Chevrolet TrailBlazer Service Manual Download Page 577 | Manualshive

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To Install:

1. Install the gasket onto the power vacuum brake booster.
2. For 2002 through 2004 vehicles, attach the power vacuum brake booster to the

vehicle. Torque the mounting nuts to

30 ft-lb (40 Nm)

.

3. For 2005 through 2007 vehicles, attach the power vacuum brake booster to the

vehicle. Torque the mounting nuts to

27 ft-lb (36 Nm)

.

4.  Install the stop lamp switch and pushrod onto the brake pedal pin.
5.  Connect the pushrod retainer to the brake pedal pin.
6.  Install the left insulator panel under the instrument panel (I/P).
7.  Install the power vacuum brake booster hose onto the power vacuum brake

booster and the engine.

8. Install the master cylinder assembly onto the power vacuum brake booster.

Testing

Vacuum Leak Test

1.  Operate the engine at idle without touching the brake pedal for at least one minute.
2.  Turn off the engine and wait one minute.
3.  Test for the presence of assist vacuum by depressing the brake pedal and

releasing it several times. If vacuum is present in the system, light application will
produce less and less pedal travel. If there is no vacuum, air is leaking into the
system.

System Operation Test

1. With the engine

OFF

, pump the brake pedal until the supply vacuum is entirely

gone.

2. Put light, steady pressure on the brake pedal.
3. Start the engine and let it idle. If the system is operating correctly, the brake pedal

should fall toward the floor if the constant pressure is maintained.

Brake Fluid

Bleeding the Brake System (Non ABS)

1. Clean all dirt from around the master cylinder fill cap, remove the cap and fill the

master cylinder with brake fluid until the level is within 1/4 in. (6mm) of the top edge
of the reservoir.

2. Clean the bleeder screws at all 4 wheels. The bleeder screws are located on the

top of the brake calipers.

3. Attach a length of rubber hose over the bleeder screw and place the other end of

the hose in a glass jar, submerged in brake fluid.

4. Starting at the right rear proceed in this order left front, left rear and right front.
5. Open the bleeder screw 1/2 - 3/4 turn. Have an assistant slowly depress the brake

pedal.

6. Close the bleeder screw and tell your assistant to allow the brake pedal to return

slowly. Continue this process to purge all air from the system.

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Summary of Contents for TrailBlazer

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Page 2: ...cific purpose Before substituting another tool or procedure you must be completely satisfied that neither your personal safety nor the performance of the vehicle will be endangered Although information in the data is based on industry sources and is complete as possible at the time of publication the possibility exists that some vehicle manufacturers made later changes which could not be included ...

Page 3: ...ers including cancer You should make every effort to minimize your exposure to used engine oil Protective gloves should be worn when changing oil Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil Soap and water or waterless hand cleaner should be used All new vehicles are now equipped with an air bag system often referred to as a Supplemental Re...

Page 4: ...until you want it to come down Whenever the vehicle is raised block the wheels remaining on the ground and set the parking brake Do use adequate ventilation when working with any chemicals or hazardous materials Like carbon monoxide the asbestos dust resulting from some brake lining wear can be hazardous in sufficient quantities Do disconnect the negative battery cable when working on the electric...

Page 5: ...gasoline to wash your hands there are excellent soaps available Gasoline contains dangerous additives which can enter the body through a cut or through your pores Gasoline also removes all the natural oils from the skin so that bone dry hands will suck up oil and grease Don t service the air conditioning system unless you are equipped with the necessary tools and training When liquid or compressed...

Page 6: ...Fig 1 Always support your vehicle on jackstand while working underneath Fig 2 If you re using portable electric tools make sure they re grounded preferably at the plug by a three wire connector ...

Page 7: ...g the battery Never open service or drain the radiator or cooling system when the engine is hot serious burns and blindness can occur from the steam and hot coolant Observe all applicable safety precautions when working around fuel Whenever servicing the fuel system always work in a well ventilated area Do not allow fuel spray or vapors to come in contact with sparks open flame or excessive heat a...

Page 8: ...stem When carrying a non deployed air bag be sure the bag and trim cover are pointed away from your body When placing a non deployed air bag on a work surface always face the bag and trim cover upward away from the surface This will reduce the motion of the module if it is accidentally deployed Refer to the additional air bag system precautions later in this section Disconnecting the negative batt...

Page 9: ...c sensor in electronic ignition system is made up of a small coil of wire wrapped around an iron core a permanent magnet and a toothed wheel called a reluctor These sensors can be found mounted in a distributor or at the front middle or rear of the crankshaft or camshaft and are two wire sensors The permanent magnet produces a magnetic field that passes thru the center of the pick up coil As the r...

Page 10: ...ed turns of heavy wire while the secondary winding consists of thousands of turns of fine wire The iron core is used to conduct magnetic lines of force efficiently When current flows through the primary winding a magnetic field is created The more time current is permitted to flow the stronger the magnetic field becomes When the current is turned off the magnetic field collapses causing a high vol...

Page 11: ...spark tester looks just like a spark plug Attach the clip to ground and crank the engine to check for spark This spark tester has an adjustable air gap for measuring spark strength and testing different voltage ignition systems ...

Page 12: ... and the spark voltage is detected the bulb on the top will flash with each pulse NOTE The best way to perform this procedure is to use a spark tester available at most automotive parts stores Three types of spark testers are commonly available The Neon Bulb type is connected to the spark plug wire and flashes with each ignition pulse ...

Page 13: ... spark but also the intensity of the spark Orange yellow is weak blue is strong 1 Disconnect a spark plug wire at the spark plug end 2 Connect the plug wire to the spark tester and ground the tester to an appropriate location on the engine or frame 3 Crank the engine and check for spark at the tester 4 If spark exists at the tester the ignition system is functioning properly 5 If spark does not ex...

Page 14: ...ng Orders 4 2L Engine 1 5 3 6 2 4 5 3L 6 0L Engines 1 8 7 2 6 5 4 3 Ignition Coil On Plug Removal Installation 4 2L Engine To Remove 1 Remove the air cleaner outlet resonator from the engine Ignition coils ...

Page 15: ...l 1 Attach the ignition coils to the engine Torque the retaining bolts to 89 in lb 10 Nm 2 Connect the ignition coil connectors 3 Install the air cleaner outlet resonator to the engine 5 3L 6 0L Engines To Remove 1 If equipped remove the intake manifold sight shield from the engine Ignition coils ...

Page 16: ...tors 4 Detach the ignition coils from the engine To Install 1 Attach the ignition coils to the engine Torque the bolts to 71 in lb 8 Nm 2 Connect the ignition coil connectors 3 Connect the spark plug wires to the ignition coils 4 If equipped install the intake manifold sight shield to the engine ...

Page 17: ...ator is producing current greater than that produced by the battery electricity is forced into the battery and the battery is returned to full charge The generator is belt driven by a pulley from the engine s crankshaft Generators actually produce alternating current AC commonly used in homes As the current leaves the generator it is converted to direct current DC that is used by the storage batte...

Page 18: ...rmed in good working order under and overcharging is caused by a defective generator or internal regulator Replacement of these components will then repair the condition No Load Test 1 Connect a tachometer to the engine CAUTION Place the transmission in P Park set the emergency brake and chock the rear wheels to prevent vehicle movement 2 Turn off all electrical loads radio blower motor wipers etc...

Page 19: ...l then repair the condition Removal Installation 4 2L Engine To Remove 1 Disconnect the negative battery cable from the battery 2 Remove drive belt from the pulleys 3 Detach the A C line mounting bracket from the engine lift hook 4 Detach the right engine lift hook from the engine Generator removal and installation ...

Page 20: ... hook to the engine Torque the bolts to 37 ft lb 50 Nm 4 Attach the A C line mounting bracket to the engine lift hook Torque the bolt to 89 in lb 10 Nm 5 Install the drive belt onto the pulleys 6 Connect the negative battery cable to the battery 5 3L 6 0L Engines To Remove 1 Disconnect the negative battery cable from the battery 2 Remove the drive belt from of the pulleys 3 Disconnect the generato...

Page 21: ...ator to the engine Torque the bolts to 37 ft lb 50 Nm 2 Attach the generator cable to the generator Torque the nut to 80 in lb 9 Nm 3 Connect the generator connector 4 Install the accessory drive belt on to the pulleys 5 Connect the negative battery cable to the battery ...

Page 22: ...ent 4 Mark the position of the clips on the negative battery harness 5 Remove the clips from the negative battery harness 6 Remove the generator battery control module securing tape from the negative battery harness 7 Squeeze together the branches of the negative battery harness 8 Remove the generator battery control module by sliding it off of the negative battery harness To Install 1 Squeeze tog...

Page 23: ... manufacturer s warranty requirements If you have an owner s manual for your vehicle we would still recommend that you consult it and see what the manufacturer specifically recommends there may be some odd or atypical components on your vehicle that require special attention Because this chart is designed to cover all vehicles we may have included items which are not applicable to your exact model...

Page 24: ...here is to pay attention to the directions supplied with your replacement parts and if you have never replaced an item before check with the manufacturer for suggestions about original equipment Is My Driving Normal or Severe Sometimes we are puzzled at how manufacturer s chose the term Normal for the style of driving which most refer to in their maintenance charts as the opposite of Severe Check ...

Page 25: ...ossibly even your life kept safe by tires and brakes so remember the general rule maintenance is cheaper than repair Don t be afraid of not being Normal Go ahead and admit that your driving is Severe and maintain your vehicle to match Fig 1 Typical underhood maintenance locations for inline type engines Refer to chart for descriptions Fig 2 Typical underhood maintenance locations for V or opposing...

Page 26: ...Fig 3 Typical body and undervehicle maintenance locations Refer to chart for descriptions ...

Page 27: ...Fig 4 Typical lubricants from left to right Engine Oil Gear Oil ATF Wheel Bearing Grease Brake Fluid Chassis Grease White Grease and Silicone Spray ...

Page 28: ...Fig 5 Special tools make lubrication easier from left to right Oil Suction Gun Oil Can Funnel Grease Gun and Wheel Bearing Packers ...

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Page 32: ...g the battery Never open service or drain the radiator or cooling system when the engine is hot serious burns and blindness can occur from the steam and hot coolant Observe all applicable safety precautions when working around fuel Whenever servicing the fuel system always work in a well ventilated area Do not allow fuel spray or vapors to come in contact with sparks open flame or excessive heat a...

Page 33: ...stem When carrying a non deployed air bag be sure the bag and trim cover are pointed away from your body When placing a non deployed air bag on a work surface always face the bag and trim cover upward away from the surface This will reduce the motion of the module if it is accidentally deployed Refer to the additional air bag system precautions later in this section Disconnecting the negative batt...

Page 34: ... engine with a waste spark system The coil over plug system also benefits from a minimum amount of energy lost due to the resistance of spark plug wires Magnetic Sensor Pick Up Coil The magnetic sensor in electronic ignition system is made up of a small coil of wire wrapped around an iron core a permanent magnet and a toothed wheel called a reluctor These sensors can be found mounted in a distribu...

Page 35: ...ry winding is made up of several hundred turns of heavy wire while the secondary winding consists of thousands of turns of fine wire The iron core is used to conduct magnetic lines of force efficiently When current flows through the primary winding a magnetic field is created The more time current is permitted to flow the stronger the magnetic field becomes When the current is turned off the magne...

Page 36: ... To prevent damage caused by excessive starter armature rotation when the engine starts the starter incorporates an over running clutch in the pinion gear This disengages the starter motor from the engine when the engine begins to run on its own Battery Removal Installation To Remove CAUTION Make sure to connect the correct battery cables to the correct battery terminals Reversing the battery s po...

Page 37: ...voltmeter No voltage should be consumed by the vehicle wiring A If the battery cable connects directly to the starter motor there should be no more than a 0 2 volt drop measured B If the vehicle uses a starter solenoid between the battery and the starter motor terminal there should be no more than 0 4 volt displayed on the voltmeter Starter Ground Circuit 1 Disable the fuel system by removing the ...

Page 38: ...e ignition key to the START position and note the voltage displayed on the voltmeter Ideally there should be no more than 0 2 volt drop across the starter solenoid displayed on the voltmeter In general there should be no more than a 1 0 volt drop throughout the entire starter motor feed and ground circuit Any voltage drops measured in either the feed or ground circuits after connections have been ...

Page 39: ...o Remove 1 Disconnect the negative battery cable from the battery 2 Disconnect the brake booster hoses from the engine Starter 3 Remove the positive battery cable and s terminal lead from the starter 4 Remove the starter from the engine ...

Page 40: ...battery cable nut to 80 in lb 9 Nm Tighten the s terminal nut to 20 in lb 2 3 Nm 3 Connect the vacuum brake booster hose to the engine 4 Connect the negative battery cable to the battery 5 3L 6 0L Engines To Remove 1 Disconnect the negative battery cable from the battery 2 Raise and support the vehicle 3 Remove the rear steering gear crossmember from the frame Starter ...

Page 41: ...tall 1 Place the starter between the engine oil pan and transmission oil cooler lines 2 Attach the battery positive cable to the starter and starter lead Torque the battery positive cable nut to 80 in lb 9 Nm Torque the starter lead nut to 30 in lb 3 4 Nm 3 Install the heat shield to the starter 4 Attach the starter from the engine Torque the bolts to 37 ft lb 50 Nm 5 Install the right transmissio...

Page 42: ...e 1 Remove the underhood fuse block cover 2 Find the starter the relay 3 Use the J 43244 relay puller pliers to remove the relay To Install 1 Place the relay in the same orientation as before it was removed 2 Replace the electrical center cover ...

Page 43: ...ilure to do so may result in fire and or personal injury The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders including cancer You should make every effort to minimize your exposure to used engine oil Protective gloves should be worn when changing oil Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil Soa...

Page 44: ... or retained in a specific order for reassembly At the time of installation components should be installed in the same location and with the same mating surface as when removed An automobile engine is a combination of many machined honed polished and lapped surfaces with tolerances that are measured in millimeters or thousandths of an inch These surfaces should be covered or protected to avoid com...

Page 45: ...Engine Mechanical WARNING To avoid personal injury and or vehicle damage refer to the service precautions at the beginning of this section ...

Page 46: ...ve the bolt from the intake camshaft sprocket 3 Remove the bolt from the exhaust camshaft actuator J 44222 Installation 4 Attach a J 44222 camshaft sprocket holding tool to the camshaft sprockets 5 Remove the camshaft sprockets with the J 44222 camshaft sprocket holding tool and timing chain from the camshafts ...

Page 47: ...Camshaft cap removal and installation 6 Detach the camshafts caps from the cylinder head Make sure to place the caps in a rack to ensure they are installed in the same location they were removed from ...

Page 48: ...shaft flats are facing up 4 Attach the camshaft caps to the cylinder head Torque the bolts to 106 in lb 12 Nm 5 Detach the J 44221 camshaft holding tool from the camshafts 6 Install the camshaft sprockets onto the camshafts 7 Detach the J 44222 camshaft sprocket holding tool from the camshafts 8 Install the bolt and washer into the intake camshaft sprocket Torque the bolt to 15 lb ft 20 Nm 9 Use a...

Page 49: ... 12 Install the camshaft cover onto the cylinder head 5 3L 6 0L Engines To Remove 1 Remove the condenser from the radiator 2 Remove the left and right cylinder heads and gaskets from the engine block 3 Remove the valve lifters from the engine block Camshaft sensor removal and installation 4 Detach the camshaft sensor from the engine block 5 Align the timing marks on the camshaft and crankshaft spr...

Page 50: ...the timing chain from the camshaft CAUTION In order to prevent damage to the piston assemblies or valves do not turn the crankshaft assembly after the camshaft sprocket has been removed Camshaft retainer removal and installation 7 Detach the camshaft retainer from the engine block ...

Page 51: ...mshaft 9 Rotate and pull the camshaft out of the engine block using the bolts as a handle 10 Clean sealing surfaces as necessary To Install 1 Use clean engine oil to lubricate the camshaft 2 Rotate and push the camshaft into the engine block using the bolts as a handle 3 Remove the bolts from the bolt holes in the front of the camshaft ...

Page 52: ...crankshaft sprockets are lined up Torque the bolts to 26 ft lb 35 Nm 6 Make sure the camshaft sensor is undamaged and lubricate it with clean engine oil 7 Attach the camshaft sensor onto the engine block Torque the bolt to 18 ft lb 25 Nm 8 Install the valve lifters into the engine block 9 Install the left and right cylinder heads and gaskets onto the engine block 10 Install the condenser into the ...

Page 53: ...kshaft balancer bolt from the crankshaft balancer Crankshaft balancer 3 crankshaft end protector into the end of the crankshaft and use a 3 jaw puller to remove the crankshaft balancer 4 crankshaft end protector from the end of the crankshaft 5 Remove and discard the crankshaft balancer shim from the crankshaft snout ...

Page 54: ...stall the crankshaft balancer to the crankshaft 6 Remove the EN 48034 harmonic balancer installer from the crankshaft balancer 7 Install a new crankshaft balancer washer and bolt Torque the bolt to 110 ft lb 150 Nm Use a J 36660 A torque angle meter to turn the bolt an additional 180 degrees 8 Remove the J 44226 crankshaft balancer holder from the torque converter 9 Install the torque converter ac...

Page 55: ...rom the engine 4 Install a J 42386 A flywheel holding tool onto the flywheel Torque the bolt to 37 ft lb 50 Nm 5 Remove the crankshaft balancer bolt from the crankshaft balancer Crankshaft balancer removal 6 crankshaft end protector into the end of the crankshaft and remove the crankshaft balancer 7 crankshaft end protector from the crankshaft balancer ...

Page 56: ...re the nose of the crankshaft is recessed 0 094 0 176 in 2 4 4 48 mm into the balancer bore If the dimensions are not correct start over at step 1 5 Install a new crankshaft balancer bolt into the crankshaft Tighten the bolt to 37 ft lb 50 Nm Use a J 45059 angle meter to turn the bolt an additional 140 degrees 6 Remove the J 42386 A flywheel holding tool from the flywheel 7 Install the cooling fan...

Page 57: ...s to the thermostat housing through the wheelhouse 10 Remove the left front wheel and wheelhouse liner 11 Place a drain pan under the thermostat housing 12 Detach the thermostat housing from the engine and slowly remove it 13 Remove the thermostat housing from the engine when the coolant stops draining from the engine 14 If necessary replace the thermostat housing o ring 15 Make sure cylinder 1 is...

Page 58: ...open end wrench on the camshaft hexes 25 Remove and discard the bolts from the cylinder head near intake and exhaust timing chain tensioner shoes 26 Remove the upper timing chain tensioner shoes bolts from the engine block 27 Remove and discard the bolts from the intake and exhaust camshaft sprockets 28 Remove the intake and exhaust camshaft sprockets from the camshafts with the timing chain 29 Re...

Page 59: ...Cylinder head bolt removal and installation 32 Remove and discard the bolts from the cylinder head ...

Page 60: ...Remove the cylinder head from the engine block 34 Set the cylinder head with the combustion chambers face up on a flat clean surface 35 Remove and discard the cylinder head gasket from the engine block 36 Clean the sealing surfaces as necessary ...

Page 61: ...To Install 1 Place the new cylinder head gasket on the engine block 2 Place the cylinder head on the engine block Cylinder head bolt tightening sequence ...

Page 62: ...m Use a J 45059 angle meter to rotate bolt an additional 100 degrees 14 Torque the exhaust camshaft sprocket bolt to 18 ft lb 25 Nm Use a J 45059 angle meter to rotate bolt an additional 135 degrees 15 Detach the J 44221 camshaft holding tool from the back of the camshafts 16 Remove the EN 48464 lower timing gear tensioner holding tool from the engine block 17 Turn the crankshaft clockwise two com...

Page 63: ...Install the air cleaner outlet resonator assembly powertrain control module PCM and generator onto the engine 31 Install the drive belt onto the pulleys 32 Install the air cleaner element into the air outlet duct 33 Refill the engine with oil and coolant 34 Use scan tool the check for DTCs 35 Road test the vehicle ...

Page 64: ... engine 5 Remove the left exhaust manifold from the cylinder head 6 Remove the pushrods from the cylinder head 7 Remove the auxiliary A C bracket bolt from the auxiliary A C bracket Left cylinder head removal and installation 1 Detach the cylinder head from the engine block 2 Set the cylinder head on wooden block 3 Remove the cylinder head gasket and locating pins from the engine block 4 Clean the...

Page 65: ... to turn the bolts in sequence an additional 70 degrees 2 Torque the M8 bolts 11 through 15 to 22 ft lb 30 Nm 3 Install the auxiliary A C bracket bolt from the auxiliary A C bracket Torque the bolt to 15 ft lb 20 Nm 4 Install the pushrods into the cylinder head 5 Install the left exhaust manifold onto the cylinder head 6 Install the coolant air bleed pipe onto the engine 7 Refill the engine with c...

Page 66: ...st manifold from the cylinder head 5 Remove the pushrods from the cylinder head 6 Remove the auxiliary A C bracket nut from the auxiliary A C bracket Right cylinder head removal and installation 7 Detach the cylinder head from the engine block 8 Set the cylinder head on wooden block 9 Remove the cylinder head gasket and locating pins from the engine block 10 Clean the sealing surfaces as necessary...

Page 67: ...al 90 degrees Use a J 45059 angle meter to turn the bolts in sequence an additional 70 degrees 4 Torque the M8 bolts 11 through 15 to 22 ft lb 30 Nm 5 Install the auxiliary A C bracket bolt from the auxiliary A C bracket Torque the nut to 15 ft lb 20 Nm 6 Install the pushrods into the cylinder head 7 Install the right exhaust manifold onto the cylinder head 8 Install the coolant air bleed pipe ont...

Page 68: ... Installation 4 2L Engine To Remove 1 Install a 3 8 inch breaker bar onto the drive belt tensioner arm 2 Turn the breaker bar clockwise until the tension on the drive belt is relieved Drive belt removal and installation ...

Page 69: ...ll 1 Install the drive belt onto all the pulleys except the drive belt tensioner pulley 2 Install a 3 8 inch breaker bar onto the drive belt tensioner arm 3 Turn the breaker bar clockwise 4 Install the drive belt onto the drive belts tensioner pulley 5 Turn the breaker bar counterclockwise to release the tensioner arm ...

Page 70: ...move 1 Remove the air cleaner resonator outlet duct from the throttle body 2 Install a hex head socket breaker bar onto the drive belt tensioner 3 Turn the breaker bar clockwise until the tension on the drive belt is relieved ...

Page 71: ...ive belt onto all the pulleys except the generator pulley 2 Install a hex head socket breaker bar onto the drive belt tensioner 3 Turn the breaker bar clockwise until the tension on the drive belt is relieved 4 Install the drive belt onto the generator pulley 5 Turn the breaker bar counterclockwise to release the tensioner arm 6 Remove the breaker bar from the tensioner 7 Install the air cleaner r...

Page 72: ...emove the drive belt from the pulleys Drive belt tensioner removal and installation 2 Detach the drive belt tensioner from the engine To Install 1 Attach the drive belt tensioner to the engine Torque the bolt to 37 ft lb 50 Nm 2 Install the drive belt onto the pulleys ...

Page 73: ... belt from the pulleys accessory drive belt tensioner 5 3L 6 0L 2 Detach the drive belt tensioner from the engine To Install 1 Attach the drive belt tensioner to the engine Torque the bolt to 37 ft lb 50 Nm 2 Install the drive belt onto the pulleys ...

Page 74: ...old absolute pressure MAP sensor from the engine 8 Remove the grille from the front of the vehicle 9 Remove the headlamp housings from the vehicle 10 Remove the hood latch from the radiator support 11 Remove the radiator support brace from the front of the vehicle 12 Disconnect the A C lines from the condenser 13 Disconnect the transmission cooler lines from the engine 14 Remove the cooling fan fr...

Page 75: ...injection AIR port on the engine head 21 Disconnect the heated oxygen sensor HO2S connector 22 Disconnect the camshaft phaser actuator valve connector 23 Detach the transmission cooler lines from the engine block on the right side 24 Disconnect the ignition coil connectors 25 Detach the ignition coil harness from the engine 26 Disconnect the power brake booster hose from the power brake booster ...

Page 76: ...CM removal and installation 27 Remove the powertrain control module PCM from the engine 28 Detach the harnesses and front differential vent hose from the engine harness bracket 29 Detach the engine harness bracket from the engine ...

Page 77: ...and s terminal lead from the starter 31 Disconnect the A C pressure sensor and A C clutch connectors 32 Remove the battery positive cable from the generator 33 Disconnect the generator knock sensor crankshaft sensor and camshaft sensor connectors ...

Page 78: ...ust manifold and move it towards the rear of the vehicle 40 If equipped remove the fuel tank shield from the frame 41 Remove the secondary air injection AIR pipes from the Remove the secondary air injection AIR pump 42 Remove the access covers and bolts from the torque converter 43 Support the transmission with a transmission jack under the transmission oil pan 44 Remove the transmission support f...

Page 79: ...engine mounts 51 Lower the vehicle 52 Remove the nuts from the upper engine mounts 53 Install the engine hoist to the engine 54 Lift the engine out of the engine compartment lift the engine slowly while continuing to support the transmission 55 Remove the upper engine mounts to gain clearance 56 Detach the secondary air injection AIR pipes fasteners from the back of the engine head and remove the ...

Page 80: ...ipe to the exhaust manifold Torque the bolts to 37 ft lb 50 Nm 22 Connect the oil pressure sensor connector 23 Install the oil drain plug into the oil pan Torque the plug to 19 ft lb 26 Nm 24 Install the left and right wheel drive shafts 25 Lower the vehicle 26 Install the grounds onto the engine block on the left side 27 Connect the generator knock sensor crankshaft sensor and camshaft sensor con...

Page 81: ... the engine 49 Install the throttle body and manifold absolute pressure MAP sensor to the engine 50 Install the hood latch to the radiator support 51 Install the headlamp housings into the vehicle 52 Install the grille onto the front of the vehicle 53 Install the air cleaner assembly and windshield washer solvent container into the vehicle 54 Install the hood onto the vehicle 55 Refill the engine ...

Page 82: ...om the HVAC system 6 Drain the oil from the engine 7 Remove the radiator from the vehicle 8 Remove the radiator support brace from the front of the vehicle 9 Remove the engine protection shield from under the vehicle 10 For vehicles with 4WD remove the front differential drive axle from the vehicle 11 Remove the wheel drive shafts from the vehicle 12 Remove the intake manifold from the engine Rear...

Page 83: ... bank 1 sensor 1 heated oxygen sensor HO2S bank 2 sensor 1 and camshaft position CMP sensor connectors 14 Remove the A C compressor hose from the vehicle 15 Detach the A C compressor pipe from the engine and set aside Engine coolant temperature sensor ECT connector ...

Page 84: ...gine coolant temperature ECT sensor connector 17 Detach the ground terminal from the engine near the engine coolant temperature ECT sensor 18 Disconnect the A C pressure switch connector 19 Lift the vehicle Engine grounds ...

Page 85: ...rness to the side 26 Remove the generator from the engine 27 Use a set of J 38185 hose clamp pliers to remove the inlet and outlet hoses from the water outlet 28 Disconnect the auxiliary heater inlet and outlet hose pipe assembly from the heater water shutoff valve pipes 29 Use a set of J38185 hose clamp pliers to remove the auxiliary heater inlet and outlet hoses pipes from the water pump Lift br...

Page 86: ...ove the bolts from the torque converter 35 Detach the oil level indicator tube from the engine Transmission bolts and studs removal and installation 36 Remove the right transmission bolt and stud 37 Remove the lower transmission bolts and studs 38 Lower the vehicle 39 Remove the upper transmission bolts and studs 40 Attach an engine hoist to the J 41798 engine lift bracket 41 Support the transmiss...

Page 87: ...ater inlet and outlet hose pipe assembly to the heater water shutoff valve pipes 18 Use a set of J 38185 hose clamp pliers to install the inlet and outlet hoses to water outlet 19 Install the generator onto the engine 20 Reposition the engine harness onto the engine 21 Lift the vehicle 22 Connect the A C compressor connector 23 Attach the battery cable channel to the oil pan Torque the bolt to 106...

