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INDICE
Diagramas Elctricos

Motor

15

733

Consola Central, Panel de Instrumentos

782

Puertas, accesorios, espejos

825

SIR (Airbags)

855

Tabla de Conversin de Medidas

871

Transmisin Automtica

900

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Tren Delantero

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DIAGRAMAS ELECTRICOS
Electrical Center Identification Views
Document ID: 353473
Underhood Bussed Electrical Center (UBEC) Details (Base Pickup)

Fuse/Circuit
No.
Breaker Rating
Maxi Fuses
1

INT BATT

50A

2
ABS
3-4

5
IGN B
6
RAP
7
IGN A
8
STUD #2
Mini Fuses
9
11
12 VEH B/U

60A

50A
50A
40A
30A

Description
HDLP SW, MIR/LKS, AUX PWR, RDO BATT,
CIGAR LTR, CTSY LP, and PWR LKS Fuses
Electronic Brake Control Module (EBCM) Assembly
Not Used
Ignition Switch
Retained Accessory Power Relay
Starter Relay and Ignition Switch
Not Used
Not Used

15A Backup Lamps, Right and Left

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RT TURN
LT TURN
LT TRN
RT TRN

10A
10A
10A
10A

17

RR PRK

10A

18

FR PRK

10A

19

20

LT HDLP

10A

21

RT HDLP

10A

22

ENG 1

10A

23

ECM B

20A

24

HORN

15A

25

ECM 1

15A

26

BTSI

10A

27
28
29
30

B/U LP

IGN E
FOG LP

25A

10A
15A

31

OXYSEN

20A

32

LR PRK

10A

33
34
35
36
37
38
3940
41

IGN C

PARK LP

HVAC

20A

20A

30A

CRANK

Turn Signal Assembly, Right Front


Turn Signal Assembly, Left Front
Tail Lamp Assembly, Left Rear
Tail Lamp Assembly, Right Rear
License Lamp, Marker Lamp Assembly, and Tail Lamp
Assembly (All Right Side)
Turn Signal Lamp Assembly and Tail Lamp Assembly
(All Right Side)
Not Used
Headlamp Low Beam, Left Side, and Daytime Running
Lamp (DRL) Relay
Headlamp Low Beam and Headlamp High Beam (All
Right Side)
Evaporative Emission Canister Purge Solenoid,
Evaporative Emission Canister Vent Solenoid, Mass Air
Flow Sensor (4.3L), and Camshaft Position Sensor
(4.3L)
Fuel Pump Relay, Powertrain Control Module (PCM)
(2.2L), Vehicle Control Module (4.3L), and Fuel Pump
and Engine Oil Pressure Gauge Sensor
Horn, Left and Right Side
Electronic Ignition Control Module, Powertrain Control
Module/Vehicle Control Module, Crankshaft Position
Sensor, Fuel Injectors 1-6, and Ignition Coil
Stop Lamp Switch Assembly and Transfer Case Control
Module
Backup Lamps Switch/Transmission Range Switch
Not Used
A/C Compressor Clutch Relay
Fog Lamp Relay and Headlamp Ground Relay
Heated Oxygen Sensor, Post-Converter (2.2L), Heated
Oxygen Sensor, Left Front, Heated Oxygen Sensor,
Post-Converter, Heated Oxygen Sensor, Right Front, and
Heated Oxygen Sensor, Pre-Converter
Tail Lamp Assembly, Left Side, Marker Lamp
Assembly, Left Rear, and License Lamp, Left Side
Ignition Switch
Not Used
Park Lamp Relay and Headlamp Switch Assembly
Not Used
Not Used
Blower Motor Relay
Not Used

10A Transfer Case Control Module, Manual Transmission

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13
14
15
16

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42

HAZ LP

20A

43

VECHMSL

10A

44
45

STOP LP

20A

46

TBC

10A

Power Supply to the Headlamps


Power Supply to the Daytime Running Lamps (DRL)
Power Supply to the Fuel Pump
Power Supply to the Horns
Not Used
Ground Supply to the Headlamps
Not Used
Power Supply to the Rear Brake Lamps

Power Supply to the Starter


Not Used

Prevent Feedback from the DRL Relay

Underhood Bussed Electrical Center (UBEC) Details (Uplevel Pickup)

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Micro Relays
47 HDLP PWR
48
DRL
49
F/Pump
50
Horn
51

52 HDLP GRD
53

54
CHMSL
Mini Relays
55
Starter
56

Diode
57
DRL

Clutch Start Switch, and Transmission Range Switch


(Automatic)
Hazard Switch
Dome and High Mounted Stop Lamp and Cruise Control
Module
Not Used
High Mounted Stop Lamp Relay and Stop Lamp Switch
Truck Body Control Module (TBC) and RFA Module
Assembly (Remote Keyless Entry)

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Fuse/Circuit
No.
Breaker Rating
Maxi Fuses
1

INT BATT

50A

2
ABS
3-4

5
IGN B
6
RAP
7
IGN A
8
STUD#2
Mini Fuses
9
11
12 VEH B/U
13 RT TURN
14 LT TURN
15
LT TRN
16
RT TRN

60A

50A
50A
40A
30A

17

RR PRK

18

FR PRK

19

15A
10A
10A
10A
10A

Description
HDLP SW, MIR/LKS, AUX PWR, RDO BATT,
CIGAR LTR, CTSY LP, and PWR LKS Fuses
Electronic Brake Control Module (EBCM) Assembly
Not Used
Ignition Switch
Retained Accessory Power Relay
Starter Relay and Ignition Switch
Not Used
Not Used

Backup Lamps, Right and Left


Turn Signal Assembly, Right Front
Turn Signal Assembly, Left Front
Tail Lamp Assembly, Left Rear
Tail Lamp Assembly, Right Rear
License Lamp, Marker Lamp Assembly, and Tail Lamp
10A
Assembly (All Right Side)
Turn Signal Lamp Assembly and Tail Lamp Assembly
10A
(All Right Side)
Not Used

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LT HDLP

21

RT HDLP

22

ENG 1

23

ECM B

24

HORN

25

ECM 1

26

BTSI

27
28
29
30

B/U LP
A/C
IGN E
FOG LP

31

OXYSEN

32

LR PRK

33
34
35
36
37
38
3940

IGN C

PARK LP
ATC

HVAC

Headlamp Low Beam Left, Headlamp High BeamLeft


10A (ZR2 w/ Service Harness), and Daytime Running Lamp
(DRL) Relay
10A Right Headlamps
Evaporative Emission Canister Purge Solenoid,
Evaporative Emission Canister Vent Solenoid, Mass Air
10A
Flow Sensor (4.3L), and Camshaft Position Sensor
(4.3L)
Fuel Pump Relay, Powertrain Control Module (PCM)
20A (2.2L), Vehicle Control Module (4.3L), and Fuel Pump
and Engine Oil Pressure Gauge Sensor
15A Horn, Left and Right Side
Electronic Ignition Control Module, Powertrain Control
15A Module/Vehicle Control Module, Crankshaft Position
Sensor, Fuel Injectors 1-6, and Ignition Coil
Stop Lamp Switch Assembly and Transfer Case Control
10A
Module
25A Backup Lamps Switch/Transmission Range Switch
10A A/C Compressor Clutch Relay
10A A/C Compressor Clutch Relay
15A Fog Lamp Relay and Headlamp Ground Relay
Heated Oxygen Sensor, Post-Converter (2.2L), Heated
Oxygen Sensor, Left Front, Heated Oxygen Sensor,
20A
Post-Converter, Heated Oxygen Sensor, Right Front, and
Heated Oxygen Sensor, Pre-Converter
Tail Lamp Assembly, Left Side, Marker Lamp
10A
Assembly, Left Rear, and License Lamp, Left Side
20A Ignition Switch
Not Used
20A Park Lamp Relay and Headlamp Switch Assembly
20A Transfer Case Control Module
Not Used
30A Blower Motor Relay

41

CRANK

10A

42

HAZ LP

20A

43

VECHMSL

10A

44
45

STOP LP

20A

46

TBC

10A

Not Used
Transfer Case Control Module, Manual Transmission
Clutch Start Switch, and Transmission Range Switch
(Automatic)
Hazard Switch
Dome and High Mounted Stop Lamp and Cruise Control
Module
Not Used
High Mounted Stop Lamp Relay and Stop Lamp Switch
Truck Body Control Module (TBC) and RFA Module
Assembly (Remote Keyless Entry)

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Power Supply to the Headlamps


Power Supply to the Daytime Running Lamps (DRL)
Power Supply to the Fuel Pump
Power Supply to the Horns
A/C Compressor Relay
Ground Supply to the Headlamps
Power Supply to the Fog Lamps
Power Supply to the Rear Brake Lamps

Power Supply to the Starter


Not Used

Prevent Feedback from the DRL Relay

Underhood Bussed Electrical Center (UBEC) Details (Uplevel Utility)

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Fuse/Circuit
No.
Breaker
Rating
Maxi Fuses
1

INT BATT

ABS

Description

HDLP SW, MIR/LKS, AUX PWR, RDO BATT,


CIGAR LTR, CTSY LP, and PWR LKS Fuses
60A Electronic Brake Control Module (EBCM) Assembly
50A

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Micro Relays
47 HDLP PWR
48
DRL
49
F/Pump
50
Horn
51
A/C
52 HDLP GRD
53
FOG LP
54
CHMSL
Mini Relays
55
Starter
56

Diode
57
DRL

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50A
50A
40A
30A

Not Used
Ignition Switch
Retained Accessory Power Relay
Starter Relay and Ignition Switch
AUX PWR Stud, UBEC

10A
10A
10A
15A
10A
10A
10A
10A
10A
10A

19

TRL PRK

10A

20

LT HDLP

10A

21

RT HDLP

10A

22

ENG 1

10A

23

ECM B

20A

24

HORN

15A

25

ECM 1

15A

26

BTSI

10A

27
28
29
30

B/U LP
A/C
IGN E
FOG LP

25A
10A
10A
15A

31

OXYSEN

20A

32

LR PRK

10A

Turn Signal, Left Side Trailer


Turn Signal, Right Side Trailer
Backup Lamp, Trailer
Backup Lamps, Right and Left
Turn Signal Assembly, Right Front
Turn Signal Assembly, Left Front
Tail Lamp Assembly, Left Rear
Tail Lamp Assembly, Right Rear
Tail Lamp Assembly, Right Side
Front Turn Signal Lamp Assembly, RH, LH
Tail Lamp, Trailer, LH, RH, Vehicle Lisense Plate
Lamps
Headlamp Low Beam, Left Side, and Daytime Running
Lamp (DRL) Relay
Headlamp Low Beam and Headlamp High Beam (All
Right Side)
Evaporative Emission Canister Purge Solenoid,
Evaporative Emission Canister Vent Solenoid, Mass Air
Flow Sensor (4.3L), and Camshaft Position Sensor
(4.3L)
Fuel Pump Relay, Powertrain Control Module (PCM)
(2.2L), Vehicle Control Module (4.3L), and Fuel Pump
and Engine Oil Pressure Gauge Sensor
Horn, Left and Right Side
Electronic Ignition Control Module, Powertrain Control
Module/Vehicle Control Module, Crankshaft Position
Sensor, Fuel Injectors 1-6, and Ignition Coil
Stop Lamp Switch Assembly/BTSI Solenoid and
Transfer Case Control Module
Backup Lamps Switch/Transmission Range Switch
A/C Compressor Clutch Relay
A/C Compressor Clutch Relay
Fog Lamp Relay and Headlamp Ground Relay
Heated Oxygen Sensor, Post-Converter (2.2L), Heated
Oxygen Sensor, Left Front, Heated Oxygen Sensor,
Post-Converter, Heated Oxygen Sensor, Right Front
Tail Lamp Assembly, Left Side, Marker Lamp
Assembly, Left Rear, and License Lamp, Left Side

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3-4

5
IGN B
6
RAP
7
IGN A
8
STUD#2
Mini Fuses
9
TRL TRN
10 TRR TRN
11
TRL B/U
12 VEH B/U
13 RT TURN
14 LT TURN
15
LT TRN
16
RT TRN
17
RR PRK
18
FR PRK

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IGN C
HTD SEAT
PARK LP
ATC
RRDEFOG
HVAC
TRCHMSL
RR W/W

20A
20A
20A
20A
30A
30A
10A
15A

41

CRANK

10A

42

HAZ LP

20A

43

VECHMSL

10A

44
45

HTDMIR
STOP LP

10A
20A

46

TBC

10A

Micro Relays
47 HDLP PWR
48
DRL
49
F/Pump
50
Horn
51
A/C
52 HDLP GRD
53
FOG LP
54

Mini Relays
55
Starter
56 RR DEFOG
Diode
57
DRL

Ignition Switch
Heated Seat Assembly
Park Lamp Relay and Headlamp Switch Assembly
Transfer Case Control Module
Rear Window Defogger
Blower Motor Relay/Blower Motor
Trailer Wiring Provision
Rear Window Wiper
Transfer Case Control Module, Manual Transmission
Clutch Start Switch, and Transmission Range Switch
(Automatic)
Hazard Switch
Dome and Mounted Stop Lamp and Cruise Control
Module
Heated Mirrors
Stop Lamp Switch, High Mounted Stop Lamp Relay
Truck Body Control Module (TBC) and RFA Module
Assembly (Remote Keyless Entry)

Power Supply to the Headlamps


Power Supply to the Daytime Running Lamps (DRL)
Power Supply to the Fuel Pump
Power Supply to the Horns
A/C Compressor Relay
Ground Supply to the Headlamps
Power Supply to the Fog Lamps
Not Used

Power Supply to the Starter


Power Supply to the Rear Defog

Prevent Feedback from the DRL Relay

Underhood Bussed Electrical Center (UBEC) Details (Envoy)

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33
34
35
36
37
38
39
40

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Fuse/Circuit
No.
Breaker Rating
Maxi Fuses
1

INT BATT

60A

2
ABS
3-4

5
IGN B
6
RAP
7
IGN A
8
STUD
Mini Fuses
9
TRL TRN
10 TRR TRN
11 TRL B/U
12 VEH B/U
13 RT TURN
14 LT TURN
15
LT TRN
16
RT TRN

60A

50A
50A
40A
30A

17

RR PRK

18

FR PRK

10A
10A
10A
15A
10A
10A
10A
10A

Description
HDLP SW, MIR/LKS, AUX PWR, RDO BATT, CIGAR
LTR, CTSY LP, and PWR LKS Fuses
Electronic Brake Control Module (EBCM) Assembly
Not Used
Ignition Switch
Retained Accessory Power Relay
Starter Relay and Ignition Switch
Not Used

Turn Signal, Left Side Trailer


Turn Signal, Right Side Trailer
Backup Lamp, Trailer
Backup Lamps, Right and Left
Turn Signal Assembly, Right Front
Turn Signal Assembly, Left Front
Tail Lamp Assembly, Left Rear
Tail Lamp Assembly, Right Rear
License Lamp, Marker Lamp Assembly, and Tail Lamp
10A
Assembly (All Right Side)
10A Turn Signal Lamp Assembly and Tail Lamp Assembly

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TRL PRK

10A

20

LT HDLP

10A

21

RT HDLP

10A

22

ENG 1

10A

23

ECM B

20A

24
25
26

LT HI
RT HI
HORN

15A
15A
10A

27

ECM 1

15A

28

DRL

15A

29

BTSI

10A

30
31
32
33

B/U LP
A/C
IGN E
FOG LP

25A
10A
10A
15A

34

OXYGEN

20A

35

LR PRK

10A

36
IGN C
37 HTD SEAT
38 PARK LP
39
ATC
40 RRDEFOG
41
HVAC
42 TRCHMSL
43 RR W/W

20A
20A
20A
20A
30A
30A
10A
15A

44

CRANK

10A

45
46

LD LEV
HI BEAM

25A
20A

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19

(All Right Side)


Tail Lamp, Trailer
Headlamp Low Beam, Left Side, and Daytime Running
Lamp (DRL) Relay
Headlamp Low Beam and Headlamp High Beam (All
Right Side)
Evaporative Emission Canister Purge Solenoid,
Evaporative Emission Canister Vent Solenoid, Mass Air
Flow Sensor (4.3L), and Camshaft Position Sensor (4.3L)
Fuel Pump Relay, Powertrain Control Module (PCM)
(2.2L), Vehicle Control Module (4.3L), and Fuel Pump
and Engine Oil Pressure Gauge Sensor
Left Hi Beam
Right Hi Beam
Horn, Left and Right Side
Electronic Ignition Control Module, Powertrain Control
Module/Vehicle Control Module, Crankshaft Position
Sensor, Fuel Injectors 1-6, and Ignition Coil
Daytime Running Lamps
Stop Lamp Switch Assembly and Transfer Case Control
Module
Backup Lamps Switch/Transmission Range Switch
A/C Compressor Clutch Relay
A/C Compressor Clutch Relay
Fog Lamp Relay and Headlamp Ground Relay
Heated Oxygen Sensor, Post-Converter (2.2L), Heated
Oxygen Sensor, Left Front, Heated Oxygen Sensor, PostConverter, Heated Oxygen Sensor, Right Front, and
Heated Oxygen Sensor, Pre-Converter
Tail Lamp Assembly, Left Side, Marker Lamp
Assembly, Left Rear, and License Lamp, Left Side
Ignition Switch
Heated Seat Assembly
Park Lamp Relay and Headlamp Switch Assembly
Transfer Case Control Module
Rear Window Defogger
Blower Motor Relay
Blunt Cut Wire
Rear Window Wiper
Transfer Case Control Module, Manual Transmission
Clutch Start Switch, and Transmission Range Switch
(Automatic)
Load Leveling
HID Headlamps

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47

HAZ LP

48 VECHMSL
49
50

HTDMIR
STOP LP

51

TBC

Power Supply to the Daytime Running Lamps (DRL)


Power Supply to the Fuel Pump
Power Supply to the Horns
A/C Compressor Relay
Power Supply to the Fog Lamps

Power Supply to the Low Beam Headlamps


Power Supply to the Starter
Power Supply to the Rear Defog

IP Fuse Block Details

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Fuse
No.

Fuse/Circuit
Breaker
Rating
Description
Power
Door Lock and Side Window Switch Assembly,
30A
Windows/Circuit
Left and Right Side

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Micro Relays
52
DRL
53
F/Pump
54
Horn
55
A/C
56
FOG LP
Mini Relays
57 LOW BEAM
58 STARTER
59 RR DEFOG

20A Hazard Switch


Dome and High Mounted Stop Lamp and Cruise Control
10A
Module
10A Heated Mirrors
20A High Mounted Stop Lamp Relay and Stop Lamp Switch
Truck Body Control Module (TBC) and RFA Module
10A
Assembly (Remote Keyless Entry)

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CRUISE

GAUGES

ILLUM

MIR/LKS

CTSY LP

HVAC

10

TURN

11

CLSTR

12

PARK LPS

13

AUX PWR

14

PWR LKS

15

4WD

16

SIR

17

FRT WPR

18
19

RDO BATT
AMP F (Envoy
Only)

20
21

HVAC1

22

ABS

10A Headlamp Switch


15A Cigar Lighter and Data Link Connector
Truck Body Control Module (TBC), Cruise
10A
Control Module and Cruise Control Switch
Truck Body Control Module (TBC) and
10A
Instrument Cluster
Radio, Heater Controller (Non-A/C), Heater and
A/C Controller (w/ A/C), Fog Lamp Switch, IP
10A Module Switch, Truck Body Control Module
(TBC), Transfer Case Select Switch, and
Instrument Cluster
Not Used
Outside Rear View Mirror Switch and Door
5A Lock and Side Window Switch Assembly, Left
and Right Side
Console Courtesy Lamp, Left and Right Side,
10A Transfer Case Control Module and Inadvertent
Power Lamp Relay
Heater Controller (Non-A/C) and Heater and
20A
A/C Controller (w/ A/C)
20A Hazard Lamp Switch and Turn Signal Switch
Instrument Cluster, Powertrain Control Module
10A (2.2L), Vehicle Control Module (4.3L), and
Automatic Transmission
IP Ashtray Lamp, Truck Body Control Module
(TBC), Outside Rear View Mirror Switch, and
10A
Door Lock and Side Window Switch Assembly,
Left and Right Side
20A Auxiliary Power Outlet, Left and Right Side
Door Lock Relay, Door Unlock Relay, and
15A
Driver Door Lock Relay
Vehicle Control Module, Transfer Case Select
10A Switch, Transfer Case Control Module, and
Front Axle Switch
IP Module Switch and Supplemental Restraint
15A
Sensing and Diagnostic Module
Windshield Wiper Motor and Windshield
25A
Wiper/Washer Control Switch
Not Used
15A Radio and Instrument Cluster
25A Amplifier
Air Temperature Valve and Air Temperature
Valve Electric Actuator
10A Stop Lamp Switch and Electronic Brake Control

10A

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1
2

Breaker A
HDLP SW
CIGAR LTR

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23
24

RR WPR
RDO IGN

Module Assembly
15A Rear Wiper Switch, Rear Window Washer Motor
10A Radio

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MOTOR
Key and Lock Cylinder Coding
Document ID: 102500

The lock cylinder keyway is designed so that other model keys will not enter a current
model lock cylinder. A single key is used for all locks on the vehicle.
The key identification is obtained from the five-character key code stamped on the
knockout portion of the key head. Knock the plugs out of the key head after code
numbers have been recorded. The code list, available to owners of key cutting
equipment from equipment suppliers, determines the lock combinations from the code
numbers.

Cutting Keys
After the code has been determined from the code list or the key code diagram, perform
the following steps:
1. Cut a blank key to the proper level of each of the tumbler positions.
2. Inspect the key operation in the lock cylinder.

Replacement Lock Cylinders


New lock cylinders except ignition lock cylinders are available from the service parts
warehouse with new lock cylinder locking bars. The tumblers are also available and
must be assembled into the cylinder as recommended. For additional information, refer
to the following.

Lock Cylinder Tumbler Operation


All lock tumblers are shaped alike with the exception of the notched position on one
side. As the key is inserted into the lock cylinder, the tumblers are lowered to the correct
height so that notches on each tumbler are at the same level. When the notches on all six
tumblers line up, two small springs push the side bar into the notches, allowing the
cylinder to turn in the cylinder bore. Five types of tumblers are used in making the lock
combinations, and each is coded and stamped with a number between 1 and 5.

Assembling and Coding Ignition Lock Cylinders


Tools Required
J 41340 Ignition Lock Holding Fixture

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Key Identification and Usage

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1. Determine the tumbler numbers/arrangement:


1. Place the tip of the key directly over the tip of the illustrated key.
2. Inspect that the diagram outlines the key.
3. Starting with position 1 (open end of cylinder), find and record the
lowest level (tumbler number) that is visible.
4. Repeat the previous step for positions 210.

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2. Starting with position 1, insert the tumblers (4) into their corresponding slots in
the coded order.
3. Using your fingers, pull out the side bar (3) until the tumblers fall completely
into place.
4. Insert one tumbler spring (2) above each tumbler (4).
5. Lubricate the tumblers using Superlube GM P/N 12346241 or equivalent.
6. Insert the spring retainer (1) prongs into the slots at the end of each cylinder.

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7. Press down the retainer (1) until fully seated in the depression.

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8. Inspect for proper tumbler installation:
1. Hold the spring retainer (2) in position.
2. Insert the key (1) into the cylinder.
3. The side bar (3) should drop down flush with the cylinder diameter if
properly installed.
4. Disassemble and assemble properly as needed.
9. Remove the key.

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10. Secure the cylinder in the J 41340 .


1. Inspect that the spring retainer is facing up and positioned directly under
the punch slots.
2. Push the cylinder into the J 41340 until butted with the cylinder bezel.
3. Tighten the holding screw.

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11. Stake the bezel end of the retainer in place:
1. Hold the flat side of the punch, part of J 41340 , squarely against the face
of the cylinder bezel.
2. Stake the lock cylinder metal over the retainer corners.

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12. Stake the other end of the retainer:


1. Remove the punch, part of J 41340 .
2. Rotate the punch, part of J 41340 , 180 degrees.
3. Hold the punch, part of J 41340 , squarely against the end of the punch
slot on J 41340 .
4. Stake the metal over the other end of the retainer.

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13. Loosen the holding screw.
14. Remove the cylinder from the J 41340 .
15. Inspect that the retainer is properly staked. Restake as needed.
16. Lubricate the cylinder retainer slot.
17. Insert the following parts into the cylinder retainer slot:
o The retainer spring (2)
o The retainer (3)

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Important: Use a paste type grease, not a spray, for the following step.
18. Lubricate the following parts with GM P/N 12345996 or equivalent as needed:
o The detent pins (1)
o The cylinder retainer (3)

Fastener Tightening Specifications

Specification
Metric English
Accelerator Control Cable Bracket Nut
12 N-m 106 lb in
Accelerator Control Cable and Cruise Control Cable Bracket Nut 9 N-m 80 lb in
Accelerator Control Cable Bracket Stud to Intake Manifold
6 N-m 53 lb in
Accelerator Control Cable Bracket Stud to Throttle Body
12 N-m 106 lb in
Air Cleaner Adapter Stud
8 N-m 71 lb in
Air Conditioning (A/C) Compressor Mounting Bolt
50 N-m 37 lb ft
Balance Shaft Driven Gear Bolt
First Pass
20 N-m 15 lb ft
Application

Final Pass

Balance Shaft Retainer Bolt


Battery Negative Cable Bolt to Engine
Belt Idler Pulley Bolt
Camshaft Retainer Bolt
Camshaft Sprocket Bolt
Connecting Rod Nut
First Pass

Final Pass

Crankshaft Balancer Bolt


Crankshaft Bearing Cap Bolt (Preferred Method)
First Pass

Final Pass

Crankshaft Bearing Cap Bolt (Optional Strategy)

35 degrees
12 N-m
35 N-m
50 N-m
12 N-m
25 N-m

106 lb in
26 lb ft
37 lb ft
106 lb in
18 lb ft

27 N-m 20 lb ft
70 degrees
95 N-m 70 lb ft
20 N-m 15 lb ft
73 degrees
105 N77 lb ft
m

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Document ID: 450026

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Crankshaft Position Sensor Bolt


Crankshaft Pulley Bolt
Crankshaft Rear Oil Seal Housing Bolt and Nut
Crankshaft Rear Oil Seal Housing Retainer Stud
Cylinder Head Bolt (Preferred Method)
All Bolts First Pass in Sequence
Long Bolt Final Pass in Sequence

Medium Bolt Final Pass in Sequence

Short Bolt Final Pass in Sequence

Cylinder Head Bolt (Optional On-Vehicle Strategy)


First Pass in Sequence

Second Pass in Sequence

Final Pass in Sequence

Cylinder Head Core Hole Plug


Distributor Cap Bolt
Distributor Clamp Bolt
Drive Belt Tensioner Bolt
EGR Valve Bolt
First Pass

Final Pass

EGR Valve Inlet Pipe Clamp Bolt


EGR Valve Inlet Pipe Nut at Intake Manifold
EGR Valve Inlet Pipe Nut at Exhaust Manifold
Engine Block Left Side Oil Gallery Plug
Engine Block Left Rear Oil Gallery Plug
Engine Block Right Rear Oil Gallery Plug
Engine Block Coolant Drain Hole Plug
Engine Block Oil Gallery Plug
Engine Coolant Heater Bolt/Screw
Engine Coolant Temperature (ECT) Sensor
Engine Flywheel Bolt
Engine Front Cover Bolt

80 lb in
43 lb ft
106 lb in
53 lb in

30 N-m 22 lb ft
75 degrees
65 degrees
55 degrees

35 N-m 26 lb ft
60 N-m 44 lb ft
90 N-m 66 lb ft
20 N-m
2.4 Nm
25 N-m
50 N-m

15 lb ft
21 lb in
18 lb ft
37 lb ft

7 N-m 62 lb in
30 N-m 22 lb ft
25 N-m
25 N-m
30 N-m
20 N-m
30 N-m
20 N-m
20 N-m
20 N-m
2 N-m
20 N-m
100 Nm
12 N-m

18 lb ft
18 lb ft
22 lb ft
15 lb ft
22 lb ft
15 lb ft
15 lb ft
15 lb ft
18 lb in
15 lb ft
74 lb ft
106 lb in

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9 N-m
58 N-m
12 N-m
6 N-m

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Final Pass

Fan and Water Pump Pulley Bolt


Fuel Meter Body Bracket Bolt
Fuel Pipe Bracket Bolt
Fuel Pipe Bracket Bolt to Rear of Cylinder Head
Fuel Pipe Retainer Nut
Fuel Supply Pipe Nut (Fuel Tank Side)
Generator and Drive Belt Tensioner Bracket Bolt to Engine
Generator and Drive Belt Tensioner Bracket Stud to Engine
Generator and Drive Belt Tensioner Bracket Stud Nut
Generator Mounting Bolt
Ground Wire Bolt to Rear of Cylinder Head
Ignition Coil Stud
Knock Sensor
Lower Intake Manifold Bolt
First Pass in Sequence

15 N-m
35 N-m
74 N-m
54 N-m
50 N-m
45 N-m
45 N-m
63 N-m
30 N-m
15 N-m
12 N-m
35 N-m
25 N-m

11 lb ft
26 lb ft
55 lb ft
40 lb ft
37 lb ft
33 lb ft
33 lb ft
46 lb ft
22 lb ft
11 lb ft
106 lb in
26 lb ft
18 lb ft

10 N-m 88 lb in
15 N-m 11 lb ft
30 N-m 22 lb ft
25 N-m
10 N-m
6 N-m
30 N-m
3 N-m
30 N-m
41 N-m
20 N-m
41 N-m
50 N-m
35 N-m
12 N-m
20 N-m

18 lb ft
88 lb in
53 lb in
22 lb ft
27 lb in
22 lb ft
30 lb ft
15 lb ft
30 lb ft
37 lb ft
26 lb ft
106 lb in
15 lb ft

3 N-m 27 lb in

Second Pass in Sequence

12 N-m 106 lb in

Final Pass in Sequence

15 N-m 11 lb ft

Oil Filter Adapter Bolt


Oil Filter Fitting

21 N-m 15 lb ft
35 N-m 26 lb ft

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Engine Lift Bracket Bolt (Special Tool J 41427)


Engine Lift Front Bracket Stud
Engine Mount Bolt (Through-bolt)
Engine Mount Bolt to Engine
Engine Mount (Rear) Bolt to Transmission
Engine Mount (Rear) Nut to Crossmember
Engine Mount Bracket Bolt to Frame
Engine Mount Nut (Through-bolt)
Engine Oil Pressure Gauge Sensor
Engine Oil Pressure Gauge Sensor Fitting (Plus Required Angle)
Engine Wiring Harness Bracket Nut to Intake Manifold
Engine Wiring Harness Bracket Bolt to Rear of Cylinder Head
Engine Wiring Harness Bracket Bolt to Generator and Drive Belt
Tensioner Bracket
Evaporative Emission (EVAP) Canister Purge Solenoid Valve
Stud to Intake Manifold
Exhaust Manifold Bolt/Stud
First Pass

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All Subsequent Installations

Spark Plug Wire Support Bolt


Starter Motor Bolt
Starter Motor Wiring Harness/Transmission Cooler Pipe Bracket
Bolt to Oil Pan
Throttle Body Stud
Transmission Bolt to Oil Pan
Transmission Cover Bolt
Upper Intake Manifold Stud
First Pass

Final Pass

12 N-m
12 N-m
25 N-m
25 N-m
90 N-m
12 N-m
20 N-m

106 lb in
106 lb in
18 lb ft
18 lb ft
66 lb ft
106 lb in
15 lb ft

41 N-m
20 N-m
41 N-m
50 N-m
41 N-m
50 N-m
36 N-m

30 lb ft
15 lb ft
30 lb ft
37 lb ft
30 lb ft
37 lb ft
27 lb ft

30 N-m 22 lb ft
25 N-m 18 lb ft
10 N-m 88 lb in
35 N-m 26 lb ft
35 N-m 26 lb ft
10 N-m 88 lb in
25 N-m 18 lb ft
30 N-m 22 lb ft
15 N-m 11 lb ft
12 N-m 106 lb in
40 N-m 29 lb ft
12 N-m 106 lb in
9 N-m 80 lb in
47 N-m 35 lb ft
12 N-m 106 lb in
5 N-m 44 lb in
9 N-m 80 lb in

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Oil Level Indicator Tube Bolt


Oil Pan Baffle Bolt
Oil Pan Bolt and Nut in Sequence
Oil Pan Drain Plug
Oil Pump Bolt to Rear Crankshaft Bearing Cap
Oil Pump Cover Bolt
Power Steering Fluid Reservoir Filler Neck Bolt to Power
Steering Pump Bracket
Power Steering Pump Bracket Bolt to Engine
Power Steering Pump Bracket Stud to Engine
Power Steering Pump Bracket Stud Nut
Power Steering Pump Bolt
Power Steering Pump Nut to Engine
Power Steering Pump Rear Bracket Nut to Power Steering Pump
Radiator Inlet Hose Support Bracket Nut to Exhaust Manifold
Stud
Remote Oil Filter Adapter Mounting Bracket Bolt
Remote Oil Filter Adapter Nut
Remote Oil Filter Inlet and Outlet Hose Clip Bolt
Remote Oil Filter Inlet and Outlet Hose to Remote Oil Filter
Adapter Bolt
Remote Oil Filter Inlet and Outlet Hose to Remote Oil Filter Pipe
Adapter Bolt
Secondary Air Injection (AIR) Check Valve Pipe Bracket Bolt to
Exhaust Manifold
Secondary Air Injection (AIR) Check Valve Pipe Stud Nut
Spark Plug
Initial Installation (NEW Cylinder Head)

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Valve Lifter Pushrod Guide Bolt


Valve Rocker Arm Ball Stud
Valve Rocker Arm Cover Bolt
Valve Rocker Arm Nut
Water Outlet Stud
Water Pump Bolt

16 N-m
47 N-m
12 N-m
25 N-m
25 N-m
45 N-m

12 lb ft
35 lb ft
106 lb in
18 lb ft
18 lb ft
33 lb ft

Engine Mechanical Specifications

Application

Specification
Metric
English

General Data
Engine Type

V6

Regular Production Option (RPO) Code LF6 VIN Code X, and RPO Code
L35 VIN Code W

Displacement

Bore

Stroke

Compression Ratio

Firing Order

Spark Plug Gap

Oil Pressure (Minimum) at Normal


Operating Temperature

Balance Shaft
Rear Bearing Journal Clearance

Rear Bearing Journal Diameter

4.3L

262 CID

101.60 mm

4.012 in

88.39 mm

3.480 in
9.2:1

165432
1.52 mm

0.060 in

42 kPa at
1,000 RPM

6 psig at
1,000 RPM

125 kPa at
2,000 RPM

18 psig at
2,000 RPM

166 kPa at
4,000 RPM

24 psig at
4,000 RPM

0.0500.088 mm

0.0020
0.0035 in

38.085
38.100 mm

1.49941.500 in

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Document ID: 104659

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Camshaft
End Play
Journal Diameter

Journal Diameter Out-of-Round

Lobe Lift (Exhaust) (L35)

Lobe Lift (Exhaust) (LF6)

Lobe Lift (Intake) (L35)

Lobe Lift (Intake) (LF6)

Runout

Connecting Rod
Connecting Rod Bearing Clearance
(Production)

Connecting Rod Bearing Clearance


(Service)

Connecting Rod Side Clearance

Connecting Rod Journal Diameter

Connecting Rod Journal Taper


(Production)

Connecting Rod Journal Taper (Service)

Connecting Rod Journal Out-of-Round


(Production)

Connecting Rod Journal Out-of-Round


(Service)

Crankshaft
Crankshaft Bearing Clearance (Journal
#1Production)

Crankshaft Bearing Clearance (Journal


#2, #3, and #4Production)

0.0010
0.0090 in
1.8677
1.8696 in
0.0010 in
(Maximum)

7.207.30 mm

0.2830.287 in

6.546.64 mm

0.2570.261 in

6.977.07 mm

0.2740.278 in

6.766.86 mm

0.2660.270 in

0.065 mm

0.0026 in

0.0380.078 mm

0.0015
0.0031 in

0.0250.076 mm

0.0010
0.0030 in

0.150.44 mm

0.0060.017 in

57.116
57.148 mm

2.2487
2.2497 in

0.00508 mm
(Maximum)

0.00030 in
(Maximum)

0.025 mm
(Maximum)

0.0010 in
(Maximum)

0.007 mm
(Maximum)

0.0002 in
(Maximum)

0.025 mm
(Maximum)

0.0010 in
(Maximum)

0.020.508 mm

0.0008
0.0020 in

0.0280.058 mm

0.0011
0.0023 in

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0.0254
0.2286 mm
47.440
47.490 mm
0.025 mm
(Maximum)

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0.02540.05 mm

0.0010
0.0020 in

Crankshaft Bearing Clearance (Journal


#2, #3, and #4Service)

0.0250.063 mm

0.0010
0.0250 in

0.0500.20 mm

0.0020.008 in

62.199
62.217 mm

2.4488
2.4495 in

62.191
62.215 mm

2.4485
2.4494 in

62.179
62.203 mm

2.4480
2.4489 in

0.005 mm
(Maximum)

0.0002 in
(Maximum)

0.025 mm
(Maximum)

0.0010 in
(Maximum)

0.007 mm
(Maximum)
0.025 mm
(Maximum)

0.0003 in
(Maximum)
0.0010 in
(Maximum)

101.618
101.643 mm
0.0127 mm
(Maximum)
0.05 mm
(Maximum)
0.025 mm
(Maximum)
0.012 mm
(Maximum)
0.025 mm
(Maximum)

4.0007
4.0017 in
0.00050 in
(Maximum)
0.002 in
(Maximum)
0.0010 in
(Maximum)
0.0005 in
(Maximum)
0.0010 in
(Maximum)

0.10 mm
(Maximum)

0.004 in
(Maximum)

0.05 mm
(Maximum)

0.002 in
(Maximum)

Crankshaft End Play

Crankshaft Journal Diameter (Journal


#1)

Crankshaft Journal Diameter (Journal


#2 and #3)

Crankshaft Journal Diameter (Journal


#4)

Crankshaft Journal Out-of-Round


(Production)

Crankshaft Journal Out-of-Round


(Service)

Crankshaft Journal Taper (Production)

Crankshaft Runout

Cylinder Bore
Diameter

Out-of-Round (Production)

Out-of-Round (Service)

Taper (Production Relief Side)

Taper (Production Thrust Side)

Taper (Service)

Cylinder Head
Surface Flatness
Exhaust Manifold
Surface Flatness

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Crankshaft Bearing Clearance (Journal


#1Service)

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Intake Manifold
Surface Flatness
Oil Pan
Oil Pan Alignment at Rear of Engine
Block

0.10 mm
(Maximum)

0.004 in
(Maximum)

0.3 mm
(Maximum)

0.011 in
(Maximum)

Piston
Piston Bore Clearance (Production)

Piston Bore Clearance (Service)

Piston Pin
Clearance in Piston (Production)

Clearance in Piston (Service)

Diameter

Fit in Connecting Rod

0.0180.061 mm
0.075 mm
(Maximum)
0.0130.023 mm
0.025 mm
(Maximum)
23.545
23.548 mm
0.0210.040 mm
(Interference)

Piston Rings (End Gap Measured in Cylinder Bore)


Piston Compression Ring Gap
(ProductionTop Groove)
0.250.40 mm

Piston Compression Ring Gap


(Production2nd Groove)

Piston Compression Ring Gap (Service


Top Groove)

Piston Compression Ring Gap (Service


2nd Groove)

0.0007
0.0024 in
0.0029 mm
(Maximum)
0.0005
0.0009 in
0.0010 in
(Maximum)
0.9270
0.9270 in
0.0008
0.0016 in
(Interference)

0.0100.016 in

0.460.66 mm
(Maximum)

0.0180.026 in
(Maximum)

0.5 mm
(Maximum)

0.19 in
(Maximum)

0.8 mm
(Maximum)

0.31 in
(Maximum)

Piston Compression Ring Groove


Clearance (ProductionTop Groove)

0.0300.070 mm

0.0012
0.0027 in

Piston Compression Ring Groove


Clearance (Production2nd Groove)

0.0400.080 mm

0.0015
0.0031 in

0.085 mm
(Maximum)

0.0033 in
(Maximum)

0.250.76 mm

0.0100.029 in

Piston Compression Ring Groove


Clearance (Service)

Piston Oil Ring Gap (Production)

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Piston Oil Ring Gap (Service)

Piston Oil Ring Groove Clearance


(Production)

Piston Oil Ring Groove Clearance


(Service)

Valve System
Valve Face Angle
Valve Head Edge Margin

Valve Lash

Valve Lift (Exhaust) (L35)

Valve Lift (Exhaust) (LF6)

Valve Lift (Intake) (L35)

Valve Lift (Intake) (LF6)

Valve Lifter

Valve Rocker Arm Ratio

Valve Seat Angle

Valve Seat Runout

Valve Seat Width (Exhaust)

Valve Seat Width (Intake)

Valve Spring Free Length

Valve Spring Installed Height (Exhaust)

Valve Spring Installed Height (Intake)

Valve Spring Pressure (Closed)

Valve Spring Pressure (Open)

0.035 in
(Maximum)

0.0460.096 mm

0.0018
0.0037 in

0.10 mm
(Maximum)

0.0039 in
(Maximum)

45 degrees
0.79 mm
(Minimum)

0.031 in
(Minimum)

Net LashNo Adjustment


10.879 mm

0.4280 in

9.887 mm

0.3890 in

10.527 mm

0.4140 in

10.215 mm

0.4020 in

Hydraulic Roller
1.5:1
46 degrees
0.05 mm
(Maximum)

0.002 in
(Maximum)

1.5752.362 mm 0.0650.098 in
0.891.52 mm

0.0350.060 in

51.3 mm

2.02 in

42.9243.43 mm 1.6701.700 in
42.9243.43 mm 1.6701.700 in
338374 N at
43.2 mm
832903 N at
32.3 mm

7684 lb at
1.70 in
187203 lb at
1.27 in

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0.90 mm
(Maximum)

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0.0250.069 mm

0.0010
0.0027 in

Valve Stem Clearance (Exhaust


Service)

0.0250.094 mm

0.0010
0.0037 in

Valve Stem Clearance (Intake


Production)

0.0250.069 mm

0.0010
0.0027 in

0.0250.094 mm

0.0010
0.0037 in

12 mm

0.03937
0.07874 in

Valve Stem Clearance (IntakeService)

Valve Stem Oil Seal Installed Height


(Measured from the Top of the Large
Diameter Valve Guide Bevel to the
Bottom of the Valve Stem Oil Seal)

Oil Pressure Diagnosis and Testing


Document ID: 23360
1. With the vehicle on a level surface, allow adequate drain down time, 2
3 minutes, and measure for a low engine oil level.
Add the recommended grade engine oil, and fill the crankcase until the oil level
measures FULL on the oil level indicator.
2. Operate the engine and verify low or no oil pressure on the vehicle oil pressure
gage or the oil indicator light.
Listen for a noisy valve train or a knocking noise.
3. Inspect for the following:
o Engine oil diluted by moisture or unburned fuel mixtures
o Improper engine oil viscosity for the expected temperature
o Incorrect or faulty oil pressure gage sensor
o Incorrect or faulty oil pressure gage
o Plugged oil filter
o Malfunctioning oil filter bypass valve
4. Remove the oil pressure gage sensor or another engine block oil gallery plug.
5. Install an oil pressure gage.
6. Start the engine and then allow the engine to reach normal operation
temperature.
7. Measure the engine oil pressure at the following RPM:
Specification
1.

42 kPa (6 psig) minimum, at 1,000 RPM

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Valve Stem Clearance (Exhaust


Production)

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2.
3.

125 kPa (18 psig) minimum, at 2,000 RPM


166 kPa (24 psig) minimum, at 4,000 RPM
8. If the engine oil pressure is below minimum specifications, inspect the engine
for one or more of the following:
o Oil pump worn or dirty
o Malfunctioning oil pump pressure relief valve
o Oil pump screen loose, plugged, or damaged
o Excessive bearing clearance
o Cracked, porous or restricted oil galleries
o Engine block oil gallery plugs missing or incorrectly installed
o Broken valve lifters

The following diagnosis covers common concerns and possible causes.


When the proper diagnosis is made, the concern should be corrected by adjustment,
repair or replacement as required.
Refer to the appropriate section of the service manual for each specific procedure.
This diagnostic table will assist in engine misfire diagnosis due to a mechanical
concern such as a faulty engine camshaft, worn or damaged bearings or bent valve
pushrod.
This table will not isolate a crossed fuel injector wire, faulty fuel injector or any
other driveability component failure that may cause a misfire.
The Powertrain On-Board Diagnostic System checks must be performed first.
When using this table to make a Base Engine Misfire diagnosis, begin with the
preliminary information below and then proceed to the specific category.
Preliminary
1. Perform DTC P0300 before proceeding with Base
Engine Misfire Diagnosis information.
DTC P0300 will assist in determining which cylinder or
cylinders are misfiring.
2. Perform a visual inspection of the following:
o A loose or improperly installed engine flywheel
or crankshaft balancer
o Worn, damaged or misaligned accessory drive
system components
3. Listen to the engine for any abnormal internal engine
noises.

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Checks
Action
Engine performance diagnosis procedures are covered in Engine Controls and
should be consulted for diagnosis of any Driveability, Emissions, or
Malfunctioning Indicator Lamp (MIL) concerns.

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4.
5.
6.
7.
Intake Manifold
Leaks

Inspect the engine for acceptable oil pressure.


Verify if the engine has excessive oil consumption.
Verify if the engine has excessive coolant consumption.
Perform a compression test on the engine.

An intake manifold that has a vacuum leak may cause a


misfire.
Inspect for the following:

Improperly installed or damaged vacuum hoses


Faulty or improperly installed lower intake manifold
and/or gaskets
Cracked or damaged lower intake manifold
Improperly installed MAP sensor
The sealing grommet of the MAP sensor should not be
torn or damaged

Coolant
Consumption

Improperly installed throttle body or damaged gasket


Warped intake manifold
Warped or damaged cylinder head sealing surface

Coolant consumption may or may not cause the engine to


overheat.
Inspect for the following:

Oil Consumption

External coolant leaks


Faulty cylinder head gasket
Warped cylinder head
Cracked cylinder head
Damaged engine block

Oil consumption may or may not cause the engine to misfire.


1. Remove the spark plugs and inspect for an oil fouled
spark plug.
2. Perform a cylinder compression test.
3. If the compression test indicates worn valves or valve
guides, inspect the following:
o Worn, brittle, or improperly installed valve stem
oil seals
o Worn valve guides
o Worn valve stems
o Worn or burnt valves or valve seats
4. If the compression test indicates worn or damaged
piston rings, inspect the following:
o Broken or improperly seated piston rings
o Excessive piston ring end gap

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o
o
o

Abnormal Internal
Engine Noises

Excessive cylinder bore wear or taper


Cylinder damage
Piston damage

Important: A slight COLD knock or piston slapping


noise could be considered normal if not present after the
engine has reached normal operating temperatures.
4. If the knock is timed to the crankshaft speed, inspect the
following:
o Worn crankshaft or connecting rod bearings
o Piston or cylinder damage
o Worn piston or piston pin
o Faulty connecting rod
o Excessive carbon build-up on the top of the
piston
No Abnormal
Internal Engine
Noise

1. Inspect for a worn or improperly installed camshaft


timing chain and/or sprockets.
2. Remove the valve rocker arm cover on the side of the
engine with the cylinder that is misfiring.
3. Inspect for the following:
o Loose valve rocker arm studs
o Bent valve push rods
o Faulty valve springs
o Faulty valve lifters (bleeding down)
o Worn or improperly seated valves
o Worn engine camshaft lobes

Engine Compression Test


Document ID: 723193

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1. Start the engine and determine if the noise is timed to


the engine camshaft speed or the crankshaft speed.
2. Using a timing light, two knocks per flash is the
crankshaft speed and one knock per flash is the engine
camshaft speed.
3. If the noise is timed to the engine camshaft speed,
inspect the following:
o Missing or loose valve train components
o Worn or loose valve rocker arms
o Worn or bent valve pushrods
o Faulty valve springs
o Bent or burnt valves
o Worn engine camshaft lobes
o Worn or damaged camshaft timing chain and/or
sprockets

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1.
2.
3.
4.
5.

Ensure that the vehicle batteries are in good condition, and fully charged.
Operate the vehicle until the engine is at normal operating temperature.
Disconnect the positive ignition coil wire plug from the ignition coil.
Disconnect the fuel injector electrical connector.
Remove all of the spark plugs.
Notice: Do not insert objects into the throttle plate opening. Damage to the
throttle body can result, requiring replacement of the throttle body assembly.

The compression builds up quickly and evenly to the specified


compression.
o

Piston rings leaking


Compression is low on the first compression stroke. The compression
builds up on the following strokes, but does not reach normal.
Compression improves considerably when you add oil.

Valves leaking
Compression is low on the first compression stroke. The compression
does not build up on the following strokes, and does not reach normal.
Compression does not improve much, if at all, when you add oil.

Head gasket leaking


Compression is low on the first stroke. The compression does not build
up on the following strokes, and does not reach normal. Compression
does not improve much, if at all, when you add oil. Adjacent cylinders
have the same, or similar, low compression readings.

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6. Block the throttle linkage wide open.


7. Install the engine cylinder compression gage to the cylinder being tested.
8. Using the vehicle starter motor, rotate, or crank the engine for 4 compression
strokes, or puffs, for the cylinder being tested. If the engine rotates for more than
4 compression strokes, test the cylinder again.
9. Record the compression reading.
10. Remove the engine cylinder compression gage from the cylinder being tested.
11. Repeat steps 811 for each additional cylinder. All cylinders must be tested to
obtain valid test results.
12. If any cylinders have low compression, inject approximately 15 ml (1 oz) of
engine oil into the cylinder through the spark plug hole.
13. Repeat steps 811 for all low compression cylinders.
14. The minimum compression in any one cylinder should not be less than
70 percent of the highest cylinder. No cylinder should read less than 690 kpa
(100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa
(150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa
(105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x
70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the
lowest allowable pressure in any other cylinder.
o Normal

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15. If one or more cylinders fails to meet the minimum specified compression,
repair or replace all damaged or worn components and test the engine again.

Document ID: 41408


Lower Engine View 2

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Lower Engine View 2 4.3L L35/LF6 -

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1. Crankshaft Rear Oil Seal Housing Bolt


2. Flywheel Locator Pin
3. Crankshaft Rear Oil Seal Housing Nut
4. Crankshaft Rear Oil Seal Housing
5. Crankshaft Rear Oil Seal Housing Retainer Stud
6. Crankshaft Rear Oil Seal Housing Gasket
7. Crankshaft
8. Oil Pump Drive Shaft
9. Oil Pump Locator Pin
10. Oil Pump Drive Shaft Retainer
11. Oil Pump

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12. Oil Pump Bolt


13. Oil Pan
14. Oil Pan Bolt
15. Oil Pan Gasket
16. Crankshaft Bearing Cap Bolt
17. Crankshaft Bearing Cap

19. Crankshaft Sprocket


20. Crankshaft Position Sensor Reluctor Ring
21. Engine Front Cover
22. Crankshaft Front Oil Seal
23. Crankshaft Balancer
24. Crankshaft Balancer Bolt
25. Crankshaft Balancer Key
26. Crankshaft Bearings (Upper)

Upper Engine View 2 4.3L L35/LF6 (ST, GMT150) Document ID: 41410
Upper Engine View 2

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18. Crankshaft Bearings (Lower)

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1. Valve Rocker Arm Cover


2. Valve Rocker Arm Cover Gasket
3. Valve Rocker Arm Nut
4. Valve Rocker Arm Ball
5. Valve Rocker Arm
6. Spark Plug Wire Support
7. Spark Plug Wire Support Bolt
8. Exhaust Manifold Gasket
9. Exhaust Manifold
10. Exhaust Manifold Bolt
11. Spark Plug Wire Shields

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12. Exhaust Manifold Gasket


13. Valve Lifter
14. Valve Lifter Pushrod Guide
15. Valve Pushrod
16. Cylinder Head Gasket
17. Engine Lift Front Bracket

19. Cylinder Head

Upper and Lower Intake Manifold View 4.3L L35/LF6 Document ID: 356346
Upper and Lower Intake Manifold View

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18. Cylinder Head Bolt

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1. Fuel Pipe Retainer Bracket Nut


2. Fuel Pipe Retainer
3. Fuel Pipe
4. Fuel Pipe Bolt
5. Fuel Seal Retainer
6. Upper Fuel Seal (Yellow O-ring)
7. Spacer Ring (Metal Flat Washer)
8. Lower Fuel Seal (Black O-ring)
9. Upper Manifold Attaching Stud
10. Upper Intake Manifold

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11. Upper Intake to Lower Intake Manifold Gasket


12. Fuel Meter Body Seal (O-ring)
13. Fuel Meter Body
14. Intake Manifold
15. Throttle Body to Upper Intake Manifold Gasket
16. Throttle Body

Intake Manifold Replacement Document ID: 193909


Removal Procedure

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1. Disconnect the PCV tube from the air cleaner outlet duct.
2. Remove the air cleaner outlet duct from the throttle body.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
in Engine Controls.

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17. Throttle Body Attaching Stud

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4. Disconnect the following electrical connectors:


o The A/C pressure switch, if equipped
o The throttle position (TP) sensor
o The idle air control (IAC) motor
o The fuel meter body assembly connector
o The manifold absolute pressure (MAP) sensor
o The EVAP canister purge solenoid valve
5. Remove the EVAP canister purge solenoid valve. Refer to EVAP Canister
Purge Solenoid Valve Replacement in Engine Controls.

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6. Disconnect the vacuum hose from the intake manifold, if equipped with A/C.
7. Remove the vacuum brake booster hose.

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8. Remove the PCV valve hose assembly form the intake manifold and the valve
rocker arm cover.

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9. Disconnect the accelerator control cable from the throttle shaft and the
accelerator cable bracket. Refer to Accelerator Control Cable Replacement in
Engine Controls.
10. Disconnect the cruise control cable, if equipped from the throttle shaft and the
accelerator cable bracket. Refer to Cruise Control Cable Replacement in Cruise
Control.
11. Remove the accelerator cable bracket from the throttle body and the intake
manifold.

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12. Remove the accelerator and cruise control cable bracket from the throttle body.
Leave the accelerator and cruise control cables and the engine wiring harness on
the bracket.

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13. Remove the bracket for the engine wiring harness from the intake stud.
14. Remove the fuel lines from the fuel meter body assembly. Refer to Fuel
Hose/Pipes Replacement - Engine Compartment in Engine Controls.

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15. Remove the upper intake manifold. Refer to Intake Manifold Disassemble in
Engine Mechanical - 4.3L
16. Clean all sealing surfaces. Refer to Intake Manifold Cleaning and Inspection in
Engine Mechanical - 4.3L

Installation Procedure

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1. Install the upper intake manifold. Refer to Intake Manifold Assemble in Engine
Mechanical - 4.3L
2. Install the fuel lines to the fuel meter body assembly. Refer to Fuel Hose/Pipes
Replacement - Engine Compartment in Engine Controls.

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3. Install the bracket for the engine wiring harness on the lower intake manifold
stud.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
4. Install the engine wiring harness bracket nut.
Tighten
Tighten the engine wiring harness bracket nut to 12 N-m (106 lb in).

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5. Install the accelerator and cruise control cable bracket to the throttle body.
6. Install the accelerator and cruise control cable bracket nuts.
Tighten
Tighten the accelerator and cruise control cable bracket nuts to 9 N-m (80 lb in).

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7. Install the accelerator cable bracket to the throttle body and the intake manifold.
Tighten
Tighten the accelerator cable bracket studs and nuts to 12 N-m (106 lb in).

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8. Install the cruise control cable, if equipped to the throttle shaft and the bracket.
Refer to Cruise Control Cable Replacement in Cruise Controls.
9. Install the accelerator cable to the throttle shaft and the bracket. Refer to
Accelerator Control Cable Replacement in Engine Controls - 4.3L Engine
Controls.
10. Install the EVAP canister purge solenoid valve. Refer to EVAP Canister Purge
Solenoid Valve Replacement in Engine Controls.

11. Connect the PCV valve hose assembly to the intake manifold and the valve
rocker arm cover.

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12. Connect the vacuum hose to the intake manifold, if equipped with A/C.
13. Install the vacuum brake booster hose to the intake manifold.

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14. Connect the following electrical connectors:


o The A/C pressure switch, if equipped
o The throttle position (TP) sensor
o The idle air control (IAC) motor
o The fuel meter body assembly connector
o The manifold absolute pressure (MAP) sensor
o The EVAP canister purge solenoid valve

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15. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls.
16. Install the air cleaner outlet duct to the throttle body assembly.
17. Connect the PCV tube to the air cleaner outlet duct.

Intake Manifold Replacement -

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Document ID: 193927


Removal Procedure

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5. Drain the cooling system. Refer to Cooling System Draining and Filling in
Engine Cooling.
6. Remove the radiator inlet hose at the water outlet.
7. Remove the heater hose from the intake manifold.
8. Remove the water pump inlet hose form the intake manifold.

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1. Disconnect the battery negative cable. Refer to Battery Replacement in Engine


Electrical.
2. Disconnect the PCV tube from the air cleaner outlet duct.
3. Remove the air cleaner outlet duct from the throttle body.
4. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
in Engine Controls.

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9. Disconnect the accelerator control cable from the throttle shaft and the
accelerator cable bracket. Refer to Accelerator Control Cable Replacement in
Engine Controls.
10. Disconnect the cruise control cable, if equipped from the throttle shaft and the
accelerator cable bracket. Refer to Cruise Control Cable Replacement in Cruise
Control.
11. Remove the accelerator cable bracket from the throttle body and the intake
manifold.

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12. Remove the accelerator and the cruise control cable bracket from the throttle
bracket.
Leave the accelerator and cruise control cables and the wiring harness on the
bracket.

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13. Remove the following electrical connectors:


o The fuel meter body assembly
o The EVAP canister purge solenoid valve
o The idle air control (IAC) motor
o The throttle position (TP) sensor
o The A/C compressor high pressure switch, if equipped
o The A/C clutch switch, if equipped
o The exhaust gas recirculation (EGR) valve
o The engine coolant temperature (ECT) sensor
o The ignition coil
o The ignition control module (ICM)
14. Remove the engine wiring harness from the retainers.
15. Move the engine wiring harness aside.
16. Remove the distributor. Refer to Distributor Replacement in Engine Electrical.

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17. Remove the exhaust gas recirculation (EGR) valve inlet pipe from the intake and
exhaust manifold.
18. Disconnect the fuel supply and return pipes at the rear of the intake manifold.
Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine
Controls.

19. Disconnect the vacuum hose from the intake manifold, if equipped with A/C.
20. Disconnect the vacuum brake booster hose

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21. Disconnect the PCV hose assembly from the intake manifold and the valve
rocker arm cover.
22. Remove the EVAP canister purge solenoid valve. Refer to EVAP Canister
Purge Solenoid Valve Replacement in Engine Controls.

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23. Important: Do not discharge the refrigerant.


Perform the following in order to remove the left front bolt for the intake
manifold:
1. Remove the drive belt. Refer to Drive Belt Replacement .
2. Loosen the nut for the power steering pump rear bracket at the side of the
engine.
3. Remove the nut for the power steering pump rear bracket at the front of
the engine.
4. Remove the bolts and the nut for the power steering pump mounting
bracket.
5. Leave the A/C compressor, if equipped, and the power steering pump on
the power steering pump mounting bracket.
6. Slide the power steering pump bracket forward to access the bolt at the
front of the intake manifold.

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24. Remove the lower intake manifold. Refer to Intake Manifold Removal .
25. Clean all sealing surfaces. Refer to Intake Manifold Cleaning and Inspection in
Engine Mechanical - 4.3L .

Installation Procedure

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1. Notice: Proper lower intake manifold fastener tightening sequence and torque is
critical. Always follow the tightening sequence, and torque the intake manifold
bolts using the 3 step method. Failing to do so may distort the crankshaft bearing
bore alignment and cause damage to the crankshaft bearings.
Install the lower intake manifold. Refer to Intake Manifold Installation .

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2. Position the power steering pump mounting bracket.


3. Loosely install the power steering pump mounting bracket bolts and nuts.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
4. Install the nut for the power steering pump rear bracket at the front of the engine.
Tighten
Tighten the power steering pump mounting bracket bolts and the power steering
pump rear bracket nuts to 41 N-m (30 lb ft).
5. Install the drive belt. Refer to Drive Belt Replacement .
6. Install the EVAP canister purge solenoid valve. Refer to EVAP Canister Purge
Solenoid Valve Replacement in Engine Controls.

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7. Connect the vacuum brake booster hose.


8. Connect the vacuum hose to the intake manifold, if equipped with A/C.

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9. Install the PCV hose assembly to the intake manifold and the valve rocker arm
cover.
10. Install the fuel supply and return pipes to the rear of the intake manifold. Refer
to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls.

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11. Install the exhaust gas recirculation (EGR) valve inlet pipe to the intake
manifold and the exhaust manifold.
Tighten
1. Tighten the EGR valve inlet pipe intake manifold nut to 25 N-m
(18 lb ft).
2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N-m
(22 lb ft).
3. Tighten the EGR valve inlet pipe clamp bolt to 25 N-m (18 lb ft).

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12. Important: In order to install the distributor for the correct engine timing,
position the engine to number one cylinder top dead center.

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Remove the spark plug for number one cylinder.


13. Rotate the crankshaft until number one cylinder is in the compression stroke.
14. Align the two reference marks on the crankshaft balancer (1) and (4) with the
two alignment marks (2) and (3) on the front cover.
15. Install the spark plug. Refer to Spark Plug Replacement in Engine Electrical.
16. Install the distributor. Refer to Distributor Replacement in Engine Electrical.

17. Position the engine wiring harness.


18. Install the engine wiring harness in the retainers.
19. Install the following electrical connectors:
o The fuel meter body assembly
o The EVAP canister purge solenoid valve
o The idle air control (IAC) motor
o The throttle position (TP) sensor
o The A/C compressor high pressure switch, if equipped.
o The A/C compressor clutch switch, if equipped.
o The exhaust gas recirculation (EGR) valve
o The engine coolant temperature (ECT) sensor
o The ignition coil
o The ignition control module (ICM)

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20. Install the accelerator cable and cruise control bracket to the throttle body.
Tighten
Tighten the accelerator cable and cruise control bracket nuts to 9 N-m (80 lb in).

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21. Install the accelerator cable bracket to the intake manifold and the throttle body.
Tighten
Tighten the accelerator cable bracket studs and nuts to 12 N-m (106 lb in).
22. Install the accelerator control cable to the bracket and the throttle shaft. Refer to
Accelerator Control Cable Replacement in Engine Controls.

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23. Install the cruise control cable, if equipped to the bracket and the throttle shaft.
Refer to Cruise Control Cable Replacement in Cruise Control.

24. Install the water pump inlet hose to the intake manifold.
25. Install the heater hose to the intake manifold.
26. Install the radiator inlet hose to the water outlet. Refer to Radiator Replacement
in Engine Cooling.
27. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine
Cooling.

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28. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls.
29. Install the air cleaner outlet duct to the throttle body.

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30. Connect the PCV tube to the air cleaner outlet duct.
31. Connect the battery negative cable. Refer to Battery Replacement in Engine
Electrical.

Valve Rocker Arm Cover Replacement Document ID: 193937

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1. Disconnect the PCV tube from the air cleaner outlet duct,
2. Remove the air cleaner outlet duct from the throttle body.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
in Engine Controls.

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Removal Procedure

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4. Remove the PCV valve hose assembly from the valve rocker arm cover.
5. Disconnect the engine coolant temperature (ECT) gauge sensor.
6. Partially drain the engine coolant. Refer to Cooling System Draining and Filling
in Engine Cooling.
7. Remove the radiator inlet hose from the water outlet. Refer to Engine Coolant
Thermostat Replacement in Engine Cooling.

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8. Remove the exhaust gas recirculation (EGR) valve inlet pipe from the intake
manifold and the exhaust manifold.

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9. Important: A/C compressor and bracket removal is not necessary.


Remove the bolts and the valve rocker arm cover.
10. Clean all sealing surfaces. Refer to Valve Rocker Arm Cover Cleaning and
Inspection in Engine Mechanical - 4.3L .

Installation Procedure

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1. Install the valve rocker arm cover and bolts. Refer to Valve Rocker Arm Cover
Installation .

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2. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the exhaust gas recirculation (EGR) valve inlet pipe into the intake and
exhaust manifolds.
Tighten
1. Tighten the EGR valve inlet pipe intake manifold nut to 25 N-m
(18 lb ft).
2. Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N-m
(22 lb ft).
3. Tighten the EGR valve inlet pipe clamp bolt to 25 N-m (18 lb ft).

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3. Install the radiator inlet hose to the water outlet. Refer to Radiator Replacement
in Engine Cooling.
4. Fill the cooling system. Refer to Cooling System Draining and Filling in Engine
Cooling.
5. Install the PCV valve hose assembly to the valve rocker arm cover.
6. Connect the ECT gauge sensor.

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7. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls.
8. Install the air cleaner outlet duct to the throttle body.
9. Connect the PCV tube to the air cleaner outlet duct,

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Valve Rocker Arm Cover Replacement Document ID: 195305


Removal Procedure

1. Remove the PCV tube from the air cleaner outlet duct and the valve rocker arm
cover.
2. Disconnect the spark plug wires from the spark plugs for the right side of the
engine. Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
3. Remove the EVAP canister purge solenoid valve. Refer to EVAP Canister
Purge Solenoid Valve Replacement in Engine Controls.
4. Unfasten the heater hose retainer above the valve rocker arm cover.
5. Move and secure the heater hoses aside.

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6. Remove the bolt holding the engine wiring harness bracket to the generator.
7. Disconnect the crankcase position (CKP) sensor electrical connector.
8. Move and secure the engine wiring harness aside.

9. Remove the bolts and the right valve rocker arm cover.
10. Clean all sealing surfaces. Refer to Valve Rocker Arm Cover Cleaning and
Inspection in Engine Mechanical - 4.3L .

Installation Procedure

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1. Install the right valve rocker arm cover and bolts. Refer to Valve Rocker Arm
Cover Installation .

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2. Position the engine wiring harness.


3. Connect the CKP sensor electrical connector.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
4. Install the engine wiring harness and bolt to the generator mounting bracket.
Tighten
Tighten the engine wiring harness bolt to 25 N-m (18 lb ft),
5. Position the heater hoses.
6. Install the heater hoses in the retainer above the valve rocker arm cover.
7. Install the EVAP canister purge solenoid valve. Refer to EVAP Canister Purge
Solenoid Valve Replacement in Engine Controls.

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8. Connect the spark plug wires to the spark plugs for the right side of the engine.
Refer to Spark Plug Wire Harness Replacement in Engine Electrical.
9. Install the PCV tube to the air cleaner outlet duct and the valve rocker arm
cover.

Valve Rocker Arm and Push Rod Replacement


Document ID: 194238
Removal Procedure

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1. Remove the valve rocker arm cover. Refer to Valve Rocker Arm Cover
Replacement in Engine Mechanical - 4.3L .
2. Remove the valve rocker arm nut, valve rocker arm with the valve rocker arm
ball . Refer to Valve Rocker Arm and Push Rod Removal in Engine Mechanical
- 4.3L .
3. Remove the valve pushrods.
4. Clean and inspect the valve rocker arms, valve rocker arm nuts, valve rocker
arm ball and the valve pushrods. Refer to Valve Rocker Arm and Push Rod
Cleaning and Inspection in Engine Mechanical - 4.3L

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1. Install the valve pushrods.
2. Install the valve rocker arm nut, valve rocker arm with the valve rocker arm ball.
Refer to Valve Rocker Arm and Push Rod Installation in Engine Mechanical 4.3L .
3. Install the valve rocker arm cover. Refer to Valve Rocker Arm Cover
Replacement in Engine Mechanical - 4.3L .

Valve Stem Oil Seal and Valve Spring Replacement


Document ID: 195683
Removal Procedure
Tools Required

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Installation Procedure

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J 22794 Spark Plug Port Adapter


J 38606 Valve Spring Compressor
J 5892-D Valve Spring Compressor

1. Remove the valve rocker arms. Refer to Valve Rocker Arm and Push Rod
Replacement in Engine Mechanical - 4.3L .
2. Remove the spark plugs. Refer to Spark Plug Replacement in Engine Electrical.

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3. Install the J 22794 into the spark plug hole.
4. Apply compressed air in order to hold the valves in place.
5. Install a valve rocker arm nut.

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6. Use the J 5892-D in order to compress the valve spring.

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7. Notice: When using J 38606 ensure that the jaws are completely engaged on the
valve spring. If the jaws are not completely engaged the jaws may slip off and
scratch the valve spring. Replace the valve spring if the valve spring becomes
scratch.
Use J 38606 when J 5892-D will not fit.

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8. Remove the valve stem keys (1).


Carefully release the valve spring tension.
9. Remove the J 5892-D or the J 38606 .
10. Remove the valve spring cap (2) and the valve spring (3).
11. Remove the valve stem oil seal (4).

Installation Procedure
Tools Required

J 22794 Spark Plug Port Adapter


J 38606 Valve Spring Compressor
J 42073 Valve Stem Seal Installer
J 5892-D Valve Spring Compressor

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1. Important: The exhaust valve oil seal has the letters EX (1) molded into the top
of the seal. The seal material is brown in color (2) with a white stripe (3) painted
on the outside diameter of the seal or the material may be off-white in color (2)
with no paint stripe. The intake valve seal is black in color. The exhaust and
intake valve seals are not interchangeable.
Select the proper valve stem oil seal for the specific valve guide.
2. Lubricate the valve stem oil seal and the outside diameter of the valve guide
with clean engine oil.
3. Assemble the valve stem oil seal onto the valve guide using the J 42073 and a
hammer.
4. Install the valve stem oil seal onto the valve guide until the installation tool
bottoms against the valve spring seat.

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5. Inspect the valve stem oil seal. The valve stem oil seal should not be bottomed
against the valve guide.
There should be a 1 2 mm (0.03937 0.07874 in) gap between the bottom edge
of the seal and the valve guide.

6. Install the valve spring (3).


7. Install the valve spring cap (2) on the valve stem.
8. Compress the valve spring (3) using the J 5892-D

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9. Notice: When using J 38606 ensure that the jaws are completely engaged on the
valve spring. If the jaws are not completely engaged the jaws may slip off and
scratch the valve spring. Replace the valve spring if the valve spring becomes
scratch.

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Use the J 38606 if the clearance does not permit use of J 5892-D .
Notice: Make sure that the valve stem keys are properly seated in the valve
spring cap. Engine damage could occur if not properly installed.
10. Install the valve stem keys.
Use grease in order to hold the valve stem keys in place.

11. Carefully release the valve spring pressure, making sure the valve stem keys stay
in place.
12. Remove the J 5892-D or the J 38606 and the J 22794 .

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13. Install the spark plugs. Refer to Spark Plug Replacement in Engine Electrical.
14. Install the valve rocker arms to the cylinder head.
Refer to Valve Rocker Arm and Push Rod Replacement in Engine Mechanical 4.3L .

Valve Lifter Replacement


Document ID: 195687

Tools Required
J 3049-A Valve Lifter Remover

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1. Remove the lower intake manifold. Refer to Intake Manifold Replacement in
Engine Mechanical - 4.3L .
2. Remove the valve pushrods and the valve rocker arms. Refer to Valve Rocker
Arm and Push Rod Replacement in Engine Mechanical - 4.3L .

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Removal Procedure

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3. Remove the valve lifter pushrod guide and the bolts.

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4. Remove the valve lifters from the engine block. Refer to Valve Lifter Removal .

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5. Use the J 3049-A in order to remove stuck valve lifters.

Installation Procedure

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1. Important: It is normal for NEW lifters to make a slight ticking noise when the
engine is first started. Increasing the engine RPMs slightly to raise oil pressure
should stop the noise.
Install the valve lifters to the engine block. Refer to Valve Lifter Installation .

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2. Install the valve lifter pushrod guide. Refer to Valve Lifter Installation .

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3. Install the valve pushrods and valve rocker arms. Refer to Valve Rocker Arm
and Push Rod Replacement in Engine Mechanical - 4.3L .

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4. Install the intake manifold. Refer to Intake Manifold Replacement in Engine


Mechanical - 4.3L .

Exhaust Manifold Replacement Document ID: 194018


Removal Procedure

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1. Disconnect the PCV tube from the air cleaner outlet duct.
2. Remove the air cleaner outlet duct from the throttle body.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
in Engine Controls.

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4. Disconnect the engine coolant temperature (ECT) gauge sensor electrical


connector.
5. Remove the intermittent steering shaft.
o Refer to Lower Intermediate Steering Shaft Replacement in Steering
Wheel and Column - Standard.
o Refer to Lower Intermediate Steering Shaft Replacement in Steering
Wheel and Column - Tilt.
6. Disconnect the exhaust gas recirculation (EGR) valve inlet pipe from the
exhaust manifold.

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7. Remove the radiator inlet hose support bracket and nut.
8. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.

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9. Disconnect the exhaust pipe from the exhaust manifold. Refer to Exhaust
Manifold Pipe Replacement in Engine Exhaust.
10. Lower the vehicle to the proper height.
11. Remove the front tire to gain access to the rear exhaust manifold bolts. Wheel
Removal in Tire and Wheels.

12. Remove the fender wheelhouse extension.


13. Disconnect the spark plug wires from the spark plugs. Refer to Spark Plug Wire
Harness Replacement in Engine Electrical.

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14. Remove the exhaust manifold bolts and the stud.
15. Lower the vehicle.
16. Remove the exhaust manifold and the spark plug wire shields from the engine.
17. Clean all gasket surfaces. Refer to Exhaust Manifold Clean and Inspect .

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Installation Procedure

1. Sub-assemble the spark plug wire shields, bolts, and NEW gaskets to the
exhaust manifold.
The stud installs in the front hole.
2. Raise the vehicle to the proper height.
3. Install the exhaust manifold to the engine. Refer to Exhaust Manifold
Installation in Engine Mechanical - 4.3L .
4. Connect the spark plug wires to the spark plugs. Refer to Spark Plug Wire
Harness Replacement in Engine Electrical.

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5. Install the fender wheelhouse extension.

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6. Install the front tire. Refer to Wheel Installation in Tire and Wheels.
7. Raise the vehicle.
8. Connect the exhaust pipe to the exhaust manifold. Refer to Exhaust Manifold
Pipe Replacement in Engine Exhaust.
9. Lower the vehicle.

10. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the radiator inlet hose support bracket and nut.
Tighten
Tighten the radiator inlet hose support bracket nut to 36 N-m (27 lb ft).

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11. Connect the ECT gauge sensor electrical connector.


12. Connect the EGR valve inlet pipe to the exhaust manifold.
Tighten
Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N-m (22 lb ft).
13. Install the intermittent steering shaft.
o Refer to Lower Intermediate Steering Shaft Replacement in Steering
Wheel and Column - Standard.
o Refer to Lower Intermediate Steering Shaft Replacement in Steering
Wheel and Column - Tilt.

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14. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls.
15. Install the air cleaner outlet duct to the throttle body.
16. Connect the PCV tube to the air cleaner outlet duct.

Exhaust Manifold Replacement Document ID: 405716

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1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
2. Disconnect the exhaust pipe from the exhaust manifold. Refer to Exhaust
Manifold Pipe Replacement in Engine Exhaust.
3. Lower the vehicle.
4. Remove the bolt for the oil level indicator tube.
5. Disconnect the spark plug wires from the spark plugs. Refer to Spark Plug Wire
Harness Replacement in Engine Electrical.

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Removal Procedure

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6. Remove the exhaust manifold bolts.


7. Remove the exhaust manifold and the spark plug wire shields from the engine.
8. Clean all gasket surfaces. Refer to Exhaust Manifold Clean and Inspect .

Installation Procedure

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1. Sub-assemble the spark plug wire shields, bolts, and NEW gaskets to the
exhaust manifold.
2. Install the exhaust manifold to the engine. Refer to Exhaust Manifold
Installation in Engine Mechanical - 4.3L
3. Connect the spark plug wires to the spark plugs. Refer to Spark Plug Wire
Harness Replacement in Engine Electrical.
4. Raise the vehicle.

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5. Connect the exhaust pipe to the exhaust manifold. Refer to Exhaust Manifold
Pipe Replacement in Engine Exhaust.
6. Lower the vehicle.

7. Install the bolt for the oil level indicator tube.


Tighten
Tighten the oil level indicator tube bolt to 12 N-m (106 lb in).

Cylinder Head Replacement Document ID: 194273


Removal Procedure

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1. Disconnect the battery negative cable. Refer to Battery Replacement in Engine
Electrical .
2. Drain the engine coolant. Refer to Cooling System Draining and Filling in
Engine Cooling .
3. Disconnect the PCV tube from the air cleaner outlet duct.

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Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

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4. Remove the air cleaner outlet duct from the throttle body.
5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
in Engine Controls - 4.3L .
6. Remove the engine cooling fan assembly. Refer to Fan Clutch Replacement in
Engine Cooling .
Important: Do not evacuate the A/C system. The A/C pipes can remain on the
compressor.
7. Remove the air conditioning compressor, if equipped, and move aside. Refer to
Air Conditioning Compressor Replacement in HVAC Systems - Manual .

8. Remove the nuts holding the power steering pump rear bracket to the engine.

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9. Important: The power steering pump can remain on the power steering pump
mounting bracket. The power steering pump hoses can remain attached to the
power steering pump.
Remove the power steering pump mounting bracket and secure out of the way.
10. Remove the power steering pump mounting bracket stud from the cylinder head.
11. Remove the intake manifold. Refer to Intake Manifold Replacement in Engine
Mechanical - 4.3L
12. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement in
Engine Mechanical - 4.3L

13. Remove the spark plug wire harness and the support.

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14. Remove the ground wires at the rear of the cylinder head.
15. Remove the fuel line bracket bolt at the rear of the cylinder head.
16. Remove the valve pushrods. Refer to Valve Rocker Arm and Push Rod
Replacement in Engine Mechanical - 4.3L

17. Remove and discard the cylinder head bolts.


18. Remove the cylinder head.
19. Clean all surfaces. Refer to Cylinder Head Cleaning and Inspection in Engine
Mechanical - 4.3L

Installation Procedure

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1. Install the cylinder head. Refer to Cylinder Head Installation

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2. Install the valve pushrods. Refer to Valve Rocker Arm and Push Rod
Replacement in Engine Mechanical - 4.3L

3. Notice: Refer to Fastener Notice in Cautions and Notices .


Install the spark plug wire harness and the support.
Tighten
Tighten the support bolts to 12 N-m (106 lb in).

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4. Install the ground wires at the rear of the cylinder head.
Tighten

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Tighten the ground wire bolt to 35 N-m (26 lb ft).


5. Install the fuel pipe bracket bolt at the rear of the cylinder head.
Tighten
Tighten the fuel pipe bracket bolt to 30 N-m (22 lb ft).

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8. Install the power steering pump mounting bracket stud in the cylinder head.
Tighten
Tighten the power steering pump mounting bracket stud to 20 N-m (15 lb ft).
9. Install the power steering pump mounting bracket.
Tighten
Tighten the power steering pump mounting bracket bolts and nuts to 41 N-m
(30 lb ft).

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6. Install the exhaust manifold. Refer to Exhaust Manifold Replacement in Engine


Mechanical - 4.3L
7. Install the intake manifold. Refer to Valve Rocker Arm Cover Replacement in
Engine Mechanical - 4.3L

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10. Install the nuts holding the power steering pump rear bracket to the engine.
Tighten
Tighten the power steering pump rear bracket nuts to 41 N-m (30 lb ft).
11. Install the air conditioning compressor, if equipped. Refer to Air Conditioning
Compressor Replacement in HVAC Systems - Manual .
12. Install the engine cooling fan. Refer to Fan Clutch Replacement in Engine
Cooling in Engine Cooling.

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13. Fill the engine coolant system. Refer to Cooling System Draining and Filling in
Engine Cooling .

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14. Connect the battery negative cable. Refer to Battery Replacement in Engine
Electrical .
15. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls - 4.3L .
16. Install the air cleaner outlet duct onto the throttle body.
17. Connect the PCV tube to the air cleaner outlet duct.

Document ID: 405747


Removal Procedure

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1. Disconnect the battery negative cable. Refer to Battery Replacement in Engine
Electrical .
2. Drain the engine coolant. Refer to Cooling System Draining and Filling in
Engine Cooling .
3. Disconnect the PCV tube form the air cleaner outlet duct.
4. Remove the air cleaner outlet duct from the throttle body.
5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
in Engine Controls - 4.3L .
6. Remove the engine cooling fan assembly. Refer to Fan Clutch Replacement in
Engine Cooling .
7. Remove the intake manifold. Refer to Intake Manifold Replacement in Engine
Mechanical - 4.3L

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Cylinder Head Replacement -

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8. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement in


Engine Mechanical - 4.3L

9. Remove the spark plug wire harness and the support.

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10. Remove the ground wires at the rear of the cylinder head.

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11. Remove the generator. Refer to Generator Replacement in Engine Electrical .


12. Remove the generator mounting bracket.
13. Remove the generator mounting bracket stud from the cylinder head.
14. Remove the valve pushrods. Refer to Valve Rocker Arm and Push Rod
Replacement in Engine Mechanical - 4.3L .

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15. Remove and discard the cylinder head bolts.
16. Remove the cylinder head.
17. Clean all surfaces. Refer to Cylinder Head Cleaning and Inspection in Engine
Mechanical - 4.3L .

Installation Procedure

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1. Install the cylinder head. Refer to Cylinder Head Installation .


2. Install the valve pushrods. Refer to Valve Rocker Arm and Push Rod
Replacement in Engine Mechanical - 4.3L .

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3. Notice: Refer to Fastener Notice in Cautions and Notices .
Install the spark wire harness and support.
Tighten
Tighten the support bolts to 12 N-m (106 lb in).

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4. Install the ground wires at the rear of the cylinder head.


Tighten
Tighten the ground wire stud to 35 N-m (26 lb ft).
5. Install the exhaust manifolds. Refer to Exhaust Manifold Replacement in Engine
Mechanical - 4.3L .
6. Install the intake manifold. Refer to Intake Manifold Replacement in Engine
Mechanical - 4.3L .

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7. Install the generator mounting bracket stud to the cylinder head.
Tighten

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Tighten the stud to 20 N-m (15 lb ft).


8. Install the generator mounting bracket.
Tighten
Tighten the generator mounting bracket bolts and nuts to 41 N-m (30 lb ft).
9. Install the generator. Refer to Generator Replacement in Engine Electrical
10. Install the engine cooling fan. Refer to Fan Clutch Replacement in Engine
Cooling .

11. Fill the engine coolant system. Refer to Cooling System Draining and Filling in
Engine Cooling .
12. Connect the battery negative cable. Refer to Battery Replacement in Engine
Electrical .
13. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls - 4.3L .
14. Install the air cleaner outlet duct onto the throttle body.
15. Connect the PCV tube to the air cleaner outlet duct.

Crankshaft Balancer Replacement


Document ID: 439492
Removal Procedure

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1. Disconnect the battery negative cable. Refer to Battery Replacement in Engine


Electrical.
2. Remove the fan shroud assembly. Refer to Engine Coolant Fan Shroud
Replacement in Engine Cooling.
3. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical 4.3L .
4. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
5. Remove the steering linkage shield, if equipped. Refer to Steering Linkage
Shield Replacement in Steering Linkage (Non-Rack and Pinion).
6. Remove the front differential carrier shield, if equipped.
7. Remove the crankshaft balancer bolt.

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8. Remove the crankshaft pulley bolts.

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9. Remove the crankshaft pulley.


Notice: To prevent damage to the end of the crankshaft when using a crankshaft
balancer removal tool install a bolt in the crankshaft. Use a shorter bolt with the
same threads as the crankshaft balancer bolt. This bolt will allow a place for the
tool to push against. The shorter bolt is to keep from going past the threads in
the crankshaft and damaging the crankshaft threads.

Installation Procedure

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1. Install the crankshaft balancer. Refer to Crankshaft Balancer Installation in
Engine Mechanical - 4.3L .
2. Install the crankshaft pulley.
3. Loosely install the crankshaft pulley bolts.

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10. Remove the crankshaft balancer. Refer to Crankshaft Balancer Removal in


Engine Mechanical - 4.3L .
11. Clean and inspect all parts. Refer to Crankshaft Balancer Cleaning and
Inspection in Engine Mechanical - 4.3L .

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4. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the crankshaft balancer bolt.
Tighten
1. Tighten the crankshaft balancer bolt to 95 N-m (70 lb ft).
2. Tighten the pulley bolts to 58 N-m (43 lb ft).
5. Install the front differential carrier shield, if equipped.
6. Install the steering linkage shield, if equipped. Refer to Steering Linkage Shield
Replacement in Steering Linkage (Non-Rack and Pinion).
7. Lower the vehicle.
8. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical 4.3L .
9. Install the fan shroud assembly. Refer to Engine Coolant Fan Shroud
Replacement in Engine Cooling.
10. Connect the battery negative cable. Refer to Battery Replacement in Engine
Electrical.

Crankshaft Front Cover Oil Seal Replacement


Document ID: 439498

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Removal Procedure

1. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement in


Engine Mechanical - 4.3L .
2. Use a suitable prying tool to remove the crankshaft front oil seal.
3. Inspect the engine front cover seal bore for damage.
4. Inspect the crankshaft balancer seal area. Refer to Crankshaft Balancer Cleaning
and Inspection in Engine Mechanical - 4.3L .

