut reapplying
C. Align sealing strip (30) to locating feature
starting at rear edge of door inner panel.
D. Press sealing strip (30) into place and apply
pressure along entire surface.
Front Side Door Trim Panel Retainer Seals

Figure 22
I+-.!
126

2. Seals (126).
!++!
Install or Connect
1. Seals (126).
152
126 SEAL, FRONT SIDE DOOR TRIM PANEL RETAINER

012815
FS022108
Figure 22 Front Side Door Trim Panel Retainer Seals

(Typical)
Front Side Door Inside Handle Seal

Figure 23
!+-.!

section.
2. Seal (50).
!++!

50 SEAL, FRONT SIDE DOOR INSIDE HANDLE
Install or Connect
01-28-15
FS023108
1. Seal (50) and press down to base of handle (35).
Install seal (50) with smooth side toward door

inner panel.
section.

Counterbalance Arm Channel
Figures 24 and 25
I+-.!
CAUTION: When activated, the front side

door window switch may lock into the
express down mode causing the driver's
front side door window to lower fully
without stopping even though the switch
has been released. Failure to exercise
caution around the front side door
window regulator when operating the
switch may result in personal injury and
regulator damage.
1. Raise window.
Figure 23 Front Side Door Inside Handle Seal

3. Front side door water deflector as needed. Refer
to "Front Side Door Water Deflector" in this
section.
4. Nuts (22) attaching channel (21) to door inner
panel.
5. Channel (21) from window regulator balance arm
roller.
6. Channel (21) through access hole.
!++!
Install or Connect
NOTICE:
1. Channel (21) through access hole to window

regulator balance arm roller.
2. Channel (21) to door inner panel.
3. Nuts (22).
10-618
!~!
DOORS
Tighten
Nuts (22) to 10 N.m (89 lb. in.).

4. Front side door water deflector. Refer to "Front
Side Door Water Deflector" in this section.

Front Side Door Window Rear Guide
Channel
Figures 26 and 27
!++I
1. Front side door window. Refer to "Front Side

Door Window" in this section.
2. Nuts (27 and 29).
3. Channel (18) with rear guide channel (28)
attached from regulator rollers.
4. Channel (18) through access hole.
5. Rear guide channel (28) from channel roller.
!++!
Install or Connect
NOTICE:
1. Rear guide .channel (28) to channel roller.

2. Channel (18) with rear guide channel (28) through

152 DOOR. FRONT SIDE
01-2685
FS024106
Figure 24 Removing Front Side Door Window Regulator

Counterbalance Arm Channel Nuts (Typical)
access hole, allowing rear guide channel (28) to

drop.
3. Channel (18) to regulator rollers.
A. Insert front of channel (18) onto front
regulator roller.
B. Push forward until rear edge of channel (18)
lines up with rear roller.
C. Insert rear roller onto channel (18) by pushing
rearward.
4. Align studs on rear guide channel (28) to slots in
door inner panel.
152
I SECTION A-A I
A LUBRICATE
033195
FT025108
Figure 25 Removing Front Side Door Window Regulator Counterbalance Arm Channel (Typical)
DOORS

CHANNEL
'
CHANNEL
.
.152 DOOR, FRONT SIDE
01269&
FS026108
Figure 26 Removing Front Side Door Window Rear

Guide Channel Nuts (Typical)
5. Nuts (27 and 29).
l~!
10-6-19
I SECTION A-A I
1 WINDOW, REAR COMPARTMENT LIFT
2 LACE, LIFTGATE WINDOW OPENING FINISH
041895
FT027108
Figure 27 Removing Front Sid eDoor Window Channel

and Front Side Door Window Rear Guide Channel
(Typical)
Tighten
Nut (27) to 10 N.m (89 lb. in:).

Nuts (29) to 27 N,m (20 lb. ft.);
6. Front side door window. Refer to "Front Side
Door Window" in this section.

Rearview Mirror $elector and Door Lock
Switches
Figures 28 and 29
!++!
1. Accessory switch panel. Refer to "Accessory

Switch Panel" in this section.
2. Switch (93, 94 or 114) on Pontiac or switch (93,
94 or 218) on Chevrolet by prying with a
flat-bladed tool to release switch (93, 94, 114, or
218) from accessory switch panel (92).
!++!
Install or Connect
1. Switch (93, 111, 114, or 218) into accessory
switch panel (92).

2. Accessory switch panel. Refer to "Accessory
Switch Panel" in this section.
Front Side Door Water Deflector

Figure 30
Whenever work is performed where the.deflector
(86) is disturbed, the deflector (86) must be properly
sealed and taped to the door inner panel to prevent
waterleaks. For service sealing, strip caulking is
recommended if additional sealing material is required.
A CONNECTOR, DOOR LOCK SWITCH ELECTRICAL

C CONNECTOR, SIDE WINDOW SWITCH ELECTRICAL
MIRROR SELECTOR
012895
FS028108
Figure 28 Removing Switches (Typical) (Pontiac)
When access to the. door inner panel. is. required

to perform. service operations, the deflector (86) may
be completely or partially detached from the door
inner panel. .If the existing d,eflector (86) is damaged
so that it will not properly seal the door assembly,
.
replace the deflector (86).
If only partial removal of the deflector (86) is
required, perform only the steps that are necessary to
expose the required area of the door inner panel.
l++I
Install or Connect

10-6-20
DOORS
tFRT
152
86
B
A
~115
A PIGTAIL, OUTSIDE REMOTE CONTROL REARVIEW

MIRROR SELECTOR SWITCH
C CONNECTOR, DOOR LOCK SWITCH ELECTRICAL
D CONNECTOR, SIDE WINDOW SWITCH ELECTRICAL
MIRROR SELECTOR
012895
FS029108
. Figure 29 Removing Switches (Typical) (Chevrolet)
2. Water deflector (86).

A. Break the sealer bond with a flat-bladed tool.
B. Peel tape from door inner panel.
C. Disconnect tabs on lower edge of deflector
(86) from slots in door inner panel.
IL!
Inspect
Water deflector (86) for tears or hqles .. Repair

using waterproof body tape on both sicles of water
deflector (86) or replace deflector (86).
!++!
t
Install or Connect
Water deflector (86).
A. Apply continuous bead of string sealer to

guide water to drain slots.
B. Align arrows on deflector (86) at upper outer
corners to front and rear of door inner paneL
C. Slick down top of deflector (86):
. I:>. Pull electrical connectors through appropriate
holes or slots in deflector (86).

E. Slick outer edge of deflector (86) to door inner
panel working downward to bottom edge.
F. Insert tabs into retaining slots arid slick.
!VIEWA
86
A PANEL. DOOR INNER

86 DEFLECTOR, FRONT SIDE DOOR WATER
115 HARNESS, CROSSBOOY AND FRONT SIDE
DOOR WIRING .. . .
..
152 DOOR, FRONT 510.E _
Figure 30 Front Side Door Water Deflector (Typical)
Outside Rearview Mirror

Figures 31 and 32
!++!
Remove .or Disconnect
1.
2.
3.
4.
Bolt/screw (85).
Bezel (84).
Remote handle from bezel (84), 'if equipped.
Fron,t, side door tfim panelt if (?quipped with
electric control mrrrors. Refer to "Front Bide
Door Right and Left Trim Panels'' in this section.
5. Electrical connector, if equipped.
A. Pull rosebud clip on electrical connector from
mirror (109).
B. Pull apart connection.
6. Nuts (101).
7. Mirror (109).
I++!
NOTICE: Refer to "Notice" on page' 10~6~1.

1. Mirror (109).
2. Nuts (101).
!~!
Tighten
Nuts (101) to 6 N.m (53 lb. in.).

3. Electrical connector, if equipped.
A. Connect eiectrical connector.
B. Push rosebud clip on electrical collllector mto
hole in mirror (109).
4. Front side door trim panel, if removed. Refer. to
"Front Side Door Right and Left Trim Panels" in
this section.
5. Remote handle to bezel (84), if equipped.
DOORS
10-621
109
101
A
101
109
101
A
8
101
109
MANUAL REMOTE
ELECTRIC
NUT, OUTSIDE REARVIEW MIRROR
MIRROR, OUTSIDE REARVIEW
Ot-21-95
FS03210I
Figure 32 Removing Outside Rearview Mirror (Typical)
Outside Rearview Mirror .Reflective Glass

A HANDLE, OUTSIDE REARVIEW MIRROR REMOTE
.84 BEZEL, OUTSIDE REARVIEW MIRROR
85 BOLT/SCREW, OUTSIDE REARVIEW M_IROR BEZEL
Ot-2895
FS031108
Figure 31 - Removing Outside Rearview Mirror Bezel

(Typical)
A. Align slot in remote .handle to tab on bezel

(84).
B. Push remote handle into bezel (84) to engage
threads on remote handle onto metal clip in
bezel (84).
6. Bezel (84).
Align retainers in bezel (84) to holes in
applique.
7. Bolt/screw (85).
l~I Tighten
Bolt/screw (85) to 4 N.m (35 lb. in;).
ELECTRIC
Figure 33
!++I
CAUTION: To mm1m1ze the chance of

personal. injury, gloves and safety
glasses should be worn when removing
broken glass.
1. Move mirror to extreme outboard travel position~
2. Glass (108) by inserting finger at slot on inboard
side of mirror and pulling out.
3. Jackscrews and trunnion bar from motor pack
unit.
ILI
Inspect
Motor pack unit. If damaged, replace mirror.

Refer to "Outside Rearview Mirror" in this
section.
l++I
Install or Connect
1. Jackscrews and trunnion bar to new glass (103).

2. New glass (103).
A. Align jackscrews perpendicular to glass (103).
B. Align trunnion bar parallel to glass (103).
10622
DOORS
Glass.
A. Place tape over glass.
B. Break glass.
C. Remove broken pieces from mirror.
103
Clean
Inside of mirror with clean cloth.
j++j
Install or Connect
Glass.
A. Remove protective liner to expose adhesive.
B. Press glass firmly onto center of mirror.
A
MANUAL REMOTE CONTROL
The reflective glass on the outside rearview

mirror with manual remote control is not serviceable.
If the glass is .broken, replace the mirror. Refer to
"Outside Rearview Mirror" in this section.
Outside Rearview Mirror Applique

B
Figure 34
j++l
c
A TRUNNION, OUTSIDE REARVIEW MIRROR
8
RECEPTOR, OUTSIDE REARVIEW MIRROR
RECEPTOR, JACKSCREW
D
103
JACKSCREW
GLASS, OUTSIDE REARVIEW MIRROR REFLECTIVE
TRUNNION
01-26-15
FS033108
Figure 33 - Outside Rearview Mirror Reflective Glass

(Electric) (Typical)
C. Position end o.f jackscrews at opening

approximately 13 mm (1/2 inch) into motor
pack unit.
D. Visually align trunnion bar Vyith receptor by
lifting inboard corner of glass (103).
E. Apply pressure with palm of hand until glass
(103) is seated firmly to receptor.
F. Manually rotate glass (103) to check for
proper installation.
MANUAL
!++I
.Remove or Disconnect
CAUTION: To minimize the chance of

personal in,ury, gloves and safety
glasses shou d be worn when removing
.broken glass.
NOTICE: When breaking glass, cover door
area surrounding glass to avoid damage to paint.
1. Lower window.
to "Right Front Side Door Water Deflector" in
this section.
4. Outside rearview mirror. Refer to "Outside
5. Nut (37).
7. Washer (43).
8. Applique (55).
I++!
Install or Connect
NOTICE:
1. Applique (55) through opening between door

inner panel and door outer panel;
2. Washer (43) and bolts/screws (36).
!~l Tighten
3. Nut (37).
l~l
Tighten
Nut (37) to 6 N.m (53 lb. in.) .

4. Outside rearview mirror. Refer to "Outside
Rearview Mirror'' in this section.
DOORS
10-6-23
Radio Front Side Door (Tweeter) Speaker

PONTIAC
Figure 35
152
l++l

2. Nuts (132).
3. Speaker (131).
!++!
36. BOLT/SCREW, OUTSIDE REARVIEW MIRROR APPLIOUE
37 NUT, OUTSIDE REARVIEW MIRROR OPENING
APPLIOUE
43 WASHER, OUTSIDE REARVIEW MIRROR APPLIOUE
55 APPLIOUE, OUTSIDE REARVIEW MIRROR
'152 DOOR, FRONT SIDE
01289&
FS034106
Install or Connect
NOTICE:
Refer to "Notice" on page 10-6-1:
1. Speaker (131).
2. Nuts (132).
Figure 34 Removing Outside Rearview Mirror Applique

(Typical)

!LI
152~
.. .
fFRr
Inspect
If front side door window squeaks in outside

rearview mirror applique window channel
while returning to .up position, lubricate
channel using GM PIN 9981599 (Sol
Anti-Squeak Compound) or equivalent.
Radio Front Side Door Speaker
..'
.....
.,
-.;;;
129
Figures 35 and 36
!++I

section.
4. Speaker (128).
1-++I
Install or Connect
NOTICE:
1.
2.
3.
4.
R.efer to "Notice" on page 10-6-1.
Speaker (128).
Bolts/screws (129).
Front side door water deflector. Refer to "Front
A WITH DUAL FRONT DOOR-MOUNTED SPEAKERS

B WITH QUAD FRONT DOOR-MOUNTED SPEAKERS
C CONNECTOR, RADIO FRONT SIDE DOOR SPEAKER
ELECTRICAL
D CONNECTOR, RADIO FRONT SIDE DOOR (TWEETER).
SPEAKER ELECTRICAL
128 SPEAKER, RADIO FRONT SIDE DOOf
129 BOLT/SCREW, RADIO FRONT SIDE DOOR SPEAKER
131 SPEAKER, RADIO FRONT SIDE DOOR
(TWEETER)
132 NUT, RADIO FRONT SIDE DOOR (TWEETER) SPEAKER
012895
FS035108
Figure 35 - Removing Radio Front Side Door Speakers (Pontiac)
106-24 .. DOORS<
Front Side Door Outside Handle
152
Figure 37
!++!
1. Raise window.
2. Front side door. trim panel. Refer to "Front Side
section.
4. Handle rod (13) from fastener on clip (75).
5. Handle rod (13) from clip (75).
6. Nuts (70).
7. Handle (76) from door outer panel.
8. Filler (77) from handle (76).
!++!
Install or Connect
NOTICE:
128 SPEAKER, RADIO FRONT SIDE DOOR

129. BOLT/SCREW, RADIO FRONT SIDE DOOR SPEAKER
~'=
Figure 36 - Removing Radio Front Side Door Speaker

(Chevrolet)
1. Filler (77) to handle (76).

2. Handle (76) to door outer panel.
A. Hold handle (76) in open position and insert
studs through holes in door outer panel.
B. Move handle (76) rearward into slots and
press.
3. Nuts (70).
!~!
4.
5.
6.
7.
Nuts (70) to 7 N-m (62 lb. in.).

Handle rod (13) into clip (75) on handle (76).
Handle rod (13) onto fastener on clip (75).
Front side door trim panel. Refer to "Front Side
Front Side Door Inside Handle

Figure 38
!++!
Tighten
1. Raise window.
3. Front side door inside handle seal. Refer to
"Front Side Door Inside Handle Seal'' in this
section.
section.
5. Rivet (34).
A. Tap rivet mandrel until it falls out of
rivet (34).
B. Drill out rivet (34) with 3/16-inch drill bit.
C. Remove rivet fragments from hole.
152
13
70
75
76
77
152
ROD, FRONT SIDE DOOR OUTSIDE HANDLE

NUT, FRONT. SIDE DOOR OUTSIDE HANDLE
CLIP, FRONT SIDE DOOR OUTSIDE. HANDLE
HANDLE, FRONT SIDE DOOR OUTSIDE .
FILLER, FRONT SIDE DOOR OUTSIDE HANDLE
DOOR, FRONT SIDE
01-28-111
FS037108
Figure 37 - Front Side Door Outside Handle (Typical)
6. Handle tab from door inner panel slot by sliding

handle (35) rearward.
7. Rod (47) from fastener on clip (46).
8. Rod (47) from clip (46).
9. Handle (35) from door inner panel.
10. Clip (46) from handle (35).
Use needlenose pliers to squeeze clip (46) and
push from handle (35).
DOORS
10-6-25
jVIEWAj
46
!VIEW Bj
34
34
35
46
47
RIVET, FRONT SIDE DOOR INSIDE HANDLE

HANDLE, FRONT SIDE DOOR INSIDE
CLIP, FRONT SIDE DOOR INSIDE HANDLE ROD
jv,ewcl
03-H-H
FT03810I
Figure 38 - Installing Front Side Door Inside Handle
IL"'!
Inspect
Clip (46).
[I]
Important
If clip ( 46) is damaged, it must be replaced.

Use GM PIN 16627328 (left-hand) or GM
PIN 9835133 (right-hand).
l-++l
Install or Connect
1. Clip (46) into handle (35).

2. Handle (35) to door inner panel.
Rotate front of handle (35) into slot.
3. Rod (47) into clip (46) on handle (35).
4. Rod (47) onto fastener on clip (46).
5. Tab on handle (35) into slot on door inner panel
by rotating and sliding forward.
6. Align hole in handle (35) with hole in door inner
panel.
7. Rivet (34).
9. Front side door inside handle seal. Refer to
"Front Side Door Handle Inside Handle Seal" in
this section.
A~!f;ff().'-.C
24
?l
26
A
B
C
24
SPINDLE. REGULATOR
FRONT SIDE DOOR WINDOW UP
FRONT SIDE DOOR WINDOW DOWN
SPACER, FRONT SIDE DOOR WINDOW REGULATOR
HANDLE
.
26 HANDLE, FRONT SIDE DOOR WINDOW
REGULATOR
01-28-15
FS039108
Figure 39 - Front Side Door Window Regulator Handle

(Typical)
Front Side Door Window Regulator Handle
Figure 39
l+-+l
Tool Required:
J 9886-01 Door Handle Clip Remover
1. Handle (26) by pushing J 9886-01 between handle

(26) and spacer (24) to release clip.
2. Spacer (24) from spindle.
10-6-26
!H!
DOORS
Install or Connect
1. Spacer (24) to spindle.
NOTICE: Strike handle with mallet at hub

when installing to avoid damage.
2. Handle (26).
A. Position handle (26) to spindle pointing
forward if window is up, or rearward if
window is down.
B. Tap handle (26) with mallet until snap ring in
handle (26) engages groove in spindle.
Front Side Door Lock

Figure 40
CAUTION: Do not attempt to repair a

broken lock. A lock malfunction may
result in serious bodily injury. A broken
lock must be replaced.

express down mode causing the express
driver's front side door window to lower
fully without stopping even though the
switch has been released. Failure to
exercise caution around the front side
door window regulator may result in
personal injury or regulator damage.
!+-+!
1. Raise window.
Door. Right and Left Trim Panels" in this section.
section.
4. Electrical connector from lock (9), if equipped.
5. Inside handle rod (47) from clip (15).
6. Clip (15) using needlenose pliers.
Discard clip (15).
152
!VIEWA!
9
10
11
12
13
14
15
17
47
49
152
LOCK, FRONT SIDE DOOR

BOLT/SCREW, FRONT SIDE DOOR LOCK
RETAINER, FRONT SIDE DOOR OUTSIDE HANDLE ROD
ROD, FRONT SIDE DOOR OUTSIDE HANDLE
ROD, FRONT SIDE DOOR LOCKING
DOOR, FRONT SIDE
Figure 40 Front Side Door Lock (Typical)
01~26-95
FS0401011
DOORS
7. Locking rod (49) from clip (17).
Discard clip (17).
9. Outside handle rod (13) from retainer (12).
A. Use right-angle needlenose pliers to squeeze
retainer tabs and pull retainer (12) through
hole.
B. Unscrew retainer (12) from outside handle rod
(13).
Discard retainer (12).
10. Lock cylinder rod (14) from clip (11).
11. Clip (11) from lock (9) using needlenose pliers.
Discard clip (11).
13. Lock (9) through access hole.
!++-!
Install or Connect
NOTICE:
1. Lock (9) through access hole.

!~I
Tighten
Front Side Door Outside Handle Rod

Figures 37 and 40
!++I
Use GM PIN 16623993.

6. Outside handle rod (13) to retainer (12).
A. Line up lower end of outside handle rod (13)
to retainer (12).
B. Snap outside handle rod (13) into back half of
retainer (12).
C. Snap retainer cover closed over threaded part
of outside handle rod (13).
7. New clip (17) to lock (9).
1. Raise window.
section.
4. Outside handle rod (13) from fastener on clip
(75).
5. Outside handle rod (13) from clip (75).
6. Outside handle rod (13) from retainer (12).
A. Use right-angle needlenose pliers to squeeze

retainer tabs and pull retainer (12) through
hole.
B. Unscrew retainer (12) from outside handle rod
(13).
Discard retainer (12).
7. Outside handle rod (13) from door.
!++!
Install or Connect
1. New retainer (12) to lock (9).

2. Outside handle rod (13) to retainer (12).

8. Locking rod (49) to clip (17).
10. Inside handle rod (47) to clip (15).
11. Electrical connector to lock (9), if equipped.

regulator damage.

3. New clip (11) into lock.
4. Lock cylinder rod (14) into clip (11).
5. New retainer (12) to lock (9).
10-627
3.
4.
5.
6.
A. Line up lower end of outside handle rod ( 13)

to retainer (12).
B. Snap outside handle rod (13) into back half of
retainer (12).
C. Snap retainer cover closed over threaded part
of outside handle rod (13).
Outside handle rod (13) into clip (75).
Outside handle rod (13) onto fastener on clip (75).
10-6-28 DOORS
Front Side Door Inside Handle Rod
l++I

front side door window to lower. fully
regulator damage.
1. Raise window.
section.
4. Rod (47) from fastener on clip (46).
5. Rod (47) from clip (46).
6. Clip (46) from handle (35).
48
Use needlenose pliers to squeeze clip (46) and

push from handle (35).
Discard clip (15).
ILI
Inspect
I SECTION A-A I
A
47
48
49
152
PANEL, DOOR INNER

CLIP, FRONT SIDE DOOR LOCKI.NG ROD
ROD, FRONT .SIDE DOOR LOCKING
DOOR, FRONT SIDE
(
01-28-95
FS041106
Clip (46).
I]]
Important
If clip (46) is damaged, it . must be replaced.

Use GM PIN 16627328 (left-hand) or GM
PIN 9835133 (right-hand).
l++I
Install or Connect
1. Inside handle rod (47) to clip (48).

Line up black band on inside handle rod (47)
with slot in clip (48) and snap inside handle
rod (47) into clip (48).
Inside handle rod (47) to clip (15).
Clip (46) to handle (35).
Inside handle rod (47) to clip (46).
Inside handle rod (47) to fastener on clip (46).
3.
4.
5.
6.
7.
Figure 41 - Front Side Door Inside Handle Rod and Front

Side Door Locking Rod (Typical)
Front Side Door Locking Rod

Figures 40 and 41
j++j

regulator damage.
1. Raise window.
2. Front side door trim panel. Refer to "Front
Side Door Right and Left Trim Panels" in this
section.
DOORS 10-6-29
3. Front side door water deflector as needed.
Refer to "Front Side Door Water Deflector" in
this section.
Discard clip (17).
!++!
Install or Connect

Line up black band on locking rod (49) with
slot in clip (48) and snap locking rod (49) into
clip (48).

section.
Discard clip (11).
6. Lock cylinder rod (14) from fastener on clip (71).
!++!
Install or Connect

2. Lock cylinder rod (14) onto fastener on clip (71).
3. New clip (11) into lock (9).
Side Door Water Deflettor" in this section.
Door Right and Lpft Trim Panels" in this section.
Front Side Door Lock Cylinder Rod
Figures 40 and 42
Figure 43
!++!
!++!

regulator damage.
1. Raise window.
1. Mark position of striker (68).

3. Striker (68).
4. Spacers (67), as equipped.
5. Washer (66).
I++!
Install or Connect
NOTICE:
1. Washer (66).
2. Any spacers (67) that were removed.
3. Striker (68) to location marked.
l
14
71
152

CLIP, FRONT SIDE DOOR LICK CYLINDER PAWL
DOOR, FRONT SIDE
012815
FS042108
Figure 42 Front Side Door Lock Cylinder Rod (Typical)
66
67
68
69
WASHER, FRONT SIDE DOOR LOCK STRIKER

SPACER, FRONT SIDE DOOR LOCK STRIKER
STRIKER, FRONT SIDE DOOR LOCK
BOLT/SCREW, FRONT SIDE DOOR LOCK STRIKER
012715
FS04310I
Figure 43 Front Side Door Lock Striker
10-6-30
DOORS
D. Open door.
, !~I
1~1 Tighten
Tighten
!LI
Inspect
Striker~to-lock engagement. If adjustment is

needed, refer to "Front Side Door Lock Striker
Adjustment" in the following procedure.

E. Remove J 39346.
WITHOUT J 39346
~ Adjust
Front Side Door Lock Striker Adjustment

NOTICE: '.Refer to "Notice" on page 10-6-1.
WITH J 39346
[I]
Figure 44
Tool Required:
J 39346 "Mini-Wedge" Door Striker Aligner
Adjust
NOTICE:
[I]
Door must be properly aligned before

adjusting the striker.
1. Striker up or down and inboard or outboard.
A. Loosen striker bolts/screws;
B. Move striker up or down and inboard or
outboard, as required.
l~I
Important
Door must be properly aligned before

adjusting the striker.
Important
Tighten
Striker bolts/screws to 34 N.m (25 lb., ft.).

2. Striker forward or rearward.
A. Apply modeling clay or body caulking
compound to door lock opening.
B. Close door far enough for striker to make
impression in clay or caulking compound.
Striker (68).
A. Loosen bolts/screws (69) just enough to allow
movement of the striker (68).
B. Install J 39346 to striker (68).
C. Close door while holding outside handle in
open position.
Closing the door all the way will make

removing the clay or caulking compound
, ,
difficult.
C. Open door and check that striker impression is
centered forward and rearward in the lock
opening.
D. If adjustment is needed:
Do not slam door.
a. Remove striker. Refer to "Front Side Door

Lock Striker" in this section.
b. Add or remove spacers as needed.
c. Install striker. Refer to "Front Side Door Lock
Striker" in this section.
3. After adjusting striker, touch up any exposed,
unpainted areas.
Front Side Door Lock Striker Anchor Plate

Figure 45
l++I
68 STRIKER; FRONT SIDE DOOR LOCK
69 BOLT/SCREW, FRONT SIDE DOOR LOCK STRIKER
01279&
FS04410I
Figure 44 .Adjusting Front Side Door Lock Striker with

J 39346
1. Radio rear quarter trim panel speaker. Refer to

SECTION 10-7.
2. Front side door lock striker. Refer to "Front Side
boor Lock Striker" in this section.
3. Anchor plate (65) through speaker access hole.
DOORS
l++l
10-6-31
Install or Connect
1. Anchor plate (65).

2. Front side door lock striker. Refer to "Front Side
Door Lock Striker" in this section.
3. Radio rear quarter trim panel speaker. Refer to
SECTION 10-7.
Front Side Door Interlock Striker

Figure 46
Tool Required:
J 29843-9 Door Lock Striker and Seat Belt
TORX Wrench
l+-+l
1. Striker (63) using J 29843-9.

2. Spacers (64), as equipped.
3. Washer (81 ).
l++l
65 PLATE, FRONT SIDE DOOR LOCK STRIKER ANCHOR

01-27-95
FS04S108
Figure 45 - Front Side Door Lock Striker A~chor Plate
Install or Connect
NOTICE:
1. Spacers (64) to stud end of striker (63).

Install the same number of spacers (64) as are
installed with the ,front side door lock striker.
2. Washer (81).
3. Striker (63).
!~l
Tighten
Striker (63) to 45 N.m (33 lb. ft.).
Front Side Door Bumper

Figure 47
l++l
01-27-96
FS041108
Bumper (16) by prying with a flat-bladed tool.
l++l
63 STRIKER, FRONT SIDE DOOR INTERLOCK

64 SPACKER. FRONT SIDE DOOR INTERLOCK STRIKER
81 WASHER, FRONT SIDE DOOR INTERLOCK STRIKER
Figure 46 - Front Side Door Interlock Striker
Install or Connect
Bumper (16) by pressing into holes.
Front Side Door Lock Actuator

Figures 48 and 49
I++!
Remove or Disconnect'
1. Front side door lock. Refer to "Front Side Door

Lock" in this section.
2. Bolts/screws.
3. Actuator (8).
!-++!
Install or Connect
NOTICE:
152
16 , BUMPER, FRONT SIDE DOOR

0127-95
FS047108
Figure 47 - Front Side Door Bumper
10-632
DOORS
c
A
8
C
D
E
8
9
LEVER, INSIDE HANDLE ROD

LEVER, LOCK CYLINDER ROD
RECEIVER, ACTUATING ARM
BUMPER, ACTUATING ARM
ARM, ACTUATING
ACTUATOR, FRONT SIDE DOOR LOCK
LOCK, FRONT SIDE DOOR
(
012795
FS04810I
IYI Important
Figure 48 - Front Side Door Lock Actuator
Before installing new actuator (8), make sure

the lock (9) is in full open position..
1. Release lock (9) to be sure it is in full open
position.
A. Push up on lock cylinder rod lever.
B. Pull on inside handle rod lever.
2. Make sure actuating arm bumper is on actuating
arm.
3. Actuating arm with bumper into actuating arm
receiver.
. 4. Align bolt/screw holes.
5. Bolts/screws.
ILI
Inspect
Lock operation by pushing inward on fork bolt

until it clicks into full closed position.
- Lock (9) must operate to full closed
position without interference.
6. Electrical connector to lock.
7. Electrical connector to door lock switch.
ILI
Inspect
Actuator operation by pressing door lock

switch to ensure that actuator locks and
unlocks lock (9).
8. Front side door lock. Refer to "Front Side Door
Lock" in this section.
Front Side Door Lock Cylinder

Figure 50
!++I
Remove or D~sconnect

regulator damage.
DOORS
10-633
72
152
c
A
74
c
B
A PARTIALLY CLOSED POSITION

8 FULL CLOSED POSITION
C BOLT, FORK
jv1ewA!
012795
FS049108
Figure 49 Front Side Door Lock Positions
1. Raise window.
section.
4. Lock cylinder rod (14) from fastener on clip (71).
6. Retainer (72) using a screwdriver to slide upward.
7. Front side door lock cylinder (74).
8. Gasket (73).
1-++I
Install or Connect
1. Gasket (73) to cylinder unit (74).

2. Cylinder unit (74).
3. Retainer (7'2) to shoulder of cylinder unit (74).
4. Lock cylinder rod (14) into clip (71) ..
5. Lock cylinder rod (14) onto fastener on clip (71).
7. Front' side door trim panel. Refer to "Front Side
Front Side Door Upper Hinge

Figqres 51 and 52
l+-+I
1. Support door (152) in full open position.
14 ROD, FRONT SIDE DOOR LOCK CYLINDER

71 CLIP, FRONT SIDE DOOR LOCK CYLINDER PAWL
72 RETAINER, FRONT SIDE DOOR LOCK CYLINDER
73 GASKET, FRONT SIDE DOOR LOCK CYLINDER
74 CYLINDER UNIT, LOCK
012795
FS050108
Figure 50 Removing Front Side Door Lock Cylinder

{Typical)
2. Mark position of upper hinge (149) on door (152)

and hinge pillar.
4. Nuts (41).
5. Upper hinge (149).
!++!
Install or Connect
NOTICE:
Refer to "Notice" on page ~0-6-1.
1. Upper hinge (149) to position marked.

2; Nuts (41).
-
A. Install nuts (41), but do not tighten.

B. Loosen nuts (39).
I~!
Tighten
Nuts (41 and 39) to 50 N.m (37 lb; ft.) in

sequence.
10-6-34 DOORS
152
39
40
41
79
80
149
150
152
NUT, FRONT SIDE DOOR LOWER HINGE

GROMMET, DOOR WIRING HARNESS
NUT, FRONT SIDE DOOR UPPER HINGE
BOLT/SCREW, FRONT SIDE DOOR UPPER HINGE
SOLT/SCREW, FRONT SIDE DOOR LOWER HINGE
HINGE, FRONT SIDE DOOR UPPER
HINGE, FRONT SIDE DOOR LOWER
DOOR, FRONT SIDE
jv1ewel
012795
FS051108
Figure 51 Front Side Door Upper and Lower Hinges
A. Install bolts/screws (79), but do not tighten.
B. Loosen bolts/screws (80).
I~!
Tighten
6. Lower hinge (150).
!++l
Install or Connect
Bolts/screws (79 and 80) to 50 N.m (37 lb. ft.)

in sequence.
F=ront Side Door Lower Hinge

Figures 51 and 52
Tool Required:
J 36604 Door Hinge Spring Compressor
j++j
1. Support door (152) in full open position.

2. Mark position of lower hinge assembly (150) on
door (152) and hinge pillar.
CAUTION: Before removing spring, cover

with shop cloth to prevent sprin~ from
flying off and causing personal inJury or
damage.
3. Spring using J 36604.
5. Nuts (39).
DOORS
CAUTION: Before removing spring, cover

with shop cloth to prevent sprin~ from
flying off and causing personal inJury or
damage.
Front Side Door

Figures 51 and 52
Tool Required:
J 36604 Door Hinge Spring Compressor
I++-! Install or Connect

[I] Important
1.
2.
3.
4.
5.
10-6-35
6. Spring using J 36604.

7. Support door.
8. Nuts (39 and 41).
9. Door.
!++!
Steps 1 through 5 apply only to doors

equipped with power accessories.
Front side door water deflector as needed. Refer
section.
Electrical connectors from all components in door.
Grommet (40) from door.
Crosscar and front .side door wiring harness from
door.
Install or Connect
NOTICE:
1. Door to upper and lower hinges (149 and 150).

2. Nuts (39 and 41).
!~I
Tighten
Nuts (39 and 41) to 50 N.m (37 lb. ft.) m

sequence.
3. Spring from J 36604.
', d'(Cl(~.
4
B
A
A FRONT SIDE DOOR HINGE SOLT/SCREW-TO-HINGE

PILLAR TIGHTENING SEQUENCE
8 FRONT SIDE DOOR HINGE NUT-TO-FRONT SIDE
DOOR TIGHTENING SEQUENCE
152
DOOR, FRONT SIDE

INDICATES SEQUENCE FOR INSTALLING SCREWS
Figure 52 - Front Side Door Hinge Fastener Tightening Sequences
032595
FT052106
106-36
DOORS
3. Front side door water deflector as .needed. Refer
section.
CAUTION: Support front .side door

window. If window drops into door,
personal injury or window damage may
result.
.
.,
.
4. Support window (1) in position needed to access
rivets (19) by inserting rubber wedge door stops
at front and rear of window (1) between window
.(1) and door inner paneL
. 5. Rivets (19).
Prill out rivets (19) with 1/4-inch drill bit.
6. Window (1) by raising out of door (152).
!L!
A STOP, RUBBER WEDGE DOOR
01-27-95
FS05310t
Figure 53 - Supporting Front Side Door Window
[I]
4.
5.
6.
7.
8.
.
Important
Steps 4 through 8 apply only to doors

equipped with power accessories.
Crosscar and front side door wiring harness to
door.
Grommet (40) to door.
Electrical connectors to components in door.
I>oor Right and Left Trim Panels" in this section.
Front Side Door Window

CAUTION: Approved safety glasses and

gloves should be worn when performing
these procedures to reduce the chance of
personal injury should window breakage
occur.
regulator damage.
!++I
7.
1. Lower window about halfway.

8.
9.
10.
11.
!++I
inspect
Bushings (59), retainers (2), up stop (54), pins

(3) and wedges (60) on the window (1) for
damage.
Bushings (59) and retainers (2), if necessary,
using a flat-bladed tool covered with cloth body
tape.
Bolt/screw (53), if necessary.
Up stop (54),. nut (57) and washer (58), if
necessary.
Bolts/screws (4), if necessary.
Pins (3), nuts (61) and wedges (60), if necessary.
Install or Connect
NOTICE:
1. Wedges (60) and pins (3), if removed.

2. Bolts/screws (4), if removed.
!~!
Tighten

3. Nuts (61), if removed.
!~!
Tighten
Nuts (61) to 8 N.m (71 lb. in.).

4. Up stop (54) and washer (58), if removed.
5. Bolt/screw (53), if removed.
I~! Tighten
Bolt/screw. (53) to 7 N.m (62 lb. in.).
6. Nut (57), if removed.
!~I Tighten
Nuts (57) to 8 N.m (71 lb. in.).
7. Bushings (59) and retainers (2), if removed.
8. Window (1) into door (152) so that holes in
bushings (59) line up with holes in channel.
9. Rivets (19) in sequence.
DOORS
llJ
Adjust
10-637
Front Side Door Window Adjustment
Window (1), if necessary. Refer to "Front Side

Door Window Adjustment" in this section.
Side Door Water Deflector" in this s~ction.
Figure 56.
llJ
Adjust
NOTICE:
1. Window up or down at front.

A. Loosen nut (45).
B. Adjust up stop support (44).
19
19
I SECTION A-A I
WINDOW, FRONT SIDE DOOR
19 RIVET, FRONT SIDE DOOR WINDOW
152 DOOR ASSEMBLY, FRONT SIDE
03270
152
FTOl410I
Figure 54 Front Side Door Window Rivets (Typical)
1
2
3
4
53
54
57
58
57
'
59
60
61
59
WINDOW, FRONT SIDE DOOR

RETAINER, FRONT SIDE DOOR WINDOW BUSHING
PIN, FRONT SIDE DOOR WINDOW STABILIZER
PIN
BOLT/SCREW. FRONT SIDE DOOR WINDOW FRONT UP
STOP
STOP. FRONT SIDE DOOR WINDOW FRONT UP
NUT, FRONT SIDE DOOR WINDOW FRONT UP STOI'
WASHER, FRONT SIDE DOOR WINDOW FRONT UP
STOP
BUSHING, FRONT SIDE DOOR WINDOW
WEDGE, FRONT SIDE DOOR WINDOW
NUT, FRONT SIDE DOOR WINDOW STABILIZER PIN
61
0127-SIS
FSOl510I
Figure 55 - Front Side Door Window
10-6-38 DOORS
45
152
21
+~J
~
152/
;..../.
22
!VIEWB!
t4!l~
Q
===nroj
27
28
29
44
45
51
52
151
152
,.~~'ij-"
\ I'
1v1ewcj
5.1
!VIEW
22
V/
152
152
151

NUT, FRONT SIDE DOOR WINDOW REGULATOR
NUT, FRONT SIDE DOOR WINDOW REAR GUIDE
.
CHANNEL
CHANNEL, FRONT SIDE DOOR WINDOW
REAR GUIDE
NUT, FRONT SIDE DOOR WINDOW REAR GUIDE
CHANNEL
. ,
.
SUPPORT, FRONT SIDE DOOR WINDOW
FRONT UP STOP
. .
NUT, FRONT SIDE DOOR WINDOW FRONT UP STOP
SUPPORT
,
BOLT/SCREW; FRONT SIDE DOOR WINDOW REAR
.
CHANNEL EXTENSION
DOOR, FRONT SIDE
,._;i
fJ
LI
27
Figure 56 - Adjusting Front Side Door Window (Typical)
152
IVIEW EI
01-27-95
FSO&l106
DOORS
j~j
Tighten
Nut (45) to 10 N.m (89 lb. in.).

2 Window up or down at rear.
A. Loosen bolt/screw (151).
B. Adjust rear up stop and tighten bolt/screw
(151).
3. Window parallel to weatherstrip.
A. Lower window part .way and raise back to
within 25 mm (1 inch) of weatherstrip.
B. Loosen nuts (22).
C. Adjust channel (21).
!~I
Tighten
Nuts (22) to 10 N.m (89 lb. in.).

4. Window forward or rearward.
A. Loosen nuts (27 and 29).
B. Move window forward or rearward.
l~I
Tighten
Nut (27) to 10 N.m (89 lb. in.).

Nuts (29) to 27 N.m (20 lb. ft.).
5. Upper edge of window inboard or outboard.
A. Loosen nuts (29).
B. Move jackstuds in or out using an allen
wrench.
l~I
Tighten
Nuts (29) to 27 N.m (20 lb. ft.).
6. Stabilizers (51).
A. Raise window to full closed position.
B. Loosen bolts/screws (52) ..
C. Apply slight pressure outboard on window at
belt.
D. Move stabilizers (51).
l~I
10~.;39
Front Side Door Window Front Up Stop

Support
Figure 57
j++j

window regulator .when operating the
switch may result iri personal injury and
regulator damage.
1. Lower window.
Door Right and Left Trim Panels" in tp.is section.
3. Nut (45).
4. Spport (44).
l++I
Install or Connect
NOTICE:
1. Support (44).
2. Nut (45).
ILI
Inspect
Window alignment. Adjust if necessary. Refer

to "Front Side Door Window Adjustment" in
this section.
l~I
Tighten
Nut (45) to 10 N.m (89 lb, in.).
3.. Front side door trim panel. Refer to "Front Side
Dqor Right and Left Trim Panels" in this section:
Tighten
ILI
Inspect
Window operation and stability.
- If window binds, move stabilizers (51) inboard

slightly.
- If window is unstable, move stabilizers (51)

outboard.
:,-;-- If stabilizers (51) have been adjusted and
window squeaks while returning to up
position, lubricate outside rearview mirror
applique window channel.
44 SUPPORT, FRONT SIDE DOOR WINDOW

FRONT UP STOP
45 NUT, FRONT SIDE DOOR WINDOW FRONT UP STOP
SUPPORT
52 DOOR, FRONT SIDE
012795
FS0&7108
Figure 57 Front Side Door Window Front Up Stop

Support (Typical)
10-6-40 DOORS
Front Side Door Window Front and Rear
Bumpers
Front Side Door Window Stabilizer

Figure 58
!++!
Figure 59
!++!

2. Bolt/screw (52).
3. Stabilizer (51).
!++!
Install or Connect
NOTICE:. Refer to "Notice'' on page 10-6-1.

1. Stabilizer (51).
2. Bolt/screw (52).
!L!
Inspect
Window stability. Adjust if necessary. Refer' to

"Front Side Door Window Adjustment" in this
section.
!~!
Tighten


regulator damage.
1. Raise window.
3. Radio front side door speaker , if removing front
bumper (33). Refer to "Radio Front Side Door
Speaker" in this section.
4. Front or rear bumper (33 or 31) using a
flat-bladed tool to release adhesive strip from door
outer panel.
!++!
Install or Connect
1. Front or rear bumper (33 or 31).

52
152
18.5 (0.73") +/-'1mm (0.04")
FRONT
51
52
152
I SECTIONA-A I
REAR

DOOR, FRONT SIDE
!VIEWA!
TYPICAL (2) PLACES
Figure 58 Front Side Door Window Stabilizer (Typical)
032795
FT058106
\
DOORS 10-6-41
A. Remove protective liner from adhesive strip.
B. Insert front or rear bumper (33 or 31) through
access hole.
C. Press front or rear bumper (33 or 31) into
position on door outer panel.
2. Radio front side door speaker, if removed. Refer
to "Radio Front Side Door Speaker" in this
section.
31
152

Figures 60 and 61
these procedures to reduce the chance of
personal injury should window breakage
occur.
ACCESS HOLE "8"
ACCESS HOLE "A"

152

regulator damage.
!+-+!
1. Raise window about halfway.

section.
CAUTION: Support front side door

window. If window drops into door,
personal injury or window damage may
result.
4. Support window in position by inserting rubber
wedge door stops at front and rear of window
between window and door inner panel.
5. Front side door window rear guide channel nuts
. so rear guide channel can be moved. Refer to
"Front Side Door Window Channel and Front
Side Door Window Rear Guide Channel" in this
section.
6. Rivets (23).
A. Push rivet mandrel out of rivet (23) with a

punch.
B. Drill out rivet (23).
7. Electrical connector from motor (83) by sliding
motor (83) and regulator (82) rearward, if
equipped.
31
33
152
BUMPER, FRONT SIDE DOOR WINDOW REAR

BUMPER, FRONT SIDE DOOR WINDOW FRONT
DOOR, FRONT SIDE
03-2495
FT059106
Figure 59 Front Side Door Window Front and Rear

Bumpers {Typical)
8. Regulator (20 or 82) from channels.

9. Regulator (20 or 82), with motor (83) attached if
equipped, through rear access hole.
j++I
Install or Connect
1. Regulator (20 or 82), with motor (83) attached if

equipped, through rear access hole.
2. Regulator (20 or 82) to channels.
3. Electrical connector to motor (83), if equipped.
4. Rivets (23) in sequence shown in Figure 53.
5. Front side door window rear guide channel nuts.
Refer to "Front Side Door Window Channel and
Front Side Door Window Rear Guide Channel" in
this section.
ILI
Inspect
Window alignment. Adjust if necessary. Refer

to "Front Side Door Window Adjustment" in
this section.
10-6-42
DOORS
152
!VIEWA!
A MANUAL SHOWN, POWER SIMILAR

8 POWER
20 REGULATOR, FRONT SIDE DOOR
WINDOW
23 RIVET, FRONT SIDE DOOR
WINDOW REGULATOR
83 MOTOR, FRONT SIDE DOOR
WINDOW REGULATOR
.152 DOOR, FRONT SIDE
INDICATES. SEQUENCE FOR
INSTALLING RIVETS
jv,ew DI
040715
FT080106
Figure 60 - Front Side Door Window Regulator (Typical)

Front Side Door Window Regulator Motor

Figure 61
I++!
CAUTION: If electric motor removal from

the regulator is required, the sector gear
must be locked in position. The regulator
lift arm is under tension from the
counterbalance spring and could cause
personal injury if the sector gear is not
locked in position.
83
A DRILLED HOLE
83 MOTOR, FRONT SIDE DOOR WINDOW
REGULATOR
Figure 61 Locking Sector Gear
01-2715
FB081106
\
\
DOORS

\ express down mode causing the driver's
.front side door window to lower fully
regulator damage.
1. Front side door window regulator with motor.
Refer to "Front Side Door Window Regulator" in
this section.
2. Drill hole through window regulator sector gear
and backplate.
3. Install bolt and nut to lock sector gear into
position.
10-6-43
4. Rivets.
A. Push rivet mandrel out of rivet with a punch.
B. Drill out rivet.
5. Motor (83).
l++I
Install or Connect
L Motor (83).
2. Rivets.
3. Remove bolt and nut used to secure sector gear.
4. Front side door window regulator and motor.
Refer to "Front Side Door Window Regulator" in
this section.
SPECIFICATIONS
Front Side Door Armrest Bolt/Screw .................................................................................... 4.5 N,m (40 lb. in.)
Front Side Door Inside Handle Bezel Bolt/Screw ........................ ,....................................... 1.4 N.m (12 lb. in.)
Front Side Door Interlock Striker ........................................................................................... 45 N.m (33 lb. ft.)
Front Side Door Lock Bolt/Screw .......................................................................................... 10 N,m (89 lb. in.)
Front Side Door Lock Striker Bolt/Screw ............................................................................. 29 N.m (21 lb. ft.)
Front Side Door Lower Hinge Bolt/Screw ................................................................... ,........ 50 N,m (37 lb. ft.)
Front Side Door Lower Hinge Nut ........................................................................................ 45 N,m (33 lb. ft.)
Front Side Door Outside Handle Nut ...................................................................................... 7 N.m (62 lb. in.)
Front Side Door Upper Hinge Bolt/Screw ............................................................................. 50 N,m (37 lb. ft.)
Front Side Door Upper Hinge Nut......................................................................................... 45 N,m (33 lb. ft.)
Front Side Door Window Front Up Stop Bolt/Screw ............................................................. 7 N.m (62 lb. in.)
Front Side Door Window Front Up Stop Nut ......................................................................... 8 N.m (71 lb. in.)
Front Side Door Window Front Up Stop Support Nut ......................................................... 10 N.m (89 lb. in.)
Front Side Door Window Rear Guide Channel Nut (Lower) ............................................... 10 N.m (89 lb. in.)
Front Side Door Window Rear Guide Channel Nut (Upper) ............................................... 27 N.m (20 lb. ft.)
Front Side Door Window Regulator Counterbalance Arm Channel Nut ............................. 10 N.m (89 lb. in.)
Front Side Door Window Stabilizer Bolt/Screw .................................................................... 10 N.m (89 lb. in.)
Front Side Door Window Stabilizer Pin Bolt/Screw ............................................................... 7 N.m (62 lb. in.)
Front Side Door Window Stabilizer Pin Nut ........................................................................... 8 N,m (71 lb. in.)
Lift Off Window Body Side Weatherstrip Bolt/Screw ......................................................... 1.3 N,m (12 lb. in.)
Outside Rearview Mirror Applique Bolt/Screw ....................................................................... 6 N.m (53 lb. in.)
Outside Rearview Mirror Bezel Bolt/Screw ............................................................................. 2 N.m (18 lb. in.)
Outside Rearview Mirror Nut ............................................................................................... 12 N.m (106 lb. in.)
Outside Rearview Mirror Opening Applique Nut .................................................................... 6 N.m (53 lb. in.)
10644 DOORS
SPECIAL TOOLS
1.
2.
~-"'_ __,,,,.-1:-;-C--:::"""'
c:,
J 9886-01
J21104-B
4.
J 25070
5.
6.
J 29843-9
3.
J 36604
1.
2.
3.
4.
5.
6.
DO.OR HANDLE CUP REMOVER

UNIVERSAL WEATHERSTRIP REMOVER
DOOR LOCK STRIKER AND SEAT BELT TORX WRENCH
HEATGUN
"MINI-WEDGE" DOOR STRIKER ALIGNER
DOOR HINGE SPRING COMPRESSOR
012715
FS082108
REARQUARTERS
10-7-1
SECTION 10-1
REAR QUARTERS
after removal. General Motors will also call out the fasteners that . require thread lockers or thread sealant.
torque and the joint clamping force, and may damage the fastener. When you in.stall fasteners, use the correct
systems.
CONTENTS
Rear Quarters .................................................... 10-7-1
Interior Trim ..................................................... 10-7-1
Quarter Inner Trim Finishing Panel. ........... 10-7-1
Quarter Inner Rear Trim Finishing Panel...10-7-3
Quarter Trim Finishing Panel Extension
(With Lift-Off Windows) ......................... 10-7-4
Quarter Courtesy Lamp ............................... 10-7-5
Radio Quarter Speaker Grille ...................... 10-7-5
Radio Quarter Speaker ................................. 10-7-7
GENERAL DESCRIPTION
REAR QUARTERS
Figure 1
The information in this section provides service
procedures that apply to all rear quarter components,
as shown in Figure 1.
ON-VEHICLE SERVICE
INTERIOR TRIM
Quarter Inner Trim Finishing Panel

Figures 2 and 3
l++I
Radio Rear Speaker ................................... 10-7-7 .

Low Frequency Audio Amplifier .............. 10-7-10
.
Quarter Outer Panel Pressure
Relief Valve ............................................ 10-7-10
Exterior Trim .......................... '. ....................... 10-7-11
Rear Quarter Center Molding .................... 10-7-11
Fuel Tank Filler Door .......... :......................... 10-7-11
Fuel Tank Filler Pocket. ................................ 10-7-12
Specifications ............................ ,.......................... 10-7-13
Special Tools ...................................................... 10-7-13
4. Striker bolt/screw (2), and washer (3).
Bolt/screw (2) may be loosened to allow panel
to slide out (Coupe only).
5. Quarter inner trim finish panel extension
bolt/screw (33) (Convertible only).
6. Quarter inner trim finish panel extension (34)
(Convertible only).
7. quarter inner trim finishing panel (4 or 35).
Push lap belt through slot in quarter inner trim
finishing panel (4 or 35).
8. Speaker grille (5 or 37), if necessary.
9. Quarter courtesy lamp (36) (Convertible only), if
necessary.
l++I
Install or Connect
NOTICE:
1. Lower the folding seatback.

2. Left or right shroud side trim finishing panet
3. Coat hook (1) (Coupe only).
Release retainer with a screwdriver and pull

out.
1. Speaker grille (5 or 37), if removed.

2. Quarter courtesy lamp .(36), if removed.
3. Quarter inner trim finishing panel (4 or 35).
Thread lap belt through quarter inner trim

finishing panel ( 4 or 35).
4. Quarter inner trim finish panel extension (34)
(Convertible only).
10'."72
REAR QUARTERS
22
(
26
28
30
19
4
5
7.
8
10
14
16
PANEL, QUARTER INNER TRIM FINISHING

GRILLE, RADIO SPEAKER
PANEL. RIGHT QUARTER INNER REAR TRIM FINISHING
PANEL, LEFT QUARTER INNER REAR TRIM FINISHING
EXTENSION, QUARTER TRIM FINISHING PANEL
SPEAKER, RADIO REAR SAIL PANEL
18
19
22
25
26
28
30
SPEAKER, RADIO REAR

SPEAKER, RADIO REAR
SPEAKER, REAR (CHEVROLET ONLY)
VALVE, QUARTER OUTER PANEL PRESSURE RELIEF
MOLDING, REAR QUARTER CENTER
DOOR, FUEL TANK FILLER
02-28~96
POCKET, FUEL TANK FILLER.
FT001107
(
Figure 1 - Rear Quarter Components
REAR QUARTERS
10-7-3
d:B3
A
B
1
2
RETAINER
HOLE IN QUARTER INNER TRIM FINISHING PANEL
HOOK, COAT
BOLT/SCREW, SECOND SEATBACK CUSHION LOCK
STRIKER
3 WASHER, SECOND SEATBACK CUSHION LOCK STRIKER
4 PANEL, QUARTER INNER TRIM FINISHING
5 GRILLE, RADIO SPEAKER
031391
FT002107
Figure 2 - Quarter Inner Trim Finishing Panel (Coupe)
5. Quarter inner trim finish panel extension

bolt/screw (33) (Convertible only).
l~I
Figures 4 and 5
Tighten
Finish panel bolt/screw (33) to 1.9 N.m

(17 lb. in.).
6. Striker bolt/screw (2) and washer (3).
l~I
Quarter Inner Rear Trim Finishing Panel
Tighten
Striker bolt/screw (2) to 48 N.m (35 lb. ft.).

7. Coat hook (l) (Coupe only).
Slide into position and press retainer to lock.
8. Left or right shroud side trim finishing panel.
9. Raise the folding seatback.
Tool Required:
J 38778 Trim Pad Remover
l++I
1. Raise rear compartment lift window.

2. Sunshade.
Snap out.
3. Three retainers (6), by rotating retainers a quarter
turn using a key or coin if. removing right side.
4. Quarter inner rear trim finishing panel (7 or 8) by
first lifting from front corner.
5. Three retainers (11), using J 38778 to unsnap if
removing left side.
6. Radio speaker electrical connector..
7. Radio ~peaker grille ( 10), if necessary.
, Squeeze outer edges with fingertips and pull
out.
10-7-4 REAR QUARTERS
~
~
33
~--
2 BOLT/SCREW, SECOND SEATBACK CUSHION LOCK STRIKER

36
33 BOLT/SCREW, QUARTER INNER TRIM FINISH PANEL EXTENSION
34
35
36
37
EXTENSION, QUARTER INNER TRIM FINISH PANEL

PANEL, QUARTER INNER TRIM FINISHING
LAMP, QUARTER COURTESY
. 0228.H
FT003107
Figure 3 Quarter Inner Trim Finishing Panel (Convertible)
8. Radio rear speakers. Refer to ''Radio Rear

9. Three retainers (11) on left side, if necessary.
E3
Install or Connect
1. Three retainers (11), if removed from left side.

2. Radio rear speakers. Refer to "Radio Rear
3. Radio speaker grille (10), if removed.
Squeeze outer edges with fingertips, place in

position and release pressure.
4. Radio speaker electrical connector.
5. Quarter inner rear trim finishing panel (7 or 8).
. On left quarter inner rear trim finishing panel

(8), align three retainers (11) with holes in
quarter panel (12) and press down to lock in
position.
6. Three retainers (6), by rotating retainers a quarter
turn using a key or coin if installing right quarter
inner rear trim finishing panel (7).
7. Sunshade.
Snap into position.
8. Lower rear compartment lift window.

(With Lift-Off Windows)
Figure 6
!++I
1. Two bolts/screws {13).

2. Quarter trim finishing panel extension (14)..
E3 Install or Connect
NOTICE: Refer to "Notice" on page 10-7-L
1. Quarter trim fmishing panel extension (14).
2. 1\vo bolts/screws (13).
REAR QUARTERS
1075
I SECTION A-A I
(
-- ,l
6 RETAINER, QUARTER INNER REAR TRIM FINISHING
PANEL
7 PANEL, RIGHT QUARTER INNER REAR TRIM
FINISHING
10 GRILLE, RADIO SPEAKER
1-13-95
FS004107
. Figure 4 - Right Quarter Inner Rear Trim Finishing Panel
l~I
Radio .Quarter Speaker Grille
Tighten
FRONT
Qu21ner
Courtesy Lamp
,' '
Coupe
CONVERTIBLE
Figure 2
Figure 3
E3
'-.
l++I
Remo~e or Disconnect
1. Quarter courtesy lamp (36) by un~n,apping from

quarter inner trim finishing' panel (35).
3. Bulb.
E3
Install or Co~nect ;
1. Bulb.
3. Quarter courtesy lamp (36) to quarter inner trim
finishing panel (35).

Speaker grille (5).

-
l++I
Squeeze outer edges with fingertips and pull
out.
Install or Connect
Speaker grille (5).

-
Squeeze outer edges, place in position and

release pressure.
10-7-6 REAR QUARTERS

surface.
2. Trim finishing panel. Refer to "Quarter Inner
Trim Finishing Panel" in this se~tion.
Convertible
Figure 3
i++!
REAR
1. Trim finishing panel. Refer to "Quarter Inner

Trim Finishing Panel" in this section.
2. Speaker grille (37):
A. Using a soldering iron, melt heat stakes

retaining speaker gri1le (37).
B. Pull grille from trim finishing panel.
i++!
Install or Connect
Figures 4 and 5
!++!
Speaker grille (10).

-
l++I
Squeeze outer edges with fingertips and pull

out.
Install or Connect
1. Speaker grille (37).

A. Insert heat stakes through holes in trim
finishing panel.
B. Melt heat stakes using a soldering iron.
Speaker grille (10).

-
Squeeze outer edge with fmgertips, place in

position and release pressure.
l~o
-.,,,-,.{--
12
:-,.::
, l
I>~' &-----t
I~
I SECTION B-B I
A
8
10
11
12
PANEL, LEFT QUARTER INNER REAR TRIM FINISHING
RETAINER, QUARTER INNER REAR TRIM FINISHING PANEL
PANEL, QUARTER OUTER
Figure 5 - Left Quarter Inner Rear Trim Finishing Panel
1-13.-95
FS005107
REAR QUARTERS
1077
!VIEWAl
14
13 BOLT/SCREW, QUARTER TRIM FINISHING PANEL

14 EXTENSION, QUARTER TRIM FINISHING PANEL
1-13-96
FS008107
Figure 6 - Quarter Trim Finishing Panel Extension
Radio Quarter Speaker
RADIO REAR SPEAKER OPENING COVER
Figure 7
Convertible
'l+-+I
Figure 8
1. Quarter inner trim finishing panel. Refer to

"Quarter Inner Trim Finishing Panel" in this
section.
3. Radio speaker (16).
j++I
Install or Connect

2. Radio speaker (16).
l~I
Tighten
Four bolts/screws (15) to 1.9 N.m (17 lb. in.).

4. Quarter trim finishing panel. Refer to "Quarter
Inner Trim Finishing Panel" in this section.
E3
1. Sp~aker. Refer to "Radio Quarter Speaker" in this

section.
2. Speaker opening cover (38).
E3
Install or Connect
1. Speaker opening cover (38).

2. Speaker. Refer to "Radio Quarter Speaker" in this
section.
Radio Rear Speaker

Figure 9
l++I

"Quarter Inner Rear Trim Finishing Panel" in this
section.
2. Radio speaker (18 or 19).
A. Drill out rivets or bolts/screws, if equipped.
B. Rotate counterclockwise and pull out.
C. If replacing only one speaker (18 or 19), pull
wire out of electrical connector.
1'07'~8 REAR QUARTERS
16
15 BOLT/SCREW, RADIO REAR SPEAKER
16 SPEAKER ASSEMBLY, RADIO REAR SAIL PANEL
5-21-94
FS007107
. Figure 7 - Radio Quarter Speaker (Typical).
!++!
(
Install or Connect
NOTICE:
Refer to ''Notice'' 011 page 10...7.1.
. 1. Plug speaker. wire into electrical connector, if

removed.<
2. Radio speaker (18 or 19).

,
A. Drill two 1/16-inch holes in rear qul'ter trim
finishing panel speaker mooo,ting .posses .. as
shown in Figure 9, if necessary. .
B. Place radio speaker (18 or 19) in position and
rotate clockwise until holes in radio speaker
(18 or 19) align with drilled holes.
C. Install two self-tapping bolts/screws (20), GM
PIN 11505169, into drilled holes.
!~! Tighten
1\vo bolts/screws (20) to l.9, N.m (17 .lb. in.).
3. Quarter inner rear trim finishing . panel. Refer to
"Quarter Inner Rear Trim Finishing ];>anel" in this
section.
38 COVER, RADIO REAR SAIL PANEL

SPEAKER OPENING
1-13-95
FS008107
Flgure 8 - Radio Rear Speaker. Opening Cover

. ' (Convertible)
..
REAR QUARTERS 10-79
A
B
18
19
20
DRILL 1/16-INCH HOLES As SHOWN

CONNECTOR. ELECTRICAL
SPEAKER, RADIO REAR
SPEAKER, RADIO REAR
BOLT/SCREW, RADIO REAR SPEAKER
18
1-13-95
FS009107
Figure 9 - Radio Rear Speaker (Pontiac Coupe -Uplevel Speaker System)
CHEVROLET
Figure 10
l+-+I
1. Left quarter inner rear trim finishing panel. Refer

to "Quarter hmer Rear Trim Finishing Panel" in
this section.
2, Two bolts/screws (39).
3. Speaker (40).
!++I
Install or Connect
NOTICE:
, 2. Speaker (40)'.
3. Two bolts/screws (39).
l~I
Tighten
1\vo bolts/screws (39) to 1.9 N.m (17 lb. in.).

4. Left quarter .inner rear trim finishing panel. Refer
to "Quarter hmer Rear Trim Finishing Panel" in
this section..
22 SPEAKER, REAR
39 BOLT/SCREW, RADIO REAR SPEAKER
03-13-91
FS01ot07
Figure 10 - Rear Speaker - (Chevrolet Coupe -Bose

Uplevel Speaker System)
10-710
REAR QUARTERS
(
31 RETAINER, LOW FREQUENCY AUDIO AMPLIFIER
BRACKET
32 AMPLIFIER, LOW FREQUENCY AUDIO
32
1-13-95
FS011107
Figure 11 - Low Frequency Audio Amplifier -(Pontiac Coupe Uplevel Speaker System)
Low Frequency Audio Amplifier

PONTIAC
Figure 11
Tool Required:
J 38778 Trim Pad Remover
!++!
1. Right quarter inner trim finishing panel. Refer to

"Quarter Inner Trim Finishing Panel" in this
section.
2. Two retainers (31) using J 38778 trim pad
remover.
3. Amplifier (32).
l++I
Install or Connect
2. Amplifier (32).
3. T\vo retainers (31).

4. Right quarter inner trim finishing panel. Refer to
"Quarter Inner Trim Finishing Panel" .in this
section.
Quarter Outer Panel Pressure Relief Valve
Figure 12
l++I
1. Rear bumper fascia. Refer to SECTION 10-,4.

3. Quarter outer panel pressure relief valve (25)'.
l++I
Install or Connect
NOTICE: Refer to "Notice" onpage 10-7-1.

1. Quarter outer panel pressure relief valve (25).
REAR QUARTERS
.10711
x'r----
:~
/~~
-~~~/ , 25
..
.
)~
26
~,.
MOLDING, REAR QUARTER CENTER
01-13-91
FB013107
Figure 13 - Rear Quarter Center Molding (Typical)

24 BOLT/SCREW, QUARTER OUTER PANEL PRESSURE
RELIEF VALVE
25 VALVE, QUARTER OUTER PANEL PRESSURE RELIEF
1-13-95
FS012107
Figure 12 - Quarter Outer Panel Pressure Relief. Valve
l~I
Tighten
Four bolts/screws (24) to 1.4 N,m (13 lb. in.).

3. Rear bumper fascia. Refer to SECTION 10-4.
EXTERIOR TRIM
NOTICE: When removing or installing any
outside molding, cover adjacent finishes .with
masking tape to prevent damage to the finish.
Use proper .tools and take care to prevent
damage to the molding.
Rear Quarter Center Molding

Figure 13
l+-+I
Molding (26) from body surface.

A. Hold hot air gun 304 mm (12 inches) from
surface of molding (26).
. B. Apply heat, using circular motion for about
30 seconds.
C. Using care, peel molding (26) from body
surface.
i++I
Install or Connect
Molding (26) to body surface.

A. Body surface must be warm, 21 C (70F),
clean and wax free.
B. If installing a new part, remove adhesive
backing.
C. When installing a previously removed part, or
a partially loosened part, apply a thin, even
film of GM PIN 1052621 adhesive to adhesive
portion of molding (26).
D. Align and press molding (26) into. position.
FUEL TANK FILLER DOOR

Figure 14
!++I
1. Fuel tank filler pocket. Refer to "Fuel Tank Filler

Pocket" in the following procedure.
2. Install fuel tank filler cap.
3. Drill out four rivets (27).
4. Fuel tank filler door (28).
It may be necessary to gently pry back sound
insulating material around filler door hinge.
!++I
Install or Connect
1. Fuel tank filler door (28) .

2. Four rivets (27).
Install rivets alternately top to bottom.
3. Remove fuel tank filler cap.
4. Fuel tank filler pocket. Refer to "Fuel Tank Filler
Pocket" in the following procedure.
10-7-12
REAR QUARTERS
IVIEWA]
27 RIVET, FUEL TANK FILLER DOOR
28 DOOR, FUEL TANK FILLER
OM3N
F8014107
Figure 14 Fuel Tank Filler Door
FUEL TANK FILLER POCKET

Figure 15
E3
I++!
Install or Connect
NOTICE:. Refer to "Notice" on page 10-7-1.
1. Open fuel tank filler door (28) and remove cap.

3. Fuel tank filler pocket (30).
1. Fuel tank filler pocket (30).

l~I Tighten
Two bolts/screws (29) to 1.9 N,m (17 lb. in.).
3. Install cap and close fuel tank filler door (28).
REAR QUARTERS
10-7-13
29
28 DOOR, FUEL TANK FILLER

29 BOLT/SCREW, FUEL TANK FILLER POCKET
30 POCKET, FUEL TANK FILLER
01-1395
F8015107
Figure 15 Fuel Tank Filler Pocket
SPECIFICATIONS
Fuel Tank Filler Pocket Bolt/Screw ...................................................................................... 1.9 N.m (17 lb. in~)
Quarter Inner Trim Finish Panel Extension Bolt/Screw (Convertible Only) ....................... 1.9 N,m (17 lb. in.)
Quarter Outer Panel Pressure Relief Valve Bolt/Screw ........................................................ 1.4 N,m (13 lb. in.)
Quarter Trim Finishing Panel Bolt/Screw ............................................................................. 2.5 N.m (22 lb. in.)
Radio Rear Speaker Mounting Bolt/Screw ........................................................................... 1.9 N.m (17 lb. in.)
Rear Seatback Cushion Striker Bolt/Screw ............................................................................ 48 N.m (35 lb. ft.)
SPECIAL TOOLS
1 TRIM PAD REMOVER
38778
11-25-94
FS018107
10714 REAR QUARTERS
BLANK
BODY REAR END 10-8,;1
SECTION 10-8
BODY REAR END

CAUTION: When replacin~ a lift window, urethane adhesive GM PIN 12346284 must be used to
maintain original installation integrity. Failure to use urethane adhesive GM PIN 12346284 will
result in poor retention of the lift window which may allow unrestrained occupants to be ejected
from the vehicle with resulting personal injury.
ex.act part number for that application. General Motors will call out those fasteners that require a replacement
systems.
CONTENTS
Body Rear End.............................. ,................... 10-8-2
On-Vehicle Service ................................, .............. 10-8-2
Rear Compartment Lock System .................... 10-8-2
Rear Compartment Lid Lock Cylinder ....... 10-8-2
Endgate Latch ............................................... 10-8-2
Rear Compartment Lift Window
Lock Striker ............................................. 10-8-2
Rear Compartment Lid Lock
Release Actuator ......... ;.............................. 10:.8-3
Rear Compartment Lid Release Switch ...... 10-8-3
Rear Compartment Lift Window.
Weatherstrip .................................................. 10-8-3
Rear Compartment Exterior Trim ................... 10-8-3
Rear End Finish Panel Emblem .................. 10-8-3
Rear End Finish Panel ...... :.......................... 10-8-5
Taillamp Filler .............................................. 10-8-5
Rear End Lamps ....................... Refer to Section SB
Rear Compartment Interior Trim..................... 10-8-7
Taillamp Closeout Filler .............................. 10-8-7
Closeout Panel ......................................... 10-8-7
Rear Compartment Closeout Panel ............. 10-8-7
Rear Window Drain Panel
Garnish Molding ...................................... 10-8-7
Rear Compartment Side Trim ..................... 10-8-8
Roof Lift-Off Window
Stowage Retainers ..................................... 10.:.s-9
Rear Compartment Trim ............................ 10-8-10

Rear Compartment Lift Window Panel
and Components ............... '. ....................... 10-8-12
Rear Compartment Lift
Window Hinges ......................................... 10-8-12
Rear Compartment Lift Wmdow Strut ..... 10-8-13
Rear Compartment Lift Wmdow Panel .... 10-8-14
Adjustment ..................................................... 10-8-15
Rear End Spoiler (Coupe) ......................... 10:..8-15
Liftgate Window Opening Finish Lace..... 10-8-16
Inner Panel Cover.................................. 10-8-16
Rear Compartment Lift Wmdow
Side Finish Moldings ............................ 10-8-17
Rear Compartment Lift Window ............... 10-8-17
Rear Compartment Lid Panel
and Components ........................................ 10-8-20
Rear Compartment Lid Hinges ................. 10-8-20
Rear Compartment Lid Strut. .................... 10-8-20
Rear Compartment Lid Panel... ................. 10-8-22
Rear End Spoiler (Convertible) ................. 10-8-22
Specifications ...................................................... 10-8-23
Special Tools ............................. ;; ....................... 10-8-24
10-8-2
BODY REAR END
GENERAL DESCRIPTION
BODY REAR END
This section contains the service operations
necessary for the removal, installation, adjustment and
sealing of body rear end hardware and trim
components.
ON-VEHICLE SERVICE
REAR COMPARTMENT LOCK SYSTEM
Rear Compartment Lid Lock Cylinder
Figure 5
I++!
1. Open window panel.