Page 88: ...ont of the vehicle 38 Install the radiator into the vehicle 39 Recharge the HVAC system with refrigerant 40 Connect the negative battery cable to the battery 41 Remove the fender covers 42 Refill the engine with oil 43 Refill the engine with coolant 44 Install the hood onto the vehicle 45 Make sure the engine is working properly ...

Page 89: ...Flywheel Removal Installation 4 2L Engine To Remove Flywheel removal and installation 1 Remove the transmission from the vehicle 2 Detach the flywheel from the crankshaft ...

Page 90: ...bolts Flywheel bolt tightening sequence 2 Attach the flywheel to the crankshaft Torque the bolts in sequence to 18 ft lb 25 Nm Use a J 36660 A torque angle meter to turn the bolts an additional 50 degrees 3 Install the transmission onto the vehicle ...

Page 91: ...5 3L 6 0L Engines To Remove 1 Remove the transmission from the vehicle Flywheel removal and installation 2 Mark the position of the flywheel to the crankshaft 3 Detach the flywheel from the crankshaft ...

Page 92: ...e crankshaft Flywheel bolt tightening sequence 3 Attach the flywheel to the crankshaft Torque the bolts in sequence to 15 ft lb 20 Nm Torque the bolts again in sequence to 37 ft lb 50 Nm Torque the bolts a final time in sequence to 74 ft lb 100 Nm 4 Install the transmission onto the vehicle ...

Page 93: ... Lower the vehicle 6 Remove the forward bolt from the drive belt idler pulley through the engine compartment 7 Remove the drive belt idler pulley from the vehicle To Install 1 Install the drive belt idler pulley and forward bolt through the engine compartment 2 Lift the vehicle 3 Install the bolts into the drive belt idler pulley through the left wheelhouse Torque the bolts to 37 ft lb 50 Nm 4 Ins...

Page 94: ...5 3L Engine To Remove 1 Remove the drive belt from the pulleys Idler pulley 2 Detach the drive belt idler pulley from the engine ...

Page 95: ...To Install 1 Attach the drive belt idler pulley to the engine Torque the bolt to 37 ft lb 50 Nm 2 Install the drive belt onto the pulleys ...

Page 96: ...o the gasket surfaces and throttle body assembly may result Use care in cleaning the gasket surfaces on the intake manifold and the throttle body assembly as sharp tools may damage the gasket surfaces 4 2L Engine To Remove 1 Disconnect the negative battery cable from the battery 2 Relieve the pressure in the fuel system Powertrain control module PCM removal and installation ...

Page 97: ...etach the engine harness bracket from the engine 7 Detach the harness and vacuum lines from the intake manifold 8 Disconnect the manifold absolute pressure MAP sensor connector 9 Detach the crankcase ventilation hose from the intake manifold 10 Detach the vacuum brake booster hose from the intake manifold 11 Remove the generator from the engine Intake manifold removal and installation ...

Page 98: ...engine 4 Attach the vacuum brake booster hose to the intake manifold 5 Lubricate the inside of the crankcase ventilation hose opening and attach it to the intake manifold 6 Connect the manifold absolute pressure MAP sensor connector 7 Attach the harness and vacuum lines to the intake manifold 8 Attach the engine harness bracket to the engine Torque the bolt to 89 in lb 10 Nm 9 Attach the integral ...

Page 99: ...L Engines To Remove 1 Disconnect the negative battery cable from the battery 2 Remove the air cleaner outlet duct from the engine compartment 3 Reliever the pressure in the fuel system 4 Disconnect the A C compressor pressure switch connector 5 Detach the harness clip from the cylinder head 6 Disconnect the mass air flow MAF intake air temperature IAT sensor fuel injectors evaporative emission EVA...

Page 100: ...tach the fuel feed pipe from the fuel rail 12 Detach the vacuum brake booster hose from the intake manifold 13 Remove the engine harness retainer nut from the top of the engine 14 Move the upper engine harness to gain clearance from the intake manifold NOTE Unless the individual components are being serviced the intake manifold throttle body fuel rail and fuel injectors may be removed as an assemb...

Page 101: ...15 Detach the intake manifold from the cylinder head 16 Remove and discard the gaskets from the intake manifold 17 Clean the sealing surfaces as necessary ...

Page 102: ... actuator inlet hose to the intake manifold 9 Install the positive crankcase ventilation PCV hose from the engine 10 Install the harness clips to the fuel rail 11 Connect the mass air flow MAF intake air temperature IAT sensor fuel injectors evaporative emission EVAP purge solenoid throttle body harness manifold absolute pressure MAP sensor ignition coil harnesses and generator connectors 12 Insta...

Page 103: ...engine 5 Remove the stabilizer shaft from the vehicle 6 Remove the front differential from the engine and secure it to the frame 7 Remove the front drive axle intermediate shaft bearing assembly from the vehicle 8 Drain the oil from the engine 9 Detach the transmission cooler lines from the engine block 10 Remove the oil pan bolts from the transmission bell housing Oil pan removal and installation...

Page 104: ...tall the oil drain plug and oil filter into the vehicle 11 Install the front differential onto the engine 12 Install the stabilizer shaft onto the vehicle 13 Install the bottom bolts into the A C compressor Torque all the bolts to 37 ft lb 50 Nm 14 Install the oil level indicator and tube onto the engine 15 Connect the negative battery cable to the battery 16 Refill the engine with oil 5 3L 6 0L E...

Page 105: ...Oil pan removal and installation 12 Remove the remaining bolts from oil pan 13 Remove the oil pan from the engine 14 Remove the gasket from the oil pan by drilling out the rivets ...

Page 106: ...ts to 106 in lb 12 Nm 6 Torque the remaining oil pan bolts to 18 ft lb 25 Nm 7 Install the bottom bolts into the A C compressor Torque the bolts to 37 ft lb 50 Nm 8 Torque the top A C compressor bolts to 37 ft lb 50 Nm 9 Attach the battery cable channel to the oil pan Torque the bolt to 106 in lb 12 Nm 10 Install the flywheel inspection cover into the transmission on the left side 11 Install the s...

Page 107: ...tach the oil pump cover from the engine front cover 3 Mark the position of the inner and the outer gears in relation to the oil pump housing 4 Remove the inner and outer oil pump gears from the oil pump housing 5 Remove the oil pump pressure relief valve plug oil pump pressure relief valve and spring from the oil pump housing ...

Page 108: ...to the engine front cover Torque the bolts to 89 in lb 10 Nm 4 Install the engine front cover onto the engine block 5 3L 6 0L Engines To Remove 1 Remove the oil pan from the engine 2 Remove the engine front cover from the engine 3 Detach the oil pump screen from the oil pump 4 Remove and discard the o ring from the oil pump screen 5 Remove the crankshaft oil deflector from the engine block Oil pum...

Page 109: ...tor onto the engine block 3 Use clean engine oil to lubricate the new oil pump screen o ring and install it onto the screen 4 Attach the oil pump screen to the oil pump Torque the bolt to 106 in lb 12 Nm Torque the nuts to 18 ft lb 25 Nm 5 Install the engine front cover onto the engine 6 Install the oil pan onto the engine ...

Page 110: ...lywheel from the crankshaft Crankshaft rear oil seal removal 3 Use a suitable tool to pry the crankshaft rear oil seal from the housing To Install 1 Use a J 44227 rear seal installer to install the crankshaft rear oil seal into the housing 2 Install the flywheel onto the crankshaft 3 Install the transmission onto the engine ...

Page 111: ...e 2 Install the tapered cone and bolts of a J 41479 crankshaft rear oil seal installer onto the crankshaft 3 Place the crankshaft rear oil seal onto the tapered cone 4 Install the threaded rod of the J 41479 crankshaft rear oil seal installer into the tapered cone 5 Install the crankshaft rear oil seal by turning the handle of the J 41479 clockwise 6 Remove the J 41479 crankshaft rear oil seal ins...

Page 112: ...the oil level indicator tube 3 Detach the A C line from the engine lift hook 4 Set aside the A C line 5 Remove the engine lift hook from the engine 6 Remove the ignition coils from the camshaft cover 7 Detach the engine harness from the camshaft cover 8 Disconnect the fuel injector harness connector Camshaft cover removal and installation ...

Page 113: ...in lb 10 Nm 3 Install the ignition coils into the camshaft cover 4 Connect the fuel injector harness connector 5 Attach the engine harness to the camshaft cover 6 Attach the A C line bracket to the oil level indicator tube Torque the nut to 62 in lb 7 Nm 7 Attach the engine lift hook to the engine Torque the bolts to 37 ft lb 50 Nm 8 Attach the A C line to the engine lift hook Torque the bolt to 8...

Page 114: ...sconnect the ignition coil harness connector 3 Detach the engine harness from the engine and set aside 4 Disconnect the spark plug wires from the ignition coils 5 Remove the ignition coils from the valve rocker arm cover 6 Detach the positive crankcase ventilation PCV hose from the valve rocker arm cover Left valve rocker arm cover removal and installation ...

Page 115: ...t the spark plug wires to the ignition coils 6 Attach the engine harness to the engine 7 Connect the ignition coil harness connector 8 If necessary install the intake manifold sight shield to the engine Right Side To Remove 1 If necessary remove the intake manifold sight shield from the engine 2 Remove the A C compressor hose from the vehicle 3 Disconnect the ignition coil harness connector 4 Deta...

Page 116: ... into the valve rocker arm cover 3 Install the cap onto the oil fill tube 4 Install a new gasket onto the valve rocker arm cover 5 Attach the valve rocker arm cover to the cylinder head Torque the bolts to 106 in lb 12 Nm 6 Attach the vent hose to the valve rocker arm cover 7 Install the ignition coils onto the valve rocker arm cover 8 Connect the spark plug wires to the ignition coils 9 Attach th...

Page 117: ...945 valve spring compressor 1 valve spring compressor to the engine cylinder head using the supplied fasteners in the coil fastener hole 2 Turn the engine in clockwise until the cam is on the base circle make sure not to completely turn the engine or the piston will contact and possibly damage the valves 3 Remove the valve rocker arm from the cylinder head 4 Remove the valve lash adjuster from the...

Page 118: ...Turn the engine in the counterclockwise direction until the cam lobe is fully depressing the spring 5 valve spring compressor from the engine cylinder head 6 Install the camshaft cover onto the cylinder head 5 3L 6 0L Engines To Remove 1 Remove the valve rocker arm covers from the cylinder heads Valve rocker arm removal and installation 2 Detach the valve rocker arms from the cylinder heads ...

Page 119: ...inder heads 4 Attach the valve rocker arms to the cylinder heads do not tighten the bolts 5 Make sure cylinder 1 is at top dead center 6 Torque the exhaust valve rocker arm bolts for cylinders 1 2 7 and 8 to 22 ft lb 30 Nm 7 Torque the intake valve rocker arm bolts for cylinders 1 3 4 and 5 to 22 ft lb 30 Nm 8 Turn the crankshaft 360 degrees 9 Torque the exhaust valve rocker arm bolts for cylinder...

Page 120: ...g fan from the engine 3 Remove the drive belt from the pulleys 4 Remove the water pump from the engine 5 Remove the crankshaft balancer from the crankshaft 6 Remove the power steering pump from the engine 7 Lift the vehicle 8 Remove the oil pan from under the engine 9 Lower the vehicle Engine front cover center bolt A ...

Page 121: ... into the threaded holes and tighten evenly 12 Remove the engine front cover and jack screws from the engine 13 Remove the oil pump from the engine front cover 14 Clean the sealing surfaces as necessary To Install 1 cover alignment pins into the engine block Engine front cover sealer application ...

Page 122: ...maining engine front cover bolts 6 Torque all engine front cover bolts except the center to 89 in lb 10 Nm 7 Torque the center engine front cover bolt to 89 in lb 10 Nm 8 Lift the vehicle 9 Install the oil pan onto the engine 10 Lower the vehicle 11 Install the power steering pump onto the engine 12 Install the crankshaft balancer into the crankshaft 13 Install the water pump onto the engine 14 In...

Page 123: ...ket from the engine 2 Remove the water pump from the engine 3 Remove the crankshaft balancer from the crankshaft Engine front cover removal and installation 4 Detach the engine front cover from the engine 5 Detach and discard the gasket from the engine front cover ...

Page 124: ...t tool with the alignment surfaces of the front cover 6 Install the crankshaft balancer bolt into the crankshaft hand tighten the bolt 7 Torque the engine front cover to oil pan bolts to 18 ft lb 25 Nm 8 Torque the remaining engine front cover bolts to 18 ft lb 25 Nm 9 Remove the J 41476 front and rear cover alignment tool from the engine front cover 10 Install a new crankshaft front oil seal into...

Page 125: ... the cylinder head 2 Remove the engine front cover from the engine 3 Move the timing chain tension shoe in to release the pressure on the chain 4 Install a tee into the tensioner to hold the shoe in place Exhaust camshaft position actuator removal 5 Detach the exhaust camshaft position actuator from the exhaust camshaft ...

Page 126: ...the timing chain from the sprockets 8 Remove the crankshaft sprocket from the crankshaft 9 Remove the access hole plugs from the cylinder head 10 Detach the timing chain tensioner shoe from the engine 11 Detach the timing chain tensioner guide from the engine Timing chain tensioner removal and installation ...

Page 127: ...e bolts to 18 ft lb 25 Nm 2 Attach the timing chain tensioner guide to the engine Torque the bolts to 89 in lb 10 Nm 3 Attach the timing chain tensioner shoe to the engine Torque the bolts to 19 ft lb 26 Nm 4 Install the access hole plugs into the cylinder head Torque the plugs to 44 in lb 5 Nm J 44221 camshaft holding tool ...

Page 128: ...l a J 44221 camshaft holding tool onto the camshafts Make sure cylinder 1 is at top dead center and the camshaft flats are facing up 6 Install the crankshaft sprocket onto the crankshaft Timing chain alignment ...

Page 129: ...timing chain 11 Attach the exhaust camshaft position actuator from the exhaust camshaft Torque the bolt to 18 ft lb 25 Nm Use a J 36660 A torque angle meter to turn the bolt an additional 135 degrees 12 Torque the intake camshaft sprocket bolt to 15 ft lb 20 Nm Use a J 36660 A torque angle meter to turn the bolt an additional 100 degrees 13 Remove the tee from the tensioner 14 Remove the J 44221 c...

Page 130: ...pump from the engine 2 Turn the crankshaft until the crankshaft and camshaft sprockets are aligned Crankshaft sprocket removal and installation 3 Remove and discard the camshaft sprocket bolt 4 Remove the camshaft sprocket with the timing chain from the camshaft ...

Page 131: ...Timing chain tensioner removal and installation 5 Detach the timing chain tensioner from the engine Crankshaft sprocket removal ...

Page 132: ...rn the crankshaft until the alignment mark is in the 12 o clock position 5 Install an En 46330 into the timing chain tensioner guide 6 Attach the timing chain tensioner to the engine Torque the bolts to 18 ft lb 25 Nm 7 Install the camshaft sprocket with the timing chain onto the camshaft 8 Make sure the camshaft sprocket alignment mark is in the 6 o clock position 9 Remove the EN 46330 from the t...

Page 133: ...ngine compartment 2 Remove the accumulator from coolant recovery reservoir 3 Remove the coolant hoses from the coolant recovery reservoir 4 Install a suitable plug into the coolant recover reservoir outlets 5 Detach the coolant recovery reservoir from the vehicle To Install 1 Attach the coolant recovery reservoir to the vehicle Torque the bolt to 106 in lb 12 Nm Torque the nut to 89 in lb 10 Nm 2 ...

Page 134: ...rom the engine block on the left side To Fill 1 If a complete block drain is necessary install the plug into the engine block on the left side 2 Use a set of J 38185 hose clamp pliers to connect the lower radiator hose to the radiator 3 Lower the vehicle 4 Fill the radiator with a 50 50 mixture of antifreeze and deionized water 5 Install the radiator cap onto the radiator 6 Fill the coolant recove...

Page 135: ...move the fan clutch from the water pump 8 Remove the upper mounting bolts from the fan shroud 9 Remove the fan shroud from the radiator by lifting the shroud and pushing inward To Install 1 Attach shroud to the radiator Torque the bolts to 21 ft lb 28 Nm 2 Use a J 46406 fan clutch remover and installer to install the fan clutch onto the water pump 3 Connect the fan clutch connector 4 Attach the tr...

Page 136: ... of J 38185 hose clamp pliers to disconnect the inlet radiator hose from the radiator 6 Detach the transmission cooler lines from the radiator 7 Lower the vehicle 8 Remove the cooling fan from the engine 9 Remove the radiator support diagonal brace from the vehicle 10 Disconnect the coolant recovery line from the radiator 11 Detach the side panels from the shroud Radiator removal and installation ...

Page 137: ...or 5 Use a set of J 38185 hose clamp pliers to connect the inlet radiator hose to the radiator 6 Attach the transmission cooler lines to the radiator 7 If equipped install the lower radiator support shield onto the radiator 8 Lower the vehicle 9 Install the cooling fan onto the engine 10 Connect the coolant recovery line to the radiator 11 Install the radiator support diagonal brace onto the vehic...

Page 138: ...in the coolant from the radiator 2 Remove the generator from the engine 3 Disconnect the outlet hose from the thermostat housing Engine coolant thermostat removal and installation 4 Detach the thermostat housing from the engine block 5 Clean the sealing surfaces as necessary ...

Page 139: ...enerator onto the engine 5 Refill the radiator with coolant 6 Check the sealing surfaces for leaks 5 3L 6 0L Engines To Remove 1 Disconnect the radiator outlet hose from the engine Thermostat removal and installation 2 Detach the water pump inlet and thermostat from the water pump To Install 1 Attach the water pump inlet and thermostat to the water pump Torque the bolts to 11 ft lb 15 Nm 2 Connect...

Page 140: ...m the pulleys Water pump pulley removal and installation 4 Use a J 41240 fan clutch remover and installer to secure the water pump pulley 5 Remove the bolts from the water pump pulley 6 Remove the J 41240 fan clutch remover and installer from the water pump pulley 7 Remove the water pump pulley from the water pump Water pump removal and installation ...

Page 141: ... in lb 10 Nm 3 Install the water pump pulley onto the water pump 4 Use a J 41240 fan clutch remover and installer to secure the water pump pulley 5 Install the bolts into the water pump pulley Torque the bolts to 18 ft lb 25 Nm 6 Remove the J 41240 fan clutch remover and installer from the water pump pulley 7 Install the drive belt onto the pulleys 8 Install the fan onto the engine 9 Refill the en...

Page 142: ...ent 3 Remove the drive belt from the pulleys 4 Remove the fan from the engine 5 Use a set of J 38185 hose clamp pliers to disconnect the inlet hose from the water pump 6 Use a set of J 38185 hose clamp pliers to disconnect the outlet hose from the water pump Auxiliary heater inlet and outlet hose pipe removal and installation ...

Page 143: ...lts to 11 ft lb 15 Nm Torque the bolts again to 22 ft lb 30 Nm 3 Install the nut onto the auxiliary heater inlet and outlet hose pipe Torque the nut to 89 in lb 10 Nm 4 Use a set of J 38185 hose clamp pliers to connect the hose to the throttle body 5 Use a set of J 38185 hose clamp pliers to connect the auxiliary heater inlet and outlet hoses pipes to the water pump 6 Use a set of J 38185 hose cla...

Page 144: ...recautions at the beginning of this section Exhaust Manifold Removal Installation 4 2L Engine To Remove 1 Lift the vehicle 2 Detach the catalytic converter from the exhaust manifold 3 Lower the vehicle 4 Detach the heat shield from the exhaust manifold Exhaust manifold removal and installation ...

Page 145: ...ld bolt tightening sequence 3 Attach the exhaust manifold to the engine Torque the bolts in sequence to 15 ft lb 20 Nm Torque the bolts again in sequence to 15 ft lb 20 Nm Torque the bolts a final time in sequence to 15 ft lb 20 Nm 4 Attach the heat shield to the exhaust manifold Torque the studs to 89 in lb 10 Nm 5 Lift the vehicle 6 Attach the catalytic converter to the exhaust manifold Torque t...

Page 146: ... plugs from the cylinder head 5 Detach the heat shield from the exhaust manifold Left exhaust manifold removal and installation 6 Detach the exhaust manifold from the engine 7 Remove and discard the gasket from the exhaust manifold To Install 1 Install a new gasket onto the exhaust manifold 2 Apply threadlock GM P N 12345493 to the exhaust manifold bolts ...

Page 147: ...nifold Torque the studs to 80 in lb 9 Nm 5 Install the spark plugs into the cylinder head 6 Lift the vehicle 7 Attach the catalytic converter to the exhaust manifold Torque the nuts to 37 ft lb 50 Nm 8 Lower the vehicle Right Side To Remove 1 Lift the vehicle 2 Detach the catalytic converter from the exhaust manifold 3 Lower the vehicle 4 Remove the spark plugs from the cylinder head 5 Detach the ...

Page 148: ... engine The bolts should be tightened starting with the center two and working outward from side to side Torque the bolts in sequence to 11 ft lb 15 Nm Torque the bolts again in sequence to 18 ft lb 25 Nm 4 Attach the heat shield to the exhaust manifold Torque the studs to 80 in lb 9 Nm 5 Install the spark plugs into the cylinder head 6 Lift the vehicle 7 Attach the catalytic converter to the exha...

Page 149: ...tach the catalytic converter from the exhaust manifold 4 Remove and discard the seal from the catalytic converter Muffler removal and installation 5 Detach the catalytic converter from the muffler 6 Remove the transmission mount from the frame 7 Remove the catalytic converter from the vehicle 8 Remove the exhaust hanger from the catalytic converter pipe ...

Page 150: ...ytic converter to the exhaust manifold Torque the bolts to 37 ft lb 50 Nm 7 Install the heated oxygen sensor HO2S into the catalytic converter 8 Lower the vehicle 5 3L 6 0L Engines To Remove 1 Lift the vehicle 2 Remove the heated oxygen sensors HO2S from the catalytic converter 3 Remove the rear propeller shaft from the vehicle 4 For vehicles with 4WD remove the front propeller shaft from the vehi...

Page 151: ... to the muffler Torque the bolts evenly to 33 ft lb 45 Nm 4 Attach the catalytic converter to the left and right exhaust manifolds Torque the nuts to 37 ft lb 50 Nm 5 Install the transmission support onto the frame 6 Remove the jack supporting the transmission 7 For vehicles with 4WD install the front propeller shaft into the vehicle 8 Install the rear propeller shaft into the vehicle 9 If reinsta...

Page 152: ...pressure test can indicate possible engine bearing or oil pump failures Excessive oil consumption evidence of oil in the engine air intake area and or bluish smoke coming from the tailpipe may indicate worn piston rings worn valve guides and or valve seals In general it is acceptable for an engine to use one quart of oil every 1000 miles Engines that use one quart of oil or more in less than 1000 ...

Page 153: ...ignition systems 5 Label and disconnect all of the spark plug wires from the plugs 6 Thoroughly clean the cylinder head area around the spark plug ports and then remove the spark plugs 7 Open the throttle plate fully to the wide open throttle position 8 Block the accelerator linkage open or have an assistant fully depress the accelerator pedal 9 Install a screw in type compression gauge into the N...

Page 154: ... muddy if oil is present Oil Pressure Test Check for proper oil pressure at the sending unit passage with an externally mounted mechanical oil pressure gauge A tachometer may also be needed as some specifications may require running the engine at a specific RPM 1 While the engine is cold locate and remove the oil pressure sending unit 2 Following the manufacturer s instructions connect a mechanica...

Page 155: ...contact must be pre lubed to provide lubrication at initial start up Any product specifically formulated for this purpose can be used but engine oil is not recommended as a pre lube in most cases When semi permanent locked but removable installation of bolts or nuts is desired threads should be cleaned and coated with Loctite or another similar commercial non hardening sealant Cleaning Before the ...

Page 156: ...NING Always wear eye protection during any cleaning process involving scraping chipping or spraying of solvents Remove any oil galley plugs freeze plugs and or pressed in bearings and carefully wash and degrease all of the engine components including all fasteners Small parts such as the valves springs etc should be placed in a metal basket and allowed to soak Use pipe cleaner type brushes to clea...

Page 157: ... Minimize damage to the valve seats by removing carbon deposits before removing any valves from the cylinder heads Choosing to de carbonize the combustion chambers with the valves removed will increase the chances of damaging the valve seats ...

Page 158: ...Repairing Damaged Threads Damaged bolt hole threads can be replaced with thread repair inserts Standard thread repair insert left and spark plug thread insert ...

Page 159: ...pecified size bit Be sure to drill completely through the hole or to the bottom of a blind hole Using the kit tap the hole in order to receive the thread insert Keep the tap well oiled and back it out frequently to avoid clogging the threads ...

Page 160: ...ype for most SAE coarse SAE fine metric course and metric fine thread sizes and a spark plug type to fit most spark plug port sizes Typical thread repair kits will contain a selection of pre wound threaded inserts a tap that corresponds to the outside diameter threads of the insert and an installation tool Spark plug inserts usually differ from conventional fastener inserts because they require a ...

Page 161: ...l cylinder heads have a valve guide for each valve The guide centers the valve to the seat and allows it to move up and down within it The clearance between the valve and guide can be critical Too much clearance and the engine may consume oil lose vacuum and or damage the seat Too little and the valve can stick in the guide causing the engine to run poorly if at all and possibly causing severe dam...

Page 162: ...ker arms and or shafts 2 Position the head so that the springs are easily accessed Valve spring compressor tool 3 Use a valve spring compressor tool and relieve spring tension from the retainer A small magnet used in removal of valve locks ...

Page 163: ...Valve locks keepers 5 Remove the valve locks from the valve tip and or retainer 6 Release the spring compressor and remove the valve spring O ring type seal ...

Page 164: ...ositive type seal 8 Remove the valve seal Removing exhaust valve 9 Position the head to allow access for withdrawing the valve 10 Remove the valve from the cylinder head 11 If equipped remove the valve spring cup ...

Page 165: ...OHC Cylinder Heads Exploded view of a valve seal spring retainer and locks from an OHC cylinder head Example of a multi valve cylinder head with 2 intake and 2 exhaust valve ports ...

Page 166: ...llower s bore You will need a C clamp style valve spring compressor tool an OHC spring removal tool or its equivalent as well as a small magnet to disassemble the head C clamp type spring compressor and an OHC spring removal tool center for cup type followers 1 Remove the camshaft s and or followers Mark for reassembly Cup type bolt on bearing caps ...

Page 167: ...the valve tip and valve lock area Use a metal file to remove burrs before removing the valve from the head 6 Remove the valve from the cylinder head 7 Remove the valve seal 8 If equipped remove the valve spring shim 9 Repeat Steps 3 through 8 until all of the valves have been removed Rocker Arm Type Camshaft Followers Most cylinder heads with rocker arm type camshaft followers are easily disassemb...

Page 168: ...OHC shaft mounted rocker arms OHC rocker arm type head 1 Removed the rocker arms and or shafts and the camshaft 2 If applicable remove the hydraulic lash adjusters Mark for reassembly ...

Page 169: ...amshaft can be removed by sliding it out shown or unbolting a bearing cap not shown 4 Position the cylinder head to allow access to the valve spring 5 Use a valve spring compressor tool to relieve the spring tension from the retainer ...

Page 170: ...Compressing the valve spring Removing the valve locks 7 Remove the valve locks from the valve tip and or retainer 8 Release the spring compressor and remove the valve spring off of the valve stem ...

Page 171: ...Valve spring and retainer 9 Remove the valve seal Removing valve seal from the guide 10 Position the head to allow access for removing the valve ...

Page 172: ...alves If so use a metal file to carefully remove the high spots around the lock grooves and or tip File enough to make valve removal possible 11 Remove the valve from the cylinder head Valve spring shim 12 If equipped remove the valve spring shim 13 Repeat Steps 3 though 9 until all of the valves have been removed ...

Page 173: ...obably bad Next inspect the valve lock grooves and valve tips Check for any burrs around the lock grooves especially if they had to be filed to remove the valve Valve tips should appear flat and square to the valve stem Slight rounding with high mileage engines is considered normal Slightly worn valve tips will need to be machined flat Last measure the valve stem diameter with the micrometer Measu...