Installation Procedure
Tools Required
J 35468 Oil Seal Installer

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1. Important: The engine front cover is a plastic composition.


Lubricate the exterior of the crankshaft front oil seal with clean engine oil.
2. Use the J 35468 with a hammer in order to install the crankshaft front oil seal.
3. Inspect to ensure the crankshaft front oil seal is flush and square to the engine
front cover.
4. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement in
Engine Mechanical - 4.3L .

Document ID: 194285


Removal Procedure

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1. Remove the engine oil pan. Refer to Oil Pan Replacement in Engine Mechanical
- 4.3L .
2. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement in
Engine Mechanical - 4.3L .
3. Remove the water pump. Refer to Water Pump Replacement in Engine Cooling.

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Engine Front Cover Replacement

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4. Remove the crankshaft position (CKP) sensor. Refer to Crankshaft Position


Sensor Replacement in Engine Controls.
5. Remove the engine front cover. Refer to Engine Front Cover Removal in Engine
Mechanical - 4.3L .

Installation Procedure

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1. Notice: Do not reuse the engine front cover. Oil leaks may result. Do not reuse
the original seal (O-ring) when installing the crankshaft position (CKP) sensor to
the engine front cover. Erratic engine operation may result.
Install the engine front cover. Refer to Engine Front Cover Installation in Engine
Mechanical - 4.3L .

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2. Install the CKP sensor with a NEW seal (O-ring). Refer to Crankshaft Position
Sensor Replacement in Engine Controls.

3. Install the engine oil pan. Refer to Oil Pan Replacement in Engine Mechanical 4.3L .
4. Install the water pump. Refer to Water Pump Replacement in Engine Cooling.
5. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement in
Engine Mechanical - 4.3L .

Crankshaft Position Sensor Reluctor Ring Replacement


Document ID: 439505
Removal Procedure

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1. Remove the engine front cover. Refer to Engine Front Cover Replacement in
Engine Mechanical - 4.3L .
2. Remove the crankshaft position sensor reluctor ring.

Installation Procedure

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1. Notice: Failure to properly align the crankshaft position sensor reluctor ring may
result in component damage and effect OBD II system performance.
Important: The reluctor ring is shaped like a dish.
The dish must face the engine front cover. Failure to do so will damage the front
cover and the reluctor ring.
Install the crankshaft position sensor reluctor ring.

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2. Install the engine front cover. Refer to Engine Front Cover Replacement in
Engine Mechanical - 4.3L .

Camshaft Timing Chain and Sprocket Replacement


Document ID: 194040
Removal Procedure

J 23523-F Balancer Remover and Installer


J 5825-A Crankshaft Gear Remover

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1. Important: Once the composite engine front cover is removed, DO NOT
reinstall the engine front cover. Always install a NEW engine front cover.
Remove the engine front cover. Refer to Engine Front Cover Replacement in
Engine Mechanical - 4.3L .
2. Remove the crankshaft position sensor reluctor ring.

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Tools Required

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3. Notice: In order to rotate the crankshaft, in the end of the crankshaft install a
short bolt with the same threads or use the crankshaft balancer bolt with
sufficient spacers to keep from damaging the threads of the bolt.
Check the timing chain free play. Refer to Timing Chain and Sprockets Removal
.
4. Rotate the crankshaft until:
1. The timing marks on both sprockets line up.
2. The number four cylinder is at top dead center (TDC) of the compression
stroke.

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5. Remove the camshaft sprocket bolts.

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6. Remove the camshaft sprocket.


7. Remove the camshaft timing chain.

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8. Use the J 5825-A in order to remove the crankshaft sprocket.
9. If necessary, remove the crankshaft balancer key.

Installation Procedure
Tools Required

J 23523-F Balancer Remover and Installer


J 5590 Installer

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1. Install the crankshaft balancer key into the keyway in the crankshaft (if
removed).
The crankshaft balancer key should be parallel to the crankshaft or with the front
of the key slightly lower.
2. Align the keyway of the crankshaft sprocket with the crankshaft balancer key.
3. Use the J 5590 and a hammer in order to install the crankshaft sprocket.

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4. Important: Be sure to align the camshaft and the crankshaft sprocket alignment
marks.
Align the camshaft and crankshaft sprockets timing marks.

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5. Look to ensure that the crankshaft sprocket is aligned at the 12 o'clock position
and the camshaft sprocket is aligned at the 6 o'clock position.

6. Install the camshaft sprocket and the camshaft timing chain.

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7. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

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Install the camshaft sprocket bolts.


Tighten
Tighten the camshaft sprocket bolts to 25 N-m (18 lb ft).
8. Install the crankshaft position sensor reluctor ring. Refer to Crankshaft Position
Sensor Reluctor Ring Replacement in Engine Mechanical - 4.3L .
9. Install the engine front cover. Refer to Engine Front Cover Replacement in
Engine Mechanical - 4.3L .

Document ID: 194045


Removal Procedure

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1. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.
2. Remove the A/C condenser, if equipped. Refer to Air Conditioning Condenser
Replacement in HVAC Systems with A/C - Manual.
3. Remove the lower intake manifold. Refer to Intake Manifold Replacement in
Engine Mechanical - 4.3L .
4. Remove the valve lifter pushrod guide. Refer to Valve Lifter Replacement in
Engine Mechanical - 4.3L .
5. Remove the camshaft timing chain and sprockets. Refer to Camshaft Timing
Chain and Sprocket Replacement in Engine Mechanical - 4.3L .

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Balance Shaft Replacement

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6. Remove the balance shaft drive gear.

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7. Remove the bolt holding the balance shaft driven gear.
8. Remove the balance shaft driven gear.

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9. Remove the bolts and the balance shaft retainer.

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10. Important: The balance shaft and the balance shaft front bearing are serviced
only as a package. Do not remove the balance shaft front bearing from the
balance shaft.
Tap on the balance shaft using a soft-faced hammer in order to remove the
balance shaft. Refer to Balance Shaft Removal .
11. Clean all sealing surfaces. Refer to Balance Shaft Clean and Inspect .

Installation Procedure

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1. Install the balance shaft. Refer to Balance Shaft Installation .


2. Install the camshaft timing chain and the camshaft sprocket. Refer to Camshaft
Timing Chain and Sprocket Replacement in Engine Mechanical - 4.3L .

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3. Install the crankshaft position reluctor ring and the engine front cover. Refer to
Crankshaft Position Sensor Reluctor Ring Replacement in Engine Mechanical 4.3L .
4. Install the valve lifter pushrod guide. Refer to Valve Lifter Replacement in
Engine Mechanical - 4.3L .
Important: When the timing marks on the camshaft and the crankshaft sprocket
are aligned, the engine is at top dead center for cylinder number four. In order to
install the distributor align the crankshaft balancer marks with the engine front
cover marks for top dead center cylinder number one.

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5. Install the lower intake manifold. Refer to Intake Manifold Replacement in


Engine Mechanical - 4.3L .
6. Install the A/C condenser, if equipped. Refer to Air Conditioning Condenser
Replacement in HVAC Systems with A/C - Manual.
7. Install the radiator. Refer to Radiator Replacement in Engine Cooling.

Balancer Shaft Front Bearing and Rear Bearing Replacement


Document ID: 194049

Tools Required

J 26941Bushing/Bearing Remover
J 38834Balance Shaft Service Kit

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1. Important: The balance shaft and the balance front bearing are serviced only as
a package. Do not remove the balance shaft front bearing from the balance shaft.
Remove the balance shaft. Refer to Balance Shaft Replacement in Engine
Mechanical - 4.3L .
2. Use the J 38834 and the J 26941 in order to remove the balance shaft rear
bearing.
1. Install the J 26941 legs behind the balance shaft rear bearing and secure.
2. Install the J 38834-1 with the short threaded end through the front of the
engine block.
3. Install the J 38834-1 into the J 26941.

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Removal Procedure

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4. Slide the J 38834-2 onto the J 38834-1 and into the balance shaft bore of
the engine block.
5. Install the bearing , washer and nut on the J 38834-1.
6. Hold the J 38834-1 and turn the nut clockwise until the balance shaft rear
bearing is removed.
3. Discard the balance shaft rear bearing.

Installation Procedure
Tools Required

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1. Dip the balance shaft rear bearing in clean engine oil before installation.
2. Use the J 38834 in order to install the balance shaft rear bearing.
1. Install the J 38834-3 onto the short threaded end of the J 38834-1.
2. Install the nut, washer, and bearing on the long threaded end of the
J 38834-1.
3. Install the J 38834-2 so that the smaller diameter will be facing the front
of the engine, onto the J 38834-1.
4. Install the J 38834-2 on the inside of the balance shaft front bearing bore.
5. Install the balance shaft rear bearing on the J 38834-3.
6. Position the balance shaft rear bearing.
7. Hold the J 38834-1 with a wrench and turn the nut counterclockwise
until the balance shaft rear bearing is installed.
3. Install the balance shaft. Refer to Balance Shaft Replacement in Engine
Mechanical - 4.3L .

Camshaft Replacement

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J 38834 Balance Shaft Service Kit

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Document ID: 195588


Removal Procedure
Important: The oil pan requires removal in order to remove the engine front cover. For
a RWD vehicle remove the engine. Refer to Engine Replacement in Engine Mechanical
- 4.3L and start at step 6.

1. Disconnect the battery negative cable. Refer to Battery Replacement in Engine


Electrical.
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
in Engine Controls.
3. Drain the cooling system. Refer to Cooling System Draining and Filling in
Engine Cooling.
4. Remove the condenser. if equipped. Refer to Air Conditioning Condenser
Replacement in HVAC Systems with A/C - Manual.
5. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.
6. Remove the valve rocker arm covers. Refer to Valve Rocker Arm Cover
Replacement in Engine Mechanical - 4.3L .
7. Remove the intake manifold. Refer to Intake Manifold Replacement in Engine
Mechanical - 4.3L .
8. Remove the valve lifters and the valve pushrods. Refer to Valve Lifter
Replacement in Engine Mechanical - 4.3L .
9. Remove the engine front cover. Refer to Engine Front Cover Replacement in
Engine Mechanical - 4.3L .
10. Remove the crankshaft position sensor reluctor ring. Refer to Crankshaft
Position Sensor Reluctor Ring Replacement in Engine Mechanical - 4.3L .
11. Remove the camshaft timing chain and the camshaft sprocket. Refer to
Camshaft Timing Chain and Sprocket Replacement in Engine Mechanical - 4.3L
.
12. Remove the balance shaft drive gear.

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13. Remove the camshaft. Refer to Camshaft Removal in Engine Mechanical - 4.3L
.

Installation Procedure

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1. Important: Whenever a new camshaft is installed, do the following procedures:
o Change the engine oil.
o Change the engine oil filter.
o Add GM Engine Oil Supplement GM P/N 1052367 or the equivalent to
the engine oil.
Install the camshaft into the engine block. Refer to Camshaft Installation in
Engine Mechanical - 4.3L .

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2. Position the drive gear onto the camshaft.


o Ensure that the timing marks align.
o The number four cylinder will be at the top dead center of its
compression stroke.

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3. Line up the timing marks on the camshaft sprocket and the crankshaft sprocket
dot to dot. When these dots are lined up dot to dot, the number four cylinder is at
the top dead center of its compression stroke.
4. Install the camshaft timing chain and camshaft sprocket. Refer to Camshaft
Timing Chain and Sprocket Replacement in Engine Mechanical - 4.3L .
Notice: Failure to properly align the crankshaft position sensor reluctor ring may
result in component damage and effect OBD II system performance.

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5. Install the crankshaft position sensor reluctor ring. Refer to Crankshaft Position
Sensor Reluctor Ring Replacement in Engine Mechanical - 4.3L .
6. Install the valve lifters and the valve pushrods. Refer to Valve Lifter
Replacement in Engine Mechanical - 4.3L .
7. Install the engine front cover. Refer to Engine Front Cover Replacement in
Engine Mechanical - 4.3L .
8. Install the intake manifold. Refer to Intake Manifold Replacement in Engine
Mechanical - 4.3L .

9. Important: Rotate the engine to align the crankshaft balancer marks with the
front cover marks for cylinder number one top dead center. When the alignment
marks on the camshaft sprocket and the crankshaft sprocket are aligned the
engine is at cylinder number four top dead center,
Rotate the engine to align the crankshaft balancer marks (1) and (4) with the
engine front cover marks (2) and (3) for cylinder number one top dead center.
10. Install the distributor. Refer to Distributor Replacement in Engine Electrical.
11. Install the valve rocker arm covers. Refer to Valve Rocker Arm Cover
Replacement in Engine Mechanical - 4.3L .
12. Install the condenser, if equipped. Refer to Air Conditioning Condenser
Replacement in HVAC Systems with A/C - Manual.
13. Install the radiator. Refer to Radiator Replacement in Engine Cooling.
14. Fill the engine cooling system. Refer to Cooling System Draining and Filling in
Engine Cooling.
15. Recharge the air conditioning system, if equipped. Refer to Refrigerant
Recovery and Recharging in HVAC Systems with A/C - Manual.
16. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls.
17. Connect the battery negative cable. Refer to Battery Replacement in Engine
Electrical.

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Oil Filter Adapter and Bypass Valve Assembly Replacement


Document ID: 195276
Removal Procedure

1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
2. Position a suitable container to catch the engine oil.
3. Remove the engine oil filter (except Four Wheel Drive vehicle).

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4. Disconnect the engine oil cooler pipes (RWD vehicle) from the oil filter adapter.
Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
5. Disconnect the remote oil filter inlet and outlet hoses (Four Wheel Drive
vehicle) from the oil filter pipe adapter. Refer to Remote Oil Filter Adapter Pipe
Replacement

6. Remove the bolts for the oil filter adapter RWD vehicle or the oil pipe adapter
Four Wheel Drive vehicle.

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7. Remove the oil filter adapter and the oil filter adapter gasket.
8. Discard the oil filter adapter gasket.

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9. Remove the oil filter adapter seal (O-ring).


10. Discard the oil filter adapter seal (O-ring).
11. Clean all sealing surfaces.

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12. Remove the oil filter bypass valve.
13. Clean and inspect valve bore for damage.

Installation Procedure

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1. Caution: Wear safety glasses in order to avoid eye damage.


Install a NEW oil filter bypass valve.
1. Install the bypass valve into the oil gallery bore until slightly below flush
with the surface of the block.
2. Using a pointed punch, stake the block area around the bypass valve.
Stake in three locations 120 degrees apart.

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2. Install a NEW seal (O-ring) into the groove in the oil filter adapter.

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3. Install the oil filter adapter with a NEW oil filter adapter gasket.

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4. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the oil filter adapter bolts.

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Tighten
Tighten the oil filter adapter bolts to 21 N-m (15 lb ft).

5. Connect the engine oil cooler pipes (RWD vehicle) to the oil filter adapter. Refer
to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
6. Connect the remote oil filter inlet and outlet hoses (Four Wheel Drive vehicle) to
the oil filter pipe adapter. Refer to Remote Oil Filter Adapter Pipe Replacement .
7. Install the engine oil filter (except Four Wheel Drive vehicles). Refer to Engine
Oil and Oil Filter Replacement in Engine Mechanical - 4.3L .
8. Lower the vehicle.

Oil Pan Replacement Document ID: 194372


Removal Procedure

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1.
2.
3.
4.

Remove the engine. Refer to Engine Replacement in Engine Mechanical - 4.3L


Remove the oil pan drain plug and drain the engine oil into a suitable container.
Remove the oil pan. Refer to Oil Pan Removal .
Clean and inspect all parts. Refer to Oil Pan Cleaning and Inspection in Engine
Mechanical - 4.3L .

Installation Procedure

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1. Install the oil pan. Refer to Oil Pan Installation .
2. Install the engine. Refer to Engine Replacement in Engine Mechanical - 4.3L .
3. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement in
Engine Mechanical - 4.3L .

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Oil Level Indicator Tube Replacement


Document ID: 439507
Removal Procedure

1. Remove the oil level indicator.


2. Remove the right exhaust manifold. Refer to Exhaust Manifold Replacement in
Engine Mechanical - 4.3L .

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3. Remove the oil level indicator tube bolt.
4. Remove the oil level indicator tube from the engine using a twisting motion.
5. Clean the old sealer from the oil level indicator tube and the engine block.

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Installation Procedure

1. Apply sealer, GM P/N 12346004 or equivalent, to the area where the oil level
indicator fits into the engine block.

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2. Install the oil level indicator tube to the engine. Refer to Oil Level Indicator and
Tube Installation .
3. Align the tube bracket.

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4. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the oil level indicator tube bolt.
Tighten
Tighten the oil level indicator tube bolt to 12 N-m (106 lb in).
5. Install the right exhaust manifold. Refer to Exhaust Manifold Replacement in
Engine Mechanical - 4.3L .

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6. Install the oil level indicator.

Oil Pump Replacement


Document ID: 194382
Removal Procedure

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1. Remove the oil pan. Refer to Oil Pan Replacement in Engine Mechanical - 4.3L
.

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2. Remove the oil pump. Refer to Oil Pump Removal .


3. Clean and inspect all parts. Refer to Oil Pump Clean and Inspect .

Installation Procedure

1. Important: Install a NEW oil pump driveshaft retainer.


Install the oil pump. Refer to Oil Pump Installation .
2. Install the oil pan. Refer to Oil Pan Replacement in Engine Mechanical - 4.3L

Crankshaft Rear Oil Seal and Housing Replacement Document ID: 439513
Removal Procedure

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1. Important: Do not remove the crankshaft rear oil seal housing if only replacing
the crankshaft rear oil seal.
Remove the engine oil pan. Refer to Oil Pan Replacement in Engine Mechanical
- 4.3L .
2. Remove the transmission assembly.
o Refer to Transmission Replacement in Manual Transmission - New
Venture.
o Refer to Transmission Replacement in Automatic Transmission - 4L60E.
3. Remove the engine flywheel. Refer to Engine Flywheel Replacement in Engine
Mechanical - 4.3L .
4. Remove the three bolts and the one nut holding the crankshaft rear oil seal
housing to the engine.
5. Remove the crankshaft rear oil seal housing.

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6. Remove and discard the crankshaft rear oil seal housing gasket.
7. Clean all sealing surfaces.
8. Inspect the crankshaft rear oil seal housing for warping, cracks, wear, or
damage.

Installation Procedure

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1. Install a NEW crankshaft rear oil seal housing gasket.

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2. Important: When installing a NEW crankshaft rear oil seal housing the
crankshaft rear oil seal will come with the housing. Use the following procedure.
Refer to Crankshaft Rear Oil Seal and Housing Replacement in Engine
Mechanical - 4.3L if reusing the crankshaft rear oil seal housing.
Install the NEW crankshaft rear oil seal housing with the crankshaft rear oil seal
to the engine block using the following procedure.
Important: Do not oil or grease the crankshaft rear oil seal lip or the
crankshaft seal area.
1. Leave the sleeve in the crankshaft rear oil seal and use the sleeve as a
guide to ease the seal lip over the end of the crankshaft.
2. Push the crankshaft rear oil seal housing with the crankshaft rear oil seal,
fully onto the crankshaft until the housing is against the gasket and the
engine.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
3. Install the three bolts and the one nut to the crankshaft rear oil seal housing.
Tighten
Tighten the crankshaft rear oil seal housing bolts and nut to 12 N-m (106 lb in).

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4. Install the engine flywheel. Refer to Engine Flywheel Replacement in Engine


Mechanical - 4.3L .
5. Install the transmission assembly.
o Refer to Transmission Replacement in Manual Transmission - New
Venture.
o Refer to Transmission Replacement in Automatic Transmission - 4L60E.
6. Install the oil pan. Refer to Oil Pan Replacement in Engine Mechanical - 4.3L .

Document ID: 195276


Removal Procedure

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1. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
2. Position a suitable container to catch the engine oil.
3. Remove the engine oil filter (except Four Wheel Drive vehicle).

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Oil Filter Adapter and Bypass Valve Assembly Replacement

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4. Disconnect the engine oil cooler pipes (RWD vehicle) from the oil filter adapter.
Refer to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
5. Disconnect the remote oil filter inlet and outlet hoses (Four Wheel Drive
vehicle) from the oil filter pipe adapter. Refer to Remote Oil Filter Adapter Pipe
Replacement

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6. Remove the bolts for the oil filter adapter RWD vehicle or the oil pipe adapter
Four Wheel Drive vehicle.

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7. Remove the oil filter adapter and the oil filter adapter gasket.
8. Discard the oil filter adapter gasket.

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9. Remove the oil filter adapter seal (O-ring).
10. Discard the oil filter adapter seal (O-ring).
11. Clean all sealing surfaces.

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12. Remove the oil filter bypass valve.


13. Clean and inspect valve bore for damage.

Installation Procedure

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1. Caution: Wear safety glasses in order to avoid eye damage.
Install a NEW oil filter bypass valve.
1. Install the bypass valve into the oil gallery bore until slightly below flush
with the surface of the block.
2. Using a pointed punch, stake the block area around the bypass valve.
Stake in three locations 120 degrees apart.

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2. Install a NEW seal (O-ring) into the groove in the oil filter adapter.

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3. Install the oil filter adapter with a NEW oil filter adapter gasket.

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4. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the oil filter adapter bolts.
Tighten
Tighten the oil filter adapter bolts to 21 N-m (15 lb ft).

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5. Connect the engine oil cooler pipes (RWD vehicle) to the oil filter adapter. Refer
to Engine Oil Cooler Hose/Pipe Replacement in Engine Cooling.
6. Connect the remote oil filter inlet and outlet hoses (Four Wheel Drive vehicle) to
the oil filter pipe adapter. Refer to Remote Oil Filter Adapter Pipe Replacement .
7. Install the engine oil filter (except Four Wheel Drive vehicles). Refer to Engine
Oil and Oil Filter Replacement in Engine Mechanical - 4.3L .
8. Lower the vehicle.

Document ID: 439528


Removal Procedure

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1. Remove the transmission. Refer to Transmission Replacement in Automatic
Transmission - 4L60-E.
2. Remove the bolts and the engine flywheel.
3. Clean and inspect all parts. Refer to Engine Flywheel Clean and Inspect .

Installation Procedure

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1. Install the engine flywheel to the crankshaft.


2. Align the locator hole to the pin.

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3. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the engine flywheel bolts.

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Tighten
Tighten the engine flywheel bolts in sequence to 100 N-m (74 lb ft).
4. Install the transmission. Refer to Transmission Replacement in Automatic
Transmission - 4L60-E.

Engine Replacement

Removal Procedure
Notice: If the engine is damaged internally and a new engine assembly is installed in
the vehicle, ensure that all foreign material is flushed out of the cooling system. You
must also flush out the oil cooler system. Failure to rid the oil cooler system of debris
can result in engine damage.
Tool Required
J 41427 Engine Lift Bracket
1. Disconnect the battery negative cable. Refer to Battery Replacement in Engine
Electrical.
2. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
3. Remove the underbody shields.
4. Remove the braces from the engine to the transmission (manual transmission
only). Refer to Transmission Replacement in Manual Transmission - New
Venture.
5. Remove the exhaust pipe from the exhaust manifolds. Refer to Exhaust
Manifold Pipe Replacement in Engine Exhaust.
6. Disconnect the oil cooler pipes (RWD vehicle). Refer to Engine Oil Cooler
Hose/Pipe Replacement in Engine Cooling.
7. Disconnect the remote oil filter adapter inlet and outlet hoses (Four Wheel Drive
vehicle). Refer to Remote Oil Filter Adapter Pipe Replacement in Engine
Mechanical - 4.3L .

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Document ID: 256830

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8. Remove the bolt holding the starter wire harness and if equipped, transmission
cooler lines.
9. Remove the starter. Refer to Starter Replacement in Engine Electrical.

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10. Remove the transmission cover.
11. Disconnect the front propeller shaft (Four Wheel Drive only). Refer toFront
Propeller Shaft Replacement in Propeller Shaft.
12. Remove the transfer case, if equipped.
o Refer to Transfer Case Replacement (With Automatic Transmission) in
Transfer Case - NVG 236 (Two Speed Automatic).
o Refer to Transfer Case Replacement in Transfer Case - NVG 136-NP4
(One Speed Automatic).

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13. Remove the rear engine mount to crossmember nut.


14. Remove the crossmember.
15. In order to remove the top transmission bolts lower the rear of the transmission
after removing the crossmember.
16. Remove the transmission.
o Refer to Transmission Replacement in Automatic Transmission - 4L60E.
o Refer to Transmission Replacement in Manual Transmission - New
Venture.

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17. Remove the front engine mount through bolts.
18. Lower the vehicle.

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19. Remove the PCV tube from the right valve rocker arm cover and the air cleaner
outlet duct.
20. Remove the air cleaner outlet duct from the throttle body.
21. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
in Engine Controls.
22. Remove the radiator. Refer to Radiator Replacement in Engine Cooling.
23. Remove the inlet and outlet radiator hoses from the engine. Refer toRadiator
Hose Replacement in Engine Cooling.
24. Disconnect the heater hoses from the engine. Refer to Heater Hoses
Replacement in Heating and Ventilation (Non A/C).

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25. Disconnect the following electrical connectors:
o The fuel meter body assembly
o The EVAP canister purge solenoid valve

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The idle air control (IAC) motor


The throttle position (TP) sensor
The A/C compressor high pressure switch, if equipped
The A/C clutch switch, if equipped
The exhaust gas recirculation (EGR) valve
The engine coolant temperature (ECT ) sensor
The ignition control module (ICM)
The generator
The crankcase position (CKP) sensor
26. Release the engine wiring harness retainers and move the wiring harness aside.
o
o
o
o
o
o
o
o
o

27. Remove the battery ground cable at the engine.

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28. Remove the bolts holding the ground wires to the left cylinder head.

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29. Remove the bolt holding the fuel pipe bracket to the rear of left cylinder head.

30. Remove the bolts holding the ground wires to the right cylinder head.
Caution: In order to avoid possible injury or vehicle damage, always replace the
accelerator control cable with a NEW cable whenever you remove the engine
from the vehicle.
In order to avoid cruise control cable damage, position the cable out of the way
while you remove or install the engine. Do not pry or lean against the cruise
control cable and do not kink the cable. You must replace a damaged cable.
31. Remove the accelerator cable from the throttle shaft and the accelerator cable
bracket. Refer to Accelerator Control Cable Replacement in Engine Controls.
32. Remove the cruise control cable, if equipped from the throttle shaft and the
accelerator cable bracket. Refer to Cruise Control Cable Replacement in Cruise
Control.

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33. Remove the accelerator control cable bracket from the throttle body.
34. Remove the water pump pulley. Refer to Water Pump Replacement in Engine
Cooling.
35. Remove the A/C compressor, if equipped. Refer to Air Conditioning
Compressor Replacement in HVAC Systems with A/C - Manual.

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36. Remove the nuts holding the power steering pump rear bracket to the engine.

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37. Remove the power steering pump mounting bracket.


o The power steering pump can remain on the mounting bracket.
o The hoses do not require removal.
o Remove the three bolts and the nut.
o Slide the power steering pump mounting bracket off of the stud.
o Secure the power steering pump mounting bracket out of the way.
38. Remove the distributor cap. Refer to Distributor Replacement in Engine
Electrical.
39. Disconnect the fuel pipes. Refer to Fuel Hose/Pipes Replacement - Engine
Compartment in Engine Controls.
40. Disconnect the EVAP canister purge solenoid valve pipe.

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41. Disconnect the vacuum brake booster line from the intake manifold.
42. Remove the water outlet. Refer to Engine Coolant Thermostat Replacement in
Engine Cooling.

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43. Remove the EGR valve inlet pipe from the intake and the exhaust manifolds.

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44. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Attach the J 41427 to the left front and the right rear intake manifold mounting
bolts, using the following procedure:
1.

Remove the right rear lower intake manifold bolts.

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2.
Install the J 41427 marked RIGHT REAR.
3.
Install the retaining bolts.
4.
Remove the left front lower intake manifold bolts.
5.
Install the J 41427 marked LEFT FRONT with the arrow pointing to the front of
the engine.
Install the retaining bolts.
6.
Tighten
Tighten the retaining bolts to 15 N-m (11 lb ft).

Installation Procedure
Notice: If the engine is damaged internally and a new engine assembly is installed in
the vehicle, ensure that all foreign material is flushed out of the cooling system. You
must also flush out the oil cooler system. Failure to rid the oil cooler system of debris
can result in engine damage.
Tool Required
J 41427 Engine Lift Bracket
1. Install the engine into the vehicle.

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2. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion

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45. Attach a suitable lifting device to the engine lift brackets.


46. Remove the engine.

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inhibitors on fasteners or fastener joint surfaces unless specified. These coatings


affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the engine mount through-bolts and nuts.
Tighten
Tighten the engine mount through-bolts or the nuts to the following:

Tighten
1.
2.
3.

Tighten the bolts the first pass to 3 N-m (27 lb in).


Tighten the bolts the first pass to 12 N-m (106 lb in).
Tighten the bolts the first pass to 15 N-m (11 lb ft).

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6. Install the EGR valve inlet pipe to the intake and exhaust manifolds.
Tighten
0.
1.
2.

Tighten the EGR valve inlet pipe intake manifold nut to 25 N-m (18 lb ft).
Tighten the EGR valve inlet pipe exhaust manifold nut to 30 N-m (22 lb ft).
Tighten the EGR valve inlet pipe clamp bolt to 25 N-m (18 lb ft).
7. Install the water outlet. Refer to Water Pump Replacement in Engine Cooling.

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Tighten the through-bolts to 74 N-m (55 lb ft)


Tighten the nuts to 63 N-m (46 lb ft)
3. Remove the J 41427 and the engine lifting device.
4. Apply thread lock GM PN 12345382 or equivalent to the threads of the lower
intake manifold bolts.
5. Install the intake manifold bolts.
o
o

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8. Connect the fuel pipes at the rear of the engine. Refer to Fuel Hose/Pipes
Replacement - Engine Compartment in Engine Controls.
9. Install the bolt holding the fuel pipe bracket to the rear of the left cylinder head.
Tighten
Tighten the fuel pipe bracket bolt to 30 N-m (22 lb ft).
10. Connect the EVAP canister purge solenoid valve pipe. Refer to EVAP Canister
Purge Solenoid Valve Replacement in Engine Controls.

11. Connect the vacuum brake booster hose to the intake manifold.
12. Install the distributor cap. Refer to Distributor Replacement in Engine Electrical.

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13. Install the power steering pump mounting bracket and the three bolts and the
nut.
Tighten
Tighten the power steering pump mounting bracket bolts and nuts to 41 N-m
(30 lb ft).

14. Install the nuts holding the power steering pump rear bracket to the engine.
Tighten
Tighten the power steering pump rear bracket nuts to 41 N-m (30 lb ft).
15. Install the A/C compressor, if equipped. Refer to Air Conditioning Compressor
Replacement in HVAC Systems with A/C - Manual.
16. Install the water pump pulley. Refer to Water Pump Replacement in Engine
Cooling.

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17. Install the accelerator control cable bracket to the throttle body.
Tighten
Tighten the bolt to 9 N-m (80 lb in).
Caution: In order to avoid possible injury or vehicle damage, always replace the
accelerator control cable with a NEW cable whenever you remove the engine
from the vehicle.
In order to avoid cruise control cable damage, position the cable out of the way
while you remove or install the engine. Do not pry or lean against the cruise
control cable and do not kink the cable. You must replace a damaged cable.
18. Install a NEW accelerator control cable. Refer to Accelerator Control Cable
Replacement in Engine Controls.
19. Install the cruise control cable, if equipped to the throttle shaft and the
accelerator cable bracket. Refer to Cruise Control Cable Replacement in Cruise
Controls.

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20. Install the battery ground cable bolt.


Tighten
Tighten the ground cable bolt to 35 N-m (26 lb ft).

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21. Install the bolts holding the ground wires to the left cylinder head.
Tighten
Tighten the ground wire bolt to 35 N-m (26 lb ft).

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22. Install the stud holding the ground wires to the right cylinder head.
Tighten
Tighten the stud to 35 N-m (26 lb ft).

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23. Position the engine wiring harness.
24. Install the engine wiring harness in the retainers.
25. Connect the following electrical connectors:
o The fuel meter body assembly
o The EVAP canister purge solenoid valve
o The idle air control (IAC) motor
o The throttle position (TP) sensor
o The A/C compressor high pressure switch, if equipped

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The A/C clutch switch, if equipped


The exhaust gas recirculation (EGR) valve
The engine coolant temperature (ECT ) sensor
The ignition control module (ICM)
The generator
The crankcase position (CKP) sensor
26. Install the radiator. Refer to Radiator Replacement in Engine Cooling.
27. Install the inlet and outlet radiator hose to the engine. Refer to Radiator Hose
Replacement in Engine Cooling.
28. Connect the heater hoses to the engine. Refer to Heater Hoses Replacement in
Heating and Ventilation (Non A/C)
o
o
o
o
o
o

29. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information.
30. Install the transmission.
o Refer to Transmission Replacement in Automatic Transmission - 4L60E.
o Refer to Transmission Replacement in Manual Transmission - New
Venture.
31. Install the transfer case, if equipped.
o Refer to Transfer Case Replacement in Transfer Case - NVG 236 (Two
Speed Automatic).
o Refer to Transfer Case Replacement (With Automatic Transmission) in
Transfer Case - NVG 136-NP4 (One Speed Automatic).
32. Install the front propeller shaft (Four Wheel Drive vehicle only). Refer to Front
Propeller Shaft Replacement in Propeller Shaft.

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33. Install the transmission cover.


Tighten
Tighten the nut to 12 N-m (106 lb in).
34. Install the starter. Refer to Starter Replacement in Engine Electrical.

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35. Install the bolt holding the bracket for the starter wiring harness and if equipped,
the transmission cooler lines.
Tighten
Tighten the bracket bolt to 12 N-m (106 lb in).

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Water Pump Removal


Document ID: 42508
Tools Required
J 41240 Fan Clutch Remover and Installer

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36. Connect the oil cooler pipes (RWD vehicle). Refer to Engine Oil Cooler
Hose/Pipe Replacement in Engine Cooling.
37. Connect the remote oil filter inlet and outlet hoses (Four Wheel Drive vehicle).
Refer to Remote Oil Filter Adapter Pipe Replacement in Engine Mechanical 4.3L .
38. Install the exhaust pipe to the exhaust manifolds. Refer to Exhaust Manifold
Pipe Replacement in Engine Exhaust.
39. Install a NEW oil filter. Refer to Engine Oil and Oil Filter Replacement in
Engine Mechanical - 4.3L .
40. Install the braces from the engine to the transmission. Refer to Transmission
Replacement in Manual Transmission - New Venture.
41. Install the underbody shields.
42. Lower the vehicle.
43. Fill the engine with oil. Refer to Engine Oil and Oil Filter Replacement in
Engine Mechanical - 4.3L .
44. Fill the cooling system with coolant. Refer to Cooling System Draining and
Filling in Engine Cooling
45. Connect the battery negative cable. Refer to Battery Replacement in Engine
Electrical.
46. Recharge the air conditioning system, if equipped. Refer to Refrigerant
Recovery and Recharging in HVAC Systems with A/C - Manual.
47. Operate and test the engine. Refer to Engine Set-Up and Testing .

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1. Remove the bolts and the fan & water pump pulley using the J 41240 .

2. Remove the clamps and the water pump inlet hose.

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3.
4.
5.
6.

Remove the water pump bolts.


Remove the water pump.
Remove the water pump gaskets.
Discard the water pump gaskets.

Crankshaft Balancer Removal

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Document ID: 43093


Tools Required
J 23523-F Balancer Remover and Installer

1. Remove the crankshaft balancer bolt and washer.

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2. Remove the bolts and the crankshaft pulley.

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3. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Use the J 23523-F in order to remove the crankshaft balancer.
1. Install the J 23523-F plate and bolts onto the crankshaft balancer.
Tighten
Tighten the bolts to 25 N-m (18 lb ft).
2. Install the J 23523-F forcing screw into the plate.
3. Rotate the J 23523-F forcing screw clockwise in order to remove the
crankshaft balancer.
4. Remove the J 23523-F from the crankshaft balancer.

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5. Note the position and length of any front groove pins (crankshaft balancer) (if
applicable).

Distributor Removal
Document ID: 42613

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1. Remove the ignition coil wire harness from the ignition coil and distributor cap.

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2. Remove the distributor clamp bolt.


3. Remove the distributor and the distributor clamp.
4. Remove the distributor gasket and discard.

Intake Manifold Removal


Document ID: 42888

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1. Remove the evaporative emission (EVAP) canister purge solenoid valve
harness.
1. Push the quick disconnect clip and hold in place.
2. Pull outward on the harness elbow.

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2. Remove the engine coolant temperature (ECT) sensor wire connector (if
equipped) from the engine wiring harness bracket.
3. Remove the lower intake manifold bolts.
Important: The intake manifold may be removed as an assembly. Do not
remove the specific intake manifold components unless component service is
required.
Do not allow dirt or debris to enter the fuel system. Ensure that the ends of the
fuel system are properly sealed.
Do not disassemble the Central Sequential Fuel Injection (SFI) unit, unless
service is required.
4. Remove the intake manifold assembly.
5. Remove and discard the lower intake manifold gaskets.

Diagnostic Trouble Code Identification Document ID: 201385


Diagnostic Trouble Code (DTC) Identification (4.3L)
DTC

Description

DTC
Type*

P0218

Transmission Fluid
Overtemperature

Default Action
DTC P0218 stores in VCM
history
The VCM freezes shift
adapts from being updated

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P0502

Vehicle Speed Sensor Circuit


Low Input

P0503

Vehicle Speed Sensor Circuit


Intermittent

Transmission Fluid Temperature


P0711 Sensor Circuit
Range/Performance

P0712

Transmission Fluid Temperature


Sensor CircuitLow Input

P0713

Transmission Fluid Temperature


Sensor CircuitHigh Input

DTC P0503 stores in VCM


history
The VCM commands a
soft landing to second gear
The VCM commands
maximum line pressure
The VCM inhibits TCC
engagement
The VCM inhibits fourth
gear if the transmission is
in hot mode
The VCM freezes shift
adapts from being updated
DTC P0711 stores in VCM
history
The VCM uses a
transmission fluid
temperature default value
based on engine coolant ,
engine run time and IAT at
startup
The VCM freezes shift
adapts from being updated
DTC P0712 stores in VCM
history
The VCM uses a
transmission fluid
temperature default value
based on engine coolant ,
engine run time and IAT at
startup
The VCM freezes shift
adapts from being updated
DTC P0713 stores in VCM
history

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DTC P0502 stores in VCM


history
The VCM commands
second gear only below
3000 RPM
The VCM commands
maximum line pressure
The VCM freezes shift
adapts from being updated
The VCM inhibits TCC
engagement

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D
D

DTC P0719 stores in VCM history


DTC P0724 stores in VCM history

P0740

Torque Converter Clutch Enable


Solenoid CircuitElectrical

P0742

Torque Converter Clutch


SystemStuck ON

P0748

Pressure Control Solenoid


CircuitElectrical

1-2 Shift Solenoid Valve


P0751
Performance

P0753

1-2 Shift Solenoid Circuit


Electrical

DTC P0740 stores in VCM


history
The VCM inhibits TCC
engagement
The VCM inhibits 4th gear
if the transmission is in hot
mode
The VCM freezes shift
adapts from being updated
DTC P0742 stores in VCM
history
The VCM freezes shift
adapts from being updated
DTC P0748 stores in VCM
history
The VCM freezes shift
adapts from being updated
The PC Sol. Valve is OFF
DTC P0751 stores in VCM
history
The VCM freezes shift
adapts from being updated
The VCM commands D2
line pressure
The VCM inhibits 3-2
downshifts if the vehicle
speed is greater than
48 km/h (30 mph)
DTC P0753 stores in VCM
history
The VCM commands D2
line pressure

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Brake Switch CircuitLow


Input
Brake Switch CircuitHigh
P0724
Input
P0719

The VCM uses a


transmission fluid
temperature default value
based on engine coolant ,
engine run time and IAT at
startup
The VCM freezes shift
adapts from being updated

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P0758

2-3 Shift Solenoid Circuit


Electrical

P0785

3-2 Shift Solenoid Circuit


Electrical

Transmission Fluid Pressure


P1810 Manual Valve Position Switch
Assembly Circuit Malfunction

DTC P0756 stores in VCM


history
The VCM commands third
gear only
The VCM commands
maximum line pressure
The VCM inhibits TCC
engagement
The VCM freezes shift
adapts from being updated
DTC P0758 stores in VCM
history
The VCM commands 3rd
gear only
The VCM freezes shift
adapts from being updated
The VCM commands
maximum line pressure
The VCM inhibits TCC
engagement
DTC P0785 stores in VCM
history
The VCM commands a
soft landing to 3rd gear
The VCM inhibits TCC
engagement
The VCM commands
maximum line pressure
The VCM inhibits 4th gear
if the transmission is in hot
mode
The VCM freezes shift
adapts from being updated
DTC 1810 stores in VCM
history
The VCM commands D2
line pressure
The VCM commands D4
shift pattern
The VCM freezes shift

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2-3 Shift Solenoid Valve


P0756
Performance

The VCM inhibits 3-2


downshifts if the vehicle
speed is greater than
48 km/h (30 mph)
The VCM freezes shift
adapts from being updated

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adapts from being updated

Torque Converter Clutch Pulse


P1860 Width Modulation Solenoid
CircuitElectrical

P1870

Transmission Component
Slipping

P1875

Four Wheel Drive Low Switch


Circuit - Electrical

DTC P1870 stores in VCM


history
The VCM inhibits TCC
engagement
The VCM commands
maximum line pressure
The VCM inhibits 4th gear
if the transmission is in hot
mode
The VCM freezes shift
adapts from being updated
DTC P1875 stores in VCM
history
The VCM commands a
normal shift pattern (not a
4WD low shift pattern)

*DTC Types:

AEmission-related, turns the MIL ON after the first failure.


BEmission-related, turns the MIL ON after two consecutive trips with
failure.
CNon-emission-related, turns the service lamp ON after the first failure.
DNon-emission-related, no lamps.

Range Reference
Document ID: 19380
Range Reference Table
Range
Gear

Park Reverse Neutral

OD
D
2
1
1st 2nd 3rd 4th 1st 2nd 3rd 1st** 2nd 1st 2nd***

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DTC P1860 stores in VCM


history
The VCM inhibits TCC
engagement
The VCM inhibits 4th gear
if the transmission is in hot
mode
The VCM freezes shift
adapts from being updated

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Document ID: 19380

Shift Solenoid Valve State and Gear Ratio


Document ID: 61335
Shift Solenoid Valve State and Gear Ratio 4L60-E
Gear
1

1-2 Shift Solenoid


ON

2-3 Shift Solenoid


ON

Gear Ratio
3.059:1

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1-2 Shift
ON* ON* ON* ON OFF OFF ON ON OFF OFF ON OFF ON OFF
Solenoid
2-3 Shift
ON* ON* ON* ON ON OFF OFF ON ON OFF ON ON ON ON
Solenoid

A A A A
A
2-4 Band
Reverse

A

Input
Clutch
Overrun

A
A
A A
A
Clutch
Forward

A A A A A A A
A
A A
A
Clutch
Forward
Sprag

H H H H H H
H
H H
H
Clutch
Assembly
3-4

A A A
Clutch
Lo/Roller

H H H H

Clutch
Lo/Rev
A
A
A

Clutch
a = Applied
h = Holding
on = The solenoid is energized.
off = The solenoid is de-energized.
*Shift Solenoid state is a function of vehicle speed and may change if the vehicle
speed increases sufficiently in Park, Reverse or Neutral. However, this does not
affect the operation of the transmission.
**Manual SecondFirst gear is electronically prevented under normal operating
conditions.
***Manual FirstSecond gear is only available above approximately 4856 km/h
(3035 mph).

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2
3
4

OFF
OFF
ON

ON
OFF
OFF

1.625:1
1.000:1
0.696:1

Shift Speed
Document ID: 201386
Shift Speed (1998 S/T Truck)

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M
31 @ 32 @
23
TC
+/ 100 +/ 100 3-1
12 Shift @ 23 Shift @
34 Shift @
RPM RPM Wide Wide Ap
+/ 250 RPM +/ 200 RPM +/ 150 RPM Output Output Open Open @ 1
Output Shaft Output Shaft Output Shaft Shaft Shaft Throttle Throttle Thr
Speed
Speed
Speed
Speed Speed Shift
Shift (RP
12 25 50 12 25 50 12 25 50

% of TPS
Trans
Axle

Cal
2.2L (LN2)
A
4
683 840 1208 998 1522 2257 1575 2100 3465
4.3L (LF6/L35)
A
3.08/3.43 566 817 1131 985 1299 2011 1383 1697 2577
B 3.08/3.42/3.73 529 761 1057 909 1205 1882 1290 1586 2390
C
3.42/3.73 521 747 1042 906 1200 1857 1268 1563 2378

Automatic Transmission Electronic Component Views Document ID: 174447


Automatic Transmission Internal Electronic Components (4L60E)

N/A

893

1575

5500

N/A
N/A
N/A

796
740
725

1383
1290
1268

5000
5000
5000

19

18
16
16

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36. Vehicle Speed Sensor (VSS)


66. Torque Converter Clutch (TCC) Solenoid Valve
69. Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch
70. 1-2 Shift Solenoid (SS) Valve
71. 2-3 Shift Solenoid (SS) Valve
377.

Pressure Control (PC) Solenoid Valve

394.

3-2 Shift Solenoid (SS) Valve Assembly

396.
Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid
Valve

1998 Domestic S/T Cell 44 Figure 1 Component Locator View Document ID: 255876
Brake Control Module Connector C3 Locator View

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1. Electronic Brake Control Module (EBCM)


2. EBCM Connector C2

1998 Domestic S/T Cell 44 Figure 2 Component Location View Document ID: 255877
Forward Wiring Sensor Locator Views

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1. Wheel Speed Sensor, LH


2. Ground G106
3. Ground G118
4. Wheel Speed Sensor, RH

Document ID: 255877

1998 Domestic S/T Cell 44 Figure 3 Component Location View Document ID: 255878
LH Front Fender Area Locator View

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1. Electronic Brake Control Module Connector C1


2. Electronic Brake Control Module Connector C3
3. Connector C109 (Body Harness to 4WAL Harness)
4. Connector C106 (Utility Body Harness to Forward Lamps Harness)
5. Windshield Washer Pump, Rear (Utility)
6. Ground G110
7. Windshield Washer Pump (Pickup) or Windshield Washer Pump, Front (Utility)
8. Underhood Bussed Electrical Center (UBEC)
9. Connector C114 (Body Harness to Front Axle Switch, W/ Electric Shift 4WD)
10. Brake Pressure Warning Switch

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11. Connector C108 (Body Harness to 4WD Extension Harness)

Document ID: 255878

1998 Domestic S/T Cell 44 Figure 4 Component Location View Document ID: 255879

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1. Electronic Brake Control Module
2. Electronic Brake Control Module Connector C1
3. Electronic Brake Control Module Connector C3
4. Brake Pressure Modulating Valve

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Brake Control Module Locator View

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5. Brake Pressure Warning Switch


6. Combination Valve

Document ID: 255879

Antilock Brake System Connector End Views

Electronic Brake Control Module (EBCM) C1

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Connector Part Information


Pin
A
B
C
D
E
F
G
H
J
K

Wire Color
BRN
LT GRN
PPL

YEL/BLK
TAN/WHT
PPL
PPL
BLK

12065425
10 Way F Metri-Pack 150 Series (BLK)

Circuit No.
241
867
420

1827
799
1807
680
450

Function
Ignition 3 Power
ABS Indicator Lamp Control
Brake Switch Input
Not Used
Vehicle Speed Input
ABS Diagnostic Link (UART)
Serial Data (Class 2)
Brake Warning lamp Control
Signal Ground
Not Used

Electronic Brake Control Module (EBCM) C2

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Document ID: 211800

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Connector Part Information


Pin
A
B
C
D
E

Wire Color
LT BLU

DK GRN
YEL
TAN

12124662
4 Way F Metri-Pack 150 Series (BRN)

Circuit No.
830

872
873
833

Function
LF Wheel Speed Sensor High
Not Used
RF Wheel Speed Sensor High
LF Wheel Speed Sensor Low
RF Wheel Speed Sensor Low

Electronic Brake Control Module (EBCM) C3

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Connector Part Information


Pin
A
B

Wire Color
RED
BLK

Document ID: 211800

12085030
2 Way F Metri-Pack 630 Series P2S (BLK)

Circuit No.
442
150

Function
Motor and Solenoid Power
Power Ground

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Electronic Brake Control Module Replacement


Document ID: 195575
Removal Procedure
Important: After installation, calibrate the new EBCM to the tire size that is
appropriate to the vehicle. Refer to Tire Size Calibration and to Trim Level Calibration
portions of ABS Operation in Antilock Brake System .
Caution: Refer to Battery Disconnect Caution in Cautions and Notices.

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2. Remove the four T-25 Torx screws (1) that fasten the EBCM to the BPMV.
Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force
will damage the EBCM.
3. Partially remove the EBCM (2) from the BPMV (4) enough to access the
electrical connectors. Removal may require a light amount of force.
4. Disconnect the four electrical connectors from EBCM.
5. Fully remove the EBCM (2) from the BPMV (4).

Installation Procedure
Important: Do not reuse the old mounting screws. Always install new mounting screws
with the new EBCM.

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1. Disconnect the Negative Battery Cable.

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1. Important: Do not use RTV or any other type of sealant on the EBCM gasket
or mating surfaces.
Connect the four electrical connectors to the EBCM.
2. Install EBCM (2) on to the BPMV (4).
Notice: Refer to Fastener Notice in Cautions and Notices.
3. Install the four new T-25 Torx screws (1) in the EBCM (2).
Tighten
Tighten the four T-25 Torx screws to 5 N-m (39 lb in) in an X-pattern.
4. Connect the negative battery cable.
5. Revise the tire calibration using the Scan Tool
6. Go to Diagnostic System Check in Antilock Brake System .

Document ID: 195575

Brake Pressure Modulator Valve Replacement


Document ID: 195320
Removal Procedure
Caution: Refer to Battery Disconnect Caution in Cautions and Notices.

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1. Disconnect the Negative Battery Cable.


2. Remove the two fuse block mounting bolts from the EBCM bracket.

3. Disconnect the electrical connector from the combination valve (12).


4. Remove the front and rear brake pipes (from master cylinder) from the
combination valve.
5. Remove the right front, left front and rear brake pipes from the tube adapters (6).
6. Remove the four 10mm bolts (9) that fasten the EHCU bracket (7) to the vehicle
mounting bracket.

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7. Lift the EHCU partially out or the engine compartment.
8. Disconnect the four electrical connectors from EBCM (2).
9. Fully remove the EHCU from the vehicle.
10. Remove the three allen bolts (11) from the combination valve (12).

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11. Remove the combination valve (12).


Important: Do not reuse the transfer tubes. Always install new transfer tubes.
12. Remove the two transfer tubes (13).
13. Remove the three 13mm bolts (9) that fasten the bracket to the BPMV.
14. Remove the four T-25 Torx bolts (1) from the EBCM.
Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force
will damage the EBCM.
15. Remove the EBCM (2) from the BPMV (4). Removal may require a light
amount of force.

Installation Procedure

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1. Install the new transfer tubes (13) into the combination valve into the
combination valve (9).
2. Install the combination valve onto the BPMV (4).

3. Install the three allen bolts (11) that fasten the combination valve (12) to the
BPMV (4).
Tighten
Tighten the three allen bolts to 8 N-m (6 lb ft), then to 16 N-m (12 lb ft).
Important: Do not reuse the old EBCM mounting bolts. Always install new
mounting bolts with the new EBCM.
4. Important: Do not use RTV or any other type of sealant on the EBCM gasket
or mating surfaces.

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Install EBCM (2) onto BPMV (4).
5. Install the four new EBCM bolts (1).

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Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

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Tighten
Tighten the four bolts to 5 N-m (39 lb in) in an X-pattern.
6. Install EHCU (9) to bracket.
7. Install the three BPMV (4) to bracket retaining bolts.
Tighten
Tighten the three bolts to 9 N-m (7 lb ft).

Tighten
Tighten the three bolts to 25 N-m (20 lb ft).

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10. Install the right front, left front and rear brake pipes to the tube adapters.
Tighten
Tighten the three brake pipe fittings to 29 N-m (22 lb ft).
11. Install the front and rear brake pipes (from master cylinder) to the combination
valve.
Tighten
Tighten the three brake pipe fittings to 29 N-m (22 lb ft).
12. Connect the electrical connector to the combination valve.

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8. Connect the four electrical connectors to the EBCM.


9. Install the EHCU to the vehicle frame.

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13. Install the two fuse block mounting bolts from the EBCM bracket.
14. Connect the negative battery cable.
Important: Verify that the combination valve metering rod is depressed during
bleeding.
15. Bleed the brake system. Refer to Antilock Brake System Automated Bleed
Procedure in Antilock Brake System .
16. Go to Diagnostic System Check.

Document ID: 237221


Two Person Procedure
Important:

1.
2.
3.
4.

Use the two-person bleed procedure under the following conditions:


o Installing a new Electro-Hydraulic Control Unit (EHCU) or new Brake
Pressure Modulator Valve (BPMV).
o Air is trapped in the valve body
Do not drive the vehicle until the brake pedal feels firm.
Do not reuse brake fluid that is used during bleeding.
Use the vacuum, the pressure and the gravity bleeding procedures only for base
brake bleeding.

Raise the vehicle in order to access the system bleed screws.


Bleed the system at the right rear wheel first.
Install a clear hose on the bleed screw.
Immerse the opposite end of the hose into a container partially filled with clean
DOT 3 brake fluid.
5. Open the bleed screw 1/2 to one full turn.
6. Slowly depress the brake pedal. While the pedal is depressed to its full extent,
tighten the bleed screw.
7. Release the brake pedal and wait 1015 seconds for the master cylinder pistons
to return to the home position.
8. Repeat the previous steps for the remaining wheels. The brake fluid which is
present at each bleed screw should be clean and free of air.
9. This procedure may use more than a pint of fluid per wheel. Check the master
cylinder fluid level every four to six strokes of the brake pedal in order to avoid
running the system dry.
10. Press the brake pedal firmly and run the Scan Tool Automated Bleed Procedure .
Release the brake pedal between each test.
11. Bleed all four wheels again using Steps 39. This will remove the remaining air
from the brake system.
12. Evaluate the feel of the brake pedal before attempting to drive the vehicle.

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Antilock Brake System Automated Bleed Procedure

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13. Bleed the system as many times as necessary in order to obtain the appropriate
feel of the pedal.

Electronic Brake Control Module Replacement


Document ID: 195575
Removal Procedure

Caution: Refer to Battery Disconnect Caution in Cautions and Notices.


1. Disconnect the Negative Battery Cable.

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2. Remove the four T-25 Torx screws (1) that fasten the EBCM to the BPMV.
Important: Do not use a tool to pry the EBCM or the BPMV. Excessive force
will damage the EBCM.
3. Partially remove the EBCM (2) from the BPMV (4) enough to access the
electrical connectors. Removal may require a light amount of force.
4. Disconnect the four electrical connectors from EBCM.
5. Fully remove the EBCM (2) from the BPMV (4).

Installation Procedure

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Important: After installation, calibrate the new EBCM to the tire size that is
appropriate to the vehicle. Refer to Tire Size Calibration and to Trim Level Calibration
portions of ABS Operation in Antilock Brake System .

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Important: Do not reuse the old mounting screws. Always install new mounting screws
with the new EBCM.

1. Important: Do not use RTV or any other type of sealant on the EBCM gasket
or mating surfaces.
Connect the four electrical connectors to the EBCM.
2. Install EBCM (2) on to the BPMV (4).
Notice: Refer to Fastener Notice in Cautions and Notices.
3. Install the four new T-25 Torx screws (1) in the EBCM (2).
Tighten
Tighten the four T-25 Torx screws to 5 N-m (39 lb in) in an X-pattern.
4. Connect the negative battery cable.
5. Revise the tire calibration using the Scan Tool
6. Go to Diagnostic System Check in Antilock Brake System .

Document ID: 195575

Wheel Speed Sensor Replacement Document ID: 186839

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Removal Procedure

1.
2.
3.
4.
5.
6.
7.
8.

Raise vehicle.
Remove tire and wheel. Refer to Wheel Removal in Tires and Wheels .
Remove brake caliper. Refer to Brake Caliper Replacement in Disc Brakes .
Remove the hub and rotor. Refer to Brake Rotor Replacement in Disc Brakes .
Remove wheel speed sensor mounting clip on the control arm.
Remove wheel speed sensor mounting clip on the frame rail.
Disconnect wheel speed sensor electrical connector (2).
Remove the sensor mounting screw (5).
Important: The wheel speed sensor mounts into a bore that leads to the center
of the sealed bearing. Use caution when cleaning or working around the bore.
Do not contaminate the lubricant inside the sealed bearing. Failure to do so can
lead to premature bearing failure.

9. Notice: Carefully remove the sensor by pulling it straight out of the bore. DO
NOT use a screwdriver, or other device. Prying will cause the sensor body to
break off in the bore.
Notice: Do not attempt to remove the stainless steel shim from the bearing
assembly. The shim is permanently attached. If the shim is damaged or bent,
replace the bearing assembly. Failure to comply will result in diminished sensor
and ABS performance.
Remove wheel speed sensor from hub and bearing assembly (5).

Installation Procedure
Important: The new speed sensor will have a new O-ring. Dispose of the old Oring. Lubricate the new O-ring lightly with bearing grease prior to installation.

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You may also lubricate the sensor just above and below the new O-ring. DO
NOT lubricate the bore.

1. Install sensor into the hub and bearing assembly (6).


Tighten
Tighten the sensor mounting screw (5) to 18 N-m (13 lb ft).
Important: The new sensor has new mounting clips already installed on the
wire. DO NOT reuse the old clips.
2.
3.
4.
5.
6.
7.

Connect the wheel speed sensor electrical connector (2).


Install wheel speed sensor mounting clip to the frame rail.
Install the wheel speed sensor mounting clip to the control arm.
Install the hub and rotor. Refer to Brake Rotor Replacement in Disc Brakes .
Install brake caliper. Refer to Brake Caliper Replacement in Disc Brakes .
Install tire and wheel. Refer to Wheel Installation in Tires and Wheels .

Park Brake Lubrication


Document ID: 166401
Clean and lubricate the park brake lever assembly using Lubriplate GM P/N 1050109 or
the equivalent.
Plastic coated parking brake cables do not need periodic lubrication. However, before
performing service that involves the adjuster, perform the following steps:
1. Clean the exposed threads on each side of the nut.

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Important: Lubricate the threads of the adjusting rod before turning the nut
2. Lubricate the threads of the adjusting rod using Lubriplate GM P/N 1050109 or
the equivalent.

Document ID: 166401

Parking Brake Shoe Adjustment

The park brake must be adjusted any time the park brake cables have been replaced or
disconnected, if the park brake shoes have been replaced or if under heavy foot pressure
the pedal travel is less than half the pedal total travel. Before adjusting the park brake,
check the condition of the service brakes. Refer to Brake Pad Inspection in Disc Brakes
.

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1. Raise the vehicle and support the vehicle with safety stands. Refer to Lifting and
Jacking the Vehicle in General Information.
2. Remove the wheel and tire assembly. Refer to Wheel Removal in Tires and
Wheels .
3. Remove the caliper. Refer to Brake Caliper Replacement in Disc Brakes .
4. Remove the rotor. Refer to Brake Rotor Replacement in Disc Brakes .
5. Remove the park brake cable from the park brake lever.
6. Adjust the shoe diameter using the adjuster nut.
7. Turn the adjuster nut clockwise to increase the diameter until the rear wheel will
not rotate without excessive force in a forward direction.
8. Connect the park brake cable to the park brake lever.
9. Install the caliper. Refer to Brake Caliper Replacement in Disc Brakes .

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Document ID: 416728

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10. Install the rotor. Refer to Brake Rotor Replacement in Disc Brakes .
11. Install the wheel and the tire.
12. Adjust the rear park brake cables. Refer to Park Brake Cable Service/Adjustment
in Park Brake .
13. Lower the vehicle.

Parking Brake Lever Replacement


Document ID: 166412

1. Release the park brake.


2. Remove the left I/P sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges and Console.
3. Loosen the front cable at the equalizer.

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4. Remove the brake release handle.

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Removal Procedure

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5. Remove the mounting bolts and nut.


6. Remove the lever assembly.

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7. Disconnect the cable from the lever.
8. Remove the brake cable retainer from the park brake lever bracket. Press in on
the retaining fingers to remove.

Inspection Procedure

Inspect brake cable for fraying, binding or kinking.


Replace frayed, bound, or kinked brake cable.

Installation Procedure

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1. Lubricate the park brake assembly. Refer to Park Brake Lubrication in Park
Brake .

2. Install the front brake cable to the brake lever assembly.


3. Install the brake cable retainer into the park brake lever bracket. Verify the brake
cable retainer fingers expand when the retainer is inserted into the park brake
lever bracket.

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4. Install the brake lever assembly.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant

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are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
5. Install the park brake lever mounting bolts and the nut.
Tighten
Tighten the bolts and the nut to 25 N-m (18 lb ft).

6. Install the brake release handle.


7. Install the left side sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges and Console.
8. Adjust the park brake cable. Refer to Park Brake Cable Service/Adjustment in
Park Brake .

Parking Brake Cable Replacement Document ID: 164348


Removal Procedure
1. Release the park brake.
2. Raise the vehicle and support the vehicle with safety stands. Refer to Lifting and
Jacking the Vehicle in General Information.
3. Lubricate the park brake cable adjuster. Refer to Park Brake Lubrication in Park
Brake .

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4. Loosen the adjuster nut at the equalizer.

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5. Remove the front parking brake cable from the rear parking brake cables.
6. Remove the brake drum(s) and the brake shoes. Refer to Brake Shoe
Replacement in Drum Brakes.
7. Disconnect the rear cable from the park brake lever.
8. Disconnect the rear cable(s) attachments from the frame and/or axle and/or
equalizer.
9. Disconnect the cable retainer at the backing plate. Push the cable retainer fingers
in to disconnect.
10. Remove the rear cable from the vehicle.

Installation Procedure

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1. Connect the rear park brake cable(s) to the park brake lever.
1. Slide the brake cable into the brake backing plate opening.
2. Install the cable retainer into the backing plate.
3. Verify the cable retainer fingers expand when the cable retainer is
inserted into the backing plate.
4. Pull the cable end fitting as far rearward as possible.
5. Install the cable end fitting into the parking brake lever.
2. Install the brake shoes and drum(s). Refer to Brake Shoe Replacement in Drum
Brakes.

3. Route the rear cable(s) through the attachments and guides at the frame and/or
axle and/or equalizer.
4. Verify the cable retainers fingers expanded and the retainers are secure at all
locations for cable(s) removed.

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5. Strap the right rear park brake cable tight against the rear axle.
1. Tighten the strap so it does not move along the rear axle.
2. Secure the loose end of the strap back through the tabs in the buckle.
6. Adjust the park brake. Refer to Park Brake Cable Service/Adjustment in Park
Brake .
7. Lower the vehicle.

Parking Brake Cable Replacement Document ID: 167117


Removal Procedure

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Important: When routing the cable(s) through the guide loop, route the left side
cable first.

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1. Raise the vehicle and support the vehicle with safety stands. Refer toLifting and
Jacking the Vehicle in General Information.

2. Disconnect the right rear cable at the equalizer.


3. Remove the retainer.
4. Disconnect the left side sound insulator panel. Refer to Instrument Panel
Insulator Panel Replacement - Left Side in Instrument Panel, Gauges and
Console.

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5. Remove the retainer and the grommet.

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6. Disconnect the cable from the lever.

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7. Disconnect the front cable.

Installation Procedure

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1. Install the front cable.

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2. Connect the retainer and the grommet. All retaining fingers must be completely
through the hole.
3. Connect the cable to the lever.
4. Install the left side sound insulator panel. Refer to Instrument Panel Insulator
Panel Replacement - Left Side in Instrument Panel, Gauges and Console.

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5. Install the retainer.

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6. Connect the right rear cable to the equalizer and to the nut.
7. Adjust the park brake. Refer to Park Brake Cable Service/Adjustment in Park
Brake .
8. Lower the vehicle.

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Connector Part Information


Pin
A
B
C
D
E
F
G
H
J
K

Wire Color
BRN
LT GRN
PPL

YEL/BLK
TAN/WHT
PPL
PPL
BLK

12065425
10 Way F Metri-Pack 150 Series (BLK)

Circuit No.
241
867
420

1827
799
1807
680
450

Function
Ignition 3 Power
ABS Indicator Lamp Control
Brake Switch Input
Not Used
Vehicle Speed Input
ABS Diagnostic Link (UART)
Serial Data (Class 2)
Brake Warning lamp Control
Signal Ground
Not Used

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Connector Part Information


Pin
A
B

Wire Color
LT BLU

12124662
4 Way F Metri-Pack 150 Series (BRN)

Circuit No.
Function
830
LF Wheel Speed Sensor High

Not Used

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C
D
E

DK GRN
YEL
TAN

872
873
833

RF Wheel Speed Sensor High


LF Wheel Speed Sensor Low
RF Wheel Speed Sensor Low

Connector Part Information


Pin
A
B

Wire Color
RED
BLK

Step
1.

2.
3.
4.

12085030
2 Way F Metri-Pack 630 Series P2S (BLK)

Circuit No.
442
150

Function
Motor and Solenoid Power
Power Ground

Action
Value(s)
Verify that all of the EBCM
connectors are connected
properly.
Install the Scan Tool .
Turn the ignition to RUN.

Attempt to communicate with the


EBCM using the Scan Tool .

Is data being received from the EBCM?


Using the Scan Tool , check for any
DTCs.
2

Are any current or history DTCs


displayed?
1. Turn the ignition to OFF for
10 seconds.
2. Turn the ignition to RUN and
observe the ABS indicator lamp.
3

Did the ABS indicator lamp turn on for


three seconds and then turn off?
1. Turn the ignition to OFF.
4
2. Disconnect the 10-way EBCM

Yes

No

Go to Step 2

Go
to
Step
4

Go
Go to Symptom and to
Diagnostic Trouble Step
Code Table
3

Go
System is operating to
normally. Go to Step
Diagnostic Aids.
11
Go
1015V
Go to Step 5
to

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harness connector.
3. Turn the ignition to RUN.
4. Measure the voltage between the
10-way EBCM harness connector
terminal A and ground using the J
39200 .

Step
9

Caution: Unless directed


otherwise, the ignition and start
switch must be in the OFF or
LOCK position, and all electrical
loads must be OFF before
servicing any electrical
component. Disconnect the
negative battery cable to prevent
an electrical spark should a tool or
equipment come in contact with
an exposed electrical terminal.
Failure to follow these precautions
may result in personal injury
and/or damage to the vehicle or its
components.

0-2

3. Using the J 39200 , measure the


resistance between the negative
battery terminal and the 10-way
EBCM harness connector terminal
J.
Is the resistance measured within the
specified range?
1. Inspect the EBCM terminals and
the EBCM harness connector
terminals for poor terminal
contact.
2. Inspect the battery terminals and
the battery cable terminals for
6
poor connection. Refer to
Checking Terminal Contact in
Electrical Diagnosis.
Is the terminal contact or the connection
poor?
7 Replace the terminals or repair the poor

Go to Step 6

Go
to
Step
12

Go to Step 7
Go to Step 1

Go
to
Step
8

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Is the voltage measured within the


specified range?
1. Turn the ignition to OFF.
2. Disconnect the negative battery
cable.

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connection.
Is the repair complete?
Reconnect the EBCM connectors and the
battery cables.
8

Is the resistance measured within the


specified range.
1. Turn the ignition to OFF.
2. Remove the ABS fuse 22.
3. Using the J 39200 , measure the
resistance between the 10-way
10
EBCM connector terminal A and
ground.

12

Does the ABS indicator lamp stay on?


Repair open or high resistance in
CKT 451.

Is the repair complete?


1. Repair open or high resistance in
CKT 441.
13
2. Check the ABS fuse 22.
Is the repair complete?
1. Repair short to ground in
CKT 441.
2. Check the circuit breaker for
14
damage.
Is the repair complete?
Inspect CKT 441 and the 10-way EBCM
15
harness connector for physical damage

Go to Step 10

Go
to
Step
13

0-2

OL

Is the resistance measurement equal to the


specified value?
Observe the ABS indicator lamp.
11

Go to Step 18

Go
to
Step
14
Go
to
Step
21

Go to Step 1

Go to Step 1

Go to Step 1

Go
to

Go to Step 15

Go to Step 16

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Are the EBCM connectors and the battery


cables reconnected?
1. Disconnect the positive battery
cable.
2. Turn the ignition to RUN. (This is
to provide circuit continuity.)
3. Using the J 39200 , measure the
9
resistance between the positive
battery cable and the 10-way
EBCM connector terminal A.

Go to Data Link
Communications
System Check in
Wiring Systems

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which may result in a short to ground


with the 10-way EBCM harness
connector connected to the EBCM.

Step
17

Is there evidence of damage?


Repair the terminals which are damaged.
16

Is the repair complete?


Using the Scan Tool from the Special
Functions screen, turn the ABS indicator
18 off.

Refer to Instrument Panel (IP) Cluster


Replacement .

Refer to Electronic Brake Control Module


Replacement in Antilock Brake System .

Is the repair complete?


Using the Scan Tool from the Special
Functions screen, turn the ABS indicator
21 on.
Did the ABS indicator turn on?
DTC
DTC C0221
DTC C0222
DTC C0223
DTC C0225
DTC C0226

Go to Step 1

Go to Step 1

Go
to
Step
20

Go to Step 1

Go to Step 1

Go to Step 20

Go
to
Step
19

Is the repair complete?


Replace the EBCM.
20

Did the ABS indicator turn off?


Replace the Instrument Cluster.
19

Go to Step 1

Definition
DTC C0221 or C021 RF Wheel Speed Sensor Circuit Open in
Antilock Brake System
DTC C0222 or C022 RF Wheel Speed Signal Missing in Antilock
Brake System
DTC C0223 or C023 RF Wheel Speed Signal Erratic in Antilock
Brake System
DTC C0225 or C025 LF Wheel Speed Sensor Circuit Open in
Antilock Brake System
DTC C0226 or C026 LF Wheel Speed Signal Missing in Antilock

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Is the repair complete?


1. Replace the EBCM. Refer to
Electronic Brake Control Module
Replacement in Antilock Brake
System .
17
2. Check the ABS fuse 22 for an
open.

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DTC C0227
DTC C0229

DTC C0238
DTC C0241
DTC C0242
DTC C0243
DTC C0244
DTC C0245
DTC C0246
DTC C0247
DTC C0248
DTC C0251
DTC C0252
DTC C0253
DTC C0254
DTC C0265
DTC C0266

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DTC C0235
(4.3L)
DTC C0235
(2.2L)
DTC C0236
(4.3L)
DTC C0236
(2.2L)
DTC C0237
(4.3L)
DTC C0237
(2.2L)

Brake System
DTC C0227 or C027 LF Wheel Speed Signal Erratic in Antilock
Brake System
DTC C0229 or C029 Drop Out of Front Wheel Speed Signals in
Antilock Brake System
DTC C0235 or C035 Rear Wheel Speed Signal Circuit Open in
Antilock Brake System
DTC C0235 or C035 Rear Wheel Speed Signal Circuit Open in
Antilock Brake System
DTC C0236 or C036 Rear Wheel Speed Signal Circuit Missing in
Antilock Brake System
DTC C0236 or C036 Rear Wheel Speed Signal Circuit Missing in
Antilock Brake System
DTC C0237 or C037 Rear Wheel Speed Signal Erratic in Antilock
Brake System
DTC C0237 or C037 Rear Wheel Speed Signal Erratic in Antilock
Brake System
DTC C0238 or C038 Wheel Speed Mismatch in Antilock Brake
System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0241-C0254 or C041-C054 EBCM Control Valve Circuit in
Antilock Brake System
DTC C0265 or C0266 and C065 C066 EBCM Relay Circuit in
Antilock Brake System
DTC C0265 or C0266 and C065 C066 EBCM Relay Circuit in

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DTC C0267
DTC C0268
DTC C0271
DTC C0272

DTC C0274
DTC C0281

Application
Hold Down Spring Screw
Park Brake Cable Mounting Bracket Bolt
Park Brake Lever Mounting Bolts
Park Brake Lever Mounting Nut

Specification
Metric
English
4 N-m
35 lb in
17 N-m
12.6 lb ft
25 N-m
18 lb ft
25 N-m
18 lb ft

Park Brake Cable Service/Adjustment


Document ID: 163710
The park brake must be adjusted any time the park brake cables have been replaced or
disconnected, or if under heavy foot pressure the pedal travel is less than half the pedal
total travel. Before adjusting the park brake, check the condition of the service brakes.
Refer to Brake Drum Inspection in Drum Brakes or Brake Pad Inspection in Disc
Brakes. The rear brakes must be adjusted properly before adjusting the park brake.
1.
2.
3.
4.
5.

Block the front wheels.


Raise the rear axle and support the rear axle with safety stands.
Loosen the equalizer nut.
Fully release the park brake pedal.
Tighten the equalizer nut until the rear wheels will not rotate without excessive
force in a forward direction.
6. Loosen the equalizer nut until there is little or no drag when the rear wheels are
rotated in a forward direction.
7. Lower the vehicle.
8. Remove the blocks from the front wheels.

Front Brake Caliper Overhaul Document ID: 416114

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DTC C0273

Antilock Brake System


DTC C0267 or C0268 and C067 or C068 Pump Motor Circuit
Open/Shorted in Antilock Brake System
DTC C0267 or C0268 and C067 or C068 Pump Motor Circuit
Open/Shorted in Antilock Brake System
DTC C0271-C0273 or C071 or C073 EBCM Malfunction in
Antilock Brake System
DTC C0271-C0273 or C071 or C073 EBCM Malfunction in
Antilock Brake System
DTC C0271-C0273 or C071 or C073 EBCM Malfunction in
Antilock Brake System
DTC C0269 or C0274 and C069 or C074 Excessive Dump/Isolation
Time in Antilock Brake System
DTC C0281 or C081 Brake Switch Circuit in Antilock Brake
System

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Disassembly Procedure
1. Drain all the brake fluid from the caliper.

2. Pad the interior of the caliper with clean shop towels.


Caution: Do not place your fingers in front of the piston in order to catch or
protect the piston while applying compressed air. This could result in serious
injury.
3. Notice: Use just enough air pressure to ease the piston out of the bore. You can
damage a blown-out piston even with the padding.
Remove the piston from the caliper bore.

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4. Remove the boot from the caliper bore. Do not scratch the housing bore.

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5. Remove the piston seal from the caliper bore. Do not use a metal tool.

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6. Remove the bleeder valve from the caliper body.


7. Clean the bleeder valve, the caliper bore, the caliper passages and the piston
with denatured alcohol. Dry the parts and blow out the brake fluid passages. Use
dry and filtered compressed air.
8. Replace the piston or the caliper if any of the following conditions exist:
o Scoring on the piston surface or in the caliper bore
o Corrosion on the piston
o Chrome plating damage on the piston
o Corrosion in the caliper bore. Use crocus cloth in order to polish light
corrosion from the caliper bore. Replace the caliper if the corrosion
cannot be removed
o Pitting in the caliper bore

Assembly Procedure
Tools Required
J 26267 Piston Seal Installer

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1. Lubricate the new piston seal, the caliper bore, and the piston with clean brake
fluid.

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2. Install the piston seal. Make sure the piston seal is not twisted in the caliper bore
groove.

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3. Install the boot on the piston.

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4. Install the piston in the caliper bore.

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5. Install the boot into the caliper housing bore using J 26267 .

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6. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the bleeder valve in the caliper body.

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Tighten
Tighten the bleeder valve to 12 N-m (110 lb in).

Rear Brake Caliper Overhaul


Document ID: 416116

1. Drain all the brake fluid from the caliper.

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2. Pad the interior of the caliper with clean shop towels.
Caution: Do not place your fingers in front of the piston in order to catch or
protect the piston while applying compressed air. This could result in serious
injury.
3. Notice: Use just enough air pressure to ease the piston out of the bore. You can
damage a blown-out piston even with the padding.
Remove the piston from the caliper bore.

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Disassembly Procedure

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4. Remove the boot from the caliper bore. Do not scratch the housing bore.

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5. Remove the piston seal from the caliper bore. Do not use a metal tool.

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6. Remove the bleeder valve and bleeder valve cap from the caliper body.
7. Remove the guide pins and guide pin sleeves from the anchor bracket.
8. Clean the following components with denatured alcohol.
o The bleeder valve
o The caliper bore
o The caliper passages
o The piston
o The lining contact area on the anchor bracket.
9. Dry the parts and blow out the brake fluid passages. Use dry and filtered
compressed air.
10. Replace the piston or the caliper if any of the following conditions exist:
o Scoring on the piston surface or in the caliper bore
o Corrosion on the piston
o Chrome plating damage on the piston
o Corrosion in the caliper bore. Use crocus cloth in order to polish light
corrosion from the caliper bore. Replace the caliper if the corrosion
cannot be removed.
o Pitting in the caliper bore
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
11. Replace the bleeder valve cap.
Tighten

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Tighten the bleeder valve to 12 N-m (110 lb in).

Assembly Procedure

1. Lubricate the new piston seal, the caliper bore, and the piston with clean brake
fluid.

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2. Install the piston seal. Make sure the piston seal is not twisted in the caliper bore
groove.
3. Install the boot into the caliper housing bore by hand.

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4. Install the piston in the caliper bore. Push the piston to the bottom of the bore by
hand.

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5. Install the boot on the piston.

Master Cylinder Replacement


Document ID: 161886
Removal Procedure

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1. Apply the parking brake.

2. Disconnect the brake pipes.


3. Plug the pipes in order to prevent brake fluid loss or contamination.

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4. Remove the master cylinder nuts.
5. Remove the master cylinder.

Installation Procedure

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1. Before installing the master cylinder, bench bleed the master cylinder. Refer to
Master Cylinder Bench Bleeding in Hydraulic Brakes .
2. Install the master cylinder.

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3. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the master cylinder nuts.

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Tighten
Tighten the master cylinder nuts to 36 N-m (27 lb ft).

4. Connect the brake pipes.


Tighten
Tighten the pipe fittings to 17 N-m (13 lb ft).
5. Bleed the brakes. Refer to Hydraulic Brake System Bleeding in Hydraulic
Brakes .

Master Cylinder Overhaul


Document ID: 709767
Disassembly Procedure
Notice: Do not hone the master cylinder bore. When the brake master cylinder is
overhauled, it is recommended that the cylinder body be replaced rather than
CLEANED UP by honing the bore. The master cylinder has a hard, highly polished
BEARINGIZED surface, which is produced by diamond boring followed by ball or
roller burnishing under heavy pressure. Honing will destroy this hard smooth surface
and cause rapid wear of the rubber cups.

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1.
2.
3.
4.

Remove the reservoir cap.


Drain the brake fluid from the reservoir.
Remove the reservoir and two grommets from the master cylinder body.
Clamp the master cylinder mounting flange in a vise.

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5. Remove the snap ring.
6. Remove the primary piston assembly from the master cylinder body.
7. Remove the seal.

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8. Caution: If air pressure is used to remove the secondary piston, place the open
end of the cylinder bore approximately 25 mm (1 in) from a padded workbench
or other surface to catch the piston when it comes out of the bore. Apply low air
pressure very carefully to ease the piston out of the bore. Never point the open
end of the bore at anyone when applying air pressure. The piston may come out
of the bore with considerable force and cause personal injury.
Remove the secondary piston from the master cylinder body.
Plug the rear port. Apply a small amount of air pressure to the front port.
9. Remove the seals.
10. Remove the spring retainer and the spring from the master cylinder body.
Notice: Use only approved solvents when cleaning or flushing the master
cylinder and related components. Solvents which contain traces of mineral oil or
other contaminants will damage the rubber parts in the system.
11. Clean all the parts using the following procedure:
o Clean the metal parts in denatured alcohol.
o Clean the rubber parts in clean brake fluid.
12. Inspect the diaphragm for cuts, cracks, or swelling.
13. Inspect the cylinder bore for scoring or corrosion.
o Replace the master cylinder if corrosion is present.
o Do not attempt to hone the cylinder bore.
14. Inspect the reservoir for cracks.

Assembly Procedure

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1. Lubricate the grommets, seals, and the cylinder bore with clean DOT 3 motor
vehicle brake fluid.
2. Use new seals when assembling the master cylinder.
3. Install the secondary piston spring.
4. Install the spring retainer.

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5. Install the primary seal on the secondary piston.
6. Install the secondary seal on the secondary piston.

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7. Install the secondary piston in the master cylinder body.


8. Install the seal on the primary piston.

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9. Install the primary piston assembly in the master cylinder body.
10. Install the snap ring.
11. Compress the primary piston in order to install the snap ring.

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12. Install two new grommets to the master cylinder.


13. Install the reservoir on the master cylinder body.
14. Install the reservoir cap.

Combination Valve Replacement


Document ID: 201236
Removal Procedure
Important: Prior to replacement of the combination valve, note the identification code
on the valve. You do not need to have the proper code when replacing the valve.

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1.
2.
3.
4.

Remove the combination valve electrical connector (10).


Remove the front and rear brake pipes.
Remove three allen bolts (11) securing combination valve (12) to the BPMV (4).
Remove the combination valve from the BPMV.
Important: Do not reuse the transfer tubes (13). Always install new transfer
tubes with a new combination valve.

5. Important: Verify that the replacement combination valve has the same pin
punched identification code as the code found on the old part.
Remove two transfer tubes (13).

Installation Procedure

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1. Install two new transfer tubes (13) into the combination valve (12) until fully
seated.
2. Install combination valve (12) to BPMV (4).

3. Install three combination valve Allen bolts (11).


Tighten
Tighten bolts first to 8 N-m (6 lb ft), then to 16 N-m (12 lb ft).
4. Front and rear brake pipes to combination valve.
Tighten
Tighten brake pipe fittings to 17 N-m (13 lb ft).
5. Connect combination valve electrical connector (10).
Important: Verify that the combination valve metering rod is depressed during
bleeding.
6. Bleed the brake system. Refer to Antilock Brake System Automated Bleed
Procedure in Antilock Brake System .

Power Vacuum Brake Booster Replacement


Document ID: 163825
Removal Procedure
1. Apply the parking brake.
2. Remove the master cylinder away from the vacuum booster. Refer to Master
Cylinder Replacement in Hydraulic Brakes .
3. Support the master cylinder.

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Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

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4. Disconnect the vacuum hose from the vacuum booster.


5. Remove the left closeout insulator panel. Refer to Instrument Panel Insulator
Panel Replacement - Left Side in Instrument Panel, Gauges and Console.

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6. Remove the pushrod retainer from the brake pedal pin.

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7. Remove the stoplamp switch from the brake pedal pin.


8. Remove the pushrod from the brake pedal pin.
9. Remove the steering column support bracket. Refer to Steering Column Bracket
Replacement in Instrument Panel, Gauges and Console.

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10. Remove the vacuum booster mounting nuts.
11. Remove the vacuum booster assembly.
12. Remove the gasket.

Installation Procedure

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1. Install the vacuum booster assembly and the gasket.


Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Install the vacuum booster mounting nuts on the vacuum booster.
Tighten
Tighten the vacuum booster mounting nuts to 40 N-m (30 lb ft).
3. Install the steering column support bracket. Refer to Steering Column Bracket
Replacement in Instrument Panel, Gauges and Console.

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4. Position the pushrod on the brake pedal pin.


5. Install the stoplamp switch to the brake pedal pin.

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6. Install the pushrod retainer to the brake pedal pin.
Ensure that the retainer snaps into place.
7. Install the left closeout insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges and Console.

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8. Install the vacuum hose on the vacuum booster.


9. Install the master cylinder. Refer to Master Cylinder Replacement in Hydraulic
Brakes .

Document ID: 163825

Stop Lamp Switch Replacement


Document ID: 166214
Removal Procedure
Caution: Before servicing any electrical component, the ignition and start
switch must be in the OFF or LOCK position and all electrical loads must be
OFF, unless instructed otherwise in these procedures. If a tool or equipment
could easily come in contact with a live exposed electrical terminal, also
disconnect the negative battery cable. Failure to follow these precautions may
cause personal injury and/or damage to the vehicle or its components.
1. Disconnect the battery negative cable.
2. Remove the left closeout insulator panel. Refer to Instrument Panel Insulator
Panel Replacement - Left Side in Instrument Panel, Gauges and Console.

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3. Disconnect the electrical connector from the stoplamp switch.

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4. Remove the pushrod retainer from the brake pedal pin.

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5. Remove the stoplamp switch from the brake pedal pin.

Installation Procedure

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1. Install the stoplamp switch to the brake pedal pin.

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2. Install the pushrod retainer on the brake pedal pin.


Ensure that the retainer snaps into place.

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3. Install the electrical connector on the stoplamp switch.
4. Install the left closeout insulator panel. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges and Console.
5. Connect the battery negative cable.

Universal Joint Replacement - Nylon Injected Ring


Document ID: 1202485

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Tools Required

J 9522-3 U Joint Bearing Separator


J 9522-5 U Joint Bearing Spacer Remover

Disassembly Procedure
Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or
deform the tube causing an imbalance or unsafe condition. Always clamp on one
of the yokes and support the shaft horizontally. Avoid damaging the slip yoke
sealing surface. Nicks may damage the bushing or cut the lip seal.