2. Rear end finish panel. Refer to "Rear End Finish
Panel" in this section (Chevrolet only).
3. Taillamp filler. Refer to "Taillamp Filler" in this
4. Rivets (14).
5. Lock cylinder (13).
l++I
Install or Connect
(j]
1.
2.
3.
4.
5.
6.
Important
Tan dot on lock cylinder (13) must face

upward when installing lock cylinder (13).
Lock cylinder (13), guiding lock cylinder shaft
through hole in rear end panel into hole in lock
support.
Align lock cylinder (13).
Right rivet (14).
Left rivet (14).
Taillamp filler. Refer to "Taillamp Filler" in this
Rear end finish panel. Refer to "Rear End Finish
Panel" in this section (Chevrolet only).
Endgate Latch
Figure 6
E3

2. Rear compartment trim as needed. Refer to "Rear
Compartment Trim" in this section.
3. Rear compartment lid release switch electrical
connector. Refer to "Rear Compartment Lid
Release Switch" in this section.
4. Rear compartment lid lock release actuator

secondary lock retainer and electrical connector.
Refer to "Rear Compartment Lid Lock Release
Actuator" in this section.
6. Latch (9).
l++I
Install or Connect

1. Latch (9).
Align holes in latch (9) with holes in support.
!~!
Tighten

3. Rear compartment lid lock release actuator
electrical connector and secondary lock retainer.
Refer to "Rear Compartment Lid Lock Release
Actuator" in this section.
4. Rear compartment lid release switch electrical
connector. Refer to "Rear Compartment Lid
Release Switch" in this section.
5. Rear compartment trim. Refer to "Rear
Rear Compartment Lift Window Lock

Striker
Figure 7
l++I

2. Rear compartment lift window inner panel cover.
Refer to "Rear Compartment Lift Wmdow Inner
Panel Cover" in this section.
3. Nuts (6).
4. Striker (5).
l++I
Install or Connect

1. Striker (5).
2. Nuts (6).
!~!
Tighten
Nuts (6) to 10 N.m (89 lb. in.).

Refer to "Rear Compartment Lift Window Inner
!LI
Inspect
Window panel operation. Adjust if necessary.

Refer to "Rear Compartment Lift Window
Panel Adjustment" in this section.
BODY REAR END

Rear Compartment Lid Lock Release
Actuator
1083
6. Rear compartment trim. Refer to "Rear

Figure 8
REAR COMPARTMENT LIFT WINDOW

WEATHERSTRIP
I+-+!
Figure 9

Compartment Trim'' in.this section.
3. Secondary lock retainer from actuator (18).
4. Electrical connec.tor from actuator (l~).
6. Actuator (18) from latch (9).
I+!
Install or Connect
N.OTICE:
1.
2.
3.
4.
5.
Actuator (18) to latch (9).

Bolts/screws (10).
Electrical connector to actuator (18).
Secondary lock retainer.
Rear compartment trim. Refer to "Rear
Rear Compartment Lid Release Switch

Figure 8
!++I

3. Electrical connector from switch (11).
4. Secondary lock retainer and .electrical conne.ctor
from actuator (18).
5. Endgate latch. Refer to "Endgate Latch''. in this
section.
6. Bolt/screw (12).
7. Switch (11) from latch (9).
!++I
Install or Connect
NOTICE:
1. Switch (11) to latch (9).

2. Bolt/screw (12).
3. Endgate latch. Refer to "Endgate Latch" in this
section.
4. Electrical connector and secondary lock retainer to
actuator (18).
5. Electrical connector to switch (11).
!++I
1. Weatherstrip (7) by peeling from flarige.
Clean
Weatherstrip sealer from flange.

2. Support window panel.
3. Struts at quarter inner roof panel. Refer to "Rear
Compartment Lift Window Strut" in this section.
4. Weatherstrip (7) from opening.
!++I
Install or Connect
1. Weatherstrip (7) into opening.

2. Struts at quarter inner roof panel. Refer to "Rear
3. Weatherstrip (7).
A. Position weatherstrip (7) to top center of
flange.
B. Attach upper corners, then work from corners
to center across top.
C. Attach elbow areas, then work from elbows to
upper corners.
D. Attach rear corners, then work from rear
corners to elbows.
E. Work from rear corners to center across rear.
F. RoU entire w~atherstrip (7) to seat.
REAR COMPARTMENT EXTERIOR TRIM

Rear End Finish Panel Emblem
CHEVROLET
Figure 10
Tool Required:
J 25070 Heat Gun
!+-+I
Emblem (41).
emblem (41). Apply heat in an even and
circular motion.
B. Pull emblem (41) from panel with flat-bladed
tool, making sure not to damage paint.
~ Clean
50150 mixture by volume with water or high-flash
naphtha.
10-8-4
BODY .REAR END
!VIEWB
15
16
012111
F8001108
(
Figure 1 Body Rear End " (Chevrolet)
BODY REAR END
1
2
3
4
4
6
7
8
9
10
11
12
13
14
15
16
17
18
19
WINDOW, REAR COMPARTMENT LIFT

LACE, LIFTGATE WINDOW OPENING FINISH
SPOILER, REAR .END
PANEL, REAR COMPARTMENT LIFT WINDOW
STRIKER, REAR COMPARTMENT LIFT WINDOW LOCK
NUT, REAR COMPARTMENT LIFT WINDOW LOCK STRIKER
WEATHERSTRIP, REAR COMPARTMENT LIFT WINDOW
BOLT/SCREW, ENDGATE LATCH
LATCH, ENDGATE
BOLT/SCREW, REAR COMPARTMENT LID LOCK SWITCH
SWITCH, REAR COMPARTMENT LID LOCK
BOLT/SCREW, REAR COMPARTMENT LID LOCK SWITCH
CYLINDER, REAR COMPARTMENT llD.LOCK
RIVET, REAR COMPARTMENT LID LOCK CYLINDER
PANEL, REAR END FINISH
PANEL, REAR COMPARTMENT LIFT WINDOW CLOSEOUT
NUT, REAR END FINISH PANEL
ACTUATOR, REAR COMPARTMENT LID LOCK RELEASE
NUT, REAR COMPARTMENT LIFT WINDOW BODY SIDE
HINGE
20 GASKET, REAR COMPARTMENT LID BODY SIDE HINGE
10-85
21 HINGE, REAR COMPARTMENT LIFT WINDOW

22 NUT, REAR COMPARTMENT LIFT WINDOW SIDE HINGE
23 NUT, ROOF LIFT-OFF WINDOW STOWAGE RETAINER
24
25
26
27
28
29
31
32
33
34
35
36
37
38
BRACKET
BUMPER, REAR COMPARTMENT LIFT WINDOW
NUT, REAR END SPOILER
WASHER, REAR END SPOILER
STUD, REAR COMPARTMENT LIFT WINDOW STRUT
WINDOW SIDE
STRUT, REAR COMPARTMENT LIFT WINDOW
STUD, REAR COMPARTMENT LIFT WINDOW STRUT
BODY SIDE
COVER, REAR COMPARTMENT LIFT WINDOW INNER
PANEL
MOLDING, REAR COMPARTMENT LIFT WINDOW SIDE)
(RIGHT)
MOLDING, REAR COMPARTMENT LIFT WINDOW SIDE
(LEFT)
TRIM, REAR COMPARTMENT SIDE
RETAINER, REAR COMPARTMENT TRIM
TRIM, REAR COMPARTMENT
RETAINER, ROOF LIFT-OFF WINDOW STOWAGE (RIGHT)
RETAINER, ROOF LIFT-OFF WINDOW STOWAGE (LEFT)
01-25-85
FS002108
Figure 2 - Body Rear End - Legend - (Chevrolet)
l++I
Install or Connect
New emblem (41).

A. Heat panel surface and adhesive side of new
(80F) or 6C (l0F)above air temperature in
40C (105F).
[I]
Important

C. Press emblem (41) into place and apply

pressure.
Rear End Finish Panel

CHEVROLET
Figure 11
1. Taillamps. Refer to SECTION 8B.

2. Nuts (17).
3. Panel (15).
!HI
Install or Connect
NOTICE:
1. Panel (15).
2. Nuts (17), starting with outboard locations.
I~!
Tighten
Nuts (17) to 8 N.m (71 lb. in.).

Taillamp Filler
PONTIAC
Figure 12
l++I

2. Filler (44).
!++!
Install or Connect
1. Filler (44).
1.0;.86. BODY REAR END
4
OR
29
30
31
,,._J
lv1ewel
@
16
01-2115
f8003108
(
Figure 3 Body Rear End (Pontiac)
BODY REAR END

A TRANS AM
3 SPOILER, REAR END
4 PANEL, REAR COMPARTMENT LIFT WINDOW (TRANS
AM)
5 STRIKER, REAR COMPARTMENT LIFT WINDOW LOCK
6 NUT, REAR COMPARTMENT LIFT WINDOW LOCK STRIKER
7 WEATHERSTRIP, REAR COMPARTMENT LIFT WINDOW
8 SOLT/SCREW, ENDGATE LATCH
9 LATCH, ENOGATE
10 BOLT/SCREW, REAR COMPARTMENT LID LOCK RELEASE
ACTUATOR
11 SWITCH, REAR COMPARTMENT LID LOCK
12 SOLT /SCREW, REAR COMPARTMENT LID LOCK SWITCH
13 CYLINDER, REAR COMPARTMENT LIC LOCK
14 RIVER, REAR COMPARTMENT LID LOCK CYLINDER
16 PANEL, REAR COMPARTMENT LIFT WINDOW CLOSEOUT
18 ACTUATOR, REAR COMPARTMENT LID RELEASE
18 NUT, REAR COMPARTMENT LIFT WINDOW BODY
SIDE HINGE
20 GASKET, REAR COMPARTMENT LID BODY SIDE INGE
22 NUT, REAR COMPARTMENT LIFT WINDOW SIDE HINGE
23 NUT, ROOF LIFT-OFF WINDOW STOWAGE RETAINER
BRACKET
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
44
10-8-7
BUMPER, REAR COMPARTMENT LIFT WINDOW

NUT.REAR ENO SPOILER
WASHER, REAR ENO SPOILER
STUO,R EAR COMPARTMENT LIFT WINDOW
STUD, LIFTGATE STSRUT BODY SIDE
PANEL, REAR COMPARTMENT LIFT WINDOW (EXCEPT
TRANS AM)
COVER, REAR COMPARTMENT LIFT WINDOW INNER
PANEL
(RIGHT)
(LEFT)
TRIM, REAR COMPARTMENT SIDE
RETAINER, ROOF LIFT-OFF WINDOW STOWAGE
(RIGHT)
RETAINER, ROOF LIFT-OFF WIDNOW STOWAGE
(LEFT)
FILLER. TAILLAMP CLOSEOUT
RETAINER, TAILLAMP CLOSEOUT FILLER
FILLER, TAILLAMP
01-25-95
FS004108
Figure 4 - Body Rear End - Legend - (Pontiac)
REAR COMPARTMENT INTERIOR TRIM
Taillamp Closeout Filler

PONTIAC
Figure 13
!.-+!
1. Retainer (40) ...

2. Filler (39).
!++I
Install or Connect
1. Filler (39).
Tab on filler (39) is fitted under flange on
taillamp housing.
2. Retainer (40).
Rear Compartment Lift Window Closeout

Panel
,Figure 14
E3
!++!
e
Install or Connect
Panel (16).
- Slide panel (16) along groove of rear quarter
trim panel and snap into retainers.
Rear Compartment Closeout Panel

CONVERTIBLE
Figure 15
I++!
Closeout panel (46) by rotating fasteners (45) a

one-quarter turn.
!++!
Install or Connect
Closeout panel (46) by rotating fasteners (45) a

one-quarter turn.
Rear Window Drain Panel Garnish Molding

CONVERTIBLE
1. Close panel (16).

Panel ( 16) must be resting on rear quarter trim
panel to be removed.
2. Panel (16).
Slide panel (16) rearward to unsnap it from
retainers on rear quarter trim panel.
Figure 16
!++!
1. Retainers (50).
2. Rear window drain panel garnish right-hand
molding (51).
1088 BODY. REAR END

B
SECTION A-A
A
B
13
14
SUPPORT, ENDGATE LATCH

PANEL, REAR END
CYLINDER, REAR COMPARTMENT LID LOCK
RIVET, REAR COMPARTMENT LID LOCK CYLINDER
0121M15
FS005108
(
A SUPPORT, ENDGATE LATCH
8 BOLT/SCREW, ENDGATE LATCH
9 LATCH, ENDGATE
Figure 5 Rear Compartment Lid Lock Cylinder
3. Rear window drain panel garnish left-hand

molding (52).
4. Rear window drain panel garnish molding (53).
!++I
Install or Connect
1. Rear window drain panel garnish molding (53).

2. Rear window drain panel garnish left-hand
molding (52).
3. Rear window drain panel garnish right-hand
molding (51).
4. Retainers (50).
Rear Compartment Side Trim

COUPE
Figure 6 - Endgate Latch
3. Side trim (34).

Reposition left side of rear compartment trim
and lift out side trim (34).
!++!
Install or Connect
1. Side trim (34).

Position side trim (34) in rear compartment
with inboard edge under rear compartment
trim.
2. Rear speaker. Refer to SECTION 10-7.
3. Left quarter inner rear trim finish panel. Refer to
SECTION 10-7.
CONVERTIBLE
Figure 17
Figure 18
!++I
!++I
1. Left quarter inner rear trim finish panel. Refer to

SECTION 10-7.
2. Rear speaker. Refer to SECTION 10-7.
Ot21SH
FSOOl108
1. Trim. Refer to "Rear Compartment Trim" in this

section.
2. Side trim (48 or 49).
BODY REAR END 10-8-9

Roof lift-Off Window Stowage Retainers
Figure 19
Retainers (37 and 38) are provided in the rear
compartment for vehicles equipped with roof lift-off
windows.
l++I
1. Nuts (23).
2. Retainer (37 or 38).
!++i
4 PANEL, REAR COMPARTMENT LIFT WINDOW
5 STRIKER, REAR COMPARTMENT LIFT WINDOW LOCK
6 NUT, REAR COMPARTMENT LIFT WINDOW LOCK
STRIKER
01-25-95
NOTICE:
1. Retainer (37 or 38).

2. Nuts (23).
FS007108
Figure 7 - Rear Compartment Lift Window Lock Striker

(Convertible Similar)
I++!
Install or Connect
Install or Connect
Hold retainer (37 or 38) outboard, down and

forward when installing nuts (23).
l~I
1. Side trim' (48 or 49).
2. Trim. Refer to "Rear Compartment Trim" in this

section.
Tighten
Nuts (23) to 6 N,m (53 lb. in.).
10
18
9
A CONNECTOR, REAR COMPARTMENT LID LOCK
RELEASE ACTUATOR ELECTRICAL
B RETAINER, SECONDARY LOCK
C CONNECTOR, REAR COMPARTMENT LID LOCK
SWITCH ELECTRICAL
9 LATCH, ENDGATE
10 BOLT/SCREW, REAR COMPARTMENT LID LOCK
RELEASE ACTUATOR
11 SWITCH, REAR COMPARTMENT LID LOCK
12 BOLT/SCREW, REAR COMPARTMENT LID
LOCK SWITCH
18 ACTUATOR, REAR COMPARTMENT LID LOCK RELEASE
01215-SIS
FS008108
Figure 8 - Rear Compartment Lid Lock Release Actuator and Switch
10-8-10 BODY REAR END
15
A
15 PANEL, REAR END FINISH
17 NUT, REAR END FINISH PANEL
012515
FS011108
Figure 11 Removing 'Rear End Finish Panel -(Chevrolet)
SECTIONAA
A FLANGE
7 WEATHERSTRIP, REAR COMPARTMENT LIFT WINDOW
012595
FS009108
Figure 9 - Rear Compartment Lift Window Weatherstrip
44 FILLER, TAILLAMP
01-26-95
FS012108
Figure 12 - Removing Taillamp Filler -(Pontiac)
Rear Compartment Trim

41
COUPE
A
Figure 20
l++I
16.6 mm (0.63")
41
A TAILLAMP OPENING
41 EMBLEM, REAR END FINISH PANEL
012595
FS010108
Figure 10 - Installing Rear End Finish Panel Emblem (Chevrolet)
1. Roof lift-off window stowage retainers, if

equipped. Refer to "Roof Lift-Off Window
Stowage Retainers" in this section.
2. Quarter inner rear trim finish panels. Refer to
SECTION 10-7.
3. Retainer (35) from rear compartment 'latch
support.
4. Trim (36).
Separate hook-and-loop. retainers on trim (36)

from floor carpet.
BODY REAR END
39 FILLER, TAILLAMP CLOSEOUT

40 RETAINER, TAILLAMP CLOSEOUT FILLER
10-8-11
45 FASTENER, REAR COMPARTMENT CLOSEOUT PANEL

46 PANEL, REAR COMPARTMENT CLOSEOUT
01-21-95
FS013108
01-21-95
F8011S108
Figure 13 - TaiHamp Closeout Filler -(Pontiac)
Figure 15 - Rear Compartment Closeout Panel

(Convertible)
16 PANEL ASSEMBLY, REAR COMPARTMENT LIFT

WINDOW CLOSEOUT
01-26-95
F8014108
50 RETAINER, REAR WINDOW DRAIN PANEL GARNISH
51 MOLDING, REAR WINDOW DRAIN PANEL GARNISH
Figure 14 - Rear Compartment Lift Window Closeout Panel
!++I
Install or Connect
RIGHT-HAND
LEFT-HAND
01-26-96
FB018108
1. Trim (36).
Position in rear compartment and. under trim
line of floor carpet. Connect hook-and-loop
retainers.
2. Retainer (35) by pushing into rear compartment
latch support.
3. Quarter inner rear trim finish panels. Refer to
SECTION 10-7.
4. Roof lift-off window stowage retainers, if
equipped. Refer to "Roof Lift-Off Window
Stowage Retainers" in this section.
Figure 16 - Rear Window Drain Panel Garnish Molding
CONVERTIBLE
Figure 18
l++I
1. Closeout panel. Refer to "Rear Compartment

Closeout Panel" in this section.
2. Retainers (35) from rear compartment.
3. Rear compartment trim (47).
10812 BODY REAR END

REAR COMPARTMENT LIFr WINDOW
PANEL AND COMPONENTS
Rear Compartment Lift Window Hinges
COUPE
Figure 21
!++!
1. Rear. compartment lift window panel. Refer to

"Rear Compartment Lift Window Panel" in this
section.
2. Nuts (22).
3. Hinges (21).
i++!
34 TRIM, REAR COMPARTMENT SIDE
l++I
01-28-95
FS017108
Install or Connect
Figure 17 - Rear Compartment Side Trim (Coupe)
1. Hinges (21).
2. Nuts (22).
Install or Connect
1. Rear compartment trim (47).

2. Retainers (35) to rear compartment.
3. Closeout panel. Refer to "Rear Compartment
Closeout Panel" in this section.
!~! Tighten
Nuts (22.) to 42 N.m (31 lb. ft.).
3, Rear compartment lift wmdow panel. Refer to
"Rear Compartment Lift Window Panel" in this
section.
49
01-28-95
FS018108
Figure 18 - Rear Compartment Trim (Convertible}
BODY REAR END
10-8-13
22
21
22
HINGE, REAR COMPARTMENT LIFT WINDOW

NUT, REAR COMPARTMENT LIFT WINDOW WINDOW
SIDE HINGE
rs:1:
Figure 21 - Removing Rear Compartment Lift Window

Hinges (Coupe)
38
23
37
38
NUT, ROOF LIFT-OFF WINDOW SOTWAGE RETAINER

BRACKET
(RIGHT)
(LEFT)
~\;\\
Figure 19 - Roof Lift-Off Window Stowage Retainers
Rear Compartment Lift Window Strut

Figure 22
!++!
CAUTION: Do not attempt to remove or

loosen the struts without the window
panel fully open. A strut removed under
pressure may result in personal injury.
1. Raise and support window panel.
2. Quarter trim finish panel. Refer to
SECTION 10-7.
3. Strut (28) from stud (27) on window panel ( 4) by
unsnapping.
4. Stud (29) from strut (28).
5. Strut (28).
l++I
Install or Connect
NOTICE:
35
36

0121H
F8020108
Figure 20 - Rear Compartment Trim (Coupe)
1. Strut (28) to quarter inner roof panel.

2. Stud (29) through strut (28) to quarter inner roof
panel.
l~I
Tighten
Stud (29) to 27 N.m (20 lb. ft.).

3. Strut (28) to stud (27).
4. Quarter tr i m fin i sh p an e 1. Refer to
SECTION 10-7.
(
4
4
27
28
29

STUD, REAR COMPARTMENT LIFT WINDOW STRUT WINDOW SIDE
STUD, REAR COMPARTMENT LIFT WINDOW STRUT BODY SIDE
. !VIEW B!
012895
FS022108
Figure 22 - Rear Compartment Lift Window Strut (Coupe)
Figures 23 and 24
CAUTION: The steps .must be performed

with the assistance of a .helper to reduce
the possibility. of glass breakage or
personal injury. Approved safety glasses
and gloves should be worn to reduce the
chance of personal injury should glass
breakage occur.
!++I
A GROMMET, REAR HATCH WIRING HARNESS
8 FRAME, ROOF
4 PANEL, REAR COMPARTMENT LIFT WINDOW 012&95
FS023108
Figure 23 - Disconnecting Rear Hatch Wiring Harness

Grommet (Coupe)
1. Raise and support window panel.

2. Headlining . trim finishing panel. Refer to
SECTION 10-9:
3. Grommet.
5. Struts at window panel. Refer to "Rear
6. Nuts (19).
7. Window panel (4).
8. Gaskets (20) from hinges (21).
[II
Important
If window panel is being replaced, remove .the

hinges, spoiler if equipped, window and harness.
Refer to "Rear Compartment Lift Window
Hinges," "Rear End Spoiler" and "Rear
Compartment Lift Window" in this section.
BODY REAR END
10-8-15
A. Open window panel (4).

B. Move rear compartment trim as needed. Refer
to "Rear Compartment Trim" in this section.
C. Loosen bolts/screws (8).
D. Close window panel (4).
E. Move window panel (4) as required.
l~I
Tighten

2. Window panel (4) so it is flush to quarter trim
finish panel.
Loosen or tighten bumpers (24) as needed.
Rear End Spoiler (Coupe)

Figure 26
I++!
A FRAME, ROOF
19 NUT, REAR COMPARTMENT LIFT WINDOW BODY
SIDE HINGE
20 GASKET, REAR COMPARTMENT LID BODY SIDE
HINGE
01289S
FS024108
Figure 24 - Removing Rear Compartment Lift Window

Panel (Coupe)
I+!
Install or Connect
NOTICE:
1. Gaskets (20) to hinges (21).

2. Window panel (4) aligning studs on hinges (21) to
holes.
3. Nuts (19).
l~I
4.
5.
6.
7.
Tighten
Nuts (19) to 25 N,m (18 lb. ft.).

Struts at window panel. Refer to "Rear
Compartment Lift Window Struts" in this section.
Electrical connectors.
Grommet.
A. Route harness.
B. Apply soap solution to grommet.
C. Seat grommet at window panel and roof
frame.
Headlining trim finishing panel. Refer to
SECTION 10-9.

Adjustment
Figure 25
Ill
Adjust
1. Window panel (4) so it is flush to quarter outer

panel and centered in opening.

2. Rear compartment lift window side finish
moldings. Refer to "Rear Compartment Lift
Window Side Finish Moldings" in this section.
3. High-mounted stoplamp. Refer to SECTION 8B.
4. Wiring extension from spoiler (3).
A. Disconnect electrical connector.
B. Remove tape.
C. From outside vehicle, pull wiring extension
from spoiler (3).
5. Nuts (25).
6. Spoiler (3).
7. Washers (26).
!++I
Install or Connect
NOTICE: Refer to "Notice" on page 10-8-1

in this section.
1.
2.
3.
4.
Washers (26) to studs on spoiler (3).

Spoiler (3).
Push spoiler (3) forward.
Nuts (25).
!~I
Tighten
Nuts (25) in sequence to 6 N,m (53 lb. in.).

5. Harness into spoiler (3).
A. Route wiring extension through spoiler (3).
B. Pull on wiring extension to seat grommet.
C. Connect electrical connector.
D. Tape wiring extension to window panel.
10.;816
BODY REAR END

4

8 BOLT/SCREW, ENDGATE LATCH
9 LATCH, ENDGATE
24 BUMPER, REAR COMPARTMENT LIFT WINDOW
(
!VIEW B!
012115
FS025108
Figure 25 Rear Compartment Lift Window Panel Adjustment (Coupe)
Liftgate Window Opening Finish Lace
The wider portion of the lace goes to the

inside (Figure 29).
Figures 27 and 29
!++I
1. Lace (2) from window (1).

A. Place utility knife or razor knife flat on the
glass under the edge of the lace and remove
top of lace.
B. Place the knife along the glass edge, pointing
toward the bonding flange, and remove the
vertical portion of the lace.
2. Remove rear compartment lift window. Refer to
"Rear Compartment Lift Window" in this section.
l++I
Install or Connect
1. Lace (2) to window (1).
rn
Important
The longer portion of the lace goes to the rear.
Once the lace is on the glass, it may be

helpful to apply heat to obtain better fit of
the lace to the glass.
2. Rear compartment lift window. Refer to "Rear
Compartment Lift Window" in this section.
-
Rear Compartment Lift Window Inner

Panel Cover
Figure 28
l++I
Cover (31) by pulling to lock release retainers

(42) from window panel.
l++I
Install or Connect
Cover (31) by aligning retainers (42) to window

panel and pushing to secure.
BODY REAR END 10-617

3
26
A EXTENSION, CENTER HIGH-MOUNTED STOPLAMP WIRING

B GROMMET, CENTER HIGH-MOUNTED STOPLAMP WI.RING
EXTENSION
C TAPE
D CONNECTOR, CENTER HIGH0 MOUNTED STOPLAMP WIRING
EXTENSION ELECTRICAL
3
4
25
26
SPOILER, REAR END

NUT, REAR END SPOILER
WASHER, REAR END SPOILER
01-21-85
FS021108
Figure 26 - Rear End Spoiler (Coupe)
Rear Compartment Lift Window Side

Finish Moldings
Figure 28
2
!++!
1. Cover (31) by pulling to release retainers (42)

from window panel.
2. Molding (32 or 33) by pulling to release retainers
(42) and clips (43) from window panel.
!++!
ISECTION A-A I
l:~t\\
Figure 27 - Installing Liftgate Window Opening Finish Lace

(Coupe)
Install or Connect
1. Molding (32 or 33) by aligning retainers (42). and

. clips (43) to window panel and pushing to secure.
2. Cover (31) by aligning retainers (42) to window
panel and pushing to secure.

Figures 27 and 29
Tools Required:
J 24402-A Glass Sealant Remover (Cold
Knife)
J 39032 Stationary Glass Removal Tool
(Equalizer)
10818 BODY REAR END
SECTIONBB
SECTIONAA
31
32
l..f
SECTIONCC
32
1
~
33
SECTION DD
33
4 PANEL,. REAR .COMPARTMENT LIFT WINDOW
31 COVER, REAR COMPARTMENT LIFT WINDOW
INNER PANEL
32 MOLDING, REAR COMPARTMENT LIFT WINDOW
SIDE (RIGHT)
33 MOLDING, REAR COMPARTMENT LIFT WINDOW

SIDE (LEFT)
42 RETAINER, REAR COMPARTMENT LIFT WINDOW
INNER PANEL COVER
43 CUP, REAR COMPARTMENT LIFT WINDOW SIDE TRIM
FINISH PANEL COVER
(
01-2115
FS028108
Figure 28 Rear Compartment Lift Window Inner Panel Cover and Rear Compartment Lift Window Side Finish Molding
(Coupe)

this procedure to reduce the chance of
persol'.lal injury.
E3
1. Radio fixed antenna mast, if equipped. Refer to

SECTION 9A.
2. Lace (2) from window (1). Refer to "Liftgate
Window Opening Finish Lace" in this section.
. 4. Rear compartment lift window side finish
5. Rear window defogger electrical connector, if
_eq~ipped.
6. Mask area around window (1) to protect painted

surfaces and to aid in cleanup after installation.
Tape must not touch window sealant surface.
7. Using J 24402-A, cut rear lower edge bond and
forward outer bond across front of lift panel.
8. Using J 39032 (or equivalent), cut rear inner
urethane bead across the entire front edge of
liftpanel.
rn
Important
Cut urethane bead from inside rear

compartment area being careful not to damage
surrounding paint surfaces.
Keep blade as close to edge of window ( 1) as
possible.
- Make sure that an even bead of adhesive
remains on lift window panel (4) to serve
as base for new window (1 ).
9. Window (1).
Carefully place window upside down on a
clean work surface.
BODY REAR END 10-819
25 mm--'
i-....
....j
&.....
25 mm
r-
(1 O")
. . \~=~K:: .
~-
(1.0")
SECTIONAA
f4rr 25 mm (1.0")
r-----, (
SECTIONBB
---------....
A
'>,. ~ ~~,
SECTIONC-C
r
n_l
B
7mm(03"1\
,>.
-1.
~~.
SECTION CC
A
8
C
1
2
4
14mm(0.6")
PRIMER PATH
PRIME AND BEAD PATH
CENTERLINE
WINDOW, REAR COMPARTMENT LIFT
LACE, LIFTGATE WINDOW OPENING FINISH
0121H
F802t108
)
Figure 29 Installing Rear Compartment Lift Window Adhesive Primers and Adhesive (Coupe)
10820
BODY REAR END
Clean
A. Using a utility knife, remove most of the original

forward urethane bead and any remaining lace
from lift window panel.
B. Using compressed air, blow lift window panel (4)
of any loose material.
C. Adhesive from window (1), if not being replaced.
Use glass clean.er GM #1050427 or equivalent
to clean bond surfaces of window.
l++I
Install
or Connect
1. Lace (2) to window (1). Refer to "Liftgate

Window Opening Finish Lace" in this section.
2. With the aid of a helper, dry fit window ( 1) to lift
window panel (4) to assure proper fit.
3. Primers from urethane adhesive kit, GM
PIN 12346284, to window (1) and lift window
panel (4).
A. Apply pinchweld primer #3 from GM
PIN 12346284 to any exposed paint surfaces
on inside of lift window panel (4).
B. Apply clear primer, immediately followed by
black primer to lift window (1).
C. Allow black primer to dry five minutes prior
to application of urethane adhesive.
window (1) and lift window panel (4).
4. Urethane adhesive to rear compartment lift
window panel (4).
and nozzles provided, apply smooth continuous
bead of urethane adhesive around lift window
panel (4) in the following sizes:
A. 4 mm (3116 in) bead around the front inner,
side and rear areas.
B. 7 mm x 14 mm (5116 in x 9/16 in) bead
across the front outer area.
5. Window (1) to lift window panel (4) with aid of

helper.
Use vacuuni cups to position window (1).
Position upper corners of window ( 1) to upper
comers of lift window panel (4), then lay
window (1) onto lift window panel (4) and
press firmly on rear of window (1) forward to
ensure proper lace fit.
6. Press window (1) firmly to wet-out and set
adhesive.
Avoid squeezing out excess adhesive that
would cause an appearance problem.
[I]
Important
Allow vehicle to remain at room temperature

for 4 to 6 hours prior to installing remaining
components.
7. Rear window defogger electrical connector, if
equipped.

Refer to "Rear Compartment Lift Wmdow Inner
'
10. Radio fixed antenna mast, .if equipped. Refer t~
SECTION 9A.
REAR COMPARTMENT LID PANEL AND

COMPONENTS
Rear Compartment Lid Hinges
CONVERTIBLE
Figures 30 and 31
!+-+I
1. Rear compartment lid panel. Refer to "Rear

Compartment Lid Panel" in this section.
2. Bolts/screws (53) (Chevrolet only).
3. Nuts (55) (Pontiac only).
4. Adjustment bumper bolt (52).
6. Hinges (54).
!-++!
Install or Connect
NOTICE:
Refer to "Notice" on page 10-8-L
1. Hinges (54);
I~!
Tighten
Bolts/screws (51) to 25 N.m (18 lb.

ft.).
!~! Tighten
Adjustment bumper bolt (52) to 25 N,~
(18 lb. ft.).
4. Nuts (55) (Pontiac only).
I~!
Tighten
Nuts (55) to 50 N:m (37 lb. ft.).

5. Bolts/screws (53) (Chevrolet only).
!~!
Tighten

6. Rear compartment lid panel. Refer to "Rear
Compartment Lid Panel" in this section.
Rear Compartment Lid Strut

Figure 32,
I+-+!
CAUTION: Do not attempt to remove or

loosen the struts without the rear
compartment lid panel fully open. A strut
removed under pressure may result in
personal injury.
BODY REAR END
54
10-8-~1
I
50
50
51
52
PANEL, REAR COMPARTMENT LID

BOLT/SCREW, REAR COMPARTMENT LID PANEL HINGE
BOLT, REAR COMPARTMENT LID PANEL HINGE
ADJUSTMENT BUMPER
53 BOLT/SCREW, REAR COMPARTMENT LID PANEL HINGE
54 HINGE, REAR COMPARTMENT LID PANEL
--~=::::::~~
53
01-26-H
FS030106
Figure 30 - Rear Compartment Lid Hinges -(Chevrolet Convertible)
51
52
54
55
56
0128-H
FS031106
Figure 31 - Rear Compartment Lid Hinges -(Pontiac Convertible)
10-S-22
BODY Rl;AR END

7. Lid panel.
[I]
Important
If the rear compartment lid panel is being

replaced, remove the spoiler and harness. Refer to
"Rear End Spoiler" (Convertible) in this section.
l++I
Install or Connect
NOTICE: Refer to "Notice'' on page 10-~-1.

1. Lid panel.
l~l Tighten

57 STRUT, REAR COMPARTMENT LID
58 STUD, REAR COMPARTMENT LID STRUT BALL
59 STUD, REAR COMPARTMENT LID HINGE BALL
Ol28H
FS032108
Figure 32 - Rear Compartment Lid Struts
1. Raise and support rear. compartment lid panel.

2. Strut (57) from strut ball stud (58) on rear
compartment lid panel by unsnapping.
3. Strut (57) from hinge ball stud (59) by
unsnapping.
4. Strut (57).
5. Strut ball stud (58).
E3
Install or Connect

1. Strut ball stud (58) to rear compartment lid panel.
l~I
Tighten
Strut ball stud (58) to 50 N,m (37 lb. ft.).

2. Strut (57) to ball studs (58 and 59).
Rear Compartment Lid Panel
E3
1.
2.
3.
4.
Raise and support lid panel.
Plastic cap.
Electrical connectors.
Struts at rear compartment lid panel. Refer to
"Rear Compartment Lid Strut" in the previous
procedure.
l~I Tighten
Adjustment bumper bolt (52) to 25 N.m
(18 lb. ft.).
4. Struts at rear compartment lid panel. Refer to
"Rear Compartment Lid Strut" in the previous
procedure.
6. Plastic cap.
Adjust
Rear compartment lid fore or aft, side to side, and

front height as necessary.
Loosen or tighten bumpers as needed.
Rear End Spoiler (Convertible)
Figure 33
l++I

2. Wiring extension from spoiler (60).
A. Disconnect electrical .connector.

B. Remove tape.
C. From outside vehicle, pull wiring extension
from spoiler (60).
3. Nuts (61).
4. Spoiler (60).
5. Washers (63).
6. Seal (62).
l++I
Install or Connect
NOTICE: Refer to "Notice" on page 10-8-1

in this section.
BODY REAR END 10-$-23

1.
2.
3.
4.
Seal (62).
Washers (63).
Spoiler (60).
Nuts (61).
60
l~I Tighten
Nuts (61) to 6 N.m (53 lb. in.).
5. Harness into spoiler (60) ..
A. Route wiring extension through spoiler (60).
B. Connect electrical connector.
C. Tape wiring extension to lid panel.
6. High-mounted stoplamp. Refer to SECTION SB.
61
50 PANEL, REAR COMPARTMENT LID

60 SPOILER, REAR END
61 NUT, REAR END SPOILER
62 SEAL, REAR END SPOILER
63 WASHER, REAR END SPOILER
01-28-ts
FS033108
Figure 33 - Rear End Spoiler, (Convertible)
SPECIFICATIONS
Endgate Latch Bolt/Screw ....................................................................................................... 10 N.m (89 lb. in.)
Rear Compartment Lift Window Lock Striker Nut ............................................................... 10 N.m (89 lb. in.)
Rear Compartment Lid Hinge Body Side Bolt/Screw (Chevrolet Convertible) ................... 50- N.m (37 lb. ft.)
Rear Compartment Lid Hinge Body Side Nut (Pontiac Convertible) .................................. 50 N.m (37 lb. ft.)
Rear Compartment Lid Hinge Bumper Bolt (Convertible) ................................................... 25 N.m (18 lq. ft.)
Rear Compartment Lid Side Hinge Bolt/Screw (Convertible) .............................................. 25 N.m (18 lb. ft.)
Rear Compartment Lid Side Strut Ball Stud (Convertible) .................................................. 50 N,m (37 lb. ft.)
Rear Compartment Lift Window Body Side Hinge Nut. ...................................................... 25 N.m (18 lb. ft.)
Rear Compartment Lift Window Lock Striker Nut ............................................................... 10 N.m (89 lb. in.)
Rear Compartment Lift Window Side Hinge Nut ................................................................. 42 N.m (31 lb. ft.)
Rear Compartment Lift Window Side Strut Ball Stud.......................................................... 50 N.m (37 lb. ft.)
Rear Compartment Lift Window Strut Body Side Stud........................................................ 27 N.m (20 lb. ft.)
Rear End Finish Panel Nut (Chevrolet Only) .......................................................................... 8 N.m (71 lb. in.)
Rear End Spoiler Nut (Convertible) ......................................................................................... 6 N,m (53 lb. in.)
Rear End Spoiler Nut (Coupe) ................................................................................................. 6 N.m (53 lb. in.)
Roof Lift-Off Window Stowage Retainer Bracket Nut. ..................................... :.................... 6 N.m (53 lb. in.)
SP.ECIAL TOOLS
(
3
J 25070
J 39032
1 STATIONARY GLASS REMOVAL TOOL
2 GLASS SEALANT REMOVER (COLD KNIFE)
3 HEAT GUN
J 24402-A
012115
FB034108
ROOF AND FOLDING TOP
10-9-1
SECTION 10-9

systems.
CONTENTS
Roof ................................................................ 10-9-2
Headlining Panel ............................................ 10-9-2
Sunshade ......................................................... 10-9-2
Interior Lighting ............................................. 10-9-2
Dome Lamp ................................................ 10-9-2
Interior Moldings ............................................ 10-9-4
Windshield Side Upper Garnish
Molding (Without Lift-Off Windows) ... 10-9-4
Windshield Side Upper Garnish Molding
(With Lift-Off Windows) ....................... 10-9-4
Roof Drip Scalp Molding .............................. 10-9-5
Roof Outer Panel.. ..................... Refer to Section 11
Roof Rear Panel.. ....................... Refer to Section 11
Folding Top (Convertible) ............................. 10-9-5
Folding Top Operation ............................... 10-9-5
Electrohydraulic Diagnosis ......................... 10-9-6
Folding Top Bow ........................................... 10-9-7
Folding Top Number One Bow ................ 10-9-7
Folding Top Number 1\vo Bow ................ 10-9-11
Folding Top Number Three Bow .............. 10-9-12
Folding Top Number Four Bow ................ 10-9-13
Folding Top Number Five Bow ................ 10-9-14
Folding Top Front Latch ............................... 10-9-15
Front Latch Adjustment ............................. 10-9-15
Front Latch Replacement ........................... 10-9-15
Folding Top Rail ............................................ 10-9-16
Folding Top Number One and Number
Two Bow Links ..................................... 10-9-16
Front Side Rail Link .................................. 10-9-17
Folding Top Side Rail ............................... 10-9-17
Folding Top Outer Arm ............................. 10-9-18
Folding Top Side Rail Link ...................... 10-9-21
Folding Top Pivot Bracket ........................ 10-9-22
Folding Top Hydraulic System...................... 10-9-23
Folding Top Cylinder Upper Hose
(Left-Hand Cylinder) .............................. 10-9-23
Folding Top Cylinder Lower Hose

(Right-Hand Cylinder) ........................... 10-9-24
Cylinder ...................................................... 10-9-24
Folding Top Pump with Motor ................. 10-9-25
Hydraulic System Bleeding Procedure ...... 10-9-25
Adding Fluid .............................................. 10-9-26
Folding Top, Weatherstrips and Garnishes ... 10-9-26
Folding Top Side Rail Weatherstrip .......... 10-9-26
Folding Top Side Rail Weatherstrip
Retainers ................................................. 10-9-26
Folding Top Outer Arm Weatherstrip ....... 10-9-27
Folding Top Outer Arm Weatherstrip
Retainers ................................................. 10-9-27
Folding Top Front Weatherstrip ................ 10-9-28
Folding Top Front Weatherstrip Retainers 10-9-29
Folding Top Side Door Lower
Weatherstrip ............................................ 10-9-29
Quarter Belt Reveal Moldings and Seals . 10-9-30
Folding Top Side Rail Garnish Molding .. 10-9-30
Folding Top Cover Retention Cable ......... 10-9-31
Rear Window ............................................. 10-9-32
Folding Top Cover ..................................... 10-9-32
Folding Top Complete Replacement.. ....... 10-9-34
Headlining Trim Finish Panel ................... 10-9-34
Folding Top Adjustments .............................. 10-9-35
Downstop Adjustment.. .............................. 10-9-35
Upstop Adjustment..................................... 10-9-35
Roof Lift-Off Window ................................... 10-9-36
Roof Lift-Off Window Removal and
Installation .............................................. 10-9-36
Roof Lift-Off Window Adjustment.. ......... 10-9-36
Roof Lift-Off Window Repair ................... 10-9-37
Roof Panel Longitudinal Bow Finish
Molding .................................................. 10-9-38
Roof Lift-Off Window Lock Cylinder ...... 10-9-38
Specifications ...................................................... 10-9-39
10-9-2
GENERAL DESCRIPTION
ROOF
Figure 1
The information in this section provides service
procedures that apply to all roof components.
ON-VEHICLE SERVICE
HEADLINING PANEL
Figure 2
The headlining panel (2) is partially held in
place with headlining panel tape or two color matched
retainers (1) with lift-off windows. When the interior
moldings, sunshade and dome lamp housing are
installed, the headlining panel (2) is completely held in
place.
!++!
1. Open rear compartment lift window.

2. Sunshade. Refer to "Sunshade" in the following
procedure.
3. Dome lamp housing. Refer to "Dome Lamp" in
this section.
4. Windshield side upper garnish molding. Refer to
"Windshield Side Upper Garnish Molding
(Without Lift-Off Windows)" or "Windshield Side
Upper Garnish Molding (With Lift-Off Windows)"
in this section.
SECTION 10-7.
6. Loosen seat belt escutcheons and slide down seat
belt.
7. Retainers (1) from headlining panel (2).
8. Headlining panel (2).
A. Pull carefully on headlining panel (2) to
remove from roof panel.
B. Slide seat belt through seat belt slots.
C. Remove headlining panel (2) from vehicle
through rear compartment lift window opening.
!++!
Install or Connect
1. Peel backing from new headlining panel tape and

apply to depressions in roof panel (without lift-off
windows).
2. Headlining panel (2).
A. Place headlining panel (2) in vehicle through
rear compartment lift window opening.
B. Insert seat belt into seat belt slots.
C. Pull dome lamp electrical connector through
opening.
D. Apply pressure at centerline of headlining
panel (2) to engage headlining panel tape
(without lift-off windows).
3. Retainer (1) to headlining panel (2).

4. Slide seat belt escutcheons up seat belt and snap
into retractor.
SECTION 10-7.
(Without Roof Lift-Off Wmdows)" or ''W"mdshield
Side Upper Garnish Molding (With Roof Lift-Off
Windows)" in this section.
7. Dome lamp housing. Refer to "Dome Lamp" in
this section.
8. Sunshade. Refer to "Sunshade" in this section.
9. Close rear compartment lift window.
SUNSHADE
Figure 3
l++I
2. Sunshade (5).
!++!
Install or Connect

1. Sunshade (5).
Position sunshade support to. headlining panel.
l~I
Tighten
Bolts/screws (4) fo 1.7 N.m (15 lb. in.).
INTERIOR LIGHTING
Dome Lamp
Figure 4
!++!
Loosen enough to pull dome lamp housing (6)
from headlining panel.
2. Dome lamp housing (6) by pulling from
headlining panel.
!++!
Install or Connect

2. Dome lamp housing (6).
Use locating pins to position dome lamp
housing (6) to headlining panel.
!VIEW Bj
jVIEWA!
!VIEWC!
A
B
1
2
4
5
6
7
8
9
10
11
12
109-3
12
17
WITHOUT LIFT-OFF WINDOW ASSEMBLIES

WITH LIFT-OFF WINDOW ASSEMBLIES
RETAINER, HEADLINING TRIM FINISH PANEL
PANEL ASSEMBLY, HEADLINING TRIM FINISH
BOLT/SCREW.SUNSHADE
SUNSHADE ASSEMBLY
HOUSING ASSEMBLY, DOME LAMP
BOLT/SCREW, DOME LAMP
BULB, DOME LAMP
MOLDING ASSEMBLY, WINDSHIELD SIDE UPPER
GARNISH
BOLT/SCREW, WINDSHIELD GARNISH MOLDING
MOLDING ASSEMBLY, WINDSHIELD SIDE UPPER
GARNISH
MOLDING ASSEMBLY, ROOF DRIP SCALP
WINDOW ASSEMBLY, ROOF UFTOFF
!VIEWG!
!VIEW F!
OM395
F8001109
Figure 1 Roof Components
109-4
A SLOT, SEAT BELT

1 RETAINER, HEADLINING TRIM FINISH PANEL
2 PANEL, HEADLINING TRIM FINISH
01-1395
FS002109
Figure 2 Headlining Panel (Typical)
l++I
!~!
Tighten
INTERIOR MOLDINGS
(Without Lift-Off Windows)
PIN, LOCATING
HOUSING, DOME LAMP
BOLT/SCREW, DOME LAMP
BULB, DOME LAMP
01-1395
FS004109
Figure 4 Dome Lamp Housing
Install or Connect
Windshield side upper garnish molding (9).

A. Align tabs on windshield side upper garnish
molding (9) to holes in windshield inner side
frame and apply pressure to secure.
B. Align S-clips on windshield side upper garnish
molding (9) to door opening flange and apply
pressure to secure.

(With Lift-Off Windows)
Figure 5
!++I
A
B
6
7
8
Figure 6
Windshield side upper garnish molding (9) by

pulling away from windshield inner side frame.
!++I
_____
~
,,..., -
-----~,--~ ~
[//]\~
- --------- - ..
5
A TAB
B S-CLIP
9 MOLDING, WINDSHIELD SIDE UPPER GARNISH
01-1395
A SUPPORT, SUNSHADE
4 BOLT/SCREW.SUNSHADE
5 SUNSHADE
01-1395
FS0051ot
FS0031ot
Figure 3 Sunshade
Figure 5 Windshield Side Upper Garnish Molding

(Without Lift-Off Windows)
1095
2. Windshield side upper garnish molding (11) by

pulling away from windshield inner side frame.
!++I
Install or Connect
NOTICE:
1. Windshield side upper garnish molding (11).
Align clips to holes on windshield inner side

frame.
!~!
Tighten
12 MOLDING, ROOF DRIP SCALP
ROOF DRIP SCALP MOLDING
1-17-95
FS007109
Figure 7
1++1
Figure 7 Roof Drip Scalp Molding
Roof drip scalp molding (12) by pulling away

from door opening.
!++!
Install or Connect
Roof drip scalp molding (12) beginning at rear of

door opening and pressing entire length to secure.
FOLDING TOP (CONVERTIBLE)

Folding Top Operation
1. Ignition key must be in "ACC" or "RUN"

position.
2. Lower both sun visors.
3. Unlock front of folding top by pushing up on the
smaller part, then pulling down on larger part, of
each front latch (32). Make sure hook on each
front latch (32) is released from front latch striker
(33).
4. Be sure nothing is in or around folding top. Push
and hold "DOWN" on convertible top switch. Top
will automatically lower into storage area.
RAISING TOP
Figures B and 9
NOTICE: Do not raise the folding top while

vehicle is moving or it may be damaged.
LOWERING TOP
NOTICE: Do not lower folding top while

vehicle is moving or it may be damaged. Before
lowering the folding top into the storage area,
be sure there are no objects in the way of the
folded, stored top. The weight of a stored top on
items in the storage area .could cause the folding
top rear window glass to break.
1. Ignition key must be in "ACC" or "RUN"

position.
2. Lower both sun visors.
3. Lower both windows at least 76 mm (3 inches).
4. Push and hold "UP" on convertible top switch.
Top will automatically raise to closed position.
5. Pull down on front latch (32) and align hooks
with holes in front latch striker (33). Push forward
on larger part of each front latch (32) until it
clicks. Do not force front latch. If it is hard to
lock, top is not properly aligned.
MANUAL OPERATION
Figures 9 and 10
A CLIP
.
10 BOLT/SCREW, WINDSHIELD GARNISH MOLDING
11 MOLDING, WINDSHIELD SIDE UPPER GARNISH
01-1395
FS0081ot
Figure 6 Windshield Side Upper Garnish Molding (With

Lift-Off Windows)
If the vehicle battery is dead or disconnected,

the folding top can be manually raised or lowered by
bypassing the hydraulic pump.
1. Open rear compartment lid.
2. Locate access hole for pump valve in rear
compartment side trim. Refer to SECTION 10-8.
3. Rotate pump bypass valve (38) clockwise until it
comes to a stop (1/4 turn).
1096 ROOF AND FOLDING TOP

4. Manually lower folding top by lifting number one
bow (39) near the "A" pillar and lowering top as
required. Operate front latch (32) as described in
''Lowering Top" under ''Folding Top Operationl' in
this section.
5. Manually raise folding top by grasping number
one bow (39) near its center and raising as
required. Operate front latch (32) as described in
''Raising Top" in the preceding procedure.
[I]
(.
Important
Before operating folding top electrically, return

pump bypass valve (38) to its original position by
rotating it counterclockwise until it comes to a
stop (1/4 turn).
Electrohydraulic Diagnosis
If the folding top fails to operate, or operates
only partially, then mechanical causes such as
misalignment of linkage, damaged links, or damaged
hardware at pivot points should be checked before
looking into a possible electrohydraulic problem. If the
folding top mechanism is suspect, disconnect both
cylinder from outer arm and operate the top by hand
to diagnose mechanical problems. Refer to "Cylinder"
in this section.
If top does not operate properly after complete
check for mechanical problems, then check for
electrical or hydraulic malfunctions. Refer to
SECTION 8A-121 for diagnosis and service of
electrical components. Malfunctions in the hydraulic
system can be caused by lack of hydraulic fluid, leaks
in hydraulic system, obstructions or kinks in hydraulic
hose, or faulty operation of a cylinder pump.
If any part of the pump/motor is not working
properly, it is recommended that the entire unit be
replaced with a new one. Refer to ''Folding Top Pump
with Motor" in this section.
----1 r
------------
Operation of Cylinder
Disconnect both cylinder from outer arm. Refer

to "Cylinder" in this section.
NOTICE: To avoid part damage during this
procedure, make sure cylinder rods do not touch
body components or folding top when
extending.
1.--s-ec-r-,o-N-A--A__,I
A ADJUST FOLDING TOP FRONT LATCH HOOK

32 LATCH, FOLDING TOP FRONT
33 STRIKER, FOLDING TOP FRONT LATCH
1....:17-95
FS008109
Figure 8 - Folding Top Latch and Striker

(Right Side Shown, Left Side Similar)
Operate the convertible top switch and observe

cylinder during up and down cycles for these
conditions:
!l'I'!
Inspect
If movement of cylinder is uncoordinated or

sluggish when the motor is actuated, check
hydraulic hoses from pump/motor to cylinder for
kinks.
If one cylinder rod moves significantly slower
than the other and hydraulic hoses are free of
kinks, then the one having the slower-moving rod
is defective and should be replaced. Refer to
"Cylinder" in this section.
1097
37
34
E
j_
lv1ewel
T
OK
IVIEW c I
A
B
C
D
E
34
35
36
37
38
RESERVOIR FILLER PLUG

PINK HOSES TO TOP OF CYLINDERS
WHITE HOSES TO BOTTOM OF CYLINDERS
RESERVOIR FLUID LEVEL
PUMP WITH MOTOR, FOLDING TOP
NUT, FOLDING TOP PUMP
HOSE, FOLDING TOP CYLINDER LOWER
HOSE, FOLDING TOP CYLINDER UPPER
VALVE, FOLDING TOP PUMP BYPASS
1-17-95
FS009109
Figure 9 - Pump with Motor
FOLDING TOP BOW

Figure 10
The five bow run from one outboard side of the
vehicle to the other. They support the folding top and
keep its shape. The bow are numbered from front to
rear, with the number one bow being attached to the
windshield header and the fixed-position number five
bow serving as the rear tackstrip.
Folding Top Number One Bow

Figures 11, 12, 13, 14 and 15
I++!
1. Lower folding top to suitable working position.

3. Turn pump bypass valve to "open" position (fully

clockwise). Refer to "Manual Operation" und.er
"Folding Top Operation" in this section.
4. Side rail garnish molding. Refer to "Folding Top
Side Rail Garnish Molding" in this section.
5. Number one bow garnish molding bolts/screws
(50).
6. Number one bow garnish molding (49).
7. Rivets at each corner of headlining trim finish
panel (55) by drilling out with 5/32-inch drill bit.
8. Headlining trim finish panel (55) from number
one bow (39) by peeling away from adhesive.
9. Mark top cover to show leading edge of number
one bow (39).
10. Front cover number one bow retainer bolts/screws
(52).
11. Front cover number one bow retainer (51).
12. Cover from number one bow (39) by peeling
away from adhesive.
13. Black tape covering side front stay rivets (65).

42
41
39
32
39
40
41
42
43
44
45
46
47
48
LATCH, FOLDING TOP FRONT

BOW, FOLDING TOP NUMBER ONE
BOW, FOLDING TOP NUMBER TWO
BOW, FOLDING TOP NUMBER THREE
BOW, FOLDING TOP NUMBER FOUR
LINK, FOLDING TOP NUMBER FOUR BOW
BOW, FOLDING TOP NUMBER FIVE
BRACKET, FOLDING TOP PIVOT
FILLER, FOLDING TOP QUARTER WINDOW
ARM, FOLDING TOP OUTER
RAIL, FOLDING TOP SIDE
(
45
01-1895
F8010109
Figure 1O Folding Top Overview
14. Side front stay rivets (65) by drilling out with

15. Number one, two, three and four bow position
pad (64).
16. Number one bow links (58) from number one
bow (39) by punching out pins.
17. Number one bow bolts/screws (63) and bushings
(53).
18. Number one bow (39).
19. Old adhesive from side rail weatherstrip and
number one bow (39).
l++I
Install or Connect
NOTICE:
1. Number one bow (39).

2.Lubricant (CluberLube "Microlube" GL-261 or
equivalent) to number one bow bushings (53) and
bolts/screws (63).
3. Number one bow bushings (53) and bolts/screws
(63).
l~I Tighten

4. Number one bow links (58) to number one bow
(39) and install pins.
pad (64) to number one bow (39).
6.. Side front stay rivets (65).
7. Black tape to cover side front stay rivets (65).
8. Cover to number one bow. Refer to "Folding Top
(52).
11. Headlining trim finish panel (55) to number one
bow (39). Refer to "Headlining Trim Finish
Panel" in this section.
12. Headlining trim finish panel rivets.
(50).
1099
'
-~
I
I
J-t,..
49
IVIEW A I
,..____
50
39 BOW, FOLDING TOP NUMBER ONE

49 MOLDING, FOLDING TOP NUMBER ONE BOW GARNISH
50 BOLT/SCREW, FOLDING TOP NUMBER ONE BOW
GARNISH MOLDING
01-189$
FS011109
Figure 11 Number One Bow Garnish Molding
A
32
39
48
51
HEADLINER RIVET LOCATIONS

LATCH, FOLDING TOP FRONT
RETAINER, FOLDING TOP FRONT COVER NUMBER
ONE BOW
53 BUSHING, FOLDING TOP NUMBER ONE BOW
63 BOLT/SCREW, FOLDING TOP NUMBER ONE BOW
73 BOLT/SCREW, FOLDING TOP FRONT LATCH
!VIEWAI
OMlH
FS012109
Figure 12 Bow Number One to Side Rail
10"'.910

54
56
55
47
D
A
B
C
O
39
41
42
44
45
47
49
50
51
52
54
55
56
BOLT/SCREW, ELASTIC TENSION STRAPS
ELASTIC TENSION STRAP
HOOK-ANO-LOOP FASTENER STRAP
MOLDING, FOLDING TOP NUMBER ONE BOW GARNISH
BOLT/SCREW, FOLDING TOP NUMBER ONE BOW
GARNISH MOLDING
RETAINER, FOLDING TOP FRONT COVER NUMBER ONE
BOW
BOLT/SCREW, FOLDING TOP COVER RETAINER NUMBER
ONE BOW
COVER, FOLDING TOP
PANEL, FOLDING TOP HEADLINING TRIM FINISH
WINDOW. REAR (HEATED)
54
54
!VIEW
el
01-18-95
FS013109
Figure 13 - Folding Top Cover and Headliner
10-9-11
s.
~~-;.~
62
_,,.,,,'D
A
B
C
D
E
39
40
48
58
59
NUMBER ONE BOW LINK PIN

NUMBER TWO BOW LINK BALLSTUD CLIP
PIVOT ASSIST SPRING
JAM NUT
NUMBER TWO BOW LINK OUTER LOCK NUT
LINK, FOLDING TOP NUMBER ONE BOW
LINK, FOLDING TOP NUMBER TWO BOW
60 INSULATOR, FOLDING TOP NUMBER TWO BOW
61 BOLT/SCREW, FOLDING TOP NUMBER TWO BOW
INSULATOR
LINK, FOLDING TOP FRONT SIDE RAIL
01-1895
FS014109
Figure 14 - Number One to Number Two Bow Linkage
15. Side rail garnish moldings. Refer to "Folding Top

17. Tum pump bypass valve to "closed" position
(fully counter-clockwise). Refer to "Manual
Operation" under "Folding Top Operation" in this
section.
Folding Top Number Two Bow
Figures 11, 12, 13, 14 and 15
!++!

clockwise). Refer to "Manual Operation" under
(50).
6. Bolts/screws at each comer of headlining trim
finish panel (55).

9. Top cover from number one bow and pull back
along cover retainer cable to reveal number two
bow. Refer to "Folding Top Cover" in this
section.
two bow (40).
11. Cover (54) from number two bow (40) by peeling
away from adhesive.
12. Staples holding number one, two, three and four
bow position pad (64) to number two bow (40).
Mark location of pad and staples.
14. Outside nut from number two bow links (59).
15. Number two bow links (59) from number one
bow links (58).
16. Number two bow (40).
17. Old adhesive from number two bow (40).
!++!
Install or Connect
Use Hughes PIN HC-4183, 3M PIN 8046, or

equivalent adhesive on headliner or top cover
attaching surfaces.
1. Tape to number two bow (40).
2. Number two bow (40).
3. Number two bow links (59) to number one bow
links (58).
4. Outside nut to number two bow links (59).
-7
A
A
B
39
40
41
42
44
64
65
66
PAD STAPLE
LOOP SIDE OF HOOK-AND-LOOP FASTENER TAPE
PAD, FOLDING TOP NUMBER ONE, TWO,
THREE AND FOUR BOW POSITION
RIVET, FOLDING TOP SIDE FRONT STAY
PAD, FOLDING TOP NUMBER FOUR AND
FIVE BOW POSITION
01-1395
FS015109
Figure 15 - StaYPad

(39) and install pins. 6. Number one, two, three
and four bow position pad (64) to their original
positions on number two bow (40) and install
staples at their original locations.
6. Cover (54) to number two bow (40).
Wrap anti-ballooning strip around bow and
press into place.
7. Headlining trim finish panel to number two bow.
Refer to "Headlining Trim Finish Panel" in this
section.
8. Top cover to number one bow. Refer to "Folding
Top Cover" in this section.
10. Headlining trim finish panel to number one bow.
Refer to "Headlining Trim Finish Panel" in this
section.
11. Bolts/screws at each comer of headlining trim
finish panel (55).
(50).

section.
Folding Top Number Three Bow
Figures 10, 11, 13, 15, 16 and 17
!++!

CAUTION: Refer to ''Caution" under
4. Top cover and headliner from number one, two,
and three bow. Refer to "Folding Top Cover" in
this section.
5. Cover retainer cable (70) from outer arm (47).
6. Staples holding number one, two, three and four
pad (64) to number three bow (41).
7. Bolts/screws (68) from number three bow (41).
Reposition plastic tackstrip along channel in
number three bow to reveal bolts/screws.
8. Number three bow (41).
9. 0 Id tape from number three bow ( 41) and
adhesive from outer arm (47).
l++l
10-9-13
Install or Connect
NOTICE:
Refer to "Notice" on page 10~9-l.
Use Hughes PIN HC-4183, 3M P/N 8046, or

attaching surfaces.
1. Tape to number three bow (41).
3. Bolts/screws (68) to number three bow (41).
l~l
Tighten

- Return plastic tackstrip to its original
position.
pad (64) to their original positions on number
three bow (41) and install staples.
5. Cover retainer cable (70) to outer arm (47).
6. Top cover and headliner to number one, two and
three bow and outer arm. Refer to "Folding Top
7. Turn pump bypass valve to "closed" position
section.
Folding Top Number Four Bow

l+-+I

2. Bolts/screws connecting headlining trim finish

3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
panel elastic tension straps to number five bow

( 44) and number four bow (42).
Rear retaining nuts from number five bow (44).
Number five bow (44).
Electrical connectors from rear window defogger.
Top cover to reveal top of number four bow (42)
on both sides of vehicle.
Hook-and-loop fastener pads on number four bow
(42).
Mark position of number four and five bow
position pad (66) on number four bow (42).
Number four and five bow position pad (66) from
number four bow (42).
Lower end (inboard comer) of number four and
five bow position pad (66) to reveal rear window.
Mark position of number one, two, three and four
bow position pad (64) at number four bow (42).
Number one, two, three and four bow position
pad (64) from number four bow (42).
41
42
45
47
67
68
69

LINK, FOLDING TOP NUMBER FOUR BOW
BOLT/SCREW, FOLDING TOP NUMBER THREE BOW
BOLT/SCREW, FOLDING TOP NUMBER FOUR BOW LINK
01-18-95
FS016109
Figure 16 - Number Three and Four Bow
13. Mark top edge of number five bow (44) on rear

window fabric.
14. Center bolt/screw for rear window (56) to number
four bow (42).
15. Slide out rear window (56).
16. Slide down tackstrips on number four bow (42) to
reveal top cover number four bow retainer (72).
17. Top cover number four bow retainer (72), using
appropriate tool.
18. Top cover (54) from number four bow (42),
19. Mark ends of number four bow (42) on number
four bow links (43).
20. Number four bow link bolts/screws (69).
21. Number four bow (42) from number four bow
links (43).
22. Slide number four bow (42) off headlining trim
finish panel (55).
I++-!
Install or Connect
NOTICE:
1. Slide number four bow (42) over headlining trim

finish panel (55).
2. Number four bow (42) to its original depth on
number four bow links.
10-9-14 ROOF AND FOLDING TOP
48
47
54
!VIEW B!
40 41
lv1Ewcl
A ADHESIVE
B INSERT FEATURE STRIP
C BOLT/SCREW, REAR WINDOW
D ANTI-BALLOONING STRIP
39 BOW, FOLDING TOP NUMBER ONE
40 BOW, FOLDING TOP NUMBER TWO
41 . BOW, FOLDING TOP NUMBER THREE
42 BOW, FOLDING TOP NUMBER FOUR
47 ARM, FOLDING TOP OUTER
48 RAIL, FOLDING TOP SIDE
54 COVER, FOLDING TOP
56 WINDOW, REAR (HEATED)
70 CABLE, FOLDING TOP COVER RETAINER
71 BOLT/SCREW, FOLDING TOP SIDE TENSION CABLE SET
72 RETAINER, FOLDING TOP COVER NUMBER FOUR BOW
56
IVIEW O I
01-18-95
FS017109
Figure 17 - Top Cover Fastening Details
I~!
Tighten

4. Top cover (54) to number four bow (42).
5. Top cover number four bow retainer, using
appropriate tool.
6. Return tackstrips on number four bow (42) to
their original positions.
7. Slide rear window (56) into position.
8. Center bolt/screw for rear window (56) to number
four bow (42).
pad (64) and staples to their original positions on
10. Lower end of number four and five bow position
pad (66) and staples.
11. Number four and five bow position pad (66) and
staples to their original positions on number four
bow (42).
12. Hook-and-loop fastener pads on number four bow
(42).
[I)
Important
The number four bow uses the "loop" (soft)

portion of a hook-and-loop fastener tape to
prevent the bow from showing through top
cover. "Hook" portion is not used. Loop tape
is self-adhesive but must also be stapled to the
bow. Failure to staple the tape into place could
cause the tape to bunch up under top cover.
13.
14.
15.
16.
17.
Top cover (54) to its original position.

Electrical connectors to rear window defogger.
Number five bow (44).
Rear retaining nuts to number five bow (44).
Bolts/ screws connecting headlining trim finish
panel elastic tension straps to number four bow
(42) and number five bow (44).
Folding Top Number Five Bow

Figures 13 and 15
l++I
CAUTION: Refer to 11 Caution 11 under

2. Tum pump bypass valve to "open" position (fully
(44).
4. Rear retaining nuts from number five bow (44).
5. Raise number five bow (44) over top cover (54).
10-9-15
6. Staples attaching cover (54), rear window (56),

and number four and five bow position pad (66)
to number five bow (44).
Mark positions of all staples.
7. Number five bow (44).
!H!
Install or Connect
NOTICE:
l. Number four and five bow position pad (66), rear

window (56) and cover (54) to number five bow
( 44) by stapling into their original positions.
2. Number five bow (44) to rear mounting studs.
3. Rear retainer nuts to number five bow mounting
studs.
panel elastic tension strap to number five bow
(44).
section.
FOLDING TOP FRONT LATCH
F
H
A
B
C
D
E
F
G
H
J
74
75
76
77
LATCH HANDLE PIN

O
CLAMP BODY
RELEASE BUTION PIN
LATCH RELEASE BUTION
LATCH MOUNTING BRACKET
HEADER LATCH LEVER
CLAMP BODY SETSCREW
VIEW A
TRIMMED LENGTH OF SPRING
FOLDING TOP FRONT LATCH HOOK

SPRING, FOLDING TOP FRONT LATCH
SPRING, FOLDING TOP FRONT LATCH HOOK
PIN, FOLDING TOP FRONT LATCH
SPRING, FOLDING TOP FRONT LATCH RELEASE BUTION
Front Latch Adjustment
5-17-94
FS018109
Figures 8 and 18
Adjustment of the front latch determines the
sealing quality of the number one bow to the
windshield header and the latching or releasing effort
of the latch mechanism.
A "long" .latch hook adjustment can be identified
by low latching effort or the number one bow setting
too high off the windshield header. This condition can
cause wind noise and water leaks.
A "short" latch hook adjustment will cause
excessively high latching effort and the number one
bow to "sink" below the windshield header when
latched. This condition may cause weatherstrip damage
or latch failure.
Figure 18 - Front Latch
3. Adjust latch.
A. Raise folding top off windshield header.

B. Loosen clamp body set screw.
C. Turn front latch hook in desired direction.
rn
Important
Front latch hook must be face forward.

D. Raise and latch folding top and check latch
adjustment. If further adjustment is necessary,
return to step C. Otherwise, continue with step
E.
E. Lower folding top and tighten clamp body set

screw.
[ ] Important
A proper front latch hook adjustment should
reveal three to four threads outside of the clamp
body. If fewer than three or more than four
threads are visible, the folding top should be
checked for other mechanical problems.
If for any reason a latch needs adjustment, both
sides of the vehicle should be checked and, if
necessary, adjusted.
Use the following procedure to adjust the latch:
1. Raise folding top and latch to windshield header.
A. Note operation of latch and latching effort.
B.. Latching effort should be equal on both sides.
2. Check fit between number one bow and
windshield header.
A. Number one bow should be flush to 2 mm
(1/16 inch) below windshield header trim.
B. Check other side of vehicle.
I~!
Tighten
Clamp body set screw to 10 N .m

(89 lb. in.).
F. Repeat other side of vehicle.
Front Latch Replacement

!++!
1. Lower folding top.

2. Mark folding top to fabric along front edge of
number one bow (39) for reference.
(52).

Peel back top cover to reveal latch
bolts/screws.
5. Latch bolts/screws (73).
6. Latch (32).
!+++!
Disassemble
1. Note position of front latch spring (74) and

remove from latch handle pin.
2. Note position of front latch hook spring (75) and
drive out pin (76) to remove clamp body.
3. Note position of front latch release button spring
(77) and drive out pin to remove latch release
button.
I+;+!
Assemble
1. Latch release button to latch mounting bracket

and front latch release button spring (77).
2. Drive in release button pin.
CAUTION: Failure to trim the ends of the

front latch release button spring could
result in personal injury when operating
the front latch.
3. Trim ends of front latch release button spring
(77).
4. Clamp body and front latch hook spring (75).
5. Drive in pin (76).
6. Front latch spring (7 4) to latch handle pin.
iH!
Install or Connect
NOTICE:
1. Latch (32).
2. Latch bolts/screws (73).
!~I
Tighten

3. Cover. Refer to "Folding Top Cover" in this
section.
(52).
6. Raise folding top.

''Folding Top Operation" in this section.
NOTICE: Do not disturb the inside nut on the

forward end of number two bow links. This nut
is used as a "stopper" and is not to be adjusted.
Changing the position of the inside nut could
cause adjustment problems and part failure.
5. Outer lockouts from number two bow links (59).
6. Number two bow links (59) from number one

bow links (58).
8. Ball stud clip from front side rail link (62).
9. Number two bow links (59).
!++!
Install or Connect

1. Number two bow links (59).
2. Ball stud clip to front side rail link (62).
(39) and install pins.
4. Number two bow links (59) to number one bow
links (58).
5. Outer lockouts to number two bow links (59).
Refer to "Notice" in this procedure.
l~I Tighten
Locknut to 5 N.m (44 lb. in.).
Operation" under ''Folding Top Operation" in this
section.
Folding Top Number One and Number Two Bow
Link Adjustments
FOLDING TOP RAIL
Figure 14
Folding Top Number One and Number Two

Bow Links
After installing a number one bow link (58) to

the number two bow (40), the number one bow link
must be adjusted for proper length using the following
procedure:
1. Adjust number one bow link (58) so that forward
hole in link is 149 mm " 1 mm (5.9 inches "0.04
inches) from forward most edge of number two
bow (40).
Figure 14
I++!