Page 174: ...or squareness If a spring tension test gauge is available check each springs rating and compare to the specifications Valve springs should be replaced as a complete set Check the spring retainer to spring mating surface and the valve lock retention area for any signs of excessive wear Check for any signs of cracking Replace any retainers that are questionable Valve locks should be inspected for ex...

Page 175: ...Spring free length check Valve spring squareness check ...

Page 176: ... take a reading Compare the two readings for an out of round condition Check the readings against the specifications given An Inside Diameter I D gauge designed for valve guides will give you an accurate valve guide bore measurement If the I D gauge is used compare the readings with the specifications Any guides that fail these inspections should be replaced or machined Reading stem to guide clear...

Page 177: ...Cylinder Head Surface Flatness Clean the gasket surface of the cylinder head Check the head for flatness Machinist s straight edge and feeler gauge Diagonal check ...

Page 178: ...eat port first as this becomes the hottest area on a cylinder head Some reliable methods for finding cracks include Magnaflux a magnetic process or Zyglo a dye penetrant Magnaflux is used only on ferrous metal cast iron cylinder heads Zyglo is a method that uses a spray on fluorescent mixture along with a black light to reveal the cracks and is suitable for aluminum cylinder heads Check for physic...

Page 179: ...lished circle is evident on the valve and seat 7 Remove the tool and valve Wipe away all traces of the grinding compound and store the valve to maintain its original location NOTE Match the valves to their numbered cylinders They must be matched with the same valve seat with which they were lapped Springs Retainers Valve Locks There is no repair or refinishing possible with the springs retainers a...

Page 180: ...g it impossible to properly machine the seat Replaceable type guides commonly found in aluminum cylinder heads are pressed into the cylinder head A hammer and a stepped drift or punch may be used to install and remove the guides Before removing the guides measure the protrusion on the spring side of the head and record it for installation Use the stepped drift to hammer out the old guide from the ...

Page 181: ... align bore the camshaft bearing journals could result in severe engine damage including but not limited to valve and piston damage connecting rod damage camshaft and or crankshaft damage Cracks And Physical Damage Certain cracks can be repaired in both cast iron and aluminum heads For cast iron a tapered threaded insert is installed along the length of the crack Aluminum cylinder heads can also b...

Page 182: ... properly seated 9 Remove the spring compressor tool OHC Engines Cup Type Camshaft Followers 1 Lightly lubricate the valve stems and insert all of the valves into the cylinder head in their original locations 2 Install any valve spring shims that were removed if using the original springs 3 Install the new valve seals as follows If the valve seal presses over the guide lightly lubricate the outer ...

Page 183: ...de surfaces If the seal is an O ring type install it after compressing the spring but before installing the valve locks 4 Place the valve spring and retainer over the stem 5 Position the spring compressor tool over the spring and retainer Compress the spring and install the valve locks on the stem 6 Relieve the spring pressure slowly and ensure that both valve locks are properly held in place by t...

Page 184: ...shafts Remove the cylinder ridge from the top of any cylinder bore if required All Engines Turn the engine over so that the crankshaft is exposed Use a number punch and mark each connecting rod and cap with its respective cylinder number On V block engines always stamp the rods and caps on the side closest to the exterior of the block for proper installation The cylinder closest to the front of th...

Page 185: ... rod bolts studs to protect the crankshaft from damage Using a wooden hammer handle or piston hammer push the connecting rod up about 1 in 25mm from the crankshaft and remove the upper bearing insert Continue pushing or tapping the connecting rod up until the piston rings are out of the cylinder bore Remove the piston and rod by hand put the upper half of the bearing insert back into the rod insta...

Page 186: ...lign bored or if severe enough replaced Any burrs or high spots should be carefully removed with a de burring tool Place a machinist s straight edge along the bearing saddles in the engine block If any clearance exists between the machinist s straight edge and the saddles the block must be align bored Align boring consists of machining the main bearing saddles and caps by means of a fly cutter tha...

Page 187: ...le and finally at the bottom A total of six measurements will be taken for each cylinder bore 1 Measure the cylinder as follows A Position the gauge in a cylinder bore near the top B Loosen the gauge lock and allow it to expand C Hold the gauge squarely in the bore perpendicular 90 degrees to the crankshaft centerline D Tighten the lock E Tilt the gauge back to remove it from the bore F Measure th...

Page 188: ...er or out of roundness found A difference up to 0 0005 in 0 0127mm for taper or out of roundness is acceptable All measurements should be within the factory specifications for journal diameters If the crankshaft journals are within specifications it is recommended that they be polished before being reusing the crankshaft Polishing the crankshaft ensures that any minor burrs or scoring are smoothed...

Page 189: ...the correct size Connecting Rod Check the connecting rod for straightness If the connecting rod is bent it will unevenly wear the bearing and piston as well as place greater stress on these components Any connecting rods that are bent or twisted must be replaced If the rods are straight and the wrist pin clearance is within specifications then only the bearing end of the rod need be checked Place ...

Page 190: ...or damage The bearing should look evenly worn all around with no deep scores or pits If the bearing is severely worn scored pitted or heat blued then the bearing and the components that use it should be inspected Oil Pump NOTE The oil pump is responsible for providing constant lubrication to the entire engine Always replace the oil pump when rebuilding the engine ...

Page 191: ...ed in the correct relationship to the rod or engine damage can occur Ball type cylinder hone Pistons Connecting Rods Free floating or C clip pistons can be disassembled with conventional tools Press fit pistons require a press to remove the piston from the rod and a special heating device to install the new piston to the connecting rod All pistons will have a mark indicating the direction to the f...

Page 192: ...Front of piston mark ...

Page 193: ...arefully lower the crankshaft into place Be careful not to damage any bearing surfaces 4 Check the clearance of each main bearing by placing a piece of Plastigage or its equivalent on the bearing surface across the full width of the bearing cap about 1 4 inch off center 5 Install the corresponding bearing cap and torque the bolts to specifications Checking bearing clearance with gauging material 6...

Page 194: ...inal locations 8 After the bearings have been fitted apply a light coat of engine oil to the crankshaft journals and bearings 9 Install the rear main bearing cap 10 Install all bearing caps except the thrust bearing cap 11 Torque all bearing cap bolts to specification 12 Install the thrust bearing cap as follows A Install the bearing cap with bolts finger tight B Pry the crankshaft forward against...

Page 195: ... crankshaft end play A Mount a dial gauge to the engine block and position the tip of the gauge to read from the crankshaft end B Pry the crankshaft toward the rear of the engine and zero the gauge Measuring crankshaft end play ...

Page 196: ...stons piston rings and the cylinder walls with light engine oil 1 Install connecting rod bolt protectors or rubber hose onto the connecting rod bolts studs Select the proper ring set for the size cylinder bore Position the ring in the bore in which it is going to be used Push the ring down into the bore area where normal ring wear is not encountered Use the head of the piston to position the ring ...

Page 197: ... replaced Bearing cap notch 3 Unless new pistons are installed be sure to install the pistons in the cylinders from which they were removed The numbers on the connecting rod and bearing cap must be on the same side when installed in the cylinder bore If a connecting rod is ever transposed from one engine or cylinder to another new bearings should be fitted and the connecting rod should be numbered...

Page 198: ... pistons Install the oil control ring first then the second compression ring and finally the top compression ring Use a piston ring expander tool to aid in installation and to help reduce the chance of breakage Piston and rod assembly installation ...

Page 199: ...he connecting rod bearing seats on the crankshaft journal Be careful not to allow the bearing cap screws to strike the crankshaft bearing journals 10 After the piston and connecting rod assemblies have been installed check the connecting rod side clearance on each crankshaft journal 11 Prime and install the oil pump and the oil pump intake tube 12 Install the assembled auxiliary balance shaft s OH...

Page 200: ...he engine CAUTION Damage to the engine can result if it is allowed to run with no oil pressure Check the engine oil level to make sure that it is full Check for any leaks and if found repair the leaks before continuing If there is still no indication of oil pressure prime the system 5 Confirm that there are no fluid leaks 6 Start the engine and maintain an idle of 2500 RPM for a period of 20 minut...

Page 201: ... lines Failure to do so may result in fire and or personal injury The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders including cancer You should make every effort to minimize your exposure to used engine oil Protective gloves should be worn when changing oil Wash your hands and any other exposed skin areas as soon as possible after exposure to used engin...

Page 202: ...t you are To protect an electronic device you your tools your work bench and the electronic device must be at the same potential Practically speaking that potential value is ground In order to discharge any static electricity that might build up you need to discharge it to ground For the most technicians the best way to achieve this is by wearing an appropriate wrist strap The wrist strap will hav...

Page 203: ...aning up the exhaust post combustion instead of reducing engine emissions pre combustion auto manufacturers were able to address the Federal Government s concerns regarding pollution contributed by automobiles however this did nothing for fuel efficiency The Federal Government s emissions standards combined with the price and availability of fuel at the time created a demand for the auto manufactu...

Page 204: ...tronic fuel metering systems began incorporating oxygen sensors in the exhaust to provide feedback to the ECM on whether the air fuel mixture was rich too much fuel or lean too much air When these electronic fuel metering systems read the input from the oxygen sensor they are said to be running in closed loop Open loop describes the mode of operation when these electronic fuel metering systems dis...

Page 205: ...ncomplete combustion By weight carbon monoxide accounts for the 47 of air pollution Hydrocarbon HC Hydrocarbons consist of carbon and hydrogen Hydrocarbons are emitted in an unburned form from equipment which uses a petroleum product as a source of fuel Hydrocarbons are one of the key elements responsible for the production of photochemical smog Oxides of Nitrogen NO X Oxides of nitrogen consist o...

Page 206: ...tage of the overall pollution problem It is the direct result of decaying organic matter wind born smoke and particulates from such natural events as plain and forest fires ignited by heat or lightning volcanic ash sand and dust which can spread over a large area of the countryside Such a phenomenon of natural pollution has been seen in the form of volcanic eruptions with the resulting plume of sm...

Page 207: ...e and fog type haze was being formed and at times remained in suspension over the cities taking time to dissipate At first this smog derived from the words smoke and fog was thought to result from industrial pollution but it was determined that automobile emissions shared the blame It was discovered that when normal automobile emissions were exposed to sunlight for a period of time complex chemica...

Page 208: ...we must dispose The heat from the combustion process can rise to over 4000 F 2204 C The dissipation of this heat is controlled by a ram air effect the use of cooling fans to cause air flow and a liquid coolant solution surrounding the combustion area to transfer the heat of combustion through the cylinder walls and into the coolant The coolant is then directed to a thin finned multi tube radiator ...

Page 209: ...n O2 reacts burns with the hydrocarbons HC and produces the carbon dioxide CO2 and the water vapors H2O If this chemical process would be the only process to take place the exhaust emissions would be harmless However during the combustion process other compounds are formed which are considered dangerous These pollutants are hydrocarbons HC carbon monoxide CO oxides of nitrogen NOx oxides of sulfur...

Page 210: ...sed of approximately 97 98 percent nitric oxide NO Nitric oxide is a colorless gas but when it is passed into the atmosphere it combines with oxygen and forms nitrogen dioxide NO2 The nitrogen dioxide then combines with chemically active hydrocarbons HC and when in the presence of sunlight causes the formation of photo chemical smog Ozone To further complicate matters some of the nitrogen dioxide ...

Page 211: ...and building damage Particulate Matter A certain amount of particulate matter is present in the burning of any fuel with carbon constituting the largest percentage of the particulates In gasoline the remaining particulates are the burned remains of the various other compounds used in its manufacture When a gasoline engine is in good internal condition the particulate emissions are low but as the e...

Page 212: ...t of the road draft tube into the air To control the crankcase emission the road draft tube was deleted A hose and or tubing was routed from the crankcase to the intake manifold so the blow by emission could be burned with the air fuel mixture However it was found that intake manifold vacuum used to draw the crankcase emissions into the manifold would vary in strength at the wrong time and not all...

Page 213: ...ver this did not control the fuel vapor emission from the fuel tank It was determined that most of the fuel evaporation occurs when the vehicle is stationary and the engine is off Most vehicles carry 5 25 gallons 19 95 liters of gasoline Should a large concentration of vehicles be parked in one area such as a large parking lot excessive fuel vapor emissions would take place increasing as the tempe...

Page 214: ...ric pressure atmospheric pressure intake manifold engine vacuum fuel tank pressures and changes as the vehicle is operated MAP Sensor The EMS uses the MAP sensor on systems that have a Mass Airflow Sensor MAF as a backup The EMS also uses the MAP sensor as an EGR diagnostic device and as an engine load verification device The EMS system uses this information to calculate engine load and EGR flow r...

Page 215: ...arded spark timing A F Sensor The air fuel ratio A F sensor like the oxygen sensor is used by the powertrain control module to measure the amount of oxygen in the exhaust The PCM uses this data to control the air fuel mixture in the engine The A F sensor can meter fuel more accurately than an oxygen sensor The A F sensor changes current output by measuring the amount of oxygen in the exhaust The A...

Page 216: ...t sensors or optical sensors The Crankshaft Position Sensor CKP also known as engine speed sensor is typically located in proximity to the crankshaft In addition the PCM uses the CKP sensor in conjunction with the camshaft position sensor to calculate and perform misfire diagnostics Typical crankshaft position CKP sensor CMP Sensor The Camshaft Position CMP sensor consists of a permanent magnet yo...

Page 217: ...jector operation to the proper cylinder timing If the camshaft position sensor or circuit is faulty most engines will start However the PCM misfire diagnostic will likely be affected Typical CMP sensor HO 2S The heated oxygen sensor is used by the powertrain control module to measure the amount of oxygen in the exhaust The PCM uses this data to control the air fuel mixture in the engine The PCM se...

Page 218: ...nsor resistance will change based on air temperature The higher the temperature is the lower the resistance The Power Train Control Module PCM provides a reference voltage and monitors the voltage drop between a fixed value internal resistance and the sensor resistance This is called a voltage divider circuit IAT sensor values are used by the PCM processor to assist with the calculation of idle sp...

Page 219: ...The PCM uses this information to calculate injector pulse width and spark advance Performance issues from MAF sensor failures range from no start conditions to stalling hesitation stumble and improper air fuel mixtures The MAF sensor values vary from 0 2V 0 gm sec to 4 8V 175 gm sec Some manufacturers incorporate the Intake Air Temperature IAT sensor as part of the Mass Air Flow MAF sensor Air Flo...

Page 220: ...agnet generators or hall effect technology The PCM may use other sensors on the vehicle ABS Wheel Speed to validate VSS operation VSS information is used to calculate vehicle loads including torque converter application cruise control fuel cutoff speed governance strategies instrument panel speedometer and more Modified drivetrain components such as final gear sets and or tires can alter VSS input...

Page 221: ...Typical VSS WARNING To avoid personal injury and or vehicle damage refer to the service precautions at the beginning of this section ...

Page 222: ...porative Emission Canister Removal Installation To Remove 1 Remove the spare tire from the vehicle 2 Lift the vehicle 3 If equipped remove the fuel tank shield from the frame Evaporative emission canister ...

Page 223: ...nister To Install 1 Install the evaporative emission EVAP retaining bracket onto the evaporative emission EVAP canister 2 Attach the evaporative emission EVAP canister to the mounting bracket Torque the bolt to 15 ft lb 20 Nm 3 Attach the evaporative emission EVAP canister and mounting bracket assembly to the vehicle Torque the bolt to 15 ft lb 20 Nm 4 Connect the evaporative emission EVAP vapor p...

Page 224: ...ehicle 2 Disconnect the evaporative emission EVAP canister purge solenoid valve connector 3 Disconnect the evaporative emission EVAP purge pipe and engine vacuum pipe from the evaporative emission EVAP canister purge solenoid valve Evaporative emission canister purge solenoid valve removal and installation ...

Page 225: ...ne vacuum pipe to the evaporative emission EVAP canister purge solenoid valve 4 Connect the evaporative emission EVAP canister purge solenoid valve connector 5 Lower the vehicle 5 3L 6 0L Engines To Remove 1 If equipped remove the intake manifold sight shield from the engine 2 Disconnect the evaporative emission EVAP pipes from the evaporative emission EVAP canister purge solenoid 3 Disconnect the...

Page 226: ...noid to the fuel rail 2 Connect the evaporative emission EVAP canister purge solenoid connector 3 Connect the evaporative emission EVAP pipes from the evaporative emission EVAP canister purge solenoid 4 If equipped install the intake manifold sight shield onto the engine ...

Page 227: ...ive emission EVAP vent pipe from the evaporative emission EVAP canister vent solenoid valve 4 Remove the evaporative emission EVAP canister vent solenoid valve from the bracket To Install 1 Install the evaporative emission EVAP canister vent solenoid valve onto the bracket 2 Connect the evaporative emission EVAP vent pipe to the evaporative emission EVAP canister vent solenoid valve 3 Connect the ...

Page 228: ...sensor removal and installation 3 Remove the fuel tank pressure sensor from the fuel tank 4 Remove and discard the seal from the fuel tank pressure sensor To Install 1 Install a new seal onto the fuel tank pressure sensor 2 Install the fuel tank pressure sensor into the fuel tank 3 Connect the fuel tank pressure sensor connector 4 Install the fuel tank into the vehicle ...

Page 229: ...rque the clamps on the throttle body to 35 in lb 4 Nm 4 Connect the fuel pressure regulator vacuum supply hose to the air cleaner outlet resonator 5 Lubricate the inner diameter of the positive crankcase clean air hose 6 Connect the positive crankcase ventilation dirty air hose to the intake manifold and positive crankcase ventilation PCV orifice tube 5 3L 6 0L Engine To Remove 1 Disconnect the po...

Page 230: ...re sensor connector 2 Detach the mass airflow intake air temperature sensor from the air cleaner outlet duct To Install 1 Attach the mass airflow intake air temperature sensor to the air cleaner outlet duct Torque the screws to 5 in lb 0 6 Nm 2 Connect the mass airflow intake air temperature sensor connector 5 3L 6 0L Engines To Remove CAUTION Make sure not to dent puncture or damage the honeycell...

Page 231: ...the mass airflow intake air temperature sensor and throttle body 3 Remove the air cleaner outlet duct bolt from the engine 4 Remove the air cleaner outlet duct from the engine compartment 5 Loosen the mass airflow intake air temperature sensor clamp at the air cleaner housing 6 Remove the mass airflow intake air temperature sensor from the air cleaner housing ...

Page 232: ...ir temperature sensor clamp at the air cleaner housing to 62 in lb 7 Nm 3 Install the air cleaner outlet duct into the engine compartment 4 Install the air cleaner outlet duct bolt into the engine Torque the bolt to 89 in lb 10 Nm 5 Torque the air cleaner outlet duct clamps at the mass airflow intake air temperature sensor and throttle body to 62 in lb 7 Nm 6 Connect the mass airflow intake air te...

Page 233: ...mshaft Position Sensor Removal Installation 4 2L Engine To Remove 1 Disconnect the camshaft position CMP sensor connector Camshaft position sensor 2 Detach the camshaft position CMP sensor from the engine ...

Page 234: ...to 89 in lb 10 Nm 2 Connect the camshaft position CMP sensor connector 5 3L Engine 2003 2004 To Remove 1 Remove the intake manifold from the engine 2 Disconnect the camshaft position CMP sensor connector Camshaft position sensor 3 Detach the camshaft position CMP sensor from the engine ...

Page 235: ...es 2005 2007 To Remove 1 Remove the generator bracket assembly from the engine Camshaft position sensor removal and installation 2 Disconnect the engine harness from the camshaft position sensor jumper harness 3 Detach the camshaft position sensor assembly from the engine 4 Remove the o ring from the camshaft position sensor 5 Disconnect the camshaft position sensor from the camshaft position sens...

Page 236: ...harness 2 Install the o ring onto the camshaft position sensor 3 Attach the camshaft position sensor assembly to the engine Torque the bolts to 18 ft lb 25 Nm 4 Connect the engine harness to the camshaft position sensor jumper harness 5 Install the generator bracket assembly onto the engine ...

Page 237: ... sensor removal and installation 4 Remove the engine coolant temperature ECT sensor from the engine To Install 1 Apply thread sealer P N 12346004 or equivalent to the engine coolant temperature ECT sensor threads 2 Install the engine coolant temperature ECT sensor into the engine Torque the sensor to 12 ft lb 16 Nm 3 Connect the engine coolant temperature ECT sensor connector 4 Refill the engine w...

Page 238: ...ve the engine coolant temperature ECT sensor from the left cylinder head To Install 1 Apply thread sealer P N 12346004 or equivalent to the engine coolant temperature ECT sensor threads 2 Install the engine coolant temperature ECT sensor into the left cylinder head Torque the sensor to 15 ft lb 20 Nm 3 Connect the engine coolant temperature ECT sensor connector 4 Refill the engine with coolant ...

Page 239: ...position CKP sensor from the engine block 4 If necessary remove and discard the o ring from the crankshaft position CKP sensor To Install 1 If necessary use clean engine oil to lubricate the o ring and install it onto the crankshaft position CKP sensor 2 Attach the crankshaft position CKP sensor to the engine block Torque the bolt to 89 in lb 10 Nm 3 Connect the crankshaft position CKP sensor conn...

Page 240: ... area around the crankshaft position CKP sensor is clean Crankshaft position sensor 4 Detach the crankshaft position CKP sensor from the engine To Install 1 Attach the crankshaft position CKP sensor to the engine Torque the bolt to 18 ft lb 25 Nm 2 Connect the crankshaft position CKP sensor connector 3 Install the starter onto the engine ...

Page 241: ...ion when connector or disconnecting power to the powertrain control module PCM NOTE Make sure to remove any debris from the powertrain control module PCM connector surfaces and inspect the gaskets NOTE Do not allow the powertrain control module PCM to contact battery voltage NOTE Do not touch the connector pins or soldered components on the circuit board To Remove 1 Use a scan tool to retrieve and...

Page 242: ...3 Install the powertrain control module PCM retaining nuts and bolts into the intake manifold Torque the nuts to 71 in lb 8 Nm 4 Attach the powertrain control module PCM connectors Torque the bolts to 71 in lb 8 Nm 5 If a new powertrain control module PCM was installed program the module 6 Use a scan tool to set the engine oil life 2006 2007 NOTE Make sure the ignition is in the off position when ...

Page 243: ...le PCM connectors 3 If a new powertrain control module PCM was installed program the module 4 Use a scan tool to set the engine oil life 5 3L Engine 2003 2004 NOTE Make sure to remove any debris from the powertrain control module PCM connector surfaces and inspect the gaskets To Remove 1 Use a scan tool to retrieve and record the remaining engine oil life 2 Disconnect the negative battery cable fr...

Page 244: ...o the powertrain control module PCM Torque the bolts to 71 in lb 8 Nm 2 Install the powertrain control module PCM into the bracket 3 Install the powertrain control module PCM cover onto the powertrain control module PCM 4 Connect the negative battery cable to the battery 5 If a new powertrain control module PCM was installed program the module 6 Use a scan tool to set the engine oil life ...

Page 245: ...d inspect the gaskets NOTE Do not allow the powertrain control module PCM to contact battery voltage NOTE Do not touch the connector pins or soldered components on the circuit board To Remove 1 Use a scan tool to retrieve and record the remaining engine oil life 2 Disconnect the negative battery cable from the battery 3 Disconnect the cooling fan connector 4 Remove the cover from the transmission ...

Page 246: ...M engine control module ECM bracket to the frame Torque the bolts to 89 in lb 10 Nm 2 Install the engine control module ECM into the bracket 3 Connect the engine control module ECM connectors 4 Install the cover over the transmission control module TCM engine control module ECM 5 Connect the cooling fan connector 6 Connect the negative battery cable to the battery 7 If a new engine control module ...

Page 247: ...ensor KS removal and installation 2 Disconnect the knock sensor KS connectors 3 Detach the knock sensors KS from the engine block To Install 1 Attach the knock sensors KS to the engine block Torque the sensor to 18 ft lb 25 Nm 2 Connect the knock sensor KS connectors 3 Lower the vehicle ...

Page 248: ...knock sensor KS connectors Knock sensor KS removal and installation 4 Remove the knock sensors KS from the engine To Install 1 Install the knock sensors KS into the engine Torque the sensors to 15 ft lb 20 Nm 2 Connect the knock sensor KS connectors 3 Install the knock sensor KS covers onto the engine 4 Install the intake manifold onto the engine ...

Page 249: ...nd installation 1 Disconnect the knock sensor KS 1 connector 2 Detach knock sensor KS 1 from the left side of the engine block To Install 1 Attach knock sensor KS 1 to the left side of the engine block Torque the bolt to 15 ft lb 20 Nm 2 Connect the knock sensor KS 1 connector ...

Page 250: ... 1 Disconnect the knock sensor KS 2 connector 2 Detach knock sensor KS 2 from the right side of the engine block To Install 1 Attach knock sensor KS 2 to the right side of the engine block Torque the bolt to 15 ft lb 20 Nm 2 Connect the knock sensor KS 2 connector ...

Page 251: ...d installation 2 Detach the manifold absolute pressure MAP sensor from the intake manifold 3 If necessary remove and discard the manifold absolute pressure MAP sensor seal To Install 1 If necessary install the new manifold absolute pressure MAP sensor seal 2 Attach the manifold absolute pressure MAP sensor to the intake manifold 3 Disconnect the manifold absolute pressure MAP sensor connector ...

Page 252: ...val and installation 3 Remove the manifold absolute pressure MAP sensor from the intake manifold To Install 1 Use clean engine oil to lubricate the manifold absolute pressure MAP sensor seal 2 Install the manifold absolute pressure MAP sensor onto the intake manifold 3 Connect the manifold absolute pressure MAP sensor connector 4 If equipped install the intake manifold sight shield onto the intake...

Page 253: ... from the frame 3 Disconnect the oil pressure switch connector Oil pressure sensor 4 Remove the oil pressure switch from the engine block To Install 1 Install the oil pressure switch into the engine block 2 Connect the oil pressure switch connector 3 Install the engine shield onto the frame 4 Lowe the vehicle ...

Page 254: ...allation 3 Use a J 41712 oil pressure sensor socket to remove the oil pressure sensor from the engine To Install 1 Apply sealant GM P N 12346004 to the oil pressure sensor threads 2 Use a J 41712 oil pressure sensor socket to install the oil pressure sensor into the engine Torque the sensor to 26 ft lb 35 Nm 3 Connect the oil pressure sensor connector 4 Install the intake manifold onto the engine ...

Page 255: ...ctor Heated oxygen sensor HO2S 1 removal and installation 2 For 2002 through 2003 model years use a J 39194 C oxygen sensor wrench to remove the heated oxygen sensor HO2S from the engine 3 For 2004 through 2007 model years use a J 39194 B heated oxygen sensor wrench to remove the heated oxygen sensor HO2S from the engine ...

Page 256: ...to the engine 3 For 2004 through 2007 model years use a J 39194 B heated oxygen sensor wrench to install the heated oxygen sensor HO2S into the engine 4 Torque the heated oxygen sensor HO2S to 30 ft lb 41 Nm 5 Connect the heated oxygen sensor HO2S connector Sensor 2 To Remove 1 Lift the vehicle 2 Disconnect the heated oxygen sensor HO2S connector Heated oxygen sensor HO2S 2 removal and installatio...

Page 257: ...Connect the heated oxygen sensor HO2S connector 4 Lower the vehicle 5 3L 6 0L Engines To Remove 1 Lift the vehicle 2 Disconnect the heated oxygen sensor HO2S connector Heated oxygen sensors 3 Remove the heated oxygen sensor HO2S from the catalytic converter To Install 1 If reinstalling the old sensor apply an anti seize compound to the heated oxygen sensor HO2S threads 2 Install the heated oxygen ...

Page 258: ... sensor connector Accelerator pedal position sensor 2 Detach accelerator pedal position APP sensor from the accelerator pedal To Install 1 Attach the accelerator pedal position APP sensor to the accelerator pedal Torque the fasteners to 89 in lb 10 Nm 2 Connect the accelerator pedal position APP sensor connector ...