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3. Place the universal joint so that the lower ear of the yoke is supported on a
30 mm (1 1/8 in) socket.

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1. Support the propeller shaft in a line horizontal with the table of a press.
2. Mark the propeller shaft as to which end is the transmission end and which end
goes to the rear axle.

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4. In order to shear the plastic retaining ring on the bearing cup, place J 9522-3 on
the open horizontal bearing cups. Press the lower bearing cup out of the yoke
ear.
5. If you do not completely remove the bearing cup, lift the cross and insert J 95225 between the seal and the bearing cup you are removing. Continue to press the
bearing cup out of the yoke.
6. Rotate the propeller shaft. Press the opposite bearing cup out of the yoke.
7. Mark the orientation of the slip yoke to the tube for proper reassembly.
8. Remove the cross from the yoke.
9. Remove the remaining universal joint parts from the yoke. If you are replacing
the front universal joint, remove the bearing cups in the slip yoke in the same
manner.
10. Inspect the retaining ring grooves for plastic.
11. Inspect the bearing cup bores in the yoke ears for burrs or imperfections.
12. Clean the remains of the sheared plastic bearing retainers from the grooves in
the yoke.
13. The sheared plastic may prevent the bearing cups from pressing into place and
thus prevent the bearing retainers from properly seating.

Assembly Procedure
1. Remove the bearing cups from the universal joint.

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2. Assemble 1 bearing cup part way into 1 side of the yoke.


3. Turn the yoke ear toward the bottom.
4. Assemble the cross into the yoke so the trunnion seats freely into the bearing
cup.
5. With the trunnion seated in the bearing cup, press the bearing cup into the yoke
until the bearing cup is flush with the yoke ear.

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6. Assemble the opposite bearing cup part way into the yoke ear.
7. Ensure that the trunnions start straight and true into both bearing cups.
8. Press the opposite bearing cup into the yoke ear while working the cross all the
time in order to inspect for a free unbinding movement of the trunnions in the
bearing cups.

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Important: If there seems to be a hangup or binding, stop pressing, and inspect


the needle bearings for misalignment in the bearing cup.
9. Press the bearing cup into the yoke until the bearing retainer groove clears the
inside of the yoke.

10. Assemble the bearing retainer in the retainer groove.


11. Continue pressing until you can snap both retainers into place.

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12. If seating the retainer is difficult, spring the yoke slightly with a firm blow from
a dead blow hammer.

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13. It may be necessary to lubricate the snap ring with a slight amount of chassis
grease so the snap ring seats in the bearing cup groove.

Universal Joint Replacement - External Snap Ring


Document ID: 1202488
Tools Required

J 9522-3 U-Joint Bearing Separator


J 9522-5 U-Joint Bearing Spacer Remover

Notice: Never clamp propeller shaft tubing in a vise. Clamping could dent or deform
the tube causing an imbalance or unsafe condition. Always clamp on one of the yokes
and support the shaft horizontally. Avoid damaging the slip yoke sealing surface. Nicks
may damage the bushing or cut the lip seal.
1. Support the propeller shaft in a line horizontal with the table of a press.
2. Mark the propeller shaft in order to show which end connects to the transmission
and which end goes to the rear axle.
3. Disassemble the snap rings by pinching the ends together with a pair of pliers.
4. If the ring does not readily snap out of the groove in the yoke, tap the end of the
cup lightly in order to relieve the pressure from the ring.

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5. Place the universal joint so that the lower ear of the yoke is supported on a
30 mm (1-1/8 in) hex head socket or a 27 mm (1-1/16 in) socket.

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Disassembly Procedure

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6. Place J 9522-3 on the open horizontal bearing cups. Press the lower bearing cup
out of the yoke ear.
7. If you do not completely remove the bearing cup, lift the cross and insert J 95225 between the seal and the bearing cup you are removing. Continue pressing the
bearing cup out of the yoke.
8. Rotate the propeller shaft . Press the opposite bearing cup out of the yoke.
9. Mark the orientation of the slip yoke to the tube for proper reassembly.
10. Remove the cross from the yoke.
11. Remove the remaining universal joint parts from the yoke.
12. If you are replacing the front universal joint, remove the bearing cups in the slip
yoke in the same manner.
13. Inspect the retaining ring grooves for dirt, corrosion, or pieces of the old ring.
14. Inspect the bearing cup bores for burrs or imperfections.
15. Clean the retaining ring grooves. Corrosion, dirt, rust, or pieces of the old
retaining ring may prevent the bearing cups from pressing into place or prevent
the bearing retainers from properly seating.

Assembly Procedure
1. Remove the bearing cups from the universal joint.

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2. Assemble 1 bearing cup part way into 1 side of the yoke. Turn the yoke ear
toward the bottom.
3. Assemble the cross into the yoke so that the trunnion seats freely into the
bearing cup.

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4. With the trunnion seated in the bearing cup, press the bearing cup into the yoke
until the bearing cup is flush with the yoke ear.
5. Install the opposite bearing cup part way into the yoke ear.
6. Ensure that the trunnions start straight and true into both bearing cups.
7. Press the opposite bearing cup into the yoke ear while working the cross all the
time in order to inspect for free unbinding movement of the trunnions in the
bearing cups.

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Important: If there seems to be a hang up or binding, stop pressing. Inspect the


needle bearings for misalignment in the bearing cup.
8. Press the bearing cup into the yoke until the bearing cup retainer groove is
visible over the top of the bearing cup.

9. Assemble the bearing retainer in the retainer groove.


10. Continue pressing until both retainers can be snapped into place.

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11. If the retainer is difficult to seat, the yoke can be sprung slightly with a firm
blow from a dead blow hammer.
12. It may be necessary to lubricate the snap ring with a slight amount of chassis
grease so that the snap ring seats in the bearing cup groove.

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Ignition Lock Cylinder Replacement - On Vehicle


Document ID: 1460781
Removal Procedure
1. Disconnect the negative battery cable. Refer to Engine Electrical.
Caution: Refer to SIR Caution in Cautions and Notices.

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4. Remove the screws that retain the lower steering column trim cover to the
steering column.
5. Remove the lower steering column trim cover by tilting the trim cover down and
slide it back in order to disengage the locking tabs..
6. Remove the screws that retain the upper steering column trim cover to the
steering column.

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2. Disable the SIR system. Refer to Disabling the SIR System in SIR.
3. Lower the hush and knee bolster. Refer to Knee Bolster Replacement in
Instrument Panel.

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7. With the key installed, turn the key to the RUN position.
8. Gently lift the upper trim cover up so that you may install an allen wrench into
the hole on top of the lock cylinder housing.
Push down on the allen wrench to release the tab on the lock cylinder inside the
lock cylinder housing.

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9. Slide the lock cylinder out of the lock cylinder housing.

Installation Procedure

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1. Align the upper steering column trim cover.


Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Install the screws that retain the upper steering column trim cover to the steering
column.
Tighten
Tighten the upper steering column trim cover retaining screws to 1.4 N-m
(12 lb in).

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3. Install the key into the lock cylinder.


Important: The gears between the ignition switch and the lock cylinder housing
must be in the correct position. Failure to do so will cause a misalignment of the
gears in the ignition switch and the lock cylinder housing, which may result in a
NO START or BATTERY DRAIN.
4. Use a screwdriver to rotate the lock cylinder housing gear clockwise to the start
position - allowing it to spring return into the RUN position.

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5. Align the lock cylinder and install into the lock cylinder housing.
6. Install the lower steering column trim cover.

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7. Install the screws that retain the lower steering column trim cover to the steering
column.
Tighten
Tighten the lower steering column trim cover retaining screws to 6 N-m
(53 lb in).

Multifunction, Turn Signal, and Hazard Switch Replacement - On


Vehicle
Document ID: 288867
Removal Procedure

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1. Ensure the turn signal lever on the multifunction switch is in the neutral position
or the off position.
2. Remove the knee bolster. Refer to Knee Bolster Replacement in Instrument
Panel, Gauges and Console.
3. Loosen the steering column bracket nuts.
4. Remove the steering column upper and lower shrouds. Refer to Steering Column
Trim Cover Replacement - On Vehicle in Steering Wheel and Column Standard .

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8. Install the steering wheel. Refer toSteering Wheel Replacement in Steering


Wheel and Column - Standard .
9. Install the hush and knee bolster. Refer to Knee Bolster Replacement in
Instrument Panel.
10. Enable the SIR system. Refer to Enabling the SIR System in SIR.
11. Connect the negative battery cable. Refer to Engine Electrical.

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5. Remove the 2 wire harness straps from the steering column wire harness.
6. Remove the connector position assurance (CPA) retainer from the brake
transmission shift interlock (BTSI).
7. Disconnect the steering column bulkhead connector from the vehicle wire
harness.
8. Disconnect the gray and the black connectors of the switch from the column
bulkhead connector.
9. Remove the multifunction switch to the steering column mounting screws.
10. Remove the multifunction turn signal/hazard switch.

Installation Procedure

1. Install the multifunction turn signal/hazard switch.


o Use a small blade screwdriver in order to compress the electrical contact.
Move the multifunction switch into the position.
o

Ensure the electrical contact rests on the canceling cam assembly.

Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Install the multifunction switch to steering column mounting screws.
Tighten

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Tighten the multifunction switch mounting screws to 6 N-m (53 lb in).


3. Install the connectors of the switch to the column bulkhead connector.
4. Install the steering column bulkhead connector to the vehicle wire harness.
5. Install the connector and the connector position assurance (CPA) retainer to the
BTSI.
6. Install the 2 wire straps on the steering column wire harness.
7. Install the steering column upper and lower shrouds. Refer to Steering Column
Trim Cover Replacement - On Vehicle in Steering Wheel and Column Standard .
8. Install the steering column bracket nuts.

Tighten the steering column bracket nuts to 30 N-m (22 lb ft).


9. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel,
Gauges and Console.
10. Ensure the lever is in the center or the OFF position.

Electronic Column Lock Module Replacement


Document ID: 793607
Tools Required

J 23653-SIR SIR Lock Plate Compressor


J-42759 Ignition Switch Connector Release Tool

Removal Procedure
Caution: This vehicle is equipped with a Supplemental Inflatable Restraint
(SIR) System. Failure to follow the correct procedure could cause the following
conditions:
o
o
o

Air bag deployment


Personal injury
Unnecessary SIR system repairs

In order to avoid the above conditions, observe the following guidelines:


Refer to SIR Component Views in order to determine if you are
performing service on or near the SIR components or the SIR wiring.
o If you are performing service on or near the SIR components or the SIR
wiring, disable the SIR system. Refer to Disabling the SIR System.
2. Disable the SIR system. Refer to Disabling the SIR System in SIR.
o

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Tighten

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Important: Remove the SIR coil from the steering shaft and let the SIR coil
hang freely.
3. Remove the SIR coil. Refer to Steering Wheel Inflatable Restraint Module Coil
Replacement in SIR .

4. Install the J 23653-SIR to the steering shaft and compress the shaft lock shield
(2).
5. Remove the lock shield retainer from the steering column shaft.
6. Remove the J 23653-SIR from the steering shaft.

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7. Remove the following parts from the steering shaft:

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1. Shaft lock shield (4)


2. Turn signal cancel cam (3)
8. Rotate the steering column lock cylinder to the OFF-LOCK position.

9. Insert a small screwdriver into the slot on the electronic lock module and push
down on the park lock cable locking tab and remove park lock cable (1) from the
electronic lock module (column shift only).

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10. Disconnect the electric park lock (1) electrical connector (2) (floorshift only).

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11. Unsnap the electric park lock (2) off of the electronic lock module (1)
(floorshift only).

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12. Rotate the key alarm switch connector from the electronic lock module.
13. Disconnect the passlock electrical connector from the electronic lock module.

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14. Disconnect the ignition switch (2) from the electronic lock module using the J42759.
15. Remove the ignition switch (2) from the electronic lock module (2).
16. Let the ignition switch (2) hang freely.

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17. Remove the electronic lock module (1) mounting screws (2).
18. Remove the electronic lock module (1) from the steering column housing.

Installation Procedure

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1. Install the electronic lock module (1) to the steering column housing.
2. Install the electronic lock module(1) mounting screws (2).

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3. Install the ignition switch (2) to the electronic lock module (2).

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4. Connect the passlock electrical connector from the lock module


5. Rotate the key alarm switch connector to the electronic lock module.

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6. Snap the electric park lock (2) onto the electronic lock module (1).(floorshift
only)

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7. Connect the electric park lock (1) electrical connector (2) (floorshift only).

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8. Install park lock cable (1) to the electronic lock module (column shift only).

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9. Install the following parts to the steering shaft:


1. Turn signal cancel cam (3)
2. Shaft lock shield (4).

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10. Install the J 23653-SIR to the steering shaft and compress the shaft lock shield
(2).
11. Install the lock shield retainer to the steering column shaft.
12. Remove the J 23653-SIR from the steering column shaft.
13. Install the SIR coil. Refer to Steering Wheel Inflatable Restraint Module Coil
Replacement in SIR .
14. Enable the SIR system. Refer to Enabling the SIR System in SIR.

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Lower Intermediate Steering Shaft Replacement


Document ID: 416604
Removal Procedure
1. Turn the steering wheel so that the front wheels are pointing straight ahead.
2. Turn the ignition switch to the lock position and remove the key.

3. Remove the air cleaner assembly. Refer to Intake Air Resonator Replacement in
Engine Controls 2.2L or Air Cleaner Assembly Replacement in Engine Controls
4.3L.

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4. Remove the intermediate shaft shield from the lower intermediate shaft.

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Note the relationship of the lower intermediate shaft to the upper intermediate
shaft and the lower intermediate shaft to the steering gear input shaft in order to
ensure proper installation.

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5. Remove the bolt that retains the lower intermediate shaft coupling to the steering
gear input shaft.

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6. Remove the lower intermediate shaft from the vehicle.
1. Slide the lower intermediate shaft rearward in order to remove the lower
intermediate shaft coupling from the steering gear input shaft.
2. Slide the lower intermediate shaft forward in order to remove the lower
intermediate shaft from the upper intermediate shaft.

Installation Procedure

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1. Install the lower intermediate shaft.


1. Slide the lower intermediate shaft rearward in order to install the lower
intermediate shaft to the upper intermediate shaft.
2. Slide the lower intermediate shaft forward in order to install the lower
intermediate shaft coupling to the steering gear input shaft.

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2. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.

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Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the bolt that retains the lower intermediate shaft coupling to the steering
gear input shaft.
Tighten
Tighten the lower intermediate shaft coupling to the steering gear input shaft
bolt to 35 N-m (25 lb ft).

3. Install the shield to the lower intermediate shaft.


4. Install the air cleaner assembly. Refer to Intake Air Resonator Replacement in
Engine Controls 2.2L or Air Cleaner Assembly Replacement in Engine Controls
4.3L.

Turn Signal and Multifunction Switch Assembly - Disassemble - Off


Vehicle Document ID: 447845
1. Remove the upper and lower trim covers. Refer to Trim Covers, Shift Lever Seal
- Disassemble - Off Vehicle in Steering Wheel and Column - Standard .

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2. Remove the wire harness assembly (1) from the wire harness strap (2).
3. Disconnect the turn signal and multifunction switch assembly connector from
the inflatable restraint steering wheel module coil connector.

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4. Slide the 2 connectors (2) of the turn signal and multifunction switch assembly
out of the bulkhead connector (1).

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5. Remove the 2 pan head tapping screws (1) from the turn signal and
multifunction switch assembly (2).
6. Remove the turn signal and multifunction switch assembly (2) from the steering
column housing assembly.

Document ID: 447845

Ignition and Key Alarm Switch Assembly - Disassemble - Off Vehicle


Document ID: 1460758
Tools Required
J-42759 Ignition Switch Connector Release Tool

Removal Procedure
1. Disconnect the negative battery cable. Refer to Engine Electrical.
Caution: Refer to SIR Caution in Cautions and Notices.
2. Disable the SIR system. Refer to Disabling the SIR System in SIR.
3. Remove the hush and knee bolster. Refer to Knee Bolster Replacement in
Instrument Panel.
4. Remove the steering column trim covers. Refer to Trim Covers, Shift Lever Seal
- Disassemble - Off Vehicle in Steering Wheel and Column - Tilt .
5. With the key installed, turn the key to the RUN position.

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6. Install an allen wrench into the hole on top of the lock cylinder housing.
Push down on the allen wrench to release the tab on the lock cylinder inside the
lock cylinder housing.

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7. Slide the lock cylinder out of the lock cylinder housing.
8. Disconnect the passlock and key buzzer from the lock cylinder housing.

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9. Insert J-42759 into the lock cylinder housing to release the tabs on the ignition
switch.
10. Pull the ignition switch out of the lock cylinder housing.
11. Disconnect the connector from the ignition switch.

Steering Column Accident Damage Inspection - Off Vehicle Document ID: 447635
Inspection Procedure

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Notice: Vehicles involved in accidents that result in any of the following kinds
of damage or situations, may also have a damaged or misaligned steering
column:
o Frame damage
o Major body damage
o Sheet metal damage
o If the steering column has been impacted
o If the supplemental inflatable restraints system was deployed

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Check for jacket assembly collapse by measuring the distance from the lower
edge of the upper jacket to a defined point on the lower jacket. If measured
dimensions are not within specifications, a new jacket must be installed.

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Check the capsules on the steering column bracket assembly: all must be
securely seated in the bracket slots and checked for any loose conditions when
pushed or pulled by hand. If not, the bracket should be replaced if bolted to the
jacket assembly. If the bracket is welded to the jacket assembly replace the
jacket assembly.

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Notice: Before the shaft is rotated, remove the inflatable restraint coil assembly
from the steering column and allow it to hang freely. Failure to do so may
damage the coil assembly.
Visually inspect steering shaft for sheared injected plastic. If steering shaft
shows sheared plastic, a new steering shaft must be installed.

Any frame damage that could cause a bent steering shaft must have the steering
shaft runout checked in the following manner. Using a dial indicator at the lower
end of the steering shaft, have the steering wheel rotated. Runout must not
exceed 1.60 MM.

Tie Rod Replacement Document ID: 289609


Removal Procedure
Tools Required
J 6627-A Tie Rod Puller
1. Raise and suitably support the vehicle with safety stands. Refer to Lifting and
Jacking the Vehicle in General Information.

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2. Remove the cotter pin from outer tie rod ball stud nut.
3. Remove the outer tie rod ball stud nut.

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4. Remove the inner tie rod ball stud nut.
Notice: Do not attempt to disconnect a steering linkage joint by driving a wedge
between the joint and the attached part. Seal damage may result which will cause
premature failure of the joint.
5. Important: Use the proper tool in order to separate all tie rods and ball joints.

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Remove the outer tie rod ball stud from the steering knuckle using J 6627-A .

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6. Remove the inner tie rod ball stud from the relay rod using J 6627-A .
7. Perform the following steps in order to remove the tie rod ends from the adjuster
tube:
1. Loosen the clamp bolts.
2. Unscrew the assemblies.
8. Inspect for the following possible conditions:
o The tie rod ends for damage
o The tie rod end seals for excessive wear
o The tie rod threads for damage
o The tie rod ends for damage
o The ball stud threads for damage
o The adjuster tube for bending

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o The adjuster tube for damaged threads


9. Clean the following components:
o The ball stud threads
o The ball stud nut
o The tapered surfaces

Installation Procedure
Tools Required
J 29193 Steering Linkage Installer (12 mm)
J 29194 Steering Linkage Installer (14 mm)
Important: If the tie rod ends were removed, lubricate the tie rod ends with
chassis lubricant.
1. Connect the tie rod ends to the adjuster tube.
Ensure that the number of threads on both the inner and the outer tie rod ends
are equal within three threads.

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2. Install the inner tie rod ball stud to the relay rod.
Ensure that the seal is on the stud.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.

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Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
3. Seat the taper using J 29193 or J 29194 .
Tighten
Tighten J 29193 or J 29194 to 54 N-m(40 lb ft).
4. Remove J 29193 or J 29194 from inner tie rod ball stud.
5. Install the new nut to the inner tie rod ball stud.

Tighten the inner tie rod ball ball stud nut to 53 N-m (39 lb ft).

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6. Connect the outer tie rod ball stud to the steering knuckle.
Ensure that the seal is on the stud.

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Tighten

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7. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Seat the taper using J 29193 or J 29194 .
Tighten
Tighten J 29193 or J 29194 to 54 N-m(40 lb ft).
8. Remove J 29193 or J 29194 from outer tie rod ball stud.
9. Install the nut to the outer tie rod ball stud.
Tighten
Tighten the outer tie rod ball stud nut to 53 N-m (39 lb ft).
Important: Do not back the nut off in order to align the cotter pin hole.
Advance the nut in order to align the nut slot with the cotter pin hole.
10. Install the new cotter pin to the outer tie rod stud nut.
11. Spread the cotter pin ends.
12. Lower the vehicle.
13. Adjust the front toe. Refer to Front Toe Adjustment in Wheel Alignment.

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14. Position the two clamps (2) between the locating dimples (1) at either end of the
adjuster tube.

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15. The clamps must be positioned within the correct angular travel, as shown.
16. Ensure that the clamp slot (2) is not aligned with the adjuster tube slot (1).
17. Maintain the position of each tie rod end as the clamps are tightened in order to
ensure free movement of each joint.

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18. When clamps are tightened to specifications, the ends may touch.
19. Install the adjuster tube clamp bolts.
Tighten
Tighten the adjuster tube clamp bolts to 21 N-m (16 lb ft).

Document ID: 289609

Idler Arm Replacement Document ID: 289611


Removal Procedure
Tools Required
J 24319-B Universal Steering Linkage Puller
1. Raise and suitably support the vehicle with safety stands. Refer to Lifting and
Jacking the Vehicle in General Information.
2. Remove the idler arm mounting bolt nuts.
3. Remove the idler arm mounting bolts from the frame.

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4. Important: Use the proper tool in order to separate all ball joints.
Remove the relay rod stud nut.

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5. Disconnect the relay rod from the idler arm using J 24319-B .
6. Remove the idler arm.
7. Inspect the ball stud threads for damage.
8. Inspect the ball stud seal for cuts or other damage.
9. Clean the threads on the ball stud.
10. Clean the threads on the ball stud nut.

Installation Procedure
Tools Required

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J 29193Steering Linkage Installer (12 mm)


J 29194Steering Linkage Installer (14 mm)

1. Position the idler arm on the frame.

2. Install the idler arm mounting bolts.


Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
3. Install the idler arm mounting bolt nuts.
Tighten
Tighten the idler arm mounting bolt nuts to 108 N-m (79 lb ft).
4. Install the idler arm to the relay rod ball stud.
Ensure that the seal is on the stud.

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5. Seat the taper using J 29193 or J 29194 .


Tighten
Tighten the J 29193 or J 29194 to 82 N-m (60 lb ft).
6. Remove J 29193 or J 29194 from relay rod stud.
7. Install the new nut to the relay rod ball stud.
Tighten
Tighten the relay rod ball stud nut to 47 N-m (35 lb ft).
8. Lower the vehicle.
9. Adjust the front toe. Refer to Front Toe Adjustment in Wheel Alignment.

Pitman Arm Replacement Document ID: 289616


Removal Procedure
Tools Required

J 24319-B Steering Linkage Puller


J 29107-A Pitman Arm Puller
J 6632-01 Pitman Arm Remover

1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle
in General Information.

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2. Important: Use the proper tool in order to remove the relay ball stud nut.
Remove the relay rod ball stud at the pitman arm.

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3. Remove the relay rod ball stud from the pitman arm using J 24319-B .
Notice: Do not hammer on the pitman arm, pitman arm shaft or puller. Damage
to the pitman arm or steering gear may result.
4. Remove the pitman arm nut and washer from the steering gear.

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5.
6.
7.
8.

Remove the pitman arm from steering gear using J 6632-01 or J 29107-A .
Inspect the ball stud threads for damage.
Inspect the ball stud seals for excessive wear.
Clean the threads on the ball stud.

Installation Procedure
Tools Required

J 29193 Steering Linkage Installer (12 mm)


J 29194 Steering Linkage Installer (14 mm)

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1. Install the pitman arm to the pitman arm shaft.

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Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Install the pitman arm washer and nut to the pitman arm shaft.

Tighten the pitman arm shaft nut to 250 N-m (185 lb ft).
3. Install the relay rod ball stud to the pitman arm.
Ensure the seal is on the stud.

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4. Seat the taper using J 29193 or J 29194 .
Tighten
Tighten J 29193 or J 29194 to 62 N-m (48 lb ft).
5. Remove J 29193 or J 29194 from the relay rod ball stud.
6. Install the new nut to the relay rod ball stud.
Tighten
Tighten the relay rod ball stud nut to 82 N-m (60 lb ft).

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Tighten

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7. Lower the vehicle.

Document ID: 289616

Document ID: 289866


Removal Procedure
Tools Required
J 25034-C Power Steering Pump Pulley Remover
1. Remove the upper fan shroud. Refer to Engine Coolant Fan Shroud
Replacement in Engine Cooling.
2. Remove the drive belt. Refer to Drive Belt Replacement in Engine Mechanical
4.3L.
3. Remove the fan clutch from the water pump. Refer to Fan Clutch Replacement
in Engine Cooling.

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4. Install J 25034-C to the power steering pump pulley.

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Ensure that the pilot bottoms in the pump shaft by turning the nut to the top of
the pilot bolt.
5. Hold the pilot bolt.
6. Turn the nut clockwise.

7. Remove the power steering pump pulley.


8. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle
in General Information.
9. Remove steering linkage shield. Refer to Steering Linkage Shield Replacement
in Steering Linkage.
10. Place a drain pan below the pump.
11. Disconnect the power steering inlet hose from the power steering pump.
12. Lower the vehicle.

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13. Disconnect the power steering outlet hose from the power steering pump.
14. Cap the power steering pump hoses.

15. Remove the filler neck tube.

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16. Remove the power steering rear bracket nut from the engine stud.
17. Remove the power steering lower retaining nut from the engine stud.

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18. Remove the power steering pump front mounting bolts.


19. Remove the power steering pump.

Installation Procedure
Tools Required
J 25033-C Power Steering Pump Pulley Installer

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1. Install the power steering pump.
2. Install the power steering pump front mounting bolts.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring

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replacement or fasteners requiring the use of thread locking compound or sealant


are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
3. Install the power steering pump front mounting bolts.
Tighten

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4. Install the rear bracket nut to the engine stud.
5. Install the power steering pump lower retaining nut to engine stud.
Tighten
Tighten the power steering rear bracket nut and the lower retaining nut to 41 Nm (31 lb ft).

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Tighten the power steering pump front mounting bolts to 50 N-m (37 lb ft).

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6. Install the filler neck tube.


Tighten
Tighten the neck tube bolt to 20 N-m (15 lb ft).

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7. Connect the power steering outlet hose to the power steering pump.
8. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle
in General Information.
9. Connect the power steering inlet hose to the power steering pump.
10. Install steering linkage shield. Refer to Steering Linkage Shield Replacement in
Steering Linkage.
11. Lower the vehicle.

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12. Place the power steering pump pulley on the end of the power steering pump
shaft.

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13. Install J 25033-C .
Ensure that the pilot bolt bottoms in the shaft by turning the nut to the top of the
pilot bolt.
14. Hold the pilot bolt.
15. Turn the nut counterclockwise.
16. Install the power steering pump pulley.

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17. Install the pulley (1) flush against the end of the power steering pump shaft (2),
with an allowable variance of 0.25 mm (0.010 in).
18. Remove the fan clutch from the water pump. Refer to Fan Clutch Replacement
in Engine Cooling.
19. Install the drive belt. Refer to Drive Belt Replacement in Engine Mechanical
4.3L.
20. Remove the upper fan shroud. Refer to Engine Coolant Fan Shroud
Replacement in Engine Cooling.
21. Fill the power steering system.
22. Bleed the system. Refer to Power Steering System Bleeding in Power Steering
System .
23. Inspect the hoses for clearance.

Document ID: 289866

Power Steering Pressure Pipe/Hose Replacement Document ID: 416260


Removal Procedure
Notice: Do not start the vehicle with any power steering gear inlet or outlet hoses
disconnected. When disconnected, plug or cap all openings of components. Failure to
do so could result in contamination or loss of power steering fluid and damage to the
system.
1. Raise and suitably support the vehicle. Refer to Vehicle Lifting Caution in
General Information.

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2. Remove the steering linkage shield, if equipped. Refer to Steering Linkage


Shield Replacement in Steering Linkage.
3. Install a drain pan under the vehicle.

4. Disconnect the pressure hose from the power steering pump.


5. Lower the vehicle.
6. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
in Engine Controls 4.3L.

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7. Disconnect the power steering gear pressure hose from the power steering gear.
8. Remove the power steering gear pressure hose from the vehicle.

Installation Procedure

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Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend
or distort the inlet or outlet hoses to make installation easier. Failure to follow these
procedures could result in component damage.
1. Install the power steering gear pressure hose to the vehicle.

2. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Connect the power steering gear pressure hose to the power steering gear.
Tighten
Tighten the power steering gear pressure hose to the power steering gear to
30 N-m (22 lb ft).
3. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls 4.3L.
4. Raise the vehicle.

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5. Connect the power steering gear pressure hose to the power steering pump.
Tighten
Tighten the power steering gear pressure hose to the power steering pump to
25 N-m (18 lb ft).
6. Remove the drain pan from under the vehicle.
7. Install the steering linkage shield, if equipped. Refer to Steering Linkage Shield
Replacement in Steering Linkage.
8. Lower the vehicle.
9. Bleed the power steering system. Refer to Power Steering System Bleeding in
Power Steering System .

Document ID: 416260

Power Steering Return Hose Replacement Document ID: 416266


Removal Procedure
Notice: Do not start the vehicle with any power steering gear inlet or outlet hoses
disconnected. When disconnected, plug or cap all openings of components. Failure to
do so could result in contamination or loss of power steering fluid and damage to the
system.
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
in Engine controls 4.3L.

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2. Install a drain pan under the vehicle.

3. Disconnect the power steering gear return hose from the power steering pump
(for vehicles without power steering cooler).

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4. Disconnect the power steering gear return hose from the power steering cooler,
if equipped.

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5. Disconnect the power steering gear return hose from the power steering gear.
6. Remove the power steering gear return hose from the vehicle.

Installation Procedure
Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend
or distort the inlet or outlet hoses to make installation easier. Failure to follow these
procedures could result in component damage.
1. Install the power steering gear return hose to the vehicle.

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2. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion

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inhibitors on fasteners or fastener joint surfaces unless specified. These coatings


affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Connect the power steering gear return hose to the power steering gear.
Tighten
Tighten the power steering gear return hose to the power steering gear to 30 Nm (22 lb ft).

3. Connect the power steering gear return hose to the power steering cooler, if
equipped.
Tighten
Tighten the power steering hose clamp to 2 N-m (18 lb in).

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4. Connect the power steering gear return hose to the power steering pump (for
vehicles without power steering cooler).
Tighten
Tighten the power steering hose clamp to 2 N-m (18 lb in).
5. Remove the drain pan from under the vehicle.
6. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls 4.3L.
7. Bleed the power steering system. Refer to Power Steering System Bleeding in
Power Steering System .

Document ID: 416266

Steering Gear Pitman Shaft Seal Replacement Document ID: 289638


Removal Procedure
Tools Required
J 4245 Snap Ring Pliers
1. Remove the pitman arm from the pitman shaft. Refer to Pitman Arm
Replacement in Steering Linkage.
2. Remove the snap ring (6) using J 4245 .
3. Place a drain pan under the steering gear.

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4. Start the engine.


5. Turn the steering wheel from stop to stop.
Bounce the wheel off the stops.
6. Turn OFF the engine.

7. Remove the following components from the power steering gear (1):
o The dust seal (5)
o The return ring (4)
o The washer (3)
o The pitman shaft oil seal (2)
8. Inspect the pitman shaft seal surfaces for roughness or pitting.
Replace the pitman shaft if the shaft is pitted.
9. Clean the pitman shaft and seal areas using a wire brush.

Installation Procedure
Tools Required

J 4245 Snap Ring Pliers


J 6219 Pitman Shaft Oil Seal Installer

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1. Lubricate the new seals with grease.


2. Apply a single layer of tape to the pitman arm shaft in order to avoid damaging
the seals.
3. Install the pitman shaft oil seal (2) and washer (3) to power steering gear.

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4. Use J 6219 in order to seat the pitman shaft oil seal (2) and the washer (3) into
the power steering gear.
The seal should be in far enough to install the return ring (4), dust seal (5), and
snap ring (6).
5. Install the return ring (4) and dust seal (5) to the power steering gear.
6. Use J 6219 in order to seat the return ring (4) and dust seal (5) into the power
steering gear.

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7. Install the snap ring (6) to the pitman arm shaft using J 4245 .
8. Center the steering gear.
9. Line up steering gear to pitman arm.
10. Install the pitman arm. Refer to Pitman Arm Replacement in Steering Linkage.
11. Bleed the power steering system. Refer to Power Steering System Bleeding in
Power Steering System .

Document ID: 289638

Document ID: 416277


Removal Procedure
Notice: Do not start the vehicle with any power steering gear inlet or outlet hoses
disconnected. When disconnected, plug or cap all openings of components. Failure to
do so could result in contamination or loss of power steering fluid and damage to the
system.
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
in Engine Controls 4.3L.
2. Install a drain pan under the vehicle.

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3. Disconnect the power steering cooler hose from the power steering pump.

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4. Disconnect the power steering cooler hose from the power steering cooler.
5. Remove the power steering cooler hose from the vehicle.

Installation Procedure
Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend
or distort the inlet or outlet hoses to make installation easier. Failure to follow these
procedures could result in component damage.
1. Install the power steering cooler hose to the vehicle.

Click here for full size


2. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion

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inhibitors on fasteners or fastener joint surfaces unless specified. These coatings


affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Connect the power steering cooler hose to the power steering cooler.
Tighten
Tighten the power steering hose clamp to 2 N-m (18 lb in).

3. Connect the power steering cooler hose to the power steering pump.
Tighten
Tighten the power steering hose clamp to 2 N-m (18 lb in).
4. Remove the drain pan from under the vehicle.
5. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls 4.3L.
6. Bleed the power steering system. Refer to Power Steering System Bleeding in
Power Steering System .

Document ID: 416277

Power Steering Fluid Cooler Replacement Document ID: 416271

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Removal Procedure
Notice: Do not start the vehicle with any power steering gear inlet or outlet hoses
disconnected. When disconnected, plug or cap all openings of components. Failure to
do so could result in contamination or loss of power steering fluid and damage to the
system.
1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
in Engine Controls 4.3L.
2. Install drain pan under vehicle.

3. Disconnect the power steering cooler hoses from the power steering cooler.
4. Remove the radiator air intake baffle. Refer to Air Intake Baffle Replacement Radiator in Body Front End.

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5. Remove the power steering cooler retaining bolts.

6. Remove the power steering cooler from the radiator support.

Installation Procedure
Notice: The inlet and outlet hoses must not be twisted during installation. Do not bend
or distort the inlet or outlet hoses to make installation easier. Failure to follow these
procedures could result in component damage.

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1. Install the power steering cooler to the radiator core support.

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2. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the power steering cooler retaining bolts.
Tighten
Tighten the power steering cooler retaining bolts to 10 N-m (90 lb in).
3. Install the radiator air intake baffle. Refer to Air Intake Baffle Replacement Radiator in Body Front End.

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4. Connect the power steering cooler hoses to the power steering cooler.
Tighten
Tighten the power steering cooler hoses to the power steering cooler clamps to
2 N-m (18 lb in).
5. Remove drain pan from under the vehicle.
6. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in
Engine Controls 4.3L.
7. Bleed the power steering system. Refer to Power Steering System Bleeding in
Power Steering System .

Document ID: 416271

Steering Gear Replacement Document ID: 289900


Removal Procedure
Notice: Do not rotate steering shaft after steering column has been removed. Damage to
SIR components may occur.
1. Remove the air cleaner assembly. Refer to Air Cleaner Inlet Duct Replacement
in Engine Controls 2.2L.

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2. Place a drain pan below the steering gear.


3. Remove the inlet and the outlet hoses from the power steering gear.
Cap or tape the ends of the hoses and the gear fittings in order to prevent dirt
from entering the system.

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4. Remove the intermediate shaft shield from the steering gear.

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5. Remove the lower intermediate shaft coupling bolt.


6. Draw alignment marks on the lower intermediate shaft coupling and the steering
shaft.
7. Remove the lower intermediate shaft coupling from the steering shaft.
8. Remove the pitman arm. Refer to Pitman Arm Replacement in Steering Linkage.

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9. Remove the steering gear mounting bolts and the washers from the frame.
10. Remove the steering gear.

Installation Procedure

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1. Install the steering gear.


Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Install the power steering gear to the frame washers and the mounting bolts.
Tighten
Tighten the power steering gear to frame mounting bolts to 75 N-m (55 lb ft).
3. Install the pitman arm. Refer to Pitman Arm Replacement in Steering Linkage.

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4. Install the lower intermediate shaft to the power steering gear.


Ensure that the alignment marks line up.
5. Install the lower intermediate shaft coupling bolt.
Tighten
Tighten the lower intermediate shaft coupling bolt to 35 N-m (26 lb ft).

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6. Install the intermediate shaft shield to the power steering gear.

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7. Install the inlet and the outlet hoses to the power steering gear.
Tighten
Tighten the inlet hose to 25 N-m (18 lb ft) for the vehicle equipped with
the 2.2L engines.
o Tighten the inlet hose to 30 N-m (22 lb ft) for the vehicle equipped with
the 4.3L engines.
o Tighten the outlet hose to 25 N-m (18 lb ft).
8. Install the air cleaner assembly. Refer to Air Cleaner Inlet Duct Replacement in
Engine Controls 2.2L.
9. Bleed the power steering system. Refer to Power Steering System Bleeding in
Power Steering System .
o

Document ID: 289900

Steering Gear Worm Gear Thrust Bearing Preload Adjustment - Off


Vehicle
Document ID: 440369
Tools Required

J 42882 Adjuster Nut Socket


J 43435 Adjuster Lock Nut Wrench

1. Remove the steering gear from the vehicle. Refer to Steering Gear Replacement
in Power Steering System or Steering Gear Replacement in Power Steering
System .

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2. Rotate the stub shaft back and forth in order to drain the power steering fluid.
3. Remove the coupling shield retainer and the lock nut from the steering gear
housing using the J 43435 and a torque wrench.

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4. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

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Turn the adjuster nut assembly (1) clockwise using the J 42882 until the adjuster
nut assembly (1) and the thrust support assembly (2) are firmly bottomed in the
steering gear housing (3).
Tighten
Tighten the adjuster nut assembly (1) to 2831 N-m (2023 lb ft).

5. Place an index mark (1) on the steering gear housing (4) parallel with one of the
holes (3) in the adjuster nut assembly (2).

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6. Measure back counterclockwise 13 mm (1/2 inch).

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7. Place a second mark (2) on the steering gear housing (1).

8. Using the J 42882 and a torque wrench, turn the adjuster nut assembly (1)
counterclockwise 1525 degrees in order to align the hole (2) in the adjuster nut
assembly (1) with the second mark (4) on the steering gear housing (3).

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9. Install the coupling shield retainer and the lock nut.
10. Hold the adjuster nut assembly in position in order to maintain alignment of the
marks.
11. Tighten the coupling shield retainer and the lock nut using the J 43435 and a
torque wrench.

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Tighten
Tighten the coupling shield retainer and the lock nut (2) to 109 N-m (80 lb ft).
12. Install the steering gear. Refer to Steering Gear Replacement in Power Steering
System or Steering Gear Replacement in Power Steering System .

Document ID: 440369

Document ID: 440373


1. Remove the steering gear from the vehicle. Refer to Steering Gear Replacement
in Power Steering System or Steering Gear Replacement in Power Steering
System .
2. Rotate the stub shaft back and forth in order to drain the power steering fluid.
3. Loosen the adjuster lock nut.
4. Turn the pitman shaft adjuster screw counterclockwise until the pitman shaft is
fully extended, then turn the pitman shaft adjuster screw clockwise 1 full turn.
5. Use a 12-point socket in order to rotate the stub shaft from stop to stop. Count
the number of turns.

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6. Center the gear by turning the stub shaft back 1/2 the number of turns, starting
from either stop.

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Steering Gear Pitman Shaft Over-Center Preload Adjustment - Off


Vehicle

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7. Use the following procedure in order to ensure that the gear is properly centered:
o Ensure that the flat on the stub shaft is facing upward.
o Ensure that the flat of the stub shaft is parallel with the side cover.
o Ensure that the master spline on the pitman shaft is aligned with the
adjuster screw.

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8. Place a torque wrench on the stub shaft with the handle in the vertical position.
9. Rotate the stub shaft 45 degrees to either side of the center.
10. Ensure that the stub shaft moves smoothly and does not stick or bind.
11. Record the worm bearing preload measured at or near the center.

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12. Ensure that the recorded preload is within the range of 0.70.17 N-m (6
15 lb in) with the worm and ballnut installed. If the torque is outside this range,
the gear assembly should be readjusted or repaired as necessary.
13. Adjust the over-center torque by turning the pitman shaft adjuster screw
clockwise until the correct preload torque is obtained.
14. Add 0.71.1 N-m (610 lb in) torque to the previously measured worm bearing
preload torque.

15. Prevent the adjuster screw from turning while tightening the adjuster lock nut.
Tighten
Tighten the adjuster lock nut to 49 N-m (36 lb ft).
16. Install the steering gear. Refer to Steering Gear Replacement in Power Steering
System or Steering Gear Replacement in Power Steering System .

Steering Gear Pitman Shaft and Housing Cover Replacement - Off


Vehicle
Document ID: 440387
Removal Procedure
1. Remove the steering gear from the vehicle. Refer to Steering Gear Replacement
in Power Steering System or Steering Gear Replacement in Power Steering
System .

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Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

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2. Loosen and remove the adjuster lock nut (1).


3. Remove the bolts (2).
4. Using a 12-point socket, rotate the stub shaft (6) in order to center the steering
gear (7).
5. Remove the following items as an assembly:
o The side cover (8)
o The gasket (3)
o The pitman shaft (4)
6. Remove the pitman shaft (4) from the side cover (8).

Installation Procedure

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1. Screw the pitman shaft (4) to the side cover (8) until the shaft fully seats to the
side cover (8).
2. Install the adjuster lock nut (1). Do not tighten the adjuster lock nut (1) until the
pitman shaft adjustment is completed.
3. Install the gasket (3) to the side cover (8).
4. Bend the gasket tabs around the edges of the side cover (8).
5. Install the pitman shaft assembly (4) and the side cover (8) to the steering gear
housing (7).
6. Install the bolts (2).

Tighten
Tighten the bolts (2) to 60 N-m (45 lb ft).
7. Refer to Steering Gear Pitman Shaft Over-Center Preload Adjustment - Off
Vehicle in order to adjust the pitman shaft (4).
8. Install the steering gear. Refer to Steering Gear Replacement in Power Steering
System orSteering Gear Replacement in Power Steering System .

Steering Gear Housing Plug Replacement - Off Vehicle


Document ID: 440392
Removal Procedure
1. Remove the steering gear from the vehicle. Refer to Steering Gear Replacement
in Power Steering System or Steering Gear Replacement in Power Steering
System .
2. Rotate the stub shaft back and forth in order to drain the fluid.

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Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

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3. Insert a punch into the housing access hole (1) in order to unseat the retaining
ring (3).
4. Remove the plug (3).
5. Remove the O-ring seal (3).

Installation Procedure
1. Lubricate the O-ring seal (5) with the power steering fluid.

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2. Install the O-ring seal to the housing.
3. Install the plug (4).
4. Install the retaining ring (3) so that the retaining ring's open end is
approximately 25 mm (1 in) from the access hole in the housing.

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5. Install the steering gear. Refer to Steering Gear Replacement in Power Steering
System or Steering Gear Replacement in Power Steering System .

Document ID: 440392

Steering Gear Valve Replacement - Off Vehicle


Document ID: 440434

1. Remove the steering gear from the vehicle. Steering Gear Replacement in Power
Steering System or Steering Gear Replacement in Power Steering System .

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2. Remove the thrust support assembly. Refer to Steering Gear Worm Gear
Adjuster Seal and Stub Shaft Bearing Replacement in Power Steering System .
3. Remove the stub shaft (1) and the valve assembly (2) from the thrust support
assembly.
4. If necessary, remove the stub shaft (1) from the valve assembly (2) in the
following manner:
1. Tap the stub shaft (1) lightly on a wood block in order to loosen the shaft
cap.
2. Pull the shaft cap and the valve spool out from valve body (2) 6 mm
(1/4 inch).
3. Disengage the stub shaft pin (3) from the hole in the valve spool (4).

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Removal Procedure

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5. If the valve assembly needs repair, disassemble the valve in the following
manner:
1. Simultaneously pull and rotate the valve spool (5) from the valve
body (1).
2. Remove the valve spool O-ring seal (4).
3. Alternately remove the valve body Teflon rings (2) and the O-ring
seals (3).

Installation Procedure

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1. If disassembled, reassemble the valve assembly in the following manner:
1. Install the valve spool O-ring seal (4) to the valve spool (5).

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2. Lubricate the valve spool (5) and O-ring seal (4) using power steering
fluid.
3. Simultaneously push and rotate the valve spool (5) into the valve
body (1) until the hole in the valve spool for the stub shaft pin is
accessible from the opposite end of the valve body (1).

2. If necessary, install the stub shaft to the valve spool in the following manner:
1. Insert the stub shaft (3) into the valve spool.
2. Insert the pin.
3. Ensure that the notch in the stub shaft cap (1) fully engages the valve
body pin (2). Seat the stub shaft cap against the valve body shoulder.
4. Alternately install the O-ring seals and the Teflon rings to the valve
body.
5. Lubricate the O-ring seals and the Teflon rings using power steering
fluid.

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3. Install the stub shaft (7) and valve assembly (6) to the worm shaft (5). Ensure
the pin fits in the worm shaft to the slot in the valve assembly.
4. Install the thrust support assembly. Refer to Steering Gear Worm Gear Adjuster
Seal and Stub Shaft Bearing Replacement in Power Steering System .
5. Refer to Steering Gear Worm Gear Thrust Bearing Preload Adjustment - Off
Vehicle in order to adjust the thrust bearing preload.
6. Refer to Steering Gear Pitman Shaft Over-Center Preload Adjustment - Off
Vehicle in order to adjust the pitman shaft over-center sector.
7. Install the steering gear. Refer to Steering Gear Replacement in Power Steering
System or Steering Gear Replacement in Power Steering System .

Document ID: 440434

Rack Piston and Worm Shaft Replacement - Off Vehicle


Document ID: 440465
Removal Procedure
Tools Required
J 21552 Rack Piston Arbor
1. Remove the steering gear from the vehicle. Refer to Steering Gear Replacement
in Power Steering System or Steering Gear Replacement in Power Steering
System .

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2. Remove the pitman shaft and side cover. Refer to Steering Gear Pitman Shaft
and Housing Cover Replacement - Off Vehicle in Power Steering System .
3. Remove the housing end plug (1). Refer to Steering Gear Housing Plug
Replacement - Off Vehicle in Power Steering System .
4. Turn the stub shaft counterclockwise until the rack piston (2) begins to come out
of the steering gear housing.
5. Remove the rack piston plug (1).
6. Insert the J 21552 into the bore of the rack piston (2).
7. Hold the J 21552 tightly against the worm shaft while turning the stub shaft
counterclockwise. Turning the stub shaft forces the race piston (2) onto the J
21552 . The rack piston balls remain in place.

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Installation Procedure
Tools Required

J 8947 Rack Piston Teflon Ring Compressor


J 21552 Rack Piston Arbor

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1. Install the O-ring seal (3) and the Teflon ring (2).
2. Lubricate both parts using power steering fluid.

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8. Remove the following items as an assembly from the steering gear housing (9):
o The rack piston (4)
o The rack piston balls (5)
o J 21552
9. Remove the valve. Refer to Steering Gear Valve Replacement - Off Vehicle in
Power Steering System .
10. Remove the worm shaft (14).
11. Remove the thrust bearing (12) and the flat races (11,13).
12. Remove the flat races (11).
13. Remove the J 21552 from the rack piston (4).
14. Remove the rack piston balls (5).
15. Remove the following items from the rack piston (4):
1. The screws (8)
2. The clamp (7)
3. The ball guide (6)
16. Remove the Teflon ring (2).
17. Remove the O-ring seal (3).
18. Clean all of the disassembled parts.
19. Inspect all of the disassembled parts for wear.
20. Replace the parts if necessary.

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3. Install the worm shaft (14) to the rack piston (4) outside of the steering gear
housing (9).
Important: Reinstall all of the rack piston balls in the rack piston. Improper
rack piston ball installation may result in personal injury.
Fully seat the worm shaft to the rack piston.

4. Align the worm shaft spiral groove with the rack piston ball return guide
hole (1).
5. Lubricate the rack piston balls with power steering fluid.
Important: The black rack piston balls are smaller than the silver rack piston
balls. Install the black and the silver rack piston balls alternately into the rack
piston and the ball guide in order to maintain the rack piston to the worm shaft
preload.
6. Insert the rack piston balls through the ball return guide hole (1) while turning
worm shaft (2) counterclockwise in order to install the rack piston balls into the
rack piston.

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7. Install the remaining rack piston balls (3) into the ball guide (1) using grease at
each end (2) in order to retain the rack piston balls (3).

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8. Install the ball guide (5) to the rack piston (4).
9. Install the ball guide clamp (6).
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.

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Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
10. Install the screws (7).
Tighten
Tighten the screws (7) to 58 N-m (43 lb in).

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12. Install the flat races (2,4) and the thrust bearing (3) onto the worm shaft (1).

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11. Insert the J 21552 into the bore of the rack piston while turning the worm shaft
counterclockwise. The turning of the worm shaft forces the rack piston onto the
J 21552 . The rack piston balls remain in place.

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13. Install the worm shaft (4) to the steering gear housing (3).
14. Install the valve. Refer to Steering Gear Valve Replacement - Off Vehicle in
Power Steering System .
15. Install the rack piston (2) to the worm (4) from the J 21552 using the J 8947 in
order to compress the seals.
Important: Reinstall all of the rack piston balls into the rack piston. Improper
rack piston ball installation may result in personal injury.
16. Hold the J 21552 tightly against the worm shaft (4).
17. Turn the stub shaft clockwise until the rack piston (2) is seated on the worm
shaft (4).
18. Install the rack piston plug.
Tighten
Tighten the rack piston plug to 150 N-m (111 lb ft).
19. Install the housing end plug (1). Refer to Steering Gear Housing Plug
Replacement - Off Vehicle in Power Steering System .
20. Install the pitman shaft and side cover. Refer to Steering Gear Pitman Shaft and
Housing Cover Replacement - Off Vehicle in Power Steering System .
21. Adjust the steering gear. Refer to Steering Gear Adjustments in Power Steering
System .
22. Install the steering gear. Refer to Steering Gear Replacement in Power Steering
System or Steering Gear Replacement in Power Steering System .

Steering Gear Pitman Shaft Seal and Bearing Replacement - Off Vehicle

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Document ID: 440476


This procedure covers the seal and bearing replacement for the steering gears. The
steering gear uses one double lip seal. The seal may be replaced without removing the
power steering gear.

Removal Procedure
Tools Required
J 6278 Pitman Shaft Bearing Remover and Installer
J 4245 Internal Snap Ring Pliers

1. Remove the steering gear from the vehicle. Refer to Steering Gear Replacement
in Power Steering System or Steering Gear Replacement in Power Steering
System .

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2.
3.
4.
5.
6.

Remove the nut (5).


Remove the lock washer (4).
Remove the pitman arm (3) from the steering gear.
Remove the pitman shaft boot (2).
Remove the pitman shaft and side cover. Refer to Steering Gear Pitman Shaft
and Housing Cover Replacement - Off Vehicle in Power Steering System .
7. Clean the exposed end of the pitman shaft.
8. Clean the steering gear housing.
9. Use a wire brush in order to clean the pitman shaft splines.

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10. Remove the dust seal (1).


11. Remove the retaining ring using the J 4245 .

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12. Important: Do not score the steering gear housing bore when prying out the
seals and the washers.
Use a screwdriver in order to pry the backup washer (3) and the double lip
seal (2) from the steering gear housing (1).
13. Inspect the steering gear housing (1) for burrs.
14. Remove the steering gear housing (1) if necessary.

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15. Insert the J 6278 through the hole in the top of the steering gear housing (1).
16. Drive out the needle bearing (2).

Installation Procedure
Tools Required

J 6278 Pitman Shaft Bearing Remover and Installer


J 4245 Internal Snap Ring Pliers

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1. Coat the double lip seal (2) and the washer (3) using grease.

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2. Install the needle bearing (2) to the steering gear housing (1) using the J 6278 .

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3. Install the double lip seal (2).
4. Install the backup washer (3).

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5. Install the retaining ring using the J 4245 .


6. Install the pitman shaft and the side cover. Refer to Steering Gear Pitman Shaft
and Housing Cover Replacement - Off Vehicle in Power Steering System .
7. Install the dust seal (1).

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8. Install the pitman shaft boot (2).
9. Install the pitman arm (3) to the steering gear.
10. Install the lock washer (2).
11. Install the nut (3).
12. Install the steering gear. Refer to Steering Gear Replacement in Power Steering
System or Steering Gear Replacement in Power Steering System .

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Document ID: 440476

Steering Gear Check Valve Replacement - Off Vehicle


Document ID: 440495
Removal Procedure

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2. Important: Do not to damage the threads of the steering gear housing when
removing the check valve.
Remove the check valve (1) from the steering gear housing (2) using a small
screwdriver.

Installation Procedure

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1. Remove the steering gear from the vehicle. Refer to Steering Gear Replacement
in Power Steering System or Steering Gear Replacement in Power Steering
System .

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1. Install the check valve (1) using a 3/8 inch diameter piece of tubing 100 mm
(4 in) long in order to drive into the steering gear housing (2).
2. Install the steering gear. Refer to Steering Gear Replacement in Power Steering
System or Steering Gear Replacement in Power Steering System .

Document ID: 440495

Steering Gear Worm Gear Adjuster Seal and Stub Shaft Bearing
Replacement
Document ID: 598990
Removal Procedure
Tools Required

J 42882 Adjuster Nut Socket


J 43435 Adjuster Lock Nut Wrench

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1. Rotate the stub shaft back and forth in order to drain the power steering fluid.
2. Remove the coupling shield retainer and the lock nut from the steering gear
housing using the J 43435 and a torque wrench.

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3. Remove the adjuster nut assembly (2) from the steering gear housing (1) using
the J 42882

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4. Remove the thrust support assembly (2) from the steering gear housing (1).
5. Remove the O-ring seal (3) from the thrust support assembly (2).

Installation Procedure
Tools Required
J 42882 Adjuster Nut Socket

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1. Important: Install a new O-ring seal each time the thrust support assembly is
removed from the steering gear.

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Lubricate the new O-ring seal (3).


2. Install the new O-ring seal (3) on the thrust support assembly (2).
3. Install the thrust support assembly (2).

4. Connect the adjuster nut assembly (2) to the steering gear housing (1) using the J
42882 .
5. Install the coupling shield retainer and the lock nut (1) to the adjuster nut
assembly.
6. Adjust the worm thrust bearing preload. Refer to Steering Gear Worm Gear
Thrust Bearing Preload Adjustment - Off Vehicle in Power Steering System .

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7. Install the coupling shield retainer and the lock nut.


8. Hold the adjuster nut assembly in position to maintain alignment of the marks.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

Tighten
Tighten the coupling shield retainer and the lock nut (2) to 109 N-m (80 lb ft).
10. Adjust the pitman shaft over-center preload. Refer to Steering Gear Pitman Shaft
Over-Center Preload Adjustment - Off Vehicle in Power Steering System .

Document ID: 598990

Blower Motor and Fan Replacement Document ID: 422237


Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the battery negative cable.

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9. Tighten the coupling shield retainer and the lock nut using the J 43435 and a
torque wrench.

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2. Remove the PCM/VCM. Refer to PCM Replacement/Programming or VCM


Replacement/Programming in Engine Controls.
3. Remove the electrical connectors as necessary.
4. Remove the coolant reservoir. Refer toCoolant Recovery Reservoir Replacement
in Engine Cooling.
Important: It is important to make the cut as straight as possible as the access
cover must be replaced and part of this repair is visible to the customer. Cut the
cover as far as possible.
5. Cut through the cover on the cut line (1) with a razor blade or a sharp utility
knife.
6. Tear the remaining part of the access cover (4) from the remaining portion.
Begin with the upper half of the access cover.
7. Remove the cooling tube.
8. Remove the blower motor access cover screws. The lower screw is on the
bottom of the front cover.
9. Remove the wiring harness from the blower motor assembly.
10. Remove the blower motor assembly.

Installation Procedure

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1.
2.
3.
4.

Install the blower motor assembly.


Install the wiring harness to the blower motor assembly.
Install the access cover.
Place a piece of duct tape along the bottom edge of the lower half of the access
cover. The tape must be the full width of the cover.
Important: Do not use RTV. Make the adhesive bead as straight as possible.
Allow the adhesive to set for 15 minutes or until the adhesive becomes tacky.

5. Seal the cut line areas using black weather-strip adhesive.


6. Install the cooling tube.
7. Install the blower motor access cover.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
8. Install the blower motor access cover retaining screws.
Tighten
Tighten to 1.9 N-m(17 lb ft).
9. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement
in Engine Cooling.
10. Install the electrical connectors as necessary.

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11. Install the PCM/VCM. Refer to PCM Replacement/Programming or VCM


Replacement/Programming in Engine Controls.
12. Connect the battery negative cable.

Document ID: 422237

Air Conditioning Evaporator Core Replacement

Tools Required
J 39400-A Halogen Leak Detector

Removal Procedure
1. Disconnect the underhood lamp electrical connector, if equipped.
2. Remove the hood. Refer toHood Replacement in Body Front End Hood
Replacement in Body End.
3. Remove the PCM. Refer to the appropriate procedure:
o Powertrain Control Module Replacement/Programming in Engine
Controls-2.2L.
o VCM Replacement/Programming in Engine Controls-4.3L.
4. Remove the coolant recovery tank. Refer toCoolant Recovery Reservoir
Replacement in Engine Cooling.
5. Disconnect the electrical connectors from the grille mounted lamps, if equipped.
6. Remove the right front headlamp assembly. Refer toHeadlamp Replacement in
Lighting Systems.
7. Remove the front bumper. Refer toFront Bumper Impact Bar Replacement in
Bumpers.
8. Remove the right wheelhouse panel. Refer toWheelhouse Panel Replacement in
Body Front End.
9. Disconnect the radio antenna cable.
10. Disconnect the electrical connector for the horn.
11. Remove the right fender. Refer toFront Fender Replacement in Body Front End.
12. Remove the blower motor resistor. Refer toBlower Motor Resistor Replacement
in Heating, Ventilation and Air Conditioning .
13. Remove the accumulator. Refer toAir Conditioning Accumulator Replacement
in HVAC Systems - Manual .
14. Remove the evaporator tube. Refer toEvaporator Tube Replacement in HVAC
Systems - Manual .
15. Remove the evaporator and blower module heat shield mounting screws.
16. Remove the evaporator and blower module heat shield.
Important: Retain the evaporator and blower module heat shield mounting
bracket for installation.

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Document ID: 492540

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17. Remove the evaporator and blower module mounting bolts and nuts.
18. Remove the evaporator and blower module from the vehicle.
19. Remove the 6 retaining screws holding the evaporator case section to the blower
case section.

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20. Separate the evaporator case section from the blower case section.
21. Remove the evaporator core from the blower case section.
22. Inspect the seals and replace as necessary.

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23. Remove the expansion (orifice) tube (2) from the evaporator (1).

Installation Procedure

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1. Install the expansion (orifice) tube (2) to the evaporator (1).

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2. Install the evaporator core to the blower case section.


Important: Ensure that the seal is in place between the 2 case sections.
3. Assemble the evaporator case section to the blower case section.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
4. Install the 6 retaining screws.
Tighten
Tighten the screws to 1.9Nm (17 lb in).
Important: Ensure that the evaporator and blower module to the cowl seal is in
place.
5. Install the evaporator and blower module to the vehicle.

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6. Important: Install the evaporator and blower module heat shield mounting
bracket with the evaporator and blower module mounting nuts.
Install the evaporator and blower module mounting fasteners.
Tighten
Tighten the bolts to 4.5 N-m (40 lb in).
7. Install the evaporator and blower module heat shield.
8. Install the evaporator and blower module heat shield mounting screws.
Tighten
Tighten the screws to 2.2 N-m (19 lb in).
9. Install the evaporator tube. Refer toEvaporator Tube Replacement in HVAC
Systems - Manual .
10. Install the accumulator. Refer toAir Conditioning Accumulator Replacement in
HVAC Systems - Manual .
11. Install the blower motor resistor. Refer to Blower Motor Resistor Replacement
in Heating, Ventilation and Air Conditioning .
12. Install the right fender. Refer to Front Fender Replacement in Body Front End.
13. Connect the electrical connector for the horn.
14. Install the radio antenna cable.
15. Install the right wheelhouse panel. Refer to Wheelhouse Panel Replacement in
Body Front End.
16. Install the front bumper. Refer to Front Bumper Impact Bar Replacement in
Body Front End.
17. Install the right front headlamp assembly. Refer to Headlamp Replacement in
Lighting Systems.
18. Connect the electrical connectors to the grille mounted lamps.

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Document ID: 492540

Mode Actuator Replacement


Document ID: 446617
Removal Procedure
The mode valve actuator is located on the bottom front corner of the heater module.
1. Remove the left side instrument panel sound insulator. Refer to Instrument Panel
Insulator Panel Replacement - Left Side in Instrument Panel, Gauges and
Console.
2. Remove the knee bolster. Refer to Knee Bolster Replacement in Instrument
Panel, Gauges, and Console.
3. Remove the center instrument panel sound insulator. Refer to Closeout/Insulator
Panel Replacement - Center in Instrument Panel, Gauges, and Console.

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19. Install the coolant recovery tank. Refer to Coolant Recovery Reservoir
Replacement in Engine Cooling.
20. Install the PCM. Refer to the appropriate procedure:
o Powertrain Control Module Replacement/Programming in Engine
Controls - 2.2L
o VCM Replacement/Programming in Engine Controls - 4.3L
21. Install the hood. Refer to Hood Replacement in Body Front End in Body Front
End.
22. Connect the underhood lamp electrical connector.
23. Evacuate and recharge the A/C system. Refer toRefrigerant Recovery and
Recharging in HVAC Systems - Manual
24. Leak test the fittings components using the J 39400-A

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4. Depress the retaining clip in order to remove the vacuum connectors from the
mode valve.

5. Remove the mode valve from the heater module.

Installation Procedure

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1. Install the mode valve to the heater module.

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2. Install the vacuum connectors to the mode valve.


Ensure that the retaining clip locks into place.
3. Install the center instrument panel sound insulator. Refer to Closeout/Insulator
Panel Replacement - Center in Instrument Panel, Gauges, and Console.
4. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel,
Gauges, and Console.
5. Install the left side instrument panel sound insulator. Refer to Instrument Panel
Insulator Panel Replacement - Left Side in Instrument Panel, Gauges and
Console.

Instrument Panel Carrier Replacement


Document ID: 305815
Removal Procedure
1. On vehicles equipped with a manual transmission, remove the shift lever.
2. On vehicles equipped with an automatic transmission, perform the following
steps:
1. Apply the park brake.
2. Insert the ignition key and turn the ignition switch to the RUN position.
3. Depress the brake pedal and shift the transmission to the 1 position.
4. Turn the ignition switch to the OFF position.

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3. Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
Disconnect the battery negative cable.
4. Remove the left sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges, and Console .
5. Remove the right instrument panel sound insulator. Refer to Instrument Panel
Insulator Panel Replacement - Right Side in Instrument Panel, Gauges, and
Console .
6. If the vehicle is equipped with a multiple CD changer located in the center
console, remove the center console. Refer to Front Floor Console Replacement
in Instrument Panel, Gauges, and Console .
7. Remove the center sound insulator. Refer to Closeout/Insulator Panel
Replacement - Center in Instrument Panel, Gauges, and Console .
8. Remove the lower left instrument panel mounting bolt.
9. Remove and retain the instrument panel storage compartment. Refer to
Instrument Panel Compartment Door Replacement in Instrument Panel, Gauges,
and Console .
10. Remove the lower right instrument panel mounting bolt.

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11. Remove and retain the left and right speakers and the speaker grilles. Refer to
Radio Front Speaker Replacement in Entertainment.
12. Use a flat-bladed tool in order to remove the windshield defroster grille. Retain
the grille and sunload sensor for use on the next IP carrier.

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13. If equipped with a sun load temperature sensor, twist the sensor turn
counterclockwise in order to disengage.
14. Disconnect the brown electrical connection from the body control module
(BCM).
15. Disconnect the purple electrical connection from the body control module
(BCM).
16. Remove the knee bolster. Refer to Knee Bolster Replacement in Instrument
Panel, Gauges, and Console .

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17. Remove and retain the instrument cluster. Refer to Instrument Cluster
Replacement in Instrument Panel, Gauges, and Console .
18. Remove and retain the radio. Refer to Radio Replacement in Entertainment.
19. Remove the HVAC control assembly. Refer to the appropriate procedure:
o Control Assembly Replacement in Heating and Ventilation (Non-A/C)
o Control Assembly Replacement in HVAC Systems with A/C - Manual
o Control Assembly Replacement in HVAC Systems with A/C Automatic

o
o
o

Air bag deployment


Personal injury
Unnecessary SIR system repairs

In order to avoid the above conditions, observe the following guidelines:


Refer to SIR Component Views in order to determine if you are
performing service on or near the SIR components or the SIR wiring.
o If you are performing service on or near the SIR components or the SIR
wiring, disable the SIR system. Refer to Disabling the SIR System.
20. Disable the passenger side SIR system. Refer to Disabling the SIR System in
SIR.
o

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21. Remove the left and right instrument panel driver knee bolster brackets.
22. Lower the steering column for clearance. Refer to Steering Column Replacement
in Steering Wheel and Column.

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Caution: This vehicle is equipped with a Supplemental Inflatable Restraint


(SIR) System. Failure to follow the correct procedure could cause the following
conditions:

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23. Important: Label all of the connections in order to avoid improper installation.
Remove the top instrument panel screws.
24. Roll the instrument panel down.
25. Disconnect the electrical connections, as needed.
26. Remove the fastener that retains the radio antenna cable to the instrument panel.
27. Remove the instrument panel from the vehicle.
If replacing the instrument panel carrier, retain the parts for assembly of the new
instrument panel carrier.

Installation Procedure

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1. Install the retained parts from the original instrument panel.


2. Install the instrument panel to the vehicle.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

Tighten
Tighten the fastener to 1.9 N-m (17 lb in).
4. Connect the electrical connectors, as needed.
5. Roll the instrument panel up.
6. Install the top instrument panel screws.
Tighten
Tighten the screws to 1.9 N-m (17 lb in).

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7. Raise the steering column into position. Refer to Steering Column Replacement
in Steering Wheel and Column.
8. Install the left and right instrument panel driver knee bolster brackets.
Tighten

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3. Install the fastener that retains the radio antenna cable to the instrument panel.

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Tighten the screws/bolts to 6.3 N-m (56 lb in).

9. Enable the passenger side SIR system. Refer to Enabling the SIR System in SIR.
10. Install the HVAC control assembly to the instrument panel. Refer to the
appropriate procedure:
o Control Assembly Replacement in Heating and Ventilation (Non-A/C)
o Control Assembly Replacement in HVAC Systems with A/C - Manual
o Control Assembly Replacement in HVAC Systems with A/C Automatic
11. Install the radio. Refer to Radio Replacement in Entertainment.
12. Install the instrument cluster. Refer to Instrument Cluster Replacement in
Instrument Panel, Gauges, and Console .
13. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel,
Gauges, and Console .
14. Connect the purple electrical connection to the body control module (BCM).
15. Connect the brown electrical connection to the body control module (BCM).
16. If equipped with a sun load temperature sensor, install the sensor to the defroster
grille by twisting the sensor turn clockwise.

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17. Install the windshield defroster grille by pressing carefully pressing the grille
into place.
18. Install the left and right speakers and the speaker grilles. Refer to Radio Front
Speaker Replacement in Entertainment.

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19. Install the lower right instrument panel mounting bolt.
Tighten
Tighten the bolt to 11.5 N-m (102 lb in).
20. Install the instrument panel storage compartment. Refer to Instrument Panel
Compartment Door Replacement in Instrument Panel, Gauges, and Console .
21. Install the lower left instrument panel bolt.

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Tighten
Tighten the bolt to 11.5 N-m (102 lb in).

Vacuum Electrical Solenoid Replacement


Document ID: 440747
Removal Procedure
1. Remove the instrument panel carrier. Refer to Instrument Panel Carrier
Replacement in Instrument Panel, Gauges and Console.

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2. Disconnect the electrical connector from the vacuum electrical control solenoid.

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22. Install the center sound insulator. Refer toCloseout/Insulator Panel Replacement
- Center in Instrument Panel, Gauges, and Console .
23. Install the right sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Right Side in Instrument Panel, Gauges, and Console .
24. If the center console was removed, install the console to the vehicle. Refer to
Front Floor Console Replacement in Instrument Panel, Gauges, and Console .
25. Install the left sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges, and Console .
26. Connect the battery negative cable.
27. On vehicles equipped with an automatic transmission, perform the following
steps:
1. Turn the ignition switch to the RUN position.
2. Depress the brake pedal and shift the transmission into the PARK
position.
3. Release the park brake.
28. On vehicles equipped with a manual transmission, install the shift lever.

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3. Disconnect the vacuum harness connectors from the vacuum electrical control
solenoid.

4. Remove the vacuum electrical control solenoid retaining screws.


5. Remove the vacuum electrical control solenoid from the vehicle.

Installation Procedure

Click here for full size


1. Install the vacuum electrical control solenoid to the vehicle.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings

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affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Install the vacuum electrical control solenoid retaining screws.
Tighten
Tighten the vacuum electrical control solenoid retaining screws to 1.9 N-m
(17 lb in).

3. Connect the vacuum harness connectors to the vacuum electrical control


solenoid.
4. Connect the electrical connector to the vacuum electrical control solenoid.
5. Install the instrument panel carrier. Refer to Instrument Panel Carrier
Replacement in Instrument Panel, Gauges and Console.

Document ID: 440747

Inside Air Temperature Sensor Replacement Document ID: 440744


Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an

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electrical spark should a tool or equipment come in contact with an exposed


electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.
2. Remove the headliner from the vehicle. Refer to Headlining Trim Panel
Replacement in Interior Trim.

3. Disconnect the inside air temperature sensor from the door header panel to gain
access to the dome lamp wiring harness connection.
4. Remove the dome lamp wiring harness connection from the inside air
temperature sensor.
5. Remove the inside air temperature sensor from the vehicle.

Installation Procedure

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1. Connect the dome lamp wiring harness connection to the inside air temperature
sensor.
2. Install the inside air temperature sensor to the vehicle.
Ensure that the retainers lock into place.
3. Install the headliner to the vehicle. Refer to Headlining Trim Panel Replacement
in Interior Trim.
4. Install the negative battery cable.

Headlining Trim Panel Replacement Document ID: 304859


Removal Procedure
1. Remove the sunroof console, if equipped. Refer to Driver Information Center
Replacement in Instrument Panel, Gauges and Console.
2. Remove the dome lamp. Refer to Dome Lamp Replacement in Lighting Systems
.
3. Remove the sunroof opening trim (if equipped). Refer to Sunroof Replacement
in Roof.
4. Remove the coat hooks. Refer to Coat Hook Replacement in Interior Trim .
5. Remove the assist handles. Refer to Assist Handle Replacement in Interior Trim
.
6. Remove the sunshades and the retainers. Refer to Sunshade Replacement in
Interior Trim .
7. Remove the windshield garnish moldings. Refer to Windshield Pillar Garnish
Molding Replacement in Interior Trim .
8. Remove the body lock pillar trim panels (four-door models only). Refer to Side
Door Lock Pillar Garnish Molding Replacement in Interior Trim .
9. Remove the seat upper seat belt anchor bolts (two-door models only).
10. Remove the body side trim panel. Refer to Body Side Trim Panel Replacement
in Interior Trim .
11. Remove the rear upper garnish molding. Refer to Rear Upper Garnish Molding
Replacement in Interior Trim.

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Document ID: 440744

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12. Remove the headliner from the vehicle.

Installation Procedure

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1. Install the headliner to the vehicle. New headliners must be pierced in order to
accommodate actual vehicle accessories.
2. Install the rear upper garnish molding. Refer to Rear Upper Garnish Molding
Replacement in Interior Trim.
3. Install the upper body side panel trim. Refer to Body Side Trim Panel
Replacement in Interior Trim .
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant

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are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
4. Install the rear seat upper seat belt anchor bolts (two-door models only).
Tighten
Tighten the bolts to 70 N-m (52 lb ft).

Instrument Panel Accessory Trim Plate Replacement


Document ID: 303384
Removal Procedure
1. Remove the left instrument panel sound insulator. Refer to Instrument Panel
Insulator Panel Replacement - Left Side in Instrument Panel, Gauges, and
Console .
2. Remove the knee bolster trim panel. Refer to Knee Bolster Replacement in
Instrument Panel, Gauges, and Console .

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5. Install the body lock pillar trim panels (four-door models only).
6. Install the windshield garnish moldings. Refer to Windshield Pillar Garnish
Molding Replacement in Interior Trim .
7. Install the sunshades and the retainers. Refer to Sunshade Replacement in
Interior Trim .
8. Install the assist handles. Refer to Assist Handle Replacement in Interior Trim .
9. Install the coat hooks. Refer to Coat Hook Replacement in Interior Trim .
10. Install the sunroof opening trim (if equipped). Refer to Sunroof Replacement in
Roof.
11. Install the dome lamp (if equipped). Refer to Dome Lamp Replacement in
Lighting Systems .
12. Install the overhead or sunroof console (if equipped). Refer to Driver
Information Center Replacement in Instrument Panel, Gauges, and Console on
Instrument Panel, Gauges and Console.

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3. Remove the screws that retain the instrument panel accessory trim plate to the
instrument panel.
4. Remove the instrument panel accessory trim plate.
5. Disconnect the electrical connectors, as needed.
6. Remove and retain the control switches.

Installation Procedure
1. Install the control switches.
2. Connect the electrical connectors, as needed.

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3. Install the instrument panel accessory trim plate.

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Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
4. Install the screws that retain the instrument panel accessory trim plate to the
instrument panel.

Tighten the screws to 1.9 N-m (17 lb in).


5. Install the knee bolster trim panel. Refer to Knee Bolster Replacement in
Instrument Panel, Gauges, and Console .
6. Install the left instrument panel sound insulator. Refer toInstrument Panel
Insulator Panel Replacement - Left Side in Instrument Panel, Gauges, and
Console .

Document ID: 303384

Inside Air Temperature Sensor Replacement Document ID: 500699


Removal Procedure
1. Remove instrument panel accessory trim plate. Refer to Instrument Panel
Accessory Trim Plate Replacement in Instrument Panel, Gauges, and Console.
2. Remove the radio. Refer to Radio Replacement in Entertainment.

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Tighten

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3. Disconnect the electrical connector from the inside air temperature sensor.
4. Remove the inside air temperature sensor from the vehicle.

Installation Procedure

Click here for full size


1.
2.
3.
4.

Install the inside air temperature sensor to the vehicle.


Connect the electrical connector to the inside air temperature sensor.
Install the radio. Refer to Radio Replacement in Entertainment.
Install the instrument panel accessory trim plate. Refer to Instrument Panel
Accessory Trim Plate Replacement in Instrument Panel, Gauges, and Console.