2. Attach front end of number two bow link (59) to
number one bow link (58).
NOTICE: Do not disturb the inside nut on the

forward end of number two bow links. This nut
is used as a "stopper" and is not to be adjusted.
Changing the position of the inside .nut could
cause adjustment problems and part failure.
NOTICE:
If adjustments are performed with

the folding top in any position other than closed
and latched, the side rail link ball stud will be
sheared off.
3. Close and latch folding top.
4. Adjust (rotate) ball stud clip until it aligns well
with ball stud.
5. Cycle folding top manually and observe operation.
If inconsistent action or binding occur, readjust as
necessary.
6. Back locknut away from ball stud clip, apply
Loctite-242 (blue) and reposition locknut.
Front Side Rail Link

Figures 14 and 19
!++I


section.
Folding Top Side Rail

!++!
CAUTION:
Refer to "Caution" under
II
Disconnecting the Battery Negative
4. Side rail weatherstrip. Refer to ''Folding Top Side
Rail Weatherstrip" in this section.
5. Side rail weatherstrip retainer. Refer to ''Folding
Top Side Rail Weatherstrip Retainers" in this
section.
7. Bolt/screw (71) attaching cover retainer cable (70)
to outer arm (47).
79

4. Number two bow link (59) from front side rail
link (62). Refer to ''Folding Top Number One and
Number Two Bow Links" in the preceding
procedure.
5. Bolts/screws (82 and 83), washers (81), front side
rail link (62) and bushings (78 and 79).
6. Downstop from front side rail link (62).
l++I
109-17
Install or Connect
NOTICE:
1. Downstop to front side rail link (62).

2. Bushings (78 and 79), front side rail link (62),
washers (81) and bolts/screws (82 and 83).
!~!
Tighten
Bolts/screws (82 and

(13 lb. ft.).
3. Number two bow link (59) to
(62). Refer to ''Folding Top
Number Two Bow Links"
procedure.
83) to 17 N,m
front side rail link
Number One and
in the preceding
A
B
C
47
48
62
78
79
80
81
82
RAIL DOWNSTOP
RAIL DOWNSTOP PIN
FRONT SIDE RAIL LINK BALLSTUD
LINK, FOLDING TOP FRONT SIDE RAIL
BUSHING, FOLDING TOP FRONT SIDE RAIL LINK FRONT
BUSHING, FOLDING TOP FRONT SIDE RAIL LINK REAR
BUSHING, FOLDING TOP SIDE RAIL LINK PIVOT
WASHER, FOLDING TOP SIDE RAIL LINK PIVOT
BOLT/SCREW, FOLDING TOP FRONT SIDE RAIL LINK
FRONT
83 BOLT/SCREW, FOLDING TOP FRONT SIDE RAIL LINK
REAR
84 BOLT/SCREW, FOLDING TOP SIDE RAIL LINK PIVOT
85 LINK, FOLDING TOP SIDE RAIL
01-1895
FS019109
Figure 19 - Side Rail Links
10-9-18
8. Folding top cover retainer number one

bolts/screws (52).
10. Mark top cover fabric along front edge of number
one bow (39) for reference.
Peel back top cover from number one bow to
reveal number one bow bolts/screws. Refer to
"Folding Top Number One Bow" in this
section.
11. Number one bow bolts/screws. Refer to "Folding
Top Number One Bow" in this section.
12. Bolt/screw (82), washer (81), and bushing (78)
attaching front side rail link (62) to side rail (48).
13. Bolt/screw (84), washer (81) and bushing (80)
attaching side rail link (85) to side rail (48).
14. Cover retainer cable (70).
15. Side rail (48).
!+!+!
Disassemble
1. Number two bow insulator bolt/screw (61).

2. Number two bow insulator (60) from side rail
(48).
j+;+I
Assemble
NOTICE:
1. Number two bow insulator (60) to side rail (48).

2. Number two bow insulator bolt/screw (61).
!~!
Tighten
!++!
Install or Connect
1. Side rail (48).

2. Cover retainer cable (70) at front end of side rail
(48). 3. Bolt/screw (84), bushing (80) and washer
(81) attaching side rail link (85) to side rail (48).
I~!
Tighten

3. Bolt/screw (82), washer (81), and bushing (78)
attaching front side rail link (62) to side rail (48).
I~!
Tighten

4. Number one bow bolts/screws. Refer to "Folding
Top Number One Bow" in this section.
5. Top cover. Refer to "Folding Top Number One
Bow" in this section for proper cover installation.
8. Cover retainer cable (70) at front of side rail (48).
9. Bolt/screw (71).
11. Side rail weatherstrip retainer. Refer to "Folding

section.
12. Side rail weatherstrip. Refer to "Folding Top Side
13. Turn pump bypass valve to "closed" position.
Refer to "Manual Operation" under "Folding Top
Operation" in this section.
Folding Top Outer Arm

Figures 15, 16, 17, 19, 20, 21 and 22
11]
Important
If an outer arm is being serviced on only one side

of the vehicle, follow the procedure described in
"On-Vehicle Service. "If the outer arm are being
serviced on both sides of the vehicle, follow the
procedure described in "Off-Vehicle Service."
ON-VEHICLE SERVICE
j++!
1. Lower folding top about halfway down and prop

up with a suitable support.

3. Outer arm weatherstrip. Refer to "Folding Top
Outer Arm Weatherstrip" in this section.
4. Outer arm weatherstrip retainer. Refer to "Folding
Top Outer Arm Weatherstrip Retainers" in this
section.
5. Quarter window filler bolts/screws (95).
6. Quarter window fillers (46).
7. Cover (54) from outer arm (47) by removing
bolts/screws.
8. Cover (54) from outer arm (47) by peeling away
from adhesive.
10. Staples connecting number one, two, three and
four bow position pad (64) to number three bow
(41).
Slide plastic tackstrip along channel in number
three bow to reveal bolts/screws.
12. Front side rail link rear bolt/screw (83) and
washer (81).
13. Front side rail link (62) and bushing (79) from
outer arm (47).
14. Side rail link pivot bolt/screw (84) and washer
(81).
15. Side rail link (85) from outer arm (47).
10919
89
A
B
36
37
45
47
86
87
88
89
PINK HOSE
WHITE HOSE
HOSE, FOLDING TOP CYLINDER LOWER (RIGHT SIDE}
HOSE, FOLDING TOP CYLINDER lJPPER ILEFT SIDE}
CYLINDER. FOLDING TOP
PIN, FOLDING TOP CYLINDER PIVOT
PIN, FOLDING TOP PIVOT BRACKET LOCKING
BOLT/SCREW, FOLDING TOP CYLINDER
01-1895
FS0201ot
Figure 20 Cylinder to Main Pivot Bracket
16. Pivot bracket locking pin (88) and cylinder pivot

pin (87).
17. Cylinder (86) from outer arm (47).
19. Outer arm pivot pin retainer (92).
20. Outer arm (47) (with inner .arm link cam (91)
attached).
Clean
96
Adhesive from outer arm (47).
!++I
NOTICE:
1. Outer arm (47) (with inner arm link cam (91)

attached).
3. Bolt/screw (89).
!~I
6.
7.
8.
Tighten

Cylinder (86) to outer arm (47).
Cylinder pivot pin (87) and pivot bracket locking
pin (88).
Side rail link (85) to outer arm (47).
Front side rail link (62) and bushing (79) to outer
arm (47).
Side rail link pivot bolt/screw (84) and washer
(81).
45

attaching surfaces.
4.
5.
Install or Connect
A
B
45
47
80
84
90
91
92
93
94
96
97
IDLER LINK
BALANCE LINK
BUSHING, FOLDING TOP SIDE RAIL LINK PIVOT
BOLT/SCREW, FOLDING TOP SIDE RAIL LINK PIVOT
BUSHING, FOLDING TOP LINK CAM PIVOT
CAM, FOLDING TOP INNER ARM LINK
RETAINER, FOLDING TOP OUTER ARM PIVOT PIN
NUT, FOLDING TOP REAR SIDE RAIL LINK
WASHER, FOLDING TOP SIDE RAIL LINK PIVOT
BOLT/SCREW, FOLDING TOP OUTER ARM PIVOT
BUSHING, FOLDING TOP OUTER ARM PIVOT
01-1811
FS0211ot
Figure 21 Outer Arm to Main Pivot Bracket

section.
rn
Important
The outer arm service part .is not pre-drilled

for. weatherstrip retainer screws. Use the
weatherstrip retainer as a template to drill
holes at the appropriate locations on the new
outer arm.
17. Outer arm weatherstrip. Refer to "Folding 'fop
Outer Arm Weatherstrip " in this section.
19. Remove support and raise foldingtop.
45
OFF-VEHICLE SERVICE
!++!
45
46
47
95

FILLER, FOLDING TOP QUARTER WINDOW
BOLT/SCREW, FOLDING TOP QUARTER WINDOW
FILLER
01-1895
FS022109
Figure 22 - Quarter Window Filler
Tighten
9. Bolt/screw (83).
i~!
Tighten

10. Bolts/screws (68) attaching number three bow
(41) to outer arm (47).
!~!
11.
12.
13.
14.
15.
Tighten

position.
pad (64) to its original position on number three
bow (41) and install staples at their original
locations.
Cover retainer cable (70).
Cover (54) to outer arm (47).
A. Apply adhesive to outer arm and to portion of
cover being attached.
B. Press cover into place.
C. Install bolts/screws.
Quarter window filler (46).
Quarter window filler bolts/screws (95).
!~!
Tighten
1. Folding top from vehicle. Refer to "Folding Top

Complete Replacement" in this section.
2. Pivot bracket from outer arm. Refer to "Folding
Top Pivot Bracket" in this section.
5. Quarter window filler (46).
6. Peel top cover back from outer arm ( 47).
7. Side rail link pivot bolts/screws (84), washers (81)
and bushings (80).
8. Side rail link (85).
9. Front side rail link rear bolts/screws (83), washers
(81) and bushings (79).
10. Front side rail link (62).
11. Side tension cable set bolt/screw (71) from outer
arm (47).
12. Cover retainer cable (70) from outer arm (47).
13. Mark position of number one, two, three and four
bow position pad (64) along number three bow
(41).
pad (64) from number three bow (41).
15. Reposition number three bow tackstrips to reveal
number three bow bolts/screws (68).
16. Number three bow bolts/screws (68).
Clean
Adhesive from outer arm (47).
!++!
Install or Connect
NOTICE:

attaching surfaces.

!~I
Tighten

3. Return number three bow tackstrips to their
original positions.
pad (64) to their original positions on number
three bow (41) and install staples.
5. Cover retainer cable (70) and bolts/screws (71) to
outer arm (47).
6. Front side rail link (62).
7. Front side rail link rear bolts/screws (83), washers
(81) and bushings (79).
l~I
Tighten

8. Side rail link (85).
9. Side rail link pivot bolts/screws (84), washers (81)
and bushings (80).
I~!
Tighten

10. Apply adhesive and press top cover flap into outer
arm (47).
I~!
Tighten

14. Pivot bracket to outer arm. Refer to ''Folding Top
Pivot Bracket" in this section.
15. Folding top onto vehicle. Refer to "Folding Top
Folding Top Side Rail Link

Figures 15, 16, 17, 19, 20, 21 and 22
El
1. Lower folding top about halfway down and prop

up with a suitable support.
CAUTION: Refer to "Caution'' under

4. Outer arm weatherstrip retainer. Refer to ''Folding
section.
10-9-21

7. Cover from outer arm (47) by removing
bolts/screws and peeling cover away from
adhesive.
9. Staples connecting number one, two, three and
four bow position pad (64) to number three bow
(41).
Mark location of pad.
Slide plastic tackstrip along channel in number
three bow to reveal bolts/screws.
11. Bolt/screw (83) and washer (81).
12. Front side rail link (62) and bushing (79) from
outer arm (47).
13. Side rail link (85) and bushing (80) from outer
arm (47).
pin (87).
16. Bolt/screw (96) attaching outer arm (47) to pivot
bracket (45).
18. Outer arm (47) with inner arm link cam (91)
attached.
19. Quarter inner rear trim finish panel. Refer to
SECTION 10-7.
20. Speaker. Refer to SECTION 10-7.
21. Cylinder bolt/screw (89).
22. Number four bow links. Refer to ''Folding Top
Number Four Bow" in this section.
23. Side rail weatherstrip. Refer to ''Folding Top Side
Rail Weatherstrip " in this section.
section.
27. Side rail link (62) and bushing (80) from side rail
(48).
28. Pivot bracket nuts.
29. Pivot bracket (45).
30. Old adhesive from outer arm (47).
!+!+I
Disassemble
1. Side rail link pivot bolt/screw (84), washer (94)

and rear side rail link nut (93).
2. Balance link (part of side rail link) and bushing
(80) from idler link (part of pivot bracket).
l+;+I
Assemble
NOTICE:
1. Balance link and bushing (80) to idler link.

2. Side rail link pivot bolt/screw (84), washer (94)
and rear side rail link nut (93).
'10922
I~!

Tighten
!++I
Install or Connect

attaching surfaces.
1. Pivot bracket (45).
2. Pivot bracket nuts.
3. Side rail link (62) and bushing (80) to side rail
(48).
l~I
5.
6.
7.
8.
. 9.
Tighten

Side rail garnish molding. Refer to "Folding Top
Side rail weatherstrip retainer. Refer to "Folding
section.
Side rail weatherstrip. Refer to "Folding Top Side
Number four bow links. Refer to "Folding Top
Number Four Bow" in this section.
Cylinder bolt/screw (89).
!~I
Tighten

SECTION 10-7.
12. Outer arm (47) with inner arm cam link (91)
attached.
14. Bolt/screw (96) attaching outer arm (47) to pivot
bracket (45).
l~I
Tighten

15. Cylinder (86) to outer arm (47).
.
16. Cylinder pivot pin (87) and pivot bracket locking
pin (88).
17. Side rail link (85) and bushing (80) to outer arm
(47).
18. Bolt/screw (83) and washer (81) attaching front
side rail link (62) and bushing (79) to outer arm
(47).
!~I
Tighten

19. Number three bow bolts/screws (68).
!~I
Tighten

position.

pad (64) to its original position on number three
bow (41) and install staples at their original
locations.
22. Cover to outer arm (47).
A. Apply adhesive to outer arm and to portion of

cover being attached.
B. Press cover into place.
C. Install bolts/screws.
l~I Tighten
section.
Outer Arm Weatherstrip " in this section.
28. Remove support and raise folding top.
Folding Top Pivot Bracket

Figures 16 and 21
!++!
1. Folding top from vehicle. Refer to ''Folding Top

2. Mark end of number four bow (42) on number
four bow links (67).
4. Number four bow (42) from number four bow
links (67).
5. Side rail link pivot bolts/screws (84), washers
(94), bushings (80) and nuts (93).
6. Balance link from idler link.
7. "E" clip and roller from idler link.
8. Outer arm pivot bolt/screw (96).
9. Pivot bracket (45) from outer arm (47).
l++I
Install or Connect

1. Pivot bracket (45) to outer arm (47).
2. Outer arm pivot bolt/screw (96).
!~!
Tighten
Bolt/screw (96) to 17 N:m (13 lb. ft.).

3. Roller and "E" clip to idler link.
4. Balance link to idler link.
5. Side rail link pivot bolts/screws (84), washers
(94), bushings (80), and nuts (93).
!~I
Tighten

6. Number four bow (42) to number four bow links
(67).
l~I
Tighten

8. Folding top onto vehicle. Refer to "Folding Top
FOLDING TOP HYDRAULIC SYSTEM

(Left-Hand Cylinder)
10923
6. Pivot b:racket locking pin (88) and cylinder pivot

pin (87) from left-hand cylinder.
9. Cylinder upper hose (37) at pump (34).
Use a shop towel to control hydraulic oil
leakage.
10. Cylinder upper hose (37) at left-hand cylinder
(86).
Detach hoses from metal clips and plastic clips
as required.
leakage.
11. Cylinder upper hose (37) from vehicle.
!++!
Install or Connect
Figures 9 and 20
l++!
NOTICE: The terms "upper hose" and "lower

hose" refer to their respective connecting points
on the upper and lower sections of the PUMP,
not the cylinders.
Each hose consists of one pink. and one white
hose bundled together. The upper hose controls the
left-hand cylinder and the lower hose controls the
right-hand cylinder. Pink hoses go to the top of each
cylinder and white hoses go to the bottom of each
cylinder.
Make sure hoses are always connected as
indicated. If hoses are switched, one cylinder could
extend while the other cylinder retracts, damaging the
folding top.
[I]
Important
When servicing the hydraulic system, leave the

folding top raised but unlatched from the
windshield header. T)J.is will keep the cylinder
rods extended and minimize fluid leakage.

3. Left rear compartment side trim. Refer to
SECTION 10-8.
SECTION 10-7.
NOTICE:
1. Route cylinder upper hose (37) from lefthand

cylinder (86) to pump (34) along original path.
2. Secure hose to clips.
3. Cylinder upper hose (3]) to pump (34). Install
PINK hose to LEFT side of pump. Install WHITE
hose to RIGHT side of pump.
4. Cylinder upper hose (37) to cylinder (86) (finger
tight). Install PINK hose to TOP of cylinder.
Install WHITE hose to BOTTOM of cylinder.
5. Cylinder (86).
1~1
Tighten

pin (88).
9. Tum pump bypass valve to ''closed" position
section.
l~!
10.
11.
12.
13.
14.
Tighten
Cylinder upper hose fittings to 7 N.m (62 lb.

in.).
Speaker. Refer to SECTION 10-7.
Quarter inner rear trim finish panel. Refer to
SECTION 10-7.
Left rear compartment side trim. Refer to
SECTION 10-8.
Bleed hydraulic system. Refer to. "Hydraulic
System Bleeding Procedure" in this section.
10-9-24
ROOF AND .FOLDING TOP

(Right-Hand Cylinder)
Figures 9 and 20
I++!

hose" refer to their respective connecting points
not the cylinders.
Each hose consists of one pink and one white
left-hand cylinder and the. lower hose controls the
right-hand cylinder. Pink hoses go to the top of each
cylinder.
folding top.
rn

11
Disconnecting the Battery Negative
SECTION 10-8.
SECTION 10-7.
pin (87) from right-hand cylinder.
9. Cylinder lower hose (36) at right-hand cylinder.
Detach hoses from metal clips and plastic clips
as required.
leakage.
10. Cylinder lower hose (36) at pump (34).
leakage.
11. Cylinder lower hose (36) from vehicle.
Install or Connect
NOTICE:
1~1 Tighten
pin (88).
l~I Tighten
Important

folding top raised but unlatched from the
windshield header. This will keep the cylinder
!++!
1. Cylinder lower hose (36). Route cylinder .lower

hose (36) from right-hand cylinder (86) tb pump
(34) along original path.
2. Secure hose to clips.
3. Cylinder lower hose (36) to pump (34). Install
PINK hose to LEFT side of pump. Install WHTIE
hose to RIGHT side of pump.
4. Cylinder lower hose (36) to right-hand cylinder.

Install PINK hose to TOP of cylinder. Install
WHITE hose to BOTTOM of cylinder.
5. Cylinder (86).
9.
10.
11.
12.
13.
14.
Cylinder lower hose fittings to 7 N,m

(62 lb. in.).
SECTION 10-7.
Left rear compartment side trim. Refer to
SECTION 10-8.
Turn pump bypass valve to "closed" position
section.
Bleed hydraulic system. Refer to "Hydraulic
Cylinder
Figure 20

hose'' refer to their respective connecting points
not the cylinders.
Each hose consists of one white and one pink
left-hand cylinder and the lower hose controls the
right-:hand cylinder. Pink hoses go to the top of each
cylinder.
folding top.
rn
Important

folding raised but unlatched from the
windshield header. This will keep the cylinder
!++I
1. Tum pump bypass valve to "open" position (fully


SECTION 10-7.
pin (87).
8. Cylinder upper hose (37) (left-hand side) or lower
hose (36) (right-hand side) from cylinder (86).
leakage.
l++I
Install or Connect
NOTICE:
rn
Important
Replacement cylinder are supplied filled with

oil. Do not remove sealing caps from cylinder
until you are ready to connect cylinder hose.
1. Cylinder upper hose (37) (left-hand side) or lower
hose (36) (right-hand side).
2. Cylinder (86) and cylinder bolt/screw (89).
l~I
Tighten

pin (88).
l~I
5.
6.
7.
8.
9.
10.
Tighten
Cylinder hose fittings to 7 N.m (62 lb. in.).

SECTION 10-7.
Raise folding top.
section.
Bleed hydraulic system. Refer to "Hydraulic
10-9-25
Folding Top Pump with Motor

Figure 9
l++I

2. Pump electrical connector.
3. Cylinder hose (36 and 37) from pump (34).
leakage.
4. Pump nuts (35).
5. Pump with motor (34).
l++I
Install or Connect
NOTICE:
NOTICE: The terms "upper hose'' and "lower

hose'' refer to their respective connecting points
not the cylinders.
1. Pump with motor (34).
2. Pump nuts (35).
l~l
Tighten
Nuts (35) to 6 N.m (53 lb. in.).

3. Cylinder hose (36 and 37) to pump (34).
l~I
Tighten
Cylinder hose fittings to 7 N.m (62 lb. in.).

4. Pump electrical connector.
Hydraulic System Bleeding Procedure

Figure 9
NOTICE: When performing this procedure, do

not allow the hydraulic oil level to drop below
the lower indicator line on the reservoir or
pump damage may occur.
NOTICE: To avoid part damage during
bleeding procedure, make sure cylinder rod does
not touch body components or folding top when
extending.
l++I
1. Cylinder from outer arm. Refer to "Cylinder" in

this section.
2. Cylinder from main pivot bracket. Refer to
10926
3. Position cylinder so cylinder rods will not touch

body components or folding top when fully
extended.
SECTION 10-8.
5. Reservoir filler plug.
6. One pink hose from pump/motor (34) and place at
reservoir opening.
7. Using a rubber plug, such as a snug-fitting
vacuum fitting cap, seal the open pump fitting.
rn
Important
Fitting must be sealed to prevent air from

entering system.
8. Push and hold "UP" on convertible top switch.
After cylinders are fully extended, continue to
depress switch until hose being bled is free of air
bubbles.
l++I
Install or Connect
NOTICE:
1. Pink hose to pump/motor (34).
!~I
Tighten
Hose fitting to 7 N.m (62 lb. in.).

2. If fluid level is low, add fluid to reservoir. Refer
to "Adding Fluid" in this section.
3. Repeat bleed procedure for other cylinder.
4. Reservoir filler plug.
SECTION 10-8.
6. Rotate pump bypass valve (38) fully clockwise to
"Open" position (1/4 turn).
7. Cylinder to outer arm. Refer to "Cylinder" in this
section.
8. Cylinder to main pivot bracket. Refer to
9. Rotate pump bypass valve (38) fully
counter-clockwise to "Closed" position (1/4 turn).
10. Cycle folding top up and down several times to
check hydraulic system operation.
Adding Fluid
Figure 9
rn
Important
Vehicle must be on a level surface with top in

lowered position.
2. Remove left rear compartment side trim. Refer to
SECTION 10-8.
3. Place shop towel around pump/motor (34) to
control hydraulic oil spillage.
4. Add fluid using SAE lOW motor oil.

A. Remove reservoir filler plug.
B. Add lOW motor oil until level is tbetween
upper and lower reservoir indicator lines.
C. Install reservoir filler plug.
5. Cycle folding top up and down severaltimes.
Check fluid level with folding top in the
"DOWN" position and add fluid if necessary.
6. Install left rear compartment side trim. Refer to
SECTION 10-8.
FOLDING TOP, WEATHERSTRIPS AND

GARNISHES
Figure 23
l++I
1. Lower folding top .to suitable working position.


3. Roof side rail weatherstrip (98).
!++!
Install or Connect
1. Roof side rail weatherstrip (98).

A. Line up bottom tab of weatherstrip (98) to
notch in weatherstrip retainer (99).
B. Insert weatherstrip (98) into retainer (99) and
roll into place.

Retainers
Figures 23 and 24
l++I


3. Roof side rail weatherstrip (98) ..
(100).
!++!
Install or Connect
NOTICE:
10-9-27


3. Front side door window upper rear weatherstrip
bolts/screws (102).
(101).
98
jVIEWAj
l++l
Install or Connect
NOTICE:
101
102
J~~
!VIEW
Bl
~99 103~f"'
!VIEW
Cl
jVIEWDj
98
99
101
WEATHERSTRIP, ROOF SIDE RAIL

RETAINER, ROOF SIDE RAIL WEATHERSTRIP
WEATHERSTRIP, FRONT SIDE DOOR WINDOW
UPPER BAR
102 SOLT /SCREW, FRONT SIDE DOOR WINDOW UPPER
REAR WEATHERSTRIP
103 RETAINER, FRONT SIDE DOOR WINDOW UPPER
REAR WEATHERSTRIP
01-1895

(101).
A. Line up top tab of weatherstrip (101) to notch
in weatherstrip retainer (103).
B. Insert weatherstrip (101) into retainer (103)
and roll into place.
bolts/screws (102).
l~I
Tighten

Folding Top Outer Arm Weatherstrip Retainers
Figure 24
!++!
FS023109
Figure 23 - Side Rail and Outer Arm Weatherstrips Folding

Top Outer Arm Weatherstrip Retainers

(100).
l~I
Tighten
Bolt/screw (100) to 1.3 N.m (12 lb. in;).

3. Roof side rail weatherstrip. Refer to "Folding Top
S.ide Rail Weatherstrip" in this section.

''Disconnecting the Battery Negative

3. Front side door window upper rear weatherstrip.
Refer to "Folding Top Outer Arm Weatherstrip"
in the preceding procedure.
retainer bolts/screws (104).
retainer (103).
l++I
Install or Connect
NOTICE:

Figure 23
!++I

retainer (103).
retainer bolts/screws (104).
l~I
Tighten

108
106
104
99 RETAINER, ROOF SIDE RAii. WEATHERSTRIP

100 801.T/SCREW, ROOF SIDE RAii. WEATHERSTRIP
RETAINER
103 RETAINER, FRONT SIDE DOOR WINDOW UPPER REAR
WEATHERSTRIP
104 801.T/SCREW. FRONT SIDE DOOR WINDOW UPPER
REAR WEATHERSTRIP RETAINER

106 RETAINER, FOi.DiNG TOP FRONT WEATHERSTRIP
107 801.T/SCREW, FOi.DiNG TOP FRONT WEATHERSTRIP
RETAINER
01-1891
FS024109
Figure 24 - Weatherstrip Retainers
3. Front side door window upper rear weatherstrip.

Refer to "Folding Top Outer Arm Weatherstrip"
in the preceding procedure.
(
A PI.ASTIC NAii.
108 WEATHERSTRIP, FOi.DiNG TOP FRONT
109 BOLT/SCREW, FOLDING TOP FRONT WEATHERSTRIP
01-1895
FS0251ot
Folding Top Front Weatherstrip

Figures 8 and 25
j++j

2. Right and left windshield side upper garnish
moldings. Refer to "Windshield Side Upper
Garnish Molding (With Lift-Off Windows)" in
this section.
3. Right and left body hinge pillar trim panels. Refer
to SECTION 10-5.
4. Right and left front latch striker bolts/screws.
5. Right and left front latch striker (33).
6. Front weatherstrip (108).
!++!
Install or Connect
NOTICE:
1. Front weatherstrip (108).

A. Remove paper backing from adhesive on
molded details of weatherstrip at top of
A-pillar.
Figure 25 Front Weatherstrip
B. Position molded details of weatherstrip to top

of A-pillar.
Align hole in weatherstrip to previously
drilled hole in body.
C. Drive front weatherstrip bolt/screw (109)
through hole in weatherstrip into previously
drilled hole in body.
I~! Tighten
D. Insert front top section of weatherstrip into
retainer on windshield header and roll entire
length of channel.
E. Insert rear top section of weatherstrip onto
vertical flange and roll entire length onto
flange.
F. Remove paper backing from adhesive on
molded details of weatherstrip at top of hinge
pillar.
G. Position weatherstrip to hinge pillar and insert
plastic nail through hole in weatherstrip into
hole in body at top of hinge pillar.
ROOF AND FOLDING TOP 10929
)
2.
3.
4.
5.
6.
H. Insert weatherstrip into A-pillar retainer and

roll entire length into channel.
I. Insert tapered end of weatherstrip into hole in
front side door lower weatherstrip.
J. Insert remaining length of weatherstrip onto
flange and roll into place.
Right and left front latch striker (33).
Right and left front latch striker bolts/screws.
Right and left body hinge pillar trim panels. Refer
to SECTION 10-5.
Right and left windshield side upper garnish
moldings. Refer to ''Wind.shield Side Upper
Garnish Molding (With Lift-Off Windows)" in
this section.
Raise folding top.
Folding Top Front Weatherstrip Retainers

Figures 24 and 25
!++!

3. Folding top front weatherstrip. Refer to ''Folding
Top Front Weatherstrip" in the preceding
procedure.
4. Folding top front weatherstrip retainer
bolts/screws (107);
5. Folding top front weatherstrip retainer (106).
I++!

SECTION 10-5.
4. Quarter inner rear trim finish panel bolt/screw.
Reposition quarter inner rear trim finish panel
to allow access to weatherstrip area.
5. Front side door weatherstrip bolt/screw (110).
6. Front side door weatherstrip (111).
I++!
Install or Connect
1. Front side door weatherstrip (111).

A. Remove paper backing from adhesive on
molded detail of weatherstrip at top of B-pillar.
B. Position molded detail of weatherstrip to top
of B-pillar.
a. Compress foam portion and insert into
cavity.
b. Hook vertical tab over flange on quarter
panel. Make sure rear most horizontal tab
is overlapping splash shield.
C. Drive bolt/screw (110) through hole in
weatherstrip to body.
D. Insert weatherstrip section onto door ring
flange, down B-pillar area, forward along
rocker and up A-pillar. Roll entire length into
place.
2. Quarter inner rear trim finish panel bolt/screw.
SECTION 10-5.
111
Install or Connect
NOTICE:
1. Folding top front weatherstrip retainer (106).

2. Folding top front weatherstrip retainer
bolts/screws (107).
l~I
111
Tighten

3. Folding top front weatherstrip. Refer to "Folding
Top Front Weatherstrip" in the preceding
procedure.
111
Folding Top Side Door Lower Weatherstrip

Figure 26
I++!

2. Windshield side upper garnish moldings. Refer to
"Windshield Side Upper Garnish Molding (With
Lift-Off Windows)" in this section.
A
B
110
111
VERTICAL TAB
HORIZONTAL TAB
BOLT/SCREW, FRONT SIDE DOOR WEATHERSTRIP
WEATHERSTRIP, FRONT SIDE DOOR LOWER .
1-17-95
FS026109
Figure 26 Side Door Lower Weatherstrip

(With Lift-Off Windows)" in this section.
Quarter Belt Reveal Moldings and Seals

Figures 27 and 28
!++!
1.
2.
3.
4.
Lower folding top.

Quarter belt reveal molding bolts/screws (112).
Quarter belt reveal molding (113) with seal (114).
Quarter belt reveal molding seal (114) from
quarter belt reveal molding (113).
5. Old adhesive from quarter belt reveal molding
(113).
!++!
Install or Connect
NOTICE:
1. Remove paper backing from adhesive on quarter

belt reveal molding seal (114).
2. Quarter belt reveal molding seal (114) to quarter
belt reveal molding (113).
3. Quarter belt reveal molding (113) with seal (114)
to rear quarter.
4. Quarter belt reveal molding bolts/screws (112).
112 BOLT/SCREW, QUARTER BELT REVEAL MOLDING

113 MOLDING, QUARTER BELT REVEAL
114 SEAL, QUARTER BELT REVEAL MOLDING
01-1895
FS028109
~ r e 28 Quarter Belt Reveal Molding -(Pontiac)
~ Tighten
Bolts/screws (112) to 5 N,m (44 lb. in.)

(Chevrolet) or 1.7 N,m (15 lb. in.) (Pontiac).
Folding Top Side Rail Garnish Molding

Figure 29
l++I

section.
5. Side rail garnish molding bolts/screws (115).
6. Side rail garnish molding (116).
112 BOLT/SCREW, QUARTER BELT REVEAL MOLDING
113 MOLDING, QUARTER BELT REVEAL
114 SEAL. QUARTER BELT REVEAL MOLDING
01-18-95
!++!
Install or Connect
NOTICE:
FS027109
Figure 27 - Quarter Belt Reveal Molding -(Chevrolet)
1. Side rail garnish molding (116).

10-9-31
FRTt
48 RAIL, FOLDING TOP SIDE

115 BOLT/SCREW, FOLDING TOP SIDE RAIL GARNISH MOLDING
116 MOLDING, FOLDING TOP SIDE RAIL GARNISH
01-1895
FS029109
I~!
Figure 29 - Side Rail Garnish Molding
Tighten

3. Side rail weatherstrip retainer. Refer to ''Folding
section.
Folding Top Cover Retention Cable

!++I
7. Number one bow bolts/screws (63).

8. Cover retention cable (70) from side rail (48).
and retainer. Refer to "Folding Top Outer Ann
Weatherstrip" in this section.
12. Peel top cover upper flap at outer arm (47) to
reveal side tension cable set bolt/screw (71).
13. Adhesive from outer arm (47).
14. Cover retention cable (70) from outer arm (47).
15. Cover retention cable (70).
l++j
Install or Connect

3. Mark folding top cover fabric along front edge of
number one bow (39).
(52).
6. Peel back top cover to reveal number one bow
bolts/screws (63).

Use Hughes P/N HC-4183, 3M P/B 8046, or
equivalent adhesive on top cover attaching surfaces.
1. Cover retention cable (70).
2. Cover retention cable (70) to outer arm (47).
3. Apply adhesive to outer arm (47), and press top
cover upper flap into place.
!~I
Tighten
10-9-32

retainer and weatherstrip. Refer to "Folding Top
7. Cover retention cable (70) to side rail (48).
8. Number one bow bolts/screws (63).
!~I
Tighten

9. Top cover. Refer to "Folding Top Number One
Bow" in this section.
11. Front cover number one bow retainer bolts/ screws
(52).
Rear Window
5. Retainer nuts onto number five bow mounting

studs.
6. Electrical connectors to rear window defogger.
7. Bolts/screws attaching headlining trim finish panel
elastic tension straps to number five bo1 (44).
8. Right and left quarter inner rear trim firsh panel.
9. Turn pump bypass valve to 11closed11 position
section.
Folding Top Cover

Figures 11, 12, 13, 15, 17, 22 and 29
!++j
Figures 13 and 15
!++!

3. Right and left quarter inner rear trim finish panel.
(44).
5. Electrical connectors from rear window defogger.
6. Nuts from number five bow retainer weld studs.
7. Reposition number five bow (44) to allow easier
access to rear window and number four bow (42).
8. Bolt/screw attaching rear window (56) to number
four bow (42).
9. Staples attaching cover (54), rear window (56)
to number five bow (44).
Mark positions of all and staples.
10. Rear window (56) from channel in number four
bow (42).
I++!
Install or Connect
1. Rear window (56) into channel in number four

bow (42).
2. Staples attaching cover (54), rear window (56)
to their original positions on the number five bow
(44).
3. Bolt/screw attaching rear window (56) to number
four bow (42).
4. Number five bow (44) onto retainer weld studs.

clockwise). R~fer to "Manual Operation" under
4. Side rail weatherstrip retainers. Refer to "Folding

section.
6. Side rail garnish moldings (116).
8. Outer arm weatherstrip retainers. Refer to
"Folding Top Outer Arm Weatherstrip Retainers"
in this section.
11. Bolts/screws attaching cover (54) to outer arm
(47).
12. Cover (54) from outer arm (47) by peeling away
from adhesive.
(50).
15. Bolts/screws from each front corner of headlining
trim finish panel (55).
two bow (40).
three bow (41), including bolts/screws for elastic
tension straps,
19. Mark top cover fabric along front edge of number
one bow (39).

20. Cover (54) from number one bow (39) by peeling
away from adhesive.
21. Cover (54) from number two bow (40) by peeling
away from adhesive.
22. Cover (54) from number three bow (41) by
peeling away from adhesive.
23. Cover retainer cable (70) from outer arm ( 47)
only.
24. Right and left quarter inner rear trim finish. panel.
25. Bolts/screws attaching headlining trim finish panel
elastic tension straps to number five bow (44).
26. Nuts from number five bow retainer weld studs.
27. Reposition number five bow (44) to allow easier
access to rear window and number four bow (42).
28. Staples attaching cover (54), to number five bow
(44).
Mark positions of all staples.
29. Mark positions of number one, two, three and
30.
31.
32.
33.
34.
l,.+I
four bow position pad (64) and number four and

five bow position pad (66) on number four bow
(42).
pad (64) and number four and five bow position
pad (66) from number four bow (42).
Move tackstrips down to access cover number
fou,r bow retainer (72).
Cover number four bow retainer (72) 11sing
appropriate tool.
Cover (54) from number four bow (42).
Adhesive from number one bow (39).
F. Attach cover to number one bow starting at

center, working toward each end to pull out
wrinkles.
G. Lower and latch folding top to check for
proper tension.
6.
7.
8.
9.
10.
11.
13.
14.
15.
16.
Use Hughes PIN HC-4183, 3M P/N 8046, or

attaching surfaces.
1.
2.
3.
4.
Cover (54).
Cover to number four bow (42).
Cover number four bow retainer (72).
Staples attaching cover (54), to its original
position on the number five bow (44).
5. Cover (54) to number one bow (39).
A. Close and latch folding top and pull cover
straight forward over number one .bow to
desired tension.
B. While maintaining tension on the cover over
number one bow, make pencil mark on outer
surface of cover along forward edge of number
one bow.
C. Unlatch folding top and lower the top halfway.
D. Apply adhesive to number one bow and to the
portion of cover being attached.
E. Pull cover over number one bow about 6 mm
(1/4-inch) past reference mark. Fold cover over
number one bow.
If additional tension is needed, repeat steps

SA through G and pull cover farther
forward.
Number five bow (44) onto retainer weld studs.
Retainer nuts onto number five bow mounting
studs.
Bolts/screws attaching headlining trim finish panel
elastic tension straps to number five bow (44).
Right and left quarter inner rear trim finish panel.
Retention cable. Refer to "Folding Top Cover
Retention Cable" in this section.
Cover (54) to number two bow (40).
A. Apply adhesive to number two bow and to the

portion of cover being attached.
B. Press cover evenly into place.
12. Cover (54) to number three bow (41).
Install or Connect
NOTICE:
10-9-33
17.
18.
19.
A. Apply adhesive to number three bow and to

the portion of cover being attached.
B. Press cover evenly into place.
Headlining trim finish panel (55) to number three
bow (41), including bolts/screws for elastic
tension straps.
Headlining trim finish panel (55) to number two
bpw (40).
Headlining trim finish panel (55) to number one
bow (39). Refer to "Headlining Trim Finish
Panel" in this section.
Bolts/screws attaching headlining trim finishpanel
(55) to number one bow (39).
Number one bow garnish molding (49).
Number one bow garnish molding bolts/screws
(50).
Cover (54) to outer arm (47).
A. Clean old adhesive from outer arm (47).

B. Apply adhesive to outer arm and to the portion
of cover being attached.
C. Press cover evenly into place.
20. Bolts/screws attaching cover (54) to outer arm
(47).
l~I Tighten
23. Outer arm weatherstrip retainers. Refer to
"Folding Top Outer Arm Weatherstrip Retainers"
in this section.
25. Side rail garnish moldings (116).
10-934
!~I

Tighten
Bolts/screws (115) to 5 .N.m (44 lb. in.).

27. Side rail weatherstrip retainers. Refer to "Folding
section.
. (fully counter-clockwise). Refer to "Manual
Ope!ation" under "Folding Top Operation" in this
section.
9. Right and left quarter inner rear trim finisli panel.

lLTum pump bypass valve to "closed'" position
section.
Headlining Trim Finish Panel

Figures 11 and 13
l++l
Folding Top Complete Replacement

Figures 13 and 20
l++I
CAUTION: Refer to ':'Caution" under

Cable'' in SECTION OA.
3, Right and left quarter inner rear trim finish panel.
5. Right and left pivot bracket locking pins (88) and
cylinder pivot pins (87).
7. Right and left cylinder bolts/screws (89).
8. Nuts from number five bow retaining weld studs.
9. Mounting nuts from right and left pivot bracket
(45).
10. Electrical connectors from rear window defogger.
11. Folding top (54).
l++I
Install or Connect
NOTICE:
1.
2.
3.
4.
Folding top (54).

Electrical connectors .to rear window defogger.
Mounting nuts to right and left pivot bracket (45).
Number five bow (44) and retaining nuts onto
mounting studs.
5. Right and left cylinder (86) and bolts/screws (89).
l~I
Tighten
Bolts/screws (89) to 5 N;m (44 lb. in.).

7. Right and left cylinder pivot pins (87) and pivot
bracket locking pins (88).

''Folding Top. Operation" in this section.
3. Folding top from vehicle. Refer to ''Folding Top
Complete Replacement" in preceding procedure.
4. Hook-and-loop fasteners from side rail link.
.
5. Side rail garnish moldings. Refer to "Folding Top
(50).
8. Bolts/screws attaching lower end of side elastic
tension straps to pivot bracket (45).
9. Left and right elastic tension straps between
number three bow (41) and number four bow
(42).
10. Front and rear hook-and-loop fasteners.
one bow (39).
two bow.
three bow (41).
ILI
Inspect
Top cover flaps at number two and number

three bow and re-attach if necessary.
14. Slide out headlining trim finish panel (55) from
15. Old adhesive from number one bow (39).
l++I
Install or Connect

equivalent adhesive on headliner or. top cover
attaching surfaces.
.
1. Apply masking tape to number one bow (39) as
necessary to keep adhesive from unwanted areas .
2. Slide headlining trim finish panel (55) into

number four bow (42) and align center notch of
headlining trim finish panel (55) with center hole
in number four bow.
3. Headlining trim finish panel (55) to number three
bow (41) and align center notch with center hole.
4. Headlining trim finish panel (55) to number two
bow and align center notch with center hole.
5. Apply adhesive to number one bow (39) and to
corresponding area of headlining trim finish panel
(55).
6. Pull left and right side seams taut and install
bolts/screws at ends of number one bow (39).
7. Attach headlining trim finish panel (55; along
number one bow (39) and press into place.
8. Trim excess material with razor.
9. Pierce holes in headlining trim finish panel (55) at
locations of number one bow garnish molding
bolts/screws (50).
12. Left and right elastic tension straps through
pockets between number three bow (41) and
13. Left and right elastic tension strap bolts/screws.
14. Hook-and-loop fasteners around side rail link.
15. Side rail garnish moldings. Refer to ''Folding Top
16. Folding top. Refer to ''Folding Top Complete
Replacement" in previous procedure.
17. Rear elastic tension straps to number five bow
(44).
Section.
10935
7. Adjust octagonal downstop cams so that folding

top is level from left to right along straightedge
and allows sufficient clearance for boot cover to
be installed.
l~I
8.
9.
10.
11.
Tighten
Downstop bolts/screws to 17 N,m (13 lb. ft.).

Remove straightedge.
Raise folding top.
(fully counter-clockwise). Refer. to "Manual
section.
Connect battery negative cable.
Upstop Adjustments
Figures 21 and 30

4. Turn upstops (119) all the way in to outer arm
(47).
5. Raise and latch folding top.
47
FOLDING TOP ADJUSTMENTS
Downstop Adjustment
Figure 30

!VIEWB!

4. Lay straightedge across rearmost edge of side rail
garnish moldings with straightedge extending to
left and right edges of vehicle.
5. Reposition plastic splash shield to allow access to
downstop bolts/screws.
6. Loosen downstop bolts/screws.
.A
B
C
D
47
119
UPSTOPJAMNUT
DOWN STOP WASHER
OUTER ARM DOWNSTOP
DOWN STOP SOLT/SCREW
STOP, FOLDING TOP OUTER ARM UP
OM8N
FS030109
Figure 30 - Upstop and Downstop Adjustments

6. With top latched, turn each upstop (119) out of
outer arm (47) until it touches pivot bracket (45).
8. Turn upstops (119) out of outer arm (47) an
additional 1/4 turn.
l~.J
Tighten
Jam nut to 17 N,m (13 lb. ft.)

9. Check operation of folding top and re-adjust as
necessary.
section.
11. Connect battery negative cable.
ROOF LIFT-OFF WINDOWS

The roof lift-off windows are manually operated.
The windows are curved to match the contour of the
roof and are made of tinted, tempered glass. The front
side door weatherstrip are one piece and molded to the
shape of the roof opening. The weatherstrip are held
on by retainer. For information on service of
weatherstrip and retainer, refer to SECTION 10-6.
Roof Lift-Off Window Removal and

Installation
Figure 31
The roof lift-off window ( 17) can be removed
and stored in the roof lift-off window stowage retainer.
l++I
Roof lift-off window (17).

A. Turn window latch handle.
B. Pivot roof lift-off window (17) upw~d slightly
and pull outward to release from under
longitudinal bow finish molding (20).
C. Repeat for other roof lift-off window (17).
l++I
Install or Connect
Roof lift-off window (17).

A. Carefully insert inside edge of roof lift-off
window ( 17) under longitudinal bow finish
.
molding (20).
B. Lower roof lift-off window (17) and latch into
place.
C. Repeat for other roof lift-off window (17).
D. Check for proper fit and adjust if necessary.
Refer to "Roof Lift-Off Window Adjustment"
in the following procedure.
Roof Lift-Off Window Adjustment

Figure 32
The roof lift-off window is adjustable within the
lift-off window opening. The roof lift-off windows are
adjusted up and down by adding or removing backing
plates (26). In-and-out and fore-and-aft travel is
adjusted by loosening bolts/screws (23) and
repositioning front and rear striker (25 and 24) as
necessary. Adjustments should be made to get a flush
fit of the roof lift-off window to the roof..
24
25
24
23
17 WINDOW, ROOF LIFT-OFF

20 MOLDING, ROOF PANEL LONGITUDINAL BOW FINISH
01-1885
FS031109
Figure 31 - Installing Roof Lift-Off Windows
25
V-IEW--,A
r--1
A
23
24
25
26
SLOT CUT-OUT
BOLT/SCREW, ROOF REAR PANEL LATCH STRIKER
STRIKER, ROOF LIFT-OFF WINDOW REAR
STRIKER, ROOF LIFT-OFF WINDOW FRONT
PLATE, ROOF LIFT-OFF WINDOW FRONT STRIKER
BRACKET BACKING
27 RETAINER, ROOF LIFT-OFF PANEL/WINDOW
FRONT NUT PLATE
01-1811
FS032109
Figure 32 - Roof Lift-Off Window Strikers
!+-+I. Remove or Disconnect

)
1. Roof lift-off window. Refer to "Roof Lift-Off

Window Removal and Installation" in the
preceding procedure.
3. Quarter trim finish panel bolts/screws.
4. Quarter inner trim finish panel extension to access
rear striker (24).
5. Loosen bolts/screws (23).
Ill
Adjust

Front and rear striker (25 and 24).
A. Up and down.
Add or remove backing plates (26).
B. In and out.
Move front or rear striker (25 or 24) in or
out as required.
C. Fore and aft.
Move front or rear striker (25 or 24) fore
or aft as required.
I~!
Tighten
ILI
Inspect
!+-+!
10-9-37

Window Removal and Installation" in this section.
2. Place on a clean, protected surface.
!+++I
Disassemble
1. Handle (16), by removing handle spring (117)

with small flat-blade screwdriver.
2. Trim cover bolts/screws (18).
3. Trim cover (15).
4. Weatherstrip bolts/screws (14).
5. Weatherstrip (13) by pulling from weatherstrip
retainer (28).
6. Weatherstrip retainer bolts/screws (29).
7. Weatherstrip retainer (28).
8. Roof lift-off window latch bolts/screws.
9. Latch (31).
l+++!
Assemble

1. Latch (31).
2. Roof lift-off window latch bolts/screws.
I~!
Tighten
1. Install roof lift-off window and inspect for proper

fit.
2. Remove roof lift-off window.
I-++!
Install or Connect

1. Quarter inner trim finish panel extension.
2. Quarter trim finish panel bolts/screws.
l~I
Tighten
Quarter trim finish panel bolts/screws to 1.7

N.m (15 lb. in.).
Window Removal and Installation'' in the
preceding procedure.
Roof Lift-Off Window Repair

Figure 33
If a new roof lift-off window (17) is being
installed, transfer the hardware from the original roof
lift-off window (17) to the new one as a bench
procedure.
13 WEATHERSTRIP, ROOF. SIDE RAIL

14 SOLT/SCREW, ROOF LIFT-OFF WINDOW BODY SIDE
WEATHERSTRIP
15 COVER, ROOF LIFTOFF WINDOW LATCH TRIM
16 HANDLE, ROOF LIFT-OFF WINDOW LATCH
18 BOLT/SCREW, ROOF LIFT-OFF WINDOW LATCH TRIM
COVER
28 RETAINER, ROOF LIFT-OFF WINDOW BODY
SIDE WEATHERSTRIP WINDSHIELD FRAME
29 BOLT/SCREW, ROOF LIFT-OFF WINDOW BODY SIDE
WEATHERSTRIP WINDSHIELD FRAME RETAINER
31 LATCH, ROOF LIFT-OFF W1NDOW
117 SPRING, ROOF LIFT-OFF PANEL HANDLE
. 01-1895
F8033109
Figure 33 Roof Lift-Off Windows
10-19.;38 ROOF:AND. FOil.DiNG TOP

3. Weatherstrip retainer (28).
4. Weatherstrip retainer bolts/screws
. , ... (29) .
_
l~I .Tighten
20
Weatherstrip retainer bolts/screws (29) to

1.3 N,m (12 lb. in.).
5. Weatherstrip. (13) to weatherstrip retainer (28).
, Insert outboard lip . oLweatherstrip (13) into
weatherstrip .retainer (28) and roll inboard lip
into weatherstrip retainer (28).
6. Weatherstrip bolts/screws (14).
l~I
Tighten
Weatherstrip bolts/screws (14) to 1.3 N,m

(12 lb. in.).
7. Trim .cover (15).
I~! Tighten
Trim cover bolts/screws (18) to 1.7 N,m
(15 lb. in.).
9. Handle (16):
'Place ,h.andle (16) on spindle and secure with
handle spring (117). D Install handle in open
position.
E3
A
B
C
19
POSITION 1
POSITION 2
POSITION 3
BOLT/SCREW, ROOF PANEL LONGITUDINAL BOW
FINISH MOLDING
20 MOLDING, ROOF PANEL LONGITUDINAL
BOW FINISH
01-1895
F803410I
Figure 34 - Roof Panel Longitudinal Bow Finish Molding
Install or Connect.
Roof lift-off window. Refer to "Roof Lift-Off


Nlolding
Figure 34
l++I
Remove or: Disconnect
1. Roof lift-off window. Refer to "Roof Lift.;Off

Window Removal and Installation" in this sectiori;
3. Longitudinal lx>w fmish molditig (20).
E3

21 RETAINER, ROOF LIFT-OFF WINDOW lOCK CYLINDER
22 CYLINDER, ROOF LIFT-OFF WINDOW LOCK
01-189&
F80351ot
Install. or Connect
1. Longitudinal bow fmish molding (20).

A. Position molding so "FRT" marked on
protective paper is. forward.
B. Remove protective paper.
2. Bolts/screws (19), in order, to positions 1, 2 and
3.
l~I Tighten
Bolts/screws (19) as they are installed in
positions 1, 2 and 3 to 1.7 N.m (15 lb. in.).
3. Roof lift-off window. Refer to ''Roof Lift-Off
Figure 35 Roof Lift-Off Window Lock Cylinder

(Left Side Shown)
Roof Lift-Off Window Lock Cylinder

Figures 33 and 35
l++I
Remove or Disconnect.

2. Roof lift-off handle spring (117).
3. Handle (16).
5. Trim cover (15).
6. Lock cylinder retainer (21).
ROOFAND FOLDING TOP

l-++-1
l~I
Install or Connect
NOTICE:
10-9-39

Align tabs of lock cylinder (22) with notches
in latch support. 2. Lock cylinder retainer (21).
2. Trim cover (15).
Tighten
Trim cover bolts/screws (18) to 1.7 N.m

(15 lb. in.).
4. Handle (16).
5. Roof lift-off handle spring (117).
SPECIFICATIONS
Dome Lamp Bolt/Screw ......................................................................................................... 1.7 N.m (15 lb. in.)
Downstop Bolt/Screw .............................................................................................................. 17 N.m (13 lb. ft.)
Folding Top Cylinder Bolt/Screw ............................................................................................. 5 N,m (44 lb. in.)
Folding Top Cylinder Upper Hose Fitting ...............................................................................7 N.m (62 lb. in.)
Folding Top Front Latch Bolt/Screw ...................................................................................... 10 N,m (89 lb. in.)
Folding Top Front Side Rail Link Front Bolt/Screw ................................. ,.......................... 17 N,m (13 lb. ft.)
Folding Top Front Side Rail Link Rear Bolt/Screw ............................................................. 17 N.m (13 lb. ft.)
Folding Top Front Weatherstrip Bolt/Screw .......................................................................... 1.3 N,m (12 lb. in.)
Folding Top Front Weatherstrip Retainer Bolt/Screw ............................................................ 10 N,m (89. lb. in.)
Folding Top Number One Bow Bolt/Screw ........................................................................... 17 N.m (13 lb. ft.)
Folding Top Number 1\vo Bow Insulator Bolt/Screw ............................................................. 5 N,m (44 lb. in.)
Folding Top Number 1\vo Bow Link Nut ...............................................................................5 N,m (44 lb. in.)
Folding Top Number Three Bow Bolt/Screw ........................................................... ;............ 10 N.m (89 lb. in.)
Folding Top Number Four Bow Link Bolt/Screw ................................................................. 10 N.m (89 lb. in.)
Folding Top Outer Arm,Pivot Bolt/Screw ............................................................................. 17 N,m (13 lb. ft.)
Folding Top Pump Nut ............................................................................................................. 6 N,m (53 lb. in.)
Folding Top Quarter Window Filler Bolt/Screw .................................................................... 10 N,m (89 lb. in.)
Folding Top Side Rail Garnish Molding Bolt/Screw ................................................................ 5 N,m ( 44 lb. in.)
Folding Top Side Rail Link Pivot Bolt/Screw ....................................................................... 17 N.m (13 lb. ft.)
Front Latch Clamp Body Set Screw ...................................................................................... 10 N.m (89 lb. ft.)
Front Side Door Window Upper Rear Weatherstrip Bolt/Screw ......................................... 1.3 N,m (12 lb. in.)
Front Side Door Window Upper Rear Weatherstrip Retainer Bolt/Screw .......................... 1.3 N.m (12 lb. in.)
Quarter Belt Reveal Molding Bolt/Screw (Chevrolet) ............................................................. 5 N,m (44 lb. in.)
Quarter Belt Reveal Molding Bolt/Screw (Pontiac) ............................................................. 1.7 N,m (15 lb. in.)
Quarter Trim Finish Panel Bolt/Screw .................................................................................. 1.7 N,m (15 lb. in.)
Roof Lift-Off Window Body Side Weatherstrip Bolt/Screw ............ .,.................................. 1.3 N.m (12 lb. in.)
Roof Lift-Off Window Body Side Weatherstrip Windshield Frame Retainer Bolt/Screw.. 1.3 N,m (12 lb. in.)
Roof Lift-Off Window Latch Trim Cover Bolt/Screw ......................................................... 1.7 N,m (15 lb. in.)
Roof Panel Longitudinal Bow Finish Molding Bolt/Screw ................................................. 1.7 N.m (15 lb. in.)
Roof Rear Panel Latch Striker Bolt/Screw ............................................................................ 10 N,m (89 lb. in.)
Roof Side Rail Weatherstrip Retainer Bolt/Screw ................................................................ 1.3 N,m (12 lb. in.)
Sunshade Bolt/Screw .............................................................................................................. 1.7 N.m (15 lb. in.)
Upstop Jam Nut ....................................................................................................................... 17 N.m (13 lb. ft.)
Windshield Garnish Molding Bolt/Screw ........... ;.................................................................. 1.7 N,m (15 lb. in.)
BLANK
SEATS AND CARPET
10-10-1
SECTION 10-10
SEATS AND CARPET

systems.
CONTENTS
General Description .......................................... 10-10-1
Front Seat ..................................................... 10-10-1
Front Seatback .......................................... 10-10-1
Rear Seat ...................................................... 10-10-2
Floor Carpet ................................................. 10-10-2
Diagnosis .......................................................... 10-10-2
Front Seat ..................................................... 10-10-2
Manual Front Seat Adjuster .................... 10-10-2
Power Front Seat Adjuster ...................... 10-10-2
Pneumatic Comfort Controls ................... 10-10-2
On-Vehicle Service ........................................... 10-10-2
Front Seat ..................................................... 10-10-2
Front Seatback ......................-.................... 10-10-3
Inertia Seatback Lock Check ....................... 10-10-4
Trim Covers .............................................. 10-10-5
Front Seat Cushion .................................. 10-10-9
Lumbar and Lateral Support Bladders .... 10-10-10
GENERAL DESCRIPTION
FRONT SEAT
The front seats are bucket seats. Both seats have
inertia seatback locks, manual seatback recliners and
manual seatback adjuster. A 4-way manual or a power
6-way seat adjuster is available on the driver's seat as
an option.
Also, both front seats can be ordered with
pneumatic seats that have an adjustable thigh support,
and inflatable lumbar and lateral support bladders
(Pontiac only).
The seatback and cushion have formed foam
pads that fit the contours of the seatback and seat
cushion frames.
CAUTION: Do not try to change the

designed seat position by changing the
seat adjust-to-floor pan anchor placement
or the seat adjust-to-seat frame anchor
placement. Changing the designed seat
position could effect the safe
performance of the seat and cause
personal injury.
Head Restraint. ......................................... 10-10-12

Front Seat Recliner .................................. 10-10-14
Manual Front Seat Adjuster .................... 10-10-15
Driver Seat Adjuster and Drive Motor ... 10-10-15
Passenger Seat Adjuster ........................... 10-10-18
Power Front Seat Adjuster ...................... 10-10-19
Front Seat Adjuster Actuator Lever
Knob ..................................................... 10-10-20
Rear Seat ...................................................... 10-10-20
Rear Seat Cushion ................................... 10-10-20
Rear Seatback Cushion ............................ 10-10-21
Shoulder Restraint Guide ......................... 10-10-22
Rear Trim and Covers ............................. 10-10-22
Rear Seatback Lock and Striker ............. 10-10-24
Floor Carpet ................................................. 10-10-25
Specifications .................................................... 10-10-26
Fastener Tightening Specifications .............. 10-10-26
Special Tools .................................................... 10-10-26
Front Seatback
Bucket seats have a tubular frame seatback and a
standard manual seatback recliner. The recliner control
is mounted on the outboard side of the seat and
controls the seatback angle. The inner hinge arm
bolt/screw acts as a pivot point for the seatback. The
recliner control has an inertia seatback lock that lets
the occupant move the seatback without the lever. If
the vehicle stops or slows suddenly, or is declined 20
degrees or more, the inertia seatback lock locks the
seatback and the emergency release lever must be used
to move the seatback.
The seatback angle can be changed by lifting the
reclining control handle. Lifting the recliner control
handle releases the lock bars and lets the seatback
pivot forward and rearward. Releasing the recliner
control handle lets the cam plate move
counterclockwise, causing the lock bar teeth to lock
the seatback in a new position. The recliner control
handle should return automatically to its original
position.
10-:t 0-2
SEATS AND CARPET
REAR SEAT
The rear seat is of the solid, folding bench type.
It is fastened onto the vehicle with studs and nuts and
bolts/ screws.
FLOOR CARPET
All floor carpets consist of a molded one-piece
carpet over both front and rear floor pans.
DIAGNOSIS
3. One adjuster will not move forward and

backward.
Horizontal drive cable may be damaged.
Horizontal actuator may be damaged.
4. One adjuster will not move up or down.
Vertical drive cable may be disconnected or
damaged.
Vertical actuator may be damaged.
Pneumatic Comfort Controls

PONTIAC
FRONT SEAT
Manual Front Seat Adjuster
All passenger seats and some driver seats have
manual seat adjuster attached to the seat cushion
frame. An adjuster actuator lever is located at the
lower front edge of the seat cushion. When the. lever
is moved to the left, the seat adjuster unlocks. The set
can then be moved forward and rearward. The seat
locks in place when the lever is released.
The seat adjuster is held onto the seat cushion
frame with bolts/screws and to the floor pan with nuts
installed over studs. Adjuster channel covers are
installed between the seat cushion frame and the seat
adjuster.
1. Adjuster will not lock or will not unlock.
Linking wire may be too loose, too tight or
disconnected.
Return spring may be disconnected or
damaged.
Lock bar may be stuck or damaged.
2. One adjuster locks and other adjuster does not
lock.
One adjuster may be forward or rearward of
another adjuster. Make adjustments at floor
pan attachments.
3. Seat is hard to move forward or rearward.
Adjuster may be new. Move seat forward and
rearward several times to work tightness out of
channels.
Adjuster may not be lubricated properly.
Adjuster channels may be damaged.
Adjuster may not be parallel. Make
adjustments at floor pan attachments.
These seats have inflatable lumbar and lateral

support bladders in the seatback. The lumbar support
bladder is located in the lower middle section of the
seatback, and the lateral support bladders are located
in the sides of the seatback. The control switch lo
inflate or deflate the support bladders are located on
the lower outboard side of the seat cushion. A pump,
valve and relay are attached to the bottom of the
driver's seat cushion. The pump operates both front
seats.
1. Driver and passenger seats will not function at the
same time.
Operate one seat at a time. Although each seat
has a switch, one pump runs both seats; so the
two seats cannot be run at the same time.
2. Switch button is pushed, but no electrical "click"
is heard.
Seat may not be plugged into vehicle electrical
system.
Wiring harness fuse may be blown.
3. Wiring harness fuse blows often.
Grommet that prevents the switch from
contacting the. trim support panel may be
damaged or missing. Repair kits are available
to correct this condition.
4. Pump runs and does not shut off.
Hose may be disconnected or damaged.
Hose may be pinched.
5. Driver seat operates, but passenger seat does not.
Hose crossover may be pinched.
ON-VEHICLE SERVICE
FRONT SEAT
Power Front Seat Adjuster
Figures 1 and 2
Six-way power seat adjusters are available on

the driver's seat. The adjusters are three 12 volt
reversible, permanent-magnet motors controlled by a
switch on the forward outboard side of the seat.
1. One adjuster reaches maximum horizontal or
vertical position before other adjuster.
Adjuster may be out of phase.
2. Seat does not move smoothly.
Adjuster shoes and channels may not be
properly lubricated.
Horizontal actuator gear may be too tight.
j++!
1. Caps (5) covering nuts (3) and studs (4).

2. Nuts (3) from studs (4).
3. Body wiring harness electrical connector, if
necessary.
4. Seat air supply hose, if necessary (Pontiac only).
NOTICE: Failure to place a protective shield
over nearby trim and paint may cause damage
to the vehicle.
SEATS AND CARPET 10-103
A
1
2
3
4
5
CONNECTOR, BODY WIRING HARNESS ELECTRICAL

SEAT, DRIVER
SEAT.PASSENGER
NUT, DRIVER/PASSENGER SEAT ADJUSTER
STUD, DRIVER/PASSENGER SEAT ADJUSTER
CAP, DRIVER/PASSENGER SEAT ADJUSTER STUD
012015
FS0011010
Figure 1 Removing Seat from Floor Pan (Pontiac)
5. Place protective shield over nearby trim and paint.

6. Seat (1 or 2) from floor pan.
7. Seat (1 or 2) from vehicle.
l+I
3. Remove protective shield.

4. Nuts (3) to studs (4).
l.r:;'\ I
~
Tighten
Install or Connect
CAUTION: Replace belts, retractors, and

hardware in use during all but a minor
collision. Also, restraint systems should
be replaced and anchorage properly
repaired if they were in areas damaged
by a collision, whether the belt was in
use or not. If there is any question,
replace the belt system. Damage,
whether visible or not, could result in
serious personal Injury in the event of an
accident.
NOTICE: Refer to "Notice" onpage 10-10-1.
1. Seat (1 or 2) to vehicle.
2. Seat (1 or 2) over studs (4) to floor pan.
Nuts (3) to 24 N.m (18 lb. ft.).

5. Body wiring harness electrical connector, if
disconnected.
6; Seat air supply hose, if removed (Pontiac only).
7. Caps (5) covering nuts (3) and studs (4).
Front Seatback
Figure 3
!++I
1. Front seat. Refer to "Front Seat" in this section.

2. Hinge arm trim covers. Refer to "Trim .Covers"
in this section.
3. Bolts/screws (6 and 7) attaching hinge arm (8) to
cushion (9).
10104 SEATS AND CARPET

INERTIA SEATBACK LOCK CHECK
IN-VEHICLE
!L!
Inspect
1. Inertia seatback lock.
CAUTION: Perform the check in an area

clear of other vehicles or obstructions.
The driver must be buckled into the
restraint system, and a helper must be
buckled into the rear seat restraint
system. The helper should hold the sides
of the passenger seatback near the top
with arms still and body relaxed. Failure
to perform these precautions may cause
damage to the vehicle and possible
personal injury.
A. Drive vehicle forward between 16 and
24 km/h (10 and 15 mph).
1
3
4
5
SEAT, DRIVER
NUT, DRIVER/PASSENGER SEAT ADJUSTER
STUD, DRIVER/PASSENGER SEAT ADJUSTER
CAP, DRIVER/PASSENGER SEAT ADJUSTER STUD
01-2095
FS0021010
Figure 2 Removing Seat from Floor Pan (Driver Seat

Shown, Passenger Seat Similar) (Chevrolet)
4. Seatback (10) from cushion (9) by unsnapping

from front seatback pivot bushing (11).
j++!
Install or Connect
OUT-OF-VEHICLE
Figure 4
!L!
Inspect
1. Inertia seatback lock.
NOTICE:
NOTICE: Anytime the front seatback is

removed, a new seatback pivot bushing must be
installed.
1. Front seatback pivot busing (11).
2. Seatback (10) to cushion (9).
Align pivot shaft on seatback with hole in
cushion (9).
I~!
When performing check on driver's

seatback, driver should lean forward
slightly.
Helper must not push forward on seatback
before driver applies brakes.
B. Quickly apply brakes to stop vehicle as fast as
possible without skidding .tires.
C. Inertia seatback lock should lock and top of
seatback should only move forward about 100
mm (4 inches).
2. If either inertia seatback lock does not lock,
perform out-of-vehicle check.
Tighten

4. Hinge arm trim covers. Refer to "Trim Covers"
in this section.
A. Remove seat from vehicle. Refer. to "Front

Seat" in this section.
B. Place seat right side up on clean surface.
C. Raise rear of seat until seatback is 6 degrees
forward of vertical.
D. Place blocks under rear of seat to hold seat in
position.
E. Check that seatback is located in position.
F. Install seat .into vehicle if inertia seatback lock
works properly. Refer to "Front Seat" in this
section.
2. If inertia seatback lock does not work properly,
entire recliner control must be replaced. Refer to
"Front Seat Recliner" in this section
SEATS AND CARPET
10-10-5
Trim Covers
FRONT TRIM COVERS
Figure 5
!++!
1. Bolts/screws ( 13 and 16) attaching covers

( 15 and 17) to driver seat adjuster track.
2. Covers (15 and 17) from driver seat adjuster
track.
!++!
Install or Connect
NOTICE:
1. Covers (15 and 17) to driver seat adjuster track.

2. Bolts/screws (13 and 16) to covers (15 and 17).
!~I
Tighten
Bolts/screws (13 and 16) to 1.7 N.m

(15 lb. in.).
A~
I.
A
6
7
8
9
10
11
SHAFT, PIVOT
BOLT/SCREW, FRONT SEATBACK HINGE ARM
ARM, FRONT SEATBACK HINGl:
CUSHION, FRONT SEAT
SEATBACK, FRONT
BUSHING, FRONT SEATBACK PIVOT
01-20-95
F80031010
Figure 3 - Removing Front Seatback (Typical)
A
B
C
D
SIX DEGREES FORWARD OF VERTICAL

METER, ANGLE
LEVER, EMERGENCY RELEASE
BLOCK
01-20-95
F80041010
Figure 4 - Checking Inertia Seatback Lock (Typical)

OUTER ADJUSTER LOWER COVER
Figure 5
!++i
1. Bolt/screw (12) attaching cover (14) to driver seat

adjuster track.
2. Cover (14) from driver seat adjuster track.
j++!
Install or Connect
NOTICE:
1. Cover (14) to driver seat adjuster track.

2. Bolt/screw (12) to cover (14).
!~!
Tighten

HINGE ARM TRIM COVERS
Figure 6
!++!
1. Bolts/screws (21 and 22) attaching cover

(18 or 19) to seat (1 or 2).
2. Cover (18 or 19).
3. Bolts /screws (23 or 27) attaching panel
(20 or 26) to seat (1 or 2) (Pontiac only).
4. Panel (20 or 26) (Pontiac only).
I++!
Install or Connect

1. Panel (20 or 26) (Pontiac only).
2. Bolts/screws (23 or 27) attaching panel (20 or 26)
to seat (1 or 2) (Pontiac only).
3. Cover (18 or 19) to seat (1 or 2).
!~!
Tighten

5. Secure bolts/screws (22, 23 and 27).
UPLEVEL SEAT TRIM (PONTIAC)
Seat Cushion Trim
Figure 7
l++I
1. Cushion outer finish panel bolts/screws (23).

2. Cushion outer finish panel (20).
3. Pneumatic pump and valve switch. Refer to "Seat
Pneumatic Pump and Valve Switch" under
"Lumbar and Lateral Support Bladders" in this
section.
1 SEAT, DRIVER
12 BOLT/SCREW, DRIVER SEAT OUTER ADJUSTER LOWER
13 BOLT/SCREW, DRIVER SEAT ADJUSTER FRONT TRIM
COVER
14 COVER, DRIVER SEAT OUTER ADJUSTER. LOWER
15 COVER, DRIVER SEAT INNER ADJUSTER FRONT TRIM
16 BOLT/SCREW, DRIVER SEAT ADJUSTER FRONT TRIM
COVER
17 COVER, DRIVER SEAT OUTER ADJUSTER FRONT TRIM
012391
FS0051010
Figure 5 Driver Seat Adjuster and Trim Covers
4.
5.
6.
7.
Cushion inner finish panel bolts/screws (27).