Page 259: ...g C 2 Detach the vehicle speed sensor from the transfer case 3 Remove the o ring from the vehicle speed sensor To Install 1 Apply transmission fluid to the o ring 2 Install the o ring onto the vehicle speed sensor 3 Attach the vehicle speed sensor to the transfer case Torque the bolt to 97 in lb 11 Nm 4 Connect the vehicle speed sensor connector ...

Page 260: ...almost every single 1996 and later model a new form of trouble code reporting was developed which required the use of a scan tool On Board Diagnostic II OBD II compliant vehicles use a 5 digit alpha numeric code which would be difficult or impossible to read using a flashing light Trouble code reading on an OBD II compliant vehicle requires a scan tool Flashing trouble codes are a thing of the pas...

Page 261: ...ostat Coolant Temp Below Thermostat Operating Temp P0129 Barometric Pressure Too Low P0130 O2 Sensor Circuit Bank 1 Sensor 1 P0131 O2 Sensor Circuit Low Voltage Bank 1 Sensor 1 P0132 O2 Sensor Circuit High Voltage Bank 1 Sensor 1 P0133 O2 Sensor Circuit Slow Response Bank 1 Sensor 1 P0134 O2 Sensor Circuit No Activity Detected Bank 1 Sensor 1 P0135 O2 Sensor Heater Circuit Bank 1 Sensor 1 P0136 O2...

Page 262: ...rcuit Low P0179 Fuel Composition Sensor Circuit High P0180 Fuel Temperature Sensor A Circuit P0181 Fuel Temperature Sensor A Circuit Range Performance P0182 Fuel Temperature Sensor A Circuit Low P0183 Fuel Temperature Sensor A Circuit High P0184 Fuel Temperature Sensor A Circuit Intermittent P0185 Fuel Temperature Sensor B Circuit P0186 Fuel Temperature Sensor B Circuit Range Performance P0187 Fue...

Page 263: ...lator Control Circuit High P0005 Fuel Shutoff Valve A Control Circuit Open P0006 Fuel Shutoff Valve A Control Circuit Low P0007 Fuel Shutoff Valve A Control Circuit High P0008 Engine Position System Performance Bank 1 P0009 Engine Position System Performance Bank 2 P0010 a A Camshaft Position Actuator Circuit Bank 1 P0011 a A Camshaft Position Timing Over Advanced or System Performance A P0012 a A...

Page 264: ... Control Circuit Low Bank 2 Sensor 1 P0052 HO2S Heater Control Circuit High Bank 2 Sensor 1 P0053 HO2S Heater Resistance Bank 1 Sensor 1 P0054 HO2S Heater Resistance Bank 1 Sensor 2 P0055 HO2S Heater Resistance Bank 1 Sensor 3 P0056 HO2S Heater Control Circuit Bank 2 Sensor 2 P0057 HO2S Heater Control Circuit Low Bank 2 Sensor 2 P0058 HO2S Heater Control Circuit High Bank 2 Sensor 2 P0059 HO2S Hea...

Page 265: ...Circuit Intermittent P0105 Manifold Absolute Pressure Barometric Pressure Circuit P0106 Manifold Absolute Pressure Barometric Pressure Circuit Range Performance P0107 Manifold Absolute Pressure Barometric Pressure Circuit Low Input P0108 Manifold Absolute Pressure Barometric Pressure Circuit High Input P0229 Throttle Pedal Position Sensor Switch C Circuit Intermittent P0230 Fuel Pump Primary Circu...

Page 266: ...tribution Balance P0270 Cylinder 4 Injector Circuit Low P0271 Cylinder 4 Injector Circuit High P0272 Cylinder 4 Contribution Balance P0273 Cylinder 5 Injector Circuit Low P0274 Cylinder 5 Injector Circuit High P0275 Cylinder 5 Contribution Balance P0276 Cylinder 6 Injector Circuit Low P0277 Cylinder 6 Injector Circuit High P0278 Cylinder 6 Contribution Balance P0279 Cylinder 7 Injector Circuit Low...

Page 267: ...or 1 Circuit High Bank 1 or Single Sensor P0329 Knock Sensor 1 Circuit Input Intermittent Bank 1 or Single Sensor P0330 Knock Sensor 2 Circuit Bank 2 P0331 Knock Sensor 2 Circuit Range Performance Bank 2 P0332 Knock Sensor 2 Circuit Low Bank 2 P0333 Knock Sensor 2 Circuit High Bank 2 P0334 Knock Sensor 2 Circuit Input Intermittent Bank 2 P0335 Crankshaft Position Sensor A Circuit P0336 Crankshaft ...

Page 268: ...B Too Many Pulses P0377 Timing Reference High Resolution Signal B Too Few Pulses P0378 Timing Reference High Resolution Signal B Intermittent Erratic Pulses P0379 Timing Reference High Resolution Signal B No Pulses P0380 Glow Plug Heater Circuit A P0381 Glow Plug Heater Indicator Circuit P0382 Glow Plug Heater Circuit B P0383 P0384 Reserved by document P0385 Crankshaft Position Sensor B Circuit P0...

Page 269: ...4 Heated Catalyst Temperature Below Threshold Bank 2 P0435 Catalyst Temperature Sensor Bank 2 P0436 Catalyst Temperature Sensor Range Performance Bank 2 P0437 Catalyst Temperature Sensor Low Bank 2 P0438 Catalyst Temperature Sensor High Bank 2 P0439 Catalyst Heater Control Circuit Bank 2 P0440 Evaporative Emission System P0441 Evaporative Emission System Incorrect Purge Flow P0442 Evaporative Emis...

Page 270: ...t Gas Recirculation Sensor B Circuit P0487 Exhaust Gas Recirculation Throttle Position Control Circuit P0488 Exhaust Gas Recirculation Throttle Position Control Range Performance P0489 Exhaust Gas Recirculation Control Circuit Low P0490 Exhaust Gas Recirculation Control Circuit High P0491 Secondary Air Injection System Insufficient Flow Bank 1 P0492 Secondary Air Injection System Insufficient Flow...

Page 271: ...nge Performance P0537 A C Evaporator Temperature Sensor Circuit Low P0538 A C Evaporator Temperature Sensor Circuit High P0539 A C Evaporator Temperature Sensor Circuit Intermittent P0540 Intake Air Heater A Circuit P0541 Intake Air Heater A Circuit Low P0542 Intake Air Heater A Circuit High P0543 Intake Air Heater A Circuit Open P0544 Exhaust Gas Temperature Sensor Circuit Bank 1 Sensor 1 P0545 E...

Page 272: ... Cruise Control Vent Control Circuit Low P0588 Cruise Control Vent Control Circuit High P0589 Cruise Control Multi Function Input B Circuit P0590 Cruise Control Multi Function Input B Circuit Stuck P0591 Cruise Control Multi Function Input B Circuit Range Performance P0592 Cruise Control Multi Function Input B Circuit Low P0593 Cruise Control Multi Function Input B Circuit High P0594 Cruise Contro...

Page 273: ... Actuator Control Range Performance Bank 2 P0640 Intake Air Heater Control Circuit P0641 Sensor Reference Voltage A Circuit Open P0642 Sensor Reference Voltage A Circuit Low P0643 Sensor Reference Voltage A Circuit High P0644 Driver Display Serial Communication Circuit P0645 A C Clutch Relay Control Circuit P0646 A C Clutch Relay Control Circuit Low P0647 A C Clutch Relay Control Circuit High P064...

Page 274: ...e Circuit Open P0689 ECM PCM Power Relay Sense Circuit Low P0690 ECM PCM Power Relay Sense Circuit High P0691 Fan 1 Control Circuit Low P0692 Fan 1 Control Circuit High P0693 Fan 2 Control Circuit Low P0694 Fan 2 Control Circuit High P0695 Fan 3 Control Circuit Low P0696 Fan 3 Control Circuit High P0697 Sensor Reference Voltage C Circuit Open P0698 Sensor Reference Voltage C Circuit Low P0699 Sens...

Page 275: ...CM Engine Speed Output Circuit High P0740 Torque Converter Clutch Circuit Open P0741 Torque Converter Clutch Circuit Performance or Stuck Off P0742 Torque Converter Clutch Circuit Stuck On P0743 Torque Converter Clutch Circuit Electrical P0744 Torque Converter Clutch Circuit Intermittent P0745 Pressure Control Solenoid A P0746 Pressure Control Solenoid A Performance or Stuck Off P0747 Pressure Con...

Page 276: ...cuit Range Performance P0793 Intermediate Shaft Speed Sensor A Circuit No Signal P0794 Intermediate Shaft Speed Sensor A Circuit Intermittent P0795 Pressure Control Solenoid C P0796 Pressure Control Solenoid C Performance or Stuck off P0797 Pressure Control Solenoid C Stuck On P0798 Pressure Control Solenoid C Electrical P0799 Pressure Control Solenoid C Intermittent P0800 Transfer Case Control Sy...

Page 277: ...mission Fluid Pressure Sensor Switch A Circuit Low P0843 Transmission Fluid Pressure Sensor Switch A Circuit High P0844 Transmission Fluid Pressure Sensor Switch A Circuit Intermittent P0845 Transmission Fluid Pressure Sensor Switch B Circuit P0846 Transmission Fluid Pressure Sensor Switch B Circuit Range Performance P0847 Transmission Fluid Pressure Sensor Switch B Circuit Low P0848 Transmission ...

Page 278: ... Relay Sense Circuit Range Performance P0890 TCM Power Relay Sense Circuit Low P0891 TCM Power Relay Sense Circuit High P0892 TCM Power Relay Sense Circuit Intermittent P0893 Multiple Gears Engaged P0894 Transmission Component Slipping P0895 Shift Time Too Short P0896 Shift Time Too Long P0897 Transmission Fluid Deteriorated P0898 Transmission Control System MIL Request Circuit Low P0899 Transmiss...

Page 279: ...od Too Short P0944 Hydraulic Pressure Unit Loss of Pressure P0945 Hydraulic Pump Relay Circuit Open P0946 Hydraulic Pump Relay Circuit Range Performance P0947 Hydraulic Pump Relay Circuit Low P0948 Hydraulic Pump Relay Circuit High P0949 Auto Shift Manual Adaptive Learning Not Complete P0950 Auto Shift Manual Control Circuit P0951 Auto Shift Manual Control Circuit Range Performance P0952 Auto Shif...

Page 280: ...nce P0994 Transmission Fluid Pressure Sensor Switch F Circuit Low P0995 Transmission Fluid Pressure Sensor Switch F Circuit High P0996 Transmission Fluid Pressure Sensor Switch F Circuit Intermittent P0997 Shift Solenoid F Control Circuit Range Performance P0998 Shift Solenoid F Control Circuit Low P0999 Shift Solenoid F Control Circuit High P0A00 Motor Electronics Coolant Temperature Sensor Circu...

Page 281: ...h Circuit Low Bank 1 a P2017 Intake Manifold Runner Position Sensor Switch Circuit High Bank 1 a P2018 Intake Manifold Runner Position Sensor Switch Circuit Intermittent Bank 1 a P2019 Intake Manifold Runner Position Sensor Switch Circuit Bank 2 a P2020 Intake Manifold Runner Position Sensor Switch Circuit Range Performance Bank 2 a P2021 Intake Manifold Runner Position Sensor Switch Circuit Low B...

Page 282: ...h P2065 Fuel Level Sensor B Circuit P2066 Fuel Level Sensor B Performance P2067 Fuel Level Sensor B Circuit Low P2068 Fuel Level Sensor B Circuit High P2069 Fuel Level Sensor B Circuit Intermittent P2070 Intake Manifold Tuning IMT Valve Stuck Open a P2071 Intake Manifold Tuning IMT Valve Stuck Closed a P2075 Intake Manifold Tuning IMT Valve Position Sensor Switch Circuit a P2076 Intake Manifold Tu...

Page 283: ... Position Sensor F Minimum Stop Performance P2118 Throttle Actuator Control Motor Current Range Performance P2119 Throttle Actuator Control Throttle Body Range Performance P2120 Throttle Pedal Position Sensor Switch D Circuit P2121 Throttle Pedal Position Sensor Switch D Circuit Range Performance P2122 Throttle Pedal Position Sensor Switch D Circuit Low Input P2123 Throttle Pedal Position Sensor S...

Page 284: ...dal Position Sensor D Maximum Stop Performance P2167 Throttle Pedal Position Sensor E Maximum Stop Performance P2168 Throttle Pedal Position Sensor F Maximum Stop Performance P2169 Exhaust Pressure Regulator Vent Solenoid Control Circuit Open P2170 Exhaust Pressure Regulator Vent Solenoid Control Circuit Low P2171 Exhaust Pressure Regulator Vent Solenoid Control Circuit High P2172 Throttle Actuato...

Page 285: ...ater Control Circuit High Bank 2 P2221 NOx Sensor Heater Sense Circuit Bank 2 P2222 NOx Sensor Heater Sense Circuit Range Performance Bank 2 P2223 NOx Sensor Heater Sense Circuit Low Bank 2 P2224 NOx Sensor Heater Sense Circuit High Bank 2 P2225 NOx Sensor Heater Sense Circuit Intermittent Bank 2 P2226 Barometric Pressure Circuit P2227 Barometric Pressure Circuit Range Performance P2228 Barometric...

Page 286: ...mance P2266 Water in Fuel Sensor Circuit Low P2267 Water in Fuel Sensor Circuit High P2268 Water in Fuel Sensor Circuit Intermittent P2269 Water in Fuel Condition P2270 O2 Sensor Signal Stuck Lean Bank 1 Sensor 2 P2271 O2 Sensor Signal Stuck Rich Bank 1 Sensor 2 P2272 O2 Sensor Signal Stuck Lean Bank 2 Sensor 2 P2273 O2 Sensor Signal Stuck Rich Bank 2 Sensor 2 P2274 O2 Sensor Signal Stuck Lean Ban...

Page 287: ...ry Circuit P2318 Ignition Coil G Primary Control Circuit Low P2319 Ignition Coil G Primary Control Circuit High P2320 Ignition Coil G Secondary Circuit P2321 Ignition Coil H Primary Control Circuit Low P2322 Ignition Coil H Primary Control Circuit High P2323 Ignition Coil H Secondary Circuit P2324 Ignition Coil I Primary Control Circuit Low P2325 Ignition Coil I Primary Control Circuit High P2326 ...

Page 288: ...ck Open P2422 Evaporative Emission System Vent Valve Stuck Closed P2423 HC Adsorption Catalyst Efficiency Below Threshold Bank 1 P2424 HC Adsorption Catalyst Efficiency Below Threshold Bank 2 P2425 Exhaust Gas Recirculation Cooling Valve Control Circuit Open P2426 Exhaust Gas Recirculation Cooling Valve Control Circuit Low P2427 Exhaust Gas Recirculation Cooling Valve Control Circuit High P2428 Ex...

Page 289: ...rcuit P2520 A C Request A Circuit Low P2521 A C Request A Circuit High P2522 A C Request B Circuit P2523 A C Request B Circuit Low P2524 A C Request B Circuit High P2525 Vacuum Reservoir Pressure Sensor Circuit P2526 Vacuum Reservoir Pressure Sensor Circuit Range Performance P2527 Vacuum Reservoir Pressure Sensor Circuit Low P2528 Vacuum Reservoir Pressure Sensor Circuit High P2529 Vacuum Reservoi...

Page 290: ... Sensor Circuit High P2571 Direct Ozone Reduction Catalyst Temperature Sensor Circuit Intermittent Erratic P2572 Direct Ozone Reduction Catalyst Deterioration Sensor Circuit P2573 Direct Ozone Reduction Catalyst Deterioration Sensor Circuit Range Performance P2574 Direct Ozone Reduction Catalyst Deterioration Sensor Circuit Low P2575 Direct Ozone Reduction Catalyst Deterioration Sensor Circuit Hig...

Page 291: ...ment Feedback Signal B High P2645 A Rocker Arm Actuator Control Circuit Open Bank 1 P2646 A Rocker Arm Actuator System Performance or Stuck Off Bank 1 P2647 A Rocker Arm Actuator System Stuck On Bank 1 P2648 A Rocker Arm Actuator Control Circuit Low Bank 1 P2649 A Rocker Arm Actuator Control Circuit High Bank 1 P2650 B Rocker Arm Actuator Control Circuit Open Bank 1 P2651 B Rocker Arm Actuator Sys...

Page 292: ...rmance or Stuck Off P2724 Pressure Control Solenoid E Stuck On P2725 Pressure Control Solenoid E Electrical P2726 Pressure Control Solenoid E Intermittent P2727 Pressure Control Solenoid E Control Circuit Open P2728 Pressure Control Solenoid E Control Circuit Range Performance P2729 Pressure Control Solenoid E Control Circuit Low P2730 Pressure Control Solenoid E Control Circuit High P2731 Pressur...

Page 293: ...t No Signal P2768 Input Turbine Speed Sensor B Circuit Intermittent P2769 Torque Converter Clutch Circuit Low P2770 Torque Converter Clutch Circuit High P2771 Four Wheel Drive 4WD Low Switch Circuit P2772 Four Wheel Drive 4WD Low Switch Circuit Range Performance P2773 Four Wheel Drive 4WD Low Switch Circuit Low P2774 Four Wheel Drive 4WD Low Switch Circuit High P2775 Upshift Switch Circuit Range P...

Page 294: ...e Valve Control Circuit High P3421 Cylinder 3 Exhaust Valve Control Circuit Open P3422 Cylinder 3 Exhaust Valve Control Performance P3423 Cylinder 3 Exhaust Valve Control Circuit Low P3424 Cylinder 3 Exhaust Valve Control Circuit High P3425 Cylinder 4 Deactivation Intake Valve Control Circuit Open P3426 Cylinder 4 Deactivation Intake Valve Control Performance P3427 Cylinder 4 Deactivation Intake V...

Page 295: ...ve Control Circuit Low P3472 Cylinder 9 Exhaust Valve Control Circuit High P3473 Cylinder 10 Deactivation Intake Valve Control Circuit Open P3474 Cylinder 10 Deactivation Intake Valve Control Performance P3475 Cylinder 10 Deactivation Intake Valve Control Circuit Low P3476 Cylinder 10 Deactivation Intake Valve Control Circuit High P3477 Cylinder 10 Exhaust Valve Control Circuit Open P3478 Cylinder...

Page 296: ...ation Bus High U0024 Low Speed CAN Communication Bus Open U0025 Low Speed CAN Communication Bus Low U0026 Low Speed CAN Communication Bus High U0027 Low Speed CAN Communication Bus shorted to Bus U0028 Vehicle Communication Bus A U0029 Vehicle Communication Bus A Performance U0030 Vehicle Communication Bus A Open U0031 Vehicle Communication Bus A Low U0032 Vehicle Communication Bus A High U0033 Ve...

Page 297: ... Vehicle Communication Bus E shorted to Bus E U0073 Control Module Communication Bus Off U0074 Reserved by Document U0075 Reserved by Document U0076 Reserved by Document U0077 Reserved by Document U0078 Reserved by Document U0079 Reserved by Document U0080 Reserved by Document U0081 Reserved by Document U0082 Reserved by Document U0083 Reserved by Document U0084 Reserved by Document U0085 Reserved...

Page 298: ...6 Lost Communication With Steering Angle Sensor Module U0127 Lost Communication With Tire Pressure Monitor Module U0128 Lost Communication With Park Brake Control Module U0129 Lost Communication With Brake System Control Module U0130 Lost Communication With Steering Effort Control Module U0131 Lost Communication With Power Steering Control Module U0132 Lost Communication With Ride Level Control Mo...

Page 299: ...stem Sensor I U0179 Lost Communication With Restraints System Sensor J U0180 Lost Communication With Automatic Lighting Control Module U0181 Lost Communication With Headlamp Leveling Control Module U0182 Lost Communication With Lighting Control Module Front U0183 Lost Communication With Lighting Control Module Rear U0184 Lost Communication With Radio U0185 Lost Communication With Antenna Control M...

Page 300: ...rol Module Left U0233 Lost Communication With Side Obstacle Detection Control Module Right U0234 Lost Communication With Convenience Recall Module U0235 Lost Communication With Cruise Control Front Distance Range Sensor U0300 Internal Control Module Software Incompatibility U0301 Software Incompatibility with ECM PCM U0302 Software Incompatibility with Transmission Control Module U0303 Software In...

Page 301: ...eceived From Alternative Fuel Control Module U0410 Invalid Data Received From Fuel Pump Control Module U0411 Invalid Data Received From Drive Motor Control Module U0412 Invalid Data Received From Battery Energy Control Module A U0413 Invalid Data Received From Battery Energy Control Module B U0414 Invalid Data Received From Four Wheel Drive Clutch Control Module U0415 Invalid Data Received From An...

Page 302: ...ure that all fuel spillage should it occur is quickly removed from engine surfaces Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container Always keep a dry chemical Class B fire extinguisher near the work area Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame Always use a back up wrench when loosening and tightening fuel line...

Page 303: ...ly of pressurized fuel from the fuel system The primary function of the fuel injector is to atomize gasoline into the surrounding air at the proper time Throttle body injectors atomize fuel into the intake manifold or combustion chamber in much the same manner as a conventional carburetor wet intake port fuel injectors direct the atomized fuel at the back side of each cylinders intake valve s dry ...

Page 304: ...tal Collar To Remove 1 Relieve the pressure in the fuel system Quick connect retainer 2 Detach the retainer from the fitting CAUTION When using compressed air be sure to wear safety glasses 3 Use compressed air to remove any dirt in the fitting J 37088 A fuel line disconnect tool ...

Page 305: ...ricate the male pipe end 2 Insert the male pipe end into the female connection and push on both sides until the retaining tabs snap into place 3 Make sure the connection is secure by pulling on both sides of the quick connect fitting 4 Attach the retainer to the quick connect fitting Quick Connect Fitting S Service Plastic Collar To Remove Types of plastic quick connect fittings 1 Relieve the pres...

Page 306: ...nectors squeeze the plastic release tabs Q release 4 For Q release connectors push the tab to the other end of the slot to release the fitting Squeeze to release 5 For squeeze to release connectors squeeze the plastic ring where shown ...

Page 307: ...onnector press down on the tab where shown 8 Pull the male side of the connection from the female To Install 1 Use a few drops of clean engine oil to lubricate the male pipe end 2 Insert the male pipe end into the female connection and push on both sides until the retaining tabs snap into place 3 Make sure the connection is secure by pulling on both sides of the quick connect fitting ...

Page 308: ...omputer are operating as designed Continue testing all the injectors this way All Injectors Clicking If you ve determined that all injectors are clicking but the problem is the fuel system continue diagnostics Make sure that you have checked fuel pump pressure as outlined An easy way to determine a weak or unproductive cylinder is a cylinder drop test This is accomplished by cancelling one cylinde...

Page 309: ...One or More Injectors Are Not Clicking Unplug the fuel injector connector Probe the two terminals of a fuel injector to check resistance ...

Page 310: ...running the injector driver circuit inside the PCM is working If one or more injectors are found to be inoperative testing the injector driver circuit and computer can be accomplished using a noid light First with the engine not running and the ignition key in the OFF position remove the connector from the injector you plan to ...

Page 311: ...t a fuel pressure gauge to the fuel rail pressure connection 2 Connect a Scan Tool turn the to ON and Select Special Functions Fuel System Injector Balance Test 3 Select injector 1 the fuel system will prime Record the initial pressure reading immediately after the fuel pump shuts off 4 Press the soft key to pulse the first injector Record the Pressure After Pulse reading immediately after the inj...

Page 312: ... removing the fuel injectors in order to prevent damage to the connector pins and nozzles Submerging the injectors in any cleaners or solvents may damage the injectors CAUTION Fuel injector leakage may contaminate the engine oil Fuel injector removal and installation ...

Page 313: ...nstall Fuel injector A Part number B Build date code C Month D Day E Year F Shift G NOTE Use the correct part number when ordering new fuel injectors 1 Use clean engine oil to lubricate the new o ring seals 2 Install new fuel injector o ring seals to the fuel injectors 3 Install new retainer clips to the fuel injectors 4 Install the fuel injectors into the fuel rail 5 Connect the fuel injector con...

Page 314: ... the injectors CAUTION Fuel injector leakage may contaminate the engine oil Fuel injector removal and installation 1 Remove the fuel rail assembly from the cylinder head 2 Disconnect the fuel injector connectors 3 Remove and discard the fuel injector retainer clips from the fuel injectors 4 Remove the fuel injectors from the fuel rail 5 Remove and discard the fuel injector o ring seals ...

Page 315: ...ng new fuel injectors 1 Use clean engine oil to lubricate the new o ring seals 2 Install new fuel injector o ring seals to the fuel injectors 3 Install new retainer clips to the fuel injectors 4 Install the fuel injectors into the fuel rail 5 Connect the fuel injector connectors 6 Install the fuel rail assembly to the cylinder head ...

Page 316: ...engine 3 Disconnect the fuel feed pipe from the fuel rail 4 Use GM X 30A or an equivalent spray type cleaner to clean the fuel rail assembly and cylinder head 5 Disconnect the fuel injector harness connector from the engine harness 6 Detach the fuel injector harness connector from the camshaft cover Fuel rail assembly removal and installation ...

Page 317: ...el injector spray tips and the fuel injector connector terminals 1 Remove the air cleaner outlet duct from the engine compartment 2 Relieve the pressure in the fuel system 3 Disconnect the positive crankcase ventilation dirty air hose from the intake manifold and positive crankcase ventilation PCV orifice tube 4 Detach the fuel injector harness connectors from the valve rocker arm covers 5 Disconn...

Page 318: ...s from the cylinder heads 14 Loosen the fuel rail crossover pipe retainer clip screws 15 Remove the fuel rail assemblies from the cylinder heads 16 To avoid system contamination plug the holes and cap the fittings 17 Remove and discard the lower o ring seals from the fuel injectors ...

Page 319: ...el rail 11 Reposition the upper engine harness onto the top of the engine and install the retainer nut into the engine Torque the nut to 44 in lb 5 Nm 12 Attach the harnesses to the ignition coil brackets 13 Connect the A C compressor pressure switch mass airflow intake air temperature sensor generator ignition coil harnesses electronic throttle control fuel injector harnesses evaporative emission...

Page 320: ...fuel tank shield from the frame 4 Make sure the fuel pipe and hose connections as well as the surrounding areas are clean 5 Disconnect the fuel pipes from the fuel filter keep the retaining clips with the filter 6 To avoid fuel loss and fuel system contamination cap off the fuel pipes Fuel filter removal and installation 7 Remove the screw from the fuel filter bracket 8 Remove the fuel filter from...

Page 321: ...screw into the fuel filter bracket Torque the screw to 106 in lb 12 Nm 4 Uncap the fuel pipes 5 Connect the fuel pipes to the fuel filter 6 Turn on the ignition for 2 seconds with the engine off and then turn off the ignition After 10 seconds turn the ignition back on with the engine off 7 Check for leaks in the fuel lines 8 Lift the vehicle 9 If previously removed install the fuel tank shield to ...

Page 322: ...ing seal from the fuel pressure regulator To Install 1 If the fuel pressure regulator is not being replaced install a new fuel pressure regulator screen 2 Use clean engine oil to lubricate the o ring 3 Install a new o ring seal to the fuel pressure regulator 4 Install the fuel pressure regulator onto the fuel rail 5 Install the fuel pressure regulator retainer onto the fuel pressure regulator Torq...

Page 323: ... the fuel rail To Install 1 If necessary install the backup ring o ring seal and regulator filter onto the fuel pressure regulator 2 Use clean engine oil to lubricate the o ring 3 Install a new o ring seal to the fuel pressure regulator 4 Install the fuel pressure regulator onto the fuel rail 5 Install the new fuel pressure regulator retainer onto the fuel pressure regulator 6 Connect the fuel pre...

Page 324: ...k from the vehicle 2 Use a J 45722 fuel tank sending unit wrench and a long breaker bar to turn the fuel sender lock ring counterclockwise CAUTION Handling the fuel sender assembly by the fuel pipes may cause damage to the joints Fuel sender assembly removal and installation ...