Document ID: 500699

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Emission Hose Routing Diagram


Document ID: 227177

1. To EVAP Canister
2. Positive Crankcase Ventilation (PCV)
3. To HVAC (When Used)
4. Throttle Body
5. Manifold Absolute Pressure (MAP) Sensor
6. Crankcase Vent (To Fresh Air)
7. EVAP Canister Purge Solenoid Valve
8. EVAP Service Port
9. EVAP Canister Purge Hose

Document ID: 227177

98 S/T MAF and IAT Comploc Graphic -

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Document ID: 247967


Mass Air Flow (MAF) Sensor and Intake Air Temperature (IAT) Sensor

1. Intake Air Temperature (IAT) Sensor


2. Air Outlet from Filter
3. Distributor
4. Knock Sensor (KS)
5. Mass Air Flow (MAF) Sensor

98 P32/42 CKP Sensor Figure Comploc Document ID: 235317


Crankshaft Position (CKP) Sensor

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1. Crankshaft
2. Front Engine Cover
3. Crankshaft Position (CKP) Sensor

Document ID: 235317


Engine
| Engine Controls - 4.3L
| Component Locator
Prev. Page
Next Page

Bulletins
General Information
o
Cautions and Notices
o
General Information
o
Maintenance and Lubrication
o
Vibration Diagnosis and Correction

Specifications

Diagnostic Information and Procedures

Repair Instructions

General Service Precautions

Correcting Tire and Wheel Vibration

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Tire and Wheel Balancing


Correcting Non-Uniform Tires
Correcting Driveline Vibration - RWD and 4WD
Front Wheel Driveline Vibrations
Description and Operation





HVAC
o
o

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Heating, Ventilation and Air Conditioning


HVAC Systems - Manual

Specifications

Schematic and Routing Diagrams

Component Locator

Diagnostic Information and Procedures

Repair Instructions

Odor Correction

Refrigerant Recovery and Recharging

Air Conditioning Compressor Replacement - 2.2L
Engine

Air Conditioning Compressor Replacement - 4.3L
Engine

Compressor Clutch Plate and Hub Assembly Removal HT6/HD6/HU6

Compressor Clutch Plate and Hub Assembly Removal V7 - Direct Mount

Clutch Rotor and Bearing Removal - HT6/HD6/HU6

Clutch Rotor and Bearing Removal - V7 - Direct Mount

Air Conditioning Clutch Coil Removal - HT6/HD6/HU6

Air Conditioning Clutch Coil Removal - V7 - Direct
Mount

Compressor Control Valve Assembly Removal - V7 Direct Mount

Compressor Shaft Seal Removal - HT6/HD6/HU6

Compressor Shaft Seal Removal - V7 - Direct Mount

Compressor Pressure Relief Valve Removal HT6/HD6/HU6

Compressor Pressure Relief Valve Removal - V7 - Direct
Mount

Compressor Control Switches Removal - HT6/HD6

Compressor Control Valve Assembly Install - V7 - Direct
Mount

Compressor Clutch Plate/Hub Assembly Install HT6/HD6/HU6

Compressor Clutch Plate/Hub Assembly Install - V7 Direct Mount

Clutch Rotor and/or Bearing Install - HT6/HD6/HU6

Clutch Rotor and/or Bearing Install - V7 - Direct Mount

Air Conditioning Clutch Coil Installation HT6/HD6/HU6

Air Conditioning Clutch Coil Installation - V7 - Direct
Mount

Compressor Shaft Seal Install - HT6/HD6

Compressor Shaft Seal Install - V7 - Direct Mount

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Compressor Pressure Relief Valve Installation HT6/HD6



Compressor Pressure Relief Valve Installation - V7 Direct Mount

Compressor Control Switches Install - HT6/HD6/HU6

Compressor Leak Testing - HT6/HD6

Compressor Sealing Washers Replacement

O-Ring Replacement

Air Conditioning Compressor Hose Replacement - 2.2L
Engine

Air Conditioning Compressor Hose Replacement - 4.3L
Engine

Evaporator and Accumulator Hose Assembly

Evaporator Tube Replacement

Compressor Relay Replacement

Air Conditioning (A/C) Refrigerant Pressure Sensor
Replacement

Air Conditioning Condenser Replacement

Air Conditioning Accumulator Replacement - 2.2L
Engine

Air Conditioning Accumulator Replacement - 4.3L
Engine

Blower Motor Resistor Replacement

Blower Motor and Fan Replacement - Pickup

Blower Motor and Fan Replacement - Utility

Air Conditioning Evaporator Core Replacement

Heater Core Replacement

Control Assembly Replacement

Mode Actuator Replacement

Temperature Actuator Replacement

Defroster Valve Actuator Replacement

Air Distributor Duct Replacement

Defroster Air Outlet Replacement

Floor Air Outlet Replacement - Center - Pickup

Floor Air Outlet Replacement - Rear - Utility

Lap Air Outlet Replacement

Air Inlet Assembly Replacement

Description and Operation

Special Tools and Equipment
HVAC Systems - Automatic

Specifications

Schematic and Routing Diagrams

Component Locator

Diagnostic Information and Procedures

Repair Instructions

Odor Correction

Refrigerant Recovery and Recharging

Air Conditioning Compressor Replacement

Compressor Clutch Plate and Hub Assembly Removal HT6/HD6/HU6

Clutch Rotor and Bearing Removal - HT6/HD6/HU6


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Air Conditioning Clutch Coil Removal - HT6/HD6/HU6


Compressor Shaft Seal Removal - HT6/HD6/HU6
Compressor Pressure Relief Valve Removal HT6/HD6/HU6

Compressor Control Switches Removal - HT6/HD6

Compressor Clutch Plate/Hub Assembly Install HT6/HD6/HU6

Clutch Rotor and/or Bearing Install - HT6/HD6/HU6

Air Conditioning Clutch Coil Installation HT6/HD6/HU6

Compressor Shaft Seal Install - HT6/HD6

Compressor Pressure Relief Valve Installation HT6/HD6

Compressor Control Switches Install - HT6/HD6/HU6

Compressor Leak Testing - HT6/HD6

Compressor Sealing Washers Replacement

O-Ring Replacement

Air Conditioning Compressor Hose Replacement - 4.3L

Evaporator and Accumulator Hose Assembly

Evaporator Tube Replacement

Air Conditioning (A/C) High Pressure Cut-Out Switch
Replacement

Pressure Cycling Switch Replacement

Air Conditioning Condenser Replacement

Air Conditioning Accumulator Replacement

Blower Motor Resistor Replacement

Blower Motor and Fan Replacement - Utility

Air Conditioning Evaporator Core Replacement

Control Assembly Replacement

Temperature Actuator Replacement

Mode Actuator Replacement

Defroster Valve Actuator Replacement

Vacuum Electrical Solenoid Replacement

Inside Air Temperature Sensor Replacement - Roof

Inside Air Temperature Sensor Replacement - Floor

Inside Air Temperature Sensor Replacement - Vent

Compressor Relay Replacement

Air Distributor Duct Replacement

Defroster Air Outlet Replacement

Floor Air Outlet Replacement - Rear - Utility
Description and Operation
Special Tools and Equipment




Steering
o
Power Steering System

Specifications

Visual Identification

Diagnostic Information and Procedures

Repair Instructions

Power Steering Pump Replacement - 2.2L

Power Steering Pump Replacement - 4.3L

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Power Steering Fluid Reservoir Replacement - Off


Vehicle - CB Series

Power Steering Fluid Reservoir Replacement - Off
Vehicle - P Series

Power Steering Pump Flow Control Valve Replacement Off Vehicle - CB Series

Power Steering Pump Flow Control Valve Replacement Off Vehicle - P Series

Power Steering Pump Shaft Seal Replacement - CB
Series

Power Steering Pump Shaft Seal Replacement - P Series

End Plate and Rotating Group Replacement - CB Series

End Plate and Rotating Group Replacement - P Series

Checking and Adding Power Steering Fluid

Power Steering System Bleeding

Power Steering System Flushing

Power Steering Pressure Pipe/Hose Replacement - 2.2L

Power Steering Pressure Pipe/Hose Replacement - 4.3L

Power Steering Return Hose Replacement - 2.2L

Power Steering Return Hose Replacement - 4.3L

Steering Gear Pitman Shaft Seal Replacement - RWD

Steering Gear Pitman Shaft Seal Replacement - 4WD

Power Steering Cooler Pipe/Hose Replacement - 2.2L

Power Steering Cooler Pipe/Hose Replacement - 4.3L

Power Steering Fluid Cooler Replacement - 2.2L

Power Steering Fluid Cooler Replacement - 4.3L

Steering Gear Replacement - RWD

Steering Gear Replacement - 4WD

Steering Gear Adjustments

Steering Gear Worm Gear Thrust Bearing Preload
Adjustment - Off Vehicle

Steering Gear Pitman Shaft Over-Center Preload
Adjustment - Off Vehicle

Steering Gear Pitman Shaft and Housing Cover
Replacement - Off Vehicle

Steering Gear Housing Plug Replacement - Off Vehicle

Steering Gear Valve Replacement - Off Vehicle

Rack Piston and Worm Shaft Replacement - Off Vehicle

Steering Gear Pitman Shaft Seal and Bearing
Replacement - Off Vehicle

Steering Gear Check Valve Replacement - Off Vehicle

Steering Gear Worm Gear Adjuster Seal and Stub Shaft
Bearing Replacement

Description and Operation

Special Tools and Equipment
Steering Linkage (Non-Rack & Pinion)
Steering Wheel and Column - Standard

Specifications

Component Locator

Schematic and Routing Diagrams

Visual Identification


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o

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Diagnostic Information and Procedures


Repair Instructions

Ignition Lock Cylinder Replacement - On Vehicle

Multifunction, Turn Signal, and Hazard Switch
Replacement - On Vehicle

Shift Lever Replacement - On Vehicle

Steering Wheel Inflator Module Replacement

Horn Switch Replacement - On Vehicle

Electronic Column Lock Module Replacement

Steering Wheel Replacement

Upper Intermediate Steering Shaft Replacement

Lower Intermediate Steering Shaft Replacement

Intermediate Steering Shaft Seal Replacement

Steering Column Trim Cover Replacement - On Vehicle

Steering Column Replacement

Trim Covers, Shift Lever Seal - Disassemble - Off
Vehicle - Column Shift

Trim Covers, Shift Lever Seal - Disassemble - Off
Vehicle - Floor Shift

Trim Covers, Shift Lever Seal - Assemble - Off Vehicle Column Shift

Trim Covers, Shift Lever Seal - Assemble - Off Vehicle Floor Shift

Inflatable Restraint Steering Wheel Module Coil
Disassemble - Off Vehicle - Column Shift

Inflatable Restraint Steering Wheel Module Coil
Disassemble - Off Vehicle - Floor Shift

Inflatable Restraint Steering Wheel Module Coil
Assemble - Off Vehicle - Column Shift

Inflatable Restraint Steering Wheel Module Coil
Assemble - Off Vehicle - Floor Shift

Turn Signal and Multifunction Switch Assembly Disassemble - Off Vehicle - Column Shift

Turn Signal and Multifunction Switch Assembly Disassemble - Off Vehicle - Floor Shift

Turn Signal and Multifunction Switch Assembly Assemble - Off Vehicle - Column Shift

Turn Signal and Multifunction Switch Assembly Assemble - Off Vehicle - Floor Shift

Ignition and Key Alarm Switch Assembly - Disassemble
- Off Vehicle

Ignition and Key Alarm Switch Assembly - Assemble Off Vehicle

Electric Park Lock Module - Disassemble - Off Vehicle Floor Shift

Electric Park Lock Module - Assemble - Off Vehicle Floor Shift

Automatic Transmission Shift Lock Control Disassemble
- Off Vehicle

Automatic Transmission Shift Lock Control Assemble Off Vehicle

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Linear Shift Assembly - Disassemble - Off Vehicle


Linear Shift Assembly - Assemble - Off Vehicle
Turn Signal Cancel Cam and Bearing Thrust Washer Disassemble - Off Vehicle - Column Shift

Turn Signal Cancel Cam and Bearing Thrust Washer Disassemble - Off Vehicle - Floor Shift

Turn Signal Cancel Cam and Bearing Thrust Washer Assemble - Off Vehicle - Column Shift

Turn Signal Cancel Cam and Bearing Thrust Washer Assemble - Off Vehicle - Floor Shift

Electronic Column Lock Module - Disassemble - Off
Vehicle

Electronic Column Lock Module - Assemble - Off
Vehicle

Inflatable Restraint Coil Centering - Off Vehicle Column Shift And Floor Shift

Steering Column Accident Damage Inspection - Off
Vehicle - Column and Floor Shift

Steering Shaft, Lower Bearing, and Jacket - Disassemble
- Off Vehicle - Column Shift

Steering Shaft, Lower Bearing, and Jacket - Disassemble
- Off Vehicle - Floor Shift

Steering Shaft, Lower Bearing, and Jacket - Assemble Off Vehicle - Column Shift

Steering Shaft, Lower Bearing, and Jacket - Assemble Off Vehicle - Floor Shift

Description and Operation

Special Tools and Equipment
Steering Wheel and Column - Tilt

Specifications

Visual Identification

Steering Column Disassembled View - Column Shift and
Floor Shift Tilt

Schematic and Routing Diagrams

Tilt Wheel/Column Schematic References

Shift Lock Control Schematics

Column/Ignition Lock Schematics

Component Locator

Diagnostic Information and Procedures

Repair Instructions

Ignition Lock Cylinder Replacement - On Vehicle

Multifunction, Turn Signal, and Hazard Switch
Replacement - On Vehicle

Shift Lever Replacement - On Vehicle

Tilt Lever Replacement - On Vehicle

Steering Wheel Inflator Module Replacement

Horn Switch Replacement - On Vehicle

Steering Wheel Replacement

Upper Intermediate Steering Shaft Replacement

Lower Intermediate Steering Shaft Replacement

Intermediate Steering Shaft Seal Replacement




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Steering Column Trim Cover Replacement - On Vehicle


Electronic Column Lock Module Replacement
Steering Column Replacement
Trim Covers, Shift Lever Seal - Disassemble - Off
Vehicle - Column Shift
Trim Covers, Shift Lever Seal - Disassemble - Off
Vehicle - Floor Shift
Trim Covers, Shift Lever Seal - Assemble - Off Vehicle Column Shift
Trim Covers, Shift Lever Seal - Assemble - Off Vehicle Floor Shift
Inflatable Restraint Steering Wheel Module Coil
Disassemble - Off Vehicle - Column Shift
Inflatable Restraint Steering Wheel Module Coil
Disassemble - Off Vehicle - Floor Shift
Inflatable Restraint Steering Wheel Module Coil
Assemble - Off Vehicle - Column Shift
Inflatable Restraint Steering Wheel Module Coil
Assemble - Off Vehicle - Floor Shift
Ignition and Key Alarm Switch Assembly - Disassemble
- Off Vehicle
Ignition and Key Alarm Switch Assembly - Assemble Off Vehicle
Electric Park Lock Module - Disassemble - Off Vehicle Floor Shift
Electric Park Lock Module - Assemble - Off Vehicle Floor Shift
Linear Shift Assembly - Disassemble - Off Vehicle Column Shift
Linear Shift Assembly - Assemble - Off Vehicle Column Shift
Tilt Spring - Disassemble - Off Vehicle - Column Shift
Tilt Spring - Disassemble - Off Vehicle - Floor Shift
Tilt Spring - Assemble - Off Vehicle - Column Shift
Tilt Spring - Assemble - Off Vehicle - Floor Shift
Electronic Column Lock Module - Disassemble - Off
Vehicle
Electronic Column Lock Module - Assemble - Off
Vehicle
Inflatable Restraint Coil Centering - Off Vehicle Column Shift And Floor Shift
Turn Signal and Multifunction Switch Assembly Disassemble - Off Vehicle - Column Shift
Turn Signal and Multifunction Switch Assembly Disassemble - Off Vehicle - Floor Shift
Turn Signal and Multifunction Switch Assembly Assemble - Off Vehicle - Column Shift
Turn Signal and Multifunction Switch Assembly Assemble - Off Vehicle - Floor Shift
Automatic Transmission Shift Lock Control Disassemble
- Off Vehicle - Column Shift

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Automatic Transmission Shift Lock Control Assemble Off Vehicle - Column Shift

Turn Signal Cancel Cam and Upper Bearing Inner Race Disassemble - Off Vehicle - Column Shift

Turn Signal Cancel Cam and Upper Bearing Inner Race Disassemble - Off Vehicle - Floor Shift

Turn Signal Cancel Cam and Upper Bearing Inner Race Assemble - Off Vehicle - Column Shift

Turn Signal Cancel Cam and Upper Bearing Inner Race Assemble - Off Vehicle - Floor Shift

Steering Shaft, Lower Bearing, and Jacket - Disassemble
- Off Vehicle - Column Shift

Steering Shaft, Lower Bearing, and Jacket - Disassemble
- Off Vehicle - Floor Shift

Steering Shaft, Lower Bearing, and Jacket - Assemble Off Vehicle - Column Shift

Steering Shaft, Lower Bearing, and Jacket - Assemble Off Vehicle - Floor Shift

Steering Column Accident Damage Inspection - Off
Vehicle
Description and Operation
Special Tools and Equipment


Suspension
o
Suspension General Diagnosis
o
Wheel Alignment
o
Front Suspension
o
Rear Suspension
o
Tires and Wheels
o
Automatic Level Control
Driveline/Axle
o
Propeller Shaft

Specifications

Visual Identification

Diagnostic Information and Procedures

Repair Instructions

Front Propeller Shaft Replacement

One-Piece Propeller Shaft Replacement

Two-Piece Propeller Shaft Replacement

Double Cardan Universal Joints Replacement - Flange
Yoke Replacement

Double Cardan Universal Joints Replacement - Centering
Ball Replacement

Double Cardan Universal Joints Replacement - Ball Seat
Assembly

Center Bearing Replacement

Universal Joint Replacement - Nylon Injected Ring

Universal Joint Replacement - External Snap Ring

Description and Operation

Special Tools and Equipment
o
Wheel Drive Shafts

Specifications

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Visual Identification
Diagnostic Information and Procedures
Repair Instructions

Wheel Drive Shaft Replacement

Wheel Drive Shaft Inner Joint and Boot Replacement

Wheel Drive Shaft Outer Joint and Boot Replacement

Special Tools and Equipment
Front Drive Axle

Specifications

Component Locator

Diagnostic Information and Procedures

Repair Instructions

Axle Lubricant Change

Shield Replacement

Four-Wheel Drive Indicator Switch Replacement

Vacuum Actuator Solenoid Valve Replacement

Vent Hose Replacement

Clutch Cable Replacement - Front Drive Axle

Clutch Cable Housing Replacement - Front Drive Axle

Front Drive Axle Inner Shaft and Inner Shaft Housing
Replacement - S4WD

Front Drive Axle Inner Shaft and Inner Shaft Housing
Replacement - A4WD

Front Drive Axle Clutch Fork Replacement

Front Drive Axle Clutch Fork Inspection

Front Drive Axle Clutch Shaft Bearing Replacement

Front Drive Axle Inner Shaft Seal and Inner Shaft
Bearing Replacement

Front Drive Axle Actuator Replacement

Front Differential Drive Pinion Flange/Yoke, Seal, and
Dust Deflector Replacement

Differential Carrier Assembly Bushing Replacement

Differential Carrier Assembly Replacement

Differential Carrier Assembly Disassemble - S4WD

Differential Carrier Assembly Disassemble - A4WD

Thrust Washers, Shims, and Adjuster Sleeves Inspection

Front Differential Case Disassemble

Differential Case Bearings Inspection

Differential Case and Gears Inspection

Pinion and Ring Gear Inspection

Front Differential Drive Pinion Gear Bearing Cup
Installation

Pinion Depth Adjustment

Front Differential Case Assemble

Differential Carrier Assembly Assemble

Backlash Inspection and Adjustment

Differential Carrier Assembly Final Assembly

Gear Tooth Contact Pattern Inspection

Description and Operation

Special Tools and Equipment
Rear Drive Axle




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o
o
o

Rear Drive Axle - Locking/Limited Slip Rear Axle


Transfer Case - NVG 233-NP1 (Two Speed Selectable)
Transfer Case - NVG 136-NP4 (One Speed Automatic)

Brakes
o

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Hydraulic Brakes

Specifications

Schematic and Routing Diagrams

Component Locator

Repair Instructions

Master Cylinder Reservoir Filling

Master Cylinder Replacement

Master Cylinder Overhaul

Master Cylinder Bench Bleeding

Brake Pedal Replacement

Combination Valve Replacement

Brake Pipe Replacement

Front Brake Hose Replacement - Dual Piston Caliper

Front Brake Hose Replacement - Single Piston Caliper

Rear Brake Hose Replacement

Hydraulic Brake System Bleeding

Hydraulic Brake System Flushing

Power Vacuum Brake Booster Replacement

Power Brake Booster Vacuum Hose Replacement

Stop Lamp Switch Replacement

Diagnostic Information and Procedures

Description and Operation

Special Tools and Equipment
Disc Brakes

Specifications

Diagnostic Information and Procedures

Repair Instructions

Brake Pad Inspection

Front Disc Brake Pads Replacement - Single Piston
Caliper

Front Disc Brake Pads Replacement - Dual Piston
Caliper

Rear Disc Brake Pads Replacement

Brake Pad and Rotor Burnishing

Brake Caliper Replacement - Front-Single Piston

Brake Caliper Replacement - Rear

Brake Caliper Replacement - Front-Dual Piston

Brake Caliper Inspection

Front Brake Caliper Overhaul - Single Piston

Front Brake Caliper Overhaul - Dual Piston

Rear Brake Caliper Overhaul

Brake Caliper Bracket Replacement - Rear

Brake Rotor Replacement - Front Wheel

Brake Rotor Replacement - Rear Wheel

Brake Rotor Refinishing

Description and Operation

Special Tools and Equipment

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Drum Brakes

Specifications

Repair Instructions

Brake Drum Inspection

Brake Drum Refinishing

Brake Shoe Replacement

Brake Shoe Inspection

Brake Backing Plate Replacement

Wheel Cylinder Replacement

Wheel Cylinder Overhaul

Drum Brake Adjustment

Description and Operation
Park Brake

Specifications

Fastener Tightening Specifications

GM SPO Group Numbers

Repair Instructions

Parking Brake Shoe Replacement

Parking Brake Shoe Adjustment

Park Brake Lubrication

Parking Brake Lever Replacement

Parking Brake Cable Replacement - Rear Cables for
RWD

Parking Brake Cable Replacement - Rear Cables for
4WD, Utilities

Parking Brake Cable Replacement - Front Cables

Parking Brake Cable Inspection

Park Brake Cable Service/Adjustment

Description and Operation
Antilock Brake System

Specifications

Schematic and Routing Diagrams

Component Locator

ABS Components

Antilock Brake System Component Views

Antilock Brake System Connector End Views

Diagnostic Information and Procedures

Self-Diagnostics

Displaying Diagnostic Trouble Codes (DTC)

Clearing DTCs

Intermittents and Poor Connections

Scan Tool Diagnostics

Diagnostic System Check

Diagnostic Trouble Code (DTC) List

DTC C0221 or C021 RF Wheel Speed Sensor Circuit
Open

DTC C0222 or C022 RF Wheel Speed Signal Missing

DTC C0223 or C023 RF Wheel Speed Signal Erratic

DTC C0225 or C025 LF Wheel Speed Sensor Circuit
Open

DTC C0226 or C026 LF Wheel Speed Signal Missing

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DTC C0227 or C027 LF Wheel Speed Signal Erratic


DTC C0229 or C029 Drop Out of Front Wheel Speed
Signals

DTC C0235 or C035 Rear Wheel Speed Signal Circuit
Open - 4.3L

DTC C0235 or C035 Rear Wheel Speed Signal Circuit
Open - 2.2L

DTC C0236 or C036 Rear Wheel Speed Signal Circuit
Missing - 4.3L

DTC C0236 or C036 Rear Wheel Speed Signal Circuit
Missing - 2.2L

DTC C0237 or C037 Rear Wheel Speed Signal Erratic 4.3L

DTC C0237 or C037 Rear Wheel Speed Signal Erratic 2.2L

DTC C0238 or C038 Wheel Speed Mismatch

DTC C0241-C0254 or C041-C054 EBCM Control Valve
Circuit

DTC C0265 or C0266 and C065 C066 EBCM Relay
Circuit

DTC C0267 or C0268 and C067 or C068 Pump Motor
Circuit Open/Shorted

DTC C0269 or C0274 and C069 or C074 Excessive
Dump/Isolation Time

DTC C0271-C0273 or C071 or C073 EBCM
Malfunction

DTC C0281 or C081 Brake Switch Circuit
Repair Instructions

Antilock Brake System Automated Bleed Procedure

Electronic Brake Control Module Replacement

Brake Pressure Modulator Valve Replacement

Wheel Speed Sensor Replacement - S Pickup

Wheel Speed Sensor Replacement - S Utility

Wheel Speed Sensor Replacement - T Trucks

Tube Adapter Replacement
Description and Operation
Special Tools and Equipment






Engine
o
o
o
o
o
o

Engine Mechanical - 2.2L


Engine Mechanical - 4.3L
Engine Cooling
Engine Electrical
Engine Controls - 2.2L
Engine Controls - 4.3L

Specifications

Schematic and Routing Diagrams

Emission Hose Routing Diagram

Engine Controls Schematic References

Engine Controls Schematic Icons

Engine Controls Schematics

Component Locator

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Engine Controls Components


Engine Controls Component Views
VCM Connector End Views
Engine Controls Connector End Views

Diagnostic Information and Procedures

Repair Instructions

Description and Operation

Special Tools and Equipment
o
Engine Exhaust
Transmission/Transaxle
Body and Accessories
o
Lighting Systems
o
Wipers/Washer Systems
o
Entertainment
o
Wiring Systems
o
Cellular Communication
o
Body Control System
o
Instrument Panel, Gauges, and Console

Specifications

Schematic and Routing Diagrams

Component Locator

Diagnostic Information and Procedures

Repair Instructions

Instrument Panel Service Precautions

Instrument Cluster Replacement

Instrument Cluster Lens Replacement

S4WD Select Switch Replacement

Instrument Panel Lamp Dimmer Switch Replacement

Instrument Panel Accessory Trim Plate Replacement

Driver Knee Bolster Panel Replacement

Knee Bolster Replacement

Instrument Panel Compartment Door Replacement

Console Shift Boot Replacement

Front Floor Console Replacement - Full Length (Auto
Trans)

Front Floor Console Replacement - Full Length (Manual
Trans)

Front Floor Console Replacement - Full Length (Envoy)

Front Floor Console Replacement - Non-Full Length

Front Floor Console Cup Holder Replacement

Instrument Panel Carrier Replacement

Steering Column Bracket Replacement

Instrument Panel Insulator Panel Replacement - Right
Side

Instrument Panel Insulator Panel Replacement - Left Side

Closeout/Insulator Panel Replacement - Center

Fuse Block Replacement

Driver Information Center Replacement - Non-Sunroof

Driver Information Center Replacement - Sunroof
Equipped

Driver Information Center Module Replacement





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Ambient Air Temperature Gage Sensor Replacement


Electronic Compass Module Replacement

Description and Operation

Special Tools and Equipment
Keyless Entry
Horns
Theft Deterrent
Cruise Control
Retained Accessory Power
Garage Door Opener
Exterior Trim
Waterleaks
Stationary Windows
Bumpers
Body Front End
Doors
Roof
Seats
Interior Trim

Specifications

Repair Instructions

Eliminating Unwanted Odors in Vehicles

Front Floor Mat/Carpet Replacement - Extended Cab

Front Floor Mat/Carpet Replacement - Pickup

Front Floor Mat/Carpet Replacement - Utility

Door Sill Plate Replacement

Rear Floor Rear Trim Plate Replacement

Liftgate Door Sill Plate Replacement

Rear Floor Panel Carpet Replacement

Headlining Trim Panel Replacement - Pickup

Headlining Trim Panel Replacement - Utility

Headlining Trim Panel Replacement - Extended Cab
Pickup

Assist Handle Replacement

Coat Hook Replacement - Extended Cab

Coat Hook Replacement - Standard Cab

Coat Hook Replacement - Utility

Electronic Compass Sensor Module Replacement

Sunshade Replacement

Side Door Lock Pillar Garnish Molding Replacement

Windshield Pillar Garnish Molding Replacement

Rear Upper Garnish Molding Replacement

Body Rear Inner Panel Carpet Replacement

Third Pillar Trim Replacement - Extended Cab PU w/ Rr
Sde Door

Third Pillar Trim Replacement - 4 Door Utility

Body Hinge Pillar Trim Panel Replacement - Left Side

Body Hinge Pillar Trim Panel Replacement - Right Side

Body Side Trim Panel Replacement - Standard Cab
Pickup

Body Side Trim Panel Replacement - 4 Door Utility



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o
o
o
o
o
o
o
o
o
o
o
o
o
o
o

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Body Side Trim Panel Replacement - Extended Cab


Body Side Trim Panel Replacement - 2 Door Utility
Cleaning Vinyl Trim
Cleaning Agents
Interior Cleaning
Cleaning of Fabric Trim
Cleaning Glass Surfaces
Grease or Oil Stains
Non-Greasy Stains
Combination Stains

Special Tools and Equipment
o
Body Rear End
o
Plastic Panel Information and Repair
o
Paint/Coatings
o
Frame and Underbody
Restraints











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Reference on Schematic
Automatic Transmission Cell 21
Automatic Transmission Control Assembly Cell
138
Body Control Module (BCM) Cell 51
Camshaft Position Sensor Cell 21
Cigar Lighter Cell 19
Compass/Temperature Console Cell 86
Cruise Control Module Cell 34
Data Link Connector Cell 50
Driver Information Display Module Cell 86
Electronic Brake Control Module Cell 44
Engine Controls Cell 21
Engine Oil Pressure Guage Sensor Cell 21
Exhaust Gas Recirculation Valve Cell 21
Exterior Lights Cell 110
Front Axle Switch Cell 38
Fuel Level Sensor Cell 21
Fuel Pump Relay Cell 21

Section Number - Subsection


Name
6 - Engine Controls - 4.3L
2 - Steering Wheel and Column
8 - Body Control System
6 - Engine Controls - 4.3L
8 - Wiring Systems
8 - Instrument Panel, Gauges and
Console
8 - Cruise Control
8 - Wiring Systems
8 - Instrument Panel, Gauges and
Console
5 - Antilock Brake System
6 - Engine Controls - 4.3L
6 - Engine Controls - 4.3L
6 - Engine Controls - 4.3L
8 - Lighting Systems
4 - Transfer Case
6 - Engine Controls - 4.3L
6 - Engine Controls - 4.3L

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Ground Distribution Cell 14


Heated Oxygen Sensor, LH Front (Bank 1,
Sensor 1) Cell 21
HVAC Blower Controls: Manual Cell 83
Instrument Cluster Cell 81

Icon

1 - HVAC Systems with A/C Manual


8 - Instrument Panel, Gauges and
Console
6 - Engine Controls - 4.3L
8 - Wiring Systems
8 - Entertainment
6 - Engine Controls - 4.3L
6 - Engine Controls - 4.3L
8 - Lighting Systems
4 - Transfer Case
4 - Transfer Case
4 - Transfer Case
4 - Transfer Case
4 - Transfer Case
6 - Engine Controls - 4.3L
6 - Engine Controls - 4.3L

Icon Definition
Notice: Electrostatic discharge (ESD) can damage many
solid-state electrical components. ESD susceptible
components may or may not be labeled with the ESD
symbol. Handle all electrical components carefully. Use
the following precautions in order to avoid ESD damage:

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6 - Engine Controls - 4.3L

Touch a metal ground point in order to remove


your body's static charge before servicing any
electronic component; especially after sliding
across the vehicle seat.
Do not touch exposed terminals. Terminals may
connect to circuits susceptible the ESD damage.
Do not allow tools to contact exposed terminals
when servicing connectors.
Do not remove components from their protective
packaging until required to do so.
Avoid the following actions unless required by the
diagnostic procedure:
o Jumpering or grounding of the components
or connectors.
o Connecting test equipment probes to
components or connectors. Connect the
ground lead first when using test probes.
Ground the protective packaging of any

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Mass Air Flow Sensor cell 21


Power Distribution Cell 10
Radio Cell 150
Sensor 5 Volt Reference Cell 21
Sensor Ground Cell 21
Trailer Wiring Provision Cell 110
Transfer Case Control Module (TCCM) (NP1)
Cell 38
Transfer Case Control Module (TCCM) (NP4)
Cell 38
Transfer Case Select Switch Cell 38
Transfer Case Speed Sensor, Front Cell 38
Transfer Case Select Switch, RR Cell 38
Vehicle Control Module Cell 21
VSS Shield Ground Cell 21

8 - Wiring Systems

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component before opening. Do not rest solid-state


components on metal workbenches, or on top of
TVs, radios, or other electrical devices.
Notice: The OBD II symbol is used on the circuit
diagrams in order to alert the technician that the circuit is
essential for proper OBD II emission control circuit
operation. Any circuit which fails and causes the
malfunction indicator lamp (MIL) to turn ON, or causes
emissions-related component damage, is identified as an
OBD II circuit.

Name

Location

1-2 Shift Solenoid Inside the automatic


(1-2 SS) Valve transmission

2-3 Shift Solenoid Inside the automatic


(2-3 SS) Valve transmission

3-2 Shift Solenoid


Inside the automatic
(3-2 SS) Valve
transmission
Assembly

A/C Compressor Part of A/C


Clutch
Compressor

A/C Compressor
Clutch Diode (4.3
L Engine)
A/C Compressor
Clutch Relay (4.3L
Engine)

Locator View
Automatic
Transmission
Electronic
Component Views
in Automatic
Transmission
Automatic
Transmission
Electronic
Component Views
in Automatic
Transmission
Automatic
Transmission
Electronic
Component Views
in Automatic
Transmission
HVAC Component
Views in HVAC
Systems with A/C
- Manual

Connector End
View
Automatic
Transmission
Internal Connector
End Views in
Automatic
Transmission
Automatic
Transmission
Internal Connector
End Views in
Automatic
Transmission
Automatic
Transmission
Internal Connector
End Views in
Automatic
Transmission
HVAC Connector
End Views in
HVAC Systems
with A/C - Manual

In engine harness
HVAC Component HVAC Connector
breakout, 7.5 cm from
Views in HVAC
End Views in
the breakout to the
Systems with A/C HVAC Systems
A/C Compressor and
- Manual
with A/C - Manual
high pressure switch
In the Underhood
Power and

Grounding
Bussed Electrical
Component Views
Center

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A/C Compressor
High Pressure Rear of A/C
Cutoff Switch Compressor
(4.3L Engine)
A/C Compressor
Cycling Switch At the Accumulator
(4.3L Engine)

Body Control
Module (BCM)
Connector C1,
Brown (24
Cavities)

Lower rear of IP on
the heater assembly

Body Control
Module (BCM) Lower rear of IP on
Connector C2, Blue the heater assembly
(24 Cavities)

LH side of dash, near


Body Relay Block
IP fuse Block

Power and
Grounding
Component Views
in Wiring Systems

Engine Controls
Component Views
in Engine Controls
- 4.3L
Central Sequential
Engine Controls
Fuel Injection Top center of engine, Component Views
(CSFI) Connector forward of distributor in Engine Controls
(4.3L Engine)
- 4.3L
Engine Controls
Crankshaft Position Below RH front of
Component Views
(CKP) Sensor engine near harmonic
in Engine Controls
(4.3L Engine) balancer
- 4.3L
Camshaft Position
(CMP) Sensor Rear of Distributor
(4.3L Engine)

Cruise Control
Module

Cruise Control
LH rear of engine
Component Views
compartment on cowl
in Cruise Control

Electronic Brake On the Brake Pressure


Control Module Modulator Valve

Antilock Brake
System

HVAC Connector
End Views in
HVAC Systems
with A/C - Manual
HVAC Connector
End Views in
HVAC Systems
with A/C - Manual
Automatic
Transmission
Internal Connector
End Views in
Automatic
Transmission
Body Control
System Connector
End Views in
Body Control
System
Body Control
System Connector
End Views in
Body Control
System
Power and
Grounding
Connector End
Views in Wiring
Systems
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Cruise Control
Connector End
Views in Cruise
Control
Antilock Brake
System Connector

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Automatic
Transmission Fluid
Inside the automatic
Pressure (TFP)
transmission
Manual Valve
Position Switch

in Wiring Systems
HVAC Component
Views in HVAC
Systems with A/C
- Manual
HVAC Component
Views in HVAC
Systems with A/C
- Manual
Automatic
Transmission
Electronic
Component Views
in Automatic
Transmission
Body Control
System
Component Views
in Body Control
System
Body Control
System
Component Views
in Body Control
System

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(EBCM)

(BPMV), LH rear
wheelwell

Component Views
in ABS/Traction
Control

End Views in
ABS/Traction
Control

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Body harness
Antilock Brake
Antilock Brake
Electronic Brake connector on LH of
System
System Connector
Control Module Electronic Brake
Component Views
End Views in
(EBCM) Connector Control Module/Brake
in ABS/Traction
ABS/Traction
C1 (10 Cavities) Pressure Modulator
Control
Control
Valve
Body harness
Antilock Brake
Antilock Brake
Electronic Brake connector on LH of
System
System Connector
Control Module Electronic Brake
Component Views
End Views in
(EBCM) Connector Control Module/Brake
in ABS/Traction
ABS/Traction
C2 (2 Cavities) Pressure Modulator
Control
Control
Valve
HVAC Connector
Electronic Climate
HVAC Component
End Views in
Control (ECC) Center of Instrument
Views in HVAC
HVAC Systems
Module (W/ Auto Panel, below radio
Systems with A/C
with A/C A/C)
- Automatic
Automatic
Engine Coolant
Engine Controls
Engine Controls
Temperature (ECT) Front of engine near
Component Views Connector End
thermostat housing
Sensor (4.3L
in Engine Controls Views in Engine
- 4.3L
Engine)
Controls - 4.3L
Engine Oil
Engine Controls
Engine Controls
Top
rear
of
engine
Pressure Gauge
Component Views Connector End
below distributor
Sensor (4.3L
in Engine Controls Views in Engine
Engine)
- 4.3L
Controls - 4.3L
Evaporative
Engine Controls
Engine Controls
(EVAP) Emission Top RH center of
Component Views Connector End
Canister Purge engine, near fuel
in Engine Controls Views in Engine
injector connector
Valve (4.3L
- 4.3L
Controls - 4.3L
Engine)
Engine Controls
Crossmember area of
Evaporative
fuel tank, to the rear
Connector End
Emission Canister

LH center of
Views in Engine
Vent Valve
crossmember
Controls - 4.3L
Exhaust Gas
Engine Controls
Engine Controls
Top front of engine
Recirculation
Component Views Connector End
near drive belt
Valve (4.3L
in Engine Controls Views in Engine
Engine)
- 4.3L
Controls - 4.3L
Transfer Case
Transfer Case
Front axle, right of
Control
Control Connector
Front Axle Switch
differential
Component Views
End Views in
in Transfer Case
Transfer Case
Engine Controls
Engine Controls
Fuel Pump and Internal to the fuel
Component Views Connector End
Sender
tank
in Engine Controls Views in Engine

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- 4.3L
Controls - 4.3L
Power and
In the Underhood Fuse
Grounding
Fuel Pump Relay

Block
Component Views
in Wiring Systems
Engine Controls
Engine Controls
Fuel Tank Pressure Top of fuel tank, three Component Views Connector End
Sensor
wire connector
in Engine Controls Views in Engine
- 4.3L
Controls - 4.3L
Engine Controls
Engine Controls
Generator (4.3L
Component Views Connector End
RH front of engine
Engine)
in Engine Controls Views in Engine
Controls - 4.3L
- 4.3L
Heated Oxygen On the rear of the LH
Engine Controls
Sensor (HO2S) exhaust pipe on the
Component Views

Bank 1, Sensor 1 left side of the


in Engine Controls
(4.3L Engine) transmission
- 4.3L
Heated Oxygen
Engine Controls
Rear of the catalytic
Component Views
Sensor (HO2S)
converter in the

in Engine Controls
Bank 1 Sensor 3
exhaust pipe
(4.3L Engine)
- 4.3L
Heated Oxygen
Engine Controls
Sensor (HO2S) RH rear of engine, in Component Views

in Engine Controls
Bank 2 Sensor 1 exhaust pipe
- 4.3L
(4.3L Engine)
Heater And A/C
HVAC Component HVAC Connector
Controller (W/
Bottom center
Views in HVAC
End Views in
Manual A/C)
Systems with A/C HVAC Systems
Connector C1 (10 connector
- Manual
with A/C - Manual
Cavities) (Heater
Control Lamp)
Heater And A/C
HVAC Component HVAC Connector
Controller (W/
Next to the vacuum
Views in HVAC
End Views in
Manual A/C)
Systems with A/C HVAC Systems
Connector C2 (3 harness connector
- Manual
with A/C - Manual
Cavities) (Heater
Control Lamp)
Engine Controls
Engine Controls
Idle Air Control
Top of the engine, on Component Views Connector End
(IAC) Valve (4.3L
the throttle body
in Engine Controls Views in Engine
Engine)
- 4.3L
Controls - 4.3L
Engine Controls
Engine Controls
Ignition Coil (4.3L
Component Views Connector End
Top RH side of engine
Engine)
in Engine Controls Views in Engine
- 4.3L
Controls - 4.3L
Ignition Control
Engine Controls
Engine Controls
Module (ICM) Top RH side of engine Component Views Connector End
in Engine Controls Views in Engine
(4.3L Engine)

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IP Fuse Block

Power and
LH of the IP, near the
Grounding
door jamb switch, LF Component Views
in Wiring Systems

Engine Controls
Component Views
in Engine Controls
- 4.3L
Manifold Absolute
Engine Controls
Pressure (MAP)
Component Views
Top center of engine
in Engine Controls
Sensor (4.3L
- 4.3L
Engine)
Engine Controls
LH front of engine
Mass Air Flow
Component Views
compartment on air
(MAF) Sensor
in Engine Controls
intake duct
- 4.3L
Park/Neutral
Engine Controls
Position (PNP)
Component Views
LH of the transmission
Switch, Connector
in Engine Controls
C1 (7 Cavities)
- 4.3L
Park/Neutral
Engine Controls
Position (PNP)
Component Views
LH of the transmission
Switch, Connector
in Engine Controls
C2 (4 Cavities)
- 4.3L
Automatic
Transmission
Pressure Control
Inside the automatic
Electronic
Solenoid (PC SOL)
transmission
Component Views
Valve
in Automatic
Transmission
Radio (Except
Entertainment
Center of the
Bravada)
Component Views
Connector C1, (10 Instrument Panel
in Entertainment
Cavities)
Radio (Except LH rear of radio
Entertainment
Top rear of engine
Knock Sensor (KS)
above transmission
(4.3L Engine)
bell housing

Controls - 4.3L
Instrument Panel,
Gages, and
Console Connector
End Views in
Instrument Panel,
Gauges, and
Console
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Power and
Grounding
Connector End
Views in Wiring
Systems
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Automatic
Transmission
Internal Connector
End Views in
Automatic
Transmission
Entertainment
Connector End
Views in
Entertainment
Entertainment

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- 4.3L
Instrument Panel,
Gages, and
Console
In the IP, ahead of the
Instrument Cluster
Component Views
steering column
in Instrument
Panel, Gauges, and
Console
Intake Air
Engine Controls
LH front of engine
Temperature (IAT)
Component Views
compartment in air
Sensor (4.3L
in Engine Controls
intake duct
Engine)
- 4.3L

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Bravada)
Connector C2 (10
Cavities)

Component Views
in Entertainment

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Lighting Systems
Component Views
in Lighting
Systems
Engine Controls
Throttle Position Top LH side of
Component Views
(TP) Sensor (4.3L engine, on the throttle
in Engine Controls
Engine)
body
- 4.3L
Automatic
Torque Converter
Transmission
Clutch Pulse Width
Inside the automatic
Electronic
Modulation
transmission
Component Views
Solenoid (TCC
in Automatic
PWM SOL) Valve
Transmission
Automatic
Transmission
Torque Converter
Inside the automatic
Electronic
Clutch Solenoid
transmission
Component Views
(TCC SOL) Valve
in Automatic
Transmission
Transfer Case
Transfer Case Shift
Control
Control Module Behind Center of
Component Views
Connector C1 (32 Instrument Panel
in Transfer Case Cavities)
NV136
Transfer Case
Transfer Case Shift
Control
Control Module
Lower Connector
Component Views
Connector C2 (4
in Transfer Case Cavities)
NV136
Transfer Case
Transfer Case
Front center of
Select Switch (w/
Control
instrument panel
Push Button
Component Views
above and to the left of
Control) Connector
in Transfer Case the radio
C1 (8 Cavities)
NV233
Transfer Case
Transfer Case
Front center of
Select Switch (W/
Control
instrument panel
Electric Shift
Component Views
above and to the left of
4WD) Connector
in Transfer Case the radio
C2 (4 Cavities)
NV233
Transmission Fluid
Inside the automatic

Temperature (TFT)
transmission
Sensor
Underhood Fuse Over left front fender
Power and
Block
well
Grounding
TCC/Stop Lamp Mounted on brake
Switch
pedal

Connector End
Views in
Entertainment
Lighting Systems
Connector End
Views in Lighting
Systems
Engine Controls
Connector End
Views in Engine
Controls - 4.3L
Automatic
Transmission
Internal Connector
End Views in
Automatic
Transmission
Automatic
Transmission
Internal Connector
End Views in
Automatic
Transmission
Transfer Case
Control Connector
End Views in
Transfer Case NV136
Transfer Case
Control Connector
End Views in
Transfer Case NV136
Transfer Case
Control Connector
End Views in
Transfer Case NV233
Transfer Case
Control Connector
End Views in
Transfer Case NV233

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Component Views
in Wiring Systems
Underhood Fuse
Power and
Block Connector Below the Underhood
Grounding
C1 (68 Cavities) Fuse Block
Component Views
(Body)
in Wiring Systems

Underhood Fuse
Power and
Block Connector Below the Underhood
Grounding
C3 (32 Cavities) Fuse Block
Component Views
(Chassis)
in Wiring Systems
Underhood Fuse
Power and
Block Connector Below the Underhood
Grounding
C3 (32 Cavities) Fuse Block
Component Views
(Chassis)
in Wiring Systems
Vehicle Control
Module (VCM)
(4.3L Engine)

RH side of engine
compartment

Vehicle Control
Module (VCM)
RH side of engine
(4.3L Engine)
compartment
Connector C1 (32
Cavities)
Vehicle Control
Module (VCM)
RH side of engine
(4.3L Engine)
compartment
Connector C2 (32
Cavities)
Vehicle Control
Module (VCM)
RH side of engine
(4.3L Engine)
compartment
Connector C3 (32
Cavities)
Vehicle Control
Module (VCM)
RH side of engine
(4.3L Engine)
compartment
Connector C4 (24
Cavities)
Vehicle Speed RH rear of automatic
Sensor (VSS) (4.3L transmission

Engine Controls
Component Views
in Engine Controls
- 4.3L

Engine Controls VCM Connector


Component Views
End Views in
in Engine Controls Engine Controls - 4.3L
4.3L
Engine Controls VCM Connector
Component Views
End Views in
in Engine Controls Engine Controls - 4.3L
4.3L
Engine Controls VCM Connector
Component Views
End Views in
in Engine Controls Engine Controls - 4.3L
4.3L
Engine Controls VCM Connector
Component Views
End Views in
in Engine Controls Engine Controls - 4.3L
4.3L
Automatic
Transmission

Engine Controls
Connector End

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Underhood Fuse
Power and
Block Connector Below the Underhood
Grounding
C2 (68 Cavities) Fuse Block
Component Views
(Engine)
in Wiring Systems

Power and
Grounding
Connector End
Views in Wiring
Systems
Power and
Grounding
Connector End
Views in Wiring
Systems
Power and
Grounding
Connector End
Views in Wiring
Systems
Power and
Grounding
Connector End
Views in Wiring
Systems

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Engine W/ A/T,
W/O 4WD)

Vehicle Speed
Sensor (VSS) (4.3L LH Rear of the auto
Engine W/ Auto 4WD Transfer Case
4WD) (Bravada)

C100 (Engine
Harness to Oxygen
Sensor Harness)
(4.3L Engine, 6
Cavities)
C101 (Engine
Harness to Body
Harness) (4.3L
Engine, 10
Cavities)
C104 (Chassis to
4.3L Engine
Harness) (6
Cavities)
C105 (Engine
Harness to LH
Front Heated
Oxygen Sensor
Pigtail Connector)
(4.3L Engine) (4
Cavities)
C108 (W/ Active
Transfer Case
Active Transfer
Case extension
harness to Body
Harness) (7
Cavities)
C114 (W/ Electric
Shift 4WD, Body
harness to front
axle switch
extension harness)

Views in Engine
Controls - 4.3L

Engine Controls
Connector End
Views in Engine
Controls - 4.3L

Engine Controls
Connector End
Views in Engine
Controls - 4.3L

RH rear of engine
compartment, near the
accumulator

Harness Routing
Views in Wiring
Systems

Inline Harness
Connector End
Views in Wiring
Systems

RH engine
compartment, near
VCM

Harness Routing
Views in Wiring
Systems

Inline Harness
Connector End
Views in Wiring
Systems

LH side of
transmission

Harness Routing
Views in Wiring
Systems

Inline Harness
Connector End
Views in Wiring
Systems

On the LH side of the


transmission

Harness Routing
Views in Wiring
Systems

Inline Harness
Connector End
Views in Wiring
Systems

LH rear engine
compartment near
cowl penetration P100

Harness Routing
Views in Wiring
Systems

Inline Harness
Connector End
Views in Wiring
Systems

LH center of engine
compartment, near the
electronic brake
control module)

Harness Routing
Views in Wiring
Systems

Inline Harness
Connector End
Views in Wiring
Systems

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Vehicle Speed
Sensor (VSS) (4.3L To the left rear of the
Engine w/ M/T w/o M/T
Transfer Case)

Electronic
Component Views
in Automatic
Transmission
Automatic
Transmission
Electronic
Component Views
in Automatic
Transmission
Automatic
Transmission
Electronic
Component Views
in Automatic
Transmission

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(2 Cavities)
C116 (M to M) (W/ Near the top rear of
A/T and Transfer the automatic
Case) (2 Cavities) transmission

Harness Routing
Views in Wiring
Systems

C116 (M to M) (W/ Near the LH rear of


M/T and Transfer the manual
Case) (2 Cavities) transmission

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Inline Harness
Connector End
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Inline Harness
Connector End
Views in Wiring
Systems

Automatic
Transmission
Harness Routing
Inline Harness
Views in Wiring
Connector End
Systems
View in Automatic
Transmission
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring

Inline Harness
Connector End
Views in Wiring
Systems
Inline Harness
Connector End
Views in Wiring
Systems
Inline Harness
Connector End
Views in Wiring
Systems

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C125 (Oxygen
Sensor Harness to
Post-Converter Chassis harness near
Heated Oxygen the Post-Converter
Sensor Pigtail (Bank 1, Sensor 3)
Connector) (4.3L Heated Oxygen Sensor
Engine) (4
Cavities)
C126 (Oxygen
Sensor Harness to
Chassis harness near
RH Front Heated
the RH Front (Bank 2,
Oxygen Sensor
Sensor 1) Heated
Pigtail Connector)
Oxygen Sensor
(4.3L Engine) (4
Cavities)
C175 (Engine
Harness to
Automatic
RH rear of the
Transmission
automatic transmission
Connector) (4.3L
Engine) (13
Cavities)
C203 (Body
Harness to IP
RH side of dash
Harness) (116
Cavities)
C209 (Pickup Body
Harness to Dome LH front of dash at LH
front side window
Harness) (16
Cavities)
C209 (Utility Body
Harness to Dome LH front of dash at LH
front side window
Harness) (16
Cavities)
G102 (Circuit 350,
LH rear of engine
4.3L Engine
block
Harness)
G103 (Circuit 351, LH rear of engine
4.3L Engine
block

Inline Harness
Connector End
Views in Wiring
Systems
Inline Harness
Connector End
Views in Wiring
Systems

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Harness)
G104 (Circuit 450,
4.3L Engine
Harness)
G105 (Circuit 451,
4.3L Engine
Harness)

RH rear of engine
block
RH rear of engine
block

P100 (IP Bulkhead LH rear of engine


Pass-Through) compartment, on cowl
Between the breakouts
S100 (Circuit 452, for the starter and the
4.3L Engine
generator, 4 cm from
Harness)
the breakout to the
generator
Between the breakouts
to the generator and
S101 (Circuit 474,
the fuel injector
4.3L Engine
connector, 5 cm from
Harness)
the breakout to the
generator
Between the breakouts
for the generator and
S102 (Circuit 470,
the fuel injection
4.3L Engine
connectors, 5 cm from
Harness)
the breakout to the fuel
injection connector

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

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LH rear of engine
G117 (Circuit 850,
compartment, near
Body Harness)
cruise control module
G200 (Circuit LH front of dash
1850, Body
panel, above grommet
Harness)
P100
G201 (Circuit LH front of dash
1850, Body
panel, above grommet
Harness)
P100
G402 (Circuit
Inside rear of LH
1750, Pickup
Frame Rail
Chassis Harness)
Near top center of
G402 (Circuit 22,
second cross-member
1650 Four-Door
from rear, with fuel
Utility Chassis
filler neck ground
Harness)
strap
G402 (Circuit 22, LH rear crossmember
1650 Two-Door near LH frame rail,
Utility Chassis with fuel filler ground
Harness)
strap

Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems

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Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing

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In the breakout to the


S103 (Circuit 350,
A/C compressor and
4.3L Engine
cutoff switch, 7.5 cm
Harness W/ A/C)
from the breakout
In the breakout to the
S104 (Circuit 59,
A/C compressor and
4.3L Engine
cutoff switch, 7.5 cm
Harness W/ A/C)
from the breakout
Between the breakouts
to the connector for
the rear oxygen
S106 (Circuit 351,
sensors and the body
4.3L Engine
harness connector, 6.5
Harness)
cm from the breakout
to the oxygen sensor
connector
Between the Blower
Motor breakout and
S113 (Circuit 1020, the Blower Motor
Body Harness) Relay breakout, 13 cm
from the breakout to
the blower motor
Between the Vehicle
Control Module
S118 (Circuit 850, breakout and the
Body Harness W/ Blower Motor Relay
4.3L Engine)
breakout, 25 cm from
the breakout to the
VCM
Between the breakouts
S121 (Circuit 1695,
to the VCM and the
Body Harness W/
blower motor relay, 13
Electric Shift
cm from the breakout
4WD)
to the VCM
S133 (Circuit 839,
Inside the Automatic
Automatic
Transmission-A/T
Transmission
only.
harness)
S134 (Circuit 850, In the breakout to the
Active Transfer front speed sensor, 10
Case Harness) cm into the breakout
Between the breakout
to Vehicle Control
S138 (Circuit 420, Module Connector C4
Body harness, W/ and the Windshield
Auto A/C)
Wiper Motor breakout,
32 cm from the
breakout to the motor.
S138 (Circuit 420, Between the Blower

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Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems
Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

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Body harness, W/O Motor Resistor


Auto A/C)
breakout and the
Windshield Wiper
Motor breakout, 6 cm
from the breakout to
the resistor.
S140 (Circuit 450, 15 cm from the end of
4.3L Engine
vehicle speed sensor
Harness W/ A/T) connector
S140 (Circuit 450, 20 cm from the end of
4.3L Engine
vehicle speed sensor
Harness W/ M/T) connector
Between the breakouts
S150 (Circuit 539, to the RH Front and
4.3L Engine
the post-catalytic
Oxygen Sensor oxygen, 10 cm from
Harness)
the breakout to the RH
Front sensor
Between the breakouts
S151 (Circuit 350, to the RH Front and
4.3L Engine
the post-catalytic
Oxygen Sensor oxygen, 10 cm from
Harness)
the breakout to the RH
Front sensor
Between the breakouts
for the LR and RR
S152 (Circuit 351,
engine block grounds,
413, and 451, 4.3L
15 cm from the
Engine Harness)
breakout to the LR
engine grounds
Between the breakouts
for Truck Body
Control Module
S240 (Circuit 340,
Connector C3 and the
IP Harness, Utility
instrument cluster, 4
W/ Auto A/C)
cm from the breakout
to the body control
module
SP200 (Circuits 41, Strapped to the body
241, 341, 817
harness in the center
Splice Pack, Body front of dash area, to
Harness)
the right of SP204
SP201 (Data Link
Connector Spice LH side of dash panel,
below IP Fuse Block
Pack, Body
Harness)
SP202 (379, 1850 Strapped to body
Splice Pack, Body harness at LH center
Harness)
of the front of dash

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Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Harness Routing
Views in Wiring
Systems

Click here for full size

Connector Part Information


Pin
12
3
46
7
8
9
10
1112
13
14
15
1618
19
20
21

Wire Color

BRN/WHT

TAN
PNK/BLK
PPL
TAN/BLK

WHT

YEL/BLK

PPL/WHT

PPL

12129025
32 Pin VCM Connector C1 (BLU)

Circuit No.

633

1667
632
30
422

687

1827

1665

1666

Function
Not Used
1X CMP Signal
Not Used
HO2S Bank 2 Sensor 1 Low
CMP Sensor Ground
Fuel Level Output
TCC Solenoid Control
Not Used
32 Shift Solenoid Control
Not Used
VSS Output Signal (EBCM)
Not Used
HO2S Bank 1 Sensor 1 Signal
Not Used
HO2S Bank 2 Sensor 1 Signal

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area
SP422 (Pickup On the LH frame rail
Chassis W/ 4.3L behind the
Engine, Circuit crossmember at the
470)
transmission
SP423 (Circuit 470,
On front of
1650, 2109 Splice
crossmember near LH
Pack, Chassis
frame rail, near
Harness) (Fourcanister vent valve
Door Utility)
SP423 (Circuit 470,
1650, 2109 Splice
On top of rear
Pack, Chassis
crossmember
Harness) (TwoDoor Utility)

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PPL/WHT

TAN/WHT
TAN/WHT

PPL
LT GRN/BLK
PPL/WHT
YEL

1668

1653
1669

574
822
821
573

HO2S Bank 1 Sensor 3 Signal


Not Used
HO2S Bank 1 Sensor 1 Low
HO2S Bank 1 Sensor 3 Low
Not Used
CKP Sensor Ground
VSS Low
VSS High
3X CKP Sensor Signal
Not Used

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Connector Part Information


Pin
1
2
3
4
5
6
7
8
9
10
1112
13
14
15
16
1718
19

Wire Color

WHT

YEL/BLK

LT GRN
BRN
BLK
YEL/BLK
BRN

LT GRN/WHT
LT BLU/WHT
LT GRN/BLK
PNK/BLK

DK BLU

12129025
32 Pin VCM Connector C2 (RED)

Circuit No.

1310

1223

1222
418
1744
846
1456

1749
1747
1745
1746

496

Function
Not Used
EVAP Canister Vent Solenoid Control
Not Used
2-3 Shift Solenoid Control
Not Used
1-2 Shift Solenoid Control
TCC PWM Solenoid Control
Fuel Injector #1 Control
Fuel Injector #6 Control
EGR Pintle Position Signal
Not Used
IAC Coil B High
IAC Coil A High
Fuel Injector #2 Control
Fuel Injector #3 Control
Not Used
KS Signal

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22
23-24
25
26
27
28
29
30
31
32

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WHT
LT GRN
TAN
YEL
DK BLU
DK GRN

YEL/BLK
YEL
LT GRN/BLK
LT BLU/BLK
BLK/WHT
LT BLU/BLK

121
432
472
410
417
890

1227
492
444
1748
845
844

Tachometer Output
MAP Sensor Signal
IAT Sensor Signal
ECT Sensor Signal
TP Sensor Signal
Fuel Tank Pressure Sensor Signal
Not Used
TFT Sensor Signal
MAF Sensor Signal
IAC Coil B Low
IAC Coil A Low
Fuel Injector #5 Control
Fuel Injector #4 Control

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Connector Part
Information
Pin
1
2
3
4
5
6
78
9
10
11
12
13
14

12129025
32 Pin VCM Connector C3 (CLR)

Wire Color Circuit No.


DK
459
GRN/WHT
DK
428
GRN/WHT

BLK
452
RED
225
RED/BLK
1228

WHT
423

RED
1226
GRY
416
PPL
1589

Function
A/C Compressor Enable Relay Control
EVAP Canister Purge Solenoid Control
Not Used
ECT/TP Sensor Ground
Generator Control/Monitoring
PC Solenoid High
Not Used
IC Control
Not Used
Transmission Range C Signal
TP Sensor 5 V Reference
Fuel Level Sensor Signal
Not Used

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20
21
22
23
24
25
26
27
28
29
30
31
32

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15
16
17
18
19

27
28
29
30
31
32

1229

PC Solenoid Low

351
351

VCM Ground
VCM Ground
IAT/MAP/EGR Pintle Position/Fuel Tank Pressure/TFT
BLK
470
Sensor Ground

Not Used
ORN
440
Battery Positive Voltage (B+)
DK BLU
1225
Transmission Range B Signal
PNK
1224
Transmission Range A Signal

Not Used
GRN/WHT GRN/WHT A/C Request Signal
WHT
776
PRNDL P Signal
Fuel Tank Pressure/EGR Pintle Position/MAP Sensor
GRY
474
5 V Reference
GRY
773
PRNDL C Signal

Not Used
GRN
603
A/C Pressure Signal
BLK/WHT
771
PRNDL A Signal
YEL
772
PRNDL B Signal

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Connector Part
Information
Pin
1
2
3
4

Wire Color
DK
GRN/WHT

DK
GRN/WHT
DK GRN

12129225
24 Pin VCM Connector C4 (BLK)

Circuit
Function
No.
465

Fuel Pump Relay Control

Not Used
VSS Output (TCCM, Cruise Control Module,
Console,TBC Module
VSS Output Signal (Speedo, Radio)

817
389

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20
21
22
23
24
25
26

LT BLU
WHT
BLK/WHT
BLK/WHT

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419

MIL Control

Not Used

420
1807

241
710

1676
1020
439
1695
257

379
1694
396

Brake Signal
Serial Data (Class II)
Not Used
Ignition Positive Voltage
Serial Data (Class II)
Not Used
EGR Valve Control
Ignition Positive Voltage
Ignition Positive Voltage
4WD Front Wheel Lock Input
EGR Valve Low
Not Used
CPP Switch Signal
4WD Low Signal
Cruise Engaged Signal

98 C/K 4.3L Comploc Figure Document ID: 212707


Throttle Position (TP) Sensor, Idle Air Control (IAC) Valve, and Positive Crankcase
Ventilation Valve (PCV)

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5 BRN/WHT
6

9
10
PPL
11
PPL
12

13
BRN
14
YEL
15

16
RED
17
PNK
18
PNK
19 BLK/WHT
20
WHT
21

22 BRN/WHT
23 GRY/BLK
24 LT BLU/BLK

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1. Throttle Position (TP) Sensor
2. Idle Air Control (IAC) Valve
3. Ignition Coil
4. Evaporative (EVAP) Canister Purge Solenoid
5. Fuel Pump/Oil Pressure Switch

7. Fuel Pressure Connection Valve


8. Positive Crankcase Ventilation Valve (PCV)

98 S/T 4.3L ECT Comploc Figure Document ID: 247978


Left Side of the Engine Components (4.3L)

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1. Bank 1 Cylinder Head

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6. Knock Sensor (KS)

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2. Engine Coolant Temperature (ECT) Sensor

Document ID: 247978

98 C/K 4.3L Comploc Figure Document ID: 212705

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1. EVAP Pipe
2. Injector Assembly Electrical Connector
3. Throttle Body

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Ignition Coil, Ignition Control (IC) Module, MAP, Throttle Body, and Evaporative
(EVAP) Canister Purge Valve

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4. Manifold Absolute Pressure (MAP) Sensor


5. Ignition Control (IC) Module
6. Ignition Coil
7. Evaporative (EVAP) Canister Purge Valve

Document ID: 212705

Document ID: 212702


Camshaft Position (CMP) sensor, Knock Sensor (KS), and Fuel Pump/Oil Pressure
Switch

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1. Camshaft Position (CMP) sensor
2. Fuel Pump/Oil Pressure Switch
3. Knock Sensor (KS)

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98 C/K 4.3L Comploc Figure -

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Document ID: 212702

98 C/K 4.3L HO2S Component Location Views Document ID: 214002


HO2S

1. HO2S Bank 1 Sensor 3


2. HO2S Bank 1 Sensor 1
3. HO2S Bank 1 Sensor 2 (If Applicable)
4. HO2S Bank 2 Sensor 1

Document ID: 214002

98 M/L VSS 2WD Comploc Figure Document ID: 241147

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Automatic Transmission (4.3L w/2WD)

1. Vehicle Speed Sensor (VSS)

Document ID: 241147

98 S/T 4.3L VSS 2WD M/T Comploc Graphic Document ID: 247972
Manual Transmission (4.3L w/2WD)

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1. Vehicle Speed Sensor (VSS)

Document ID: 247972

98 S/T 4.3L EVAP Vent/Canister Comploc Figure Document ID: 247973


EVAP Canister and EVAP Vent Valve (4DR Utility and Pickup)

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1. Evaporative (EVAP) Vent Solenoid Valve


2. Crossmember
3. EVAP Canister
4. Fuel Tank
5. Fuel Tank Sender Assembly

Document ID: 247973

Canister and Vent Valve Comp loc 1998 S/T 2DR Document ID: 406835
Canister and Vent Valve (2DR Utility)

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1. Vent Valve
2. Frame
3. Canister
4. Fuel Tank
5. Fuel Sender

Document ID: 406835

98 S/T 4.3L FTPS and Sender Assm Comploc Figure Document ID: 247975
Fuel Tank Pressure Sensor and Fuel Level Sender Assembly

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1. Fuel Tank
2. Fuel Tank Pressure Sensor Connector
3. Fuel Level Sender Connector
4. Fuel Tank Sender Assembly

Document ID: 247975

VCM Connector End Views


Document ID: 240163
VCM Connector C1 (BLU)

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Pin
12
3
46
7
8
9
10
1112
13
14
15
1618
19
20
21
22
23-24
25
26
27
28
29
30
31
32

Wire Color

BRN/WHT

TAN
PNK/BLK
PPL
TAN/BLK

WHT

YEL/BLK

PPL/WHT

PPL
PPL/WHT

TAN/WHT
TAN/WHT

PPL
LT GRN/BLK
PPL/WHT
YEL

VCM Connector C2 (RED)

12129025
32 Pin VCM Connector C1 (BLU)

Circuit No.

633

1667
632
30
422

687

1827

1665

1666
1668

1653
1669

574
822
821
573

Function
Not Used
1X CMP Signal
Not Used
HO2S Bank 2 Sensor 1 Low
CMP Sensor Ground
Fuel Level Output
TCC Solenoid Control
Not Used
32 Shift Solenoid Control
Not Used
VSS Output Signal (EBCM)
Not Used
HO2S Bank 1 Sensor 1 Signal
Not Used
HO2S Bank 2 Sensor 1 Signal
HO2S Bank 1 Sensor 3 Signal
Not Used
HO2S Bank 1 Sensor 1 Low
HO2S Bank 1 Sensor 3 Low
Not Used
CKP Sensor Ground
VSS Low
VSS High
3X CKP Sensor Signal
Not Used

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Connector Part Information

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Pin
1
2
3
4
5
6
7
8
9
10
1112
13
14
15
16
1718
19
20
21
22
23
24
25
26
27
28
29
30

Wire Color

WHT

YEL/BLK

LT GRN
BRN
BLK
YEL/BLK
BRN

LT GRN/WHT
LT BLU/WHT
LT GRN/BLK
PNK/BLK

DK BLU
WHT
LT GRN
TAN
YEL
DK BLU
DK GRN

YEL/BLK
YEL
LT GRN/BLK
LT BLU/BLK

12129025
32 Pin VCM Connector C2 (RED)

Circuit No.

1310

1223

1222
418
1744
846
1456

1749
1747
1745
1746

496
121
432
472
410
417
890

1227
492
444
1748

Function
Not Used
EVAP Canister Vent Solenoid Control
Not Used
2-3 Shift Solenoid Control
Not Used
1-2 Shift Solenoid Control
TCC PWM Solenoid Control
Fuel Injector #1 Control
Fuel Injector #6 Control
EGR Pintle Position Signal
Not Used
IAC Coil B High
IAC Coil A High
Fuel Injector #2 Control
Fuel Injector #3 Control
Not Used
KS Signal
Tachometer Output
MAP Sensor Signal
IAT Sensor Signal
ECT Sensor Signal
TP Sensor Signal
Fuel Tank Pressure Sensor Signal
Not Used
TFT Sensor Signal
MAF Sensor Signal
IAC Coil B Low
IAC Coil A Low

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Connector Part Information

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31
32

BLK/WHT
LT BLU/BLK

845
844

Fuel Injector #5 Control


Fuel Injector #4 Control

VCM Connector C3 (CLR)

Connector Part
Information
Pin
1
2
3
4
5
6
78
9
10
11
12
13
14
15

12129025
32 Pin VCM Connector C3 (CLR)

Wire Color Circuit No.


DK
459
GRN/WHT
DK
428
GRN/WHT

BLK
452
RED
225
RED/BLK
1228

WHT
423

RED
1226
GRY
416
PPL
1589

17
18

LT BLU
WHT
BLK/WHT
BLK/WHT

19

BLK

470

20
21

ORN

440

16

Function
A/C Compressor Enable Relay Control
EVAP Canister Purge Solenoid Control
Not Used
ECT/TP Sensor Ground
Generator Control/Monitoring
PC Solenoid High
Not Used
IC Control
Not Used
Transmission Range C Signal
TP Sensor 5 V Reference
Fuel Level Sensor Signal
Not Used

1229

PC Solenoid Low

351
351

VCM Ground
VCM Ground
IAT/MAP/EGR Pintle Position/Fuel Tank Pressure/TFT
Sensor Ground
Not Used
Battery Positive Voltage (B+)

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22
23
24
25
26
27

VCM Connector C4 (BLK)

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Connector Part
Information
Pin
1
2
3
4
5
6
9
10
11
12
13

Wire Color
DK
GRN/WHT

DK
GRN/WHT
DK GRN
BRN/WHT

12129225
24 Pin VCM Connector C4 (BLK)

Circuit
Function
No.
465

Fuel Pump Relay Control

389
419

Not Used
VSS Output (TCCM, Cruise Control Module,
Console,TBC Module
VSS Output Signal (Speedo, Radio)
MIL Control

Not Used

PPL
PPL

BRN

420
1807

241

817

Brake Signal
Serial Data (Class II)
Not Used
Ignition Positive Voltage

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28
29
30
31
32

DK BLU
1225
Transmission Range B Signal
PNK
1224
Transmission Range A Signal

Not Used
GRN/WHT GRN/WHT A/C Request Signal
WHT
776
PRNDL P Signal
Fuel Tank Pressure/EGR Pintle Position/MAP Sensor
GRY
474
5 V Reference
GRY
773
PRNDL C Signal

Not Used
GRN
603
A/C Pressure Signal
BLK/WHT
771
PRNDL A Signal
YEL
772
PRNDL B Signal

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710

1676
1020
439
1695
257

379
1694
396

Serial Data (Class II)


Not Used
EGR Valve Control
Ignition Positive Voltage
Ignition Positive Voltage
4WD Front Wheel Lock Input
EGR Valve Low
Not Used
CPP Switch Signal
4WD Low Signal
Cruise Engaged Signal

Document ID: 240163

Engine Controls Connector End Views


Document ID: 418969
Camshaft Position (CMP) Sensor Connector

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Connector Part Information

Pin
A
B
C

Circuit No.
632
633
239

Wire Color
PNK/BLK
BRN/WHT
PNK

12110293
3-Way M Metri-Pack 150 Series, Sealed (BLK)
Function
Camshaft Position Sensor Return
Camshaft Position Sensor Signal
Fuse Output - Ignition 1

Central Sequential Fuel Injection (CSFI) Connector

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14
YEL
15

16
RED
17
PNK
18
PNK
19 BLK/WHT
20
WHT
21

22 BRN/WHT
23 GRY/BLK
24 LT BLU/BLK

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Connector Part
Information
Pin
A
B
C
D
E
F
G
H
J
K
L
M

Wire Color
BLK/WHT
PNK
PNK/BLK
PNK
PNK
BLK
LT GRN/BLK
PNK
PNK
LT BLU/BLK
PNK
YEL/BLK

12177083
12-Way F Micro-Pack 100 Series, Sealed
(BLK)

Circuit No.
845
439
1746
439
439
1744
1745
439
439
844
439
846

Function
Fuel Injector 5 Output
Fuse Output - Ignition 1
Fuel Injector 3 Output
Fuse Output - Ignition 1
Fuse Output - Ignition 1
Fuel Injector 1 Output
Fuel Injector 2 Output
Fuse Output - Ignition 1
Fuse Output - Ignition 1
Fuel Injector 4 Output
Fuse Output - Ignition 1
Fuel Injector 6 Output

Crankshaft Position (CKP) Sensor Connector

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Connector Part Information

12059595

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Pin
A
B
C

Wire Color
PNK
PPL
YEL

3-Way F Metri-Pack 150 Series Sealed (BLK)

Circuit No.
Function
439
Fuse Output - Ignition 1
574
Crankshaft Position Sensor Return
573
Crankshaft Position Sensor Signal

Engine Coolant Temperature (ECT) Sensor Connector

Connector Part
Information
Pin
A
B

Wire Color
BLK
YEL

12162194
2-Way F Metri-Pack 150.2 Series, Pull-to-Seat
(BLK)

Circuit No.
Function
452
Sensor Return
410
Coolant Temperature Sensor Signal

Engine Oil Pressure Gauge Sensor Connector

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Connector Part
Information

12065299
1-Way F Metri-Pack 150 Series, Sealed (LT

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GRY)
Pin
A

Wire Color
TAN/WHT

Circuit No.
331

Function
Oil Pressure Sensor Signal

Evaporative (EVAP) Emission Canister Purge Valve

12052643
Connector Part Information
Pin
A
B

Wire Color
PNK
DK GRN/WHT

2-Way F Metri-Pack 150 Series Sealed (RED)


Circuit No.
Function
239
Fuse Output-Ignition 1
428
Canister Purge Solenoid Output

Evaporative (EVAP) Emission Canister Vent Valve Connector

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Connector Part Information


Pin
A
B

Wire Color
PNK
WHT

12052643
2-Way F Metri-Pack 150 Series, Sealed (RED)

Circuit No.
Function
239
Fuse Output - Ignition 1
1310
Canister Vent Valve Solenoid Output

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Fuel Tank Pressure Sensor Connector

Connector Part Information


Pin
A
B
C

Wire Color
BLK/WHT
DK GRN
GRY

12059595
3-Way F Metri-Pack 150 Series, Sealed (BLK)

Circuit No.
Function
470
Sensor Return
890
Fuel Tank Pressure Sensor Signal
474
Reference Voltage Feed - 5 Volt

Fuel Pump and Sender Connector

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Connector Part Information


Pin
A
B
C
D

Wire Color
PPL
GRY
BLK
BLK/WHT

Generator Connector

12160482
4-Way M Metri-Pack 150 Series (BLK)

Circuit No.
1589
120
1650
470

Function
Fuel Gauge Sensor Signal
Fuel Pump Motor Feed
Ground
Sensor Return

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Connector Part
Information

12186566
1-Way F Metri-Pack 150 Series, Sealed (NAT)

Pin
A

Wire Color

Circuit
No.

RED

225

C-D

Function
Not Used
Alternator Output - Regulator Reference
Voltage
Not Used

Heated Oxygen Sensor (H2OS) Connector, Bank 1, Sensor 1

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Connector Part
Information

12162144
4-Way M Metri-Pack 150 Series (BLK)

Pin

Wire Color

Circuit
No.

TAN/WHT

1653

PPL/WHT

1665

BLK

450

Function
Oxygen Sensor Return - Left - Forward of
Catalytic Converter
Oxygen Sensor Signal - Left - Forward of
Catalytic Converter
Ground

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PNK

539

Fuse-Output-Ignition 1

Heated Oxygen Sensor (H2OS) Connector, Bank 1 Sensor 3

Connector Part
Information

12162144
4-Way M Metri-Pack 150 Series (BLK)

Pin

Wire Color

Circuit
No.

TAN/WHT

1669

PPL/WHT

1668

C
D

BLK
PNK

350
539

Function
Oxygen Sensor Return-Left-Rear of Catalytic
Converter
Oxygen Sensor Signal-Left-Rear of Catalytic
Converter
Ground
Fuse-Output-Ignition 1

Heated Oxygen Sensor (H2OS) Connector, Bank 2 Sensor 1

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Connector Part
Information

12162144
4-Way M Metri-Pack 150 Series (BLK)

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Pin

Wire Color

Circuit
No.

TAN

1667

PPL

1666

C
D

BLK
PNK

350
539

Function
Oxygen Sensor Return-Right-Forward of
Catalytic Converter
Oxygen Sensor Signal-Right-Forward of
Catalytic Converter
Ground
Fuse-Output-Ignition 1

Idle Air Control (IAC) Valve Connector

Connector Part
Information

12162190
4-Way M Metri-Pack 150.2 Series, Pull-to-Seat
(BLK)

Pin

Wire Color

Circuit
No.

LT GRN/BLK

444

LT GRN/WHT

1749

LT BLU/BLK

1748

LT BLU/WHT

1747

Ignition Coil Connector

Function
Idle Air Control Valve Motor Feed - Coil B
Low
Idle Air Control Valve Motor Feed - Coil B
High
Idle Air Control Valve Motor Feed - Coil A
Low
Idle Air Control Valve Motor Feed - Coil A
High

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Connector Part Information


Pin
A
B
C

Wire Color
PNK

WHT/BLK

12146121
3-Way F Metri-Pack 150 Series, Sealed (BRN)

Circuit No.
Function
439
Fuse Output - Ignition 1

Not Used
1847
Ignition Coil Output - Bank A

Ignition Control Module (ICM) Connector

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Connector Part
Information
Pin
A
B
C
D

Wire Color
PNK
WHT
BLK/WHT
WHT/BLK

12162189
4-Way F Metri-Pack 150.2 Series, Pull-to-Seat
Sealed (BLK)

Circuit No.
439
423
451
1847

Function
Fuse Output - Ignition 1
Electronic Spark Timing Control Signal
Engine Control Module Ground
Ignition Coil Output - Bank A

Intake Air Temperature (IAT) Sensor Connector

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Connector Part
Information
Pin
A
B

Wire Color
TAN
BLK

12162198
2-Way F Metri-Pack 150.2 Series, Sealed, Pull-toSeat (GRY)

Circuit No.
Function
472
Manifold Absolute Temperature Sensor Signal
470
Sensor Return

Knock Sensor (KS) Connector

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Connector Part Information


Pin
1

Wire Color
DK BLU

12146549
1-Way F Weather Pack (BLK)

Circuit No.
496

Function
Knock Sensor Signal #1

Manifold Absolute Pressure (MAP) Sensor Connector

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Connector Part
Information
Pin
A
B
C

Wire Color
BLK
LT GRN
GRY

12129946
3-Way Metri-Pack 150 Series Sealed (MD
GRY)

Circuit No.
Function
470
Sensor Return
432
Manifold Absolute Pressure Sensor Signal
474
Reference Voltage Feed-5 Volt Reference

Mass Air Flow (MAF) Sensor Connector

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Connector Part Information


Pin
A
B
C

Wire Color
YEL
BLK/WHT
PNK

12059595
3-Way F Metri-Pack Series, Sealed (BLK)

Circuit No.
Function
492
Mass Air Flow Sensor Signal
451
Engine Control Module Ground
239
Fuse Output - Ignition 1

Throttle Position (TP) Sensor Connector

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Connector Part
Information
Pin
A
B
C

Wire Color
GRY
BLK
DK BLU

12110192
3-Way F Micro-Pack 150 Series, Sealed, Pull-toSeat (BLK)

Circuit No.
Function
416
Reference Voltage Feed - 5 Volt Reference
452
Sensor Return
417
Throttle Position Sensor Signal

Vehicle Speed Sensor (VSS)

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12162194
Connector Part Information
Pin
A
B

Wire Color
PPL/WHT
LT GRN/BLK

2-Way F Metri-Pack 150.2 Series Sealed P2S (BLK)


Circuit No.
Function
821
Vehicle Speed Sensor Signal
822
Vehicle Speed Sensor Return

VCM Replacement/Programming
Document ID: 214937

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Notice: In order to prevent possible electrostatic discharge (ESD) damage to the VCM,
do not touch the connector pins or soldered components on the circuit board.
Important:

A shorted solenoid, relay coil, or harness will not damage the output driver module
(ODM) in the VCM. A shorted solenoid, relay coil, or harness will cause the circuit and
the controlled component to be inoperative.
When the circuit fault is not present or the technician has repaired the fault, the output
driver module (ODM) will again operate in a normal manner due to its fault protected
design.

Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.

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Service of the vehicle control module (VCM) consists of either replacement of


the VCM or reprogramming of the VCM.
If the VCM is being replaced, the knock sensor (KS) module must be transferred
to the replacement VCM.
The replacement VCM must be programmed before the vehicle will run.
The replacement VCM must have the Passlock Reprogramming procedure
performed before the vehicle will run.
The replacement VCM must have the CKP System Variation Learn procedure
performed or a DTC P1336 will set.

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2. Remove the VCM bracket bolts.
3. Lift the inside edge of the VCM bracket until the bottom of the bracket can clear
the A/C accumulator.
4. Slide the VCM bracket over the A/C accumulator.
5. Continue sliding the VCM bracket until the fender side of the bracket is no
longer underneath the fender lip.

6. Remove the retainer clips and VCM connectors.

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7. Remove the VCM from the VCM bracket.

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8. The remaining steps are only necessary for a VCM replacement:


Remove the access cover screws.
9. Remove the VCM access cover.

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10. Important: Since the Knock Sensor (KS) module will be used in the
replacement VCM, place the module in an area where it will not be damaged.
Gently pinch the retaining clip and pull upward to remove the KS module.

Installation Procedure

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Important: Ensure that the VCM being installed is the original VCM, or that the
replacement VCM service number is identical to the original VCM service number.
Steps 13 are only necessary for a replacement VCM installation:

1. Notice: In order to prevent possible electrostatic discharge (ESD) damage to the


VCM, do not touch the connector pins or soldered components on the circuit
board.
Align the notches of the KS module with the notches in the socket.
Important: Press only on the ends of the KS module. Gently press on the KS
module until it is firmly seated in the socket. Listen for the click.
2. Install the KS module in the KS module socket.

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3. Install the access cover on the VCM.

4. Install the access cover screws.


Tighten
Tighten the access cover screws to 5.0 N-m (44 lb in).

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5. Important: Make sure that the snap retainer is up in the normal position and
retaining the module.
Insert the VCM into the VCM bracket until it is fully seated.

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Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

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6. Connect the VCM connectors and retainer clips.

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7. Insert the VCM bracket at an angle so that the fender side of the bracket is
positioned underneath the fender lip.
8. Push the VCM bracket underneath the lip until the inside edge of the bracket
clears the A/C accumulator.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.

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Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
9. Install the VCM bracket bolts.
Tighten
Tighten the bolts to 10 N-m (89 lb in).

VCM Programming
1. Perform the following steps in order to prepare for programming the VCM
(EEPROM).
o Make sure that both the Tech 2 and the Techline terminal software are
updated to the most current level.
o Verify that the vehicle battery is properly charged prior to performing the
reprogramming process.
o Make sure the connection at the Data Link Connector (DLC) is secure.
o Turn ON the ignition.
o Turn OFF all the accessories (i.e., radio, HVAC controls, interior lamps,
etc.).
2. Refer to the Techline terminal and follow the user's instructions for VCM
programming.
3. If the VCM fails to program, perform the following functions:
o Check all the VCM connections.
o Try again to program the VCM. If the programming fails again, replace
the VCM.
4. Perform the VTD Password Learn Procedure. Refer to Password Learn in
Engine Controls - 4.3L .
5. Perform the CKP System Variation Learn Procedure. Refer to Crankshaft
Position System Variation Learn in Engine Controls - 4.3L .
6. For a functional check, perform the Powertrain On-Board Diagnostic (OBD)
System Check.

Document ID: 214937

Crankshaft Position System Variation Learn


Document ID: 248092
1. Install the scan tool.
2. Apply the vehicle's parking brake.
3. Block the drive wheels.

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10. Connect the negative battery cable.


11. When installing a replacement VCM, perform the VCM Programming
procedure.

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4.
5.
6.
7.

Close the hood.


Place the vehicle's transmission in Park (A/T) or Neutral (M/T).
Idle the engine until the coolant temperature reaches 65C (150F).
Turn OFF all the accessories.
Important: If the CKP System Variation Learn Procedure cannot be completed
successfully, refer to DTC P1336 Crankshaft Position (CKP) System Variation
Not Learned in Engine Controls - 4.3L for additional diagnostic information.

8. Enable the Crankshaft Position System Variation Learn Procedure with the scan
tool.

9. Apply and hold the service brakes.


Important: While the learn procedure is in progress, release the throttle
immediately when the engine starts to decelerate. The engine control is returned
to the operator and the engine will respond to throttle position after the learn
procedure is complete.
10. Slowly raise the engine speed to 4000 RPM.
11. Immediately release the throttle when the engine speed decreases.
12. Turn OFF the ignition for 15 seconds after the learn procedure is completed
successfully.

Password Learn
Document ID: 247178
Important: Refer to Theft Deterrent System Check in Body and Accessories if the
Passlock Learn Procedure cannot be completed successfully.

Passlock Learn Procedure Using a Tech 2 Scan Tool (Seed and Key)
Important: In addition to the time involved in performing the specific steps, the Seed
and Key Procedure accomplishes the same task in 10 minutes as the Auto Learn
Procedure does in 30 minutes. Use either one of these two procedures.
The following is the Seed and Key Learn Procedure:
1. Clear all Vehicle Theft Deterrent (VTD), or (Passlock), module and VCM
DTCs.
2. Turn the ignition to the ON position.
3. With the scan tool (TECH 2) connected to the vehicle, select
'Programming/Request Info' from the menu, then follow the instructions.

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Important: After the ignition switch is turned to the CRANK position, the
VCM must see a change in the state of brake switch (Released to Applied) to run
the learn procedure. Also, the service brakes, not the parking brake, must be held
throughout the duration of the learn procedure.

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4. Disconnect the scan tool from the vehicle and perform 'Service Programming
System/VTD Learn' with Techline terminal, then follow the instructions.
5. Reconnect the scan tool to the vehicle.
6. Follow the instructions on the scan tool to perform the VTD (Passlock)
password learn on the vehicle, this takes about 10 minutes.
7. After 10 minutes, the SECURITY indicator will turn OFF and the module will
learn the new component on the next ignition lock cylinder cycle from OFF-toCRANK-to-ON (start attempt).

Passlock Learn Procedure without Tech 2 Scan Tool

1.
2.
3.
4.
5.

Clear all VTD (Passlock) module and VCM DTCs.


Turn the ignition switch to the OFF position.
Replace the module or the sensor if necessary.
Turn the ignition switch to the ON position.
Momentarily rotate the ignition switch to the CRANK position. Do not start the
vehicle.
6. Release the ignition switch to the ON position.
7. Wait 10 minutes. Observe the SECURITY indicator. Refer to the following list
for the appropriate responses:
o If the Passlock sensor was replaced, the SECURITY indicator will flash
for the 10 minute duration.
o If the VTD (Passlock) module was replaced, the SECURITY indicator
will flash for a few seconds and then remain ON for the remainder of the
10 minute duration.
o If the VCM was replaced with a new VCM off the shelf, the vehicle will
start and this procedure may not be necessary.
o If the replacement VCM was plugged at any other time, even
momentarily, the SECURITY indicator will flash for a few seconds and
then remain ON for the 10 minute duration.
8. The SECURITY indicator will make a transition from flashing to ON briefly,
then to OFF after 10 minutes if remaining in the ignition ON position.
9. Turn the ignition switch to the OFF position and wait for 10 seconds.
10. Repeat steps 38 two more times. The module will learn the new component on
the next ignition lock cylinder cycle from OFF-to-CRANK-to-ON (start
attempt).

Engine Coolant Temperature Sensor Replacement


Document ID: 254481
Removal Procedure

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Important: While the VCM is in the Auto Learn Procedure, maintain the battery
voltage at all times. Follow the procedure exactly as indicated or the procedure will
have to be repeated from the beginning.

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Notice: Use care when handling the coolant sensor. Damage to the coolant sensor will
affect the operation of the fuel control system.
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.

2. Loosen the wing nuts on the air cleaner cover and air cleaner outlet duct.
3. Move the air intake assembly aside.
Caution: Allow sufficient time for the engine to cool before removing the ECT
sensor. A hot engine may cause an excessive coolant loss or a personal injury.
4. Relieve the coolant pressure.
5. Drain the cooling system below the level of the sensor.

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6. Disconnect the ECT sensor electrical connector.

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7. Remove the ECT sensor.

Installation Procedure
1. Coat the threads (only) with GM P/N 12346004 sealer or equivalent.

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2. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the ECT sensor in the engine.
Tighten
Tighten the sensor to 20 N-m (15 lb ft).

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3. Connect the ECT sensor electrical connector.


4. Refill the cooling system. Refer to Draining and Filling Cooling System in
Engine Cooling.

5. Install the air intake assembly and tighten the wing nuts.
6. Connect the negative battery cable.

Document ID: 254481

Mass Airflow Sensor Replacement


Document ID: 310158
Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.

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2. Disconnect the MAF sensor harness connector.

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3. Notice:
o Handle the MAF sensor carefully.
o Do not drop the MAF sensor in order to prevent damage to the MAF
sensor.
o Do not damage the screen located on the air inlet end of the MAF.
o Do not touch the sensing elements.
o Do not allow solvents and lubricants to come in contact with the sensing
elements.
o Use a small amount of a soap based solution in order to aid in the
installation.

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Disconnect the MAF sensor from the air cleaner cover and air cleaner outlet duct
by loosening the hose clamps.

Installation Procedure

1. Important: The embossed arrow on the MAF sensor indicates the proper air
flow direction. The arrow must point towards the engine.
Attach the MAF sensor to the air cleaner outlet duct and the air cleaner cover.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Secure the air cleaner cover and outlet duct to the MAF sensor.
Tighten
Tighten the clamps to 4 N-m (35 lb in)

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3. Connect the MAF sensor harness connector.


4. Connect the negative battery cable.

Document ID: 310158

Manifold Absolute Pressure Sensor Replacement


Document ID: 449345
Removal Procedure
Other than checking for a worn grommet and loose electrical connectors, the only
service possible is a unit replacement if the diagnosis shows a malfunctioning MAP
sensor.
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.

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2. Disconnect the MAP sensor harness connector.

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3. Notice: Do not rotate or pry on the MAP sensor when removing. Damage to the
MAP sensor or the intake manifold may result.
Important: After removing the MAP sensor from the intake manifold, replace
the MAP sensor to the intake manifold grommet.
Remove the MAP sensor.
4. Discard the MAP sensor grommet.

Installation Procedure

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1. Install a new MAP sensor grommet on the MAP sensor.

2. Install the MAP sensor.

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3. Connect the MAP sensor harness connector.
4. Connect the negative battery cable.

Document ID: 449345

Heated Oxygen Sensor Replacement

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Document ID: 313231


Removal Procedure
Tools Required
J 39194 Oxygen Sensor Wrench

Do not apply contact cleaner or other materials to the sensor or vehicle harness
connectors. These materials may get into the sensor causing poor performance.
Do not damage the sensor pigtail and harness wires in such a way that the wires
inside are exposed. This could provide a path for foreign materials to enter the
sensor and cause performance problems.
Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp
bends or kinks could block the reference air path through the lead wire.
Do not remove or defeat the oxygen sensor ground wire, where applicable.
Vehicles that utilize the ground wired sensor may rely on this ground as the only
ground contact to the sensor. Removal of the ground wire will cause poor engine
performance.
Ensure that the peripheral seal remains intact on the vehicle harness connector in
order to prevent damage due to water intrusion. The engine harness may be
repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no
circumstances should repairs be soldered since this could result in the air
reference being obstructed.

The Heated Oxygen Sensor (HO2S) may be difficult to remove when the engine
temperature is below 48C (120F). Excessive force may damage the threads in the
exhaust manifold or the exhaust pipe.
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.

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Notice: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the
oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor
operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical
connector and the louvered end free of grease, dirt, or other contaminants. Do not use
cleaning solvents of any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the
pigtail wiring, connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and
heater wires. Any attempt to repair the wires, connectors, or terminals could result in the
obstruction of the air reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:

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2. Determine the location of the HO2S to be removed. Refer to Engine Controls


Component Views in Engine Controls - 4.3L
3. Raise the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information .

4. Remove the HO2S electrical connector by releasing the locking tab. The
electrical connector may typically have either a 1x4 or 2x2 configuration.

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5. Use the J 39194 in order to remove the HO2S.

Installation Procedure
Important: A special anti-seize compound is used on the Heated Oxygen Sensor
(HO2S) threads. The compound consists of liquid graphite and glass beads. The

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graphite tends to burn away, but the glass beads remain, making the sensor easier to
remove. New, or service replacement sensors already have the compound applied to the
threads. When installing a previously removed sensor, the threads must have anti-seize
compound applied before the installation.
1. Coat the threads of the oxygen sensor with anti-seize compound GM P/N
5613695 or the equivalent if necessary.

2. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the HO2S.
Tighten
Tighten the sensor to 42 N-m (31 lb ft).

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3. Connect the HO2S electrical connector.


4. Lower the vehicle. Refer to Lifting and Jacking the Vehicle in General
Information .
5. Connect the negative battery cable.

Document ID: 313231

Throttle Position Sensor Replacement


Document ID: 310162
Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.

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2. Disconnect the IAT sensor connector.

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3. Disconnect the breather tube from the air cleaner outlet duct.

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4. Remove the wing nut retaining the air outlet duct.

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5. Loosen the clamp on the outlet of the MAF sensor.
6. Lift the air cleaner outlet duct from the throttle body and remove the assembly
from the MAF sensor.

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7. Disconnect the TP sensor electrical connector.


8. Remove the throttle body. Refer to Throttle Body Assembly Replacement in
Engine Controls - 4.3L .

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9. Remove the mounting screws from the TP sensor.

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10. Notice: The TP sensor is an electrical component. Do not soak the TP sensor in
any liquid cleaner or solvent as damage may result.
Remove the TP sensor from the throttle body assembly.

Installation Procedure

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1. Important: Make sure the throttle valve is closed during installation.
Place the TP sensor over the throttle shaft and align the TP mounting holes with
their corresponding holes in the throttle body assembly.

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2. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Important: The screws used to attach the TP sensor are coated with thread
locking adhesive. Clean the attaching screw threads and apply thread locking
material GM P/N 1052624 or equivalent.
Install the TP sensor mounting screws.
Tighten
Tighten the screws to 2.0 N-m (18 lb in).
3. Install the throttle body. Refer to Throttle Body Assembly Replacement in
Engine Controls - 4.3L .