Cushion inner finish panel (26).
Front seatback hinge arm bolts/screws (6 and 7).
Cushion finish panel outer support bolts/screws
(28).
8. Cushion finish panel outer support (29).
9. Cushion finish panel inner support bolts/screws
(30).
10. Cushion finish panel inner support (31).
!++I
Install or Connect

1. Cushion finish panel inner support (31).
2. Cushion finish panel inner support bolts/screws
(30).
3. Secure bolts/screws (30).
4. Cushion finish panel outer support (29).
5. Cushion fmish panel outer support bolts/screws
(28).
Secure bolts/screws (28).
6. Front seatback hinge arm bolts/screws (6 and 7).
!~I
Tighten

7. Cushion inner finish panel (26).
8. Cushion inner finish panel bolts/screws (27).
SEATS AND CARPET

24
10-10-7
19
21
B
A
B
1
2
18
19
20
21
22
23
24
25
26
27
DRIVER AND PASSENGER SEAT

DRIVER SEAT ONLY (PONTIAC ONLY)
SEAT, DRIVER
SEAT.PASSENGER
COVER, FRONT SEATBACK FRAME HINGE ARM TRIM
PANEL, DRIVER SEAT CUSHION OUTER FINISH (PONTIAC ONLY)
BOLT/SCREW, DRIVER SEAT ADJUSTER
BOLT/SCREW, FRONT SEATBACK FRAME HINGE
BOLT/SCREW, DRIVER SEAT CUSHION OUTER FINISH PANEL (PONTIAC ONLY)
ADJUSTER, FRONT SEAT
SWITCH, DRIVER SEAT PNEUMATIC PUMP AND VALVE (PONTIAC ONLY)
PANEL. DRIVER SEAT CUSHION INNER FINISH {PONTIAC ONLY)
BOLT/SCREW, DRIVER SEAT CUSHION INNER FINISH PANEL (PONTIAC ONLY)
01-23-SI&
FS0081010
Figure 6 - Hinge Arm Trim Covers (Typical)
26
36
39
(
37 , ~ -
32//,-,
33
6
7
8
9
10
20
23
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39

ARM, FRONT SEATBACK HINGE
CUSHION, FRONT SEAT
SEATBACK, FRONT
PANEL, DRIVER SEAT CUSHION OUTER FINISH
BOLT/SCREW, DRIVER SEAT CUSHION OUTER FINISH PANEL
SWITCH, DRIVER SEAT PNEUMATIC PUMP AND VALVE
PANEL, DRIVER SEAT CUSHION INNER FINISH
BOLT/SCREW, DRIVER SEAT CUSHION INNER FINISH PANEL
BOLT/SCREW, DRIVER SEAT CUSHION FINISH PANEL
OUTER SUPPORT
SUPPORT, DRIVER SEAT CUSHION FINISH PANEL OUTER
BOLT/SCREW, DRIVER SEAT CUSHION FINISH PANEL
INNER SUPPORT
SUPPORT, DRIVER SEAT CUSHION FINISH PANEL INNER
CAP, DRIVER SEATBACK FINISH PANEL BOLT/SCREW
BOLT/SCREW, DRIVER SEATBACK FINISH PANEL
RETAINER, DRIVER SEAT TRIM FINISH PANEL
BOLT/SCREW, DRIVER SEATBACK FINISH PANEL
PANEL, DRIVER SEATBACK FINISH
NET, DRIVER SEATBACK MAP POCKET
BOLT/SCREW, DRIVER SEATBACK INNER TRIM PANEL
PANEL, DRIVER SEATBACK INNER TRIM
Figure 7 Uplevel Seat Trim (Pontiac)
34
0123-95
FS0071010
SEATS AND CARPET 10-109

9. Cushion outer finish panel (20).
10. Pneumatic pump and valve switch (25). Refer to
"Seat Pneumatic Pump and Valve Switch" under
"Lumbar and Lateral Support Bladders" in this
section.
1l. Cushion outer finish panel bolts/screws (23).
Seatback Trim
!++!
l. Seatback finish panel bolt/screw caps (32).

2. Bolts/screws (33) and retainer (34).
3. Seatback finish panel bolts/screws (35).
4. Seatback finish panel (36).
5. Seatback map pocket net (37).
6. Seatback inner trim panel bolts/screws (38).
7. Seatback inner trim panel (39).
!++I
Install or Connect
NOTICE:
1. Seatback inner trim panel (39).

2. Seatback inner trim panel bolts/screws (38).
. 3. Seatback map pocket net (37).
4. Seatback finish panel (36).
5. Seatback finish panel bolts/screws (35).
6. Bolts/screws (33) with retainers (34).
7. Seatback finish panel bolt/screw caps (32).
Front Seat Cushion

SEAT CUSHION COVER
Figure 8
l++I
Install or Connect
1. Cover (40) over seat cushion frame.

Cap front and rear corners of cover (40) over
cushion (9) and regulate to desired appearance.
2. J-retainers to seat cushion frame.
Seatback Cover (Base Level)
Figure 9
!++!
01-23-H
FS0081010
Figure 8 - Front Seat Cushion Cover
2. Head restraint. Refer to "Base Level" under

"Head Restraint" in this section.
3. Seatback lock release knob (42).
4. Seat shoulder belt guide and bolts/screws
(Chevrolet only).
5. Cover (41).
l++I
Install or Connect
1. Cover (41) to seat cushion pad.

2. Seat shoulder belt guide and bolts/screws
(Chevrolet only).
3. Head restraint. Refer to "Base Level" under
"Head Restraint" in this section.
4. Seatback lock release knob (42).
5. Seatback. Refer to "Front Seatback" in this
section.
SEATBACK COVER (UPLEVEL)
Pontiac
Figure 10

2. J-retainers from seat cushion frame.
3. Cover (40).
E+I
A J-RETAINER
9 CUSHION, FRONT SEAT
40 COVER, FRONT SEAT CUSHION

section.
!++l
1. Seat trim. Refer to "Uplevel Seat Trim" under

"Trim Covers" in this section.
2. Head restraint. Refer to "Uplevel" under "Head
Restraint" in this section.
section.
4. Rings (43) attaching cover (41) to seat cushion
pad and wire (44).
5. Wire (44).
6. Cover (41).
!++!
Install or Connect
1. Cover (41) to seat cushion pad.

2. Wire (44) attaching cover (41) to seat cushion
pad.
10-1010 SEATS AND CARPET

3. Rings (43).
section.
5. Head Restraint. Refer to "Uplevel" under "Head
Restraint" in this section.
6. Seat trim. Refer to "Uplevel Seat Trim" under
"Trim Covers" in this section.
Lumbar and Lateral Support Bladders

BLADDER REPLACEMENT
Pontiac
43
Figure 11
!++!
1. Seatback cover. Refer to "Seatback Cover

(Uplevel)" under "Front Seat Cushion" in this
section.
2. Seatback pad (45) from frame (46).
3. Seatback lumbar bladder (47) .and hose.
~42
41
A
9
41
42
J-RETAINERS
SEATBACK, FRONT
COVER, FRONT SEATBACK
KNOB. SEATBACK LOCK RELEASE
A
8
C
41
43
OPEN POSITION
CLOSED POSITION
HOSE ASSEMBLIES, BLADDER
COVER, FRONT SEATBACK
RING, FRONT SEATBACK COVER RETAINER
44 WIRE, FRONT SEATBACK BOLSTER
Ol20-95
FS0181010
012095
FSOOl1010
Figure 9 - Front Seatback Cover (Base Level) - (Typical)
Figure 10 - Front Seatback Cover (Uplevel) - (Pontiac)
SEATS AND CARPET 10-10-11

4. Seat lateral support bladder retainer (48).
5. Seat lateral support bladders (49) and hose.
!-++I
49
Install or Connect
1. Seat lateral support bladders (49) and hose.
2. Seat lateral support bladder retainer (48).

3. Seatback lumbar bladder (47) and hose.
4. Seatback pad (45) to frame (46).
5. Seatback cover. Refer to "Seatback Cover
(Uplevel)" under "Front Seat Cushion" in this
section.
PUMP, VALVE AND MODULE
Pontiac
Figure 12
I++!

2. Adjuster. Refer to "Manual Front Seat Adjuster"
in this section.
3. Air supply hoses.
5. Seat pneumatic control module bolts/screws (50).
Driver side only.
6. Seat pneumatic control module (51). Driver side
only.
7. Seat inflator pump bolts/screws (52).
8. Seat inflator pump (53).
45 PAO. DRIVER SEATBACK

46 FRAME, DRIVER SEAT
47 BLADDER, DRIVER SEATBACK LUMBAR
48 RETAINER, SEAT LATERAL SUPPORT BLADDER
49 BLADDER, SEAT LATERAL SUPPORT
012395
FS0111010
Figure 11 Bladder Replacement (Pontiac)
!VIEWA!
50
51
52
53
54
55
58
57
BOLT/SCREW, DRIVER SEAT PNEUMATIC CONTROL MODULE

MODULE, DRIVER SEAT PNEUMATIC CONTROL
BOLT/SCREW, SEAT INFLATOR PUMP
PUMP, SEAT INFLATOR
BOLT/SCREW, SEAT PNEUMATIC VALVE
VALVE, SEAT PNEUMATIC
BOLT/SCREW, SEAT CUSHION PNEUMATIC MOUNTING PLATE
PLATE, SEAT CUSHION PNEUMATIC MOUNTING
Figure 12 Pump, Valve and Module (Pontiac)
012395
FS0121010
10-10-12 SEATS AND CARPET

9. Seat pneumatic valve bolts/screws (54).
10. Seat pneumatic valve (55).
11. Seat cushion pneumatic mounting plate
bolts/screws (56), if necessary.
12. Seat cushion pneumatic mounting plate (57), if
necessary.
!H!
20
Install or Connect
NOTICE:
1. Seat cushion pneumatic mounting plate (57), if.

necessary.
2. Seat cushion pneumatic mounting plate
bolts/screws (56), if necessary.
20 PANEL, DRIVER SEAT CUSHION OUTER FINISH

25 SWITCH, DRIVER SEAT PNEUMATIC PUMP AND VALVE

3. Seat pneumatic valve (55).
4. Seat pneumatic valve bolts/screws (54).
Figure 13 - Seat Pneumatic .Pump and Valve Switch (Pontiac)

5. Seat inflator pump (53).
6. Seat inflator pump bolts/screws (52).
7. Seat pneumatic control module (51). Driver side
only.
8. Seat pneumatic control module bolts/screws (50).
Driver side only.
10. Air supply hoses.
11. Adjuster. Refer to "Manual Front Seat Adjuster"
in this section.
SEAT PNEUMATIC PUMP AND VALVE SWITCH
Pontiac
Figure 13
!+-+!
1. Cushion outer finish panel. Refer to "Hinge Arm

Trim Covers" under "Trim Covers" in this
section.
2. Electrical connector from switch (25).
3. Switch (25) by unsnapping from outer finish panel
(20).
!-++!
01-23-95
FS0131010
Head Restraint
BASE LEVEL
Pontiac
Figure 14
Tool Required:
J 39641 Removal Tool
!+-+!
1. Seatback release knob.

2. Separate J-retainers at bottom of seat and pull seat
cover past head restraint posts.
3. Slide J 39641 up head restraint posts with tool
tabs fitting into open slots between head restraint
guide tabs.
4. With headrest removal tools in place, rotate each
tool so head restraint guide tabs expand outward
5. Head restraint (58).
!-++!
Install or Connect

2. Pull down on seat cover firmly to enable
J-retainers at the bottom of seat to lock together.
3. Seatback release knob.
UP LEVEL
Pontiac
Figure 14
Install or Connect
1. Switch (25).
2. Electrical connector to switch (25).
3. Cushion outer finish panel. Refer to "Hinge Arm
Trim Covers" under "Trim Covers" in this
section.
Tool Required:
J 39641 Headrest Removal Tool
!+-+!
1. Seatback trim. Refer to "Uplevel Seat Trim"

under "Trim Covers" in this section.
SEATS AND CARPET 101013
61
62
62
J 39641
A
B
43
58
59
60
61
62
63
64
65
66
BASE LEVEL
UP LEVEL
RING, FRONT SEATBACK COVER RETAINER
RESTRAINT, SEAT HEAD
GUIDE, SEAT HEAD RESTRAINT
BOLT/SCREW, SEAT SHOULDER BELT GUIDE
RESTRAINT, SEAT HEAD
GUIDE, SEAT HEAD RESTRAINT
BOLT/SCREW, SEAT SHOULDER BELT GUIDE
RETAINING RINGS. HEAD RESTRAINT POST
GUIDE, SEAT SHOULDER BELT
GUIDE, SEAT SHOULDER BELT
0123H
FS0141010
Figure 14 - Head Restraint - (Pontiac)

2. Cover retainer rings (43) and raise cover to access
guides (62).
3. Head restraint post retaining rings (64) from
bottom of posts.
4. Slide J 39641 up head restraint posts with tool
tabs fitting into open slots between head restraint
guide tabs.
5. With headrest removal tools in place, rotate each
tool so head restraint guide tabs expand outward.
7. Bolts/screws (60 and 63) and seat shoulder belt
guide (65 and 66), if necessary.
I++!
Install or Connect

1. Head restraint post retaining rings (64) to bottom
of posts.
3. Cover retainer rings (43).
4. Seatback trim. Refer to "Uplevel Seat Trim"
5. Seat shoulder belt guide (65 and 66) and
bolts/screws (60 and 63), if necessary.
Secure bolts/screws (60 and 63).
Front Seat Recliner

Figures 15 and 16
!++I
1. Bolts/screws (23 ) attaching panel (20) to front

seat (Pontiac only).
2. Panel (20) (Pontiac only).
3. Seat cushion trim. Refer to "Seat Cushion Trim"
4. Pull seatback cover far enough forward to access
bolts/screws (68).
5. Bolts/screws (68) attaching recliner (67) to front
seat.
6. Front seatback. Refer to "Front Seatback" in this
section.
7. Recliner (67).
I++!
Install or Connect

1. Recliner (67) to front seat.
2. Bolts/screws (68) attaching recliner (67) to front
seat.
l~I Tighten
70
A
1
20
23
67
68
69
70
COVER', FRONT SEATBACK

SEAT, DRIVER
PANEL, DRIVER SEAT CUSHION OUTER FINISH
BOLT/SCREW, DRIVER SEAT CUSHION OUTER FINISH PANEL
RECLINER, DRIVER/PASSENGER SEAT
BOLT/SCREW, DRIVER/PASSENGER SEAT RECLINER,
FASTENER, DRIVER SEAT RECLINER HANDLE
HANDLE, DRIVER SEAT RECLINER
Figure 15 Removing Recliner (Typical) (Pontiac)
012395
F80t&1010

3. Front seatback. Refer to "Front Seatback" in this
section.
4. Seatback cover to original position.
5. Seat cushion trim. Refer to "Seat Cushion Trim"
6. Panel (20) over recliner (67) (Pontiac only).
7. Secure bolts/screws (23) through panel (20) to
front seat (Pontiac only).
RECLINER CONTROL CHECK
!L1'!
Inspect
68
L Recliner control
A. Lift recliner control handle and press seatback
rearward into fully-reclined position, checking
ease of recliner control handle operation and
seatback movement.
B. Release recliner control handle, checking that
it returns to its original position and that
seatback remains fully reclined..
C. Lift recliner control handle and pull seatback
forward to an intermediate reclined position.
D. Release recliner control handle.
E. Press seatback rearward to check that seatback
is locked and stays in position.
F. Lift recliner control handle and move seatback
to normal position, checking ease of recliner
control handle operation and seatback return.
G. Release recliner control handle.
H. Press seatback rearward to check that seatback
is locked and stays in position.
2. If recliner control does not operate correctly,
remove or replace. Refer to "Front Seat Recliner"
in this section.
Manual Front Seat Adjuster

Figure 17
!++!

2. Bolts/screws (71 and 78) attaching adjuster (75) to
front seat.
3. Adjuster (75).
4. Bolts/screws (72 and 79) attaching adjuster (76) to
front seat.
5. Adjuster (76).
!..+!
Install or Connect
NOTICE:
Refer to "Notice" on 10-10-1.
1. Adjuster (76) to front seat.

l~!
Tighten
Bolts/screws (72 and 79) to 24 N .m

(18 lb. ft.).
67
1
6
7
67
68
SEAT, DRIVER
RECLINER, DRIVER SEAT
BOLT/SCREW, DRIVER SEAT RECLINER
01-:13-95
FS0181010
Figure 16 - Removing Recliner (Driver Seat Shown,

Passenger Seat Similar) (Typical)
3. Adjuster (75) to front seat.

I~!
Tighten
Bolts/screws (71 and 78) to 24 N.m

(18 lb. ft.).
5. Front seat. Refer to "Front Seat" in this. section.
Driver Seat Adjuster and Drive Motor

Figures 18 and 19
!++j

2. Drive cables (86).
3. Nut (83) securing motor support (84) with motor
(85) attached.
4. Motor support (84) with motor (85) attached.
6. Adjuster (82).
7. Adjuster cover bolts/screws, if necessary.
8. Adjuster covers, if necessary.
79
__
72
1
71
72
73
74
75
76
77
78
79
76
SEAT, DRIVER
BOLT/SCREW, DRIVER SEAT OUTER ADJUSTER UPPER
BOLT/SCREW, DRIVER SEAT INNER ADJUSTER UPPER
SPACER, DRIVER SEAT OUTER ADJUSTER
FASTENER, DRIVER SEAT OUTER ADJUSTER SPACER
ADJUSTER, DRIVER SEAT OUTER
ADJUSTER, DRIVER SEAT INNER
SILENCER, DRIVER SEAT ADJUSTER RETURN SPRING
BOLT/SCREW, DRIVER SEAT ou:rER ADJUSTER LOWER
BOLT/SCREW, DRIVER SEAT INNER ADJUSTER LOWER
(
01-23-96
FS0171010
Figure 17 - Driver Seat Adjuster (Manual) (Typical)
I+!+!
Disassemble
CAUTION: Failure to place the power

adjuster in a bench vise before removing
the rear vertical actuator will cause
ejection of the compressed assist spring
and possible personal injury.
1. Rear adjuster nut (92).
2.
3.
4.
5.
6.
7.
A. Place adjuster (82) in a bench vise and remove

rear adjuster (82) from vise.
B. Open vise slowly to relieve assist spring
compression and remove adjuster (82) from
vise.
Vertical assist spring (88).
Front adjuster nut (91).
Bolts/screws (90) from adjuster horizontal actuator
(81).
Adjuster horizontal actuator (81).
Adjuster bolts/screws (93).
Rear vertical actuator (89).
8. Front vertical actuator (87).
!+;+!
Assemble
1.
2.
3.
4.
5.
Front vertical actuator (87).

Rear vertical actuator (89).
Adjuster bolts/screws (93).
Adjuster horizontal actuator (81).
Bolts/screws (90) to adjuster horizontal actuator
(81).
6. Front adjuster nut (91).
7. Vertical assist spring (88).
8. Rear adjuster nut (92).
A. Place adjuster (82) into a bench vise.
B. Carefully compress vertical assist spring (88)
and install rear adjuster nut (92).
C. Remove power adjuster (45) from bench vise.
!++!
Install or Connect
NOTICE:
82
012311
F80181010
Figure. 18 Driver Seat Adjuster Drive Motor
1. Adjuster covers, if removed.

2. Adjuster cover bolts/screws, if removed.
!~!
Tighten
Adjuster cover bolts/screws to 1.7 N.m

(15 lb. ft).
3. Adjuster (82).
l~I
5.
6.
7.
B.
Tighten

Motor support (84) with motor (85) attached.
Nut (83) securing motor support (84).
Drive cables (86)'.
Front seat. Refer to "Front Seat" in this section.
I
93
MOTOR REPLACEMENT
l++I
2.
3.
4.
5.
6.
Drive cables (86).

Nuts (83).
Motor support (84) with motor (85) attached.
Electrical connectors from motor (85).
Motor (85) from motor support (84).
Grind off ends of grommet to .separate motor
(85) from motor support (84).
81
87
88
89
90
91
92
93
88
"'
ACTUATOR, DRIVER SEAT ADJUSTER HORIZONTAL

ACTUATOR, DRIVER SEA.T ADJUSTER FRONT VERTICAL
SPRING, DRIVER SEAT VERTICAL ASSIST
.. .
ACTUATOR, DRIVER SEAT ADJUSTER REAR VERTICAL
BOLT/SCREW, DRIVER SEAT ADJUSTER .
NUT; DRIVER SEAT FRONT ADJUSTER
NUT, DRIVER SEAT REAR ADJUSTER
BOLT/SCREW, DRIVER SEAT ADJUSTER
Figure 19 " Adjuster Horizontal and Vertical Actuator
Install or Connect
NOTICE:
Refer to ''Notice" on page 10,.JO~l.
1. Motor (85) to motor support (84).

A. Drill out top . end of grommet, using a
B. Secure motor (85) to motor support (84) with
3/16-inch rivets.
2. Electrical connectors to motor (85).
3. Motor support (84) with motor (85) attached.
4. Nut (83).
5. Drive cables (86).
Passenger Seat Adjuster
E3
Install or Connect
NOTICE:
1. Covers (94 and 95).

2. Adjuster (97 and 99).
l~I Tighten
Bolts/screws (96 and 98) to 24 N,ltl
(18 lb; ft.).
4. Seat. Refer to "Front Seat'' in this section;
Figure 20
E3
2. Bolts/screws (96 and 98) attaching adjuster (91

and 99) and covers (94 and 95) to seat (2).
3. Adjuster (97 and 99).
4. Covers (94 and 95).
1. Seat. Refer to "Front Seat" in this section.
94
2 SEAT, PASSENGER
94 COVER, PASSENGER SEAT OUTER ADJUSTER
REAR TRIM
95 COVER, PASSENGER SEAT INNER ADJUSTER
REAR TRIM
.
96 BOLT/SCREW. PASSENGER SEAT OUTER ADJUSTER
97 ADJUSTER, PASSENGER SEAT OUTER
.
.
98 BOLT/SCREW, PASSENGER SEAT INNER ADJUSTER
99 ADJUSTER, PASSENGER SEAT INNER
100 SPRING, PASSENGER SEAT ADJUSTER RETURN
Figure 20 Passenger Seat Adjuster (Typical)
01-23-IS
FS0201010
SEAT$ ANP CAR.P~T
101019
Power Front Seat Adjuster

Figure 21
!++!
1. Driver seat. Refer to "Front Seat" in this section.

2. Hinge arm trim cover. Refer to "Hinge Ann Trim
Cover" under "Trim Covers" in this section.
3. Connector (101) from adjuster (24) by releasing
retainers (102).
l~I
Install or Connect
1. Connector (101) to adjuster (24) by engaging

retainers (102).
2. Hinge arm trim cover. Refer to "Hinge Ann Trim
Cover" under "Trim Covers" in this section.
3. Driver seat. Refer to "Front Seat" in this section.
POWER FRONT SEAT ADJUSTER ADJUSTMENTS
Figure 22
With the seat adjuster installed, chucking or
jerking can be corrected by tightening or loosening the
horizontal actuator and pinion gear to the adjuster
lower track rack gear.
[l]
Adjust

Actuator (104).
A SCREWDRIVER
103. BOLT/SCREW, DRIVER SEAT ADJUSTER ACTUATOR
104 ACTUATOR, DRIVER SEAT ADJUSTER.
0123H
FBCl221010
Figure 22 Adjusting Seat Adjuster Actuator
A. Operate seat to full-up position _and about

3/4-forward position.
B. Loosen bolt/screw (103).
C. Using farge screwdriver, apply 67 to 111 N
(15 to 25 pounds) of" outward pressure on
actuator (104). At same time, use
horizontal adjuster switch to move seat
forward and backward to help seat
horizontal actuator pinion gear teeth tight
to lower track rack gear teeth and eliminate
any free play.
D. While keeping pressure on actuator (104),
tighten bolt/screw (103) to 28 N.m
(20 lb. ft.).
POWER FRONT SEAT ADJUSTER PHASE
. When one adjuster reaches either maximum

horizontal or maximum vertical travel before the other,
the adjuster are out of phase. Out-of-phase adjuster
can occur over time or when the seat are serviced.
1lJ Adjust
1. Horizontal phase.
A. Operate horizontal adjuster switch until one
. adjuster reaches full-forward position.
B. Detach horizontal drive cable from
full-forward adjuster.
C. Operate horizontal adjuster switch until other
adjuster reaches full-forward position.
D. Connect horizontal drive cable.
!L!
24
1
17
24
101
102
SEAT, DRIVER
ADJUSTER, FRONT SEAT
CONNECTOR, FRONT SEAT ADJUSTER ELECTRICAL
RETAINER, FRONT SEAT ADJUSTER
01-23-95
FS0211010
Figure 21 - Front Seat Ac:IJuster (Power)
Inspect
Horizontal travel.
2. Vertical phase ..
A. Operate vertial adjuster :switch . until one.
adjuster reach~s.full-up _poSitfon . at both front
and rear.
B. Disconnect both front and rear vertical drive
cable from full-up adjuster.
10-10-20
SEATS AND CARPET
C. Operate vertical adjuster switch until other

adjuster reaches full-up position at both front
and rear.
D. Connect vertical drive cable.
ILI
NOTICE: While installing the adjuster

actuator lever knob, take care not to bend the
adjuster actuator lever.
D. Insert knob (105) onto adjuster actuator lever.
Inspect
Gate marks on knob (105) must face to

rear.
E. Press knob (105) firmly onto adjuster actuator
lever.
Vertical travel.
Front Seat Adjuster Actuator Lever Knob

Figure 23
REAR SEAT
The adjuster actuator lever knob fits over the

end of the adjuster actuator lever that comes out from
the lower seat cushion. The knob can generally be
removed and installed several times without becoming
too loose.
Rear Seat Cushion
l+-.1
Knob (105) from adjuster actuator lever.

A. Place protective covering over nearby trim.
B. Clamp locking pliers onto adjuster actuator
lever.
C. Using body spoon, pry downward to remove
knob (105).
1-.+I
Install or Connect
Knob (105) to adjuster actuator lever.

A. Place protective covering over nearby trim.
B. Draw pencil line on adjuster actuator lever 25
mm (1 inch) from end as guide for full-depth
fit of knob (105).
C. Secure locking pliers to adjuster actuator lever
and seat.
Figure 24
l+-.1
2. Seat Cushion ( 106) by pulling upward and
forward.
to the vehicle.

4. Seat cushion (106) from vehicle.
A. Remove seat cushion (106) through rear
compartment lift window, being careful not to
damage rear seatback.
B. Remove protective shield.
!-.+I
Install or Connect
NOTICE:

2. Seat cushion (106) into vehicle.
to the vehicle.
c
A
8
C
D
105
SPOON, BODY
COVERING, PROTECTIVE
PLIERS, LOCKING
LEVER, ADJUSTER ACTUATOR
KNOB, DRIVER/PASSENGER SEAT ADJUSTER
ACTUATOR LEVER
01-239&
FS0231010
Figure 23 - Adjuster Actuator Lever Knob
A. Load seat cushion (106) through rear

dent rear seatback.
3. Seat cushion (106) by pushing rearward.
4. Bolt/screw (107) through anchor wire loop in hole
in floor pan.
l~I
Tighten
A ANCHOR WIRE LOOP

108 CUSHION, REAR SEAT
107 BOLT/SCREW, REAR SEAT CUSHION
012311
FS0241010
Figure 24 Rear Seat Cushion
Rear Seatback Cushion

Figure 25
!+-+!
1. Rear seat cushion. Refer to "Rear Seat Cushion"

in this section.
2. Shoulder restraint guide. Refer to "Shoulder
Restraint Guide" in this section.
3. Lock (109) from striker (108).
4. Nuts (111) from rear seatback cushion studs.
5. Seat studs from outer pivot supports by lifting
upward on outboard side of cushion (110).
NOTICE: Failure to place protective shield

to vehicle.
7. Cushion (110) from vehicle.
A. Remove cushion ( 110) through rear
damage front seat.
!++!
A
B
108
109
110
111
SUPPROT, OUTER PIVOT

STUD, REAR SEATBACK CUSHION
STRIKER, REAR SEATBACK
LOCK, REAR SEATBACK
CUSHION, REAR SEATBACK
NUT, FOLDING REAR SEATBACK CUSHION PIVOT
012395
FS0281010
Install or Connect
Figure 25 Rear Seatback Cushion

NOTICE: Failure to place protective shield
to vehicle.
(
1. Protective shield over nearby trim and paint.
2. Cushion (110) into vehicle.
3.
4.
5.
6.
Load cushion (110) through rear compartment

window.
Remove protective shield.
Seat studs into outer pivot supports.
Nuts (111) to seat studs loosely.
Lock (109) to striker (108).
I~!
Tighten
Nuts (111) to 24 N,m (18 lb. ft.).

in this section.
Restraint Guide" in the following procedure.
Shoulder Restraint Guide

Figures 26 and 27
l++I
1. Bolts/screws (113 or 128) attaching guide

(112 or 127) to rear seatback cushion.
2. Guide (112 or 127).
l++l
Install or Connect
NOTICE:
1. Guide (112 or 127) to rear seatback cushion.

2. Bolts/screws (113) or (128).
l~l
112 GUIDE, REAR SEAT BELT SHOULDER RESTRAINT

113 BOLT/SCREW, REAR SEAT BELT SHOULDER
fl
01 23
RESTRAINT GUIDE
FS0281010
Figure 26 - Shoulder Restraint Guide
REAR SEATBACK COVER
Figures 28 and 29
I++!
1. Rear seatback from vehicle. Refer to "Rear

Seatback Cushion" in this section.
2. Rear Seatback lock. Refer to "Rear Seatback
Lock and Striker'' in this section.
3. Shoulder Restraint guide. Refer to "Shoulder
4. Rear seatback cover (117).
!++!
Install or Connect
1. Rear seatback cover (117).

3. Seatback lock. Refer to "Rear Seatback Lock and
Striker" in this section.
4. Rear seatback to the vehicle. Refer to "Rear
Seatback Cushion" in this section.
Tighten
Bolts/screws (113 or 128) to 10 N,m

(89 lb. in.).
Rear Trim and Covers

The rear seat cushion and rear seatback cushion
have formed foam pads that fit the contour of the seat
frames. The seat covers are either cloth or leather.
They are held on to the seat with trim retainer rings,
bolster wires and zippers. A shoulder restraint guide is
attached to the outboard sides of the seat with bolts
and screws.
REAR SEAT CUSHION COVER
The rear seat cushion cover and foam pad are

bonded together with an adhesive glue. If the seat
cushion cover needs to be replaced, the entire rear seat
cushion must be replaced.
127 GUIDE, REAR SEAT BELT SHOULDER RESTRAINT

128 BOLT/SCREW, REAR SEAT BELT SHOULDER
RESTRAINT GUIDE
01-2395
F80271010
Figure 27 - Shoulder Restraint Guide (Convertible Only)
A J-RETAINERS
117 COVER, REAR SEATBACK
118 PAD.REAR SEATBACK
01~23-15
FS02t1010
Figure 28 Rear Seatback Cover Bottom Attachment

1. Washer (122) and lock (120).
!~I
Tighten

3. Rear seatback cushion. Refer to "Rear Seatback
Cushion" in this section.
in this section.
REAR SEATBACK LOCK STRIKER
Figure 31
!+-+I
Bolt/screw (125), sleeve (124) and washer (123).
1-++I
Install or Connect
117
NOTICE:
1. Washer (123) and sleeve (124) over bolt/screw

(125).
l~I Tighten
117 COVER, REAR SEATBACK

118 PAD, REAR SEATBACK
119 PANEL, FOLDING REAR SEATBACK
012395
FS0301010
Figure 29 - Rear Seatback Cover
Rear Seatback Lock and Striker

The rear seat folds down to provide additional
storage space in the rear of the vehicle. The seatback
lock are located on the outboard sides of the seat. The
strikers are located on the wheelhouse panel.
REAR SEATBACK LOCK
Figure 30
l+-+I

in this section.
2. Rear seatback cushion. Refer to "Rear Seatback
Cushion" in this section.
4. Lock (120) and washer (122).
!++!
110
120
121
122

LOCK, REAR SEATBACK
BOLT/SCREW, REAR SEATBACK LOCK
WASHER, REAR SEATBACK LOCK
Install or Connect
NOTICE:
01-23-15
FS0311010
Figure 30 - Rear Seatback Lock
SEATS AND CARPET
1010-25
FLOOR CARPET
Figure 32
Floor carpet have been designed for the high
floor pan temperatures caused by the catalytic
converter in the exhaust system. When servicing a
vehicle in the field, it is essential that any floor pan
carpet that have been disturbed or removed be
reinstalled in the original sequence and location.
CAUTION: Any carpet service repair or

replacement should be the same
thickness, size and location as the
original installation in the vehicle or
vehicle damage and personal injury could
result.
When servicing or replacing interior carpets, the
following instructions must be observed.
.Carpets must be installed in the original position
and sequence. Pieces should be butted together to
avoid gapping or overlapping.
If it is necessary to replace a carpet, specified
material must be used.
Use original part to determine the amount of
replacement material and as a template for cutting
and fitting new piece to floor pan.
When installing a carpet, do not enlarge cutouts or
holes used for attachment of interior components
such as seat or seat belt.
Spray-on deadeners and trim adhesives should not
be applied to the top of the floor pan at the area
directly over the catalytic converter or muffler.
!+--+I
123 WASHER, FOLDING SEATBACK LOCK STRIKER

124 SLEEVE, FOLDING REAR SEATBACK CUSHION
LOCK STRIKER
125 BOLT/SCREW, FOLDING REAR SEATBACK CUSHION
LOCK STRlKER
012396
FS0321010
Figure 31 Folding Rear Seatback Lock
1.
2.
3.
4.
5.
Front seat. Refer to "Front Seat" in this section.

Rear seat. Refer to "Rear Seat" in this section.
Front seat belt. Refer to SECTION 10-11.
Rear seat belt. Refer to SECTION 10-11.
Body hinge pillar trim panels. Refer to
SECTION 10-5.
6. Quart er trim finish panel. Re fer to
SECTION 10-7.
8. Floor carpet (126).
lH!
Install or Connect
1. Floor carpet (126).

SECTION 10-7.
4. Body hinge pillar trim panels. Refer to
SECTION 10-5.
5. Rear seat belt. Refer to SECTION 10-11.
A CONNECTOR, SEAT BELT ALARM ELECTRICAL

B CONNECTOR, DRIVER/PASSENGER SEAT WIRING
ELECTRICAL
C CONNECTOR, POWER SEAT ADJUSTER ELECTRICAL
126 CARPET, FLOOR
012395
FS0331010
Figure 32 Floor Carpet (Typical)
6. Front seat belt. Refer to SECTION 10-11.

7. Rear seat. Refer to "Rear Seat" in this section.
10-1026
SEATS AND CARPET
SPECIFICATIONS
Driver Seat Adjuster Bolt/Screw ............................................................................................. 24 N.m (18 lb. ft.)
Driver Seat Adjuster Front Trim Cover Bolt/Screw (Left), .............................................. ,. 1.7 N.m (15 lb. in.)
Driver Seat Adjuster Front Trim Cover Bolt/Screw (Right) .............................................. 1.7 N.m (15 lb. m.)
Driver Seat Inner Adjuster Lower Bolt/Screw ....................................................................... 24 N.m (18 lb. ft.)
Driver Seat Inner Adjuster Upper Bolt/Screw ....................................................................... 24 N.m (18 lb. ft.)
Driver Seat Outer Adjuster Lower Bolt/Screw ...................................................................... 24 N.m (18 lb. ft.)
Driver Seat Outer Adjuster Lower Bolt/Screw (Trim Cover) ............................................. 1.7 N.m (15 lb. in.)
Driver Seat Outer Adjuster Upper Bolt/Screw ............................................................ '. .......... 24 N.m (18lb. ft.)
Driver/Passenger Seat Adjuster Actuator Bolt/Screw ............................................................ 28 N.m (20 lb. ft.)
Driver/Passenger Seat Adjuster Nut. ....................................................................................... 32 ,N.m (24, lb. ft.)
Driver/Passenger Seat Recliner Bolt/Screw ............................................................................ 24 ,N.m (18 lb. ft.)
Folding Rear Seatback Cushion Lock Striker Bolt/Screw ..................................................... 35 N.m (26 lb. ft.)
Folding Rear Seatback Cushion Pivot Nut ............................................................................ 24 N.m (18 lb. ft.)
Front Seatback Hinge Arm Bolt/Screw (Front) ............................. :........................................ 24 N.m (18 lb. ft.)
Front Seatback Hinge Arm Bolt/Screw (Rear) ...................................................................... 24 N.m (18 lb. ft.)
Passenger Seat Inner Adjuster Bolt/Screw ............................................................................. 24 N.ni '(18 lb. ft.)
Passenger Seat Outer Adjuster Bolt/Screw .............................................................................. 24 N.m (18 lb. ft.)
Rear Seatback Lock Bolt/Screw ..................................................... ,............... ;~ .......... ;............ 27 N.m (20.lb. ft.)
Rear Seat Belt Shoulder Restraint Guide Bolt/Screw ............................................. ,..... ;....... 10 N.m (89 lb. in.)
Rear Seat Cushion Bolt/Screw .............. ;................................................................................. 24 N.m (18 lb. ft.)
SPECIAL TOOLS.
1.
1. HEADREST REMOVAL TOOL
J 39641
01-23-9&
FS0341010
SEAT BELTS
10-11-1
SECTION 10-11
SEAT BELTS
CAUTION: Replace belts, retractors, and hardware in use during all but a minor collision. Also,
restraint systems should be replaced and anchorage properly repaired if they were in areas
damaged by a collision, whether the belt was in use or not. If there is any question, replace the
belt system. Damage, whether visible or not, could result in serious personal injury in the event
of an accident.
inhibitors) on threaded fasteners or fastener joint interfaces .. Generally, such coatings adversely affect the fastener
tightening sequence and specifications. Following these instructions , can help you avoid damage to parts and
systems.
CONTENTS
Restraint System ............................................. 10-11-1
Front Seat System .......................................... 10-11-2
Rear Seat System ........................................... 10-11-2
Child Restraint................................................ 10-11-2
General Service Instructions .......................... 10-11-2
Operational and Functional Checks ............... 10-11-3
Seat Belts .................................................... 10-11-3
Emergency Locking Retractors .................. J 0-11-3
Front Seat Belts ............................................. 10-11-3
Front Driver and Passenger Seat Buckle.Side Belts ............................................... 10-11-3
Front Driver and Passenger Seat RetractorSide Belts ............................................. 10-11-4

Rear Seat Belts ............................................ 10-11-5
Rear Seat Buckle-Side Belts ................... 10-11-5
Rear Seat Retractor-Side Belts ................ 10-11-5
Rear Seat Shoulder Belt Retractor Trilli
Cover .................................................... 10-11-7
Rear Seat Shoulder Belt Retractor
Bracket .................................................. 10-11-7
Child Restraint Installation .......................... 10-11-8
Child Seat ................................................. 10-11-8
Child Seat Restraint System Belt Kit ..... 10-11-8
Specifications .................................................... 10-11-10
Fastener Tightening Specifications .............. 10-11-10
GENERAL DESCRIPTION
position by a pendulum that causes a locking bar to

engage a cog on the spool of the retractor mechanism
under the following conditions:
RESTRAINT SYSTEM
Seat belts are the primary means of occupant
restraint Seat belts help to keep .the occupant inside
the passenger compartment and to ride down the crash
forces more gradually during .the following events:
Frontal impact type crashes.
Rear impact type crashes.
Side impact type crashes.
Roll-over type crashes.
All seat belts have emergency locks in the
retractors. During normal operation, the retractors
remain unlocked to allow free movement of the
occupant's upper body under normal driving
conditions. The seat belt webbing is locked into
The rapid extraction of the seat belt webbing. from

the retractor.
The speed of the vehicle changes abruptly.
The direction of the vehicle changes abruptly.
The vehicle is on a steep upgrade or a downgrade.
The front and rear seat belts have an automatic
locking (cinch) feature. The cinch feature is activated
when the seat belt webbing is completely extended
from the retractor. The cinch feature will not allow the
webbing to extend from whatever position it is
allowed to retract. It is recommended that the cinch
feature is used when securing a child seat. The cinch
feature is canceled by allowing the webbing to be
completely wound back into the retractor. After the
cinch feature is canceled, the webbing is unlocked and
will extend from the retractor.
10112
SEAT BELTS
The front and rear seat belts are also equipped

with a dual mode latchplate that has the ability to lock
or cinch itself along the webbing. This feature
eliminates the need for a locking clip when securing a
child seat.
In conjunction with the seat belts, this vehicle is
equipped with a Supplemental Inflatable (SIR) System.
Refer to SECTION 9J for more information about the
SIR (air bag) system.
FRONT . SEAT SYSTEM

The front seat belt system includes the following
components:
The front driver and passenger seat buckle-side
belt is attached to floor panel inboard of the front
seats.
The front driver and passenger seat retractor-side
belt is attached to floor panel and the roof. panel
(coupe) or the body lock pillar reinforcement
(convertible).
The driver's seat belt system includes a seat belt
switch in the driver seat buckle-side belt which
controls a reminder lamp and a tone alarm. When the
driver's seat belt is buckled, the driver's door is
closed, and the ignition switch is turned "ON,'' the
following events will occur:
The tone alarm will not operate.
The reminder lamp will not operate.
When the driver's seat belt is not buckled, the
driver's door is closed, and the ignition switch is
turned "ON", the following events will occur:
The tone alarm will operate for 4 to 8 seconds
and then go ''OFF."
The reminder lamp will operate until the driver's
seat belt is buckled.
To diagnose a failure of the reminder lamp or
tone alarm, refer to SECTION 8A-76.
REAR SEAT SYSTEM
The rear seat belt system includes the following
components:
The rear seat buckle-side belt is attached to the
floor panel inboard of the rear seats.
The rear seat retractor-side belt is attached to the
floor panel and the inner wheelhouse panel
(coupe) or the floor panel and the rear seat
shoulder belt retractor bracket.
CHILD RESTRAINT
CAUTION: A child in a rear-facing child
restraint can be seriously injured if the
right-front passenger's air bag inflates.
This is because the back of a rear-facing
child restraint would be very close to the
inflating air bag. It is always better to
secure a child restraint in the rear seat. If
a forward-facing child seat is suitable for
your child, ALWAYS move front
passenger seat as far back as it will go
and then install the child restraint. Be
sure the child restraint position does not
conflict with any additional requirements
provided by the manufacturer. For more
information, refer to the vehicle owners
manual and the instructions that came
with the child restraint.
The child seat should be installed and secured
according to the manufacturer's directions. The
automatic locking (cinch) feature can be used to
secure the child seat. If the child seat has a top strap it
will need to be anchored, refer to "ON-VEHICLE
SERVICE" in this section. Passengers should not be
allowed to sit at locations where the seat belts are
being used to used secure the child seat.
ON-VEHICLE SERVICE
CAUTION: Replace belts, retractors, and

hardware in use in all but a minor
collision. Also, restraint systems should
be. replaced and anchorage properly
repaired if they were in area damaged by
a collision, whether the belt was in use
or not. If there is any question, replace
the belt system. Damage, whether visible
or not, could result in serious personal
injury in the event of an accident.
GENERAL SERVICE INSTRUCTIONS

Do not bleach or dye seat belt webbing. Clean
only with a mild soap and water solution and a
soft brush or cloth.
Keep sharp edges and damaging objects away
from seat belts. Avoid bending or damaging any
part of the belt buckle or latch plate. Replace any
seat belts which are cut or damaged in any way.
Use only the correct seat belt anchor bolts/screws
and tighten to the correct torque value, refer to
"SPECIFICATIONS" in this section. When
installing seat belt anchor bolts, start the bolt by
hand to ensure that the bolt is threaded straight.
SEAT BELTS
10-11-3
Some seat belts and retractors must be serviced as

a set with service replacement parts only. Do not
attempt to make repairs to the individual
components which are only serviced as a set.
Verify that the replacement ~art nu~~er is correct
for the vehicle at that seatmg position. Do not
substitute a seat belt from a different seating
position.
OPERATIONAL AND FUNCTIONAL

CHECKS
Seat Belts
Begin in the driver seat.
1. Tum the ignition switch "ON" and verify proper
operation of the seat belt reminder lamp with the
belt buckled and unbuckled, refer fo "General
Description-Front Seat System."
2. Inspect the shoulder belt guide. Check th~1.t t~e
guide swivels freely, the seat belt we?bmg 1s
seated flat in the guide slot that the webbmg does
not bind.
3. Check that seat belt buckle faces inboard and is
accessible.
4. Check that the seat belt retractor units are
securely attached.
5. Check the seat belt anchor bolts to verify that
they are secure.
6. Fully extend the seat belt w~bbing and ~heck that
there are no twists or tears m the webbmg.
7. Allow the seat belt webbing to retract and check
that the webbing returns freely and completely
back in the retractor.
8. Snap seat belt latch plate into buckle.
9. Tug sharply on the seat belt latch plate and buckle
check that it remains locked.
10. Push the button on buckle. The seat belt latch
plate must release from the buckle easily and the
button must return to its original position.
11. Repeat steps 2 to 10 from the front passenger
seat.
12. Repeat steps 2 to 10 from the rear seats. To
remove seats or cushions refer to
SECTION 10-10.
040595
AT0021011
Figure 1 - Seat Belt Retractor (Typical)
3. Verify that the seat belt locks when braking

firmly.
4. If the belt does not lock, proceed with steps 5 to
8.
5. Remove seat belt retractor.
6. Tilt the seat belt retractor slowly.
7. Check that the seat belt webbing can be pulled
from the retractor at an inclination of 15 degrees
or less and cannot be pulled from the retractor at
an inclination of 45 degrees or more (Figure 1).
8. If the seat belt retractor does not operate as
described, replace the retractor.
FRONT SEAT BELTS

CAUTION: The seat belt assembly and/or
bracket assembly must be replaced as a
unit only. Do not substitute parts for any
reason, or personal injury could result in
the event of a collision.
Front Driver and Passenger Seat

Buckle-Side Belts
Figure 2
Emergency Locking Retractors

Figure 1
CAUTION: Perform this test in an area
clear of other vehicles or obstructions.
Do not conduct this test on the open
road. A large, empty parking lot ~s
suitable. Failure to observe thas
precaution may ~esult in dam~g.e to the
vehicle and possible personal mJury.
1. Fasten the seat belts, an assistant is needed when
the retractor under test is not part of the driver
seat belt.
2. Accelerate the vehicle slowly to 16 km/h
(10 mph) and apply the brakes firmly.
Driver seat buckle-side belt is shown, passenger

seat buckle-side belt is similar.
l++I
1.
2.
3.
4.
5.
!++!
Front seat, if necessary. Refer to SECTION 10-10.
Driver side seat belt warning electrical connector.
Plug (2) from bolt/screw (3).
Bolt/screw (3) attaching belt (1) to floor pan.
Belt (1).
Install or Connect
NOTICE:
10114 SEAT BELTS
(
4
A PLATE, FRONT SEAT BELT ANCHOR

4 PLUG, PASSENGER SEAT RETRACTOR-SIDE BELT
SLEEVE
5 BOLT/SCREW, FRONT SEAT BELT ANCHOR PLATE
7 BELT, FRONT SEAT RETRACTOR-SIDE
012595
F80021011
A. CONNECTOR, DRIVER SIDE SEAT BELT WARNING
ELECTRICAL
1 BELT, DRIVER SEAT BUCKLE-SIDE
2 PLUG, DRIVER SEAT BUCKLE-SIDE BELT SLEEVE
3 BOLT/SCREW, DRIVER SEAT BUCKLE-SIDE BELT
012595
FS0011011
Figure 3 - Front Seat Belt Anchor Plate (Typical)

(Passenger Side Shown - Driver Side Similar)
l++I
Install or Connect

Figure 2 - Front Driver and Passenger Seat Buckle-Side
Belts (Typical)
1. Belt (1).
2. Bolt/screw (3) attaching belt (1) to floor pan.
l~I
l~l
Tighten

3. Plug (2) to bolt/screw (3).
4. Driver side seat belt warning electrical connector.
5. Front seat. Refer to SECTION 10-10.

Retractor-Side Belts
COUPE
Figures 3 and 4
l++I
1. Belt (7) to rear roof panel.

1. Plug (4) from bolt/screw (5).

2. Bolt/screw (5) attaching plate to rocker panel.
3. Plate.
4. Pull webbing and plate out of shoulder belt guide.
5. Lower rear portion of headlining finishing trim
panel. Refer to SECTION 10-9.
6. Bolts/screws (8) attaching belt (7) to rear roof
panel.
7. Belt (7) from rear roof panel.
3.
4.
5.
6.
Tighten

Raise rear portion of headliner finishing trim
panel back into position. Refer to SECTION 10-9.
Route webbing and plate through shoulder belt
guide.
Plate to rocker panel.
Bolt/screw (5).
!~!
Tighten

7. Plug (4) to bolt/screw (5).
CONVERTIBLE
Figures 3 and 5
!++!
1. Front quarter trim finishing panel. Refer to

SECTION 10-7.
2. Plug (4) from bolt/screw (5).
4. Shoulder belt guide bolt/screw (40).
5. Shoulder belt retractor-side bolt/screw (41).
6. Retractor-side belt (42).
SEAT BELTS
10115
40 BOLT/SCREW, FRONT SEAT SHOULDER BELT GUIDE

41 BOLT/SCREW, FRONT SEAT SHOULDER BELT
RETRACTOR-SIDE
42 BELT, FRONT SEAT
!VIEWA
RETRACTOR-SIDE SHOULDER
012195
FS0041011
Figure 5 - Front Seat Retractor-Side Belt (Convertible)
REAR SEAT BELTS

7 BELT, PASSENGER SEAT RETRACTOR-SIDE
8 BOLT/SCREW{ PASSENGER SEAT. SHO.ULDER BELT
CAUTION: Th~ seat belt assembly and/or

Rear Seat Buckle-Side Belts

Figure 6
01-28-911
FS0031011
Figure 4 - Front Seat Retractor-Side Belt

(Passenger Side Shown - Driver Side Similar) (Coupe)
!+!
Install or Connect
NOTICE:
1. Retractor-side belt (42).

2. Shoulder belt guide bolt/screw (40).
!~I
Tighten

3. Shoulder belt retractor-side bolt/screw (41).
l~I
Tighten

!~!
!++! .Remove or Disconnect

1. Rear seat cushion. Refer to SECTION 10-10.
2. Bolt/screw (27) attaching belt (18) to floor panel
(19).
3. Belt (18).
!++I
Install or Connect

. 1. Belt (18).
2. Bolt/screw (27).
l~I
Tighten

Rear Seat Retractor-Side Belts

COUPE
Figure 6
Tighten

5. Front quarter trim finishing panel. Refer to
SECTION 10-7.
!++!

SECTION 10-7.
10-11-6 SEAT BELTS

14
3. Shoulder belt guide (13) to rear seatback cushion

(17).
15
!~I
Tighten

5. Belt retractor to inner wheelhouse panel (28).
6. Nut (16).
!~!
Tighten
Nut (16) to 55 N.m (41 lb. ft.).

SECTION 10-7.
12
CONVERTIBLE
Figures 7 and 8
!++!
9
10
11
12
13
14
15
BOLT/SCREW, REAR SEAT SHOULDER BELT

BELT, REAR SEAT RETRACTOR-SIDE
SPACER, REAR SEAT BELT ANCHOR PLATE
CUSHION, REAR SEAT
GUIDE, REAR SEAT SHOULDER BELT
BOLT/SCREW, REAR SEAT SHOULDER BELT GUIDE
ESCUTCHEON, QUARTER LOWER TRIM FINISH PANEL
REAR SEAT BELT
NUT, REAR SEAT SHOULDER BELT RETRACTOR
BELT, REAR SEAT BUCKLE-SIDE
PANEL, FLOOR
BOLT/SCREW, CENTER BELT
02-279&
PANEL, INNER WHEELHOUSE
15
17
18
19
27
28
1. Retractor trim cover. Refer to "Rear Seat

Shoulder Belt Retractor Trim Cover" in this
section.
3. Rear seat shoulder belt guide bolt/screw (33).
4. Rear seat retractor-side shoulder belt bolt/
screw (34).
FT00&1011
Figure 6 - Rear Seat Retractor-Side and Rear Seat

Buckle-Side Belts (Coupe)

3. Nut (16) attaching rear seat shoulder belt retractor
to inner wheelhouse panel (28).
4. Bolts/screws (14) attaching rear seat shoulder belt
guide (13) to rear seatback cushion (17).
5. Bolt/screw (9) and spacer (11) attaching belt (10)
to floor panel (19).
6. Belt (10) from vehicle.
!++I
Install or Connect
NOTICE:
1. Belt anchor plate to floor panel (19).

2. Bolt/screw (9) through belt anchor plate and
spacer (11) to floor panel (19).
!~I
35
33 BOLT/SCREW, REAR SEAT SHOULDER BELT GUIDE

34 BOLT/SCREW, REAR SEAT RETRACTOR-SIDE BELT
35 BELT, REAR SEAT RETRACTOR-SIDE
02-278&
Tighten
FT0081011
Figure 7 - Rear Seat Belt (Convertible)
SEAT BELTS
10-11-7
2. Trim cover retainer (31).

3. Cover (32) from retractor trim cover.
!++!
Install or Connect
1. Cover (32) to retractor trim cover.

2. Trim cover retainer (31).
3. Trim cover (30).
Rear Seat Shoulder Belt Retractor Bracket

CONVERTIBLE
Figures 7 and 10
35
36
37
BELT, REAR SEAT RETRACTOR-SIDE

BOLT/SCREW, REAR SEAT SHOULDER BELT _ _
02 27 95
SPACER, REAR SEAT BELT ANCHOR PLATE FT0071011
Figure 8 - Rear Seat Belt, Forward Attachment
(Convertible)
5. Bolt/screw (36) and spacer (37) attaching belt (35)

to floor panel.
6. Rear seat belt (35).
!-++!
Install or Connect
NOTICE:
1. Rear seat belt anchor plate to floor panel.

2. Bolt/screw (36) through belt anchor plate and
spacer (37) to floor panel.
I~!
l++l

section.
3. Rear seat retractor-side belt bolt/screw (34).
4. Retractor from bracket (39).
5. Bracket bolts/screws (38).
6. Bracket (39).
!++I
Install or Connect
Tighten

3. Rear seat shoulder belt retractor-side bolt/screw
(34).
I~!
Tighten

!~I
Tighten

6. Retractor trim cover. ' Refer to "Rear Seat
section.
Rear Seat Shoulder Belt Retractor Trim

Cover
CONVERTIBLE
Figure 9
!++I
1. Trim cover (30) by unsnapping from cover (32) to

retractor trim cover.
30 COVER, REAR SEAT SHOULDER BELT RETRACTOR TRIM

31 RETAINER. REAR SEAT SHOULDER BELT RETRACTOR
TRIM COVER
32 COVER, REAR SEAT SHOULDER BELT RETRACTOR TRIM
COVER
.
01-25~95
FS0081011
Figure 9 - Rear Seat Shoulder Belt Retractor Trim Cover

(Convertible)
10-118
SEAT BELTS
1. Bracket (39).
2. Bracket bolts/screws (38).
I~!
Tighten
~--

3. Retractor to bracket (39).
4. Rear seat retractor-side belt bolt/screw (34),
l~I
38
Tighten

!~!
Tighten

Shoulder Belt Retractor Trim Cover" in. this
section.
38
39
BOLT /SCREW, REAR SEAT SHOULDER BELT

RETRACTOR BRACKET
BRACKET, REAR SEAT SHOULDER BELT
RETRACTOR
i:J~tf1
CHILD RESTRAINT INSTALLATION .

CAUTION: A child in a rear.facing child
restraint can be seriously injured if the
right-front passenger's air bag inflates.
This is because the back of a rear-facing
child restraint would be very close to the
inflating air bag. It is always better to
secure a child restraint in the rear seat. If
a forward-facing child seat is suitable for
your child, ALWAYS move front
passenger seat as far back as it will go
and then install the child restraint. Be
sure the child restraint position does not
conflict with any additional requirements
provided by the manufacturer. For more
information, refer to the vehicle owners
manual and the instructions that came
with the child restraint.
Child Seat
When the child seat is used in a front seat
location, it is installed by connecting the child seat
tether to the seat belt at the seating position to the
rear.
When a child seat that requires a top strap is to
be used in a rear seat position, a special
dealer-installed anchor must be used to secure the
child seat tether. In order to ensure the correct child
seat tether angle, the child seat must only be used at
the seating position for which the anchor is installed.
Child .seat Restraint System. Belt. Kit

CAUTION: The child seat tether anchor is
intended for use only on the left or right
outboard second row seats. Installation
at any other seating pQsition could result
in system failure, leading to. injury in the
event of a collision.
Figure 1O - Rear Seat Shoulder Belt Retractor Bracket

(Convertible)
CHILD SEAT RESTRAINT SYSTEM BELT KIT

INITIAL INSTALLATION
Figure 11
AH.vehicles are equipped with drilled and tapped
plates welded to the rear compartment front panel.
These plates serve as mounting points for Child Seat
Restraint System Belt Kits (25).
If an anchor bracket (25) is being installed for
the first time, use the following procedure.
!Hl
Install or Connect

1. Remov.e quarter i.nner trim finishing panel. Refer
to SECTION 10-7.
2. Carefully lift up on rear edge of carpeting to
reveal anchor bracket mounting plate locations.
3. Choose either driver or passenger side mounting
locations depending on which seating position
child restraint is to be installed.
4. Position anchor bracket (25) to anchor bracket
mounting plate.
11]
Important
Do not use a nut driver to tighten this

hardware, or fasteners will not be properly
seated.
i~i
Tighten
Bolts/screws (26) until fully seated, but not

stripped.
SEAT BELTS
10-11.;.9
CHILD RESTRAINT SYSTEM BELT KIT

REPLACEMENT
CAUTION: The seat belt assembly and/or

If the anchor bracket (25) becomes damaged, it
must be replaced.
!++!
2. Anchor bracket (25).
I++!
A MOUNTING PLATE, CHILO RESTRAINT SYSTEM
BELT KIT
25 BRACKET, CHILO RESTRAINT SYSTEM BELT KIT
26 BOLT/SCREW, CHILD RESTRAINT SYSTEM BELT KIT
02-27-95
FT0111011
Figure 11 - Child Seat Restraint System Belt Kit
6. Replace carpeting, noting bump created by anchor

bracket (25).
7. Carefully slit carpeting to allow anchor bracket to
protrude through.
rn
Important
Make sure carpet is pulled taut before making

cut in carpet.
8. Follow instructions in owner's manual and in
product information accompanying child seat
regarding positioning and installation using rear
safety belts.
Install or Connect
NOTICE:
1. Anchor bracket (25) to anchor bracket mounting

plate.
rn
Important
Do not use a nut driver to tighten this

hardware, or fasteners will not be properly
seated.
!~!
Tighten
Bolts/screws (26) until fully seated, but not

stripped.
101110 SEAT BELTS
SPECIFICATIONS
Front Driver and Passenger Seat Buckle"."Side Belt Bolt/Screw ................... ;........................ 42 N.m (31 lb. ft.)
Front Driver and Passenger Seat Retractor-Side Belt Bolt/Screw ........................................ 28 N.m (20 lb. ft.)
Front Driver and Passenger Seat Retractor-Side Belt (Anchor Plate) Bolt/Screw ............... 42 N.m (31 lb. ft.)
Front Driver and Passenger Seat Retractor-Side Belt Bolt/Screw (Convertible) .................. 42 N.m (31 lb. ft.)
Front Driver and Passenger Seat Shoulder Belt Guide Bolt/Screw (Convertible) ............... 42 N.m (31 lb. ft.)
Rear Seat Buckle-Side Belt Bolt/Screw ................................................................................. 42 N.m (31 lb. ft.)
Rear Seat Retractor-Side Belt Bolt/Screw (Convertible) ....................................................... 42 N.m (31 lb. ft.)
Rear Seat Retractor-Side Belt Bolt/Screw (Coupe) ................................................................ 42 N.m (31 lb. ft.)
. Rear Seat Retractor-Side Belt Guide Bolt/Screw (Convertible) ............................................ 42 N.m (31 'lb; ft.)
Rear Seat Retractor-Side Belt Guide Bolt/Screw (Coupe) ................................................... 10 N.m (89 lb. in.)
Rear Seat Retractor-Side Belt Retractor Bracket Bolt/Screw (Convertible) ......................... 30 N.m (22 lb; ft.)
Rear Seat Retractor-Side Belt Retractor Nut (Coupe) ........................................................... 55 N.m (41 lb. ft.)
STRUCTURAL BODY REPAIR AND DIMENSIONS
11-1
SECTION 11
STRUCTURAL BODY REPAIR AND

DIMENSIONS
CONTENTS
Panel Identification................................................
Radiator Support ...................................................
Upper Rail .............................................................
Engine Compartment Front Outer Side. Rail ...
Front Wheelhouse Panel Upper Side Rail .......
Lower Rail .............................................................
Front Wheelhouse .................................................
Side Door Opening Frame....................................
Replacement. .......................................................
Sectioning ...... .. .. ... .... .... .. .......... .. .. ...... ..... .... ......
Door Service..........................................................
11-2
11-4
11-5
11-5
11-8
11-12
11-13
11-16
11-16
11-18
11-21
Door Outer Panel Replacement. ........................ 11-21

Roof Outer Panel ................................................... 11-23
Windshield Replacement. ....................................... 11-25
Quarter Panel ......................................................... 11-26
Body Dimensions ................................................... 11-30
Convertible ............................................................. 11-37
Miscellaneous Parts ............................................ 11-37
Side Door Opening Frame ................................ 11-38
Outer Rocker Panel.. .......................................... 11-41
Quarter Panel ..................................................... 11-44
Rear Wheelhouse ............................................... 11-46
11-2 STRUCTURAL BODY REPAIR AND DIMENSIONS
PANEL IDENTIFICATION
031595
FT00111
11-3
.SMC
RRIM URETHANE
INTEGRATED STEEL PARTS
GALVANIZED METAL
03-08-96
FT00211
RADIATOR SUPPORT
The radiator support
assembly consists of
eight pieces: four
upper, two sides (left
and right) and-two lower
(Figure 2-1).
Replacement of the
radiator support assembly has been noticeably
improved over past
vehicle models. Virtually
all attaching surfaces
are easily accessible for
service, which makes
replacement much less
complicated, as well as
economical.
The radiator support is
available as an entire
unit including all brackets and reinforcements.
Note: the lower outer
support is serviced
separately (Figure 2-2).
In addition, the lower
left, right,and inner
support are also available separately
(Figure 2-1).
Figure2-1.
Radiator
Support
Assembly
(Exploded
View)
F/gure2-2.
Radiator
Support
Assembly and
Lower.Outer
Support
0315-95
FT00311
11-5
UPPER RAIL
ENGINE coMPARTMENT fRQ-NT OUTER s1oE RAIL
Before attempting to remove the engine compartment front outer side rail, visually inspect
the damage and restore as much of the damage as possible to factory specifications. The
engine compartment front outer side rail is attached to the front wheelhouse panel upper
side rail assembly with spotwelds. To remove the outer side rail, the spot welds must be
drilled out. On the service part outer side rail, plug weld holes are not included. They must
be drilled in the same location as the original spot welds.
Remove front fender

assembly, hood assembly -and hood hinge
assembly.
lfl
Ill
Ill
B
B
Flgure3-1.
Drilling Plug
Welds
Note number and

location of welds for
installation of new outer
side rail.
Drill out all related
factory welds
(Figure 3-1).
Remove outer side rail.
Remove air baffle
material from side rail
assembly (Figure 3-2).
Figure3-2.
Removing Air
Baffle Material
Remove sealant from

side rail assembly, as
necessary.
Install or Connect
Position the new outer

side rail to side rail
assembly and clamp
in place.
A AIRBAFFLE
031595
FT00411
116 STRUCTURAL BODY REPAIR AND DIMENSIONS
Install or Connect (Continued)
Mark seven formed and

pierced locations from
the side rail assembly to
the new outer side rail.
III Mark the hood hinge hole

locations (Figure 3-3).
. . Remove clamps and outer
side rail.
Drill 1/8-inch holes in

marked locations on the
new outer-side rail at
formed and pierced
~-~
---_ ~0
F/gure3-3.
Marking Hole
Locations
Drill two 3/8-inch holes at

hood hinge hole locations
(Figure 3-4).
Drill 5/16-inch holes

3/4-inch fore and aft of
seven formed and pierced
Figure3-4.
Hole Size
and Locations
HOOD HINGE HOLES
ml Drill 5/16-inch holes on

remaining locations as
noted from old outer side
rail (Figure 3-4).
ml
If the original outer side rail is

damaged beyond recognition,
place holes for welding 1-1/2
inches apart.
Install J-clips included with

rail, GM P/N 10079170, at
five formed and pierced
~d~F::~~~~~~~~;ln) Figure 35.

lnstal/lng J
Clips
Two formed-and pierced

locations at hood hinge mounting panel do not require J-Clips.
03-0691
FT00511
117
lllliJ
1111
Position the new outer

side rail in place, insert
locating tab through slot
(Figure 3~6).
Install fender mounting
bolts/screws included with
rail, GM P/N 11505023, at
five J-clips to secure outer
side rail in place. Note:
The new outer rail may be
manually positioned to
accommodate the J-Clips
at the five formed locations.
ro'\
o---\1
...J-o
o.
~
. . . :::::-- 'e"l
~.-
'-.e..
A
,.
.
-----0 . .=-:======:..:.:===~=
~
~
oJNooc Flgure3-6.
Installing
Outer Side Rall
MEASURE
llfJ
Refer to service manual for

proper dimensions.
Follow the next steps

accordingly:
Outer Rail Replacement Only.
Match the new outer rail to the
contour of the two formed
locations at the hood hinge.
(Use hood hinge bracket with
original spacers intact.)
Inner and Outer
Rail Replacement.
Replace original two spacers on
hood hinge bracket bolt/screw
with two washers provided.
Install hood hinge bracket
upside down, washers and bolts/
screws to outer side rail assembly at hood hinge mounting
panel (Figure3-7).
Flgure3-7.
lnstalllng
Hood Hinge
Bracket
A SERVICE KIT WASHERS
Using MIG welder,

randomly plug weld new
outer side rail in place
(Figure 38).
Figure3-B.
Welding Outer
Side Rall
IMPORTANT
1111
Be sure to measure continually

throughout welding process to
maintain correct dimensions.
Glean and prepare welded

surfaces. Apply 3M
Brushable Seam Sealer,
part number 08361 or
equivalent, as necessary.
.FAT
031595
FT00611
Apply "Handi Foam" to replace air baffle material. "Handi Foam" kit is
available from FoMo Products Inc., 2775 Barber Rd., P.O. Box 1078,
Norton, Ohio 44203, or call 1-800-321-5585 or 216-753-4585. Note: It
is recommended that a small amount be applied into a disposable
container to become familiar with the rate of discharge.
11m Refinish according to paint manufacturer's recommendations.
Apply anticorrosion material, as necessary.
Install hood hinge assembly, hood assembly and front fender assembly.
FRONT WHEELHOUSE PANEL

UPPER SIDE RAIL
When replacing the upper side rail assembly, it will be necessary to cut a section of the
damaged side rail assembly away and section a new side rail assembly in its place.
Removal of the side rail assembly requires the use of a template to help in determining the
location of the cut to be made.
-
Outer side rail. Refer to

"Engine Compartment
Front Outer Side Rail".
Position template
included with rail to
side rail assembly at
forward edge where
indicated by arrows and
scribe line onto side rail
assembly where shown
(Figure 3-9).
Figure3-9.
Scribing Line
on Inner
Side Rall
031515
FT00711
11-9
Remove or Disconnect (Continued)
Drill out welds at

cowl panel.
Drill out welds at cowl
panel only. Remaining welds
will hold side rail assembly in
place while cutting.
Figure 3-10.
Separating
Inner Side
Rall Assembly
from Cowl
Separate side rail

assembly away from
cowl panel (Figure 3-10).
Ill Cut side rail assembly

at scribed lines, being
careful not to cut
adjacent panels
(Figure 3-11).
Figure 3-11.
Cutting Inner
Side Rall
Assembly
Note number and

location of remaining
welds for installation of
new side rail assembly.
Drill out remaining welds.
. . Remove side rail

Figure 3-12.
Removing
Inner Side Rail
Assembly
Install or Connect
-
Prepare mating
surfaces f~r proper fit of
ne~ side rail assembly.
Clean sealer away from
mating surfaces, as
necessary (Figure 3-13).
Figure 3-13.
Preparing
. Mating Surface
031595
FT00811
(
Ill On new side rail assembly, drill 5/16-inch holes

in remaining locations as
noted.from original side
rail assembly.
If original side rail assembly is

place holes for welding 1 112
inches apart.
Clean the surface of

seven pierced locations
on side rail assembly
with mild soap and water
and wipe dry. Clean with
wax and grease remover.
Figure 3-14.
Installing
Adhesive
Washers
Remove backing from

washers included with
rail and carefully apply to
motor compartment side
of new side rail assembly
at pierced locations
f
shown (Figure 3-14).
>I~
t{j5
-:::;;i~~
NOTICE:
Use only service kit

washers provided with rail,
GM PIN 12520407. Use of any
other washer could cause
improper positioning of side
rail assembly.
Position new side rail

assembly to overlap
remainder of original side
rail assembly by 35 mm.
Align to arrows on
remainder of original side
rail assembly and clamp.
NOTE:
The forward pierced location

may need to be manually
positioned according to upper
body dimensions, utilizing
common tools and techniques.
MEASURE
Refer to service manual for

proper dimensions.
030lts
FTOOl11
STRUCTURAL.BODY REPAIR AND DIMENSIONS
11-11
IIJI Using MIG welder at

overlap, plug weld alt
8 mm pre-drilled holes in
new side rail assembly
in sequence shown.
Using MIG welder, make

1-inch stitch welds along
seam leaving 1-inch
gaps.
II.Ill Using MIG welder,

randomly plug weld all
remaining holes in new
side rail assembly.
Figure 3-15.
Welding Inner
IMPORTANT

Complete stitch
welding along seam
(Figure 3,.15).
IID Remove clamps.

ll!J Clean and prepare
welded surfaces. Prime
with two-part catalyzed
primer. Do not combine
paint systems. Refer to
paint manufacturer's
recommendations.
11111 Install outer side rail.