Page 325: ...ock ring on a flat surface and measure the clearance between the ring and the surface at seven points 6 If the clearance is more that 0 016 in 0 41 mm replace the lock ring To Install 1 Install a new fuel sender assembly seal onto the fuel tank 2 Install a new fuel sender assembly into the fuel tank 3 Use a J 45722 fuel tank sending unit wrench and a long breaker bar to turn the fuel sender lock r...

Page 326: ...rom the fuel supply manifold 5 Connect a suitable fuel pressure gauge to the fuel pressure test port Wrap a shop towel around the fitting while connecting the gauge to prevent fuel spillage 6 Install the gauge bleed hose into a suitable container and open the valve to bleed the system 7 Drain any remaining fuel from the gauge into the container and remove the gauge from the test port Fuel system c...

Page 327: ...ply line Wrap a shop towel around the fitting while connecting the gauge to prevent fuel spillage 4 Turn ignition ON 5 Install the gauge bleed hose into a suitable container and open the valve to bleed air from the system 6 Activate fuel pump with scan tool 7 Close bleed valve 8 Check for leaks With the key on and engine off the pressure should be within the manufactures recommended specifications...

Page 328: ...he frame 4 Remove the fuel tank shield from the fuel tank 5 Drain the fuel from the tank into an approved container 6 Loosen the fuel hose clamp and disconnect the hose from the fuel tank 7 Disconnect the evaporative emission EVAP vent valve and fuel tank pressure sensor connectors Evaporative emission cansister pipes removal and installation ...

Page 329: ...moval and installation 5 Detach the fuel tank straps from the frame 6 Lower the fuel tank 7 Disconnect the fuel sender connector 8 Remove the fuel tank from the vehicle To Install 1 Place the fuel tank under the vehicle 2 Connect the fuel sender connector 3 Attach the fuel tank straps to the frame Torque the bolts to 24 ft lb 32 Nm 4 Remove the caps from the evaporative emission EVAP and fuel pipe...

Page 330: ...n off the ignition After 10 seconds turn the ignition back on with the engine off 12 Lift the vehicle 13 Check for leaks in the fuel lines 14 Install the fuel tank shield onto the fuel tank 15 Install the frame brace onto the frame 16 Lower the vehicle 2005 2007 To Remove 1 Relieve the pressure in the fuel system 2 Lift the vehicle 3 Remove the frame brace from the frame 4 Remove the fuel tank shi...

Page 331: ...ct the pipe from the fuel tank 9 Disconnect the fuel feed and evaporative emission EVAP pipes from the fuel tank 10 To avoid system contamination cap the pipes 11 Use a jack to support the fuel tank Fuel tank removal and installation 12 Detach the fuel tank straps from the frame 13 Lower the fuel tank 14 Disconnect the evaporative emission EVAP vent valve fuel tank pressure sensor and fuel sender ...

Page 332: ...el tank Torque the clamp to 22 in lb 2 5 Nm 8 Connect the fuel filler pipe recirculation hose to the fuel tank 9 Connect the evaporative emission EVAP canister fresh air solenoid and purge pipes to the evaporative emission EVAP canister 10 Lower the vehicle 11 Refill the fuel tank 12 Turn on the ignition for 2 seconds with the engine off and then turn off the ignition After 10 seconds turn the ign...

Page 333: ...ator from engine 2 Disconnect the evaporative emission EVAP canister purge line from the throttle body 3 Disconnect the throttle body connector Throttle body removal and installation 4 Disconnect the throttle body with the gasket from the intake manifold 5 Clean the sealing surfaces as necessary ...

Page 334: ... throttle body 5 Install the air cleaner outlet resonator onto the engine 5 3L 6 0L Engines To Remove WARNING Do not insert a screwdriver or other small tools into the throttle body to hold the throttle plate open 1 Drain the cooling system 2 Remove the air cleaner outlet duct from the engine compartment 3 Disconnect the throttle actuator motor connector 4 Disconnect the throttle body coolant hose...

Page 335: ...ntake manifold Torque the nuts and bolts to 53 in lb 6 Nm 4 Connect the throttle body coolant hoses to the throttle body 5 Connect the throttle actuator motor connector 6 Install the air cleaner outlet duct into the engine compartment 7 Refill the cooling system 8 Make sure the vehicle is not in a reduced engine power mode the ignition switch is in the on position and the engine is off 9 Use a sca...

Page 336: ... Failure to do so may result in fire and or personal injury The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders including cancer You should make every effort to minimize your exposure to used engine oil Protective gloves should be worn when changing oil Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil ...

Page 337: ...acing a live inflator module air bag on a bench or other surface always face bag and trim cover up away from the surface Never rest a steering column assembly on the steering wheel with the inflator module air bag face down and column vertical This is necessary so that a free space is provided to allow the inflator module air bag to expand in the unlikely event of accidental deployment Otherwise p...

Page 338: ...uld then maintain its balanced condition The pressure that the electrons exert when returning to its source is called voltage When voltage V is measured with a voltmeter the value displayed represents the attractive force or electromotive force available to get the atoms in balance again Amperage Amperage is a measure of the actually quantity of electrons that flow from the net negative charge to ...

Page 339: ...rohibits its use as common wiring Airbag systems commonly use gold plated terminal to ensure that current will readily flow through the system Gold while cost prohibitive will not react to air and contaminants that can contribute to unwanted voltage drops Larger diameter wires provide more surface area for current flow The larger the wire size being used the less resistance the wire will have Soli...

Page 340: ...the light could be turned on and off This example illustrates a simple circuit When the switch is closed power from the positive battery terminal flows through the fuse and the switch and then to the light bulb The light illuminates and the circuit is completed through the ground wire back to the negative battery terminal In reality the two ground points shown in the illustration are attached to t...

Page 341: ... measured in units called volts v When a voltmeter is connected to a circuit it is measuring the electrical pressure The actual flow of electricity depends not only on voltage and amperage but also on the resistance of the circuit The higher the resistance the higher the force necessary to push the current through the circuit The standard unit for measuring resistance is an ohm Resistance in a cir...

Page 342: ... the voltage in volts I is the current in amps and R is the resistance in ohms The basic point to remember is that as the resistance of a circuit goes up the amount of current that flows in the circuit will go down if voltage remains the same The amount of work that the electricity can perform is expressed as power The unit of power is the watt w The relationship between power voltage and current ...

Page 343: ...the battery is replaced by the alternator restoring the battery to its original chemical state The Alternator Some older vehicles use a generator instead of an alternator The difference is that an alternator supplies alternating current which is then changed to direct current for use on the vehicle while a generator produces direct current Alternators tend to be more efficient and that is why they...

Page 344: ...t Most vehicles use one or more fuse panels Fuse panel inside driver s side kick panel Circuit Breaker a circuit breaker is basically a self repairing fuse It will open the circuit in the same fashion as a fuse but when the surge subsides the circuit breaker can be reset and does not need replacement Fusible Link a fusible link fuse link or main link is a short length of special high temperature i...

Page 345: ...were connected from the load to the control switch the switch would have to carry the high amperage load and the fairing or dash would be twice as large to accommodate the increased size of the wiring harness To prevent these problems a relay is used Relays are composed of a coil and a set of contacts When the coil has a current passed though it a magnetic field is formed and this field causes the...

Page 346: ...lay coil to the control switch for the circuit and from the opposite side of the relay coil to ground Load Every electrical circuit must include a load something to use the electricity coming from the source Without this load the battery would attempt to deliver its entire power supply from one pole to another This is called a short circuit All this electricity would take a short cut to ground and...

Page 347: ...hind instrument panels Since automotive electrical systems are very sensitive to changes in resistance the selection of properly sized wires is critical when systems are repaired A loose or corroded connection or a replacement wire that is too small for the circuit will add extra resistance and an additional voltage drop to the circuit The wire gauge number is an expression of the cross section ar...

Page 348: ... be straightened once they are bent Make certain that the connectors are properly seated and all of the sealing rings are in place when connecting leads Molded these connectors require complete replacement of the connector if found to be defective This means splicing a new connector assembly into the harness All splices should be soldered to insure proper contact Use care when probing the connecti...

Page 349: ...s accomplished by the use of special test equipment The following describes different types of commonly used test equipment and briefly explains how to use them in diagnosis In addition to the information covered below the tool manufacturer s instructions booklet provided with the tester should be read and clearly understood before attempting any test procedures Jumper Wires CAUTION Never use jump...

Page 350: ...o locate open electrical circuits on either the ground side of the circuit or on the power side If an electrical component fails to operate connect the jumper wire between the component and a good ground If the component operates only with the jumper installed the ground circuit is open If the ground circuit is good but the component does not operate the circuit between the power feed and componen...

Page 351: ...similar in design to the 12 volt test light but contains a 1 5 volt penlight battery in the handle It is most often used in place of a multimeter to check for open or short circuits when power is isolated from the circuit continuity test The battery in a self powered test light does not provide much current A weak battery may not provide enough power to illuminate the test light even when a comple...

Page 352: ...uit Checks for short circuits are made in the same manner as checks for open circuits except that the circuit must be isolated from both power and normal ground Infinite resistance indicates no continuity while zero resistance indicates a dead short CAUTION Never use an ohmmeter to check the resistance of a component or wire while there is voltage applied to the circuit Ammeter an ammeter measures...

Page 353: ...s there power going to electrical switches and motors Performing careful systematic checks will often turn up most causes on the first inspection without wasting time checking components that have little or no relationship to the problem Test all repairs after the work is done to make sure that the problem is fixed Some causes can be traced to more than one component so a careful verification of r...

Page 354: ...e sections of the circuit sequentially 3 If the light is out or there is infinite resistance the open is between the probe and the circuit ground 4 If the light is on or the meter shows continuity the open is between the probe and the end of the circuit toward the power source Short Circuits NOTE Never use a self powered test light to perform checks for opens or shorts when power is applied to the...

Page 355: ... available from the battery and should be the first step in any electrical troubleshooting procedure after visual inspection Many electrical problems especially on computer controlled systems can be caused by a low state of charge in the battery Excessive corrosion at the battery cable terminals can cause poor contact that will prevent proper charging and full battery current flow 1 Set the voltme...

Page 356: ...ground 3 Operate the circuit and check the voltage prior to the first component load 4 There should be little or no voltage drop in the circuit prior to the first component If a voltage drop exists the wire or connectors in the circuit are suspect 5 While operating the first component in the circuit probe the ground side of the component with the positive meter lead and observe the voltage reading...

Page 357: ... any components or the battery 3 Where necessary also isolate at least one side of the circuit to be checked in order to avoid reading parallel resistances Parallel circuit resistances will always give a lower reading than the actual resistance of either of the branches 4 Connect the meter leads to both sides of the circuit wire or component and read the actual measured ohms on the meter scale Mak...

Page 358: ...assenger in a frontal impact exceeding a certain set speed limit The system consists of the SRS unit including safing sensor and impact sensor the cable reel the driver s airbag the front passenger s airbag side airbags side curtain airbags seat belt tensioners front impact sensors side impact sensors and roll rate sensor Since the driver s and front passenger s airbags use the same sensors both n...

Page 359: ...yourself in front of the airbag during removal inspection or replacement Disarming Arming Air Bag Fuse To Disarm 1 Straighten the front wheels of the vehicle 2 Turn the ignition switch to off 3 Remove all the fuses supplying power to the inflatable restraint sensing and diagnostic module SDM 4 Do not work on the air bag system for 1 minute To Arm 1 Turn the ignition switch to off 2 Install all the...

Page 360: ...G To avoid personal injury and or vehicle damage refer to the service precautions at the beginning of this section Underhood Fuse Block 4 2L Engine Except Saab Underhood Fuse Block 2002 2005 Early Production ...

Page 361: ...5 3L Engine Except Saab Underhood Fuse Block 2003 2005 Early Production ...

Page 362: ...m the instrument panel I P 2 For Oldsmobile vehicles remove the center console shift lever bezel from the center console 3 Remove the accessory trim plate from the instrument panel I P 4 Remove the retaining screws from the radio 5 Pull the radio out of the instrument panel I P far enough to gain access to the radio connectors 6 Disconnect the radio antenna cable from the radio 7 Disconnect the ra...

Page 363: ...io 4 Install the radio into the instrument panel I P 5 Install the retaining screws into the radio Torque the screws to 18 in lb 2 Nm 6 Install the accessory trim plate to the instrument panel I P 7 For Oldsmobile vehicles install the center console shift lever bezel onto the center console 8 For GMC vehicles install the lower closeout insulator panel onto the instrument panel I P ...

Page 364: ...nts Switches Brake Light Switch Removal Installation To Remove 1 Remove the left sound insulator from the instrument panel I P 2 Remove the pushrod retainer stop lamp switch and pushrod from the brake pedal pin 3 Disconnect the stop lamp switch connector To Install 1 Connect the stop lamp switch connector 2 Install the pushrod stop lamp switch and pushrod retainer onto the pedal pin 3 Install the ...

Page 365: ...e instrument panel I P 3 Pull the headlamp switch out through the access hole 4 Disconnect the headlamp switch connectors To Install 1 Connect the headlamp switch connectors 2 Place the headlamp switch behind the instrument panel I P through the access hole 3 Install the headlamp switch into the retaining tabs behind the instrument panel I P 4 Install the access cover onto the left of the instrume...

Page 366: ...in access to the instrument panel cluster IPC connector 6 Disconnect the instrument panel cluster IPC connector To Install 1 Connect the instrument panel cluster IPC connector 2 Place the instrument panel cluster IPC into the instrument panel 3 Install the retaining screws into the instrument panel cluster IPC Torque the screws to 22 in lb 2 5 Nm 4 Install the instrument panel cluster IPC bezel in...

Page 367: ...to the service precautions at the beginning of this section Front Fog Lamp Removal Installation Chevrolet GMC and Isuzu To Remove 1 Remove the fog lamp bulb and socket fro the fog lamp Cornering and fog lamps GMC and Chevrolet 2 Detach the fog lamp from the fascia ...

Page 368: ...et into the fog lamp 3 Aim the fog lamp Oldsmobile and Buick To Remove 1 Remove the fog lamp bulb and socket from the fog lamp housing Front fog lamp Buick 2 Remove the fog lamp retaining pins from the fog lamp bracket 3 Remove the aim adjustment screw from the fog lamp 4 Remove the fog lamp from the fog lamp bracket ...

Page 369: ...ulb only handle the bulb by the base CAUTION Do not allow a halogen bulb to come into contact with dirt or moisture CAUTION Make sure to dispose of a used halogen bulb properly CAUTION Do not allow children to handle halogen bulbs 1 Turn the lamp switch to the off position 2 Make sure the bulb is cool before changing 3 Remove the headlamp assembly from the headlamp panel 4 Remove the rear access c...

Page 370: ...ect the headlamp connector 5 Remove the park turn and side marker bulb sockets from the headlamp assembly 6 Remove the headlamp assembly from the headlamp panel To Install 1 Place the headlamp assembly into the headlamp panel 2 Install the park turn and side marker bulb sockets into the headlamp assembly 3 Connect the headlamp connector 4 If equipped connect the headlamp leveling motor connector 5...

Page 371: ...ormally carried The vehicle should be facing a wall that is no less than six feet 1 8m high and 12 feet 3 7m wide The front of the vehicle should be about 25 feet from the wall If aiming is to be performed outdoors wait until dusk to properly see the headlight beams on the wall If done in a garage darken the area around the wall as much as possible by closing shades or hanging cloth over windows 2...

Page 372: ...High beam headlight pattern alignment 6 Perform the necessary repairs 7 Turn the headlights ON 8 Adjust the beams to match the marks on the wall ...

Page 373: ...ion 2 Pull the bottom of the cargo lamp out from the body trim panel 3 Remove the cargo lamp from the body trim panel by pulling down on the lamp 4 Remove the bulb socket from the cargo lamp To Install 1 Install the bulb socket into the cargo lamp 2 Install the bottom of the cargo lamp into the body trim panel 3 Push on the top of the cargo lamp to engage the locking tab ...

Page 374: ...g the lamp forward Dome lamp removal and installation 3 Remove the dome lamp from the headliner 4 Disconnect the dome lamp connector To Install 1 Connect the dome lamp connector 2 Place the dome lamp into the headliner 3 Engage the retaining tab by moving the dome lamp rearward 4 Install the lens onto the dome lamp ...

Page 375: ...stop lamp retaining screws into the liftgate window molding Torque the screws to 22 in lb 2 5 Nm 3 Close the liftgate window 4 Lift the liftgate 5 Install the high mount stop lamp grommet into the body 6 Connect the high mount stop lamp connector 7 Install the rear of the headliner by inserting the retaining pins Cornering Lamp Removal Installation To Remove 1 Remove the bulb socket from the corne...

Page 376: ... a flat bladed tool to pry up the rear of the clearance lamp lens 4 Remove the clearance lamp lens from the lamp by pulling the lens rearward 5 Remove the bulb from the cornering lamp To Install 1 Install the bulb into the cornering lamp 2 Place the forward edge of the lens in the opening in the lamp and push down on the rear of the lens 3 Install the push pin into the clearance lamp ...

Page 377: ...1 Detach the license lamp lens from the liftgate 2 Remove the license lamp bulb from the socket To Install 1 Install the license lamp bulb into the socket 2 Make sure the bulb is clean 3 Attach the license lamp lens to the liftgate Torque the screws to 12 in lb 1 4 Nm ...

Page 378: ... rearward 3 Disconnect the tail lamp assembly connector 4 Remove the tail lamp circuit board from the assembly To Install 1 Install the tail lamp circuit board into the assembly 2 Connect the tail lamp assembly connector 3 Push the assembly directly forward into the opening to engage the locking pins 4 Install the tail lamp assembly retaining screws into the body Torque the screws to 17 in lb 1 9 ...

Page 379: ...oosen the wiper arm pivot by pushing inward 4 Remove the wiper arm from the pivot shaft use a battery terminal puller if necessary 5 Remove the wiper blade from the wiper arm 6 Use a soft wire brush to clean the pivot shaft knurls To Install 1 Install the wiper blade onto the wiper arm 2 Install the wiper arm onto the pivot shaft 3 Install the wiper arm nut onto the wiper arm Torque the nut to 22 ...

Page 380: ... clip locking tab and pull down on the wiper blade 3 Remove the wiper blade from the inside radius of the wiper arm 4 Pull the wiper blade through the wiper arm opening To Install 1 Insert the wiper blade into the wiper arm opening 2 Install the wiper blade onto the inside radius of the wiper arm 3 Pull up on the wiper blade and engage the wiper blade clip locking tab 4 Lower the wiper arm onto th...

Page 381: ...iper arm 2 Remove the cover from the wiper arm 3 Detach the wiper arm from the pivot shaft 4 If necessary remove the wiper blade from the wiper arm To Install 1 If necessary install the wiper blade onto the wiper arm 2 With the wiper motor in the park position attach the wiper arm to the pivot shaft Torque the nut to 15 ft lb 20 Nm 3 Install the cover onto the wiper arm 4 Connect the washer hose t...

Page 382: ... soft wire brush to clean the pivot shaft knurls 5 If necessary remove the wiper blade from the wiper arm To Install 1 If necessary install the wiper blade onto the wiper arm 2 With the engine off and the ignition switch in the run position turn the rear wiper on to full speed 3 Remove the rear wiper fuse from the rear fuse block 4 Turn the rear wiper off 5 Install the rear wiper fuse into the rea...

Page 383: ...m 11 Make sure the endgate window is operating properly Rear Window Wiper Blade Removal Installation Chevrolet GMC Except Envoy XUV Oldsmobile Buick and Isuzu To Remove CAUTION Do not let the windshield wiper arm snap back against the window 1 Pull the wiper arm off of the park ramp Wiper blade A Wiper arm B Wiper blade clip locking tab C 2 Disengage the wiper blade clip locking tab and pull down ...

Page 384: ...e window Saab and GMC Envoy XUV To Remove CAUTION Do not let the windshield wiper arm snap back against the window 1 Pull the wiper arm off of the park ramp 2 Rotate the wiper blade until it is horizontal to the wiper arm 3 Remove the wiper blade from the wiper arm by pushing the blade away from the arm To Install 1 Install the wiper blade onto the wiper arm by pushing the blade onto the arm 2 Low...

Page 385: ...nsmission assembly rearward 5 Disconnect the windshield wiper motor connector 6 Remove the wiper transmission assembly from the plenum To Install 1 Install the wiper transmission assembly into the plenum 2 Connect the windshield wiper motor connector 3 Engage the wiper motor into the slot in the plenum by pushing the wiper transmission assembly forward 4 Install the wiper transmission assembly ret...

Page 386: ...haft 3 Remove the interior trim panel from the liftgate 4 Disconnect the wiper motor connector 5 Detach the wiper motor from the liftgate To Install 1 Attach the wiper motor to the liftgate Torque the bolts to 71 in lb 8 Nm 2 Connect the wiper motor connector 3 Install the interior trim panel to the liftgate 4 Install the nut and spacer onto the pivot shaft Torque the nut to 71 in lb 8 Nm 5 Instal...

Page 387: ...wiper motor removal and installation GMC Envoy XUV 5 Detach the rear wiper motor from the endgate To Install 1 Attach the wiper motor to the endgate Torque the nuts and bolts to 71 in lb 8 Nm 2 Connect the rear wiper motor connector 3 Install the window onto the endgate 4 Install the interior trim panel to the endgate 5 Install the spacer and wiper arm onto the pivot shaft 6 Make sure the rear wip...

Page 388: ...move the trim plate from the instrument panel I P Rear window wiper washer switch 2 Disconnect the rear window wiper washer switch connector 3 Detach the rear window wiper washer switch from the trim plate To Install 1 Connect the rear window wiper washer switch connector 2 Attach the rear window wiper washer switch to the trim plate 3 Install the trim plate onto the instrument panel I P ...

Page 389: ...shield washer pump 3 Pull the windshield washer pump from the retainer 4 Remove and discard the grommet from the windshield washer pump To Install 1 Install a new grommet to the windshield washer pump 2 Push the windshield washer pump into the retainer 3 Connect the washer hose to the windshield washer pump 4 Install the washer solvent container into the vehicle ...

Page 390: ...indow washer pump 3 Pull the rear window washer pump from the retainer 4 Remove and discard the grommet from the rear window washer pump To Install 1 Install a new grommet to the rear window washer pump 2 Push the rear window washer pump into the retainer 3 Connect the washer hose to the rear window washer pump 4 Install the washer solvent container into the vehicle ...

Page 391: ...r Removal Installation To Remove Remove the trim panel water deflector and door latch assembly from the door Remove the door lock actuator retaining screws from the lock Disengage the rubber bumper from the latch by lifting up and rotating the door lock actuator Lock actuator removal and installation Remove the door lock actuator from the latch ...

Page 392: ...etaining screws into the lock Torque the screws to 6 in lb 0 75 Nm 5 Install the door latch assembly water deflector and trim panel onto the door Liftgate Lock Actuator Removal Installation To Remove 1 Remove liftgate latch assembly from the liftgate 2 Remove the liftgate lock actuator retaining screws from the lock 3 Disengage the rubber bumper from the latch by lifting up and rotating the liftga...

Page 393: ...atch 4 Install the liftgate lock actuator retaining screws into the lock Torque the screws to 6 in lb 0 75 Nm 5 Install the liftgate latch assembly onto the liftgate Window Regulator Motor Removal Installation Front To Remove 1 Remove the door trim panel speaker and water deflector from the front door 2 Loosen the window carrier bolts 3 Lift the window off of the carrier 4 Disconnect the window re...

Page 394: ...or 3 Install the window regulator through the door opening 4 Position the window regulator retaining bolts into the keyhole slots Install the remaining window regulator retaining bolts Torque the middle bolt to 80 in lb 9 Nm Torque the remaining bolts to 88 in lb 10 Nm Connect the window regulator motor connector Lower the window into the carrier and loosely tighten the bolts Operate the window un...

Page 395: ...dow regulator motor connector 4 Lower the window into the carrier and loosely tighten the bolts 5 Operate the window until it is in the full up position and the window is in the carrier 6 Torque the window carrier bolts to 88 in lb 10 Nm 7 Install the speaker water deflector and door trim panel onto the rear door Long Wheel Base To Remove 1 Lower the window to the midway point 2 Remove the door tr...

Page 396: ... regulator through the door opening 11 Detach the window regulator motor from the window regulator To Install 1 Attach the window regulator motor to the window regulator Torque the bolts to 9 in lb 5 Nm 2 Install the window regulator through the rear door opening 3 Position the window regulator retaining bolt into the keyhole slots 4 Install the remaining window regulator retaining bolts into the ...

Page 397: ...Connect the window regulator connector 10 Lower the window into the carrier and loosely tighten the bolts 11 Operate the window until it is in the full up position and the window is in the carrier 12 Torque the window carrier bolts to 89 in lb 10 Nm 13 Install the water deflector and door trim panel into the rear door ...

Page 398: ...nstallation To Remove 1 Remove the seat from the vehicle 2 Remove the trim panel from the seat 3 Detach the seat belt buckle from the seat 4 Disconnect the driver seat harness connector from the body harness connector 5 Disconnect the seat belt buckle and lumbar motor connectors 6 Remove the SIR harness from the seat Power seat adjuster mechanism removal and installation ...

Page 399: ...l the seat back onto the seat 3 Attach the power seat adjuster to the seat pan Torque the nuts to 18 ft lb 25 Nm 4 Install the SIR harness into the seat 5 Connect the seat belt buckle and lumbar motor connectors 6 Connect the driver seat harness connector to the body harness connector 7 Attach the seat belt buckle to the seat Torque the nut to 41 ft lb 55 Nm 8 Install the trim panel onto the seat ...

Page 400: ... top of the seat back frame Front seat lumbar assembly removal and installation 6 Detach the lumbar assembly from the seat back frame To Install 1 Attach the lumbar assembly to the seat back frame Torque the screw to 71 in lb 8 Nm 2 Install the lumbar clip onto the top of the seat back frame 3 Connect the lumbar motor connector 4 Install the panel into the seat back 5 Install the cover and pad ont...

Page 401: ...lure to do so may result in fire and or personal injury The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders including cancer You should make every effort to minimize your exposure to used engine oil Protective gloves should be worn when changing oil Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil Soap...

Page 402: ... or retained in a specific order for reassembly At the time of installation components should be installed in the same location and with the same mating surface as when removed An automobile engine is a combination of many machined honed polished and lapped surfaces with tolerances that are measured in millimeters or thousandths of an inch These surfaces should be covered or protected to avoid com...

Page 403: ... functions 1 It allows the engine to idle with the vehicle at a standstill even with the transmission in gear 2 It allows the transmission to shift from range to range smoothly without requiring that the driver close the throttle during the shift 3 It multiplies engine torque to an increasing extent as vehicle speed drops and throttle opening is increased This has the effect of making the transmis...

Page 404: ...he energy picked up in the impeller If the fluid was now returned directly into the impeller both halves of the converter would have to turn at approximately the same speed at all times and torque input and output would both be the same In flowing through the impeller and turbine the fluid picks up two types of flow or flow in two separate directions It flows through the turbine blades and it spin...

Page 405: ...ditions the torque converter begins to behave almost like a solid shaft with the impeller and turbine speeds being almost equal Lock up Converter The lock up converter contains the same components as a conventional converter but also includes a clutch assembly that when applied connects the engine directly to the transmission The result is no slippage and therefore virtually no power loss An elect...

Page 406: ...er surface a sun gear mounted on a shaft and located at the very center of the outer gear and a set of three planet gears held by pins in a ring like planet carrier meshing with both the sun gear and the outer gear Either the outer gear or the sun gear may be held stationary providing more than one possible torque multiplication factor for each set of gears Also if all three gears are forced to ro...

Page 407: ...nd or clutches Servo operation The accumulators are used to cushion the engagement of the servos The transmission fluid must pass through the accumulator on the way to the servo The accumulator housing contains a thin piston which is sprung away from the discharge passage of the accumulator When fluid passes through the accumulator on the way to the servo it must move the piston against spring pre...

Page 408: ...pressure rises with an increase in vehicle speed and modulator pressure rises as the throttle is opened wider By responding to these two pressures the shift valves cause the up shift points to be delayed with increased throttle opening to make the best use of the engine s power output Older transmissions also make use of an auxiliary circuit for downshifting This circuit may be actuated by the thr...