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4. Connect the TP sensor connector.

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5. Install the air cleaner outlet duct.

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6. Tighten the air cleaner outlet duct wing nut.


7. Secure the air cleaner outlet duct to the MAF sensor.
Tighten
Tighten the air cleaner outlet duct clamp to 4 N-m (35 lb in) .

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8. Connect the breather tube to the air cleaner outlet duct.

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9. Connect the IAT sensor connector.


10. Connect the negative battery cable.

Document ID: 310162

Throttle Body Assembly Replacement


Document ID: 449056
Cleaning Procedure
Notice: Do not subject a throttle body assembly which contains the following
components to an immersion cleaner or a strong solvent:

Throttle position (TP) sensor


Idle air control (IAC) valve
Sealed throttle shaft bearings

The cleaners will damage the electric components or sensors.


The cleaners will damage some of these components that contain seals or O-rings.
Solvents can wash away or break down the grease used on non-serviceable throttle shaft
bearings.
Never use a wire brush or scraper to clean the throttle body. A wire brush or sharp tools
may damage the throttle body components.
Do not use a cleaner that contains methyl ethyl ketone. This extremely strong solvent
may damage components and is not necessary for this type of cleaning.
Clean the throttle body bore and throttle valve plate on the vehicle using a clean shop
towel with GM Top Engine Cleaner, P/N 1052626 or AC-Delco Carburetor Tune-Up
Conditioner, P/N X66P, or equivalent. Remove and disassemble the throttle body if the

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deosits are excessive. Refer to Idle Air Control Valve Replacement in Engine Controls 4.3L
for IAC removal or
Throttle Position Sensor Replacement in Engine Controls - 4.3L
for TP sensor removal. After disassembly, clean the throttle body using a parts cleaning
brush. DO NOT immerse the throttle body in any cleaning solvent.

Removal Procedure

1. Disconnect the negative battery cable.

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2. Disconnect the IAT sensor harness connector.

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3. Disconnect the breather tube from the air cleaner outlet duct.

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4. Remove the air cleaner outlet duct retaining wing nut.

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5. Loosen the clamp on the outlet of the MAF sensor.
6. Lift the air cleaner outlet duct from the throttle body and remove the assembly
from the MAF sensor.

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Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.

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7. Remove the air cleaner outlet adapter stud.

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8. Disconnect the cruise control cable from the throttle body.

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9. Disconnect the accelerator cable from the throttle body.

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10. Remove the nuts retaining the accelerator cable routing bracket and position
bracket aside.

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11. Remove the stud and nuts retaining the accelerator control cable bracket and
position bracket aside.

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12. Disconnect the IAC valve harness connector.

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13. Disconnect the TP sensor harness connector.

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14. Remove the throttle body retaining studs.

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15. Remove the throttle body assembly.


16. Discard the throttle body seal.

Installation Procedure

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1. Clean the seal surface on the intake manifold.
2. Install the throttle body assembly with a new flange seal.

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3. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the throttle body assembly retaining studs.
Tighten
Tighten the studs to 9 N-m (80 lb in).

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4. Install the accelerator control cable bracket using the mounting stud and nuts.
Tighten
Tighten the stud and nuts to 12 N-m (108 lb in).

5. Install the accelerator cable routing bracket using the mounting nuts.
Tighten
Tighten the accelerator cable routing bracket nuts to 9 N-m (75 lb in).

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6. Connect the TP sensor harness connector.

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7. Connect the IAC valve harness connector.

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8. Important: The accelerator pedal should operate freely without binding
between closed and wide open throttle.
Install the accelerator cable onto the throttle body.

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9. Install the cruise control cable onto the throttle body..

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10. Install the air cleaner outlet duct adapter stud.
Tighten
Tighten the studs to 8 N-m (72 lb in).

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11. Connect the clamp on the outlet of the MAF sensor


12. Install the air cleaner outlet duct on the throttle body and install the assembly on
the MAF sensor.
Tighten
Tighten the clamp to 4 N-m (35 lb in).

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13. Install the air cleaner outlet duct retaining wing nut.
Tighten
Tighten the wingnut to 2 N-m (18 lb in).

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14. Connect the breather tube from the air cleaner outlet duct.
15. Connect the negative battery cable.

Document ID: 449056

Throttle Position Sensor Replacement


Document ID: 310162
Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.

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2. Disconnect the IAT sensor connector.

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3. Disconnect the breather tube from the air cleaner outlet duct.

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4. Remove the wing nut retaining the air outlet duct.

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5. Loosen the clamp on the outlet of the MAF sensor.
6. Lift the air cleaner outlet duct from the throttle body and remove the assembly
from the MAF sensor.

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7. Disconnect the TP sensor electrical connector.


8. Remove the throttle body. Refer to Throttle Body Assembly Replacement in
Engine Controls - 4.3L .

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9. Remove the mounting screws from the TP sensor.

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10. Notice: The TP sensor is an electrical component. Do not soak the TP sensor in
any liquid cleaner or solvent as damage may result.
Remove the TP sensor from the throttle body assembly.

Installation Procedure

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1. Important: Make sure the throttle valve is closed during installation.
Place the TP sensor over the throttle shaft and align the TP mounting holes with
their corresponding holes in the throttle body assembly.

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2. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Important: The screws used to attach the TP sensor are coated with thread
locking adhesive. Clean the attaching screw threads and apply thread locking
material GM P/N 1052624 or equivalent.
Install the TP sensor mounting screws.
Tighten
Tighten the screws to 2.0 N-m (18 lb in).
3. Install the throttle body. Refer to Throttle Body Assembly Replacement in
Engine Controls - 4.3L .

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4. Connect the TP sensor connector.

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5. Install the air cleaner outlet duct.

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6. Tighten the air cleaner outlet duct wing nut.


7. Secure the air cleaner outlet duct to the MAF sensor.
Tighten
Tighten the air cleaner outlet duct clamp to 4 N-m (35 lb in) .

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8. Connect the breather tube to the air cleaner outlet duct.

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9. Connect the IAT sensor connector.


10. Connect the negative battery cable.

Document ID: 310162

Fuel Injector Cleaning


Document ID: 784216
Tools Required

J 44466-12 CSFI Fuel Metering Body Jumper Block


J 44466-13 Screws
J 44466-11 IAFM fuel Transfer Tube Recycling Tube
J 41413 EVAP Pressure/Purge Diagnostic Station
J 44466-10 Regulator and Hose Assembly
J 39021 Fuel Injector Coil/Balance Tester
J 39021-210 Injector Switch Box
J 39021-301 Injector Harness Connector (4.3L)
J 38500-A Fuel Injector Cleaner

Fuel Injector Cleaning Procedure

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1. Loosen the fuel filler cap to relieve vapor pressure in the fuel tank.
2. Remove the positive crankcase ventilation (PCV) clean air tube from air inlet
duct and set aside.
3. Remove the resonator and air inlet duct from throttle body.
4. Remove the brake booster vacuum hose and connector from intake manifold.
5. Remove the electrical connector from the central sequential fuel injection (CSFI)
fuel metering body.
6. Remove the spark plug wires from 1, 3 and 5 from the distributor cap.
7. Remove the fuel line bolt (4) at the rear of intake manifold.

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8. Relieve the fuel system pressure.
9. Remove the nuts (1) and clamp (2) from the fuel pipe.
10. Remove fuel pipes from the metering body.

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Important: Make sure that the fuel pipe O-rings, washers, and spacers are
present and in their proper position.

11. Install the J 44466-12 (2) and the J 44466-13 (1) to the metering body and
tighten.

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12. Install the J 44466-11 (4) , clamp (2) and J 44466-13 (1) to the fuel pipe and
tighten.

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13. Obtain the J 41413 , close the valve (2) on the tank (3), and remove the regulator
assembly.
14. Install the J 44466-10 (5) to the J 41413 tank (3)

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15. Connect the J 44466-10 hose (1) to the J 44466-12 (3).
16. Install the J 39021 , the J 39021-210 and J 39021-301 (4) to the metering body
electrical connector.
17. Adjust the amperage selector switch on J 39021 to 0.5 amps.

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18. Open the valve (2) on the tank (3).


19. Open the valve (4) on the J 44466-10 to pressurize the fuel system. Then close
valve (4) before firing injectors.
Important: The minimum pressure required on the gage (6) is 150 psi. If
150 psi is not obtained, the tank (3) must be refilled prior to performing this
procedure.
20. Fire one injector using the J 39021 . Observe a pressure drop on the gage (6) and
verify the injector/poppet valve operation. An injector/poppet that is stuck and
not operational will have no pressure drop on the gage. If an injector remains
stuck, repeat the procedure multiple times (as required) until the injector is
operational.
21. Repeat steps 19 and 20 for each individual injector to verify that all
injector/poppet valve assemblies are unstuck and functional.
22. Shut off pressure valve (2) on the tank (3) of the J 41413 .
23. Bleed off the pressure at the J 44466-10 .
24. Install the PCV fresh air tube to the air inlet duct.

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25. Disconnect and remove the J 44466-10 (1) from the J 44466-12 (3) and the J
41413 .
26. Remove the J 39021-301 J 39021-210 and J 39021 from the metering body.
27. Install the vehicle electrical connector to the metering body.
28. Install brake booster vacuum hose and connector to the intake manifold.
29. Install ignition wires 1, 3, and 5 to the distributor cap.
30. Install the resonator and air intake duct to the throttle body and hand tighten
wing nut.

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31. Obtain J 38500-A (2).
Important: Make sure the valve at the bottom of the canister (3) is closed.

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32. Remove the canister top and add Top Engine Cleaner GM P/N 12346535 to the
canister.
33. Fill the remainder of the canister with regular unleaded gasoline and install the
canister top.
34. Suspend J 38500-A from a convenient underhood location.

35. Connect the hose from J 38500-A (1) to the service port on the J 44466-12 (3).

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36. Open valve (3) at the bottom of J 38500-A .
37. Connect a shop air source to the fitting at the top of J 38500-A and adjust the
regulator (1) to 75 psi.
38. Let the vehicle run at idle until the canister is empty and the vehicle stalls.
39. Remove the shop air supply from J 38500-A .

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40. Depressurize the J 38500-A .


41. Disconnect the J 38500-A hose from the J 44466-12 .
42. Remove the PCV clean air tube from the air inlet duct and set aside.
43. Remove the resonator and air inlet duct from the throttle body and set aside.
44. Remove ignition wires 1, 3, and 5 from the distributor cap.
45. Remove brake booster vacuum hose and connector from the intake manifold.
46. Bleed the residual pressure from J 44466-12 .

47. Remove J 44466-13 (1) and J 44466-12 (2) from the metering body.

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48. Remove J 44466-13 (1), clamp (2) and J 44466-11 (4) from the fuel pipe (3).

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Important: Make sure that all of the O-rings (6 and 8), washers (7), and spacers
(5) are present and in proper position.

49. Install the fuel pipe (3) to the metering body.


Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
50. Install the clamp (2) and nuts (1).
Tighten
Tighten nuts to 3 N-m (27 lb ft).
51. Apply threadlock GM P/N 12345382 or equivalent to the threads of the fuel pipe
bolt (4).
52. Install the fuel pipe bolt.
Tighten
Tighten the bolt to 6 N-m (53 lb ft).
53. Install the brake booster vacuum hose and connector to the intake manifold.
54. Install the resonator and air inlet duct to the throttle body.
55. Install the PCV clean air tube to the inlet duct.
56. Install brake booster vacuum hose and connector to the intake manifold.

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57. Install ignition wires 1, 3, and 5 to the distributor cap.


58. Add one (1) ounce of Port Fuel Injector Cleaner GN P/N 12345104 (in Canada
P/N 12345515) to the vehicle fuel tank for each gallon of gasoline estimated to
be in the tank.
Important: Instruct the customer to add the remainder of the bottle of Port Fuel
Injector Cleaner to the vehicle fuel tank at the next fill up.

Important: Advise the customer to change brands of fuel.

Document ID: 784216

Intake Air Temperature Sensor Replacement


Document ID: 21219
Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.

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59. Hand tighten the fuel tank filler cap.


60. Start the vehicle and check for fuel leaks.
61. Using a Tech II scan tool, check for any stored Powertrain DTC codes. Clear
codes as required.
62. Disconnect Tech II scan tool.

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2. Disconnect the electrical connector.

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3. Remove the IAT sensor by pulling straight out using a rotating motion.

Installation Procedure

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1. Install the IAT sensor by gently pushing the sensor into the air cleaner outlet
duct until seated.

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2. Connect the electrical connector.
3. Connect the negative battery cable.

Document ID: 21219

Idle Air Control Valve Replacement


Document ID: 310172

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Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.

2. Disconnect the IAT sensor connector.

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3. Disconnect the breather tube from the air cleaner outlet duct.

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4. Remove the wing nut retaining the air cleaner outlet duct.

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5. Loosen the clamp on the outlet of the MAF sensor.
6. Lift the air cleaner outlet duct from the throttle body and remove the assembly
from the MAF sensor.

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7. Disconnect the IAC valve electrical connector.

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8. Remove the IAC valve mounting screws.

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9. Remove the IAC valve and O-ring from the throttle body assembly.

Cleaning and Inspection Procedure


Notice: If the IAC valve has been in service: DO NOT push or pull on the IAC
valve pintle. The force required to move the pintle may damage the threads on
the worm drive. Also, DO NOT soak the IAC valve in any liquid cleaner or
solvent, as damage may result.
1. Clean the IAC valve O-ring sealing surface, pintle valve seat, and air passage.
o Remove excess carbon deposits with a small amount of carburetor
cleaner on a parts cleaning brush. Follow any instructions on the cleaner
container regarding cleaner usage.
o Do not use a cleaner containing an extremely powerful solvent such as
methyl ethyl ketone.
o Shiny spots on the pintle and seat do not represent a bent or misaligned
pintle shaft.
o If heavy deposits are present in the air passage, remove the throttle body
for a complete cleaning. Refer to Throttle Body Assembly Replacement
in Engine Controls - 4.3L .
Important: Do not reuse the original O-ring.
2. Replace the IAC valve O-ring.

Installation Procedure

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1. Notice: The IAC valve may be damaged if installed with the cone (pintle)
extended more than 28 mm (1-1/8 in). Measure the distance that the valve is
extended before installing a new valve. The distance from the idle air control
valve motor housing to the end of the idle air control valve pintle should be less
than 28 mm (1-1/8 in). Manually compress the pintle until the extension is less
than 28 mm (1-1/8 in).
Important: Use an identical part when installing a new Idle Air Control (IAC)
valve. The IAC valve pintle shape and dimensions are designed for specific
applications.
On a new IAC valve, measure the distance between the IAC valve pintle and
mounting flange. Use finger pressure to slowly retract the pintle if the distance is
greater than 28 mm (11/8 in).

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2. Lubricate the IAC valve O-ring with clean engine oil.


3. Align the flange holes with the mounting holes on the throttle body assembly.
4. Insert the IAC valve through the O-ring into the throttle body assembly.

5. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Important: The screws used to attach the IAC valve are coated with thread
locking adhesive. Clean the attaching screw threads and apply thread locking
material GM P/N 1052624 or equivalent.
Install the IAC valve mounting screws.
Tighten
Tighten the screws to 3 N-m (27 lb in).

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6. Connect the IAC valve electrical connector.

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7. Install the air cleaner outlet duct.

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8. Tighten the air cleaner outlet duct wing nut.


9. Secure the air cleaner outlet duct to the MAF sensor.
Tighten
Tighten the air cleaner outlet duct clamp to 4 N-m (35 lb in).

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10. Connect the breather tube to the air cleaner outlet duct.

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11. Connect the IAT sensor connector.


12. Connect the negative battery cable.
13. Perform the following steps to reset the IAC valve pintle position:

IAC Valve Reset Procedure


1.
2.
3.
4.

Turn ON the ignition for 20 seconds.


Turn OFF the ignition for 10 seconds.
Start the engine.
Check for the proper idle speed.

Document ID: 310172

Accelerator Control Cable Replacement


Document ID: 425932
Removal Procedure

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1. Disconnect the IAT sensor connector.

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2. Disconnect the breather tube from the air cleaner outlet duct.

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3. Remove the air cleaner outlet duct retaining wing nut.

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4. Loosen the clamp on the outlet of the MAF sensor.
5. Lift the air cleaner outlet duct from the throttle body and remove the assembly
from the MAF sensor.

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6. Disconnect the accelerator cable from the throttle body.

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7. Remove the accelerator cable from the accelerator control cable bracket.

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8. Remove the accelerator cable from the cable routing bracket.

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9. Remove the accelerator cable from the accelerator pedal.

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10. Remove the accelerator cable from the dash panel (1).

Installation Procedure

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1. Install the accelerator cable to the dash panel (1).

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2. Install the accelerator cable to the accelerator pedal (2).

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3. Install the accelerator cable to the cable routing bracket.

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4. Install the accelerator cable to the accelerator cable control bracket.

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5. Install the accelerator cable onto the throttle body.

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6. Install the air cleaner outlet duct.

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7. Tighten the air cleaner outlet duct wing nut.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
8. Secure the air cleaner outlet duct to the MAF sensor.

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Tighten
Tighten the air cleaner outlet duct clamp to 4 N-m (35 lb in).

9. Connect the breather tube to the air cleaner outlet duct.

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10. Connect the IAT sensor connector.
Important: The accelerator pedal should operate freely without binding
between closed and wide open throttle.
11. Check the accelerator pedal operation.
1. Turn ON the ignition leaving the engine OFF.
2. Using a scan tool, observe the parameter for the TP sensor.
3. Depress the accelerator pedal to the floor.

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4. Release the accelerator pedal.


5. Verify the throttle position has gone from 0% to 100% and back to 0%.

Accelerator Pedal Replacement


Document ID: 425587
Removal Procedure

1. Lift upward on the accelerator pedal to relieve tension on the cable.


2. Remove the retainer from the pedal lever hole by compressing the tabs on the
retainer.
3. Remove cable from the slot in the pedal lever.

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4. Remove the accelerator pedal mounting nuts (2).


5. Remove the accelerator pedal assembly.

Installation Procedure
Important: The accelerator cable must not be kinked or damaged in any way during
installation.
Ensure that the mounting surface between the accelerator pedal assembly and the dash
panel is free of insulation. The carpet and padding in the pedal and tunnel area must be
positioned to lay flat and be free of wrinkles and bunches. Wire, hoses, cables, and other
flexible components should not be within 13 mm (0.52 in) of the cable or lever, at any
point in their travel.

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1. Place the accelerator pedal assembly over the mounting studs and onto the
mounting surface.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

Tighten
Tighten the accelerator pedal mounting nuts to 9 N-m (84 lb in).

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3. Lift upward on the accelerator pedal.
4. Insert the cable through the pedal lever slot.
5. Press the retainer into the lever hole until fully seated.
Important: The pedal must operate freely without binding through the full
range of pedal movement.
6. Check the accelerator pedal for free movement by depressing and releasing the
pedal several times.

Document ID: 425587

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2. Install the accelerator pedal mounting nuts (2).

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Fuel Pump Relay Replacement


Document ID: 21220
Removal Procedure

1. Disconnect the negative battery cable.


2. Remove the underhood electrical center cover.
3. Remove the fuel pump relay. The location is indicated on the electrical center
cover.

Installation Procedure
1. Install the fuel pump relay. The location is indicated on the electrical center
cover.
2. Install the underhood electrical center cover.
3. Connect the negative battery cable.

Document ID: 21220

Fuel Pump and Engine Oil Pressure Sensor Replacement


Document ID: 310179
Removal Procedure
Tools Required
J 35748 Oil Pressure Sending Unit Socket
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.

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Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.

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2. Disconnect the spark plug wires and the ignition coil wire from the distributor.

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3. Disconnect the CMP electrical connector from the distributor.

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4. Remove the distributor cap screws.

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5. Remove the distributor cap.

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6. Important: A DTC P1345 will set if the rotor is not reinstalled in the exact
position the rotor was in prior to removal.
Observe the alignment of the rotor in relation to the distributor base (1).

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7. Remove the distributor mounting bolt.

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8. Remove the distributor assembly.


9. Discard the distributor gasket.

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10. Disconnect the fuel pump and engine oil pressure sensor electrical connector.

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11. Remove the fuel pump and engine oil pressure sender with a J 35748 Oil
Pressure Sending Unit Socket.

Installation Procedure
Important: Do not use the old cap, CMP sensor, and rotor screws. Use replacement
screws that have been coated with a thread locking compound. Precoated replacement
cap and CMP sensor screws can be acquired using GM P/N 10475922 (pkg of
10 screws). Precoated replacement rotor screws can be acquired using GM
P/N 10475924 (pkg of 10 screws).
Tools Required
J 35748 Oil Pressure Sending Unit Socket

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1. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the fuel pump and engine oil pressure sender with a J 35748 Oil Pressure
Sending Unit Socket.

Tighten the sender to 30 N-m (22 lb ft)

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2. Connect the fuel pump and engine oil pressure sensor electrical connector.

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Tighten

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3. Important: The proper CKP/CMP correlation will be lost if the rotor is not be
reinstalled in the same exact position. A DTC P1345 will result from improper
distributor shaft alignment.
Align the rotor in its original position in relation to the distributor base (1).

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4. Install the distributor assembly using a new distributor gasket.

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5. Install the distributor mounting bolt.


Tighten
Tighten the bolt to 25 N-m (18 lb ft)

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6. Install the distributor cap.

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7. Install new distributor cap screws.


Tighten
Tighten the screws to 2.4 N-m (21 lb in)

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8. Connect the CMP electrical connector.

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9. Connect the spark plug wires and the ignition coil wire.
10. Connect the negative battery cable.

Document ID: 310179

Evaporative Emission Canister Purge Solenoid Valve Replacement


Document ID: 314440
Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.

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2. Disconnect the EVAP purge line.

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3. Disconnect the purge solenoid electrical connector.

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4. Remove the purge solenoid mounting nuts.


5. Remove the engine wiring harnesss bracket from the mounting stud.

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6. Remove the purge solenoid from the intake manifold.

Installation Procedure

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1. Install the purge solenoid to the intake manifold.


2. Install the engine wiring harness bracket to the mounting stud.

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3. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

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Install the purge solenoid mounting nuts.


Tighten
Tighten the bolts to 12 N-m (106 lb in).

4. Connect the purge solenoid electrical connector.

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5. Connect the EVAP purge line.
6. Connect the negative battery cable.

Document ID: 314440

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Evaporative Emission Vent Valve Replacement


Document ID: 22482
Removal Procedure
1. Raise the vehicle.

2. Disconnect the vent solenoid electrical connector.

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3. Disconnect the vacuum hose.

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4. Bend back the tang on the bracket.

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5. Remove the vent solenoid.

Installation Procedure

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1. Slide the vent solenoid onto the bracket.

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2. Connect the vacuum hose

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3. Install the electrical connector.


4. Lower the vehicle.

Document ID: 22482

Evaporative Emission Canister Replacement


Document ID: 11712
Removal Procedure
1. Raise the vehicle.

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2. Remove the canister mounting bolts.


3. After marking the hoses, disconnect the hoses from the canister.
4. Remove the canister.

Installation Procedure

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1.
2.
3.
4.

Connect the hoses to the canister.


Install the canister to the bracket.
Install the canister mounting bolts.
Lower the vehicle.

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Document ID: 11712

Fuel Pressure Relief


Document ID: 214945
Tools Required

Caution: Remove the fuel tank cap and relieve the fuel system pressure before
servicing the fuel system in order to reduce the risk of personal injury. After you relieve
the fuel system pressure, a small amount of fuel may be released when servicing the fuel
lines, the fuel injection pump, or the connections. In order to reduce the risk of personal
injury, cover the fuel system components with a shop towel before disconnection. This
will catch any fuel that may leak out. Place the towel in an approved container when the
disconnection is complete.

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1. Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
Disconnect the negative battery cable in order to avoid possible fuel discharge if
an accidental attempt is made to start the engine.

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J 34730-1A Fuel Pressure Gauge

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2. Loosen the fuel filler cap in order to relieve the tank vapor pressure.
3. Connect the J 34730-1A fuel pressure gauge or the equivalent to the fuel
pressure connection.
4. Wrap a shop towel around the fitting while connecting the gauge in order to
avoid spillage.
5. Install the bleed hose of the gauge into an approved container.
6. Open the valve on the gauge in order to bleed the system pressure. The fuel
connections are now safe for servicing.
7. Drain any fuel remaining in the gauge into an approved container.

Metal Collar Quick Connect Fitting Service


Document ID: 404518
Removal Procedure
Tools Required
J 41769 Fuel Line Quick Disconnect Tool
Important: Relieve the fuel system pressure before servicing any fuel system
connection. Refer to the Fuel Pressure Relief Procedure .

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1. Slide the dust cover from the quick-connect fitting.

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Document ID: 214945

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2. Grasp both sides of the fitting. Twist the female connector 1/4 turn in each
direction to loosen any dirt within the fitting.

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3. Caution: Wear safety glasses when using compressed air, as flying dirt particles
may cause eye injury.
Blow dirt out of the fitting using compressed air.

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4. Choose the correct tool from J 41769 Tool Set for the size of the fitting. Insert
the tool into the female connector, then push inward to release the locking tabs.

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5. Pull the connection apart.
Notice: If necessary, remove rust or burrs from the fuel pipes with an emery
cloth. Use a radial motion with the fuel pipe end in order to prevent damage to
the O-ring sealing surface. Use a clean shop towel in order to wipe off the male
tube ends. Inspect all the connections for dirt and burrs. Clean or replace the
components and assemblies as required.
6. Using a clean shop towel, wipe off the male pipe end.
7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the
components as required.

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Installation Procedure

1. Caution: In order to reduce the risk of fire and personal injury, before
connecting fuel pipe fittings, always apply a few drops of clean engine oil to the
male pipe ends.
This will ensure proper reconnection and prevent a possible fuel leak.
During normal operation, the O-rings located in the female connector will swell
and may prevent proper reconnection if not lubricated.
Apply a few drops of clean engine oil to the male pipe end.

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2. Push both sides of the fitting together to cause the retaining tabs to snap into
place.

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3. Once installed, pull on both sides of the fitting to make sure the connection is
secure.

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4. Reposition the dust cover over the quick-connect fitting.

Document ID: 404518

Plastic Collar Quick Connect Fitting Service


Document ID: 404520
Removal Procedure

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1. Important: Relieve the fuel system pressure before servicing any fuel system
connection. Refer to the Fuel Pressure Relief Procedure .
Grasp both sides of the quick-connect fitting. Twist the female connector 1/4
turn in each direction in order to loosen any dirt within the quick-connect fitting.

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2. Caution: Wear safety glasses when using compressed air in order to prevent eye
injury.
Using compressed air, blow any dirt out of the quick-connect fitting.

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3. Squeeze the plastic retainer release tabs.

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4. Pull the connection apart.

Installation Procedure

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1. Caution: In order to reduce the risk of fire and personal injury, before
connecting fuel pipe fittings, always apply a few drops of clean engine oil to the
male pipe ends.
This will ensure proper reconnection and prevent a possible fuel leak.
During normal operation, the O-rings located in the female connector will swell
and may prevent proper reconnection if not lubricated.
Apply a few drops of clean engine oil to the male fuel pipe end.

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2. Push both sides of the quick-connect fitting together in order to cause the
retaining tabs/fingers to snap into place.

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3. Once installed, pull on both sides of the quick-connect fitting in order to make
sure the connection is secure.

Document ID: 404520

In-Line Fuel Filter Replacement


Document ID: 214954
Removal Procedure
1. Relieve the fuel pressure. Refer to Fuel Pressure Relief Procedure .
2. Remove the fuel filler cap.

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3. Remove the fuel feed nut and plastic quick connect fitting from either side of the
filter. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .

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4. Remove the clamp bolt.
5. Remove the filter and the clamp from fuel lines.

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6. Remove the clamp from filter.

Installation Procedure

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1. Install the clamp to filter.

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2. Install the filter and clamp to fuel lines.


3. Install the clamp bolt.

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4. Install the fuel feed nut and plastic quick connect fitting on either side of the fuel
filter. Refer to Quick Connect Fitting(s) Service (Plastic Collar) .
5. Install the fuel filler cap.
6. Check for leaks.

Crankshaft Position Sensor Replacement


Document ID: 260277

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Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.

Disconnect the negative battery cable.


2. Raise the Vehicle. Refer to Lifting and Jacking the Vehicle in General
Information .

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3. If the vehicle is equipped with the underbody shield package, then remove the
steering linkage shield mounting bolts.

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1. Important: The CKP System Variation Learn Procedure will need to be


performed whenever the Crankshaft Position (CKP) sensor is removed or
replaced. Refer to Crankshaft Position System Variation Learn in Engine
Controls - 4.3L .

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4. Remove the steering linkage shield.

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5. Disconnect the CKP sensor electrical connector.

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6. Remove the CKP sensor mounting bolt.

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7. Remove the CKP sensor.

Installation Procedure
Important: When installing the CKP sensor, make sure the sensor is fully seated before
tightening the mounting bolt. A poorly seated CKP sensor may perform erratically;
possibly setting false DTCs.
Important: Do not reuse the original O-ring.
1. Replace the CKP sensor O-ring.
2. Lubricate the O-ring with clean engine oil before installing the CKP sensor.

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3. Important: Make sure the CKP sensor mounting surface is clean and free of
burrs.
Install the CKP sensor.

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4. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

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Install the CKP sensor mounting bolt.


Tighten
Tighten the CKP sensor mounting bolt to 20 N-m (15 lb ft).

5. Connect the CKP sensor electrical connector.

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6. Install the steering linkage shield.

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7. Install the steering linkage shield mounting bolts.


Tighten
Tighten the bolts to 33 N-m (24 lb ft).
8. Lower the Vehicle. Refer to Lifting and Jacking the Vehicle in General
Information .
9. Connect the negative battery cable.
10. Perform the CKP System Variation Learn Procedure. Refer to Crankshaft
Position System Variation Learn in Engine Controls - 4.3L .

Document ID: 260277

Camshaft Position Sensor Replacement


Document ID: 310185
Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.

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2. Disconnect the spark plug wires and the ignition coil wire from the distributor.

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3. Disconnect the CMP sensor harness connector.

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4. Remove the distributor cap screws.

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5. Remove the distributor cap.

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6. Remove the rotor screws.


7. Remove the rotor.

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8. Align the square slot in the reluctor wheel with the CMP sensor.

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9. Remove the CMP screws.


10. Remove the CMP sensor.

Installation Procedure
Important: Do not use the old cap, CMP sensor, and rotor screws. Use replacement
screws that have been coated with a thread locking compound. Precoated replacement
cap and CMP sensor screws can be acquired using GM P/N 10475922 (pkg of
10 screws). Precoated replacement rotor screws can be acquired using GM
P/N 10475924 (pkg of 10 screws).

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1. Insert the CMP sensor through the reluctor wheel slot.

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Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Install new CMP mounting screws.

Tighten the bolts to 2.2 N-m (20 lb in)

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3. Install the rotor onto the reluctor wheel.
4. Install new rotor screws.
Tighten
Tighten the screws to 2 N-m (18 lb in)

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Tighten

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5. Install the distributor cap.

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6. Install new distributor cap screws.
Tighten
Tighten the screws to 2.4 N-m (21 lb in)

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7. Connect the CMP sensor harness connector.

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8. Connect the spark plug wires and the ignition coil wire.
9. Connect the negative battery cable.

Document ID: 310185

Knock Sensor Replacement


Document ID: 310192

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Removal Procedure
Tools Required
J 35748 Oil Pressure Sending Unit Socket

1. Disconnect the negative battery cable.

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2. Disconnect the spark plug wires and ignition coil wire from the distributor.

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3. Disconnect the CMP sensor harness connector from the distributor.

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4. Remove the distributor cap screws.

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5. Remove the distributor cap.

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6. Important: A DTC P1345 will set if the rotor is not reinstalled in the exact
position the rotor was in prior to removal.
Observe the alignment of the rotor in relation to the distributor base (1).

Click here for full size

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Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.

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7. Remove the distributor mounting bolt.

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8. Remove the distributor assembly.
9. Discard the distributor gasket.

10. Disconnect the fuel pump and engine oil pressure sensor harness connector.

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11. Remove the fuel pump and engine oil pressure sender with a J 35748 Oil
Pressure Sending Unit Socket.

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12. Remove the knock sensor harness connector.

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13. Remove the knock sensor.

Installation Procedure
Tools Required
J 35748 Oil Pressure Sending Unit Socket

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1. Notice: Replacement components must be the correct part number for the
application. Components requiring the use of the thread locking compound,
lubricants, corrosion inhibitors, or sealants are identified in the service
procedure. Some replacement components may come with these coatings
already applied. Do not use these coatings on components unless specified.
These coatings can affect the final torque, which may affect the operation of the

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component. Use the correct torque specification when installing components in


order to avoid damage.
Install the knock sensor.
Tighten
Tighten the sensor to 20 N-m (15 lb ft)

2. Connect the knock sensor harness connector.

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3. Install the fuel pump and engine oil pressure sender with a J 35748 Oil Pressure
Sending Unit Socket.

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Tighten
Tighten the sender to 30 N-m (22 lb ft)

4. Connect the fuel pump and engine oil pressure sensor harness connector.

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5. Important: The proper CKP/CMP correlation will be lost if the rotor is not
reinstalled in the same exact position. A DTC P1345 will result from improper
distributor shaft alignment.
Align the rotor in its original position in relation to the distributor base (1).

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6. Install the distributor assembly using a new distributor gasket.

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7. Install the distributor mounting bolt.
Tighten
Tighten the bolt to 25 N-m (18 lb ft)

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8. Install the distributor cap.

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9. Important: Do not use the old screws for the cap, CMP sensor, and rotor. Use
replacement screws that have been coated with a thread locking compound.
Precoated replacement cap and CMP sensor screws can be acquired using GM
P/N 10475922 (pkg of 10 screws). Precoated replacement rotor screws can be
acquired using GM P/N 10475924 (pkg of 10 screws).
Install new distributor cap screws.
Tighten
Tighten the screws to 2.4 N-m (21 lb in)

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10. Connect the CMP sensor harness connector.

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11. Connect the spark plug wires and the ignition coil wire.
12. Connect the negative battery cable.

Fuel Sender Assembly Replacement Document ID: 255164


Removal Procedure

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Caution: In order to reduce the risk of fire and personal injury that may result
from a fuel leak, always replace the fuel sender gasket when reinstalling the fuel
sender assembly.
1. Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.

2. Remove the fuel tank. Refer to Fuel Tank Replacement in Engine Controls 4.3L .

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3. Remove the fuel sender assembly by using the J 39765 in a counter clockwise
motion.
Important: Note the position of the fuel pump strainer.
4. Remove the strainer (2) from the fuel pump.
5. Inspect the fuel pump strainer (2). Replace the strainer if it is contaminated and
clean the fuel tank.
6. Disconnect the fuel level sensor electrical connector (7).
7. Remove the fuel level sensor (3) from the sender assembly.
8. Remove the fuel tank pressure sensor (1).

Assembly Procedure
Notice: Do not fold or twist the strainer when installing the sending unit. This action
restricts fuel flow.

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Disconnect the negative battery cable.

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1. Support the pump with one hand and position the new pump strainer on pump in
the same position as noted during disassembly.
2. Push on the outer edge of the ferrule until fully seated.

Installation Procedure

1. Install the fuel tank pressure sensor (1).


2. Install the fuel level sensor on the sender assembly (3).
3. Connect the fuel level sensor electrical connector (7).
4. Install the fuel pump strainer in its original position (2).
5. Install a new O-ring seal and lock ring.
6. Install the fuel sender assembly.
7. Use the J 39765 to lock the fuel sender assembly retaining ring.
8. Install the fuel tank. Refer to Fuel Tank Replacement in Engine Controls - 4.3L .
9. Add fuel removed from the tank.
10. Connect the negative battery cable.
11. Inspect for fuel leaks.
1. Turn the ignition ON for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Again, turn the ignition switch to the ON position.
4. Inspect for fuel leaks.

Document ID: 255164

Fuel Tank Pressure Sensor Replacement


Document ID: 215014
Removal Procedure

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Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.
2. Raise the vehicle.
3. Remove the fuel tank. Refer to Fuel Tank Replacement in Engine Controls 4.3L .

4. Disconnect the fuel tank vapor pressure sensor electrical connector.

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5. Remove the fuel tank pressure sensor.

Installation Procedure

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1. Install the fuel tank vapor pressure sensor.

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2.
3.
4.
5.

Connect the fuel tank vapor pressure sensor electrical connector.


Install the fuel tank. Refer to Fuel Tank Replacement in Engine Controls - 4.3L .
Lower the vehicle.
Reconnect the negative battery cable.

Document ID: 215014

Exhaust Gas Recirculation Valve Replacement


Document ID: 310198
Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.

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2. Important: Note the orientation of the EGR valve at the BASE before
removing. Do not use the electrical connector as an indication of valve
orientation. It is possible to install this EGR valve backwards. An EGR valve
installed backwards may cause a rough idle and set DTCs.
Disconnect the EGR valve electrical connector.

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3. Remove the EGR retaining bolts.

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4. Remove the EGR valve and gasket.

Installation Procedure
1. Clean any remaining gasket material from the EGR mounting surface.

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2. Important: Ensure the EGR valve is oriented in the proper direction.
Place the EGR gasket between the EGR valve and the intake manifold EGR
mounting location.

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3. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Insert the retaining bolts through the EGR valve and gasket into the mounting
holes.
Tighten
First tighten the bolts to 10 N-m (89 lb in), and then tighten the bolts to 25 N-m
(18 lb ft).

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4. Connect the EGR valve electrical connector.


5. Connect the negative battery cable.

Document ID: 310198

Exhaust Gas Recirculation Pipe Replacement


Document ID: 490081
Removal Procedure
1. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct
Replacement in Engine Controls - 4.3L .

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2. Remove the EGR pipe bracket retaining fastener.


3. Loosen the pipe fittings at both ends of the EGR pipe.
4. Remove the EGR pipe.

Installation Procedure

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1. Install the EGR pipe in the proper location and start the pipe fittings by hand. Do
not fully tighten at this step.
2. Ensure that the EGR pipe fittings are correctly lined up on the adaptors to the
exhaust and intake manifolds.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant

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are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
3. Install the EGR pipe fitting to the exhaust manifold.
Tighten
Tighten the EGR pipe fitting to exhaust manifold to 30 N-m (22 lb ft).

Tighten
Tighten the EGR pipe fitting to intake manifold to 25 N-m (18 lb ft).
5. Install the EGR pipe bracket retaining fastener.
Tighten
Tighten the fastener to 25 N-m (18 lb ft).
6. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement
in Engine Controls - 4.3L .

Fuel Hose/Pipes Replacement - Engine Compartment


Document ID: 255309
Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .

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4. Install the EGR pipe fitting to the intake manifold.

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3. Remove the air cleaner assembly.


4. Disconnect the fuel hoses at the rear of intake manifold.

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5. Remove the injector fuel inlet and outlet pipe retainer nuts.
6. Remove the injector fuel inlet and the outlet pipe retainer.

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7. Remove the rear fuel pipe bracket retaining bolt.

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8. Pull straight up on the fuel pipe in order to remove the fuel pipes from the
injector assembly.
9. Remove the O-ring seals from both ends of the fuel feed and return pipes.
10. Discard the O-ring seals.

Installation Procedure

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1. Assemble the new O-rings into the inlet and outlet of the fuel injector assembly.
Caution: Always apply a few drops of clean engine oil to the male pipe ends
before connecting the fuel pipe fittings in order to reduce the risk of fire and
personal injury. This will ensure proper reconnection and prevent a possible fuel
leak. During normal operation, the O-rings located in the female connector will
swell and may prevent proper reconnection if not lubricated.
2. Apply a few drops of clean engine oil to the male tube ends.
3. Install the fuel feed and return pipes to the fuel assembly.

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4. Install the fuel pipe retainer and the attaching nuts.

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Once installed, pull on both ends of each connection in order to make sure they
are secure.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

Tighten
1. Tighten the rear fuel line bracket bolt to 6.0 N-m (53 lb in).
2. Tighten the fuel pipe retainer nuts to 3.0 N-m (27 lb in).

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6. Install the new O-ring seals on the engine fuel feed and the return pipes.
7. Install the fuel feed and return lines to the engine fuel pipes.
Tighten
Tighten the fuel pipe nuts to 30.0 N-m (22 lb ft).
8. Inspect for fuel leak through the following steps:
1. Connect the negative battery cable.
2. Turn ON the ignition switch for 2 seconds.
3. Turn the ignition switch to the OFF position for 10 seconds.
4. Again, turn the ignition switch to the ON position.
5. Check for fuel leaks.

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5. Install the rear fuel pipe bracket retaining bolt.

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9. Tighten the fuel filler cap.


10. Install the air cleaner assembly.

Document ID: 255309

Fuel Hose/Pipes Assembly Replacement Document ID: 330197

Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .

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3. Disconnect the fittings at the engine compartment fuel feed and return pipes (1)
and the attaching hardware (2). Be careful not to bend the fuel feed and return
pipes (3).

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Removal Procedure

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4. Disconnect the fuel pipes (1) and the attaching hardware (2) at the transmission.
5. Remove the fuel tank.
6. Refer to Fuel Tank Replacement in Engine Controls - 4.3L .

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7. Disconnect the fuel feed and vapor hoses.
8. Remove the hardware retaining section of pipe to be replaced. Note location of
attaching hardware for installation.
9. Remove the section of pipe and hoses.
10. Remove rust or burrs from the engine compartment fuel pipes by the following
procedure:
1. Use emery cloth in a radial motion with the fuel pipe end in order to
prevent damage to the O-ring sealing surface.
2. Using a clean shop towel, wipe off the male tube ends.

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3. Inspect all the connectors for dirt and burrs. Clean or replace the
components/assemblies as required.

Cleaning and Inspection Procedure


Notice: If necessary, remove rust or burrs from the fuel pipes with an emery cloth. Use
a radial motion with the fuel pipe end in order to prevent damage to the O-ring sealing
surface. Use a clean shop towel in order to wipe off the male tube ends. Inspect all the
connections for dirt and burrs. Clean or replace the components and assemblies as
required.

Caution: In order to reduce the risk of fire and personal injury, before connecting fuel
pipe fittings, always apply a few drops of clean engine oil to the male pipe ends.
This will ensure proper reconnection and prevent a possible fuel leak.
During normal operation, the O-rings located in the female connector will swell and
may prevent proper reconnection if not lubricated.
1. Install the new O-rings on the engine fuel feed and return pipes.

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2. Connect the fuel feed and return pipes (3) to the engine fuel pipes (1).
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

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Installation Procedure

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3. Connect the fuel pipe attaching hardware (2).


Tighten
Fuel pipe attaching nuts to 27 N-m (20 lb ft) using a back-up wrench.

4. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Position the new fuel pipe harness (1) in the original location and the fuel pipe
harness attaching hardware (2), tighten to specification.
Tighten
Fuel pipe attaching nuts to 27 N-m (20 lb ft) using a back-up wrench.
5. Remove protective caps from one end of both fuel pipes.
Leave caps on other end of pipes to prevent dirt from entering.
6. Apply a few drops of clean engine oil to the male connector tube ends.
7. Connect the quick-connect fittings at the fuel feed and return pipe near the inline filter and at the fuel sender assembly. Refer to Quick Connect Fitting(s)
Service (Metal Collar) and Quick Connect Fitting(s) Service (Plastic Collar) .

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8. Install the fuel tank and attaching fuel pipe hardware. Refer to Fuel Tank
Replacement in Engine Controls - 4.3L .
9. Tighten the fuel filler cap.
10. Connect the negative battery cable.
11. Check for fuel leaks.
1. Turn the ignition switch to the ON position for 2 seconds.
2. Turn the ignition switch to the OFF position for 10 seconds.
3. Again, turn the ignition switch to the ON position.
4. Check for fuel leaks.

Document ID: 330197

Fuel Pressure Service Valve Replacement


Document ID: 215124
Removal Procedure

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1. Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
Disconnect the negative battery cable.
2. Remove the fuel pressure connection valve cap (3).
3. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
4. Use a standard valve core tool in order to remove the valve core (2).

Installation Procedure

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1. Use a standard valve core tool in order to install a new valve core (2).
2. Connect the negative battery cable.
3. Inspect for leaks.
1. Turn ON the ignition for 2 seconds.
2. Turn OFF the ignition for 10 seconds.
3. Turn ON the ignition for 2 seconds.
4. Inspect for fuel leaks.
4. Install the fuel pressure connection valve cap (3).

Fuel Pressure Regulator Replacement


Document ID: 255396
Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
3. Remove the upper manifold assembly. Refer to Engine Mechanical.

Disassembly Procedure

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Document ID: 215124

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1. Important: If the fuel pressure regulator is to be reinstalled, inspect the filter


screen (if equipped) for contamination. If the filter screen is contaminated,
replace the regulator.
Disassemble the fuel pressure regulator snap ring retainer.

2. Disassemble the regulator assembly and the O-rings.


3. Discard the O-rings.

Assembly Procedure

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1. Lubricate the new O-rings with clean engine oil.
2. Install the backup O-ring, the large O-ring, the filter and the small O-ring.

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3. Assemble the regulator with the vacuum tube pointing down into the snap ring
retainer.

Installation Procedure
1. Install the upper manifold assembly. Refer to Engine Mechanical.
2. Connect the negative battery cable.

Document ID: 255396

Fuel Meter Body Assembly Replacement


Document ID: 255319
Cleaning and Inspection Procedure
Notice: Cover the injector sockets in order to prevent dirt and other contaminants from
entering the open fuel passages.
Removing the fuel meter body assembly from the engine requires removing the top
portion of the intake manifold, called the upper manifold assembly and throttle body.
An 8 digit part identification number is on a mylar label affixed to one of the fuel meter
body assemblies. Refer to this number if servicing or part replacement is required.
Notice: Do not use a cleaner which contains methyl ethyl ketone. This
extremely strong solvent may damage components and is not necessary for this
type of cleaning.

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Use a carburetor cleaner in order to remove deposits.


Refer to the instructions provided with the cleaner.

Before removal, the fuel meter body assembly may be cleaned with a spray type
engine cleaner, GM X-30A or the equivalent.
Follow the package instructions.
Do not soak fuel meter body assemblies in liquid cleaning solvent.

Removal Procedure

1. Disconnect the negative battery cable.


2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .

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3. Remove the electrical connector to the fuel meter body.

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Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.

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4. Remove the fuel feed and the return hoses from the engine fuel pipes.
5. Remove the engine fuel pipe retainer nuts and retainer.
6. Remove the engine fuel pipes by lifting straight up and away from the fuel meter
body.
7. Remove the upper manifold assembly.

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8. Important: When disconnecting the poppet nozzles, remember the sequence in
order to ensure correct poppet nozzle placement to each cylinder.
Squeeze the poppet nozzle locking tabs together while lifting the nozzle out of
the casting socket.

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9. Remove the fuel meter body from the bracket by releasing the lock tabs on the
bracket.

Installation Procedure

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1. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

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Install the fuel meter body retaining bracket in the intake manifold.
Tighten
Tighten the attaching bolts to 10 N-m (88 lb in).

2. Caution: Verify that the poppet nozzles are firmly seated and locked in their
casting sockets in order to reduce the risk of fire and personal injury. An
unlocked poppet nozzle could work loose from its socket and produce a fuel
leak.
Push the fuel meter body into the bracket.
3. Make sure all of the tabs are locked into place.

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4. Important: The fuel meter body assemblies are numbered to indicate poppet
nozzle order.
Push the poppet nozzles into the casting sockets.
5. Inspect the poppet nozzles in order to ensure they are firmly seated and locked in
the casting sockets.
6. Install the upper manifold assembly. Refer to Engine Mechanical.

7. Connect the upper manifold electrical connector.

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8. Install the new O-ring seal on the engine fuel feed and the return pipes.
Tighten

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Tighten the fuel feed and return pipe retainer nuts to the fuel meter body to
3.0 N-m(27 lb in).
9. Install the fuel feed and the return hoses to the engine fuel pipes.
Tighten
Tighten the fuel pipe nuts to 30.0 N-m (22 lb ft).

Document ID: 255319

Fuel Injector Replacement


Document ID: 215131
Removal Procedure
Notice: Use care in removing the fuel injectors to prevent damage to the electrical
connector terminals.
The fuel injector is serviced as a complete assembly only.
Also since the injectors are electrical components, these injectors should not be
immersed in any type of liquid solvent or cleaner as damage may occur. Fuel injector
cleaning is not recommended.
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure .
3. Remove the Upper Manifold Assembly. Refer to Upper Intake Manifold
replacement in Engine Mechanical.
4. Remove the Fuel Meter Body Assembly. Refer to Fuel Meter Body Assembly
Replacement in Engine Controls - 4.3L .

Disassembly Procedure

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10. Inspect for fuel leaks.


1. Connect the negative battery cable.
2. Turn ON the ignition switch for 2 seconds.
3. Turn the ignition switch to the OFF position for 10 seconds.
4. Turn the ignition switch back to the ON position.
5. Check for fuel leaks.
6. Tighten the fuel filler cap.

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1. Disassemble the lower hold down plate and the nuts (1).
2. While pulling the poppet nozzle tube downward, push with a small tip punch
down between the injector terminals until the injector is removed.

Assembly Procedure
Important: Each injector is calibrated for a specific flow rate. Order the correct injector
for the application being serviced when replacing the fuel injectors.

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1. Lubricate the new injector O-ring seals with clean engine oil (2).
2. Install the O-rings on the injector assembly (2).
3. Assemble the Central SFI fuel injector assembly into the fuel meter body
injector socket.

4. Assemble the lower hold down plate and nuts (1).


Tighten
Tighten the nuts to 3.0 N-m (27 lb in).

Installation Procedure
1. Install the fuel meter body assembly. Refer to Fuel Meter Body Assembly
Replacement in Engine Controls - 4.3L .
2. Install the upper manifold assembly. Refer to Engine Mechanical.
3. Connect the negative battery cable.
4. Turn the ignition On for 2 seconds.
5. Turn the ignition Off for 2 seconds.
6. Turn the ignition On for 2 seconds.
7. Inspect for fuel leaks.

Document ID: 215131

Information Sensors/Switches Description


Document ID: 194432
Engine Coolant Temperature (ECT) Sensor

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Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

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1. ECT Electrical Connector


2. Connector Tab
3. Engine Coolant Temperature (ECT) Sensor
The engine coolant temperature sensor is a thermistor (a resistor which changes value
based on the temperature) mounted in the engine coolant passage. A low coolant
temperature produces a high resistance (100,000 ohms at 40C/40F) while a high
temperature causes a low resistance (70 ohms at 130C/266F).
The VCM supplies a 5 volt signal to the engine coolant temperature sensor through a
resistor in the VCM and then measures the voltage. The voltage will be high when the
engine is cold. The voltage will be low when the engine is hot. By measuring the
voltage, the VCM calculates the engine coolant temperature. The engine coolant
temperature affects most systems the VCM controls.
The scan tool displays the engine coolant temperature in degrees. After engine startup,
the temperature should rise steadily to about 90C (194F), then stabilize when
thermostat opens. If the engine has not been run for several hours (overnight), the
engine coolant temperature and the intake air temperature displays should be close to
each other. When the VCM detects a malfunction in the ECT sensor circuit, the
following DTCs will set:

DTC P0117 circuit low


DTC P0118 circuit high
DTC P0125 excessive time to Closed Loop
DTC P1114 circuit intermittent low
DTC P1115 circuit intermittent high

The above DTCs contain a table in order to check for sensor resistance values that are
relative to temperature.

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Mass Air Flow (MAF) Sensor

The mass air flow (MAF) sensor measures the amount of air entering the engine.
The VCM uses this information to determine the operating condition of the
engine in order to control the fuel delivery. A large quantity of air indicates an
acceleration. A small quantity of air indicates a deceleration or an idle.
The scan tool reads the MAF value and displays the MAF value in grams per
second (gm/Sec). At idle, the MAF value should read between 5 gm/sec
7 gm/sec on a fully warmed up engine. The values should change rather quickly
on acceleration, but values should remain fairly stable at any given RPM. When
the VCM detects a malfunction in the MAF sensor circuit, the following DTCs
will set:
o
o
o

DTC P0101 System performance


DTC P0102 Frequency low
DTC P0103 Frequency high

Intake Air Temperature (IAT) Sensor

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1. Intake Air Temperature (IAT) Sensor


2. Electrical Harness Connector
The intake air temperature (IAT) sensor is a thermistor which changes the value based
on the temperature of the air entering the engine. A low temperature produces a high
resistance (100,000 ohms at 40C/40F). A high temperature causes a low resistance
(70 ohms at 130C/266F). The VCM supplies a 5.0 volt signal to the sensor through a
resistor in the VCM and measures the voltage. The voltage will be high when the
incoming air is cold, and low when the air is hot. By measuring the voltage, the VCM
calculates the incoming air temperature. The IAT sensor signal is used in order to adjust
the spark timing according to the incoming air density.
The scan tool displays the temperature of the air entering the engine, which should read
close to the ambient air temperature when the engine is cold. The temperature should
rise as the underhood temperature increases. If the engine has not been run for several
hours (overnight), the IAT sensor temperature and the engine coolant temperature
should read close to each other. If the VCM detects a malfunction in the IAT sensor
circuit, the following DTCs will set:

DTC P0112 circuit low


DTC P0113 circuit high
DTC P1111 circuit intermittent high
DTC P1112 circuit intermittent low

Manifold Absolute Pressure (MAP) Sensor

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The manifold absolute pressure (MAP) sensor responds to any changes in the intake
manifold pressure. The pressure any changes as a result of the engine load and speed.
The MAP sensor converts this to a voltage output.
A closed throttle on the engine coast down would produce a relatively low MAP output
voltage. A wide open throttle would produce a high MAP output voltage. This high
output voltage is produced because the pressure inside of the manifold is the same as
outside the manifold. The MAP is inversely proportional to what is measured on a
vacuum gauge. The MAP sensor is used for the following:

Altitude determination
Ignition timing control
EGR diagnostic
Speed density fuel management default

When the VCM detects a malfunction in the MAP sensor circuit, the following DTCs
will set:

DTC P0106 circuit performance malfunction


DTC P0107 circuit low
DTC P0108 circuit high
DTC P1106 intermittent circuit high
DTC P1107 intermittent circuit low

Heated Oxygen Sensor (Cutaway View)

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1. Four Wire In-Line Connector


2. Heater Termination
3. Water Shield Assembly
4. Sensor Lead
5. Flat Seat Shell
6. Seat Gasket
7. Outer Electrode and Protective Coating
8. Rod Heater

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9. Inner Electrode
10. Zirconia Element
11. Insulator
12. Clip Ring
13. Gripper

Heated Oxygen Sensors (HO2S)

When the VCM detects an HO2S signal circuit that is low, the VCM will set the
following DTCs:

DTC P0131 Bank 1 Sensor 1 HO2S


DTC P0151 Bank 2 Sensor 1 HO2S
DTC P0143 Bank 1 Sensor 3 HO2S

When the VCM detects an HO2S signal circuit that is high, the VCM will set the
following DTCs:

DTC P0132 Bank 1 Sensor 1 HO2S


DTC P0152 Bank 2 Sensor 1 HO2S
DTC P0144 Bank 1 Sensor 3 HO2S

When the VCM detects no HO2S activity, the VCM will set the following DTCs:

DTC P0134 Bank 1 Sensor 1 HO2S


DTC P0154 Bank 2 Sensor 1 HO2S
DTC P0146 Bank 1 Sensor 3 HO2S

A fault in the heated oxygen sensor heater element or its ignition feed or ground will
result in an increase in time to Closed Loop fuel control. This may cause increased
emissions, especially during startup. When the VCM detects a malfunction in the
HO2S heater circuits, the following DTCs will set:

DTC P0135 Bank 1 Sensor 1 HO2S heater


DTC P0155 Bank 2 Sensor 1 HO2S heater
DTC P0147 Bank 1 Sensor 3 HO2S heater

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The Heated Oxygen Sensors are mounted in the exhaust system where they can monitor
the oxygen content of the exhaust gas stream. The oxygen present in the exhaust gas
reacts with the sensor to produce a voltage output. This voltage should constantly
fluctuate from approximately 100 mV (high oxygen content lean mixture) to 900 mV
(low oxygen content rich mixture). The heated oxygen sensor voltage can be
monitored with a scan tool. By monitoring the voltage output of the oxygen sensor, the
VCM calculates what fuel mixture command to give to the injectors (lean mixture
low HO2S voltage = rich command, rich mixture high HO2S voltage = lean
command).

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The VCM also has the ability to detect HO2S response, switching, transition time, and
incorrect ratio voltage problems. If an HO2S response switching, transition time, or
ratio problem is detected, the VCM will store a DTC which indicates degraded an
HO2S performance.

Heated Oxygen Sensors (HO2S)

The HO2S sensors which are used in order to monitor the catalyst function are the same
as the HO2S sensors which are used in order to control the fuel. Bank 1 Sensor 1 and
Bank 1 Sensor 3 are used primarily for catalyst monitoring. These sensors also play a
limited role in fuel control. If a sensor output indicates a voltage either above or below
the 450 millivolt bias voltage for an extended period of time, the VCM will make a
slight adjustment to the fuel trim in order to ensure that the fuel delivery is correct for
catalyst monitoring.

Throttle Position (TP) Sensor

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1. Vehicle Control Module (VCM)

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In order to control the emissions of Hydrocarbons (HC), Carbon Monoxide (CO), and
Oxides of Nitrogen (NOx), a three-way catalytic converter is used. The catalyst within
the converter promotes a chemical reaction which oxidizes the HC and CO present in
the exhaust gas, converting them into harmless water vapor and carbon dioxide. The
catalyst also reduces NOx, converting it to nitrogen. The VCM has the ability to
monitor this process by using the Bank 1 Sensor 1 and the Bank 1 Sensor 3 heated
oxygen sensors. The Bank 1 Sensor 1 sensor produces an output signal which indicates
the amount of oxygen present in the exhaust gas entering the three-way catalytic
converter. The Bank 1 Sensor 3 sensor produces an output signal which indicates the
oxygen storage capacity of the catalyst; this in turn indicates the ability of the catalyst to
convert the exhaust gases efficiently. If the catalyst is operating efficiently, the Bank 1
Sensor 1 sensor will produce a far more active signal than that produced by the Bank 1
Sensor 3 sensor.

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2. Throttle Position (TP) Sensor


3. Throttle Valve
The Throttle Position (TP) sensor is a potentiometer. The TP sensor is connected to the
throttle shaft on the throttle body. By monitoring the voltage on the signal line, the
VCM calculates the throttle position. As the throttle valve angle is changed (the
accelerator pedal is moved), the TP sensor signal also changes. At a closed throttle
position, the output of the TP sensor is low. As the throttle valve opens, the output
increases so that at Wide Open Throttle (WOT), the output voltage should be above
4.0 volts.

When the VCM detects a malfunction with the TP sensor circuits, the following DTCs
will set:

DTC P0121 circuit performance malfunction


DTC P0122 circuit low
DTC P0123 circuit high
DTC P1121 intermittent circuit high
DTC P1122 intermittent circuit low

EVAP Canister Vent Valve

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The VCM calculates the fuel delivery based on the throttle valve angle (driver demand).
A broken or loose TP sensor may cause intermittent bursts of fuel from an injector. This
may cause an unstable idle because the VCM detects the throttle is moving.

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The Evaporative Canister Vent Valve replaces the fresh air vent used on past EVAP
canisters. The vent valve now not only allows the fresh outside air to the EVAP canister
during the purge modes, but also allows the diagnostic to pull a vacuum on the fuel tank
by closing the vent valve. This valve is normally open.

Evaporative Canister Purge Valve

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The Evaporative Canister Purge Valve allows the fuel vapor to flow from the EVAP
canister to the engine when active. The normally closed valve is pulse width modulated
by the VCM in order to control vapor flow.

Fuel Tank Pressure Sensor

The Fuel Tank Pressure Sensor is similar to the MAP sensor; however, the sensor is
calibrated to different tolerances. The sensor measures the air pressure differences
between the fuel tank and outside air.
The sensor uses a 5 volt reference voltage to send an output signal to the VCM.
Depending upon the atmospheric pressure, the output voltage with the fuel cap removed
will vary between 1.31.7 volts. A high voltage output (near 5 volts) indicates a very
negative pressure (vacuum below 4 Kpa).

Knock Sensor (KS) Sensor

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The knock sensor (KS) system is used in order to detect the engine detonation. The
VCM will retard the spark timing based on the signals from the KS module. The knock
sensors produce an AC voltage that is sent to the KS module. The amount of the AC
voltage produced is proportional to the amount of knock.
An operating engine produces a normal amount of engine mechanical vibration (Noise).
The knock sensors will produce an AC voltage signal from this Noise. When an engine
is operating, the VCM will learn the minimum and maximum frequency of the noise
that the engine produces. When the VCM determines that this frequency is less than or
greater than the expected amount, a knock sensor DTC will set.

A/C Request Signal


The A/C request circuit signals the VCM when an A/C mode is selected at the A/C
control head. The VCM uses this information in order to enable the A/C compressor
clutch and to adjust the idle speed before turning ON the A/C clutch. If this signal is not
available to the VCM, the A/C compressor will be inoperative.
Refer to A/C Control Circuit Diagnostics for A/C wiring diagrams and diagnosis of the
A/C electrical system.

Vehicle Speed Sensor (VSS)

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The vehicle speed sensor (VSS) is a pulse counter type input that informs the VCM how
fast the vehicle is being driven. The VSS system uses an inductive sensor mounted in
the tail housing of the transmission and a toothed reluctor wheel on the tail shaft. As the
reluctor rotates, the teeth alternately interfere with the magnetic field of the sensor
creating an induced voltage pulse.
The VSS produces an AC voltage signal that increases with the vehicle speed. The
VCM processes this signal and sends it to the following components:

The instrument panel


The cruise control module

Crankshaft Position (CKP) Sensor

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The crankshaft position sensor provides the VCM with the crankshaft speed and the
crankshaft position. The VCM utilizes this information in order to determine if an
engine Misfire is present. The VCM monitors the CKP sensor for a momentary drop in
the crankshaft speed in order to determine if a misfire is occurring. When the VCM
detects a misfire, a DTC P0300 will set.
The VCM also monitors the CKP sensor signal circuit for malfunctions. The VCM
monitors CKP signal and the High and Low resolution signals. The VCM calculates
these signals in order to determine a ratio. When the VCM detects that the ratio is out of
normal operating range, the VCM will set a DTC P0337 or a DTC P0338.

The Camshaft Position (CMP) sensor is located within the distributor. The operation of
the CMP sensor is very similar to the Crankshaft Position (CKP) sensor. The CMP
sensor will provide one pulse per camshaft revolution (1x signal). This signal will not
affect the driveability of the vehicle. The VCM utilizes this signal in conjunction with
the crankshaft position in order to determine which cylinder(s) are misfiring.

Document ID: 194432

Central Sequential Duel Injection Fuel System Description


Document ID: 192059
The fuel system is controlled by the control module located in the engine compartment.
The control module is the control center of the system.
The basic function of the fuel system is to control fuel delivery to the engine under all
operating conditions. The following two types of fuel injection systems deliver the fuel
to the engine:

The Central Sequential Fuel Injection (Central SFI) (4.3L, 5.0L, 5.7L)
The Sequential Fuel Injection (SFI) (7.4L only)

The main control sensor is the heated oxygen sensor (HO2S). The HO2S is located in
the exhaust manifold. The HO2S tells the control module the amount of oxygen in the
exhaust gas. The control module changes the air to fuel ratio to the engine by
controlling the fuel injector. Efficient catalytic converter operation requires a 14.7:1 air
to fuel ratio. Because the constant measuring and adjusting of the air to fuel ratio, the
fuel injection system is called a Closed Loop system.
Several other important engine operation parameters include the following items:

The engine speed


The manifold pressure
The engine coolant temperature

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Camshaft Position (CMP) Sensor

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The throttle position

These parameters determine the mode of engine operation.


The following are the 3 separate classifications of fuel systems:

The Central Sequential Fuel Injection (Central SFI) (4.3L, 5.0L, 5.7L)
The Sequential Fuel Injection (MFI) (7.4L)
The fuel supply system

Modes of Operation

Starting Mode
When the ignition switch is turned to the ON position, before engaging the starter, the
control module energizes the fuel pump relay for 2 seconds allowing the fuel pump to
build up pressure. The control module then checks the engine coolant temperature
(ECT) sensor and the throttle position (TP) sensor in order to determine the proper air
and fuel ratio for starting. The control module controls the amount of fuel delivered in
the starting mode by changing how long the injectors are energized. This is done by
pulsing the injectors for very short times.

Clear Flood Mode


If the engine floods, clear the engine by depressing the accelerator pedal down to the
floor. The control module then pulses the injector at a 16.5:1 air to fuel ratio. The
control module holds this injector rate as long as the throttle stays wide open and the
engine is below 600 RPM. If the throttle position becomes less than 65 percent, the
control module returns to the starting mode.

Run Mode
The Run Mode is the mode under which the engine operates most of the time. In this
mode, the engine operates in either Open Loop or Closed Loop.
Open Loop
When the engine is first started and it is above 400 RPM, the system goes into the open
loop operation. In the open loop, the control module ignores the signal from the HO2S,
and the control module calculates the air to fuel ratio based on the inputs from the
engine coolant temperature (ECT) sensor and manifold absolute pressure (MAP) sensor.
The system stays in open loop until the following conditions are met:
1. The HO2S has varying voltage output, showing that it is hot enough to operate
properly. This depends on engine temperature.

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The control module monitors the voltages from several sensors in order to determine
how much fuel to give the engine. The fuel is delivered under one of several conditions
called modes. The control module controls all of the modes.

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2. The engine coolant temperature (ECT) sensor is above a specified temperature.


3. A specific amount of time has elapsed after starting the engine.
A normal functioning system may go into an open loop at idle if the heated oxygen
sensor (HO2S) temperature drops below the minimum requirement to produce the
voltage fluctuation.
Closed Loop

Acceleration Mode
When the control module senses rapid changes in the throttle position and the manifold
pressure, the system enters the acceleration mode. The system provides the extra fuel
needed for smooth acceleration.

Deceleration Mode
When the driver releases the accelerator pedal, the air flow into the engine is reduced.
The corresponding changes in the throttle position and the manifold air pressure are
relayed to the control module, which reduces the injector pulse width, in order to reduce
the fuel flow. If the decel is very rapid, or for long periods (such as long closed throttle
coast-down), the control module shuts OFF the fuel completely in order to protect the
catalytic converter.

Fuel Cutoff Mode


In order to prevent possible engine damage from over-speed, the control module cuts off
fuel from the fuel injectors when the engine speed is above approximately 5,500 RPM
with the vehicle in any forward gear or reverse. In order to prevent tire damage, the
control module also has a fuel cutoff in excess of 108 mph (173 km/h) based on the
speed rating of the tires.
Fuel is also cutoff during rapid deceleration. See Deceleration Mode.

Converter Protection Mode


The control module constantly monitors engine operation and estimates the conditions
that could result in high converter temperatures. If the control module determines the
converter may overheat, this causes the system to return to the Open Loop operation and
enriches the fuel mixture.

Battery Voltage Correction Mode


When battery voltage is low, the control module can compensate for a weak spark
delivered to the distributor by increasing the following items:

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The specific values for the above conditions vary with different engines. When these
conditions are met, the systems goes into a closed loop operation. In a closed loop, the
control module calculates the air to fuel ratio (injector on-time) based on the signal from
the HO2S. This allows the air to fuel ratio to stay very close to 14.7:1.

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The injector ON time


The idle RPM
The ignition dwell time

Controlled Idle Speed

Engine

Gear
IAC
(Drive/Neutral) Idle Speed Counts
Transmission
(1)
(RPM)
(2)
Automatic
Drive
60025
Varies

Open/Closed
Loop (3)
Closed Loop

Manual
Automatic

Neutral
Drive

70025
70025

Varies
Varies

Closed Loop
Closed Loop

Manual
Automatic

Manual
Drive

70025
55025

Varies
Varies

Closed Loop
Closed Loop

Manual
Automatic

Manual
Drive

67525
55025

Varies
Varies

Closed Loop
Closed Loop

Manual
Automatic

Manual
Drive

67525
60025

Varies
Varies

Closed Loop
Closed Loop

5.0L
5.7L (Under
8500 GVW)
5.7L (Over
8500 GVW)
7.4L
Manual
Manual
72525
Varies
Closed Loop
Important: The engine should be at operating temperature 92C to 104C (196F
to 222F).
(1) On manual transmission vehicles, the scan tool will display RDL in neutral
(2) Add 2 counts for engines with less than 500 miles. Add 2 counts for every
1000 ft. above sea level (4.3L and V8).
(3) Let the engine idle until the engine reaches proper fuel control status
(Open/Closed Loop).

Document ID: 192059

Fuel Supply Component Description


Document ID: 255214
Central SFI Fuel System with Fuel Pressure Gauge

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4.3L

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1. Fuel Inlet
2. Bleed Hose
3. J 347301A Fuel Pressure Gage Assembly
4. Fuel Pressure Connection
5. In-Line Fuel Filter
6. Fuel Line Pressure Side
7. Fuel Pump Feed Hose
8. In-Tank Fuel Pump
9. Fuel Pump Strainer
10. Return Line
11. Flexible Hose
12. Fuel Return Line
The fuel supply system consists of the following components:

The fuel tank(s) (fuel balance control system when equipped with dual tanks.
The fuel sender assembly (fuel sender, fuel pump and fuel pump strainer).
The fuel filter
The fuel feed and return pipes
The fuel pump electrical circuit
The accelerator control components

Fuel Tank

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The fuel tank, at the rear of the underbody, is held in place by 2 metal straps. Antisqueak pieces are used on top of the tank to reduce rattles.

Filler Neck
In order to help prevent refueling with leaded gasoline, the fuel filler neck on a gasoline
engine vehicles has a built-in restrictor and deflector. The opening in the restrictor will
only admit the smaller unleaded gas nozzle spout, which must be fully inserted to
bypass the deflector.

Fuel Filler Cap


The fuel tank filler neck is equipped with a tethered fuel tank filler cap. Turn the cap
counterclockwise in order to remove. A built-in torque-limiting device prevents
overtightening. In order to install the cap, turn the cap clockwise until a clicking noise is
heard. The clicking is a signal to the operator that the correct torque has been reached
and the cap is fully seated.

Fuel Sender Assembly


The fuel sender assembly is located inside the fuel tank and attaches to the top of the
fuel tank.
The fuel sender assembly consists of the following major components:

The fuel sender


The fuel pump
The fuel pump strainer
The fuel tank pressure sensor
The fuel level sensor

Fuel Pump
The fuel pump is a high pressure rollervane type, electric pump, which mounts in the
fuel tank. Fuel is pumped, at a specified flow and pressure from the fuel pump, through
the in-line filter to the pressure regulator in the fuel injection unit. Excess fuel is
returned to the fuel tank through the fuel return line.
The fuel pump attaches to the fuel sender assembly. A fuel strainer attaches to the fuel
pump inlet line. The strainer prevents dirt particles from entering the fuel line and tends
to separate water from the fuel. A ceramic resistor card for the fuel level sensor is also
attached to the outside of the sender assembly. The function of the ceramic resistor card
is to vary the resistance, depending on the position of the float and to send a signal to
the fuel gage via the BCM. The modular fuel sender assembly is serviced as a complete
assembly. The only serviceable components on the modular unit are the strainer, fuel
level sensor, and the OBD II fuel tank pressure sensor.

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Attempted refueling with a leaded gas nozzle or failure to fully insert the unleaded gas
nozzle results in gasoline splashing back out of the filler neck.

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Fuel Pump Strainer


A woven plastic filter attaches to the lower end of the fuel pump in the fuel tank. The
functions of the strainer are to filter contaminants and to wick fuel.
The life of the fuel pump strainer is generally considered to be that of the fuel pump.
The fuel pump strainer is self-cleaning and normally requires no maintenance. Fuel
stoppage at this point indicates that the fuel tank contains an abnormal amount of
sediment or water. In which case the fuel tank should have a thorough cleaning. Refer to
Fuel System Cleaning in Engine Controls - 4.3L . If the fuel strainer is plugged, replace
the strainer with a new fuel pump strainer.

A steel in-line fuel filter is used in the fuel feed pipe ahead of the fuel injection system.
The filter element is made of paper and is designed to trap particles in the fuel that may
cause damage to the injection system. The filter housing is constructed to withstand
maximum fuel system pressure, exposure to fuel additives and changes in temperature.

Nylon Fuel Pipes


Caution: In order to Reduce the Risk of Fire and Personal Injury:

If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not
attempt to repair the sections of the nylon fuel pipes. Replace them.
When installing new fuel pipes, Do Not hammer directly on the fuel harness
body clips as it may damage the nylon pipes resulting in a possible fuel leak.
Always cover nylon vapor pipes with a wet towel before using a torch near
them. Also, never expose the vehicle to temperatures higher than 115C (239F)
for more than one hour, or more than 90C (194F) for any extended period.
Before connecting fuel pipe fittings, always apply a few drops of clean engine
oil to the male pipe ends. This will ensure proper reconnection and prevent a
possible fuel leak. (During normal operation, the O-rings located in the female
connector will swell and may prevent proper reconnection if not lubricated.)

Nylon fuel pipes are designed to perform the same job as the steel or rubber fuel tubes
they replace. Nylon pipes are constructed to withstand maximum fuel system pressure,
exposure to fuel additives and changes in temperature. There are two sizes used: 3/8 in.
ID for the fuel feed and 5/16 in. ID for the fuel return.
The fuel feed and return pipes are assembled as a harness. Retaining clips hold the pipes
together and provide a means for attaching the pipes to the vehicle. Quick-connect type
fittings are used at the fuel tank ends of the fuel feed/return pipes and at the in-line fuel
filter. They are described below. Sections of the pipes that are exposed to chafing, high
temperature or vibration are protected with a heat resistant rubber hose and/or
corrugated plastic conduit.
Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under
the vehicle. However, if forced into sharp bends, nylon pipes will kink and restrict fuel
flow. Once exposed to fuel, nylon pipes may become stiffer and are more likely to kink

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In-Line Fuel Filter

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if bent too far. Special care should be taken when working on a vehicle with nylon fuel
pipes.

Quick-Connect Fittings
Quick-connect type fittings provide a simplified means of installing and connecting the
fuel system components. The quick-connect fittings consists of a female socket and a
compatible male connector. O-rings, located inside the female socket, provide the fuel
seal. Integral locking tabs or fingers hold the fittings together. The metal collar quickconnect fittings have locking tabs that require a special tool to release. Refer to Quick
Connect Fitting(s) Service (Metal Collar) .

Caution: In order to Reduce the Risk of Fire and Personal Injury:

If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not
attempt to repair the sections of the nylon fuel pipes. Replace them.
When installing new fuel pipes, Do Not hammer directly on the fuel harness
body clips as it may damage the nylon pipes resulting in a possible fuel leak.
Always cover nylon vapor pipes with a wet towel before using a torch near
them. Also, never expose the vehicle to temperatures higher than 115C (239F)
for more than one hour, or more than 90C (194F) for any extended period.
Before connecting fuel pipe fittings, always apply a few drops of clean engine
oil to the male pipe ends. This will ensure proper reconnection and prevent a
possible fuel leak. (During normal operation, the O-rings located in the female
connector will swell and may prevent proper reconnection if not lubricated.)

The vapor pipe extends from the fuel sender assembly to the charcoal canister. It is
made up of nylon pipe and is connected to the fuel sender assembly and the EVAP
canister with the fuel resistant rubber hoses.

Fuel Pipe O-Rings


The fuel feed and return pipe threaded connections at the fuel injection unit are sealed
with replaceable O-ring seals. These O-ring seals are made of special material and
should only be serviced with the correct service part.

Fuel Pump Electrical Circuit


When the key is turned ON with out the engine running, the control module turns a fuel
pump relay ON for two seconds. This builds up fuel pressure quickly. If the engine is
not started within two seconds, the control module shuts the fuel pump OFF and waits
until the engine starts. As soon as the engine is cranked, the control module turns the
relay ON and runs the fuel pump. When the engine is cranking or running, the control
module receives the Crankshaft Position (CKP) sensor reference pulses which in turn
energize the fuel injectors. The VCM will also energize the fuel pump for two seconds
when the key is turned to the OFF position.

Accelerator Control

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Vapor Pipes and Hoses

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The accelerator control system is a control cable type attached at one end to an
accelerator pedal assembly. On the other end is the throttle valve.

Document ID: 255214

uel Metering System Component Description


Document ID: 636284

The function of the fuel metering system is to deliver the correct amount of fuel to the
engine under all operating conditions.
Fuel is delivered to the engine by individual fuel injectors and poppet nozzles mounted
in the intake manifold near each cylinder.

Fuel Metering System Components


The fuel metering system consists of the following parts:

The fuel supply components (fuel tank, pump, lines)


The fuel pump electrical circuit
The fuel meter body assembly which includes the following components:
o The fuel injectors and poppet nozzles
o The fuel pressure regulator
o The electrical wiring harness
The upper manifold assembly which includes the following items:
o The throttle body
o The Idle Air Control (IAC) valve
o The Throttle Position (TP) sensor
o The Manifold Absolute Pressure (MAP) sensor

Fuel Metering System


The fuel pump relay is mounted in the underhood electrical center located in the engine
compartment. For diagnosis of the fuel pump relay circuit, refer to Fuel Pump Relay
Circuit Diagnosis.The fuel pump and engine oil pressure indicator switch is mounted in
the engine block near the distributor. For diagnosis of the fuel pump circuit, refer to
Fuel Pump Relay Circuit Diagnosis. Some failures of this system will result in an
Engine Cranks But Will Not Run symptom. This table determines if the problem is
caused by the ignition system, VCM, or fuel pump circuit.
This includes the fuel injector poppet assembly, fuel pressure regulator, fuel pump and
fuel pump relay. The fuel system wiring schematic diagram is covered in Fuel Pump
Circuit Diagnosis.

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Purpose

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If a problem occurs in the fuel metering system, it usually results in either a rich or lean
exhaust condition. This condition is sensed by the HO2S. This condition causes the
VCM to change the fuel calculation (injector pulse width). The change made to the fuel
calculation is indicated by a change in the short and long term fuel trim values which
can be monitored by a scan tool. A momentary change to the fuel calculation is
indicated by the short term fuel trim value, while a prolonged change is indicated by the
long term fuel trim value. Average fuel trim values will measure around 128. The
averages may vary slightly from engine to engine.
Important: When using a scan tool to observe fuel trim values, remember that if the
system is in control, no action is required unless a driveability symptom is present.

A momentary lean HO2S signal (system is in control) will appear on the scan
tool as the following items:
o Short term fuel trim value above 128 (adding fuel).
o Long term fuel trim value around 128.
A prolonged lean HO2S signal (system is in control) will appear on the scan tool
as the following items:
o Short term fuel trim value around 128.
o Long term fuel trim value above 128 (added fuel).
A prolonged lean HO2S signal (system is out of control) will appear on the scan
tool as the following items:
o Short term fuel trim value well above 128 (adding fuel).
o Long term fuel trim value well above 128 (added fuel).

If both fuel trim values are fixed well above 128, see DTC P0131 for items which can
cause a lean system. Refer to DTC DTC P0131 HO2S Circuit Low Voltage Bank 1
Sensor 1 in Engine Controls - 4.3L .

A momentary rich HO2S signal (system is in control) will appear on the scan
tool as the following items:
o Short term fuel trim value less than 128 (reducing fuel).
o Long term fuel trim value around 128.
A prolonged rich HO2S signal (system is in control) will appear on the scan tool
as the following items:
o Short term fuel trim value around 128.
o Long term fuel trim value less than 128 (reduced fuel).
A prolonged rich HO2S signal (system is out of control) will appear on the scan
tool as the following items:
o Short term fuel trim value much less than 128 (reducing fuel).
o Long term fuel trim value much less than 128 (reduced fuel).

If the fuel trim values are fixed well below 128, see DTC P0132 for items which can
cause the system to run rich. Refer to DTC P0132 HO2S Circuit High Voltage Bank 1
Sensor 1 in Engine Controls - 4.3L .
If a driveability symptom exists, refer to the particular symptom in Symptoms, for
additional items to check.

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Listed below are examples of lean and rich HO2S signals with the system in control and
out of control.

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Fuel Control
Fuel delivery is controlled by the control module system.
The diagnosis of fuel control starts with Engine Cranks But Will Not Run. This table
will test the fuel system to determine if there is a problem. Refer to Engine Cranks But
Does Not Run in Engine Controls - 4.3L .

Fuel Injector

A fuel injector which does not open may cause a nostart condition. An injector which
is stuck partially open could cause loss of pressure after sitting, resulting in extended
crank times on some engines. Also, dieseling could occur because some fuel could be
delivered to the engine after the key is turned OFF.

Fuel Pressure Regulator


If the pressure regulator supplies pressure which is too low, poor performance could
result. If the pressure is too high, exhaust odor may result.

Idle Air Control (IAC)


The diagnosis of Idle Air Control (IAC) can be found in Idle Air Control (IAC) System
Diagnosis in Engine Controls - 4.3L .
If the IAC valve is disconnected or connected when the engine is running, the idle RPM
may be wrong. The IAC valve may be reset by turning the ignition switch ON for
10 seconds, OFF for 5 seconds.
The IAC valve affects the idle characteristics of the engine as well as throttle followup
to compensation for sudden throttle closing. If it is open fully too much air will be
allowed in the manifold and idle speed will be high. If it is stuck closed, too little air
will be allowed in the manifold, and idle speed will be too low. If it is stuck part way
open, the idle may be rough, and will not respond to engine load changes.

Fuel Pump Circuit


The relay has a terminal to test the fuel pump operation which is a separate terminal
located near the fusible link cluster. By applying voltage at this terminal, it can be
determined if the fuel pump will operate. This terminal will also prime the fuel line to
the fuel injection unit.
For diagnosis of the Fuel Pump Circuit refer toFuel Pump Electrical Circuit Diagnosis
in Engine Controls - 4.3L .
An inoperative fuel pump will cause a no start condition. A fuel pump which does not
provide enough pressure can result in poor performance.

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Testing of the fuel injector circuit is located in theFuel Injector Circuit Diagnosis in
Engine Controls - 4.3L table.

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Engine Coolant Temperature (ECT) Sensor


The engine coolant temperature sensor is a thermistor (a resistor which changes value
based on temperature) mounted in the engine coolant stream. Low coolant temperature
produces a high resistance (100,000 ohms at 40C/40F) while high temperature
causes low resistance (70 ohms at 130C/266F).

The scan tool displays engine coolant temperature in degrees. After engine startup, the
temperature should rise steadily to about 90C (194F) then stabilize when thermostat
opens. If the engine has not been run for several hours (overnight), the engine coolant
temperature and intake air temperature displays should be close to each other. A fault in
the engine coolant sensor circuit should set DTC P0117 or DTC P0118.

Intake Air Temperature (IAT) Sensor


The Intake Air Temperature (IAT) sensor is a thermistor which changes value based on
the temperature of air entering the engine. Low temperature produces a high resistance
(100,000 ohms at 40C/40F), while high temperature causes low resistance
(70 ohms at 130C (266F)). The VCM supplies a 5 volt signal to the sensor through a
resistor in the VCM and measures the voltage. The voltage will be high when the
incoming air is cold, and low when the air is hot. By measuring the voltage, the VCM
calculates the incoming air temperature.
The IAT sensor signal is used to adjust spark timing according to incoming air density.
The scan tool displays temperature of the air entering the engine, which should read
close to ambient air temperature when engine is cold, and rise as underhood temperature
increases. If the engine has not been run for several hours (overnight) the IAT sensor
temperature and engine coolant temperature should read close to each other. A failure in
the IAT sensor circuit should set DTC P0112 or DTC P0113.

Manifold Absolute Pressure (MAP) Sensor


DTC P0107 or DTC P0108 indicates a failure in the MAP sensor circuit, which may
effect fuel metering.

Heated Oxygen Sensor (HO2S 1)


The exhaust Heated Oxygen Sensor (HO2S 1) is mounted in the exhaust manifold
where it can monitor the oxygen content of the exhaust gas stream.
The oxygen content in the exhaust reacts with the sensor to produce voltage output. This
voltage should constantly fluctuate from approximately 100 mV (high oxygen content

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The VCM supplies a 5 volt signal to the engine coolant temperature sensor through a
resistor in the VCM and measures the voltage. The voltage will be high when the engine
is cold, and low when the engine is hot. By measuring the voltage, the VCM calculates
the engine coolant temperature. Engine coolant temperature affects most systems the
VCM controls.

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lean mixture) to 900 mV (low oxygen content rich mixture). The heated oxygen
sensor voltage can be monitored with a Scan tool.
By monitoring the voltage output of the heated oxygen sensor, the VCM calculates what
fuel mixture command to give to the injector (lean mixturelow HO2S 1 voltage=rich
command, rich mixturehigh HO2S 1 voltage=lean command).

HO2S 2 (Catalyst Monitor)


In order to control emissions of Hydrocarbons (HC), Carbon Monoxide (CO) and
Oxides of Nitrogen (NOx), a threeway catalytic converter is used. The catalyst within
the converter promotes a chemical reaction which oxidizes the HC and CO present in
the exhaust gas, converting them into harmless water vapor and carbon dioxide. The
catalyst also reduces NOx, converting it to nitrogen. The VCM has the capability to
monitor this process using HO2S 2. HO2S 2, located in the exhaust stream past the
threeway catalytic converter, produces an output signal which indicates the oxygen
storage capacity of the catalyst; this in turn indicates the catalysts ability to convert
exhaust emissions effectively. A problem with the HO2S 2 electrical circuits should set
DTC P0137, P0138 or P0140, depending on the specific condition. If the catalyst is
functioning correctly, the HO2S 2 signal will be far less active than that produced by
HO2S 1. If a problem exists which causes the VCM to detect excessive HO2S 2 activity
outside of an acceptable range for an extended period of time, the VCM will set DTC
P0420, indicating that the threeway catalytic converters oxygen storage capacity is
below a threshold considered acceptable.