Refer to "Engine
Compartment Front
Outer Side Rail".
G3-11MII
FT01011
(
\
LOWER RAIL
Replacement of the
engine compartment
inner and outer side rail
assemblies has been
noticeably improved
over past vehicle
models. Virtually all
attaching surfaces are
easily accessible from
underneath for
service, which makes
replacement much-less
complicated.
The service part
comes as an entire unit,
including all brackets
and reinforcements as
shown in Figure 4-1 .
The outer side rail
extension is also
available as shown in
Figure 4-2.
NOTICE:
At this time, sectioning

of the engine compartment inner and outer
side rail assemblies is
not recommended,
as doing so could
compromise the
structural integrity
of the vehicle.
Figure4-1.
Engine
Compartment
Side Rail
Assemblies
(
Figure42.
Engine
Compartment
Side Rall with
Extension
Removed
031595
n01111
11-13
FRONT WHEELHOUSE
This service part is available as an entire part including all brackets and reinforcements,
as shown in Figure 5-1. The Front Wheelhouse Apron is also available separately as
shown in Figure 5-2.
1111 Remove outer body

panels and related
components.
B
B
Visually inspect
the damage.
Restore as much of the
damage aspossible to
factory specifications.
Remove sealants and
corrosion materials
as necessary.
Figure 5-1.
Front
Wheelhouse
Available as
Complete
Assembly
II.II Note number and

installation of the
new front wheelhouse
assembly.
B
B
B
Drill out all related

factory welds.
Remove front
wheelhouse assembly.
Prepare mating
surfaces for proper fit of
assembly.
Figure5-2.
Front
Wheelhouse
Apron
Available
Separately
03-11-15
FT01211
(
Install or Connect
Ill Set the new front

wheelhouse assembly
on a work surface with
underside up.
Figure5-3.
Positioning
Template to
Wheelhouse
IEI Position template

(included in service kit)
in the front wheelhouse
assembly as shown
(Figure 5-3).
Ill With a center punch,

locate four strut attaching holes (Figure 5-4).
Ill Remove template. Drill

12-mm (15/32-inch)
holesin marked
locations on new front
wheelhouse assembly
(Figure 5-5).
RIGHT HANO
Figure5-4.
Punching Strut
Attaching
Holes
Drill 8-mm (5/16-inch)

holes in remaining
locations 1 1/2 inches
apart.
Kii Position new front

wheelhouse assembly
in place, align and
clamp:
MEASURE
Refer to the appropriate

service manual for proper
dimensions or see Body
Dimensions Section in this
publication.
8-
-~-0'
F/gure5~5.
Dr/I/Ing Strut
Attaching
Holes
0
'
\..:..---"'----0
03-GlH
FT01311
11-15
Using a MIG welder,

randomly plug weld the
assembly in place
(Figure 5-6).
IMPORTANT

Remove clamps. Clean

and prepare welded
surfaces. Apply 3M
Brushable Seam Sealer,
part number 08361 or
equivalent, as necessary.
'-o-o-~-
7------r-; _) .
0
Figure 5-6.
Welding
Wheelhouse
Assembly
Refinishaccording to
recommendations.
llliJ Apply anticorrosion

material, as necessary.
031191
FT01411
11-16
SIDE DOOR OPENING FRAME
The side door opening frame on the Camaro/Firebird can be either replaced as a unit or
sectioned, following the proper techniques. The service part frame will come as a complete
unit and will need to be trimmed to fit each application such as coupe, T-Tops, etc.
Templates are provided with the service part as a guide for trimming.
The following items may need to beremovedor protected before replacing or sectioning
the frame, the Door hinges, outer rocker panel, upper outer side rail, windshield,
weatherstripping, roof outer panel and T-Tops (if applicable), quarter panel assembly
and rear end deck lid assembly.
REPLACEMENT
. . Removeall
applicable panels
and components.
If.I Remove appropriate

sealer.
Ill Drill out factory welds

around the frame
perimeter with a
NOTICE:
When drilling out welds, use

caution so that inner panels
arenot damaged.
Figure 6-1.
Recommended
Locations for
Sectioning
Note number and

installation of new
door frame.
Remove frame .
. . Prepare mating
surfaces for installation
of new frame.
The recommended locations for sectioning are shown in Figure 6-1. A sectioning
procedure may be performed at these locations by overlapping the original panel by
20mm. Use the MIG welding procedures previously discussed.
03-16-95
FT01611
11-17
Install or Connect
. . On the new frame, drill
5/16-inch holes in
locations as noted from
the original frame.
NOTICE:
If the original frame is

place holes for welding 1 1/2
inches apart.
IEII Align frame and clamp

to hold in place.
Ill Using a MIG welder,

plug weld at same
locations as original.
Ill Clean and prepare

welded surfaces.
Apply Brushable Seam
Sealer 3M P/N 08361
or equivalent, as
necessary.
Ill Refinish according to

recommendations.
1111 Apply anticorrosion

-
Install all panels and

components that were
removed.
031595
FT01811
(
SECTIONING
When sectioning the door opening frame, note that there are five locations where
sectioning should not take place (Figure 6-2). Sectioning in these areas would jeopardize
the structural integrity of the vehicle. When sectioning in an area with no reinforcement, a
backing plate or sleeve must be used.
-
Remove all applicable

panels and components.
lfll Measure, mark, cut and

remove the damaged
panel, being careful in
areas where there are
multiple layers of steel.
Ill Measure, mark, cut and

install the new panel to
check for a proper fit
(Figure 6-3).
Flgure6-2.
Ar.eas Where
Sectioning
Should Not
Take Place
A gap of 1 112 times the

thickness of the metal must
be maintained at the joint
between the old panel and
the replacement panel. Trim
as required.
When the replacement

panel fits properly,
remove it from the
vehicle and set aside.
Figure 6-3.
Fitting the.
New Panel
030895
FT01711
B
-
In areas having no inner

reinforcements, cut
pieces to serve as backing plates of the same
configuration (approximately 3 inches long)
from the areas where the
splices are to be made.
Use the damaged panel
or the excess portions of
the replacement panel
(Figure 6-4).
Modify the. pieces
so they fit snugly to
the backside of the
splice joints.
11-19
Figure 64.
Fitting the
Backing Plate
Figure6-5.
Pre-drilling
Plug Weld
Holes
Pre-drill 5/16-inch plug

weld holes indicated on
the following illustrations
for installation of new
panel (Figure 6-5).
Fit the backing plate
halfway into the splice
joint on the vehicle.
Clamp and MIG weld the ~~
backing plate to the
~
.vehicle (Figure 6-6).
~
Flgure6-6.
Fitting the
Backing Plate
for Welding
When all the backing

plates are welded in
place, reinstall the new
part and check the fit.
When the replacement
panel is properly fit and
aligned, clamp and MIG
weld it to the backing
plates (Figure 6-7).
An alternating weld
sequence is recommended to reduce heat
and metal distortion.
Figure6-7.
Welding the
Joint Gap
030795
FT01811
1111 Complete the splice joint

(Figure 6-7) by welding
the joint gap closed
using an alternating stitch
MIG weld. This will
minimize heat build up
and distortion. MIG weld
the remaining weld holes
to attach the panel
permanently (Figure 6-8).
llfJ Grind excess weld off

joints and inspect.
Figure6-8.
Welding the
Remaining
Holes
1111 When satisfied that the

weld and splice joints
are structurally sound,
proceed with the
recommended finishing
procedures.
1111 Clean and prepare

welded surfaces. Apply
Brushable Seam Sealer
3M P/N 08361, as
necessary.
llil Paint and refinish

according to paint
manufacturer's
recommendations.
ml Apply anticorrosion
llD Install all panels and

components that were
removed.
031591
FT01911
11-21
DOOR SERVICE
The inner and outer door panels on the new Camaro/Firebird are composed of
sheet molded compound (SMC). (Figure 7-1) Repair of the door assembly can be
performed using conventional procedures. Detailed information and instructions are
available by obtaining General Motors Corporation STG Composite (plastic) Panel Repair
publication No. 22005.35-1.
The steps listed below are provided as a reference for removal and replacement
of the door outer panel.
Door Outer Panel Replacement

Door outer panels
are available through
General Motors Service
Parts Operations
(GMSPO). When a door
outer panel requires
replacement, remove it
from the vehicle and
place it on a suitable
surface, door outer panel
facing up, being careful
not to damage the door
assembly.
Figure7-1.
Complete Door
Assembly
Ill Using the Chicago

Pneumatic Pneu-nife
CP 838, cut an access
hole into the bottom of
the door panel. Cut
through the outer panel,
being careful not to cut
into the inner panel, as
shown in Figure 7-2.
Figure 7-2.
Door Outer
Panel
Replacement
031595
FT02011
El Using a heat gun, apply

heat to the door outer
panel while prying with a
putty knife. When the
adhesive reaches
approximately 400F, the
bond will begin to break.
(Figure 7-3)
NOTICE:
Figure 7-3.
Door Outer
Panel Removal
Do not heat the door inner

panel more than necessary as
this will soften the panel and
cause damage.
II.I Continue applying heat

and prying with the putty
knife until the entire panel
is removed. (Figure 7-4)
After the door panel has

beenremoved, clean off
any excess adhesive left
on the inner panel.
Install or Connect
Check the fit of the new

outer panel. Apply
adhesive to the door
inner panel.
Figure 7-4.
Entire Door
Outer Panel
Removed
NOTE:
GM Goodwrench Strucural
Bonding Epoxy
Part No. 12345726
material is recommended.
IEI Set the outer panel in

place and clamp until the
adhesive is cured.
lb=::::i~====u::::==)..t:::::;_-
NOTICE:
To avoid unnecessary work, be

sure the clamps do not distort
the outer door panel.
II.I Clean up excess adhesive.

B Reinstall door to vehicle.
030715
FT02111
STRUCTURAL BODY REPAIR AND DIMENSIONS 1123
ROOF OUTER PANEL

The roof outer panel assembly is composed of sheet molded compound (SMC).
It attaches to the steel roof structure with urethane adhesive. Repair of the roof outer
panel assembly can be performed using.conventional procedures. Detailed information
and instructions are available by obtaining General Motors Corporation STG Composite
(plastic) Panel Repair publication No. 22005.35-1.
The steps listed below are provided as a reference for removal and replacement of the
roof outer panel assembly. Refer to Figure 8-1 for illustrations of the T-top and coupe
outer roof panels.
NOTICE:
When cutting, use care to

protect adjacent panels,
glass, weatherstrips and
moldings.
Figure 8-1.
Replacing the
Roof Outer
Panel
. . Using a Chicago pneumatic knife with a panel

blade, cut roof outer
panel 3 inches from all
edges and lift off.
With a Chicago
pneumatic knife with
a urethane blade or
service wire or
Equalizer Magnum, cut
urethane adhesive and
remove remaining roof
outer panel.
Remove all loose or
damaged urethane as
necessary.
r-----:1/Ir------'1
/
I
r, , . - . _ - _I - ~ , - - - - - -
...,
'\1
'I'
I
-------
,
~
J\
. , , . , " ,,..\
--
'--------------- --------- ---
- j - CUT LINES
--URETHANE
131195
FT02211
11-24 STRUCTURAL BODY REPAJR AND DIMENSIONS
Install or Connect
-
Temporarily set
new roof outer panel
into place and check
alignment.
Ill Remove roof outer panel

and set aside.
Use appropriate body

primer supplied in
Adhesive Caulkin_g Kit
GM PIN 12346284, on
both inner structure and
new roof outer panel as
required.
NOTICE:
Do not prime over remaining

urethane adhesive.
&
Apply urethane adhesive,

GM P/N 12346284,
approximately 1O mm in
diameter, around the
perimeter of the roof
outer panel.
(
\
With the aid of a helper,

install new roof outer
panel and press firmly to
set adhesive.
install.surrounding
weatherstrips and moldings while tne roof outer
panel cures.
031595
FT02311
11-25
WINDSHIELD REPLACEMENT
CAUTION:
When replacing a windshield or

hatch roof glass, urethane adhesive
GM PIN 12346284 must be used to
maintain original Installation
Integrity. Failure to use the
urethane adhesive GM PIN 12346284
or equivalent will result In
poor retention of the windshield
which may allow unrestrained
occupants to be ejected from
the vehicle with resulting
personal Injury.
Proper Installation of the

windshield is extremely
Important so that occupant
protection provided by the
supplemental inflatable restraint
(SIR) system Is maintained.
GM material is available in
kit form, GM P/N 12346284,
through your local GM Dealer.
Essex materials may be ordered
through your local PTI jobber
or call: 1-800-453-3779 for
additional information.
The tools listed below are approved and recommended for GM automotive glass replace ment. Tools may be orded through Kent-Moore. Specify part number when ordering glass.
J 24852
J 28628
J3602D
J 39032
J24402-A
Stationary Glass
Removal Tool
Hot Knife Blade

J 24709-01
Urethane Glass
Sealan1 Remover
Handle
Windshield Remover Blade
Molding Remover
Heat Gun
03-1695
FT02411
QUARTER PANEL
The quarter panel assembly has been specially designed for improved serviceability.
Additional panels have been added allowing for easier and faster service. The quarter
panel assembly is attached to the structure with plug welds. To remove the quarter panel
assembly, the welds must be drilled out using a 5/16-in.ch drill bit. The roof outer panel
covers a section of the quarter panel assembly at the top and must be positioned out of the
way to provide access to the welds. At the bottom of the quarter panel assembly at the
rocker panel, there are four hidden welds. They can only be accessed after all the other
welds have been drilled out. The quarter panel assembly can be pulled forward and the
welds drilled from inside.
NOTICE:
Care must be taken when

working around the roof outer
panel. Failure to use care may
result in damage to the roof
outer panel. In this case,
additional time will be needed
in repairing it. Refer to "Rigid
Plastic Repair" procedures.
NOTICE:
Service of the quarter-panel

assembly by splicing a joint
just below the roof panel is not
recommended. The panel is
structural in this area, and
splicing will reduce the integrity
of the vehicle.
Figure 10-1.
Cutting the
Top and
Bottom of the
Quarter Panel
-
Make a cut at the top

of the quarter panel
assembly, as close to the
roof panel overlap as
possible without damaging it (Figure 10-1 ).
Drill out visible plug
welds around the
quarter panel assembly.
Be sure to note the
number and location of
welds for the new
quarter panel assembly.
03-115-H
FT02S11
1127
Cut inboard flanges fore

and aft of the lower
quarter panel assembly
at the rocker panel
Figure 102.
Separating the
Quarter Panel
from.the
Vehicle
. . Pull upper portion of

the quarter panel
assembly away from the
vehicle and drill out the
four inner plug welds at
the rocker panel
Remove the quarter
panel assembly.
With a hammer and

flat punch, flatten the
quarter panel flange
remaining at the roof line
(Figure 10-3).
Figure 10-3.
Cutting the
Roof Outer
Panel
With a Chicago pneumatic

knife using the 3 1/2-inch
offset blade, part number
KF-140665 or the Equalizer Magnum, cut the
urethane adhesive at the
bottom edge of the roof
outer panel (Figure 10-3).
With a service wire,

using upward movements, saw urethane
from the roof panel away
from the "B" pillar area.
Cut to the top of the roof
outer panel, using caution to avoid damage
(Figure 10-4).
Figure 10-4.
Cutting the
Urethane from
the Roof Panel
NOTICE:
When working around the roof

outer panel, care must be taken
to avoid causing damage.
030795
FT026tl
Rem.o ve or Disconnect (Continued)
To reveal welds, pull the

roof outer panel outward
and support it out of the
way, being careful not to
lift too far as damage to
the roof outer panel may
occur.
Drill out exposed welds
to remove flange
(Figure 10-5).
Stress areas when li~ed
Install or Connect
1111 Prepare mating

surfaces for installation
of the new quarter
panel assembly.
_/ _/
I
Figure 10-5.
Plug Welds
at Roof Outer
Panel
Drill holes in locations

as noted from the
original quarter panel
assembly.
IMPORTANT
If original is beyond recognition, place holes for welding

1 112 inches apart.
Align the new quarter

panel assembly and
measure.
03-07-95
FT02711
1129
1111 With the upper quarter

panel assembly pulled
away from the vehicle,
use a MIG welder to
replace the welds in the
bottom at the rocker
panel (Figure 10-6).
Ill.I Align the remainder

of the quarter panel
assembly and clamp
in place.
B
B
Plug weld remaining

At the roof.outer panel,
remove loose adhesive
and clean all surfaces
for refinishing, as
necessary.
Figure 1D-6.
Welding the
Quarter
Panel at the
Bottom of the
Rocker Panel
1111 Prime with an

anticorrosion-type
primer to restore
damaged ELPO
surface. If additional
primer for adhesive
area is required,
see package for
appropriate primer.
NOTICE:
Be careful not to prime over

existing or remaining
urethane.
Rebond roof outer

panel using GM Urethane PIN 12345633,
or equivalent.
03070
FT02811
11-30
BODY DIMENSIONS
FRONT
HEIGHT
557
690
557
DATUM LINE
- - 3 5 8 - - - + - - - 358
WIDTH
- - - 4 2 6 - - - + - - - 426
- - - t - - . . - - - - 4 9 4 - - - + - - - 494
I I
I I
I I
I I
I I
I I
I
LENGTH
I
1613---J.
1 -L..-1613
1613
FORM AND PIERCE
ALL MEASUREMENTS ARE READ

FROM (FORMED SURFACES) AND
CENTER OF HOLE
1410
1613~
I
I
L1613
1613
ICi.
031'191
FT02911
UNDER BODY
DRIVER SIDE
WIDTH
't
I, I
I I)
I II
I I
)J I
.I I I
II
Ct.
en
.....
:::0
c:
~
c:
:::0
....)>
m
0
:::0
HEIGHT
430
561
540
413
350
333
375
785
470
;g
598
470
601
z
c
c
1-------1188.5-------1
517
76
LENGTH
492
670
-----~950---~--~
..__ _ _ _ _ _ 1 4 5 0 - - - - - - - - t
ti
.al
r-~-~730---1-~~~~1so,~~~--
3:
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1--------1275-------
WHEELBASE 2566
:a
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DATUM LINE
-------1275--------
........
w
.....
.....
.....
ROOF
0
WIDTH
HEIGHT
884-- - -
912----
.-------879
889-- - - -
-c=759
413
482
469
~
::u
c:
: :__r_ -1--====:::::
868------,
HEIGHT
WIDTH
LENGTH
LENGTH
873
-,788
309
404
c:
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f-- -
879
884-----HEIGHT
340
--:::_J__ -t====-==::
873
WIDTH
LENGTH
LENGTH
WIDTH
HEIGHT
STRUCTURAL BODY .REPAIR AND DIMENSIONS
FRONT/TOP
0
WIDTH
754
7 0
11-33
757
764
LENGTH
767
I I
769
HEIGHT
1439
- - -822
1186
---914
1006
---957
796
---990
686
---999
597
-- -
508
-1005
1365.5
-862
1003
771
649
-<t
Y.
)
1366.5
---S62
508
---1005
597
- - -1003
686
---999
796
---990
1006
---957
1186
---914
1439
---822
649
754
750
757
764
767
769
771
WIDTH
LENGTH
HEIGHT
030795
FT03211
....
....
RIGHT SIDE
.s:i,
0
I
772
WIDTH
1a2
I I
I I
I I
c:
~TI
164
~
c:
:u
LENGTH
:u
)>
r-
HEIGHT
c
-<
:u
:il
)>
s:
m
350
333
:ti,
538.s
331
DATUM LINE
HEIGHT
538.5
1188.5
235
I'
863 CHEV.
325
I I
I I
I I
I
I I
I II
I I
I I
895CHEV.
461
I I
606
1i
....
~
1017
LENGTH
1177
I
I I
I I
s13
--446.5
673
385
385
WIDTH
783.5
/~
II
LEFT SIDE
782
WIDTH
I
I
112
164
LENGTH
_164
HEIGHT
568
896
:D
c:
~
c:
:D
)>
HEIGHT
53.8.5
I 331
I
331
538.5
r333
DATUM LINE
8:5::r+
1188.5
235-I
TT
I
CHEV., 788
1017
I I
I I
I I
1177
I I
I II
I
I
,i.....
......
385
WIDTH
385
I 6J3
I
446.5-"
673
:D
356J
I I :D
76
3251
LENGTH
11~~
I I
I 606
763.5
I
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I
I
461
)>
CHEV. 863
I
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I
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CHEV.895
c
2
s:
z
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0
z
CJ)
II~w
UI
11-36
REAR
LENGTH
1463
1463
1463
1463
I
I
rr==-==ti
WIDTH
HEIGHT
681
681
681
6r
(
HEIGHT
CHEV. 876
581
581
581
961
581
876 CHEV.
DATUM LINE
WIDTH
I
I
I
I
LENGTH
I
I
I
I
I
1463
CHEV 1374
I
I
I
I
488
385-
608
505
I
I
I
732 PONT.
795 CHEV.
PONT. 732
CHEV. 795
I
I
I
I
I
I
I
1587
I
I
I
1463
't
1463
I
I
I
I
I
I
I
1463
I
I
I
I
I
1374 CHEV.
030795
FT03511
11-37
CONVERTIBLE
MISCELLANEOUS PARTS
Rear Window
Drain-Panel Brace

Extension Reinforcement
Rear Seat Shoulder

Belt Retrador Bracket
floor Panel Rear ~

Reinforcement ~
Rear Compartment Front

Upper Center Bar
Rear Seat
Shoulder Belt
Guide Bracket
l~/Emm
front Top
Pivot Bracket
'1.J
Rear Window
lf/.
O
Quarter Outer Panel

Belt Reinforcement
mTt9' Quarter Inner Panel

W . Reinforcement
Rocker Inner Panel Reinforcement

Rocker Outer Panel Reinforcement
-0
0
Rocker Outer Panel Reinforcement

Rocker Outer Panel
Body Lock Pillar

Reinforcement
Note: All panels must be replaced at factory seams, with the exception of the rocker panel outer.
031595
FT03811
1138 STRUCTURAL B.ODY REPAIR AND DIMENSIONS
SIDE DOOR OPENING FRAME
When sectioning the door opening frame on the Camaro/Firebird convertible,

there are three locations where sectioning should not take place (figure 1).
Sectioning in these areas could jeopardize the structural integrity of the vehicle. The
door ring service panel is unique for convertibles. The panel can be installed as a
complete assembly or modified for sectioning. When sectioning in an area with
no reinforcement, a backing plate or sleeve must be used.
REMOVE OR DISCONNECT
1.
Remove all related panels and components.
2.
Visually inspect and restore as much damage as possible to factory

specifications.
3.
Remove sealers, sound deadeners and corrosion materials, as necessary.
4.
Locate, mark and drill out factory welds, as necessary. Note the number of
welds for installation of the new assembly.
5.
Measure, mark, cut and remove the damaged section of the frame, being
careful in areas where there are multiple layers of steel.
FIGURE I
AREAS WHERE SECTIONING
SHOULD NOT TAKE PLACE
031591
FT03711
11-39
INSTALL OR CONNECT
1.
Prepare the new door opening

frame by measuring and cutting to
match the removed section. Check .
for proper fit.
-NOTICEDo not section within 4 inches
(100 mm) of either inner lower

curve of the door o~ning frame or
outer rocker panel sectioning
(see figure 1)
...;.NOTICE-
A gap 1 112 times the thickness of

the metal must be maintained at
the joint between the old frame
and replacement frame (figure 2).
Trim -the replacement frame, as
required,:to achieve this fit.
2.

reinforcements, cut pieces to serve
as backing plates of the same
configuration from the areas where
sectioning is to be done. These
should be approximately 3 inches
(75 mm) in length. Use the
damaged frame- or the exc,ess
portions of the replacement frame
(figure 3).
3.
Modify the pieces so they fit snugly

to the backside of the section joints.
4.
Pre-drill 5116-inch plug weld holes

for installation of the new frame
(figure 4).
III FIGURE 211

FITTING THE NEW PANEL
III FIGURE 3 111

FlmNG THE BACKING PLATE
III FIGURE 4111

PRE-DRIWNG.PLUG WELD HOLES
030785
FT03811
III FIGURE 5111

FITIING THE BACKING PLATE FOR WELDING
\--'~
5. Fit the backing plate halfway into

the section joint on the vehicle.
Clamp and MIG wekl the backing
plate to the vehicle !figure 5).
6. When oil the backing plates ore
welded in place, reinstall the new
part and check the fit using body
dimensions.
7. When the replacement frame is
properly fitted and aligned, clomp
and MIG weld it to the backing
plates !figure 6). An alternating
weld sequence is recommended to
reduce heat and metal distortion.
8. MIG weld the remaining weld
holes to attach the panel
permanently Ifigure 7).
9. Clean and prepare welded
surfaces. Prime with two-part
catalyzed primer. Apply sealers
and corrosion protection materials,
as necessary. Do not combine
paint systems. Refer to paint
manufacturer's re.commendations.
Reinstall all related components.
III FIGURE 6111

WELDING THE JOINT GAP
III FIGURE7111
WELDING THE REMAINING HOLES
030795
FT03911
11-41
OUTER ROCKER PANEL

The outer rocker panel is attached to the rear quarter panel and the side door opening
frame with factory welds. The outer rocker panel must be removed before servicing the
side door frame. When sectioning in on area with no reinforcement, a bocking plate or
sleeve must be used.
-NOTICE-
When sectioning the outer rocker panel, do not section within 4 inches ("100
mm) of any other sectioning on adiacent com~nents. Also, do not section the
ouler rocker ~nel within 4 inches (100 mm) of either inner lower curve of the
door opening frame (figure 1). Sectioning in these areas could ieopardize the
structural integrity of the vehicle.
1.
Remove all related panels and components.
2.
3.
Visually inspect and restore as much damage as possible to factory specifications.

4.
Locate, mark and drill out factory welds, as necessary. Note the number of welds
for installation of the. new assembly.
5.
Measure, mark, cut and remove the damaged section of the outer rocker panel,
being careful in areas where there are multiple layers of steel.
Do not sedion the outer rocker within

1OOmm of inner door frame sedions
FIGURE 1
AREAS WHERE SECTIONING
SHOULD NOT TAKE PLACE
03159S
FT04011
INSTALL OR CONNECT
1 . Prepare the new panel by measuring
and cutting to match the removed
section. Check for proper fit.
-NOTICE-
A gap 1.5 times the thickness of the

metal must be maintained
at the ioint between the old panel
and replacement panel (figure 2).
Trim the replacement ~nel, as
required, to achieve this fit.
2.
3.
4.

reinforcements, cut pieces to seNe
as backing plates of the same
configuration [approximately 3
inches 175 mm) long] from the areas
where sectioning is to be done. Use
the damaged panel or the excess
portions of the replacement panel
!figure 3).
Modify the pieces so they fit snugly
to the backside of the section joints.
Pre-drill 5'16-inch plug weld holes
for installation of the new frame
!figure 4).
FIGURE 2 a
FITTING THE NEW PANEL
~.
\
(
FIGURE 3
FllTING THE BACKING PLATE
FIGURE 4
PRE-DRIWNG PLUG WELD HOLES
03-078&
FT04111

5.
6.
Fit the backing plate halfway into the

sectioning joint on the vehicle.
Clamp a,:,d MIG weld the backing
plate to the.vehicle !figure 5).
When all the backing plates are
welded in place, reinstall the new
part and check the fit using body
dimensions.
7.
When the replacement panel is

properly fitted and aligned, clamp
and MIG weld it to the backing
plates (figure 6). An alternating weld
sequence is recommended to reduce
heat and metal distortion.
8.
Complete the section joint (figure 71

by welding the joint gap closed
using an alternating stitch MIG weld.
9.
Cleon and prepare welded surfaces.

Prime with two-part catalyzed primer.
Apply sealers and corrosion
protection materials, as necessary.
Do not combine paint systems. Refer
to paint manufacturer's recom
mendotions. Reinstall all related
components.
FIGURE 5
FlmNG THE BACKING PLATE FOR WELDING
11-43
FIGURE 6 ..
WELDING THE JOINT GAP
Alternating stitch MIG weld
FIGURE 7
WELDING THE REMAINING HOLES
0307H
FT04211
QUARTER PANEL
The Camaro/Firebird convertible quarter panel assembly is specially designed for added
strength and rigidity. Additional panels hove been added to the service part to permit easier
and foster service. The quarter panel assembly is attached to the vehicle structure with factory
welds. To remove the quarter panel assembly, the welds must be drilled out.
Replacement procedures for the quarter panel assembly on convertibles ore not the same as
for the hardtop. On convertibles, the OEM quarter panel assembly must be cut just above where
it is welded to the rocker panel. The service port is then trimmed and plug welded to the flange
of the OEM panel:
1. Remove oil related panels and components.
2. Visually inspect and restore as much damage as possible to factory specifications.
3. Remove sealers, sound deadeners and corrosion materials, as necessary. Pay special
attention to the joint where the outer quarter panel attaches to the rocker panel.
4. locate, mark and drill out factory welds, as necessary. Do not drill out the factory
welds attaching the quarter panel to the rocker panel. Note the number of welds for
installation of the new assembly.
5. Apply a piece of one-inch tape at the bottom of the front lower section of the original
quarter panel where it attaches to the rocker panel !figure l ).
6. Cut the original quarter panel at the top edge of the tape. Remove the panel from the
vehicle. Remove the tape from the flange .
.7. Bend the remaining portion of the original quarter panel assembly up and inboard. This
will allow the new panel to be positioned properly when it is installed.
Cut the damaged panel here
,f:~\ff!.,'
FIGURE I
APPLY TAPE ACROSS QUARTER PANEL ASSEMBLY
03-1581
FT04311
11 45
INSTALL OR CONNECT
1. Prepare the new quarter panel
assembly by trimming the inner
flange on the lower front section to
approximately 1/4 inch 17 mm!
{figure 2).
2. Prepare the mating surfaces of the
new assembly and check for proper
fit.
Drill five 5116-inch 18 mm! holes in
the face of the front lower portion of
the new quarter panel assembly
{figure 31. Space the holes evenly
across the front surface,
approximately 35 mm apart.
4. Drill holes in the remaining locations
as noted from the original quarter
panel assembly.
3.
a FIGURE 211
TRIM INNER FLANGE ON NEW ASSEMBLY
-NOTICE-
If the original component is

damaged beyond rec~nition,
or the location for replacement
welds is unknown, locate the
weld holes 1 11.2-inches
(35 mm) apart.
5.
Position the new assembly, check fit

using body dimensions, and plug
weld accordingly with frequent
measurement to ensure proper fit.
--NOTICE-
Do not stitch weld at the front edge

. of the quarter panel where. it
contacts the rocker panel (figure 4).
III FIGURE 3111

DRILL PLUG WELD HOLES IN NEW ASSEMBLY
6. Clean and prepare the welded

catalyzed primer. Apply sealers and
corrosion protection materials, as
necessary. Do not combine paint
systems. Refer to paint
Reinstall all r-elated components.
111 FIGURE 4111
DO NOT STITCH WELD WHERE NEW OU.ARTER
PANEL CONTACTS ROCKER PANEL
030795
FT04411
REAR WHEELHOUSE
INNER
The Camaro/firebird convertible inner rear wheelhouse assembly is replaced at the factory seams.
OUTER
The Camaro/Firebird convertible outer rear wheelhouse assembly is a one-piece assembly
consisting of the wheelhouse with a forward flange that attaches to the door opening frame and
inner rocker reinforcement.
To simplify service when the vehicle is only damaged in the rear portion of the wheelhouse assembly,
sectioning con be used to install the service part. The procedure requires removing the forw9rd
flange from the new assembly so it can be installed onto the still-attached flange of the original part.
1 . Remove all related panels and components.
2.
3.
Visually inspect and restore as much damage as possible.

4.
Locate, mark and drill out factory welds, as necessary. Note the number of welds for
instcillation of the new assembly.
5.
Apply a piece of one-inch wide tape along the inner surface of the front wheelhouse,
approximately 15 inches up from the base of the wheelhouse (figure l ),
6.
Cut the wheelhouse along the outer edge of the tape.
7.
Remove the wheelhouse, leaving the forward flange.
Damaged panel
III FIGURE I
TAPE APPLIED ON INNER SURFACE OF WHEELHOUSE
03-15-95
FT04511
INSTALL OR CONNECT
1. Prepare the new rear wheelhouse
assembly by removing the forward
flange. Leave approximately 7 mm
on the lip running along the outer
surface of the wheelhouse !figure 2).
2. Prepare the mating surfaces of the
new assembly. Check for proper fit,
making sure.the wheelhouse tucks
between the inner wheelhouse and
the existing flange.
3. Drill approximately ten ( 10)
5116-inch 18 mm) holes in the face of
the front lower portion of the new
wheelhouse panel assembly {figure 31.
Space the holes evenly across the
front surface, approximately 1 11.2
inches (35 mml apart.
4. Drill holes in the remaining locations
as noted from the original wheelhouse
panel assembly.
-NOTICEIf the original component is

damaged beyond rec~nition,
or the location for replacement
welds is unknown, locate the
weld holes 1 11.2-inches
(35 .mm). apart.
11-47
Service panel
AFTER
lmm flange
a FIGURE 2
TRIM FLANGE FROM NE\11 ASSEMBLY
5. Position the new assembly, check

the fit, and plug weld accordingly.
6. Clean and prepare the welded
catalyzed primer. Apply sealers and
corrosion protection materials, as
necessary. Do not combine paint
systems. Refer to paint
Reinstall all related components.
Service panel
FIGURE 3 a
DRILL PLUG WELD HOLES IN NE\111 ASSEMBLY
030781
FT04811
BLANK
BOOK 1 INDEX 1
A
A!C Performance Test ................ :.............. lB 1-17
A/C System Diagnostic Charts ................. lB 1-17
A/C System Noise Diagnosis ............. :...... lB 1-17
A/C System Oil Charge
.
Replenishing, On-Vehicle Service ,............ lB-17
AIC System Replacement Procedur~s ........ .lB-19
A/C System, Charging the, (Engine Oft) .. .lB-18
A!C System, TXV, General Description ....... lB-3
A/C System, VDOT, General Description .... lB-3
Abbreviations. and Symbols ... ,.................... OA-15
Abbreviations/Definitions, Aritilock
Brake System With Traction Control.. ...... 5E2-3

Abbreviations/Definitions, Aritilock
Brake System.............................................. 5El-2
Valves, On-Vehicle Service .................... 5El-171
Valves, On-Vehicle Service .................. ,.5E2-232
ABS Hydraulic Modulator Solenoid,
On-Vehicle Service ................................. 5El-171
ABS Hydraulic Modulator
.
Solenoid, On-VehicleService .................. 5E2-232
ABS Hydraulic Modulator,
..
Unit Repair ............................................. 5E2-246
ABS Hydraulic Modulator/Motor
. Pack Assembly, On-Vehicle Service...... 5El-172
Pack Assembly, On-Vehicle Service...... 5E2-233
Pack Assembly .............. ,........ , .................... SEl-6
Pack Assembly ........................................... 5E2-8
ABS Relay, On-Vehicle Service........ ,..... 5El-175
ABS Relay ............................................... ,... SEl-7
ABS/TCS Relay (Enable),
On-Vehicle Service .................. ,.............. 5E2-242
ABS/TCS Relay (Enable) .......................... 5E2-10
Absorber, Fascia Energy,
General Description ................................... 10-4-2
Absorber, Front Bumper Energy,
On-Vehicle Service .................................... 10-4-6
Absorber, Rear Bumper Energy,
On-Vehicle Service .... ;............................... 10-4-9
Absorber, Rear Shock, On-Vehicle
Service ..............~ ............. ;.......................... 30-10
Absorbers, Shock, Diagnosis ......................... 3-18
Absorbers, Shock, Leaks ................... '. ........... 3-19
Absorbers, Shock, Noisy ............................... 3-18
Absorbers, Shock, Weak ................................ 3-18
Accelerator Pedal Cable and Cruise
Cable Replacement, On-Vehicle
Service .................................................... 5E2-240

Accelerator Pedal Replacement,
On-Vehicle Service ............................... ;.5E2-240
Accessories, Engine, 3800 VIN K
Engine, Unit Repair ................................ 6A8B-3
Accessory Drive Belt Noise .......................... 6-10
Accessory Drive Belt Tensioner
Assembly, 3800 VIN K Engine,
Unit Repair ........................................... 6A8B-10
Switch Opening Cover, On-Vehicle

Service ..................... ,; ............................... 10-6-7
Accident With Deployment .Component Replacement and
Inspections, Supplemental Inflatable
Restraint (SIR) ........................................... 9J-51
Accident With or Without
Deployment - Component
Inspections, Supplemental Inflatable
Restraint (SIR) ........................................... 9J-51
Accumulator, Air Conditioning,
General Description ...................................... lB-3
Accumulator, Air Conditioning,
On-Vehicle Service ..................................... lB-25
Accumulator/Receiver and
Dehydrator, Air Conditioning,
General Description ................................. 1B 1-12
Accumulators, Automatic
Transmission, On-Vehicle Service ............. 7A-21
Actuator, Dimmer Switch Rod,
Unit Repair ............................................... 3F5B-9
Actuator, Front Side Door Lock,
On-Vehicle Service .................................. 10-6-31
Actuator, Rear Compartment Lid Lock
Release, On-Vehicle Service ..................... 10-8-3
Actuators, Vacuum, On-Vehicle Service ..... lA-19
Adapter & Bearing Assembly,
Unit Repair ............................................. 3F5B-15
Adapter, EGR Valve, 3800 VIN K
Engine, On-Vehicle Service .................. 6A8A-12
Adapter, EGR Valve, 3800 VIN K
Adding Fluid, Folding Top
Hydraulic System ............ :....................... 10-9-26
Adhesive Caulking Kit, General
Description ................................................. 10-2-1
Adhesive Moldings, General Description .. 10-1-3
Adhesive Nameplates/Emblems,
Adjuster Assembly, On-Vehicle
Service .................................................... 5E2-235
Adjuster Assembly ....................................... 5E2-9
Adjuster, Driver Seat and Drive
Motor, On-Vehicle Service ... ,............... 10-10-15
Adjuster, Manual Front Seat,
Diagnosis ................................................. 10-10-2
Adjuster, Manual Front Seat,
On-Vehicle Service ................................ 10:.10-15
Adjuster, Passenger Seat,
On-Vehicle Service ................................ 10-10-18
Adjuster, Power Front Seat, Diagnosis .... 10-10-2
Adjuster, Power Front Seat,
Adjustment and Alignment, Body
Panel ........................................................ 10-1-19
Adjustment Procedure - Throttle
Body and Cruise Control Cables,
On-Vehicle Service ................................ 5E2-236
Adjustment, Folding Top, Downstop ....... 10-9-35
Adjustment, Folding Top, Upstop ............ 10-9-35
Adjustment, Front Camber and Caster ......... 3A-4
Adjustment, Front Toe .................................. 3A-4
2 - BOOK 1 INDEX
Adjustment, Hood ........... :......................... 10-5-26
Adjustment, Parking Brake
Free-Travel, On-Vehicle Service ............... 5B2-9
Adjustment, Rear Thrust Angle ................... 3A-6
Aiming, Headlamp, After a
Collision, On-Vehicle Service .................... 8B-11
Aiming, Headlamp, Alternate
Procedure, On-Vehicle Service ................. 8B-10
Aiming, Headlamp, by Screen
Method, On-Vehicle Service ....................... 8B-9
AIR BAG Warning Lamp,
General Description ....................................... 9J-3
Air Cleaner and Crankcase
Ventilation Filter Replacement.. .................. OB-9
Air Conditioning Accumulator Hose,
On-Vehicle Service ........................ ;........... lB-23
Air Conditioning Accumulator,
General Description ..................................... lB-3
Air Conditioning Accumulator,
On-Vehicle Service .................................... lB-25
Air Conditioning Accumulator/
Receiver and Dehydrator,
General Description ................................. lB 1-12
Condenser Hose, On-Vehicle Service ....... lB-19
Front Bracket, On-Vehicle Service ........... lB-30
Relief Valve, General Description ............. .' lB-8
Relay, General Description ......................... lB-8
Air Conditioning Compressor Relay,
On-Vehicle Service ................................... lBl-27
Air Conditioning Compressor,
General Description .................................. ;.. lB-5
General Description .......... ;....................... lBl-11
On-Vehicle Service ..................................... lB-27
Air Conditioning Condenser,
General Description ................................ ;.... lB-5
General Description .................................. lB 1-11
Temperature Sensor, General Description .. 1B-8
Temperature Sensor, On-Vehicle
..
Service ....................................................... lBl-27
Tube Orifice, General Description .... '. ......... lB-5
Tube Orifice, General Description ........... 1B 1-11
Tube Orifice, On-Vehicle Service .............. lB-25
Air Conditioning Evaporator Tube,
Air Conditioning Evaporator,

On-Vehicle Service ................................... lB 1-28
Air Conditioning Odor, Eliminating ........... lB-10
Dehydrator Tube, On-Vehicle Service ....... lB-23
Dehydrator, General Description .................. lB-3
Dehydrator, On-Vehicle Service ................ lB-26
Sensor, General Descriptiori......................... lB-8
Air. Conditioning Refrigerant Pressure
Sensor, On-Vehicle Service ...................... lB 1-27
Air Conditioning Refrigerant Service
Valve Core, On-Vehicle Service ..... ,.......... lB-30
Air Conditioning System Diagnosis ............. lB-8
Air Deflectors, On-Vehicle Service ........... lA-20
Air Delivery, Improper, Diagnosis ............ lB 1-13
Air Distribution System;
General Description ............. :....................... lA-3
Air Distribution System,
General Description ............... :........... ,........ lB 1-5
Air Inlet Screens, On-Vehicle Service ..... 10-5-21
Air Inlet Valve, General Description .......... lBl-5
Air Outlets, General Description ................. lA-6
Alignment Angles, Measuring Front ........... JA-4
Alignment Angles, Measuring Rear ............ 3A-5
Alignment Checking ................................... 10-3-2
Alignment Specifications, Tire and Wheel.. 3A-6
Alignment, Body Panel Adjustment ........ 10-5-26
All Season Tires, General Descriptiop. ......... 3E-2
Alternative Repair Methods, SIR ................. 9J-67
Aluminum Radiator Service,
On-Vehicle Service ..................................... 6B-10
Aluminum Wheel Hub Cap,
On-Vehicle Service ..................................... 3E-13
Aluminum Wheel Porosity Repair .............. 3E-13
Aluminum Wheel Refinishing ..................... 3E-13
Aluminum Wheels, On~ Vehicle Service ..... 3E-13
AM/FM Stereo and Clock Radio,
On-Vehicle Service ....................................... 8C-8
AMAX Stereo Certification, ETR
AM/FM Stereo/Cassette Tape (Pontiac),
General Description .... ,............................... 9A-8
AM/FM Stere.o/Cassette Tape with
Graphic Equalizer (Pontiac), General
Description ................................................. 9A-9
AM/FM. Stereo/Compact Disc with
Graphic Equalizer (Pontiac), General
Description ........... ,...... ;: ............................ 9A-11
AMAX Stereo Certification,
General Description ..................................... 9A-3
Amplifier, Low Frequency Audio,
On-Vehicle Service .................................. 10-7-lO
Analyzer, Electronic Vibration (EVA),
General Description ................ ;..................... OC-2
Annulus Assembly, Dust and
Bearing, Seal, Pinion, Unit Repair ......... 3B1A-6
Antenna Care, Radio Power....................... 9A-16
Antenna Check, Radio Power .................... 9A-14
Antenna Diagnosis, Radio Fixed ............... 9A-13
BOOK 1 INDEX - 3
Antenna Lead-In Cable Check,

Radio Power .............................................. 9A-14
Antenna Mast, Radio Power,
On-Vehicle Service .................................... 9A-17
Antenna Mounting and Connections,
Radio Power, Diagnosis ........................... 9A-13
Antenna; Radio Fixed,
. General Description ..................................... 9A-2
Antenna, Radio Fixed,
On-Vehicle Service .................................... 9 A-16
Antenna, Radio Power,
Antenna, Radio Power,
Anti-Corrosion Protection,
Body Front End ................................ ;: ....... 10-5-3
Anti-Corrosion Treatment. .......................... 10-1-7
Antilock Brake System With Traction
Control, Abbreviations/Definitions ............ 5E2-3
Antilock Brake System With Traction
Control, General Description ..................... 5E2-3
Antilock brake System With Traction
Control, System Components .................... 5E2-8
Antilock Brake System with
Traction Control ......................................... 5E2-1
Antilock Brake System With
Traction Control ......................................... 5E2-3
Antilock Brake
System, Abbreviations/Definitions ............. 5El-2
Antilock Brake System,
General Description .................................... 5E 1-3
System Components ................................... 5El-6
System Operation ...... :............................... 5El-3
Antilock Brake System............................... 5El-1
Applique, Outside Rearview Mirror;
On-Vehicle Service ...... ;........................... 10-6-22
Approximate Fluid Capacities .................... OB-13
Arm and Pushrod, Rocker, 3800
VINK Engine, Unit Repair ................. 6A8B-12
Arm, Folding Top Outer,
Arm, Front Lower Control,
On-Vehicle Service ................................. ;..... 3C-7
Arm, Front Upper Control,
On-Vehicle Service .................................... 3C-16
Arm, Rear Axle Lower Control,
On-Vehicle Service ... ;.................................. 3D-6
Arm, Rear Axle Torque,
On-Vehicle Service...................................... 3D-6
Arm, Valve Rocker, 5.7 Liter
VIN P Engine, Recondition .................. 6A3B-32
Arm, Wiper, Replacement,
Arming the System, Universal
Theft Deterrent System ............................. 9D-5
Armrest, Front Side Door,

Armrest, Front Side Door,
On-Vehicle Service; ................................... 10-6-3
Arms and Pushrods, Valve Rocker,3800
VINK Engine, On-Vehicle Service ....... 6A8A-9
Arms, Valve Rocker, 5.7 Liter

VIN P Engine, On-Vehicle Service ..... 6A3A-11
Arms, Valve Rocker, 5.7 Liter
VIN P Engine, Unit Repair.................. 6A3B-12
Ashtray Lamp, General Description ............. 8B-3
Ashtray Lamp, On-Vehicle Service ............ 8B-15
Assembling and Coding Lock Cylinders ......OA-8
Audio System (UQO), Base,
Audio System, Optional,
Automatic Transmission Case
Extension, On-Vehicle Service .................. 7A-20
Automatic Transmission Control
Lever Solenoid, On-Vehicle Service ......... 7A-12
Automatic Transmission Control,
Automatic Transmission Diagnosis ...... 7A-14A-l
Flushing Procedure, On-Vehicle
Service ...................................................... 7A-17
Upper and Lower Pipes,
On-Vehicle Service ................................... 7A-16
Upper Hose, On-Vehicle Service .............. 7A-14
Automatic Transmission Park
Lock Cable, On-Vehicle Service ................ 7A-10
Automatic Transmission Range
Selector Indicator Lamp,
General Description .................................... 8B-3
Selector Indicator Lamp,
On-Vehicle Service ................................... 8B-15
Selector Lever Cable,
On-Vehicle Service .....................................7A-9
Automatic Transmission,
Axle Operation, Rear ................................... .4B-3
Axle, Housing Replacement,
Rear, Unit Repair ....................................... 4B-25
Axle, Limited Slip Rear,
General Description .................................... .4B-5
Axle, Rear, Differential Ring
Gear Tooth Nomenclature, Diagnosis ........ .4B-8
Axle, Rear, Effects of Differential
Drive Pinion Gear Position on
Tooth Pattern, Diagnosis ........................... .4B-9
Axle, Rear, Effects of Increasing
Load on Tooth Contact Pattern,
Diagnosis .................................................... 4B-9
Axle, Rear, Identification .............................. 4B-5
Axle, Rear, Inspection and Diagnosis ......... .4B-7
Axle, Rear, inspection and Diagnosis .......... .4B-7
Axle, Rear, Limited Slip,
General Description .................................... .4B-7
Axle, Rear, Lubricant Fill and
Check, On-Vehicle Service ........................ 4B-12
Axle, Rear, Maintenance and Lubrication ... .4B-5
Axle, Rear, Noises ......................................... 4B-6
Axle, Rear, On-Vehicle Service .................. 4B-15
Axle, Rear, Standard and Limited
Slip Diagnosis .............................................. 4B-8
Axle, Rear, Standard, General Description .. 4B-1
4 BOOK 1 INDEX
B
Backup Lamp Switch, On-Vehicle Service . 7B-9
Backup Lamps, General Description\ ........ 8B-2
Backup Lamps, On-Vehicle Service ............ 8B-4
Baffle, Radiator Air Lower,
On-Vehicle Service ................. ,....... :. ,....... 6B-22
Baffle, Radiator Air Upper,
On-Vehicle Service ... ;................... .'... ;: .. ;;. 6B-23
Baffles, Radiator Air,
On-Vehicle Service ............................. ;; ... 6B-22
Balanc~ Shaft, 3800 VINK Engine,
Cleanmg , Inspeet"ion an. d Reparr...........
.
: 6A8B -28
Balance Shaft, 3800 VIN K Engin~,
On-Vehicle Service .............. ;; ...... ,: ....... 6A8A-20

. Bal~ce Sh~ft, 3800 VINK Engine,
Umt Repair .............................. ,.......... ;;6A8B-17
Balance Shaft, Rattle ............................. ,....... 6-10
Balance, General Precautions ...................... 3E-11
Balance, Tire and Wheel..., ................ , .......... 3-20
Balancer, Crankshaft, 3800
VIN K Engine, On-Vehicle Service .... 6A8A-16

Balancer, Crankshaft, 3800 VIN K
Engine, Unit. Repair .... ,.... ,........... ;........ 6A8B-13
Balancer, Crankshaft, 5.7 Liter
VIN P Erigine, On-Vehicle 'service ..... 6A3A-13
Balancer, Crankshaft, 5.7 Liter
VIN P Engine; Unit Repair .................. 6A3B-13
Balancing Tire and Wh~eL......................... 3E-11
Balancing, Off-Vehicle ................................ :3E-12
Balancing, On-Vehicle ................ '. ................ 3E-12
Ball Stud Inspection, Control Arm.... .'......... 3C-3
Ball Stud, Control Arm, Replacement .. .. . 3C-4
Ball Stud, Front Lower Control Ann
On-Vehicle Service: .......................... .'.......... 3C-3
Ball Stud, Front Lower Control Arni
On-Vehicle Service .. ,.. -:, ................... .'...... ;... 3C-4

Ball Stud, Front Upper Control Arm,
On-Vehicle Service ....................... ;.............. 3C-4
Ball Stud, Front Upper Control Ann
On-Vehicle Service ........................... :.......... 3C-4
Bar, Front Bumper Impact; ..
On-Vehicle Service .. :................................. 10-4-6

Bar, Rear Bumper Impact,
}
On-Vehicle Service ......... ,........................ 10-4-11
Barrier, Dash Sound,
Barriers, Body Hinge Pillar
.
Inner Sound, On-Vehicle Service ........... 10-5-22
Base Audio System (UQO), .
.
General Description ..... '.: .............................. 9A-2
Base Heater S:yst~m, General Description ... lA-1
BasecoatApphcat1on ... :............................ 10-1-l O
Basecoat/Clearcoat Preparation ........ :...... ,... 10-1-9
Battery Alternate Parasitic Load Test. ....... 601-5
Battery Cable, Replacement .
and Routing ......... :............................... :...... 601-8

Battery Charging ......................... ,........... ,.. 6D 1-6
Battery Cold Cranking Amps ................ :.. :. 601-2
Battery Common Causes of Failure ...... :... 601-2
Battery Electrical Drain .......... ,............... :... 601-4
Battery Electrolyte Free,zing ,........ ,............. 6D 1-2
Battery Parasitic Load '!'est ........... :......... :., 6Dl-4

Battery Protectiqn During
Vehicle Storage ...... :.............. ,.......... ,..... ,., 6Dl-3

B~ttery. Ratings .................. ;; ....................... 6Dl-2
Battery Recommendation, Remote.
Transmitter .............. ,......... ,.....,. ...... ,................. 9K-3
Battery Replacement, Remote Transmitter .. 9K-2
Battery Replacement ................................. ,:.' 6Dl-8
Battery Reserve Capacity ......................... ,. 6Dl-2
Battery Testing ............... ,................... ,..... ,... 6D 1-3
Battery Tray and Cool.ant Recovery
Reservoir,. On~Vehicl,~ Service .................. :6B-20
Battery Tray and Hokl-Down Retainer ..... 6Dl-3
Battery_ Tray ReplacemenL, ......................... 6Dl-8
Battery Usage ........ ,.,., ....... ;........ ,............ ,. 6Dl-15
Battery, ,13uilt~In Hydrometer .. ,..... ,., ........... 601-3
B11ttery, Chargiqg a Very Low or.
Completely Discharged .........-. .....:.............. 6Dl-7

Battery, Charging Equipment ...............;....6Dl-12
Battery, Chargil}g Procedure ......................~ 6Dl-6
Battery, Charging Time Required .......... , ... 6Dl-7
Battery, General Description ... :., ................ 601-2
Battery, Jump.Starting in Case. of
Emergency with Auxiliary (Booster) ....... 6Dl-7
Bearing (6~Speed), Clu.tch Fork and
Clutch Release, On-Vehicle Service .......... 7C-l3
Bearing Assembly, &. Adapter,
Unit Repair ............................................. 3F5B-15
l3earing Assembly, Unit. Repair ........... :.. 3F5B-11
.. .
Bearing Clearance, Measuring,
> 3800,VIN K Engine ............................. 6A8B-26
Bearing Installation,
..
.
3800 VIN K. Engine .... :, ....................... 6A8B-27
Bearing Preload, Rack, Unit Repair ........ 3B lA-4
Bearing, and/or Seal,Rear

Axle.Shaft, On-Vehicle Service ............. .,.4B-13
BearingfCenter Support, : ,
Gem;ral Description .................................:-.. 4A-1

Bearing, Center Support, .Unit Repair ..... :. 4A-12
Bearing, Clutch Pilot, General

., Descript,i,on ...... ,,, ......................... :..... ,.... ,...... 7C-2
Bearing, Clutch Pilot,
On-Vehicle Service ..................................... 7C-14
Bearing, Connecting Rod Noise ..................... 6-9
. Bearing, Differenti;ilprive
.
Pinion Gear Inner, Unit Repair ,..... :......... .4B-23
Bearing, Differential Drive
Pinion Gear Outer; Unit Repair .... ,........... 4B-22

Bearing, Front Wheel,
.
.
On-Vehicle Service.................................... :3C-18
Bearing, Front Wheel, Repack ......... ,.;,. ...',., .. OB-8
Bearing, Main, Noise ........ ;............................. 6-9
Be~ng, Tapered Roller, Diagno~is ...... :.. :: ... 3-23
Beanngs Camshaft, 5.7 :Liter
\
.
VIN PE. ngn).e,
.
Umt
. R. eparr
. .................. 6A3B-21
..
Bearings, Camshaft, 3800
.
........ ,.......
,.. qA8B-19
.
.. . . ngme, U"R
mt eparr
.VINKE.
Beanngs, Connecting Rod, 3800
,
VIN K Engine, On~Vehicle Service ..... 6A8A-28
Bearings, Connecting Rod, 5.7 Liter .
VIN P Engi11e, Cleaning, Inspection . .
and- Repair .......................................... 6A3B-27
Bearings,. Connecting Rod, 5.7 Liter
BOOK 1 INDEX - 5
Bearings, Crankshaft, 3800
VINK Engine, On-Vehicle Service ..... 6A8A-30
Bearings,. Crankshaft, 5.7 Liter
VIN P Engine, On-Vehicle Service......6A3A-25
Bearings, Main and Rod, 3800
VIN K Engine, Cleaning,
Inspection and Repair ........................ 6A8B-25
Belt (Serpentine Belt), Power
Steering Pump, On-Vehicle Service ............ 3B-4
Belt and Tensioner, Serpentine Drive,
3800 VIN K Engine,
On-Vehicle Service .................................. 6A8A-2
Belt Kit, Child Seat Restraint
System, On-Vehicle Service ................... 10-11-8
Belt Seals, Front Side Door
Front and Rear, On-Vehicle Service ...... 10-6-15
Belt, Accessory Drive, Noise ........................ 6-10
Belt, Serpentine Drive, and Drive
Belt Tensioner, 5.7 Liter
VIN P Engine, On-Vehicle Service........ 6A3A-2
Belt, Serpentine Drive, Diagnosis ................. 6B-6
Belt, Serpentine Drive, General
Description .................................................... 6B-3
Belt, Serpentine Drive, Inspection ................ OB-8
Belts, Front Driver and
Passenger Seat Buckle-Side,
Belts, Front Driver and
Passenger Seat Retractor-Side,
On-Vehicle Service ............................. ;;, 10-11-3
Belts, Front Seat, On-Vehicle Service ..... 10-11-3
Belts, Rear Seat Buckle-Side,
On-Vehicle Service ........................ ,......... 10-11-5
Belts, Rear Seat Retractor-Side,
Belts, Rear Seat, On-Vehicle Service ...... 10-11-4
Belts, Seat, On-Vehicle Service ............... 10-11-3
Bench-Check Procedures, Leak
Testing, HD6/HR6 Unit Repair ............... 102-11
Bezel, Front Side Door Inside
Handle, On-Vehicle Service ...................... 10-6-9
Bezel, Instrument Panel Cluster
Trim Plate, On-Vehicle Service ................. 8C-30
Bi-Level. Valve, General Description .......... lB 1-8
Bladders, Lumbar and Lateral
Support, On-Vehicle Service .................. 10-10-10
Blade Element Cleaning,
Off-Vehicle Service .................................... 8E-16
Blade Element. Set Check,
Blade, Wiper, Assembly
Replacement, On-Vehicle Service.............. 8E-11
Blade, Wiper, Element Replacement,
On-Vehicle Service: .......................... ;: ........ 8E-13
Bleeding Air from the Power
Steering System ....................... ;.................... 3B-4
Bleeding Hydraulic System, Clutch .............. 7C-4
Bleeding Procedure, Antilock
Brake System With Traction Control....5E2-227
Bleeding Procedure, Folding
Top Hydraulic System ........................... :10-9-25
Bleeding System, Antilock
Brake System .............. ;..........................SEl-167
Block, Cylinder, 3800 VIN K Engine,

Cleaning, Inspection and Repair .......... 6A8B-20
Block, Engine, 5.7 Liter VIN P
Engine, Cleaning, Inspection
and Repair ............................................. 6A3B-22
Block, Engine, 5.7 Liter VIN P
Engine ... :........... ;........ ,............................. 6A3B-2
Block, Instrument Panel Fuse,
Blower Motor and Blower
Motor Fan, On-Vehicle Service ................. lA-17
Blower Motor and Evaporator;
General Description ................................... 1B 1-5
Blower Motor Noise ...................................... lA-9
Blower Motor Relay, General Description ... 1B-8
Blower Motor Relay,
On-Vehicle Service ............ ,...................... lBl-27
Blower Motor Resistor,
On-Vehicle Service ................................ ;... lA-17
Blower Motor Speed Control Knob,
General Description ... ;................ ;................ lA-3
Blower Motor Speed Control,
General Description .............. :.................... 1B 1-4
Body Control Module (BCM),
PASS-Key II System,
General Description .................................... 90-3
Programming .a New, PASS-Key II
System......... ;....... ;: .......... ,.......................... 90-4
Universal Theft Deterrent System,
Body Control Module, Programming ........... 9K-2
Body Control Module, Remote
Keyless Entry, General Description ............ 9K-2
Body Dimensions ......................................... 11-30
Body Front End, General Description ....... 10-5-1
Body Hinge Pillar Inner Panel
Sound Barriers, On-Vehicle Service ....... 10-5-22
Body Hinge Pillar Trim Panel,
On-Vehicle Service ............. ;............ ,...... 10-5-22
Body Identification ........................................ OA-2
Body Panel Adjustment and
Alignment .................. :............................. 10-1-19
Body Panel Adjustment and
Alignment .................... :........................... 10-5-26
Body Rear End, General Description ........ 10-8-2
Body, Control Valve,
Body, Throttle, 3800 VINK Engine,
Unit Repair ...................... :....................... 6A8B-8
Body-to-Cradle Fastener Repair ................. 10-3-2
Bolster, Instrument Panel .
Driver Knee, On-Vehicle Service .............. 8C-l 2
Bolsters, Knee, General Description .............. 9J-6
Bolt Replacement, Wheel,
On-Vehicle Service ......... ;..................... .:~ .... 3E-4
Bolt, Front Wheel, On-Vehicle Service ........ 3C-7
Bolt, Lock, Unit Repair ..... ,.................... 3F5B-11
Booster, Power Brake,
General Description ................................... SD 1-1
Booster, Power Brake,
On Vehicle-Service .................................... 501-1
6 - BOOK 1 INDEX
Booster, Power Brake, Vacuum
Check Valve, General Description ........... 5D 1-4
Booster, Power Brake, Vacuum Hose
and Routing,, General Description .. ;.. ;..... 5Dl-4
Boot, Manual Transmission
.
Control Lever, On-Vehicle Service........... :. 7B-4
Boot, Rack & Pinion, Unit Repair .......... 3B1A-4
Bow, Folding Top Number Five,
On-Vehicle Service ............................ ,..... 10-9-14
Bow, Folding Top Number Four,
On-Vehicle Service .... ,.; ............. ;............. to-9-13
Bow, Folding Top Number One,
Bow, Folding Top Number Three,
Bow, Folding Top Number Two,
Bow, Folding Top, General Description .... 10-9-7
Brace, Front Crossmember,
Brace, Generator Rear,
On-Vehicle Service .................................... 6D3-6
Bracket and Link, Rear Stabilizer
Shaft, On-Vehicle Service ......................... 3D-10
Bracket, Air Conditioning Compressor
Front, On-Vehicle Service ......................... lB-30
Bracket, Electronic Ignition Control
Module, On-Vehicle Service ................... 6D4-10
Bracket, Exhaust Muffler Interior
Hanger, On-Vehicle Service ...................... 6F-10
Bracket, Folding Top Pivot, On-Vehicle
Service ......................... :............... :........... 10-9-22
Bracket, front License Plate, On-Vehicle
Service ............................. ,......................... 10-4-5
Bracket; Generator and Air
Conditioning Compressor and Power
Steering Pump, On-Vehicle Service ........ lB-31
Bracket, Generator Rear Brace,
On-Vehicle Service ............................... :.... 6D3-6
Bracket, Hood Open Assist Rod,
Bracket, Power Steering Fluid
Reservoir, On-Vehicle Service .................. 3B-12
Bracket, Rear Seat Shoulder Belt
Retractor, On-Vehicle Service ................ 10-11-7
Brackets, Engine Mount and Engine
Mounts 5.7 Liter VIN P Engine,
On-Vehicle Service .............................. 6A3A-3
Brackets, Headlamp Housing
Panel and, On-Vehicle Service ................. 10-5-3
Braided Lead Wire Repair ..................... :.. 10-2-9
Brake Combination Valve,
General Description ........................................ 5-2
On-Vehicle Service ...................................... 5-14
On-Vehicle Service ................................. 5E2-242
Brake Combination Valve ............ ;............... 5El-7
Brake Combination Valve.: ....... ,................ 5E2-10
Brake Fluid and Fluid Handling .......... 5A- l, 5-2
Brake Fluid Leaks ........................................... 5-5
Brake Fluid, Diagnosis .................................... 5-5
Brake Fluid, Substandard or Contaminated .... 5-2

Brake Fluid, Substandard or Contaminated. 5A-2
Brake Hose and Pipe Inspection ..................... 5-5
Brake Hoses, On-Vehicle Service ..... ,..... ;..... 5-21
Brake Master Cylinder Bench
Bleeding, Unit Repair ..................... :...... , .... 5A-4
Brake Master Cylinder Check, Diagnosis ... 5A-2
Brake Master Cylinder Reservoir,
General Description .................................... 5A-1
Brake Master Cylinder Reservoir,
Unit Repair .................................................. 5A-5
Brake Master Cylinder,
General Description .................................... 5A-l
Brake Master Cylinder,
On-Vehicle Service ............. :........................ 5A-3
Brake Master Cylinder, Unit Repair ............ 5A-4
Brake Pedal Travel .......................................... 5-3
Brake Pedal with Bracket,
On-Vehicle Service......................................... 5-5
Brake Pedal, On-Vehicle Service .................... 5-9
Brake Pipe, On-Vehicle Service .................... 5-10
Brake Pressure Differential Warning
Switch, General Description .......................... 5-2
Brake Proportion Valve,
General Description ....................................... 5-2
Brake System Testing ....... ,.............................. 5-3
(BTSI), General Description ........................ 3F-2
Brake Warning Lamp,
General Description ..................................... 5F-2
Bulb Usage Chart ......................... ,.............. 8B-19
Bulb, Control Lamp,
On-Vehicle Service ................................. ,.. lA-10
Bulbs, Halogen, General Description ........... 8B-2
Bumper, Front Side. Door,
On-Vehicle Service ..... :........:................... 10-6-31
Bumper, Front, OnNehicle Service ........... 10-4-2
Bumper, Hood Adjust Front,
Bumper, Rear Suspension Jounce,
On-Vehicle Service...................................... 3D-1
Bumper, Rear, On-Vehicle Service ............ 10-4-8
Bumpers, Front Side Door Window
Front and Rear, On-Vehicle Service ...... 10-6-40
Bumpers, General Description .... , .............. 10-4-1
Burnishing Front Brake Rotors,
Unit Repair ................................................. 5B 1-7
Burnishing Rear Brake Rotors,
Unit Repair ................................... :; ...........:5B2-11
Bushing, Front Lower Control Arm,
Bushing, Front Upper Control Arm,
On-Vehicle Service ............. ,....................... 3C-17
Bushing, Rear Axle Lower
Control Arm, On-Vehicle Service .............. 3D-3
Buzzer Switch Assembly, Unit Repair .... 3F5B-4
c
Cable Adjustment (Optional),
On-Vehicle Service; ....................................... 9B-7
Cable Adjustment (Standard),
On-Vehicle Service ....................................... 9B-7
BOOK 1 INDEX - 7
Cable Adjustment, Temperature Control ..... lA-9
Cable Replacement (Optional),
Cable Replacement (Standard),
On-Vehicle Service ............ .-........................... 9B-6
Cable Replacement, Accelerator
Pedal and Cruise, On-Vehicle Service .. 5E2-240
Cable, Automatic Transmission Park
Lock, On-Vehicle Service ......................... 7A-10
Cable, Automatic Transmission Range
Selector Lever, On-Vehicle Service ............ 7A-9
Cable, Battery, Replacement and
Routing ................. ,........ ,........................... 601-8
Cable, Cruise Control, On-Vehicle
Service .......................................................... 9B-6
Cable, Disconnecting the Battery
Negative., ..................................................... OA-1
Cable, Folding Top Cover Retention,
On-Vehicle Service ...... ,........................... ! 0-9-31
Cable, Hood Primary Latch Release,

Cable, Negative, On-Vehicle Service ......... 601-9
Cable, Positive, On-Vehicle Service ........ 6D 1-10
Cable, Replacement, Throttle,
Cable, Temperature Control
On-Vehicle Service ................... ,................ lA-16
Cables, .Parking Brake,
General Description ....................................... 5F-1
Cables, Parking Brake,
On-Vehicle Service ............................... ,.... ;.. 5F-2

Calibrating Testers, Coolant ........................ 6B-23
Caliper, Front Brake,
General Description .................................... 5B 1-1
Inspection, Diagnosis ................................. 5B 1-3
On-Vehicle Service ..................................... 5B 1-3
Caliper, Front Brake, Unit Repair .............. 5B 1-8
Caliper, Rear Brake,
Inspection, Diagnosis ................................. 5B2-3
Caliper, Rear Brake, On-Vehicle Service ... 5B2-3
Caliper, Rear Brake, Unit Repair ............. 5B2-11
Cam Assembly, Turn Signal Cancelling,
Unit Repair .............................................. 3F5B-4
Camber, General Description ....................... 3A-1
Camshaft Bearings, 3800 VIN K
Engine, Unit Repair ........................... ,.. 6A8B-19
.Camshaft Bearings, 5.7 Liter VIN P
Engine, Unit Repair .............................. 6A3.B-21
Camshaft Position Sensor,
General Description ...... ,............................ 604-2
Camshaft Position Sensor,
On-Vehicle Service ............................. ,.... 604-12
Camshaft Timing Chain,. Crankshaft
Pump Driveshaft, 5.7 Liter VIN P
Pump Driveshaft Assembly, 5.7 Liter
VIN P Engine, Unit Repair .............. 6A3B-17
and Camshaft Sprock;ets, and Water
Camshaft, 3800 VIN K Engine,
On-Vehicle Service ............................ 6A8A-22
Camshaft, 3800 VIN K Engine,

Unit Repair ............................................ 6A8B-17
Camshaft, 5.7 Liter VIN P Engine,
General Description ................................ 6A3B-2
Camshaft, 5.7 Liter VIN P Engine;
On-Vehicle Service ............................... 6A3A-16
Recondition ............................................ 6A3B-31
Unit Repair ............................................ 6A3B-18
Cap and Lines Inspection, Fuel Tank .......... OB-9
Cap, Aluminum Wheel Hub,
On-Vehicle Service .................................... 3E-13
Cap, Col Hsg End, Unit Repair ............... 3F5B-9
Cap, Radiator Fill, Diagnosis ........................ 6B-6
Cap, Radiator Fill, General Description ....... 6B-2
Capsules, Headlamp, On-Vehicle Service..... 8B-5
Capsules, Headlamps, General
Description ................................................... 8B-2
Carpet Insert Reattachment.. .................... 10-1-19
Carpet, Floor, General Description .......... 10-10-2
Carpet, Floor, On-Vehicle Service ......... 10-10-25
Carrier, Instrument Panel,
Case Extension Oil Seal,
Case, Differential, (Limited Slip),
Unit Repair ................................................. 4B-25
Cassette Tape Player, Delco-GM/Bose
Music System/Cassette (Chevrolet),
Cassette Tape Player, ETR
AM/FM Stereo/Cassette (Chevrolet),
AM/FM. Stereo/Cassette Tape with
Graphic Equalizer (Pontiac),
General Description .................................. 9A-10
Caster, General Description ........................... 3A-1
Catalyst Monitoring ......................................... 6-3
Catalytic Converter Hanger,
On-Vehicle Service ...................................... 6F-8
Catalytic Converter Heat Shield,
On-Vehicle Service .................................... 6F-11
Catalytic Converter, General Description ..... 6F-1
Caulking Kit, Adhesive,
Stationary Windows .................................. 10-2-1
Center Support Bearing,
General Description .................................... .4A-1
Center Support Bearing, Unit Repair ........ .4A-12
Centering Infl Restraint Coil,
Unit Repair ............................................... 3F5B-4
Certification, AMAX Stereo, ETR
Certification, AMAX Stereo, ETR
AM/FM Stereo/Cassette Tape with
8 - BOOK 1 INDEX
Certification,. AMAX Stereo, ETR
AM/FM Stereo/Compact Disc with
General Description ................................. 9A-11
Chain and Sprockets, Timing, 3800
VIN K Engine, Cleaning, Inspection and
Repair ............................ ;..................... 6A8B-28
Chain and Sprockets, Timing, 3800.
VIN K Engine, Unit Repair ................. 6A8B-14
Chain Usage, Tire .......................................... 3E-3
Chain, Camshaft Timing, 5.7 Liter
Chain, Camshaft Timing, 5.7 Liter
VIN P Engine, Recondition .................. 6A3B-32
Chain, Timing Camshaft, 5.7 Liter
VIN P Engine, Unit Repair .................. 6A3B-17
Chamber, Plenum, General Description ... 10-5-21
Changing Transmission Fluid and
Filter, On-Vehicle Service ......................... 7A-13
Channel, Front Side Door Window
Rear Guide, On-Vehicle Service............. 10-6-18
Channel, Front Side Door Window
Regulator Counterbalance Arm,
Channel, Front Side Door Window,
Charging a Very Low or Completely
Discharged Battery .................................... 6D 1-7
Charging Equipment, Battery ................... 6Dl-12
Charging Procedure, Battery ..................... ; 6Dl-6
Charging the A/C System (Engine Off) .... lB-18
Charging Time Required, Battery .............. 6D 1-7
Charging, Battery ........................................ 6D 1-6
Chassis Lubrication ....................................... OB-8
Chatter, Wiper, Repair, Off-Vehicle
Service ........................................................ 8E-16
Checking and Adding Fluid, Antilock
Brake System With Traction Control.. .. 5E2-224
Checking and Adding. Fluid, Antilock
Brake System ......................................... 5El-164
Checking and Adding Power Steering
Fluid ............................................................. 3B-4
Checking and Filling Procedures,
Transmission Fluid ................... :.................. 7A-3
Checking Engine Coolant ............................. 6B-4
Checking Limited Slip Operation,
Rear Axle ......................... ;.......................... 4B-7
Checking Manual Transmission
Fluid Level .................................................. 7B-4
Child Restraint Installation ....................... 10-11-8
Child Restraint, General Description ....... 10-11-2
Child Seat Restraint System Belt Kit,
Child Seat, On-Vehicle Service ................ 10-11-8
Chimes, Warning/Reminder,
General Description ..................................... 8C-7
Cigarette Lighter, On-Vehicle Service ....... 8C-15
Circuit Description, Supplemental
Inflatable Restraint (SIR) ............................ 9J-10
Clamps and Welded Connections,
General Description ...................................... 6F-2
Classifying a Vibration Complaint... ............ OC-3
Cleaning, 3800 VIN K Engine,
Unit Repair .............................................. 6A8B-3
Cleaning, Blade Element,