Page 409: ...shield from the fuel tank 10 Remove the transmission support from the frame 11 Detach the transmission mount from the transmission 12 Remove the front exhaust pipe from the vehicle 13 Lower the transmission enough to gain access to the top of the transmission 14 If equipped remove the transfer case from the vehicle 15 Remove the range selector cable from the bracket 16 Detach the transmission heat...

Page 410: ...es in the transmission 25 Install a safety chain around the transmission 26 Detach the fuel line bracket from the bell housing 27 Remove the coolant pipe bracket bolts from the bell housing Transmission removal and installation 28 Remove the transmission nuts studs and bolts from the engine 29 Retain the torque converter by installing a J 21366 converter holding strap onto the bell housing 30 Remo...

Page 411: ...e into the vehicle 15 Install the front exhaust pipe into the vehicle 16 Attach the transmission mount to the transmission Torque the bolts to 18 ft lb 25 Nm 17 Install the transmission support onto the frame 18 Install the fuel tank shield onto the fuel tank 19 Attach the evaporative emission EVAP canister to the mounting bracket 20 Lower the transmission jack and remove from under the vehicle 21...

Page 412: ...ch the transmission heat shield from the transmission 14 Disconnect the transmission vent hose from the transmission 15 Detach the transmission harness from the transmission 16 Detach the fuel line bracket from the left side of the transmission Torque converter access plug removal and installation 17 Remove the torque converter access plug from the transmission 18 Mark the orientation of the flywh...

Page 413: ...er tube from the transmission Transmission removal and installation 24 Remove the transmission nuts studs and bolts from the engine 25 Retain the torque converter by installing a J 21366 converter holding strap onto the bell housing 26 Remove the transmission from the engine by pulling the transmission rearward 27 Lower the transmission ...

Page 414: ...of the transmission 11 Attach the transmission harness to the transmission 12 Attach the transmission heat shield to the transmission Torque the bolts to 13 ft lb 17 Nm 13 Install the range selector cable onto the bracket 14 If equipped install the transfer case to the vehicle 15 Install the front exhaust pipe into the vehicle 16 Attach the transmission mount to the transmission Torque the bolts t...

Page 415: ...hot check procedure can be made NOTE Use this cold check procedure to check fluid level when the fluid temperature is between 80 90 F 27 32 C Start the engine and remove the dipstick from the tube then wipe the dipstick end with a clean rag or paper towel Install the dipstick completely in the dipstick tube wait three seconds and then pull it back out again CAUTION Always check the fluid level at ...

Page 416: ...inting down and check both sides of the dipstick Read the lower level Repeat the check procedure to verify the reading 4 A safe operating fluid level is within the HOT crosshatch band on the dipstick If the fluid level is not within the HOT band and the transmission temperature is between 180 200 F 82 93 C add or drain fluid as necessary to bring the level into the HOT band If the fluid level is l...

Page 417: ...utral position switch removal and installation 6 Detach the park neutral position switch from the transmission 7 Remove the park neutral position switch from the manual shaft If the switch does not slide off the shaft file the edge of the shaft to remove and burrs To Install 1 Install the park neutral position switch onto the manual shaft aligning the switch hub flats with the shaft flats 2 Attach...

Page 418: ...switch aligner until the upper pin is aligned with the slot on the switch 6 Torque the park neutral switch bolts to 18 ft lb 25 Nm 7 Remove the J 41364 A park neutral switch aligner or positive assurance bracket from the switch 8 Connect the park neutral position switch connector 9 Attach the transmission control lever to the manual shaft Torque the nut to 18 ft lb 25 Nm 10 Lower the vehicle 11 Ma...

Page 419: ...itch mounting bolts 6 Put the vehicle in the neutral position and attempt to start the vehicle while turning the park neutral position switch 7 When the engine starts turn off the engine 8 Torque the park neutral position switch mounting bolts to 18 ft lb 25 Nm 9 Lower the vehicle 10 Make sure the switch is operating properly If the switch is not operating properly replace the switch Range Selecto...

Page 420: ...r cable from the transfer case 8 Remove the range selector lever cable grommet from the floor panel by pushing up on the grommet from under the vehicle 9 Lower the vehicle 10 Remove the center console from the vehicle 11 Remove the carpet and floor mat from the driver s side floor panel Floor shift control assembly removal and installation 12 Remove the range selector lever cable from the floor sh...

Page 421: ...e driver s side floor panel 6 Install the center console into the vehicle 7 Lift the vehicle 8 For 4WD vehicles attach the range selector lever cable to the transfer case 9 For 2WD vehicles attach the range selector lever cable to the floor panel 10 Install the range selector lever cable into the range selector bracket 11 Install the range selector lever cable retainer onto the range selector brac...

Page 422: ...ift the vehicle Range selector lever A Range selector lever cable bracket B Range selector lever cable C Range selector lever cable retainer D Range selector lever cable end E 4 Remove the range selector cable from the transmission range selector lever ball stud 5 Make sure the range selector lever is in the park position ...

Page 423: ...ctor lever cable end primary lock 10 Align the range selector lever cable to the transmission range selector lever ball stud 11 Install the range selector lever cable to the transmission range selector lever ball stud 12 Push down on the primary lock 13 Slide the range selector lever cable end secondary lock over the range selector lever cable primary lock 14 Make sure the range selector lever cab...

Page 424: ...filter by pulling down on the filter while twisting 13 Remove and discard the filter seal from the transmission 14 Inspect the transmission fluid color and the filter 15 Clean the sealing surfaces as necessary To Install 1 Apply transmission fluid to the new filter seal 2 Install the filter seal into the transmission using a mallet and a suitable size socket 3 Install the filter onto the transmiss...

Page 425: ...ssmember from the frame Front axle pinion yoke 3 Mark the orientation of the front propeller shaft to the front axle pinion yoke 4 Detach the retainers from the front axle pinion yoke CAUTION Do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint If the propeller shaft is removed by using such means the injection joints may fracture...

Page 426: ...aft To Install 1 Apply GM P N 12377985 grease to the transfer case output shaft 2 Install the front propeller shaft onto the transfer case output shaft 3 Align the front propeller shaft to the marks on the front axle pinion yoke 4 Connect the front propeller shaft from the front axle pinion yoke 5 Attach the retainers to the front axle pinion yoke Torque the bolts to 15 ft lb 20 Nm 6 Install the s...

Page 427: ...removal and installation 4 Detach the retainers from the rear axle pinion yoke CAUTION Do not attempt to remove the shaft by pounding on the yoke ears or using a tool between the yoke and the universal joint If the propeller shaft is removed by using such means the injection joints may fracture and lead to premature failure of the joint 5 Remove the rear propeller shaft from the rear axle pinion y...

Page 428: ... transaxle 3 Install the rear propeller shaft into the transmission or transaxle 4 Align the rear propeller shaft to the marks on the rear axle pinion yoke 5 Install the front propeller shaft onto the rear axle pinion yoke 6 Attach the retainers to the rear axle pinion yoke Torque the bolts to 15 ft lb 20 Nm 7 Lower the vehicle ...

Page 429: ...on or pieces of the old ring 11 Check the bearing cup bores for burrs or imperfections 12 Clean the retaining ring grooves To Install 1 Remove the bearing cups from the universal joint 2 Install the bottom bearing cup partially into the yoke 3 Install the cross into the yoke with the trunnion seated freely in the bearing cup 4 Press the bearing cup into the yoke until the cup is even with the yoke...

Page 430: ...erfections 13 Clean the remaining sheared plastic from the grooves of the yoke To Install 1 Remove the bearing cups from the universal joint 2 Install the bottom bearing cup partially into the yoke 3 Install the cross into the yoke with the trunnion seated freely in the bearing cup 4 Press the bearing cup into the yoke until the cup is even with the yoke ear 5 Install the top bearing cup partially...

Page 431: ...ing cup bores for burrs or imperfections 12 Clean the retaining ring grooves To Install 1 Remove the bearing cups from the universal joint 2 Install the bottom bearing cup partially into the yoke 3 Install the cross into the yoke with the trunnion seated freely in the bearing cup 4 Press the bearing cup into the yoke until the cup is even with the yoke ear 5 Install the top bearing cup partially i...

Page 432: ...tic from the grooves of the yoke To Install 1 Remove the bearing cups from the universal joint 2 Install the bottom bearing cup partially into the yoke 3 Install the cross into the yoke with the trunnion seated freely in the bearing cup 4 Press the bearing cup into the yoke until the cup is even with the yoke ear 5 Install the top bearing cup partially into the yoke ear 6 Make sure that the trunni...

Page 433: ...om under the frame 3 Drain the fluid from the differential carrier 4 Remove the front propeller shaft from the differential carrier 5 Detach the antilock brake system ABS harnesses from the wheel wells 6 Detach the brake hose retainers from the frame 7 Remove the vent hose from the differential carrier Upper ball pinch nut and bolt removal and installation ...

Page 434: ...per shock modules 10 Remove the front stabilizer bar links and shock modules from the frame 11 Remove the steering knuckle from the upper control arm 12 Remove the front wheel drive shafts from the differential carrier 13 Secure the front wheel drive shafts to the frame 14 Use mechanics wire to support the front shock modules and steering knuckle ...

Page 435: ...arrier to the oil pan Torque the bolts to 63 ft lb 85 Nm 4 Install the inner shaft into the differential carrier 5 Install the power steering gear assembly into the vehicle 6 Detach the front wheel drive shafts from the frame 7 Detach the front shock modules and steering knuckle from their supports 8 Install the front wheel drive shafts into the differential carrier 9 Install the vent hose onto th...

Page 436: ...ront wheels onto the vehicle 5 3L 6 0L Engines To Remove 1 Remove the front wheels from the vehicle 2 Remove the engine protection shield from under the frame 3 Drain the fluid from the differential carrier 4 Detach the antilock brake system ABS harnesses from the wheel wells 5 Disconnect the wheel speed sensor WSS connectors 6 Detach the brake hose retainers from the frame 7 Remove the sway bar l...

Page 437: ...Upper ball pinch nut and bolt removal and installation 10 Remove the nut and bolt from the upper ball pinches 11 Remove the steering knuckles from the upper control arms ...

Page 438: ...de the front wheel drive shafts 16 Secure the front shock modules to the frame 17 Remove the jack stands supporting the lower control arms 18 Remove the front propeller shaft from the pinion yoke 19 Set aside and secure the front propeller shaft 20 Remove the inner shaft from the differential carrier 21 Detach the differential carrier from the oil pan and secure it to the frame 22 Remove the oil p...

Page 439: ...r ball pinches Torque the nut and bolt to 30 ft lb 40 Nm 10 Remove the jack stands supporting the lower control arms 11 Install the retaining nuts onto the upper shock modules Torque the nuts to 33 ft lb 45 Nm 12 Install the steering gear into the vehicle 13 Attach the brake hose retainers to the frame Torque the bolts to 18 ft lb 25 Nm 14 Install the sway bar link pins into the lower control arms...

Page 440: ...ver installer 2 Install the control arm to the axle housing Do not tighten the fasteners at this time 3 Load the suspension and tighten the control arm fasteners when the suspension is at normal vehicle ride height Intermediate Shaft Bearing Oil Seal Removal Installation To Remove 1 Lift the vehicle 2 Remove the right drive shaft from the vehicle 3 Install a J 29369 2 bushing and bearing remover a...

Page 441: ...4 Remove and discard the outboard intermediate shaft bearing oil seal from the intermediate shaft bearing Intermediate shaft bearing Automatic 4WD Intermediate shaft bearing Selectable 4WD ...

Page 442: ...wire harness from the intermediate shaft bearing 8 Detach the intermediate shaft bearing from the oil pan Actuator removal and installation 9 For vehicles with selectable 4WD detach the actuator from the intermediate shaft bearing 10 Install the intermediate shaft bearing into a vise ...

Page 443: ...tall a J 29369 2 bushing and bearing remover and a J 269 01 slide hammer with adapter into the inboard intermediate shaft bearing oil seal 12 Remove and discard the inboard intermediate shaft bearing oil seal from the intermediate shaft bearing ...

Page 444: ...all a new inboard intermediate shaft bearing oil seal into the intermediate shaft bearing using a J 45225 axle seal installer and a J 8092 universal driver handle 2 For vehicles with selectable 4WD attach the actuator to the intermediate shaft bearing ...

Page 445: ...t bearing 5 For vehicles with selectable 4WD connect the actuator connector J 45359 and J 8092 installation 6 Install the outboard intermediate shaft bearing oil seal into the intermediate shaft bearing using a J 45359 axle seal installer and a J 8092 universal driver handle 7 Install the right drive shaft into the vehicle 8 Lower the vehicle ...

Page 446: ... crossmember from the frame Drive pinion torque measurement 6 Use an inch pound torque wrench to measure the amount of torque needed to turn the drive pinion Write down this measurement 7 Mark the orientation of the pinion yoke to the drive pinion shaft 8 Install a J 8614 01 flange and pulley holding tool onto the drive pinion 9 Remove the pinion nut from the pinion while holding the J 8614 01 fla...

Page 447: ...yoke NOTE Make sure not to distort or scratch the aluminum case while removing the seal from the bore 12 Use a seal removal tool to remove the drive pinion seal from the drive pinion 13 Use a soft faced hammer to remove the dust deflector from the pinion yoke Discard the deflector To Install 1 Use a soft faced hammer to install the dust deflector onto the pinion yoke Drive pinion seal installation...

Page 448: ... pinion end play is just taken up Seat the bearings by rotating the pinion while tightening the nuts 10 Use an inch pound torque wrench to measure the amount of torque needed to turn the drive pinion 11 If the torque of the pinion nut is not 3 5 in lb 0 40 0 57 Nm greater that the recorded value tighten the nut until it is 12 Rotate the pinion several times to make sure the bearing have been seate...

Page 449: ... 9 Remove the rear drive pinion shaft yoke and seal from the drive pinion 10 Remove the drive pinion from the rear axle housing To Install 1 Install the drive pinion into the rear axle housing 2 Install the rear drive pinion shaft yoke and seal onto the drive pinion 3 Install the rear differential assembly into the vehicle 4 Adjust the differential side bearing preload and the backlash 5 Perform a...

Page 450: ...ear wheels from the vehicle 3 Remove the brake caliper from the hub 4 Remove the rear wheel speed sensor from the hub 5 Remove the cover and gasket from the rear axle housing 6 Remove the pinion shaft locking bolt from the rear axle housing 7 For axles without a locking differential remove the pinion shaft from the rear axle housing 8 For axles with a locking differential partially remove the pini...

Page 451: ...Axle shaft removal and installation 11 Remove the axle shaft from the rear axle housing J 45859 and J 2619 01 Installation ...

Page 452: ...e shaft flange outward 6 Install the pinion shaft into the rear axle housing 7 For a 8 0 8 6 inch axle install the pinion shaft locking bolt into the rear axle housing Torque the bolt to 27 ft lb 36 Nm 8 For a 9 5 LD inch axle install the pinion shaft locking bolt into the rear axle housing Torque the bolt to 37 ft lb 50 Nm 9 Install the brake caliper onto the hub 10 Install the rear wheel speed s...

Page 453: ... J 45857 bearing remover and a J 2619 01 slide hammer to remove the axle shaft bearing and seal To Install J 23690 and J 8092 Installation 1 Use a J 23690 bearing installer and a J 8092 universal driver handle to install the axle shaft bearing ...

Page 454: ...a J 21128 axle pinion oil seal installer to install the axle shaft seal 3 Install the axle shaft into the vehicle 4 Install the cover and gasket onto the rear axle housing 5 Install the wheel onto the vehicle 6 Lower the vehicle ...

Page 455: ...ers and rotors from the rear hubs 4 Remove the rear propeller shaft from the vehicle Drive pinion torque measurement 5 Use an inch pound torque wrench to measure the amount of torque needed to turn the drive pinion Write down this measurement 6 Mark the orientation of the pinion yoke to the drive pinion J 8614 Installation ...

Page 456: ...Align the pinion yoke to the marks on the drive pinion 4 Install the pinion yoke onto the drive pinion shaft 5 Seat the pinion yoke by tapping it with a soft faced hammer 6 Install a new washer and pinion nut onto the pinion shaft 7 Install a J 8614 01 flange and pulley holding tool onto the pinion yoke 8 Hold the J 8614 01 and tighten the pinion nut until the pinion end play is just taken up Seat...

Page 457: ...tank 3 If equipped remove the transfer case shield from the transfer case 4 Remove the front propeller shaft from the vehicle 5 Remove the dust shield from the front output shaft Front output shaft seal removal 6 Remove the front output shaft seal from the front output shaft by taping a screwdriver around the edge of the seal and prying it away ...

Page 458: ...ront output shaft using a J 45236 1 front output shaft seal installer 4 Remove the J 45236 1 and J 45236 2 front output shaft seal installer from the front output shaft 5 Install the dust shield onto the front output shaft 6 Install the front propeller shaft into the vehicle 7 Check the fluid level in the transfer case 8 If equipped install the transfer case shield onto the transfer case 9 If equi...

Page 459: ... Seal Removal Installation To Remove 1 Lift the vehicle 2 Remove the rear propeller shaft from the vehicle Rear output shaft seal removal 3 Remove the rear output shaft seal from the rear output shaft by prying it away ...

Page 460: ...stallation 1 Install the rear output shaft seal onto the rear output shaft using a J 37668 A output shaft seal installer 2 Install the rear propeller shaft into the vehicle 3 Check the fluid level in the transfer case 4 Lower the vehicle ...

Page 461: ... from the vehicle 5 Drain the fluid from the transfer case 6 Remove the fuel lines from the retainer 7 Detach the electrical harness from the transfer case 8 Disconnect the speed sensor connectors 9 Disconnect the motor encoder connector 10 Disconnect the vent hose from the transfer case Transfer case removal and installation 11 Remove the transfer case mounting nuts from the transfer case adapter...

Page 462: ...transfer case 9 Install the fuel lines into the retainer 10 Install the front and rear propeller shafts into the vehicle 11 Refill the fluid in the transfer case 12 If equipped install the fuel tank shield onto the fuel tank 13 If equipped install the transfer case shield onto the transfer case 14 Lower the vehicle NR9 Transfer Case To Remove 1 Lift the vehicle 2 Drain the fluid from the transfer ...

Page 463: ... Install the gasket onto the transfer case 2 Lift the transfer case 3 Attach the electrical harness to the transfer case 4 Install the transfer case mounting nuts into the transfer case adapter Torque the nuts to 35 ft lb 47 Nm 5 Remove the transfer case jack 6 Connect the speed sensor connector 7 Connect the vent hose to the transfer case 8 Install the front and rear propeller shafts into the veh...

Page 464: ...e the engine protection shield from under the frame 4 Detach the wheel speed sensor harnesses from the wheel wells 5 Disconnect the wheel speed sensor connectors 6 Detach the front brake hose retainers from the wheel wells 7 Remove the stabilizer bar link from the lower control arm Shock module retaining nuts removal and installation 8 Remove the upper shock module retaining nuts from the shock to...

Page 465: ...ing knuckles 14 Support the front shock modules and steering knuckles to the frame using mechanics wire 15 Place a brass drift against the tripot housing of the left half shaft and remove the shaft from the differential carrier by striking the drift with a hammer 16 Place a brass drift against the tripot housing of the right half shaft and remove the shaft from the clutch fork housing by striking ...

Page 466: ...me 16 Install the front wheels onto the vehicle 17 Lower the vehicle CV Joints Overhaul These vehicles use several different types of joints Engine size transaxle type whether the joint is an inboard or outboard joint even which side of the vehicle is being serviced could make a difference in joint type Be sure to properly identify the joint before attempting joint or boot replacement Look for ide...

Page 467: ...de of the boot with the specified grease Often the grease supplied in the replacement parts kit is meant to be divided in half with half being used to lubricate the joint and half being used inside the boot 1 Install the cage onto the halfshaft so the small diameter side of the cage is installed first With a brass drift pin tap lightly and evenly around the inner race to install the race until it ...

Page 468: ...er 2 Install the joint spider assembly to the shaft and install the snap ring 3 Fill the inside of the boot with the specified grease Often the grease supplied in the replacement parts kit is meant to be divided in half with half being used to lubricate the joint and half being used inside the boot Keep grease off the rubber part of the dynamic damper if used 4 Secure the boot bands with the halfs...

Page 469: ...Removing the outer band from the CV boot Removing the inner band from the CV boot ...

Page 470: ...Removing the CV boot from the joint housing Clean the CV joint housing prior to removing boot ...

Page 471: ...Removing the CV joint housing assembly Removing the CV joint ...

Page 472: ...Inspecting the CV joint housing Removing the CV joint outer snap ring ...

Page 473: ...Checking the CV joint snap ring for wear CV joint snap ring typical ...

Page 474: ...Removing the CV joint assembly Removing the CV joint inner snap ring ...

Page 475: ...Installing the CV joint assembly typical ...

Page 476: ...es Failure to do so may result in fire and or personal injury The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders including cancer You should make every effort to minimize your exposure to used engine oil Protective gloves should be worn when changing oil Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oi...

Page 477: ...When components are removed for service they should be marked organized or retained in a specific order for reassembly At the time of installation components should be installed in the same location and with the same mating surface as when removed An automobile engine is a combination of many machined honed polished and lapped surfaces with tolerances that are measured in millimeters or thousandth...

Page 478: ...cated near the C pillars Steering WARNING To avoid personal injury and or vehicle damage refer to the service precautions at the beginning of this section WARNING Most vehicles are equipped with an air bag system also known as the Supplemental Inflatable Restraint SIR system or Supplemental Restraint System SRS The system must be disabled before performing service on or around system components st...

Page 479: ...nition lock cylinder housing and pushing down Ignition lock cylinder removal and installation Except Saab 6 Remove the ignition lock cylinder from the ignition lock cylinder housing To Install 1 Install the key into the ignition lock cylinder 2 Use a screwdriver to torn the ignition lock cylinder housing gear clockwise to the start position let the spring return it to the run position 3 Install th...

Page 480: ...ove the trim covers from the steering column 4 Release the ignition lock cylinder locking tab by inserting an allen wrench into the hole on the top of the ignition lock cylinder housing and pushing down 5 Ignition lock cylinder removal and installation Except Saab 6 Remove the ignition lock cylinder from the ignition lock cylinder housing 7 Disconnect the passlock and key buzzer from the ignition ...

Page 481: ...ol to release the tabs on the ignition switch 8 Release the ignition switch tabs by inserting a J 42759 ignition switch connector release tool into the ignition lock cylinder housing Ignition switch removal installation ...

Page 482: ...e position shown above 2 Use a screwdriver to rotate the ignition lock cylinder housing gear counterclockwise until it hits a stop 3 Connect the ignition switch connector 4 Install the ignition switch into the ignition lock cylinder housing 5 Install the trim covers onto the steering column 6 Install the left insulator panel and knee bolster under the instrument panel I P 7 Connect the negative ba...

Page 483: ...4 Disconnect the turn signal multifunction switch connectors 5 Detach the turn signal multifunction switch from the steering column To Install 1 Attach the turn signal multifunction switch to the steering column Torque the top screw to 27 in lb 3 Nm Torque the side screw to 62 in lb 7 Nm 2 connect the turn signal multifunction switch connectors 3 Install the trim covers onto the steering column 4 ...

Page 484: ... the engine compartment 2 Remove the drive belt from the pulleys 3 Place a drain pan under the vehicle Power steering pump hoses removal and installation 4 2L 4 Disconnect the power steering pressure and cooler hoses from the power steering pump 5 Detach the wiring harness from the power steering pump ...

Page 485: ... 2 Attach the power steering pump to the engine Torque the bolts to 18 ft lb 25 Nm 3 Connect the power steering pressure and cooler hoses to the power steering pump Torque the hose fittings to 18 ft lb 25 Nm 4 Remove the drain pan from under the vehicle 5 Install the drive belt onto the pulleys 6 Bleed the power steering system 7 Check the power steering hoses for leaks and clearance 8 Install the...

Page 486: ...trol module ECM from the mounting bracket and set aside 3 For 2003 2004 vehicles remove the powertrain control module PCM from the mounting bracket and set aside 4 Power steering pump hoses removal and installation 5 3L 6 0L 5 Disconnect the power steering pressure and pump return hoses from the power steering pump ...

Page 487: ...power steering pump to the engine Torque the bolts to 18 ft lb 25 Nm 3 Connect the power steering pressure and cooler hoses from the power steering pump Torque the hose fittings to 18 ft lb 25 Nm 4 For 2003 through 2004 vehicles install the powertrain control module PCM onto the mounting bracket 5 For 2005 through 2007 vehicles install the engine control module ECM onto the mounting bracket 6 Inst...

Page 488: ...ngine To Remove 1 Lift the vehicle 2 Remove the engine protection shield from under the frame 3 Place a drain pan under the vehicle Power steering gear hoses removal and installation 4 2L 4 Detach the power steering hose assembly from the power steering gear ...

Page 489: ...Power steering cooler hoses removal and installation 5 Disconnect the power steering return and cooler hoses from the power steering cooler Power steering pump hoses removal and installation 4 2L ...

Page 490: ...from the fuse block 13 Disconnect the fuse block connectors from the fuse block and bracket 14 Remove the fuse block harnesses from the wiring loops 15 Detach the wiring harness from the fender 16 Detach the upper fuse block from the lower fuse block and set it on the engine Power steering hose assembly removal and installation 4 2L 17 Detach the power steering hose assembly from the wheel well an...

Page 491: ...ar oil seal removal 21 Use the removal end of a J 44586 power steering gear oil seal remover installer and a flat head screwdriver to remove the power steering gear oil seal from the power steering gear Discard the seal ...

Page 492: ...rtment 4 Attach the power steering hose assembly to the frame Torque the bolts to 89 in lb 10 Nm 5 Attach the power steering hose assembly to the wheel well Torque the bolts to 89 in lb 10 Nm 6 Attach the upper fuse block to the lower fuse block Torque the bolts to 53 in lb 6 Nm 7 Attach the wiring harness to the fender 8 Install the fuse block harnesses into the wiring loops 9 Connect the fuse bl...

Page 493: ...Torque the hose fittings to 18 ft lb 25 Nm 17 Connect the power steering return and cooler hoses to the power steering cooler 18 Attach the power steering hose assembly to the power steering gear 19 Remove the drain pan from under the vehicle 20 Install the engine protection shield under the frame 21 Lower the vehicle 22 Bleed the power steering system 5 3L 6 0L Engines To Remove 1 Lift the vehicl...

Page 494: ...ering cooler hoses removal and installation 4 Disconnect the power steering return and cooler hoses from the power steering cooler 5 Lower the vehicle Power steering pump hoses removal and installation 5 3L 6 0L ...

Page 495: ...de 8 For 2005 through 2007 vehicles remove the engine control module ECM from the mounting bracket and set it aside Power steering hose assembly removal and installation 5 3L 6 0L 9 Detach the power steering hose assembly from the frame 10 Remove the power steering hose assembly from the engine compartment 11 Lift the vehicle 12 Thoroughly clean the power steering gear inlet and outlet ports of an...

Page 496: ...the removal end of a J 44586 power steering gear oil seal remover installer and a flat head screwdriver to remove the power steering gear oil seal from the power steering gear Discard the seal To Install Power steering gear oil seal installation ...

Page 497: ...ressure and pump return hoses from the power steering pump Torque the hose fittings to 18 ft lb 25 Nm 6 For 2003 through 2004 vehicles install the powertrain control module PCM onto the mounting bracket 7 For 2005 through 2007 vehicles install the engine control module ECM onto the mounting bracket 8 Lift the vehicle 9 Connect the power steering return and cooler hoses to the power steering cooler...

Page 498: ...allation To Remove 1 Lift the vehicle 2 Place a drain pan under the vehicle 3 Remove the front wheels from the vehicle Outer tie rod retaining nut removal and installation 4 Remove the retaining nuts from the outer tie rod ends ...