Throttle Position Sensor


The Throttle Position (TP) sensor is a potentiometer connected to the throttle shaft on
the throttle body. By monitoring the voltage on the signal line, the VCM calculates
throttle position. As the throttle valve angle is changed (accelerator pedal moved), the
TP sensor signal also changes.
At a closed throttle position, the output of the TP sensor is low. As the throttle valve
opens, the output increases so that at Wide Open Throttle (WOT), the output voltage
should be above 4 volt.
The VCM calculates fuel delivery based on throttle valve angle (driver demand). A
broken or loose TP sensor may cause intermittent bursts of fuel from an injector and
unstable idle because the VCM thinks the throttle is moving. A problem in the TP
sensor 5 volt reference or signal circuits should set either a DTC P0122 or DTC P0123.
A problem with the TP sensor ground circuit may set DTCs P0123 and P0117. Once a
DTC is set, the VCM will use an artificial default value based on mass air flow for TP
sensor and some vehicle performance will return. A high idle may result when either
DTC P0122 or DTC P0123 is set.

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The heated oxygen sensor circuit, if open, should set a DTC P0134 and the Scan tool
will display a constant voltage between 350-550 mV. A constant voltage below 250 mV
in the sensor circuit should set DTC P0131, while a constant voltage above 750 mV in
the circuit should set DTC P0132. DTC P0131 and DTC P0132 could also be set as a
result of fuel system problems.

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TP Sensor Output
This check should be performed when TP sensor attaching parts have been replaced. A
scan tool can be used to read the TP signal output voltage.

Idle Speed
When there is a problem with the idle refer toIdle Air Control (IAC) System Diagnosis
in Engine Controls - 4.3L .

System too lean (High air/fuel ratio) - Idle speed may be too high or too low.
Engine speed may vary up and down, disconnecting the IAC valve has no effect.
System too rich (Low air/fuel ratio) - Idle speed too low. Scan counts usually
above 80. System obviously rich and may exhibit black exhaust smoke. Scan
tool and/or voltmeter will read a Heated Oxygen Sensor (HO2S) signal fixed
above 800 mV (.8 volt).

Crankshaft Position Sensor


The scan tool scan tool displays crankshaft position sensor data as engine speed (RPM).
An error in the crankshaft position sensor circuit should set a DTC P0336, P0337,
P0338, or a P0339. The crankshaft position sensor provides a signal through the ignition
control module which the VCM uses as reference to calculate RPM and crankshaft
position.

Camshaft Position Sensor


The scan tool scan tool will display camshaft position sensor data as a 0 and 1 as the
sensor pulses, the scan data will switch from 0 to 1. All camshaft position sensor data
should be checked at idle. An error in the camshaft position sensor circuit should set a
DTC P0340. The camshaft position sensor sends a signal to the VCM which uses it as a
sync pulse to trigger the injectors in proper sequence.

Cam Signal
The VCM uses this signal to determine the position of the #1 piston during its power
stroke. This signal is used by the VCM to calculate fuel injection mode of operation. A
loss of this signal will set DTC P0340.
If the cam signal is lost while the engine is running, the fuel injection system will shift
to a calculated fuel injection mode based on the last fuel injection pulse, and the engine

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1. Connect the DMM from TP sensor connector terminal B (BLK wire) to terminal
C (DK Blue wire). Jumpers for terminal access can be made using terminals
1214836 and 12014837.
2. With ignition ON, engine stopped, the TP signal voltage should be less than
1.25V if more than 1.25V verify free throttle movement. If still more than
1.25V, replace TP sensor.
3. Remove the voltmeter and jumpers, reconnect the TP sensor connector to the
sensor.

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will continue to run. The engine can be restarted and will run in the calculated mode as
long as the fault is present .

Fuel Supply Components


The fuel supply is stored in the fuel tank. An electric fuel pump, located in the fuel tank
with the gauge sending unit, pumps fuel through an in-line fuel filter to the fuel meter
body assembly.

Fuel Pump Electrical Circuit


When the ignition switch is turned to the ON position (before engaging the starter), the
VCM energizes the fuel pump relay for 2 seconds causing the fuel pump to pressurize
the fuel system. If the VCM does not receive the ignition reference pulses (engine
cranking or running) within 2 seconds, the control module shuts off the fuel pump relay,
causing the fuel pump to stop.
As a backup system to the fuel pump relay, the fuel pump oil pressure switch can
energize the fuel pump. The switch has 2 internal circuits. One circuit operates the oil
pressure indicator or gage in the instrument cluster. The other circuit is a normally open
switch which closes when the oil pressure reaches about 28 kPa (4 psi). If the fuel pump
relay fails, the fuel pump oil pressure switch runs the fuel pump.
An inoperative fuel pump relay can result in long cranking times, particularly if the
engine is cold. The fuel pump oil pressure switch energizes the fuel pump as soon as oil
pressure reaches about 28 kPa (4 psi).
Fuel Meter Body Assembly

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The pump provides fuel at a pressure greater than is needed by the injectors. The fuel
pressure regulator, part of the fuel meter body assembly, keeps the fuel to the injectors
at a regulated pressure. The unused fuel is returned to the fuel tank via a separate line.

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1. Fuel Pressure Regulator Assembly


2. Fuel Meter Body
3. Fuel Line
4. Fuel Injector Assembly
5. Poppet Nozzle
6. Fuel Pressure Regulator Assembly Retainer
The fuel meter body assembly is mounted to the lower portion of the intake manifold.
The assembly performs the following functions:

Allows for an even distribution of fuel to the injectors


Integrates the fuel pressure regulator into the fuel metering system

Injectors and Poppet Nozzles

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Each fuel injector assembly is a solenoid-operated device, controlled by the VCM. The
fuel injector assembly meters the pressurized fuel through a poppet nozzle (5) to a
single engine cylinder.
The VCM energizes the injector solenoid, which opens an armature valve (3), allowing
fuel to flow past the ball valve and through a fuel tube (1) to the poppet nozzle.
An increase in fuel pressure causes the poppet nozzle ball to open from its seat against
the extension spring force. This allows the fuel to flow from the nozzle (at
approximately 280 kPa (40 psi)).
De-energizing the injector solenoid (4) closes the armature. De-energizing also reduces
the fuel pressure acting on the poppet nozzle ball. The extension spring closes the ball
to the seat. The extension spring also checks the pressure between the ball and seat and
the injector armature and fuel tube shutoff. The flow control solenoid assembly (2) is
electrically activated to allow fuel to flow from the injector to the flexible fuel line to
the poppet nozzle.
An injector poppet nozzle that is stuck partly open would cause a loss of pressure after
the engine shut down. Consequently, the driver would notice long cranking times on
some engines. Dieseling could also occur because the fuel injector could deliver some
fuel to the engine after the driver turns the ignition to OFF. These components are
diagnosed in The Injector Balance Test and The Injector Coil Test. Refer to Fuel
Injector Solenoid Coil Test in Engine Controls - 4.3L and to Fuel Injector Balance Test
in Engine Controls - 4.3L .

Fuel Pressure Regulator Assembly

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The fuel pressure regulator (1) is a diaphragm-operated cartridge relief valve with the
fuel pump pressure on one side and the regulator spring pressure and intake manifold
vacuum on the other. A retainer (2) holds the fuel pressure regulator.
The regulator's function is to maintain a constant pressure differential across the
injectors at all times. The pressure regulator compensates for engine load by increasing
the fuel pressure as engine vacuum drops.
With the ignition ON leaving the engine off (zero vacuum), the fuel pressure at the
pressure test connection should be 415455 kPa (6066 psi). If the pressure is too low,
poor performance could result. If the pressure is too high, excessive odor may result.
The Fuel System Diagnosis has information on diagnosing fuel pressure conditions.
Refer to Fuel System Diagnosis in Engine Controls - 4.3L .

Throttle Body Assembly

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The throttle body assembly is a downdraft design. The throttle body is mounted on the
intake manifold plenum. The VCM uses the throttle body in order to control the air flow
into the engine, thereby, controlling the engine output.
The throttle valve within the throttle body is opened by the driver through the
accelerator controls. During the engine idle, the throttle valve is almost closed, and the
iIdle air control (IAC) valve handles the air flow control.

Idle Air Control (IAC) Valve Assembly


The purpose of the IAC valve assembly is to control the engine idle speed while
preventing engine stalls due to changes in the engine load.
The IAC valve, mounted in the throttle body assembly, controls the bypass air around
the throttle valve. By moving a conical valve known as a pintle IN toward the seat (in
order to decrease the air flow), or OUT away from the seat (in order to increase the air
flow), a controlled amount of air moves around the throttle valve.
If the engine speed is too low, more air is bypassed around the throttle valve in order to
increase the RPM. If the engine speed is too high, less air is bypassed around the
throttle valve in order to decrease the RPM.
The VCM moves the IAC valve in small steps, called counts which can be measured by
using a scan tool connected to the Data Link Connector (DLC).
During idle, the proper position of the IAC valve is calculated by the VCM. This
position is based on the battery voltage, the engine coolant temperature, the engine load,
and the engine RPM. If the RPM drops below specification and the throttle valve is
closed, the VCM senses a near stall condition, and then the VCM calculates a new valve
position in order to prevent stalling.
If the IAC valve is disconnected and reconnected while the engine is running, the
resulting idle RPM may be wrong. This will require the resetting of the IAC valve.
After running the engine, the IAC valve will reset when the ignition is turned OFF. The
IAC valve should only be disconnected or connected with the ignition OFF.
If the VCM is without battery power for any reason, the programmed position of the
IAC valve pintle is lost. The control module replaces the lost position with a default
value. In order to return the IAC valve pintle to the correct position, see the Idle Learn
Procedure.

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The throttle body also provides the location for mounting the throttle position (TP)
sensor. The throttle body also senses changes in the engine vacuum due to the throttle
valve position. The vacuum ports are located at, above, or below the throttle valve in
order to generate the vacuum signals that are needed by the various components.

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The IAC valve affects the idle characteristics of the vehicle. A fully retracted valve
allows too much air into the manifold causing a high idle speed. A valve which is stuck
closed allows too little air in the manifold, causing a low idle speed. If the valve is stuck
part way open, the idle may be rough, and the idle will not respond to the engine load
changes.

Throttle Position (TP) Sensor

Document ID: 636284

Evaporative Emission Control System Operation Description Document ID: 222842


EVAP System Components

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The non-adjustable TP sensor is mounted on the throttle body assembly opposite the
throttle lever. The TP sensor senses the throttle valve angle and relays that information
to the VCM. Throttle angle is one of the inputs needed by the VCM to generate the
required injector control signals (injector on time). It also is an important input for
transmission shift scheduling.

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1. EVAP Purge Solenoid Ignition Positive Voltage


2. To Intake Manifold Port
3. Fuel Tank Pressure Sensor
4. Fuel Tank Pressure Sensor Ground Circuit
5. Fuel Tank Pressure Sensor Signal Circuit
6. Fuel Tank Pressure Sensor 5V Reference Circuit
7. Fuel Filler Neck
8. Rollover Valve
9. Fuel Tank
10. EVAP Vent Valve

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11. EVAP Vent Valve Control Circuit


12. EVAP Vent Valve Ignition Positive Voltage
13. EVAP Canister
14. EVAP Purge Solenoid
15. EVAP Purge Solenoid Control Circuit

When the engine is able to use the extra fuel vapor, the intake air flow purges the fuel
vapor from the carbon element, and then the normal combustion process consumes the
fuel vapor.
The system is designed to detect the evaporative fuel system leaks as small as 0.040 of
an inch between the fuel filler cap and the purge solenoid. The system can test the
evaporative system integrity by applying a vacuum to the fuel tank in order to create a
small vacuum. The vehicle control module (VCM) then used the fuel tank pressure
sensor to determine system integrity.

Operation
The control module monitors the ability of the system to maintain the vacuum. If the
vacuum remains for a specified period of time, then there are no evaporative leaks, and
a PASS report is made by the control module. If there is a leak, the system either will
not achieve a vacuum, or a vacuum cannot be maintained. Usually a fault can only be
detected after a cold start with a trip of sufficient length and driving conditions to run
the needed tests. The enhanced evaporative system diagnostic conducts up to 8 specific
sub-tests in order to detect the fault conditions. If the diagnostic fails a sub-test, the
control module stores a diagnostic trouble code (DTC) in order to indicate the type of
fault detected.

Evaporative (EVAP) Emissions System Diagnostic Tests


The control module performs diagnostic tests in order to monitor the performance of the
evaporative emissions (EVAP) system. These test are as follows:

Excess Vacuum Tests


The control module monitors the fuel tank pressure (FTP) sensor signal during the
normal purging of the EVAP canister under various driving conditions in order to detect
a malfunction in the fuel tank vent control components. If the Excess Vacuum tests run
and pass, the Purge Valve Leak Test will run. If the Excess Vacuum tests run and fail, a
DTC P0446 is set.

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The purpose of the evaporative emission (EVAP) control system is to prevent the fuel
vapors from escaping into the atmosphere. The EVAP transfers the fuel vapor from the
sealed fuel tank to an activated carbon, or charcoal, storage device, or EVAP canister.
The EVAP canister stores the vapors until the engine is able to use the extra fuel vapor.

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Loaded Canister Test


The control module monitors the oxygen sensors during normal EVAP purging in order
to determine if the EVAP canister is storing a sufficient amount of fuel vapors. If the
test indicates that the EVAP canister is storing a sufficient amount of fuel vapors, the
remaining diagnostic tests for the EVAP system will store a pass. If the Loaded Canister
Test indicates to the control module that an insufficient amount of fuel vapors are being
stored by the EVAP canister, the Weak Vacuum Tests will run.

Weak Vacuum Tests

Command the EVAP vent valve ON or closed


Monitor the fuel tank pressure sensor signal

If the control module determines that sufficient vacuum is not achieved, the control
module will perform the following steps:

Store a DTC P0440 after the first failed test


Store the data in the Freeze Frame and Failure Records
Turn the malfunction indicator lamp (MIL) ON after a second consecutive failed
test

If the control module determines that sufficient vacuum is achieved, the control module
will perform the following steps:

While the EVAP vent valve is ON or closed, turn the EVAP purge solenoid OFF
or closed, and run the Small EVAP Leak Test.
Run the Purge Solenoid Leak Test if the first Weak Vacuum Test passes.
Turn OFF the MIL, if the MIL is ON because of a previous failed Weak
Vacuum Test.
Clear the data stored in the Freeze Frame for the DTC P0440.

The Weak Vacuum Tests will not run unless the Loaded Canister Test has run and
failed.

Small EVAP Leak Test


The control module performs the Small EVAP Leak Test in order to detect a small leak
in the following components of the EVAP system:

The fuel tank


The fuel filler cap
The fuel filler neck
The EVAP canister
The EVAP vent valve

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The Weak Vacuum Test is performed by the control module in order to determine if the
EVAP control system is capable of achieving a sufficient vacuum in the system. During
the normal purging of the EVAP control system, the control module will perform the
following:

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The EVAP vapor pipes and hoses

The Small EVAP Leak Test does not test the EVAP purge solenoid for leaks.
In order to run the Small EVAP Leak Test the control module performs the following
steps:

Turn OFF the EVAP purge valve.


Following the passed Weak Vacuum Test and while the EVAP vent valve is still
turned ON or closed, run the Small EVAP Leak Test .
Monitor the fuel tank pressure sensor signal.

Purge Valve Leak test


The control module monitors the fuel tank pressure sensor signal during a cold start in
order to test the EVAP purge valve. With the purge valve OFF or closed, the VCM
expects to detect no vacuum in the system. If the control module detects a vacuum
while the Purge Valve Leak Test is being performed, a DTC P1441 is set.

Evaporative (EVAP) System Canister

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The control module monitors the vacuum trapped in the system. If the control module
detects an excessive decrease in the vacuum that is trapped in the system, a DTC P0442
is set.

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1. Purge Line
2. Vapor From Fuel Tank
3. Air
The evaporative system canister, filled with activated carbon pellets, stores the fuel
vapors from the fuel tank. The engine vacuum purges the vapor canister during normal
driving.

Fuel Tank Pressure Sensor

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The fuel tank pressure (FTP) sensor is a 3 wire strain gauge sensor much like that of the
manifold absolute pressure (MAP) sensor, however this sensor has a very different
electrical characteristic due to its pressure differential design. The sensor measures the
difference between the air pressure, or vacuum in the fuel tank and the outside air
pressure.
The sensor mounts at the top of the fuel tank sending unit. A three wire electrical
harness connects it to the control module. The control module supplies a 5 volt
reference voltage and ground to the sensor. The sensor varies a voltage between 0.14.9 volts. When the air pressure in the fuel tank is equal to the outside air pressure, such
as when the fuel fill cap is removed, the output voltage of the sensor will measure 1.3
1.7 volts.
When the air pressure in the tank is 4.5 inches Hg (1.25 kPa), the sensor output voltage
should measure 0.30.7 volts.
The sensor voltage will be approximately 1.5 volts when the fuel tank pressure is
equalized with ambient pressure. The sensor voltage increases to approximately
4.5 volts when a vacuum of 14 inches Hg (3.75 kPa) is detected.

Evaporative Canister Purge Solenoid

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When energized, the evaporative canister purge solenoid allows the fuel vapor to flow
from the EVAP canister to the engine. The normally closed valve is pulse width
modulated by the control module in order to precisely control the vapor flow. The valve
opens during the Enhanced Evaporative Diagnostic Test in order to create a vacuum in
the fuel tank and then closes in order to seal the system.

Evaporative System Service Port

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The evaporative system service port is located in the evaporative hose located between
the purge solenoid and the canister. The service port is identified by a green colored
cap.

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Document ID: 222842

Enhanced Ignition System Description


Document ID: 208949

The ignition system uses a primary and secondary sub system in order to accomplish the
timed spark distribution. The primary system consists of a low voltage trigger device
which determines the base timing. This signal is modified by the ignition control driver
(ICD) module. The signal travels to either or both the engine and transmission processor
(control module) for base timing reference. Another signal is sent back to the ignition
control driver (ICD) module, which has been adjusted by the control module (advanced
or retarded) in order to trigger the coil, according to the requirements of the engine.
The secondary system consists of the ignition coil which has primary, or low voltage,
windings and secondary, or high voltage, windings. The secondary side of the ignition
coil generates a high voltage which high tension spark plug wires deliver to the spark
plugs.
The control module controller now controls the ignition control (IC) and bypass
functions.
In order to properly control the ignition and combustion timing, the control module
needs to know the following things:

The crankshaft position


The engine speed or RPM
The engine load manifold pressure or vacuum
The atmospheric or barometric pressure
The engine coolant temperature
The camshaft position sensor

System Operation
The enhanced ignition system used on all OBD II engines somewhat resembles the
current distributor ignition (DI) system described in the ignition systems. However, the
system has been greatly enhanced in order to make it compatible with the new OBD II
regulations. The enhanced ignition system provides a spark at precisely the correct time
in order to ignite the air and fuel mixture for optimum performance and fuel economy.
The system consists of the following components:

Vehicle control module (VCM)

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The ignition system initiates combustion by providing a spark to ignite the compressed
air and fuel mixture at the correct time. In order to provide an improved engine
performance, fuel economy, and control of exhaust emissions, the control module
controls the distributor spark advance, or timing, with the ignition control (IC) system.

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Distributor
Ignition coil driver module
Ignition coil
Crankshaft position (CKP) sensor

This system does not use the ignition module used on the DI systems in the past. The
VCM controller now controls the ignition control (IC) and bypass functions.

The VCM then utilizes this 3x (V6) or 4x (V8) signal in order to provide the correct
spark to the engine by way of the single coil driver module. The single coil driver
module is basically an electronic switch that when commanded by the VCM, causes the
primary coil voltage to breakdown, energizing the secondary coil and providing a spark
via the coil wire to the distributor cap. The distributor consists of the following
components:

Cap and rotor


Camshaft position (CMP) sensor
Gear drive and shaft

The camshaft drives the distributor shaft which rotates providing a spark to the correct
cylinder by way of the cap and rotor. The camshaft position sensor functions much like
the crankshaft sensor previously described but provides only a 1x signal to the VCM.
That is, for every 2 rotations of the crankshaft, there is 1 rotation of the camshaft. Note
that the CMP sensor will not affect driveability. The sole purpose of the CMP sensor is
to provide the VCM with the necessary information for the misfire DTCs.

Ignition Control (IC)


The vehicle control module (VCM) software controls all of the ignition control (IC) and
bypass functions. This reduces the number of circuits outside of the controller and
ultimately reduces the possibility for shorts or opens in those circuits that could result in
driveability complaints or diagnostic trouble codes (DTCs).

System Components
Crankshaft Position Sensor

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The crankshaft sensor, located in the front engine cover, is perpendicular to a target
wheel attached to the crankshaft. The target wheel is equipped with slots situated
60 degrees apart. As the crankshaft rotates, the target wheel rotates past the crankshaft
position sensor. The rising and falling edges created by the slots cause a signal to be
sent back to the VCM. This signal occurs three times per crankshaft revolution and is
referred to as the 3x signal for V6 applications. The signal occurs four times per
crankshaft revolution and is referred to as the 4x signal for V8 applications.

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The crankshaft position (CKP) sensor is located in the front engine cover and is
perpendicular to the crankshaft target wheel. The air gap between the sensor and the
wheel is preset and not adjustable. The target wheel has four slots 60 degrees apart and
is keyed to the crankshaft. As the target wheel rotates, the slots passing by the sensor
create a change in the magnetic field of the sensor which results in an induced voltage
pulse. One revolution of the crankshaft results in four pulses (4x signal). Based on these
pulses, the VCM is able to determine crankshaft position and engine speed. The VCM
then activates the fuel injector and provides a spark to the distributor. The relation
between the CKP sensor and the target wheel is crucial. The sensor must be exactly
perpendicular to the target wheel with the correct air gap.
Distributor

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The distributor is actually an assembly that contains the camshaft position (CMP)
sensor, cap, rotor, and shaft. The distributor is splined by a helical gear to the camshaft
and rotates providing a spark to each spark plug wire. When servicing the distributor, it
is critical to ensure proper cap sealing to the distributor body and correct installation to
the camshaft. If the distributor is installed a tooth off in relation to the camshaft, a DTC
sets. The distributor is repairable.
Camshaft Position Sensor

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The camshaft position (CMP) sensor is located within the distributor. The operation is
very similar to the crankshaft position (CKP) sensor however it provides one pulse per
camshaft revolution (1x signal). This signal is not detrimental to the driveability of the
vehicle. The VCM utilizes this signal in conjunction with the crankshaft position to
determine which cylinders are misfiring.
Ignition Coil Driver Module and Ignition Coil
The ignition coil driver module is mounted on a bracket next to the coil. The VCM
signals the ICD to turn ON primary current to the ignition coil by pulling the IC line
high (4 volts). The ICD turns the primary current ON and OFF by applying and
removing the ground to the primary winding at the appropriate time. This module is of
minimum function. The module does not contain backup calibrations that allows the
engine to continue to run if the IC signal is lost.

Document ID: 208949

Knock Sensor (KS) System Description


Document ID: 208911

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Purpose

Varying octane levels in gasoline can cause a detonation in an engine. This detonation is
sometimes called a spark knock.
All of the engines use a knock sensor (KS) system with a knock sensor. The KS system
reduces the spark knock in the engine. This allows the engine to have maximum spark
advance for improved driveability and fuel economy.

Operation
A vehicle control module (VCM) is used in conjunction with one knock sensor in order
to control detonation. On a VCM application no KS module will be found as it is
internal to the control module.
A 5 volt reference is applied to the knock sensor which has an internal resistance of
about 100,000 ohms. This resistance will lower the applied voltage to about half or
2.5 volts. When a knock is present, a small AC voltage is produced by the knock sensor
and transmitted to the control module riding on top of the already existing 2.5 volts. An
AC voltage monitor inside the control module will detect the knock and trigger the
control module to start retarding the spark incrementally.

Document ID: 208911

Exhaust Gas Recirculation (EGR) System Description


Document ID: 208690
Purpose

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The exhaust gas recirculation (EGR) system lowers the NOx (Oxides of Nitrogen)
emission levels created by the high combustion temperatures.

Operation
The EGR valve will open when the conditions of operation have been met. This allows
the exhaust gasses to re-enter the combustion chamber. When too much exhaust gas is
allowed to enter the chamber, the proper combustion will not occur. For this reason,
only very little exhaust gas is allowed to re-enter the combustion chamber.

1. Last 5 Digits of Assembly Part Number


2. Julian Date (3 Digits) Last Digit of Year Shift Number
3. Plant Code Letters
The linear exhaust gas recirculation (EGR) valves look like a small motor.

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The control module command exclusively operates the linear EGR valve (1). The
control module monitors the following various engine parameters:

The Throttle Position (TP) sensor


The Manifold Absolute Pressure (MAP)
The Engine Coolant Temperature (ECT) sensor
The EGR Pintle position sensor

Output messages are then sent to the EGR system indicating the proper amount of
exhaust gas (2) recirculation [with intake air (3)] necessary in order to lower the
combustion temperatures. This electronic metering of exhaust gas is ten times faster
than the vacuum-operated models as well as an improved diagnostic capabilities.
Positioned at the top of the linear EGR assembly are 5 terminals.

A is the pulse width modulated negative signal from the control module.
B is the sensor ground.
C is the sensor output.
D is the +5 volts supply.
E is the positive from ignition.

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A 12 volt current which enters the valve through an electrical connector (terminal E)
energizes the solenoid (bobbin and coil) assembly (3). The 12 volt current then flows
through the solenoid assembly to the control module and creates an electromagnetic
field. This field causes the armature assembly (4, 6) to be pulled upward, lifting the
pintle (5) a variable amount off the base.
The exhaust gas then flows from the exhaust manifold through the orifice into the intake
manifold. The pintle position sensor (2,1sensor cap) reads the height of the pintle, and
the control module closes the loop on a desired position versus the actual position read.
This changes the pulse width modulated command to the solenoid accordingly, until the
actual pintle position equals the desired pintle position.
The linear EGR valve is unique in that the control module continuously monitors the
pintle position. The control module adjusts the pintle position in order to obtain accurate
flow, making linear EGR a Closed Loop system.
When the solenoid is de-energized (the control module breaks the circuit), the pintle
seals against the orifice, blocking the exhaust flow to the intake manifold.

Document ID: 208690

Crankcase Ventilation System Description


Document ID: 208081

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A crankcase ventilation system is used in order to provide a more complete scavenging


of crankcase vapors. The air cleaner supplies fresh air through a filter to the crankcase.
The crankcase mixes the fresh air with blow-by gases. This mixture then passes through
a crankcase ventilation valve into the intake manifold.
The primary control is through the crankcase ventilation valve (1), which meters the
flow at a rate depending on the manifold vacuum.
In order to maintain an idle quality, the crankcase ventilation valve restricts the flow
when the intake manifold vacuum is high. If abnormal operating conditions arise, the
system is designed in order to allow the excessive amounts of blow-by gases to back
flow through the crankcase vent tube into the air cleaner in order to be consumed by
normal combustion.

Spark Plug Wire Resistance


Document ID: 340591
Tools Required
J 39200 Digital Multimeter
1. Disconnect both ends of each spark plug wire you are testing.
Ensure that the wire terminals are clean before proceeding.
2. Use the J 39200 on the high scale.
3. Connect an ohmmeter lead to each end of the wire.
4. Gently twist the wire while watching the ohmmeter reading.

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5. If the ohmmeter reads above 30,000 ohms, no matter how long the wire is, or
fluctuates from infinity to any value, replace the wire.

Document ID: 340591

Generator Usage
Document ID: 236953

Engine
2.2L
4.3L

Model
CS-130D
CS-130D

Rated Output
100 A
100 A

Load Test
70 A
70 A

Document ID: 236953

1998 Dom S/T Cell 30 Figure 3 Component Location View Document ID: 255078
4.3 L Engine Generator And Starter

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Generator Specifications

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1. Exhaust Gas Recirculation Valve


2. Generator
3. Crankshaft Position Sensor
4. Starter Motor
5. Starter Solenoid
6. Splice S100
7. Splice S101
8. Splice S102
9. Electronic Ignition Control Module
10. Ignition Coil
11. Ignition Coil Assembly

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12. G107

Document ID: 255078

1998 Dom. S/T Cell 30 Figure 5 Component Location View Document ID: 255084

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1. Oxygen Sensor, Pre-Converter
2. Connector C118 (2.2L Engine Harness to Oxygen Sensor Extension Harness)
3. Starter Solenoid
4. Starter Motor

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2.2L Engine RH Front Locator View

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Document ID: 255084

Document ID: 255098


Underhood Fuse Block Internal Location View

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1. BTSI Fuse (10 A) (W/ A/T)
2. B/U LP Fuse (UBEC) (25 A)

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1998 Dom. S/T Cell 30 Figure 6 Component Location View -

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3. Starter Relay (Mini Relay)


4. IGN B MaxiFuse (50 A)
5. IGN E Fuse (UBEC) (10 A)
6. RAP MaxiFuse (40 A)
7. OXYSEN Fuse (UBEC) (20 A)
8. IGN A MaxiFuse (UBEC) (40 A)

10. PARKLP Fuse (20 A)


11. STUD #2 MaxiFuse (30 A) (Utility)
12. ATC Fuse (20 A)
13. HVAC Fuse (30 A)
14. TRCHMSL Fuse (10 A)
15. HAZLP Fuse (20 A)
16. VECHMSL Fuse (10 A)
17. Rear Defogger Relay (Mini) Relay (Utility)
18. RRDFOG Fuse (30 A) (Utility)
19. HTDMIR Fuse (10 A) (Utility)
20. Headlamp Grounding Relay (Micro Relay)
21. RR W/W Fuse (15 A) (Utility)
22. CRANK Fuse (10 A)
23. STOPLP Fuse (20 A)
24. TBC Fuse (10 A)
25. High Mounted Stop Lamp Relay (Micro Relay) (Pickup)
26. Fog Lamp Relay (Micro Relay)
27. HTDSEAT Fuse (20 A) (Utility)
28. IGN C Fuse (15 A)

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9. LR PRK (10 A)

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29. FOG LP Fuse (15 A)


30. Horn Relay (Micro Relay)
31. Daytime Running Lights Relay Diode
32. A/C Fuse (10 A)
33. A/C Compressor Clutch Relay (Micro Relay)
34. HORN Fuse (15 A)

36. Fuel Pump Prime Connector


37. RT HDLP Fuse (10 A)
38. FR PRK Fuse (10 A)
39. LT TURN Fuse (Front) (10 A)
40. RT TURN Fuse (Front) (10 A)
41. Headlamp Power Relay (Micro Relay)
42. LT HDLP Fuse (10 A)
43. TRL PRK Fuse (10 A) (Utility)
44. RR PRK Fuse (10 A)
45. VEH B/U Fuse (15 A)
46. ECM B Fuse (20 A)
47. TRL B/U Fuse (10 A) (Utility)
48. TRRTRN Fuse (10 A) (Utility)
49. TRLTRN Fuse (10 A) (Utility)
50. RT TRN Fuse (Rear) (10 A)
51. LT TRN Fuse (Rear) (10 A)
52. ENG I Fuse (UBEC) (10 A)
53. ECM I Fuse (UBEC) (15 A)
54. INT BAT MaxiFuse (50 A)

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35. Daytime Running Lights Relay (Micro Relay)

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55. ABS MaxiFuse (60 A) Fuel Pump Relay (Micro Relay)


56. Fuel Pump Relay

Document ID: 255098

1998 Dom. S/T Cell 30 Figure 7 Component Location View -

Transmission Range Switch Connector

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1. Connector C104 (Engine Harness to Chassis Harness)
2. Transmission Range Switch Connector C2
3. Transmission Range Switch Connector C1

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Document ID: 255089

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4. Connector C105 (4.3 L Engine Harness to LH Front Heated Oxygen Sensor


Harness)
5. Heated Oxygen Sensor, LH Front (Bank 1, Sensor 1) (4.3 L Engine)

Document ID: 255089

Engine Electrical Connector End Views

Generator

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Connector Part Information


Pin
B

Wire Color
RED

12186566
ASM 1F M/P 150 Sealed (BLK)

Circuit No.
Function
225
Charge Indicator Lamp Output

Clutch Pedal Position (CPP) Switch

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Document ID: 418476

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Connector Part
Information
Pin
A
B
C

PPL
PPL
PPL/WHT

Circuit
No.
806
420
1035

BRN/WHT

379

Wire Color

Function
Fuse Output - Crank - Type III Fuse
Stoplamp Switch Output
Starter Relay Feed - Coil
Cruise Control Clutch Pedal Position Switch
Output

Document ID: 418476

Charging System Check


Document ID: 328273
Step

Action
Normal Result(s)
Move the ignition switch from the Battery indicator lamp
OFF position to the RUN
turns ON, voltmeter
position.
gage reads between
12-14 volts.

Move the Ignition Switch to the The engine starts, the


START position and then release. voltage gage reads
2
between 13-16 volts,
the battery indicator
lamp turns OFF.
Run the engine at idle while
Voltmeter gage
observing the voltmeter gage and holdssteady between
3 the battery indicator lamp.
1316 volts and the
battery indicator lamp
is OFF.
1. Turn on the following
Voltmeter gage holds
4
electrical components:
steady between 1316

Abnormal
Result(s)*
Refer to
Charge
Indicator
Inoperative
in Engine
Electrical .
Refer to
Voltmeter
Displaying
High or Low
in Engine
Electrical .
Refer to Charge
Indicator Always
On in Engine
Electrical .
Refer to Generator
Not Operating
Properly in Engine
Electrical .
Refer to Generator
Not Operating

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12129136
CONN 4F M/P 280 FLXLK (BLK)

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Headlamps
volts and the battery Properly in Engine
Rear defogger
indicator lamp is OFF. Electrical .
Heater blower
motor to HI
2. Increase the engine speed
to 2500 RPM for
2 minutes and observe the
voltmeter gage.
o
o
o

* Refer to the appropriate symptom diagnostic table for the applicable abnormal
result.

Voltmeter Displaying High or Low


Document ID: 240302
Voltmeter Reading High/Low
Step

Action
Turn all electrical loads OFF. Start the engine and
allow it to idle briefly. Use a DMM to check the
1 voltage across the battery terminals.

Value(s)
13.0
16.0 V

Is the voltage within the specified range?


Compare the DMM reading with a reading taken at
the same time (engine at idle) from the vehicle
voltmeter.
2

Yes

No

Go to
Go to Step
Step 2
5

2V

Is the difference between the vehicle voltmeter


reading and the DMM reading within the specified
range?
Increase the engine speed to 2500 RPM. Use a
DMM to check the voltage across the battery
3 terminals.

Go to
Go to Step
Step 3
6

13-16 V

Is the voltage within the specified range?


Compare the DMM reading with a reading taken at
the same time (engine at 2500 RPM) from the
vehicle voltmeter.
4
Is the difference between the vehicle voltmeter
reading and the DMM reading within the specified
range?
5 Perform the Charging System Check in Engine

Go to
Go to Step
Step 4
5

2V

Go to
System Step
OK
6
Go to Go to

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Document ID: 328273

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Electrical .

Is the generator OK?


Repair the PCM and/or Instrument cluster for an
incorrect voltmeter reading condition.

Is the repair complete?


Replace the generator. Refer to Generator
Replacement in Engine Electrical .
Is the repair complete?

Step
8

Go to
Step 1

Go to
Step 1

Go to
Step 1

Document ID: 240302

Ignition Coil Not Operating Properly


Document ID: 221045
Tools Required
J 39200Digital Multimeter
1. Turn OFF the ignition switch.
2. Disconnect the distributor lead and wiring from the ignition coil.
Notice: Do not insert the J 39200 digital multimeter probe into the ignition coil
connectors. The female terminals could be deformed, resulting in intermittent
operation. Only make contact with the front edge of the terminals.

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Is the repair complete?


1. Disconnect the battery negative cable.
2. Disconnect and clean all connections
between the battery positive terminal and the
generator output terminal.
3. Disconnect and clean all connections in the
7
ground circuit between the battery negative
terminal and the generator housing. Check all
cables for an intermittent open condition.
4. Connect the battery negative cable.

Step 7

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3. Connect an ohmmeter as shown.


o Use the high scale.
o If the reading is not infinite, replace the coil.
Refer to Ignition Coil and Ignition Coil Module Replacement in Engine
Electrical .

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4. Connect an ohmmeter as shown.
o Use the low scale.
o The reading should be 0.1 ohms. If not, replace the coil.
Refer to Ignition Coil and Ignition Coil Module Replacement in Engine
Electrical .

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5. Connect an ohmmeter as shown.


o Use the high scale.
o If the reading is not 525k ohms, replace the coil.
Refer to Ignition Coil and Ignition Coil Module Replacement in Engine
Electrical .
6. Reconnect the distributor lead and wiring to the coil.

Document ID: 221045

Starter Replacement Document ID: 183252


Removal Procedure
Caution: Before servicing any electrical component, the ignition and start switch must
be in the OFF or LOCK position and all electrical loads must be OFF, unless instructed
otherwise in these procedures. If a tool or equipment could easily come in contact with a
live exposed electrical terminal, also disconnect the negative battery cable. Failure to
follow these precautions may cause personal injury and/or damage to the vehicle or its
components.
1. Disconnect the battery negative cable.
2. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle
in General Information.
3. Remove the front tire and wheel assembly from the right side of the vehicle.
Refer to Wheel Removal in Tires and Wheels.

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4. Remove the differential carrier shield mounting bolts, if equipped.


5. Remove the differential carrier shield, if equipped.

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6. Remove the wires from the solenoid.

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7. Remove the starter mounting bolts by accessing them below the right wheel
house panel.

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8. Remove the starter from the vehicle.
Note the location of the shims, if equipped.

Installation Procedure

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1. Install the starter and the inboard starter mounting bolt. Do not tighten.
2. Install the starter shims, if equipped.

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3. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the outboard starter mounting bolt.

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Tighten
Tighten the starter mounting bolts to 50 N-m (37 lb ft).

4. Connect the wires to the solenoid.


Tighten
o
o

Tighten the battery positive cable nut to 9 N-mN-m (80 lb in).


Tighten the engine wiring harness to starter nut to 1.9 N-m (16 lb in).

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5. Install the differential carrier shield, if equipped.
6. Install the differential carrier shield mounting bolts, if equipped.

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Tighten
Tighten the differential carrier bolts to 25 N-m (18 lb ft).
7. Install the tire and wheel assembly. Refer to Wheel Installation in Tires and
Wheels.
8. Lower the vehicle.
9. Connect the negative battery cable.

Starter Inspection Document ID: 95918


Cleaning, Inspection and Electrical Tests
Notice: Do not clean the starter motor parts in a degreasing tank. Soaking parts will
dissolve the permanent lubrication and may damage the electrical insulation. This will
shorten starter motor life.
1. Clean all parts by wiping with a clean cloth.
2. Inspect the bushing or armature bearing fit in the drive end frame, the lever
housing, and the drive end frame housing. If the bushings or bearings are
damaged or worn, replace them.
o Lubricate the bushings before assembling the starter motor. Avoid
excessive lubrication.
o Do not lubricate the roller bearings. They are permanently lubricated.
3. Inspect the armature for runout or scoring. Replace the armature assembly if the
condition of the armature shaft is questionable.
4. Inspect the commutator for discolored or uneven conductors.
o Do not turn the commutator
o Do not undercut the insulation
o Clean the commutator with 240 grit emery cloth. Blow away any copper
dust present. If the commutator cannot be cleaned, replace the armature.

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Document ID: 183252

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5. Inspect the armature for short circuits.


o Rotate the armature in a growler with a steel strip such as a hacksaw
blade. Hold the blade on the armature parallel to the shaft. The steel strip
will vibrate when it finds the short circuit.
o Shorts between the commutator bars are sometimes produced by brush
dust or copper dust.
6. Inspect armature for opens.
o Look for loose connections where the conductors join the commutator
bars.
o Poor connections cause arcing and burning of the commutator.

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7. Inspect the armature for grounds using a self powered test lamp. If the test lamp
lights when one test probe is placed on the commutator and the other test lamp

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probe is placed on the armature core shaft, the armature is grounded. Replace the
armature.
8. Inspect the brushes for wear. If the brushes are worn to half the size of a new
brush, replace the assembly.
9. Inspect the brush holders for dirt or damage. Make sure that the brushes are not
binding in the holders.
10. Inspect the brush springs for distortion or discoloring. If the springs are weak,
bent, or discolored, replace the frame and field assembly.
11. Inspect the field coils.
o Look for burned or damaged insulation, damaged connections or loose
poles.
o If the conditions of the coils is doubtful, replace the field and frame
assembly.
12. Inspect the field coils for grounds.
o Connect a self-powered test lamp between the field frame and the field
connector. Make sure the brush ends do not contact the field frame.
o If the test lamp lights, the field coils are grounded. Replace the field and
frame assembly.
13. Inspect the field coils for opens.
o Connect a self-powered lamp between the field connector and each of the
brushes.
o If the test lamp does not light at both brushes, the field coils are open.
Replace the frame and field assembly
14. Inspect for field coils for shorts.
o Shorts are indicated by poor motor performance after everything else has
been checked out.
o The coils cannot be replaced separately because of the integral frame
construction. The frame and field assembly must be replaced.
15. Inspect the drive assembly (clutch) by turning the drive pinion in the cranking
direction. If the drive pinion turns or slips in the cranking direction, replace the
over-running clutch assembly.

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16. Inspect the solenoid for grounds using a self-powered 12 volt test lamp.
1. Connect the test lamp between the BAT terminal and the case. The lamp
should not light (terminal should not be grounded).
2. Connect the test lamp between the S terminal and the case. Then connect
the test lamp between the M terminal and the S terminal or between the
M terminal and the case. The lamp should turn on.
3. If the solenoid does not pass these checks, replace it.
Notice: To prevent overheating of the solenoid pull-in winding, do not leave the
winding energized for more than 15 seconds. The current draw will decrease as
the winding temperature increases.

17. Inspect the hold-in winding and the pull-in winding.


0. If the solenoid is not removed from the starter motor, the field lead must
be removed from the terminal on the solenoid before making these tests.
1. To check both windings, connect an ammeter in series with a 12 volt
battery and the switch terminal on the solenoid. Connect a carbon pile
across the battery. Ground the solenoid motor terminal. Adjust the
voltage to 10 volts and note the ammeter reading. It should be 60 to 85
amperes.
2. Note the ampere reading. A high reading indicates a shorted or grounded
winding, and a low reading indicates excessive resistance.
 The resistance of the windings can be read directly using a digital
ohmmeter that can measure tenths of an ohm.
 Coil resistance can be determined by dividing the voltage by the
current (amperes).

Document ID: 95918

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Underhood Fuse Block Replacement Document ID: 198530


Removal Procedure

1. Disconnect the battery negative cable.

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2. Remove the battery positive cable cover.

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Caution: Before servicing any electrical component, the ignition and start
switch must be in the OFF or LOCK position and all electrical loads must be
OFF, unless instructed otherwise in these procedures. If a tool or equipment
could easily come in contact with a live exposed electrical terminal, also
disconnect the negative battery cable. Failure to follow these precautions may
cause personal injury and/or damage to the vehicle or its components.

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3. Remove the battery positive cable bolt.


4. Remove the battery positive cable.

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5. Remove the bolts that attach the underhood electrical center to the underhood
electrical center support bracket.

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6. Loosen the bolts that secure the electrical connectors to the bottom of the
underhood electrical center.

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7. Disconnect the electrical connectors.
8. Remove the underhood electrical center from the vehicle.

Installation Procedure

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1. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Connect the electrical connectors.
Tighten
Tighten the electrical connector bolts to 7 N-m (62 lb in).

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2. Install the bolts that attach the underhood electrical center to the underhood
electrical center support bracket.
Tighten
Tighten the electrical connector bolts to 7 N-m (62 lb in).

3. Attach the battery positive cable with bolt.


Tighten
Tighten the battery positive cable bolt to 10 N-m (88 lb in).

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4. Replace the battery positive cable cover.

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5. Connect battery negative cable.

Document ID: 198530

Cooling System Draining and Filling


Document ID: 199018

The use of a waterless, GM approved coolant recycling system on the vehicle eliminates
the need for evacuation. This system is available through the GM Dealer Equipment
program (or the equivalent). This method removes the used coolant and replaces the
used coolant with approved new or with recycled coolant. When this equipment is not
available use the following procedure.

Draining Procedure
Caution: To avoid being burned, do not remove the radiator cap or surge tank cap
while the engine is hot. The cooling system will release scalding fluid and steam under
pressure if radiator cap or surge tank cap is removed while the engine and radiator are
still hot.
Caution: As long as there is pressure in the cooling system, the temperature can be
considerably higher than the boiling temperature of the solution in the radiator without
causing the solution to boil. Removal of the pressure cap while the engine is hot and
pressure is high will cause the solution to boil instantaneously possibly with
explosive force spewing the solution over the engine, fenders and the person
removing the cap.

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Engine Coolant Recycling

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1. Ensure that the system has cooled, then remove the radiator filler cap.
2. Place a drain pan under the radiator drain cock.
3. Install a tube on the drain cock, if necessary.

4. Place the end of the tube in the drain pan.


5. Open the drain cock completely.
6. Allow the cooling system to drain until the flow stops. If only the radiator is
drained, up to 40 percent of the old coolant will remain in the system.

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7. Place a drain pan under the engine.
8. Remove the drain plug from the side of the engine block, 2.2L shown.

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9. Remove the drain plugs from each side of the engine block, 4.3L shown.
o There may be more drainage from the radiator at this time.
o Allow the engine block to drain until the flow stops.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
10. Apply a sealer (GM P/N 12346004) to the threads and then tighten the engine
block drain plug(s).
Tighten
o
o

Tighten the engine block drain plugs (2.2L) to 15 N-m (11 lb ft).
Tighten the engine block drain plugs (4.3L) to 18 N-m (13 lb ft).

Important: Dispose of the used engine coolant properly. Store the used coolant in a
used coolant Holding Tank awaiting proper disposal or recycling. Do not pour used
coolant down the drain. DexCool antifreeze is a very toxic chemical. Disposal into
the sewer system or into the ground water is both environmentally irresponsible and
illegal.

If the drained coolant is discolored, flush the cooling system. Refer to Flushing
in Engine Cooling .
If the drained coolant appears normal, continue with the filling procedure.

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Filling Procedure
Notice: Do not add cold water to the cooling system with the engine at or above
operating temperature. Adding cold water causes rapid cooling, resulting in possible
engine damage.
Notice: Do not use a solution stronger than 70 percent antifreeze. Pure antifreeze can
freeze at -22C (-8F).

1. Ensure that the radiator drain cock is closed.


2. Inspect the strength of the old coolant, before attempting to reuse. Refer to
Coolant Concentration Testing in Engine Cooling .
3. When you need additional antifreeze solution:
o For coolant use Dex-Cool orange-colored silicate free coolant.
o Pre-mix Dex-Cool at a ratio of 50/50 with clean, drinkable water.
4. Place a large mouth funnel in the radiator fill opening.
5. Slowly add the coolant mixture.
6. Fill to inch below the radiator fill opening.
7. Start the engine.
8. As the cooling system warms up and the thermostat opens, the coolant level will
drop.
9. Add coolant until the level is up to the radiator fill opening.
o Do not spill the coolant onto the exhaust system or other hot engine
parts.
o Under some conditions, Dex-Cool is combustible.
10. Replace the radiator filler cap.

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11. Inspect the level in the coolant recovery reservoir, add coolant if needed.
12. Test the cooling system for leaks. Refer to Cooling System Leak Testing in
Engine Cooling .

Document ID: 199018

Fan Clutch Replacement


Document ID: 179324
Removal Procedure
Tools Required
J 41240 Fan Clutch Wrench
1. Remove the upper fan shroud. Refer to Engine Coolant Fan Shroud
Replacement in Engine Cooling .
Important: To maintain a balanced fan assembly, align the yellow paint mark
on the fan clutch hub with the yellow paint mark on the water pump hub.

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2. Remove the fan clutch from the coolant pump using J 41240 .
1. Install J 41240-1 into the water pump access holes.
2. With J 41240-2 secure on the fan clutch nut, hold J 41240-1 firmly in
place while turning J 41240-2 counter-clockwise.
3. Remove the fan and the fan clutch as an assembly.

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4. Remove the fan-to-fan clutch mounting screws (2.2L, RWD w/AC).

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5. Remove the fan-to-fan clutch mounting screws (2.2L, RWD w/o AC).

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6. Remove the fan-to-fan clutch mounting screws (4.3L w/AC).

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7. Remove the fan-to-fan clutch mounting screws (4.3L w/o AC).


8. Remove the fan from the clutch.

Installation Procedure
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

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1. Install the fan to the fan clutch mounting (4.3L all and 2.2L w/AC).
Tighten
Tighten the screws to 33 N-m (24 lb ft).

2. Install the fan to the fan clutch mounting (2.2L w/o AC).
Tighten
Tighten the screws to 33 N-m (24 lb ft).

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3. Install the fan-to-fan clutch mounting screws (4.3L w/AC).

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Tighten
Tighten the screws to 33 N-m (24 lb ft).

4. Install the fan-to-fan clutch mounting screws (4.3L w/o AC).


Tighten
Tighten the screws to 33 N-m (24 lb ft).
5. Install the upper fan shroud. Refer to Engine Coolant Fan Shroud Replacement
in Engine Cooling .

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6. Install the fan clutch to the coolant pump pulley using the J 41240.

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7. Install the attaching nuts.

Document ID: 179324

Engine Coolant Thermostat Replacement Document ID: 181878

1. Remove the air inlet duct.


2. Remove the necessary coolant from the radiator. Refer to Cooling System
Draining and Filling in Engine Cooling .
3. Remove the upper radiator inlet hose.

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4. Remove the coolant outlet bolts.

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Removal Procedure

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5. Remove the coolant outlet from the lower intake manifold.


6. Remove the thermostat gasket.

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7. Remove the coolant thermostat.
8. Clean all the sealing surfaces of the coolant outlet.
9. Clean the sealing surface on the lower intake manifold.

Installation Procedure

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1. Important: In order to prevent leakage, thoroughly clean all parts and sealing
surfaces.
Install the coolant thermostat in the lower intake manifold.

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2. Install a new gasket (if used). Otherwise, place a 3 mm (⅛ in) bead of
RTV sealer (GM P/N 1052289, or equivalent) at the groove on the coolant outlet
sealing surface.
3. Install the coolant outlet on the lower intake manifold.

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4. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the attaching bolts.
Tighten
Tighten coolant outlet bolts to 19 N-m (14 lb ft).
5. Install the radiator inlet hose.
6. Fill the cooling system with specified coolant and concentration. Refer to
Cooling System Draining and Filling in Engine Cooling .
7. Inspect all sealing surfaces for leaks after starting the engine. Refer to Cooling
System Leak Testing in Engine Cooling .

Radiator Drain Cock Replacement


Document ID: 523164
Removal Procedure
1. Drain the coolant from the radiator. Refer to Cooling System Draining and
Filling in Engine Cooling .

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2. Remove the radiator drain cock.

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3. Remove the seal.

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4. Remove the drain cock body.

Installation Procedure

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1. Install the drain cock body.

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2. Install the seal.

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3. Install the drain cock.
4. Fill the radiator with the specified coolant and concentration. Refer to Cooling
System Draining and Filling in Engine Cooling .
5. Inspect the coolant system for leaks. Refer to Cooling System Leak Testing in
Engine Cooling .

Engine Coolant Fan Shroud Replacement -

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Document ID: 199161


Removal Procedure
1. Remove the air inlet duct.

2. Remove the upper fan shroud screws.


3. Disconnect the evaporator line tubing from the upper fan shroud.
4. Remove the upper fan shroud.

Installation Procedure
1. Install the upper fan shroud to the vehicle.

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2. Install the upper fan shroud attaching screws.


Tighten
Tighten the screws to 10 N-m (89 lb in).

3. Connect the evaporator line tubing to the upper fan shroud.

Document ID: 199161

Coolant Heater Replacement Document ID: 418974


Removal Procedure
1. Drain the engine coolant. Refer to Cooling System Draining and Filling in
Engine Cooling .
2. Remove the coolant jacket plug, if not originally equipped with an engine
coolant heater, by using the following procedure:
1. Carefully tap the coolant jacket plug near the outer edge. This causes the
plug to rotate in the hole.
Do not score the machined surface of the hole.
2. Grasp the plug with pliers and pull the plug out.
3. Remove the cord from the engine coolant heater.
4. Loosen the bolt.

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Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

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5. Remove the engine coolant heater.


6. Clean the core plug hole. Remove any the following conditions:
o Burrs
o Compound
o Paint
o Rough spots

Installation Procedure
1. Apply a coating of lubricant to the O-ring seal and the cleaned surface of the
plug opening in the block. Use a water spray resistant, high-temperature grease
lubricant (GM P/N 9985164 or equivalent).

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2. Important: Install the heater element. Avoid element contact to the inner walls
of the engine block.
Install the engine coolant heater and push tight to the block.

3. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Tighten the bolt until both locking wings draw tight against the inner wall of the
engine block.
Tighten
Tighten the bolt to 1.9 N-m (17 lb in).

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4. Important: The heater cord must not touch the following components:
o The engine
o The hot pipes
o The manifold
o Any moving components
Install the heater cord to the coolant heater.

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5. Route the heater cord (RWD).

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6. Route the heater cord (4WD).


7. Fill the reservoir with engine coolant. Refer to Cooling System Draining and
Filling in Engine Cooling .
8. Inspect the system for leaks.

Document ID: 418974

Base Engine Misfire Diagnosis


Document ID: 195364
Checks
Action
Engine performance diagnosis procedures are covered in Engine Controls and
should be consulted for diagnosis of any Driveability, Emissions, or
Malfunctioning Indicator Lamp (MIL) concerns.
The following diagnosis covers common concerns and possible causes.
When the proper diagnosis is made, the concern should be corrected by adjustment,
repair or replacement as required.
Refer to the appropriate section of the service manual for each specific procedure.
This diagnostic table will assist in engine misfire diagnosis due to a mechanical
concern such as a faulty engine camshaft, worn or damaged bearings or bent valve
pushrod.
This table will not isolate a crossed fuel injector wire, faulty fuel injector or any

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other driveability component failure that may cause a misfire.


The Powertrain On-Board Diagnostic System checks must be performed first.
When using this table to make a Base Engine Misfire diagnosis, begin with the
preliminary information below and then proceed to the specific category.
Preliminary
1. Perform DTC P0300 before proceeding with Base
Engine Misfire Diagnosis information.
DTC P0300 will assist in determining which cylinder or
cylinders are misfiring.

Intake Manifold
Leaks

An intake manifold that has a vacuum leak may cause a


misfire.
Inspect for the following:

Improperly installed or damaged vacuum hoses


Faulty or improperly installed lower intake manifold
and/or gaskets
Cracked or damaged lower intake manifold
Improperly installed MAP sensor
The sealing grommet of the MAP sensor should not be
torn or damaged

Coolant
Consumption

Improperly installed throttle body or damaged gasket


Warped intake manifold
Warped or damaged cylinder head sealing surface

Coolant consumption may or may not cause the engine to


overheat.
Inspect for the following:

External coolant leaks


Faulty cylinder head gasket
Warped cylinder head

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2. Perform a visual inspection of the following:


o A loose or improperly installed engine flywheel
or crankshaft balancer
o Worn, damaged or misaligned accessory drive
system components
3. Listen to the engine for any abnormal internal engine
noises.
4. Inspect the engine for acceptable oil pressure.
5. Verify if the engine has excessive oil consumption.
6. Verify if the engine has excessive coolant consumption.
7. Perform a compression test on the engine.

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Oil Consumption

Cracked cylinder head


Damaged engine block

Oil consumption may or may not cause the engine to misfire.

Abnormal Internal
Engine Noises

1. Start the engine and determine if the noise is timed to


the engine camshaft speed or the crankshaft speed.
2. Using a timing light, two knocks per flash is the
crankshaft speed and one knock per flash is the engine
camshaft speed.
3. If the noise is timed to the engine camshaft speed,
inspect the following:
o Missing or loose valve train components
o Worn or loose valve rocker arms
o Worn or bent valve pushrods
o Faulty valve springs
o Bent or burnt valves
o Worn engine camshaft lobes
o Worn or damaged camshaft timing chain and/or
sprockets
Important: A slight COLD knock or piston slapping
noise could be considered normal if not present after the
engine has reached normal operating temperatures.
4. If the knock is timed to the crankshaft speed, inspect the
following:
o Worn crankshaft or connecting rod bearings
o Piston or cylinder damage
o Worn piston or piston pin
o Faulty connecting rod
o Excessive carbon build-up on the top of the

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1. Remove the spark plugs and inspect for an oil fouled


spark plug.
2. Perform a cylinder compression test.
3. If the compression test indicates worn valves or valve
guides, inspect the following:
o Worn, brittle, or improperly installed valve stem
oil seals
o Worn valve guides
o Worn valve stems
o Worn or burnt valves or valve seats
4. If the compression test indicates worn or damaged
piston rings, inspect the following:
o Broken or improperly seated piston rings
o Excessive piston ring end gap
o Excessive cylinder bore wear or taper
o Cylinder damage
o Piston damage

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piston
No Abnormal
Internal Engine
Noise

Engine Compression Test


Document ID: 723193
1.
2.
3.
4.
5.

Ensure that the vehicle batteries are in good condition, and fully charged.
Operate the vehicle until the engine is at normal operating temperature.
Disconnect the positive ignition coil wire plug from the ignition coil.
Disconnect the fuel injector electrical connector.
Remove all of the spark plugs.
Notice: Do not insert objects into the throttle plate opening. Damage to the
throttle body can result, requiring replacement of the throttle body assembly.

6. Block the throttle linkage wide open.


7. Install the engine cylinder compression gage to the cylinder being tested.
8. Using the vehicle starter motor, rotate, or crank the engine for 4 compression
strokes, or puffs, for the cylinder being tested. If the engine rotates for more than
4 compression strokes, test the cylinder again.
9. Record the compression reading.
10. Remove the engine cylinder compression gage from the cylinder being tested.
11. Repeat steps 811 for each additional cylinder. All cylinders must be tested to
obtain valid test results.
12. If any cylinders have low compression, inject approximately 15 ml (1 oz) of
engine oil into the cylinder through the spark plug hole.
13. Repeat steps 811 for all low compression cylinders.
14. The minimum compression in any one cylinder should not be less than
70 percent of the highest cylinder. No cylinder should read less than 690 kpa
(100 psi). For example, if the highest pressure in any one cylinder is 1035 kPa
(150 psi), the lowest allowable pressure for any other cylinder would be 725 kPa
(105 psi). Multiply the highest cylinder pressure by 70 percent, 1035 kPa x
70 percent = 725 kPa (150 psi x 70 percent = 105 psi), in order to determine the
lowest allowable pressure in any other cylinder.
o Normal

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1. Inspect for a worn or improperly installed camshaft


timing chain and/or sprockets.
2. Remove the valve rocker arm cover on the side of the
engine with the cylinder that is misfiring.
3. Inspect for the following:
o Loose valve rocker arm studs
o Bent valve push rods
o Faulty valve springs
o Faulty valve lifters (bleeding down)
o Worn or improperly seated valves
o Worn engine camshaft lobes

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The compression builds up quickly and evenly to the specified


compression.
o

Piston rings leaking


Compression is low on the first compression stroke. The compression
builds up on the following strokes, but does not reach normal.
Compression improves considerably when you add oil.

Valves leaking

Head gasket leaking


Compression is low on the first stroke. The compression does not build
up on the following strokes, and does not reach normal. Compression
does not improve much, if at all, when you add oil. Adjacent cylinders
have the same, or similar, low compression readings.

15. If one or more cylinders fails to meet the minimum specified compression,
repair or replace all damaged or worn components and test the engine again.

Document ID: 723193

Engine Front Cover Removal


Document ID: 42970

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Compression is low on the first compression stroke. The compression


does not build up on the following strokes, and does not reach normal.
Compression does not improve much, if at all, when you add oil.

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1. Remove the crankshaft position sensor bolt.
2. Remove the crankshaft position sensor.

3. Remove the crankshaft position sensor seal (O-ring).


4. Discard the crankshaft position sensor seal (O-ring).

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5. Remove the engine front cover bolts.
Important: After the composite engine front cover is removed do not reinstall
the engine front cover. Always install a NEW engine front cover.
6. Remove the engine front cover.

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7. Discard the engine front cover.

Document ID: 42970

Oil Pump Disassemble


Document ID: 195049

1. Remove the oil pump driveshaft and oil pump driveshaft retainer.

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2. Important: Do not remove the oil pump screen from the pipe. The pipe and oil
pump screen are serviced as a complete assembly.
Remove the oil pump pipe, if necessary. The oil pump pipe has a press fit into
the oil pump cover.

3. Remove the oil pump cover bolts.

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4. Remove the oil pump cover.

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5. Remove the oil pump drive gear and the oil pump driven gear.
6. Matchmark the gear teeth for assembly.

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7. Caution: Wear safety glasses in order to avoid eye damage.
Remove the following items:
1. The oil pump pressure relief valve spring straight pin
2. The oil pump pressure relief spring
3. The oil pump pressure relief valve

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Document ID: 195049

Oil Pump Cleaning and Inspection


Document ID: 35473

1. Caution: Wear safety glasses in order to avoid eye damage.


Clean the oil pump components in cleaning solvent.
2. Dry the components with compressed air.
3. Inspect the oil pump for the following conditions:
o Scoring on the top of the gears (1)
o Damaged gears (2) for the following:
 Chipping
 Galling
 Wear
o Scoring, damage or casting imperfections to the body (3)
o Damaged or scored gear shaft (4)
o Damaged or scored gear shaft (5)
o Damaged bolt hole threads
o Worn oil pump driveshaft bore
o Damaged or sticking oil pump pressure relief valve
Minor imperfections may be removed with a fine oil stone.
Collapsed or broken oil pump pressure relief valve spring
4. If the oil pump is to be reused, install a NEW oil pump pressure relief valve
spring.
o

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5. During oil pump installation, install a NEW oil pump driveshaft retainer.

Document ID: 35473

Oil Pump Assemble


Document ID: 195035

J 21882 Oil Suction Pipe Installer

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1. Apply clean engine oil to the oil pump pressure relief valve, oil pump pressure
relief valve spring, and oil pump body.
Important: Replace the oil pump pressure relief valve spring when you reuse
the oil pump.
2. Install the following items:
1. The oil pump pressure relief valve
2. The oil pump pressure relief valve spring
3. The oil pump pressure relief valve spring straight pin

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Tools Required

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3. Apply clean engine oil to the oil pump drive gear, the oil pump driven gear, and
the oil pump body internal surfaces.
4. Install the oil pump drive gear and the oil pump driven gear into the oil pump
body.
1. Align the matchmarks on the oil pump drive and driven gears.
2. Install the smooth side of the oil pump drive and driven gears toward the
oil pump cover.

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5. Install the oil pump cover.

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6. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the oil pump cover bolts.
Tighten
Tighten the bolts to 12 N-m (106 lb in).
7. Inspect the oil pump for smoothness of operation by turning the oil pump
driveshaft by hand.

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8. Install the oil pump screen.


1. If removed, replace the oil pump screen. The oil pump screen must have
a good press fit into the oil pump body.
2. Mount the oil pump in a soft jawed vise.
3. Apply pipe sealant to the end of the oil pump screen pipe.
4. Use the J 21882 and a soft-faced hammer in order to tap the oil pump
screen into the pump body. The oil pump screen must align parallel with
the bottom of the oil pan when the oil pan is installed.

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9. Important: Install a NEW oil pump driveshaft retainer during assembly.
Install the oil pump driveshaft and the NEW oil pump driveshaft retainer.

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Document ID: 195035

Intake Manifold Disassemble


Document ID: 199695

1. Remove the nuts, the studs, and the accelerator control cable bracket.

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2. Remove the throttle body attaching studs.

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3. Remove the throttle body.


4. Remove the throttle body to upper intake manifold gasket.
5. Discard the throttle body to upper intake manifold gasket.

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6. Remove the water outlet studs.
7. Remove the water outlet.
8. Remove the engine coolant thermostat.

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9. Important: Note the position and direction of the exhaust gas recirculation
(EGR) valve before removal. It is possible to improperly install the EGR valve
180 degrees from the original position.
Remove the exhaust gas recirculation (EGR) valve bolts.

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10. Notice: The Linear EGR valve is an electrical component. DO NOT soak in any
liquid cleaner or solvent because damage may result.
Remove the EGR valve and the EGR valve gasket from the lower intake
manifold.
11. Discard the EGR valve gasket.

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12. Remove the engine coolant temperature (ECT) sensor from the front of the
lower intake manifold (if equipped).

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13. Remove the studs and the ignition coil.

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14. Remove the manifold absolute pressure (MAP) sensor.


15. Remove the MAP sensor seal from the MAP sensor.
16. Discard the MAP sensor seal.

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17. Remove the fuel pipe bolt (4).
18. Remove the fuel pipe retainer nuts (1).
19. Remove the fuel pipe retainer (2).
20. Remove the fuel pipe (3).
21. Remove and discard the fuel seal retainers (5).
22. Remove and discard the fuel seals (6) (yellow O-rings).
23. Remove and discard the spacer rings (7) (flat washers).
24. Remove and discard the fuel seals (8) (black O-rings).

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25. Remove the studs and the evaporative emission (EVAP) canister purge solenoid
valve.
26. Remove the nut and the engine wiring harness bracket.

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27. Remove the upper intake manifold attaching studs.
28. Remove the upper intake manifold.
29. Remove the upper intake manifold to lower intake manifold gasket.
30. Discard the upper intake manifold to lower intake manifold gasket.

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31. Remove the TBI fuel meter body seal and discard.
32. Remove the 6 poppet nozzles from the lower intake manifold bores.
33. Remove the TBI fuel meter body.
34. Remove the bolt and the TBI fuel meter body bracket.

Document ID: 199695

Intake Manifold Cleaning and Inspection


Document ID: 199892

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1. Caution: Wear safety glasses in order to avoid eye damage.


Clean the upper intake manifold in cleaning solvent.
2. Dry the upper intake manifold with compressed air.

3. Clean the lower intake manifold in cleaning solvent.


4. Dry the lower intake manifold with compressed air.

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5. Inspect the upper intake manifold for the following:
o Cracks or other damage to the exterior
o Cracking or damage in the gasket grooves
o Loose or damaged bolt hole thread inserts
o Damage to the throttle body mounting surface

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6. Inspect the lower intake manifold for the following:


o Cracks or damage
o Damage to the gasket sealing surfaces
o Damage to the threaded bolt holes
o Restricted exhaust gas recirulation (EGR) system passages
o Restricted cooling system passages

Document ID: 199892

Document ID: 199785

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1. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
If reusing the fastener, apply threadlock GM P/N 12345382 or equivalent to the
threads of the TBI fuel meter body bracket bolt.
2. Install the TBI fuel meter body bracket and bolt.
Tighten

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Tighten the TBI fuel meter bracket bolt to 10 N-m (88 lb in).
3. Install the TBI fuel meter body into the TBI fuel meter body bracket.
4. Install the 6 poppet nozzles into the proper lower intake manifold bores.
5. Inspect the poppet nozzles in order to ensure that the poppet nozzles are firmly
seated and locked in the lower intake manifold bores.
6. Install a NEW TBI fuel meter body seal into the groove of the TBI fuel meter
body.

7. Install a NEW upper intake manifold to lower intake manifold gasket into the
groove of the upper intake manifold.
8. Install the upper intake manifold onto the lower intake manifold.
9. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the
threads of the upper intake manifold attaching studs.
10. Install the upper intake manifold attaching studs.
Tighten
1. Tighten the upper intake manifold attaching studs on the first pass to
5 N-m (44 lb in).
2. Tighten the upper intake manifold attaching studs on the final pass to
9 N-m (80 lb in).

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11. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the
threads of the evaporative emission (EVAP) canister purge solenoid valve studs.
12. Install the EVAP canister purge solenoid valve and studs.
Tighten
Tighten the EVAP canister purge solenoid valve studs to 10 N-m (88 lb in).
13. Install the engine wiring harness bracket and nut.
Tighten
Tighten the engine wiring harness bracket nut to 12 N-m (106 lb in).

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14. Install the NEW fuel seals (8) (black O-rings) into the TBI fuel meter body.
15. Install the NEW spacer rings (7) (flat washers) into the TBI fuel meter body.
16. Install the NEW fuel seals (6) (yellow O-rings) into the TBI fuel meter body.
17. Install the NEW fuel seal retainers (5) into the TBI fuel meter body.
18. Install the fuel pipe (3) into the TBI fuel meter body.
19. Install the fuel pipe retainer bracket (2) onto the fuel pipe.
20. Install the fuel pipe retainer bracket nuts (1).
21. If reusing the fastener, apply threadlock GM P/N 12345382 or equivalent to the
threads of the fuel pipe bolt.
22. Install the fuel pipe bolt (4).

1. Tighten the fuel pipe bracket nuts to 3 N-m (27 lb in).


2. Tighten the fuel pipe bolt to 6 N-m (53 lb in).

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23. Install a NEW manifold absolute pressure (MAP) sensor seal onto the MAP
sensor.
24. Apply a small amount (1 drop) of clean engine oil to the MAP sensor seal.
25. Install the MAP sensor into the upper intake manifold.

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Tighten

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26. Install the ignition coil and studs.


Tighten
Tighten the ignition coil studs to 12 N-m (106 lb in).

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27. If reusing the engine coolant temperature (ECT) sensor (if equipped), apply
sealant GM P/N 12346004 or equivalent to the threads of the ECT sensor.
28. Install the ECT sensor (if equipped) into the front of the lower intake manifold.
Tighten
Tighten the ECT sensor to 20 N-m (15 lb ft).

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29. Important: The exhaust gas recirculation (EGR) valve must be installed in the
original orientation.
Install a NEW EGR valve gasket and the EGR valve.

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30. Install the EGR valve bolts.
Tighten
1. Tighten the EGR valve bolts on the first pass to 7 N-m (62 lb in).
2. Tighten the EGR valve bolts on the final pass to 30 N-m (22 lb ft).

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31. Install the engine coolant thermostat.


32. Install the water outlet.
33. Install the water outlet studs.
Tighten
Tighten the water outlet studs to 25 N-m (18 lb ft).

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34. Install a NEW throttle body gasket into the groove in the upper intake manifold.
35. Install the throttle body onto the upper intake manifold.

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36. If reusing the fasteners, apply threadlock GM P/N 12345382 or equivalent to the
threads of the throttle body attaching studs.
37. Install the throttle body attaching studs.
Tighten
Tighten the throttle body attaching studs to 9 N-m (80 lb in).

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38. Install the accelerator control cable bracket, the studs, and the nuts.
Tighten
1. Tighten the accelerator control cable bracket stud to the intake manifold
to 6 N-m (53 lb in).

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2. Tighten the accelerator control cable bracket nuts to 12 N-m (106 lb in).
3. Tighten the accelerator control cable bracket stud to the throttle body to
12 N-m (106 lb in).

Document ID: 199785

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TREN DELANTERO
Wheel Alignment Specifications
Document ID: 162608

Cross Caster

Camber

Crosss Camber

Steering Angle

Toe (Total)

ZR2/Z85/ZM6/G51
Caster

Cross Caster

Camber

Cross Camber

Steering Angle

Toe (Total)

Operation
Exc ZR2/Z85/ZM6/G51

Service Allowable

Service Preferred

2 to 4

1
-1 to 1

1
-0.5 to 0.5

-.10 to .10

0.1

1 to 3

1
-1 to 1

1
-0.5 to 0.5

-.10 to .10

0.1

Service Allowable

Service Preferred

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Exc ZR2/Z85/ZM6/G51
Caster

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Caster

Cross Caster

Camber

Crosss Camber

Steering Angle

Toe (Total)

2 to 4
1
-1 to 1

Cross Caster

Camber

Cross Camber

Steering Angle

Toe (Total)

ZR2/Z85/ZM6/G51
Caster

-0.5 to 0.5

-.10 to .10

0.1

1 to 3

1
-1 to 1

1
-0.5 to 0.5

-.10 to .10

0.1
Specification
Metric
English
21 N-m
16 lb ft
75 N-m
55 lb ft
115 N-m 85 lb ft

Application
Tie Rod Adjuster Sleeve Nuts
Upper Control Arm Bolts to Frame Nuts (RWD)
Upper Control Arm Bolts to Frame Nuts (4WD)
Application
Steering Knuckle Upper Control Arm Bolt and Cam Kit
Drive Type/Model
Z Trim Height
RWD (except ZQ8)

RWD (ZQ8)

4WD (except ZR2)

4WD (ZR2)

D Trim Height

GM SPO Group Number


6

Service Allowed

Service Preferred

67-79 mm (2.6-3.1 in)

73 mm (2.9 in)

64 mm (2.5 in)

64 mm (2.5 in)

116-128 mm (4.6-5 in)

122 mm (4.8 in)

116-131 mm (4.6-5.2 in)

123.5 mm (4.9 in)

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Utility

Pickup (except ZQ8)

130.08-148.11 mm (5.1-5.8 in) 139.1 mm (5.4 in)


130.7-161.5 mm (5.1-6.4 in)

146.1 mm (5.8 in)

122 mm (4.8 in)

122 mm (4.8 in)

Pickup (ZQ8)

Excessive wheel or Refer to Tire and Wheel Runout Measurement in Vibration


tire runout
Diagnosis and Correction Vibration Diagnosis and Correction.
Checks
Action
Lack of lubrication of the ball Lubricate the ball joints and the linkage. Refer to
joints and the steering linkage Fluid and Lubricant Recommendations in
Maintenance and Lubrication.
Low or uneven front or rear Inflate the tires to the recommended pressure. Refer
tire pressure
to Tire Inflation Description in Tires and Wheels.
Worn or loose hub and wheel Replace the hub and wheel bearing assembly.
bearing
Refer to Front Wheel Hub, Bearing, and Seal
Replacement in Front Suspension or
Front Wheel Hub, Bearing, and Seal
Replacement in Front Suspension.
Incorrect front wheel
alignment (caster)
Broken or sagging spring
(RWD)
Broken or sagging torsion
bars (4WD)
Malfunctioning shock
absorber

Check and align the front suspension. Refer to


Wheel Alignment Specifications in Wheel
Alignment.
Replace the spring. Refer to Front Coil Springs
Replacement in Front Suspension.
Adjust the torsion bar. Refer to Trim Height
Specifications in Suspension General Diagnosis.
Check and replace the shock absorber.

Refer to Shock Absorber Replacement in

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Checks
Action
DEFINITION: Abnormal bounce or hop of the wheel under normal driving
conditions.
Tire and wheel are Balance the wheels. Refer to Tire and Wheel Balancing in
out of balance
Vibration Diagnosis and Correction.
Tire and wheel are Replace the tire. Refer to Tire Description in Tires and
out of round
Wheels.
Blister or bump on Replace the tire. Refer to Tire Description in Tires and
the tire
Wheels.
Improper shock
Replace the shock absorber.
absorber action
For RWD, refer to Shock Absorber Replacement in
Front Suspension.
For 4WD, refer to Shock Absorber Replacement in
Front Suspension.

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Broken stabilizer shaft or a


missing link

Front Suspension or
Shock Absorber Replacement in Front
Suspension.

Replace the stabilizer shaft or link.

Refer to Stabilizer Shaft Replacement in


Front Suspension or
Stabilizer Shaft Replacement in Front
Suspension.

Document ID: 167389


Important: Before you adjust caster and camber angles, raise and release the front
bumper. Do this twice in order to allow the vehicle to return to a normal height. Refer to
Wheel Alignment Specifications in Suspension Wheel Alignment.
1. Make adjustments to the caster and the camber by inserting shims between the
upper control arm shaft and the frame bracket. Add shims or subtract shims or
transfer shims in order to change the readings.
2. To adjust the caster and the camber, loosen the upper control arm shaft-to-frame
nuts (1). Add shims or remove shims (2) as required. Tighten the nuts. Check the
toe-in after you change the caster and the camber.

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3. CasterTransfer the shims from front to rear, or from rear to front. The transfer
of one shim from the rear bolt to the front bolt decreases positive caster.

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Front Caster and Camber Adjustment 4x2

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4. CamberChange the shims at the front and the rear of the cross shaft. Add an
equal number of shims at the front and the rear of the cross shaft. This decreases
positive camber.
5. A normal shim pack will leave at least two threads of the bolt exposed beyond
the nut (1). The difference between the front shim pack and the rear shim pack
must not exceed 10 mm (0.40 in). If you cannot meet these requirements, check
for damage to the control arms and to related parts.
6. Tighten the nut on the thinner shim pack first. This improves the shaft-to-frame
clamping force. This also improves torque retention.

4x4

Front Caster and Camber Adjustment Document ID: 167394


Important: Before adjusting the caster angle and camber angle, raise and release the
front bumper. Do this twice in order to allow the vehicle to return to a normal height.
Refer to Wheel Alignment Specifications in Suspension Wheel Alignment .

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Use the cams on the upper control arm frame attaching bolts to adjust the caster and the
camber.
To adjust the caster and the camber, loosen the upper control arm-to-frame attaching
nuts. Rotate the cam by rotating the bolt head.

CasterTo increase positive caster, move the front cam lobe inboard and move
the rear cam lobe outboard.
CamberTo increase positive camber, move the front and the rear cam lobes
inboard.

Tighten the nuts after you select the proper cam position. Refer to Fastener Tightening
Specifications .

Blazer, Bravada, Jimmy, S10 Pickup, Sonoma (VIN S/T) Se...


Logged in as: GALCON. Time remaining: 23 hours.
1998 Chevrolet Blazer - 2WD
Suspension
| Wheel Alignment

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| Repair Instructions
Prev. Page
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Bulletins
General Information
HVAC
Steering
Suspension
o
Suspension General Diagnosis

Specifications

Trim Height Specifications

Diagnostic Information and Procedures

Suspension General Diagnosis

Ride

Vehicle Leads/Pulls

Body Leans or Sways in Corners

Suspension Bottoms

Dog Tracking

Trim Height

Wheel Tramp

Noisy Front Suspension

Poor Directional Stability

Struts or Shock Absorbers Weak

Struts or Shock Absorbers Noisy

Struts or Shock Absorbers Leak

Wheel Bearings Diagnosis - Utility and 4WD Pickup

Wheel Bearings Diagnosis - RWD Pickup

Special Tools and Equipment
o
Wheel Alignment

Specifications

Wheel Alignment Specifications

Fastener Tightening Specifications

GM SPO Group Numbers

Repair Instructions

Wheel Alignment Measurement

Front Caster and Camber Adjustment - RWD

Front Caster and Camber Adjustment - 4WD

Front Toe Adjustment

Rear Axle Housing Alignment

Description and Operation
o
Front Suspension
o
Rear Suspension
o
Tires and Wheels
o
Automatic Level Control
Driveline/Axle
Brakes
Engine
Transmission/Transaxle
Body and Accessories
Restraints

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{"DhtmlHistory_pageLoaded":tru

Cross Caster

Camber

Crosss Camber

Steering Angle

Toe (Total)

Service Allowable

Service Preferred

2 to 4

1
-1 to 1
1

ZR2/Z85/ZM6/G51
Caster

Cross Caster

Camber

Cross Camber

Steering Angle

Toe (Total)

-0.5 to 0.5

-.10 to .10

0.1

1 to 3

1
-1 to 1

1
-0.5 to 0.5

-.10 to .10

0.1

Application
Tie Rod Adjuster Sleeve Nuts
Upper Control Arm Bolts to Frame Nuts (RWD)
Upper Control Arm Bolts to Frame Nuts (4WD)
Application
Steering Knuckle Upper Control Arm Bolt and Cam Kit
Drive Type/Model
Z Trim Height

Service Allowed

Specification
Metric
English
21 N-m
16 lb ft
75 N-m
55 lb ft
115 N-m 85 lb ft
GM SPO Group Number
6
Service Preferred

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Operation
Exc ZR2/Z85/ZM6/G51
Caster

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RWD (except ZQ8)

RWD (ZQ8)

4WD (except ZR2)

4WD (ZR2)

67-79 mm (2.6-3.1 in)

73 mm (2.9 in)

64 mm (2.5 in)

64 mm (2.5 in)

116-128 mm (4.6-5 in)

122 mm (4.8 in)

116-131 mm (4.6-5.2 in)

123.5 mm (4.9 in)

D Trim Height

Pickup (except ZQ8)

Pickup (ZQ8)

130.08-148.11 mm (5.1-5.8 in) 139.1 mm (5.4 in)


130.7-161.5 mm (5.1-6.4 in)

146.1 mm (5.8 in)

122 mm (4.8 in)

122 mm (4.8 in)

Checks
Action
DEFINITION: Abnormal bounce or hop of the wheel under normal driving
conditions.
Tire and wheel are Balance the wheels. Refer to Tire and Wheel Balancing in
out of balance
Vibration Diagnosis and Correction.
Tire and wheel are Replace the tire. Refer to Tire Description in Tires and
out of round
Wheels.
Blister or bump on Replace the tire. Refer to Tire Description in Tires and
the tire
Wheels.
Improper shock
Replace the shock absorber.
absorber action
For RWD, refer to Shock Absorber Replacement in
Front Suspension.
For 4WD, refer to Shock Absorber Replacement in
Front Suspension.
Excessive wheel or Refer to Tire and Wheel Runout Measurement in Vibration
tire runout
Diagnosis and Correction Vibration Diagnosis and Correction.
Checks
Action
Lack of lubrication of the ball Lubricate the ball joints and the linkage. Refer to
joints and the steering linkage Fluid and Lubricant Recommendations in
Maintenance and Lubrication.
Low or uneven front or rear Inflate the tires to the recommended pressure. Refer
tire pressure
to Tire Inflation Description in Tires and Wheels.
Worn or loose hub and wheel Replace the hub and wheel bearing assembly.
bearing
Refer to Front Wheel Hub, Bearing, and Seal
Replacement in Front Suspension or
Front Wheel Hub, Bearing, and Seal
Replacement in Front Suspension.

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Utility

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Incorrect front wheel


alignment (caster)
Broken or sagging spring
(RWD)
Broken or sagging torsion
bars (4WD)
Malfunctioning shock
absorber

Check and align the front suspension. Refer to


Wheel Alignment Specifications in Wheel
Alignment.
Replace the spring. Refer to Front Coil Springs
Replacement in Front Suspension.
Adjust the torsion bar. Refer to Trim Height
Specifications in Suspension General Diagnosis.
Check and replace the shock absorber.

Broken stabilizer shaft or a


missing link

Replace the stabilizer shaft or link.

Refer to Stabilizer Shaft Replacement in


Front Suspension or
Stabilizer Shaft Replacement in Front
Suspension.

Front Toe Adjustment


Document ID: 166759
Tie rod adjuster parts often rust in service. Discard the nuts and the bolts if the torque
required to remove the nut from the bolt exceeds 9 N-m (80 lb in) after breakaway.
1. Apply penetrating oil between the clamp and the tube.
2. Rotate the clamps until the clamps move freely.
3. Install new bolts and nuts with the correct part number if needed.
Change the length of the tie rods in order to increase or decrease toe-in. Use the
threaded sleeve to change the length of the tie rods. When the tie rods are mounted
ahead of the steering knuckle, the rods must be decreased in length to increase toe-in or
increased in length to decrease toe-in.

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Refer to Shock Absorber Replacement in


Front Suspension or
Shock Absorber Replacement in Front
Suspension.

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1. Loosen the clamp bolts at each end of the adjustable sleeves of the steering tie
rod.
2. Set the steering wheel in the straight ahead position.
3. Turn the tie rod adjusting sleeves in order to obtain the proper toe-in
specification.
4. Check the number of threads inside the adjuster sleeve. These must be equal to
within three threads. Refer to Tie Rod Replacement (RWD) or Tie Rod
Replacement (4WD) in Steering Linkage.

Rear Axle Housing Alignment


Document ID: 10076
If rear tire wear indicates that the rear axle housing may be bent, or that the rear springs
may be dislocated, check the alignment.
Important: Do not straighten the axle housing in order to correct an alignment
problem. If the axle housing is not straight, the axle assembly must be replaced.
1. Back the vehicle squarely onto an alignment machine.
2. Compensate for wheel runout the same way you check front wheel toe.
3. Check the camber reading. This should be 0.03 degrees negative0.05 degrees
positive.
4. Check the amount of toe. This should be 00.05 degrees or 01.58 mm (0
1/16 in).
o When the vehicle is backed onto an alignment machine, the actual toeout will read on the scale as toe-in. If toe-out is checked with a tram
gauge, disregard this step.

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If a tram gauge is used for checking toe, perform steps 1 and 2 to check
camber.

You can not align the rear wheels by regular means. Replace bent or damaged axle
housing and springs. The frame often is not straight. You can straighten the frame using
frame straightening equipment, or by relocating the spring to the axle without removing
the axle housing from the vehicle. In this way you can determine when the axle and
spring assemblies are within the correct limits during the straightening operation.
If the frame and the springs are within specification, then the rear axle assembly is not
straight, and you must replace the rear axle.