Cleaning, Exterior Radiator ........................... 6E-4
Cleaning, Inspection and Repair,
3800 VIN K Engine ............................. 6A8B-20
Cleanliness and Care, Engine .. .;; .................... 6-2
Clearcoat Application ............................... 10-1-10
Clearcoat Repair without Repainting ......... 10-1-9
Clearcoat Thickness .................................. 10-1-11
Clearing Diagnostic Trouble
Codes (DTCs), Antilock Brake System .... 5El-8
Clearing Diagnostic Trouble
Codes (DTCs) .......................................... 5E2-l 1
Cluster Warning/Indicator Lamps,
General Description ........................... ,....... ,.8C-5
Cluster, Instrument, General Description ...... 8C-3
Cluster, Instrument, On-Vehicle Service ..... 8C-22
Clutch Actuator Cylinder (5-Speed),
On-Vehicle Service....................................... 7C-8
Clutch Anticipate Switch,
On-Vehicle Service............. ;......................... 7C-9
Clutch Driven Plate (5-Speed),
On-Vehicle Service ........ :: ............................. 7C-9
Clutch Driven Plate (6-Speed);
On-Vehicle Service ..................................... 7C-l 1
Clutch Fork and Clutch Release
Bearing (6-Speed), On-Vehicle Service .... 7C-13
Clutch Master and Actuator Cylinder
(6-Speed), On-Vehicle Service..................... 7C-8
Clutch Master Cylinder (5-Speed),
Clutch Pedal Position Switch
(Clutch Start Switch),
On-Vehicle Service .............................. :...... 7C-9
Clutch Pedal, On-Vehicle Service ................. 7C-9
Clutch Pilot Bearing, General Description ... 7C-2
Clutch Pilot Bearing,
Clutch System Diagnosis .............. ,............... 7C-3
.Clutch System Preliminary Checks .............. 7C-2
Clutch System, Driven Member,
General Description ..................................... 7 C-1
Clutch System, Driving Members,
Clutch, Hydraulic, General Description ........ 7C-1
Coast Test, Propeller Shaft, Diagnosis ........ 4A-2
Cock, Radiator Drain,
.
Cock, Radiator Drain ..................................... 6B-2
Codes, Clearing Diagnostic
Trouble (DTCs) ........................................ 5E2-1 l
Codes, Clearing Diagnostic
Trouble (DTCs), Antilock Brake System, .. 5El-8
Codes, Displaying Diagnostic .
Trouble (DTCs), Antilock Brake
System ....................................................... 5El-8
Codes, Displaying Diagnostic
Trouble (DTCs) ........................................ 5E2-1 l
Codes, Option and Process ........................ OA-19
Codes, Option ............................................. OA-18
Coil Assembly, Inflatable Restraint,
Unit Repair .... ,....... u................................ 3F5B-4
Coil Assembly, SIR, General Description ..... 9J-3
BOOK 1 INDEX - 9
Coil, Centering Intl Restraint,
Unit Repair .............................................. 3F5B-4
Coil, Compressor Clutch, HD6/HR6
Unit Repair ............. ,.................................. 102-7
Coil, Compressor Clutch, V5
Unit Repair ................................................ 103-7
Coil, Electronic Ignition control Module,
3800 VINK Engine, UnitRepair.......... 604-15
Coil, Ignition Control Module, 5.7 Liter
VIN P Engine, Unit Repair .................... 604-15
Coil, Ignition, On-Vehicle Service ............ 604-11
Col Hsg .Cover End Cap, Unit Repair .... 3F5B-9
Cold Cranking Amps, Battery ........... ;........ 601-2
Column Removal, Steering ......................... 3F-12
Column, Lower ....................................... 3F5B-15
Column, Mid, Unit Repair ........ ,............. 3F5B-11
Column, Steering, Diagnosis ........................... 3-7
Column, Steering, Diagnosis ...... ;......... ;.......... 3-9
Column, Steering, General Description ........ 3F-2
Column, Steering, General Description ......... 9J-6
Column, Steering, Parts ............. : .......... 3F5B-2
Column, Upper, Unit Repair .................... 3F5B-4
Column-Mounted Dimmer Switch
Diagnosis ...................................................... 3-15
Common Causes of Failure, Battery ......... 601-2
Compact Disc Care .................................... 9A-16
Compact Disc Player, Delco-GM/Bose
Music System/Compact Disc (Chevrolet) .. 9A-6
Compact Disc Player, ETR
AM/FM Stereo/Compact Disc
(Chevrolet), General Description .............. 9A-7
Compact Disc Player, ETR
General Description .................................. 9 A-11
Compact Spare Tire,
General Description.................................... 3E-10
Compartment Lamp Switch,
Component Description, Supplemental
Inflatable Restraint (SIR) .............................. 9J-3
Component Replacement,
Compressor On-Vehicle, Minor ................. lB-31
Component Replacement,
Exhaust System ...................... ;.................... 6F-3
Components, Daytime Running Lamp
(DRL) (Canadian Only),
Compression Test, Engine ........... ;................. 6-11
Compressor Clutch Coil, HD6/HR6
Unit Repair ................................................ 102-7
Compressor Clutch Coil, V5
Unit Repair ............................................. :.. 103-7
Compressor Clutch Plate and Hub
Assembly, HD6/HR6 Unit Repair ............ 102-3
Compressor Clutch Plate and Hub
Assembly, V5 Unit Repair ....................... 103-2
Compressor Clutch Rotor and/or
Bearing, HD6/HR6 Unit Repair ....... ;,...... 102-4
Compressor Clutch Rotor and/ or
Bearing,. V5 Unit Repair .......................... 103-5
Compressor Control Switches,
HD6/HR6 Unit Repair ..... ;....................... 102-11
Compressor Control Switches,

V5 Unit Repair ........................................ 103-10
Compressor Control Valve Assembly,
Unit Repair ................................................ 103-11
Compressor Leak Testing (External),
HD6/HR6 Unit Repair ............................ 102-11
Compressor Leak Testing (External),
V5 Unit Repair ........................................ 103-12
Compressor On-Vehicle Minor
Component Replacement ........................... lB-31
Compressor Pressure. Relief Valve,
HD6/HR6 Unit Repair ............................. 102-10
Compressor Pressure Relief Valve,
V5 Unit Repair ........................................ 103-10
Compressor Repair Procedures, Major,
HD6/HR6 .................................................... l 02-8
Compressor Repair Procedures, Major,
v5 ............................................................... 1D3-8
Compressor Repair Procedures,
Minor, HD6/HR6 ....................................... 102-3
Compressor Repair Procedures,
Minor, V5 ................................................... 1D3-2
Compressor Shaft Seal Replacement,
HD6/HR6 Unit Repair .............................. 102-8
Compressor Shaft Seal Replacement,
V5 Unit Repair .............. ;........................... 103-9
Compressor System, General
Description ................................................. 1B-18
Compressor, Air Conditioning,
General Description ..................................... 18-5
General Description ................................. lB 1-11
On-Vehicle Service .................................... 18-27
Compressor, V5, Theory of Operation ....... 103-1
Condenser, Air Conditioning,
On~Vehicle Service ............ ;....................... lB-27
Connecting Rod Bearing Noise ...................... 6-9
Connecting Rod Bearings, 3800
VIN K Engine, On-Vehicle Service ..... 6A8A-28
Connecting Rod Bearings, 5.7
Liter VIN P Engine, Cleaning,
Inspection and Repair ......................... 6A3B-27
Connecting RodBearings, 5.7
Liter VIN P Engine,
Connector (Plastic Body and
Terminal Metal Pin) Repair, SIR ............. 9J-66
Connector Body Face Views, SIR ................. 9J-8
Connector Position Assurance (CPA) .......... 9J-67
Connector, Data Link (DLC),
Connector, Electrical, and Seal,
Connectors, Electrical,
Console Lamp, General Description ............. 8B-3
Console, Front Floor, General Description .. 8C-2
Console, Front Floor, On-Vehicle
Service, General Description ..................... 8C-14
10 - BOOK 1 INDEX
Construction, 3800 VIN K Engine .......... 6A8B-2
Construction, 5.7 Liter VIN P Engine .... 6A3B-2
Contamination Repair, Surface Level ...... 10-1-10
Control. (5-Speed), Manual
Transmission, On-Vehicle Service ... ;.......... 7B-6
Control (6-Speed), Manual
Transmission, On-Vehicle Service ............. 7B-8
Control and Shift Solenoids,
Control and Vacuum Selector
Valve and/or Blower Motor Switch,
On-Vehicle Service .................................... lA-9
Control Arm Ball Stud Inspection ............... 3C-3
Control Arm Ball Stud Replacement. .......... 3C-4
Control Effort, High or Low Heater ........... lA-9
Control Lamp Bulb, On-Vehicle Service ... lA-10
Control Valve Assembly, Unit Repair ..... 3B lB-6
Control Valve Body and Pressure
Switch, On-Vehicle Service ...................... 7 A-26
Control, Automatic Transmission,
Control, Blower Motor Speed,
General Description ................................... lB 1-4
Control, Heater and Air
Conditioning, On-Vehicle Service ............ 8C-10
Control, HVAC, General Description ........ 13BlControl, Mode, General Description .......... 1B 1-4
Control, Temperature,
General Description ................................... lBl-3
Controls, HVAC, General Description ......... lA-2
Controls, Pneumatic Comfort,
Diagnosis ................................................. 10-10-2
Controls, Radio, General Description .......... 9A-4
Controls, Steering Wheel,
Convenience Center, General Description ... 8C-2
Convenience Center, On-Vehicle Service .. 8C-27
Conversions, English-Metric ....................... OA-11
Converter, 3-Way Catalytic,
On-Vehicle Service ....................................... 6F-3
Converter, Catalytic, General Description .... 6F-1
Converter, Oxidation Catalytic,
Convertible Top Switch,
Convertible, Body Structures,
On-Vehicle Service ..................................... 11-37
Coolant Level Indicator Module,
On-Vehicle Service ......... ;;.;.................... ;. 6B-20
Coolant Outlet Housing and Thermostat,
3800 VIN K Engine, Unit Repair .......... 6A8B-8
Coolant Pump, 3800 VIN K Engine,
Unit Repair ............................................ 6A8B-13
Coolant Radiator, General Description ........ 6B-2
Coolant Recovery System,
General Description ..................................... 6B-3
Coolant, Checking Engine ............................ 6B-4
Coolant, Long Life Engine .......................... 6B-3
Cooler, Transmission Oil,
Cooling and Radiator
Maintenance Recommendations .................. 6B-3
Cooling and Radiator, Description
of Section 6B ................................................. 6-2
Cooling System Diagnosis Chart .................. 6B-6

Cooling System Overheating, Diagnosis ...... 6B-4
Cooling System Service ................................ OB-8
Cord, Engine Coolant Heater,
On-Vehicle Service ....................................... 9E-2
Core, Air Conditioning Refrigerant
Service Valve, On-Vehicle Service~ ........... lB-30
Core, Cross-Flow Radiator,
Core, Heater, On-Vehicle Service .............. lA-22
Correcting Non-Uniform Tires .................... 3E-12
Corrosion Repair ......................................... 10-1-8
. Cover (ABS), Gear, Unit Repair ............ 5E2-244
Cover Assembly,. Lock Housing,
Uriit Repair ........................... ;;,.. ;;............. 3F5B-9
Cover, Accessory Switch Opening,
On-Vehicle Service.................................... 10-6-7
Cover, Engine Front, 3800
Cover, Engine Front, 5.7 Liter
Cover, Engine Front, 5.7 Liter
Cover, Engine Front, Recondition,
5.7 Lite.r VIN P Engine ........................ 6A3B-32
. Cover, Folding Top,
On-Vehicle Service.................................. 10-9-32
Cover, Front. Fog Lamp Opening,
On-Vehicle Service....... :............. u............. 10-4-7
Cover, Front, 3800 VIN K Engine,
Unit Repair ............................................ 6A8B-14
Cover, Gear, Unit Repair ........................ 5El-176
Cover, Hood Hinge, ..
On-Vehicle Service ................... .c; ............. 10-5-12
Cover, Housing, Unit Repair ................... 3F5B-9
Cover, Rear Axle Housing
and Gasket, On-Vehicle Service ............... .4B-12
Cover, Rear Compartment Lift
Window Inner Panel, On-Vehicle
Service ................................................... 10-8-16
Cover, Rear Seat Shoulder Belt Retractor
Trim, On-Vehicle Service ....................... 10-11-7
Cover, Transmission converter,
On-Vehicle Service.......;............................ 7A-24
Cover, Valve Rocker.Arm, Left, 5.7
Liter VIN P Engine, Unit Repair ........ 6A3 B-11
Cover, Valve Rocker Arm, Right, 5.7
Liter VIN P Engine, Unit Repair ...... ,. 6A3B- ll
Covers And/Or Gaskets, Rocker Arm,
3800 VIN K Engine, Unit Repair ...... 6A8B-12
Covers, Trim, On-Vehicle Service .......... ,.10-10-5
Covers, Valve Rocker Arm Covers,
5. 7 Liter VIN P Engine,
On-Vehicle Service................................ 6A3A-10
.Covers, Valve Rocker Arm, 3800
VIN K Engine, On-Vehicle Service ....... 6A8A-8
Covers, Valve Rocker Arm, 5.7
Liter VIN P Engine, Recondition ........ 6A3B-33
Covers, Valve Rocker Arm, 5.7
Liter VIN P Engine, Unit Repair ........ 6A3B-ll
Cradle-to-Body Fastener Repair ................. 10-3-2
Cranking Circuit ......................................... 6D2- l
Crankshaft Balancer and Hub, 5.7 Liter
BOOK 1
Crankshaft Balancer and Hub, 5.7
Liter VIN P Engine, Unit Repair ........ 6A3B-13
Crankshaft Balancer, 3800 VIN K
Crankshaft Balancer, 3800 VIN K
Engine, Unit Repair .............................. 6A8B-13
Crankshaft Bearing Fit, 5.7 Liter VIN P
Engine, Cleaning, Inspection and
Repair .................................................... 6A3B-23
Crankshaft Bearings, 3800 VIN K
Crankshaft Bearings, 5.7 Liter VIN P
Engine, On~Vehlcle Service .................. 6A3A-25
Crankshaft Front Oil Seal, 3800 VIN K
Crankshaft Position Sensor Reluctor
Ring, 5. 7 Liter VIN P Engine,
Recondition .......................................... 6A3B-31
Ring, 5.7 Liter VIN P Engine;
Unit Repair .......................................... 6A3B-17
Ring, On-Vehicle Service ....................... 604-14
Crankshaft Position Sensor, 5.7 Liter
Crankshaft Position Sensor,
General Descriptiorn .................................. 604-2
Crankshaft Position. Sensor,
On-Vehicle Service .................................. 604-13
Crankshaft Rear Main Oil Seal Housing,
3800 VIN K Engine, Unit Repair........ 6A8B-16
Crankshaft Rear Main Oil Seal, 3800
and Crankshaft, 5.7 Liter VIN P
Engine, Unit Repair ............................. 6A3B-21
and Gasket, 3800 VIN K Engine,
and Gasket, 5.7 Liter VIN P
Engine, On-Vehicle Service ................ 6A3A-28
Crankshaft Rear Oil Seal, 3800 VIN K
Crankshaft Rear Oil Seal, 5. 7 Liter
VIN P Engine, On-Vehicle Service...... 6A3A-28
Crankshaft, 3800 VIN K Engine,
Crankshaft; 3800 VIN K Engine,
Unit Repair ............................................ 6A8B-19
Crankshaft, 5.7 Liter VIN P Engine,
Crankshaft, 5.7 Liter VIN P Engine,
Unit Repair ............................................ 6A3B-21
Crankshaft, General Description .............. 6A3B-2
Cross-Flow Radiator Core and Inlet
and Outlet Tanks, General Description~ ...... 6B-2
Crossmember, Front, On-Vehicle Service .. 10-3-2
Cruise Control Cable, On-Vehicle Service ... 9B-6
Cruise Control Module,
General Description...................................... 9B-1
Cruise Control Module,
On-Vehicle Service ............................... ,....... 9B4-
INDEX - 11
Cruise Control Switches,

Cruise Control Switches,
On-Vehicle Service ...................................... 9B-3
Cruise Control, Cable Adjustment
(Optional), On-Vehicle Service.................... 9B-7
Cruise Control, Cable Adjustment
(Standard), On-Vehicle Service ................... 9B-7
Cruise Control, Cable Replacement
(Optional), On-Vehicle Service............. ;...... 9B-6
Cruise Control, Cable Replacement
(Standard), On~ Vehicle Service ................... 9B-6
CS-1300 and CS-144 Generators,
General Description ................................... 603-1
CS-130D Generator, On~Vehicle .Service.... 603-3
CS-130D Generator, Unit Repair ................ 603-6
CS-144 Generator Disassembly,
Test and Re-Assembly, Unit Repair......... ,603-6
CS-144 Generator, On-Vehicle Service ...... 603-4
CS-Generator Bench Check ........................ 603-2
CS-Generator On-Vehicle Check ................ 603-2
Current Adjustment, Homs,
On-Vehicle Service .................................... 8B-17
Cushion, Front Seat,
On-Vehicle Service ................................. 10-10-9
Cushion, Rear Seat,
On-Vehicle Service ............................... 10-10-20
Cushion, Rear Seatback,
On-Vehicle Service ............................... 10-10-21
Customization Charts, Universal
Theft Deterrent System................................ 90-7
Cutting Keys .......... ,....................................... OA-8
Cylinder (5-Speed), Clutch Actuator,
On-Vehicle Service ................................... ;.. 7C-8
Cylinder (5-Speed), Clutch Master,
On-Vehicle Service ................................... ;.. 7C-6
Cylinder (6-Speed), Clutch Master and
Actuator, On-Vehicle Service ...................... 7C-8
Cylinder Block, 3800 VINK Engine,
Cylinder Coding, Lock .................................. OA-8
Cylinder Head and Gasket, 3800
Cylinder Head, 3800 VINK Engine,
Cylinder Head, 3800 VINK Engine,
Unit Repair ............................................ 6A8B-13
Cylinder Head, 5.7 Liter VIN P
Repair ............. :..................................... 6A3B-29
Cylinder Head, 5.7 Liter. VIN P Engine,
Unit Repair .................................... ;....... 6A3B-18
Cylinder Heads and Cylinder Head
Gaskets, 5.7 Liter VIN P Engine,
On-Vehicle Service ................... ;.......... 6A3A-18
Cylinder Heads, 5.7 Liter VIN P
Engine, General Description ........... ,....... 6A3B-2
Cylinder Leak Test ................................. ;....... 6-11
Cylinder Line Assembly and 0-Ring Seals,
Unit Repair .............................................. 3BlA-5
Cylinder, Brake Master, Bench Bleeding,
Unit Repair .................................................... 5A-4
Cylinder, Brake Master, Check, Diagnosis ... 5A-2
12 - BOOK 1
INDEX
Cylinder, Brake Master,

General Description ..................................... SA-1
Cylinder, Brake Master,
On-Vehicle Service ...................................... SA-3
Cylinder, Brake Master, Unit Repair ....'....... SA-4
Cylinder, Folding Top,
Cylinder, Front Side Door Lock,
Cylinder, Master, Unit Repair ................. SEl-180
Cylinder, Master, Unit Repair ................. 5E2-246
Cylinder, PASS-Key II System,
Steering Column Lock and Ignition,
General Description ..................................... 9D-2
Cylinder, Rear Compartment Lid
Lock, On-Vehicle Service ,........................ 10-8-2
Cylinder, Rear Wheel,
On Vehicle-Service .................... :............... 5C2-5
Cylinder, Rear Wheel, Unit Repair............ 5C2-8
Cylinders, Assembling and Coding Lock .... OA-8
Cylinders, Replacement Lock,
General Description ..................................... OA-8
D
Dampener, Exhaust Pipe,
On-Vehicle Service ..................................... 6F-13
Dampener, Rear Axle Torque Arm
Vibration, On-Vehicle Service .................... 3D-8
Dash Sound Barrier,
Data Link Connector (DLC),
Daytime Running Lamp (DRL) Ambient
Light Sensor (Canadian Only),
General Description ......... ,.u ...................... 8C-5
Components (Canadian Only),
On-Vehicle Service ................................. : 8C-12
Light Sensor Module,
On-Vehicle Service .................................. 8C-12
Daytime Running, Lamp Ambient
Light Sensor, On-Vehicle Service............. 8C-12
Daytime Running Lamps
(Canadian Only), General Description ....... 8B-2
Daytime Running Lamps (DRL)
(Canadian Only), General Description ....... 8C-2
Deactivating the Alarm, Universal
Theft Deterrent System ............................... 9D-6
Decal, Headlamp Opening Door,
On-Vehicle Service .................. ,............... 10-5-24
Decal, Rear Bumper Fascia,
Decals and Stripes, .General Description .. 10-1-2
Decals, Exterior Molding and,
Decals, Hood, On-Vehicle Service ........... 10-5-25
Decimal and Metric Equivalents ................ OA-11
Deflector, Front Side Door Water,
Deflector, Instrument Panel Driver Knee
Bolster, On-Vehicle Service ...................... 8C-12
Deflector, Radiator Air Lower,

Deflector, Radiator Air,
Deflectors and Baffles, Radiator
Air Lower, General Description .................. 6B-3
Deflectors, Air, On-Vehicle Service........... lA-20
Deflectors, Front Bumper Fascia
Lower, On-Vehicle Service ....................... 10-4-8
Deflectors, Front Door Water,
General Description .................................. 10-6-2
Defogger, Rear Window,
Delco-GM/Bose Music System/
Cassette (Chevrolet), General
Description .............................................. ,.. 9A-5
Delco-GM/Bose Music System/
Compact Disc (Chevrolet), General
Description ................................................... 9A-6
Delco-GM/Bose Music Systems,
Wheel Module, General Description ........... 3F-4
Deployed Inflator Module Handling ............ 9J-65
Deployed Inflator Module, On-Vehicle
Service ......................................................... 91-53
.. Deployment Inside Vehicle (Vehicle
Scrapping Procedure) .................................. 9J-61
Deployment Outside Vehicle (Driver
_
Inflator Module) .......................................... 9J-:,5
Inflator Module) .......................................... 9J-61
Description of Section 6A - Engine
Mechanical. ..................................................... 6-2
Description of Section 6B - Cooling
and Radiator ................................................... 6-2
Description of Section 6C - Engine Fuel ...... 6-2
Description of Section 6D Engine Electrical ............................................ 6-2
Description of Section 6E - Driveability
and Emissions -General Information ............. 6-2
Description of Section 6F Exhaust System .............................................. 6-2
Determining Factory Backup Unlocking
Code for Secured Radio ................:.......... 9A-l3
Devices, Restraint, General Description ........ 9J-2
Diagnosis and Repair, Waterleak ............... 10-1-4
Diagnosis and Repair, Windnoise :............. 10-1-6
Diagnosis of Propeller Shaft and
Universal Joint ............................................ 4A-5
Diagnosis, Air Conditioning System ............ lB-8
Diagnosis, and Repair, Squeak
and Rattle,ldr 10-1-7 Diagnosis, Clutch
System ......................................................... 7C-3
Diagnosis, Electrohydraulic,
Folding Top ....................... :; ............. ,........ .10-9-6
Diagnosis, Engine Knock .............................. 6-10
Diagnosis, Engine Mechanical ........................ 6-5
Diagnosis, Engine Misfire Mechanical.. ..:...... 6-5
Diagnosis, Engine Noise ......... :....................... 6-8
Diagnosis, Engine Performance ....... ,.............. 6-3
Diagnosis, Fluid Leak, Automatic
Transmission ....................................... :........ 7 A-6
BOOK 1 INDEX - 13
Diagnosis, Heavy Knock Hot with
Torque Applied ................ :. ;,,,,;,'.... :.. ....... 6-10
Diagnosis, Knocks at Idle Hot ...................... 6-11
Diagnosis, Knocks Cold and Continue for
Two to Three Minutes and Increases
with Torque .............. :.................................. 6-10
Diagnosis, Knocks on Initial Start-Up bu~
Only Lasts a Few Seconds .......................... 6-11
Diagnosis, Light Knock Hot ......................... 6-10
Diagnosis, Lighting System

Troubleshooting .... 1 : .............. , .............. 8B-4
Diagnosis, Oil Leak ..................... ,., .... ,.............. 6-5
Diagnosis-Electrical, Antilock, Brake
System With .Traction Contfol... .............. 5E2-10
Diagnosis-Electrical, Antilock Brake .
System .................... ,.. ,....... ,......................... 5El-8
Diagnostic Aids, .Supplemental
lriflatable .Restraint (SIR), .................... .;.,. .. 9J-10
Diagnostic Charts, A/C System ................. lB 1-17
Diagnostic Charts, VDOT NC. Systern .... lBl-19
Diagnostic Process (1 of 3), Antilock
Brake System With Traction, Control.. .. ,,5E2-13
Diagnostic Process (1 of 3),
..
Antilock Brake System ............ '. ...., ... ,, ...... 5El-11
.. Diagnostic System Check (1 of 4);
Antilock Brake .System With T~action
Control .......... :: .......................... ,............. 5E2-18
Diagnostic System Check (1 of 4),
Antilock Brake system ......................... ,.,5El-16
Diagnostic System Check, SIR.'.; ............ :;; .. 9J-10
Diagnostic Tape Error Indicator, ETR
AM/FM Stereo/Cassette Tape (Pontiac) ..... 9A-9
Diagnostic Tape Error Indicator, ETR,
AM/FM Stereo/Cassette Tape whh
Graphic Equalizer (Pontiac): ........; .......... 9A-10
Diagnostic Trouble. Code and Symptom
Table, Antilock Brake System With ,
Traction Control. ...............'.~ .................. ;:5E2-26
Table, Antilock Brake Syst~rn; ... :......... :.. 5El-22
Diagnostic Trouble Codes, 4L60:E
Automatic Transmission, 3.8L
.
VIN K ........... ;.............................. :..... 7A~14Al-1
Diagnostic Trouble Codes, 4L60-E
:Automatic Transmission, 5. 7L
VIN P ................... ;.... ~ ..~ ... ;:,., ......... :. 7A~l4A2-1
Diagnostic TroubJe Codes; .
Supplemental Inflatable Restraint (SIR) ...... 9J-7
Diagnostics, Enhanced, Antiloc.k Brake
System .............. ;.. :... ;............. ,,u... ,.......'i.......5El-9
Diagnostics, On-Board, II (OBD 11) .......... :. ... 6-3
Diagnostics, Tech 1, 'Antilock Brake
System .:. ;, ........................................ :....... ,. :. 5El-9
Differential Bearing Preload Adjustment,
Rear Axle, UniLRepair ............... :.............. 4B-20
Differential Case (Limited Slip); :

Unit Repair ................................................. 4B-25
Differential. Case, Rear Axle,
Unit Repair :.. ,..... ,.................................... :.'..4B-17
Differential Drive Pinion Gear Depth,
Unit Repair ......................::............ ;; ........... .4B-23
Differential Drive, Pinion Gear
Inner Bearing, Unit Repair ........:..............AB-23
'Bearing, Unit Repair .................................. 4B-22
Differential Drive Pinion Gear Yoke

and Seal, On-Vehicle Service .................... 4B-14
Differential Drive Pinion Gear YokE
Runout Measurement, On-Vehicle
Service................ ............................. ;: ...... 4A-6
Differential Drive Pinion Gear,
Unit Repair ........................ , ................. ,....... 4B-21
Differential Ratios and Tire Information ...... OA-4
Differential Ring Gear Tooth
Nomenclature, .Rear Axle, Diagnosis ......... .4B-8
Differential Ring Gear-to-Differential
Drive Pinion Gear Backlash, Rear Axle,
Unit Repair .............. :............... ;................ 4B-20
Dimensions, Body ....................... ,................ 11-30
Dimensions, Exhaust System Clearance .... , 6F-13
Dimmer Switch Adjustment,
Unit Repair .............................. ;.............. 3F5B-15
.
Dimmer Switch Assembly,
Unit Repair ......................... , ....... '. ........... 3F5B-15
Dimmer Switch Rod Actuator,
Unit Repair ....................................... ,; .. .s... 3F5B-9
Disabling the SIR
System ...................... 3F-4, 8C-7, 3F5B-4, .91-50
Disarming the System, Un.iversal
Theft Deterrent System...................,.... :........ 90-6
Disc Care, Compact ........: ........................... 9A-16
Disc Player, Compact, Delc'o-GM/
Bose Music System/Compact Disc
(Chevrolet), General Description ............... 9A-6
Disc Player, Compact, ETR
.
AM/FM Stereo/Compact Disc
(Chevrolet), General Description ... :.......... :9A-7
Disc Player, Compact; ETR
General Description ................................ 9A-11
Disconnecting the Battery Negative Cable... OA-1
(DTCs), Antilock Bra,ke System ....... /....... 5El-8
(DTCs) ...................................................... 5E2-11
Distribution System, Air,
General Description ..................................... lA-3
Distribution System, Air,
General Description .................................. ; 1B 1-5
Distributor Cap, Cover, Rotor and
Base, On-Vehicle Service .......................... 604-9
Distributor Ventilation System,
On-Vehicle Service ......................... ;.......... 604-7
Distributor, 5.7 Liter VIN P Engine,
On-Vehicle Service ............................ :i.6A3A-13
Distributor, 5.7 Liter VIN P Engine,
Unit Repair; .... :.................... ~ ................. 6A3B-13
Distributor, Air, On-Vehicle Service ........... SC-19
Distributor, On-Vehicle Service .................. 604-7
Dome and Reading Lamps,
General Description ........;.......... ;.................. 8B-3
Dome Lamp, On-Vehicle Service ... :.......... 10-9-2
Dome Lamp, On-Vehicle Service ............... 8B-16
Door Edge Protector, On-Vehicle .
Service ..................................................... 10-6-13
Door Jamb and Rear Lid Release
Switches, Universal Theft
Deterrent System ........................................ 90-7
14 - BOOK 1 INDEX
Door Jamb Switches, On-Vehicle
Service ................................ ;.............;....... 10-5-22
Door Outer Panel Replacement,
On-Vehicle Service ................................... 11-21
Door Service, On-Vehicle Service .............. 11-21
Door, Front Side, On-Vehicle Service ..... 10-6-35
Door, .Fuel Tank Filler,
On-Vehicle. Service .................. ,.............. 10-7-11
Door, Headlamp Opening,
Replacement, On-Vehicle Service... ,........... 8B-7
Door, Instrument .Panel
Compartment, On-Vehicle Service., .......... 8C-30
Door, Instrument Panel Fuse Block
Access On-Vehicle Service ...................... 8C-33
Drain Battery Electrical.. ........................... 6D 1-4
Draining and Refilling Cooling
System, .On-Vehicle Service ....................... 6B-8
Draining the Engine, 5. 7 Liter VIN P
Drive Shaft Seal Replacement, Power
Steering Pump, Unit Repair .._. ................ 3B lB-4
Drive Shaft Seal, Power Steering Pump,
Unit Repair ............................................ ,.3B1B-7
Driveability and Emissions
Fuel Injection (Port) (3800) ....................... 6E3-1
Driveability and Emissions General Information, Description of
Section 6E .............. ,..................... ,........ ,....... 6-2
Driveability and Emissions Sequential Multiport Fuel Injection
(SFI) (5.7L) ............................................... 6E3-1
Driveability and Emissions ............................ 6E-1
Driveline Angles, Vibration Diagnosis ........ OC-7
Driven Member, Clutch System,
Driver Seat Adjuster and Drive
Motor, On-Vehicle Service.................... 10-10-15
Driveshaft Assembly, Water Pump,
5. 7 Liter VIN P Engine,
Recondition ............................................ 6A3B-32
Driveshaft Assembly, Water Pump,
5.7 Liter VIN P Engine, Unit Repair .. 6A3B-17
Driveshaft, Water Pump, 5.7 Liter
Driving Members, Clutch System,
Drum, Rear Brake, Adjustment,
On-Vehicle Service .................................... 5C2-6
Drum, Rear Brake, Inspection.
Diagnosis ..................................... ,............. 5C2-1
Drum, Rear Brake, On Vehicle-Service ...... 5C2-2
Drum, Rear Brake, Unit Repair ................. 5C2-7
Drums, Rear Brake, Refinishing,
.
Unit Repair ................................................ 5C2-7
Drums, Replacing, Unit Repair .................. 5C2-8
.
Duct, Floor Air Outlet,
Duct, Side Window Defogger Outlet,
Ducts and Outlets, General Description ... ; lBl-9
Ducts, Heat, Ventilation and Air
Conditioning, On-Vehicle. Service ............ 8C-l 9
Ducts, Instrument Panel Center Air
Outlet, On-Vehicle Service ....................... 8C-21
Ducts, Instrument Panel Outer Air

Outlet, On-Vehicle Service ........................ 8C-22
Duplicating Ignition Keys ............................ 90-4
E
Effects of Differential Drive Pinion
Gear Position on Tooth Pattern,
Rear Axle, Diagnosis ................................. 4B-9
Contact Pattern, Rear Axle, Diagnosis .. ,.... 4B-9
EGR Valve Adapter, 3800 VIN K
Engine, On-Vehicle Service ................... 6A8A-12
EGR Valve Adapter, 3800 VIN K Engine,
.............................................
.
Reparr
. 6A8B-8
Unit
EGR Valve Oudet Pipe, 3800 VIN K
Engine, On-Vehicle Service ........ ,......... 6A8A-12
EGR Valve Outlet Pipe, 3800 VIN K
Engine, Unit Repair ................. :.............. 61\SB-3
EGR Valve Pipe, 5.7 Liter VIN P
.
Engine, On-Vehicle Service ..................... 6A3A-7
EGR Valve, 3800 VIN K Engme,
Unit Repair .............................................. 6A8B-3
Electric Engine Coolant Fan,
Electric Engine Coolant Fan,
Electric Halogen Leak Detector,
Electrical Connector and Seal,
On-Vehicle Service.............................. ,..... 7A-28
Electrical Connectors,
On-Vehicle Service................................. 5E2-242
Electrical Diagnosis ..................................... 8A-1
Electrohydraulic Diagnosis, ;Folding Top ... 10-9-6
Electrolyte Freezing, Battery,
General Description .................................. 6D 1-2
(EBCM), On-Vehicle Service ................ 5El-173
Electronic Brake Control
Module (EBCM) ........................................ 5El-7
Module (EBTCM),
On-Vehicle Service: 5E2-234
. Module (EBTCM) ................... ,............... ,.. 5E2-8
Electronic Ignition Control Module and
Coils, 3800 VIN K Engine,
Unit Repair ............................................. 604-15
Electronic Ignition Control Module
.
Bracket, .On-Vehicle Service ................... 604-10
Electronic Ignition Control Module,
On-Vehicle Service, .. ,.............................. 604-10
Electronic Speed Sensor (6-Speed),
On-Vehicle Service.......................... ,.......... 7B-11
Electronic Vibration Analyzer (EVA),
General Description ............................. ,....... OC-2
Eliminating Air Conditioning Odor .. ,......... lB-10
Emblem,. Front Fender,
On-Vehicle Service ............... ,................... 10-5-7
Emblem, Front Side Door,
Emblem, Rear End Finish Panel,
On-Vehicle Service................................ ;... 10-8-3
BOOK 1 INDEX - 15
Emblems, Front Bumper Fascia,
Emergency Locking Retractors,
Enabling the SIR
System ...................... 3F-4, 8C-7, 3F5B-4, 91-50
End Plate and Rotating Group
Replacement, Unit Repair ....................... 3B1B-4
Endgate Latch, On-Vehicle Service ........... 10-8-2
Engagement Switch, On-Vehicle Service ..... 9B-3
Engine Accessories, 3800 VIN K
Engine Block Coolant Drain Hole Plug,
General Description .............................. :....... 6B-3
Engine Block, 5.7 Liter VIN P Engine,
Cleaning, Inspection and Repair ......... 6A3B-22
Engine Block, 5;7 Liter VIN P Engine,
General Description ........ ,........................ 6A3B-2
Engine Cleaning, 3800 VIN K Engine,
Unit Repair .............................................. 6A8B-3
Engine Cleanliness and Care .......................... 6-2
Engine Compartment Front Outer
Side Rail, On-Vehicle Service ..................... 11-5
Engine Compression Test. ............................. 6-11
Engine Construction, 3800 VIN K
Engine ...................................................... 6A8B-2
Engine Construction, 5.7 Liter VIN P .
Engine ....................................................... 6A3B-2
Engine Coolant Air Bleed Pipe,
Engine Coolant Concentration....................... 6B-4
.
Engine Coolant Flushing and
Recycling, On-Vehicle Service .................... 6B-8
Engine Coolant Heater Cord,
On-Vehicle Service ....................................... 9E-2
Engine Coolant Heater,
On~Vehicle Service ....................................... 9E-1
Engine Coolant Hoses,
Engine Coolant Temperature (ECT)
Sensor Monitoring .......................................... 6-5
Engine Coolant Temperature (ECT)
Sensor, General Description ................. '. ...... 6B-3
Engine Coolant Temperature Gage
Sensor, General Description .............. ,......... 6B-3
Engine Coolant Thermostat Test,
Diagnosis ...................................................... 6B-5
Engine Coolant Thermostat,
Engine Coolant Thermostat,
On-Vehicle Service..................................... 6B-16
Engine Electric Coolant Fans,
General Description ................................... ,.. lB-5
Engine Electrical, Description of
Section 6D ....................................................... 6-2
Engine Flywheel, 5.7 Liter VIN P Engine,
Unit Repair .............................................. 6A3B-3
Engine Front Cover Oil Seals, 5.7 Liter
VIN P Engine, Recohdition .................. 6A3B-32
Engine Front Cover, 3800 VIN K
Engine Front Cover, 5.7 Liter VIN P
Engine, On-Vehicle Service ................ ,.6A3A-13
Engine Front Cover, 5.7 Liter. VIN P
Engine, Recondition: ............................. 6A3B-32

Engine Front Cover, 5.7 Liter VIN P
Engine, Unit Repair .............................. 6A3B-l 4
Engine Fuel, Description of Section 6C ........ 6-2
Engine Fuel. ............................ : ............. 6C-1
Engine Identification ..................................... OA-4
Engine Knock Diagnosis ....... ,................ ;...... 6-10
Engine Lubrication, 3800 VINK
.Engine ....................................................... 6A8B-2
Engine Mechanical Diagnosis ......................... 6-5
Engine Mechanical, Description of
Section 6A ...................................................... 6-2
Engine Misfire Mechanical Diagnosis ............ 6-5
Engine Mounts and Brackets, 3800
Engine Mounts and Engine Mount
Brackets, 5.7 Liter VIN P Engine,
On-Vehicle Service ............................. :.. 6A3A-3
Engine Noise Diagnosis .................................. 6-8
Engine Oil and Oil Filter Change ................ OB-7
Engine Performance Diagnosis ....................... 6-3
Engine Service, General Information on ........ 6-3
Engine Specifications, 3800 VIN K
Engine .................................................... 6A8B-47
Engine Speed Sensitive Only,
Vibration Diagnosis ...................................... OC-5
Engine Speed Sensitive, Vibration
Diagnosis ........................................... ;; ......... OC-4
Engine, 3800 VIN K Engine,
Engine, 5.7 Liter VIN P,
Engine, Draining the, 5.7 Liter VIN P
Engine, On-Vehicle Service ............... ,... 6A3A-14
English-Metric Conversions ........................ OA-11
Enhanced Diagnostics, Antilock Brake
System With Traction Control ................ 5E2-11
Enhanced Diagnostics,Antilock
Brake System ............................................. 5E 1-9
Equipment, Tools and Shop, 3800
VIN K Engine, Unit Repair ................... 6A8B-3
ETR AM/FM Stereo/Cassette
(Chevrolet), General Description ................. 9A-4
ETR AM/FM Stereo/Cassette Tape
(Pontiac), General Description .................... 9A-8
ETR AM/FM Stereo/Cassette Tape with
ETR AM/FM Stereo/Compact Disc
(Chevrolet), General Description ................. 9A-7
ETR AM/FM Stereo/Compact Disc with
Evacuation, Refrigerant, On-Vehicle
Service ........................................................ lB-16
Evaporative Emission Canister Purge
Valve Monitoring ........................................... 6-5
Evaporator Tube Orifice, Air
Conditioning, General Description .......... 1B 1-11
Evaporator, Air Conditioning,
Evaporator, Air Conditioning,
16 - BOOK 1
INDEX
Evaporator, Ai.r Conditioning,

On-Vehicle Service ..... ;............................. lBl-28
Evaporator, Blower Motor and,
General. Description ....... ,........................... lBl-5
Excessive Heat ............. ,................................ lA-9
Excessive Oil Loss .......................................... 6-5
Exhaust Gas. Recirculatj.on (EOR)
System Monitoring ......................................... 6-4
Exhaust Heat Shield, On~ Vehicle Service .. 6F-12
Exhaust Manifold, 3800 VINK
Engine, Unit Repair .... ,............ ,............ 6A8B-11
Exhaust Manifold, .5. 7 Liter VIN P
. Engine, 011-Vehicle Service ................... 6A3A-8
Exhaust Manifolds, 3800 VIN K
Engine, On-Vehicle Service .. ,.............. 6A8A-12
Exhaust Manifolds, 5.7 Liter VIN P
Engine, General Description ......... ,..... ,... 6A3B-2
Exhaust Manifolds, 5.7 Liter VIN P
Exhaust Muffler Hangers,
.
On-Vehicle Service .................
6F-9
Exhaust Muffler Interior Hanger
Bracket, On-Vehicle Service ...................... 6F-10
Exhaust Muffler, General Description .......... 6F-2
Exhaust Muffler; On-Vehicle Servic:e............ 6F-6
Exhaust Pipe Dampener,
On-Vehicle Service .......... ,.......................... 6F-13
Exhaust Pipe Heat Shield. and Exhaust
Muffler Heat Shield,
On-Vehicle Service ............................... ;... 6F-12
Exhaust Pipe, On-Vehicle Service.............. ,.. 6F-5
Exhaust System Clearance Dimensions ... :;. 6F-13
Exhaust System, Description of Section 6F ... 6-2
Exhaust Tailpipe Extensions,
On-Vehicle Service ............ ;.................... ,..... 6F-7
Extended Method, Windshield,
Extension, Automatic Transmission
Case, On-Vehicle Service .......................... 7A-20

Extensions, Exhaust Tailpipe,
On-Vehicle Service .............................. :.;...... 6F-7
Exterior Lighting, General Description.,.: .... 8B-2
Exterior Lighting, On-Vehicle Service ......... 8B-4
Exterior Moldings and Decals,
On-Vehicle Service .............................. ;... l 0-5-24
Exterior Radiator Cleaning ........................... 6B-4
Exterior Trim, On-Vehicle Service ........... 10-7-11
External Conditions That Affect . .
Brake Performance ............................. ,........... 5-3
External Leakage Check,.
Power Steering System .... ,........................... 3-16
Extractors, Hood Air,
On-Vehicle Service .................................. ! 0-5-19
.-.' .................
F
Fabricating a Patch Panel. ........................ 10-1-11
Fan, Blower Motor and Blower
Motor, On-Vehicle Service........................ lA-17
Fan, Electric Engine Coolani,
General Description ................... '. ................. 6B-3
Fan, Electric Engine Coolant,
.On-Vehicle Service ....................... ,............ 6B-17
Fans, Engine Electric Coolant,

.
General Description .......................... ,... ,...... lB-5
Fascia Energy Absorber, ,, .
General Desci:iption ......,, .... , ..................... 10-4-2
Fascia, Front Bumper,
On-Vehicle Service ............. ,.... ,................. 10-4-2
Fascia, Rear Bumper,
On-Vehicle Service.. ;................................. 10-4-8
Fastener Su:ength Identification .......... ,...... OA-10
Fastener, Recommendations for Reuse .. ,... OA-10
Fasteners, Body Front End,
General Description ... :.............. .,; .... ,, ....... 10-5-3

Fasteners, General Body,
.
General Description ....... ;.......................... 10-1-1
Fasteners, Metric, General Description .... ., OA-10
Fasteners, Prevailing, Torqlle ...................... OA-10
Fasteners, .Thread Locking, Doors ............. 10-6-2
Feature Custimization, Universal
Theft Deterrent, System .... :.... ,........... ,......... 9D-7
Federal Vehicle Theft
Prevention Standard .................................... OA-2
Fender, Front, and Brackets,
,. .
On-Vehicle Service .......... ,.................... ;.... 10-5-6
Fender, Front, On-Vehicle Service ......... ,... 10-5-5
Filler, Hood Close-out,
.
Filler, Taillamp Closeout,
. .
On-Vehicle Service ...................... ~; ............ 10-8-7
Filler, Taillamp, On-Vehicle Service ...... ,... 10-8-5
Filling. Brake Master Cylinder .
Reservoir; On~Vehicle Service .................... 5A-3
Filter, Air. Cleaner and Crankcase
Ventilation, Replacement ......;'. ............. ,....... OB-9
Filter, Changing .Transmission Fluid
. and, On-Vehicle Service ......... ,....... ,......... 7A-13
Filter, Engine Oil and, Change ..................... OB-7
Finding the Leak, Oil. ................ ,.................... 6-5
Finesse Polishing, Slight Clearcoat
Damage - Wet Sanding ........... t , .. , ........ 10-1-10
Fitting, Piston Ring, 3800 V~'N K
Engine,. Cleaning, Inspection at1d
Repair ............... ,.. ,: .... ,............................ 6A8B-24
Fitting, Piston, 3~00 VIN K Engine, .
, Cleaning, Inspection anq. Repair ...... ,... 6A8B-24
Flasher, Hazard Lamp,
General Description ., ................................... 8B-2
Flasher, Hazard Lamp,
Flasher, Tum Signal Lamp,
General Description ... ;., ..................... ,.... ,.... 8B-3
Flasher, Tum Signal Lamp,
.

Flexible Plastic Part Refinishing: ............. 10-1-16
Flexible Plastic .Part Repair .and
Refinishing ....................................... ,.... ,.. 10-1-11
Flexible Plastic Part Repair .................... '. 10-1-15
Floor Air Outlet Duct,
Floor Carpet, General Description .. .,.; ..... 10-10-2
Floor Carpet, On~Vehicle Service .......... 10-10-25
Floor Panel Reinforcement,
'On-Vehicle Service .................................... 10-3-2
Fluid Capacities, Approxirrtate: .............. ., ... OB-13
Fluid.Le?k Diagnosis, Automatic .
Transmission ................................................ 7A-6
BOOK 1 INDEX - 17
Fluid Recommendations, Power Steering ... 3B-13
Fluid Replacement, Power Steering .............. 3B-4
Fluid, Changing Transmission and
Filter, On-Vehicle Service ......................... 7A-13
Fluid, Checking and Adding
Power Steering ............................................. 3B-4
Fluid, Checking and Adding, Antilock
Brake System ......................................... 5El-164
Fluid, Hydraulic Clutch,
General Description ...................................... 7C-2
Fluids and Lubricants, Recommended ........ OB-12
Fluorescent Leak Detector,
Flushing Brake Hydraulic System .................. 5-2
Flushing Brake Hydraulic System ................ 5-24
Flushing Procedure, Antilock Brake System
with Traction Control.. ........................... 5E2-224
Flushing Procedure, Antilock Brake
System ..................................................... 5El-164
Flushing the .Power Steering System ............ 3B-4
Flywheel Noises (Automatic
Transmission) ................................................ 6-10
Flywheel, 3800 VIN K Engine,
On-Vehicle Service ................................ 6A8A-32
Unit Repair ............................................ 6A8B-16
Flywheel, 5.7 Liter VIN P Engine,
Flywheel, Engine, 5.7 Liter VIN P Engine,
Unit Repair .............................................. 6A3B-3
Flywheel/Torque Converter Clutch Vibration
Test Procedure, Automatic Transmission ... 7A-6
FM Stereo, General Description .................. 9A-3
Folding Top (Convertible), On-Vehicle
Service ....................................................... 10-9-5
Folding Top Bow, General Description ..... 10-9-7
Folding Top Cover Retention Cable,
On-Vehicle Service ............. ,.................... 10-9-31
Folding Top Cover,
(Right-Hand Cylinder), On-Vehicle
Service.................................................... 10-9-24
(Left-Hand Cylinder),
Folding Top Cylinder, On-Vehicle
Service ................................................... ,.10-9-24
Folding Top Electrohydraulic Diagnosis .... 10-9-6
Folding Top Front Latch,
Folding Top Front Weatherstrip
Retainers, On-Vehicle Service ................ 10-9-29
Folding Top Front Weatherstrip,
On-Vehicle Service ....................... ., ......... 10-9-28
Folding Top Hydraulic System
Bleeding Procedure ........................... ,..... 10-9-25
Folding Top Hydraulic System,
Adding Fluid ........................................... 10-9-26
Folding Top Hydraulic System,
General Description..... ,........................... 10-9-23
Folding Top Latch, Front Adjustment ..... 10-9-15
Folding Top Latch, Front Replacement ... 10-9-15
Folding Top Number Five Bow,

Folding Top Number Four Bow,
On-Vehicle Service ............. ;................... 10-9-13
Folding Top Number One and Number
Two Bow Links, On-Vehicle Service .... 10-9-16
Folding Top Number One Bow,
On-Vehicle Service ...... ,............................ 10-9-7
Folding Top Number Three Bow,
Folding Top Number Two Bow,
Folding Top Operation ............................... 10-9-5
Folding Top Outer Arm
Weatherstrip, On-Vehicle Service ........... 10-9-27
Folding Top Outer Arm,
. On-Vehicle Service ................................. 10-9-18
Folding Top Pivot Bracket,
OnNehicle Service ................................. 10-9-22
Folding Top Pump with Motor,
Folding Top Rail, On-Vehicle Service .. .'. 10-9-16
Folding Top Rear Window,
Folding Top Side Door Lower
Folding Top Side Rail Garnish
Molding, On-Vehicle Service ................. 10-9-30
Folding Top Side Rail Link,
Folding Top Side Rail Weatherstrip,
Folding Top Side Rail,
Folding Top Weatherstrips
and Garnishes .......................................... 10-9-26
Force Variation Check, Tire .......................... 3-23
Fork and Clutch Release Bearing
(6-Speed), Clutch, On-Vehicle Service ..... 7C-13
Frame and Underbody, General
Description ................................................ 10-3-2
Frame, Side Door Opening,
On-Vehicle Service ...... ;.............................. 11-38
Replacement, On-Vehicle Service .............. 11-16
Sectioning, On-Vehicle Service .................. 11-18
Front Brake Caliper Inspection,
Diagnosis .................................................... SB 1-3
Front Brake Caliper,
General Description ................................... SB 1-1
Front Brake Caliper, On-Vehicle Service ... 5Bl-3
Front Brake Caliper, Unit Repair ............... SB 1-8
Front Brake Rotor Inspection, Diagnosis ... SB 1-2
Front Brake Rotor, General Description..... SB 1-1
Front Brake Rotor, On-Vehicle Service ...... SB 1-7
Front Bumper Energy Absorber,
On-Vehicle Service ................................... 10-4-6
18 - BOOK 1 INDEX
Front Bumper Fascia Emblems,
On-Vehicle Service ................................. ,: .. 10-4-6
Front Bumper Fascia Lower
Deflectors, On-Vehicle Service ................. 10-4-8
Front Bumper Fascia;
Front Bumper Impact Bar,
Front Bumper, On~Vehicle Service .... ,....... 10-4-2
Front Camber and Caster Adjustment ......... 3A-4
Front Cover Oil Seal, 3800 VIN K
Front Cover, 3800 VIN K Engine,
Unit Repair ............................................ 6A8B-14
Front Crossmember Braces,
Front Crossmember, On-Vehicle Service ... 10-3-2
Front Disc Brake Pad Inspection,
Diagnosis ................................................... 5B 1-2
Front Disc Brake Pads,
On-Vehicle Service .................................... 5Bl-5
Buckle-Side Belts, On-Vehicle Service .. 10-11-3
Retractor-Side Belts, On-Vehicle
Service ...............................~ ..................... 10-11-3
Front End Panels, On-Vehicle Service ...... 10-5-3
Front End Sealing ..................................... 10-5-21
Front End, Body ......................................... 10-5-1
Front Engine Wiring Harness
(3800 VIN K) ............................................ 605-5
Front Fender and Brackets,
Front Fender Center Rear Molding,
Front Fender Emblem,
Front Fender, On-Vehicle Service .......... :... 10-5-5
Front Floor Console Lamp,
Front Floor Console Tape Storage
Tray, On-Vehicle Service .......................... 8C-15
Front Floor Console Transmission Shift
Opening Trim Plate,
On-Vehicle Service .................................. 8C-19
Front Floor Console,
Front Floor Console ...................................... 8C-2
Front Fog Lamp Aiming Procedure,
Front Fog Lamp Opening Cover,
Front Fog Lamp Switch.'. ............................. 8C-4
Front Fog Lamps, On-Vehicle Service ........ 8B-4
Front Fog Lamps .......................................... 8B-2
Front License Plate Bracket,
Front Lower Control Arm. Ball Stud,
On-Vehicle Service .......... , ........................... 3C-3
Front Lower Control Arm Ball Stud,
On-Vehicle Service ...................................... 3C-4
Front Lower Control Arm Bushing,
Front Lower Control Arm,
Front Reading Lamps,

On-Vehicle Service ........................... ;......... 8B-16
Front Seat Adjuster Actuator Lever
Knob, On-Vehicle Service .................... 10-10-20
Front Seat Belts, On-Vehicle Service ...... 10-11-3
Front Seat Cushion,
Front Seat Diagnosis ................................ 10-10-2
Front Seat Recliner,
Front Seat System, Restraint .................... 10-11-2
Front Seat, General Description ............... 10-10-1
Front Seat, On-Vehicle Service ................ 10-10-2
Front Seatback, General Description ....... 10-10-1
Front Seatback, On-Vehicle Service ........ 10-10-3
Front Side Door Armrest and Radio
Front Side Door Speaker Grille,
On-Vehicle Service ............... ;, ................. 10-6-3
Front Side Door Armrest, Map Pocket
and Radio Front Side Door Speaker
Grilles, On-Vehicle Service ..................... 10-6-3
Strip, On-Vehicle Service ....................... 10-6-16
Front Side Door Bumper,
On-Vehicle Service ............... :.................. 10-6-31
Front Side Door Center Molding,
Front Side Door Courtesy Lamps,
Front Side Door Courtesy Lamps,
On-Vehicle Service ..................................... 8B- l 6
Front Side Door Emblem,
Front Side Door Exterior Trim,
On-Vehicle Service ........................ ,......... 10-6-11
Front Side Door Front and Rear
Belt Seals, On-Vehicle Service............... 10-6-15
Front Side Door Hardware and Front Side
Door Window, On-Vehicle Service ........ 10-6-14
Front Side Door Inside Handle
Bezel, On-Vehicle Service ........ :................ 10-6-9

Front Side Door Inside Handle Rod,
Front Side Door Inside Handle Seal,
Front Side Door Inside Handle,
Front Side Door Interior Trim,
On-Vehicle Service .................................. ;.10-6-2
Front Side Door Interlock Striker,
Front Side Door Lock Actuator,
Front Side Door Lock Cylinder Rod,
Front Side Door Lock Cylinder,
Adjustment, On-Vehicle Service ............. 10-6-30
Front Side Door Lock Striker Anchor
Plate, On-Vehicle Service ....................... 10-6-30
Front Side Door Lock Striker,
Front Side Door Lock Strikers,
BOOK 1 INDEX - 19
Front Side Door Lock,
Front Side Door Locking Rod Knob,
Front Side Door Locking Rod,
Front Side Door Locks ............................... 10-6-2
Front Side Door Lower Hinge,
From Side Door Outside Handle
Rod, On-Vehicle Service ......................... 10-6-27
Front Side Door Outside Handle,
Front Side Door Outside Handles,
Front Side Door Sill Trim Plate,
On-Vehicle. Service .................................... 10-3-4
.
Front Side Door Speaker Grille,
Front Side Door. Trim Panel Retainer
Seals, On-Vehicle Service ............ ,.......... 10-6-17
Front Side Door Trim Panels,
Front Side Door Upper and Lower
Hinges, General Description ..................... 10-6-2
Front Side Door Upper Hinge,
Front Side Door Water Deflector,
Front Side Door Water Deflectors,
General Descriptfon ............................ '. ...... 10-6-2
Front Side Door weatherstrip,
On-Vehicle Service .............. ;................... 10-6-14
Front Side Door Window
Adjustment, On-Vehicle Service .............. 10-6-37
Front Side Door Window Rear Guide .
Channel, On-Vehicle Service ................ 10-6-18
Front Side Door Window Front
and Rear Bumpers,
Front Side Door Window Front
Up Stop Support, On-Vehicle Service ... 10-6-39
Front Side Door Whidow
Regulator Counterbalance Arm
Channel, On-Vehicle Service ................ 10-6-17
Front Side. Door Window Regulator
Handle, On-Vehicle Service .................... 10-6-25
Motor, On-Vehicle Service ..................... 10-6-42
Front Side Door Window Regulator,
Front Side Door Window Stabilizer,
Front Side Door Window,
Front Side Door, On-Vehicle Service ...... 10-6-35
Front Side Rail Link,
Front Sidemarker Lamp,
Front Sidemarker Lamps,

General Description ..................... ;... ,........... 8B-2
Front Toe Adjustment ..... ;............................. 3A-4
Front Upper Control Arm Ball Stud,
On-Vehicle Service .................................. ;... 3C-4
Front Upper Control Arm Ball Stud,
On-Vehicle Service; ..................................... 3C-4
Front Upper Control Arm Bushing,
On-Vehicle Service .............................. ;... :.3C-17
Front Upper Control Arm,
Front Wheel Bearing and Speed
Sensor Assembly, On-Vehicle Service .. SE 1-17 4
Front Wheel Bearing and Speed
Sensor Assembly, On-Vehicle Service .. 5E2-241
Front Wheel Bearing,
On-Vehicle Service .................................... 3C- l 8
Front Wheel Bearing, Repack ....................... OB-8
Front Wheel Bolt, On-Vehicle Service ......... 3C-7
Front Wheel Hub, On-Vehicle Service ......... 3C-6
Harness ,On-Vehicle Service ................. SE2-241
Harness, On-Vehicle Service ................. SE 1-17 4
Front Wheel Speed Sensor Rings ............... SE 1-7
Front Wheel Speed Sensor Rings ............. SE2-10
Front Wheel Speed Sensors ........................ SE 1-7
Front Wheel Speed Sensors ........................ SE2-9
Front Wheelhouse Panel Liner,
On-Vehicle Service .............................. , .... 10-5-5
Front Wheelhouse Panel Upper Side
Rail, On-Vehicle Service .............................. 11-8
Front Wheelhouse, On-Vehicle Service ... ;... 11-13
Fuel Enable Output, PASS-Key II
System, General Description ....................... 90-4
Fuel Enable Output, Universal Theft
Deterrent System, General Description ....... 9D-7
Fuel System Pressure Relief, 3800
Fuel System Pressure Relief, 5.7 Liter
VIN P Engine, On-Vehicle Service ....... 6A3A-2
Fuel Tank Filler Door,
On-Vehicle Service ................................. 10-7 -11
Fuel Tank Filler Pocket,
On-Vehicle Service ................................. 10-7 -12
Fuel Tank, Cap and Lines Inspection .......... OB-9
Fuel Trim System Monitoring ........................ 6-4
Fuel, Engine ................................................... 6C-1
Functional. Control Switches,
Functional Operation, Remote
Keyless Entry ............................................... 9K-1
Functional Test, Heater and Ventilation ....... lA-6
Functional Test, Manual Control
Air Conditioning ...................................... 1B 1-12
Fuse. and Fusible Links,
On-Vehicle Service ................................ SE2-244
Fuses and Fusible Links ............................. 5El-8
Fuses and Fusible Links ........................... SE2- l O
G
Gages, General Description ........................... 8C-3
Gages, Paint, General Description ... ;....... 10-1-11
20
BOOK 1 INDEX
Gasket, Crankshaft Rear Oil Seal
Housing, 5.7 Liter VIN P Engine,
On~Vehicle Service ............................. 6A3A-28
Gasket, Cylinder Head and, 3800
VIN K Engine, On-Vehicle Service .... 6A8A-24
Gasket, Cylinder Head, 5.7 Liter
Gear and Pump Leaks, Power Steering ........ 3-16
Gear Assembly, Power Rack & Pinion
Steering, Unit Repair .............................. 3B1A-2
Gear Cover (ABS), Unit Repair :............ 5E2-244
Gear Cover, Unit Repair ;............... ;........ 5El-176
Gear or Chain and Sprocket, Timing,
Noise ................................................................ 6-9
Gear Replacement, ABS .......................... 5E2-244
Gear Replacement, Unit Repair .............. 5El-178
Gear Set, Oil Pump, 3800 VINK
Engine, On-Vehicle Service ................. 6A8A-28
Gear Set, Oil Pump, 3800 VIN K
Engine, Unit Repair ................ ;,.......... ;;6A8B-16
Gear, Differential Drive Pinion,
Unit Repair ................................................ 4B-21
Gear, Power Steering, Diagnosis ....................... 3-5
Gear Power Steering, General Descnpt10n. 3B-1
Gear'. Power Steering, On-Vehicle Service .. 3B-7
General Balance Precautions ...... ,................ 3E-11
General Body Constuction .......................... 10-3-1
General Information on Engine Service ......... 6-3
General Service Instructions,
Restraint System ...................................... 10-11-2
General Service Procedures,
General Vehicle Lifting and Jacking ........... OA-4
Generator and Air Conditioning Compressor
and Power Steering Pump Bracket,
On-Vehicle Service .................................. lB-31
Generator Brace Bracket,
Generator Rear Brace,
Generator Replacement,
Generator, CS, Bench Check ..................... 6D3-2
Generator, CS, On-Vehicle Check .............. 6D3-2
Generator, CS-130D, .On-Vehicle .Service .. 6D3-3
Generator, CS-130D, Unit Repair ........... ;.. 6D3-6
Generator, CS-144, Disassembly,
.
Test and Re-Assembly, Unit Repair ......... 6D3-6
Generator, CS-144, On-Vehicle Service ..... 6D3-4
Generators, CS-130D and CS-144,
General Description ................................... 6D3-1
Glass Cleaning, Windshield, Off-Vehicle
Service ........................................................ 8E-16
Glass, Outside Rearview Mirror
Reflective, On-Vehicle Service ............... 10-6-21
Graphic Equalizer, ETR AM/FM
Stereo/Cassette Tape with, (Pontiac),
General Description ................................... 9A-9
Graphic Equalizer, ETR AM/FM
Stereo/Compact Disc with, (Pontiac),
General Description ................................. 9A-11
Grid Line Repair, Rear Window
Defogger ..... :, ........................................ :.... 10-2-8
Grid Lines, Testing, Rear Window

Defogger .................................................... 10-2-7
Grille, Quarter Inner Trim Finishing
Panel Speaker, On-Vehicle Service .......... 10-7-6
Grille, Radio Front Side Door
Speaker, On-Vehicle Service..................... 10-6-3
Grille, Radio Quarter Speaker,
Grilles, Front Side Door Speaker,

Ground Straps, On-Vehicle Service ......... 6Dl-12
Guide, Shoulder Restraint,
On-Vehicle Service...................... ,......... 10-10-22
H
Halogen Bulbs, General Description ............ 8B-2
Handle, Front Side Door Inside,
On-Vehicle Service....:............................. 10-6-24
Handle, Front Side Door Outside,
On-Vehicle Service .... :, ............................ 10-6-24
Handle, Front Side Door Window
Regulator, On-Vehicle Service ................ 10-6-25
Handles, Front Side Door Outside,
General Description ...... '. ........................... 10-6-2
Handling Electrostatic Discharge (ESD).
Sensitive Parts ................................... OA-1, 8C-l
Handling Refrigerant Lines and Fittings .... lB-12
Handling Refrigerant-134a .......................... lB-11
Handling/Installation/Oiagnosis,.
Supplemental Inflatable Restramt (SIR1 .... 9J-51
Hanger, Catalytic Converter,
On-Vehicle Service .................. ,.................... 6F-8
Hangers, Exhaust Muffler,
On-Vehicle Service.......................... ;............ 6F-9
Hangers, General Description ....................... 6F-2
Hardware, Front Side Door,
Harness, Front Engine Wiring .
(3800 VIN K), General Description ........ 6D5-5
Harness, Front Wlleel Speed Sensor
Jumper, On-Vehicle Service ................... 5El-174
Harness, Front Wheel Speed Sensor
Jumper, On-Vehicle Service::............... 5E2-241
Harness, Instrument Panel Wrrmg,
On-Vehicle Service..................................... 8C-26
Harness, Left-Hand Side Engine Wiring,
(5.7L VIN P) ............................................. 6D5-7
Harness, Left-Hand Side Engine Wiring,
(3800 VIN K) ....................... ;................... 6D5-4
Harness, Rear Wheel Speed Sensor
Jumper, .On-Vehicle Service................... 5El-174
Harness, Rear Wheel Speed Sensor
Jumper, On-Vehicle S~rvice..................:.. 5E2-242
Harness, Right-Hand Side Engme Wlflilg,
(5.7L VIN P) ,.........................................:..... 6D5-6
Harness, Right-Hand Side Engme Wmng,
(3800 VIN K) ........................................... 6D5-2
Harness, Spark Plug Wire, Diagnosis ........ 6D4-4
Harness, Spark Plug Wire,
Replacement, 5.7 Liter YIN P
Engine, On-Vehicle Service .................... 6D4-4
Harness, Spark Plug,
General Description .................................. 6D4-2
BOOK 1 INDEX - 21
Harness, Transmission Engine Wiring
(5.7 VIN P) ............................................... 6D5-9
Harness, Transmission Engine Wiring,
(3800 VIN K) ........................................... 6D5-8
Harness, Vacuum, On-Vehicle Service ....... lA-18
Harness, Wheel Speed Sensor Jumper ....... 5El-7
Harness, Wheel Speed Sensor Jumper ..... 5E2-10
Harness, Wiring ........................................... 5E 1-7
Harness, Wiring .. ;............................ ,......... 5E2-10
Hazard Lamp Flasher,
Hazard Lamp Flasher,
Hazard Warning Switch Knob,
Hazard Warning Switch,
Head and Gasket, Cylinder, 3800 VINK
Head Restraint, On-Vehicle Service....... 10-10-12
Head, Cylinder, 3800 VIN K Engine,
Head, Cylinder, 3800 VIN K Engine,
Unit Repair ............................................ 6A8B-13
Head, Cylinder, 5.7 Liter VIN P
Repair ................................................... 6A3B-29
Head, Cylinder, 5.7 Liter VIN P
Engine, On-Vehicle Service ................. ,6A3A-18
Head, Cylinder, 5.7 Liter VIN P Engine,
Unit Repair ............................................ 6A3B-18
Headlamp Aiming After a Collision,
On-Vehicle Service ...... ;.......................... :.... 8B-11
Headlamp Aiming Alternate
Procedure, On-Vehicle Service .................. 8B-10
Headlamp Aiming by Screen
Method, On-Vehicle Service .... ,................... 8B-9
Dimmer Switch, General Description ......... 8C-4
Dimmer Switch, On-Vehicle Service ........ 8C-25
Headlamp Capsules and Headlamps,
General Description .................... ,........... ;..... 8B-2
Headlamp Capsules, On-Vehicle Service ...... 8B-5
Headlamp Housing Panel and
Brackets, On-Vehicle Service ................... 10-5-3
Headlamp Opening Door Actuator
Control Module, On-Vehicle Service .......... 8B-8
Headlamp Opening Door Decal,
Headlamp Opening Housing and
Door Replacement, On-Vehicle Setvice ... ;.. 8B-7
Headlamps, On-Vehicle Service .................... 8B-6
Headlining Trim Finish Panel,
On-Vehicle Service .................0. ............... 10-9-34
Headlining, Panel, On~Vehicle Service ...... 10-9-2
Heads, Cylinder, 5.7 Liter VIN P
Engine, General Description ................... 6A3B-2
Heat, Excessive ............................................. lA-9
Heat, Ventilation and Air Conditioning
Ducts, On-Vehicle Service ......................... 8C-19
Heated Oxygen Sensor (H02S)

Monitoring ...................................................... 6-3

Lamp, General Description .......................... 8B-4
Lamp, On-Vehicle Service ......................... 8B-17
Heater and Air Conditioning Control,
Heater and Defrost Valve,
Heater Core, On-Vehicle Service ................ 1A-22
Heater Core, Temperature Valve and,
Heater Core, Temperature Valve and,
Heater Hose and Heater Hose Pipes,
On7 Vehicle Service .................................... lA-20
Heater Output Temperature Check ............... lA-8
Heater System, Base, General Description .. lA-1
Heater, Engine Coolant,
On-Vehicle Service., .................................... 9E-1
System Operation ......................................... lB-2
Heating or Defrosting, Insufficient.. ............. lA-8
Heavy Knock Hot with Torque Applied ...... 6-10
Height, Trim .................................................. 3-25
Height, Valve Stem, 3800 VIN K
Engine .................................................... 6A8B-32
High or Low Heater Control Effort ............. 1A-9
High-Mount Stoplamp,
High-Mount Stoplamp,
Hinge, Front Side Door Lower,
Hinge, Front Side Door Upper,
On-Vehicle Service .................... ;.... ;....... 10-6-33
Hinge, Hood, On-Vehicle Service ............ 10-5-12
Hinges, Front Side Door Upper and
Lower, General Description ...................... 10-6-2
Hinges, Rear Compartment .Lid,
Hinges, Rear Compartment Lift
Window, On-Vehicle Service .................. 10-8-12
Hood Adjust Front Bumper,
Hood Adjustment ...................................... 10-5-26
Hood Air Extractors,
On-Vehicle Service ........... ,..................... 10-5-19
Hood Close-out Filler,
On-Vehicle Service ...............~ .... ;............ 10-5-12
Hood Decals, On-Vehicle Service ........... 10-5-25
Hood Hinge Cover, On-Vehicle Service. 10-5-12
Hood Hinge, On-Vehicle Service........... ;. 10-5-12
Hood Insulator, On-Vehicle Service ........ 10-5-11
Hood Open Assist Rod Bracket,
Hood Open Assist Rod,
Hood Primary Latch Release Cable,
On.:.Vehicle Service ................................. 10-5-17
Hood Primary Latch,
Hood Rear Seal,
On-Vehicle Service .............................. ;.. 10-5-19
22 - BOOK 1 INDEX
Hood Secondary Latch,
On-Vehicle Service ................................ i.10-5-16
Hood, On-Vehicle Service .......................... 10-5-8
Hom and Parking Lamp Relays, Universal
Theft Deterrent System,
General Description ................................... 9D-7
Hom Relay, On-Vehicle Service ............. ;.. 8B-18
Homs, Diagnosis ........................................... 8B-4
Homs, General Description .......................... 8B-4
Homs, On-Vehicle Service ......................... 8B-17
Hose and Clamp Inspection ......................... 6B-4
Hose and Heater Hose Pipes, Heater,
On-Vehicle Service ..................................... lA-20
Hose, Air Conditioning Accumulator,
On-Vehicle Service ............... ;.................... lB-23
Hose, Air Conditioning Compressor
and Condenser, On-Vehicle Service ......... lB-19
Hose, Automatic Transmission Oil Cooler
Upper, On-Vehicle Service ........................ 7A-14
Hose, Folding Top Cylinder Lower
(Right-Hand Cylinder),
Hose, Folding Top Cylinder Upper
(Left-Hand Cylinder),
Hose, Power Steering Fluid
Reservoir, On-Vehicle Service .................. 3B-12
Hose, Transmission Ventilation,
On-Vehicle Service ............... ,.................... 7A-19
Hoses, Brake, On-Vehicle Service ................ 5-21
Hoses, Engine Coolant,
Hoses, Power Steering Gear Inlet and
Outlet, On-Vehicle Service ......................... 3B-8
Housing and Gasket, Crankshaft Rear
. Oil Seal, 3800 VIN K Engine,
On-Vehicle Service ............................. 6A8A-33
Housing and Thermostat, Coolant Outlet,
3800 VIN K Engine, Unit Repair .......... 6A8B-8
Housing Assembly, Steering Column,
Unit Repair ....... ,......................... :.......... 3F5B-11
Housing Cover, Unit Repair ...... ,.............. 3F5B-9
Housing, Crankshaft Rear Main Oil Seal,
3800 VIN K Engine, Unit Repair ........ 6A8B-16
Housing, Crankshaft Rear Oil Seal, 5.7
Liter VIN P Engine,
On-Vehicle Service ............................ , 6A3A-28
Housing, Crankshaft Rear Oil Seal, 5.7
Liter VIN P Engine, Unit Repair......... 6A3B-21
Housing, Headlamp Opening,
Housing, Mode Valve,
. General Description ............ ,........................ lA-4
How to Identify Plastic Parts .... ;.............. 10-1-11
Hub, Crankshaft Balancer, 5.7 Liter
Hub, Crankshaft Balancer, 5.7 Liter
Hub, Front Wheel, On-Vehicle Service ....... 3C-6
HVAC Control, General Description ......... lBl-3
HVAC, Controls, General Description ......... lA-2
Hydraulic Clutch Fluid,
Hydraulic Clutch, General Description ........ 7C-1
Hydraulic Modulator, Unit Repair .......... 5El-179

Hydraulic Pump Assembly,
Unit Repair ... .s 3B1B-7
Hydraulic Pump Flow Control Valve,
Hydraulic System Bleeding Procedure,
Folding Top .............................................. 10-9-25
Hydraulic System, Clutch, Bleeding ............. 7C-4
Hydraulic System, Folding Top,
Hydrometer, Battery, Built-In,
General Description .................................. 6Dl-3
Identification and Usage, Key ..................... OA-8

Identification, Body ...................................... OA-2
Identification, .Engine ................................... OA-4
Identification, Fastener Strength ................ OA-10
Identification, Model .................................... OA-4
Identification, Panel ....................................... 11-2
Identification, Plastic Part ........................ 10-1-ll
Identification, Transmission ..................... :.... OA-4
Ignition Coil, On-Vehicle Service ............. 6D4-11
Ignition Control Module and Coil, 5.7
Liter VIN P Engine, Unit Repair ........... 6D4-15

Ignition Input, PASS-Key II System,
General Description .................................... 9D-3
Ignition Key, On-Vehicle Service ................ 9D-4
Ignition Key, PASS-Key II System,
General Description .................................... 9D-2
Ignition Lock Systems,
Ignition Switch Adjustment,
Unit Repair .................. ,........................... 3F5B-15
Ignition Switch and Dimmer Switch, .
On-Vehicle Service....................................... 3F-5
Ignition Switch Assembly,
Unit Repair ............................................ 3F5B-15
Ignition Switch Diagnosis ............................. 3-12
Ignition Switch, General Description ......... 6D4-3
Ignition System, General Desctjption ........ 6D4-1
Ignition Timing, General Description ........ 6D4-3
Improper Air Delivery, Diagnosis ............. 1.B 1-13
Indicator, OilLevel, 3800 VIN K Engine,
Unit Repair ................ :.... ,..................... 6A8B-l 1
Industrial Fallout (Acid Rain) ............ ,.... 10-1-10
Inertia Seatback Lock Check ................... 10-10-4
Inflatable Restraint Coil Assembly,
Unit Repair ............... :........ ,... ,................. 3F5B-4
Inflatable Restraint Steering .