Page 499: ...tie rod ends from the steering knuckles 6 Remove the steering gear crossmember from under the vehicle 7 Remove the lower intermediate shaft from the steering gear 8 Detach the power steering hose assembly from the steering gear 9 Use a jack to support the steering gear 10 Remove the mounting bolts from the steering gear ...

Page 500: ...olts to 81 ft lb 110 Nm 4 Remove the steering gear jack 5 Attach the power steering hose assembly to the steering gear Torque the bolt to 106 in lb 12 Nm 6 Install the lower intermediate shaft onto the steering gear 7 Install the steering gear crossmember under the vehicle 8 Attach the outer tie rods to the steering knuckles 9 Install the retaining nuts into the outer tie rod ends 10 Install the f...

Page 501: ...ator is fully charged by starting the engine press the brake pedal ten to fifteen times then turning off the engine NOTE Pressing the brake pedal with the engine off will discharge the hydro boost accumulator 3 Lift the vehicle 4 Make sure the ignition is in the off position 5 Turn the steering wheel from the left full stop to the right full stop at least twelve times 6 Make sure the power steerin...

Page 502: ...r to lock the steering column in place 4 Remove the steering wheel from the steering column 5 Remove the knee bolster from under the instrument panel 6 Disconnect the steering column connector from the vehicle harness connector 7 Detach the body harness from the lower steering column bracket 8 Remove the retaining screw from the left HVAC floor duct 9 Disconnect the left HVAC floor duct temperatur...

Page 503: ...threadlocker or equivalent to the threads of the intermediate shaft bolt 5 Install the intermediate shaft bolt into the steering column Torque the bolt to 37 ft lb 50 Nm 6 Install the left HVAC floor duct under the instrument panel I P 7 Connect the left HVAC floor duct temperature sensor connector 8 Install the retaining screw into the left HVAC floor duct Torque the screw to 17 in lb 1 9 Nm 9 At...

Page 504: ...e supplemental inflatable restraint SIR system 2 Remove the inflator module from the steering wheel 3 Press the horn plunger inward to the stop and rotate it 90 degrees to remove it from the steering wheel 4 Disconnect the steering wheel connector 5 Remove the steering wheel nut from the steering wheel shaft Steering wheel removal and installation 6 Install a J 1859 A steering wheel puller with a ...

Page 505: ...tall the steering wheel nut onto the steering wheel shaft Torque the nut to 30 ft lb 41 Nm 3 Connect the steering wheel connector 4 Install the horn plunger into the steering wheel 5 Install the inflator module into the steering wheel 6 Connect the negative battery cable ...

Page 506: ...Tie Rod End Removal Installation Inner Tie Rod End To Remove Inner tie rod assembly Magnasteer ...

Page 507: ...housing 6 Attach a wrench to the flats of the right inner tie rod housing 7 Separate the right inner tie rod from the right rack by turning the inner tie rod housing counterclockwise while holding the rack stationary 8 Remove the left shock dampener from the left inner tie rod housing 9 Move the left shock dampener back off the left rack 10 Clamp a pipe wrench onto the left rack next to left inner...

Page 508: ...r tie rod is male coat the inner tie rod threads with LOCTITE 262 or equivalent sealant 8 Attach the left inner tie rod to the left rack 9 Clamp a pipe wrench onto the left rack next to the left inner tie rod housing 10 Attach a torque wrench and J 34028 inner tie rod wrench to the flats of the left inner tie rod housing Torque the rod to 74 ft lb 100 Nm Rack A Inner tie rod B 11 Put the inner tie...

Page 509: ...Outer Tie Rod End To Remove 1 Lift the vehicle 2 Remove the wheel from the vehicle Outer tie rod retaining nut removal and installation 3 Remove and discard the retaining nut from the outer tie rod ...

Page 510: ...eads 7 Make sure the tapered surfaces of the steering knuckle are clean To Install 1 Use chassis lubricant to coat the threads of the inner tie rod 2 Use a new jam nut to install the outer tie rod into the inner tie rod 3 Install the outer tie rod onto the steering knuckle 4 Install the new retaining nut into the outer tie rod Torque the retaining nut to 44 ft lb 60 Nm 5 Install the wheel onto the...

Page 511: ...er to the service precautions at the beginning of this section Upper Control Arm Ball Joint Removal Installation To Remove 1 Lift the vehicle 2 Remove the wheel from the vehicle 3 Remove the steering knuckle from the vehicle Upper ball joint retaining clip removal and installation ...

Page 512: ...etaining clip from the upper ball joint 5 Remove the boot from the upper ball joint Upper ball joint removal 6 Use a J 9519 E ball joint remover and installer to remove the upper ball joint from the steering knuckle ...

Page 513: ...bushing set and J 45117 ball joint installation spacer to install the upper ball joint onto the steering knuckle 2 Install the retaining clip onto the upper ball joint 3 Install the steering knuckle onto the vehicle 4 Install the wheel onto the vehicle 5 Lower the vehicle 6 Check the alignment of the front wheels ...

Page 514: ...m the vehicle 3 Remove the steering knuckle from the vehicle 4 Use a chisel to remove the flange from the lower ball joint Lower ball joint removal 5 Use a J 9519 E ball joint remover and installer and J 34874 booster seal remover and installer to remove the lower ball joint from the lower control arm ...

Page 515: ...eiver to install the lower ball joint onto the lower control arm 2 Use a J 9519 E ball joint remover and installer and J 45105 1 ball joint flaring adapter to flare the lower ball joint flange 3 Install the steering knuckle onto the vehicle 4 Install the wheel onto the vehicle 5 Lower the vehicle 6 Check the alignment of the front wheels ...

Page 516: ...ve and discard the nut and bolt from the upper control arm pinch 4 Remove the steering knuckle from the upper control arm 5 Detach the wheel speed sensor harness from the upper control arm 6 If removing the left upper control arm remove the battery and battery tray from the engine compartment 7 Pry out the inner fender body panel to gain access to the forward facing bolt ...

Page 517: ... upper control arm install the battery and battery tray into the engine compartment 3 Attach the wheel speed sensor harness to the upper control arm 4 Install the steering knuckle onto the upper control arm 5 Install a new nut and bolt into the upper control arm pinch Torque the nut and bolt to 30 ft lb 41 Nm 6 Install the front wheel onto the vehicle 7 Lower the vehicle 8 Check the alignment of t...

Page 518: ...the vehicle Outer tie rod retaining nut removal and installation 3 Remove and discard the retaining nut from the outer tie rod 4 Use a J 36607 steering linkage and tie rod puller to disconnect the outer tie rod from the steering knuckle 5 Remove the retaining nut from the stabilizer shaft link ...

Page 519: ...the mounting nut from the shock absorber module yoke 7 Use a J 36607 steering linkage and tie rod puller to disconnect the shock absorber module yoke from the lower control arm 8 Remove and discard the retaining nut from the lower ball joint Lower ball joint removal ...

Page 520: ...ting bracket 2 Install the lower control arm mounting bolts into the lower control arm mounting bracket 3 Install the lower control arm mounting nuts onto the lower control arm mounting bracket Torque the nuts to 96 ft lb 130 Nm 4 Install the shock absorber module yoke onto the lower control arm 5 Install the mounting nut onto the shock absorber Torque the nut to 82 ft lb 111 Nm 6 Install a new re...

Page 521: ...icles with 4wd remove the nut from the drive axle 2 Lift the vehicle 3 Remove the wheel from the vehicle 4 Remove the brake rotor from the hub 5 For vehicles with 4wd use a hammer and brass drift to disengage the drive axle from the hub and bearing 6 Detach the wheel speed sensor from the hub ...

Page 522: ...ld into the steering knuckle 2 Attach the hub and bearing to the steering knuckle Torque the bolts to 77 ft lb 105 Nm 3 Attach the wheel speed sensor to the hub Torque the bolts to 13 ft lb 18 Nm 4 Install the brake rotor onto the hub 5 Install the wheel onto the vehicle 6 Lower the vehicle 7 For vehicles with 4wd install the nut onto the drive axle Torque the nut the 103 ft lb 140 Nm ...

Page 523: ...stallation To Remove Drive axle nut removal and installation 1 For vehicles with 4WD remove the nut from the drive axle 2 Lift the vehicle 3 Remove the wheel from the vehicle 4 Remove the hub and bearing from the steering knuckle ...

Page 524: ...Outer tie rod retaining nut removal and installation 5 Remove and discard the retaining nut from the outer tie rod end J 24319 B steering linkage and tie rod puller ...

Page 525: ...steering knuckle 8 Detach the wheel speed sensor from the steering knuckle Upper ball pinch nut and bolt removal and installation 9 Remove and discard the nut and bolt from the upper control arm pinch 10 Remove the steering knuckle from the upper control arm 11 Remove and discard the retaining nut from the lower ball joint ...

Page 526: ...olt into the upper control arm pinch Torque the nut to 30 ft lb 40 Nm 5 Attach the wheel speed sensor to the steering knuckle 6 Attach the brake hose bracket to the steering knuckle Torque the nut to 89 in lb 10 Nm 7 Install the outer tie rod onto the steering knuckle 8 Install a new retaining nut into the outer tie rod end Torque the nut to 44 ft lb 60 Nm 9 Install the hub and bearing onto the st...

Page 527: ...er Module Removal Installation To Remove Shock module retaining nuts removal and installation 1 Remove the upper retaining nuts from the shock absorber module 2 Lift the vehicle 3 Remove the wheel from the vehicle ...

Page 528: ...he shock absorber module yoke 7 Remove the shock absorber module from the shock tower To Install 1 Install the shock absorber module into the shock tower 2 Install the shock absorber module yoke to the lower control arm 3 Lower the vehicle 4 Install the upper retaining nuts into the shock absorber Torque the nuts to 33 ft lb 45 Nm 5 Lift the vehicle 6 Install the mounting nut onto the shock absorb...

Page 529: ...bsorber module yoke pinch bolt removal and installation 4 Remove the shock absorber module yoke pinch nut and bolt from the shock absorber 5 Use a flat bladed tool and hammer to spread the shock absorber module yoke 6 Remove the shock absorber module yoke from the shock absorber module 7 Install the shock absorber module into a J 45400 strut spring compressor ...

Page 530: ...hock absorber 10 Remove the shock absorber from the shock absorber module 11 Remove the washer dust boot jounce bumper and lower spring isolator from the shock absorber 12 Turn the J 45400 strut spring compressor compression screw to decompress the shock absorber module spring 13 Remove the upper mounting plate and coil spring from the J 45400 strut spring compressor ...

Page 531: ...per retaining nut and washer onto the shock absorber Torque the retaining nut to 33 ft lb 45 Nm 6 Turn the J 45400 strut spring compressor compression screw to decompress the shock absorber module spring 7 Remove the shock absorber module from the J 45400 strut spring compressor 8 Install the shock absorber module yoke onto the shock absorber module 9 Install the shock absorber module yoke pinch n...

Page 532: ...n 4 Detach the stabilizer shaft insulator clamps from the stabilizer shaft 5 Remove the stabilizer shaft insulator from the stabilizer shaft 6 For vehicles with a 4 2L engine remove the engine protection shield from under the frame 7 For vehicles with a 4 2L engine remove the engine mount bracket nuts from the frame 8 For vehicles with a 4 2L engine place a block of wood on a jack and use the jack...

Page 533: ...ts into the frame Torque the nuts to 52 ft lb 70 Nm 4 For vehicles with a 4 2L engine remove the jack to supporting the oil pan 5 For vehicles with a 4 2L engine install the engine protection shield under the frame 6 Install the stabilizer shaft insulator onto the stabilizer shaft 7 Attach the stabilizer shaft insulator clamps onto the stabilizer shaft Torque the bolts to 40 ft lb 54 Nm 8 Install ...

Page 534: ...s section Coil Spring Removal Installation To Remove 1 Lift the vehicle 2 Install a support for the rear axle Shock absorber mounting bolt removal and installation 3 Remove the lower mounting bolts from the shock absorber NOTE Do not let the upper control arm contact the frame while lowering the rear axle 4 Lower the rear axle ...

Page 535: ...emove the rear coil spring from the vehicle To Install 1 Install the rear coil spring into the vehicle 2 Lift the rear axle 3 Install the lower mounting bolts into the shock absorber 4 Remove the support from the rear axle 5 Lower the vehicle ...

Page 536: ...the panel from the wheelhouse 4 Lift the rear axle to drive height 5 If equipped with air suspension depressurize the air suspension system 6 If equipped with air suspension detach the air suspension leveling sensor from the rear axle upper control arm Upper control arm axle mounting bolt removal and installation ...

Page 537: ...control arm into the vehicle 2 Attach the upper control arm the axle and frame Torque the bolts to 97 ft lb 131 Nm 3 If equipped with air suspension attach the air suspension leveling sensor to the rear axle upper control arm 4 Lower the rear axle 5 Install the panel into the wheel house 6 Install the wheel onto the vehicle 7 Lower the vehicle ...

Page 538: ... rear axle to drive height 3 If equipped with air suspension depressurize the air suspension system Lower control arm axle mounting bolt removal and installation Lower control arm frame mounting bolt removal and installation 5 Detach the lower control arm from the axle and frame ...

Page 539: ...r the vehicle Shock Absorber Removal Installation To Remove 1 Lift the vehicle 2 Install a support for the rear axle Shock absorber mounting bolt removal and installation 3 Remove the upper mounting bolt from the shock absorber 4 Remove the lower mounting bolt from the shock absorber 5 Remove the shock absorber from the vehicle ...

Page 540: ...Install the upper mounting bolt into the shock absorber Torque the bolt to 63 ft lb 85 Nm 4 Remove the support from the rear axle 5 Lower the vehicle Stabilizer Shaft Removal Installation To Remove 1 Lift the vehicle 2 Remove wheels from the vehicle Stabilizer link removal and installation 3 Detach the stabilizer shaft links from the stabilizer shaft ...

Page 541: ...insulators from the stabilizer shaft To Install 1 Install the stabilizer shaft insulators onto the stabilizer shaft 2 Install the stabilizer shaft into the vehicle 3 Install the mounting nuts onto the stabilizer shaft insulator clamps Torque the nuts to 55 ft lb 75 Nm 4 Attach the stabilizer shaft links to the stabilizer shaft Torque the nuts to 66 ft lb 90 Nm 5 Install the wheels onto the vehicle...

Page 542: ... the vehicle 2 Lift the rear axle to drive height 3 If equipped with air suspension depressurize the air suspension system Rear axle brace tie rod mounting bolt removal and installation 4 Remove the rear axle brace mounting bolt from the rear axle tie rod ...

Page 543: ...ar axle brace from the vehicle To Install 1 Install the rear axle brace into the vehicle 2 Install the rear axle brace mounting nut onto the frame Torque the nut to 70 ft lb 95 Nm 3 Install the rear axle brace mounting bolt into the rear axle tie rod Torque the bolt to 140 ft lb 190 Nm 4 Lower the rear axle 5 Lower the vehicle ...

Page 544: ...o ensure that there are no lacerations puncture marks nails and other sharp objects compromising the integrity of the tread area and sidewall When inspecting the tires check for proper air pressure and adequate tread depth Repair or replace as necessary Always check tire inflation with cold tires Check the wheel assemblies for dents cracks and rust Repair or replace as necessary ...

Page 545: ...e 1 Raise and safely support the vehicle 2 Remove the wheel and tire assembly CAUTION Failure to support the brake caliper could result in brake hose failure 3 Remove and support the brake caliper 4 Remove the rotor from the spindle 5 Support the rotor using press bars 6 Rotor and stud ...

Page 546: ... press NOTE If a press is not available carefully drive the old stud out using a blunt drift Ensure that the rotor is properly and evenly supported or damage may result To Install 1 Clean the stud hole with a wire brush and start the new stud with a hammer and drift pin ...

Page 547: ...he bore in the hub B Place approximately four flat washers over the stud and thread the lug nut to the stud C Hold the hub rotor while tightening the lugnut Draw the stud into position D Remove the lug nut and washers CAUTION Ensure that the stud is fully seated E Install the brake rotor F Install the brake caliper G Install the wheel and tire assembly ...

Page 548: ... Removable Rotor To Remove 1 Raise and safely support the vehicle 2 Remove the wheel and tire assembly CAUTION Failure to support the brake caliper could result in brake hose failure 3 Remove and support the brake caliper 4 W rear disc brakes remove the anchor bracket 5 Remove the brake rotor from the hub axle flange ...

Page 549: ...lamp and socket 6 Use a large C clamp and socket to press the stud from the hub axle flange To Install 1 Clean the stud hole with a wire brush 2 Start the lug stud through the bore in the hub axle flange Installing lug stud ...

Page 550: ...nd washers CAUTION Ensure that the stud is fully seated 6 Install the brake rotor 7 W rear disc brakes install the anchor bracket 8 Install the brake caliper 9 Install the wheel and tire assembly Wheel lug nut tightening sequence 10 Torque the lug nuts to specification 11 Lower the vehicle Rear W Drum Brakes To Remove 1 Raise and safely support the vehicle 2 Remove the wheel and tire assembly ...

Page 551: ...lange and stud 3 Remove the brake drum from the axle shaft flange 4 Remove the brake shoes if necessary to provide clearance Removing stud with C clamp and socket 5 Use a large C clamp and socket to press the stud from the axle flange ...

Page 552: ...r flat washers over the stud and thread the lug nut to the stud 4 Hold the axle flange while tightening the lugnut Draw the stud into position 5 Remove the lug nut and washers CAUTION Ensure that the stud is fully seated 6 Install the brake shoes if removed 7 Install the brake drum 8 Install the wheel and tire assembly Wheel lug nut tightening sequence ...

Page 553: ...9 Torque the lug nuts to specification 10 Lower the vehicle ...

Page 554: ...ints to steer the vehicle When the upper point is tilted back this is described as positive caster Having positive caster tends to make the wheels self centering increasing directional stability Excessive positive caster makes the wheels hard to steer while an uneven caster will cause a pull to one side Overloading the vehicle or sagging rear springs will affect caster as it will raise the rear of...

Page 555: ...oo much negative camber compromises straight line stability increases bump steer and torque steer Camber influences tire contact with the road Camber Toe Looking down at the wheels from above the vehicle toe angle is the difference in distance between the front of the wheels to the back of the wheels If the wheels are closer at the front they are said to be toed in or to have negative toe A small ...

Page 556: ...Toe in Frame Misalignment Frame misalignment ...

Page 557: ... a misalignment of the front wheels Movement of the subframe usually causes an increase in caster on one side of the vehicle and decrease in caster on the other side This can cause the exhaust system to bind up problems with control cables and unacceptable noise Check the frame subframe for any obvious damage especially on a used vehicle with an unknown history Setback Subframe setback Setback app...

Page 558: ... angle is geometrically aligned with the body centerline If for example the toe in on the left rear wheel is out of specification it moves the thrust line off center The resulting deviation from the centerline is the thrust angle Lead Pull Torque steer Lead is the deviation of the vehicle from a straight path on a level road without hand pressure on the steering wheel Lead is usually the result of...

Page 559: ...gles The side with the higher transaxle pan has the most downward sloping axle angle Memory Steer Memory steer is when the vehicle wants to lead or pull in the direction the driver previously turned the vehicle Additionally after turning in the opposite direction the vehicle will want to lead or pull in that direction Wander Wander is the undesirable drifting or deviation of a vehicle toward eithe...

Page 560: ...rol arms should be checked for loose or worn bushings The stabilizer shaft sway bar attachments should be checked for loose or missing components The frame fasteners should be checked for proper torque The frame insulators should be checked for wear or damage ...

Page 561: ...e or drain the radiator or cooling system when the engine is hot serious burns can occur from the steam and hot coolant Observe all applicable safety precautions when working around fuel Whenever servicing the fuel system always work in a well ventilated area Do not allow fuel spray or vapors to come in contact with a spark open flame or excessive heat a hot drop light for example Keep a dry chemi...

Page 562: ...s First fluid under pressure can be carried to all parts of an automobile by small pipes and flexible hoses without taking up a significant amount of room or posing routing problems Second a great mechanical advantage can be given to the brake pedal end of the system and the foot pressure required to actuate the brakes can be reduced by making the surface area of the master cylinder pistons smalle...

Page 563: ... actuated directly by mechanical linkage from the brake pedal through the power booster The secondary piston is actuated by fluid trapped between the two pistons If a leak develops in front of the secondary piston it moves forward until it bottoms against the front of the master cylinder and the fluid trapped between the pistons will operate the rear brakes If the rear brakes develop a leak the pr...

Page 564: ...so the equal clamping action of the two brake pads tends to ensure uniform straight line stops Disc brakes are inherently self adjusting There are three general types of disc brake A fixed caliper A floating caliper A sliding caliper The fixed caliper design uses two pistons mounted on either side of the rotor in each side of the caliper The caliper is mounted rigidly and does not move The sliding...

Page 565: ... Depressing the brake pedal closes off the vacuum source and allows atmospheric pressure to enter on one side of the diaphragm This causes the master cylinder pistons to move and apply the brakes When the brake pedal is released vacuum is applied to both sides of the diaphragm and springs return the diaphragm and master cylinder pistons to the released position If the vacuum supply fails the brake...

Page 566: ...ch Brake line wrenches sometimes called Flare Nut Wrenches should be used These wrenches wrap around the fitting grasping it on five of the six wrench flats on the fitting This reduces but doesn t eliminate the chance of rounding off the fitting s corners so that it cannot be removed or if removed cannot be adequately tightened at installation Brake line wrenches are available at most auto supply ...

Page 567: ...Installation To Remove Brake master cylinder assembly 1 Remove the brake master cylinder assembly from the power vacuum brake booster 2 Drain the brake fluid from the master cylinder reservoir 3 Place the master cylinder assembly in a vise clamp the vise onto the master cylinder flange 4 Remove the master cylinder reservoir retaining pins from the brake master cylinder assembly ...

Page 568: ...he brake master cylinder assembly To Install 1 Use DOT 3 brake fluid to lubricate the new master cylinder reservoir seals 2 Install the master cylinder reservoir seals onto the brake master cylinder assembly 3 Install the master cylinder reservoir onto the brake master cylinder assembly 4 Install the master cylinder reservoir retaining pins into the brake master cylinder assembly 5 Remove the mast...

Page 569: ...t vehicle movement 3 Raise and safely support the vehicle 4 Remove any wheel and tire assemblies necessary for access to the particular line you are removing 5 Thoroughly clean the surrounding area at the joints to be disconnected Use a brush to clean the fittings of any debris 6 Place a suitable drain pan under the connection to be disconnected 7 Using two line wrenches one to hold the connection...

Page 570: ... wrench to avoid damaging the fitting 9 Disconnect any retaining clips or brackets holding the line and remove the line from the vehicle NOTE If the brake system is to remain open for more time than it takes to swap lines tape or plug each remaining clip and port to keep contaminants out and fluid in Any gaskets crush washers should be replaced with new ones during installation ...

Page 571: ...inal location WARNING Make sure the hose is NOT kinked or touching any part of the frame or suspension after installation These conditions may cause the hose to fail prematurely 1 Using two line wrenches as before tighten each fitting 2 Install any retaining clips or brackets on the lines 3 If removed install the wheel and tire assemblies then carefully lower the vehicle to the ground 4 Install th...

Page 572: ... pipes from the master cylinder CAUTION Install a rubber cap or plug to the exposed brake pipe ends to prevent brake fluid loss and contamination 4 Install plugs into the open brake pipe ends Brake master cylinder assembly 5 Detach the master cylinder assembly from the power vacuum brake booster 6 Drain the brake fluid from the master cylinder reservoir ...

Page 573: ...r vacuum brake booster Torque the mounting nuts to 27 ft lb 36 Nm 3 Remove the plugs from the open brake pipe ends 4 Install the brake pipes into the master cylinder Torque the fittings to 24 ft lb 32 Nm 5 Connect the master cylinder fluid level sensor connector 6 Bleed the hydraulic brake system ...

Page 574: ...er cylinder reservoir with clean fresh brake fluid until the level is within 0 25 in of the reservoir top NOTE Ensure the bleeding tubes are below the level of the brake fluid otherwise air may get into the system making your bleeding efforts ineffective 5 Use a blunt tipped rod to slowly depress the master cylinder piston Make sure the piston travels its full stroke 6 As the piston is depressed b...

Page 575: ...g brake Brake master cylinder assembly 2 Remove the master cylinder assembly from the power vacuum brake booster 3 Remove the power vacuum brake booster hose from the power vacuum brake booster and the engine 4 Remove the left insulator panel from under the instrument panel I P ...

Page 576: ...pushrod retainer from the brake pedal pin 6 Remove the stop lamp switch and pushrod from the brake pedal pin Brake booster removal and installation 7 Detach the power vacuum brake booster from the vehicle 8 Remove the gasket from the power vacuum brake booster ...

Page 577: ...ill produce less and less pedal travel If there is no vacuum air is leaking into the system System Operation Test 1 With the engine OFF pump the brake pedal until the supply vacuum is entirely gone 2 Put light steady pressure on the brake pedal 3 Start the engine and let it idle If the system is operating correctly the brake pedal should fall toward the floor if the constant pressure is maintained...

Page 578: ...n tool establish communications with the ABS TCS system Select Special Functions from the ABS TCS menu Select Automated Bleed from the Special Functions menu 7 Bleed the base brake system 8 Follow the scan tool directions until the desired brake pedal height is achieved 9 If the bleed procedure is aborted a malfunction exists Perform the following steps before resuming the bleed procedure 10 If a ...

Page 579: ... Brake Caliper Removal Installation Front To Remove 1 Lift the vehicle 2 Remove the wheel from the vehicle Brake caliper hose removal and installation 3 Detach the brake caliper hose from the brake caliper 4 To prevent excessive brake fluid loss install a plug into the front brake caliper hose 5 Discard the brake caliper hose gasket ...

Page 580: ...the brake caliper to the mounting bracket Torque the bolts to 31 ft lb 42 Nm 5 For 2006 through 2007 vehicles attach the brake caliper to the mounting bracket Torque the bolts to 47 ft lb 64 Nm 6 Install new brake caliper hose gaskets to the front brake caliper hose bolt 7 For 2003 through 2007 vehicles attach the brake caliper hose to the brake caliper Torque the bolt to 30 ft lb 40 Nm 8 For 2002...

Page 581: ...el from the vehicle Rear brake caliper hose removal and installation 3 Detach the brake caliper hose from the brake caliper 4 To prevent excessive brake fluid loss install a plug into the front brake caliper hose 5 Discard the brake caliper hose gasket ...

Page 582: ...rake caliper mounting bolts 4 Attach the brake caliper to the mounting bracket Torque the bolts to 23 ft lb 31 Nm 5 Install new brake caliper hose gaskets to the front brake caliper hose bolt 6 For 2003 through 2007 vehicles attach the brake caliper hose to the brake caliper Torque the bolt to 30 ft lb 40 Nm 7 For 2002 vehicles attach the brake caliper hose to the brake caliper Torque the bolt to ...

Page 583: ...to remove the piston from the caliper Refer to the brake pad replacement procedure to make sure you have the correct procedure for your vehicle 2 The first procedure is as follows A Stuff a shop towel or a block of wood into the caliper to catch the piston B Remove the caliper piston using compressed air applied into the caliper inlet hole Inspect the piston for scoring nicks corrosion and or worn...

Page 584: ...Removing piston from caliper bore 4 For the second procedure you must rotate the piston to retract it from the caliper 5 If equipped remove the anti rattle clip Removing anti rattle clip ...

Page 585: ...6 Use a pry tool to remove the caliper boot being careful not to scratch the housing bore Prying edge of boot Removing boot from caliper ...

Page 586: ...ove the brake bleeder valve cap and valve from the caliper housing 10 Inspect the caliper bores pistons and mounting threads for scoring or excessive wear 11 Use crocus cloth to polish out light corrosion from the piston and bore 12 Clean all parts with denatured alcohol and dry with compressed air ...

Page 587: ...ed 3 Lubricate the piston bore 4 Install the pistons and boots into the bores of the calipers and push to the bottom of the bores 5 Use a suitable installer to seat the boots in the housing Installing boot 6 Install the caliper in the vehicle 7 Install the wheel and tire assembly then carefully lower the vehicle 8 Properly bleed the brake system ...

Page 588: ...Bleeding caliper ...