Document ID: 382976

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Caster is the tilting of the uppermost point of the steering axis either forward or
backward from vertical (1)(when viewed from the side of the vehicle). A backward tilt
is positive (3) and a forward tilt is negative (2). Caster influences directional control of
the steering but does not affect the tire wear. Caster is affected by the vehicle height,
therefore it is important to keep the body at its designed height. Overloading the vehicle
or a weak or sagging rear spring will affect caster. When the rear of the vehicle is lower
than its designated trim height, the front suspension moves to a more positive caster. If
the rear of the vehicle is higher than its designated trim height, the front suspension
moves to a less positive caster.
If there is too little positive caster, steering may be touchy at high speed and wheel
returnability may be diminished when coming out of a turn. If one wheel has more
positive caster than the other, it will cause that wheel to pull toward the center of the
vehicle. This condition will cause the vehicle to pull or lead to the side with the least
amount of positive caster.

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er Description

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Camber Description
Document ID: 382974

Camber is the tilting of the wheels from the vertical when viewed from the front of the
vehicle. When the wheels tilt outward at the top, the camber is positive (+). When the
wheel tilts inward at the top, the camber is negative (). The amount of tilt is measured
in degrees from the vertical. Camber settings influence the directional control and the
tire wear.
Too much positive camber will result in premature wear on the outside of the tire and
cause excessive wear on the suspension parts.
Too much negative camber will result in premature wear on the inside of the tire and
cause excessive wear on the suspension parts.
Unequal side-to-side camber, of 1 degree or more, will cause the vehicle to pull or lead
to the side with the most positive camber.

Toe Description
Document ID: 382972

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Toe is a measurement of how much the front wheels are turned in or out from a straightahead position. When the wheels are turned in, toe is positive (+). When the wheels are
turned out, toe is negative (). The actual amount of toe is normally only a fraction of a
degree. The purpose of toe is to ensure that the wheels roll parallel.
Toe also serves to offset the small deflections of the wheel support system that occur
when the vehicle is rolling forward. In other words, with the vehicle standing still and
the wheels set with toe-in, they tend to roll parallel on the road when the vehicle is
moving.
Improper toe adjustment will cause premature tire wear and cause steering instability.

Ball Joint Wear Check


Document ID: 853409
Tools Required
J 8001 Dial Indicator

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1. Important:
o The vehicle must rest on a level surface.
o The vehicle must be stable. Do not rock the vehicle on the floor stands.
o The upper control arm bumper must not contact the frame.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in
General Information.
2. Support the lower control arm with a floor stand or jack, as far outboard as
possible, under the stabilizer bar bracket.
Important: If a seal is cut or torn, replace the ball joint.
3. Clean and inspect the ball joints seals for cuts or tears. If the ball joint seals are
damaged, replace the ball joint. Refer to Upper Control Arm Ball Joint
Replacement in Front Suspension or Lower Control Arm Ball Joint Replacement
in Front Suspension.
4. Check the wheel bearing for looseness. If looseness in the wheel bearing is
present, refer to Wheel Bearings Diagnosis in Suspension General Diagnosis.
5. Check the ball joints for horizontal looseness.
1. Position the J 8001 dial indicator against the lowest outboard point on the
wheel rim.
2. Rock the wheel in and out while reading the dial indicator. This shows
horizontal looseness in both joints.
3. The dial indicator reading should be no more than 2.00 mm (0.080 in). If
the reading is too high, check the lower ball joints for vertical looseness.

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6. Important: Do not support the lower control arm with a jack stand for a RWD
vehicle, this will unload or cause compression on the wear indicator and will
cause the wear indicator to give a false reading.
For RWD vehicles, check the lower ball joints for wear and for vertical
looseness using the following procedure:
0. Remove the safety stand from under the lower control arm.
1. Inspect by sight the lower ball joint for wear. The position of the housing
into which the grease fitting is threaded indicates wear. This round
housing projects 1.27 mm (0.050 in) beyond the surface of the ball joint
cover on a new lower ball joint. Under normal wear, the surface of the
ball joint housing retreats inward very slowly.
2. First observe, then scrape a scale, a screwdriver, or a fingernail across the
cover. If the round housing is flush with or inside of the cover surface,
replace the lower ball joint.

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7. Notice: Do not pry between the lower arm and the wheel drive shaft boot or in
such a manner that the ball joint seal is contacted. Damage to the wheel drive
shaft boot will result (4WD).
For 4WD vehicles, place a J 8001 dial indicator (1) against the spindle in order
to show vertical movement.

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8. Pry between the lower control arm (2) and the outer bearing race (1) while
reading the dial indicator. This shows vertical looseness in the lower ball joints.
The lower ball joint may show some looseness.

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9. If the dial indicator reading is more than 3.18 mm (0.125 in), replace the lower
ball joint. Refer to Lower Control Arm Ball Joint Replacement in Front
Suspension .
10. If the lower ball joint is within specifications, and there is too much horizontal
looseness, check the upper ball joint for wear.
0. Disconnect the upper ball joint from the steering knuckle. Refer to Upper
Control Arm Ball Joint Replacement in Front Suspension .
1. If you find any looseness or can twist the stud with your fingers, replace
the upper ball joint. Refer to Upper Control Arm Ball Joint Replacement
in Front Suspension .

Upper Control Arm Ball Joint Replacement Document ID: 162660


Removal Procedure
Tools Required
J 23742 Ball Joint Separator
Caution: Floor jack must remain under the lower control arm during removal
and installation to retain the lower control arm in position. Failure to do so could
result in personal injury.

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1. Raise and suitably support lower control arm with safety stands. Refer to Lifting
and Jacking the Vehicle in General Information.
2. Because the weight of the vehicle is used to relieve spring tension on the upper
control arm, position the floor stands between the spring seats and the ball joints
of the lower control arms.
3. Remove the tire and wheel assembly. Refer to Wheel Removal in Tires and
Wheels.
Notice: Support the caliper with a piece of wire to prevent damage to the brake
line.
4.
5.
6.
7.
8.

Remove the brake caliper. Refer to Brake Caliper Replacement in Disc Brakes.
Disconnect the wheel speed sensor electrical connector from upper control arm.
Disconnect wheel speed sensor electrical connector.
Remove the cotter pin.
Remove the upper ball joint stud nut.

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9. Seperate the ball joint from the steering knuckle using J 23742 .
10. Apply pressure on the tool until the stud breaks loose.
11. Remove J 23742 .
12. Pull the ball joint stud away from the steering knuckle.

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13. Remove the rivets from the upper ball joint.
14. Use a 3.175 mm (⅛ in) drill in order to cut a 6.35 mm ( in) deep hole in
the center of each rivet.

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15. Drill away the rivet heads. Use a 12.7 mm ( in) drill.

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16. Punch the rivets out. Use a small pin punch.

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17. Remove the upper ball joint.

Installation Procedure

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1. Install a new upper ball joint to the upper control arm.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.

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Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Install the upper ball joint retaining bolts and nuts.
Tighten
Tighten the upper ball joint retaining nuts to 23 N-m (17 lb ft).

3. Install the upper ball joint to the steering knuckle.


4. Install the upper ball joint stud nut
Tighten
Tighten the upper ball joint stud nut to 83 N-m (61 lb ft).
Tighten the stud nut in order to align the slot in the stud nut with the hole
in the stud.
5. Install a new cotter pin.
6. Install the grease fittings.
7. Lubricate the upper ball joint.
8. Connect the wheel speed sensor electrical connector.
9. Install the wheel speed sensor electrical connectro to the upper control arm.
10. Install the brake caliper. Refer to Brake Caliper Replacement in Disc Brakes.
11. Install the tire and wheel assembly. Refer to Wheel Installation in Tires and
Wheels.
12. Lower the vehicle.
13. Check the front wheel alignment. Refer to Wheel Alignment Specifications in
Wheel Alignment.
o
o

Lower Control Arm Ball Joint Replacement -

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Document ID: 162649


Removal Procedure
Tools Required

J 23742 Ball Joint Separator


J 9519-D Ball Joint Remover and Installer Set

Caution: Floor jack must remain under the lower control arm during removal
and installation to retain the lower control arm in position. Failure to do so could
result in personal injury.
3. Place a floor jack under the control arm spring seat. Raise the jack in order to
support the control arm.
Notice: Support the caliper with a piece of wire to prevent damage to the brake
line.
4. Remove the brake caliper. Refer to Brake Caliper Replacement in Disc Brakes.

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5. Remove the cotter pin and the nut.

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1. Raise and suitably support the vehicle with safety stands. Refer to Lifting and
Jacking the Vehicle in General Information.
2. Remove the tire and wheel assembly. Refer to Wheel Removal in Tires and
Wheels.

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6. Break the ball joint loose from the steering knuckle using the J 23742 .

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7. Important: Place a wooden block between the frame and the upper control arm
in order to block the knuckle assembly out of the way.
Remove the lower control arm out of the opening in the splash shield. Use a
putty knife or a similar tool in order to guide the control arm past the splash
shield.

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8. Remove the lower ball joint from the lower control arm using the J 95197, the
J 951928 and the J 951930 as shown.
9. Inspect the tapered hole in the steering knuckle and remove any dirt. If the
tapered hole is out of round, deformed, or damaged, replace the steering
knuckle.

Installation Procedure
Tools Required
J 9519-D Ball Joint Remover and Installer Set

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1. Install a new ball joint into the lower control arm.

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1. Press in the ball joint using the tools as shown. The ball joint will bottom
on the control arm.
2. Locate the grease fitting facing inboard.

2. Install the ball joint stud into the steering knuckle.


Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
3. Install the lower ball stud nut.
Tighten
Tighten the lower ball stud nut to 108 N-m (79 lb ft). Tighten in order to align
the slot in the stud nut with the hole in the stud.
4.
5.
6.
7.

Install a new cotter pin to the stud.


Lubricate the lower ball joint.
Install the brake caliper. Refer to Brake Caliper Replacement in Disc Brakes.
Install the tire and wheel assembly. Refer to Wheel Installation in Tires and
Wheels.
8. Lower the vehicle.
9. Check the front wheel alignment. Refer to Wheel Alignment Specifications in
Wheel Alignment.

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Upper Control Arm Replacement Document ID: 162692


Removal Procedure
Caution: Floor jack must remain under the lower control arm during removal and
installation to retain the lower control arm in position. Failure to do so could result in
personal injury.

1. Raise the front of the vehicle. Refer to Lifting and Jacking the Vehicle in
General Information.
o Support the lower control arm with floor stands.
o Place floor stands under the lower control arms as far outboard as
possible (between spring seats and ball joint) to maintain maxium
leverage.
2. Remove the tire and wheel assembly. Refer to Wheel Removal in Tires and
Wheels.

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3. Remove the wheel speed sensor harness and the brake hose bracket from the
upper control arm.
4. Remove the upper ball joint stud from the steering knuckle. Refer to Upper
Control Arm Ball Joint Replacement in Front Suspension .

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5. Remove the retaining bolts and nuts from the upper control arm. Note the
location of any shims.

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6. Remove the upper control arm.


7. Inspect all of the parts for wear and damage.

Installation Procedure

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1. Install the upper control arm to the frame.

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2. Install the upper control arm retaining bolts.


3. Install the shims to the original position.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
4. Install the upper control arm retaining nuts.
Tighten
Tighten the upper control arm retaining nuts with the front suspension
loaded.
o Tighten the upper control arm retaining nuts to 115 N-m (85 lb ft).
5. Install the upper ball joint stud to the steering knuckle. Refer to Upper Control
Arm Ball Joint Replacement in Front Suspension .
6. Tighten the upper control arm shaft nuts.
o

Tighten
Tighten the upper control arm shaft nuts to 115 N-m (85 lb ft).

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7. Install the ABS wire and the brake hose bracket to the upper control arm.
8. Install the ABS wire and the brake hose bracket to the upper control arm
mounting bolts and nuts.
Tighten
Tighten the ABS wire and the brake hose bracket to the upper control arm nuts
to 24 N-m (18 lb ft).
9. Install the tire and wheel assembly. Refer to Wheel Installation in Tires and
Wheels.
10. Lower the vehicle.
11. Check the front wheel alignment. Refer to Wheel Alignment Specifications in
Wheel Alignment.

Upper Control Arm Bushings Replacement Document ID: 162709


Removal Procedure
Tools Required

J 21474-01 Control Arm Bushing Service Set


J 22269-1 Tie Rod End Installer

1. Remove the upper control arm from the vehicle. Refer to Upper Control Arm
Replacement in Front Suspension .

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2. Install the upper control arm in a vise.

3. Remove the washers and the nuts from upper control arm shaft.

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4. Remove the upper control arm bushings. Use the J 22269-1 and J 21474-01 .

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5. Remove the upper control arm shaft from the upper control arm.

Installation Procedure
Tools Required
J 22269-1 Tie Rod End Installer

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1. Install the upper control arm shaft to the upper control arm.
2. Install the control arm bushings to the upper control arm. Use the J 22269-1 and
a short piece of pipe that is the same outer diameter as the rubber bushing.

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3. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Tighten J 22269-1 until the bushing is positioned on the shaft and the upper
control arm as shown. The measurement should be 12.813.8 mm (0.480.52 in)
on both ends.

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4. Install the washers and the nuts to the upper control arm shaft. Do not tigten the
nuts.
5. Remove the upper control arm from the vise.
6. Install the upper control arm to the vehicle. Refer to Upper Control Arm
Replacement in Front Suspension .

Lower Control Arm Replacement -

Removal Procedure
Tools Required
J 23028-A Coil Spring Remover and Installer
1. Remove the front coil spring. Refer to Front Coil Springs Replacement in Front
Suspension .
2. Remove the lower ball joint from the steering knuckle. Refer to Lower Control
Arm Ball Joint Replacement in Front Suspension .

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3. Support the lower control arm using J 23028-A .

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Document ID: 162702

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4. Guide the lower control arm out of the splash shield opening.

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5. Remove the nuts from the lower control arm bolts.
6. Remove the lower control arm bolts.
7. Remove the lower control arm from the frame.

Installation Procedure

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1. Install the lower control arm to the frame.


2. Install the lower control arm bolts with the head forward.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
3. Install the nuts to the lower control arm bolts.
Tighten
Tighten the nuts with the front suspension loaded.
Tighten the lower control arm front nut to 115 N-m (85 lb ft).
Tighten the lower control arm rear nut to 98 N-m (72 lb ft).
4. Install the lower ball joint stud to the knuckle. Refer to Lower Control Arm Ball
Joint Replacement in Front Suspension .
5. Install the front coil spring. Refer to Front Coil Springs Replacement in Front
Suspension .
6. Check the front wheel alignment. Adjust if necessary. Refer to Wheel Alignment
Specifications in Wheel Alignment.
o
o
o

Front Lower Control Arm Bushing Replacement -

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Document ID: 405286


Removal Procedure
Tools Required

J 21474-01 Control Arm Bushing Service Set


J 22269-1 Tie Rod End Installer

1. Remove the lower control arm from the vehicle. Refer to Lower Control Arm
Replacement in Front Suspension .

2. Install the lower control arm in a vise.


3. Remove the rear bushing.
1. Install J 22269-01 and 21474-8, 12, 13.
2. Tighten until the rear bushing becomes free.

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4. Using a blunt chisel, drive the front bushing flare down flush with the rubber
part of the bushing.
5. Prior to removing or installing the front bushing, place a wedge or spacer
between the control arm bushing housing. This keeps the control arm bushing
housing from bending while removing or installing the bushing.
6. Remove the front bushing.
1. Install J 21474-3, 4, 5, 6. Tighten until the bushing is partially removed.
2. Then, reverse J 21474-6 and tighten until the front bushing becomes free.

Installation Procedure

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1. Prior to removing or installing the bushing, place a wedge or spacer between the
control arm bushing housing. This keeps the control arm bushing housing from
bending while removing or installing the bushing.

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2. Install the front bushing into the lower control arm.


3. Install J 21474-4, 5,13. The lip is on the outside of the control arm.
4. Tighten until the front bushing seats fully into the lower control arm. Remove
the tools.

5. Install the rear bushing into the lower control arm.


1. Install J 22269-01 and 21474-2, 13. The lip is on the outside of the
control arm.
2. Tighten until the rear bushing seats fully into the lower control arm.
Remove the tools.
6. Remove the lower control arm from the vise.
7. Install the lower control arm to the vehicle. Refer to Lower Control Arm
Replacement in Front Suspension .

Front Coil Springs Replacement


Document ID: 162682
Removal Procedure
Tools Required
J 23028-A Coil Spring Remover and Installer
1. Remove the shock absorber. Refer to Shock Absorber Replacement in Front
Suspension .

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2. Cradle the inner control arm bushings using J 23028-A .

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3. Remove the stabilizer shaft from the lower control arm.
4. Raise the jack in order to relieve tension on the lower control arm pivot bolts.

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5. Important: The chain is not to take place for safety, but to retain the coil spring
to the upper control arm.
Secure the upper control arm with a chain around the spring and through the
upper control arm.

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6. Turn the steering wheel to one side in order to allow the steering linkage to clear
the lower control arm front pivot bolt.
7. Remove the lower control arm pivot bolts and nuts.
1. Take the lower control arm rear pivot bolt out.
2. Take the lower control arm front pivot bolt out.
8. Lower the control arm by lowering the jack.
9. When compression is removed from the coil spring, take the chain away.

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10. Remove the coil spring and the insulators. While removing the coil spring, do
not apply force to the lower control arm and ball joint.
Position the coil spring properly for easy removal.

Installation Procedure

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1. Install the coil spring and the insulators on the lower control arm.
Ensure that the coil spring covers all or part of one inspection drain hole. The
other hole must be partly and completely uncovered. Rotate coil spring as
necessary.

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2. Support the control arm using J 23028-A .

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3. In order to maintain adequate steering linkage clearance, install the bolts in the
direction shown.
4. Install the lower control arm to the frame.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.

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Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
5. Install the lower control arm front pivot bolt and the new nut.
6. Install the lower control arm rear pivot bolt and the new nut.
Tighten

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7. Install the stabilizer shaft to the lower control arm.
8. Install the shock absorber. Refer to Shock Absorber Replacement in Front
Suspension .
9. Check the front wheel alignment. Refer to Wheel Alignment Specifications in
Wheel Alignment.

Stabilizer Shaft Replacement Document ID: 167368


Removal Procedure

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1. Tighten the lower control arm pivot bolts nuts with the front suspension
loaded.
2. Tighten the lower control arm front bolt to 115 N-m (85 lb ft).
3. Tighten the lower control arm rear bolt to 98 N-m (72 lb ft).

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1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle
in General Information.
2. Remove the following parts from the stabilizer links:
o The lower nuts
o The washers
o The bolts

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3. Remove the nuts from the U-bolts.
4. Remove the following part:
o The U-bolts
o The clamps
o The insulators
5. Remove the stabilizer shaft.

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Installation Procedure

1. Install the stabilizer shaft to the rear axle.


2. Install the following parts:
o The insulators
o The clamps
o The U-bolts
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
3. Install the nuts to the U-bolts.
Tighten
Tighten the nuts to 60 N-m (44 lb ft).
4. Install the stabilizer shaft to the link mounting bolt.

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5. Install the stabilizer shaft to the link nut.


Tighten
Tighten the upper link nut to 35 N-m (25 lb ft).
6. Lower the vehicle.

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CONSOLA CENTRAL, PANEL DE


INSTRUMENTOS, TECHO
Front Floor Console Replacement Document ID: 366848

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1. Remove the shift handle retaining clip at the front of the handle.
2. Remove the shift handle from the shift lever.

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Removal Procedure

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3. Open the console lid.
4. Remove the console compartment inserts.

5.
6.
7.
8.

Remove the nuts that retain the front of the console.


Remove the cup holder insert.
Remove the screws that retain the front of the console to the vehicle.
Remove the console from the vehicle.

Installation Procedure

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1. Install the console to the vehicle.

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Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Install the screws that retain the front of the console.

Tighten the screws to 7 N-m (63 lb in).


3. Install the cup holder insert.
4. Install the nuts that retain the rear of the console.
Tighten
Tighten the nuts to 10 N-m (89 lb in).

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5. Install the console compartment insert.
6. Install the console compartment insert screws.
Tighten
Tighten the nuts to 1.9 N-m (17 lb in).

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7. Install the shift handle to the shift lever.


8. Install the shift handle retaining clip at the front of the handle.

Document ID: 366848

Front Floor Console Replacement Document ID: 369192


Removal Procedure

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1. Remove the front ashtray from the console by gently prying out the ashtray with
a flat-bladed tool.
2. Carefully lift up on the wood shifter assembly close-out in order to remove the
assembly from the console. Rotate the closeout panel in order to fit the panel
over the shift handle.
3. Remove the passenger side toe-panel by gently prying out the panel with a flatbladed tool.
4. Disconnect the instrument panel to console wiring harness connection.

5. Open the armrest in order to expose and remove the convenience tray from the
storage compartment.

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6. Remove the fasteners (2) that retain the console (1) to the shifter assembly and
the vehicle floor.

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7. Remove the console from the vehicle by lifting the console over the floor studs.
8. If replacing the center console, remove the compact disc player from the
console. Refer to Remote CD Changer Replacement in Entertainment.
9. Remove the amplifier from the console. Refer toRadio Speaker Amplifier
Replacement in Entertainment.
10. Remove the rear seat audio control from the console. Refer toRear Seat Audio
Control Replacement in Entertainment.
11. Remove and retain the console wiring harness for use on the new console.

Installation Procedure

1. Install the console wiring harness to the console.


2. Install the rear seat audio control to the console. Refer to Rear Seat Audio
Control Replacement in Entertainment.
3. Install the amplifier to the console. Refer to Radio Speaker Amplifier
Replacement in Entertainment.
4. Install the compact disc player to the console. Refer to Remote CD Changer
Replacement in Entertainment.
Important: Do not pinch the instrument panel to console wiring harness during
this process.
5. Install the console to the vehicle by lifting the console (1) over and onto the
floor studs.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.

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Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
6. Install the fasteners (2) that retain the console to the vehicle.
Tighten
Tighten the console to the vehicle retainers to 10 N-m (88 lb in).

7. Install the convenience tray to the armrest storage compartment.

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8. Connect the instrument panel to console wiring harness connection.
9. Install the passenger side toe-panel by firmly pressing the panel into place.

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10. Carefully press the wood shifter assembly close-out into place. Rotate the
closeout panel in order to fit the panel over the shift handle.
11. Install the front ashtray to the console by firmly pressing the ashtray into place.

Document ID: 369192

Instrument Panel Carrier Replacement

Removal Procedure
1. On vehicles equipped with a manual transmission, remove the shift lever.
2. On vehicles equipped with an automatic transmission, perform the following
steps:
1. Apply the park brake.
2. Insert the ignition key and turn the ignition switch to the RUN position.
3. Depress the brake pedal and shift the transmission to the 1 position.
4. Turn the ignition switch to the OFF position.

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3. Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
Disconnect the battery negative cable.

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Document ID: 305815

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11. Remove and retain the left and right speakers and the speaker grilles. Refer to
Radio Front Speaker Replacement in Entertainment.
12. Use a flat-bladed tool in order to remove the windshield defroster grille. Retain
the grille and sunload sensor for use on the next IP carrier.

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4. Remove the left sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges, and Console .
5. Remove the right instrument panel sound insulator. Refer to Instrument Panel
Insulator Panel Replacement - Right Side in Instrument Panel, Gauges, and
Console .
6. If the vehicle is equipped with a multiple CD changer located in the center
console, remove the center console. Refer to Front Floor Console Replacement
in Instrument Panel, Gauges, and Console .
7. Remove the center sound insulator. Refer to Closeout/Insulator Panel
Replacement - Center in Instrument Panel, Gauges, and Console .
8. Remove the lower left instrument panel mounting bolt.
9. Remove and retain the instrument panel storage compartment. Refer to
Instrument Panel Compartment Door Replacement in Instrument Panel, Gauges,
and Console .
10. Remove the lower right instrument panel mounting bolt.

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13. If equipped with a sun load temperature sensor, twist the sensor turn
counterclockwise in order to disengage.
14. Disconnect the brown electrical connection from the body control module
(BCM).
15. Disconnect the purple electrical connection from the body control module
(BCM).
16. Remove the knee bolster. Refer to Knee Bolster Replacement in Instrument
Panel, Gauges, and Console .
17. Remove and retain the instrument cluster. Refer to Instrument Cluster
Replacement in Instrument Panel, Gauges, and Console .
18. Remove and retain the radio. Refer to Radio Replacement in Entertainment.
19. Remove the HVAC control assembly. Refer to the appropriate procedure:
o Control Assembly Replacement in Heating and Ventilation (Non-A/C)
o Control Assembly Replacement in HVAC Systems with A/C - Manual
o Control Assembly Replacement in HVAC Systems with A/C Automatic
Caution: This vehicle is equipped with a Supplemental Inflatable Restraint
(SIR) System. Failure to follow the correct procedure could cause the following
conditions:
o
o
o

Air bag deployment


Personal injury
Unnecessary SIR system repairs

In order to avoid the above conditions, observe the following guidelines:


o
o

Refer to SIR Component Views in order to determine if you are


performing service on or near the SIR components or the SIR wiring.
If you are performing service on or near the SIR components or the SIR
wiring, disable the SIR system. Refer to Disabling the SIR System.

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20. Disable the passenger side SIR system. Refer to Disabling the SIR System in
SIR.

21. Remove the left and right instrument panel driver knee bolster brackets.
22. Lower the steering column for clearance. Refer to Steering Column Replacement
in Steering Wheel and Column.

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23. Important: Label all of the connections in order to avoid improper installation.
Remove the top instrument panel screws.
24. Roll the instrument panel down.
25. Disconnect the electrical connections, as needed.
26. Remove the fastener that retains the radio antenna cable to the instrument panel.

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27. Remove the instrument panel from the vehicle.


If replacing the instrument panel carrier, retain the parts for assembly of the new
instrument panel carrier.

Installation Procedure

1. Install the retained parts from the original instrument panel.


2. Install the instrument panel to the vehicle.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
3. Install the fastener that retains the radio antenna cable to the instrument panel.
Tighten
Tighten the fastener to 1.9 N-m (17 lb in).
4. Connect the electrical connectors, as needed.
5. Roll the instrument panel up.
6. Install the top instrument panel screws.
Tighten
Tighten the screws to 1.9 N-m (17 lb in).

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7. Raise the steering column into position. Refer to Steering Column Replacement
in Steering Wheel and Column.
8. Install the left and right instrument panel driver knee bolster brackets.
Tighten
Tighten the screws/bolts to 6.3 N-m (56 lb in).

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9. Enable the passenger side SIR system. Refer to Enabling the SIR System in SIR.
10. Install the HVAC control assembly to the instrument panel. Refer to the
appropriate procedure:
o Control Assembly Replacement in Heating and Ventilation (Non-A/C)
o Control Assembly Replacement in HVAC Systems with A/C - Manual

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Control Assembly Replacement in HVAC Systems with A/C Automatic


11. Install the radio. Refer to Radio Replacement in Entertainment.
12. Install the instrument cluster. Refer to Instrument Cluster Replacement in
Instrument Panel, Gauges, and Console .
13. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel,
Gauges, and Console .
14. Connect the purple electrical connection to the body control module (BCM).
15. Connect the brown electrical connection to the body control module (BCM).
16. If equipped with a sun load temperature sensor, install the sensor to the defroster
grille by twisting the sensor turn clockwise.
o

17. Install the windshield defroster grille by pressing carefully pressing the grille
into place.
18. Install the left and right speakers and the speaker grilles. Refer to Radio Front
Speaker Replacement in Entertainment.

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19. Install the lower right instrument panel mounting bolt.


Tighten
Tighten the bolt to 11.5 N-m (102 lb in).
20. Install the instrument panel storage compartment. Refer to Instrument Panel
Compartment Door Replacement in Instrument Panel, Gauges, and Console .
21. Install the lower left instrument panel bolt.
Tighten
Tighten the bolt to 11.5 N-m (102 lb in).
22. Install the center sound insulator. Refer toCloseout/Insulator Panel Replacement
- Center in Instrument Panel, Gauges, and Console .
23. Install the right sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Right Side in Instrument Panel, Gauges, and Console .
24. If the center console was removed, install the console to the vehicle. Refer to
Front Floor Console Replacement in Instrument Panel, Gauges, and Console .
25. Install the left sound insulator. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges, and Console .
26. Connect the battery negative cable.
27. On vehicles equipped with an automatic transmission, perform the following
steps:
1. Turn the ignition switch to the RUN position.
2. Depress the brake pedal and shift the transmission into the PARK
position.
3. Release the park brake.
28. On vehicles equipped with a manual transmission, install the shift lever.

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Steering Column Bracket Replacement


Document ID: 417507
Removal Procedure

1. Important: The upper steering column support bracket is not serviceable.


Remove the instrument panel. Refer to Instrument Panel Carrier Replacement in
Instrument Panel, Gauges, and Console .
2. Remove the brake switch. Refer to Stop Lamp Switch Replacement in Hydraulic
Brakes.
3. Remove the brake booster pushrod from the brake pedal. Refer to Power
Vacuum Brake Booster Replacement in Hydraulic Brakes.
4. Remove the following upper steering column support bracket fasteners:
o The 4 flange nuts
o The 2 bolts
5. Remove the brake pedal from the upper steering column support bracket. Refer
to Brake Pedal Replacement in Hydraulic Brakes.

Installation Procedure

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1. Install the brake pedal to the upper steering column support bracket. Refer to
Brake Pedal Replacement in Hydraulic Brakes.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Install the upper steering column support bracket fasteners.
Tighten
Tighten the nuts to 25 N-m (18 lb ft).
Tighten the bolts to 25 N-m (18 lb ft).
3. Install the brake switch. Refer to Stop Lamp Switch Replacement in Hydraulic
Brakes.
4. Install the brake booster pushrod to the brake pedal. Refer to Power Vacuum
Brake Booster Replacement in Hydraulic Brakes.
5. Install the instrument panel. Refer to Instrument Panel Carrier Replacement in
Instrument Panel, Gauges, and Console .
o
o

Document ID: 417507

Instrument Panel Insulator Panel Replacement - Right Side


Document ID: 354099

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Removal Procedure

1. Remove the screws that retain the instrument panel sound insulator to the
following components:
o The instrument panel
o The cowl
2. Remove the instrument panel sound insulator from the vehicle.

Installation Procedure

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1. Install the instrument panel sound insulator to the vehicle.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring

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replacement or fasteners requiring the use of thread locking compound or sealant


are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Install the screws that retain the instrument panel sound insulator to the
following components:
o The instrument panel
o The cowl

Tighten the screws to 1.9 N-m (17 lb in).

Instrument Panel Insulator Panel Replacement - Left Side


Document ID: 469039
Removal Procedure
1. Remove the screws that retain the data link connector (DLC) to the instrument
panel sound insulator.
Feed the DLC lines through the hole in the sound insulator.

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2. Remove the screws that retain the instrument panel sound insulator to the knee
bolster and the cowl panel.

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Tighten

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3. Disconnect the electrical connectors from the remote control door lock receiver
module.
4. Remove the remote control door lock receiver module from the instrument panel
sound insulator.

Installation Procedure
1. Install the remote control door lock receiver module to the instrument panel
sound insulator.
2. Connect the electrical connector to the remote door lock receiver module.

3. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the screw that retains the instrument panel sound insulator to the cowl
panel.
Tighten
Tighten the screw to 1.9 N-m (17 lb in).
4. Install the screws that retain the instrument panel sound insulator to the knee
bolster.
Tighten

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Tighten the screws to 1.9 N-m (17 lb in).


5. Feed the DLC through the hole in the instrument panel sound insulator.
6. Install the screws that retain the DLC to the instrument panel sound insulator.
Tighten
Tighten the screws to 2.4 N-m (21 lb in).

Document ID: 829873


Removal
1. Remove the left insulator/closeout panel. Refer toInstrument Panel Insulator
Panel Replacement - Left Side in Instrument Panel, Gauges, and Console .

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2. Remove the screw (1) securing the junction block (2) to the instrument panel.
3. Peel the wrapping (3) on the wiring harness back to give more play in the
individual wires going to the junction block.
4. Remove each wire and terminal from the old junction block. Refer to Electrical
Center Identification Views in Wiring Systems.

Installation

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1. Install each wire and terminal in the new junction block. Refer to Electrical
Center Identification Views in Wiring Systems.
2. Rewrap the wrapping (3) on the wiring harness.
3. Install the junction block (2) to the instrument panel with the screw (1).
4. Install the left insulator/closeout panel. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges, and Console .

Driver Information Center Replacement Document ID: 299892


Removal Procedure

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1. Remove the screw at the front of the console that retains the console to the roof.
2. Pull downward at the rear of the console in order to remove the console from the
roof.
3. Disconnect the electrical connections as needed.

Installation Procedure
1. Connect the electrical connections as needed.

2. Insert the mounting tabs into the roof panel and push upward on the rear of the
console in order to install the console to the roof.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
3. Install the screw at the front of the console that retains the console to the roof.
Tighten
Tighten the screw to 1.9 N-m (17 lb in).

Driver Information Center Replacement Document ID: 366860

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Removal Procedure

1. Remove the screw at the front of the console that retains the sunroof console to
the roof.
2. Pull downward on the rear of the console in order to expose the electrical
connections (1,4,5 and 6) and remove the sunroof console from the roof.

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3. Disconnect the electrical connectors (1,4,5 and 6) as needed.
4. Remove the screw that retains the sunroof console mounting bracket to the roof.
5. Release the tabs at the rear of the bracket in order to remove the sunroof console
mounting bracket from the roof.

Installation Procedure

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1. Important: Ensure that the Flux Gate wire (4) is not trapped between the
retainer and the roof steel.
Install the sunroof console bracket to the roof.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Install the screw that retains the sunroof console mounting bracket to the roof.
Tighten
Tighten the screw to 1.9 N-m (17 lb ft).

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3. Install the electrical connectors (1,4,5 and 6) as needed.


4. Insert the console mounting tabs into the mounting bracket and push upward on
the rear of the console in order to install the console.
5. Install the screw at the front of the console that retains the console to the roof.
Tighten
Tighten the screw to 1.9 N-m (17 lb in).

Driver Information Center Module Replacement


Document ID: 299878
Removal Procedure

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1. Using a flat-bladed tool, carefully pry the display lens (1) from the console (3).
2. Remove the electronic display module (2) from the console (3).
3. Disconnect the electrical connection.

Installation Procedure

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1.
2.
3.
4.

Connect the electrical connection.


Install the electronic display module (2) to the console (3).
Install the display lens (1) by snapping the lens into place.
Calibrate the compass. Refer to Electronic Compass Operation in Instrument
Panel, Gauges, and Console .

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Ambient Air Temperature Gage Sensor Replacement


Document ID: 366862
Removal Procedure

1. Remove the radiator grille. Refer to Grille Replacement in Exterior Trim.


2. Lift the temperature sensor upward in order to remove the temperature sensor.
3. Disconnect the electrical connector.

Installation Procedure

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1. Connect the electrical connector.

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2. Install the temperature sensor by sliding the temperature sensor downward.


3. Install the radiator grille. Refer to Grille Replacement in Exterior Trim.

Electronic Compass Operation


Document ID: 388667
The compass is capable of distinguishing eight primary directions:
North (N)
Northeast (NE)
East (E)
Southeast (SE)
South (S)
Southwest (SW)
West (W)
Northwest (NW)

The calibration procedures that are described in this section establish a base direction
for the compass to work from. Once the compass is properly calibrated, the electronic
display indicates the direction that the vehicle is facing. Under normal circumstances,
no further attention to the compass should be required for a period of 2 years.
Calibration may be necessary under the following conditions:

The vehicle is involved in a collision or experiences a jarring force that is


sufficient to disturb the vehicles inherent magnetic field.
The vehicle is operated a significant distance away from the point of initial
calibration such as a different area of the country.

Calibration
The compass is self-calibrating. This eliminates the need to manually set the compass.
For a short time when the vehicle is new, the compass may appear to operate erratically
and the CAL symbol or the letter C will display. Correct this by driving the vehicle in a
complete circle 3 consecutive times. The symbol will turn off and the compass will
function normally. If the compass displays a C at all times, the compass needs to be
calibrated.

Fast Calibration
The compass module is shipped to the assembly plant in the fast calibration mode. In
this mode, a C shows in the portion of the display that typically shows the compass
heading. When is vehicle is calibrated outside the assembly plant, drive the vehicle in an
area that is free from metal objects. Reset the compass by cycling the ignition (Off and
ON). Drive the vehicle in a circle, oval or square until the C is replaced by the display
heading.

Slow Calibration

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If the compass is displaying a heading, then the compass is in the slow calibration
mode. In this mode, the compass automatically calibrates for changes in the vehicle
magnetism over the life of the vehicle. This autocalibration assures that the compass
heading is always accurate and does not require manual calibration.

Compass Heading is Blank

Important: Remove the Driver Information Center (DIC) before you degauss the
vehicle.
If you install a new compass, use the following procedure in order to calibrate the
compass:
1. Turn the ignition switch to the RUN position.
2. Depress and hold both the US/MET and the ON/OFF or the MODE buttons for
approximately 10 seconds, or until the display reads CAL or C.
3. Drive the vehicle in a complete circle 3 consecutive times. The symbol turns off
when the compass is calibrated. The compass will then function normally.

Variance
Variance is the difference between magnetic North and geographic North. In some areas
of the world, the difference between magnetic and geographic North is great enough to
cause false readings.
Use the following procedure in order to set the variance for the vehicle's particular
locations. On vehicles with a MODE switch, the display must be in the COMP/TEMP
mode before setting the variance.
World Magnetic Variation Map

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Excessive magnetism in or near the vehicle may cause the compass display to go blank.
In order to distinguish between vehicle magnetics and surrounding magnetics, drive the
vehicle to an area that is free from large metal objects. Rest the compass by cycling the
ignition (OFF and ON). If the compass display goes blank within 20 seconds after the
reset of power, then the vehicle magnetism is too high and the vehicle should be
degaussed.

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1. Determine the location on the zone map.


2. Note the zone number.
3. Press and hold both the US/MET and the ON/OFF or the MODE switches.
The display will turn off.
4. After approximately 5 seconds, the variance setting appears on the display (w/o
trip computer).
With the trip computer, only a number is revealed at the present zone.
When the variance setting appears, release both of the buttons.
5. Press the ON/OFF or the MODE switch in order to enter the geographical zone
number.
The compass is now adjusted for variance.
6. Press the MODE button (w/ trip computer) or the ON/OFF button (w/o trip
computer) in order to return to the main screen. This action will save the setting.
Due to the nature of the magnetic detection devices in the module, the compass may
occasionally show false directions even when operating properly. Since the
circumstances that give rise to these false readings may vary, some general knowledge
of how the compass works is helpful in determining why false readings occur. Such
perceived malfunctions may be the result of special circumstances, or a true system
malfunction. Regardless of the problem, the first step in diagnosing the compass system

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is recalibration. If the problem persists after recalibration, review the following


information regarding compass system functions for help in determining if the system is
operating properly.

Long Distance Travel


Recalibration of the compass may be necessary if the vehicle is operated a long distance
away from the point of the initial compass calibration. There are many reasons for this,
including the following:

Differences in the magnetic declination


Changes in the angle formed between the magnetic needle and the geographical
meridian across the country
The coordinate system used by the compass to determine direction (magnetic
north)

When these circumstances arise, a malfunction may be suspected when, in fact, the
system is operating normally.
An approximate 15 degree deviation (declination) from true NORTH occurs between
the east and west coasts. This declination is the result of the earth's curvature. Various
other deviations throughout the country are the result of differences in the magnetic
fields.

Vehicles Involved in a Collision


The compass system may require recalibration if the vehicle's structure is altered
sufficiently. This occurs because any significant alterations in the vehicle's structure
will cause corresponding alterations in the vehicle's inherent magnetic field. Thus, when
the vehicle's structure is altered, as in a collision, the compass readings may reflect the
offset in the vehicle's magnetic field. The vehicle operator may then discover
differences in compass readings from those previously observed along familiar routes.

Operation in Urban Areas


The electronic compass, like any compass, is influenced by external magnetic fields.
Filters that are programmed into the compass function to counteract much of this
external magnetic interference. These filters vary with the vehicle speed. They function
by relating the vehicle speed to the time in which the vehicle could conceivably change
directions. The filters correspond to the following speeds:

016 km/h (010 mph)


1664 km/h (1040 mph)
Above 64 km/h (40 mph)

The filters function by taking into account that vehicle directional changes ordinarily do
not occur as quickly at higher speeds as at lower speeds. The filters help avoid false
readings caused by large steel structures, such as the following objects:

Skyscrapers

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Bridges
Roads with steel reinforcement
Railroad tracks

Sometimes, the field projected by these structures leads to a reading that represents too
drastic a change of direction for the prevailing driving conditions. When this happens,
the filters intervene in order to prevent changes in the directional display. However,
under borderline conditions, as in large cities with slow driving, the compass may give
false readings and appear to be malfunctioning. If this occurs, test the compass in an
open area, free from magnetic disturbances.

When travelling on winding roads, the compass readings may oscillate between
2 neighboring directions, such as NORTH and NORTHWEST. This occurs when the
road coordinates coincidentally border the coordinates used by the system for the
2 different directions.

Electronic Compass Module Replacement


Document ID: 417522
Removal Procedure

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Due to the complexity of the compass system and the extent of outside influences on the
compass' performance, thoroughly inspect the system prior to performing repairs.
Inspect the compass in an area that is free from potential interference such as in an open
field. Inspect that the compass is calibrated in order to verify the existence of a problem.
1. Remove the overhead console. Refer to Driver Information Center Replacement
in Instrument Panel, Gauges, and Console .

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Operation on Winding Roads

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2. Remove the compass sensor from the overhead console bracket.

Installation Procedure

1. Install the compass sensor to the overhead console bracket.


2. Install the overhead console. Refer to Driver Information Center Replacement in
Instrument Panel, Gauges, and Console .
3. Calibrate the compass. Refer to Electronic Compass Operation in Instrument
Panel, Gauges, and Console .

Document ID: 417522

Driver Information Center (DIC) or Message Center Description


Document ID: 297897
Overhead Console

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The overhead console is a convenience package which contains some or all of the
following features:

A multi-function electronic display (4) that indicates the outside temperature and
the direction that the vehicle is facing
On some models, the display is also used for the driver information system.

A compartment for a garage door opener transmitter that can be adapted to many
brands of transmitters
The transmitter can be activated by pressing the button on the compartment
door.

A universal transmitter that can be programmed to replace up to three hand-held


transmitters
A compartment for storing sunglasses
A compartment for compact disc or cassette tape storage
A dome lamp
A location for the sunroof switch, if equipped with a sunroof

Button Operation
The two button user interface consists of the following switches:

US/MET
MODE

The US/MET switch allows the user to toggle the display readout between the English
and the metric systems.

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The MODE switch serves the function of toggling the display between the following
modes of operation:

OFF
COMP/TEMP
TRIP

Once in the TRIP mode of operation, the MODE switch served to step the user through
the TRIP functions. Refer to the following table for information about the applicable
states and the sequencing order of the MODE switch.
Function
Display Off
Compass and Outside Temperature
Average Fuel Economy
Instantaneous Fuel Economy
Trip Range
Fuel Used
Average Speed

Display Dimming
Display dimming follows the radio dimming characteristics. Upon activation of the park
lamp, the display dims to the maximum brightness in the dim mode. Further dimming is
controlled by the analog dimming signal of the IP dimming control. The display goes
blank when the IP dimming control is at the lowest setting.

Temperature Display Operation

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Sequence
1
2
3
4
5
6
7

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The outside temperature is displayed on the electronic display (2). The electronic
display is located at the front of the console. Temperature readings may be displayed in
either degrees Fahrenheit (F) or degrees Celsius (C). Pushing the US/MET switch (4)
that is located on the left side of the display alternates the temperature readings between
Fahrenheit and Celsius. If the outside temperature is 3C (37F) or lower, the display
toggles between the word ICE and the current temperature every eight seconds in order
to warn the driver of the possibility of icy road conditions.

When the vehicle is first started, the electronic module uses an internal timer in order to
determine how long the vehicle has been turned off. If the vehicle has been turned off
for less than four hours, the sensor may be warmer than the actual ambient because the
engine and the radiator may not have cooled down yet. In order to prevent a false
temperature from being displayed, the electronic module displays the same temperature
as when the vehicle was last turned off. A new sensor reading is not displayed until the
vehicle speed meets the above mentioned criteria. If the vehicle has been off for more
than 4 hours, the module takes an immediate temperature reading from the sensor and
displays that temperature. Further updates then must meet the vehicle speed criteria.

Temperature Will Not Rise


The temperature routines do not allow a displayed temperature to rise unless the vehicle
is in motion. Motion of the vehicle is determined by a vehicle speed message that is
received from the PCM/VCM. The temperature does not increase if there is a speed
sensor failure and the speed sensor received a message that is inaccurate.

Horn Replacement Document ID: 417579


Removal Procedure

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The outside temperature is measured from a sensor that is located behind the front
grille. In this location, heat from the radiator may warm the sensor above the actual
ambient temperature if there is insufficient airflow across the sensor. In order to prevent
false temperature displays, the electronic module monitors the vehicle speed. The
vehicle speed must meet certain conditions before the module displays a new reading
from the sensor. If the vehicle speed is less that 29 km/h (18 mph), the temperature
display is not updated. If the vehicle speed is between 2958 km/h (1836 mph), the
temperature display is updated at a slow rate. If the vehicle speed is over 58 km/h
(35 mph) for longer than 2 minutes, the sensor will be at the correct ambient
temperature. The display then updates continuously in order to reflect the ambient
temperature more accurately.

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1. Remove the windshield washer solvent container. Refer to Windshield Washer


Solvent Container and Pump Replacement in Wiper/Washer Systems.
2. Disconnect the electrical connector.

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3. Remove the bolt that retains the horn assembly to the fender.
4. Remove the horn assembly from the fender.

Installation Procedure

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1. Install the horn assembly to the fender.


Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Install the bolt that retains the horn assembly to the fender.
Tighten
Tighten the bolt to 17 N-m (13 lb ft).

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3. Connect the electrical connector.


4. Install the windshield washer solvent container. Refer to Windshield Washer
Solvent Container and Pump Replacement in Wiper/Washer Systems.

Document ID: 417579

Horn Replacement Document ID: 417581


Removal Procedure

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1. Disconnect the electrical connector.

2. Remove the bolt that retains the horn assembly to the fender.
3. Remove the horn assembly from the fender.

Installation Procedure

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1. Install the horn assembly to the fender.
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant

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are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Install the bolt that retains the horn assembly to the fender.
Tighten
Tighten the bolt to 17 N-m (13 lb ft).

3. Connect the electrical connector.

Horn Relay Replacement


Document ID: 389799
Removal Procedure

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1. Open and support the hood.


2. Remove the protective cover from the underhood fuse block.
3. Remove the horn relay from the underhood fuse block.

Installation Procedure

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1. Install the horn relay to the underhood fuse block.
2. Install the protective cover to the underhood fuse block.
3. Close the hood.

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PUERTAS, ACCESORIOS Y
ESPEJOS
Front Side Door Replacement
Document ID: 299143

Tools Required
J 36604 Door Hinge Spring Compressor
1. Remove the door trim panel. Refer to Front Side Door Trim Panel Replacement
in Doors .
2. Disconnect the electrical connectors as needed.
3. Remove the rubber conduit from the door and the body hinge pillar.
4. Apply cloth-backed tape to the door and the body hinge pillar in order to protect
the door and the body hinge pillar from scratches.

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5. Caution: Before removing the spring, cover the spring with a towel to prevent
the spring from flying and possibly causing damage or personal injury.
Use the J 36604 in order to remove the door hinge spring.
6. Remove the hinge pin retainers from the hinge pins.

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Removal Procedure

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Discard the hinge pin retainers.

7. Use a soft-faced hammer and locking pliers in order to remove the lower hinge
pins.
8. Temporarily install a bolt through the lower hinge in order to hold the door in
place.
9. Remove the upper hinge pin.
10. Remove the temporary bolt from the lower hinge.
11. Remove the door from the vehicle.
12. Remove and discard the door hinge pin bushings.

Installation Procedure
1. Install the new door hinge pin bushings.
2. Install the door to the vehicle.

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3. Install a temporary bolt through the lower hinge in order to hold the door in
place.
4. Install the upper hinge pin.
Ensure that the pointed end of the pin points upward.
5. Remove the temporary bolt from the lower hinge.
6. Install the lower hinge pin.

7. Install new hinge pin retainers to the hinge pins.

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8. Use the J 36604 in order to install the door hinge spring.
9. Remove the tape from the door and the body hinge pillar.
10. Install the rubber conduit to the door and the body hinge pillar.
11. Connect the electrical connectors as needed.
12. Install the door trim panel. Refer to Front Side Door Trim Panel Replacement in
Doors .

Door Window Replacement


Document ID: 448974
Removal Procedure

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Ensure that the pointed end of the pin points upward.

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Caution: To prevent personal injury, gloves should be worn when removing


broken glass.
1. Lower the window about one half of the way down.
In this position, the window regulator rollers should be accessible through the
openings in the door panel.

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6. Remove the window (1) from the door.

Installation Procedure

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2. Remove the window run channels. Refer to Refer to Window Channel


Replacement in Doors .
3. Remove the window weather-strip. Refer to Front Side Door Weatherstrip
Replacement in Doors .
4. Remove the door outer weather-strip. Refer to Front Side Door Weatherstrip
Replacement in Doors .
5. Perform the following steps in order to remove the window (1) from the
regulator:
1. Move the window (1) forward in order to release the sash channel from
the rear regulator roller.
2. Carefully tilt the window forward to a vertical position.
3. Pull the window upward in order to release the sash channel from the
front regulator roller.

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1. Install the window (1) to the door.


2. Perform the following steps in order to install the window (1) to the regulator:
1. Carefully rotate the glass vertically.
2. Slide the sash channel downward into the front regulator roller.
3. Move the window (1) forward.
4. Align the rear of the sash channel with the rear regulator roller.
5. Slide the sash channel into the rear regulator roller.
3. Install the door outer weather-strip. Refer to Front Side Door Weatherstrip
Replacement in Doors .
4. Install the window weather-strip. Refer to Front Side Door Weatherstrip
Replacement in Doors .
5. Install the door window run channels. Refer to Window Channel Replacement in
Doors .

Rear Bumper Impact Bar Replacement Document ID: 310137


Removal Procedure
1. Remove the rear bumper step pads. Refer to Rear Bumper Step Pad
Replacement in Bumpers .
2. Remove the license plate lamps. Refer to Rear License Plate Lamp Replacement
in Lighting Systems.

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3.
4.
5.
6.

Remove the nuts and the bolts that retain the bracket to the bumper.
Remove the nuts and the bolts that retain the brace to the bumper.
Remove the bumper impact bar from the vehicle.
Remove the following components that retain the brace to the frame:
o The nuts
o The washers
o The bolts
7. Remove the brace.

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8. Remove the following components that retain the bracket to the frame:
o The nuts
o The washers
o The bolts

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9. Remove the bracket.

Installation Procedure

1. Install the bracket.


Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Install the following components that retain the bracket to the frame:
o The nuts
o The washers
o The bolts
Tighten
Tighten the bolts to 40 N-m (30 lb ft).
3. Install the brace.
4. Install the following components that retain the brace to the frame:
o The nuts
o The washers
o The bolts
Tighten

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Tighten the bolts to 40 N-m (30 lb ft).


5. Install the bumper impact bar to the vehicle.
6. Install the nuts and the bolts that retain the brace to the bumper.
Tighten
Tighten the bolts to 40 N-m (30 lb ft).

7. Install the nuts and the bolts that retain the bracket to the bumper.
Tighten
Tighten the bolts to 40 N-m (30 lb ft).
8. Install the license plate lamps. Refer to Rear License Plate Lamp Replacement in
Lighting Systems.
9. Install the rear bumper step pads. Refer to Rear Bumper Step Pad Replacement
in Bumpers .

Rear Bumper Step Pad Replacement Document ID: 310141


Removal Procedure

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1. Remove the step pads from the bumper.

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2. Use a flat bladed tool in order to remove the step pads from the bumper.

Installation Procedure

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Install the step pads to the bumper.

Rear Bumper Extension Replacement Document ID: 310143


Removal Procedure

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1. Remove the screws from the wheel opening trim ring.
2. Remove the bolt that retains the brace to the extension.
3. Remove the nuts that retain the extension to the rear quarter panels.

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Installation Procedure

1. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the nuts that retain the extension to the rear quarter panels.
Tighten
Tighten the nuts to 3 N-m (27 lb in).
2. Install the bolt that retains the brace to the extension.
Tighten
Tighten the bolt to 40 N-m (30 lb ft).
3. Install the screws to the wheel opening trim ring.
Tighten
Tighten the screws to 1.9 N-m (17 lb in).

Inside Rearview Mirror Replacement


Document ID: 300994

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Removal Procedure

1. Use a flat-bladed tool in order to remove the wire cover (if equipped).
2. Disconnect the electrical connector (if equipped).

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3. Insert a small, flat-bladed tool into the slot from the bottom.
4. Press slightly in order to release the tab.
5. Slide the mirror off of the support.

Installation Procedure
1. Slide the mirror on to the mirror support.
2. Connect the electrical connector (if equipped).

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3. Install the wire cover (if equipped).

Rearview Mirror Support Installation


Document ID: 300996
Removal Procedure

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1. Use the following procedure in order to determine the location of the mirror
support:

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Installation Procedure

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1. Sand the bonding surface of the rear view mirror support with no. 320 or no. 360
fine grit emery cloth or sandpaper. If the you reuse the original rear view mirror
support, remove all traces of the factory installed adhesive.
2. Wipe the sanded mirror support with a clean alcohol saturated paper towel.
Allow the alcohol to dry.
3. Apply Loctite Minute-Bond Adhesive 312 or the equivalent to the mirror
support. Follow the manufacturer's instructions.
4. Position the bottom of the support at the marked line. The rounded edge of the
support should face upward.
5. Press the support against the glass for 30-60 seconds with a steady pressure.
Allow the adhesive 5 minutes to dry before cleaning.
6. Clean the excess adhesive from around the mirror support using an alcohol
moistened paper towel.
7. Clean the wax marks from the windshield using an alcohol moistened paper
towel.

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1. Draw a centerline on the outside of the glass from the roof panel to the
windshield base with a wax pencil.
2. Draw a line intersecting the centerline 53.4 cm (21 in) from the top of the
bottom black-out strip of the glass. Locate the base of the support at the
intersection of these lines.
3. Use a razor blade in order to remove old adhesive from the windshield
and the support.
2. Use the following procedure in order to clean the inside glass surface within
75 mm (3 in) of the intersecting lines:
1. Rub the area with a paper towel and glass cleaning solution until the
glass is completely clean and dry.
2. Remove all the traces of the cleaning solution from the glass with an
alcohol saturated paper towel.

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Cruise Control Module Replacement


Document ID: 418928
Removal Procedure

1. Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
Disconnect the battery negative cable.
2. Disconnect the cruise control cable. Refer to Cruise Control Cable Replacement
in Cruise Control .
3. Disconnect the electrical connectors, as necessary.
4. Remove the 3 nuts that retain the cruise control module to the mounting bracket
studs.
5. Remove the cruise control module from the mounting bracket.
6. Remove the 3 screws that retain the mounting bracket to the cowl panel.

Installation Procedure

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1. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the mounting bracket to the cowl panel with the 3 screws.
Tighten
Tighten the screws to 4.5 N-m (40 lb in).
2. Install the cruise control module to the vehicle.
3. Install the 3 nuts that retain the cruise control module to the mounting bracket.
Tighten
Tighten the nuts to 9.0 N-m (6.6 lb ft).
4. Connect the electrical connectors, as necessary.
5. Install the cruise control cable. Refer to Cruise Control Cable Replacement in
Cruise Control .
6. Connect the battery negative cable.
7. Test the systems operation.

Cruise Control Cable Replacement -

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Document ID: 418931


Removal Procedure

1. Disconnect the electrical connector from the cruise control servo module.

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2. Disconnect the cruise control cable locator clip from the outboard rectangular
hole in the routing bracket at the left front corner of the engine.
3. Disconnect the cruise contorl cable conduit fitting from the round hole in the
engine cable bracket.
4. Disconnect the cruise control cable engine-end fitting from the nail-head stud on
the throttle lever.

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5. Disconnect the cruise control cable fitting from the cruise control module.

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6. Disconnect the cruise control cable bead from the fitting on the cruise control
module ribbon.
7. Remove the cruise control cable from the vehicle.

Installation Procedure

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1. Install the cruise control cable to the vehicle.


2. Connect the cruise control cable bead to the fitting on the cruise control module
ribbon.

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3. Pull the cruise control cable until the cable is taut.
4. Turn the cruise control cable at the engine-end fitting in order to straighten the
cruise control module ribbon, as needed.
Ensure that the ribbon is flat and vertical.

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5. Slide the cruise control cable conduit over the ribbon.


1. Install the tangs to the cruise control module housing.
2. Ensure that the tangs snap securely into place.

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6. Route the cable over the brake booster, along the left side rocker cover, under
the preplenum air inlet tube, and above the radiator inlet hose.

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7. Snap the cruise control cable engine-end fitting over the nail head stud on the
throttle cam lever.
8. Connect the cruise control cable conduit fitting to the round hole in the engine
cable bracket.
Ensure that the tabs snap securely into the hole.
9. Connect the cruise control cable locator clip to the outboard rectangular hole in
the routing bracket at the left front corner of the engine.
1. Route the cruise control cable above the accelerator cable.
2. Ensure that the clip snaps securely into place.

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10. Important: Secure all of the components of the accelerator and the cruise
control cables as specified. Ensure that the throttle linkage operates freely
without binding between the idle position and the wide open throttle.

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Push the cable adjuster plunger into the locked position (2). Ensure that the
white paint area is no longer visible.
o
o

The lash should automatically be set at 0.01.0 mm (0.00.04 in) by the


adjuster.
If an adjustment is required, refer to Cruise Control Cable Adjustment in
Cruise Control .

11. Connect the electrical connection to the cruise control servo module.
12. Test the systems operation.

Cruise Control Cable Adjustment Document ID: 418933


The cruise control cable lash should be automatically set within 0.01.0 mm (0.0
0.04 in) when the cable is installed. If an adjustment is necessary, use the following
procedure:
1. Squeeze the tangs at the top of the cruise control adjuster in order to unlock the
cable adjuster plunger.
2. Allow the throttle lever to return to the idle position.
3. Push the cable adjuster plunger into the locked position. Ensure that the white
paint area is no longer visible.

Document ID: 418933

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PASSLOCK Reprogramming Auto Learn


Document ID: 486331
You must perform a Passlock Learn Procedure if any of the following components
have been replaced:

Passlock sensor
Body control module
Powertrain control module
Vehicle control module

There are 2 types of Passlock learn procedures:

A 10 minute procedure which requires a Techline Terminal and a Tech 2 scan


toolPASSLOCK Reprogramming Seed and Key in Theft Deterrent .
A 30 minute procedure which requires a scan tool used in order to clear codes.
This procedure is listed below.

30 Minute Procedure
1. Ensure that the battery is fully charged.
2. Use a scan tool in order to clear the Passlock DTCs.
3. Turn the ignition switch from the OFF position to the CRANK position, and
then to the RUN position.
The vehicle will start and then stall.
4.
5.
6.
7.

Leave the ignition ON until the security telltale turns OFF in 10 minutes.
Repeat Steps 35 for 2 more times (3 times total)
The Passlock controller will learn the new data on the next start attempt.
Use a scan tool in order to clear all DTCs.

Windshield Washer Solvent Container and Pump Replacement


Document ID: 425975
Removal Procedure
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.

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Both of the above modules except for the Passlock sensor must be programmed using
their own vehicle configuration. See the individual module service manual section.

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1. Disconnect the negative battery cable.


2. Remove the washer solvent.

3.
4.
5.
6.

Disconnect the electrical connector from the washer pump.


Disconnect the washer hose assembly from the washer pump.
Remove the mounting screw retaining the solvent container to the vehicle.
Remove the air filter housing, if necessary.
Slide the air filter housing up, in order to remove the housing.

7. Remove the solvent container from the vehicle.


8. Remove the washer pump from the container.

Installation Procedure

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1. Important: Push the washer pump as far into the container seal as possible.
Connect the washer pump to the container.
2. Insert the solvent container legs into the holes in the inner fender.

3. Install the mounting screw retaining the solvent container to the vehicle.
Tighten
Tighten the screw to 3 N-m (27 lb in)
4. Connect the washer hose assembly from the washer pump.
5. Connect the electrical connector to the washer pump.
6. Replace the washer solvent.
Caution: Unless directed otherwise, the ignition and start switch must be in the
OFF or LOCK position, and all electrical loads must be OFF before servicing
any electrical component. Disconnect the negative battery cable to prevent an
electrical spark should a tool or equipment come in contact with an exposed
electrical terminal. Failure to follow these precautions may result in personal
injury and/or damage to the vehicle or its components.
7. Connect the negative battery cable.

Rear Window Washer Hose Replacement - Pump to Endgate


Document ID: 752565
Removal Procedure
1. Remove the left front seat. Refer to Driver or Passenger Seat Replacement in
Seats.
2. Remove the rear seat. Refer to Rear Seat Replacement in Seats.
3. Remove the endgate/liftgate door sill plate. Refer to Rear Floor Rear Trim Plate
Replacement in Interior Trim or Liftgate Door Sill Plate Replacement in Interior
Trim.
4. Remove the left front and left rear door sill plates. Refer to Door Sill Plate
Replacement in Interior Trim.

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Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.

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5. Remove the left body side trim panel. Refer to Body Side Trim Panel
Replacement in Interior Trim.
6. Remove the left hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel
Replacement - Left Side in Interior Trim.
7. Fold over the left side of the carpet to allow access to the body harness. Refer to
Front Floor Mat/Carpet Replacement in Interior Trim and Rear Floor Panel
Carpet Replacement in Interior Trim.

8. Disconnect the washer hose connection (1) from the body harness (2) at the
endgate.
9. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement
in Engine Controls.

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10. Disconnect the hose (1) from the rear washer pump.
11. Install a plug to the rear washer pump nozzle to prevent washer fluid loss.

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12. Push the hose grommet (2) in through the bulkhead.

13. Pull the washer hose (1) into the vehicle though the bulkhead.
14. Cut the old washer hose off where it enters the body wiring harness (2).
15. Remove the hose from the vehicle.

Installation Procedure
1. Install the hose to the vehicle.

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2. Route the hose (1) out though the bulkhead.
3. Route the hose along the side of body harness (2), and tape the hose to the body
harness with 3 wraps of electrical tape every 100 mm (4 in.).
4. Seat the hose grommet (2) into the bulkhead.
5. Remove the plug from the rear washer pump nozzle.

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6. Connect the hose (1) to the rear washer pump.


7. Install the air cleaner assemby. Refer to Air Cleaner Assembly Replacement in
engine controls.

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8. Connect the washer hose connection (1) at the endgate.
9. Install the carpet. Refer to Front Floor Mat/Carpet Replacement in Interior Trim
and Rear Floor Panel Carpet Replacement in Interior Trim.
10. Install the left hinge pillar trim panel. Refer to Body Hinge Pillar Trim Panel
Replacement - Left Side in Interior Trim.
11. Install the left body side trim panel. Refer to Body Side Trim Panel Replacement
in Interior Trim.
12. Install the left front and left rear door sill plate. Refer to Door Sill Plate
Replacement in Interior Trim.

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13. Install the endgate/liftgate door sill plate. Refer to Rear Floor Rear Trim Plate
Replacement in Interior Trim or Liftgate Door Sill Plate Replacement in Interior
Trim.
14. Install the rear seat. Refer to Rear Seat Replacement in Seats.
15. Install the left front seat. Refer to Driver or Passenger Seat Replacement in
Seats.

Console Lamp Replacement


Document ID: 389667

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1. Gently pry the lens from the bulb housing.
2. Release the locking tabs in order to remove the bulb and socket from the lens.
3. Pull the bulb straight out of the socket.

Installation Procedure

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Removal Procedure

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1. Install the bulb to the socket.


2. Carefully snap the lens into position.

Document ID: 389667

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SISTEMA SIR (BOLSAS DE AIRE)


Disabling the SIR System
Document ID: 192733
Turn the steering wheel so that the vehicle's wheels are pointing straight ahead.
Turn the ignition switch to the LOCK position.
Remove the key from the ignition switch.
Remove the SIR Fuse from the IP fuse block.
Important: With the SIR Fuse removed and the ignition switch in the ON
position, The AIR BAG warning lamp illuminates. This is normal operation, and
does not indicate an SIR system malfunction.
5. Remove the sound insulator-LH. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges and Console.
6. Remove the knee bolster (if equipped). Refer to Knee Bolster Replacement in
Instrument Panel, Gauges and Console.

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7. Remove the Connector Position Assurance (CPA) from the driver yellow 2-way
connector located at the base of the steering column.

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1.
2.
3.
4.

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8. Disconnect the driver yellow 2-way connector located at the base of the steering
column.
9. Open the IP compartment door, lift stop and allow door to fully open.

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10. Remove the Connector Position Assurance (CPA) from the passenger yellow 2way connector located behind the glove box.
11. Disconnect the passenger yellow 2-way connector located behind the glove box.

Instrument Panel Insulator Panel Replacement - Left Side


Document ID: 469039

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Removal Procedure
1. Remove the screws that retain the data link connector (DLC) to the instrument
panel sound insulator.
Feed the DLC lines through the hole in the sound insulator.

2. Remove the screws that retain the instrument panel sound insulator to the knee
bolster and the cowl panel.
3. Disconnect the electrical connectors from the remote control door lock receiver
module.
4. Remove the remote control door lock receiver module from the instrument panel
sound insulator.

Installation Procedure
1. Install the remote control door lock receiver module to the instrument panel
sound insulator.
2. Connect the electrical connector to the remote door lock receiver module.

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3. Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the screw that retains the instrument panel sound insulator to the cowl
panel.
Tighten
Tighten the screw to 1.9 N-m (17 lb in).
4. Install the screws that retain the instrument panel sound insulator to the knee
bolster.
Tighten
Tighten the screws to 1.9 N-m (17 lb in).
5. Feed the DLC through the hole in the instrument panel sound insulator.
6. Install the screws that retain the DLC to the instrument panel sound insulator.
Tighten
Tighten the screws to 2.4 N-m (21 lb in).

Enabling the SIR System

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Document ID: 192734


1. Remove the key from the ignition switch.

2. Connect the passenger yellow 2-way connector located behind the glove box.
3. Install the Connector Position Assurance (CPA) to the passenger yellow 2-way
connector located behind the glove box.
4. Close the IP compartment door.

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5. Connect the driver yellow 2-way connector located at the base of the steering
column.

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6. Install the Connector Position Assurance (CPA) to the driver yellow 2-way
connector located at the base of the steering column.
7. Install the knee bolster (if equipped). Refer to Knee Bolster Replacement in
Instrument Panel, Gauges and Console.
8. Install the sound insulator-LH. Refer to Instrument Panel Insulator Panel
Replacement - Left Side in Instrument Panel, Gauges and Console.
9. Install the SIR Fuse to the IP fuse block.
10. Staying well away from both air bags, turn the ignition switch to the RUN
position.
1. The AIR BAG warning lamp will flash seven times.
2. The AIR BAG warning lamp will then turn OFF.
11. Perform the SIR Diagnostic System Check if the AIR BAG warning lamp does
not operate as described.

Inflatable Restraint Sensing and Diagnostic Module Replacement


Document ID: 192736
Caution: Be careful when you handle a sensing and diagnostic module (SDM). Do not
strike or jolt the SDM. Before applying power to the SDM:

Remove any dirt, grease, etc. from the mounting surface


Position the SDM horizontally on the mounting surface
Point the arrow on the SDM toward the front of the vehicle
Tighten all of the SDM fasteners and SDM bracket fasteners to the specified
torque value

Failure to follow the correct procedure could cause air bag deployment, personal injury,
or unnecessary SIR system repairs.

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Caution: If any water enters the vehicle's interior up to the level of the carpet or higher
and soaks the carpet, the sensing and diagnostic module (SDM) and the SDM harness
connector may need to be replaced. The SDM could be activated when powered, which
could cause deployment of the air bag(s) and result in personal injury. Before
attempting these procedures, the SIR system must be disabled. Refer to Disabling the
SIR System.
With the ignition OFF, inspect the SDM mounting area, including the carpet. If any
significant soaking or evidence of significant soaking is detected, you must perform the
following tasks:
Remove all water.
Repair the water damage.
Replace the SDM harness connector.
Replace the SDM.

Failure to follow these tasks could result in possible air bag deployment, personal
injury, or otherwise unneeded SIR system repairs.

Removal Procedure
1. Disable the SIR system. Refer to Disabling the SIR System in SIR .
2. Remove the drivers seat. Refer to Driver or Passenger Seat Replacement in
Seats.
3. Remove driver seat belt from floor. Refer to the Seat Belt Replacement - Driver
in Seat Belts.
4. Remove the carpet retaining sill trim molding - LH. Refer to Sill Trim Plate
Replacement in Interior Trim.
5. Remove the floor console (if equipped). Refer to Front Floor Console
Replacement in Instrumenet Panel, Gauges and Console.
Important: Remove the left body side trim panel for extended cab pickup.
6. Remove the LH Kick Panel.
7. Fold back the carpet to access the inflatable restraint Sensing and Diagnostic
Module (SDM).
8. Remove the Connector Position Assurance (CPA) from the SDM harness
connector.
9. Disconnect the SDM harness connector from the SDM.

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1.
2.
3.
4.

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10. Remove the SDM mounting fasteners (1).


11. Remove the SDM (2) from the vehicle (3).

Installation Procedure

Click here for full size


1. Install the SDM (2) to the vehicle (3).
2. Install the SDM mounting fasteners (1).
Tighten
Tighten fasteners to 12 N-m (106 lb in).
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring

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replacement or fasteners requiring the use of thread locking compound or sealant


are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
3. Install the SDM harness connector to the SDM.
4. Install the Connector Position Assurance (CPA) to the SDM harness connector.
5. Position the carpet to cover the inflatable restraint Sensing and Diagnostic
Module (SDM).

6. Install the LH Kick Panel.


7. Install the floor console (if equipped). Refer to Front Floor Console
Replacement in Instrument Panel, Gauges and Console.
8. Install the carpet retaining sill trim molding LH, Refer to Sill Trim Plate
Replacement in Interior Trim.
9. Install driver seat belt to floor. Refer to Seat Belt Replacement - Driver in Seat
Belts .
10. Install the driver seat. Refer to Driver or Passenger Seat Replacement in Seats.
11. Enable the SIR system. Refer to Enabling the SIR System in SIR .

Instrument Panel Inflatable Restraint Module Replacement


Document ID: 186781
Removal Procedure

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Important: Install the left body side trim panel for extended cab pickup.

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1. Remove the instrument panel. Refer to Instrument Panel Carrier Replacement in


Instrument Panel, Gauges and Console.
2. Remove the fasteners (5) (4) that retain the inflatable restraint IP module to the
instrument panel (3).
3. Remove the inflatable restraint module (2) from the instrument panel (3).
4. Fully deploy the module before disposal. If the module was replaced under
warranty, fully deploy and dispose of the module after the required retention
period. Refer to Inflator Module Handling, Shipping, and Scrapping in SIR .

Installation Procedure

1. Install the inflatable restraint IP module (2) to the instrument panel (3).
Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
2. Install the fasteners (4) (5) that retain inflatable restraint IP module (2) to the
instrument panel (3).
Tighten
Tighten the fasteners to 8.0 N-m (70 lb in).
3. Install the instrument panel. Refer to Instrument Panel Carrier Replacement in
Instrument Panel, Gauges and Console.

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Inflatable Restraint Front End Discriminating Sensor Replacement


Document ID: 192742
Caution: Be careful when you handle a sensor. Do not strike or jolt a sensor. Before
applying power to a sensor:
Remove any dirt, grease, etc. from the mounting surface.
Position the sensor horizontally on the mounting surface.
Point the arrow on the sensor toward the front of the vehicle.
Tighten all of the sensor fasteners and sensor bracket fasteners to the specified
torque value.

Failure to follow the correct procedure could cause air bag deployment, personal injury,
or unnecessary SIR system repairs.

Removal Procedure

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1. Disable the SIR system. Refer to Disabling the SIR System in SIR .
2. Remove off road skid plate if equipped.
3. Remove the Connector Position Assurance (CPA) from the inflatable restraint
front end discriminating sensor harness connector.
4. Disconnect the inflatable restraint front end discriminating sensor harness
connector from the sensor.

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5. Drill out the mounting rivets.

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6. Remove the inflatable restraint front end discriminating sensor from the vehicle.
Important: The following procedures should be utilized in the event that sensor
mounting holes or fasteners are damaged to the extent that the sensor can no longer be
properly mounted.

First Fastener Repair


1. Remove and discard the improperly installed rivet.
2. Reattach sensor with new rivet.
Second Fastener Repair
1. Remove the improperly installed rivet.

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2. Enlarge the mounting holes in the lower radiator support to 9.0 mm


(0.35 in).
3. Insert and properly seat rivnut GM P/N 15715058

4. Install sensor with screw.


Tighten
Tighten fasteners to 8.0 N-m (71 lb in).

Installation Procedure

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1. Install the inflatable restraint front end discriminating sensor to the lower
radiator support surface make sure the arrow is pointing toward the front of the
vehicle.

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Notice: Use the correct fastener in the correct location. Replacement


fasteners must be the correct part number for that application. Fasteners
requiring replacement or fasteners requiring the use of thread locking
compound or sealant are identified in the service procedure. Do not use
paints, lubricants, or corrosion inhibitors on fasteners or fastener joint
surfaces unless specified. These coatings affect fastener torque and joint
clamping force and may damage the fastener. Use the correct tightening
sequence and specifications when installing fasteners in order to avoid
damage to parts and systems.

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2. Install the inflatable restraint front end discriminating sensor mounting rivets
(P/N 15715058).

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3. Connect the inflatable restraint front end discriminating sensor harness
connector to the sensor.
4. Install the Connector Position Assurance (CPA) to the inflatable restraint front
end discriminating sensor harness connector.
5. Install the off road skid plate in equipped.
6. Enable the SIR system. Refer to Enabling the SIR System in SIR .

Instrument Panel Inflatable Restraint Module Switch Replacement

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Document ID: 186785


Removal Procedure

1. Caution: This vehicle is equipped with a Supplemental Inflatable Restraint


(SIR) System. Failure to follow the correct procedure could cause the following
conditions:
o Air bag deployment
o Personal injury
o Unnecessary SIR system repairs
In order to avoid the above conditions, observe the following guidelines:
o
o

Refer to SIR Component Views in order to determine if you are


performing service on or near the SIR components or the SIR wiring.
If you are performing service on or near the SIR components or the SIR
wiring, disable the SIR system. Refer to Disabling the SIR System.

Disable the SIR system. Refer to Disabling the SIR System in SIR .
2. Use a flat-bladed tool in order to pry the switch from the instrument panel.

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3. Remove the switch from the instrument panel.


4. Disconnect the electrical connections, as needed.

Installation Procedure

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1. Connect the electrical connections, as needed.
2. Install the switch to the instrument panel by firmly pressing the switch into
place.
3. Enable the SIR system. Refer to Enabling the SIR System in SIR .

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TABLA DE CONVESION DE
MEDIDAS
US English/Metric Conversion

In order to convert English units to metric units, multiply the English units by the
conversion factor shown in the conversion table.
In order to convert metric units to English units, divide the metric units by the
conversion factor shown in the conversion table.
English
in
ft
yd
mi

sq in
sq ft
sq yd

cu in
qt
gal
cu yd
lb
ton

kg
oz
lb

Multiply/ Divide by
LENGTH
25
0.3048
1
2
AREA
645
6
0.0929
1
VOLUME
16387
16
0.0164
1
4
1
MASS
0.4536
907
1
FORCE
10
0.2780
4

Metric
mm
m
km
sq mm
sq cm
sq m

cu mm
cu cm
L
cu m

kg
tonne (t)

newtons (N)

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Document ID: 201550

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ft/s
in/s
lb in
lb ft
hp

Foot Candle
mph
F
C
mpg

m/s

N-m

kW
kPa
kPa

lm/m
km/h
C
F
L/km

Decimal and Metric Equivalents


Document ID: 228262
Fraction (in)
1/64
1/32
3/64
1/16
5/64
3/32
7/64
1/8
9/64
5/32
11/64
3/16
13/64

Decimal (in)
0.015625
0.03125
0.046875
0.0625
0.078125
0.09375
0.109375
0.125
0.140625
0.15625
0.171875
0.1875
0.203125

Metric (mm)
0.39688
1
1
2
2
2
3
3
4
4
4
5
5

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inches of Mercury
inches of H2O
lb/sq in

ACCELERATION
0.3048
0.0254
TORQUE
0.11298
1
POWER
1
PRESSURE (STRESS)
3
0.2491
7
LIGHT
11
VELOCITY
2
TEMPERATURE
5/9(F-32)
9/5(C+32)
FUEL PERFORMANCE
2

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0.21875
0.234375
0.25
0.265625
0.28125
0.296875
0.3125
0.328125
0.34375
0.359375
0.375
0.390625
0.40625
0.421875
0.4375
0.453125
0.46875
0.484375
0.5
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

6
6
6
7
7
8
8
8
9
9
10
10
10
11
11
12
12
12
13
13
13
14
14
15
15
15
16
16
17
17
17
18
18
19
19
19
20
20
21
21
21
22

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7/32
15/64
1/4
17/64
9/32
19/64
5/16
21/64
11/32
23/64
3/8
25/64
13/32
27/64
7/16
29/64
15/32
31/64
1/2
33/64
17/32
35/64
9/16
37/64
19/32
39/64
5/8
41/64
21/32
43/64
11/16
45/64
23/32
47/64
3/4
49/64
25/32
51/64
13/16
53/64
27/32
55/64

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7/8
57/64
29/32
59/64
15/16
61/64
31/32
63/64
1

1
1
1
1
1
1
1
1
1

22
23
23
23
24
24
25
25
25

Document ID: 204389


This service manual uses various symbols in order to describe different service
operations.

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1. Front of Vehicle
2. View Detail

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Arrows and Symbols

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2. View Detail
3. Ambient Air Mixed With Another Gas or Indicate Temperature Change
4. Motion or Direction
5. View Angle
6. Dimension (1:2)
7. Ambient/Clean Air Flow or Cool Air Flow

9. Task Related
10. Sectioning (1:3)
11. Gas Other Than Ambient Air or Hot Air Flow
12. Lubrication Point Grease or Jelly
13. Multidirectional Arrow

Document ID: 204389

Transmission ID and VIN Derivative Location Document ID: 142147

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8. Lubrication Point Oil or Fluid

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All engines and transmissions, as well as removable roof panels are stamped or
laser etched with a partial Vehicle Identification Number (VIN), which was
derived from the complete VIN. A VIN derivative contains the following nine
positions:
o

Position 1 is the GM division identifier.


1 = Chevrolet

Position 2 is the model year code.

Position 3 is the assembly plant code.


5 = Bowling Green, KY

Positions 49 contain the assembly plant sequential number for the


vehicle.

A VIN derivative can be used to determine if a vehicle contains the original


engine, transmission or removable roof panel, by matching the VIN derivative
positions to their accompanying positions in the complete VIN:
o
o
o
o

VIN derivative position 1 = VIN position 3


VIN derivative position 2 = VIN position 10
VIN derivative position 3 = VIN position 11
VIN derivative positions 49 = VIN positions 1217

Borg Warner T-56 Manual Transmission

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v = 1997

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The 6-speed manual transmission, the Borg Warner T-56 (RPO MM6), is
stamped with a VIN derivative on the LH side of the transmission case.

Hydra-Matic 4L60E Automatic Transmission


The 4-speed overdrive automatic transmission, the Hydra-Matic 4L60-E (RPO
M30), is stamped or laser etched with a transmission identification number and a
VIN derivative.

The transmission identification number provides the transmission model and


when it was built. The transmission ID number is located on the bottom of the
case just rear of the oil pan.
VIN Location

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1. VIN Derivative Optional Location LH
2. VIN Derivative Primary Location

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3. VIN Derivative Optional Location RH


4. VIN Derivative Optional Location RH
The VIN derivative will be placed in one of four locations illustrated.

Transmission ID and VIN Derivative Location Document ID: 179231

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1. (8 = 1998)
2. Hydra-Matic 4L60-E
4. Julian Date (or Day of the Year)
5. Shift Built (A, B, j = First Shift; C, H, w = Second Shift)

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6. Model
7. Transmission ID Location
8. Hydra-Matic 4L60-E
9. Julian Date (or Day of the Year)
10. Serial No.
11. Shift Built (A, B, j = First Shift; C, H, w = Second Shift)

13. (8 = 1998)
14. Transmission ID Location

Document ID: 179231

Transmission ID and VIN Derivative Location Document ID: 179596

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1. Calendar Year
2. Julian Date of the Year
3. Shift and Line Number
4. Calendar Year

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12. Model

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5. Model
6. Serial Number in Base Code 31
7. Plant
8. Broadcast Date
9. Transaxle
10. Transaxle I.D. Tag Location

Document ID: 179596

Transmission ID and VIN Derivative Location Document ID: 228377


Transmission ID and VIN Derivative Location 4T60E/4T65E

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11. Transaxle Partial Vin Location

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1. Goodwrench Tag Location


2. Year
3. Not Used
4. Remanufacturing Site Code
5. Serial Number
6. Julian Date
7. Year Remanufactured
8. Model

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9. Transmission Identification Plate Location


10. Model Year
11. Line Build
12. GM Production Code
13. Julian Date
14. Shift

16. Serial Number in Base Code 31


17. w = Warren Assembly Plant
18. 4T65E
19. Model
20. Vehicle Identification Number (VIN) Derivative Stamping Location
All automatic transmissions have a metal identification (ID) nameplate (9) attached to
the case exterior.
Transmission VIN Location 4T65E, M15/MN3/MN7

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The primary (1) and secondary (2) Manual Tooling VIN Derivative Locations are on the
casting of the transmission housing.
Transaxle VIN Derivative Stamping

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15. Model

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The location for the Semi-Automatic VIN derivative (1) is on the transmission housing.

Document ID: 228377

Transmission ID and VIN Derivative Location Document ID: 228531

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All automatic transmissions have a metal identification (ID) nameplate (1)
attached to the case exterior.

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1. Transaxle
1. Transaxle
2. Calendar Year
2. Calendar Year
3. Julian Date or Day of the Year
3. Julian Date or Day of the Year
4. Shift (a=First Shift, b=Second Shift, c=Third Shift)
5. Model
6. Serial Number in Base Code 31
7. Plant
8. Hydramatic 4T40 E
9. Serial Number

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10. Model
10. Model
11. Model Year
11. Model Year
12. Control Number
13. Line Built (1=Line 1, 2=Line 2, 3=Line 3, 4=Line 4)

Document ID: 228759

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1. Windsor, Canada
2. Calendar Year (6 = 1996)
3. Julian Date
4. Model Year (6 = 1996)
5. No Meaning
6. Model
7. Shift Built (a = First Shift; b = Second Shift; c = Third Shift)
8. Calendar Year (6 = 1996)

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Transmission ID and VIN Derivative Location -

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9. Model Year (96 = 1996)


10. Model
11. Serial Number
12. Julian Date
13. Transmission ID Location
14. VIN Location

Transmission Usage Document ID: 179070


S/T Truck Applications
TRUCK
BODY LINE &
TYPE TRUCK
TYPE
Chevrolet /
GMC
GMT325
2WD S Pick-Up /
S
Sonoma
Pick-Up
And
Extended
Cab
GM Postal
POST
S-Chassis
Chevrolet /
GMC
GMT325
4WD S Pick-Up /
T
Sonoma
Pick-Up
And
Extended
Cab

ENGINE FUEL ENGINE TRANSMISSION TRANSMISSION


SIZE SYSTEM RPO
USED
RPO
2.2L L4
4.3L V6

SFI
CSFI

LN2
LF6

4L60E / NV1500
4L60E / NV3500

M30 / MW2
M30 / M50

4.3L V6

CSFI

L35

4L60E / NV3500

M30 / M50

2.2L L4

SFI

LN2

3L30

MD2

4.3L V6

CSFI

LF6

4L60E / NV3500

M30 / M50

4.3L V6

CSFI

L35

4L60E / NV3500

M30 / M50

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Document ID: 228759

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CSFI

LF6

4L60E / NV3500

M30 / M50

CSFI

L35

4L60E / NV3500

M30 / M50

CSFI

L35

4L60E

M30

Document ID: 179070

Transfer Case Identification


Document ID: 232748
New Venture Transfer Case Identification

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Borg-Warner Transfer Case Identification

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Chevrolet / 4.3L V6
GMC
GMT325
4WD
T
Blazer / 4.3L V6
Jimmy
Sport
Utility
Oldsmobile
GMT325
OLDS
4WD
4.3L V6
T
Bravada
Sport
Utility

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An identification tag is attached to the rear half of the transfer case. The tag provides the
following information:

The transfer case model number


The low range reduction ratio
An assembly number

The information on this tag is necessary for servicing the transfer case. If the tag is
removed or becomes dislodged during service operations, keep the identification tag
with the unit.

Document ID: 232748

Abbreviations and Meanings


Document ID: 102499
The following abbreviations may appear in this manual.