Wheel Module Scrapping Procedures ......... 3F-5
Inflatable Restraint Steering
Wheel Module Shipping Procedures ........... 3F-5
Inflatable Restraint Steering
Wheel Module, On-Vehicle Service ............ 3F-7
Inflation, Tire, On-Vehicle Service ............... 3E-4
Inflator Module Handling/Shipping/
Scrapping : ...................... :....................... 91-54
Inflater Module Scrapping Procedure .......... 91-54
Inflator Modules, General Description .......... 91-5
Inner Race, Unit Repair ........................... 3F5B-4
Inner Tie Rod, Unit Repair ...................... 3B1A-4
BOOK 1 INDEX 23
Inside Rearview Mirror Support,
Inside Rearview Mirror,
On-Vehicle Service ....... ;............................ 10-2-6
Inspection and Repair, Cleaning, 3800
VIN K Engine ....................................... 6A8B-20
Inspection and Services, Owner .................... OB-9
Inspection, .Hose and Clamp ......................... 6B-4
Installed Height, Valve Spring, 3800
VIN K Engine ..................................... 6A8B-32
Instrument Cluster, General Description ....... 8C-3
Instrument Cluster, On-Vehicle Service ...... 8C-22
Instrument Panel Carrier,
. Instrument Panel Center Air Outlet
Instrument Panel Cluster Trim Plate
Bezel, Instrument Panel Compartment
and Instrument Panel Upper Trim
Panel, On-Vehicle Service ...................... 8C-30
Instrument Panel Cluster Trim Plate
Bezel, On-Vehicle Service ............ ;............ 8C-30
Instrument Panel Compartment Door,
On-Vehicle Service ......................................8C-30
Instrument Panel Compartment Lamp.
Switch, On-Vehicle Service ;...................... 8C-32
Instrument Panel Compartment Lamp,
Instrument .Panel Compartment
Lamp, On-Vehicle Service ......................... 8B-17
Instrument Panel Compartment,
Instrument Panel Driver Knee Bolster
and Deflector, On-Vehicle Service ............ 8C-12
Instrument Panel Fuse Block Access
Door, On-Vehicle Service .... ;..................... 8C-33
Instrument Panel Fuse Block,
Instrument Panel Fuse Block,
Instrument Panel Inflatable Restraint
Module, On-Vehicle Service ...................... 8C-33
Instrument Panel Insulator, On-Vehicle
Service ........................................................ 8C-29
Instrument Panel Outer Air Outlet
Instrument Panel Switches,
Instrument Panel Switches,
Instrument Panel Upper Trim Panel,
On-Vehicle Service ................ ;.................... 8C-30
Instrument Panel Upper Trim Panel,
On-Vehicle Service.................................... 8C-33
Instrument Panel Wiring Harness,
Instrument Panel, General Description ......... 8C-4
Insufficient Cooling. Check, Manual
Control Air Conditioning ......................... 1B 1-13
Insufficient Heating or Defrosting ............... lA-8
Insulator, Hood, On-Vehicle Service .. ,..... 10-5-11
Insulator, Instrument Panel,
Intake Manifold, 5.7 Liter VIN P

Engine, On-Vehicle Service ............. ;..... 6A3A-5
Engine, Recondition .............................. 6A3B-33
Intake Manifold, 5.7 Liter VIN P Engine,
Unit Repair ........................................... ,.. 6A3B-3
Interior Lighting, General Description ......... 8B-3
Interior Lighting, On-Vehicle Service ......... 8B-15
Interior Moldings, General Description ..... 10-9-4
Interior Trim,. On-Vehicle Service ............. 10-7-1
Interlock, Brake Transmission Shift
(BTSI), General Description .................... ,... 3F-2
Irregular or Premature Wear, Tires ............... 3-19
J
Joint, Propeller Shaft,
General Description .................................... .4A-2
Joint, Universal, General Description .......... .4A-2
Joints, Universal, Unit Repair .................... .4A-12
Jounce or Load Sensitive, Vibration
.
. ......................................................
.
oc-4
D1agnos1s
Jump Starting in Case of Emergency
with Auxiliary (Booster) Battery .............. 601-7
K
Key Identification and Usage ....................... OA-8
Key Reminder Diagnosis .............................. 3-13
Key Resistor Inputs, PASS-Key II
Key, Igniti?n, On-Vehicle Service ................ 9D-:
Keys, Cuttmg ................................................. OAKeys, Duplicating Ignition ............................ 90-4
Keys, Replacing Lost Ignition ...................... 90-4
Knee Bolsters, General Description ............... 9J-6
Knob, Actuator Lever, Front Seat
Adjuster, On-Vehicle Service ................ 10-10-20
Knob, Blower M.otor Speed Control,
Knob, Front Side Door Locking Rod,
Knob, Hazard Warning Switch,
On-Vehicle Service ................ :: .................... 3F-6
Knob, Mode Control, General Description .. lA-2
Knob, Temperature Control,
General Description ................. ;................... lA-2
Knock Sensor System,
Knocks at Idle Hot.. ....................................... 6-11
Knocks Cold and Continue for Two to
Tirree Minutes and Increases with Torque . 6-10
Knocks on Initial Start-Up but Only Lasts a
Few Seconds ................................................. 6-11
Knuckle, Steering, On-Vehicle Service ...... 3C-14
L
Label, Odometer Repair Notice,
.
24 - BOOK 1
INDEX
Label, Service Parts Identification ............. OA-18

Labels, Replacement,
General Description ........................ , .......... OA-18
Lace, Liftgate Window Opening
Finish, On-Vehicle Service ..................... 10-8-16
Lamp, "Brake" Warning,
Lamp, AIR BAG Warning,
General Description ....................................... 9J-3
Lamp, Ashtray, General Description ............ 8B-3
Lamp, Ashtray, On-Vehicle Service ........... 8B-15
Lamp, Automatic Transmission Range
Selector Indicator, General Description ...... 8B-3
Lamp, Automatic Transmission Range
Selector Indicator, On-Vehicle Service ..... 8B-15
Lamp, Console, General Description ........... 8B-3
Lamp, Dome, On-Vehicle Service ............. 10-9-2
Lamp, Dome, On-Vehicle Service ............. 8B-16
Lamp, Front Floor Console,
Lamp, Front Fog Lamp, Aiming
Procedure, On-Vehicle Service ................... 8B-5
.
Lamp, Front Sidemarker,
Lamp, Heater and Air Conditioning,
On-Vehicle Service ................................ ~ ... 8B-17
Lamp, Instrument Panel Compartment,
Lamp, Instrument Panel
Compartment, On-Vehicle Service............ 8B-17
Lamp, Quarter Courtesy,
Lamp, Rear Compartment,
General Description., ................................... 8B-4
Lamp, Rear License, General Description ... 8B-3
Lamp, Rear License,
On-Vehicle Service ................... ;................ 8B-12
Lamp, Warning/Indicator, Antilock,
Operation ........................................................ 5-3
Lamp, Warning/Indicator, Brake,
Operation .......... ,................................... ,......... 5-3
Lamps, Backup, General Description .......... 8B-2
Lamps, Backup, On Vehicle Service ........... 8B-4
Lamps, Cluster Warning/Indicator,
Lamps, Daytime Running (DRL),
Canadian Only), General
Description ....................................... 8B-2, 8C-2
Lamps, Dome and Reading,
Lamps, Front Fog, General Description ...... 8B-2
Lamps, Front Fog, On-Vehicle Service ....... 8B-4
Lamps, Front Reading,
Lamps, Front Side Door Courtesy,
General Description .............. ;...... ,............... 8B-3
Lamps, Front Side Door Courtesy,
On-Vehicle Service ..................... ;.............. 8B-16
Lamps, Front Sidemarker,
Lamps, Heater and Air Conditioning,
Lamps, Parking and Turn Signal,
Lamps, Parking and Turn Signal,

Lamps, Reading and Dome,
Lamps, Rear Quarter Courtesy,
Lamps, Rear Sidemarker,
Lamps, Rear Sidemarker,
Lamps, Turn Signal and Parking,
Lamps, Turn Signal and Parking,
on-Vehicle Service ..................................... 8B-12
Lamps, Warning .............................. :............ 5El-7
Lamps, Warning/Indicator,
Lamps, Warning/Indicator,
Latch, Endgate, On-Vehicle Service .......... 10-8-2
Latch, Folding Top Front,
Latch, Folding Top, Front Adjustment .... 10-9-15
Latch, Folding Top, Front
Replacement ............................................ 10-9-15
Latch, Hood Primary,
Latch, Hood Secondary,
Lead/Pull, Radial Tire .... ;.............................. 3-20
Leak Detection, Seal, HD6/HR6
Compressor Unit Repair ........................... 102-8
Leak Detection, Seal, vs. Compressor
Unit Repair ................................................ 1D3-9
Leak Detector, Electric Halogen,
Leak Detector, Fluorescent,
Leak Detectors, Liquid, and Pressure
Testing .......................................................... 1B-9
Leak Test, Cylinder ....................................... 6-1 l
Leak Testing (External), Compressor,
HD6/HR6 Unit Repair ............................. 1D3-1 l
Leak Testing (External), Compressor, V5
Unit Repair .............................................. 103-12
Leak Testing, Bench-Check
Procedures, HD6/HR6 Unit Repair ......... 1D2- ll
Leak, Finding the, Oil. ............ ;....................... 6-5
Leak, Oil, Repairing the.... ;; ............................ 6-7
Leak-Testing the Refrigeration System ......... lB-8
Left Exhaust Manifold, 5.7 Liter VIN P
Left Valve Rocker Arm Cover, 5.7 Liter
(3800 VIN K) ..................................... ;...... 605-4
(5.7L VIN P) ..... :....................................... 605-7
Lever, Parking Brake,
Lever, Parking Brake,
On-Vehicle Service.......................... ;............ 5F-2
Lever, Steering Column Tilt Wheel
Release, On-Vehicle Service ........................ 3F-7
BOOK 1
Lever, Tum Signal and Headlamp

Dimmer Switch and Cruise Control
Actuator and Windshield Wiper
and. Windshield Washer,
On-Vehicle Service ................ :................. 3F-6
Lifter Diagnosis, Valve, 3800 VIN K
Engine ...................... ;............................ ,6A8B-32
Lifters, Valve, 3800. VIN K Engine,
On-Vehicle Service ... ;................... :........ 6A8A-11
Lifters, Valve, 3800 VIN K Engine,
Unit Repair ......... ,.. :....... :...................... ;6A8B-13
Lifters, Valve, 5.'J.. Liter VIN P
Engine, On-Vehicle Service............ ;...... 6A3A-12
Lifters, Valve, 5.7 Liter.VIN P
Engine, Recondition .......................... ;... 6A3B-32
Lifters, Valve, 5.7 Liter VIN P
Liftgate Window Opening Finish
Lace, On-Vehicle Service ............ :.......... 10-8-16
Lifting and Jacking, General Vehicle ... '.' ..... OA-4
Light Emitting Diode (L.E.D.),
' Security Indicator, Universal Theft
Deterrent System, On~Yehicle Service ..... 9D-9
Light Knock Hot ................................. ;.......... 6-10
Lighter, Cigarette, On-Vehicle Service .. ,.... 8C-15
Lighting System Troubleshooting,
Diagnosis ..................................................,... 8B-4
Lighting, Exterior, General Description ........ 8B-2
Lighting; Interior, General Description ......... 8B-3
Lighting, Interior, On-Vehicle Service ...... ; 10-9-2
Limited Slip Rear Axle,
General Description ................. ;............. ,...... 4B-5
Limited Slip Rear Axle,
General Description...... :..............~ .......... ;i; . .4B-7
Line Assembly, Cylinder and 0-Ring .
Seals, Unit .Repair....... :l,,, ... ;.... :............... 3B1A-5
Liner, Front Wheelhouse Panel;
On-Vehicle Service ................. :............. ,... ; 10-5-5
Link, Folding Top Side Rail,
Link, Front Side Rail
On-Vehicle Service ................... :....... :.... ,: 10-9-17
Link, Stabilizer Shaft,
. On-Vehicle Service ............................ ::... ;.;.3C-14
Linkage, Wiper, Assembly
Replacement, On-Vehicle Service............ ,. 8E-14
Links, Folding Top Number One and
Number Two Bow,
On-Vehicle Service ............................ ,... 10-9-16
Links, Fuse and Fusible,
On-Vehicle Service ........................... :.....5E2-244
Links, Fusible and Fuses ................ ,............ 5El-8
Links, Fusible and Fuses .... ;;;; ................ ;.. 5E2-10
Lip Seals, Power Steering System,
General Description ............................ ;......... 3-16
Liquid Leak Detectors and
Pressure Testing ... :................................. ;; ..... 1B-9
Live (Undeployed) Inflator Module,
On-Vehicle Service .................... :................. 91-53
Live (Undeployed) Inflator Module,
.
Location View, SIR Component and
Wiring, General Description .......... ;.............. 91-4
INDEX ~ 25
Lock and Striker, Rear Seatback,

On-Vehicle Service ....................... ,....... 10-10-24
Lock Bolt, Unit Repair ................... ,...... .3F5B-11
Lock Check, Inertia Seatback .................. 10-10-4
Lock Cylinder Coding ............ ;...................... OA-8
Lock Cylinder Set, Steering Column
Pass Key, Unit Repair ........... /............ ;.... 3F5B-4
Lock Cylinder, Roof Lift-Off
Lock Housing Cover Assembly,
Unit Repair ............................. ;................. 3F5B-9
Lock System Diagnosis ................................... 3-7
Lock System, Rear Compartment,
Lock Systems, Ignition,.
General Description ........ :............................ 3F-2
Lock, Front Side Door,
On-Vehicle .Service ............. ,............ ;....... 10-6-26
Lock, Shaft; Unit Repair ........................... 3F5B-4
Locking without Arming, Universal
Theft Deterrent System..........~ ................... :.9D-6
Lockout (6-Speed), Reverse,
On-Vehicle Service ................ :................... 7B-14
Locks, Front Side. Door,
General Description ....................... '. ........... 10-6-2
Long Life Engine Coolant,
.Low Frequency Audio Amplifier,
On-Vehicle Service ..................... ;; ...... ;... 10-7-10
Low or No Oil Pressure ................................. 6-8
Lower Column ......................................... 3F5B-15
Lower Intake Manifold, 3800 VIN K
Engine, On-Vehicle Service .................. 6A8A- l O
Lower Intake Manifold, 3800 VIN K
Engine, Unit Repair ............................... 6A8B-10
Lower Rail, On-Vehicle Service ........ :......... 11-12
Lubrication, 5.7 Liter VIN P Engine .. ;; .. 6A3B-3
Lubrication, Body Front End,
Lubrication, Chassis, General Description ... OB-8
Lubrication, Engine, 3800
VIN K Engine ......................................... 6A8B-2
Lubrication, General Body,
Lubrication, Steering Column .......... ;............ 3F-2
Lumbar and Lateral. Support
Bladders, On-Vehicle Service ........... ;... 10-10-10
M
Main and Rod Bearings, 3.800 VINK
Repair .................. i ................,. ................ 6A8B-25
Main Bearing Noise ............................... ;, ....... 6-9
Maintaining Chemical Stabil.ity
in the Refrigeration System....................... lB-12
Maintenance Items .......................... :., .......... OB-12
Maintenance Recommendations; .
Cooling and Radiator ......... 1......................... 6B-3

Maintenance, Scheduled Service ................... OB-1
Major HD6/HR6 .Compressor Repair
Procedures .................................................. 1D2-8
26 - BOOK 1 INDEX
Major V5 Compressor Repair
Procedures ................................. ;.... :........... 103-8
Manifold, Exhaust, 3800 ,VIN K
Engine, Unit Repair ....... :................... ;,6A8B-11
Manifold, Exhaust, 5.7 liter VIN P
Engine, On~Vehicle Service .. ~........ ,....... 6A3A-8
Manifold,. Exhaust, Left, 5.7 Liter
VIN P Engine; Unit Repair ....:............ 6A3B-11
Manifold, Exhaust, Right, .5.7 Liter
Manifold, Intake, 5.7 Liter VIN P
Engine, OnNehicle Service.~.: ............... 6A3A-5
Engine, Unit Repair .......... ;....... ;; ............ 6A3B-3
Manifold, Lower Intake, 3800 VIN K
Manifold, Lower Intake, 3800 VIN K
Manifold, Upper Intake, 3800 VIN K
Manifold, Upper Intake, 3800 VIN K
Engine, Unit Repair ..... ;........... ,.............. 6A8B-9
Manifolds, Exhaust, 3800 VIN K
Engine, On-Vehicle Service ............ ,.... 6A8A-12
Manifolds, Exhaust, 5.7 Liter VIN P
Manifolds, Exhaust, 5.7Liter VIN P
Manual Bleeding, Antilock Brake
System With Traction Control... ............ 5E2-230
Manual Bleeding, Antilock Brake
System ......................................... ;.......... 5El-170
Manual Control Air Conditioning,
Functional Test ................. ;...................... lB 1-12
Insufficient Cooling Check ...................... lB 1-13
Other Components, General Description .. lBl-5
Manual Control Air Conditioning;
Overview ...................................... :............. lBl-1
Manual Front Seat Adjuster Diagnosis .... 10-10-2
Manual Front Seat Adjuster,
Manual Transmission (RPO M49),
5-Speed, General Description .... :................ 7B-1
Manual Transmission (RPO M49),
5-Speed, On-Vehicle Servi.ce .................... 7B-14
,
Manual Transmission (RPQ MM6),
6-Speed, General Description, .................... 7B-1
Manual Transmission (RPO MM6),
'
6-Speed, On-Vehicle Service ............. :...... 7B-16
Manual Transmission Control
(5-Speed), On-Vehicle Service ........ :..... i..... 7B-6
Manual Transmission: Control
(6-Speed), On-Vehicle Service .................... 7B-8

Manual Transmission Control Lever
Boot, On-Vehicle Service ................. :.......... 7B-4
Map Pocket, On-Vehicle Service ............... 10-6-3
Mast, Radio Power Antenna,
Master Cylinder, Unit Repair .................. 5El-180

Master Cylinder, Unit Repair .................. 5E2-246
Measuring Bearing Clearance,
3800 VIN K Engine ................ ~: ........... 6A8B-26
Measuring Front Alignment Angles ............ 3A-4
Measuring Rear Alignment Angles ............. 3A-5
Measuring Wheel Runout,
On-Vehicle Service....................................... 3E-9
Metal Part Refinishing Basecoat/Clearcoat..................................... 10-1-8
Metric Fasteners, General Description ....... OA-10
Metric Thread Size Information .... 103-1, 1D2-l
Metric Wheel Nuts and Bolts,
On-Vehicle Service....................................... 3E-4
Metric, Decimal and, Equivalents ......... ,..... OA-11
Mid Column, Unit Repair ....................... 3F5B-1 l
Minor HD6/HR6 Compressor Repair
Procedures ................................................. 102-3
Minor V5 Compressor
Repair Procedures ......................... :........... 103-2
Mirror, Inside Rearview,
Mirror, Outside Rearview,
On-Vehicle Service................................ ;.10-6-20
Mirrors; Outside Rearview,
General Description .................... :............. 10-6-2
Miscellaneous Parts, Body Structures.;: ...... 11-37
Misfire Monitoring ..................... :.................... 6-4
Mode Control Knob, General Description .. lA-2
Mode Control, General Description ........ \... lBl-4
Mode Valve Housing,
General Description .................................... lA-4
Model Identification ............................ ;........ OA-4
Modulator, ABS Hydraulic,
Unit Repair ........... :: .... ;........................... 5E2-246
Modulator: Hydraulic, Unit Repair ....... :. 5El ~ 179
Modulator, TCS Hydraulic,
Unit Repair .. :.......................................... 5E2-246
Module (SDM), Sensing and
Diagnostic, On-Vehicle Service .. ,............... 9J-52
Module Handling, Deployed lnflator ........... 9J-65
Module Ignition Control, 5.7 Liter
. VIN P Engine, Unit Repair ........ ;........... 604-15
Module Scrl!,pping Procedure, Inflatot ......... 9J-54
Module, Coolant Level Indicator,
Module, Cruise Control,
General Description ..................................... 9B-l
Module, Cruise Control,
On-Vehicle. Service....................................... 9B4Module, Daytime Running Lamp Ambient
Light Sensor, On-Vehicle Service ............. 8C-12
Module, Deployed Inflator,
On-Vehicle Service ...................................... 9J-53
. Module, Electronic Brake Control
(EBCM), On-Vehicle Service ................ 5E 1-173
Module, Electronic Brake Control
(EBCM) ...................................................... 5El-7
Module, Electronic Brake Traction
Control (EBTCM), On-Vehicle
Service ......... :... :.................................... 5E2-234
Module, Electronic Brake Traction
Control' (EBTCM) ...................................... 5E2-8
BOOK 1 INDEX - 27
Module, Electronic Ignition Control, 3800

VIN K Engine, Unit Repair ....... ;........... 604-15
Module, Electronic Ignition Control,
On-Vehicle Service ................................~. 604-10
Module, Headlamp Opening Door
Actuator Control, On-:Vehicle Service ......... 8B-8
. Module, Inflatable Restraint .Steering
Wheel Scrapping Procedures .......... 1............ 3F-5
Module, Inflatable Restraint .Steering
Wheel Shipping Procedures ..... :................... 3F-5
Module, Inflatable Restraint Steering
Wheel, Deployed ................................... ;...... 3F-4
Wheel, Live (Undeployed) .......................... 3F-4
Wheel, On-Vehicle Service .......................... 3F-7
Module, lnflator; Handling/Shipping/
Scr~pping ............................................. o'.;,.o. .. 9J-54
Module, Instrument .Panel Inflatable.
Restraint, On: Vehicle Service .................... 8C-33
Module, Live (Undeployed) Inflator;
Module, Live (Undeployed) Inflator,
On-Vehicle Service...................................... 9J-54
..
Module, Passenger Inflator, .
Module, Power Window Control,
General Description ........ ,.... u .. , ........, ........ 10-6-2
. General Description .............. ,....................... 8C-2
Module, Sensing and Diagnostic .(SDM),
General Description ..... ,.,u,, . 9J-3
Modules, Inflator, General Description .......... 9J-5
Modules, Shipping Procedures for
Live (Undeployed) Inflator ;...................., ... 9J-54
(Method 1) ................................... ;............ 10-1-3
Molding Completely. Removed
(Method 2) ....,............................................ 10-1-3
Molding Replacement. .. ,............... ., ..........;, 10-1-4
Molding, Folding Top Side Rail
Garnish, On-Vehicle Service................... 10-9-30
Molding, Front Fender Center Rear,
On-Vehicle Service....................... ;o. ........ 10-5-24
Molding, Front Side Door Center,
On-Vehicle Service ............................. ,.... 10-6-ll
Molding, Rear Quarter Center,
On-Vehicle Service.; ................................ 10-7-11
Molding, Rear Window brain Panel
Garnish, On-Vehicle Service ..................... 10-8-7
.
Molding, Rocker Panel,
Molding, Roof Drip Scalp,
Molding, Roof Panel Longitudinal Bow
Finish, On.._Vehicle Service ................ ,.... 10-9-38
Molding, Windshield Reveal,
General Description ..................... '. ........... ;.10-2-1
Molding, Windshield. Reveal,
Molding, Windshield Side Upper Garnish
. (With Lift-Off Windows),
Molding, Windshield Side, Upper

Garnish (Without Lift-Off
Windows), On-Vehicle Service ............... 10-9-4
Moldings and Seals, .Quarter Belt ,
Reveal ...................................................... 10-9-30
Moldings, Adhesives .................................. 10-1-3
Moldings, Interior', General Description .... 10-9-4
Moldings, Interior, On:Vehicle Service ..... 10-9-4
Moldings, Rear Compartment Lift
Window Side Finish, On-Vehicle
Service ................................................... 10-8-17
Moldings, Secure Loose ............................. 10-1-3
Monitoring, Catalyst ........................................ 6-3
Monitoring, Engine Coolant Temperature
(ECT) Sensor ............................. ;...... ,............ 6-5
Monitoring, Evaporative Emission
Canister Purge Valve .... ;................................ 6-5
Monitoring, Exhaust Gas Recirculation
(EGR) System .................. ,.................... :........ 6-4
Monitoring, Fuel Trim System ....................... 6-4
Monitoring, Misfire ;......................................... 6-4
Monitoring, Secondary Air Injection
(AIR) System ............................................. ;.... 6-4
Motor and Evaporator, Blower,
{General Description ................................... lBl-5
Motor Noise, Blower............................ ;........ lA-9
Motor Pack (ABS), Unit Repair ............. 5E2-244
Motor Pack Assembly/ABS
Hydraulic Modulator, On-Vehicle
.Service ......1........................................~ 5El-172
Motor Pack Assembly/ABS
Service ................................................... 5E2-233
.
Motor Pack Assembly/ABS Hydraulic
. Modulator ................................................... 5El-6
Motor Pack Assembly/ABS Hydraulic
Modulator ............................................... 5E2-8
Motor Pack Assembly/TC$
Service .................................................. 5E2-234
Motor Pack Assembly/TCS Hydraulic
Modulator ................................ ,.............. ; .. 5E2-8
Motor Pac~ Unit Repair.......;...... ;.......... 5El-177
Motor, Front Side Door Window
Regulator, On-Vehicle Service................ 10-6-42
Motor, Starter PG-260, On-Vehicle
Service ........................................................ 602-7
Motor, Starter, Diagnosis ........................... ,.602-1
Motor, Starter, General Description.: .......... 602-1
Motor, Starter, .Lubrication,
. On-Vehicie Service .................................... 602-2
Motor, .Starter, Replacement,
Motor, Wiper, Assembly
Replacement, On-Vehicle Service ............. 8E-13
Mount, Transmission Support and
Transmission, On-Vehicle Sertice ............... 7B-4
. Mounting and Dismounting, Trre ................. 3E-8
Mounting, Steering Unit,
On-Vehicle Service ........................ ,, ......... 10-3-4
Mounts and Brackets, Engine, 3800
VINK Engine, On-Vehicle Service....... 6A8A-4
Mounts, Engine and Engine
Mount Brackets, 5.7 Liter VIN P
Engine, On-Vehicle Service .................... 6A3A-3
28 - BOOK 1
INDEX
Muffler, Exhaust, General Description........ 6F-2

Muffler, Exhaust, On~ Vehicle Service.;....... 6F-6
Music System/Cassette.
.
(Chevrolet); Delco@~GM/Bose,;
General Description ........................... ;;;..... 9A-5
Music.System/Compact Disc
(Chevrolet), Delco-GM/Bose,
General Description ........ ;i;; : ,;;,! ..... '. .. 9A-6
Music Systefus,.Delco-GWBose,
General Description ............ ;......... ::: .......... 9A-2
Nameplates/Etnblems,. Adh~iiv,e, . ,~ ............i 0-1-3

Negative C~ble, ()n-Vehic~e Service ......... ,601-9
No .Air Tool Recommenqation,
:
Automatic Transmission .onNehicle .
Serv_ice .. :................ :.................. :... ,..,... 7 A-4
No-L()ad .'fest,_ lJnit Repair ... :.. ,.......... ,, ..... 602-7
Noise ~nd Vibratipp .Analysis;. , , ,
Automatic Transmissipn;... ,.. i" 7 A-3
.... Noise. Cqm:litions, Atomatic
,
Transmission On.;.Vehicle Service ................, 7A-3
Noi~e Diagnosis, A/C Systejn;,,. :... ,, ....... :lBl-17
Noises, FJywheel, (Aqtomatic
.
.
.. Transmission) ....... ;, ......... ,,,_, .. ,.,. . ;,..... ;,;\... 6~10
Noises, Piston .... :.,:...... ;.... ,...,.~.:.... ;;,;~;( . ;.~.;~;.;... 6-9
Noises, Valve.Mechanism or. Valve.Train ..... 6-9
Notes on System Check Chart,
::
Supplemental Inflatable Restraint (SIR) ..... 9J-10
Nozzle, Windshield Defroster,
On-Vehicle Service ....................... ;.; .... ,.... 8C-19
Number, Vehicle Identification .. ;;;, ....... ;... ::. OA-2
0-Ring Seals, Power Steering 'System ......... 3-16

O~Ring~, Replacing .... ,........ .-', 1B-11
Odometer Repair Nptice ~a~l,
:, . .
On-Vehicle Service ...... ,..... ,.................. ,,,.. 8C-29
Odor, E,Jiminating Air. Condi!i.oning :.: ..... lB-10
Off-On-Resume/Accelerate. Switch,
General _Desiription., ......: ......... ,.. :.. ,, ... ,. 9B-2
Off-Vehicle. Balancing .......... ,............... ,, ....3E-12
. ..
Oil ('.harge Reple11ishi11g, A/C
System, .On-Ve.hide Service.r lB-17
Oil Coqler Flushing Procedure, .
Automatic Trans111i~sio11:, OnNehi~le
.. Service ............_.................,,; ..... ,.,._.-;_.., ...... 7A-17
Oil Distribution, Reftigerant ........... ,.., ..... , lB-17
Oil Filter .Adapter ..and Pressure Relief
Valve, 3800 VIN K Engine, Un.it
. Repair ....L ..........._; .... ;;: ..........-. ;6A8B-13

Oil Filter Adapter .and Pressure Relief
Valve, 3800 VINK Engine, On-Vehicle;
.. Service ........ :................ ;;.,; .................... 6A8A-26
Oil Leak Diagnosis ........ ,... ;; ......... ,................ 6-5
Oil Level Indicator and OiLLevel
Indicator Tube, 5.7 Liter,.VIN P
Engine;, On~Vehicle Service.,, .............. 6A3A-5
,
Oil Level Indicator and Tube, $.800
VINK Engine, On-Vehicle Service .... ; 6A8A-6
Oil <LeveLlndicator, 3800 VIN K

Engine, Unit Repair.:: ............. ;... :.; 6A8B-ll
Oil Loss Due to a Large Leak,
.
Refrigerant ............................ ;.................... lB-17
Oil Loss, Excessive; .. ,., ................. , ................ 6-5
Oil Pan:, '3800 VIN K Engine,
On-Vehicle Service ... :.: .... ;.e . ; 6A8A-26

Oil Pan, 3800 VIN K Engine, .
Unit Repair; .... :, ..... ,.;;:; ..................... :~: .. ; 6A8B-15
Oil Pan, 5.7 Liter VIN P Engine,

On-Vehicle Service.: ................ ;............. 6A3A-21
Oil Pan, 5.7 Liter VIN P Engine,
Recondition::... '. ..... :.... :...................... ;.. 6A3B-32
: Oil Pan, 5.7 Liter VIN P Engine,
Unit Repair ;.;..ti .... ;..... :.............'. .. ,........ 6A3B-14
Oil Pressure, Low or No ................... , .... ,, ..... 6-8
Oil Pump Gear Set; 3800 VIN K
.
Oil Putnp Gear Set, 3800 VIN.K
Engine, Unit Repair ................ L.... ;.... ,,6A8B-16
Oil Pump Screen, 3800 VIN K
,
.
Engine, On-Vehicle Service:.;........... ;... 6A~A-27
Oil Pump Screen, 3800 VIN _K
' , .
Engine, Unit Repair ........................... 6A8B-15
Oil Putnp Unit Repair, 3800 VIN K
Engine1 ............................ ;.;f0.; .. :.L .. '. ... ,6J\.8B-33
Oil Putnp, 5.7 Liter VIN P Engme, .
Cleaning, Inspec~ion and Rep~., ........ 6A3B-28
'
Oil Putnp,, 5.7' Liter VIN P Engme,
OnVehicle Service ........... ;... ;;:.: ........ ;, .. 6A3A-22
Oil Pump, 5.7'Liter VIN P Engine,
unit.Repair .. i:............. '. .............. uu ..... ,.6A3B-19
Oil, Engine and Oil-Filter, C~ange ...... ;.::~!... OB-7
Oil Finding the Leak ... ;..':.... ;................. :........ 6-5
' ... ..
. .
..
. '
67
Oil, Repairing the Leak .... ;.:: ............... :.. ;.. ,...
.On-Board Diagnostics II (OBD II),
General Description: ............... ,........... ,..... ,..... 6-3

On-Vehicle Balancing ............ ;... ;; ..... :;. .... ,.. 3E-12
One and Two Piece Propeller Shaft
Replacement, On-Vehicle Service .;; ......... 4A-10
Operation, Radio, Delco-GM/Bose
Music' System/Compact Disc (Chevrolet):'.9A-6
Operation, Radio, ETR AM/FM
.
' Stereo/Cassette (Chevrolet) .. ."... ,, ................. 9A-4
Operation, Radio, ETR AMfFM . .

Stereo/Casse.tte Tape (Pontiac) .._................. 9A-8
Operation, Radio, ETR AM/FM
..
Stereo/Cassette Tape_ with Graphic
Equalizer (Pontiac): ................ '.\.,;~ ........... 9A-9
Operation, Radio, . ETR, _AM/FM
.Stereo/Compact Disc '(Chevrolet) .............. 9A-7
Operation, Radio, ETR AM!Ffyi .
Stereo/Compact Disc with Graphic
.
Equalizer (Pontiac) ., .. .,.. ,......... ;............... ,.9A-11
Operational and Functional. Checks,
.;
Restra:i,nt System ............._......... ,. 1........ , ... 10-11-3
Option and Process Codes""'.,.... :................ OA-19
Option Codes ........ ;,_;,.,:,~ OA-18
Optional Audio System, .. .
General Description ... :.........: 9A-2
Orifice, Air Conditioning Evaporator
Tube, General Descriptiori ............ ,............ lB-5

. Tube, General Description: .. :-: 1B 1-11
BOOK 1
Tube, On-Vehicle Service .......................... 1B-25
Other Components, Manual Control
Air Conditioning, General Description ..... 1B 1-5
Outer Rocker Panel, On-Vehicle Service ... 11-41
Outer Tie Rod, Unit Repair ..................... 3B1A-3
Outlets, Air, General Description ................. lA-6
Outlets, Ducts and, General Description .... lB 1-9
Output Shaft Seal, On-Vehicle Service ........ 7B-8
Outside Rearview Mirror Applique,
Outside Rearview Mirror Reflective
Glass, On-Vehicle Service ...................... 10-6-21
Outside Rearview Mirror,

Outside Rearview Mirrors, General
Description ................................................. 10-6-2
Overheating, Cooling System, Diagnosis ..... 6B-4
Overview, Manual Control
Air Conditioning ..................................... :.. lB 1-1
Owner Inspection and Services ..................... OB-9
Oxidation Catalytic Converter,

Assembly, Unit Repair ............................ 3B1B-2
Service, Unit Repair......................... ,...... 3B lB-3
P-Metric Tires, General Description ............. 3E-2
Pack (ABS), Motor, Unit Repair ............ 5E2-244
Pack, Motor, Unit Repair ........................ SE 1-177
Pad, Front Disc Brake, Inspection,
Diagnosis .................................................... 5Bl-2
Pad, Rear Disc Brake, Inspection,
Diagnosis ........................... ,............. ,......... ,582-2
Pads, Front Disc Brake,
On-Vehicle Service ..................................... SB 1-5
Pads, Rear Disc Brake,
On Vehicle-Service ..................................... 5B2-7
Paint Gages ............................................... 10-1-11
Pan, Oil, 3800 VINK Engine,
Pan, Oil, 3800 VIN K Engine,
Unit Repair .................. :, ................ 6A8B-15
Pan, Oil, 5.7 Liter VIN P Engine, .
Pan, Oil, 5.7 Liter VIN P Engine,
Recondition ............................................ 6A3B-32
Pan, Oil, 5.7 Liter VIN P Engine,
Unit Repair ............................................ 6A3B-14
Panel Adjustment, Rear Compartment
Lift Window, On-Vehicle Service ....... ,.. 10-8-15
Panel and Components, Rear Compartment
Lid, On-Vehicle Service ......................... , 10-8-20
Panel and Components, Rear Compartment
Lift Window, On-Vehicle Service .......... 10-8-12
Panel Identification ........................................ 11-2
Panel, Accessory Switch,
Panel, Body Hinge Pillar Trim,
INDEX
29
Panel, Door Outer, Replacement,

Panel, Headlamp Housing and
Brackets, On-Vehicle Service ................... 10-5-3
Panel, Headlining Trim Finish,
Panel, Headlining, On-Vehicle Service ...... 10-9-2
Panel, Instrument Panel Upper trim
Panel, On-Vehicle Service ......................... 8C-33
Panel, Instrument Panel Upper Trim,
Panel, Instrument, General Description ........ 8C-4
Panel, Outer Rocker, On-Vehicle Service ... 11-41
Panel, Quarter Inner Rear Trim
Finishing, On-Vehicle Service .................. 10-7-3
Panel, Quarter Inner Trim Finishing,
Panel, Quarter Trim Finishing, Extension
(With Lift-Off Windows), On-Vehicle
Service ..................................................... 10-7-4
Panel, Quarter, Convertible, On-Vehicle
Service ......................................................... 11-44
Panel, Quarter, On-Vehicle Service ............. 11-26
Panel, Radiator Upper Mounting,
Panel, Rear Compartment Closeout,
Panel, Rear Compartment Lid,
Panel, Rear Compartment Lift Window
Closeout, On-Vehicle Service ................... 10-8-7
Panel, Rear Compartment Lift
Panel, Rear End Finish,
Panel, Roof Outer, On-Vehicle Service ....... 11-23
Panels, Front End, On-Vehicle Service ..... 10-5-3
Panels, Front Side Door Trim,
Using New Switch, On-Vehicle Service ... 7A-13
. Park/Neutral Position Switch Adjustment
Using Old Switch, On-Vehicle Service .... 7A-12
Park/Neutral Position Switch,
Parking and Tum Signal Lamps,
Parking and Turn Signal. Lamps,
Parking Brake Adjustment ............................ SF-7
Parking Brake Cables,
Parking Brake Cables,
, On-Vehicle Service ...................................... 5F-2
Parking Brake Free-Travel Adjustment,
On Vehicle-Service .................................... 5B2-9
Parking Brake Lever, General Description ... 5F- l
Parking Brake Lever, On-Vehicle Service .... 5F-2
Parking Brake System,
Parts Cleaning, Inspection and
Replacement, Automatic Transmission ....... 7A-4
Parts, Handling Electrostatic Discharge
(ESD) Sensitive ............................................ OA-1
30 - BOOK 1
Parts, Miscellaneous, Body Stmctures ........ 11-37
PASS-Key II System, Body Control
Module (BCM), General Description ......... 9D-3
PASS-Key II System, Fuel Enable
Output, General Description ....................... 9D-4
PASS-Key II System,
General Description ............................. ;....... 9D-2
PASS-Key II System, Ignition Input,
PASS-Key II System, Ignition Key,
PASS-Key II System, Key Resistor
Inputs, General Description ........................ 9D-3
PASS-Key II System, Powertrain
Control Module (PCM), General
Description ................................................. 9D-4
PASS-Key II System, Security Indicator
Lamp Output, General Description ............ 9D-4
PASS-Key II System, .Starter Enable
Output, General Description ....................... 9D-3
PASS-Key II System,
System Components .................................... 9D-2
PASS-Key II System, System Operation .. 9D-2
PASS-Key II System, Theft Deterrent
Relay, General Description ......................... 9D-4
Passenger Inflator Module,
Passenger Seat Adjuster,
On-Vehicle Service ............................. , .. 10-10-18
Passenger Tire Service Description ............... 3E-2
Patch Panel, Fabricating a ........................ 10-1-11
Pedal Replacement, Accelerator,
Pedal, Brake, On-Vehicle Service ................... 5-9
Pedal, Brake, with Bracket,
OnVehicle Service ......................................... 5-5
Pedal, Clutch, On-Vehicle Service ............... 7C-9
PG-260 Starter Motor,
On--Vehiclc Service .................................... 6D2-7
Pinion Seal, Dust and Bearing
Annulus Assembly, Unit Repair ............. 3B lA-6
Pipe, Brake, On-Vehicle Service ................... 5-10
Pipe, EGR Valve Outlet, 3800 VIN K
Pipe, ECR Valve Outlet, 3800 VIN K
Pipe, EGR Valve, 5.7 Liter VIN P
Pipe, Engine Coolant Air Bleed,
Pipe, Exhaust, On-Vehicle Service................ 6F-5
Pipes, Automatic Transmission Oil Cooler
Upper and Lower, On-Vehicle Service .... 7 A-16
Piston and Connecting Rod Assemblies,
5.7 Liter VIN P Engine,
General Description ............... , ............... 6A3B-2
Piston and Connecting Rod Assembly,
5.7 Liter VIN P Engine, Cleaning,
Inspection and Repair .......................... 6A3B-24
Piston and Connecting Rod Assembly,
5.7 Liter VIN P Engine, Unit Repair .. 6A3B-19
Piston and Connecting Rod, 3800
VIN K Engine, Cleaning, Inspection
and Repair ............................................ 6A8B-23
Piston and Connecting Rod, 3800

Piston and Connecting Rod, 5.7 Liter
VIN P Engine, On-Vehicle Service,
General Description ............................. 6A3A-24
Piston Fitting, 3800 VIN K Engine,
Piston Noises ................................................... 6-9
Piston Ring Fitting, 3800 VIN K
Repair ................................... ;............... 6A8B-24
Piston, 5.7 Liter VIN P Engine,
Pistons and Connecting Rods, 3800
Pivot & (Pulse) Switch Assembly,
Unit Repair .............................................. 3F5B-9
Pivot and Switch Diagnosis .......................... 3-15
Placard, Tire, General Description ................ 3E3
Plastic Part Identification ......................... 10-1-11
Plastic Parts, How to Identify .................. 10-1-11
Plate (5-Speed), Clutch Driven,
On-Vehicle Service ....................................... 7C.9
Plate (6-Speed), Clutch Driven,
Plate and Hub Assembly, Compressor
Clutch, HD6/HR6 Unit Repair ................. 1D2-3
Plate and Hub Assembly, Compressor
Clutch, VS Unit Repair ............................ 1D3-2
Plate, Front Floor Console
Transmission Opening Trim, On-Vehicle
Service ....................................................... 8C-19
Plate, Front Side Door Lock Anchor,
Plate, Front Side Door Sill Trim,
Plate, Rear Brake Backing,
On Vehicle-Service ..................................... 5C2-6
Plate, Rear Brake Caliper Anchor
Bracket and Mounting, On-Vehicle
Service ...................................................... 5B2-8
Plates, Steering Unit Rack and Pinion
Support Mount, On-Vehicle Service ........ 10-3-4
Player and Cassette Care, Tape ................. 9A-15
Plenum Chamber, General Description .... 10-5-21
Plug, Engine Block Coolant Drain Hole ...... 6B-3
Plugs, Spark, Diagnosis .............................. 6D4-3
Plugs, Spark, General Description ............. 6D4-2
Plugs, Spark, On-Vehicle Service .............. 6D4-7
Pneumatic Comfort Controls Diagnosis .. 10-10-2
Pocket, Fuel Tank Filler,
Pocket, Map, On-Vehicle Service .............. 10-6-3
Positive Cable, On-Vehicle Service ......... 6D 1-10
Power Brake Booster Vacuum Check
Valve, General Description ....................... SD 1-4
Power Brake Booster Vacuum Hose and
Routing ................ '. ..................................... 5Dl-4
Power Brake Booster,
General Description .................................. SD 1-1
Power Brake Booster,
On-Vehicle-Service .................................... SD 1-1
Power Front Seat Adjuster Diagnosis ..... 10-10-2
BOOK 1 INDEX - 31
Power Front Seat Adjuster,

Power Rack & Pinion Steering Gear
Assembly, Unit Repair ............................ 3B1A-2
Power Steering Fluid Recdmmendations .... 3B-13
Power Steering Fluid Replacement ............... 3B-4
Bracket, On-Vehicle Service ...................... 3B-12
Hose, On-Vehicle Service ................... ,...... 3B-12
Power Steering Fluid Reservoir,
Power Steering Gear and Pump Leaks ........ 3-16
Power Steering Gear Diagnosis ..;................... 3-5
Power Steering .Gear Inlet and Outlet
Hoses, On-Vehicle Service .. ;................... ,... 3B-8
Power Steering Gear, General Description ... 3B-1
Power Steering Gear, On-Vehicle Servic~ .... 3B-7
Power Steering Pump Belt (Serpentine
Belt), On-Vehicle Service .... ;....................... 3B-4
Power Steering Pump Diagnosis ......... :..... ;..... 3-6
Power Steering Pump Pulley,
Power Steering Pump,
General Description ...................... :.............. 3B-1
Power Steering :Pump,
On-Vehicle Setvice ........................ ,............ 3B-10
Power Steering System Test Procedure ........ 3-16
Power Steering System, Bleeding Air
from the .................. ,..................................... 3B-4
Power Steering System, External Leakage
Check .................. ,...... ,.. ,...................... ,........ 3-16
Power Steering System, f<lushing the ........... 3B-4
Power Steering System>Lip Seals ................ 3-16
Power Steering System, 0-Ring Seals:.; ...... 3-16
Power Steering System; Seal
Replacement Recommendations .................. 3-16

Power Window Control Module,
General Description .......... ,.... , ........ 8C-2, 10-6-2
Power Window Control Module,
Powertrain Control Module (PCM),
PASS-Key II System, General
Description; ........... ;..................................... 9D-4
Precautions, Service, On-Vehicle Service .. 6D4-4
Preliminary Checks, Clutch System .............. 7C-2
Preliminary Inspections, Wheel
Alignment ................. ;............ ;..................... 3A-3
Pressure Bleeding , Antilock Brake
System .................................................... 5El-168
Pressure Bleeding, Antilock Brake
system with Traction Control ................ 5E2-228
Pressure Check, Wiper Arm Tip,
Off-Vehicle Service .............................. i ..... 8E-16
Pressure Regulator Valve,
. .
Automatic Transmission, On-Vehicle
Service ....................................................... 7 A-25
Pressure Relief, Fuel System, 3800
VIN K Engine, On-Vehide Service ....... 6A8A-2
Pressure Testing, Radiator ............................. 6B-4
Pressures, Tire; ................. ;'. .................. ,... ::.. 3E-14
Prevailing Torque Fasteners ....................... OA-10
Principle Components, Clutch System .......... 7C-1
Principle Components, Clutch System .......... 7C-1
Programming a New Body Control

Module (BCM), PASS-Key II System .... 9D-4
Programming Body Control Module ............ 9K-2
Programming Mode, Universal Theft
Deterrent System .......................................... 9D-7
Propeller Shaft and Universal Joint,
Diagnosis of ................................................. 4A-5
Propeller Shaft Balance Check,
On-Vehicle Service ...................................... 4A-7
Propeller Shaft Balance,
Propeller Shaft Balancing,
On-Vehicle Service ..................................... .4A-8
Propeller Shaft Joint, General Description .. .4A-2
. Propeller Shaft Runout Measurement,
Propeller Shaft Runout,
Propeller Shaft, General Description ........... .4A-1
Propeller Shaft, Vibration Diagnosis ............ OC-6
Protector, Door Edge,
Pulley, Power Steering Pump,
Pump Assembly, Hydraulic,
Unit Repair .............................................. 3B1B-7
Pump Assembly, CB Series Power
Steering, Unit Repair ............ ;................. 3B1B-2
Pump Assembly, Reverse Rotation
Power Steering, Unit Repair .................. 3B1B-6
Pump Driveshaft Assembly, 5.7 Liter
VIN P Engine, Recondition ................. 6A3B-32
Pump Reservoir Replacement,
Unit Repair .............................................. 3B1B-4
Pump Service, CB Series Power
Steering, Unit Repair ............................. , 3B lB-3
Pump Service, Reverse Rotation Power
Steering, Unit Repair, .............................. 3B1B-7
Pump Water, 5.7 Liter VIN P
Engine, Unit Repiur .............................. 6A3B-12
Pump, Coolant, 3800 VIN K
Pump, Folding Top with Motor,
Pump, Oil, 3800 VIN K. Engine,
Unit Repair ............................................ 6A8B-33
Pump, Oil, 5.7 Liter VIN P Engine,
Unit Repair ............................................ 6A3B-19
Pump, Power Steering, Diagnosis ... ,............... 3-6
Pump, Power Steering,
General Description ... ,................................. 3B-1
Pump, Power Steering,
Pump, Washer, Replacement,
Pump, Water, 5.7 Liter VIN P
Pump, Wl!ter, 5.7 Liter VIN P
Pump, Water, On-Vehicle Service ............... 6B-18
32 - BOOK 1
INDEX
Pushrod, Rocker Arm and, 3800 VIN. K

.. Repair
. ,. ............................... 6A8B-12
E11gme,
.
U mt
Pushrod, Valve, 5.7 Liter VIN P
Engine, .On-Yehicle Service ... ,.............. 6A3A-11
Pushrod, Valve, 5.7 Liter VIN P
Engine, Recondition............................... 6A3B-32
Pushrods, Valve Rocker Arms and, 3800
VIN K Engine, On 7Vehicle Service ...... 6A8A-9
Pus~ods~ ':7alve, 5.7 Liter VIN P Engine,
Unit Reparr ............................................ 6A3B-12
Q
Quarter. Belt Reveal Moldings and
Seals ......................................................... 10-9-30
Quarter Courtesy Lamp,
Quarter Inner Rear Trim Finishing
Panel, On-Vehicle Service ........................ 10-7-3
Quarter Inner Trim Finishing Panel
Speaker Grille, On-Vehicle Service.; ........ 10-7-6
- Quarter Inner Trim Finishing Panel,
On-Vehicle Service .. ;................................. 10-7-1
Quarter Outer Panel .Pressure Relief
Valve, On-Vehicle Service ...................... 10-7-10
Quarter Panel, Convertible,
Quarter Panel, On-Vehicle Service ............. 11-26
(With Lift-Off Windows), On-Vehicle
Service ...................................................... l 0-7-4
Quarters, Rear, General Description .......... 10-7-1
R
R-134a, Refrigerant,
General Description ................... ;.............. 181-11
Race, Inner, Unit Repair .......................... 3F5B-4
Rack & Pinion Boot, Unit Repair ...... ,.... 3B1A-4
Rack Bearing Preload, Unit Repair ......... 3B1A-4
Rack, Switch Actuator, Unit Repair ...... 3F5B-11
Radial Tire Lead/Pull..: .................................. 3-20
Radial Tire Road Test ................................... 3-20
Radial Tire Vibration ..................................... 3-20
Radiator Air Baffles and Deflectors
On-Vehicle Service .... ,.................... .'.......... 68-22
Radiator Air Lower Baffle and
Deflector, On-Vehicle Service ........ .; ......... 68-22
Radiator Air Lower Baffles and
Deflectors, General Description .................. 68-3
Radiator Air Lower Deflector,
On-Vehicle Service ........... ,............ :........... 10-5-3

Radiator Air Upper Baffle,
On-Vehicle Service; ....... :........................... 68-23
Radiator Drain Cock,
Radiator Drain Cock ..................................... 6B-2
Radiator Fill Cap; Diagnosis ........................ 6B-6
Radiator Fill Cap, General Description ....... 68-2
Radiator Support, On-Vehicle Service .......... 11-4
Radiator Upper Mounting Panel,
Radiator, Aluminum,
Radiator, Coolant, General Description ........ 68-2

Radiator, On-Vehicle Service ...................... 68-20
Rad~o Anti-Theft Feature, Setting ............ ,. 9A-12
Radio Co11trol Switch,
On-Vehicle Servke....... ,............................... 3F-11

Radio Controls, General Description ........... 9A-4
Radio Fixed Antenna Diagnosis ................ 9A-13
.. Radio Fixed Antenna,

Genera1 Descnptlon
. . .................................... 9A-2
Radio Fixed Antenna,
On-Vehicle. Service .................................... 9A-l6
Radio Front Side Door (Tweeter)
Speaker, On-Vehicle Service................... 10-6-23

Radio Fropt Side Door Speaker,
On-Vehicle Service ...... ,................ ;.......... 10-6-23
Radio Operation, Delco-GM/Bose
. Music System/Cassette (Chevrolet) ............ 9A-5
.
Music System/Cassette (Chevrolet) ............ 9A-5
Music System/Compact Disc
(Chevrolet) ......... ,... ,.................................... ; 9A-6
Ra.dio Operation, ETR AM/FM
Stereo/Cassette (Chevrolet) ................. :....... 9A-4
Radio Operation, ETR AM/FM
Stereo/Cassette Tape (Pontiac) ................... 9A-8
Radio Operation, ETR AM/FM
Stereo/Cassette Tape with Graphic
m Equalizer (Pontiac) ......... ,....................... 9A-9
Radio Operation,. ETR AM/FM
.
Stereo/Compact Disc (Chevrolet) ........... ,.. ; 9A-7
Radio Operation,. ETR AM/FM
s;reo/~ompact ~isc with Graphic
quahzer.(Pontiac) ................................... 9A-11
Ra.dio Power Antenna Care ........................ 9A-16
Radio Power Antenna Check ..................... 9A-14
Radio Power Antenna Lead,.,Jn Cable
Check ........................ ,., .................. :........... 9A-14
Radio Power An.tenna Mast,
Radio Power Antenna Mounting
and Connections, Diagnosis ...................... 9A-13
Radio Power Antenna,
General Description ......... ,.................. :... ;... 9A-2
Raqio Power Antenna,
Radio Quarter Speaker Grille,
.
On-Vehicle Service ........:....... :..... ,............. 10-7-5
Radio Quarter Speaker,

Radio Rear Speaker, On-Vehicle Service .. 10-7-7
Radio_ Speaker Diagnosis
(Cassette Only) ......... ,, ............................. ,. 9A-14
Radio Suppression Equipmen~,
On-Vehicle Service........ ,, ... ,, .................... 9A-16
Radio, AM/FM Stereo and Clock,
On-Vehicle Service ....... :............................... 8C-8
Radio, Determining Factory Backup
.
Unlocking Code for Secured .................... 9A-13
Radio, On-Vehicle Servic_e :..... :.................. 9A-16
Radio, Unlocking Secured after Power
Loss ........................ ,.................................. 9A-13
Radio, Unlocking;Secured ............ i .............. 9A-13
Rd'
.. al D.escnpt1011
' . ......................... 9A-2
a 10s, Gener
BOOK 1 INDEX - 33
Rail, Engine Compartment Front Outer

Side, On-Vehicle Service ............................. 11-5
Rail, Folding Top Side, On-Vehicle
Service ..................................................... 10-9-17
Rail, Folding Top, On-Vehicle Service .... 10-9-16
Rail, Front Wheelhouse Panel Upper
Side, On-Vehicle Service ............................. 11-8
Rail, Lower, On-Vehicle Service ................ 11-12
Rail, Upper, On-Vehicle Service ................... 11-5
Ratings, Battery ........................................'.. 601-2
Rattle (Balance Shaft) ................................... 6-10
Re-Synchronizing, Transmitter and Body
Control Module ..... .'..................................... 9K-3
Rear Axle Housing Cover and
Gasket, On-Vehicle Service ...................... .4B-12
Rear Axle Housing Replacement,
Unit Repair .... ;............................. :.............. 4B-25
Rear Axle Identification ............................... .4B-5
Rear Axle Lower Control Arm
Bushing, On-Vehicle Service ...................... 30-3
Rear Axle Lower Control Arm,
Rear Axle Lubricant Fill and Check,
Rear Axle Maintenance and Lubrication ...... 4B-5
Rear Axle Noises ........................................... 4B-6
Rear Axle Operation ...................................... 4B-3
Rear Axle Shaft Bearing and/or, Bearing
Seal, On-Vehicle Service .......................... .4B-13
Rear Axle Shaft Bearing Noise ................... .4B-6
Rear Axle Shaft, On-Vehicle Service ........ .4B-12
Re~ Axl~ Standard and Limited Slip
D1agnos1s ...................................................... 4B-8
Rear Axle ,Suspension,
Rear Axle Tie Rod, On-Vehicle Service ..... 30-5
Rear Axle Torque Arm Vibration
Dampener, On-Vehicle Service ................... 30-8
Rear Axle Torque Arm, On-Vehicle
Service ......................................................... 30-6
Rear Axle Usage Chart ............................... 4B-28
Rear Axle, On-Vehicle Service ......... ,......... 4B-15
Rear Axle, Rear Wheel Bolt/Screw,
Rear Brake Backing Plate,
On-Vehicle Service ........ ;............................ 5C2-6
Rear Brake Caliper Anchor Bracket ,
and Mounting Plate,
On-Vehicle Service ................................... 5B2-8
Re~ Br~e Caliper Inspection,
D1agnos1s ............... ;........................ ,........... 5B2-3
Rear Brake Caliper, On-Vehicle Service .... 5B2-3
Rear Brake Caliper, Unit Repair .. ,............ 5B2-11
Rear Brake Drum Adjustment,
On-Vehicle Service ..................................... 5C2-6
Rear Brake Drum Inspection, Diagnosis .... 5C2-1
Rear Brake Drum, On-Vehicle Service ...... 5C2-2
Rear Brake Drum, Unit Repair ................... 5C2-7
Rear Brake Rotor Inspection, Diagnosis .. ,.5B2-2
Rear Brake Rotor, On-Vehicle Service.:..... 5B2-8
Rear Brake Shoe Inspection, Diagnosis ..... 5C2-1
Rear Brake Shoes, On-Vehicle Service ...... 5C2-2
Rear Bumper Energy Absorber,
Rear Bumper Fascia Decal,

Rear Bumper Fascia,
Rear Bumper Impact Bar,
On-Vehicle Service ............... ;................. 10-4-11
Rear Bumper, On-Vehicle Service ............. 10-4-8
Rear Compartment Closeout Panel,
Rear Compartment Exterior Trim,
Rear Compartment Interior Trim,
Rear Compartment Lamp ........................ :..... 8B-4
Rear Compartment Lid Hinges,
Rear Compartment Lid Lock
Cylinder, On-Vehicle Service ................... 10-8-2
Rear Compartment Lid Lock Release
Actuator, On-Vehicle Service ................... 10-8-3
Rear Compartment Lid Panel and
Components, On-Vehicle Service ........... 10-8-20
Rear Compartment Lid Panel,
On-Vehicle Service .............................. 10-8-22
Rear Compartment Lid Release
Switch, General Description ........................ 8C-5
Switch, On-Vehicle Service ...................... 10-8-3
Switch, On-Vehicle Service ....................... 8C-25
Rear Compartment Lid Strut,
On-Vehicle Service .............. :.................. 10-8-20
Rear Compartment Lift Window Closeout
Panel, On-Vehicle Service ........................ 10-8-7
Hinges, On-Vehicle Service ..,.................. 10-8-12
Rear Compartment Lift Window Inner
Panel Cover, On-Vehicle Service ........... 10-8-16
Rear Compartment Lift Window Lock
Striker, On-Vehicle Service ...................... 10-8-2
Panel Adjustment, On-Vehicle Service .. 10-8-15
Panel and Components, On-Vehicle
Service ................................................... 10-8-12
Panel, On-Vehicle Service ...................... 10-8-14
Rear Compartment Lift Window Side
Finish Moldings, On-Vehicle Service .... 10-8-17
Strut, On-Vehicle Service ..... ,................. 10-8-13
Weatherstrip, On-Vehicle Service ............. 10-8-3
Rear Compartment Lift Window,
Rear Compartment Lock System,
, Rear Compartment Side Trim,
Rear Compartment Trim,
Re~ Dis~ Brake Pad Inspection,
D1agnos1s .................. ,.................... ;........... 5B2-2
Rear Disc Brake Pads,
On-Vehicle Service .................................... 5B2-7
34 - BOOK 1 INDEX
Rear End Finish Panel Emblem,

Rear End Finish Panel,
Rear End Spoiler (Convertible),
Rear End Spoiler (Coupe),
Rear End, Body, General Description ........ 10-8-2
Rear License Lamp, General Description .... 8B-3
Rear License Lamp, On-Vehicle .Service ... SB-12
Rear Quarter Center Molding,
Rear Quarter Courtesy Lamps ...................... 8B-4
Rear Quarters, General Description ........... 10-7-1
Rear Seat Belts, On-Vehicle Service ....... 10-11-4
Rear Seat Buckle-Side Belts,

Rear Seat Cushion,
Rear Seat Retractor-Side Belts,
On-Vehicle Service ............. ;.................... 10-11-5
Rear Seat Shoulder Belt Retractor
Bracket, On-Vehicle Service ................... 10-11-7
Rear Seat Shoulder Belt Retractor Trim
Cover, On-Vehicle Service ...................... 10-11-7
Rear Seat System, Restraint,
General Description ................................. 10-11-2
Rear Seat, General Description ................ 10-10-2
Rear Seat, On-Vehicle Service ............... 10-10-20
Rear Seatback Cushion,
Rear Seatback Lock and Striker,
Rear Shock Absorber,
Rear Sidemarker Lamps,
Rear Sidemarker Lamps,
On-Vehicle Service .................................... SB-13
Rear Spring Seat, On-Vehicle Service ......... 30-4
Rear Springs, On-Vehicle Service ................ 30-4
Rear Stabilizer Shaft Bracket and
Link, On-Vehicle Service .......................... 30-10
Rear Stabilizer Shaft, On-Vehicle Service ... 30-9
Rear Suspension Jounce Bumper,
Rear Thrust Angle Adjustment .................... 3A-6
Rear Trim and Covers,
Rear Wheel Bolt/Screw,
On-Vehicle Service ................................... 4B-16
Rear Wheel Cylinder,
On-Vehicle Service .................................... 5C2-5
Rear Wheel Cylinder, Unit Repair ............ 5C2-8
Rear Wheel Speed Sensor and Ring .......... 5El-7
Harness, On-Vehicle Service .................. 5El-174
Harness, On-Vehicle Service .................. 5E2-242
Ring, On-Vehicle Service ....................... 51-174
Rings, On-Vehicle Service ..................... 5E2-242
Rear Wheel Speed Sensor,

On-Vehicle Service ................................. 5E 1-17 4
Rear Wheel. Speed Sensor,
Rear Wheel Speed Sensors and Rings ..... 5E2-l O
Rear Wheelhouse, On~ Vehicle Service ....... 11-46
Rear Window Defogger Switch,
Rear Window Defogger,
On-Vehicle Service ................. ,... :............. 10-2-7
Rear Window Drain Panel Garnish
Molding, On~Vehicle Service ................... 10-8-7
Receiver and Dehydrator, Air
Conditioning Accumulator/, General
Description .............................................. 1Bl-l2
,
Conditioning, General Description .. ;.... ;...... lB-3
Conditioning, On-Vehicle Service .......... ;,.lB-26
Recliner, .Front Seat,
On-Vehicle Service................................ 10-10-l4
Recommendations for Reuse, Fastener ...... OA-lO
Recommended Fluids and Lubricants ......... OB-l2
Recovery, Refrigerant,
On-Vehicle Service..................................... 1B-l4
Reed Tachometer, General Description ... ;.... OC-1
Refilling and Draining, Cooling
System, On-Vehicle Service ........................ 6B-8
Refinishing - Basecoat/Clearcoat,
Metal Part .......................................... ,........ 10-1-8
Refinishing Front Brake Rotors,
Unit Repair ..................................... :........... 5Bl-7
Refinishing Rear Brake Drums,
Unit Repair ......................... ,...................... 5C2-7
Refinishing Rear Brake Rotors, .
Unit Repair ................................................. 5B2-9
Refinishing, Flexible Plastic Part Repair
and ........................................................... 10-1-ll
Refinishing, Flexible Plastic Part ............. 10-1-16
Refinishing, Rigid Plastic Part Repair
and ........................................ ................... ;.10-1-16
Refinishing, Rigid Plctstic Part ................ 10-1-19
Refrigerant. Evacuation,
On-Vehicle Service ........................ ,............ lB-16
Refrigerant Lines and Fittings, Handling ... lB-12
Refrigerant Oil Distribution ........................ 1B-17
Refrigerant Oil Loss Due to a
Large Leak ...................... ;; ............ ;.......... ,.lB-17
.Refrigerant R-134a,
Refrigerant Recovery and Recycling,
Adding Oil, Evacuating and
Recharging Procedures ................ ;............ lB-13
Refrigerant Recovery, On-Vehicle
Service, ........................... '............................ lB-14
Refrigerant-134a, Handling ......................... lB-11
Refrigerant-134a ...................................... ,...... 1B-2
Refrigeration System Services .................. lB-11
Refrigeration System, General Description .. lB-2
Refrigeration System,
Refrigeration System, Leak-Testing the ....... lB-8
Refrigeration System, Maintaining
Chemical Stability in the ........................... lB-12
BOOK 1 INDEX - 35
Regulator, Front Side Door Window,
Rehome Procedure, Antilock Brake
System ..................................................... 5El-168
Reinforcement, Floor Panel,
On-Vehicle Service ........................ ;........... 10-3-2
Relay (Enable), ABS/TCS,
Relay, (Enable) ABS/TCS ......................... 5E2-10
Relay, ABS, On-Vehicle Service............. 5El-175
Relay, ABS .................................................. ~el-7
Relay, Air Conditioning Compressor,
Relay, Air Conditioning Compressor,
On-Vehicle Service ................................... lBl-27
Relay, Blower Motor, General
Description ............................... :.................... lB-8
Relay, Blower Motor, On-Vehicle
Service ..................... :................................ lBl-27
Relay, Horn, On-Vehicle Service ................ 8B-18
Relay, Theft Deterrent, On-Vehicle
Service ......................................................... 9D-4
Relays and Switches, General Description ... lB-8
Relays, Hom and Parking Lamp, Universal
Theft Deterrent System ............................... 9D-7
Reminder, Key, Diagnosis ............................. 3-13
Remote Control Door Lock Transmitter,
General Description ..................................... 9K-2
Remote Control Door Lock
, Transmitter, Universal Theft Deterrent
System ........................................................ 9D-6
Remote Keyless Entry, Body Control
Module, General Description ...................... 9K-2
Remote Keyless Entry, Functional
Operation ..................................................... 9K-1
Remote Transmitter, Battery
Recommendation ......................................... 9K-3
Remote Transmitter, Battery Replacement .. 9K-2
Removal and Installation, Wheel .................. 3E-5
Repair Materials, Flexible Plastic Part .... 10-1-11
Repair Materials, Rigid Plastic Part ........ 10-1-17
Repair, Cleaning, Inspection and, 3800
VIN K Engine ....................................... 6A8B-20
Repair, Cradle-to-Body Fastener ................ 10-3-2
Repair, Flexible Plastic Part ...... '. .............. 10-1-15
Repair, Rigid Plastic Part ...... :.................. 10-1-17
Repair, Thread, 3800 VIN K Engine,
Repair, Thread ......................................... 6A8B-34
Repair, Tire .................................................... 3E-9
Repair, Wheel, On-Vehicle Service............... 3E-4
Repairing the Leak, Oil... ................................ 6-7
Repairs and Inspections Required After
an Accident, Supplemental Inflatable
Restraint (SIR) ........................................... 9J-51
Repairs, Adjustments and ............................. lA-9
Replacement Labels .................................... OA-18
Replacement Lock Cylinders ....................... OA-8
Replacement Procedures, A/C System........ lB-19
Replacement Tires ......................................... 3E-1
Replacement, Component,
Exhaust System ...................... :..................... 6F-3
Replacement, Generator,
Replacement, Seal, Power Steering .............. 3B-4