Page 589: ...tion 4 Install a large C clamp over the brake caliper housing and against the back of the outboard brake pad 5 Tighten the clamp until the brake caliper is pushed in enough to slide the brake caliper from the rotor 6 Remove the clamp from the brake caliper 7 Detach the brake caliper assembly from the steering knuckle 8 Remove the retaining clips from the brake rotor 9 Mark the orientation of the b...

Page 590: ...otor onto the wheel hub 3 Attach the brake caliper assembly to the steering knuckle Torque the bolt to 110 ft lb 150 Nm 4 Install the wheel onto the vehicle 5 Lower the vehicle 6 Fill the brake master cylinder reservoir to the proper level 7 Seat the brake pads by pumping the brake pedal slowly Rear To Remove 1 Make sure the fluid level in the brake master cylinder reservoir is between the MIN and...

Page 591: ...e pad 5 Tighten the clamp until the brake caliper is pushed in enough to slide the brake caliper from the rotor 6 Remove the clamp from the brake caliper 7 Remove the brake caliper assembly from the mounting surface 8 Remove the retaining clips from the brake rotor 9 Mark the orientation of the brake rotor to the wheel stud ...

Page 592: ...brake shoes or worn bent or damaged backing plates To Install 1 Use denatured alcohol to clean the park brake shoes 2 Use non lubricated filtered air to dry the park shoes 3 Use high temperature silicone brake lubricant to lubricate the area between the park brake shoe and the backing plate 4 Adjust the park brake 5 Slowly turn the axle flange while installing the brake rotor onto the wheel hub 6 ...

Page 593: ...tween the MIN and MAX level 2 Lift the vehicle 3 Remove the wheel from the vehicle 4 Front C clamp installation 5 Install a large C clamp over the brake caliper housing and against the back of the outboard brake pad 6 Tighten the clamp until the brake caliper is pushed in enough to slide the brake caliper from the rotor ...

Page 594: ...Brake caliper mounting bolt removal and installation 7 Remove the lower mounting bolt from the brake caliper Brake caliper ...

Page 595: ...8 Lift the bottom of the brake caliper out of the mounting bracket Outboard brake pad removal and installation 9 Remove the outboard brake pad from the brake caliper ...

Page 596: ...Inboard brake pad removal and installation 10 Remove the inboard brake pad from the brake caliper ...

Page 597: ...nstall the outboard brake pad into the brake caliper 4 Lower the bottom of the brake caliper into the mounting bracket 5 For 2002 through 2005 vehicles install the lower mounting bolt into the brake caliper Torque the bolt to 31 ft lb 42 Nm 6 For 2006 through 2007 vehicles install the lower mounting bolt into the brake caliper Torque the bolt to 47 ft lb 64 Nm 7 Install the wheel onto the vehicle ...

Page 598: ...installation 4 Install a large C clamp over the brake caliper housing and against the back of the outboard brake pad 5 Tighten the clamp until the brake caliper is pushed in enough to slide the brake caliper from the rotor 6 Remove the clamp from the brake caliper 7 Remove the upper mounting bolt from the brake caliper 8 Pull the top of the brake caliper out of the mounting bracket ...

Page 599: ... brake pad retaining clips into the brake caliper mounting bracket 2 Install the brake pads into the brake caliper 3 Lower the top of the brake caliper into the mounting bracket 4 Install the upper mounting bolt into the brake caliper Torque the bolt to 23 ft lb 31 Nm 5 Install the wheel onto the vehicle 6 Lower the vehicle 7 Fill the brake master cylinder reservoir to the proper level 8 Seat the ...

Page 600: ...e the wheel from the vehicle 4 Remove the brake caliper from the mounting bracket 5 Remove the brake rotor from the hub 6 Disconnect the parking brake cable from the parking brake lever Actuator mechanism A Parking brake shoe B Hold down spring C 7 Disengage the parking brake shoe from the hold down spring by sliding the shoe down 8 Lift the parking brake shoe away from the backing plate and slide...

Page 601: ... new parking brake shoe into the baking plate over the axle flange 2 Place the parking brake shoe onto the actuation mechanism 3 Slide the parking brake shoe down over the top of the hold down spring while holding the lower end of the shoe away from the backing plate 4 Push the lower end of the shoe to the backing plate 5 Make sure the shoe is central on the backing plate with both tips in the slo...

Page 602: ...Adjustment 1 Remove the rotor from the rear hub Brake rotor measurement 2 Adjust a J 21177 A drum to brake shoe clearance gage until it contact the inside diameter of the rotor Brake shoe measurement ...

Page 603: ...the widest point 4 Turn the adjuster nut until the lining comes into contact with the J 21177 A drum to brake shoe clearance gage 5 The clearance between the rear parking brake shoe lining and the rotor should be between 0 010 in 0 25mm and 0 020 in 0 50 mm 6 Install the rotor onto the rear hub ...

Page 604: ... assembly from the mounting surface 7 Remove the brake rotor from the hub 8 Remove the axle shaft from the vehicle 9 Remove the parking brake shoe from the backing plate Parking brake actuator removal and installation 10 Detach the park brake actuator from the backing plate 11 Clean the sealing surfaces as necessary 12 Use brake parts cleaner to clean the threads of the park brake actuator bolts 1...

Page 605: ...the backing plate 4 Install the axle shaft into the vehicle 5 Adjust the parking brake shoe 6 Install the brake rotor onto the hub 7 Install the parking brake cable onto the parking brake actuator lever 8 Install the parking brake cable onto the mounting bracket 9 Install the brake caliper assembly onto the mounting surface 10 Install the wheel onto the vehicle 11 Lower the vehicle 12 Enable the p...

Page 606: ...l Installation To Remove 1 Disable the parking brake cable adjuster 2 Lift the vehicle 3 Remove the rear propeller shaft from the vehicle Parking brake equalizer 4 Remove the parking brake cables from the parking brake equalizer ...

Page 607: ...les from the frame retainers 6 Place a pole jack with a wooden block under the fuel tank 7 Remove the fuel tank shield from the fuel tank 8 Remove the rear support bracket from the fuel tank 9 Lower the fuel tank enough to gain access to the parking brake cable retainer about the fuel tank ...

Page 608: ...Under body mounting studs 10 Detach the parking brake cables from the underbody mounting studs Park brake cable retainers 11 Remove the parking brake cables from the retainers ...

Page 609: ...e cables from the vehicle To Install 1 Route the parking brake cable through the vehicle 2 Attach the parking brake cables to the underbody mounting studs Torque the nuts to 7 ft lb 10 Nm 3 Lift the fuel tank 4 Install the rear support bracket onto the fuel tank 5 Remove the pole jack supporting the fuel tank 6 Install the parking brake cables onto the parking brake actuators 7 Install the parking...

Page 610: ... retainers 10 Install the fuel tank shield onto the fuel tank 11 Install the parking brake cables into the parking brake equalizer 12 Install the rear propeller shaft into the vehicle 13 Lower the vehicle 14 Enable the parking brake cable adjuster 15 Make sure the parking brakes are operating properly 16 Adjust the parking brake shoes ...

Page 611: ...ectronic brake control module EBCM connectors Brake pressure modulator valve A Electronic brake control module B Brake pressure modulator vale bracket C Brake pressure modulator valve retaining bolts D 2 Detach the electronic brake control module EBCM from the brake pressure modulator valve BPMV A light amount of force may be necessary do not pry about with a tool Discard the screws 3 Clean the se...

Page 612: ... BPMV Torque the new T 25 TORX screws to 39 in lb 5 Nm 2 For 2006 through 2007 vehicles attach the electronic brake control module EBCM from the brake pressure modulator valve BPMV Torque the new screws to 26 in lb 3 Nm 3 Connect the electronic brake control module EBCM connectors 4 Use the scan tool to revise the tire calibration ...

Page 613: ...e control module B Brake pressure modulator vale bracket C Brake pressure modulator valve retaining bolts D 3 Detach the brake pressure modulator valve BPMV from the mounting bracket 4 Disconnect the ABS pump motor connector 5 Detach the electronic brake control module EBCM from the brake pressure modulator valve BPMV A light amount of force may be necessary do not pry about with a tool Discard th...

Page 614: ...d the system NOTE Use this procedure only for base brakes 1 Lift the vehicle high enough to access the bleed screws 2 Start the procedure with the right rear wheel 3 Install a clear hose onto the bleed screw 4 Place the other end of the clear hose into a container partially filled with clean DOT 3 brake fluid 5 Turn the bleed screw to one turn 6 Slowly depress the brake pedal 7 When the brake peda...

Page 615: ... the vehicle 2 Remove the wheel from the vehicle 3 Remove the brake rotor from the hub 4 Remove the wheel speed sensor harness from the frame and control arm retainers 5 Disconnect the wheel speed sensor connector Front wheel speed sensor removal and installation ...

Page 616: ... the wheel speed sensor connector NOTE If installing a new wheel speed sensor the harness will have retainers already installed on it Use these instead of the old retainers 3 Install the wheel speed sensor harness into the frame and control arm retainers 4 Install the rotor onto the hub 5 Install the wheel onto the vehicle 6 Lower the vehicle ...

Page 617: ...ove the wheel speed sensor from the sensor boss To Install 1 Make sure the wheel speed sensor and sensor boss are clean 2 Lubricate the inside of the sensor boss with a small amount of axle grease 3 Install the wheel speed sensor into the sensor boss Torque the screw to 115 in lbs 13 Nm 4 Connect the wheel speed sensor connector 5 Lower the vehicle ...

Page 618: ...hicle 3 Remove the wheel speed sensor from the wheel 4 Remove the rear axle housing cover from the rear axle 5 Remove the rear axle shaft from the vehicle J 45857 and J 2619 01 Installation 6 Use a J 45857 and J2619 01 to remove the axle shaft seal bearing and wheel speed sensor ring from the axle housing ...

Page 619: ... ring installation 1 Use a J 45860 and J 8092 to install the wheel speed sensor ring into the rear axle housing J 23690 and J 8092 Installation 2 Use a J 23690 and J 8092 to install the axle shaft bearing into the rear axle housing ...

Page 620: ... the rear axle housing 4 Install the rear axle shaft into the vehicle 5 Install the rear axle housing cover onto the rear axle housing 6 Install the wheel speed sensor into the wheel 7 Install the wheel onto the vehicle 8 Refill the rear axle with fluid 9 Lower the vehicle ...

Page 621: ...ne surfaces Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container Always keep a dry chemical Class B fire extinguisher near the work area Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame Wear eye protection when servicing the air conditioning refrigerant system Serious eye injury can result from eye contact with refrigerant...

Page 622: ...d refrigerant oil is used Abnormal amounts of dirt moisture or air can upset the chemical stability This may cause operational troubles or even serious damage if present in more than very small quantities When opening a refrigeration system have everything you will need to repair the system ready This will minimize the amount of time the system must be opened Cap or plug all lines and fittings as ...

Page 623: ...covered the refrigerant recovery recycling station will pull a vacuum on the system Isolate the A C system by closing the valves when the vacuum reaches 26 in Hg 88 kPa A leak free system should be able to hold vacuum for at least 15 minutes or more If you can not reach the vacuum specified air is leaking into the system and the source must be located and repaired Leaks will most likely occur at h...

Page 624: ...Manifold gauge set components Refrigerant recovery recycling station ...

Page 625: ... refrigerant from an A C system Connect the equipment to the vehicle s A C system according to the manufacturer s instructions System Flushing After a catastrophic compressor failure it is extremely important to eliminate and or contain the debris from the compressor that may have circulated through the A C system The debris generated from a catastrophic compressor failure will be discharged into ...

Page 626: ...emicals Chemicals and cleaning systems have been specifically designed for disinfecting evaporator cores and housings The use of the cleaning system will vary slightly depending on how the A C system is designed Cleaning the evaporator core and housing generally involves spraying a cleaning solution into the housing and allowing the solution to soak for a period of time The solution is then rinsed...

Page 627: ...ater hose 11 Record the temperature at the center I P PANEL air outlet and at the heater core outlet heater hose Are the two temperature readings about equal If yes go to the next step If no go to step 13 12 Inspect and repair the cowl cowl area recirculation door and the HVAC evaporator heater core case for cold air leaks Repair any problems found go to step 17 13 Inspect the temperature door ope...

Page 628: ...tep 8 If no go to step 11 7 Check the low engine temperature problem Repair any problems found go to step 13 8 Inspect for correct operation of the recirculation door If the door is operating correctly go to step 13 If the door is not operating properly go to step 12 9 Check air delivery system Repair any problems found go to step 13 10 Check the heater core for blockage Repair or replace as neede...

Page 629: ...ot correct go to step 18 4 Inspect the drive belt for excessive oil coverage If the belt is covered with oil go to step 16 If there is no oil present go to next step 5 Start the engine ensure the A C system is ON and visually inspect the compressor and the clutch If the compressor does not turn go to step 23 If the compressor and clutch are visually okay go to step 6 6 Check compressor clutch for ...

Page 630: ...und and repaired go to step 25 25 Operate the system in order to verify the repair If the system is okay the repair is complete If not repeat the entire procedure Noise from the HVAC Housing Evaporator Case 1 Start the engine Cycle through all blower speeds A C mode settings and temperature control settings Determine the type of noise whether it is a scraping popping ticking clicking chirping or g...

Page 631: ...he components removed in step 5 When complete go to the next step 11 Operate the system to verify the repair If system operates without noise the repair is complete If noise still exists repeat the entire procedure ...

Page 632: ...Remove the HVAC control module from the instrument panel I P by depressing the retaining tabs 4 Disconnect the HVAC control module connectors To Install 1 Connect the HVAC control module connectors 2 Install the HVAC control module into the instrument panel I P 3 Install the retaining screws into the HVAC control module Torque the screws to 17 ft lb 1 9 Nm 4 Install the accessory trim plate onto t...

Page 633: ...accumulator from the vehicle To Install 1 Install the accumulator into the vehicle 2 Install the nut onto the accumulator clamp Torque the nut to 88 in lb 10 Nm 3 Install the A C low pressure switch into the accumulator Torque the switch to 44 in lb 5 Nm 4 Install the O rings onto the accumulator 5 Install the accumulator retaining nut onto the evaporator Torque the nut to 21 ft lb 28 Nm 6 Install...

Page 634: ...he console mode actuator connector 4 Detach the console mode actuator from the center console To Install 1 Attach the console mode actuator to the center console Torque the screws to 17 in lb 1 9 Nm 2 Connect the console mode actuator connector 3 Attach the air outlet duct to the center console Torque the screw to 17 in lb 1 9 Nm 4 Install the center console into the vehicle ...

Page 635: ...Remove 1 Remove the instrument panel carrier from the instrument panel 2 Disconnect the left side air temperature actuator connector HVAC control module left side 3 Detach the left side air temperature actuator from the HVAC module ...

Page 636: ...nt panel 2 Disconnect the right side air temperature actuator connector 3 Detach the right side air temperature actuator from the HVAC module To Install 1 Attach the right side air temperature actuator to the HVAC module Torque the screw to 17 in lb 1 9 Nm 2 Connect the left side air temperature actuator connector 3 Install the instrument panel carrier onto the instrument panel 4 Recalibrate the r...

Page 637: ...the instrument panel I P 5 Recalibrate the mode actuator Defrost Valve To Remove 1 Remove the instrument panel carrier from the instrument panel 2 Disconnect the defrost valve actuator connector HVAC control module left side 3 Detach the defrost valve actuator from the HVAC module To Install 1 Attach the defrost valve actuator to the HVAC module Torque the screw to 17 in lb 1 9 Nm 2 Connect the de...

Page 638: ...n actuator connector 4 Detach the recirculation actuator from the HVAC module To Install 1 Attach the recirculation actuator to the HVAC module Torque the screw to 17 in lb 1 9 Nm 2 Attach the air inlet assembly to the HVAC module Torque the screw to 17 in lb 1 9 Nm 3 Connect the recirculation actuator connector 4 Install the HVAC module into the instrument panel 5 Recalibrate the recirculation ac...

Page 639: ...tor connectors 4 Remove the air outlet duct from the auxiliary blower motor 5 Detach the auxiliary blower motor from the HVAC module To Install 1 Attach the auxiliary blower motor to the HVAC module Torque the screws to 88 in lb 10 Nm 2 Install the air outlet duct onto the auxiliary blower motor 3 Connect the auxiliary blower motor connectors 4 For all vehicles except Buick and Saab install the ce...

Page 640: ... Removal Installation To Remove 1 Remove the right rear quarter trim panel from the vehicle Rear auxiliary HVAC module removal and installation 2 Detach the rear auxiliary HVAC module from the right side and floor of the vehicle ...

Page 641: ...l 1 Attach the rear auxiliary blower motor to the rear auxiliary HVAC module Torque the screws to 18 in lb 2 Nm 2 Connect the rear auxiliary blower motor connectors 3 Attach the rear auxiliary HVAC module from the right side and floor of the vehicle Torque the side bolts and under floor nuts to 88 in lb 10 Nm 4 Install the right rear quarter trim panel into the vehicle ...

Page 642: ...nel I P 2 Remove the storage compartment door from the instrument panel I P 3 Disconnect the blower motor connector Blower motor removal and installation 4 Remove the mounting screws from the blower motor 5 Disconnect the cooing tube from the blower motor 6 Remove the blower motor from the HVAC module ...

Page 643: ...ube to the blower motor 3 Install the mounting screws into the blower motor Torque the screws to 18 in lb 2 Nm 4 Connect the blower motor connector 5 Install the storage compartment door onto the instrument panel I P 6 Install the right insulator panel onto the instrument panel I P ...

Page 644: ... Remove 1 Remove the right insulator panel from the instrument panel 2 Disconnect the blower motor connector Blower motor control processor removal 3 Disconnect the blower motor control processor connector 4 Detach the blower motor control processor from the HVAC module ...

Page 645: ...otor control processor from the HVAC module Torque the screws to 17 in lb 1 9 Nm 2 Connect the blower motor control processor connector 3 Connect the blower motor connector 4 Install the right insulator panel onto the instrument panel ...

Page 646: ...he blower motor resistor assembly connector 3 Detach the blower motor resistor assembly from the HVAC module To Install 1 Attach the blower motor resistor assembly from the HVAC module Torque the screws to 17 in lb 1 9 Nm 2 Connect the blower motor resistor assembly connector 3 Install the right insulator panel onto the instrument panel ...

Page 647: ... refrigerant from the A C system 2 Remove the generator from the engine 3 Remove the idler pulley from the engine 4 Disconnect the a c compressor connector 5 Detach the a c compressor hose assembly block from the a c compressor A C compressor removal and installation 4 2L ...

Page 648: ... onto the engine 6 Install the generator onto the engine 7 Evacuate and recharge the refrigerant in the A C system 8 Use a J 39400 A halogen leak detector to leak test the component fittings 5 3L 6 0L Engines To Remove 1 Recover the refrigerant from the A C system 2 Remove the washer solvent container from the engine compartment 3 Remove the air cleaner resonator outlet duct from the engine compar...

Page 649: ... the engine Torque the bolts to 37 ft lb 50 Nm 4 Install the upper a c compressor mounting bolts into the bracket Torque the bolts to 37 ft lb 50 Nm 5 Lift the vehicle 6 Install the lower a c compressor mounting bolts into the bracket Torque the bolts to 37 ft lb 50 Nm 7 Connect the a c compressor connector 8 Install the lower coolant hose into the engine compartment 9 Lower the vehicle 10 Attach ...

Page 650: ...ndenser to the radiator Torque the bolts to 80 in lb 9 Nm 2 Attach the upper left hand bracket to the condenser Torque the bolts to 80 in lb 9 Nm 3 Attach the inlet and outlet studs to the condenser Torque the bolts to 40 in lb 4 5 Nm 4 Attach the evaporator tube to the condenser Torque the nut to 21 ft lb 28 Nm 5 Attach the upper radiator support from the radiator Torque the nut to 37 ft lb 50 Nm...

Page 651: ... HVAC module 5 Remove the HVAC module seal from between the two halves To Install NOTE Add refrigerant oil to the evaporator core if the core is being replaced 1 Install the HVAC module seal between the two halves 2 Install the evaporator core into the HVAC module 3 Attach the top of the HVAC module to the bottom 4 Install the screws into the HVAC module Torque the screws to 17 in lb 1 9 Nm 5 Inst...

Page 652: ...ccess cover from the HVAC module Front heater core removal and installation 3 Remove the heater core from the HVAC module To Install 1 Install the heater core into the HVAC module 2 Attach the heater core access cover from the HVAC module Torque the screws to 17 in lb 1 9 Nm 3 Install the HVAC module onto the instrument panel carrier ...

Page 653: ...ove the pass through seal from the auxiliary rear HVAC module 4 Remove the heater core from the rear auxiliary HVAC module To Install 1 Install the heater core into the rear auxiliary HVAC module 2 Install the pass through seal into the auxiliary rear HVAC module 3 Attach the heater core access cover to the rear auxiliary HVAC module Torque the screws to 18 in lb 2 Nm 4 Install the rear auxiliary ...

Page 654: ...e engine Heater hoses 2 Use a set of J 43181 heater line quick connect release tool to disconnect the heater inlet hose from the heater core inlet tube 3 Use a set of GE 47622 hose clamp pliers to disconnect the heater inlet hose from the engine block heater inlet hose fitting ...

Page 655: ...on from the vehicle 3 Remove the generator from the engine 4 Use a set of J 43181 heater line quick connect release tool to disconnect the heater outlet hose from the heater core outlet tube 5 Use a set of 47622 or J 38185 hose clamp pliers to disconnect the heater outlet hose from the water pump hose fitting To Install 1 Use a set of 47622 or J 38185 hose clamp pliers to connect the heater outlet...

Page 656: ...he instrument panel carrier from the instrument panel I P 4 Use a J 43181 heater line quick connect release tool to removes the heater hoses from the heater core 5 Detach the accumulator from the evaporator 6 Disconnect the evaporator tube from the evaporator 7 Disconnect the HVAC module connectors Front HVAC module removal and installation ...

Page 657: ...anel I P 3 Connect the HVAC module connectors 4 Connect the heater hoses to the heater core 5 Connect the evaporator tube to the evaporator 6 Attach the accumulator to the evaporator Torque the nut to 40 in lb 4 5 Nm 7 Install the instrument panel carrier to the instrument panel I P 8 Evacuate and recharge the refrigerant in the A C system 9 Use a J 39400 A halogen leak detector to leak test the c...

Page 658: ...the rear block fittings under the vehicle 5 Cap the a c refrigerant lines 6 Remove and discard the o rings from the a c line block fittings 7 Remove the heater hoses from the rear auxiliary HVAC module under the vehicle 8 Lower the vehicle 9 Remove the right rear quarter trim panel 10 Disconnect the rear auxiliary HVAC module connectors 11 Disconnect the rear auxiliary air outlet ducts from the re...

Page 659: ... module 2 Attach the rear auxiliary HVAC module from the right side and floor of the vehicle Torque the bolts to 89 in lb 10 Nm 3 Connect the rear auxiliary air outlet ducts to the rear auxiliary HVAC module 4 Connect the rear auxiliary HVAC module connectors 5 Install the right rear quarter trim panel 6 Lift the vehicle 7 Install the heater hoses onto the rear auxiliary HVAC module under the vehi...

Page 660: ...ittings under the vehicle Torque the nuts to 15 ft lb 20 Nm 11 Lower the vehicle 12 Refill the cooling system 13 Evacuate and recharge the refrigerant in the A C system 14 Use a J 39400 A halogen leak detector to leak test the component fittings ...

Page 661: ...the instrument panel I P 11 Remove the instrument cluster from the instrument panel I P 12 Remove the right insulator panel from the instrument panel I P 13 Remove the storage compartment door from the instrument panel I P 14 Remove the radio from the instrument panel I P 15 Remove the front HVAC module from the instrument panel I P 16 Remove the HVAC module harness from the instrument panel I P s...

Page 662: ...Lower instrument panel retaining volts 25 Remove the lower retaining bolts from the instrument panel I P ...

Page 663: ...ing locators by lifting up on the bottom of the instrument panel I P 3 Remove the instrument panel I P from the vehicle 4 If replacing the instrument panel I P remove the inflatable restraint instrument panel I P module from the instrument panel I P 5 If replacing the instrument panel I P remove the air distribution duct vents from the instrument panel I P ...

Page 664: ...he instrument panel I P 14 Install the headlamp switch into the instrument panel I P 15 Install the left access cover onto the instrument panel I P 16 Install the HVAC module harness into the instrument panel I P substrate 17 Install the front HVAC module into the instrument panel I P 18 Install the radio into the instrument panel I P 19 Install the instrument cluster into the instrument panel I P...

Page 665: ...sion tube from the evaporator tube To Install 1 Use a J 26549 E to install the expansion tube into the evaporator tube install the shorter screen end first 2 Install a new o ring onto the evaporator 3 Attach the evaporator tubes to the block fittings Torque the nut to 21 ft lb 28 Nm 4 Attach the evaporator tube to the evaporator Torque the nut to 21 ft lb 28 Nm 5 Install the coolant reservoir into...

Page 666: ...o Remove 1 Remove the grille from the vehicle Ambient air temperature sensor 2 Remove the ambient air temperature sensor from the panel assembly 3 Disconnect the ambient air temperature sensor connector To Install 1 Connect the ambient air temperature sensor connector 2 Install the ambient air temperature sensor onto the panel assembly 3 Install the grille onto the vehicle ...

Page 667: ...Inside Air Temperature Sensor Removal Installation To Remove 1 Remove the trim panel from the upper portion of the left B pillar Inside air temperature sensor removal and installation ...

Page 668: ...ch the inside air temperature sensor assembly from the B pillar To Install 1 Connect the inside air temperature sensor connector 2 Attach the inside air temperature sensor assembly to the B pillar 3 Install the trim panel onto the upper portion of the left B pillar ...

Page 669: ...om the compressor hose block 4 Remove and discard the o ring from the a c refrigerant pressure sensor To Install 1 Install a new o ring onto the a c refrigerant pressure sensor 2 Install the a c refrigerant pressure sensor into the compressor hose block Torque the sensor to 42 in lb 4 8 Nm 3 Connect the a c refrigerant pressure sensor connector 4 Use a J 39400 A halogen leak detector to leak test ...

Page 670: ...l and installation 2 Turn the sun load sensor counterclockwise and remove it from the upper trim pad 3 Disconnect the sun load sensor connector To Install 1 Connect the sun load sensor connector 2 Install the sun load sensor into the upper trim pad and turn it clockwise 3 Install the upper trim pad onto the instrument panel I P ...

Page 671: ...ure sensors 1 Remove the upper left air temperature sensor from the upper air duct 2 Disconnect the upper left air temperature sensor connector To Install 1 Connect the upper left air temperature sensor connector 2 Install the upper left air temperature sensor into the upper air duct 3 Install the radio and HVAC control module into the instrument panel I P ...

Page 672: ...e sensor 2 Disconnect the lower left air temperature sensor connector 3 Remove the lower left air temperature sensor from the lower left air duct To Install 1 Install the lower left air temperature sensor into the lower left air duct 2 Connect the lower left air temperature sensor connector 3 Install the instrument panel into the vehicle ...

Page 673: ...upper right air temperature sensor connector 3 Remove the upper right air temperature sensor from the upper air duct To Install 1 Install the upper right air temperature sensor into the upper air duct 2 Connect the upper right air temperature sensor connector 3 Install the radio and HVAC control module into the instrument panel I P ...

Page 674: ...ature sensor connector Lower right air temperature sensor 4 Remove the lower right air temperature sensor connector from the instrument panel I P To Install 1 Install the lower right air temperature sensor connector into the lower right air duct 2 Connect the lower right air temperature sensor connector 3 Install the lower insulator panel onto the instrument panel I P 4 Install the right insulator...

Page 675: ... Remove the a c low pressure switch from the accumulator 3 Remove and discard the o ring from the accumulator To Install 1 Install a new o ring onto the accumulator 2 Install the a c low pressure switch onto the accumulator Torque the switch to 42 in lb 4 8 Nm 3 Connect the a c low pressure switch connector ...

Page 676: ...A C Specifications ...

Page 677: ......

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