Abbreviations Table
Abbreviation

Meaning
A

A
ABS
A/C
AC

Ampere(s)
Antilock Brake System
Air Conditioning
Alternating Current

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B+
BBARO
batt
BBV
BCM
BHP
BLK
BLU
BP
BPM
BPMV
BPP
BRN
BTDC
BTSI
Btu

Accessory, Automatic Climate Control


Air Cleaner
Air Conditioning Refrigerant, Recovery, Recycling, Recharging
Analog to Digital
Automatic Door Lock
Air/Fuel (Ratio)
Secondary Air Injection
Automatic Level Control
Amplitude Modulation/Frequency Modulation
Antenna
Accelerator Pedal
American Petroleum Institute
Accelerator Pedal Position
Adjustable Part Throttle
Automatic Restraint System
Acceleration Slip Regulation
Automatic Transmission/Transaxle
Automatic Temperature Control
After Top Dead Center
Automatic
average
All Wheel Drive
American Wire Gage
B
Battery Positive Voltage
Battery Negative Voltage
Barometric (pressure)
battery
Brake Booster Vacuum
Body Control Module
Brake Horsepower
Black
Blue
Back Pressure
Brake Pressure Modulator
Brake Pressure Modulator Valve
Brake Pedal Position
Brown
Before Top Dead Center
Brake Transmission Shift Interlock
British thermal units
C

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ACC
ACL
ACR4
A/D
ADL
A/F
AIR
ALC
AM/FM
Ant
AP
API
APP
APT
ARS
ASR
A/T
ATC
ATDC
Auto
avg
AWD
AWG

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Degrees Celsius
Charge Air Cooler
Corporate Average Fuel Economy
Calibration
Camshaft
California Air Resources Board
cubic centimeters
Central Control Module
Cycling Clutch Orifice Tube
Climate Control Panel
Compact Disc
Commutator End
Cold Engine Air Bleed
Counter Electromotive Force
cubic feet per minute
center of gravity
Cubic Inch Displacement
Crankshaft Position
Circuit
Closed Loop
Cigar Lighter
Camshaft Position
Compressed Natural Gas
Carbon Monoxide
Carbon Dioxide
Coaxial
Communication
Connector
Connector Position Assurance
Clutch Pedal Position
Central Power Supply
Central Processing Unit
Cathode Ray Tube
Cathode Ray Tube Controller
Charging System
Closed Throttle Position
cubic foot/feet
cubic inch/inches
Contant Velocity (joint)
Continuously Variable Road Sensing Suspension
Cylinder(s)
D

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C
CAC
CAFE
Cal
Cam
CARB
cc
CCM
CCOT
CCP
CD
CE
CEAB
CEMF
cfm
cg
CID
CKP
CKT
CL
C/Ltr
CMP
CNG
CO
CO2
Coax
COMM
Conn
CPA
CPP
CPS
CPU
CRT
CRTC
CS
CTP
cu ft
cu in
CV
CVRSS
Cyl

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Delayed Accessory Bus


decibels
decibels on A-weighted scale
Direct Current
Door Control Module
Drive End
Digital Electronic Controller
Diagnostic Energy Reserve Module
Distributor Ignition
diameter
Driver Information Center
Differential
Dark
Data Link Connector
Digital Multimeter
Dual Overhead Camshafts
Driver
Daytime Running Lamps
Diagnostic Trouble Code
E
EBCM Electronic Brake Control Module
EBTCM Electronic Brake and Traction Control Module
EC
Electrical Center
ECC
Electronic Climate Control
ECI
Extended Compressor at Idle
ECL
Engine Coolant Level
ECM
Engine Control Module
ECS
Emission Control System
ECT
Engine Coolant Temperature
EEPROM Electronically Erasable Programmable Read Only Memory
EEVIR Evaporator Equalized Values in Receiver
EFE
Early Fuel Evaporation
EGR
Exhaust Gas Recirculation
EGR TVV Exhaust Gas Recirculation Thermal Vacuum Valve
EI
Electronic Ignition
ELAP
Elapsed
ELC
Electronic Level Control
E/M
English / Metric
EMF
Electromotive Force
Eng
Engine
EOP
Engine Oil Pressure
EOT
Engine Oil Temperature

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DAB
dB
dBA
DC
DCM
DE
DEC
DERM
DI
dia
DIC
Diff
DK
DLC
DMM
DOHC
DR
DRL
DTC

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F
FC
FDC
FED
FEDS
FF
FI
FMVSS
F/P
ft
FT
F4WD
4WAL
4WD
FW
FWD
g
GA
gal
gas
GCW
Gen
GL
GM
GM SPO
gnd
gpm
GRN
GRY

Environmental Protection Agency


Exhaust Pressure Regulator
Erasable Programmable Read Only Memory
Electronic Suspension Control
Electrostatic Discharge
Electronic Throttle Control, Electronic Temperature Control
Electronic Touch Climate Control
Electronically Tuned Receiver
Evaporative Emission
Electronic Variable Orifice
Exhaust
F
Degrees Fahrenheit
Fan Control
Fuel Data Center
Federal (all United States except California)
Fuel Enable Data Stream
Flexible Fuel
Fuel Injection
Federal Motor Vehicle Safety Standards
Fuel Pump
foot/feet
Fuel Trim
Full Time Four Wheel Drive
Four Wheel Antilock
Four Wheel Drive
Flat Wire
Front Wheel Drive
G
grams, gravitational accelaration
Gage
gallon
gasoline
Gross Combination Weight
Generator
Gear Lubricant
General Motors
General Motors Service Parts Operations
ground
gallons per minute
Green
Gray

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EPA
EPR
EPROM
ESC
ESD
ETC
ETCC
ETR
EVAP
EVO
Exh

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GVWR

IAC
IAT
IC
ICM
ID
IDI
ign
ILC
in
INJ
inst
I/P
IPC
I/PEC
ISC
ISO
ISS

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H
H2O
Harn
HC
H/CMPR
HD
HDC
hex
Hg
Hi Alt
HO2S
hp
HPL
HPS
HPV
Htd
HTR
HUD
HVAC
HVACM
HVM
Hz

Gross Vehicle Weight Rating


H
Hydrogen
Water
Harness
Hydrocarbons
High Compression
Heavy Duty
Heavy Duty Cooling
hexagon
Mercury
High Altitude
Heated Oxygen Sensor
horsepower
High Pressure Liquid
High Performance System
High Pressure Vapor
Heated
Heater
Head-up Display
Heater-Vent-Air Conditioning
Heater-Vent-Air Conditioning Module
Heater Vent Module
Hertz
I
Idle Air Control
Intake Air Temperature
Integrated Circuit, Ignition Control
Ignition Control Module
Identification, Inside Diameter
Integrated Direct Ignition
ignition
Idle Load Compensator
inch/inches
Injection
instantaneous
Instrument Panel
Instrument Panel Cluster
Instrument Panel Electrical Center
Idle Speed Control
International Standards Organization
Input Speed Shaft

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K
Keep Alive Memory
Keyboard Display Driver
kilogram
kilohertz
kilometer
kilometers per hour
kilometers per liter
kilopascals
Knock Sensor
kilovolts
L
L
L4
L6
lb
lb ft
lb in
LCD
LDCL
LDCM
LED
LF
LH
lm
LR
lt
LT
MAF
Man
MAP
MAT
max
M/C
MDP
MFI
mi
MIL
min
ml
mm

Liter
Four Cylinder Engine, In-line
Six Cylinder Engine, In-Line
pound
pound feet (torque)
pound inch (torque)
Liquid Crystal Display
Left Door Closed Locking
Left Door Control Module
Light Emitting Diode
Left Front
Left Hand
lumens
Left Rear
left
Light
M
Mass Air Flow
Manual
Manifold Absolute Pressure
Manifold Absolute Temperature
maximum
Mixture Control
Manifold Differential Pressure
Multiport Fuel Injection
miles
Malfunction Indicator Lamp
minimum
milliliter
millimeter

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KAM
KDD
kg
kHz
km
km/h
km/l
kPa
KS
kV

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mpg
mph
ms
MST
M/T
MV
mV

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miles per gallon


miles per hour
millisecond
Manifold Surface Temperature
Manual Transmission/Transaxle
Megavolt
millivolt
N
NAES
North American Export Sales
NC
Normally Closed
NEG
Negative
Neu
Neutral
NLGI
National Lubricating Grease Institute
N-m
Newton-meter (torque)
NO
Normally Open
NOx
Oxides of Nitrogen
NPTC
National Pipe Thread Coarse
NPTF
National Pipe Thread Fine
NVRAM Non Volatile Random Access Memory
O
O2
Oxygen
O2S
Oxygen Sensor
OBD II On-Board Diagnostics II
OC
Oxidation Converter (Catalytic)
OD
Outside Diameter
ODO
Odometer
OE
Original Equipment
OEM
Original Equipment Manufacturer
OHC
Overhead Camshaft
OL
Open Loop
ORN
Orange
OSS
Output Shaft Speed
oz
ounce(s)
P
PAG
Polyalkylene Glycol
PASS
Passenger
PASS-Key Personalized Automotive Security System
P/B
Power Brakes
PC
Pressure Control
PCB
Printed Circuit Board
PCM
Powertrain Control Module
PCS
Pressure Control Solenoid

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qt
R-12
R-134a
RAM
RAP
RAV
RCDLR
RDCM
Ref
Rev
RF
RFA
RFI
RH
RKE
Rly
ROM
RPM

Positive Crankcase Ventilation


Permanent Magnet (Generator)
Part Number
Pink
Park/Neutral Position
Park, Reverse, Neutral, Drive, Low
Pilot Operated Absolute (Valve)
Positive
Potentiometer (Variable Resistor)
Purple
parts per million
Programmable Read Only Memory
Power Steering
Power Sliding Door
Power Steering Pressure
pounds per square inch
pounds per square inch absolute
pounds per square inch gage
pint
Pulse Width Modulated
Q
quart(s)
R
Refrigerant-12
Refrigerant-134a
Random Access Memory (non permanent memory devise, memory
contents are lost when power is removed)
Retained Accessory Power
Remote Activation Verification
Remote Control Door Lock Receiver
Right Door Control Module
Reference
Reverse
Right Front, Radio Frequency
Remote Function Actuation
Radio Frequency Interference
Right Hand
Remote Keyless Entry
Relay
Read Only Memory (permanent memory devise, memory contents are
retained when power is removed)
Engine Speed (Revolutions Per Minute)

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PCV
PM
P/N
PNK
PNP
PRNDL
POA
POS
POT
PPL
ppm
PROM
P/S
PSD
PSP
psi
psia
psig
pt
PWM

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RPO
RR
rt
RTD
RTV
RWAL
RWD

Tach
TBI
TC
TCC
TCS
TDC
TEMP
Term
TFP
TFT

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s
SAE
SC
SCB
SCM
SDM
SEO
SFI
SI
SIR
SLA
sol
SO2
SP
SPO
sq ft
sq in
SRC
SRI
ST
S4WD
Sw
syn

Regular Production Option


Right Rear
right
Real Time Damping
Room Temperature Vulcanizing (sealer)
Rear Wheel Antilock
Rear Wheel Drive
S
second(s)
Society of Automotive Engineers
Supercharger
Supercharger Bypass
Seat Control Module
Sensing and Diagnostic Module
Special Equipment Option
Sequential Multiport Fuel Injection
System International (modern version of metric system)
Supplemental Inflatable Restraint
Short/Long Arm (suspension)
solenoid
Sulfur Dioxide
Splice Pack
Service Parts Operations
square foot/feet
square inch/inches
Service Ride Control
Service Reminder Indicator
Scan Tool
Selectable Four Wheel Drive
Switch
synchronizer
T
Tachometer
Throttle Body Fuel Injection
Turbocharger
Torque Converter Clutch
Traction Control System
Top Dead Center
Temperature
Terminal
Transmission Fluid Pressure
Transmission Fluid Temperature

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UART
U/H
U/HEC
U-joint
UTD
UV
V
V6
V8
Vac
VAC
VATS
VCM
VDOT
VDV
vel
VES
VF
VIO
VIN
VMV
VR
V ref
VSS
w/
W/B
WHL

Transmission Oil Cooler


Throttle Position
Terminal Positive Assurance
Tire Pressure Monitoring
Transmission Range
Transmission/Transaxle
Throttle Valve
Television and Radio Suppression
Thermal Vacuum Valve
Three Way Converter (Catalytic)
Three Way + Oxidation Converter (Catalytic)
Thermal Expansion Valve
U
Universal Asynchronous Receive and Transmit
Underhood
Underhood Electrical Center
Universal Joint
Universal Theft Deterrent
Ultraviolet
V
Volt(s), Voltage
Six Cylinder Engine, V-Type
Eight Cylinder Engine, V-Type
Vacuum
Vehicle Access Code
Vehicle Anti-Theft System
Vehicle Control Module
Variable Displacement Orifice Tube
Vacuum Delay Valve
velocity
Variable Effort Steering
Vacuum Fluorescent
Violet
Vehicle Identification Number
Vacuum Modulator Valve
Voltage Regulator
Voltage Reference
Vehicle Speed Sensor
W
with
Wheel Base
Wheel

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TOC
TP
TPA
TPM
TR
TRANS
TV
TVRS
TVV
TWC
TWC+OC
TXV

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WHT
w/o
WOT
W/P
W/S
WSS
WU-OC
WU-TWC

yd
YEL

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X-valve

White
without
Wide Open Throttle
Water Pump
Windshield
Wheel Speed Sensor
Warm Up Oxidation Converter (Catalytic)
Warm Up Three Way Converter (Catalytic)
X
Expansion valve
Y
yard(s)
Yellow

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TRANSMISION AUTOMATICA
4L60
Fastener Tightening Specifications Document ID: 191229

Application
Accumulator Cover to Case Bolt
Case Extension to Case Bolt
Case Extension to Case Bolt (4WD Shipping)
Converter Housing to Case Screw
Cooler Pipe Connector
Detent Spring to Valve Body Bolt
Forward Accumulator Cover to Valve Body Bolt
Line Pressure Plug
Manual Shaft to Inside Detent Lever Nut
Oil Passage Cover to Case Bolt
Park Brake Bracket to Case Bolt
Plate to Case Bolt (Shipping)
Plate to Converter Bolt (Shipping)
Pressure Control Solenoid Bracket to Valve Body Bolt
Pump Assembly to Case Bolt
Pump Cover to Pump Body Bolt

Specification
Metric
English
8.014.0 N610 lb ft
m
42.0
35.0
48.0 N-m
39.4 lb ft
11.2
8.3
22.6 N-m
16.7 lb ft
65.0
4855 lb ft
75.0 N-m
35.0
2630 lb ft
41.0 N-m
20.0
1520 lb ft
27.0 N-m
8.014.0 N610 lb ft
m
8.014.0 N610 lb ft
m
27.0
2025 lb ft
34.0 N-m
814.0 N-m 610 lb ft
27.0
2025 lb ft
34.0 N-m
27.0
2025 lb ft
34.0 N-m
27.0
2025 lb ft
34.0 N-m
8.014.0 N610 lb ft
m
26.0
1924 lb ft
32.0 N-m
20.0
1520 lb ft
27.0 N-m

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Fastener Tightening Specifications (Diagnosis 4L60-E)

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Speed Sensor Retainer Bolt


Transmission Fluid Pressure Manual Valve Position
Switch to Valve Body Bolt
Transmission Oil Cooler Pipe Fitting
Transmission Oil Pan to Case Bolt
Valve Body to Case Bolt

Fluid Capacity
Document ID: 6951
Fluid Capacity
Specification
Application

Metric
4.7 liters
10.6 liters

Pan Removal
Overhaul

English
5 quarts
11 quarts

Transmission End Play Check


Document ID: 19572
Transmission End Play Washer Selection Chart
Identification
67
68
69
70
71
72
73
74

Washer Thickness (mm)


1.871.97
2.042.14
2.212.31
2.382.48
2.552.65
2.722.82
2.892.99
3.063.16

Low and Reverse Clutch Spacer Plate Selection

Washer Thickness (in)


0.0740.078
0.0800.084
0.0870.091
0.0940.098
0.1000.104
0.1070.111
0.1130.117
0.1200.124

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8.014.0 N610 lb ft
m
10.5
7.710 lb ft
13.5 N-m
8.014.0 N610 lb ft
m
35.0
2630 lb ft
41.0 N-m
9.513.8 N710 lb ft
m
8.014.0 N610 lb ft
m

Solenoid Assembly to Case Bolt

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Document ID: 19577


Measured Dimension
28.06527.545 mm (1.105
1.084 in)
28.58628.066 mm (1.125
1.105 in)
27.54427.026 mm (1.084
1.064 in)

Identification
None
0
1

Selective Plate
Thickness
1.6841.829 mm (0.066
0.072 in)
1.3141.168 mm (0.052
0.046 in)
2.1982.344 mm (0.087
0.092 in)

Forward Clutch Backing Plate Selection


Document ID: 58260
Forward Clutch Backing Plate Selection
Plate Thickness
6.927.07 mm (0.2720.278 in)
6.336.48 mm (0.2490.255 in)
5.745.89 mm (0.2260.232 in)
5.155.30 mm (0.2030.208 in)
4.564.71 mm (0.1800.185 in)
Backing Plate Travel: 0.7661.756 mm (0.0300.069 in)

Identification
A
B
C
D
E

Third and Fourth Clutch Backing Plate Selection


Document ID: 57950
3rd and 4th Clutch Backing Plate Selection Table
Dimension
Identification
5.885.68 mm (0.2310.224 in)
A
4.994.76 mm (0.1960.187 in)
B
4.103.90 mm (0.1610.154 in)
C
Use a backing plate which gives the correct travel. The travel should be 2.10
0.90 mm (0.0830.035 in).

Document ID: 57950

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Document ID: 19577

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Reverse Input Clutch Backing Plate Selection


Document ID: 19581
Reverse Input Clutch Backing Plate Selection Table
Identification
2
3
4

Document ID: 19581

Fluid Pump Rotor and Slide Measurement


Document ID: 19582
Oil Pump Rotor and Slide Measurement
Thickness (mm)
Oil Pump Rotor
17.94817.961
17.96117.974
17.97417.987
17.98718.000
18.00018.013
Oil Pump Slide
17.94817.961
17.96117.974
17.97417.987
17.98718.000
18.00018.013

Document ID: 19582

Thickness (in)
0.70660.7071
0.70710.7076
0.70760.7081
0.70810.7086
0.70860.7091
0.70660.7071
0.70710.7076
0.70760.7081
0.70810.7086
0.70860.7091

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Plate Thickness
7.2497.409 mm (0.2850.292 in)
6.6786.519 mm (0.2630.257 in)
5.9475.787 mm (0.2340.228 in)
Backing Plate Travel: 1.021.94 mm (0.0400.076 in)

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TRANSAXLE/ TRANSAXLE/
BODY CAR LINE ENGINE FUEL ENGINE
TRANSMISSION TRANSMISSION
TYPE (DIVISION) SIZE SYSTEM RPO
USED
RPO
Prism
S
1.6L L4
MFI
L01
A131 / M5
MB3 / MB5
(Chevrolet)
Prism
S
1.8L L4
SFI
LV6
A245E / M5
M57 / MB4
(Chevrolet)
Metro /
Firefly
M (Chevrolet) / 1.0L L3
TBI
LP2
M5
M58
(GM Of
Canada)
Metro /
Firefly
M (Chevrolet) / 1.3L L4
MFI
L72
A3 / M5
M60 / M42
(GM Of
Canada)
Cavalier
3T40 / 4T40E /
MD9 / MN4 /
J
2.2L L4
SFI
LN2
(Chevrolet)
M5
MK7
Cavalier
J
2.4L L4
SFI
LD9
4T40E / M5
MN4 / MJ1
(Chevrolet)
Sunfire
3T40 / 4T40E /
MD9 / MN4 /
J
2.2L L4
SFI
LN2
(Pontiac)
M5
MK7
Sunfire
J
2.4L L4
SFI
LD9
4T40E / M5
MN4 / MJ1
(Pontiac)
Malibu
N
2.4L L4
SFI
LD9
4T40E
MN4
(Chevrolet)
Malibu
N
3.1L V6
SFI
L82
4T40E
MN4
(Chevrolet)
Skylark
N
2.4L L4
SFI
LD9
4T60E / M5
M13 / MJ1
(Buick)
Skylark
N
3.1L V6
SFI
L82
4T60E
M13
(Buick)
Achieva
N
2.4L L4
SFI
LD9
4T60E / M5
M13 / MJ1
(Oldsmobile)
Achieva
N
3.1L V6
SFI
L82
4T60E
M13
(Oldsmobile)
Cutlass
N
3.1L V6
SFI
L82
4T40E
MN4
(Oldsmobile)
Grand Am
N
2.4L L4
SFI
LD9
4T60E / M5
M13 / MJ1
(Pontiac)
Grand Am
N
3.1L V6
SFI
L82
4T60E
M13
(Pontiac)
Venture
U
3.4L V6
SFI
LA1
4T60E
M13
(Chevrolet)
U
Trans Sport 3.4L V6
SFI
LA1
4T60E
M13

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U
W
W
W

W
W
W
W

F
F
F
F
G
G
C
V
P
H

3.4L V6

SFI

LA1

4T60E

M13

3.8L V6

SFI

L36

4T65E

M15

3.5L V6

SFI

LX5

4T65E ADV.
CONTROL

MN3

3.1L V6

SFI

L82

4T60E

M13

3.8L V6

SFI / SFI
(SC)

L36 /
L67

4T65E / 4T65EHD

M15 / MN7

3.1L V6

SFI

L82

4T60E

M13

3.1L V6

SFI

L82

4T60E

M13

3.8L V6

SFI / SFI
(SC)

L36 /
L67

4T65E / 4T65EHD

M15 / MN7

3.1L V6

SFI

L82

4T60E

M13

3.8L V6

SFI

L36

4T65E

M15

3.8L V6

SFI

L36

4L60E / M5

M30 / M49

5.7L V8

SFI

LS1

4L60E / M6

M30 / MM6

3.8L V6

SFI

L36

4L60E / M5

M30 / M49

5.7L V8

SFI

LS1

4L60E / M6

M30 / MM6

4.0L V8

SFI

L47

4T80E

MH1

3.8L V6

SFI / SFI
(SC)

L36 /
L67

4T65E / 4T65EHD

M15 / MN7

3.8L V6

SFI / SFI
(SC)

L36 /
L67

4T65E / 4T65EHD

M15 / MN7

3.0L V6

SFI

L81

4L30E

ML4

EV

N/A

LN1

N/A

N/A

3.8LV6

SFI

L36

4T65E

M15

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(Pontiac)
Silhouette
(Oldsmobile)
Intrigue
(Oldsmobile)
Intrigue
(Oldsmobile)
Grand Prix
(Pontiac)
Grand Prix
(Pontiac)
Century
(Buick)
Regal
(Buick)
Regal
(Buick)
Monte Carlo
/ Lumina
(Chevrolet)
Monte Carlo
Z34 /
Lumina LTZ
(Chevrolet)
Camaro
(Chevrolet)
Camaro
(Chevrolet)
Firebird
(Pontiac)
Firebird
(Pontiac)
Aurora
(Oldsmobile)
Riviera
(Buick)
Park Avenue
/ Ultra
(Buick)
Catera
(Cadillac)
EV1
(GMEV)
Eighty-Eight
/ Regency
(Oldsmobile)

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3.8L V6

SFI / SFI
(SC)

L36 /
L67

4T65E / 4T65EHD

M15 / MN7

3.8L V6

SFI / SFI
(SC)

L36 /
L67

4T65E / 4T65EHD

M15 / MN7

3.8L V6

SFI

L36

4T65E

M15

4.6L V8

SFI

LD8 /
L37

4T80E

MH1

4.6L V8

SFI

LD8 /
L37

4T80E

MH1

4.6L V8

SFI

LD8/
L37

4T80E

MH1

5.7L V8

SFI

LS1

4L60E / T-56

M30 / MM6

TRUCK
LINE &
BODY TRUCK ENGINE FUEL ENGINE TRANSMISSION TRANSMISSION
TYPE TYPE
SIZE SYSTEM RPO
USED
RPO
C1500 Chevrolet 5.7L V8 CSFI
L31
4L60E
M30
/ GMC
GMT430
Suburban
2WD 1/2 TON
C2500 Chevrolet 5.7L V8 CSFI
L31
4L60E
M30
/ GMC 7.4L V8
SFI
L29
4L80E
MT1
GMT430
Suburban
2WD 3/4 TON
C1500 Chevrolet 5.7L V8 CSFI
L31
4L60E
M30
/ GMC
GMT420
Tahoe /
Yukon
2WD 1/2 TON
K1500 Chevrolet 5.7L V8 CSFI
L31
4L60E
M30
/ GMC 6.5L V8
SFI
L56
4L80E
MT1
GMT430 DSL
Suburban TURB.

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LSS
(Oldsmobile)
Bonneville /
H
SSE / SSEi
(Pontiac)
Le Sabre
H
(Buick)
Eldorado /
Eldorado
E
Touring
Coupe
(Cadillac)
Seville SLS /
K
Seville STS
(Cadillac)
DeVille /
DeVille
K-sp
Concours
(Cadillac)
Corvette
Y
(Chevrolet)
H

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Body
Type

C2500

K2500

C3500

5.7L V8
6.5L V8
DSL
TURB.
7.4L V8

CSFI
SFI

L31
L65

4L60E
4L80E

M30
MT1

SFI

L29

4L80E

MT1

5.7L V8
6.5L V8
DSL
TURB.

CSFI
SFI

L31
L56

4L80E / NV4500
4L80E / NV3500

MT1 / MW3
MT1 / MG5

5.7L V8

CSFI

L31

4L60E

M30

Truck Line &


Truck Type

Chevrolet / GMC
Chassis Cab
2WD - 3/4 TON
Single And Dual
Rear Tires

Chevrolet / GMC
Chassis Cab
4WD - 1TON
Single And Dual
Rear Tires

Engine Fuel Engine Transmission


Size System RPO
Used
4L80E /
5.7L V8 CSFI L31
NV4500
6.5L V8
SFI
L56
4L80E
DSL
TURB.
6.5L V8
4L80E /
SFI
L65
DSL
NV4500
TURB.
L29
4L80E
7.4L V8 SFI
4L80E /
5.7L V8 CSFI L31
NV4500
6.5L V8
SFI
L56
4L80E
DSL
TURB.
6.5L V8
4L80E /
SFI
L65
DSL
NV4500
TURB.
7.4L V8 SFI
L29
4L80E
6.5L V8
SFI
L65
4L80E
DSL
TURB.

Chevrolet / GMC
Chassis Cab
2WD - 1 TON
Single And Dual
7.4L V8
Rear Tires

SFI

L29

4L80E

Transmission
RPO
MT1 / MW3
MT1

MT1 / MW3
MT1
MT1 / MW3
MT1

MT1 / MW3
MT1
MT1
MT1

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4WD 1/2 TON


K2500 Chevrolet
/ GMC
GMT430
Suburban
4WD 3/4 TON
K1500 Chevrolet
/ GMC
GMT410
Tahoe /
Yukon
4WD 1/2 TON
K1500 Chevrolet
/ GMC
GMT420
Tahoe /
Yukon
4DR,
4WD 1/2 TON

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Chevrolet / GMC
Chassis Cab
K3500
4WD - 1 TON
Single And Dual
Rear Tires
Chevrolet / GMC
Crew Cab And
Chassis Crew
C3500HD
Cab 2WD - 1
TON Single And
Dual Rear Tires

K3500

SFI

L65

4L80E

MT1

7.4L V8

SFI

L29

4L80E

MT1

6.5L V8
DSL
TURB.

SFI

L65

4L80E /
NV4500

MT1 / MW3

7.4L V8

SFI

L29

4L80E /
NV4500

MT1 / MW3

5.7L V8 CSFI

L31

4L80E /
NV4500

MT1 / MW3

6.5L V8
DSL
TURB.

SFI

L65

4L80E /
NV4500

MT1 / MW3

7.4L V8

SFI

L29

4L80E /
NV4500

MT1 / MW3

SFI

L65

4L80E

MT1

SFI

L29

4L80E

MT1

Chevrolet / GMC 6.5L V8


Crew Cab And
DSL
Chassis Crew TURB.
Cab 4WD - 1
TON Single And 7.4L V8
Dual Rear Tires

TRUCK
BODY LINE &
TYPE TRUCK
TYPE
Chevrolet /
GMC
GMT325
2WD S Pick-Up /
S
Sonoma
Pick-Up
And
Extended
Cab
GM Postal
POST
S-Chassis
Chevrolet /
GMC
GMT325
4WD S T
Pick-Up /
Sonoma
Pick-Up
And

ENGINE FUEL ENGINE TRANSMISSION TRANSMISSION


SIZE SYSTEM RPO
USED
RPO
2.2L L4
4.3L V6

SFI
CSFI

LN2
LF6

4L60E / NV1500
4L60E / NV3500

M30 / MW2
M30 / M50

4.3L V6

CSFI

L35

4L60E / NV3500

M30 / M50

2.2L L4

SFI

LN2

3L30

MD2

4.3L V6

CSFI

LF6

4L60E / NV3500

M30 / M50

4.3L V6

CSFI

L35

4L60E / NV3500

M30 / M50

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C3500

Chevrolet / GMC
Crew Cab And
Chassis Crew
Cab 2WD - 1
TON Single And
Dual Rear Tires

6.5L V8
DSL
TURB.

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Body
Type

Truck Line &


Truck Type
Chevrolet / GMC
2WD Astro /
M
Safari Mid Size
Van
Chevrolet / GMC
4WD Astro /
L
Safari Mid Size
Van
Chevrolet / GMC
Express / Savana
G1500
1/2 TON Full
Size Van
Chevrolet / GMC
Express / Savana
G2500
3/4 TON Full
Size Van

CSFI

LF6

4L60E / NV3500

M30 / M50

CSFI

L35

4L60E / NV3500

M30 / M50

CSFI

L35

4L60E

M30

Engine
Fuel Engine Transmission Transmission
Size System RPO
Used
RPO
4.3L V6

CSFI

L35

4L60E

M30

4.3L V6

CSFI

L35

4L60E

M30

4.3L V6
5.0L V8

CSFI
CSFI

L35
L30

4L60E
4L60E

M30
M30

5.7L V8

CSFI

L31

4L60E

M30

4.3L V6
5.0L V8

CSFI
CSFI

L35
L30

4L60E
4L60E

M30
M30

5.7L V8

CSFI

L31

4L60E

M30

4.3L V6

CSFI

L35

CSFI

L31

SFI

L65

4L80E

MT1

SFI

L29

4L80E

MT1

Chevrolet / GMC
5.7L V8
Express / Savana
G3500
1 TON Full Size 6.5L V8
Van
DSL
TURB.
7.4L V8

4L60E /
4L80E
4L60E /
4L80E

M30 / MT1
M30 / MT1

Specification
Application
All Metal Prevailing Torque Fasteners
6 mm
8 mm

Metric

English

0.4 N-m
0.8 N-m

4 lb in
7 lb in

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Extended
Cab
Chevrolet / 4.3L V6
GMC
GMT325
4WD
T
Blazer / 4.3L V6
Jimmy
Sport
Utility
Oldsmobile
GMT325
OLDS
4WD
4.3L V6
T
Bravada
Sport
Utility

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12 lb in
19 lb in
27 lb in
37 lb in
62 lb in
93 lb in
3 lb in
5 lb in
10 lb in
13 lb in
20 lb in
30 lb in
49 lb in
75 lb in

Specification
Application

Metric

All Metal Prevailing Torque Fasteners


1/4 in
0.5 N-m
5/16 in
0.8 N-m
3/8 in
1.3 N-m
7/16 in
1.8 N-m
1/2 in
2.3 N-m
9/16 in
3.2 N-m
5/8 in
4 N-m
3/4 in
7 N-m
Nylon Interface Prevailing Torque Fasteners
1/4 in
0.3 N-m
5/16 in
0.6 N-m
3/8 in
1 N-m
7/16 in
1.3 N-m
1/2 in
1.8 N-m
9/16 in
2.5 N-m
5/8 in
3.4 N-m
3/4 in
5 N-m
Abbreviation

Meaning
A

A
ABS
A/C
AC

Ampere(s)
Antilock Brake System
Air Conditioning
Alternating Current

English
4.5 lb in
7.5 lb in
11.5 lb in
16 lb in
20 lb in
28 lb in
36 lb in
54 lb in
3 lb in
5 lb in
9 lb in
12 lb in
16 lb in
22 lb in
30 lb in
45 lb in

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10 mm
1.4 N-m
12 mm
2.1 N-m
14 mm
3 N-m
16 mm
4.2 N-m
20 mm
7 N-m
24 mm
10.5 N-m
Nylon Interface Prevailing Torque Fasteners
6 mm
0.3 N-m
8 mm
0.6 N-m
10 mm
1.1 N-m
12 mm
1.5 N-m
14 mm
2.3 N-m
16 mm
3.4 N-m
20 mm
5.5 N-m
24 mm
8.5 N-m

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B+
BBARO
batt
BBV
BCM
BHP
BLK
BLU
BP
BPM
BPMV
BPP
BRN
BTDC
BTSI
Btu

Accessory, Automatic Climate Control


Air Cleaner
Air Conditioning Refrigerant, Recovery, Recycling, Recharging
Analog to Digital
Automatic Door Lock
Air/Fuel (Ratio)
Secondary Air Injection
Automatic Level Control
Amplitude Modulation/Frequency Modulation
Antenna
Accelerator Pedal
American Petroleum Institute
Accelerator Pedal Position
Adjustable Part Throttle
Automatic Restraint System
Acceleration Slip Regulation
Automatic Transmission/Transaxle
Automatic Temperature Control
After Top Dead Center
Automatic
average
All Wheel Drive
American Wire Gage
B
Battery Positive Voltage
Battery Negative Voltage
Barometric (pressure)
battery
Brake Booster Vacuum
Body Control Module
Brake Horsepower
Black
Blue
Back Pressure
Brake Pressure Modulator
Brake Pressure Modulator Valve
Brake Pedal Position
Brown
Before Top Dead Center
Brake Transmission Shift Interlock
British thermal units
C

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ACC
ACL
ACR4
A/D
ADL
A/F
AIR
ALC
AM/FM
Ant
AP
API
APP
APT
ARS
ASR
A/T
ATC
ATDC
Auto
avg
AWD
AWG

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Degrees Celsius
Charge Air Cooler
Corporate Average Fuel Economy
Calibration
Camshaft
California Air Resources Board
cubic centimeters
Central Control Module
Cycling Clutch Orifice Tube
Climate Control Panel
Compact Disc
Commutator End
Cold Engine Air Bleed
Counter Electromotive Force
cubic feet per minute
center of gravity
Cubic Inch Displacement
Crankshaft Position
Circuit
Closed Loop
Cigar Lighter
Camshaft Position
Compressed Natural Gas
Carbon Monoxide
Carbon Dioxide
Coaxial
Communication
Connector
Connector Position Assurance
Clutch Pedal Position
Central Power Supply
Central Processing Unit
Cathode Ray Tube
Cathode Ray Tube Controller
Charging System
Closed Throttle Position
cubic foot/feet
cubic inch/inches
Contant Velocity (joint)
Continuously Variable Road Sensing Suspension
Cylinder(s)
D

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C
CAC
CAFE
Cal
Cam
CARB
cc
CCM
CCOT
CCP
CD
CE
CEAB
CEMF
cfm
cg
CID
CKP
CKT
CL
C/Ltr
CMP
CNG
CO
CO2
Coax
COMM
Conn
CPA
CPP
CPS
CPU
CRT
CRTC
CS
CTP
cu ft
cu in
CV
CVRSS
Cyl

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Delayed Accessory Bus


decibels
decibels on A-weighted scale
Direct Current
Door Control Module
Drive End
Digital Electronic Controller
Diagnostic Energy Reserve Module
Distributor Ignition
diameter
Driver Information Center
Differential
Dark
Data Link Connector
Digital Multimeter
Dual Overhead Camshafts
Driver
Daytime Running Lamps
Diagnostic Trouble Code
E
EBCM Electronic Brake Control Module
EBTCM Electronic Brake and Traction Control Module
EC
Electrical Center
ECC
Electronic Climate Control
ECI
Extended Compressor at Idle
ECL
Engine Coolant Level
ECM
Engine Control Module
ECS
Emission Control System
ECT
Engine Coolant Temperature
EEPROM Electronically Erasable Programmable Read Only Memory
EEVIR Evaporator Equalized Values in Receiver
EFE
Early Fuel Evaporation
EGR
Exhaust Gas Recirculation
EGR TVV Exhaust Gas Recirculation Thermal Vacuum Valve
EI
Electronic Ignition
ELAP
Elapsed
ELC
Electronic Level Control
E/M
English / Metric
EMF
Electromotive Force
Eng
Engine
EOP
Engine Oil Pressure
EOT
Engine Oil Temperature

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DAB
dB
dBA
DC
DCM
DE
DEC
DERM
DI
dia
DIC
Diff
DK
DLC
DMM
DOHC
DR
DRL
DTC

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F
FC
FDC
FED
FEDS
FF
FI
FMVSS
F/P
ft
FT
F4WD
4WAL
4WD
FW
FWD
g
GA
gal
gas
GCW
Gen
GL
GM
GM SPO
gnd
gpm
GRN
GRY

Environmental Protection Agency


Exhaust Pressure Regulator
Erasable Programmable Read Only Memory
Electronic Suspension Control
Electrostatic Discharge
Electronic Throttle Control, Electronic Temperature Control
Electronic Touch Climate Control
Electronically Tuned Receiver
Evaporative Emission
Electronic Variable Orifice
Exhaust
F
Degrees Fahrenheit
Fan Control
Fuel Data Center
Federal (all United States except California)
Fuel Enable Data Stream
Flexible Fuel
Fuel Injection
Federal Motor Vehicle Safety Standards
Fuel Pump
foot/feet
Fuel Trim
Full Time Four Wheel Drive
Four Wheel Antilock
Four Wheel Drive
Flat Wire
Front Wheel Drive
G
grams, gravitational accelaration
Gage
gallon
gasoline
Gross Combination Weight
Generator
Gear Lubricant
General Motors
General Motors Service Parts Operations
ground
gallons per minute
Green
Gray

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EPA
EPR
EPROM
ESC
ESD
ETC
ETCC
ETR
EVAP
EVO
Exh

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GVWR

IAC
IAT
IC
ICM
ID
IDI
ign
ILC
in
INJ
inst
I/P
IPC
I/PEC
ISC
ISO
ISS

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H
H2O
Harn
HC
H/CMPR
HD
HDC
hex
Hg
Hi Alt
HO2S
hp
HPL
HPS
HPV
Htd
HTR
HUD
HVAC
HVACM
HVM
Hz

Gross Vehicle Weight Rating


H
Hydrogen
Water
Harness
Hydrocarbons
High Compression
Heavy Duty
Heavy Duty Cooling
hexagon
Mercury
High Altitude
Heated Oxygen Sensor
horsepower
High Pressure Liquid
High Performance System
High Pressure Vapor
Heated
Heater
Head-up Display
Heater-Vent-Air Conditioning
Heater-Vent-Air Conditioning Module
Heater Vent Module
Hertz
I
Idle Air Control
Intake Air Temperature
Integrated Circuit, Ignition Control
Ignition Control Module
Identification, Inside Diameter
Integrated Direct Ignition
ignition
Idle Load Compensator
inch/inches
Injection
instantaneous
Instrument Panel
Instrument Panel Cluster
Instrument Panel Electrical Center
Idle Speed Control
International Standards Organization
Input Speed Shaft

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K
Keep Alive Memory
Keyboard Display Driver
kilogram
kilohertz
kilometer
kilometers per hour
kilometers per liter
kilopascals
Knock Sensor
kilovolts
L
L
L4
L6
lb
lb ft
lb in
LCD
LDCL
LDCM
LED
LF
LH
lm
LR
lt
LT
MAF
Man
MAP
MAT
max
M/C
MDP
MFI
mi
MIL
min
ml
mm

Liter
Four Cylinder Engine, In-line
Six Cylinder Engine, In-Line
pound
pound feet (torque)
pound inch (torque)
Liquid Crystal Display
Left Door Closed Locking
Left Door Control Module
Light Emitting Diode
Left Front
Left Hand
lumens
Left Rear
left
Light
M
Mass Air Flow
Manual
Manifold Absolute Pressure
Manifold Absolute Temperature
maximum
Mixture Control
Manifold Differential Pressure
Multiport Fuel Injection
miles
Malfunction Indicator Lamp
minimum
milliliter
millimeter

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KAM
KDD
kg
kHz
km
km/h
km/l
kPa
KS
kV

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mpg
mph
ms
MST
M/T
MV
mV

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miles per gallon


miles per hour
millisecond
Manifold Surface Temperature
Manual Transmission/Transaxle
Megavolt
millivolt
N
NAES
North American Export Sales
NC
Normally Closed
NEG
Negative
Neu
Neutral
NLGI
National Lubricating Grease Institute
N-m
Newton-meter (torque)
NO
Normally Open
NOx
Oxides of Nitrogen
NPTC
National Pipe Thread Coarse
NPTF
National Pipe Thread Fine
NVRAM Non Volatile Random Access Memory
O
O2
Oxygen
O2S
Oxygen Sensor
OBD II On-Board Diagnostics II
OC
Oxidation Converter (Catalytic)
OD
Outside Diameter
ODO
Odometer
OE
Original Equipment
OEM
Original Equipment Manufacturer
OHC
Overhead Camshaft
OL
Open Loop
ORN
Orange
OSS
Output Shaft Speed
oz
ounce(s)
P
PAG
Polyalkylene Glycol
PASS
Passenger
PASS-Key Personalized Automotive Security System
P/B
Power Brakes
PC
Pressure Control
PCB
Printed Circuit Board
PCM
Powertrain Control Module
PCS
Pressure Control Solenoid

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qt
R-12
R-134a
RAM
RAP
RAV
RCDLR
RDCM
Ref
Rev
RF
RFA
RFI
RH
RKE
Rly
ROM
RPM

Positive Crankcase Ventilation


Permanent Magnet (Generator)
Part Number
Pink
Park/Neutral Position
Park, Reverse, Neutral, Drive, Low
Pilot Operated Absolute (Valve)
Positive
Potentiometer (Variable Resistor)
Purple
parts per million
Programmable Read Only Memory
Power Steering
Power Sliding Door
Power Steering Pressure
pounds per square inch
pounds per square inch absolute
pounds per square inch gage
pint
Pulse Width Modulated
Q
quart(s)
R
Refrigerant-12
Refrigerant-134a
Random Access Memory (non permanent memory devise, memory
contents are lost when power is removed)
Retained Accessory Power
Remote Activation Verification
Remote Control Door Lock Receiver
Right Door Control Module
Reference
Reverse
Right Front, Radio Frequency
Remote Function Actuation
Radio Frequency Interference
Right Hand
Remote Keyless Entry
Relay
Read Only Memory (permanent memory devise, memory contents are
retained when power is removed)
Engine Speed (Revolutions Per Minute)

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PCV
PM
P/N
PNK
PNP
PRNDL
POA
POS
POT
PPL
ppm
PROM
P/S
PSD
PSP
psi
psia
psig
pt
PWM

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RPO
RR
rt
RTD
RTV
RWAL
RWD

Tach
TBI
TC
TCC
TCS
TDC
TEMP
Term
TFP
TFT

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s
SAE
SC
SCB
SCM
SDM
SEO
SFI
SI
SIR
SLA
sol
SO2
SP
SPO
sq ft
sq in
SRC
SRI
ST
S4WD
Sw
syn

Regular Production Option


Right Rear
right
Real Time Damping
Room Temperature Vulcanizing (sealer)
Rear Wheel Antilock
Rear Wheel Drive
S
second(s)
Society of Automotive Engineers
Supercharger
Supercharger Bypass
Seat Control Module
Sensing and Diagnostic Module
Special Equipment Option
Sequential Multiport Fuel Injection
System International (modern version of metric system)
Supplemental Inflatable Restraint
Short/Long Arm (suspension)
solenoid
Sulfur Dioxide
Splice Pack
Service Parts Operations
square foot/feet
square inch/inches
Service Ride Control
Service Reminder Indicator
Scan Tool
Selectable Four Wheel Drive
Switch
synchronizer
T
Tachometer
Throttle Body Fuel Injection
Turbocharger
Torque Converter Clutch
Traction Control System
Top Dead Center
Temperature
Terminal
Transmission Fluid Pressure
Transmission Fluid Temperature

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UART
U/H
U/HEC
U-joint
UTD
UV
V
V6
V8
Vac
VAC
VATS
VCM
VDOT
VDV
vel
VES
VF
VIO
VIN
VMV
VR
V ref
VSS
w/
W/B
WHL

Transmission Oil Cooler


Throttle Position
Terminal Positive Assurance
Tire Pressure Monitoring
Transmission Range
Transmission/Transaxle
Throttle Valve
Television and Radio Suppression
Thermal Vacuum Valve
Three Way Converter (Catalytic)
Three Way + Oxidation Converter (Catalytic)
Thermal Expansion Valve
U
Universal Asynchronous Receive and Transmit
Underhood
Underhood Electrical Center
Universal Joint
Universal Theft Deterrent
Ultraviolet
V
Volt(s), Voltage
Six Cylinder Engine, V-Type
Eight Cylinder Engine, V-Type
Vacuum
Vehicle Access Code
Vehicle Anti-Theft System
Vehicle Control Module
Variable Displacement Orifice Tube
Vacuum Delay Valve
velocity
Variable Effort Steering
Vacuum Fluorescent
Violet
Vehicle Identification Number
Vacuum Modulator Valve
Voltage Regulator
Voltage Reference
Vehicle Speed Sensor
W
with
Wheel Base
Wheel

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TOC
TP
TPA
TPM
TR
TRANS
TV
TVRS
TVV
TWC
TWC+OC
TXV

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WHT
w/o
WOT
W/P
W/S
WSS
WU-OC
WU-TWC

yd
YEL

Application
Transmission Oil Pan Bolt
Vacuum Modulator Assembly Bolt
Extension Housing to Case Bolt
Line Pressure Test Plug
Converter Housing to Cylinder Block Bolt
Transmission Support to Case Extension Bolt
Shift Lever to Selector Lever Shaft Bolt
Detent Cable Retainer to Case Bolt
Oil Cooler Fittings to Case
Oil Cooler Fittings to Radiator
Oil Cooler Hose Clamps to Cooler Lines
Shifter Assembly to Console Bolt
Neutral Safety Switch to Bracket Bolt
Lower Cover to Converter Housing Bolt
Flexplate to Converter Bolt
Reinforcement Plate to Case Bolt
Control Valve Body Assembly to Case Bolt
Servo Cover to Case Bolt
Converter Housing To Case Bolt
Converter Housing to Oil Pump Bolt
Manual Shaft Lever Locknut
Governor Body to Governor Hub Bolt
Servo Adjusting Bolt Locknut
Governor Pressure Switch
Solenoid
Oil Filter Bolt
Liters

N-m
11
52
31
8
34
44
27
9
20
27
1
9
2
10
48
19
19
24
33
19
12
8
18
10
19
19

Lb Ft

33
23

25
33
20

15
20

35
14
14
18
25
14
9

14

14
14

Quarts

Lb In
96

71

80

9
80
18
89

71

89

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X-valve

White
without
Wide Open Throttle
Water Pump
Windshield
Wheel Speed Sensor
Warm Up Oxidation Converter (Catalytic)
Warm Up Three Way Converter (Catalytic)
X
Expansion valve
Y
yard(s)
Yellow

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(approximate)
Dry

Specification
Planetary Carrier Pinion Gear Clearance

Thickness (mm)
0.1270.889

Thickness (in)
0.0050.035

Thickness (in) Identification Number Use Washer Part Number


0.0690.074
2
96013761
0.0750.079
3
96013762
0.0800.084
4
96013763
0.0850.089
5
96013764
0.0900.094
6
96013765
0.0950.100
7
96013766
Application

Accumulator Cover to Case Bolt


Case Extension to Case Bolt
Case Extension to Case Bolt (4WD Shipping)
Converter Housing to Case Screw
Cooler Pipe Connector
Detent Spring to Valve Body Bolt
Forward Accumulator Cover to Valve Body Bolt
Line Pressure Plug
Manual Shaft to Inside Detent Lever Nut
Oil Passage Cover to Case Bolt
Park Brake Bracket to Case Bolt
Plate to Case Bolt (Shipping)
Plate to Converter Bolt (Shipping)
Pressure Control Solenoid Bracket to Valve Body Bolt
Pump Assembly to Case Bolt
Pump Cover to Pump Body Bolt

Specification
Metric
English
8.014.0 N610 lb ft
m
42.0
35.0
48.0 N-m
39.4 lb ft
11.2
8.3
22.6 N-m
16.7 lb ft
65.0
4855 lb ft
75.0 N-m
35.0
2630 lb ft
41.0 N-m
20.0
1520 lb ft
27.0 N-m
8.014.0 N610 lb ft
m
8.014.0 N610 lb ft
m
27.0
2025 lb ft
34.0 N-m
814.0 N-m 610 lb ft
27.0
2025 lb ft
34.0 N-m
27.0
2025 lb ft
34.0 N-m
27.0
2025 lb ft
34.0 N-m
8.014.0 N610 lb ft
m
26.0
1924 lb ft
32.0 N-m
20.0
1520 lb ft
27.0 N-m

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Thickness (mm)
1.781.88
1.932.03
2.062.16
2.182.29
2.312.41
2.462.57

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Speed Sensor Retainer Bolt


Transmission Fluid Pressure Manual Valve Position
Switch to Valve Body Bolt
Transmission Oil Cooler Pipe Fitting
Transmission Oil Pan to Case Bolt
Valve Body to Case Bolt

Specification
Application

Metric
4.7 liters
10.6 liters

Pan Removal
Overhaul
Identification
67
68
69
70
71
72
73
74

English
5 quarts
11 quarts

Washer Thickness (mm)


1.871.97
2.042.14
2.212.31
2.382.48
2.552.65
2.722.82
2.892.99
3.063.16

Measured Dimension
28.06527.545 mm (1.105
1.084 in)
28.58628.066 mm (1.125
1.105 in)
27.54427.026 mm (1.084
1.064 in)

Identification
None
0
1

Washer Thickness (in)


0.0740.078
0.0800.084
0.0870.091
0.0940.098
0.1000.104
0.1070.111
0.1130.117
0.1200.124
Selective Plate
Thickness
1.6841.829 mm (0.066
0.072 in)
1.3141.168 mm (0.052
0.046 in)
2.1982.344 mm (0.087
0.092 in)

Plate Thickness
6.927.07 mm (0.2720.278 in)
6.336.48 mm (0.2490.255 in)
5.745.89 mm (0.2260.232 in)
5.155.30 mm (0.2030.208 in)
4.564.71 mm (0.1800.185 in)
Backing Plate Travel: 0.7661.756 mm (0.0300.069 in)
Dimension
5.885.68 mm (0.2310.224 in)
4.994.76 mm (0.1960.187 in)

Identification
A
B
C
D
E
Identification
A
B

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8.014.0 N610 lb ft
m
10.5
7.710 lb ft
13.5 N-m
8.014.0 N610 lb ft
m
35.0
2630 lb ft
41.0 N-m
9.513.8 N710 lb ft
m
8.014.0 N610 lb ft
m

Solenoid Assembly to Case Bolt

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4.103.90 mm (0.1610.154 in)


C
Use a backing plate which gives the correct travel. The travel should be 2.10
0.90 mm (0.0830.035 in).
Plate Thickness
7.2497.409 mm (0.2850.292 in)
6.6786.519 mm (0.2630.257 in)
5.9475.787 mm (0.2340.228 in)
Backing Plate Travel: 1.021.94 mm (0.0400.076 in)

2-4 Band Servo Piston Pin Selection


Document ID: 58266

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2-4 Servo Pin Selection

Thickness (in)
0.70660.7071
0.70710.7076
0.70760.7081
0.70810.7086
0.70860.7091
0.70660.7071
0.70710.7076
0.70760.7081
0.70810.7086
0.70860.7091

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Thickness (mm)
Oil Pump Rotor
17.94817.961
17.96117.974
17.97417.987
17.98718.000
18.00018.013
Oil Pump Slide
17.94817.961
17.96117.974
17.97417.987
17.98718.000
18.00018.013

Identification
2
3
4

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Pin Length
mm
65.8266.12
67.2367.53
68.6468.94

inch
2.592.60
2.652.66
2.702.71

Pin Identification
1 Groove
2 Grooves
No Groove

Document ID: 58266

Document ID: 20455


Notice: Do not use air powered tools in order to disassemble or assemble any vehicle
component. Bolt torques are vital to diagnosis. You can detect bolt torques only when
using hand tools. Improper bolt torques can contribute to vehicle repair problems.

Document ID: 20455

Transmission Fluid Pan and Filter Assembly Removal


Document ID: 191296

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Spray the ends of the transmission oil pan screws (76) with penetrating oil.

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Do Not Use Air Tools

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Remove the transmission oil pan screws (76).


Remove the transmission oil pan (75) and the transmission oil pan gasket (73).

Remove the transmission oil filter assembly (72).


Pry the metal from the top of the filter and pull the top away.
Open the filter.
The filter may help in diagnosis. Inspect for the following items which may indicate
wear or corrosion:
Clutch material
Bronze slivers indicating bushing wear
Steel particles

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Remove the oil filter seal (71).

Document ID: 191296

Control Valve Body and Wiring Harness Removal


Document ID: 283920

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Remove all electrical connectors (16) from the electrical components.

Remove the TCC PWM retainer clip (379).


Remove the TCC PWM solenoid (396).

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Remove the TCC solenoid bolts (68).

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Remove the TCC solenoid and wiring harness (66). Turn the wiring harness over so
that it hangs over the side of the transmission.

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Remove the transmission fluid pressure (TFP) manual valve position switch
assembly bolts (62, 70).
Remove the TFP manual valve position switch (69).

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Remove the manual detent spring bolt (64).


Remove the manual detent spring assembly (63).

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Remove all valve body bolts (62).
Remove the fluid level indicator stop bracket (93).

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Lift the valve body carefully so that the checkballs remain on the spacer plate in the
correct location. While lifting the valve body, disconnect the manual valve link
from the manual valve.

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Remove the seven valve body checkballs (26, 8, 12).

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Remove the accumulator cover bolts (58, 59).


Remove the 1-2 accumulator cover and pin assembly (57).
Disassemble the 1-2 accumulator assembly (54, 56, 57, 104).

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Remove the spacer plate support bolts (77).
Remove the spacer plate support (53).

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Remove the valve body gasket (52), the valve body spacer plate (48) and the case
gasket (47).
Discard gaskets. Do not reuse.

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Remove the 3-4 accumulator spring (model dependent) and the 3-4 accumulator
piston.

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Remove the case checkball.

Document ID: 283920

Inner Manual Linkage Removal


Document ID: 5193

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Remove the following parts: hex head nut (90) and the manual valve link (89);
inside detent lever (88) and the parking lock actuator assembly (85); manual
shaft retainer (83) and the manual shaft (84).

Remove the manual shaft seal (82) with a screwdriver.

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Remove the following components:
The parking lock bracket bolt (87)
The parking lock bracket (86)

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Document ID: 5193

Case Assembly Inspection


Document ID: 4233

Inspect the spacer plate to case gasket for witness marks. The witness marks should
be complete. Incomplete witness marks may come from an uneven case surface
or from cross channel leaks.

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Using compressed air, blow into all of the case fluid passages (3, 7, 8, 11, 16, 18,
26, 29, 37, 45) to ensure that all case fluid passages are clear of any obstruction.

Inspect the 2-4 servo bore, the 3rd accumulator retainer and ball assembly (40), the
orifice cup plug (11) in the servo bore, and the 2nd apply piston pin bore for any
of the following conditions:
Porosity
Burrs
Debris
Any other damage

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Inspect the 3-4 accumulator bore and the orifice cup plug (38) for any of the
following conditions:
Porosity
Burrs
Blockage
Any other damage
Inspect all bolt holes for thread damage. Use heli-coil to repair damaged threads.
Inspect the cooler connectors for damage and proper torque.
Specification
Cooler connector torque should be 38 N-m (28 lb ft)

3rd Accumulator Retainer with Ball Assembly Leak Check


Document ID: 191377
Installation Procedure
Tools Required
J 29714-A Servo Cover Compressor

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Install the 2-4 servo into the case.

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Install oil pan with only four bolts to align pan to case.
Use the J 29714-A in order to compress the servo cover.
Install the servo cover retaining ring.

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Remove oil pan.


Pour solvent into the accumulator bore until the channel is filled. Watch for leaks in
the case channel.
Important: It is normal to see leakage from the small hole next to the larger
oval hole, see arrow.
If leakage from the oval shaped hole is observed, replace the third accumulator
retainer and ball assembly.

3rd Accumulator Retainer with Ball Replacement


Document ID: 19634

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Remove the third accumulator retainer and ball assembly, using a 44.8 mm
(1.763 in) #4 screw extractor.

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Scribe a mark at 44.8 mm (1.763 in) (a) on a 9.5 mm (0.375 in) (b) diameter metal
rod. The scribe mark is used to gage the proper depth of the third accumulator
retainer and ball assembly.

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Perform the following functions:


Line up the oil feed slots in the third accumulator retainer and ball
assembly (40) with the servo bore.
Using the 9.5 mm (0.375 in) diameter metal rod, install the third accumulator
retainer and ball assembly.

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Ensure that the third accumulator retainer and ball assembly and the scribe mark on
the rod are flush with the case surface.

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Check the third accumulator retainer and ball assembly (40) for alignment. The slot
in the retainer must be completely open in the servo bore.

Manual Shift Shaft Seal Installation


Document ID: 19633

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Install a new manual shaft seal (82).

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Document ID: 19633

Inner Manual Linkage Installation


Document ID: 5187

Install the parking lock bracket (86).


Notice: Use the correct fastener in the correct location. Replacement fasteners
must be the correct part number for that application. Fasteners requiring
replacement or fasteners requiring the use of thread locking compound or sealant
are identified in the service procedure. Do not use paints, lubricants, or corrosion
inhibitors on fasteners or fastener joint surfaces unless specified. These coatings
affect fastener torque and joint clamping force and may damage the fastener.
Use the correct tightening sequence and specifications when installing fasteners
in order to avoid damage to parts and systems.
Install the parking lock bracket bolt (87).
Tighten
Tighten the bolt to 31 N-m (23 lb ft).
Inspect the following items:
The parking brake pawl (81) for damage or cracks

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The parking pawl return spring (80) for being broken or missing

Inspect the following items:


The manual shaft retainer (83) for damage or cracks
The manual shaft (84) for damage or burrs
The parking lock actuator assembly (85) for damage
The inside detent lever (88) for damage or cracks
The manual valve link (89) for damage
The hex head nut (90) for damage or stripped threads
Install the following items:
The inside detent lever (88)
The parking lock actuator assembly (85)
The manual shaft (84) (model dependent)
The manual shaft retainer (83)
The hex head nut (90)
The manual valve link (89)
Tighten

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Tighten the nut to 31 N-m (23 lb ft).

Control Valve Body Installation


Document ID: 283930
Tools Required

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Install the checkballs (26, 8, 12) in the valve body and retain checkballs with
Transjel J 36850 or an equivalent.

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J 25025-5 Guide Pins

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Install the valve body over the J 25025-5 Guide Pins, and connect the manual valve
link to the manual valve.
Install two bolts to hold the valve body in place.
Remove the J 25025-5 .

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Install the fluid level indicator stop bracket (93) and the valve body bolts (62) that
are shown only.
Finger tighten the bolts.

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Inspect the Transmission Fluid Pressure Manual Valve Position Switch (TFP Val.
Position Sw.) Assembly for the following conditions:
Damage
Debris
Damaged or missing O-rings
Cracked connector
Loose pins

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Install the TFP Val. Position Sw. (69) and bolts (62, 70).

Inspect the wiring harness solenoid assembly for the following conditions:
Damage
Cracked connectors
Exposed wires
Loose pins

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Install the transmission wiring harness on the valve body.

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Install the TCC solenoid and bolts (68).


Important: You must tighten certain bolts in a spiral pattern as indicated by the
arrows. If you tighten these bolts at random you may distort valve bores. This
will inhibit valve operation.

Tighten the bolts in the order shown.


Tighten
Tighten the bolts to 11 N-m (8 lb ft).
Refer to Fastener Notice .
Each bolt number refers to a specific bolt size, as indicated by the following list:
1 M6 x 1.0 x 65.0
2 M6 x 1.0 x 54.4
3 M6 x 1.0 x 47.5
4 M6 x 1.0 x 35.0
5 M8 x 1.25 x 20.0
6 M6 x 1.0 x 12.0
7 M6 x 1.0 x 18.0

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Install the TCC PWM solenoid (396) and the solenoid retainer (379).

Oil Filter Assembly Installation


Document ID: 191478

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Use a socket the same size diameter as the filter seal (71) and install the seal.

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Install the transmission oil filter assembly (72).

Case Extension Bushing Replacement Document ID: 191439


Special Tools
J 8092 Driver Handle
J 23062-14 Bushing Remover
J 34196-B Transmission Bushing Service Set

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Inspect the case extension for the following conditions:
Porosity
Cracks
Nicks
Burrs

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Remove the case extension oil seal assembly (34) (model dependent).

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Worn bushings

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Using the J 23062-14 and the J 8092 , remove the case extension bushing (33).

Using the J 34196-4 which is part of kit J 34196-B and the J 8092 , install a case
extension bushing (33).

Automatic Transmission Electronic Component Views Document ID: 174447


Automatic Transmission Internal Electronic Components (4L60E)

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Vehicle Speed Sensor (VSS)


Torque Converter Clutch (TCC) Solenoid Valve
Automatic Transmission Fluid Pressure (TFP) Manual Valve Position Switch
1-2 Shift Solenoid (SS) Valve
2-3 Shift Solenoid (SS) Valve
Pressure Control (PC) Solenoid Valve
3-2 Shift Solenoid (SS) Valve Assembly
Torque Converter Clutch Pulse Width Modulation (TCC PWM) Solenoid Valve

Case and Associated Parts (1 of 2) 1998 4L60-E -

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Document ID: 181627


Case and Associated Parts (1 of 2)

Torque Converter Assembly (Model Dependent)


Bolt, Pump to Case
O-Ring, Pump to Case Bolt
Pump Assembly, Oil
Seal, Oil (Pump to Case)
Gasket, Pump Cover to Case
Bushing, Case
Vent Assembly, Transmission

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Connector, Oil Cooler Pipe (Model Dependent)


Plug, Case Servo
Spring, Servo Return
Pin, 2nd Apply Piston
Ring, Retainer (2nd Apply Piston)
Retainer, Servo Cushion Spring

Piston, 2nd Apply


Ring, Oil Seal (2nd Apply Piston - Outer)
Ring, Oil Seal (2nd Apply Piston - Inner)
Housing, Servo Piston (Inner)
Seal, O-Ring
Spring, Servo Apply Pin
Washer, Servo Apply Pin
Ring, Retainer (Apply Pin)
Piston, 4th Apply
Ring, Oil Seal (4th Apply Piston - Outer)
Seal, O-Ring (2-4 Servo Cover)
Cover, 2-4 Servo
Ring, Servo Cover Retaining
Seal, Case Extension to Case
Extension, Case (Model Dependent)
Bolt, Case Extension to Case
Bushing, Case Extension
Seal Assembly, Case Extension Oil (Model Dependent)
Seal Assembly, Case Extension Oil (Model Dependent)

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Spring, Servo Cushion (Outer)

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Bolt, Speed Sensor Retaining


Speed Sensor, Internal Transmission
Seal, O-Ring (ITSS to Case Extension)
Seal, Filter
Filter Assembly, Transmission Oil (Model Dependent)
Gasket, Transmission Oil Pan

Magnet, Chip Collector


Pan, Transmission Oil (Model Dependent)
Pan, Transmission Oil
Screw, Transmission Oil Pan
Screw, Transmission Oil Pan
Bolt, Converter Housing to Case
Connector, Oil Cooler Quick (Model Dependent)
Clip, Oil Cooler Quick Connect (Model Dependent)
Plug, Converter Housing Access Hole (Model Dependent)
Plate, Converter Bolt Inspection (Model Dependent)
Plug, Cup D4 Orifice
Stud, A/Trans. Case (Y-Car Only)
Plug Asm., A/Trans. Oil Pan
Housing, Converter (Model Dependent)
Housing, Converter (Model Dependent)
Case, Main Section (Model Dependent)
Case, Main Section
Spring, Servo Cushion (Inner) (Model Dependent)
Seal Assembly, Case Oil (Y-Car Only)

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Gasket, Transmission Oil Pan

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Case and Associated Parts (2 of 2) 98 4L60-E Document ID: 283811


Case and Associated Parts (2 of 2)

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Transmission Case Plug (Accumulator Bleed)
Pressure Plug

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Third Accumulator (#7) Retainer and Ball Assembly


Band Anchor Pin
Retainer and Ball Assembly (Double Orifice) (#10)
Accumulator Piston Pin
3-4 Accumulator Piston
Oil Seal Ring (3-4 Accumulator Piston)

Spacer Plate to Case Gasket


Valve Body Spacer Plate
Shift Solenoids Screen
Pressure Control Solenoid Screen
Spacer Plate to Valve Body Gasket
Spacer Plate Support Plate
1-2 Accumulator Spring (Outer)
Oil Seal Ring (1-2 Accumulator)
1-2 Accumulator Piston
1-2 Accumulator Cover and Pin Assembly
Accumulator Cover Bolt
Accumulator Cover Bolt
Control Body Valve Assembly
Checkball (#2, 3, 4, 5, 6, 8, 12)
Valve Body Bolt
Manual Detent Spring Assembly
Manual Detent Spring Bolt
Wiring Harness Pass-through Connector O-Ring Seal
Wiring Harness Solenoid Assembly

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3-4 Accumulator Spring (Model Dependent)

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O-Ring Seal (Solenoid)


Hex Washer Head Bolt (Solenoid)
Transmission Fluid Pressure Manual Valve Position Switch Assembly
Pressure Switch Assembly Bolt
Spacer Plate Support Bolt
Number 1 Checkball

Main Section Case (Model Dependent)


1-2 Accumulator Spring (Inner)

Control Valve Body Assembly Legend (1 of 2) 1999 4L60-E Document ID: 413572
Control Valve Body Assembly (1 of 2)

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Control Valve Body Assembly

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Dipstick Stop Bracket (Model Dependent)

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Forward Accumulator Oil Seal


Forward Accumulator Piston
Forward Accumulator Pin
Forward Accumulator Spring
Forward Abuse Valve
Forward Abuse Valve Spring

Coiled Spring Pin


Coiled Spring Pin
Low Overrun Valve
Low Overrun Valve Spring
Forward Accumulator Cover
Forward Accumulator Cover Bolt
Pressure Control Solenoid Retainer Bolt
1-2 Shift Valve Spring
1-2 Shift Valve
1-2 Shift Solenoid Valve
2-3 Shift Solenoid Valve
2-3 Shift Valve
2-3 Shuttle Valve
1-2 Accumulator Valve Spring
1-2 Accumulator Valve
1-2 Accumulator Valve Sleeve
Actuator Feed Limit Valve
Actuator Feed Limit Valve Spring
Bore Plug

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Bore Plug

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Pressure Control Solenoid Valve


Pressure Control Solenoid Retainer
Bore Plug and Solenoid Retainer
Bore Plug and Solenoid Retainer
Bore Plug and Solenoid Retainer

Document ID: 413577


Control Valve Body Assembly (2 of 2)

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Manual Valve
Control Valve Body Assembly
Bore Plug
Coiled Spring Pin
Regulator Apply Valve

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Control Valve Body Assembly Legend (2 of 2) 1999 4L60-E -

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Bore Plug
Bore Plug
Bore Plug
Bore Plug
4-3 Sequence Valve Spring
4-3 Sequence Valve

3-4 Shift Valve


3-4 Shift Valve Spring
Reverse Abuse Valve
Reverse Abuse Valve Spring
3-2 Downshift Valve
3-2 Downshift Valve Spring
3-2 Control Valve
3-2 Control Valve Spring
3-2 Control Solenoid Valve
Bore Plug and Solenoid Retainer
Bore Plug and Solenoid Retainer
Bore Plug and Solenoid Retainer
Bore Plug and Solenoid Retainer
Bore Plug and Solenoid Retainer
Bore Plug Retainer
TCC PWM Solenoid Valve
Regulator Apply Spring
Isolator Valve

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3-4 Relay Valve

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Internal Parts (1 of 2) 1998 4L60-E Document ID: 213223


Internal Parts (1 of 2)

3-4 Clutch Boost (5) Spring Assembly


Thrust Washer (Pump to Drum)
2-4 Band Assembly
Reverse Input Clutch Bushing (Front)
Reverse Input Clutch Housing and Drum Assembly
Reverse Input Clutch Bushing (Rear)
Reverse Input Clutch Piston Assembly

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Reverse Input Clutch Seal (Inner)


Reverse Input Clutch Seal (Outer)
Reverse Input Clutch Spring Assembly
Reverse Input Clutch Spring Retainer Ring
Reverse Input Clutch Plate (Belleville)
Reverse Input Clutch Turbulator Plate (Steel)

Reverse Input Clutch Backing Plate (Selective)


Reverse Input Clutch Retaining Ring
Stator Shaft/Selective Washer Bearing Assembly
Thrust Washer (Selective)
Check Valve Retainer and Ball Assembly
O-Ring Seal Location Model Dependent
Oil Seal Ring (Solid)
Retainer and Checkball Assembly
Retainer and Checkball Assembly
Input Housing and Shaft Assembly (Model Dependent)
O-Ring Input to Forward Clutch Housing Seal
3rd and 4th Clutch Piston
3rd and 4th Clutch Ring (Apply)
3rd and 4th Clutch Spring Assembly
Forward Clutch Housing Retainer and Ball Assembly
Forward Clutch Housing
Forward Clutch Piston
Overrun Clutch Piston
Overrun Clutch Ball

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Reverse Input Clutch Plate Assembly (Fiber)

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Overrun Clutch Spring Assembly


Overrun Clutch Spring Retainer Snap Ring
Input Housing to Output Shaft Seal
Input Sun Gear Bearing Assembly
Overrun Clutch Hub Retaining Snap Ring
Overrun Clutch Hub

Forward Sprag Assembly


Sprag Assembly Retainer Ring
Sprag Assembly Retainer Ring
Forward Clutch Race (Outer)
Overrun Clutch Plate (Steel)
Overrun Clutch Plate Assembly (Fiber)
Forward Clutch Plate (Apply)
Forward Clutch Plate (Waved)
Forward Clutch Plate (Steel)
Forward Clutch Plate Assembly (Fiber)
Forward Clutch Backing Plate (Selective)
Forward Clutch Backing Plate Retainer Ring
3rd and 4th Clutch Plate (Steel) (2.2L Engine Only)
3rd and 4th Clutch Apply Plate (Stepped)
3rd and 4th Clutch Apply Plate (Stepped)
3rd and 4th Clutch Plate Assembly (Fiber) (Quantity Model Dependent 5, 6 or 7
plates)
3rd and 4th Clutch Plate Assembly (Fiber) (Quantity Model Dependent 5, 6 or 7
plates)
3rd and 4th Clutch Plate (Steel) (Quantity Model Dependent)

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Forward Sprag Clutch Inner Race and Input Sun Gear Assembly

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3rd and 4th Clutch Plate (Steel) (Quantity Model Dependent)


3rd and 4th Clutch Backing Plate (Selective) (Model Dependent)
3rd and 4th Clutch Backing Plate (Selective) (Model Dependent)
3rd and 4th Clutch Backing Plate Retainer Ring
Input Sun Gear Front Bushing
Input Sun Gear Rear Bushing

Orificed Cup Plug

Internal Parts (2 of 2) 1998 4L60-E Document ID: 213211


Internal Parts (2 of 2)

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Cup Plug

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Output Shaft to Input Carrier Retainer


Input Carrier Assembly
Thrust Bearing Assembly (Input Carrier to Reaction Shaft)
Input Internal Gear
Reaction Carrier Shaft Front Bushing
Reaction Carrier Shaft
Reaction Carrier Shaft Rear Bushing
Reaction Shaft/Internal Gear Retainer Ring
Thrust Washer (Reaction Shaft Shell)
Reaction Sun Shell
Reaction Sun Gear Retainer Ring

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Reaction Sun Bushing


Reaction Sun Gear
Thrust Washer (Race/Reaction Shell)
Low and Reverse Roller Clutch Race
Low and Reverse Support to Case Retainer Ring
Low and Reverse Roller Assembly Retainer Ring (Cam)

Low and Reverse Roller Clutch Assembly


Low and Reverse Clutch Support Assembly
Low and Reverse Clutch Support Retainer Spring
Reaction Carrier Assembly
Low and Reverse Clutch Plate (Waved)
Spacer Low and Reverse Clutch Plate (Selective)
Low and Reverse Clutch Plate Assembly (Fiber)
Low and Reverse Clutch Turbulator Plate (Steel)
Thrust Bearing Assembly (Reaction Carrier/Support)
Internal Reaction Gear
Internal Reaction Gear Support
Reaction Gear/Support Retainer Ring
Output Shaft
Output Shaft Sleeve (Model Dependent)
Output Shaft Seal (Model Dependent)
Reaction Gear Support to Case Bearing
Low and Reverse Clutch Retainer Ring
Low and Reverse Clutch Spring Assembly
Low and Reverse Clutch Piston

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Low and Reverse Roller Assembly Retainer Ring (Cam)

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Low and Reverse Clutch Seal (Outer)


Low and Reverse Clutch Seal (Center)
Low and Reverse Clutch Seal (Inner)
Oil Deflector (High Output Models Only)
Internal Transmission Speed Sensor Rotor

Document ID: 65193


Parking Lock and Manual Shift Shaft Assembly

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Steel Cup Plug
Parking Brake Pawl Shaft

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Parking Lock and Manual Shift Shaft Assembly 4L60-E -

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Parking Pawl Return Spring


Parking Brake Pawl
Manual Shaft Seal
Manual Shaft Retainer
Manual Shaft (Model Dependent)
Parking Lock Actuator Assembly

Parking Lock Bracket (2) Bolt


Inside Detent Lever
Manual Valve Link
Hex Head Nut

Document ID: 65193

Seal Locations 98 4L60-E Document ID: 338649


Seals

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Parking Lock Bracket

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Pump to Case Bolt O-Ring


Oil Seal (Pump to Case)
Oil Seal Ring (2nd Apply Piston-Outer)
Oil Seal Ring (2nd Apply Piston-Inner)
O-Ring Seal
Oil Seal Ring (4th Apply Piston-Outer)
O-Ring Seal (2-4 Servo Cover)
Case Extension to Case Seal
Case Extension Oil Seal Assembly
O-Ring Seal (ITSS to Case Extension)

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Case Oil Seal Assembly (Y-Car Only)


Oil Seal Ring (Stator Shaft)
Oil Seal Assembly
Reverse Input Clutch Seal (Inner)
Reverse Input Clutch Seal (Outer)
O-Ring Seal (Turbine Shaft/Selective Washer)

O-Ring Input to Forward Housing Seal


3rd and 4th Clutch Piston
Forward Clutch Piston
Overrun Clutch Piston
Input Housing to Output Shaft Seal
Output Shaft (Model Dependent) Seal
Low and Reverse Clutch (Outer) Seal
Low and Reverse Clutch (Center) Seal
Low and Reverse Clutch (Inner) Seal

Bearing and Bushing Locations 4L60-E Document ID: 65195


Bearings and Bushings

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Oil Seal Ring (Solid)

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Case Bushing
Case Extension Bushing
Stator Shaft Bushing (Front)
Stator Shaft Bushing (Rear)
Oil Pump Body Bushing
Thrust Washer (Pump to Drum)
Reverse Input Cl. Bushing (Front)
Reverse Input Clutch Bushing (Rear)
Stator Shaft/Selective Washer Bearing Assembly
Thrust Washer (Selective)
Input Sun Gear Bearing Assembly
Input Sun Gear Bushing (Front)
Input Sun Gear Bushing (Rear)
Thrust Bearing Assembly (Input Carrier to Reaction Shaft)

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Reaction Carrier Shaft Bushing (Front)


Reaction Carrier Shaft Bushing (Rear)
Thrust Washer (Reaction Shaft/Shell)
Reaction Gear Bushing
Thrust Washer (Race/Reaction Shell)
Thrust Bearing Assembly (Reaction Carrier/Support)

Case Fluid Passages (Control Valve Body Side) 98 4L60-E Document ID: 338653
Case Fluid Passages (Control Valve Body Side)

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Reaction Gear Support to Case Bearing

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Checkball (91)
3rd Accumulator Retainer and Ball Assembly (40)
Checkball (42)
Line
Line

Line
Line
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Filtered Actuator Feed
Torque Signal
Torque Signal
Torque Signal
Torque Signal

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Line

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Torque Signal
PR
PR
PR
PR
PR

D4-3-2
Lo/Reverse
Lo/Reverse
Lo/Reverse
Reverse
Reverse Input (Rev. Clutch
Reverse Input (Rev. Clutch
Reverse Input (Rev. Clutch
Reverse Input (Rev. Clutch
D4
D4
D4
D4
Forward Clutch Feed
Forward Clutch Feed
Forward Clutch Feed
Forward Clutch Feed
Rear Lube
Accumulator

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D4-3-2

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Orificed Accumulator
Signal A
Signal A
Signal A
2nd
2nd

2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
C.C. Signal
C.C. Signal
3-4 Signal
3-4 Signal
3rd Accumulator
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
4th Signal
Servo Feed
4th
4th
3-4 Accumulator

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2nd

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3-4 Accumulator
3-4 Accumulator
3-4 Accumulator
3-4 Accumulator
D3
D3

D3
D3
Overrun
Overrun
Overrun Clutch Feed
Overrun Clutch Feed
Overrun Clutch
Overrun Clutch
Overrun Clutch
D2
D2
D2
D2
Orificed D2
Lo
Lo
Lo
Lo/1st
Lo/1st

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D3

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Exhaust
Exhaust
Orificed Exhaust
Orificed Exhaust
Void
Void

Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Regulated Apply
Regulated Apply

Spacer Plate to Case Gasket 98 4L60-E Document ID: 338654

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Void

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Spacer Plate to Case Gasket

Line
Line
Line
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit

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Actuator Feed Limit


Actuator Feed Limit
Actuator Feed Limit
Filtered Actuator Feed
Filtered Actuator Feed
Filtered Actuator Feed

Filtered Actuator Feed


Torque Signal
Torque Signal
Torque Signal
PR
PR
PR
PR
PR
D4-3-2
D4-3-2
Lo/Reverse
Lo/Reverse
Lo/Reverse
Reverse
Reverse
Reverse Input (Rev. Cl.)
Reverse Input (Rev. Cl.)
Reverse Input (Rev. Cl.)

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Filtered Actuator Feed

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D4
D4
D4
D4
Forward Clutch Feed
Forward Clutch Feed

Forward Clutch Feed


Forward Clutch Feed
Accumulator
Accumulator
Accumulator
Accumulator
Orificed Accumulator
Orificed Accumulator
Signal A
Signal A
2nd
2nd
2nd
2nd
2nd
2nd
2nd
2nd
2nd Clutch

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Forward Clutch Feed

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2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch

2nd Clutch
2nd Clutch
2nd Clutch
C.C. Signal
C.C. Signal
C.C. Signal
3-4 Signal
3-4 Signal
3-4 Signal
3rd Accumulator
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
4th Signal
4th Signal

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2nd Clutch

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Servo Feed
Servo Feed
Servo Feed
4th
3-4 Accumulator
3-4 Accumulator

D3
D3
D3
D3
D3
D3
Overrun
Overrun
Overrun Clutch Feed
Overrun Clutch Feed
Overrun Clutch
D2
D2
D2
D2
Orificed D2
Orificed D2
Lo
Lo

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3-4 Accumulator

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Lo
Lo
Lo/1st
Lo/1st
Exhaust
Exhaust

Orificed Exhaust
Void
Void
Regulated Apply
Regulated Apply

Spacer Plate Fluid Passages 98 4L60-E Document ID: 338656


Spacer Plate Fluid Passages

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Orificed Exhaust

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Line
Line
Line
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit

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Actuator Feed Limit


Actuator Feed Limit
Actuator Feed Limit/Filtered Actuator Feed
Actuator Feed Limit/Filtered Actuator Feed
Filtered Actuator Feed
Filtered Actuator Feed

Filtered Actuator Feed/Signal B


Torque Signal
Torque Signal
Torque Signal
PR
PR
PR
PR
PR
D4-3-2
D4-3-2
Lo/Reverse
Lo/Reverse
Lo/Reverse
Reverse
Reverse
Reverse/Reverse Input (Rev. Clutch
Reverse/Reverse Input (Rev. Clutch
Reverse Input (Rev. Clutch

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Filtered Actuator Feed/Signal A

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D4
D4
D4
D4
D4
D4

Forward Clutch Feed


Forward Clutch Feed
Forward Clutch Feed
Accumulator
Accumulator
Accumulator
Accumulator/Orificed Accumulator
Accumulator/Orificed Accumulator
Orificed Accumulator
Signal A
Signal A
2nd
2nd
2nd
2nd
2nd
2nd
2nd
2nd

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D4

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2nd/2nd Clutch
2nd/2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch

2nd Clutch
C.C. Signal
C.C. Signal
3-4 Signal
3-4 Signal
3-4 Signal
3-4 Signal
3rd Accumulator
3-4 Clutch/3rd Accumulator
3-4 Clutch/3rd Accumulator
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
4th Signal
4th Signal
Servo Feed
Servo Feed

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2nd Clutch

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Servo Feed
4th
3-4 Accumulator
3-4 Accumulator
3-4 Accumulator
D3

D3
D3
D3
D3
Overrun
Overrun
Overrun/Overrun Clutch Feed
Overrun/Overrun Clutch Feed
Overrun/Orificed D2
Overrun Clutch Feed
Overrun Clutch
D2
D2
D2
D2
D2/Orificed D2
Lo
Lo
Lo

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D3

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Lo
Lo/1st
Lo/1st
Exhaust
Exhaust/Orificed Exhaust
Exhaust/Orificed Exhaust

Void
Regulated Apply
Regulated Apply
Shift Solenoids Screen
Pressure Control Solenoid Screen

Spacer Plate to Control Valve Body Gasket 98 4L60-E Document ID: 338657
Spacer Plate to Control Valve Body Gasket

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Orificed Exhaust

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Line
Line
Line
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit

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Actuator Feed Limit


Actuator Feed Limit
Filtered Actuator Feed
Filtered Actuator Feed
Filtered Actuator Feed
Filtered Actuator Feed

Torque Signal
Torque Signal
PR
PR
PR
PR
PR
D4-3-2
D4-3-2
Lo/Reverse
Lo/Reverse
Lo/Reverse
Reverse
Reverse
Reverse
Reverse Input (Rev. Cl.)
D4
D4
D4

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Torque Signal

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D4
D4
D4
Forward Clutch Feed
Forward Clutch Feed
Forward Clutch Feed

Accumulator
Accumulator
Orificed Accumulator
Signal A
Signal A
Signal A
Signal B
2nd
2nd
2nd
2nd
2nd
2nd
2nd
2nd
2nd
2nd Clutch
2nd Clutch
2nd Clutch

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Accumulator

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2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch

C.C. Signal
3-4 Signal
3-4 Signal
3rd Accumulator
3rd Accumulator
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
3-4 Clutch
4th Signal
4th Signal
Servo Feed
Servo Feed
Servo Feed
4th
3-4 Accumulator
3-4 Accumulator

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C.C. Signal

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3-4 Accumulator
D3
D3
D3
D3
D3

Overrun
Overrun
Overrun/Orificed D2
Overrun Clutch Feed
Overrun Clutch
D2
D2
D2
D2
D2
3-2 Signal
3-2 Signal
Lo
Lo
Lo
Lo
Lo/1st
Lo/1st
Exhaust

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D3

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Exhaust
Orificed Exhaust
Orificed Exhaust
Void
Regulated Apply
Regulated Apply

Document ID: 338658


Control Valve Body Fluid Passages (Case Side)

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Control Valve Body Fluid Passages (Case Side) 98 4L60-E -

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Checkball (61)
Checkball (61)
Checkball (61)
Checkball (61)
Checkball (61)
Checkball (61)

Line
Line
Line
Line
Line
Line
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Actuator Feed Limit
Filtered Actuator Feed
Filtered Actuator Feed
Torque Signal
Torque Signal

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Checkball (61)

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Torque Signal
Torque Signal
PR
PR
PR
D4-3-2

Lo/Reverse
Lo/Reverse
Reverse
Reverse
Reverse
Reverse Input (Rev. Clutch
D4
D4
D4
D4
D4
D4
D4
Forward Clutch Feed
Forward Clutch Feed
Accumulator
Accumulator
Signal A
Signal A

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D4-3-2

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Signal B
2nd
2nd
2nd
2nd
2nd

2nd
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
2nd Clutch
C.C. Signal
C.C. Signal
3-4 Signal
3-4 Signal
3rd Accumulator
3rd Accumulator
3-4 Clutch
3-4 Clutch
3-4 Clutch
4th Signal
4th Signal
Servo Feed

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2nd

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Servo Feed
Servo Feed
4th
3-4 Accumulator
3-4 Accumulator
D3

D3
D3
D3
Overrun
Overrun
Overrun Clutch Feed
Overrun Clutch
D2
D2
D2
3-2 Signal
Lo
Lo
Lo
Lo/1st
Lo/1st
Lo/1st
Exhaust
Exhaust

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D3

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Exhaust
Exhaust
Exhaust
Exhaust
Exhaust
Void

Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void
Void

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Void

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Void

Regulated Apply

Regulated Apply

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