Replacement, Windshield,
Replacing Drums, Unit Repair ................... 5C2-8
Replacing Lost Ignition Keys ....................... 90-4
Replacing 0-Rings ....................................... lB-11
Reserve Capacity, Battery ........................... 601-2
Reservoir Replacement, Pump,
Unit Repair .............................................. 3B1B-3
Reservoir, Brake Master Cylinder,
Reservoir, Brake Master Cylinder,
Unit Repair ................................................... 5A-5
Reservoir, Coolant Recovery,
Reservoir, Filling Brake Master
Cylinder, On-Vehicle Service ...................... 5A-3
Reservoir, Power Steering Fluid,
Reservoir, Washer, Replacement,
On-Vehicle Service ............ ;....................... 8E-10
Resistor, Blower Motor,
Restraint (SIR), Supplemental
Inflatable Restraint (SIR) Handling ............ OA-1
Restraint Devices, General Description ......... 9J-2
Restraint System, General Description .... 10-11-1
Restraint System, General Service
Instructions .............................................. 10-11-2
Restraint System, Operational and
Functional Checks................................... 10-11-3
Restraint, Child, General Description ...... 10-11-2
Restraint, Child, Installation ..................... 10-11-8
Restraint, Front Seat System,
General Description .. .... . .. . .. ... .. ...... .... .. .. . 10-11-2
Restraint, Head, On-Vehicle Service ..... 10-10-12
Restraint, Rear Seat System,
General Description ................................ 10-11-2
Restraint, Supplemental Inflatable (SIR),
Retained Accessory Power,
Retainer, Battery Tray and Hold-Down,
Retainer, Roof Side Weatherstrip,
Retainers, Folding Top Front
Retainers, Folding Top Outer Arm
Retainers, Folding Top Side Rail
Retainers, Roof Lift-Off Window
Stowage, On-Vehicle Service ................... 10-8-9
Retractors, Emergency Locking,
Reverse Lockout (6-Speed),
Reverse Lockout Solenoid (6-Speed),
On-Vehicle Service .......... :......................... 7B-11
Pump Assembly, Unit Repair ................ 3B1B-6
Reverse Rotation Power Steering Pump
Service, Unit Repair ............................... 3B1B-7
36 - BOOK 1
INDEX
Right Exhaust Manifold, 5.T Liter

VIN P Engine, Unit Repair ..... :; ............ ,6A3B-3
Right Valve Rocker Arm Cover, 5.7 Liter
(3800 VIN K) ............................... :.. ;........ 6D5-2
(5.7L VIN P) .............................................. 605-6
Rigid Plastic Part Refinishing ................. ;10-1-19
Rigid Plastic Part Repair and
Refinishing ....................... .':;..................... 10-1-16
Rigid Plastic Part Repair .......................... 10-1-17
Ring and Sensor, Front Wheel Speed ........ 5El-7
Ring, Crankshaft Position Sensor Reluctor,
Recondition ...... :................... :: .............. 6A3B-31
Ring, Crankshaft Position Sensor
Reluctor, 5.7 Liter VIN P Engine,
Unit Repair ............... ;; ............... .-:........ 6A3B-l 7
Ring, Crankshaft Position Sensor
Reluctor, On-Vehicle Service .................. 604-14
Ring, Rear Wheel Speed Sensor
Toothed, On-Vehicle Service ................. 5El-174
Rings, Front Wheel Speed Sensor ........ ;;; ... 5El-7
Rings, Front Wheel Speed Sensor ............ 5E2-10
Rings, Rear Wheel Speed Sensor
Toothed, On-Vehicle Service ........ , ........ 5E2-242
Rings, Rear Wheel Speed Sensor ......... ;... ;5E2-10
Road Test, Propeller Shaft, Diagnosis ......... 4A-2
Road Test, Radial Tire .............. ;................... 3-20
Road Test, Vibration Complaint. .. ,.; ............. OC-3
Rocker Arm and Pushrod, 3800 VINK
Rocker Arm Covers And/Or Gaskets, 3800
VIN K Engine, Unit Repair .... ,............. 6A8B-12
Rocker Panel Molding, On-Vehicle
Service ..................................................... 10-5-24
Rod, Connecting, 5.7 Liter VIN P
Engine, On-Vehicle Service ............... 6A3A-24
Rod, Front Side Door Inside Handle,
Rod, Front Side Door Lock Cylinder,
On-Vehicle Service ........... ,...................... 10-6-29
Rod, Front Side Door Locking,
On-Vehicle Service .................. ;............... 10-6-28
Rod, Front Side Door Outside
Handle, On-Vehicle Service .................... 10-6-27
Rod, Hood Open Assist,
Rod, Inner Tie, Unit Repair ..................... 3B1A-4
Rod, Outer Tie, Unit Repair .......... ;......... 3B1A-3
Rod, Piston and Connecting, 3800
and Repair .................... ;.......................6A8B-23
Rod, Piston and Connecting, 3800
VIN K Engine, Unit.Repair ................. 6A8B-16
Rod, Piston and Connecting, S. 7 Liter
VIN P Engine, Unit Repair ................. ;6A3B-19
Rod, Piston. and Connecting,
Assemblies, 5.7 Liter VIN P Engine ... :.6A3B-2
Rod, Piston and Connecting,
Unit Repair, Cleaning Inspection and
Repair, 5.7 Liter VIN P Engine ......... 6A3B-24
Rod, Rear Axle Tie, On-Vehicle Service.: .. 3D-5
Rods, Pistons and Connecting, 3800

Roof Drip Scalp Molding,
On-Vehicle .Service.................................... 10-9-5
Roof Lift-Off Window Lock
Cylinder, On-Vehicle Service ................. 10-9-38
Roof Lift-Off Window Stowage
Retainers, On-Vehicle Service .................. 10-8-9
Roof Lift-Off Window, Adjustment.. ....... 10-9-36
Roof Lift-Off Window, Removal and
Installation ............................................... 10-9-36
Roof Lift-Off Window, Repair ............... ;.10-9-36
Roof Outer Panel, On-Vehicle Service ....... 11-23
Molding, On-Vehicle Service ................. 10-9-38
Roof Side Rail Weatherstrip
Retainer, On-Vehicle Service .................. 10-5-25
Roof................ ;............................................ 10-9-2
Rotation, Tire and Wheel Inspection and .... OB-8
Rotation, Tire and Wheel. ............................. 3E-8
Rotor and/or Bearing, Compressor
Clutch, HD6/HR6 Unit Repair ................. 1D2-4
Rotor and/ or Bearing, Compressor
Clutch, V5 Unit Repair ............................ 1D3-5
Rotor, Front Brake, General Description .... 5Bl-1
Rotor, Front Brake, Inspection,
Diagnosis .................................................... 5B 1-2
Rotor, Front. Brake, On-Vehicle Service ..... 5B 1-7
Rotor, Rear Brake, On-Vehicle Service ...... 5B2-8
Rotor, Rear Disc, Inspection, Diagnosis ...... 5B2-2
Rotors, Front .Brake, Burnishing,
Unit Repair ................................................. 5Bl-7
Rotors, .Front Brake, Refinishing,
Unit Repair ......................................... ;....... SB 1-7
Rotors, Rear Brake, Burnishing,
Unit Repair ............................... ;............... 5B2-11
Rotors, .Rear Brake, Refinishing,
.Unit Repair ......... ;.......................... , ............. 582-9
Runout Check, Tire ....................................... 3-20
s
Scan Tool Diagnostics, Supplemental
Inflatable Restraint (SIR) .......................... ,... 91-7
Scheduled Maintenance Service .................. ,.OB-1
Scrapping. Procedures, Inflatable
Restraint Steering Wheel Module ............... 3F-5
Screen, Oil Pump, 3800 VIN K
Screen, Oil Pump, 3800 YIN K
Screens, Air Inlet, On-Vehicle Service.'. .. 10-5-21
SDM, General Description ............................. 91-3
Seal Leak Detection, HD6/HR6 Compressor
Unit Repair ................................. ;.............. 1D2-8
Seal Leak Detection, V5 Compressor
Unit Repair ........ ,, ...'... ,.............. '., ............... 1D3-9
Seal Replacement Recommendations,
Power Steering System ................................ 3-16
Seal Replacement, Compressor Shaft,
HD6/HR6 Unit Repair ............... ,............. , 1D2-8
Seal Replacement, Compressor Shaft, V5
Unit Repair ................................................ 1D3-9
BOOK 1
Seal Replacement, Drive Shaft, Power
Steering pump, Unit Repair .................... 3B1B-4
Seal Replacement, Power .Steering ............... 3B-4
Seal, Case Extension Oil, On-Vehicle
Service ................ ;...................................... 7A-28
Seal, Crankshaft Front Oil, 3800 VIN K
Seal, Crankshaft Rear Main Oil, 3800
Seal, Crankshaft Rear. Oil, 3800 VIN K
Engine; On-Vehicle Service .................. 6A8A-33
Seal, Crankshaft Rear Oil, 5.7 Liter
VIN P Engine, On-Vehicle Service...... 6A3A-28
Seal, Differential Drive Pinion Gear Yoke
and, On-Vehicle Service ........................... .4B-14
Seal, Drive Shaft, Power Steering Pump,
Unit Repair .................................. ;............ 3B1B-7
Seal, Electrical Connector. and,
On-Vehicle Service ....................... ,.. ;......... 7 A-28
Seal, Front Cover Oil, 3800 VIN K Engine,
Unit Repair ............................................ 6A8B-14
Seal, Front side Door Inside Handle,
On-Vehicle Service ...................... ;........... 10-6-17
Seal, Hood Rear, On-Vehicle Service.: .... 10-5-19
Seal, Output Shaft On-Vehicle Service ........ 7B-8
Seal, Pinion, Dust and Bearing
Annulus Assembly, Unit Repair ,............ 3.BlA-6
Seal, Rear Axle Shaft Bearing
and/ or, On-Vehicle Service ...................... ..AB-13
Seal, Valve Stem Oil, 5.7 Liter
VIN P Engine, .On-Vehicle Service...... 6A3A-17
Sealing Strip, Auxiliary, Front Side
Door Bottom, On-Vehicle Service.......... 10-6-16
Sealing Strip; Front Side Door Window
Inner, On-Vehicle Service ............ ,... ;;; .... 10-6-15
Sealing Strip, Front Side Door. Window
Outer, On-Vehicle Service ...................... 10-6-14
Sealing, Front End ..................................... 10-5-21
Seals, Engine Front Cover Oil, 5.7
Seals, Front Side door Trim Panel
Retainer, On-Vehicle Service .................. 10-6-17
Seals, 0-Ring and Cylinder Line
Assembly, Unit Repair,., ... ;..... ,............... 3B1A-5
Seals, Valve Springs and Stem, 3800
Seat Belts, On-Vehicle Service ................ 10-11-3
Seat, Child, On-Vehicle Service ............... 10-11-8
Seat, Front, Diagnosis .............................. 10-10-2
Seat, Front, General Description .......... ,... 10-10-1
Seat, Front, On-Vehicle Service ............... 10-10-2
Seat, Rear Spring, On-Vehicle Service ........ 3D-4
Seat, Rear, General Description ............... 10-10-2
Seat, Rear, On-Vehicle Service .............. 10-10-20
Seat, Upper Bearing Race, Unit Repair.; 3F5B-4
Seatback, Front, On-Vehicle Service ....... 10-10-3
Seatback, Front ......................................... 10-10-1
Second Gear Start Switch (V6
Automatic), On-Vehicle Service ................. 8C-16
Secondary Air Injection (AIR)
System Monitoring ....................... ,................. 6-4
Sector, Switch Actuator, Unit Repair ..... 3F5B- l 1
Secure Loose Moldings .............................. 10-1-3
INDEX - 37
Security Indicator L.E.D. Output,

Universal Theft Deterrent System ............... 9D-7
Security Indicator L.E.D., Universal
Theft Deterrent System, On-Vehicle
Service ........................................................ 90-9
Security Indicator Lamp Output,
PASS-Key II System ................................ 90-4
Seepage, Water Pump Coolant. ..................... 6B-4
Sensing and Diagnostic Module
(SDM), On-Vehicle Service ........................ 9J-52
Sensor (5-Speed), Speed,
Sensor (6-Speed), Electronic Speed,
Sensor (VSS), Vehicle Speed,
Sensor Assembly, Front Wheel
Bearing and Speed, On-Vehicle Service. 5E-17 4
Sensor, Air Conditioning
Evaporator Temperature,
General Description .................................... lB-8
Sensor, Air Conditioning
Evaporator Temperature,
On-Vehicle Service ................................. lBl-27
Sensor, Air Conditioning Refrigerant
Pressure, General Description ..................... lB-8
Sensor, Air Conditioning Refrigerant
Pressure, On-Vehicle Service ................... lB 1-27
Sensor, Camshaft Position,
Sensor, Camshaft Position,
Sensor, Crankshaft Position, 5.7 Liter
VIN P Engine, Unit Repair.................. 6A3B-14
Sensor, Crankshaft Position,
Sensor, Crankshaft Position,
Sensor, Daytime Running Lamp (DRL)
Ambient Light, (Canadian Only),
General Description .................................... 8C-5
Sensor, Daytime Running Lamp Ambient
Light, On-Vehicle Service ......................... 8C-12
Sensor, Engine Coolant Temperature
(ECT), General Description ......................... 6B-3
Sensor, Engine Coolant Temperature
Gage, General Description .......................... 6B-3
Sensor, Heated Oxygen (H02S),
Monitoring ...................................................... 6-3
Sensor, Rear wheel Speed,
On-Vehicel Service ................................ 5E 1-174
Sensor, Rear Wheel Speed,
Sensor, Shock, Universal Theft
Deterrent System, General Description ...., .. 9D-6
Sensor, Shock, Universal Theft
Deterrent System, On-Vehicle Service ...... 9D-10
Sensor, Speed and Front Wheel
Bearing Assembly, On-Vehicle
Service .................................................. 5E2-241
Sensor, Speed, General Description .............. 9B-2
Sensor, System Knock,
38 - BOOK 1
INDEX
Sensor, Vehicle Speed, (VSS),

Sensors, Front wheel Speed ........................ 5E 1-7
Sensors., Front Wheel Speed ...................... 5E2-9
Serpentine Drive Belt and Drive Belt
Tensioner, 5.7 Liter VIN P Engine,
Serpentine Drive Belt and Tensioner,
3800 VIN K Engine,
On-Vehicle Service .............. ;................ 6A8A-2
Serpentine Drive Belt Inspection ................. OB-8
Serpentine Drive Belt, Diagnosis ................. 6B-6
Serpentine Drive Belt ................................... 6B-3
Service Parts Identification Label.. ............ OA-18
Service Precautions, Antilock Brake
System with Traction Control ............... 5E2-224
Service Precautions, Antilock
Brake System ......................................... 5El-164
Service Precautions, On-Vehicle Service ... 604-4
Service Precautions, On-Vehicle Service ..... 8C-7
Service Precautions, Supplemental
Inflatable Restraint (SIR) .... :....................... 91-50
Service, Door, On-Vehicle Service.............. 11-21
Servo, 2-4 Band, Automatic
Transmission, On-Vehicle Service ............ 7A-21
Set/Coast Button Switch,
Setting Radio Anti-Theft Feature ............... 9A-12
Setup and Maintenance, Station (ACR4) .. lB-13
Shaft Assembly, Steering, Unit Repair .. 3F5B-11
Shaft Lock., Unit Repair .......................... 3F5B-4
Shaft, Balance, 3800 VIN K Engine,
Cleaning, Inspection and Repair........... 6A8B~28
Unit Repair ............................................ 6A8B-l 7
Shaft, Propeller, Balance Check,
Shaft, Propeller, Balancing,
Shaft, Propeller, General Description ........... 4A-1
Shaft, Propeller, Replacement, .One
and Two-Piece, On-Vehicle Service ......... 4A-10
Shaft, Propeller, Runout
Measurement, On-Vehicle Service .............. 4A-5
Shaft, Propeller, 1\vo-Piece, Unit Repair... 4A-12
Shaft, Rear Axle, Bearing Noise ................. 4B-6
Shaft, Rear Axle, On-Vehicle Service ....... 4B-12
Shaft, Rear Stabilizer, On-Vehicle Service .. 3D-9
Shaft, Stabilizer, On-Vehicle Service ......... 3C-14
Shaft, Steering Gear Coupling,
Shield, Catalytic Converter Heat,
On-Vehicle Service .. ;.................................. 6F-11
Shield, Exhaust Heat,
Shield, Exhaust Muffler Heat,
Shield, Exhaust Pipe Heat,
On-Vehicle Service ................... ;......... ;....... 6F-12
Shield, Starter, On-Vehicle Service ............ 602-2
Shift Conditions, Automatic
Transmission On-Vehicle Service ............... 7A-2
Shipping Procedures for Live

(Undeployed) Inflator Modules .................. 91-54
Shipping Procedures, Inflatable
Restraint Steering Wheel Module ............... 3F-5
Shock Absorber and Spring,
Shock Absorbers Diagnosis ........................... 3-18
Shock Absorbers, Leaks ................................ 3-19
Shock Absorbers, Noisy ................................ 3-18
Shock Absorbers, Weak .......... ;..................... 3-[8
Shock Sensor, Universal Theft Deterrent
System, General Description.; .................... 9D-6
Shock Sensor, Universal Theft Deterrent
System, On-Vehicle Service ..................... 9D-l O
Shoe, Rear Brake, Inspection, Diagnosis ... 5C2-1
Shoe, Steering Wheel Lock,
Unit Repair ............................................. 3F5B-l 1
Shoes, Rear Brake, On-Vehicle Service ..... 5C2-3
Short Method, Windshield,
On~Vehicle Service ........................ ;........... 10-2-2
Shoulder Restraint Guide,
Side Door Opening Frame,
On-Vehicle Service ..................................... 11-l 6
Replacement, On-Vehicle Service ............. 11-l 6
Sectioning, On-Vehicle Service ................. 11-l 8
Side Window Defogger Outlet Duct,
On-Vehicle Service...... ;.............................. 8C-21
Rearview Mirror Selector and Door
Lock Switches, On-Vehicle Service ..... 10-6-l 9
SIR Coil Assembly, General Description ...... 91-3
SIR Component and Wiring Location
View, General Description ............................ 91-4
SIR Connector (Plastic Body and Terminal
Metal Pin) Repair ....................................... 91-66
SIR Connector Body Face Views .................. 91-8
SIR Diagnostic System Check ..................... 91-10
SIR System Wire Splice Repair .................. 91-67
SIR System, Disabling
the, ............................ 3F-4, 8C-7, 3F5B-4, 91-50
SIR System, Enabling
the, ............................ 3F-4, 8C-7, 3F5B-4, 91-50
SIR Wire Pigtail Repair ............................... 91-66
SIR Wire Repair ......................... ,.... ;............ 91-66
SIR, Alternative Repair Methods ................. 91-67
Skip Shift Solenoid (6-Speed),
On-Vehicle Service..................................... 7B- l 4
Finesse Polishing ..................................... 10-1-10
Solenoid (6-Speed), Reverse
Lockout, On-Vehicle Service ..................... 7B- l 1
Solenoid (6-Speed), Skip Shift,
Solenoid, ABS Hydraulic Modulator,
On-Vehicle Service................................. 5El-171
Solenoid, ABS Hydraulic Modulator,
Solenoid, Automatic Transmission Control
Lever, On-Vehicle ..................................... 7A-12
BOOK 1
Solenoid, Torque Converter Clutch and
Wiring Harness Replacement,
On-Vehicle Service .................................. 7A-28
Solenoids Control and Shift,
Spark Plug Replacement ......................... ;..... 08-8
Spark Plug Wire Harness Replacement,
On~Vehicle Service .................................. 604-4
Spark Plug Wire Harness, Diagnosis ......... 604-4
Spark Plug Wire Harness ................ ;.......... 604-2
Spark Plug Wire Inspection .......................... 08-8
Spark Plugs, Diagnosis ............................... 604-3
Spark Plugs, General Description .............. 604-2
Spark Plugs, On-Vehicle Service ............... 604-7
Speaker Diagnosis (Cassette Only),
Radio .......................................................... 9A-14
Speaker Systems, General Description ........ 9A-2
Speaker, Radio Front Side Door
(Tweeter), On-Vehicle Service ................ 10-6-23
Speaker, Radio Front Side Door,
Speaker, Radio Quarter,
Speaker, Radio Rear,
Speakers, On-Vehicle Service .................... 9A-16
Special Tool Ordering Information .............. OA-2
Specifications, Engine, 3800
VIN K Engine ....................................... 6A88-47
Speed Sensor (5-Speed),
Speed Sensor Reluctor Wheel,
Unit Repair ................................................. 48-20
Speed Sensor, General Description ............... 98-2
Spoiler (Convertible), Rear End,
Spoiler (Coupe), Rear End,

Spring Assembly, Tilt, Unit Repair ......... 3F5B-9
Spring, Shock Absorber and,
Spring, Upper Bearing, Unit Repair ........ 3F5B-4
Spring, Valve, 5.7 Liter VIN P
Springs, Rear, On-Vehicle Service ............... 30-4
Sprocket, Camshaft, 5.7 Liter VIN P
Sprocket, Crankshaft, 5.7 Liter VIN P
Sprockets, Camshaft and Crankshaft,
Recondition .......................................... 6A3B-32
Sprockets, Camshaft and Crankshaft,
Unit Repair .......................................... 6A3B-17
Sprockets, Timing Chain,
Crankshaft and Camshaft, 3800 VINK
Squeak and Rattle Diagnosis and Repair .. 10-1-7
Stabilizer Shaft Link,

Stabilizer Shaft, On-Vehicle Service ........... 3C-14
Stabilizer, Front Side Door Window,
INDEX - 39
Standard Rear Axle, General Description .... 4B-1

Starter Enable Output, PASS-Key II
Starter Enable Output, Universal Theft
Deterrent System, General Description ....... 90-7
Starter Motor Diagnosis .............................. 602-1
Starter Motor Lubrication,
Starter Motor Replacement,
Starter Motor, General Description ............. 602-1
Starter Shield, On-Vehicle Service ............. 602-2
Station (ACR4) Setup and Maintenance .... lB-13
Stationary Windows,
Steel Wheel Mounting Surface Check ......... 3E-9
Steering Column Diagnosis ............................. 3-7
Steering Column Diagnosis ............................. 3-9
Steering Column Housing Assembly,
Unit Repair ....... ;.....................................3F5B-11
Cylinder, PASS-Key II System ................ 90-2
Steering Column Lubrication ........................ 3F-2
Steering Column Pass Key Lock
Cylinder Set, Unit Repair ........................ 3F5B-4
Steering Column Removal .......................... 3F-12
Steering Column Tilt Wheel Release
Lever, On-Vehicle Service ........................... 3F-7
Steering Column, General Description ......... 3F-2
Steering Column, General Description .......... 9J-6
Steering Column, Parts .............................. 3F5B-2
Steering Gear Coupling Shaft,
On-Vehicle Service .................................... 3F-12
Steering Knuckle, On-Vehicle Service ....... 3C- l 4
Steering Shaft Assembly, Unit Repair .... 3F5B-11
Steering Unit Mounting,
On-Vehicle Service .................. ,................ 10-3-4
Steering Unit Rack and>Pinion Support
Mount Plates, On-Vehicle Service ........... 10-3-4
Steering Wheel Controls,
Steering Wheel Horn Switch,
On-Vehicle Service ...................................... 3F-9
Steering Wheel Lock Shoe,
Unit Repair ............................................. 3F5B-11
Steering Wheel, On-Vehicle Service........... 3F-10
Stereo Certification, AMAX,
Stereo, FM, General Description .................. 9A-3
Stereo/Cassette (Chevrolet), ETR
AM/FM, General Description ...................... 9A-4
Stereo/Cassette Tape (Pontiac), ETR
Stereo/Cassette Tape with Graphic
Equalizer (Pontiac), ETR AM/FM,
Stereo/Compact Disc (Chevrolet), ETR
Stereo/Compact Disc with Graphic
Equalizer (Pontiac), ETR AM/FM,
Stoplamp and Cruise Control
Switches, Adjustment ..................................... 5-9
Stoplamp and Cruise Control Switches,
General Description ....................................... 5-9
40 - BOOK 1 INDEX
Stoplamp, High-Mount,
General Description ................................. ;... 8B-3
Stoplamp, High-Mount,
Straps, Ground, On-Vehicle Service ........ 601-12
Strg Column Housing Support
Assembly, Unit Repair .......................... 3F5B-11
Striker, Front Side Door Interlock,
On-Vehicle Service ....................... :.......... 10-6-31
Striker, Front Side Door Lock,
Striker, Front Side Door Lock,
Striker, Rear Compartment Lift Window
Lock, On-Vehicle Service ......................... 10-8-2
Striker, Rear Seatback Lock and,
Strikers, Front Side Door Lock,
Stripes and Decals, General Description ... 10-1-2
Strut, Rear Compartment Lid,
Strut, Rear Compartment Lift
Stud, Weld, Replacement. ........................... 10-1-1
Studs, Valve Rocker Arm, 5.7 Liter
VIN P Engine, On-Vehicle Service..... 6A3A-12
Substandard or Contaminated Brake Fluid ..... 5-2
Substandard or Contaminated Brake Fluid .. 5A-2
Substitution Method, Tire .................. ;; .......... 3-23
Sunshade, On-Vehicle Service .................... I 0-9-2
Handling ...................................................... OA-1
(SIR), Accident With Deployment Component Replacement and
Inspections ................................................ 9J-51
(SIR), Accident With or Without
Deployment - Component Inspections ...... 9J-51
Supplemental Inflatable Restraint (SIR),
Circuit Description ............................ ......... 9J-10
(SIR), Component Description ..................... 9J-3
(SIR), Diagnostic Aids ................................ 91-10
(SIR), Diagnostic Trouble Codes ................. 9J-7
(SIR), Handling/Installation/Diagnosis ........ 9J-51
Notes on System Check Chart ................... 9J-10
Repairs and Inspections Required
After an Accident ...................................... 91-51
Scan Tool Diagnostics ................................... 91-7
Service Precautions .... ;................................ 91-50
System Description ............... ,........................ 91-2
Use of Special Tools ..................................... 91-7
Support Assembly, Strg Column

Housing, Unit Repair ............ ;; ............... 3F5B-11
Support, Front Side Door Window
Front Up Stop, On-Vehicle Service ....... 10-6-39
Support, Inside Rearview Mirror,
On-Vehicle Service...................:................. 10-2-6
Support;Radiator, On-Vehicle Servfoe ......... l 1-4
Suppression Equipment, Radio,
On-Vehicle Service.................................... 9A-16
Surface Level Contamination Repair ....... 10-1-10
Suspension, Rear Axle,
General Description .,.................................. 3D-1
Switch (Clutch Start Switch), Clutch
Pedal Position, On-Vehicle Service ............. 7C-9
Switch Actuator Rack, Unit Repair ........ 3F5B-11
Switch Actuator Sector, Unit Repair ...... 3F5B-11
Switch Adjustment, Dimmer,
Unit Repair ......................................... , ... 3F5B-15

Switch Adjustment 1 Ignition, . .
Unit Repair ............................................. 3F5B-15
Switch Assembly, Buzzer; Unit Repair ... 3F5B-4
Switch Assembly, Dimmer,
Unit Repair ............ ,...... ,......................... 3F5B-15
Switch Assembly, Ignition,
.
Unit Repair .................................. ;.......... 3F5B-15
Switch Assembly, Pivot & (Pulse),
Unit Repair .............................................. 3F58-9
Switch Assembly, Turn 'Signal,
Unit Repair ........ u.................................... 3F5B-4
Switch, Backup Lamp,
On-Vehicle Service .......................................78-9
Switch, Brake Pressure Differential
Warning, General Description ....................... 5-2
Switch, Clutch Anticipate,
Switch, Column-Mounted Dimmer,
Diagnosis .............................................:........ 3-15

Switch, Compartment Lamp,
Switch; Control and Vacuum Selector
Valve and/or Blower Motor,
Switch, Convertible Top,
On-Vehicle Service............... ,..................... 8C-16
Switch, Door Lock,
On-Vehicle Service ............... ,.................. 10-6-19
Switch, Engagement, On-Vehicle Service .... 98-3
Switch, Front Fog Lamp,
Switch, Hazard Warning,
.
On-Vehicle Service....................... ,........... :.... 3F-6
Switch, Headlamp and Instrument
Panel Dimmer, On-Vehicle Service ........... 8C-25
Switch, Headlamp and Instrument Panel
Lamp Dimmer, General Description ........... 8C-4
Switch, Ignition Switch and Dimmer,
On-Vehicle Service ............. ,. .. ,..................... 3F-5
Switch, Ignition, Diagnosis ........................... 3-12
Switch, ignition, General Description.;'., 6D4-3
Switch, Instrument Panel Compartment
Lamp, On-Vehicle Service, ........................ 8C-32
Switch, Off-On-Resume/Accelerate;
General Description .................................... :9B-2
BOOK 1 INDEX - 41
Switch, Outside Remote Control

Rearview Mirror Selector,
Switch, Park/Neutral Position, Adjustment
Using New Switch, On-Vehicle Service .. 7A-13
Switch, Park/Neutral Position, Adjustment
Using Old Switch, On-Vehicle Service; ... 7A-12
Switch, Park/Neutral Position,
Switch, Pivot and, Diagnosis ........................ 3-15
Switch, Pressure, On-Vehicle Service ........ 7A-26
Switch, Radio Control,
Switch, Rear Compartment Lid Release,
General Description ..................... ,................ 8C-5
Switch, Rear Compartment
Lid Release, On~ Vehicle Service .............. 10-8-3
Switch, Rear Compartment
Lid Release, On-Vehicle Service ...... ;....;.;;SC-25
Switch, Rear Defogger,
General Description .............................. :....... 8C-5
Switch, Second Gear Start (V6
Automatic), On-Vehicle Service ................ SC-16
Switch, Set/Coast Button,
General Description ................................~;; ... 9B-2
Switch, Side Window,
Switch, Steering Wheel Hom,
On-Vehicle Service .......... ;...... :...................... 3F-9
Switch, Tum Signal, Diagnosis .............. :...... 3-10
Switches, Compressor Control, HD6/HR6
Unit Repair ...... ;...................................... ,; 102-11
Switches, Compressor Control, V5
Unit Repair ............................................. , 103-10
Switches, Cruise Control,
General Description ..................... ;................ 9B-2
Switches, Cruise Control,
On-Vehicle Service .................................. :.... 9B-3
Switches, Door Jamb and Rear .Lid .
Release, Universal Theft Deterrent
System, General Description ..................... 9D-7
Switches,. Door Jamb, On-Vehicle
Service ...................................................... 10-5-22
Switches, Functional Control,
Switches, Instrument Panel,
General Description ................................... :.. 8C-4
Switches, Instrument Panel,
On-Vehicle Service ......................... ;........ ;.. SC-25
Switches, Relays and,
Switches, Stoplamp and Cruise
. Control, Adjustment. ............. :........................ 5-9
Switches, Stoplamp and Cruise Control.. .. ,.: .. 5-9
Switches, Traction Control,
On-Vehicle Service ..................................... SC-19
Symbols, Abbreviations and ......... ,......... ,... OA-15
System Components, Antilock Brake
System With Traction Control... ................ 5E2-8
System Components, Antilock Brake
System ........................................... ,............:5El-6
System Components, PASS-Key II
System ......................................................... 9D-2
System Components, Universal Theft

Deterrent System .......................................... 90-6
System Description, Supplemental
Inflatable Restraint (SIR) .............................. 9J-2
System Diagnosis, Lock .................................. 3-7
System Operation, Antilock Brake
System ........................................................ 5El-3
System Operation, Antilock Brake
System With Traction Control .................. 5E2-3
System Operation, Heater, Ventilation and
Air Conditioning ........................................... I B-2
System Operation, PASS-Key II
System ..........;............................................... 90-2
System Operation, Universal Theft
Deterrent System .......................................... 90-5
System, PASS-Key II, General
Description ................................................... 90-2
System, Refrigeration,
System, Restraint, General Description ... 10-11-1
System, Vacuum, General Description ......... lA-3
System, Vacuum, General Description ....... lBl-5
Systems, Speaker, General Description ,....... 9A-2
T
Tachometer, Reed, General Description ....... OC-1
Taillamp Closeout Filler,
Taillamp Filler, On-Vehicle Service ........... 10-8-5
Taillamps, General Description ..................... 8B-3
Taillamps, On-Vehicle Service .................... 88-13
Tank, Inlet, Radiator, General Description ... 6B-2
Tank, Outlet, Radiator,
Tank, Vacuum, On-Vehicle Service ............ 1A-18
Tape Error Indicator, Diagnostic, ETR
AM/FM Stereo/Cassette Tape (Pontiac) ...... 9A-9
Tape Error Indicator, Diagnostic, ETR
Graphic Equalizer (Pontiac) ..................... 9A-10
Tape Player and Cassette Care ................... 9A-15
Tape Player, Cassette ETR
AM/FM Stereo/Cassette (Chevrolet),
Tape Player, Cassette, Delco-GM/Bose
Music System/Cassette (Chevrolet),
Tape Player, Cassette, ETR
Tape Player, Cassette, ETR
General Description ............................... ;9A-10
Tapered Roller Bearing Diagnosis ................ 3-23
TCS Hydraulic Modulator,
Unit Repair ............................................. 5E2-246
Assembly, . On-Vehide Service .............. 5E2-234
Assembly ........................ ,........................... 5E2-8
42 - BOOK 1 INDEX
Tech 1 Diagnostics, Antilock Brake
System With Traction Control... .............. 5E2-11
Tech 1 Diagnostics, Antilock
Brake System ............................................. 5El-9
Temperature Check, Heater Output. ............. lA-8
Temperature Control Cable Adjustment ...... lA-9
Temperature Control Cable,
Temperature Control Knob,
Temperature Control,
General Description. ................................... lBl-3
Temperature Valve and Heater Core,
Temperature Valve and Heater Core,
General Description ..........~ ........................ lB 1-5
Tensioner Assembly, Accessory Drive
Belt, 3800 VINK Engine,
Unit Repair .......................................... 6A8B-10
Tensioner, Drive Belt, and Belt Serpentine
Drive, 5.7 Liter VIN P Engine,
Tensioner, Serpentine Drive Belt and,
3800 VINK Engine,
Terminal Position Assurance (TPA) ............. 9J-67
Test Procedure, .Power Steering System ....... 3-16
Test, AJC Performance .............................. lBl-17
Test, Battery Parasitic Load ....................... 601-4
Test, Battery, Alternate Parasitic Load ...... 601-5
Test, Cylinder Leak ....................................... 6-11
Test, Engine Compression ............................. 6-11
Test, Functional, Heater and Ventilation ...... lA-6
Test, No Load, Unit Repairo. ..................... 602-7
Testing the Coolant Concentration ............. 6B-23
Testing, Battery ........................................... 601-3
Testing, Pressure, Radiator ........................... 6B-4
Theft Deterrent Relay, On-Vehicle
Service ....... ,.................................................. 9D-4
Theft Deterrent Relay, PASS-Key II
System, General Description ...................... 9D-4
Theft Deterrent System, Universal,
Theft Prevention, Federal Vehicle
Standard .... :.................................................. OA-2
Thermostat, Coolant Outlet Housing
and, 3800 VIN K Engine,
Unit Repair ....... ,................... ;................ 6A8B-8
Thermostat, Engine Coolant,
Thermostat, Engine Coolant,
On-Vehicle Service .................... ;............... 6B-16
Thermostatic Expansion Valve,
General Description.:.; ..... ;............................ lB-7
General Description .................................. lBl-11
Thread Locking Fasteners, Doors,
General Description: ................................ ;.10-6-2
Thread Repair, 3800 VIN K Engine,
On-Vehicle Service ....................... ;....... 6A8A-36
Thread Repair, 5.7 Liter VIN P
Engine, On-Vehicle Service ................. 6A3A-3 l
Thread Repair ......................................... 6A8B-34

Thread Size Information, Metric ... 103-1, 1D2-1
Throttle Body and Cruise Control
Cables, Adjustment Procedure,
On~Vehicle Service ............................... 5E2-236
Throttle Body, 3800 VIN K Engine,
Unit Repair .............................................. 6A8B-8
Throttle Cable Replacement,
Throttle Positions, Automatic
Transmission On-Vehicle Service ............... 7A-2
Thrust Angle, General Description .............. 3A-3
Tilt Spring Assembly, Unit Repair .......... 3F58-9
Timing Chain and Sprockets, 3800
and Repair ........................................... 6A8B-28
Timing. Chain and Sprockets, 3800
Timing Chain, Crankshaft and
Camshaft Sprockets, 3800 VIN K
Timing Gear or Chain and Sprocket Noise ... 6-9
Timing, Ignition, General Description ....... 6D4-3
Tire and Wheel Alignment Specifications ... 3A-6
Tire and Wheel Balance; ............................... 3-20
Tire and Wheel Inspection and Rotation ..... 08-8
Tire and Wheel Rotation:; ............................. 3E-8
Tire and Wheel, Balancing ......................... 3E-1 l
Tire Chain Usage ......................... :................. 3E-3
Tire Force Variation Check ........................... 3-23
Tire Inflation, On-Vehicle Service ................ 3E-4
Tire Information, Differential Ratios and .... OA-4
Tire Mounting and Dismounting .................. 3E-8
Tire Placard, General Description ................. 3E-3
Tire Pressures ............................................... 3E-14
Tire Repair ..................................................... 3E-9
Tire Runout Check ........................................ 3-20
Tire Service Description, Passenger ............. 3E-2
Tire Substitution Method .............................. , 3-23
Tire Waddle Complaint ........... :..................... 3-19
Tire, Compact Spare .................................... 3E-10
Tire, Radial, Lead/Pull .. ,............................... 3-20
Tires, All Season, General Description ........ 3E-2
Tires, Correcting Non-Uniform .. ;............... 3E-12
Tires, frregular or Premature Wear ............... 3-19
Tires, P-Metric, General Description ............ 3E-2
Tires, Replacement, General Description ..... 3E-1
Toe, General Description .............................. 3A-l
Tool, Special Ordering Information ............. OA-2
Tools and Shop Equipment, 3800 VIN K
Top, Folding (Convertible),
On-Vehicle Service .......... ,......................... 'I 0-9-5
Top, Folding, Complete Replacement ...... 10-9-34
Top, Folding, Downstop Adjustment. ...... 10-9-35
Top, Folding, Operation ............................. 10-9-5
Top, Folding, Upstop Adjustment.. ....... ,.. 10-9-35
Torque and Engine Speed Sensitive,
Torque and Vehicle Speed Sensitive,
Vibration Diagnosis ............................. :........ OC-6
Torque Converter Clutch Diagnosis,
Automatic Transmission .............................. 7A-9
BOOK 1 INDEX - 43
Torque Converter Clutch Electrical

Controls, Automatic Transmission,
General Description ................................... 7A-9
Torque Converter Clutch Solenoid and
Wiring Harness Replacement,
On-Vehicle Service .................................. 7A-28
Torque Sensitive, Vibration Diagnosis .......... OC-4
Traction Control Switches,
Transmission Automatic Diagnosis ...... 7A-14A-1
Transmission (RPO M49), 5-Speed
Manual, General Description ....................... 7B-1
Transmission (RPO M49), 5-Speed
Manual, On-Vehicle Service ...................... 7B-14
Transmission (RPO MM6), 6-Speed
Manual, General Description ....................... 7B-1
Transmission (RPO MM6), 6-Speed
Manual, On-Vehicle Service ................... ~ .. 7B-16
Transmission Converter Cover,
Transmission Definitions ........... ;.................. 7A-2
Transmission EngineWiring Harness
(3800 VIN K) ................ :...... ;................... 6D5-8
(5.7 VIN P) ............................................... 6D5-9
Transmission Fluid Checking and
Filling Procedures ....................................... 7A-3
Transmission Fluid Fill Tube,
On-Vehicle Service......... ;.......................... 7A-18
Transmission Fluid Level,
Checking Manual ............................ ;............. 7B-4
Transmission Identification Information ...... 7A-2
Transmission Identification ........................... OA-4
Transmission Oil Cooler,
Transmission Service ..................................... OB-8
Transmission Support and Transmission
Mount, On-Vehicle Service.......................... 7B-4
Transmission Usage ...................................... OA-4
Transmission Ventilation Hose;
Transmission, Automatic,
Transmitter and Body Control
Module, Re-Synchronizing .......... ;............... 9K-3
Transmitter, Remote Control Door Lock,
General Description ..................................... 9K-2
Transmitter, Remote Control Door
Lock, Universal Theft Deterrent
System, General Description ..................... 9D-6
Tray, Battery Replacement ..................... ;; .. 6Dl-8
Tray, Battery, and Hold-Down Retainer,
General Description ................................... 6Dl-3
Tray, Battery, On-Vehicle Service ............... 6B-20
Tray, Front Floor Console Tape
Storage, On-Vehicle Service ...................... 8C-15
Tread Wear Indicators ................................... 3-19
Trim and Covers,. Rear, On-Vehicle
Service ................................................... 10-10-22
Trim Covers, On-Vehicle Service ............ 10-10-5
Trim Height.................................................... 3-25
Trim, Exterior, On-Vehicle Service .......... 10-7-11
Trim, Front Side Door Exterior,
Trim, Front Side Door Interior,

Trim, Interior, On-Vehicle Service............. 10-7-1
Trim, Rear Compartment Exterior,
Trim, Rear Compartment Interior,
Trim, Rear Compartment Side,
Trim, Rear Compartment,
Troubleshooting, Lighting System,
Diagnosis ...................................................... 8B-4
Tube, Air Conditioning Evaporator,
Tube, Air Conditioning Receiver and
Dehydrator, On-Vehicle Service ................ lB-23
Tube, Oil Level Indicator and, 3800
Tube, Oil Level Indicator, 5.7 Liter
VIN P Engine, On-Vehicle Service ....... 6A3A-5
Tube, Transmission Fluid Fill,
Tum Signal and Headlamp Dimmer Switch
and Cruise Control Actuator and
Windshield Wiper and Windshield
Washer Lever, On-Vehicle Service .......... 3F-6
Tum Signal Cancelling Cam
Assembly, Unit Repair ............................. 3F5B-4
Tum Signal Lamp Flasher,
Tum Signal Lamp Flasher,
On-Vehide Service .................................... 8B-14
Tum Signal Switch Assembly,
Unit Repair ............................................... 3F5B-4
Tum Signal Switch Diagnosis ...................... 3-10
Two Piece Propeller Shaft, Unit Repair .... .4A-12
TXV NC System, General Description ....... lB-3
u
Underbody Flush, General Description ..... 10-3-3
Universal Joint, General Description ........... .4A-2
Universal Joints, Unit Repair ..................... .4A-12
Universal Joints, Vibration Diagnosis ........... OC-7
Arming the System ...................................... 90-5
Universal Theft Deterrent System, Body
Control Module (BCM),
Customization Charts ................................... 90-7
Deactivating the Alarm ................................ 90-6
Disarming the System.................................. 90-6
Feature Custimization .................................. 90-7
Universal Theft Deterrent System, Fuel
Enable Output .............................................. 90-7
Locking without Arming ............................. 90-6
44 - l~OOK 1 INDEX
Programming Mode...................................... 9D-7
Univers.al Theft Deterrent System,
Security Indicator L.E.D.Output.. ............... 9D-7
Univers.al Theft Deterrent System, Starter
Enable Output, General Description ........... 9D-7
Univ~rsal Theft Deterrent System,
System Components ............ :....................... 9D-6
System Operation ........................................ 9D-5
Unlocking Secured Radio after
Power Loss ........................................ ;....... 9A-13
Unlocking Secured Radio ........................... 9A-13
Upper Bearing Inner Race Seat,
Unit Repair ........... ,.................................. 3F5B-4
Upper Bearing Spring, Unit Repair ......... 3F5B-4
Upper Column, Unit Repair ..................... 3F5B-4
Upper Intake Mru:iifold, 3800 VINK
Upper Intake Manifold, 3800 VIN K
Upper Rail, On-Vehicle Service ............. ,...... 11-5
Usage, Transmission ..................................... OA-4
Use. of Special Tools, Supplemental
Inflatable Restraint (SIR) .............................. 91-7
v
V5 Compressor - Theory of Operation ..... 1D3-1
Vacuum Actuators, On-Vehicle Service ..... lA-19
Vacuum Harness, On-Vehicle Service ........ lA-18
Vacuum System, General Description .......... lA-3
Vacuum System, General Description ........ lBl-5
Vacuum Taruc, On-Vehicle Service ............ lA-18
Valve and Heater Core, Temperature,
General Description ................. u, ............... lBl-5
Valve and Heater Core, Temperature ........... lA-4
Valve and/or Blower Motor Switch,
Control and Vacuum Selector,
Valve Assembly, Compressor
Control, Unit Repair .................:...... ;.. ;... 103-11
Valve Assembly, Control, Unit Repair .... 3B lB-6
Valve Lifter Diagnosis, 3800
VIN K Engine ..................... ,................. 6A8B-32
Valve Lifters, 3800 VIN K. Engine,
On-Vehicle Service .......... ;..................... 6A8A-11
Valve Lifters, 3800 VIN K Engine,
Unit Repair ............................................. 6A8B-13
Valve Lifters, 5.7 Liter VIN P
Engine, 011-Vehicle Service ................. 6A3A-12
Valve Lifters, 5.7 Liter VIN P
Engine, Recondition ... ,...................... , ... 6A3B-32
Valve Lifters, 5.7 Uter VIN P
Valve Mechanism or Valve Train
Noises .............................................................. 6-9
Valv.e Rocker Arm Covers, 3800
VIN .K Engine, On-Vehicle Service ...... 6A8A-8
Valve Rocker Arm Covers, 5.7
Liter VIN P E:ngine,
On-Vehicle Service ............................. 6A3A-10

Liter VIN P Engine, Unit Repair ........ 6A3B-11
Valve Rocker Arm Studs, 5.7 Liter
VIN P .Engine, On-Vehicle Service ..... 6A3A-12
Valve Rocker Arms and Pushrods, 3800
VINK Engine, On-Vehicle Service ....... 6A8A-9
Valve Rocker Arms and Pushrods, 5.7
Liter VIN P Engine,
Pushrods, 5.7 Liter VIN P Engine,
Recondition ................................. ;........ 6A3B-32
Pushrods, 5.7 Liter VIN P Engine,
Unit Repair ;............................. ;.... ;...... 6A3B-12
Valve Spring and Valve Stem Oil Seal,
5.7 Liter VIN P Engine, On-Vehicle
Service ............................. ;................... 6A3A-17
Valve Spring Installed Height,
3800 VIN K Engine ............................. 6A8B-32
Valve Springs and Stem Seals, 3800
VINK Engine, On-Vehicle Service ..... 6A8A-23
Valve Stem Height, 3800 VIN K
Engine .................................................... 6A8B-32
Valve Train, 5.7 Liter VIN P Engine,
General Description ................................ 6A3B-2
Valve, Air Conditioning Compressor
Pressure Relief ................................. ;; .......... lB-8
Valve, Air Inlet, General Description......... IE 1-5
Valve, Bi-Level, General Description ....... ,.lBl-8
Valve, Brake Combination,
General Description ............ ,.......................... 5-2
On-Vehicle Service....................................... 5-14
On-Vehicle Service ................ ;................ 5El-175
Valve, Brake Combination .......................... 5El-7
Valve, Brake Combination ........................ 5E2-10
Valve, Brake Proportion,
General Description .............................. ;........ 5-2
Valve, Compressor Pressure Relief;
HD6/HR6 Unit Repair .............................. 1D2-10
Valve, Compressor Pressure Relief,
V5 Unit Repair ............... ;...................... ; 1D3-10
Valve, EGR, 3800 VIN K Engine,
Unit Repair ............................................... ;6A8B-3
Valve, Heater and Defrost,
Valve, Hydraulic Pump Flow
Control, On-Vehicle Service ........................ 3B-9
Valve, Oil Filter Adapter and Pressure
Relief, 3800 VIN K Engine,
Unit Repair .......................................... 6A8B-13
Valve, Oil Filter Adapter and Pressure
.
Relief, 3800 VINK Engine,
On-Vehicle Service .... ;......................... 6A8A-26
Valve, Pressure Regulator,
On-Vehicle Service................................... 7A-25
Valve, Quarter Outer Panel Pressure
Relief, On-Vehicle Service ..................... 10-7-10
BOOK 1
Valve, Thermostatic Expansion,

General Description ...................................... 18-7
On-Vehicle Service ........................ /............ 1B-25
Valves, ABS Hydraulic Modulator
Bleeder, On-Vehicle Service .................. 5E 1-171
Valves, ABS Hydraulic Modulator
Bleeder, On.,Vehicle Service .................. 5E2-232
VDOT A/C System Diagnostic Charis ..... lB 1-19
VDOT A/C System, General Description ..... lB-3
Vehicle Identification Number ..................... OA-2
Vehicle Speed Sensitive Only,
Vibration Diagnosis.. ;................................... OC-5
Vehicle Speed Sensitive,
Vehicle Speed Sensor (VSS);
General Description ..................................... ;9B-2
Vehicle Speed Sensor (VSS),
On-Vehicle Service ......................... '. ......... 7A-19
Ventilation, General Description ................. 1B 1-9
Ventilation, System, Distributor,
Ventilation ..................................................... lA-6
Vibration Analysis, Noise and,
Automatic Transmission .............................. 7A-3
Vibration Complaint, Test, Road ................... OC-3
Vibration Diagnosis, briveline Angles ......... OC-7
Vibration Diagnosis, Engine
Speed Sensitive Only ...................... ., ........... OC-5
Vibra~i?n Diagnosis, Engine Speed
Sens1t1ve ........................................................ OC-4
Vibra~i?n Diagnosis, Jounce or Load
Sens1t1ve ........................................................ OC-4
Vibration Diagnosis, Propeller
Shaft Balance ............................................... OC-6
Vibration Diagnosis, Propeller
Shaft Runout ................................................ OC-6
Vibration Diagnosis, Propeller Shaft ............. OC-6
Vibration Diagnosis, Torque and Engine
Speed Sensitive ............................................ OC-6
Vibration Diagnosis, Torque and Vehicle
Speed Sensitive ............................................OC-6
Vibration Diagnosis, Torque Sensitive .......... OC-4
Vibration Diagnosis, Universal Joints ........... OC-7
Vibration Diagnosis, Vehicle Speed
Sensitive Only .............................................. OC-5
Vibration Diagnosis, Vehicle Speed
Sensitive ......................................................... OC-4
Vibration, Classifying a Complaint. .............. OC-3
Vibration, General Description ...................... OC-1
Vibration, Radial Tire .................................... 3-20
w
Waddle Complaint, Tire ................................ 3-19
Warning Lamps ............................................ 5El-7
Warning/Indicator Lamp Operation,
Antilock .......................................................... 5-3
Warning/Indicator Lamp Operation, Brake ..... 5-3
Warning/Indicator Lamps, On-Vehicle
Service .................................................... 5El-175
INDEX - 45
Warning/Indicator Lamps,
On-Vehicle Service .... ;........................... 5E2-242
Warning/Reminder Chimes............................. 8C-7
Washer Pump Replac~ment,
On-Vehicle Service ...... , ........ :.................... 8E-10
Washer Reservoir Replacement,
On-Vehicle Service .......... -' .............. :......... 8E-10
Washer, Windshield, On~Vehicle Service ... 8E-13
Water Pump Coolant Seepage....................... 6B-4
Water Pump, 5.7 Liter VIN P
Engine, On-Vehicle Service .......... ,....... 6A3A-13
Engine, Recondition ............................. ,6A3B-32
.
Engine, Unit Repair ...... ;................. :., ... 6A3B-12
Water Pump, On-Vehicle Service ............ :.. 68-18
Waterleak Correction ............ ,..................... 10-2-5
Waterleak Diagnosis and Repair ..... ,.......... 10-1-4
Wear Indicators, Tread .................................. 3-19
Wear, Irregular or Premature, Tires .............. 3-19
Weatherstrip, Folding Top Front;
Weatherstrip, Folding Top Outer
Arm, On-Vehicle Service ....................... : 10-9-27
Weatherstrip, Folding Top Side Door
Lower, On-Vehicle Service ........... ;......... 10-9-29
Weatherstrip, Folding Top Side Rail,
On-Vehicle Service ........... ;; .................... 10-9-26
Weatherstrip, Front Side Door,
On-Vehicle Service ............................ ,.... 10-6-14
Weatherstrip, Rear Compartment Lift
Window, On-Vehicle Service .................... 10-8-3
Weatherstrips and Garnishes, Folding
Top, General Description ........................ 10-9-26
Weights, Wheel Balance ............................. 3E- l 2
Weld Stud Replacement ............................. 10-1-1
Wheel Alignment, Preliminary
Inspections .................................................... 3A-3
Wheel Balance Weights .............................. 3E-12
Wheel Bolt Replacement,
On-Vehicle Service ...................................... 3E-4
Wheel Mounting Surface Check, Steel ........ 3E-9
Wheel Nuts and Bolts, Metric,
Wheel Porosity Repair, Aluminum ............. 3E-13
Wheel Refinishing, Aluminum ................... 3E-13
Wheel Removal and Installation ................... 3E-5
Wheel Repair, On-Vehicle Service ............... 3E-4
Wheel Runout, Measuring,
Wheel Speed Sensor Jumper Harness ........ 5El-7
Wheel Speed Sensor Jumper Harness ...... 5E2-10
Wheel, Steering, On-Vehicle Service .......... 3F-10
Wheelhouse, Front, On-Vehicle Service ...... 11-13
Wheelhouse, Rear, On-Vehicle Service ....... 11-46
Wheels, Aluminum, On-Vehicle Service .... 3E-13
Wheels, General Description ......................... 3E-4
Windnoise Diagnosis and Repair ............... 10-1-6
Window, Adjustment, Roof Lift-Off ........ 10-9-36
Window, Folding Top, Rear,
Window, Front Side Door,
46 - BOOK 1 INDEX
Window, .Rear Compartment Lift,
On,:.Vehicle Service .................................. 10-8-17
. Window, Repair, Roof Lift-Off ................ 10-9-36
Window, Roof Lift-Off, Removal and
Installation ....................... ,.................. :..... 10-9-36
Windows, Stationary,
General Description ............. ,..... '. ........... ,... 10-2-1
Windshield Defroster Nozzle and Air
Distributor, On-Vehicle Service ................ 8C-19
Windshield Glass Cleaning,
Off-Vehicle Service ................................. ;.. 8E-16
Windshield Replacement,
.
.
On-Vehicle Service ................................ ;.... 11-25
Windshield Reveal Molding,
General Description .........................;.... ;.... 10-2-1
Windshield Reveal Molding,
On-Vehicle Service .................................... 10-2-l
Wmdshield Side Upper Garnish Molding
(With Lift-Off Windows),
Windshield Side Upper Garnish
Molding (Without Lift-Off
Windows), On~Vehicle Service ... ;........... 10-9-4
Windshield Washer, OnNehicle Service ..... 8E-13
Windshield Wiper/Washer System,
General. Description ...................................... 8E-1
Windshield Wiper/Washer System,
System Diagnosis ......................................... 8E-3
Windshield Wiper/Washer System ................ 8E-1
Windshield, General Description ................ 10-2-2
Wiper Arm Replacement,

On-Vehicle Service............. , ..................... ;.8E-10
Wiper Arm Tip Pressure Check,
Wiper Blade Assembly Replacement,
On-Vehicle Service ............. ;... :................... 8E-11
Wiper Blade Element Replacement,
On~Vehicle Service,.................................... 8E-13
Wiper Chatter Repair,
Off-Vehicle Service ........... ,........................ 8E-16
Wiper.Linkage Assembly
Replacement, On-Vehicle Service ............. 8E-14
Wiper Motor Assembly
Replacement, On-Vehicle .Service ............. 8E-13
Wiper Motor Cover Assembly
Replacement, Off-Vehicle Service.......... :.. 8E-15
Wire Pigtail Repair, SIR ...... ,., ..................... 91-66
Wire Repair, SIR .............. ;.; .... ;.;~ ................ 91-66
Wire Splice Repair, SIR System ................. 91-67
Wire, Spark Plug, Inspection ...... ,., ............... 08-8
Wiring Harness ............................................ 5El -7
Wiring .Harness ........................ ;................. 5E2-10
Wiring Repair ............................................... 91-66
y
Yoke, and Seal Differential Drive Pinion
Gear, OnNehicle Service... ,.. :.... ,....... ;....... 4B-14
Yoke, Differential Drive Pinion. Gear,
Runout Measurement,
On-Vehicle Service............... ,.................... 4A-6
BOOK 2 INDEX
Accelerator Controls ............................ 6E-380, 6E-382,

6E-862, 6E-864
A/C Clutch Circuit .............................................. 6E-925
Air Check Valve and
Pipes Replacement... ....................... 6E-909, 6E-9i O
Air Cleaner Assembly
Replacement ...................... 6E-379, 6E-859, 6E-861
Air Filter Element
Replacement.. .................... 6E-379, 6E-859, 6E-861
Air Induction System Description ...................... 6E-433
Air Intake System Description ........................... 6E-930
Air Pump Replacement... ................................... 6E-907
Air Vacuum Bleed Valve Replacement.. ........... 6E-911
Automatic Transmission
Genera! Information ....................................... 7 A-191
Scan Tool Data Definitions ............................ 7A-194
Automatic Transmission 4L60-E
Component Location Table ................. 7 A-61, 7A-62
Connector End Views ...................................... 7A-65
Controls - Cell 39 ............................................ 7A-51
-Diagnosis
3-2 Flare or Tie-Up ..................................... 7 A-44
Component Resistance ............................... 7 A-38
Electronic Component Malfunctions ........... 7A-40
Fluid Checking Procedure ........................... 7A-26
Fluid Leak .................................................... 7A-48
Functional Test Procedure .......................... 7A-26
.Harsh Garage Shift ..................................... 7A-46
Harsh Shifts ................................................. 7A-41
Inaccurate Shift Points ................................ 7A-42
Line Pressure Check Procedure ................ 7A-28
Malfunction Trouble Code ........................... 7A-50
Noise and Vibration Analysis ...................... 7A-30
No Park ........................................................ 7A-47
No TCC Apply ............................................. 7A-46
Oil Out the Vent .......................................... 7A-47
Oil Pressure High or Low ........................... 7A-41
Road Test Procedure .................................. 7A-29
Slipping or Rough 1-2 Shift ........................ 7A-43
Slips in ist Gear ......................................... 7A-42
Tech 1 Data Value Examples ..................... 7A-34
Torque Converter Clutch ............................. 7A-32
Disassembled View ........................................... 7A-7
Electrical Connector Description ................... 7A-201
Electronic Component Description ................ 7A- i 97
Electronic Component Location Table ............ 7A-67
Forward Clutch Piston Travel Check ................ 7A-5
Input Carrier Pinion End Play ........................... 7A-5
Oil Pump Rotor and Slide Measurement ......... 7A-6
On-Car Lubrication Specifications ..................... 7A-3
Ra11ge Reference Table .................................... 7A-3
Reverse Input and Input Clutches .................... 7A-5
Schematic Icon Table ...................................... 7A-60
Schematic Reference Table ............................ 7A-60
Shift Speed Table .............................................. 7A-4
Torque Converter End Play Check ................... 7A-6
Transmission End Play Check .......................... 7A-4
Automatic Transmission Diagnosis (4L60-E) .... 7A-194
Camshaft Position Sensor Replacement .......... 6E-406

Clean Air Cover and Gasket Replacement ...... 6E-870
Clutch Anticipate Switch .................................... 6E-378
Coolant Cover Assembly Replacement ............ 6E-868
Crankcase Ventilation
System Description .......................... 6E-441, 6E-940
Crankshaft PositionSensor
Replacement.. .............................. 6E-405, 6E-899
Distributor Ignition System Description ............. 6E-927

Draining Fuel Tank ............................... 6E-384, 6E-872
Diagnostic Trouble Codes
Engine ............................................... 6E-64 - 6E-803-Transmission .................................... 7 A-70 - 7 A-187
ECT Sensor Replacement... ................ 6E-372, 6E-853

EE PROM ............................................................ 6E-91 ~
EGR System Description ..................... 6E-440, 6E-93~
EGR Vacuum Control Signal
Sol Valve Replacement.. ............................... 6E-902
EGR Valve Replacement.. ................... 6E-408, 6E-90:
Electric Cooling Fan Description ......... 6E-426, 6E-92 7
Electronic Ignition System Description .............. 6E-42:
Engine Controls 3.8L
Component Location Table ............................. 6E-3~
Connector End Views ...................................... 6E-3&
GM SPO Group Numbers ................................. 6E-3
Scan Tool Data Definitions ............................. 6E-i2
Scan Tool Data List... ........................................ 6E-?
Schematic Icon Table ...................................... 6E-32
Special Tools ................................................ 6E-442
System/Fuel System Torqw.3
..... 6E-:
Temperature vs Resistance Table ............... .".... 6E-:
Engine Controls3.8L
Emission Hose Routing Diagram .................... 6E-32
Schematic and Routing Diagrams .................. 6E- F
Schematic Reference Table ............................ 6E-32
Engine Controls 5.7L
Component Location Table ........................... 6E-477
Connector End Views .................................... 6E-470
Scan Tool Data Definitions ........................... 6E-449
Scan Tool Data List... .................................... 6E-446
Schematic and Routing Diagrams ................ 6E-453
Schematic Icon Table .................................... 6E-469
Schematic Reference Table .......................... 6E-469
Special Tools ................................................. 6E.. 942
System/Fuel System Torque
Specifications ............................................. 6E-445
Temperature vs Resistance Table ................ 6E-445
Engine Diagnosis 3.8L ...................................... 6E-322
Alcohol-in-Fuel/Contaminants
Testing Procedure ..................................... 6E-367
Backfire .......................................................... 6E-327
Cuts Out ........................................................ 6E-317
Data Link Connector ....................................... 6E-51
Detonation ...................................................... 6E-312
Dieseling ........................................................ 6E-326
I
r
Engine Diagnosis 3.8L ....................................... (cont.)

Electric Cooling Fan ...................................... 6E-345
Engine Cranks but Does Not Run .................. 6E-53
EVAP Control System .......................... ."........ 6E-368
Fuel Injector Balance Test ............................ 6E-360
Fuel Injector Coil Test ................ ,.......... '. ....... 6E-363
Fuel Pump Relay Circuit ................................. 6E-6.0
Fuel System ..................................................... 6E-63
Fuel System Pressure Test ........................... 6E-354
Hard Start ...................................................... 6E-304
Hesitation ....................................................... 6E-314
Idle Air Control System Check ..................... 6E-334
Important Preliminary Checks ....................... 6E-304
Incorrect Idle .................................................. 6E-322
lntermittents ................................................... 6E-304
Lack of Power, Sluggishness,
or Sponginess ........................................... 6E-310
Misses ............................................................ 6E-317
No Malfunction Indicator Lamp ....................... 6E-49
OBD System Check ........................................ 6E-47
PCM Controlled Air Conditioning .................. 6E-337
PCM Controlled Warning Lamps .................. 6E-342
Poor Fuel Economy ....................................... 6E-320
Powertrain Control Module ............................ 6E-330
Restricted Exhaust System Check ............... 6E-328
Rough Idle ..................................................... 6E-322
Run-On ........................................................... 6E-326
Sag ..... '. ........................................................... 6E-314
Spark Knock .................................................. 6E-312
Stalling ........................................................... 6E-322
Strategy Based Diagnostic Flow ..................... 6E-46
Surges/Chuggles ............................................ 6E-307
Visual/Physical Checks .................................. 6E-304
Engine Diagnosis 5.7L.. ..................................... 6E-8i8
A/C Request Circuit Check ........................... 6E-828
Alcohol/Contaminants-in-Fuel
Testing Procedure ..................................... 6E-849
Backfire, ......................................................... 6E-821
Cuts Out ........................................................ 6E-813
Detonation ...................................................... 6E-81 O
Dieseling ........................................................ 6E-821
Distributor Ignition System Check ................. 6E-836
Distributor Vent System Check ..................... 6E-840
Electric Cooling Fan ...................................... 6E-830
Engine Cranks but Does Not Run ................ 6E-486
Fuel Injector Balance Test ............................ 6E-842
Fuel Injector Coil Test ..................... 6E-845, 6E-847
Fuel Pump Relay Circuit ............................... 6E-489
Fuel System ................................................... 6E-492
Fuel Tank Leak Check .................................. 6E-841
Fuel Tank Vent Valve Check ......................... 6E-841
Hard Start ...................................................... 6E-806
Hesitation ....................................................... 6E-81 i
Incorrect Idle .................................................. 6E-818
Lack of Power, Sluggishness,
or Sponginess ........................................... 6E-809
Misses ............................................................ 6E-813
No Scan Tool Data ........................................ 6E-483
OBD System Check ...................................... 6E-481
PNP Switch Check ........................................ 6E-826
Poor Fuel Economy ....................................... 6E-815
Restricted Exhaust System Check ............... 6E-824
Rough Idle ..................................................... 6E-818
Run-On ........................................................... 6E-821
BOOK 2 INDEX
Engine Diagnosis 5.7L ...................................... (cont.)
Sag .................................................................. 6E-811
Spark Knock .................................................. 6E-810
Stalling ........................................................... 6E-818
Strategy Based Diagnostic Flow ................... 6E-479
Surges/Chuggles ........................................... 6E-808
Symptoms ...................................................... 6E-806
EVAP Canister Hoses Replacement.. ............... 6E-907
EVAP Canister Purge Solenoid ......................... 6E-409
EVAP Canister Purge Solenoid
Valve Replacement ........................................ 6E-906
EVAP Canister Replacement..: ............ 6E-410, 6E-903
EVAP Control System Description ..... 6E-437, 6E-935
EVAP Purge Vacuum Switch
Replacement .................................................. 6E-905
EVAP System Cleaning ..................................... 6E-904
EVAP Vacuum Switch Replacement.. ............... 6E~409
Fuel Crossover Tube Replacement .................. 6E-881

Fuel Hose and
Pipes Replacement .......... 6E-395, 6E-396, 6E-398,
6E-890, 6E-891, 6E-893
Fuel injector Replacement .................. 6E-390, 6E-883
Fuel Metering Modes of Operation ..... 6E-435, 6E-931
Fuel Metering System Components .... 6E-435, 6E-932
Fuel Outlet Tube Replacement.. ....................... 6E-879
Fuel Pressure Connection Valve
Replacement ....................................... ,....... ,... 6E-878
Fuel Pressure Regulator
Replacement .................................... 6E-391, 6E-885
Fuel Pressure Relief Procedure .......... 6E-394, 6E-890
Fuel Pump Relay Replacement ...........6E-403, .6E-895
Fuel Rail Assembly Replacement ....... 6E~392, 6E-887
Fuel Sender Assembly ...................................... 6E-387
Fuel Sender Assembly Replacement... .......... ,.. 6E-876
Fuel Sender Assembly Service ........... 6E-388, 6E-877
Fuel Supply Components .................... 6E-433, 6E-930
Fuel System Cleaning ......................... 6E-386, 6E-874
Fuel Tank Replacement... .................... 6E-385, 6E-872
Fuel Tank Vent Valve ......................................... 6E-875
Heated Oxygen Sensor (H02S)

Replacement. ...................... 6E-375, 6E-856, 6E-857
I
IAC Valve Replacement... .................... 6E-382, 6E-864
IAT Sensor Replacement... .................. 6E-377, 6E-859
Idle Air Control Valve Replacement .................. 6E-868
Ignition Control Moduie ....................... 6E-404, 6E-405
Information Sensors ............................. 6E-420, 6E-920
In-Line Fuel Filter Replacement.. ........ 6E-384, 6E-870
Knock Sensor Module

Replacement.. .................................. 6E-407, 6E-900
Knock Sensor Replacement.. .............. 6E-407, 6E-899
Knock Sensor System Description ...... 6E-426, 6E-926

1996 Chevrolet Camaro &amp; Pontiac Firebird Service Manual Volume 1

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1996 Chevrolet Camaro &amp; Pontiac Firebird Service Manual Volume 1

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1996 CHEVROLET CAMARO AND PONTIAC FIREBIRD SERVICE MA\JUAL

HEATING AND AIR CONDITIONING

STEERING, SUSPENSION, TIRES AND WHEELS

Manual Transmission On-Vehicle

Diagnostic Trouble Codes 5.7L VIN P (LT1)

ELECTRICAL BODY AND CHASSIS

Diagnostic Trouble Codes 3.BL VIN K (L36)

Key Identification and Usage ........................... OA-8

SUPPLEMENTAL INFLATABLE RESTF,IAINT ,

HANDLING ELECTROSTATIC DISCHARGE

CAUTION: This. vehicle is equipped with

DISCONNECTING THE BATTERY

NOTICE: In order to avoid possibly damaging

FEDERAL VEHICLE THEFT PREVENTION

Figure 1 - ESD Sensitive Parts Label

5. Do not remove the solid state component from its

SPECIAL TOOL ORDERING INFORMATION

Federal law requires General Motors to place a

THESE LABELS ARE NOT TO BE DEFACED,

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number (VIN) legally

PLANT SEQUENCE NUMBER

G.M. PLANT CODES

MODEL YEAR CODES

SERIES AND MODEL TABLE

CAMARO SPORT COUPE

TWO DOOR COUPE/SEDAN

TWO DOOR HATCHBACK

TWO DOOR CONVERTIBLE

ACTIVE (MANUAL) BELTS WITH DRIVER

ACTIVE MANUAL BELTS WITH DRIVER INFLATABLE

PASSIVE (AUTOMATIC) BELTS

PASSIVE (AUTOMATIC) BELTS WITH DRIVER

PASSIVE (AUTOMATIC) BELTS WITH DRIVER

Figure 2 VIN Codes

A derivative of the VIN is stamped on the

VIN NUMBER PLATE

Figure 3 VIN Plate Location

The VIN code /(Figure 2,) provides detailed

Vehicle Identification Number

Figure 4 VIN Derivative (Typical)

transmission identification number is located either on

DIFFERENTIAL RATIOS AND TIRE

GENERAL VEHICLE LIFTING AND

The ~a!ls~ssioI?, has. two identifying stampings:

E;ngine Identification Number

GU4-3.08, GUS-3.23, GU6-3.42

GU2-2.73, GUS-3.23, GU6-3.42

Figure 7 - Transmission Usage Chart

Figure 8 Hydra-Matic 4L60-E Transmission 1.0. Location

CAUTION: To help avoid personal injury

NOTICE: When jacking or lifting a vehicle at

Figure 9 - Manual Transmissi,on Identification

When a vehicle is lifted with a vehicle jack or

GENERAL INFORMATION OA-7

A USING FRAME CONTACT HQilST REARWARD OF

Figure 10 Vehicl,e Lifting Points

The vehicle should be on a clean, hard, level

1UM Of' IXCELlf'-Ct:

LOCK CYLINDER COD,ING

Figure 11 Key Code Diagram

Key Identification and Usage

Replacement Lock Cylinders

Figure 12 Lock Cylinder Components

1996 Chevrolet Camaro & Pontiac Firebird Service Manual Volume 1

1996 Chevrolet Camaro & Pontiac Firebird Service Manual Volume 1